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Summary of Contents for Condux APS75
- Page 1 USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL APS75 T4F Underground Pulling Trailer...
- Page 2 Important Safety Notice Read and understand all procedures and safety instructions before using a Condux Underground Pulling Trailers. Observe all safety information on this page and note specific safety requirements as explained by procedures in this manual. Failure to follow these instructions could result in serious personal injury or death.
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Page 3: Table Of Contents
Unloading Rope or Conductor Reels ..8 M. Cap, Anti Slosh Hyd Filler ....... 38 H. Electrostatic Discharges ......8 N. Panel, Control-Assem-APS75 ....39 Inhalation Engine Exhausting Gas .... 8 O. Fairlead, Capstan Mount APS-75 ... 40 Transporting ............... 9 P. -
Page 4: General Information
General Information PRODUCT DESCRIPTION The APS75 pulling trailer provides up to 7,500 lbs of pulling force, and a max speed of 170 ft/min. It comes equipped with an Electronic Control system which monitors system pressures, engine data, pull distance and pull force. Tension Limit control, Pul... - Page 5 • All maintenance operations, both scheduled and repair, must be carried out per the instructions included in this manual or following technical instructions provided by the manufacturer. Failure to follow these instructions relieves the manufacturer from any responsibility and voids their warranty. MACHINE USAGE The machine must not be used: •...
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Page 6: Technical Specifications
Industry leading features like a standard Electronic Control System, a mobile joystick, and anti-twist rope make the APS75 the most advanced puller in the market today. GENERAL SPECIFICATIONS PULLER MAX LINE PULL, POUNDS... -
Page 7: Safety Information
Safety Information A. SAFETY DEVICES Machine has been equipped with the following safety devices: • A load-limiting device that automatically disables the pump once the max. pre-set load value has been exceeded • Where possible, guards and covers are provided to protect personnel from moving parts !DANGER: it is absolutely forbidden to use this machine with protective guards removed or with damaged or disconnected... -
Page 8: Rotating Component Pinch-Point Hazards
• Assume only the recommended operation locations indicated in this manual (Figure 2) !WARNING: Rope failure can cause serious injury or death if safety precautions are not followed. F. ROTATING COMPONENT PINCH-POINT HAZARDS Due to the nature of the work being performed and important system functionality, it is not possible to fully guard all rotating components. -
Page 9: Transporting
Transporting A. MACHINE LIFTING For machine lifting use only devices (overhead traveling cranes, lift trucks, ropes, cables, hooks, etc.) with a capacity equal to the weight to be lifted. Personnel should not be on the machine when it is lifted. !DANGER: Failure to follow the recommendations in this section may create a dangerous situation and/or damage to the machine. -
Page 10: Versatile Control Panel
Versatile Control Panel The Electronic Control and Monitoring system is an integral part of the APS75 Underground Pulling Trailer. In addition to monitoring pulling tensions, pull distance, hydraulic pressures, and fuel levels, it also allows the operator to record pull data and set tension limits. - Page 11 Air Filter Indicator - Turn on in case of air filter obstruction...
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Page 12: Electronic Controls & Display
E. ELECTRONIC CONTROLS AND DISPLAY See Section 6 for detailed instructions and information F. FILTER LIGHTS Filter lights, F1 and F2 indicate that a hydraulic filter needs to be replaced. Replacement filters and maintenance instructions can be found in Section 12.A of this manual. -
Page 14: Advanced Electronic Control
Advanced Electronic Control The Electronic Control and Monitoring system is an integral part of the APS75 Underground Pulling Trailer. In addition to monitoring pulling tensions, pull distance, hydraulic pressures, and fuel levels, it also allows the operator to record pull data and set tension limits. - Page 15 Figure 4. Sample Rate Screen...
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Page 16: Reset Length
C. RESET LENGTH (Figure 6) The Distance Counter on the APS75 Figure 6. Reset Length Electronic Control maintains length data, even after machine shut down. To reset the counter to 0 at any time, press and hold the RESET LENGTH button until the footage returns to 0. -
Page 17: Record Pull Data
(Figure 8) NOTE: The system will not reset unless the joystick is in the Neutral position. E. RECORDING PULL DATA The APS75 Electronic Controls allow the user to record pull data, including time of pull, pull distance, and pulling tensions. -
Page 18: Operating Procedures
Operating Procedures It is essential that the APS75 Underground Pulling Trailer be properly set up before operation. Using the following procedure will allow the unit to be set up in a short period of time and yield optimum performance. A. POSITIONING THE TRAILER & LOWER BOOM Position the APS75 Puller within an approximate boom arm reach of the manhole or duct bank. -
Page 19: Stabilize Trailer
Raise and lower jacks by rotating crank handle (Figure 3A). Adjust the two jacks on the boom arm until the arm is level to the ground. NOTE: If using the APS75 with hydraulic Jacks to stabilize the APS75 use hydraulic control panel (Figure 3B) located below the control box to raise and lower hydraulic cylinders. -
Page 20: Start Puller
In typical applications, the winch line will need to be paid out to reach the work area first, i.e. manhole, duct bank, etc. The winch line can then either be pulled through duct bank with a pulling rope or tape, or installed with a Condux Winch Line Blower. -
Page 21: Prepare For Pullback
E. PREPARE FOR PULLBACK Adjust the Maximum Tension Limit (if desired) to the desired maximum pulling tension value (measure in lbs). See detailed instructions on page 13. Turn on RECORD function (if desired) to record pull data. See detailed instructions on page 14. Select from the following three options: 1. -
Page 22: Maintenance
Maintenance A. GENERAL PROCEDURES !CAUTION: Any customer repairs not authorized by the manufacturer relieves the manufacturer of any responsibility for any resulting damage of property or injury to personnel. B. FLUID LEVELS Due to safety and/or regulatory reasons, this machine may arrive without hydraulic oil and fuel. -
Page 23: Oil Maintenance
!CAUTION: Disposal of all drained system oils and fluids must be in accordance with local regulations. Fill the hydraulic oil using the filler spout designated on (Maintenance drawing, item 1). !CAUTION: Ensure that no foreign matter enters the system along with the oil;... -
Page 24: Electronics Note
H. ELECTRONICS NOTE When cleaning the machine, avoid direct spraying of water or steam on electronic components or the control panel. For the other periodic operations refer to the summary table for the ordinary maintenance. I. SUMMARY TABLE FOR ORDINARY MAINTENANCE This table lists the recommended service intervals for the systems noted. -
Page 26: Troubleshooting Guide
Troubleshooting Guide PROBLEM: CAUSE: SOLUTION: Burned fuse Replace Run down battery (Light on Recharge or replace Kohler Controller) Disconnected contacts of the Reconnect The diesel engine starter ignition system / starter doesn’t work. Oxidized contacts of the Clean or spray with a ignition system / starter suitable vaporizer Replace / Technical... - Page 27 PROBLEM: CAUSE: SOLUTION: Allow oil to warm up by Hydraulic oil temperature running the engine at too low idle for several minutes. Use oil with lower The clogged filter The oil is too thick viscosity as per the warning light turns on. with respect to the indications in the environmental conditions...
- Page 28 PROBLEM: CAUSE: SOLUTION: Add engine oil Defective sensor Engine oil pressure too low – check contacts / (Light on Kohler Controller) replace Engine anomaly – technical assistance Add cooling liquid Diesel engine turns off Defective sensor during operations. Engine cooling liquid –...
- Page 29 PROBLEM: CAUSE: SOLUTION: Diesel engine rpm not Speed up the engine sufficient Diesel engine decreases Decrease pull on the rpm and turns off joystick Wait for oil to cool. Hydraulic oil The machine doesn’t Excessive hydraulic oil cooler should run reach the max.
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Page 31: Appendices
Appendices QUICK REF. SERVICE & PARTS LIST A. ENGINE Condux Part # Manufacturer Engine Model P.N. Kohler KDI 1903TCR Engine Service Part Part Number 02291828 Oil filter ED0021750010S 02291825 Fuel Filter ED0021753180S 02291827 Pre-Air Filter ED0021751750S 02291826 Air Filter ED0021751260S... -
Page 32: Suggested Lubricants
B. SUGGESTED LUBRICANTS SUGGESTED LUBRICANTS HYDRAULIC CIRCUIT AND STATIONARY BRAKE GEAR BOX GREASE ENGINE OIL ARCTIC COLD TEMPERATE ARCTIC COLD TEMPERATE TROPICAL TYPE UNIVERSAL TROPICAL NLGI TYPE OIL ATF 40°C+ -30°C -10°C 30°C -30°C -10°C 30°C 40°C+ SAE 10w-40 VISCOSI VG 33-VG VG22 VG32... -
Page 33: Maintenance Points
C. MAINTENANCE POINTS MAINTENANCE POINTS 08771000---3---4 ITEM DESCRIPTION HYDRAULIC OIL FILL HYDRAULIC OIL DRAIN HYDRAULIC OIL LEVEL GAUGE ENGINE COOLANT FILL GREASE POINT --- REEL BEARINGS FUEL FILL (DIESEL ONLY) GEARBOX OIL FILL GREASE POINT --- LEVELWIND SHAFT GREASE POINT --- CHAINS... - Page 34 02230401 SCREW,TAP .190-24X0.75 PNF CZ 02289180 LIGHT,LICENSE PLATE W/BRKT 02290459 LIGHT,OVAL TAIL LED - KIT 08771174 AXLE,BASE BOOM ARM 08771282 DECAL,CONDUX APS75 4.50X 22.00 12000901 FLATWASHER,0.37 TYPEA-W-ST CZ 12013500 NUT,0.37-16 NYLOC ST GR5 CZ 21033937 TOOLBOX,TRAILER TONGUE 08771320 EXTENDABLE ARM...
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Page 35: Trlr, Aps-75 08771000-01
E. TRLR, APS-75 7500LB CABLE TRLR TRLR,APS---75 7500LB CABLE TRLR 08771000--- ITEM PART NO DESCRIPTION 02264100 JACK,SDEWND---PIPE MNT---2,000 15" 02265001 RING,ADJUSTABLE TOW --- PAINTED 02289571 SPROCKET,IDLER HB40A17 02290186 LINK,HALF #40---1/2PITCH SINGLE 02290302 SPROCKET, 60BS20 X 1.00 BORE 02290304 SPROCKET, 40BS46 X 3/4 BORE 02290305 CHAIN,#60---3/4PTCH 70 PTCHS SGL 02290306... - Page 36 08771207 CLUSTER,SPKT---TKUPREEL APS---75...
- Page 37 SCREW,DRIVE #4 X 0.375 SS 02289856 FTG,HYD 12-NPT_M;12-NPT_F 90SW 02290641 REEL,HOSE .75" X 50' W/STOP 02291060 COMPRESSOR-DIESEL 185CFM-KAESER 08771282 DECAL,CONDUX APS75 4.50X22.00 08771290 HOSE,AIR PIPE SUPPLY 08771319 SPACER,KAESER COMP MTG 12000901 FLAT WASHER,0.37 TYPEA-W-ST CZ 12008301 FLAT WASHER,0.50 TYPEA-N-ST CZ 12013500 NUT,0.37-16 NYLOC ST GR5 CZ...
- Page 38 02290459 LIGHT,OVAL TAIL LED - KIT 02290615 LABEL,HYD ARM CONTROL 02290841 LABEL,HYD JACK CONTROL 08771174 AXLE,BASE BOOM ARM 08771282 DECAL,CONDUX APS75 4.50X 22.00 08771366 COVER,HYD CONTROL 12000901 FLATWASHER,0.37 TYPEA-W-ST CZ 12013500 NUT,0.37-16 NYLOC ST GR5 CZ 21033937 TOOLBOX,TRAILER TONGUE SEE ARM ASSY...
- Page 39 FTG,HYD 12-NPT_M;12-NPT_F 90SW 02290641 REEL,HOSE .75" X 50' W/STOP 02290883 LIGHT,FENDER MARKER, RED/AMB 02290887 MOUNT,FENDER LIGHT W/PLUG 02291060 COMPRESSOR-DIESEL 185CFM-KAESER 08771282 DECAL,CONDUX APS75 4.50X22.00 08771290 HOSE,AIR PIPE SUPPLY 08771319 SPACER,KAESER COMP MTG 12000901 FLATWASHER,0.37 TYPEA-W-ST CZ 12008301 FLATWASHER,0.50 TYPEA-N-ST CZ 12013500 NUT,0.37-16 NYLOC ST GR5 CZ...
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Page 40: Fairlea
AD, LEVELWIND J. FAIRLE FAIRLEAD,LEVELWIND APS-75 08771122 ITEM PART NO DESCRIPTION 02021501 LOCKWSHR 0.25 REGULAR ST CZ 02288426 CAPSRW 0.25-20X1.25 HHSTGR5 CZ 21011189 PAWL,BRNZ FNGR D00-00197 21032472 BLOCK,LEVELWIND FINGER MNT... -
Page 41: Arm, Complete-Assy
CAPSRW 0.50-13X7.00 HHSTGR5 CZ 08763155 JACK,BOOM ARM 08771125 SPACER,NYLON-ROPE GUIDE APS-75 08771158 SHEAVE,MAIN ROLLER-NYL APS-75 08771170 SHAFT,SHEAVE-MAIN RLR APS-75 08771258 TUBE,SPACER-MAIN ROLLER APS75 08771321 ARM,BASE ADJUSTABLE WELD APS-75 08771323 ARM,BOOM-EXT END-WELD APS-75 08771326 ARM,BOOM-BASE END-WELD APS-75 08771333 AXLE,PIVOT ARM-BOOM EXT APS-75 08771392... -
Page 42: Arm, Boom Pivot Extensn
L. ARM, BOOM PIVOT EXTENSN APS-75 ARM,BOOM PIVOT EXTENSN APS---75 08771155 ITEM PART NO DESCRIPTION 02289141 PIN,HITCH .50" DIAM 4.0" GRIP 02290577 RING,RETAINING 1.188 EXT(1000) 08763155 JACK,505 BOOM ARMS---WELD 08771158 SHEAVE,MAIN ROLLER---NYL APS---75 08771170 SHAFT,SHEAVE---MAIN RLR APS---75 08771224 ARM,BOOM---PIVOT END---ASSY---APS75 08771258 TUBE,SPACER---MAIN ROLLER APS75... -
Page 43: Cap, Anti Slosh Hyd Filler
M. CAP, ANTI SLOSH HYD FILLER CAP,ANTI SLOSH HYD FILLER 02290602 ITEM PART NO DESCRIPTION 02290602 CAP,ANTI SLOSH HYD FILLER... -
Page 44: Panel, Control-Assem-Aps75
N. PANEL, CONTROL-ASSEM-APS75 PANEL,CONTROL-ASSEM-APS75 08771040 ITEM PART NO DESCRIPTION 02290370 NUT #04-40 NYLOC ST GR2 CZ 02290375 CAPSRW #04-40X.31 BHSS 18-8 02290378 SPRING,GAS-15LBS 3.54" STROKE 08771053 CONTROL,REMOTE-ASSEY APS75... -
Page 45: Fairlead,Capstan Mount Aps-75
O. FAIRLEAD,CAPSTAN MOUNT APS-75 FAIRLEAD,CAPSTAN MOUNT APS-75 08771139 ITEM PART NO DESCRIPTION 02290380 CAPSRW M12-1.75X110 HHST8.8 CZ 02290381 NUT M12-1.75 NYLOC THN ST8.8CZ 08771125 SPACER,NYLON-ROPE GUIDE APS-75 08771138 ROLLER,ASSY-FAIRLEAD APS-75 08771219 FAIRLEAD,CAPSTAN-WELD APS75... -
Page 46: Fairlead,Midway Guide Aps-75
P. FAIRLEAD,MIDWAY GUIDE APS-75 FAIRLEAD,MIDWAY GUIDE APS-75 08771147 ITEM PART NO DESCRIPTION 02290380 CAPSRW M12-1.75X110 HHST8.8 CZ 02290381 NUT M12-1.75 NYLOC THN ST8.8CZ 08771125 SPACER,NYLON-ROPE GUIDE APS-75 08771138 ROLLER,ASSY-FAIRLEAD APS-75 08771220 FAIRLEAD,MIDWAY-WELDMENT-APS75 12008301 FLATWSHR 0.50 TYPEA-NARR ST CZ... - Page 47 Notes...
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Page 48: Warranty Information
Condux’s and the original manufacturer’s written instructions. Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under this limited warranty, and for any and all claims arising out of the purchase and use of the goods, shall be limited to the repair and replacement of the goods that do not conform to this warranty. - Page 50 Condux International, Inc. P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA 1-507-387- 6576 • 1-800-533-2077 • FAX 1-507-387-1442 Internet: http://www.condux.com • e-mail: cndxinfo@condux.com © Copyright 2012, Condux International, Inc. Printed in USA Literature Part Number: 91000016 Revision Number: 1.1...
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