PILOT WIRES

During conductor paying out it is used

for pulling of ACSR conductors.
 PILOT WIRES
CHECK POINTS
• Broken wires,
• Worn out wires,
• Reduction in rope diameter,
• Rope stretch,
• Bird cage.
FIVE SHEAVE AERIAL ROLLER

The aerial roller is fixed

at bottom of the
Insulator. It is used to
ensure smooth running
of the ACSR conductor
during conductor paying
out and bear ACSR
conductor till clipping
work.
 FIVE SHEAVE AERIAL ROLLER
CHECK POINTS
• The 5 wheels of the aerial rollers should
be checked for free running.
• The neoprene rubber cushion on the
rollers shall be checked for any
cracks/wearing out.
• Bearing condition
• Proper size nut-bolt must be used in
plate
• Damage, Crack, Corrosion in frame.
 RUNNING/HEAD BOARD
The sub conductors
are attached to the
running board by
means of end socks
and swivel joints.
The pilot wire is
attached to the
other end of the
running board with
swivel joint. It is
used during
conductor paying
out.
 RUNNING/HEAD BOARD
CHECK POINTS
• Each Joints,
• Crack,
• Corrosion,
• Worn out body,
• Ensure frictionless rotation of wheel,
• Bearing condition.
 PILOT WIRE CONNECTOR

It is used to connect one pilot wire with another

CHECK POINTS
SWL, Pin condition,
Corrosion, Worn out
body, Thread
condition, opening
up, wear in the
portion where load
are subjected.
DRUM LIFTING JACK

It is used to lift the

conductor drum,
earth wire drum to
facilitate its rotation
during paying out.
CHECK POINTS
• No bend in base frame,
• Must be placed on a firm and level
ground,
• Proper lock pin must be used with slip
pin,
• Brake shoes condition
 TURN BUCKLE
It is used to tight guy support used to anchor
the angle tower or dead end tower and
stay used to anchor Puller and Tenssionr
machine.
 TURN BUCKLE
CHECK POINTS
• Corrosion or Wear in Eye hook,
• Corrosion or Wear in Body,
• Thread condition.
PILOT WIRE STAND / RILL WINDER MACHINE
It is used to wind the pilot wire during
conductor paying out. It is installed behind
the puller machine
CHECK POINTS
Condition of shaft carrying Pilot wire drum,
corrosion, damage, wear in Body.
SINGLE SHEAVE AERIAL ROLLER

It is used for earth wire paying out to

facilitate smooth running of earth wire.
 SINGLE SHEAVE AERIAL ROLLER
CHECK POINTS
• Crack, damage, wear in body and
bearing
• Shaft condition,
• Ensure frictionless rotation of the wheel.
 HYDRAULIC WIRE CUTTER
Used for cutting the ACSR conductor

CHECK POINTS
Lock pin must be fixed properly, check oil
level, no leakage of oil.
• Causes of failure to take load _
1) Damage of Piston O-ring
2) Reduce oil Level.
3) Sharpness of Cutter blade
MANUAL HYDRAULIC COMPRESSOR MACHINE
Used for mid span compression joint and the
dead end cones compression.
Reasons of failure -
1)Broken of bucket washer –Symptom (
Leaking of black oil)
2)Less Oil quantity
3)Entry of Dust in Pump
4)Damage of Low and High pressure ball
& spring- Cause oil leakage from Pump
inside the machine and fail to take
load.
N.B.-“Nike” Make 100ton capacity HYD
Joint Compressor Machine
CHECK POINTS
• Tested machines must be used for this
purpose,
• Oil level must be checked,
• No leakage in oil container,
BOLED TYPE COME ALONG CLAMP FOR CONDUCTOR
It is used during rough sag and final sag of
conductor to tightly grip the conductor
BOLED TYPE COME ALONG CLAMP FOR CONDUCTOR
CHECK POINTS
• Worn out body, crack, corrosion,
• Improper casting,
• Stretch the U-hook and decrease the
inside gap of U-hook,
• Use of proper nuts.
 AUTOMATIC CLAMP
It is used mainly in final sag to tightly
grip the ACSR conductor.

CHECK POINTS: Batterered and worn out

body, Proper nuts must be used, Thread
condition, Locked properly.
BOLTED TYPE COME ALONG CLAMP FOR EARTH WIRE
It is used during rough sag and final
sag of earth wire to tightly grip the
earth wire .
 FLAT CLAMP
It is used to hold wire rope, Earth Wire
during Final sag of conductor and
earth wire .

Batterered and worn out body,

Proper nuts and bolts must be used and
tight properly.
 JOINT PROTECTOR
It is used to protect the Ariel Roller from
damage caused by mid span
conductor joint.

Check points: Split or rough surface

 MANUAL WINCH MACHINE
It is used in final sag operation and
clipping operation.
CHECK POINTS
• Proper fixing with tower leg,
• Worn or batterered or tempered gears and
bearing condition,
• Oil seal,
• Packing arrangement,
• Worn out body.
REASONS OF FAILURE
Due to damage of oil Seal and packing oil will
leak from the machine.
LUBRICATION
Gear oil “90” 10 ltrs and 5 kgs Bearing grease
mixture
 DOUBLE END SOCKS
It is used to tightly grip the ACSR conductor

Check Point: All mesh condition and

end grip.
TENSIONER MACHINE & PULLER MACHINE
Purpose :Used in conductor paying out
Check Points:
• Maintenance and handling must be done in accordance with the manufacturer
instruction, Check tyre pressure, Provide back stay, body earthing.
• For safety reasons, during the transport machine comes without hydraulic oil and
fuel.
• Do not ingest hydraulic liquids because injurious to health and potentially lethal.
• Tyres inflation pressure has to be 7 bar. The non-respect of tyres inflation pressure
causes dangerous situations during transport operations.
• The suitable filters protecting the hydraulic circuit have to be replaced after 500
working.
• Grease 2-3 times per day the crown gear of the bull wheels using the suitable
greasing pump.
• Weekly grease all the other parts subjected to rotation translation.
• 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.
• Safety Devices used in machine
• Load limiting device with endothermic engine stop in case of exceeding of the
maximum preset load.
• Mechanical negative safety brake for movement stop in case of lack of hydraulic
pressure.
• Timing case and protections on moving parts, where technologically possible.
• It is absolutely forbidden the use of the machine without protecting timing cases or
with damaged / disconnected safety devices.
• The emergency stop device for stopping the machine while working must only be
used in emergencies.
• Daily, before starting the work, the operator has to verify the functionality of the
machine safety devices.
 FOUR SHEAVE PULLEY

Mainly used in sag final sag and clipping

operation.
 FOUR SHEAVE PULLEY
Check point:
• Check for signs of opening up,
• Wears and Crack in hook,
• Proper bolts and slip pin are used,
• Condition of Shaft and Bearing,
• Ensure frictionless rotation of the wheel,
• worn out or batterered body
 ARTICULATED JOINT
Periodically oiling, worn or batterered body, rotate freely without
friction, pin condition, condition of roller bearing.

It is used to joint pilot wire with the head board. It’s

revolving characteristics permit pilot wire to move
without twisting during conductor paying out.
Equalizer Pulley

It is used during final

sag. It’s function is to
equalize tension
applied in both
conductor by four
sheave pulley during
final sag.
Check point:
• Condition of Shaft,
• Bush
• Ensure frictionless rotation of the wheel,
• Worn out or batterered body.
 TURN TABLE
Purpose :It’s facilitate easy rotation of the conductor drum,
earth wire drum. It is mainly used during earth wire paying out.

Check point:
•Ensure firm structure
capable of carrying load of
conductor drum and earth
wire drum,
•Bearing,
•Roller condition,
DEE SHACKLE
Check Points:
• Safe Working Load,
• Identification mark,
• Distorted Body,
• Worn out body or pin,
• Corrosion,
• pin must be seated,
• Shackle is not opening
up.

Prepared By: S.BHATTACHARYA