INSTRUCTIONS FOR USE

TENSIONER MOD. FRS403

- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Fax 0039 / 035 / 4522445 Fax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]
ATTENZIONE
Per motivi di sicurezza durante il trasporto la macchina è fornita senza olio idraulico e senza
carburante. Nel presente fascicolo troverete informazioni sulle caratteristiche e le quantità
richieste. In caso di dubbio consultare la TESMEC.

WARNING
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
et sans carburant.
Référez-vous à ce manuel pour renseignements nécessaires sur les caractéristiques et
quantités. En cas de doute veuillez contacter TESMEC.

ATENCION
Por motivos de seguridad la máquina se transporta sin aceite hidráulico y sin combustible.
En el presente fascículo encontrarán informaciones acerca de las características y de las
cantidades requeridas. En caso de dudas, consultar a TESMEC.

ATENÇÃO
Por razões de segurança durante o transporte, a máquina é fornecida sem óleo hidráulico e
combustível. No presente folheto poderão encontrar as informações sobre as características
a as quantidades requeridas.
Caso tenham alguma dúvida, rogamos-lhes pôr-se em contacto com a TESMEC.

ACHTUNG
Aus Sicherheitsgründen während des Transportes, wird die Maschine ohne Öl und Kraftstoff
geliefert. Im vorliegenden Gebrauchsanweisungsheft werden Sie Informationen über die
Eigenschaften und Mengen des Öls finden.
Wenn Sie im Zweifel sind, fragen Sie TESMEC um Rat.

ПРЕДУПРЕЖДЕНИЕ
Из соображений безопасности, при поставке машина транспортируется без рабочей
жидкости в гидравлической системе и топлива.
Пожалуйста, пользуйтесь настоящим руководством для получения любых сведений,
касающихся характеристик и заправочных емкостей.
В случае каких-либо сомнений, пожалуйста, свяжитесь с компанией ТЕСМЕК.

- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Telefax 0039 / 035 / 4522445 Telefax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]
 TENSIONER
Model: FRS403

TENSIONER

Model: FRS403

Serial number
……………………
Manufacturing year
……………………
Working order
……………………

USE AND MAINTENANCE INSTRUCTIONS

 TENSIONER
Model: FRS403

1. GENERAL INDEX
Page
1. GENERAL INDEX 1
2. GENERAL DATA AND PRESCRIPTIONS 3
2.1 MANUFACTURER 3
2.2 COMMUNICATIONS WITH THE MANUFACTURER 3
2.3 TYPOLOGY AND USING FIELD 3
2.4 PERFORMANCES 3
2.5 TECHNICAL CHARACTERISTICS 3
2.6 ACOUSTIC EMISSION 3
2.7 GENERAL INFORMATION FOR THE MACHINE USE 4
2.8 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE 4
2.9 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE
MAINTENANCE 4
2.10 KNOWLEDGE AND CARE OF THE INSTRUCTION MANUAL 5
2.11 CONDITION OF USE 5
2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL 5
2.13 USE NOT ALLOWED 6
2.14 RESPONSIBILITY 6
2.15 APPLIED NORMS 6
3. TRANSPORT AND POSITIONING INSTRUCTIONS 7
3.1 MACHINE LIFTING 7
3.2 TRANSPORT TYPOLOGIES AND PACKAGE 7
3.3 UNPACKING 7
3.4 ASSEMBLING OPERATIONS 8
3.5 TRANSPORT ON TRAILER 8
3.6 POSITIONING AND ANCHORING 8
4. INSTRUCTION FOR USE 10
4.1 PRESCRIPTIONS FOR THE OPERATOR 10
4.2 CONTROLS 10
4.3 PRELIMINARY OPERATIONS 10
4.4 MACHINE USE 11
4.5 MACHINE STOP 11
4.6 THINGS TO REMEMBER 12
4.7 END OF OPERATIONS 12
5. SAFETY CONDITIONS 13
5.1 SAFETY DEVICES 13
5.2 EMERGENCY STOP DEVICE 13
5.3 PERIODIC OPERATIONS 13
5.4 RESIDUAL RISKS 14
6. MAINTENANCE 15
6.1 GENERAL PRESCRIPTIONS 15
6.2 LEVELS CONTROL 15
6.3 TYRES INFLATION PRESSURE 15
6.4 SUGGESTED LUBRICANTS 15
6.5 HYDRAULIC CIRCUIT MAINTENANCE 16
6.6 REDUCTION GEAR AND NEGATIVE SAFETY BRAKE MAINTENANCE 16
6.7 RADIATOR’S MAINTENANCE 16
6.8 GREASING 17
6.9 OTHER PERIODIC OPERATIONS 17
6.10 SUMMARY TABLE FOR ORDINARY MAINTENANCE 17
7. HOW TO DISABLE THE MACHINE 18
7.1 TRANSPORT 18
7.2 EXTENDED SERVICE STOP 18
7.3 STRIPPING 18
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8. ENCLOSED DOCUMENTS 19
8.1 TABLES 19
8.2 SYSTEMS 19
8.3 OTHER DOCUMENTS 19

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Model: FRS403

2. GENERAL DATA AND PRESCRIPTIONS

2.1 MANUFACTURER

TESMEC S.p.A.
Via Zanica, 17/O Via Pertegalli, 2
24050 - GRASSOBBIO 24060 - ENDINE GAIANO
BG - ITALY BG - ITALY
tel. (+39)-035-4232911 tel. (+39)-035-825024
fax (+39)-035-4522445 fax (+39)-035-826375
e-mail: [email protected] e-mail: [email protected]

2.2 COMMUNICATIONS WITH THE MANUFACTURER

For any information related to the machine (use, maintenance, spare parts) always state Model, Serial
Number, Manufacturing Year and Order. These data can be found in the machine identifying-table.

2.3 TYPOLOGY AND USING FIELD

The machine is suitable to string one or two ropes or bundled conductors.
The bull-wheel grooves are made up of wear-proof interchangeable nylon sectors.

2.4 PERFORMANCES
Max. tension: 40 kN
Max. continuous tension: 35 kN
Max. speed: 5 km/h

ATTENTION: the use with conductors with diameter lower than the max. admitted one,
causes the reduction of the max. applicable pull in comparison with the min. working
load granted by conductor.

Performances are referred to the machine without optional, at sea level and at 20°C.

2.5 TECHNICAL CHARACTERISTICS

Bull-wheels nominal diameter: 1500 mm
Max. conductor diameter: 34 mm (standard sectors with 6 grooves for 1 conductor)
24 mm (optional set of sectors with 10 grooves for 2
conductors)
Transmission: open hydraulic circuit with hydraulic oil cooling
Mechanical transmission at 3 positions: neutral - maximum ratio (MAXIMUM PULL) - minimum ratio
(MINIMUM PULL)
Safety brake: negative and self-acting type
Meter-counters: mechanical type
Axle: rigid type with mechanical parking brake for towing at max.
speed of 30-km/h
Dimensions: length - 3960 mm
width - 1800 mm
height - 2900 mm
Mass: 2300 kg

2.6 ACOUSTIC EMISSION

Level of continuous sound pressure to the operator seat (UNI 9432) Lep = 85 dB(A)

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Model: FRS403

2.7 GENERAL INFORMATION FOR THE MACHINE USE

a. Only employed and qualified operators must use the machine.
Qualified operators is intended to be the person who has received a qualified training from the
using Company or, as alternative, from the manufacturer.
b. Machine must be used only for the work it was designed for.
c. Machine cannot be used with non-authorised personnel on the working site.
d. For safety reasons, during transport machine comes without hydraulic oil and fuel.
Characteristics and required quantities are listed in the present manual.
e. For any doubt concerning use, functioning, maintenance or everything else, contact the After-sales
Service of the manufacturer.

2.8 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE
a. Operator has to know safety directives for accident prevention in force in the machine using
country, for a correct use of the same.
b. The operator in charge with the installation and maintenance of the machine must use suitable
clothes to the working site and to the situation where he finds himself; in particular he must avoid
the use of very large clothes, chains, bracelets, rings or whatever can get entangled with moving
parts.
c. The operator has to use the necessary protecting devices (i.e. gloves, boots, helmet, etc.).
It is compulsory the use of personal protecting devices for hearing.
d. The operator must not carry out on his own initiative operations or interventions that are not up to
him.
e. The operator must carefully follow danger and/or prohibition prescriptions contained in the
instruction manual or indicated on the machine.
f. The working area of the operator has to be cleaned from possible oil or liquids wastes and free of
materials or equipment that may be considered as on obstacle for the operator work.
g. The operator must absolutely avoid the direct inhalation of the exhaust gas of the endothermic
engine.

2.9 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).
b. Before carrying out any maintenance operations, stop the energy feeding (except for the cases
indicated in the present manual) and wait till the cooling of the elements subjected to heating.
c. All the maintenance operations of the machine must be carried out with machine on a level surface
and not under load.
d. Authorised and trained personnel must do all the maintenance operations, ordinary and not
ordinary. Trained personnel are intended to be the person who has received a qualified training
from the using Company or, as alternative, from the manufacturer.
e. The operator in charge with the machine maintenance must use suitable clothes to the working site
and to the situation where he finds himself; in particular he must avoid the use of very large
clothes, chains, bracelets, rings or whatever can get entangled with moving parts.
f. The operator has to use the necessary protecting devices (i.e. gloves, boots, helmet, etc.).
g. All the maintenance operations, ordinary and not ordinary, must be effectuated respecting the
prescriptions included in the present manual or following technical indications written by the
manufacturer. The non-respect of the prescribed restrains relieves the manufacturer from any
responsibility causing also the loss of warranty.

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2.10 KNOWLEDGE AND CARE OF THE INSTRUCTION MANUAL

a. The information contained in the instruction manual applies to all the operators charged with the
use and/or the maintenance of the machine.
b. The instruction manual is not a training manual.
c. Before using the machine the chief of the job site and the operator must read the instruction
manual.
d. The chief of the job site is obliged to inform all the operators about the instructions contained in
the manual.
e. The user must carefully follow the instructions listed in the present manual.
f. Before using the machine, the operator must be able to use it and has to exactly know the
positions and the operations of all the controls.
g. The chief of the job site must verify that the instructions contained in the manual are applied.
h. The instruction manual must be kept, in order to be consulted, for all the life of the machine and
also when it is given to another user.
i. The instruction manual must be kept in a sheltered and dry place.

ATTENTION: present manual belongs exclusively to the manufacturer.

The reproduction, event partial, of the text is forbidden.

2.11 CONDITION OF USE

a. Temperature: from -10°C to +40°C.
b. Relevant moisture: from 30% to 90% ± 5%.
c. Weather conditions: any (in line with working conditions).
d. Natural and/or artificial lighting of the working site.

2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL

When using the machine, please verify to respect the following temperature limits that can be reached
with the hydraulic oil as function of the working conditions.

TEMPERATURE LIMITS FOR HYDRAULIC OIL (°C)

Hydraulic oil viscosity
Working condition
VG 22 VG 32 VG 46 VG 68
Minimum temperature running in neutral position -21 -14 -7 -1
Minimum temperature running in full load 8 16 24 32
Maximum temperature running in full load 48 57 67 76
Maximum temperature running in neutral position 63 73 83 93

For additional information about the hydraulic oil, see "Maintenance" chapter and the enclosed
comparative table for the machine usable oils.

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Model: FRS403

2.13 USE NOT ALLOWED

The machine must not be used:
a. lifting persons and/or goods
b. in grounds on which the machine can not be positioned and anchored in a proper way
c. in areas with brushwood or other materials presence that can be easily set on fire
d. in closed/unventilated sites or, however, not sufficiently airy (tunnel or similar)
e. in sites with presence of gas that can be easily set on fire or explosives
f. in sites with presence of explosive materials
g. on aircraft, crafts, floating platforms and similar
h. for structure demolition, shafts felling or similar
i. for pulling flexible elements that can be highly lengthening, which allow elastic power accumulation
j. with ropes or joints having a bigger diameter than the one specified in present manual
k. with inhibited and broken safety devices installed on the machine
l. when winding on the bull-wheels ropes and/or conductors having a smaller diameter as a
succession of ropes and/or conductors having a bigger diameter.

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.

The non-respect of the prescribed restrains causes a situation of improper use for technical
and persons safety purposes and relieve the manufacturer from any responsibility, civil or
penal, in case of accidents to persons or damages to things, causing the loss of warranty.

The manufacturer responsibility declines even when one of the following situations happens:
a. for the consequences caused by tampering and/or modifications carried out without the
manufacturer’s written acceptance (in this case the operator becomes the manufacturer with
relevant obligations and responsibilities, both civil and penal)
b. for the use of not original spare parts
c. or bad maintenance
d. for the use with disconnected safety devices
e. for the connection to machine and/or plans not produced and not directly authorised by the
manufacturer in a written acceptance.

2.15 APPLIED NORMS

Machine is manufactured in conformity with the following norm:

98/37/CE Norm of the European Parliament and Council, dated 22 June 1998 referring to the
laws of the machines member States.

89/336/CE Norm of the European Council, dated 03 May 1989 referring to the laws of the
electromagnetic compatibility member States.

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Model: FRS403

3. TRANSPORT AND POSITIONING INSTRUCTIONS

3.1 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. 1).

During machine lifting operations, the presence of persons on the machine is strictly forbidden.

DANGER: the non-respect of the above mentioned conditions may cause dangerous
situations as well as damages to the machine with the consequent decline of any warranty
condition.

3.2 TRANSPORT TYPOLOGIES AND PACKAGE

Transport by land by truck
The machine comes without all the liquids that can be set on fire and protected in the most exposed
and delicate parts by means of cardboard and/or plywood and/or polyethylene extensible film.
To fix the machine on the platform of the transporting unit, use nailed wedges and/or metal brackets
and/or tie rods.

Transport by sea in wooden cases or container

The machine comes without all the liquids that can be set on fire; metal parts are protected with
waterproof wax.
To fix the machine on the package, use nailed wedges and/or metal brackets and/or tie rods.
At the inside, the wooden case foreseen a protection with tarpaper.

Materials usually used for the package are:

⇒ wooden
⇒ nails and/or steel screws
⇒ cardboard and/or paper
⇒ polyethylene extensible film
⇒ adhesive tape.

3.3 UNPACKING
When receiving the machine verify the integrity of the package; advise immediately the manufacturer
and the person in charge of the transport (even with photos) when possible damages due to transport
or tampering with removal, even partial, of the content happen.

Verify if the supplied material corresponds to the ordered one; immediately advise the manufacturer if
there are some discrepancies.

In case of transportation on wooden case, take away, in sequence, the upper cover and lateral panels,
before removing the machine.

During unpacking operations, avoid any shock to the structure or to the machine units, in order to
avoid any damage to the machine itself.

ATTENTION: the elimination of packaging materials must be effectuated in conformity with the
norms in force in the relevant country.

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3.4 ASSEMBLING OPERATIONS

Assemble the entry rollers in the suitable seats.

3.5 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. 11) and in the respect of the speed limits
of the axle.
The used towing unit must be homologated for towing trailers with mass and dimensions as per the
described machine.

Before transport operation, lift the support front share by means of the jack (table 1, pos. 8).

Check the inflation pressure of tyres (3,5 bar).

During trailer machine transport operations is nobody must stay in the machine itself.

ATTENTION: dangerous situations during towing if the tyres inflation pressure and the speed
limit are not respected may happen.

When transporting on truck or trailer, verify if the machine has been fixed on the platform with nailed
wedges and/or metal brackets and/or tie rods.

3.6 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).

It is possible to use the machine at a distance from the pole included between 1 and 2 times the
height of the pole itself. In this case, the anchorage described thereafter must be over dimensioned of
125% compared to the reported data and some moorings must be provided on the front side of the
machine.

PROHIBITION: when the distance between the machine and the pole is lower than the
height, the machine cannot be used.

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Machine anchoring sequence is the following:

a. machine must be aligned as much as possible with the pull direction.
b. anchor the machine to the ground by means of 2 stakes with min. granted load equal to 130% of
the machine max. pull, connecting the foreseen connections (table 3, pos. 1) with the anchoring
stakes and respecting the described scheme and angles (table 3).
c. recover the clearance on the anchoring stakes without tensioning them.
d. test the machine pull (see use instructions on the following chapter) to allow the machine to freely
align as regards as the pull itself.
e. tension the anchoring stakes in a uniform way.
f. block the machine brakes acting on the special hand-wheel (table 1, pos. 7) or on the knob
(table 1, pos. 6) if mounted.

ATTENTION: the non-respect of the foreseen anchoring operations may cause dangerous
situations during machine use.

Around the machine must be a free space of at least 2-m to make easier the operations of use,
adjustment, maintenance, etc.

Be sure that around the radiator (hydraulic oil) cooling air can freely circulate.
Otherwise overheating situations with damage for the installed components may happen.

DANGER: machine has not a proper grounding device; for the system machine-rope-
conductor in the job site must foreseen a grounding device on the towing rope or on the
conductors.

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4. INSTRUCTION FOR USE

4.1 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.

Daily, before starting the work, check:

a. if the protection and safety devices are activated and functioning according to the lamps
b. if the machine liquids levels are in conformity with the indications in maintenance chapter
c. if the anchoring conditions are in conformity with the indications of this manual.

4.2 CONTROLS
Position and meaning of the elements on the control panel are described on table 5 enclosed.

4.3 PRELIMINARY OPERATIONS

a. Load the conductors or the cables on the bull-wheels as shown on tables 3 and 4 moving on “O”
position the lever (table 3, pos. 6) and making the bull-wheels turn manually.

ATTENTION: do not use excessively lubricated or greased ropes because possible

adherence problems on the bull-wheels with a consequent sliding of the ropes themselves
may arise.

b. Lubricate the gears before each starting of the machine using the proper greasers (table 3, pos. 10).
c. Position both the lever of mechanical transmission (table 3, pos. 6) into the proper ratio in
accordance with the job to do:
⇒ pos. B: high pull (normal tensioning)
⇒ pos. A: low pull (precision tensioning).

ATTENTION: this operation must be made only with stopped machine and without applied
loads.

DANGER: please pay attention to the risk to be squeezed during the operations above
described.

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4.4 MACHINE USE

a. Close the cock (table 5, pos. 3).
b. Move the distributor lever (table 5, pos. 4) on “B” BLOCKED position.
Move the lever of the manual pump (table 5, pos. 6) till reading on the manometer (table 5, pos. 1)
a pressure of 30 bar at least. During all working operations, the above-mentioned pressure must
never drop below 16 bars otherwise the negative safety brake locks the bull-wheels.
Once started the work, the manometer (table 5, pos. 1) will indicate the high pressure of the main
hydraulic circuit.
c. Partially close the valve (table 5, pos. 5) and move the distributor lever (table 5, pos. 4) on “A”
FREE position. At this point the bull-wheels can freely turn.
d. Adjust the desired pull using the valve (table 5, pos. 5).
The pull value can be read on the outer scale of the dynamometer (table 5, pos. 2).

ATTENTION: the dynamometer is calibrated with 2 scales: high pull (external scale), low pull
(internal scale). Read the values of the pull on the scale correspondent to the use of the
machine (high pull or low pull).

e. Open the cock (table 5, pos. 3) that grants the negative safety brake automatic closure in case of
failure in the main circuit.
f. To stop temporarily the machine functioning, close the cock (table 5, pos. 3) before moving the
distributor lever (table 5, pos. 4) on “B” BLOCKED position.
In this way, the release pressure for the negative safety brake is maintained.
To resume the work it is sufficient to move the lever (table 5, pos. 4) on “A” FREE position.

ATTENTION: when starting a cold machine, limit the maximum working performances of the
machine for the first 15 minutes, in particular do not exceed 30% of the maximum stringing
speed. Close the cock (table 5, pos. 7) to cut off the hydraulic oil cooling and open it when the
oil reaches a temperature of about 40°C (table 1, pos. 4).

Cut out the functioning of the hydraulic oil ventilator using the suitable cock (table 5, pos. 7), till
reaching the correct working temperature for the oil (40-50°C).

4.5 MACHINE STOP

To stop the machine, act as follows:
a. partially close the valve (table 5, pos. 5) turning the hand-wheel clockwise about half a turn in order
to have a better control of the conductors when the negative safety brake will be released to
resume the work.
b. move the lever (table 5, pos. 4) to “B” BLOCKED position to stop the bull-wheels rotation.
Before carrying out this manoeuvre, unless it is an emergency, it is advisable to wait till the bull-
wheels stop in order to avoid any damages to the negative safety brake.
c. close the cock (table 5, pos. 3) so as to maintain the pressure for the negative safety brake release
for the following start.

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4.6 THINGS TO REMEMBER

a. During all working operations, the pressure indicated on the manometer (table 5, pos. 1) must
never go below 16 bars otherwise the negative safety brake locks the bull-wheels.
Once started the work, the manometer will indicate the high pressure of the main hydraulic circuit.
b. Unless case of emergency, it is advisable to wait till the bull-wheels stop, before put the lever
(table 5, pos. 4) in “B” BLOCKED position to engage the negative safety brake.
c. Before beginning the works, check the levels.
d. Do not work with the hydraulic oil temperature more than 80°C
e. After an emergency intervention of the negative safety brake, verify the condition of the brake
discs.
f. The connecting operations of the mechanical reduction gear (table 3, pos. 7) must be made only
with stopped machine.
g. The dynamometer is calibrated with 2 scales: high pull (external scale), low pull (internal scale).
Read the values of the pull on the scale correspondent to the use of the machine (high alto or low
pull).

4.7 END OF OPERATIONS

At end of operations, discharge the conductors’ tension.

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5. SAFETY CONDITIONS

5.1 SAFETY DEVICES

Machine has been equipped with the following safety devices:
1. mechanical negative safety brake for movement stop in case of lack of hydraulic pressure
2. timing case and protections on moving parts, where technologically possible.

DANGER: it is absolutely forbidden the use of the machine without protecting timing
cases or with damaged/disconnected safety devices.

ATTENTION: after a serious emergency use of the negative safety brake, check the wear
condition of the discs and the efficiency of the brake itself; if necessary, replace the brake
discs before re-use the machine.

5.2 EMERGENCY STOP DEVICE

The emergency stop function is carried out by means of negative safety brake by means of a
distributor operated by the lever (table 5, pos. 4).

ATTENTION: use the emergency stop device ONLY in danger situations for the operators’
safety.

The emergency stop device for stopping the machine while working must only be used in
emergencies.

5.3 PERIODIC OPERATIONS

Daily, before starting the work, the operator has to verify the functionality of the machine safety
devices.

ATTENTION: do not modify for any reason safety devices of the machine because the
manufacturer declines any responsibility as consequence of the non-functioning of the same.

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5.4 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.
To reduce to min. the risks the operator has to:
⇒ check the rope and replace it as soon as appear some defects or wear signs
⇒ respect the working positions indicated in the manual.

2. Sudden break of the anchoring stakes. The sudden break of the anchoring stakes causes the
machine instability and sudden movements of the same.
To reduce to min. the risks the operator has to:
⇒ periodically check the anchoring stakes and replace them as soon as appear some defects or
wear signs
⇒ follow the anchoring indications described in the present manual
⇒ respect the working positions indicated in the manual.

3. Entangling or dragging of the accessible rotating units. It is not technologically possible to

foreseen covering in correspondence of some rotating units (i.e. winding of the rope or of the
conductor on the bull-wheels or on the driving gears), due to an excessive restriction of the
machine functionality and operative functions.
To reduce to min. the risks the operator has to:
⇒ avoid any possible contact with the machine rotating units except for the control devices
⇒ follow the anchoring indications described in the present manual
⇒ respect the prescriptions indicated in the present manual concerning wearing and the necessary
safety devices.

4. Limbs crushing during loading or removal of the reel and during conductor loading.
These operations have a large risk margin due to the use of mechanical parts to be moved.
To reduce to min. the risks the operator has to:
⇒ know the directives for accident prevention and apply them.

5. Electrostatic discharges. The machine has not a proper grounding device for this reason during
stringing operation it is possible to have dangerous electrostatics discharges on ropes and
conductors.
To reduce to min. the risks the operator has to:
⇒ know the directives for accident prevention and apply them
⇒ check if the job site has a suitable grounding device for the machine-rope-conductors system.

Manual: MI-FRS403-03-01-GB Date: 22.09.2006 Author: A. Oscar Page: 14 of 19

 TENSIONER
Model: FRS403

6. MAINTENANCE

6.1 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.

6.2 LEVELS CONTROL

For safety reasons, during the transport machine comes without hydraulic oil and fuel.
Fill the levels as per the following table:
Quantity
a. Hydraulic oil level (table 1, pos. 2) 200 l
b. Reduction gear oil level (table 3, pos. 2) 1,2 l
c. Negative safety brake oil level (table 3, pos. 5) 0,3 l

ATTENTION: the non-respect of the correct levels causes serious damages to the installed
components.

DANGER: do not ingest hydraulic liquids because injurious to health and potentially lethal.

6.3 TYRES INFLATION PRESSURE

Tyres inflation pressure has to be 3 bars.

ATTENTION: the non-respect of tyres inflation pressure causes dangerous situations during
transport operations.

6.4 SUGGESTED LUBRICANTS

The manufacturer tests the machine with the following oils and lubricants:
a. hydraulic circuit and negative safety brake: AGIP OSO 46 (ISO HM 46)
b. reduction gear: AGIP BLASIA 150 (ISO CKC 150).

Possible different trademarks must be chosen based on the enclosed table "SUGGESTED
LUBRICANTS". It is possible to use different trademarks but with same characteristics and ISO
specifications.

When using oil with characteristics and ISO specifications different from the ones declared during test,
completely empty out the hydraulic circuit.

ATTENTION: the use of lubricants not in conformity with the technical specifications indicated
in the present manual seriously damages the machine components and, consequently, the
warranty conditions are not valid.

Manual: MI-FRS403-03-01-GB Date: 22.09.2006 Author: A. Oscar Page: 15 of 19

 TENSIONER
Model: FRS403

6.5 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. 5).

DANGER: let the hydraulic oil be completely cooled before removing it and always use the
suitable safety wears (gloves, etc.).

ATTENTION: the discharge of the exhaust oils has to be effectuated in conformity with the
laws in force in the relevant country.

c. Fill the oil in the tank by means of the suitable filler (table 1, pos. 2).

ATTENTION: make maximum care when filling to make sure no foreign matter, which could
cause irreparable damages to the circuit’s components, enters along with the oil; if possible
filter the oil with a 10 μm filter.

d. To clean or to replace the suction filter immersed in the oil hydraulic tank after 500 working hours
and, then, every 1500 hours (or every year at least).

For further maintenance operations of installed hydraulic components (pumps and motors), refer to the
enclosed documentation.

6.6 REDUCTION GEAR AND NEGATIVE SAFETY BRAKE MAINTENANCE

a. Change the oil of the reduction gear and negative safety brake after 50 working hours and, then,
every 500 hours (or every year at least).
b. To discharge the exhaust oil of the reduction gear and negative safety brake, use the suitable caps
on the lower part of the casing of the same.

DANGER: let the hydraulic oil be completely cooled before removing it and always use the
suitable safety wears (gloves, etc.).

ATTENTION: the discharge of the exhaust oils has to be effectuated in conformity with the
laws in force in the relevant country.

c. Fill the oil of the reduction gear and negative safety brake by means of the suitable caps on the
upper part of the casing of the same.

ATTENTION: make maximum care when filling to make sure no foreign matter, which could
cause irreparable damages to the circuit’s components, enters along with the oil.

For further maintenance operations of installed hydraulic components (pumps and motors), refer to the
enclosed documentation.

6.7 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.

Manual: MI-FRS403-03-01-GB Date: 22.09.2006 Author: A. Oscar Page: 16 of 19

 TENSIONER
Model: FRS403

6.8 GREASING
Grease 2-3 times per day the crown gear of the bull-wheels using the suitable greaser
(table 3, pos. 10).

Weekly grease all the other parts subjected to rotation or translation and that not foreseen a forced
lubrication or an automatic greasing.

Use IP ATHESIA GR2 (ISO XBCEA 2) grease or equivalent of another trademark based on the
enclosed "SUGGESTED LUBRICANTS" table.

6.9 OTHER PERIODIC OPERATIONS

When cleaning the machine, avoid direct jets of water or steam on the components of the electric
system of the machine and on the control panel.

For the other periodic operations, refer to the summary table for the ordinary maintenance (see next
paragraph).

6.10 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
Hydraulic oil CL ST1 ST(*)
Hydraulic circuit
Filter ST1 ST(*)
Oil CL ST1 ST(*)
Negative safety brake
Disc
Reduction gear Oil CL ST1 ST(*)
Bull-wheels greasing circuit Gears GR
Front jack Sliding shaft GR
Tyres pressure VF
Axle
Negative brake GR

Legend:
CL Check the level (and possible filling up)
GR Grease
ST Replace
ST1 Replace (only for the first time)
VF Check
(*) Or in any case every year

Manual: MI-FRS403-03-01-GB Date: 22.09.2006 Author: A. Oscar Page: 17 of 19

 TENSIONER
Model: FRS403

7. HOW TO DISABLE THE MACHINE

7.1 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).

7.2 EXTENDED SERVICE STOP

When foreseeing an extended service stop (two months at least) protect the external parts with
waterproof wax and empty the fuel tank.

During service stop, start the machine at least once every two months and let the machine idle for one
hour at least, so that the oil enters in the hydraulic system and to prevent the gaskets drying.

We recommend stocking the machine under a roof; do not cover the machine with pieces of cloth
and/or plastic materials that cause an excessive increase of the temperature and humidity.

If the machine does not work for a year or more, before re-starting the machine it is necessary to
replace the hydraulic oil and filters of the hydraulic circuit.

7.3 STRIPPING
Machine stripping has to be carried out by the manufacturer or by a specialised factory.

All the stripping operations have to be effectuated in conformity with the norms in force for accidents
prevention.

Waste materials have to be divided for typology (i.e. iron scrap, aluminium, plastic, rub, etc.) and
disposed of by means of authorised structures in conformity with the laws in force.

Exhausted oils and polluting substances have to be disposed of by means of authorised structures in
conformity with the laws in force.

Manual: MI-FRS403-03-01-GB Date: 22.09.2006 Author: A. Oscar Page: 18 of 19

 TENSIONER
Model: FRS403

8. ENCLOSED DOCUMENTS

8.1 TABLES
TABLE 1.2 Machine in working position – Lateral view
TABLE 2.2 Machine in towing position – Lateral view
TABLE 3.2 Machine set for pulling conductor – Upper view
TABLE 4.2 Machine set for pulling two conductors – Upper view
TABLE 5.3 Control panel
Comparative table for suggested oils

8.2 SYSTEMS
367850 Nylon roller assembly
389470 Control panel assembly
389680 Frame assembly
389731 Feeding group assembly
391070 Meter-counter assembly
419700 Functional hydraulic system
636460 Bull-wheels assembly

8.3 OTHER DOCUMENTS

Instruction for assembling and maintenance for reduction gear Reggiana Riduttori mod. RR 510 MSS

Manual: MI-FRS403-03-01-GB Date: 22.09.2006 Author: A. Oscar Page: 19 of 19

 TENSIONER MOD. FRS403

TABLES

- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Fax 0039 / 035 / 4522445 Fax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]
 TENSIONER
Model: FRS403

TABLE 1.2

1) Connection for machine lifting.

2) Hydraulic oil filling cap (AGIP OSO 46, qty 200 lt.).
3) Hydraulic oil breather cap.
4) Hydraulic oil level.
5) Hydraulic oil drain cap.
6) Air-brake control device (opt).
7) Safety brake for machine.
8) Plough lifting jack.
9) Meter-counter.
10) Meter-counter zero-setting lever.
11) Towing drawbar.
12) Rear stabiliser.
 TENSIONER
Model: FRS403

TABLE 3.2

1) Anchoring connections.
2) Reduction gear oil filling cap (AGIP BLASIA 150, qty 1,2 lt.).
3) Negative safety brake filling cap (AGIP OSO 46, qty 0,3 lt.).
4) Negative safety brake drain cap (under the filling cap pos. 3).
5) Negative safety brake oil level.
6) Lever for reduction gear speed change.
• pos. A: low pull (precision tensioning)
• pos. 0: idle bull-wheels
• pos. B: high pull (normal tensioning)
7) Reduction gear oil drain cap (under the filling cap pos. 2).
8) Reduction gear oil level.
9) Tools box.
10) Bull-wheels greaser.
 TENSIONER
Model: FRS403

TABLE 5.3

1) Negative safety brake opening manometer.

2) Dynamometer-manometer.
3) Negative safety brake connecting cock (pos. A: open, pos. B: closed).
4) Negative safety brake distributor (pos. A: free, pos. B: blocked).
5) Max. relief valve for braking regulation.
6) Manual pump for negative safety brake release.
7) Ventilator cock.
 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
ARTIC WINTER SUMMER TROPICAL ARTIC WINTER SUMMER TROPICAL AMBIENT

VISCOSITY
VG 22 VG 32 VG 46 VG 68 VG 100 VG 150 VG 220 VG 320 NLGI 2
(ISO 3448)
AGIP OSO 22 OSO 32 OSO 46 OSO 68 BLASIA 100 BLASIA 150 BLASIA 220 BLASIA 320 GR MU EP 2

API APILUBE CIS 22 APILUBE CIS 32 APILUBE CIS 46 APILUBE CIS 68 DT 100 DT 150 DT 220 DT 320 PGX 2

ARAL ARAL VITAM GF 22 ARAL VITAM GF 32 ARAL VITAM GF 46 ARAL VITAM GF 68 DEGOL BG 100 DEGOL BG 150 DEGOL BG 220 DEGOL BG 320 ARALUB HL 2

AVIA AVILUB RSL 22 AVILUB RSL 32 AVILUB RSL 46 AVILUB RSL 68 AVILUB RSX 100 AVILUB RSX 150 AVILUB RSX 220 AVILUB RSX 320 -

BP ENERGOL HLP 22 ENERGOL HLP 32 ENERGOL HLP 46 ENERGOL HLP 68 ENERGOL GR-XP 100 ENERGOL GR-XP 150 ENERGOL GR-XP 220 ENERGOL GR-XP 320 GREASE LTX 2

CASTROL HYSPIN AWS 22 HYSPIN AWS 32 HYSPIN AWS 46 HYSPIN AWS 68 ALPHA SP 100 ALPHA SP 150 ALPHA SP 220 ALPHA SP 320 SUPERGREASE 2

CHEVRON EP HYDRAULIC 22 EP HYDRAULIC 32 EP HYDRAULIC 46 EP HYDRAULIC 68 COMPOUND GEAR 100 COMPOUND GEAR 150 COMPOUND GEAR 220 COMPOUND GEAR 320 DURALITH EP 2

ELF ELFOLNA DS 22 ELFOLNA DS 32 ELFOLNA DS 46 ELFOLNA DS 68 REDUCTELF SP 100 REDUCTELF SP 150 REDUCTELF SP 220 REDUCTELF SP 320 ROLEXA 2

ESSO NUTO H 22 NUTO H 32 NUTO H 46 NUTO H 68 SPARTAN EP 100 SPARTAN EP 150 SPARTAN EP 220 SPARTAN EP 320 BEACON 2

FINA HYDRAN 22 HYDRAN 32 HYDRAN 46 HYDRAN 68 GIRAN 100 GIRAN 150 GIRAN 220 GIRAN 320 MARSON EP L2

FUCHS RENOLIN MR 5 RENOLIN MR 10 RENOLIN MR 15 RENOLIN MR 20 - RENEP COMPOUND 104 - RENEP COMPOUND 108 -

GULF HARMONY 22 AW HARMONY 32 AW HARMONY 46 AW HARMONY 68 AW - EP LUBRICANT HD 150 EP LUBRICANT HD 220 EP LUBRICANT HD 320 CROWN EP 2

IP HYDRUS OIL 22 HYDRUS OIL 32 HYDRUS OIL 46 HYDRUS OIL 68 MELLANA 100 MELLANA 150 MELLANA 220 MELLANA 320 ATHESIA EP GR 2

KLUBER LAMORA 22 LAMORA 32 LAMORA 46 LAMORA 68 LAMORA 100 LAMORA 150 LAMORA 220 LAMORA 320 CENTOPLEX 2 EP

MOBIL DTE 22 DTE 24 DTE 25 DTE 26 - MOBILGEAR 629 MOBILGEAR 630 MOBILGEAR 632 MOBILUX EP 2

Q8 HAYDIN 22 HAYDIN 32 HAYDIN 46 HAYDIN 68 GOYA 100 GOYA 150 GOYA 220 GOYA 320 REMBRANDT EP 2

ROLOIL LI 22 LI 32 LI 46 LI 68 EP 100 EP 150 EP 220 EP 320 LITEX EP 2

SHELL TELLUS 22 TELLUS 32 TELLUS 46 TELLUS 68 OMALA 100 OMALA 150 OMALA 220 OMALA 320 SUPERGREASE EP2

SYNECO - PACEMAKER 32 PACEMAKER 46 PACEMAKER 68 - PACEMAKER RODI 12 - PACEMAKER RODI 24 SINT GREASE EP 2

TAMOIL HYDRAULIC OIL 22 HYDRAULIC OIL 32 HYDRAULIC OIL 46 HYDRAULIC OIL 68 CARTER EP 100 CARTER EP 150 CARTER EP 220 CARTER EP 320 TAMLITH GREASE EP2

TEXACO RANDO HD 22 RANDO HD 32 RANDO HD 46 RANDO HD 68 MEROPA 100 MEROPA 150 MEROPA 220 MEROPA 320 MULTIFAK EP 2

TOTAL AZOLLA ZS 22 AZOLLA ZS 32 AZOLLA ZS 46 AZOLLA ZS 68 CARTER EP 100 CARTE EP 150 CARTER EP 220 CARTER EP 320 MULTIS EP 2

VALVOLINE ELIOS HVI 22 ELIOS HVI 32 ELIOS HVI 46 ELIOS HVI 58 ELIOS EP 100 ELIOS EP 150 ELIOS EP 220 ELIOS EP 320 LITHIUM BASE EP 2

Tavole Oli - 16/09/2004 - Pagina 1 di 1 - GB

 TENSIONER MOD. FRS403

ENCLOSED DOCUMENTS

- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Fax 0039 / 035 / 4522445 Fax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]
 IMPORTANTE
Per qualsiasi informazione riguardante questa macchina/attrezzatura (utilizzo, manutenzione, ricambi) citare sempre Modello, Numero di
matricola, Commessa, Anno di fabbricazione rilevabile nella targa d'identificazione della macchina.
Questo manuale non descrive le procedure di tesatura, né si è cercato di dare istruzioni all’utilizzatore sui metodi di tesatura.
Il contenuto di questo manuale prevede unicamente un testo di base per l’uso, manutenzione e l’elenco dei pezzi di ricambio della macchina
stessa e come s'intende e si suggerisce di utilizzarla. Saranno graditi suggerimenti da parte degli Utilizzatori per migliorare questa pubblicazione.
Scriveteci all’indirizzo sottoindicato.

IMPORTANT NOTE
State always “Model, Serial Number and Manufacturing Year” of the machine/equipment in case you need information on use, maintenance and
spare parts. The a/m data can be found on the identification plate of the machine itself.
This is not a stringing procedures manual, and no attempt is made or implied herein to instruct the user in stringing methods.
The contents of this manual are intended as base line for operation, maintenance and part list of the unit as it stands alone and as it is intended
and anticipated to be used. Recommendation by the individual user for improving this publication is encouraged and should be forwarded to the
address on this page.

IMPORTANT
Indiquer toujours le modèle, le numéro de série et l’année de fabrication de la machine/équipement même, en demandant à TESMEC
renseignements sur l’utilisation, l’entretien et les pièces de rechange. Ces informations se trouvent sur la plaque d'identification de la machine.
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. Pour chaque suggestion pour améliorer cette machine, écrire à l’adresse au-dessous.

IMPORTANTE
Para cualquier información relativa a esta máquina/equipo (utilización, mantenimiento, repuestos) citar siempre Modelo, Número de serie, Orden
de compra, Año de fabricación que se hallan en la tarjeta de identificación de la máquina.
Este manual no describe los procedimientos de tensado y tampoco se ha tratado de dar instrucciones al utilizador acerca de los métodos de
tensado. El contenido de este manual prevé únicamente un texto básico para el uso, mantenimiento y el listado de repuestos de la misma
máquina y cómo se pretende y se sugiere utilizarla. Se apreciarán sugerencias por parte de los utilizadores para mejorar esta publicación.
Nos pueden escribir a la dirección indicada abajo.

IMPORTANTE
Para qualquer informação a respeito desta máquina/equipamento (utilização, manutenção, peças sobresselentes) citar sempre o Modelo, o
Número de Série, a Encomenda, o Ano de fabrico,dados que podem ser encontrados na placa de identificação da máquina.
Este manual não descreve os procedimentos de entesadura, tão pouco foi nossa intenção dar instruções ao utilizador sobre os métodos de
entesadura. O conteúdo deste manual de instruções prevê unicamente um texto básico para o uso, a manutenção e a lista das peças
sobresselentes da mesma máquina e como se entende e se sugere utilizá-la.
Serão muito bem aceitas sugestões por parte dos Utilizadores, no intento de melhorar esta publicação.
Escrevam-nos no endereço abaixo indicado.

WICHTIG
Geben Sie für alle Informationen über diese Maschine/Ausrüstung (Verwendung, Wartung, Ersatzteile) immer Modell, Matrikelnummer,
Bestellung und Baujahr an, was Sie dem Identifizierungsschild der Maschine entnehmen können.
Dieses Handbuch beschreibt nicht die Verfahren des Spannens, und es wurde auch nicht versucht, dem Verwender Anleitungen über die
Methoden des Spannens zu geben. Der Inhalt dieses Handbuchs enthält allein einen Basistext für den Gebrauch und die Wartung, die
Ersatzteilliste der Maschine und außerdem, welche Verwendung für sie bezweckt und empfohlen wird.
Wir freuen uns über Tipps von Seiten der Verwender, um diese Veröffentlichung zu verbessern.
Schreiben Sie uns an unten angegebene Adresse.

ВАЖНОЕ ПРИМЕЧАНИЕ
Всегда следует указывать «модель, серийный номер и год выпуска» машины/оборудования в случае, если вам необходима
информация по эксплуатации, техническому обслуживанию и запасным частям. Вышеупомянутые данные можно найти на
паспортной табличке на самой машине.
Руководство по эксплуатации не является руководством по методикам натяжения, и в нем не делается никаких попыток
инструктирования пользователя способам натяжения, и они не подразумеваются.
Цель настоящего руководства состоит только в том, чтобы дать описание эксплуатации и технического обслуживания, а также список
запасных частей машины, и указать ее назначение и рекомендуемое использование. Рекомендации отдельных пользователей по
улучшению данной публикации приветствуются, и их следует направлять по адресу, указанному в руководстве.

- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Telefax 0039 / 035 / 4522445 Telefax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]