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INTERMEDIATE & TENSIONER
Ref. PN 7000

07

06

EXTENSION ARM
Ref. PN 7000

If the System has been provided with the Extension Arm, this shall be 
installed in place of Upper Mounting Bracket as in step:

1.  The  Extension  Arm  is  provided  pre-installed  with  the  Mounting 

Bracket for the Upper end of the system.

Follow the simple steps for easy installation-Top Rung 

*

Hold the extension arm against the upper last three rungs of the 
ladder.

Hold the fisher plate in front of the extension arm.

*

Insert  the  given  U-  bolts  through  the  rung  in  to  the  fisher  plate. 
Tighten the nuts of the U-bolts Repeat the exercise for the Second 
Rung from the top On the third rung of the ladder, from the top Insert 
the given U-bolt through the ladder rung in to the slot so as to pass 
through the extension arm tighten the nuts of the U-Bolt.

Step 06- Installation of the Extension Arm: Ref. PN7000 (06) 

Step 4:  Installation of the Intermediate: Ref. PN 2001 (04)

Place the fisher plate of the Intermediate on the back of the ladder rung. 
Fasten the Intermediate Plate with the fisher plate with the help of the 
given fasteners. Ensure that the cable is in between the two arms of the 
intermediate. It is recommended to install an Intermediate at an interval 
of every 10 m length of the Cable.

The intermediates reduces large deflections in the cable due to wind 
pressure.

Ÿ

The Tensioner is installed at the lower end of the system. 

Ÿ

Open the threads of the extension rod of the tensioner from both 
ends. Ensure that 75% of the thread is open.

Ÿ

Insert the eye of the tensioner to the mounting bracket at the lower 
ladder rung.

Ÿ

Insert the stainless steel locking pin so as to pass through the eye of 
the tensioner and the mountin brackets.

Ÿ

Insert the pin ring in the locking pin to lock it.

Fix the tensioner to the wire rope.

Ÿ

Fix the thimble (part of Ref PN 6000 (01)) to the eye of the tensioner 
by the given fastener

Ÿ

Loop the Cable across the thimble and ensure at least 300mm of the 
cable is overlapping.

Ÿ

Next, fasten the stainless steel U bolts (part of Ref PN 6000 (01)) 
approximately 50 mm apart.

Ÿ

If the cable is in excess make a loop and tie the loop with cable ties.

Ÿ

If it is necessary to cut the cable, seal the loose end of the cable by 
adhesive tape after cutting it.

Providing tension to the wire rope: 

Ÿ

Open both the chuck nuts and hold the tensioner eye. 

Ÿ

Insert  a  steel  rod  in  the  housing  of  the  tensioner  and  rotate  the 
tensioner in anti clock wise direction. 

Ÿ

Rotate it until reasonable tension is achieved in the cable.

Ÿ

Tighten both the chuck nuts.

Step 5: Installation of the Tensioner: Ref PN 7000 (05)

50mm

The Label is fixed to the lower most rung of the ladder using cable ties 

Step 07- Label 

ADDRESS 

Helpline: 09323123468

KARAM INDUSTRIES C-35A, PHASE-III, ESIP, SITARGUNJ,
DISTT. UDHAM SINGH NAGAR, UTTARAKHAND

PRODUCT  

CODE 

INSTALLATION DATE

LENGTH

 INSPECTION REPORT 

/                 / 

MTRS.

                                     Date :      /                 / 

BATCH NO. 

YEAR OF MANUFACTURE :

REVALIDATION DUE ON 

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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