AFS303 Hydraulic Puller-Tensioner

5 Blue Heron Drive
Comstar Supply, INC Collegeville, PA 19426

Think Cable... Think Comstar Phone: 610-831-5020
Fax: 610-831-5012
1-866-326-6782 www.comstarsupply.com
USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL
AFS303 Hydraulic Puller-Tensioner
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
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Important Safety Notice

Before using a Condux AFS303 Hydraulic Puller-Tensioner, operators must read and understand all
procedures and safety instructions. Note all safety information on this page, and note specific safety
requirements as explained by the procedures in this manual.
Failure to follow these instructions could result in serious personal injury or death.
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.
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 International, Inc.
145 Kingswood Drive
Mankato, MN 56002-0247
1-507-387-6576
Fax 1-507-387-1442
E-mail: cndxinfo@condux.com
For questions on:
SAFETY - OPERATIONS - APPLICATIONS
CALL 1-800-533-2077
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Table of Contents
IMPORTANT SAFETY NOTICE.......................................... 2 G. DETERMINE PULLING OR TENSIONING RANGE... 16

COMMUNICATION WITH THE MANUFACTURER............ 2 H. SET PULLING/TENSIONING RANGE LEVER........... 17
1 GENERAL INFORMATION................................................. 4 I. TENSIONING OPERATION........................................ 18
A. COMMUNICATION WITH THE MANUFACTURER...... 4 J. PULLER OPERATION............................................... 19
B. TYPOLOGY AND FIELD USE..................................... 4 5 MAINTENANCE............................................................... 21
C. PERFORMANCES...................................................... 4 A. GENERAL INSTRUCTIONS...................................... 21
D. TECHNICAL CHARACTERISTICS ............................ 4 B. LEVELS CONTROL.................................................. 21
E. ACOUSTIC EMISSION............................................... 5 C. TIRE INFLATION PRESSURE................................... 21
F. GENERAL SAFETY INFORMATION............................. 5 D. SUGGESTED LUBRICANTS..................................... 21
G. GENERAL OPERATOR INSTRUCTIONS.................. 5 E. ENDOTHERMIC ENGINE MAINTENANCE................ 22
H. GENERAL MAINTENANCE INSTRUCTIONS............ 5 F. HYDRAULIC CIRCUIT MAINTENANCE..................... 22
I. THE INSTRUCTION MANUAL . ................................. 6 G. REDUCTION GEAR MAINTENANCE........................ 22
J. CONDITION OF USE................................................ 6 H. RADIATOR MAINTENANCE................................... 23
K. TEMPERATURE LIMITS FOR HYDRAULIC OIL....... 6 I. GREASING................................................................ 23
L. USE NOT ALLOWED............................................... 7 J. OTHER PERIODIC OPERATIONS............................. 23
M. RESPONSIBILITY................................................... 7 K. SUMMARY TABLE FOR ORDINARY
N. APPLIED NORMS................................................... 7 MAINTENANCE........................................................ 24
2 TRANSPORT AND POSITIONING INSTRUCTIONS.......... 8 6 TROUBLESHOOTING GUIDE.......................................... 25
A. MACHINE LIFTING.................................................... 8 7 APPENDICES.................................................................. 31
B. PACKAGING FOR SHIPMENT.................................... 8 1. SIDE VIEW............................................................... 31
C. UNPACKING............................................................... 8 2. TOP VIEW................................................................ 32
D. TRANSPORT ON TRAILER........................................ 9 3. SUGGESTED OILS AND GREASES.......................... 33
E. POSTIONING AND ANCHORING............................... 9 8 HOW TO DISABLE THE MACHINE................................. 34
3 SAFETY CONDITIONS.................................................... 11 A. TRANSPOST............................................................ 34
A. SAFETY DEVICES.................................................... 11 B. EXTENDED SERVICE STOP..................................... 34
B. EMERGENCY STOP DEVICE.................................... 11 C. STRIPPING.............................................................. 34
C. PERIODIC OPERATIONS......................................... 11 9 WARRANTY INFORMATION........................................... 35
D. RESIDUAL RISKS.................................................... 11 FACTORY ASSISTANCE............................................... 35
4 OPERATING PROCEDURE.............................................. 13 LIMITED WARRANTY.................................................. 35
A. SET-UP.................................................................... 13
B. START UP PROCEDURE.......................................... 13
C. STABILIZE PULLER-TENSIONER............................ 14
D. REEVING THE DRUM.............................................. 16
E. GUIDE ROLLERS..................................................... 16
F. POSITION REEL ELEVATOR..................................... 16
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General Information
1.
A. COMMUNICATIONS WITH THE MANUFACTURER
To receive 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 Machine-identifying Table.
B. TYPOLOGY AND FIELD USE

Puller-tensioner model AFS303 is suitable for stringing one conductor with a
maximum diameter of 36 mm (1.42 in.) and for recovering a single 10 mm (.39 in.)
diameter rope with a connector with maximum diameter of 48.5 mm (1.9 in.).
The machine is controlled by a hydraulic system that allows the machine to work
automatically in PULLER or in TENSIONER mode.
Power is transmitted to the large groove bull-wheels through a closed hydraulic circuit
with a variable delivery pump and fixed displacement motor, making it possible to
continuously change the speed in both rotating directions.
A hydraulic vacuum brake automatically stops the two bull-wheels if a hydraulic circuit
failure occurs.
The machine is equipped with quick hydraulic couplers for connection to all types of
reel winders and reel elevators provided by Condux.
C. PERFORMANCES
Maximum pull............................2490 daN (5600 lbs.)
Continuous pull..........................2000 daN (4496 lbs.)
Maximum tension......................2490 daN (5600 lbs.)
Continuous tension....................2000 daN (4496 lbs.)
Maximum speed........................ 3 mph
!ATTENTION: Using a rope with a 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 equipment, at sea level
and at 20°C (68°F)
D. TECHNICAL CHARACTERISTICS
Bull-wheels diameter:................ 1500 mm (60 in.)
Diesel engine:............................ 46 HP
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:........................................... Torison axle with electric brakes, DOT lighting, pintle
hitch & safety chains
Dimensions:............................... length - 4648 mm (183 in.)
width - 2133 mm (84 in.)
height - 2451 mm (96.5 in.)
Mass:......................................... 3248 kg (7161 lbs.)

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E. ACOUSTIC EMISSION
Level of continuous sound pressure to the operator seat (UNI 9432) Lep = 85 dB(A)
F. GENERAL SAFETY INFORMATION

a. Only trained and qualified operators should use this machine. Qualified
operators are those persons who have received training from the machine
owner’s company or from the manufacturer.
b. Use this machine only for the work it was designed to do.
c. Do not use this machine when unauthorized personnel are on the work site.
d. For safety during transport, this machine is shipped with no hydraulic oil and
fuel. Find characteristics and required quantities in the manual.
e. For questions regarding operation, function, maintenance, etc., contact the
manufacturer’s After-Sales Service.
G. GENERAL OPERATOR INSTRUCTIONS

a. Operators must be aware of all local, state, and federal safety regulations
governing the use of this equipment.
b. Operators must wear suitable clothing to reduce the possibility of
entanglement in the machine’s moving parts. Operators must not wear chains
or other jewelry for the same reason.
c. Operators must use personal protective gear (i.e. gloves, boots, helmet, etc.).
Hearing protection is required.
d. Operators must carefully follow all hazard-related instructions contained in this
instruction manual or indicated on the machine.
e. The work area for this machine must be as free as possible of oil or other
liquid spills as well as materials or equipment that may be considered an
obstacle to proper operation.
f. The operator must absolutely avoid direct inhalation of the system’s engine
exhaust gas.
H. GENERAL MAINTENANCE INSTRUCTIONS

a. It is absolutely forbidden to perform any maintenance or to adjust any
settings on this machine while stringing (except where otherwise indicated).
b. Stop the engine before performing any maintenance (except for those
instances indicated otherwise in this manual) and wait until the system
components are cool to the touch.
c. All maintenance performed on this machine must be done on a level surface
and while the system is not under load.
d. Only authorized and trained personnel are to perform maintenance, either
scheduled maintenance or repairs. Authorized and trained personnel are those
persons who have received training on the maintenance of this equipment
from the machine owner’s company or from the manufacturer.
e. Maintenance personnel must wear suitable clothes to reduce the possibility
of entanglement in the machine’s moving parts. Maintenance personnel must
not wear chains or other jewelry for the same reason.
f. Maintenance personnel must use personal protective gear (i.e. gloves, boots,
helmets, etc.).
g. All maintenance operations, either scheduled or repair, must be done
according to the instructions included in this manual and/or following technical
instructions provided by the manufacturer.
Failure to follow these instructions relieves the manufacturer from any responsibility
and voids the warranty.

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I. THE INSTRUCTION MANUAL

a. Information contained in this manual applies to all the operators charged with
the use and/or the maintenance of the machine.
b. This instruction manual is not a training manual.
c. Before using this machine, the job site supervisor and the operators must read
this instruction manual.
d. The supervisor must inform all operators about the instructions contained in
this manual.
e. All operators must carefully follow the instructions contained in this manual.
f. Before using the machine, the operator must know the positions and the
operation of all the controls.
g. The job site supervisor must verify that the instructions contained in this
manual are followed.
h. This instruction manual must be kept with the machine for the entire life of the
machine in order to be available to all potential users and operators.
i. The instruction manual must be kept in a sheltered and dry place.
!ATTENTION: This manual belongs exclusively to the manufacturer.

Reproduction (even in part) of its contents is forbidden.
J. CONDITION OF USE
a. Temperature:........................... from -10°C to +40°C. (14°F to 104°F)
b. Relevant moisture:.................. from 30% to 90% ± 5%.
c. Weather conditions:................. any (in line with working conditions).
d. Natural and/or artificial light of the work site.
K. TEMPERATURE LIMITS FOR HYDRAULIC OIL

When using the machine, you must always be aware of the operating conditions and
their effects on the possibility of exceeding the following temperature limits for the
system’s hydraulic oil.
TEMPERATURE LIMITS FOR HYDRAULIC OIL - °C (°F)

Hydraulic oil viscosity
Working condition ATF oil
VG 22 VG 32 VG 46 VG 68
-15°C -21 -14 -7 -1
Minimum temperature running in neutral position
(5°F) (-6) (7) (19) (30)
19°C 8 16 24 32
Minimum temperature running in full load
(66.2°F) (46) (61) (75) (90)
66°C 48 57 67 76
Maximum temperature running in full load
(150.8°F) (118) (135) (153) (169)
84°C 63 73 83 93
Maximum temperature running in neutral position
(183.2°F) (145) (163) (181) (199)
For additional information concerning the hydraulic oil, see the chapter on
“Maintenance” and the attached Comparative Table of the oils used on the machine.
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L. USES NOT ALLOWED

Never use the machine:
a. for lifting persons and/or goods.
b. in areas where the machine cannot be properly positioned and anchored.
c. in areas with brush or other materials that can easily catch fire.
d. in closed/unventilated sites or those that are poorly ventilated (tunnels or
similar areas).
e. at sites where fuels or explosives are present.
f. on aircraft, watercraft, floating platforms, and similar locations.
g. for structure demolition.
h. for pulling elastic elements.
i. with ropes or joints having larger diameters than those specified in this manual.
j. when the engine is off but the bull-wheels are moving.
k. with over-ridden or broken safety system devices.
l. when winding ropes and/or conductors having a smaller diameter after ropes
and/or conductors having a bigger diameter on the bull-wheels.
m. for handling trucks or other movable equipment.
M. RESPONSIBILITY
It is extremely dangerous and forbidden to use this machine in situations different
from those indicated in this manual.
Failure to use recommended restraints creates a situation of wrongful and

improper use and relieves the manufacturer of any responsibility for accidents
and/or injuries to persons and/or damage to property. This voids the
manufacturer’s warranty.
Similarly, the manufacturer’s responsibility ends when the following situations

occur:
a. tampering and/or modifying the system without the manufacturer’s express
written consent (in this case the operator becomes the manufacturer assuming
all obligations and responsibilities, both civil and penal).
b. using non-original spare parts for the machine.
c. performing poor maintenance on the machine.
d. using the machine while it is disconnected or when safety devices are
over-ridden.
e. for the connection to machine and/or plans not produced and not directly
authorized by the manufacturer in a written acceptance.
N. APPLIED NORMS
This machine is manufactured in conformity with the following norm:
98/37/CE Norm of the European Parliament and Council, dated 22 June 1998
referring to the laws of the machine’s member States.
89/336/CE Norm of the European Council, dated 03 May 1989 referring to the
laws of the electromagnetic compatibility of member States.
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Transport and Positioning

Instructions
2.
A. MACHINE LIFTING
When lifting the machine, use only devices (overhead traveling cranes, lift trucks,
ropes, cables, hooks, etc.) with a load capacity equal to or greater than the mass to
be lifted.
The instruments used for lifting (ropes, cables, hooks, etc.) must have a load
capacity equal to or greater than the mass to be lifted and must be connected to the
proper points on the machine (shown in Appendix 2, callout 3).
Personnel should not be on the machine when it is lifted.
!DANGER: Failure to follow the recommendations in this section

may create a dangerous situation and/or damage the machine,
resulting in the manufacturer’s warranty being voided.
B. PACKING FOR SHIPMENT

Transport by land by truck
This machine ships without flammable liquids. Certain surfaces may be protected by
cardboard and/or plywood and/or polyethylene film.
To prevent movement, nail wheel chocks securely in place. Attach the machine to the
floor of a truck box or trailer using chains and hooks at the attachment points
provided.
Transport by sea in wooden cases or container

This machine ships without flammable liquids. Metal parts are protected with
waterproof wax.
To prevent movement of the machine during transportation, nail wheel chocks

securely in place. Attach the machine to the floor of the container using chains and
hooks at the attachment points indicated (red flanges).
Materials usually used for packing are:

• wood
• nails and/or steel screws
• cardboard and/or paper
• polyethylene film
• adhesive tape
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 notify
the manufacturer of any discrepancies.
Use caution when unpacking to avoid damaging the product.
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!ATTENTION: Dispose all packaging materials in accordance with

local regulations.
!ATTENTION: Packaging materials must be eliminated in

conformity with the norms in force in the relevant country.
D. TRANSPORT ON TRAILER
Moving the unit from location to location at the job site must be done by connecting
the unit to the tow vehicle by means of the towing eye on the drawbar.
Before transporting this machine, lift the rear stabilizer (Appendix 1, callout 7) and the
front jack using the handle provided.
Check the tires for proper inflation pressure (5 bar / 72.5 psi).
No personnel may ride on the machine at any time while towing the machine at ANY
speed.
!ATTENTION: It is dangerous to tow the machine at speeds in

excess of the axle’s rated capacity or if the tires are not properly
inflated.
To prevent movement of the machine during transportation, nail wheel chocks

securely in place. Attach the machine to the floor of the truck box or trailer using
chains and hooks at the attachment points provided.
E. POSITIONING AND ANCHORING

Positioning and anchoring the machine must be done only by trained personnel who
can verify if the ground allows the necessary stability, support, and anchoring.
For best rope and/or conductor pulling, the machine should be placed at a distance
of no less than 2 times and no greater than 4 times the height of the first poll or
trestle (see Table 1).
Table 1
It is possible to use the machine at a distance of 1 to 2 times the height of the pole.
In that case the anchorage described below must be over-dimensioned by 125%
compared to the reported data, and more rings must be provided on the front side of
the machine.
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!PROHIBITION: Do not use the machine if the distance between

the machine and the pole is less than the height of the pole itself.
The following is the machine anchoring sequence:

a. The machine must be aligned as much as possible with the pull direction.
b. Properly position the anchor ram (Appendix 1, callout 5) operating on the
handle and set the rear stabilizer (Appendix 1, callout 7).
c. Anchor the machine to the ground by means of 2 stakes with a min. load
rating equal to 130% of the machine’s maximum pull force and connect
(Appendix 2, callout 3) with the anchoring stakes per the angles and lengths
indicated.
d. Take up the slack to the anchoring stakes prior to tensioning the system.
e. Test the machine pull (see Use Instructions in the following chapter) to allow
the machine to freely align itself to the pull.
f. Tension the anchoring stakes in a uniform way.
!ATTENTION: Dangerous situations may occur during machine

use if the anchoring instructions are not followed.
An 8 foot radius around the machine must be free of obstacles to make the
operation, adjustment, and maintenance of the machine as easy as possible.
To avoid overheating that may damage the system’s components, be sure air can
circulate freely through the cooling system’s radiator.
!DANGER: This machine is not a proper grounding device. Proper

grounding for the conductor system being installed must be
provided via other means.
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Safety Conditions
3.
3.
A. SAFETY DEVICES
This machine has the following safety devices:
1. a load-limiting device which automatically stops the endothermic engine once
the maximum pre-set load value has been exceeded.
2. a mechanical negative safety brake to stop movement in case of a lack of
hydraulic pressure.
3. a timing case to protect moving parts where technologically possible.
!DANGER: It is absolutely forbidden to use the machine without

protecting the timing cases or with damaged/disconnected safety
devices.
!ATTENTION: After a serious emergency and/or use of the

negative safety brake, check the wear condition of the discs and
the efficiency of the brake itself. If necessary, replace the brake
discs before re-using the machine.
B. EMERGENCY STOP DEVICE

An emergency stop device acts directly on the diesel engine.
!ATTENTION: Use the emergency stop device ONLY in dangerous

situations and for the operators’ safety.
NOTE: For restoring the machine, unlock the emergency device by

turning the push-button one quarter turn in a clockwise direction.
!PROHIBITION: Use the emergency stop device only for

emergency situations.
C. PERIODIC OPERATIONS
Every day, before starting work, the operator must verify the performance of the
machine’s safety devices.
!ATTENTION: Do not, for any reason, modify the machine’s safety

devices. The manufacturer declines any responsibility as a
consequence of the non-functioning of those devices.
D. RESIDUAL RISKS
The machine has the following residual risks:
1. Sudden break of the rope-conductor. The break of the rope causes

sudden movements of the machine and the rope or conductor connected to the
machine. To minimize the risks, the operator has to:
• Check the rope and replace it as soon as defects or wear signs appear.
• Comply with the working positions indicated in the manual.
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2. Sudden break of the anchoring stakes. The sudden break of the anchoring
stakes causes machine instability and sudden movements. To minimize the
risks the operator has to:
• Periodically check the anchoring stakes and replace them as soon as
defects or wear signs appear.
• Follow the anchoring suggestions described in the present manual.
• Comply with the working positions indicated in the manual.
3. Entangling or dragging the accessible rotating units. Due to the effective

use of the machine, it is not possible to cover some rotating parts (i.e. winding
of the rope or of the conductor on the bull-wheels or on the driving gears). To
minimize the risks, the operator has to:
• Avoid contact with the machine’s rotating units except for the control
devices.
• Respect the prescriptions indicated in the present manual about wearing
and using necessary safety devices.
4. Limb crushing during loading or removal of the reel and during rope-
conductor loading. These operations have a large risk margin due to the use
of mechanical parts to be moved. To minimize the risks the operator has to:
• Know the directives for accident prevention and apply them.
5. Electrostatic discharges. Since the machine does not have a proper

grounding device for during stringing operations, it is possible to have
dangerous electrostatics discharges on ropes and conductors. To minimize the
risks, the operator has to:
• Know the directives for accident prevention and apply them.
• Check if the job site has a suitable grounding device for the machine-rope-
conductors system.
6. Inhalation of the endothermic engine exhausting gas. This machine

discharges exhaust gas. To minimize the risks, the operator has to:
• Respect the working recommendations indicated in the manual.
• Respect the attentions and prohibitions indicated in the present manual.
• If necessary, use safety devices for respiratory tracts.
7. Command lever that can be locked in working position. For functional

reasons and for comfort, the control joystick will stay where it is positioned. The
machine is equipped with two security devices which prevent the creation of
dangerous situations: an electric limiting device of the pull on the dynamometer
which stops the power station when the stated value is reached, and a pull
limiting device which maintains a preset pulling load regardless of the speed
that the machine is operated. To minimize the risks, the operator must:
• Put the electric limiting device of the pull on a value just superior to the
regulating valves of the pull.
• Plan the desired pull as described in the manual.
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Operating Procedure
5.
4.
A. SET-UP
1. Position puller-tensioner slightly to left or to the right of the first overhead
structure being worked with. The machine should not be positioned directly
inline with the overhead structure. A slight offset to the right or left will provide
better engagement during operation.
The puller-tensioner also needs to be positioned far enough away from the
first structure to obtain a 1.5- to 2-degree fleet angle. This distance can be
calculated by multiplying 2.5 by the height of the first block on the pulling
structure. For example if the first block is at 80 feet high, the puller-tensioner
should be positioned 240 feet back.
2. Set rear stabilizer leg by removing the keeper pin (See Figure 1) and lowering
the leg as close to the ground as possible and replacing pin. (See Figure 2)
Figure 1. Remove Keeper Pin Figure 2. Lower Leg, Replace Pin
B. START UP PROCEDURE
!IMPORTANT: Read all instructions before starting the AFS 404
Puller-Tensioner.
1. To start the machine, insert the key

into the ignition, push in and turn
one position clockwise.
2. Push glow plug toggle switch down.
(See Figure 3)
3. Wait for yellow glow plug light to
turn off.
4. Push ignition key in and turn the
key clockwise to start.
5. Adjust engine throttle to 2,200 rpm.
(See Figure 4)
6. Set cooling fan to 700 psi., 50 bar.
(See Figure 5)
7. Set reel elevator hydraulic pressure
to 500 psi., 40 bar. (See Figure 6) Figure 3. Push Glow Plug Toggle
Switch Down
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Figure 4. Adjust Engine Throttle Figure 5. Set Cooling Fan
Figure 6. Set Rear Elevator Figure 7. Engage Leveling

Hydraulic Pressure Joystick Down
C. STABILIZE PULLER-TENSIONER
1. Set the front of the unit as low as possible by engaging the leveling joystick
down. (See Figure 7)
!NOTE: The engine compartment should be level or parallel with

the ground for operation. (See Figure 8)
2. Re-adjust the rear stabilizer leg by removing the keeper pin (See Figure 9) and
lowering the leg as close to the ground as possible and replace pin.
(See Figure 10)
3. Re-adjust the front of the machine. Push up on the leveling joystick to raise
the front end of the puller-tensioner and adjust accordingly until pressure is
placed on the rear jack stand. (See Figure 11)
4. Anchor the puller-tensioner in two locations. The first position in on the left
side of the upper drum, directly in the center of the machine. (See Figure 12)
The second position is adjacent to the operator panel. (See Figure 13)
Temporary ground anchors or solid structures are required for proper
machine anchoring.
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Figure 8. Engine Compartment Figure 9. Remove Keeper Pin

Level or Parallel with Ground
Figure 10. Lower Leg Replace Pin Figure 11. Push Up on Leveling
Joystick
Figure 12. Anchor Figure 13. Anchor
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D. REEVING THE DRUM

1. Reeve the drum appropriately for the type of operation being performed.
When reeving the drums, always start on the inside of the drum, toward the
center of the machine and reeve the rope so that it goes over the top of the
lower drum and enters within the first groove of the upper drum and comes
back around entering on the first groove of the lower drum. The rope then
travels to the second groove of the upper drum. Continue reeving accordingly
moving one position to the left each time. (See Figure 14)
E. GUIDE ROLLERS
1. Align guide rollers to correspond with the pulling position of the reel stand.
Loosen guide roller bracket bolts. Slide guide rollers to the left or right to
properly align. Re-tighten bolts. Thread poly rope through guide rollers.
(See Figure 15)
Figure 14. Continue Reeving, Figure 15. Thread Poly Rope

Moving One Position to Left Through Guide Rollers
F. POSITION REEL ELEVATOR

1. Position and connect reel elevator according to specific reel elevator
instructions.
G. DETERMINE PULLING OR
TENSIONING RANGE
Determine the proper pulling or tensioning
range for the particular operation.
The inside scale of the dynamometer

represents pulling or tensioning in the low
range, between 400 to 1,500 foot-pounds.
The center scale represents tensioning in
the high range between 1,500 to 10,000
foot-pounds. The outer scale represents
pulling in the high range between 1,500
and 10,000 foot-pounds. (See Figure 16)
Figure 16. Dynamometer
Scale Settings
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To determine pulling or tensioning ranges use the following formula: (See Table 2)
A (Final Sag Tension) minus B (Max Pulling Tension Below Final Sag
Tension) minus C (1,000 ft-pounds)= Dynamometer setting
Example:
Final Sag Tension= 2,500 ft-pounds

-minus-
Maximum Pulling Tension Under Final Sag Tension= 500 ft-pounds
Equals: 2,000 ft-pounds
-minus-
Tension setting of 1,000 ft-pounds below pulling tension
Equals: 1,000 ft-pounds
Table 2
H. SET PULLING/TENSIONING RANGE LEVER

1. Position range lever according to the range of pulling or tensioning being
performed. The center position is neutral. The position toward the machine is
high range. And the position moving away from the machine is for low range
operation. To move the lever, pull out and hold the lever detent then push or
pull the lever into the appropriate position. (See Figures 17 & 18) Release
detent.
Figure 17. Pull Out and Hold Figure 18. Push or Pull the Lever
Lever Detent to Appropriate Postition
!IMPORTANT! The pulling range lever will not set when there is
pressure on the drum. Also, never set or adjust pulling range
lever when there is tension on placed conductor. Moving the lever
to neutral will release conductor tension.
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I. TENSIONING OPERATION
1. Start the puller tensioner per start up instructions.
2. Engage negative brake by turning negative brake switch one position

clockwise. (See Figure 19)
3. Move bull wheel control joystick to the down position. (See Figure 20)
Figure 19. Engage Negative Brake Figure 20. Move Bull Wheel
Joystick to Down Position
4. Set dynamometer according to the specific tensioning range required by

turning the dynamometer knob clockwise to increase and counter clockwise to
decrease until range is appropriately set. (See Figure 21)
5. Move the bull wheel joystick to the neutral position. (See Figure 22)
Figure 21. Set Dynamometer Figure 22. Move Bull Wheel

Joystick to Neutral Position
6. Move bull wheel joystick to the down position and begin tension operations.
(See Figure 23)
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7. Disengage the negative brake by turning the negative brake switch

counterclockwise.
J. PULLER OPERATION
1. Start the puller tensioner per start up instructions.
2. Engage negative brake by turning negative brake switch one position

clockwise. (See Figure 24)
Figure 23. Move Bull Wheel Figure 24. Engage Negative Brake
3. Move bull wheel control joystick to the down position (See Figure 25)
4. Establish the failsafe emergency brake value at 1,000 foot-pounds above final
sag tension. Set level by inserting the turnkey into center of the dynamometer
gauge and adjusting the red indicator arm to appropriate failsafe level.
(See Figure 26)
Figure 25. Move Bull Wheel Figure 26. Set Failsafe Emergency
Joystick to Down Position Brake Value
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5. Set dynamometer according to the specific pulling range required by

turning the dynamometer knob clockwise to increase and counter clockwise to
decrease until range is appropriately set. (See Figure 27)
6. Move the bull wheel joystick to the neutral position. (See Figure 28)
Figure 27. Set Dynamometer Figure 28. Move Bull Wheel

Joystick to Neutral Position
7. Disengage the negative brake by

turning the negative brake switch
counterclockwise.
8. Move bull wheel joystick to the

down position and begin pulling
operations. The puller-tensioner
will continually adjust speed to
maintain proper pulling tension
throughout operation.
(See Figure 29)
Figure 29. Move Bull Wheel

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Maintenance
5.
A. GENERAL INSTRUCTIONS
!ATTENTION: Repairs not done by the manufacturer and not
allowed by a written authorization relieve the manufacturer of any
responsibility in the case of accidents to persons or damages to
things and/or the machine, causing the loss of the warranty.
B. LEVELS CONTROL
For safety reasons during transport, the machine comes without hydraulic oil and fuel.
Fill the levels per the following table:
Amount in liters
a. Hydraulic oil level (Appendix 1, callout 1) 140 (37 gal)
b. Reduction unit oil level 1.6 (0.4 gal)
c. Parking brake oil level (Appendix 2, callout 10) 0.3 (0.1 gal)
d. Engine oil level (see enclosed engine booklet)
e. Fuel level (Appendix 1, callout 4) 50 (13.2 gal)
!ATTENTION: Non-respect for the correct levels causes serious

damage to the installed components.
!DANGER: Do not ingest hydraulic liquids, fuels, and cooling

liquids because they can be injurious to health and
potentially lethal.
C. TIRE INFLATION PRESSURE

Tire inflation pressure has to be 5 bar (72.5 psi).
!ATTENTION: Ignoring proper tire inflation pressure causes

dangerous situations during transport operations.
D. SUGGESTED LUBRICANTS
The manufacturer tests the machine with the following oils and lubricants:
a. hydraulic circuit, reduction gear, and stationary brake: IP HYDRUS OIL
46 (ISO HM 46).
b. mechanical reduction unit: IP MELLANA-220 (ISO CKC 220).
Possible different trademarks must be chosen on the basis of the enclosed table
“SUGGESTED LUBRICANTS.” It is possible to use different trademarks with the
same characteristics and ISO specifications. When using oil with characteristics and
ISO specifications different from the ones declared during testing, completely empty
the hydraulic circuit.
!ATTENTION: Using lubricants not in conformity with the technical

specifications indicated in the present manual may seriously
damage the machine components and, consequently, the invalidate
the warranty conditions.
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E. ENDOTHERMIC ENGINE MAINTENANCE

See the enclosed use and maintenance booklet. To fill the fuel tank, use the filling
cap on the tank (Appendix 1, callout 4).
!DANGER: To fill with fuel, turn off the engine. Before any
operation, let the engine cool.
F. HYDRAULIC CIRCUIT MAINTENANCE

a. Change the hydraulic oil after 500 working hours and, thereafter, every 1500
hours (at least every year).
b. Use the suitable tap on the bottom of the tank to discharge the hydraulic oil.
!DANGER: Let the hydraulic oil cool completely before removing it

and always use suitable safety gear (gloves, etc.).
!ATTENTION: Discharging the oil must be done in conformity with

the laws of the relevant country.
c. Fill the oil in the tank with the correct quantity (Appendix 1, callout 1).

!ATTENTION: When filling the oil tank, make sure no foreign matter,
which could cause irreparable damage to the circuit’s components,
enters with the oil. If possible, filter the oil with a 10 µm filter.
d. Replace the filter cartridges (Appendix 2, callout 5 & 6) after 500 working hours
and, thereafter, every 1500 hours (at least every year).
e. Each day, verify the correct operation of the hydraulic oil filters by checking the
filter indicators on the control panel. If necessary, replace the cartridges by taking
care of the following filtering grade:
• Intake filter (Appendix 2, callout 2): 10 µ (nominal values)
• Intake filter (Appendix 2, callout 6): 90 µ (nominal values)
• Intake filter: 25 µ (nominal values) – opt
For further maintenance operations of installed hydraulic components (pumps and

motors), refer to the enclosed documentation.
G. REDUCTION GEAR MAINTENANCE

a. Change the oil of the reduction gear after 50 working hours and, thereafter,
every 500 hours (at least every year).
b. To discharge the oil of the reduction gear, use the suitable caps on the lower
part of the casing of the reduction gear.
!DANGER: Let the hydraulic oil cool completely before removing it

and always use suitable safety gear (gloves, etc.).
!ATTENTION: Discharging the exhaust oil must be done in

conformity with the laws of the relevant country.
c. Fill the oil of the reduction gear through the cap located on the upper part of
the casing.
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!ATTENTION: When filling the oil tank, make sure no foreign

matter, which could cause irreparable damage to the circuit’s
components, enters with the oil.
For further maintenance operations of installed hydraulic components (pumps and

motors), refer to the enclosed documentation.
H. RADIATOR MAINTENANCE
Clean all radiators at least once a year and more if the machine is very dirty.
!ATTENTION: Persons in charge of maintenance, besides wearing

all the protection devices shown in this manual, must also wear
devices for protecting their respiratory organs.
I. GREASING
Grease the crown gear of the bull-wheels 2-3 times per day, using the suitable
greaser (Appendix 2, callout 2).
Grease all other machine parts subjected to rotation or translation, which do not
have a grease zerk or an automatic greasing system every week. Use IP ATHESIA
GR2 (ISO XBCEA 2) grease or an equivalent trademark on the basis of the enclosed
“SUGGESTED LUBRICANTS” Table.
J. OTHER PERIODIC OPERATIONS

When cleaning the machine, avoid direct jets of water or steam on the components
of the electric system of the machine and on the control board.
For the other periodic operations, refer to the Summary Table for ordinary
maintenance.
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K. SUMMARY TABLE FOR REGULAR MAINTENANCE

Following are the procedures and intervals for periodic maintenance.
Interval
Part Object
Daily 50 h 250 h 500 h 1500 h
Engine oil CL ST
Oil filter ST
Cooling liquid CL ST
Diesel engine (***)
Air filter VF ST
Fuel CL
Fuel filter ST
Hydraulic oil CL ST1 ST(*)
Hydraulic circuit
Filters VF ST1 ST(*)
Negative brake Discs (**)
Reduction gear Oil CL ST1 ST(*)
Bull-wheels Gears GR
Front plough Rod GR
Tire pressure VF
Axle
Stationary brake GR
Legend:
CL Check the level (and possibly fill up)
GR Grease
ST Replace
ST1 Replace (only for the first intervention)
VF Check
(*) At least once a year
(**) Check the wear-condition of the discs after an emergency stop.
(***) For further information, see the engine booklet.
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Troubleshooting Guide
6.
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Appendices
7.
1. SIDE VIEW
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2. TOP VIEW
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3. SUGGESTED OILS AND GREASES
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How to Disable the Machine
8.
A. TRANSPORT
Before transporting the machine, empty any flammable liquids contained in the
machine (oils and fuels).
Transport must be done per the specifications described in chapter 3 (Transport and
Positioning instructions).
B. EXTENDED SERVICE STOP

When anticipating an extended service stop (two months at least), protect the
external parts with waterproof wax and empty the fuel tank.
During a service stop, start the machine at least once every two months and let the
machine idle for at least one hour, so the oil enters the hydraulic system to prevent
the gaskets from drying.
Store the machine under a roof. Do not cover the machine with pieces of cloth and/or
plastic materials that may cause an increase in the temperature and/or humidity.
If the machine is not used for one or more years, replace the hydraulic oil and
hydraulic circuit filters before re-starting the machine.
C. STRIPPING
Machine stripping has to be done by the manufacturer or by a specialized factory.
All the stripping operations must conform to company norms for accident prevention.
Waste materials must be divided by type (i.e. iron scrap, aluminium, plastic, rub, etc.)
and disposed according to the laws in force.
Used oils and polluting substances must be disposed by means of authorized

structures in conformity with the laws in force.
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Warranty Information
3.
9.
FACTORY ASSISTANCE
Condux International, Incorporated (Condux) can provide further advice regarding
any problems with the installation, service, assembly, or disassembly of the Condux
AFS303 Hydraulic Puller-Tensioner. Call toll free at 1-800-533-2077 (USA and
Canada) or 1-507-387-6576 and ask for assistance. The Condux AFS303 Hydraulic
Puller-Tensioner can be returned to the factory at any time for service or repair;
however, a Return Material Authorization (RMA) must be obtained from Condux
before shipping.
Condux will not accept returned items without an RMA.
LIMITED WARRANTY
Condux International, Incorporated (Condux) extends the following warranty to the
original purchaser of these goods for use, subject to the qualifications indicated:
Condux warrants to the original purchaser for use that the goods or any component
thereof manufactured by Condux will be free from defects in workmanship for the
period of one year from the date of purchase, provided such goods are installed,
maintained, and used in accordance with Condux’s written instructions.
Components not manufactured by Condux, but used within the assembly provided
by Condux, are subject to the warranty period as specified by the individual
manufacturer of said component, provided such goods are installed, maintained, and
used in accordance with Condux’s and the original manufacturer’s written instructions.
Condux’s sole liability and the purchaser’s sole remedy for a failure of goods under
this limited warranty, and for any and all claims arising out of the purchase and use
of the goods, shall be limited to the repair and replacement of the goods that do not
conform to this warranty.
To obtain repair or replacement service under the limited warranty, the purchaser
must contact the factory for a Return Material Authorization (RMA). When the RMA is
received, send the RMA with the defective part or goods, transportation prepaid, to:

145 Kingswood Drive
Mankato, MN 56001 USA
THERE ARE NO EXPRESS WARRANTIES COVERING THESE GOODS OTHER

THAN AS SET FORTH ABOVE.
THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE YEAR FROM
DATE OF PURCHASE.
CONDUX ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION

OR USE OF THIS PRODUCT, EXCEPT AS STATED IN THIS LIMITED WARRANTY.
CONDUX IS NEVER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL

DAMAGES.
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P.O. Box 247 • 145 Kingswood Drive, Mankato, MN 56002-0247 USA
1-507-387-6576 • 1-800-533-2077 • FAX 1-507-387-1442
Internet: http://www.condux.com • e-mail: cndxinfo@condux.com
© Copyright 2008, Condux International, Inc.
Printed in USA
Literature Part Number: 21032244
Revision Number: 1.0

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5 Blue Heron Drive

Comstar Supply, INC Collegeville, PA 19426

USER'S GUIDE & SAFETY MANUAL USER'S GUIDE & SAFETY MANUAL

AFS303 Hydraulic Puller-Tensioner

Important Safety Notice

Save this user’s guide for future reference.

COMMUNICATION WITH THE MANUFACTURER:

For questions on:

SAFETY - OPERATIONS - APPLICATIONS

IMPORTANT SAFETY NOTICE.......................................... 2 G. DETERMINE PULLING OR TENSIONING RANGE... 16

B. TYPOLOGY AND FIELD USE

!ATTENTION: Using a rope with a smaller diameter will reduce the

F. GENERAL SAFETY INFORMATION

G. GENERAL OPERATOR INSTRUCTIONS

H. GENERAL MAINTENANCE INSTRUCTIONS

I. THE INSTRUCTION MANUAL

!ATTENTION: This manual belongs exclusively to the manufacturer.

K. TEMPERATURE LIMITS FOR HYDRAULIC OIL

TEMPERATURE LIMITS FOR HYDRAULIC OIL - °C (°F)

L. USES NOT ALLOWED

Failure to use recommended restraints creates a situation of wrongful and

Similarly, the manufacturer’s responsibility ends when the following situations

Transport and Positioning

Personnel should not be on the machine when it is lifted.

!DANGER: Failure to follow the recommendations in this section

B. PACKING FOR SHIPMENT

Transport by sea in wooden cases or container

To prevent movement of the machine during transportation, nail wheel chocks

Materials usually used for packing are:

Use caution when unpacking to avoid damaging the product.

!ATTENTION: Dispose all packaging materials in accordance with

!ATTENTION: Packaging materials must be eliminated in

!ATTENTION: It is dangerous to tow the machine at speeds in

To prevent movement of the machine during transportation, nail wheel chocks

E. POSITIONING AND ANCHORING

!PROHIBITION: Do not use the machine if the distance between

The following is the machine anchoring sequence:

!ATTENTION: Dangerous situations may occur during machine

!DANGER: This machine is not a proper grounding device. Proper

!DANGER: It is absolutely forbidden to use the machine without

!ATTENTION: After a serious emergency and/or use of the

B. EMERGENCY STOP DEVICE

!ATTENTION: Use the emergency stop device ONLY in dangerous

NOTE: For restoring the machine, unlock the emergency device by

!PROHIBITION: Use the emergency stop device only for

!ATTENTION: Do not, for any reason, modify the machine’s safety

1. Sudden break of the rope-conductor. The break of the rope causes

3. Entangling or dragging the accessible rotating units. Due to the effective

5. Electrostatic discharges. Since the machine does not have a proper

6. Inhalation of the endothermic engine exhausting gas. This machine

7. Command lever that can be locked in working position. For functional

Figure 1. Remove Keeper Pin Figure 2. Lower Leg, Replace Pin

1. To start the machine, insert the key

Figure 4. Adjust Engine Throttle Figure 5. Set Cooling Fan

Figure 6. Set Rear Elevator Figure 7. Engage Leveling

!NOTE: The engine compartment should be level or parallel with

Figure 8. Engine Compartment Figure 9. Remove Keeper Pin

Figure 12. Anchor Figure 13. Anchor

D. REEVING THE DRUM

Figure 14. Continue Reeving, Figure 15. Thread Poly Rope

F. POSITION REEL ELEVATOR

The inside scale of the dynamometer

Final Sag Tension= 2,500 ft-pounds

H. SET PULLING/TENSIONING RANGE LEVER