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head rush technologies ZIPBACK ZB-01 Repair Manual

Retraction device
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R E P A I R
G U I D E
z ipB ACK RET R ACT I ON DEV I C E
Models: ZB-01

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Summary of Contents for head rush technologies ZIPBACK ZB-01

  • Page 1 R E P A I R G U I D E z ipB ACK RET R ACT I ON DEV I C E Models: ZB-01...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. INTRODUCTION 2. SAFETY 3. PARTS LIST 4. PART IDENTIFICATION 4.1 Retraction Spring Side 4.2 Void Side 5. REPAIR 5.1 Tools & Consumables Required 5.2 Torque Value Table 5.3 Service Procedure 5.3.1 Retraction Spring Side 5.3.2 Void Side 12252-01 www.headrushtech.com +1-720-565-6885...

  • Page 3: Introduction

    WARNING: This document and all content incorporated within is confidential and intended solely for the use of Head Rush Technologies Authorized Service Centers. This document is for internal use only and shall not be disseminated or distributed to any party outside of the Authorized Service Center. All parties are hereby notified that disclosing, copying, distributing, or taking any alternative action in regard to the content of this document is strictly prohibited;...

  • Page 4: Safety

    2. SAFETY While working on Head Rush Technologies’ Units, there are many safety concerns that you must be aware of to mitigate risk. Work deliberately, wear safety glasses, and be aware of conditions and of those around you; these actions are paramount while servicing Units.

  • Page 5: Parts List

    3. PARTS LIST These part names are for reference only. Please use the Service Center Parts List to order replacement parts. ABBREVIATIONS USED Head Rush Technologies zipSTOP zipBACK QUICKjump FlightLine ZIPBACK PARTS LIST ITEM QUANTITY PART NAME Central Plate - ZS...

  • Page 6: Part Identification

    4. PART IDENTIFICATION 4.1 Retraction Spring Side 12252-01 www.headrushtech.com +1-720-565-6885...

  • Page 7: Void Side

    4.2 Void Side 12252-01 www.headrushtech.com +1-720-565-6885...

  • Page 8: Repair

    5. REPAIR 5.1 Tools & Consumables Required TOOLS TORQUE WRENCHES HEX KEYS Head Rush Unit Bench 47 Nm 6 mm Flathead Screwdriver 18 Nm 2.5 mm Soft Head Hammer 2.5 Nm Adjustable Pliers PROTECTIVE EQUIPMENT SOCKETS Flashlight Impact Driver Gloves 18 mm Standard Wrench Safety Glasses...
  • Page 9 Lay the unit down so that the Spring Side is up. Place the Unit Spring Side up on workbench. It is important to ensure that the PSD is not damaged in a way that allows the Retraction Spring to release unintentionally. Secure the Unit with the bench arm, and look inside the Unit while slowly pulling out Webbing.
  • Page 10 Loosen the remaining four Housing Bolts (6 mm hex key). Lift the Housing off the unit. Inspect all bolts for damage or corrosion. Inspect the Housing for any damage or sharp points. Expel any foreign debris from the Housing using compressed air and a toothbrush, particularly around the Nozzle.
  • Page 11 Remove the Isolation Insert, and inspect for any damage, cracking, or cuts. Isolation Insert should be flexible yet firm. Remove the Housing Insert, and inspect for damage. If Housing Insert is difficult to remove, use a gear puller to facilitate removal. Remove the Plastic Spring Drum (PSD) Cover Plate Spacer.
  • Page 12 Secure the unit to the bench using the Bench Arm. Remove the Webbing Roller and Roller Pin. Inspect them for damage, corrosion, change in diameter, and foreign debris. Ensure the Roller spins freely on the Pin. Clean and set aside. Remove Nozzle, pull apart, and inspect for damage.
  • Page 13 Pull out all the webbing. Pin down the Short Webbing Loop. Remove Shackle and Shackle Pin (2.5 mm hex key). 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 14 Unpin the Short Webbing Loop and guide it back into the unit, preventing it from becoming stuck in the Webbing Guide Band. Using gloved hands, control the PSD as the Retraction Spring unwinds. Unscrew the PSD Cover Plate Screws (T08 torx), keeping a hand on top of the PSD Lid.
  • Page 15 Lift the PSD Lid and slide one hand over the entire Retraction Spring. Keep one hand on top of the PSD Lid. Remove the PSD Lid and ensure that the Retraction Spring will not move. Unscrew the Retraction Spring Nut (8 mm socket).
  • Page 16 Turn the PSD so the PEM Stud is furthest away from you (close to the bench arm) and lift the outer coils of the Retraction Spring. While holding the outer coils of the Retraction Spring lift the Retraction Spring where the arbor is attached to the Shaft.
  • Page 17 Inspect Webbing Guide Band. Ensure that it does not rub heavily on the Webbing Guide Plates, that the Webbing Guide Band Clips are securely in place, it is not over-bent, and that it is not damaged. Using a gloved finger, press the Webbing Guide Band towards the Center Plate to observer the edges of the Webbing Guide Band, looking for damage;...
  • Page 18 Slide the Retraction Spring arbor into the notch in the Shaft. Lower the Retraction Spring into the PSD and ensure the Retraction Spring is pushed all the way down at the Shaft. Screw the Retraction Spring Nut (8 mm socket) onto the PEM Stud and torque to 2.5 Nm.
  • Page 19 Place the PSD Lid onto the PSD and align the holes of the Lid and PSD. Install the five PSD Cover Plate Screws (T08 torx). Attach the Spring Winder Clamp around the upper edge of the PSD. 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 20 Start winding and guide the Short Webbing Loop between the Guide Plates. Wind in a counter-clockwise direction until coming to a complete stop. Unwind the PSD and find the Short Webbing Loop; secure the Short Webbing Loop to the bench. Ensure the PSD has not unwound more than one and a half turns.
  • Page 21 Lock the bench arm in place onto the Shaft. Remove the Spring Winder Clamp. Slide a Shackle into the end of the Short Webbing Loop. Slide the end of the webbing into the Shackle and screw in a new Shackle Pin (2.5 mm hex key). 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 22 Ensure the Shackle Pin is completely screwed into the Shackle; the Shackle Pin end should protrude slightly from the Shackle. Hold the top of the PSD and unwind it slightly to loosen the tension on the webbing to remove the bench pin.
  • Page 23 Once most of the webbing has been retracted into the unit, slide a Nozzle Half into the Housing and slide the webbing into the Nozzle Insert. Slide the second Nozzle Half into place and install the Nozzle Clip. Press or use a soft-headed hammer to fully seat the Nozzle Clip in place.
  • Page 24 Slide the PSD Spacer onto the Shaft. Slide the Housing Insert onto the Shaft. Slide the Isolation Insert onto the Housing Insert and ensure it is fully seated as shown. 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 25 Install the Housing onto the unit. Tighten down the Shaft nut (18 mm socket). Tighten the four Housing Bolts (6 mm hex key) in a star pattern. 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 26 Tighten the Security Bolt (Security Housing Bolt key) last. Torque the Shaft Nut (18 mm socket) to 47 Nm. Torque the Housing Bolts (6 mm hex key) and the Security Bolt (Security Bolt key) to 18 Nm. The Retraction Spring Side is now complete. 12252-01 www.headrushtech.com +1-720-565-6885...

  • Page 27: Void Side

    5.3.2 VOID SIDE Turn the unit over so that the Void Side is up. Unscrew the Shaft Nut (18 mm socket). Unscrew the four Housing Bolts (6 mm hex key) and the Security Bolt (Security Bolt key). 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 28 Remove the Housing. Inspect all bolts for damage or corrosion. Remove the Isolation and Housing Inserts. Inspect the Isolation Insert for any damage, cracking, or cuts; it should be flexible yet firm. Remove the Orientation Unit Spacer from the Shaft and inspect for corrosion or damage. Replace if corroded or damaged.
  • Page 29 Install the Housing Spacer onto the Shaft. Slide the Isolation Insert onto the Housing Insert and ensure it is fully seated as shown. Pull the Nozzle Assembly out of the way and slide the Webbing Roller and Roller Pin into place on the right of the two holes in the Housing.
  • Page 30 Install the Housing onto the unit. Tighten down the Shaft nut (18 mm socket). Tighten the Housing Bolts (6 mm hex key) and Security Bolt (Security Bolt key) in a star pattern, tightening the Security Bolt last. Torque the Shaft Nut (18 mm socket) to 47 Nm. 12252-01 www.headrushtech.com +1-720-565-6885...
  • Page 31 Torque the Housing Bolts (6 mm hex key) and Security Bolt (Security Bolt key) to 18 Nm. Turn the unit on its side and retract some webbing from the device, ensuring smooth operation. The Void Side is now complete. Ensure the sticker “NOT FOR ZIPLINE BRAKING” is attached to the side of the unit.
  • Page 32 1835 38th Street, Suite C, Boulder, CO 80301 USA +1-720-565-6885 www.headrushtech.com info@headrushtech.com Apr 2020...