Alien flier Zip series Operating instructions

Alien Flier Zip Line Products

Installation/Owner’s Manual

Table of Contents

SAFETY –PLEASE READ CAREFULLY................................................................................................. 4

Constructing your Zip Line Xtreme Models ..................................................................................... 6

Installing your Alien Flier Trolley on an Existing Zip Line.......................................................................... 11

Preparing the Flexi-Seat ........................................................................................................................... 13

Final Assembly.......................................................................................................................................... 14

Recommendations for Launching Reaching the Top................................................................................ 15

Trolleys without a seat A word of caution................................................................................................ 15

Installing a Stop Block.................................................................................................................... 16

Replacing the Brake Pad................................................................................................................ 17

Setting up a Zip Line with Turnbuckle Tensioner All Explorer T, TD and S models........................ 18

Setting up a Zip Line with Ratcheting Harness Tensioner Explorer P-100..................................... 19

REPLACEMENT PARTS.................................................................................................................... 21

PARTS LIST - BRAKE ASSEMBLY................................................................................................................. 22

PARTS LIST - TROLLEY ............................................................................................................................... 23

FLEXIBLE SEAT ASSEMBLY......................................................................................................................... 24

PARTS LIST - SHEAVE REPLACEMENT KIT.................................................................................................. 25

PARTS LIST –TROLLEY W/DISC SEAT ........................................................................................................ 26

PARTS LIST - AF ORIGINAL –continued .................................................................................................... 27

PARTS LIST –XTREME, EXPLORER S & CABLE-FREE.................................................................................. 28

PARTS LIST –XTREME, EXPLORER S & CABLE-FREE - continued............................................................... 29

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SAFETY –PLEASE READ CAREFULLY

DO NOT USE ALIEN FLIER ZIP LINE PRODUCTS UNTIL YOU HAVE READ THE SAFETY

WARNINGS BELOW

Assumption of Risk

Zip line construction and use can be dangerous. Ensure you know what you are doing before

building or using your Alien Flier Zip Line kit or other Alien Flier LLC products. Alien Flier LLC

takes no responsibility for the installation, servicing, maintenance, tree issues, and periodic

inspection, related components or of any installed zip line using our products.

No warranty related to Alien Flier Products is expressed or implied by installation tips or by any

representative of Alien Flier LLC, including warranties of merchantability or fitness. Ensure you

educate yourself on the proper installation, maintenance and use of everything related to your

Alien Flier product. Seek competent local assistance if you are unsure of how to work with

trees, cable installation or maintenance. All information related to Alien Flier products received

from any representative, printed, or digital, distributed by Alien Flier LLC is only an opinion and

shall not be interpreted as an expert or professional advice. Contact component manufacturer

for information about warranty and use of their products

A zip line can be very dangerous.

Do not use this kit if you do not understand the risk involved in riding a zip line. The cable

can hold weights many times that of most riders and is the least part of the system to fail.

Pay special attention to your workmanship making the loops and slings for these are the

areas where failures are more common to occur.

Use under adult supervision only.

Do not mount your zip line to anything other than proper size trees.

Inspect the entire zip line system including the pulley and sling for damage or wear before

every use. DO NOT ride a system that is damaged.

Falling x Fast Speeds x Rough Landings (stumps, rocks etc) = Serious injury

Ignoring safety recommendations = Serious injury

Poor installation workmanship = Serious injury

Single riders only! Do not ride double. Never overload the cable. We do not recommend

riders over 275 lbs.

Always hold onto the T-bar with both hands. Always ride seated (seat models)

Do not jump off your zip line while you are traveling on it.

Make sure there are no obstructions in the path of the rider.

Do not install a zip line around a high voltage line, over roads or ravines.

Never set the cable rate of descent to unsafe angles or heights.

Always include a safety back up STOP BLOCK in conjunction with all of our models

Constructing your Zip Line

Xtreme Models

Some things you will need:

If these parts are not included with the kit you purchased, most hardware stores and home

centers carry these items.

(1) 2-4 TON COME ALONG

Up to (18) 3/16” to 7/16” WIRE ROPE CLAMPS, as appropriate to your wire rope diameter.

Up to (6) 3/16 TO 7/16 THIMBLES, as appropriate to your wire rope diameter.

7x19 GALVANIZED WIRE ROPE 3/16 TO 7/16 DIAMETER WIRE ROPE

1. Determine a distance for your zip line. Typically 100-200ft. Be sure the trees you choose

to anchor the zip line are big enough (8-10 inches + recommended) There should be no

obstruction in the path of your zip line. You want a straight clear path. Once you have

chosen your area and anchor trees, measure the distance from tree to tree to

determine your cable length. Remember to add enough cable to loop around both

anchor trees, plus (if not included pre-made with your kit) an additional 4-6 feet for the

lower end safety link.

2. Stretch out your cable between the trees to be sure there is enough. If not pre-made on

your cable, make a loop on one end as shown below. Be sure to include a thimble.

Clamps should be approximately 3 inches apart. This will be the high end of the zip line.

NOTE: Use black electrical tape to keep the cable from fraying on the end

3. Using a ladder, climb the tree you have chosen for the high end of the zip line. A typical

height is 8 - 12 feet.

Nail a series of 2” thick wooden blocks around a tree where the cable will be tightened.

DO NOT drive the nails in too far, only enough to hold the blocks temporarily. The nails

will be removed later. The blocks will protect the tree from damage by the cable. Wrap

your cable around the tree and blocks –rest the cable on the nails to help keep the cable

in place. Slip the cable through the loop and position as shown below.

4. Add the trolley

Slip the cable through the pulley as shown below.

Cut-away view showing cable route

5. Determine a length for the lower anchor sling. Cut a piece of extra cable and install a

loop on each end. Make one loop slightly bigger than the other. Be sure to use 3 cable

camps and a thimble on each loop. (see step 1)

Decide a height for your lower anchor sling. Install wooden blocks and place your sling

around the tree as shown below. NOTE: This is a good time to think about stopping the

rider safely*.

When determining a height for the lower cable anchor, consider that the cable will

stretch as the rider travels on it. The lower anchor height determines the riders landing

height.

*There are 2 easy ways to stop the rider at the end of a zip line. You can adjust the cable

by raising or lowering the cable anchor so that the rider will stop by landing on their feet

before running out of line, or you can add our recommended Stop Block.

6. Attach 2- ton come-a-long to the lower tree anchor loop. Be sure to place the solid end

on the tree anchor side and NOT the cable end.

a. Pull 2-3 feet of cable out of the come-a-long.

b. Make a loop on the zip line where the come along will connect. Be sure to use a

thimble and 3 clamps 3 inches apart (see step 1 for proper loop construction).

c. Insert the come along hook into the zip line loop. Tighten the cable by pulling

the lever on the come along. Put a fair amount of tension on the cable then

check all your cable clamps for tightness.

7. Safety link: Do not use your zip line without this link.

The purpose of this link is to maintain tension on the zip line in the event that the come

along fails. A few minutes spent could make the difference between a load of fun and a

serious injury. This link should always be maintained and kept tight. NEVER use your zip

line without this safety link installed.

a. If the Safety Link is not included with your kit, make another sling with a loop on

one end (see step 5).

b. Wrap the safety link around the lower anchor tree just below the anchor sling.

Slip the end of the cable through the loop and pull the cable snug around the

blocks

c. Take the end of the cable and run it through the loop on the zip line making a

connecting loop. Clamp the loop together as in step 2.

Testing the safety link: Tighten the zip line cable to a good tension. Remove all nails from the

blocks/tree. Readjust the safety link so that it is very tight. Once the safety link is ready-loosen

the come along until the safety link is holding the zip line tension. Inspect all your clamps and

line. After inspection tighten the come along so that it carries approximately ½ of the tension of

the zip line load. If later adjustments are made to the zip line always readjust the safety link as

well.

NEVER use your zip line if this link is not tight.

Installing your Alien Flier Trolley on an Existing Zip Line

Tools needed:

5/32 Allen wrench

7/16 wrench

Philips screw driver

1. Remove the (4) lower screws, nuts and spacers using a 5/32 Allen wrench for the screw

head, 7/16 wrench for the nuts. Remove the trigger bolt using Philips screwdriver (units

with brakes only).

2. Drop the trolley onto the line.

3. Re-install the (4) lower screws, nuts and spacers using a 5/32 Allen wrench for the screw

head, 7/16 wrench for the nuts. Replace the trigger bolt using Philips screwdriver (units

with brakes only).

Preparing the Flexi-Seat

Thread the webbing through the seat as show. Be sure to have 2 equal lengths when you are

done.

Final Assembly

Study the picture above:

1. Thread the seat kit webbing ends through the trolley and plastic tri glide buckles as

shown.

2. Tie the towrope to the spacer as shown above.

3. Slide the T-bar though the trolley then slide the foam grip onto the T-bar end.

Recommendations for Launching

Reaching the Top

We HIGHLY recommend towing the rider to reach the top of the run. The rider sits safely on the

seat while holding the T-bar. An adult using the provided towline pulls the rider to the top

eliminating the need for a platform or ladder where falling accidents most commonly occur.

Trolleys without a seat

A word of caution

It is extremely important to understand when setting up a seatless zip line there is the potential

for the rider to lose grip and fall. TAKE EXTREME CARE in the line design so that if the rider does

lose grip that the fall is but a few feet. PLEASE READ OUR ASSUMPTION OF RISK STATEMENT.

Installing a Stop Block

A stop block is a simple device. It rides on the cable and is attached to a shock cord or bungee

cord, which is anchored to a tree or is staked into the ground. As the rider nears the end of the

line, the trolley comes in contact with the stop block causing the shock cord to stretch and slow

the rider to a stop. These are very inexpensive, safe and tensions can be adjusted for different

size riders.

(top view)

Replacing the Brake Pad

Required Tools:

7/16”wrench, 5/32 Allen Wrench, Philips head screwdriver

1. Remove long bolt on trigger.

2. Remove brake from above.

3. Use screwdriver to pop out old pad.

4. Slip new pad in.

5. Replace brake unit.

6. Replace long bolt.

Setting up a Zip Line with Turnbuckle Tensioner

All Explorer T, TD and S models

Required Tools:

leather gloves, wrenches for tightening clamps and turnbuckle

1. Select the location for your line. Only use trees that are about 8+ inches in diameter

(hardwood trees are recommended)

2. Be sure that there are no obstructions, electrical wires, ravines, roads, etc. in the

way.

3. Determine distance to be sure that your line will fit between your trees.

4. Wrap one end around tree and thru loop, approximately 8-12 ft up the tree.

5. Thread line thru the trolley.

6. Move to the next tree.

7. Wrap the sling (cable with loop at each end) around the tree approximately 6-8ft

high.

8. With the turnbuckle fully extended, attach it to the sling.

9. Attach the end of the line to the turnbuckle using the clamps provided

(see illustration on page 4 for correct clamp installation)

10. Using the wrench, tighten turnbuckle until there is no slack in the line.

SAFETY NOTES

We highly recommend the following:

Install a Stop Block at the termination point of all zip lines.

Install a Safety Link from the lower tree to the looped end of the cable.

Setting up a Zip Line with Ratcheting Harness Tensioner

Explorer P-100

1. Select the location for your line. Only use trees that are about 8+ inches in diameter

(hardwood trees are recommended)

2. Be sure that there are no obstructions, electrical wires, ravines, roads, etc. in the way.

3. Determine distance to be sure that your line will fit between your trees.

4. Nail the 4 wooden blocks on the higher tree

5. Wrap one end around tree and thru loop, approximately 8-10ft up the tree.

6. Thread the line through the trolley

7. Attach the cable to the webbing d ring using the same method that is shown on page 5

of this manual. Note: bend the thimble so that it fits around the d-ring

8. Tighten 3 clamps as shown on page 4 of this manual.

9. Wrap the webbing sling around the tree approximately 6-8 feet high.

10. Insert the end of the webbing into the ratchet and tighten. Handle ratchet with care!

SAFETY NOTES

We highly recommend the following:

Install a Stop Block at the termination point of all zip lines.

Install a Safety Link from the lower tree to the looped end of the cable.

Maximum height for this type of line is 10ft.

Enjoy Your Zip Line SAFELY!

For parts and accessories please visit our Website

www.AlienFlier.com

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