WARNING: This product is part of a personal fall arrest system. The user

or rescuer must read and follow the manufacturer’s instructions for each component or part of the complete system. These instructions must be provided to the user/rescuer utilizing this equipment. The user/rescuer must read and understand these instructions or have them explained to them before using this equipment. Manufacturer’s instructions must be followed for proper use and maintenance of this product. Alterations or misuse of this product or failure to follow instructions may result in serious injury or death. If this product is resold outside the original country of destination, the re-seller must provide these instructions in the language of the country in which the product will be used.

IMPORTANT: If you have questions on the use, care, or suitability of this equipment for your application, contact Capital Safety.

IMPORTANT: Before using this equipment, record the product identifi cation information from the ID Label in the “Inspection and Maintenance Log” at the back of this manual

Figure 1 - FlexiGuard Boxed-Frame Rail Fall Arrest System

NOTE: This fi gure illustrates a Four-Leg Boxed-Frame System. Boxed-Frame Systems are custom designed to customer requirements and will vary with the intended application.

DESCRIPTION

BOXED-FRAME RAIL FALL ARREST SYSTEM: The four and/or six leg Boxed-Frame System is a frame supported trolley rail assembly for overhead anchorage of Capital Safety fall arrest or fall arrest restraint equipment. Wheeled trolleys travel along rail assemblies and serve as moving anchorage points for Self-Retracting Lifelines (SRLs) and Lanyards. The rail assemblies are supported in an overhead position by an overhead super structure. Swiveling wheel assemblies and top-wind jacks provide portability and secure positioning.

IMPORTANT: The Boxed-Frame Rail Fall Arrest System shall only be used as supporting structure for Personal Fall Protection Equipment. It shall not be used as supporting structure for lifting equipment.

GLIDE RAIL: The Glide Rail System (Figure 2) is the main component of the frame system. It is a rail and trolley system for horizontal anchorage of Capital Safety personal fall arrest or fall restraint equipment. Wheeled Trolleys travel along a Rail Assembly and serve as moving anchorage points for Self Retracting Lifeline (SRLs) or Lanyards. Rail sections are supported from the overhead structure by Mounting Brackets comprised of various combinations of Beam Clamps, Connector Channels, and Extensions.

© Copyright 2014, Capital SafetyForm: 5903123 Rev: D

USER INSTRUCTION MANUALBOXED-FRAME RAIL FALL ARREST SYSTEM

This manual is intended to meet industry standards, including OSHA and ANSI Z359.1-2007, and should be used as part of an employee training program as required by OSHA.

The Ultimate in Fall Protection

Boxed Frame RailFall Arrest System

Model Numbers: 8530245, 8530345, 8530491, 8546050, 8560588

CEN/TS 16415:2013

CE Type Test

No. 0086BSI Product Services

Kitemark CourtDavy Avenue

Knowlhill, Milton KeynesMK5 8PP, UK

CE Production Quality Control

No. 0086BSI Product Services

Kitemark CourtDavy Avenue

Knowlhill, Milton KeynesMK5 8PP, UK

2

Figure 2 - Glide Evolution Rail System

A

D

CB

E A Rail Assembly

B SRL Trolley

C Lanyard Trolley (Purchased Seperately)

D Self Retracting Lifeline (Purchased Seperately)

E Lanyard (Purchased Seperately)

Figure 3 - Typical System Layout Design

L

W

≥30° or 6 ft.

L Length of safe walking area

W Width of safe working area

≥30° or 6 ft.

3

SYSTEM DESIGN

HEAT: The frame system is not designed for use in high temperature environments (greater than 130° F, 54° C). Protection of the system must be provided if exposure to welding, metal cutting, or similar activities are expected.

CORROSION: System components may be damaged by exposure to environments where caustic vapors or chemicals are present. Do not install the frame system where rapid corrosion due to chemical attack could occur. Caution must be used to assure that small parts such as fasteners are not subjected to rapid galvanic corrosion due to contact with similar metals.

ELECTRICAL HAZARDS: Due to the possibility of electrical current fl owing through the rail or the user equipment, use extreme caution when locating the system relative to electrical hazards.

MOVING EQUIPMENT: It is recommended to put the unit in the lowered position before moving. Hazards associated with frame system installations near moving machinery (e.g. conveyors, rotating shafts, rotating gears, etc.) must be addressed either by the frame system design (such as using restraint equipment to prevent contact with moving equipment) or other controls agreed to by the site management.

SHARP EDGES AND ABRASIVE SURFACES: Avoid installing the frame system where fall protection equipment may contact sharp edges or abrasive surfaces that may damage it. If working around sharp edges is unavoidable, provide protection by securing a heavy pad over the exposed edge or use other administrative controls.

WHEEL OPTIONS: The following wheels are available for Boxed-Frame Rail Fall Arrest System applications requiring additional mobility.

Wheel Options for Boxed-Frame Rail Fall Arrest Systems that Require Wheels

8” Solid Urethane 12” Solid Rubber 16” Pneumatic 18” Dual Pneumatic

GLIDE RAIL TROLLEYS: Table 1 presents the available Trolley options and defi nes criteria for selecting the appropriate Trollies for your frame system and Glide 360 rail.

IMPORTANT: After the Glide Rail has been fully installed, reinspect all components for damage, correct orientation, and proper torque on all nuts and bolts. Attach the intended fall arrest equipment (SRLs, Lanyards, etc.) to each Trolley and walk the Trolley the entire length of the Track Assembly to ensure the Trolley Wheels travel smoothly in the Track.

PERSONAL FALL ARREST SYSTEMS: This product is approved for use with retractable devices and energy absorbing lanyards with a maximum arresting force (M.A.F.) rating of 900 lbs. (4 kN) or less. Retractable devices and lanyards must be installed, maintained, and used according to the manufacturer’s instructions.

HYDRAULIC SYSTEM CONFORMANCE: Some Boxed-Frame Rail Fall Arrest Systems are equipped with hydraulics for raising and lowering the frame. Equipment comprising the Hydraulic System is compliant with the following directives:

• Directive 2004/108/EC - Electromagnetic Compatibility (EMC)• Directive 2006/95/EC - Low Voltage (LVD)

INSTALLATION DOCUMENTATION: After installation of the Boxed-Frame Rail Fall Arrest System, “Installation Documentation” meeting the informational requirements of EN 795:2012 Annex A must be completed by the installer and handed over to the user’s designated representative. The Installation Documentation should be kept at the job site for purposes of subsequent examination of the Boxed-Frame Rail Fall Arrest System.

4

Table 1 - Trolleys

Four-Wheeled, Small-Eyed SRL Trolleys

Connection point for SRLs attached with an approved Double-Locking Carabiner. Small eye minimizes loss of overhead clearance, keeping the worker’s attachment point as high as possible relative to their dorsal D-Ring. Model Numbers and dimensions are as follows:

Part W L

8521711 2.38” (60.45 mm) 6.50” (165.10 mm)

8522028 1 2.77” (70.36 mm) 6.50” (165.10 mm)

1 Wider wheel-based Trolley for use with “Super Extrusion” Rail Assemblies.

Four-Wheeled, Large-Eyed Lanyard Trolleys

Connection point for Double-Locking Snap Hooks used on various types of Lanyards. Model Numbers and dimensions are as follows:

Part W L

8521713 2.38” (60.45 mm) 6.50” (165.10 mm)

8525169 1 2.77” (70.36 mm) 6.50” (165.10 mm)

1 Wider wheel-based Trolley for use with “Super Extrusion” Rail Assemblies.

5

APPLICATIONS

Purpose: Personal Protective Equipment Against Falls From Height

The frame system combines easy access to elevated work areas with fall protection from the ground for the duration of the work performed. The system included is a horizontal rail assembly with up to four trolleys that ride in track rails to any position along the rail assembly. The trolleys serve as attachment points for the anchorage of a Personal Fall Arrest System (PFAS). If your system is mobile, it can be moved by hand (if small enough), forklift, or towed by a maintenance vehicle when equipped with proper accessories.

Limitations: The following limitations must be considered before using this product. Failure to observe product limitations could result in serious injury or death.

A. ASSEMBLY: The rail system must be assembled in accordance with the requirements stated in this instruction and any instruction provided by the manufacturer.

B. PERSONAL FALL ARREST SYSTEMS: PFAS used with the frame system must meet applicable state and federal regulations.

C. CAPACITY: The maximum capacity for the product is one or more people, each with a combined weight (person, clothing, tools, etc.) of 310 lbs. Use of various accessories may reduce the number of workers that may be anchored.

D. PHYSICAL AND ENVIRONMENTAL HAZARDS: Use of this equipment in areas with physical or environmental hazards may require additional precautions to be taken in order to reduce the possibility of damage to this equipment or injury to the user. Hazards may include, but are not limited to: high heat (welding or metal cutting), acid or caustic chemicals, corrosive environments such as exposure to seawater, high voltage power lines, explosive or toxic gases, moving machinery, or sharp edges. Contact Capital Safety if you have questions about the application of this equipment in areas where physical or environmental hazards are present.

E. TRAINING: This equipment must be installed and used by persons who have been properly trained in its correct application and use. Installation and use of this equipment must be supervised by a qualified person, as defined by OSHA fall protection standards.

STANDARDS: Refer to national standards, local, state, and OSHA requirements for more information on the application of this and associated equipment.

APPLICATION RESTRICTIONS:

IMPORTANT: Consult system labeling and specifi cations for user capacities.

• Depending on the equipment, a maximum of up to four (4) persons may be tied off to the frame at any one time. Review all labels for specifi c capacities. The combined weight of various Personal Fall Arrest Systems (PFAS), work tools, and accessories may restrict the use of the frame system to a single individual. Consult product specifi cation sheets for all components of any system, and be aware of any restrictions before using the equipment.

• Retractable devices and shock absorbers must have a maximum arrest force (M.A.F.) rating of 900 lbs. (4 kN) or less, and must be installed and used in accordance with the manufacturer’s instructions.

SYSTEM REQUIREMENTS

COMPATIBILITY OF COMPONENTS: Capital Safety equipment is designed for use with Capital Safety approved components and subsystems only. Substitutions or replacements made with non-approved components or subsystems may jeopardize compatibility of equipment and may affect the safety and reliability of the complete system.

COMPATIBILITY OF CONNECTORS: Connectors are considered to be compatible with connecting elements when they have been designed to work together in such a way that their size and shapes do not cause their gate mechanisms to inadvertently open regardless of how they become oriented. Contact Capital Safety if you have any questions about compatibility. Connectors (hooks, carabiners, and D-rings) must be capable of supporting at least 5,000 lbs (22 kN). Connectors must be compatible with the anchorage or other system components.

Do not use equipment that is not compatible. Non-compatible connectors may unintentionally disengage (see Figure 4). Connectors must be compatible in size, shape, and strength. Self-locking snap hooks and carabiners are required by OSHA and ANSI Z359.1.

6

CONNECTIONS: Only use self-locking snap hooks and carabiners with this equipment. Only use connectors that are suitable to each application. Ensure all connections are compatible in size, shape, and strength. Do not use equipment that is not compatible. Ensure all connectors are fully closed and locked.

Capital Safety connectors (snap hooks and carabiners) are designed to be used only as specifi ed in each product’s user instructions. See Figure 5 for inappropriate connections. Capital Safety snap hooks and carabiners should not be connected to:

A. To a D-ring which another connector is attached

B. In a manner that would result in a load on the gate

NOTE: Large throat snap hooks should not be connected to standard size D-rings or similar objects which will result in a load on the gate if the hook or D-ring twists or rotates. Large throat snap hooks are designed for use on fi xed structural elements such as rebar or cross members that are not shaped in a way that can capture the gate of the hook.

Figure 4 - Unintentional Disengagement (Rollout)

If the connecting element to which a snap hook (shown) or carabiner attaches is undersized or irregular in shape, a situation could occur where the connecting element applies a force to the gate of the snap hook or carabiner. This force may cause the gate (of either a self-locking or a non-locking snap hook) to open, allowing the snap hook or carabiner to disengage from the connecting point.

Small ring or other non-compatible shaped element

1.) Force is applied to the snap hook.

2.) The gate presses against the connecting ring.

3.) The gate opens allowing the snap hook to slip off

C. In a false engagement, where features that protrude from the snap hook or carabiner catch on the anchor, and without visual confirmation seems to be fully engaged to the anchor point.

D. To each other.

E. Directly to webbing or rope lanyard or tieback (unless the manufacturer’s instructions for both the lanyard and connector specifically allows such a connection).

F. To any object which is shaped or dimensioned such that the snap hook or carabiner will not close and lock, or that roll-out could occur.

G. In a manner that does not allow the connector to align properly under load.

ASSEMBLY

When assembling a Frame System, refer to this instruction and any instructions supplied by the manufacturer.

Figure 5 - Inappropriate Connections

7

LOWERING AND RAISING A MANUAL ADJUSTABLE FRAME SYSTEM

NOTE: This section only applies to Frame Systems that are manually adjusted. If your system is hydraulically adjustable, move to the section titled Positioning and Stabilizing the Frame System. If your system is not adjustable, disregard this section and move to the section titled Positioning and Stabilizing the Frame System.

IMPORTANT: On each leg of the frame system there is an angle that allows a cross-over connection bar to be installed. This bar allows the user to raise and lower the unit with a small forklift in a safe position.

Step 1: Position the cross-over connection bar across two legs of the frame system that are on the same end and secure with the provided fasteners.

Step 2: Support the cross-over connection with a forklift rated lifting the weight of the frame system.

Step 3: Using the wheel jacks, raise or lower the system until the pins are loose enough to remove.

Step 4: Remove the pins holding the inner tube through the outer tube of the leg and slowly raise one end of the frame with the forklift. Once the desired height is achieved, replace the pins through both tubes.

Figure 6 - Lift Using the Cross-Over Connection Bar

Lift where cross-over connection bars are located.

Figure 7 - Setting the Frame System to the Desired Height.

Install both leg bolts to maintain height

8

Step 5: Repeat steps 1 and 4 for the two remaining legs on the other side and install the pins to hold position.

Figure 8 - Finished Setting Desired Height

Count the exposed holes in the tubes to ensure the same number are showing on all legs.

9

POSITIONING AND STABILIZING THE FRAME SYSTEM

NOTE: Once the unit is raised and all legs are secured with the provided hardware, the unit can be positioned to the required fall-protection area. It is recommended that the unit be moved in the lowered position.

IMPORTANT: Be sure to have someone spot the unit while moving the system near overhead power lines, electrical outlets, or any other dangerous overhead objects.

Step 1: To move the unit, crank on the leg jack assemblies until the wheel caster is on the ground and the stabilizer pad is up and off the ground.

Figure 9 - Lowering and Raising the Adjustable Frame System

Wheel Crank Jack

Swivel Lockable Caster

Stabilizer Pad

Wheel Crank Jack Designed to lower and raise the wheel assembly

Swivel Lockable Caster Assembly

Pull out and rotate 90 degrees to allow the wheel to caster 360 degrees

Stabilizer Pad Designed to be on the ground when the unit is use for fall-arrest

IMPORTANT: This unit is not intended for use on un-level ground. Be sure the area where the Frame System will be used is level.

Step 2: After the frame system is in position on a level surface, raise the Swivel Lockable Caster up so the Stabilizer is fi rmly planted on the ground.

NOTE: Use a level to verify that the system is level.

10

LOWERING AND RAISING A HYDRAULIC ADJUSTABLE FRAME SYSTEM

NOTE: This section only applies to Frame Systems that are hydraulically adjusted. If your system is not hydraulically adjustable and has been properly set up, disregard this section and move to the section titled Operation and Use.

Figure 10 - Hydraulic Adjustable Frame System - Round Leg

Raising - Lock Lever Engaged

Locking Pin

LockLever

Lowering - Lock Lever Disengaged

Locking Pin

LockLever

Figure 11 - Hydraulic Adustable Frame System - Square Leg

Raising - Lock Lever Engaged

Lock Tension Spring

Lock Lever

LockingRope

Lowering - Lock Lever Disengaged

RAISING THE HYDRAULIC FRAME SYSTEM:

Step 1: Verify the frame system is on level ground.

Step 2: Crank the wheels until they are completely off the ground and verify the frame system is fi rmly resting on the support pads.

Step 3: Unwrap the hydraulic hoses and connect them to the power unit. Verify the hose connections are secure and properly connected.

IMPORTANT: The hydraulic hoses and power unit must be inspected before each use. Verify the hydraulic hoses are not leaking, cracked, kinked, or contain any other defect that could cause them to fail. Inspect the hydraulic fi ttings to ensure they are not leaking and working properly. Inspect the power unit according to the supplied manufacturer’s instructions.

11

Step 4: On the frame system, release the four (4) lock levers so they are in the “Engageg Position”.

Step 5: Plug in the power unit’s electrical cord.

IMPORTANT: Be sure to have someone spot the frame system while raising the system near overhead power lines, electrical outlets, or any other dangerous overhead objects.

Step 6: Press the I/START button on the power unit.

Step 7: After the power unit starts, move the lever and raise the frame system to the desired height.

NOTE: While the frame system is raising, the lock levers will make a ‘clicking’ sound as they engage the lock notch.

Step 8: After the frame system has reached the desired height, verify the lock levers are seated into a locking notch. If the lock levers are not engaged in a locking notch, raise or lower the unit until they are seated in the lock notches.

IMPORTANT: Do not disconnect the hydraulic lines from the power unit until after reading and understanding Disconnecting the Power Unit section.

DISCONNECTING THE POWER UNIT

IMPORTANT: Failure to properly disconnect the hydraulic lines from the power unit can cause the system to pressure lock. If pressure lock occurs, move the control lever back-and-forth until the pressure gauge reads zero (0).

Step 1: Power off the power unit.

Step 2: Move the hydraulic control level back-and-forth until the hydraulic pressure gauge reads zero (0).

Step 3: Disconnect the hydraulic lines from the power unit.

NOTE: After the lock levers are engaged in the lock notches, the hoses can be disconnected from the power unit and the power unit can be stored in the recommended environment.

LOWERING THE HYDRAULIC FRAME SYSTEM

IMPORTANT: If the hydraulic hoses were disconnected from the power unit, attach them according to steps 3, 5, 6, 7, and 8 in the previous section.

Step 1: With the power unit turned on and properly hooked up to the frame system, raise the frame system until the lock levers are disengaged from the lock notches.

Step 2: After the lock levers are disengaged from the lock notches, secure them in the disengaged position (see Figures 10 & 11).

Step 3: After the lock levers have been secured in the disengaged position, move the lever in the lowering position until the frame system reaches the desired height.

Step 4: After the frame system has reached the desired height, engage the lock levers. If the system is not completely lowered, continue lowering the system until the lock levers are seated into a locking notch. If the lock levers are not engaged in a locking notch, raise or lower the unit until they are seated in the lock notches.

NOTE: After the lock levers are engaged in the lock notches, the hoses can be disconnected and the power unit can be stored in the recommended environment.

12

TOWING THE SYSTEM

Towing kits are an optional accessory for a box frame system. If your system was not supplied with this accessory please skip to the next section.

Towing kits come in two basic styles: tow bar style (Figure 12) and fork pocket style (Figure 13).

Tow bar style is intended for pintle or ball style hitches. This style towing kit includes a tow bar that pivots in one direction and can be be towed by many different types of vehicles.

Fork pocket style is intended to be chained or strapped to the forks of a forklift. It rotates horizontally and is great for both push and pull applications.

Figure 12 - Towing Kit Installation and Use - Tow Bar Style

STEP 1: If not yet installed, install the clamp assemblies onto all for legs. make sure all clamps are oriented with the detent pins facing outward.

STEP 2: Remove the detent pins from the clamp assemblies. Attach the tow bar hich reciever tube to the leg clamp assemblies on the desired side of the system.

STEP 3: Re-insert the detent pins to secure the hitch reciever tube into position.

STEP 4: Insert the tow bar assembly into the hitch receiver pocket and secure using the supplied hitch pin.

STEP 5: Attach the leg connector tubes between the front and rear clamp assemblies on both sides of the unit. Secure using detent pins.

STEP 6: The system is now ready for towing. See the warnings above.

WARNING: Do not tow this system at speeds greater than 5 mph (8 kph). Do not tow adjustable systems in any position but fully lowered. All Cross leg support bars (if supplied) must be secured into position before the system can be towed. When transporting this system, be aware of overhead obstructions and power sources which may cause damage to the system and/or electrocution resulting in serious injury or death.

Step 1:

DetentPins

DetentPins

NOTE: Wheel hidden for clarity NOTE: Orient clamps as shown with detent pins facing outward.

Steps 2, 3 & 4:

Pin

Pin

HitchReceiverTube

HitchPin

Tow BarAssembly

Step 5:

DetentPins

Leg Connector Tube

Front ClampAssembly

Rear ClampAssembly

13

Figure 13 - Towing Kit Installation and Use - Fork Pocket Style

STEP 1: Using a crane or forklift set the fork pocket tube assembly into position on the desired side of the system. Secure using the supplied pin and clevis assemblies.

STEP 2: Set the remaining leg connecting tubes into postion and secure them using the supplied pin and clevis assemblies.

STEP 3: Insert both forks from the forklift that will be transporting the system all the way into the fork pockets.

STEP 4: Secure the forklift carriage to the fork pocket hooks using ratchet straps or chain.

STEP 5: The system is now ready to be towed. Caster rotation locks may need to be engaged on the two wheels opposite the side that is being towed to maintain optimal towing control.

NOTE: Ensure straps and chains are rated appropriately for the system that is to be towed.

WARNING: Do not tow this system at speeds greater than 5 mph (8 kph). Do not tow adjustable systems in any position but fully lowered. All Cross leg support bars (if supplied) must be secured into position before the system can be towed. When transporting this system, be aware of overhead obstructions and power sources which may cause damage to the system and/or electrocution resulting in serious injury or death.

Step 1:

Step 2:

ConnectingTubes

Steps 3 & 4:

Fork

Fork

ForkPocketHooks

ForkPockets

OPERATION AND USE

WARNING: Do not alter or intentionally misuse this equipment.

WARNING: Consult Capital Safety when using this equipment in combination with components or subsystems other than those described in this manual. Some subsystem and component combinations may interfere with the operation of this equipment. Use caution when using this equipment around moving machinery, electrical hazards, chemical hazards, and sharp edges.

WARNING: Working at height has inherent risks. Some risks are noted here but are not limited to the following: falling, suspension/prolonged suspension, striking objects, and unconsciousness. In the event of a fall arrest and/or subsequent rescue (emergency) situation, some personal medical conditions may affect your safety. Medical conditions identifi ed as risky for this type of activity include but are not limited to the following: heart disease, high blood pressure, vertigo, epilepsy, drug or alcohol dependence, psychiatric illness, impaired limb function, and balance issues. Capital Safety recommends that your employer/physician determine if you are fi t to handle normal and emergency use of this equipment.

14

Figure 14 - Safe Working Zone

Top ViewFront View

Safe Working ZoneSafe Working Zone

Safe Working Zone

6 ft.

6 ft. 6

ft.6 ft.

NOTE: Do not allow the lifeline to exceed a 30 degree working angle from the anchor point;

OR,

work outside of a 6 ft working radius from the anchor point, whichever comes fi rst.

BEFORE EACH USE: Inspect this equipment carefully to ensure it is in good working condition. Check for worn or damaged parts. Ensure all parts are present and secure. Check the entire system for damage and corrosion. Do not use if inspection reveals an unsafe condition.

PLANNING: Plan your system and how it will function before starting your work. Consider all factors that affect your safety during use. Some important points to consider when planning your system are:

A. HAZARD EVALUATION: Evaluate job site hazards prior to starting work. Consult applicable OSHA (or CE) and industry standards for guidelines and regulatory requirements on equipment such as personal fall arrest systems (PFAS).

B. WORK SITE GEOMETRY: The use of the frame system and attached PFAS must be consistent with the geometric requirements stated in the manufacturer’s instruction manual(s). Check for obstructions or sharp edges in the work path. Avoid working where the user may swing and hit an object, or where lines may cross or tangle with that of another worker.

C. FALL CLEARANCE: There must be sufficient clearance in your fall path to prevent striking an abject or lower level in the event of a fall. A minimum of 6 ft. (1.8 m) from the working level to the lower level or nearest obstruction is recommended but may vary with you application and attached PFAS. See the PFAS manufacturers’ instructions.

D. SWING FALLS: Swing Falls occur when the anchorage point is not directly overhead. The force of striking an object in a Swing Fall may cause serious injury or death. Minimize Swing Falls by maintaining a work position as directly below the anchorage point as possible. In planning your system, increased clearance is required with Self-Retracting Lifelines or other variable length subsystems to negate the possibility of Swing Falls.

E. SHARP EDGES: Avoid working where components of the Boxed-Frame Rail Fall Arrest System and attached subsystem(s) will contact with or abrade against unprotected sharp edges.

F. RESCUE: When using this equipment, the employer must have a rescue plan and the means at hand to implement it and communicate that plan to authorized persons, users, and rescuers.

G. AFTER A FALL: Any equipment which has been subjected to the forces of arresting a fall or exhibits damage consistent with the effect of fall arrest forces as described, must be removed from service immediately and destroyed by the user, the rescuer, or an authorized person.

REQUIREMENTS FOR PERSONAL FALL ARREST SYSTEMS (PFAS): PFAS used with the frame system must meet applicable OSHA requirements.

The PFAS should be rigged to minimize any potential free fall and never allow a free fall greater than six (6) ft. (1.8 m). The PFAS used with this equipment are required to include a full body harness as the body support component. PFAS that incorporate full body harnesses must maintain fall arrest forces below 1,800 lbs. (8.0 kN) and arrest the fall within 42 in. (1.1 m). Body belts, unless incorporated into a full body harness, are not allowed for use with this equipment. A typical PFAS includes a full body harness, connecting subsystem or component (self retracting lifeline or shock absorbing lanyard), and the necessary connectors to couple the system together.PFAS may only be attached to the Trolleys which move along the Rail Assembly.

15

WARNING: Read and follow the manufacturer’s instructions for the personal fall arrest equipment selected for use with the frame system.

IMPORTANT: Body belts are not allowed for free fall situations. Body belts increase the risk of injury during fall arrest in comparison to a full body harness. Limited suspension time and the potential for improperly wearing a body belt may result in added danger to the user’s health.

USING THE BOXED-FRAME RAIL FALL ARREST SYSTEM: General steps for using the frame system are as follows:

Step 1. Position the frame system around the desired work area/object: Push the unit into position so that the Rail Assembly is centered in the work area to maximize the effective safe work area and reduce the potential for a fall (see Figure 14). Wheels and Jacks must be positioned over a stable, level surface or leveled with blocks.

Step 2. Don a Full Body Harness: Don a Full Body Harness per the manufacturer’s instructions.

Step 3. Connect the SRL Lifeline to the Full Body Harness: Connect the Self Locking Snap Hook or Self Locking/Self Closing Carabiner on the end of the SRL Lifeline to the Front or Back D-Ring on the Full Body Harness. To ensure a safe connection, always follow the instructions provided in the SRL and Full Body Harness manufacturers’ instructions and observe the requirements in this manual regarding Compatibility of Connectors and Connections.

Step 4. When attached to the SRL: The worker is free to move about within recommended working areas at normal speeds. The Trolley should roll freely in the Rail Assembly. The Lifeline should extend smoothly and retract without hesitation. If slack line condition is created in normal use, the unit should be inspected and serviced by an authorized service center. Should a fall occur, the SRL will lock and arrest the fall. Upon rescue, remove the SRL from use. Inspect as described in manufacturer’s instructions. When working with the SRL, allow the lifeline to recoil back into the device under control. Allowing the lifeline to be fully extended for long periods of time may cause premature weakening of the retraction spring.

NOTE: A Tagline should be attached to the SRL’s Lifeline Hook so the Lifeline can be pulled down to a proper position for connection to the Full Body Harness.

IMPORTANT: A maximum of four (4) persons may be attached to the frame system; each using an individual Trolley and SRL. No more than one (1) person should be attached to a single Trolley at any time.

NOTE: The SRL line must not drag or bend over a leading edge while accessing the work area. To eliminate that problem reposition the unit. Follow the SRL manufacturer’s instructions carefully.

TRAINING

It is the responsibility of all users of this equipment to understand these instructions, and are trained in the correct installation, use, and maintenance of this equipment. These individuals must be aware of the consequences of improper installation of this equipment. Users must also be aware of the operating characteristics, application limits, and the consequences of improper use of this equipment. This user manual is not a substitute for a comprehensive training program. Training must be provided on a periodic basis to ensure profi ciency of the users.

IMPORTANT: Training must be conducted without exposing the trainee to a fall hazard. Training should be repeated on a periodic basis.

INSPECTION

IMPORTANT: After the frame system has been fully installed, perform a complete inspection. Make sure all supplied labels are present and legible. Inspect for loose bolts, cracks, corrosion, or any other type of abnormality. Inspect the Glide Rail and its components to ensure the trolleys roll smoothly along the entire span of the system. Check all nuts and bolts for proper torque and orientation.

FREQUENCY: Before each use, visually inspect per steps listed in this instruction.

IMPORTANT: If this equipment has been subjected to forces resulting from the arrest of a fall, it must be immediately removed from the fi eld of service and replaced or inspected by authorized Capital Safety personnel for possible repair.

16

INSPECTION STEPS:

Step 1. Inspect the frame system for physical damage. Look carefully for any signs of cracks, dents, or deformities in the metal. Make certain the components are not deformed in any way and that they move correctly.

Step 2. Inspect the frame system for signs of excessive corrosions.

Step 3. Ensure the condition of the mounting surface will support system loads.

Step 4. Inspect each system component or subsystem (e.g. self-retracting lifeline, full body harness, etc.) per associated manufacturer’s instructions.

Step 5. If the Boxed-Frame Rail Fall Arrest System includes the hydraulic adjustment option, inspect all hoses and fi ttings for cracks, damage, or excessive wear. Inspect the lever lock mechanisms on all legs for proper functionality. Inspect the power unit per the manufacturer’s instructions. If any part of the system inspection uncovers questionable conditions, remove the system from service and contact Capital Safety.

Step 6. Record the inspection date on the inspected equipment. Record the inspection date and results on the “Inspection and Maintenance Log at the back of this manual”.

IMPORTANT: Only Capital Safety or parties authorized in writing may make repairs to this equipment.

MAINTENANCE - SERVICING - STORAGE

WHEEL MAINTENANCE: If the wheel assembly has grease zerks, ensure they are properly greased every six months.

NOTE: Not all Boxed-Frame models have a grease zerk for the wheel assembly. If the Boxed-Frame wheel assembly doesn’t have a grease zerk, then the wheel assembly should not be greased.

JACK MAINTENANCE: If the Top-Wind Jacks have grease zerks, ensure they are properly greased every month.

NOTE: Not all Boxed-Frame models have a grease zerk for the Top-Wind Jacks. If the Top-Wind Jack doesn’t have a grease zerk, then the jack assembly should not be greased.

CLEANING: Clean the Boxed-Frame Rail Fall Arrest System with a mild soap detergent solution. Excessive buildup of dirt, tar, etc. may prevent the system from working properly. If you have any questions concerning the condition of your frame system or have any doubt about putting it into service, contact Capital Safety.

NOTE: Additional maintenance and servicing procedures (i.e. replacement parts) must be completed by a factory authorized service center. Authorization must be in writing.

STORAGE: The Boxed-Frame Rail Fall Arrest System is designed for storage outdoors during normal weather conditions. If the weather environment is severe, it is recommended to store the Boxed-Frame system in an area that prevents damage to the system.

HYDRAULIC SYSTEMS (if so equipped): Hydraulic Boxed-Frame Rail Fall Arrest Systems must have roller assemblies and moving parts lubricated with a non-corrosive lube every 20 cycles or monthly (whichever comes fi rst). Refer to the hydraulic system manufacturer’s product instructions for additional maintenance and service information, including recommended power unit maintenance.

The hydraulic system’s power unit must be stored indoors in a dry, clean environment.

IMPORTANT: Additional maintenance and servicing of the hydraulic system (parts replacement, etc) must be performed by a factory authorized service center. Authorization must be in writing.

SPECIFICATIONS

Materials and Finish Zince plated or powder coated, 6061-T6 aluminum anodized, steel anchor plate.

Hardware Grade 5/Grade 8 zinc plated.

Capacity The maximum working load for this product is one (1) or more person(s) (check system labeling for approved number of users) with a combined weight of 310 lbs. (141 kg) per person. Only one person and PFAS may be connected to a trolley. Use of various accessories may reduce the number of workers that may be anchored.

Static Load Capacity Strength of system maintains a minimum safety factor of 2 as required by OSHA when according to this user instruction manual (reference OSHA 1926.502 and 1910.66)/

17

TERMINOLOGY

Authorized Person A person assigned by the employer to perform duties at a location where the person will be exposed to a fall hazard (otherwise referred to as “user” for the purpose of these instructions).

Rescuer Person or persons other than the rescue subject acting to perform an assisted rescue by operation of a rescue system.

Certifi ed Anchorage An anchorage for fall arrest, positioning, restraint, or rescue systems that a qualifi ed person certifi es to be capable of supporting the potential fall forces that could be encountered during a fall or that meet the criteria for a certifi ed anchorage prescribed in this standard.

Qualifi ed Person A person with a recognized degree or professional certifi cate and with extensive knowledge, training, and experience in the fall protection and rescue fi eld who is capable of designing, analyzing, evaluating, and specifying fall protection and rescue systems to the extent required by this standard.

Competent Person One who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

18

LABELING

The following labels should be securely attached to the frame system and fully legible:

A

B

C

D

E

G

H

G

H

I

A B

C D

E

ELECTROCUTION HAZARD:Watch for Overhead Power Lines.

F

9509349 Rev. A

READ INSTRUCTIONS:The user/rescuer must read and understand these instructions or have them explained to them before using this equipment.

G H

DO NOT REMOVE THIS LABEL. FULLYRETRACT OR ROTATE JACK BEFORETOWING. ENGAGE LOCKING PIN ON SWIVELJACK BEFORE TOWING OR USING JACK.BLOCKS USED TO INCREASE HEIGHT CANCAUSE INSTABILITY AND MAY CAUSEINJURYORDEATH.

WARNING

Pt# 18723 Rev.01

MAXIMUM LIFT CAPACITY 5000 Lbs / 22kN

I(Example only. When ordering replacement label, please specify 7 digit part number in lower left corner.)

95XXXXX REV A

INSPECTION AND MAINTENANCE LOG

SERIAL NUMBER:

MODEL NUMBER:

DATE PURCHASED: DATE OF FIRST USE:

INSPECTION DATE INSPECTION ITEMS NOTED

CORRECTIVE ACTION MAINTENANCE PERFORMED

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

Approved By:

LIMITED LIFETIME WARRANTY

Warranty to End User: D B Industries, Inc., dba CAPITAL SAFETY USA (“CAPITAL SAFETY”) warrants to the original end user (“End User”) that its products are free from defects in materials and workmanship under normal use and service. This warranty extends for the lifetime of the product from the date the product is purchased by the End User, in new and unused condition, from a CAPITAL SAFETY authorized distributor. CAPITAL SAFETY’S entire liability to End User and End User’s exclusive remedy under this warranty is limited to the repair or replacement in kind of any defective product within its lifetime (as CAPITAL SAFETY in its sole discretion determines and deems appropriate). No oral or written information or advice given by CAPITAL SAFETY, its distributors, directors, offi cers, agents or employees shall create any different or additional warranties or in any way increase the scope of this warranty. CAPITAL SAFETY will not accept liability for defects that are the result of product abuse, misuse, alteration or modifi cation, or for defects that are due to a failure to install, maintain, or use the product in accordance with the manufacturer’s instructions.

CAPITAL SAFETY’S WARRANTY APPLIES ONLY TO THE END USER. THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO OUR PRODUCTS AND IS IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES, EXPRESSED OR IMPLIED. CAPITAL SAFETY EXPRESSLY EXCLUDES AND DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND SHALL NOT BE LIABLE FOR INCIDENTAL, PUNITIVE OR CONSEQUENTIAL DAMAGES OF ANY NATURE, INCLUDING WITHOUT LIMITATION, LOST PROFITS, REVENUES, OR PRODUCTIVITY, OR FOR BODILY INJURY OR DEATH OR LOSS OR DAMAGE TO PROPERTY, UNDER ANY THEORY OF LIABILITY, INCLUDING WITHOUT LIMITATION, CONTRACT, WARRANTY, STRICT LIABILITY, TORT (INCLUDING NEGLIGENCE) OR OTHER LEGAL OR EQUITABLE THEORY.

I S O9001

CSG USA & Latin America3833 SALA Way Red Wing, MN 55066-5005 Toll Free: 800.328.6146Phone: 651.388.8282Fax: 651.388.5065solutions@capitalsafety.com

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CSG Northern Europe5a Merse RoadNorth Moons, MoatReditch, Worcestershire, UKB98 9HLPhone: + 44 (0)1527 548 000Fax: + 44 (0)1527 591 000csgne@capitalsafety.com

CSG EMEA(Europe, Middle East, Africa)Le Broc CenterZ.I. 1ère Avenue5600 M B.P. 15 06511CarrosLe Broc CedexFrancePhone: + 33 4 97 10 00 10Fax: + 33 4 93 08 79 70information@capitalsafety.com

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Shanghai:Rm 1406, China Venturetech Plaza819 Nan Jing Xi Rd,Shanghai 200041, P R ChinaPhone: +86 21 62539050Fax: +86 21 62539060

www.capitalsafety.com

The Ultimate in Fall Protection

© Copyright 2014, Capital SafetyFORM NO: 5903233REV: A

USER INSTRUCTION MANUAL

The Ultimate in Fall Protection

Boxed-Frame RailFall Arrest System

Model Numbers:853003885300678530117

853014785301898530227

853028885303338530361

853036285304278530454

8560489

1

2

2

A

B

B

D

D

D

E

E

E

A

A

H

C

B

D

E

G

F

3

3

H

V F

A A≤30°

H ≤ 6’ (1.82 m)

H ≤ 6’ (1.82 m)

H ≤ 6’ (1.82 m)

H ≤ 6’ (1.82 m)

H ≤

6’ (1

.82 m

)

H ≤

6’ (1

.82 m

)

Fft (m)

H - ft (m) 0

(0.0) 1

(0.3)2

(0.6)3

(0.9)4

(1.2)5

(1.5)6

(1.8)

V

- f

t (m

)

0 (0.0)

0.0(0.0)

1.0(0.3)

2.0(0.6)

3.0(0.9)

4.0(1.2)

5.0(1.5)

6.0(1.8)

1(0.3)

1.0(0.3)

1.4(0.4)

2.2(0.7)

3.2(1.0)

4.1(1.3)

5.1(1.6)

6.1(1.9)

2 (0.6)

2.0(0.6)

2.2(0.7)

2.8(0.9)

3.6(1.1)

4.5(1.4)

5.4(1.6)

6.3(1.9)

3(0.9)

3.0(0.9)

3.2(1.0)

3.6(1.1)

4.2(1.3)

5.0(1.5)

5.8(1.8)

6.7(2.0)

4 (1.2)

4.0(1.2)

4.1(1.3)

4.5(1.4)

5.0(1.5)

5.7(1.7)

6.4(2.0)

7.2(2.2)

5(1.5)

5.0(1.5)

5.1(1.6)

5.4(1.6)

5.8(1.8)

6.4(2.0)

7.1(2.2)

7.8(2.4)

6 (1.8)

6.0(1.8)

6.1(1.9)

6.3(1.9)

6.7(2.0)

7.2(2.2)

7.8(2.4)

8.5(2.6)

7(2.1)

7.0(2.1)

7.1(2.2)

7.3(2.2)

7.6(2.3)

8.1(2.5)

8.6(2.6)

9.2(2.8)

8 (2.4)

8.0(2.4)

8.1(2.5)

8.2(2.5)

8.5(2.6)

8.9(2.7)

9.4(2.9)

10.0(3.0)

9(2.7)

9.0(2.7)

9.1(2.8)

9.2(2.8)

9.5(2.9)

9.8(3.0)

10.3(3.1)

10.8(3.3)

10 (3.0)

10.0(3.0)

10.0(3.1)

10.2(3.1)

10.4(3.2)

10.8(3.3)

11.2(3.4)

11.7(3.6)

11(3.4)

11.0(3.4)

11.0(3.4)

11.2(3.4)

11.4(3.5)

11.7(3.6)

12.1(3.7)

12.5(3.8)

12 (3.7)

12.0(3.7)

12.0(3.7)

12.2(3.7)

12.4(3.8)

12.6(3.9)

13.0(4.0)

13.4(4.1)

13(4.0)

13.0(4.0)

13.0(4.0)

13.2(4.0)

13.3(4.1)

13.6(4.1)

13.9(4.2)

14.3(4.4)

14 (4.3)

14.0(4.3)

14.0(4.3)

14.1(4.3)

14.3(4.4)

14.6(4.4)

14.9(4.5)

15.2(4.6)

15(4.6)

15.0(4.6)

15.0(4.6)

15.1(4.6)

15.3(4.7)

15.5(4.7)

15.8(4.8)

16.2(4.9)

16 (4.9)

16.0(4.9)

16.0(4.9)

16.1(4.9)

16.3(5.0)

16.5(5.0)

16.8(5.1)

17.1(5.2)

17(5.2)

17.0(5.2)

17.0(5.2)

17.1(5.2)

17.3(5.3)

17.5(5.3)

17.7(5.4)

18.0(5.5)

18 (5.5)

18.0(5.5)

18.0(5.5)

18.1(5.5)

18.2(5.6)

18.4(5.6)

18.7(5.7)

19.0(5.8)

19(5.8)

19.0(5.8)

19.0(5.8)

19.1(5.8)

19.2(5.9)

19.4(5.9)

19.6(6.0)

19.9(6.1)

20 (6.1)

20.0(6.1)

20.0(6.1)

20.1(6.1)

20.2(6.2)

20.4(6.2)

20.6(6.3)

20.9(6.4)

21(6.4)

21.0(6.4)

21.0(6.4)

21.1(6.4)

21.2(6.5)

21.4(6.5)

21.6(6.6)

21.8(6.7)

22(6.7)

22.0(6.7)

22.0(6.7)

22.1(6.7)

22.2(6.8)

22.4(6.8)

22.6(6.9)

22.8(7.0)

23(7.0)

23.0(7.0)

23.0(7.0)

23.1(7.0)

23.2(7.1)

23.3(7.1)

23.5(7.2)

23.8(7.2)

24(7.3)

24.0(7.3)

24.0(7.3)

24.1(7.3)

24.2(7.4)

24.3(7.4)

24.5(7.5)

24.7(7.5)

25(7.6)

25.0(7.6)

25.0(7.6)

25.1(7.6)

25.2(7.7)

25.3(7.7)

25.5(7.8)

25.7(7.8)

4

A

5 6

A. B. C. D.

E. F. G.

A B C

4

7

12

3

4

5

5

8

1

2 3

4

6

9

1

2 3

10

1

A B C

2

A B C

7

11

8

WARNING: This product is part of a Personal Fall Arrest and Work Positioning system. The user must follow the manufacturer’s instructions for each component of the system. These instructions must be provided to the user of this equipment. The user must read and understand these instructions before using this equipment. Manufacturer’s instructions must be followed for proper use and maintenance of this equipment. Alterations or misuse of this product or failure to follow instructions may result in serious injury or death.

IMPORTANT: If you have questions on the use, care, or suitability of this equipment for your application, contact Capital Safety. For general questions, refer to national Standards including the ANSI Z359 (.0, .1, .2, .3, and .4) family of standards on fall protection, ANSI A10.32, and applicable local, state, and federal (OSHA) requirements governing occupational safety for more information about fall protection systems.

IMPORTANT: Prior to installation and use of this equipment, record the product identifi cation information from the ID label in the Inspection and Maintenance Log (Table 2) at the back of this manual.

PRODUCT DESCRIPTION:Figure 1 illustrates FlexiGuard® Boxed-Frame Rail Fall Arrest Systems (FAS). Typical components are illustrated in Figure 2 and specifi ed in Table 1. The Boxed-Frame Rail FAS is a Box-Frame (A) supported Trolley Rail (B) system for overhead anchorage of Capital Safety Fall Arrest or Fall Restraint equipment. Boxed-Frame Rail Systems are custom designed to customer requirements. Dimensions, number of Rails, and number of Legs will vary with the intended application:

• TROLLEY RAILS: Wheeled Trolleys (C), traveling along Rail Assemblies (B), serve as moving anchorage points for Self-Retracting Lifelines (SRLs) or Lanyards.

• LEGS: Systems with multiple Trolley Rails or longer rail spans may require additional Leg pairs to support the Trolley Rail(s). Legs have Swiveling Wheel Assemblies (D) with Crank Jacks (E) for portability and secure positioning. Taller Boxed-Frame Rail Systems may have Adjustable Legs (F) with Lifting Bars (G) or Lifting Eyes (H) for raising and lowering the Frame with a Forklift, Hoist, or similar equipment.

Table 1 – Specifi cations

Component Specifi cations:

Figure 2 Reference Component Materials Rating

A Box-Frame Aluminum and Steel

B Trolley Rail Rail Halves - AluminumStiffener Beam - AluminumStiffener Bar - Aluminum

Maximum of 1 Person up to 420 lbs (191 kg) including clothes, tools, etc. per Trolley

C Trolley Wheels - NylonBearings - SteelPlate - Stainless Steel

1,800 lbs (817 kg) Vertical () Load

SRLSmall Eye

LanyardLarge Eye

D Swiveling Wheel AssemblyWheel Options:

8”Solid Urethane

12” Solid Rubber

16” Pneumatic

18” Dual Pneumatic

E Crank Jack Tube - Steel TubeMounting Plates - Steel PlateCrank - Steel Bar

7,000 lbs (3,175 kg) Capacity

F Adjustable Leg Leg Tubes - AluminumFoot Plate - SteelPins - Steel

G Lifting Bar Steel Tube

H Lifting Eye Steel 5,000 lbs (22 kN)

System Specifi cations:

Capacity: Maximum of 2 Trolleys per Trolley Rail. 1 Person per Trolley, up to 420 lbs (191 kg) including clothes, tools, etc. per Trolley

Anchorage: Structure supporting the Fall Arrest System must be capable of withstanding a 16,000 lb (7,257 kg) vertical load.

9

1.0 PRODUCT APPLICATION

1.1 PURPOSE: Flexiguard® Anchorage Systems are designed to provide anchorage connection points for a Personal Fall Arrest System (PFAS).

WARNING: Unless otherwise noted, Capital Safety equipment is designed for use with Capital Safety approved components and subsystems only. Substitution or replacement with non-approved components or subsystems may jeopardize compatibility of equipment and may affect safety and reliability of the complete system. Do not hang, lift, or support tools or equipment from the Anchorage System, or attach guy lines for antennas, phone lines, etc.

1.2 SUPERVISION: Installation of this equipment must be supervised by a Qualifi ed Person1. Use of this equipment must be supervised by a Competent Person4.

1.3 TRAINING: This equipment must be installed and used by persons trained in its correct application. This manual is to be used as part of an employee training program as required by OSHA. It is the responsibility of the users and installers of this equipment to ensure they are familiar with these instructions, trained in the correct care and use of this equipment, and are aware of the operating characteristics, application limitations, and consequences of improper use of this equipment.

IMPORTANT: Training must be conducted without exposing the user to a fall hazard. Training should be repeated periodically.

1.4 RESCUE PLAN: When using this equipment and connecting subsystem(s), the employer must have a rescue plan and the means at hand to implement and communicate that plan to users, authorized persons2, and rescuers3. A trained, on-site rescue team is recommended. Team members should be provided with the equipment and techniques to perform a successful rescue. Training should be provided on a periodic basis to ensure rescuer profi ciency.

1.5 INSPECTION FREQUENCY: The Flexiguard Anchorage System shall be inspected by the user before each use and, additionally, by a competent person4 other than the user at intervals of no more than one year5. Inspection procedures are described in the “Inspection and Maintenance Log” (Table 2). Results of each Competent Person inspection should be recorded on copies of the “Inspection and Maintenance Log”.

1.6 AFTER A FALL: If the Flexiguard Anchorage System is subjected to the forces of arresting a fall, it must be removed from the fi eld of service immediately and replaced or inspected by an Authorized Capital Safety Representative.

2.0 SYSTEM CONSIDERATIONS

2.1 ANCHORAGE: Structure on which the Flexiguard Anchorage System is placed or mounted must meet the Anchorage specifi cations defi ned in Table 1.

FROM OSHA: Anchorages used for attachment of Personal Fall Arrest Systems shall be independent of any anchorage being used to support or suspend platforms, and capable of supporting at least 5,000 lbs (22 kN) per user attached, or be designed, installed, and used as part of a complete Personal Fall Arrest System which maintains a safety factor of a least 2, and is under the supervision of a qualifi ed person.

2.2 PERSONAL FALL ARREST SYSTEM: Figure 1 illustrates typical Fall Arrest applications of this Flexiguard Anchorage System. Personal Fall Arrest Systems (PFAS) used with the system must meet applicable OSHA, ANSI, state, and federal requirements. The PFAS shall incorporate a Full Body Harness and meet the following capabilities:

Maximim Arresting Force Maximum Free Fall DistancePFAS with Shock Absorbing Lanyard 900 lb (4 kN) 6 ft (1.8 m)

Arresting Force Maximum Free Fall DistancePFAS with Self Retracting Device 900 lb (4 kN) Maximum Arresting Force

or 900 lb (4 kN) Average Arresting Force (as defi ned in ANSI Z359.14)

2 ft (0.61 m)

IMPORTANT: Under NO circumstances is a PFAS with a Free Fall distance greater than 6 ft (1.8 m) acceptable for use with the Flexiguard Anchorage System.

2.3 FALL PATH AND SRL LOCKING SPEED: A clear path is required to assure positive locking of an SRL. Situations which do not allow for an unobstructed fall path should be avoided. Working in confined or cramped spaces may not allow the body to reach sufficient speed to cause the SRL to lock if a fall occurs. Working on slowly shifting material, such as sand or grain, may not allow enough speed buildup to cause the SRL to lock.

2.4 HAZARDS: Use of this equipment in areas with environmental hazards may require additional precautions to prevent injury to the user or damage to the equipment. Hazards may include, but are not limited to: heat, chemicals, corrosive environments, high voltage power lines, explosive or toxic gases, moving machinery, sharp edges, or overhead materials that may fall and contact the user or Personal Fall Arrest System.

1 Qualifi ed Person: A person with a recognized degree of professional certifi cate and with extensive knowledge, training, and experience in the fall protection and rescue fi eld who is capable of designing, analyzing, evaluating, and specifying fall protections and rescue systems to the extent required by OSHA and other applicable standards.

2 Authorized Person: For purposes of the Z359 standards, a person assigned by the employer to perform duties at a location where the person will be exposed to a fall hazard.

3 Rescuer: Person or persons other than the rescue subject acting to perform an assisted rescue by operation of a rescue system.

4 Competent Person: One who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazard-ous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them.

5 Inspection Frequency: Extreme working conditions (harsh environments, prolonged use, etc.)may require increasing the frequency of competent person inspections.

10

2.5 FALL CLEARANCE: There must be suffi cient clearance below the user to arrest a fall before the user strikes the ground or other obstruction. Fall Clearance is dependent on the following factors:

• Deceleration Distance • Worker Height • Elevation of Anchorage Connector• Free Fall Distance • Movement of Harness Attachment Element • Connecting Subsystem Length

See the Personal Fall Arrest System manufacturer’s instructions for specifi cs regarding Fall Clearance calculation.

2.6 SWING FALLS: Swing Falls occur when the anchorage point is not directly above the point where the fall occurs (see Figure 3). The force of striking an object while swinging from the pendulum effects of a Swing Fall can cause serious injury. Swing Falls can be minimized by limiting the horizontal distance (H) between the user and the anchorage point. In a Swing Fall, the total vertical fall distance (F) will be greater than if the user had fallen directly below the anchorage point, thus increasing Fall Clearance required to safely arrest the user’s fall. See the PFAS manufacturer’s instructions for details regarding Swing Falls and Fall Clearance calculation.

2.7 SHARP EDGES: Avoid working where Lifeline or Lanyard components of the Personal Fall Arrest System (PFAS) can contact or abrade against unprotected sharp edges (see Figure 4). Where contact with a sharp edge is unavoidable, cover the edge with protective material (A).

2.8 COMPONENT COMPATIBILITY: Capital Safety equipment is designed for use with Capital Safety approved components and subsystems only. Substitutions or replacements made with non-approved components or subsystems may jeopardize compatibility of equipment and may effect the safety and reliability of the complete system.

IMPORTANT: Equipment substitutions require written consent from Capital Safety.

2.9 CONNECTOR COMPATIBILITY: Connectors are considered to be compatible with connecting elements when they have been designed to work together in such a way that their sizes and shapes do not cause their gate mechanisms to inadvertently open regardless of how they become oriented. Contact Capital Safety if you have any questions about compatibility.

Connectors (hooks, carabiners, and D-rings) must be capable of supporting at least 5,000 lbs. (22.2 kN). Connectors must be compatible with the anchorage or other system components. Do not use equipment that is not compatible. Non-compatible connectors may unintentionally disengage (see Figure 5). Connectors must be compatible in size, shape, and strength. If the connecting element to which a snap hook or carabiner attaches is undersized or irregular in shape, a situation could occur where the connecting element applies a force to the gate of the snap hook or carabiner (A). This force may cause the gate to open (B), allowing the snap hook or carabiner to disengage from the connecting point (C).

Self-locking snap hooks and carabiners are required by ANSI Z359 and OSHA.

2.10 MAKING CONNECTIONS: Snap hooks and carabiners used with this equipment must be self-locking. Ensure all connections are compatible in size, shape and strength. Do not use equipment that is not compatible. Ensure all connectors are fully closed and locked.

Capital Safety connectors (snap hooks and carabiners) are designed to be used only as specifi ed in each product’s user’s instructions. See Figure 6 for examples of inappropriate connections. Do not connect snap hooks and carabiners:

A. To a D-ring to which another connector is attached.

B. In a manner that would result in a load on the gate.

NOTE: Large throat snap hooks should not be connected to standard size D-rings or similar objects which will result in a load on the gate if the hook or D-ring twists or rotates, unless the snap hook complies is equipped with a 3,600 lb (16 kN) gate. Check the marking on your snap hook to verify that it is appropriate for your application.

C. In a false engagement, where features that protrude from the snap hook or carabiner catch on the anchor, and without visual confi rmation seems to be fully engaged to the anchor point.

D. To each other.

E. Directly to webbing or rope lanyard or tie-back (unless the manufacturer’s instructions for both the lanyard and connector specifi cally allows such a connection).

F. To any object which is shaped or dimensioned such that the snap hook or carabiner will not close and lock, or that roll-out could occur.

G. In a manner that does not allow the connector to align properly while under load.

11

3.0 INSTALLATION

IMPORTANT: The FlexiGuard® Boxed-Frame Rail Fall Arrest System must be assembled by a Qualifi ed Person and the installation must be certifi ed by a Qualifi ed Person as: meeting the criteria for a Certifi ed Anchorage, or capable of supporting the potential forces that could be encountered during a fall.

1

IMPORTANT: Do not alter or intentionally misuse this equipment. Consult Capital Safety when installing or using this equipment in combination with components or subsystems other than those described in this manual. Some subsystems and component combinations may interfere with the operation of this equipment.

3.1 PLANNING: Plan your fall protection system prior to installation of the FlexiGuard Boxed-Frame Rail Fall Arrest System (FAS). Account for all factors that may affect your safety before, during, and after a fall. Consider all requirements, limitations, and specifi cations defi ned in Section 2 and Table 1.

3.2 LOWERING AND RAISING THE ADJUSTABLE BOXED-FRAME: On Boxed-Frame Rail FAS equipped with Adjustable Legs and Lifting Bars, frame height can be adjusted with a Forklift or similar equipment (see Figure 7). To raise or lower the Boxed-Frame:

1. Attach the Lifting Bar across two Legs of the Frame with the provided fasteners.

2. Support the Lifting Bar with a Forklift rated for lifting the weight of the Boxed-Frame Rail FAS.

3. Raise or lower the Frame with the Wheel Assembly Crank Jacks until the Pins can be removed from the Adjustable Legs and then pull the Pins out of the Outer and Inner Leg Tubes.

4. Raise the end of the Frame with the Forklift. When the Frame is at the desired height, reinsert the Pins through the Outer and Inner Leg Tubes.

5. Repeat Steps 1 thru 4 to raise the other end of the Frame. Insert the Pins through corresponding Pin Holes on the Leg Tubes so the same number of Pin Holes are exposed on each Leg.

NOTE: Boxed-Frame models without a Lifting Bar may be lifted from the top cross structure or Lifting Eyes on the top of each leg if so equipped.

3.2 TOWING THE BOXED-FRAME RAIL FALL ARREST SYSTEM: Some Boxed-Frame Rail Fall Arrest Systems are equipped with a Tow Bar Kit for longer distance transport (see Figure 8). The Tow Bar Kit consists of a Hitch Receiver Cross Bar that clamps to the Boxed-Frame Legs and a Tow Bar that hitches to a Pintle or Ball style hitch.

Tow Bar Installation: Figure 8 illustrates installation of the Tow Bar:

1. Attach Tow Bar Clamps to all four legs with the longer Clamp Brackets extending out from the front and rear of the Boxed-Frame.

2. Remove the Detent Pins from the Tow Bar Clamps on one end of the Boxed-Frame; position the Hitch Receiver Crossbar in the Clamp Brackets; and re-insert the Detent Pins through the Clamp Brackets and Crossbar.

3. Assemble the Tow Bar as illustrated (Figure 8-3) and then secure the Tow Bar in the Hitch Receiver with a bolt, washer, and nut.

4. Position the Side Support Tubes between the front and back Tow Bar Clamps and pin in place with the provided Detent Pins.

ADJUSTABLE SIDE SUPPORT TUBES: Longer leg spans may have adjustable two-piece Side Support Tubes. Remove the middle Detent Pin; adjust the length of the Support Tube; and then re-insert the Detent Pin through aligned holes in the two Tube Sections.

Towing: The Tow Bar is used with a Pintle Hitch or Ball Hitch (see Figure 10). On Adjustable Height Boxed-Frames, fully lower the Boxed-Frame before towing (see Section 3.2). To hitch and tow the Boxed-Frame Rail Fall Arrest System:

WARNING: The Boxed-Frame Rail Fall Arrest System should be towed in a fully lowered position to limit the possibility of tip-overs that may damage equipment or result in injury or death.

1. Secure the Tow Bar Eye on the Tow Vehicle Hitch.

2. Crank the Wheel Assembly Jacks clockwise until the Caster Wheels contact the ground and raise the Leg Stabilizer Pads off the ground.

3. Tow the Boxed-Frame Rail FAS to the desired work location. When moving the system near overhead power lines, electrical outlets, or any other dangerous overhead objects always have a spotter present to prevent accidental contact.

WARNING: Do not tow at speeds exceeding 5 mph (8 kph). Never tow the system on slopes greater than 10°. Excessive speed or slope may cause system and tow vehicle tip-overs resulting in equipment damage, serious injury, or death.

1 Qualifi ed Person: A person with a recognized degree of professional certifi cate and with extensive knowledge, training, and experience in the fall protection and rescue fi eld who is capable of designing, analyzing, evaluating, and specifying fall protections and rescue systems to the extent required by OSHA and other applicable standards

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3.3 POSITIONING AND STABILIZING THE BOXED-FRAME RAIL FALL ARREST SYSTEM:

Position and stabilize the Boxed-Frame Rail FAS in the work area as illustrated in Figure 10:

1. For each Leg:

A. Crank the Wheel Assembly Jack clockwise until the Caster Wheel contacts the ground and raises the Leg Stabilizer Pad off the ground.

B. If present, pull the Swivel Lock Pin and rotate the Swivel Lock 90° to allow 360° rotation of the wheel.

C. If present, unlock the Wheel Lock so the wheel can roll.

2. Position the Boxed-Frame Rail Fall Arrest System as desired and then stabilize by adjusting each leg as follows:

A. Position the Boxed-Frame Rail(s) over the desired work area. When moving the system near overhead power lines, electrical outlets, or any other dangerous overhead objects always have a spotter present to prevent accidental contact.

B. Crank the Wheel Assembly Jack counterclockwise until the Leg Stabilizer Pad contacts the ground firmly.

C. If present, pull the Swivel Lock Pin and rotate the Swivel Lock 90° to prevent the wheel from swiveling.

D. If present, lock the Wheel Lock to prevent the wheel from rolling.

WARNING: The Boxed-Frame Rail Fall Arrest System must be used on level ground. After positioning and stabilizing the Boxed-Frame, inspect the system with a Level to ensure the entire system is within 1° of level. Using the system when not level could tip the system, resulting in serious injury or death.

4.0 USE

WARNING: Consult your doctor if there is any reason to doubt your fi tness to safely absorb the shock from a fall arrest or suspension. Age and fi tness seriously affect a worker’s ability to withstand falls. Pregnant women or minors must not use DBI-SALA equipment unless in an emergency situation.

WARNING: Never exceed the Capacity maximums specifi ed in Table 1. Exceeding the stated capacity could collapse or tip the system, resulting in serious injury or death.

4.1 BEFORE EACH USE: Verify that your work area and Personal Fall Arrest System (PFAS) meet all criteria defi ned in Section 2 and a formal Rescue Plan is in place. Inspect the Boxed-Frame Rail FAS per the ‘User’ inspection points defi ned on the “Inspection and Maintenance Log” (Table 2). If inspection reveals an unsafe or defective condition, do not use the Boxed-Frame Rail FAS. Remove the system from service and contact Capital Safety regarding replacement or repair.

SAFE WORK AREA: Figure 3 illustrates the Safe Work Area for the Fall Arrest System. The gray shading on the table designates safe working distances where the angle of the Lifeline is less than or equal to 30° from vertical and the Horizontal Distance (H) from the anchorage connection point is less than or equal to 6 ft (1.82 m). NEVER work at a Horizontal Distance (H) and Vertical Distance (V) that results in a calculated Vertical Fall Distance (F) exceeding the gray shaded values on the table in Figure 3.

4.2 FALL ARREST CONNECTIONS: Figure 11 illustrates application of the Boxed-Frame Rail Fall Arrest System and its Fall Arrest Connections. The Boxed-Frame Rail must always be used with a Full Body Harness and Fall Arrest subsystem. Trolley Rails are equipped with Four-Wheel Trolleys that travels back-and-forth inside the Rail Halves. A Self-Retracting Lifeline (SRL) can be connected to the eye on the Trolley. Connect the other end of the SRL to the back Dorsal D-Ring on the Harness. A Tag Line can be attached to the SRL Lifeline and used to retrieve the lifeline for connection to the user’s harness.

WARNING: When transferring between SRL’s, always maintain 100% tie-off to ensure fall arrest protection in the event of a fall.

IMPORTANT: No more than one person, meeting the Capacity requirements specifi ed in Table 1, shall be attached to each Trolley.

WARNING: Inappropriate or incompatible connections between components of the Personal Fall Arrest System (PFAS) may result in serious injury or death. See Section 2 for details regarding connector compatibility and safe connections.

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5.0 INSPECTION

5.1 INSPECTION FREQUENCY: The Flexiguard System must be inspected at the intervals defi ned in Section 1. Inspection procedures are described in the “Inspection and Maintenance Log” (Table 2). Inspect all other components of the Fall Protection System per the frequencies and procedures defi ned in the manufacturer’s instructions.

i-Safe™ RFID: Some Flexiguard Systems are equipped with an i-Safe Radio Frequency Identifi cation (RFID) Tag. The RFID Tag can be used in conjunction with the i-Safe Handheld Reading Device to simplify inspection and inventory control and provide records for you fall protection equipment. If you are a fi rst-time i-Safe user, contact Capital Safety or visit www.capitalsafety.com.

5.2 DEFECTS: If inspection reveals an unsafe or defective condition, remove the Flexiguard System from service immediately and contact Capital Safety regarding replacement or repair. Do not attempt to repair the System.

IMPORTANT: Only Capital Safety or parties authorized in writing by Capital Safety may make repairs to this equipment.

5.3 PRODUCT LIFE: The functional life of the System is determined by work conditions and maintenance. As long as the product passes inspection criteria, it may remain in service.

6.0 MAINTENANCE, SERVICING, STORAGE

6.1 CLEANING: Periodically clean the System’s metal components with a soft brush, warm water, and a mild soap solution. Ensure parts are thoroughly rinsed with clean water.

IMPORTANT: Although highly resistant to chemicals and environmental conditions, avoid contaminating the Flexiguard System with acids, bitumen, cement, paint, cleaning fl uids, etc. If the equipment contacts acids or other caustic chemicals, remove from service and wash with water and a mild soap solution. Inspect per Table 2 before returning to service.

6.2 SERVICE: Only Capital Safety or parties authorized in writing by Capital Safety may make repairs to this equipment. If the equipment has been subject to fall force or inspection reveals an unsafe or defective conditions, remove the equipment from service and contact Capital Safety regarding replacement or repair.

6.3 STORAGE: When not in use, store the Flexiguard System and associated fall protection equipment in a cool, dry, clean environment out of direct sunlight. Avoid areas where chemical vapors may exist. Thoroughly inspect components after extended storage.

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LABELS

The following labels must be present on the Flexiguard I-Beam Sliding Anchor Post. Labels must be replaced if they are not fully legible. Contact Capital Safety for replacement label.

CD

E

F G

AF

G

AC

DE

B

AC

DE

F GA

C

D

EF

G

A

Pt#: 16399

ELECTROCUTIONHAZARD

WATCH FOR OVERHEADPOWER LINES

DANGER

B C D

E F G

DO NOT REMOVE THIS LABEL. FULLYRETRACT OR ROTATE JACK BEFORETOWING. ENGAGE LOCKING PIN ON SWIVELJACK BEFORE TOWING OR USING JACK.BLOCKS USED TO INCREASE HEIGHT CANCAUSE INSTABILITY AND MAY CAUSEINJURYORDEATH.

WARNING

Pt# 18723 Rev.01

MAXIMUM LIFT CAPACITY 5000 Lbs / 22kN

Table 2 – Inspection and Maintenance Log

Inspection Date: Inspected By:

Components: Inspection: (See Section 1 for Inspection Frequency) UserCompetent

Person

Boxed-Frame Inspect the Boxed-Frame for structural defects or damage including bends, corrosion, etc.

Inspect fasteners Rail Supports, Wheel Clamps, Tow Bar Clamps, etc. to ensure they are tight.

Visually inspect the Gussets and Support Tubes for straightness. Ensure there is no visible deformation or bend, indicating previous exposure to fall arrest forces.

Trolley Rails Visually inspect fasteners on the Trolley Rails to ensure they are tight.

Inspect the Rail Tracks for structural defects. Rail Tracks must be straight without any bends or dents.

Visually inspect the Trolleys for damage to the trolley and excessive wheel wear. Ensure the Trolleys roll freely in the Trolley Rails and the wheels are securely attached.

Wheel Assemblies and Crank Jacks

Inspect Wheels And Casters for excessive wear. Make sure Wheels roll smoothly and swivel on their Casters, Inspect Wheel Locks and Swivel Locks for proper operation. Make Sure Wheel and Crank Jack assemblies are clamped securely to Frame Legs.

Inspect Crank Jacks for any wear, corrosion, or deformities. Make sure Crank Jacks function properly

If Wheel Assemblies and/or Crank Jacks have Grease Zerks, grease Zerks every six months.

Anchorage Connection Points

Make sure all Anchorage Connection Points are free of corrosion, cracks, or other imperfections that my cause malfunction during operation.

Labels Verify that all labels are securely attached and are legible (see ‘Labels’)

PFAS and Other Equipment

Additional Personal Fall Arrest System (PFAS) equipment (harness, SRL, etc) that are used with the Flexiguard Anchorage System should be installed and inspected per the manufacturer’s instructions.

Serial Number(s): Date Purchased:

Model Number: Date of First Use:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

Corrective Action/Maintenance: Approved By:

Date:

LIMITED LIFETIME WARRANTY

Warranty to End User: D B Industries, Inc., dba CAPITAL SAFETY USA (“CAPITAL SAFETY”) warrants to the original end user (“End User”) that its products are free from defects in materials and workmanship under normal use and service. This warranty extends for the lifetime of the product from the date the product is purchased by the End User, in new and unused condition, from a CAPITAL SAFETY authorized distributor. CAPITAL SAFETY’S entire liability to End User and End User’s exclusive remedy under this warranty is limited to the repair or replacement in kind of any defective product within its lifetime (as CAPITAL SAFETY in its sole discretion determines and deems appropriate). No oral or written information or advice given by CAPITAL SAFETY, its distributors, directors, offi cers, agents or employees shall create any different or additional warranties or in any way increase the scope of this warranty. CAPITAL SAFETY will not accept liability for defects that are the result of product abuse, misuse, alteration or modifi cation, or for defects that are due to a failure to install, maintain, or use the product in accordance with the manufacturer’s instructions.

CAPITAL SAFETY’S WARRANTY APPLIES ONLY TO THE END USER. THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO OUR PRODUCTS AND IS IN LIEU OF ALL OTHER WARRANTIES AND LIABILITIES, EXPRESSED OR IMPLIED. CAPITAL SAFETY EXPRESSLY EXCLUDES AND DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND SHALL NOT BE LIABLE FOR INCIDENTAL, PUNITIVE OR CONSEQUENTIAL DAMAGES OF ANY NATURE, INCLUDING WITHOUT LIMITATION, LOST PROFITS, REVENUES, OR PRODUCTIVITY, OR FOR BODILY INJURY OR DEATH OR LOSS OR DAMAGE TO PROPERTY, UNDER ANY THEORY OF LIABILITY, INCLUDING WITHOUT LIMITATION, CONTRACT, WARRANTY, STRICT LIABILITY, TORT (INCLUDING NEGLIGENCE) OR OTHER LEGAL OR EQUITABLE THEORY.

I S O9001

USA3833 SALA Way Red Wing, MN 55066-5005

MissouriDistributed by Engineered Fall ProtectionSales@EngineeredFallProtection.comwww.EngineeredFallProtection.comTel: (314) 492-4422