POWERED DUCT ROD PUSHER OPERATION & MAINTENANCE 89004 – USA POWERED DUCT ROD PUSHER Copyright 2008 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 whatsoever without the written permission of General Machine Products Co., Inc.
REVISION HISTORY Rev # Date Details Author 01 07.27.05 Original issue A. Sibun 02 10.16.08 US Version 1 A. Konschak 03 05.26.09 US Version 2 A. Konschak 04 08.29.09 US Version 3 A. Konschak Page 2 of 40 General Machine Products Co., Inc.
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. Monthly Service – Check List 11. Service History Record 12. Troubleshooting Guide 13.
INTRODUCTION Founded by engineer George M. Pfundt in 1936, GMP started operations in a downtown Philadelphia building as a specialty machine shop doing work for the local Bell Telephone company and for the electric utility company. GMP expanded to a production shop after landing a contract with Western Electric Company and, subsequently, forming a close relationship with Bell Telephone Laboratories in Murray Hill, N.J.
1. SAFETY INSTRUCTIONS This Equipment should be used only by personnel who have been given the appropriate 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. ! CAUTION: This machine is designed to work with one piece, continuous rod with no breaks.
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. 14. Prior to installation insure the sub-duct route is connected properly. 15. Beware of exposed electrical contacts. Do not touch. Or allow metal objects to come into contact.
GENERAL HYDRAULICS SAFETY INSTRUCTIONS Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards: - 1. 2. 3. 4. Insure all hydraulic connections are securely tightened before operating the machine. Check for leaks with a piece of cardboard. Do not use your hands! Do not exceed working pressure of hydraulic hoses. Visually inspect hoses regularly and replace if damaged.
2. CRITICAL POINTS THAT DRAMATICALLY AFFECT THE OPERATION OF THE ROD PUSHING MACHINE a. b. c. d. e. f. g. Two (2) turns on the rod clamping screw. Tractor drive to be closed at all times when rod is installed into machine. Sub-Duct clamp height adjustment correctly set. Rod in-feed bracket height adjustment correctly set. Sub-duct fully connected. Rod drum must be located directly behind and in line with the pushing machine.
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. The hydraulically powered rod feed system controls the rod.
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 calibration Length counter tracking in feet or meters through a separate calibration Hydraulic pressure display gauge Hydraulic on/off control valve Emergency stop connection socket Adjustable speed control for drive belts Battery Charging Connection Control panels are anti corrosion treated and may be removed independen
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.
5. OPERATING PROCEDURE It is imperative that all persons using, operation or maintaining this cable blowing machine: Have received comprehensive training in the use of this machine. Are competent and authorized to use it and have read and understand this manual. General Machine Products Co., Inc. cannot be held responsible for misuse of this equipment. Charging the 12 volt battery before use: Plug in the supplied battery charger in the charging jack found on the right of the control panel.
7. Open tractor drive enough to feed the duct rod through the pusher. 8. Place sub-duct from the manhole into out-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 subduct from the out-feed of the Duct Rodder into the larger duct causing the smaller duct to act like a feeder. Tie off the small duct to a ladder or some other permanent fixture if possible.
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 machine. It should be set as follows: Tighten the handle with one hand rotating the clamp washers with the other. The clamp washers will turn easily until the handle begins to clamp them. When the clamp washers become almost impossible to turn with one hand, this is the start point for the clamp force setting.
14. Insure that the hydraulic control lever is in the “OFF” position and the speed control knob is in the “Min” position (fully rotated counter-clockwise). 15. The emergency stop button is set to on (upper most position). If not set, twist counter-clockwise to reset. 16. Start the engine on the power pack. Insure that you have enough fuel for the duration of the pushing operation. 17. Select desired pushing direction from the valve to the rear of the machine. Direction is indicated.
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 distance (ft) and speed (ft/min) (designated by R). Pressing RST will reset the distance reading to zero (0). 20. Turn the speed control valve clockwise (towards ‘max’) until the desired speed (130 ft/min max) is achieved. 21. Continue to install rod into sub-duct.
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. B) The power pack has developed a problem or has run out of fuel. IN THE EVENT OF AN EMERGENCY 1. Push the emergency stop push button. 2.
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. Turn the speed control valve clockwise until the desired speed (up to 130 ft/min max) is achieved. Page 18 of 40 General Machine Products Co., Inc.
6. MAINTENANCE To insure reliable service from your Rod Pushing Machine, we recommend the unit be completely 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). The chain should slightly lift off the chain guides, when pulled at the center by finger. THE CHAIN SHOULD BE LUBRICATED EACH TIME USED by application of Metaflux spray grease 70-88.
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. CHECK the tire pressures and tire condition weekly.
6.1.
6.2. TYPICAL PROBLEMS EXPERIENCED WHEN ROD PUSHING: PROBLEM SOLUTION Tractor feed does not pull the rod off the drum Assist the drum by turning it or pulling the rod off the drum by hand. Loosen friction brake. The Rod Pushing Machine stops. Hydraulic pressure gauge reads zero. Machine has tripped out on pressure switch, rod has hit an obstruction or become jammed. Turn hydraulic valve to off position. Turn speed control knob to ‘min’.
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. Remove the stop washer on the bottom of the main jacking screw – using a 6 mm allen key. c. Unscrew the main clamping screw and separate the top and the bottom of the pusher unit. Step 2 Bottom Housing – Chain Removal a.
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. Refit swing bolt – using a 13mm wrench. Step 6 Top Housing – Chain Refitting a. Reassembling the top and the bottom parts of the pusher unit. b.
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). Step 2 Collet Refitting a. Select he replacement collets b. Clean the sub-duct clamp with a dry cloth. c. Fit the required collets and secure with a socket head cap screws – using a 4mm allen key. d.
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. Select the adjustment required – using the increment gauge on the side of the unit. c. Tighten the locking ring to prevent any movement during installation. 10. MONTHLY SERVICE – CHECK LIST a. Remove the drive chains from the pusher unit.
11. SERVICE HISTORY RECORD Service no Date Carried out by Page 27 of 40 Record of service/repair General Machine Products Co., Inc.
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. WILL NOT ACHIEVE MAX PRESSURE a. Hydraulic control valve not open fully b. Speed control not positioned fully c. Faulty power pack (check performance) d.
13. RECOMMENDED SPARES LIST Part No 89191 89158 89156 OR 89151 31727 89153 32512 Description Chain ½ Duplex (Blue) Motor (32 cc/rev) Wheel (Pneumatic) Qty Required 2 2 2 Wheel (Solid) Chain Support Slide Bar Metaflux chain spray 70-88 Battery 12 V.dc 2 2 1 1 For spare parts always quote the machine type and serial number and contact: General Machine Products Co. 3111 Old Lincoln Highway, Trevose PA 19053 USA TEL: +1 215 357 5500 FAX: +1 215 357 6216 E-MAIL: info@GMPtools.com Website: www.GMPtools.
Appendix 1 LAYOUT OF ROD PUSHING MACHINE 12 1 4 7 13 2 3 8 5 6 11 10 9 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 11 Mounting Frame 12 Tractor Drive Movement Indicator 13 Directional Valve Page 30 of 40 General Machine Products Co., Inc.
Appendix 2 Page 31 of 40 General Machine Products Co., Inc.
Appendix 3 HYDRAULIC AND ELECTRONIC CONTROL PANEL LAYOUT 2 6 3 5 1 7 4 8 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 40 General Machine Products Co., Inc.
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. ON 2. OFF 3. ON 4. ON Please see the attached CUB5 Programming Overview attached to this document. a. Press and hold SEL for 2 seconds to enter DIP Switch programming mode b.
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. Pro-no will be displayed, press RST to move through the relevant sections. The following parameters are required for the counter: Press RST Once: Counter Parameters (1-INPUT) INPA-B = QUAD 4 – if correct press SEL.
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GMP Limited Warranty 1a. General Machine Products Co., Inc. ("GMP") warrants to the purchaser and/or end user: (1) that a new product sold and manufactured by GMP will be free from original defects in material and workmanship for one year from the date the product was delivered to the purchaser and/or end user, or for the lifetime of the Modular Plug Presser; (2) that a new product sold and not manufactured by GMP will be covered exclusively by the manufacturer's warranty.
4a. GMP products or parts which become part of a total assembly which has been designated and/or manufactured by others, are not covered by this Warranty unless GMP reviews the total assembly and expressly extends its warranty. 4b. 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. 4c.
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GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: info@gmptools.com Page 39 of 40 General Machine Products Co., Inc.
