Condux Tesmec RS20 Instruction Manual

USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL
RS20/RS26 Reel Stand

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Before using a Condux Tesmec RS20/RS26 Reel Stand, operators must read and understand all proce-
dures and safety instructions. Note all safety information on this page, and note specific safety require-
ments as explained by the procedures in this manual.
Failure to follow these instructions could result in serious personal injury or death.
Important Safety Notice
ADVERTENCIA:
Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si
Ud. No comprende las instrucciones favor de consultarle a su jefe.
For questions on:
SAFETY - OPERATIONS - APPLICATIONS
CALL 1-877-854-1750
Save this user’s guide for future reference.
COMMUNICATION WITH THE MANUFACTURER:
For information related to the machine (use, maintenance, spare parts), always state the Model Number,
Serial Number, Manufacturing Year, and Order Number. This information can be found in the
Parts-Identification Table.
Manufacturer:
Condux Tesmec, Inc.
145 Kingswood Drive, Suite 1
Mankato, MN 56002-0668
1-507-387-6576
Fax [phone]
E-mail: [email protected]

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Table of Contents
IMPORTANT SAFETY NOTICE ..............................................2
COMMUNICATION WITH THE MANUFACTURER ...............2
GENERAL INFORMATION..................................................... 4
A. PRODUCT DESCRIPTION...............................................4
B. SAFETY INFORMATION..................................................4
C. OPERATOR INFORMATION ..........................................4
D. GENERAL MAINTENANCE INFORMATION ................4
E. MACHINE USAGE............................................................5
F. RESPONSIBILITY .............................................................5
G. OPERATORS MANUAL................................................5
TECHNICAL SPECIFICATIONS..............................................6
SAFETY CONDITIONS............................................................6
A. SAFETY DEVICES............................................................6
B. PERIODIC OPERATIONS................................................6
C. CAUTIONS & WARNINGS...............................................7
D. PULLING ROPE FAILURE ...............................................7
E. ROTATING COMPONENT, PINCH-POINT HAZARDS ..7
F. CRUSHING INJURY WHEN LOADING OR UNLOADING
ROPE OR CONDUCTOR REELS....................................7
G. ELECTROSTATIC DISCHARGES...................................7
H. INHALATION ENGINE EXHAUSTING GAS....................7
TRANSPORTING .....................................................................8
A. MACHINE LIFTING...........................................................8
B. PACKING FOR SHIPMENT.............................................8
C. UNPACKING .....................................................................8
D. TOWING............................................................................8
OPERATING PROCEDURES..................................................8
A. INITIAL SET-UP ................................................................8
B. REEL INSTALLATION ...................................................10
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2
3
6
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PARTS ...............................................................................14-31
A. REPLACEMENT LABELS ........................................ 14-15
B. RS20 REEL STAND ASSY.........................................16-17
C. RS26 REEL STAND ASSY.........................................18-19
D. CHAIN DRIVE DETAIL ............................................. 20-23
E. HYDRAULIC DRIVE DETAIL ................................... 24-27
F. HYDRAULIC HAND PUMP........................................ 28-31
G. HYDRAULIC CONTROL VALVE............................... 32-33
H. CHAIN GUARD.......................................................... 34-35
I. HOSE RACK/GROUND ATTACHMENT.................... 36-37
J. HYDRAULIC HOSE DETAIL........................................... 38
K. CONTROL VALVE DETAIL.............................................. 39
NOTES...............................................................................30-31
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General Information
A. PRODUCT DESCRIPTION
The RS20 Reel Stand provides up to 20,000 lbs of load capacity. The RS26 Provides
upt to 26,000lbs of load cpapacity. both come equipped with a hydraulic negative
brake, reel arbor bar and hose storage.
B. SAFETY INFORMATION
▪ Only trained and qualied operators should use this machine.
▪ Qualied operators are those persons who have received training from the ma-
chine owner’s company or, alternatively, from the manufacturer.
▪ This machine must be used only for the work it was designed for.
▪ This machine should not be used with unauthorized personnel on the work site.
▪ For any questions regarding operation, function, maintenance, etc., contact the
After-Sales Service of the manufacturer.
C. OPERATOR INFORMATION
▪ Operators must be aware of all local, state and federal safety regulations gov-
erning the use of this equipment.
▪ Operators must wear suitable clothing to reduce the possibility of entanglement
in the machine’s moving parts. They should avoid the wearing of chains, and
other jewelry for the same reason.
▪ Operators must use personnel protective gear (i.e. gloves, boots, helmet, etc.).
▪ Operators must carefully follow hazard related instructions contained in this
instruction manual or indicated on the machine.
▪ This machine’s work area should be free as possible of oil or other liquid spills
as well as materials or equipment that may be considered as an obstacle to
proper operation.
D. GENERAL MAINTENANCE INFORMATION
▪ It is absolutely forbidden to carry out any maintenance, or adjust any settings
on this machine while pulling (except for those indicated in this manual).
▪ Before carrying out any maintenance stop the machine (except for those in-
stances indicated otherwise in this manual) and wait till the system components
subject to heating have cooled sufciently.
▪ All the maintenance performed on this machine must be carried out on a level
surface and while the system is not under load.
▪ Authorized and trained personnel must perform all of the maintenance, both
scheduled maintenance and repair.
▪ Authorized and trained personnel are those persons who have received training
on the maintenance of this equipment from the machine owner’s company or,
as alternative, from the manufacturer.
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▪ Maintenance personnel must wear suitable clothes to reduce the possibility of
entanglement in the machine’s moving parts. They should avoid the wearing of
chains, and other jewelry for the same reason. Operators must use personal
protective gear (i.e. gloves, booths, helmet, etc.).
▪ All maintenance operations, both scheduled and repair must be carried out
per the instructions included in this manual or following technical instructions
provided by the manufacturer. Failure to follow these instructions relieves the
manufacturer from any responsibility and voids their warranty.
E. MACHINE USAGE
▪ The machine must not be used for the following:
▪ For lifting person and/or goods.
▪ For tensioning or pulling.
▪ In a location where the machine cannot be positioned and anchored in a proper
way.
▪ In areas with brush or other materials that can be easily set on re.
▪ In closed/unventilated sites or those poorly ventilated (tunnel or similar).
▪ At sites where fuels or explosives are present.
▪ For structure demolition.
▪ For the pulling of elastic elements.
▪ With over-ridden or broken safety system devices.
▪ For handling trucks or other movable equipment.
F. RESPONSIBILITY
Use of the reel stand in situations different from those indicated (Typology and using
eld), or not described in this manual, is to be considered extremely dangerous and/
or forbidden. Persons not using recommended restraints cause a situation of improper
use, and relive the manufacturer from any responsibility for accidents, injuries to per-
sons or damage to property. The manufacturer’s warranty is also voided. Similarly the
manufacturer’s responsibility ends when the following situations occur:
▪ Tampering and/or modifying of the system without the manufacturer’s written
acceptance (in this case the operator becomes the manufacturer assuming all
obligations and responsibilities, both civil and penal).
▪ The use of non-original spare parts.
▪ Poor maintenance.
▪ Use with disconnected or over-ridden safety devices.
▪ For the connection to machine and/or plans not produced and not directly au-
thorized by the manufacturer in a written acceptance.
G. OPERATORS MANUAL
▪ Information contained in this manual applies to all the operators charged with
the use and/or the maintenance of this machine

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▪ This instruction manual is not a training manual
▪ Before using the machine the job site supervisor and the operators must read
this instruction manual.
▪ All operators user must carefully follow the instructions contained in this manual
▪ Before using the machine the operator must know the positions and the opera-
tion of all controls.
▪ The job site supervisor must verify that the instructions contained in this manual
are applied.
▪ This instruction manual must be kept with the machine, for the entire life of the
machine, so it is available to all potential users and operators.
▪ The instruction manual must be kept in a sheltered and dry place.
Technical Specications
The Condux Tesmec RS20/RS26 Reel Stands were developed for paying in or out
conductor reels when used in conjunction with Condux Tesmec Puller-Tensioners and
Tensioners. Industry leading features like Self Acting Hydraulic Brake and Advanced
Hydraulic
Systems.
Safety Information
A. SAFETY DEVICES
Machine has been equipped with the following safety devices:
▪ A mechanical negative safety brake that stops all movement if hydraulic
pressure is lost.
▪ Where possible, guards and covers are provided to protect personnel from the
moving parts.
!DANGER: It is absolutely forbidden to use this machine with protective
guards removed or with damaged or disconnected safety devices.
B. PERIODIC OPERATIONS
Proper functioning of safety systems should be veried daily.
!CAUTION: Any customer alterations to the provided safety devices relieves
the manufacturer of any responsibility for any resulting damage of property or injury to
personnel.
2. General Specications RS20 RS26
Reel OD Capacity 102 inches 102 inches
Reel Width Capacity 70 inches 72 inches
Weight Capacity 20,000 lbs 26,000 lbs
Total Weight (Skid Mounted) 2,600 lbs 2,600 lbs
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C. CAUTIONS & WARNINGS
When operating this machine users must be aware of other risks associated with the
work for which the machine is intended.
D. PULLING ROPE FAILURE
Obviously this will cause uncontrolled movement of the entire machine. Both this and
the danger then presented by the pulling rope and/or conductor can cause serious
injury or death.
To reduce operator exposure to these dangers owners must:
▪ Regularly check the rope and replace it as soon as defects or signs of wear are
detected.
▪ Assume only the recommended operation positions indicated in this manual.
E. ROTATING COMPONENT, PINCH-POINT HAZARDS
Due to the nature of the work being preformed and important system functionality, it is
possible to fully guard all rotating components. To minimize risks operators must:
▪ Avoid any contact with the machine’s rotating components.
▪ Follow the anchoring instructions described in this manual.
▪ Follow all recommendations in this manual regarding the use of personal safety
equipment.
F. CRUSHING INJURY WHEN LOADING OR UNDLOADING ROPE OR
CONDUCTOR REELS
Operators must know the proper methods for executing these tasks and should be
trained to do them properly.
G. ELECTROSTATIC DISCHARGES
To reduce the risk presented by static electric charge build up in the ropes and conduc-
tors during pulling operations, the machine must be properly grounded. To minimize
these risks operators must:
▪ Be trained in, and apply, the proper methods used to ground the machine
before using the machine.
H. INHALATION ENGINE EXHAUSTING GAS
To minimize these risks operators must:
▪ Assume the proper operating position during operation and use appropriate
safety equipment as needed.

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Transporting
A. MACHINE LIFTING
For machine lifting use only devices (overhead traveling cranes, lift trucks, ropes,
cables, hooks, etc.) with a capacity equal to the weight to be lifted. Personnel should
not be on the machine when it is lifted.
!DANGER: Failure to follow the recommendations in this section may cre-
ate a dangerous situation and/or damage to the machine. The manufac-
turer’s warranty may also become void as a result.
B. PACKAGING FOR SHIPMENT
Transport by land or truck. Certain surfaces may be protected by cardboard and/or ply-
wood and/or polyethylene lm. To prevent movement, use nailed wheel chocks. Attach
the machine to the oor of a truck box or trailer using chains and hooks at the attach-
ment points provided.
C. UNPACKING
When receiving the machine verify the condition of the package; immediately notify
the transportation company and the manufacturer (use photos whenever possible) of
any damage that may have occurred during shipment. Verify that the supplied product
matches that which was ordered; immediately advise the manufacturer if there is a
discrepancy. Use caution when unpacking to avoid damaging the product.
!CAUTION: Disposal of all packaging materials must be in accordance with
local regulations.
D. TOWING
This machine is designed for towing at highway speeds. No personnel may ride on the
machine at any time while towing the machine at ANY speed.
!CAUTION: Always make sure to hook safety chains, attach lights & safety
brake to transporting vehicle before towing machine.
Operating Procedures
!WARNING: the “Freewheel” mode is to be used only for positioning the
reel/drum for loading and unloading. the reel stands are designed to slowly
bleed off pressure form the negative brake for safety reasons. Using the
freewheel mode for extended rotations of the reel/drum can result in dam
age to the negative brake and motor.
It is essential that the RS20 or RS26 are properly set up before operation. Using the
following procedure will allow the unit to be set up in a short period of time and yield
optimum performance.
A. INITIAL SET-UP
1. Locate RS20 or RS26 Reel Stand at least 20-30 feet behind the stringing equip-
ment as the site allows
4.
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2. Securely anchor using the anchor points provided ( Figure 1)
3. Properly ground the reel stand using the grounding connections provided
(Figure 2)
4. Connect the hydraulic hoses to the stringing machine (Figure 3)
5. Secure the area between the stringing equipment and this reel stand to limit
personnel entry.
Figure 1. Anchoring Bracket Figure 2. Grounding Lug
Figure 3. Connecting Hydraulic Hoses

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B. REEL INSTALLATION
1. Ensure that the hydraulic supply from the stringing equipment is shut-off
2. Push in the selector valve handle (Figure 4)
3. Close the valve (clockwise) on the pump (Figure 5)
Figure 4. Push in Selector Valve Handle Figure 5. Close Valve on Pump

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4. Open the Ball Valve (in line with) as shown (see Figure 6)
5. Operate the pump handle until the pressure on the gauge reads approximately
450 PSI. Use caustion as the brake begins to release as the arbor bar will
begin to rotate. (Figure 7)
6. Disengage drive side pin by removing keeper pin and pulling out the drive pin.
(Figure 7 & 8)
7. Remove bearing retainer pin and lift hinged keeper to fully open position.
(Figure 9 & 10)
Figure 9. Remove Retainer Pin from Bearing
Keeper
Figure 10. Open Bearing Keeper to Fully
Open Position
Figure 7. Remove Keeper Pin from Drive Pin Figure 8. Pull Out Drive Pin
Figure 6. Open Ball Valve Figure 7. Pump Handle until Gauge Reads
450 PSI

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8. Repeat number 6 on other side.
9. Remove arbor bar.
10. Remove bearing from arbor bar. (Figure 11)
11. Remove Lifting Bracket using a 1-1/8” wrench (Figure 12)
12. Install Arbor Bar through the reel hole ensuring drive pins engage drive holes
(Figure 14).
Figure 11. Remove Bearing Figure 12. Remove Ling Bracket
Figure 13. Install Arbor Bar

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13. Reverse steps 9 through 11 to install components back onto arbor bar.
14. Once arbor has been secured to the reel, lift the reel utilizing the lifting brackets
and install onto reel stand. (Figure 14)
15. Reference operational label located on the reel stand for brake release.
Figure 14. Load Reel

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CONDUX TESMEC, INC., REEL STAND
REPLACEMENT LABELS
21032700
ITEM PART NO DESCRIPTION QTY
1 02266200 STRIP,ANTI-SLIP FO TRAILER 4
2 02269300 LABEL,WARNING-READ MANUAL 2X6 1
3 02269303 LABEL,WARNING-HYD FLUID 2X6 1
4 02269603 LABEL,WARNING-CAPSTN CATCH 2X6 2
5 02269604 LABEL,WARNING-CABLE TENSION 2X6 2
6 02269731 LABEL,WARNING-STAY CLR 1.5 X 4.5 1
7 02289355 LABEL,LIFT POINT ISO STD 4
8 02289499 TAPE,ABRASIVE ANTISLIP 2IN X 80IN 2
9 02289504 SCREW,DRIVE #4 X 0.375 SS 4
10 02289636 DECAL,CONDUX LOGO BLUE/CLEAR 1
11 02289640 LABEL,GROUND - ISO 1.5 X 1.5 2
12 02289740 TAG,METAL SERIAL NUMBER 1
13 21032542 LABEL,INST-REEL LOADING URW24 1
Parts
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ITEM PART NO DESCRIPTION QTY
1 02266200 STRIP,ANTI-SLIP FO TRAILER 4
2 02269300 LABEL,WARNING-READ MANUAL 2X6 1
3 02269303 LABEL,WARNING-HYD FLUID 2X6 1
4 02269603 LABEL,WARNING-CAPSTN CATCH 2X6 2
5 02269604 LABEL,WARNING-CABLE TENSION 2X6 2
6 02269731 LABEL,WARNING-STAY CLR 1.5 X 4.5 1
7 02289355 LABEL,LIFT POINT ISO STD 4
8 02289499 TAPE,ABRASIVE ANTISLIP 2IN X 80IN 2
9 02289504 SCREW,DRIVE #4 X 0.375 SS 4
10 02289636 DECAL,CONDUX LOGO BLUE/CLEAR 1
11 02289640 LABEL,GROUND - ISO 1.5 X 1.5 2
12 02289740 TAG,METAL SERIAL NUMBER 1
13 21032542 LABEL,INST-REEL LOADING URW24 1
CONDUX TESMEC, INC., REEL STAND
REPLACEMENT LABELS
21032700

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CONDUX TESMEC INC.,
RS20 REEL STAND ASSY (20000LBS)

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ITEM PART NO DESCRIPTION QTY
1 02036601CT 3/4-10 X 4.00 HEX HD CAPSCREW GR8 YZ 2
2 02123904CT 3/4 FLATWASHER TYPEA W CZ 4
3 02129105CT 3/4-10 X 2.00 HEX HD CAPSCREW SS T316 2
4 02200600CT 3/4-10 NYLOC NUT GR5 CZ 10
5 02202701CT 1.00 LOCKWASHER REG CZ 2
6 02266400CT
#10-24 X 0.50 HEX FLANGE HD CAPSCREW GR5
CZ 2
7 02288518CT 3/4 FLATWASHER TYPEA NARR CZ 16
8 02289465CT 1.00-08 X 2.50 HEX HD CAPSCREW GR8 YZ 2
9 02289600CT 3/4-10 HEX JAM NUT CZ 2
10 02289601CT 3/4-10 X 2.25 HEX HD CAPSCREW GR5 CZ 8
11 02289700CT BEARING,MBB 3.500 6.299 3.781 2
12 02289729CT 3/4 X 2.50 QUICK RELEASE PIN 2
13 02290123CT 4IN SHAFT COLLAR-2 PIECE 1
14 02290601CT 1.00 FENDER WASHER CZ 2
15 02290619CT LABEL,MAX LOAD CAP 20000 LBS 4
16 21032541 LABEL,UP DIRECTIONAL URW24 2
17 21032730 4IN ARBOR BAR ASSY - RS20 1
18 21032734 LIFT PLATE ASSY 1
19 21032753 DRUM DRIVE STUD 2
20 21032786 BEARING SADDLE ASSY - RS20 2
21 21032795 4IN DRUM PILOT HUB-NYLON 1
22 21032700SUB REEL STAND-SUBASSY RS20/26 1
21032700 RS20 REEL STAND ASSY (20000LBS)

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CONDUX TESMEC INC.,
RS26 REEL STAND ASSY (26000LBS)

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21034200 RS26 REEL STAND ASSY (26000 LB)
ITEM PART NO DESCRIPTION QTY
1 02036601CT 3/4-10 X 4.00 HEX HD CAPSCREW GR8 YZ 2
2 02123904CT 3/4 FLATWASHER TYPEA W CZ 4
3 02129105CT 3/4-10 X 2.00 HEX HD CAPSCREW SS T316 2
4 02200600CT 3/4-10 NYLOC NUT GR5 CZ 10
5 02202701CT 1.00 LOCKWASHER REG CZ 2
6 02266400CT #10-24X0.50 HEX FLANGE HD CAPSCREW GR5 CZ 2
7 02288518CT 3/4 FLATWASHER TYPEA NARR CZ 16
8 02289465CT 1.00-08 X 2.50 HEX HD CAPSCREW GR8 YZ 2
9 02289600CT 3/4-10 HEX JAM NUT CZ 2
10 02289601CT 3/4-10 X 2.25 HEX HD CAPSCREW GR5 CZ 8
11 02289729CT 3/4 X 2.50 QUICK RELEASE PIN 2
12 02290601CT 1.00 FENDER WASHER CZ 2
13 02290608CT BEARING,MBB 100MM 180MM 98.4MM 2
14 02290609CT 4IN SHAFT COLLAR-HEAVY 1
15 02290620CT LABEL,MAX LOAD CAP 26000 LBS 4
16 21032541 LABEL,UP DIRECTIONAL URW24 2
17 21032734 LIFT PLATE ASSY 1
18 21032753 DRUM DRIVE STUD 2
19 21032795 4IN DRUM PILOT HUB-NYLON 1
20 21034220 4IN ARBOR BAR ASSY - RS26 1
21 21034221 BEARING SADDLE ASSY - RS26 2
22 21032700SUB REEL STAND-SUBASSY RS20/26 1

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CONDUX TESMEC INC.,
CHAIN DRIVE DETAIL - REEL STAND ASSY