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Sherman + Reilly PTR-7230 Operator's Manual

Puller tensioner reconductorer
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PTR-7230(S)/7240(S)
Puller Tensioner Reconductorer
Operators Manual
Rev.
2015

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  • Page 1 PTR-7230(S)/7240(S) Puller Tensioner Reconductorer Operators Manual Rev. 2015...

  • Page 3: Table Of Contents

    Safety Zone Cab Operator Controls- [Operator Console] Master Power Key Switch Engine Power Switch Engine Start Button Emergency Stop Button Pull Mode Selection Button Joystick Control Winter/Summer Mode Switch Maintain Speed/”Cruise” Control Button S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 4 Overhead Pulling Swivels and Cable Connections Towing and Road Safety Positioning the Machine Start-Up/Set-Up Procedure Pull Mode Tension Mode Shutdown Procedure Emergency Stop Procedure Section 5: Troubleshooting Quick Tips General Faults S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 5 Hydraulic Power Engine Arctic Kit Safe-Zone Cab™ Inspection of Operators Chair Climate Control System Trailer Assembly Brakes Towing Tires Wheels Axle Drum Oil Trailer Lighting Lighting Replacement Electrical Equipment Pre-Operation Inspection Checklist S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 6 Appendix A: Manufacturer Manuals DEUTZ TCD 2013 L06 2V Engine Manual Caterpillar C9 Engine Manual Webasto Arctic Kit Timer Appendix B: Manufacturer Manuals Honda GX390 Engine Manual Trailer Axle Manual Ridewell Trailer Suspension Manual S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 7: Section 1: Introduction

    There are significant hazards inherent to the use of this machine; therefore, all operators should be educated on all functions, procedures, and safety measures outlined in this manual prior to their use or maintenance of this machine. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 8: Terms Of Use

    It is the operator’s responsibility to watch for situations and conditions which could affect the normal performance of the machine and the safety of the operating/work environment. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 9: Section 2: Specifications

    72 inch bullwheels provide constant tension and can handle transmission-class conductors. The PTR-7230 features a fully electronic, integrated control system for precision application of force to conductors, and an integrated drum for steel hardline; no separate reel trailer is required.
  • Page 10 Tie Downs (2) 1 in. dia. steel D-Rings Rope Tie-Off s (2) 1 in. dia. steel D-Rings Grounding (6) ¾ in. dia. copper-clad steel loops Wheel Chocks Standard Fire Extinguisher Color S+R White S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 11  72” Bullwheels- Hydraulically Driven  84 in. Rope Reel with Optional 25,000 ft. (Max) Unitrex Synthetic Rope ™  Horizontal Automatic Levelwind/Fairlead  Centralized Engine Controls- CAN-bus technology  Digital Controls and Self Diagnostics S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 12 (4) ¾ in. dia. copper-clad (4) ¾ in. dia. copper-clad steel loops steel loops steel loops steel loops *Specifi cations may alter for pintle eye trailer confi gurations. Contact Sherman + Reilly for more information. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 13  72” Bullwheels- Hydraulically Driven  112 in. Rope Reel with Optional 30,000 ft. (Max) Unitrex Synthetic Rope ™  Horizontal Automatic Levelwind/Fairlead  Centralized Engine Controls- CAN-bus technology  Digital Controls and Self Diagnostics S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 14 Tie Downs (2) 1 in. dia. steel D-Rings Rope Tie-Off s (2) 1 in. dia. steel D-Rings Grounding (6) ¾ in. dia. copper-clad steel loops Wheel Chocks Standard Fire Extinguisher Color S+R White S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 15  72” Bullwheels- Hydraulically Driven  112 in. Rope Reel with Optional 30,000 ft. (Max) Unitrex Synthetic Rope ™  Horizontal Automatic Levelwind/Fairlead  Centralized Engine Controls- CAN-bus technology  Digital Controls and Self Diagnostics S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 16 Rope Tie-Off s (5) (2) 1 in. dia. steel D-Rings (3) 1 in. dia. steel D-Rings Grounding (8) (4) ¾ in. dia. copper-clad steel loops (4) ¾ in. dia. copper-clad steel loops S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 17: Section 3: Safety

    NOTE information is important to the correct information relates specific operation or maintenance of the immediate hazard or unsafe practice machine. which, if disregarded, could result in personal injury or death. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 18: General Warnings

    Engine exhaust, some of its elements, and otherwise gangrene may develop. certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 19: Operator Safety Precautions

     Do not operate equipment if work ability is impaired by fatigue, illness, or other causes.  Always use employer approved grounding procedures when operating the machine. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 20: Employer Safety Precautions

    A record of training dates, employee names, and level of training shall be maintained. Only persons who have a full understanding of the provided manual- S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 21: Chemical Safety

    Materials Transportation Act, OSHA’s Hazard Communication Standard- (29 CFR) Part 1910.1200, and all applicable EPA Standards and Regulations- . For further (additional standards may apply) information on safety standards regarding chemicals see OSHA and EPA websites. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 22 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 23 Drum/Reel Fire Extinguisher Engine Exhaust Drum/Reel Coupling/Retaining Bar Fairlead Engine Air Intake Filter Housing Levelwind Fuel Tank Fill Access Door Arctic Kit Burner Exhaust Drum Roller/’Hoop” Exterior Work Lighting Bullwheels (2) S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 24: Terms You Need To Know- Long Models

    Operation - [Long Models] Terms You Need to Know S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 25 [RC3000X] Reel Trailer Hydraulic Power Pack [RC3000X] Front/Nose [L/R] Jacks (2) Arctic Kit Burner Exhaust Bullwheels (2) [RC3000X] Air Brake/Lights Hook-Up Exterior Work Lighting Hose Storage/Tool Box [RC3000X] Hydraulic Jack Controls Wheel Chocks/Holders (2) Drum/Reel Stand S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 26: Terms You Need To Know- Split Models

    Operation [Split Models] Terms You Need to Know- S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 27: Under The Hood- Ptr-7230/7230S

    Hydraulic Drive Motor Engine Air Intake Pipe AC Compressor Hydraulic Cooling Fan Motor Engine Fuel Pre-filter/Water Separator Arctic Kit Burner Hydraulic Tank w/Filters Fuel/Water Separator Drain Cock Sight Gauge Main Fuel Filter S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 28 Operation [PTR-7230] Under the Hood- S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 29: Under The Hood- Ptr-7240/7240S

    Engine Fuel Primary Filter/Water Separator AC Compressor Hydraulic Cooling Fan Motor Fuel/Water Separator Drain Cock Engine Oil Fill Port Hydraulic Tank w/Filters Engine Fuel Priming Pump Arctic Kit Burner Sight Gauge Engine Fuel Pre-Filter S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 30 Operation [PTR-7240] Under the Hood- S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 31 Ergonomic Operators Chair damage to the polycarbonate material, thereby degrading the impact resistance of the front window. This can create a hazard for the operator should a line brakeage situation occur. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 32 The PTR-Series Safe-Zone Cab comes equipped with a climate control system providing customized air temperature controls for both heating and cooling. The climate control system has variable air fan speed, with overhead multidirectional vents. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 33 Operation Operator Controls- [Operator Console] S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 34: Operator Controls- [Operator Console]

    Operation [Operator Console] Operator Controls- S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 35: Master Power Key Switch

    For more engine off, or turn off power to the engine, information on emergency shutdown situations press the bottom [O]/Off button. If the [O]/Off see the Emergency Stop Procedure Section on page S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 36: Pull Mode Selection Button

    Button. This will allow the joystick to retain control. Winter/Summer Mode Switch This switch controls the engine coolant flow for the engine, to precisely manage heat distribution for added heating of machine components. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 37: Ats/Tension Mode Selection Button

    Off/Closed position, if not using it. tension at the current potentiometer setting. This can create either a sudden rise or drop in tension. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 38: System Control Panel

    Some display fields require the remains empty and the input of numbers or the selection of options. page numbers at the To this effect, appropriate input fields are bottom are not indicated. displayed, if necessary. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 39: Upper Indicator Bar

    Oil pressure indicator: “Engine oil pressure too low“. This display must go out when the engine is running. Air filter indicator: “Dirty air filter” – clean S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 40: Lower Control Bar

    NOTE: If no action is made on this page for a period mode. of 10 seconds, the display returns automatically to the MAIN screen, and changes are not applied. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 41 Accessing INPUT OVERLOAD SETTINGS Screen. Changing value. Saving the changes. The adjusted overload limit will take effect once the setting is saved. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 42: Meter Counter Reset Button

    When the corresponding button for the active pressed, returns the user to the error indicator is pressed, the system will previous or MAIN Screen. display the error page where the operator can access individual errors. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 43: Information Screen

    The gauge on the far right displays previous or MAIN Screen. the engine coolant temperature. The middle gauge shows the fuel level. The third gauge displays the hydraulic oil temperature. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 44: Settings Screen/Button

    The gray indicator signifies that the data recorder is not active. The green indicator signifies that the data recorder is active. See the Data Recorder On/Off Button section. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 45: Data Settings Screen/Button

    Operators must save the new date setting before exiting the screen. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 46: Data Recording Screen

    Status indicator “Print file“ Status indicator “Copy file NOTE: A Data Recording On/Off indicator is on USB stick” also displayed on the main menu screen. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 47: Recording Intervals Screen/Button

    To increase the frequency of recording segments, reduce the length by pressing the Down arrow button. To decrease the frequency of recording segments, increase the length by pressing the Up arrow button. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 48: Additional Settings Screen/Button

    Once the password is entered correctly, This screen field shows the press the green check mark button to diameter cable/rope submit the password and access the programmed in the system. corresponding screen (Client or Service). S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 49: Input Cable/Rope Diameter Screen

    The back/return button is present on all saved, and the new rope/cable diameter setting will sub level screens, and when pressed not take effect. returns the user to the previous or MAIN Screen. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 50 Client menu can be read but not edited. To edit NOTE: It is recommended that the user select a the system parameters, the user must be signed in suitable UOM prior to conduction operations. using the Service menu level password. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 51: Usb Interface

     Remove the USB drive/stick. NOTE: If copy errors are reported, this may be due to a faulty USB Drive, or that the USB drive is smaller than the data being transferred. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 52 Microsoft Excel and Word will list the events in a single column by data/time stamp, whereas Note Pad will display the information in block format- making it difficult to read. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 53 .csv files with other computer programs. The information contained in the file is displayed with a Start and End time using increments of length. See the RECORDING INTERVALS Screen/Button section. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 54: Exterior Work Lighting Power Switch

    NOTE: The data port has two metal pins on the top to allow the data cable to be locked in place. This helps prevent the cable from unintentionally becoming detached during diagnostics. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 55: Hydraulic Control Switches

    To retract the jack, depress and hold the bottom portion of the CAUTION: Ensure that all jacks are fully raised and clear of the ground before attempting to tow trailer. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 56 Hydraulic Control Switches (Cont.) Jack Controls (Cont.) All models of the PTR-7230 have a view of the jacks when in motion. Operators should utilize the available jack cameras, where available. Using the provided cameras and spotters to ensure that the area is clear while moving the jacks is a critical safety measure.

  • Page 57: Drum Roller Control

    NOTE: On most models, the drum roller hydraulic controls are on a separate circuit, and therefore enabling the jacks/drum roller is not required prior to operating the drum roller. View from top camera on single display model. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 58: Levelwind

    Right and left positions correspond with right and left motions of the levelwind.  To engage levelwind, rotate the control lever CW. To disengage levelwind, rotate lever CCW. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 59: Integral Reel Stand/Rc3000X

    CAUTION: Always set the manual brake prior to CAUTION: Before starting the engine, ensure that transporting machine/trailer prevent all Reel Stand Potentiometers are rotated CCW to unintended drum/reel rotations during transit. the lowest setting. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 60 This will provide access to the set collar, and in turn free the bearings and cones on the shaft allowing the drive shaft to be removed. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 61: Reel Stand Hydraulics

    This valve must also be On/Opened in order to operate the reel stand and levelwind hydraulic motors. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 62: External Reel Stand

    Residual pressures existing in the hydraulic lines, even with valve Off, can inhibit connecting hose. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 63 External Reel Stand (cont.)  Once the hydraulic valves are enabled/opened, the operator has full control of the external reel stand tension, using the reel stand potentiometer on the operators control console. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 64: Quick Start Guide

    Level, stabilize, anchor, and ground the machine. Adjust drum roller/“hoop” height, as needed- only Route rope/conductor through levelwind and fairleads, available on long models. thread around bullwheels, and route over hoop. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 65 Otherwise, serious personal injury and/or equipment damage will result. Also, limit off road vehicle speed to lowered secured prevent account for sudden accidental changes in line tension. them coming in contact with the rope or conductor. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 66 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 67: Overhead Pulling Swivels And Cable Connections

    The drum stands should – if possible, hydraulically –be slowed down. The ropes must not display any slippage on the grooved wheels of the tensioner. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 68: Towing And Road Safety

     Ensure that the hydraulic cut off valves for the reel controls are set to closed.  Chock wheels on both sides of the machine/unit trailer, then start machine/unit engine- ( See Operator Controls pg.34 and Start-Up Procedure pg. 70) S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 69 Turn Signals o Brakes (See Trailer Assembly Section: pages 109-113) CAUTION: Do not tow the machine/unit unless all the trailer lights and brakes are working correctly. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 70: Positioning The Machine

    The operator must chock all trailer wheels and dump the trailer air system prior to operations and any time the vehicle is parked. All appropriate grounding, anchoring, and protective equipment must be installed and secured to machine prior to operations. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 71: Start-Up/Set-Up Procedure

    CAUTION: Ensure that all hydraulic hoses are hooked-up and valves are turned to the On/Open position prior to operations to prevent the drive system components from overheating. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 72 This can create hazard. unanticipated line jolts as well as life threatening or severe bodily impacts to surrounding personnel if they are not aware of the line/conductor take up and/or reel spin. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 73 Also, view the engine information screen to make sure everything is working properly. NOTE: If faults or warnings are found, they should be resolved prior to conducting operations- Troubleshooting Section). S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 74  Level and stabilize the pulling machine using the available hydraulic jacks. CAUTION: All jacks must be extended for stabilization, and the machine must be leveled prior to conduction operations. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 75 The contained instructions and illustrations are specific to “right lay” type of conductor, as well as standard pulling ropes. NOTE: If using “left lay” conductor, the reeving pattern will need to be reversed for both single and dual patterns. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 76 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 77 Then return the joystick to the neutral position to set the brake.  Adjust drum roller/”hoop” height as needed. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 78: Pull Mode

    30,000 lbs. or 40,000 lbs. of pulling force respectively to the pulling line. Both the PTR-7230(S) and the PTR-7240(S) come equipped with a variable speed drive system. The Pull Mode for the machine is primarily used for pulling conductor using either pulling rope or old conductor, in the case of reconductoring operations.
  • Page 79 CAUTION: Rotate reel potentiometers slowly, and ensure all personnel are clear of the area and aware of rope take-up. Rapid increases in reel tension can create large jolts in the line and possible equipment/rope/conductor damage. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 80 Once positioned, disengage the automatic levelwind by pushing the lever downward to the [O] position. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 81 If the cruise button is not depressed prior to releasing the joystick, the /conductor end could be pulled from its anchor bullwheel rotation will stop, and the hydraulic point. brake will set. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 82: Tension Mode

    CAUTION: Rotate reel potentiometers slowly, and ensure all personnel are clear of the area and aware of rope take-up. Rapid increases in reel tension can create large jolts in the line and possible equipment/rope/conductor damage. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 83 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 84: Shutdown Procedure

     Complete all towing and road safety procedures prior to towing machine- (See Towing and Road Safety Section on page 67) CAUTION: The drum/reel manual brake must be set prior to transport. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 85: Emergency Stop Procedure

    Follow employer emergency procedures. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 86 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 87: Section 5: Troubleshooting

    TRAILER LIGHTS DO NOT WORK AFTER CONNECTED TO VEHICLE  Check vehicle/trailer wire connectors for damage or corrosion.  The vehicle/trailer wire connectors can vary dependent upon owner/customer requirements. (Also, see Trailer Lighting Section). S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 88: General Faults

    Sensor failure Cooling fluid sensor Varying, incomplete or wrong data Sensor failure Charging air temperature sensor Varying, incomplete or wrong data Sensor failure Fuel temperature sensor Varying, incomplete or wrong data S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 89 Varying, incomplete or wrong data Internal Hardware failure Reference 1 Varying, incomplete or wrong data Internal Hardware failure Reference 2 Varying, incomplete or wrong data Internal Hardware failure Reference 4 varying, incomplete or wrong data S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 90: Machine Control Error Codes

    Broken wire CR0232 / CR0032 Pressure sensor rope out 1 Short cut CR0232 / CR0032 Pressure sensor rope out 2 Broken wire CR0232 / CR0032 Pressure sensor rope out 2 Short cut S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 91 1 Program SPS Error tension automatic supply Supply pressure too low pressure side 2 Program display Typographical errors while Memory full, delete login data in backup menu. creating a logging file S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 92 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 93: Section 6: Maintenance

    The indicated intervals for maintenance work apply to normal operating conditions and stress. The manufacturer is not responsible for damages caused through faulty maintenance or inappropriate handling/operation of the machine. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 94: Safety

    S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 95: General Care And Inspections Instructions

    Safety devices described are, e.g. brakes, rope reeling devices, devices against overcharging, etc. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 96: Hydraulic System

    OSHA, EPA, and Hazard Communication Act, with regard to the storage, maintenance, and disposal of hydraulic fluid and other chemicals used in the maintenance of described mechanical equipment. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 97: Hydraulic System/Hose Inspection

     All hydraulic hoses must be replaced after 2,500 working hours or, at the latest, every 10 years (starting from the year of the construction of the machine. ( See Preventive Maintenance Schedule Section.) S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 98: Checking Hydraulic Fluid

    ¾ of the way full just below the HIGH mark is recommended. NOTE: For split model reel trailer power packs, the hydraulic fluid level should ¾ full.  Replace and tighten the fluid reservoir cap. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 99: Replacing Hydraulic Fluid And Filter

    NOTE: Once removed, filter(s) will still have fluid in remove filter. it. Use care when removing filter so as not to spill remaining hydraulic fluid. A small collection reservoir many be needed. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 100 Preventive Maintenance Schedule. However, the filters can be changed sooner as needed. Operators should watch for maintenance indicators on the system display. PTR-7230/7240 Hydraulic Reservoir RC-3000X Reel Trailer Hydraulic Reservoir S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 101: Hydraulic Hose Replacement

    Refill tank, run system at idle to purge air, and  then replenish any lost hydraulic fluid, using sight gauge or line of sight for proper level. ( Adding Hydraulic Fluid section.) S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 102 Section. hands or body. When under pressure, leaks can puncture skin. Small or pinhole size leaks may be invisible during visual inspection. (Using a piece of cardboard or wood is recommended). S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 103: Drive Assembly

    If oil begins to pour out of the plug at the half point, then the oil level is Maintenance at the appropriate half full level. PTR-7230 Gear Oil Plugs S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 104  Once complete, reinstall and tighten plugs. Replace outside covers  PTR-7230/7230S: using original screws. Remove any used tools,  PTR-7240/7240S: rags, and other items from the engine compartment. Close and latch engine compartments. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 105: Changing Bullwheel Gear Oil

      Replace dust cap on fitting, once Clean up any residual oil and replace plugs completed. and panels and close compartments once complete. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 106: Integral Reel Stand/Rc3000X

    (See Preventive Maintenance Schedule and Lubrication Chart).  Apply Grease to the both of the ports on the front of the levelwind. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 107: Checking/Adding Reel Stand Gear Oil

     Reinstall bottom oil plug.  Rotate gear slowly so that plug is at the half way point.  Refill oil to the halfway point. (See adding oil section above for steps.) S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 108: Greasing Manual Reel Brake Crank Bearing

     For maintenance regarding the hydraulic components, see the Hydraulic System section.  For maintenance information on the Honda engine and related components, see Appendix B. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 109: Hydraulic Power Engine

    OSHA, EPA, and Hazard Communication Act, with regard to the storage, maintenance, and disposal of engine oils, coolants, and other chemicals used in the maintenance of described mechanical equipment. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 110: Arctic Kit

    OSHA, EPA, and Hazard Communication Act, with regard to the storage, maintenance, and disposal of engine coolants, fuel, and other chemicals used in the maintenance of described mechanical equipment. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 111: Safe-Zone Cab

    Sherman+Reilly CAUTION: For Turret Models: The operator must Parts & Service Department at be seated while rotating the turret to avoid being repairs@sherman-reilly.com. accidentally thrown from the machine. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 112: Trailer Assembly

    CAUTION: Some older brake linings may contain NOTE: See specification sections for approximate asbestos dust which can cause serious health trailer weights. problems. Certain precautions should be taken when servicing brakes- see manufacturer’s manual for instructions. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 113: Tires

    For all additional inspection, cleaning, adjustment, and replacement instructions see the manufacturer’s manual. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 114: Axle Drum Oil

     If axle drum oil level is low, remove axle drum oil cap plug, pour in fluid until fluid level is just below oil cap plug hole, and replace the plug. (A funnel may be required to avoid spilling fluid.) S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 115: Trailer Lighting

     Also, check lighting junction box for damage. Open and inspect wires for loose connectors for damage or corrosion. or corroded connections. The vehicle/trailer wire connectors can vary depending upon owner/customer requirements. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 116: Lighting Replacement

    Once out of the rubber, unplug the connection and replace with new pod.  Pop Tabs: Some lighting may require the use of a screw driver to unsnap the light from its retaining tabs. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 117: Electrical Equipment

     The electrical circuit diagrams of the machine describing the cable routes in detail can be made available upon request to S+R. The fuses and relays are located under the dash in the operators cab. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 118: Pre-Operation Inspection Checklist

    Ensure proper hydraulic fluid level in reservoir for hydraulic system by viewing the sight gauge on the side of the tank. Inspect hydraulic pump, drive motors, and hoses for loose fittings, leaking fluid, and damaged hoses. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 119 Inspect levelwind and fairleads for any obvious signs of damage, leaking hydraulic components or hoses, and ensure rollers move freely. [Reel Trailer Only]: Check reel trailer power pack fuel, oil, and hydraulic fluid levels. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 120 Ensure air suspension system controls are set correctly, and that air system is charged. d. Ensure that all jacks are raised and that trailer is clean and free from trash or debris. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 121: Post-Operation Inspection Checklist

    S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 122 Periodic refilling of the tire air pressure during seasonal temperature changes may be required- always see the specified air psi. ratings listed on the tire sidewall. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 123: Preventive Maintenance Schedule

    Check Trailer Wheel Lug Nut Torque - First 50 miles See Trailer Wheels Section. Check Trailer Wheel Lug Nut Torque- First 100 miles See Trailer Wheels Section. Adjust Brakes- First 200 miles See Brake Section. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 124 Inspect Trailer Air Brake System Components 6 Months/6,000 Miles See Brake Section. Inspect Trailer Suspension for bending, loose fasteners, and wear. 6 Months/6,000 Miles Inspect wheels for damage, (i.e. cracks, dents, or distortions) 6 Months/6,000 Miles S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 125 Oil filter cartridge at the hydraulic pump Transmission oil in the bull wheel gearing — — Motor oil Coolant Hydraulic and engine coolant — — Battery — — — Fuel filter Air filter — Lubrication Groove tread S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 126: Torque Ratings For Machine Fasteners

    Torque ratings for ¼” and 5/16” are listed in inch-pounds. All other torque ratings are listed in foot-pounds. (K = .15 for “lubricated” conditions) (K= .17 for Zinc plated and dry conditions) (K= .20 for plain and dry conditions). S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 127 All torque ratings are listed in foot-pounds. Torque value formula T=KDF where; (K = .15 for “lubricated” conditions) (K= .17 for Zinc plated and dry conditions) (K= .20 for plain and dry conditions). CAUTION: Under/Over tightening fasteners can result in costly equipment failure or personal injury. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 128: Lubrication Chart

    Texaco TDX 10W-40 Hydra 46 5W-30 RUBIA TIR RUBIA TIR AZOLLA AF 32 8900 10W-40 9200 FE 5W- Biohydran SE 46 EQUIVIS ZS 32 Carter SH 220 MULTIS EP 2 TOTAL S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 129: Section 7: Service & Repair

    Sherman+Reilly Parts & Service Department. Further operation should not continue until the issue or fault is resolved- (See Fault and Malfunction Detection Section) Scan with Smartphone to complete and email repair request form. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 130 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 131: Section 8: Parts

    Running Board (1) D-300 / (2) C-100 602056 Reel Stand CRS-96/67-20K 601233 Transmission Unit Hydraulic Hose Kit 600298 Miscellaneous Replacement Parts: Fire Extinguisher 553858 Wheel Chocks, Rubber, (8”x5 ¼”x9”H) 552974 S+R Logo Mud Flap 550620 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 132 S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...

  • Page 133: Appendix A: Manufacturer Manuals

    **Appendixes are located separately in a CD and may not be included with this manual. If not included as a CD, contact Sherman+Reilly Parts & Service Department at parts@sherman-reilly.com or call (423)756-5300 to request the additional appendix documentation. S+R Revolution Series PTR-7230(S) / PTR-7240(S) Puller Tensioner Reconductorer...
  • Page 135 Sherman + Reilly, Inc. reserves the right to continually improve and expand our product line.

This manual is also suitable for:

Ptr-7230sPtr-7240Ptr-7240s

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