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