KStrong FXline AFF6000 User manual

THESE INSTRUCTIONS APPLY TO THE FOLLOWING MODEL:

FXLINE SYSTEMS

INSTALLATION GUIDE

FXline AFF6000

Horizontal Life Line Systems

FXline AFF5000FXline AFF8000

Vertical Life Line Systems

FXline AFF9000

FXline AFF4000 Floor & OverheadFXline AFF7000

FXline AFF4000 Roof Mounted

Disclaimer: Illustrations may be changed without notice. All dimensions and specifications are approximate and drawings not to scale.

If there are any questions or queries about installation, usage, inspection or maintenance our team would be Happy to Help.

Please forward your inquiry to: [email protected]

Warning: The products enumerated in this instruction manual are a part of personal protective, work support, or rescue system. The user must read

and follows the manufacturer's instructions for each component of the system. This manual contains information that is important to the user's safety

and should be kept in a safe place for future reference as needed. Please contact KStrong for any questions regarding the use of this equipment. Fall

arrest systems and equipment are lifesaving products and are designed to reduce the potential of serious injury in the event of a fall. However, in the

event of a fall, the user may experience a force on their body. In case there is a doubt about the user's ability to utilize this product, the user must

consult a physician. Pregnant women and minors are not considered fit for the use of this equipment..

Please read and understand the manufacturer's instructions for each component or part of the complete system. Manufacturer's instructions

must be followed for proper use, care, and maintenance of this product. These instructions must be retained and be kept available for the

user's reference at all times. Alterations or misuse of this product, or failure to follow instructions, may result in serious injury or death.

Note: The user is advised to keep this user instructions document for the life of the product.

Vertical Anchorage Lifeline System on Aluminium Rail System and

Vertical Anchorage Lifeline System on Aluminium Rails with Rungs

Product Code Page No.

Vertical Anchorage Lifeline System on Rigid Cable Line FXline AFF6000 2

FXline AFF7000 3-9

AFF4000

(Floor/Ceiling Mounted)

AFF4000

(Roof MOUNTED)

Horizontal Anchorage Life Line System

INDEX

Vertical Anchorage Lifeline System on Rigid Cable Line

11-21

AFF8000 & AFF9000

AFF5000

Horizontal Aluminum System

22-26

27-30

Proof loading

Pre-Use Checks

Precautions

Kstrong Compass App

Tools

Torque Chart

Equipment Record

1. VERTICAL ANCHORAGE LINE SYSTEM ON RIGID CABLE LINE

Ref: FXline AFF6000

ŸMaterial: Stainless Steel 316

ŸConstruction: 7x19

ŸDiameter: 8mm

ŸD Shackle: Stainless Steel

Wire Rope (Cable Wire) with D Shackle

Conforms to: EN353-1:2014 + A1:2017

Ref. AFF518XXX(DS) (where XXX is the

length of the wire rope in meters)

Wire Rope Cap

Ref. AFF513100

ŸMaterial : Aluminium Alloy

Set of 2 U-Bolts and 1 Thimble

Ref. AFF513000

ŸU- Bolts : Qty- 2 nos.

Material : Stainless Steel 316

ŸThimble : Qty- 1 no.

Material : Stainless Steel 316

Mounting Bracket

Ref. AFF511000

ŸMaterial of Rope Grab:

Stainless Steel Grade 316

ŸMaterial of Karabiner: Alloy

Steel

ŸAnti inversion mechanism

Rope Grab

Ref. AFG805203

Intermediate

Ref. AFF511500

ŸMaterial: Stainless Steel Grade 316

ŸRecommended Installation - Every 10 m

Tensioner

Ref. AFF514000

ŸQuantity: 1 nos

ŸRegulates tensioning of the cable

Equipped with a Tension Indicator

ŸMaterial: Stainless Steel Grade

316

Shock Absorber

Inspection Plate

Ref. AFF115100

Extension Arm (Finish-ED Coating Black) - Ref.: AFF516600

Optional

ŸMaterial: Stainless Steel 316

ŸCompatible with rung

diameter: Ø25.0mm -

Ø96.0mm

ŸComplies with EN 795 Type A

ŸBreaking Strength > 23 kN

Optional

ŸMaterial: Stainless Steel.

ŸMinimum Breaking Strength:

23 kN

Mounting Bracket

Ref. AFF511001

ŸCompatible with rung

diameter- Ø22.0mm-

Ø114.0mm

Intermediate

ŸRecommended Installation- Every 10 m

ŸMaterial: Stainless Steel 316

Ref. AFF511500

Shock Absorber

Ref. AFF512000

ŸLimits the impact of force in the

event of fall to less than 6 kN

ŸMaterial: Stainless Steel 316

ŸConstruction: 7x19

ŸDiameter: 8mm

ŸMaterial: Stainless Steel 316

ALSO AVAILABLE

Wire rope without loop Ref. AFF518XXX(S)

Wire Rope (Cable Wire)

Ref. AFF518XXX (Where XXX is the Length of

the wire rope in meters)

Wire Rope Cap

ŸMaterial: Aluminium Alloy

Ref. AFF513100

Inspection Plate

Ref. AFF115100

Mounting Bracket*

Ref. AFF511000

ŸBreaking Strength > 23 kN

ŸComplies with EN 795 Type A

ŸMaterial: Stainless Steel 316

Wire Crimping Assembly

ŸMaterial of Rope Grab: Stainless Steel

316

ŸAnti inversion mechanism

ŸMaterial of Karabiner: Alloy Steel

Rope Grab

Ref. AFG805101

ŸU - Bolts: Qty - 2 nos. Material:

Stainless Steel 316

ŸThimble: Qty - 1 no. Material:

Stainless Steel 316

Set of 2 U-Bolts & 1 Thimble

Ref. AFF513000

Tensioner

Ref. AFF514000

ŸQuantity: 1 nos.

ŸMaterial: Stainless

Steel 316.

ŸRegulates tensioning

of the cable.

Equipped with a

Tension Indicator

2. VERTICAL LIFE LINE SYSTEM

Ref: FXline AFF7000

Conforms to: EN353-1:2014 + A1:2017

CABLE TERMINATION

Ref. AFF6000 & AFF7000

Ÿ A suitable cable termination may be selected according to the

site condition, u-bolts and thimbles are only allowed at bottom

termination according to EN353.1:2014

STEP 1: CABLE TERMINATION

Wire Crimping

Assembly

(Step 2)

Aluminum

Ferrules

Aluminum

Endcap

SS Thimble

Heat Shrink

Tube

Ÿ Ensure that the first ferrule is as close as possible to the thimble,

the next ferrule should be 50mm apart from the first one.

Ÿ Crimp the Ferrule using a 20 Ton Hydraulic Crimping head and

300mm2 crimping dies.

Ÿ Insert the wire in heat shrinking tube.

Ÿ Loop the wire across the Stainless Steel Thimble.

Ÿ Shrink the tube with a hot air gun.

Ÿ Insert the aluminum cap in the free end of wire and crimp it.

STEP 2: WIRE CRIMPING ASSEMBLY

Ÿ Insert 2 ferrules in the wire.

Ÿ Insert the end of the wire back into the Ferrule.

Ÿ Cover the entire assembly up to the bottom edge of the ferrule

with a heat Shrinkable tube.

CABLE TERMINATION

Ref. AFF6000 & AFF7000

Ÿ The swage tube has markings to identify exact positions of

swaging.

STEP 3: CABLE SWAGING

Ÿ Insert the cable into the swage tube.

Ÿ Operate the machine to start the swaging operation until the

green light is on.

Ÿ Repeat the process for all markings(5 times minimum).

Ÿ Ensure that the mark on the swage tube is in the center of the

die.

Ÿ Place the swage tube on the hex loc die of a hydraulic swaging

tool (130kN capacity).

50mm

U bolt & Thimbles

AFF513000

Ÿ Loop the Cable across the thimble and ensure at least 300mm of

the cable is overlapping.

Ÿ If it is necessary to cut the cable, insert aluminium cap in the free

end of wire rope and crimp it

STEP 4: U BOLT & THIMBLE

Ÿ Next, fasten the stainless steel U bolts (Part of Ref AFF513000)

approximately 50 mm apart.

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

INTERMEDIATE & TENSIONER

Ref. AFF6000 & AFF7000

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

Ÿ Place fisher plate of the Intermediate on the back of ladder rung.

Fasten the Intermediate Plate with the fisher plate with help of

given fasteners. Ensure that the cable is in between the two arms

of intermediate. It is recommended to install an Intermediate at an

interval of every 10 m length of the Cable.

STEP 5: INSTALLATION OF THE INTERMEDIATE: Ref. AFF511500

Ÿ Next, fasten the stainless steel U bolts (part of Ref AFF513000)

approximately 50 mm apart.

Ÿ Rotate it until reasonable tension is achieved in the cable and the

tension indicator disc is free to rotate.

Ÿ Tighten both the chuck nuts.

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

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 Insert the eye of tensioner to the mounting bracket at the lower

ladder rung.

Ÿ Open the threads of extension rod of the tensioner from both ends.

Ensure that 75% of the thread is open.

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

FIX THE TENSIONER TO THE WIRE ROPE:

Ÿ Insert the stainless steel locking pin so as to pass through the eye

of the tensioner and the mountin brackets.

Ÿ If it is necessary to cut the cable, insert aluminum cap in the free

end of wire rope and crimp it.

Ÿ Loop the Cable across the thimble and ensure at least 300mm of

the cable is overlapping.

PROVIDING TENSION TO THE WIRE ROPE:

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

Ÿ Fix the thimble (part of Ref AFF513000) to the eye of the tensioner

by the given fastener.

STEP 6: INSTALLATION OF THE TENSIONER: REF AFF514000

SHOCK ABSORBER & CABLE TERMINATION

Ref. AFF7000

Ÿ A suitable cable termination may be selected according to the

site condition, u-bolts and thimbles are only allowed at bottom

termination according to EN 353.1:2014

STEP 8: CABLE TERMINATION

ŸEnsure that the energy absorber is fitted with red arrow on label pointing

down wards.

ŸThe spacer ensure the correct position of energy absorber.

ŸConnect the shock absorber to top mounting bracket by inserting the

fastener and the nylon spacer so as to pass through mounting bracket

and eye of energy absorber.

ŸConnect the end extremity to energy absorber by inserting fastener

through eye of energy absorber.

STEP 7: INSTALLATION OF SHOCK ABSORBER

EXTENSION ARM

Ref. AFF6000 & AFF7000

ADDRESS

PRODUCT

CODE

INSTALLATION DATE

LENGTH

INSPECTION REPORT

/ /

MTRS.

Date : / /

BATCH NO. YEAR OF MANUFACTURE :

REVALIDATION DUE ON

STEP 9: INSTALLATION OF THE EXTENSION ARM: Ref. AFF516600

Ÿ 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

If the System has been provided with the Extension Arm, this shall be

installed in place of Upper Mounting Bracket as in step:

Ÿ 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.

Ÿ Repeat the exercise for the Second Rung from the top.

Ÿ Hold the extension arm against the upper last three rungs of the

ladder.

Ÿ Hold the fisher plate in front of the extension arm.

Ÿ Insert the given U- bolts through the rung in to the fisher plate.

Tighten the nuts of the U-bolts

STEP 10: LABEL AFF115100

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

cable ties.

FALL ARRESTER

Ref. AFF6000 & AFF7000

A/2

Ÿ Check the harness that all the straps are connected and buckles

are secured and the harness has been adjusted to give it a snug

fit.

STEP 12: CONNECT THE HARNESS TO THE ROPE GRAB

Ÿ Connect the Rope Grab to the front attachment point of the full

body harness with the help of the Karabiner of the connecting

lanyard.

Ÿ Ensure that the gate of the karabiner is closed and locked

properly.

STEP 11: INSTALLATION OF THE ROPE GRAB:

Ref. AFG805203

Ÿ Hold the Rope Grab as shown in the figure.

Ÿ Push the Rope Grab through the cable and rotate it counter

clockwise.

Connect Rope Grab to the Cable following the given simple

steps:

Ÿ Ensure the arrow on Rope Grab points up wards.

Ÿ Connect the other end of the shock absorbing lanyard to the

harness of the user by the other Karabiner.

Ÿ Insert the karabiner of the shock absorbing lanyard AFG8052031

12 in the eye of the Rope Grab.

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