FALSE CAR & INT. Installation and Service Manual

Transcription

1 FALSE CAR Installation and Service Manual 6200 Brent Drive Toledo, Ohio 1

2 Table of Contents Overview... 3 General Warnings... 4 Description of Equipment and Intended Use... 5 Personal Protective Equipment... 6 Installation/Assembly Tools Required... 6 Section A: False Car Assembly... 7 Section B: Safety Block Arrangement Section C: Adjustable Platform Section D: Slant Top Breakaway Canopy Section E: Telescoping Breakaway Canopy Section F: Telescoping Handrails Bill of Materials Declaration of Incorporation from Declaration of Conformity Type Examination Certificate Safety Checklist / Maintenance Log

3 Overview The purpose of this manual is to provide the user with detailed instructions on the proper installation and inspection of the Wurtec False Car, Adjustable Platform, and Slant Top Break Away Canopy. This includes: Hazards associated with the use of this product; Assembly and Installation procedures; Recommended Daily Inspection & Servicing instructions. After reading this manual, the reader will be able to properly install a Wurtec False Car in a hoistway, along with the Adjustable Platform and Slant Top Break Away Canopy. Once installed, the reader will be able to inspect the False Car for damage and wear. For more information on False Cars and other devices used in the hoistway, refer to the Elevator Industry Field Employee s Safety Handbook. It is available online at NOTICE About This Manual 1. The equipment covered in this manual should only be installed, used, and serviced by qualified personnel trained in proper work and safety procedures. This manual is intended to assist such trained individuals in the installation and use of this equipment and is not intended as a substitute for proper training and experience. 2. This document or any other information regarding this equipment is not intended to cover all of the possible situations which may be encountered while using the equipment described herein. Should specific situations arise which are not covered by the information provided, or should the user desire further details, the specifics should be directed to Wurtec, Inc. 3. In the effort of continuous product improvement, Wurtec, Inc. reserves the right to modify the design and specifications of this product at any time without notice. CAUTION The installation of the False Car, Platform, Canopy, and Handrails contains numerous potential pinch points. Be mindful of the body placement of yourself and others during installation to avoid injuries such as smashed fingers, toes, etc. The Adjustable Platform is very heavy and should not be installed by one person alone. 3

4 General Warnings WARNING The Wurtec False Car is not intended for hoisting material. It is a man-riding suspended work platform rated for use by up to two people including their tools and equipment. The Wurtec False Car is intended to be used only with approved man-rated cable-climbing hoists. (ex: Dual-Lift, Tirak, Power Climber, etc.) If over speed limiter from hoist is engaged, lower attachment point must be inspected prior to putting false car back into service. All persons entering the hoistway should wear appropriate safety gear with a lanyard that is tied off to an independent lifeline. Lifelines should be run on the outside of the platform. Rigging attachments must be rated for man-riding applications. The hoist point must be determined with a factor of safety based on the total weight of the False Car and its payload. Failure to tighten hardware on the False Car Cross Channel clamps may result in uncontrolled descent down the hoistway, which may cause serious injury or death! Failure to tighten platform support hardware or overloading the platform may result in the platform separating from the false car, which may cause serious injury or death! Failure to tighten handrail or canopy hardware may result in someone falling off of the platform or handrail/ canopy parts falling down the hoistway, both of which may cause serious injury or death! Use of materials other than those specified for the platform decking or canopy roofing may result in someone stepping through the deck and potentially falling down the hoistway, or someone getting hit by falling objects. Any of these scenarios may cause serious injury or death! Excessive wear or improper setting of Rail Guides may result in the false car becoming unrestrained in the hoistway and potentially tipping over, which may cause serious injury or death! Objects falling through the gap at the peak of the canopy may cause serious injury or death! Avoid working under the platform during installation. A rigging error that results in the platform tipping or falling may cause serious injury or death! Large falling objects may not be deflected by the canopy and may cause serious injury or death! EN :2010 states: The roof of the False Car must withstand at least the impact of a 7-kg steel ball dropped from a height of 2m, whereby the plastic deformation of the roof may not exceed 50mm Secure all entrances and openings to the platform from the hoistway. If replacing missing hardware, make sure any replacements have the same grade/class or better than the originals. Failure to use proper hardware may result in connection failures which may cause serious injury or death! 4

5 Description of Equipment and Intended Use The Wurtec False Car is a man-riding suspended work platform for use by up to two people. It is constructed of lightweight aluminum for ease of handling and installation, while still providing the strength for a high capacity car. The False Car integrates seamlessly with the Adjustable Platform (11-305, MID, INT), Slant Top Breakaway Canopy ( & INT), Telescoping Breakaway Canopy ( ), and Telescoping Handrail ( , , ). Specifications False Car Capacity: 1500 Lbs. (680 Kg) PartNo DBG Range Rail Sizes Platform Canopy Handrails INT 3 3 to mm, 16mm, 19mm INT INT (1m to 1.65m) MID 4 6 to 7 1 5/8, 3/4, 1-1/8, 1-1/ MID , (1.37m to 2.16m) to 9 0 (1.65m to 2.75m) 5/8, 3/4, 1-1/8, 1-1/ , The total load on the false car safety is not to exceed Assembly Weights (for total load calculation) 1500 pounds (680 Kg). Remember to include the False Car INT 178 Lbs. (80 Kg) weight of the false car, your platform, canopy, wire rope MID 201 Lbs. (91 Kg) climber, people, tools and miscellaneous equipment in Lbs. (95 Kg) your total load calculation. See the False Car Applications Worksheet for assistance calculating load/payload Platform INT 81 Lbs. (37 Kg) MID 129 Lbs. (58 Kg) capacity Lbs. (67 Kg) Overhead protection must be set up and tested before Canopy INT 45 Lbs. (21 Kg) putting the False Car into service. For ease of as Lbs. (21 Kg) sembly, use the Slant Top Breakaway Canopy ( & Lbs. (21 Kg) INT) or Telescoping Breakaway Canopy (10- Handrails Lbs. (16 Kg) ), along with the Adjustable Platform (11-305, Lbs. (22 Kg) MID, & INT) Lbs. (35 Kg) Platform Payload Table The total payload placed on the Adjustable Platform should not exceed the following values: Load Table Lifting Height Platform area 2.5m 2 (26.5 Ft 2 ) >2.5m 2 (26.5 Ft 2 ), 3.9m 2 (42 Ft 2 ) > 3.9m 2 (42 Ft 2 ) Up to 140m (460 Ft) 363 kg (800 Lbs) 312 kg (687 Lbs) 250 kg (550 Lbs) 140m (460 Ft) to 200m (655 Ft) 342 kg (753 Lbs) 284 kg (626 Lbs) 222 kg (489 Lbs) 200m (655 Ft ) to 300m (990 Ft) 294 kg (648 Lbs) 236 kg (521 Lbs) 174 kg (384 Lbs) 5

6 False Car Hoist Options Generic Specs Example Hoists Hoist Model - Titan 651 XE 701 P Manufacturer - Power Climber Tirak CE Marked Required Yes Yes Voltage (V) Phase(s) Frequency (Hz) 50/60 50/60 60 Motor Power (kw) 1.5/ Hoist Weight (kg) Load Capacity (kg) Elevator Speed (m/min) Wire Rope Diameter 5/16 8.4mm 5/16 FAD Model 680kg capacity, 9m/min max speed - Blocstop BSO 500 Personal Protective Equipment Safety Glasses Hard Hat Work boots with steel toe and sole Abrasion resistant gloves Fall Protection Harness Installation / Assembly Tools Required , MID, , & MID 5/16 X 3/8 drive 6 pt. socket 3/8 X 3/8 drive 6 pt. socket 7/16 X 3/8 drive 6 pt. socket 9/16 X 3/8 drive 6 pt. socket 3/4 X 3/8 drive 6 pt. socket 3/8 drive ratchet wrench 7/16 long pattern wrench 9/16 long pattern wrench 3/4 long pattern wrench 25 Tape measure Needle nose pliers Diagonal cutting pliers INT & INT 5/16 X 3/8 drive 6 pt. socket 17mm X 3/8 drive 6 pt. socket 19mm X 3/8 drive 6 pt. socket 3/8 drive ratchet wrench 17mm long pattern wrench 19mm long pattern wrench 25 Tape measure Needle nose pliers Diagonal cutting pliers 6

7 Section A: False Car Assembly 1/2-13 SERRATED HEX FLANGE NUT GR.5 SIDE STILE 1/2-13 X 1-1/4" HEX HEAD CAP SCREW GR.5 PLATFORM SUPPORT ANGLE Image A1. Platform Support Angles. 1. Attach the Platform Support Angles to the top of the Side Stiles. 2. Bolt the Diagonal Braces to the Side Stiles. 3. Tighten the hardware holding the Diagonal Brace to the Platform Support Angle. 4. Once the Diagonal Braces are secured, tighten the hardware at the connection between the Platform Support Angle and the Side Stile. NOTICE For ease of assembly, leave the fasteners at the top of the Side Stile loosely secured until after the Diagonal Braces are attached to the Platform Support Angles. PLATFORM SUPPORT ANGLE DIAGONAL BRACE Image A2. Diagonal Brace Attachment 7

8 Section A: False Car Assembly BLOCKS 5. If installed, remove the plumb lines from the main rails if they prevent installation. 6. Temporarily secure the side stile assemblies to the rails and block them up so that they are level with each other. Leave 1/16 overall clearance between the Side Stiles and the nose of the rails. 7. Position and tighten the Fixed and Adjustable Guide Angles. Leave 1/16 clearance between the Guide Angles and the rail. If possible, use the shims provided in the False Car Tool Kit to provide the necessary clearance. a. Tighten the fixed angle hardware. b. Locate the adjustable angle to suit the guide rail width and tighten the hardware. Image A3. Leveled & Secured Side Stile Assemblies. 3/8-16 X 1" HEX HEAD CAP SCREW GR.5 3/8-16 NYLON INSERT HEX NUT GR.5 ADJUSTABLE GUIDE ANGLE FIXED GUIDE ANGLE 3/8-16 SERRATED FLANGE HEX NUT GR.5 3/8-16 X 1" CARRIAGE BOLT GR.5 Image A4. Fixed and Adjustable Guide Angles. 8

9 Section A: False Car Assembly UPPER CROSS CHANNELS LOWER CROSS CHANNELS 8. Swing the upper and lower cross channels on each side into a horizontal position 9. Fasten the Cross Channels together with the four carriage bolts and serrated hex nuts (2 upper, 2 lower) provided. 10. Temporarily bolt the two Lift Bars together through the hole and slot at the top of the Lift Bars. 11. Fasten the bottom of the Lift Angles to the upper, inside bolts on the lower Zee Brackets. Image A5. Upper and Lower Cross Channels. 1/2-13 X 1-1/4" CARRIAGE BOLT GR.5 ADJUSTABLE CROSS CHANNEL NOTICE Keep the Side Stiles pressed against the guide rails while fastening the Cross Channels. 1/2-13 SERRATED FLANGE HEX NUT GR.5 Image A6. Cross Channel fastening. LIFT ANGLE ZEE BRACKET 1/2-13 X 2-1/2" HEX HEAD CAP SCREW GR. 8 LIFT BAR Image A7. Lift Bars. Image A8. Lift Angles to Zee Brackets. 9

10 Section A: False Car Assembly LIFT ANGLES 1/2-13 X 1-1/4" CARRIAGE BOLT GR.5 ADJUSTABLE CROSS CHANNEL 1/2-13 SERRATED FLANGE HEX NUT GR.5 Image A9. Lift Angles to Upper Cross Channels. 12. Fasten the Lift Angles to the upper Cross Channels using the Carriage Bolts and Serrated Hex Nuts. 13. Attach joist bracket to the lower cross channels using the included Carriage Bolts and Serrated Hex Nuts. 1/2-13 SERRATED FLANGE HEX NUT GR.5 1/2-13 X 1-1/4" CARRIAGE BOLT GR.5 NOTICE The Joist Brackets and support timbers must be used when the platform depth exceeds 7-0 to provide additional support to the platform. You can also use the Support Kit ( SK) to achieve the same purpose. JOIST BRACKET ADJUSTABLE CROSS CHANNEL Image A10. Joist Brackets. 10

11 Section A: False Car Assembly EYE BOLT COT SPRING LINKAGE WIRE ROPE SLINGS 14. Use the Safety Retraction Kit (11-310) to create a connection between the Eye Bolt in the top spring loaded Safety Pawl Assembly to the two safety retraction arms at the bottom of the side stiles. a. Make the connection to the Safety Pawl Assembly i. Connect the loop ends of the wire rope slings to the linkage. ii. Connect the linkage to the cot spring iii. Connect the cot spring to the eye bolt of the safety pawl. Image A11. Safety Retraction Kit to Safety Pawl. b. Attach each wire rope to the Safety Retraction Arms i. Connect the cot spring to the safety retraction arm ii. Loop the free end of the rope sling through the cot spring iii. Tension the rope sling appropriately and tighten wire rope grips on the rope WIRE ROPE GRIPS WIRE ROPE SLING COT SPRING SAFETY RETRACTION ARM Image A12. Safety Retraction Kit Lower Connection. 11

12 Section A: False Car Assembly ADJUSTABLE PLATFORM FALSE CAR 15. Build a suitable platform for your car size. Make sure you securely attach your platform to the aluminum platform support angles. A better solution is to use the Adjustable Platform (11-305). The Adjustable Platform can be mounted to the Side Stiles, with or without the Platform Support Angle. The Diagonal Braces can also mount directly onto the Adjustable Platform. Image A13. False Car with Adjustable Platform Image A14: Adjustable Platform mounting to False Car 12

13 Section A: False Car Assembly HOIST 1/2-13 X 2-1/2" HEX HEAD CAP SCREW GR.8 1/2-13 SERRATED FLANGE HEX NUT GR.8 LIFT BAR Image A15. Lift Bars attachment to Hoist. 16. Attach your hoisting device to the lift bars. Use the two (2) 1/2-13 X 2-1/2 Grade 8 bolts included in the Safety Retraction Kit (11-310). 17. Remove the temporary fastenings which were installed to hold the side stile assemblies to the rails while the Cross Channels were fastened together. 18. Raise the car and check the operation of the safety to ensure that everything is in proper working order. CAUTION Do not attempt to release the safety when it is set. The L-Rods are designed to break if the car is not raised. Always raise the car before attempting to operate the safety levers. 13

14 Section A: False Car Assembly NOTICE When using a false car, it is required that approved guard rails and toe boards be provided on your platform. Wurtec recommends the use of the Adjustable Platform, which includes toe guards, and the Telescoping Handrails as preferred and approved assemblies to satisfy the guard rail and toe guard requirements. The Slant Top Breakaway Canopy (11-357) or the Telescoping Breakaway Canopy ( ) can be used to provide overhead protection and as a way to attach handrails. Both the Slant Top Breakaway Canopy and the Telescoping Breakaway Canopy mount directly to the outside corners of the Adjustable Platform SLANT TOP CANOPY ADJUSTABLE PLATFORM FALSE CAR Image A , , & CORNER BRACKET CANOPY POST 3/8-16 X 3/4" SERRATED HEX FLANGE SCREW GR.5 Image A17. Canopy Mount to Adjustable Platform 14

15 Section B: Safety Block Arrangement , MID Use the following sketches to determine the correct safety block arrangement for your rail size. Note the location of the 1/8 and 1/2 spacers in relation to the tapped spacers and each other in each case. ITEM QTY PartNo Description Size Length TAPPED PLATE /8" SPACER /2" SPACER SAFETY BLOCK 1500# SERRATED HEX FLANGE SCREW Z 1/4-20 3/4" HEX HEAD CAP SCREW 1/ /4" SPRING LOCKWASHER 1/2" Image B1. 5/8 Rails (T89, T114, T127-1, T127-2) Image B2. 3/4 Rails (T140-1) Image B3. 1-1/8 Rails (T140-2) Image B4. 1-1/4 Rails (T140-3) 15

16 Section B: Safety Block Arrangement INT ITEM QTY. PartNo Description Size Length INT TAPPED PLATE INT 1/8" SPACER INT SAFETY BLOCK 1500 # INT 1/4" SAFETY SPACER INT 3/16" SAFETY SPACER METRIC SPLIT LOCK WASHER M METRIC HEX HEAD CAP SCREW M MM Image B5. 5-7mm Rails (T45, T50) Image B mm Rails (T70, T75-3, T82) Image B7. 16mm Rails (T89, T114, T127-1, T127-2) Image B8. 19mm Rails (T140-1) 16

17 Section C: Adjustable Platform The Adjustable Platform is designed to be used in two configurations. The two configurations differ only in the available adjustment in both width and depth INT MID Configuration 1 2 Width (DBG) Depth Width (DBG) Depth Width (DBG) Depth DEPTH WIDTH (DBG) Image C1. Adjustable Platform Width & Depth. SHORT LONG SHORT LONG ROTATE CROSS CHANNELS 90 CROSS CHANNEL Image C2. Change Platform Configuration. Image C3. Configuration 1. To Change the Configuration: 1. Remove the four sets of cross channels and rotate Remount the cross channels on the opposite outer telescoping members so that they are in the opposite orientation in relation to the long and short legs of the corner weldments. 3. Adjust to the desired dimensions. LONG LONG SHORT SHORT CROSS CHANNEL Image C4. Configuration 2. 17

18 Section C: Adjustable Platform Image C5. Platform Expanded for Plywood. Platform Assembly Method 1 1. Loosen all bolts and adjust the platform to the desired finished size as determined by your False Car and hoistway size. 2. Take a measurement to determine your flooring (plywood) dimensions. 3. Cut your plywood to fit the dimensions, preferably in at least 2 pieces since you will need a cutout opening for the False Car Lift Angles. 4. Expand the platform so that it is approximately 2 larger than your final size. This will allow you to easily install your flooring under the hold-down lip. 5. Place the cut pieces of plywood onto the platform. 6. Adjust the platform to its final size and tighten all fasteners securely. 7. Attach the Platform to the Side Stiles of the False Car with the hex bolts and nuts provided. 8. Attach False Car Diagonal Braces to the platform. Image C6. Platform Adjusted to Final Size. NOTICE Split the plywood perpendicular to the direction of the cross channels. The Adjustable Platform Cross Channels must run parallel with the False Car Cross Channels. Make sure that the opening for the Lift Angles is in the correct location prior to tightening the platform adjustment hardware. Image C7. Platform Attachment to False Car. 18

19 Section C: Adjustable Platform Image C8. Adjust Platform Width (DBG). Platform Assembly Method 2 1. Adjust platform width (DBG). a. Remove the False Car Lift Angles or any other item that will prevent you from installing the platform or its flooring. b. Install the platform onto your False Car. c. Loosen or temporarily remove the cross channel hardware as needed to achieve the desired width (DBG). d. Replace and tighten hardware. 2. Adjust platform depth. a. Loosen the adjustment hardware on the sides of the platform adjacent to the rails. b. Adjust the depth of the platform to the desired size. c. Tighten the adjustment hardware. 3. Add plywood flooring. a. Measure and cut your plywood flooring. b. Remove the end of the platform closest to the landing. c. Slide the plywood flooring into place on the platform under the hold-down lip. d. Replace the end of the Platform snugly with the plywood. e. Tighten all hardware securely. Image C9. Adjust Platform Depth. Image C10. Remove Landing Side of Platform. Image C11. Add Plywood Flooring. 19

20 Section C: Adjustable Platform SUPPORT KIT Image C SK Support Kit. 3/4-10 SERRATED FLANGE HEX NUT Support Kit For False Car installations over 84 in the depth direction, attach the Support Kit ( SK) to the platform. Traditional 2 X 4 wood supports attached to the False Car Joist Brackets are also acceptable. Loosen the Serrated Flange Hex Nut and rotate the threaded rod to adjust the length of the support kit. Image C13. Support Kit Length Adjustment 20

21 Section D: Slant Top Breakaway Canopy The Canopy mounts directly to the inside corners of the Adjustable Platform. It provides overhead protection, and the roof has the ability to break away from the Post Members in the event of a freefall scenario. The breakaway feature is designed to prevent the canopy from causing injury to personnel connected to fall protection. Assembly & Installation 1. Attach two (2) U-Brackets to the two (2) the Post Members on the entrance side (4 total). 2. Attach all four (4) Post Members to the inside of the Corner Brackets on the Adjustable Platform. 3. Bolt both sets of Roof Supports together at the peak. U-BRACKET 1/4-20 X 3/4" CARRIAGE BOLT GR.5 1/4-20 SERRATED FLANGE HEX NUT GR.5 CANOPY POST Image D1. U-Bracket attachment to Canopy Posts. CORNER BRACKET Image D3. Canopy Posts Installed. CANOPY POST 3/8-16 X 3/4" SERRATED HEX FLANGE SCREW GR.5 Image D2. Canopy Post attachment to Platform. Image D4. Roof Peak Connection 21

22 Section D: Slant Top Breakaway Canopy 4. Measure and cut plywood to fit Roof Supports. 5. Attach a plywood cover over the Roof Supports. 6. Install Canopy Roof by placing the Hinge Tubes at each end of the Roof Supports into the tubes on top of the Canopy Posts. 7. Measure and cut 2 X 4 handrails. 8. Attach 2 X 4 handrails to the Post Members. For the side closest to the landing, place the 2 X 4 handrails into the U -Brackets. QUICK- RELEASE PIN HINGE TUBE CANOPY POST Image D5. Roof attachment to Canopy Post Image D6. Canopy Roof Placement. Image D7. Attaching 2X4 Handrails. NOTICE The plywood roof thickness should be at least 3/8 (10mm), and no more than 5/8 (16mm). Remove the Quick-Release Pin at the top of the Canopy Post prior to use to enable break away capability of the canopy roof. Image D8. 2X4 Gate Installation. 22

23 Section E: Telescoping Breakaway Canopy The Telescoping Breakaway Canopy provides overhead protection and the flexibility to adjust the roof pitch independent of the width of the platform. The roof has the ability to break away from the Post Members or split open at the peak in the event of a freefall scenario. The breakaway feature is designed to prevent the canopy from causing injury to personnel connected to fall protection. CORNER BRACKET CANOPY POST Assembly & Installation 1. Attach the four (4) Post Members to the inside of the Corner Braces on the Adjustable Platform. 2. Insert the Hinge Tube at the end of each Canopy Hitch and Canopy Receiver Assembly into the tubes at the top of the Canopy Posts. 3. Measure and cut plywood to fit Roof Supports. 4. Attach one of the plywood roof sections to the Canopy Receiver assemblies. a. Slide the plywood in between the Canopy Outer Extrusion and the Top Angles. b. Adjust the height of the Top Angles, if necessary, by loosening the fasteners that connect the Top Angle to the Canopy Outer Extrusion. c. Use the flat head wood screws to fasten the plywood in place. Image E1. Canopy Post Installation. 3/8-16 X 3/4" SERRATED HEX FLANGE SCREW GR.5 HINGE TUBE CANOPY POST QUICK- RELEASE PIN Image E2. Roof to Canopy Post Connection. TOP ANGLE CANOPY OUTER EXTRUSION PLYWOOD CANOPY OUTER EXTRUSION TOP ANGLE Image E3. Plywood Attachment. Image E4. Top Angle Adjustment. 23

24 Section E: Telescoping Breakaway Canopy Image E5. Compressing the Quick-Release Buttons. 5. Attach the other plywood roof section to the Canopy Hitch assemblies, in the same manner as described in step If necessary, adjust the length of the exposed section of the Inner Roof Tube. a. Compress the Quick-Release Button Connector. b. Rotate the Inner Roof Tube so that the button is not aligned with the holes in the Canopy Outer Extrusion. c. Move the Inner Roof Tube to the desired location. d. Rotate the Inner Roof Tube so that the button extends through the Canopy Outer Extrusion to hold itself in place. 7. Connect each set of Canopy Receivers and Canopy Hitches to form the roof peak. The Canopy Rod End should fit over the Rubber Spacer and Clevis Pin to form a hinge connection. Image E6. Telescopic Adjustment. CANOPY ROD END RUBBER SPACER 12MM X 38MM CLEVIS PIN HITCH ROOF TUBE Image E7. Hitch To Receiver. Image E8. Assembled Canopy Roof. 24

25 Section E: Telescoping Breakaway Canopy (Optional) To prevent objects from falling through the gap at the peak of the assembly, the following two methods can be applied to your canopy plywood: Method 1: Overlap the plywood at the peak to eliminate the gap. You will need to notch out the plywood to allow for the hoisting ropes to pass through. Image E9. Canopy Plywood Overlap. CUT NOTCHES FOR HOIST ROPES NOTICE The Canopy Rod End can be used as a break-away connection, or as a locked hinge connection. To switch the connection type: i. Remove the fasteners that hold the Canopy Rod End in place. ii. Pull out the Canopy Rod End and rotate it 180. iii. Replace the Canopy Rod End and tighten its fasteners. Image E10. Cut Notches for Hoist Ropes. Method 2: Cover the gap at the peak with a mesh covering, such as PearlWeave Safety Netting. Leave an opening for the hoist ropes. NOTICE This method will prevent the canopy from splitting apart at the peak in the event of a freefall scenario where the canopy breaks away from the rest of the False Car. Image E11. Canopy Rod End. 25

26 Section F: Telescoping Handrail The Telescoping Handrail Kit provides an adjustable barrier around the Platform. It attaches directly to the Post Members of the Canopy. Installation: 1. Loosen the Slip-Joint Nut so that the Inner and Outer Tubes can freely telescope in and out. 2. Attach the ends of each handrail section to the Post Members. a. Use the Quick-Release Pins for the end of the handrails closest to the landing that will act as the gate. b. Use the lynch pins for all other handrail-tocanopy post connections. 3. Tighten the Slip-Joint Nut until it is snug and the handrail tubes cannot move relative to each other. OUTER TUBE SLIP-JOINT NUT INNER TUBE Image F1. Handrail Length Adjustment. GATE CAUTION Avoid allowing any body parts to get in between the handrails and canopy post members during installation. QUICK-RELEASE PIN Image F2. Handrail Length Adjustment. WIRE LOCK LYNCH-PIN Image F3. Completed Handrail Installation. 26

27 Bill Of Materials ITEM QTY PartNo Description Size Length SIDE STILE PLATFORM SUPPORT ANGLE ADJUSTABLE GUIDE ANGLE FIXED GUIDE ANGLE ZEE BRACKET ADJUSTABLE CROSS CHANNEL LIFT ANGLES DIAGONAL BRACE LIFT BAR TENSION BRACKET SAFETY RETRACTION BAR JOIST BRACKET TAPPED PLATE /8" SPACER /2" SPACER SAFETY COVER PLATE RETAINING PLATE 1500 LBS SAFETY BLOCK 1500# SAFETY PAWL ASSEMBLY SAFETY ROLLER ASSEMBLY LAB LABEL, 1500 LB (680 kg) FALSE CAR KIT, FALSE CAR SAFETY RETRACTION HEX HEAD CAP SCREW 3/8-16 1" HEX HEAD CAP SCREW 3/ /2" HEX HEAD CAP SCREW 1/ /4" HEX HEAD CAP SCREW 1/ /2" HEX HEAD CAP SCREW 1/ /2" HEX HEAD CAP SCREW 1/ /4" CARRIAGE BOLT GR. 5 3/8-16 1" CARRIAGE BOLT GR.5 1/ /4" SOCKET HEAD CAP SCREW /2" FLAT HEAD SCREW 1/4-20 1" FLATWASHER 3/8" /2" BEVELED WASHER PLAIN 1/2" SPRING LOCKWASHER 1/2" HEX NUT Z 3/ HEX NUT NYLON INSERT GR. 5 Z 1/ HEX NUT NYLON INSERT GR. 5 Z 3/ SERRATED HEX FLANGE SCREW Z 1/4-20 3/4" COTTER PIN Z 1/8" 1" CNSF5Z SERRATED HEX FLANGE NUT GR.5 3/ CNSF5Z SERRATED HEX FLANGE NUT GR.5 1/

28 Bill Of Materials

29 Safety Pawl Assembly Bill Of Materials ITEM QTY PartNo Description Size Length COT SPRING C SAFETY PAWL WELD HEX NUT Z 3/ I BOLT Z 3/8-16 3" Safety Roller Assembly Bill Of Materials ITEM QTY PartNo Description Size Length SAFETY RETRACTION SPRING FORK KNURLED ROLLER L-ROD HEX NUT Z 3/ SPRING PIN 1/4" 1 1/2" 29

30 Safety Retraction Kit Bill Of Materials ITEM QTY PartNo Description Size Length WIRE ROPE W/LOOP 1/ WIRE ROPE CLIP 1/ COT SPRING T44 THREADED CONNECTING LINK HEX HEAD CAP SCREW 1/ / SAE FLATWASHER Z 1/ NYLON INSERT LOCK NUT GR.8 YZ 1/ INT Bill Of Materials ITEM QTY. PartNo Description Size Length INT SIDE STILE ASSEMBLY INT LIFT ANGLE LIFT BAR JOIST BRACKET SAFETY PAWL ASSEMBLY KIT, FALSE CAR SAFETY RETRACTION METRIC HEX HEAD CAP SCREW M MM METRIC HEX HEAD CAP SCREW M MM NYLON INSERT HEX NUT M CARRIAGE BOLT M12 30MM CNSF0Z METRIC SERRATED HEX FLANGE NUT CL.8 Z M

31 INT Side Stile Assembly Bill Of Materials ITEM QTY. PartNo Description Size Length INT SIDE STILE INT PLATFORM SUPPORT ANGLE ADJUSTABLE GUIDE ANGLE FIXED GUIDE ANGLE ZEE BRACKET INT CROSS CHANNEL DIAGONAL BRACE INT TENSION BRACKET INT SAFETY RETRACTION BAR INT INT SAFETY ROLLER ASSEMBLY LAB-INT LABEL, 1500 LB (680 kg) FALSE CAR INTERNATIONAL INTERNATIONAL SAFETY ASSEMBLY SOCKET HEAD CAP SCREW /2" /2" BEVELED WASHER PLAIN 1/2" METRIC HEX HEAD CAP SCREW M10 X MM METRIC HEX HEAD CAP SCREW M MM METRIC HEX HEAD CAP SCREW M MM METRIC HEX HEAD CAP SCREW M MM NYLON INSERT HEX NUT M NYLON INSERT HEX NUT M HEX NUT M METRIC FLAT WASHER M METRIC HEX HEAD CAP SCREW M10 X MM CARRIAGE BOLT M10 25MM CNSF0Z METRIC SERRATED HEX FLANGE NUT CL.8 Z M CNSF0Z METRIC SERRATED HEX FLANGE NUT CL.8 Z M

32 International Safety Assembly Bill Of Materials ITEM QTY PartNo Description Size Length INT TAPPED PLATE INT 1/8" SPACER INT SAFETY COVER PLATE INT RETAINING PLATE 1500 # INT SAFETY BLOCK 1500 # INT 1/4" SAFETY SPACER INT 3/16" SAFETY SPACER METRIC FLAT HEAD SCREW M MM METRIC FLAT HEAD SCREW M MM METRIC HEX HEAD CAP SCREW M MM METRIC SPLIT LOCK WASHER M

33 INT International Safety Roller Assembly Bill Of Materials ITEM QTY PartNo Description Size Length SAFETY RETRACTION SPRING INT FORK INT 3/4" WIDE KNURLED ROLLER L-ROD COTTER PIN Z 1/8" 1" SPRING PIN 1/4" 1" HEX NUT Z 3/ MID Bill Of Materials ITEM QTY. PartNo Description Size Length SIDE STILE ASSEMBLY LIFT ANGLES LIFT BAR JOIST BRACKET SAFETY PAWL ASSEMBLY KIT, FALSE CAR SAFETY RETRACTION HEX HEAD CAP SCREW 1/ /4" CARRIAGE BOLT GR.5 1/ /4" HEX HEAD CAP SCREW 1/ /2" HEX NUT NYLON INSERT GR. 5 Z 1/ CNSF5Z SERRATED HEX FLANGE NUT GR.5 1/ COTTER PIN Z 1/8" 1" 33

34 Side Stile Assembly Bill Of Materials ITEM QTY. PartNo Description Size Length FIXED GUIDE ANGLE ADJUSTABLE GUIDE ANGLE DIAGONAL BRACE MID SIZE PLATFORM SUPPORT ANGLE ADJUSTABLE CROSS CHANNEL SIDE STILE ZEE BRACKET TENSION BRACKET SAFETY RETRACTION BAR TAPPED PLATE /8" SPACER /2" SPACER SAFETY COVER PLATE SAFETY ROLLER ASSEMBLY RETAINING PLATE 1500 LBS SAFETY BLOCK 1500# LAB LABEL, 1500 LB (680 kg) FALSE CAR SOCKET HEAD CAP SCREW /2" SERRATED HEX FLANGE SCREW Z 1/4-20 3/4" FLAT HEAD SCREW 1/4-20 1" HEX HEAD CAP SCREW 3/8-16 1" HEX HEAD CAP SCREW 3/ /2" HEX NUT Z 3/ FLATWASHER 3/8" CARRIAGE BOLT GR. 5 3/8-16 1" HEX NUT NYLON INSERT GR. 5 Z 3/ CNSF5Z SERRATED HEX FLANGE NUT GR.5 3/ HEX HEAD CAP SCREW 1/ /4" HEX HEAD CAP SCREW 1/ /2" HEX HEAD CAP SCREW 1/ /2" HEX HEAD CAP SCREW 1/ /4" /2" BEVELED WASHER PLAIN 1/2" SPRING LOCKWASHER 1/2" HEX NUT NYLON INSERT GR. 5 Z 1/ CNSF5Z SERRATED HEX FLANGE NUT GR.5 1/ COTTER PIN Z 1/8" 1" 34

35 Adjustable Platform Bill Of Materials ITEM QTY PartNo Description Size Length OUTER SUPPORT LL CORNER SUPPORT LS CORNER SUPPORT RL CORNER SUPPORT RS CORNER SUPPORT CROSS CHANNEL CORNER BRACKET SPACER CORNER BRACE STICKER PLATFORM STICKER SERRATED HEX FLANGE SCREW Z 1/4-20 3/4" SERRATED HEX FLANGE SCREW Z 1/4-20 1" SQUARE HEAD SET SCREW 3/8-16 1" HEX HEAD CAP SCREW 1/ /2" CARRIAGE BOLT GR.5 1/ /4" CNSF5Z SERRATED HEX FLANGE NUT 1/2"

36 INT Bill Of Materials ITEM QTY PartNo Description Size Length INT OUTER SUPPORT LL-INT CORNER SUPPORT LS-INT CORNER SUPPORT RL-INT CORNER SUPPORT RS-INT CORNER SUPPORT INT CROSS BRACE INT CORNER BRACKET SPACER CORNER BRACE STICKER PLATFORM STICKER METRIC HEX HEAD CAP SCREW M MM SERRATED FLANGE HEAD CAP SCREW CL8.8 Z M MM SERRATED FLANGE HEAD CAP SCREW CL8.8 Z M MM CARRIAGE BOLT M12 30MM METRIC HEX HEAD CAP SCREW M MM CNSF0Z METRIC SERRATED HEX FLANGE NUT CL.8 Z M MID Bill Of Materials ITEM QTY PartNo Description Size Length OUTER SUPPORT CORNER SUPPORT CORNER SUPPORT CORNER SUPPORT CORNER SUPPORT CROSS CHANNEL CORNER BRACKET SPACER CORNER BRACE STICKER PLATFORM STICKER CNSF5Z SERRATED HEX FLANGE NUT GR.5 1/2" HEX HEAD CAP SCREW 1/ /2" CARRIAGE BOLT GR.5 1/ /4" SQUARE HEAD SET SCREW 3/8-16 1" SERRATED HEX FLANGE SCREW Z 1/4-20 3/4" SERRATED HEX FLANGE SCREW Z 1/4-20 1" 36

37 Slant Top Breakaway Canopy Bill Of Materials ITEM QTY PartNo Description Size Length ROOF SUPPORT U-BRACKET- FALSE CAR HANDRAIL HINGE TUBE V1 CANOPY POST A631 CLEVIS PIN W/ COTTER PIN 1/4" 13/16" A389 QUICK-RELEASE PIN WITH LANYARD 1/4" 1.6" HEX HEAD CAP SCREW 1/4-20 3/4" CARRIAGE BOLT 1/4-20 3/4" HEX NUT NYLON INSERT Z 1/ SERRATED HEX FLANGE NUT 1/

38 INT Slant Top Breakaway Canopy Bill Of Materials ITEM QTY PartNo Description Size Length INT ROOF SUPPORT U-BRACKET- FALSE CAR HANDRAIL HINGE TUBE V1 CANOPY POST - INT NYLON INSERT HEX NUT M METRIC HEX HEAD CAP SCREW M6 X MM A631 CLEVIS PIN W/ COTTER PIN 1/4" 13/16" CARRIAGE BOLT M6 20MM METRIC SERRATED HEX FLANGE NUT M A389 QUICK-RELEASE PIN WITH LANYARD 1/4" 1.6" Telescoping Breakaway Canopy Bill Of Materials ITEM QTY. PartNo Description Size Length V1 CANOPY POST HITCH ROOF TUBE CANOPY OUTER EXTRUSION SHORT CANOPY OUTER TOP ANGLE RUBBER SPACER INNER ROOF TUBE CANOPY ROD END II HINGE TUBE A510 METRIC CLEVIS PIN, 12mm DIA X 38mm UL M12 53MM A370 QUICK-RELEASE BUTTON CONNECTOR A389 QUICK-RELEASE PIN WITH LANYARD 1/4" 1.6" A631 CLEVIS PIN W/ COTTER PIN 1/4" 13/16" A224 KEY RING 1-5/8" OD - X 1-3/8" ID METRIC BUTTON HEAD SOCKET CAP SCREW M METRIC SERRATED HEX FLANGE NUT M METRIC HEX HEAD CAP SCREW M6 X MM HAIRPIN COTTER Z ø1/8" 2-9/ FLAT HEAD WOOD SCREW, Z #10 5/8" 38

39

40 Telescoping Handrails Bill Of Materials ITEM QTY PartNo Description Size Length INNER TUBE OUTER TUBE K62 SLIP-JOINT NUT WASHER K35 SLIP-JOINT NUT LB-0139-BOX PINCH POINT WARNING STICKER 1.25" 3" 6 6 CLP-570 WIRE LOCK LYNCH PINS Ø1/ GRIP LENGTH 7 8 WMG-115 WIRE LOCK LYNCH PINS Ø1/4 2 GRIP LENGTH A224 KEY RING 1-5/8" OD X 1-3/8" ID A389 QUICK-RELEASE PIN WITH LANYARD Ø1/4 1.6" Telescoping Handrails Bill Of Materials ITEM QTY PartNo Description Size Length INNER TUBE OUTER TUBE K62 SLIP-JOINT NUT WASHER K35 SLIP-JOINT NUT LB-0139-BOX PINCH POINT WARNING STICKER 1.25" 3" 6 6 CLP-570 WIRE LOCK LYNCH PINS Ø1/ GRIP LENGTH 7 8 WMG-115 WIRE LOCK LYNCH PINS Ø1/4 2 GRIP LENGTH A224 KEY RING 1-5/8" OD X 1-3/8" ID A389 QUICK-RELEASE PIN WITH LANYARD Ø1/4 1.6" Telescoping Handrails Bill Of Materials ITEM QTY PartNo Description Size Length INNER TUBE OUTER TUBE K62 SLIP-JOINT NUT WASHER K35 SLIP-JOINT NUT LB-0139-BOX PINCH POINT WARNING STICKER 1.25" 3" 6 6 CLP-570 WIRE LOCK LYNCH PINS Ø1/ GRIP LENGTH 7 8 WMG-115 WIRE LOCK LYNCH PINS Ø1/4 2 GRIP LENGTH A224 KEY RING 1-5/8" OD X 1-3/8" ID A389 QUICK-RELEASE PIN WITH LANYARD Ø1/4 1.6" 40

41

42 Declaration of Incorporation from Declaration of Conformity: 42

43 Type Examination Certificate: 43

44 Safety Checklist / Maintenance Log: Move the False Car in the down direction, check that both safeties engage and hold. Mon. Tue. Wed. Thu. Fri. Sat. Sun. Check that guard rails and toe guards are in place & meet OSHA and/or EN1808/EN81 requirements. Check overhead supports and rigging. Check the entire False Car for worn or damaged parts, missing parts, loose bolts, etc. Check the Safety Rollers very carefully. Make sure the safety springs work and rollers rotate freely. Lubricate all moving parts. Check the operation of the Safety Retraction System. Make sure the Wire Rope Grips are in place and tight. 44