GMP 89004 Troubleshooting guide
Page 1 of 36 General Machine Products (KT), LLC
89004 – USA
POWERED DUCT ROD PUSHER
Copyright 2017 by General Machine (KT), LLC
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 (KT), LLC
POWERED DUCT ROD PUSHER
OPERATION & MAINTENANCE
GMP • 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:__________________
July 12 2017 USA Ver 3a
Manual P/N 32297
Page 2 of 36 General Machine Products (KT), LLC
Rev # Date Details Author
01 07.27.05 Original issue A. Sibun
02 10.16.08 US Version 1 A. Konschak
REVISION HISTORY
03 05.26.09 US Version 2 A. Konschak
04 08.29.09 US Version 3 A. Konschak
05 07.12.17 US Version 3a - Changed Company Name A. Konschak
GMP product warranty can be found at http://www.gmptools.com/warranty/
Page 3 of 36 General Machine Products (KT), LLC
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 Counter programming parameters
Warranty
Page 4 of 36 General Machine Products (KT), LLC
Founded by engineer George M. Pfundt in 1936, GMP started op-
erations in a downtown Philadelphia building as a specialty ma-
chine 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 Compa-
ny and, subsequently, forming
a close relationship with Bell Telephone Laborato-
ries in Murray Hill, N.J., which enabled it to manu-
facture 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 Tre-
vose, PA (a Philadelphia suburb) and moved there
in 1957. Today GMP is recognized as a premier
worldwide supplier of specialty tools and equip-
ment for the outside plant marketplace. The company's products are known for their
robust design and durability to withstand many years of frequent use.
INTRODUCTION
Page 5 of 36 General Machine Products (KT), LLC
1. SAFETY INSTRUCTIONS
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.
This Equipment should be used only by personnel who have been given the appropri-
ate 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
Page 6 of 36 General Machine Products (KT), LLC
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.
Page 7 of 36 General Machine Products (KT), LLC
GENERAL HYDRAULICS SAFETY INSTRUCTIONS
Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Ob-
serve 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.
Page 8 of 36 General Machine Products (KT), LLC
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/in-
feed 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.
2. CRITICAL POINTS THAT DRAMATICALLY AFFECT THE
OPERATION OF THE ROD PUSHING MACHINE
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.
Page 9 of 36 General Machine Products (KT), LLC
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 protec-
tion 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 man-
hole (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.
Page 10 of 36 General Machine Products (KT), LLC
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 calibraon
▪ Length counter tracking in feet or meters through a separate calibraon
▪ 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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