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BEND
Ref. PN 5000 

Step 3A:  Curved Alu. Rail (Outer Wall Mounted): 

Ref. PN 5000 (09A)

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Join the curved Alu. Rail with the Alurail intermediate. Match the 
sections of both the Alu. Rail.

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Place the junction plate on either side of the Alu. Rail with the holes 
of junction   plate matching with those of Alu. Rail intermediate and 
curved alu rail fix both the plates by 4 sets of fasteners.

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Ensure  that  the  gap  between  the  two  rails  is  not  greater  than 
1.5 mm.

Step 3B: Curved Alu. Rail (Inner Wall Mounted): 

Ref. PN 5000 (09B)

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Join  the  curved  alurail  with  the  Alurail  intermediate.  Match  the 
sections of both the Alu.rail. 

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Place the junction plate on either side of the Alu. Rail with the holes 
of junction plate matching with those of Alu. Rail intermediate and 
curved alu rail fix both the plates by 4 sets of fasteners.

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Ensure that the gap between the two rails is not greater than 1.5 
mm.

Step 3C: Curved Alu. Rail (Floor/ceiling): 

Ref. PN 5000 (10)

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Join  the  curved  alurail  with  the  Alurail  intermediate.  Match  the 
sections of both the Alu.rail. 

è

Place the juncti-on plate on either side of the Alu. Rail with the holes 
of junction plate matching with those of Alu. Rail intermediate and 
curved alu rail fix both the plates by 4 sets of fasteners.

è

Ensure that the gap between the two rails is not greater than 1.5 
mm.

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TROLLEY & RECOMMENDED PPE
Ref. PN 5000 

Step 4A:  Trolley For Wall  Ref. PN 5000 (13) 

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Insert the trolley in the Alu. Rail extremity. Press the termination of 
the extremity and pass the trolley over the termination.

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After the trolley slides on the Alu. Rail the termination cones back to 
its original position ensuring that the trolley does not slide off the 
Alu. Rail.

Step 4B:  Trolley For Ceiling/Floor: Ref. PN 5000 (12)

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Insert the trolley in the Alu. Rail extremity. Press the termination of 
the extremity and pass the trolley over the termination.

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After the trolley slides on the Alu. Rail the termination comes back 
to its original position ensuring that the trolley does not slide off the 
Alu. Rail.

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Once  the  system  is  installed  the  user  can  use  a  work  positioning  harness  along  with  a  shock 
absorbing twin lanyard to climb up. He can use the double lanyard when he needs to exit the fall 
arrest system while working on towers. When the user needs to exit from the fall arrest system in a 
horizontal plane towards the edge of the tower he may need to travel restraint lanyard model 2003. 
While working on the tower a work positioning lanyard helps in attaining a comfortable position.

RECOMMENDED PPE

Summary of Contents for Vertex PN 7000

Page 1: ...tex PN 7000 Vertex PN 8000 Vertex PN 9000 Horizontal Life Line Systems Horizon PN 4000 Horizon PN 5000 FIXED LINE SYSTEMS www karam in For further details on all our products contact below C 35A Phase III ESIP Sitarganj Distt Udham Singh Nagar Uttarakhand 262405 India Customer Care No 1800 103 7085 Toll Free e mail customercare karam in ...

Page 2: ...rker workinginsomeofthe mosthazardousindustrialconditions OperationsatKARAMareunderconstantvigilancetoprovidethefinestinQualityofproductandservice FALL PROTECTION EQUIPMENT MANUFACTURING 01 CongratulationsonyourPurchase You are now a proud owner of KARAM FIXED LINE SYSTEM and CONGRATULATIONS again that you have steppedintothebusinessofsavingpreciouslives To ensure the fixed line systems lives up t...

Page 3: ...o channel grips and fastened on the same with the help of the given fasteners The drawings below illustrate thepositionofthechannelgripsfordifferentsections COMPATIBLE SUPPORT SECTION PROCESS Recommended Torque VERTICAL LIFE LINE SYSTEM Ref PN 7000 MOUNTING BRACKET Ref PN 7000 03 02 Step 1A on the Upper Ladder Rung Installation of the Mounting Bracket Ref SA12 Step 1A Step 1B Step 1C Some Structur...

Page 4: ... Cable Extrimit Poke Pi STEP 1 STEP 2 STEP 3 STEP 4 05 04 STEP 3C Cable Swaging Ÿ Insertthecableintotheswagetube Ÿ Theswagetubehasmarkingstoidentifyexactpositionsofcrimping Ÿ Place the swage tube on the hex loc die of a hydraulic crimping tool 130kNcapacity Ÿ Ensurethatthemarkontheswagetubeisinthe centerofthedie Ÿ Operate the machine to start the swaging operation until the green lightison Ÿ Repea...

Page 5: ...nd pressure Ÿ TheTensionerisinstalledatthelowerendofthesystem Ÿ Open the threads of the extension rod of the tensioner from both ends Ensurethat75 ofthethreadisopen Ÿ Insert the eye of the tensioner to the mounting bracket at the lower ladderrung Ÿ Insert the stainless steel locking pin so as to pass through the eye of thetensionerandthemountinbrackets Ÿ Insertthepinringinthelockingpintolockit Fix...

Page 6: ...ected and buckles are securedandtheharnesshasbeenadjustedtogiveitasnugfit Connect the Rope Grab to the front attachment point of the full body harness with the help of the Karabiner of the connecting lanyard RefPN7000 07 Ensurethatthegateofthe karabinerisclosedandlockedproperly 09 08 RECOMMENDED PPE Ref PN 7000 Once the system is installed the user can use a work positioning harness along with a s...

Page 7: ...4000 10 CableExtremity Ref PN7000 03 7 STRANDS OF 19 WIRES Roof Top Anchor Port Extremity Ref PN07 A Roof Top Anchor Port Intermediate Ref PN07 B 11 Ref HORIZON PN 4000 Over the Head Wire Rope Ref PN 9XXXS Intermediate Ref PN 4000 10 Carriage Body Ref PN 4000 08 Spring Type Shock Absorber Ref PN 4000MU 02 Cable Extremity with swaged end PN 4000 15 Inspection Plate Ref PN 4000 20 Wheel Type Carriag...

Page 8: ...kets on the base plates using nutsandbolts Step C Intermediate Bracket Ref PN 4000 10 è Insertthecablethroughtheintermediate è Connect the intermediate to the receiving structure with the fastener è The angle of the Intermediate may be changed by inserting the intermediatefastenertodifferentholesprovided Standing Seam Roof Sheets Upto 430 Mm Seam Distance These posts arefitted ontheseams using alu...

Page 9: ...ets These Posts are suitable for a variety of trapezoidal roof sheet designs It has multiple holes to suit different peak distances 15 Step A Roof Top Anchor Post Extremity Ref SA 07G è Stick the base plates of the post to the roof with double adhesive EPDMsheet è Drill 16 holes for the blind rivets four at each corner rotate the base 0 plateby90 iftheholesdoesnotmatchtheseamposition è Rivetwithar...

Page 10: ...POSTS Ref PN 4000 Trapezoidal Roof Sheets Blank Posts These are blank posts on which holes may be punched to match the roof Profile on trapezoidal roof 17 Step A Roof Top Anchor Post Extremity Ref SA 07K è Using the template identify the location of the holes to be punched intheblankbaseplate è Mount the template and the blank base plate on the base of the drill machine è DrillholesontheblankBasep...

Page 11: ...aseofanIBeam è Insertthestuds è Tightenthenutsonthetopandbottomoftheposts è Placetheuniversalextremityplateonthetopflange è Tightenthenutsandboltstosecuretheuniversalextremityplateto thepost Step B Intermediate Roof Top Anchor Post SA25 è Place the top flange of the post on the metal rafter of the roof or gratingofthewalkway è Holdthebottomplateonthebottomsideofthestructure è Insertthestuds è Tigh...

Page 12: ...000 09 è ConnecttheotherconnectortothetensionerPN4000 03 è Apply tension to the cable until the Ltension indicator plate touches thespring è Take the shock absorber out of service when the spring is elongatedduetoanimpactfromafalloftheuser Step 3 Shock Absorber Ref PN 4000MU 02 TENSIONER INTERMEDIATE Ref PN 4000 è Open the threads of the tensioner from both ends Ensure 75 of thethreadisopen è Inse...

Page 13: ...es along the length of the line with the user who is connected to it by using a karabiner followed by a Connecting element connected to the full body harness of the user Thecarriagemaybeattachedordetachedfromthelineatanygivenpointbytwoconsecutivedeliberateaction Inapplicationson roofs thecarriermaybeusedoneithersideoftheroof RECOMMENDED PPE Step 7 Carriage Body VERTICAL ANCHORAGE LIFE LINE SYSTEM ...

Page 14: ...lu Rail extremity Press the termination of theextremityandpassthe trolleyoverthetermination After the trolley slides on theAlu Rail the termination cones back to its original position ensuring that the trolley does not slide off the Alu Rail SAFETY LOCKING PIN L CLAMP LOCKING JIB L CLAMP LOCKING JIB 25 Step 3 Installation of Alu Rail Extension PN 8000 03 Repeat step 3 to join the Alu rail Extensio...

Page 15: ...rt to the end of the Alurail Extensionusingamountingnut For trapezoidal roof sheets use blind rivits to install the Alurail Extension support to the roof for standing seam fasten the bracket usingnutbolts 27 MOUNTING BRACKET Ref PN 8000 PN 9000 Step 1 Installation of Mounting Nut PN5000 03 Insert the mounting nut into the alu rail extremity The first mounting nut must be at 300mm from the bottom e...

Page 16: ...th Recess Ref PN 5000 05 è Connectthebrackettothemountingnutasshowninthedrawing è To install the mounting bracket in concrete use 12 mm Chemical fasteners OptionalAccessory ChemicalFastenerSA12 04 Concrete 25mPA Step 2C Ceiling Mounting Bracket Ref PN 5000 06 è Connectthebrackettothemountingnutasshowninthedrawing è To install the mounting bracket in concrete use 12 mm Chemical fasteners è Optional...

Page 17: ...Rail intermediate and curvedalurailfixboththeplatesby4setsoffasteners è Ensure that the gap between the two rails is not greater than 1 5 mm 30 TROLLEY RECOMMENDED PPE Ref PN 5000 Step 4A Trolley For Wall Ref PN 5000 13 è Insert the trolley in the Alu Rail extremity Press the termination of theextremityandpassthetrolleyoverthetermination è After the trolley slides on theAlu Rail the termination co...

Page 18: ...ncerned personnel on the subject of Pre Use Inspection of the System as per a defined guideline afterthesystemhasbeeninstalledbyKARAMpersonnel Post Installation Inspection Pre Use Checks Donotusethesystemreceivingstructureisfoundweak Checking the receiving structure Checking the System è Cleanthesystemfromdust dirt Checkforanymechanicaldefects è Checkforwearandtearinallcomponentsorunusualbendingor...

Page 19: ...eadditionalprecautionstolimitthepossibility ofinjurytotheuserordamagetotheequipment Hazardsmayincludebutarenotlimitedto extreme temperatures caustic chemicals corrosive environments high voltage power lines explosive or toxic gases moving machinery sharp edges high velocity winds Etc Do not expose the equipment toanyhazardwhichitisnotdesignedtowithstand Consultthemanufacturerifindoubt Rescue Plan ...

Page 20: ...ench Size Socket Size 6 8 10 12 16 10 13 16 19 24 10 13 16 19 24 Allen Bolt Size Allen Key Size Allen Grub Screw Key Size 6 8 10 12 4 6 8 10 3 4 5 6 WRENCH SIZE ALLEN KEY SIZE TORQUE CHART Bolt size Recommended Torque 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 9 Nm 22Nm 29 Nm 50 Nm 80 Nm 125Nm Measuring Tools Detect Digital Torque Wrench Distance Meter Laser Tool Tape Vernier Consumables Miscellanous Tools...

Page 21: ...ising out of faulty or defective materialsorworkmanshipforaperiodofONEYEARfromthedateofpurchase in case of any defect develop in this equipment during the period of warranty KARAM undertakes the responsibilitytoreplace repairtheequipmentfreeofcost Thiswarranty however isnotvalidinthecaseofthefollowingevents 1 TheequipmentisnotusedaccordingtotheInstructionsgivenintheUser sManual 2 Thedefectsarecaus...

Page 22: ... Ÿ Easytoinstallatsite Ÿ Tailormadesolutionsarealsoavailable Ÿ Indigenouslymade Ÿ Fireretardant Ÿ Corrosionandmoistureresistantmaterial Ÿ Longlifespan Ÿ It can be used along with horizontal life line systems designed for overtheroof Application Material of Constructions MOC FRP walkways with Hot Dipped Galvanised SS316 Mounting Brackets Operating temperature 30 to 60 C Life Span 20 Years Recommend...

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