GMP 89000 Tornado Operation & Maintenance Manual
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GMP 89000 Tornado Operation & Maintenance Manual

Cable and tube blowing machine
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TORNADO CABLE AND TUBE BLOWING MACHINE
CABLE BLOWING MACHINE
Copyright 2009 by General Machine Products Co., Inc.
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
General Machine Products Co., Inc. • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA
OPERATION & MAINTENANCE
89000 – USA
TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com
Page 1 of 64
Date:__________________
General Machine Products Co., Inc
General Machine Products Co., Inc.
.
December 11, 2009 USA Ver 1

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Summary of Contents for GMP 89000 Tornado

  • Page 1 TORNADO CABLE AND TUBE BLOWING MACHINE OPERATION & MAINTENANCE 89000 – USA CABLE BLOWING MACHINE Copyright 2009 by General Machine Products Co., Inc. QC Final Inspection by:_________________________ Date:__________________ Unit Serial Number:__________________ Build Date:__________________ All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form General Machine Products Co., Inc whatsoever without the written permission of General Machine Products Co., Inc.
  • Page 2 Cable seal, collets and plug selection chart updated A. Miller 02-2007. Recommended spares list revised A. Crawford 01-2008 Programming Instructions Updated A. Sibun 03-2008 Programming Instructions Updated A. Sibun 11-2009 US GMP Version 1 A. Konschak Page 2 of 64 General Machine Products Co., Inc.

  • Page 3: Table Of Contents

    Appendix 2 Reserved Appendix 3 Cable Blowing Machine Service Connections Appendix 4 Hydraulic & Electrical Panel Layout Appendix 5 Appendix 6 Tornado Configuration Guide Appendix 6 Counter/Rate meter Programming Instructions GMP Limited Warranty Page 3 of 64 General Machine Products Co., Inc.
  • 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 must only be used by authorized personnel who have been suitably trained and competent to do so. These instructions are to be made available to operators of this equipment at all times. Failure to observe these safety instructions could result in se- rious personal injury and or property damage.
  • Page 6 16) Waste hydraulic oils are to be disposed of via an environmentally acceptable method. 17) Wear ear defenders if noise levels are considered high to prevent ear damage. 18) Machine may cause additional fire hazard if involved in an existing fire due to compressed air and hydraulic oils.
  • Page 7 4) Visually inspect hoses regularly and replace if damaged. GENERAL PNEUMATIC SAFETY INSTRUCTIONS The GMP Fiber Optical Cable Blowing Machine is a pneumatic device, using pressurized air to project cable at high velocities. Please observe the following precautions when operating the Cable Blowing Machine: 1) Compressed air can cause flying debris.

  • Page 8: Critical Points

    2. CRITICAL POINTS THAT DRAMATICALLY AFFECT THE OPERATION OF THE CABLE BLOWING MACHINE ▪ One (1) turn on the cable clamping screw ▪ Tractor drive to be closed at all times when cable is installed into machine. ▪ Air Chamber height adjustment correctly set. ▪...
  • Page 9 DISCLAIMER GMP and CBS Products takes care in the design of its products to ensure that the cable is protected during installation. Due to the variety and differ- ent methods of cable manufacture the responsibility of checking the cable compatibility with the equipment lies with the operator. Therefore, GMP and CBS Products cannot accept liability for any damage to the cable.

  • Page 10: General Description

    The unit is supplied as standard with a Chicago fitting. The air supply hose should be 1 1/4” (32 mm) minimum bore, (not supplied by GMP). The unit is supplied with 2 x hydraulic hoses x 23 feet (7 meters) and an emergency stop lead x 26 foot (8 meters) long for connecting between the cable blowing machine and hydraulic power pack (or hydraulic power source).
  • Page 11 FEATURES Fully labeled control panel containing: • Power ON/OFF button (silver) • Emergency Stop Button (red) • Blowing speed read out in either ft/min or m/min through a separate calibration • Length counter recording in feet or meters through a separate calibration •...

  • Page 12: Specification

    4. SPECIFICATION Serial No.: OPERATING CAPACITIES 0 - 220 lbs (0 - 100kg) Pushing Force: 0 - 260 ft/min (0 - 80m/min) Pushing Speed: (6 - 32mm OD) Cable Size: 1/2 - 2 1/2 inch (10 - 63mm OD) Sub – Duct Size: HYDRAULIC DRIVE SYSTEM 1450 psi (100 Bar) Max Operating Pressure:...
  • Page 13 ELECTRONIC CONTROL SYSTEM 12 Volts DC ( gel cell battery supplied) Power Requirements: 3.15 amp (slow-blow) Fuse Rating: DIMENSION AND WEIGHTS 48 1/2” (1230mm) Height: 42” (1060mm) Length: 27 1/2” (700mm) Width: 155 lbs. (70kg) Weight: 3.00 - 4 / 260 x 85 Tire Size: 25 psi (1.72 Bar ) Tire Pressure:...

  • Page 14: Operating Procedure Sub-Duct Integrity And Lubrication

    5. OPERATING PROCEDURE SUB-DUCT INTEGRITY AND LUBRICATION Sub-duct integrity and lubrication is entirely the responsibility of the operator. 1. Ensure that the sub-duct is fully prepared for use i.e.: Fully connected Pressure tested Cable exit retaining device fitted lubricated (if required) VERIFYING AIR FLOW AND LUBRICATION (IF RE- QUIRED) 2.
  • Page 15 5. Fit the cable seal plug and two cable seals (coated with silicon grease) into the lower half cable seal col- let. Ensure that the split of the innermost seal is in the lower half of the air chamber slightly rotated from the vertical.
  • Page 16 9. Notify installation team that preparations are competed and that checking the air flow through the sub-duct is about to commence. 10. Note: Only authorized fully trained operators should be allowed to operate the air compressor. With the air compressor ready to provide air, turn the air valve to the “open” position. 11.
  • Page 17 12. Ensure all air has exhausted from the air chamber and sub-duct. Open the air chamber and sub-duct clamp and withdraw the sub-duct. Add GMP’s Air- Glide lubricant to the sub-duct at the rate of 1 quart (.95 liters) of lubricant per 2000 ft (600 m) of sub-duct assuming a 1 1/4 bore.
  • Page 18 15. NOTIFY INSTALLATION TEAM Notify installation team that preparations for lubricating the sub-duct are complete and ready to commence. 16. With the compressor ready to provide air, turn the air valve to the open position. 17. When the foam plug has been expelled from the end or the sub-duct, turn the air valve to the “closed”...

  • Page 19: Operating Procedure-Cable Blowing

    6. OPERATING PROCEDURE CABLE BLOWING It is imperative that all persons using, operating or maintaining this cable blowing ma- chine be fully trained and competent and authorized to do so and have read the entire operation manual. General Machine Products Co., Inc. and CBS Products Ltd, CANNOT BE HELD RE- SPONSIBLE FOR MISUSE OF THIS EQUIPMENT.
  • Page 20 8. Unscrew the sub-duct clamp retaining bolts. Refer to the Section 4 “SPECIFICATION” for the correct pressure settings for the relief valve and pressure switch and to Section 6 “MAINTENANCE” for the setting procedures. NOTE: The cable blowing machine is sup- plied as standard with the pressure relief valve set at 1600 psi (110 Bar) and the pressure switch set at 1450 psi (100 Bar),...
  • Page 21 12. Release the adjusting screw locking ring, turn the adjusting knob until the mark on the air chamber support bracket aligns with the size of the cable to be installed on the increment gauge. Tighten the locking ring to prevent any movement during installation. (Refer to sec- tion 11 for details).
  • Page 22 15. Select the correct size cable infeed collet to suit the size of the cable to be installed and secure with the cap screw into each housing. Note: Sealing cord is not required on this collet. Always check and verify the correct size collets are fitted before operating the blowing machine.
  • Page 23 Close the infeed cable guide upper housing and secure with the swing bolt and thumb nut, ensure the cable is correctly located in the bore of the collet. Note: Ensure that the compressor air supply is never allowed to enter the air chamber or sub- duct when the top tractor drive frame is in the upper position.
  • Page 24 21. Install the second seal into the outer groove with the seal split in the lower half of the air chamber rotated slightly to the other side of the vertical (compared to the first cable seal). Ensure the groove seal lip is away from the tractor drive facing the sub-duct.
  • Page 25 26. The emergency stop button is set. (i.e. in upper po- sition). If not set, twist counter-clockwise to reset. 27. Connect the two hydraulic hoses and the emergency stop cable from the power pack (or hydraulic power source). Never run the blowing machine without the emergency stop ca- ble being connected.
  • Page 26 31. Turn hydraulic valve to “ON” position. 32. Ensure the emergency stop button is in the reset position. (Twist counterclockwise to reset). 33. Press the on/off button. The display will indicate the speed and distance Note: Do not press the RST Button while travelled by the cable.
  • Page 27 35. Continue to install cable into sub-duct. The operator wearing work gloves should hand guide the cable into the blowing machine through a dry clean cloth to prevent any debris on the cable entering the blowing machine and to ensure the cable enters the machine inline with the tractor drive belt without and bending or deviation.
  • Page 28 40. IF THE BLOWING MACHINE STOPS SUDDENLY If the cable blowing machine stops suddenly during the blowing operation it is likely that the pressure switch has tripped stopping the power pack because: A) The cable has reached its destination and the cable exit retaining device has stopped the travel of the cable.
  • Page 29 IN THE EVENT OF AN EMERGENCY Push the emergency stop push button. Turn the hydraulic valve to the “off” position. Turn the speed control knob to “MIN” position Press the on/off button to turn the electric’s (fully counter clockwise) off. Turn off the air supply (if required).
  • Page 30 TO RESTART 1. Ensure the power pack is running 2. Turn the hydraulic valve to the “on” position. 3. Press the power on/off button 4. Turn the air valve to the open position (assuming the required amount of cable in in the duct) 5.

  • Page 31: Maintenance

    7. MAINTENANCE To ensure reliable service from your Cable Blowing Machine, we recommend the unit be completely serviced every 6 months AIR CHAMBER The air chamber should be inspected after each op- eration for seal damage or wear. Seal cord should be replaced if damaged or missing and secured in posi- tion with the adhesive provided.
  • Page 32 GENERAL The machine should be stored under cover when not in use. The machine should be wiped clean after each time used. ALWAYS ensure that there are sufficient cable seals, cord seal, cord adhesive and silicone grease available in the toolbox to cover the next installation. ALWAYS ensure that the battery is fully charged, before the cable blowing machine is to be used.
  • Page 33 PROCEDURE FOR SETTING THE RELIEF VALVE AND PRESSURE SWITCH FOR CA- BLE SIZES 6-12 OD When installing small diameter cables with “soft/flexible” characteristics, it will be necessary to reduce the pressure relief valve and pressure switch settings to prevent the cable buckling or being jammed in the air chamber mounted collet.
  • Page 34 TO SET PRESSURE SWITCH SMALL DIAMETER (UNDER 12MM) OR FLEXIBLE CABLE Clamp a piece of 1” O.D. dowel/round bar x 13” long between top and bottom housings so it butts up to the air chamber mounted collets (in effect placing the motors in stall mode). 1.

  • Page 35: Maintenance Schedule

    7.1. 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 Clean air chamber Check / replace cord seals Check / replace cable seals...
  • Page 36 7.2. TYPICAL PROBLEMS EXPERIENCED WHEN CABLE BLOWING: PROBLEM SOLUTION Assist the drum by turning it or pulling the ca- Tractor feed does not pull the cable off the ble off the drum by hand. drum Machine has tripped out on pressure switch, cable has hit an obstruction or become jammed.
  • Page 37 7.3. BASIC TOOL KIT SUPPLIED WITH CABLE BLOWING MACHINE: PART No. DESCRIPTION 32838 1/8” Allen Key 89142 3mm Allen Key 89143 4mm Allen Key 89144 5mm Allen Key 89145 6mm Allen Key 31552 3mm dia O-Ring Cord 89148 Silicone Grease Dow Corning 7 100gr Tube 89149 Sealing Cord Glue 89153...

  • Page 38: Procedure For Replacement Of Chain Drives

    8. PROCEDURE FOR REPLACEMENT OF CHAIN DRIVES Tools required: 6mm Allen Key 13mm Wrench Ensure the hydraulic hoses to the power pack are disconnected from the blowing ma- chine before carrying out this procedure. 1. Remove the hydraulic motor from the top 2.
  • Page 39 7. Remove the tension sprocket assembly 8. Remove the chain-connecting link. 9. Remove the chain. 10. Check the chain support slide bars for wear. Clean and relubricate. 11. Pass the pre-lubricated new chain 12. Align the tension sprocket with the chain around the drive sprocket.
  • Page 40 Reassembling the top and the bottom parts of the pusher unit.▪ ▪ Refit the main clamping screw. ▪ Replace the stop washer on the bottom of the main jacking screw using a 6mm Allen key. ▪ Replace the hydraulic motor using the 6mm Allen key. Adjust top chain, do not over tighten chain.

  • Page 41: Procedure For Replacement Of Cable Collets

    9. PROCEDURE FOR REPLACEMENT OF CABLE COLLETS Ensure the air supply is disconnected from the blowing machine before carrying out this procedure. Tools Required 4mm Allen Key Step 1 Collet Removal ▪ Ensure that the air valve is closed and the air pressure is at zero.

  • Page 42: Procedure For Replacement Of Sub-Duct Clamp Collets

    10. PROCEDURE FOR REPLACEMENT OF SUB-DUCT COLLETS Ensure the air supply is disconnected from the blowing machine before carrying out this procedure. Always check and verify the correct size collets are fitted before operating the blowing machine. SUB-DUCT CLAMP COLLETS Tools Required 4mm Allen Key Step 1 Collet Removal...

  • Page 43: Procedure For Replacement Of Cable Seals

    11. PROCEDURE FOR REPLACEMENT OF CABLE SEALS Ensure the air supply is disconnected from the blowing machine before carrying out this procedure. Always check and verify the correct size collets are fitted before operating the blowing machine. Tools Required No tools are required. Step 1 Seal Removal / Refitting Ensure that the air valve is closed and that the air pressure gauge is at zero.
  • Page 44 12. PROCEDURE FOR THE AIR CHAMBER AND COLLET TYPE CABLE INFEED CABLE GUIDE ASSEMBLY HEIGHT Step 1 When changing collets and seals to accept smaller / larger sizes of cable it is necessary to adjust the height of the air chamber and the collet type infeed guide assembly. This setting must be carried out accurately, as failure to do so will seriously impair the function of the machine.

  • Page 45: Alignment Of Air Chamber To The Cable Pusher Unit

    13. ALIGNMENT OF AIR CHAMBER TO THE CABLE PUSHER UNIT 1. Insert a round parallel bar between the top and bottom cable pusher housings and clamp down. Ensure the rod doesn't inter- fere with metering wheel and that it passes through he air cham- ber.

  • Page 46: Monthly Service Check List

    14. MONTHLY SERVICE – CHECK LIST 1. Remove the drive chains from the pusher unit. Check both of the chains for excessive wear. Replace, if required and lubricate with the spray grease provided. 2. Remove any debris from the housings. 3.

  • Page 47: Service History Record

    15. SERVICE HISTORY RECORD Service no Date Carried out by Record of service/repair Page 47 of 64 General Machine Products Co., Inc.

  • Page 48: Troubleshooting Guide

    16. TROUBLESHOOTING GUIDE Initial starting hydraulic pressure at the point of starting a cable installation the hydrau- lic pressure must be between 290 - 580 psi (20-40 bar). If not, do not continue. See the below sections “Will Not Achieve Max Pressure” and “Runs At Higher Than Ex- pected Pressure”...
  • Page 49 EXCESSIVE AIR LEAKAGE FROM AIR CHAMBER • Damaged cord seal • Cable seals worn, incorrect size, wrong way round, misalignment of air chamber bracket in relation to cable diameter • Incorrect collets COUNTER NOT READING OR GIVING INCORRECT READINGS • Battery low on power •...

  • Page 50: Recommended Spare Parts

    17. RECOMMENDED SPARE PARTS Part No Description Qty Required 89155 Chain ½ Duplex (Black red) 89158 Motor (32 cc/rev) 31552 Seal Cord (Cut to length as required) 30 ft. 89148 Silicon Grease 1 Tube 89149 Sealing Cord Glue 1 Tube 89156 Wheel .
  • Page 51 Appendix 1 LAYOUT OF CABLE BLOWING MACHINE 1 Cable Pusher 9 Air Hose Connection 2 Air Chamber 10 Hydraulic Hose Connection (at rear of unit) 3 Sub-Duct Clamp 11 Emergency stop socket (on side of unit) 4 Cable infeed bracket assembly 12 Frame Leveling Foot 5 Unit Lifting Point 13 Tool Box...
  • Page 52 Appendix 2 Page 52 of 64 General Machine Products Co., Inc.
  • Page 53 Appendix 3 CABLE BLOWING MACHINE SERVICE CONNECTIONS Hydraulic Hose Connections Compressed Air Hose Power Pack to Cable Blowing Connected to Cable Blowing Machine Machine Compressor Duct Power Pack Emergency Stop Cable Cable Blowing Power Pack to Cable Cable Fiber Optic Machine Drum Blowing Machine...
  • Page 54 Appendix 4 HYDRAULIC AND ELECTRONIC CONTROL PANEL LAYOUT 1 Air Pressure Gauge 2 Hydraulic Pressure Gauge 3 Speed Control Knob 4 Hydraulic “On / Off” Lever 5 Power “On / Off” Button 6 Emergency Stop Button 7 Length / Speed Digital Display 8 Hydraulic Control Panel 9 Electronic Control Panel Page 54 of 64...
  • Page 55 Tornado Configuration Guide Appendix 5 Let our "Cable Blowing Experts" tailor your configuration. Please don't hesitate to call our Hotline at 1-800-345-6009 for any questions you may have. Locator Description Qty needed Duct Clamp 1 (2 halves) In order to configure your Tornado to work Duct Seal 1 (2 halves) with your specific cable requirements you...
  • Page 56 Notes: Page 56 of 64 General Machine Products Co., Inc.
  • Page 57 Appendix 6 Programming Parameters for CUB5R Counter/rate Meter Serial Numbers 0315 Onwards The device must be wired and installed into the machine prior to programming. Tornado is fitted with C-M-DEV-CUB5R, reflective version The DIP switch positions are as follows: 1 OFF 2 OFF 3 OFF 4 OFF...
  • Page 58 First reset the current settings to Factory Settings on the counter: 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 59 CUB5 PROGRAMMING QUICK OVERVIEW Page 59 of 64 General Machine Products Co., Inc.
  • Page 60 GMP, and are not covered by this Warranty.
  • Page 61 . GMP products or parts which become part of a total assembly which has been designated and/or manufac- tured by others, are not covered by this Warranty unless GMP reviews the total assembly and expressly extends its warranty. Design, material and workmanship furnished by others to install or operate a GMP product or part are not covered by this Warranty with respect to GMP's products or parts which are used in that particular assembly.
  • Page 62 GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com Page 62 of 64 General Machine Products Co., Inc.

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