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Installation of Heavy Kits

What are "heavy kits"? Please use the link if you need general information first. This page is about the assembly of such kits or self-assembled sets of M12 rope holders and 4 mm rope. All information on this page can be seen in connection with the 10 - 25 assembly graphics for the respective cable system. Please use the link and go to the cable system you have purchased. The images shown here complement the flow charts there and also apply to the medium design, if only cross holders and no eyebolts are included. Please clarify before ordering if you need tools!

The symbols in the graphic mark the cross mounts, the red bars show the alignment of the grooves of the head. After drilling, all holes are cleaned with a drill hole brush and / or blower. Then the rope holder is installed without grub screws (photo). Please refer to the product sheet of the wall holder (standard for kits usually WM 12191 together with SD 16130 and VM 00300).

For some systems it is necessary to cut one or more pieces of wire rope with approx. 30 cm excess length from the wire rope reel and loosely insert them into the grooves of the holders (photo) without inserting or tightening the grub screws. On both sides the wire rope has a minimum of 10 cm overhang. Further details can be found in the respective graphic. Sagging ropes are always recognizable as such due to the wavy shape (graphic).

On the graphics of the respective basic form an assembly with as little cutting as possible is shown, which does not require any cable tensioner. For this purpose, the rope is initially laid slack in the first holder with about 10 cm overhang. The grub screw is inserted, moderately tightened and in the second step tightened again by holding the holder with an open-end wrench (photo).

Then the wire rope is guided to the opposite holder and placed in the groove, gripped behind the mount with a mounting vice and pulled taut by hand (about 10 - 20 kg). Often a second mounting vice for temporary fixing directly behind the holder (photo one line below) is helpful so that inserting and tightening the grub screw is easier. Then - again with about 10 cm of overhang - the rope is cut behind the holder with a wire rope cutter.

In some processes, it is necessary to temporarily fix a tightened wire rope, without screwing the set screw into the cross mount, because later another wire rope will be inserted there. This fixation of the pre-tensioned state is done with a second mounting vice directly behind the cable holder (photo), or with a clamping ring or a cross clamp, which is often part of the kit. After tightening the grub screw, the fixation is removed.

If a rope runs through more than two holders, it is initially only fixed to the outer holders. In the middle holder, it is only inserted, the grub screws there are not screwed in or if only for temporary fixation of the rope, so it does not slip out. The final tightening of these grub screws is done at the end or then, if in the respective holder a second rope is inserted a little later (photo) and the holder is marked bold red on the corresponding graphic.

In places where wire ropes intersect, free-floating cross clamps are placed when the graphics show it. Finally, projecting rope ends behind the respective cable holder are bent so that they, for example, represent an extension of the cable axis. Thereafter, the rope ends still get pressed end sleeves. If the ropes protruded about 10 cm each, as indicated, they can be gripped and re-tightened there in later years, if necessary.