Installation of light kits

What are 'light kits'? Please use the general information link if you need help . This site is about the mounting of such kits or self collected sets from 6 mm-cross holders and 1.5 mm cable. All information on this page can be seen on the 10-25 mounting graphics in connection with the respective cable system. Please use the link and go to the cable system you have purchased. The images shown here complement the local flow graphs. Please check before ordering, if you need tools!

The symbols shown in the graphic mark the wire rope holders / mounts. The little red bars indicate the alignment of the cross heads grooves. After drilling the boreholes are cleaned with borehole brushes and blow pumps. The cross holders are inserted into there dowels and fastened without the set screws (Photos). Please, note the product sheet of the holder WM 06093. When installing into exposed brickwork, fastening into the joints is an option. Then without the washer.

It can be helpful, for some systems, to begin with one, or a number of wire rope strands, each with approx. 30 cm overhang. These are loosely laid into the cross holders grooves (photo) without tightening the set screws. Behind each holder there should be at least 5 cm wire rope left. Please, gather further details from the respective graphic. Wavy red lines always represent loose wire rope.

The graphics of the respective basic forms are designs that minimize cutting, and that can do without a turnbuckle. Begin by laying the the wire rope loosely into the first holder with an approx. 4 - 5 cm overhang. Then, insert the set screws into the cross heads and fasten them, by hand, with an Allen key.

Subsequently, the wire rope is lead to the holder on the opposite side and laid into the groove. Attach a mounting vice directly behind the holder and tighten the rope by hand. Sometimes, it is helpful to use a second vice to fixate the wire rope immediately behind the holder (see photo one step below). You then can insert and fasten the set screw easily with both hands free. Proceed by cutting the wire rope behind the holder with a wire cutter, leaving a 4 - 5 cm overhang.

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

If a wire rope runs through more than two holders, it is initially only fixed to the outer holders. It is only inserted in the middle holder. The grub / set 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 takes place at the end or when, in the respective holder, a second rope is fastened a little later (photo) and the holder on the corresponding graphic is then marked in bold red.

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