Installation of massive kits

What is a “Massive” Kit? Please use the link if you initially require general information. This page is about  the installation of such construction kits or self-assembled sets of 12 mm cross mounts and 4 mm cable. All the information on this page must be viewed in connection with the 10 to 25 installation graphics of the respective cable system. Please use the link and navigate to the cable system you have purchased. The pictures shown here complemet the sequence graphics there, and also apply to the medium construction style if only cross holders (and no eye screws) are involved. Please determine, 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 drill hole brushes and/or with a small air pump, and then the cross holders are installed without the set screws (photo); to do so, please refer to the product sheet of the cross holder WM 12153.

For some systems it is necessary to cut off one or more pieces of rope with approx. 30 cm  overhang from the cable reel and loosely insert them into the grooves of the cable holders (photo) without inserting or tightening the grub screws. On both sides, the wire ropes end at least 10 cm behind the mount. 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, an installation with as little cutting as possible is shown, which does not need a wire rope tensioner. For this purpose, the rope is initially laid slack in the first holder with about 10 overhang. The grub screw is inserted, moderately tightened and in the second step again tightened whilst 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 cable 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.