Briggs & Stratton Figure-8 User Manual

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Figure-8 Eliminator Trailer

USER'S GUIDE & SAFETY MANUAL

CONDUX

Read and understand all procedures and safety instructions before using a Condux Figure-8 Eliminator Trailer. Observe all safety information on this page and note specific safety requirementsas explained by procedures in this manual. Failure to follow these instructions could result in serious personal injury or death.

Important Safety Notice

ADVERTENCIA:

Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si Ud. no comprende las instrucciones favor de consultarle a su jefe.

READ MANUAL

FIRST

If you have questions on:

SAFETY - OPERATIONS - APPLICATIONS

CALL 1-800-533-2077

Save this user’s guide for future reference.

COMMUNICA TIONS WITH THE MANUFA CTURER

For any information related to the machine (use, maintenance, spare parts) always state Model, Serial

Number, Manufacturing Year and Order. This data can be found in the machine identification table.

Manufacturer:

Condux International Inc.

145 Kingswood Rd

Mankato, MN 56002-0247

1-507-387-6576

Fax 1-507-387-1442

Internet: http://www.condux.com

E-mail: cndxinfo@condux.com

CONDUX

Table of Contents

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Jobsite Set-Up Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electronic Control Features and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

A. Hand-Held Wired Remote Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

B. Electronic Machine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

C. Filters, Gate and Emergency Stop Details . . . . . . . . . . . . . . . . . . . . . . 10

Prepare for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Load Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Unload Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Prepare for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Appendices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Parameters Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Technical Information

The Condux Figure-8 Eliminator Trailer is designed to greatly reduce cable splicing and the need to manually “figure-eight” cable by allowing longer continuous runs when no cable end is available. The Trailer removes cable from a cable reel, and then dispenses it.

This unit is not intended for use where cable ends are available, nor is it a device for transporting cable.

Do not figure-eight any dual strength member fiber optic cable using the Condux Figure-8 Eliminator Trailer. Condux will not warranty or be held liable for any cable damage resulting from the use of dual strength member fiber optic cable on the Condux Figure-8 Eliminator Trailer.

In addition, the Condux Figure-8 Eliminator Trailer can be used as a hydraulic power source in tandem with a Condux Fiber Optic Cable Blower.

• Figure 8 Eliminator trailer used to eliminate the need to manually figure-eight fiber optic cable.

• Electronic control system to control all functions of the trailer.

• Single person operation.

• Drum and arm assembly fully enclosed (four sides) by safety cages.

• Cable to be loaded from ground level without having to climb into trailer - access doors through safety cages.

• Storage for remote controller and its harness.

• Freewheel mode with variable drag - adjustable through electronic controls. Used when cable is being pulled off the drum by the FO Blower.

• Arm assembly can be free wheel by switching on the solenoid.

• All components to be made of non-corrosive materials or be plated or painted.

• Arms must be locked into position during transport to prevent the beam from fatiguing.

• Trailer is to be used for handling cable in a figure 8 situation only. Not for transporting cable. Occasional transport of cable may be required to reposition the trailer on the job site.

B. CABLE HANDLING SPECIFICATIONS

• Maximum cable diameter of 1.05 inch.

• Theoretical cable pulling tension of 187 lbs.

• Minimum bend radius of 20 times the cable diameter through the guide roller blocks (20 * 1.05 = 21" bend radius).

• Minimum drum diameter 42 inches.

• Average cable loading speed 612 ft/ min or 40 RPM.

• Roller blocks can be easily operated with one hand.

• Cable capacity of 44000 ft of 1/2" cable, 20,000 ft of 3/4" cable, 11000 ft of

1.05" cable.

C.TRAILER SPECIFICATIONS

• Dual axle, rated for 12,000 lb capacity.

• Electric brake or surge brake.

• Pintle ring hitch for electric brake and ball hitch for surge brake.

• Dual safety chains, minimum 10,000 lb capacity

GENERAL SPECIFICATIONS

Figure-8 Eliminator

Trailer

Used to eliminate the need to manually figure-eight fiber optic cable.

Electronic Control

System

Control all functions of the trailer.

Drum & Arm Assembly

Fully enclosed on all four sides by safety cages.

Loading Cable

Loaded from ground level without having to climb into trailer - access doors through safety cages.

Freewheel Mode with

Variable Drag

Adjustable through electronic controls, used when cable is being pulled off the drum by Fiber Optic Blower.

Arm Assembly

Can be freewheel by switching on the disengage arm switch.

Arm Placement

Arms must be locked into position during transport to prevent the beam from fatiguing.

Trailer to be used for handling cable in figure-8 situation only. Not for transporting cable.

Roller Block Operation

Easily operated with one hand.

CABLE HANDLING SPECIFICATIONS

1.05" (26.67 mm)

Maximum Cable

Diameter

48,000 ft of 1/2" diameter cable (15 km of 13 mm cable)

31,000 ft of 5/8" diameter cable (10 km of 16 mm cable)

Cable Capacity

Arm Speed

Stabilizer Jacks

Manual outrigger jacks.

40 RPM

22,000 ft of 3/4" diameter cable (7 km of 19 mm cable)

16,000 ft of 7/8" diameter cable (5 km of 22 mm cable)

12,000 ft of 1" diameter cable (4 km of 25 mm cable)

Minimum Drum

Diameter

Cable Loading Speed

42" (1,067 mm)

Maximum speed is 785 ft/min (239 m/min) on a full drum, Maximum speed is 440 ft/min (134 m/min) on an empty drum

Max. Cable Loading

Tension

Minimum Bend Radius

20 times the cable diameter through guide roller (20 x 1.05= 21" (533 mm) bend radius)

160 lb. (712 N)

Trailer to be used for

Handling Cable

OUT OF RANGE

• Full DOT approved lighting package with reflective tape

• Front tongue jack, rated for 7,000 lb capacity.

• Target trailer weight 5,500 lb.

• Trailer width of 8' ft.

• Spare tire included.

• Maximum tongue weight 500 lb.

D. HYDRAULIC SPECIFICATIONS

• 16 HP gasoline engine set at 3000 RPM (16 HP diesel engine is an option).

• 8.4 cc or 0.51 cu. in. Sunstrand pump is used to generate up to 6.5 GPM fo hydraulic fluid.

• System pressure is set at 2500 psi on the apitech valve.

• 12 Gallon fuel tank estimated to last up to 12 hours of operation.

• Hydraulic oil sight gauge is mounted on hydraulic tank to monitor oil level.

• A5 micron high pressure and 10 micron low filter are used to keep the hydraulic oil clean. Both filters will indicate on the ECB when elements are plug.

• Apitech valve controlled (ECB controlled) hydraulic ME-24 Ross motor to drive arms. Motor to have pulse sensor (30 pulses per rev).

• Apitech valve controlled (ECB controlled) 56 inches hydraulic cylinder to move drum. Drum to have potentiometer mounted to provide signal feedback on drum location.

• 2500 psi, 6.5 gpm external hydraulic circuit, controlled by Apitech valve (ECB controlled). Plumbed at rear of trailer with quick connects for Condux FO Blower.

• Thermostatic control valve is used on the inlet of the cooler to prevent hydraulic fluid flowing through 7.8 HP cooler when the temperature has yet to reach 100 C.

E. ELECTRONIC CONTROL SYSTEM SPECIFICATIONS

Contained within a separate set of documents:

• Remote Electronic Control Box Specification: K:\PRODUCT\Product Dev Projects\1995\95—52 Figure 8 Trailer\Electronic Controls\Electronic functions.lwp

• Machine Electronic Control Box Specification: K:\PRODUCT\Product Dev Projects\1995\95—52 Figure 8 Trailer\Electronic Controls\Machine Control Panel.lwp

F. ELECTRICAL / ELECTRONIC SPECIFICATIONS

• 12 volt DC electrical system.

• Two12 VDC battery.

• A20 ampere attenuettor is used to generate enough power for the electrical system.

• Throttle, free wheel, strobe lights, work light, blower and controller switches with fuse are place on the control panel.

• Glow plug is offer for diesel engine.

• Hour meter, emergency switch, hydraulic system pressure, fuel gauge choke and push start button are also place on the control panel.

• Two strobe and four clearance lights are offered to satisfy the DOT specification.

Mounts

For remote in/near control panel, also a mount on the Fiber Optic Cable Blower for the remote.

Controls: throttle, arm disengage, strobe lights, work light, blower and controller switches with fuses, also the hour meter, emergency stop switch, hydraulic system pressure, fuel gauge, choke and push start button.

Glow Plug

Charges through main system, and it is isolated by a diode to prevent drawing from this power supply for the work light, strobe lights, starter, blower, free wheel solenoid and throttle.

Storage Area

Secured, weather resistant, and shock absorbing for the remote control and 65' (20 m) of control cable.

Limit Switches

On all openings and tipping gates

Rear Electric Turk

Connector

To power to Fiber Optic Cable Blower

Tongue Weight

Engine

ELECTRICAL / ELECTRONIC SPECIFICATIONS

Electrical System

12 volt DC

System Pressure

3,000 psi (207 bar)

600-650 lb. (272-295 kg)

12 Gallon (45 liters) estimated to last up to 12 hours of operation

Filtration

TRAILER SPECIFICATIONS

Dual axle, rated for 12,000 lb. (5,443 kg) capacity

Electric

Pintle ring hitch for electric brake

Axle

Brakes

Hitch

Full DOT approved lighting package with reflective tape

Rated for 7,000 lb. (3,175 kg) capacity

6,500 lb. (2,948 kg)

8' (2.44 m) wide x 9' 6" (2.90 m) high x 21' 6" (6.55 m) long

Isolated 12 VDC Power

Supply for ECB

Used on inlet of the cooler to prevent hydraulic fluid flowing through 7.8 HP (5.8 kW) cooler when temperature has yet to reach 100 C.

5 Micron high pressure and 10 micron low pressure filters used to keep hydraulic oil clean.

Batteries

Two 12 volt VDC Batteries

2,500 psi (172 bar), 6.5 gpm (25 lpm) external hydraulic circuit.

Offered for the diesel engine

Lights

Two strobe and four clearance lights are offered to satisfy the DOT specification. Work light is offered to operate the machine in the dark.

Dual Safety Chains

HYDRAULIC SPECIFICATIONS

16 HP @ 3170 RPM (12 kW @ 3170 RPM) Briggs & Stratton V-Twin Vanguaard *16 HP (12 kW) Diesel engine is an option

Plumbed at rear of trailer with quick connects for Condux Fiber Optic Blower.

Lighting

Hydraulic Flowrate

7 gpm (26 lpm)

Hydraulic Fluid Sight

Gauge With

Thermometer

Mounted on hydraulic tank to monitor fluid level and fluid temperature

External Hydraulics

Thermostatic Control

Valve

Control Panel

Fuel Capacity

Front Tongue Jack

Trailer Weight

Trailer Dimension Size

Minimum 10,000 lb (4,536 kg) capacity

Safe Operating Practices

Read and understand all procedures and safety instructions before using the Condux Figure-8 Eliminator Trailer. Observe all safety information on this page and note specific safety requirements as explained by procedures called out in this manual. Failure to follow these instructions could result in serious personal injury, property damage or death.

A.WORK AREA SAFETY

1. Wear personal protective equipment: hard hat, safety glasses, safety shoes, and leather work gloves.

2. The safe operation of this equipment requires that the operators be on stable footing.

3. Stay clear of cables or lines under tension.

4. Do not place cable spool too close to unit. Place the spool far enough away from the unit to ensure proper control.

5. Do not tamper with relief valves or pressure reducing valves.

B. HYDRAULIC DEVICES

Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards:

1. Tighten all connections before applying pressure. Relieve pressure when connecting or disconnecting hoses when servicing the unit.

2. Check for leaks with a piece of cardboard. Do not use your hands!

3. Do not exceed working pressure of hydraulic hoses.

4. Visually inspect hoses regularly and replace if damaged.

C. ELECTRIC DEVICES

The Hand-Held Wired Remote Controller is an electrical device. Electric shock hazards exist that could result in severe personal injury or death. Observe the following precautions to avoid electrical hazards:

1. Do not operate in or near water. This includes setting the Hand-Held Wired Remote Controller on a wet surface or exposing them to rain.

2. Do not remove cover of the Hand-Held Wired Remote Controller or Electronic Machine Controller. There are no user-serviceable parts inside. Refer servicing to qualified service personnel.

3. The Hydraulic Power Unit Controls Power Switch and Controller Power Switch should be in the off position before connecting or disconnecting any cords.

Jobsite Set-Up Guidelines

Time spent planning your equipment’s placement (layout) at the job site will benefit both the operation of the equipment and the safety of your crew at the site. It is best to determine the layout of all equipment before disconnecting, stabilizing and leveling the Figure-8 Eliminator Trailer. Because no two job sites are the same, the illustrations that follow should be used as general guidelines to get the most benefit and safest operation from your Figure-8 Eliminator Trailer.

Cable Installation—First Run

Prepare Figure-8 Eliminator Trailer for Cable Loading

Load Cable to Figure-8 Eliminator Trailer

Cable Installation—Second Run

Electronic Control Features and Operation

A. HAND-HELD WIRED REMOTE CONTROLLER

Load Dial

• Controls the speed of the rotating arms from 0 rpm to maximum 40 rpm.

Load Drum button

• Moves the drum to the rear of the machine so the cable can be loaded onto

the machine.

• Stop button will stop the drum from moving and stop this function.

• Pressing the Load Drum button while the function is active will have the same effect as pressing the Stop button.

Transport Drum button

• Moves the drum to the front of the machine for transport.

• Stop button will stop the drum from moving and stop this function.

• Pressing the Transport Drum button while the function is active will have the same effect as pressing the Stop button.

Start / On button

• Starts the machine so the Load Dial is functional and allows the arms to rotate.

• Stop button will stop the arms from rotating and stop this function.

• Load Dial must be turned all the way to zero (counterclockwise) in order to activate the start button. LED will flash if the Load Dial is not all the way to zero.

4 digit 7 segment LED display

• Normally displays the cable diameter in millimeters or the Drum Position.

• Also displays error codes when an error condition is encountered: FL 1-FULL if the pressure filter is full; FL 2-FULL if the return filter is full; or door-OPEn when one of the safety gates is open. These error conditions will flash between the first and second words and will display for 5-10 seconds before going back to displaying the cable diameter or Drum Position. They will cycle on approximately every 20-30 seconds.

• An additional error code will be displayed when connected to the Condux FO Blower and the blower has been stopped by the blower electronics: FOCBStOP. This error condition will flash between the first and second words and will display as long as the trailer has been disabled by the blower. This condition can be cleared by pressing the Stop button.

Stop button

• This button will stop all operations of the machine.

• LED beside button is lit when none of the other functions are operating. Also functions as a “power on” indicator.

• If arms are rotating, they will take approximately 2 seconds to stop.

• If the Condux FO Blower has stopped the machine, pressing the Stop button will clear the stop forced by the blower.

+ / In / Up button and - / Out / Down button

• Increments the cable diameter when the Cable Diameter LED is selected.

• Moves the Drum Position backwards or forwards while loading or unloading cable.

Select button

• Allows selection between Cable Diameter and Drum Position.

Cable Diameter LED

• Indicates that the cable diameter can be adjusted up or down with the + / - buttons.

• Cable diameter can be adjusted only when NOT loading or unloading cable. Cannot be adjusted when Load Drum or Transport Drum are operating or when Condux FO Blower has stopped the machine.

Drum Position LED

• Drum Position can be adjusted at any time when loading or unloading cable.

• (+) Key speeds drum up, (-) key slows drum down.

• Readout on the LCD display is relative to the Drum Position on the trailer and is not an indication of speed or distance.

LH Stab Jack & RH Stab Jack LEDs

• These functions are not used.

Drag Dial

• Controls the amount of drag on the rotating arms when in free wheel mode.

• Dial will control drag from very little drag on the arms to a very large amount of drag.

Fiber Blower button

• Activates the external circuit that provides hydraulic fluid to the Condux FO Blower.

• LED beside button is lit when the circuit is activated.

• Free Wheel button and function will also be activated when the Fiber Blower button is pressed.

• Stop button will remove power from this circuit and stop this function and the free wheel function, both LED’s will go out.

• Pressing the Fiber Blower button while the function is active will close the hydraulic circuit and the fiber blower LED will go out, however, the Free Wheel button and function will NOT be stopped.

Free Wheel button

• Places the trailer into free wheel mode.

• Free Wheel button and function will also be activated when the Fiber Blower button is pressed. However, the Fiber Blower button and function will NOT be automatically activated when the Free Wheel button is pressed.

• Stop button will stop this function and the fiber blower function.

• Pressing the Free Wheel button while the function is active will stop the free wheel mode and the Fiber Blower will also be stopped.

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