Frb518 Hydraulic Tensioner

Comstar Supply,

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

INC

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USER'S GUIDE & SAFETY MANUAL

USER'S GUIDE & SAFETY MANUAL

FRB518 Hydraulic 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

www.comstarsupply.com

Important Safety Notice Before using a Condux FRB518 Hydraulic 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

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

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Table of Contents IMPORTANT SAFETY NOTICE.......................................... 2 1

2

3

4

OPERATING PROCEDURE.............................................. 12

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



A. SET-UP.................................................................... 12

GENERAL DATA AND INSTRUCTIONS............................. 4



B. START UP PROCEDURE.......................................... 12



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



C. STABILIZE TENSIONER........................................... 14



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



D. REEVING THE DRUM.............................................. 15



C. PERFORMANCE........................................................ 4



E. GUIDE ROLLERS..................................................... 15



D. TECHNICAL CHARACTERISTICS ............................ 5



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



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



G. DETERMINE TENSIONING RANGE......................... 16



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



H. SET TENSIONING RANGE LEVER........................... 17 I. TENSIONING OPERATION (Single Drum)................ 18



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





H. GENERAL MAINTENANCE INSTRUCTIONS............ 6



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

J. TENSIONING OPERATION (Two Independent Drums)....................................... 21



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



K. TEMPERATURE LIMITS FOR HYDRAULIC OIL....... 7



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



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

5



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

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



B. PACKING FOR SHIPMENT......................................... 8



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



D. TRANSPORT ON TRAILER........................................ 8



E. POSITIONING AND ANCHORING.............................. 9



F. RESIDUAL RISKS.................................................... 10

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

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



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



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

MAINTENANCE............................................................... 23 A. GENERAL INFORMATION........................................ 23



B. FLUID LEVELS........................................................ 23



C. SUGGESTED LUBRICANTS..................................... 23



D. DIESEL ENGINE MAINTENANCE............................. 23



E. HYDRAULIC CIRCUIT MAINTENANCE.................... 24



F. STATIONARY BRAKE MAINTENANCE.................... 24



G. RADIATOR MAINTENANCE................................... 25



H. GREASING............................................................... 25



I. OTHER PERIODIC OPERATIONS.............................. 25

J. SUMMARY TABLE FOR REGULAR MAINTENANCE........................................................ 26

6

TROUBLESHOOTING GUIDE.......................................... 27

7

HOW TO DISABLE THE MACHINE................................. 33

8



A. TRANSPORT............................................................ 33



B. EXTENDED SERVICE STOP..................................... 33

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

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



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



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

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1.

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General Data And Instructions 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 The FRB518 is a tensioner suitable for stringing one or two conductors. The machine has two bull-wheels with independent controls. The bull-wheels’ grooves are made of high resistance interchangeable nylon. The diesel engine allows the machine to be used as puller for the recovery of conductors at low speeds and for the pre-setting phases; in addition, it hydraulically checks the rotation of the conductor’s reels. Always start the diesel engine when using the machine. C. PERFORMANCE Functioning in Tensioner Mode

Maximum pull Continuous pull Maximum speed

1 conductor 23,000 lbs (10.433 Metric Tons) 18,000 lbs (5.1647 Metric Tons) 1 mph (4.8 Km/hr)

2 conductors 2 x 11,240 lbs (5.0984 Metric Tons) 2 x 9,000 lbs (4.0823 Metric Tons) 3 mph (4.8 Km/hr)

1 conductor

2 conductors

23,000 lbs (10.433 Metric Tons) 18,000 lbs (5.1647 Metric Tons)

2 x 11,240 lbs (5.0984 Metric Tons) 2 x 9,000 lbs (4.0823 Metric Tons)

Functioning in Puller Mode

Maximum pull Continuous pull Recovery speed

.25 mph (.40234 Km/hr) .25 mph (.40234 Km/hr)

!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)



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D. TECHNICAL CHARACTERISTICS Bull-wheels diameter:................60 inches (1,524 mm) Bull-wheels lining:......................nylon sectors Maximum conductor dia.:..........1.57 inches (39.8780 mm) Diesel engine:............................37 HP – 3600 rpm (27.59 Kw) Electric system:.........................12 V Transmission:............................hydraulic circuit with hydraulic oil cooling Safety brake:............................. 2 negative and self-acting type Meter counter:...........................mechanical type Dynamometer:...........................hydraulic type Axle:...........................................Dual Torsion axle with electric brakes, breakaway kit and safety chains. Dimensions:...............................length – 196 inches (4,978 mm) width – 102 inches (2,590 mm) height – 110 inches (2,794 mm) Mass:.........................................14,500 pounds (6,577 kg) 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 the 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 carefully follow danger and/or prohibition prescriptions contained in the instruction manual or indicated on the machine. g. The operator must absolutely avoid direct inhalation of the system’s engine exhaust.

 5 Blue Heron Drive

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

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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.

!ATTENTION: Failure to follow these instructions relieves the manufacturer from any responsibility and voids the warranty. 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. The 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. The 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.



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(610) 831-5020

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Fax: (610) 831-5012

Comstar Supply,

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

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K. TEMPERATURE LIMITS FOR HYDRAULIC OIL When using the machine, always remember to respect the following temperature limits that can be reached with hydraulic oil as function of the working condition. TEMPERATURE LIMITS FOR HYDRAULIC OIL in °F (°C) Hydraulic oil viscosity Working condition VG 22 VG 32 VG 46 VG 68 -5.8 6.8 18 30 Minimum temperature running in neutral position (-21.00) (-14) (-7.778) (-1.111) 46 61 75 90 Minimum temperature running in full load (7.7) (16.1) (23.8) (32.2) 118 135 153 169 Maximum temperature running in full load (47.7) (57.222) (67.2) (76.1) 163 181 199 145 Maximum temperature running in neutral position (72.7) (82.7) (92.7) (62.7) For additional information concerning the hydraulic oil, see the chapter on “Maintenance” and the attached comparative table of the oils used on the machine. L. USE NOT ALLOWED The machine must not be used for the following: a. for lifting persons and/or goods b. in areas where the machine can not be positioned and anchored properly c. in areas with brushwood or other materials that can be easily set on fire d. in closed/unventilated sites or those that are poorly ventilated (tunnels or similar areas) or 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 conductors having a bigger diameter than the one specified in present 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 moving equipment. M. RESPONSIBILITY 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. 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. connecting to the machine and/or plans not produced and not directly authorized by the manufacturer in a written acceptance 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

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

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2.

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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. 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 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. 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.

!ATTENTION: Dispose all packaging materials in accordance with local regulations and in conformity with the norms in force in the relevant country. D. TRANSPORT ON TRAILER

NOTE: This operation must be carried out with a functioning engine. Before transporting this machine, lift the rear stabilizer and the front jack, using the suitable lever and the connecting the safety pin. Check the tires for proper inflation pressure. No personnel may ride on the machine at any time while towing the machine at ANY speed.



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!ATTENTION: It is dangerous to tow the machine at speeds in excess of the tire and axle’s ratings 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 pole or trestle (see Table 1).

Table 1 It is possible to use the machine at a distance from the pole included between 1 and 2 times the height of the pole itself. In this case, the anchorage described thereafter must be over-dimensioned of 125% compared to the reported data and some moorings must be provided on the front side of the machine.

!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. Align the machine as much as possible with the pull direction b. Adjust the rear stabilizers. c. NOTE: This operation must be carried out with a functioning engine Adjust the plow by removing the safety pin, adjusting the pressure by means of the valve and acting on the control lever. d. Anchor the machine to the ground by installing 2 stakes with a minimum rated load equal to 130% of the machine’s rated load. Anchor the machine. e. Install anchoring stakes without tensioning them. f. Test the machine pull to allow the machine to freely align as regards to the pull. g. Tension the anchoring stakes in a uniform way.

!ATTENTION: Dangerous situations may occur during machine use if the anchoring instructions are not followed.



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You must provide proper grounding of the conductor system for this machine. You must maintain a space of at least 7 feet around the machine for ease of use, adjustments, maintenance, etc. Be sure that air can circulate freely around the radiators (diesel motor, hydraulic oil). Otherwise overheating situations with damage for the installed components may happen.

!DANGER: Dangerous situations may occur during machine use if the anchoring instructions are not followed. You must provide proper grounding of the conductor system for this machine. F. 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-conductor connected to the machine. To minimize the risks the operator must • Check the rope and replace it as soon as defects or wear signs appear. • Comply with the working positions indicated in the manual. 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 must: • Periodically check the anchoring stakes and replace them as soon as defects or wear signs appear. • Follow the anchoring indications described in the manual. • Comply with the working positions indicated in the manual. 3. Entangling or dragging in the accessible rotating units. It is not technologically possible to cover some rotating units (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 must: • Avoid contact with the machine’s rotating units except for the control devices. • Follow the anchoring instructions in the manual. • Respect the prescriptions indicated in the manual concerning wearing and using necessary safety devices. 4. Limb crushing during loading or removal of the rope-conductor. These operations have a large risk margin due to the use of mechanical parts to be moved. To minimize the risks the operator must • Know the methods for accident prevention and apply them. 5. Electrostatic discharges. Since the machine does not have a proper grounding device during stringing operations, it is possible to have dangerous electrostatics discharges on ropes and conductors. To minimize the risks the operator must • Know the methods for accident prevention and apply them. • Check the job site for a suitable grounding device for the machine rope-conductors system

10 5 Blue Heron Drive

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Comstar Supply,

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

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6. Inhalation of the diesel engine exhaust. The FRB518 discharges exhaust. To minimize the risks, the operator must: • Follow the working recommendations indicated in the manual. • Heed the ATTENTIONS and PROHIBITIONS indicated in the manual. • Use safety devices for breathing, if necessary.

Safety Conditions

3.

3.

A. SAFETY DEVICES

This machine has the following safety devices: 1. a load-limiting device which automatically stops the diesel 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.

!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 emergeny stop 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.

11

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4.

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Operating Procedure A. SET-UP

1. Position 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 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 multiply 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 tensioner should be positioned 200 feet back. 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 FRB 518 Tensioner. 1. To start the machine, insert the key into the ignition, push in and turn one position clockwise. (See Figure 3 & 3A) 2. Push glow plug toggle switch down. (See Figure 3 & 3A) 3. Wait for yellow glow plug light to turn off. 4. Push ignition key in and turn the key clockwise to start. 5. Adjust engine throttle to 2,200 rpm. (See Figure 4 & 3A) 6. Set cooling fan to 700 psi., 50 bar. (See Figure 5 & 3A) 7. Set reel elevator hydraulic pressure to 500 psi., 40 bar. (See Figure 6 & 3A)

12

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Figure 3. Insert the Key, Turn Clockwise, Push Glow Plug Down Fax: (610) 831-5012

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ITEM # QTY 1 2 2 2 3 2 4 2 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 2 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 3 22 2 23 2 24 1 25 2 26 2 27 3 28 1 29 2 30 5 31 5 32 2 33 1 34 1 35 1 36 1 37 1

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DESCRIPTION CONDUX P/N DYNAMOMETER 21011583 KEY, DYNAMOMETER SETTING 21011080 COUNTER, DISTANCE 21011538 COUNTER, SPEED 21011559 SWITCH, EMERGENCY STOP 21011250 PLATE, EMERGENCY STOP SWITCH 21011251 DISPLAY, ENGINE RPM & RUNNING TIME 21011544 FUSE HOLDER 21011442 LENS, ALARM 21011125 LENS, GLOW PLUG 21011122 LENS, LOW ENG. OIL PRESSURE 21011115 LENS, ALTERNATOR FAILURE 21011114 LENS, FILTER CLOGGED 21011121 LENS, HIGH ENGINE TEMPERATURE 21011092 GAGE, FUEL LEVEL 21011623 GAGE, HYDRAULIC OIL TEMPERATURE 21011333 SWITCH, KEY START 21011435 SWITCH, BYPASS STARTING 21011112 CONTROL, ENGINE SPEED 21011098 JOY STICK, FRONT PLOW 21011098 SWITCH, SELECTOR 21011568 GAGE, REEL WINDER & FAN PRESSURE 21011077 VALVE, REEL WINDER & FAN CONTROL 21011286 GAGE, FEEDING PRESSURE 21011075 POTENTIOMETER, PULL ADJUST 21011123 HANDLE, PULL ADJUST POTENTIOMETER 21011089 SWITCH, SELECTOR 21011099 LAMP, INDICATOR 21011624 JOY STICK, CAPSTAN 21011100 LATCH, PANEL 21011445 FUSE - 3 AMP 21011431 FUSE - 5 AMP 21011102 FUSE - 20 AMP 21011561 LABEL, MAX. HYD. OIL TEMPERATURE 08763187 LABEL, MIN. OPERATING PRESSURE 08763188 08763189 LABEL, MAX. OPERATING PRESSURE LABEL, MIN. OPERATING PRESSURE 21032311

Figure 3A. Control Panel Identification 5 Blue Heron Drive

Collegeville, PA 19426

(610) 831-5020

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REF. 08100402 08200403 09100699 09100700 09101190 09100941 09101302 09100515 09102713 09102550 09102136 09102135 09102549 09101004 09102552 09102045 09102990 09102064 09101196 09101196 09101229 08100067 07300158 08100061 09102609 09100668 09101216 09101202 09101230 09101275 09101761 09101381 09102692 -----------------

13

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Figure 4. Adjust Engine Throttle

Figure 5. Set Cooling Fan

Figure 6. Set Reel Elevator Hydraulic Pressure

Figure 7. Engage Leveling Joystick Down

C. STABILIZE 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. 2. Re-adjust the rear stabilizer leg by removing the keeper pin and lowering the leg as close to the ground as possible and replace pin. (See Figure 8) 3. Readjust the front of the machine. Push up on the leveling joystick to raise the front end of the tensioner and adjust accordingly until pressure is placed on the rear jack stand. 4. Anchor the 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 9) The second position is adjacent to the operator panel. (See Figure 10) Temporary ground anchors or solid structures are required for proper machine anchoring.

14 5 Blue Heron Drive

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Figure 8. Lower Leg Replace Pin

Figure 9. Anchor, Left Side Upper Drum, Directly in Center of Machine

Figure 10. Anchor, Adjacent to the Operator Panel

Figure 11. Reeving the Drum

D. REEVING THE DRUM 1. Reeve the drum appropriately for the tensioning configuration being used, single drum or two independent drums. When reeving the drums, reeve toward the center of the machine so that 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 11) E. GUIDE ROLLERS 1. Align guide rollers to correspond with the 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 12)

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Figure 12. Thread Poly Rope Through Guide Rollers F. POSITION REEL ELEVATOR 1. Position and connect reel elevator according to specific reel elevator instructions. G. DETERMINE TENSIONING RANGE Determine the proper tensioning range for the particular operation. The FRB 518 can accommodate up to two reel elevators at one time. The hydraulic connections for reel elevator number one are located on the left. The hydraulic connections for reel elevator number two are located on the right. If using URW series reel elevator(s), use the hydraulic connections located above connections set one and two. The inside scale of the dynamometer represents pulling or tensioning in the low range, between 400 to 1,500 foot-pounds. The center scale represents tensioning in the high range between 1,500 to 10,000 foot-pounds. The outer scale represents pulling in the high range between 1,500 and 10,000 foot-pounds. 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

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H. SET TENSIONING RANGE LEVER 1. Position range lever(s) (See Figure 13) according to the range of tensioning being performed and the configuration of the tensioner. For example if the tensioner is being used as a single drum, both the number 1 and number 2 range levers need to be set. If utilizing the unit as two independent drums, set the range lever that corresponds to the drum being used. Or set both according to their independent tensioning ranges. 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 Figure 14) Release detent.

Figure 13. Position Range Lever

Figure 14. Put Lever into Proper Position, Release Detent

!IMPORTANT: The tensioning range lever will not set when there is pressure on the drum. Also, never set or adjust tensioning 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 (Single Drum) 1. Mechanically lock drums together. The drums need to be aligned properly in order to insert the locking rod in place. Once drums are aligned, remove drum cover, insert and secure locking rod and replace cover. (See Figures 15-18)

Figure 15. Remove Drum Cover

Figure 16. Locking Rod

Figure 17. Remove Locking Rod

Figure 18. Secure Locking Rod inside Drum Cover

!Important: After aligning the drums, make sure to shut the unit off before installing the locking rod. Never install the locking rod while the machine is running.

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2. Set drum configuration selector to single drum. (See Figure 19 & 3A) 3. Start the tensioner per start up instructions. 4. Set operating speed to slow (snail). (See Figure 20 & 3A) 5. Engage negative brake under the number 2 control set or the center control set by turning either negative brake switch one position clockwise. (See Figure 21 & 3A) 6. Move bull wheel control joystick to the down position. (See Figure 22 & 3A)

Figure 19. Set drum configuration selector to single drum

Figure 20. Set Operating Speed to Slow (snail)

Figure 21. Engage Negative Brake

Figure 22. Move Bull Wheel Joystick to the Down Position

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7. 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 23 & 3A) 8. Move the bull wheel joystick to the neutral position. (See Figure 24 & 3A) 9. Disengage the negative brake by turning the negative brake switch counterclockwise. (See Figure 25 & 3A) 10. Moving bull wheel joystick to the down position and begin tension operations. (See Figure 26 & 3A)

Figure 23. Set Dynamometer

Figure 24. Move Bull Wheel Joystick to Neutral Position

Figure 25. Disengage Negative Brake

Figure 26. Move Bull Wheel Joystick to Down Position

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J. TENSIONING OPERATION (Two Independent Drums) 1. Start the tensioner per start up instructions. 2. Set operating speed to slow (snail). (See Figure 27 & 3A) 3. Set drum configuration selector to two independent drums. 4. Engage negative brake under the corresponding drum being used (Number 1 or Number 2 or both) by turning negative brake switch one position clockwise. (See Figure 28 & 3A) 5. Move bull wheel control(s) joystick to the down position. (See Figure 29 & 3A) 6. Set dynamometer(s) according to the specific tensioning range required by turning the dynamometer knob(s) clockwise to increase and counter clockwise to decrease until range(s) is appropriately set. (See Figure 30 & 3A)

Figure 27. Set Operating Speed to Slow (snail)

Figure 28. Engage Negative Brake

Figure 29. Move Bull Wheel Joystick to Down Position

Figure 30. Set Dynamometer

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7. Move the bull wheel joystick(s) to the neutral position. (See Figure 31 & 3A) 8. Disengage the negative brake(s) by turning the negative brake switch(es) counterclockwise. (See Figure 32 & 3A) 9. Moving bull wheel joystick(s) to the down position and begin tension operations. (See Figure 33 & 3A)

Figure 31. Move Bull Wheel Joystick to Neutral Position

Figure 32. Disengage Negative Brake

Figure 33. Move Bull Wheel Joystick to Down Position

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Maintenance A. GENERAL INFORMATION

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

5.

B. FLUID LEVELS For safety reasons, during the transport machine comes without hydraulic oil and fuel. Fill the levels as per the following table: Quantity a. Hydraulic oil level

71 Gallons (268.69 liters)

b. Engine oil level

See enclosed engine booklet

c. Reduction gear oil level

0.42 Gallons (1.5894 liters)

d. Negative brake oil level

0.08 Gallons (0.3027 liters)

e. Fuel level

4 Gallons (15.137 liters)

!ATTENTION: Disregarding the correct fluid levels causes serious damage to the machine’s components. !DANGER: Do not ingest hydraulic liquids, fuels, and cooling liquids. They may be injurious to health and potentially lethal. C. SUGGESTED LUBRICANTS The manufacturer tests the machine with the following oils and lubricants: a. Hydraulic circuit and stationary brake: IP HYDRUS OIL 46 (ISO VG 46). b. Mechanical reduction gear: IP MELLANA 220 (ISO CKC 220). Possible different trademarks must be chosen based on the enclosed table “SUGGESTED LUBRICANTS.” It is possible to use different trademarks but with same characteristics and ISO specifications. When using oil with characteristics and ISO specifications different from the ones declared during test, completely empty the hydraulic circuit.

!ATTENTION: Using lubricants not in conformity with the technical specifications indicated in the present manual seriously damages the machine components and, consequently, invalidating the warranty conditions. D. DIESEL ENGINE MAINTENANCE For specific maintenance of the engine, see the enclosed use and maintenance booklet. For filling the fuel, use the filling cap on the tank.

!DANGER: Turn off and cool the engine before any filling operation.

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E. HYDRAULIC CIRCUIT MAINTENANCE Change the hydraulic oil after 500 working hours and, thereafter, every 1500 hours (or at least every year). a. To drain the exhaust hydraulic oil tank, use the cap located on the bottom of the tank.



!DANGER: Cool the hydraulic oil completely before removing it. Always use suitable safety gear (gloves, etc.).



!ATTENTION: Disposing of used oil must be done in conformity with the laws in force in the relevant country.

b. Use the correct quantity of oil in the tank.



!ATTENTION: When filling the oil tank, be sure no foreign matter, which could cause irreparable damages to the circuit’s components, enters with the oil. If possible filter the oil with a 10 µm filter.

c. Replace the filter cartridges after 500 working hours and, thereafter, every 1500 hours (or every year at least). d. Each day, check the oil filters by means of the pilot lamps. If necessary, replace the cartridges per the following: • suction filter 25 µ (F2) • return filter 25 µ (F1) For further maintenance of hydraulic components (pumps and motors), refer to the enclosed documentation. F. STATIONARY BRAKE MAINTENANCE a. Change the oil of the reel winder stationary brake after 50 working hours and, thereafter, every 500 hours (or at least every year). b. To drain the oil of the reel winder stationary brake, use the suitable caps on the lower part of the casing.

!DANGER: Completely cool the hydraulic oil before removing it. Always use suitable safety gear (gloves, etc.). !ATTENTION: Disposing of used oils must be done in conformity with the laws of the relevant country. c. Fill the oil of the reel winder stationary brake using caps on the upper part of the casing.

!ATTENTION: When filling the oil, make sure no foreign matter, which could cause irreparable damages to the circuit’s components, enters with the oil. For further maintenance operations of mechanical components (reduction gears, negative brakes), refer to the enclosed documentation. 24

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G. RADIATOR MAINTENANCE At least once a year (or more when used in dusty places) use compressed air to clean the radiators.

!ATTENTION: Always use suitable safety gear (gloves, etc.) and breathing apparatus. H. GREASING Grease the crown gear of the bull-wheels 2-3 times per day using the suitable greaser check the crowns from the inspection doors Every week, grease all other parts subjected to rotation or translation that do not have an automatic greasing schedule. Use IP ATHESIA GR2 (ISO XBCEA 2) grease or grease of an equivalent trademark based on the enclosed “SUGGESTED LUBRICANTS” table. I. 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 panel. For the other periodic operations, refer to the summary table for ordinary maintenance (see next page).

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J. SUMMARY TABLE FOR REGULAR MAINTENANCE This table lists the main operations of periodic maintenance and relevant intervals.

Part

Diesel engine

Hydraulic circuit Negative brake

Object Engine oil Oil filter Cooling liquid Air filter Fuel Fuel filter Hydraulic oil Filter Oil

Daily CL

50 h

1500 h

CL

ST ST

VF CL CL VF CL

ST1

ST ST1 ST1 ST(*)

ST1

ST(*)

Discs

Reduction gear

Oil

CL

Bull-wheels

Gears

GR

Front plow

Sliding Rod

GR

Tire pressure

VF

Stationary brake

GR

Axle

Interval 250 h 500 h ST 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

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ST(*) ST(*)

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Troubleshooting Guide

6.

Blown fuse Low battery

starts

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correct

When activating the control lever the bull-wheels don’t work (electric control)

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release

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cooling fan for the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm

cooling fan for the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm

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The cooling fan for the hydraulic oil cooling fan The cooling fan for the hydraulic oil

cooling fan

cooling fan cooling fan hydraulic motor cooling fan pump

cooling fan for the hydraulic oil radiator and by completely opening the reel winder valve with diesel engine at medium-high rpm

plow

plow plow

plow

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How to Disable the Machine A. TRANSPORT

Before transporting the machine, empty flammable liquids in the machine (oils and fuels). Transport must be done per the specifications described in chapter 2 (Transport and Positioning).

7.

B. EXTENDED SERVICE STOP When anticipating an extended unit storage (two months at least) protect the external parts with waterproof wax and empty the fuel tank. During extended storage, start the machine at least once every two months and let the machine idle for one hour at least. This allows the oil to enter the hydraulic system and prevents the gaskets from drying. Store the machine under a roof. Do not cover the machine with pieces of cloth and/ or plastic materials that could cause an excessive increase of temperature and/or humidity. If the machine is not used for a year or more, replace the hydraulic oil and hydraulic circuit filters before re-starting the machine.

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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 FRB518 Hydraulic Tensioner. Call toll free at 1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The Condux FRB518 Hydraulic 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.

8.

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 2007, Condux International, Inc. Printed in USA Literature Part Number: 21032344 Revision Number: 1.0

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