FRB518 Hydraulic 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
FRB518 Hydraulic Tensioner
5 Blue Heron Drive Collegeville, PA 19426 (610) 831-5020 Fax: (610) 831-5012
www.comstarsupply.com
5 Blue Heron Drive
Fax: 610-831-5012
Important Safety Notice

Before using a Condux FRB518 Hydraulic 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 4 OPERATING PROCEDURE.............................................. 12

COMMUNICATION WITH THE MANUFACTURER............ 2 A. SET-UP.................................................................... 12
1 GENERAL DATA AND INSTRUCTIONS............................. 4 B. START UP PROCEDURE.......................................... 12
A. COMMUNICATION WITH THE MANUFACTURER...... 4 C. STABILIZE TENSIONER........................................... 14
B. TYPOLOGY AND FIELD USE..................................... 4 D. REEVING THE DRUM.............................................. 15
C. PERFORMANCE........................................................ 4 E. GUIDE ROLLERS..................................................... 15
D. TECHNICAL CHARACTERISTICS ............................ 5 F. POSITION REEL ELEVATOR..................................... 16
E. ACOUSTIC EMISSION............................................... 5 G. DETERMINE TENSIONING RANGE......................... 16
F. GENERAL SAFETY INFORMATION............................. 5 H. SET TENSIONING RANGE LEVER........................... 17
G. GENERAL OPERATOR INSTRUCTIONS.................. 5 I. TENSIONING OPERATION (Single Drum)................ 18
H. GENERAL MAINTENANCE INSTRUCTIONS............ 6 J. TENSIONING OPERATION
(Two Independent Drums)....................................... 21
I. THE INSTRUCTION MANUAL . ................................. 6
5 MAINTENANCE............................................................... 23
J. CONDITION OF USE................................................ 6
A. GENERAL INFORMATION........................................ 23
K. TEMPERATURE LIMITS FOR HYDRAULIC OIL....... 7
B. FLUID LEVELS........................................................ 23
L. USE NOT ALLOWED............................................... 7
C. SUGGESTED LUBRICANTS..................................... 23
M. RESPONSIBILITY................................................... 7
D. DIESEL ENGINE MAINTENANCE............................. 23
2 TRANSPORT AND POSITIONING INSTRUCTIONS.......... 8
E. HYDRAULIC CIRCUIT MAINTENANCE.................... 24
A. MACHINE LIFTING.................................................... 8
F. STATIONARY BRAKE MAINTENANCE.................... 24
B. PACKING FOR SHIPMENT......................................... 8
G. RADIATOR MAINTENANCE................................... 25
C. UNPACKING............................................................... 8
H. GREASING............................................................... 25
D. TRANSPORT ON TRAILER........................................ 8
I. OTHER PERIODIC OPERATIONS.............................. 25
E. POSITIONING AND ANCHORING.............................. 9
J. SUMMARY TABLE FOR REGULAR
F. RESIDUAL RISKS.................................................... 10
MAINTENANCE........................................................ 26
3 SAFETY CONDITIONS.................................................... 11
6 TROUBLESHOOTING GUIDE.......................................... 27
A. SAFETY DEVICES.................................................... 11
7 HOW TO DISABLE THE MACHINE................................. 33
B. EMERGENCY STOP DEVICE.................................... 11
A. TRANSPORT............................................................ 33
C. PERIODIC OPERATIONS......................................... 11
B. EXTENDED SERVICE STOP..................................... 33
8 WARRANTY INFORMATION........................................... 35
FACTORY ASSISTANCE............................................... 35
LIMITED WARRANTY.................................................. 35
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General Data And Instructions
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

The FRB518 is a tensioner suitable for stringing one or two conductors.
The machine has two bull-wheels with independent controls. The bull-wheels’ grooves
are made of high resistance interchangeable nylon.
The diesel engine allows the machine to be used as puller for the recovery of
conductors at low speeds and for the pre-setting phases; in addition, it hydraulically
checks the rotation of the conductor’s reels.
Always start the diesel engine when using the machine.
C. PERFORMANCE
Functioning in Tensioner Mode
1 conductor 2 conductors
23,000 lbs 2 x 11,240 lbs
Maximum pull
(10.433 Metric Tons) (5.0984 Metric Tons)
18,000 lbs 2 x 9,000 lbs
Continuous pull
Maximum speed 1 mph (4.8 Km/hr) 3 mph (4.8 Km/hr)
Functioning in Puller Mode

1 conductor 2 conductors
23,000 lbs 2 x 11,240 lbs
Maximum pull
18,000 lbs 2 x 9,000 lbs
Continuous pull
Recovery speed .25 mph (.40234 Km/hr) .25 mph (.40234 Km/hr)
!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)
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D. TECHNICAL CHARACTERISTICS
Bull-wheels diameter:................60 inches (1,524 mm)
Bull-wheels lining:......................nylon sectors
Maximum conductor dia.:..........1.57 inches (39.8780 mm)
Diesel engine:............................37 HP – 3600 rpm (27.59 Kw)
Electric system:.........................12 V
Transmission:............................hydraulic circuit with hydraulic oil cooling
Safety brake:............................. 2 negative and self-acting type
Meter counter:...........................mechanical type
Dynamometer:...........................hydraulic type
Axle:...........................................Dual Torsion axle with electric brakes, breakaway kit
and safety chains.
Dimensions:...............................length – 196 inches (4,978 mm)
width – 102 inches (2,590 mm)
height – 110 inches (2,794 mm)
Mass:.........................................14,500 pounds (6,577 kg)
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 the 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 carefully follow danger and/or prohibition prescriptions
contained in the instruction manual or indicated on the machine.
g. The operator must absolutely avoid direct inhalation of the system’s engine
exhaust.
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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.
!ATTENTION: Failure to follow these instructions relieves the

manufacturer from any responsibility and voids the warranty.
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. The 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. The 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.
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K. TEMPERATURE LIMITS FOR HYDRAULIC OIL

When using the machine, always remember to respect the following temperature
limits that can be reached with hydraulic oil as function of the working condition.
TEMPERATURE LIMITS FOR HYDRAULIC OIL in °F (°C)

Hydraulic oil viscosity
Working condition
VG 22 VG 32 VG 46 VG 68
-5.8 6.8 18 30
Minimum temperature running in neutral position
(-21.00) (-14) (-7.778) (-1.111)
46 61 75 90
Minimum temperature running in full load
(7.7) (16.1) (23.8) (32.2)
118 135 153 169
Maximum temperature running in full load
(47.7) (57.222) (67.2) (76.1)
145 163 181 199
Maximum temperature running in neutral position
(62.7) (72.7) (82.7) (92.7)
For additional information concerning the hydraulic oil, see the chapter on
“Maintenance” and the attached comparative table of the oils used on the machine.
L. USE NOT ALLOWED

The machine must not be used for the following:
a. for lifting persons and/or goods
b. in areas where the machine can not be positioned and anchored properly
c. in areas with brushwood or other materials that can be easily set on fire
d. in closed/unventilated sites or those that are poorly ventilated (tunnels or
similar areas) or
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 conductors having a bigger diameter than the one specified in
present 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 moving equipment.
M. RESPONSIBILITY
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.
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. connecting to the machine and/or plans not produced and not directly
authorized by the manufacturer in a written acceptance
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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 capac-
ity equal to or greater than the mass to be lifted and must be connected to the proper
points on the machine.
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 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.
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.
!ATTENTION: Dispose all packaging materials in accordance with

local regulations and in conformity with the norms in force in the
relevant country.
D. TRANSPORT ON TRAILER
NOTE: This operation must be carried out with a functioning
engine.
Before transporting this machine, lift the rear stabilizer and the front jack, using the
suitable lever and the connecting the safety pin.
Check the tires for proper inflation pressure.
No personnel may ride on the machine at any time while towing the machine at ANY
speed.
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!ATTENTION: It is dangerous to tow the machine at speeds in

excess of the tire and axle’s ratings 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 pole or
trestle (see Table 1).
Table 1
It is possible to use the machine at a distance from the pole included between 1 and
2 times the height of the pole itself. In this case, the anchorage described thereafter
must be over-dimensioned of 125% compared to the reported data and some
moorings must be provided on the front side of the machine.
!PROHIBITION: 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. Align the machine as much as possible with the pull direction
b. Adjust the rear stabilizers.
c. NOTE: This operation must be carried out with a functioning engine
Adjust the plow by removing the safety pin, adjusting the pressure by means
of the valve and acting on the control lever.
d. Anchor the machine to the ground by installing 2 stakes with a minimum rated
load equal to 130% of the machine’s rated load. Anchor the machine.
e. Install anchoring stakes without tensioning them.
f. Test the machine pull to allow the machine to freely align as regards to the
pull.
g. Tension the anchoring stakes in a uniform way.
!ATTENTION: Dangerous situations may occur during machine use

if the anchoring instructions are not followed.
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You must provide proper grounding of the conductor system for this machine.
You must maintain a space of at least 7 feet around the machine for ease of use,
adjustments, maintenance, etc.
Be sure that air can circulate freely around the radiators (diesel motor, hydraulic oil).
Otherwise overheating situations with damage for the installed components may
happen.
!DANGER: Dangerous situations may occur during machine use

if the anchoring instructions are not followed. You must provide
proper grounding of the conductor system for this machine.
F. 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-conductor connected to the machine.
To minimize the risks the operator must
• Check the rope and replace it as soon as defects or wear signs appear.
• Comply with the working positions indicated in the manual.
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 must:
• Periodically check the anchoring stakes and replace them as soon as
defects or wear signs appear.
• Follow the anchoring indications described in the manual.
• Comply with the working positions indicated in the manual.
3. Entangling or dragging in the accessible rotating units. It is not

technologically possible to cover some rotating units (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 must:
• Avoid contact with the machine’s rotating units except for the control
devices.
• Follow the anchoring instructions in the manual.
• Respect the prescriptions indicated in the manual concerning wearing and
using necessary safety devices.
4. Limb crushing during loading or removal of the rope-conductor. These

operations have a large risk margin due to the use of mechanical parts to be
moved. To minimize the risks the operator must
• Know the methods for accident prevention and apply them.
5. Electrostatic discharges. Since the machine does not have a proper

grounding device during stringing operations, it is possible to have dangerous
electrostatics discharges on ropes and conductors. To minimize the risks the
operator must
• Know the methods for accident prevention and apply them.
• Check the job site for a suitable grounding device for the machine
rope-conductors system
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6. Inhalation of the diesel engine exhaust. The FRB518 discharges exhaust. To

minimize the risks, the operator must:
• Follow the working recommendations indicated in the manual.
• Heed the ATTENTIONS and PROHIBITIONS indicated in the manual.
• Use safety devices for breathing, if necessary.
Safety Conditions
3.
3.
A. SAFETY DEVICES
This machine has the following safety devices:
1. a load-limiting device which automatically stops the diesel 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 emergeny stop 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.
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Operating Procedure
4.
A. SET-UP
1. Position 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 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 multiply 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 tensioner should
be positioned 200 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 FRB 518
Tensioner.
1. To start the machine, insert the key

into the ignition, push in and turn
one position clockwise.
(See Figure 3 & 3A)
2. Push glow plug toggle switch down.
(See Figure 3 & 3A)
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 & 3A)
6. Set cooling fan to 700 psi., 50 bar.
(See Figure 5 & 3A)
7. Set reel elevator hydraulic pressure Figure 3. Insert the Key, Turn
to 500 psi., 40 bar. Clockwise, Push Glow Plug Down
12 (See Figure 6 & 3A)
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ITEM # QTY DESCRIPTION CONDUX P/N REF.

1 2 DYNAMOMETER 21011583 08100402
2 2 KEY, DYNAMOMETER SETTING 21011080 08200403
3 2 COUNTER, DISTANCE 21011538 09100699
4 2 COUNTER, SPEED 21011559 09100700
5 1 SWITCH, EMERGENCY STOP 21011250 09101190
6 1 PLATE, EMERGENCY STOP SWITCH 21011251 09100941
7 1 DISPLAY, ENGINE RPM & RUNNING TIME 21011544 09101302
8 1 FUSE HOLDER 21011442 09100515
9 1 LENS, ALARM 21011125 09102713
10 1 LENS, GLOW PLUG 21011122 09102550
11 1 LENS, LOW ENG. OIL PRESSURE 21011115 09102136
12 1 LENS, ALTERNATOR FAILURE 21011114 09102135
13 2 LENS, FILTER CLOGGED 21011121 09102549
14 1 LENS, HIGH ENGINE TEMPERATURE 21011092 09101004
15 1 GAGE, FUEL LEVEL 21011623 09102552
16 1 GAGE, HYDRAULIC OIL TEMPERATURE 21011333 09102045
17 1 SWITCH, KEY START 21011435 09102990
18 1 SWITCH, BYPASS STARTING 21011112 09102064
19 1 CONTROL, ENGINE SPEED 21011098 09101196
20 1 JOY STICK, FRONT PLOW 21011098 09101196
21 3 SWITCH, SELECTOR 21011568 09101229
22 2 GAGE, REEL WINDER & FAN PRESSURE 21011077 08100067
23 2 VALVE, REEL WINDER & FAN CONTROL 21011286 07300158
24 1 GAGE, FEEDING PRESSURE 21011075 08100061
25 2 POTENTIOMETER, PULL ADJUST 21011123 09102609
26 2 HANDLE, PULL ADJUST POTENTIOMETER 21011089 09100668
27 3 SWITCH, SELECTOR 21011099 09101216
28 1 LAMP, INDICATOR 21011624 09101202
29 2 JOY STICK, CAPSTAN 21011100 09101230
30 5 LATCH, PANEL 21011445 09101275
31 5 FUSE - 3 AMP 21011431 09101761
32 2 FUSE - 5 AMP 21011102 09101381
33 1 FUSE - 20 AMP 21011561 09102692
34 1 LABEL, MAX. HYD. OIL TEMPERATURE 08763187 -----
35 1 LABEL, MIN. OPERATING PRESSURE 08763188 -----
36 1 LABEL, MAX. OPERATING PRESSURE 08763189 -----
37 1 LABEL, MIN. OPERATING PRESSURE 21032311 -----
Figure 3A. Control Panel Identification

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Figure 4. Adjust Engine Throttle Figure 5. Set Cooling Fan
Figure 6. Set Reel Elevator Figure 7. Engage Leveling

Hydraulic Pressure Joystick Down
C. STABILIZE 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.
2. Re-adjust the rear stabilizer leg by removing the keeper pin and lowering the
leg as close to the ground as possible and replace pin. (See Figure 8)
3. Readjust the front of the machine. Push up on the leveling joystick to raise
the front end of the tensioner and adjust accordingly until pressure is placed
on the rear jack stand.
4. Anchor the 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 9) The
second position is adjacent to the operator panel. (See Figure 10) Temporary
ground anchors or solid structures are required for proper machine anchoring.
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Figure 8. Lower Leg Replace Pin Figure 9. Anchor, Left Side Upper
Drum, Directly in Center of
Machine
Figure 10. Anchor, Adjacent to Figure 11. Reeving the Drum

the Operator Panel
D. REEVING THE DRUM

1. Reeve the drum appropriately for the tensioning configuration being used,
single drum or two independent drums. When reeving the drums, reeve
toward the center of the machine so that 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 11)
E. GUIDE ROLLERS
1. Align guide rollers to correspond with the 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 12)
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Figure 12. Thread Poly Rope

Through Guide Rollers
F. POSITION REEL ELEVATOR

1. Position and connect reel elevator according to specific reel elevator
instructions.
G. DETERMINE TENSIONING RANGE

Determine the proper tensioning range for the particular operation. The FRB 518
can accommodate up to two reel elevators at one time. The hydraulic connections for
reel elevator number one are located on the left. The hydraulic connections for reel
elevator number two are located on the right. If using URW series reel elevator(s),
use the hydraulic connections located above connections set one and two.
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.
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
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H. SET TENSIONING RANGE LEVER

1. Position range lever(s) (See Figure 13) according to the range of tensioning
being performed and the configuration of the tensioner. For example if the
tensioner is being used as a single drum, both the number 1 and number 2
range levers need to be set. If utilizing the unit as two independent drums, set
the range lever that corresponds to the drum being used. Or set both
according to their independent tensioning ranges.
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 Figure 14) Release detent.
Figure 13. Position Range Lever Figure 14. Put Lever into Proper
Position, Release Detent
!IMPORTANT: The tensioning range lever will not set when there
is pressure on the drum. Also, never set or adjust tensioning
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 (Single Drum)

1. Mechanically lock drums together. The drums need to be aligned properly in
order to insert the locking rod in place. Once drums are aligned, remove drum
cover, insert and secure locking rod and replace cover. (See Figures 15-18)
Figure 15. Remove Drum Cover Figure 16. Locking Rod
Figure 17. Remove Locking Rod Figure 18. Secure Locking Rod
inside Drum Cover
!Important: After aligning the drums, make sure to shut the unit
off before installing the locking rod. Never install the locking rod
while the machine is running.
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2. Set drum configuration selector to single drum. (See Figure 19 & 3A)
3. Start the tensioner per start up instructions.
4. Set operating speed to slow (snail). (See Figure 20 & 3A)
5. Engage negative brake under the number 2 control set or the center control set
by turning either negative brake switch one position clockwise.
(See Figure 21 & 3A)
6. Move bull wheel control joystick to the down position. (See Figure 22 & 3A)
Figure 19. Set drum configuration Figure 20. Set Operating Speed to
selector to single drum Slow (snail)
Figure 21. Engage Negative Brake Figure 22. Move Bull Wheel
Joystick to the Down Position
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7. 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 23 & 3A)
8. Move the bull wheel joystick to the neutral position. (See Figure 24 & 3A)
9. Disengage the negative brake by turning the negative brake switch

counterclockwise. (See Figure 25 & 3A)
10. Moving bull wheel joystick to the down position and begin tension operations.
Figure 23. Set Dynamometer Figure 24. Move Bull Wheel

Joystick to Neutral Position
Figure 25. Disengage Negative Figure 26. Move Bull Wheel

Brake Joystick to Down Position
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J. TENSIONING OPERATION (Two Independent Drums)

1. Start the tensioner per start up instructions.
2. Set operating speed to slow (snail). (See Figure 27 & 3A)
3. Set drum configuration selector to two independent drums.
4. Engage negative brake under the corresponding drum being used (Number 1 or
Number 2 or both) by turning negative brake switch one position clockwise.
5. Move bull wheel control(s) joystick to the down position. (See Figure 29 & 3A)
6. Set dynamometer(s) according to the specific tensioning range required by

turning the dynamometer knob(s) clockwise to increase and counter clockwise
to decrease until range(s) is appropriately set. (See Figure 30 & 3A)
Figure 27. Set Operating Speed to Figure 28. Engage Negative Brake
Slow (snail)
Figure 29. Move Bull Wheel Figure 30. Set Dynamometer

Joystick to Down Position
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7. Move the bull wheel joystick(s) to the neutral position. (See Figure 31 & 3A)
8. Disengage the negative brake(s) by turning the negative brake switch(es)

counterclockwise. (See Figure 32 & 3A)
9. Moving bull wheel joystick(s) to the down position and begin tension operations.
Figure 31. Move Bull Wheel Figure 32. Disengage Negative

Joystick to Neutral Position Brake
Figure 33. Move Bull Wheel

Joystick to Down Position
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Maintenance
5.
A. GENERAL INFORMATION
!ATTENTION: Repairs not done by the manufacturer and not
allowed by written authorization relieve the manufacturer of any
responsibility in case of accidents to persons or damage to things
and/or to the machine, causing loss of the warranty.
B. FLUID LEVELS
For safety reasons, during the transport machine comes without hydraulic oil and fuel.
Fill the levels as per the following table:
Quantity
a. Hydraulic oil level 71 Gallons (268.69 liters)
b. Engine oil level See enclosed engine booklet
c. Reduction gear oil level 0.42 Gallons (1.5894 liters)
d. Negative brake oil level 0.08 Gallons (0.3027 liters)
e. Fuel level 4 Gallons (15.137 liters)
!ATTENTION: Disregarding the correct fluid levels causes serious

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

liquids. They may be injurious to health and potentially lethal.
C. SUGGESTED LUBRICANTS
The manufacturer tests the machine with the following oils and lubricants:
a. Hydraulic circuit and stationary brake: IP HYDRUS OIL 46 (ISO VG 46).
b. Mechanical reduction gear: IP MELLANA 220 (ISO CKC 220).
Possible different trademarks must be chosen based on the enclosed table

“SUGGESTED LUBRICANTS.” It is possible to use different trademarks but with
same characteristics and ISO specifications.
When using oil with characteristics and ISO specifications different from the ones
declared during test, completely empty the hydraulic circuit.
!ATTENTION: Using lubricants not in conformity with the technical

specifications indicated in the present manual seriously damages
the machine components and, consequently, invalidating the
warranty conditions.
D. DIESEL ENGINE MAINTENANCE

For specific maintenance of the engine, see the enclosed use and maintenance
booklet. For filling the fuel, use the filling cap on the tank.
!DANGER: Turn off and cool the engine before any filling operation.
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E. HYDRAULIC CIRCUIT MAINTENANCE

Change the hydraulic oil after 500 working hours and, thereafter, every 1500 hours
(or at least every year).
a. To drain the exhaust hydraulic oil tank, use the cap located on the bottom of
the tank.
!DANGER: Cool the hydraulic oil completely before removing it.

Always use suitable safety gear (gloves, etc.).
!ATTENTION: Disposing of used oil must be done in conformity

with the laws in force in the relevant country.
b. Use the correct quantity of oil in the tank.

!ATTENTION: When filling the oil tank, be sure no foreign matter,
which could cause irreparable damages to the circuit’s
components, enters with the oil. If possible filter the oil with a
10 µm filter.
c. Replace the filter cartridges after 500 working hours and, thereafter, every
1500 hours (or every year at least).
d. Each day, check the oil filters by means of the pilot lamps. If necessary,
replace the cartridges per the following:
• suction filter 25 µ (F2)
• return filter 25 µ (F1)
For further maintenance of hydraulic components (pumps and motors), refer to the
enclosed documentation.
F. STATIONARY BRAKE MAINTENANCE

a. Change the oil of the reel winder stationary brake after 50 working hours and,
thereafter, every 500 hours (or at least every year).
b. To drain the oil of the reel winder stationary brake, use the suitable caps on
the lower part of the casing.
!DANGER: Completely cool the hydraulic oil before removing it.

Always use suitable safety gear (gloves, etc.).
!ATTENTION: Disposing of used oils must be done in conformity

with the laws of the relevant country.
c. Fill the oil of the reel winder stationary brake using caps on the upper part of
the casing.
!ATTENTION: When filling the oil, make sure no foreign matter,

which could cause irreparable damages to the circuit’s
components, enters with the oil.
For further maintenance operations of mechanical components (reduction gears,

negative brakes), refer to the enclosed documentation.
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G. RADIATOR MAINTENANCE
At least once a year (or more when used in dusty places) use compressed air to
clean the radiators.
!ATTENTION: Always use suitable safety gear (gloves, etc.) and

breathing apparatus.
H. GREASING
Grease the crown gear of the bull-wheels 2-3 times per day using the suitable
greaser check the crowns from the inspection doors
Every week, grease all other parts subjected to rotation or translation that do not
have an automatic greasing schedule.
Use IP ATHESIA GR2 (ISO XBCEA 2) grease or grease of an equivalent trademark

based on the enclosed “SUGGESTED LUBRICANTS” table.
I. 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 panel.
For the other periodic operations, refer to the summary table for ordinary
maintenance (see next page).
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J. SUMMARY TABLE FOR REGULAR MAINTENANCE

This table lists the main operations of periodic maintenance and relevant intervals.
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
Filter VF ST1 ST(*)
Oil CL ST1 ST(*)
Negative brake
Discs
Reduction gear Oil CL ST1 ST(*)
Bull-wheels Gears GR
Front plow Sliding 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
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Troubleshooting Guide
6.
Blown fuse
Low battery
starts
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correct
When activating the control lever

the bull-wheels don’t work
(electric control)
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When activating the control lever

the bull-wheels don’t work
(hydraulic control) release
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cooling fan for the hydraulic oil

radiator and by completely opening
the reel winder valve with diesel
engine at medium-high rpm

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The cooling fan for the hydraulic oil
cooling fan
The cooling fan for the hydraulic oil cooling fan
cooling fan
cooling fan hydraulic motor

cooling fan pump

plow
plow
plow
plow
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How to Disable the Machine
7.
A. TRANSPORT
Before transporting the machine, empty flammable liquids in the machine (oils and
fuels).
Transport must be done per the specifications described in chapter 2 (Transport and
Positioning).
B. EXTENDED SERVICE STOP

When anticipating an extended unit storage (two months at least) protect the external
parts with waterproof wax and empty the fuel tank.
During extended storage, start the machine at least once every two months and let
the machine idle for one hour at least. This allows the oil to enter the hydraulic
system and prevents the gaskets from drying.
Store the machine under a roof. Do not cover the machine with pieces of cloth and/
or plastic materials that could cause an excessive increase of temperature and/or
humidity.
If the machine is not used for a year or more, replace the hydraulic oil and hydraulic
circuit filters before re-starting the machine.
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Warranty Information
3.
8.
FACTORY ASSISTANCE
Condux International, Incorporated (Condux) can provide further advice regarding
any problems with the installation, service, assembly, or disassembly of the Condux
FRB518 Hydraulic Tensioner. Call toll free at 1-800-533-2077 (USA and Canada) or
1-507-387-6576 and ask for assistance. The Condux FRB518 Hydraulic 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 2007, Condux International, Inc.
Printed in USA
Literature Part Number: 21032344
Revision Number: 1.0

FRB518 Hydraulic Tensioner

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5 Blue Heron Drive

Comstar Supply, INC Collegeville, PA 19426

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

FRB518 Hydraulic 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 4 OPERATING PROCEDURE.............................................. 12

General Data And Instructions

B. TYPOLOGY AND FIELD USE

Always start the diesel engine when using the machine.

Functioning in Puller Mode

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

F. GENERAL SAFETY INFORMATION

G. GENERAL OPERATOR INSTRUCTIONS

H. GENERAL MAINTENANCE INSTRUCTIONS

!ATTENTION: Failure to follow these instructions relieves the

I. THE INSTRUCTION MANUAL

!ATTENTION: This manual belongs exclusively to the manufacturer.

K. TEMPERATURE LIMITS FOR HYDRAULIC OIL

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

L. USE NOT ALLOWED

The manufacturer’s responsibility ends when the following situations occur:

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

Use caution when unpacking to avoid damaging the product.

!ATTENTION: Dispose all packaging materials in accordance with

Check the tires for proper inflation pressure.

!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 use

!DANGER: Dangerous situations may occur during machine use

3. Entangling or dragging in the accessible rotating units. It is not

4. Limb crushing during loading or removal of the rope-conductor. These

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

6. Inhalation of the diesel engine exhaust. The FRB518 discharges exhaust. To

!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

!PROHIBITION: Use the emergency stop device only for

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

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

1. To start the machine, insert the key

ITEM # QTY DESCRIPTION CONDUX P/N REF.

Figure 3A. Control Panel Identification

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

Figure 6. Set Reel Elevator Figure 7. Engage Leveling

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

Figure 10. Anchor, Adjacent to Figure 11. Reeving the Drum

D. REEVING THE DRUM

Figure 12. Thread Poly Rope

F. POSITION REEL ELEVATOR

G. DETERMINE TENSIONING RANGE

Final Sag Tension= 2,500 ft-pounds

H. SET TENSIONING RANGE LEVER