General Machine Products Tornado Hydraulic Power Pack Vertical Style User Manual

POWER PACK

OPERATION & MAINTENANCE

FOR THE TORNADO CABLE/MICRODUCT BLOWING

MACHINES AND THE POWERED DUCT ROD PUSHER

Copyright 2010 by General Machine Products Co., Inc

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 2010 USA Ver 2

Manual P/N 32839

REVISION HISTORY

Rev # Date Details Author

01 11.01.01 Original issue D. North

02 09.01.09 US Version 1 A. Konschak

03 08.11.10 US Version 2 A. Konschak

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General Machine Products Co., Inc.

CONTENTS

1. Safety Instructions

2. General Description

3. Specification

4. Operating procedures

5. Maintenance

6. Troubleshooting Guide

7. Service History Record

8. Recommended Spares List

APPENDICES

Appendix 1 Hydraulic Drawing

Warranty

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General Machine Products Co., Inc.

1. SAFETY INSTRUCTIONS

This power pack 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.

WORK AREA AND GENERAL SAFETY

1. Read and understand the operation and maintenance manual supplied with
this equipment. 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 lubrication 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.

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. 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.

15. Wear hearing protection when noise level are above acceptable limits. To
reduce noise, position Power Pack away from user.

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General Machine Products Co., Inc.

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

17. The machine must be operated on firm ground.

18. Only use the machine for its intended purpose.

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

20. To prevent damage to the hydraulic hoses and the emergency stop cable
never leave them on the ground when not in use.

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. Caution: Do not use your
hands! Oil may be hot

3. Do not exceed working pressure of hydraulic hoses.

4. Visually inspect hoses regularly and replace if damaged.

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General Machine Products Co., Inc.

2. GENERAL DESCRIPTION

The Hydraulic Power Pack sits on a tubular steel frame with 2 wheels for easy
transportation.

The gas driven air-cooled engine drives a fixed displacement gear pump fitted
with an integral pressure relief valve. The hydraulic circuit has an oil tank fitted
with a suction filter and a replaceable return line filter to protect the pump and
motor. The tank is also fitted with a filler/breather and sight level gauge.

The hydraulic power pack is connected to the remote equipment via detachable
dual hoses fitted with male/female quick release couplers.

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General Machine Products Co., Inc.

3. SPECIFICATIONS

DIMENSIONS

LENGTH: 30”
HEIGHT: 38”
WIDTH: 21”
DRY WEIGHT: 110 lbs.

Model

No. type l/min US gal/min bar psi

32481 Honda 15 4 115 1670

Engine Flow Pressure

Honda Engine Type: GXV 160 (5HP)
Approximate operating time is 45 minutes with a full tank of gas at maximum R.P.M.
Hydraulic Oil Type: Shell Tellus T-32
Hydraulic Oil Tank Capacity: 6 US gallons
For Engine Details refer to manufacturers manual.

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General Machine Products Co., Inc.

4. OPERATING PROCEDURE

It is imperative that all persons using, operating or maintaining this power pack
be fully trained and competent to do so, and have read the entire operating
manual.

General Machine Products Co., Inc. and CBS Products Ltd cannot be held re­sponsible for misuse of this equipment.

The power pack is designed to work with an open center control valve. There­fore it is imperative that the hoses are connected to a system having the facility
prior to starting the engine.

Connecting Hoses

The hydraulic power pack must be connected by the two detachable hoses to
the driven machine by plugging in the male/female quick release couplings be­fore starting the engine.

IMPORTANT: Do not try to start the engine on the Power Pack until the hoses

between the Power Pack and the remote equipment have been connected.
Do not disconnect the hydraulic hoses when the power pack is running (if the
engine continues to run serious overheating will occur as the oil continues to
pass through the relief valve).

Hydraulic Oil Level

Check hydraulic oil level and top off with the appropriate grade of hydraulic oil
(refer to 3.0 specification for details) or equivalent if necessary, each time the
power pack is used.

Starting the Engine

Refer to the engine manufacturer manual before starting the engine.

NOTE:The engine manufacturer recommends the addition of a gas stabilizer to
unleaded gas if the unit is to be stored for an extended period. This prevents
the build up of gum and varnish in the gas, keeps the carburetor and gas system
clean and improves engine performance.

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General Machine Products Co., Inc.

5. MAINTENANCE AND SERVICING

To insure reliable service from your power pack, we recommend the unit be
completely serviced every 6 months.

Hydraulic Circuit

The circuit should be drained off and replaced with the appropriate grade of hy­draulic oil (refer to 3.0 specification for details) or
equivalent until it is almost to the top of the sight glass
when the power pack is on level ground. The circuit is
fitted with two filters, only one of these requires replac­ing. Replace the Return Line Filter when the filter gauge
is in the red (indicating higher return pressure - i.e.,
clogged filter). The gauge is found on the side of the fil­ter housing.

Return Line Filter Replacement

1. Unscrew the return
line filter top cap with a
24mm box wrench or
socket and remove.

2. Remove old filter
and replace with the
new one.

3. Replace the top cap
making sure not to cross
the thread. Check for
leaks after tightening.

Gas Engine

Refer to manufacturer’s manual.

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General Machine Products Co., Inc.

6. TROUBLESHOOTING GUIDE

Engine Will Not Start

● Check gas level

● Check throttle in "on" position

● Check emergency stop button is "reset" on either the Tornado or the

Powered Duct rod Pusher

● Insure hoses are connected from power pack to blower (if they are not

connected or have a faulty coupling, engine will not turn over).

● Contaminated gas

Difficult to Start Engine

● Check above points

● Insure gas has additional additive

● Engine may be flooded

● Check hydraulic valve on blower unit is switched “off”

● Check spark plug

Engine is Running Erratic

● Insure additive is mixed with gas

● Damage to throttle

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General Machine Products Co., Inc.

7. SERVICE HISTORY RECORD

Service no Date Carried out by Record of service/repair

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General Machine Products Co., Inc.

8. SPARES

For spare parts always quote the machine type and serial number and contact:

General Machine Products Co.

3111 Old Lincoln Highway, Trevose PA 19053 USA

TEL: [phone]

FAX: [phone]
E-MAIL: [e-mail]
Website: www.GMPtools.com

Please give as much information as possible to insure correct identification and

supply of spare parts.

RECOMMENDED SPARES LIST

PART No Description Qty required

89154 Filler Breather 1
89156 Wheel (pneumatic) 2
89157 Oil Level Gauge 1
89159 Suction Filter 1
89163 Return Line Filter 1

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General Machine Products Co., Inc.

APPENDIX 1

Hydraulic Circuit

Ref PART

1 Hydraulic Tank
2 Gas Engine
3 Hyd. Pump & Relief Valve
4 Suction Filter
5 Filler/Breather
6 Oil Level Gauge
7 Quick Release Coupling—High Pressure
8 Quick Release Coupling—Low Pressure
9 Return Line Filter

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General Machine Products Co., Inc.

GMP Limited Warranty

1a. General Machine Products Co., Inc. ("GMP") warrants to the purchaser and/or end user:

(1) that a new product sold and manufactured by GMP will be free from original defects in material and
workmanship for one year from the date the product was delivered to the purchaser and/or end user,
or for the lifetime of the Modular Plug Presser;

(2) that a new product sold and not manufactured by GMP will be covered exclusively by the manufac­turer's warranty. However, if that warranty coverage shall provide less coverage than the GMP War­ranty for its manufactured products, then the warranty set forth in Paragraph 1(a)(1) above shall apply
instead;

(3) that a reconditioned used GMP product sold by GMP, or a non-owned product repaired by GMP,
or a new part sold by GMP, will be free from original defects in material and workmanship for ninety
days from the date the product was delivered to the purchaser and/or end user.

1b. The above warranties are contingent upon and subject to the condition that: (1) the end user sub-

stantiates the date it purchased and received delivery of the product or part, and (2) the product or
part shall have been installed, maintained and used in accordance with GMP's or the manufacturer's
written instructions.

2. The end user shall determine the suitability of GMP's product or part for intended use, and the end

user assumes all risk and liability whatsoever in connection therewith except to the extent set forth in
this Limited Warranty.

3a. GMP reserves the right to request that the product or part be returned to us for examination and

cannot be responsible for user charges incurred in the replacement of any product. GMP's agreement
to repair or replace is also subject to its inspection of the product and verification of the defect.

3b. Subject to immediate written notification of a defect or malfunction, GMP will repair or replace that

product or part, at GMP's option, returned freight prepaid to Trevose, PA.

3c. 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 product, transportation prepaid to:

General Machine Products Co., Inc.

3111 Old Lincoln Highway
Trevose, PA 19053-4996 USA

Tel: [phone]

Fax: [phone]

3d. The field labor and material charges incurred by an authorized GMP dealer or an end user to dis-

assemble, inspect, repair and reassemble our product or part at their respective prime locations will
not be reimbursed unless GMP has first reviewed and approved those charges.

3e. Incidental repair charges incurred by an authorized dealer or an end user for items such as labor,

transportation, tolls, lodging and meals at a location remote from its prime facility, or to demount our
product or part from its remote location and forward to its prime facility, are not the responsibility of
GMP, and are not covered by this Warranty.

3f. Incidental repair charges incurred by an authorized GMP dealer or end user to remove construc-

tion hardware, modify a vehicle or otherwise gain access to GMP's product or part, is a condition be­yond GMP's control, and is not covered by this Warranty.

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General Machine Products Co., Inc.

4a. GMP products or parts which become part of a total assembly which has been designated and/or

manufactured by others, are not covered by this Warranty unless GMP reviews the total assembly and
expressly extends its warranty.

4b. Design, material and workmanship furnished by others to install or operate a GMP product or part

are not covered by this Warranty with respect to GMP's products or parts which are used in that par­ticular assembly.

4c. Hydraulic, pneumatic, electrical or mechanical control equipment which is not manufactured by

GMP and which becomes a part of a GMP assembly, is not covered by this Warranty.

4d. This warranty does not cover a GMP product or part which others have subjected to abuse,

improper installation, improper operation, alteration or negligence in storage or handling.

5a. THE ABOVE WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL WARRANTIES OF

MERCHANTABILITY, FITNESS FOR PURPOSE OR OTHER WARRANTIES OR GUARANTEES OF
ANY KIND OR DESCRIPTION, EXPRESS OR IMPLIED.

5c. GMP'S SOLE LIABILITY AND THE PURCHASER'S SOLE REMEDY FOR A FAILURE OF A

PRODUCT OR PART UNDER THIS LIMITED WARRANTY, AND FOR ANY AND ALL CLAIMS
ARISING OUT OF THE PURCHASE AND USE OF THE PRODUCT OR PART SHALL BE LIMITED
TO THE REPAIR OR REPLACEMENT OF THE PRODUCT OR PART THAT DOES NOT CONFORM
TO THIS WARRANTY.

6. GMP reserves the right, without notice, to make changes in equipment design or components as

progress in engineering or manufacturing methods may warrant.

7. This Warranty shall be construed in accordance with the laws of the State of Pennsylvania, of The

United States of America.

8. This Limited Warranty may not be modified, in whole or in part, except by writing signed by an au-

thorized officer of GMP.

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General Machine Products Co., Inc.

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

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

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General Machine Products Co., Inc.