•Operation •Service •Parts SHERMAN&REILLY,INC.sherman-reilly.com/wp-content/uploads/2015/01/product_media-bwt… · tional and OPGW fiber optic. Each bullwheel is controlled

Tensioner

• Operation• Service• Parts

SHERMAN & REILLY, INC.P.O. Box 11267 • 400 West 33rd StreetChattanooga, TN 37401 USAPhone 423•756•5300Fax No. 423•756•2948Toll-Free 800•251•7780Web Site www.sherman-reilly.com

© Copyright August 26, 2003 Sherman & Reilly, Inc.

August 26, 2003 I

TABLE OF CONTENTS

Section 1 • INTRODUCTIONImportant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Section 2 • SAFETYWarning Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Operator Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Employer Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Section 3 • OPERATIONDescription of Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Terms You Need To Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Set-up to Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5Reel Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9Hydraulic Retriever (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10Spider Rewind System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

Section 4 • SERVICEGeneral Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Hydraulic System (Optional Power Pack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3Service Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

II

1.1

Section 1 • INTRODUCTION

IMPORTANT INFORMATION

It is very important to all of us at Sherman &Reilly that every machine is operated in a safemanner. We have taken every precaution toguard against the possibility of an accident. Toproperly, safely operate this machine, it is neces-sary and important that operators and servicepeople read and understand the information inthis and the engine manufacturer’s manual.ANYONE working around the machine shouldread the safety precautions in the manuals. Beaware each warning and precaution is to helpprotect against needless injury. Taking unneces-sary risks and ignoring warnings is the primarycause of personal injury and fatal accidents inthe work place. If you have any questions regard-ing operation or safety of a procedure or situa-tion, contact the Sherman & Reilly CustomerService Manager at 1-800-251-7780.

The Sherman & Reilly BWT-1303 Tensioner uti-lizes precision machined urethane lined groovesfor ultimate control of conductors, both conven-tional and OPGW fiber optic. Each bullwheel iscontrolled by a fully adjustable, articulatedcaliper braking system with a ventilated bronzedisc. Options include manual retriever, hydraulicretriever, hydraulic spider rewind, spider levelwind, and hydraulic power pack to make it inde-pendent of any other power source. Conductorreels are easily changed by disengaging thebrake from the reel bar.

This manual is of no value if the operator doesnot read and understand the instructions andprecautions (before starting and trying to operatethe machine). The operator must be aware of themachine’s capacities and limitations. It is theoperator’s responsibility to watch for situationsand conditions which could affect the normalperformance of the machine and safety in thework area.

Publication of this manual and the safety pre-cautions in it does not in any way represent anall inclusive list. It is the operator’s responsibilityto make sure the machine is operated in accor-dance with all state and local safety require-ments and codes, including all applicable OSHA(Occupational Safety and Health Act) and ANSI(American National Standards Institute) regulations.

Should a problem or unsafe condition arise,shut the machine down using the normal shut-down procedure. In the event of an emergency,use the emergency stop procedure. Turn igni-tion key off, then apply emergency/parkingbrake. Notify the proper authority or follow youremployer’s prescribed procedure for an emer-gency situation.

Sherman & Reilly strongly rec-ommends that only persons lit-erate and understanding theEnglish language be consid-ered as operators or servicepersonnel for this machine.

1.2

Section 1 • INTRODUCTION

GENERAL SPECIFICATIONS*

TENSIONERMaximum Tension Capacity . . . . . . . . 3,000 lbs.Maximum Line Speed. . . . . . . . . . Four (4) MPHBullwheel Diameter . . . . . . . . . . . . . . 30 inchesNumber of Grooves . . . . . . . . . . . . . . . . Five (5)Groove Diameter . . . . . . . . . . . 1.500" StandardGroove Lining . . . . . . . . . . . . Cast PolyurethaneBrake . . . . . . . . . . . . Caliper/Disc 20" DiameterBrake Control. . . . . . . . . 3-Axis Caliper, ManualFairlead Roller . . . . . . . . . . . . . . . . . . AdjustableNote: Larger Bullwheels also available

REEL CARRIERMaximum Reel Diameter . . . . . . . . . . . . . . . 72"Maximum Reel Width . . . . . . . . . . . . . . . . 44.5"Maximum Reel Weight. . . . . . . . . . . . 6,500 lbs.Reel Shaft . . . . . . . . . . . . . . . . . . . . . . . . 2.625"Brake . . . . . . . . . . . . Caliper/Disc 16" Diameter

Ventilated BronzeBrake Control . . . . . . . . . . . . . . . . . . . HydraulicRewind . . . . . . . . . . . . . . . . . Manual/HydraulicNOTE: Larger Reel Carrier also available

TRAILEROverall Length . . . . . . . . . . . Approx. 16 ft. 6 in.Overall Width . . . . . . . . . . . . . . . . Approx. 8 ft.Overall Height . . . . . . . . . . . . . . . . Approx. 8 ft.Maximum Gross Vehicle Weight . . . 11,000 lbs.Axle Capacity. . . . . . . . . . . . . . . . . . 10,000 lbs.Suspension . . . . . . . . . . . . . . . . . . . . Leaf SpringTire Size . . . . . . . . 11R17.5HC, 14 Ply TubelessBrake . . . . . . . . . . . . . . . . . . Electric (Standard);

Air (Optional)Front JackDrop Leg and Screw Type (1);

Hydraulic (Optional)Rear Jacks . . . . . Two (2) Drop Leg and Pin TypeLights . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VoltTowing . . . . . . . . . . . . . 3" Adjustable Pintle EyeSafety Chains and Hook. . . . . . . . . . . . . Two (2)

HYDRAULIC SPIDER REWINDMaximum Torque . . . . . . . . . . . . 10,500 in. lbs.Maximum Pulling Capacity . . . . . . . 700 lbs. on

30" Diameter ReelMaximum Line Speed . . . . . . . . . . Five (5) MPHFailsafe Brake . . . . . . Spring Applied, Hydraulic

Released, AutomaticHydraulic Motor . . . . . Low Speed, High TorqueSpider Levelwind . . . . 12-Volt Electric Actuated

HYDRAULIC RETRIEVERMaximum Torque . . . . . . . . . . . . 25,500 in. lbs.Maximum Pulling Capacity. . . . . . 1,700 lbs. on

30" Diameter ReelMaximum Line Speed . . . . . . . . . . Two (2) MPHHydraulic Motor . . . . . Low Speed, High Torque

POWER PACKEngine. . . . . . . . . . . . . . . . . . . 18 HP (Gasoline)

Electric StartHydraulic Fluid . . . . . . . . . . . . . Dexron Quality

Transmission FluidHydraulic System Filtration . . . . . . . . 10 MicronMaximum Hydraulic Pressure . . . . . . . 2750 PSIMaximum Hydraulic Flow . . . . . . . . . . 10 GPM* Dimensions, weights, capacities are approximate. Manufac-

turer’s specifications subject to change without notice.

2.1

Section 2 • SAFETY

WARNING TERMS

Signal words in this manual call the operator’sattention to safety concerns.

The word DANGER indicates the informationrelates to a specific immediate hazard which, ifdisregarded, will result in severe personal injuryor death.

The word WARNING indicates the informationrelates to a specific immediate hazard or unsafepractice which, if disregarded, could result inpersonal injury or death.

The word CAUTION indicates the informationpertains to a potential hazard or unsafe practicewhich, if disregarded, may result in minor per-sonal injury or equipment damage.

The word NOTE indicates the information isimportant to the correct operation or mainte-nance of the machine.

NOTE

CAUTION

WARNING

DANGER

Do not place any part of the body into a poten-tial pinch point. The machine must be turnedoff and locked out in accordance with OSHAregulations before attempting to correct a prob-lem, working on the machine, or performingregularly scheduled service.

Do not attempt to operateSherman & Reilly equip-ment without properinstruction, including read-ing and understanding themanual.

Obey and enforce all warnings including OSHArequirements and ANSI standards.

Never allow anyone to ride on the unit while it isbeing towed.

Always wear proper safetyequipment as requiredby employer.

Never bypass safety switches oroperate equipment with faultysafety devices.

Be sure all guards and accesscovers are secure in placewhen the machine is beingoperated.

Be aware of people in thework area who may be atrisk during operation.

Know all emergency shut-down procedures.

Do not obstruct controls or fire extinguisher.

DANGEROPERATOR SAFETY PRECAUTIONS

2.2


Make sure fire extinguisher is fully charged.

Never operate equipment while under the influ-ence of any substance which could impair oper-ator ability or judgement. This presents a safetyhazard in the work place.

Always use employer approved grounding pro-cedures when operating the machine.

Do not operate equipment if work ability isimpaired by fatigue, illness, or other causes.

Never use hands to check for hydraulic systemleaks. Hydraulic fluid escaping under pressurecan cause personal injury.

Keep all body parts, head, and limbs away fromall moving parts.

Know location and function of all controls,gauges, instruments, and protective devices.

Never use controls or hoses for hand holds.

Do not climb on machine – use the operationplatform.

Do not exceed unit specifica-tions and limitations forweight.

Know where to get help inthe event of an emergencyor injury.

Maximum towing speed is 60 miles per hour.Towing speed may be slower in certain conditions.

Avoid contact with pumps, hoses, engine com-ponents, and exhaust system. (Optional PowerPack Only)

Do not refuel unit while the engine is running orhot. (Optional Power Pack Only)

Do not jump start with cable ground connectiondirectly on the battery. (Optional Power Pack Only)

Do not make physical contact with rope, cable,or conductor as it enters or leaves machine orreel.

To prevent the possibility ofelectrocution, do not enter orleave the unit while it is operat-ing or allow anyone to touch orlean on the machine when inuse.

2.3


This guideline is intended to assist owners/employers to ensure equipment is serviced andoperated in a safe manner. Each job site mayhave additional situations and conditions whichneed consideration.

Monitor the operators to be sure they observeand practice safety procedures and operate thesupport equipment as outlined in this manual.

Establish a regular inspection program whichincludes malfunction reports, inspection, andservice records. This inspection should cover themachine condition, adjustment, and ensure allsafeguards are in place and functional.

Make sure that any malfunction or breakdownthat will affect the safe operation of the equip-ment is properly corrected or repaired beforereturning machine to service.

The employer shall provide training and instruc-tion in safe methods of work before assigningworkers to operate, service, or repair the equip-ment. A record of training dates, employeenames, and level of training should be main-tained. Only persons literate and understandingthe English language should be considered tooperate this machine.

Employer shall utilize a lock-out/tag-out proce-dure which complies with part 1910.147 of Title29 of the Code of Federal Regulations (OSHA).The procedure will include control of all keys.

The employer will specifically inspect all safetyequipment and protective devices on the equip-ment to ensure they are not bypassed or disabled.Operation of the equipment will not be permittedunless all safety devices are functional and inplace. The employer shall meet the appropriateprotection requirements for the workers.

EMPLOYER SAFETY REQUIREMENTS

2.4


3.1

Section 3 • OPERATION

DESCRIPTION OF OPERATING CONTROLS

IGNITIONSWITCH

PAYOUT/PULL IN CONTROL(SPIDER REWIND OPTION)

HYDRAULICREEL BRAKEPRESSURE GAUGE

LEVELWIND CONTROL(SPIDER LEVELWIND OPTION)

HYDRAULICRETRIEVER

CONTROL LEVER(OPTIONAL)

POWER PACKOPTION

REEL BRAKE

UPPER BULLWHEEL BRAKE

LOWERBULLWHEELBRAKE

HYDRAULIC REEL BRAKE CONTROL

PAYOUT/PULL-IN CONTROL(Spider Rewind Option)This three-position lever is used to operate the“rewind unit”. It controls the direction of traveland speed. The lever is proportional; the furtherthe lever is moved, the faster the reel rotates. Thelever returns to the neutral position whenreleased.

HYDRAULIC REEL BRAKE PRESSURE GAUGEThis gauge indicates the brake pressure mea-sured in pounds per square inch (PSI).

LEVELWIND CONTROL(Spider Levelwind Option)The levelwind is used in conjunction with therewind unit when pulling-in pilot line. Thisswitch is used to oscillate the levelwind arm leftto right so the pilot line is evenly applied to thestorage reel. The lever returns to neutral whenreleased.

HYDRAULIC REEL BRAKE CONTROLThis handle is used to increase and decreasepressure on the hydraulic reel brake.

HYDRAULIC RETRIEVER CONTROL LEVER(OPTIONAL)This three-position control lever controls thespeed and direction of the hydraulic retriever.The lever returns to neutral when released.

IGNITION SWITCH(Power Pack Option)Key-operated three-position switch. Turn key to“start” engine. When released, the switch willreturn to the on “run” position. Turn the key to“off” to turn the engine off.

UPPER/LOWER BULLWHEEL BRAKEThis handle is used to set the brake pressure onthe bullwheel. Clockwise tightens or increasespressure and counterclockwise loosens ordecreases pressure on the brake calipers.

3.2


DESCRIPTION OF OPERATING CONTROLS

TERMS YOU NEED TO KNOW

3.3


UPPER BULLWHEEL

FRONT JACK

PINTLEEYE SAFETY

CHAIN

LOWERBULLWHEEL

MANUALSTORAGE

REEL BAR HYDRAULICRETRIEVER

FAIRLEADROLLERS

REARJACKLEG

RETRIEVER COUPLER

REEL BRAKE

CONTROL PANEL

UPPER BULLWHEEL BRAKE

ADJUSTABLESEAT

LOWER BULLWHEEL BRAKEGROUNDING LOOP

SAFETY CHAIN

BREAKAWAYSWITCH

TOWING

Connecting the tensioner to the tow vehicle:

1. Make certain tow vehicle has the capacityand rating to tow safely.

2. Inspect pintle eye and safety chains forexcessive wear, corrosion, cracked welds orstructural damage.

3. Inspect tow vehicle hitch and ensure hitchhas no worn or damaged parts.

Do not attempt to tow if there is any questionabout the service condition of the safety chainsor hitch.

4. Make sure the unit is ready for towing.a. Tires are in good condition and properly

inflated.b. Correct fluid level in both wheel hubs.

c. Make sure the rear leveling jacks are inthe full up position, and secured withpins and retainers.

d. Make sure there are no tools, objects, ordebris on the unit which could fall off themachine during transport.

5. Chock or block the wheels on both sides ofthe machine.

6. Use the front jack to raise or lower the pin-tle eye to the correct height for the towvehicle hitch.

8. Open the tow vehicle hitch and back intoposition under the pintle eye. Set the park-ing brake on the tow vehicle.

9. Close and secure the tow vehicle hitch.

The hitch coupler is a pinch point. Keephands and fingers clear.

10. Attach the break-away switch cable to thetow vehicle.

11. Properly connect the safety chains. Thesafety chains should be crossed and shortenough to prevent the tongue from digginginto the ground, should the unit uninten-tionally become disconnected. The chainsshould be no longer than necessary toallow slack for turning – crossing the chainsprovides directional control.

12. Completely retract front jack.

13. Connect the electrical plug to the tow vehi-cle and check clearance lights, brake lights,turn signals and brakes.

Do not tow the unit unless all lights andbrakes are working correctly.

14. Remove the wheel chocks or blocks.

CAUTION

CAUTION

WARNING

3.4


3.5


SET-UP TO TENSION

1. Position the tensioner in a suitable location.When installing overhead the tensionershould be approximately three times thedistance of the first structure/pole height.

Example: If the first structure/pole is 40 feethigh, it is recommended the puller beapproximately 120 feet from the basewhenever possible.

2. The unit should be set up as level as possi-ble, centered on the lead block and parallelto the line being pulled. Chock or block thetrailer tires on both sides and disconnectfrom the tow vehicle. Level the unit usingall three jacks.

Most of the weight should be off of the tires andaxles.

NOTE

120'

40'

3.6


The procedure for installing or removing a reel isthe same for all types of reels.

Make sure there is adequate overhead clear-ance with no obstructions before attempting toremove or install a reel.

1. Disengage the payout brake coupler fromthe reel shaft.

On units with optional hydraulic retriever, theretriever must be disengaged.

Make sure the reel lock-ing pin is unlocked.

2. Remove the locking pins and unlatch thepillow block housing on both sides. Rotatethe top of the housing to the full open posi-tion and make sure the latch is folded backout of the way.

3. Use a spreader bar on the chains to the lift-ing device to lift the reel and drive barassembly up out of the pillow block housing.

Lift straight up keeping the bar level with themachine to prevent the bearings from bindingin the pillow block housings and possibly caus-ing damage to the machine.

CAUTION

NOTE

NOTE

CAUTION

REEL INSTALLATION/REMOVAL

RETRIEVER

COUPLER

COUPLER

3.7


4. Remove the bearing from the end of thedrive bar, loosen the set screws and removethe lifting eye/tapered cone.

The conductor reel should be placed so that theconductor will feed off the bottom of the reeland toward the front of the machine.

5. Slide the drive bar into the reel tobe installed. Adjust the drive pins ifnecessary.

6. Slide the reel lifting eye/taperedcone onto the drive bar.

Two (2) sizes of tapered cone lifting collars areprovided. Be sure to use the proper size basedon the diameter of the arbor hole.

The tapered cone is turned in and slid into thearbor hole on wooden reels when necessary tostabilize the reel.

7. Align the reel lifting eye with the lifting eyeon the drive bar and tighten the set screws.

8. Slide the bearing into place on the drive bar.

9. Attach the lifting device chains with a spread-er bar to the reel and drive bar lifting eyes.

10. Position the reel over the pillow blockhousings and lower the reel into place.

Lower the reel straight and level with themachine to keep the bearings from binding inthe pillow block housings as the reel is loweredinto position.

11. Remove the lifting device, close, latch andsecure the pillow block housings with thelocking pins.

12. Rotate the reel by hand to make sure itmoves freely and turns correctly.

NOTE

NOTE

NOTE

NOTE


3.8

REEVING

The tensioner is designed for the conductor tofeed off the bottom of the reel and toward thefront of the machine.

When reeving the bullwheels, it is recommend-ed that:

1. All three disc brakes be disengaged, so thebullwheels and conductor reel can beturned by hand.

2. A synthetic rope may be reeved in the bull-wheels and used to pull the conductorthrough the bullwheels.

3. Standing at the front of the machine, facingtoward the rear of the machine, the con-ductor should lead through the fairlead intothe bottom of the left hand groove of thelower bullwheel. The conductor should bereeved in each bullwheel groove and leavethe top right hand groove of the upper bull-wheel going to the pole over the rear of themachine.

Following this procedure will lessen thetendency to loosen the strands of right handlay conductor (standard for aluminum con-ductor) as the conductor passes through thebullwheel.

NOTE

FAIRLEAD

FAIRLEAD

3.9


TENSIONING

If the situation permits, it is better to set thebrakes moderately and adjust upward to thedesired stringing tension. For smoother opera-tion, it is recommended that the over-spin brakeon the conductor reel be set as lightly as the jobwill permit. The tensioning force should be gen-erated and regulated by the bullwheel brakes.The bullwheel brakes should be adjusted evenly.If one brake appears to be heating more than theother, then the braking force on it should bedecreased and the braking force on the othershould be increased.

Keep hands, arms, and other parts of the bodyand all clothing away from all moving parts orsevere injury is possible.

On all brakes, rotate the handle clockwise toincrease tension and counter-clockwise todecrease tension.

The machine is equipped with reel locking pins.They should be engaged when transporting thereel or when leaving the conductor under ten-sion for long periods of time.

WARNING

REEL LOCKING PIN

3.10


The retriever device is intended for rewindingonly short sections of conductor onto the reel.The unit is engaged by connecting the drive shaftto the reel shaft with a sliding coupling.

This unit was designed to retrieve loose cable orrope and should not be used as a “puller”.

The drive motor is operat-ed with a three-positioncontrol lever whichreturns to neutral whenreleased.

Be sure the retriever isdisengaged before ten-sioning.

CAUTIONCAUTION

HYDRAULIC RETRIEVER (OPTIONAL)

3.11


INSTALLING PULLING GRIP

1. Select the correct size grip. (Refer to manu-facturer’s chart or specifications.)

2. Use a feed tube or contain the end of therope or conductor. Slide the grip into place.

The conductor or rope should be installedup to the elbows of the aluminum shouldersto assure full and complete gripping action.

3. Lock the mesh on the tail end of the grip tothe rope or conductor, using two punch-lokbands, positioned 1" to 2" from tail of grip.

4. It is a good practice to apply tape over thebanded grip tail only, to assure smoothpassage through the sheaves. Do not tapethe entire grip.

NOTE

The spider rewind system is used to wind up spi-der line or pilot rope when pulling the bull linethrough the stringing blocks. The rewind systemutilizes a levelwind to ensure smooth even dis-tribution of the pilot line onto the spider reel.

1. Move the spider rewind control to pull theline over the top of the drum. The levermust be held to operate the unit.

2. As the spider line/pilot line goes on the reel,move the levelwind control back and forthgradually to wind the cable on the reelevenly.

SPIDER REWIND SYSTEM (OPTIONAL)

3.12


4.1

Section 4 • SERVICE

GENERAL SERVICE

Close attention to proper preventive measuresand service procedures will ensure and extendtrouble-free operation of equipment. Properlubrication and careful attention to the hydraulicsystem suction filter are two vital areas. Theobjective of scheduled service should be toanticipate and prevent operational problemsbefore they require extended shutdown forrepairs.

Refer to the engine manufacturer’s manual for allservice related information, oil and fuel require-ments on units with power pack option.

IMPORTANT INFORMATION

The service guidelines outlined in this manual areeffective methods. These guidelines are not allinclusive. Anyone who performs service or repairon a Sherman & Reilly machine must be com-pletely satisfied that no one’s safety will be jeop-ardized and take responsibility for these actions.

If there are any questions about safety, procedureor precautions, contact Sherman & Reilly at800-251-7780 before attempting to do the work.

Service should be scheduled to allow adequatetime so the procedure can be completed correct-ly. It must be done byskilled, trained servicepersonnel with a goodbasic knowledge ofequipment, procedures,and safety practices.

Accurate records shouldbe kept of all service andrepairs.

WARNING

4.2


SAFETY PRECAUTIONS

1. Make sure the machine is locked out inaccordance with OSHA requirements.

2. Make sure that all precautions are taken tosupport components before loosening orremoving bolts.

3. When working on any hydraulic connec-tion or part:

a. Be sure there is no pressure on fluid atthe location of the work.

b. Make sure nothing will move or dropwhen loosening a connection.

c. Collect all thehydraulic fluidwhich willdrain from theloosened con-nection.

d. Use oil-dry orsome absorbentmaterial tosoak up anyfluid spills to keep working surfacesfrom becoming slippery.

e. Cover all open connections to preventloss and contamination to the hydraulicsystem.

4. Take all fire preven-tion safety measuresbefore using awelder or cuttingdevice, includinggrinders. Have afully charged fireextinguisher nearthe location of thework.

5. Be sure everyone involved in the mainte-nance, service or repair process under-stands what is being done and all of thesafety precautions which need to be takenduring the procedure.

6. Make sure all lifting devices, chains, slings,and hooks are in good condition and havethe rated capacity to do the job. Use guidelines when necessary for control during thelifting process.

7. Always wear properprotective clothing andequipment when per-forming service: gloves,safety glasses, etc.

4.3


Absolute cleanliness of the hydraulic system is amust! The smallest amount of foreign material inthe system can cause extensive damage to thepump, motor or valves. Sherman & Reilly hastaken every precaution to assure that each com-ponent and fitting was thoroughly cleaned andthe system purged before this machine was deliv-ered. Therefore, maintenance of the systemshould be carried out with extreme care.

ADDING HYDRAULIC OILWipe all dirt and grime from around reservoirfiller cap before removing.

COMPONENTREPLACEMENTWhen replacing hoses, fit-tings or other components,clean thoroughly and thenassemble carefully.

The hydraulic fluid and filter should be changedafter the first 25 hours of operation.

Use only Dexron quality transmission fluid witha viscosity index of 212 SSU at 100° F., Texaco-Dexron 3 or equivalent.

NOTE

NOTE

HYDRAULIC SYSTEM (OPTIONAL POWER PACK)

4.4


SERVICE REQUIREMENTS

CALIPER DISC BRAKES ONREEL CARRIER/BULLWHEELThe brake linings should be inspected weeklyand replaced before the rivet heads damage thebrake disc.

AXLEThe wheel bearing reservoirs should be visuallyinspected before towing the machine and main-tained at the level line with SAE-90, SAE 80W-90, SAE 80W-85W-90, or SAE 75W-90 Hypoidgear oil. The wheel bearings should be replacedas necessary.

WHEEL MOUNTINGIt is important to maintain proper torque specifi-cations to ensure safe and secure attachment ofthe wheel to the hub.

Star lug nuts by hand to prevent cross threading.

Tighten lug nuts in three stages using a cross starpattern. When using clamp ring and 90° conenuts, tighten the wheel nuts to a final torque of200 ft. lbs.

The proper torque must be maintained by check-ing every 50 miles for the first 200 miles, thenper periodic maintenance and after every chargein wheel mounting.

TRAILER BRAKESThe brakes are self-adjusting. When the leadingshoe leaves the anchor pin during a reversebrake application, the adjuster cable pulls theadjuster pawl upward to engage the next tooth ofthe adjuster star wheel if adjustment is necessarydue to normal wear. To release the shoes, theadjuster pawl must be pulled away before thestar wheel can be turned backward to decreasebrake adjustment. To obtain access to theadjuster, remove the bottom half of the dustcover. When reinstalling the dust cover, tightento five ft. lbs.

Over torquing may damage the cover.

Upon reinstallation, the shoes should be adjust-ed to the point of lightly dragging the drum andwith approximately .010" of clearance on theshoe with the most shoe to drum clearance mea-sured at the 3 or 9 o’clock position.

The brakes should be checked for adjustmentevery 3000 miles or six months and the liningsinspected for wear and contamination every5000 miles and replaced as necessary. Actualservice may indicate more frequent adjustments.

NOTE

NOTE

SHERMAN & REILLY, INC.P.O. Box 11267 • 400 West 33rd StreetChattanooga, TN 37401 USAPhone 423•756•5300Fax No. 423•756•2948Toll-Free 800•251•7780Web Site www.sherman-reilly.com

Manual No. BWT1303 Printed in the U.S.A.

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•Operation •Service •Parts SHERMAN&REILLY,INC.sherman-reilly.com/wp-content/uploads/2015/01/product_media-bwt… · tional and OPGW fiber optic. Each bullwheel is controlled