Textron SHERMAN+REILLY Revolution Series User manual

PT‐3500 / PT‐7500 Puller Tensioner
Operators Manual

Table of Contents
6 Section 1: Introduction
7Terms of Use
8Section 2: Specifications
8 PT-3500 General Overview
8 PT-3500 Key Features
9 PT-3500 Specification Details
10 PT-7500 General Overview
10 PT-7500 Key Features
11 PT-7500 Specification Details
12 Section 3: Safety
12 Hazard Overview
12 Safety Warning Terms
13 General Warnings
14 Operator Safety Precautions
15 Employer Safety Precautions
16 Chemical Safety
17 Section 4: Operation
17 Terms You Need to Know
18 Safe-Zone Cab
20 Operator Controls
24 Tier 4 Engine PT-3500
29 System Control Panel
33 USB Interface
35 Joystick Control
38 Jack Controls
39 Automatic Levelwind Controls
41 Outside Hydraulic Control Panel
42 Emergency Manual Override Controls
43 Quick Start Guide
49 Towing and Road Safety
51 Positioning the Machine
52 Start-Up Procedure
53 Payout Operations
57 Pulling Operations
61 Drum/Reel Removal and Installation
63 Tensioning Operations
66 Spider System Operations
69 Emergency Stop Procedure

70 Section 5: Troubleshooting
70 Quick Tips
71 Troubleshooting Guide for Fault Codes
76 Torque Ratings for Machine Fasteners
78 Fuse/Relay Block Diagram
79 Fuse/Relay Wiring Schematic
80 PT Trailer Wiring Schematic
81 PT Hydraulic Schematic
82 Section 6: Maintenance
82 Safety and Reliability Disclaimer
82 Safety
83 Safety Warning Terms
84 General Care and Inspections Instructions
85 Cleaning
86 Fault and Malfunction Detection
87 Hydraulic System
88 Hydraulic System/Hose Inspection
89 Checking Hydraulic Fluid
90 Adding Hydraulic Fluid
91 Replacing Hydraulic Fluid and Filters
92 Hydraulic Hose Replacement
94 Drum/Reel Drive Assembly
94 Drive Shaft
94 Drive Shaft Cones
95 Drive Barn and Pins
95 Drive Couplings
96 Drive Motors
97 Inspecting Pillow Block Bearings
98 Tightening Set Screws
98 Greasing Pillow Block Bearings
99 Spider System Assembly
100 Hydraulic Power Engine
101 Safe-Zone Cab
101 Inspection of Operators Chair
101 Climate Control System
102 Trailer Assembly
102 Brakes
102 Towing
103 Tires
103 Wheels
104 AxleDrumOil
105 Trailer Lighting
106 Lighting Replacement
107 Pre-Operation Inspection Checklist
110 Post-Operation Inspection Checklist
112 Preventive MaintenanceSchedule
118 Torque Ratings for Machine Fasteners

122 Section 7: Service & Repair
122 Equipment Information
122 Major Fault Issues
122 When to Send for Serviceor Repair?
124 Section 8: Parts
124 Sherman+Reilly Accessories
124 Miscellaneous Replacement Parts
127 Appendix A: Manufacturer Manuals
Kubota V3800TB Engine Manual
Kubota V1505T Engine Manual
Dexter 10,000 lbs. Axle Manual

1
Introduction
This manual is provided to assist operators and owners with the functions and proper methods for safely
and efficiently getting the most from this Sherman-Reilly equipment. It is very important that every
machine be operated in a safe manner. Precautions to guard against the possibility of an accident are a
prerequisitetooperatinganytypeofequipment. Toproperlyandsafelyoperatethismachine,itisnecessary
thatoperatorsandmaintenancepersonnelreadandunderstandtheinformationinthismanual,toincluding
appendixes and other provided materials.
Anyone working around this machine should also, at a minimum, read the safety precautions listed in the
manuals. Be aware each warning and precaution is to help protect against injury. Taking unnecessary risks
and ignoring warnings is the primary cause of personal injury and fatal accidents in the work place. If
you have any questions regarding operation or safety of a procedure or situation, contact the Sherman+
-800-251-7780, via email at [e-mail], or via our
website:www.sherman-reilly.com
This manual is of no value if the operator does not read and understand the instructions and precautions
(beforestartingandtryingtooperatethemachine).
and limitations.
for situations and conditions which could affect the normal
performance of the machine and safety in the work area.
The Sherman+Reilly Models PT-3500 and PT-7500 Puller/Tensioners are diesel engine powered,
hydraulically actuated machines. Both machines have variable speed and line tension controls; however, if
pulling multiple conductors using a running board, the total line tension applied from all conductors must
not exceed the pulling capacity of the machine.

Introduction
Terms of Use
Publication of this manual and the safety precautions in it does not in any way represent an all-inclusive list
and should not be interpreted as an all-inclusive comprehensive list of precautions and procedures.
kesure themachineisoperatedinaccordancewith allstateandlocal
safety requirements and codes, including all applicable OSHA- (Occupational Safety and Health
Administration) and EPA- (Environmental Protection Agency) regulations, as well as ANSI- (American
National Standards Institute) accredited standards. .
Sherman + Reilly also recommends following the guidance published by the Institute of Electrical and
Electronics Engineers (IEEE), and specifically IEEE Standard 524 Guide to the Installation of Overhead
Transmission Line Conductors (IEEE 524-2003 or Subseq.).
Shouldaproblemorunsafeconditionarise,shutthemachinedownusingthenormalshut-downprocedure.
In the event of an emergency, use the Emergency Stop Proceduredescribed in this manual, and then notify
the proper authorities or follow your
Sherman+Reilly strongly recommends that only personnel who have a full understanding of the provided
manual and who are competent in the use of overhead line pulling and tensioning machines, to include all
applicable laws, regulations, and safety standards, be allowed to operate this machine.
Therearesignificanthazardsinherenttotheuseofthismachine;therefore,alloperatorsshouldbeeducated
on all functions, procedures, andsafety measures outlined in this manual prior to their use or maintenance
of this machine.
If you have questions regarding any operational steps or the safety of a procedure listed in this manual,
contactSherman+Reillyat1-800-251-7780or423-756-5300,[e-mail],orviaour
website:www.sherman-reilly.com

Revolution Series PT-3500 / PT-7500 Puller Tensioner 2
2
Specifications
PT-3500 General Overview
Sherman+Reilly Revolution Series PT-3500 Single Drum Puller/Tensioner is a multi-purpose
puller and tensioner capable of pulling up to 3,500 lbs., with additional re-conductoring
capabilities. This distribution class puller utilizes an automatic horizontal floating levelwind
that permits overhead rope retrieval with precision control. The PT-3500 is equipped with an
ACG (advanced control group), allowing for a single operator at a protected central console to
control payout speed, pulling speed and tension, levelwind controls, and jack position. The
operator controls employ electronic machine control with CAN-bus technology, providing for
accurate to-the-second display readouts ofthe machine system status.
Thehydraulicallyactuated,automaticfloatinglevelwindhelpsensureevendistributionofrope
during pulling operations, thereby minimizing the risk of tangles and overlap, and maximizing
rope life. The horizontal floating style of the levelwind also allows for easy upright standby
positioning during payout and tensioning operations. The PT-3500 is equipped with a turbo-
charged industrial Tier 4 Final diesel engine that delivers 71 HP at 2700 RPM and 3,500 lbs. of
line pull, at the top of the drum. The fully hydraulic direct drive system provides the operator
with precise and intuitive automatic drive/drum braking. The PT- single axle trailer is
equipped with three hydraulic jacks, an adjustable pintle eye, safety chains/hooks, and U.S.
DOT-approved LED lighting.
ThePT-3500featuresaSafe- providingultimatesafetyandcomfortfortheoperator.
The Safe-Zone Cab employs a floor to ceiling polycarbonate front window for maximum
visibilitywhileprovidingsuperior protection againstimpact. Thecabincludes climatecontrol,
a fully adjustable ergonomic seat, and all required electronic controls and gauges. The Safe-
Zone Cab is designed to reduce operator fatigue off-ground envelope for
greatly reducing the risk .
Key Features
 Fully Hydraulic/Direct Drive System
 Safe-
 Synthetic Rope
 HorizontalFloating Automatic Levelwind
 71 HP Tier4f Kubota Diesel Engine
 3 Hydraulic Jacks
 10.4 cu. ft. Frame Mounted Tool Box
 Centralized Engine Controls- CAN-bus technology

Revolution Series PT-3500 / PT-7500 Puller Tensioner 9
Specifications
Specifications Details: PT-3500
(Dimensions,weights,andcapacitieslistedareapproximate. Allspecificationsaresubjecttochangewithoutnotice.)
Pulling Capacity
TOD: 3,500 lbs., (Rated atthetopofdrum)
Max: 4,500 lbs., (Ratedmaximum)
Average Line Speed
Pulling: 4 mph / Payout: 10 mph
Maximum Conductor Reel Size
66 in. Diameter . wide) / 48 in. Width / 6,500 lbs. Weight
Drum Dimensions
Core Diameter: 24 in.
Total Width: 48 in.
Flange Diameter: 44 in.
Drum Capacity
11 mm. dia. Unitrex 21,000 ft.
10,500 ft.
Drive System
Direct Drive: single hydraulic motor, drum/reel shaft coupler and
drive bar/dual pin
Drive System Engine
Vertical 4-cycle, liquid cooled, turbo-charged, direct drive 71 HP
Fuel Capacity
30 gallon
Hydraulic Fluid
ISO Grade 32
Hydraulic Reservoir
40 gallon (32useablegallons)
Hydraulic Fluid Filtration (2)
10 micron, bothsupplyandreturnfilters
Levelwind
Hydraulically driven, automatically-controlled
Safe- -enclosed/single door
Frame Construction
Steel tubing, steel plate, continuous weld
Length (Overall, Nom.)
18 ft., 11 in.
Width (Overall, Nom.)
7 ft., 6.5 in.
Height (Overall, Nom.)
8 ft., 8 in.
Weight (With Rope)
9,400 lbs.
GVWR
12,000 lbs.
Suspension
Torsion
Axle Configuration
Single
Wheel Configuration and Tires
Single 245/70R 17.5
Brakes (Trailer)
Electric, with break-away switch
Towing Attachment
3 in. pintle eye, with two safety chains and hooks
Tie Downs (4)
(2) 5/8 in. dia. steel D-Rings, (2) 1 in. dia. steel D-Rings
Rear (R/L) Jacks (2)
Hydraulic, with shoe
Front/Nose Jack (Rear)
Hydraulic, with shoe
Electrical System
12 VDC
Battery (2)
12 V, 585 CCA, BCI group 24
Lights /Navigation
12 V, LED, U.S. DOT-approved
Grounding (4)
¾ in. dia. copper-clad steel loops
Wheel Chocks
Standard
Fire Extinguisher
ABC
Color
S+R White

Revolution Series PT-3500 / PT-7500 Puller Tensioner 10
Specifications
PT-7500 General Overview
The Sherman+Reilly Revolution Series PT-7500 Single Drum Puller/Tensioner is a multi-purpose
puller and tensioner capable of pulling up to 7,500 lbs., with additional re-conductoring
capabilities. This distribution class puller utilizesan automatic horizontal floatinglevelwind that
permits overhead rope retrieval with precision control. The PT-7500 is equipped with an ACG
(advancedcontrolgroup),allowingforasingleoperatorataprotectedcentralconsoletocontrol
payout speed, pulling speed and tension, levelwind controls, and jack position. The operator
controlsemployelectronicmachinecontrolwithCAN-bustechnology,providingforaccurateto-
the-second display readouts of the machine system status.
The hydraulically actuated, automatic floating levelwind helps ensure even distribution of rope
during pulling operations, thereby minimizing the risk of tangles and overlap and maximizing
rope life. The horizontal floating style of the levelwind also allows for easy upright standby
positioning during payout and tensioning operations. The PT-7500 is equipped with a turbo-
charged industrial diesel engine delivering 99HP at 2600 RPM and a full 7,500 lbs. of line pull,
from the top to the core of the drum. The fully hydraulic direct drive system provides the
operator with precise and intuitive automatic drive/drum braking. The PT-
trailer is equipped with three hydraulic jacks, an adjustable pintle eye, safety chains/hooks, and
U.S. DOT-approved LED lighting.
The PT-7500 features a Safe-
The Safe- employs a floor to ceiling polycarbonate front window for maximum
visibility whileproviding superior protection against impact. The cab includes climatecontrol, a
fullyadjustableergonomicseat,andallrequiredelectroniccontrolsandgauges. TheSafe-Zone
-
energizedenvironments.
Key Features
 Fully Hydraulic/Direct Drive System
 Safe-
 48 inch Drum withOptional 11,500 ft. (Max) of
Unitrex Synthetic Rope
 Horizontal Floating Automatic Levelwind
 99 HPDieselEngine
 3 Hydraulic Jacks
 10.4 cu. ft. Frame Mounted Tool Box
 Centralized Engine Controls- CAN-bus technology

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 11
Specifications
Specifications Details: PT-7500
(Dimensions,weights,andcapacitieslistedareapproximate. Allspecificationsaresubjecttochangewithoutnotice.)
Maximum Pulling Capacity
7,500 lbs.- (Ratedfromtopofdrumtocore)
Average Line Speed
Pulling: 4 mph / Payout: 10 mph
Maximum Conductor Reel Size
66 in. Diameter . wide) / 48in. Width / 6,500 lbs. Weight
Drum Dimensions
Core Diameter: 24 in.
Total Width: 48 in.
Flange Diameter: 48 in.
Drum Capacity
16 mm. dia. Unitrex 11,500 ft.
5,500 ft.
Drive System
Direct Drive: dual hydraulic motors, drum/reel shaft coupler and
drive bar/ dual pin
Drive System Engine
Diesel, 99 HP, water-cooled
Fuel Capacity
30 gallon
Hydraulic Fluid
ISO Grade 32
Hydraulic Reservoir
40 gallon (32usablegallons)
Hydraulic Fluid Filtration (2)
10 micron, bothsupplyandreturnfilters
Levelwind
Hydraulically driven, automatically-controlled
Safe- -enclosed/single door
Frame Construction
Steel tubing, steel plate, continuous weld
Length (Overall, Nom.)
18 ft., 11 in.
Width (Overall, Nom.)
8 ft., 6 in.
Height (Overall, Nom.)
8 ft., 8 in.
Weight (With Rope)
11,360 lbs.
GVWR
14,500 lbs.
Suspension
Torsion
Axle Configuration
Single
Wheel Configuration and Tires
Dual 235/85R 16
Brakes (Trailer)
Electric, with break-away switch
Towing Attachment
3 in. pintle eye, with two safety chains and hooks
Tie Downs (4)
(2) 5/8 in. dia. steel D-Rings, (2) 1 in. dia. steel D-Rings
Rear (R/L) Jacks (2)
Hydraulic, with shoe
Front/Nose Jack (Rear)
Hydraulic, with shoe
Electrical System
12 VDC
Battery (2)
12 V, 585 CCA, BCI group 24
Lights /Navigation
12 V, LED, U.S. DOT-approved
Grounding (4)
¾ in. dia. copper-clad steel loops
Wheel Chocks
Standard
Fire Extinguisher
ABC
Color
S+R White

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 12
3
Safety
Hazard Overview
Please pay attention to all safety warning labels and information placards posted on the machine,
components, and trailer assembly. These labels and placards are provided to assist in identifying
areas containing potential hazards while also providing information regarding equipment
specification and limitations. Please see below for examples:
Warning Terms:
The word DANGER indicates the
information relates to a specific
immediate hazard which, if disregarded,
will result in severe personal injury or
death.
The word WARNING indicates the
information relates to a specific
immediate hazard or unsafe practice
which, if disregarded, could result in
personal injury or death.
The word CAUTION indicates the
information pertains to a potential
hazard or unsafe practice which, if
disregarded, may result in minor
personal injury or equipment damage.
The word NOTE indicates the
information is important to the correct
operation or maintenance of the
machine.

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 13
Safety
General Warnings
WARNING: Ear protection should be
worn when operating machines with
operator ear noise levels above 85dB.
WARNING: California Proposition 65:
Engineexhaust,someofitselements,and
certain vehicle components contain or
emit chemicals known to the State of
California to cause cancer and birth
defects or other reproductive harm.
WARNING: To prevent serious injury
from hot and high pressure oil, never use
your hands to check for oil leaks; use
paper or cardboard. Hydraulic fluid
escaping under pressure can have
sufficient force to penetrate skin. If fluid
is injected into the skin, it must be
surgically removed within afew hours by
a doctor familiar with this form of injury,
otherwise gangrenemay develop.
WARNING: Batteries produce explosive
gases, contain corrosive acid, and supply
levelsofelectrical currenthighenoughto
causeburns.
WARNING: This machine must not be
used as a winch for pulling another
vehicle. For trailer models, this trailer
must not be modified to allow towing of
another trailer behind and in tandem
with this trailer.

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 14
Safety
Operator Safety Precautions
 Do not place any part of the body into a
potential pinch point. The machine must be
turned off and locked out in accordance with
OSHAregulationsbeforeattemptingtocorrecta
problem, work on the machine, or perform
preventive maintenance.
 Do not attempt to operate any Sherman+Reilly
equipment without proper instruction,
including reading and understanding the
providedmanual.
 Obey and enforce all warnings including OSHA
requirements and ANSI standards.
 Neverallowanyone torideontheunitwhile itis
beingtowed.
 Always wear proper safety equipment as
required by employer.
 Never bypass safety switches or operate
equipment withfaulty safety devices.
 Be sure all guards and access covers are in place
and secured when the machine is being
operated.
 Beawareofpeopleintheworkareawhomay be
at risk duringoperation.
 Know all emergency shutdown procedures.
 Donotobstructcontrolsor fireextinguisherand
make sure fire extinguisher is fully charged.
 Never operate equipment while under the
influence of any substance which could impair
ability or judgment.
 Do not operate equipment if work ability is
impaired byfatigue, illness, or other causes.
 Always use employer-approved grounding
procedures when operating the machine.
 Never use hands to check for hydraulic system
leaks. Hydraulic fluid escaping under pressure
can cause personal injury.
 Avoid contact with pumps, cylinders, hoses,
engine components, and exhaust system.
 Do not refuel unit while the engine is running or
hot.
 Keep all body parts, to include head and limbs,
away from all moving parts.
 additional safety precautions which relate to
engine operation and service.
 Know location and function of all controls,
gauges, instruments, and protective devices.
 Never useunit to towor winch another vehicle.
 Never use controls or hosesfor hand holds.
 Do not exceed unit specifications and
limitations,to includeweight.
 Know where to get
help in the event of an
emergencyor injury.
 Whentowingthismachine/unittrailer,thedriver
should use caution and adjust speed based on
road, weather, and terrain conditions, as well as
applicable laws and speed limits.
 Donotmake physicalcontactwithropeor cable
as it entersor leaves the machine or drum.
 To prevent the possibility of electrocution, do
notenterorleavetheunitwhileitisoperatingor
allow anyone to touch or lean on the machine
whenin use.

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 15
Safety
Employer Safety Precautions
This guideline is intended to assist
owners/employers to ensure equipment is
serviced and operated in a safe manner. Each
job site may have additional situations and
conditions which need consideration.
Monitor the operators to be sure they observe
andpracticesafetyproceduresandoperatethe
support equipment as outlined in this manual.
Establish a regular inspection program which
includes malfunction reports, inspection, and
service records. This inspection should cover
themachinecondition,adjustment,andensure
all safeguards are in place and functional.
Additionally, all pre/post-operation
inspectionsshouldbeconductedatprescribed
intervals.
Make sure that any malfunction or breakdown
affecting the safe operation of the equipment
is properly corrected or repaired before
returning the machine to service.
The employer shall provide training and
instruction in chemical safety and safe
methods of work before assigning workers to
operate, service, or repair the machine and
equipment. A record of training dates,
employee names, and level of training shall be
maintained. Only persons who have a full
understanding of the provided manual-
(providedinEnglishonly),andwhoarecompetentin
the use of overhead pulling and tensioning
machines; to include all applicable laws,
regulations, and safety standards, should be
allowed to operate this machine. There are
significant hazards inherent to the use of this
machine; therefore, all operators should be
educated on all functions, procedures, and
safety measures outlined in this manual- prior
to their use or maintenance of this machine.
Employer shall utilize a lock-out/tag-out
procedure which complies with OSHA
Standard,Part 1910.147, Title 29 of the Code of
Federal Regulations. This procedure must
include control of all keys.
The employer will specifically inspect all safety
equipment and protective devices on the
equipment to ensure they are not bypassed or
disabled. Operation of equipment will not be
permitted unless all safety devices are in place
and functional. The employer shall meet all
appropriate information dissemination and
protection requirements for the workers.

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 16
Safety
Chemical Safety
Exposure to chemicals during normal operation of the machine is limited; however, chemical
exposure may be encountered through preventive maintenance and repair. Operators and
maintenance/service personnel should take appropriate precautions, to include wearing all (PPE)-
Personal ProtectionEquipment, prior tothe operation,maintenance, orserviceof the machine. All
or forOEMchemicalspresentupon
initial manufacture/shipment of machine can be made available upon request to Sherman+Reilly.
Any additional chemicals introduced to the machine or used in conjunction with maintenance or
repair ofthe machinemust havea MSDS/SDS available forwork being done,andwould therebybe
employer or the organization providing the maintenance. All
chemical handling and disposal should be done in accordance with environmental, federal, state,
and local laws and regulations. Sherman+Reilly is not liable for the mishandling, misuse, or
improperdisposalofchemicals,withregardtotheuseormaintenanceofSherman+Reillymachines
or equipment.
Allresponsibilities,includingbutnotlimitedto: handlinganddisposalofchemicals,availabilityand
, labeling of chemical containers, and training of employees and
operators, should be fulfilled in accordance with the Hazard Communication Act, Hazardous
Hazard Communication Standard- (29 CFR) Part 1910.1200,
and all applicable EPA Standards and Regulations- (additional standards may apply). For further
information on safety standards regarding chemicals see OSHA and EPA websites.

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 17
4
Operation
Terms You Need to Know
1. Pintle Hitch
2. Safety Chains
3. Safety Breakaway Switch
4. Safe-
5. Diesel Fuel Tank
6. Hydraulic Tank w/Filter
7. Sight Gauge
8. Hydraulic Power Engine
9. Hydraulic Pump
10. Hydraulic Drive Motor(s)
11. Emergency Manual Override
12. Rear/Nose Jack
13. Side [L/R] Jacks (2)
14. Drum/Reel
15. Drum Drive Bar
16. Levelwind Arm
17. Levelwind Head
18. Tool Box
19. Fire Extinguisher
20. Level Gauge
21. Battery
22. Grounding Bracket (4)
23. Exterior Hydraulic Control Panel
24. Drum/Drive Coupling(s)

Revolution Series PT-3500 / PT-7500 Puller Tensioner Page 18
Operation
Safe-Zone Cab
The Safe-Zone Cabis designed to keep the operator off the ground
while the equipment is in use, and is built with a polycarbonate front
window, fully adjustable ergonomic seat, high-resolution color LCD
screen, and a full set of electronic controls. The Safe-Zone Cab
comes in several sizes andforms, dependent upon the machine. It is
designed toreduce operator fatigue, reduce errors andinjuries in the
and also reduce
environments.
OperatorsControls
Ergonomic Operators Chair
Auxiliary Power Port
A12-VoltDCpower port has been
provided on the operator control
console. This port can be used to charge
cellular
telephones, or
provide power
for other
similar
devices.
CAUTION:Do not use ammonia-based
cleaners. Use only non-ammonia-based
cleaners to clean the front polycarbonate
window. Using ammonia on polycarbonate will
cause structural damage to the polycarbonate
material, thereby degrading the impact
resistance of the front window. This can create
a hazardfortheoperatorshould alinebrakeage
situation occur.