GMP 89915 Troubleshooting guide

Page 1 General Machine Products (KT), LLC
WHISPER FLAT DROP CABLE BLOWING MACHINE
P/N 89915
Copyright  2018 by General Machine Products (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
WHISPER MICRO CABLE BLOWING MACHINE
for FLAT DROP FIBER
OPERATION & MAINTENANCE
GMP • 3111 Old Lincoln Hwy • Trevose, PA 19053 • USA
TEL: [phone] • FAX: [phone] • EMAIL: [e-mail]
October 2018 USA Ver 3f
QC Final Inspection by:_________________________ Date:__________________
Unit Serial Number:__________________
Build Date:__________________
Manual Part Number 33513

Page 2 General Machine Products (KT), LLC
REVISION HISTORY
Rel.no Date Details Author
01 03/16 Original issue A KONSCHAK
02 12/16 Updated to show cable pressure indicator
Added part numbers to spares A KONSCHAK
03 12/16 Added seal direction recommendation P14 A KONSCHAK
03a 02/17 Added roller follower kit to spares A KONSCHAK
03b 03/17 Minor verbiage changes A KONSCHAK
03c 07/17 Company name change A KONSCHAK
03d 02/18 Removed Encoder Reference A KONSCHAK
03e 05/18 Updated supplied tools A KONSCHAK
03f 10/18 Removed p/n 89951 (Corning ROC Option) A KONSCHAK

Page 3 General Machine Products (KT), LLC
CONTENTS
1. Safety Instructions
2. Critical Points
3. General Description
4. Specification
5. Operating procedures
6. Maintenance
7. Monthly Service – check list
8. Service History Record
9. Tube integrity and Lubrication
10. Recommended Spares List
APPENDICES
Appendix 1 Determining the correct drill torque setting
Appendix 2 Counter/Ratemeter Programming Instructions
GMP Limited Warranty can be found at http://www.gmptools.com/warranty/

Page 4 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 compressed air and electrical services to carry out
lubrication 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 compressed air.
12. When operating machine always wear appropriate safety clothing, hearing protection, eye
protection, hard hat, safety shoes and leather gloves, machine operates with compressed
air at up to 220 psi.
13. Prior to installation insure the tube route is connected properly.
14. Beware of exposed electrical contacts. Do not touch, or allow metal objects to come into
contact.
15. Machine may cause additional fire hazard if involved in an existing fire due to com-
pressed air.
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.

Page 5 General Machine Products (KT), LLC
16. No personnel are to be in manholes or ducts when the Cable Blowing Machine is being
operated.
17. The machine must be operated on firm ground.
18. Stay clear of cables or lines under tension.
19. Stay clear of pressurized air line and tube.
20. Only use the machine for its intended purpose. Do not use the roller drive without the air
chamber to push or to retrieve cable or blow air in the far end of tube to help cable
recovery.
21. Do not place cable drum too close to the Cable Blowing Machine.
22. Do not tamper with pressure relief valves or pressure reducing valves.
23. Ensure the cable drum rotates freely on its stand, the cable should leave from the top of
the drum.
24. The cable should enter the machine in a clean and dry condition. In damp, dusty atmos-
pheres, the cable should be cleaned continuously as it enters the machine.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, AS THE CABLE
COULD BE EJECTED FROM THE CABLE BLOWING MACHINE WITH HIGH
FORCE AND VELOCITY.

Page 6 General Machine Products (KT), LLC
GENERAL PNEUMATIC SAFETY INSTRUCTIONS
The GMP Whisper Micro Cable Blowing Machine is a pneumatic device, using pressurized air
to project cable at high velocities. Please observe the following precautions when operating
the Cable Blowing Machine:
1. Compressed air can cause flying debris. This could cause 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 machine has electronic circuits. Observe the following precautions to avoid electrical
hazards:
1. Do not operate in water.
2. Do not expose the machine to rain.
3. Refer servicing to qualified service personnel.

Page 7 General Machine Products (KT), LLC
2. Critical points that dramatically affect the operation of the cable blowing
machine.
• Pressure on the cable should be set as per the instructions.
• Rollers to be closed at all times when cable is installed into machine.
• Cord seals in air chamber correctly fitted to provide good sealing.
• Correct cable seal fitted.
• Tube fully connected and pressure-tested.
• Tube connecting fittings are suitable for operating at 220 PSI air pressure.
• Tube clamp securely tightened.
• Compressor capacity 220 PSI and suitable for size of tube being used.
• Cable drum must be located directly behind and in line with the blowing machine.
• Air chamber, drive rollers, cable guides, must be clean and free from 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 required amount of ca-
ble has been installed.
• The counter/display is powered by (2) 9 volt batteries. To maximize battery life, turn dis-
play off by pressing power button on left side of display box when unit is not in use.

Page 8 General Machine Products (KT), LLC
DISCLAIMER
General Machine Products (KT), LLC takes care in the design of its products to insure that the
cable is protected during installation. Due to the variety and different methods of cable manu-
facture the responsibility of checking the cable compatibility with the equipment lies with the
user. Therefore, GMP can not accept liability for any damage to the cable.

Page 9 General Machine Products (KT), LLC
3. GENERAL DESCRIPTION
The GMP Whisper Micro Cable Blowing Ma-
chine is designed to install flat drop fiber cable
into micro tubes.
The Whisper uses a user supplied variable
speed drill to drive the drive roller.
The pressure the rollers apply to the cable is
adjustable.
A full range of accessories is available to allow
the machine to handle a wide range of cables
and micro tubes.
The Whisper may be placed on a stand or on
the optional tripod kit to bring the cable to a suit-
able height. The Whisper is supplied with a re-
inforced soft case which will protect the ma-
chine from damage during transit and storage.
On left is the Whisper assembled for a
typical blowing operation. Shown is the
unit with the optional Tripod Mounting Kit
(P/N 89945) and a user supplied variable
speed drill.

Page 10 General Machine Products (KT), LLC
4. SPECIFICATIONS
Cable size: Manufacturer Specific, See configuration
Tube size: (OD) 12-18mm
Cable speed: 0-300 ft/min 0-90 m/min
Maximum air pressure: 220 psi. 15 bar.
Power requirements: Variable Speed Drill
with adjustable torque (not included)
Weight 12 lbs. approx. 5.4Kgs approx.
Dimensions (ht x length x width) 8.5” x 9.7” x 8.1” 216mm x 246mm x 206mm

Page 11 General Machine Products (KT), LLC
5. OPERATING PROCEDURE
IT IS IMPERATIVE THAT ALL PERSONS USING, OPERATING OR MAINTAINING THIS
CABLE BLOWING MACHINE:
● HAVE RECEIVED COMPREHENSIVE TRAINING IN THE USE OF THIS MACHINE.
● ARE COMPETENT AND AUTHORIZED TO USE IT AND HAVE READ AND UNDER-
STAND THIS MANUAL.
GENERAL MACHINE PRODUCTS (KT), LLC CANNOT BE HELD RESPONSIBLE FOR
MISUSE OF THIS EQUIPMENT.
Set up for installing cable with the machine mounted above ground:
1. Position the machine in line with the route of the duct.
2. Position the cable drum behind the machine and in line with the machine.
See illustration below (this shows a plan view of the recommended set up).
3. Ensure the machine is secure (either on its own stand or a separate suitable stand).
4. Ensure the machine is fitted with the appropriate guides and collets to suit the cable being
installed and the tubes into which the cable is to be installed. (See appendix 1 for details
of interchangeable parts).
To set the machine up to install cable it will be necessary to:
1. Fit the tube into which the cable is to be installed into the tube clamp and air box .
2. Fit the cable through the machine. Adjust drive roller tension.
3. Connect the air supply to the machine.
4. Connect the variable speed drill to the machine.
Cable Drum Whisper Machine
Tube route

Page 12 General Machine Products (KT), LLC
Outfitting the Whisper for Flat Drop Fiber Cable
When preparing the Whisper for use, you must know the type and manufacturer of the cable
being blown and the size of the duct you are blowing in.
Preparing the Whisper for the proper cable size
Measure the OD of the cable. Select the corresponding cable collet kit for the size cable
you’re blowing
Install Cable Collet Components into the Whisper
A. Install infeed guide
Install infeed guide by securing to the unit with the 2 supplied M6X25 screws as shown in
above photo.
B. Install Cable Seal Guide
Cable Collet Kit
89952 Corning SST
89954 Corning ROC Fast Access
89956 Commscope
Repeat for the upper guide.Tighten the mounting screws. Place the guide in the
grove on the exit side of
the roller

Page 13 General Machine Products (KT), LLC
C. Drive Shaft Bearing Support
The drive shaft bearing supports are specific to the size of the fiber that you're blowing in order
to maintain the center distance of the fiber running through the machine.
Slide the bearing block over the shaft
(dimple side up and bearing surface even
with block towards outside) and secure
with 2 screws.
Install the flat washer
Repeat on the other side.
Washer
Bearing
Block
Roller/Shaft Assy
Tighten the two screws re-
taining the top plate of the
air-box in-feed guide.
Tighten the mounting screws.
Place the guide in the
grove on the exit side of
the roller
If using Corning ROC Fast Access cable, use the pictured cable guide and follow the
instructions below.

Page 14 General Machine Products (KT), LLC
TUBE COLLET AND
CLAMP ASSEMBLIES
89923 12mm O.D.
89921 12.7mm O.D.
89928 14mm O.D.
89925 16mm O.D.
89924 18mm O.D.
Loosen the thumb nut, rotate the swing bolt
to open the air box
Insert the top and bottom tube clamps align-
ing the grooved edge to the outside. Tighten
the 4 screws.
Insert the the top and bottom airbox halves
and tighten the screws
Fit the tube into the air box and tube
clamp.
Slide a tube seal, sized for the tubing you
are using, over the end of the tube.
Fit the tube half way or more into the air
box housing as shown in the photo, posi-
tioning the tube seal so that it sits against
the seal face.
Positioning the tube further into the air
box helps prevent the buckling of smaller
fiber.
Place a cable seal sized to the cable you
are blowing in the wide groove.
Preparing the Whisper for the proper duct size
Measure the OD of the duct. Select the corresponding tube collet and clamps
Other tube sizes available –Contact
GMP for information.
Note:
If the seal has a small taper, place the
large side toward the airbox as shown in
the illustration to the right.

Page 15 General Machine Products (KT), LLC
Fit the cable through the machine.
Pass the cable through the in-feed guide, through the gap
between the drive rollers. Continue to feed the cable
through the cable seal into the airbox and into the duct.
Tighten the clamping screw until the pressure indicator is at
the halfway mark. Some cables may require less clamping
due to their size or construction. The amount of compression
required will become clear as more experience is gained with
the machine.
See appendix 2 for more information.
The cable is now positioned in the machine.
Back off the clamping
screw turning CCW far
enough to fit the cable
between the rollers.
Tighten the airbox chamber/duct
clamping screw.
Pressure Indicator

Page 16 General Machine Products (KT), LLC
Connect the air supply
to the machine.
Connect the variable speed drill to the machine.
The machine is now ready to start the cable installation.
The Whisper is designed to operate with a commercial qual-
ity 3/8” variable speed drill, preferably 18 volts or larger.
See appendix 2 for proper setting of drill’s clutch.
Check the battery
with the battery
level indicator.
The air inlet to the
machine is a male
fitting for a quick
release coupling.

Page 17 General Machine Products (KT), LLC
NOTE: THE MACHINE MUST NOT BE SUBMERGED IN WATER.
Installing Cable
Speed Distance indicator:
This device will measure and display the distance traveled by the cable and also the speed at
which the cable is traveling. The functions are controlled by the small green push button on
the right of the display. If this button is depressed twice, the display will “toggle” between
speed and distance. Pressing the red button will reset the display to zero. Before starting an
installation, it will be necessary to depress the red button to set the distance display to zero.
Should it be necessary to replace the speed distance measuring indicator, it will be necessary
to reprogram it.
To install cable:
1. Attach drill to Whisper drive motor shaft (if not already attached) and tighten drill
chuck. Be sure that the drill is set in the forward or clockwise rotation setting and low speed.
2. Set drill torque setting starting at the minimum and work your way up.
3. Start air compressor and open air output valve, or if using nitrogen open the tank output
valve to full flow. Keep the valve on the Whisper closed.
4. Activate cordless drill to desired speed and monitor distance and speed with the counter.
Average installation speeds are between 150-300 FPM. It is sometimes necessary to gently
hand assist the fiber cable into the cartridge to initiate forward motion. (Do Not Bend or Over
Stress the cable.) When approximately 150’ of cable is installed, gradually open the air valve
on the Whisper
5. When cable exits duct end, take the desired amount of slack, stop drill and turn off air valve
and allow it to vent all the residual air before opening airbox.
6. Turn the power off on the counter to preserve battery life when not in use.
Caution: If during the installation, the cable hits an obstruction and stops, immediately
stop the drill. Continuing could severely damage the cable.
!

Page 18 General Machine Products (KT), LLC
6. Maintenance
The GMP Whisper Cable Blowing Machine has been designed to give reliable, trouble free
service over long periods. The machine requires no sophisticated maintenance procedures,
simple common sense checks and precautions are all that are needed.
The main source of breakdown and/or malfunction of a machine being used outdoors is con-
tamination by the elements, this contamination may be introduced into the machine in a num-
ber of different ways.
There may be mud, dust or other contaminants carried into the machine on the cable or tube
(there may be surface coatings of lubricants or other release type agents on the outer surfac-
es of the cable and tube, this could build up on the rollers and make them slip).
The machine may be set down on a muddy surface, or be splashed by vehicles when it is be-
ing used by the roadside.
Battery Replacement
Remove the cover by removing 4 screws
Replace batteries (2) 9 volt Lithium recommended
Replace the cover and the 4 screws
Battery Check—use supplied battery checker.

Page 19 General Machine Products (KT), LLC
The machine should be returned to the General Machine Products Co,, Inc., Trevose, Pa.
after every 1000 hours use (or at intervals of 12 months) for a major service.
As a general rule, every time an interchangeable part is removed and replaced by a part of a
different size, the part being removed should be thoroughly cleaned before being returned to
its box. Similarly the cavity from which it was removed can also be cleaned prior to the as-
sembly of the replacement part.
Air box parts: Keep clean. A build
up of moisture and dust will pre-
vent the joint faces from mating,
preventing the housing seal from
sealing. Use any traditional work-
shop cleaning agent.
Tube clamp inserts:
Keep clean. A build up of
moisture and dust, partic-
ularly in the grooves, will
reduce the clamping ef-
fect. Use any traditional
workshop cleaning agent.

Page 20 General Machine Products (KT), LLC
Procedure for replacing the air box housing seal
Cut a length of  0.08inch seal-
ing material 2 1/8” long (a little
longer than is necessary).
Apply a thin coat of 3M Rubber
and Gasket Adhesive to the top of
the cut sealing material
Place the pre-cut length in the groove,
glue surface down, starting at the end
with the retainer plate and aligning
flush with the end of the groove.
Work your way around, pressing the
seal into the groove and allowing the
excess material to hang over the oppo-
site side.
Repeat the
procedure for
the second
groove
Trim excess material flush with
end of groove.
Spread adhesive along one
side of cord.