Vertical Reality MFZBRT Operation Manual

Mobile free fall/ zip combo with optional bungee trampoline and rock wall

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Mobile Free Fall/ Zip Combo with optional Bungee Trampoline and

Rock Wall

Operations Manual

Model: MFZBRT

Travel Weight: 9,980 lbs. and 10,780 lbs. with optional bungee

REVISION 01/09/17

MIAMI, FL 33157

Tel (305) 238-4522 Fax (305) 238-4401

Web Page

www.verticalreality.com

info@verticalreality.com

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Page 1 Mobile Free Fall/ Zip Combo with optional Bungee Trampoline and Rock Wall Operations Manual Model: MFZBRT Travel Weight: 9,980 lbs. and 10,780 lbs. with optional bungee REVISION 01/09/17 MIAMI, FL 33157 Tel (305) 238-4522 Fax (305) 238-4401 Web Page www.verticalreality.com Email info@verticalreality.com...
Page 2 Zip Combos for the amusement, entertainment and special attractions market. Our goal is to establish a relationship with your company. One that will promote Vertical Reality and your company, as successful partners, providing entertainment for those who are looking for the best new attraction in the market.
Page 3 Mobile Free Fall/ Zip Combo. Disposition This manual is the property of the Mobile Free Fall/ Zip Combo owner and Vertical Reality. It must be returned to Vertical Reality upon receipt of an updated manual or discarded. Revision Vertical Reality may make periodic additions, deletions and modifications to this manual.
Page 4 I understand that the information outlined in this manual is subject to change at the sole discretion of Vertical Reality at any time. It is further understood that the owner of the Mobile Free Fall/ Zip Combo has the responsibility to ensure the correct and latest version of the manual is being used.
Page 5 Mobile Free Fall / Zip Combo Product Overview Welcome to the Mobile Free Fall / Zip Combo, Vertical Reality's latest in revenue generating interactive sports products designed for the amusement, entertainment, and fitness industries. The Mobile Free Fall / Zip Combo is designed to meet ASTM F24 standards for the Amusement Industry. This means that the Mobile Free Fall / Zip Combo is designed, manufactured, tested, and supported by comprehensive quality assurance and quality control measures to ensure product reliability and safety.
Page 6 In other words, the information in section one pertains to the information in section two. The philosophy of Vertical Reality is centered on a commitment to excellence in meeting the needs of its customers and associates by providing them with the enclosed information.
Page 7 The ZipSTOP caters to a range of rider weights and approach speeds and offers a consistent and smooth braking force for all riders. The design of the ZipSTOP permits simple installation and incorporates an advanced self-regulating brake system and automatic line reset. The patented braking mechanism offers riders a smooth stop and is designed to minimize variations in deceleration rate and stopping distance of both children and adults.
Page 8  Zip Line Brake rated for 41KN.  Model: ZP 150-17 Classification: Zipline Braking Device  Dimensions: 80 x 350 x 140 mm (15 x 12.6 x 5.5 in)  Net Weight: 21 kg (48 lbs)  Materials: Casing Aluminium Alloy ...
Page 9 Hitch and Wiring - To pull the Mobile Free Fall Tower you will need a 2 5/16 -inch ball, a seven- (7) prong Round Trailer wiring plug and a tow vehicle rated for 12k or higher. Vertical Reality recommends at least a 2500 series truck to tow the trailer.
Page 10 The trailer is equipped with electric brakes as the standard configuration. The trailer can also be equipped with surge brakes as an option. Please ensure that you have an electric brake controller installed for the electric brakes to operate. Site Selection ...
Page 11 Setting up the Free Fall/ Zip Tower Upon positioning the Mobile Free Fall Tower trailer in place, we begin by removing the trailer from Vehicle. Then;  Rotate front Jack by removing its respective pin and re-inserting once the jack is 90 degrees with the trailer.
Page 12  Raise the jacks at the rear of the trailer followed by the middle jacks. The middle jacks are located just before the fenders. Slide out middle jack arms 20 inches and turn jacks to operational position. Make sure that the jack pins are properly inserted before engaging the jacks. Jacks should be raised until tensioned against the ground.
Page 13  Remove Bungee Support Arms from trailer and begin to install them on the bungee base. Each arm is marked with a letter to a corresponding corner. The arms are split into a base section and a top section. Assemble all four support-arms at this time by sliding and pining the top section. ...
Page 14  Remove Bungee poles from their travel brackets on the trailer base. Remove the two front pole holder brackets from the trailer. Brackets are held in place via clevis pin. Store brackets in the toolbox.  Remove both of the tower travel locks in the front and store all brackets and pins in the toolbox. Each travel lock consists of two pins, rectangle tube and U shape bracket that must be removed.
Page 15  Make sure there is proper clearance for the arc of the Mobile Free Fall Zip Tower before up righting. Caution: Be aware of possible-over-head obstacles before raising Mobile Free Fall Zip Tower.  Install the retract winch to the top of the tower at this time. The retract winch is attached via two grade eight fasteners.
Page 16  Grab one of the side rails for the Zip platform and attach them to the tower via the supplied fasteners. The tower has two holes on each side to receive the side rails. Grab the rail for the opposite side and repeat the procedure. ...
Page 17  Install both of the gates using the supplied clevis pins and locking rings.  At this time, we must raise the tower slightly in order to install the platform supports.  The platform supports attach to the vertical tower beams and the front of the zip platform using the supplied fasteners.
Page 18  We can now begin with the installation of the vertical support brackets. Remove all of the support pieces attached to the trailer.  There are two support brackets attached to each side of the tower. Remove the pin holding the bottom section to the tower.
Page 19  Install the Jack to the vertical support bracket. The support bracket has a jack coupler welded on one end where the jack is secured via the attached clevis pin. Move the jack handle to align jackleg to trailer bracket if necessary. Secure the lower side of jack to the trailer using the supplied grade eight fastener.
Page 20  The vehicle anchor can only be used for zip line distances of 300ft. or less. You need one vehicle and anchor per zip station. Any distance above 300 ft. will require a sled anchor or universal anchor.  If Zip distance is going to be above 401 ft. you must install the supplied counter weight on the front of tower once erected.
Page 21  Place tire chucks behind front wheels and rear wheels. Vehicle keys must be removed and stored in locked box to prevent accidental movement.  Connect blue line to the brake block on the Zip line and the pulley to the guideline anchor attachment.
Page 22  Anchor Point location is approximately 40 ft. from the end. The brake point can be moved further forward if you want to slow the participants down sooner.
Page 23  Install back-up brake trolley. The backup brake uses the supplied elastic cords as an emergency stop.  Tension the Zip line to 500-750 lbs. on the gauge by turning the chain hoist. With only the trolley, primary brake trolley and back up brake trolley on the Zip Line. ...
Page 24  Install the anchor support cables to the truck bed. Sled Anchor Assembly: Zip Distance 300 ft. to 500 ft. , 500 ft. is the max distance allowed.  Sled anchor has a center section, three long beams as legs, three short bases that go under the long beams, three rear uprights, rear hoist bracket and two support beams that connect the rear base legs to the center section of the anchor.
Page 25  Begin installing the three short beams under the long base legs using the supplied grade 8 fasteners. The short beams are also marked to indicate their installation location.  Connect the three rear upright supports at this time using the supplied grade 8 fasteners. The three supports are also marked to indicate their locations.
Page 26  We can now install the main hoist beam on top of the three upright supports using the supplied grade fasteners. The beam has markings to indicate its location on the three uprights. (Please see pictures below.)  Begin installing the two diagonal beams that connect the hoist beam to the rear of the main anchor frame.
Page 27  Tighten all installed fasteners at this time for the sled anchor.  Locate the four aluminum leg supports for the landing platform. Each leg is marked to indicate its location on the frame. The two rear legs consist of a single vertical support while the front supports have a diagonal support.
Page 28  Move the platform exit staircase into location at this time. The exit staircase can be installed on either the left or right side of the platform. The staircase is attached to the platform via the two supplied fasteners. (Please see pictures on next page.)
Page 29  Tighten all grade 8 fasteners for the landing platform and staircase at this time.  Install both railings for the staircase at this time. The railings have marks to indicate their install location. All of the railing bolts are stainless steel. (Please see pictures below.) ...
Page 30  Install the left and right platform railings at this time. The shorter railing is installed on the stair case side. The side railings will each have a v shaped partition pre-installed that faces the front of the anchor. (Please see pictures below and on next page.)
Page 31  The next step is to install each of the three ramps. Begin with the left ramp followed by the narrower middle ramp and finally the right ramp. Each ramp is attached to the landing platform by two grade 8 fasteners and are marked to indicate its install location. The ramps have a lip that slides into the open grove of the landing platform.
Page 32  Install the left and right ramp rails at this time. The rails attach to the ramps and to the existing platform rails. (Please see pictures below.)  Tighten all of the stainless steel rail fasteners at this time and the grade 8 ramp fasteners. ...
Page 33  Install concrete ballast anchor to the anchor at this time. The anchor must have a minimum of four, 3,000 lbs. blocks. Three blocks must be loaded at the rear of the anchor and the fourth in the front section underneath the landing platform. Connect both tension meters to each side of the rear anchor bracket.
Page 34  Zip line pre-tension should be 1000 lbs. to 1,400 lbs. for distances up to 400 ft.  Zip line pre-tension should be 1,400 lbs. to 1,800 lbs. for distances of 400 ft. to 500 ft.  Do not exceed 1,800 lbs. of pre tension! ...
Page 35  Connect the backup brake to the second brake bracket on the centerline. The backup brake uses bungees to stop a participant in the event of a brake failure. The backup brake has a rope anchored to the zip platform. ...
Page 36 ZIP STOP OPERATION 1. The ZipSTOP is designed to provide consistent and reliable braking to a zip line ride. System performance relies on operators using the correct equipment and operating the system in accordance with the instructions contained within this manual. 2.
Page 37 FREE Fall Set-UP  Move the hydraulic selector valve at the back of the tower. The valve has two positions; one position lifts the entire tower the second is to extend QuickJump extension arms. Please extend the arms out completely using the hydraulic control. ...
Page 38  Place landing matt at the front of the tower, directly below the extension davits on the ground. (See picture below)
Page 39 If equipped with optional Bungee Trampoline  Attach the poles to the swivel bases with the 5/8 pins and secure. Attach all 4 poles (See pictures on next page)  Attach the jump set to the eye nuts on each pole except for the rear inner two facing the tower. ...
Page 40  Remove the top pin on the support arm.  Carefully Raise either of the end poles and walk them toward the receiving cradle, and pin the pole into place using the pins you just removed. Repeat for all other poles. ...
Page 41 Takedown of the Mobile Free Fall Tower structure –  Upon the end of an event or use of the Mobile Free Fall Tower, please follow the following steps to ensure safe and proper takedown of the Mobile Free Fall Tower. ...
Page 42  Remove wheel chocks and store in toolbox.  Once the Mobile Free Fall Tower has been properly lowered, it can be re-attached to your tow vehicle. Make sure that the hitch lock is secure. You can now connect your trailer plug for lighting and attach your safety chains.
Page 43 Inspections, Preventive Maintenance & Wear Limits Checklist. Daily Inspections  Check QuickJump trolley wheels for wear and smoothness. Wheels must spin freely.  Check the QuickJump quick release latches to make sure they lock firmly. The quick release latch has a small round port that can be inspected to make sure the latch is locking.
Page 44 Ensure adequate lighting and unrestricted access are available to permit a thorough inspection of all areas of the QuickJump, Zipstop and TruBlue. Inspect the QuickJump, ZipStop and TruBlue units and the entire length of webbing. Clean any dust, dirt or contamination off the casing and fittings with a clean cloth. DO NOT USE SOLVENTS OR ABRASIVES ON ANY OF THE UNITS.
Page 45 31. Return QuickJump, ZipStop and TruBlue devices to install location. If equipped with optional Rock wall the following procedures MUST be performed every day before you use the Rock wall:  The first step is to check that the auto belays are functioning properly, pull the webbing to the down position using the attached rope and gently release if the webbing retracts the system has passed the first test.
Page 46 Monthly Check List 1. Inspect all trailer welds for cracks. 2. Inspect welds on frame 3. Inspect all Hydraulic Pumps and ensure all Hydraulic connections are free from leaks. 4. Check fluid level in tank, fluid should be ¾‘s of the way full. (Required Fluid is 32 weight Hydraulic Fluid) 5.
Page 47 4 in) of the drum lead.  Place a line holding pin through the loop in the drum lead, above the joining link to prevent it retracting back into the unit.  Inspect both the upper (drum) webbing and the webbing line by passing the webbing slowly through your hands under a good light.
Page 48 Documentation of employee training and status as well as a list of each employee have address and phone number. A training manual is to be on site at all times; Copies of this documentation are also to be handed out to Park’s Games Department Management, to the Site Manager, and to a Vertical Reality Representative.
Page 49 Wear Dated Items for Free Fall / Zip Line Combo.  Lanyard - Full body harness- QuickJump Trolley- Zip Line Trolley- Zip Line brake Trolley- Zip line Brake line- Bungee harness. If equipped with optional rock wall  TruBlue must be sent back for recertification every year. ...
Page 50 warning. If warning is not followed, operator must ask patron to exit the ride.  The weight range for the Mobile Free Fall Tower is 30 – 285 lbs. & with a Minimum Height of 42” and max height of 6ft 3”. No age limits. ...
Page 51 Emergency Evacuation Procedure for Free Fall In the event of a participant stopping or being stuck in the middle when Free Falling. 1. Switch the hydraulic selector on the tower to bring in the Free Fall Davits. Using the hydraulic control bring the davits in closer to the tower. 2.
Page 52  Guide Lines For Zip Line 1. One attendant at the top of zip tower at all times. 2. Make sure retract line is attached and working. 3. A maximum of 2 attendants and two participants allowed on Zip platform 4.
Page 53  Always monitor the rope of the winch for tautness and that it is entering the winch smoothly and not rubbing against the housing of the winch.  Failure to notice this could result in serious damage to the rope. ...
Page 54 Be sure to store the elastics in a dry place. Should the elastics get wet, dry them completely before using them again. If you have any questions or concerns about the installation of the elastics, contact VERTICAL REALITY FOR SERVICE. You should expect a cost of .11c to 15c per jumper as replacement costs for bungees.
Page 55 111 to 130 3 blue 131 to 160 3 blue + 1 amber 161 to 180 4 blue 181 to 200 4 blue + 1 amber 201 to 220 pound 5 blue NEVER USE LESS THAN 2 LOOPS OR POWERCORDS PER SIDE ...
Page 56  Put the leg straps around the legs. A rough general adjustment of these straps should occur prior to feeding the strap in-between the legs of the jumper.  Close the buckle and make sure it is locked.  Tighten the strap around the leg and check the jumpers’ comfort. ...
Page 57  Once the jumper is standing safely on the trampoline, attach the harness immediately like described above and then pull the winch up slightly at first to ensure the jumper does not fall off of the trampoline. Make sure that the jumper is always connected to tensioned elastics while on the trampoline.
Page 58  Vertical Reality cannot be held responsible for any injuries incurred and/or items lost or broken while on the Bungee.  You must follow all daily inspections before operation.  You must follow guidelines for bungee portion  You must enforce and follow all posted rules for bungee portion.
Page 59 5. Using the Zipstop for any purposes other than that intended by the manufacturer is not permitted. 6. The TruBlue auto-belay is specified for uses on the climbing wall portion of the tower. 7. Using the TruBlue for any purpose other than that intended by the manufacturer is not permitted.
Page 60 POSTED RULES AND SAFETY SIGN FOR PARTICIPANTS Zip Line Tower Please read all safety rules. Ensure loose clothing is secured and empty pockets of loose objects e.g. coins, Mobile phones etc. For ZipZONE Stations 1. You must weigh between 30-250 lbs & have a minimum height of 42”and max of 6ft 3”. 2.
Page 61 POSTED RULES AND SAFETY SIGN FOR PARTICIPANTS Rock Climbing Before climbing please read and follow these rules! Rock Climbing is a physically demanding sport activity. Attention all guests: Read Important Safety Information and follow the instructions of the attendants at all times. You must weigh between 30-250 lbs &...
Page 62 POSTED RULES AND SAFETY SIGN FOR PARTICIPANTS Bungee Trampoline Before riding please read and follow these rules! BUNGY-TRAMPOLINE is a physically demanding sport activity. Attention all guests: Read Important Safety Information and follow the instructions of the attendants at all times. •...
Page 63 This guideline has been written to assist in the proper installation and operation of the Mobile Free Fall/ Zip Tower. Vertical Reality has tried in its best effort to address relative issues; however, there will additional information learned or situations that occur that we are unaware of at this time. Please, do not hesitate to call seven days a week with any technical question.
Page 64 WARRANTIES. Seller warrants that all Goods shall be free of defects in material and workmanship Vertical Reality MFG, INC products have a limited two-year warranty on the Mobile Free Fall / Zip Tower systems including the frame, trailer and panels. Warranty does not include consumables (harnesses, handholds, cables, pulleys, Batteries, tires these are covered by the individual respective manufacturer’s...
Page 65 Daily Maintenance Inspection FreeFall Tower and Zip Line Date_____________ Name ____________________________________________________ Print Name Name ____________________________________________________ Sign Name Items replaced ___________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________  Check QuickJump trolley wheels for wear and smoothness. Wheels must spin freely.  Check the QuickJump quick release latches to make sure they lock firmly. The quick release latch has a small round port that can be inspected to make sure the latch is locking.
Page 66  Ensure that service/inspection staff are adequately belayed during inspections. Failure to do so can result in serious injury or death.  NO UNAUTHORIZED SERVICING. Do not attempt to carry out any maintenance, repair or service actions not detailed in the User Manual. Any unauthorized maintenance, repair or modifications to the QuickJump or ZipStop Devices will compromise safety, render the unit not fit for use, and void the warranty provisions.
Page 67  Check Brake trolley for smooth operation throughout its operating range and that it correctly resets to the start of the braking zone.  Inspect reduction line and pulleys for freedom of movement.  Check overall condition of line and ensure it is in a safe and serviceable condition. ...
Page 68 Daily Operator Inspection FreeFall Tower and Zip Line Date_____________ Operator name ____________________________________________________ Print Name Operator name ____________________________________________________ Sign Name Items replaced ___________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________  Check lanyard and lanyard padding. Replace lanyard if excessive wear or fraying is detected. ...
Page 69   All personnel performing these actions must be trained in the correct Procedures and deemed competent to do so. INSPECTION AND MAINTENANCE REQUIRED Failure to perform scheduled maintenance and inspections on the QuickJump or ZipStop devices may result in serious injury or death. ...
Page 70 Daily Maintenance Inspection Bungy Trampoline Date_____________ Name ____________________________________________________ Print Name Name ____________________________________________________ Sign Name Items replaced ___________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ Check all cables and cable attachments for tautness and stability. Check the winch for proper movement and that all cables/ ropes move freely. Check to see that the ropes are moving freely through the pulleys.
Page 71 Daily Operator Inspection Bungy Trampoline Date_____________ Operator name ____________________________________________________ Print Name Operator name ____________________________________________________ Sign Name Items replaced ___________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ Check all carabineers (snap-links) for unusual wear. Be sure they open and close properly. Check all elastics / power cords for wear and tear--replace if necessary. If equipped with inflatable trampoline check the jump matt and all seams for tears.
Page 72 Daily Maintenance Inspection Rock Climbing Wall Date_____________ Name ____________________________________________________ Print Name Name ____________________________________________________ Sign Name Items replaced ___________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________  The first step is to check that the auto belays are functioning properly, pull the webbing to the down position using the attached rope and gently release if the webbing retracts the system has passed the first test.
Page 73 the warranty provisions.      Service in a clean environment. Remove TruBlue from its operational location for service, ensure that the service area is clean and free from contaminants. Ensure unit is securely placed on a sturdy work table and plastic side covers are not subject to damage.
Page 74 Daily Operator Inspection Rock Climbing Wall Date_____________ Operator name ____________________________________________________ Print Name Operator name ____________________________________________________ Sign Name Items replaced ___________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________  Inspect all harnesses for wear, special attention must be given to the main attachment point. In addition, check each and every harness to ensure the stitching is tight.
Page 75 FreeFall, Zipline, Rock Wall, Bungy Trampoline Monthly Maintenance Checklist. 1. Inspect all trailer welds for cracks. 2. Inspect welds on frame 3. Inspect all Hydraulic Pumps and ensure all Hydraulic connections are free from leaks. 4. Check fluid level in tank, fluid should be ¾‘s of the way full. (Required Fluid is 32 weight Hydraulic Fluid) 5.
Page 76 FreeFall, Zipline, Rock Wall, Bungy Trampoline Six Month Inspections for entire unit.  Remove the Nozzle – Refer to ‘Nozzle removal’ on Appendix A for QuickJump, Appendix B for ZipStop and Appendix C for TruBlue Auto-Belays  Check for excessive wear to slot. ...
Page 77  For webbing line replacement. Refer to page 35 of appendix A for QuickJump at the rear of manual. Refer to page 64 and 65 of appendix B for ZipStop. Refer to page 34 and 35 of appendix C for TruBlue auto-belay. FreeFall, Zipline, Rock Wall, Bungy Trampoline Yearly Inspection Checklist ...
Page 78 Free Fall and Zip Full Body Harness, designed for safety. Qualifications  This product has been pull tested to 5000 lb. (22.24 kN)  Complies to PRCA/ANSI 1.0-1.3 5000 lb. (MBS) minimum breaking strength  Complies to ANSI z359.1 required 5000lb. Breaking strength. ...
Page 79 ___________________________________________________________________________________ Was the person intoxicated or under the influence of alcohol or drugs YES NO Were Vertical Reality's safety rules posted? YES NO Was your staff properly trained in the operation of the Mobile Free Fall Tower? YES NO Was the Mobile Free Fall Tower shut down for inspection after the accident occurred? YES NO...
Page 80 That the following persons have been trained in the proper assembly, operation and maintenance of the above-mentioned rides by a certified installer and Trainer of Vertical reality and are now fully familiar with the operational manual and correct operating and setup procedures. This also authorizes the following individuals to train their own personnel to operate the Mobile Free Fall/ Zip Tower with optional Bungee Trampoline and Rock Wall.
Page 81 Confirmation of Shipping list and Certification of Fabrication  Inspections were performed by a Vertical Reality supervisor at a level of frequency sufficient enough to ensure compliance; as a result, the ride as fabricated, is in compliance with the applicable drawings, specifications and shop drawings.
Page 82 NOTES...
Page 83 QUICKFLIGHT / QUICKFLIGHT XL FREE FALL DEVICE Operator Manual Models: QF150-12A / QFXL150-20A NOTE TO OWNERS, INSTALLERS, AND OPERATORS Always Read Instructions Before Use The Operator Manual contains information relating to the proper installation, operation, and maintenance of the QuickFlight Free Fall Device and includes all product registration and warranty information.
Page 85: Table Of Contents
TABLE OF CONTENTS Important Safety Warnings Health and Safety Site Rescue Plan 1.0 SAFETY INFORMATION Symbols Used in this Manual 2.0 WARRANTY CONDITIONS 2.1 Owner Responsibility 3.0 CERTIFICATION 3.1 Standards 4.0 DESCRIPTION 5.0 SPECIFICATIONS 5.1 All QuickFlight Models 5.2 Mounting Heights 6.0 QUICKFLIGHT PARTS 6.1 Labels 6.2 Icon Descriptions...
Page 86 8.2.7 Mounting Diagram 8.2.8 Location Diagram 9.0 OPERATION 9.1 Operator Training 9.2 User Instruction 9.3 Proper Harness Connections 9.4 Carabiner Operation 9.5 Proper Webbing Retraction 10.0 INSPECTION AND MAINTENANCE 10.1 Annual Recertification 10.2 Scheduled Maintenance 10.2.1 Safety Precautions 10.3 Daily Inspection 10.3.1 Upper Webbing Inspection 10.3.2 RipCord Webbing Inspection 10.4 Weekly Inspection...
Page 87: Important Safety Warnings
Important Safety Warnings READ BEFORE INSTALLATION & OPERATION RECREATIONAL DESCENT IS A DANGEROUS ACTIVITY. THE QUICKFLIGHT FREE FALL DEVICE IS PRIMARILY USED AS A RECREATIONAL FREE FALL DEVICE. IT CAN BE USED FOR CLIMBING PROTECTION. A MANDA- TORY FALL ATTUENTATION SURFACE IS REQUIRED UNDER THE PARTICIPANT/ CLIMBER AT ALL TIMES.
Page 88: Health And Safety
Health and Safety Owners and Operators must abide by all Standards, International, Federal, State and Provincial laws, and any specific health and safety regulations pertaining to the installation and use of this product. Site Rescue Plan Owners and Operators must have devised an emergency rescue plan for any Participant in distress at all sites operating QuickFlight Free Fall Devices.
Page 89: Safety Information
SAFETY INFORMATION Symbols Used in this Manual The following safety symbols are used throughout this manual to highlight potential dangers. One or more precautions may be associated with practices and procedures described within this manual. Failure to adhere to any precau- tions highlighted can result in death, serious injury, or equipment damage.
Page 90: Warranty Conditions
2.0 WARRANTY CONDITIONS This QuickFlight Free Fall Device is warrantied against factory defects in ma- terials and workmanship (excluding “Replacement Parts” – see below) for a period of two (2) years from date of purchase. This warranty applies only to the original purchaser, and is contingent upon the Owner/Operator maintaining and using the device in accordance with Manufacturer’s instructions, including the requirement to continue to maintain annual re-certification as described in...
Page 91 ƒ Wearing parts such as nozzle, webbing lines, RipCord webbings, cara- biners, attachment rings, side covers, and lanyard keepers. ƒ Normal deterioration due to use and exposure. This warranty is subject to the following of the requirements of the Operator Manual supplied, Manufacturer’s instructions, and the advice given by Head Rush Technologies service technicians.
Page 92: Certification
3.0 CERTIFICATION Standards NOTE If the QuickFlight Free Fall Device is resold outside of the country of desti- nation, the reseller must provide instructions for use, service, maintenance and repair in the language of the country of use. The QuickFlight and the QuickFlight XL Free Fall Devices can be used as a climbing/descent/free fall system device only in combination with other components.
Page 93: Description
4.0 DESCRIPTION THE FIGURES PRESENTED IN THIS MANUAL ARE NOT TO SCALE AND MAY NOT SHOW ALL REQUIRED COMPONENTS OR STRUCTURES, INCLUDING, BUT NOT LIMITED TO: MOUNTING POINTS, CONNECTORS, SAFETY EQUIPMENT, ETC. The QuickFlight Free Fall Device is a descent device designed specifically for use as a component within a free fall system or climbing system.
Page 94: Specifications
5.0 SPECIFICATIONS Every QuickFlight Free Fall Device comes with two Upper Webbings and a RipCord assembly pre-installed. The Owner should keep the original packaging to use for storage and shipping of the device. ALL QUICKFLIGHT MODELS IN ACCORDANCE WITH EN 341:2011-1A AND CERTIFICATION EN 360:2002 DIMENSIONS...
Page 95: Mounting Heights
METRIC UNITS ARE THE CONTROLLING UNITS OF MEASURE IN THIS MANUAL. IMPERIAL UNITS ARE PROVIDED AS A COURTESY AND HAVE BEEN ROUNDED. IF THE OWNER/OPERATOR/INSTALLER MUST MAKE ANY UNIT CONVERSIONS, THE METRIC UNITS SHOULD BE REFERENCED. MOUNTING HEIGHTS Nozzle to Platform MODEL MINIMUM MAXIMUM...
Page 96 QuickFlight Webbing Configurations 1M RIPCORD 2M RIPCORD THE QUICKFLIGHT FREE FALL DEVICE WITH LOW MOUNT UPPER WEBBINGS MAY NOT BE USED WITH THE 2M RIPCORD. ENSURE THAT AN ALLOWABLE COMBI- NATION OF DEVICE, UPPER WEBBINGS, RIPCORD WEBBINGS, AND MOUNTING HEIGHT IS IN PLACE BEFORE LIVE OPERATION OF THE QUICKFLIGHT FREE FALL DEVICE.
Page 97: Quickflight Parts
6.0 QUICKFLIGHT PARTS Handle / Secondary Primary Mounting Casing Mounting Point (Red) Point (Black) QuickFlight Device Side Cover Side Cover (Back) (Front) Upper Webbing RipCord Webbing Nozzle Webbing Connection Rings OPA Jacket Hand Grip Primary Attachment Carabiner RipCord Bungee Secondary Attachment Carabiner Lanyard Keeper...
Page 98: Labels
Labels SERIAL LABEL QF150-12A SN QF00000 SPECIFICATION LABEL INFORMATION QFXL150-20A SN QFXL00000 (VARIES BY MODEL) LABEL ALWAYS READ AND FOLLOW MODEL: QFXL150-20A MODEL: QF150 12A THE WARNINGS AND INSTRUCTIONS FOR USE RATED BODY WEIGHT: RATED BODY WEIGHT: 20 to 130kg (44 to 285lbs) 20 to 130 kg (44 to 285 lbs) DEVICE WEIGHT: DEVICE WEIGHT:...
Page 99: Icon Descriptions
Icon Descriptions Device Weight Only one user at a time Body Weight Harness standards EN 12277, UIAA 105, EN 361 Do not alter the line. Do Landing Speed not clamp, knot or tie on additional line Do not store the line Country of Manufacture inside the device wet Never install the device...
Page 100 Connect the carabiner to the designated belay Maximum Height loop of your harness, making sure the gate is locked Check descent path is clear, Always land with Inspect the Webbing slightly bent knees to absorb landing Both lines must be fully Fall attenuation surface retracted before use.
Page 101: Unpacking
UNPACKING Precautions LEAVE THIS USER MANUAL ATTACHED TO THE QUICKFLIGHT UNTIL INSTALLATION IS COMPLETE The Operator Manual contains information relating to the safe use of the QuickFlight Free Fall Device and includes all product registration and war- ranty information. The Operator Manual document may only be removed by the end user.
Page 102: Storage
3. Check the Certification Label for the ‘Next Recertification Required’ date. If the date shown has passed or the label is missing or illegible the Quick- Flight Free Fall Device must not be put into service. 4. Register your QuickFlight Free Fall Device online at www.headrushtech. com/registration 5.
Page 103: Installation
8.0 INSTALLATION Precautions ALWAYS USE DESIGNATED MOUNTING POINTS Never install the Free Fall Device using any part of the device apart from the designated mounting points. Incorrect mounting can result in serious injury or death. ALWAYS USE THE CORRECT MOUNTING HEIGHT Failure to install the device at the correct mounting height could result in damage to the device or loss in device performance.
Page 104: Harness
Head Rush Technologies requires anchor points to have a minimum load ca- pacity of 12 kN (2640 lbs) in expected directions of application. Other national and international standards for anchor points may apply and require higher load capacity. Consult with the authority having jurisdiction for your required load capacity.
Page 105: Selecting A Location
Two EN 362 certified triple locking carabiners are installed on the primary and secondary attachment points of the RipCord assembly for Participant connec- tion. Two plastic Lanyard Keepers prevent the carabiners from rotating within their attachment points. Two EN 362 certified attachment rings are installed to connect the RipCord to the two Upper Webbings.
Page 106: Outdoor Installations
When selecting a location to install the QuickFlight Free Fall Device, check: ƒ Install the device where it can be safely reached for inspections and servicing. ƒ The QuickFlight Free Fall Device will hang vertically over the line of de- scent with the nozzle pointing down.
Page 107: Mounting Diagram
The QuickFlight Free Fall Device provides color-coded mounting points to en- sure that it hangs centrally and vertically with the webbing line nozzle pointing down. The black Primary Mounting Point should be used to hold the weight of the device and all associated forces. The red Secondary Mounting Point should be connected for redundancy using hardware that can withstand all associated forces, but with no tension during normal operation.
Page 108: Location Diagram
8.2.8 LOCATION DIAGRAM Jump Direction NOZZLE TO PLATFORM 1.75m - 2.5m MINIMUM Any areas that may come in contact with the participant must be padded or protected. NOZZLE TO GROUND Mounting height range varies. See limits for device and webbing configuration.
Page 109: Operation
9.0 OPERATION Owners and purchasers of the QuickFlight Free Fall Device are responsible for the safety and supervision of any person using this equipment and are required by the manufacturer to read, understand and follow all instructions in this Op- erator Manual regarding the correct installation and operation of the Free Fall Device prior to any use.
Page 110: Operator Training
Operator Training All personnel involved in the operation of the Free Fall Device must be trained and deemed competent in the following aspects of QuickFlight Free Fall Device operation; ƒ Transportation and storage. ƒ Installation, use of attachment points and attachment methods and hardware.
Page 111 ‚ If the Free Fall Device line fails to retract, do not clip into the Free Fall Device and request assistance. ƒ Ensure that the daily device inspection has been performed and that the webbing line, carabiners, and device have not been damaged. ƒ...
Page 112 ƒ Never pass the attachment points of the RipCord Webbing through any loops on the harness. ƒ Attach both carabiners to either the front attachment points or the rear attachment points of a harness. Never attach the carabiners on both the front and back of the harness, and never attach the carabiners to the side of the harness.
Page 113: Proper Harness Connections
Proper Harness Connections WAIST CONNECTION Primary carabiner on waist attachment with gate facing away from participant. Secondary carabiner on waist attachment with gate opposite primary carabiner. CHEST AND WAIST CONNECTION Both carabiners on separate attachment points with gate facing away from participant. Primary carabiner connected lower than secondary carabiner.
Page 114: Proper Webbing Retraction
The carabiners are closed by releasing the gate and allowing it to snap shut, ensuring the collars have rotated back and slid back to their fully locked posi- tion. Ensure that no clothing, webbing, incompatibly shaped D-rings, or other objects are obstructing the gate or its latching function. Step 1 –...
Page 115: Inspection And Maintenance
10.0 INSPECTION AND MAINTENANCE 10.1 Annual Recertification DO NOT OPERATE AFTER THE DATE SHOWN ON THE CERTIFI- CATION LABEL Operation of a QuickFlight Free Fall Device without a current Certification Label visible is strictly forbidden. Severe bodily injury or death may occur. The QuickFlight Free Fall Device requires an annual service and recertification inspection to be carried out by an authorized Head Rush Technologies service agent.
Page 116: Safety Precautions
NO UNAUTHORIZED SERVICING Do not attempt to carry out any maintenance, repair or service actions not detailed in the User Manual. Any unauthorized maintenance, repair or modifications to the Free Fall Device will compromise safety, render the unit not fit for use, and void the warranty provisions.
Page 117: Daily Inspection
10.3 Daily Inspection The daily webbing inspection must include at least a visual inspection suffi- cient to evaluate the wear and integrity of the device’s webbing. Please see “Webbing Wear” below for a detailed description of when a webbing should be taken out of service.
Page 118 Face Edge Webbing Inspection Surfaces headrushtech.com | +1-720-565-6885...
Page 119 UPPER WEBBING WEAR TABLE - QUICKFLIGHT Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immediately to continue using the QuickFlight Free Fall Device. The green outlined photos show webbing that can be kept in operation.
Page 120 UPPER WEBBING WEAR TABLE - QUICKFLIGHT XL Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immediately to continue using the QuickFlight Free Fall Device. The green outlined photos show webbing that can be kept in operation.
Page 121 WEBBING WEAR TROUBLESHOOTING TABLE Symptoms Potential Causes Potential Solutions Encourage Participants to step off the platform rather than jumping out. Partic- Participants are swing- ipants should also jump vertically. Flailing ing excessively as they motions (swinging arms and legs, leaning descend forward/back, etc.) can create more lateral movement.
Page 122: Ripcord Webbing Inspection
10.3.2 RIPCORD WEBBING INSPECTION The RipCord Webbing does not wear significantly under normal operation, but requires daily inspection for damage and degradation. Webbing must be removed from service if it does not pass inspection. Continued use of webing beyond stated limits may result in separation, disconnecting the Participant from the QuickFlight Free Fall Device.
Page 123 tacks, and stitching for damage. Check that the OPA Jacket is not dam- aged and that webbing is still clamped to the OPA Jacket and positioned so that the Jacket is centered between the bar tacks at the ends of the OPA section.
Page 124: Weekly Inspection
RIPCORD WEBBING DEGRADATION TABLE Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immediately to continue using the QuickFlight Free Fall Device. The green outlined photos show webbing that can be kept in operation. Degree of Wear UV Damage STAGE 1...
Page 125 3. Mounting Hardware - Check that all hardware used to connect the QuickFlight mounting points to the structure anchor points is in opera- tional condition, secure, and free of corrosion. 4. Webbing Extension and Retraction - Check that the webbing extension and retraction is smooth and maintains resistance throughout its range.
Page 126: Bi-Annual Inspection
Check for cracks or damage. Inspection of Lanyard Keeper 10.5 Bi-Annual Inspection The QuickFlight Free Fall Device requires an in depth six (6) month inspection by the Operator to maintain its safe and efficient operation. For the six monthly inspections the unit must be dismounted and removed to a sturdy work table. 10.5.1 INSPECTION PROCEDURE 1.
Page 127: Upper Webbing Replacement
ANNUAL RECERTIFICATION OPERATION OF THE QUICKFLIGHT FREE FALL DEVICE WITHOUT A CURRENT CERTIFICATION LABEL VISIBLE WILL RENDER THE DEVICE NOT FIT FOR USE AND VOID THE WARRANTY. CONTINUED OPERATION PAST THE “NEXT RECERT REQUIRED” DATE MAY RESULT IN SERIOUS INJURY OR DEATH. The QuickFlight Free Fall Device requires an annual service and recertification inspection to be carried out by an authorized Head Rush Technologies Autho- rized Service Agent.
Page 128 Drum Lead Holding Pin Shackle Shackle Pin (2) Shackle (2) Pin Flush with Shackle Shackle Pin Drum Lead Upper Webbing Upper Webbing (2) Drum Lead Diagram To replace an Upper Webbing: 1. Disconnect the Webbing Connection Ring from the Upper Webbing being replaced.
Page 129 ALWAYS USE A NEW SHACKLE PIN PROVIDED WITH THE WEBBING REPLACE- MENT KIT. NEW SHACKLE PINS COME WITH THREAD LOCKING COMPOUND THAT CAN ONLY BE USED ONCE. 6. Install the new Upper Webbing and new Shackle Pin, ensuring the shackle loop is fitted to the drum lead and shackle pin to the end of the webbing.
Page 130: Nozzle Replacement
10.7 Nozzle Replacement The nozzle assembly is located on the QuickFlight device casing and pro- vides guidance for the dual Upper Webbings during extraction/retraction. the nozzle assembly is a wear component and will need to be inspected regularly; replacement is on a conditional basis. Service of the nozzle assembly may be carried out with the QuickFlight in place or removed and secured to a work- bench.
Page 131: Side Cover Replacement
10.8 Side Cover Replacement The QuickFlight Free Fall Device side covers are removable and simply snap into place on the device casing. Remove side covers by placing a flat head screwdriver under the edge of the cover and carefully levering it up. To re- place, align the outer profile of the side cover with the profile of the casing and snap into place.
Page 132: Ripcord Webbing Replacement
10.9 RipCord Webbing Replacement Replacement of a RipCord Webbing assembly may be carried out with the QuickFlight in place or removed and secured to a workbench. To replace a RipCord Webbing: 1. Disconnect both Webbing Connection Rings from their respective Upper Webbings.
Page 133: Long Term Storage
10.10 Long Term Storage If the QuickFlight Free Fall Device is to be placed into storage or left unused for longer than two weeks, ensure the device and all webbing components are clean and dry and protected from the environment. Ensure the Upper Web- bings are fully retracted into the device.
Page 134: Replacement Part
10.11 Replacement Parts Your QuickFlight Free Fall Device is fitted with a number of user replaceable parts that may be refitted without the need to return the device to an autho- rized Head Rush Technologies Service Center. Always follow the Manufac- turer’s instructions as detailed in this User Manual and any Part Replacement Guide supplied when undertaking replacement of a part.
Page 135: Manufacturer's Details
11.0 MANUFACTURER’S DETAILS For Recertification or unscheduled service or repairs, return your QuickFlight Free Fall Device to your nearest Head Rush Technologies Authorized Service Center or to the Manufacturer at the address shown below. ADDRESS CONTACT DETAILS Head Rush Technologies +1-720-565-6885 1699 Cherry St, Suite C www.headrushtech.com...
Page 136 headrushtech.com | +1-720-565-6885...
Page 137 headrushtech.com | +1-720-565-6885...
Page 138 REGISTER YOUR DEVICE Get automatic updates on recertification and product information – visit headrushtech.com/register ANNUAL RECERTIFICATION IS REQUIRED Please keep the shipping box for your device. For instructions on annual recertification, visit headrushtech.com/recertification +1-720-565-6885 www.headrushtech.com info@headrushtech.com Feb 2021...
Page 139 APPENDIX B ZIPSTOP ZIP LINE BRAKE Installation, Operation & Maintenance Manual Models: ZS125-08 / ZSIR150-20A NOTE TO INSTALLERS Always Read Instructions Before Use Leave this manual attached to the zipSTOP Brake unit. The Installation, Operation and Maintenance manual contains information relating to the proper use of the zipSTOP and includes all product registration and warranty information.
Page 141 TABLE OF CONTENTS 1. SAFETY INFORMATION 1.1 Symbols Used in this Manual 2. EMERGENCY ARREST DEVICE (EAD) CONFIRMATION 3. SAFETY & INFORMATION LABELS 3.1 Location of Safety Labels 4. WARRANTY INFORMATION 4.1 Warranty Conditions 4.2 Customer Responsibility 5. SPECIFICATIONS 5.1 Introduction 5.2 zipSTOP Brake Unit, ZS125-08 5.3 zipSTOP Brake Unit, ZSIR150-20A 5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A...
Page 142 8.11 zipSTOP Braking Distance Charts 8.12 Configuration Notes 8.13 zipSTOP Configuration Worksheet 9. ZIPSTOP BRAKE ASSEMBLY INSTALLATION 9.1 General 9.2 Safety Precautions 9.3 Primary Anchor Point 9.4 Secondary Anchor Point 9.4.1 Position of the Secondary Anchor Point 9.5 Redirection and Support Lines 9.6 Fitting zipSTOP Brake Unit 9.7 Fitting the Brake Trolley 9.8 Fitting Type I Pulley...
Page 143 13.4 1:1 Ratio – Metric ZS125-08 13.5 1:1 Ratio – Imperial ZS125-08 13.6 2:1 Ratio – Metric, ZS125-08 13.7 2:1 Ratio – Imperial, ZS125-08 13.8 3:1 Ratio – Metric 13.9 3:1 Ratio – Imperial 14. APPENDIX A: EAD WARRANTY/REGISTRATION FORM 14.1 Warranty Registration Form 15.
Page 144 IMPORTANT SAFETY NOTICE Zip Lining is a Dangerous Activity Read Before Installation & Operation Failure by the installer or operator to heed any and all instructions, warnings and cautions for the correct installation, operation, care and maintenance of the zipSTOP may result in serious injury or death. The zipSTOP Brake assembly, including zipSTOP Brake Unit Model ZB125-08B and ZSIR150-20A, zipSTOP Brake Trolley Model ZT125-17 and all associated equipment are designed and specified for use in the recre- ational zip line industry as components of a well designed zip line brake system.
Page 145: Safety Information
1. SAFETY INFORMATION 1.1 Symbols Used in this Manual The following safety symbols are used throughout this manual to highlight potential danger to operators and equipment. One or more precautions may be associated with practices and procedures described within this manual.
Page 146: Emergency Arrest Device (Ead) Confirmation
2. EMERGENCY ARREST DEVICE (EAD) CONFIRMATION Zip lines using the zipSTOP Brake are required to use both primary and emergency arrest devices functioning together to arrest the motion of passengers. The EAD must engage with no input from the passenger upon failure of the primary arrest device.
Page 147: Safety & Information Labels
3. SAFETY & INFORMATION LABELS Safety and Information Labels located on the zipSTOP components are not to be removed. Ensure labels are in place and remain legible at all times. 3.1 Location of Safety Labels Location of Labels – Brake Unit Location of Labels –...
Page 148: Warranty Information
4. WARRANTY INFORMATION 4.1 Warranty Conditions Manufacturers sole warranty. The zipSTOP Brake assembly will be sold free from defects in materials and workmanship, excluding field replaceable wear parts, for a period of one (1) year from date of purchase. This warranty only applies to the original purchaser, and is contingent upon the owner/operator using and main- taining the device in accordance with the zipSTOP instructions, including the requirement to maintain annual recertification as described in the Installation, Operation and Maintenance Manual.
Page 149: Specifications
5. SPECIFICATIONS 5.1 Introduction The zipSTOP Brake assembly is a controlled braking force device designed specifically for use in the zip line industry as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and approach speeds, and offers a smooth, consistent braking force for all riders.
Page 150: Zipstop Brake Unit, Zs125-08
5.2 zipSTOP Brake Unit, ZS125-08 zipSTOP Mount Top Mounting Pin zipSTOP Brake Unit Nozzle Assembly Braking Line Side Cover Pulley MODEL ZS 125-08B CLASSIFICATION Zip Line Braking Device DIMENSIONS 380 x 320 x 216 mm (15 x 12.6 x 8.5 in) NET WEIGHT 23.5 kg (52 lbs) OPERATING TEMPERATURE...
Page 151: Zipstop Brake Unit, Zsir150-20A
5.3 zipSTOP Brake Unit, ZSIR150-20A zipSTOP Mount Top Mounting Pin zipSTOP Brake Unit Nozzle Assembly Braking Line Side Cover Pulley MODEL ZSIR150-20A CLASSIFICATION Zip Line Braking Device DIMENSIONS 380 x 320 x 216 mm (15 x 12.6 x 8.5 in) NET WEIGHT 23.5 kg (52 lbs) OPERATING TEMPERATURE...
Page 152: Zipstop Brake Trolley, Zs125-08 And Zsir150-20A
5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A Bump Stops Redirection Line Mounting Point Upper Sheave Lower Sheaves MODELS ZT 125-17-1/2 – For use with 12.7 mm (½”) zip lines ZT 125-17-3/4 – For use with 19 mm (¾”) zip lines ZT 125-17-35/8 –...
Page 153: Operating Principles
6. OPERATING PRINCIPLES 6.1 General The zipSTOP Brake assembly is a controlled braking force device designed specifically for use as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and approach speeds and offers a smooth, consistent braking force for all riders.
Page 154: Zipstop Brake Assembly
7. zipSTOP BRAKE ASSEMBLY 7.1 General The zipSTOP Brake assembly will be supplied as a kit of parts. Additional components are required to com- plete the braking system. Refer to Section ”Appendix B: List of Accessories and Replaceable Parts” for part number information.
Page 155: Long Term Storage
Do not use the zipSTOP after date shown here 3. Check the Certification Label on the zipSTOP Brake Unit for the ‘Next Recertification Required’ date. If the date shown has passed or the label is missing or illegible then the zipSTOP Brake Unit must not be put into service.
Page 156: Supplied Parts
When returning the zipSTOP Brake assembly to operation after an extended period of inactivity, always carry out a full inspection and operational check of all components in the assembly. Refer to Section “Operation of zip- STOP” for Inspection procedures. 7.4 Supplied Parts The following parts will be included in each Brake Assembly Kit: ƒ...
Page 157: Redirection Pulleys
weight, corrosion resistant, and engineered to be virtually resistant to snagging. Head Rush Technologies also offers the Gorilla Rope, a 6mm rope specifically designed for used as a redirection line. 7.6 Redirection Pulleys The following parts are not supplied as part of the zipSTOP kit and may be purchased separately from your zipSTOP distributor.
Page 158: Minimum Hardware Requirements
7.8 Minimum Hardware Requirements All required hardware is to be purchased separately. The following are minimum requirements for all hardware used for zipSTOP installation: DESCRIPTION SIZE NOTES Grade 4.6 (M12) M12 or 1/2” ASTM A307 Grade A or B (1/2”) ZIPSTOP BRAKE UNIT MOUNTING BOLTS, WASHERS &...
Page 159: Redirection Line Specifications: Zs125-08/Zs150-20A
7.9.1 REDIRECTION LINE SPECIFICATIONS: ZS125-08/ZSIR150-20A MAXIMUM DIAMETER 10.0 mm/0.394 in (6mm/0.236 in recommended) MINIMUM STRENGTH 13 kN, Stretch <3% at 13 kN STRETCH <4% at 15 kN WEAR RESISTANCE High abrasion resistance and UV resistance WATER RESISTANCE Dry, non-absorptive TYPE Kernmantle or single braid construction TYPICAL Redirection LINE EXAMPLE ZS125-08...
Page 160: Zipstop Brake Assembly Configuration
8. zipSTOP BRAKE ASSEMBLY CONFIGURATION 8.1 General The zipSTOP Brake assembly is designed to be utilized as part of a complete zip line braking system, and can be used for a wide range of zip line installations. The zipSTOP Brake assembly is suitable for use in both exist- ing and new zip line installations.
Page 161: Rider Arrival Speed
8.3 Rider Arrival Speed Rider arrival speed is unique to each zip line installation and is a factor of line slope, zip line length, rider weight, rider descent position, wind and friction. It is necessary to know the acceptable minimum and maxi- mum rider velocities prior to configuring the zipSTOP.
Page 162: 1:1 Ratio
REDIRECTION LINE WILL BE SUBJECT TO WEAR AND ABRASION Any Redirection Line selected for use will wear and must be replaced from time to time. Lines must be care- fully inspected prior to use each day, and failure to do so may result in serious injury or death. 8.5.1 1:1 RATIO Attach redirection pulley Attach zipSTOP braking line to redirection...
Page 163: 2:1 Ratio
8.5.2 2:1 RATIO Attach zipSTOP braking line to Attach redirection pulley redirection line with a quicklink and to overhead line recommended swivel, support pulley and sling Brake Trolley *EAD not shown but it is mandated* Overhead Cable – 2:1 Redirection Ratio The 2:1 Redirection Ratio connects the zipSTOP Brake Unit to the zipSTOP Brake Trolley via both Type I and Type II pulleys.
Page 164: Possible System Configurations (Informative Only)
8.6 Possible Configurations (Informative Only) 8.6.1 3:1 RATIO 3:1 installation formats are a unique situation and the following information should be used to develop an appropriate site plan. The 3:1 ratio connects the zipSTOP unit to the braking trolley via redirection pulleys and supplementary line. With a 3:1 ratio the braking trolley travels three meters for every meter of zipSTOP line.
Page 165: Other Configurations
8.6.2 OTHER CONFIGURATIONS The zipSTOP Brake assembly may be used with other zip line configurations and higher rider velocities. Con- figurations shown are based on a single line zip line. Dual zip lines and side-by-side configurations may also be accommodated. Please contact your zipSTOP Distributor for information on alternate set-ups. When higher Redirection Ratios (3:1 and higher) are employed (for model ZS125-08 only), retraction force is reduced and a manual reset of the Brake Trolley will be necessary.
Page 166: Positive Slope Line
8.7.1 POSITIVE SLOPE LINE This is the ideal configuration when designing a zip line incorporating the zipSTOP Zip Line Brake. The positive line slope configuration equalizes the braking distance between heavy and light riders, therefore minimizing the length needed for the arrival platform. zipSTOP Reset Position Positive Line Slope...
Page 167: Negative Slope Line
8.9 Negative Slope Line On negative line installations riders will decelerate within the rider Arrest Zone and may roll backwards at the completion of braking. It is recommended that the platform is positioned to allow all riders to safely dismount. zipSTOP Negative Line Slope Reset...
Page 168: Definition Of Terms
8.10.1 DEFINITION OF TERMS The following terms are used when configuring and installing the zipSTOP Brake assembly: Pivot Length Brake Line Extension zipSTOP Buffer Zone Brake Trolley Rider Arrival Speed Maximum Arrival Speed = ASmax Minimum Braking Distance (BD min) Minimum Arrival Speed = ASmin Maximum Braking Distance (BD max) Reset...
Page 169: Zipstop Braking Distance Charts
Difference between maximum and minimum brak- RIDER BRAKING RANGE ing distances. NOTE: Landing Area will vary depending on rider arrival speed, stopping distances and line slope. RESET POSITION The reset position defines the start of the Arrest Zone and is the location on the zip line the Brake Trolley will return to once the rider is removed.
Page 170 2. LINE EXTENSION (LEX) – Line extension is the distance the Braking Line extends out of the zipSTOP brake Unit. If LEX is greater than 12.0m then reduce maximum permissible approach speed (ASmax), permissible rider weight (RWmax) or increase Redirection Ratio (RR). Exceeding 12m runs the risk of an abrupt stop when the webbing reaches its termination as well as damage to the zipSTOP, webbing and other equipment.
Page 171: Zipstop Configuration Worksheet
8.13 zipSTOP Configuration Worksheet Use this worksheet in conjunction with the braking distance charts at the back of this manual. Worksheet must be completed in metric. Read the zipSTOP Brake assembly configuration notes and definitions before completing the worksheet. Distances calculated by this worksheet are based on a flat line with no outside influences such as wind, friction etc.
Page 172: Zipstop Brake Assembly Installation
9. zipSTOP BRAKE ASSEMBLY INSTALLATION 9.1 General Simply put, the zipSTOP Brake is designed to be mounted to a primary anchor point to slow the decent of riders on a zip line. The primary anchor point is exactly what it sounds like; it is the main attachment point for the brake.
Page 173: Primary Anchor Point
ENSURE ALL CABLES, ATTACHMENT LINES AND PULLEYS ARE CORRECTLY ATTACHED AND MAINTAINED TO PREVENT TANGLING, SNAGGING, BINDING AND ABRASION. Ensure that the Redirection Line is routed cleanly and in line through the pulley system, to prevent contact with any surface other than the pulley sheaves. ALL STRUCTURES, SUPPORTS AND ANCHORS MUST BE EVALUATED AND DESIGNED AC- CORDING TO PROPER INDUSTRY AND ENGINEERING PRACTICES.
Page 174: Position Of The Secondary Anchor Point
9.4.1 POSITION OF THE SECONDARY ANCHOR POINT The Secondary Anchor Point is located in line with the start of the Arrest Zone (Brake Trolley Reset Point). It provides the location for the attachment of the Type I Pulley above the zip line and also attachment of any secondary or support lines that may be required.
Page 175: Fitting Zipstop Brake Unit
9.6 Fitting zipSTOP Brake Unit The zipSTOP Brake Unit may be mounted horizontally or vertically. The mounting bracket is designed for use with a flat or curved surface. Curved surfaces must have a minimum 150 mm (6“) diameter. ONLY INSTALL THE ZIPSTOP BRAKE UNIT ORIENTED DIRECTLY INLINE WITH THE TYPE 1 PULLEY The Braking Line feeds straight out of the device, without twist, and centered within the Nozzle.
Page 176 Install the RattleStop washers to both sides Install the RattleStop screws to both sides. Tighten the screws on both sides ATTACH MOUNTING BRACKET TO PRIMARY SUPPORT Attach the supplied mounting bracket to the primary support with three (3) M12 or ½” hex head through bolts. The bolt holes are located 100mm (3.94in) apart on center.
Page 177 INSTALL ZIPSTOP TO MOUNTING BRACKET Line up zipSTOP Brake Unit with the bottom mounting hole and insert the corre- sponding retaining pin and lynch pin. Swing the zipSTOP Brake Unit up and apply a small amount of pressure against the RattleStop until upper mounting holes align. Fit the upper mounting pin and lynch pin.
Page 178: Fitting The Brake Trolley
9.7 Fitting the Brake Trolley The Brake Trolley is installed on the zip line and is used to transfer the energy of the rider to the zipSTOP Braking Unit. ALWAYS USE THE CORRECT BRAKE TROLLEY SIZE FOR THE ZIP LINE Failure to use the correct size may prematurely wear the trolley or zip line.
Page 179 >>…Upper Sheave…>> >>…and top half of the Bump Stop from the Brake Trolley. Place the Brake Trolley on the zip line with the Bump Stop facing the direction of the approaching rider. Refit the upper half of the Bump Stop. Torque to 6 Nm (4.5 lb-ft) Refit the Redirection Line mounting point.
Page 180: Fitting Type I Pulley
Refit the Upper Sheave to the Brake Trolley, ensuring that all spacers are cor- rectly positioned. Secure the upper wheel with bolt, washer and self-locking nut. Torque to 15 Nm (11 lb-ft). Check all fasteners are properly torqued. Do not over tighten. Check Brake Trolley rolls smoothly on zip line.
Page 181: Fitting Type Ii Pulley
9.9 Fitting Type II Pulley The Type II Pulley is fitted between the zipSTOP Brake Unit and the Type I Pulley as required to provide support and redirection for the Redirection Line and connections to the Braking Line. The Type II Pulley is only re- quired on the 2:1 Redirection Ratio set-ups.
Page 182: 1:1 Redirection Ratio
ENSURE THAT THE REDIRECTION LINE IS ROUTED CLEANLY & IN LINE THROUGH THE PULLEY SETUP Contact between Redirection Line and any surface other than the pulley sheaves must be prevented in order to eliminate abrasion and undue wear. The redirection line must remain free and clear of all obstacles, the Arrest Zone and rider travel path.
Page 183 INSTALLATION NOTES ƒ Check that the Redirection Line diameter is compatible with the redirection pulley size. ƒ Check that the Redirection Line meets the specified strength, diameter, wear resistance and UV resis- tance requirements. ƒ Ensure that the Redirection Line is routed cleanly and in line through the pulley system, to prevent con- tact with any surface other than the pulley sheaves.
Page 184: 2:1 Redirection Ratio
FOLLOWING THE INSTALLATION OF THE REDIRECTION LINE ƒ Remove temporary restraint from the Brake Trolley. ƒ Check the Redirection Line to ensure that the Brake Trolley is in the correct Reset Position when zip- STOP Braking Line is fully retracted. ƒ...
Page 185 tact with any surface other than the pulley sheaves. Fixed support pulley(s) can be used to ensure that Redirection Lines are kept free and clear. 2:1 AND HIGHER RATIOS CAN ONLY BE USED WITH THE ZS125-08 DO NOT use the ZSIR150-20A in 2:1 or higher configurations. ENSURE THAT THE ZIPSTOP BRAKING LINE IS FULLY RETRACTED INTO THE ZIPSTOP DEVICE AT BRAKE INITIATION If any Braking Line is extended, braking force will be increased, resulting in participant injury or damage to...
Page 186 Run the Redirection Line towards the zipSTOP Brake Unit, pass the Re- direction Line around the Type II Pulley ensuring it passes through the sheave in the direction of the Secondary Anchor Point. Tension the Redirection Line and connect to the dedicated mounting point on the Secondary Anchor Point using an approved proper termi- nation method.
Page 187: Operation Of Zipstop
10. OPERATION OF zipSTOP 10.1 Safety Precautions ALWAYS CORRECTLY INSTALL, MAINTAIN AND OPERATE THE ZIPSTOP BRAKE ASSEMBLY Failure to do so may result in serious injury or death to participants. ALWAYS OPERATE A ZIPSTOP BRAKE ASSEMBLY WITH AN EMERGENCY ARREST DEVICE (EAD) ACTIVE Failure to do so may result in serious injury or death to participants ALWAYS CARRY OUT UNMANNED TESTING TO DETERMINE ACTUAL BRAKING DISTANCE...
Page 188: Zipstop Operation As A Primary Brake
NSURE BRAKE TROLLEY ALWAYS RESETS TO THE START OF THE ARREST ZONE Failure to reset the Brake Trolley will compromise braking performance and may result in serious injury or death and/or equipment damage. THE BRAKE TROLLEY CANNOT BE TIED BACK IN ANY WAY, BY ANY METHOD, OR BY ANY ACTION DURING OPERATIONAL HOURS Any restriction of the brake trolley during operational hours may result in serious injury or death, or equip- ment damage.
Page 189: Operation During Extreme Weather Conditions
10.5 Operation During Extreme Weather Conditions zipSTOP equipment has been designed for use in a wide range of temperature and weather conditions. Ex- treme heat and cold weather will not alter the performance of the equipment, nor will operations in wet con- ditions, however, the following should be observed: WET LINE WARNING When the line is wet it may slightly alter the performance of the zipSTOP device.
Page 190: Operational Retraction Spring Cycle Limit
zipSTOP Brake Unit fully retracted An arrival platform attendant should always check for the correct reset position of the Brake Trolley and the zipSTOP Braking Line at the completion of each run, prior to a subsequent run. Redirection lines should be visually checked after brake trolley reset to ensure they are running free and clear, have not become tangled, etc.
Page 191: Troubleshooting
11. TROUBLESHOOTING Use this information to assist in troubleshooting problems that might occur during operation. If a problem can- not be resolved, remove components from service and contact your Head Rush Technologies Service Center. SYMPTOM POTENTIAL CAUSE RESOLUTION In most cases your redirection point has been established. Hopefully this distance correlates to the performance of the brake you wanted to Pivot height is too achieve.
Page 192 SYMPTOM POTENTIAL CAUSE RESOLUTION Check your pulleys to ensure that the sheaves are operating smoothly and without drag. Also ensure that all your angles to and from all redirection pulleys are straight and that the brake trolley angle is parallel to its im- mediate redirection point.
Page 193 SYMPTOM POTENTIAL CAUSE RESOLUTION Auxiliary Retraction Devices are not recommended. Occasionally extreme 2:1 installations or 3:1 or greater installations will have alternative clothes- line type reels or weight assisted retraction devices to help facilitate auto- Braking matic reset. These devices RADICALLY alter the brake application forces and add to the brake resistance of the zipSTOP.
Page 194 SYMPTOM POTENTIAL CAUSE RESOLUTION Check your pulleys to ensure that the sheaves are rotating smoothly and without drag. Also ensure that all your angles to and from all redirection pulleys are straight and that the brake trolley angle is parallel to its im- mediate redirection point.
Page 195: Before You Call
SYMPTOM POTENTIAL CAUSE RESOLUTION If the prevailing wind is particularly a crosswind, the redirection lines can be pulled way out of alignment with the redirection points increasing friction and drag in the system. Where possible, wind should be shielded or blocked or lines shortened to minimize side wind loading on the redirection assem- bly.
Page 196: Recertification And Maintenance
12. RECERTIFICATION AND MAINTENANCE 12.1 General Complete inspection and servicing of the zipSTOP unit, Brake Trolley, and associated pulleys and lines in ac- cordance with the Service Schedule. Service actions are detailed in their relevant sections. 12.2 Annual Recertification DO NOT OPERATE THE ZIPSTOP BRAKE UNIT AFTER THE DATE SHOWN ON THE CERTIFICATION LABEL Operation of the zipSTOP Brake Unit without a current Certification Label visible will render the unit not fit for use and will void all warranty.
Page 197: Daily Inspections
NO UNAUTHORIZED SERVICING Do not attempt to carry out any maintenance, repair or service actions not detailed in the User Manual. ipSTOP unit, Brake Trolley, and asso- Any unauthorized maintenance, repair or modifications to the z ciated pulleys and lines will compromise safety, render the unit not fit for use, and void the warranty provisions.
Page 198: Webbing Wear
The zipSTOP Brake Unit and Braking Line, Brake Trolley, Redirection Line and associated hardware must be in- spected on a daily basis for condition and correct operation. The single most important aspect of safe zip line operation is a daily inspection. Example log sheets are included in Section “Appendix C: Example Inspection Logs”.
Page 199 WEAR TABLES Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immedi- ately to continue using your zipSTOP. The green outlined photos show webbing that can be kept in operation. zipSTOP Degree of Wear Side Wear...
Page 200 WEAR TABLES Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immedi- green ately to continue using your zipSTOP. The outlined photos show webbing that can be kept in operation. zipSTOP IR Degree of Wear Side Wear...
Page 201: Braking Line Replacement Procedure
The troubleshooting webbing failure table below describes the symptoms, potential causes, and potential solutions of webbing failure. TROUBLESHOOTING WEBBING WEAR Symptoms Potential Causes Potential Solutions Ensure that the zipSTOP is mounted according to Op- zipSTOP is mounted incorrectly erator Manual. Make sure that the zipSTOP is pointed at your redirection point with no large offset.
Page 202 To replace the Braking Line: Remove the zipSTOP Brake Unit from service and place securely on the work bench. 2. Remove the Nozzle assembly – Refer to Section “Remove Nozzle Assembly”. 3. While holding zipSTOP Brake Unit securely, pull out the Braking Line until the end of the Drum Lead and the Shackle Link are exposed.
Page 203: Brake Trolley Inspection And Maintenance
9. Tighten the Shackle Pin to 2 Nm (18 lb-in), ensuring the threads are fully engaged and the end of the pin is flush with the Shackle Link as shown. 10. Remove the Holding Pin and allow the new line to slowly retract until Drum Lead and Shackle Link are inside casing ONCE SHACKLE PIN IS TIGHTENED IT MUST NOT BE LOOSENED OR RETIGHTENED This will break the locking compound and the shackle pin may become loose.
Page 204: Webbing Line Inspection
12.8 Webbing Line Inspection BRAKING LINE MUST BE REPLACED IMMEDIATELY IF IT IS WORN OR DAMAGED OR AT 12 MONTH INTERVALS, WHICHEVER COMES SOONER Failure to do so may result in equipment failure, serious injury or death to participants. The Braking Line is the line that extends during the zipSTOP activation. The inside end of the Braking Line attaches to the zipSTOP Brake Unit via a Shackle Link to assist with ease of replacement.
Page 205: Braking Distance Charts
13. BRAKING DISTANCE CHARTS CAUTION Always complete unmanned testing to determine actual braking distances and allowable swing up of rider at given weight and arrival speed. Riders stopping too abruptly will swing up and potentially contact the cable. Do not operate the zipSTOP with an excessive amount of rider swing up. Calculated braking distances shown on charts are for guidance use only.
Page 206: 1:1 Ratio - Metric, Zsir150-20A
13.2 1:1 Ratio – Metric, ZSIR150-20A Braking Distance(m) vs. Arrival Speed(kph) vs. Rider Weight(kg) Braking Distance (m) vs. Arrival Speed (km/h) vs. Rider Weight (kg) zipSTOP IR zipSTOP IR Weight (kg) Weight(kg) Arrival Speed (km/h) Arrival Speed (kph) 13.3 1:1 Ratio – Imperial, ZSIR150-20A Braking Distance(ft) vs.
Page 207 13.4 1:1 Ratio – Metric ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 1:1 Reduction Line Ratio 1:1 Redirection Line Ratio BDmin BDmin Rider Weight (kg) Rider Weight (kg) Arrival Speed (kph) Arrival Speed (kph) 13.5 1:1 Ratio – Imperial ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 1:1 Reduction Line Ratio 1:1 Redirection Line Ratio...
Page 208 13.6 2:1 Ratio – Metric, ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 2:1 Reduction Line Ratio 2:1 Redirection Line Ratio BDmin BDmin Rider Weight (kg) Rider Weight (kg) Arrival Speed (km/h) Arrival Speed (kph) 13.7 2:1 Ratio – Imperial, ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 2:1 Reduction Line Ratio 2:1 Redirection Line Ratio...
Page 209: 3:1 Ratio - Metric
13.8 3:1 Ratio – Metric NOTE 3:1 braking charts are available by contacting Head Rush Tech directly. 13.9 3:1 Ratio – Imperial NOTE 3:1 braking charts are available by contacting Head Rush Tech directly. www.headrushtech.com +1-720-565-6885...
Page 210: Appendix A: Ead Warranty/Registration Form
14. APPENDIX A: EAD WARRANTY/REGISTRATION FORM Correct installation procedures as well as the signed and returned registration form below is required for all warranty requests. Incorrect installation or non-registration will void the manufacturer’s warranty (see Section “Warranty Information” for details). 14.1 Warranty Registration Form zipSTOP Model #: Serial #:...
Page 211: Appendix B: Accessories And Replaceable Parts
15. APPENDIX B: ACCESSORIES AND REPLACEABLE PARTS The zipSTOP Brake assembly is fitted with a number of user-replaceable parts and upgrades that may be refit- ted without returning the device to an authorized Head Rush Technologies Service Center. Always follow the manufacturer’s instructions as detailed in this manual when undertaking replacements or upgrades.
Page 212: Specifications
Trolley contacts the Brake Trolley, the Catch Wire captures the Hook so that a rider arriving short of the plat- form can easily be recovered by reeling in the brake trolley. Use of this accessory eliminates the need for an operator to go out onto the line to retrieve stranded riders, increasing throughput.
Page 213 DO NOT REUSE NYLOCK NUTS Nylock nuts are a single use item. Reuse of the item will compromise the nuts locking power and render it susceptible to backing out. 2. Gently separate the two backing plates and slip over the zip line. Do not detach the Catch Wire from the backing plates.
Page 214 4. In order to function properly, the Catch Wire must be horizontal when the Brake Trolley Assembly is fully reset. If using an offset redirection point, rotate the Backing Plate and Catch Wire Assembly such that the Wire is horizontal when reset. If using a directly overhead redirection point, the Catch wire will be perpendicular to the Brake Trolley side plates.
Page 215: Operation
Offset Redirection Point 5. Ensure the Catch Wire rotates freely. Do not rotate the Catch Wire past vertical to prevent damage to the torsion springs. FAILURE TO INSTALL AND INSPECT THE BRAKE TROLLEY CATCH ACCESSORY ACCORDING TO THE PROVIDED SPECIFICATIONS MAY RESULT IN SERIOUS INJURY OR DEATH OF A PARTICIPANT Any indication of the Brake Trolley Catch Accessory or associated hardware being out of specification man- dates the immediate removal of the device from service.
Page 216 Upon arrival at the platform, disconnect the rider from the Impact Trolley and remove the primary and backup cara- biners. Push forward, rotate the Impact Trolley and Hook to the side, then pivot up to remove the Hook from the Catch Wire.
Page 217 Rotate Trolley Pivot Up Remove Trolley UNSAFE OPERATION Remove the Brake Trolley Catch Accessory from service immediately if there is any concern over its correct operation or user safety. Do not return the Brake Trolley Catch Accessory to service until it has been inspected and tested by an ap- proved Head Rush Technologies Service Agent.
Page 218: Zipstop Brake Unit Side Cover Replacement
ENSURE RETRIEVAL ROPE DOES NOT BECOME ENTANGLED Always ensure the retrieval rope used in conjunction with this device does not become entangled with trolley path, any fixed object, including the zip line, or the rider. Entanglement with a fixed object may prevent the brake trolley traveling over the entire braking distance.
Page 219: To Refit The Nozzle Assembly
1. Nozzle Assembly 2. Remove Nozzle Pin 3. Lift out top half 4. Lift out bottom half Inspect the Nozzle assembly for: ‚ Splitting, cracking and deformation around slot and mounting flanges. ‚ Correct fitment in housing. 15.2.8 TO REFIT THE NOZZLE ASSEMBLY: ENSURE THAT THE BRAKING LINE FEEDS SQUARELY AND WITHOUT TWISTS WHEN RETRACTING BACK INTO THE BRAKE UNIT Failure to do so may result in equipment failure, serious injury, or death to participants.
Page 220: Brake Trolley Bump Stop Replacement
3. Fit pin 4. Assembled Nozzle Refit the lower half of the Nozzle assembly into the recess on the casing. 2. Fit the upper half of the Nozzle assembly. 3. Insert pin into nozzle halves. 4. Check zipSTOP for correct operation. 5.
Page 221: Composition
THE ZIPSTOP PIVOT MOUNT IS NOT DESIGNED OR INTENDED FOR USE WITH ANY OTHER DEVICE The zipSTOP Pivot Mount has been specifically engineered for safe use with only the zipSTOP line of devices. Both zipSTOP and zipSTOP IR Zip Line Braking devices can utilize the Pivot Mount, but the Pivot Mount must be used without any external redirection (i.e.
Page 222: Installation
15.3.3 INSTALLATION The following parts are included in the zipSTOP Pivot Mount kit: 1. 1 x Left Pivot Mount Plate 2. 1 x Right Pivot Mount Plate 3. 2 x Center Plate Spacer 6. 8 x 5/8”-11 Stainless Steel 4. 4 x 3/16” O-Ring 5.
Page 223 Inspect all components for damage, cracks, or corrosion prior to installation. Assemble according to the fol- lowing diagram: 5. Upper Spacer 9. 3 x 5/32” Cotter Pin 1. Left Pivot Mount Plate 2. Right Pivot Mount Plate 6. 8 x 5/8” SS Washer 10.
Page 224: Performance
15.3.4 PERFORMANCE Use zipSTOP Braking Distance charts in the zipSTOP Operator’s Manual and the diagram below to determine braking distances and performance. Due to the direct connection between the unit and the brake trolley in the zipSTOP Pivot Mount setup, the braking distances may be shorter than in the zipSTOP Braking Distance charts. Use the zipSTOP Braking Distance charts only as a starting point for tuning performance and braking distance as external and installation factors can change performance.
Page 225: Inspection Procedures
perature and weather conditions. If a component is found to be damaged or worn during inspection, replace- ment parts are available from Head Rush Technologies and Authorized Service Centers. 15.3.6 INSPECTION PROCEDURES Weekly Inspection: Prior to installation and operation of the zipSTOP Pivot Mount, it should be fully inspected according to the procedure below.
Page 226: Appendix C: Example Inspection Logs
16. APPENDIX C: EXAMPLE INSPECTION LOGS Inspections are the single most important step in ensuring correct operation and rider safety. Logging your inspections will help to ensure rider safety and provide an accurate way to track issues and determine correc- tive actions.
Page 227 SAFETY INSPECTION CHECKLIST SITE NAME ZIP LINE INSPECTED: INSPECTED BY: DATE: CORRECTIVE ACTION ITEM PASS FAIL / NOTES – DATE DAILY Visually inspect the zipSTOP Brake Unit for damage, corrosion, and loose fittings and fasteners. Inspect the zipSTOP Brake Unit mounting bracket and pins for damage and ensure that it remains secured correctly.
Page 228: Manufacturer's Details
17. MANUFACTURER’S DETAILS Replacement parts for the zipSTOP and other related products can be purchased at store.headrushtech.com or from an Authorized Head Rush Technologies Distributor. Return the zipSTOP to the manufacturer at the address shown below for any replacement or unscheduled service or repairs.
Page 230 REGISTER YOUR DEVICE Get automatic updates on recertification and product information – visit headrushtech.com/register ANNUAL RECERTIFICATION IS REQUIRED Please keep the shipping box for your device. For instructions on annual recertification, visit headrushtech.com/recertification +1-720-565-6885 www.headrushtech.com info@headrushtech.com Feb 2017...
Page 231 APPENDIX C TRUBLUE / TRUBLUE XL AUTO BELAY Operator Manual Models: TB150-12C / TB150-20A NOTE TO INSTALLERS Always Read Instructions Before Use Leave this Operator Manual attached to the auto belay. The Operator Manual contains information relating to the safe use of the TRUBLUE Auto Belay and includes all product registration and warranty information.
Page 233 TABLE OF CONTENTS SAFETY INFORMATION Symbols Used in this Manual WARRANTY CONDITIONS Customer Responsibility CERTIFICATION Standards DESCRIPTION SPECIFICATIONS AUTO BELAY PARTS Certification Label Location of Safety Labels UNPACKING Precautions Receipt of the Auto Belay Unpacking the Auto Belay Storage INSTALLATION Precautions Standards Anchor Points...
Page 234 INSPECTION & MAINTENANCE Annual Recertification Scheduled Maintenance Safety Precautions Daily Inspection Inspection Procedure Webbing Wear Six Month Inspection Inspection Procedure Webbing Inspection Nozzle Replacement Webbing Line Replacement Safety Precautions Webbing Line Replacement Procedure Replacemant Parts Troubleshooting Transportation MANUFACTURER’S DETAILS www.headrushtech.com | +1-720-565-6885...
Page 235 IMPORTANT SAFETY NOTICE Climbing Is a Dangerous Activity Read Before Installation & Operation Failure by the operator to heed any and all instructions, warnings and cau- tions for the correct installation, operation, care and maintenance of the TRUBLUE Auto Belay may result in death and/or serious injury. TRUBLUE Auto Belay Model TB150-12C, TRUBLUE XL Auto Belay Model TB150-20A and their associated equipment are designed and specified for use in the recreational climbing industry as a controlled descent device.
Page 236: Safety Information
SAFETY INFORMATION Symbols Used in this Manual The following safety symbols are used throughout this manual to highlight po- tential dangers. One or more precautions may be associated with practices and procedures described within this manual. Failure to adhere to any precautions highlighted can result in death, serious injury, or equipment damage.
Page 237: Warranty Conditions
WARRANTY CONDITIONS The TRUBLUE and TRUBLUE XL Auto Belay Devices are warranted against factory defects in materials and workmanship (excluding specific Field Re- placeable Wear Parts - see “Replacement Parts” section below) for a period of two (2) years from date of purchase. This warranty applies only to the original purchaser, and is contingent upon the owner/operator maintaining and using the device in accordance with TRUBLUE Auto Belay instructions, including the requirement to continue to maintain annual re-certification as described in...
Page 238 ƒ Normal replacement of service items. ƒ Replacements required because of abuse, misuse or improper opera- tional habits of the operator. ƒ Field replaceable wear parts. ƒ Normal deterioration due to use and exposure. Adherence to the this Operator Manual, manufacturer’s instructions, and ad- vice given by authorized Head Rush service technicians is the responsibility of the buyer, installer, and operator.
Page 239: Certification
CERTIFICATION Standards NOTE If the TRUBLUE Auto Belay is resold outside of the country of destination, the reseller must provide instructions for use, service, maintenance and repair in the language of the country of use. The TRUBLUE and the TRUBLUE XL Auto Belay can be used as a climbing system device only in combination with other components.
Page 240: Description
DESCRIPTION The TRUBLUE Auto Belay is a controlled descent device designed specifical- ly for use in the climbing industry. The TRUBLUE offers a maximum descent height of 12.5 m (41 ft), and the TRUBLUE XL offers a maximum descent height of 20 m (65.6 ft).
Page 241: Specifications
SPECIFICATIONS TRUBLUE: TB150-12C MODELS TRUBLUE XL: TB150-20A CLASSIFICATION Class A Descent Control Device DIMENSIONS 80 x 320 x 216 mm (15 x 12.6 x 8.5 in) NET WEIGHT 19.75 kg (44 lbs) MATERIALS CASING Aluminum Alloy INTERNAL PARTS Zinc plated steel NOZZLE Modified Acetal plastic NOZZLE INSERT...
Page 242: Auto Belay Parts
AUTO BELAY PARTS MOUNTING POINTS HANDLE CASING COVER (BACK) COVER (FRONT) NOZZLE WEBBING LINE CARABINER Certification Label www.headrushtech.com | +1-720-565-6885...
Page 243: Location Of Safety Labels
Location of Safety Labels SPECIFICATION LABEL INFORMATION LABEL SERIAL LABEL TB150-12C SN0000000 TB150-20A SN0000000 CERTIFICATION LABEL COVER LABEL (Both Sides) www.headrushtech.com | +1-720-565-6885...
Page 244: Unpacking
UNPACKING Precautions LEAVE THIS USER MANUAL ATTACHED TO THE AUTO BELAY UNTIL INSTALLATION IS COMPLETE The Operator Manual contains information relating to the safe use of the TRUBLUE Auto Belay and includes all product registration and warranty information. The Operator Manual document may only be removed by the end user.
Page 245: Storage
3. Check the Certification Label for the ‘Next Recertification Required’ date. If the date shown has passed or the label is missing or illegible, the Auto Belay must not be put into service. 4. Register your Auto Belay online at headrushtech.com/register. PRODUCT REGISTRATION MUST BE COMPLETED Product Registration is critical for receiving product notifications, recertifi- cation notices, and up-to-date information for the safe use of the TRUBLUE...
Page 246: Installation
INSTALLATION Precautions ALWAYS USE DESIGNATED MOUNTING POINTS Never install the Auto Belay using any part of the device apart from the desig- nated mounting points. Incorrect mounting can result in serious injury or death. HARD IMPACTS MAY RESULT IN STRUCTURAL DAMAGE Dropping of, or hard impacts to, the Auto Belay can result in serious damage to mounting points and internal parts and may compromise safety of operation.
Page 247: Harness
The location and anchor points for the TRUBLUE Auto Belay should comply with the following: ƒ Anchor points are not to be used by additional devices or as attach- ments for hardware not associated with the Auto Belay installation. ƒ Anchor points should be of a suitable size to correctly install any mount- ing hardware.
Page 248: Outdoor Installations
ƒ All paths that can be used by the climber when connected to the Auto Belay are free of sharp edges and high-friction surfaces that may dam- age the webbing line. ƒ Ensure that the descent path and landing area are free of other climbers, pedestrians or obstacles that may cause entanglement or restrict the climber’s ascent or descent.
Page 249: Single Point Mounting
The TRUBLUE Auto Belay is manufactured with a single central pivot mounting point, an offset mounting point and formed handle located at the top of the cas- ing. These mounting points are located on the central plate and are located to ensure the unit hangs centrally and vertically with the line nozzle pointing down.
Page 250: Orientation
ORIENTATION Always mount the Auto Belay with the round covers parallel to the face of the climbing wall. Mounting in this direction will allow the Auto Belay to swing laterally and minimize the wear on the webbing line, nozzle assembly and mounting points.
Page 251: Operation
OPERATION Owners and purchasers of the TRUBLUE Auto Belay are responsible for the safety and supervision of any person using this equipment and are required by the manufacturer to read, understand and follow all instructions in this Oper- ator Manual regarding the correct installation and operation of the Auto Belay prior to any use.
Page 252: Climbing Harness
Prior to climbing the user must be aware of, and completely understand, the following precautions: ƒ Check Auto Belay operation by pulling out a short section and allowing it to retract. ‚ If the Auto Belay line fails to retract, do not clip into the Auto Belay and request assistance.
Page 253: Operation
OPERATION The carabiner is opened by sliding the gate down, rotating the gate’s collar and pushing the gate open towards the center of the carabiner. ƒ Attach the carabiner to the correct loop on the harness with the latch facing away from the user. ƒ...
Page 254: Inspection & Maintenance
INSPECTION & MAINTENANCE Annual Recertification DO NOT OPERATE AFTER THE DATE SHOWN ON THE CERTIFI- CATION LABEL Operation of a TRUBLUE Auto Belay without a current Certification Label visible will render the unit not fit for use and void all warranty. The TRUBLUE Auto Belay requires an annual service and recertification inspec- tion to be carried out by an authorized Head Rush Technologies service agent.
Page 255: Safety Precautions
NOTE Service in a clean environment. If Auto Belay has been removed from its operational location for service, ensure that the service area is clean and free from contaminants. Ensure unit is securely placed on a sturdy work table and that side covers are not subject to damage.
Page 256 1. Clean any dust, dirt or contamination off the casing and fittings with a clean cloth. DO NOT USE SOLVENTS OR ABRASIVES Clean with a cloth only. Do not use any cleaners, solvents or abrasives on any part of the Auto Belay or its associated equipment. 2.
Page 257: Webbing Wear
WEBBING WEAR INSPECT WEBBING DAILY Webbing in your TRUBLUE must be evaluated on a daily basis. A detailed description of when a webbing should be taken out of service is included in the Wear Tables below. Webbing MUST be taken out of service by the time the webbing resembles the stage of wear designated in the Wear Tables.
Page 258 WEAR TABLES Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immediately to continue using your TRUBLUE The green outlined photos show webbing that can be kept in operation. TRUBLUE XL Degree of Wear Edge Wear Face Wear...
Page 259 TROUBLESHOOTING WEBBING WEAR Symptoms Potential Causes Potential Solutions Climbers are excessively Mark out auto belay boundaries so climbers swinging as they descend do not pendulum greatly as they descend. Stainless steel nozzle Inspect nozzle insert for burrs and other insert is damaged damage.
Page 260: Six Month Inspection
Six Month Inspection The TRUBLUE Auto Belay requires an in depth six (6) month inspection by the Operator to maintain its safe and efficient operation. For the six monthly in- spections the unit must be dismounted and removed to a sturdy work table. INSPECTION PROCEDURE 1.
Page 261 ƒ UV degradation – although difficult to detect, visual indications are discoloration, fading and chalking of the webbing surface. ƒ Chemical attack, this can result in soft or weak fibers, color change or flaking of the surface. ƒ Heat or friction damage, indicated by hard fibers or glazing of the surface.
Page 262: Nozzle Replacement
Nozzle Replacement If the nozzle assembly shows signs of excessive wear, damage, or poor fit it must be replaced. USE ONLY GENUINE TRUBLUE REPLACEMENT PARTS ALWAYS REPLACE NOZZLE AS A PAIR If nozzle requires replacement, always replace as a matched pair – do not mix worn and new nozzle pieces.
Page 263: Webbing Line Replacement
Refit the Nozzle assembly: 1. Refit the lower half of the nozzle assembly into the recess on the casing. 2. Fit the upper half of the nozzle assembly. 3. Remove webbing pin and allow the webbing to slowly rewind into the casing until fully retracted.
Page 264: Webbing Line Replacement Procedure
WEBBING LINE REPLACEMENT PROCEDURE To replace the webbing line: 1. Remove the Auto Belay from service and place securely on the work bench. 2. Remove the Nozzle assembly – Refer to ‘Remove Nozzle Assembly’ above. 3. While holding Auto Belay securely, pull out the webbing line until and the end of the drum lead and the joining shackle are exposed.
Page 265 TORQUE = 2 Nm Correct shackle fit 9. Tighten the shackle pin to 2 Nm (18 lb-in), ensuring the threads are fully engaged and the end of the pin is flush with the joining shackle as shown. 10. Remove the holding pin and allow the new line to slowly retract until drum lead and joining link is inside casing.
Page 266: Troubleshooting
tions as detailed in this User Manual and any Part Replacement Guide supplied when undertaking replacement of a part. NOTE For optimal performance of your TRUBLUE Auto Belay, only use genuine TRUBLUE parts and accessories. When ordering replacement parts, please specify the part number and descrip- tion of the part.
Page 267 authorized Head Rush Technologies service agent, or online at https://store. headrushtech.com. You will be responsible for the cost of any damage and necessary repairs due to shipping your auto belay in unauthorized packaging. CARE FOR THE ENVIRONMENT Reuse the original packaging when shipping Auto Belay. www.headrushtech.com | +1-720-565-6885...
Page 268: Manufacturer's Details
MANUFACTURER’S DETAILS For Recertification or unscheduled service or repairs, return your TRUBLUE Auto Belay to your nearest Head Rush Technologies Authorized Service Center or to the Manufacturer at the address shown below. ADDRESS CONTACT DETAILS Head Rush Technologies +1-720-565-6885 1835 38th Street, Suite C www.headrushtech.com Boulder, CO 80301 info@headrushtech.com...
Page 270 REGISTER YOUR DEVICE Get automatic updates on recertification and product information – visit headrushtech.com/register ANNUAL RECERTIFICATION IS REQUIRED Please keep the shipping box for your device. For instructions on annual recertification, visit headrushtech.com/recertification +1-720-565-6885 www.headrushtech.com info@headrushtech.com Jan 2017...
Page 271 APPENDIX D Robertson Harness Inc. Proudly Made In The USA Robertson Harness Inc. P.O. BOX 90086-0086 Henderson, NV. 89009 USA www.robertsonharness.com (702) 564-4286 Zip Tour Harness # Item CRC 300 Series These instructions are provided to the user by the manufacturer and # CRC301 26 to 36"...

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