ENTEC PCW071406
Portable Climbing Wall
Operations Manual
REVISION 07/14/06
7591 Renken Rd
Worden, IL 62097
Phone: (618) 580-3742
Webpage: www.etgear.com
Email:
Welcome
Thank you for purchasing your portable climbing wall and welcome you to Extec Gear. We are excited about our equipment and are confident that through the experience and advanced safety systems utilized in building our climbing walls you will find it a rewarding and profitable purchase. Our business mission is based on excellence in equipment quality and safety while meeting the needs of our customers. Together with your similar commitment, we can become leaders in the portable climbing walls for the amusement, entertainment and special attractions market.
Our mission includes:
· Commitment to quality, safe and profitable equipment design
· Continuous customer service support
· Manufacturing to "ASTM F-1159-97a" safety standards for the amusement industry
· Cycle time that generates high profits
Your part in building a successful business using Extec Gear products is:
· Commitment to safe operation and replacement of wear dated parts
· Consistent inspection for proper maintenance
· Effective marketing and promotion
· Active promotion of the activity
Should you have any comments or questions, please do not hesitate to contact us!
Company Overview
Extec Gear (also dba: Extreme Concepts) has facilities located in the communities of Worden and Edwardsville, Illinois. We are manufacturer, rebuilder and distributor of commercial interactive sports and amusement equipment and parts. Designed for fun, safety and profit, Extec Gear products provide maximum income and years of safe and exciting entertainment for your customers.
Confidentiality Agreement
This manual contains proprietary information belonging to Extec Gear. This manual and its content are for the exclusive use and operation of an Extec portable climbing wall by its owner and those authorized operators, marketing and service personnel of the owner or Extec Gear. This manual is designed to provide accurate and authoritative information in regard to the subject matter covered, however, is not warranted as to accuracy or reliability. This manual may not be reproduced in whole or part without the prior written consent of Extec Gear.
Revision & Disposition
Extec Gear may make periodic revisions to this manual. The owner agrees to keep this manual up to date, reflecting all updates currently in use. This manual remains the property Extec Gear and must be returned or shredded upon receipt of an updated version.
Receipt and Acknowledgment
This Training/Operations Manual is an important document intended to help you become acquainted with the portable climbing wall, Extec Gear and guidelines as to safe and recommended operation.
Please read the following statement and sign below to indicate your receipt and acknowledgment of the portable climbing wall/ Extec Gear Training Manual.
Receipt and Acknowledgment And Warrantee Registration
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PLEASE FILL IN AND MAIL TO: Extec Gear, 7591 Renken Rd, Worden, IL 62097
I have received and read my copy of the portable climbing wall/ Extec Gear Training Manual.
I understand that the information outlined in this manual are subject to change at the sole discretion of Extec Gear at any time. It is further understood that the owner of the portable climbing wall has the responsibility to ensure the correct and latest version of the manual is being used.
As an owner of the portable climbing wall or authorized representative, it is my responsibility to keep this manual up-to-date with any chances that are made by Extec Gear. I understand that my signature below indicates that I have received the portable climbing wall/ Extec Gear Training Manual and that I have read it.
Owner’s Business Name: ________________________________________________________________
Authorized Representative:______________________________________________________________
Printed Name and Title: ________________________________________________________________
Date: ____/____/20____
VIN Number: ________________________________
Date Purchased: ____/____/20____
The signed original copy of this agreement will be held in the Extec Gear Corporate Office in Illinois.
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Training Overview
This training course is an introduction to the portable climbing wall and its operation. The purpose of this manual is to provide a compilation of information that will assist you in proper and safe operation.
This manual is designed to aid in training you and your associates. The sections within this manual are prerequisite to each other. In other words, the information in section one pertains to the information in section two.
The philosophy of Extec Gear is centered on a commitment to excellence in meeting the needs of its customers and associates by providing them with the enclosed information. This manual is designed to provide the wall owner with the information, tips, and techniques that will help the employees and owner operate the wall as effectively and safely as possible. It is no way a total representation of all facts. Safe operation of this wall is the sole responsibility of the wall owner/operator. Good and reasonable judgment must be used when traveling, promoting and/or operating the wall.
Training Objectives
Upon reviewing this training, you will be able to complete the following:
· Understand the process for proper set-up of the portable climbing wall
· Identify and understand the inspection points for day-to-day maintenance.
· Understand the replacement of wear dated parts
· Define and understand the safe operation of the portable climbing wall.
· Identify and explain the rules for safe usage of the portable climbing wall.
Portable Climbing Wall
Through an analysis of portable climbing wall history, Extec Gear's portable climbing wall provides a new level of safety through a layer of redundancy and back up of potential fail points. Designed to meet “ASTM F-1159-97a” standards for the Amusement Industry, its fully automatic, redundant hydraulic belays to protect the climber rather than a human holding a rope. Extec Gear’s climbing wall provides a higher degree of safety than may be found in climbing gyms or in nature and with the auto-belays doing the work and ensuring safety, person(s) operating the wall act more like a coach offering encouragement and direction.
Physical Dimensions. The portable climbing wall meets all requirements for physical size as outlined by the Department of Transportation. The dimensions of the portable climbing wall are:
Specifications. 3-person portable climbing wall trailer:
· Width – 7’6” to 8' 0"
· Height – 8'6" to 9'6"
· Length – 28'0"
· Weight – 3,140 lbs
Mechanical Engineering Approval. The portable climbing wall has been designed and reviewed by engineers that stand behind the portable climbing wall design. Components (or equivalents) have tested in actual field use for over a decade.
The "Auto-Belay” (“A-B”)
In traditional rock climbing, the belay is the climber’s safety line and person holding it. If the climber falls or needs lowered back down after completing the climb, the belay safely does this at a rate that is not too fast or too slow. If the belayer fails to continuously hold the rope, the climber may fall to the ground.
Extec Gear uses a pressurized air & oil hydraulic system to automatically belay each of 3 climbers on the portable climbing wall. No human is needed to hold the line and the much stronger 4,200# load cable steel cables that are used instead of ropes. A 4,200# test roller-bearing swivel prevents cable twisting or binding as the autobelay (“A-B”) system pulls in the slack at the climber ascends and safely controls the rate of descent when a climber falls or chooses to come down.
We know of no other organization taking such steps to assure and backup safety on their wall.
A-B Function.
Approximately 20 lbs of upward pull is continuously exerted on the climber’s safety cable by the A-B system. As a climber ascends the wall, his weight is taken off the cable and the A-B system pulls up the slack. What happens is the positive air pressure in the hydraulic system forces hydraulic oil into the then twin pistons, causing the cable pulleys to retract and take up the cable slack. The sequence is reversed for the controlled decent of the climber.
A-B Safety.
While failures on a well maintained auto-belay (“A-B”) climbing wall are very rare, the primary fail points reported in the national database “RideAccidents.com” relate to the hydraulic cylinders, cable-to-user and cable-to-wall connections.
Redundant Cylinders. Extec Gear’s portable climbing wall has with two parallel hydraulic cylinders (pistons) for each climber. One cylinder alone can handle a climber’s needs so redundant safety is provided.
Cable-to-User Backup. While a single cable crimp fitting can properly fasten a cable, Extec Gear’s climber cables use three on each cable-to-user end. Two are placed next to the swivel connection and a third about 2 feet back up the cable for triple redundancy. In addition, a shoulder strap using 9/16”+ tubular webbing (with 1,500+ lbs. nominal breaking strength) is added using a prussic knot to the climber’s cable immediately above the 3rd cable crimp. A slip ball allows this webbing to be placed snuggly under the climbers arms without being so loose as to get in the climber’s way or allow the climber to fall through the loop should it ever be needed. This shoulder strap protects against any unforeseen failure of the swivel, carabineer, climber’s harness and even the triple crimps creating a new level of protection not available through other manufacturers.
Note: The Cable-to-User Backup is a back up of the primary climber safety equipment provided on an A-B system. It is not intended to and should never be used by itself. The components should be replaced immediately if wear is noted or at each A-B cable replacement.
Cable-to-Wall Backup. The climber’s cable is looped through a welded fitting on the climbing wall to securely attach that end. Extec Gear adds two crimps to fasten the cable instead of one and adds a second, normally non-load bearing, cable to loop around the frame should the first loop or welded fitting every fail.
3X safety factor. The impact force on the catastrophic failure of parts protected by the Cable-to-User Backup is calculated at 500 lbs, based on a 250 lb person falling a maximum two feet (2’) before the redundant devices engage. Using the webbing’s 1,500+ lbs nominal breaking strength, a 3X safety factor is provided.
Disclaimer. Even with redundant safety devices all rock climbing has inherent risks. A climber using an A-B system can be injured or killed. Even though automated, a responsible person must be assigned to ensure that the portable climbing wall is mechanically sound and operating properly. As an owner of the portable climbing wall it is your responsibility to make sure constant care and supervision is taken regarding its maintenance, operation and use.
WARRANTIES. Extec Gear (“Seller”) warrants that from the date of invoice or cash sale all Goods shall be free of initial defects in material and workmanship and that portable climbing wall products have a limited one-year warranty on the climbing wall systems including the frame, trailer, climbing panels, handholds and auto-belays. Warranty does not include consumables (including harnesses, handholds, cables, pulleys, batteries and tires) although the individual manufacturer’s warrantees may cover these). Seller provides a 90-day warranty on electronics. This warranty does not apply towards normal wear and tear on products nor does it apply towards misuse on products.
Warning. Rock climbing is a dangerous sport. Whether one is climbing outdoors, on a portable product or in a gym, all are dangerous without the proper training and safety practices. The purchasers and users of any Extec Gear products are completely liable for and accept full responsibility for any and all damages or injury, which may result from the use and/or misuse of any products. The Seller makes no warranties, expressed or implied, except as specifically stated above.
SUCH WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, WRITTEN OR ORAL, STATUTORY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SELLER SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES OF ANY NATURE, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
The Seller shall only be obligated to repair a defective item. If the item(s) cannot be repaired, the Seller shall only be obligated to pay damages up to an amount equal to the sale price of the item(s).
How to set-up the portable climbing wall
Safety Summary. Extec Gear’s portable climbing wall locks hydraulically in the raised position with two-doubled 1-ton manual cam tie-downs providing 3+ tons of backup safety. Four load jacks keep the rock wall leveled while in use. For climber safety there are three fully automatic climber belays (A-B systems) that require no human rope handlers. These auto-belays have dual redundant hydraulic/pneumatic load handling systems and use 4,200# load cable with an anti-binding, roller-bearing 4,000# swivel. On the wall end of the load cable there is a 4,200# backup cable to wall connector and on the climber end there is a 1,000# chest strap backing up the swivel, auto-locking 4,000# carabineer and harness. This system provides a 2 points connection of the climber to the load cable.
Transportation. The portable climbing wall travels on the road in the closed (down) position. Because of its hollow, aerodynamic shape towing is usually easier than with an enclosed trailer. Please follow all local traffic laws and requirements.
Required Personnel. One lead operator can operate the portable climbing wall. In sparsely attending activities where the portable climbing wall us is being used by one person at a time, one operator staff person may be all that is necessary. A good rule of thumb is one operator for each climber using the wall at the same time. The required duties of the operators are: (1) the wall attendant who acts as the climbing coach, double checking the harness before a climber begins, connecting and disconnecting the climber to the belay cable and supervising the climbers as they go up and down the wall. The climbing coach offers encouragement and most importantly watches the belay cable to see that there is no excess slack in the cable or that the climber does climb above the auto-belay device; and (2) the harness fitter who helps put on and removing the harness from the climber, double checking the harness to ensure it is worn correctly and obtaining a hold harmless signature (from a parent if the climber is a minor).
Hitch and Wiring. To pull the portable climbing wall you will need a 2-inch ball and a Class II or better hitch. To use the trailer’s electric brakes, the tow vehicle must be outfitted with an electric brake controller and a circular 6-prong receptacle. The portable climbing wall also has a flat 4-prong receptacle for towing by a vehicle that does not need the trailer’s electric brakes. Your receptacle must be equipped with a 12-volt positive feed if you want the portable climbing wall’s dedicated battery to charge as you are towing the unit.