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Installation of Light Kits

This page is about the installation of 'Light Kits' (see link for general information) and of self assembled sets/kits from 6 mm-cross mounts and 1.5 mm cable. All information on this page should be considered in connection with the 10-25 mounting 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/graphs. Before ordering, please check to see if you need tools!

The symbols in the diagram represent the wire rope mounts. The little red bars indicate the alignment of the cross head grooves. After drilling, the boreholes are cleaned with borehole brushes and blow pumps. The cross mounts are inserted into the dowels and fastened without grub screws (photos). Please note the product sheet of the mount WM 06093. When installing into exposed brickwork, fastening into the joints is an option; in this case, then without the washer. 

For some systems, it is necessary to begin by cutting off one or more pieces of rope approx. 30 cm from the rope spool/reel. These are loosely inserted into the grooves of the rope mounts (photo) without inserting or tightening the grub screws. Behind each mount there should be at least 5 cm wire rope overhang. Further details can be found in the respective diagram/graphic. Wavy red lines represent loose/slack wire rope. 

The diagrams of the respective basic forms show installations that require minimal cutting and that do not require a turnbuckle. Begin by laying the wire rope loosely into the first mount with an approx. 4 - 5 cm overhang. Then, insert the grub screws into the cross heads and fasten them by hand with an Allen key (Allen wrench/hex key).

The rope is then lead to the mount on the opposite side and placed into the groove. Attach a mounting vice directly behind the mount and tighten the rope by hand (a little manual force: 2-5 kg). Sometimes, it is helpful to use a second vice to temporarily fix the wire rope behind the mount (see photo below). You then can insert and fasten the grub screw easily with both hands free. Proceed by cutting the wire rope behind the mount with a wire cutter, leaving a 4 - 5 cm overhang.

Sometimes it is necessary to temporarily fix/fasten a tightened wire rope without screwing in the grub screw to the rope mount; this is because an additional wire rope will be inserted there. This fixation of the pre-tightened condition is done with a second mounting vice directly behind the rope mount (photo), or with a clamping ring or a cylinder cross clamp, which is often part of the rope/cable system. After tightening the grub screw, the fastener is removed.

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

In places where wire ropes intersect, floating cross clamps are placed as the diagrams show. Finally, protruding rope ends are bent behind the respective cross mounts so that they represent an extension of the rope axis. Thereafter, the rope ends are fitted with end sleeves (ferrules). If the wire ropes each protrude about 4 - 5 cm, as stated, they can be easily gripped and tightened there in later years, if necessary.