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: sales@etgear.com
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:
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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:
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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.
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ENTEC PCW071406
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
--------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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ENTEC PCW071406
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:
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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.
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ENTEC PCW071406
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-touser 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.
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ENTEC PCW071406
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 AB 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).
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ENTEC PCW071406
How to set-up the portable climbing wall
Safety Summary. Extec Gear’s portable climbing wall locks hydraulically in the raised position with twodoubled 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.
Absolutely no climbing should be allowed: (1) on any route that does not have a fully functioning autobelay or (2) if wind speeds exceed 30 mph. It is the responsibility of the operator, climbing coach, owner,
or other responsible party to be aware of weather conditions and make the appropriate call for closure
of the wall if necessary. When closure of the wall is necessary, put the wall in the down position.
PORTABLE CLIMBING WALL SETUP
(The order shown below is important, please follow it closely.)
1. Pull portable climbing wall trailer into final position and keep it attached to the tow vehicle. Insure a level
position has been selected with AT LEAST 28-feet of overhead clearance. STAY AWAY from power lines.
2. If back-end wall trailer storage box is attached, remove cam lever strap then remove both the snap
locking pin and the padlock from the hitch bolt installed in box attach point. Lift box safely out of the
way. Move the box to near the middle of the passenger side of the wall trailer and reinsert it into the
side-hitch mount located there. Re-install the hitch bolt; snap locking pin and padlock so the storage
box cannot be removed. Store the cam lever straps nearby so they can be used to secure the wall
once it is raised (a few minutes from now).
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ENTEC PCW071406
3. Inspect each of the three auto-belay climber cables. Do not use any cable that has a loosened crimp
connector or shows fraying, kinking or penetrating rust. Lock out any such cable and report condition.
4. At the top of the lowered wall (inside the "tunnel" near the hitch), find and remove the cam lever
strap from the wall lay-down "Y" support. The strap is hooked on the front metal tie loops attached to
the trailer. Save the cam lever strap for use in securing the wall once it is raised.
5. At the top of the lowered wall (inside on the support beams), find and turn on the horn switch.
6. Attach "UP/DOWN" (“RAISE/LOWER”) control box wire to the round quick connect located on the
driver's side near the back end of wall trailer.
7. Have a second person put tow vehicle into neutral (engine does not need to be on) and then stay in
the driver’s seat to make sure the vehicle does not roll until the wall pulls it backwards. The first
person then presses the "UP" button to raise wall to full upright position. Once the wall touches the
ground (it will not yet be straight up), the wall will pull the tow vehicle backwards a few feet. The
person in the driver’s seat should allow this to happen – if he uses the breaks at this time the wall will
dig into the ground (or pavement) and scratch it up a bit. When the wall is fully raised, the sound of
the hydraulic motor will change (to more of a struggling sound). Do not continue to operate hydraulic
motor once wall is fully raised.
 DO NOT PUSH AND RELEASE THE CONTROL BUTTON MULTIPLE TIMES WHILE RAISING OR
LOWERING THE WALL. Hold the button in continuously until the wall is upright (or lowered).
 Make sure that only the metal frame is resting on the ground. If there is an obstacle or high point
on the ground, you will break the wall’s fiberglass. As an option, if only a portion of the metal
wall frame is resting on the ground, shim up the portion of the wall base not touching the ground
with wood or metal shims. Shim only the metal frame!
8. Put tow vehicle into park. Chock trailer wheels with 2x4 blocks. Remove control box and store in safe
location in tow vehicle. Remove keys and lock tow vehicle or disconnect tow vehicle and park it
elsewhere.
9. If the tow vehicle is removed, lower the front tongue jack until the hitch is level. Attach the ball-hitch
ball lock, the ball-hitch lever lock and the wheel and axle chain and lock to secure the trailer from
theft or misuse.
10. Lower the two rear leveling jacks and level the back portion of the trailer. Lower the two mid-front
leveling jacks and level the front portion of the trailer. You do not need to raise the trailer tires off
the ground, although most of the trailer weight should be on the leveling jacks.
11. WALL LOCKING STRAPS. Find the cam lever straps removed earlier above. On each side of the wall
(behind the climbing surface) do the following: (1) Each strap has two hooks; hook both ends into the
eyebolt at the bottom of the wall. (2) Run the long end (the piece without the cam lock) around the
upright behind the taillight (look for the labeling "STRAP -->" to show where to run it). (3) Loop the
strap securely around the upright for extra support. (4) Thread the long end through the cam lock and
use the cam lever to tighten firmly. Do this on both sides of the wall. This is redundant safety to secure
the raised wall in the upright position.
12. Remove rope stands and barrier rope from the black Integral Storage Box (“ISB”) mounted near the
front of the trailer. Rope off area. Leave space for two 6'-8’ tables to be located ~20' in front of
wall and entry-exit space next to tables. Set up tables at front of roped area. Remove literature,
business cards, waiver forms & pen-clip boards & holders from the ISB and set up on 1st table.
Remove yellow rope from ISB and layout on ground halfway between wall and tables. This is the "do
not cross until it’s your turn" line for those that are harnessed up and ready to climb.
13. Remove the universal harnesses from the ISB and place on 2nd table. Do not lay harnesses on ground
– dirt is not a good thing! Inspect the harnesses to make sure harnesses loops are not inside out and
straps are properly tied through and back over buckles. Red marking on buckle should not be seen if
strapped correctly.
14. Unlock chain holding auto-belay cables. Do not let go of cables or you will have to either climb (if
one auto-belay is available) or lower wall to retrieve them. (Remember to remove the WALL
LOCKING STRAPS if you must lower the wall.)
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ENTEC PCW071406
15. When the wall is raised, inspect the hydraulic reservoir. It should be between the high and low level
marks. If not, fill to the high level with standard multi-vehicle ATF (automatic transmission fluid). Do not
use type “F” ATF. Be careful when releasing pressure from unit. If the high and low level marks are
obscured, ATF level should be 3 to 5 inches from the bottom of tank (or approximately 4 fingers from
the bottom of the tank) with the cables at the top of the wall.
16. "Pump" each of the A-B cables individually by pulling down 3-4 feet 5 or 6 times on each. This
removes air that may be trapped in the auto-belay system.
17. An operator on the front of the wall is to manually, quickly raise each individual A-B cable to arm’s
length while he and a second person behind the wall inspects the retraction of the cable to ensure
there is smooth operation with NO SLACK.
18. Attach one auto-locking carabineer to the end of each auto-belay cable. Latch cable to wall by
locking the carabineer onto one of the short green retainer straps (do not attach to the metal bracket
- the metal to metal contact can damage the carabineer.
19. Inspect the air pressure on the hydraulic reservoir should be between 40-45 psig. If less than 40 psig,
fill to 45 psig using the 12-volt mini compressor stored in the ISB. Attach the compressor’s alligator
clips to the wall trailer’s 12-volt battery – red to positive and black to negative. Do not overpressure
system.
20. Lay out “crash pads”, gym mats or similar in front of each belay station. This will help prevent ankle
and other injuries should a climber come down incorrectly.
WALL USE
1. Have climbers step into a harness that is near their size. It is OK to loosen straps, but do not allow
climbers to pull the straps out of the buckles. It is unnecessary, will create a lot of work for you to rethread them through the buckles and can lead to potentially dangerous mistakes.
2. Allow no more than 12 persons into the roped climbing area at a time, lines should be no more than 3
deep and not cross the yellow line. More can put on harnesses at a time, but they should stay in line in
front of the tables.
3. Only the wall attendant(s) should clip climbers into the wall. Do not allow climbers to clip or unclip.
Clip the auto-locking carabineer onto a climber by pushing in on the locking button while twisting the
locking mechanism and pushing the carabineer gate open. Clip onto the rappel loop on the front of
the harness.
4. Place the chest loop (attached to the auto-belay cable) over the climber’s head and have them bring
their arms up through the loop. Tighten the loop loosely high on the climber’s chest (right under their
armpits is best) by pulling the plastic binder circle down to the climber.
5. If the climber weighs less than 40 pounds, a pull-down strap should be attached to the back of their
harness and allowed to trail behind them as they climb. If they are too light for the auto-belay, a
wall attendant can help pull them down with the strap.
6. Allow the climber to climb. Typically, if the climber falls from higher than the 1st wall section (about
8’) if counts as a climb, otherwise the climber may make one more attempt before the turn is up.
Climbers should not attempt to climb outside their section (left–middle–right) this will interfere with
other climbers and can lead to dangerous swings if they fall. If a climber reaches the top, they can
press the horn button at the top of each section to signal their accomplishment.
7. When a climber is ready to come down, tell them to simply lean back and walk down the wall with
their legs shoulder width apart. Trying to climb down or coming down with their body vertical does
not work well at all.
8. If allowing two climbs per admission, when the climber’s first turn is up they may choose to climb the
same section again or go to the back of one of the other lines inside the roped climbing area. Once
they have completed 2 climbs, they must go to the end of the line – outside the roped climbing area
and wait for another turn. If there are not enough harnesses to handle those waiting in line, the
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ENTEC PCW071406
climber will have to remove the harness and place on the harness table before leaving the roped
climbing area.
9. Have the climber wait for a wall attendant to unclip them. The wall attendant can then clip in the next
person in that line or clip the auto-belay to the cable holding loop for that section, located near the
bottom of the wall.
Absolutely no climbing should be allowed: (1) on any route that does not have a fully functioning autobelay or (2) if wind speeds exceed 30 mph. It is the responsibility of the operator, climbing coach, owner,
or other responsible party to be aware of weather conditions and make the appropriate call for closure
of the wall if necessary. When closure of the wall is necessary, put the wall in the down position.
WALL DIFFICULTY. Facing the wall, the middle section is the easiest. The left side is more difficult and the
right side is the most difficult. Routes are marked with colored tags. If you want to climb a designated
route (this is more difficult!), only use holds with the color tags of the route you want to climb.
WALL TAKE DOWN.
1. Remove and store the barrier rope-off stands, rope and parts in the ISB. Disconnect 120 VAC power.
Store extension cords in the ISB. Return literature, materials and climbing harnesses to the ISB. Return
any tables you borrowed or securely store on trailer if you brought them
2. Return tables in the wall trailer table storage area. Secure firmly with the blue cam adjustable straps
(one strap per pile of tables). Make sure the strap hooks are pointed open side of the “S” facing
down when mounted.
3. Remove the auto-locking carabineers and store in the ISB. Thread the locking chain through the loop
end of each auto-belay cable. Thread the chest webbing of each auto-belay cable onto the locking
chain. Make sure this is done in such a way the plastic quick adjust ball on the chest webbing can not
fall off when the trailer is transported. Lock the locking chain into the middle climb’s retainer strap.
4. Store any other loose items that will not be needed in the ISB. Close the ISB fully. Remove the cam
lever straps connecting each side of the upright wall frame to the trailer frame and set aside for use
in a few minutes.
5. Raise and lock into the transportation position both the two rear leveling jacks and the two front
leveling jacks. Re-attach the tow vehicle completely, if it was removed earlier. (If you did remove the
tow vehicle, you must remove the ball-hitch ball lock, the ball-hitch lever lock and the wheel and axle
chain and lock.) Raise the front hitch tongue jack fully.
6. Attach yellow "UP/DOWN" (“RAISE/LOWER”) control box wire to the round quick connect located on
the driver's side near the back end of wall trailer.
7. Remove the 2x4 chock blocks from the wall trailer wheels and remove the wheel chain lock and store
all in the ISB. Put tow vehicle into neutral (engine does not need to be on). Press "DOWN" button to
lower wall to full lowered position. Have everyone stand back during this operation; the wall comes
down fairly hard. It is best not to stop the lowering until complete. Do not continue to operate
hydraulic motor once wall is fully lowered. Put tow vehicle into park.
8. At the top of the lowered wall (inside on the support beams), find and turn off the horn switch. At the
top of the lowered wall (inside the "tunnel" near the hitch), reinstall the cam lever strap around the
wall lay-down "Y" support. Loop the strap twice around the wall beam and hook the straps into the
red colored metal tie loops on each side of the trailer. Use the cam lever to firmly securing the strap.
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9. If back-end wall trailer storage box needs to be attached, remove hitch bolt from box attach point
and lift box back onto wall trailer brackets. Re-install the hitch bolt with both the snap pin and
padlock. Install the cam tie-down strap by hooking the long strap to the eyebolt at the bottom right
side of the box. Run this up through the eyebolt on bottom right hand side of the backside of the wall.
Continue running strap through the eyebolt on the bottom left hand side of the backside of the wall.
Attach the short cam lever strap to the eyebolt on the bottom left of the box. Thread the long strap
through the cam lever and tighten firmly. (Note: If the box does not need to be re-attached, save the
strap with the yellow UP/DOWN control box inside the tow vehicle.)
TRANSPORTATION.
1. Connect the wall trailer wiring harness to the tow vehicle wiring harness. Verify lights, break lights
and turn signals are working properly.
2. Check the wall trailer tires to insure they are properly inflated. Verify the crank-down lifting
mechanism near the trailer tongue is fully retracted. Verify that the wall trailer ball connector release
is PADLOCKED in the closed position. Verify that the 2 safety chains are properly attached. If backend wall trailer storage box is attached, verify the hitch bolt with both snap pin and padlock are
installed. Insure cam tie-down strap is installed to help lift weight of box.
3. Wall trailer will tow similar to a large boat. At higher speeds, when being passed by large vehicles
or in windy conditions, the trailer may begin to sway. Slow down to correct this condition. Remember
to allow extra stopping distance due to the weight you are towing.
4. Do not tow with a cover on the portable climbing wall or trailer. The wind will damage it.
5. Be sure the ball-hitch lever is down and the ball-hitch lever lock is in place whenever the trailer is
being towed.
STORAGE.
Install the ball-hitch ball lock, the ball-hitch lever lock and the wheel and axle chain and lock to help
protect your investment from theft or misuse.
SLACKLINE USE ON ROCKWALL TRAILER.
The Extec Gear portable climbing wall can be used as one base for a slackline. While the slackline
manufacturer’s instructions must be followed completely, these additional instructions must be added:
1. Remove slackline kit from ISB. Mount the ratchet end onto one of the metal tie-down loops near the
wall "Y" support at the front of the wall trailer.
2. Mount the long end to an available tree, vehicle or other structure on site. Run slackline over a
grassed area for soft dismounts. If onsite mounts not available install portable webbing supports (also
stored in the ISB). This requires installing the 3 welded-loop ground anchors with equalization
webbing and the 30” tripod for webbing height support. The tripods can be installed in any setup to
standardize the slackline height. Carefully follow the tripod set-up and anchoring instructions per the
manufacturer’s requirements.
3. To better protect against injuries, line the ground under the slackline with the 4 or more crash pads.
Follow the manufacturer’s slackline setup instructions to complete a proper setup.
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RULES AND SAFETY TIPS
Wall attendant double-checks the climber’s harness, clips the climber on and off the belay cable and
properly instructed the climber on the climbing rules; which are:
1. Climbers stay within the respective climbing route (left, middle or right side). The four-foot area
directly under the belay cable outlines the climbing zone up the wall.
2. No swinging from side to side.
3. No stepping on the belay cable.
4. No climbing if cable does not retract.
5. Communications with the climbing coach only, no distracting other climbers with idle conversation.
6. When rappelling, keep the kick-off distance to a minimum (approximately. 2 - 3 feet from the wall).
7. DO NOT allow a climber to climb beyond the wall top. A climber should never climb higher than chest
high to the top of the wall.
8. The weight range for the wall is 40-250lbs. Minimum height 42”. It is possible for a child weighing
less than 40 lbs. to climb the wall as long as the climbing harness is properly fitted and a pull-down
rope is attached to the child's harness so the child can be pulled down after the climb if needed.
9. Do not allow someone to sit and bounce on the belay cable when finished rappelling. Have them
rappel onto their feet.
10. Climbing helmets are not required however they are provided and we strongly recommend their use.
Entertainment Tips
Your portable climbing wall is a fun attraction and will draw attention. Use this unique feature to book
company picnics, birthday parties, corporate promotion events, special events, public attractions, fairs
and festivals. The wall can be equipped for corporate advertising to generate additional revenue. The
belay coach should be someone who enjoys people and has a positive rapport with people making your
attraction fun for the entire family. Portable climbing walls are not necessarily designed for climbers –
instead they are more for those who have always wanted to give rock climbing a try. The portable
climbing wall is a product designed for fun!
Accident Report Form
We anticipate that you never will have to use this form, however in the unlikely event of an accident,
please email the following details to Extec Gear as soon as possible:
 Date of accident
 Was the person intoxicated or under the
 Place of accident

 Time of accident

 Name of injured person
 Address of injured person

 Phone of injured person
 Was 911 called (attach a coy of the report)
 Extent and nature of injury
 What caused the accident


influence of alcohol or drugs
Were Extec Gear’s safety rules posted
Was your staff properly trained in the operation
of the wall
Was the wall shut down for inspection after the
accident occurred
Name of person signing the report
Signature
PAGE 11 OF 16
ENTEC PCW071406
Inspections and Preventive Maintenance
FORM-CWINSP1 (“ 24’ 3-Autobelay portable Climbing Wall Set-up, Preventative Maintenance and
Inspection Log”, included with this document) should be completed prior to each day’s use of the portable
climbing wall. Keep these records for at least one year or longer (check your State and local records
requirements to assure compliance).
With all parts supplied from manufacturers other than Extec Gear (i.e. harnesses, Carabiner's, swivels)
make sure to read and understand their respective warnings and instructions.
WEAR DATED ITEMS
Below is a list of wear-dated items along with suggested guidelines for replacement. Please contact Extec
Gear for replacements.
Replace annually or sooner:
 Cables. Replace annually or every 10,000 cycles whichever comes first regardless of condition.
Replace if cable or crimps show signs of deterioration or being frayed, rusted or kinked.
Replace when any malfunction or damage noted:
 Carabineers, swivels, pulleys, harnesses and handholds. These items deteriorate progressively with use.
Metal-to-metal contact, surface damage, cuts, tears, corrosion, loose stitching, mechanical wear or
impairment is easily observed. Replace when any malfunction, impairment or damage noted.
 Harnesses - Replace when the fabric has visible cuts, tears, abrasion and/or damage caused by use,
heat chemicals etc. The stitching is cut, tom worn or loose threads. Or, when the buckles are not
functioning properly
Trouble Shooting Guide
Wall won't raise. If NO:
 Is the hydraulic motor getting power?
o Check battery voltage and connections.
o Check hand control connections.
If YES:
 Has the tie downs been removed.
 Check hydraulic fluid level.
Wall won't go down.
 Is the hydraulic motor getting power? IF NO:
o Check battery voltage and connections.
o Check hand control connections.
IF YES
 Make sure wall is raised of the ground
Auto belay cable will not retract when wall is vertical.
 Check air tank pressure is between 35-40 psig.
 Check for air leaks using soapy water
 Check cable routing for obstructions
 Check that pulleys are rotating freely
 Check ram alignment
PAGE 12 OF 16
FORM-CWINSP1
ENTEC
PCW071406
24’ 3-Autobelay portable Climbing Wall
Set-up, Preventative Maintenance and Inspection Log
FAIL
PASS
Inspection Date:
Inspected by:
Trailer VIN #:
Last Cable Change:
Owner:
BEFORE TAKING TRAILER ON ROAD:
Verify wall battery disconnect is set to DISCONNECTED.
Check tires for proper pressure. Use 12V wall air compressor or other air source to adjust.
Check axles for proper alignment and grease. Adjust or add grease as needed.
Connect trailer to tow vehicle. Verify trailer lighting working correctly. Replace any failed bulbs.
Verify electrical breaks are working correctly. Adjust as needed.
BEFORE RAISING WALL AT EACH SET-UP:
Set wall battery disconnect to CONNECTED.
Check auto-belay (“A-B”) cable. Lock out for replacement if frayed or rusted.
Check both A-B cable ends. Lock out for replacement if any broken strands by crimp or if any crimp loose.
Check A-B cables are tracking along pulleys without restriction. Lock out for maintenance if not.
Check A-B cables-to-frame back-up loop clamp to verify tight attachment. Adjust or lock out for maintenance if not.
Inspect hydraulic cylinders for rusting. Clean any rust with fine steel wool then wipe down with clean cloth. Lock out if excessive pitting.
Inspect pulleys to verify proper function. Lock out for maintenance if worn or not functioning properly.
Inspect trailer frame and pulley beams for proper attachment and weld condition. Lock out for maintenance if any cracks or concerns.
Inspect hydraulic hoses for road damage and proper function. Minor weepage permitted. If observable leaks, lock out for maintenance.
Verify hydraulic fittings are tight. Tighten any loose fittings/connections.
Turn ON switch for climber route completion horn.
AFTER RAISING WALL AND BEFORE USE AT EACH SET-UP:
Verify there is no A-B cable slack in front or behind the wall.
“Pump” each A-B system 3-4 times to remove any air pockets by raising cable 3-4 feet and then pulling down on it.
Verify A-B cables operate without excess slack. Test cable to ensure proper A-B function. Lock out any system that fails.
Check A-B cable climber chest harness. Repair, replace or lock out if webbing frayed or tightening ball missing or frayed.
Verify that the hydraulic oil level is at least 3 inches in the tank and not over 6” deep with all cables at the top.
Verify hydraulic oil level is between the upper and lower marks on the reservoir with all cables in ready position.
Verify harness stitching. If stitching is pulling apart label “DO NOT USE – REPAIR” and place in storage away from usable harnesses.
Verify Air Tank Pressure Gauge reads between 35-40 psig. Use wall’s 12V air compressor to adjust as needed.
Install & inspect auto-locking carabineers. If not positively locking, sticking open or showing wear - replace immediately or lock out.
Inspect cable swivels and verify each turns freely.
Inspect handholds on the wall to insure they are tight. If any of the handholds spin or are loose, tighten or replace them.
FAILURE CORRECTIVE ACTIONS TAKEN (detail all corrections to failures noted above):
PAGE 13 OF 16
ENTEC PCW071406
AUTO-BELAY CABLE REPLACMENT
PACK
Part #06-001
While failures on a well-maintained auto-belay climbing wall are very rare, the primary fail points
reported in the national database “RideAccidents.com” relate to the cable-to-user and cable-to-wall
connections. The Onsite Challenge update pack is designed not only to meet OEM standards, but to exceed
them by backing up these potential fail points based on the design and structural criteria stated below:
REPLACEMENT CABLE: Each pack contains 80 feet of prime quality 0.250” diameter, 4,200-lb test, 7x19
galvanized aircraft cable, swages and thimbles.
USER END. The user (climber) end is
threaded into a roller bearing swivel through
a galvanized wire rope thimble and into an
aluminum swage sleeve forced against the
thimble to tightly hold the cable. The swage
is then crimped at three points with in excess
of 2-tons force to securely connect the end.
This holding force of this swage exceeds the
4,200 lb test of the cable. Extec Gear goes
significantly further, using another 2-ton, 3point crimped swage immediately adjacent
to the first more than doubling the holding
power. Twenty-one inches of cable extends
beyond these first two swages and a third 3ton, 3-point crimp is installed on the end of
this cable. The combined holding force of
these 3 swages exceeds the 4,200-lb test of
the cable by 150%.
A 1-1/4” I.D. rubber tube is slipped over the
swages and cable to protect the user’s hands when climbing or lowering. This tube can be quickly slipped up the
cable and out of the way for inspection of the fittings underneath.
CABLE-TO-USER BACKUP. The cable end, swages, thimble, swivel, locking carabineer and user’s harness
are backed-up using a loop of 1,500-lb test tubular webbing that a slip ball has been added and the
webbing connected in one flat, non-twisted loop using a non-slip webbing knot. The webbing is attached
to the belay cable immediately above the 3rd swage using a modified self-tightening prussic knot. Any
downward pressure causes the knot to tighten around the cable and hold firm. The 3 layers of swages
each act as a positive barrier to further prevent slippage. This loop is placed over the user’s head and
under his/her shoulders then loosely tightened using the slip ball the webbing is treaded through. In the
event of a catastrophic failure of any downstream component, this chest harness will handle the load
while the user is safely lowered to the ground. At all other times the chest harness handles no load and
does not interfere with mobile climbing wall use.
 SAFETY FACTOR: Based upon a 250 lb person falling a maximum 2-feet, the impact force of a
catastrophic failure of any part protected by the Cable-to-User Backup is 500-lbs. This provides a 3X
safety factor based upon the 1,500-lb webbing test strength.
PAGE 14 OF 16
ENTEC PCW071406
 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.
 USE: To use the CABLE-TO-USER BACKUP simply have each climber place their head and arms through
the webbing loop and tighten loosely under their armpits using the tie-ball. Reverse the process to
remove at the end of each climber’s turn.
WALL END. The wall (auto-belay) end of the 4,200-lb test aircraft cable is attached to the integral wall
anchor through a galvanized wire rope thimble and into an aluminum swage sleeve forced against the
thimble to tightly hold the cable. The swage is then crimped at four points using a portable long-handle
swage-crimping tool capable of providing in excess of 2-tons force on the swage to securely connect the
end. The holding force of this swage exceeds the 4,200-lb test of the cable. Again, this alone conforms to
most OEM specifications. The Onsite Challenge system goes significantly further, using another 2-ton, 4point crimped swage against the first more than doubling the holding power. A final malleable
galvanized wire rope clips is installed after the 2nd swage to complete the connection. The combined
holding force of these 3 swages exceeds the 4,200-lb test of the cable by 100% or more.
CABLE-TO-WALL BACKUP. The wall end cable attachment is backed up using a 3’ piece of 4,200-lb test
aircraft cable by looping the cable over a horizontal wall support beam near the integral wall anchor.
Both ends of the backup cable are attached to the belay cable using two (2) malleable galvanized wire
rope clips so that there is normally a slight amount of play in the back-up loop.
 SAFETY FACTOR: The holding power of the Cable-to-Wall Backup matches the original integral wall
anchor provided the double cable is double looped around a support beam equal to that supporting
the integral wall anchor.
 NOTE: The Cable-to-Wall Backup is a back up of the primary Cable-to-Wall connection provided on
a mobile climbing wall system. It is not intended to and should never be used by itself. The components
should be replaced immediately if wear is noted and at each cable replacement.
CABLE REPLACEMENT
Disconnect the user end of the old cable and connect the user end of the new cable to it. Cut the end off the
old cable and use electrical tape to tape the wall end of the new cable end-to-end to the user end of the
old cable. Disconnect the wall end of the old cable and carefully pull the new cable into place by pulling
out the old cable. Once the cable is in place, complete the “WALL END” efforts listed above. Cut off any
excess cable (if long enough, this can be used in the “CABLE-TO-WALL BACKUP” also listed above).
INSPECTION
Before each use, inspect each auto-belay cable system. Lock out any cable for replacement if it shows
kinks, frays or rust. Lock out any cable for replacement if the cable end shows broken strands by a
swage or if any swage is loose. Lock out for maintenance any cable that is not tracking along pulleys
without restriction. Lock out for maintenance any cable that the “CABLE-TO-WALL BACKUP” shows kinks,
frays, rust, loose fittings or improper attachment. Lock out for maintenance any cable that the “CABLETO-USER BACKUP” shows frays, loose webbing knot or improper attachment.
PAGE 15 OF 16
ENTEC PCW071406
Manufacturer Certification
AUTO-BELAY CABLE UPDATE PACK Part #06-001
Quantity: |______|
Manufacture Date: |___|___|20___|
Design Criteria
REPLACEMENT CABLE: 80-feet, 0.250-inch diameter, 4,200-lb test, 7x19 galvanized aircraft cable.
USER END: Roller bearing swivel, galvanized wire rope thimble, 3 aluminum swage sleeves (3 point crimp, 3+
tons force). Total holding force: 7+ tons. Slip tube installed on end: 1-1/4” I.D. x 24” rubber tube.
CABLE-TO-USER BACKUP. 1,500-lb test tubular webbing w/slip ball. Non-twisted loop w/non-slip
webbing knot attached w/modified self-tightening prussic knot.
WALL END. Galvanized wire rope thimble, 2 aluminum swage sleeves (4 point crimp, 2+ tons force), and
1 malleable galvanized wire rope clip. Total holding force: 5+ tons.
CABLE-TO-WALL BACKUP. 3-ft, 0.250-inch diameter, 4,200-lb test, 7x19 galvanized aircraft cable, 2
malleable galvanized wire rope clips.
Manufacturer Certification: ___________________________________________
Installer Certification
Quantity: |______|
Installation Date: |___|___|20___|
Installer Certification: ___________________________________________
Entex Gear
7591 Renken Rd
Worden, IL 62097
Phone: (618) 580-3742
Webpage: www.etgear.com
Email: sales@etgear.com
PAGE 16 OF 16