Professional Documents
Culture Documents
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5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
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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.
Manufacturer:
Condux International, Inc.
145 Kingswood Drive
Mankato, MN 56002-0247
1-507-387-6576
Fax 1-507-387-1442
E-mail: cndxinfo@condux.com
CALL 1-800-533-2077
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
Table of Contents
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
1.
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.
The AFB506 has a load pre-setting system. This system maintains the pre-set value,
automatically adjusting the speed depending on the friction and unexpected loads
that may develop along the line. Even at “0” speed, the system keeps the rope in
tension at the pre-set value.
The machine is equipped with quick hydraulic couplers to connect to all types of reel
winders and reel elevators made by Condux; the frame has a rigid axle for towing at
a maximum of 28.7 km/h (18 mph).
C. PERFORMANCE
HIGH PULL LOW PULL (OPT)
45 kN (10116 lb x 2) or
Maximum pull 14 kN (3147 lb x 2)
90 kN (20232 lb x 1)
37.5 kN ()8430 lb x 2 or
Continuous pull 12 kN (2697 lb x 2)
75 kN (16860 lb x 1)
Speed at continuous
2.5 km/h (1.55 mph) 2.5 km/h (1.55 mph)
pull
Maximum speed 5 km/h (3.1 mph) 5 km/h (3.1 mph)
15 kN (3372 lb x 2) or
Pull at max. speed /
30 kN (6744 lb x 1)
Min. pull / 3 kN (674 lb x 2)
Performances are referred to the machine without optional equipment, at sea level
and at 20°C (68°F)
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5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
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D. TECHNICAL CHARACTERISTICS
Bull-wheels diameter:........................ 1500 mm (59.06 in.)
Maximum conductor diameter:.......... 34 mm (1.33 in.)
Maximum connector diameter:.......... 54 mm (2.12 in.)
Diesel engine:.................................... 89 kW (114 HP – 2500 rpm)
Electrical system:.............................. 12 V
Transmission:.................................... closed hydraulic circuit with hydraulic oil cooling
Mechanical transmission
at 3 positions:.................................... neutral
minimum ratio (MINIMUM PULL)
maximum ratio (MAXIMUM PULL)
Safety brakes:................................... negative and self-acting types
Meter-counter:................................... 2 electronic types
Axle: rigid with mechanical stationary brake for towing
at maximum speed of 30 km/h (18.63 mph)
Dimensions:....................................... length – 4075 mm (4.45 yd)
width – 2360 mm (2.58 yd)
height – 2800 mm (3.06 yd)
Mass without oil:................................ 6000 kg (13,230 lb)
The manufacturer has the right to carry out technical and constructive modifications
without notice.
E. NOISE EMISSIONS
Level of continuous noise to the operator (UNI 9432) Lep = 85 dB(A)
F. GENERAL INSTRUCTIONS
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.
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5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
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J. CONDITION OF USE
a. Temperature:.......................... from -10°C to +40°C. (14°F to 104°F)
b. Relevant moisture:.................. from 30% to 90% ± 5%.
c. Weather conditions:................ any (in line with working conditions).
d. Natural and/or artificial lighting of the working site.
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5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
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For additional information concerning the hydraulic oil, see the chapter on
“Maintenance” and the attached Comparative Table of the oils used on the machine.
M. LIABILITY
Never use this machine in situations different from those indicated in paragraph 2.3
(Typology and Field Use) or those situations not described in this manual.
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5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
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N. APPLIED NORMS
This machine is manufactured in conformity with the following norm:
98/37/CE Norm of the European Parliament and Council, dated 22 June 1998
referring to the laws of the machines member states.
89/336/CE Norm of the European Council, dated 03 May 1989 referring to the
laws of the electromagnetic compatibility member states.
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
capacity equal to or greater than the mass to be lifted and must be connected to the
proper points on the machine (shown on Table 1, pos. 3).
To prevent movement of the machine during transportation, use nailed wedges and/or
metal brackets and/or tie rods.
To prevent movement of the machine during transportation, use nailed wedges and/or
metal brackets and/or tie rods.
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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.
During unpacking, avoid any shock to the structure or to the machine units.
D. ASSEMBLY OPERATIONS
Assemble the tires in the suitable places.
E. TRANSPORT ON TRAILER
At the job site, tow the machine at maximum speed of 30 km/h (18.6 mph).
Moving the unit from location to location at the job site must be done by connecting
the unit to the tow vehicle by means of the towing eye on the drawbar (Table 2, pos.
12). When towing, follow the speed limits declared for the axle: 30 km/h (18 mph).
Before transporting the machine, lift the rear stabilizers (Table 2, pos. 11) and the
front ones (Table 2, pos. 14) using the proper lever (Table 1, pos. 14) and inserting
the safety pin (Table 2, pos. 13).
No personnel may ride on the machine at any time while towing the machine at ANY
speed.
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For the rope passage (or conductor), the machine must be placed between 2 and 4
times the height of the pole from the first pole or trestle (see Table 1).
Table 1
Use the machine at a distance from the pole between 1 and 2 times the height of
the pole itself. In this case, the anchorage described thereafter must be over-dimen-
sioned by 125% compared to the reported data and some moorings must be pro-
vided on the front side of the machine.
e. Put the anchoring ropes under tension using the suitable turnbuckles. If
necessary, anchor the machine in the front, too.
f. Engage the wheel brakes (Table 2, pos. 10).
10
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A 2 m (6.5 ft) radius around the machine must be free of obstacles to make the
operation, adjustment, and maintenance of the machine as easy as possible.
Be sure that cooling air can circulate freely around the radiator (diesel motor,
hydraulic oil). Otherwise overheating can occur and damage the components.
Safety
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.
NOTE: Never use the emergency stop button for the normal
stopping of machine working activities.
C. PERIODIC OPERATIONS
Every day, before starting work, the operator must test the machine’s safety devices
to make certain they are working properly.
D. RESIDUAL RISKS
The machine has the following residual risks:
11
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1. Sudden break of the rope-conductor. The break of the rope causes sudden
movements of the machine and the rope or conductor connected to the
machine.
To minimize the risks, the operator has to:
• Check the rope and replace it as soon as defects or wear signs appear.
• Comply with the working positions indicated in the manual.
2. Sudden break of the anchoring stakes. The sudden break of the anchoring
stakes causes machine instability and sudden movements.
To minimize the risks the operator has to:
• Periodically check the anchoring stakes and replace them as soon as
defects or wear signs appear.
• Follow the anchoring suggestions described in the present manual.
• Comply with the working positions indicated in the manual.
3. Entangling or dragging the accessible rotating units. Due to the effective use
of the machine, it is not possible to cover some rotating parts (i.e. winding of
the rope or of the conductor on the bull-wheels or on the driving gears).
To minimize the risks, the operator has to:
• Avoid contact with the machine’s rotating units except for the control devices.
• Respect the prescriptions indicated in the present manual about wearing
and using necessary safety devices.
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Operating Procedure
5.
4.
A. SET-UP
1. Position puller-tensioner slightly to the left or to the right of the first overhead
structure being worked with. The machine should not be positioned directly in
line with the overhead structure. A slight offset to the right or left will provide
better engagement during operation.
The puller-tensioner also needs to be positioned far enough away from the
first structure to obtain a 1.5- to 2- degree fleet angle. This distance can be
calculated by 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 puller-tensioner
should be positioned 200 feet back. (See Figure 1)
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 replace pin. (See Figure 2)
B. START UP PROCEDURE
!IMPORTANT: Read all instructions before starting the AFB 506
Puller-Tensioner.
1. To start the machine, insert the key into the ignition, push in and turn one
position clockwise. (See Figure 2A)
2. Wait for yellow glow plug light to turn off. (See Figure 2A)
3. Push ignition key in and turn the key clockwise to start. (See Figure 2A)
4. Adjust engine throttle to 2,200. (See Figure 2A)
5. Set cooling fan to 700 psi. 50 bar. (See Figure 2A)
6. Set reel elevator hydraulic pressure to 500 psi. 40 bar. (See Figure 2A)
13
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1 2
14
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15
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C. STABILIZE PULLER
1. Set the front of the unit as low as possible by engaging the leveling joystick
down. (See Figure 3)
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 4)
3. Readjust the front of the machine. Push up on the leveling joystick to raise
the front end of the puller-tensioner and adjust accordingly until pressure is
placed on the rear jack stand.
4. Anchor the puller-tensioner in two locations. The first position in on the left
side of the upper drum, directly in the center of the machine. (See Figure 5)
The second position is adjacent to the operator panel. Temporary ground
anchors or solid structures are required for proper machine anchoring.
(See Figure 6)
16
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E. GUIDE ROLLERS
1. Align guide rollers to correspond with the pulling position of the reel stand.
Loosen guide roller bracket bolts. Slide guide rollers to the left or right to
properly align. Re-tighten bolts. Thread poly rope through guide rollers
(See Figure 8)
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. (See Table 2)
To determine pulling or tensioning ranges use the following formula:
17
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A (Final Sag Tension) minus B (Max Pulling Tension Below Final Sag
Tension) minus C (1,000 ft-pounds)= Dynamometer setting
Example:
Table 2
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 appropri-
ate position. Release detent. (See Figure 10)
Figure 9. Position Range Lever Figure 10. Put Lever into Proper
Position, Release Detent
18
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!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.
19
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4. 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 15)
5. Move bull wheel control joystick to the down position (See Figure 16)
7. Move the bull wheel joystick to the neutral position (See Figure 18)
Figure 15. Engage Negative Brake Figure 16. Bull Wheel Joystick
To Down Position
Figure 17. Turn Knob Until Range Figure 18. Bull Wheel Joystick
Is Appropriately Set To Neutral Position
20
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2. Set drum configuration selector to two independent drums. (See Figure 20)
3. 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 21)
Figure 20. Set Selector To Two Figure 21. Engage Negative Brake
Independent Drums
21
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4. Move bull wheel control(s) joystick to the down position (See Figure 22)
6. Move the bull wheel joystick(s) to the neutral position (See Figure 24)
8. Moving bull wheel joystick(s) to the down position and begin tension
operations. (See Figure 25)
Figure 22. Bull Wheel Joystick To Figure 23. Turn Knob Until Range
Down Position Is Appropriately Set
Figure 24. Move Bull Wheel Figure 25. Move Bull Wheel
Joystick To Neutral Position Joystick to Down Position
22
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!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.
Figure 28. Secure Locking Rod Figure 29. Set Drum Selector To
inside Drum Cover Single Drum
23
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5. Move bull wheel control joystick to the down position (See Figure 31)
6. Establish the fail safe emergency brake value at 1,000 foot-pounds above final
sag tension. Set level by inserting the turnkey into center of the dynamometer
gauge and adjusting the red indicator arm to appropriate fail safe level.
8. Move the bull wheel joystick to the neutral position (See Figure 33)
Figure 30. Engage Negative Brake Figure 31. Move Bull Wheel
Joystick To Down Position
Figure 32. Turn Knob Until Range Figure 33. Move Bull Wheel
Is Appropriately Set Joystick to Neutral Position
24
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2. Set drum configuration selector to two independent drums. (See Figure 35)
3. 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 36)
Figure 35. Set Drum Selector To Figure 36. Engage Negative Brake
Two Independent Drums
25
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4. Move bull wheel control(s) joystick to the down position (See Figure 37)
8. Moving bull wheel joystick to the down position and begin pulling operations.
The puller-tensioner will continual adjust speed to maintain proper pulling
tension throughout operation. (See Figure 40)
Figure 37. Move Bull Wheel Figure 38. Turn Knob Until Range
Joystick to Down Position Is Appropriately Set
26
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Maintenance
5.
A. GENERAL INFORMATION
!ATTENTION: Repairs not done by the manufacturer and not
allowed by a written authorization relieve the manufacturer of any
responsibility in the case of accidents to persons or damages to
things and/or the machine, causing the loss of the warranty.
B. LEVELS CONTROL
For safety reasons, the machine comes without hydraulic oil and fuel. Fill the levels
per the following table:
Quantity
a. Hydraulic oil level 280 (74 gal)
b. Engine oil level ---
c. Reduction gear oil level 1.6 (1.69 qt))
d. Stationary brake oil level 0.3 (10.14 fl. oz)
e. Coupler oil level 1.4 (1.47 qt)
f. Fuel level 90 (23.78 gal)
g. Gears’ grease 2 kg (4.4 lb)
C. TIRE INFLATION
Tires inflation pressure has to be o6 bar (87 psi).
D. SUGGESTED LUBRICANTS
The manufacturer tests the machine with the following oils and lubricants:
a. hydraulic circuit and negative brake: IP HYDRUS OIL 46 (ISO HM 46)
b. mechanical reduction gears, coupler and differential gear:
IP MELLANA 220 (ISO CKC 220).
Lubricants from different trademarks must be chosen based on the enclosed table’s
“SUGGESTED LUBRICANTS”. It is possible to use different trademarks with same
characteristics and ISO specifications. When using oil with characteristics and ISO
specifications different from the ones recommenced, completely empty the hydraulic
circuit.
27
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!DANGER: To fill with fuel, turn off the engine and let the engine
cool.
All the electric components of the diesel engine are positioned in the box (Table 2,
pos. 21) where the connecting point for the diagnostic of the electronic gear case is
located.
Possible engine alarms for the electronic gear case of the diesel are signified by one
or both warning lights (Table 1, pos. 42 or 43).
The alarm codes can be seen by the use of the diagnostic device called Insite™ or by
the operator by the rpm device/electronic display (Table 1, pos. 40).
By pushing the button (Table 1, pos. 41) operators can see the following information
in sequence:
• OIL PR: shows the pressure of the engine oil (in bars)
• V BATT: shows the battery charge (in volts)
• % LOAD: shows the percentage of the engine input power as compared to
the maximum power of the same
• BOOST P: shows the overfeeding pressure of the turbo compressor (in kPa)
• F RATE: shows the gas-oil consumption of the engine (in l/h)
• INLET: shows the entry air temperature in the engine (in °C)
• _____ : shows the number of working hours
• DTC nnn: shows the numeric alarm code of the electronic gear case of the
diesel engine (if there are several alarms, all the alarms are shown in
sequence by pushing the button (Table 1, pos. 41). The alarm code shows
the following:
• NN SPN
• MM FMI
The numbers NN and MM identify the alarm codes of the shown instrument.
The legend of the alarm codes is indicated in the table enclosed to the present
manual in the column SPN/FMI (TB-04002-01-RS-Diagnostic-GB).
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c. Fill the oil in the tank with the correct quantity using a proper filler
(Table 2, pos. 5).
For the coupler, use the proper cap (Table 2, pos. 16).
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c. Fill the oil of the reduction gear and of the stationary brake with the proper
caps on the upper part of the casing of the same (Table 3, pos. 5 and 10).
For the coupler, use the proper cap (Table 2, pos. 15).
!ATTENTION: When filling the oil tank, make sure no foreign matter,
which could cause irreparable damage to the circuit’s components,
enters with the oil.
I. RADIATOR MAINTENANCE
Clean all radiators at least once a year and more if the machine is very dirty.
J. GREASING
Grease the crown gear of the bull-wheels 2-3 times per day, using the proper greaser
(Table 3, pos. 2); check the crowns greasing from the timing case doors (Table 3,
pos. 1).
Grease all other machine parts subjected to rotation or translation, which do not have
a grease zerk or an automatic greasing system every week.
For the other periodic operations, refer to the Summary Table for ordinary
maintenance (see next page).
30
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Interval
Component Object
Daily 50 h 250 h 500 h 1500 h
Engine oil CL ST
Oil filter ST
Cooling liquid CL ST
Diesel engine (***)
Air filter VF ST
Fuel CL
Fuel filter ST
Hydraulic oil CL ST1 ST(*)
Hydraulic circuit
Filters VF ST1 ST(*)
Oil CL ST1 ST(*)
Negative brakes
Discs VF1(**) VF(**)
Reduction gears Oil CL ST1 ST(*)
Coupler Oil CL ST1 ST(*)
Bull-wheels Gears GR
Plow Cylinder GR
Tire pressure VF
Axle
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
(**) Check the wear-condition of the discs after an emergency stop.
(***) For further information, see the engine booklet
31
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Troubleshooting Guide
6.
Blown fuse
Low battery
starts
tarts
32
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correct
33
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
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5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
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Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
34
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
35
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
36
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
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Comstar Supply, INC Collegeville, PA 19426
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cooling fan
cooling fan
plow
plow
plow
plow
37
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7.
A. TRANSPORT
Before transporting the machine, empty any flammable liquid in the machine (oils and
fuels).
Transport must be done per the specifications described in chapter 3 (Transport and
Positioning instructions).
During a service stop, start the machine at least once every two months and let the
machine idle for at least one hour, so the oil enters the hydraulic system to prevent
the gaskets from drying.
Store the machine under a roof. Do not cover the machine with pieces of cloth and/or
plastic materials that may cause an increase in the temperature and/or humidity.
If the machine is not used for one or more years, replace the hydraulic oil and
hydraulic circuit filters before re-starting the machine.
C. STRIPPING
Machine stripping has to be done by the manufacturer or by a specialized factory.
All the stripping operations must conform to company norms for accident prevention.
Waste materials must be divided by type (i.e. iron scrap, aluminium, plastic, rub, etc.)
and disposed according to the laws in force.
38
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Warranty Information
3.
8.
FACTORY ASSISTANCE
Condux International, Incorporated (Condux) can provide further advice regarding
any problems with the installation, service, assembly, or disassembly of the Condux
AFB506 Hydraulic Puller. Call toll free at 1-800-533-2077 (USA and Canada) or
1-507-387-6576 and ask for assistance. The Condux AFB506 Hydraulic Puller
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.
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:
39
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5 Blue Heron Drive
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Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
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5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com