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Page 1 

 

General Machine Products (KT), LLC

 

Operation and Maintenance

 

Model 89950

 

All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form whatso-

ever without the written permission of General Machine Products (KT), LLC

 

 

General Machine Products (KT), LLC 

• 3111 

Old Lincoln Hwy 

• 

Trevose, PA 19053 

• 

USA

 

TEL: +1

-

215

-

357

-

5500 

• 

FAX: +1

-

215

-

357

-

6216 

• 

WEB: www.gmptools.com

 

CABLE BLOWING MACHINE

 

Manual P/N 33829 Ver 5b

 

050319 AKK

 

Summary of Contents for Jetstream 89950

Page 1: ...ion may be copied reproduced or transmitted in any form whatso ever without the written permission of General Machine Products KT LLC General Machine Products KT LLC 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 WEB www gmptools com CABLE BLOWING MACHINE Manual P N 33829 Ver 5b 050319 AKK ...

Page 2: ...Updated photo to show current air connection Updated toolkit A Konschak 04b January 23 2017 Toolkit number correction A Konschak 04c April 20 2017 Updated specifications on P8 A Konschak 05 April 25 2017 Relief valve settings updated Location of pressure switch adjustment updated Procedure to set the pressure relief valve added A Konschak 05a July 17 2017 Change company name A Konschak 05b May 03 ...

Page 3: ...cing the air box housing seal 11 0 Procedure for changing the cable drive belts 12 0 Procedure for tensioning the drive belts 13 0 Procedure for checking and replacing the motor drive belt 14 0 Procedure to set the Pressure Switch 15 0 Procedure to set the Pressure Relief Valve 16 0 Monthly Service check list 17 0 Service History Record 18 0 Duct integrity and Lubrication 19 0 Troubleshooting 20 0...

Page 4: ...hen lifting care must be taken ensure sufficient man power lifting gear is available to prevent personal injury and damage to the machine 14 Prior to installation ensure the duct route is connected properly 15 Beware of exposed electrical contacts Do not touch or allow metal objects to come into contact 16 Waste hydraulic oils are to be disposed of via an environmentally acceptable method e g pass...

Page 5: ...fore operating the machine Check for leaks with a piece of cardboard Do not use your hands Do not exceed working pressure of hydraulic hoses Visually inspect hoses regularly and replace if damaged GENERAL PNEUMATIC SAFETY INSTRUCTIONS The GMP Jetstream Cable Blowing Machine is a pneumatic device using pressurised air to project cable at high velocities Please observe the following precautions when...

Page 6: ...OM DEBRIS SLUDGE DIRT WATER AND LUBRICANT THE CABLE MUST BE HAND GUIDED INTO THE BLOWING MACHINE THROUGH A DRY CLEAN CLOTH BY THE OPERATOR WEARING WORK GLOVES ENSURE THE COMPRESSED AIR SUPPLY IS NOT APPLIED TO THE CABLE UNTIL APPROXIMATELY 300 100 METERS OF CABLE HAVE BEEN INSTALLED OR THE HYDRAULIC PRESSURE BEGINS TO RISE THE HYDRAULIC PRESSURE SHOULD BE BETWEEN 290 435 PSI 20 30 BAR AT THE START...

Page 7: ...speed and distance and automatic protection against duct obstruction The belts are covered with a compliant coating to help prevent damage to the cable The belts offer a large surface area in contact with the cable ensuring high grip with reduced compressive loading During installation the torque applied to the cable by the belts adjusts automatically up to a pre set maximum value after which the ...

Page 8: ...imum operating pressure 1015 psi 70 Bar Recommended flow 4 gal min US 15 l min Pressure switch setting 12 20mm OD Cable 1015 psi 70 Bar 4 12mm OD Cable 725 psi 50 Bar 12 20mm OD Cable 1160 psi 80 Bar Relief Valve setting 4 12mm OD Cable 870 psi 60 Bar Initial starting pressure if greater the set up needs checking 290 435 psi 20 30 Bar HYDRAULIC DRIVE SYSTEM 4 0 SPECIFICATION Power requirement 18 V...

Page 9: ...sketch below this shows a plan view of the recommended set up Ensure the machine is secure either on its own stand or a separate suitable stand Ensure the machine is fitted with the appropriate guides and collets to suit the cable being installed and ducts into which the cable is to be installed See Appendix 1 for details of interchangeable parts and sections 7 8 9 for procedures on how to fit the...

Page 10: ...ar in size to the duct into which the cable is to be installed be fitted in the duct clamp This length of duct may then be connected to the installed duct the length of duct underground into which the cable is to be installed using a suitable connector For duct sizes Ø12 22mm slide a suitable size O ring over the end of the duct Fit the duct into the end of the air box housing so that it protrudes...

Page 11: ...djustment wheel fully counter clockwise to fully open the drive belts Select the appropriate split cable seal see appendix 1 and position it in the groove in the cable collet Turn to hydraulic control valve to the ON position Slowly turn the speed control knob clockwise until the belts are just moving Replace top half of the cable collet Take the cable to be installed and pass it through the cable...

Page 12: ...remove the top half of the cable seal collet Ensure the correct collets are fitted see appendix 1 and sec tion 8 Select the appropriate split cable seal see appendix 1 and posi tion it around the cable Take the cable and simultane ously place it into the duct and into the air box Thread it be tween the belts Ensure the ca ble seal seats in the appropriate groove in the cable seal collet Replace th...

Page 13: ...e cable has been positioned in the machine the belts must be closed on the cable in order to drive the cable The closed belts will also stop the cable being dragged back out of the machine by any tension in the cable Turn the adjustment wheel clockwise until the belts close onto the cable The amount of pressure applied to the cable can be adjusted by turning the adjustment wheel either clockwise o...

Page 14: ...o the duct at the other side of the manhole The machine should be aligned with both the incoming cable and the outgoing duct path both side to side and up and down NOTE THE MACHINE MUST NOT BE SUBMERGED IN WATER If the hole is full of water it must be pumped out before placing the machine on the bottom of the hole Connect the hydraulic supply to the machine Note Please refer to Section 4 0 Specifi...

Page 15: ...ion bypasses the oil and stops the motor moving the lever to the ON position allows flow to the motor Emergency stop In the event that an emergency situation occurs and the machine needs to be stopped and prevented from restarting this button will ground the spark plug on the engine powering the hydraulic power pack The power pack can only be restarted once the emergency stop has been reset by twi...

Page 16: ...l see this as an increase in torque demand and increase the drive system pressure Assuming the pressure switch has been set at an appropriate level the hydraulic power pack will cut out and the belts will stop turning before they push the cable so hard as to cause it to buckle If due to lack of previous knowledge of the cable characteristics the pressure switch has been set at a figure which is to...

Page 17: ... by the roadside Please Note Due to their intended use cord seals cable seals duct clamps drive belts and cable drive belts are considered consumable items and are therefore not covered by the limited warranty It is convenient to consider each function of the machine in turn As a general rule every time an interchangeable part is removed and replaced by a part of a different size shape etc the par...

Page 18: ... The machine should be wiped clean after each time used ALWAYS ensure that there are sufficient cable seals cord seal and cord adhesive available in the toolbox to cover the next installation ALWAYS ensure that the service battery and spare battery are have sufficient charge before the cable blowing machine is to be used SERVICE CONNECTIONS CHECK the condition of the hydraulic hoses each time used...

Page 19: ...ther housing half To fit the new duct clamp reverse the disassembly procedure For cable collets loosen the screw in the upper insert Remove the upper insert from the lower insert Now loosen and remove the screw in the lower cable seal insert Do not lose this screw it will be needed for the replacement insert Re move the lower cable collet For duct seals loosen and remove the screw Do not lose this...

Page 20: ... 9 0 Procedure for changing cable guide inserts in infeed Loosen and remove the screws securing the up per guide housing Loosen and remove the screw securing the ca ble guide insert into the housing Remove and replace the cable guide insert ...

Page 21: ...seal and the duct seal Take care to make the cut accurately in line with the end of the groove the cable seal and duct seal need to make an effective seal against the ends of the housing seal Place the pre cut length in the groove with some of the excess length overhanging each end of the groove Repeat the procedure for the lower seal groove and the collet seal grooves in the air box lower and lid...

Page 22: ...e plate This should then provide enough slack at the drive pulley side to remove the belt Remove the 6 screws retaining the belt guards and remove the guards Tension Screws Always remove the belt from the drive pulley side first Replace the drive belt by reversing the disassembly procedure NOTE NEVER POWER THE MACHINE UP OR RUN WITH THE GUARDS REMOVED DOING SO MAY RESULT IN INJURY TO THE OPERATOR ...

Page 23: ...ate tension is reached tighten the tension nut Check the belt tension this should be approximately 1 4 of slack if necessary loosen the tension nut and re adjust the tension screws until the correct tension is achieved check that the tension nut is tight upon completion Note The belt tension should be checked periodically Replace the drive belt guards and the 6 retaining screws NOTE NEVER POWER TH...

Page 24: ...Page 24 General Machine Products KT LLC 13 0 Procedure for checking and replacing the motor drive belt Loosen 6 screws indicated to permit access ...

Page 25: ...n the speed control knob towards max clockwise until the pressure gauge reads the required pressure switch setting Turn the pressure switch adjusting screw slowly out until the power pack stops Turn the speed control knob to minimum turned fully counter clockwise After 5 seconds has elapsed restart the power pack and turn the speed control knob slowly towards max observe at what pressure the power...

Page 26: ... Loosen the lock nut on pressure relief valve by using a 1 2 open ended wrench in the slot at back of the base see below 15 0 Procedure to set the Pressure Relief Valve Using a 5 32 long series hex key adjust the pressure as required Turn screw counterclockwise to re duce the pressure and clockwise to increase the pressure Tighten pressure relief valve lock nut via the slot in the back of the mach...

Page 27: ... and repair jobs are completed can be entered into the spaces provided in this table This will give the user a record of what service has been carried out and when 1 Check the tool box ensure all tools and interchangeable parts are present clean and ready for use 2 Remove the clear belt guards clean the outside of the machine and replace 3 Ensure the slide mechanism operates smoothly lubricate if ...

Page 28: ...Page 28 General Machine Products KT LLC Service no Date Carried out by Record of service repair 17 0 SERVICE HISTORY RECORD ...

Page 29: ...way to complete these checks is to set the machine up for a normal cable insertion but fit a seal plug in place of the cable The duct can then be pressurised without running the belt drive CAUTION ANY OBJECT INADVERTENTLY LEFT IN THE DUCT DURING THE DUCT LAYING MAY BE EXPELLED FROM THE END OF THE DUCT WITH HIGH FORCE AND VELOCITY IT IS IMPERATIVE THAT NO PERSONNEL BE IN THE VICINITY OF THE END OF ...

Page 30: ...een confirmed by the method outlined above the duct may be lubricated Open the air box and duct clamp assembly withdraw the duct and raise it so that the lubricant will pour into it easily and not overflow from the top Pour lubricant of recommended quality and quantity down the duct Insert a suitable foam plug into the duct and put the duct back into the air box and duct clamp Tighten the thumbnut...

Page 31: ...ficient out put from compressor See recommendations for duct diameter on page 8 Incorrect seal collet fitted Dirt debris in belt drive PROVISIONAL BELT ROTATION TEST With Hydraulic power pack running and without cable revolve the Drive Belts and monitor the minimum hydraulic pressure required This should be around 220 360 psi 15 25 Bar as a benchmark CABLE BLOWING MACHINE STOPS SUDDENLY DURING CAB...

Page 32: ...attery compartment at the rear of the hydraulic control panel 21 0 Toolkit Contents 22 0 Spares Cable Drive Belt 33772 2 req Motor Drive Belt 33770 Install 9 volt lithium batteries for longest service life 33958 89588 32411 30069 89150 89148 34075 33816 34757 89146 33812 33813 33814 32617 34444 36292 ...

Page 33: ... matches your cable s size 6 Select one 1 Cable Seal Plug locator F that matches your cable size Loc A DUCT CLAMPS O D Controlled Metric Imperial P N Size SDR P N Size 89960 3 4 89964 12mm 89961 1 89959 12 7mm 89962 1 25 89965 16mm 89963 1 50 89966 18mm 89958 22mm 89967 25mm 89968 32mm 89969 40mm 89970 50mm D APPENDIX 1 Loc F CABLE SEAL PLUGS 6 28mm 89125 6 7 5mm 23 29 89126 7 5 9mm 29 35 89127 9 ...

Page 34: ...d Press Enter value 00 0200 for meters 00 0656 for feet Use to move to next digit Use to increment digit this instruction applies to all following number inputs Hold and press diV Cnt is displayed Press Enter value 01 0000 Hold and press dP Cnt is displayed Press until 0 is displayed Hold and press rES Cnt is displayed Press until MAnrE is displayed Hold and press FAc tAc is displayed Press Enter ...

Page 35: ...oducts KT LLC Press Enter value 01 0 Hold and press EndPro is displayed Press until YES is displayed Hold and press Programming completed OR Press until no is displayed Hold and press Programming mode restarted APPENDIX 2 con t ...

Page 36: ...Page 36 General Machine Products KT LLC General Machine Products KT LLC 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 Web www gmptools com ...

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