Transcript
10,000 lb. Cable Puller
Service/Repair Manual
CP10K
User must read and understand all the instructions and safety information in this manual before repairing or operating the machine.
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Safety Symbol Definitions . . . . . . . . . . . . . . . . . Warning Labels on Product. . . . . . . . . . . . . . . . Key Safety Information . . . . . . . . . . . . . . . . . . . . Electrical Safety Information. . . . . . . . . . . . . . . . Safe Pulling Guidelines. . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . .
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7.0 8.0 9.0 10.0 11.0
Motor, Guage & Wiring Troubleshooting Guide . . . . . . . . . . . . . . . . . . 4–5 Hydraulics Troubleshooting Guide. . . . . . . . . . . 6 Index Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Capstan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
www.gardnerbender.com PO Box 3241 Milwaukee, WI 53201-3241 | 414.352.4160 | fax 414.352.2377 6615 Ordan Drive | Mississauga, Ontario L5T 1x2 | 905.564.5749 | fax 905.564.0305 IS-001 | September 2009
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1.0 SAFETY SYMBOL DEFINITIONS The instruction manual and labels applied to the product provide information for avoiding injury or death from unsafe practices related to setting up and operating this machine. It is critical that all personnel involved with the use of this machine understand these hazards and unsafe practices. The three levels (Danger, Warning, and Caution) define the severity of the hazard. DANGER: Immediate hazards that if not avoided WILL result in severe injury or death. WARNING: Serious injury or death COULD occur if proper attention is not observed. CAUTION: Injury or property damage MAY occur if proper attention is not observed.
2.0 WARNING LABELS ON PRODUCT The product has safety related labels securely adhered to it in several locations. They serve to highlight the areas of this machine that have the potential to cause injury if the operator does not use caution. The labels include internationally recognized symbols that are described below. ! Read and understand the instruction sheet before setting up or operating this machine.
! !
Body parts are in danger of being crushed by moving or moveable parts.
!
Body parts are in danger of being entangled in rope. Read instruction sheet before operation.
3.0 KEY SAFETY INFORMATION
1. Do not use the cable puller for any other purpose or application beyond its intended use. It is intended for pulling wire or cable through fixed conduit, with the conduit adaptor engaged in the conduit and fastened to the cable puller. 2. Do not operate the cable puller in poorly lit areas. 3. Do not exceed the maximum rated 10,000 lbs. pulling force. 4. Inspect all cable puller components prior to operation. 5. Keep the pull rope away from the operator’s feet. Gather the tailing rope in an area where the operator or crew cannot become entangled. 6. Never stand directly under a vertical pull or directly in line with pull rope under tension. 7. Never use general purpose rope; always use double braided polyester rope and inspect the rope for damage after each pull. Do not use damaged rope for pulling cable. 8. Do not allow the rope coils to overlap on the Capstan. 9. Keep bystanders away from operations. Distractions increase chances of injury. 10. Do not use the cable puller while under the influence of drugs, alcohol or medication. 11. Do not operate near water or other liquids.
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12. D o not wear jewelry or loose-fitting clothes. Long hair, clothing, body parts and gloves should be clear of moving parts. 13. A lways use all personal safety equipment, including eye protection and a hard hat. 14. Do not wrap rope around legs, arms or torso of body. 15. D o not plug Power Cord directly into power source. Power Cord must be plugged into the Footswitch.
4.0 CP10K SERVICE INSTRUCTIONS Service Instructions IS-164 These Service instructions are intended to be used by a qualified personal at Authorized Gardner Bender Service Centers. Users of Gardner Bender equipment should see the CP10K instruction sheet for installation, operation and maintenance information.
5.0 REQUIRED TOOLS AND TEST EQUIPMENT • 3/8"–1-1/4", 1/2" Drive Socket Set • 1-1/16" Box-end Wrench • 11/16" Box-end Wrench • 7/16" Box-end Wrench • 10" Adjustable Wrench • C-Keeper Wrenches – A-230 – A-210 – A-200 • SAE Allen Wrench Set • 3/8" Socket Allen Wrench • 3/16" Flat Head Screwdriver • #2 Phillips Screwdriver • 3/8" Socket Allen Wrench Optional • Insulated Crimp Tool • Wire Stripper-Cutter
6.0 PARTS IDENTIFICATION 12. Pulley-B Housing 13. P ulley-B Housing Lock Pin 14. Pull Orientation Pivot 15. Pull Orientation Pin 16. Conduit Adaptors 17. Power Cord 18. Footswitch 19. P ull Meter & Switch Box 20. Capstan 21. Motor 22. Pin Clips
1. Steering Handles 2. Caster Wheels & Brakes 3. Hydraulic Pump 4. Main Boom 5. Boom-A 6. Boom-B 7. Boom-A Lock Pin 8. Pulley-A Housing 9. Boom-B Lock Pin 10. Boom-B Extension 11. Boom-B Extension Lock Pin
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9
14
6 13
5
10
15 11
4 7 12 20 21
22 19
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18
16 2
3
7.0 MOTOR, GUAGE & WIRING TROUBLESHOOTING GUIDE
Electrical Capstan will not rotate. • No AC power to the puller. – Check the meter box switch is in the “ON” position. – Check power supply cord for breaks or scarring. – Verify supply voltage at the receptacle is 120 VAC. – Check voltage at receptacle end of footswitch is 12 VAC when footswitch is pressed. If voltage at foot switch is 120 VC proceed to next step. No DC power (If AC power is ok). • Unplug puller. • Pump main boom to 30 degrees. • Remove on motor end cap (carefully note wire configuration of rectifier). • Remove wires from rectifier, replace rectifier. See end cap drawing page 6.
SPST On/Off Switch
(note orientation)
Electrical Terminals
(note orientation)
Load Meter
Ground Screw
Electric Motor WARNING: Unplug puller power cord prior to removing motor or wiring. Ground Wire
(Can be connected to either point)
DC to Motor
Flag Connectors
120 VAC Supply Wires Bridge Rectifier
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Note Direction of Connectors
7.0 MOTOR, GUAGE & WIRING TROUBLESHOOTING GUIDE
Complete Wiring Schematic
METER BOX GROUND SCREW GREEN
LOAD METER
GREEN
PULLER MOTOR
RECTIFIER BLACK
BLACK
FOOT SWITCH
BLACK
ON/OFF SWITCH
WHITE
RED
GREEN
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8.0 HYDRAULICS
CP-10-114 Cylinder Kit RC53K1 Cylinder Seal Kit P392ALK Pump Seal Kit
CP10-116
CP10-115 DA6301900
Part Number
Description
Part Number
Description
CP10-114
Cylinder Kit
P392ALK
Pump Seal Kit
CP10-115
Hydraulic Hand Pump
RC53K1
Cylinder Seal Kit
CP10-116
Hydraulic Hose
Disassembly Instructions • Turn release valve on hand pump counter clock wise to release pressure. • Using 11/16" wrench remove hydraulic hose from hand pump Use caution! Hydraulic fluid will leak. • Remove other end of hose from cylinder (To be explained in assembly instructions). • Using Allen wrench remove (3) Machine screws from pump mounting base. • Remove Pump. Assembly Instructions 1. Place pump on mounting plate. 2. Install (3) Allen bolts. 3. Check fluid level see pump instructions. 4. Turn release valve clockwise to close. 5. Attach hydraulic hose to hand pump. 6. Place free end of hose into clean container. CAUTION: Hydraulic fluid may be under pressure! 7. Pump hand pump 3–4 times. 8. Check fluid level. 9. Repeat steps 6 to 8 until fluid is free of air. 10. Attach free end of hose to cylinder. 11. Loosen bleeder valve and repeat steps 7 and 8 fluid is free of air. CAUTION: Hydraulic fluid may be under pressure! 12. Check all fittings are secure. See enclosed maintance, assembly, and troubleshooting literature.
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9.0 INDEX PIN
Part Number
Description
CP10-144
Boom B Lock Pin Assembly (sold as complete assembly only)
Explanation of how to remove pin: 1. Remove 3 Allen head capscrews. 2. Using C Keepber tool, remove center “C” keeper using tool A-230. CAUTION: Spring may be under pressure.
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10.0 CAPSTAN
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Part Number
Description
CP10-130
Capstan
11.0 FIGURES
FIGURE 1
1
2 2
3 3
Item
Part Number
Description
1
CP10-100
Cart Weldment
2
CP10-106
Wheel Set
3
CP10-107
Castor Set
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11.0 FIGURES
FIGURE 2 Item 2
3
3
Part Number
Description
1
CP10-200
Main Boom Assembly
2
CP10-127
Boom A Lock Pin
3
CP10-124
Main Boom Upper Pins
4
CP-10-122
Main Boom Bottom Pins
1
4
4
FIGURE 3
2
1
Item
Part Number
Description
1
CP10-101
Lifting Linkage Kit
2
CP10-127
Clevis Spacer
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11.0 FIGURES FIGURE 4
1&
4
3
2
1&
4
5
4
Item
Part Number
Description
1
CP10-130
Capstan
2
CP10-128
Motor Mount Plate
3
CP10-186
Meter and Switch Box
Item
Part Number
Description
4
CP10-129
Motor and Capstan
5
CP15
Foot Switch
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11.0 FIGURES FIGURE 5
2
1 Part Number
Description
1
Item
CP10-400
Boom A Assembly
2
CP10-189
Pull Orientation Pin
FIGURE 6
1
3
2
Part Number
Description
1
Item
CP10-600
Boom B Assembly
2
CP10-138
Boom B Extension Pin
3
CP10-215
Boom B Extension
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11.0 FIGURES FIGURE 7 3
Item
Part Number
Description
1
CP10-700
Pulley B Assembly
2
CP10-216
CP10K Pulley B Roller
3
CP10-203
Pulley B Pin
1
2
FIGURE 8 5 4 3 2
Part Number
Description
1
Item
CP10-188
Conduit Adapter 4"
2
CP10-217
Conduit Adapter 3.5"
3
CP10-217
Conduit Adapter 3"
4
CP10-219
Conduit Adapter 2.5"
5
CP10-220
Conduit Adapter 2"
1
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NOTES
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NOTES
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REPAIR AND SERVICE INSTRUCTIONS: For repair service and parts contact your nearest Gardner Bender Service Center or refer to enclosed service manuals. The Gardner Bender Service Center will provide complete and prompt service on all Gardner Bender products.
PARTS AND SERVICE: For quality workmanship and genuine Gardner Bender parts, select an Authorized GB Service Center for your repair needs. Only repairs performed by an Authorized Service Center displaying the official GB Authorized sign are backed with full factory warranty. Contact Gardner Bender (414)352-4160 for the name of the nearest GB Authorized Service Center. WARRANTY: Gardner Bender warrants its product against defects in workmanship and materials for 1 year from date of delivery to user. Warranty does not cover ordinary wear and tear, abuse, misuse, overloading, altered products or use of improper fluid. WARRANTY RETURN PROCEDURE: When question of warranty claim arises, send the unit to the nearest GB Authorized Service Center for inspection, transportation prepaid. Furnish evidence of purchase date. If the claim comes under the terms of our warranty the Authorized Service Center will REPAIR OR REPLACE PARTS AFFECTED and return the unit prepaid.
IMPORTANT: RECEIVING INSTRUCTIONS Visually inspect all components for shipping damage. If you find damage, notify the carrier at once. Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replacement costs resulting from damage in shipment.
www.gardnerbender.com 16
PO Box 3241 Milwaukee, WI 53201-3241 | 414.352.4160 | fax 414.352.2377 6615 Ordan Drive | Mississauga, Ontario L5T 1x2 | 905.564.5749 | fax 905.564.0305 IS-001 | September 2009
