How to Install Zip Line

INSTALLATION & SAFETY HANDBOOKCONTACT ZIPLINEGEAR 903 NW F ST. GRANTS PASS, OR 97526 888.476.3701 ZIPLINEGEAR.COM • INFO@ZIPLINEGEAR.COM ACTIVITIES INVOLVING THE INSTALLATION AND USE OF ZIP LINES, TROLLEYS, HARNESSES, BRAKING SYSTEMS AND OTHER RELATED GEAR ARE POTENTIALLY HAZARDOUS BY THEIR VERY NATURE. DISCLAIMERS ANYONE PURCHASING, INSTALLING OR USING EQUIPMENT FROM ZIPLINEGEAR MUST: READ ALL INSTRUCTIONS REGARDING ITS CORRECT INSTALLATION AND SAFE USE; ENSURE PROPER OVERSIGHT, SUPERVISION AND INSTRUCTION (INCLUDING THE USE OF APPROPRIATE SAFETY EQUIPMENT) FOR THEMSELVES AND OTHERS USING THE EQUIPMENT; ENSURE ALL EQUIPMENT IS PROPERLY MAINTAINED AND INSPECTED FOR DAMAGE OR WEAR PRIOR TO EACH USE; ASSUME ALL RISKS AND ACCEPT FULL RESPONSIBILITY FOR ANY DAMAGE OR INJURY, INCLUDING DEATH, THAT MAY ARISE FROM ITS USE. ALL INSTRUCTIONS IN THIS MATERIAL ARE EXTREMELY IMPORTANT. OVERLOOKING OR IGNORING ANY OF THE FOLLOWING INSTRUCTIONS COULD RESULT IN RIDER INJURY OR DEATH. PLEASE TAKE ALL THESE INSTRUCTIONS SERIOUSLY. !! WARNING !! DO NOT ATTEMPT TO RIDE YOUR ZIP LINE WITHOUT FIRST TESTING. !! WARNING !! DO NOT ATTEMPT INSTALLATION OR USE OF ZIP LINE EQUIPMENT WHILE UNDER THE INFLUENCE OF INTOXICANTS OR WHILE DRINKING ALCOHOL, SINCE THESE IMPAIR JUDGMENT AND REASONING, THEREBY MAKING INSTALLATION MISTAKES MORE LIKELY.TABLE OF CONTENTS SECTION ONE – CONCEPTS SITE SELECTION ANCHORS CABLE SLOPE & SAG SLOPE & SAG WORKSHEET INSTALLATION EXAMPLE SAMPLE WORKSHEET SECTION TWO – CABLE INSTALLATION CHETCO & 1/4” CABLE KITS ROGUE SERIES OR 5/16” & 3/8” CABLE KITS ROGUE PRO KIT TENSIONING KIT SLEADD KITS TENSIONING SLEADD KITS ALTERNATE TERMINATION STYLES SECTION THREE – COMPONENT ASSEMBLY TREE SAVERS STOP BLOCK RIDING GEAR SEAT HARNESS BUNGEE BRAKE SECTION FOUR – INSPECTION CABLE WEIGHT TEST STOP BLOCK RIDING GEAR TROLLEY CARABINERS LANYARD HARNESS BUNGEE BRAKE TEST BUNGEE BRAKE INSPECTION & MAINTENANCE SECTION FIVE – OPERATION 4 CONCEPTS 1–CONCEPTS THE SITE SELECTION PROCESS MUST BE PERFORMED BY A COMPETENT ADULT AFTER ALL INSTRUCTIONAL MATERIAL HAS BEEN COMPLETELY REVIEWED AND UNDERSTOOD. DETERMINE THE MOST ACCESSIBLE LOCATIONS FOR YOUR RIDER TO LAUNCH AND DISMOUNT. THIS WILL DICTATE THE INSTALLATION OF YOUR ZIP LINE. DEPENDING ON THE TERRAIN, THE DISMOUNT LOCATION MAY BE AT THE END OF THE ZIP LINE RATHER THAN THE LOW POINT OF THE CABLE. A PLATFORM MAY BE REQUIRED FOR ACCESS. CLEAR THE ZIP LINE AVENUE OF OBSTRUCTIONS AT LEAST 7 FT. BELOW AND 5 FT. ON BOTH SIDES OF THE ZIP LINE. REMOVE LARGE ROCKS, LOGS, BRANCHES, SHARP OBJECTS, AND OTHER POTENTIAL HAZARDS. SAFETY RIDING GEAR IS REQUIRED FOR ANY HEIGHT AND TERRAIN WHERE A FALL COULD RESULT IN INJURY. SITE SELECTION LAUNCH LOW POINT END CONCEPTS5 CONCEPTS 1–CONCEPTS ANCHORS DID YOU KNOW? A TYPICAL ZIP LINE CABLE CAN APPLY 800 TO 3,000 POUNDS OF HORIZONTAL FORCE TO AN ANCHOR WHEN LOADED. DO NOT USE BUILDINGS OR PLAYGROUND STRUCTURES (UNLESS SPECIFICALLY BUILT FOR ZIP LINES), LIVE POWER/ TELEPHONE POLES, DEAD TREES OR STUMPS, TREES WITH ROT, DISEASE, STRUCTURAL CRACKS, EXCESSIVE LEAN, EXPOSED ROOTS, OR TREES IN BOGGY, WET, SANDY, LOOSE SOIL. THIS IS ONLY A PARTIAL LIST. YOU MUST USE YOUR GOOD JUDGMENT IN DETERMINING WHAT IS NOT AN APPROPRIATE ANCHOR POINT. IF IN DOUBT, CALL US TO DISCUSS. TREES TREE TRUNKS MUST HAVE A 12-INCH DIAMETER , MINIMUM, AT THE ATTACHMENT POINT. DO NOT ATTACH TO ANY LIMBS/BRANCHES OTHER THAN A CENTRAL TRUNK. POSTS WOOD POSTS MUST BE 12” DIAMETER, MINIMUM. POSTS MUST BE SUNK 4 FT. IN GROUND, OR 10% OF POST LENGTH PLUS 2 FT. (WHICHEVER IS GREATER). SECURE WITH CONCRETE 6 INCHES THICK AROUND POST. SOIL MEDIA SUCH AS SAND, ROCK OR HIGH GROUND WATER ENVIRONMENTS MAY REQUIRE ALTERNATIVE INSTALLATION TECHNIQUES AND CONSULTATION WITH AN ENGINEER. GUY CABLES AND GROUND ANCHORS >12” 6” 4' POSTS WITH GUY CABLES AND GROUND ANCHOR POSTS MUST BE 8 INCHES DIAMETER, MINIMUM . CABLE ATTACHMENT MUST BE 12 INCHES FROM TOP OF POLE, MINIMUM, AND AS CLOSE AS POSSIBLE TO ZIP LINE ATTACHMENT POINT.6 CONCEPTS 1–CONCEPTS LENGTH EQUAL TO OR GREATER THAN HEIGHT INSTALL GUY ANCHOR POST AT A DISTANCE EQUAL TO OR GREATER THAN ATTACHMENT HEIGHT. GROUND ANCHOR POSTS MUST BE SUNK 4 FT. IN GROUND, OR 10% OF POST LENGTH PLUS 2 FT. (WHICHEVER IS GREATER). SECURE WITH CONCRETE 6 INCHES THICK AROUND POST. SOIL MEDIA SUCH AS SAND, ROCK OR HIGH GROUND WATER ENVIRONMENTS MAY REQUIRE ALTERNATIVE INSTALLATION TECHNIQUES AND CONSULTATION WITH AN ENGINEER. MEASURING TAPE LASER OR SIGHT LEVEL LADDER CLEARANCE IT IS RECOMMENDED THAT THE ZIP LINE MAINTAIN AT LEAST A 7 FT. CLEARANCE OVER THE ENTIRETY OF THE ZIP LINE AVENUE WHILE SUPPORTING THE HEAVIEST RIDERS. THE FOLLOWING TOOLS ARE RECOMMENDED FOR MEASURING ELEVATION CHANGE OF YOUR ZIP LINE SITE. HELPFUL HINT: WE RECOMMEND FINDING A LANDSCAPE WITH A NATURAL SLOPE OF 3% TO 6%, (A 3 FT. TO 6 FT. OF DROP PER 100 FT.). GROUND ANCHOR GUY ANCHOR7 CONCEPTS 1–CONCEPTS CABLE SAG CABLE TENSION IS MEASURED BY CABLE SAG: • THE CABLE, WHEN BEARING A TEST WEIGHT, SHOULD SAG BELOW THE END WHERE CABLE IS ATTACHED. • THE SAG NEEDS TO BE APPROXIMATELY 2% OF ZIP LINE’S TOTAL LENGTH. (2 FT. PER 100 FT. OF CABLE ) • THE SAG IS MEASURED AT THE CABLE’S LOWEST POINT. CABLE SLOPE & SAG !! WARNING !! DO NOT ATTEMPT TO RIDE YOUR ZIP LINE WITHOUT FIRST TESTING. THE MAXIMUM ALLOWABLE SLOPE IS 3% (3 FT. DROP PER 100 FT. OF DISTANCE) FOR ZIP LINES THAT WILL NOT UTILIZE A BUNGEE BRAKE (A STOP BLOCK IS NOT A BRAKING SYSTEM). THE MAXIMUM ALLOWABLE SLOPE IS 6% (6 FT. DROP PER 100 FT. OF DISTANCE) FOR ZIPLINES THAT UTILIZE A BUNGEE BRAKE. CABLE SLOPE !! WARNING !! ZIP LINE MUST NEVER EXCEED 6% (6 FT. DROP PER 100 FT. OF DISTANCE) RIDING SLOPE. HIGH SPEED COLLISION WITH END POINT MAY CAUSE INJURY OR DEATH.8 CONCEPTS 1–CONCEPTS 4. MEASURE AND CALCULATE ELEVATION CHANGE. IF GROUND IS LEVEL, ENTER “0” IN BOX 4C . IF NOT, USE A SIGHT LEVEL AND HAVE A FRIEND ASSIST IN MEASURING. DETERMINE YOUR SIGHTING HEIGHT AND ENTER IT IN BOX “4B” . CABLE SLOPE & SAG WORKSHEET 1. MEASURE THE DISTANCE BETWEEN START AND END ANCHORS. USING “FEET” ENTER YOUR MEASUREMENT IN BOX 1 . THIS WILL BE YOUR LENGTH. (ROUND UP TO NEAREST FT.) USE THIS WORKSHEET TO HELP SET UP YOUR ZIPLINE. BY USING THESE STEPS YOU WILL BE ABLE TO DETERMINE THE LENGTH, SLOPE, SAG, ELEVATION CHANGE (IF ANY) IN YOUR LANDSCAPE AND YOUR STARTING AND ENDING ANCHOR. 2. CALCULATE THE SLOPE OF THE ZIP LINE AND ENTER IN BOX 2 . a. MULTIPLY BOX 1 BY .03 IF YOU ONLY HAVE A STOP BLOCK b. MULTIPLY BOX 1 BY .06 IF YOU HAVE A BUNGEE BRAKE 3. CALCULATE THE SAG. a. MULTIPLY BOX 1 BY .02 AND ENTER THE ANSWER IN BOX 3 . 5. DETERMINE YOUR ENDING ANCHOR POINT HEIGHT BY ADDING BOX 3 PLUS 7 FT . AND ENTER THE ANSWER IN BOX 5 . THIS IS THE HEIGHT OF YOUR ENDING ANCHOR POINT. 6. TO DETERMINE THE HEIGHT OF YOUR STARTING ANCHOR POINT, ADD BOX 2 AND BOX 5 TOGETHER THEN SUBTRACT BOX 4C. ENTER THE ANSWER IN BOX 6 . THIS IS THE HEIGHT OF YOUR STARTING ANCHOR POINT. 4A=END ANCHOR LEVEL MARK 4B=SIGHT HEIGHT LEVEL LINE OF SIGHT GROUND LEVEL OF END ANCHOR GROUND LEVEL OF STARTING ANCHOR 4C=ELEVATION CHANGE START ANCHOR END ANCHOR SIGHT A LEVEL LINE TO YOUR END ANCHOR THROUGH YOUR SIGHT LEVEL. TILT SIGHT LEVEL UP OR DOWN UNTIL BUBBLE ALIGNS WITH CENTER CROSSHAIRS. FIND A LEVEL LINE AND HAVE YOUR FRIEND MARK THE END ANCHOR. MEASURE THE HEIGHT OF THE MARK FROM THE GROUND AND ENTER IN BOX “4A”. A-B=C (ELEVATION CHANGE) – NOT TO BE CONFUSED WITH CABLE SLOPE. HELPFUL HINT: AS AN ALTERNATIVE TO A SIGHT LEVEL YOU CAN USE AN ALTIMETER APP.9 CONCEPTS 1–CONCEPTS ZIP LINE SLOPE = ZIP LINE SAG = ENDING ANCHOR HEIGHT STARTING ANCHOR HEIGHT END LEVEL MARK BOX 3 BOX 4C BOX 2 BOX 5 A-B= CHANGE BOX 4C BOX 5 BOX 6 DISTANCE BETWEEN ANCHORS IN FEET BOX 1 X .03 OR .06 BOX 1 X .02 START SIGHT HEIGHT END ANCHOR HEIGHT START ANCHOR HEIGHT THE DISTANCE FROM START TO END ANCHORS = LENGTH THE AMOUNT OF DROP FROM YOUR START ANCHOR TO YOUR END ANCHOR = SLOPE BOX 2 BOX 1 BOX 3 BOX 4 BOX 5 BOX 6 LENGTH = THE AMOUNT THE ZIPLINE DROPS WHEN A RIDER’S WEIGHT IS ADDED = SAG ELEVATION CHANGE = A B C 7 FEET – – + + = = = SAG10 CONCEPTS 1–CONCEPTS BROCK’S BACKYARD IS PERFECT FOR A ZIP LINE. HE ORDERED A 200-FT LINE AND IN ORDER TO INSTALL IT, HE NEEDS TO FIGURE OUT WHERE TO ANCHOR THE CABLE ON EACH OF HIS TWO TREES. SO HERE’S WHAT HE DID. FIRST, BROCK READ THROUGH THE ENTIRE MANUAL THE EVENING BEFORE HE PLANNED ON SETTING UP HIS ZIP LINE. THE NEXT DAY HE PACED OFF THE DISTANCE TO MAKE SURE HE KNOWS THE EXACT DISTANCE. THE DISTANCE IS 180-FT. HE FILLS IN BOX 1 = 180 NEXT, HE FIGURED OUT THE AMOUNT OF SLOPE HE WILL NEED. SINCE HE PURCHASED A ZIP LINE THAT ONLY INCLUDED A STOP BLOCK , HIS CALCULATIONS WILL BE FOR A 3% SLOPE. WHIPPING OUT HIS SMART PHONE HE MULTIPLIES 180 X 0.03 AND GETS 5.4 , WHICH HE ROUNDS TO THE NEAREST WHOLE NUMBER AND ENTERS 5 IN BOX 2. USING HIS LENGTH OF 180 FROM BOX 1 HE MULTIPLIES IT BY 0.02 . HIS ANSWER WAS 3.6 WHICH HE ROUNDS TO THE NEAREST WHOLE NUMBER 4 AND ENTERS IT INTO BOX 3 . TO FIGURE OUT HOW MUCH HIS YARD ELEVATION CHANGE IS BETWEEN THE TWO ANCHOR POINTS HE ORDERED A SIGHT LEVEL. HE IS SIX FEET TALL , SO HE PENCILS 6 IN BOX 4B , NEXT HE LOOKS THROUGH THE SITE LEVEL UNTIL THE BUBBLE LINES UP WITH THE CENTER CROSSHAIRS ON THE END ANCHOR TREE. THERE HAPPENS TO BE A NICE BRANCH THAT HE CAN IDENTIFY EASILY WHICH WILL BE WHAT HE WILL USE FOR A MARK. HE HIKES TO THE END ANCHOR TREE, SETS A LADDER AGAINST THE TREE AND CLIMBS UP THE LADDER WITH A TAPE MEASURE. HE MEASURES FROM THE GROUND TO HIS MARK, WHICH WAS A NICE BRANCH. THE TAPE MEASURES 14-FT . HE PENCILS IN 14 IN BOX 4A AND THEN CALCULATES WHAT BOX 4C IS. [14 - 6 = 8] AND HE PENCILS 8 IN BOX 4C . JUST FOR THE FUN OF DOUBLE CHECKING HIS FIGURES, HE DOWNLOADS AN ALTIMETER APP ON HIS SMART PHONE. STANDING AT THE BASE OF THE START ANCHOR TREE HE TAKES THE FIRST MEASURE - MENT WHICH IS 1743 FT. FROM SEA LEVEL. HE JOTS DOWN THAT NUMBER WHILE STRIDING OVER TO THE END ANCHOR TREE. TAKING ANOTHER MEASUREMENT ON HIS APP AT THE BASE OF THE END AN - CHOR TREE, THE READING SHOWS 1735 FT. FROM SEA LEVEL WHICH HE PENCILS BELOW THE FIRST FIGURE. CALCULATING THE DIFFERENCE BETWEEN THESE TWO MEASUREMENTS WILL BE THE ELEVATION CHANGE BETWEEN HIS TWO ANCHOR POINTS AND THIS CAN BE ENTERED INTO BOX 4C . WITH ALL OF HIS PHYSICAL MEASUREMENTS COMPLETED, HE SITS DOWN ON HIS BACKYARD DECK AND FILLS OUT THE REST OF HIS WORKSHEET. TO CALCULATE HIS ENDING ANCHOR HEIGHT [ BOX 3 + 7 FEET = BOX 5] 4 + 7 FEET = 11 FOR THE END ANCHOR HEIGHT. TO CALCULATE HIS STARTING ANCHOR HEIGHT [ BOX 2 + BOX 5 ] – [ BOX 4C ] = [ BOX 6 ] [5 + 11 = 16]– [8] = 8 FOR THE START ANCHOR HEIGHT. NOW BROCK IS READY TO MOVE ON TO HIS NEXT STEP. INSTALLATION EXAMPLE GO TO NEXT STEPS CABLE INSTALLATION 2 BOX 2 BOX 1 BOX 3 BOX 4 BOX 5 BOX 6 1743ft.- 1735ft.= 8ft.11 CONCEPTS 1–CONCEPTS SAMPLE WORKSHEET ZIP LINE SLOPE = ZIP LINE SAG = ENDING ANCHOR HEIGHT STARTING ANCHOR HEIGHT END LEVEL MARK BOX 3 BOX 4C BOX 2 BOX 5 A-B= CHANGE BOX 4C BOX 5 BOX 6 DISTANCE BETWEEN ANCHORS IN FEET BOX 1 X .03 OR .06 BOX 1 X .02 START SIGHT HEIGHT END ANCHOR HEIGHT START ANCHOR HEIGHT THE DISTANCE FROM START TO END ANCHORS = LENGTH THE AMOUNT OF DROP FROM YOUR START ANCHOR TO YOUR END ANCHOR = SLOPE BOX 2 BOX 1 BOX 3 BOX 4 BOX 5 BOX 6 LENGTH = THE AMOUNT THE ZIPLINE DROPS WHEN A RIDER’S WEIGHT IS ADDED = SAG ELEVATION CHANGE = A B C 7 FEET – – + + = = = 6 8 4 5 180 4 11 5 8 11 8 14 SAG13 INSTALLATION 2–CABLE INSTALLATION THE MAXIMUM ALLOWABLE SLOPE IS 3% (3 FT. DROP PER 100 FT. OF DISTANCE) FOR ZIP LINES THAT WILL NOT UTILIZE A BUNGEE BRAKE (A STOP BLOCK IS NOT A BRAKING SYSTEM). THE MAXIMUM ALLOWABLE SLOPE IS 6% (6 FT. DROP PER 100 FT. OF DISTANCE) FOR ZIPLINES THAT UTILIZE A BUNGEE BRAKE. CHETCO & 1/4’’ CABLE KITS 1 UNSCREW NUTS OR PULL COTTER PINS FROM BOLTS. DRAW BOLTS FROM TURNBUCKLE JAWS. CABLE INSTALLATION !! WARNING !! ZIP LINE MUST NEVER EXCEED 6% RIDING SLOPE. HIGH SPEED COLLISION WITH END POINT MAY CAUSE INJURY OR DEATH.14 INSTALLATION 2–CABLE INSTALLATION ANCHOR ANCHOR CABLE SLING TROLLEY CABLE CABLE CLAMPS TURNBUCKLE BACK-UP TURNBUCKLE 2 ASSEMBLE TURNBUCKLE BY SCREWING SHAFTS UNTIL EXTENDED AS SHOWN. R WITH R, L WITH L (REVERSE THREADS). 3 WRAP CABLE SLING AROUND ANCHOR (FOR TREE SAVERS SEE SECTION 3). 4 PLACE LOOP ENDS OF SLING INTO TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. 5 PLACE THIMBLE END OF MAIN CABLE INTO OTHER TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN.15 INSTALLATION 2–CABLE INSTALLATION 6 THREAD CABLE THROUGH CHETCO TROLLEY AND A CABLE CLAMP. WRAP CABLE AROUND ANCHOR AND THREAD BACK THROUGH CLAMP. 7 TENSION ZIP LINE CABLE BY PULLING ON DEAD END OF CABLE OR BY USING TEN - SIONER KIT (ADD-ON ITEM). 8 PULL CABLE TAUT. U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE. TIGHTEN CABLE CLAMPS MODERATELY PAST SNUG (≈ 15 FT. LBS) 1-2 INCHES APART. U-BOLT DEAD END OF CABLE !! WARNING !! NEVER ATTEMPT TO RIDE OR APPLY WEIGHT TO ZIP LINE BEFORE WEIGHT TEST OR WHILE TENSION REMAINS ON TENSIONING WINCH.16 INSTALLATION 2–CABLE INSTALLATION 10 INSTALL TURNBUCKLE BACK-UP CABLES. THREAD BOTH ENDS OF CABLE SECTION THROUGH CABLE EYES AND SECURE WITH CABLE CLAMPS. HELPFUL HINT: IN CHETCO KIT, THE TURNBUCKLE BACK-UP CABLES ARE 5/16’’, TORQUE THE CABLE CLAMPS ON THE BACK-UP CABLES TO 30 FT.LBS. 9 CRANK TURNBUCKLE IF CABLE NEEDS MORE TENSION. ZIP LINE LENGTH CLAMP TORQUE UP TO 200’ 15 LBS. UP TO 500’ 30 LBS. UP TO 1000’ 45 LBS. RECCOMENDED CABLE SIZE 1/4 ‘‘ 5/16 ‘‘ 3/8 ‘‘ GO TO NEXT STEPS COMPONENT ASSEMBLY 317 INSTALLATION 2–CABLE INSTALLATION ROGUE SERIES OR – 5/16’’ & 3/8” CABLE KITS 2 ASSEMBLE TURNBUCKLE BY SCREWING SHAFTS UNTIL EXTENDED AS SHOWN. R WITH R, L WITH L (REVERSE THREADS). 3 WRAP CABLE SLING AROUND ANCHOR (FOR TREE SAVERS SEE SECTION 3). 4 PLACE LOOP ENDS OF SLING INTO TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. 1 UNSCREW NUTS OR PULL COTTER PINS FROM BOLTS. DRAW BOLTS FROM TURNBUCKLE JAWS. 18 INSTALLATION 2–CABLE INSTALLATION 6 ATTACH WINCH TO SECOND ANCHOR WITH LANYARD AND CABLE GRAB TO CABLE. TENSION ZIP LINE. (FOR TENSIONING KIT FLIP TO ROGUE- PRO INSTRUCTIONS) 7 WRAP CABLE SLING AROUND ANCHOR AT CALCULATED HEIGHT, CONNECT TURNBUCKLE TO CABLE SLING LOOPS AND SECURE WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. TURNBUCKLE BACK-UP TURNBUCKLE BACK-UP ANCHOR ANCHOR CABLE SLING CABLE SLING CABLE SLING LOOPS CABLE SLING LOOPS TURNBUCKLE BRAKE ANCHOR TROLLEY CABLE BRAKE BLOCK STOP BLOCK CABLE CLAMPS THIMBLE TURNBUCKLE BUNGEE BUNGEE BACKUP SLING 5 PLACE THIMBLE-END OF MAIN CABLE INTO OTHER TURNBUCKLE JAW. SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. 19 INSTALLATION 2–CABLE INSTALLATION 8 AFTER BOLTING THIMBLE INTO TURNBUCKLE, SECURE BOLT WITH NUT OR COTTER PIN. USE A WRENCH TO TIGHTEN NUT. USE PLIERS TO BEND COTTER PIN. THREAD MAIN CABLE FIRST THROUGH THREE CABLE CLAMPS, AROUND THIMBLE AND BACK THROUGH CABLE CLAMPS. THIMBLE 9 PULL CABLE TAUT. U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE. TIGHTEN CABLE CLAMPS MODERATELY PAST SNUG, FOR ROGUE SERIES OR 5/16” CABLE (≈ 30 FT. LBS), FOR 3/8” CABLE (≈ 45 FT. LBS) AT 1-2 INCHES APART. U-BOLT 3RD CLAMP DEAD END OF CABLE 10 INSTALL TURNBUCKLE BACK-UP CABLES. BACK-UP CABLE MUST THREAD THROUGH CABLE LOOPS ON BOTH SIDES. 11 IF USING A TENSIONING KIT, RELEASE TENSION AND TRANSFER LOAD TO MAIN ZIP LINE. !! WARNING !! NEVER ATTEMPT TO RIDE OR APPLY WEIGHT TO ZIP LINE WHILE TENSION REMAINS ON WINCH. GO TO NEXT STEPS COMPONENT ASSEMBLY 320 INSTALLATION 2–CABLE INSTALLATION ROGUE PRO KIT WRAP CABLE SLING AROUND ANCHOR. PULL UP TO DESIGNATED HEIGHT. TREE SAVER BLOCKS AT LEAST 1/2 OF ANCHOR DIAMETER CONNECT LOOPS OF CABLE SLING TO 9/16 QUICK LINK AT CALCULATED HEIGHT , CONNECT QUICK LINK TO LOOP OF MAIN CABLE. TIGHTEN QUICK LINK WITH WRENCH. DISTANCE BETWEEN QUICK LINK AND TREE MUST BE AT LEAST HALF THE TREE’S DIAMETER. IF THE CABLE SLING ISN’T LONG ENOUGH, CALL US AND ASK FOR A CUSTOM CABLE SLING. 1 UNROLL CABLE ACROSS CABLE AVENUE TO OPPOSITE ANCHOR. HOOK WINCH CABLE GRAB HANDLE DIRECTION SWITCH RATCHET SWITCH WINCH CABLE SHAFT LATCH JAW 221 INSTALLATION 2–CABLE INSTALLATION TO EXTEND TENSIONING KIT: PUT DIRECTION SWITCH INTO NEUTRAL. PUSH RATCHET SWITCH TO DISENGAGE GEAR WHILE PULLING OUT CABLE TO UNWIND. 1” U N D U N D U N D NEUTRAL POSITION PUSH RATCHET SWITCH DIRECTION SWITCH 3 TENSIONING KIT WRAP TENSIONER STRAP AROUND SECOND ANCHOR, ABOUT A FOOT OVER CALCULATED ZIP LINE HEIGHT, AND HOOK TENSIONER IN STRAP LOOPS. OPEN GRAB BY PUSHING SHAFT TOWARD JAW. ATTACH CABLE GRAB TO CABLE . 422 INSTALLATION 2–CABLE INSTALLATION CLOSE LATCH TO LOCK CABLE IN PLACE. 1” U N D U N D U N D UP POSITION SWITCH DIRECTION SWITCH TO “UP” (U). CRANK HANDLE TO TENSION UNTIL ZIP LINE CABLE IS LIFTED OFF GROUND TO APPROPRIATE HEIGHT. 1” U N D U N D U N D !! WARNING !! NEVER ATTEMPT TO TENSION ZIP LINE WHILE WINCH IS SWITCHED TO “DOWN” (D) POSITION. DIRECTION SWITCH 5 6 WRAP SECOND CABLE SLING AROUND ANCHOR AT CALCULATED HEIGHT, CONNECT TO THIMBLE AND 9/16 QUICK LINK. TIGHTEN QUICK LINK WITH WRENCH. 723 INSTALLATION 2–CABLE INSTALLATION THREAD CABLE THROUGH QUICK LINK, AROUND THIMBLE AND BACK ON ITSELF, PULLING TAUT. SECURE WITH CAMBLE CLAMPS. U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE AND THE SADDLE PRESS AGAINST LIVE END OF THE CABLE. U-BOLT SADDLE DEAD END OF CABLE LIVE END CLAMPS SHOULD BE SPACED 1 TO 2 INCHES APART AND MUST BE TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS). !! WARNING !! NEVER ATTEMPT TO RIDE OR APPLY WEIGHT TO ZIP LINE WHILE TENSION REMAINS ON WINCH. 1” U N D U N D U N D U N D DOWN POSITION RELEASE WINCH TENSION BY FLIPPING SWITCH TO “DOWN” (D) AND CRANKING THE HANDLE. 1” U N D U N D U N D 8 9 10 DIRECTION SWITCH24 INSTALLATION 2–CABLE INSTALLATION TENSION WILL TRANSFER TO MAIN CABLE AND TENSIONING KIT WILL HANG SLACK. REMOVE GRAB BY PUSHING FORWARD. REMOVE TENSIONING KIT AND STRAP. BUNGEE ANCHOR BUNGEE BRAKE SYSTEM STOP BLOCK BUNGEE BLOCK TROLLEY FIST GRIPS CLAMPS THIMBLE QUICK LINK QUICK LINK MAIN CABLE CABLE SLING TREE SAVER BLOCKS TREE SAVER BLOCKS CABLE SLING GO TO NEXT STEPS COMPONENT ASSEMBLY 325 INSTALLATION 2–CABLE INSTALLATION SLEADD KITS 1/2”, 11/16” AND 7/8” WRENCHES (INCLUDED) 3/16” HEX KEY (INCLUDED) GLOVES (NOT INCLUDED) THE CABLE SLING, TRI-LINK™ AND WINCH CAN BE INSTALLED ON EITHER END OF THE ZIP LINE. BE AWARE THAT THESE COMPONENTS WILL TAKE UP 3-4 FT. OF LENGTH; DECIDE WHICH END WILL BE MOST PRACTICAL FOR YOUR RIDERS. 150LX AND 250LX KITS THREAD CABLE SLING THROUGH CENTER HOLES OF 8 TREE-SAVER BLOCKS. WRAP CABLE SLING AROUND ANCHOR. PULL UP TO DESIGNATED HEIGHT. CREATE LOOP AT OPEN END OF CABLE SLING AND ADJUST SO LOOPS OF SLING MEET AT A DISTANCE HALF OF THE ANCHOR’S DIAMETER. CLAMP END OF CABLE SLING INTO SMALL LOOP USING THREE CABLE CLAMPS. CLAMPS SHOULD BE SPACED 1 TO 2 INCHES APART AND MUST BE TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS). U-BOLT OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE AND THE SADDLE PRESS AGAINST LIVE END OF THE CABLE. TREE SAVER BLOCKS AT LEAST 1/2 OF ANCHOR DIAMETER U-BOLT SADDLE DEAD END 26 INSTALLATION 2–CABLE INSTALLATION CONNECT CABLE SLING LOOPS USING A 9/16 QUICK LINK TO ATTACHMENT POINT LABELED ‘ANCHOR’ ON TRI-LINK™ MAKING SURE TO ORIENT TRI-LINK™ WITH ATTACHMENT POINT LABELED ‘MAIN’ ON TOP. TIGHTEN 9/16 QUICK LINK USING COMBINATION WRENCH. UNROLL CABLE ACROSS CABLE AVENUE TO OPPOSITE ANCHOR. CONNECT HOOK ON WINCH TO ATTACHMENT POINT LABELED ‘WINCH’ ON TRI-LINK™. TRI-LINK QUICK LINK HELPFUL HINT: USE PIPE OR BROOM HANDLE IN CENTER HOLE OF SPOOL TO MAKE UNWINDING EASIER.27 INSTALLATION 2–CABLE INSTALLATION AT LEAST 1/2 OF ANCHOR DIAMETER CLAMPS WRAP CABLE AROUND OPPOSITE ANCHOR AT DESIGNATED HEIGHT. PULL AS TIGHT AS POSSIBLE BY HAND, IDEALLY UNTIL THE ENTIRE LENGTH OF CABLE IS OFF THE GROUND. BE SURE TO WEAR GLOVES. HAVE A FRIEND SECURE CABLE IN PLACE AROUND ANCHOR WITH THREE CABLE CLAMPS. CLAMPS SHOULD BE SPACED 1 TO 2 INCHES APART AND MUST BE TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS). U-BOLT PORTION OF CLAMPS MUST PRESS AGAINST DEAD END OF CABLE AND THE SADDLE PORTION MUST PRESS AGAINST THE LIVE END OF THE CABLE. TROLLEY ASSEMBLY PLACE WHEELED PORTION OF TROLLEY OVER CABLE. SLIDE HANDLEBAR COLLAR UP INTO SIDE PLATES. INSERT TWO BOLTS THROUGH TROLLEY AND HANDLEBAR COLLAR. SECURE WITH NUTS. TIGHTEN HEX BOLTS MODERATELY TIGHT (≈20 FT. LBS) WITH PROVIDED WRENCHES. THREAD CABLE THROUGH CENTER HOLES OF 8 TREE-SAVER BLOCKS.28 INSTALLATION 2–CABLE INSTALLATION SWITCH DIRECTION SWITCH TO “UP” (U) POSITION. CRANK TO TENSION CABLE. WHEN ZIP LINE IS TIGHTENED TO DESIRED TENSION, CLAMP SHORT TRI-LINK™ CABLE TO MAIN CABLE IN FRONT OF WINCH USING FOUR FIST GRIPS. FIST GRIPS MUST BE SPACED 1 TO 2 INCHES APART AND TIGHTENED WITH A WRENCH MODERATELY PAST SNUG (≈30 FT. LBS). SWITCH DIRECTION SWITCH TO “DOWN” (D) POSITION. CRANK TO DETENSION WINCH. TENSIONING SLEADD KITS UP UP DOWN NEUTRAL UP UP DOWN DOWN NEUTRAL U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D U N D !! WARNING !! NEVER ATTEMPT TO TENSION ZIP LINE WHILE WINCH IS SWITCHED TO “DOWN” (D) POSITION. !! WARNING !! NEVER ATTEMPT TO RIDE OR APPLY WEIGHT TO ZIP LINE WHILE TENSION REMAINS ON WINCH. FIST GRIP29 INSTALLATION 2–CABLE INSTALLATION WINCH WILL HANG LOOSE WHEN ALL TENSION HAS TRANSFERRED TO TRI- LINK CABLE. OPTIONAL: USE INCLUDED HOOK-AND- EYE STRAP TO FASTEN WINCH HANDLE TO QUICK LINK. THIS WILL SECURE THE HANDLE FROM JOSTLING DURING ZIP LINE RIDES. HOOK & EYE STRAP GO TO NEXT STEPS COMPONENT ASSEMBLY 330 INSTALLATION 2–CABLE INSTALLATION EYEBOLTS ARE IDEAL FOR WOOD OR METAL POLES. THE EYEBOLT MUST BE LONG ENOUGH TO HAVE THREADS PROTRUDE THROUGH POLE, WASHER AND NUT, AND HAVE A PROPER STRENGTH RATING. A THIMBLE MUST BE USED TO CREATE THE TIGHT CONNECTION LOOP ON THE ZIPLINE CABLE. THE QUICK LINK IS OPTIONAL, BUT MUST HAVE THE STRENGTH RATING EQUAL TO OR GREATER THAN THE ZIPLINE CABLE. A QUICK LINK MAY ALSO BE USED TO CONNECT THE CABLE TO THE SLING INSTEAD OF TURNBUCKLE. EYEBOLTS & QUICK LINKS TURNBUCKLES CAN BE UTILIZED FOR FINER CABLE TENSION ADJUSTMENTS. WHEN USING A TURNBUCKLE, ATTACH IT TO A CABLE SLING WRAPPED AROUND THE ANCHOR, OR TO AN EYEBOLT. TURNBUCKLES AND SLINGS GO TO NEXT STEPS COMPONENT ASSEMBLY 3 ALWAYS INSTALL TURNBUCKLE BACK-UP CABLES. BACK-UP CABLE MUST THREAD THROUGH CABLE LOOPS ON BOTH SIDES. ONE OF THE MOST SIMPLE CONNECTIONS IS JUST A LENGTH OF RAW CABLE TERMINATED WITH AT LEAST 3 CABLE CLAMPS PER SIDE. THIS TERMINATION METHOD IS IDEAL WHEN USING TREES. ALTERNATE TERMINATION STYLES RAW CABLE WITH CLAMPS ATTENTION CHETCO TROLLEY OWNERS - HELPFUL HINT: WE RECOMMEND PULLING THE CABLE THOUGH THE CHETCO TROLLEY BEFORE TERMINATING THE CABLE ON BOTH ENDS.31 ASSEMBLY 3–COMPONENT ASSEMBLY CABLE CABLE STRAP TREE SAVER KIT WITH CAM STRAP WITH CABLE THREAD STRAP THROUGH CENTER HOLE IN EACH BLOCK. WRAP BLOCKS, STRAP AROUND BASE OF TREE OR POLE. LIFT STRAP TO DESIRED ATTACHMENT HEIGHT. THREAD END OF STRAP THROUGH CAM, PRESS TAB TO PULL STRAP THROUGH, RELEASE IT TO SECURE THE STRAP IN PLACE. WRAP CABLE AROUND BLOCKS, SECURING CABLE INTO BLOCK GROOVES. TERMINATE CABLE WITH DESIGNATED HARDWARE. THREAD CABLE SLING OR ZIP LINE CABLE THROUGH BLOCKS. WRAP CABLE, BLOCKS AROUND TREE OR POLE. LIFT CABLE TO DESIRED ATTACH - MENT HEIGHT. TERMINATE CABLE WITH DESIGNATED HARDWARE. HELPFUL HINT: DO NOT PUT CABLE DIRECTLY ON THE TREE. IF YOU DO NOT HAVE THE TREE SAVER KIT, PLACE WOOD BLOCKS UNDER THE CABLE TO PROTECT YOUR TREES. (AVAILABLE AS ADD-ON IF NOT INCLUDED IN THE KIT) COMPONENT ASSEMBLY32 ASSEMBLY 3–COMPONENT ASSEMBLY !! WARNING !! THE STOP BLOCK IS A SAFETY BACK-UP AT THE VERY END OF THE RIDE AND IS NOT A BRAKING SYSTEM. RIDERS SHOULD HAVE LITTLE TO NO SPEED WHEN THEIR TROLLEY MAKES CONTACT WITH THE STOP BLOCK. STOP BLOCK MUST BE PLACED 5 FT. FROM END ANCHOR MOUNT STOP BLOCK ONTO CABLE WITH RUBBER BUMPER FACING TOWARD MAIN LINE AND AT LEAST 5 FT. FROM THE ENDING ANCHOR. INSERT BOLTS THROUGH BLOCK AND WASHERS. TIGHTEN NUTS WITH A WRENCH. MOUNT FIST GRIPS TO CABLE SNUGLY AGAINST STOP BLOCK AS SHOWN. TIGHTEN WITH A WRENCH TO THE PROPER SPECIFICATIONS (SEE CHART BELOW). STOP BLOCK ROD SPACER FIST GRIPS CABLE FOR 1/4’’ CABLE, CLAMP A ROD SPACER TO CABLE WITH FIST GRIPS. 1/4” STOP BLOCK 5/16” STOP BLOCK 3/8” STOP BLOCK 1/2” STOP BLOCK 30 FT. LBS. 30 FT. LBS. 30 FT. LBS. 45 FT. LBS. FIST GRIP TORQUE CHART (FOR STOP BLOCK ONLY)33 ASSEMBLY 3–COMPONENT ASSEMBLY ATTACHMENT POINT ONLY ATTACH CARABINERS TO THE ATTACHMENT POINT OF TROLLEY. EACH RIDING GEAR ACCESSORY (E.G. HARNESS, SEAT, HANDLEBAR) MUST USE ITS OWN DEDICATED CARABINER ATTACHED DIRECTLY TO THE TROLLEY. RIDING GEAR BEFORE EACH RIDE, SQUEEZE-TEST CARABINERS TO ENSURE LOCKING GATE IS FULLY ENGAGED. !! WARNING !! DO NOT CHAIN-LINK CARABINERS OR ATTACH MULTIPLE ACCESSORIES INTO ONE CARABINER.34 ASSEMBLY 3–COMPONENT ASSEMBLY SEAT THE KNOT THREAD THE ROPE THROUGH SEAT AND TWIST INTO A FIGURE-EIGHT. THREAD ROPE THROUGH ITSELF, PULLING 5-INCHES OF ROPE, MINIMUM. PULL UPPER HALF OF ROPE WHILE PUSHING DOWN ON KNOT TO CREATE A FLAT TOP. DO NOT USE SEAT WITH LESS THAN 5” OF ROPE FOLLOWING THE KNOT. !! WARNING !! ACCESSORIES SUCH AS HANDLEBAR OR HARNESS SHOULD NEVER BE AT- TACHED TO THE SPLICED EYE OR THROUGH OPEN STRANDS ON THE ROPE. ACCESSORIES MUST ALWAYS BE CLIPPED DIRECTLY TO THE TROLLEY. HELPFUL HINT: A FRESH COAT OF OUTDOOR WOOD STAIN ONCE A YEAR AND KEEP - ING THE SEAT INDOORS WHILE NOT IN USE IS RECOMMENDED TO EXTEND SEAT LIFETIME. (AVAILABLE AS ADD-ON) 5” MINIMUM35 ASSEMBLY 3–COMPONENT ASSEMBLY LANYARD SHORT LOOP COW HITCH KNOT TIE- IN LOOP LONG LOOP HARNESS TIE-IN LOOP BEFORE EACH RIDE, SQUEEZE-TEST CARABINERS TO ENSURE LOCKING GATE IS FULLY ENGAGED. THREAD LONG LOOP OF LANYARD THROUGH HARNESS TIE-IN LOOP THEN THREAD LANYARD SHORT LOOP THROUGH ITS LONG LOOP TO CREATE COW-HITCH KNOT. ATTACH SHORT LOOP OF LANYARD TO TROLLEY WITH ONE CARABINER. !! WARNING !! ALWAYS USE RIDING GEAR THAT IS DESIGNED FOR SAFETY-CRITICAL APPLICATIONS AND APPROVED FOR ZIP LINE USE. HARNESS (AVAILABLE AS ADD-ON) ALWAYS USE A HARNESS FOR ZIP LINES WHERE A FALL COULD RESULT IN INJURY. HARNESSES MUST BE CORRECTLY SIZED AND FITTED BASED ON THE AGE, SIZE AND BODY TYPE OF PARTICIPANT. WITH TIE-IN LOOP IN FRONT, STEP THROUGH WAIST LOOP, THEN LEG LOOPS OF HARNESS, AND PULL HARNESS UP TO WAIST. STRAIGHTEN CLOTHING UNDER HARNESS. TIGHTEN STRAPS FOR FIRM (NOT TIGHT) FIT.36 ASSEMBLY 3–COMPONENT ASSEMBLY MOUNT ON CABLE WITH RUBBER BUMPER FACING TOWARD MAIN LINE. INSERT BOLTS THROUGH BLOCK AND WASHERS. TIGHTEN NUTS WITH A WRENCH. ATTACH BUNGEE TO BRAKE BLOCK WITH QUICK LINK. TIGHTEN QUICK LINK WITH WRENCH. SCREW THE EYE LAG SCREW INTO A TREE OR POST AT LEAST 10 FT. OFF TO THE SIDE OF THE ZIP LINE. WRAP BACK-UP CABLE SLING AROUND BRAKE ANCHOR. USE QUICK LINK TO CONNECT EYE LAG SCREW, CABLE SLING LOOPS AND BUNGEE. TIGHTEN QUICK LINK WITH WRENCH. EYE LAG SCREW QUICK LINK BACK-UP CABLE SLING BRAKE ANCHOR BUNGEE !! WARNING !! NEVER USE A BUNGEE BRAKE WITHOUT A BACK-UP CABLE SLING. BUNGEE BRAKE SYSTEM (AVAILABLE AS ADD-ON IF NOT INCLUDED IN THE KIT) HELPFUL HINT: DRILLING A 1/4” PILOT HOLE CAN BE HELPFUL FOR SCREWING EYE LAG SCREW INTO BRAKE ANCHOR TREE OR POST. !! WARNING !! EYE-LAG SCREW MUST EMBED TO FULL DEPTH IN SOLID WOOD. SCRAPE AWAY ANY BARK THAT PREVENTS THE SCREW FROM EMBEDDING FULLY INTO WOOD. QUICK LINK BLOCK BUMPER37 ASSEMBLY 3–COMPONENT ASSEMBLY !! WARNING !! DO NOT ALLOW BUNGEE TO SAG INTO THE RIDER’S WAY, IT CAN ENTANGLE THE RIDER. BRAKE BLOCK >8’ >10’ STOP BLOCK – 5 FT. FROM END ANCHOR INSTALL THE BUNGEE AT LEAST 8 FT. UP THE BRAKE ANCHOR. !! WARNING !! BUNGEE MUST NOT STRETCH TO MORE THAN 175% ITS LENGTH. BUNGEE MAY FAIL AND INJURE ZIP LINE RIDER OR BYSTANDERS. !! WARNING !! DO NOT ATTEMPT TO RIDE YOUR ZIP LINE WITHOUT FIRST TESTING. 20-FT. BUNGEE BRAKE - 29.5 FT. AWAY FROM THE ENDING ANCHOR OR STOP BLOCK 30-FT. BUNGEE BRAKE - 47 FT. AWAY FROM THE ENDING ANCHOR OR STOP BLOCK. LENGTH OF BUNGEE MINUS 3 FT. X 1.75 = DISTANCE FROM BUNGEE ANCHOR TO STOP BLOCK. 3 FT. TO ACCOUNT FOR KNOTS. EXAMPLE: 20 FT. BUNGEE - 3 = 17 X 1.75 = 29.5 FT. OR 30 FT. BUNGEE - 3 = 27 FT. X 1.75 = 47 FT. BRAKE BLOCK LOCATION GO TO NEXT STEPS INSPECTION 439 INSPECTION 4–INSPECTION CABLE WEIGHT TEST MARK CABLE AT EACH CABLE CLAMP AND FIST GRIP. AFTER USING TEST WEIGHT TO TEST ZIP LINE, INSPECT MARKS FOR INDICATION OF CLAMP SLIPPAGE. !! WARNING !! NEVER USE A PERSON AS A TEST WEIGHT WHEN PERFORMING THE WEIGHT TEST. !! WARNING !! NEVER PLACE MORE THAN 350 POUNDS ON ZIP LINE. ATTACH A TEST WEIGHT, EQUAL TO WEIGHT OF HEAVIEST PARTICIPANT, TO TROLLEY MOUNTED ON CABLE. BOUNCE TEST WEIGHT UP AND DOWN. OBSERVE ANCHORS AT EITHER END OF CABLE FOR EXCESSIVE MOVEMENT. ALLOW TEST WEIGHT TO SETTLE AT THE LOWEST POINT OF THE CABLE. CABLE SAG IS MEASURED FROM THE LOWEST POINT ON THE CABLE TO THE ATTACHMENT HEIGHT OF THE CABLE ON THE ENDING ANCHOR. INSPECTION40 INSPECTION 4–INSPECTION DETACH TEST WEIGHT AND INSPECT TERMINATION HARDWARE AND ANCHORS FOR PROPER CONFIGURATION AND STRENGTH. CHECK FOR SLIPPAGE OF CABLE THROUGH CABLE CLAMPS AND FIST GRIPS TO VERIFY THEY ARE ADEQUATELY TIGHTENED. CHECK ANCHORS FOR DEFORMATION. !! WARNING !! DO NOT USE ZIP LINE IF ANY SLIPPAGE, DEFORMATION, MISCONFIGURATION, INADEQUATE CABLE SAG OR OTHER POTENTIALLY HAZARDOUS CONDITION IS FOUND WHEN PERFORMING THE ABOVE TEST. THE CLAMPS OR FIST GRIPS MUST BE RE- TIGHTENED, EQUIPMENT REPLACED OR RECONFIGURED, CABLE SAG INCREASED, ANCHORS REINFORCED WITH GUY CABLES OR DIFFERENT ANCHORS CHOSEN, OR FURTHER PROFESSIONAL ADVICE SOUGHT AS APPROPRIATE FOR THE SITUATION BEFORE A PARTICIPANT IS ALLOWED ON THE ZIP LINE. STOP BLOCK INSPECT STOP BLOCK TO CONFIRM NUTS AND BOLTS ARE TIGHTLY SECURING THE TWO HALVES TOGETHER. BLOCK MUST BE SNUG AROUND THE CABLE. CONFIRM FIST GRIPS ARE PROPERLY TIGHTENED AND NOT SLIPPING CLOSER TO THE END ANCHOR. STOP BLOCK MUST MAINTAIN 5 FT. MINIMUM DISTANCE FROM END ANCHOR. CONFIRM THERE ARE NO CRACKS IN THE BLOCK OR OTHER OBSERVABLE DAMAGE. !! WARNING !! DO NOT USE ZIP LINE IF THERE IS DAMAGE TO THE STOP BLOCK. RETIRE AND REPLACE IMMEDIATELY.41 INSPECTION 4–INSPECTION INSPECT RIDING GEAR FOR IMPROPER CONFIGURATION, DAMAGE, FRAYING, BENDING, TEARING, CRACKING, SLIPPING OR ANY OTHER CHARACTERISTIC THAT WOULD INDICATE EQUIPMENT’S PERFORMANCE AND/OR STRENGTH HAVE BEEN COMPROMISED. TROLLEY – SPIN WHEELS TO CHECK FOR EXCESSIVE FRICTION OR ROUGHNESS. CHECK FOR LOOSE HARDWARE AND INSIDE OF HOUSING FOR EXCESSIVE WEAR FROM CABLE ABRASION. THE SIDE PLATES MUST NOT RUB AGAINST THE CABLE OR WHEELS. RETIRE AND REPLACE TROLLEY IF SIDE PLATES HAVE EXCESSIVE FRICTION MARKS FROM CABLE OR WHEELS. TWIST HANDLEBAR GRIPS IN BOTH HANDS TO CHECK FOR ROTATION OR SLIPPING. (IF APPLICABLE) RIDING GEAR !! WARNING !! DO NOT USE ZIP LINE IF THERE IS DAMAGE TO THE TROLLEY, LOOSE OR MISSING GRIPS. RETIRE AND REPLACE IMMEDIATELY. INSPECT ALL RIDING GEAR BEFORE EACH RIDE. !! WARNING !! DO NOT USE ZIP LINE IF THERE IS DAMAGE TO THE RIDING GEAR. RETIRE AND REPLACE IMMEDIATELY.42 INSPECTION 4–INSPECTION CARABINERS – CHECK THAT GATE PROPERLY CLOSES AND LOCKING MECHANISM OPERATES WITHOUT FAULT. CHECK FOR EXCESSIVE WEAR AT POINTS OF CONTACT BETWEEN CARABINER AND LANYARD, AND BETWEEN CARABINER AND TROLLEY. LANYARDS – INSPECT FOR EXCESSIVE WEAR OR LOOSE STITCHING. HARNESSES – EXAMINE ALL STRAPS, TIE-IN- POINTS AND SEAMS FOR LOOSE STITCHING, ABRASION OR UNRAVELING. CHECK METAL BUCKLES FOR BENDS, CRACKS OR SHARP SPOTS. GO TO NEXT STEPS OPERATION 5 IF YOUR ZIPLINE DOES NOT HAVE A BUNGEE BRAKE SYSTEM. !! WARNING !! RETIRE CARABINER IF LOCKING MECHANISM IS NOT CLOSING PROPERLY. !! WARNING !! IF ANY DAMAGE, FAULT, EXCESSIVE WEAR OR OTHER POTENTIALLY HAZARDOUS CONDITION IS OBSERVED, THE EQUIPMENT MUST IMMEDIATELY BE RETIRED AND REPLACED. !! WARNING !! WEIGHT SUPPORTING EQUIPMENT SUCH AS LANYARDS OR CARABINERS MUST BE ATTACHED ONLY TO FULL STRENGTH TIE-IN LOOPS ON HARNESS.43 INSPECTION 4–INSPECTION BUNGEE BRAKE TEST SEND TEST WEIGHT FROM VERY BEGINNING OF ZIP LINE TO TEST BUNGEE BRAKE SYSTEM. BUNGEE MAX BUNGEE STRETCH BUNGEE ANCHOR END ANCHOR !! WARNING !! DO NOT ALLOW BUNGEE TO STRETCH TO MORE THAN 175% THE BUNGEE’S LENGTH. BUNGEE MAY FAIL AND INJURE ZIP LINE RIDER OR BYSTANDERS. MEASURE TO AVOID OVERSTRETCH WHEN THE BUNGEE STRETCHES TO ITS MAX, DROP A VISUAL MARKER ON THE GROUND BELOW THE TEST WEIGHT AT THAT POINT. MEASURE FROM THIS MARKER TO THE BUNGEE ANCHOR POINT. IF THE BUNGEE IS OVERSTRETCHING OR IMPACTING THE STOP BLOCK WITH TOO MUCH FORCE: • DOUBLE UP THE BUNGEE’S STRENGTH BY ADDING A SECOND BUNGEE CORD PARALLEL TO THE ORIGINAL CORD. -OR- • REDUCE CABLE SLOPE AND/OR INCREASE CABLE SAG TO SLOW THE RIDER’S SPEED. TEST WEIGHT STOP BLOCK 5 FT. FROM END ANCHOR 5 FT. LENGTH OF BUNGEE MINUS 3 FT. X 1.75 = DISTANCE FROM BUNGEE ANCHOR TO STOP BLOCK. 3 FT. TO ACCOUNT FOR KNOTS. EXAMPLE: 20 FT. BUNGEE - 3 = 17 X 1.75 = 29.5 FT. OR 30 FT. BUNGEE - 3 = 27 FT. X 1.75 = 47 FT.44 INSPECTION 4–INSPECTION GO TO NEXT STEPS OPERATION 5 INSPECTING YOUR BUNGEE BRAKE PRIOR TO EACH USE IS A GOOD PRACTICE. THE BUNGEE BLOCK IS MADE OF NYLON AND THE FRONT BUMPER IS MADE OF RUBBER. THE BUMPER TAKES ALL THE HITS FROM YOUR TROLLEY. IF YOUR TROLLEY IS NO LONGER CUSHIONED BY THE RUBBER BUMPER AND IS HITTING THE NYLON BLOCK, THE BLOCK MUST BE RETIRED AND REPLACED. THE BUNGEE CORD HAS A BLACK SHEATH THAT SURROUNDS DOZENS OF WHITE ELASTIC CORDS. WITH USE AND EXPOSURE TO THE ELEMENTS, THE BUNGEE WILL EVENTUALLY SHOW SIGNS OF WEAR. IF ANY OF THE FOLLOWING IS OBSERVED DURING INSPECTION, YOUR BUNGEE CORD MUST IMMEDIATELY BE RETIRED AND REPLACED: • FRAYING, EXPOSED WHITE ELASTIC ALONG THE LENGTH OF THE BUNGEE CORD. • A NOTICEABLY SMALLER DIAMETER OR BULGING ALONG THE LENGTH OF BUNGEE CORD (A SIGN OF INTERNAL STRANDS BREAKING). • STRETCHED OUT BUNGEE THAT DOESN’T RETRACT WHEN PULLED. CONFIRM BOTH QUICK-LINK GATES ARE TIGHTENED WITH A WRENCH. AS A BACKUP TO PREVENT SLIPPAGE OF THE EYE-LAG SCREW, A CABLE SLING MUST BE WRAPPED AROUND THE BACK SIDE OF THE SAME ANCHOR AND THE TWO LOOPS CONNECTED TO THE QUICK LINK HOLDING THE EYE-LAG SCREW. BUNGEE CORDS MAY LAST UP TO ONE YEAR, HOWEVER WITH MORE USE AND EXPOSURE TO THE ELEMENTS, IT MAY WEAR OUT SOONER. TO EXTEND THE LIFE OF THE BUNGEE CORD, DISCONNTECT BUNGEE AT EACH QUICK-LINK AND BRING INDOORS WHEN ZIP LINE IS NOT IN USE. BUNGEE BRAKE INSPECTION & MAINTENANCE !! WARNING !! DO NOT RIDE ZIP LINE BEFORE INSPECTION OF BUNGEE SYSTEM HAS BEEN COMPLETED.45 OPERATION 5–OPERATION BEFORE EACH RIDE, CHECK TO ENSURE TROLLEY IS STRAIGHT UPRIGHT AND WHEELS ARE CENTERED ON CABLE. !! WARNING !! NEVER ALLOW CHILDREN TO USE ZIP LINE WITHOUT ADULT SUPERVISION. !! WARNING !! ALWAYS WEAR A HELMET WHEN RIDING ZIP LINE. !! WARNING !! DO NOT ATTEMPT TO SWITCH RIDING GEAR BETWEEN PARTICIPANTS OR PUT RIDING GEAR ON WHILE STANDING ON AN ELEVATED LAUNCH PLATFORM WHERE A FALL COULD RESULT IN INJURY. !! WARNING !! NEVER ‘JUMP’ FROM A LADDER OR PLATFORM ONTO ZIP LINE. !! WARNING !! KEEP HAIR AWAY FROM CABLE. !! WARNING !! DO NOT ALLOW RIDERS TO SPIN WHILE CONNECTED WITH A HARNESS OR DRIFTER SEAT. OPTIONAL SWIVEL EQUIPMENT IS OFFERED AT ZIPLINEGEAR.COM OPERATION46 OPERATION 5–OPERATION A SECOND PERSON MAY BE REQUIRED TO HOLD PARTICIPANT IN PLACE TO PREVENT THEM FROM DESCENDING DOWN THE ZIP LINE BEFORE THEIR TURN TO RIDE. IF NO HAZARDS ARE OBSERVED ALONG CABLE AVENUE AND IF RIDING GEAR SUCCESSFULLY HOLDS WEIGHT OF PARTICIPANT, THE PARTICIPANT MAY SLOWLY PUSH AWAY FROM PLATFORM AND ALLOW GRAVITY TO PROPEL THEM DOWN THE ZIP LINE. !! WARNING !! NEVER PLACE HANDS IN FRONT OF TROLLEY. DO NOT TOUCH CABLE WITH BARE HANDS. IF BRAKING WITH LEATHER GLOVES, ONLY GRAB CABLE BEHIND TROLLEY, NEVER IN FRONT OF TROLLEY. !! WARNING !! NEVER ATTACH A RIDER TO THE ZIPLINE UNTIL THE PREVIOUS RIDER HAS DISMOUNTED AND PROVIDES CLEARANCE! !! WARNING !! DO NOT COIL OR LOOP TOW ROPE DURING RIDE. IT MAY CAUSE ENTANGEMENT A ND STRANGULATION. RETURNING THE TROLLEY BACK TO THE BEGINNING OF YOUR ZIP LINE CAN BE ACHIEVED BY USING A ROPE OR SIMILAR TOW LINE. THE TOW LINE MUST BE ATTACHED TO THE TROLLEY AFTER COMPLETION OF THE RIDE. DO NOT RIDE WITH THE TOW LINE ATTACHED TO THE TROLLEY, HARNESS OR RIDER.47 OPERATION 5–OPERATION !! WARNING !! PARTICIPANT MUST NOT DISMOUNT FROM ZIP LINE UNTIL THEY HAVE COME TO A COMPLETE STOP. !! WARNING !! BE AWARE THAT ZIP LINE CABLE MAY SPRING UPWARDS WHEN RIDER DISMOUNTS. BE SURE ANY EQUIPMENT STILL ATTACHED IS REMOVED OR RAISED UP SLOWLY TO AVOID INJURING PARTICIPANT OR OPERATOR. PARTICIPANT MUST DISMOUNT FROM ZIP LINE BY TRANSFERRING THEIR WEIGHT OFF CABLE AND ONTO A RAMP, PLATFORM, GROUND, ETC. !! WARNING !! DO NOT ALLOW TOW ROPE TO DRAG BEHIND PARTICIPANT DURING ZIP LINE RIDE. IT MAY CAUSE ENTANGLEMENT AND INJURY. !! WARNING !! NEVER PLACE MORE THAN 350 POUNDS ON ZIP LINE.TAG YOUR ZIP LINE ADVENTURE @ZIPLINEGEAR LIKE US FACEBOOK.COM/ZIPLINEGEAR FOLLOW US TWITTER.COM/ZIPLINEGEAR