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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
1-866-326-6782 www.comstarsupply.com

USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL

AFB506 Hydraulic Puller

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

Important Safety Notice


Before using a Condux AFB506 Hydraulic Puller, operators must read and understand all procedures
and safety instructions. Note all safety information on this page, and note specific safety requirements as
explained by the procedures in this manual.

Failure to follow these instructions could result in serious personal injury or death.

ADVERTENCIA:
Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si
Ud. No comprende las instrucciones favor de consultarle a su jefe.

Save this user’s guide for future reference.

COMMUNICATION WITH THE MANUFACTURER:


For information related to the machine (use, maintenance, spare parts), always state the Model Number,
Serial Number, Manufacturing Year, and Order Number. This information can be found in the
Parts-Identification Table.

Manufacturer:
Condux International, Inc.
145 Kingswood Drive
Mankato, MN 56002-0247
1-507-387-6576
Fax 1-507-387-1442
E-mail: cndxinfo@condux.com

For questions on:

SAFETY - OPERATIONS - APPLICATIONS

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

IMPORTANT SAFETY NOTICE.......................................... 2 D. REEVING THE DRUM.............................................. 17


COMMUNICATION WITH THE MANUFACTURER............ 2 E. GUIDE ROLLERS..................................................... 17
1 GENERAL DATA AND INSTRUCTIONS............................. 4 F. POSITION REEL ELEVATOR..................................... 17
A. COMMUNICATION WITH THE MANUFACTURER...... 4 G. DETERMINE PULLING OR TENSIONING RANGE... 17
B. TYPOLOGY AND FIELD USE..................................... 4 H. SET PULLER OR TENSIONING RANGE LEVER...... 17
C. PERFORMANCE........................................................ 4 I. TENSIONING OPERATION (Single Drum)................ 18
D. TECHNICAL CHARACTERISTICS ............................ 5 J. TENSIONING OPERATION
(Two Independent Drums)....................................... 20
E. NOISE EMISSIONS................................................... 5
K. PULLER OPERATION (Single Drum)....................... 23
F. GENERAL INSTRUCTIONS......................................... 5
L. PULLER OPERATION (Two Independent Drums)... 25
G. GENERAL OPERATOR INSTRUCTIONS.................. 5
5 MAINTENANCE............................................................... 27
H. GENERAL MAINTENANCE INSTRUCTIONS............ 6
A. GENERAL INFORMATION........................................ 27
I. THE INSTRUCTION MANUAL . ................................. 6
B. LEVELS CONTROL.................................................. 27
J. CONDITION OF USE................................................ 6
C. TIRE INFLATION...................................................... 27
K. TEMPERATURE LIMITS FOR HYDRAULIC OIL....... 7
D. SUGGESTED LUBRICANTS..................................... 27
L. USES NOT ALLOWED............................................. 7
E. DIESEL ENGINE MAINTENANCE............................. 28
M. LIABILITY.............................................................. 7
F. DIAGNOSTIC OF ELECTRONIC DIESEL ENGINE...... 28
N. APPLIED NORMS................................................... 8
G. HYDRAULIC CIRCUIT MAINTENANCE.................... 29
2 TRANSPORT AND POSITIONING INSTRUCTIONS.......... 8
H. REDUCTION GEARS-STATIONARY BRAKES-
A. MACHINE LIFTING.................................................... 8
COUPLER-DIFFERENTIAL GEAR MAINTENANCE.. 29
B. PACKAGING FOR SHIPPING..................................... 8
I. RADIATOR MAINTENANCE.................................... 30
C. UNPACKING............................................................... 9
J. GREASING............................................................... 30
D. ASSEMBLY OPERATIONS......................................... 9
K. OTHER PERIODIC OPERATIONS............................. 30
E. TRANSPORT ON TRAILER........................................ 9
L. SUMMARY TABLE FOR REGULAR
F. POSITIONING AND ANCHORING............................. 10 MAINTENANCE........................................................ 31
3 SAFETY ........................................................................ 11 6 TROUBLESHOOTING GUIDE.......................................... 32
A. SAFETY DEVICES.................................................... 11 7 HOW TO DISABLE THE MACHINE................................. 38
B. EMERGENCY STOP DEVICE.................................... 11 A. TRANSPORT............................................................ 38
C. PERIODIC OPERATIONS......................................... 11 B. EXTENDED SERVICE STOP..................................... 38
D. RESIDUAL RISKS.................................................... 11 C. STRIPPING.............................................................. 38
4 OPERATING PROCEDURE.............................................. 13 8 WARRANTY INFORMATION........................................... 39
A. SET-UP.................................................................... 13 FACTORY ASSISTANCE............................................... 39
B. START UP PROCEDURE.......................................... 13 LIMITED WARRANTY.................................................. 39
C. STABILIZE PULLER................................................. 16

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

General Data And Instructions

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.

B. TYPOLOGY AND FIELD USE


The AFB506 can recover or string one or two conductors, even with optical fibres.
The machine is controlled by a hydraulic system that allows the machine to work
automatically in PULLER or in TENSIONER mode.

Each pair of bull-wheels can be independently controlled.

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 performances are the same in puller and tensioner modes.

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)

!ATTENTION: Using a rope with a smaller diameter will reduce the


pulling capacity of the machine, in accordance with the breaking
load of the rope or of the conductor.

Performances are referred to the machine without optional equipment, at sea level
and at 20°C (68°F)

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

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.

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
obstacles to proper operation.
f. The operator must never inhale the exhaust.

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

H. GENERAL MAINTENANCE INSTRUCTIONS


a. Never perform any maintenance or 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
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. The information contained in this manual applies to all operators using the
machine and/or the maintenance of the machine.
b. This instruction manual is not a training manual.
c. Before using the machine, the supervisor of the job site and the operator must
read the instruction manual.
d. The supervisor must inform all operators about the instructions contained in
this manual.
e. All operators must follow the instructions 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 make certain that the instructions contained in
this manual are followed.
h. This instruction manual must be kept with the machine for the entire life of the
machine in order to be available to all potential users and operators.
i. The instruction manual must be kept in a sheltered and dry place.

!ATTENTION: This manual belongs exclusively to the manufacturer.


Reproduction (even in part) of its contents is forbidden.

J. CONDITION OF USE
a. 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.

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

K. TEMPERATURE LIMITS FOR HYDRAULIC OIL


When using the machine, always follow the temperature limits of the hydraulic oil:
TEMPERATURE LIMITS FOR HYDRAULIC OIL - °C (°F)
Hydraulic oil viscosity
Working condition
VG 22 VG 32 VG 46 VG 68
-21°C -14°C -7°C -1°C
Minimum temperature running in neutral position
(-5.8°F) (6.8°F) (19.4°F) (30.2°F)
8°C 16°C 24°C 32°C
Minimum temperature running in full load
(46.6°F) (60.8°F) (75.2°F) (89.6°F)
48°C 57°C 67°C 76°C
Maximum temperature running in full load
118.4°F) (134.6°F) (152.6°F) (168.8°F)
63°C 73°C 83°C 93°C
Maximum temperature running in neutral position
(145.4°F) (163.4°F) (181.4°F) (199.4°F)

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. USEs NOT ALLOWED


Never use the machine for the following:
a. for lifting persons and/or goods
b. in areas where the machine cannot be properly positioned and anchored.
c. in areas with brush or other materials that can easily catch fire.
d. in closed/unventilated sites or those that are poorly ventilated (tunnels or
similar areas).
e. at sites where fuels or explosives are present.
f. on aircraft, watercraft, floating platforms, and similar locations.
g. for structure demolition.
h. for pulling elastic elements.
i. with ropes or joints having larger diameters than those specified in this manual.
j. when the engine is off but the bull-wheels are moving.
k. with over-ridden or broken safety system devices.
l. when winding ropes and/or conductors having a smaller diameter after ropes
and/or conductors having a larger diameter on the bull-wheels.
m. for handling trucks or other moving equipment.

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.

Failure to use recommended restraints creates a situation of wrongful and


improper use and relieves the manufacturer of any responsibility for accidents
and/or injuries to persons and/or damage to property. This voids the
manufacturer’s warranty.

Similarly, the manufacturer’s responsibility ends when the following situations


occur:
a. tampering and/or modifying the system without the manufacturer’s express
written consent (in this case the operator becomes the manufacturer assuming
all obligations and responsibilities, both civil and penal):
b. using non-original spare parts for the machine.
c. performing poor maintenance on the machine.

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

d. using the machine while it is disconnected or when safety devices are


over-ridden.
e. for the connection to machine and/or plans not produced and not directly
authorized by the manufacturer in a written acceptance.
f. for the connection to machines and/or plans not produced and not directly
authorized by the manufacturer in a written acceptance.

N. APPLIED NORMS
This machine is manufactured in conformity with the following norm:

98/37/CE Norm of the European Parliament and Council, dated 22 June 1998
referring to the laws of the 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.

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
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).

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, thus
voiding the manufacturer’s warranty.

B. PACKAGING FOR SHIPPING


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 of the machine during transportation, use nailed wedges and/or
metal brackets and/or tie rods.

Transport by sea in wooden cases or container


This machine ships without flammable liquids. Metal parts are protected with
waterproof wax.

To prevent movement of the machine during transportation, use nailed wedges and/or
metal brackets and/or tie rods.


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

Protect the inside the wooden case with tar paper.

Materials usually used for packaging:


• wood
• nails and/or steel screws
• cardboard and/or paper
• polyethylene film
• adhesive tape

C. UNPACKING
When receiving the machine, verify the condition of the package. Immediately notify
the transportation company and the manufacturer (use photos whenever possible) of
any damage that may have occurred during shipment.

Verify that the supplied product matches that which was ordered. Immediately notify
the manufacturer of any discrepancies.

Use caution when unpacking to avoid damaging the product


For transportation in a wooden case, remove, in sequence, the upper cover and lat-
eral panels before removing the machine.

During unpacking, avoid any shock to the structure or to the machine units.

!ATTENTION: Dispose all packaging materials in accordance with


local regulations.

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).

PROHIBITION: Never tow this machine on public roads.

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).

NOTE: This operation must be done with engine running.

Check the tires for proper inflation: 6 bar (87 psi).

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

!ATTENTION: It is dangerous to tow the machine at speeds in


excess of the axle’s rated capacity or if the tires are not properly
inflated.


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

To prevent movement of the machine during transportation, secure the machine on


the platform with nailed wedges and/or metal brackets and/or tie rods.

F. 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 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.

!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 with the pull as much as possible.
b. Anchor the machine using the connections (Table 3, pos. 4) and adjust the
tension uniformly: use suitable anchoring ropes with working loads equal to
130% of the maximum pull for the machine.
c. Set the supporting points (Table 2, pos. 11).
d. Position the plough (Table 2, pos. 14) by removing the safety pin (Table 2,
pos. 13). Adjust the tension by means of the valve (Table 1, pos. 21) and
acting on the plow control lever (Table 1, pos. 14).

NOTE: The machine must be anchored with the engine running.

!IMPORTANT: Before starting stringing operations, test the pull,


reaching the maximum value for these operations in order to
check the anchoring and the machine settling. Have the rear
anchoring slightly released so that the machine can settle freely.

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).

ATTENTION: Disregarding the anchoring operations may cause


dangerous situations during machine use.

10

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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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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.

!DANGER: This machine is not a proper grounding device. Proper


grounding for the conductor system being installed must be
provided via other means.

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.

!DANGER: Never use of the machine without protecting 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


The mushroom push-button emergency stop acts directly on the diesel engine.

!ATTENTION: Use the emergency stop device ONLY in dangerous


situations and for the operators’ safety.

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.

!ATTENTION: Do not, for any reason, modify the machine’s safety


devices. The manufacturer declines any responsibility as a
consequence of the non-functioning of those devices.

D. RESIDUAL RISKS
The machine has the following residual risks:

11

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Comstar Supply, INC Collegeville, PA 19426
Think Cable... Think Comstar Phone: 610-831-5020
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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.

4. Limb crushing during loading or removal of the reel and during


rope-conductor loading. These operations have a large risk margin due to
the use of mechanical parts to be moved.
To minimize the risks the operator has to:
• Know the directives for accident prevention and apply them.

5. Electrostatic discharges. Since the machine does not have a proper
grounding device for during stringing operations, it is possible to have
dangerous electrostatics discharges on ropes and conductors.
To minimize the risks, the operator has to:
• Know the directives for accident prevention and apply them.
• Check if the job site has a suitable grounding device for the
machine-rope-conductors system.

6. Inhalation of the endothermic engine exhaust gas. This machine
discharges exhaust gas.
To minimize the risks, the operator has to:
• Respect the working recommendations indicated in the manual.
• Respect the attentions and prohibitions indicated in the present manual.
• If necessary, use safety devices for respiratory tracts.

7. Command lever that can be locked in working position. For functional


reasons and for comfort, the control joystick will stay where it is positioned.
The machine is equipped with two security devices which prevent the creation
of dangerous situations: an electric limiting device of the pull on the
dynamometer which stops the power station when the stated value is
reached, and a pull limiting device which maintains a preset pulling load
regardless of the speed that the machine is operated.
To minimize the risks, the operator must:
• Put the electric limiting device of the pull on a value just superior to the
regulating valves of the pull (see par. 4.5)
• Plan the desired pull as described in the manual (see par. 4.5).
12

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

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)

Figure 1. Remove Keeper Pin Figure 2. Lower Leg, Replace Pin

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)

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1 2

Figure 2A. Control Panel Identification

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ITEM # QTY DESCRIPTION CONDUX P/N REF.


1 2 DYNAMOMETER 21011081 08200602
2 2 KEY, DYNAMOMETER SETTING 21011080 08200403
3 2 COUNTER, DISTANCE 21011538 09100699
4 1 SWITCH, EMERGENCY STOP 21011250 09101190
5 1 PLATE, EMERGENCY STOP SWITCH 21011251 09100941
6 2 LENS, LOW RANGE 21011124 09102639
7 1 DISPLAY, ENGINE RPM AND DIAGNOSTIC 21011432 09101822
8 1 FUSE HOLDER 21011442 09100515
9 1 LENS, ALARM 21011125 9102713
10 1 LENS, GLOW PLUG 21011122 09102550
11 1 LENS, LOW ENG. OIL PRESSURE 21011115 09102136
12 1 LENS, LOW FUEL LEVEL 21011113 09102134
13 1 LENS, ALTERNATOR FAILURE 21011114 09102135
14 3 LENS, FILTER CLOGGED 21011121 09102549
15 1 LENS, YELLOW 21011447 09102327
16 1 LENS, RED 21011446 09102321
17 1 GAGE, ENGINE COOLANT TEMPERATURE 21011444 09101849
18 1 GAGE, HYDRAULIC OIL TEMPERATURE 21011443 09101850
19 1 SWITCH, KEY START 21011435 09102990
20 1 GAGE, FUEL LEVEL 21011552 09103218
21 1 CONTROL, ENGINE SPEED 21011123 09105021
22 1 JOY STICK, FRONT PLOW 21011098 09101196
23 3 GAGE, REEL WINDER & FAN PRESSURE 21011077 08100067
24 3 VALVE, REEL WINDER & FAN CONTROL 21011286 07300158
25 2 POTENTIOMETER, PULL ADJUST 21011123 09102609
26 2 HANDLE, PULL ADJUST POTENTIOMETER 21011089 09100668
27 3 SWITCH, SELECTOR 21011099 09101216
28 2 JOY STICK, CAPSTAN 21011081 08200602
29 2 GAGE, FEEDING PRESSURE 21011075 08100061
30 1 CONTACT BLOCK 21011284 09101192
31 1 HANDLE, CONTACT BLOCK 21011099 09101216
32 1 BASE, CONTACT 21011265 09101203
33 1 LAMP, 12 VDC 21011108 09102013
34 3 LATCH, PANEL 21011445 09101275
35 3 FUSE - 3 AMP 21011431 09101761
36 3 FUSE - 5 AMP 21011102 09101381
37 3 FUSE - 15 AMP 21011088 09100579
38 1 LABEL, MAX. HYD. OIL TEMPERATURE 08763187 ---
39 2 LABEL, MIN. OPERATING PRESSURE 08763188 ---
40 2 LABEL, MAX. OPERATING PRESSURE 08763189 ---
41 1 DECAL, NUMBER 1 02289658 ---
42 1 DECAL, NUMBER 2 02289659 ---

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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)

NOTE: The engine compartment should be level or parallel with


the ground for operation.

2. Re-adjust the rear stabilizer leg by removing the keeper pin and lowering the
leg as close to the ground as possible and replace pin. (See Figure 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)

Figure 3. Engage Leveling Figure 4. Lower Leg Replace Pin


Joystick Down

Figure 5. Anchor Center Figure 6. Anchor Adjacent To


of Machine Operation Panel

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D. REEVING THE DRUM


1. Reeve the drum appropriately for the type of operation being performed.
When reeving the drums, always start on the inside of the drum, toward the
center of the machine and reeve the rope so that it goes over the top of the
lower drum and enters within the first groove of the upper drum and comes
back around entering on the first groove of the lower drum. The rope then
travels to the second groove of the upper drum. Continue reeving accordingly
moving one position to the left each time. (See Figure 7)

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)

Figure 7. Reeving the Drum Figure 8. Thread Poly Rope


Through Guide Rollers
F. POSITION REEL ELEVATOR
1. Position and connect reel elevator according to specific reel
elevator instructions.

G. DETERMINE PULLING OR TENSIONING RANGE


Determine the proper pulling or tensioning range for the particular operation.

The inside scale of the dynamometer represents pulling or tensioning in the low
range, between 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:

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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:

Final Sag Tension= 2,500 ft-pounds


-minus-
Maximum Pulling Tension Under Final Sag Tension= 500 ft-pounds
Equals: 2,000 ft-pounds
-minus-
Tension setting of 1,000 ft-pounds below pulling tension
Equals: 1,000 ft-pounds

Table 2

H. SET PULLING/TENSIONING RANGE LEVER


1. Position range lever(s) (See Figure 9) according to the range of pulling or
tensioning being performed and the configuration of the puller/tensioner. For
example if the puller/tensioner is being used a single drum, both the number 1 and
number 2 range levers need to be set. If utilizing the unit as two independent drums,
set the range lever that corresponds to the drum being used. Or set both according
to their independent tensioning ranges.

The center position is neutral. The position toward the machine is high range. And
the position moving away from the machine is for low range operation. To move the
lever, pull out and hold the lever detent then push or pull the lever into the appropri-
ate position. Release detent. (See Figure 10)

IMPORTANT! The pulling/tensioning range lever will not set when


there is pressure on the drum. Also, never set or adjust pulling/
tensioning range lever when there is tension on placed conductor.
Moving the lever to neutral will release conductor tension.

Figure 9. Position Range Lever Figure 10. Put Lever into Proper
Position, Release Detent

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I. TENSIONING OPERATION (Single Drum)

1. Mechanically lock drums together. The drums need to be aligned properly


in order to insert the locking rod in place. Once drums are aligned, remove
drum cover, insert and secure locking rod and replace cover.
(See Figure 11,12 &13)

!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.

2. Set drum configuration selector to single drum. (See Figure 14)

3. Start the tensioner per start up instructions.

Figure 11. Remove Drum Cover Figure 12. Locking Rod

Figure 13. Secure Locking Rod Figure 14.


inside Drum Cover

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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)

6. 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 17)

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

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8. Disengage the negative brake


by turning the negative brake
switch counterclockwise.

9. Moving bull wheel joystick to


the down position and begin
tension operations.
(See Figure 19)

Figure 19. Move Bull Wheel


Joystick To Down Position

J. TENSIONING OPERATION (Two Independent Drums)

1. Start the tensioner per start up instructions.

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

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4. Move bull wheel control(s) joystick to the down position (See Figure 22)

5. 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 23)

6. Move the bull wheel joystick(s) to the neutral position (See Figure 24)

7. Disengage the negative brake(s) by turning the negative brake switch(es)


counterclockwise.

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

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K. PULLER OPERATION (Single Drum)


1. Mechanically lock drums together. The drums need to be aligned properly in
order to insert the locking rod in place. Once drums are aligned, remove drum
cover, insert and secure locking rod and replace cover.
(See Figure 26, 27 & 28)

!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.

2. Set drum configuration selector to single drum. (See Figure 29)

3. Start the puller tensioner per start up instructions.

Figure 26. Remove Drum Cover Figure 27. Locking Rod

Figure 28. Secure Locking Rod Figure 29. Set Drum Selector To
inside Drum Cover Single Drum

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4. Engage negative brake by turning negative brake switch one position


clockwise. (See Figure 30)

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.

7. Set dynamometer according to the specific pulling range required by


turning the dynamometer knob clockwise to increase and counter clockwise
to decrease until range is appropriately set. (See Figure 32)

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

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9. Disengage the negative brake


by turning the negative brake
switch counterclockwise.

10. 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 34)

Figure 34. Move Bull Wheel To


Down Position

L. PULLER OPERATION (Two Independent Drums)

1. Start the tensioner per start up instructions.

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

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4. Move bull wheel control(s) joystick to the down position (See Figure 37)

5. Set dynamometer(s) according to the specific pulling range required by


turning the dynamometer knob(s) clockwise to increase and counter clockwise
to decrease until range(s) is appropriately set. (See Figure 38)

6. Move the bull wheel joystick to the neutral position

7. Disengage the negative brake(s) by turning the negative brake switch(es)


counterclockwise. (See Figure 39)

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

Figure 39. Disengage The Figure 40. Move Bull Wheel to


Negative Brake Down Position

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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)

!ATTENTION: Disregarding the correct levels will cause serious


damage to the installed components.

!DANGER: Do not swallow hydraulic liquids, fuels, and cooling


liquids because they can be injurious to health and potentially
lethal.

C. TIRE INFLATION
Tires inflation pressure has to be o6 bar (87 psi).

!ATTENTION: Ignoring proper tire inflation pressure causes


dangerous situations during transport operations.

D. SUGGESTED LUBRICANTS
The manufacturer tests the machine with the following oils and lubricants:
a. hydraulic circuit 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.

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!ATTENTION: Using lubricants that do not conform to the


specifications indicated in the present manual may seriously
damage the machine components and, consequently, invalidate
the warranty conditions.

E. Diesel ENGINE MAINTENANCE


See the enclosed use and maintenance booklet.
To fill the fuel tank, use the filling cap on the tank (Table 2, pos. 20).

!DANGER: To fill with fuel, turn off the engine and let the engine
cool.

F. DIAGNOSTIC OF ELECTRONIC DIESEL ENGINE


The machine has a diesel engine at completely electronic management.

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).

To reset the engine alarms:


- turn the ignition key to the first position (Table 1, pos. 12) by pushing the
button (Table 1, pos. 41)
- release the button (Table 1, pos. 41) after 4 seconds
- after the reset sequence, turn the ignition key (Table 1, pos. 12) to the “0”
position
- wait 30-60 seconds, then restart the machine
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G. HYDRAULIC CIRCUIT MAINTENANCE


a. Change the hydraulic oil after 500 working hours and, thereafter, every 1500
hours (at least every year).

b. Use the proper tap at the bottom of the tank (Table 2, pos. 7) to discharge the
hydraulic oil.

!DANGER: Let the hydraulic oil cool completely before removing it


and always use suitable safety gear (gloves, etc.).

!ATTENTION: Disposing the used oil must be done in conformity


with the laws of the relevant country.

c. Fill the oil in the tank with the correct quantity using a proper filler
(Table 2, pos. 5).

!ATTENTION: When filling the oil tank, make sure no foreign


matter, which could cause irreparable damage to the circuit’s
components, enters with the oil. If possible, filter the oil with a
10 µm filter.

d. Periodically check the tank levels (Table 2, pos. 6). If necessary, fill up with
the same oil up to the maximum level.

e. Replace the filters’ cartridges (Table 2, pos. 4 and 9) after 500 working hours
and, then, every 1500 hours (or every year at least).

f. Check the oil filters to avoid clogging by means of the warning lights
(Table 1, pos. 5-6-7).

If necessary replace the cartridges making certain of the following filtering


degrees:
• suction filter (Table 2, pos. 9): 10 µ
• return filter (Table 2, pos. 4): 25 µ

For further maintenance operations of installed hydraulic components (pumps


and motors), refer to the enclosed documentation.

H. REDUCTION GEARS – STATIONARY BRAKES – COUPLER – DIFFERENTIAL


GEAR MAINTENANCE
a. Change the oil of the reduction gears, stationary brakes, coupler, and
differential gear after 50 working hours and, then, every 500 hours (or every
year at least).

b. To discharge the old oil of the reduction gear and of the stationary brake, use
the proper caps on the lower part of the casing of the same (Table 3, pos. 6
and 11).

For the coupler, use the proper cap (Table 2, pos. 16).

!DANGER: Let the hydraulic oil cool completely before removing it


and always use suitable safety gear (gloves, etc.).
29

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!ATTENTION: Disposing the used oil must be done in conformity


with the laws of the relevant country.

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.

For further maintenance operations of installed hydraulic components (pumps


and motors), refer to the enclosed documentation.

I. RADIATOR MAINTENANCE
Clean all radiators at least once a year and more if the machine is very dirty.

!ATTENTION: Persons in charge of maintenance, besides wearing


all the protection devices shown in this manual, must also wear
devices for protecting their respiratory organs.

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.

Use IP ATHESIA GR2 (ISO XBCEA 2) grease or an equivalent trademark on the


basis of the enclosed “SUGGESTED LUBRICANTS” Table.

K. OTHER PERIODIC OPERATIONS


When cleaning the machine, avoid direct jets of water or steam on the components of
the electric system of the machine and on the control board.

For the other periodic operations, refer to the Summary Table for ordinary
maintenance (see next page).

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L. SUMMARY TABLE FOR REGULAR MAINTENANCE


Following are the procedures and intervals for periodic maintenance.

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

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

Troubleshooting Guide

6.
Blown fuse
Low battery

starts

tarts

32

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

correct

When activating the control lever


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

33

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

When activating the control lever


the bull-wheels don’t work
(hydraulic control) release

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

cooling fan for the hydraulic oil


radiator and by completely opening
the reel winder valve with diesel
engine at medium-high rpm

cooling fan for the hydraulic oil


radiator and by completely opening
the reel winder valve with diesel
engine at medium-high rpm

36

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

The cooling fan for the hydraulic oil

cooling fan

The cooling fan for the hydraulic oil cooling fan

cooling fan

cooling fan hydraulic motor


cooling fan pump

cooling fan for the hydraulic oil


radiator and by completely opening
the reel winder valve with diesel
engine at medium-high rpm

plow

plow
plow

plow

37

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

How to Disable the Machine

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).

B. EXTENDED SERVICE STOP


When anticipating an extended service stop (two months at least), protect the
external parts with waterproof wax and empty the fuel tank.

During a service stop, start the machine at least once every two months and let the
machine idle for at least one hour, so the oil enters the hydraulic system to prevent
the gaskets from drying.

Store the machine under a roof. Do not cover the machine with pieces of cloth and/or
plastic materials that may cause an increase in the temperature and/or humidity.

If the machine is not used for one or more years, replace the hydraulic oil and
hydraulic circuit filters before re-starting the machine.

C. STRIPPING
Machine stripping has to be done by the manufacturer or by a specialized factory.

All the stripping operations must conform to company norms for accident prevention.

Waste materials must be divided by type (i.e. iron scrap, aluminium, plastic, rub, etc.)
and disposed according to the laws in force.

Used oils and polluting substances must be disposed by means of authorized


structures in conformity with the laws in force.

38

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

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.

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.

39

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

Condux International, Inc.


P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA
1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442
Internet: http://www.condux.com • e-mail: cndxinfo@condux.com
© Copyright 2007, Condux International, Inc.
Printed in USA
Literature Part Number: 21031644
Revision Number: 1.0

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

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