USER'S GUIDE & SAFETY MANUAL
Deluxe Blower
Patent # 6264171
Important Safety Notice
Read and understand all procedures and safety instructions before using the Deluxe Blower. Observe all
safety information on this page and note specific safety requirements as explained by 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.
READ MANUAL
FIRST
Save this user’s guide for future reference.
COMMUNICATIONS WITH THE MANUFACTURER
For any information related to the machine (use, maintenance, spare parts) always state Model, Serial
Number, Manufacturing Year and Order. This data can be found in the machine identification table.
Manufacturer:
Condux International Inc.
145 Kingswood Drive
Mankato, MN 56002-0247
1-507-387-6576
Fax 1-507-387-1442
Internet: http://www.condux.com
E-mail: cndxinfo@condux.com
If you have questions on:
SAFETY - OPERATIONS - APPLICATIONS
CALL 1-800-533-2077
2
Table of Contents
General Information ..........................................................................4
1
Technical Specifications ......................................................................6
2
A. Hydraulic ..........................................................................6
B. Condition of Use ....................................................................6
C. Air Compression Requirements ........................................................6
D. Operational Capacities ...............................................................8
E. Electronic Control Box ...............................................................8
F. Physical Specifications ...............................................................8
G. Acoustic Emission ..................................................................8
H. Caterpillar Drive Specifications .........................................................8
I. Conduit Coupling Requirements ........................................................8
Safe Operating Procedures ....................................................................9
3
A. Work Area Safety ...................................................................9
B. Hydraulic Devices ...................................................................9
C. Pneumatic Devices ..................................................................9
D. Electric Devices ....................................................................10
Unpacking the Deluxe Blower .................................................................10
4
A. Blower Components ................................................................10
B. Tools and Materials .................................................................10
Set Up the Blower ..........................................................................11
5
A. Attach Blower to Job Box ............................................................11
6
Cable Crash Test ...........................................................................12
Pressure Test Conduit .......................................................................17
7
Prepare Conduit for Cable ....................................................................22
8
Prepare Cable .............................................................................25
9
Final Set-Up ..............................................................................27
10
11
12
13
14
15
16
A. Final Inspection ....................................................................28
Blower Operating Instructions .................................................................28
A. Observer at Exit Pit .................................................................28
B. Connect Hydraulic Systems ..........................................................28
C. Set up the Electronic Control Box ......................................................29
D. Panel Layout ......................................................................30
E. Traction Control .................................................................... 32
F. Operation .........................................................................32
Tear Down Procedures ......................................................................34
A. Remove Power from Unit ............................................................34
B. Remove Cable from Blower ..........................................................35
C. Separate Unit from Conduit ..........................................................35
Maintenance ..............................................................................36
A. Track Cleaning & Tightening ..........................................................36
B. Replacement of Drive Belt ...........................................................36
Troubleshooting Guide .......................................................................38
Appendices ...............................................................................39
A. Blower with Job Box ................................................................39
B. Upper Drive Shaft Replacement Kit ....................................................40
C. Lower Drive Shaft Replacement Kit ....................................................41
D. Hydraulic Motor Replacement Kit ......................................................42
E. Idler Bracket Bushing & Idler Bracket Screw Replacement Kits ...............................43
F. Air Block Assembly Replacement Kits ...................................................44
G. Counter Clamp Roller & Cable Guide Replacement Kits ....................................46
H. Timing & Takeup Roller & Idler Roller Replacement Kits ....................................47
I. Hydraulic Coupler (Male) Replacement Kit ...............................................48
J. Hydraulic Coupler (Female) Replacement Kit .............................................49
K. Clamp Adjustment Replacement Kit ....................................................50
L. Lower Counter Roller Replacement Kit ..................................................51
M. RH Cable Guide Roller Replacement Kit ................................................52
N. LH Cable Guide Roller Replacement Kit ................................................53
O. Counter Spring Replacement Kit ......................................................54
P. Base Mount ......................................................................55
Q. Pneumatic & Electrical Circuits .......................................................56
R. Hydraulic Circuit ...................................................................57
S. Hydraulic Flow Control Valve .........................................................58
T. Possible Wear & Replacement Parts & Accessories ........................................59
Warranty Information ........................................................................67
3
1.
General Information
The operating instructions contain a full description of the Deluxe Blower, which has
been designed for the purpose of feeding fiber optic cable through round conduits of
uniform cross section. The conduit must previously have been installed underground
or overhead to receive the fiber optic cable and must be of sufficient length on exit to
be received by the machine. The conduit must be made of material with sufficient
compression strength for it to be adequately sealed in the exit of a machine. The
conduit must be airtight up to a pressure of 175 psi (12 bar). For this purpose,
connectors of screw, compression or fusion type must be used. Conduits from
(10 mm) to 1.97" (50.00 mm) and fiber optic cables from 1/4" (6 mm) to 1.13"
(28.7 mm) diameter can be accepted by the machine.
Fiber optic cable is fed into the conduit by combining pulling and pushing forces,
which draw the fiber optic cable through the conduit. The pulling force is achieved
by connecting the leading end of the fiber optic cable to a piston or carrier, which
fits exactly into the conduit to make an airtight seal. Air under pressure is fed in
behind the carrier causing it to be forced through the conduit. As the carrier moves
through the conduit, it pulls the fiber optic cable behind it. The fiber optic cable is
continuously pushed into the conduit by a tractor drive. This consists of two
caterpillar tracks, which grip the top and bottom of the fiber optic cable moving it into
the conduit. This ensures the fiber optic cable is always free as it moves into the
conduit and reduces the magnitude of the pulling forces needed to carry the leading
end through. Special lubricants are used to make it easier for the carrier to pass
through the conduit.
The exit of the machine consists of an air box that is made in two halves that clamp
together. The air box contains special removable seals on entry and exit, which
clamp around either the end of the conduit or the fiber optic cable to be fed into the
conduit. The seals can be changed to accommodate different conduit and fiber optic
cable sizes. The conduit is clamped between a pair of seals at the entrance to the
air block. A clamp located in front of the entrance to the air block holds the conduit
mechanically to prevent it from moving axially. The fiber optic cable enters through
two seals located in an aluminum nozzle that splits in half. The aluminum nozzle is
located in the entrance to the air box and is shaped to ensure an airtight seal around
the fiber optic cable. When the two halves of the air box are closed, air pressure is
admitted into the space between the seals on entry and exit.
The use of the Deluxe Blower for operations different from those discussed in this
manual are considered extremely dangerous and thus forbidden. The non-respect for
the
prescribed restraints of the machine causes a situation of improper use and relieves
the manufacturer from any responsibility, civil or penal. The manufacturer’s
responsibility declines even when one of the following happens:
a. The consequences caused by tampering and/or modifications carried out
without the manufacturer’s written acceptance.
b. The use of imitative spare parts.
c. Bad maintenance.
d. Use with disconnected safety devices.
e. The connection to machine and/or parts not produced and not directly
authorized by the manufacturer in a written acceptance.
The Deluxe Blower is a unique device for inserting fiber optic cable directly into
conduit. The Deluxe Blower is comprised of an air block and a tractor drive that,
4
when combined with an air compressor and a hydraulic power unit, will propel fiber
optic cable measuring from 1⁄4" to 1.13" (6 mm to 28.7 mm) into an unobstructed,
unoccupied, airtight conduit run at speeds of 0 to 300 feet per minute (0-91 m/min).
A cable carrier must be placed at the front end of the cable.
The Deluxe Blower greatly reduces pulling stress on the cable. When equipped with
the electronic counter box, the tractor drive will automatically shut down if the cable
hits an obstruction or if it begins to slip on the tractor drive.
The blower comes standard with job box, hydraulic hoses with couplings, digital
LCD electronic counter box, and an adjustable control valve to the tractor drive for
speed adjustment.
GENERAL MACHINE USE
a. Only qualified operators should use the machine. The operator should only be
the person who received qualified training from the product owning company or
trained by the manufacturer.
b. Machine must only be used for the work it was designed for.
c. Machine is not to be used with unauthorized personnel on the job site.
d. Should there be any doubt concerning use, functioning, maintenance or
anything else, please contact the factory or factory representative.
OPERATOR QUALIFICATIONS
a. Operator must know the required safety directives to run the machine that are
pertinent to the country where it is being used.
b. Operator in charge of the machine and installation project must be appropriately
dressed, avoiding large clothes, hanging jewelry or whatever might become
entangled in the moving parts.
c. Operator must also wear the necessary protective equipment such as gloves,
boots, helmet, etc.
d. Operator must carefully follow all advisements contained in the instruction
manual or on the machine.
e. Operator must have work area kept clean of obstacles that might inhibit a safe
working area.
MAINTENANCE QUALIFICATION
a. All of the machine maintenance must be carried out with the machine on a level
surface and not attached to any form of power source: electrical, pneumatic, nor
hydraulic.
b. Authorized and trained personnel must do all maintenance operations. Trained
personnel are defined as people who have received qualified training from the
using company or from the manufacturer.
5
2.
Technical Information
A. HYDRAULIC SYSTEM REQUIREMENTS
•HydraulicOperatingPressure:1500psi(103bar)maximum
•HydraulicFlow:6.8gpm(20.8l/m)maximum
•HydraulicCircuitType:OpenCenter
•5micronfiltration
•FittedwithBHTMAstandard1/2"flatfacedquickreleasecouplings
•Propersizedpowerunitshouldbeusedtoruntheblowermachineto
prevent overheating
IMPORTANT: Operators must take any precautions that may have been
recommended by the suppliers of lubricants or hydraulic fluids. This applies to
the use and disposal of lubricants and hydraulic fluids including the
lubricant used to ease the passage of fiber optic cables through conduits.
B. CONDITION OF USE
Temperature from 21° F ( -6° C) to 110° F (+43° C)
Humidity from 30% to 90% +/- 5%
Weather conditions relevant to working conditions
Natural and/or artificial lighting of the work site, minimum 200 lux
C. AIR COMPRESSOR REQUIREMENTS
•PneumaticPressure:175psi(12bar)Maximum
•RequiredFlowCapacity:375SCFM(11m3/min)Maximum
•ConduitSize:10mm-1.97"(50mm)OD
•Aircoolersarerecommendedforblowingfiber
•Compressorflowmayneedtobedoubledifblowingdistanceisgreaterthan
3,500 feet (1,067 meters)
•AirhosefittingsneedtobecompatiblewithDixon“AirKing”universal
couplings.
The following charts help to determine the compressor size requirement based on
testing the conduit system (Figures 1-3).
1. Pressurize the conduit up to the maximum compressor pressure. That is the
Pstart - value.
2. Time for 10 seconds and record the ending pressure, Pend.
3. Subtract Pstart-Pend and divide by 10.
4. Find the appropriate x value and approximate length of conduit run then correlate
that information with the size of the conduit on the graph. The resulting zone is the
approximate compressor requirement.
6
Figure 1. Compressor Sizing for 3,280 ft (1,000 m) of Conduit Run
OUT OF RANGE
Figure 2. Compressor Sizing for 4,921 ft (1,500 m) of Conduit Run
OUT OF RANGE
Figure 3. Compressor Sizing for 8,202 ft (2,500 m) of Conduit Run
7
D. OPERATIONAL CAPACITIES
•PushingForce:175lbs(778N)maximum
•PushingSpeed:300ft/min(91m/min)maximum
•CableSizes:.25"to1.13"(6mmto28.7mm)
•ConduitSizes:1/2",3/4",1",1-1/4"TRUE,1-1/4",1-1/2"SDR11&13.5,
2" and metric O.D. conduit; 10 & 12 mm, 12.7 mm, 14 mm, 16 mm,
18 mm, 25 mm, 32 mm, 36 mm, 37 mm, 40 mm, 42 mm, 44 mm, 46 mm
and 50 mm
E. ELECTRONIC CONTROL BOX
•PowerRequirements:12voltsDC
•Powerconsumptionis24Watts
•Powerconnectionmustbetoautomotivepowerpointorpowerpoint
connection on Condux hydraulic power unit
•Fusedwitha2.5ampfuse,250volt-5x20mm-GMAtype
•Displays:TotalMachineDistance,DistanceofRun,OperationalSpeed,
Errors Descriptions
•AutomaticShutdownSpeeds:300ft/min(91m/min)maximum
F. P H YSICAL SPECIFICATIONS (DOES NOT INCLUDE LEGS OR JOB BOX)
•Height 16.5"(419mm)
•Length 30"(761mm)
•Width 14.8"(375mm)
•Weight 82lbs(37kg)
G. ACOUSTIC EMISSION
•Levelofmax.soundpressuretotheoperatorseat(ISO11202)Lep=85dB(A)
H. CATERPILLAR DRIVE SPECIFICATIONS
•Maximumpushingforce:175lbs(778N),dependingoncablediameter
•Maximumpushingspeed:300ft/min(91.5m/min)
•Maximumclampingforce:<114lbf/in(20N/mm)
•Independentpushingdrivebeltswithpolyurethanepadsprofiledforcable
0.23" (5.8 mm) to 1.13" (28.7 mm)
•Mechanicalgaschargedshockabsorberclamptopreventcablecrush.
•Side
guards.
I. CONDUIT COUPLING REQUIREMENTS
•Mustwithstandmaximumairpressureof175psi(12bar).
•Mustwithstandaxialloadingandvibration.
•Mustbescrewtype,compressiontype,orfusiontype.
•SightHolesmustbesealed.
•Mustfitsnugly.
•Conduitendsmustbecutoffsquarelyanddeburred.
•Conduitmustbefullyseatedintothecoupler.
•Couplersshouldbeinstalledinastraightsectionofconduit.
•Mustbesamesizeconduit.
8
Safe Operating Practices
Read and understand all procedures and safety instructions before using the Deluxe
Blower. Observe all safety information on this page and note specific safety
requirements as explained by procedures called out in this manual. Failure to follow
these instructions could result in serious personal injury, property damage or death.
A. WORK AREA SAFETY
1. Wear personal protective equipment: hard hat, safety glasses, safety shoes, and
leather work gloves.
2. The safe operation of this equipment requires that the operators be on
stable footing.
3. Stay clear of cables or lines under tension.
4. Stay clear of pressurized line and conduit.
5. Stay out of manhole while blower is in use.
6. Use the blower only for its intended purpose. Do not use the tractor drive
without the air block to push or pull cable.
7. Do not place cable reel too close to unit. Place the reel far enough away from
the unit to ensure proper control.
8. Do not tamper with relief valves or pressure reducing valves.
9. Place cable grip on end of conduit to catch cable carrier and cable.
10. Keep hands away from tractor drive while blower is in operation.
B. HYDRAULIC DEVICES
Escaping fluids under pressure can penetrate the skin and cause serious personal
injury. Observe the following precautions to avoid hydraulic hazards:
1. Tighten all connections before applying pressure. Relieve pressure when
connecting or disconnecting hoses when servicing the unit.
3.
2. Check for leaks with a piece of cardboard. Do not use your hands!
3. Do not exceed working pressure of hydraulic hoses.
4. Visually inspect hoses regularly and replace if damaged.
C. PNEUMATIC DEVICES
The Deluxe Blower is a pneumatic device, using pressurized air to project cable at
high velocities. Please observe the following precautions when operating the blower:
1. Forced air creates flying debris. Always wear personal protective equipment.
Severe personal injury could result.
2. Ensure no personnel are in the destination access vault during the blowing
operation. Severe personal injury could result.
9
4.
D. ELECTRIC DEVICES
The electronic counter box and power supply are electrical devices. Electric shock
hazards exist that could result in severe personal injury or death. Observe the
following precautions to avoid electrical hazards:
1. Do not operate in or near water. This includes setting the electronic counter box
or battery pack on a wet surface or exposing them to rain.
2. Do not remove cover of electronic counter box. There are no user-serviceable
parts inside. Refer servicing to qualified service personnel.
3. The electronic counter box power switch should be in the off position before
connecting or disconnecting any cords.
Unpacking the Blower
A. BLOWER COMPONENTS
Each Deluxe Blower Package contains the following items.
•Hydraulichosefromhydrauliccontrolassemblytohydraulicpowerunit
•Owner’sManual
•ShippingCrate
•Metric&StandardAllenWrenchSet
•
•
•VenturiAirPlug
•PlasticDividedCasew/PartsLabel
•PartsandUserManual
•1Qt.BlowingLubricant
•CapscrewSet(10)(M04-0.7’s)
•O-RingSealKit
3
⁄8" Drive Ratchet & 9⁄16" Deep Well Socket
5
⁄8" x 600 lb. Swivel
10
NOTE: If any parts are missing: please contact your Condux representative or call
Condux International at 1-800-533-2077 (USA or CANADA), or 1-507-387-6576.
B. TOOLS AND MATERIALS REQUIRED
The tools and materials are necessary to connect the Deluxe Blower to a hydraulic
power source, and to change the inserts:
1. Allen Wrench (
2. Allen Wrench (2.5 mm)
3. Allen Wrench (5 mm)
4. Screwdriver, Flat
5. Screwdriver, Phillips
6. 3⁄8" Drive Ratchet
7.
9
⁄16" Deep Well Socket
3
⁄32")
Set Up the Blower
This manual contains setup and operating instructions for the Deluxe Blower with
job box.
IMPORTANT: The Deluxe Blower must not be located below overhead gantries,
power lines or walkways where there might be a risk of falling objects. The operator
must be wearing recommended protective gear before operating the blower.
Operating light levels should be at least 200 lux of light intensity.
A. ATTACH BLOWER TO JOB BOX
CAUTION: The machine should be removed with two people or lifted
mechanically by the lift rings located on the top of the machine (Figure 4).
IMPORTANT: The Deluxe Blower should not be parked on a slope in excess of 13°.
It should not be parked on a side hill of more that 15°.
Remove the ball detent pin from the bottom of the blower. Attach the Deluxe Blower
to the job box by aligning the guide tracks on the bottom of the blower with the
channel on the top of the box. Holes in the box channel need to align with holes on
the blower guide track. Once aligned, replace ball detent pin so it locks the blower in
place (Figure 5).
5.
Lift
Rings
Figure 4. Lift out Blower with
Lift Rings
Figure 5. Replace Ball Detent Pin
11
6.
Cable Crash Test
Cable Crash Testing is a very quick and easy step to be completed before attempting
the installation of cable with the Deluxe Blower. This test is necessary to set the
hydraulic motor pressure of the blower below the point that it may cause cable
damage as a result of over pushing or encountering an obstruction in the
sub-duct system.
Every cable has different pushing values and these values vary depending on
duct I.D. Example: A cable with a crash test value of 75 bar in 33 mm I.D. duct,
may have a crash value of only 60 bar in a 40 mm I.D. duct. This is because the
area of lateral movement is larger as the duct size increases.
!CAUTION: Always wear protective equipment: hard hat, safety glasses,
safety shoes and work gloves.
NOTE: The hydraulic motor pressure adjustment will have no effect on the
installation speed of the blowing unit. This is not a flow adjustment. This is a
pressure adjustment to prevent damage to the cable that can be caused by excessive
pushing force.
IMPORTANT: For the Crash Test to work properly use the same size cable and duct
that will be used for the job.
Set the hydraulic motor pressure on your Deluxe Blower using the following
procedure.
1. Attach 12' (4 m) of duct to the Deluxe Blower (Figure 6).
2. Install Conduit Pulling Eye on the receiving end of the duct (Figure 7).
Figure 6. Placement of Conduit in
Conduit Seal & Conduit Clamp
Figure 7. Installing Conduit
Pulling Eye
12
3. Cut a piece of fiber optic cable 15' (5 m) long. This is your test piece of cable.
4. Attach the correct size Venturi to fit the cable being installed (Figure 8).
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
ELECTRICAL HOOK UP
TO POWER SOURCE
Figure 8. Install Venturi
5. Attach Hydraulic Hoses (Figure 9).
The Deluxe Blower’s hydraulic system
uses quick-disconnect couplings.
Keep all connections clean to avoid
contamination and possible system
failure. Use hose end caps (supplied).
A contaminated hydraulic system will
effect the operation of the cable
blower and may invalidate your
product warranty. Take caution in
routing the hoses to prevent a tripping
hazard. Follow these steps to
connect the hydraulic components:
INNERDUCT
DELUXE LW
BLOWER
OPERATOR
AIR HOSE
COMPRESSOR
Figure 9. Typical Set-Up
FIBER
OPTIC CABLE
AIR
CABLE
REEL
A. Attach the quick-disconnect
couplings to the hydraulic power
Figure 10. Attach Hydraulic
Hoses
supply (Figure 10).
B. Start the hydraulic power unit and check all connections for leaks with a
piece of cardboard. In cold weather, run hydraulic power supply until
hydraulic oil warms up.
WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Observe the following precautions to
avoid hydraulic hazards:
•Tightenallconnectionsbeforeapplyingpressure.Relievepressure
before connecting or disconnecting hoses.
•Checkforleakswithapieceofcardboard.Donotusehands!
•Donotexceedworkingpressureofhydraulichoses.Visually
inspect hoses regularly and replace if damaged.
C. Run the blower for approximately 1 minute to remove any trapped air and
then stop the blower and hydraulic power source.
B. ELECTRONIC CRASH TEST
To run the Crash Test utilizing the Electronic Control Boxes PRESSURE LIMIT
feature, follow Crash Test steps 1-5 to set up the blower.
13
6. Press Touch Screen “LIMIT: XXXX” to open the Limit keypad.
7. Enter the desired pressure – suggested starting point is 800 PSI.
8. Place Cable in Blower from Rear Rollers through Tractor Drive. Push cable
through the duct until it stops against the Pulling Eye (Figure 13).
9. Place a mark on the Cable about 2" (51 mm) behind the Rear Rollers
(Figure 14).
Figure 13. Install Cable
Figure 14. Mark the Cable
10. Install top Venturi (Figure 15). Close Air Block and tighten (Figure 16).
Figure 15. Install Top Venturi
Figure 16. Close Air Block
and tighten
11. From the Rear Rollers, pull out approximately 8' (2.4 m) of cable from
the blower.
14
12. To avoid start up pressure spikes, which will register on the pressure
transducer and produce a false pressure error, set the Hydraulic Flow Control
to the lowest speed by rotating the flow control knob clockwise until it stops.
13. Lower the Tractor Drive Cover, and tighten until the tracks make contact
with the cable. Give one additional turn to the clamp screw.
14. Turn on Hydraulic Power, and press the ECB DRIVE button ON.
15. Increase speed as quickly as possible by turning the Hydraulic Flow Control
counter-clockwise. The Cable should be pushed into the duct. Continue to
speed up the tracks until the cable stops and the ECB gives a
HI-PRESSURE ERROR screen.
16. If a HI-PRESSURE ERROR appears, follow the on-screen instructions to
reset the electronics and return to the Operations screen.
17. Raise Tractor Drive Cover. Pull out 8' (2.4m) of cable from the blower.
18. Lower and tighten Tractor Drive Cover. Repeat steps 6-7 to increase the
pressure by 50 PSI.
19. Repeat steps 12-16 until cable damage
is seen – either in the form of jacket
damage or bends in the cable, the
cable folds over, or you reach 1500 psi.
You will notice cable fold-over because
the line drawn on the cable will
disappear inside the machine or duct.
(Figure 17).
20. Repeat steps 6 and 7 to reduce the
PRESSURE LIMIT by 50 PSI.
21. Remove folded fiber and test again at
current PRESSURE LIMIT settings to
ensure no fiber fold over or
Figure 17. Cable folds over
damage occurs.
22. Remove test piece of fiber optic cable.
23. If the re-test is confirms no cable damage, Re-adjust Flow Control setting to
the slowest speed.
24. Remove test duct piece from the Deluxe Blower.
25. Crash test is complete.
15
16
Pressure Test Conduit
The conduit system must be able to withstand a maximum pressure of 175 psi, and
be free of leaks. A Conduit Pressure Test Kit, part number 08761457, is available to
perform this test. Conduit may also be tested for pressure using the Deluxe Blower,
follow the steps below.
1. Loosen the 6 nuts on the Air Block assembly (Figure 20). Open the Conduit
Clamp Cover and Air Block Cover (Figure 21).
Figure 20. Loosen Air
Block Assembly
2. Select the correct Conduit and Cable Components according to conduit and
cable size. Refer to the Conduit and Cable Pack selection charts
(Tables 1 and 2, page 18).
Figure 21. Open Conduit Clamp
Cover & Air Block Cover
7.
3. Choose the correct Conduit Seal and install both halves securely. (Figure 22).
4. Choose the correct Conduit Clamp and install both halves (same color as the
conduit seal). (Figure 23).
Figure 22. Install Conduit Seal
Figure 23. Install Conduit Clamp
17
PACK
1
2
3
4
CABLE PACK VENTURI CABLE SEAL CABLE GRIP
Cable OD P/N Cable OD P/N Cable OD P/N Cable OD P/N
0.23-0.34 08780393 0.23-0.34
(5.8-8.8) Pack #1 (5.8-8.8) 0.29-0.34
08780281
(5.8-7.2) 0.21-0.35 08643754
(7.3-8.8)
0.35-0.42
0.23-0.28
0.35-0.48
(8.9-12.2) 0.43-0.48
08780282
(8.9-10.7) 0.32-0.48 08643755
0.35-0.60 08780394 (10.8-12.2)
(8.9-15.2) Pack #2 0.49-0.55
0.49-0.60
(12.3-15.2) 0.56-0.60
08780283
(12.3-14.0) 0.42-0.61 08643756
(14.1-15.2)
0.61-0.67
0.61-0.73
(15.3-18.5) 0.68-0.73
08780284
(15.3-17.0) 0.53-0.74 08643757
0.61-0.85 08780395 (17.1-18.5)
(15.3-21.6) Pack #3 0.74-0.79
0.74-0.85
(18.6-21.6) 0.80-0.85
08780285
(18.6-20.1) 0.64-0.87 08643758
(20.2-21.6)
0.86-0.92
0.86-0.97
(21.7-24.6) 0.93-0.97
08780286
(21.7-23.4) 0.75-1.00 08643759
0.86-1.13 08780396 (23.5-24.6)
(21.7-28.7) Pack #4 0.98-1.04
0.98-1.13
(24.7-28.7) 1.05-1.13
08780446
(24.7-26.4) 1.00-1.24 08643137
(26.5-28.7)
08780406
08780407
08761424
08761425
08761426
08761427
08761428
08761429
08761430
08761431
08761432
08761433
08761434
08761435
(5.3-8.9) 033-29-1194
(8.1-12.2) 033-29-1195
(10.7-15.5) 033-29-1196
(13.5-18.8) 033-29-1197
(16.3-22.1) 033-29-1198
(19.1-25.4) 033-29-1199
(25.4-31.5) 033-03-013
Table 1. Cable Packs
PACK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DUCT PACK DUCT CLAMP DUCT SEAL CARRIER FOAM CARRIER CABLE GRIP INNERDUCT EYE
Duct Size P/N Duct OD P/N Duct OD P/N Carrier P/N Carrier OD P/N Duct OD P/N P/N and ID Range
1/2" 08780795 0.84
SDR 11-13.5 Pack #1 (21.30) (21.30) (17.50) (19.0) (19-25) 033-03-012
3/4" 08780680 1.050
SDR 11-13.5 Pack #2 (26.6) (26.6) (19.0) (19.0) (25.4-31.5) 033-03-013
1" 08780386 1.315
SDR 11/13.5 Pack #3 (33.4) (33.4) (28.5) (31.8) (25.4-31.5) 033-03-013
1.25" 08780392 1.660
SDR 11/13.5 Pack #4 (42.2) (42.2) (35.9) (38.1) (38.1-50.5) 033-03-016
1.5" 08780397 1.900
SDR 11/13.5 Pack #5 (48.3) (48.3) (41.1) (44.5) (38.1-50.5) 033-03-016
2" 08780930 2.023
SDR 11/13.5 Pack #6 (51.4) (50.8) (50.8-63.2)
25 mm
32 mm
36 mm
37 mm
1.25" TRUE
40 mm
42 mm
44 mm
46 mm
50 mm
08780240 0.984
08780385 1.260
08780387 1.417
08780388 1.457
08780389 1.500
08780390 1.575
Pack #12 (40.0) (40.0) (33.0) (38.1) (38.1-50.5) 033-03-016
08780391 1.653
Pack #13 (42.0) (42.0) (35.0) (38.1) (38.1-50.5) 033-03-016
08780545 1.732
Pack #14 (44.0) (44.0) (38.0) (38.1) (38.1-50.5) 033-03-016
08780460 1.811
Pack #15 (46.0) (46.0) (33.0) (38.1) (38.1-50.5) 033-03-016
08780575 1.969
Pack #16 (50.0) (50.0) (40.0) (50.8) (38.1-50.5) 033-03-016
_______ _______ _______ _______
Pack #7 (25.0) (25.0) (20.0) (31.8) (25.4-31.5) 033-03-013
Pack #8 (32.0) (32.0) (27.0) (31.8) (31.8-37.8) 033-03-015
Pack #9 (36.0) (36.0) 1.220 (31.0) 08761555 (31.8) (31.8-37.8) 033-03-015
Pack #10 (37.0) (37.0) (31.0) (31.8) (31.8-37.8) 033-03-015
Pack #11 (38.1) (38.1) (31.7) (38.1) (31.8-37.8) 033-03-015
08780791
08780682
08780369
08780375
08780404
08780099
08780368
08780370
08780371
08780372
08780373
08780374
08780546
08780466
08780435
0.84
1.050
1.315
1.660
1.900
0.984
1.260
1.417
1.457
1.500
1.575
1.653
1.732
1.811
1.969
08780786
08780685
08780307
08780051
08780398
08780134
08780306
08780308
08780309
08780333
08780334
08780335
08780547
08780461
08780431
0.688
0.75
1.121
1.414
1.618
0.787
1.063
1.181 (30.0) 08761643 1.25
1.220
1.250
1.299
1.378
1.496
1.299
1.606
08780793
08780690
08761250
08761255
08761260
08761265
08780230
08761560
08761555
08761670
08761579
08761660
08761786
08761579
08761579
0.75
0.75
1.25
1.50
1.75
2.00
1.25
1.25
1.25
1.50
1.50
1.50
1.50
1.50
2.00
08078300
08078300
08761439
08761440
08761441
08761442
08761439
08761439
08761439
08761439
08761440
08761440
08761440
08761440
08761440
08761442
.75-.99 08643131
1.00-1.24 08643137
1.00-1.24 08643137
1.50-1.99 08643149
1.50-1.99 08643149
2.00-2.49 08643155
1.00-1.24 08643137
1.25-1.49 08643143
1.25-1.49 08643143
1.25-1.49 08643143
1.25-1.49 08643143
1.50-1.99 08643149
1.50-1.99 08643149
1.50-1.99 08643149
1.50-1.99 08643149
1.50-1.99 08643149
033-03-017
08761840
.78-.87
(20-22)
08761840
.71-.89
(18-22)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761844
1.37-1.68
(35-43)
08761844
1.37-1.68
(35-43)
08761840
.71-.89
(18-22)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761842
1.06-1.43
(27-37)
08761844
1.37-1.68
(35-43)
18
Table 2. Conduit Packs
5. Choose the correct Venturi to fit the cable being installed. Do not install at
this time!
6. Place conduit in the Conduit Seal and Conduit Clamp. Note placement up to
ridge on Conduit Seal (Figure 24).
7. Clamp conduit in place (Figure 25).
Figure 24. Placement of Conduit
in Conduit Seal & Conduit Clamp
Figure 25. Clamp Conduit
in Place
8. Place Seal Disk in Venturi slot. (Figure 26).
9. Close Air Block Cover and secure (Figure 27). Tighten nuts securely, but do
not over tighten. Use a cross-tightening procedure.
Figure 26. Installing Seal Disk
Figure 27. Tighten Air Block
Cover
19
10. Plug receiving end of Conduit with a properly sized Conduit Pulling Eye
(Figure 28) (Appendix R pg. 62).
11. Choose the correct Pulling Grip & install on receiving end of Conduit
(Figure 29).
Figure 28. Installing Conduit
Figure 29. Installing Pulling Grip
Pulling Eye
12. Connect the Air Compressor (Figure 30).
a. Ensure Air Valve is off before connecting air hose.
b. Attach the hose supplied with the air compressor to the air compressor
coupling. The blower air valve assembly is equipped with a claw type
connector. Use safety clips on all pneumatic hose connections (Figure 31).
c. Observe all safety procedures.
d. Route all hoses properly to prevent tripping over them.
!WARNING: Forced air creates flying debris. Always wear personal
protective equipment. Severe personal injury could result.
!WARNING: Ensure no personnel are in the destination access vault
during the blowing operation. Severe personal injury could result.
HYDRAULIC
POWER
SOURCE
HYDRAULIC
HOSES
ELECTRICAL HOOK UP
TO POWER SOURCE
20
INNERDUCT
DELUXE LW
BLOWER
OPERATOR
AIR HOSE
OPTIC CABLE
AIR
COMPRESSOR
FIBER
Figure 30. Typical Connections
CABLE
REEL
Figure 31. Installing Air Hose with
Safety Clips
13. Slowly open Air Control Valve. Pressurize conduit to 80-100 psi (5.5-6.9 bar)
(Figure 32).
Figure 32. Open Air Control Valve
Figure 33. Close Air Control Valve
14. Prove conduit integrity.
a. Close Air Control Valve (Figure 33).
b. Conduit must not lose more than 20 psi (1.38 bar) over a 2-minute period.
c. After 2 minutes, relieve air pressure. Open air pressure relief valve by
moving the blower pressure valve handle counter clockwise to the 9 o’clock
position (Figure 34).
d. If conduit fails to hold required pressure, check entire conduit run for leaks
and repair them.
e. Repeat the pressure test until all leaks are found and repaired.
!WARNING: Air Block Assembly contains compressed air when blower is
operated. Opening Air Block while under pressure may cause serious
personal injury. Ensure blower is depressurized before removing Air
Block cover, or removing conduit pulling eye.
15. Decompress the Air Block by
turning the Air Valve to the 9 o’clock
position. Shut off the air at the
compressor, decompress the air
hose and disconnect the air hose
from the fiber blower.
Figure 34. Decompress Air Block
21
Prepare Conduit for Cable
1. Remove Conduit Pulling Eye and Pulling Grip from receiving end of Conduit.
After removing pulling eye, re-install pulling grip in order to catch Foam Carrier
during conduit lubrication (Figure 35).
8.
2. Open the Air Block Cover (Figure 36).
Figure 35. Install Pulling Grip on
Conduit
3. Tilt Blower forward (Figure 37).
4. Pour recommended (silicon-based) lubricant into Conduit opening before
Foam Carrier: 1 quart/6000 feet (1 liter/2 km) (Figure 38)
(See Appendix T for lubricant ordering information).
Figure 36. Open Air Block Cover
22
Figure 37. Loosen Handle to Tilt
Blower
5. Insert Foam Carrier (selected according to conduit size) into Conduit
(Figure 39) (See Table 2 on page 18).
6. Insert Seal Disk in venturi slot if not already in place. (Figure 40).
Figure 38. Pour Lube into Conduit
Figure 39. Insert Foam Carrier
Figure 40. Insert Seal Disk
7. Close the Air Block Cover. Tighten spanner nuts securely, but do not over
tighten (Figure 41). Use cross tightening procedure with the spanner wrench to
secure completely.
Figure 41. Tighten Air Block
Figure 42. Close Air Control Valve
Cover
8. Prove conduit integrity and spread lubricant through Conduit.
a. Re-connect the air hose to the fiber blower and attach all safety clips.
b. Turn the Air Control Valve handle to the 12 o’clock position and turn on the
air from the compressor (Figure 42).
c. Slowly open Air Control Valve by turning to the 3 o’clock position.
d. Blow Foam Carrier through conduit to spread lubricant and check for
blockage. Follow all safety precautions.
e. After the Foam Carrier exits, close Air Control Valve.
NOTE: Foam Carrier must exit in a reasonable time, allow for approximately
10 seconds per 1,000 feet (300 m) or conduit may be contaminated or blocked.
23
9. Ensure Air Block is depressurized. Open air pressure relief valve by moving
the blower pressure valve handle counter clockwise to the 9 o’clock position
(Figure 43). Shut off the air from the compressor, decompress the air in the
hose and disconnect the hose from the blower.
10. Remove Seal Disk and install Venturi (Figure 44).
Figure 43. Decompress Air Block
NOTE: The venturi with the groove
goes into the bottom and gets
screwed into place while the top half
has the protrusions and sets into the
groove (Figure 45).
Figure 44. Install Venturi
Figure 45. Install Venturi Bottom
and Attach with Screw
24
Prepare Cable
The Deluxe Blower is designed so cable may be installed from the side. Follow these
steps so cable is properly positioned to begin operation.
1. Choose the correct Cable Grip and install on fiber optic cable (Figure 46)
(See Tables 1 & 2, on page 18).
2. Install 5/8" (16 mm) Swivel on Cable Grip. Grip must be firmly secured to
cable (Figure 47). The eye on the grip can be compressed to fit smaller
diameter conduits. The eye of a new grip can be taped with electrical tape in
order to make it narrower and travel more easily through the conduit.
9.
Figure 46. Install Cable Grip on
Fiber Optic Cable
3. Choose the correct Carrier and install on Swivel (Figure 48).
4. Raise upper Tractor Drive Cover with turn crank (Figure 49). Open the rear
cable guide roller by pulling out spring plunger and rotating the roller out
(Figure 50).
Figure 47. Install Swivel on
Cable Grip
Figure 48. Install Carrier
5. Tilt Blower forward (Figure 51).
Figure 49. Raise Tractor Drive
with Turn Crank
25
Figure 50. Open Rollers
Figure 51. Tilt Blower
6. Add lubricant to Conduit before Carrier: 1/2 quart/6000 feet (.5 liter/2 km)
(Figure 52).
7. Feed Cable Assembly through the counter rollers by lifting the Counter Roller
Bracket. Lock the Rear Cable Guide Roller into place, and feed the cable
through the Tractor Feed. (Figure 53).
26
Figure 52. Add Lubricant before
Cable Assembly
8. Push Cable Assembly, including entire
Cable Grip, into Conduit.
9. Add lubricant to Conduit behind Cable
Assembly: 1/2 quart/3000 feet
(.5 liter/1 km) (Figure 54).
Figure 53. Feed Cable Assembly
Through Blower
Figure 54. Add Lubricant Behind
Cable Assembly
10. Choose the correct Cable Seals and install on cable. Grooved side of Cable
Seal faces conduit. Place Cable Seals into Venturi, split side down
(Figure 55).
11. Close Air Block Cover (Figure 56). Tighten nuts securely, but do not over
tighten. Use cross tightening procedure to completely secure.
Figure 55. Install Cable Seals
Figure 56. Close Air Block Cover
Final Set-Up
1. Lower Tractor Drive Cover with turn crank until the cover reaches the stopper-
bushing. The stopper-bushing will prevent the tractor cover from being clamped
too tightly on the cable (Figure 57).
2. Level the height of Air Block’s Venturi Tube with Tractor Drive and the
approximate center line of the cable (Figure 58). Tighten slide cap screws after
adjustments are made.
11.
10.
Figure 57. Lower Tractor Drive
Cover With Turn Crank
3. Notify crew that preparations are complete and cable blowing is to begin.
Figure 58. Level Air Block With
Tractor Drive
27
IMPORTANT: It is recommended that if a reel-tensioning unit is not being used,
the cable reel should then be kept under control by a second operator who is
required to wear proper safety equipment and maintain a proper distance from
the cable.
A. FINAL INSPECTION
!CAUTION: Before placing the blower into operation, always perform a
final inspection of all components used.
1. Check that the Cable Grip is attached to conduit on receiving end.
2. Notify crew that preparations are complete and cable blowing is to begin.
Blower Operating Instructions
A. OBSERVER AT EXIT PIT
Station an observer with a 2-way communication device, at the far end of the Conduit,
where the Cable carrier will exit.
11.
B. CONNECT THE HYDRAULIC SYSTEMS (Figure 59)
The Deluxe Blower’s hydraulic system uses quick-disconnect couplings. Keep all
connections clean to avoid contamination and possible system failure. Use hose end
caps (supplied). A contaminated hydraulic system will effect the operation of the
cable blower and may invalidate your product warranty. Take caution in routing the
hoses to prevent a tripping hazard. Follow these steps to connect the hydraulic
components:
1. Attach the quick-disconnect couplings to the hydraulic power supply (Figure 60).
HYDRAULIC
POWER
INNERDUCT
DELUXE LW
BLOWER
SOURCE
OPERATOR
AIR HOSE
HYDRAULIC
HOSES
ELECTRICAL HOOK UP
TO POWER SOURCE
OPTIC CABLE
AIR
COMPRESSOR
FIBER
CABLE
REEL
28
Figure 59. Typical Set-Up
Figure 60. Attach Hydraulic
Hoses
2. Start the hydraulic power unit and check all connections for leaks with a piece
of cardboard. In cold weather, run hydraulic power supply until hydraulic oil
warms up.
WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Observe the following precautions to
avoid hydraulic hazards:
•Tightenallconnectionsbeforeapplyingpressure.Relievepressure
before connecting or disconnecting hoses.
•Checkforleakswithapieceofcardboard.Donotusehands!
•Donotexceedworkingpressureofhydraulichoses.Visuallyinspect
hoses regularly and replace if damaged.
3. Run the blower for approximately 1 minute to remove any trapped air and then
stop the blower and hydraulic power source.
C. SET UP THE ELECTRONIC CONTROL BOX
1. Install Electronic Control Box on blower and secure with 1/4 turn fasteners
(Figure 61).
2. Attach Power Cord and plug into 12 volt power supply (Figure 62). Take
caution in routing the electrical cord to prevent a tripping hazard.
Figure 61. Install Electronic
Control Box
3. Attach solenoid valve, front tractor sensor,
rear counter sensor, and transducer plugs
(Figure 63).
4. Turn on control box power (Figure 64).
Select the Traction Control required.
Press the Traction Control button ON to
activate. This stops the blower's tractor
drive if the slippage or speed parameters
are exceeded. Press OFF to disable this
function.
Figure 62. Attach Power Cord
Figure 63. Attach Sensor Plugs
29
D. PANEL LAYOUT
The Deluxe Blower Electronic Control Box
uses a touch screen controller with four
function buttons.
Figure 64. Turn on Control
Box Power
30
Figure 65. Control Panel
DRIVE:
OFF/F1: Disengages Hydraulics from the Blower. The OFF touch screen button
will be highlighted when the unit is stopped. The operator can use either the
touch screen button of the Function button.
ON/F2: Engages Hydraulics to the Blower. The ON touch screen button will be
highlighted when the unit is running. The operator can use either the touch
screen button of the Function button.
CAUTION! Make sure the Hydraulic Flow Control Knob is turned all the way in
before switching electronics to ON. Failure to do so could damage the cable.
TRACTION CONTROL (TRAC CTRL):
OFF/F3: Turns Traction Control feature OFF. The OFF touch screen button will be
highlighted when the Traction Control feature is turned OFF. The operator can
use either the touch screen button of the Function button.
ON/F4: Turns Traction Control feature ON. The ON touch screen button will be
highlighted when the Traction Control feature is turned ON. The operator can
use either the touch screen button of the Function button.
SCALE: Touching the touch screen on any of the Units (FPM/MPM, FT/M,
PSI/BAR) will open a UNITS screen. Select from Metric or Imperial units, and
press ENTER.
SPEED: Displays cable speed in Feet/Min or Meters/Min
DIST: Displays distance of current installation in Feet or Meters – Resettable
RESET: Touch Screen button that will reset DIST to 0
TOTAL: Displays lifetime distance on the machine in Feet or Meters –
Non Resettable.
PRSSR: Displays hydraulic working pressure in PSI or BAR. This pressure should
match the pressure shown on the analog pressure gauge.
LIMIT: Displays the pressure limit set point in PSI or BAR. When the PRSSR value
exceeds this set limit, the tractor drive will be stopped. This feature is NOT
dependent on having the TRACTION CONTROL system turned ON. To change
the LIMIT value, touch the screen in the LIMIT: XXXX area, and a keypad will
appear. Enter the desired limit value and press ENTER to save the new value.
Press ESC to exit screen without saving the new value.
When the pressure LIMIT is exceeded, the display will show:
HI-PRESSURE ERROR – follow on-screen instructions and press RESET at
bottom of screen to return to operation (Figure 66).
EMERGENCY STOP BUTTON: Press the Emergency Stop button at any time to
immediately stop the tractor drive. When the Emergency Stop button is pressed,
the display will show:
!!EMERGENCY STOP!! – follow on-screen instructions and press RESET at
bottom of screen to return to operation. The EMERGENCY STOP screen will not
clear until the Emergency Stop button is pulled up (Figure 66A).
Figure 66A. Emergency StopFigure 66. Hi-Pressure Error
31
E. TRACTION CONTROL
Once activated, the traction control will stop the blower’s tractor drive if track speed
goes above the maximum speed setting of 300 ft/min. (91 m/min.), or if the
slippage allowance is exceeded. Slippage is measured by comparing the speed of
the tracks with the speed of the cable being installed.
If slippage or speed parameters are exceeded, the display will show one of the
following screeens:
SLIP ERROR – follow on-screen instructions and press RESET at bottom of screen
to return to operation (Figure 66B).
HI-SPEED ERROR – follow on-screen instructions and press RESET at bottom of
screen to return to operation (Figure 66C).
Figure 66C. Hi-Speed ErrorFigure 66B. Slip Error
DRIVE will be in OFF position after RESET. Press ON/F2 to resume cable
installation.
F. O PERATION
1. Re-connect hose from air compressor and attach all safety clips. Start the Air
Compressor and Hydraulic Power Supply. Refer to respective manufacturers
operating instructions for these units.
2. Make sure Electronics DRIVE is switched to ON. ON will be highlighted.
Introduce a small amount of air to the system in order to straighten out the
cablecarrierinsidetheconduit.Tur n thehydraulicstothe“on”position
(Figure 67). Slowly rotate the flow control knob, counterclockwise to engage
tractor drive and increase speed (Figure 68). Push cable 50 to 100 feet
(15 to 30 m) into Conduit.
3. Slowly open the Air Control Valve to allow air flow to the Air Block by turning
flow control handle clockwise to the 3 o’clock position so it is in line with the air
compressor hose (Figure 69).
4. Maintain control of cable reel to ensure smooth, stable flow. Failure to do so
may cause cable to unwind too quickly. Continue to control cable speed with
the flow control knob.
32
Figure 67. Turn on Hydraulics
Figure 68. Rotate Hydraulic Flow
Control Knob
Figure 69. Turn On Air
Figure 70. Turn Off Air at the
Air Block
!WARNING: Never wrap line around your hand, arm, foot, or leg. Severe
personal injury or death could result from entanglement.
!CAUTION: Always wear protective equipment: hard hat, safety glasses,
safety shoes and work gloves.
5. Turn Tractor Drive off immediately when the observer indicates the Cable
Carrier has exited the Conduit (air pressure will decrease sharply).
•TheTractor Drive will continue to travel unless the track speed exceeds the
slippage allowance, or the maximum speed of 300 ft/min. (91 m/min.) is
exceeded for more than 2 seconds. The OFF/F1 button will also stop the
tractor drive.
•PressstarttoallowTractor Drive to resume.
NOTE: If the TRACTION CONTROL (TRAC CTRL) is set to OFF, the Tractor
Drive will continue to operate regardless of the slippage and speed parameters.
6. Turn off compressed air flow to the Air Block (Figure 70).
33
!WARNING: Air Block Assembly contains compressed air when blower
is operated. Opening Air Block while under pressure may cause serious
personal injury. Ensure blower is depressurized before removing Air
Block cover.
7. Remove Cable Grip from receiving end of Conduit.
8. If electronics stop blower before Cable Carrier exits, restart blower, making sure
speed is within minimum and maximum allowance. Also see Troubleshooting
Guide.
Tear Down Procedures
!WARNING: Air Block Assembly contains compressed air when blower is
operated. Opening Air Block while under pressure may cause serious personal
injury. Ensure blower is depressurized before removing Air Block cover.
12.
A. REMOVE POWER FROM UNIT.
1. Turn off compressed air by closing the Air Control Valve at the blower
(Figure 71). Shut off air at the compressor and decompress air hose.
Depressurize the air block by turning the air control valve to the 9 o’clock
position (Figure 72). Remove air hose when system is relieved of pressure.
Figure 71. Turn Off Air at the
Air Block
Figure 72. Decompress Air Block
34
2. Raise Tractor Drive Cover with turn crank (Figure 73).
3. Turn off Hydraulic Power Supply and disconnect hydraulic hoses (Figure 74).
Keep all connections free of dirt and particles. Use hose end caps (supplied).
4. Disconnect electronic cords.
!WARNING: Escaping fluids under pressure can penetrate the skin and
cause serious personal injury. Release pressure before disconnecting
hoses.
Figure 73. Raise Tractor Drive
Cover
Figure 74. Turn Off Hydraulic
Power
B. REMOVE CABLE FROM BLOWER.
1. Open Air Block Cover and remove Cable Seals (Figure 75).
2. Pull the Guide Roller Knob and move Rear Guide Roller into open position.
Lift Counter Roller Knobs so rollers are clear of cable (Figure 76). Pull cable
out from side of unit.
Figure 75. Remove Cable Seals
Figure 76. Open Rollers To
Remove Cable
C. SEPARATE UNIT FROM CONDUIT.
1. Open Conduit Clamp.
2. Pull unit away from Conduit.
3. If repositioning the machine, the Deluxe Blower should not be parked on a slope
in excess of 13°. It should not be parked on a side hill of more that 15°.
35
13.
Maintenance
Figure 77. Maintenance Schedule
CAUTION: Operators are not permitted to perform maintenance tasks
unless Condux personnel or representatives have appropriately trained
them. Disconnect the machine from its electrical, pneumatic, and
hydraulic power sources before servicing.
A. TRACK CLEANING AND TIGHTENING
1. Inspect track before and after each use.
2. Clean after each use, or when necessary. Remove the top assembly to clean
thoroughly by:
•Removetopcapscrewwitha3mmallenwrenchandtheflatwasheron
clamp adjustment screw. This will allow for the top track assembly to be
unscrewed off the blower with the clamp adjustment (Reference Appendix K).
•Pressurewashifnecessary
3. To compensate for normal belt stretching, there is a rubber dampening bushing
part number 08780028, which is lobed larger on one side than the other,
located at the pivot position of the idler skid part number 08780105. It is in the
smaller lobe position when it leaves the factory. If a tighter belt is needed,
rotate the bushing so the skid presses against the larger lobe. Be sure to have
both bushings in the same configuration before locking the skid back into
position. If this is not enough, then new tracks must be purchased (Reference
Appendix B & C).
B. REPLACEMENT OF THE DRIVE BELT
The drive belt needs to be replaced when the machine is unable to tractor drive the
specified range of cable diameters. Only genuine spares should be used otherwise
the machine may be unsafe and void warranty (Reference Appendix B & C).
36
1. Remove the 2 capscrews which hold the sled in place with a 3 mm T-handled
allen wrench. This should allow the sled to rotate up.
2. Remove the pivot shaft with an 8 mm allen wrench.
3. On the bottom drive, remove the 3 capscrews from the prox cover with a 2 mm
allen wrench.
4. The bearing cap can be removed from both the top and bottom assembly using
a 5 mm allen wrench.
5. At this point, the drive pulley can be removed straight out the same hole as the
bearing cap and the belt can be removed. This sequence is reversed for the
reassembly of the new belt with a key note, the dampening bushing must be
rotated back to the smaller lobe position on the pivot shaft.
NOTE: Become familiar with the Replacement and Wear Parts associated with
the LW Blower, they are listed in Appendix T pg. 59.
Figure 78. Torque Specifications for Steel into Steel
Figure 79. Torque Specifications for Steel Capscrew into Aluminum
37
Troubleshooting Guide
Problem Solution
14.
Cable becomes jammed in the conduit
system.
Tractor Feed does not pull the cable off
the reel.
Blower cuts out with electronic error or
highspeed error.
1. Inform the people at the other end of
the conduit that a problem has been
experienced and the operator is going to
shut down the system.
2. Shut off the hydraulic valve at the blower.
3. Shut off the pneumatic air supply with the
Air Control Valve turning it to the 9 o’clock
position, allowing the air pressure to be
depressurized from the conduit and the air
block.
3. Using the counter or the measurement on
the cable, determine where the
blockage might be located.
5. Notify supervisor about problem and
determine a solution accordingly.
Assist the reel by pushing it, and/or by pulling
the cable off the reel.
Blower has exceeded the maximum speed
allowance. Adjust speed accordingly, or wipe
cable clean from mud and dirt.
It is difficult to keep the cable moving
near the end of the conduit run.
The cable run is hard to restart after
having stopped.
Tractor feed doesn’t start.
Assist the blower by manually pushing the
cable into the conduit.
Do not bend or crimp the cable.
Put air to the system with the track down. The
tractor feed can be restarted after the air
pressure has increased and stabilized.
1. Hydraulic flow control is at the lowest
speed-increase flow speed slowly.
2.Hydraulic“on”/”off”isinthe“off”
position-rotatehandletothe“on”
position.
3.Electronicsisinthe“stop”position-pushthe
“start”button.
4.“E-stop”isstillintheactivemode-rotate
clockwise to allow the button to reset.
5.Hydraulicpowerpackisinthe“off”
position-turnittothe“on”position.
38
6. Check that the hydraulic hoses are
connected correctly.
Blower with Job Box
A.
APPENDIX
Blower with Job Box
ITEM PART NO DESCRIPTION QTY
1 02288701 Pin, Hitch Cotterless 3/8 x 4.50 1
2 08780195 Cart, Job Box LW FO Blower-Assy 1
3 08782000 Blower, LW Fiber Optic-Deluxe 1
ITEMS 1, 2 ARE NOT INCLUDED WITH 08782000
Parts List, Blower with Job Box
39
B.
APPENDIX
Upper Drive Shaft Kit
Upper Drive Shaft Repair Kit
08780625
REQUIRED
ITEM PART NO DESCRIPTION
1 02288583 Capsrw M06-1.0 X 10 BHSS 18-8 2 2
2 02288656 Ring, Retaining 28MM Ext (3100) 1 1
3 08780010 Cap, Bearing Assy-Upper Drvshft 1 1
4 08780011 Shaft, Upper Drive-Upr Drv Assy 1 1
5 08780642 Bushing, Dampening (Kit includes 2) 1 NA
6 08780029 Shaft, Pivot-Idler Assy 1 NA
7 08780105 Bracket, Idler Roller Mnt Assy 1 NA
8 08780181 Key, Drive Shaft 7mm-8mm-19.5mm 1 1
9 08780664 Pulley, Timing Drv-Assy 1 1
10 08780904 Belt, Cable 50mm x 260mm Center 1 NA
08780625 KIT INCLUDES ITEMS: 1, 2, 3, 4, 8 & 9
Parts List, Upper Drive Shaft Repair Kit
08780625
40
QTY
KIT
QTY
Lower Drive Shaft Kit
C.
APPENDIX
Lower Drive Shaft Replacement Kit
08780626
REQUIRED
ITEM PART NO DESCRIPTION
1 02288583 Capsrw M06-1.0 X 10 GHSS 18-8 2 2
2 02288656 Ring, Retaining 28MM Ext (3100) 1 1
3 08780642 Bushing, Dampening-(Kit includes 2) 1 NA
4 08780029 Shaft, Pivot-Idler Assy 1 NA
5 08780105 Bracket, Idler Roller Mnt Assy 1 NA
6 08780181 Key, Drive Shaft 7mm-8mm-19.5mm 1 1
7 08780277 Shaft, Lower Drive-Lwr Drv Assy 1 1
8 08780278 Cap, Bearing Assy-Lower Drvshft 1 1
9 08780664 Pulley, Timing Drv-Assy 1 1
10 08780904 Belt, Cable 50mm x 260mm Center 1 NA
08780626 KIT INCLUDES ITEMS: 1, 2, 6, 7, 8 & 9
Parts List, Lower Drive Shaft Replacement Kit
08780626
QTY
KIT
QTY
41
D.
APPENDIX
Hydraulic Motor Kit
Hydraulic Motor Replacement Kit
ITEM PART NO DESCRIPTION
1 02269664 CAPSRW 0.25-20X0.62 CSSTALY PL 3 3
2 02269694 FTG,HYD 06 O-RING;06-JIC 2 2
3 08780940 MOTOR,HYD 5/8 SHAFT-PAINTED 1 1
Parts List, Hydraulic Motor Replacement Kit
42
08780636
08780636
REQUIRED
QTY
KIT
QTY
Idler Bracket Bushing & Screw Kits
E.
APPENDIX
Idler Bracket Bushing Replacement Kit
08780642
Idler Bracket Screw Replacement Kit
08780643
REQUIRED
ITEM PART NO DESCRIPTION
1 08780028 Bushing, Dampening-Polyurethane 2 2
Parts List, Idler Bracket Bushing Replacement Kit
08780642
ITEM PART NO DESCRIPTION
1 02290189 Screw, Shoulder M05 Dia-8mm Lg 2 2
Parts List, Idler Bracket Screw Replacement Kit
08780643
QTY
REQUIRED
QTY
KIT
QTY
KIT
QTY
43
F.
APPENDIX
Air Block Assembly Kits
Airblock Bracket Replacement Kit
08780629
Airblock Clamp Assembly
Replacement Kit
08780942
44
Airblock Assembly Replacement Kit
08780935
REQUIRED
ITEM PART NO DESCRIPTION
1 02129701 Coupling, Universal 3/4 Male 1 NA
2 02288573 Capsrw M05-0.8 X 16 CSSS 18-8 8 8
3 02288605 Screw, Shoulder M10 Dia-16mm Lg 2 2
4 02288606 Flatwasher M10-Narr St Cz 2 2
5 02288671 Muffler, Pneumatic Exhaust 12MP 1 NA
6 08780159 Mount, Airblock (W/Insert) LW FO Blwr 1 1
7 08780258 Pad, Guide-LW Airblock Mount 2 2
8 08780935 AIRBLOCK, LW BLOWER ASSEM - NEW 1 NA
9 08780942 BLOCK, CLAMP(ASSY) SWINGBOLT 1 NA
08780629 KIT INCLUDES ITEMS: 2, 3, 4, 6 & 7
QTY
Parts List, Airblock Bracket Replacement Kit - 08780629
KIT
QTY
REQUIRED
ITEM PART NO DESCRIPTION
1 02288416 1/4-20 THIN NYLOC NUT (CLEAR ZINC) 2 1
2 02289401 5/16 DIA X 5/8 SHOULDER SCREW (1/4-20 THRDS) 2 1
3 02290167 5/16-18 SWIVEL FLANGE HEX NUT 2 1
4 NA LOCATOR PIN NA NA
5 NA LOCATOR BUSHING NA NA
6 NA LOWER SWING BOLT CLAMP BODY NA NA
7 NA UPPER SWING BOLT CLAMP BODY NA NA
8 08782314 SWING BOLT-MACHINED 4 1
08782321 CLAMP BODY (INCLUDES 4, 5, 6 & 7) 1 NA
08782322 SWING BOLT KIT(INCLUDES 1ea 1, 2, 3 & 8) 2 NA
QTY
Parts List, Airblock Clamp Assembly Replacement Kit - 08780942
REQUIRED
ITEM PART NO DESCRIPTION
1 08780126 QUAD-RING, 3.5MM-KIT 1 NA
2 02288416 NUT 0.25-20 NYLOC STGR2 THN CZ 4 1
3 02288571 CAPSRW M04-0.7X 12 BHSS 18-8 2 NA
4 02288582 GAUGE, PRESS 0- 200 1.50 BCK MT 1 NA
5 02289401 SCREW, SHOULDER 0.312 DIA-0.625 4 1
6 02290167 NUT 0.31-18 HEX SWIVEL FLANGE 4 1
7 08780937 AIRBLOCK, UPPER MACH - LW 1 NA
8 08780938 GUARD, GAUGE-MACH- LW FOB 1 NA
9 08780941 AIRBLOCK, LOWER MACH-SWINGBOLT 1 NA
10 08782314 BOLT, SWING-MODIFIED-DLX BLOWER 4 1
08782322 SWING BOLT KIT (INCLUDES 1ea - 2, 5, 6 &10) 4 NA
QTY
KIT
QTY
KIT
QTY
Parts List, Airblock Assembly Replacement Kit - 08780935
45
Counter Clamp Roller & Cable Guide Kits
G.
APPENDIX
Counter Clamp Roller Replacement Kit
08780630
REQUIRED
ITEM PART NO DESCRIPTION
1 08780091 Roller, Cable Clamp-Assy 1 1
2 08780094 Shaft, Cable Clamp Roller 1 1
3 08780095 Spacer, 10mm-14mm-21.5mm Nylon 1 1
4 08780096 Spacer, 10mm-14mm-1.5mm Nylon 1 1
Parts List, Counter Clamp Roller Replacement Kit
08780630
QTY
KIT
QTY
Counter Cable Guide Replacement Kit
ITEM PART NO DESCRIPTION
1 02288649 Capsrw M03-0.5 X 12 SHAA 18-8 2 2
2 08780266 Guide, Cable-Upper Entrance 1 1
Parts List, Counter Cable Guide Replacement Kit
46
08780631
08780631
REQUIRED
QTY
KIT
QTY
Timing & Takeup Roller & Idler Roller Kits
H.
APPENDIX
Timing & Takeup Roller
Replacement Kit
08780632
REQUIRED
ITEM PART NO DESCRIPTION
1 02288573 Capsrw M05-0.8 X 16 CSSS 18-8 4 1
2 08780006 Shaft, Idler Pulley-BT Blower 4 1
3 08780037 Retainer, Idler Plly-12mm Shaft 4 1
4 08780663 Pulley,Timing Idler-Assy 1 1
Parts List, Timing & Takeup Roller Replacement Kit
08780632
QTY
KIT
QTY
Idler Roller Replacement Kit
08780633
REQUIRED
ITEM PART NO DESCRIPTION
1 02288573 Capsrw M05-0.8 X 16 CSSS 18-8 3 1
2 08780007 Shaft, Idler Roller-LW Blower 3 1
3 08780031 Retainer, Idler Roll-10mm Shaft 3 1
4 08780250 Pulley, Idler Assy-54mm 3 1
Parts List, Idler Roller Replacement Kit
08780633
QTY
KIT
QTY
47
I.
APPENDIX
Hydraulic Coupler (Male) Kit
ITEM PART NO DESCRIPTION
1 02260200 Cap, Dust (Male Flat Face Cplrs) 1 1
2 02286710 Hose 06 x 22.0-06sw 1
3 02288620 Coupler, Male-Flat Face Metric 1 1
4 02288643 Hose 06 x 21.0-06sw 1
5 02288643 Hose 06 x 21.0-06sw 1 1
6 02288703 Ftg, Hyd 18mm-Thread Bond Seal 1
ITEMS 2, 4, 5 ARE NOT INCLUDED IN KIT 08780634
Parts List, Hydraulic Coupler (Male) Replacement Kit
Hydraulic Coupler (Male)
Replacement Kit
08780634
08780634
REQUIRED
QTY
KIT
QTY
48
Hydraulic Coupler (Female) Kit
J.
APPENDIX
Hydraulic Coupler (Female)
Replacement Kit
08780635
REQUIRED
ITEM PART NO DESCRIPTION
1 02260201 Cap, Dust (Fem Flat Face Cplrs) 1 1
2 02286710 Hose 06 x 22.0-06sw 1
3 02288619 Coupler, Female-Flt Face Metric 1 1
4 02288643 Hose 06 x 21.0-06sw 1
5 02288643 Hose 06 x 21.0-06sw 1
6 02288703 Ftg, Hyd 18mm-Thread Bond Seal 1 1
ITEMS 2, 4, 5 ARE NOT INCLUDED IN KIT 08780634
Parts List, Hydraulic Coupler (Female) Replacement Kit
08780635
QTY
KIT
QTY
49
K.
APPENDIX
Clamp Adjustment Kit
Clamp Adjustment Replacement Kit
ITEM PART NO DESCRIPTION
1 02240800 Capsrw, #10-24 x 0.50 BHSS 18-8 1 1
2 02288610 Cylinder, Lift-Pnuematic Chrgd 1
3 02288644 Lever, Ball Knob 10mm 08mm Thr 2 2
4 02288646 Zerk, Grease, 6mm-1.0 Straight 1 1
5 02289031 Bearing , Thr 1.265-2.0-0.062 1 1
6 02290172 Washer, Fender #10-1.00-.113 1 1
7 08780081 Shaft, Tension Adjustment 1 1
8 08780106 Body, Handle-Clamp Cylinder 1 1
9 08780661 Bushing, Clamp Stopper 1 1
ITEM 2 IS NOT INCLUDED IN KIT 08780637
Parts List, Clamp Adjustment Replacement Kit
50
08780637
08780637
REQUIRED
QTY
KIT
QTY
Lower Counter Roller Kit
L.
APPENDIX
Lower Counter Roller Replacement Kit
08780638
REQUIRED
ITEM PART NO DESCRIPTION
1 02288574 Capsrw, M05-0.8 x 12 BHSS 18-8 4 4
2 08780022 Shaft, Counter (Assy) LW FO Blwr 1 1
3 08780257 Housing, Brg Assy - (Front) 1 1
4 08780260 Housing, Brg Assy - Cntr Rllr 1 1
Parts List, Lower Counter Roller Replacement Kit
08780638
QTY
KIT
QTY
51
M.
APPENDIX
RH Cable Guide Roller Kit &
Adjustable Rear Cable Guide Kit
REQUIRED
ITEM PART NO DESCRIPTION
1 02186901 Nut, #10-24 Nyloc St GR2 CZ 1 1
2 02288574 Capsrw M05-0.8 x 12 BHSS 18-8 6 1
3 02288584 Capsrw M06-1.0 x 20 CSSS 18-8 5 2 3
4 02288925 Screw, Shoulder M06 Dia-35mm Lg 2 2
5 02288926 Capsrw M04-0.7 x 10 CSSS 18-8 4 4
6 02288989 Flatwasher M06-Fender SS 18-8 2 1
7 02289053 Setscrew M04-0.7 x 10 HXSO NTST 2 2
8 02290177 Knob, Hand-Knurled .75 Dia SS 1 1
9 08780133 Roller, Rear Entry (Assy) 2 1
10 08780135 Pad, Guide-Rear Cable Entry 1 1
11 08780252 Shaft, Vert Guide Roller 1 1
12 08780473 Arm, Pivot RH-Adj Cbl Guide 1 1
13 08780474 Arm, Pivot LH-Adj Cbl Guide 1 1
14 08780475 Shaft, Adjustment-ADJ CBL Guide 1 1
15 08780476 Pin, Pivot RH-ADJ CBL Guide 1 1
QTY
KIT
QTY
KIT
QTY
16 08780477 Pin, Pivot LH-ADJ CBL Guide 1 1
17 08780479 Plate, Bearing Mnt Assy 2 2
18 08780481 Block, Pivot Mount Assy 1 1
ITEMS 2, 3, 6, 9, 11 COME IN KIT 08780639
ITEMS 1, 3, 4, 5, 7, 8, 10, 12, 13, 14, 15, 16, 17, 18 COME IN KIT 08780482
Parts List, RH Cable Guide Roller Replacement Kit
52
08780639
LH Cable Guide Roller Kit
N.
APPENDIX
LH Cable Guide Roller Replacement Kit
08780640
REQUIRED
ITEM PART NO DESCRIPTION
1 02288574 Capsrw M05-0.8 x 12 BHSS 18-8 6 1
2 02288579 Plunger, Spring-M10x1.5 SS 1 1
3 02288585 Screw, Shoulder M08 Dia-16mm LG 1 1
4 02288989 Flatwasher M06-Fender SS 18-8 2 1
5 08780059 Shaft, Pivot Guide Roller 1 1
6 08780133 Roller, Rear Entry (Assy) 2 1
Parts List, LH Cable Guide Roller Replacement Kit
08780640
QTY
KIT
QTY
53
O.
APPENDIX
Counter Spring Kit
Counter Spring Replacement Kit
08780641
REQUIRED
ITEM PART NO DESCRIPTION
1 02288583 Capsrw M06-1.0x 10 BHSS 18-8 2 1
2 02288588 Flatwshr M06-Narr ST CZ 2 1
3 02288639 Cap, Vinyl .75id-.88od-1.00 Blk 2 1
4 02288677 Sensor, Pickup-Turck Picoprox 1
5 02288721 Spring, Comprss .063-0.600-2.50 2 1
6 02288727 Shaft, Counter (assy) LW FO Blwr 1
7 02290215 Clamp, Cable Counter-Assy 1
8 08780022 Retainer, Spring-Cable Clamp 1 1
9 08780090 Pad, Guide-Rear Cable Entry 1
10 08780097 Cordset Assy 2pin W/Connectors 2
11 08780135 Panel, Control-Touch LW Blower 1
12 08780193 Cordset, Rear Sensor LW Blower 1
13 08781011 Cordset, Front Sensor LW Blower 1
QTY
KIT
QTY
14 08781026 Cordset, Transducer LW Blower 1
ITEMS 4, 6, 7, 9, 10, 11, 12, 13, 14 ARE NOT INCLUDED IN KIT 08780641
Parts List, Counter Spring Replacement Kit
54
08780641
Base Mount
P.
APPENDIX
ITEM PART NO DESCRIPTION QTY
1 02288654 Handle, Adjustable Clamping 1
2 02288701 Pin, Hitch Cotterless 3/8 x 4.50 1
3 08780160 Base, Adjustable Assy-LW FO Blowr 1
ITEMS 1 AND 2 INCLUDED WITH ITEM 3
Base Mount Individual Replacement Parts
55
Q.
APPENDIX
Pneumatic & Electrical Circuits
Pneumatic Circuit
08780994
56
Electrical Circuit
08780996
Hydraulic Circuit
R.
APPENDIX
Hydraulic Circuit
08780997
57
Hydraulic Flow Control Valve
S.
APPENDIX
Parts List, Hydraulic Control Flow Valve
Replacement Kit
08780945
ITEM PART NO DESCRIPTION QTY
1 02260200 Cap, Dust (male Flat Face Cplrs) 1
2 02260201 Cap, Dust (fem Flat Face Cplrs) 1
3 02269708 Valve, Cartridge-Direc. Control 1
4 02288589 Valve, Cartridge-Flow Control 1
5 02288590 Knob, Cartridge Valve Flow Ctrl 1
6 02288619 Coupler, Female-Flt Face Metric 1
7 02288620 Coupler, Male-Flat Face Metric 1
58
8 02288637 Gauge, Press 0-2000 1.50 Bck Mt 1
9 02288638 Ftg, Hyd 06-jic, M14 O-Ring 2
10 02288641 Lever, Ball Handle 2 Pos Detent 1
11 02288703 Ftg, Hyd 18mm-Thread Bond Seal 2
12 02288859 Valve, Cartridge-Solenoid 12vlt 1
13 02290614 Valve, Cartridge-Hex Adj Relief 1
14 02290766 Transducer, Prsr 2000psi-4/20ma 1
15 02290768 Ftg, Hyd 04 O-Ring_m;04 Npt_f 1
16 02290769 Ftg, Hyd 04 Npt_m;04 Npt_f Tee 1
17 02290770 Ftg, Hyd 04 Npt_m;02 Npt_f 1
ECB Upgrade Kit - 08781022
PART NO DESCRIPTION QTY
08781020 Panel, Control-Touch LW Blower 1
08781023 Kit, Pressure Transducer-LWB 1
BREAKDOWN of 08781023 Kit
PART NO DESCRIPTION QTY
02289187 Bag, 8.00-11.50 Plastic Bubble 1
02290766 Transducer, Prsr 2000psi-4/20ma 1
02290768 Ftg, Hyd 04 O-Ring_M;04 Npt_f 1
02290769 Ftg, Hyd 04 Npt_M;04 Npt_f Tee 1
02290770 Ftg, Hyd 04 Npt_M;02 Npt_f 1
08781026 Cordset, Transducer LW Blower 1
Possible Wear & Replacement Parts
For replacement parts please contact the factory or Condux representative.
List of possible wear items:
Part Number Description
08780904 Belt, Cable 50MM X 260MM Center
See Table 1, pg 18 for
correct cable seal size
08780126 Kit, Seal Replacement-LW Blower
08780424 Machine Screws,M04-0.7X16 (10)
08780135 Pad, Guide-Rear Cable Entry
08780266 Guide, Cable-Upper Entrance
08780133 Rear Entry Rollers
08780091 Upper Counter Roller
08780022 Lower Counter Roller
See Table 2, pg 18 for
correct carrier size
OTHER WEAR OR REPLACEMENT PARTS
Part Number Description
08780126 KIT,SEAL REPLACEMENT-LW BLOWER
08780223 PLUG,VENTURI AIR-LW FO BLOWER
08761248 CORD,POWER ASSY W/LIGHTER PLUG
02286416 CORD,EXTENSION-2PIN STRGHT 20'
08780904 BELT,CABLE 50MM X 260MM CENTER
08780135 PAD,GUIDE-REAR CABLE ENTRY
08780266 GUIDE,CABLE-UPPER ENTRANCE
08780133 ROLLER,REAR ENTRY(ASSY)
08780091 ROLLER,CABLE CLAMP-ASSY
08780022 SHAFT,COUNTER(ASSY)LW FO BLWR
Cable Seals
Carrier Seals
T.
APPENDIX
BLOWING LUBRICANT
Part Number Description
08230600 LUBRICANT, POLY PL2K 1 QT 12/C EA
08230601 LUBRICANT, POLY PL2K 1 GL 4/C EA
08230900 LUBRICANT, POLY WPL2K 1 QT 12/C EA
08230901 LUBRICANT, POLY WPL2K 1 GL 4/C EA
MANUALS
Part Number Description
08780998 MANUAL, QUICK REF LW FO BLOWER
08780999 MANUAL, FO CABLE BLOWER
59
Possible Wear & Replacement Parts
PACKAGE ADD-ONS
Part Number Description
08780393 CABLE PACK 0.23"-0.34" (5.8-8.6
08780394 CABLE PACK 0.35"-0.60" (8.9-15.2
08780395 CABLE PACK 0.61"-0.85" (15.3-21.6
08780396 CABLE PACK 0.86"-1.05" (21.7-26.7
08780795 DUCT PACK .50" DUCT OD SDR 13.5/ SDR 11
08780680 DUCT PACK .75" DUCT OD SDR 13.5/ SDR 11
08780240 DUCT PACK 1.00" (25 MM) DUCT OD SDR 13.5/ SDR 11
08780385 DUCT PACK 1.25" DUCT OD SDR 13.5/ SDR 11
08780389 DUCT PACK 1.50" (32 MM) DUCT OD SDR 13.5/ SDR 11
08780930 DUCT PACK 2.00" (50.8 MM) DUCT OD SDR 13.5/ SDR 11
08780386 DUCT PACK 33.4MM (1.315) DUCT OD LW
08780387 DUCT PACK 36.0MM (1.417) DUCT OD LW
08780388 DUCT PACK 37.0MM (1.457) DUCT OD LW
08780389 DUCT PACK 38.1MM (1.500) DUCT OD LW (1.25 TRUE)
08780390 DUCT PACK 40.0MM (1.575) DUCT OD LW
08780391 DUCT PACK 42.0MM (1.653) DUCT OD LW
08780392 DUCT PACK 42.2MM (1.660) DUCT OD LW
08780397 DUCT PACK 48.3MM (1.900) DUCT OD LW
08780545 DUCT PACK 44.0MM (1.732) DUCT OD LW
08780460 DUCT PACK 46.0MM (1.811) DUCT OD LW
08780575 DUCT PACK 50.0MM (1.968) DUCT OD LW
MM) CABLE-LW
MM) CABLE-LW
MM) CABLE-LW
MM) CABLE-LW
60
Possible Wear & Replacement Parts
CABLE PACK WEAR PARTS
Part Number Description
08780406
SEAL,CABLE 0.23-0.28 (5.8-7.3
08780407 SEAL,CABLE 0.29-0.34 (7.4-8.8
08761424 SEAL,CABLE 0.35-0.42 (8.9-10.7
08761425 SEAL,CABLE 0.43-0.48 (10.8-12.2
08761426 SEAL,CABLE 0.49-0.55 (12.3-14.0
08761427 SEAL,CABLE 0.56-0.60 (14.1-15.2
08761428 SEAL,CABLE 0.61-0.67 (15.3-17.0
08761429 SEAL,CABLE 0.68-0.73 (17.1-18.5
08761430 SEAL,CABLE 0.74-0.79 (18.6-20.1
08761431 SEAL,CABLE 0.80-0.85 (20.2-21.6
08761432 SEAL,CABLE 0.86-0.92 (21.7-23.4
08761433 SEAL,CABLE 0.93-0.97 (23.5-24.6
08761434 SEAL,CABLE 0.98-1.04 (24.7-26.4
08761435 SEAL,CABLE 1.05-1.13 (26.5-28.7
08780424 MACHINE SCREWS,M04-0.7X16 (10)
08643754 CABLE GRIP- .21- .35-14 1400#
08643755 CABLE GRIP- .32- .48-19 2000#
08643756 CABLE GRIP- .42- .61-21 2500#
08643757 CABLE GRIP- .53- .74-23 3000#
08643758 CABLE GRIP- .64- .87-25 4200#
08643759 CABLE GRIP- .75-1.00-28 4200#
08643137 CABLE GRIP-1.00-1.24-20 6800#
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
MM) OD CABLE
61
Replacement Parts & Accessories
DUCT PACK WEAR PARTS
Part Number Description
08078300 CARRIERS,FOAM 0.75 OD
08761439 CARRIERS,FOAM 1-1/4 OD
08761440 CARRIERS,FOAM 1-1/2 OD
08761441 CARRIERS,FOAM 1-3/4 OD
08761442 CARRIERS,FOAM 2 OD
CARRIER ASSEMBLIES
08780793 CARRIER ASSY-0.688 OD
08780690 CARRIER ASSY-0.750 OD
08780230 CARRIER ASSY-0.787 OD
08761560 CARRIER ASSY-1.063 OD
08761250 CARRIER ASSY-1.121 OD
08761643 CARRIER ASSY-1.181 OD
08761555 CARRIER ASSY-1.220 OD
08761670 CARRIER ASSY-1.250 OD
08761525 CARRIER ASSY-1.299 OD
08761660 CARRIER ASSY-1.378 OD
08761255 CARRIER ASSY-1.414 OD
08761786 CARRIER ASSY-1.496 OD
08761579 CARRIER ASSY-1.606 OD
08761260 CARRIER ASSY-1.618 OD
08761265 CARRIER ASSY-2.023 OD
62
CABLE GRIPS
Part Number Description
08643131 CABLE GRIP-.75-.99-20 4000#
08643137 CABLE GRIP-1.00-1.24-20 6800#
08643143 CABLE GRIP-1.25-1.49-21 6800#
08643149 CABLE GRIP-1.50-1.99-23 6800#
08643155 CABLE GRIP-2.00-2.46-25 8500#
TOOLS
Part Number Description
02284000
02290520
02290168 STANDARD & METRIC ALLEN WRENCH SET
3
⁄8" DRIVE RATCHET
9
⁄16" DEEP WELL SOCKET
Replacement Parts & Accessories
REPLACEMENT DISCS FOR CARRIERS
08780794 DISC CARRIER-0.688 OD
08780691 DISC CARRIER-0.750 OD
08780235 DISC CARRIER-0.787 OD
08761558 DISC CARRIER-1.063 OD
08761144 DISC CARRIER-1.121 OD
08761646 DISC CARRIER-1.181 OD
08761553 DISC CARRIER-1.220 OD
08761671 DISC CARRIER-1.250 OD
08761528 DISC CARRIER-1.299 OD
08761661 DISC CARRIER-1.378 OD
08761147 DISC CARRIER-1.414 OD
08761785 DISC CARRIER-1.496 OD
08761574 DISC CARRIER-1.606 OD
08761150 DISC CARRIER-1.618 OD
08761153 DISC CARRIER-2.023 OD
DUCT COUPLER CLAMP
Part Number Description
08676844 CLAMP,INNERDUCT COUPLER-ASSY
08676830 COUPLING,SPLIT 1.50"/2.00"
08676859 COUPLING,INSRT-1" DCT 1.315 W/S
08676860 COUPLING,INSRT-1.25" DCT 1.66 W/S
08676861 COUPLING, INSRT-1.5" DCT 1.90 W/S
08676862 COUPLING, INSRT-2" DCT 2.37 W/S
08676863 COUPLING, INSERT-40MM DUCT W/S
08676864 COUPLING, INSERT-46MM DUCT W/S
63
Replacement Parts & Accessories
FIXED HEAD INNERDUCT PULLING EYE
Tapered buttress threads thread into the innerduct for maximum pulling strength.
These eyes connect directly to a Condux swivel. When properly sized and installed,
these eyes will not pull out of the innerduct until the pulling tensions have greatly
exceeded the maximum pulling tensions recommended by the innerduct
manufacturers.
NOTE: To determine correct pulling eye size, obtain the actual innerduct inside
diameter (I.D.). The I.D. measurement must be greater than dimension A and
smaller than dimension B.
F
D
Max OD Hole Dia Eye Dia Thickness
Part Innerduct range Innerduct ID range C D E F
Number (in) (mm) A-B (in) A-B (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
08761840 .5-.75 18-22 .71-.87 18-22 1.25 32 0.25 6 0.5 13 0.5 13
08761842 1-1.25 27-37 1.06-1.43 27-37 1.75 44 0.38 10 0.5 13 0.5 13
08761844 1.5-2 35-43 1.37-1.68 35-43 2 51 0.38 10 0.5 13 0.5 13
08761846 2 45-51 1.80-2.19 46-55 2.5 63 0.38 10 0.5 13 0.5 13
A
B
C
E
64
Replacement Parts & Accessories
08010220
08010210
CABLE JACKET SLITTER
This popular tool makes quick, safe work of removing sheath and turnplate from
communication cables. With a turn of the handle, the toothed wheel pulls the tool
forward while the angled blade makes a clean cut. Blade guard protects conductors
from damage. Also excellent for slitting innerduct. Minimum cable diameter 1"
(25 mm).
Part Number Description
08012900 Cable Jacket Slitter
08012901 Replacement Blade
INNERDUCT SLITTER
The Innerduct Slitter is designed for fast, safe cutting of
innerducts from 1" (25 mm) to 2" (51 mm) OD.
Part Number Description
08013100 Innerduct Slitter
08013101 Replacement Blade
TURBOSLITTER™
The TurboSlitter from Condux can easily split HDPE pipe with wall
thicknesses ranging from 0.097 to 0.216 inches! The unit
quickly adjusts to fit almost any rechargeable drill,
14-volt and larger. Save time and effort on the job
with the TurboSlitter from Condux.
Part Number Description
08010210 Pneumatic Duct Slitter
08010220 Duct Slitter Drill Attachment
08010203 Replacement Blades
PVC & POLYETHYLENE CUTTER
Razor sharp cutting blade makes a fast, clean, burr-free cut in
PVC and polyethylene. Ratcheting handle provides for sure,
steady cutting action. Reduces cutting and preparation time.
Part Number Description
08948050 Small diameter—up to 1
08948070 Large diameter—up to 2" (51 mm) conduit with 23⁄8" (60 mm) O.D.
08948051 Replacement Blade for Small Cutter
08948071 Replacement Blade for Large Cutter
1
⁄4" (32 mm) conduit with 11⁄2" (38 mm) O.D.
08010220
08010210
65
Replacement Parts & Accessories
INNERDUCT PRESSURE TEST KIT
Use the Innerduct Pressure Test Kit to pressure test innerduct
before setting up the Deluxe Blower. The conduit
system must be able to withstand and hold 150 psi (10.3 bar) for
the Cable Blower to work properly.
Part Number Description
08761457 Pressure Test Kit for 1", 11⁄4" & 11⁄2" SDR 11 & 13.5 Innerduct
•ControlValveAssembly
•Seal-OffHeads
•PullingEyes
•PullingGrips
•ToolBox
Other Components Available
Part Number Description
08034318 Seal-Off Head for 2.00" SDR 11 & 13.5 Innerduct
08761846 Pulling Eye for 2.00" SDR 11 & 13.5 Innerduct
08643155 Pulling Grip for 2.00" SDR 11 & 13.5 Innerduct
PO LY WATER® PRELUBE 2000™
Specially formulated for use with fiber optic cable blowing
systems, Polywater
the Deluxe Blower. This lubricant is a special lubricant used to
prelubricate the conduit system before installing the cable.
Prelube 2000 is compatible with all types of cable jackets and
conduit types.
Part Number Description Std. Pkg. Qty.
08230600 1 Quar t (.9 liter) Squeeze Bottle 12/case
08230601 1 Gallon (3.8 liter) Jug 4/case
08230900 1 Quar t (.9 liter) Squeeze Bottle, (Winter Grade) 12/case
08230901 1 Gallon (3.8 liter) Jug, (Winter Grade) 4/case
®
Prelube 2000™ has been field proven with
66
COMFIT COUPLERS
Comfit is a unique Hi-Tech coupler for HDPE cable ducts. Leak
tested at 230 PSI and resistant to corrosion and most chemicals.
Comfit is designed in accordance with the special demands of the
leading cable duct companies and contractors.
Comfit is excellent for both blowing and pulling methods.
Comfit has a compact profile reducing difficulties traditionally
encountered in manholes, narrow trenches and plowing
machines.
Comfit’s push-fit method ensures fast and simple assembly and
disassembly. Push the duct ends into the coupler for a locked
and air sealed assembly. No special tools are needed.
COMFIT COUPLER
Part No. Nominal OD (mm/inches) Max Tension Max Pressure (PSI) Units per box
08566110 33.4mm / 1" 580 230 70
08566112
08566115
42.2mm / 1
48.3mm / 1
08566120 60.3mm / 2" 2400 230 34
COMFIT PLUG
Part No. Nominal OD (mm/inches) Range (inches) Units per box
08047110 33.4mm / 1" 1.024-1.220 120
08047112
08047115
42.2mm / 1
48.3mm / 1
08047120 60.3mm / 2" 1.85-2.441 35
1
⁄4"
1
⁄2"
1
⁄4"
1
⁄2"
1130 230 56
1470 230 36
1.201-1.535 90
1.496-1.929 60
Warranty Information
A. FACTORY ASSISTANCE
Condux International can provide further advice regarding any problems with the
installation, service, assembly, or disassembly of the Deluxe Blower. Call toll free at
1-800-533-2077 (USA and Canada) or 1-507-387-6576 and ask for assistance. The
Deluxe Blower 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.
B. LIMITED WARRANTY
Condux International, Inc. extends the following warranty to the original purchaser of
these goods for use, subject to the qualifications indicated: Condux International,
Incorporated warrants to the original purchaser for use that the goods or any
component thereof manufactured by Condux International 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.
Lack of routine maintenance as specified in the maintenance section of the
User’s Guide will void the warranty.
Components not manufactured by Condux International but used within the assembly
provided by Condux International 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.
Listed wear parts as called out in the User’s Guide are not covered under
the warranty.
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 from 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). Once obtained,
send the RMA along with the defective part or goods, transportation prepaid, to:
Condux International, Inc.
145 Kingswood Drive
Mankato, MN 56001 USA
16.
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 WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES.
67
Condux International, Inc.
P. O . Box247•145KingswoodDrive,Mankato,MN56002-0247USA
1-507-387-6576•1-800-533-2077•FAX1-507-387-1442
Internet:http://www.condux.com•e-mail:cndxinfo@condux.com
68
© Copyright 2013, Condux International, Inc.
Printed in USA
Literature Part Number: 08780999
Revision Number: 4.0
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