Tesmec AFS404 Owner's manual

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ATTENZIONE
Per motivi di sicurezza durante il trasporto la macchina è fornita senza olio idraulico e senza
carburante. Nel presente fascicolo troverete informazioni sulle caratteristiche e le quantità
richieste. In caso di dubbio consultare la TESMEC.
WARNING
The machine is supplied without hydraulic oil and fuel during transport for precautionary
measures. Please refer to this manual for all information regarding the characteristics and
quantities required. Should you have any doubt, please get in touch with TESMEC.
ATTENTION
Pour mesures de sécurité, pendant le transport la machine est livrée sans huile hydraulique
et sans carburant.
Référez-vous à ce manuel pour renseignements nécessaires sur les caractéristiques et
quantités. En cas de doute veuillez contacter TESMEC.
ATENCION
Por motivos de seguridad la máquina se transporta sin aceite hidráulico y sin combustible.
En el presente fascículo encontrarán informaciones acerca de las características y de las
cantidades requeridas. En caso de dudas, consultar a TESMEC.
ATENÇÃO
Por razões de segurança durante o transporte, a máquina é fornecida sem óleo hidráulico e
combustível. No presente folheto poderão encontrar as informações sobre as características
a as quantidades requeridas.
Caso tenham alguma dúvida, rogamos-lhes pôr-se em contacto com a TESMEC.
ACHTUNG
Aus Sicherheitsgründen während des Transportes, wird die Maschine ohne Öl und Kraftstoff
geliefert. Im vorliegenden Gebrauchsanweisungsheft werden Sie Informationen über die
Eigenschaften und Mengen des Öls finden.
Wenn Sie im Zweifel sind, fragen Sie TESMEC um Rat.
ПРЕДУПРЕЖДЕНИЕ
Из соображений безопасности, при поставке машина транспортируется без рабочей
жидкости вгидравлической системе итоплива.
Пожалуйста, пользуйтесь настоящим руководством для получения любых сведений,
касающихся характеристик изаправочных емкостей.
Вслучае каких-либо сомнений, пожалуйста, свяжитесь скомпанией ТЕСМЕК.
- 24050 Grassobbio (Bg) via Zanica, 17/O - 24060 Endine Gaiano (Bg) via Pertegalli
Tel. 0039 / 035 / 4232911 Tel. 0039 / 035 / 825024
Telefax 0039 / 035 / 4522445 Telefax 0039 / 035 / 826375
E-mail: [email protected] E-mail: [email protected]

PULLER-TENSIONER
Model: AFS404
PULLER-TENSIONER
Model: AFS404
Serial number
...........
Manufacturing year
...........
Working order
............
USE AND MAINTENANCE INSTRUCTIONS

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 1 of 35
1. GENERAL INDEX
Page
1. GENERAL INDEX 1
2. GENERAL DATA AND PRESCRIPTIONS 3
2.1 MANUFACTURER 3
2.2 COMMUNICATIONS WITH THE MANUFACTURER 3
2.3 TYPOLOGY AND USING FIELD 3
2.4 PERFORMANCES 3
2.5 TECHNICAL CHARACTERISTICS 4
2.6 ACOUSTIC EMISSION 4
2.7 GENERAL INFORMATION FOR THE MACHINE USE 4
2.8 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE 4
2.9 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE
MAINTENANCE 5
2.10 KNOWLEDGE AND CARE OF THE INSTRUCTION MANUAL 5
2.11 CONDITION OF USE 5
2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL 6
2.13 USE NOT ALLOWED 6
2.14 RESPONSIBILITY 7
2.15 APPLIED NORMS 7
3. TRANSPORT AND POSITIONING INSTRUCTIONS 8
3.1 MACHINE LIFTING 8
3.2 TRANSPORT TYPOLOGIES AND PACKAGE 8
3.3 UNPACKING 8
3.4 ASSEMBLING OPERATIONS 9
3.5 TRANSPORT ON TRAILER 9
3.6 POSITIONING AND ANCHORING 10
4. INSTRUCTION FOR USE 11
4.1 PRESCRIPTIONS FOR THE OPERATOR 11
4.2 CONTROLS 11
4.3 PRELIMINARY OPERATIONS 11
4.4 MACHINE SET-UP 12
4.5 ELECTRONIC MULTI-FUNCTIONS DISPLAY PAGES 13
4.6 STARTING OF THE MACHINE 16
4.7 PULL CONTROL 16
4.7.1 PULL LIMITING DEVICE SETTING 17
4.7.2 PULL PROGRAMMING DEVICE SETTING 17
4.8 CONNECTION MACHINE-HYDRAULIC HEAD OF THE REEL ELEVATOR OR REEL WINDER 18
4.9 PULLING OPERATIONS 18
4.10 RELEASING THE ROPE 19
4.11 COMPRESSOR CONNECTION (OPTIONAL) 19
4.12 PREHEATING KIT (OPTIONAL) 20
4.13 PREHEATING CONTROL PANEL PROGRAMMING (OPTIONAL) 20
4.13.1 GENERAL (OPTIONAL) 20
4.13.2 OPERATION (OPTIONAL) 20
4.13.3 SWITCHING THE HEATER ON (OPTIONAL) 21
4.13.4 SWITCHING THE HEATER OFF (OPTIONAL) 21
4.13.5 SETTING TIME/DAY OF THE WEEK (OPTIONAL) 21
4.13.6 VIEWING THE TIME (OPTIONAL) 21
4.13.7 PROGRAMMING HEATER STARTING TIME (OPTIONAL) 21
4.13.8 RECALLING/ERASING PRE-SET TIMES (OPTIONAL) 21
4.13.9 PROGRAMMING DURATION OF OPERATING TIME (OPTIONAL) 21
4.13.10 SETTING THE REMAINING OPERATING TIME (OPTIONAL) 21
4.13.11 SETTING THE WAKEUP TIME (OPTIONAL) 21
4.13.12 RECALLING/ERASING THE WAKEUP TIME (OPTIONAL) 22
4.14 ROPE LOCKING CLAMP (OPTIONAL) 22
4.15 POINTS TO REMEMBER 22

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 2 of 35
4.16 END OF THE OPERATIONS 22
5. INSTRUCTION FOR USE –CONNECTED MACHINES 23
5.1 GENERAL ASPECTS 23
5.2 MACHINES SET-UP 24
5.3 CONNECTED MACHINES OPERATIONS 26
5.4 PULL CONTROL SETTING 26
5.4.1 PULL LIMITING DEVICE SETTING 26
5.4.2 PULL PROGRAMMING DEVICE SETTING 26
5.5 USING OF ELECTRONIC SPEED SYNCHRONIZER DEVICE (OPTIONAL) 27
5.6 ROPE LOCKING CLAMP (OPTIONAL) 27
5.7 ALARM CONDITION WHEN USING CONNECTED MACHINES 27
5.7.1 STRINGING LENGTH ERROR 27
5.7.2 SWITCH ON THE MACHINE WITH CONTROL NOT IN NEUTRAL 27
5.7.3 EMERGENCY STOP 27
5.7.4 CAN-BUS DIS-CONNECTION BETWEEN THE MACHINES 28
5.7.5 ROPE-CLAMP POSITION 28
5.7.6 GEAR-BOX LOW-PULL POSITION 28
5.7.7 CONNECTION MACHINE SELECTOR 28
5.7.8 COMPONENT FAULT 28
6. SAFETY CONDITIONS 29
6.1 SAFETY DEVICES 29
6.2 EMERGENCY STOP DEVICE 29
6.3 PERIODIC OPERATIONS 29
6.4 RESIDUAL RISKS 30
7. MAINTENANCE 31
7.1 GENERAL PRESCRIPTIONS 31
7.2 LEVELS CONTROL 31
7.3 TYRES INFLATION PRESSURE 31
7.4 SUGGESTED LUBRICANTS 31
7.5 ENDOTHERMIC ENGINE MAINTENANCE 31
7.6 HYDRAULIC CIRCUIT MAINTENANCE 32
7.7 REDUCTION GEAR MAINTENANCE 32
7.8RADIATOR’S MAINTENANCE 33
7.9 GREASING 33
7.10 OTHER PERIODIC OPERATIONS 33
7.11 SUMMARY TABLE FOR ORDINARY MAINTENANCE 33
8. HOW TO DISABLE THE MACHINE 34
8.1 TRANSPORT 34
8.2 EXTENDED SERVICE STOP 34
8.3 STRIPPING 34
9. ENCLOSED DOCUMENTS 35
9.1 TABLES 35
9.2 SYSTEMS 35
9.3 OTHER DOCUMENTS 35

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 3 of 35
2. GENERAL DATA AND PRESCRIPTIONS
2.1 MANUFACTURER
TESMEC S.p.A.
Via Zanica, 17/O
24050 - GRASSOBBIO
BG - ITALY
tel. [phone]
fax [phone]
e-mail: [email protected]
Via Pertegalli, 2
24060 - ENDINE GAIANO
BG - ITALY
tel. [phone]
fax [phone]
e-mail: [email protected]
2.2 COMMUNICATIONS WITH THE MANUFACTURER
For any information related to the machine (use, maintenance, spare parts) always state Model, Serial
Number, Manufacturing Year and Order. These data can be found in the machine-identifying table.
2.3 TYPOLOGY AND USING FIELD
Puller-tensioner mod. AFS404 is suitable for stringing no. 1 or 2 bundled conductors with max.
diameter of 34 mm and for recovering no. 1 or 2 ropes with 16 mm in diameter with a connector with
max. diameter of 48 mm.
The machine is controlled by a hydraulic system that allows the machine to automatically work in
PULLER or in TENSIONER mode.
The power transmission to the large groove bull-wheels is transmitted through a closed hydraulic
circuit with a variable delivery pump and fixed displacement motor, with the possibility to change
continuously the speed in both rotating directions.
A hydraulic vacuum brake stops automatically the two bull-wheels should the work be interrupted and
a damage in the hydraulic circuit occur.
The machine is equipped with rapid couplers for connection to all types of reel winders and reel
elevators made by Tesmec; the frame is complete with a rigid axle for towing at max. 30 km/h.
2.4 PERFORMANCES
PULLER PERFORMANCES
Max. pull 45 kN
Speed at continuous pull 2,9 km/h
Max. speed 5 km/h
Pull at max. speed 25 kN
TENSIONER PERFORMANCES
Max. tension 45 kN
Max. speed 5 km/h
ATTENTION: the use of ropes with smaller diameter will reduce the pulling capacity of
the machine, in accordance with the breaking load of the rope or of the conductor.
Performances are referred to the machine without optional, at sea level and at 20°C.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 4 of 35
2.5 TECHNICAL CHARACTERISTICS
Bull-wheels diameter: 1500 mm with interchangeable nylon sectors
Diesel engine: 63 kW –2600 rpm –Cummins B3.3T
Electric system: 12 V
Transmission: closed hydraulic circuit with hydraulic oil cooling
Safety brake: negative and self-acting type
Dynamometer: hydraulic with set-point and automatic control of maximum pull
Axle: rigid type with mechanical parking brake for towing at a max.
speed of 30-km/h
Dimensions: length - 3125 mm
width - 1960 mm
height - 2570 mm
Mass: 2700 kg
2.6 ACOUSTIC EMISSION
Level of continuous sound pressure to the operator seat (UNI 9432) Lep = 85 dB(A)
2.7 GENERAL INFORMATION FOR THE MACHINE USE
a. Only employed and qualified operators must use the machine.
Qualified operators is intended to be the person who has received a qualified training from the using
Company or, as alternative, from the manufacturer.
b. Machine must be used only for the work it was designed for.
c. Machine cannot be used with non-authorised personnel on the working site.
d. For safety reasons, during transport machine comes without hydraulic oil and fuel.
Characteristics and required quantities are listed in the present manual.
e. For any doubt concerning use, functioning, maintenance or everything else, contact the After-sales
Service of the manufacturer.
2.8 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE USE
a. Operator has to know safety directives for accident prevention in force in the machine using
country, for a correct use of the same.
b. The operator in charge with the installation and maintenance of the machine must use suitable
clothes to the working site and to the situation where he finds himself; in particular he must avoid
the use of very large clothes, chains, bracelets, rings or whatever can get entangled with moving
parts.
c. The operator has to use the necessary protecting devices (i.e. gloves, boots, helmet, etc.).
It is compulsory the use of personal protecting devices for hearing.
d. The operator must not carry out on his own initiative operations or interventions that are not up to
him.
e. The operator must carefully follow danger and/or prohibition prescriptions contained in the
instruction manual or indicated on the machine.
f. The working area of the operator has to be cleaned from possible oil or liquids wastes and free of
materials or equipment that may be considered as on obstacle for the operator work.
g. The operator must absolutely avoid the direct inhalation of the exhaust gas of the endothermic
engine.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 5 of 35
2.9 GENERAL PRESCRIPTIONS FOR THE OPERATOR CHARGED OF THE MACHINE
MAINTENANCE
a. It is absolutely forbidden to carry out any work of maintenance, adjustment or setting on units
while stringing (except for the operations indicated in the present manual).
b. Before carrying out any maintenance operations, stop the energy feeding (except for the cases
indicated in the present manual) and wait till the cooling of the elements subjected to heating.
c. All the maintenance operations of the machine must be carried out with machine on a level surface
and not under load.
d. Authorised and trained personnel must do all the maintenance operations, ordinary and not
ordinary. Trained personnel are intended to be the person who has received a qualified training
from the using Company or, as alternative, from the manufacturer.
e. The operator in charge with the machine maintenance must use suitable clothes to the working site
and to the situation where he finds himself; in particular he must avoid the use of very large
clothes, chains, bracelets, rings or whatever can get entangled with moving parts.
f. The operator has to use the necessary protecting devices (i.e. gloves, boots, helmet, etc.).
g. All the maintenance operations, ordinary and not ordinary, must be effectuated respecting the
prescriptions included in the present manual or following technical indications written by the
manufacturer. The non-respect of the prescribed restrains relieves the manufacturer from any
responsibility causing also the loss of warranty.
2.10 KNOWLEDGE AND CARE OF THE INSTRUCTION MANUAL
a. The information contained in the instruction manual applies to all the operators charged with the
use and/or the maintenance of the machine.
b. The instruction manual is not a training manual.
c. Before using the machine the chief of the job site and the operator must read the instruction
manual.
d. The chief of the job site is obliged to inform all the operators about the instructions contained in
the manual.
e. The user must carefully follow the instructions listed in the present manual.
f. Before using the machine, the operator must be able to use it and has to exactly know the
positions and the operations of all the controls.
g. The chief of the job site must verify that the instructions contained in the manual are applied.
h. The instruction manual must be kept, in order to be consulted, for all the life of the machine and
also when it is given to another user.
i. The instruction manual must be kept in a sheltered and dry place.
ATTENTION: present manual belongs exclusively to the manufacturer.
The reproduction, event partial, of the text is forbidden.
2.11 CONDITION OF USE
a. Temperature: from -10°C to +40°C.
b. Relevant moisture: from 30% to 90% 5%.
c. Weather conditions: any (in line with working conditions).
d. Natural and/or artificial lighting of the working site.
NOTE: the machine using and stocking is allowed till -20°C with preheating kit.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 6 of 35
2.12 TEMPERATURE LIMITS FOR HYDRAULIC OIL
When using the machine, always remember to respect the following temperature limits that can be
reached with hydraulic oil as function of the working condition.
TEMPERATURE LIMITS FOR HYDRAULIC OIL (°C)
Working condition
Hydraulic oil viscosity
VG 22
VG 32
VG 46
VG 68
Minimum temperature running in neutral position
-21
-14
-7
-1
Minimum temperature running in full load
8
16
24
32
Maximum temperature running in full load
48
57
67
76
Maximum temperature running in neutral position
63
73
83
93
For additional information concerning the hydraulic oil, see chapter "Maintenance" and the attached
comparative table of the oils used on the machine.
2.13 USE NOT ALLOWED
The machine must not be used:
a. for lifting persons and/or goods
b. in grounds on which the machine cannot be positioned and anchored in a proper way
c. in areas with brushwood or other materials presence that can be easily set on fire
d. in closed/unventilated sites or, however, not sufficiently airy (tunnel or similar)
e. in sites with presence of gas that can be easily set on fire or explosives
f. in sites with presence of explosive materials
g. on aircraft, crafts, floating platforms and similar
h. for structure demolition, shafts felling or similar
i. for pulling flexible elements that can be highly lengthening, which allow elastic power accumulation
j. with ropes or joints having a bigger diameter than the one specified in present manual
k. when engine is off and adherence units are moving
l. with inhibited and broken safety devices installed on the machine
m. when winding on the bull-wheels ropes and/or conductors having a smaller diameter as a
succession of ropes and/or conductors having a bigger diameter
n. for handling trucks or other moving equipment.
PROHIBITION: is not allowed to install on board radio equipments. These could create
electronic equipment malfunctions, putting the personnel at serious risk.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 7 of 35
2.14 RESPONSIBILITY
The use of the machine for scopes different from those foreseen on paragraph 2.3 (Typology and
using field), even if not well described in this manual, has to be considered extremely dangerous and
then forbidden.
The non-respect of the prescribed restrains causes a situation of improper use for technical
and persons safety purposes and relieve the manufacturer from any responsibility, civil or
penal, in case of accidents to persons or damages to things, causing the loss of warranty.
The manufacturer responsibility declines even when one of the following situations happens:
a. for the consequences caused by tampering and/or modifications carried out without the
manufacturer’s written acceptance (in this case the operator becomes the manufacturer with
relevant obligations and responsibilities, both civil and penal)
b. for the use of not original spare parts
c. or bad maintenance
d. for the use with disconnected safety devices
e. for the connection to machine and/or plans not produced and not directly authorised by the
manufacturer in a written acceptance.
2.15 APPLIED NORMS
If the machine is commercialized in C.E. responds to the following regulatory framework:
2006/42/CE Norm of the European Parliament and Council referring to the laws of the machines
member States.
2004/108/CE Norm of the European Council referring to the laws of the electromagnetic
compatibility member States.
If the machine is commercialized outside the C.E. was made reference to the following regulatory
framework:
2006/42/CE Norm of the European Parliament and Council referring to the laws of the machines
member States.
2004/108/CE Norm of the European Council referring to the laws of the electromagnetic
compatibility member States.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 8 of 35
3. TRANSPORT AND POSITIONING INSTRUCTIONS
3.1 MACHINE LIFTING
For the machine lifting use only devices as overhead travelling cranes or lift trucks, with a capacity
equal to the mass to be lifted.
The instruments used for the machine lifting (ropes, cables, hooks, etc.) have to be exactly
dimensioned as compared to the mass to be lifted and have to be connected to the proper elements
foreseen on the machine (table 1, pos. 2).
During machine lifting operations, the presence of persons on the machine is strictly forbidden.
DANGER: the non-respect of the above mentioned conditions may cause dangerous
situations as well as damages to the machine with the consequent decline of any warranty
condition.
3.2 TRANSPORT TYPOLOGIES AND PACKAGE
Transport by land by truck
The machine comes without all the liquids that can be set on fire and protected in the most exposed
and delicate parts by means of cardboard and/or plywood and/or polyethylene extensible film.
To fix the machine on the platform of the transporting unit, use nailed wedges and/or metal brackets
and/or tie rods.
Transport by sea in wooden cases or container
The machine comes without all the liquids that can be set on fire; metal parts are protected with
waterproof wax.
To fix the machine on the package, use nailed wedges and/or metal brackets and/or tie rods.
At the inside, the wooden case foreseen a protection with tarpaper.
Materials usually used for the package are:
wooden
nails and/or steel screws
cardboard and/or paper
polyethylene extensible film
adhesive tape.
3.3 UNPACKING
When receiving the machine verify the integrity of the package; advise immediately the manufacturer
and the person in charge of the transport (even with photos) when possible damages due to transport
or tampering with removal, even partial, of the content happen.
Verify if the supplied material corresponds to the ordered one; immediately advise the manufacturer if
there are some discrepancies.
In case of transportation on wooden case, take away, in sequence, the upper cover and lateral panels,
before removing the machine.
During unpacking operations, avoid any shock to the structure or to the machine units, in order to
avoid any damage to the machine itself.
ATTENTION: the elimination of packaging materials must be effectuated in conformity with the
norms in force in the relevant country.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 9 of 35
3.4 ASSEMBLING OPERATIONS
Mount the tyres in the suitable holes.
3.5 TRANSPORT ON TRAILER
The machine in its standard version is not adapted for the carriage in tow on the road if not supplied
with All.112.
Possible displacements on trailer in the working site must be carried out by a connection to the towing
unit by means of the towing eye on the drawbar (table 1, pos. 6) and in the respect of the speed limits
of the axle. The used towing unit must be homologated for towing trailers with mass and dimensions
as per the described machine.
Before transporting operation, lift the rear stabiliser (table 1, pos. 11) and the front plough
(table 1, pos. 5) acting on the lever (table 3, pos. 29) (NOTE: during this operation the diesel engine
has to be always started-up).
Check the inflation pressure of tyres (5 bars).
During trailer machine transport operations is nobody must stay in the machine itself.
ATTENTION: dangerous situations during towing if the tyres inflation pressure and the speed
limit are not respected may happen.
When transporting on truck or trailer, verify if the machine has been fixed on the platform with nailed
wedges and/or metal brackets and/or tie rods.
If the machine has been purchased with All.112 is equipped with components that make homologated
for road transport at speeds up to 80km/h. The approval must be made directly by the customer in the
country of interest. Once approved, the machine must comply with the laws of the homologating
institution of the chosen country.
Before the operation of transport lift and lock in the disengaged position the support foot rear (tab. 1,
pos. 13) and the support front plough (tab. 1, pos. 8). Attach air attacks (Table 10, pos. 8) to those of
the motive as well as that of the lighting system (Table 10, pos. 8).
ATTENTION: The motive used must be homologated to tow trailers with a mass and size of
the machine in question.
ATTENTION: The machine must be homologated with 140l of Hydraulic oil in the tank and at
least half tank with gasoil (approx. 45-50l).

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 10 of 35
3.6 POSITIONING AND ANCHORING
Positioning and anchoring of the machine have to be carried out only by trained personnel, verifying if
the ground grants the foreseen stability, support and anchoring.
The machine has to be placed in a distance from the first pylon or trestle for the rope passage (or
conductor) included between 2 and 4 times the height h of the pylon itself (see diagram here below).
It is possible to use the machine at a distance from the pole included between 1 and 2 times the height
of the pole itself. In this case, the anchorage described thereafter must be over dimensioned of 125%
compared to the reported data and some moorings must be provided on the front side of the machine.
PROHIBITION: when the distance between the machine and the pole is lower than the
height of the pole itself, the machine use is not possible.
Machine anchoring sequence is the following:
a. machine must be aligned as much as possible with the pull direction.
b. position the rear stabiliser (table 1, pos. 10) and then load properly the plough (table 1, pos. 5)
operating on the lever (table 3, pos. 29) (NOTE: during this operation the diesel engine has to be
always started-up).
c. anchor the machine to the ground by means of 2 stakes with min. granted load equal to 130% of
the machine max. pull, connecting the foreseen connections (table 2, pos. 3) with the anchoring
stakes and respecting the described scheme and angles (table 2).
d. recover the clearance on the anchoring stakes without tensioning them.
e. test the machine pull (see use instructions on the following chapter) to allow the machine to freely
align as regards as the pull itself.
f. tension the anchoring stakes in a uniform way.
g. block the machine brakes acting on the special hand-wheel (table 1, pos. 9).
ATTENTION: the non-respect of the foreseen anchoring operations may cause dangerous
situations during machine use.
Around the machine must be a free space of at least 2-m to make easier the operations of use,
adjustment, maintenance, etc.
Be sure that around the radiator (endothermic engine, hydraulic oil) cooling air can freely circulate.
Otherwise overheating situations with damage for the installed components may happen.
DANGER: machine has not a proper grounding device; for the system machine-rope-
conductor in the job site must foreseen a grounding device on the towing rope or on the
conductors.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 11 of 35
4. INSTRUCTION FOR USE
4.1 PRESCRIPTIONS FOR THE OPERATOR
PROHIBITION: it is forbidden to walk or stop in front or backward the machine and/or under
the towing rope due to a constant residual risk of crushing in case of a possible giving in of the
rope or of the anchoring.
Daily, before starting the work, check:
a. if the protection and safety devices are activated and functioning
b. if the connections with power unit are in good conditions
c. if the machine liquids levels are in conformity with the indications in maintenance chapter
d. if the anchoring conditions are in conformity with the indications of present manual.
NOTE: when using the machine at room temperature between -10°C and -20°C it is
necessary to carry out the preheating sequence as indicated at paragraph 4.10 and
4.11.
4.2 CONTROLS
Position and meaning of the elements on the control board are described on table 3 enclosed.
4.3 PRELIMINARY OPERATIONS
a. Load the conductors or the cables on the bull-wheels as shown on tables 2 and 4 positioning the
entering guide-rope rollers (table 2 and 4) in the proper position.
ATTENTION: do not use excessively lubricated or greased ropes because possible
adherence problems on the bull-wheels with a consequent sliding of the ropes
themselves may arise.
b. Lubricate the gears before each starting of the machine using the proper greasers (table 2, pos. 2).
c. Position the lever of mechanical transmission (table 2, pos. 9) into the proper ratio in accordance
with the job to do:
high pull (tension higher than 7kN) (table 2, pos. 9C)
low pull (tension lower than 7kN) (table 2, pos. 9B)
NOTE: the stringing speed can be read on the manometer scale (table 3, pos. 1)
relevant to the selected reduction ratio.
ATTENTION: this operation must be made only with stopped machine and without
applied loads.
PROHIBITION: when you position the mechanical transmission control lever on the low
pull (table 2, pos. 9B) on the panel switch on the red light (table 3, pos. 23), which
advise that the machine cannot absolutely be used as puller but only as tensioner.
DANGER: please pay attention to the risk to be squeezed during the operations above
described.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 12 of 35
4.4 MACHINE SET-UP
Before the use, the machine must be set in stand-alone using mode, operating on the control panel
(table 3).
a. insert and turn the ignition key (table 3, pos. 3) in "1" position
b. wait up to the multifunction display switch on (table 3, pos. 1)
c. on the display press ()
d. on the screen page “MACHINE ID:” set the number “1” by using the up ( ) or down ( )
key. Press the return key ( ) to save the settings.
NOTE: in case of stand-alone
using mode the ID of the machine
must always be set at 1
When the machine is used in stand-alone
configuration the two plug connectors must be
closed with the related caps

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 13 of 35
4.5 ELECTRONIC MULTI-FUNCTIONS DISPLAY PAGES
The electronic multifunction display shows 4 working pages:
1. METER COUNTER & SPEED PAGE
diesel engine r.p.m
Water cooling temperature
speed of conductor
string meters of conductor
This page shows the diesel engine rpm, cooling liquid
temperature, speed of conductor and the meter
counter
2. DIESEL ENGINE PAGE
diesel engine rpm
hydraulic oil temperature
diesel engine fuel level
diesel engine oil pressure
alarm or engine fails
This page shows the rpm of the diesel engine, diesel
engine oil pressure, diesel engine fuel level and water
cooling temperature.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 14 of 35
3. DIESEL ENGINE DATA PAGE
working hours of the diesel engine
hydraulic oil temperature
battery tension
This page shows:
4. Multifunction Bar
Allows you to reset the counter and select the menu
page.
Set Up Menu
Meter counter reset button
Diagnostic Menu
Page Change
5. Set up Menu
It allows to adjust the brightness of the display and change
the language
Display brightness
Measuring system (metric –USA )
Available languages :
- English
- French
- German
- Spanish
- Italian
- Chinese
System information AF3-CV

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 15 of 35
Selecting "System Information", will appear on the menu bar icon dedicated
in which will be displayed serial number and firmware version installed
6. Diagnostic Menu
Displays the menu and the engine list alarms
Displays active alarms
DM1 from engine ECU (if present)
Displays alarms
DM2 saved by engine ECU
(if present)
Erase memory
DM2 engine ECU alarms
Selecting the center button on the menu bar,
you enter the page describing the error
appeared.
SPN / FMI Alarms
Alarms Description
Alarm list DM1/DM2
(DM2 only from engine)
Unit failed and its address:
0 = engine
128 = AF3-CV

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 16 of 35
7. Diagnostic Message
Appears spontaneously with the arrival of a
new alarm message.
If the alarm persists even after it has been
confirmed, you will see an icon in the center
of the page and will remain lit the yellow light
or red.
Confirmation:
If the alarm is no longer present, the
message is deleted.
To move from page to page using the arrow keys up ( ) or down ( ) .
4.6 STARTING OF THE MACHINE
a. Operate from the principal control panel (table 3).
b. Position to centre the control lever of the variable delivery pump (table 3, pos. 4).
c. Turn of one point the starting key (table 3, pos. 14).
d. Push and turn up to starting the starting key (table 3, pos. 14) and simultaneously keep the lever
(table 3, pos. 13) lowered.
The lever (table 3, pos. 13) must be lowered for a few seconds after the engine start-up.
e. Regulate the rpm with the accelerator (table 3, pos. 12).
f. Verify that the pressure indicate on the feeding manometer (table 3, pos. 7) is more than 20 bars
with minimum rpm; on the contrary stop the machine.
ATTENTION: when starting a cold machine, after heating the hydraulic oil as previously
described, begin stringing operations limiting the maximum working performances for
at least the first 15 minutes, that means to keep at half accelerator the Diesel rpm and
don’t exceed the 30% of the maximum stringing speed.
4.7 PULL CONTROL
The machine is equipped with two pull control devices for the control of the max. pull value on the line:
1. PULL LIMITING DEVICE that stops the machine when reaching the max. pull
2. PULL PROGRAMMING DEVICE that stops only the bull-wheels rotation keeping the diesel engine
turned-on when reaching the max. pull.

PULLER-TENSIONER
Model: AFS404
Manual: MI-AFS404-609-01-GB
Date: 15.03.2016
Author: MC
Page: 17 of 35
4.7.1 PULL LIMITING DEVICE SETTING
Completely turn right the knob (table 3, pos. 6).
With the suitable pawl, connected to the dynamometer (table 3, pos. 1), move the red arrow in
correspondence of the max. pulling value that has not to be exceeded.
When the pre-set pull value is reached, the machine stops automatically and the diesel engine turns
off while the negative brakes automatically insert with the consequent stop of the bull-wheels
rotation. When the pull value is exceeded the warning light (table 3, pos. 20) on the control panel
turns on.
DANGER: when using a machine as tensioner, position the pull limiting device
(table 3, pos. 1) on the maximum scale, to avoid dangerous stopping.
This operation is absolutely indispensable when the machine “tensioner” works with a
puller without pull limiting device.
4.7.2 PULL PROGRAMMING DEVICE SETTING
ATTENTION: THE OPERATIONS TO SET THE PULL MUST BE CARRIED OUT WITH
STARTED DIESEL ENGINE BUT WHEN THE MACHINE IS TURNED OFF.
Start the diesel engine and set the engine at about 1600 rpm.
Move the selector (table 3, pos. 5) on position (rightwards).
Gently move towards (downwards) the lever (table 3, pos. 4).
Turn the knob (table 3, pos. 6) till on the manometer ring nut (table 3, pos. 1) can be read the pull
value that must not be exceeded.
ATTENTION: the red arrow of the pull limiting device (par. 4.7.1) has to be positioned at
a higher value than the one pre-set with the PULL PROGRAMMING DEVICE to avoid the
machine stop.
DANGER: when using a machine as tensioner, position the pull limiting device
(table 3, pos. 1) on the maximum scale, to avoid dangerous stopping.
This operation is absolutely indispensable when the machine “tensioner” works with a
puller without pull limiting device.
Gently move the lever (table 3, pos. 4) to central position (neutral position).
Re-place the selector (table 3, pos. 5) on position (leftwards).
Once reached the set pull the bull-wheels automatically stop without the diesel engine turning off
with the consequent machine stop. The bull-wheels will remain stopped till when the cause which
tried to raise the pull over the imposed value is removed (line obstacles, increase of friction on the
pulleys, braking mistakes, etc.).
ATTENTION: after finishing the above mentioned operations and beginning stringing
operations, it is important not to touch the knob (table 3, pos. 6).
In fact, should the knob be rotated while the machine is stringing, this operation
cancels the previous carried out calibration and the systems set on the new values
congruent with new position of the knob.
Then, avoid this operation, using it only in emergency situations.
ATTENTION: before starting the work, check if the selector (table 3, pos. 5) is on
position . It is forbidden to move the selector (table 3, pos. 5) during working
operations because dangerous situations because the machine immediately stops may
happen.
ATTENTION: the dynamometer is calibrated with 3 scales: puller, tensioner and fine
braking. Read the desired values in function of the operations to be carried out (pulling
or tensioning).