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Summary of Contents for Sherman + Reilly Revolution Series
- Page 1 Sherman + Reilly Revolution Series PT-3000 Puller Tensioner Operator’s Manual...
- Page 2 SHERMAN + REILLY™ Revolution Series PT-3000 Puller Tensioner OPERATOR’S MANUAL ©2018 by Sherman + Reilly Inc. Revision B August 2018...
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Page 3: Important Safety Notice
Save this operator’s manual for future reference. This material is copyrighted and proprietary to Sherman + Reilly™ Inc. and is not to be reproduced, used, or disclosed except in accordance with express written permission from Sherman + Reilly™ Inc. Information is provided for the purpose of product usage and maintenance descriptions only. -
Page 5: Table Of Contents
Table of Contents ..................................3 MPORTANT AFETY OTICE ..............................3 OMMUNICATION WITH THE ANUFACTURER INTRODUCTION ..................................1 ....................................1 ERMS OF SAFETY ..................................... 2 ..................................2 AZARD VERVIEW ISO S : ................................3 OMMON YMBOLS ..............................4 PERATOR AFETY RECAUTIONS .............................. - Page 6 – N ............................38 AYOUT PERATIONS OWERED Manual Payout Brake ..............................38 Non-powered Walk-off ..............................39 ....................................40 ULLING Tension................................... 42 ......................................42 ENSIONING Spider System ................................44 ............................... 45 NDERGROUND ONNECTORS ................................46 NDERGROUND ULLING ............................48 PERATION NSPECTION HECKLIST TROUBLESHOOTING ................................
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Page 7: Introduction
Sherman + Reilly™ strongly recommends that only personnel that are literate in the English language and who verbally understand the English language be considered as operators or service personnel for this machine. -
Page 8: Safety
Safety Safety Hazard Overview Familiarize yourself with the following symbols before operating machinery. These safety alert symbols are used to alert you to potential hazards. Please pay attention to all safety warning labels and information placards posted on the machine, components, and trailer assembly. -
Page 9: Common Iso Symbols
Safety Common ISO Symbols: Not all symbols apply to all machines Eye and/or Ear Hazard High voltage hazard Risk of Explosion Hazard Electrical shock hazard Toxic Hazard Pinch point and/or entanglement hazard Cutting and/or crushing hazard Flammable Material Hazard Crushing of body hazard Automatic Start-Up Hazard Crushing of Toes or Foot Hazard Carcinogen Hazard... -
Page 10: Operator Safety Precautions
Safety Operator Safety Precautions Do not attempt to operate any Sherman + Never use hands to check for hydraulic system Reilly™ equipment without proper instruction, leaks. Hydraulic fluid escaping under pressure can cause personal injury. including reading and understanding the provided manual. -
Page 11: Employer Safety Precautions
Safety Employer Safety Precautions This guideline is intended to assist owners, employers, job site supervisors, and operators in ensuring that the equipment is operated in a safe manner. Each job site may have additional situations and conditions which need consideration. Information in this manual applies to all the operators charged with the use and/or maintenance of the machine. -
Page 12: Chemical Safety
All chemical handling and disposal should be done in accordance with environmental, federal, state, and local laws and regulations. Sherman + Reilly™ is not liable for the mishandling, misuse, or improper disposal of chemicals, with regard to the use or maintenance of Sherman + Reilly™... -
Page 13: Before Starting Operations
Safety Before Starting Operations • Only trained and authorized personnel can operate and maintain the machine. • Follow all safety, precautions, and instructions in this manual when operating or performing inspection or maintenance on the machine. • If you are not feeling well, of if you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger. - Page 14 Safety Precautions for Inside the Cab • Do not leave tools or machine parts lying around inside the operator’s cab. If tools or parts get into the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in serious personal injury or death.
- Page 15 Safety Keep all the electric wiring connections clean and securely tightened. • • Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring. Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are •...
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Page 16: Pre-Towing Checklist
Safety Pre-Towing Checklist 1. Make certain tow vehicle has the capacity and rating to tow machine safely. 2. Inspect pintle eye for excessive wear, corrosion, cracked welds or structural damage. Check the bolts holding the pintle eye in place. 3. Inspect tow vehicle hitch and ensure hitch. 4. -
Page 17: In The Event A Fire Occurs
Proper training must also be provided by employer before engaging in any firefighting efforts. Should a fire occur with Sherman + Reilly™ equipment, the operator should not use the equipment until it has been inspected for safety and approved to be returned to service- regardless of the size of the fire. -
Page 18: Emergency Stop Procedure
Safety Emergency Stop Procedure In the event of an emergency, the operator must be aware of how to shut down the machine so as to avoid any additional injuries or equipment damage. In these emergency situations, the lives of lineman, work crews, surrounding bystanders, as well as the operator may become at risk- dependent upon the severity of the situation. -
Page 19: Unauthorized Modifications
Safety Unauthorized Modifications • Sherman + Reilly™ will not be responsible for any personal injuries, product failures, physical loss or damage, or impacts to the environment resulting from modifications made without written authorization from Sherman + Reilly™. Any modifications made without written authorization from Sherman + Reilly™ can create hazards. Before •... -
Page 20: Positioning The Machine
Safety Positioning the Machine WARNING: DO NOT OVERSTRESS THE HITCH AND TRAILER TONGUE. The trailer frame is not designed to support the weight of the pulling vehicle. If the unit is to remain connected to the towing vehicle, extreme caution should be taken to assure that the pintle-eye hitch does not lift the towing vehicle in conjunction with leveling and lifting with the trailer’s hydraulic jacks. -
Page 21: Controls
Controls General Overview Sherman + Reilly™ Revolution Series PT-3000 Single Drum Puller/Tensioner is a multi-purpose puller and tensioner capable of pulling up to 3000 lb overhead with underground pulling capabilities up to 7500 lb, and a Spider™ Pilot Line system with an integrated levelwind. -
Page 22: Specifications
Specifications Specifications Details: PT-3000 (Dimensions, weights, and capacities listed are approximate. All specifications are subject to change without notice.) Pulling Capacity 3,000 lb Tensioning Capcity 2,000 lb Average Line Speed Pulling: 4 mph / Payout: 10 mph 66 in. Diameter (≤39 in. wide) / 38 in. Width / 6,000 lb Weight Core Diameter: 18 in Maximum Conductor Reel Size... -
Page 23: Terms To Know
Controls Terms to Know 1. Cab 11. Exterior Hydraulic Controls 21. Engine 2. System Control Panel 12. PMTA Boom Mount 22. Fuel Tank 3. Operator’s Chair 13. Steps 23. Hydraulic Filter 4. Control Box 14. Tie-downs 24. Reel Motor 5. Emergency Stop 15. -
Page 24: Operator Controls
Controls Operator Controls Control Panel on the Unit ❶ Control Screen ❷ Control Switches ❸ Key Switch ❹ Payout Brake Control ❺ 12 v DC outlet ❻ USB Accessory Charger ❼ Joystick Control ❽ Emergency Stop NOTE: Product images shown are for illustration purposes only and may not be an exact representation of your product. - Page 25 Controls Master Power Key Switch This switch is used to control power to the operator controls and engine. CAUTION: Always ensure that the master power key switch is turned to the [OFF] position when the machine is not in use. If the machine is to be left unattended, remove key from the key switch and stow in a secure place, while also securing the operators cab to prevent any unauthorized access to the controls or operation of the machine.
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Page 26: Handling And Operation
Controls Handling and Operation Pre-Operation Inspection Perform the following checks before starting the engine. At the beginning of the day’s work to ensure that there is no problem with the operation of the machine. If these checks are not performed properly, problems may occur with the operation of the machine, and there is a danger which may lead to serious personal injury or death. - Page 27 Controls Ensure that trailer brakes work and that wheel chocks are available. Check tire pressure- tire pressures are posted on the tire sidewall. If tire pressure slow, inspect tire for damage or punctures. If damaged or punctured, have repaired or replace. Ensure that all jacks are raised and that trailer is clean and free from trash or debris.
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Page 28: Start Up And Set Up Procedure
Controls Start Up and Set Up Procedure 1) Perform all pre-operation inspections. 2) Position the machine in a suitable location for the pull. The machine should be positioned centered on the lead block, and parallel to the line being pulled prior to beginning operations. Wheels should be chocked to prevent the unit from rolling. -
Page 29: System Control Screen Descriptions
Controls System Control Screen Descriptions Main Screen The Main Screen visible on the System Control Panel when the machine is first turned on shows the main system parameters that are of interest to an operator: current operating mode, fuel level, line tension, line speed, engine load, and distance. -
Page 30: Engine Information Screen
Controls Engine Information Screen Screen is accessed by using Screen Selection Window on MAIN screen. Press ESC soft-key to return to MAIN screen. All values on this screen are received from ECU. Backgrounds of value fields will turn RED to indicate flawed value due to ECU communications error. -
Page 31: Hydraulic Information Screen
Controls CAUTION: HIGH EXHAUST TEMPERATURE Active ReGen - Hot Exhaust warning. Engine Warning Icon Be sure that exhaust will not come into contact with any combustible materials. DPF Auto ReGen Active Engine Stop Icon DPF Regen Inhibited Engine Malfunction Indicator Hydraulic Information Screen Screen is accessed by using Screen Selection Window on MAIN screen. -
Page 32: Set Up Screen - Security Level 0
Controls Set Up Screen – Security Level 0 Screen is accessed by pressing SET UP soft-key on MAIN screen. Press ESC Soft-key to return to MAIN screen. 1 Machine Model indicator Shows selected engine type: DSL = diesel, T4F, engine (default) GAS = gas engine 2 Security Code Use Left / Right cursor soft-keys to move highlight box, when box is NOT flashing, to desired field. -
Page 33: Automatic Control System Shutdown
Controls Automatic Control System Shutdown The system is programmed with an automatic shutdown feature. If the System Control is powered up but the engine has been off for 30 minutes, the System Control will power off after 5 minutes, if the engine is not started. This helps protect from draining the battery. The screen will display time before automatic shut-down Controller Communications Error Screen Screen appears if there is a communications error between Cr0233... -
Page 34: Dpf And Engine Indicators
Controls Screen is accessed by using Screen Selection Window on MAIN screen. Displays Active Engine Error codes (maximum of 10) being reported by ECU. Contact engine supplier for detailed information on SPN / FMI codes. Press ESC soft-key to return to MAIN screen. Engine Warning Icon signifies an error code. -
Page 35: Engine Throttle Control
Controls Engine Throttle Control Engine throttle control is managed automatically by the control system depending upon the power demand. The RPM on the engine can also be increased or decreased from the System Control Panel Engine Information Screen in 100 RPM increments, depending upon the power demands of the pull, using the Up/Down arrows on the Control Panel, Jack Controls The engine must be running for the jacks to function. -
Page 36: Pmta Boom Control
Controls PMTA Boom Control The optional PMTA Boom is controlled via the joystick when the unit is in PMTA Mode at the System Control Panel. See optional PMTA Instructions for additional information. To utilize the PMTA Boom: 1) At the MAIN Screen at the System Control Panel, go to the SETUP Screen. -
Page 37: Brake Operation
Controls Brake Operation The drum brake status is shown in the center of the Main system control panel screen. This symbol indicates that reel brake is ON / applied. Disappears when the brake is released. By default, the drum brake will be ON when the machine is started. To disengage the hydraulic drum brake, depress the joystick trigger then pull the joystick slightly backward and out of neutral. -
Page 38: Hydraulic Manual Override
For safe operations, it is recommended that the hydraulic fluid be allowed to warm-up to a working temperature prior use pulling. Sherman + Reilly™ units ship with ISO 32 hydraulic fluid. Cold hydraulic fluid can damage the machine. This blue temperature message on the System Control Panel indicates that the oil temperature is below 60°... -
Page 39: Diesel Particulate Filter (Dpf) Re-Generation Information
Controls Diesel Particulate Filter (DPF) Re-Generation Information PT-3000 employs a T4 Diesel Engine that utilizes a Diesel Particulate Filter (DPF) to remove soot and undesired combustion gas from the exhaust system. This filter must be periodically cleaned. During normal operation, the regeneration (ReGen) of the DPF occurs automatically. -
Page 40: Reel Removal And Installation
Controls Reel Removal and Installation Make sure there is adequate overhead clearance with no obstructions before attempting to remove or install a reel. WARNING: Injury or Death: CRUSH HAZARD: Personnel assisting during Drum/Reel removal and installation must wear appropriate PPE and must remain vigilant and ready to quickly move clear of in the of a load shift or restraint failure. - Page 41 Controls Slide the reel lifting eye/tapered cone onto the drive bar. The tapered cone is turned in and slid into the arbor NOTE: hole on wooden reels when necessary to stabilize the reel. Align the reel lifting eye with the lifting eye on the drive bar and tighten the set screws.
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Page 42: Payout Operations - Pull Mode
Controls Payout Operations – PULL Mode NOTE: Before beginning payout operations, the operator must perform all pre-operation inspections. (See Pre- Operation Inspection Checklist on page 38.) Pre-operation inspections are important for the safe operation of the machine and are required under OSHA Regulations. The PT-3000 is designed to offer two payout operation options: powered and non-powered. - Page 43 Controls NOTE: The reason the joystick must first be pulled back during payout is that this motion triggers the release of the hydraulic brake and begins the hydraulic pressure building sequence. As soon as the brake releases, the operator will notice the drum beginning to rotate very slowly backward toward the operator.
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Page 44: Payout Operations - Non-Powered
Controls Payout Operations – Non-Powered Line can be pulled off with the hydraulic motor disengaged from the reel and the engine and system shut down. The method is essentially a freewheel with a manual, low-tension payout brake (Manual Payout Brake). NOTE: When pulling the line of with the hydraulic motor disengaged, there is no counter to indicate line length. -
Page 45: Non-Powered Walk-Off
Controls Non-powered Walk-off 1) The unit should be positioned, anchored, and appropriately grounded. (See Positioning the Machine). 2) If not done already, remove the rope from the Levelwind. 3) The Levelwind out of the way, all the way to the street side -right side when viewed from the cab. -
Page 46: Pulling
Controls Pulling Setup 1) The unit should be positioned, anchored, level, and appropriately grounded. (See Positioning the Machine) Disengage the manual payout brake coupler. 3) Install the pulling drum, if not already installed. (See Reel/Drum installation section.) 4) The pulling line/bull line should be already paid out and ready to connect. (See Payout section.) Attach the pulling line/bull line to the conductor with pulling grips and pulling swivel. - Page 47 Controls Pulling continued 5) At the System Control Panel, switch the unit to [PULL] by pressing the [MODE] button. 6) Adjust the Line Tension limit using the Up/Down arrow keys. NOTE: The tension limits can be adjusted in 100 lb. increments without halting operations by using Up/Down arrow keys on the control panel.
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Page 48: Tension
Controls Tension Tensioning Position the unit in a suitable location where it will be free from obstructions and clear of any apparent hazards, centered on the lead block, and parallel to the line being tensioned. Chock the wheels. Set up as level as possible using the jacks. Install appropriate anchoring and grounding. - Page 49 Controls 8) Begin tensioning operations by depressing the joystick trigger. Pull back slightly on the joystick, bringing it out of neutral, and then pause for the brake to release. Once the brake is released, release the joystick trigger, then continue to pull backward on the joystick until it is all the way back.
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Page 50: Spider System
Controls Spider System The Spider System is used to haul a pulling line (“bull rope”) from a pulling unit to a tensioning unit. The rewind system utilizes a levelwind to ensure smooth even distribution of the pilot line onto the spider reel. To utilize the Spider System: 1) At the MAIN Screen at the System Control Panel, go to the SETUP Screen. -
Page 51: Underground Connectors
OEM specifications used when replacing pulling cable. Sherman + Reilly has developed a testing procedure and specification assurance with a wire rope manufacturer. This pulling cable is available from stock at Sherman + Reilly at a competitive price - Part Number: 700092. -
Page 52: Underground Pulling
Controls Underground Pulling To use the PT-3000 for pulling underground, the unit must be equipped with: an underground pulling drum containing steel pulling cable. (An optional Pad Mount Transformer Adapter (PMTA) is available.). Additionally, non-swiveling underground line connector must be used. Never used overhead line swivels or pulling rope for pulling conductor underground. - Page 53 Controls Underground Pull Engine is running. Hydraulic fluid is warmed- up. 1) The hydraulic motor is engaged. (See Engaging the Hydraulic Drive Motor.) 2) System is in “UG” Mode. 3) Set the desired maximum Tension Limit. NOTE: The tension limits can be adjusted without halting...
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Page 54: Post-Operation Inspection Checklist
Controls Post-Operation Inspection Checklist When parking the machine, the wheels should be chocked Check engine oil, radiator coolant, and hydraulic fluid levels- to ensure no leakage after operations. Store all grips, blocks, and other tools/equipment used during operations back into the tool box. Then close and ... -
Page 55: Troubleshooting
Troubleshooting Quick Tips ENGINE WILL NOT START OR RUN Dead battery. No fuel- check fuel gauge. Other- Refer to engine manufacturer’s manual. DRUM WILL NOT ROTATE Low system pressure drum clutch not releasing. Drum clutch out of adjustment. ... - Page 56 Licensee under this agreement may only be used by the Licensee for the purpose of operating, servicing, maintaining, and repairing said Sherman + Reilly™ equipment and must not be disclosed to any third party or used to create any machine which is substantially similar to said Sherman + Reilly™ equipment.
- Page 58 Some product ™ improvements may have taken place after this manual was published. For the latest information on Sherman + Reilly products, contact us by phone at (423) 756-5300 or 1-800-251-7780 or via email at help@sherman-reilly.com or at the mailing address listed above.
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