1© Copyright 2001, DB Industries, Inc.

SAYFGLIDA ENGINEERED PERMANENT HORIZONTALLIFELINE INSTALLATION MANUAL

CONTROLLED

UNCONTROLLED

MANUAL SERIAL NO. __________

Document No. : 5902165 Revision: A

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Contents1.0 General Information 5

1.1 Safety .................................................................................................................................................................51.2 Purpose of Multispan Sayfglida Horizontal Lifeline System ......................................................................... 51.3 The Sayfglida System Design ..........................................................................................................................51.4 Inspection .......................................................................................................................................................... 51.5 Safety .................................................................................................................................................................51.6 System Types .................................................................................................................................................... 6

2.0 System Ratings and Limitations 62.1 User Limitations ................................................................................................................................................ 62.2 Anchorage Strength .......................................................................................................................................... 6

3.0 Physical Limitations 63.1 Maximum Weight. .............................................................................................................................................. 6

4.0 Site Hazards 64.1 General Safety Precautions .............................................................................................................................. 64.2 Hazard Assessment .......................................................................................................................................... 64.3 Obstructions ...................................................................................................................................................... 74.4 Heat ....................................................................................................................................................................74.5 Corrosion ...........................................................................................................................................................74.6 Chemical Hazards ............................................................................................................................................. 74.7 Electrical Hazards ............................................................................................................................................. 74.8 Moving Equipment ............................................................................................................................................74.9 Sharp Edges and Abrasive Surfaces ............................................................................................................... 74.10 Fall Clearance .................................................................................................................................................... 74.11 Swing Falls ........................................................................................................................................................7

5.0 Rescue Plan 85.1 Rescue Plan ....................................................................................................................................................... 8

6.0 Training 86.1 Training ..............................................................................................................................................................8

7.0 Labeling 87.1 Site Label ...........................................................................................................................................................8

8.0 Installation 88.1 Installation Order .............................................................................................................................................. 88.2 Stage 1. Installing the Support Hardware. ....................................................................................................... 9

8.2.1 Types of Anchors ......................................................................................................................................98.2.2 End Anchor Installation ............................................................................................................................ 98.2.3 Intermediate Bracket ................................................................................................................................. 98.2.4 Intermediate Bracket Orientation. .......................................................................................................... 108.2.5 Intermediate Bracket Installation ........................................................................................................... 108.2.6 Types of Corners ..................................................................................................................................... 108.2.7 Corner Unit Orientation .......................................................................................................................... 108.2.8 Reinforced 90 ° Corner ........................................................................................................................... 118.2.9 Reinforced 135 ° Corner ......................................................................................................................... 118.2.10 135 ° Ox-Bow Corner .............................................................................................................................. 118.2.11 90 ° Ox-Bow Corner ................................................................................................................................ 118.2.12 90 ° Corner ............................................................................................................................................... 128.2.13 2 X 45 ° Corner ......................................................................................................................................... 128.2.14 Corner Unit Installation........................................................................................................................... 12

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8.3 Stage 2: String the Cable ................................................................................................................................ 128.4 Stage 3: Install Entry/Exit Units ..................................................................................................................... 12

8.4.1 Toggle-swage Entry/Exit Unit ................................................................................................................. 138.4.2 Mid-entry/Exit Unit .................................................................................................................................. 13

8.5 Stage 4: Install Terminations .......................................................................................................................... 138.5.1 Swageless Terminator ............................................................................................................................ 148.5.2 Toggle/Swage Termination ..................................................................................................................... 148.5.3 Toggle/Swage Tensioner......................................................................................................................... 148.5.4 In-Line Splice ........................................................................................................................................... 148.5.5 Toggle/Toggle Tensioner ........................................................................................................................ 158.5.6 Second Termination Considerations ..................................................................................................... 15

8.6 Stage 5: Tension the Cable ............................................................................................................................. 158.7 Stage 6: Inspect the System ........................................................................................................................... 17

8.7.1 Site Label ................................................................................................................................................. 178.7.2 Inspection and Recertification ............................................................................................................... 178.7.3 Inspection Steps ..................................................................................................................................... 17

9.0 Maintenance - Servicing - Storage 189.1 Cleaning ........................................................................................................................................................... 189.2 Storage ............................................................................................................................................................. 189.3 Lubricants ........................................................................................................................................................ 189.4 Additional Maintenance .................................................................................................................................. 18

10.0 Warranty Information 18

Appendix ASwageless Termination Instructions 19

A.1 Safety ............................................................................................................................................................... 19A.2 Measure the cable and mark the position of the terminator. ....................................................................... 19A.3 Secure the terminator onto the cable. ........................................................................................................... 20

Appendix BSwager Assembly 22

B.1 Die assembly ................................................................................................................................................... 22B.2 Hydraulic Cylinder Assembly ......................................................................................................................... 23B.3 Draw Bar Assembly ......................................................................................................................................... 23B.4 Final Assembly ................................................................................................................................................ 23B.5 Warnings and Safety Precautions.................................................................................................................. 23

Appendix CSwaging Operation 24

C.1 Swage Tube Adapters ..................................................................................................................................... 24C.2 Connect the Swage Tube to the Drawing Block............................................................................................ 24C.3 Swage the Cable Into the Swage Tube .......................................................................................................... 24C.4 Reassemble the Swage Tube Unit ................................................................................................................. 25

Appendix D Parts and Components 26D.1 Cable (Part No. 7202372) ............................................................................................................................... 26D.2 Intermediate Bracket (Part No. 7209205) ....................................................................................................... 26D.3 In-line Swage (Part No. 7209222) .................................................................................................................. 26D.4 In-line Entry/Exit (Part No. 7209219) ............................................................................................................. 27D.5 RH/LH Entry/Exit Units ( Part No. 7209278 Right Hand) ............................................................................. 27D.6 End Termination (Part No. 7209239) ............................................................................................................. 28D.7 Tensioner Toggle – Toggle (Part No. 7209213) .............................................................................................. 28D.8 Tensioner Toggle – Swage (Part No. 7209212) .............................................................................................. 29D.9 Standard Sayflink Sleeve (Part No. 7209237) ................................................................................................ 29D.10 Rolling Sleeve Sayflink Sleeve (Part No. 7210189) ....................................................................................... 30D.11 Detachable Sayflink Sleeve (Part No. 7209284) ............................................................................................ 30

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D.12 Detachable Rolling Sayflink Sleeve (Part No. 7204902) ............................................................................... 31D.13 90° Reinforced Corner Unit (Part No. 7211897) ............................................................................................. 31D.14 135° Reinforced Corner Unit (Part No. 7200002) ........................................................................................... 32D.15 135° Oxbow Corner Unit (Part No. 7209217) ................................................................................................. 32D.16 90° Oxbow Corner Unit (Part No. 7209218) ................................................................................................... 33D.17 90° Corner Unit (Part No. 7209206) ................................................................................................................ 33D.18 90° Internal Corner Unit (Part No. 7209220) .................................................................................................. 34D.19 End Anchor - Weld On (Part No. 7210451)..................................................................................................... 35D.20 End Anchor - Bolt On (Part No. 7209251) ...................................................................................................... 35

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1.0 General Information

1.1 Safety

DBI/SALA requires certified installers be trained by a DBI/SALA Horizontal Lifeline Representative or anycertified personnel, as defined by DBI/SALA, before they are allowed to perform the installation of the SayfglidaHorizontal Lifeline. The installer must read (or have explained), understand and heed all instructions, labels andwarnings supplied with this product and products associated with it. FAILURE TO DO SO MAY RESULT INSERIOUS INJURY OR DEATH.

WARNING: Some installation and service procedures contained in these instructions can be hazardous and mayresult in personal injury.

A separate means of fall protection must be utilized during the installation of a Sayfglida System. A separatemeans of fall protection must be used when inspecting or servicing a Sayfglida System following a fall. Theinstaller’s lanyard must not exceed the maximum allowable length determined for the application.

DBI/SALA recommends the use of certified eye protection, steel toe boots and gloves be worn during theinstallation of the horizontal lifeline system.

WARNING: Use of parts, tools or procedures not specified or supplied by DBI/SALA in installing and servicing thissystem may be dangerous and could result in serious or fatal injury to the user(s). Only DBI/SALA Sayfglidacomponents may be used in the installation and repair of Sayfglida Systems.

1.2 Purpose of Multispan Sayfglida Horizontal Lifeline SystemThe Sayfglida Horizontal Lifeline System is a cable based horizontal system designed with the compatibleSayflink Sleeve to provide a multispan, mobile anchorage connector for DBI/SALA personal fall arrest or fallrestraint equipment. The Sayfglida Horizontal Lifeline system provides a mobile anchorage without therequirement to attach and detach between suitable intermediate anchorages. The Sayfglida system may not beused for the fall protection of material or equipment. The Sayfglida Horizontal Lifeline System may only beinstalled by certified installers as defined and trained by DBI/SALA.

1.3 The Sayfglida System DesignThe Sayfglida system is designed to be installed in a horizontal plane. Contact DBI/SALA prior to installation insituations where:

• The cable is intended to be installed at an incline.• The walking/working surface is at an incline.• The cable is intended to be installed to follow a curved surface.

The overall system design must be completed prior to installation. The installer shall utilize the Sayfglida Lifelinecomputer analysis program when designing the system. The installer is responsible for determining if theattachment structure is capable of supporting the required loads based on the system design, customerrequirements, and all applicable standards and regulations ( ref. OSHA, ANSI).

1.4 InspectionUpon receipt of the Sayfglida Horizontal Lifeline System, inspect all components and user equipment for defectsand/or damage. If any Sayfglida components or DBI/SALA equipment are found to be damaged, defective, ormissing, contact DBI SALA immediately for replacements. Do not use any defective or damaged parts in aSayfglida Horizontal Lifeline System installation.

WARNING: Use of defective or damaged parts will hinder the performance of the Sayfglida system, potentiallycausing serious injury or death in the event of a fall.

1.5 SafetyA separate means of fall protection must be utilized during the installation of a Sayfglida System. A separatemeans of fall protection must be used when inspecting or servicing a Sayfglida System following a fall.

DBI/SALA recommends the use of certified eye protection, steel toe boots and gloves be worn during theinstallation of the horizontal lifeline system.

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WARNING: Some installation and service procedures contained in this manual can be hazardous and may result inpersonal injury.

WARNING: Use of parts, tools, or procedures not specified or supplied by DBI/SALA in installing and servicing thissystem may be dangerous and could result in serious or fatal injury to the user(s). Only DBI/SALA Sayfglidacomponents may be used in the installation and repair of Sayfglida Systems.

1.6 System TypesEach Sayfglida System is designed for either fall restraint or fall arrest:

A. A fall restraint system prevents falls from occurring by restraining the worker from reaching the fall hazard.

B. A fall arrest system prevents the worker from colliding with an obstruction of lower level by arresting a fallafter the fall has occurred.

Only DBI/SALA approved personal fall arrest equipment, including shock absorbing lanyards and Self RetractingLifelines my be used with the Sayfglida System. Other equipment may not meet DBI/SALA standards which maycompromise the performance of the system.

2.0 System Ratings and Limitations

2.1 User LimitationsThe maximum number of users allowed on a system is determined by the span lengths, available clearance,anchorage strength, and the strength of the Sayfglida components. DBI/SALA and/or certified installers willspecify the maximum number of users allowed on each specific installation. No more than the maximum numberof users specified on the Site Label (see Figure 1 on page 8) may be connected to the Sayfglida system at anytime

WARNING: Consult your doctor if there is reason to doubt your fitness to safely absorb the shock from a fall arrest.Age and fitness seriously affect a worker's ability to withstand falls. Pregnant women or minors must not use DBI/SALA Horizontal Lifeline System

2.2 Anchorage StrengthAll anchorage requirements have been pre-engineered based on the system requirements as provided by theend user. Please see the site label (figure 1) for complete system ratings. Do not exceed the limitations of thesystem.

3.0 Physical Limitations

3.1 Maximum Weight.The Sayfglida System is designed to accommodate users with a maximum weight of 310 lbs. including clothing,tools, and equipment.

Note: A DBI/SALA Sayflink Sleeve is the only connector allowed to be directly attached to the Sayfglida cable.Snap hooks and carabiners are not allowed to be connected directly to the Sayfglida cable.

4.0 Site Hazards

4.1 General Safety PrecautionsVisually inspect the installation area for all potential installation hazards. A separate means of fall protection mustbe utilized during the installation of a Sayfglida System. A separate means of fall protection must be used wheninspecting or servicing a Sayfglida System following a fall. The installer must follow the user’s instruction for allcomponents of the installation fall protection equipment.

4.2 Hazard AssessmentPrior to the installation of the Sayfglida Horizontal Lifeline system, the certified installer must perform a hazardassessment of the installation area to address any potential damage to the Sayfglida System. The materialsused in the construction of a Sayfglida System may not be damaged after the installation is complete. Damageto any Sayfglida component may hinder the performance of the system and may cause serious injury or death.

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Hazards that should be identified include, but are not limited to:Chemicals Environmental contaminants Electrical hazards Sharp edgesHot Objects Anchorage availability/Location Abrasive surfaces Moving equipmentSparks Unguarded openings Unstable/uneven surfaces Slippery surfacesFlames Heat-producing operations Confined space hazards

4.3 ObstructionsThe cable should be routed so that it does not contact the anchoring structure or nearby obstructions. The cableshould not contact any obstructions when deflected under load. This will protect the cable from abrasion andallow the Sayflink sleeve to travel the system without assistance from the user.

At entry/exit points, several inches of clearance between the cable and any nearby obstruction are required toallow the Sayflink sleeve to enter and exit the system easily.

4.4 HeatThis equipment is not designed for use in high temperature environments. Protection should be provided for thisequipment when used near welding, metal cutting or similar activities. Consult DBI/SALA for details on hightemperature environments.

4.5 CorrosionDo not leave user equipment of the Sayfglida Horizontal Lifeline Systems (ie. full body harness, shock absorbinglanyard, or Sayflink) for long periods of time in environments where corrosion of metal parts could take place asa result of vapors rising into the atmosphere from organic materials. Caution should be exercised when workingaround sewage or fertilizer because of their high concentration of ammonia which is very corrosive. Use frequentinspections or servicing to assure corrosion is not affecting the performance of this product.

4.6 Chemical HazardsSolutions containing acids, alkali, or other caustic chemicals especially at elevated temperatures may causedamage to this equipment. When working with such chemicals, frequent inspection of this equipment must beperformed. Consult DBI/SALA if doubt exists concerning using this equipment around chemical hazards.

4.7 Electrical HazardsDue to the possibility of electrical current flowing through this equipment, or connecting components (hooks), useextreme caution when working near high voltage power lines.

4.8 Moving EquipmentWhen performing tasks near moving machinery (i.e. conveyors, rotating shafts, rotating gears, etc..), make surethat no loose elements can become entangled in the equipment.

4.9 Sharp Edges and Abrasive SurfacesDo not expose the Sayfglida System to any sharp edges or abrasive surfaces that may damage the systemcomponents. If working with this equipment around sharp edges is unavoidable, provide protection by securing aheavy pad over the exposed sharp edge.

4.10 Fall ClearanceThere must be sufficient clearance below the user to arrest a fall before the user strikes the ground or otherobstruction. The clearance required is determined by a computer analysis of the system based on the followingfactors:

• Elevation of anchorage • Connecting subsystem length • System Span Length/Number of Spans• Free fall distance • Deceleration distance • System Cable Tension• Worker height • Total System Length • Movement of harness attachment element

4.11 Swing FallsSwing falls occur when the anchorage point is not directly above the point where a fall occurs. The force ofstriking an object while swinging (horizontal speed of the user due to the pendulum effect) can be great and maycause serious injury. Also in a swing fall situation, the total vertical fall distance of the user may be greater than ifthe user had fallen vertically (directly below the anchorage point) thus, an increase in the total free fall distance,and the distance needed to arrest the fall may increase. Working as directly below the anchorage point aspossible can minimize swing falls. If a swing fall situation exists in your application, contact DBI/SALA beforeproceeding.

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5.0 Rescue Plan

5.1 Rescue PlanIt is vital that a rescue plan can be implemented should a user fall at any point along a Sayfglida System. Itshould be assumed that the fallen user will not be able to participate in their rescue. Differing rescue solutionswould apply for different types of application. DBI/SALA will recommend a suitable rescue system for eachapplication and, if applicable, will supply relevant equipment.

6.0 Training

6.1 TrainingIt is the responsibility of the user to assure they are familiar with these instructions, and are trained in the correctinstallation, care, and use of this equipment. The user must also be aware of the operating characteristics,application limits, and the consequences of improper use of this equipment.

IMPORTANT NOTE: Training must be conducted without exposing the trainee to a fall hazard. Training should berepeated periodically.

WARNING: Do not alter or intentionally misuse this equipment. Consult DBI/SALA when using this equipment incombination 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 using this equipmentaround moving machinery, electrical hazards, chemical hazards, and sharp edges.

WARNING: This product is part of a personal fall arrest, restraint, work positioning, personnel riding, climbing, orrescue system. The user must follow the manufacturer's instructions for each component of the system. Theseinstructions must be provided to the user of this equipment. The user must read and understand these instructionsbefore using this equipment. Manufacturer's instructions must be followed for proper use and maintenance of thisequipment. Alterations or misuse of this product or failure to follow instructions may result in serious injury or death.

7.0 Labeling

7.1 Site LabelThe site label should be located near all entry/exit points of the system.The label will contain the following: the maximum number of users thesystem is designed for, what user equipment should be used on thesystem, the system number, when and who installed the system.See Figure 1.

8.0 Installation

8.1 Installation OrderThe recommended order for installing the components of a SayfglidaHorizontal Lifeline System is:

Stage 1. Install the support hardware: anchors, intermediate brackets, andcorner units.

Stage 2. Thread the cable(s) through the support hardware.Stage 3. Install the entry/exit unit(s).Stage 4. Install the terminations.Stage 5. Tension the cable(s).Stage 6. Inspect the system.

Before performing the installation of the Sayfglida Horizontal LifelineSystem, inspect all components and user equipment for damage and/ordefects. If defects or damage to Sayfglida components or DBI/SALA userequipment are found contact DBI/SALA immediately for replacements.

WARNING: Installation of defective or damaged parts will hinder the performance of the Sayfglida system, potentiallycausing serious injury in the event of a fall.

Figure 1 - Site Label

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DBI/SALA recommends the use of gloves, approved safety glasses, steel toe work boots, and hard hats duringthe installation of the Sayfglida System to reduce injury to the installation crew.

8.2 Stage 1. Installing the Support Hardware.

8.2.1 Types of AnchorsThere are two types of anchors: weld-on anchors and bolt-on anchors.

Weld-on Anchor ( Part No. 7210457) See Figure 2.Material: ASTM A36 Carbon steel angleWeight: 3.1 lbs.Breaking Strength: 20,000 lbs.

Bolt-on Anchor (Part No. 7209251) See Figure 3.Material: 304 Stainless Steel

316 Stainless Steel Washers316 Stainless Steel locknut with nylon insert

Weight: 3.2 lbs.Breaking Strength: 20,000 lbs.Notes: Requires two 1/2 – 13 UNC fasteners.

8.2.2 End Anchor InstallationAll anchor points must be pre-approved by the installer.

The end anchor must be installed with all parts included in the package.The maximum hole diameter in the desired attachment structure for theanchor bolt cannot exceed 9/16 in.

The two 9/16 in. diameter holes are used to mount the end anchors to theanchoring structure. The three 3/4 in. diameter holes on the leg withchamfered corners are used for attaching the Sayfglida System.

DBI/SALA requires the attachment of the intermediate bracket be used with two Grade 8 – 1/2 in. diameter bolts atminimum, along with the parts supplied.

The user supplied 1/2 in. bolts may be installed either through the support structure and into the anchor orthrough the anchor and into the support structure. In either case, the stainless steel washer must be installednext to the nut rather than next to the bolt head.

Ensure at least four full threads of the anchor bolt are exposed beyond the nylon insert of the locknut. Tightenthe locknuts to a torque of 75 ft./lbs. ±10 ft./lbs. Place a wrench on the bolts to eliminate bolt rotation duringtightening.

The end anchor must be orientated so that the system is installed straight off the end anchor and the togglehinge does not bend.

8.2.3 Intermediate Bracket(Part No. 7210152) See Figure 4Material: 316 Stainless Steel

316 Stainless Steel WasherNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insert

Weight: 0.9 lbs.Breaking Strength: 6,800 lbs.Notes: Requires one ½ – 13 UNC fastener.

Figure 3 - Bolt on Anchor

Figure 2 - Weld on Anchor

Figure 4 - Intermediate Bracket

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8.2.4 Intermediate BracketOrientation.Bracket orientation is determinedby the system location in referenceto the worker. It is dependent uponthe vertical distance between thewalking/working surface and thehorizontal cable. See Figure 5 forcorrect bracket orientation.

It is important that the correctorientation is used to ensure thatthe Sayflink will bypass theintermediate brackets without anyassistance from the user.

The intermediate bracket isdesigned to allow bypasscapabilities with the user walkingon the ‘neck’ side (the side thatretains the cable) of the bracket.The bracket should be installed sothat the user is located on the neckside of the bracket. Two systemsplaced back-to-back may berequired in cases where bypasscapabilities are needed on bothsides of the bracket.

8.2.5 Intermediate Bracket InstallationAll intermediate bracket attachment points must be pre-approved by the installer.

The intermediate bracket must be installed with all parts included in the package. The maximum hole diameter inthe desired attachment structure for the anchor bolt cannot exceed 9/16”.

DBI/SALA requires the intermediate bracket be attached with a Grade 8 – 1/2 in. diameter bolt at minimum,along with the parts supplied. Ensure the intermediate bracket is installed in the correct orientation previouslydetermined in section 8.2.4.

The brackets are usually installed with the bolt placed through the anchor structure and into the bracket, but thebolt may also be placed through the bracket and into the anchoring support. In either case, the nylon washermust always be placed between the bracket and the structure and the stainless steel washer must be installedinside the bracket.

Tighten the locknut to a torque of 18 ft./lbs. ± 5 ft./lbs. Place a wrench on the bolt to eliminate bolt rotation duringtightening. Ensure at least four full threads of the anchor bolt are exposed beyond the nylon insert of the locknut.

Do not overtighten the intermediate bracket. The intermediate bracket is designed to rotate and deform to absorbenergy in the event of a fall. Double check intermediate bracket orientation to ensure the Sayflink Sleeve willbypass the bracket correctly.

8.2.6 Types of CornersThere are six types of corner units:1. Reinforced 90° Corner Unit 3. Reinforced 135° Corner Unit 5. 135° Ox-Bow Corner Unit2. 90° Ox-Bow Corner Unit 4. 90° Corner Unit 6. 2 X 45° Corner Unit

8.2.7 Corner Unit OrientationMost of the corner units can be oriented for an inside or an outside corner. To create the correct orientation of acorner unit, refer to the applicable corner bracket drawing in Appendix D.

Figure 5 - Selecting the Intermediate Bracket Orientation

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8.2.8 Reinforced 90 ° Corner(Part No. 7211897) See Figure 6.Material: 316 Stainless Steel bracket

316 Stainless Steel tubes316 Stainless Steel washerNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insertZinc Plated steel backer platesZinc Plated steel square plates

Weight: 7.4 lbs.Notes: Corner units can be adapted to inside or outside cornerbends. See Appendix D, Drawing 7211897, for the proper bracketorientation. The bracket may be oriented in one of severalorientations based on the specific application. Requires one ½ - 13 UNC fastener.

8.2.9 Reinforced 135 ° Corner(Part No. 7200002) See Figure 7.Material: 316 Stainless Steel bracket

316 Stainless Steel tubes316 Stainless Steel washerNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insertZinc Plated steel backer platesZinc Plated steel square plates

Weight: 7.4 lbs.Notes: Corner units can be adapted to inside or outside cornerbends. See Appendix D Drawing 7200002, for the proper bracketorientation. The bracket may be oriented in one of severalorientations based on the specific application. Requires one½ - 13 UNC fastener.

8.2.10 135 ° Ox-Bow Corner(Part No. 7209217) See Figure 8.Material: 316 Stainless Steel bracket

316 Stainless Steel tubes316 Stainless Steel washerNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insert

Weight: 1.5 lbs.Notes: Corner units can be adapted to inside or outside cornerbends. See Appendix D, Drawing 7209217, for the proper bracketorientation. The bracket may be oriented in one of severalorientations based on the specific application. Requires one½ - 13 UNC fastener.

8.2.11 90 ° Ox-Bow Corner(Part No. 7209218) See Figure 9.Material: 316 Stainless Steel bracket

316 Stainless Steel tubes316 Stainless Steel washerNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insert

Weight: 1.8 lbs.Notes: Corner units can be adapted to inside or outside cornerbends. See Appendix D, Drawing 7209218, for the proper bracketorientation. The bracket may be oriented in one of severalorientations based on the specific application. Requires one½ - 13 UNC fastener.

Figure 6 - Reinforced 90°Corner Unit

Figure 7 - Reinforced 135°Corner Unit

Figure 8 - 135° Ox-Bow CornerUnit

Figure 9 - 90° Ox-bowCorner Unit

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8.2.12 90 ° Corner(Part No. 7209206) See Figure 10.Material: 316 Stainless Steel bracket

316 Stainless Steel tubes316 Stainless Steel washerNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insert

Weight: 1.8 lbs.Notes: Corner units can be adapted to inside or outside cornerbends. See Appendix D, Drawing 7209206, for part assembly andproper bracket orientation. The bracket may be oriented in one ofseveral orientations based on the specific application. Requires one½ - 13 UNC fastener.

8.2.13 2 X 45 ° Corner(Part No. 7209220) See Figure 11.Material: 316 Stainless Steel bracket

316 Stainless Steel tubes316 Stainless Steel washerNylon 6/6 isolation washer316 Stainless Steel locknut with nylon insert

Weight: 1.8 lbs.Notes: Corner units can be adapted to inside or outside cornerbends. See Appendix D, Drawing, 7209220, for part assembly andproper bracket orientation. The bracket may be oriented in one ofseveral orientations based on the specific application. Required½ - 13 UNC fastener is included.

8.2.14 Corner Unit InstallationCorner bracket attachment points must be pre-approved by the installer.

1. If using a reinforced corner, attach the backer plate to the anchor structure.2. Attach the intermediate brackets to the backer plate or anchor structure. For some corner units, it may benecessary to assemble some of the tubes to the bracket before the bracket is attached to the backer plate oranchor structure. For each intermediate bracket, make sure that the nylon washer is installed between thebracket and the backer plate or anchor structure and that the stainless steel washer is installed inside thebracket.3. Ensure that all intermediate brackets included in the corner unit are installed in the correct orientation aspreviously determined in section 8.2.4.4. Slide the intermediate tube into the intermediate bracket.5. Press the individual parts together as indicated in the individual drawing in Appendix D.

8.3 Stage 2: String the CableWhen unrolling and stringing the cable it is important not to damage the cable by allowing to kink or bendsharply.

After all intermediate brackets and corner units (if used) are installed, thread the cable starting from one end ofthe system and continuing to the other end, ensuring the cable passes through each component.

Note: Stringing the cable may require more than one person to perform the operation correctly. Longer systemswill require more assistance.

Note: When threading the cable through corner units it may be helpful to disassemble the corners. Take care tokeep the components in the correct order when reassembling them.

8.4 Stage 3: Install Entry/Exit UnitsEntry/Exit Unit SwagingIf the system has entry/exit units, DBI/SALA recommends that they be swaged and completed before installingother terminations, to facilitate the system installation.

Figure 11 - 2 X 45° Corner Unit

Figure 10 - 90° Corner Unit

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There are two types of entry/exit units:1. Toggle-swage entry/exit unit2. Mid-entry/exit unit

8.4.1 Toggle-swage Entry/Exit UnitPart No. 7209278 or 7209279 See Figure 12. SeeAppendix D for part drawings.

The toggle-swage entry/exit unit is available with aright-handed thread or left-handed thread. A stampedletter “R” or “L” on the machined flat on the swage tubewill identify which model you have.

Prior to swaging a mid-entry/exit unit onto the cableassemble the unit and install a Sayflink Sleeve ontothe cable to be certain the unit is installed in the correct position to allow the Sayflink Sleeve to bypass theintermediate brackets.

For swaging instructions see Appendix C.

8.4.2 Mid-entry/Exit UnitPart No. 7209219 See Figure 13. See Appendix D forpart drawings

Installing a mid entry/exit unit requires marking thelocation of the unit on the cable, cutting the cable,swaging the unit’s swage tubes onto the cable andreassembling the unit.

To mark the location of the unit on the cable, pull thefree end of the cable through the intermediate bracketsand corner units (if applicable) until the excess cable sag has been removed. Mark the desired location of themid-entry/exit on the cable.

Prior to swaging a mid entry/exit unit onto the cable assemble the unit and install a Sayflink Sleeve onto thecable to be certain the unit is installed in the correct position to allow the Sayflink Sleeve to bypass theintermediate brackets.

Cut the cable at the desired location and disassemble the mid-entry/exit unit.

Swage the tubes onto the cable, following the swaging instructions in Appendix C.

After swaging, reassemble the unit. Ensure the swage tube and components are fully threaded on the entry/exitcomponent of the unit and the two roll pins are in place to prevent the unit from unthreading. If holes are not inline to allow the installation of the roll pins, use Loctite 242 (Semi-Permanent Type) to prevent the terminationfrom unthreading.

A mid-entry / exit unit should be installed before the system has been completely swaged and tensioned.If a mid-entry / exit unit is installed after the completion of a system installation it will add 6” to an existing systemwithout removing cable. The system tension will decrease and cable sag will increase if the section of cable forthe in-line splice is not removed. Remove the amount of cable that will be replaced by the mid-entry/exit body ofthe unit.

8.5 Stage 4: Install Terminations

There are 3 types of terminations:1. Swageless Terminator2. Toggle/Swage Termination3. Toggle / Swage Tension Termination

Figure 13 - Mid-Entry/Exit Unit

Figure 12 - Toggle-Swage Entry/Exit Unit

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8.5.1 Swageless TerminatorPart No 7202137. See Figure 14.

The swageless termination allows on location termination of alifeline system without the use of a swaging machine. Aninstallation tool kit (part no. 7204624) is required for installing theswageless terminator and a single kit can be used for allswageless terminator installations. For detailed installationinstructions see Appendix A.

8.5.2 Toggle/Swage Termination(Part No 7209239) See Figure 15. See Appendix D for partdrawing.

Swage the termination onto the cable following the swagingprocedure in Appendix C.

8.5.3 Toggle/Swage Tensioner(Part No 7209212) See Figure 16. See Appendix D forpart drawing.

Prior to swaging a toggle/swage tensioner onto thecable, thread the swage tube and the toggle all the wayinto the turnbuckle then unthread each part to ensurethe threads are not damaged.

Disassemble the swage tube component of thetensioner and remove the jam nut from the swage tube.

Swage the cable to the tube by following the swaginginstructions in Appendix C. After swaging the tube ontothe cable, reassemble the unit.

8.5.4 In-Line SplicePart No. 7209222 See Figure 17. See Appendix D forpart drawing.

If the system has been impacted or otherwisedamaged, an in-line splice may be used to repair thesystem.

Pull the free end of the cable through the brackets untilthe excess cable sag has been removed. Mark thedesired location of the In-Line Splice on the cable.

Prior to swaging an In-Line Splice unit onto the cable,determine the amount cable that will be replaced by themiddle body of the unit. This amount of cable should becut out of the system prior to swaging.

Cut the cable using the hydraulic cable cutters at the desired location and disassemble the splice unit. Swagethe cable to the tube by following the swaging instructions in Appendix C.

After swaging, reassemble the unit. Ensure the swage tube and components are fully threaded on the mid bodycomponent of the unit and the two roll pins are in place to prevent the unit from unthreading. If holes are not inline to allow the installation of the roll pins, use Loctite 242 (Semi Permanent Type) to prevent the terminationfrom unthreading.

The addition of an In-Line Splice will add 6” to an existing system without removing cable. The system tensionwill decrease and cable sag will increase if the section of cable for the In-Line Splice is not removed.

Figure - 17 In-Line Splice

Figure 16 - Toggle/Swage Tensioner

Figure 14 - Swageless Terminator

Figure 15 - Toggle/Swage Termination

15

8.5.5 Toggle/Toggle TensionerPart No. 7209213 See Figure 18. See Appendix D forpart drawing.

If entry/exit terminations are used at both ends of thesystem or the system is very long, a toggle/toggletensioner will be required to provide adequatetensioning to the system.

Tensioner links (Part No. 7210083) should be usedwhen attaching a toggle/toggle tensioner to other endterminations.

Connect the termination and the tensioner using the clevis pin and cotter pin, unthread the turnbuckle until onlyfour threads are visible inside the turnbuckle body to allow for the maximum tensioning adjustment after all endcomponents are assembled make certain both legs of the cotter pin are bent back around the clevis pin.

8.5.6 Second Termination ConsiderationsA. If the second termination is a toggle/swage tensioner, unthread the turnbuckle until only four threads are

visible inside the turnbuckle body. If the first termination also incorporates a turnbuckle, make sure it isunthreaded with only four threads showing as well; this will allow for the maximum tensioning adjustmentafter the second termination is swaged.

B. If a toggle/toggle tensioner is required at the second end of the system install a toggle/toggle tensioner to thesecond termination use the following the procedure prior to swaging the second termination.

Step 1. Connect the second termination and toggle/toggle tensioner to the end anchor using only the clevis pin.Retain the cotter pin for use when finally attaching the termination to the anchor.

Step 2. Measure the finished length of the cable by pulling the free end of the cable until the excess sag isremoved. While maintaining tension on the cable, hold the termination along side of the cable. At thepoint where the cable will enter the swage tube mark the cable.

Step 3. Cut the cable using the hydraulic cable cutters a distance of 6 inches toward the free end of the cablefrom the mark.

WARNING: Before proceeding with the final swage of the system inspect each intermediate bracket and end anchorto ensure each component has been installed in the correct orientation.

Step 4. Swage the termination onto the cable following the swaging procedure in Appendix C.

Step 5. Attach the second termination and toggle/toggle tensioner to the end anchor using the clevis pin andinstall the cotter pin at this time. Ensure both legs of the cotter pin are bent back around the clevis pin.

8.6 Stage: 5 Tension the CableBegin tensioning the system by rotating the turnbuckle body of the tensioning unit. If two tensioners are used,the adjustment should be divided equally between the two.

Note: Several times during the tensioning process the installer should walk along the system and shake thecable in each subspan to free any static friction buildup in the intermediate brackets and corner units.

If corner units are used, they should be checked and adjusted during tensioning to make sure they are not beingdeformed.

Do not over tension the system. Over tensioning the system will create potentially higher end loads than thesystem terminations were designed for. This could cause the system anchorages to fail.

The amount of sag in a horizontal cable can be used as means of determining if the desired tension level hasbeen achieved. See Table 1 on page 16.

Figure 18 - Toggle/Toggle Tensioner

16

To determine how much sag the cable should have in each span (the distance between intermediate supports),locate the desired pretension amount in a column across the top of the table (250 lbs, 500 lbs, or 1000 lbs), thenlocate the span in a row down the side of the table. The required amount of sag (in inches) needed to achievethe desired pretension is displayed at the intersection of the selected column and row.

1elbaT)sehcnini(epoReriW7X7mm21fonoitcelfeDyranetaCdnagninoisneTmetsyS

)tf(napS )sbl(noisneterP )tf(napS )sbl(noisneterP052 005 0001 052 005 0001

1 200.0 100.0 100.0 15 217.5 658.2 824.12 900.0 400.0 200.0 25 839.5 969.2 484.13 020.0 010.0 500.0 35 961.6 480.3 245.14 530.0 810.0 900.0 45 404.6 202.3 106.15 550.0 720.0 410.0 55 346.6 123.3 166.16 970,0 040.0 020.0 65 788.6 344.3 227.17 801.0 450.0 720.0 75 531.7 765.3 487.18 141.0 070.0 530.0 85 783.7 496.3 748.19 871.0 980.0 440.0 95 446.7 228.3 119.101 022.0 011.0 550.0 06 609.7 359.3 679.111 662.0 331.0 660.0 16 171.8 680.4 340.221 613.0 851.0 970.0 26 144.8 122.4 011.2

31 173.0 681.0 390.0 36 617.8 853.4 971.2

41 034.0 512.0 801.0 46 599.8 794.4 942.251 494.0 742.0 421.0 56 872.9 936.4 023.2

61 265.0 182.0 141.0 66 665.9 387.4 193.2

71 536.0 713.0 951.0 76 858.9 929.4 464.281 217.0 653.0 871.0 86 451.01 770.5 935.291 397.0 693.0 891.0 96 554.01 822.5 416.202 878.0 934.0 022.0 07 067.01 083.5 096.212 869.0 484.0 242.0 17 070.11 535.5 867.222 360.1 135.0 662.0 27 483.11 296.5 648.232 261.1 185.0 092.0 37 207.11 158.5 629.242 562.1 236.0 613.0 47 520.21 310.6 600.352 373.1 686.0 343.0 57 353.21 671.6 880.362 484.1 247.0 173.0 67 486.21 243.6 171.372 106.1 008.0 004.0 77 020.31 015.6 552.382 227.1 168.0 034.0 87 063.31 086.6 043.392 748.1 329.0 264.0 97 507.31 358.6 624.303 679.1 889.0 494.0 08 450.41 720.7 415.313 011.2 550.1 825.0 18 804.41 402.7 206.323 942.2 421.1 265.0 28 667.41 383.7 196.333 193.2 691.1 895.0 38 821.51 465.7 287.343 935.2 962.1 536.0 48 594.51 747.7 478.353 096.2 543.1 376.0 58 668.51 339.7 769.363 648.2 324.1 217.0 68 242.61 121.8 060.473 600.3 305.1 257.0 78 226.61 113.8 551.483 171.3 685.1 397.0 88 600.71 305.8 152.493 043.3 076.1 538.0 98 593.71 796.8 943.404 415.3 757.1 878.0 09 887.71 498.8 744.414 196.3 648.1 329.0 19 581.81 390.9 645.424 478.3 739.1 869.0 29 785.81 392.9 746.434 060.4 030.2 510.1 39 399.81 794.9 847.444 152.4 621.2 360.1 49 404.91 207.9 158.454 744.4 322.2 211.1 59 918.91 909.9 559.464 746.4 323.2 261.1 69 832.02 911.01 060.574 158.4 524.2 312.1 79 266.02 133.01 661.584 060.5 035.2 562.1 89 090.12 545.01 372.594 372.5 636.2 813.1 99 325.12 167.01 183.505 094.5 547.2 373.1 001 069.12 089.01 094.5

17

After tensioning has been completed tighten the jam nut on the swage tube against the turnbuckle, insert theprovided cotter pin into the hole at the end of the toggle component threaded into the turnbuckle and bend eachend to extend past the turnbuckle.

Tensioning the system may require several people to perform the operation correctly. Longer systems will requiremore assistance.

If a toggle/toggle tensioner is required at the first end of the system, install the toggle/toggle tensioner on thatend of the system by following the swaging procedure in Appendix C.

If the termination is a toggle/swage tensioner, unthread the turnbuckle until only four threads are visible insidethe turnbuckle body. This will allow for the maximum tensioning adjustment after the second termination isswaged.

Attach the first termination to the system end anchor or custom end anchor using the clevis pin and cotter pin.Ensure both legs of the cotter pin are bent back around the clevis pin.

8.7 Stage 6: Inspect the SystemAfter the Sayfglida System has been fully installed, reinspect all the installed components for damage, correctorientation and proper torque on each anchor bolt.

Install a Sayflink attached to the applicable user equipment and walk the system to ensure that eachintermediate bracket was installed correctly and the system allows for ‘hands free’ by pass along the length ofthe system.

8.7.1 Site LabelThe site label should be installed near every entry/exit point of the system. The label contains the followinginformation; the maximum amount of users the system is designed for, what user equipment should be used onthe system, the system number, the date of installation, and who installed the system. See Figure 1 on page 8.

8.7.2 Inspection and RecertificationFrequency:• Monthly, the end user should visually inspect per the steps listed in section 7.3.• Annually, DBI/SALA recommends that the Sayfglida System be inspected and recertified by a factoryauthorized person.

8.7.3 Inspection StepsStep 1. Inspect the system components (entry/exit units, terminations, end anchors, intermediate brackets,

corner units, and cable) for excessive corrosion, dents, cracks, fraying and deformities.

Step 2. Check the fasteners of the end anchors and intermediate brackets making sure the end anchors andtorqued at 75 ft./lbs ± 10 ft./lbs. and the intermediate brackets at 18 ft./lbs ± 5ft./lbs.

Step 3. Inspect all Sayflink sleeves for excessive wear, corrosion, or deformities.

Step 4. Check the site label(s) making sure they are present, fully legible and secured near an entry/exit unit.

IMPORTANT NOTE: The specific tension of the cable is determined when the system is ordered, if there aretensioning questions contact DBI/SALA.

If inspection reveals a defective condition, prevent the system from being used and contact DBI/SALA forreplacement components. Refer to the applicable component section of the manual for installation.

18

9.0 Maintenance - Servicing - Storage

9.1 CleaningRemove dirt from the cable using a fiber brush. Do not use a wire brush and do not apply any solvents orlubricants without prior approval from DBI/SALA. Clean all other Sayfglida components using a nonabrasivecloth and hot water/mild detergent mix. Dry with a clean cloth. Do not use solvents to clean any SayfglidaComponent.

9.2 StoragePlease refer to the instructions supplied with the harness, lanyard, and self retracting lifeline for cleaning andservicing procedures. Store harness, lanyard, or self retracting lifeline in cool, dry, clean environment out ofdirect sunlight.

9.3 LubricantsAs required, apply a light water repellent lubricant (such as WD40) sparingly to the link hinge on Sayflink Sleeveonly. Do not apply any lubricant to the inner surfaces of the Sayflink Sleeve without the prior approval of DBI/SALA. Do not apply any lubricant to the cable without the prior approval of DBI/SALA.

9.4 Additional MaintenanceAdditional maintenance and servicing procedures (ie. replacement parts) must be completed by a factoryauthorized service center. Authorization must be in writing.

10.0 Warranty InformationSystem and components offered by DBI/SALA is warranted against factory defects in workmanship and materialfor a period of one year from the date of installation of the system or used by the owner provided that this periodshall not exceed two years from the date of shipment. Upon notice in writing, DBI/SALA will replace all defectiveparts. DBI/SALA reserves the right to elect to have any defective part returned to it’s plant for inspection beforemaking a replacement. Warranty does not cover component damages resulting from abuse, damage in transit orother damage beyond the control of DBI/SALA. This warranty applies only to the original purchaser and is theonly one applicable to our products and is in lieu of all other warranties expressed or implied.

Limits of WarrantyThe warranty does not cover• The anchoring structure• Damaged parts caused by unauthorized post installation strength tests.• Installation when not installed by a authorized installer• Use of system beyond its rated capacity

19

Appendix ASwageless Termination Instructions

A.1 Safety

DBI/SALA requires certified installers be trained by a DBI/SALA Horizontal Lifeline Representative or anycertified personnel, as defined by DBI/SALA, before they are allowed to perform the installation of the SayfglidaHorizontal Lifeline. The installer must read (or have explained), understand and heed all instructions, labels andwarnings supplied with this product and products associated with it.FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH

WARNING: Some installation and service procedures contained in these instructions can be hazardous and mayresult in personal injury.

A separate means of fall protection must be utilized during the installation of a Sayfglida System. A separatemeans of fall protection must be used when inspecting or servicing a Sayfglida System following a fall. Theinstaller’s lanyard must not exceed the maximum allowable length determined for the application.

DBI/SALA recommends the use of certified eye protection, steel toe boots and gloves be worn during theinstallation of the horizontal lifeline system.

WARNING: Use of parts, tools or procedures not specified or supplied by DBI/SALA in installing and servicing thissystem may be dangerous and could result in serious or fatal injury to the user(s). Only DBI/SALA Sayfglidacomponents may be used in the installation and repair of Sayfglida Systems.

A.2 Measure the cable and mark the position of the terminator.

Step 1. Lengthen the turnbuckle by unscrewing it until only four threads are visible inside the body. This willallow for the maximum tensioning adjustment after the terminator is secured.

Step 2. Pin the strap to the turnbuckle, then pin both to the anchor structure.

Step 3. Thread the cable through the strap and pull the free end of the cable until the excess sag is removed.

Strap

Handle

Terminator

Plunger(Inside Terminator)

Spanner Wrench

Set Screws

Figure 19 - Swageless Terminator

20

Step 4. While maintaining tension on the cable, measure 1.5 inches from the outside of the strap and mark thecable. See Figure 20.

Step 5. Remove the strap from the turnbuckle and move the strap up the cable, past the mark made in step 4.

Caution: Before proceeding with the final securing of the termination of the system, inspect each intermediate bracketand end anchor to ensure each component has been installed in the correct orientation.

A.3 Secure the terminator onto the cable.

Step 1. Prepare the terminator to slide onto the cable byunscrewing (counterclockwise) the plunger by hand until theplunger stops at the deformed thread.

Step 2. Screw the handle into the largest threaded hole on the sideof the terminator.

Step 3. Slide the terminator onto the free end of the cable, smallend first. See Figure 3. Slide the small end of the terminatorup to the mark on the cable.

Step 4. Fit the spanner wrench over the cable and into the holes inthe plunger inside of the terminator. See Figure 4. Turningthe wrench clockwise, tighten the plunger to clamp thecable. The cable is properly clamped when firm resistanceis felt while rotating the wrench and the cable cannot bepulled through the terminator. Complete the connection byturning the wrench an additional 1/4 turn clockwise.

Step 5. Insert two set screws into the small threaded holes in theside of the terminator and tighten using a 5/64 in. hex key.

Step 6. Remove the wrench and handle from the terminator.

Step 7. Cut the free end of the cable 1.5 in. to 2.0 in. from the largeend of the terminator. See Figure 5.

Step 8. Slide the strap up the cable to the terminator and feed thesmall end of the terminator into the hole in the flat of thestrap. See Figure 6.

Step 9. Attach the strap to the turnbuckle.

NOTE: Tensioning the system may require several people to perform theoperation correctly. Longer systems will require more assistance. Begintensioning the system by rotating the turnbuckle body of the tensioningunit. If two tensioners are used, the adjustment should be divided equallybetween the two.

StrapPin Turnbuckle Pin

End AnchorCable

Maintain tensionon the cable

Mark the cable1.5 in. from strap

Orient the terminator so that the smallend goes onto the cable first.

Plunger

To tighten

Cut cable 1.5 to 2.0 inches fromthe large end of the terminator.

Figure 22 - Using the spanner wrench

Figure 21 - Slide terminator onto cable

Figure 24 - Strap and terminator

Figure 23 - Trim the cable

Figure 20 - Marking the cable

21

The amount of sag in a horizontal cable can be used as means of determining if the desired pretension level hasbeen achieved. See Table 1 on page 16.

22

Appendix BSwager Assembly

B.1 Die AssemblyPlace the 10 mm dies on the gears of theswage machine body. See Figure 26.

It is important that the 10mm dies are placedcorrectly on the gear pins on the main swagerbody. Locate the stamped arrow on eachswager die, these arrows show the correctrotation of the dies during a swaging operation.

The swager die will be assembled correctly ifthe arrow on the die and the rounded leadingedge of the die are facing the back of themachine.

WARNING: Be certain the dies are correctly set the gear pins on the main body of the swager. If the dies are notlevel with the machine the swage will not be crimped correctly and the dies make crack under pressure. Never usedamaged dies when completing a swage.

Stamped ArrowsGear Pins

Hand Pump

Draw Bar

10 MM Dies

Hydralic Cylinder

Swage Machine Body

Urethane Support Padand Cap Screws

Draw Bar Guide

Hex Allen Wrench

Figure 25 - Swaging Machine

Figure 26 - Die assembly

Right-hand and Left-handSwage Tube Adapters

Clevis Adapter

Adapter Bolt

Terminator Tube Adapterand Adapter Bolt

23

B.2 Hydraulic Cylinder AssemblyNext, assemble the hydraulic cylinder to the swage machine body. Locatethe two 1/4 in. cap screws and the urethane support pad. Place the twocap screws through the urethane support pad, and slide the screwsthrough the two mounting holes in the rear of the swage machine body.See Figure 27. Thread the cap screws into the threaded holes in thehydraulic cylinder. Tighten the screws using the hex wrench and draw thehydraulic cylinder tight against the swage machine body.

WARNING: The cap screws should be tight against the support pad and the cylinder should be tight against theswage machine body. The hydraulic cylinder and screws could be damaged if a swage operation is attempted withoutproperly tightening the screws to the cylinder and swage machine body.

B.3 Draw Bar AssemblyAttach the draw bar by removing thestop at the end of the cylinder ram, slidethe draw bar end assembly onto thecylinder ram and replace the end stop.See Figure 28. Both bars of theassembly should be located on eitherside of the urethane support padinstalled earlier. The draw bar shouldslide across the nylon pad without anyresistance.

WARNING: Do not use the draw bar assembly if bent or damaged, this could cause the swage to be crimpedincorrectly.

B.4 Final AssemblyThe final assembly will require theattachment of the hydraulic pumpavailable, hand pump or electric. SeeFigure 29. Place the free end of thehydraulic hose into the receptacle on thehydraulic cylinder and firmly tighten thecoupling nut.

B.5 Warnings and Safety PrecautionsDBI/SALA recommends the use of certifiedeye protection, steel toe boots and glovesbe worn during the operation of the swagemachine. The assembled swage machineis heavy and should not be manually handled by a single individual. Personal injury could occur if the machine ishandled incorrectly.

Figure 27 - Hydraulic cylinder

End Stop Draw Bar

Cylinder Ram

Figure 28 - Draw bar assembly

Figure 29 - Completed swaging machine assembly

24

Appendix CSwaging Operation

Note: It may be necessary to detach one or more intermediate brackets from their anchors to allow the free endof the cable to reach the swage machine. Do not remove the brackets from the cable. After swaging reinstall thebrackets.

C.1 Swage Tube AdaptersThere are four types of swage tube adapters:1. One adapter is designed for use with the toggle tensioner unit (part no. 7209212).2. One adapter is designed for the toggle swage unit (part no. 7209239). The toggle slides into the adapter and isheld in place with the clevis pin.3. One adapter is designed for right-hand swage tubes which are found in mid-entry/exit units, right-hand entryunits, and in-line swage units. The swage tube has an “R” stamped in the machined flat near the threaded end ofthe tube.4. One adapter is designed for left-hand swage tubes which are found in mid-entry/exit units, left-hand entryunits, and in-line swage units. The swage tube has an “L” stamped in the machined flat near the threaded end ofthe tube.

C.2 Connect the Swage Tube to the Drawing BlockAfter the correct adapter has been attached to theswage tube, slide the adapter past the dies andinto the drawbar from the front of the swagemachine. Use the appropriate adapter bolt toconnect the swage adapter to the drawing blockon the swage machine. See Figure 30.

Remove any tape or debris from the cable thatwill be inserted into the swage tube.Remove dirt from the cable using a fiber brush.Do not use a wire brush and do not apply anysolvents or lubricants without prior approval fromDBI/SALA. Clean all other Sayfglida componentsusing a nonabrasive cloth and hot water/milddetergent mix. Dry with a clean cloth. Do not usesolvents to clean any Sayfglida Component.

C.3 Swage the Cable Into the Swage TubeMark the cable 6 inches from the end to be swaged. Insert the end of the cable into the swage tube. The 6-inchmark should be just visible at the bore opening of the swage tube.

WARNING: The cable must be inserted the full 6inches into the swage tube. If the cable cannot beinserted the full 6 inches, any obstructions must beremoved or the swage tube must be rejected.

Use the large hex wrench to rotate the roller diesuntil they contact the swage tube. See Figure 31.

Adjust the length of the draw bar by adjusting theknurled wheel until the radial faces of the dies arepositioned at the two machined flats on the swagetube. Close the relief valve thumb wheel andbegin the swage by operating the hydraulic handpump.

Apply pressure to the hex wrench in the directionof the die rotation until the dies have a secure gripon the swage tube.

Hex Wrench

10 mm dies

Swage Tube

Adapter Bolt

Drawing Block

Figure 30 - Attaching a swage tube

Figure 31 - Aligning the dies

Adapter

25

During the swage operation, hold the cable securely in the swage tube to ensure the dies are swaging the fittingonto the cable rather than pushing the cable out of the swage tube. The cable should be held in place until theswage is at least half its finished length.

Continue the swage until the swage tube has fully passed through the dies. Open the relief valve thumb wheelon the hand pump.

WARNING: Measure the swaged diameter. The measurement must be taken off the compressed faces of the swage,not the two raised edges. The diameter must be between .600 and .626 inches. If completed swages are consistentlyout of range contact DBI/SALA immediately for swager re-calibration.

Remove the swage tube from the swage machine by unscrewing adapter bolt.

C.4 Reassemble the Swage Tube UnitAfter swaging, reassemble the termination or entry/exit unit. Ensure the swage tube and components are fullythreaded onto the unit and the two roll pins are in place. This will prevent the termination from unthreading. Ifholes are not in line to allow the installation of the roll pins, unthread the parts and apply Loctite 242 (SemiPermanent Type) to the threads to prevent the unit from unthreading.

WARNING: Do not install any component with damaged threads. Contact DBI/SALA for replacement parts, ifdamaged threads are discovered.

26

D.3 In-line Swage (Part No. 7209222)Material:316 Stainless Steel swage tubes431 Stainless Steel in-line swage bodyStainless Steel roll pinsWeight: 2.0 lbs.Breaking Strength:14,000 lbs.Swage Strength exceeds breaking strength of cable

Appendix DParts and Components

D.1 Cable (Part No. 7202372)Material – 316 Stainless SteelConstruction:12mm (0.472”) diameter7 strands x 7 wires constructionRight Hand Ordinary LayWeight: 0.366 lbs. / ft.Breaking Strength 18,600 lbs.

D.2 Intermediate Bracket (Part No. 7209205)Material:316 Stainless Steel Bracket Body316 Stainless Steel WasherNylon 6/6 Isolation Washer316 Stainless Steel Locknut w/ Nylon InsertBreaking strength:Greater than 6,800 lbs.

27

D.4 In-line Entry/Exit (Part No. 7209219)Material:316 Stainless Steel swage tubes431 Stainless Steel in-line swage bodyStainless Steel roll pinsWeight: 2.0 lbs.Breaking Strength:14,000 lbs.Swage Strength exceeds breaking strength of cable

D.5 Entry/Exit Units (Part No. 7209278 Right HandPart No. 7209279 Left Hand)

Material:316 Stainless Steel toggle assemble316 Stainless Steel swage tube431 Stainless Steel entry/exit bodyStainless Steel roll pinsWeight: 2.4 lbs.Breaking strength:16,000 lbs.Swage strength exceeds breaking strength of cable

28

D.6 Toggle Swage Termination (Part No. 7209239)Material:316 Stainless Steel toggle assembly316 Stainless Steel swage tubeWeight: 1.5 lbs.Breaking Strength:23,000 lbs.Swage strength exceeds breaking strength of cable.

D.7 Tensioner Toggle – Toggle (Part No. 7209213)Material:316 Stainless Steel toggle assembliesForged silicon bronze turnbuckle body, chrome platedWeight: 3.4 lbs.Breaking Strength:23,000 lbs.

29

D.8 Tensioner Toggle – Swage (Part No. 7209212)Material:316 Stainless Steel toggle assembliesForged silicon bronze turnbuckle body, chrome platedWeight: 2.9 lbs.Breaking Strength:23,000 lbs.Swage Strength exceeds breaking strength of cable

D.9 Standard Sayflink Sleeve (Part No. 7209237)Material:17-4 PH Stainless Steel body component17-4 PH Stainless Steel hinge pinStainless Steel SwivelZinc plated steel delta link and locking tabWeight: 1.0 lbs.Breaking Strength5,000 lbs.Notes: User must attach and detach from lifelineonly at entry/exit unit

30

D.10 Rolling Sleeve Sayflink Sleeve (Part No. 7210189)Material:17-4 PH Stainless Steel body component17-4 PH Stainless Steel hinge pinStainless Steel Swivel with roll pinsNylon rollersZinc plated steel delta link and locking tabWeight: 1.1 lbs.Breaking Strength5,000 lbs.Notes: User must attach and detach from lifelineonly at entry/exit unit

D.11 Detachable Sayflink Sleeve (Part No. 7209284)Material:17-4 PH Stainless Steel body components.17-4 PH Stainless Steel locking pins and hinge pin.Stainless Steel Swivel with springs.Zinc plated steel delta link and locking tab.Weight: 1.3 lbs.Breaking Strength5,000 lbs.Notes: Allows user to attach and detach at any pointalong the lifeline.

31

D.12 Detachable Rolling Sayflink Sleeve(Part No. 7204902)Material:17-4 PH Stainless Steel body components.17-4 PH Stainless Steel locking pins and hinge pin.Stainless Steel Swivel with springs.Nylon RollersZinc plated steel delta link and locking tab.Weight: 1.3 lbs.Breaking Strength5,000 lbs.Notes: Allows user to attach and detach at anypoint along the lifeline.

D.13 90° Reinforced Corner Unit (Part No. 7211897)Material:316 Stainless Steel bracket.316 Stainless Steel tubes316 Stainless Steel washer.Nylon 5/6 isolation washer316 Stainless Steel lock nut with nylon insert.Zinc plated steel backer plate.

32

D.14 135° Reinforced Corner Unit (Part No. 7200002)Material:316 Stainless Steel bracket.316 Stainless Steel tubes316 Stainless Steel washer.Nylon 5/6 isolation washer316 Stainless Steel lock nut with nylon insert.Zinc plated steel backer plate.

D.15 135° Oxbow Corner Unit (Part No. 7209217)Material:316 Stainless Steel bracket.316 Stainless Steel tubes316 Stainless Steel washer.Nylon 5/6 isolation washer316 Stainless Steel lock nut with nylon insert.

33

D.16 90° Oxbow Corner Unit (Part No. 7209218)Material:316 Stainless Steel bracket.316 Stainless Steel tubes316 Stainless Steel washer.Nylon 5/6 isolation washer316 Stainless Steel lock nut with nylon insert.

D.17 90° Oxbow Corner Unit (Part No. 7209218)Material:316 Stainless Steel bracket.316 Stainless Steel tubes316 Stainless Steel support arms.316 Stainless Steel washer.Nylon 5/6 isolation washer316 Stainless Steel lock nut with nylon insert.

D.18 90° Internal Corner Unit (Part No. 7209220)Material:316 Stainless Steel bracket.316 Stainless Steel tubes.316 Stainless Steel support arms.316 Stainless Steel washer.Nylon 5/6 isolation washer.316 Stainless Steel lock nut with nylon insert.

D.19 Tensioner Link (Part No. 7210451)Material:UNS S30400 Stainless Steel Bar

D.20 End Anchor - Weld On (Part No. 7210451)Material:ASTM A36 Carbon Steel Angle

Breaking Strength: Greater than 20,000 Lbs.

D.21 End Anchor - Bolt On (Part No. 7209251)Material:ASTM A36 Carbon Steel Angle

Breaking Strength: Greater than 20,000 Lbs.316 Stainless Steel washer.316 Stainless Steel lock nut with nylon insert.

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USA Canada3965 Pepin Avenue 260 Export BoulevardRed Wing, MN 55066-1837 Mississauga, Ontario L5S 1Y9Toll Free: 800-328-6146 Toll Free: 800-387-7484Phone: (651) 388-8282 Phone: (905) 795-9333Fax: (651) 388-5065 Fax: (905) 795-8777www.salagroup.com

I S O9 0 0 1

Certificate No. FM 39709

Form: 5902165Rev: A