KStrong FXline AFF6000 User manual

THESE INSTRUCTIONS APPLY TO THE FOLLOWING MODEL:
FXLINE SYSTEMS
INSTALLATION GUIDE
FXline AFF6000
Horizontal Life Line Systems
FXline AFF5000FXline AFF8000
Vertical Life Line Systems
FXline AFF9000
FXline AFF4000 Floor & OverheadFXline AFF7000
FXline AFF4000 Roof Mounted

Disclaimer: Illustrations may be changed without notice. All dimensions and specifications are approximate and drawings not to scale.
If there are any questions or queries about installation, usage, inspection or maintenance our team would be Happy to Help.
Please forward your inquiry to: [email protected]
Warning: The products enumerated in this instruction manual are a part of personal protective, work support, or rescue system. The user must read
and follows the manufacturer's instructions for each component of the system. This manual contains information that is important to the user's safety
and should be kept in a safe place for future reference as needed. Please contact KStrong for any questions regarding the use of this equipment. Fall
arrest systems and equipment are lifesaving products and are designed to reduce the potential of serious injury in the event of a fall. However, in the
event of a fall, the user may experience a force on their body. In case there is a doubt about the user's ability to utilize this product, the user must
consult a physician. Pregnant women and minors are not considered fit for the use of this equipment..
Please read and understand the manufacturer's instructions for each component or part of the complete system. Manufacturer's instructions
must be followed for proper use, care, and maintenance of this product. These instructions must be retained and be kept available for the
user's reference at all times. Alterations or misuse of this product, or failure to follow instructions, may result in serious injury or death.
Note: The user is advised to keep this user instructions document for the life of the product.
01
Vertical Anchorage Lifeline System on Aluminium Rail System and
Vertical Anchorage Lifeline System on Aluminium Rails with Rungs
Product Code Page No.
Vertical Anchorage Lifeline System on Rigid Cable Line FXline AFF6000 2
FXline AFF7000 3-9
AFF4000
(Floor/Ceiling Mounted)
AFF4000
(Roof MOUNTED)
Horizontal Anchorage Life Line System
Horizontal Anchorage Life Line System
INDEX
Vertical Anchorage Lifeline System on Rigid Cable Line
10
11-21
AFF8000 & AFF9000
AFF5000
Horizontal Aluminum System
22-26
27-30
Proof loading
Pre-Use Checks
Precautions
Kstrong Compass App
Tools
Torque Chart
Equipment Record
31
31
32
32
33
34

1. VERTICAL ANCHORAGE LINE SYSTEM ON RIGID CABLE LINE
Ref: FXline AFF6000
02
ŸMaterial: Stainless Steel 316
ŸConstruction: 7x19
ŸDiameter: 8mm
ŸD Shackle: Stainless Steel
Wire Rope (Cable Wire) with D Shackle
Conforms to: EN353-1:2014 + A1:2017
Ref. AFF518XXX(DS) (where XXX is the
length of the wire rope in meters)
Wire Rope Cap
Ref. AFF513100
ŸMaterial : Aluminium Alloy
Set of 2 U-Bolts and 1 Thimble
Ref. AFF513000
ŸU- Bolts : Qty- 2 nos.
Material : Stainless Steel 316
ŸThimble : Qty- 1 no.
Material : Stainless Steel 316
Mounting Bracket
Ref. AFF511000
ŸMaterial of Rope Grab:
Stainless Steel Grade 316
ŸMaterial of Karabiner: Alloy
Steel
ŸAnti inversion mechanism
Rope Grab
Ref. AFG805203
Intermediate
Ref. AFF511500
ŸMaterial: Stainless Steel Grade 316
ŸRecommended Installation - Every 10 m
Tensioner
Ref. AFF514000
ŸQuantity: 1 nos
ŸRegulates tensioning of the cable
Equipped with a Tension Indicator
ŸMaterial: Stainless Steel Grade
316
Shock Absorber
Inspection Plate
Ref. AFF115100
Extension Arm (Finish-ED Coating Black) - Ref.: AFF516600
Optional
ŸMaterial: Stainless Steel 316
ŸCompatible with rung
diameter: Ø25.0mm -
Ø96.0mm
ŸComplies with EN 795 Type A
ŸBreaking Strength > 23 kN
Optional
ŸMaterial: Stainless Steel.
ŸMinimum Breaking Strength:
23 kN
Mounting Bracket
Ref. AFF511001
ŸCompatible with rung
diameter- Ø22.0mm-
Ø114.0mm

Intermediate
ŸRecommended Installation- Every 10 m
ŸMaterial: Stainless Steel 316
Ref. AFF511500
Shock Absorber
Ref. AFF512000
ŸLimits the impact of force in the
event of fall to less than 6 kN
ŸMaterial: Stainless Steel 316
ŸConstruction: 7x19
ŸDiameter: 8mm
ŸMaterial: Stainless Steel 316
ALSO AVAILABLE
Wire rope without loop Ref. AFF518XXX(S)
Wire Rope (Cable Wire)
Ref. AFF518XXX (Where XXX is the Length of
the wire rope in meters)
Wire Rope Cap
ŸMaterial: Aluminium Alloy
Ref. AFF513100
Inspection Plate
Ref. AFF115100
Mounting Bracket*
Ref. AFF511000
ŸBreaking Strength > 23 kN
ŸComplies with EN 795 Type A
ŸMaterial: Stainless Steel 316
Wire Crimping Assembly
ŸMaterial of Rope Grab: Stainless Steel
316
ŸAnti inversion mechanism
ŸMaterial of Karabiner: Alloy Steel
Rope Grab
Ref. AFG805101
ŸU - Bolts: Qty - 2 nos. Material:
Stainless Steel 316
ŸThimble: Qty - 1 no. Material:
Stainless Steel 316
Set of 2 U-Bolts & 1 Thimble
Ref. AFF513000
Tensioner
Ref. AFF514000
ŸQuantity: 1 nos.
ŸMaterial: Stainless
Steel 316.
ŸRegulates tensioning
of the cable.
Equipped with a
Tension Indicator
2. VERTICAL LIFE LINE SYSTEM
Ref: FXline AFF7000
03
Conforms to: EN353-1:2014 + A1:2017

CABLE TERMINATION
Ref. AFF6000 & AFF7000
Ÿ A suitable cable termination may be selected according to the
site condition, u-bolts and thimbles are only allowed at bottom
termination according to EN353.1:2014
STEP 1: CABLE TERMINATION
Wire Crimping
Assembly
(Step 2)
Aluminum
Ferrules
Aluminum
Endcap
SS Thimble
Heat Shrink
Tube
Ÿ Ensure that the first ferrule is as close as possible to the thimble,
the next ferrule should be 50mm apart from the first one.
Ÿ Crimp the Ferrule using a 20 Ton Hydraulic Crimping head and
300mm2 crimping dies.
Ÿ Insert the wire in heat shrinking tube.
Ÿ Loop the wire across the Stainless Steel Thimble.
Ÿ Shrink the tube with a hot air gun.
Ÿ Insert the aluminum cap in the free end of wire and crimp it.
STEP 2: WIRE CRIMPING ASSEMBLY
Ÿ Insert 2 ferrules in the wire.
Ÿ Insert the end of the wire back into the Ferrule.
Ÿ Cover the entire assembly up to the bottom edge of the ferrule
with a heat Shrinkable tube.
04

CABLE TERMINATION
Ref. AFF6000 & AFF7000
Ÿ The swage tube has markings to identify exact positions of
swaging.
STEP 3: CABLE SWAGING
Ÿ Insert the cable into the swage tube.
Ÿ Operate the machine to start the swaging operation until the
green light is on.
Ÿ Repeat the process for all markings(5 times minimum).
Ÿ Ensure that the mark on the swage tube is in the center of the
die.
Ÿ Place the swage tube on the hex loc die of a hydraulic swaging
tool (130kN capacity).
50mm
U bolt & Thimbles
AFF513000
Ÿ Loop the Cable across the thimble and ensure at least 300mm of
the cable is overlapping.
Ÿ If it is necessary to cut the cable, insert aluminium cap in the free
end of wire rope and crimp it
STEP 4: U BOLT & THIMBLE
Ÿ Next, fasten the stainless steel U bolts (Part of Ref AFF513000)
approximately 50 mm apart.
Ÿ If the cable is in excess make a loop and tie the loop with cable ties.
05

INTERMEDIATE & TENSIONER
Ref. AFF6000 & AFF7000
The intermediates reduces large deflections in the cable due to wind pressure.
Ÿ Place fisher plate of the Intermediate on the back of ladder rung.
Fasten the Intermediate Plate with the fisher plate with help of
given fasteners. Ensure that the cable is in between the two arms
of intermediate. It is recommended to install an Intermediate at an
interval of every 10 m length of the Cable.
STEP 5: INSTALLATION OF THE INTERMEDIATE: Ref. AFF511500
06
Ÿ Next, fasten the stainless steel U bolts (part of Ref AFF513000)
approximately 50 mm apart.
Ÿ Rotate it until reasonable tension is achieved in the cable and the
tension indicator disc is free to rotate.
Ÿ Tighten both the chuck nuts.
Ÿ The Tensioner is installed at the lower end of the system.
Ÿ Open both the chuck nuts and hold the tensioner eye.
Ÿ Insert a steel rod in the housing of the tensioner and rotate the
tensioner in anti clock wise direction.
Ÿ Insert the eye of tensioner to the mounting bracket at the lower
ladder rung.
Ÿ Open the threads of extension rod of the tensioner from both ends.
Ensure that 75% of the thread is open.
Ÿ Insert the pin ring in the locking pin to lock it.
FIX THE TENSIONER TO THE WIRE ROPE:
Ÿ Insert the stainless steel locking pin so as to pass through the eye
of the tensioner and the mountin brackets.
Ÿ If it is necessary to cut the cable, insert aluminum cap in the free
end of wire rope and crimp it.
Ÿ Loop the Cable across the thimble and ensure at least 300mm of
the cable is overlapping.
PROVIDING TENSION TO THE WIRE ROPE:
Ÿ If the cable is in excess make a loop and tie the loop with cable ties.
Ÿ Fix the thimble (part of Ref AFF513000) to the eye of the tensioner
by the given fastener.
STEP 6: INSTALLATION OF THE TENSIONER: REF AFF514000

SHOCK ABSORBER & CABLE TERMINATION
Ref. AFF7000
Ÿ A suitable cable termination may be selected according to the
site condition, u-bolts and thimbles are only allowed at bottom
termination according to EN 353.1:2014
STEP 8: CABLE TERMINATION
ŸEnsure that the energy absorber is fitted with red arrow on label pointing
down wards.
ŸThe spacer ensure the correct position of energy absorber.
ŸConnect the shock absorber to top mounting bracket by inserting the
fastener and the nylon spacer so as to pass through mounting bracket
and eye of energy absorber.
ŸConnect the end extremity to energy absorber by inserting fastener
through eye of energy absorber.
STEP 7: INSTALLATION OF SHOCK ABSORBER
07

EXTENSION ARM
Ref. AFF6000 & AFF7000
ADDRESS
PRODUCT
CODE
INSTALLATION DATE
LENGTH
INSPECTION REPORT
/ /
MTRS.
Date : / /
BATCH NO. YEAR OF MANUFACTURE :
REVALIDATION DUE ON
STEP 9: INSTALLATION OF THE EXTENSION ARM: Ref. AFF516600
Ÿ The Extension Arm is provided pre-installed with the Mounting
Bracket for the Upper end of the system.
Follow The Simple Steps For Easy Installation-top Rung
If the System has been provided with the Extension Arm, this shall be
installed in place of Upper Mounting Bracket as in step:
Ÿ On the third rung of the ladder, from the top Insert the given U-bolt
through the ladder rung in to the slot so as to pass through the
extension arm tighten the nuts of the U-Bolt.
Ÿ Repeat the exercise for the Second Rung from the top.
Ÿ Hold the extension arm against the upper last three rungs of the
ladder.
Ÿ Hold the fisher plate in front of the extension arm.
Ÿ Insert the given U- bolts through the rung in to the fisher plate.
Tighten the nuts of the U-bolts
STEP 10: LABEL AFF115100
Ÿ The Label is fixed to the lower most rung of the ladder using
cable ties.
08

FALL ARRESTER
Ref. AFF6000 & AFF7000
A/2
A/2
Ÿ Check the harness that all the straps are connected and buckles
are secured and the harness has been adjusted to give it a snug
fit.
STEP 12: CONNECT THE HARNESS TO THE ROPE GRAB
Ÿ Connect the Rope Grab to the front attachment point of the full
body harness with the help of the Karabiner of the connecting
lanyard.
Ÿ Ensure that the gate of the karabiner is closed and locked
properly.
STEP 11: INSTALLATION OF THE ROPE GRAB:
Ref. AFG805203
Ÿ Hold the Rope Grab as shown in the figure.
Ÿ Push the Rope Grab through the cable and rotate it counter
clockwise.
Connect Rope Grab to the Cable following the given simple
steps:
Ÿ Ensure the arrow on Rope Grab points up wards.
Ÿ Connect the other end of the shock absorbing lanyard to the
harness of the user by the other Karabiner.
Ÿ Insert the karabiner of the shock absorbing lanyard AFG8052031
12 in the eye of the Rope Grab.
09
RECOMMENDED PPE