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GMP 89004 Operation & Maintenance Manual

Powered duct rod pusher
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POWERED DUCT ROD PUSHER
QC Final Inspection by:_________________________
Unit Serial Number:__________________
Build Date:__________________
All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form
whatsoever without the written permission of
OPERATION & MAINTENANCE
89004 – USA
POWERED DUCT ROD PUSHER
Copyright 2017 by General Machine (KT), LLC
GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA
TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com
Date:__________________
General Machine Products (KT), LLC
Page 1 of 36
General Machine Products
July 12 2017 USA Ver 3a
(KT), LLC
Manual P/N 32297

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Summary of Contents for GMP 89004

  • Page 1 All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form General Machine Products (KT), LLC whatsoever without the written permission of GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com July 12 2017 USA Ver 3a...
  • Page 2 A. Konschak 05.26.09 US Version 2 A. Konschak 08.29.09 US Version 3 A. Konschak 07.12.17 US Version 3a - Changed Company Name A. Konschak GMP product warranty can be found at http://www.gmptools.com/warranty/ Page 2 of 36 (KT), LLC General Machine Products...

  • Page 3: Table Of Contents

    CONTENTS 1. Safety Instructions 2. Critical Points 3. General Description 4. Specification 5. Operating procedures 6. Maintenance 7. Procedure for Replacement of Chain Drives 8. Procedure for Replacement of sub-duct clamp collets 9. Procedure for Adjusting the sub duct clamp and collet type rod infeed guide assembly height 10.
  • Page 4 INTRODUCTION Founded by engineer George M. Pfundt in 1936, GMP started op- erations in a downtown Philadelphia building as a specialty ma- chine shop doing work for the local Bell Telephone company and for the electric utility company. GMP expanded to a production...

  • Page 5: Safety Instructions

    1. SAFETY INSTRUCTIONS This Equipment should be used only by personnel who have been given the appropri- ate training and who are competent to use it. These instructions are to be made available to operators of this equipment at all times. Failure to observe these safety instructions could result in serious personal injury and/ or property damage.
  • Page 6 13. Some component and assembly parts are in excess of 55 lbs. (25kg) . When lifting care must be taken, insure sufficient man power/lifting gear is available, to prevent personal injury and damage to the machine. Beware of exposed electrical contacts. Do not touch, or allow metal objects to come into contact.
  • Page 7 GENERAL HYDRAULICS SAFETY INSTRUCTIONS Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Ob- serve the following precautions to avoid hydraulic hazards: - 1. Insure all hydraulic connections are securely tightened before operating the machine. 2. Check for leaks with a piece of cardboard. Do not use your hands! 3.

  • Page 8: Critical Points

    NOTE: This machine is primarily designed to work with the GMP 1/2 Duct Rodder. Other manufacturer’s Duct Rodders may be able to be modified to work. Please contact the factory for details.

  • Page 9: General Description

    3. GENERAL DESCRIPTION The Duct Rod Pushing machine has been designed to provide an effective and safe method of rod installation and removal. The system installs rod of 1/2” overall diameter at up to 130 ft/ min into pre-installed sub-ducts. The machine is protected by preset pressure relief valve and preset pressure sensor.
  • Page 10 FEATURES Fully labeled control panel containing: ▪ Power ON/OFF button ▪ Emergency Stop Button ▪ Installation speed and direction readout in m/min or ft/min through a separate calibra on ▪ Length counter tracking in feet or meters through a separate calibra on ▪...

  • Page 11: Specification

    4. SPECIFICATIONS OPERATION CAPACITIES Pushing Force 0-300 lbs. (0 - 136 kg) Pushing Speed 0-130 ft/min (0 - 40m/m) Rod Size 1/2” (12.7mm) Sub-Duct Size 1-1/4 SDR HYDRAULIC DRIVE SYSTEM Operating Pressure 2030 psi (max) (110 Bar) Flow 5.3 gallons/min (recommended) Pressure Switch Setting 1450 psi (100 Bar) Relief Valve Setting...

  • Page 12: Operating Procedures

    5. OPERATING PROCEDURE It is imperative that all persons using, operation or maintaining this cable blowing ma- chine: Have received comprehensive training in the use of this machine.  Are competent and authorized to use it and have read and understand this manual. ...
  • Page 13 7. Open tractor drive enough to feed the 8. Place sub-duct from the manhole into out duct rod through the pusher. -feed sub-duct clamp and tighten with 3/4” wrench (provided). TIP: If the duct that is to be rodded is larger than 1 1/4”, insert a piece of 1 1/4 sub- duct from the out-feed of the Duct Rod- der into the larger duct causing the...
  • Page 14 11. Feed the duct rod through the pusher and into the sub-duct that’s placed in the manhole. 12. The correct rod clamping force is vital to the performance of the ma- chine. It should be set as follows: Tighten the handle with one hand rotating the clamp washers with the other.
  • Page 15 14. Insure that the hydraulic control lever is in the “OFF” position and the speed control knob is in the “Min” position (fully rotated coun- ter-clockwise). 15. The emergency stop button is set to on (upper most position). If not set, twist counter-clockwise to re- set.
  • Page 16 18. Turn the Hydraulic lever valve to the “ON” position. 19. Turn on the digital display by pressing the “power on/off” button. Allow approx. five (5) seconds for the display to appear. Pressing SEL toggles between installation dis- tance (ft) and speed (ft/min) (designated by R). Pressing RST will reset the distance reading to zero (0).
  • Page 17 24. IF THE PUSHING MACHINE STOPS SUDDENLY If the rod pushing machine stops suddenly during the pushing operation it is likely that the pressure switch has tripped, the probable reasons for this are: - A) The rod has become jammed, has hit an obstruction in the duct or the rod pushing operation has reached its maximum capability.
  • Page 18 TO RESTART 1. Take machine out of emergency stop by turning the red button counter clock wise. Restart the hydraulic power pack. 2. Turn the hydraulic on/off valve to “on’” position. 3. Turn on the digital display by pressing the “power on/off” button. (If the electric’s have been switched off) 4.

  • Page 19: Maintenance

    6. MAINTENANCE To insure reliable service from your Rod Pushing Machine, we recommend the unit be com- pletely serviced every 6 months. TRACTOR DRIVE Inspect the chain drive blocks for wear each week. CHECK the chain tension weekly and adjust if necessary with the two external adjustment screws (do not over tension).
  • Page 20 GENERAL The machine should be stored under cover when not in use. The machine should be wiped clean after each time used. ALWAYS insure that the service battery and spare battery (if available) are fully charged, before this rod-pushing machine is to be used. The machine uses a conventional lead – acid batterie, this may be charged using the supplied battery charger for a maximum of 8 hours.
  • Page 21 6.1. MAINTENANCE SCHEDULE PROCEDURE DAILY WEEKLY MONTHLY Clean all assemblies and components thoroughly Inspect hydraulic hoses for leaks and cracks Inspect fasteners, screws and retaining pins / wire Check / adjust chain tension Check tractor drive pads for wear / damage Tire pressure / condition Check condition of emergency stop lead Clean rod infeed guide bracket and collets...
  • Page 22 6.2. TYPICAL PROBLEMS EXPERIENCED WHEN ROD PUSHING: PROBLEM SOLUTION Tractor feed does not pull the rod off the Assist the drum by turning it or pulling the rod drum off the drum by hand. Loosen friction brake. The Rod Pushing Machine stops. Hydrau- Machine has tripped out on pressure switch, lic pressure gauge reads zero.

  • Page 23: Procedure For Replacement Of Chain Drives

    7. PROCEDURE FOR REPLACEMENT OF CHAIN DRIVES Tools required: 6mm Allen Key 13mm wrench INSURE THE HYDRAULIC HOSES ARE DISCONNECTED FROM THE PUSHING MACHINE BEFORE CARRYING OUT THIS PROCEDURE. Step 1 a. Disconnect the hydraulic motor from the top frame – using 6mm Allen Key. b.
  • Page 24 Step 5 Top Housing – Chain Refitting a. Pass the pre-lubricated chain round the drive sprocket. Feed the chain along the unit and reconnect the chain-connecting link. b. Align the tension sprocket with the chain and locate into position. c. Insert the tension pin through the tension sprocket, placing the tensioner pin spacer on the tension pin.

  • Page 25: Procedure For Replacement Of Sub-Duct Clamp Collets

    8. PROCEDURE FOR REPLACEMENT OF SUB-DUCT COLLETS THE MACHINE IS SUPPLIED WITH COLLETS FITTED FOR 1 1/4” SDR SUB DUCT. SUB-DUCT CLAMP COLLETS Tools Required 4mm Allen Key Step 1 Collet Removal a. Open the sub-duct clamp. b. Remove the socket head cap screws (2) – using a 4mm allen key and remove the collet (2).

  • Page 26: Monthly Service - Check List

    9. PROCEDURE FOR THE OUTFEED AND INFEED SUB DUCT CLAMP INFEED AND OUTFEED SUB DUCT CLAMP: a. To adjust the sub duct clamp bracket in either direction, release the adjusting knob locking ring and turn the knob placed directly under the sub duct clamp. b.

  • Page 27: Service History Record

    11. SERVICE HISTORY RECORD Service no Date Carried out by Record of service/repair Page 27 of 36 (KT), LLC General Machine Products...

  • Page 28: Troubleshooting Guide

    12. TROUBLESHOOTING GUIDE INITIAL STARTING HYDRAULIC PRESSURE AT THE POINT OF STARTING A ROD INSTALLATION THE HYDRAULIC PRESSURE MUST BE BETWEEN 290-580 psi (20-40 BAR). IF NOT DO NOT CONTINUE, SEE SECTIONS ‘WILL NOT ACHIEVE MAX PRESSURE’ AND ‘RUNS AT HIGHER THAN EXPECTED PRESSURE’ TO RECTIFY PROBLEM BEFORE COMMENCING ROD INSTALLATION.

  • Page 29: Recommended Spares List

    13. RECOMMENDED SPARES LIST Part No Description Qty Required 89191 Chain ½ Duplex (Blue) 89158 Motor (32 cc/rev) 89156 Wheel (Pneumatic) 89151 Wheel (Solid) 31727 Chain Support Slide Bar 89153 Metaflux chain spray 70-88 32512 Battery 12 V.dc For spare parts always quote the machine type and serial number and contact: General Machine Products 3111 Old Lincoln Highway, Trevose PA 19053 USA TEL: +1 215 357 5500...
  • Page 30 Appendix 1 LAYOUT OF ROD PUSHING MACHINE 1 Rod Pusher 2 Sub-Duct Outfeed Clamp 3 Sub-Duct Infeed Clamp 4 Unit Lifting Point & Clamping Handle 5 Hydraulic Control Panel 6 Electronic Control Panel 7 Hydraulic Hose Connection (at rear of unit) 8 Emergency stop socket (on side of unit) 9 Frame Leveling Foot 10 Tool Box...
  • Page 31 Appendix 2 Page 31 of 36 (KT), LLC General Machine Products...
  • Page 32 Appendix 3 HYDRAULIC AND ELECTRONIC CONTROL PANEL LAYOUT 1 Hydraulic Pressure Gauge 2 Speed Control Knob 3 Hydraulic “On / Off” Lever 4 Power “On / Off” Button 5 Emergency Stop Button 6 Length / Speed Digital Display 7 Hydraulic Control Panel 8 Electronic Control Panel Page 32 of 36 (KT), LLC...
  • Page 33 Appendix 4 Programming Parameters for CUB5R counter/rate meter fitted to Rod Pushing machines – REV 2 The device must be wired and installed into the machine prior to programming. The Duct Rod Pusher is fitted with CUB5R, reflective version The DIP switch positions are as follows: 1.
  • Page 34 Counter programming parameters for the Duct Rod Pusher Scroll to 3-DSPLAY Skip through the parameters until FACT SET is displayed. Change this to YES by pressing RST PRO NO should be displayed, Press SEL. Continue to re-program the Counter by pressing and holding SEL to re-enter programming mode.
  • Page 35 Page 35 of 36 (KT), LLC General Machine Products...
  • Page 36 GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com Page 36 of 36 (KT), LLC General Machine Products...

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