ZECK Puler

STRINGING MACHINES
MADE IN GERMANY
Instructions
Original instructions
Tensioner
B 1500/14
8285 ─ 8292
Rev.: 2017-03
: 3/3/2017
: EN-US
Table of contents
1 Identification ............................................................................................................................ 9
1.1 Identification of this document................................................................................................................ 9
1.2 Name and address of the manufacturer............................................................................................... 9
1.3 Service telephone number ......................................................................................................................... 9
2 User information ...................................................................................................................... 9

2.1 About these instructions............................................................................................................................. 9
2.2 Locations in this document..................................................................................................................... 10
2.3 Illustrations used ......................................................................................................................................... 10
2.4 Terms used .................................................................................................................................................... 12
2.5 Representation of safety instructions ................................................................................................. 12
2.6 Other applicable documents.................................................................................................................. 13
2.7 Copyright notice.......................................................................................................................................... 13
2.8 Copyright of third parties ........................................................................................................................ 13
3 Basic safety instructions ........................................................................................................ 14

3.1 Intended use ................................................................................................................................................. 14
3.2 Reasonably foreseeable misuse ............................................................................................................ 14
3.3 Risks when handling the machine........................................................................................................ 15
3.3.1 Danger arising from the mechanical system .................................................................... 15
3.3.2 Danger arising from electric energies ................................................................................. 16
3.3.3 Danger arising from pressurized media ............................................................................. 16
3.3.4 Danger arising from high temperatures............................................................................. 17
3.3.5 Danger arising from operating materials........................................................................... 17
3.3.6 Danger arising from inadequate maintenance ................................................................ 18
3.3.7 Danger arising from emissions .............................................................................................. 19
3.3.8 Danger caused by modifications........................................................................................... 19
3.4 Residual risks ................................................................................................................................................ 19
3.5 Duty of the operator.................................................................................................................................. 20
3.6 Duty of the personnel ............................................................................................................................... 20
3.7 Qualification of the personnel ............................................................................................................... 21
3.8 Personal protective equipment ............................................................................................................. 21
3.9 Safety equipment and protective devices......................................................................................... 21
3.9.1 Emergency stop............................................................................................................................ 22
3.9.2 Overload protection ................................................................................................................... 22
3.9.3 Safety brake ................................................................................................................................... 22
3.9.4 Main switch .................................................................................................................................... 22
3.9.5 Machine cladding ........................................................................................................................ 23
3.9.6 Engine protection ....................................................................................................................... 23
3.10 Workplaces – operating personnel...................................................................................................... 23
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3.11 Machine labeling......................................................................................................................................... 23
3.11.1 Type plate ....................................................................................................................................... 24
4 Machine description .............................................................................................................. 24

4.1 Field of application..................................................................................................................................... 25
4.2 Functional principle of the machine.................................................................................................... 25
4.3 Further functions......................................................................................................................................... 26
4.3.1 Overload protection ................................................................................................................... 26
4.3.2 Recording the pulling data ...................................................................................................... 26
4.4 Machine description .................................................................................................................................. 28
4.5 Structural components and other components.............................................................................. 28
4.5.1 Engine .............................................................................................................................................. 28
4.5.2 Hydraulic system.......................................................................................................................... 29
4.5.3 Bull wheel........................................................................................................................................ 29
4.5.4 Rope guide..................................................................................................................................... 29
4.5.5 Control desk .................................................................................................................................. 30
4.5.6 Remote control............................................................................................................................. 30
4.5.7 Supports.......................................................................................................................................... 30
4.5.8 Chassis ............................................................................................................................................. 30
4.5.9 Connection for reel winder / drum stand (optional) ..................................................... 31
4.6 Rope routing................................................................................................................................................. 31
4.7 Labeling icons used.................................................................................................................................... 31
4.8 Technical data .............................................................................................................................................. 34
4.8.1 Dimensions and weights........................................................................................................... 34
4.8.2 Performance .................................................................................................................................. 35
4.8.3 Bull wheel........................................................................................................................................ 35
4.8.4 Hydraulic ......................................................................................................................................... 35
4.8.5 Engine .............................................................................................................................................. 36
4.8.6 Electrical system........................................................................................................................... 36
4.8.7 Tires................................................................................................................................................... 36
4.8.8 Airborne Sound Emission ......................................................................................................... 37
4.8.9 Filling capacities ........................................................................................................................... 37
4.8.10 Temperatures, environmental conditions .......................................................................... 37
4.9 EC Declaration of conformity ................................................................................................................. 38
5 Operating and display elements........................................................................................... 39

5.1 Position of the operating and display elements............................................................................. 39
5.2 Control desk.................................................................................................................................................. 40
5.2.1 Operating elements of the control desk ............................................................................ 40
5.3 Control panel................................................................................................................................................ 43
5.3.1 Design and application of control panel............................................................................ 43
5.3.2 Starting process of machine control system..................................................................... 43
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5.3.3 “Main view" mask ........................................................................................................................ 43
5.3.4 Overview mask hierarchy.......................................................................................................... 46
5.3.5 "Overload protection" mask.................................................................................................... 47
5.3.6 "Error display" mask ................................................................................................................... 47
5.3.7 “Settings” mask ............................................................................................................................ 49
5.3.8 Information bar icons................................................................................................................. 59
5.3.9 Toolbar icons................................................................................................................................. 60
5.4 Radio remote control / cable remote control.................................................................................. 62
5.4.1 Operating elements of the remote control ....................................................................... 63
5.5 Support ........................................................................................................................................................... 65
5.6 Hydraulic auxiliary circuits ....................................................................................................................... 66
5.6.1 Connection block for reel winder / drum stand .............................................................. 66
5.7 Pressure roller............................................................................................................................................... 66
5.8 Engine.............................................................................................................................................................. 67
6 Operating modes.................................................................................................................... 67
6.1 Pulling mode................................................................................................................................................. 67
6.2 Tensioning mode ATS ............................................................................................................................... 67
7 Transportation and initial operation ................................................................................... 68

7.1 Transport the machine.............................................................................................................................. 68
7.1.1 Means of transport ..................................................................................................................... 68
7.1.2 Prepare for transport.................................................................................................................. 68
7.1.3 Transport by crane ...................................................................................................................... 69
7.1.4 Transport on the loading area................................................................................................ 69
7.1.5 Transport by towing vehicle.................................................................................................... 70
7.2 Initial machine operation......................................................................................................................... 72
8 Installation and configuration .............................................................................................. 72

8.1 Installing the machine............................................................................................................................... 72
8.1.1 Place of installation of the machine ..................................................................................... 72
8.1.2 Support and anchor the machine ......................................................................................... 75
8.1.3 Ground the machine .................................................................................................................. 79
8.2 Install reel winder / drum stand ............................................................................................................ 80
8.3 Connect components ................................................................................................................................ 80
8.3.1 Connect the remote control.................................................................................................... 80
8.3.2 Connect reel winder / drum stand........................................................................................ 82
8.4 Adjust the wire direction guiding device........................................................................................... 83
9 Handling and operation ........................................................................................................ 84

9.1 Switch the machine on and off.............................................................................................................. 84
9.1.1 Before switching on the machine.......................................................................................... 84
9.1.2 Switch on the machine .............................................................................................................. 86
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9.1.3 Start the drive engine ................................................................................................................ 86
9.1.4 Stop the drive engine ................................................................................................................ 87
9.1.5 Switch off the machine.............................................................................................................. 87
9.2 Behavior in case of emergency.............................................................................................................. 88
9.2.1 Shutdown in an emergency..................................................................................................... 88
9.2.2 Restart after an emergency ..................................................................................................... 88
9.3 Actions at the control panel ................................................................................................................... 88
9.3.1 Open "Maintenance history" mask....................................................................................... 88
9.3.2 Set overload protection ............................................................................................................ 89
9.3.3 Reset meter counter................................................................................................................... 89
9.3.4 Record pulling data .................................................................................................................... 89
9.3.5 Indicate errors............................................................................................................................... 89
9.3.6 Display information .................................................................................................................... 90
9.3.7 Open "Settings" mask................................................................................................................ 90
9.3.8 Display error codes help ........................................................................................................... 90
9.3.9 Set time and date ........................................................................................................................ 91
9.3.10 Save, print or delete data ......................................................................................................... 92
9.3.11 Set measuring point interval................................................................................................... 93
9.3.12 Switch on/off debug mode...................................................................................................... 93
9.3.13 Open the "Advanced settings" mask ................................................................................... 93
9.3.14 Open the overview I/O test ..................................................................................................... 94
9.3.15 Open error history....................................................................................................................... 95
9.3.16 Reset maintenance message................................................................................................... 95
9.3.17 Open maintenance history....................................................................................................... 95
9.3.18 Set rope diameter........................................................................................................................ 96
9.3.19 Switch units.................................................................................................................................... 96
9.3.20 Display parameters ..................................................................................................................... 96
9.3.21 Open factory menu..................................................................................................................... 97
9.4 Check safety devices.................................................................................................................................. 97
9.5 Start pulling mode...................................................................................................................................... 97
9.6 Start and stop tensioning mode ........................................................................................................... 98
9.7 Adjust tensioning force ............................................................................................................................ 99
9.8 Position the rope....................................................................................................................................... 100
Position a right-hand-lay rope ............................................................................................. 102
Position a left-hand-lay rope ................................................................................................ 102
Position the auxiliary rope and pull in rope .................................................................... 103
9.9 Connect ropes............................................................................................................................................ 106
9.10 Control rope sag ....................................................................................................................................... 106
9.11 Prevent rope problems........................................................................................................................... 108
9.12 Operate external components............................................................................................................. 109
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9.12.1 Operate reel winder / drum stand ...................................................................................... 109
10 Servicing and troubleshooting ........................................................................................... 111

10.1 Error codes of the control unit ............................................................................................................ 111
10.1.1 Help for error codes ................................................................................................................. 111
11 Maintenance ......................................................................................................................... 121
11.1 Qualifications.............................................................................................................................................. 121
11.2 Machine maintenance plan................................................................................................................... 122
11.3 Maintenance work .................................................................................................................................... 123
11.3.1 Inspect the machine visually ................................................................................................. 123
11.3.2 Clean the machine..................................................................................................................... 124
11.3.3 Lubricate and grease the machine...................................................................................... 125
11.3.4 Clean the cooler ......................................................................................................................... 126
11.3.5 Check and service batteries................................................................................................... 126
11.3.6 Check hydraulic oil filling level, replenish and change oil......................................... 127
11.3.7 Replace the hydraulic oil filter .............................................................................................. 130
11.3.8 Check hydraulic hoses ............................................................................................................. 131
11.3.9 Check engine oil level, replenish and change oil.......................................................... 132
11.3.1 Maintain engine ......................................................................................................................... 132
0
11.3.1 Check, replenish and change gear oil................................................................................ 133
1
11.3.1 Check coolant level, add and change coolant ............................................................... 136
2
11.3.1 Check pneumatic springs ....................................................................................................... 136
3
11.3.1 Check the profiles of the groove treads........................................................................... 137
4
11.4 Tightening torque shaft screws........................................................................................................... 137
11.5 Operating materials and supplies ...................................................................................................... 138
Engine oil ...................................................................................................................................... 138
Gear oil .......................................................................................................................................... 139
Hydraulic oil................................................................................................................................. 139
Multi-purpose grease .............................................................................................................. 140
Antifreezer.................................................................................................................................... 140
Diesel.............................................................................................................................................. 140
12 Decommissioning................................................................................................................. 141
12.1 Temporary decommissioning .............................................................................................................. 141
12.2 Storage conditions ................................................................................................................................... 142
12.3 Permanent decommissioning .............................................................................................................. 142
12.3.1 Safety during disassembly and disposal........................................................................... 142
12.3.2 Disassembly ................................................................................................................................. 143
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12.3.3 Destruction and recycling ...................................................................................................... 143
Glossary ................................................................................................................................. 144
Index ...................................................................................................................................... 145
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1 | Identification
B 1500/14 Tensioner
1 Identification
1.1 Identification of this document

The following indications identify this document and are on the title page and in
the footer:
n Type of document
n Machine type for which this document is valid
n Chassis number:
n Version number
n Printed:
1.2 Name and address of the manufacturer

ZECK GmbH
Columba-Schonath-Str. 6
96110 Schesslitz, Germany
Tel. +49 9542 9494 - 0
Fax +49 9542 9494 - 94
info@zeck-gmbh.com
www.zeck-gmbh.com
1.3 Service telephone number

Within business hours:
Tel. +49 9542 9494 - 0
Outside business hours:
Tel. +49 9542 9494 - 99
2 User information
2.1 About these instructions

These instructions provide information on the following points:
n The save operation of the machine.
n The functioning, operation and maintenance of the machine.
The operating instructions must always be available at the machine. They are a
component of the machine and must be handed over with the machine if the
machine is resold.
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2 | User information
B 1500/14 Tensioner
Target group for these instructions

Every person who works with or at the machine must read and apply the proce-
dures and safety measures described in these instructions. This applies espe-
cially to persons who have been given the following tasks:
n Operation
n Setup, troubleshooting, care, disposal of operating materials and supplies.
n Maintenance and repair.
n Transport and setup.
Possible deviations
It is possible that figures in these instructions depict parts of a different ma-
chine. Nevertheless the basic information contained in these figures also applies
to the machine described here.
Options
It is possible that reference is made in these instructions to product features and
options that are only available in machines of a different type. Neither the use of
these instructions, nor the safe functioning of the machine described here, are
impaired by this. There is no entitlement that each of the options described
must also be possible on this machine.
2.2 Locations in this document

The following specifications apply to all directional and locational information
that is not otherwise explained:
Front The front is the narrow side of the machine, to which the drawbar of the chassis
is attached.
Rear The back is, accordingly, the narrow side of the machine that is located opposite
the front.
Left and right The directions left and right are yielded if the observer stands to the rear of the
machine and looks in the direction of travel.
2.3 Illustrations used
Procedural instructions Procedural instructions and system reactions

Step-by-step actions to be taken by the user as part of a procedural instruction
are presented in a numbered list. The sequence of the instructions must be ob-
served. The interim outcomes of the respective steps and the final result are de-
noted by an arrow. Prerequisites are listed before procedural instructions and
are denoted with a check mark.
Example:
ü This describes a prerequisite in order to carry out a procedural instruction.
ü This is a further prerequisite.
1. Carry out step 1.
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ð This is an interim outcome after step 1.

2. Carry out step 2a.
- or -
Carry out step 2b.
3. Carry out step 3.
4. Further steps ...
ð This is the final result of a procedural instruction.
Enumerations Enumerations
Enumerations are presented as a list of enumerated items. Example:
n Enumerated item 1
n Enumerated item 2
n ...
Item numbers Item numbers in figures and text

In figures, item numbers appear as numerals in a circle.
References to position numbers always relate to the figure that is depicted
above this text. The item number is put in parenthesis and abbreviated in the
descriptive text.
Example:
This is an example (pos. 4) of the representation of a reference to position num-
ber 4.
Digits in icons Digits in display depictions

The display shows, in part, icons containing small digits. In such instances, the
digit in the icon indicates the number of the machine component to which this
icon refers. In these instructions, such icons are predominantly represented by
the digit "1".
Operating elements: Names of operating elements

control desk and remote The names of operating elements on the control desk and the remote control
control are written in capital letters. A precondition for this is that the operating ele-
ments can be directly activated and then carry out a specific function. The
names of the remaining operating elements are written in the usual manner.
Examples: ENGINE START button; TENSIONING FORCE potentiometer; parking
brake.
Decimal separators Decimal separators

A decimal separator is a symbol used to separate the integer part of the frac-
tional part of a number written in decimal form. In this document, the period "."
is used as a decimal separator. Examples: 123.45 N, 20.3 m/min
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B 1500/14 Tensioner
2.4 Terms used

In this document, specific terms are used to represent a number of other terms.
The most important of these terms are specified below.
Machine Machine: The puller or tensioner described in this document.
Rope Rope: Generic term for all materials that are installed using the machine. For ex-
ample conductor, braided rope, steel rope or synthetic fibre rope.
Stringing operation Stringing operation: Stringing rope over overhead power line towers.
Bull wheel Bull wheel: A wheel with grooves on the circumferential surface. The groove pro-
file consists of a synthetic material to increase frictional force. The bull wheel is
hydraulically powered/braked.
Fig. 1: Bull wheel
Bull wheel Bull wheel: Two grooved wheels operating together as a pair constitute a bull
wheel drive. The rope passes, in a thread formation, over the bull wheel by way
of multiple turns.
Fig. 2: Bull wheel
Machine side Machine side: The term "machine side" is identical to the term "bull wheel".
2.5 Representation of safety instructions

Safety instructions and warnings are indicated by a pictogram and a signal
word. Signal words describe the seriousness of the imminent risk.
DANGER
Warning notice "DANGER"
Very dangerous situation which WILL lead to death or serious injury if the safety
instructions are not observed.
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WARNING
Warning notice “WARNING”
Dangerous situation which CAN lead to death or severe injury if the safety in-
struction is not observed.
CAUTION
Warning notice “CAUTION”
Dangerous situation which can lead to minor injury if the safety instructions are
not observed.
NOTICE
Warning notice "NOTICE"
Failure to observe these safety instructions can lead to property damage.
2.6 Other applicable documents

In addition to this document, the documents specified below are also applica-
ble:
n Instructions and maintenance instructions for the drive engine
n Circuit diagrams and parts lists for the hydraulic system
n Circuit diagrams and parts lists for the electrical system
These documents are in the appendix to these instructions. Any documents that
are missing must be requested from the manufacturer of the machine.
2.7 Copyright notice

All textual matter, figures, photographs and other representations are – unless
otherwise specified – the property of the manufacturer or its suppliers, and are
protected by copyright legislation. Reproduction and distribution to third par-
ties, even in the form of excerpts, is only admissible with the prior consent of
the manufacturer or the respective holder of the rights.
2.8 Copyright of third parties

All trademarks mentioned in this document are the rightful property of their re-
spective owners, even if each owner is not mentioned individually.
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3 | Basic safety instructions
B 1500/14 Tensioner
3 Basic safety instructions
3.1 Intended use

This machine is exclusively intended for tasks directly related to the installation
of overhead power lines. The machine can maintain tension on the rope (ten-
sioning mode).
Intended use also encompasses the following:

n Observing all guidelines set forth in these instructions.
n Carrying out all inspection and maintenance tasks.
n Using only original spare parts.
n Complying with the technical limits of the machine as defined in the section
“Technical Data”.
3.2 Reasonably foreseeable misuse
WARNING
The transport of people in all forms is strictly prohibited!
This machine may not be used for the transport of persons.
WARNING
Dangers in the event of inappropriate use
Severe injury or death may result from inappropriately using the machine.
Any application deviating from or exceeding the use indicated in "Intended use"
is deemed inappropriate. Risks arising from inappropriate use have not been in-
cluded by the manufacturer. Inappropriate use increases the risk in handling the
machine. The operator bears the sole responsibility for injury to persons and
damage to material caused by inappropriate use.
When using this machine, observe the following:
n Never use this machine to transport persons.
n Never use this machine to move loads that exceed the machine's safe work-
ing load (see the machine's technical data).
n Never use the machine to move trapped or jammed loads.
n Never use the machine to recover vehicles or other machines.
n Never use the machine to pull materials that may store elastic energy (for
instance, ropes made of rubber).
n Always use the machine in a well ventilated area, never in closed buildings
or tunnels.
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n Operate the machine only if no combustible or potentially explosive materi-

als or gases are in the vicinity of the machine.
n Operate the machine only on a solid surface. The machine must be posi-
tioned and anchored so as to be stable.
n Only operate the machine if it is flush-aligned with the pulling direction of
the rope.
n Operate the machine only with a rope that meets the specifications in the
technical data.
3.3 Risks when handling the machine

When using the machine, risks and impairments can occur:
n Specific to the health and life of the user or third parties.
n To the machine.
n To other material assets.
In order to reduce risks specific to personal injury and material damage, and to
avoid dangerous situations, observe the safety instructions specified here as well
as the safety instructions in the further sections of these instructions.
3.3.1 Danger arising from the mechanical system
Stringing operation Moving rope

During installation operations and setup operations, the machine moves the
rope and places the rope under tension. In the instance of unprotected contact,
the rope can cause burns, abrasions, puncture wounds or cuts to the hands and
limbs. Hands, fingers, and limbs may be drawn in, crushed, or severed between
the rope and machine components. If an incident occurs, a rupturing rope can
bring about severe injuries owing to the whiplike motion.
1. Wear suitable personal protective equipment: protective gloves, safety
shoes, protective goggles, and head protection.
2. Maintain the greatest possible distance from the machine during opera-
tion.
3. If available, carry out work using the remote control. The remote control
gives the user an improved overview of the overall situation, enabling
him/her to maintain the greatest possible distance.
4. Never stand directly below the rope.
5. Erect barriers and display warning signs to demarcate the hazardous area
around the machine and under the rope. Observe the applicable regula-
tions specific to workplace safety.
6. Remove personnel from the danger zone or assign this task to auxiliary
personnel.
7. During setup operations, ensure that the machine is protected against
inadvertent startup at all times.
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Loss of stability Anchoring the machine

If the supporting surface is soft and yielding, or if anchoring is inadequate or
slack, the machine may move uncontrollably or may tip over. This can result in
severe to fatal injuries and material damage.
1. Always install the machine on a firm and level surface.
2. Ensure that the machine cannot roll away and that it does not disengage
from the anchor pole.
3. Check the anchor poles for stability prior to and during operation.
4. If users leave the construction site, the machine should never be left in a
loaded state. For unloading the machine, anchor the rope.
3.3.2 Danger arising from electric energies
Electric shock
Electrostatics, lightning Electrostatic charging can occur during the stringing operation. Discharges or
strike, induction lightning strikes during thunderstorms can cause injury or death. Touching
damaged live components can result in serious injury or death.
1. Always ensure that the machine is grounded.
2. Damaged components for the grounding of the machine must be re-
paired immediately by qualified personnel.
3. Damaged insulations or components used to supply the machine with
electric power must be repaired immediately by specialized personnel.
Battery
Short circuit of the The battery can supply current with a high current rating. Inappropriate use of
rechargeable battery, the battery e.g. by accidentally connecting the battery poles to a metallic object
explosion the battery can explode. Electric sparks caused by a short circuit can cause a fire.
Severe injuries and burnings of persons are possible. Inside the battery elec-
trolytic gas can develop e.g. by loading the battery over a long period. A spark
can inflame the electrolytic gas. Persons can be injured by the explosion and can
be burnt by the battery acid.
1. Follow the instructions of the instructions when loading the battery.
2. Keep away fire and sparks from the battery.
3. Never short-out the battery poles.
3.3.3 Danger arising from pressurized media
Pressurized hoses, lines, Liquids under pressure

and structural components Liquids under high pressure can penetrate the body through the skin and cause
serious injuries.
The following liquids are under high pressure:
n Hydraulic oil
n Diesel fuel
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n Coolant
1. Observe maintenance instructions for all pressurized lines and hoses.
2. Never trace leaks with bare hands.
3. Keep the body and face away from leaks.
4. Immediately consult a physician if liquids penetrate the body. Danger of
infection!
5. When working on the cooling system, wait until the engine has cooled
down.
3.3.4 Danger arising from high temperatures
Hot liquids Hot liquids

Hydraulic oil, engine oil and coolant can become very hot during operation.
Scalds, burns and severe to fatal injuries are possible.
1. If possible, carry out work when the machine has cooled down.
2. Wear appropriate protective gloves and safety goggles.
3. Avoid direct contact of hot liquids with the skin.
4. Immediately consult a physician if liquids come into contact with an open
wound. Danger of infection!
Hot surfaces Hot surfaces

The following parts can become very hot during operation:
n Engine
n Exhaust system
n Engine and hydraulics cooler
n All hydraulic structural components
Severe burns may be sustained to the hands and limbs from unprotected con-
tact with the hot surfaces.
1. If possible, perform any work when the machine has cooled down.
2. Maintain a sufficient distance between the hot surfaces and body parts.
3. Wear appropriate protective gloves.
Hot surfaces can cause a fire.
1. Maintain sufficient distance between the hot surfaces and combustible
materials.
2. Do not install the machine on a combustible surface.
3. Keep fire extinguishing equipment (fire extinguisher, fire blanket etc.)
ready and practice use of the fire extinguishing equipment.
3.3.5 Danger arising from operating materials
Fuel vapor poisoning Fuel

Fuel vapors are carcinogenic. If swallowed, fuel can also damage the lungs.
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B 1500/14 Tensioner
1. Ensure sufficient ventilation and do not inhale vapors.

2. Do not swallow fuel.
3. Avoid skin contact to prevent skin injuries.
Burns Combustible operating materials and supplies

Combustible operating materials and supplies can cause severe or fatal burns
and poisoning through smoke inhalation. Deflagrating or exploding fuel vapors
can severely injure or kill persons, even at a substantial distance.
n Only fill the fuel tank if the machine is switched off and has cooled down.
n Only fill or drain the fuel tank if the surrounding area is well ventilated.
n It is essential to avoid naked flames and smoking in the vicinity of the ma-
chine.
Poisoning and Safe handling of operating materials and supplies

environmental pollution Inappropriate handling of operating materials and supplies can cause the poi-
soning and death of persons and poses a risk to the environment.
1. Do not store operating materials and supplies in the machine.
2. Dispose of used operating materials and supplies and their containers in
an appropriate manner.
3. Do not allow operating materials and supplies to be released into the en-
vironment.
4. Soak up spilled operating materials and supplies using an absorbent
medium and dispose of it appropriately.
3.3.6 Danger arising from inadequate maintenance
Damage to the machine Damage to the machine

Damage to the machine can impair the operating safety of the machine and
cause accidents. This can result in severe or even fatal injury to persons. The fol-
lowing parts of the machine are particularly important for ensuring safety:
n Safety equipment and protective devices
n Hydraulic and electrical system
n Lighting
In case of doubt as to the safe operation of the machine, e.g. in case of leaking
operating materials or visible damage:
1. Switch off the machine.
2. Immediately eliminate possible causes of damage, e.g. eliminate inten-
sive contamination or tighten loose screws.
3. Determine the cause of the damage and eliminate it, if possible or have it
eliminated by specialist personnel.
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Servicing Servicing and repair

Improper service and repair work adversely affects operating safety. This can
cause accidents and persons can be severely injured or even die.
1. Only carry out the work that is described in these instructions.
2. All work not described in this manual must be carried out by the manu-
facturer or by qualified personnel after consultation with the manufac-
turer.
Safe spare parts Additional equipment and spare parts

Additional equipment and spare parts that do not meet the manufacturer’s re-
quirements can impair the operating safety of the machine and cause accidents.
1. In order to ensure operating safety, use genuine parts or parts that meet
the manufacturer’s requirements. In case of doubt, consult the dealer or
the manufacturer.
3.3.7 Danger arising from emissions
Exhaust fumes Exhaust fumes

Exhaust fumes from the drive engine are injurious to health and can result in
drowsiness, nausea, fainting, and even death.
1. Maintain a distance from the exhaust pipe during operation.
2. Keep all persons away from the exhaust pipe during setup operations
and when the drive engine is in operation.
3. In closed spaces, start the drive engine only if the exhaust unit for ex-
haust fumes is in operation and only for the purposes of maintenance.
Noise Noise arising from the machine

The drive engine of the machine generates noise. A high noise level or sustained
noise can lead to impairment to and loss of the hearing.
1. Maintain as much distance as possible from the drive engine of the ma-
chine.
2. Wear personal protective equipment (hearing protection).
3.3.8 Danger caused by modifications

Modifications to the Modifications to the machine are only allowed if the following conditions apply:
machine n Safety of persons will not be reduced by the modifications
n The manufacturer of the machine has already approved the modification of
the machine in writing beforehand.
3.4 Residual risks

The machine is constructed in accordance with state-of-the-art technology and
recognized safety regulations. When observing the intended use and the com-
pliance with all safety regulations there are still the following residual risks:
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n Risks arising from unforeseeable human or technical error, e.g. erroneous

operation or a rupturing rope.
n Risks of injury from structural components that cannot be protected owing
to the configuration of the machine's functionality.
n Risks through residual energies after switching off the machine or after an
emergency stop. Examples for residual energies:
n Pressure energy: Hydraulic lines, hydraulic cylinders.
n Heat energy: Cooler, drive engine, coolant, hydraulic oil.
n Mechanical energy: Tensioned rope, tensioned spring, hanging load.
3.5 Duty of the operator

The operator owns the machine or rents the machine.
It is the duty of the operator only to let any person work on the machine pos-
sessing the following qualification:
n Knowledge of the fundamental regulations on occupational safety and acci-
dent prevention.
n Successful orientation in working with this machine
n A complete understanding of these instructions.
Moreover, the operator also agrees to comply with the provisions applicable at
the site for work safety, workplace setup and execution of work.
If regulations prevailing at a national level, legally binding regulations, or speci-
fications of other manufacturers should contradict the specifications in these
operating instructions, the operator must inform the manufacturer of this ma-
chine of the contradiction. The machine is only permitted to be used by way of
derogation from these operating instructions if the manufacturer of the ma-
chine has already approved this in writing beforehand. The operator is acting at
his/her own risk if she/he uses the machine in deviation from these instructions
without such prior approval.
3.6 Duty of the personnel

Prior to commencing work, all persons commissioned with working on the ma-
chine must have read these instructions in their entirety, and must have under-
stood them.
n Only personnel instructed and authorized by the operator may operate the
machine.
n Users must always work in compliance with the instructions.
n Personnel being trained or those under instruction may only work on the
machine when supervised by an experienced person.
n Maintenance and servicing may only be carried out by specifically qualified
personnel.
n Users must report faults and damage sustained by the machine immediately
to the operator.
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Users must be physically in a position to operate the machine safely.

n Only work when healthy and relaxed.
n Never work under the influence of alcohol or drugs.
n Never work under the influence of medications that impair responsiveness.
n Only work in conditions of good visibility and with good personal vision and
hearing.
n Take breaks regularly.
Open questions must be directed to the manufacturer. The address is provided
in Chapter 1.
3.7 Qualification of the personnel

Ensure that only personnel who meet the necessary requirements work on the
machine. The personnel must be informed of all dangers and risks associated
with the machine. Depending on the work to be carried out, the following per-
sons meet the necessary requirements:
Transport: Persons with specialist knowledge in the field of transportation, es-
pecially persons who know how to avoid material damage during transporta-
tion.
Installation: Persons with specialist knowledge in the field of mechanics, electri-
cal engineering and hydraulics.
Operation: Operating personnel trained for the specific application.
Servicing and maintenance: Persons with specialist knowledge according to
the work to be carried out.
Disposal: Persons with specialist knowledge in the field of professional disposal.
3.8 Personal protective equipment

Wearing personal protective equipment is an important component of safety.
Missing or incomplete personal protective equipment increases the risk of phys-
ical injuries and injuries to person's health.
Personal protective equipment includes for example:
n Head protection
n Protective gloves
n Safety shoes
n Fall arrest harness
n Hearing protection
3.9 Safety equipment and protective devices
Keep all protective equipment specific to the machine functional.

The protective equipment is mandatorily required for safe operation of the ma-
chine. If protective equipment is missing or damaged, persons can be severely
injured or can be killed by moving machine parts.
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1. Replace damaged protective equipment.

2. Reassemble disassembled protective equipment and other parts prior to
the machine's commissioning and bring them to a position of safety.
3. Contact the manufacturer in the event of any doubt as to the proper as-
sembly and functionality of all protective equipment.
3.9.1 Emergency stop

If an emergency stop switch is pushed while the machine is in operation, the fol-
lowing occurs:
n The engine stops
n Each bull wheel is automatically blocked by the safety brake
n Reel winders or drum stands connected to the machine are no longer
braked and no longer powered
The drum stands only continue to brake passively by way of their internal
frictional forces
n The machine control system and the display remain switched on
n For the duration that the emergency stop switch is pressed down, the drive
engine can no longer be started up
Prior to startup following an emergency, ensure that the machine is undam-
aged and that the cause of the emergency stop has been identified and ad-
dressed.
3.9.2 Overload protection

If the rope is too tautly pulled, it can rupture, thus endangering the health of
persons.
In order to limit the maximally effective rope force to a specific value, overload
protection is integrated within the machine control system. The overload pro-
tection automatically reduces pulling speed as soon as the tractive force me-
tered approximates the defined maximum value. If the measured pulling force
reaches or exceeds the set maximum value, the machine's overload protection
stops the machine operation.
3.9.3 Safety brake

Each bull wheel has an automatically acting safety brake. In an emergency stop
situation or upon failure of the hydraulic system, the safety brake blocks the bull
wheel.
3.9.4 Main switch

The main switch is located on the machine's control desk. The main switch can
only be activated and deactivated by means of the corresponding key. Always
remove the key after switching off the machine and retain it in safekeeping so
as to prevent the machine from being switched on by unauthorized persons.
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3.9.5 Machine cladding

The power unit room housing with the drive engine is fully cladded. The
cladding protects against damage sustained in consequence of rotating ma-
chine components and reduces the noise of the machine.
When the machine is in operation, only the flap covering of the control desk is
to be left open. All other flaps are to be kept closed during standard operation.
An exception to this rule: If the temperature of the engine is excessive when the
ambient temperature is high. In such an instance, the flaps may be opened in
order to allow some of the engine's heat to dissipate.
The flaps covering gas pressure cylinders are kept open. When opening a flap,
note that after a specific aperture angle, by way of the gas pressure cylinders,
the flap springs open by itself once it is released.
3.9.6 Engine protection

In certain situation the control stops the engine. Example: If oil pressure is too
low.
3.10 Workplaces – operating personnel

Single-person operation No-one is permitted to stand in front of and behind the machine during opera-
tion. Only the user is permitted to remain by the side of the machine during op-
eration. The machine is designed to be operated by a single person. Operation
by more than one person at a time is prohibited.
Apart from the user, other persons are permitted to remain in the direct vicinity
of the machine only to carry out the following tasks:
n Setup operations
n Maintenance and repair
Without remote control If the machine has no remote control, the workstation of the user is by the Con-
trol Desk on the side of the machine.
With remote control If the machine is equipped with Remote Control , the workstation of the user is
by the remote control. The user is thereby to stand at a safe distance from the
machine at a good vantage point that affords a view of the overall situation.
3.11 Machine labeling

Safety instructions All warnings affixed to the machine in regard to residual risks and safety instruc-
tions must be observed. Ensure that such labeling is legible at all times. Replace
at once in the event of damage.
CE marking If this CE marking is present, the machine meets one or multiple EU directive/s.
In such an instance, the CE marking is prescribed and is not permitted to be re-
moved.
Type plate The type plate provides the following machine specifications:
n Machine designation
n Machine number
n Construction year
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n Weight
n Company address
n Further technical details depending on the type of machine: pulling force,
tensioning force, safe working load, etc.
Further type plates may be present. The technical and other data specified on
them relate to the components on which the type plates are affixed. Examples
of such components:
n Engine
n Chassis
n Oil cooler
n Auxiliary heating
3.11.1 Type plate
1
2
3
4 5 6
7
8
9
Fig. 3: Type plate
1 Max. speed in pulling mode 2 Max. speed in tensioning mode

3 Group of gear: 4 Max. pulling force bull wheel 1
5 Max. tensioning force bull wheel 6 Type
1
7 Chassis number (machine num- 8 Construction year
ber)
9 Net weight
If the machine has more than one bull wheel there are further data below pos. 4
and pos. 5.
4 Machine description
This chapter provides a comprehensive overview of the machines structure and
function. Read as much as possible about the machine so as to become opti-
mally familiar with it.
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4.1 Field of application

This machine is deployed to install overhead transmission lines.
When the brakes are activated, the machine keeps the rope at a constant ten-
sion. The extent of this tension (tensioning force) can be adjusted on the ma-
chine.
In pulling mode, the machine draws the rope in. In this machine, pulling mode is
intended to regulate the sag of the rope. The rope speed in pulling mode is sig-
nificantly slower than during brake operation.
4.2 Functional principle of the machine
2
Fig. 4: Bull wheel
Bull wheel The machine exerts a specific pulling force on the rope that runs over the ma-
chine's bull wheel. The Bull Wheel consists of two bull wheels (pos. 1, pos. 2).
The rope is turned around the bull wheels multiple times in the form of a thread
and, thereby, runs within the grooves. Depending on the type of machine, this
machine can have multiple bull wheels.
1 2
Fig. 5: Working directions in tensioning mode and pulling mode
1 Tensioning mode 2 Pulling mode (drawing rope in)

pulling mode (drawing rope out)
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Tensioning mode Functional principle in tensioning mode (pos. 1): Rope that is unwound from a
braked rope drum, is turned around the bull wheels multiple times, and exits the
machine in the direction of the first mast. The machine decelerates the bull
wheels and, thus, the rope. The rope is thereby pulled by another machine
(puller).
Pulling mode Functional principle in pulling mode pos. 2): Rope that runs from the direction
of the first mast to the machine, is turned around the bull wheels multiple times
and is wound around the powered rope drum. The machine propels the bull
wheels and, thus, the rope.
The working direction in pulling mode can also be reversed. The machine then
pays out the line.
4.3 Further functions
4.3.1 Overload protection

Overload protection In pulling mode, the overload protection limits pulling force on the rope. To this
end, the machine control system compares the existing pulling force with the
defined maximum value defined by the user on the display. If the existing force
is approximating the defined maximum value, the machine control system re-
duces the driving force at the bull wheel. If the existing force reaches the de-
fined maximum value, the machine control system switches off the drive of the
bull wheel.
4.3.2 Recording the pulling data

During stringing operation, the measured pulling or tensioning force can be
recorded in the internal memory of the control. For each measuring point, the
following data are recorded:
n The complete rope length installed since the beginning of the measurement.
n The average stringing speed since the previous measuring point.
n The maximum force acting since the previous measuring point.
The distance between to measuring points is predefined by a certain length dif-
ference (in meters) for the installed rope. For example, every 5 meters one mea-
suring point. Set length difference
When starting the data recording, the control creates a new file and names it
according to the following structure: Chassis Number_Bull Wheel Num-
ber_Date_Counter.csv.
Designation Example
Chassis number: 123456
Bull wheel: 1
Date (YYYYMMDD): 20150926
Counter: 03
Tab. 1: Example for a file name "123456_1_20130226_03.csv”
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Limited Number of Recorded Files
A maximum of 99 files can be created per day and machine bull wheel number.
If more files are necessary, first copy the existing files to a flash drive and then
delete them from the control.
The ASCII files created can be read and processed in standard computer pro-
grams. To do this, copy the created file to a USB flash drive. The recording lan-
guage is English and cannot be changed.
Fig. 6: File recording auto mode, example
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4.4 Machine description
1 2 3
14
4
5
13 6
12 11
10
8
Fig. 7: Machine description
1 Rope outlet 2 Lifting point for loading by

crane
3 Rope feed 4 Bull wheel
5 Parking brake 6 Drawbar eye
7 Eye bolt for machine anchoring 8 Front support
9 Connection for auxiliary hy- 10 Behind the flap:
draulic system (reel winder / Control desk, storage of the re-
drum stand) mote control
11 Eye bolt for machine anchoring 12 Back support (sprag)
13 Rope feed on back side (option) 14 Behind the flap:
Engine, fuel tank, hydraulic oil
tank, hydraulic system
4.5 Structural components and other components
4.5.1 Engine
The engine supplies the machine with hydraulic and electric energy.
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4.5.2 Hydraulic system

The hydraulic system essentially consists of the following components:
n Hydraulic pump, directly built onto the drive engine and powered by the
drive engine
n Hydraulic oil tank and filter
n Regulating and operating elements (valves)
n Hoses and pipes
n Hydraulic oil cooler
4.5.3 Bull wheel

Basic principle A bull wheel consists of two, concomitantly acting Bull wheels. The two bull
wheels are arranged one in front of the other. Rope that is to be tensioned or
pulled by means of the bull wheel and runs in multiple turns over the grooves of
the two bull wheels. By means of the resultant friction between rope and bull
wheel, the machine is able to exert force on the rope. So that there is sufficient
friction and so that the rope does not begin to slip on the bull wheels, the rope
must be sufficiently pre-tensioned on both sides of the bull wheel. On the side
facing the first mast, a puller ensures that pulling force is exerted on the rope so
as to bring about this pre-tension. On the side facing the drum stand, Pretension
force in the rope is generated by means of the drum stand being actively braked
while the machine pulls the rope from the drum stand.
Bull wheel drive Each bull wheel is powered separately by means of a hydraulic motor deploying
a gearbox. An automatically acting safety brake blocks each bull wheel if the
machine is idle or in the instance of an emergency stop.
4.5.4 Rope guide

Wire direction guiding The rope is routed over the rollers of the wire direction guiding device to the
device, rope feed, rope bull wheel and then away from the bull wheel. The wire direction guiding device
outlet is thereby accorded the function of routing the rope along an optimal path or of
protecting it from damage. The rope feed denotes the wire direction guiding
device that faces into direction of the drum stand. The rope outlet denotes the
wire direction guiding device that appears on the first mast.
Pressure roller The pressure roller exerts spring force to push the rope into the groove of the
bull wheel. The rope remains under tension in the grooves of the bull wheels
even if the tractive force on the rope to the front or rear of the machine dimin-
ishes. To install the rope, the pressure roller can either be lifted manually or, op-
tionally, by hydraulic means.
The pressure rollers are connected to the machine frame by means of a flexible
earth cable. Through this, electrical charge from the rope (electrostatic charging,
induction, lightning strike) is conducted into the ground.
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4.5.5 Control desk

The most important operating and display elements are summarized at the con-
trol desk. The control desk is the user's central working place. For the design
and function of the operating and display elements, see sections Operating and
Display Elements.
4.5.6 Remote control

Depending on the specifications of the machine, the remote control is con-
nected to the machine control system either via cable or via radio. Using the re-
mote control, the user can operate the machine from a safe distance and with
an optimal overview of the overall situation.
4.5.7 Supports
The front and rear supports give the machine stability during rope pulling and
unload the load on the chassis wheels. Depending on the machine type, the
supports are extended either manually or hydraulically.
4.5.8 Chassis
The chassis frame bears all the machine's components. The chassis includes the
following components:
Parking brake
The parking brake blocks the chassis wheels. Engage the parking brake to park
the machine. To enable the machine to be drawn by a towing vehicle, fully dis-
engage the parking brake.
Attachment points
So that the machine can be lifted by a crane, the chassis on the upper side of
the machine has a lifting point or multiple lifting points. The lifting points are
identified with the icon of a load hook.
Cladding
The aluminum cladding protects the machine against environmental influences.
Drawbar
For connecting the machine with a traction vehicle there is a drawbar mounted
at the machine frame. When transporting the machine on a loading platform
the drawbar can be removed.
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4.5.9 Connection for reel winder / drum stand (optional)

The machine may be equipped with a hydraulic connection block for a Reel
winder / Drum stand. Other hydraulic devices may only be attached to this con-
nection subject to prior approval by the manufacturer. The machine may also be
equipped with several such connections.
4.6 Rope routing
3
1 2
7 4
6
5
Fig. 8: Rope routing
1 Rope outlet 2 Direction to the first tower

3 Rope feed 4 Drum stand orientation
5 Front bull wheel 6 Rear bull wheel
7 Pressure roller
4.7 Labeling icons used

The following labels are located on the machine:
Icon Meaning
Hydraulic oil
Diesel
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Icon Meaning
Hydraulic sprag
Mechanical support
Top: Valve lever to FREE WHEEL

Bottom: Valve lever to DRIVE
Parking brake
Gear oil
Drum stand or reel winder:

Drive (left) or Free wheel (right).
Pressure setting
Rope out
Rope in
Hydraulic feed line (pressure)
Hydraulic feed line (pressure)
Hydraulic return flow
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Icon Meaning
Lifting point for means of transportation
Structural component designation according to circuit diagram,

e.g. "1Z2"
Read the instructions before working on this machine
Remote control
Wear hearing protection
Wear protective gloves
Caution: Hot components and surfaces
Caution: Crush hazard
No smoking!
Wear head protection
Wear tight-fitting protective clothing
Wear safety shoes
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Icon Meaning
Suspension point for anchorage
Grounding
Ensure that labels are legible at all times and do not remove them. Request re-
placement from the manufacturer in the event of damage.
4.8 Technical data
NOTICE
Actuality of technical data
The following technical data are valid for the delivery state of the machine from
the manufacturer. If the operator modifies the machine the technical data can
change. Therefore the operator needs a written authorization of the manufac-
turer before modifying the machine. The technical data on the type plate and in
these instructions respectively the operator has to let change by the manufac-
turer.
See also
2 Basic safety instructions [} 14]
4.8.1 Dimensions and weights

Outside dimensions:
Length [m] 5.0
Width [m] 2.4
Height [m] 3.0
Weights:
Total weight approx. [kg] 6300
Permissible vertical load [kg] See type plate (0 - ...)
Permissible axle load front side [kg] See type plate (1 - ...)
Permissible axle load back side [kg] See type plate (2 - ...)
Permissible total weight [kg] See type plate (T - ...)
The dimensions indicated apply to the standard configuration of the machine.

The actual dimensions may deviate from that.
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4.8.2 Performance
Tensioning mode:
Tensioning force max. [kN] 140
Tensioning force min. [kN] 0-140
Speed [m/min (km/ 0 – 83 (5)
h)]
Max. tensioning force [kN] 140
(then at max. possible speed)
Max. speed [m/min] 5
(then at max. possible tension-
ing force)
Pulling mode:
Pulling force max. [kN] 140
Speed [m/min (km/ 36 (2.2)
h)]
Max. speed [m/min] 8.3
(then at max. possible pulling
force)
Other:
Group of gear: M3
All performance values apply on sea level at 20 °C.
4.8.3 Bull wheel

Diameter of grooved wheels [mm] 1500
Number of grooves front side 12
Number of grooves back side 12
Diameter of groove profile [mm] 45
Max. number of ropes fastened 4
to the right
Max. number of ropes fastened 3
to the left
4.8.4 Hydraulic
Machine:
Hydraulic oil type HVLP46
Flow rate max. [l/min] 258
Pulling mode:
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Pressure max. [bar] 445
Tensioning mode:
Support:
Hydraulic auxiliary circuit for drum stand / reel winder:

Number of auxiliary circuits 4
4.8.5 Engine
Manufacturer Deutz
Model BF04M 2011
Performance (for rotational [kW (rpm)] 63 (2600)
speed)
Displacement [cm3] 3108
Cylinders 4
Cooling Oil
Emission standard II, Tier 2
Fuel type Diesel
Regeneration particulate filter -
(if available)
Further technical data: See instructions for the drive engine.
4.8.6 Electrical system

Voltage of machine [V] 24
Voltage of rechargeable bat- [V] 12
tery
Number of rechargeable bat- 2
teries
Capacity of rechargeable bat- [Ah] 74
tery
4.8.7 Tires
Size 10.00-20
Filling pressure [bar] 5.5
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4.8.8 Airborne Sound Emission

Acoustic power level [dB(A)] 99
Sound pressure level at work [dB(A)] 92
site control desk
Sound pressure level at work [dB(A)] 71
site remote control,
(if remote control is technically
available)
Distance from machine: 15 m
4.8.9 Filling capacities

Substance Filling capacity
Engine oil [l] See engine instructions
Coolant [l] See engine instructions
Fuel tank [l] See engine instructions
Hydraulic oil tank [l] 65
Gear oil grooved wheel [l] 7
4.8.10 Temperatures, environmental conditions
NOTICE
Operating the machine at other ambient temperatures
Only the manufacturer is allowed to decide if the machine can be operated at
other ambient temperatures than those mentioned below. The machine opera-
tor must have the decision of the manufacturer in writing.
In general: All materials used, especially Operating materials [} 138], must be
suitable for the ambient temperature range that the machine operates in.
Ambient temperature Depending on the hydraulic oil used. See sec-

tion "Hydraulic oil".
Max. operating temperature of [°C] 80
hydraulic oil
An operating temperature of
hydraulic oil above 80 °C up to
100 °C is possible, but oil and
seals will be worn considerably
faster.
Humidity [%] 30 – 90
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4.9 EC Declaration of conformity

Manufacturer:
ZECK GmbH, Columba-Schonath-Str. 6, 96110 Schesslitz, Germany
Product name: Tensioner
Type: B 1500/14
Serial Number: 8285 ─ 8292
Construction Year: 2017
The manufacturer hereby declares that the product specified above complies
with all relevant regulations of the following directive/s:
n Directive 2006/42/EC on machinery
n Directive 2004/108/EC to electromagnetic compatibility
n Directive 2000/14/EC to the noise emission in the environment by equip-
ment for use outdoors
The following harmonized standards were applied:
n EN ISO 12100:2010 (Safety of machinery – General principles for design)
n EN ISO 4413:2010 (Hydraulic fluid power – General rules and safety require-
ments for hydraulic systems and their components)
n EN 60204-1:2006/AC:2010 (Safety of machinery – Electrical equipment of
machines, Part 1: General requirements)
Authorized for assembling the technical file:

n ZECK GmbH, Columba-Schonath-Str. 6, 96110 Schesslitz, Germany,
Tel.: +49 9542 9494 - 0
This declaration of conformity loses its validity if modifications are undertaken
to the machine which are not agreed and approved by the manufacturer in writ-
ing beforehand. The declaration of conformity refers to the state of the machine
at the point in time of placing on the market.
Schesslitz, 01.04.2017
Michael Zeck
Managing Director
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5 | Operating and display elements
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5 Operating and display elements
5.1 Position of the operating and display elements
Fig. 9: Position of the operating and display elements
1 Behind the flap:

Control desk, storage of the re-
mote control, operating ele-
ments for support and auxiliary
hydraulic system
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5.2 Control desk
1 2 3 4
12 6
11 8
10 9
Fig. 10: Control desk
1 Control panel 2 ENGINE START button

3 IGNITION button 4 Arctic Kit (optional)
5 MAIN SWITCH 6 TENSIONING MODE button
7 TENSIONING FORCE poten- 8 USB port
tiometer
9 EMERGENCY STOP 10 ROPE DIRECTION joystick
11 SAVE SPEED button 12 PULLING MODE button
5.2.1 Operating elements of the control desk
EMERGENCY STOP
Switch.
n Stops the machine as swiftly as possible in an emergency situation
n Stops the machine and the engine
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MAIN SWITCH
Key switch
ON position: n Switches the machine on

OFF position: n Switches the machine off
IGNITION
Dual button with indicator lamp. 1 upper button, 1 lower button.
Upper button (I) IGNITION ON

n Prepares the engine for starting
n Indicator lamp glows
Lower button (O) IGNITION OFF
n Interrupts ignition and stops the
running engine
n Indicator lamp goes out
ENGINE START
Button with indicator lamp.
n Starts the engine
n The indicator lamp comes on if the engine is ready to be started
USB port
Socket
n Connector for USB storage device or USB printer
TENSIONING FORCE
Potentiometer.
n Adjusts the tensioning force in tensioning mode.
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TENSIONING MODE
n Switches the machine over to tensioning mode
n Indicator lamp glows in tensioning mode
PULLING MODE
n Switches the machine over to pulling mode
n Indicator lamp glows in pulling mode
ROPE DIRECTION
Joystick.
This functions only if the machine is in pulling mode.
n Determines whether the machine pulls rope or pays off rope.
The greater the deflection of the joystick, the higher the rope speed.
KEEP SPEED
Button.
n Keeps the current rope speed (position of the ROPE DIRECTION joystick)
n If the KEEP SPEED button is depressed and held, the ROPE DIRECTION joy-
stick can be released.
Vehicle input
Laterally on the control desk there is a vehicle input installed. The vehicle input
is only to connect the battery charger or the rechargeable battery of the radio
remote control.
5.2.1.1 Control panel

Control panel of the machine control system
n Displays important information of the machine control system.
n The operator can navigate through different masks and enter data.
Information about the masks: See chapter Operating and display elements
[} 39].
Information about handling: See chapter Handling and operation [} 84].
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5.3 Control panel
5.3.1 Design and application of control panel
Fig. 11: Control panel: Display and function key
Components The control panel consists of the display (Item 1) and 8 function keys (Item 3).
Display In the display (Item 1) the machine control system displays the different masks
(views) like e.g. current measured data, settings and operating states.
Function key With 8 function keys the user can open other masks or issue commands to the
machine control system. The function keys can have different functions in each
mask. The machine control system displays the assigned functions at the lower
margin of the display above each function key (Item 2). If a function is assigned
to a function key the button is lit.
Example:
In this example the user presses the function key for which the Information icon
is assigned in the display.
5.3.2 Starting process of machine control system

After switching on the main switch, the machine control starts. This takes ap-
proximately 30 seconds. During this time the initial screen is displayed. When
the starting process is complete, the control replaces the starting screen with
the “Main view” mask.
5.3.3 “Main view" mask

All important information and function key assignments for the ongoing opera-
tion are displayed.
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1 2
12 11 10 9 8 7 6
1 Operating mode and further in- 2 Current pulling or tensioning

formation. See next table. force. The indicated value is
rounded and is to be regarded
as orientation because it can
vary from the actual force value.
3 Rotational speed and operating 4 Current stringing speed and
hours drive engine. rope length installed.
5 Set value for overload protec- 6 Open the "Settings" mask.
tion. Is displayed in pulling
mode only.
7 Open the "Information" mask. 8 Open the "Error display" mask.
Icon is lit yellow: At least one er-
ror message available.
9 Perform or interrupt regenera- 10 Start or stop recording.
tion. Is displayed just under cer-
tain circumstances
11 Reset the meter counter. 12 Open the "Overload protection"
mask.
Information icons at the display

Depending on the type and equipment of the machine some of the following
icons will not be displayed.
Icon Meaning Icon Meaning

Tensioning mode Pulling mode
Synchro mode: Master ma- Synchro mode: Slave ma-

chine. chine.
Synchro mode: Connection Synchro mode: Set Syn-

with slave machine estab- chro function is not possi-
lished. ble with this machine.
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Icon Meaning Icon Meaning

First set the operating Connection to the display
lever to pulling mode then is interrupted.
start the machine.
Torque switch: Tensioning Torque switch: Max. possi-
force too high. ble force.
Pulling mode: Set value for Pretension regulation is ac-
overload protection. tive. Aside: Nominal value
Flashes yellow: Overload set.
protection reduces the
pulling force.
Flashes red: Overload pro-
tection has switches off the
machine operation.
Pretension regulation for
SLAVE machine is active.
Aside: Nominal value set.
See also
2 "Overload protection" mask [} 47]
2 "Error display" mask [} 47]
2 “Settings” mask [} 49]
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5.3.4 Overview mask hierarchy

This overview illustrates the most important masks. All masks can be opened ei-
ther directly or via other masks from the main view.
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5.3.5 "Overload protection" mask
7 6 5 4 3 2
1 Value for overload protection. 2 Accept value and return to pre-

vious mask.
3 Increase value by 10. 4 Increase value by 1.
5 Reduce value by 1. 6 Reduce value by 10.
7 Back to previous mask.
5.3.6 "Error display" mask
4 3 2
1 Error codes of current errors. 2 Open the "Error codes help"

mask.
3 Open the "Engine error" mask. 4 Back to previous mask.
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5.3.6.1 “Engine error" mask
1 Flashing codes and error num- 2 Back to previous mask.

bers SPN and FMI of the errors
reported by the engine control.
Meaning of error codes: See in-
structions for drive engine.
5.3.6.2 “Error codes help" mask
1
2
3
4
10 9 8 7 6 5
Fig. 12: “Error codes help" mask
1 Name of the selected PDF file. 2 Overview of lists.

3 Overview PDF files. 4 Current file path.
5 Open selected PDF file (ENTER). 6 Back (BACKSEL).
7 Down (DOWN). 8 Up (UP).
9 Select (SELECT). 10 Back to previous mask.
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5.3.7 “Settings” mask
11 10 9 8 7 6 5 4
1 Set date. 2 Set metering point interval.

3 Set time. 4 Open factory menu (only for
manufacturer).
5 Open the "Advanced settings" 6 Open "Remote diagnosis” mask
mask. (option).
7 Open "Measuring point interval" 8 Open the "Data saving" mask.
mask
9 Open the "Date" mask. 10 Open the "Time" mask.
See also
2 "Time" mask [} 50]
2 "Date" mask [} 50]
2 “Data saving” mask [} 51]
2 "Measuring point interval" mask [} 51]
2 "Advanced settings" mask [} 52]
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5.3.7.1 "Time" mask
7 6 5 4 3 2
1 Time 2 Accept value and return to pre-

vious mask.
3 Right. 4 Left.
5 Increase value. 6 Reduce value.
See also
2 Set time and date [} 91]
5.3.7.2 "Date" mask
7 6 5 4 3 2
1 Date 2 Accept value and return to pre-

vious mask.
3 Right. 4 Left.
See also
2 Set time and date [} 91]
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5.3.7.3 “Data saving” mask
10 9 8 7 6 5 4
1 Example for selected data 2 Check mark visible: USB printer

record. connected.
3 Check mark visible: USB flash 4 Copy selected file to USB flash
drive connected. drive.
5 Print selected file. 6 Delete selected file.
7 Down. 8 Up.
9 Select all. 10 Back to previous mask.
See also
2 Save, print or delete data [} 92]
5.3.7.4 "Measuring point interval" mask
5 4 3 2
1 Current value. 2 Accept value and return to pre-

vious mask.
3 Increase value by 10. 4 Reduce value by 10.
See also
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2 Set measuring point interval [} 93]
5.3.7.5 "Advanced settings" mask
1 2 3
11 10 9 8 7 6 5 4
1 Set rope diameter. 2 Yellow icon: Maintenance is due.

3 Next maintenance: Operating 4 Open the "Parameter" mask.
hours or date.
5 Open the "Units" mask. 6 Open "Rope diameter" mask.
7 Open the "Maintenance history" 8 Reset maintenance message.
mask. Service password re- Customer password or service
quired. password required.
9 Open the "Error history" mask. 10 Open the "Overview I/O test"
Service password required. mask.
See also
2 "Overview I/O test" mask [} 53]
2 “Error history" mask [} 56]
2 “Maintenance history” mask [} 57]
2 "Rope diameter" mask [} 57]
2 "Units" mask [} 58]
2 "Parameter" mask [} 59]
2 Open the "Advanced settings" mask [} 93]
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5.3.7.5.1 “Password” mask
4 3 2
1 Current position for password 2 Accept password.

input.
3 Digits 1 to 6 for password input. 4 Back to previous mask.
Password for user: 4444

Password for service staff: Request from manufacturer.
5.3.7.5.2 "Overview I/O test" mask
4 3 2
1 Overview over CAN bus of the 2 If available: Open I/O page for
machine. Display of active com- remote control and other CAN
munication errors. bus devices.
3 Open the I/O page for illustrated 4 Back to previous mask.
PLC module.
The illustration above is just an example. The display on the machine can vary.
But the functions are similar.
Icon Meaning
Connection is established.
Connection is interrupted.
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Icon Meaning
Drive engine is idle.
CAN connection is interrupted.
See also
2 Open the overview I/O test [} 94]
5.3.7.5.2.1"I/O test PLC" mask
1 2
...
...
8 7 6 5 4 3
1 Inputs of PLC module. 2 Outputs of SPS module.

3 Change value or accept changed 4 Increase value by 10.
value.
5 Reduce value by 10. 6 Down.
7 Up. 8 Arrow: Back to previous mask.
Red X: Resets edited value to
zero.
Type of inputs and outputs:

Possible types of inputs:
n Digital (logically true or false)
n Analog (current value in mA)
n Analog (ratiometric value from 0 to 255)
Possible types of outputs:
n Digital (logically true or false)
n analogue, current-controlled.
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State of digital inputs and outputs

TRUE: Green highlighted icon "I" (logically true).
FALSE: Grey highlighted icon "O” (logically false).
Display of analog inputs:

For analog inputs the current values or the ratiometric values are displayed.
Display of analog outputs:

For current-controlled outputs, two current values are displayed: The actual
value and on the right side the reference value. The reference value is high-
lighted in grey.
5.3.7.5.2.2"I/O test remote control" mask
5 4 3 2
1 Display of remote control and 2 Changes between TRUE and

status of all inputs and outputs. FALSE.
3 Right. 4 Left.
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5.3.7.5.3 “Error history" mask
1 2 3 4 5
11 10 9 8 7
1 Error code. 2 Information when this error oc-

curred for the first time: time,
date, operating hour, battery
tension, engine speed.
3 Is lit yellow (right): This error is 4 Number, indicating how often
currently active. this error has occurred all in all.
Is lit green (left): This error is
currently not active.
5 Number indicating how often 6 Information when this error oc-
this error has occurred since the curred last: time, date, operating
last time ignition was switched- hour, battery tension, engine
on. speed.
7 Increase error code by 10. 8 Increase error code by 1.
9 Reduce error code by 1. 10 Reduce error code by 10.
See also
2 Open error history [} 95]
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5.3.7.5.4 “Maintenance history” mask
1 Protocol entries for reseted 2 Back to previous mask.

maintenance messages with
number of operation hours and
date.
Letter "K": Maintenance mes-
sage was reseted with the user
password.
Letter "S": Maintenance message
was reseted with the service staff
password.
See also
2 Open maintenance history [} 95]
5.3.7.5.5 "Rope diameter" mask
5 4 3 2
1 Set value. 2 Accept value and return to pre-

vious mask.
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See also
2 Set rope diameter [} 96]
5.3.7.5.6 "Units" mask
5 4 3 2
1 Left: Metric units. 2 Accept selection.

Right: American units.
3 Left. 4 Right.
Metric units American units

km/h mph
°C °F
m ft
kN lbs
mm inch
Tab. 2: Basic units
See also
2 Switch units [} 96]
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5.3.7.5.7 "Parameter" mask
6 5 4 3 2
1 Parameter: Number and value. 2 Increase number by 10.

3 Increase number by 1. 4 Reduce number by 1.
5 Reduce number by 10. 6 Back to previous mask.
See also
2 Display parameters [} 96]
5.3.8 Information bar icons

At the upper edge of the display the machine control indicates via different
icons operational modes and warnings. The messages marked with a (*) are not
only indicated by an icons but additionally with a warning tone.
Some of the icons described here just come with certain machine types.
Icon Message, meaning, possible corrective measure

Maintenance is due.
Carry out service.
Hydraulic oil is too hot.
Eliminate cause immediately.
Hydraulic oil is too hot.
n Yellow: Eliminate cause immediately.
n Red: The control stopped the engine.
Engine preheats.
Battery is not charging. Eliminate cause.
Engine oil pressure is too low. The control stopped the engine.
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Icon Message, meaning, possible corrective measure

Air filter is blocked. Clean or replace.
Coolant is too hot.

n Yellow: Eliminate cause immediately.
n Red: The control stopped the engine.
Not enough coolant. Replenish.
Not enough or no fuel.

n Yellow: Replenish fuel soon.
n Orange: Replenish fuel immediately.
n Red: No more fuel. Replenish fuel.
5.3.9 Toolbar icons

At the lower edge of the display the machine control system has icons for possi-
ble actions on each mask. To perform an action press the function key directly
under the icon.
Some of the icons described here just come with certain machine types.
Icon Meaning
Back to previous mask.
Accept value or change value.
Set overload protection.
Start or stop data recording.
Open information.
Open engine errors.
Open help for error codes.
Set date.
Set time.
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Icon Meaning
Set measuring point interval.
Open settings.
Open the "Advanced settings" mask.
Select all.
Print selected file.
Reset maintenance (password protected).
Display maintenance history (password protected).
Switch units.
Open the Overview I/O test.
Open the I/O mask for remote control.
Open the I/O mask for illustrated PLC module.
Go to previous mask.
Go to next mask.
Indicate error.
Reset the meter counter.
Open data saving.
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Icon Meaning
Open factory menu (only for manufacturer).
Delete selected file.
Copy selected file to USB flash drive.
Set rope diameter.
Open parameters.
Display error history (password protected).
5.4 Radio remote control / cable remote control
1 2 3 4 5 6
15 14 13 12 11 10 9 8 7
Fig. 13: Radio remote control
1 TENSIONING FORCE potentiometer 2 Tensioning mode lamp
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3 TENSIONING MODE button 4 PULLING MODE button

5 Pulling mode lamp 6 ROPE DIRECTION joystick
7 FREQUENCY SELECTION switch 8 Operating mode display lamp
9 EMERGENCY STOP 10 Overload lamp
Auxiliary function: Switches radio remote con-
trol on and off
11 ENGINE START button 12 IGNITION OFF button
13 Ignition indicator lamp 14 SAVE SPEED button
15 IGNITION ON button
1 TENSIONING FORCE potentiometer 2 Tensioning mode lamp

3 TENSIONING MODE button 4 PULLING MODE button
5 Pulling mode lamp 6 ROPE DIRECTION joystick
7 FREQUENCY SELECTION switch 8 Operating mode display lamp
9 EMERGENCY STOP 10 Overload lamp
Auxiliary function: Switches radio remote con-
trol on and off
11 ENGINE START button 12 IGNITION OFF button
13 Ignition indicator lamp 14 SAVE SPEED button
15 IGNITION ON button
5.4.1 Operating elements of the remote control

Unless otherwise specified the operating elements of the remote control have
the same functions as the operating elements on the control desk. Information
about these operating elements: See Operating elements of the control desk
[} 40].
Difference between radio remote control / cable remote control

The radio remote control imaged above is almost identically with the cable re-
mote control. Sole exception: The cable remote control has no FREQUENCY SE-
LECTION button.
5.4.1.1 ENGINE START

Button.
n Starts the engine.
n If available, corresponds to position 3 at ignition switch of drive engine.
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Ignition lamp
n Is lit if the ignition is switched on
Tensioning mode lamp

n Is lit if the machine is in tensioning mode
Pulling mode lamp

n Is lit if the machine is in pulling mode
Overload lamp
n Is lit when the machine control system switches off the machine due to
overload.
5.4.1.2 TENSIONING FORCE

Potentiometer.
n Adjusts the tensioning force of the machine.
5.4.1.3 IGNITION ON
Button.
n Switches the ignition on.
5.4.1.4 IGNITION OFF

Button.
n Switches the ignition off.
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5.5 Support
Fig. 14: Support: Valves
1 Icons for front or rear support 2 Operating lever LIFT/LOWER

SUPPORT
3 Operating lever LIFT/LOWER
SUPPORT
The operating levers can be installed horizontally or vertically. This is applicable

to the moving direction of the support:
n Horizontal operating lever up: Support is lifted.
n Horizontal operating lever down: Support is lowered.
n Vertical operating lever pushed away from user: Support is lifted.
n Vertical operating lever pushed towards user: Support is lowered.
Depending on the machine type, either all or just certain supports can be
moved hydraulically.
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5.6 Hydraulic auxiliary circuits
5.6.1 Connection block for reel winder / drum stand
1 2
3
4
5
Fig. 15: Connection block for auxiliary hydraulic system
1 Pressure setting with star grip 2 Pressure hydraulic system dis-

optional: Pressure setting via play
DRUM STAND TENSIONING
FORCE potentiometer on control
desk
3 FREE WHEEL / DRIVE gear lever 4 Leakage oil connector
5 Return flow connector 6 Feed line connector
Identification: Black dot
5.7 Pressure roller
3
4
Fig. 16: Pressure roller
1 Pressure roller 2 Lock bar

3 Pressure roller, locked in pivoted 4 Operating lever
position
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6 | Operating modes
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5.8 Engine
See the separate instructions for operating and display elements of the engine.
6 Operating modes
This chapter describes all operating modes in which the machine can work.
6.1 Pulling mode

In pulling mode, the machine pulls the rope in or out. The favored working di-
rection and the working speed are controlled by the user.
Even machines that are primarily intended for rope tensioning have a pulling
mode. The pulling mode of tensioners is thereby intended to regulate the sag of
the rope. In this context, pulling mode is also termed Sagging mode .
See also
2 Start pulling mode [} 97]
6.2 Tensioning mode ATS

In tensioning mode, the machine keeps the rope at a constant tension. The fa-
vored tension (tensioning force) is adjusted on the machine by the user. The
rope is pulled by another machine (puller). The automatic tensioning mode is
also termed ATS. ATS stands for Automatic Tensioning System.
See also
2 Start and stop tensioning mode [} 98]
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7 | Transportation and initial operation
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7 Transportation and initial operation
7.1 Transport the machine
NOTICE
Machine damage due to vibrations
The machine has shock-sensitive parts that can be damaged due to careless
transport.
1. Avoid jerky lifting movements and violent setting down.
2. Use the intended and labeled lifting points only for transporting the ma-
chine.
WARNING
There is a risk of injury from any cover flap that remains open.
A cover flap that is not secured can spring open during transportation. Because
of the gas pressure springs, the flap raises itself, its sharp edge protruding later-
ally beyond the machine. If this edge strikes persons passing by, this can result
in severe cuts, abrasions, or broken bones.
1. Prior to any transportation, close all of the machine's cover flaps.
2. Turn each turning handle to close it and secure each cover flap with a pad-
lock.
3. If available: Secure each cover flap with the flap holders.
7.1.1 Means of transport

There are the following transportation options:
n Hitching to a towing vehicle.
n Loading with a crane.
7.1.2 Prepare for transport

1. Bring the front and rear support to the upper stop position.
2. If present, fold down the hoop guard of the rear support.
3. Close all machine cladding flaps and secure them.
4. Ensure that no tools or other loose parts are present on the machine that
might fall off during transportation.
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7.1.3 Transport by crane
WARNING
Danger of accidents through falling loads
Severe injury or death possible.
1. Only use hoisting devices that is approved for a safe working load. Weight:
See “Technical data”.
2. Wear your personal protective equipment: Head protection, safety shoes,
and protective gloves.
3. For transporting the machine, only use the intended, labeled lifting points.
4. Never remain under a swinging load.
5. Send other persons out of the danger zone.
NOTICE
Machine damage due to vibrations
The machine has shock-sensitive parts that can be damaged due to careless
transport.
1. Avoid jerky lifting movements and violent setting down.
2. Use the intended and labeled lifting points only for transporting the ma-
chine.
Secure the lifting tackle for transportation by crane at the designated lifting
points only. The lifting point is identified with the adjoining symbol. Depending
on the size of the machine, multiple lifting points may be present.
Fig. 17: Lifting point for loading by crane
7.1.4 Transport on the loading area

The machine's axle and wheels must be relieved of any load prior to being
lashed. To do this, lower the front and rear support.
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Lashing supports If the machine is equipped with lashing supports (optional), the lashing supports
may be used instead of the rear support. The machine then needs a smaller
loading area.
Remove drawbar
When transporting the machine on a loading platform remove the drawbar.
1
Fig. 18: Remove drawbar
1 Screws
1. Loosen the two screws (Item 1) and remove the drawbar.
7.1.5 Transport by towing vehicle
7.1.5.1 Fix towing eye with drawbar
DANGER
Danger of accident through loosely fitted drawbar
A loosely fitted drawbar can completely loosen during transportation of the ma-
chine. Persons can get severely injured or even die by a machine moving uncon-
trolled.
1. Always secure a drawbar using all provided screws.
2. Tighten nuts and screws applying 430 Nm torque.
1
Fig. 19: Install drawbar
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1 Screws
To have the machine towed with a traction vehicle, proceed as follows:

1. Fix the drawbar with 2 screws and nuts.
7.1.5.2 Hitch to a towing vehicle

ü If adjustable: Adjust height of the ball coupling / drawbar eye of the machine
to the height of the coupling of the towing vehicle.
1. Hitch the machine. Consider the instructions of the towing vehicle and
the trailer coupling.
2. Keep and secure the chocks in the brackets at the chassis.
3. Release the parking brake completely.
4. Raise the supports completely and secure them in lifted position.
5. If available:
Lighting: Establish an electrical connection.
Hoop guard above the sprag: Swivel it downwards.
Lashing supports: Swivel it upwards and secure it.
Braking system: Establish a pneumatic connection.
7.1.5.3 Move the machine with towing vehicle
WARNING
Danger of accident by the use of unsafe trailer
Brakes or lighting which does not work can endanger other road users or the
driver of the towing vehicle. Severe injury or death possible.
Check before each drive:
1. Check tires for correct tire inflation pressure.
2. If available: Check function of the trailer brake. Therefore do a brake test in
a separate area.
3. If available: Check function of lighting system.
When driving the machine with a towing vehicle observe the local standards for
speed limits.
7.1.5.4 Uncouple towing vehicle and park the machine

1. Apply parking brake:
2. Secure the machine against rolling away by means of the chocks.
3. Lower the front support.
4. Uncouple the machine from the towing vehicle.
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8 | Installation and configuration
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5. If available:
Disconnect electrical connection for lighting.
Disconnect pneumatic connection for brake system.
7.1.5.5 Park the machine for a longer period

If the machine is parked for longer than one month the tires and chassis have to
be relieved. Therefore support the machine at the front and back side. See sec-
tion Support and anchor the machine [} 75].
7.2 Initial machine operation

Prior to delivery, the machine was put into operation by the manufacturer and
subjected to comprehensive testing. Before the machine is put into operation
for the first time, carrying out the everyday maintenance tasks is sufficient.
See also
2 Machine maintenance plan [} 122]
2 Machine maintenance plan [} 122]
8 Installation and configuration
8.1 Installing the machine
8.1.1 Place of installation of the machine
Site requirements
WARNING
Deviating from default situations
In this section a generally accepted default situation is described for installing
the machine. The operator of the machine is only allowed to deviate from the
default situation described if he is exactly aware of the resulting risks and he un-
dertakes all additional measures ensuring at any time the safety of persons.
In order to be able to safely install and operate the machine, the following pre-
conditions are important:
n Sustainable underground.
n The danger zone around the machine must be capable of being appreciably
isolated.
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n Good view of the overall work environment on the part of the user.
Orientation towards and clearance from the pylon

Minimum clearance To determine the minimum clearance, ascertain the height of the rope pulley at
the first mast from the ground. Install the machine such that the clearance be-
tween machine and mast is at least equivalent to the height of the pulley block
at the first mast from the ground. With this as the minimum distance, the rope is
raised at an angle of 45°.
Maximum clearance The further away the machine is from the first mast, the flatter is the angle at
which the rope exits the machine. For the maximum clearance, the following are
applicable:
n The rope is not permitted to come into contact with the rollers of the rope
outlet when the machine is in operation
n A sagging rope is not to drag on the ground
Ideal clearance The ideal distance between the machine and the mast is in the range two to
four times the height of the first pulley block. Location-specific regulations gov-
erning clearance are to be observed.
Fig. 20: Suitable area for a clearance between the machine and the first mast
Clearance between ma- Angle of the rope be- Suitability as a place of

chine and first mast tween the machine and installation
the first pulley block
Closer than 1 x height H 45° and steeper Deviation from the de-
fault situation. Permitted
under the following con-
ditions:
n The operator is aware
of and eliminates the
dangers which are re-
sulting from deviating
from the default situ-
ation.
n The operator ensures
that especially the
static loads of the first
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Clearance between ma- Angle of the rope be- Suitability as a place of

chine and first mast tween the machine and installation
the first pulley block
pulley block and the
first mast are uncriti-
cal.
1 x height H to 2 x height 45° to 27° Permitted, but the load of
H the rope on the first pul-
ley block is relatively high
2 x height H to 4 x height 27° to 14° Ideal
H
4 x height H and greater 14° and flatter Permitted under the fol-
lowing conditions:
n The rope does not
come into contact
with the rope outlet
rollers of the ma-
chine.
n The rope does not
sag to the point
where it grazes the
ground.
Fig. 21: Orientation and Clearance of the Machine
Orientation Rotate the machine such that the sprag points towards the mast. The grooves of
the bull wheels must be flush-aligned with the rope pulley block. Lateral devia-
tion may not exceed 5°.
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8.1.2 Support and anchor the machine

The pulling force exerted on the rope during operation can overturn a machine
that is not adequately anchored. This poses a risk to the lives of all people in the
vicinity of the machine. Therefore, to ensure safe operation always support and
anchor the machine.
Measure Function Component of the ma-

chine
Support Gives the machine stabil- Front support
ity Rear support (sprag)
Relieves the load on the
chassis wheels
Anchoring Dissipates the pulling Eyelets on the machine's
forces that act upon the frame
machine during the
stringing operation
If the surface is too soft, use appropriate bases beneath the supports to distrib-
ute the pressure. Examples of bases:
n Squared timber
n Timber planks
n Steel plates
For installing the hydraulic support the machine has to be started [} 84].
WARNING
Crushing hazard by extending supports
Crushing, severance of limbs, broken bone, and severe injuries are possible.
1. Prior to and during removal of the support, remove all persons from the
danger zone.
2. Activate the operating elements for the machine's support delicately.
3. Avoid moving the support backward.
Handle the front support

Rotate the crank handle to lower or raise the support.
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Model with double crank:

n Pull out the crank and rotate using the short crank arm so as to handle the
support speedily.
n Slide in the crank and rotate using the long crank arm so as to handle the
support with maximum force.
Model with single crank:

n Pull out the crank and rotate so as to handle the support speedily.
n Slide in the crank and rotate so as to handle the support with maximum
force.
Handling the back support
Fig. 22: Back support (sprag)

The back support (sprag) is hydraulically lowered and raised. The operating lever
is identified with the adjoining symbol.
ü The machine is correctly positioned.
ü The front support is extended.
1. Lower the back support until the wheels of the chassis are fully relieved
of their load.
2. If present, fold the hoop guard above the back support upward and lock
into place in a folded-up position.
Slight inclination of the machine of up to 10° along the longitudinal and trans-
verse axis does not impact the safe functioning of the machine.
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NOTICE
Damage sustained by the rollers of the rope outlet
While the machine is in operation, the rope is highly tensioned. The rollers of
the rope outlet are not designed for this. The rope may only rest upon the
rollers of the rope outlet during setup operations. While the machine is in oper-
ation, the rope can damage the rollers.
1. Position the machine such that the rope does not come into contact with
the rollers of the rope outlet during operation.
2. If necessary, lower the rear support (sprag) until the machine is sufficiently
angled and the rope outlet is completely free.
Anchor the machine
WARNING
Danger arising from the machine tipping over
If the machine's anchoring is not sufficiently secure, the machine may tip over in
consequence of the pulling force of the rope. Extremely severe or fatal injuries
may result. The machine would, in any case, be severely damaged.
1. Support the machine securely.
2. Anchor the machine such that the pulling force of the rope cannot cause
the machine to tip over.
3. Use only suitable lifting tackle for purposes of anchoring. Suitable means
are, for instance, chains and braided steel ropes.
4. Just fix the lifting tackles for anchoring only at the lifting points of the ma-
chine.
5. As far as possible, load anchoring eyelets along the machine's length. En-
sure reliable angle ranges for the anchor pole.
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2 3
Fig. 23: Anchoring the machine

Anchor the machine such that the greatest pulling force that is generated dur-
ing operation cannot overturn the machine. To do this, secure anchor poles
(ropes or chains) (pos. 2) to the eyelets of the machine (pos. 1) and anchor in
the ground (pos. 3).
Marking The anchoring eye bolts of the machine are marked with an icon (chain with
hook). Labeling icons used
Ensure that the eye bolts primarily bear the load along the machine's length.
The anchor pole angels must stay within the following area:
Anchor pole angle Reliable angle range Recommended angle

Relative to the longitudi- -30° to +30° -15° to +15°
nal axis of the machine:
In relation to the ground: This angle is roughly
equivalent to the angle of
the rope between the
machine and the first
mast.
As an alternative to anchoring in the ground, the ropes or chains can also be se-
cured to major weights. The weights should not be able to be displaced by the
maximal pulling forces. Observe the specifications pertaining to the angle of the
anchor poles in this instance, too.
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Fig. 24: Anchor pole angle
8.1.3 Ground the machine
WARNING
Electric shock arising from static charging, induction, or lightning
strike
Electrostatic charging can occur during the stringing operation. Electrical dis-
charge, induction by way of proximity to live high voltage power lines or light-
ning strike in consequence of thunderstorms can result in electric shock. Severe
injuries or death are possible.
1. Ensure that the machine is always grounded during operation.
2. Arrange to have damaged structural components for the machine's
grounding repaired by specialist personnel at once.
Connecting point for On the machine's frame, there is at least one connecting point for grounding.
grounding All connecting points for grounding are identified by the icon for grounding.
Only copper grounding cables may be connected at these connecting points.
Establish machine-to-earth equipotential bonding

Grounding stake Drive the grounding stake into the ground. Connect the machine to the ground-
ing stake with a grounding cable. Moisten dry ground surrounding the ground-
ing stake and keep it moist so that electrical resistance between grounding
stake and the ground is minimized.
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Mast If the next mast is grounded: Connect the machine to the mast with a grounding
cable.
Establish machine-to-user equipotential bonding.

Grounding plate (optional) Connect the grounding plate (optional) with a connecting point for machine
grounding using a grounding cable. The machine must be grounded. Place the
grounding plate at the site where the user who must establish contact with the
machine during its operation is to stand.
8.2 Install reel winder / drum stand

Orientation Position the reel winder / drum stand such that the rope runs from the rope
drum along the bull wheels of the machine in as straight a line as possible.
Maximum and minimum Install the reel winder / drum stand as far away from the machine as possible.
clearance from the The maximum distance is predetermined by the length of the hydraulic hoses
machine between the machine and the reel winder / drum stand. If there is no nationally
applicable regulation, and none issued by the rope manufacturer, pertaining to
the minimum clearance between the reel winder / drum stand and the machine,
the manufacturer prescribes a minimum of 5 meters for this clearance. Keep a
clearance of at least 5 meters.
Maximum lateral deviation Install the reel winder / drum stand such that the rope is deflected laterally by a
from the pulling direction maximum of 5°. If necessary, increase the clearance between the machine and
the reel winder / drum stand.
Grounding The reel winder / drum stand must be anchored and grounded. Refer to the
separate instructions for the reel winder / drum stand in this regard.
Connection For connection and operation of the reel winder / drum stand, refer to the sepa-
rate instructions for the reel winder / drum stand.
8.3 Connect components
8.3.1 Connect the remote control
NOTICE
Operating elements without function on the control desk
When the remote control is connected, the operating elements on the remote
control assume precedence. The same operating elements on the control desk
then have no function.
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The socket for the connection to the remote control is located on the side wall
of the control desk. If no remote control is connected, the dummy plug must re-
main inserted in the socket. The dummy plug is secured to the control desk with
a safety chain.
NOTICE
An interruption in the plug connection triggers the emergency stop.
If the user removes a plug for the remote control from the socket while the ma-
chine is in operation, the emergency stop is triggered and the machine is
stopped immediately.
1. Before you remove a plug in order to connect or disconnect the remote
control:
Switch off the machine at the main switch.
Connecting the cable remote control:

ü The machine is switched off.
1. Remove the dummy plug.
2. Insert the cable remote control in the socket.
Connecting the radio remote control:

1. Remove the dummy plug.
2. Insert the plug of the radio receiver in the socket.
Disconnecting the cable radio remote control or radio remote

control:
1. Remove the plug of the remote control.
2. Insert the dummy plug in the socket.
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8.3.2 Connect reel winder / drum stand
1 2
3
4
5
Fig. 25: Auxiliary hydraulic system: Connection block
The hydraulic hoses are connected to the connections of the connector block by
means of quick-action couplings.
NOTICE
Failure of the hydraulic unit owing to soiling
Dust and dirt particles deposited in the hydraulic oil lead to malfunctions and
damage the hydraulic components. This results in repairs and machine down-
time.
1. Ensure optimal cleanliness of the hydraulic connections and quick-action
couplings.
2. Remove soiling immediately.
3. Always protect hydraulic connections that are not in use with dust caps.
Connect the hydraulic hoses of the reel winder / drum stand to the
machine.
ü The machine and reel winder / drum stand are anchored and grounded.
ü The hydraulic hoses are connected to the reel winder / drum stand.
ü The engine is stopped.
1. Position the operating lever (pos. 3) to free wheel.
2. Remove the dust caps from the connectors (pos. 4, pos. 5, and pos. 6).
3. Connect the hydraulic hoses to the feed line connectors (marked with a
black dot), return flow, and leakage oil. This involves inserting the quick-
action coupling in the respective connector and tighten firmly so that the
valve stopper in the connector is pushed open. Always tighten the quick-
action coupling only by hand.
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ð The reel winder / drum stand is connected.
If the quick-action coupling cannot be fully screwed:
Assess the following options:
1. The residual hydraulic pressure in the machine is too high. To carry out a
check, read the value on the pressure indicator (pos. 2). If residual pressure is
present, turn the star grip (pos. 1) counterclockwise until the pressure has suffi-
ciently diminished. In the model incorporating electromagnetic adjustment:
Switch on the ignition and turn the corresponding potentiometer on the control
desk or on the remote control counterclockwise.
2. Hydraulic pressure in the hose too high. This is caused by the hydraulic hose
heating up owing to exposure to sunlight.
Corrective measure: Either cool down the hydraulic hoses or switch the drum
stand to free wheel, reduce pressure like described above and screw the quick-
action coupling again.
Disconnect the hydraulic hoses of the reel winder / drum stand from
the machine.
ü Hydraulic hoses are connected to the machine and to the reel winder / drum
stand.
1. Disconnect the hydraulic hoses for feed line, return flow, and leakage oil.
2. Fix the dust caps to the connectors (pos. 4, pos. 5, and pos. 6).
ð The reel winder / drum stand is disconnected.
8.4 Adjust the wire direction guiding device

Rope feed The rollers of the rope feed form one or several wire direction guiding devices
depending on the machine type. Precisely one rope may pass through each wire
direction guiding device of the rope feed.
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Orientation of the rope in relation to the groove
Fig. 26: Rope comes in on the groove profile (sectional view)

Adjust the rope feed rollers such that the rope approaches the grooved wheel
parallel to the grooves. The rope (pos. 1) should not meet the groove profile lat-
erally but must feed precisely into the center of the groove.
Rope outlet Adjust the rope outlet such that the rope comes into contact with the rollers of
the rope outlet only during setup operations. The rope is not to come into con-
tact with the rollers during the stringing operation. If possible, adjust the rope
outlet. Alternatively change the inclination of the machine.
9 Handling and operation
9.1 Switch the machine on and off
9.1.1 Before switching on the machine
NOTICE
Before turning the machine on ensure its functional safety.
1. Visual check of the whole machine: See Inspect the machine visually.
2. Check all lubricants, fuel and auxiliary material fill levels.
3. Ensure that no persons, other than the user, are in the immediate vicinity
of the machine.
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9.1.1.1 Inspect the machine visually
WARNING
Using the machine in an unsafe condition
Severe or fatal injury to persons is possible if machines are used in an unsafe
condition.
1. Prior to each use, check the machine for visible damage.
2. Only switch on the machine if structural frame elements as well as hy-
draulic and electrical components are undamaged.
3. Only switch on the machine if all safety and operating elements are freely
accessible and functional.
4. Only switch on the machine if no leakages of operating materials and sup-
plies are apparent.
5. Only switch on the machine if the filing levels of operating materials and
supplies are sufficient.
Always perform a visual inspection before starting to operate the machine. Elim-
inate any detected faults immediately or have qualified personnel do this for
you. Only operate the machine when safe operation is guaranteed.
Check the following features with special care:
n Machine is supported sturdy and anchored tightly
n Structural frame elements are not damaged or cracked
n All safety-relevant elements of the machine are freely accessible
n All operating elements of the machine work properly
n There are no loose screw joints
n No damages and abrasions at electrical and hydraulic components and con-
nections
n No leakages at the following elements:
n Engine (fuel, coolant, engine oil).
n Hydraulic unit and at all hydraulic components (hydraulic oil)
n Gearbox (gear oil)
n Battery (battery acid)

n The following filling levels are sufficient:
n Fuel for engine
n Engine oil for engine
n Coolant for engine
n Hydraulic oil
n All operating elements must be free of ice, snow, dirt (especially oil or
grease).
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n Operating symbols, warnings and signs must be clearly visible

n Danger zone around the machine is secured
9.1.2 Switch on the machine

ü If available: Battery master switch is in horizontal position.
1. Insert the key into the MAIN SWITCH.
2. Turn the MAIN SWITCH to the ON position.
ð During machine control system startup, the startup screen will show on the
display.
ð After approximately 30 seconds, the machine control system is ready. The
"Main View" mask is shown on the display.
9.1.3 Start the drive engine
WARNING
Danger arising from a engine that is starting up
As soon as the drive engine has started, hydraulic pressure is produced. Parts of
the machine, and components attached to the machine, can unexpectedly start
to move. The rope between the machine and the drum stand can suddenly whip
up. Crushing hazard and entanglement of fingers, hands or limbs at rope-guid-
ance rollers and bull wheels. A rope that suddenly whips up can result in severe
or fatal injuries.
Before starting up the engine, note the following:
1. You must be familiar with all the functions and operating elements of the
machine and the components attached to it. To ensure this, read the in-
structions, particularly the safety instructions and the chapter on handling
and operation of the machine.
2. Adjust all operating elements of the machine such that the machine does
not cause any unexpected movements upon being started up.
3. Remove all persons from the danger zone of the machine.
1. Press the IGNITION ON button (I) .

ð The IGNITION button is lit.
ð The control unit prepares the engine for startup.
2. If the ENGINE START button is lit: Briefly press the ENGINE START but-
ton.
ð The control unit starts the engine.
If the engine does not start, wait for at least five seconds and then briefly press
the ENGINE START button again.
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9.1.3.1 Allow the machine to warm up

If the environmental temperature is below 5 °C, the cold machine must first
warm up. If possible, the hydraulic system should only be strained fully if the hy-
draulic oil has warmed up.
NOTICE
While the machine is warming up, do not work with the machine.
1. Start the engine.

2. Open up (unscrew) all hydraulic hoses and hydraulic auxiliary circuits that
way that the hydraulic connection is separated.
3. Set the operating lever of the hydraulic auxiliary circuits to DRIVE.
4. Set the pressure for the hydraulic auxiliary circuits to approx. 200 bar.
5. Let the machine run in this state for about 15 min.
9.1.4 Stop the drive engine
WARNING
Rope rupture caused by blocked bull wheels
If the engine stops, no hydraulic power is available and the bull wheels are
blocked with an automatic brake. If rope pulling is not immediately stopped by
the other machine pulling at the rope, the rope may rupture, resulting in severe
or fatal injuries.
1. Stop the engine only if no further hydraulic energy is needed.
2. Stop the engine only if the bull wheels may be blocked or are supposed to
be blocked.
ü The machine is not in operation; the bull wheels are motionless.

ü The IGNITION button is lit.
ü The tensioning MODE button is not lit.
1. Press the IGNITION OFF (O) button .
ð The control unit stops the engine.
9.1.5 Switch off the machine

ü The engine is stopped and the ignition is switched off. The IGNITION button
is not lit.
ü There are no upcoming activities for which hydraulic power is necessary.
1. Turn the MAIN SWITCH on the control desk from ON to OFF.
2. Remove the key from the MAIN SWITCH.
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3. Keep key separate from machine and avoid access for third persons.
4. If available and if the machine will be parked for longer than two weeks:
Set the battery master switch into vertical position.
9.2 Behavior in case of emergency
9.2.1 Shutdown in an emergency

In an emergency situation, press the EMERGENCY STOP switch. The machine will
then be shutdown as swiftly as possible.
For the positions of the EMERGENCY STOP buttons, refer to section .
9.2.2 Restart after an emergency
CAUTION
Danger arising from machine instability
Following an emergency stop, implement the following measures before the
machine is put into operation again.
1. Ascertain the cause of the emergency stop.
2. Eliminate the cause or make sure that the cause has been eliminated.
3. Ensure that the machine is undamaged.
ü The cause of the preceding shutdown in an emergency case is known and has
been eliminated.
ü The machine is undamaged. It is possible to work safely using the machine.
1. Unlock the EMERGENCY STOP switch. To unlock, either pull out the
switch button or turn the switch button clockwise until the switch springs
out.
ð The machine is ready to be put into operation again. The drive engine can be
started.
9.3 Actions at the control panel
9.3.1 Open "Maintenance history" mask

The Main view is the central mask from which the user can open all other masks.
When the machine is restarted, the machine control system first displays the ini-
tial mask and then the main view.
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To return to the main view from another mask, press the function key several
times until the main view is displayed.
9.3.2 Set overload protection

ü The "Main view" mask is opened.
1. Press function key .
ð The "Overload protection" mask is open.
2. Cancel setting: Press left function key . The display returns to the main
view. Changed values are not accepted.
If the engine is running and for 10 seconds no function key is pressed
the display automatically returns to the main view.
3. Change the value: Press function keys or .
4. Accept displayed value: Press right function key .
See also
2 "Overload protection" mask [} 47]
9.3.3 Reset meter counter

1. Press function key.
ð Meter counter is reset to zero.
9.3.4 Record pulling data

1. Start recording or finish current recording: Press function key.
ð Recording is running: Function key is lit green.
ð Recording is not running: Function key is not lit.
9.3.5 Indicate errors

ð The "Error display" mask will be opened.
ð The error codes of current machine errors are displayed.
Display special engine errors: Press function key. If this icon is not visible this
function is not available for the machine’s engine.
If the engine is running and for 10 seconds no function key is pressed the dis-
play automatically returns to the main view.
See also
2 "Error display" mask [} 47]
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9.3.6 Display information

ð The "Information" mask will be opened.
9.3.7 Open "Settings" mask

ð The "Settings" mask will be opened.
See also
2 “Settings” mask [} 49]
9.3.8 Display error codes help

The meaning of the error codes are summarized in a list. This list is part of the
instructions and also saved in the display as PDF file. To open, first start the PDF
display module, then select and display the PDF file with the error codes in the
chosen language.
NOTICE
Display temporarily blocked
When the user ends the PDF display, the machine control system restarts the
display, displaying the initial mask.
During displying PDFs or during the restart of the display, the machine can be
controlled as usual via the operating elements. During this time, the machine
control does not display any information, warning or status messages.
1. Please bear in mind that switching from the display of “Help for error
codes” to normal display takes a few seconds. During this time you can op-
erate the machine via the control panel or read information specific to the
machine from the display.
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Detect error codes when Machine is at a standstill
To access the control panel at any time while the machine is running proceed
with one of the following:
Memorize or make a note of the occurred error code. Stop the machine, stop
the engine and then open the display “Help for error codes”.
Or:
Read the meaning of the error codes in the list included in these instructions.
Start PDF display module ü The "Error display" mask is opened.

1. Press function key .
ð The "Error codes help" mask will be opened.
2. Select "OPEN NEW PDF-FILE" with the function keys (arrows).
3. Press function key ENTER.
ð The "PDF file directory" mask will be opened.
Select PDF file 1. Select the favored PDF file with the function keys (arrows). The last two
letter of the file name indicate the file’s language.
ð The selected PDF with the error codes help is displayed.
Use the function key "Page +” and "Page -” to browse in the PDF file.
Quit PDF display module 1. To quit the PDF file, press the “Exit” function key.
ð The "PDF file directory" mask will be opened.
2. Press MENU function key.
ð The "Error codes help" mask will be opened.
3. Select "RETURN TO APPLICATION” with the function keys (arrows).
ð The Display program starts again. The initial view is displayed for a few sec-
onds.
ð After die Display started again the “Main View” mask is displayed.
9.3.9 Set time and date

ü “Settings” mask is opened.
1. Set time: Press function key .
Set date. Press function key.
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ð The "Time" mask or the "Date" mask will be opened.

3. Select value: Press function key or until the selected value is high-
lighted.
4. Change the value: Press function key or .
5. Accept the displayed values and return to previous mask: Press func-
tion key.
See also
2 "Time" mask [} 50]
2 "Date" mask [} 50]
9.3.10 Save, print or delete data

To write out stored pulling data to a USB flash drive or a USB printer, first con-
nect the device to the USB port. If next to the icon of the device there is a green
checkmark the device is correctly connected.
Open the "Data saving" ü "Settings mask is opened.
mask 1. Press function key.
ð The "Data saving" mask will be opened.
Select individual data 1. To select all data records, press function key .
record or all data records 2. To select one data record, press function key or .
Print data ü A suitable USB printer is connected to the USB port.
ð The control sends the selected data records to the USB printer.
Copy data ü A suitable USB flash drive is connected to the USB port.
ð The control sends the selected data records to the USB flash drive.
Delete data 1. Press function key.
2. Confirm safety query: Press function key and mark the checkmark.
ð The selected data records are deleted from the control memory.
See also
2 “Data saving” mask [} 51]
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9.3.11 Set measuring point interval

The measuring point interval determines in which distances pulling data will be
measured and recorded. Depending on the machine type the measuring point
interval either is a length indication (rope length installed in meters) or a time
value (temporal distance in seconds).
ü “Settings” mask is opened.
ð The "Measuring point interval" mask will be opened.
4. Accept the displayed values and return to previous mask: Press right
function key .
See also
2 "Measuring point interval" mask [} 51]
9.3.12 Switch on/off debug mode

ü "Remote diagnosis" mask is opened.
1. Switch Debug mode on or switch debug mode off: Press function key.
ð Debug mode is switched on: Icon for function key is lit in green.
ð Debug mode is switched off: Icon for function key is not lit.
9.3.13 Open the "Advanced settings" mask

ð The "Settings" mask will be opened.
ð The "Advanced settings" mask will be opened.
From this mask:
n Open the Overview I/O test.
n Open error history,
n Reset maintenance message.
n Open maintenance history.
n Set rope diameter.
n Switch units.
n Display parameters.
See also
2 "Advanced settings" mask [} 52]
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9.3.14 Open the overview I/O test

ü The "Advanced settings" mask is open.
ð The Overview I/O test" mask will be opened.
Open “I/O test” mask for a single PLC module.

1. Depending on your wishes and the machine type, press one of the func-
tion keys , or .
ð The “I/O test” mask for the favored PLC module will be opened.
Open "I/O test” mask for remote control:

1. If necessary, press the right function key as often, until the icon for
the remote control is visible.
ð The “I/O test” mask for the remote control will be opened.
See also
2 "Overview I/O test" mask [} 53]
Edit I/O signals of PLC
Change a digital value:

1. The input can be stopped at any time with function key .
2. To select a value, press function key or .
3. Switch the selected digital value from TRUE to FALSE or vice versa: Press
function key.
Change an analog value:

3. Open the selected analog value in order to change it: Press function
key.
ð In the toolbar now the function keys , and are displayed.
4. Change the analog value: Press function key or .
5. Cancel changed value: Press function key.
6. Accept changed value: Press function key.
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Edit I/O signals of the remote control
Change the value:

3. Switch the selected digital value from TRUE to FALSE or vice versa: Press
function key.
9.3.15 Open error history

2. Enter password for service staff.
ð The "Error history" mask will be opened.
To increase or decrease the error code press the function keys or .
See also
2 “Error history" mask [} 56]
9.3.16 Reset maintenance message

2. Enter password for service staff or user.
ð The maintenance message is reseted.
ð The operation is recored in the maintenance history.
ð The icon for the due maintenance is not lit anymore.
ü “Client menu" or "Service menu" mask is opened.
ð The maintenance interval is reset. The information symbol in the main view
disappears. Resetting the maintenance interval is recorded in the service his-
tory.
9.3.17 Open maintenance history

2. Enter password for service staff.
ð The "Maintenance history" mask will be opened.
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See also
2 “Maintenance history” mask [} 57]
9.3.18 Set rope diameter

ð The "Rope diameter" mask will be opened.
2. Cancel setting: Press left function key . Changed values are not ac-
cepted.
4. Accept displayed value: Press right function key .
See also
2 "Rope diameter" mask [} 57]
9.3.19 Switch units

ð The "Basic units" mask will be opened.
3. Change selection: Press function key or .
4. Accept selection: Press function key.
9.3.20 Display parameters

ð The "Parameter" mask will be opened.
To increase or decrease the number of the parameter indicated press the func-
tion keys or .
See also
2 "Parameter" mask [} 59]
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9.3.21 Open factory menu

The factory menu is password protected. Only the manufacturer is allowed to
access the factory menu.
9.4 Check safety devices

Information about type and position of the machine's safety devices: See Safety
equipment and protective devices [} 21]. Check the machine's safety devices at
least once a day.
DANGER
Standstill of the Machine
Sudden standstill of the machine can endanger persons. Check safety devices
only under the following conditions:
ü The machine is running idle.
ü There is no load hanging at the machine.
ü There is no danger caused by stopping the engine and as a consequence the
loss of hydraulic energy.
1. Perform the following tests:
EMERGENCY STOP
ü The engine is started.
1. Press the EMERGENCY STOP button.
ð The engine has to stop immediately.
Perform this test for each EMERGENCY STOP button at the machine and the re-
mote control.
9.5 Start pulling mode
WARNING
Rope Rupture Caused by an Incorrect Set Overload Protection
If the rope gets blocked unexpectedly during stringing operation (e.g. when it
clamps in a rope guide or because of a stoppage of the other machine which
tensions the rope) and therefore the machine pulls stronger on the rope the
rope can crack.
Cracking rope can cause severe or fatal injuries to persons because of flagelli-
form movements.
The overload protection of the machine prevents the rope from being strained
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too strong. The max. pulling force, at which the overload protection interrupts
the stringing operation, has to be verified for the rope and must be set from the
user in the machine control system.
1. Only start the pulling mode if the value of the overload protection is set
correctly. For setting the value see section Set overload protection.
After each restart of the engine, the control unit automatically initiates pulling
mode for reasons of safety. In pulling mode with the engine running idle the
bull wheels are blocked until the joystick ROPE DIRECTION is moved.
Switching from tensioning mode into pulling mode

ü The engine is running.
ü The bull wheels are standing still.
1. Press the PULLING MODE button.
ð The machine is working in pulling mode.
ð The PULLING MODE button is lit.
ð The machine blocks the bull wheels until the joy ROPE DIRECTION is moved.
Control Rope Direction and Rope Speed
NOTICE
Handle operating elements sensitively
The machine's working speed, work direction and forces exerted may not be
abruptly changed by the user. The operating elements intended for this control
these functions in a variable manner. Carry out all changes in small steps and
with careful steering movements, always allowing time for the machine to re-
spond. Avoid hectic operation and excessive typing.
Define the direction and speed of rope movement in pulling mode using the
ROPE DIRECTION joystick.
9.6 Start and stop tensioning mode
NOTICE
Set tensioning of the drum stand
An important condition for tensioning is that the drum stand sufficiently ten-
sions the rope between drum stand and machine and therefore pretensions the
rope. For this see the instructions of the drum stand.
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Start tensioning mode

ü The bull wheels are standing still.
ü The drum stand’s tensioning is set.
ü The machine is in pulling mode.
1. Press the TENSIONING MODE button.
ð The TENSIONING MODE button flashes.
ð The machine blocks the bull wheels.
2. Set desired tensioning force with TENIONING FORCE potentiometer
[} 99].
ð The defined tensioning force is shown on the display.
3. Press the TENSIONING MODE button again.
ð The machine is working in tensioning mode.
ð The machine releases the grooved wheels.
ð The TENSIONING MODE button glows continuously.
Stop Tensioning Mode

ü The stringing operation was stopped by the other, pulling machine (puller).
1. Press the PULLING MODE button
or
press the IGNITION OFF button.
ð The machine blocks the bull wheels.
ð The tensioning mode is stopped.
9.7 Adjust tensioning force
Adjust tensioning force

Define the tensioning force in tensioning mode using the TENSIONING FORCE
potentiometer. The higher the tensioning force the lower the rope sag.
Set tensioning force for a rope which is not under tension.

1. Turn the potentiometer into the left, minimum position.
2. Start tensioning mode.
3. Turn the potentiometer to the right (clockwise direction) until the rope
has the desired sag.
4. Start stringing operation.
Set tensioning force for a rope which is under tension.

1. Turn the potentiometer into the right, maximum position.
2. Start tensioning mode.
ð The bull wheels turn slowly and pull in rope.
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3. Turn the potentiometer to the left (counterclockwise) until the bull

wheels stand almost still.
4. Start stringing operation.
9.8 Position the rope

Principle The rope to be installed is generally too rigid for being positioned around the
bull wheels by hand. Therefore, a flexible auxiliary rope made of synthetic fiber
is first routed around the bull wheels. The end of the auxiliary rope is attached
to the beginning of the rope. The machine is then used to slowly route the aux-
iliary rope out of the machine. The auxiliary rope thereby pulls the rope until the
rope is finally completely positioned in the grooves of the bull wheels.
Number of turns
DANGER
Danger arising from not enough or too many turns
The auxiliary rope or the rope is coiled around the bull wheels in multiple turns.
If there are not enough turns, the friction between bull wheel and the rope can
be insufficient. The rope then slips during the stringing operation and cannot be
sufficiently tensioned in the worst case. The rope can then sag to the ground
and cause severe injuries to persons. If the rope is slipping both the rope and
the groove profile get damaged.
If there are too many turns the machine gets overloaded and get damaged.
Both variants can compromise safety during stringing operation, can result in
people being severely or fatally injured, and can damage the rope or the ma-
chine.
The rope runs alternately over the outer side of one bull wheel and then over
the outer side of the other bull wheel. At each direction change, the rope com-
pletes half a turn. This is applicable to the number of turns: two half turns make
one full turn.
If the operator of the machine, the manufacturer of the rope, or other regula-
tions applicable to the place of installation do not stipulate otherwise, the fol-
lowing number of turns is applicable:
n Minimum:
Route the rope around the bull wheels using no less than 3 turns.
If rope feed and rope outlet are on the same machine side (option): Route
the rope around the bull wheels using no less than 2.5 turns.
n Maximum:
Route the rope around the bull wheels not exceeding 5 turns.
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Example
Fig. 27: Turns: Example for Four Turns
In the figure (example), all eight half turns are shaded black. These eight half
turns make four full turns.
Fig. 28: Turns: Example for 2.5 turns ( with rope feed on the back side, option)
Right-hand-lay or left- If the rope runs over the grooves of the bull wheels, a twist occurs in the rope.
hand-lay rope The rope is marginally skewed into the twist. The individual strands of the rope
may not be opened out by the twist. Therefore, observe the direction of the
thread pitch in which the rope is positioned around the bull wheels. The follow-
ing apply:
n Route the right-hand-lay rope around the bull wheels like a left-hand
thread.
n Route the left-hand-lay rope around the bull wheels like a right-hand
thread.
If it is not known whether a left-hand-lay or right-hand-lay rope is involved, re-
quest this information from the rope manufacturer.
As a rule, the rope can be positioned onto the machine from two sides: From
the direction of the rope feed or from the direction of the rope outlet. In the fol-
lowing the positioning of rope is described from the rope feed direction. Posi-
tioning the rope from the rope outlet direction occurs correspondingly reverse.
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Position a right-hand-lay rope

Position the right-hand-lay rope onto the two bull wheels such that the rope ef-
fects a left-hand thread while coiling around the bull wheels.
Fig. 29: Position a right-hand-lay rope
Checking whether the right-hand-lay rope has been correctly posi-

tioned:
1. Stand adjacent to the machine, look head-on at the bull wheel and imagine
following the rope clockwise. The rope spirals towards the observer.
2. Look beyond the machine in the direction of the first mast: The rope comes
into contact with the bull wheel further away first on the left, coils in multiple
turns from left to right over the bull wheel and exits the more proximal bull
wheel on the right in the direction of the mast.
Position a left-hand-lay rope

Position the left-hand-lay rope onto the two bull wheels such that the rope ef-
fects a right-hand thread while coiling around the bull wheels.
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Fig. 30: Position a left-hand-lay rope
Checking whether the left-hand-lay rope has been correctly posi-

tioned:
1. Stand adjacent to the machine, look head-on at the bull wheel and imagine
following the rope clockwise. The rope spirals away from the observer.
2. Look beyond the machine in the direction of the first mast: The rope comes
into contact with the bull wheel further away first to the right, coils in multiple
turns from right to left over the bull wheel and exits the more proximal bull
wheel to the left in the direction of the mast.
Position the auxiliary rope and pull in rope
WARNING
Moving rope
Rubbing ropes can cause skin abrasion, burnings, stab wounds or cuts at hands.
Crushing hazard and entanglement of fingers, hands or limbs at rope-guidance
rollers and bull wheels.
2. When equipping the machine, make sure that it is protected against unin-
tentional operation.
The following are required to position the rope using an auxiliary rope:
n A second person
n An auxiliary rope made of synthetic fiber that is approx. 50 meters long
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n A fixed joint. Maximum diameter of the rope connector: Refer to the ma-
chine's type plate or technical data.
Position the auxiliary rope around the bull wheels.

ü The machine is switched off and secured against inadvertent restart.
1. Route the auxiliary rope over the rope feed rollers.
2. Route the auxiliary rope around the bull wheels in a spiral formation.
Note the direction of the thread pitch.
Lift off the pressure rollers manually. If necessary, use a length of tubing
to extend the lever.
3. Route the auxiliary rope over the rope outlet rollers.
ð The auxiliary rope is ready to draw in the rope.
If multiple ropes are to be installed using the machine, position an auxiliary rope
for each one.
Connecting the Auxiliary Rope to the Rope

Connect the auxiliary rope to the rope using a fixed joint.
Fig. 31: Auxiliary Rope and Rope Connector
1 Auxiliary rope, positioned on 2 Fixed joint between auxiliary

bull wheels. rope and rope.
3 Rope on the rope drum.
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WARNING
Danger arising from a engine that is starting up
As soon as the drive engine has started, hydraulic pressure is produced. Parts of
the machine, and components attached to the machine, can unexpectedly start
to move. The rope between the machine and the drum stand can suddenly whip
up. Crushing hazard and entanglement of fingers, hands or limbs at rope-guid-
ance rollers and bull wheels. A rope that suddenly whips up can result in severe
or fatal injuries.
Before starting up the engine, note the following:
1. You must be familiar with all the functions and operating elements of the
machine and the components attached to it. To ensure this, read the in-
structions, particularly the safety instructions and the chapter on handling
and operation of the machine.
2. Adjust all operating elements of the machine such that the machine does
not cause any unexpected movements upon being started up.
3. Remove all persons from the danger zone of the machine.
Pull the rope into the machine.

While the machine is pulling the rope in, another person must maintain tension
on the auxiliary rope. To do this, the person concerned must stand on the side
of the rope outlet and apply force to pull out the auxiliary rope of the machine.
Ensure that the rope that has been pulled in does not spring out of the grooves.
ü The drum stand is switched to free wheel.
1. Switch on the machine.
2. Start the engine.
ð The machine is in pulling mode.
3. Tilt the operating element slowly to the right or upward in order to pull
out the rope.
ð The bull wheels are driven forward and propel the auxiliary rope out of
the machine. The auxiliary rope thereby pulls the rope.
4. Once the rope has been completely pulled in and is routed over the last
rope-guidance roller, stop the machine. To do this, move the operating
element to a neutral position.
5. Stop the drive engine.
6. Switch off the machine and secure it against inadvertent restart.
7. Disengage the auxiliary rope from the rope.
ð The rope is positioned on the machine.
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9.9 Connect ropes

Rope connectors are not within the scope of supply of this machine. The regula-
tions in respect of the connector's safe mechanical working load applicable at
the site of deployment must be observed.
Swiveling Connector
In order to connect the pulling rope with the conductor, use a swivel joint.
The swivel joint is not permitted to transfer torsions arising from the pulling
rope to the conductor. For this reason, the swivel joint must rotate easily even at
full load.
The bull wheels must not be traversed by a swivel joint.
Fixed joint
Use a fixed joint to connect the auxiliary rope to the conductor when position-
ing the conductor.
The bull wheels may be traversed by a fixed joint.
Pulling Grip / Connection Grip
Use a pulling grip to connect the conductor with a rope connector.

Use a connection grip to connect the conductor with another conductor.
The bull wheels may be traversed by a pulling grip or connection grip. If the
pulling grip / connection grip has a spliced eye bolt, no other measures need to
be taken to traverse the bull wheels. A pulling grip / connection grip with a
pressed sleeve must be prepared as described below before traversing the bull
wheels.
Pulling grip with pressed

sleeve – Attention!
Fig. 32: Pulling grip with pressed sleeves: Critical zone when traversing the bull wheels
If the pulling grip / connection grip has a pressed sleeve, there is a significant
difference in diameter between the pressed sleeve and rope. When traversing
the bull wheels, the pulling grip lifts the rope off at the end of the pressed
sleeve and stretches the rope intensively at these points. In order to keep this
load to a minimum, slip a rubber hose that has been slit open over the thinner
zone "x". The diameter of the rubber hose must be roughly the same as the di-
ameter of the pressed sleeve.
9.10 Control rope sag
Increase or decrease sag

ü Stringing operation has been stopped.
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1. Start pulling mode.

2. Increase hydraulic pressure for the drum stand in pulling mode. For ref-
erence values, see Operate reel winder / drum stand [} 109].
3. Tilt the joystick/ROPE DIRECTION operation lever in the desired direction
and adjust the sag of the rope.
Before switching to tensioning mode, readjust the hydraulic pressure for the
drum stand to tensioning mode.
Gradually increase or decrease the sag in tensioning mode.
WARNING
Danger arising from rope slippage
If the rope slips on the bull wheels, the machine can no longer exert full force on
the rope. Consequently, the rope can unexpectedly plunge and cause injury.
Rope slippage damages the grooves of the bull wheels. This results in replace-
ment of the groove profiles and machine failure.
1. Immediately increase the pre-tension of the rope between the machine
and the drum stand as soon as the rope begins to slip on the bull wheels.
2. During the entire stringing operation, ensure that the rope does not slip on
the bull wheels.
ü The machine is working in tensioning mode.

1. Gradually decrease the sag: Increase hydraulic pressure for the drum
stand in tensioning mode. For reference values, see Operate reel winder /
drum stand [} 109].
2. Gradually increase the sag: Decrease hydraulic pressure for the drum
stand in tensioning mode. For reference values, see Operate reel winder /
drum stand [} 109].
Manually increase the sag of a single rope
WARNING
Crushing hazard and risk of being pulled in between the rope and
the bull wheel
In the course of rope setup operations, there is a significant risk of injury arising
from crushing and ingress wherever the rope runs onto a bull wheel. Crushed or
separated fingers or limbs, and minor to severe injuries, can result.
1. Wear your personal protective equipment: protective gloves, close-fitting
work gear, and a hair net if necessary.
2. Ensure that your fingers and limbs never enter the area between the rope
and the bull wheel.
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ü Stringing operation has been stopped.

1. Set the operating lever of the drum stand to FREE WHEEL.
ð The rope drum on the drum stand can be rotated freely.
2. Push the rope out of the drum stand in the direction of the rear bull
wheel.
ð This gives rise to slackness in a section of the rope.
3. Lift up the rope in the first groove between the bull wheels below.
4. The slack section of the rope is drawn around the rear bull wheel.
5. Repeat this procedure with the remaining grooves until the slack section
of rope exits the front bull wheel and the sag of the rope has increased.
6. Repeat this entire procedure until the rope has attained the desired de-
gree of sag.
9.11 Prevent rope problems

Conductors with a relatively loose outer layer are prone to Bird-caging. If a con-
ductor bird-cages during stringing operation:
1. Stop stringing operation.
2. Increase the hydraulic pressure at the drum stand so as to increase the
pre-tension between the machine and the drum stand.
3. Wind the rope up onto the drum stand again in pulling mode.
ð The outer layer of the rope is made rigid again by being wound up. The rope
can subsequently be pulled out again. Observe the following guidelines when
doing this.
In order to prevent bird-caging, observe the following guidelines:

n User a swivel joint.
The rope connector must rotate easily even at full load.
n Optimize the orientation of the machine.
The rope running from the drum stand to the machine must approach the
machine in as straight a line as possible. The rope running from the machine
to the mast must approach the rope pulley block at the first mast in as
straight a line as possible.
n Optimize the orientation of the rope pulley block at the first mast.
Suspend the rope pulley block such that the rope is fed into the deepest
point of the groove. The rope is not to be laterally fed onto the grooved wall
of the rope pulley block because the rope will be skewed.
n Install the drum stand as far away from the machine as possible.
The maximum clearance is prescribed by the length of the connecting hy-
draulic hoses and by the construction site surroundings.
n Carry out stringing operation with the greatest possible rope sag.
n Increase the hydraulic pressure for the drum stand.
At no time the rope may slip on the bull wheels.
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n Release the fastening of the conductor end on the rope drum.

The conductor end must be able to be turned and taken in by the rope
drum during rope unwinding. To do this, remove the fastening medium with
which the conductor end is secured to the rope drum's flange for purposes
of transportation.
9.12 Operate external components
9.12.1 Operate reel winder / drum stand

To operate the reel winder / drum stand: See the separate instructions.
A connected reel winder / drum stand can be controlled as follows by the ma-
chine.
Operating ele- Icon Impact exerted Impact exerted

ment on the connected on the connected
reel winder drum stand
Operating lever in The reel can be The rope drum can
the FREE WHEEL freely rotated. be freely rotated.
position.
Operating lever in The reel is hy- The rope drum is

the DRIVE position. draulically pow- hydraulically pow-
ered. The rope be- ered. The drive's
tween the reel direction of rota-
winder and the tion is the opposite
machine is ten- of the direction of
sioned if the reel rotation in which
winds up the rope the machine pulls
more quickly than the rope from the
the machine lets it rope drum. The
out. drum stand brakes
the rope drum and
maintains tension
on the rope be-
tween the drum
stand and the ma-
chine.
Star grip. The higher the hy- The higher the hy-
Optional: draulic pressure, draulic pressure,
Potentiometer on the higher the the higher the
the control desk or driving force at the driving force at the
on the remote reel winder and drum stand and
control. the pre-tension of the pre-tension of
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Operating ele- Icon Impact exerted Impact exerted

ment on the connected on the connected
reel winder drum stand
Turning clockwise the rope between the rope between
increases hydraulic reel winder and drum stand and
pressure; turning machine. machine.
counterclockwise
reduces hydraulic
pressure.
Adjusting Hydraulic Pressure for the Reel Winder / Drum Stand

The following values are reference values for adjusting hydraulic pressure in ten-
sioning mode or in pulling mode. Depending upon the rope diameter and the
weight of the rope drum, the requisite pressure may also be higher or lower
than the values provided below. If the rope starts to slip on the bull wheels, in-
crease the hydraulic pressure for the reel winder / drum stand and, thus, the
Pre-Tension .
Operating mode Reference Values for Hydraulic Pres-

sure
Tensioning mode 80 – 120 bar
Pulling mode 120 – 160 bar
WARNING
Danger arising from rope suddenly whipping up
Working in the immediate vicinity of the machine when the engine is running is
hazardous. If, in the course of such work, the bull wheels or the drum stand are
inadvertently put into motion, the machine tautens the rope to the front and
rear of the machine. The rope can thereby suddenly whip up and knock over or
injure people, Equipment securely suspended from the rope can be spun away.
Abrasions, contusions, crushing, broken bones, and severe to fatal injuries are
possible.
If persons are required to work in the immediate vicinity of the machine, ob-
serve the following:
1. Do not initiate operations with the machine. The machine may be operated
only if there is no-one within the danger zone around the machine.
2. Do not activate any operating elements on the control desk or on the re-
mote control that put the reel winder / drum stand or the bull wheels of
the machine in motion. Ensure that no other persons activate such operat-
ing elements, either.
Check pretension force

ü The rope is positioned on the machine.
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ü Tensioning mode has been initiated.
ü Stringing operation is not taking place. The bull wheels are standing still.
1. Pull the rope between the machine and the reel winder / drum stand
downward by hand and release it again.
ð The drive of the reel winder / drum stand slowly pulls the rope upward again.
The rope is re-tensioned.
If the reel winder / drum block does not re-tension the rope, increase the hy-
draulic pressure for the reel winder / drum stand. Check the pre-tension again.
10 Servicing and troubleshooting
10.1 Error codes of the control unit
10.1.1 Help for error codes

The following error code table contains information about:
n Error code
n Error class
n Location where the error can occur.
n Possible error cause.
n Possible suggestion to eliminate the error.
10.1.1.1 Meaning of the 3 error classes

The error class of each error code is indicated in the second column of the error
code table, which is a combination of digit and icon:
1 ,2 or 3 .
The following 3 safety warnings describe the meaning of each error class and
the necessary measures for each to be carried out by the user.
NOTICE
Error class 1
General error without impact to the machine’s safety.
1. Eliminate the error as soon as possible.
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CAUTION
Error class 2
The machine can possibly not be operated safely. Ignoring this error can cause
injuries to persons.
1. Terminate the current operation as fast and careful as possible.
2. Only switch on the machine again if the error is eliminated.
WARNING
Error class 3
The machine can not be operated safely. Certain functions can be operated only
in a limited manner or not at all. Ignoring this error can cause injuries or death
to persons.
1. If the engine is still running: Terminate the current operation as fast and
careful as possible.
2. Only switch on the machine again if the error is eliminated.
10.1.1.2 Error code table

Code EC Location Possible cause Possible corrective measure
1 2 Engine Charge air pressure too high. Contact engine manufacturer.
SPN 102, FMI 2
2 2 Engine Charge air too hot. Clean charge air cooler.
SPN 105, FMI 0
3 3 Engine Coolant too hot. Clean the cooler.
SPN 110, FMI 0
4 2 Engine Not enough coolant. Stop engine.
SPN 111, FMI 1 Add coolant.
5 2 Engine Speed sensor: Signal defective. Contact engine manufacturer.
SPN 190, FMI 8
6 2 Engine Speed sensor: No signal. Contact engine manufacturer.
SPN 190, FMI 12
7 2 Engine Speed sensor: Deviation too Contact engine manufacturer.
SPN 190, FMI 2 large.
8 2 Engine Water in fuel. Drain condensed water at fuel
SPN 97, FMI 3.4 pre-filter.
Use appropriate fuel.
9 2 Engine Primary pressure of fuel too Contact engine manufacturer.
SPN 94, FMI 1 low.
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10 3 Engine Fuel too hot. Contact engine manufacturer.
SPN 174, FMI 0
11 2 Engine Oil pressure too high. Contact engine manufacturer.
SPN 100, FMI 0
12 2 Engine Oil pressure too low. Check oil level.
SPN 100, FMI 1
13 3 Engine Oil too hot. Contact engine manufacturer.
SPN 175, FMI 0
14 2 Engine Not enough oil. Stop engine.
SPN 98, FMI 1 Top up with oil.
15 2 Engine Air filter: Differential pressure Clean or replace the air filter.
SPN 107, FMI 0 too high.
50 3 Engine Other engine error. Contact engine manufacturer.
100 3 CAN Disturbed communication. Check fuses and wiring.
EMR2 / EMR3 / EMR4
Display
Node ID 32, Module CR2012
remote control
108 3 Program PLC Radio contact: Disturbed com- Reduce distance between radio
Side 1 munication. remote control and machine.
109 3 Program PLC Radio contact: Disturbed com- Reduce distance between radio
Side 2 munication. remote control and machine.
Node ID 52, joystick 1
Node ID 22, remote diagnosis
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Node ID 21, drum stand drive Disconnect connection and
CR2530 control drum stand manually.
120 2 CR0232 / CR0032 No contact. Check fuses and wiring.
System pressure sensor 1
121 2 CR0232 / CR0032 Short circuit. Check wiring.
System pressure sensor 1 Replace sensor.
122 2 CR0232 / CR0032 No contact. Check fuses and wiring
Pressure sensor rope in (1)
Pressure sensor rope in (1) Replace sensor.
Pressure sensor rope out (1)
Pressure sensor rope out (1) Replace sensor.
Temperature sensor oil
Temperature sensor oil Replace sensor.
Level sensor fuel tank
Level sensor fuel tank Replace sensor.
Boost pressure sensor 1
Boost pressure sensor 1 Replace sensor.
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B 1500/14 Tensioner

Boost pressure sensor 2
Boost pressure sensor 2 Replace sensor.
Pressure sensor release brake 1
Pressure sensor release brake 1 Replace sensor.
Pressure sensor release brake 2
Pressure sensor release brake 2 Replace sensor.
Ultrasonic sensor upper winch
Ultrasonic sensor upper winch Replace sensor.
Ultrasonic sensor lower winch
Ultrasonic sensor lower winch Replace sensor.
Pressure sensor reel
Pressure sensor reel Replace sensor.
150 3 CR0232 / CR0032 Temperature hydraulic oil too Check:
Program PLC high. Oil cooler function?
Stringing speed too high?
151 2 CR0232 / CR0032 Disturbed communication Check wiring.
Program PLC (Synchro Couple).
152 3 CR0232 / CR0032 Boost pressure 1 too low. Contact ZECK service.
Program PLC
153 3 CR0232 / CR0032 Boost pressure 2 too low. Contact ZECK service.
Program PLC
154 2 CR0232 / CR0032 Error direction recognition PSL Check wiring.
Program PLC valve, signal from 2 directions Replace path recognition PSL
valve.
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B 1500/14 Tensioner

167 2 CR0232 / CR0032 Engine protection triggered. Contact ZECK service.
Program PLC
168 2 CR0232 / CR0032 Thermistor protection trig- Let the engine cool down.
Program PLC gered.
169 2 CR0232 / CR0032 Wrong phase rotation. Check electrical connection:
Program PLC Right-hand phase rotation re-
quired.
170 1 CR1083 / OPUS A3 Error while writing a file, dis- Copy saved files to an USB
Program Display play memory full. flash drive and delete them
from display memory.
171 2 CR0232 / CR0032 Pressure too low. Contact ZECK service.
Pressure sensor reel
172 2 CR0232 / CR0032 Error linear engine spool Contact ZECK service.
Linear motor spool winder winder.
173 2 CR2530 No contact. Check fuses and wiring.
Pressure sensor drum stand 1
174 2 CR2530 Short circuit. Check wiring.
Pressure sensor drum stand 1 Replace sensor.
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B 1500/14 Tensioner

Ultrasonic sensor drum stand 1
Ultrasonic sensor drum stand 1 Replace sensor.
Control hydraulic rope in for
bull wheel 1
bull wheel 1
bull wheel 2
bull wheel 2
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B 1500/14 Tensioner

bull wheel 3
bull wheel 3
bull wheel 4
bull wheel 4
Control hydraulic rope out for
bull wheel 1
bull wheel 1
bull wheel 2
bull wheel 2
bull wheel 3
bull wheel 3
bull wheel 4
bull wheel 4
Proportional valve oil cooler
Proportional valve oil cooler
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Control hydraulic tensioning
force for bull wheel 1
Drum stand 1 pre-tension
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Non-return valve rope out 1.1
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Torque switch bull wheel front
Torque switch bull wheel front
Torque switch bull wheel rear
Torque switch bull wheel rear
Proportional valve force con-
trol drum stand 1
trol drum stand 1
trol drum stand 2
trol drum stand 2
11 Maintenance
11.1 Qualifications
Personnel commissioned with servicing and maintenance tasks must have
knowledge and experience with all relevant regulations and be able to perform
all delegated tasks and recognize and avoid danger independently due to their
technical education. Servicing and maintenance personnel is specialized in the
referring working area and know the relevant standards and regulations.
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11 | Maintenance
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The operating company must make sure that the assigned staff is competent for
executing the work.
11.2 Machine maintenance plan

The maintenance work specific to the machine is described in the section Main-
tenance work. (The maintenance work specific to the drive engine is described
in the maintenance instructions of the engine manufacturer.)
Immediately address any malfunctions detected or have defects repaired by
specialist personnel.
Interval Maintenance work

Daily Inspect the machine visually
Check fuel, coolant, engine oil and hydraulic oil fill
levels
If available: Load rechargeable battery of radio re-
mote control.
Weekly Lubricate the machine
Clean the cooler
Annually Change the hydraulic oil and the hydraulic oil filter
or every 500 Gear oil: Check filling level
hours of operation
Check the gas pressure springs of the cover flaps
Check hydraulic hoses
Check the tread of the grooves
Every two years Replacing the gear oil
or every 1000
operating hours
Every 10 years Replace hydraulic hoses
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11 | Maintenance
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11.3 Maintenance work
11.3.1 Inspect the machine visually
WARNING
Using the machine in an unsafe condition
Severe or fatal injury to persons is possible if machines are used in an unsafe
condition.
1. Prior to each use, check the machine for visible damage.
2. Only switch on the machine if structural frame elements as well as hy-
draulic and electrical components are undamaged.
3. Only switch on the machine if all safety and operating elements are freely
accessible and functional.
4. Only switch on the machine if no leakages of operating materials and sup-
plies are apparent.
5. Only switch on the machine if the filing levels of operating materials and
supplies are sufficient.
Always perform a visual inspection before starting to operate the machine. Elim-
inate any detected faults immediately or have qualified personnel do this for
you. Only operate the machine when safe operation is guaranteed.
Check the following features with special care:
n Machine is supported sturdy and anchored tightly
n Structural frame elements are not damaged or cracked
n All safety-relevant elements of the machine are freely accessible
n All operating elements of the machine work properly
n There are no loose screw joints
n No damages and abrasions at electrical and hydraulic components and con-
nections
n No leakages at the following elements:
n Engine (fuel, coolant, engine oil).
n Hydraulic unit and at all hydraulic components (hydraulic oil)
n Gearbox (gear oil)
n Battery (battery acid)

n The following filling levels are sufficient:
n Fuel for engine
n Engine oil for engine
n Coolant for engine
n Hydraulic oil
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11 | Maintenance
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n All operating elements must be free of ice, snow, dirt (especially oil or
grease).
n Operating symbols, warnings and signs must be clearly visible
n Danger zone around the machine is secured
11.3.2 Clean the machine
NOTICE
Prevent water and dust from penetrating at bearings
Untimely bearing failures due to corrosion and wear caused by abrasion are
possible.
1. Never aim a pressure washer or compressed air directly at the bearings.
NOTICE
Do not use road salt
Road salt attacks bare metal parts. Together with melt water, road salt can cause
and speed up the corrosion of components.
1. For removing snow and ice from the machine, do not use road salt or any
other chemical agents.
2. Just remove snow an ice mechanically e.g. with a broom or snow shovel.
NOTICE
Dispose of operating and cleaning materials as well as utilities in an
environmentally sound manner
Soiled utilities are not general waste.
Coolants, cleaning agents, oil and grease can cause serious environmental dam-
age if they enter wastewater or groundwater.
1. Dispose of all waste products in an environmentally sound manner and in
accordance with the regulations.
Use the following materials to clean the machine:

n Soft, non-fibrous and non-abrasive cloths or cleaning rags.
n Solvent-free, mild cleaning agents.
n For degreasing machine components: Fresh cleaning solvents.
Clean exposed metal parts and protect them against corrosion with a slightly
oiled cloth or cleaning rag.
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11 | Maintenance
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11.3.3 Lubricate and grease the machine

Before lubricating and greasing, remove all visible residues of old oil and grease.
Keep the lubricating nipples clean. Immediately replace missing coverings of lu-
bricating nipples.
When working near the brake take care that the brake pads and disc remain free
of oil.
Lubricating
This icon indicates that these spots have to be lubricated with lubricating
grease. If there are lubricating nipples apply the lubricating grease with a grease
gun. If there are no lubricating nipples apply the lubricating grease directly.
NOTICE
Use lithium saponified grease
The machine is lubricated with lithium saponified grease ex works. Therefore
continue to use lithium saponified grease only.
NOTICE
Observe maximum lubrication pressure
Maximum pressure when lubricating with grease gun: 15 bar. Avoid higher pres-
sure and impacts when lubricating.
Lubricating
This icon indicates that these spots have to be oiled with oil.
This icon indicates that these spots have to be oiled with spray oil.
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11.3.4 Clean the cooler
WARNING
Hot surfaces on all hydraulic components
Burns to hands and limbs.
All hydraulic parts can become very hot during operation.
1. As far as possible, carry out work when the hydraulic system has suffi-
ciently cooled down.
2. Keep a sufficient distance from hot surfaces.
The cooling fins of all coolers must be free of pollution and damages.
Remove dirt , insects or other particles with compressed air or with a low-pres-
sure water jet.
Carefully straighten out bent fins with a small flat screwdriver.
11.3.5 Check and service batteries
CAUTION
Corrosive battery acid, high electrical current
In the case of a short circuit of the battery, it can overheat and explode. Battery
acid splashing out of the battery can cause severe acid burns of eyes and skin.
Metal objects which short circuit the battery poles become very hot.
1. Observe the accident prevention regulations when handling batteries.
2. Never wear metal rings or jewelery when working on the battery poles.
The batteries are "maintenance-free".
Servicing battery connections:

1. Check the position of the connecting clamps at the battery poles. If nec-
essary, tighten the screw joint at the connecting clamp.
2. Protect battery poles against corrosion: Regularly lubricate with pole
grease.
If the machine will not be put into operation for a long time:
n Disconnect the rechargeable batteries.
n Regularly recharge the batteries in order to prevent them from total dis-
charge and freezing-over at low temperatures.
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11.3.6 Check hydraulic oil filling level, replenish and change oil
WARNING
Unsafe machine if insufficient hydraulic oil
If the filling level of the hydraulic oil is too low, the machine does not function
safely.
1. Detect and eliminate the cause of too low a hydraulic oil filling level.
2. Replenish hydraulic oil in sufficient quantities.
WARNING
Hot liquids
Scalding and severe to fatal injury due to direct contact with hot liquids.
1. If possible, only carry out work when the machine has cooled down.
2. Wear your personal protective equipment: Protective glasses, appropriate
protective gloves.
WARNING
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NOTICE
Fig. 33: Hydraulic tank

An inspection glass (item 4) with two marking lines is located on the outside of
the hydraulic oil tank. The upper line corresponds to the maximum admissible
filling level and the lower line to the minimum.
The hydraulic oil filling level must be between these two markings. If the filling
level is too low, refill.
Replenish hydraulic oil:

ü The drive engine is switched off.
1. Open and remove the screw plug (item 2) on the upper side of the hy-
draulic oil tank.
2. Replenish hydraulic oil up to the maximum marking (oil level inspection
glass).
3. Remount the screw plug on the upper side of the hydraulic oil tank and
tighten by hand.
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Changing the hydraulic oil:
NOTICE
Only use appropriate hydraulic oil
Observe the manufacturer's specifications. See .
ü Increase the hydraulic oil temperature to at least lukewarm by letting the ma-
chine run.
ü The drive engine is stopped and secured against inadvertent switching on.
1. Place an appropriate piece of hose with collecting vessel under the drain
plug.
2. Open and remove the screw plug (item 2) on the upper side of the hy-
draulic oil tank.
3. Open the drain plug and completely evacuate the hydraulic oil of the
tank into the collecting vessel.
4. Close the drain plug.
5. Dispose of old hydraulic oil according to the regulations.
6. Replace the hydraulic oil filter [} 130].
7. Refill with new hydraulic oil.
8. Remount the screw plug on the upper side of the hydraulic oil tank and
tighten by hand.
ð The hydraulic tank is filled with new hydraulic oil.
9. Start the drive engine and load the hydraulic system.
10. Stop the drive engine.
11. Check the tightness and filling level of the hydraulic tank. If necessary, re-
fill a residual quantity of hydraulic oil.
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11.3.7 Replace the hydraulic oil filter
WARNING
Hot liquids
protective gloves.
WARNING
NOTICE
Depending on the machine version, there are one or two hydraulic oil filters. If
there are two filters, replace both filters.
ü The drive engine is stopped and secured against inadvertent switching on.
1. Open and take off the screw plugs (item 2) on the upper side of the hy-
draulic oil filter.
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2. Take off the hydraulic oil filter cap.

3. Take out the used filter unit by pulling it upward and dispose of it ac-
cording to the regulations.
4. Insert a new filter unit.
5. Replace the hydraulic oil filter cap.
6. Mount the screw plugs of the tank cap and tighten.
11.3.8 Check hydraulic hoses
WARNING
Hot liquids
protective gloves.
WARNING
Check hydraulic hoses and Check each hydraulic hose and fitting according to the following questions:
fittings n Is the outer layer damaged by abrasion, cuts or cracks so severely that the
inlay is visible?
n Is the outer layer brittle?
n Is there an unnatural deformation under pressure or without pressure, or
when bending the hydraulic hose?
n Is there a leaky spot?
n Is the hydraulic hose "migrating away" from the fitting?
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11 | Maintenance
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n Is the hydraulic hose clamped and cannot move freely?

n Is there a crushing point or chafe mark on the hydraulic hose caused by a
subsequent reconstruction?
n Has the hydraulic hose been painted? (Identifications and cracks are then no
longer recognizable)
n Is the identification of the hydraulic hose recognizable (indication of the
manufacturer, permissible pressure, year of construction)?
n Is the identification of the fitting recognizable (indication of the manufac-
turer, permissible pressure, year of construction)?
n Is the fitting damaged or deformed?
n Is the fitting corroded?
As soon as one of these questions is answered with "Yes", immediately replace
the respective hydraulic hose or fitting. Correct each cause of damage immedi-
ately.
After checking the hydraulic hoses and fittings, fit the covers again.
Check documents The following documents must be available at the machine:
n Hydraulic diagram
n Parts list with all hydraulic elements
n Instructions or maintenance instructions
Immediately request missing documents from the manufacturer and keep them
with the machine.
11.3.9 Check engine oil level, replenish and change oil

For this, see the separate operating and maintenance instructions of the engine
manufacturer. These instructions are either in the appendix of this document or
are included as a separate printout.
11.3.10 Maintain engine

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11 | Maintenance
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11.3.11 Check, replenish and change gear oil
WARNING
Danger due to engine or gear oil
Oil can become very hot during operation of the machine.
Scalds and severe burns caused by direct contact with hot engine or gear oil.
2. Wear your personal protective equipment: Safety goggles, oil-resistant
protective gloves.
3. Avoid direct contact of the oil with the skin.
4. Immediately consult a physician if oil comes into contact with an open
wound.
NOTICE
NOTICE
Only use appropriate oil
Observe the manufacturer's specifications. See the section on operating materi-
als and supplies.
If it is not possible to move the gearbox into the maintenance position by hand,
start the engine. For all other maintenance work at the gearbox stop the engine.
11.3.11.1 Gearbox with 2 maintenance bores

This instruction is for gearboxes with 2 maintenance bores. Depending on the
type the maintenance bores are located either at the circumference or at the
face of the gearbox. The 2 maintenance bores can stand in 90 degrees or in 180
degrees to each other.
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11 | Maintenance
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Fig. 34: Gearbox with 2 maintenance bores
Checking gear oil:

Check oil level ü One maintenance hole of the gearbox (pos. 1) is in horizontal position (3 or 9
o'clock).
1. Open a locking screw of one maintenance hole and remove it.
2. Check, if the fill level is sufficient: Oil has to reach the lower edge of the
maintenance hole.
3. If the fill level is sufficient replace the locking screw of the maintenance
hole.
Top up with gear oil, if the fill level is not sufficient:

Replenish 1. Add gear oil through the open maintenance hole until the oil is at the
lower edge of the maintenance hole.
2. Renew the joint washer of the locking screw if necessary and close the
maintenance hole with the locking screw.
Change gear oil:

Replace ü The gearbox is at operating state temperature.
ü The maintenance bores of the gearbox (pos. 1) are in horizontal position.
1. CAUTION! Danger caused by hot Oil. Wear oilproof protective work-
ing gloves. Avoid direct contact of oil with skin.
Open and remove both locking screws (pos. 1).
2. Insert appropriate hose part with collecting vessel in one of the mainte-
nance bores.
3. Rotate the gearbox so that one maintenance hole is at the top and one
at the bottom and let the gear oil drain completely.
4. Rotate the gearbox so that the maintenance bores (pos. 1) are in hori-
zontal position.
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5. Renew the joint washer of the locking screw if necessary and close one of
the maintenance bores with the locking screw.
6. Add gear oil through the open maintenance hole until the oil is at the
lower edge of the maintenance hole.
maintenance hole with the locking screw.
Check leak tightness:

Check leak tightness 1. After the next operation check the maintenance bores for leak tightness
again.
2. Re-tighten the locking screws, if necessary.
11.3.11.2 Gearbox with 3 maintenance bores

This instruction is for gearboxes with 3 maintenance bores. Depending on the
type the maintenance bores are located either at the circumference or at the
face of the gearbox.
Fig. 35: Gearbox with 3 maintenance bores
Checking gear oil:

Check oil level ü The drain hole (pos. 3) and the refilll hole of the gearbox (pos. 1) are standing
in vertical position.
1. Open and remove the locking screw (pos. 2) of the inspection hole.
2. Check, if the fill level is sufficient: Oil has to reach the lower edge of the
inspection hole.
3. If the fill level is sufficient replace the locking screw of the inspection
hole.
Top up with gear oil, if the fill level is not sufficient:

Replenish 1. Open and remove the locking screw of the inspection hole.
2. Add gear oil through the open inspection hole until the oil is at the lower
edge of the hole.
inspection hole with the locking screw.
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Change gear oil:

Replace ü The gearbox is at operating state temperature.
ü The drain hole and the replenish hole of the gearbox (pos. 1 and pos. 3) are
standing in vertical position.
ü Position a drain tray for the oil under the drain hole (pos. 3).
1. CAUTION! Danger caused by hot Oil. Wear oilproof protective work-
ing gloves. Avoid direct contact of oil with skin.
Open and remove all locking screws (pos. 1, pos. 2 and pos. 3).
2. Let the oil drain out.
4. Add gear oil through the open inspection hole until the oil is at the lower
edge of the hole.
Check leak tightness:

Check leak tightness 1. After the next operation check the maintenance bores for leak tightness
again.
2. Re-tighten the locking screws, if necessary.
11.3.12 Check coolant level, add and change coolant

11.3.13 Check pneumatic springs

Pneumatic springs at the flaps of the machine cladding ensure that the flaps re-
main open in opened state.
The loading force of the pneumatic springs may decline. If a flap does not safely
remain open replace all pneumatic springs of this flap.
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11.3.14 Check the profiles of the groove treads
Fig. 36: Groove tread profile

1. Check all groove tread profiles of each grooved wheel for damage
(dents, deep furrows).
2. Check for wear and tear of the groove tread profiles: The groove tread
may not approximate the screw heads.
Replace worn or damaged groove tread profiles. Request spare parts and sepa-
rate instructions on the replacement of groove tread profiles from the manufac-
turer.
11.4 Tightening torque shaft screws

For shaft screws of property class 8.8 and a coefficient of sliding friction of 0.15
the following maximum seating torques apply:
Thread Max seating torque in Nm

M8 25
M10 50
M12 87
M14 145
M16 220
M20 430
M24 740
M8x1 28
M10x1.25 53
M12x1.5 92
M16x1.5 230
M20x1.5 480
M24x2 810
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11.5 Operating materials and supplies
Engine oil
Ambient temperature: -10 °C to +40 °C -15 °C to +30 °C -20 °C to +30 °C -30 °C to +30 °C
Arctic kit (optional): Without Without With With
Engine emission level II Engine oil accord- Engine oil according to column B
or IIIA: ing to
column A
Engine emission level Engine oil according to column C
IIIB or Tier 4i:
A B C
ZECK no: 80-2031 80-2033 80-2034
Identification/Qualifica- SAE 10W-40 SAE 5W-30 SAE 5W-30
tion: ACEA E4-99 ACEA E4-99 ACEA E9, API CJ4
MB 228.5 MB 228.5 MB 228.51
MAN 3277 MAN 3277 CAT ECF-3
DEUTZ DQC IV 10 DEUTZ DQC 3LA
Manufacturer and trade names (selection)
AGIP / ENI: I-SIGMA PERFORMANCE I-SIGMA TOP 5W-30 I-SIGMA TOP MS 5W-30
E4 10W-40
ARAL: EXTRA TURBORAL SUPER TURBORAL SUPER TURBORAL LA
10W-40 5W-30 5W-30
AVIA: TURBOSYNTH HT-E TURBOSYNTH HT-U TURBOSYNTH LS 5W30
10W-40 5W-30
BP: VANELLUS E7 Plus VANELLUS E8 Ultra » Castrol
10W-40 5W-30
CASTROL: ENDURON 10W-40 ENDURON PLUS 5W-30 ENDURON LOW SAPS
5W-30
CHEVRON TEXACO LU- URSA SUPER TDX URSA PREMIUM FE URSA ULTRA X 5W-30
BRICANTS: 10W-40 5W-30
EXXON MOBIL: DELVAC XHP LE 10W-40 DELVAC XHP Ultra DELVAC 1LE 5W-30
5W-30
FINKE: AVIATICON FINKO AVIATICON FINKO AVIATICON FINKO SU-
TRUCK LD 10W-40 TRUCK LD 5W-30 PER TRUCK LA 5W-30
FUCHS: TITAN CARGO MC TITAN CARGO SL 5W-30 TITAN CARGO MAXX
10W-40 5W-30
SHELL: RIMULA R6 M 10W-40 RIMULA R6 ME 5W-30 RIMULA R6 LME 5W-30
TOTAL: RUBIA TIR 8900 10W-40 RUBIA TIR 9200 FE RUBIA TIR 9900 FE
5W-30 5W-30
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Gear oil
ZECK no: 80-4011
Identification/Qualification: CLP 320 on the basis of PAO DIN 51517-3
AGIP / ENI: BLASIA SX 320
ARAL: DEGOL PAS 320
AVIA: GEAR RSX 320
BP: ENERSYN HTX 320
CASTROL: ALPHASYN T 320
CHEVRON TEXACO LUBRICANTS: PINNACLE EP 320
EXXON MOBIL: MOBILGEAR SHC 320
FINKE: AVIATICON FINKOL PA 320
FUCHS: RENOLIN UNISYN CLP 320
SHELL: OMALA S4 GX 320
TOTAL: CARTER SH 320
Hydraulic oil
Ambient temperature: -10 °C to +40 °C -15 °C to +30 °C -20 °C to +30 °C -30 °C to +30 °C
Arctic kit (optional): Without Without With With
Mineral: Hydraulic oil ac- Hydraulic oil according to column E
cording to column
D
Biodegradable: Hydraulic oil ac- Hydraulic oil according to column G
cording to column
F
D E Regional G
ZECK no: 80-0031 80-0060 80-0065 80-0064
Identification/Qualifica- HVLP 46 HVLP(D) 32 HEPR 46 HEPR 25
tion: DIN 51524-3 DIN 51524-3 DIN 51524-3 DIN 51524-3
Bosch Rexroth RE
90 220-1
AGIP / ENI: ARNICA 46 PRECIS HVLP-D
32
ARAL: VITAM HF 46 VITAM HF 32
AVIA: FLUID HVI 46 FLUID HVI 32 AVILUB FLUID AVILUB FLUID
PAO 46 PAO 25
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D E Regional G
BP: ENERGOL SHF-HV ENERGOL SHF-HV
46 32
CASTROL: HYSPIN AWH-M HYSPIN AWH-M
46 46
CHEVRON TEXACO LU- RANDO HDZ 46 RANDO HDZ 32
BRICANTS:
EXXON MOBIL: MOBIL DTE 10 Ex- UNIVIS HVI 26
cel 46
FINKE: AVIATICON OEL AVIATICON OEL AVIATICON HE-PR AVIATICON HE-PR
HV 46 HV 32 46 25
FUCHS: RENOLIN B 46 RENOLIN MR 520
HVI
SHELL: TELLUS S2 V46 TELLUS S4 VX 32
TOTAL: AZOLLA ZS 46 EQUIVIS ZS 32
Multi-purpose grease
ZECK no: Loose: 80-6043
Cartridge: 80-6044
Identification/Qualification: KP2K-30
DIN 51502
MB 267
MAN 283 Li-P 2
AGIP / ENI: AUTOL TOP 2000
AVIA: KALZIUM LANGZEITFETT
FUCHS: RENOLIT CA-LZ
Antifreezer
ZECK no: 80-0020
Identification/Qualification: ASTM D3306, D4985, G12+
AGIP / ENI: ANTIFREEZE SPEZIAL
FINKE: AVIATICON LONGTIME COOLANT
TOTAL: GLACELF AUTO SUPRA
Diesel
ZECK no: 80-6010
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Identification/Qualification: DIN EN 590
12 Decommissioning
WARNING
Risks due to residual energies in the machine
After switching off the machine or after stopping the machine in the event of an
emergency, mechanical, hydraulic or thermal residual energies can be present
on or in the machine.
In addition to the countermeasures specified by the manufacturer, countermea-
sures must be taken by the operator. The personnel must be instructed regard-
ing these risks and the countermeasures during orientation.
NOTICE
12.1 Temporary decommissioning

If the machine has to be temporarily decommissioned, implement the following
measures:
Decommissioning for longer than two weeks:

n Disconnect the rechargeable batteries.
Decommissioning for longer than three months:

n Apply preserving agents to all machine parts that are bare and not noncor-
rosive.
n Completely fill the fuel tank in order to prevent the formation of condensa-
tion and corrosion in the fuel tank.
n Remove the rechargeable batteries, store suitably and maintain the full state
of charge.
B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 141 / 147

B 1500/14 Tensioner
n Check the coolant's antifreeze.

n Drive engine: Observe the specifications of the engine manufacturer (see
Appendix).
12.2 Storage conditions

If possible, protect the machine from direct weather influences for purposes of
storage, e.g. in a hall or under a roof. Do not cover the machine with spreads or
tarpaulins as it can become too hot and moist underneath them.
12.3 Permanent decommissioning
12.3.1 Safety during disassembly and disposal

As a rule, the following risks must be factored in when dismantling and dispos-
ing of the machine.
Liquids under pressure

Liquids under high pressure can penetrate the body through the skin and cause
serious injuries.
The following liquids are under high pressure:
n Hydraulic oil
n Diesel fuel
n Coolant
1. Observe maintenance instructions for all pressurized lines and hoses.
2. Never trace leaks with bare hands.
3. Keep the body and face away from leaks.
4. Immediately consult a physician if liquids penetrate the body. Danger of
infection!
5. When working on the cooling system, wait until the engine has cooled
down.
Fuel
Fuel vapors are carcinogenic. If swallowed, fuel can also damage the lungs.
1. Ensure sufficient ventilation and do not inhale vapors.
2. Do not swallow fuel.
3. Avoid skin contact to prevent skin injuries.
142 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

B 1500/14 Tensioner
WARNING
Risks due to residual energies in the machine
After switching off the machine or after stopping the machine in the event of an
emergency, mechanical, hydraulic or thermal residual energies can be present
on or in the machine.
In addition to the countermeasures specified by the manufacturer, countermea-
sures must be taken by the operator. The personnel must be instructed regard-
ing these risks and the countermeasures during orientation.
Safe handling of operating materials and supplies

Inappropriate handling of operating materials and supplies can cause the poi-
soning and death of persons and poses a risk to the environment.
1. Do not store operating materials and supplies in the machine.
2. Dispose of used operating materials and supplies and their containers in
an appropriate manner.
3. Do not allow operating materials and supplies to be released into the en-
vironment.
4. Soak up spilled operating materials and supplies using an absorbent
medium and dispose of it appropriately.
12.3.2 Disassembly
Prior to dismantling:
n Switch off the machine and secure against being switched on again.
n Discharge stored residual energies in the machine.
n Remove operating materials and supplies as well as residual processed ma-
terial and dispose of them in an environmentally sound manner.
Professionally clean and dismantle the modules and structural components. Ob-
serve the applicable occupational health and safety regulations and environ-
mental protection legislation.
12.3.3 Destruction and recycling

n Scrap metal parts.
n Recycle plastic parts.
n Electrical scrap, electronic components, electric cables, rechargeable batter-
ies, operating materials and supplies:
Have these disposed of by authorized specialist companies.
n Once sorted, have remaining components recycled or disposed of.
B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 143 / 147

|
B 1500/14 Tensioner
Glossary
Bird-caging Remote control
Problem occurring with ropes with multiple lay- Control unit enabling the machine to be con-
ers if the outer layer of the rope slackens. trolled from a distance. The remote control com-
municates with the machine control system ei-
Bull wheel ther via cable or via a wireless radio link.
Combination of 2 bull wheels or 2 bull wheel
drives, respectively. Rope
All materials stringed by means of the machine.
Bull wheel For instance, conductor, steel rope, or synthetic
A wheel profiled on the circumferential surface. fiber rope.
The profiles are present in order to increase the
frictional force derived from a rubber coating. Sagging mode
The bull wheel is hydraulically powered/braked. Special operating mode for adjusting the sag of
the rope and pulling rope in at the same time.
Control desk Same like pulling mode.
Control box located on the machine incorporat-
ing the most important operating elements and Stringing operation
display elements. A process by means of which the rope is stringed
over overhead power line towers.
Debug mode
Operation mode in remote diagnosis. In debug
mode the manufacturer can change certain val-
ues of the machine control system via Internet.
Drum stand
Device permitting a rope drum to be pivot-
mounted. The machine rolls away from the rope
drum during rope pulling. The rope drum is
thereby braked by the drum stand.
Machine side
Combination of two bull wheels. See bull wheel.
Pretension force
Tension in the rope part between rope drum /
reel and bull wheel (machine).
Reel winder
Device permitting a reel to be pivot-mounted
and hydraulically rotated. The rope is wound
around the reel.
144 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

|
B 1500/14 Tensioner
Index
D
Debug mode 93
Display information 90
Display operating hours 90
Display software version 90
B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 145 / 147

|
B 1500/14 Tensioner
E
Error
Display current errors 89
Meaning of error codes 90
M
Maintenance
Display next maintenance date 90
Display previous maintenance 95
Reset maintenance message 95
Measuring system
Resetting 89
O
Overload protection
Set value 89
P
Pressure roller
Description 66
Pulling data
Recording, stop recording 89
Save, print, delete 92
Q
Qualifications
Servicing and maintenance 121
R
Remote diagnosis
Switch on/off debug mode 93
Risks 15
Rope
Set diameter 96
S
Safety warnings
Representation 12
Set date 91
Set measuring point interval 93
Set time 91
Switch units 96
146 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

|
B 1500/14 Tensioner
T
Type plate
Information 24
U
USB
Flash drive 92
Printer 92
B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 147 / 147

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STRINGING MACHINES

2 User information ...................................................................................................................... 9

3 Basic safety instructions ........................................................................................................ 14

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 iii

4 Machine description .............................................................................................................. 24

5 Operating and display elements........................................................................................... 39

iv B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

7 Transportation and initial operation ................................................................................... 68

8 Installation and configuration .............................................................................................. 72

9 Handling and operation ........................................................................................................ 84

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 v

vi B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

10 Servicing and troubleshooting ........................................................................................... 111

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 vii

viii B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

1.1 Identification of this document

1.2 Name and address of the manufacturer

1.3 Service telephone number

2.1 About these instructions

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 9 / 147

Target group for these instructions

2.2 Locations in this document

2.3 Illustrations used

Procedural instructions Procedural instructions and system reactions

10 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

ð This is an interim outcome after step 1.

Item numbers Item numbers in figures and text

Digits in icons Digits in display depictions

Operating elements: Names of operating elements

Decimal separators Decimal separators

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 11 / 147

2.4 Terms used

Fig. 1: Bull wheel

Fig. 2: Bull wheel

2.5 Representation of safety instructions

12 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

2.6 Other applicable documents

2.7 Copyright notice

2.8 Copyright of third parties

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 13 / 147

3 Basic safety instructions

3.1 Intended use

Intended use also encompasses the following:

3.2 Reasonably foreseeable misuse

14 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

n Operate the machine only if no combustible or potentially explosive materi-

3.3 Risks when handling the machine

3.3.1 Danger arising from the mechanical system

Stringing operation Moving rope

B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03 15 / 147

Loss of stability Anchoring the machine

3.3.2 Danger arising from electric energies

3.3.3 Danger arising from pressurized media

Pressurized hoses, lines, Liquids under pressure

16 / 147 B 1500_14 Z342_EN (8285 ─ 8292) | Rev.: 2017-03

3.3.4 Danger arising from high temperatures

Hot liquids Hot liquids

Hot surfaces Hot surfaces

3.3.5 Danger arising from operating materials