DCD FALCON LASHER 61800-000 User manual

FALCON LASHER
61800-000
Operating Manual

1 | P a g e
Rev. D 20-July-22
Contents
Specifications: ................................................................................................................................................................... 2
Safety: ............................................................................................................................................................................... 3
1. Loading the Wire Spools on the Lasher ...................................................................................................................... 4
2. Threading the Lashing Wire ......................................................................................................................................... 7
3. Setting the Front Gate: .............................................................................................................................................. 12
4. To open the Strand Lock: ........................................................................................................................................... 13
5. Setting the Rear Gate: ............................................................................................................................................... 15
6. Installing the overlash assembly front rollers ............................................................................................................ 20
Troubleshooting .............................................................................................................................................................. 21
If you need any parts or repairs: ..................................................................................................................................... 21

2 | P a g e
Rev. D 20-July-22
FALCON LASHER
Part # 61800-000
Pull-Type Lasher
Specifications:
Lasher Weight: 21 lbs.
Shipping Weight: 45 lbs. (Including Carry Case)
Lasher Dimensions: 19.5” long x 10-5/8” wide x 9-1/4” high
Capacity:
 Single cable – 3-1/4” OD maximum
 Multiple Cables – not to exceed 3-1/2” OD as a bundle
Capabilities:
The Falcon Lasher will single or double lash without strand traction. It is compatible
with standard size coils of .045” and .038” lashing wire, metallic or non-metallic.
Depending on bundle size, double lashing provides a support approximately every
6”, while single lashing provides a support approximately every 12”. It is also
equipped with a clutch handle to allow easy mounting and passing the unit around a
pole without cutting the lashing wire or removing it from the drive wheels.
General Information:
The DCD Falcon Lasher is a lightweight lasher that was designed to lash cables or
up to 3-1/4” diameter. It weighs just 21 pounds and does not need traction from the
supporting strand to drive the lasher making it very beneficial to use when
overlashing existing cables.
This lasher is a piece of precision equipment. Treat is as such. Keep the lasher,
operating manual and accessories in the protective storage case after use. This
measure will prolong the useful life of your lasher.

3 | P a g e
Rev. D 20-July-22
Safety:
- The Falcon Lasher is intended for use only as described in this manual. Do not
modify or dismantle the lasher. It has been assembled and inspected and is only
covered by a warranty in its “as shipped” form. Any attempt to dismantle or modify
the lasher will void the warranty and may result in property damage, severe bodily
harm, or death.
- Keep hair, loose clothing, and all parts of body away from openings and moving
components. Wear gloves and other appropriate safety equipment to avoid pinch
hazards.
- Never use a worn, defective or incomplete equipment. Ensure that all components
of the setup are able to withstand the maximum pulling loads. Components not
rated for the pull force may break and release the stored energy during operation.
- Do not operate in live environment. The lasher is composed of metal components,
and tow ropes connected to the unit can conduct electricity. The weight of the lasher
can cause cables to sag and could increase proximity to live wires. Plan work
accordingly.
- Do not operate when judgement is impaired (medication, alcohol or otherwise).
Improper use can result in property damage, injury or death.
- Be aware of and follow all safety rules applicable to overhead cable installation,
including, but not limited to, the Occupational Safety and Health Act of 1970,
Subpart V - Power Transmission and Distribution.

4 | P a g e
Rev. D 20-July-22
1. Loading the Wire Spools on the Lasher
To prepare the Falcon Lasher for lashing, the first step is to load the lashing wire.
Whether using .045” or .038” lashing wire, follow these steps.
1a) Release latch located under the handle and on top front of magazine door.
Swing open magazine door.

5 | P a g e
Rev. D 20-July-22
1b) Remove two coil ties from the wire coil and pull out approximately 12” of wire
from inside of coil. Take loose end of wire and insert through wire guide in
center of the wire magazine door pulling out at least a 12” length.
1c) Place coil in magazine. Remove the last two wire ties and close magazine
door. Load the second wire magazine in same manner.

6 | P a g e
Rev. D 20-July-22
1d) It is optional to take the Outside coil of wire and, pulling out approx 12”, feed
it through the small hole in the outside of the magazine. This can later be
attached to the body of the Lasher once the magazine is closed. This will
prevent any possibility of the Wire coil spinning inside the magazine.

7 | P a g e
Rev. D 20-July-22
2. Threading the Lashing Wire
You have loaded the lashing wire, now you are ready to thread the lashing wire.
Note that when facing the direction the Lasher will travel, the LHS is on your left and
the RHS is on your right. Just follow these steps: For the RHS:
2a) Take the free end of the lashing wire from center of wire magazine door and
pull out approximately 2 feet of wire.

8 | P a g e
Rev. D 20-July-22
2b) Pass the wire over the guide roller on the magazine cover and then form a
loop with wire such that the entry onto the drive wheel is at the BOTTOM and
toward the outside of the drive wheel and the exit from drive wheel also at the
BOTTOM but toward the inside. Follow the label above the Drive wheel.
2c) Repeat steps for the LHS of lasher. Take the free end of the lashing wire from
center of wire magazine door and pull out approximately 2 feet of wire.
2d) Pass the wire over the guide roller on the magazine cover and then form a
loop with the wire such that the entry onto the drive wheel is at the TOP and
toward the outside of the drive wheel and the exit from drive wheel also at the
TOP but toward the inside. The LHS and RHS looping pattern should form a
mirror image from eachother.
Follow the label above the Drive wheel.

9 | P a g e
Rev. D 20-July-22
2e) When using non-metallic wire, it is recommended that the wire is threaded
under the guide wheel on the lashing wire door as shown. This will ensure
alignment of the wire to prevent it from falling off the drive wheel.
Note: Alternate lasher shown, threading method is the same.
2e) Alternate threading method:
When using metallic wire, additional friction may be encountered, resulting in a
higher pull force. If your model has rubber drive wheels, the lashing wire can
be threaded in reverse orientation to reduce pull force, as shown:
Note: Alternate lasher shown, threading method is the same.

10 | P a g e
Rev. D 20-July-22
2f) Alternate threading method for wrap on aluminum wheels:
When galvanized or stainless lashing wire on aluminum hub wheels, in poor
weather conditions, a double wrap around the roller at the lasher wire door may be
used to add tension to the wire to ensure grip:

11 | P a g e
Rev. D 20-July-22

12 | P a g e
Rev. D 20-July-22
3. Setting the Front Gate:
To open the front gate, follow these steps:-
3a) Pull front cable roller until lock releases.
3b) Once the lock is released, swing roller completely open to clear the cable.
This will engage the drum lock and keep the drum from rotating.

13 | P a g e
Rev. D 20-July-22
3c) To release drum lock, push front cable roller back to the closed position.
4. To open the Strand Lock:
To open the Strand Lock, follow these steps:-
4a) Pull the strand lock lever on the LH side of the strand lock. The center pin
should drop down to the level of the retaining ring.

14 | P a g e
Rev. D 20-July-22
4b) To turn the strand lock out of the way, turn the top lever 180 degrees. The
lever can be pulled up until it locks into position to lock the strand lock in
position. Note that when overlashing, leave strand lock open.
Strand lock locked in open position

15 | P a g e
Rev. D 20-July-22
Strand lock locked in closed position.
5. Setting the Rear Gate:
To open rear gate, follow these steps:-
5a) To open rear gate simply pull the level and swing the roller to the side.
The pin will lock the roller in the open position:

16 | P a g e
Rev. D 20-July-22
5b) To close rear gate, pull the lever again and swing into the closed position.
5c) To adjust the height of the rear gate roller up or down, push down on the side
tab and the roller sub assembly to slide it on it’s supporting post. Grab this
same tab to slide the roller back up the supporting post:

17 | P a g e
Rev. D 20-July-22
To open the rear bearing race, follow these steps:-
5d) In order to insert a cable, the rear bearing race needs to be opened. Pull on
the lever on the RH side of the machine and the bearing race will swing open:
Manually swing the rear bearing race shut once the cable is in place, before
operating the machine.

18 | P a g e
Rev. D 20-July-22
You are now ready to proceed to place the Falcon Lasher on the supporting strand.
Position the cable in the lasher. Close front and rear gates and rear bearing race.
Adjust rear roller to center and support the cable. Raise the clutch handle to allow
additional wire to be pulled out of the machine without rotating the machine to tie off
lashing wire to strand:

19 | P a g e
Rev. D 20-July-22
Attach towing rope to pulling rings on front of lasher.