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General Machine Products Co., Inc.

TORNADO CABLE AND TUBE BLOWING MACHINE

OPERATION & MAINTENANCE

89000 – USA

CABLE BLOWING MACHINE

All rights reserved. No part of this publication may be copied, reproduced or transmitted in any form
whatsoever without the written permission of

General Machine Products Co., Inc

General Machine Products Co., Inc. • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • EMAIL: [email protected]

QC Final Inspection by:_________________________

Date:__________________

Unit Serial Number:__________________

Build Date:__________________

December 11, 2009 USA Ver 1

Содержание 89000 Tornado

Страница 1: ...on may be copied reproduced or transmitted in any form whatsoever without the written permission of General Machine Products Co Inc General Machine Products Co Inc 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 EMAIL info gmptools com QC Final Inspection by _________________________ Date __________________ Unit Serial Number __________________ Build Date __________...

Страница 2: ...tructions Updated A Sibun 03 07 2006 New photo with air inlet pipe added A Crawford 04 12 2006 Cable seal collets and plug selection chart updated A Miller 05 02 2007 Recommended spares list revised A Crawford 06 01 2008 Programming Instructions Updated A Sibun 07 03 2008 Programming Instructions Updated A Sibun 08 11 2009 US GMP Version 1 A Konschak ...

Страница 3: ...cedure for Replacement of Cable Seals 12 Procedure for Adjusting the Air Chamber and collet type cable infeed guide assembly height 13 Alignment of air chamber to the cable pusher unit 14 Monthly Service Check List 15 Service History Record 16 Troubleshooting Guide 17 Recommended Spare Parts APPENDICES Appendix 1 Layout of Cable Blowing Machine Appendix 2 Reserved Appendix 3 Cable Blowing Machine ...

Страница 4: ...g a close relation ship with Bell Telephone Laboratories in Murray Hill N J which enabled it to manufacture proto types 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 pre mier worldwide supplier of specialty to...

Страница 5: ...ulic services to carry out lubrication and servicing 6 Check machine before starting for worn or damaged parts Check that all nuts and bolts are tight 7 If machine is left unattended ensure 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 10 Beware of pinch points involved with rotating ...

Страница 6: ...e without the air chamber to push or pull cable 24 Do not place cable drum too close to the Cable Blowing Machine 25 Do not tamper with pressure relief valves or pressure reducing valves 26 The compressed air supply must not be allowed to enter the air chamber or sub duct be fore the top tractor drive frame has been closed and the cable inserted into the intake cable guide bracket assembly 27 Do n...

Страница 7: ...personal injury Always wear personal protective equipment 2 Ensure no personnel are in the manhole at the far end of the cable run Severe personal injury may result 3 Never open the air chamber when pressurized 4 Only authorized fully trained personnel should operate the air compressor GENERAL ELECTRICAL SAFETY INSTRUCTIONS The electronic control assembly and power supply are electrical devices El...

Страница 8: ...nd lubricant each time the blowing machine is used The cable must be hand guided into the blowing machine through a dry clean cloth by the operator wearing work gloves This will remove any dirt debris and water on the cable Ensure the compressed air supply is not applied to the cable until approximately 650 feet 200 meters of cable have been installed or the hydraulic pressure begins to rise The h...

Страница 9: ... products to ensure that the cable is protected during installation Due to the variety and differ ent methods of cable manufacture the responsibility of checking the cable compatibility with the equipment lies with the operator Therefore GMP and CBS Products cannot accept liability for any damage to the cable ...

Страница 10: ...ontrol system provides read out of speed and distance and automatic protection against duct obstruction The system comes mounted on sturdy height adjustable wheeled tubular steel trolley unit for ease of site maneuverability and is pow ered by a hydraulic supply system operating from a recommended supply of 2000 psi x 5 gpm 140 Bar x 20 liters min The cable blowing unit can be detached from the tr...

Страница 11: ... is detachable from the trolley for trench manhole location AIR BOX Manufactured from aluminum Range taking of cables from 6 32mm by means of interchangeable collets with double split cable sealing arrangements Sub duct sealing at mouth of box Sub duct gripping facility with non duct crush and distortion design All seals are one size cord seals except cable seals Upper section of air box is retain...

Страница 12: ...alve Setting 1595 psi 110 Bar 12 32 OD cables 1015 psi 70 Bar 6 12 OD cables Initial starting pressure 290 580 psi 20 40 Bar if greater the set up needs checking PNEUMATIC SYSTEM Air Hose Bore min 1 32 mm Operating Pressure 174 psi 12 Bar Flow The air supply should ideally be filtered cooled and de humidified For Ducts with an Inner Diameter of Minimum Flow Acceptable 150CFM 4m min 1 up to 1 1 8 i...

Страница 13: ... standard Viscous Drag Method Optional Missile System 12 Volts DC gel cell battery supplied 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 Rem...

Страница 14: ... cloth fit the cor rect size cable seal collet sub duct seal collets and sub duct clamp collets refer to sections 8 9 and ap pendices 7 8 for further details The collet with the horizontal O Ring grooves is fitted into the base of the air chamber and secured with a cap screw Refit the radial seal cords 3 Open the sub duct clamp and place the sub duct into the sub duct seal collet and sub duct clam...

Страница 15: ...e split of the outer most seal is also in the lower half of the air chamber slightly rotated from the vertical in the other direction to the innermost seal Both grooves face away from the tractor drive 6 Fit the upper cable guide collet ensure both seals are correctly located 7 Re fit the air chamber lid ensuring correct location on the dowels and tighten down the 4 retaining knobs 8 Check the air...

Страница 16: ...sor With the air compressor ready to provide air turn the air valve to the open position 11 Confirm that air is being expelled from the far end of the sub duct under pressure If not this indicates the run is too long there is leak an obstruction or the sub duct is crushed or otherwise damaged or disconnected This must be remedied before any cable blowing is undertaken when confirmation is received...

Страница 17: ...nsert a suitable foam plug into the sub duct and re fit the sub duct into the air chamber and secure with the sub duct clamp as already described The foam plug should be sized so as to be a snug fit in the sub duct By blowing this plug down the sub duct the lubricant will be evenly distributed along the length of the sub duct Before blowing the plug through the sub duct ensure the sub duct cable e...

Страница 18: ...ready to provide air turn the air valve to the open position 17 When the foam plug has been expelled from the end or the sub duct turn the air valve to the closed position and shut down the compressor Allow the air chamber and sub duct to exhaust all the com pressed air Note Never open the air chamber un til the air pressure gauge reads zero 18 Open the air chamber and remove the cable seal collet...

Страница 19: ...e should be taken when wheeling the trolley around not to catch the ad justable feet pads on curbs or boulders this may damage the pivoting foot 4 Position the cable drum some 20 to 25 ft 6 to 8 meters directly behind and in line with the cable blowing machine Cable carrying device to be suitably leveled and restrained 5 Ensure the battery is fully charged before commencement of installation The b...

Страница 20: ... changed refer to the section 4 SPECIFICATION for the correct pressure settings for the relief valve and pressure switch and to section 6 MAINTENANCE for the pressure setting pro cedures 9 Open the sub duct clamp on the pivot bolts select and fit the correct size cable seal sub duct seal and sub duct clamp collets for the cable and sub duct being used Refer to Tornado configu ration guide on page ...

Страница 21: ...le to be installed on the increment gauge Tighten the locking ring to prevent any movement during installation Refer to sec tion 11 for details 13 Ensure that the sub duct is fully prepared for use i e Fully connected Pressure tested Cable exit retaining device fitted Lubricated For further details on sub duct lubrication refer to Section 5 14 Open the collet retaining bracket on the pivot bolt ...

Страница 22: ...ange of cable collet being used to the outside diameter O D cable size to be installed in the same color band for each marker plate i e silver to i e silver for a 12 16mm cable collet range with a 16mm O D cable or blue to blue for a 16 20mm cable collet range with a 16mm O D cable When the correct setting is achieved hold the adjusting screw and turn the locking clock wise to lock in position and...

Страница 23: ... one hand this is the start point for the clamp force setting Continue to turn the handle a fur ther 1 full turn This will ensure the correct cable clamp force 20 Apply a smear of silicone grease to each seal and install the first cable seal into the groove nearest the tractor drive Ensure the split of the seal is in the lower half of the air chamber rotated slightly to one side of the vertical en...

Страница 24: ... seal Ensure the groove seal lip is away from the tractor drive facing the sub duct 22 Fit the upper cable guide collet in po sition ensuring both seals are located correctly 23 Re fit the air chamber lid ensuring cor rect location on the dowels and tighten down the 4 retaining knobs 24 The hydraulic control lever is in the OFF position 25 The speed control knob is in the MIN position fully rotate...

Страница 25: ...power source 28 Check the air valve is in the closed position and connect the air supply from the compressor if not already connected NOTE ENSURE THE AIR VALVE REMAINS IN THE CLOSED POSITION UNTIL REQUIRED 29 NOTIFY INSTALLATION TEAM Notify installation team that preparations are complete and cable blowing opera tions are ready to commence 30 Note Only authorized fully trained operators should be ...

Страница 26: ...e counter The display will indicate the speed and distance travelled by the cable To toggle between speed and distance press the SEL green button R displayed on the left side of the screen desig nates speed rate To reset the distance press RST red button Note It is possible to reset the distance to zero while installing even if speed is being displayed on the screen 34 Turn the speed control valve...

Страница 27: ...essed air to enter the air chamber This assists the installation of the cable through the duct 37 When the cable has reached its destination the worker stationed at the other end of the duct will notify the operator to stop the machine by turning the hydraulic valve to the off position 38 Turn the speed control knob to the MIN counter clockwise and press the reset button 39 Turn the air valve to t...

Страница 28: ...that the pressure switch has tripped stopping the power pack because A The cable has reached its destination and the cable exit retaining device has stopped the travel of the cable B The cable has become jammed has hit an obstruction in the duct or the cable blowing operation has reached its maximum capability C The power pack has developed a problem or has run out of fuel ...

Страница 29: ...utton Turn the hydraulic valve to the off position Turn the speed control knob to MIN position fully counter clockwise Press the on off button to turn the electric s off Turn off the air supply if required Correct the problem that caused it to stop IN THE EVENT OF AN EMERGENCY ...

Страница 30: ...s running 2 Turn the hydraulic valve to the on position 3 Press the power on off button 4 Turn the air valve to the open position assuming the required amount of cable in in the duct 5 Turn the speed control valve towards MAX until the required speed is achieved TO RESTART ...

Страница 31: ...adjustment screws Do not over tension the chain should slightly lift off the chain guides when pulled at the center by finger THE CHAIN SHOULD BE LUBRICATED EACH TIME USED by application of Metaflux spray grease 70 88 This is achieved by running the cable blowing machine at about 150 ft min 45m min without any cable or applied air and carefully inserting the spray tube from the can ister into the ...

Страница 32: ...t debris from the cable measuring wheel measuring disc and speed pick up probe Oil air chamber adjusting screw and cable infeed guide adjusting screw monthly Grease axles every month Check function of electrical panel each time SERVICE CONNECTIONS CHECK the condition of the hydraulic hoses each time they re used and replace if worn or damaged CHECK the condition of the emergency stop cable each ti...

Страница 33: ... rapidly heat the oil Try to keep the time in bypass to a minimum as the heated oil could change your readings 1 Connect and start the power pack With the electric control panel switched off turn hy draulic on off valve to the on position 2 Rotate the speed control knob fully clockwise to MAX and observe pressure gauge read ing of approximately 1600 psi 110 Bar 3 Adjust pressure relief valve see f...

Страница 34: ...the panel see fig 2 5 Start the power pack 6 Turn the hydraulic on off valve to on position 7 Turn the speed control knob towards max clockwise until the pressure gauge reads 870 psi 60 Bar 8 Turn the pressure switch adjusting screw slowly out until the power pack stops 9 Turn the speed control knob to minimum turned fully counter clockwise 10 After 5 seconds has elapsed restart the power pack and...

Страница 35: ...n of emergency stop lead Clean rod infeed guide bracket and collets Clean measuring wheel measuring disc and speed pick up probe Function of electronic panel Oil the frame pivot points Grease jacking screw thread Oil air chamber adjusting screw Oil Oilite bearings with light machine oil Grease mounting frame axles Clean and lubricate chain Clean and lubricate the chain support slide bars Check the...

Страница 36: ...tigate obstruction in duct If all else fails it may be necessary to remove the sub duct and remake the bad connection It is difficult to keep the cable moving near the end of a duct run Assist the Cable Blowing Machine by manu ally pushing the cable into the tractor drive DO NOT BEND OR CRIMP THE CABLE The cable is hard to re start having stopped Put air to the system with the cable clamped betwee...

Страница 37: ...89144 5mm Allen Key 1 89145 6mm Allen Key 1 31552 3mm dia O Ring Cord 1 89148 Silicone Grease Dow Corning 7 100gr Tube 1 89149 Sealing Cord Glue 1 89153 Metaflux 70 88 chain spray 1 89150 Pliers 6 1 87096 Screwdriver 6 slot 1 89152 Knife 1 89146 13 17mm open ended wrench 1 The toolbox is mounted on the underside of the Cable Blowing Machine Frame 32838 1 8 Allen Key 1 ...

Страница 38: ... using 6mm Allen Key Do not discon nect hydraulic hoses connected to the motor 2 Remove the stop washer on the bottom of the main jacking screw using a 6 mm Allen key 3 Unscrew the main clamping screw and separate the top and the bottom of the pusher unit Place in a safe location 4 On the lower unit slacken the 2 chain ad justers using a 13mm wrench 5 Remove the swing bolt from the side of unit us...

Страница 39: ...ain connecting link Remember to install the 2 center connecting link plates 12 Align the tension sprocket with the chain and locate into position Insert the tension pin through the tension sprocket Place the ten sion pin spacer on the tension pin through the opposite hole Refit swing bolts using a 13mm wrench Adjust the chain evenly via the swing bolts checking free rotation of the chain Do not ov...

Страница 40: ... the top and the bottom parts of the pusher unit Refit the main clamping screw Replace the stop washer on the bottom of the main jacking screw using a 6mm Allen key Replace the hydraulic motor using the 6mm Allen key Adjust top chain do not over tighten chain ...

Страница 41: ...collets refer to appendix 7 for collet information Clean the air chamber with a dry cloth Fit the appropriate collets and secure with a socket head cap screw using a 4mm Allen key The collet with horizontal O ring grooves is fitted into air chamber base Re new any worn or damaged radial cord seals and always renew both air chamber split cord seals Ensure there is sufficient cord to butt up to the ...

Страница 42: ...ad cap screws using a 4mm Allen key Close the sub duct clamp SUB DUCT SEAL COLLETS Tools Required 4mm Allen Key Step 1 Collet Removal Ensure that the air valve is closed and the air pressure gauge is at zero Open the air chamber to expose the collets Remove the socket head cap screw 2 using a 4mm Allen key Step 2 Collet Refitting Select the collets refer to Appendix 6 for collet information Clean ...

Страница 43: ...t the air valve is closed and that the air pressure gauge is at zero Open the air chamber to expose the cable seals Remove the seals Refit the required seals Apply silicone grease to the seal bore and groove ensure the seal groove is fitted away from the pusher unit i e towards the sub duct Ensure split in innermost seal faces downwards and offset to one side and the split in the outermost seal fa...

Страница 44: ...he increment gauge on the side of the unit Tighten the locking ring to prevent any movement during installation CABLE INFEED GUIDE ASSEMBLY To adjust the collet type cable infeed guide assembly bracket in either direction release the adjusting knob lock ing ring and turn the knob placed directly under the infeed guide bracket down for smaller OD cables and up for larger OD cables Select the adjust...

Страница 45: ...d infeed guide assembly height and the height of the air chamber Adjust the air chamber such that the top face of the lower housing is inline with the centre line of the rod 3 The lateral alignment of the air chamber needs to be checked adjusted The objective is to position the air chamber such that the center line of the rod is parallel with the center line of the air chamber adjustment is made b...

Страница 46: ...sprockets etc and lubricate 5 Check main jacking screw and lubricate 6 Check all hydraulic fittings and check for leaks 7 Check the hydraulic hoses for external damage 8 Check the electrical lead for external damage 9 Check the electrical plug and sockets 10 Check the function of the electronic control module 11 Check the operation of the emergency stop button 12 Check condition of cable seals and...

Страница 47: ...Page 47 of 64 General Machine Products Co Inc Service no Date Carried out by Record of service repair 15 SERVICE HISTORY RECORD ...

Страница 48: ...ve lubrication of chains on to pads causing belt slip RUNS AT HIGHER THEN EXPECTED PRESSURE Chains too tight excessive clamping force Poor lubrication Seized chain links Over tightening of jacking screw Misalignment of air chamber slider Cable drum not rotating freely Misalignment of entry guide Poor duct installation friction Insufficient out put from compressor Incorrect seal collet fitted Dirt ...

Страница 49: ...ord seal Cable seals worn incorrect size wrong way round misalignment of air chamber bracket in relation to cable diameter Incorrect collets COUNTER NOT READING OR GIVING INCORRECT READINGS Battery low on power Counter program has been changed clear program and re program as described on page 60 ...

Страница 50: ...plex Black red 2 89158 Motor 32 cc rev 2 31552 Seal Cord Cut to length as required 30 ft 89148 Silicon Grease 1 Tube 89149 Sealing Cord Glue 1 Tube 89156 Wheel Ref 260 Pneumatic 2 89151 Wheel Ref PBW280 2 Solid 2 31727 Chain Support Slide Bar 2 89153 F Metaflux chain spray 70 88 1 32512 Battery 12 VDC lead acid battery 1 ...

Страница 51: ... Point 6 Hydraulic Control Panel 7 Electronic Control Panel 8 Air Open Close Valve 9 Air Hose Connection 10 Hydraulic Hose Connection at rear of unit 11 Emergency stop socket on side of unit 12 Frame Leveling Foot 13 Tool Box 14 Mounting Frame 15 Tractor Drive Movement Indicator 16 12 Volt Battery Access door under unit Appendix 1 14 9 6 13 8 3 2 15 1 5 10 7 11 4 12 16 ...

Страница 52: ...Page 52 of 64 General Machine Products Co Inc Appendix 2 ...

Страница 53: ...ack Compressed Air Hose Connected to Cable Blowing Machine Hydraulic Hose Connections Power Pack to Cable Blowing Machine Cable Blowing Machine Emergency Stop Cable Power Pack to Cable Blowing Machine Fiber Optic Cable Cable Drum Sub Duct CABLE BLOWING MACHINE SERVICE CONNECTIONS ...

Страница 54: ...draulic Pressure Gauge 3 Speed Control Knob 4 Hydraulic On Off Lever 5 Power On Off Button 6 Emergency Stop Button 7 Length Speed Digital Display 8 Hydraulic Control Panel 9 Electronic Control Panel HYDRAULIC AND ELECTRONIC CONTROL PANEL LAYOUT 2 8 5 9 6 7 4 3 1 Appendix 4 ...

Страница 55: ... at additional charge 89021 DUCT CLAMP 1 89041 DUCT CLAMP 1 25 89061 DUCT CLAMP 1 50 89071 DUCT CLAMP 2 Loc A DUCT CLAMPS 1 00 2 00 I D Loc C D CABLE COLLETS 6 28 MM GUIDES 6 12 MM 89081 6 9 MM 23 35 1 Collet REQ exit side Collet guide used together for this size cable 89082 6 9 MM 23 35 1 Guide REQ in feed side 89083 9 12 MM 35 47 1 Collet REQ exit side Collet guide used together for this size ca...

Страница 56: ...Page 56 of 64 General Machine Products Co Inc Notes ...

Страница 57: ...s and Hold SEL for 2 seconds Pro no should now be flashing press RST Press RST to move through the various sections 1 input 2 rate 3 display sections 4 and 5 will be unavailable see the next page of instructions for the parameters required Press SEL to enter that section To change the value of a parameter press RST Press SEL to move to the next parameter You will have to hold for 2 seconds on cert...

Страница 58: ...A SCF 0 01 Metric m or 0 0328 Imperial ft once correct press Hold SEL CNT A RST TO ZERO if correct press SEL CNT A DIR NOR if correct press SEL CNT B LD 0 once correct press Hold SEL CNT B BAT NO if correct press SEL RST P UP NO if correct press SEL USER INP NO if correct press SEL Press RST Twice Rate Parameters 2 RATE RATE ENB YES if correct press SEL RATE DP 0 if correct press SEL RATE DSP 60 o...

Страница 59: ...Page 59 of 64 General Machine Products Co Inc CUB5 PROGRAMMING QUICK OVERVIEW ...

Страница 60: ...o 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...

Страница 61: ...n improper operation alteration or negligence in storage or handling 5a THE ABOVE WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL WARRANTIES OF MER CHANTABILITY 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 ...

Страница 62: ...Page 62 of 64 General Machine Products Co Inc GMP 3111 Old Lincoln Hwy Trevose PA 19053 USA TEL 1 215 357 5500 FAX 1 215 357 6216 EMAIL info gmptools com ...

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