General Machine Products 89004 User Manual

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

GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA

TEL: [phone] • FAX: [phone] • EMAIL: [e-mail]

General Machine Products Co., Inc.

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General Machine Products Co., Inc.

August 29 2009 USA Ver 3

Manual P/N 32297

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

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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. Recommended Spares List

APPENDICES

Appendix 1 Layout of Rod Pushing Machine

Appendix 2 Drawing – Rod Pushing Machine

Appendix 3 Hydraulic & Electrical Panel Layout

Appendix 4

Warranty

Counter programming parameters

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General Machine Products Co., Inc.

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., which enabled it to manufacture proto­types of products for experimental use within the
Bell System.

Having outgrown the original factory building, the
company built a 100,000 square foot plant in
Trevose, PA (a Philadelphia suburb) and moved
there in 1957. Today GMP is recognized as a pre­mier worldwide supplier of specialty tools and equipment for the outside plant market­place. The company's products are known for their robust design and durability to with­stand many years of frequent use.

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General Machine Products Co., Inc.

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. Rods that
have been repaired and have a coupling at any point along its length, cannot be used since

!

the coupling cannot safely pass through the Duct Rod Pusher.

FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY

WORK AREA AND GENERAL SAFETY

1. Read and understand the operation and maintenance manual supplied with this equip-

ment. Keep it in a convenient place for future reference.

2. Keep children and untrained personnel away from this equipment while in operation.

3. Keep all guards and safety devices in place. Do not operate this equipment with guards

removed or damaged.

4. Keep hands, feet and loose clothing away from moving parts, especially at cable entry

points.

5. Always stop the machine and isolate hydraulic and electrical services to carry out lubrica-

tion and servicing.

6. Check machine before starting for worn or damaged parts. Check for signs of loose nuts

and bolts etc.

7. If machine is left unattended, insure that unauthorized use is prevented.

8. Never leave the machine unattended while in use.

9. Consider the use of safety barriers, especially when used in public places, observe all

statutory requirements for working environments.

10. Beware of pinch points involved with rotating components.

11. Beware of hot surfaces, machine uses hydraulics.

12.

When operating machine always wear eye protection, hard hat, safety shoes and leather

gloves, machine operates with hydraulic oil at 2030 psi.

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General Machine Products Co., Inc.

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. Waste hydraulic oils are to be disposed of via an environmentally acceptable

method.

16. Wear hearing protection when noise level are above acceptable limits. To reduce noise,

position Power Pack away from user.

17. Machine may cause additional fire hazard if involved in an existing fire due to hydraulic

oils.

18. No personnel are to be in manholes or ducts when the duct rod pusher is in operation.

19. The machine must be operated on firm ground.

20. Stay clear of rods or lines under tension.

21. Only use the machine for its intended purpose.

22. Do not place duct rod carrier too close to the powered duct rodder.

23. Do not tamper with pressure relief valves or pressure reducing valves.

24. Never operate the rod pushing machine with the electronic control panel immersed in wa-

ter.

25. To prevent damage to the hydraulic hoses and the emergency stop cable never leave

them on the ground when not in use.

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General Machine Products Co., Inc.

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. Insure all hydraulic connections are securely tightened before operating the machine.

2.

Check for leaks with a piece of cardboard. Do not use your hands!

3. Do not exceed working pressure of hydraulic hoses.

4. Visually inspect hoses regularly and replace if damaged.

GENERAL ELECTRICAL SAFETY INSTRUCTIONS

The machine has electronic and electrical power and control circuits. Electric shock hazards
exist that could result in severe personal injury. Observe the following precautions to avoid
electrical hazards:

1. Do not operate in water.

2. Do not expose the machine to rain.

3. Do not remove cover of electronic control assembly.
There are no user serviceable parts inside.

4. Refer servicing to qualified service personnel.

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General Machine Products Co., Inc.

2. CRITICAL POINTS THAT DRAMATICALLY AFFECT THE
OPERATION OF THE ROD PUSHING MACHINE

a. Two (2) turns on the rod clamping screw.
b. Tractor drive to be closed at all times when rod is installed into machine.
c. Sub-Duct clamp height adjustment correctly set.
d. Rod in-feed bracket height adjustment correctly set.
e. Sub-duct fully connected.
f. Rod drum must be located directly behind and in line with the pushing machine.
g. Sub-duct clamp, tractor drive belts/chains, housing framed and rod guide intake assembly must be

clean and free from debris, sludge, dirt, water and lubricant. (Each time the pushing machine is
used.)

h. The hydraulic pressure should be between 290-580 PSI at the start of an installation. If greater do

not proceed. Check rod clamping screw setting, sub-duct, rod, rod collet sizes, sub-duct clamp/in­feed guide height setting. Rectify before re-commencing the installation.

i. Lubricate the drive chains before use.
j. Do not repeatedly press the on/off button on the length/speed readout. This may result in irrelevant

digits being displayed or may alter the program. Always fit the hydraulic hose dust caps when the
hose is not in use, clean and check the quick release couplings before use.

NOTE:

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

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General Machine Products Co., Inc.

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. The electronic control system
displays speed, distance, direction and the preset pressure sensor provides automatic protec­tion against duct obstruction.

The system comes mounted on a sturdy anti-corrosion, height adjustable, wheeled, tubular
steel trolley unit for ease of site maneuverability, and is powered by a hydraulic supply system
operating at 2030 psi x 5.3 gallons/min.

The rod pushing unit can be easily detached from the trolley and located in a trench or man­hole (depending on the size of the manhole).

The unit is supplied with two (2) x hydraulic hoses x 23 feet and a 26 foot long emergency
stop lead.

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General Machine Products Co., Inc.

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 independently for repair work.

CHASSIS

▪ Front mounted wheels for ease of maneuverability
▪ Light painted tubular steel frame
▪ Adjustable frame allowing unit to be tilted at 20º to manhole
▪ Adjustable legs for uneven terrain
▪ Detachable rod pushing unit for trench / manhole location

ROD FEEDER

▪ Manufactured from cast aluminum
▪ Hydraulically powered
▪ Unit lifts and splits to allow insertion of rod between drive belts
▪ Drive belts are polyurethane and molded to unit ensuring long life between replacements.
▪ Lifting hook built into adjustable jack screw to allow unit level lift.
▪ Belt tension can be set by means of adjustable chain drive tensioners fitted to the side of

the unit

▪ System relief valve factory set to 1500 psi.

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General Machine Products Co., Inc.

4. SPECIFICATIONS

OPERATION CAPACITIES

Pushing Force
Pushing Speed
Rod Size
Sub-Duct Size

HYDRAULIC DRIVE SYSTEM

Operating Pressure
Flow
Pressure Switch Setting
Relief Valve Setting

Initial starting pressure

ELECTRONIC CONTROL SYSTEM

0-300 lbs. (0 - 136 kg)

0-130 ft/min (0 - 40m/m)

1/2” (12.7mm)

1-1/4 SDR

2030 psi (max) (110 Bar)

5.3 gallons/min (recommended)

1450 psi (100 Bar)

1500 psi (103 Bar)

290-580 psi (20-40 Bar) (if greater the set-up
needs checking)

Power requirements:
Fuse Rating

DIMENSION AND WEIGHTS

Height
Length
Width
Weight
Tire Size
Tire Pressure
Drive Chain Lubrication

12 Volts DC

3.15 amp (Slow-Blow)

49”

42”

28”

210 lbs.

3.00-4/260x85

25 psi (1.72 Bar)

Metaflux 70-88 Chain Spray

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General Machine Products Co., Inc.

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. Initially charge the battery for 8 hours before
use (to approximately 13 volts). Continuous charging of the battery with
your charger will reduce the life of the battery. Remove the charger
when charging is complete. When voltage dips to 12 volts, recharge the

battery. Optimize battery life by turning off the display when not in use.

1. Position the Rod Pushing Machine in a suitable position in line with the proposed sub-duct.

2. Adjust the mounting frame to the desired height and angle by means of the front frame sup­ports. Withdraw the front ‘R’ clip and retaining pin while supporting the weight of the rod
pushing unit. Raise or lower the pushing unit and locate onto the support bar for the desired
position. Refit the retaining pin and ‘R’ clip. Alternatively the pushing unit may be detached
from the trolley frame by withdrawing both ‘R’ clips and retaining pins, while supporting the
weight of the pushing unit.

3. Stabilize the frame on uneven ground by adjusting the height on the pivoting feet at the rear
of the unit and locking in position.
NOTE: CARE SHOULD BE TAKEN WHEN WHEELING THE TROLLEY AROUND NOT TO
CATCH THE ADJUSTABLE FEET PADS ON CURBS OR BOULDERS, THIS MAY DAM­AGE THE PIVOTING FOOT.

4. Position Duct Rod approximately 5’ behind the Duct Rod Pusher at about a 35° angle.

Duct Rod

5. Insure the battery is fully charged before commencement of installation.

6. Open tractor drive.

CLEAN ANY DEBRIS, SLUDGE, DIRT, WATER, LUBRICANT,
ETC, FROM FRAME HOUSINGS AND ROD INTAKE GUIDE
BRACKET ASSEMBLY EACH TIME BEFORE USE.

LUBRICATE BOTH CHAINS BEFORE USE.

CLEAN BOTH TRACTOR DRIVE BELTS BEFORE USE.

5ft 1 1/4” Duct 1 1/4” Duct

Duct Rod Pusher

Lubrication Points

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General Machine Products Co., Inc.