Creative engineering Rock-a-fire explosion User manual

CREATIVE ENGINEERING

INCORPORATED

•

ROCK-A-FIRE EXPLOSION

SERVICE

MANUAL

CREATIVE

ENGINEERING

INCORPORATED

Rock-A-Fire

Explosion

SERVICE

MANUAL

This

manual

will

provide

you

with

the

necessary

information

in

order

to

maintain

and

service

your

Rock-A-Fire

Explosion

Show

for

years

to

come.

The

manual

is

divided

up

into

five

main

parts.

Each

part

may

be

considered

as

a

unit

in

itself

with

occasional

references

being

made

to

other

parts

of

the

manual.

All

the

necessary

diagrams,

charts,

schematics,

drawings

and

instructions

are

contained

in

this

manual.

For

ordering

parts,

please

refer

to

Part

1,

pages

1-015

thru

1-017.

All

part

numbers

are

available

in

the

"Parts

Catalog".

It

should

be

noted

that

the

Trouble-Shooting

Guides

are

designed

to

be

used

by

experienced

technicians

who

are

familiar

with

the

operation

of

the

system.

Our

approach

to

this

manual

is

one

that

assumes

that

the

show was

installed

correctly

and

has

functioned

correctly

for

a

period

of

time.

We

do

not

intend

to

deal

with

improper

installation,

nor

modifications

made

to

the

system

outside

of

instructions

from

Creative

Engineering

Inc.

The

Trouble-Shooting

Guide

is

meant

to

be

read

in

a

descending

order

until

you

find

the

exact

cause

of

the

problem

and

make

the

necessary

corrections.

Find

the

symptom

that

best

describes

the

problem

you

are

experiencing.

Begin

in

the

left

column

with

the

first

step

and

move down

the

numbered

steps

for

each

procedure.

The

right

column

will

give

you

the

location

for

more

detailed

information,

as

well

as

anticipated

results.

If

the

problem

is

not

corrected

after

each

step

is

completed,

move

to

the

The

repair

section

contains

a

more

detailed

account

on

the

methods

of

repair

and

maintenance.

If

at

any

point

you

do

not

feel

that

you

have

a

good

grasp

of

the

information

from

the

Trouble~Shooting

Guides,

then

turn

immediately

to

the

repair

section

for

a

further

explanation.

"Property

of

Creative

Engineering,

Inc.

Reproduction

W/0

Authorization

is

strictly

prohibited."

ii

Part

1.

Part

2.

Part

3.

Part

4.

Part

5.

Table

of

Contents

Power

up,

Power

Down

Procedures and

Preventive

Maintenance Pages 1-001

thru

1-018

Mechanical Trouble-Shooting Guide

Pages 2-001

thru

2-010

Repairs:

Air,

Mechanical and Cosmetics

Pages 3-001

thru

3-187

Electronic

Trouble-Shooting Guide

Pages 4-001

thru

4-019

Electronic

Repair Pages 5-001

thru

5-082

Glossary

Actuation

Levers:

A

front

mount

lever

of

the

air

cylinder

that

moves

during

the

cylinder

action.

Adjustment

Tape:

V.C.

tape.

Aircraft

bolt:

A

gold

anodized

bolt

with

a

long

shaft

and

fine

threads,

used

where

a

cylinder's

front

mount

rod

end

joins

with

a

flanged

block.

An

example

is,

the

head-left-right

cylinder's

front

mount.

Air

Dryer:

The

part

of

the

air

system

located

down

line

from

the

storage

tank.

It

removes

the

moisture

from

the

air.

Air

Regulator:

An

adjustable

device

that

controls

air

pressure

flowing

through

it.

Amps:

Amplifiers

Barb

fitting:

The

fitting

used

to

attach

air

lines

to

other

devices.

BD:

Bottom

drawer

Blow

by:

A

type

of

air

leakage

where

the

air

escapes

past

a

seal.

Brass

Washer:

Composed

of

brass

and

gold

in

color.

It

is

a

commonly

used

as

a

thrust

bearing.

One

place

it

is

used

is

between

the

upper

neck

and

lower

neck

shaft.

c.c.

Panel:

The

original

light

control

panels

consisting

of

Eight

and

Twenty

Triac

lighting

control

boxes.

C.F.M.:

Cubic

feet

of

air

per

minute.

The

show

consumes,

at

full

speed,

approximately

95

cfm.

at

80

psi.

C.L.:

Colored

overhead

stage

Lights

Clevis

nut

or

Jam

Nut:

A

standard

thread

size

nut

but

constructed

thinner,

used

for

locking

threaded

devices.

Collar

Pin:

A

collar

is

a

custom

pivot

used

in

high

stress

areas.

In

particular,

it

is

used

in

the

rear

mount

of

a

cylinder.

Controller:

Gray

box

controller

sometimes

called

a

"computer"

Convenience

outlet:

A

specific

electrical

outlet

located

on

the

back

wall

of

the

platform.

Cosmetics:

The

cosmetic

aspect

of

the

show

is

concerned

with

the

outward

appearance

of

the

show

and

all

that

is

involved

in

making

it

look

correct.

Critical

Adjustment:

Those

adjustments

that

must

be

made,

with

pre-determined

dimensions,

for

either

aesthetic

or

mechanical

reasons

for

the

best

operating

conditions

of

a

movement.

iv

C.S.:

Center

Stage

Curtain

Control

Board:

Drapery

Control

Board

used

to

open

and

close

the

draperies.

Cylinder

bore:

The

inside

diameter

of

a

cylinder.

Distribution

Manifold:

An

air

manifold

that

distributes

air

from

the

main

air

line

into

the

smaller

air

lines

which

control

characters

and

movements.

Down

(critical)

Show:

A

show

is

deemed

critical

or

down,

if

the

loss

of

function

is

obviously

distracting

from

the

enjoyment

of

the

show.

Dual

Pressure

Regulator:

Is

an

electrically

controlled

mechanism

that

shifts

the

air

pressure

from

one

pressure

level

to

another

pressure

level.

Abbreviated:

DPR.

'E'

Hinge:

A

hinge

constructed

in

the

shape

of

a

'E'.

These

are

used

in

the

head-up-down

mechanism.

"Electronimation"™

The

term

coined

by

Creative

Engineering

Inc.

to

describe

the

combination

of

electronic

and

mechanically

controlled

animated

objects.

Fas-pin:

A

fastener

type

that

is

easily

removable

due

to

it's

construction.

This

is

used

in

cylinder

front

and

rear

mounts.

It

is

held

in

position

by

a

ball

detent.

Finger

contacts:

The

pins

on

the

printed

circuit

card

edge

connector.

Flow

Control:

A

metering

device

that

adjust

the

volume

of

air

coming

out

of

the

cylinder.

It

meters

the

flow

in

one

direction

and

allows

free

flow

in

the

other

direction.

FUM:

Female

uni-mount

hinge

used

in

elbows

and

other

similar

positions.

Ground

Thrust

Washer:

A

thin

flat

washer

with

smooth

sides

and

edges

that

goes

into

an

assembly

of

two

hinges.

It

reduces

the

friction

on

the

materials

that

it

separates.

H.L.:

House

lights

'K'

Hinge:

A

hinge

constructed

in

the

shape

of

an

'K',

used

in

the

shoulder

assembly.

Large

'C'

Hinge:

Constructed

in

the

shape

of

a

'C'

and

is

used

in

the

pelvis.

Light

Control

Module:

Located

inside

the

RAF

100

Box

is

a

small

Printed

Circuit

board

that

controls

both

lights

and

other

external

devices,

such

as

draperies,

(CEI

Board).

Limit

Switch:

Switches

that

can

adjust

the

number

of

revolutions

a

motor

will

travel,

thus

setting

the

traveling

distance

of

the

draperies.

These

ar~

located

on

the Drapery

Motor

unit.

v

Load

Washer:

A

thin

bent

washer

used

in

hinge

points

and

other

positions

used

to

help

reduce

friction

and

provide

spacing.

Lubricator:

An

in

line

oil

mist

lubricator

for

the

air

line

system

that

is

located

between

the

distribution

manifold

and

the

valve

bank.

Manual

override:

Manual

overrides

are

located

in

various

positions

throughout

the

system;

on

valves,

air

compressor,

controller

dual

p.c.

mount,

wall

switches,

and

even

the

House

Light

Dimmer

Board

itself.

(

Take

care

to

identify

in

which

section

your

override

is

needed)

•

Muffler:

The

aluminum

box

filled

with

foam

used

to

muffle

the

noise

of

the

air

exchange.

MUM:

Male

uni-mount

used

specifically

in

Beach

Bear

leg

kick.

Needle

Bearing:

This

is

a

high

quality

bearing

used

in

high

stress

areas.

Note:

It

must

be

used

with

hardened

pins.

Opto,

Opto-isolator

:

Optically

coupled

intergrated

circuit.

O'scope:

Oscilloscope

Pillow

Block

Bearing:

A

bearing

with

a

cast

base

and

two

holes

for

mounting.

It

is

commonly

used

in

the

Beach

Bear

guitar

rock

and

body-turn

movement.

Pinch

roller,

capstan,

heads:

Parts

of

the

Tape

Deck

(refer

to

the

manual

on

the

Tape

Decks).

To

Pin:

This

gives

the

dimension

between

the

center

of

the

front

cylinder

mount

hole

and

the

center

of

the

rear

cylinder

mount

hole.

up

or

jumper

bit:

The

action

of

attaching

a

jumper

wire

between

D.C.

ground

(0)

and

+25v

D.C.

on

the

collector

leg

of

the

transistor

of

the

Long

Driver

Board.

P.M.:

Abbreviation

of

Preventive

Maintenance.

Pots:

Potentiometers

Props:

Consisting

of

moving

and

non

moving

props.

Moving

ones

are:

Sun,

Moon,

Spider

and

Baby

Bear.

Non

moving

ones

are:

Organ,

Sign,

Backdrops,

Smitty's

Super

Service

Station,

rocks,

flowers,

etc.

P.S.I.:

Pounds

per

square

inch.

40

psi.

and

80

psi.)

(Note,

the

show

runs

off

of

both

RAF

100:

The

newer

model

of

light

control

unit

that

switches

the

A.C.

circuitry,

may

be

referred

to

as

RAF

100-B.

The

RAF

100-B

refers

to

the

main

show.

Receiver;

That

part

of

the

air

system

near

the

air

dryer

that

is

actually

a

storage

tank

of

air.

Rod

end:

A Rod

end

is

spherical

type

bearing

used

in

cylinder

front

mounts.

vi

Roll

Pin:

A

spring

action

type

that

expands

and

contracts

upon

entry.

Self

Locking

nut:

A

nut

with

a

plastic

insert

that

creates

friction

on

the

bolt,

thus,

locking

it

into

position.

They

are

typically

used

on

aircraft

bolts.

Shuttle

Cock: A Dual

Pressure

System Control

valve

that

allows

high

air

pressure

to

flow

and

stops

the

flow

of

the

low

pressure

air.

S.L.:

Stage

Left-on

your

left

as

you

face

the

audience,

on

your

right

as

you

face

the

stage.

Small

'C'

Hinge:

A

hinge

constructed

in

the

shape

of

a

'C'.

A

common

use

is

in

the

head-up-down

pivot

hinge.

Snaps:

Snaps

are

made

of

three

parts;

the

male,

the

female,

and

the

grommet.

The

male

snap

has

a

stud

and

a

post.

The

female

snap

has

a

socket

and

a

cap.

The

grommet

just

has

a

socket.

The

snaps

are

used

to

attach

various

materials

together.

Solenoid:

Electro

magnetic

actuator,

commonly

used

to

shift

air

valve

spools.

S.R.:

Stage

right-on

your

right

as

you

face

the

audience.

S.E.:

Stage

Effects

lighting.

Stainless

Steel

Washer:

A

stainless

steel

thrust

washer.

These

are

used

typically

in

hinge

assemblies.

Super

Pillow

Block

Bearing:

A

re-circulating

ball

beaiing

used

for

linear

motion;

typically

used

in

Sun,

Moon

and

Looney

Bird

raise

mechanisms.

Sync:

Synchronization

Tape

Control

Board:

Show

Control

Board,

a

microprocessor

controlled

real

time

P.

C.

card.

TD:

Top

Drawer

Tolerance:

Tolerance

is

the

amount

that

a

measurement

may

very

from

its

intended

value.

It

is

stated

on

the

Critical

Adjustment

Chart

with

a

(+)

or

(-)

dimension.

Tol-0-Matic

Cylinders:

A

brand

name

of

cable

cylinder

used

in

all

the

mechanical

props

except

Baby

Bear.

Valve

Bank:

A

group

of

air

valves

connected

together

to

form

a

unit.

VCR

Tape:

Video

Cassette

Recorder

Cartridge

Tape

VCR:

Video

Cassette

Recorder

VU

Meter:

The

meters

on

the

front

of

the

tape

decks

vii

Suggested

Tool

List

Description:

The

following

is

a

list

of

suggested

tools,

that

all

Store

Technicians

will

need.

Not

having

the

suggested

tools

will

cause

replacement

of

a

part

that

could

have

been

repaired.

There

is

a

list

of

miscellaneous

Tools

in

the

Parts

Catalog

under

character

supplies,

they

are

the

only

tools

that

"Creative

Engineering"

supplies.

The

rest

of

the

tools

can

be

purchased

through

a

Department

Store

or

from

a

tool

supplier.

Description

1)

Arbor

Press

2)

Drill

Set

1/16"

through

1/2",

1/64"

Increments

3)

Tap

Set

from

#6-32

through

5/16"-18

4)

Drill

and

Tap

Chart

5)

Work

Table

Vise

6) Awl

7)

14

Piece

Allen

Wrench

Set,

1/16"-1/2"

8)

Needle

Nose

Pliers

9)

Wire

Cutters

10)

Regular

Pliers

11)

Channel

Locks

12)

Vice

Grips

13)

6"

Combination

Square

14)

Measuring

Tape

3/4"

x

12'

15)

Replacement

Tape

3/4"

x

12'

16)

1/8"

Drift

Punch

17)

3/16"

Drift

Punch

18)

1/4"

Drift

Punch

19)

5/16"

Drift

Punch

20)

3/8"

Drift

Punch

21)

Center

Punch

22)

6"

Mill

File

23)

10"

Mill

File

24)

File

Handle

25)

Ball

Pien

Hammer,

8

oz.

26)

Plastic

Tipped

Hammer

27)

Flat

Screwdriver,

4

Piece

Set

28)

Phillips

Screwdriver,

4

Piece

Set

viii

Suggested

Tool

List

Description

29)

Ignition

Wrench

Set,

Open

End

10

Piece

30)

Combination

Wrench,

7/16"

31)

Combination

Wrench,

1/2"

32)

Combination Wrench, 9/16"

33)

Combination

Wrench,

11/16"

34)

Combination

Wrench,

3/4"

35)

Open

End

Wrench,

3/8"

x

7/16"

36)

Open

End

Wrench,

l/2"

x

9/16"

37)

Open

End

Wrench,

17/32"

x

7/16"

38)

Adjustable

Wrench,

10"

(Crescent)

39)

Chucking

Ream,

1/4"

.250

40)

41)

42)

43)

Chucking

Ream,

5/16"

.3125

3/8"

.375

1/2"

.500

5/8"

.625

44)

"T"

Handle

(To

Hold

Reams)

45)

Oil

Can

46)

Electrical

Hand

Drill

With

1/2"

Chuck

47)

Grease

Gun

48)

Pocket

Screwdriver

1/8"

x

2"

49)

Nut

Driver

Set,

7

Piece

3/16"-1/2"

50)

Jacobs

Chuck

51)

Pop

Rivet

Gun

52)

Automatic

Wire

Stripper

53)

Small

Needle

Nose

Pliers

54)

Amphenol

Hand

Crimping

Tool

55)

Molex

Extraction

Tool

56)

Molex

Crimping

Tool

57)

Air

Pressure

Gauge

with

Male

Quick

Release

ix

TABLE

OF

CONTENTS

Power

Up,

Down

and

P.M.

A.

Power

Up

and

Power

Down

Pages 1-002

thru

1-004

B.

Preventive

Maintenance Pages 1-005

thru

1-018

1-001

INTRODUCTION

POWER

UP

AND

POWER

DOWN

PROCEDURES

Description:

The

animated

show

is

a

computer

controlled

entertainment

feature

of

ShowBiz

Pizza

Place.

Contents:

Strict

adherence

to

the

following

Power

Up

and

Power

Down

procedures

is

essential.

Page

1-003)

Power

Up

procedures

for

the

show.

The

procedures

must

be

completed

in

the

order

given,

each

morning

before

the

restaurant

opens.

Page

1-004)

Power

Down

procedures

for

the

show.

The

procedures

must

be

completed

in

the

order

given,

each

night

at

closing

time.

1-002

PROCEDURES

FOR

POWER

UP

A.

In

the

compressor

room:

1.

Close

the

drain

valves

on

the

Compressor,

Air

Dryer

and

Receiver.

2.

Empty

the

drainage

collectors.

3.

Turn

on

the

power

to

the

Compressor

and

Air

Dryer.

(Note:

Refer

to

the

Air

Dryer

manual

as

to

constant

operation.)

(SEE

DRAWING

BELOW)

~&Mo..,.e

.....

.,

-~~~

B.

In

the

Control

Room,

clean

the

Tape

Heads,

Guides,

Pinch

Rollers

and

the

Capstan.

To

clean

these

parts

use

denatured

alcohol

or

a

name

brand

tape

head

cleaner.

C.

Power

up

the

Audio

Rack.

(NOTE:

BE

SURE

THE

AMPLIFIER

VOLUME

CONTROLS

ARE

TURNED

FULLY

COUNTER

CLOCKWISE,

OR

DOWN,

BEFORE

YOU

POWER

UP)

1.

Turn

on

the

Equalizer.

2.

Turn

on

the

tape

decks.

3.

Turn

on

the

Amplifier,

and

set

the

volume

controls

to

the

marked

levels.

D.

Rewind

the

tape

decks

#1

and

#2.

E.

Reset

the

tape

counter

to

~oooo".

1.

Run

the

tape

until

a

signal

first

appears

on

the

v.u.

meter,

channel

#4.

2.

Reset

the

tape

counter

to

"0000".

3.

Rewind

the

tape

counter

ten

(10)

counts,

the

counter

should

read

"9990".

4.

Reset

the

tape

counter

to

"0000".

F.

At

approximately

15

minutes

before

the

restaurant

opens.

1.

Push

PLAY

on

the

Dual

P.C.

Mount.

2.

After

tape

deck

#1

stops,

turn

the

"House

Light

Override

Switches"

into

the

"Computer"

mode.

1-003

POWER

DOWN

PROCEDURES

A.

Turn

the

House

Lights

to

the

Over-ride

Mode.

B.

Turn

all

four

amplifier

volume

controls

fully

counter

clockwise

and

turn

off

power

to

the

amplifiers.

C. Turn

off

the

Equalizer.

D.

Turn

off

Tape

Decks

#1

and

#2.

E.

Turn

off

all

power

at

panel

L3.

1.

Gray

Show

Controller

2.

Stage

Flood

Lights

3.

Audio

4.

Stage

Effect

Lights

5.

Spot

Lights

6.

Drape

Motors

F.

Go

to

the

Compressor

room.

1.

Turn

off

the

Air

Dryer

2.

Turn

off

the

Compressor

G.

Empty

all

Drainage

collectors,

and

check

all

drains

for

blockage.

Open

the

Drain

Valves

on

the

Compressor,

Air

Dryer

and

Receiver

a

small

amount,

these

valves

will

remain

open

all

night.

H.

Check

the

Compressor

oil

level,

if

low

add

Non-Detergent

oil,

fill

to

the

proper

level.

(Note:

Use

30wt.

oil

in

the

colder

areas,

and

40wt.

oil

in

the

warmer

areas.)

I.

Check

the

Compressor

for

any

loose

components.

ie,

Belts,

Mounting

bolts,

fittings,

etc.,

tighten

any

found.

J.

If

any

problems

are

noted

during

the

day,

they

are

to

be

documented

and

left

on

top

of

the

Controller.

This

will

insure

that

the

person

coming

in

the

will

be

aware

of

any

problems,

before

powering

up

the

show.

K.

Be

sure

the

Controller

and

Compressor

room

doors

are

locked.

(Please

Double

Check

the

Doors)

(Note:

Security

policy

may

prohibit

leaving

the

building

during

night

hours.

Use

the

indoor

shut

off,

and

do

the

required

steps

during

power

up

procedures.)

1-004

INTRODUCTION

PREVENTIVE

MAINTENANCE

Description:

Preventive

maintenance

(P.M.)

is

essential

for

the

proper

operation

of

the

animated

show.

Billy

Bob

and

all

the

gang

are

counting

on

you

to

check

them

out

regularly.

If

P.M.

is

performed

properly

the

chances

of

the

show

becoming

inoperative

during

open

hours

is

reduced.

(Saving

you

and

the

audience

aggravation)

So

please

read

over

and

follow

the

Daily,

Weekly,

Monthly,

Quarterly

and

Semi

Yearly

P.M.

procedures.

Contents:

Page

1-006)

Daily

P.M.,

each

step

included

must

be

COMPLETED

every

day

the

show

is

in

operation.

Pages

1-007

and

1-008)

Weekly

P.M.,

each

step

included

must

be

COMPLETED

a

minimum

of

once

a

week.

Page

1-008)

Monthly

P.M.,

the

6

steps

under

monthly

P.M.

should

be

spread

over

the

month

as

time

allows.

Keep

a

check

list

so

that

each

step

is

COMPLETED

once

a

month.

Page

1-009)

Quarterly

P.M.,

these

steps

are

simple

and

can

be

done

in

one

day.

But

they

must

be

COMPLETED

once

every

3

months.

Page

1-009)

Semi

Annually

P.M.,

this

step

is

the

character

rebuilding,

the

disassembly

and

reassembly

of

all

the

characters.

One

character

can

be

done

over

a

period

of

several

days,

but

all

the

characters

Billy

Bob,

Beach

Bear,

Fatz,

Mitzi,

Dook,

Rolfe

and

Earl,

Looney

Bird,and

the

props

Sun,

Moon,

Spider

and

Baby

Bear,

must

be

rebuilt

every

6

months.

Keep

a

check

list,

and

mark

the

date

the

character

was

completely

rebuilt,

and

in

6

months

do

it

again.

Pages

1-010

thru

1-014)

Video

Testing

Procedures.

Pages

1-015

thru

1-017)

Part

Ordering

Procedures

and

Spare

Parts

List.

1-Q05

Daily

P.M.:

A.

Check

the

Air

Filter

bowl

at

the

Dual

Pressuie

Regulator

and

drain

off

any

accumulated

water.

No

water

should

be

present

at

the

Air

Filter,

if

water

is

present,

refer

to

Page

3-005,

Step

c.

B.

Check

the

lubricators,

located

at

each

character's

trap

door

under

the

stage.

1.

If

any

water

is

present,

refer

to

Page

3-005,

Step

C.

2.

Fill

to

3/4

full

with

10

wt.

Non-Detergent

Oil.

See

page

3-003,

step

G,

for

filling

instructions.

C.

Lubricate,

check

over

and

tighten

one

character

daily.

Rotate

the

characters

and

keep

a

check

list

so

that

all

the

characters

are

checked

over

every

8

days.

Do

the

Sun

and

Moon

on

the

same

day

and

the

Spider

and

Baby

Bear

in

one

day.

1.

Lubricate

all

hinge

points

using

black

C.E.I.

lube,

e.g.

shoulders,

waist,

neck

pivot,

etc.

(Do

Not

disassemble

the

hinges

to

lubricate)

2.

Lubricate

all

the·

Cylinders,

Piston

Shaft,

using

black

C.E.I.

lube.

Actuate

the

cylinders

and

check

for

a

smooth

and

complete

movement.

3.

Clean

any

loose

fur

and,

or

accumulated

dirt

from

cylinder

rods

and

guide

shafts,

wipe

away

any

excess

grease.

4.

Remove

the

latex

mask

and

clean

the

Eye

Balls

using

a

Household

type

cleaner

(Fantastic

or

409)

and

a

soft

clean

cloth.

Allow

the

eye

ball

to

dry

completely

before

reattaching

the

mask.

5.

Check

all

the

welded

joints

for

cracks.

6.

Tighten

any

loose

parts,

set

screws,

shaft

collars,

cap

screws,

nuts

and

bolts.

7.

Tighten

all

jam

nuts

on

cylinders.

If

any

jam

nuts

are

found

loose

refer

to

Pages

3-094

thru

3-135,

Critical

Adjustments,

to

check

the

les.

(SEE

DRAWING

BELOW)

JAM

NUT

D.

Set

up

the

Video

Adjustment

tape,

and

run

the

tape.

Run

the

character

through

the

show

without

sound.

Listen

and

watch

for

movements

being

out

of

sync

with

the

Video

Display,

mechanical

defects

or

Cosmetic

binding

i.e.

air

leaks,

squeaks,

rattles,

movements

not

working,

etc.

(See

Pages

1-010

thru

1-014

Video

Testing

Procedures

and

Charts)

E.

Verify

that

the

manager

is

aware

of

any

problems

that

do

exist.

F.

If

any

problems

do

exist

that

must

be

repaired

immediately,

refer

to

the

Trouble

Shooting

and,

or

Repair

Parts.

1-006

Weekly

P.M.:

A.

Lubricate

the

tops

of

the

plastic

eyelids,

and

the

eye

sockets

in

the

mask,

using

C.E.I.

eyelid

lube.

(Part

#APK

1301)

Check

the

eyelids

for

any

rough

spots

or

wear

spots,

replace

if

necessary.

B.

Durins

normal

grooming

of

the

fur,

a

blast

of

air

from your

air

gun

will

help

appearance.

Use

a wire

wig

brush

only

in

the

areas

that

are

knotted

or

matted.

Check

the

costumes

and

masks

for

any

wear

spots

or

rips.

Make

sure

the

manager

is

aware

of

any

problems

that

do

exist.

C.

Remove

the

audio

tapes

from

the

tape

decks.

D.

Using

a

Demagnetizing

tool,

demagnetize

the

tape

heads

and

tape

guides.

(Note:

The

Demagnetizing

tool

will

erase

the

tapes,

if

it

gets

near

them)

Do

Not

touch

the

tape

heads

with

the

Demagnetizing

tool.

Pass

the

end

of

the

tool

near

the

head

but

don't

touch

it.

E.

Place

the

audio

tapes

back

onto

the

tape

decks.

F.

The

characters

in

the

past

have

been

oiled

using

10wt.

non-detergent

oil

on

the

cylinder

shafts

and

at

hinge

points.

The

use

of

such

oil

has

been

amended

to

the

use

of

grease,

(C.E.I.

lube)

available

only

through

Creative

Engineering.

G.

Check

all

electrical

cables

for

damaged

insulation,

loose

wires,

damaged

connectors,

etc.,

repair

if

needed.

H.

Using

soapy

water,

check

for

air

leakage

at

the

valve

bank

and

the

distribution

manifold.

Check

the

air

lines

for

any

deterioration,

i.e.

cuts,

air

bubbles,

oil

damage,

etc.

If

problems

exist,

refer

to

Pages

3-002

thru

3-030

The

Air

System.

I.

Check

the

protective

coverings

on

the

character

plumbing

harness,

they

may

have

slipped

from

their

original

placement.

The

coverings

should

protect

the

air

lines

from

abrasion

on

the

metal

frame,

during

the

complete

movement

of

the

character.

J.

Remove

the

leather

shoulder

and

elbow

pieces

from

the

characters,

rub

a

small

amount

of

Saddle

Soap

into

the

pieces,

this

will

keep

them

soft

and

flexible

and

prolong

their

usB.

Remove

and

replace

the

leather

pieces

one

at

a

time.

(Do

Not

get

them

mixed

up,

for

ease

in

replacement

mark

them)

•

1-007

Weekly

P.M.

Cont.

Monthly

P.M.:

K.

The

muffler

is

located

at

each

character's

valve

bank

under

the

platform.

Remove

the

bolt

holding

the

foam

into

the

aluminum

muffler.

Oil

may

have

collected

inside

the

muffler,

remove

the

foam

and

clean

it

and

the

muffler

using

water

and

a

mild

soap.

Allow

the

foam

to

dry

completely

before

reassembling.

L.

Make

sure

all

areas

around

the

platform

floor

lighting

and

electrical

receptacles

are

free

from

any

debris.

Wipe

off

the

light

lenses

using

alcohol

and

a

clean

rag,

Do

Not

disassemble

the

lights

to

clean,

all

lighting

should

be

cold

before

cleaning.

A.

Using

the

spare

parts

list,

make

a

inventory

of

all

spare

parts

and

ORDER

replacements

for

any

missing

parts.

(See

Pages

1-015

thru

1-017)

B.

Clean

all

the

spot

lights

using

alcohol

and

a

soft

piece

of

cloth.

(Make

sure

the

lights

are

cold

before

cleaning)

C.

Clean

the

compressor

room,

the

compressor

and

air

dryer.

D.

Clean

the

controller

room.

E.

Wipe

down

all

props

with

a

dampened

sponge.

F.

Clean

and

lubricate

the

drapery

motors

gear

box,

and

the

main

drive

wheel.

G.

Lubricate

the

drapery

track,

using

silicone

lube,

place

lubrication

only

on

the

inside

of

the

aluminum

channel.

Check

the

curtain

track

mounting

in

the

ceiling.

H.

Test

the

lights

using

the

lighting

video

tape.

Replace

any

blown

lamps.

Adjust

corresponding

spot

light

numbers,

to

their

character

positions.

See

page

1-018

for

an

illustration

of

the

characters,

with

the

spot

light

adjustments.

The

light

can

be

kept

on

by

"Pinning

Up"

the

appropriate

bit.

(Refer

to

Electronics

Repair,

Pages

5-005

and

5-006,

and

all

drawings

referred

to

by

that

text)

1-008

Quarterly

P.M.:

A.

Compressor

P.M.

1.

Turn

power

off

to

the

compressor.

2.

Check

the

compressor

for

oil

leaks,

if

any

are

found

see

the

compressor

service

manual,

if

necessary.

3.

Drain

the

compressor

crank

case

oil,

refill

with

30wt.

Non-Detergent

oil.

(Note:

Use

30wt.

oil

in

the

colder

areas,

and

40wt.

oil

in

the

warmer

areas.)

4.

Clean

the

entire

compressor.

B.

Tape

deck

P.M.

Semi

Annual

P.M.:

Check

the

tape

Pinch

roller

for

wear

and

tear.

Replace

pinch

roller

and

belts

if

necessary.

A.

Remove

the

head

from

the

character

you

want

to

rebuild,

first.

Then

on

another

day,

remove

one

arm,

then

the

other

arm.

Do

the

Chest

next,

and

finally

the

leg

movements.

1.

Label

and

pull

the

air

lines

to

the

cylinders.

2.

Detach

the

body

part

at

the

easiest

location

possible.

3.

Check

the

Hinges

and

Cylinder

mounts,

look

for

sloppy

mounts,

dry

Hinge

Points,

loose

set

screws,

etc.,

repair

or

replace

what's

needed.

4.

Check

the

cylinders,

look

for

gasket

shavings

or

a

dragging

not

smooth

movement,

if

a

problem

is

evident

rebuild

the

cylinder.

You

can

rebuild

the

double

acting

cylinders

and

Tol-0-Matic

cylinders,

but

Clippard

cylinders

cannot

be

rebuilt.

5.

Disassemble

the

bad

hinges

and

clean

them.

6.

Check

all

the

Needle

Bearings

and

Bushings

for

wear

and

tear,

replace

them

if

necessary.

7.

Check

all

Rod

Ends,

and

cylinder

mount

holes

for

wear

and

tear.

Repair

what

problems

you

can,

and

note

the

problems

you

can't.

If

you

can't

repair

the

problem

you

may

want'to

order

the

replacement

parts

now.

Use

these

noted

problems

for

trouble

spots

you

can

check

for

more

carefully

during

Daily

P.M.

(Page

1-006)

8.

Reassemble

the

parts,

refer

to

Pages

3-001

thru

3-093

Part

3,

Repair

for

drawings,

and

instructions

on

the

individual

parts

or

movements

you

are

working

on.

Video

Testing

Procedures:

A.

Locate

the

video

test

equipment,

at

a

point

where

the

video

display

and

character

to

be

tested,

can

be

viewed

simultaneously.

1.

Connect

the

cable

from

the

audio

output

#2,

on

the

Tape

Deck,

to

the

tape

select

box,

(Front

Panel)

input

channel

#3

or

#4.

2.

The

correct

input

channel

is

determined

by

selecting

which

character

is

to

be

stimulated,

channel

#3

is

the

top

drawer

and

channel

#4

is

the

bottom

drawer.

(see

Bit,

Valve

and

Movement

Charts,

Pages

1-011

thru

1-014)

3.

Power

up

the

video

tape

deck.

4.

Load

the

tape

and

rewind

it

completely.

5.

Set

the

unit

counter

to

zero.

B.

Play

the

tape

and

follow

the

adjustment

procedures

described

below.

View

the

tape

long

enough

to

correctly

determine

that

the

movement

is

truly

out

of

adjustment.

(Do

Not

adjust

the

Flow

Control

unless

you

are

sure

the

movement

needs

adjusting)

The

video

display

and

character

must

be

synchronized

exactly.

If

a

movement

is

in

question:

1.

Isolate

the

valve

in

the

valve

bank

that

operates

the

movement

in

question.

(see

"Bit,

Valve

and

Movement

Charts",

Pages

1-011

thru

1-014)

Manually

operate

the

valve,

by

pressing

the

white

manual

override

button

on

the

valve's

solenoid.

2.

Observe

the

movement

by

operating

it

manually.

Look

for

a

smooth

operation

of

the

movement

in

question,

check

for

Cosmetic

parts

that

are

binding,

if

problems

are

present

refer

to

PART

2

Mechanical

Trouble

Shooting.

c.

After

determining

that

the

movement

truly

does

need

adjusting,

turn

the

Flow

Control

Adjustment

screw.

Remember

the

air

coming

out

of

the

cylinder

is

what

you

are

adjusting.

(For

a

explanation

of

the

air

system

see

Pages

3-002

thru

3-030,

The

Air

System.

1-010

Video

Testing

Bit,

Valve

And

Movement

Charts:

MITZI FATS

Movement

Bit

#

Valve

#

Movement

Bit

#

Valve

#

Mouth

35

BD

1*

Mouth

45

TO

1*

Left

Ear

26

BD

2

SA

Left

Lid

41

TO

2

Right

Ear

27

BD

3

SA

Right

Lid

42

TO

3

Left

Lid

31

BD

4

Eyes

Left

43

TO

4

SA

Right

Lid

32

BD

5

Eyes

Right

44

TO

5

SA

Eyes

Left

33

BD

6

SA

Head

Left

54

TO

6

Eyes

Right

34

BD

7

SA

Head

Right

55

TO

7

Head

Left

28

BD

8

Head

Tip

Left

51

TO

8

Head

Right

29

BD

9

Head

Tip

Right

52

TO

9

Head

Up

30

BD

10

Head

Up

53

TO

10

Left

Arm

Raise

23

BD

11*

Left

Arm

Swing

57

TO

11

Right

Arm

Raise

18

BD

12*

Right

Arm

Swing

58

TO

12

Left

Elbow

24

BD

13

Left

Elbow

59

TO

13

Right

Elbow

19

BD

14

Right

Elbow

60

TO

14

Left

Arm

Twist

25

BD

15

Foot

Tap

61

TO

15

Right

Arm

Twist

20

BD

16

Bodx:

Lean

62

TO

16*

Body

Twist

Left

36

BD

17

Body

Twist

Right

37

BD

18

Body

Lean

38

BD

19*

(SA)

Single

Acting

Cylinder

(

*)

Flow

Controls

At

Cylinder

In

The

Body

(TO)

Top

Drawer

(BD)

Bottom

Drawer

1-011

Creative Engineering ROCK-A-FIRE EXPLOSION User manual

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