DBI SALA RPD Operator's manual

Copyright 2005 DB Industries, Inc.
User Instruction Manual For
Rescue-Positioning Device
Systems (RPD)
This manual is intended to meet the
Manufacturer'sInstructionsasrequired
bythestandardsandshouldbeused
aspartofanemployeetraining
programasrequiredbyOSHA.
WARNING:Thisproductispartof arescue and
positioning system. The user must read and follow the
manufacturer's instructions for each component part of
the complete system. These instructions must be
provided to the user of this equipment. The user must
read and understand these instructions or have them
explained to them before using this equipment.
Manufacturer's instructions must be followed for proper
use and maintenance of this product.Alterations or
misuse of this product or failure to follow instructions
may result in serious injury or death.
IMPORTANT: Ifyouhave anyquestionson the use,
care, application, or suitability for use of this safety
equipment, contact DBI/SALA immediately.
IMPORTANT: Beforeusingthis equipment,recordthe
product identification information found on the I.D. label
of your RPD on the inspection and maintenance log in
section 9.0 of this manual.

3
Figure 1 - Parts Identification

4
DESCRIPTIONS
Rescue Positioning Device (RPD ): 3/8in.statickernmantle rope,mode
indicator, swiveling connection loop, and aluminum, stainless steel and
brassconstruction. (3:1 or 4:1 ratio)
• Calculate rope length as follows:
(3:1) multiply working travel length by 4 and add 10 feet for total.
(4:1) multiply working travel length by 5 and add 10 feet for total.
1.0 APPLICATIONS
1.1 PURPOSE: DBI/SALA rescue and positioning devices are designed
to be components of a rescue-positioning system.This equipment is
used for applications where personnel need to be raised or lowered
over a vertical distance.The maximum working load for this
equipment is one person [350 lbs.(160 Kg.)] The system is available
with 3:1 or 4:1 lifting ratios. When using this equipment for personnel,
federal law (OSHA) requires that a secondary or back-up fall
protection system be used.
NOTE: The back-up or secondary fall protection system is not required in
applications where the RPD is only used to retrieve personnel (i.e.
emergency rescue operations).
A. POSITIONING APPLICATION: In this application, the RPD is
used as part of a complete positioning and personnel riding
system. Such systems typically include a full body harness,
boatswain'schair orwork-seat, independentpersonal fall
protection system, and the RPD. See Figure 2.
Figure 2 - Positioning Operation Figure 3 - Emergency Operation
Operator raising
and/or lowering
himself.
Co-worker raising
and/or lowering a
person.

5
B. RESCUE APPLICATION: In this application, the RPD is used as
part of a complete rescue system. Such systems typically include
a full body harness or rescue sling, anchorage connector (i.e.
carabiner, etc.) and the RPD.See Figure 3.
1.2 LIMITATIONS: The following application limitations must be
recognized and considered before using this product:
A. CORROSION: Donot leave thisequipment for longperiods in
environments where corrosion of metal parts could take place as
a result of vapors rising into the atmosphere from organic
materials. Caution should be exercised when working around
sewage or fertilizer because of their high concentration of
ammonia, which is very corrosive. Use near sea water or other
corrosive environments may require more frequent inspections or
servicing to assure corrosion damage is not affecting the
performance of the product.
B. CHEMICAL HAZARDS: Solutionscontaining acids,alkali or other
caustic chemicals, particularly at elevated temperatures, may
damage DBI/SALA RPD’s.When working with such chemicals,
frequent inspection of the entire RPD must be completed. Consult
DBI/SALA if doubt exists concerning using this equipment around
chemicalhazards.
C. HEAT: In general, RPD equipment is not intended for use in
environments where incendiary sparking could cause an
explosion or fire. Use of this equipment is prohibited where there
exists the possibility of the rope coming into contact with power
lines, live cables, etc. Consult the manufacturer for special
applications of this equipment. Do not use where air
temperatures exceed 300° F (145°C) or where the rope may
come into contact with material that is above 250° F (120°C).
D. CAPACITY: These RPD’s are designed for use by persons with a
combined weight (person, clothing, tools, etc.) of 350 lbs.
maximum.At no time shall more than one person connect to a
single RPD for rescue or personnel riding applications. In
emergency or life threatening situations, the capacity is 500 lbs.
and two (2) people maximum.
E. TRAINING: This equipment is intended to be installed and used
by persons who have been properly trained in its correct
application and use.
1.3 Refer to national consensus standards (including ANSI A10.14, ANSI
Z117.1,29 CFR 1910-146and applicable local,state and federal

6
(OSHA)requirements governingthis equipmentfor moreinformation
on personal fall arrest systems and associated system components.
WARNING: Manufacturer's instructionsmust be followed forproper system
use and maintenance of this product. Alterations or misuse of this system
or failure to follow instructions may result in serious injury or death.
2.0 SYSTEM REQUIREMENTS
2.1 COMPATIBILITY OF COMPONENTS:TheRPD(rescue-positioning
device) isdesigned for use only withDBI/SALAapproved components.
Substitutionsor replacementsmade withnon-approved components
and subsystems may jeopardize compatibility of equipment and may
affect the safety and reliability of the complete system.The RPD rope
has been especially selected to provide the user with the maximum
performance and safety.Substituting standard safety rope must not be
attempted. Contact DBI/SALA if you have any questions about
compatibility.
2.2 COMPATIBILITY OF CONNECTORS:Connectors areconsideredto
becompatible with connecting elementswhen they have been
designed to work together in such a way that their sizes and shapes
do not cause their gate mechanisms to inadvertently open regardless
ofhow they becomeoriented.Connectors (hooks, carabiners,and D-
rings) must be capable of supporting at least 5,000 lbs.(22 kN).
Connectors must be compatible with the anchorage or other system
components.SeeFigure 4andsection 3.4 onmaking anchorage
connections. Do not use equipment that is not compatible. Non-
compatibleconnectors mayunintentionally disengage. SeeFigure 5.
Connectors must be compatible in size, shape, and strength. Self
Figure 4 - Anchoring

7
lockingsnap hooks and carabinersare required by ANSI Z359.1and
OSHA.
2.3 MAKING CONNECTIONS: Onlyuseself-locking snap hooksand
carabiners with this equipment. Only use connectors that are suitable
to each application. Ensure all connections are compatible in size,
shape and strength. Do not use equipment that is not compatible.
Ensure all connectors are fully closed and locked.
DBI/SALAconnectors (snap hooks andcarabiners) are designed to be
used only as specified in each product’s user’s instructions.See
Figure6 for inappropriateconnections. DBI/SALA snap hooksand
carabinersshould not beconnected:
A. To a D-ring to which another connector is attached.
B. In a manner that would result in a load on the gate.
NOTE: Large throat opening snaphooksshouldnotbe connected to
standard size D-rings or similar objects which will result in a load on the
gate if the hook or D-ring twists or rotates. Large throat snap hooks are
designed for use on fixed structural elements such as rebar or cross
members that are not shaped in a way that can capture the gate of the
hook.
Figure 5 - Unintentional Disengagement (Roll-out)
If the connecting element that a snap hook (shown) or carabiner attaches to is
undersized or irregular in shape, a situation could occur where the connecting
element applies a force to the gate of the snap hook or carabiner. This force may
cause the gate (of either a self-locking or a non-locking snap hook) to open,
allowing the snap hook or carabiner to disengage from the connecting point.
1. Force is applied to
the snap hook. 2. The gate presses against the connecting ring. 3.The gate opens allowing the snap
hook to slip off.
Small ring or other
non-compatibly
shapedelement

8
C. Ina false engagement, where featuresthat protrude from the snap
hook or carabiner catch on the anchor and without visual
confirmation seems to be fully engaged to the anchor point.
D. Toeachother.
E. Directly to webbing or rope lanyard or tie-back (unless the
manufacturer’s instructionsforboth the lanyard and connector
specifically allow such a connection).
F. To any object which is shaped or dimensioned such that the snap
hook or carabiner will not close and lock, or that roll-out could occur.
2.4 ANCHORAGE STRENGTH:Anchoragesselectedforrescueor
personnel riding systems (RPD’s) shall have a strength capable of
sustaining static loads applied in the directions permitted by the RPD
of at least 2,500 lbs.
2.5 In applications where the RPD is used in conjunction with a horizontal
system (i.e. horizontal I-beams and trolleys), compatibility between
the RPD and horizontal system components must be achieved.
Horizontal systems must be designed and installed under the
supervisionof aqualified person(engineer).
Figure 6 - Inappropriate Connections

9
3.0 OPERATION AND USAGE
WARNING: Do notalterorintentionallymisuse this equipment.Consult
DBI/SALA when using this equipment in combination with components or
subsystems other than those described in this manual. Some subsystem
andcomponent combinations may interfere with the operation of this
equipment.Use caution when usingthisequipmentaround moving
machinery, electrical hazards, chemical hazards, and sharp edges.
WARNING:Consult your doctor if there is any reason to doubt your fitness
to safely absorb the shock from a fall arrest or suspension. Age and fitness
seriously affect a worker's ability to withstand falls. Pregnant women or
minors must not use DBI/SALA rescue and positioning devices unless in
anemergency situation.
3.1 BEFORE EACH USE: Before each use of this or any rescue and
positioning system equipment, carefully inspect it to assure that it is
in serviceable condition.Check for worn or damaged parts.Ensure all
screws are present and secure. Inspect the rope for cuts, fraying,
burns, etc. Check locking action by pulling sharply on the appropriate
line.Refer to section 5.0 for further inspection details. Do not use if
inspectionreveals an unsafe condition.
3.2 PLANNING: Plan your rescue and positioning system and how it will
be used before starting your work.Take into consideration factors that
affect your safety before, during, and after a fall.The following list
gives some important points to consider when planning your system:
A. ANCHORAGE:Selectan anchoragepoint thatis rigidandcapable
of supporting 2,500 lbs.(11kN).See Figure 4 and section 2.3.The
anchorage location must be carefully selected to reduce possible
swing fall hazards and to avoid striking an object during a fall. Do
notwork above theRPD anchorage point.
B. SWING FALL: Swing falls occur when the anchorage point is not
directly above the working point.The force of striking an object
whileswinging (horizontal speed ofthe user due tothe pendulum
affect) can be great and may cause serious injury.Swing falls can
be minimized by working as directly below the anchorage point as
possible, never permit a swing if injury could occur.If a swing
situation exists in your application, contact DBI/SALA before
proceeding.SeeFigure 7.
C. TOTAL FALL DISTANCE: Shouldthe operatorreleasethe line
while in the free mode, there must be sufficient clearance in the
area below to avoid hitting an obstruction or a lower level.The

10
total fall distance is the
distancemeasured from
the onset of a fall to the
point where the fall is
arrested.A numberof
factors can influence the
total fall distance
including;user'sweight,
anchoragelocation
relative to the fall (swing
fall), body support with a
slidingD-ring, etc.With
theanchoragelocated
directly overhead, it is
recommendedthat at
least 2 ft. of clearance be
maintainedbetweenthe
worklevel and the nearest
obstruction in the fall path. See Figure 7.
D. SHARP EDGES: Avoid workingwhere therope will be in contact
withor abrade against sharpedges. Ifworkingwiththisequipment
aroundsharpedgesisunavoidable,provideprotectionbyusinga
heavypadovertheexposedsharpedge.
E. RESCUE: Should a fall occur, the employer must have a rescue
plan and the ability to implement it.
WARNING:Read andfollowmanufacturer's instructionsforassociated
equipment (full body harness, etc.) used in your rescue and positioning
system.
IMPORTANT: For special (custom) versions of this product, follow the
instructionsherein.Ifenclosed,seeattachedsupplementforadditional
instructions to be followed when using a custom RPD.
3.3 BODY SUPPORT:Whenusing DBI/SALA’sRPD,itis recommended
that a work-seat or boatswain's chair be used. A full body harness
shouldalso be worn forconnection to the independentpersonal fall
protectionsystem.TheD-ringonthebackbetweentheshoulders(dorsal
D-ring)shouldbeusedtoconnectthepersonalfallprotectionsystem.
IMPORTANT: Body belts are not allowed for free fall situations.Body belts
increase the risk of injury during fall arrest in comparison to a full body
harness.Limitedsuspension time and the potential for improperly wearing a
body belt may result in added danger to the user’s health.
Figure 7 - Swing Falls

11
3.4 MAKING CONNECTIONS: Selflocking snap hooks orselflocking and
self closing gate carabiners must be used to reduce the possibility of
roll-out when making connections. See sections 2.2 and 2.3. Do not
use hooks or connectors that will not completely close over the
attachment object. Do not use non-locking snap hooks. Always follow
the manufacturer's instructions supplied with each system component.
3.5 SET UP AND INSTALLATION:The anchoragepoint for the RPD must
be capable of supporting a 2,500 lb.minimum static load in the
directionofoperationalpull.The anchor may be a tripod, building
structure or other suitable anchoring point.The unit may be attached in
thefollowingmanner:
A. Attachment can be made directly through the top loop in the RPD
housingusingthe connection hook provided.Thehook can be
connected directly to the anchor point or to the connection sling
which has been attached to the anchorage via a straight loop,
choker, or basket loop.See Figure 4.
B. Attachment can be made directly through the top loop in the RPD
housingusingthe connection sling provided. Use a choker or
basket loop to connect the sling to the RPD.See Figure 4.
C. Rig the RPD system
directly above the
intendedworkingarea.
If the RPD is not rigged
directlyoverhead, a
swing fall situation
could occur.Swing falls
occurwhen aworker
swings and strikes an
immovableobject. See
Figure7.
D. After attaching the RPD
totheproper anchorage
overthe workingarea,
attach the travelling
pulleyto the personnel
support device using a
self locking/closing
carabiner.See Figure8.
Figure 8 - Attaching Travelling Pulley
Travelling
pulley
Self closing
carabiner

12
IMPORTANT:Anindependent fallprotectionsystem isrequiredbylaw
(OSHA)whenusing this systemduringnormalworkpositioningoperations.
Do not connect fall protection equipment directly to the RPD system.Fall
protection systems must be connected to an independent anchor with a
minimum tensile strength of 5,000 lbs. (measured in direction of possible
fall). Refer to ANSI Z359.1, ANSI A10.14, applicable local, state, and
federal(OSHA) requirements and DBI/SALA foradditionalinformationon
independentfall protection systems.
E. Before every use inspect the RPD system as described in
section 5.0
3.6 OPERATION OFRPD:
A. Before securing to the RPD
system, operate the unit so
that the silver indicator flag is
showing and the unit is in a
lockedposition.SeeFigure 9.
B. Connectyourself orco-worker
tothe personnel support
device. If the rescue sling
(provided with the system) is
used, slip it over the
shoulders.Position it below the
arms and move the adjuster
buckle to snug it up. See
Figure10. If a work-seat,
accidentcradle(3610000) or
other support device is used,
followtheinstructions furnished
withthatequipment.Always
contactmedical personnel
beforemovinginjured
personnel.
C. To raise, pull on the free end of
the rope with a smooth
hand-over-handactionor use
theoptionalrope gripping
handle.To lock it in position,
raise until the silver indicator flag is showing. Gradually release
therope. SeeFigure11.
D. To lower, grasp the free rope and raise it slightly until the orange
indicator flag appears.This will occur approximately every two
Silver
Indicator
Flag
Pulldown
to ensure
device
is locked
Figure 7 - Indicator Flag

13
inchesof personnel
travel.Whenthe
orangeindicator
appears,lowering
maybegin. Lowerby
usingahand-over-
handaction or the
optionalgripping
handle.Toposition,
raise slightly until the
indicator flag is
showing silver.The
unit will now be
lockedin position.
Always maintain safe
speedswhenraising
orlowering.See
Figure11.
Anoptional rope
grippinghandle(9503008
righthand, 9503037left
hand) may be used to aid
inraising orlowering
operations.Tooperate,
pull back on the spring
loaded jaw and insert the
rope.Raise orlower as
required.Toreposition,
releasethe jaw and move
it to the desired location.
Release the jaw to lock it
inplace. See Figure 11. In
addition,an optional
methodto aid inlowering
yourself can be used.The
freerope end can be
passedthrougha D-ring
and/orconnecting hook
andthen controlled easily
by hand.Take care that
edgesof thehardware,
which the rope passes
through,are smoothand
willnot damage the rope.
E. Raising and lowering may be done by the user or an assistant.
Figure 11 - Raising & Lowering
Figure 10 - Connecting Rescue Sling

14
WARNING:Ifropetensioneasesduringlowering,theperson beinglowered
mayhavereachedaworklevelorobstruction.Donotcontinueoperation
withoutcommunicating with the person beinglowered.Alwaysmaintain
tension on the personnel line. Slack line could cause a free fall situation.
F. Do not use the RPD for lifting or lowering more than one person
pertrip.
G. Operate the device bymanual power only.Do not use power
winches or other similar devices to operate this system.
4.0 TRAINING
4.1 It is the responsibility of the user to assure they are familiar with these
instructions, and are trained in the correct care and use of this
equipment.Users mustalso beaware ofthe operatingcharacteristics,
application limits, and the consequences of improper use of this
equipment.
IMPORTANT:Trainingmustbeconducted without exposingthe traineetoa
fall hazard.Training should be repeated on a periodic basis.
5.0 INSPECTION
5.1 FREQUENCY:
•Before Each Use: Visually inspect per steps listed in sections
5.2 and 5.3.
•Monthly: A formal inspection of the RPD should be done by a
competent person other than the user. See sections 5.2 and 5.3
for guidelines. Record the results in the Inspection and
Maintenance Log in section 9.0.
•Annual: It is recommended that the RPD be serviced by a
factory authorized service center or the manufacturer. Extreme
working conditions may indicate the necessity to increase the
frequency. Annual servicing shall include, but not be limited to,
an intensive inspection and cleaning of all internal and external
components.Failuretoprovide properservicemayconsiderably
shortenproductlifeandcouldendangerperformance.Arecord
of annual service dates can be found on the face label of the
RPD. See section 8.0.
IMPORTANT: Extreme workingconditions(harsh environment,prolonged
use, etc.) may require increasing the frequency of inspections.

15
5.2 INSPECTION STEPS:
Step 1. Inspect for loose screws and bent or damaged parts.
Step 2. Inspect the housing for distortion, cracks or other damage.
Make certain the anchorage point is not damaged or distorted
in any way (the RPD has a swiveling anchorage point).
Step 3. Inspect the rope for cuts, severe abrasion, or wear.Check for
contact with acids or other chemicals.
Step 4. Inspect the compression sleeves on both ends of the rope.
The rope should fully pass through each sleeve twice. Make
certain the compression sleeve is not cracked.
Step 5. Check the pulleys for any sign of wear or strain. Check for
distortion in the connecting loops.
Step 6. Do not disassemble the RPD block. It is not user serviceable.
See section 6.0.
Step 7. With the unit properly mounted from any sturdy structure, test
theover-speed protection system.
A. Position the travelling pulleyapproximately 4 feet below the RPD
block.
B. Position the system so that the orange indicator flag can be seen
and is to the side nearest you.
C. With the right hand, grasp the rope exiting the right side of the
RPD.Grip it near the bottom of the housing.
D. With the left hand, lightly restrain the free end of the rope.
E. Pull down sharply with the right hand to engage the over speed
brake.The unit should lock up. If the brake fails to engage,
immediately remove the unit from service. See Figure 12.
Step 8. Inspect all identification and warning labels.Make certain they
are securely attached. See section 8.0.
Step 9. Operate the system in both directions.Keep a moderate back
pressureon therope.
A. The indicator flag should cycle between the locking mode (silver)
and the lowering mode (orange) as the system is being raised.

16
B. Theorange flagshould be
visible when the system is in
loweringmode.
C. The silver flag should be
visible when the system is in
alocking (positioning) mode.
Step 10. Inspect each system
componentor subsystem
(i.e. full body harness,
anchorageconnector,
etc.) per associated
manufacturer's
instructions.
Step 11. Recordinspection results
onInspection and
MaintenanceLog foundin
section 9.0.
5.3 If inspection or operation reveals a
defective condition, remove the
RPD from service immediately
and contact an authorized service
centerforrepair.
NOTE:Only DBI/SALA or parties
authorizedinwritingmay make repairs
to this equipment.
6.0 MAINTENANCE - SERVICING - STORAGE
6.1 Periodically clean the exterior of the RPD using water and a mild soap
detergent solution.Position the RPD so no water gets inside the block.
Cleanlabels asrequired.
6.2 Cleanthe rope withwater and mildsoapdetergent solution. Rinseand
thoroughly air dry.Do not force dry with heat.Immediately wash the
entire rope assembly if it has been exposed to acidic vapors
WARNING: If the rope comes in contact with liquid or solid acids, remove it
from service and wash it with a water and mild detergent solution. Do not
return the system to service without it first being inspected by a qualified
inspector.Acids in contact with rope for extended periods of time can
weakentherope without visible evidence of damage. Only a qualified
inspectorcandetermineropestatus.
To Test -
Step 1 -
Position with
orange flag
showing
Step 2 -
Grip Rope here
with one hand
and pull down
sharply while
lightly restraining
free end of rope.
Unit will lock
when operating
properly.
Figure 12 - Testing

17
6.3 Ropereplacement, as wellas additional maintenanceandservicing
procedures, must be completed by a factory authorized service center.
Both an authorization and a return number must be issued by
DBI/SALA.Do not attempt to disassemble the RPD.See section 5.1
for servicing frequency.Do not lubricate any parts.
6.4 EMERGENCY RELEASE OF“JAMMED”ROPE:In some use
situations, if the load has been raised very close to the RPD unit, it
maynot appear possibleto reach thelowering mode (orange
indicator).However, an override system consisting of an override
ferruleandlever
(see steps 1 & 3)
is provided to
releasethebrake.
Tooverride the
brake,continue
raisingthe load
(effort will
increase)andthen
lower it, repeat as
requireduntil
loweringmode is
reached. If this
fails to work,
removethe load
and use the
procedurebelow.
Step 1.
A.Removethe load.
B.Removescrew or plug.See
Figure13.
Step 2. Insert a nail or
similar object into
thescrew hole. See
Figure 14.
Step 3. Tip the nail as
shown to activate
thebrakeover-ride
lever.Thebrake
overridelever is
locatedinternally on
Figure 13 - Removing Screw or Plug
Figure 14 - Insert Nail

18
Figure 16 - Lowering
Figure15-ActivatingBrakeOver-Ride
the side opposite the nail.The override lever may be partially
visible through the screw hole. Some force may be required to
move the override lever.See Figure 15.
Step 4. While
maintaining
pressure
on the nail,
pulldown
on the line
asshown.
Pull out
enoughline
to easily
allowthe
loweringmodeto bereached.
Replacethescreworplug.SeeFigure
16.
6.5 Cleanand store the body supportand
associated system components according
to separate instructions provided with that
equipment.
6.6 Store the RPD in a cool, dry, and clean
environment out of direct sunlight.Avoid
areas where chemical vapors may exist.
Inspect the RPD after any period of
extendedstorage.

19
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7.0 SPECIFICATIONS
U.S.Pat.No.4934660, U.K.Pat.No.G.B.2,210597 B, Can.Pat.No.
1,293969,GER.Pat.#P3832890, Jap.Pat.No.1948336
8.0 LABELING
8.1 These labels should be securely attached to the RPD.See Figure1.
8.1 continued:

20