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C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

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USER'S GUIDE & SAFETY MANUAL

USER'S GUIDE & SAFETY MANUAL

FRB518 Hydraulic Tensioner

GUIDE & SAFETY MANUAL FRB518 Hydraulic Tensioner 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

5 Blue Heron Drive

SAFETY MANUAL FRB518 Hydraulic Tensioner 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
SAFETY MANUAL FRB518 Hydraulic Tensioner 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

Hydraulic Tensioner 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012
Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 Important Safety Notice 5

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

Important Safety Notice

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

www.comstarsupply.com

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.

comprende las instrucciones favor de consultarle a su jefe. Save this user’s guide for future reference.
comprende las instrucciones favor de consultarle a su jefe. Save this user’s guide for future reference.
comprende las instrucciones favor de consultarle a su jefe. Save this user’s guide for future reference.
comprende las instrucciones favor de consultarle a su jefe. Save this user’s guide for future reference.
comprende las instrucciones favor de consultarle a su jefe. Save this user’s guide for future reference.

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 5600-047

1-507-387-6576

Fax 1-507-387-144

E-mail: cndxinfo@condux.com

For questions on: SAFETY - OPERATIONS - APPLICATIONS CALL 1-800-533-077

For questions on:

SAFETY - OPERATIONS - APPLICATIONS

CALL 1-800-533-077

5 Blue Heron Drive

- APPLICATIONS CALL 1-800-533-077  5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
- APPLICATIONS CALL 1-800-533-077  5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

CALL 1-800-533-077  5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

CALL 1-800-533-077  5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

CALL 1-800-533-077  5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

Table of Contents

 

IMPORTANT SAFETY NOTICE

2

COMMUNICATION WITH THE MANUFACTURER

2

1
1

GENERAL DATA AND INSTRUCTIONS

4

A. COMMUNICATION WITH THE MANUFACTURER

4

B. TYPOLOGY AND FIELD USE

4

C. PERFORMANCE

4

D. TECHNICAL CHARACTERISTICS

5

E. ACOUSTIC EMISSION

5

F. GENERAL SAFETY INFORMATION

5

G. GENERAL OPERATOR INSTRUCTIONS

5

H. GENERAL MAINTENANCE INSTRUCTIONS

6

I. THE INSTRUCTION MANUAL

6

J. CONDITION OF USE

6

K. TEMPERATURE LIMITS FOR HYDRAULIC OIL

7

L. USE NOT ALLOWED

7

M. RESPONSIBILITY

7

2
2

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

3
3

SAFETY CONDITIONS

11

A. SAFETY DEVICES

11

B. EMERGENCY STOP DEVICE

C. PERIODIC OPERATIONS

11

11

4
4

OPERATING PROCEDURE

12

A. SET-UP

12

B. START UP PROCEDURE

12

C. STABILIZE TENSIONER

14

D. REEVING THE DRUM

15

E. GUIDE ROLLERS

15

F. POSITION REEL ELEVATOR

16

G. DETERMINE TENSIONING RANGE

16

H. SET TENSIONING RANGE LEVER

17

I. TENSIONING OPERATION (Single Drum)

18

J. TENSIONING OPERATION (Two Independent Drums)

21

5
5

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

 

26

6
6

TROUBLESHOOTING GUIDE

27

7
7

HOW TO DISABLE THE MACHINE

33

A. TRANSPORT

33

B. EXTENDED SERVICE STOP

33

8
8

WARRANTY INFORMATION

35

FACTORY ASSISTANCE

35

LIMITED WARRANTY

35

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35 LIMITED WARRANTY 35 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
35 LIMITED WARRANTY 35 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

WARRANTY 35 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 3

(610) 831-5020

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WARRANTY 35 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 3

Fax: (610) 831-5012

3

WARRANTY 35 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 3
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

General Data And Instructions

 

A.

COMMUNICATIONS WITH THE MANUFACTURER

1.

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

 

1

conductor

2

conductors

Maximum pull

3,000 lbs (10.433 Metric Tons)

x 11,40 lbs (5.0984 Metric Tons)

Continuous pull

18,000 lbs (5.1647 Metric Tons)

x 9,000 lbs

(4.083 Metric Tons)

Maximum speed

1 mph (4.8 Km/hr)

3 mph (4.8 Km/hr)

Maximum speed 1 mph (4.8 Km/hr) 3 mph (4.8 Km/hr) 4 5 Blue Heron Drive Functioning

4

5 Blue Heron Drive

1 mph (4.8 Km/hr) 3 mph (4.8 Km/hr) 4 5 Blue Heron Drive Functioning in Puller

Functioning in Puller Mode

 

1

conductor

2

conductors

Maximum pull

3,000 lbs (10.433 Metric Tons)

x 11,40 lbs (5.0984 Metric Tons)

Continuous pull

18,000 lbs (5.1647 Metric Tons)

x 9,000 lbs

(4.083 Metric Tons)

Recovery speed

.5 mph (.4034 Km/hr)

.5 mph (.4034 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 0°C (68°F)

optional equipment, at sea level and at 0°C (68°F) Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

at sea level and at 0°C (68°F) Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

at sea level and at 0°C (68°F) Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

at sea level and at 0°C (68°F) Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 D. TECHNICAL CHARACTERISTICS Bull-wheels

Comstar supply, INC

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D. TECHNICAL CHARACTERISTICS

Bull-wheels diameter:

Bull-wheels lining:

Maximum conductor dia.:

60

inches (1,54 mm)

nylon sectors

1.57 inches (39.8780 mm)

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

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Diesel engine:

37

HP – 3600 rpm (7.59 Kw)

Electric system:

1

V

Transmission:

hydraulic

circuit with hydraulic oil cooling

Safety brake:

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 – 10 inches (,590 mm)

height – 110 inches (,794 mm)

Mass:

14,500

pounds (6,577 kg)

E. ACOUSTIC EMISSION

Level of continuous sound pressure to the operator seat (UNI 943) 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

of the system’s engine exhaust. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
of the system’s engine exhaust. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

engine exhaust. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 5

(610) 831-5020

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engine exhaust. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 5

Fax: (610) 831-5012

5

engine exhaust. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 5
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

610-831-5020 Fax: 610-831-5012 www.comstarsupply.com H. GENERAL MAINTENANCE INSTRUCTIONS a. It is absolutely
610-831-5020 Fax: 610-831-5012 www.comstarsupply.com H. GENERAL MAINTENANCE INSTRUCTIONS a. It is absolutely

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. Temperature:

b. Relevant moisture:

c. Weather conditions:

d. Natural and/or artificial light of the work site.

from -10°C to +40°C. (14°F to 104°F)

from 30% to 90% ± 5%.

any (in line with working conditions).

6

5 Blue Heron Drive

any (in line with working conditions). 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020
any (in line with working conditions). 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

Collegeville, PA 19426

working conditions). 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

working conditions). 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

working conditions). 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

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1-866-326-6782

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

www.comstarsupply.com

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)

 

Working condition

Hydraulic oil viscosity

 

VG 22

VG 32

VG 46

VG 68

 

-5.8

6.8

18

30

Minimum temperature running in neutral position

(-1.00)

(-14)

(-7.778)

(-1.111)

Minimum temperature running in full load

46

61

75

90

(7.7)

(16.1)

(3.8)

(3.)

 

118

135

153

169

Maximum temperature running in full load

(47.7)

(57.)

(67.)

(76.1)

Maximum temperature running in neutral position

145

163

181

199

(6.7)

(7.7)

(8.7)

(9.7)

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

the manufacturer in a written acceptance 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
the manufacturer in a written acceptance 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

a written acceptance 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

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a written acceptance 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

7

a written acceptance 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

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

www.comstarsupply.com

Transport and Positioning Instructions

2.

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 capac- ity equal to or greater than the mass to be lifted and must be connected to the proper points on the machine.

and must be connected to the proper points on the machine. Personnel should not be on

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.

Immediately notify the manufacturer of any discrepancies. Use caution when unpacking to avoid damaging the product.

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.

8

5 Blue Heron Drive

and the connecting the safety pin. 8 5 Blue Heron Drive Check the tires for proper

Check the tires for proper inflation pressure.

No personnel may ride on the machine at any time while towing the machine at ANY

speed.

machine at any time while towing the machine at ANY speed. Collegeville, PA 19426 (610) 831-5020

Collegeville, PA 19426

while towing the machine at ANY speed. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

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while towing the machine at ANY speed. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

while towing the machine at ANY speed. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 !ATTENTION: It is dangerous

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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.

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

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610-831-5020 Fax: 610-831-5012 www.comstarsupply.com E. POSITIONING AND ANCHORING Positioning and anchoring the

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 times and no greater than 4 times the height of the first pole or trestle (see Table 1).

times the height of the first pole or trestle (see Table 1). Table 1 It is

Table 1

It is possible to use the machine at a distance from the pole included between 1 and times the height of the pole itself. In this case, the anchorage described thereafter must be over-dimensioned of 15% 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 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.

machine use if the anchoring instructions are not followed. 9 5 Blue Heron Drive Collegeville, PA
machine use if the anchoring instructions are not followed. 9 5 Blue Heron Drive Collegeville, PA

9

5 Blue Heron Drive

instructions are not followed. 9 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
instructions are not followed. 9 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

are not followed. 9 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)

(610) 831-5020

www.comstarsupply.com

are not followed. 9 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)

Fax: (610) 831-5012

are not followed. 9 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

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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.

the machine for ease of use, adjustments, maintenance, etc. Be sure that air can circulate freely

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.

. 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

for the machine rope-conductors system 10 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
for the machine rope-conductors system 10 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

system 10 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

system 10 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

system 10 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

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

A. SAFETY DEVICES

3. 3.

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. 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.

An emergency stop device acts directly on the diesel engine. !ATTENTION: Use the emergency stop device
An emergency stop device acts directly on the diesel engine. !ATTENTION: Use the emergency stop device

!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.

stop push-button one quarter turn in a clockwise direction. !PROHIBITION: Use the emergency stop device only

!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.

as a consequence of the non-functioning of those devices. 5 Blue Heron Drive Collegeville, PA 19426

5 Blue Heron Drive

of the non-functioning of those devices. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
of the non-functioning of those devices. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

of those devices. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

of those devices. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

11

of those devices. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

Operating Procedure

4.

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 - degree fleet angle. This distance can be calculated by multiply .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 00 feet back.

. 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 )

to the ground as possible and replacing pin. (See Figure ) 1 5 Blue Heron Drive

1

5 Blue Heron Drive

and replacing pin. (See Figure ) 1 5 Blue Heron Drive Figure 1. Remove Keeper Pin
and replacing pin. (See Figure ) 1 5 Blue Heron Drive Figure 1. Remove Keeper Pin

Figure 1. Remove Keeper Pin

B. START UP PROCEDURE

Drive Figure 1. Remove Keeper Pin B. START UP PROCEDURE Figure 2. Lower Leg, Replace Pin

Figure 2. Lower Leg, Replace Pin

!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) 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 ,00 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)

pressure to 500 psi., 40 bar. (See Figure 6 & 3A) Collegeville, PA 19426 (610) 831-5020

Collegeville, PA 19426

psi., 40 bar. (See Figure 6 & 3A) Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Figure 3.

(610) 831-5020

www.comstarsupply.com

Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Figure 3. Insert the Key, Turn Clockwise, Push Glow Plug

Figure 3. Insert the Key, Turn Clockwise, Push Glow Plug Down

(610) 831-5020 www.comstarsupply.com Figure 3. Insert the Key, Turn Clockwise, Push Glow Plug Down Fax: (610)

Fax: (610) 831-5012

(610) 831-5020 www.comstarsupply.com Figure 3. Insert the Key, Turn Clockwise, Push Glow Plug Down Fax: (610)
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

ITEM # QTY DESCRIPTION CONDUX P/N REF. 1  DYNAMOMETER 1011583 0810040   KEY,

ITEM #

QTY

DESCRIPTION

CONDUX P/N

REF.

1

DYNAMOMETER

1011583

0810040

KEY, DYNAMOMETER SETTING

1011080

0800403

3

COUNTER, DISTANCE

1011538

09100699

4

COUNTER, SPEED

1011559

09100700

5

1

SWITCH, EMERGENCY STOP

101150

09101190

6

1

PLATE, EMERGENCY STOP SWITCH

101151

09100941

7

1

DISPLAY, ENGINE RPM & RUNNING TIME

1011544

0910130

8

1

FUSE HOLDER

101144

09100515

9

1

LENS, ALARM

101115

0910713

10

1

LENS, GLOW PLUG

10111

0910550

11

1

LENS, LOW ENG. OIL PRESSURE LENS, ALTERNATOR FAILURE

1011115

0910136

1

1

1011114

0910135

13

LENS, FILTER CLOGGED

101111

0910549

14

1

LENS, HIGH ENGINE TEMPERATURE

101109

09101004

15

1

GAGE, FUEL LEVEL

101163

091055

16

1

GAGE, HYDRAULIC OIL TEMPERATURE

1011333

0910045

17

1

SWITCH, KEY START

1011435

0910990

18

1

SWITCH, BYPASS STARTING

101111

0910064

19

1

CONTROL, ENGINE SPEED JOY STICK, FRONT PLOW SWITCH, SELECTOR

1011098

09101196

0

1

1011098

09101196

1

3

1011568

091019

GAGE, REEL WINDER & FAN PRESSURE VALVE, REEL WINDER & FAN CONTROL GAGE, FEEDING PRESSURE

1011077

08100067

3

101186

07300158

4

1

1011075

08100061

5

POTENTIOMETER, PULL ADJUST HANDLE, PULL ADJUST POTENTIOMETER SWITCH, SELECTOR

101113

0910609

6

1011089

09100668

7

3

1011099

0910116

8

1

LAMP, INDICATOR JOY STICK, CAPSTAN

101164

091010

9

1011100

0910130

30

5

LATCH, PANEL

1011445

0910175

31

5

FUSE - 3 AMP FUSE - 5 AMP

1011431

09101761

3

101110

09101381

33

1

FUSE - 0 AMP

1011561

091069

34

1

LABEL, MAX. HYD. OIL TEMPERATURE

08763187

-----

35

1

LABEL, MIN. OPERATING PRESSURE

08763188

-----

36

1

LABEL, MAX. OPERATING PRESSURE

08763189

-----

37

1

LABEL, MIN. OPERATING PRESSURE

103311

-----

5 Blue Heron Drive

OPERATING PRESSURE 103311 ----- 5 Blue Heron Drive Figure 3A. Control Panel Identification Collegeville, PA

Figure 3A. Control Panel Identification

5 Blue Heron Drive Figure 3A. Control Panel Identification Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

Figure 3A. Control Panel Identification Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com 13 Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Figure 3A. Control Panel Identification Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com 13 Fax: (610) 831-5012

13

Fax: (610) 831-5012

Figure 3A. Control Panel Identification Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com 13 Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 Figure 4. Adjust Engine

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

s upply , INC Think Cable Think Comstar 1-866-326-6782 Figure 4. Adjust Engine Throttle Figure 6.

Figure 4. Adjust Engine Throttle

Comstar 1-866-326-6782 Figure 4. Adjust Engine Throttle Figure 6. Set Reel Elevator Hydraulic Pressure 5 Blue

Figure 6. Set Reel Elevator Hydraulic Pressure

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

www.comstarsupply.com

610-831-5020 Fax: 610-831-5012 www.comstarsupply.com Figure 5. Set Cooling Fan Figure 7. Engage Leveling Joystick

Figure 5. Set Cooling Fan

610-831-5012 www.comstarsupply.com Figure 5. Set Cooling Fan Figure 7. Engage Leveling Joystick Down C. STABILIZE

Figure 7. Engage Leveling Joystick Down

5. Set Cooling Fan Figure 7. Engage Leveling Joystick Down C. STABILIZE TENSIONER 1. Set the

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.

.

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

required for proper machine anchoring. 14 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
required for proper machine anchoring. 14 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

machine anchoring. 14 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

machine anchoring. 14 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

machine anchoring. 14 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 Figure 8. Lower Leg

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

s upply , INC Think Cable Think Comstar 1-866-326-6782 Figure 8. Lower Leg Replace Pin Figure

Figure 8. Lower Leg Replace Pin

Think Comstar 1-866-326-6782 Figure 8. Lower Leg Replace Pin Figure 10. Anchor, Adjacent to the Operator

Figure 10. Anchor, Adjacent to the Operator Panel

D. REEVING THE DRUM

Anchor, Adjacent to the Operator Panel D. REEVING THE DRUM Figure 9. Anchor, Left Side Upper

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

Anchor, Left Side Upper Drum, Directly in Center of Machine Figure 11. Reeving the Drum 5

Figure 11. Reeving the Drum

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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 1)

5 Blue Heron Drive

through guide rollers. (See Figure 1) 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
through guide rollers. (See Figure 1) 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

(See Figure 1) 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

(See Figure 1) 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

15

(See Figure 1) 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 Figure 12. Thread Poly

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

s upply , INC Think Cable Think Comstar 1-866-326-6782 Figure 12. Thread Poly Rope Through Guide

Figure 12. Thread Poly Rope Through Guide Rollers

F. POSITION REEL ELEVATOR

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

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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 )

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= ,500 ft-pounds

-minus-

Maximum Pulling Tension Under Final Sag Tension= 500 ft-pounds Equals: ,000 ft-pounds

-minus-

Tension setting of 1,000 ft-pounds below pulling tension Equals: 1,000 ft-pounds

16

5 Blue Heron Drive

tension Equals: 1,000 ft-pounds 16 5 Blue Heron Drive Collegeville, PA 19426 Table 2 (610) 831-5020
tension Equals: 1,000 ft-pounds 16 5 Blue Heron Drive Collegeville, PA 19426 Table 2 (610) 831-5020

Collegeville, PA 19426

1,000 ft-pounds 16 5 Blue Heron Drive Collegeville, PA 19426 Table 2 (610) 831-5020 www.comstarsupply.com Fax:

Table 2

(610) 831-5020

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ft-pounds 16 5 Blue Heron Drive Collegeville, PA 19426 Table 2 (610) 831-5020 www.comstarsupply.com Fax: (610)

Fax: (610) 831-5012

ft-pounds 16 5 Blue Heron Drive Collegeville, PA 19426 Table 2 (610) 831-5020 www.comstarsupply.com Fax: (610)
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 H. SET TENSIONING RANGE

Comstar supply, INC

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H. SET TENSIONING RANGE LEVER

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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 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.

the appropriate position. (See Figure 14) Release detent. Figure 13. Position Range Lever Figure 14. Put

Figure 13. Position Range Lever

Figure 14) Release detent. Figure 13. Position Range Lever Figure 14. Put Lever into Proper Position,

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.

Moving the lever to neutral will release conductor tension. 5 Blue Heron Drive Collegeville, PA 19426

5 Blue Heron Drive

neutral will release conductor tension. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
neutral will release conductor tension. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

conductor tension. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 17

(610) 831-5020

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conductor tension. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 17

Fax: (610) 831-5012

17

conductor tension. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 17
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 I. TENSIONING OPERATION (SINGLE

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I. TENSIONING OPERATION (SINGLE DRUM)

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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)

secure locking rod and replace cover. (See Figures 15-18) 18 5 Blue Heron Drive Figure 15.

18

5 Blue Heron Drive

and replace cover. (See Figures 15-18) 18 5 Blue Heron Drive Figure 15. Remove Drum Cover
and replace cover. (See Figures 15-18) 18 5 Blue Heron Drive Figure 15. Remove Drum Cover

Figure 15. Remove Drum Cover

15-18) 18 5 Blue Heron Drive Figure 15. Remove Drum Cover Figure 17. Remove Locking Rod

Figure 17. Remove Locking Rod

Figure 15. Remove Drum Cover Figure 17. Remove Locking Rod Figure 16. Locking Rod Figure 18.

Figure 16. Locking Rod

Cover Figure 17. Remove Locking Rod Figure 16. Locking Rod Figure 18. Secure Locking Rod inside

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.

Never install the locking rod while the machine is running. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

locking rod while the machine is running. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

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locking rod while the machine is running. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

locking rod while the machine is running. Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

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. 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 0 & 3A)

5. Engage negative brake under the number control set or the center control set by turning either negative brake switch one position clockwise. (See Figure 1 & 3A)

6. Move bull wheel control joystick to the down position. (See Figure & 3A)

joystick to the down position. (See Figure  & 3A) Figure 19. Set drum configuration selector

Figure 19. Set drum configuration selector to single drum

Figure 19. Set drum configuration selector to single drum Figure 21. Engage Negative Brake Figure 20.

Figure 21. Engage Negative Brake

selector to single drum Figure 21. Engage Negative Brake Figure 20. Set Operating Speed to Slow

Figure 20. Set Operating Speed to Slow (snail)

Brake Figure 20. Set Operating Speed to Slow (snail) Figure 22. Move Bull Wheel Joystick to

Figure 22. Move Bull Wheel Joystick to the Down Position

5 Blue Heron Drive

Bull Wheel Joystick to the Down Position 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020
Bull Wheel Joystick to the Down Position 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

Collegeville, PA 19426

to the Down Position 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)

(610) 831-5020

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to the Down Position 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)

Fax: (610) 831-5012

19

to the Down Position 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

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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 3 & 3A)

8. Move the bull wheel joystick to the neutral position. (See Figure 4 & 3A)

9. Disengage the negative brake by turning the negative brake switch counterclockwise. (See Figure 5 & 3A)

10. Moving bull wheel joystick to the down position and begin tension operations. (See Figure 6 & 3A)

0

5 Blue Heron Drive

operations. (See Figure 6 & 3A) 0 5 Blue Heron Drive Figure 23. Set Dynamometer Figure
operations. (See Figure 6 & 3A) 0 5 Blue Heron Drive Figure 23. Set Dynamometer Figure

Figure 23. Set Dynamometer

& 3A) 0 5 Blue Heron Drive Figure 23. Set Dynamometer Figure 25. Disengage Negative Brake

Figure 25. Disengage Negative Brake

23. Set Dynamometer Figure 25. Disengage Negative Brake Figure 24. Move Bull Wheel Joystick to Neutral

Figure 24. Move Bull Wheel Joystick to Neutral Position

Figure 24. Move Bull Wheel Joystick to Neutral Position Figure 26. Move Bull Wheel Joystick to

Figure 26. Move Bull Wheel Joystick to Down Position

Figure 26. Move Bull Wheel Joystick to Down Position Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

Move Bull Wheel Joystick to Down Position Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Move Bull Wheel Joystick to Down Position Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

Move Bull Wheel Joystick to Down Position Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 J. TENSIONING OPERATION (TWO

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J. TENSIONING OPERATION (TWO INDEPENDENT DRUMS)

1. Start the tensioner per start up instructions.

. Set operating speed to slow (snail). (See Figure 7 & 3A)

3. Set drum configuration selector to two independent drums.

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

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4. Engage negative brake under the corresponding drum being used (Number 1 or Number or both) by turning negative brake switch one position clockwise. (See Figure 8 & 3A)

5. Move bull wheel control(s) joystick to the down position. (See Figure 9 & 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)

range(s) is appropriately set. (See Figure 30 & 3A) Figure 27. Set Operating Speed to Slow

Figure 27. Set Operating Speed to Slow (snail)

30 & 3A) Figure 27. Set Operating Speed to Slow (snail) Figure 29. Move Bull Wheel

Figure 29. Move Bull Wheel Joystick to Down Position

(snail) Figure 29. Move Bull Wheel Joystick to Down Position Figure 28. Engage Negative Brake Figure

Figure 28. Engage Negative Brake

Joystick to Down Position Figure 28. Engage Negative Brake Figure 30. Set Dynamometer 5 Blue Heron

Figure 30. Set Dynamometer

5 Blue Heron Drive

Negative Brake Figure 30. Set Dynamometer 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
Negative Brake Figure 30. Set Dynamometer 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

30. Set Dynamometer 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

30. Set Dynamometer 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

1

30. Set Dynamometer 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

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

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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 3 & 3A)

9. Moving bull wheel joystick(s) to the down position and begin tension operations. (See Figure 33 & 3A)

5 Blue Heron Drive

operations. (See Figure 33 & 3A)  5 Blue Heron Drive Figure 31. Move Bull Wheel
operations. (See Figure 33 & 3A)  5 Blue Heron Drive Figure 31. Move Bull Wheel

Figure 31. Move Bull Wheel Joystick to Neutral Position

Figure 31. Move Bull Wheel Joystick to Neutral Position Figure 33. Move Bull Wheel Joystick to

Figure 33. Move Bull Wheel Joystick to Down Position

Figure 33. Move Bull Wheel Joystick to Down Position Figure 32. Disengage Negative Brake Collegeville, PA

Figure 32. Disengage Negative Brake

to Down Position Figure 32. Disengage Negative Brake Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

Figure 32. Disengage Negative Brake Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Figure 32. Disengage Negative Brake Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

Figure 32. Disengage Negative Brake Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

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

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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 (68.69 liters)

b.

Engine oil level

See enclosed engine booklet

c.

Reduction gear oil level

0.4 Gallons (1.5894 liters)

d.

Negative brake oil level

0.08 Gallons (0.307 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:

tests the machine with the following oils and lubricants: a. Hydraulic circuit and stationary brake: IP
tests the machine with the following oils and lubricants: a. Hydraulic circuit and stationary brake: IP
tests the machine with the following oils and lubricants: a. Hydraulic circuit and stationary brake: IP

a. Hydraulic circuit and stationary brake: IP HYDRUS OIL 46 (ISO VG 46).

b. Mechanical reduction gear: IP MELLANA 0 (ISO CKC 0).

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.

Turn off and cool the engine before any filling operation. 3 5 Blue Heron Drive Collegeville,
Turn off and cool the engine before any filling operation. 3 5 Blue Heron Drive Collegeville,

3

5 Blue Heron Drive

engine before any filling operation. 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
engine before any filling operation. 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

filling operation. 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

filling operation. 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

filling operation. 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

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

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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.

oil tank, use the cap located on the bottom of the tank. !DANGER: Cool the hydraulic
oil tank, use the cap located on the bottom of the tank. !DANGER: Cool the hydraulic

!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 5 µ (F)

return filter 5 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.

use the suitable caps on the lower part of the casing. !DANGER: Completely cool the hydraulic
use the suitable caps on the lower part of the casing. !DANGER: Completely cool the hydraulic

!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.

4

5 Blue Heron Drive

refer to the enclosed documentation. 4 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
refer to the enclosed documentation. 4 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

documentation. 4 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

documentation. 4 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

documentation. 4 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 G. RADIATOR MAINTENANCE At

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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 -3 times per day using the suitable greaser check the crowns from the inspection doors

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

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610-831-5020 Fax: 610-831-5012 www.comstarsupply.com Every week, grease all other parts subjected to rotation or

Every week, grease all other parts subjected to rotation or translation that do not have an automatic greasing schedule.

Use IP ATHESIA GR (ISO XBCEA ) 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).

5 Blue Heron Drive

for ordinary maintenance (see next page). 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
for ordinary maintenance (see next page). 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

(see next page). 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

(see next page). 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

5

(see next page). 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

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

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J. SUMMARY TABLE FOR REGULAR MAINTENANCE

This table lists the main operations of periodic maintenance and relevant intervals.

Part

Object

 

Interval

Daily

50 h

250 h

500 h

1500 h

 

Engine oil

CL

 

ST

   

Oil filter

   

ST

   

Diesel engine

Cooling liquid

CL

     

ST

Air filter

   

VF

 

ST

 

Fuel

CL

       

Fuel filter

     

ST

 

Hydraulic circuit

Hydraulic oil

CL

   

ST1

ST(*)

Filter

VF

   

ST1

ST(*)

Negative brake

Oil

CL

ST1

 

ST(*)

 

Discs

         

Reduction gear

Oil

CL

ST1

 

ST(*)

 

Bull-wheels

Gears

GR

       

Front plow

Sliding Rod

 

GR

     

Axle

Tire pressure

 

VF

     

Stationary brake

 

GR

     

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

6

5 Blue Heron Drive

Check (*) At least once a year 6 5 Blue Heron Drive Collegeville, PA 19426 (610)
Check (*) At least once a year 6 5 Blue Heron Drive Collegeville, PA 19426 (610)

Collegeville, PA 19426

At least once a year 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

(610) 831-5020

www.comstarsupply.com

At least once a year 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Fax: (610) 831-5012

At least once a year 6 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
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Comstar supply, INC

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Troubleshooting Guide

6.
6.

6.

6.
610-831-5012 www.comstarsupply.com Troubleshooting Guide 6. Blown fuse Low battery starts 5 Blue Heron Drive
Blown fuse Low battery
Blown fuse
Low battery
starts
starts
Troubleshooting Guide 6. Blown fuse Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610)
Troubleshooting Guide 6. Blown fuse Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610)

5 Blue Heron Drive

Guide 6. Blown fuse Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020
Guide 6. Blown fuse Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

Collegeville, PA 19426

Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012Guide 6. Blown fuse Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

7

Low battery starts 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
Comstar supply, INC Think Cable Think Comstar 5 Blue Heron Drive Collegeville, PA 19426 Phone:
Comstar supply, INC Think Cable Think Comstar 5 Blue Heron Drive Collegeville, PA 19426 Phone:
Comstar supply, INC
Think Cable
Think Comstar
5 Blue Heron Drive
Collegeville, PA 19426
Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782
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correct
When activating the control lever the bull-wheels don’t work (electric control)
When activating the control lever
the bull-wheels don’t work
(electric control)

8

5 Blue Heron Drive

don’t work (electric control) 8 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
don’t work (electric control) 8 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

(electric control) 8 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

(electric control) 8 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

(electric control) 8 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

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1-866-326-6782

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

www.comstarsupply.com

When activating the control lever the bull-wheels don’t work (hydraulic control) release
When activating the control lever
the bull-wheels don’t work
(hydraulic control)
release
the bull-wheels don’t work (hydraulic control) release 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

5 Blue Heron Drive

work (hydraulic control) release 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
work (hydraulic control) release 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

control) release 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 9

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012work (hydraulic control) release 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com 9

9

control) release 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 9
Comstar supply, INC Think Cable Think Comstar 5 Blue Heron Drive Collegeville, PA 19426 Phone:
Comstar supply, INC Think Cable Think Comstar 5 Blue Heron Drive Collegeville, PA 19426 Phone:
Comstar supply, INC
Think Cable
Think Comstar
5 Blue Heron Drive
Collegeville, PA 19426
Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782
www.comstarsupply.com
Fax: 610-831-5012 1-866-326-6782 www.comstarsupply.com 30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020
Fax: 610-831-5012 1-866-326-6782 www.comstarsupply.com 30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

30

5 Blue Heron Drive

1-866-326-6782 www.comstarsupply.com 30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
1-866-326-6782 www.comstarsupply.com 30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-50121-866-326-6782 www.comstarsupply.com 30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

30 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

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

5 Blue Heron Drive

with diesel engine at medium-high rpm 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
with diesel engine at medium-high rpm 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

at medium-high rpm 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012with diesel engine at medium-high rpm 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

31

at medium-high rpm 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012
Comstar supply, INC Think Cable Think Comstar 5 Blue Heron Drive Collegeville, PA 19426 Phone:
Comstar supply, INC Think Cable Think Comstar 5 Blue Heron Drive Collegeville, PA 19426 Phone:
Comstar supply, INC
Think Cable
Think Comstar
5 Blue Heron Drive
Collegeville, PA 19426
Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782
www.comstarsupply.com
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
the reel winder valve with diesel engine at medium-high rpm plow plow plow plow 3 5
plow plow plow plow
plow
plow
plow
plow

3

5 Blue Heron Drive

medium-high rpm plow plow plow plow 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020
medium-high rpm plow plow plow plow 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

Collegeville, PA 19426

plow plow plow 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)

(610) 831-5020

www.comstarsupply.com

Fax: (610) 831-5012medium-high rpm plow plow plow plow 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020

plow plow plow 3 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610)
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

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Think Cable

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

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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 (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.

5 Blue Heron Drive

filters before re-starting the machine. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
filters before re-starting the machine. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

the machine. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 33

(610) 831-5020

www.comstarsupply.com

the machine. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 33

Fax: (610) 831-5012

33

the machine. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 33
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

5 Blue Heron Drive

Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive Collegeville, PA 19426 34 (610) 831-5020
Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive Collegeville, PA 19426 34 (610) 831-5020

Collegeville, PA 19426

34

1-866-326-6782 5 Blue Heron Drive Collegeville, PA 19426 34 (610) 831-5020 www.comstarsupply.com 5 Blue Heron Drive

(610) 831-5020

www.comstarsupply.com

PA 19426 34 (610) 831-5020 www.comstarsupply.com 5 Blue Heron Drive Collegeville, PA 19426 Phone:

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

www.comstarsupply.com

Fax: (610) 831-5012

Heron Drive Collegeville, PA 19426 Phone: 610-831-5020 Fax: 610-831-5012 www.comstarsupply.com Fax: (610) 831-5012
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

Warranty Information

FACTORY ASSISTANCE

FACTORY ASSISTANCE 3 . 8.

3. 8.

FACTORY ASSISTANCE 3 . 8.

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 1-800-533-077 (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.

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.

5 Blue Heron Drive

FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com

Collegeville, PA 19426

DAMAGES. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 35

(610) 831-5020

www.comstarsupply.com

DAMAGES. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 35

Fax: (610) 831-5012

35

DAMAGES. 5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012 35
C omstar s upply , INC Think Cable Think Comstar 1-866-326-6782 5 Blue Heron Drive

Comstar supply, INC

Think Cable

Think Comstar

1-866-326-6782

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

www.comstarsupply.com

610-831-5020 Fax: 610-831-5012 www.comstarsupply.com Condux International, Inc. P.O. Box 47 • 145 Kingswood

Condux International, Inc.

P.O. Box 47 • 145 Kingswood Drive, Mankato, MN 5600-047 USA 1-507-387-6576 • 1-800-533-077 • FAX 1-507-387-144 Internet: http://www.condux.com • e-mail: cndxinfo@condux.com

5 Blue Heron Drive

• e-mail: cndxinfo@condux.com 5 Blue Heron Drive © Copyright 007, Condux International, Inc. Printed in USA
• e-mail: cndxinfo@condux.com 5 Blue Heron Drive © Copyright 007, Condux International, Inc. Printed in USA

© Copyright 007, Condux International, Inc. Printed in USA Literature Part Number: 103344 Revision Number: 1.0

Collegeville, PA 19426

Part Number: 103344 Revision Number: 1.0 Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

(610) 831-5020

www.comstarsupply.com

Part Number: 103344 Revision Number: 1.0 Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012

Fax: (610) 831-5012

Part Number: 103344 Revision Number: 1.0 Collegeville, PA 19426 (610) 831-5020 www.comstarsupply.com Fax: (610) 831-5012