Afs608 Underground Pulling Trailer

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USER'S GUIDE & SAFETY MANUAL

USER'S GUIDE & SAFETY MANUAL

AFS608 Hydraulic Puller-Tensioner

5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012

Comstar Supply,

5 Blue Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012

INC

Think Cable... Think Comstar

1-866-326-6782

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Important Safety Notice Before using a Condux AFS608 Hydraulic Puller-Tensioner, operators must read and understand all procedures and safety instructions. Note all safety information on this page, and note specific safety requirements as explained by the procedures in this manual. Failure to follow these instructions could result in serious personal injury or death.

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.

Save this user’s guide for future reference.

COMMUNICATION WITH THE MANUFACTURER: For information related to the machine (use, maintenance, spare parts), always state the Model Number, Serial Number, Manufacturing Year, and Order Number. This information can be found in the Parts-Identification Table. Manufacturer: Condux International, Inc. 145 Kingswood Drive Mankato, MN 56002-0247 1-507-387-6576 Fax 1-507-387-1442

E-mail: [email protected]

For questions on: SAFETY - OPERATIONS - APPLICATIONS CALL 1-800-533-2077 

5 Blue Heron Drive

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Table of Contents

1

2

3

4

IMPORTANT SAFETY NOTICE.......................................... 2



G. DETERMINE PULLING OR TENSIONING RANGE... 16

COMMUNICATION WITH THE MANUFACTURER............ 2



H. SET PULLING/TENSIONING RANGE LEVER........... 17

GENERAL INFORMATION................................................. 4



I. TENSIONING OPERATION........................................ 18



A. COMMUNICATION WITH THE MANUFACTURER...... 4



J. PULLER OPERATION............................................... 19



B. TYPOLOGY AND FIELD USE..................................... 4



C. PERFORMANCES...................................................... 4



D. TECHNICAL CHARACTERISTICS ............................ 4



B. LEVELS CONTROL.................................................. 21



E. ACOUSTIC EMISSION............................................... 5



C. TIRE INFLATION PRESSURE................................... 21



F. GENERAL SAFETY INFORMATION............................. 5



D. SUGGESTED LUBRICANTS..................................... 21

5

MAINTENANCE............................................................... 21

A. GENERAL INSTRUCTIONS...................................... 21



G. GENERAL OPERATOR INSTRUCTIONS.................. 5



E. ENDOTHERMIC ENGINE MAINTENANCE................ 22



H. GENERAL MAINTENANCE INSTRUCTIONS............ 5



F. HYDRAULIC CIRCUIT MAINTENANCE..................... 22



I. THE INSTRUCTION MANUAL . ................................. 6



G. REDUCTION GEAR MAINTENANCE........................ 22



J. CONDITION OF USE................................................ 6



H. RADIATOR MAINTENANCE................................... 23



K. TEMPERATURE LIMITS FOR HYDRAULIC OIL....... 6



I. GREASING................................................................ 23 J. OTHER PERIODIC OPERATIONS............................. 23 K. SUMMARY TABLE FOR ORDINARY



L. USE NOT ALLOWED............................................... 7





M. RESPONSIBILITY................................................... 7





N. APPLIED NORMS................................................... 7

MAINTENANCE........................................................ 24

TRANSPORT AND POSITIONING INSTRUCTIONS.......... 8

6

TROUBLESHOOTING GUIDE.......................................... 25



A. MACHINE LIFTING.................................................... 8

7

APPENDICES.................................................................. 31



B. PACKAGING FOR SHIPMENT.................................... 8



1. SIDE VIEW............................................................... 31



C. UNPACKING............................................................... 8



2. TOP VIEW................................................................ 32



D. TRANSPORT ON TRAILER........................................ 9



3. SUGGESTED OILS AND GREASES.......................... 33



E. POSTIONING AND ANCHORING............................... 9

8

HOW TO DISABLE THE MACHINE................................. 34

SAFETY CONDITIONS.................................................... 11



A. TRANSPOST............................................................ 34



A. SAFETY DEVICES.................................................... 11



B. EXTENDED SERVICE STOP..................................... 34



B. EMERGENCY STOP DEVICE.................................... 11



C. STRIPPING.............................................................. 34

9

WARRANTY INFORMATION........................................... 35



C. PERIODIC OPERATIONS......................................... 11



D. RESIDUAL RISKS.................................................... 11



FACTORY ASSISTANCE............................................... 35

OPERATING PROCEDURE.............................................. 13



LIMITED WARRANTY.................................................. 35



A. SET-UP.................................................................... 13



B. START UP PROCEDURE.......................................... 13



C. STABILIZE PULLER-TENSIONER............................ 14



D. REEVING THE DRUM.............................................. 16



E. GUIDE ROLLERS..................................................... 16



F. POSITION REEL ELEVATOR..................................... 16



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General Information

A. COMMUNICATIONS WITH THE MANUFACTURER To receive information related to the machine (use, maintenance, spare parts), always state the Model Number, Serial Number, Manufacturing Year, and Order Number. This information can be found in the Machine-identifying Table. B. TYPOLOGY AND FIELD USE Puller-tensioner model AFS608 is suitable for stringing one conductor with a maximum diameter of 34 mm (1.34 in.) and for recovering a single 16 mm (.6 in.) diameter rope with a connector with maximum diameter of 48.5 mm (1.9 in.). The machine is controlled by a hydraulic system that allows the machine to work automatically in PULLER or in TENSIONER mode. Power is transmitted to the large groove bull-wheels through a closed hydraulic circuit with a variable delivery pump and fixed displacement motor, making it possible to continuously change the speed in both rotating directions. A hydraulic vacuum brake automatically stops the two bull-wheels if a hydraulic circuit failure occurs. The machine is equipped with quick hydraulic couplers for connection to all types of reel winders and reel elevators provided by Condux. C. PERFORMANCES Maximum pull............................ 4000 daN (27,000 lbs.) Maximum tension...................... 4000 daN (27,000 lbs.) Maximum speed........................ 3 mph

!ATTENTION: Using a rope with a smaller diameter will reduce the pulling capacity of the machine, in accordance with the breaking load of the rope or of the conductor. Performances are referred to the machine without optional equipment, at sea level and at 20°C (68°F) D. TECHNICAL CHARACTERISTICS Bull-wheels diameter:................ 1500 mm (59.06 in.) Diesel engine:............................ 130 HP (97 kW) Electric system:......................... 12 V Transmission:............................. closed hydraulic circuit with hydraulic oil cooling Safety brake:.............................. negative and self-acting type Dynamometer:........................... hydraulic with set-point and automatic control of maximum pull Axle:........................................... Torison axle with electric brakes, DOT lighting, pintle hitch & safety chains (18.6 mph maximum) Dimensions:............................... length - 3640 mm (17.82") width - 2000 mm (8.54") height - 2815 mm (8.39") Mass:......................................... 3000 kg (14,500 lbs.) 

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E. ACOUSTIC EMISSION Level of continuous sound pressure to the operator seat (UNI 9432) Lep = 85 dB(A) F. GENERAL SAFETY INFORMATION a. Only trained and qualified operators should use this machine. Qualified operators are those persons who have received training from the machine owner’s company or from the manufacturer. b. Use this machine only for the work it was designed to do. c. Do not use this machine when unauthorized personnel are on the work site. d. For safety during transport, this machine is shipped with no hydraulic oil and fuel. Find characteristics and required quantities in the manual. e. For questions regarding operation, function, maintenance, etc., contact the manufacturer’s After-Sales Service. G. GENERAL OPERATOR INSTRUCTIONS a. Operators must be aware of all local, state, and federal safety regulations governing the use of this equipment. b. Operators must wear suitable clothing to reduce the possibility of entanglement in the machine’s moving parts. Operators must not wear chains or other jewelry for the same reason. c. Operators must use personal protective gear (i.e. gloves, boots, helmet, etc.). Hearing protection is required. d. Operators must carefully follow all hazard-related instructions contained in this instruction manual or indicated on the machine. e. The work area for this machine must be as free as possible of oil or other liquid spills as well as materials or equipment that may be considered an obstacle to proper operation. f. The operator must absolutely avoid direct inhalation of the system’s engine exhaust gas. H. GENERAL MAINTENANCE INSTRUCTIONS a. It is absolutely forbidden to perform any maintenance or to adjust any settings on this machine while stringing (except where otherwise indicated). b. Stop the engine before performing any maintenance (except for those instances indicated otherwise in this manual) and wait until the system components are cool to the touch. c. All maintenance performed on this machine must be done on a level surface and while the system is not under load. d. Only authorized and trained personnel are to perform maintenance, either scheduled maintenance or repairs. Authorized and trained personnel are those persons who have received training on the maintenance of this equipment from the machine owner’s company or from the manufacturer. e. Maintenance personnel must wear suitable clothes to reduce the possibility of entanglement in the machine’s moving parts. Maintenance personnel must not wear chains or other jewelry for the same reason. f. Maintenance personnel must use personal protective gear (i.e. gloves, boots, helmets, etc.). g. All maintenance operations, either scheduled or repair, must be done according to the instructions included in this manual and/or following technical instructions provided by the manufacturer. Failure to follow these instructions relieves the manufacturer from any responsibility and voids the warranty.  5 Blue Heron Drive

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I. THE INSTRUCTION MANUAL a. Information contained in this manual applies to all the operators charged with the use and/or the maintenance of the machine. b. This instruction manual is not a training manual. c. Before using this machine, the job site supervisor and the operators must read this instruction manual. d. The supervisor must inform all operators about the instructions contained in this manual. e. All operators must carefully follow the instructions contained in this manual. f. Before using the machine, the operator must know the positions and the operation of all the controls. g. The job site supervisor must verify that the instructions contained in this manual are followed. h. This instruction manual must be kept with the machine for the entire life of the machine in order to be available to all potential users and operators. i. The instruction manual must be kept in a sheltered and dry place.

!ATTENTION: This manual belongs exclusively to the manufacturer. Reproduction (even in part) of its contents is forbidden. J. CONDITION OF USE a. b. c. d.

Temperature:........................... from -10°C to +40°C. (14°F to 104°F) Relevant moisture:.................. from 30% to 90% ± 5%. Weather conditions:................. any (in line with working conditions). Natural and/or artificial light of the work site.

K. TEMPERATURE LIMITS FOR HYDRAULIC OIL When using the machine, you must always be aware of the operating conditions and their effects on the possibility of exceeding the following temperature limits for the system’s hydraulic oil. TEMPERATURE LIMITS FOR HYDRAULIC OIL - °C (°F) Working condition

ATF oil

Hydraulic oil viscosity VG 22

VG 32

VG 46

VG 68

Minimum temperature running in neutral position

-15°C (5°F)

-21 (-6)

-14 (7)

-7 (19)

-1 (30)

Minimum temperature running in full load

19°C (66.2°F)

8 (46)

16 (61)

24 (75)

32 (90)

Maximum temperature running in full load

66°C (150.8°F)

48 (118)

57 (135)

67 (153)

76 (169)

Maximum temperature running in neutral position

84°C (183.2°F)

63 (145)

73 (163)

83 (181)

93 (199)

For additional information concerning the hydraulic oil, see the chapter on “Maintenance” and the attached Comparative Table of the oils used on the machine.



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L. USES NOT ALLOWED Never a. b. c. d.

use the machine: for lifting persons and/or goods. in areas where the machine cannot be properly positioned and anchored. in areas with brush or other materials that can easily catch fire. in closed/unventilated sites or those that are poorly ventilated (tunnels or similar areas). e. at sites where fuels or explosives are present. f. on aircraft, watercraft, floating platforms, and similar locations. g. for structure demolition. h. for pulling elastic elements. i. with ropes or joints having larger diameters than those specified in this manual. j. when the engine is off but the bull-wheels are moving. k. with over-ridden or broken safety system devices. l. when winding ropes and/or conductors having a smaller diameter after ropes and/or conductors having a bigger diameter on the bull-wheels. m. for handling trucks or other movable equipment.

M. RESPONSIBILITY It is extremely dangerous and forbidden to use this machine in situations different from those indicated in this manual. Failure to use recommended restraints creates a situation of wrongful and improper use and relieves the manufacturer of any responsibility for accidents and/or injuries to persons and/or damage to property. This voids the manufacturer’s warranty. Similarly, the manufacturer’s responsibility ends when the following situations occur: a. tampering and/or modifying the system without the manufacturer’s express written consent (in this case the operator becomes the manufacturer assuming all obligations and responsibilities, both civil and penal). b. using non-original spare parts for the machine. c. performing poor maintenance on the machine. d. using the machine while it is disconnected or when safety devices are over-ridden. e. for the connection to machine and/or plans not produced and not directly authorized by the manufacturer in a written acceptance. N. APPLIED NORMS This machine is manufactured in conformity with the following norm: 98/37/CE

Norm of the European Parliament and Council, dated 22 June 1998 referring to the laws of the machine’s member States.

89/336/CE

Norm of the European Council, dated 03 May 1989 referring to the laws of the electromagnetic compatibility of member States.



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Transport and Positioning Instructions A. MACHINE LIFTING

When lifting the machine, use only devices (overhead traveling cranes, lift trucks, ropes, cables, hooks, etc.) with a load capacity equal to or greater than the mass to be lifted. The instruments used for lifting (ropes, cables, hooks, etc.) must have a load capacity equal to or greater than the mass to be lifted and must be connected to the proper points on the machine (shown in Appendix 2, callout 3). Personnel should not be on the machine when it is lifted.

!DANGER: Failure to follow the recommendations in this section may create a dangerous situation and/or damage the machine, resulting in the manufacturer’s warranty being voided. B. PACKING FOR SHIPMENT Transport by land by truck This machine ships without flammable liquids. Certain surfaces may be protected by cardboard and/or plywood and/or polyethylene film. To prevent movement, nail wheel chocks securely in place. Attach the machine to the floor of a truck box or trailer using chains and hooks at the attachment points provided. Transport by sea in wooden cases or container This machine ships without flammable liquids. Metal parts are protected with waterproof wax. To prevent movement of the machine during transportation, nail wheel chocks securely in place. Attach the machine to the floor of the container using chains and hooks at the attachment points indicated (red flanges). Materials usually used for packing are: • wood • nails and/or steel screws • cardboard and/or paper • polyethylene film • adhesive tape C. UNPACKING When receiving the machine, verify the condition of the package. Immediately notify the transportation company and the manufacturer (use photos whenever possible) of any damage that may have occurred during shipment. Verify that the supplied product matches that which was ordered. Immediately notify the manufacturer of any discrepancies. Use caution when unpacking to avoid damaging the product. 

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!ATTENTION: Dispose all packaging materials in accordance with local regulations. !ATTENTION: Packaging materials must be eliminated in conformity with the norms in force in the relevant country. D. TRANSPORT ON TRAILER Moving the unit from location to location at the job site must be done by connecting the unit to the tow vehicle by means of the towing eye on the drawbar. Before transporting this machine, lift the rear stabilizer (Appendix 1, callout 7) and the front jack using the handle provided. Check the tires for proper inflation pressure (5 bar / 72.5 psi). No personnel may ride on the machine at any time while towing the machine at ANY speed.

!ATTENTION: It is dangerous to tow the machine at speeds in excess of the axle’s rated capacity or if the tires are not properly inflated. To prevent movement of the machine during transportation, nail wheel chocks securely in place. Attach the machine to the floor of the truck box or trailer using chains and hooks at the attachment points provided. E. POSITIONING AND ANCHORING Positioning and anchoring the machine must be done only by trained personnel who can verify if the ground allows the necessary stability, support, and anchoring. For best rope and/or conductor pulling, the machine should be placed at a distance of no less than 2 times and no greater than 4 times the height of the first poll or trestle (see Table 1).

Table 1 It is possible to use the machine at a distance of 1 to 2 times the height of the pole. In that case the anchorage described below must be over-dimensioned by 125% compared to the reported data, and more rings must be provided on the front side of the machine.



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!PROHIBITION: Do not use the machine if the distance between the machine and the pole is less than the height of the pole itself. The following is the machine anchoring sequence: a. The machine must be aligned as much as possible with the pull direction. b. Properly position the anchor ram (Appendix 1, callout 5) operating on the handle and set the rear stabilizer (Appendix 1, callout 7). c. Anchor the machine to the ground by means of 2 stakes with a min. load rating equal to 130% of the machine’s maximum pull force and connect (Appendix 2, callout 3) with the anchoring stakes per the angles and lengths indicated. d. Take up the slack to the anchoring stakes prior to tensioning the system. e. Test the machine pull (see Use Instructions in the following chapter) to allow the machine to freely align itself to the pull. f. Tension the anchoring stakes in a uniform way.

!ATTENTION: Dangerous situations may occur during machine use if the anchoring instructions are not followed. An 8 foot radius around the machine must be free of obstacles to make the operation, adjustment, and maintenance of the machine as easy as possible. To avoid overheating that may damage the system’s components, be sure air can circulate freely through the cooling system’s radiator.

!DANGER: This machine is not a proper grounding device. Proper grounding for the conductor system being installed must be provided via other means.

10

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Safety Conditions A. SAFETY DEVICES

This machine has the following safety devices: 1. a load-limiting device which automatically stops the endothermic engine once the maximum pre-set load value has been exceeded. 2. a mechanical negative safety brake to stop movement in case of a lack of hydraulic pressure. 3. a timing case to protect moving parts where technologically possible.

3.

3.

!DANGER: It is absolutely forbidden to use the machine without protecting the timing cases or with damaged/disconnected safety devices. !ATTENTION: After a serious emergency and/or use of the negative safety brake, check the wear condition of the discs and the efficiency of the brake itself. If necessary, replace the brake discs before re-using the machine. B. EMERGENCY STOP DEVICE An emergency stop device acts directly on the diesel engine.

!ATTENTION: Use the emergency stop device ONLY in dangerous situations and for the operators’ safety. NOTE: For restoring the machine, unlock the emergency device by turning the push-button one quarter turn in a clockwise direction. !PROHIBITION: Use the emergency stop device only for emergency situations. C. PERIODIC OPERATIONS Every day, before starting work, the operator must verify the performance of the machine’s safety devices.

!ATTENTION: Do not, for any reason, modify the machine’s safety devices. The manufacturer declines any responsibility as a consequence of the non-functioning of those devices. D. RESIDUAL RISKS The machine has the following residual risks: 1. Sudden break of the rope-conductor. The break of the rope causes sudden movements of the machine and the rope or conductor connected to the machine. To minimize the risks, the operator has to: • Check the rope and replace it as soon as defects or wear signs appear. • Comply with the working positions indicated in the manual.

11

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2. Sudden break of the anchoring stakes. The sudden break of the anchoring stakes causes machine instability and sudden movements. To minimize the risks the operator has to: • Periodically check the anchoring stakes and replace them as soon as defects or wear signs appear. • Follow the anchoring suggestions described in the present manual. • Comply with the working positions indicated in the manual. 3. Entangling or dragging the accessible rotating units. Due to the effective use of the machine, it is not possible to cover some rotating parts (i.e. winding of the rope or of the conductor on the bull-wheels or on the driving gears). To minimize the risks, the operator has to: • Avoid contact with the machine’s rotating units except for the control devices. • Respect the prescriptions indicated in the present manual about wearing and using necessary safety devices. 4. Limb crushing during loading or removal of the reel and during ropeconductor loading. These operations have a large risk margin due to the use of mechanical parts to be moved. To minimize the risks the operator has to: • Know the directives for accident prevention and apply them. 5. Electrostatic discharges. Since the machine does not have a proper grounding device for during stringing operations, it is possible to have dangerous electrostatics discharges on ropes and conductors. To minimize the risks, the operator has to: • Know the directives for accident prevention and apply them. • Check if the job site has a suitable grounding device for the machine-rope- conductors system. 6. Inhalation of the endothermic engine exhausting gas. This machine discharges exhaust gas. To minimize the risks, the operator has to: • Respect the working recommendations indicated in the manual. • Respect the attentions and prohibitions indicated in the present manual. • If necessary, use safety devices for respiratory tracts. 7. Command lever that can be locked in working position. For functional reasons and for comfort, the control joystick will stay where it is positioned. The machine is equipped with two security devices which prevent the creation of dangerous situations: an electric limiting device of the pull on the dynamometer which stops the power station when the stated value is reached, and a pull limiting device which maintains a preset pulling load regardless of the speed that the machine is operated. To minimize the risks, the operator must: • Put the electric limiting device of the pull on a value just superior to the regulating valves of the pull. • Plan the desired pull as described in the manual.

12

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Operating Procedure A. SET-UP

1. Position puller-tensioner slightly to left or to the right of the first overhead structure being worked with. The machine should not be positioned directly inline with the overhead structure. A slight offset to the right or left will provide better engagement during operation. The puller-tensioner also needs to be positioned far enough away from the first structure to obtain a 1.5- to 2-degree fleet angle. This distance can be calculated by multiplying 2.5 by the height of the first block on the pulling structure. For example if the first block is at 80 feet high, the puller-tensioner should be positioned 240 feet back.

5.

4.

2. Set rear stabilizer leg by removing the keeper pin (See Figure 1) and lowering the leg as close to the ground as possible and replacing pin. (See Figure 2)

Figure 1. Remove Keeper Pin

Figure 2. Lower Leg, Replace Pin

B. START UP PROCEDURE

!IMPORTANT: Read all instructions before starting the AFS608 Puller-Tensioner. 1. To start the machine, insert the key into the ignition, push in and turn one position clockwise. (See Figure 3) 2. Wait for yellow glow plug light to turn off. 3. Push ignition key in and turn the key clockwise to start. 4. Adjust engine throttle to 2,200 rpm. (See Figure 4) 5. Set cooling fan to 700 psi., 50 bar. (See Figure 5) 6. The AFS608 can accommodate up to 3 reel stands simultaneously. Set hydraulic pressure to 500 psi., 40 bar by using the corresponding hydraulic pressure knob. (See Figure 6a & 6b) 5 Blue Heron Drive

Collegeville, PA 19426

Figure 3. Start machine. 13

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Figure 4. Adjust Engine Throttle

Figure 5. Set Cooling Fan

Figure 6a. Reel Stand Hydraulic Connections

Figure 6b. Reel Stand Hydraulic Pressure

C. STABILIZE PULLER-TENSIONER 1. Set the front of the unit as low as possible by engaging the leveling joystick down. (See Figure 7)

!NOTE: The engine compartment should be level or parallel with the ground for operation. (See Figure 8) 2. Re-adjust the rear stabilizer leg by removing the keeper pin (See Figure 9) and lowering the leg as close to the ground as possible and replace pin. (See Figure 10)

Figure 7. Engage Leveling Joystick Down

3. Re-adjust the front of the machine. Push up on the leveling joystick to raise the front end of the puller-tensioner and adjust accordingly until pressure is placed on the rear jack stand. (See Figure 11) 14 5 Blue Heron Drive

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4. Anchor the puller-tensioner in two locations. The first position in on the left side of the upper drum, directly in the center of the machine. (See Figure 12) The second position is adjacent to the operator panel. (See Figure 13) Temporary ground anchors or solid structures are required for proper machine anchoring.

Figure 8. Engine Compartment Level or Parallel with Ground

Figure 9. Remove Keeper Pin

Figure 10. Lower Leg Replace Pin

Figure 11. Push Up on Leveling

Figure 12. Anchor

Figure 13. Anchor 15

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D. REEVING THE DRUM 1. Reeve the drum appropriately for the type of operation being performed. When reeving the drums, always start on the inside of the drum, toward the center of the machine and reeve the rope so that it goes over the top of the lower drum and enters within the first groove of the upper drum and comes back around entering on the first groove of the lower drum. The rope then travels to the second groove of the upper drum. Continue reeving accordingly moving one position to the left each time. (See Figure 14) E. GUIDE ROLLERS 1. Align guide rollers to correspond with the pulling position of the reel stand. Loosen guide roller bracket bolts. Slide guide rollers to the left or right to properly align. Re-tighten bolts. Thread poly rope through guide rollers. (See Figure 15)

Figure 14. Continue Reeving, Moving One Position to Left

Figure 15. Thread Poly Rope Through Guide Rollers

F. POSITION REEL ELEVATOR 1. Position and connect reel elevator according to specific reel elevator instructions. G. DETERMINE PULLING OR TENSIONING RANGE Determine the proper pulling or tensioning range for the particular operation. The inside scale of the dynamometer represents pulling or tensioning in the low range, between 500 to 4,500 foot-pounds. The center scale represents tensioning in the high range between 2,500 to 27,500 foot-pounds. The outer scale represents pulling in the high range between 2,500 and 27,500 foot-pounds. (See Figure 16) Figure 16. Dynamometer Scale Settings 16

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To determine pulling or tensioning ranges use the following formula: (See Table 2)

A (Final Sag Tension) minus B (Max Pulling Tension Below Final Sag Tension) minus C (1,000 ft-pounds)= Dynamometer setting Example: Final Sag Tension= 2,500 ft-pounds -minusMaximum Pulling Tension Under Final Sag Tension= 500 ft-pounds Equals: 2,000 ft-pounds -minusTension setting of 1,000 ft-pounds below pulling tension Equals: 1,000 ft-pounds

Table 2 H. SET PULLING/TENSIONING RANGE LEVER 1. Position range lever according to the range of pulling or tensioning being performed. The center position is neutral. The position toward the machine is high range. And the position moving away from the machine is for low range operation. To move the lever, pull out and hold the lever detent then push or pull the lever into the appropriate position. (See Figures 17 & 18) Release detent.

Figure 17. Pull Out and Hold Lever Detent

Figure 18. Push or Pull the Lever to Appropriate Postition

!IMPORTANT! The pulling range lever will not set when there is pressure on the drum. Also, never set or adjust pulling range lever when there is tension on placed conductor. Moving the lever to neutral will release conductor tension.

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I. TENSIONING OPERATION 1. Start the puller tensioner per start up instructions. 2. Engage negative brake by turning negative brake switch one position clockwise. (See Figure 19) 3. Move bull wheel control joystick to the down position. (See Figure 20)

Figure 19. Engage Negative Brake

Figure 20. Move Bull Wheel Joystick to Down Position

4. Set dynamometer according to the specific tensioning range required by turning the dynamometer knob clockwise to increase and counter clockwise to decrease until range is appropriately set. (See Figure 21) 5. Move the bull wheel joystick to the neutral position. (See Figure 22)

Figure 21. Set Dynamometer

Figure 22. Move Bull Wheel Joystick to Neutral Position

6. Disengage the negative brake by turning the negative brake switch counterclockwise.

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7. Move bull wheel joystick to the down position and begin tension operations. (See Figure 23) J. PULLER OPERATION 1. Start the puller tensioner per start up instructions. 2. Engage negative brake by turning negative brake switch one position clockwise. (See Figure 24)

Figure 23. Move Bull Wheel Joystick to Down Position

Figure 24. Engage Negative Brake

3. Move bull wheel control joystick to the down position (See Figure 25) 4. Establish the failsafe emergency brake value at 1,000 foot-pounds above final sag tension. Set level by inserting the turnkey into center of the dynamometer gauge and adjusting the red indicator arm to appropriate failsafe level. (See Figure 26)

Figure 25. Move Bull Wheel Joystick to Down Position

Figure 26. Set Failsafe Emergency Brake Value

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5. Set dynamometer according to the specific pulling range required by turning the dynamometer knob clockwise to increase and counter clockwise to decrease until range is appropriately set. (See Figure 27) 6. Move the bull wheel joystick to the neutral position. (See Figure 28)

Figure 27. Set Dynamometer

Figure 28. Move Bull Wheel Joystick to Neutral Position

7. Disengage the negative brake by turning the negative brake switch counterclockwise. 8. Move bull wheel joystick to the down position and begin pulling operations. The puller-tensioner will continually adjust speed to maintain proper pulling tension throughout operation. (See Figure 29)

Figure 29. Move Bull Wheel Joystick to Down Position

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Maintenance A. GENERAL INSTRUCTIONS

!ATTENTION: Repairs not done by the manufacturer and not allowed by a written authorization relieve the manufacturer of any responsibility in the case of accidents to persons or damages to things and/or the machine, causing the loss of the warranty.

5.

B. LEVELS CONTROL For safety reasons during transport, the machine comes without hydraulic oil and fuel. Fill the levels per the following table:

Amount in liters a. Hydraulic oil level (Appendix 1, callout 1)

180 (47.5 gal)

b. Reduction unit oil level

1.6 (0.4 gal)

c. Parking brake oil level (Appendix 2, callout 10)

0.3 (0.1 gal)

d. Engine oil level (see enclosed engine booklet) e. Fuel level (Appendix 1, callout 4)

50 (13.2 gal)

!ATTENTION: Non-respect for the correct levels causes serious damage to the installed components. !DANGER: Do not ingest hydraulic liquids, fuels, and cooling liquids because they can be injurious to health and potentially lethal. C. TIRE INFLATION PRESSURE Tire inflation pressure has to be 5 bar (72.5 psi).

!ATTENTION: Ignoring proper tire inflation pressure causes dangerous situations during transport operations. D. SUGGESTED LUBRICANTS The manufacturer tests the machine with the following oils and lubricants: a. hydraulic circuit, reduction gear, and stationary brake: IP HYDRUS OIL 46 (ISO HM 46). b. mechanical reduction unit: IP MELLANA-220 (ISO CKC 220). Possible different trademarks must be chosen on the basis of the enclosed table “SUGGESTED LUBRICANTS.” It is possible to use different trademarks with the same characteristics and ISO specifications. When using oil with characteristics and ISO specifications different from the ones declared during testing, completely empty the hydraulic circuit.

!ATTENTION: Using lubricants not in conformity with the technical specifications indicated in the present manual may seriously damage the machine components and, consequently, the invalidate the warranty conditions.

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E. ENDOTHERMIC ENGINE MAINTENANCE See the enclosed use and maintenance booklet. To fill the fuel tank, use the filling cap on the tank (Appendix 1, callout 4).

!DANGER: To fill with fuel, turn off the engine. Before any operation, let the engine cool. F. HYDRAULIC CIRCUIT MAINTENANCE a. Change the hydraulic oil after 500 working hours and, thereafter, every 1500 hours (at least every year). b. Use the suitable tap on the bottom of the tank to discharge the hydraulic oil.

!DANGER: Let the hydraulic oil cool completely before removing it and always use suitable safety gear (gloves, etc.). !ATTENTION: Discharging the oil must be done in conformity with the laws of the relevant country. c. Fill the oil in the tank with the correct quantity (Appendix 1, callout 1).

!ATTENTION: When filling the oil tank, make sure no foreign matter, which could cause irreparable damage to the circuit’s components, enters with the oil. If possible, filter the oil with a 10 µm filter. d. Replace the filter cartridges (Appendix 2, callout 5 & 6) after 500 working hours and, thereafter, every 1500 hours (at least every year). e. Each day, verify the correct operation of the hydraulic oil filters by checking the filter indicators on the control panel. If necessary, replace the cartridges by taking care of the following filtering grade: • Intake filter (Appendix 2, callout 2): 10 µ (nominal values) • Intake filter (Appendix 2, callout 6): 90 µ (nominal values) • Intake filter: 25 µ (nominal values) – opt For further maintenance operations of installed hydraulic components (pumps and motors), refer to the enclosed documentation. G. REDUCTION GEAR MAINTENANCE a. Change the oil of the reduction gear after 50 working hours and, thereafter, every 500 hours (at least every year). b. To discharge the oil of the reduction gear, use the suitable caps on the lower part of the casing of the reduction gear.

!DANGER: Let the hydraulic oil cool completely before removing it and always use suitable safety gear (gloves, etc.). !ATTENTION: Discharging the exhaust oil must be done in conformity with the laws of the relevant country. c. Fill the oil of the reduction gear through the cap located on the upper part of the casing. 22

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!ATTENTION: When filling the oil tank, make sure no foreign matter, which could cause irreparable damage to the circuit’s components, enters with the oil. For further maintenance operations of installed hydraulic components (pumps and motors), refer to the enclosed documentation. H. RADIATOR MAINTENANCE Clean all radiators at least once a year and more if the machine is very dirty.

!ATTENTION: Persons in charge of maintenance, besides wearing all the protection devices shown in this manual, must also wear devices for protecting their respiratory organs. I. GREASING Grease the crown gear of the bull-wheels 2-3 times per day, using the suitable greaser (Appendix 2, callout 2). Grease all other machine parts subjected to rotation or translation, which do not have a grease zerk or an automatic greasing system every week. Use IP ATHESIA GR2 (ISO XBCEA 2) grease or an equivalent trademark on the basis of the enclosed “SUGGESTED LUBRICANTS” Table. J. OTHER PERIODIC OPERATIONS When cleaning the machine, avoid direct jets of water or steam on the components of the electric system of the machine and on the control board. For the other periodic operations, refer to the Summary Table for ordinary maintenance.

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K. SUMMARY TABLE FOR REGULAR MAINTENANCE Following are the procedures and intervals for periodic maintenance.

Part

Object

Daily CL

Interval 50 h 250 h 500 h ST ST

Negative brake

Engine oil Oil filter Cooling liquid Air filter Fuel Fuel filter Hydraulic oil Filters Discs

Reduction gear

Oil

CL

Bull-wheels

Gears

GR

Front plough

Rod

GR

Tire pressure

VF

Stationary brake

GR

Diesel engine (***)

Hydraulic circuit

Axle

1500 h

CL

ST ST

VF CL ST ST1 ST1

CL VF (**) ST1

ST(*)

Legend: CL Check the level (and possibly fill up) GR Grease ST Replace ST1 Replace (only for the first intervention) VF Check (*) At least once a year (**) Check the wear-condition of the discs after an emergency stop. (***) For further information, see the engine booklet.

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ST(*) ST(*)

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Troubleshooting Guide

6.

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Appendices

7.

1. SIDE VIEW

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2. TOP VIEW

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3. SUGGESTED OILS AND GREASES

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8.

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How to Disable the Machine A. TRANSPORT

Before transporting the machine, empty any flammable liquids contained in the machine (oils and fuels). Transport must be done per the specifications described in chapter 3 (Transport and Positioning instructions). B. EXTENDED SERVICE STOP When anticipating an extended service stop (two months at least), protect the external parts with waterproof wax and empty the fuel tank. During a service stop, start the machine at least once every two months and let the machine idle for at least one hour, so the oil enters the hydraulic system to prevent the gaskets from drying. Store the machine under a roof. Do not cover the machine with pieces of cloth and/or plastic materials that may cause an increase in the temperature and/or humidity. If the machine is not used for one or more years, replace the hydraulic oil and hydraulic circuit filters before re-starting the machine. C. STRIPPING Machine stripping has to be done by the manufacturer or by a specialized factory. All the stripping operations must conform to company norms for accident prevention. Waste materials must be divided by type (i.e. iron scrap, aluminium, plastic, rub, etc.) and disposed according to the laws in force. Used oils and polluting substances must be disposed by means of authorized structures in conformity with the laws in force.

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Warranty Information

3.

FACTORY ASSISTANCE Condux International, Incorporated (Condux) can provide further advice regarding any problems with the installation, service, assembly, or disassembly of the Condux AFS608 Hydraulic Puller-Tensioner. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Condux AFS608 Hydraulic Puller-Tensioner can be returned to the factory at any time for service or repair; however, a Return Material Authorization (RMA) must be obtained from Condux before shipping.

9.

Condux will not accept returned items without an RMA. LIMITED WARRANTY Condux International, Incorporated (Condux) extends the following warranty to the original purchaser of these goods for use, subject to the qualifications indicated: Condux warrants to the original purchaser for use that the goods or any component thereof manufactured by Condux will be free from defects in workmanship for the period of one year from the date of purchase, provided such goods are installed, maintained, and used in accordance with Condux’s written instructions. Components not manufactured by Condux, but used within the assembly provided by Condux, are subject to the warranty period as specified by the individual manufacturer of said component, provided such goods are installed, maintained, and used in accordance with Condux’s and the original manufacturer’s written instructions. Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any and all claims arising out of the purchase and use of the goods, shall be limited to the repair and replacement of the goods that do not conform to this warranty. To obtain repair or replacement service under the limited warranty, the purchaser must contact the factory for a Return Material Authorization (RMA). When the RMA is received, send the RMA with the defective part or goods, transportation prepaid, to: Condux International, Inc. 145 Kingswood Drive Mankato, MN 56001 USA THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER THAN AS SET FORTH ABOVE. THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM DATE OF PURCHASE. CONDUX ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THIS PRODUCT, EXCEPT AS STATED IN THIS LIMITED WARRANTY. CONDUX IS NEVER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. 35

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Condux International, Inc.

P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA 1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • e-mail: [email protected] © Copyright 2008, Condux International, Inc. Printed in USA Literature Part Number: 21032644 Revision Number: 1.0

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