4.0 Operating Instructions

4.1 General

As mentioned at the beginning of this manual, you should never operate a lasher unless you've been properly trained in advance or are being directed by a properly trained linesperson who is responsible for your work. However, you should find this section of the book helpful in outlining the correct sequence of steps to take in using your Apollo lasher.

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4.2 Preparing a lashing wire coil

The first step in any lashing operation is to prepare the lashing wire coil. Note: It is important that the lashing wire is loaded properly to ensure proper lasher operation.

1. If the lashing wire is wrapped with wire ties, rotate the head of the wire tie attached to the looped end of the lashing wire to the center of the coil (see figure 4). This will facilitate the cutting of the wire tie in a later step and help ensure that the complete wire tie is removed.

2. Do not cut all of the cable ties! Leave the cable tie attached to the looped end of the lashing wire, and cut the remaining 3 cable ties on the lashing wire coil.

3. Cut the looped end of the wire on the inside diameter of the wire coil. This step will help in the loading of the coil onto the hub and subsequent steps.

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4.3 Install the prepared wire coil

The proper installation of the wire coil is a must for hassle-free lashing. Many of the problems in lashing can be traced to improper preparation of the lashing wire coil.

1. Open the cover with a screwdriver or 7/16 in. socket as found on the 216C tool, or any tool used to tighten the bugnut. Turn the fastener 1/4 turn (counterclockwise) until the fastener unseats. The spring loaded cover should open to expose the lashing wire reel.

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2. Verify that the adjustable tension roller is in the correct position for the type of lashing. The roller should be in the lowermost position for normal lashing wire tension, including lashing broadband coaxial cables. The roller should be in the upper-most position for higher lashing wire tension.

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3. Depress the reel brake into cutout on rear flange. Unscrew and remove the wire reel cover and slide the lashing wire coil over the hub and onto the reel keeping the free end of the wire towards the front of the machine.

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4. Install the wire reel cover and thread completely onto the reel until snug against the wire coil. It is important to ensure that the reel cover is tight against the wire coil to prevent the lashing wire from "snagging" on itself.

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5. Hold on to the looped end of the coil. Cut and remove the remaining cable tie and then continue to snug the reel cover against the wire coil ensuring a tight fit. The reel brake can be depressed into cutout on rear flange to hold the reel stationary as you tighten the reel cover. Make certain that the head or knot on the cable tie is not pulled through the coil and that the entire cable tie is removed, because portions of the cable tie may cause snagging of the lashing wire.


Note: As a check for proper cover tightness, at least 1 full thread on the hub should be exposed after the wire reel cover has been installed and tightened.

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6. Make a hook with the end of the lashing wire. Feed the wire over the first tension roller (bottom roller).

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7. Feed the wire behind the second tension roller (top roller). Pull the wire out from behind the roller.

8. Pull up on the handle to de-clutch and disengage the drive wheel.

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9. Feed the wire into the drive wheel from the rearward direction so the wire moves around the drive wheel toward the front of the lasher.

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10. Continue feeding wire until it exits the drive wheel. The wire exiting the drive wheel must be below the wire entering the drive wheel.

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11. Pull up on the handle to disengage the drive wheel and feed wire into the exit rollers on the end of the machine.

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12. Ensure the wire is captivated between the roller and the housing.

13. If more wire is needed, disengage the drive wheel to pull out more lashing wire. (See Figure 16)

14. Close the cover and using a screwdriver or 7/16 in. socket as found on the 216C tool, or any tool used to tighten the bugnut, tighten the fastener (clockwise) 1/4 turn until the fastener seats and can't be tightened further. Ensure that the cover is secure to the hub.

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4.4 Lashing to bare suspension strand

1. Check the lashing wire coils to ensure there is enough lashing wire for the span, if the lashing wire wasn't loaded recently.

2. Lower the rear gate to its lowest position. Ensure that the rear gate is open and the drum is locked in position.

3. Set the rear vertical cable rollers to their widest opening.

4. Open both the front and rear strand locks by pulling up on the release knob. There should be an audible "click" when the locks travel from the locked position to the open position. (See Figure 18)

5. Open the front gate by actuating the release lever towards the front of the lashing machine. The roller on the front gate will pivot 180 degrees and out of the way.

6. Attach a handline to the lasher handle and raise the lasher to the strand. Attach one of the lasher bridle snap hooks to one of the lasher towing eyes. Attach the other snap hook to the strand to serve as a tether.

7. Place the lasher on the strand and ensure that the strand is centered in the grooves of both of the front and rear rollers.

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8. Close the front strand locks by depressing simultaneously on both hooks until audibly and visibly locked.

9. Close the rear strand locks by simultaneously depressing on both hooks until audibly and visibly locked. The lasher is now secured to the strand.

10. Using the proper cable raising procedure for your application, lift the cable or cables up to the strand, close the front gate and let the cable(s) rest on the horizontal roller.

11. Adjust the position of the vertical rollers on the rear gate so that they barely touch the sides of the cable(s). This step will have to be done every time the bundle size changes.

12. Close the rear gate until it locks in its detented position.

13. Raise the rear cable lifter by pushing up on the bottom of the lifter that contacts the D shaft. The lock doesn't have to be activated to raise the cable lifter. If the rear cable lifter is too high, press the locking lever to lower the rear cable lifter and try again.

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14. Now the final steps. Pull up on the handle to de-clutch and disengage the drive wheel to pull some lashing wire from the lasher. Secure the lashing wire to the strand by using a GMP D or E lashing wire clamp. Attach the bridle assembly to the towing eyes on the Apollo lasher and you are ready to lash.

See section 4.6 for more information on terminating lashing wire.

4.5 Over-lashing procedure

Here is the proper way to overlash onto existing cable installations using the Apollo lasher:

1. Check the lashing wire coils to ensure there is enough lashing wire for the span.

2. Lower the rear gate to its lowest position by fully depressing the thumb latch and sliding the roller down. Ensure that the rear gate is open and the drum is locked in position.

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3. Open both the front and rear strand locks by pulling up on the release knob. There should be an audible "click" when the strand locks travel from the locked position to the open position. The strand locks aren't used in the over-lashing procedure and should remain in the open position.

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4. Open the front gate by actuating the release lever towards the front of the lashing machine. The roller on the front gate should pivot 180 degrees and out of the way.

5. Attach a handline to the lasher handle and raise the lasher to the strand.

6. Attach one of the snap hooks on the lasher bridle to one of the towing eyes. Attach the other snap hook around the strand and existing cables to serve as a tether.

7. Place the lasher on the strand and ensure that the strand is centered in the grooves of both of the front and rear rollers.

8. Using the proper cable raising procedure for your application, lift up to the strand the cable or cables you want to lash, close the front gate and let the cable(s) rest on the horizontal roller.

9. Raise the rear cable lifter by pushing up on the bottom of the lifter that contacts the D shaft. The thumblatch doesn't have to be activated to raise the cable lifter.

10. Adjust the position of the vertical rollers so that they barely touch the sides of the cable(s). This will have to be done as the bundle size changes.

See section 4.6 for more information on terminating lashing wire.

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11. Now the final steps. Pull up on the handle to de-clutch and disengage the drive wheel to pull some lashing wire from the lasher. Secure the lashing wire to the strand by using a GMP D or E lashing wire clamp. Attach the bridle assembly to the towing eyes on the Apollo lasher and you are ready to lash.

4.6 Lashing wire termination

4.6.1 General

A common cause of lashing wire failure is improper termination. The following steps outline the suggested method for proper lashing wire termination.

1. Lashing wire termination should be accomplished and cable supports installed as soon as practical after the cable is placed.

2. Measurement marks made in making terminations should be made on the strand rather than on the cable sheath. Avoid scoring the cable sheath with the lashing wire end when terminating lashing wire.

3. Cable guards should be used to prevent abrasion of the cable sheath where the separation is less than 1/2 inch between the cable and suspension clamps. While the D lashing wire grip and D and E lashing wire clamps may be used on strand sizes up to and including 7/16 in (11mm) (16M) or larger, the discussion on lashing wire termination will only cover the strand sizes of .25 to .38 in. diameter (6 to 10 mm) (6M, 6.6M and 10M), the only strand sizes compatible with the Apollo lasher.

4.6.2 Lashing wire termination

1. Secure the lashing wire to the strand with a lashing wire grip before cutting or otherwise releasing tension in the lashing wire. The lashing wire grip should be placed far enough from where the supports, spacers and lashing wire clamps are to be installed to avoid having to move the grip.

Note: The situation can exist where the .038 in. (0,97 mm) dia. lashing wire may nest in the space between the wires of the 10M strand. Ensure that the D lashing wire grip is securely contacting both the lashing wire and the strand to prevent loss of tension in the lashing wire.

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4.6.3 Lashing wire clamps

Figure 25, D Cable Lashing Clamp


See figure 25

1. The D or E lashing wire clamp may be used with .038 (0,97 mm) and .045 (1,1 mm) dia. lashing wire on strand sizes of .25 to .38 in. (6 to 10 mm) diameter (6M, 6.6M and 10M).

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2. The nuts of the clamp are tightened and loosened with the 7/16 in. end of a 216C tool or B ratchet wrench.

Figure 26, Terminating Lashing Wire

4.6.4 Terminating lashing wire using D or E lashing wire clamps

See figure 26 for steps 1, 3 and 4.

1. The lashing wire clamp should be located 2 inches outside of the first lashed cable support or cable suspension clamp. The lashing wire should be wrapped twice around the strand and then terminated on the cable lashing clamp.

See figure 25 steps 2, 3, 5 and 6.

2. Terminate one lashing wire using a lashing wire clamp by placing the wire below the stud and between the second washer and stud shoulder.

3. Remove any slack in the lashing wire by maintaining tension on the wire and tapping the strand sharply. Form the wire over the stud and tighten the nut. Cut the free end of the lashing wire off 1/4 in. (6 mm) beyond the end of the clamp.

4. Form the end of the lashing wire 90 degrees around the end of the clamp to minimize exposure of the free end of the lashing wire.

5. Terminate a second lashing wire (if used) with the D lashing wire clamp as outlined above; however, temporarily clamp the first lashing wire using a D lashing wire grip to maintain lashing wire tension.

6. Loosen the nut on the lashing wire clamp and terminate the second lashing wire between the first and second washers. Tighten the nut to complete the termination.

7. Remove the D lashing wire grip(s).

4.7 Moving your lasher around a pole

When you need to move your Apollo lasher around a pole or other obstruction, follow these steps.

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Warning: While aloft, ALWAYS wear a safety belt with a safety strap securely attached to help prevent you from falling.

Caution: Ensure the rear vertical cable rollers are set to their widest opening before placing the lasher on the side of a bucket.

1. Before doing anything, make sure you are working from a secure perch where you can safely move your Apollo lasher without overreaching. This is extremely important.

See section 4.6 for more information on terminating lashing wire.

2. Clamp the lashing wire to the strand.

3. To pull a length of lashing wire from the Apollo lasher without rotating the drum, actuate the de-clutch lever and pull out enough lashing wire from your machine so you can terminate it with a clamp or continue lashing past the obstruction.

4. Attach one of the lasher bridle snap hooks to a lasher towing eye on the front of the machine.

5. Now pass the bridle under the strand, past the obstruction and attach the other snap hook to another lasher pulling eye.

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6. Open the front gate by actuating the release lever towards the front of the lashing machine. The roller on the front gate will pivot 180 degrees and out of the way.

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7. Open the rear gate making sure it is fully open in the detented position.

8. Open both the front and rear strand locks by pulling up on the release knob. There should be an audible "click" when the locks travel from the locked position to the open position.

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9. Carefully lift the lasher off the strand and move it over to the strand on the other side of the obstruction. If you accidentally drop the lasher while making this transfer, the bridle assembly will keep the lasher from falling to the ground.

4.8 Removing the lasher from the strand

The procedure for taking your lasher off the strand is basically the same as for moving it around a pole, except that you should also:

1. attach a secured handline to the lasher handle;

2. disconnect the lasher bridle only after completing step 1; and

3. carefully lower the lasher to the ground.

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