Cerrowire ReelRover Manuel

P/N: PU-USEMAN-RR37

A Marmon/Berkshire Hathaway Company

Contents of the User Manual & Operating Instructions specify the manner in which the

ReelRover™ is to be operated as intended by Cerrowire®. The ReelRover is designated for use

only as stipulated within this document. Any deviation from the User Manual & Operating

Instructions is unauthorized and represents improper use of the equipment. This designated

document is used by Cerrowire to conduct training ofdistribution customers for proper use so that

the ReelRover is safely and correctly operated in both the distribution facility and on the job site.

Cerrowire provides the User Manual & Operating Instructions document to distribution customers

so that subsequent internal training as well as external contractor training may be provided by the

distributor. It is the responsibility of the distributor to ensure that all internal and external users are

properly trained and qualified in accordance with the procedures presented in this manual.

Do not use ReelRover unless you have read this manual completely along with viewing the

training videos. Using ReelRover without reading this manual and watching the training videos

can be dangerous and could lead to injury or death.

The center of gravity of the ReelRover will vary according to the wire and how it is loaded onto

the ReelRover. This must be taken into consideration when the ReelRover is moved, loaded, and

unloaded on to and off of a vehicle, and while being transported.

Revision Date

Description of Changes

Change Owner

March 2020

Initial release

Rich Hawley

April 2022

Add Lull Adaptor, take-up adaptors, warnings

Joshua East

4 
 
Table of Contents 
Components .................................................................................................................................. 6 
Reel Options...................................................................................................................... 6 
GPS Unit............................................................................................................................ 7 
Specifications................................................................................................................................. 8 
Safety Procedures......................................................................................................................... 9 
Warnings...................................................................................................................................... 10 
Gearbox Operation...................................................................................................................... 12 
Driving the ReelRover ................................................................................................................. 14 
Operating in PARK ..........................................................................................................14 
Operating in NEUTRAL ................................................................................................... 14 
Steering in NEUTRAL...................................................................................................... 14 
Operating in DRIVE ......................................................................................................... 15 
Steering in DRIVE............................................................................................................ 16 
Operating in DRIVE on Incline or Decline .......................................................................16 
Free-Spinning Ground Reel........................................................................................................18 
Lock the Free-Spinning Ground Reel.............................................................................. 19 
Unlock the Free-Spinning Ground Reel.......................................................................... 20 
WireTake-upProcess..................................................................................................................21 
Inspect Left Gearbox Securing Bolt................................................................................. 21 
ReelPower STU Shaftless Take-Up Machine.................................................................23 
Wemco 2800-series Shafted Take-up Machine..............................................................26 
Graham H8T20 Take-up Machine................................................................................... 30 
Wemco 2500 Take-up Machine.......................................................................................31 
Wire Unloading (Payout).............................................................................................................35 
Transportation and Shipping......................................................................................................36 
Forklift Locations..............................................................................................................36 
Secure ReelRover for Shipping....................................................................................... 38 
Load ReelRover Using a Liftgate.....................................................................................38 
ReelRover Lock-outProcedure...................................................................................................40 
Troubleshooting...........................................................................................................................41 
Equipment Inspection Prior to Use.............................................................................................42 
 
Table of Figures 
Figure 1 ReelRover 3+1 (model RR-131136)............................................................................................ 6 
Figure 2 Reel Options................................................................................................................................. 7 
Figure 3 GPS Unit....................................................................................................................................... 7 
Figure 4 ReelRover Specifications Side View............................................................................................ 8 
Figure 5 ReelRover Specifications Top View............................................................................................. 8 
Figure 6 Gearbox Settings........................................................................................................................12
Figure 7 Gearshift in PARK ...................................................................................................................... 13 
Figure 8 Gearshift in NEUTRAL...............................................................................................................13
Figure 9 Gearshift in DRIVE..................................................................................................................... 13 

5 
 
Figure 10 Sharp Turn in NEUTRAL..........................................................................................................14
Figure 11 Gradual Turn in NEUTRAL ...................................................................................................... 14 
Figure 12 Reel and Drive Wheel Rotation................................................................................................15
Figure 13 Sharp Turn in DRIVE................................................................................................................ 16 
Figure 14 Gradual Turn in DRIVE ............................................................................................................ 16 
Figure 15 Caster Wheels Trail on Incline and Lead on Decline............................................................... 17 
Figure 16 Never Stand or Walk Behind ReelRover on an Incline............................................................ 17 
Figure 17 Reel Lock.................................................................................................................................. 18 
Figure 18 Free-Spinning Reel Locked (left) and Unlocked (right)........................................................... 18 
Figure 19 Free-Spinning Reel Lock Procedure........................................................................................ 19 
Figure 20 Free-Spinning Reel Unlock Procedure ....................................................................................20
Figure 21 Left Hand Gearbox Securing Bolt ............................................................................................21
Figure 22 Undamaged Securing Bolt Head ............................................................................................. 22 
Figure 23 Damaged Bolt Head................................................................................................................. 22 
Figure 24 ReelPower STU Shaftless Take-up Machine ..........................................................................23
Figure 25 ReelPower STU Take-up Adaptor ........................................................................................... 23 
Figure 26 Take-up Adaptor Insertion (left and right sides) ......................................................................24
Figure 27 Position ReelRover into the Shaftless Take-up Machine........................................................ 24 
Figure 28 Centerline Alignment of Machine Cone with Outer Bore of Take-up Adaptor ........................ 25 
Figure 29 Align ReelRover and Take-up Machine Centerline and Drive Pin..........................................25
Figure 30 Align ReelRover Adaptors with Take-up Machine Cones ....................................................... 25 
Figure 31 Gearshift in PARK .................................................................................................................... 26
Figure 32 Wemco 2800 Shafted Take-up Machine .................................................................................26
Figure 33 Insert Take-up Adaptor............................................................................................................. 27
Figure 34 Use NEUTRAL or DRIVE to Position ReelRover into Take-up Machine................................ 27 
Figure 35 Align Take-up Adaptor with Take-up Machine Spindle Drive..................................................28
Figure 36 Align Drive Pins with Take-up Adaptor Holes.......................................................................... 28 
Figure 37 Slide Spindle Drive Pins in Take-up Adaptor Holes................................................................ 29 
Figure 38 Gearshift in PARK .................................................................................................................... 29
Figure 39 Graham H8T20 Take-up Machine ...........................................................................................30
Figure 40 Take-up Adaptor for Graham H8T20....................................................................................... 30 
Figure 41 Wemco 2500 Take-up Machine and Adaptor.......................................................................... 31 
Figure 42 Remove Locating Block............................................................................................................ 31 
Figure 43 Engage the Motor.....................................................................................................................32
Figure 44 Lock the Output Shaft...............................................................................................................32
Figure 45 Align ReelRover........................................................................................................................ 32 
Figure 46 Align Shaft and Hub .................................................................................................................33
Figure 47 Connect Shaft and Hub............................................................................................................33
Figure 48 Engage Reel Lift Lock..............................................................................................................33
Figure 49 Disengage the Adaptor............................................................................................................. 34
Figure 50 Insert Retaining Pin.................................................................................................................. 34 
Figure 51 ReelRover in Park for Wire Payout..........................................................................................35
Figure 52 Forklift Tube Locations............................................................................................................. 36 
Figure 53 Forks Correctly in Tubes.......................................................................................................... 37 
Figure 54 Forks Outside of Tubes............................................................................................................ 37 
Figure 55 ReelRover onto Liftgate............................................................................................................ 38 
Figure 56 ReelRover into Truck................................................................................................................ 39 
Figure 57 Lock-out Connections............................................................................................................... 40 
Figure A1 Left-hand 180° Driven Turn ..................................................................................................... 43 
Figure A2 Right-hand 180° Driven Turn...................................................................................................43
 

Components

Each ReelRover has common components as shown below:

Figure 1: ReelRover 3+1 (model RR-131136)

Reel Options

Three different reel versions are available, as shown in Figure 2:

▪1+1 –ground reel and a single, large conductor reel

▪3+1 –ground reel and conductor reel divided into three sections for three different wires

▪4+1 –ground reel and conductor reel divided into four sections for four different wires

Figure 2: Reel Options

GPS Unit

A Fleet Complete Model B1-MIOT-GA GPS tracking unit is attached to each ReelRover. The units are

self-sustained and do not require users to complete any tasks to function properly.

Figure 3: GPS Unit

The devices are tied to a ReelRover via the IMEI number listed on the side of the unit. Users can request

tracking for their unit by providing the IMEI number located on the GPS label.

Specifications

Height

60 inches

Wheel Base Length

65 inches

Wheel Base Width

32 inches

Unloaded Vehicle Weight

700 lbs.

Total Vehicle Capacity (vehicle + wire)

2700 lbs.

Conductor Reel Capacity

1500 lbs.

Ground Reel Capacity

500 lbs.

Figure 4: ReelRover Specifications Side View

Figure 5: ReelRover Specifications Top View

Safety Procedures

The User must read and completely understand prior to using this product.

The ReelRover is designed for certain industrial/commercial applications only. Cerrowire cannot be

responsible for issues arising from modification.

If you have any questions relative to a particular application, DO NOT use the ReelRover until you have

contacted Cerrowire to determine if that application is appropriate for the ReelRover.

Be aware of these requirements before operating the ReelRover for any purpose:

▪Do not modify the ReelRover in any way.

▪Do not use the ReelRover in any application other than that for which it was designed.

▪Do not operate the ReelRover if damaged or not in proper working order.

▪Never put your feet, hands or any other body part under the frame assembly.

▪Do not leave ReelRover unattended or in NEUTRAL on a hill or incline.

▪Do not operate ReelRover on a hill or incline with an angle greater than 10°.

▪Do not allow the ReelRover to drop from one level to another.

▪Do not leave ReelRover unattended without being placed in PARK.

▪Always ensure both gearboxes are in PARK when securing ReelRover for loading or unloading wire

from reel.

▪When not in use, place both gearboxes in PARK.

▪Do not drag, push, or tow ReelRover with another vehicle or device.

▪Always keep hands on ReelRover while it is in motion.

▪Do not stand or sit on any part of the ReelRover, or allow any person to stand, sit, or attempt to ride

on the ReelRover.

▪Do not attempt to disassemble or repair the ReelRover unless doing so with authorization from

Cerrowire or by ReelRover maintenance technicians/organizations.

▪Do not attempt to lift the ReelRover using a strap or chain.

▪The ReelRover should only be lifted by a qualified operator using a properly rated forklift with the

forks positioned in the fork tubes as shown in this manual.

▪Do not lift ReelRover using the take-up adaptors or wire loading equipment.

▪Always use proper safety equipment when using ReelRover, including protective eyewear and

appropriate safety footwear.

▪Do not overload the ReelRover. Do not exceed the rated wire capacity of 2,000 lbs. or gross vehicle

weight of 2,700 lbs.

WARNING: OVERLOADING A REELROVER MAY RESULT IN DEATH OR INJURY.

▪Use only ReelRover take-up adaptors for wire loading.

▪The ReelRover center of gravity will vary according to the wire and how it is loaded. This must be

taken into consideration when the ReelRover is moved, loaded onto or unloaded from a vehicle, and

while being transported.

For technical questions, please contact Cerrowire at

800.367.2906 or reelrover@cerrowire.com.

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