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Alien Flier Zip Series, Installation & Owner'S Manual

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Alien Flier Zip Series Installation & Owner'S Manual Download Page 1

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Copyright 

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 2012 Alien Flier LLC. All Rights Reserved 

 

Alien Flier Zip Line Products 

Installation/Owner’s Manual 

 
 
 

 

 
 
 

 
 
 
 
 
 
 

 

 
 
 

Summary of Contents for Zip Series

Page 1: ...1 Copyright 2012 Alien Flier LLC All Rights Reserved Alien Flier Zip Line Products Installation Owner s Manual ...

Page 2: ... 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 P...

Page 3: ...3 Copyright 2012 Alien Flier LLC All Rights Reserved page intentionally left blank ...

Page 4: ...al 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...

Page 5: ...5 Copyright 2012 Alien Flier LLC All Rights Reserved ...

Page 6: ...ts 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 ...

Page 7: ...re 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 sh...

Page 8: ...oved 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 extr...

Page 9: ...e 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 li...

Page 10: ... 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 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 ...

Page 11: ...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 ...

Page 12: ...ights Reserved 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 ...

Page 13: ...13 Copyright 2012 Alien Flier LLC All Rights Reserved Preparing the Flexi Seat Thread the webbing through the seat as show Be sure to have 2 equal lengths when you are done ...

Page 14: ...nal 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 ...

Page 15: ... 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 f...

Page 16: ...ttached 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 ...

Page 17: ...rved 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 ...

Page 18: ...n 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...

Page 19: ...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 in...

Page 20: ...20 Copyright 2012 Alien Flier LLC All Rights Reserved Enjoy Your Zip Line SAFELY For parts and accessories please visit our Website www AlienFlier com ...

Page 21: ...21 Copyright 2012 Alien Flier LLC All Rights Reserved REPLACEMENT PARTS ...

Page 22: ... ASSEMBLY Number Description Part Number Quantity 1 Brake Pad Holder 30200000 1 2 Brake Pad 30150000 1 3 Trigger Screw 30950000 1 4 Trigger Spacer 31100000 3 5 Nut 30800000 1 6 Brake Return O Ring 30250000 2 7 Grooveless Retainer 31370000 2 8 Brake Assembly 1 7 21000000 1 ...

Page 23: ...0000 1 2 Frame Gold 30500000 1 3 Frame Screw 30900000 7 4 Frame Nut 30800000 7 5 Sheave Assembly 24000000 1 6 Tow Rope Assembly 21260000 1 7 CD discontinued 30300000 1 8 Handle 30700000 1 9 Handle End Cap 31350000 2 10 Foam Grip 30400000 2 11 Handle Assembly 8 10 24250000 1 12 Brake Assembly 21000000 1 13 Frame Spacer 31100000 7 ...

Page 24: ... Alien Flier LLC All Rights Reserved FLEXIBLE SEAT ASSEMBLY Number Description Part Number Quantity 1 Seat Yellow 30060000 1 2 Webbing 8 Ft 31400000 1 3 Tri Glide 1 In 31300000 2 4 Flexible Seat Assembly 1 3 22500000 1 ...

Page 25: ...ien Flier LLC All Rights Reserved PARTS LIST SHEAVE REPLACEMENT KIT Number Description Part Number Quantity 1 Sheave 040 Wide 31000000 2 2 Bearing Spacer 31150000 4 3 Bearing R4 30100000 4 4 Sheave Assembly 1 3 24000000 1 ...

Page 26: ...26 Copyright 2012 Alien Flier LLC All Rights Reserved PARTS LIST TROLLEY W DISC SEAT ...

Page 27: ...0000 7 4 Frame Screw 30900000 7 5 Frame Nut 30800000 7 6 Sheave Assembly 24000000 1 7 Brake Assembly Optional Kit 21000000 8 Tow Rope Assembly 21260000 1 9 CD discontinued 30300000 1 10 Blue Disc Seat 30350000 1 11 Handle 30700000 1 12 Foam Grip 30400000 2 13 Handle End Cap 31350000 2 14 Handle Assembly 11 13 24250000 1 15 Decal discontinued 30010000 1 16 Washer 31620000 1 17 Webbing 31450000 1 ...

Page 28: ...28 Copyright 2012 Alien Flier LLC All Rights Reserved PARTS LIST XTREME EXPLORER S CABLE FREE Front frame plate cut away one nut not shown for clarity ...

Page 29: ...1 3 Frame Spacer 31100000 7 4 Frame Screw 30900000 7 5 Frame Nut 30800000 7 6 Sheave Assembly 24000000 1 7 Brake Assembly 21000000 1 8 Tow Rope Assembly 21260000 1 9 CD discontinued 30300000 1 10 Flexible Seat Assembly 22500000 1 11 Handle 30700000 1 12 Foam Grip 30400000 2 13 Handle End Cap 31350000 2 14 Handle Assembly 11 13 24250000 1 15 Decal discontinued 30010000 1 16 Webbing 31400000 1 ...

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