Read me first!... 3 Important precautions Table of contents. About your G Lasher Using your G Lasher Appendix: Parts summary...

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2 GMP G Lasher Table of contents Read me first! Important precautions Check your machine first Use the proper safety equipment Use the bridle assembly at pole transfers About your G Lasher Cable capacities Lashing wire magazines and capacities Adjustable rear gates and cable lifter Front gate and pulling eye Strand tensioning mechanism Automatic brake Using your G Lasher Preparing a lashing wire coil Placing the lasher on the strand Transferring the lasher around a pole or other obstruction Instructions for over-lashing Lubrication advice Repairs and maintenance Appendix: Parts summary

3 Read me first! This manual covers the care, operation and maintenance of your GMP model G Cable Lasher, which you can use to lash cables from about in. up to 5 in. (125 mm) dia. to suspension strand, or smaller cable sizes to an existing lashed cable and strand (a process called over-lashing ). This machine is intended for use ONLY by properly trained journey linespeople or other craftspeople under the DIRECT supervision and responsibility of those individuals. As such, this manual s scope is specifically limited to the machine s functions, and no attempt is made to describe the proper procedure for placing and lashing aerial cable plant. We cannot be held liable for any direct or indirect consequences arising from use of the product by any individuals not already properly trained in its use. If you would like information about professional training programs, call us for details. 3

4 GMP G Lasher Important precautions The proposed cable run should be pre-surveyed to determine the terrain and field conditions that will be encountered in the lashing operation. Among those factors to be considered (not by limitation) are: (a) vehicle & pedestrian safety (b) condition of poles, anchors, guys and strand (c) proper bonding and grounding of strand and attachments (d) obstructions such as trees, limbs and drop wires (e) clearances and separations on poles shared by other utilities (f) clearances over roads, driveways, walkways and crossings Protect your work site with advance warning devices at strategic points to warn traffic and pedestrians of the obstruction in the area. Check your machine first! Prior to using the machine, check that it is in good repair, that all of the parts and mechanical assemblies are intact and in good working order. If the machine has not been properly maintained it may well be unsafe to use and pose unnecessary risk to the user. GMP Lashers can be professionally repaired and/or overhauled at the factory with quick turnaround and minimal downtime. Use the proper safety equipment! Before working aloft, inspect all your climbing and safety equipment to make certain it is in good repair. And while you are aloft, ALWAYS wear a body belt with a safety strap securely attached to help prevent you from falling. Also, you should always raise and lower your lasher only with a proper aerial handline (such as our or 08192) or a truck lift. Use the bridle assembly at pole transfers! When transferring the lasher around a pole or other obstruction, use the bridle assembly as a tether to prevent damage to the machine in case it is dropped. This also allows you to concentrate on your own safety first rather than the safety of the machine. 4

5 About your G Lasher Look at your G Lasher for a moment. You will see it consists of a rotating drum supported on a carriage; the strand and cable pass through this carriage during the lashing operation. As you look at the carriage, you will see it also has a forward direct gear drive mechanism, cable and strand rollers, front and rear gates, various pulling eyes and an anti-backroll brake. The major components are made of heat-treated, highstrength aluminum alloy, bronze, stainless or zinc-plated steel. Sealed aircraft-type, dust-proof ball bearings are on all shafts and the drum, with other moving parts mounted on Oilite bushings. At about 71 lbs. (32 kgs) without wire, your machine s weight and features give it an optimal strength-to-weight ratio for the heavy-duty work of lashing large telephone cable(s) or electrical distribution cables. Cable capacities The G Cable Lasher can be used for securing aerial cable from about in. up to 5 in. ( mm) diameter to suspension strands from 3 8 in. to 3 4 in. (9-19 mm) diameter with a spiral lashing of.065 in. (1.65 mm) stainless steel lashing wire. (A modification for.045 in. / 1.1 mm stainless steel wire is also available.) The G Lasher has the capability of lashing any number of cables to a single suspension strand provided that the entire diameter of the cable bundle not exceed 5 in. (125 mm). Front Gate and Latch Towing Bridle Strand Tensioning Roller (closed) Rear Strand Roller Rear Cable Lifter in closed position Strand Drive Wheels Underside of Lasher 5

6 GMP G Lasher Handle Strand Tensioning Roller Lever in closed position Cable Lifter Adjusting Knob Vertical Cable Rollers Cable Lifter Adjusting Knob Spring Lock Rear Cable Lifter and Release Knob Spring Lock 6

7 Lashing wire magazines & capacities The lasher has two magazines for loading of lashing wire; each can hold a coil of.065 in. x 450 ft. (1.65 mm x 137 m) wire. Note:.045 in. x 1200 ft. (1.1mm x 365 m) coils may be used as an alternate. Each magazine has two rollers for guiding and tensioning wire during lashing. The wire coils are held stationary in the magazines, with the wire feeding from the center of the coil eye through a throated hole and over a guiding roller; it is then threaded around the rollers and wound onto the cable/strand bundle. Your lasher can use a single wire or two wires simultaneously (often called double-lashing ) wherever extra strength is desired. Unlike other machines, the balance of a GMP lasher is not adversely affected by the amount of wire loaded in either magazine. There are two rubber strand drive wheels mounted in the forward part of the machine in the drive housing and geared directly to the rotatable drum. A smaller trailer wheel located in the rear of the carriage supports the rear end of the lasher on the strand. Maximum traction is provided by forcing the strand into the groove of the two rubber drive wheels by means of a tensioning device actuated through a system of levers. This feature provides uniform traction regardless of the angle between the pulling line and the strand. Adjustable rear gates & cable lifter The rear cable lifter rollers are adjustable vertically to accommodate cables of various diameters and are held in the open position by a spring catch on each side. To open the rear cable lifter loosen the bottom knurled knob sufficiently to swing free. Swing both gates open until the spring catches are engaged. DO NOT force the gates open past the point of engagement of the spring catches to avoid deforming the springs. To adjust the rear cable lifter, open the rear cable lifter, and loosen the bottom knurled knob sufficiently to swing free. Raise or lower the cable lifter rollers on each side by turning the knurled knobs at the top of each vertical adjusting screw until the desired height is obtained. Observe that the rollers are in proper alignment and swing the bottom knurled knob up into the closed position and tighten securely. 7

8 GMP G Lasher Front gate & pulling eye The front cable lifter or gate is opened by releasing a latch. When in the open position, this locks the drum automatically when its cable slot registers with the slots in the carriage. The drum is free to revolve when the front cable lifter is closed. The rear cable lifter is held in the open position by means of spring catches on each side. There are two pulling eyes located forward of the front cable lifter. These eyes also function as the connection point for the towing bridle when used as a tether to prevent the lasher from being accidentally dropped while transferring around a pole or other obstruction. Strand tensioning mechanism The strand tensioning mechanism works through a system of levers. When engaged and locked under the strand, it provides uniform traction through a wide range of pulling line and strand angles. Automatic brake The anti-backroll brake is a ratchet device which operates automatically when the lasher stops and tension is removed from the towing line, and is released when towing is resumed. It is not necessary to maintain tension in the towing line when the lasher is not in motion. The automatic brake will be released when the towing eye assembly is pressed toward the rear of the lasher. To move the lasher backwards, first clamp the lashing wire to the strand. If the lasher is within reach, release the brake by pushing back against the towing assembly. If it is not within reach and the towing line is attached to the towing eye assembly, release the brake by pulling back on the towing line. When the towing line is attached to one of the pulling eyes on the front of the gear housing a separate line attached to the towing eye assembly may be used to release the brake. Using your G Lasher As we stated in the beginning of this book, 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 remembering the right sequence of steps to take in using your lasher. 8

9 Preparing a lashing wire coil 1. Remove the lasher from its case. Remember! It weighs 71 lbs. (32 kgs). 2. Cut and remove the coil binding holding the looped end of the wire at the coil eye or center (inside end) of coil. 3. Cut and remove two opposite bindings. Do not cut the other two bindings. 4. Pull out the looped end of the wire until the first turn is tight against the binding, and cut off the loop. Pull out about 12 in. (30 cm) of wire from the inside of the coil. The loose end should come out of the face side of the coil. 5. Cut off the loop on the outside end of the lashing wire to prevent snarling. 6. If the coils are installed aloft, see that the strand tension roller is engaged under the strand, the rear cable lifter is closed, the front cable lifter is open and the rotating drum locked. 7. Loosen the wing nut on the cover latch and open the latch. The cover will open automatically. 8. Place the coil in the magazine. The top side of the coil should be toward the open side of the magazine. Position the coil with the two coil bindings in the recesses. Feed the free (inside) end of the wire from the center of the coil through the throat in the cover and over the grooved pulley in the hinged cover of the magazine. 9. Close the cover, latch, and tighten the wing nut until the cover contacts the coil lightly. 10. Cut the two remaining bindings and remove them. 11. Tighten the wing nut as far as it will go by hand. Do not use pliers. 12. Thread the lashing wire around the snubbing pulleys in the direction indicated by the arrows and then through the wire guide roller. 13. The front lifter of the lasher should be left open and the drum in the locked position as the machine was removed from the lasher case. 9

10 GMP G Lasher Placing the lasher on the strand 1. Open the rear cable lifter, adjust it to its lowest position and close it. 2. The strand tensioning roller assembly should be in the open position, placed against the side of the aluminum housing. This is done by depressing the lever projecting up through top of cover of gear unit and turning it clockwise to the open position. 3. Attach a handline to the strand and to the lasher handle and raise the lasher to the strand by means of the handline. 4. With the machine at the required height, open the rear cable lifter past the spring lock and place the lasher on the strand. Also, attach one of the snap hooks on the lasher tow bridle (rope) to a pulling eye and the other hook to the strand as a tether. 5. Engage the strand tension roller assembly by pressing the lever all the way down and turning it counterclockwise, allowing it to rise. When the strand tension roller assembly is in the engaged position, the end of its supporting casting is engaged in the grooved guide on the inside of the gear housing. 6. Raise the cable to the strand (by hand), close rear cable lifter and let the cable rest on the rollers. Estimate the amount the rollers should be raised to elevate the cable to within 1 4 in. (6 mm) of the strand. Lift the cable slightly (by hand), open the cable lifter, lower the cable clear of the opening and turn the adjusting knobs on top of the threaded posts until the lifter is raised the desired amount. Raise the cable (by hand) and close the lifter. 10

11 7. Pull out sufficient lashing wire for termination and clamp the lashing wire to the strand at least 12 in. (30 cm) behind the lasher. 8. Close the front gate assembly. Remove the tow line snap hook from the strand and attach the snap hook to the other tow eye of the lasher. 9. The lasher is now prepared to lash cable. Transferring the lasher around a pole or other obstruction 1. Before transferring around a pole, temporarily terminate the lashing wire near the pole with a lashing wire grip, pull out sufficient wire for the final termination and the cut. 2. Open the front gate all the way. 3. Move the lasher forward or backward along the strand until the drum locks. 4. Attach one of the lasher bridle snap hooks to a lasher towing eye on the front of the machine. Now pass the bridle under the strand, past the obstruction and attach the other snap hook to another lasher pulling eye. 5. Press down the strand tension roller lever and turn it clockwise to disengage it from the strand. 6. Raise the lasher from the strand and transfer the machine to the strand in the next span following the instructions beginning in step 5 of the preceding section. Instructions for over-lashing When lashing a cable or cables to an existing cable the same procedure is followed with one exception. The strand tension roller assembly should be removed so as not to interfere with existing lasher cable. This is a simple procedure which should only be attempted while on the ground and working on a suitably stable work surface. 11

12 GMP G Lasher Note: Do not set the lasher vertically on the rear gate to avoid damage to the spring catches. 1. Remove the four screws holding the gear housing cover and remove the cover. 2. Position the lasher with the gear housing facing to the right and the rear gate to the left. 3. Remove the three #10-25 filister head screws which will allow the complete strand tension roller assembly to drop out through the bottom of the gear housing. 4. Reinstall the gear housing cover and your G lasher is now capable of over-lashing cable(s) up to the capacity of the machine. Note: Be sure to save the parts. To reinstall simply reverse the above procedure. When placing the lasher into its case, have the front cable lifter assembly open and put the rotor assembly in the locked position. Keep the lasher in the carrying case at all times when not in use. Lubrication advice The gears of the G Lasher are lubricated at the factory with a specially formulated graphite-based lubricant. This lubrication will last indefinitely provided that the gear housing is left unopened and uncontaminated by solvent or debris. If, during the course of your G Lasher s service life, it is ever returned to the factory for repair and reconditioning, it will receive a thorough cleaning during disassembly and will be freshly relubricated as it was when new. Do not attempt to lubricate the gears as improper lubrication can cause eventual slippage due to lubricant flowing to other surface areas during operation. The only parts which should require occasional lubrication with S.A.E. 10 or 20 motor oil, are the threads of the rear cable lifter and hinges to keep them operating freely. Wipe off any excess oil. Repairs & maintenance From time to time it may be necessary to make minor field repairs; the following list of parts will prove helpful in ordering what you need. However, nobody can give your lasher as thorough a check-up as the people who built it...gmp. Our experienced technicians will check every detail, thoroughly clean and re-lubricate your machine and put your lasher back in like-new shape within 10 working days, guaranteed. Just call the factory for full details on our lasher maintenance program. 12

13 G1 Gear Housing G2 Gear Housing Cover G3 Towing Bridle Assembly G4 Towing Bridle Stop Bolt Towing Bridle Stop Nut G5 Strand Drive Wheel G6 Strand Drive Wheel Nut G7 Pulling Eye G8 Top Roller Assembly Screw Top Roller Assembly Washer G9 Top Roller Assembly G10 Pulling Eye Screw Pulling Eye Nut G11 Clamping Washer G12 Rear Strand Drive Shaft (shaft, gears & bearing) G13 Front Strand Drive Shaft (shaft, gear & bearing) G14 Ratchet Pawl Spring G15 Rubber Sleeve G16 Steel Guide G17 Shoulder Screw Shoulder Nut G18 Ratchet Brake Pawl G19 Idler Gear G20 Oilite Bearing G21 Idler Gear Shaft G22 Clamping Nut G24 Ratchet Brake Collar G25 Ratchet Brake Copper Latch G26 Tru-Arc Ring # G27 Drive Shaft G28 Collar G29 Timing Gear G30 Drive Shaft Gear Assy G31 Spring Screw G32 Towing Bridle Pivot G33 Spacer G34 Stop Pin G35 Retaining Ring Screw Retaining Ring Lockwasher G Bearing G37 Bearing Retainer Rings 3 ea. required ea. required ea. required G38 Tru-Arc Ring # G39 Towing Bridle Spring G40 Pivot Retaining Ring G x 3 4 Filister Screw G x 5 8 Flathead Screw G43 Strand Lifter Assembly G x 5 8 Filister Screw G45 Wire Coil Door Assembly G46 Door Pulley G47 Door Pulley Bearing G48 Door Release Spring G50 Handle G x 20 Flathead Screw G in. Wire Pulley G53 Front Plate Assembly G54 Left Lock G55 Right Lock G x 1 2 Filister Screw G57 Locking Bolt G58 Locking Bolt Spring G59 Locking Bolt Retainer G60 Locking Bolt Retainer Nut G61 Rotor Body G62 Ring Gear G x 1 Allen Screw G64 Spacer G65 Strand Roller w/bearings G66 Strand Roller Shaft G x 1 Flathead Screw G68 Rear Plate Assembly G69 Swing Bolt Spring G70 Swing Bolt Assembly G71 Front Bearing Ring G72 Rear Bearing Ring G x 3 8 Filister Screw G74 Ball Bearing G75 Eccentric Screw G76 Wire Guide Assembly G x 7 8 Filister Screw G78 Front Cable Lifter Assembly G79 Hex Head Screw G x Filister Screw G x 3 4 Filister Screw G82 Side Roller Assembly G x 3 4 Filister Screw G84 Rear Lifter Assembly

14 GMP G Lasher 14 G2 G1 G5 G5 G6 G8 G7 G9 G11 G12 G10 G13 G15 G14 G22 G27 G27 G28 G29 G32 G32 G38 G38 G31 G41 G42 G40 G39 G43 G44 G33 G35 G26 G34 G37 G25 G24 G23 G36 G20 G21 G19 G18 G17 G16 G3 G4 G30

15 G45 G49 G45 G46 G46 G47 G71 G48 G51 G50 G61 G73 G52 G62 G69 G72 G54 G57 G59 G63 G70 G55 G56 G58 G60 G74 G75 G67 G53 G64 G65 G66 G68 G84 G78 G82 G81 G80 G79 G76 G77 G83 15

16 General Machine Products (KT), LLC 3111 Old Lincoln Hwy Trevose, PA USA TEL: FAX: WEB: http: tp:// s.com GMP reserves the right, without notice, to make changes to equipment design or components as progress in engineering or manufacturing methods may warrant.