Special Case 01 for Installing Medium Kits "Classic"

The following installation instructions are only valid for some medium "Classic" kits. They are about kits that contain not only wire rope holders also called "Cross Mounts", but also eye bolts / ring screws ("mixed construction"). This applies to the wire rope systems 2030, 2040, 4010, 4050, 5010, 6020, 6030, 6040, 7050 and 7060. Such arrangements can be built up quickly, the eyelets serve, for example, to redirect an encircling "frame rope" in the corners. All information on this page can be seen in connection with the 10 - 25 assembly graphics in one of the cable systems above. Please use these links and go to the wire rope system you have purchased. The pictures shown here complete the flow charts there. Please also clarify before ordering if you need tools!

The symbols in the diagram mark the wall mounts and thus the drilling points. Small grey circles (graphic) show cross holders/mounts, grey ellipses mark eye bolts and show their alignment according to the later forces. After drilling, all holes are cleaned with a hole brush and / or blower. The thimbles contained in the kit are inserted into the eye bolts where later rope loops with rope grips are formed and pressed together with a pair of pliers (photo).

The tiny red bars show how to align the grooves of the cross holders. Sometimes the grooves must be diagonal, i.e. at a 45 degree angle. Now install all holders, please note the product sheet of the respective wall mounts (standard for kits usually WH 10151 or WH 10150). Usually, the holders are slightly greased on the shaft, grasped with an open-end wrench on the flange nut and then screwed in. In exceptional cases, as with WM 10081, a screwdriver blade is inserted through the grooves and the holder is screwed in. Grub screws on cable holders are removed for assembly.

On the graphics of the respective basic form an assembly with as little wire rope cutting as possible is shown, which does not require any wire rope tensioners. In some basic forms, the frame rope is not attached with loops and rope grips, but directly in the cross holders. For this purpose, the rope is threaded through several eye bolts, as shown, and laid loosely in the cable holder with approx. 10 cm protrusion. The grub screw is inserted, moderately tightened and in the second step, tighten a bit more by gripping the holder at the flange nut, or in exceptional cases at the flat nut directly behind the head (photo) with a open-end wrench.

In many basic forms, the outer "frame rope" is attached with two loops. For this, the wire rope is initially pulled through several or even all ring screws, in the order shown in each case. The wire rope is not yet laid into the cross mounts / holders. A double kink in the wire rope (photo) with 15 cm overhang facilitates the formation of the following, first loop.

After threading, the first loop of rope is formed at a specific eye bolt (diagram). The rope is wound around the pressed together thimble and clamped immediately behind it with a wire rope grip. The rope overhang behind the clamp should be approx. 10 cm.

Subsequently, the rope is also guided limply through the grooves of the cable holder (graphic) without the grub screws being inserted or tightened.

The next steps take place at the eye bolt, through which the rope was threaded through first. There, then, the other end of the rope behind the holder is now grasped by means of a mounting vice and tightened by hand (about 5 - 10 kg). Here, a second mounting vice for fixing both strands just behind the eye bolt (photo) is helpful, so that the wire rope grip (graphic) can be set calmly. Then the vices are loosened and the rope is - with about 10 cm over length - cut behind the clamp with a wire rope cutter.

If a wire rope is tightened in a holder (graphic), the second mounting vice is clamped directly behind the holder (photo) onto the rope to temporarily fix the tightened state. This can also be done with a clamping ring or a cross clamp, which is often included anyway in the cable system. After tightening the grub screw in the cable holder, the fixation is removed.

If the wire rope - here the frame rope - runs through one or more holders it is, at first, laid into the holders without screwing in or tightening the grub screws, or if only for provisional fixation of the rope. 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.

If more rope sections are shown on the graphics, they are laid according to the principle shown above. In places where wire cables intersect (graphic), floating cross clamps are set when the graphics show this. Finally, all projecting ends of the rope receive pressed-on wire end sleeves (photo). If the wire ropes protrude approx. 10 cm, they can, in later years, be gripped and re-tightened if necessary.