Table of Contents
|CABLE DROP & SAG||STOP BLOCK||BUNGEE BRAKE TEST|
|BUNGEE BRAKE SYSTEM||RIDING GEAR|
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 obstruction at least 7 feet below and 5 feet on both sides of the zip line. Remove large rocks, logs, branches, sharp objects, and other potential hazards.
Keep in mind that Safety riding gear is required for any height and terrain where a fall could result in injury.
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), 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.
Tree Trunks must have a 12-inch diameter, minimum. Do not attach to any limbs/branches other than a central Trunk.
Wood or Metal posts must be 12” diameter, minimum.
Posts must be sunk 4 feet in ground, or 10% of post length plus 2 feet (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
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.
Install Guy Cables at a distance equal to or greater than attachment height.
Ground Anchor Posts must be sunk 4 feet in ground, or 10% of post length plus 2 feet (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.
For zip lines with a braking system, the ideal difference in cable height between start Anchor and end Anchor is approximately 6% of the zip line’s length.
(The zip line should drop approximately 6 feet per 100 feet of Cable.)
Cable Sag (Cable Tension is measured by 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 feet per 100 feet of cable)
- The Sag is measured at the cable's lowest point.
It is recommended that the zip line has at least 7-foot clearance over the entirety of the zip line terrain.
Use the Worksheet below to calculate measurements.
Use a laser level or a sight level to find a level line over your terrain. Have a friend assist in measuring (A). (See diagram above) The Elevation Change (C) of your terrain is (A) minus (B).
Set your end anchor height based on the sum of clearance (7 feet or greater) and sag.
Set your start anchor height based on the end anchor height plus the drop (6 feet per 100 feet of zip line) minus the Terrain Elevation change.
1. MEASURE DISTANCE BETWEEN SIGHT LEVEL AND THE GROUND (B)
2. MARK LEVEL LINE. MEASURE DISTANCE BETWEEN MARK AND THE GROUND (A)
Look at end Anchor through your sight level while standing at start Anchor. Tilt sight level up or down until bubble aligns with center crosshairs. Tell a friend where to mark the spot on the end anchor at this level line, by stapling a paper or tying a string around the anchor. Measure from this mark to the ground.
3. CALCULATE ELEVATION CHANGE (D)
4. MEASURE TOTAL LENGTH (L) OF ZIP LINE SITE
5. CALCULATE CABLE DROP (D)
6. CALCULATE CABLE SAG (S)
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 feet of length; decide which end will be most practical for your riders.
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 tightened with a wrench moderately past snug (≈30ft. lbs.)
U-Bolt of Clamps must press against dead end of cable and the saddle press against live end of the cable.
Assemble Tri-Link™ and Winch together. Connect Hook on Winch to attachment point labeled ‘Winch’ on Tri-Link™.
Connect Cable Sling Loops using a 9/16 Quick Link.
Connect 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.
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.
Switch Direction Switch to “Up” 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 (≈30ft. lbs.)
Switch Direction Switch to “Down” position. Crank to release tension on cable.
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.
(Included in 150LX, 250, 250LX Zip Line Kits)
Open Brake Block wide enough to mount on cable with Rubber Bumper facing away from the end 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 moderately past snug (≈30ft. lbs.)
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 feet 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.
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.
Hardware and Cable - Physically and visually examine cable terminations and cable sling for wear, proper configuration, and adjustment. Check Torque of all cable clamps and fist grips to ‘moderately past snug’ (≈30 ft. lbs). Visually inspect main cable. Walk entire length of zip line looking for damage to cable, kinks, twists, corrosion, etc.
Tree Anchors - Inspect for structural integrity and health. If there is any doubt as to the structural integrity or health of the tree, a qualified person, such as a certified arborist, MUST be consulted.
Pole Anchors - Visually observe that pole is aligned vertically and has not diverged from originally installed position.
Visual Inspection- Survey ground under zip line cable for any objects such as people, animals, vehicles, or other obstructions.
Physical Inspection - Walk along the entire length of the zip line, looking for any objects that a rider may come in contact with when riding or dismounting.
Weight Test - Attach a test weight, equal to the weight of the heaviest participant, to the trolley mounted on the cable. Perform Tests described in pages 22,23 to assess the zip line’s speed and Clearance and the braking system (if installed).
Riding Gear - 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. 250, 250LX ZIP LINE KITS: Inspect bumper block for cracking, or excessive deformation. Twist handlebar grips in both hands to check for rotation or slipping.
Carabiners - Check that gate properly closes and locking-mechanism operates without fault. Check for excessive wear at points of contact between carabiner and trolley.
Harnesses - Examine all straps, tie-in-points, stitching, and buckles for abrasion and unraveling.
Lanyards - Inspect for excessive wear or loose stitching. If any damage, fault, excessive wear, or other potentially hazardous condition is found when performing the above inspections the equipment MUST BE REPLACED, or further professional advice sought before a participant is permitted to use the equipment on the zip line.
Mark cable at each Cable Clamp and Fist Grip. After using test weight to test zip line, inspect marks for indication of clamp slippage.
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.
Send Test Weight from very beginning of zip line to test Bungee Brake System.
Measure to Avoid Over Stretch
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 Over Stretching or Impacting the Stop Block with Too Much Force:
- Double up the bungee’s strength by adding a second 30-foot bungee cord parallel to the original cord.
- Reduce cable slope and/or increase cable sag to slow the rider’s Speed.
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.
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.
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.
Riding gear elements must be attached only to harnesses’s Full Strength Tie-in Loop.
Attach Short Loop of Lanyard to Trolley via one Carabiner.
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. The included harness (250, 250LX zip line kits) is appropriate for children and adults with waist sizes from 18 inches to 52 inches.
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.
Before each ride, check to ensure trolley is straight upright and wheels are centered on cable.
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.
If braking with Leather Gloves, only grab cable behind trolley, never in front of trolley.
If braking with Leather Gloves, only grab cable behind trolley, never in front of trolley.
Activities involving the installation and use of zip lines, trolleys, harnesses, braking systems and other related gear are potentially hazardous by their very nature.
Anyone purchasing, installing or using equipment from Sleaddventures LLC (dba 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.
You can download the entire 150, 150LX, 250, 250LX User Guide PDF Below.
Still have questions? Call us at 888.476.3701.
© Zip Line Gear 2016