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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...
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PULLER-TENSIONER Model: AFS404 PULLER-TENSIONER Model: AFS404 Serial number ... Manufacturing year ... Working order .... USE AND MAINTENANCE INSTRUCTIONS...
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PULLER-TENSIONER Model: AFS404 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...
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PULLER-TENSIONER Model: AFS404 4.16 END OF THE OPERATIONS INSTRUCTION FOR USE – CONNECTED MACHINES GENERAL ASPECTS MACHINES SET-UP CONNECTED MACHINES OPERATIONS PULL CONTROL SETTING 5.4.1 PULL LIMITING DEVICE SETTING 5.4.2 PULL PROGRAMMING DEVICE SETTING USING OF ELECTRONIC SPEED SYNCHRONIZER DEVICE (OPTIONAL)
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The machine is equipped with rapid couplers for connection to all types of reel winders and reel elevators made by Tesmec; the frame is complete with a rigid axle for towing at max. 30 km/h. PERFORMANCES PULLER PERFORMANCES Max.
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PULLER-TENSIONER Model: AFS404 TECHNICAL CHARACTERISTICS Bull-wheels diameter: 1500 mm with interchangeable nylon sectors 63 kW – 2600 rpm – Cummins B3.3T Diesel engine: Electric system: 12 V Transmission: closed hydraulic circuit with hydraulic oil cooling Safety brake: negative and self-acting type...
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PULLER-TENSIONER Model: AFS404 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).
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PULLER-TENSIONER Model: AFS404 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)
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PULLER-TENSIONER Model: AFS404 2.14 RESPONSIBILITY The use of the machine for scopes different from those foreseen on paragraph 2.3 (Typology and using field), even if not well described in this manual, has to be considered extremely dangerous and then forbidden.
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PULLER-TENSIONER Model: AFS404 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.
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PULLER-TENSIONER Model: AFS404 ASSEMBLING OPERATIONS Mount the tyres in the suitable holes. TRANSPORT ON TRAILER The machine in its standard version is not adapted for the carriage in tow on the road if not supplied with All.112. 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.
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PULLER-TENSIONER Model: AFS404 POSITIONING AND ANCHORING Positioning and anchoring of the machine have to be carried out only by trained personnel, verifying if the ground grants the foreseen stability, support and anchoring. The machine has to be placed in a distance from the first pylon or trestle for the rope passage (or conductor) included between 2 and 4 times the height h of the pylon itself (see diagram here below).
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PULLER-TENSIONER Model: AFS404 4. INSTRUCTION FOR USE PRESCRIPTIONS FOR THE OPERATOR PROHIBITION: it is forbidden to walk or stop in front or backward the machine and/or under the towing rope due to a constant residual risk of crushing in case of a possible giving in of the rope or of the anchoring.
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PULLER-TENSIONER Model: AFS404 MACHINE SET-UP Before the use, the machine must be set in stand-alone using mode, operating on the control panel (table 3). a. insert and turn the ignition key (table 3, pos. 3) in "1" position b. wait up to the multifunction display switch on (table 3, pos. 1) c.
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PULLER-TENSIONER Model: AFS404 ELECTRONIC MULTI-FUNCTIONS DISPLAY PAGES The electronic multifunction display shows 4 working pages: 1. METER COUNTER & SPEED PAGE This page shows the diesel engine rpm, cooling liquid temperature, speed of conductor and the meter counter diesel engine r.p.m...
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PULLER-TENSIONER Model: AFS404 3. DIESEL ENGINE DATA PAGE This page shows: working hours of the diesel engine hydraulic oil temperature battery tension 4. Multifunction Bar Allows you to reset the counter and select the menu page. Set Up Menu Meter counter reset button...
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PULLER-TENSIONER Model: AFS404 Selecting "System Information", will appear menu icon dedicated in which will be displayed serial number and firmware version installed 6. Diagnostic Menu Displays the menu and the engine list alarms Displays active alarms DM1 from engine ECU (if present)
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PULLER-TENSIONER Model: AFS404 7. Diagnostic Message Appears spontaneously with the arrival of a new alarm message. If the alarm persists even after it has been confirmed, you will see an icon in the center of the page and will remain lit the yellow light or red.
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PULLER-TENSIONER Model: AFS404 4.7.1 PULL LIMITING DEVICE SETTING Completely turn right the knob (table 3, pos. 6). With the suitable pawl, connected to the dynamometer (table 3, pos. 1), move the red arrow in correspondence of the max. pulling value that has not to be exceeded.
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PULLER-TENSIONER Model: AFS404 CONNECTION MACHINE-HYDRAULIC HEAD OF THE REEL ELEVATOR OR REEL WINDER Each hydraulic head (or each reel-winder) has a connecting kit consisting of two pipes. Each of these pipes has to be connected at the proper rapid connection (table 5, pos. 1-3 or 2-4) taking care to connect them properly (otherwise the installation will not work).
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This is the maximum acceptable value for the hydraulic components in case the oils suggested by Tesmec are used. If other kinds of oils are used, the maximum acceptable working temperature depends on their characteristics in relation also to the viscosity limits imposed by the hydraulic pumps and motors.
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PULLER-TENSIONER Model: AFS404 4.12 PREHEATING KIT (OPTIONAL) The machine is equipped with a preheating kit (see table 8) to be used when room temperatures are included between -10°C and -20°C. This kit is composed by a gas-oil burner and by an heating circuit that uses the cooling liquid of the diesel engine: the consumption heated by the preheating kit are the diesel engine block, the hydraulic oil tank, the diesel engine gas-oil tank and the delivery of the gas-oil to the diesel engine.
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PULLER-TENSIONER Model: AFS404 4.13.3 SWITCHING THE HEATER ON (OPTIONAL) Manually: by pressing the button (continuous heating mode). Automatically: by programming the heater starting time. 4.13.4 SWITCHING THE HEATER OFF (OPTIONAL) Manually: by pressing the button Automatically: after the programmed operating time has elapsed.
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PULLER-TENSIONER Model: AFS404 4.13.12 RECALLING/ERASING THE WAKEUP TIME (OPTIONAL) appears on the display – read off wakeup Repeatedly press the button until the bell symbol time. To erase the wakeup time: press the button until the bell symbol is no longer visible on the display.
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Is possible to connect a maximum 12 machines between them, with the possibility to work with 12 independent ropes configurations. Tesmec suggest to use this configuration device on machine working at the puller station, to allow to recover multiple ropes or conductors with the same speed.
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PULLER-TENSIONER Model: AFS404 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 The gear-box configuration is HIGH-PULL in each machine (optional)
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PULLER-TENSIONER Model: AFS404 NOTE: The machine ID must be set from 1 to the total number of machines connected from left to right (looking at the machines from the back - position reel winder) e. on the page “BULL WHEELS PIN CONNECTION?” sett the option (see point 4.4), depending on the configuration, using the key up () or down () push the enter key (...
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PULLER-TENSIONER Model: AFS404 CONNECTED MACHINES OPERATIONS When using connected machines, the following controls effect on all machines when operated from the master machine: Speed control (joy-stick) Pull-adjusting control (potentiometer) Negative brake open – close selector Diesel engine accelerator ...
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PULLER-TENSIONER Model: AFS404 USING OF ELECTRONIC SPEED SYNCHRONIZER DEVICE (OPTIONAL) The machine could be provided with an electronic speed synchronizer device as a optional package; to activate operate on the selector (table 3, pos. 9) (rightwards) on the master machine.
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PULLER-TENSIONER Model: AFS404 5.7.4 CAN-BUS DIS-CONNECTION BETWEEN THE MACHINES In case the connection cables between the machine may disconnect (ex. removing plugs, accidental cutting of one cable, …), the stringing operations stops on all the connected machines. To reset the alarm move the joy-stick to neutral on the master machine and check the cause of the fault.
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PULLER-TENSIONER Model: AFS404 6. SAFETY CONDITIONS SAFETY DEVICES Machine has been equipped with the following safety devices: 1. load-limiting device with automatically stop of the endothermic engine once the max. pre-set load value has been exceeded 2. mechanical negative safety brake for movement stop in case of lack of hydraulic pressure 3.
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PULLER-TENSIONER Model: AFS404 RESIDUAL RISKS In the machine there are still the following residual risks: 1. Sudden break of the rope-conductor. The break of the rope causes sudden movements of the machine and of the rope or conductor connected to the machine.
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PULLER-TENSIONER Model: AFS404 7. MAINTENANCE GENERAL PRESCRIPTIONS ATTENTION: possible repairs not carried out by the manufacturer and not allowed by a written authorisation 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.
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PULLER-TENSIONER Model: AFS404 HYDRAULIC CIRCUIT MAINTENANCE a. Change the hydraulic oil after 500 working hours and, then, every 1500 hours (or in any case every year). b. To discharge the exhaust hydraulic oil, use the suitable tap (table 1, pos. 13) on the bottom of the tank.
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PULLER-TENSIONER Model: AFS404 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.
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PULLER-TENSIONER Model: AFS404 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).
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PULLER-TENSIONER Model: AFS404 9. ENCLOSED DOCUMENTS TABLES General assembly – Lateral view TABLE 1.5 General assembly – Upper view TABLE 2.5 TABLE 3.7 Control panel TABLE 4.3 Machine set to pull 2 conductors TABLE 5.1 Hydraulic heads connection TABLE 6.2 Compressor connection (optional) TABLE 7.1...
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PULLER-TENSIONER Model: AFS404 TABLE 2.5 1) Hydraulic oil filling cap (IP HYDRUS OIL 46, qty 140 lt.). 2) Crown-pinion lubricator. 3) Anchoring ears. 4) Fuel filling cap. 5) Filter. 6) Filter. 7) Oil filling cap for diesel engine. 8) Liquid filling cap for diesel engine radiator.
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PULLER-TENSIONER Model: AFS404 TABLE 3.7 1) Manometer with graduated ring nut. 2) Emergency stop push button. 3) Connected machines selector (optional) 4) Bull-wheels control lever. 5) Pull value setting device. 6) Pull value setting knob. 7) Manometer for overfeeding pressure.
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PULLER-TENSIONER Model: AFS404 TABLE 5.1 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.
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PULLER-TENSIONER Model: AFS404 TABLE 6.2 (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.
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PULLER-TENSIONER Model: AFS404 TABLE 7.1 (OPTIONAL) 1) Receiving unit for radio control. 2) Connector for receiving unit for radio control. 3) Connector for pull recording unit.
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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.
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DATE REVISION RECORD D99-10017 GRANO FORATO - 8x12 - FORO ø1 [] DOWL 0 kg D99-10006 NIPPLO FORATO - 1/4" Gas - FORO M8 [] NIPPLE 0 kg H58-1010-025 VITE - ISO 10642 - M 10 x 25 - 10.9 - Z - TSEI - PG [] BOLT 0 kg V00-9000-014 MORSETTO A CAVALLOTTO D.
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DATE REVISION RECORD Sezione A-A H99-8900-002 VITE 0274 06 16 - M 6 x 16 - 8 - Z - WURTH [] BOLT 0 kg H99-8900-091 VITE - DIN 7984 - M 8 x 30 8.8 - Z [] BOLT 0 kg D00-00323 CHIAVETTA PER SETTORI 20 x 25 x 360 [] FEATHER KEY...
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DATE REVISION RECORD Sezione A-A ( 1 : 5 ) D00-00309 TUBO D. 8 x 1 x lg. 400 [] PIPE 0.1 kg H99-8900-002 VITE 0274 06 16 - M 6 x 16 - 8 - Z - WURTH [] BOLT 0 kg V00-2231-059 TUBO CORRUGATO MULTI PA 6 ID70 NERO - D.
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DATE REVISION RECORD Dettaglio B ( 1 : 2.5 ) V00-2232-014 V00-9800-025 ADESIVO T. 60 EQUIPOTENZIALE [] STICKER 0 kg V00-9800-024 ADESIVO T. 60 MESSA A TERRA GENERALE [] STICKER 0 kg V00-8401-038 INTERRUTTORE STACCABATTERIA - 12-24 V - 250 A - IP 65 - COBO : 13.007.000.01 [] SWITCH 0.3 kg V00-7050-014 FASCETTA SERRATUBO D.
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DATE REVISION RECORD Sezione "A-A" N°3+1 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 : GN425-8-88-CR [] HANDLE 0.1 kg V00-9040-022...
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DATE REVISION RECORD E-E ( 1 : 2 ) F-F ( 1 : 2 ) V00-9030-044 COPIGLIA A MOLLA - DOPPIO GIRO D. 4 - AMA : ART. 469 [] COTTER PIN 0 kg D00-00302 PERNO D. 20 x lg. 435 - A MANIGLIA [] PIN 1.3 kg D00-00301 PERNO D.
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18-07-2011- Foresti DATE REVISION RECORD Vista da "B" V00-9000-046 FUNE FRENO - ACCELERATORE - D. 1.9 mm - AMA : Art.638 [] CABLE 0,32 0 kg V00-9000-013 MORSETTO SERRAFILO - D. 2÷4 - AMA : Art.304 [] CLAMP 0 kg V00-9000-011 MORSETTO SERRAFILO - D.
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VITE - M 10 x 60 - ISO 10642 - 10.9 - Z - TSEI [] BOLT 0 kg E10-9800-107 TARGA ADESIVA CANTAMESSA TESMEC L400 [] PLATE 0 kg D00-01917 TELAIO COPERTURA MOTORE 730 x 1035 x 1270 - AFS 404 602 [] FRAME 57.7 kg...
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-Fc2 FINECORSA A PULSANTE CON ROTELLA - CONTA V00-8510-036 11/D6 FINECORSA BLOCCAFUNE [OPT 071] FUSIBILE A LAME 5 A BEIGE INTERASSE LAME FUSIBILE PROTEZIONE RELE AVVIAMENTO V00-8401-036 2/B2 V00-8401-011 2/B2 FUSIBILE A LAME 3 A VIOLETTO INTERASSE L FUSIBILE PROTEZIONE ARRESTO MOTORE FUSIBILE A LAME 3 A VIOLETTO INTERASSE L FUSIBILE PROTEZIONE ARRESTO MOTORE V00-8401-011...
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DIODO A LED - GIALLO 12 V DC - 8 MM - IP V00-8400-023 7/E3 LED ALLARME SCHEDA DIODO A LED - ROSSO 12 V DC - 8 MM - IP SPIA ALLARME TIRO MASSIMO V00-8400-022 4/D5 V00-8400-022 3/B6 DIODO A LED - ROSSO 12 V DC - 8 MM - IP LED FILTRO IDRAULICO F1 INTASATO DIODO A LED - ROSSO 12 V DC - 8 MM - IP LED FILTRO IDRAULICO F2 INTASATO...
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RELE 12 V 2 SC - 8 A - FINDER : 46.52.9. V00-8402-014 4/D4 RELE ALLARME TIRO MAX MODULO DIODO + LED 6-24 V DC/AC - FINDER V00-8402-020 4/D4 V00-8402-039 4/D4 ZOCCOLO RELE 2SC MORSETTO A MOLLA MONTAG RELE 12 V 2 SC - 8 A - FINDER : 46.52.9. RELE VENTOLA RADIATORE V00-8402-014 5/D2...
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K8.2 RELE 12 V 2 SC - 8 A - FINDER : 46.52.9. V00-8402-014 5/D6 RELE PRESSA MODULO DIODO + LED 6-24 V DC/AC - FINDER V00-8402-020 5/D6 V00-8402-039 5/D6 ZOCCOLO RELE 2SC MORSETTO A MOLLA MONTAG RELE 12 V 2 SC - 8 A - FINDER : 46.52.9. RELE ABILITAZIONE COMANDO A DISTANZA K9.1 V00-8402-014...
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RELE 12 V 2 SC - 8 A - FINDER : 46.52.9. V00-8402-014 7/E6 RELE BLOCCAFUNE CHIUSO MODULO DIODO + LED 6-24 V DC/AC - FINDER V00-8402-020 7/E6 V00-8402-039 7/E6 ZOCCOLO RELE 2SC MORSETTO A MOLLA MONTAG RELE 12 V 2 SC - 8 A - FINDER : 46.52.9. RELE PRERISCALDO V00-8402-014 2/D4...
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DISTINTA MATERIALI DISTINTA MATERIALI Codice Nuova codifica Descrizione da Archivio Materiali Qtà tot. U.M. Codice Nuova codifica Descrizione da Archivio Materiali Qtà tot. U.M. 00000000 ENGINE.PART....(CODICI MOTORE) V00-2225-011 COPERTURA POSTERIORE - DEUTSCH : DRC 40- 99999999 IDRAULIC.PART..(CODICE IDRAULICO) V00-2225-012 CONNETTORE - Nø 2 POLI - FEMMINA GRIGIO V00-1500-003 BATTERIA 100 AH 12 V - EN 760 A - LUNGH.
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DISTINTA MATERIALI DISTINTA MATERIALI Codice Nuova codifica Descrizione da Archivio Materiali Qtà tot. U.M. Codice Nuova codifica Descrizione da Archivio Materiali Qtà tot. U.M. V00-2227-061 CONNETTORE - Nø 5 + PE POLI - FEMMINA FI V00-8400-022 DIODO A LED - ROSSO 12 V DC - 8 MM - IP V00-2227-062 CONNETTORE - Nø...
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DISTINTA MATERIALI DISTINTA MATERIALI Codice Nuova codifica Descrizione da Archivio Materiali Qtà tot. U.M. Codice Nuova codifica Descrizione da Archivio Materiali Qtà tot. U.M. V00-8410-004 CONTATTO NC - CEMA : P9B01VN V00-8600-008 DISPLAY GRAFICO 9 - 32 V - DSF : J1939 E V00-8410-005 ALIMENTAZIONE - CEMA : P9PDNV0 V00-2225-045...
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