GMP PULLDOG 70625 Operation And Maintenance

Model 70625 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 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 PULLDOG Overhead Line Winch Trailer 5/16/2018 Ver 2 USA AK 36202

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com Rev.no Date Details Author 1 9/21/15 First U.S. Version A Konschak 2 07/18/17 Changed company name A Konschak CONTENTS 1. Introduction 2. Safety Instructions 3. General Description 4. Specification 5. Operating Procedures 6. Maintenance 7. Towing Instructions 8. Equipment Layout GMP Limited Warranty can be found at http://www.gmptools.com/warranty/ QC Final Inspection by:_________________________ Date:__________________ Unit Serial Number:__________________ Build Date:__________________

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com Founded by engineer George M. Pfundt in 1936, GMP started operations in a downtown Philadelphia building as a specialty machine 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 Company and, subsequently, form- ing a close relationship with Bell Telephone Laboratories in Murray Hill, N.J., which enabled it to manufacture 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 Trevose, PA (a Phila- delphia suburb) and moved there in 1957. Today GMP is recognized as a premier worldwide supplier of specialty tools and equipment for the outside plant marketplace. The company's products are known for their robust design and durability to withstand many years of frequent use. 1.0 INTRODUCTION

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 2.0 SAFETY INSTRUCTIONS THIS EQUIPMENT MUST ONLY BE USED BY AUTHORIZED PERSONNEL, WHO HAVE BEEN SUITABLY TRAINED AND COMPETENT TO DO SO. 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. 5. Always stop the machine to carry out lubrication or 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 components, e.g. rope/cable drums, capstans, bull wheels, shafts and chain drives. 11. Beware of hot surfaces, especially around the engine, engine exhaust pipe and hy- draulic oil tank. 12.Some component and assembly parts are in excess of 55 lbs. (25kg) . When lifting care must be taken, ensure sufficient man power/lifting gear is available, to pre- vent personal injury and damage to the machine. 13.Beware of exposed electrical contacts especially around the engine. Do not touch, or allow metal objects to come into contact. 14. Waste engine and hydraulic oils are to be disposed of via an environmental- ly acceptable method – e.g. passed on for recycling. 15. Wear ear protection when engine is running to prevent ear damage. 16. Machine may cause additional fire hazard if involved in an existing fire due to gaso- line, diesel, oil and hydraulic oils involved. 17. No personnel are to be in manholes or ducts when the winch is being operated. 18. The machine must be operated on firm ground. 19. Stay clear of cables or lines under tension. 20. Only use the machine for its intended purpose. 21. Do not tamper with pressure relief valves or pressure reducing valves. 22. Rear stabilizing props must be down and on solid surface before use. 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.

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 3.0 GENERAL DESCRIPTION 4.0 SPECIFICATION Max. Pulling Capacity (Bare Drum) 1100 lbs. (500kg) Max. Pulling Capacity (Full Drum) 400 lbs. (181kg) Rope Speed Max. (Bare Drum) 170 ft./min (52m/min) Rope Speed Max. (Full Drum) 470 ft./min (143m/min) Take-up Drum Capacity 2000 ft. X 5/16” rope 610m X 8mm rope Dimensions: Length: 91.5” (2325mm) Overall Width: 55” (1400mm) Height: 40” (1016mm) Weight: 650 lbs. ( 295kg) Tire Size: 5.70 x 8 Coupling: 1 7/8 ball Lighting Adapter: 4-Way flat (others available by request) Power Supply: Honda GX390 11.7 HP, Recoil Start, Overhead Valve, Cast Iron Cylinder Sleeve, 1.5 Gallon tank Main Drive: Fixed displacement tandem pump to fixed displacement high torque motor. Controls: Pay-in / pay-out spring centered control valve. Hydraulic Circuit: Closed circuit system with full filtration and overload protection Hydraulic Oil Tank Capacity: 2.9 Gal. (11 liters) Hydraulic Oil Grade: Tellus S2V32 Four Way Plug Wiring Right Turn Left Turn Tail Lights Ground (White) The Pulldog winch is a compact, transportable unit for any number of outside plant activities that’s easily pulled behind a small SUV or truck. The self-contained winch is powered by an 11.7 hp gasoline engine and the precise control required is provided by the hydraulic circuit. The Honda GX390 engine drives a fixed displacement pump, which in turn drives a fixed displacement high torque motor. The circuit is controlled by a spring centered hydraulic valve, which provides selective direction of drum rotation. The lever acts as a dead mans handle in that letting go stops everything in a safe mode. The circuit design also includes the ability to provide inching or very slow speed control in both directions under tension, ideal for overhead line use. The sturdy steel construction chassis is equipped with manually operated stabilizing props to assist when pulling. The Pulldog Winch is designed to meet the needs of overhead line engineers. The various options permit use on aerial bundle (ABC), Copper, Aluminum and ACSR Conductors.

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 5.0 OPERATING PROCEDURE IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS WINCH BE FULLY TRAINED AND COMPETENT TO DO SO, AND HAVE READ THE ENTIRE OPERATING MANUAL. GENERAL MACHINE PRODUCTS (KT), LLC CANNOT BE HELD RESPONSIBLE FOR MIS-USE OF THIS EQUIPMENT. To enable safe and trouble free operation the following points should be followed. Prior to employing the winch for any hauling applications it is important to ensure that the winch is suita- bly anchored to a Vehicle. 5.1 Ensure that the ball coupling and the center of the drum width is oriented with the line of pull. See Fig 5.1. This ensures that reeling of the rope takes place without undue pressure on the layering de- vice and extends rope life. 5.2 Vehicle Anchoring - Preferred method of anchoring Align the winch as in 5.1 keeping the ball coupling securely attached to the vehicle. Lower the rear prop legs and lift winch weight off wheels onto legs and fix. Ensure winch is level from side to side. 5.3 Ground Rod Anchoring (if vehicle anchoring is not obtainable) Lower the rear prop legs and front prop to the ground, such that the winch is level from side to side and the weight is off the wheels. Drive a ground anchor through each chassis anchor bracket at the tow eye end of the chassis, See Fig 5.3A, The quality of the ground needs to be assessed with regards suitability for winch anchoring prior to winch operation. 5.4 Loading/Unloading drums To load/unload a drum it is necessary to remove the rear spool guard. This should be stored in a suitable place and re-fitted when the trailer is to be used in transit again. Open the split bearing and slide the drum to the right. Lift the drum vertically initially favoring the side with the split bearing. Re- verse to install. Remove pins and remove spool guard Open split bearing Slide drum out of coupling Remove drum Fig 5.3A Fig 5.1

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 5.5 Pulling Out Winch Line Place the drum free wheel mode by disengaging the coupling and the winch line can be simply pulled out as required. 5.6 Starting Engine The engine fuel tank should be filled with the correct grade of fuel before commencing, refer to the Engine Operating Manual for details. Switch the ig- nition, switch it ‘ON’. Turn on the choke, set the throttle to half and pull starting handle in a long steady stroke to start. For further details refer to the Engine Operating Manual. 5.7 Driving Drum Rotate the drum until the couplings on drum and motor align and slide drum towards motor, and then rotate drum to ensure the drum is engaged. With engine running the control valve can now be engaged. Pulling the handle back wards towards the towing eye will com- mence drum rotation, pulling the rope in. The handle controls direction and speed. Pushing handle toward reverses direction of rotation. 5.8 Layering Device The arrangement fits to the side arm with the motor mounted on, and is secured with a ‘R’ clip. The layering device is used to assist layering of the winch line. Careful setting of the equipment will prevent excessive forces on the layering device. Always wear protective gloves when operating the layering arm. The layering arm MUST NOT be used for conductor recovery. 5.9 Holding Ratchet This device is fitted to the drum drive coupling and should be kept in the open position (i.e. non operational). The holding ratchet should only be used after pulling through heavy conductor when winching has stopped and conductor is held ready for sagging. To remove holding ratchet after engaging, it is necessary to start the winch and pull further to remove load, prior to removal of ratchet. IN OUT

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 6.0 MAINTENANCE IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS WINCH BE FUL- LY TRAINED AND COMPETENT TO DO SO, AND HAVE READ THE ENTIRE OPERATING MANUAL. GMP CANNOT BE HELD RESPONSIBLE FOR MIS-USE OF THIS EQUIPMENT. It is recommended that this winch is serviced every 12 months, regardless of its condition or the number of operating hours used. This will help to ensure reliable, trouble free service. 6.1 PRE-WINCHING MAINTENANCE CHECK This should be carried out each day prior to the start of winching. • Check hydraulic oil level. Oil should be visible within the black lines marked on the oil level sight gauge. Replenish if necessary with the correct grade of hydraulic oil to suit the climatic conditions. (Refer to the section 4 for grades of hydraulic oil required) • Check the engine oil level as indicated in the Engine Operating Manual. Replenish if necessary. • Check that there is enough fuel in the tank to complete the planned winching schedule. • Check the condition of the hydraulic hoses, replace if damaged. • Check that the drum arm split bearing is clean and lightly greased. • Check that the drum shaft bearing spigot is clean. • Check the tire condition and tire pressures, refer to section 4 of details. b) MONTHLY MAINTENANCE • This should be carried out at intervals not exceeding 12 weeks. These intervals will depend upon the degree of use of the winch. • Carry out all the pre-winching checks as detailed above. • Apply a general purpose, medium grade grease to the towing hitch grease nipples (if applicable) and also to the towing ball up if fitted. • With the engine and drum running, check the return filter condition indicator. This is red/green indicator mounted on the hydraulic oil tank filter. If the indicator is well over into the red area, re- place the filter. • Apply grease to the layering arm spindle. ! !

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 6.3 ANNUAL SERVICING This service should be carried out at approximately 12 monthly intervals by a qualified and experienced workshop team. • Carry out all the work as specified above in section 6.2 • Drain the hydraulic circuit of oil. Clean the filler/breather and replace. Renew the suction filter element and the return filter element. Refill with fresh oil, refer to specification Section 4 for fur- ther details. Check and reset all relief valves. • Service the engine as per the engine manufacturers manual supplied as part of this manual. • Check the condition of the tires and running gear. Adjust and reset if necessary. • Check the condition of the towing breakaway cable. If frayed, kinked or damaged, replace imme- diately. ! Typical User Replaceble Parts: Part Number: Oil Tank Filler Breather 36268 Oil Tank Suction Filter 36269 Return Line Filter Element 36270 Sight Level Gauge 36271 Return Line Filter Element Replacement Replace the Return Line Filter Element when the arrow of the clogging indicator is in the red range. 1. Unscrew the return line filter top cap using a suitable wrench. 2. Remove the clogged ele- ment and plastic carrier. Twist and pull the element to separate it from the car- rier. Install new element in carrier and drop in filter housing. 3. Replace the top cap mak- ing sure not to cross the thread. Check for leaks after USER REPLACEABLE PARTS Indicator showing need for filter element replacement. Return Line Filter Element

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 7.0 TOWING INSTRUCTIONS BEFORE TOWING a) Check that the ball coupler cup is well greased. b) Lower the trailer’s coupler on the towing vehicles towing hitch ball. c) Grasp locking handle on top of coupling and press trigger backwards with thumb. Then lift handle (you can now release trigger). With handle still raised wind up jockey wheel until ball on towing vehicle enters ball cup on coupling. Now release handle and continue winding up jockey wheel until locking handle automatically drops down and trigger snaps shut. If this does not occur lift handle again and check if ball seats this time and trigger snaps shut. If there is still no success, check if ball or head is worn. SERVICING a) Apply grease to ball and to cup of ball head after cleaning each item. (Alternatively towing eye and jaw if fitted). This to be carried out each time the trailer’s to be towed. b) Oil all moving parts weekly having wiped away all corrosion and dirt deposits.

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com 8.0 EQUIPMENT LAYOUT 1 12 10 7 4 5 6 11 12 9 8 3 1. HYDRAULIC OIL TANK 2. ENGINE 3. HYDRAULIC PUMP 4. WINCH IN / OUT CONTOL LEVER 5. LAYERING ARM 6. HITCH COUPLING 7. HYDRAULIC MOTOR 8. HYDRAULIC OIL TANK SIGHT LEVEL GLASS 9. HYDRAULIC OIL TANK FILLER BREATHER 10. RETURN LINE FILTER 11. ROPE DRUM 12. REAR PROP 13. FRONT PROP 14. SUCTION FILTER 15. REMOVABLE REAR BUMPER 15 2

TEL: +1-215-357-5500 • FAX: +1-215-357-6216 • www.gmptools.com