INSTALLATION & SAFETY
HANDBOOK
CONTACT
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
4
4
5
7
8
10
11
13
13
17
20
21
25
28
30
31
31
32
33
34
35
36
39
39
40
41
41
42
42
42
43
44
45
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
CONCEPTS
5
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 ANCHOR
7
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
–
–
+
+
=
=
=
SAG
10
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
1743 ft. - 1735 ft. = 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
5 811 8
14
SAG
13
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
3
17
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
3
20
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
2
21
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 .
4
22
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.
7
23
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
SWITCH
24
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
3
25
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 GRIP
29
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
3
30
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 ASSEMBLY
32
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” MINIMUM
35
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
BUMPER
37
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
4
39
INSPEC TION
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.
INSPECTION
40
INSPEC TION
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
INSPEC TION
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
INSPEC TION
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
INSPEC TION
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
INSPEC TION
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
OPERATION
46
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 AND
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.
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