Tesmec FRB616 Installation, Operation And Maintenence Handbook
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Tesmec FRB616 Installation, Operation And Maintenence Handbook

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  • Page 1 F F F F R R R R B B B B 6 6 6 6 1 1 1 1 6 6 6 6 6 6 6 6 F F F F R R R R B B B B 6 6 6 6 1 1 1 1 6 6 6 6...
  • Page 2 The machine is supplied without hydraulic oil and fuel during transport for precautionary measures. Please refer to this manual for all information regarding the characteristics and quantities required. Should you have any doubt, please get in touch with TESMEC. ATTENTION Pour mesures de sécurité, pendant le transport la machine est livrée sans huile hydraulique...
  • Page 3 TENSIONER Model: FRB616 TENSIONER Model: FRB616 Serial number ..... Manufacturing year ..... Working order ..... USE AND MAINTENANCE INSTRUCTIONS...
  • Page 4 TENSIONER Model: FRB616 1. GENERAL INDEX Page GENERAL INDEX GENERAL DATA AND PRESCRIPTIONS MANUFACTURER COMMUNICATIONS WITH THE MANUFACTURER TYPOLOGY AND USING FIELD PERFORMANCES TECHNICAL CHARACTERISTICS ACOUSTIC EMISSION GENERAL INFORMATION FOR THE MACHINE USE GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE...

  • Page 5: Table Of Contents

    TENSIONER Model: FRB616 ROPE LOCKING CLAMP (OPTIONAL) 5.10 CONNECTED MACHINES USE WITH SYNCHRONIZER FOR A SIMULTANEOUS BRAKING OF ALL INDEPENDENT CIRCUITS 5.11 CONNECTED MACHINES USE CON SINCRONIZADOR Y ENCHUFE MECÁNICO PARA FOR A SIMULTANEOUS BRAKING OF ALL INDEPENDENTS CIRCUITS 2 BY 2 5.12...
  • Page 6 Number, Manufacturing Year and Order. These data can be found in the machine-identifying table. TYPOLOGY AND USING FIELD The machine mod. FRB616 is suitable for the simultaneous drive of 2 conductors with a max. diam. of 46 mm with two couple of bull-wheels at independent control.
  • Page 7 TENSIONER Model: FRB616 TECHNICAL CHARACTERISTICS Bull-wheels nominal diameter: 1700 mm Max. conductor diameter: 46 mm 46 kW – 2600 rpm Diesel engine: Electric system: 24 V Transmission: 2 open hydraulic circuits with hydraulic oil cooling Safety brake: 2 negative and self-acting type...
  • Page 8 TENSIONER Model: FRB616 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE MAINTENANCE a. It is absolutely forbidden to carry out any work of maintenance, adjustment or setting on units while stringing (except for the operations indicated in the present manual).
  • Page 9 TENSIONER Model: FRB616 2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL When using the machine, always remember to respect the following temperature limits that can be reached with hydraulic oil as function of the working condition. TEMPERATURE LIMITS FOR HYDRAULIC OIL (°C)
  • Page 10 TENSIONER Model: FRB616 2.15 APPLIED NORMS If the machine is commercialized in C.E. responds to the following regulatory framework: 2006/42/CE Norm of the European Parliament and Council referring to the laws of the machines member States. 2004/108/CE Norm of the European Council referring to the laws of the electromagnetic compatibility member States.
  • Page 11 TENSIONER Model: FRB616 3. TRANSPORT AND POSITIONING INSTRUCTIONS MACHINE LIFTING For the machine lifting use only devices as overhead travelling cranes or lift trucks, with a capacity equal to the mass to be lifted. The instruments used for the machine lifting (ropes, cables, hooks, etc.) have to be exactly dimensioned as compared to the mass to be lifted and have to be connected to the proper elements foreseen on the machine (table 1, pos.
  • Page 12 TENSIONER Model: FRB616 ASSEMBLING OPERATIONS Assemble the tyres in the suitable seats. Assemble the entry rollers in the suitable seats (see tables 4 and 5). TRANSPORT ON TRAILER Machine is not suitable for road towing. Possible displacements on trailer in the working site must be carried out by a connection to the towing unit by means of the towing eye on the drawbar (table 1, pos.
  • Page 13 TENSIONER Model: FRB616 Machine anchoring sequence is the following: a. keep the wheel brakes of the machine disengaged. b. anchor the machine to the ground using adequate ropes and turnbuckles, connecting the ears (table 2, pos. 4), located at the rear of the machine, to the anchoring stakes.
  • Page 14 Load the rope on the bull-wheels as shown on tables 2 and 3 and place the intake rollers for rope guiding in the most suitable position. Tensioner mod. FRB616 Recommended number of grooves to be used Pulling force in every...
  • Page 15 TENSIONER Model: FRB616 DANGER: please pay attention to the risk to be squeezed during the operations above described. MACHINE SET-UP Before the use, the machine must be set in stand-alone using mode, operating on the control panel (table 4). a. insert and turn the ignition key (table 4, pos. 1) in "1" position b.
  • Page 16 TENSIONER Model: FRB616 ELECTRONIC MULTI-FUNCTIONS DISPLAY PAGES The electronic multifunction display shows 4 working pages: 1. METER COUNTER & SPEED PAGE This page shows the speed and the meter counter for each independent circuit speed of capstan nr.1 meter counter of capstan nr.1 speed of capstan nr.2...
  • Page 17 TENSIONER Model: FRB616 4. HOUR COUNTER PAGE This page shows the working hour of the diesel engine in the center and 4 percentage check icons on the edges: diesel engine water cooling temperature hydraulic oil temperature diesel engine fuel level Switch from one page to the other one by using the up () or down () key...
  • Page 18 TENSIONER Model: FRB616 MACHINE USE FOR THE INDEPENDENT BRAKING OF RIGHT AND LEFT BULL-WHEELS a. Check if the connecting pins (table 5) of the bull-wheels are disengaged. If not, disengage them. b. Move the selector (table 4, pos. 38, 39) towards left .
  • Page 19 TENSIONER Model: FRB616 4.10 MACHINE USE WITH ONE CIRCUIT FOR BRAKING (TENSIONER) AND THE OTHER FOR RECOVERY (PULLER) To set the 1 capstan circuit for recovery (puller) follow these instructions: a. Increase the Diesel rpm till the max. value (2600 rpm) acting on the accelerator (table 4, pos. 3).
  • Page 20 (table 4, pos. 17), the brake by the potentiometer (table 4, pos. 16). 4.13 REEL ELEVATORS USE The machine can feed all the reel elevators made by Tesmec. It can feed 2 reel elevators for the use as tensioner or puller. If using two ropes or two conductors, act as follows: a.
  • Page 21 4.15 COMPRESSOR CONNECTION (OPTIONAL) The machine has been studied to be connected to a Tesmec compressor. a. Connect the rapid couplers (table 7, pos. 3 and 4). b. Start the machine, turn the selector (table 4, pos. 33) towards right position c.
  • Page 22 TENSIONER Model: FRB616 5. INSTRUCTION FOR USE – CONNECTED MACHINES GENERAL ASPECTS This machines could be equipped with an electronic connection package as an optional device. This device allow to use multiple machines connected between them, controlled and operated by a single operator for the main working parameters (basically speed, pull, diesel engine rpm).
  • Page 23 TENSIONER Model: FRB616 Prior to operate the set-up of the machines, check that:  The machines are connected through the special connecting cable  The ground devices are installed and connected MACHINES SET-UP Before the use the machine must be set in connected mode by assign to each machine the correct ID number, starting from left to right, as described in the previous chapter.
  • Page 24 TENSIONER Model: FRB616 e. on the screen page “BULL WHEELS PIN CONNECTION?” set the “YES” or “NO” option, depending on the configuration of use, by using the up () or down () key press the return key ( ) to save the settings.
  • Page 25 TENSIONER Model: FRB616 MACHINE USE FOR THE SIMULTANEOUS BRAKING OF RIGHT AND LEFT BULL- WHEELS a) Connect right and left bull-wheels by the suitable pin (table 6). b) Move the selector (table 4, pos. 22) towards left. c) Move the selectors (table 4, pos. 38,39) towards left.

  • Page 26: Rope Locking Clamp (Optional)

    TENSIONER Model: FRB616 MACHINE USE AS PULLER (RECOVERY FUNCTION) FOR THE CONDUCTORS SAGGING REGULATION a) Increase the Diesel rpm till the max. value (2600 rpm) acting on the accelerator (table 4, pos. 3). b) Move the selectors (table 4, pos. 38, 39) towards right.
  • Page 27 TENSIONER Model: FRB616 To program the same pull value simultaneously on all circuits: 1. Move the joystick downwards (tab.4, pos.11) on recovery position 2. Turn the potentiometer (tab. 4, pos. 12) until read on the dynamometer (tab. 4, pos. 14) the desired pull value (puller scale) 3.

  • Page 28: Alarm Condition When Using Connected Machines

    TENSIONER Model: FRB616 DANGER: Always remember to move the selectors (tab.4, pos.13,17) leftwards (BLOCKED) before execute the following operations: 1. Disconnect the cable that maintains united the machine. 2. Interrupt the feeding on one control panel. Worth the loss of the conductors pull in case the selectors (tab.4, pos.13,17) were not positioned to the left (BLOCKED).

  • Page 29: Safety Conditions

    PROHIBITION: is not allowed to install on board radio equipments if not authorized by Tesmec. These could create electronic equipment malfunctions, putting the personnel at serious risk. EMERGENCY STOP DEVICE The machine is equipped with an emergency stop device (table 4, pos.

  • Page 30: Residual Risks

    TENSIONER Model: FRB616 RESIDUAL RISKS In the machine there are still the following residual risks: 1. Sudden break of the conductor. The break of the conductor causes sudden movements of the machine and of the conductor connected to the machine.

  • Page 31: Maintenance

    TENSIONER Model: FRB616 7. MAINTENANCE GENERAL PRESCRIPTIONS ATTENTION: possible repairs not carried out by the manufacturer and not allowed by a written authorization relieve the manufacturer for any responsibility in case of accidents to persons or damages to things and/or to the machine, causing also the loss of warranty.

  • Page 32: Hydraulic Circuit Maintenance

    TENSIONER Model: FRB616 HYDRAULIC CIRCUIT MAINTENANCE Suitable filters protect the hydraulic circuit. The filters have to be replaced after the first 500 working hours and every time that the warning lights (table 4, pos. 29, 30, 31) light with hot oil.

  • Page 33: Radiator's Maintenance

    TENSIONER Model: FRB616 RADIATOR’S MAINTENANCE At least once a year, or more in case of use in dusty places, is foreseen a blowhole with compressed air of the radiant mass of the radiators. ATTENTION: in order to make this operation the one in charge of maintenance, besides wearing all the protection devices already shown in this manual, must also wear a device for protecting respiratory organs.

  • Page 34: Summary Table For Ordinary Maintenance

    TENSIONER Model: FRB616 SUMMARY TABLE FOR ORDINARY MAINTENANCE In this card are listed main operation of periodic maintenance and relevant intervals. Interval Part Object Daily 50 h 250 h 500 h 1500 h Engine oil Oil filter Cooling liquid Diesel engine (***)

  • Page 35: How To Disable The Machine

    TENSIONER Model: FRB616 8. HOW TO DISABLE THE MACHINE TRANSPORT Before transporting the machine, empty any liquid that can be set on fire contained in the machine (oils and fuels). Transport must be effectuated as per the specifications described in chapter 3 (Transport and positioning instructions).

  • Page 36: Enclosed Documents

    TENSIONER Model: FRB616 9. ENCLOSED DOCUMENTS TABLES Machine in working position – Lateral view Table 1.1 Machine set for pulling one conductor with nylon bull-wheels – Upper view Table 2.1 Machine set for pulling two conductors with nylon bull-wheels – Upper view Table 3.1...
  • Page 37                          ...
  • Page 38 TENSIONER MOD. FRB616 TABLES - 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli, 2 Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024 Fax 0039 / 035 / 4522445 Fax 0039 / 035 / 826375 E-mail: info@tesmec.it...
  • Page 39 PULLER-TENSIONER Model: FRB616 TABLE 1.1 1) Air suction filter for diesel engine. 2) Machine lifting point. 3) Inlet rollers. 4) Hydraulic oil return filter. 5) Hydraulic oil filling cap. 6) Hydraulic oil level. 7) Hydraulic oil draining plug. 8) Rapid couplers (see table 5).
  • Page 41 PULLER-TENSIONER Model: FRB616 TABLE 2.1 1) Inspection doors for crowns lubrication. 2) Manual greasing pump. 3) Control panel (see table 4). 4) Machine anchoring. 5) Reduction gear oil filling cap. 6) Reduction gear oil draining plug. 7) Reduction gear oil level.
  • Page 43                          ...
  • Page 45 PULLER-TENSIONER Model: FRB616 TAVOLA 4.1 1) Diesel engine ignition key. 2) IPO push button. 3) Diesel engine accelerator 4) Lifting plough control lever. 5) Selector for automatic/manual fan functioning. 6) Valve for pressure adjusting reel wheel. 7) Manometer for pressure reel wheel.
  • Page 47 PULLER-TENSIONER Model: FRB616 TABLE 5.1 1) Pin. 2) Referring point. 3) Referring point. 4) Nylon sector. 5) Fixing key for sectors. 6) Keys fixing screw.
  • Page 49 PULLER-TENSIONER Model: FRB616 TABLE 6.1 1) Rapid coupler for return hose connection of hydraulic head no. 1. 2) Rapid coupler for return hose connection of hydraulic head no. 2. 3) Rapid coupler for delivery hose connection of hydraulic head no. 1.
  • Page 51 PULLER-TENSIONER Model: FRB616 TABLE 7.1 (OPTIONAL) 1) Pressure adjusting valve. 2) Manometer. 3) Valve block. 4) Opening/closing lever for compressor feeding (pos. A: compressor connection, pos. B: compressor release). 5) Rapid coupler for high pressure. 6) Rapid coupler for low pressure.
  • Page 53 PULLER-TENSIONER Model: FRB616 TABLE 8.1 (OPTIONAL) 1) Machine connection cable. 2) Machine ground cable.
  • Page 56 Comparative table of suggested oils and greases REDUCTION UNIT - COUPLERS GREASING TYPE HYDRAULIC CIRCUIT OIL FOR ENVIROMENTAL CONDITION: REDUCTION UNIT OIL FOR ENVIROMENTAL CONDITION: GREASE FOR EACH AMBIENT ARTIC WINTER SUMMER TROPICAL ARTIC WINTER SUMMER TROPICAL VISCOSITY VG 22 VG 32 VG 46 VG 68...
  • Page 57 TENSIONER MOD. FRB616 ENCLOSED DOCUMENTS - 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli, 2 Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024 Fax 0039 / 035 / 4522445 Fax 0039 / 035 / 826375 E-mail: info@tesmec.it...
  • Page 58 Ce manuel ne décrit pas les procédures de déroulage, ni on a tache de donner instructions à l'Utilisateur sur les méthodes de déroulage. Le contenu de ce manuel prévoit seulement un texte pour l’utilisation, l’entretien et la liste de pièces de rechange et comme TESMEC conseille d’utiliser la machine même.
  • Page 59 DATE REVISION RECORD 17 1 9 V00-9030-024 COPIGLIA - ISO 1234 D. 8 x 45 - St [] COTTER PIN 0 kg V00-9030-022 COPIGLIA - ISO 1234 D. 6.3 x 50 - St [] COTTER PIN 0 kg V00-9020-010 PERNO x TERZO PUNTO - AMA : Art.178 D. 19 x lg. 120 - CATENELLA E SPINA A SCATTO [] PIN 0.4 kg V00-9020-004 SPINOTTO - AMA : Art.9 D.
  • Page 60 DATE REVISION RECORD DETTAGLIO B ( 1 : 2 ) SEZIONE A-A ( 1 : 5 ) V00-6800-048 CHIAVE A T A SNODO CON BUSSOLA - CH: 27 [] KEY 0.7 kg V00-5303-002 INGRASSATORE UNI 7663 - A - DIRITTO M 10x1 [] GREASE FITTING 0 kg V00-5300-025 ANELLO NILOS - 6040 - 16040 - 23040 AV [] RING...
  • Page 61 DATE REVISION RECORD 17 31 V00-9010-058 ANELLO - UNI 7435 - 85 - E (SEEGER) [] RING 0 kg V00-9010-045 ANELLO - UNI 7437 - 130 - I (SEEGER) [] RING 0.1 kg V00-6204-007 VALVOLA DI RITEGNO ADR 32 TAR.0.5 bar - ATOS [] VALVE 2.5 kg V00-6050-025 MOTORE IDRAULICO - A2FM 80 61W PAB 020 - REXROTH [] MOTOR...
  • Page 62 RONDELLA RAME D. 1/4" x 3 [] WASHER 0 kg F04-0001-003 NIPPLO - 1/4" GAS - 1/4" GAS [] NIPPLE 0 kg E10-9800-106 TARGA ADESIVA CANTAMESSA TESMEC L300 [] PLATE 0 kg D99-90190 LETTERA ADESIVA (NUMERO) - kN - H. 60 [] ADHESIVE LETTER 0 kg D99-90189 LETTERA ADESIVA (NUMERO) - 0 - H.
  • Page 63 DATE REVISION RECORD V00-8510-091 INDICATORE DIFFERENZIALE 2 bar - MP : K 6 1 H P01 [] INDICATOR 0.2 kg V00-8401-038 INTERRUTTORE STACCABATTERIA 12-24 V - 250 A - IP 65 - COBO : 13.007.005 [] SWITCH 0.3 kg V00-6600-056 FILTRO - MP : LMP 400 4 B A G2 P25 N P01 [] FILTER 8.4 kg V00-6200-006...
  • Page 64 DATE REVISION RECORD SEZIONE A-A ( 1 : 2 ) V00-9040-052 LUCCHETTO + CHIAVE - CISA 21010-30 KA D. 5 [] PADLOCK 0.1 kg V00-9040-045 CHIUSURA CROMATA - EMKA - D.20 - GH=13.5 - H=13.5 - CH. TRIANG. 6.5 [] LOCKING 0 kg V00-9040-023 MANIGLIA - ELESA : GN425-10-88-CR [] HANDLE...
  • Page 65 DATE REVISION RECORD Sezione "A-A" Sezione "B-B" V00-9030-044 COPIGLIA A MOLLA - DOPPIO GIRO D. 4 - AMA : ART. 469 [] COTTER PIN 0 kg V00-5100-010 CUSCINETTO 6304-RSH - RADIALE A SFERE - d 20 / D 52 x B 15 [] BEARING 0.1 kg H88-1008-002 ROSETTA - UNI 1751 - A - 8 - Z [] WASHER...
  • Page 90    ...

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