Creative Engineering ROCK-A-FIRE EXPLOSION Service Manual Download Page 1

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Summary of Contents for ROCK-A-FIRE EXPLOSION

Page 1: ...CREATIVE ENGINEERING INCORPORATED ROCK A FIRE EXPLOSION SERVICE MANUAL ...

Page 2: ...ed 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 Beg...

Page 3: ...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 ...

Page 4: ...ed 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 ...

Page 5: ...construction This pin 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 ...

Page 6: ...les 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 Pin To Pin This gives the dimension between the center of the front cylinder mount hole and the center of the rear cylinder mount hole Pin up or jumper bit The action of attaching a jumper wire between D C ground 0 and 25v...

Page 7: ...ther 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 mechanism...

Page 8: ...er 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 ...

Page 9: ...nch 10 Crescent 39 Chucking Ream 1 4 250 40 41 42 43 Chucking Chucking Chucking Chucking Ream Ream Ream 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 H...

Page 10: ...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 ...

Page 11: ...ents 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 ...

Page 12: ...URE 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...

Page 13: ...ll 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 t...

Page 14: ... 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 charac...

Page 15: ...mplete 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 collar...

Page 16: ...iled 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 l...

Page 17: ... 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 pla...

Page 18: ...es 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 C...

Page 19: ...e 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 ov...

Page 20: ...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 ...

Page 21: ...53 BD 8 Right Arm Raise 11 BD 8 Head Tip Right 54 BD 9 Right Arm Twist 12 BD 9 Head Up 55 BD 10 Right Elbow Twist 13 BD 10 Left Hand Slide 39 BD 11 Right Wrist 14 BD 11 Right Arm Raise 56 BD 12 Left Hand Slide 4 BD 12 Right Arm Twist 57 BD 13 Guitar Raise 5 BD 13 Right Elbow Twist 58 BD 14 Left Leg Kick 9 BD 14 Right Wrist 59 BD 15 Right Leg Kick 10 BD 15 Guitar Raise 40 BD 16 Bodl Lean 15 BD 16 B...

Page 22: ... 25 TO 8 Head Right 7 TO 9 Head Right 21 TO 9 Head Up 8 TO 10 Head Up 22 TO 10 Left Arm Raise 11 TO 11 Left Arm Swing 33 TO 11 Left Arm Twist 12 TO 12 Right Arm Swing 34 TD 12 Left Elbow 13 TO 13 Left Elbow 35 TD 13 Right Arm Raise 17 TO 14 Right Elbow 31 TO 14 Right Arm Twist 18 TD 15 Cymbals 32 TD 15 Right Elbow Twist 19 TO 16 Base Drum 63 TO 16 Earl Head Tilt 20 TO 17 Body Lean 64 TD 17 Earl Mo...

Page 23: ...ft Eye Lid 41 BD 2 Sun Raise Right Eye Lid 42 BD 3 Moon Mouth Eye Cross 43 BD 4 SA Moon Raise Head Left 21 BD 5 Spider Bird Raise 22 BD 6 Bab t Bear SA Single Acting Cylinder Flow Control At Cylinder In The Body TD Top Drawer BD Bottom Drawer 1 014 Props Bit Valve 38 TO 1 39 TD 2 46 TD 4 47 TD 5 49 TD 7 50 TD 8 ...

Page 24: ... for a Non Emergency parts 1 Order these parts only on form SPP 08 Electronic Parts Materials Requisition 2 Each requisition will bear the restaurant s stamp and store number and shall requisition parts for 1 character only 3 Forward your requisition through the appropriate chain of command to Creative Engineering Inc 778 West Washington Street Orlando Florida 32805 ATTENTION Parts Department c Re...

Page 25: ... 015 040 28 015 070 28 015 085 28 016 003 28 016 010 28 016 012 28 016 013 28 016 014 28 018 005 28 018 010 28 018 015 28 020 010 28 020 230 28 025 945 28 025 950 28 032 010 28 032 015 28 032 020 28 045 917 28 045 960 28 045 961 1 1 8 Bore x 3 4 Stroke Cylinder 1 1 8 Bore x 1 Stroke Cylinder 1 5 8 Bore x 1 Stroke Cylinder 1 5 8 Bore x 3 Stroke Cylinder 1 4 28 x 15 16 Aircraft Bolt 3 8 24 x 15 16 A...

Page 26: ...ings 3 M Super Whether Strip Adhesive 3 M Adhesive Glue 1 oz Bottles Spanner Wrench 1 1 4 to 3 Spanner Wrench 3 4 to 2 Rolfe Fur 1 Sq Foot Fatz Fur 1 Sq Foot Beach Bear Fur 1 Sq Foot Mitzi Fur 1 Sq Foot Billy Bob Fur 1 Sq Foot Eyelid Lubricant Small Dook Drumstick Spring Fiberglass 3 32 x 25 Spider Cable 250 LB Line Dook B Bob Wolf B Bear Eye Lid Fatz Eye Lid Mitzi Eye Lid Looney Bird Eye Lid Part...

Page 27: ...8 NOTE Adjust the lights using the outer edge of the ring or rectangle in the illustrations co 0 I ...

Page 28: ...Then list the repair section you need to refer to for repairs There are three guides to use The Main Air Guide it covers the main air system The Character Air System it covers the valve bank to the cylinder The Mechanical Guide it covers all mechanical movements The next few pages will explain how to use the guides and list the most common problem areas Table of Contents A brief introduction page ...

Page 29: ... repair it right then by referring to the repair section of this manual 2 SECTIONALIZE THE PROBLEM This is where troubling shooting really begins To sectionalize the problem you have to ask yourself is the problem ELECTRICAL MECHANICAL or AIR To answer this question you need refer to the Trouble Shooting Guide in this manual and follow those procedures step by step 3 ISOLATE THE PROBLEM Now that y...

Page 30: ...Arm Rolfe R L Arm Mitzi Dook Gorilla R Arm Beach Bear R Arm Billy Bob R Arm Rolfe Rolfe Dook Fatz Beach Bear Billy Bob Fatz Billy Bob Fatz Billy Bob Common Twisting Movements Movement Location Eye Brows Earl Eye Cross Beach Bear Looney Bird Eyes Left Right All Character except Beach Bear Looney Bird Head Left Right All Characters Arm Twist Rolfe Beach Bear Mitzi Billy Bob Elbow Twist R Arm Rolfe R...

Page 31: ...s running check compressor tank gauge 4 If Compressor not running Be sure the compressor main power switch is off Check the compressor oil level Turn on the compressor main power switch 5 Check the Air Dryer by pass valve setting 2 004 See pages 3 003 and 3 004 If valve is closed SEE page 3 005 Less than 80 p s i Call Compressor Service Co The oil level is OK or is corrected and compr ssor still d...

Page 32: ...ssor room 2 Turn off the main power switch to the compressor Check the oil level If level is high Drain off to proper level Turn main power switch on 2 oos RESULTS See pages 3 003 and 3 004 Oil found in the filters Clean or replace the filters Possible compressor failure Call Compressor Service Co ...

Page 33: ... the air filters in the compressor room 2 Check the intake air filters on the compressor 2 o06 RESULTS See pages 3 003 and 3 004 Excessive dirt found in filter bowls Clean or replace filters Dirt found in intake filters clean or replace the filters See page 1 009 ...

Page 34: ...Air Dryer by pass valve setting 2 Check electrical power to air dryer unit 3 Check drainage valve on Dryer unit RESULTS See pages 3 003 and 3 004 Valve setting incorrect See pages 3 005 3 013 If Drainage valve OK Possible dryer failure Call Air Dryer Service Co See pages 1 003 1 004 ...

Page 35: ...08 See pages 3 003 thru 3 005 and 3 014 If either or both air regulators do not hold a set and constant air pressure Replace the regulator in question If the air pressure is less than 80 p s i 5 Repair the D P R Valve See pages 3 005 3 014 If D P R valve does shift and air pressure is steady and constant at 40 p s i 5 See page 5 011 If D P R valve does not shift repair the valve See pages 3 005 th...

Page 36: ...ing the valve Check plumbing hose connection at the cylinder 2 o09 RESULTS See pages 1 011 thru 1 014 and pages 3 003 and 3 004 If valve shifts See page 5 005 If valve does not shift Repair valve in question See pages 3 06 thru 3 08 No air Flow controls See pages 3 008 No air A port override is activated No air B port override is activated Air flow A port override is not activated No air B port ov...

Page 37: ... See pages 3 009 thru 3 030 Worn cylinder front and rear mount Broken welds Bushings Bearings Steel pins Attaching hardware Refer to the chart below for the area being worked on to make the necessary repairs Description Hinges Head Assemble Chest Head Up Down Head Tilt and Guitar Arms Shoulders and Arm Raise Legs Pelvis Body Lean and Body Turn All Mechanical Props 2 010 Page Number 3 032 thru 3 04...

Page 38: ...TABLE OF CONTENTS Repair A The Air System Pages 3 002 thru 3 030 B Mechanical Repair Pages 3 031 thru 3 093 C Critical Adjustments Pages 3 094 thru 3 135 D Cosmetics Pages 3 136 thru 3 187 3 001 ...

Page 39: ...d in the order given Note DO NOT attempt any disassembly or repair of any parts while the system is under pressure Pages 3 003 and 3 004 Deals with the normal operation of the parts in the air system and should be fully understood before attempting any repairs Also by knowing how the system operates you can test it after repair Pages 3 005 thru 3 012 Explains repair of parts in the air system and ...

Page 40: ...ir lines are next applied to an electronically controlled 4 way valve This valve will decide whether the show is operated at a 80 P S I pressure or at a 40 P S I pressure The last stop in the Dual Pressure Manifold System is a Shuttle Cock When the 40 P S I mode is selected it will quickly allow the 40 P S I pressure to pass by while closing off the 80 P S I line Step F The next step in the air sy...

Page 41: ... located near the cylinder they effect Refer to the Bit Valve and Movement Charts for a listing of flow control locations Pages 1 011 thru 1 014 All the valves unless the valve is unused have 2 flow controls The Flow control adjusts the air coming out of the cylinder hence the statement When in doubt Meter Out Inglis s Law the arrow on the Flow Control points toward the valve bank In the case of a...

Page 42: ...ould damage the characters if you open it quickly Always apply air to the characters slowly Step E Dual Pressure Regulator System 1 Air filter if a yellow signal pops up into the upper cone depressurize the system and remove the bottom bowl Clean it using soapy water Allow it to dry completely before reassembly 2 Air R gulator The regulator is adjusted using the removable key For any problems othe...

Page 43: ...e could be water inside of the valve check the Air Dryer by pass system See Drawing 3 013 Another cause of a sticking valve is the air return line coming off the top of the valve could be crimped check for this first before disassembling the valve If a valve is sticking or has blow by it is in need of a internal cleaning a First pull the retaining ring D and remove the cap F the cap extension G th...

Page 44: ...air chamber Remove the retaining ring D and replace the 0 Ring E in the cap if this does not work go to the step 1 to repair or replace the parts in question 4 Blow By When you pull the lines from the valve and depress the manual override button air should come out Port A with no air coming out Port B Release the manual over ride button Air should come out Port B with no air coming out Port A If a...

Page 45: ... valv or leaky gasket Always apply a small amount of grease to the gasket before reassembly d Reassemble the valve bank by attaching the end cap and 2 Allen Head screws Tighten down the screws equally snuggling down one then the other and tightening the rest of the way working back and forth between the screws Step G The Flow Control Refer to Drawing Page 3 016 1 First double check yourself by pul...

Page 46: ... air line will not stay attached to the barb at the cylinder simply cut off a small piece at the end and reattach the line The Chicago Cylinder Disassembly and Reassembly 1 After Trouble Shooting you have determined that the cylinder is in need of repair a Measure and note the Critical Angles that the Cylinder affects Refer to Pages 3 094 thru 3 135 Critical Angles b Detach the Front Mount of the ...

Page 47: ...rimped at the factory and is not removable e Slide the nose end cap off the piston shaft assembly 6 then slide the piston shaft assembly out of the cylinder barrel 3 f Inspect all the cylinder components for signs of abnormal wear It would be a waste of time to rebuild a damaged cylinder 1 Look for signs of scoring on the internal cylinder barrel 3 piston 5 or on the piston shaft 7 2 Also check th...

Page 48: ...r barrel 3 and push it in until it seats against the rear end cap b Lubricate the barrel bore thoroughly with black C E I lube Thoroughly lubricate the piston shaft assembly 6 and install the U cup seals onto the piston shaft assembly c Install the piston shaft assembly 6 back into the cylinder bore 3 You will need to use 003 Brass Shim Stock as a seal compressor See Drawing Page 3 018 1 Wrap abou...

Page 49: ...piston should move free and easily in the bore the piston should also hit squarely on the bumper 0 ring If the cylinder does not operate properly take it back apart and double check your work 4 Disassembly and repair of the the Pan Cake cylinder See Drawing Page 3 019 a Remove the rear end cap using the screws as indicated in the drawing b Clean and check the part using the same steps as described...

Page 50: ... R D APPROVAL DATE 11 E 4 Tllv PreftmY C IIw Non eccumui UV rA Jl E aum rru ll IIW 0 PRODUCTION APP DATE ENGINEE R IN0 JMC t t REVISIONS Q C APPROVAL DATE l D SCALE DRAWN BY BY SH P C ERS DATE 9 4 CHK D BY ITEM WN W Oioli IU tt8ED DIM DR Y P f IY e ee etMAt Iii GM AJ F r ti MQ __ fta MAT L DRAWING NUMBER j 37 3 c I ...

Page 51: ... f 0 1 sI p I I I h n g Q oz 0 t I Q r 0 n Vol w 0 J 1 I I 1 oz 1 nm i r _ n14 ...

Page 52: ...ITOCit iiATL UUIIPIICIVA DATaiCREATIVE r ENGINEERING MVISION8 ro c A A MV lDAniiiY YI W WING N Il 3 015 Lt c I f ...

Page 53: ... flowing against the Arrow A the Flow Control is open and does not effect the air flow R D APPROVAL DATE CREATIVE R llditni W 0 I PRODUCTIONAPP DATE ENGINEERING MC Alltol Non eccumul8tlve I DEBURR AND Er REVISIONS Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY g 1 I I SHARP CORNERS 2 REV DATE BY 010 DATE J B 7 CHK D BY ttN JBt ERIAN8E8 BIMa P M8 Pt BE81MAt ITEM l l tl FLOW CONIROL OPEI ATJON 818 l 881...

Page 54: ...o NOS 5CAL LE ATHE F WI P Fr Rl IV 1 1 3 CREATIVE ENGINEERING DIC 111v11101111 IICALE z 1 1APPROVED IIY DATE 111v IDATII n DA 2 I 0 B 3 I I I I ITIII EX PLO CJE D VIEW CJIJCA O CYLI 0 F DESCRIPTION Pro _ of Creatlw _ lrte lk P ductJOn Jf 0 AutllorVaUon II lllrlcaly JJrOialllIW DRAWN IIY CHK D IIY TOLERANCES FRACTL DECIMAL ct20 t 11 DRAWING _ 3 7 _______________________ __ I c I I ...

Page 55: ...n eccumullltlve CREATIVE Hw I I lt fiW 0 PRODUCTION APP DATE ENG JNEE RINGnee REVISIONS Q C APPROVAL DATE I G ltt D ISCALE IDRAWN BY a 1 REV IDATE I BY ITEM MATL SHARPCORNERS a 010 DATE J e Q CHK D BY CHIC AbO AS EMBJ Y CYLINPER TEP UNTOLEIRANCED DIM FRACTL DECIMAL XX 010 020 XXX 005 DRAWING NUMBER 3 r _s__ a c I ...

Page 56: ...AL 0 I IN CREATIVE ENGINEERING J1IC Rlv IONI ISCALE Yz I 1 APPROVED BY RIV lDATil v DATE I 3 8 3 I I I I ITIII EX PLOOE 0 VIEW PIIIICAKE C YL 1Nl R DESCRIPTION ho n7 of C llw _ Inc ltejlrooduetJOn fl 0 Autlloriutlon tr c l7 proiii61W DRAWN IIY CHK D Y TOLERANCES FRACTL DECIMAL 020 t 11 DRAWING NUMIIEA 3 J I J I C1 c I f l ...

Page 57: ...air cylinder ar 1 Piston SINGLE ACTING CYLINDER CYCLE 4 way valve in normal position Piston not in motion Quick disconnect B 0 Port A Plugged ManuaJ 4 way valve Air pressurized to 80 P s i Air of lesser volume 0 N 0 I M ...

Page 58: ...Exhausting air being metered by now control B Speed or piston being controlled by flow control B Air exl austs from air cylinder through 4 way valve and muffler not shown quick disconnect valves port A plugged manual override button 1 4 way valve Air pressurized to 80 psi i Air or le l er volume i ___ N 0 I r ...

Page 59: ...linder piston 1r 4 way valve in shifted position Piston not in motion f quick disconnect port A plugged manual override button __l_____ 1 I I j 4 way valve Air pressurized to 80 Psi 1 l l l l Air of les ttf l volume N N 0 I ...

Page 60: ...d back to normal position Piston in motion under air pressure Ingoing air being metered by flow control A Speed if piston being controlled by flow control A quick disconnect Flow control valves port A plugged manual override button 4 way valve to ss olume N 0 I ...

Page 61: ...ting 1ir cylinder rS il piston u way valve in normal position Piston not in motion No air in motion 0 quick disconnect valves port A plugged manual override button J Air pressurized to 80 psi lessr 11 wne r N 0 I ...

Page 62: ... CYLINDER CYCLE 4 way valve in normal position Fiston not in motion No air in motion quick disconnect flow control valve A flow controJ valve B port A port B manual override buttc r 1 r L I _ 4 way valve Air pressurized to 80 psi Air of lesser lume i L Ll N 0 I ...

Page 63: ...ng air being metered by flow control B Speed of piston being controlled by flow control B Air exhausts from cylinder through 4 way valve and muffler not shown quick disconnect flow control valve A I flow control valve B manual override butt on 4 way valve Air pressurized to 8Q psi Ai of less lll Jn t D N 0 I ...

Page 64: ... cylinder is ton 4 way valve in shifted position Piston not in motion No air in motion quick disconnect flow control valve A manual override button 1 I j 4 way valve ir pressurized to 80 psi m t r lesse 6 1 ltL Ile N 0 I ...

Page 65: ...osition Exhausting air being meter d by flow control A Speed of piston being controlled by flow control A Air exhausts from air cylinder through 4 way valve and muffler not shown quick disconnect flow control valve A flow control valve B manual override button r l I I ______j 4 way valve pressurized to lesse lume co N 0 I 1 1 ...

Page 66: ...ton 4 way valve in normal position piston not in motion No air in motion quick disconnect flow control valve A I flow control valve B manual override butt on _ l I __j 4 way valve Air pressurized to 80 psi Air of les vol urn a c I f l ...

Page 67: ... W 0 I PRODUCTION APP DATE ENGINEE RIN0 INC I DEBURR AND a J REVISIONS Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY 1 I I SHARP CORNERS 0 2 B 2 REV DATE BY 010 DATE CHK D BY UNTOLERANCED DIM FRACTL DECIMAL I I I liTEM BASIC AS SEMBL y XX 010 020 XXX 00 1 TOL 0 MATJC CYL Y0 1 MArL DRAWING NUMBER 3 030 0 0 I ...

Page 68: ...oved enough to allow easy access to the movements in question Refer to Pages 3 136 thru 3 187 Cosmetics for further information Air down the character for any repair steps requiring removal of cylinders from the character unless noted in the text Save any Retro Fit drawings you receive Three notes to be followed in all repair steps are Contents One NEVER attempt to repair a problem unless you are ...

Page 69: ...ut the aluminum around the pivot hole has not been elongated you may want to replace the bushing 1 Remove the part from the character and work with it in a vise Refer to the characters movements Pages 3 042 thru 3 093 2 Drill out the old bushing using a 23 64 drill Hold the drill as square as possible to the hole and drill through the bushing You may need to press out pieces of the bushing use a s...

Page 70: ...pe hinge should have few problems if the hinge is greased properly in P M Just apply grease C E I lube between the flanges of the hinge and actuate the hinge to work the grease in The new style hinge will only be disassembled during rebuilding of the character and for repair See Page 1 009 Semi Annual P M F Repair of the new style hinge is limited because the hole is usually marred and the bearing...

Page 71: ...o Pages 3 038 thru 3 041 You will notice that in the assembly drawings of all the hinges their are 2 5 16 Load Washers Part 28 085 125 and 2 5 16 Flat Washers used The Flat Washers have 2 types used one is a 5 16 Stainless Steel Washer Part 28 045 960 and the other is a 5 16 Ground Thrust Washer Part 28 045 961 In the case of all hinge assemblies except the M U M Male Uni Mount to the F U M Female...

Page 72: ... E HINGE WITH HINGE SHAFT USit J 1 LOAD f y WAS ER5 TO REMOVE SIDE PLAY g G SECURE A 5S5 MBLY WIT F INAL SWAP Rl G CALir OtJ tJOT USE AWY T RtW GRE ASE ALL G BEARINGS _ OIR CTION Or 8E NO DURING AS5 M8LY I NOT AND REAM 8U WINGS 5 1 TH C Wit E co a U5E NY 5ETOCREW6 I ri _ IIGAU r ULL 0o11r1 vloud IY o ft G Z1 et A 1 10 92 I I I liT E UNGE f ETk O FIT Dl 1 1001 I I I I A55E MBLY PROCE DU E Ltl rtl 0...

Page 73: ...EARINGS W LL 8RI PLATE H NeE SHAFT S NAPR NG C IEST IDE5 I 1N STAL 10 2 Ai LEN 5 T SCREW S 8 REQ D SNAP RING C HIN6E r t OAO WASHERS PE t V 5 Pt A7E CREATIVE ENGINEERING JlfO DATE DATE 7 J 82 I 7 l A 8 0 92 1 ITEM ci Esr ro MOUNTINe R ATE RerRO FIT DESCRIPTIONASSEMBLY ProJHrlY of CNotiH Brwtneerw Inc Rej lroductlOn W 0 Autlaorllrotktn ltrlc ly prohibited CHK D BY TOLERANCES FRACTL DECIMAL t 020 XX...

Page 74: ...OVE OLO 8US I N6S FROM J I CJ IEST 510 5 AND REPLACE WITH NEW 28 0 30 040 ANO 1 J ND RE AM INSTALL I llNtSE CREATIVE ENGINEERING me BY DATE 7 z a2 1YL IJ ZZ B 1 SHAFT USING LOAD WASI IERS TO REMOVE SID C PLAY t IN JTALL FINAL cJ JNAP RING DATE Pro _ y of Creatlw BrWf BIIV lne Repi ductJOn ilto Aut orLioUon u mletly prohlb lted 8 ICHK D BY TOLERANCES FRACTL DECIMAL 1 1 1 1 ITEM CI IE ST MOUNT No PL...

Page 75: ...TION APP DATE CREATIVE r R lioa W 0 ENGINEERINGJMC t t Q C APPROVAL r _ f DATE I G lt D ISCALE IDRAWN BY 1 1 I SHA RP C ERS DATE J 8 e3 CHK D BY I I I I ITEM ASSEMBLY OW6 K HIN6 ro E HJN6 UNTOLERANCED DIM FRACT L DECIMAL xx 010 020 XXX 005 MAT L DRAWING NUMBER 3 38 00 0 I ...

Page 76: ...AP P DA TE IENG INEE RIN0 JlfC 5 5 0 REVISIONS I Q C APPROVAL REV IDATE I BY DATE I Bl ltt D ISCALE IDRAWN BY A I SHARP CORNERS G 4 B 1 010 DATE eJ U CHK D BY I I I I ITEM MAT L A 5EM SLY OW HINt TO C HIN6E UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 DRAWING NUMBER 3 1 3 9 0 t 0 I t ...

Page 77: ... ofc w Non eccumulattve E I_ W 0 PRODUCTION APP DATE ENGINEE RING IIC w Q C APPROVAL DATE IDEBURR AND SCALE DRAWN BY 8 BREAKALL SHARP CORNERS C3 B R 3 010 DATE CHK D BY I I I I ITEM A S MBLY DWu CH 5T FRAME UNTOLERANCED DIM FRACT L DECIMAL r l XX 010 J 020 xu 005 MAT L DRAWING I IIUIII BER 040 0 qo 0 I ...

Page 78: ... PIN 6 A 5 M8LY FOf THE M U M HIWI FLAT WASM R III VIIIONI I Q c a r r MV IDATI I y I I I IITI II A5 EMBLY owe MALE UN 1 MOUNT TO FEMALE T I I I I FEMAL VN MOIINT TO 51110 ITOCK UNTOLEIIANC D DIM FIIACT _CiliA t oto t 008 DIIAWING NUM II 3 0 I ...

Page 79: ...t mount and the Head Tip Cylinders front mount as required to free the head 3 Unscrew the E Hinge at the T Top of the neck shaft Only disassemble a hinge while it is still attached to the character if absolutely necessary It is best to work with the part in a vise B The eyes left right and ear movements use Clippard cylinders They are not repairable and must be replaced if bad 1 The front and rear...

Page 80: ...ther and pulling the eye lid from its pivot points 2 Attach the new eye lid to its pivot pins just squeeze the sides together and allow it to snap into place 3 Check the alignment of the cylinder to the eye lid they should attach together easily If the alignment is off loosen the 2 shaft collars at the cylinder rear mount and align the parts 4 Re attach the cylinder front mount to the eye lid usin...

Page 81: ...Start with the eye turn mechanism Remove one part at a time and place it on the new head 2 Disassemble and re assemble the eye lid mechanism next one part at a time 3 Disassemble and re assemble the mouth mechanism next 4 Do the ear mechanism last Remember one part at a time 5 Refer to Critical Adjustments Pages 3 094 thru 3 135 and set all the adjustments H For a drawing of Earl s Head and instru...

Page 82: ... DE R EYE TIIRN NtECN 15 NOT SHIJWN AsseMbly of Billy Bob s mouth cylinder rear mount Set Screws holes A are not used in this asseably Note The Eye Lid Cylinders rear mount pin Holes Hole B is used with a 2 stroke Eye Lid Cylinder Hole e ia used w th a 1 stroke Eye Lid Cylinder ...

Page 83: ... di W Celfct f N DUK EAR M lJI Itt eh clitiA Jt id luL ALL CLIPPAWP CYLINPE8S ATTACH IJ 1Nb H5 CtJTTFii INS D AI NOVAL fiAftlCREATIVE 5 UP ENOINEERINOnoc y 1111 I DAn I CHK D y UtnOUIIAIICED I IIACT L HCIMAL 010 t 010 t 001 I I I Im11 ASS EMB LY f WI l lYE lR DSS EYE 7tJHN ANO EAFr M N 1 L WIHO MR 3 0 U ...

Page 84: ...CRniS MtlrT SIA 7CDLlA S J 5TT Cr fTTIItl CYJ IIDIIt fltWitT MM Cn lofR r lltlt W7 IIU J64il IAQI tiiZ _ 2 sWT UJ UAA 7T 1Ltx K IIUN ur Tr R1n rP lillY IDAft I II srrsc v lfrAif IHWMITS 1 11tt1 r Vl r rs lltJI 711 _ 6UJUIS I 1 1 1 A MBL Y EARL MA I L ITOCIC II CHII D y UIITOU m nucn a OtO t 020 001 3 047 I 0 I ...

Page 85: ...Roll Pin The problem with the old styles is the Roll Pin shears off if the set screw in the Actuation Lever loosens So if you have an old style Head Left Right front mount keep a close watch on the set screws If the Roll Pin does shear off it is suggested that you replace it with the new style front mount Part M07420 It is a clamp on type that does not use a Roll Pin and will have fewer problems I...

Page 86: ...ront mount for a 5 16 Male Rod End Part 28 065 027 If a 5 16 Rod End is already attached check it for wear The ball should not move back and forth inside the race replace it if necessary 8 Attach the front mount of the cylinder to the Actuation Lever using a 5 16 x 11 16 Aircraft Bolt Part 28 016 012 and a 5 16 Self Locking Nut Part 28 018 010 0 9 Refer to Pages 3 094 thru 3 135 Critical Adjustmen...

Page 87: ...e steel block D that is welded to the neck shaft e Re attach the new carrier to the steel block D using the hardware previously removed f Re attach the Head Up Down and Head Tilt cylinders g Set the critical adjustments See Pages 3 094 thru 3 135 2 If Fatz Head Tilt cylinder s front mount pin breaks See Drawing Page 3 056 a Remove the old pin from the aluminum block E that is welded to the head fr...

Page 88: ... shaft collar is attached to the twist shaft D using set screws and the shaft collar is drilled and pinned to the twist shaft using a 3 16 Roll Pin If the Roll Pin breaks it is probably due to the set screws being loose watch them closely during P M To repair a broken Roll Pin a Loosen the set screws in the double shaft collar Pull the Fas Pin cylinder front mount align the holes through the colla...

Page 89: ...ever using a steel pin and a hammer e Loosen the set screws in the Pillow Blocks E and the Actuation Lever C and pull the twist shaft from the assembly f Unbolt and remove the broken Pillow Block E and re attach the new block using the same bolts previously removed g Check the twist shaft D to see if it is bent File off any burs on the twist shaft h Re assemble the mechanism re attach the guitar a...

Page 90: ...mount holes and bring the guitar to the Technical Room c Remove the fiberglass guitar from the mechanism and place it to the side put it where it won t get scratched d Try the mechanism again if it works properly the problem is that the wood mount pieces in the fiberglass guitar have warped Plane the wood pieces or shim the mounting screws After it works re assemble the guitar back on to the chara...

Page 91: ...ZRE Q 2 10 LDCKWA HER Zf EQ 3 8 3Z 4 5ET RE W 2 Rf Q 4 14 L XK WAUER 4 REQ S 2 8 04 S 4371 4 F EQ 3J Z4 HUT I R Q 7 318 LOl K WMI ICR IREQ 9 1 96S I R Q ITOCIIl r D AI IiiiOVAL liAniC REATIVE if NAPP DAn ENGINEERINGno IIlEY C API IIOVAL Ill IllATa I IY I I I I 1n11 EXPW 1 VIEW UNTOLIEIIANCID DIM I IIACT L DICIIIAI TYPICAL CHEST A S M8LY 010 020 oos TL DRAWING NUM III 3 054 ...

Page 92: ...ITOCK I IIIUIT I 0 i i 0 II D AL CREATIVE St 5 DATil ENGJNEERJNGnoc AND __ y CMK D IY I I I lm TYPJCAJ CIIE5T Af f E IJBL f UNTOLEIIANCID DIM I IIACT L DI CIMAI t 010 020 i 001 MATL IHIAWING NUM IR OS5 ...

Page 93: ...Af 1 J1 B W EIIlf lw _ wiW W 0 PRODUCTIONAPP DATE EN JINEE RJ N0 11c I DEBURRAND I I I 1 1Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY BY SH RP c ERS DATE 9 23 B3 CHK D BY ITEM UNTOLERANCED DIM TILT1 UP II FATz HEAP FRACT L DECIMAL XX t 010 t 020 XXX 00 5 MArL DRAWING NUMBER 3 056 ...

Page 94: ...TIONAPP DATE ENGINEE RIN0 IIIC t I DEBURR AND r r REVISIONS Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY Q 1 I I SHARP CORNERS 9 23 Q3 REV DATE BY 010 DATE CJ CHK D BY ITEM UNTOLERANCED DIM FRACrL DECIMAL XX 010 020 XXX 005 GVJTAR ROCH MOY M 1YT MArL DRAWING NUMBER 3 057 If 0 I rtl ...

Page 95: ...I W 0 PRODUCTIONAPP DATE fD T ll TE1D V T A 11is A 13 A J l A u IIIC Jtrictly Jwollilntal Q C APPROVAL _ _ __ DEBURR AND I I c I DATE I BREAK ALL SCALE DRAWN BY _ SHARP coRNERS a z3 8 010 DATE J CHK D BY ITEM UNTOLERANCED DIM FRACT L DECIMAL XX 010 GUITAR MECHANI SM 020 XXX 005 MAT L DRAWIIIIG NUMBER 3 058 co a n 0 I rtl ...

Page 96: ...broken pin from the chest or shoulder and remove the cylinder from the frame Do not detach the cylinder from the air lines 3 Refer to the Rock A fire Explosion Parts Catalog and replace the pin tighten the pin up firmly 4 Re attach the cylinder to the shoulder and chest using the Shaft Collars removed in step 2 5 Check and set the critical adjustment related to the movement 6 Check the shoulder hi...

Page 97: ...shoulder assembly to the Technical Room D To replace or repair any parts connected with the Arm Twist movement See Drawing Page 3 065 1 To replace a broken Roll Pin detach the Arm Twist cylinder from the actuation lever A a Loosen the set screws in the actuation lever A Align the holes through the lever A and the Twist Shaft B b Tap out the broken Roll Pin using a small pin and a hammer c Attempt ...

Page 98: ...assemble the shoulder a If new bushings were pressed in ream them using a Hand Ream b Loosen and tighten the Twist Blocks C to the K Hinge to help align the Twist Shaft B c Grease the bushings with black C E I lube before assembly 5 Set the critical adjustment of the arm mount block D and re attach the shoulder to the character using all the hardware previously removed 6 Check all critical adjustm...

Page 99: ... parts 1 For any problems in the cylinder including the rear mount bushing refer to Pages 3 009 thru 3 011 and all drawings referred to by that text 2 If the pivot bushings A wear out and need replacement a Disassemble the Elbow cylinders front mount from the lower arm Remember to note the assembly prior to disassembly b Remove the Shaft Collar B from the lower arm mount Collar Pin Remove the lowe...

Page 100: ...67 1 For any broken welds replacement of the upper or lower arm is required It is not suggested to have a part welded in the field 2 For any problems in the cylinder refer to Pages 3 009 thru 3 011 and all drawings referred to by that text 3 For problems in the F U M to Stud elbow hinge refer to Pages 3 032 thru 3 041 Hinges 4 If the bushing in the welded front cylinder mount is in need of replace...

Page 101: ... parts replacement of the parts are required 4 After repair or replacement of any part set the critical adjustments K The cylinder mount blocks welded to the arms have set screws in them to hold the mount pin into place If the set screw holes strip out and will not hold re drill them to the larger size If re drilling the set screws is impossible don t worry about it But when the mount pin hole enl...

Page 102: ...ITOCK_____ T uY L Flu 1r AL DAftiCREATIVE rrta _ DAnENOJNEERfNG S FI A UN10U IIANCID DIM I IIACT DIICIMAL t o o 020 t 001 I I I ImASSEMBLY ARM TWISr un IIIlA WlNG 11 3 Q 6 1 1 loG 0 I ...

Page 103: ...51101 J DER MOVNT Fl A l OWER AlrM 0 ...

Page 104: ...3 067 ...

Page 105: ...LY 806 WHIST lilY I DATE I v I DATEICREATIVE DATE ENGINEERINoDIC r t WN Y_ 1 DI UIIII AND fKALE c API IIOYAL DATEI CIA h IINIIIS Q 8 3 CHK D y 010 DAD J I I I liTEM I VI 517 Ml VEMENT UNTOLIIIANCID M FIUCT L DECIMAL xa t OtO 020 001 MAT L DRAWING NUM III 3 owB CIO a 0 I M ...

Page 106: ...e Body Lean cylinder are attached using Fas Pins For any broken welds in the front replace the part If the weld breaks at the rear mount replacement of the leg frame is required numbers are available in the Parts Catalog If you have a problem in the pelvis hinge refer to Pages 3 032 thru 3 041 Hinges For any problems in the Body Lean cylinder refer to Pages 3 009 thru 3 011 and all drawings referr...

Page 107: ...3 The Clamp on type Rear Mount is similar to the welded one and all the instructions described above apply except one If the pin hole is enlarged or elongated you can replace only the rear mount and not the whole leg frame To replace the rear mount See Drawing Page 3 073 a Detach the Body Turn cylinder s front and rear mount from the Collar Pins using an Allen wrench b Cut the cable ties holding t...

Page 108: ... not available use a hammer and steel pin d Press in the new bushing Hand ream it and make sure it will attach easily to the Body Lean cylinder File the sides of the bushing if it won t fit on the cylinder s front mount clevis e Re attach the front mount to the chest and cylinder set the critical adjustments B The Body Turn movement See Drawing Page 3 073 is a 4 way movement This is accomplished b...

Page 109: ...problems in the cylinder refer to Pages 3 009 thru 3 011 and all drawings referred to by that text 1 Keep the set screws in the blocks G tight Drill and re tap the set screws holes bigger if necessary 2 If the bushings in the lever H need replacing a Pull the Fas Pins and remove the lever from the leg b Press out the old bushing and press back in the new c Re assemble the mechanism and set the cri...

Page 110: ... 3 073 i ...

Page 111: ... CI Niiw NoiHiccumullltlve E p m i Iac R aW 0 PRODUCTION APP DATE ENGINEERINGINC N REVISIONS Q C APPROVAL DATE DEBURRAND SCALE DRAWN BY f 1 BREAK ALL REV DATE BY SHARP CORNERS DATE 0 2 83 010 CHK D BY ITEM UNTOLERANCED DIM BEACII BEAR L 6 f JCf FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER 3 07 o r c I M ...

Page 112: ...the next larger size thread if necessary If Re Tapping the set screw holes is impossible the Fas Pin will eventually wear the mount holes oversized and the movement will get sloppy If the mount holes becomes oversized replacement of the mount box is required 2 If the bushings in the Mouth Lever B need replacing a Detach the Mouth Lever B from the latex mask and save all the parts b Pull the Fas Pi...

Page 113: ...d of the Moon s face catches on the prop in front of it the Upper neck shaft will bend If the Upper Neck Shaft breaks at the weld replacement of the Upper mouth piece is required Move the prop to allow plenty of clearance a Label and pull the air lines away from the mouth cylinder b Remove the Upper Neck shaft and mouth assembly from the spring neck shaft c Place the rod in a vise at the bend and ...

Page 114: ...m nut B on the shaft and unscrew the shaft from the block C e Lift the shaft and remove and replace the 1 2 Pillow block in one step f Re attach the pillow block to the carrier actuate the movement and check for a smooth movement on the shaft 3 If the set screws in the neck mount blocks D will not hold up the head you can place a 5 8 Shaft Collar on top of the upper block D for added support If th...

Page 115: ...he next larger Roll Pin Tap in the new larger Roll Pin and set the Critical Adjustments 2 If repairing the Roll Pin is impossible replacement of the Actuation lever is required Also if the lever must be replaced then the Lower Neck Shaft probably needs replacement a Tap out the Roll Pin loosen the set screws in the Pillow Blocks and Actuation Lever b Remove the 2 piece Clamping Collar and remove t...

Page 116: ...arrier A by unscrewing the two screws D c Using a Arbor press and a steel pin press out the steel pin If an Arbor press is not available use a hammer and a steel pin Press out the old bushings and press in the new if a tight press is not available mar the hole using an Awl if that does not wor replace the Actuation Block and Plate The bushings used in the block are 1 4 I D x 3 8 O D x 1 4 long Par...

Page 117: ...the Spider to the lines at the noted height off the floor 2 If the bushings in the Pulleys E need replacing a Loosen the set screws in the pulley mount plates F or remove the bolt Tap out the Pivot Pin G and remove the parts b The bushing pressed into the Pulleys is a 5 16 I D x 3 8 0 D x 3 8 long Flange Bushing Part 28 030 040 Place the Pulley in a vise wrap it with a rag to protect it and drill ...

Page 118: ...llow Block and attach the new Pillow Block in one step Do not tighten the Pillow Block into place This allows you to make the repair without removing the mechanism from the platform d Place the guide shaft back into the assembly Tighten the Pillow Block and guide shaft into place Actuate the movement and check for a smooth and easy function 3 See Drawing Page 3 092 There are two springs used in th...

Page 119: ... size tap a Detach the cylinders front mount from the block attached to the Foot Pedal b Unscrew the four bolts C holding the frame to the welded mount pieces D c The original set screws used in the assembly are 8 32 x 1 4 or 3 8 long So drill out the hole or holes for a 10 32 screw Run the Tap and re assemble the mechanism Set the critical adjustments 3 The front mount of the cylinder is attached...

Page 120: ...P DATE l l14 T lJ T 10 0 V T AlitAoriutie u A A A A A 1J INC strictlyfMitilliu l REVISIONS I Q C APPROVAL REV IDATE I BY ITEM 11 1 1 5VN MATL DATE 1R trD 1 scALE 1 DRAWN BY a SHARP CORNERS Q Q 8 010 DATE 1 J 3 CHK D BY UNTOLERANCED DIM M CI1 FRACTL DECIMAL u 010 020 XXX 005 MOUTH DRAWING NUMBER 3 8 3 t Q c I W ...

Page 121: ...REATIVE IM B tie WIO ENG INEE RINOu c n REVISIONS I Q C APPROVAL REV IDATE I BY ITEM t 1 tlt jlt tl M 00N MAT L DATE 1G trD ISCALE IDRAWN BY SHARP CORNEAS 9 za 8 3 010 DATE J CHK D BY UNTOLERANCED DIM M CII FRACT L DECIMAL xx 010 020 XXX 005 MOUTH DRAWING NUMBER 37 14 qo X 0 I rtl ...

Page 122: ...H AiS COMPI E S SPH Nb rJ ATTACH EMAININ6 I ETANJN CLIP Alltol R D APPROVAL DATE g 1I D lD4 4 ITTlVlD4 CP Mlfw Norteccumulatlve r r t Jl r r t t pwm 1 ll IIW 0 PRODUCTIONAPP DATE ENGINEERINOJN N REVISIONS I Q C APPROVAL REv IDATEI BY BREAKALL DATE I DEBURRAND ISCALE IDRAWN BY d7 SHA RP C t ERS DATE g 2 9 8 3 CHK D BY UNTOLERANCED DIM ITEM 1 _ _ ____ 1 1 1 SPii INv NECI A EM BL Y FRACT L DECIMAL XX...

Page 123: ...IIEYIIIONI IIEY I DATE I aT ii O A AL DAft rr 11 t 1 1 o 611 lili ITOCK iiAT I CREATIVE JC TIO N DA n IENG JNEE RJNOnoc C API IIOYAL DATI UNTOLI IIANCED 0111 RACY OI CIMAL t 010 oao 001 I I I I WNEY BJI O CARl I T L flAWING NUMHII 3 0B co 0 I 1 1 ...

Page 124: ......

Page 125: ... 3 088 ...

Page 126: ...r I INPICArES EX ITI1 u PAHT3 IIA M lOONEY BIRO HANP li ETRO F T 0 CX 0 I ...

Page 127: ...ss lt5 Z REO a 32 Ve r SCREW 4 REt ITOCK _ lli D API IIOYALDUIIIC REATIVE I IIOOUCTIONAI P IMTII ENGINEERINGJIIC 1 DfU y IIIV I DATil I ay CHK D aY UNTOU IIANCID DIM PIUCT L OICIMAL Y I 020 DA lWIIIG N HII 3 0 JO 0 0 1 0 I rtl ...

Page 128: ...tiOVAL CREATIVE noNAPP DATil ENGJNEERJNOnoc lillY I DATil I 11Y I 1 T o o J no 7 1 1 1 1m A 5J M BL Y EVI Er J SPJ 0 R M CHANI M UtnOLIEIIAIICIED Dill PMACT L L 010 C 20 001 un MAWIIIG IIUIIIIIEII 3 091 0 0 I rt ...

Page 129: ... 1110 I DATil I 11Y 1 1 1 1 ITI BABY SEAl MECIIANISM IIATL ITO I liiAT I N 0 1 0 I M ...

Page 130: ...TJVE r f cr w ll fw W 0 IPRODUCTIONAPP DATE I E N G I N E E RING c t DATEl BI Q lt D ISCALE IDRAWN av C RUTT 1 SHARPCORNERS 2Q 8 010 DATE v v o CHK D BY ITEM UNTOLERANCED DIM FRACT L DECIMAL lUI 010 020 xxx 005 t GH Hffr Gl B ASt DRUM Mt Cr MAT L DRAWING NUMBER 3 1 33 ...

Page 131: ...rom the center of the front cylinder mount hole to the center of the rear cylinder mount hole On the Critical Adjustment Charts a or tolerance is refered to this means that the Pin to Pin or angular dimension can vary the allotted amount Example The Pin to Pin on Rolfe s ear is 4 5 8 1 8 or a Pin to Pin from 4 1 2 to 4 3 4 And the angle on Rolfe s ear is 90 degrees 2 degrees or an angle from 88 de...

Page 132: ...C C Earl s Eyebrow C C Body Turn R O F C Body Lean c o 7 1 4 4 5 8 7 3 8 8 11 16 3 3 8 3 3 8 8 9 16 9 6 3 8 6 3 4 4 5 1 2 7 7 8 7 15 16 3 3 4 4 9 16 7 3 4 10 3 8 90 D 90 D N A 90 D N A 110 D 13 D 125 D 120 D 55 D 90 D 90 D 90 D 119 D 90 D N A 0 D 6 D R C F O Rear Cylinder Closed Front Cylinder Open N A 2 D N A 1 D N A 1 D 1 D 1 D 1 D 1 D 1 D 1 D 1 D 1 D N A N A 1 D 1 D Information on the chart is ...

Page 133: ...ead Left c c 3 3 8 N A N A 110 Head Right c c 3 3 8 110 D 1 D 110 Head Up Down c o 8 1 2 15 D 1 D 111 Left Arm Swing c o 4 11 16 52 D 1 D 120 Right Arm Swing c o 5 3 4 60 D 1 D 120 Left Right Elbow c c 7 3 16 87 D 1 D 121 Body Lean c o 9 7 8 2 D 1 D 126 Cymbals c o 7 5 16 18 D 2 D 129 Base Drum c o 7 3 8 23 D 2 D 129 R C F O Rear Cylinder Closed Front Cylinder Open Information on the chart is not ...

Page 134: ...p c o 7 1 8 23 D 1 D 112 Right Arm Raise c c 6 5 8 128 D 1 D 115 Right Arm Twist c o 6 1 16 90 D 1 D 118 Right Elbow Twist c o 8 3 16 45 D 1 D 123 Right Wrist c c 7 5 8 35 D 1 D 123 Left Hand Slide c c N A N A N A 125 Guitar Raise c o 9 7 8 N A N A 125 Body Turn R C F O 7 11 16 0 D 1 D 126 Body Lean c c 9 1 8 7 D 1 D 126 Foot Tap c o 7 3 16 90 D 2 D 127 R C F O Rear Cylinder Closed Front Cylinder ...

Page 135: ...0 Head Up Down c o 8 1 2 10 D 1 f 111 Right Arm Raise c c 6 1 4 117 D 1 D 115 Right Arm Twist c o 6 1 16 90 D 1 D 118 Right Elbow Twist c o 8 3 16 45 D 1 D 123 Right Wrist c o 9 1 4 35 D 1 D 123 Left Hand Slide c c N A N A N A 125 Guitar Raise c o 9 7 8 N A N A 125 Body Lean c c 8 7 8 8 D 1 D 126 Left Rt Leg Kick c c 7 3 8 70 D 2 D 128 R C F O Rear Cylinder Closed Front Cylinder Open Information o...

Page 136: ... O Left Arm Twist C O Right Arm Twist C O Body Twist R C F O Body Lean C O 7 1 4 4 5 8 7 3 8 8 11 16 3 3 8 3 3 8 8 3 16 8 1 2 8 1 2 8 1 8 4 3 4 4 3 4 7 7 8 10 9 16 90 D 90 D N A 90 D N A 110 D 10 D 125 D 125 D 15 D 90 D 90 D 0 D 0 D R C F O Rear Cylinder Closed Front Cylinder Open N A 1 D N A 1 D N A 1 D 1 D 1 D 1 D 2 D 1 D 1 D 1 D 1 D Information on the chart is not complete refer to the Drawing ...

Page 137: ...g c o Right Arm Swing c o Left Right Elbow c c Body Lean c c Foot Tap c o 7 1 4 7 3 8 8 11 16 3 3 8 3 3 8 7 1 2 6 1 4 4 7 8 4 7 8 7 1 4 8 3 4 7 3 16 90 D N A 90 D N A 110 D 0 D 70 D 125 D 125 D 85 D 34 D 90 D R C F O Rear Cylinder Closed Front Cylinder Open N A N A 1 D N A 1 D 1 D 1 D 1 D 1 D 2 D 1 D 2 D Information on the chart is not complete refer to the Drawing C C Cylinder Closed C O Cylinder...

Page 138: ...N A c c 7 11 16 N A c c 10 1 2 N A Critical Adjustment Chart Props Cyl Open Cyl Pin to Cyl Closed Pin 1 8 Degree c c 6 7 8 N A c c 12 1 2 N A c c 6 1 2 55 D c c 17 1 2 11 N A N A N A N A c c 16 1 4 11 N A Tolerance On Angle N A N A N A N A N A Tolerance On Angle N A N A N A N A N A N A Information on the chart is not complete refer to the Drawing c c Cylinder Closed c o Cylinder Open 3 101 Drawing...

Page 139: ...F TNE PROTRAl TOR OFF SQUAF E WIT THE HJJV WILL CA IJS A INCOR F ECT R ADINC1 TOP YI W HOW It THE Pli OTii ACTOFr TWI 6TEI7 Off S61tJAR TYl IIIN6E All tol NorH ccumuletlft TSEJ cREATIVE o T ie E I II T ll I II E E RTr T t A ll A Jl A 11 nK mct y f1rolli _ REVISIO S I D C APPROVAL DATE DRAWN BY AEv loATE I BY J 83 I CHK D BY UNTOLERANCED DIM FRACT L DECIMAL XJI 010 020 XXX 005 I I I liTEM P i OPEF1...

Page 140: ...L ____ ____________ _ 0 Alltol are Non eccumulatlve R V PPROVAL DATE lf 4 ll a ITWVE o C t Ji 6 m A W 0 PRODUCTION APP DATE ENGINE E R IN0 IMC 1 i t 4 Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY IDEBURR AND I I I SHARP CORNERS 010 DATE tb ZZ 83 CHK D BY ITEM SIDE VI w OF Ht AD I I I I SHOWINb MOUTH LEVER ONL Y I IN F81r ER f tt8EB BIM FAAQ Piau 81i 1Mti L Q IO 888 t 881 MAl L DRAWING NUMBER 103 M 0...

Page 141: ...oucnoNAPP DATE I E N G JNEE RING IIC 0 REVISIONS I Q C APPROVAL REV IDATE I BY ITEM DATE I K r tl D ISCALE IDRAWN BY 8 I SHARP CORNERS 010 DATE 10 1 B CHK D BY UNTOLEIIANCED Dill t l tl l II M ITZ I ROLF EAR FRACT l DECIMAL D 010 020 JUIX 005 IIAT l DRAWING NUMBER 3 Jr 0 I ...

Page 142: ...RO D uc T IO NA P P D A TE I ENG HNEE RIN0 JNc 1 0 REVISIONS I Q C APPROVAL REv IDATE I BY DATE I DEBURR AND ISCALE IDRAWN BY l r BREAKALL SH RP C ERS DATE J0 8 3 CHK D BY UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 I I I I ITEM DOOK S A If MAT L DRAWING NUMBER 3 r an 0 I C l ...

Page 143: ...PRODUCTION APP DATE I ENGINEE RINGINC a REVISIONS I Q C APPROVAL REv l DATE I BY DATE I g t D ISCALE IDRAWN BY EJ2 I SHARP CORNERS n a 7 CHK D BY 010 DATE C7 J 1 1 1 IITEM Y L O AD JVSTM Yr UNTOLERANCED DIM FRACT L DECIMAL I OLT MITZJ FATZ Ui NEY Blf V XX 010 020 XXX 00 5 MArL DRAWING NUMBER 3 0 4 I t ...

Page 144: ... Mriutio_ is A lt J ll A fed lCif A A Il r smctlyl l etl REVISIONS Q C APPROVAL BREAKALL DATE I DEBURR AND ISCALE IDRAWN BY L 1 REV IDATE I BY SHA RP c ERS DATE 0 II B 3 cHK D BY I I I liTEM Y LJO AD fUSTMENT 1001 BILLY B0f3 8EAC H BEAT MAT L UNTOLEAANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 DRAWING NUMBER 3 I r 0 i I 1 1 ...

Page 145: ...ccumulative R t D APPROVAL DATE c R 1U4 1 J P E PrvfHrty of CrNiir r 7 Jr J t 11 1 E rqiiiHri f l c j j Rtfm durtio wm y rn 11 y lL IT w T tuiAI riUIIWN u DATE i A A l_ J A I fi_A r J t it l A JJ INC strirtl vJm ltib trd Q C API HUVAL __ _ 4 DE BURR AND ISCALE UATE I BREAK A RNERS 2 83 SHARP C 010 DATE 0 ITEM TOP AND FRONT VIEW lt 1 I ISHOW N EYES ONLY MArL DRAWN BY a CHK D SY UT8 LERAUeEB BIM t 8...

Page 146: ...TION APP DATE ENG1 NEE RINGIIIC i w REVISIONS I Q C APPROVAL REV IDATE I BY ITEM EY I I I I LOONEY MAT L DATEI t D fSC A L E D R A W N BY 1 SHARP CORNERS II t l3 CHK D BY 010 DATE L 1 rJ CROSS BII D BEACH BEAR UNTOLERANCED DIM FRACT L DECIMAL lUI 010 020 XXX 005 DRAWING NUMBER 3 0 J I 0 0 4 I f ...

Page 147: ...THE PIN 0 PIN DIM SITwrnv REAR MOUNT AND IHf CREST FRAME TOP VIEW HEAD f J6HT ONL BOTTOM VJFW HEAD LEFT ONLY 5HOULO R SA F IS SHOWN CUT OFF Allloi Non eccu I y a r I 0 III VISIONS C A oVAL DATE I iiiiiiii L L II EIIII L 2 3 IHA_R c o DATE C1 REV I DATE I I I I liTEM A D fU TMf NT 0 F HEAD LEFT Rll7H T CYLINO F7 T L _ _ ORAW NG NUMBER 3 J 0 I 0 1 I ...

Page 148: ...S MEA Uf1EO S TWEEN THF F HINbE ON THE rap OF THE NECK SHAFT AND rHE HCAO 7 g fiCREATIVE r DATI ENOINEERING c C AIPROVAL DATI I a AND IIICALE IDIIAWN g j SH I M DATI 23 CHK D BY I I I liTEM 5JPE VIEW OF HEAO _ t AND l PPER NECK 010 020 001 MA1 L DRAWING NUMBER f ...

Page 149: ..._ 1 RejmHlwctitnl W 0 ENGINEERINO t PRODUCTION APP DATE Q C APPROVAL 1 TE I DEBURR AND ISCALE IDRAWN BY q I D BREAK ALL SH RPC ERS DATE j fJ3 CHK D BY I I I liTEM BILL y BOB IEAV TilT HEAP UP UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 00 1 MAT L DRAWING NUMBER 3 1 I rt ...

Page 150: ...L DATE CREATIVE tiw 1 1 wo PRODUCTION APP DATE ENGINEE RINGINC I Q C APPROVAL 1 t DATE I G l t D ISCALE IDRAWN BY a I SHARP CORNERS a 23 B 010 DATE J 3 CHK D BY ITEM I 1 l l II FATZ HEAP TILT UP UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING 1111 BER 3 1 ...

Page 151: ...on accumuletlve R Q APP QVAL DATE cR E ATII E C c y A S E_ um Ilk _ W 0 PRODUCTION APP DATE f tl Tl T 11 1i f T 6 J ht oriut u A t l B It A 1I A ll A ii JN uti r 1 Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY c J I DE BURR AND I I r 2f SHA RP C ERS DATE fo 2 3 83 CHK D BY ITEM MArt SJ JE Ar M VIEW f A 15 SJ OW Nb HtN DRAWING NUMBER 3 4 ...

Page 152: ...J UV efrr tnot _ L r 11 E fiiNrl bf a A R f ltu1iert WIO lU4 f t 1 1J R v 1U1 IL ltJ vr T oriwio PRODUCTION APP DATE Jr d A l__ i A lf iJ it ll A j JlJNC strirtly at t C C APPROVAL 1 r t BREAK ALl _______t ___ DATE I DEBUHR AND ISCALE IDRAWN BY SHA_RP C S ERS DATE b 27 8 3 CHK D BY ITEM MArl I 0 E VIEW Rlt H T SI IOUL 0 f I ARM RA 5 J QiQ DRAWING NUMBER 3i ...

Page 153: ...ATIVE r cllw RetmJ Itu tio ll W 0 ENGINEERINGINC 1 M t PRODUCTION APP DATE Q C APPROVAL 1 or _ ITEM DATE 1R ltrD 1 scALE JDRAwN BY a z 1 SHARP CORNERS l t 1 8 a3 CHK D BY 010 DATE Jj j U UNTOLERANCED DIM I l 4 1 ELBOW MITZI f OLF FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER 1 3 J c I f ...

Page 154: ...L DATE CREATIVE r c w 1 11 W 0 PRODUCTION APP DATE ENGINEE R IN0 fMC REVISIONS I Q C APPROVAL REV IDATE I BY DATE I D Q tl D ISCALE IDRAWN BY t l I IHARP CORNERS 0 0 010 DATE v n CHK D BY ITEM I I I I SMALL SHOtJLOER 7WI51 UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 MAT I DRAWINP UMBER 3 r I ...

Page 155: ...D APPROVAL DATE g li E A TWVE fc dw Non eccumullltlve t A l t E n fltt Rejlredou tio W 0 PRODUCTION APP DATE ENGINEE R IN0 JIIC w I REVISIONS J Q c APPROVAL DATE R lt D SCALE DRAWN BY a I REV I DATE I BY SHARP CORNERS 10 8 a 010 DATE 1 f J CHK D B I ITEM I UNTOLERANCED DIM lt l l tl BEACII BEA BILLY8 8 SNOULJ ff FRACT L EC MA 010 020 XXX 005 MAT L DRAWING NUMBER 3 3 ___ ...

Page 156: ...lltol R D APPROVAL DATE 6 11 a ITTI l E C IIw Non eccumulattve 11 E _ Irte R W 0 PRODUCTIONAPP DATE ENGINEER ING IC t E Q C APPROVAL DATE I DEBURR AND ISCALE IDRAWN BY 82 I BREAKALL SH RPC ERS DATE JO JB 83 CHK D BY ITEM UNTOLERANCED DIM FRACT L DECIMAL XX 010 t l tl l ll ROLFE S L ARb SIIt Jl Ll 1 020 xxx 005 MAT L DRAWING NUMBER 3 ...

Page 157: ...L DjiTEI q 1m m TliVE l reflmy ofC IIw NOIHICCUmuletlve J1 Elfli em IrK R rtW 0 DATE ENGINEERINGJIIC PRODUCTION APP Q C APPROVAL t t CHK D BY DATE I G tl D ISCALE IDRAWN BY 1 I SHARP CORNERS 1 A o 11 7 010 DATE V c O J ITEM 1 1 1 l tl a JOI FA TZ ARM 5WING UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER 3 c I t ...

Page 158: ...ATE STOCK MAT L CREATIVE rr w I I _ W 0 PRODUCTION APP DATE ENGINEE RING INC O C APPROYAL DATE I B ltl D ISCALE IDRAWN BY 4 12 I SHARPCORNERS a 0 3 010 DATE 4 C7 e7 CHK D BY ITEM t l I l tl ELBOW MoVEMENT UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER ____ ...

Page 159: ...Umulatlve R D APPROVAL DATE CREATIVE tiw I I WIO PRODUCTION APP DATE ENG1NEE RIN0 c u w t 1 Q c APPROVAL DATE IR ltl D ISCALE IDRAWN BY SH tPC ERS DATE 0 20 83 CHK D BY I I I liTEM ROLFE ANDE AI L ELBOW TWIST N AO TILT MAT L UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 DRAWING NUMBER 3 1 ...

Page 160: ...PPROVAL DATE li D 1L 4 4 TTlVE PreflmYo C tiw No Hiccumuletlve 1 l E ofi m llf Iru ltefn 04uaiort W 0 T Tl T 1IJ Tl T AutAoriutiora u E I J Jed l Df E I J U INC strictly JlreAi itM t r r 1 Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY IDEBURR AND I I r r I SHA RPC ERS DATE 0 20 83 CHK D BY ITEM llITAR ARM IUNTOLERANCED DIM 1 I II II rw 1sT ANo WR1sr B NT FRACT L EC1MA o o 020 XXX 005 MAT L DRAWING NU...

Page 161: ...OW SING PJN TO PIN 0 q APP R01 I 0 R D APPROVAL DATE CREATIVE Hw I I W 0 PRODUCTIONAPP DATEENGINEER JNG xc _ 1Q c APPROVAL DATEl R lt D ISCALE IDRAWN BY nli SH RPC ERS DATE 0 20 83 CHK O BY ITEM l l tl EAI L EA UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER 3 12 f ...

Page 162: ...l IJ h_3l rCCfrf f OF Alltol IR D APPROVAL DATE 1I D 4 ITtlVE c w Non eccumulatlve I l E u em IJtc It W 0 PRODUCTION APP DATE ENGI NEE R IN0 JJIC M DEBURR AND I I p f Q c APPROVAL DATE IBREAK ALL SCALE DRAWN BY J 1l SHARP CORNERS 20 8 7 010 DATE 10 CHK D BY ITEM UNTOLERANCED DIM FRACT L DECIMAL XX 010 t VITAR MOYEMENrS 020 XXX 005 MAT L DRAWING NUMBER j 3 c ...

Page 163: ... D APPROVAL DATE l 4 iTll q YE fCr tlrlt Non eccumulatlve A A 11 W ErtK ItUI IIIf IJU RtfmHltldioJt W 0 PRODUCTION APP DATE ENG HNEE RINGINC i d Q C APPROVAL DATE lt D SCALE DRAWN BY 1 p p BY SHA RPC ERS DATE 0 20 33 CHK D BY UNTOLERANCED DIM FRACT L DECIMAL XX 010 ITEM t l l 1 l II BODY TIJR N I LEA1 1 020 XXX 005 MAT L DRAWING NUMBER 3 C I rt ...

Page 164: ...iCREATIVE PRODUCnoNAPP DATE ENGINEERING K I REVISIONS IQ c APPROVAL REY IDATE I BY ITEM t l l l I FOOT MAT L DATE 1DEIIURR AND ISCALE IDRAWN av 9 I fll t n io 20 83 CH n UNTOLERANCED DIM FRACT L DECIMAL XX 010 TAP 020 XXX 001 DRAWING NUMBER 3 1 7 ___ r ...

Page 165: ...S Q C APPROVAL REV DATE BY ITEM 8 At ll MAT STOCK MAT L 0 I DATE CREATIVE _ efc w E p miltf IK W 0 DATE ENGINEERING c DATE DEBURRAND SCALE DRAWN BY a BREAK ALL SHARP CORNERS DATE 10 Z 83 010 CHK D BY UNTOLERANCED DIM B F LEG f J f FRACT L DECIMAL xx 010 020 XXX 005 3 ir BER c c I ...

Page 166: ... f frr B rtW 0 ENGINEERIN0 INC PRODUCTION APP DATE Q C APPROVAL _ _ t CHK D BY DEBURR AND I 4 1 I c I DATE I BREAK ALL SCALE DRAWN BY SHARP CORNEAS 010 DATE 10 83 UNTOLEAANCED DIM ITEM t l t lG 1 AI 3 As E Dt U1 MECH FAACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER 3 29 _ c r ...

Page 167: ...L DATE D l D 4 ITTVE efC Iw Non eccumul8tlft A A A _ lrtt R W 0 PRODUCTION APP DATE ENGINEE RING JMC c r ___ I DEBUAAAND I I I REVISIONS Io c APPROVAL DATE IBREAK ALL SCALE DRAWN BY I I SHARP CORNEAS I 1 21 8 3 REV DATE BY 010 DATE IV CHK D BY ITEM L AI y 8 L t IUNTOLERANCED DIM I I I I Vc Y n oo FAACT L DECIMAL J EA L FT 020 x MAT L DRAWING NUMBER 3 Jr ...

Page 168: ... E _ 1 ll aW 0 PRODUCTIONAPP DATEENG J N E E RINGINC i t io 1 Q C APPROVAL DATE BREAK ALL SCALE DRAWN BY DEBURRAND I I I SH RPC ERS DATE 0 2 CHK D BY ITEM LOO A E y 8 17r IUNTOLERANCED DIM I I I I 1 y I rJ FRACT L DECIMAL J I A RAI 020 MAT L DRAWING NUMBER I I I I 3 ...

Page 169: ...ot R D APPROVAL DATE t 4 R E 4 ITlJVE efc Noneccumuletlve t A 11 E i lac W 0 PRODUCTION APP DATE ENGINEE RIN0 IIIC I I r 1 t 1 0 C APPROVAL DATE BREAK ALL SCALE DEBURR AND I I _ 1 SHARP CORH RS 1A BY 010 DATE IV I I I I ITEM 5uN UN MAT I MOUTH KAISE UNTOLEAANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 DRAWING NUMBER 3 r t N t I t ...

Page 170: ...6 NEC B UPPIIOVAL DATEICREATIVE i PRODUCTIONAPP DATE ENGINEERINGIJIC DEBURRAND I I J Z I REVISIONS IQ c APPROVAL DATE IBREAK ALL SCALE DRAWN IY I I SHARP CORNERS REV DATe IY 010 DATE It ZI B CHK D IY I I I I n FRACT L DECIMAL ITEM MOON MOlJ TV IUNTOLERANCEDDIM MOON RA 5 02o X MAT L DRAWING NUMBER w _ rt1 rt1 I l i ...

Page 171: ... CEIL IN _ D R 41TJVE cr NonotlccumutMM 1 E WIO PRODUCTION APP DATE ENGINEE RIN0 JJIC b REVISIONS Io c APPROVAL DATE IBl ltl D ISCALE IDRAWN av t J j I I SHARPCORNERS J t Zl 83 REV DATE BY 010 DA TE tv CHK D BY t 1 tl 1 11 IT M L r JI r r R I UNTOLERANCED DIM JY IV FRACT L DECIMAL XX 010 020 lOUt 001 MAT L DRAWING NUMBER A II t C ...

Page 172: ...nirt Tr t Rqmtdtu tio lt W 0 PRODUCTION APP DATE ENGINEERING btA riwio u A J IIC Jtrictly i Jllt REVISIONS Q C APPROVAL DATE DEBURRAND SCALE DRAWN BY 87 BREAK ALL REV DATE BY SHARP CORNERS DATE JO ZI B3 010 CltK D BY ITEM BABY BEAR UNTOLERANCED DIM FRACT L DECIMAL XX 010 020 XXX 005 MAT L DRAWING NUMBER 3 3 ...

Page 173: ... of the cosmetics used are very fragile and care must be used when performing maintenance any where on the platform Table of Contents Latex and Foam page 3 137 and 3 138 Costumes and Fur page 3 139 and 3 140 Inner body parts ie Fiberglass Duct Hose leather or vinyl page 3 141 and 3 142 SNAPS AND VELCRO page 3 143 and 3 144 Eye Ball and Eye Lids page 3 145 SHOW LIGHTING page 3 146 Drapery page 3 14...

Page 174: ...placement and positioning With these parts in place there should be no distortion and you should be able to move the character in any direction with out straining any of the latex or foam to pull it out of shape 2 Cleaning latex parts Use a clean cloth dampened with warm water NO OTHER type of cleaner should be used as it will break down he latex and damage it DO NOT get the fur on any latex parts...

Page 175: ... in step c If any are lost or damage beyond repair they can be ordered from your parts catalog e LATEX PAINTED Parts that have worn areas paint peeling off scratched can be touched up using cotton swabs Under NO circumstances are large areas to be brushed painted If an artist is available airbrushing the part would yield the best results The touch up paints can be ordered from your parts catalog T...

Page 176: ... SNAPS and VELCRO page 3 143 and 3 144 2 Installing Costume or Fur It is important that you pay close attention to the positioning and placement of the costume or fur With the costume or fur in place you should be able to move the character in any direction with out straining any of the seams restricting or binding any movements or rubbing the costume or fur parts together If any of these problems...

Page 177: ...he fur piles through to cover the repaired area Brush the repaired area lightly to blend the fur If the problem seems to be happening constantly see step B below b Fur Hot Glue repairs Fur that has a problem constantly needs to be examined closely and corrected by referring to the repair section of either Mechanics pages 3 032 thru 3 093 or Inner Body Parts pages 3 141 thru 3 142 Once the problem ...

Page 178: ...ead of leather The duct hose is used on the arms and is attached with threaded rod Maintenance is very important to the inner body parts and should be part of your characters weekly P M 1 R R Remove and Replace Inner Body Parts A Fiberglass and Duct Hose a To remove fiberglass it is necessary to mark or note the exact position before removal The threaded rod which holds the fiberglass in place sho...

Page 179: ... position the fiberglass using all the nuts lock washers and flat washers and do not drag or push the fiberglass against the threaded rod it will elongate the mounting holes making the re positioning difficult For costume repair see pages 3 139 and 3 140 and fiberglass placement pages 3 155 thru 3 186 B DUCT HOSE The duct hose repairs will mostly be rips in the fabric which make up the body of the...

Page 180: ...ed with a 3 4 X 3 4 piece of cloth backed vinyl Line up the vinyl square to the area being repaired on the inside of the costume or fur Apply hot glue sparingly to the cloth side of the vinyl and press it to the area being repaired Punch a 1 8 hole in the vinyl using the hole in costume or fur as a guide With the parts for either a male or female snap secure to the costume or fur Glue a small circ...

Page 181: ...w velcro hand stitched back on Velcro can be purchased at the local fabric store Velcro that is clogged with fur can be cleaned by running a comb or small screw driver along the edge of the velcro then brush the fur away from the velcro MALE SIDE STUD CLOTH FUR STUD 0 R L E A TH E R CAP CLOTHT FUR OR LEA HER FEMALE SIDE CAP SOCKET POST STUD 3 144 ...

Page 182: ...to be replaced or removed for any reason See the repair section on heads pages 3 042 thru 3 047 B EYE LIDS a Eye lids that have the paint worn off or scratched can be touched up using a cotton swab Under NO Circumstances is the entire eye lid to be brush painted If an artist is available airbrushing the eye lid would yield the best results You will have to remove the eye lids to have them air brus...

Page 183: ...OBLEMS AND REPAIR A EFFECT LIGHTS a Effect light have very little problems other than bulb replacements If there is an electrical problem with the effect lights See electrical repair pages 4 011 thru 4 016 Replacement bulb for the most part can be purchased at the local hardware store or refer to the Rock A Fire Parts Catalog For location and color of lights see page 5 067 B Spot Lights a Bulbs ti...

Page 184: ...e areas have strict fire codes some are not as strict After the drapes have been dry cleaned it will be necessary to retreat and recertified to the fire proofing codes in your area B The drapes should never be removed if it is necessary to remove the drapes the following instruction should apply First remove the vertical panels tied back on each side of the platform Next remove the Jaboe The velcr...

Page 185: ...d be dusting and light vacuuming Maintenance is very important to these items and should be part of your P M procedures 1 Problems and Repair A Back drop that is ripped should be stitched up as invisibly as possible B Grass Matts that need repair you may either staple a new piece over the worn portion or cut out the worn area and staple in a new piece Any replacements parts can be found in the Roc...

Page 186: ...lcro Next close the velcro on the back Be sure to match up all the closures Place the top of the vest under the collar of Rolfe s shirt c Rolfe s tie is easy to attach with velcro on the back of the tie stick it to the patch of velcro at the neck of the shirt 2 Earl s Costume A Earls vest is one piece with velcro in the back of the vest Do not try to unbutton the vest it is sewn Open the velcro cl...

Page 187: ... edge of the pants 3 Put the straps over each shoulder and snap them to each side of the back 4 To attach the hard collar place the side wings of the collar underneath each strap from the outside facing inward The velcro of the straps should match up to the velcro on the side wings of the collar The back of the collar will stick with velcro to the outside of the top of the vest Check to be sure th...

Page 188: ... and arms Close the center back velcro closure Position the jacket and shirt so that there are no strange pulls or wrinkles Check the neck edge to be sure that no fur is coming out or folded wrong Check the center front at his waist and be sure the jacket comes down to his fur pants so that none of the fiberglass body shows The shirt should have a piece of male velcro at the center top this attach...

Page 189: ...body in the center front Pull to the back and attach double snaps on each side of the back Be careful of your hands near the fiberglass Wrap the front and right back leg pants around the character s right thigh and close the velcro underneath his leg Do the same for the left thigh Position the shorts so that there are no strange tucks or wrinkles and that no fiberglass is showing 3 152 ...

Page 190: ...n her pom poms The M goes towards the front Drape the right sleeve over her right arm and shoulder and fasten the velcro closure all the way from her wrist through her under arm up to her waist Remember it is easier to start at each end and work towards the center 3 Close the left and right back of the sweater at the center Position the sweater so that the M is in the center Make sure the V neck i...

Page 191: ...eath the guitar so that no fur can be seen from the audience Place a strap over each shoulder Cross them in the back and snap them to either side of the waist There is a selection of snap placements on the straps which can be used to adjust the proper length When snapping together the crotch of the overalls be sure that the pants are not pulled up too high This will cause a funny looking fit Snap ...

Page 192: ...ACEMENT PRINTS Contents Page Number Rolfe and Earl Dook Fatz Beach Bear Mitzi Billy Bob Looney Bird 3 155 3 156 3 161 3 165 3 171 3 177 3 181 3 185 thru 3 160 thru 3 164 thru 3 170 thru 3 176 thru 3 180 thru 3 184 thru 3 186 ...

Page 193: ... _ ...

Page 194: ... oO r T f N J 11 IQl 0 rn 01 I L _ ____________ ...

Page 195: ... 2 n J 158 c l 0 ...

Page 196: ... A 12 ___ for ikod Drawing see 44 0 Bol for holdll g body in ploce ...

Page 197: ... co _ _ 3 J I I J I I r J r 1 Bolts for holdm9 2 4 SCALE 112 I I APPROVED BY DATE t 18 82 _ 5kull EARL S SKULL DRAWN BY c ar1 R DRAWING NUMBER 4 1 c 1 I t ...

Page 198: ... II 0 r 7 m fl 7 c I r ...

Page 199: ... 1 E rn I rv I r J f D _ u JTJ Jl fl t c r l I J J _ ___ r 1 I I I _ __ I r __ lr r _I r 1 I 3 162 ...

Page 200: ...ng body 51 1 5 fog Nf P X r t plAWIIIlGS l I GI TH 1 FROM TO P oFJ m TO BOTTOM OF OOY e s 1 8 UND Il Abl i 10 FROM LOWE ST T CUT OW ARM TT DOITOM OF 60DY DATE 1 19 e2 DUKE F DRAWN byCR C Ole G I DRAWING 1 10 4M0 3 163 ...

Page 201: ... eol 1 fer ho din9 Skyll il 1 57J l 2 6 2 0L 2 DR t O n I 0 SNAP See D f Viii S 481 l 48ll ATE 1 20 82 DUKE RIGHTSIDE VIE V DRAWN by C R colt l 6 r DP AVIIN l NO T 3 164 ...

Page 202: ... t J l I I i l c r I r z f 0 t o 3 165 ...

Page 203: ...s lthd d for holding Sk tll N th 1 3JJG hut J 1 3JI G 3 1ock WAshers and IG 1 fJot washers 1 1 P HFi p QB BO H Stot oE HD 1 11 l l I I I I I I I I I I I I I I I 5 4 8 4 1 d r i I C f I t Q 2 4 8 2 Fa 5 sku II awn I J r R scale Y2 DRAWtN 45 K 0 0 I M ...

Page 204: ...L o DATE 2 16 8 2 FATS FRONT VIE W DRAWN byCR 0R AWNG 45P 3 167 ...

Page 205: ... 25 h Atlnchino body to Movrng Mcthonrsf l I 3 168 0 j u Jif O or cnli 1 z a a a UJ7 _ u o OJ N t lo 7 s N w a Ci 00 ...

Page 206: ... orm Righ Side o f right o r rn _I 1 SCAlE J 8 _ I I APPROVED BY DATE 2 I 2 7 8 r 1 I t LB oJ Uor hqldlng___c_o_v _r x 2 o 4 v G C Y td 7 o k f 0 Ic f s DRAWN BY c r GORILLA RIGHT FOREARM COVER ORAWING NUMBER 4S P 0 D 4 I M ...

Page 207: ... a J I R ight SidG oF L Arrn I 0 l left Side of L Arm scALE J s 1 1 AJ PnovEo ev DATE 2 I 2 B 2 3 Bolt for holding cover 4 J DRAWN B f Cal _ Go1 IIo Lcf t r o r e or n1 Covcr DRAWING NU BEA 4t O ...

Page 208: ... 0 m 70 oo o 3 rn z 0 I I rl 6 I f f o 1 J J I _ I t r j 0 1 t t ll t I 1 I J 14 l J L r j r J I f I I ____ ...

Page 209: ...prrt of Crnllu E l rrlnr 1 llrproductlolt W 0 Aktllorlaetlolt Ill trklf prohibited n 1 nN n H HR IIN fn IHC SCALE If _ f OATE J 2 7 82 I C IHM BE AC 1 DESCRIPTION I DEBURR AND APPROVED BY DATE BREAK All IDRAWN BY I SHARP CORNERS C HK D IY 010 0 R s I TOLERANCES u A s K uLL FRACT L DECIMAL 020 t 010 006 DRAWING NUWIEA 2 _ __ _ ...

Page 210: ...13 23 D C1 r 1 See 4 2 f r I Cmicn o _ S nOC5 NOTE _C HANGE _ _____ 2 front VIew DATE 1 25 8 2 DRAWN b 1 C R 3 173 BE ACH BEAR DlMfNSICNS DR Wit l NO 4 2 ...

Page 211: ... Drow ng k tJII Se Owq 41 l r NOTE RIGHT SID 0 t i j lf l Q fer bol s_ o 1 11 bod f 9 _ 21 LEFT StDE DATE 1 2 8 2 DRAWN by C R 3 174 EACH BE AR DIMEN510NS DRAWING t 104 2W ...

Page 212: ... E Ott OL T 3 I 5 18 c 14RE t tC BOLi 4 10 5fu 1 e He N 11 P Rl c __j WI Wifr __ S G 8 r LOC K WP SHER fl 6 10 c 1C t Un WASHf J _1 r n m I r _n 1 1 1 V TJ T 4 1 1 1 11 if rA A 1 1 i TA rA ll J _ vto OAf I IIIV ID ttl UIOAII J 6 I I I I n e ACI Btl r R LtG OIICJU T IO f RnRo rn c _ 1111 1 A _ _ TOLERAIIICU ACt DlCIMA 020 t ___ 4 11 1 l f I 1 1 ...

Page 213: ...8tRGL 55 PA tt _ I S 1 18 Tt1 AOEt BoLT 3 I 5 1 t8 9 I REAtt 0 BOLT 4 IO I HE Nv s 5 CO 5 t LOCK WI I IF o 10 S IG Fl i WA HHJ q 1 4 T 11 r x t 11 n JN1 c ltte Allflltor vaa 1 1 ovt o I _ I _ 1 1 I g TOLIRAIIIICU JlllACT L DlCIMAL A20 t I I I I Bt nc f U n Ll G RtiRO fiT DISCA PliON 4 Z ll 1 0 r l I M ...

Page 214: ...0 It 4 tJ N I f II c D TT 0 ll 0 0 II 7 t 9 c I b r J tlw 0 i 0 z Q II z p i 0 p Ill iU 3 177 ...

Page 215: ...0 l 3 I l 1 I _ _ I _ I I __ I I I I 2 c _ 4 1 Side View APPROVED BY Mounting 8olt holes 81 4 DRAWN BY car R MITZI S t c fl SKl j L L 3 440 DRAWING NUMBE 41N I co 1 I M ...

Page 216: ...4 TI Iecd d bolts s fCif hold1ng bod J on d l Nuts tvJ e s A Flat wo hexs I s Locr wg5hen J 22 10 r IO f CQ_I_ tO_ _ t __ 1 OAl E 2 1 82 MITZI FRONT VIE vV ORAW J G R DRI WING 41 P 3 179 ...

Page 217: ... 13 ni ITf c Hn DRt WN bv C R f IITZI R SJDt Dlt 11 col C I DRAWI J t l 0 ...

Page 218: ... cY r SJ jJ t 0 JJ cP J 7 J c s F j 3 181 ...

Page 219: ... Holesfor 4 J 1G x 3 k Threaded boHs for holdinc Skull With IG nuts IGFiat wa hers and IG lock washers 3 each SCAl E J A r I API ROVEO BY OATE 2 2 82 5illy Bob s Skull SHEET 2 L I M DRAWN BY Carl R DRAWING NUMBER t L co 4 I f ...

Page 220: ...18 11 58 8 DATE 2 15 82 BILLYHOB FRONT vn w DRAWN by C R 9caleJJtc l DRAWING 35N 3 183 ...

Page 221: ... 2 lr BoH sfor holdmq boay 8 each 3 if He11 nuts Lock woshec aYid f ar washers DA1E 2 8 82 DRAWN by C R BILLY Bo LEFT 51DE 58 8 3 Ai DRAWING _3 Sm ...

Page 222: ... 4 I lF N In nN JFj H IllIfNo c _ ofC W IIH _ Jl uctiOII tr 0 Awt or tto II ltrlcf17 ro 1 p SCALE 12 IAPPROV 0 BY DATE 2 1 s L 2 DATE DEBURR AND C b BREAK ALL DRAWN v _ SHARP CORNERS CHIC D aY 010 TOLERANCES 7 111 211 l ITEM Loot H B RD 5 SKULL f J tw FRACTL DECIMAL 020 t 010 t 001 DES P TION DRAWIHca 6 ...

Page 223: ...SCALE 2 APPROVED BY OATE OEBURR AND BREAK ALL DATE I 0 2 0 R _ SHARP C RNERS 10 II EM L00 NE y s B DS SKULL DESCR I N S H 1 1 00 r 4 I M l ropwt of CtwtfN lrw ll nHiuctiO W 0 A utllor elloll II atrlcll ll prolalfllltcl DRAWN avC t t C CHK D IY TOLERANCES FRACT L DECIMAL 020 t 010 005 IDRAWING NU BEA t ...

Page 224: ...II l II 0 a 0 n l 0 Ji r h I S I 8 0 i5 z 0 R o fT lfi n I I 0 o I I cd It 3 187 ...

Page 225: ...ru 4 005 B Controller Problems pages 4 006 thru 4 008 c Character or Props Movement Problems pages 4 009 thru 4 010 D Lighting Problems pages 4 011 thru 4 016 Organ and Sign pages 4 011 thru 4 012 Spots and Floods pages 4 013 thru 4 014 Houselights pages 4 015 thru 4 016 E Drapery Problems pages 4 017 thru 4 018 F Miscellaneous Problems page 4 019 4 QOl ...

Page 226: ...est 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 next step The Electronics trouble shooting approach can be handled nearly the ...

Page 227: ... wiring Symptom One channel out See power up procedures in Mech Part I page 1 003 and pages 5 002 and 5 003 in Electronics If meters do not move Deck or Tape may be at fault see Tape Deck Manual or replace tape If no movement go to step 7 If fuses are blown replace See pages 5 003 and 5 015 Replace speakers if necessary If sound comes out DBX is bad replace it or see sections on DBX pages 5 003 an...

Page 228: ...on on DBX pages 5 003 and 5 019 thru 5 025 Replace if necessary Replace if necessary see page 5 003 Replace any blown fuses and if there is still no output replace amp amps Symptom Poor or Distorted Audio in both Channels Procedure Result 1 Clean tape heads and Demagnetize 2 Pull out cables from channels 1 2 of the DBX box output and plug them into channels 1 2 of the Tape Deck output 3 Check gain...

Page 229: ...X box output 4 Exchange cables on Equalizer 5 Check speakers 6 Check amplifiers 4 oos See Tape Deck Manual If problem does not move with cable the Tape Deck is at fault repair or replace it If sound comes out clear DBX is bad replace it or see section on DBX pages 5 003 and 5 019 thru 5 025 Reset and check gain or replace Replace if necessary page 5 003 See manual or replace ...

Page 230: ... pins to activate the function 8 Exchange Long Driver Bd 9 Exchange Playback Bd 10 Check wave shaper in DBX 4 Q06 If no movement replace tape and or deck see Manual on Tape Deck If function works go to steps 8 10 or see page 5 045 If voltage is not correct check power supply pages 5 004 and 5 047 See pages 5 004 and 5 047 If the function works replace Show Control Board See page 5 004 and 5 047 Re...

Page 231: ...s when it shouldn t stops where it shouldn t Erratic lighting section o lights missing Irregular movements Procedures Results 1 Manually reset the controller by pushing stop button on Dual P C Mount 2 Manually switch to other Deck and new Show 3 Identify visually which Characters are affected those in top drawer or bottom drawer 4 Check 25 volts and 5 volt power supplies 5 Switch DBX cables 6 Chec...

Page 232: ...004 and 5 047 2 Check Dual P C Mount Repair see pages 5 004 and and wiring 5 047 also 5 049 Symptoms Special deck rewinds when it shouldn t plays when it shouldn t stops where it shouldn t Procedures Results 1 Check 25 volts and 5v power supplies 2 Follow same procedures as in preceding symptom 4 oos Repair or replace see pages 5 004 and 5 005 also 5 030 ...

Page 233: ...on pages 5 005 and 5 006 5 037 5 046 If there is not 25 volts on transistor go to step 6 Repair or replace see pages 5 005 and 5 006 Adjust 3 4 bit repair wiring only or replace see page 5 006 If no 25v see charts on Tunnel wiring and make repairs See pages 5 006 and 5 037 thru 5 046 also 5 033 Repair or replace cable see pages 5 006 and 5 007 Repair or replace see pages 5 006 5 037 5 046 also 5 0...

Page 234: ...ferent Boards Procedure Result 1 Exchange Playback Board 2 Check Playback board wiring Repair or replace the board see pages 5 006 and 5 029 also 5 032 Repair wiring see pages 5 006 and 5 029 also 5 032 3 Refer to Controller or Audio Problems 4 010 ...

Page 235: ...e 25v and you could not activate it when you pinned up the bit go to step 4 Repair or replace Long Dr Bd see pages 5 005 and 5 006 also 5 026 See page 5 008 for more details See pages 5 008 and 5 059 thru 5 062 If voltage is good on voltage regulator and A C is good replace driver board See pages 5 008 5 057 thru 5 062 Repair or replace if needed See pages 5 054 and 5 057 thru 5 062 Symptom Lights...

Page 236: ... on Organ and Sign Board 5 Check leg of trans or Triac on Board 6 Check cables connectors and wiring 4 Ql2 Find the bit from the bit chart see pages 5 005 and 5 037 thru 5 046 See page 5 005 Repair or replace see page 5 026 and 5 005 See pages 5 008 and 5 055 also 5 057 thru 5 062 If 25v is switching but it doesn t work repair or replace driver board see pages 5 008 and 5 057 thru 5 062 See pages ...

Page 237: ...u 5 009 If light turns on replace Triac and CEI Module Board See also pages 5 074 5 081 Symptom Lights on all the time RAF 100 s Procedure Result 1 Unplug the controller from the wall 2 Exchange Light Module Bd and Triac with a new one from the end of the RAF 100 box spares 3 If problem still exists check cables and wiring If lights go out exchange the Long Driver Bd for bits in question see pages...

Page 238: ...iac Repair or replace board see pages 5 009 and 5 074 Repair or replace see pages 5 052 thru 5 053 and 5 065 thru 5 066 Symptom Lights on all the time CC Panel 1 2 3 Procedure Result Unplug the controller from the wall Replace the opto and or Triac in the C C Panel If problem still exists check cables and wiring 4 Q14 If lights go out exchange the Long Driver Bd for bits in question see pages 5 00...

Page 239: ...hts always dim See page 5 009 Lights do not come on bright go to Trouble Shooting Light Box see pages 5 008 thru 5 009 and 5 066 If no 5 volts trace wiring back thru Dual P C Mount and Tunnel back to the power supply Repair or replace if necessary See detailed account in pages 5 008 and 5 009 See pages 5 009 and 5 063 also 5 075 Repair if broken or replace See pages 5 009 and 5 064 Procedure Resul...

Page 240: ...ound Music Mute by issuing a manual stop and play Reset it in normal position If background music mutes but lights don t dim replace Q3 on the House Light Dimmer Bd If background music does not mute replace Show Control Board See page 5 063 Symptom Erratic Lighting flickering Procedure Result 1 Check the A C voltage on pin 5 of House Light Dimmer Board for 12 5 v A C 1 2 wave 2 Check Q3 trans coll...

Page 241: ...ntrol Module and chassis of RAF 100 box 10 Jumper the black terminal 1 to the chassis of the RAF 100 box with an insulated jumper to Control Module and chassis of RAF 100 box 4 ol7 If it does not activate move to step 3 If you can not get a reading on the A C voltage move to step 4 See details on pages 5 010 and 5 077 also 5 079 Repair or replace any components as necessary see pages 5 010 and 5 0...

Page 242: ...Symptom Draperies do not open or do not close Procedure Result 1 Follow the same procedure as for the Post 1 83 batch with the exception of step 2 where the earlier motor controls have terminals marked N Ll instead of X N See page 5 078 ...

Page 243: ...hes from 25 volts D C with the show tape operating and 0 volts when Houselights go bright DBX is source of problem see pages 5 003 and 5 019 thru 5 024 Symptom Dual Pressure Manifold does not operate Procedure Result 1 Manually override Dual Pressure Manifold with switch located on the manifold 2 Pin up bit 40 in the top drawer or bit 60 in the bottom drawer 3 Take a reading on the output of the g...

Page 244: ...06 General Information page 5 005 Long Driver Board pages 5 005 thru 5 006 Play Back Board 5 005 page Adjust 3 4 bit page 5 006 Wire Harness and Cable pages 5 006 thru 5 007 D Lishtins Problems pages 5 008 thru 5 010 Organ And Sign General Information page 5 008 RAF 100 Box pages 5 008 thru 5 009 CC Panel page 5 009 Houselight Problems pages 5 009 thru 5 010 E DraEer t Problems pages 5 010 thru 5 ...

Page 245: ...d tape alignment see manual provided with deck Move down the procedure to cables and power even speaker wires Try all the cables and wiring before you replace any components see Power Up Procedures on page 1 003 Equalizer Take a reading on the output of the Equalizer for the channel or channels in question Use your o scope to read the signal If you had a signal coming out of the DBX Box and you do...

Page 246: ...e unable to do this replace the DBX boards in question One board may load the other so unplug them or exchange cables to verify it exactly 3 Data adjust Connect the signal generator to track 3 NML in and apply a 10DBV at 2 25khz see pages 5 019 thru 5 024 Connect a millivolt meter and O scope to track 3 output On the millivolt meter obtain a reading of 7DBV Adjust the potentiometer on the DBX Tape...

Page 247: ...in Stop E Stop y Play D Play K Rewind c Rewind J The voltage should switch from high to low as the signal is processed If it does not change then the board may be bad so pull the board out of the card holder Now take a jumper and ground one end as you touch the other end to the pin and see if that causes it to function If it works then the board is bad If that does not work then trace the signal b...

Page 248: ...s section but in the majority of cases erratic movements can be attributed to either Mechanical or Art related problems and occasionally tape problems Mechanical or Art should have already been eliminated and you should instead refer to the Electronics section on Controller for erratic movements Another visually similar problem may occur when either cables are mixed or air lines exchanged This cou...

Page 249: ...rying to set it exactly Watch the LED to see if the light goes out when the tape is running If you are unable to adjust the 3 4 bit return the board for replacement Wire harness and cable trouble shooting In order to find if a cable or wire harness is good it is easier to test it with the power on In some instances like in actually trouble shooting the Playback Board or Tunnel it may be easier to ...

Page 250: ...ake the hood off and examine the wires as they are crimped into the slots If you suspect that one of them is bad take a small flat headed screw driver and gently push che wire back into the slot of the connector Then try and test it again for continuity See pages 5 037 thru 5 046 also 5 056 and 5 073 c __nn 7 ...

Page 251: ...also 5 060 and 5 062 If you have an A C 110 volt input and no voltage on the regulator then replace the Organ Driver Board If there is no A C coming in then check the breaker and reset it if necessary If you have A C input and an output on the power supply from the board find the opto isolator that controls the particular set of lights you have in question see pages 5 060 and 5 063 Take a small sc...

Page 252: ...d at the 1000 mfd cap on the power supply The positive side can be read from the black wire of the A C input Caution live 110 volts in the Triac box See the circuit layout drawing for 8 or 20 Triac Driver boxes of detailed information see pages 5 065 and 5 071 Houselight Problems Check the override switch and see if it has been switched to override by mistake If so return it to the correct positio...

Page 253: ...he Limit Switches are adjusted by use of the small knob on the side of the switch housing It is very important that when the motor is in operation this knob be in the center or neutral groove Limit switch adjustment is as follows 1 Loosen the set screws on the master carrier 2 Turn the adjustment screw until both contacts are open Instructions are on the knob 3 Find the point at which one of the c...

Page 254: ...BX Box may be bad repair or replace it It may just be the diode across pins 7 and 8 on the relay so check that first before replacing the relay see pages 5 019 thru 5 025 If it does not switch then verify that the cable is good by checking the voltage across the pins If the cable is good replace the Q1 Transistor on the Houselight Dimmer Board If that still doesn t work then replace the Houselight...

Page 255: ...and Sign Bit chart Spots and Draperies Bit chart Props Bit chart Beach Bear and Looney Bird Bit chart Mitzi Bit chart Billy Bob Bit chart Floods and Tape functions Bit chart Stage lights Dual p c mount Single p c mount Dual p c mount power w1r1ng and control buttons 20 Conductor color code and pin outs 25 Conductor color code and pin outs 10 Conductor color code and pin outs Floods and stage light...

Page 256: ... Triac box 8 Triac box Light control module Cable description and part numbers L3 panel layout A C monitor layout A C monitor schematic Drapery motor control Drapery motor control pre 1 83 Drapery control limit switches Drapery control board schematic RAF 100 control unit layout Props cable construction 20 Triac driver board schematic 5 012B 5 061 5 062 5 063 5 064 5 065 5 066 5 067 5 068 5 069 5 ...

Page 257: ...I I I L D BXCo rds Cho I V e 2 1uoJi3er r _ ___ 1_ _ _ I ELECTRONICS AUDIO SYSTEM BLOCK DIAGRAM 5 013 I 2 DBX BOX 0 BXC o rds J rue Selee Bd I ...

Page 258: ...ELECTRONICS DATA SYSTEM BLOCK DIAGRAM R tt C b fl r tMde 1 DBX Box D XC4Ak e 4 D XiCJ s le bJ 8CIA G T pe 1 Qc l Show Go t t ol Soc rei tf0 lse 11 t Dilll e r o nL 0 I __ 1 ...

Page 259: ...el STOCK IIA T L WIRING COPP R Rt D S LYt R BLACK f U5 E TO Ri D AND COPP ER R f O 10 SlDE COPPER TO NTER _ o I AL CREATIVE e PROoucTIONAPP DATE ENGJ NEE R ING J1IC Z o I REVISIONS IQ c APPROVAL RIEV I DATE I BY DATE I BREAK ALL 8CALE DRAWN BY LL _ DEIIURR AND I I rt 7 7 SHARP CORNERS r7 2 OJ J 010 DATE _ D_ c o CHK D SY q J 10 UNTDLIEMNCED DIM FRACT L DECIMAL 010 SYS T M I I I I ITEM AlJDI0 020 U...

Page 260: ...PP 11 o clc c Eq1Jal1zer LED channel indicators should not be 11t Alw d1als should be turned down bef ore Power UP na t hen reset after Power uP S Power buttor ln down POSitiOn on UP POSitiOn off LEO LnOtcator for 08X Box should onl be lit for SPecial Deck OBX left Phor o Jack vacant for VCR inF ut TOP Drawet OBi ri 9ht Phono Jack vacant for JCR inF ut BottOjOI Drawer Reel Large button out SPee l ...

Page 261: ... t t 12 f t 1 f 1 t r 1 1 1 _ GAIN 31 5 63 125 250 500 IK 2K 4K 8K 16K 31 5 63 12S 2SO SOO II 21 4K BK 16K HEitrZ 1 HERTZ All tol R D APPROVAL DATE CREATIVE rr m tc w Non eccumu ttve E u m IK PRODUCTION APP DATE ENG IINEE RING wc5a o REVISIONS Q C APPROVAL DATE DEBURRAND SCALE DRAWN BY BREAK ALL REV DATE BY SHARP CORNERS 010 DATE CHK O BY ITEM S e j fi _1 S UNTOLERAN CED DIM FRACT L DECIMAL f n ll...

Page 262: ...2 t t n 1 1 1 GAIN 16K 31 5 63 125 250 SOli II 2k 4K IK 161 31 63 125 250 500 1K 2K 4K eK H tr r I HERTZ Alltol R D APPROVAL DATE CREATIVE _ c Nen eccumulattve I Ia ODUCTION APP DATE ENG I NEE RINO wc 1iZO REVISIONS Q C APPROVAL DATE DEIIURRAND SCALE DRAWN IIY IIREAKALL SHARP CORNERS REV DATE IIY 010 BATE CHK D IIY ITEM UNTOLIRANCED DIM faudl t i i rtll FRACT L DECIMAL lUI o1e 020 ux 5 _ I d DRAWI...

Page 263: ... L __ 0 F 11 t rru t j L arr _c Y _ t J o EJ o T l o Q J lJ IJ o 0 _ JII Ir looouood t J PLAY L Vf L AU lliLC I f W I E l i At lJU5T P JQ J rt f J 0T0 fOOOl o o 1 r ro M if iJ Js r I J A I A A a j ro EJ 3 1 a IIOJ 4 oi CI fl fi 11 Qo n P Jtt L A 2 BI CKGROUNll 1l 4 JISW A If Ai _ol lt8 1l t M WA lf _ A Td MUSIC Mure El AY L DIODe LOCATION mrn ...

Page 264: ... 3 J TRK I 1 TAPE I 10 r DATA TAPE a 11 14 I t9 TRK 4 12 13 7 5 lo SELI AUDIO I AUDIO 2 Ul CD 4016 U5 TIL 113 us CD 4001 U9 CD 4016 UIO LM 4658 Ull MC 1489 If u II Ia replaced alignment Is required TO EQI MLIZER TO CONTROLL R TOP a BOTTOM pR AWERS CREATIVE DRAWINGNUMBER I W 0 ENGINEERING wc 0 N 0 I U ...

Page 265: ...6 LM 341 T 5 LM 326 N 1000 uf 16V IOOuf lev 100 uf 35 I DBX TAPE SELECT BOX POWER SUPPLY COM C3 oe C4 5 RED COM BLI s YEL C7 C3 LM 326N C OM 1 1 1f BLK s e 6 1 GRN R3 02 C3 4 7 8 Ql 2 Rl 2 R2 3 A4 I 25V OISI MJE eoo 300 uf 1 2 w 6 2r 1 4 w 501 POT 12 c II z z ic c 0 1 ttl Q ...

Page 266: ... 7 11 1 1 t I t8 Jack5 Tape2 cfumpe r ti ClO l Jock4 Ta 1 f 1Dft 4P 1 pfU Lw x z l I 19 _ _ _cr3 orr n b molex_ IV I R E LENGTH lN CH 5 COA le tl3 1 f i t 4 Jo N s b s 1 l1 it_t5 _Jo _ i IG_qL17 T3 H 8 19 8 RED G ROUND fur_ CoAX GROUND for Pi4oNo WIRE GROUND for CoA PH ONO Wt RE 1 2 RtD YELLOW B 09 n ma e Mo e 3 P1n Mo Lhite _ Vj o et Y OLE T Wttrn 8 l3lACK 0 scALE v APPROVED av DRAWN BY DATE S g ...

Page 267: ...v 2 3 op VlE W t s b C l J Tape u J c s 0 2 1 t ORANGE 2 GRl 3 GRA f 4 BL CK S BLANK C0 A GR A I 7 I I I 8 COA LACI 9 7 o S i Jvm per s p 9 9 ro rape 1 o c r 2 c f 0 0 Q J u _ t I P n o1 t e eo1 n e c t o r DBX Mot herboard Ho rnes s SCALE 2 Tl ME DATE S 1 8 2 APPROVED BY DRAWN BY CA L R DRAWINCJ NUMBER N 0 I 1 1 ...

Page 268: ...ISIONS REV DATE BY l 3 4 3 PiN MAL SLK Rr O t10l X BAN I JACKS SROWM Will FROM RELAY PI j BP O IN WiRE FROI I R A Pil l 5 BlUE VIP FRO RELAY PIN 7 T11 0 VIOL T WIRE FROM RkLA PIN AMO P t 12 01 D IC V C 101 Ull VJ IT WIR i FRQW OBX VEC Tl P M JIIUU S PIM R D APPROVAL DATE C R E ATI E r t G G PRO Oi P DATE EN B JINEE RIN INC A L 12 f Q C APPROVAL DATE DEBURA AND SCALE DRAWN BY HANNl BREAKALL SHARP C...

Page 269: ... co axial cables long lead on diode pos E 4 l l l I 0 j lXI ALL WIRES 22 AWG a 6 PIN KALE MOLEX CONNECTOR FEMALE PINS 3 PIN MALE MOLEX CONNECTOR FEMALE PINS s o25 1 8K 1 2 w 00 3 8 I raJ 00 N N 4 4 raJ raJ I I i 8 0 0 z 0 ll ll raJ raJ ...

Page 270: ... I I I I I I I I I I I I I I I C 4 cq L J ___ PLAY SAeK o Qb 24 1 5 1 SYNC I TRONT 8PE C1 11 PLUG IN PC C s lb P tl WNS f 8D rTCfl1 J A o til MMf R f l NTtf O __ t IC I lill f l N 0 I Lt _ i ii 1 e 23 a ICII UY oZ2 ot 0 DAft I I I I TOP BOrrotA DRAWER LA OUI UIROU ID I IIIICT L c a ou t a o t GIN MA I L ...

Page 271: ...L Jll JIO J9 JS J7 J6 REAR OF DRAWER All tol 1 R D APPROVAL DATE N ccumulatlve PRODUCTION APP DATE CREATIVE fr W 0 ENGINEERINO c Q C APPROVAL DATE BY DEBURRAND ISCALE IDRAWN BY KS I BREAKALL SHARPCORNERS l 010 DATE CHK D Av 1 1 ITEM UNTOLERANCED DIM FRACT L DECIMAL lUI 010 020 lUUl 005 MAT L DRAWING NUMBER ...

Page 272: ... _AL ft CR TD 41TJVE cr Noneccumu u 2 W 0 PRODucnoNAPP DATE ENOINEE RINOrJIC 1 REVISIONS 1 c APPRoVAL REV IDATE I BY DATE I l D ISCALE IDRAWN BY 1 c I SHARPCORNERS a 2 B ll 010 DATE I J c CHK D BY ITEII I I I BOTIOM DR AWE R U NNtl UNTOLERANCED DIM FRACT L DECIMAL Jill 010 020 XJUl 001 IIAT L DRAWING NUIIBER ...

Page 273: ... u fl IJ IJ BIJno IIooofiJ Bo IJo f CD OUU 6 CIID ODIJ ru m _ 1 50K IOK All tot IR D APPROVAL DATE 11 a ITYVE c tiw Non eccumu Mtve ird A A Ia E p n Co 1 R W 0 PRODUCTION APP DATE ENGINEE RIN0 INC w DAT1DEBURR AND ISCALE IDRAWN BY BREAKALL SHARP CORNERS 010 DATE CHK BY ITEM I I I I PLAYBACK UNTOLERANCED DIM B QARoIFAACrL DECIMAL XX 010 _ 020 XXX 005 MAT L DRAWING NUMBER ...

Page 274: ... 320 dels OVP 12 h o use with SV u 1ts only 3 haou unu is provided on all o d t ls Factory installed jlA ers on the output te inal clock are p ovLded fo the local sense ode r J I T I L r o t 1 J I I Ill C7 w tc 5 030 SPS I CPS SPS I CPS r I C j I I lw C 1 ___ I t o 220 320 SERIES SERIES r 1r 0 fi I t _ c w t c ru c c 1 c t e ...

Page 275: ...TUNNEL MOLEX Q14 Qu Q7 os 12 0 g GREEN 5V COMMON BLACK i V COMMON GREEN IS BROWN INSIDE OF TUNNEL RED 1 4 BLACK 3 6 ORANGE 10 1 3 GREEN 12 f5 5 031 7 19 8 3 KJ ...

Page 276: ...6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 10 11 12 13 J6 J5 I CINCH 30240 i l 2 3 BLUE 10 21 24 RED 6 5 _ _ _ _ _ _ _ _ _ _ _ _ 17 VIOLET 18 J4 7 10 12 8 9 13 24 16 15 14 11 1 12 10 1 2 RED 10 1 2 1 J1 17 J1 20 J1 18 J1 19 J3 20 J3 19 J2 17 J2 20 J2 18 J2 19 MALE SOLDER SIDE 23 Il OUTPUTS PLAYBACK BOARD WIRING E6 E9 EO E3 E7 E1 E8 E2 22 AWG ...

Page 277: ...J2 21 J1 21 J4 1 W2 Jl 17 J4 2 W3 J1 18 J4 3 W4 J1 19 J4 4 W5 Jl 20 J4 5 W6 J2 17 J4 6 W9 J2 18 J4 7 WlO J2 19 J4 8 Wll J2 20 J4 9 W12 J3 17 J4 10 Wl3 J3 18 J4 17 wo J3 19 J4 18 Wl J3 20 THESE ARE OUTPUTS FROM PLAYBACK BOARD WHICH CONTROL THE DISTRIBUTION OF DATA TO THE OUTPUT DRIVER BOARDS POWER AND GROUND DISTRIBUTION ARE NOT SHOWN 96 CHANNEL CONTROLLER REAR SIDE FRONT TUNNEL LMR 8 2 80 5 033 c ...

Page 278: ...SSO Y IN OUT CHANNELS 1 32 CHANNELS 33 64 CHANNELS 65 96 3 J SII 1 47 1 J 4 11 1 1 3 2_J 11 C M I Q I 0 N L_ v PINS SHOWN ARE FOR POWER DISTRIBUTION c 5c I N I 0 C 1 4 96 CHANNEL CONTROLLER REAR SIDE FRONT TUNING LMR 8 2 80 1 c 5c I 0 CREATIVE 11 J ENG NEERING IIC 0 r CW 0 I Ll ...

Page 279: ...LK RWND ORA PLA BRN STOP BLU COM BLK TAPE SEL ORA 24V RED BACKGROUND MUSIC YEL AC REF WHT RED 24V COM BLK PLAY VIOL 5V COM BLK NOR SPEC GRY 5 035 3 1 TO TAPE UNIT 1 4 6 3 1 TO TAPE UNIT 2 4 6 1 TO TAPE 2 Select UNIT 3 1 TO XMFR 3 1 TO MGR 2 CONTROL 3 c I I I I jl t inltM Q To Dual Pressure Jl4 ...

Page 280: ...PIN 15 gm 1 PIN 5 IEU O PIN 8 C l VIOL T PI J OAtV PIN 11_ sl f fH ILACI PIN 7 1 1 1 czev p P1 4 111 ue P1t 1 c _ _ I lhACIIC PIN J_ 1 10 Plt l IAOW 5 _ 1 PINS OAAN Po 1 _ _ F ewe _ 3 _ N 4 LACK PIN 7 N 0 ll _ J J 4 IN I ltAOW N Z __ c I w o 1 1 n M c H H Cl d t1 t 4 R PIU s OtU NG PIN CREATIVE 11 MNGO I ENG IINEE RINGIWC 5 0 ...

Page 281: ... 2 L Eye Lid J1 14 J6 20 14 Body twist L Jl 3 J6 5 3 R Eye Lid Jl 15 J6 21 15 Body twist R J1 4 J6 6 4 Eyes L Jl 16 J6 22 16 Body Lean Jl 5 J6 7 5 EyeR R J1 6 J6 8 6 Head L Jl 7 J6 9 7 Head R _ 0 I Jl 8 J6 10 8 Head Up Jl 11 J6 11 11 L Arm Raise J1 12 J6 12 12 L Arm Twist Jl 13 J6 13 13 L Elbow Jl 26 J6 14 17 R Arm Rnise Jl 27 J6 15 18 R Arm Twist Jl 28 J6 16 19 R Elbow Twist Rock AFire Show Drawe...

Page 282: ...Ear 10 3 42 R Lid 26 L Lid 11 4 4J Eyes L 27 R Lid 12 5 44 F yes R 28 Eyes L 31 6 54 Head L 32 7 55 Head R 29 Eves R 25 28 8 51 Hearl Tip L Head L Zl Head R 29 9 52 Head Tip R co to 0 30 10 53 Head Ur I 22 Head Up Ll 33 L Arm Swing 34 11 57 L Arm S rinp 34 35 12 58 R Arm Swin J R Arm Swing 35 L Elbow 36 13 59 L Elbow 31 R Elbow 37 14 60 R Elbow 32 Hiqh Hat 38 15 61 Foot Tap 63 Bass Foot 39 V 16 62...

Page 283: ...ue 13 12 JlO 10 76 Inner GRP 2 67 Red 13 11 77 Mid GRP 4 3 68 Amber 14 12 78 Outer GRP 5 4 69 Green 15 13 79 Cont Strobe 7 5 71 Leg Top v 16 v 14 80 Flash Strobe 8 6 72 Mid 9 7 73 Bottom 10 8 74 Cont Strobe 0 II 11 If 9 75 Flash Strobe 0 I Lt Drawer Top Master Sho r Rock AFire Date J w g _3 f_3 7 CREATIVE t _ j EI GINEERINGPIC 0 __j ...

Page 284: ... 85 5 I 31 6 86 6 32 7 87 7 33 8 88 8 IIIII Ill Ill IIIII l ll 1 llll 11 1 1 0 Ill 0 I J3 3 J5 1 89 SR OPN J5 1 1 13 J 11 14 89 SR OPN 35 2 90 SR CLS 14 15 90 SR CLS 36 3 91 CS CLS 15 16 91 Ut N 37 4 92 CS CLS 16 17 92 CS CLS 38 5 93 SL OPN 17 18 93 SL OPN 39 6 94 SL CLS 18 19 94 SL CLS I t Drawer Top Master Show Rock AFire Date CREATIVE ltQNUIIHO EC o NEERINO c 0 _ ...

Page 285: ...I Pin Bit Function I J2 6 J9 1 38 Sun t1outh 7 2 39 Sun Raise 8 J14 1 40 nual Pressure 14 4 46 Moon Mouth 15 5 47 Moon Raise 16 6 48 Looney Bird Hands 26 7 49 Spider v 27 v 8 50 Baby Dear I 1 c I LJ I Drawer Top taster Show Rock Afire Date 4 _ 30 6 3 7 cREATIVE t 1 1C GINEERING wc5 0 ...

Page 286: ...13 I R Elbow Twist 11 14 R Wrist 12 4 L Hand Slide 13 5 Guitar Raise 14 9 L Leg Kick 15 10 R Leg Kick 16 15 Body Lean FROM J 1 Pin Jl 26 J2 9 J2 10 J2 11 J1 30 J1 31 T O CHARACTER Bird J IPin IIBit 1 I Function J7 ll 1117 I Mouth 2 3 4 5 V 16 Show 41 42 I 4 y t JL 1 Z l 1 r lf2 L Lid R Lid Eyes Cross Head L Head Rai e i I Rock AFire N 0 I Ll Date Drawer Bottom Accessory 8 5 80 l w f 3l 6 J I a W 0...

Page 287: ...fl Pin Jlf Pin Bit 1 Function 35 Mouth J2 4 J8 17 36 Body Twist l 26 L Ear s 18 37 Body Twist R 27 R Ear 6 19 38 Body Lean 31 L Lid 32 R Lid 33 Eyes L 34 Eyes R 28 Head L 29 Head R l t 0 30 Head Up I 23 L Arm Raise 18 R Arm Raise 24 L Elbow 19 R Elbow 25 L Arm Twist 20 1R Arm Twist Show Rock AFire Drawer Bottom Accessory Date l lv 8 f 7 CREATIVE 1 11 I Er GINEERINGIIIC o ...

Page 288: ... Function 46 Mouth J2 38 J9 17 61 Body Twist L 47 L Lid 39 18 62 Body Twist R 12 19 44 Foot Tap 4R R T irt 49 Eyes L 40 20 63 Body Lean 50 Eyes R Head L 51 52 Head R 53 Head Tip L 54 Head Tip R r r 0 55 Head Up I U 39 L Hand Slide 56 R Arm Raise 57 R Arm Twist 58 R Elbow Twist 59 R Wrist 40 Guitar Raise Show Rock AFire Drawer Bottom Accessory Date 8 5 80 flu v o CREATIVE t l l I ErGINEERINO ...

Page 289: ...ols J tn ICI Sit II Function J Pin J l Pin Bit I Function 66 SR Blue J2 41 JS 2 64 Stoo 67 Green 1 t 3 65 Rewind Amber 37 J13 9 60 Dual Pressure f R Red 69 71 CS Blue 72 Green 73 Amber 74 Red 76 SL Blue It Green 77 It Amber 78 Red 79 House Lights 1 It II 2 3 Drawer Bottom Accessor Show Rock AFire 8 5 80 j JP CREATIVE t 1 W 0 uiNEERINO c w 1 DRAWING NUM8ER f3 Lr 4 0 I Lr ...

Page 290: ...JC Pin Bit I Function CKT I 94 Rainbow 1 J3 34 J 11 17 89 Moon pot 17 95 II 2 35 18 90 Spider Spot 18 Applause 41 19 96 Beach Bear Spot 19 7n t 81 Backdrop 4 82 5 II 6 R 84 Tree Line 7 85 II 8 86 9 0 Bushes 0 I 10 Ln 87 75 Drums 11 91 Gas Pump 12 Service Sta 1 3 Q2 93 14 80 Fire Still 15 88 Sun Spot 16 Show Rock AFire Drawer Bottom Accessory Date 8 5 80 J w CREATIVE w 1 n TEERINO r E JJ IIIC ...

Page 291: ... 131 12 13 K I BACKGROUND MUSIC 1 I 8 3 I J2 37 9 DIM BRIGHT N STPIN 3 I 2 I J2 41 TAPE 41 RWDIN 3 J3 1 CONTROL Q BOARD 5 I MGR PLA 18 11 6 I NOR SPEC 19 12 sl lfAPSEL 4 I 10 I cl RWND 1 5 I 1 I Dl PLA I 6 I 2 I El STP I 7 I 3 I J I RWND 2 8 I 4 I Kl PLA 2 9 5 I Ll STP 2 10 6 I EACH BOARD1 24V Com 14 I 1 A 5V 24V 15 I 22 Z GRD 5V COM 7 I 5 047 ...

Page 292: ...E F J K A 2 SINGLE P C PC INTERCONNECT CURT ST RIGHT OP IN SR CLS IN CS OP IN CS CLS IN SL OP IN SL CLS IN SR OP OUT SR CLS OUT CS OP OUT CS CLS OUT SL OP OUT SL CLS OUT 5V 24V 5VCOMM 5 048 I I I I J 5 1 2 3 4 5 6 3 4 5 6 7 8 4 1 1 ...

Page 293: ...IVE r t AifiMif 0 PROOUCTIONAPP DATI ENGINEERINOJIICA I REVISIONS IQ c APPROVAL MY IDATI I BY DATEIDE IUtAND IKALE IDMWNBY I c _ 010 DATI CHK D BY J J I I I I ITEM Duo l P c Mo ont UN10UIWICED DIM PIIACT L DECIMAL Jill 010 010 IUUI ooe MAT L DMWINGNUMHR ...

Page 294: ... 8 GREY 8 9 WHITE 9 10 BLACK 10 11 TAN 11 12 WHITE RED 12 13 PINK 13 14 WHITE YELLOW 14 15 WHITE GREEN 15 16 WHITE BLUE 16 17 RED BLACK 17 18 RED YELLOW 18 23 RED GREEN 23 24 WH I T EL B L A CK 24 P1 P2 ARE CINCH AMPHENOL 57 30240 5 050 WIRING DIAGRAM 20 COND CABLE LMR 12 23 80 ...

Page 295: ... BROWN 11 12 WHITE RED 12 13 WHITE ORANGE 13 14 WHITE YELLOW 14 15 WHITE GREEN 15 16 WHITE BLUE 16 17 WHITE VIOLET 17 18 WHITE GREY 18 19 WHITE BLACK PINK 19 20 WHITE BLACK 20 21 TAN 21 22 RED BLACK 22 23 RED YELLOW 23 24 RED GREEN 24 PINK 7 P1 P2 ARE TYPE 57 30240 CONNECTORS WIRING DIAGRAM 25 COND CABLE LMR 12 ZJ 80 ...

Page 296: ...EEN 5 6 BLUE 6 7 VIOLET 7 8 GREY 8 23 _________________________ WH __ IT_E __________________________23 24 _________________________ B_LA_C_K __________________________24 P1 P2 ARE TYPE 57 30240 CONNECTORS 5 052 WIRING DIAGRAM 10 COND CABLE LMR 12 23 80 ...

Page 297: ... 5 J10 14 6 J10 15 7 J10 16 8 J10 24 9 Jll 1 1 Jll 2 2 Jll 3 3 Jll 4 4 Jll 5 5 Jll 6 6 Jll 7 7 Jll 8 8 Jll 9 9 Jll 10 10 Jll 11 11 Jll 12 12 Jll 13 13 Jll 14 14 Jll 15 15 Jll 16 16 Jll 17 1 7 Jll 18 18 Jll 19 19 Jll 23 24 Jll 24 25 5 053 MOLEX 9 PIN TO BOX 2 MOLEX 9 PIN TO BOX 3 5 6 7 8 HOUSE LIGHTS STAGE LIGHTS DMB 25 PIN CONNECTOR ...

Page 298: ...LOW 5 GREEN 6 BWE 7 VIOlET 8 GRAY 9 WHITE 10 BLACK 11 TAN 12 WHITE RED PINK 14 WHI IE YELLOV 2 24 W B R G R Y J 10 24 PIN CINCH 5 054 15 PII JI LJ X IIWIPTACY Larp JWIALI 1 2 4 s 6 7 8 9 10 11 12 13 14 15 15 PIN MOLEX Large MALE ShowBiz Organ 81 Cable 1 15 ...

Page 299: ...D ORANGE YELLOW GREEN WHITE BLACK 15 PIN MOLEX LARGE FEMALE 1 2 3 4 5 6 7 8 9 15 BROWN 1 RED 2 ORANGE 3 YELLOW 4 GREEN 5 WHITE BLACK 6 15 PIN MOLEX SMALL FEMALE _ 6 P f HOLEX I 1 15 PIN MOLEX SMALL FEMALE RECEPTACLE 6 PIN HOLEX SMALL FEMALE RECEPTACLE SHOWBIZ ORGAN Sfi LE CREATIVE ENGINEERING INC LMR 11 05 80 SMALL FEMALE 5 055 ...

Page 300: ...ite Red NEW COLOR CODE Alternate 13 White Orange 14 White Yellow 15 White Green 16 White Blue 17 White Violet 18 White Gray 25 White Pink i I 19 White lH Pink OR REO 20 White Bl AMPHENOL CONNECTOR 21 Tan 22 Red Black 23 Red Yellow 24 Red Green SCALI it 1 Z I A ROVED IV DATI 28 9 2 DRAWN IV CQYl DRAWING NUMal 0 U 0 I U ...

Page 301: ...ro M 6 8 CONTINUOUS STROBE 3 9 FLASH S DlOBE 2 NONE STROBE COMMON 1 15 2J 1 VOLTS AC BLACK L 1 lU PIN 1 WHITE L 2 lU PIN 2 SIGN MOLEX PIN FUNCTION 8 PIN BARRIER 1 INNER GROUP 8 2 MIDDlE GROUP 7 3 OtrmR GROUP 6 4 CONTINUOUs STROBE J 5 FLASH STROBE 2 STROBE OO MMON 1 6 24 VOL IS AC BLACK L 1 TO PIN 1 OF 3 PINS BARRIER WHITE L 2 TO PIN 2 5 057 ...

Page 302: ...5 058 ...

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Page 305: ...E f t SIR Pl 4 23 I 24 1 0 4 l NNER J I 5 I9 SIGN M 10 Jf 1 I b P N MOL 0 I UT 13 3 PLUG w MALE N STR CONT l4 2 SiR FLSH 24 G 24 C IMive R o APPROVAL DATE CREATIVE Zst d lf 0 PRODUCTIONAPP DATE ENGINEERING REVISIONS Q C APPROVAL DATE n ltl 0 KALE DRAWN aY IHARP CORNERS REV DATE y 010 01 TE CHK D aY _ ITEM ORGAN AND Sl5ti NltR fAC C BLt 020 MAT L DRAWING NUMUR ...

Page 306: ... BUL f 37 I 2 Q OQANGE 11 W WHIT II R REO DIICIIIPTIOII TO ST OBt LIGHT AC lJA TiO t l BO ...

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Page 308: ...L DATE PRODUCTION APP DATE Alltol Noneccumulatlve CREATIVE f tlw W 0 ENGINEERING JMC t t REVISIONS I Q C APPROVAL REV IDATE I BY DATE I DEBURR AND SCALE IDRAWN IIY k l _ r tt BREAKALL _ SHA RPC ERS DATE 7 3 8 3 CHK D BY ITEM MAT L 40USE LIGHT D MM R BOARD UNTOLERANCED DIM FAACT L DECIMAL XX 010 020 XXX 001 1 ...

Page 309: ... 4 STAGE L GHTS P N 0 Mll l NlTt HOOt 19 ACt TO Bf_ o LONG Alltol R D APPROVAL DATE 1 4 E a rrl tll E fCNaliw Nortoeccumulatlve A 11 il W I M W 0 PRODUCTION APP DATE ENGINEE RINGINC t r R E V I S IO N S kQ c A P P R O V A L D A T E c D SCALE DRAWN BY R BY SH RPC ERS DATE 0 83 CHK D BY L D ITEM MAT L CABLE DET A L FOR CC PANEL UNTOLERANCED DIM FRACT L DECIMAL xx 010 020 XXX 005 DRAWING NUMBER ...

Page 310: ...12 GA BLK TIL 113 YEL 24 I I OR 3 IK IN 4148 IN4004 1oon LM341P 5 IN OUT 5V REG I000 16V COM I Q lOa 8KR CKT I T 41208 CKT 2 T 41208 CKT3 T 41208 CC SP CONTROLLED SPOT LIGHTS CC CL CONTROLLED CEILING FLOODS S L CC HL CONTROLLED HOUSE Ll GHTS CC CS CONTROLLED CEILING FLOODS C S S 0 0 0 I 1 1 ...

Page 311: ...IZ1 Jt 19 I MY IDA IWI ft SiAGt L f T _NOT __ To 8 lJS 0 1NCONJU ULON WI_ SPOT LIGtiT Eill J lJ t ENT P ART 2 S0 GTION tiJ ST f P c_ IL D AL fMtt c REATIVE 7 RIOiiUC ncMIAPP IMTHENOJNEE RJNGnoc rt cr 83 ICMIC O 8 _ UWt UMMCIED DIM I MoCI L HCIIIAL oto oao 0011 IIAT WIIICINUM 11 ...

Page 312: ...a C U 15 5 8 0 F SOX 3 1 t1 NOT US EO COM PlM R AND HOUSE tJG 1AC l o ES N D CN R 1 WtTC IES Mu T ae Ott If P ASI A C 1 t Alltol R D APPROVAL DATE C RE ITJVE c_ NoiMccumu MM A 1l IK tr 0 PRODUCTIONAPP DATE ENGINEE RINGJJIC a z I REVISIONS Ia c APPROVAL REV IDATE I av c DESURRAND DATI I CEAK L ISCALE IDRAWN v t R g RP o ERS DATE 2_ 83 CHK D aY f fJ ITEM __ l tiLl6HTJNG NTRCONN EC C AR T UNTOLIERANC...

Page 313: ... I 0 0 MGA CONTROL P R Tt L 61NOE R POST Antol R D APPROVAL DATE CREATIVE _ efCrr tiw Noneccumu UV A 1 E l c _ W 0 PRODUCnON APP DATE ENGINEERING Nc REVISIONS Q C APPROVAL DATE DEBURRAND SCALE DRAWN BY TR CQ BREAK ALL REV DATE BY SHARP CORNERS DATE 9 30 Sa 010 CMK D BY ITEM MANAG R CONTROL AND UNTOLERANCED DIM FRACT L DECIMAL BACKGROUND MUSIC lNTtRFAC lUI 010 020 xu 005 MAT L DRAWING NUMBER ...

Page 314: ... Cc z 30 f Ct a 1J 0 60 r i Q J 1 CREATIVE 4 r 6 diM W 0 PRODUCTIONAPP DATE ENGINEERINOrwcA _ _ir I REVISIONS r c APPROVAL REV IDATE I BY DATE I IIIX lt D ISCALE IDRAWN avTR I c I SHARP CORNERS s l lA_ 83 010 DATE c CHK D BY ITEM UNTOLEMNCED Dill 20 TR lf C DR VER Box FRACT L DECIMAL u 010 010 JWl 005 IIA M DRAwtNG NUMBER ...

Page 315: ... p 0 0 0 I I ci t s fl d b f t oo 0 l R D APPROVAL DATE CREATIVE fl c E lrtc PRODUCTION APP DATE ENGINEERINGnrc 0 Q C APPROVAL DATE DEIIURRAND SCALE DRAWN BY 1 _ c BREAK ALL SHARP CORNERS DATE e5 2 2 9 3 CHK D BY 010 ITEM DR YER UNTOLERANCED DIM 8 TRHiC FMCrL DECIMAL JU 010 020 JUUI 005 IIAT L DRAWING NUMBER ...

Page 316: ...LARGE LUG 2 N _ 0 I w Kw 1 0 U 3 Alltol uu AL CREATIVE i IIRODUCTIONAPP DATE ENGINEERIN0 IlK A c APPROVAL DATil er r 18CAU IDRAWN Carl Q_ I 1 0 25 82 010EM DATE CHK D BY J n ITE t o 1 coNl ROL MoouL I u t 010 020 001 MA1 L DRAWING IIUMMR ...

Page 317: ...d style 12 J 13 Interface Cable 13 AC monitor cable 14 Stage floods control box cable 15 Manager control cable 16 Spots cable RAF 100 panel only CC PANEL CABLES 17 Cable 1 Spotlight and curtain output 18 Cable 14 Floodlights 19 Cable 15 Stage El8 10200 El8 10210 El8 10240 El8 10250 El8 10220 El8 10230 El8 10270 El8 10260 ElS 10340 El8 10350 El8 10280 El8 10290 ElS 10300 El7 10220 El7 10400 E9 604 ...

Page 318: ... 7 Hll 1 15 25 PI J 26 15 SEB SE9 1 15 27 B0 28 15 SP5 1 15 29 C0 30 15 1 DlJSE LIGHTS 9 HL9 1 15 31 PI J 32 15 SE13J SE14 SEl5 1 15 33 B0 34 15 SP7 1 15 35 C0 36 15 FUTURE 1 37 PI J 38 B2 G2 ft2 R2 1 15 39 B0 40 15 SEl9J __SE20 1 15 41 C0 42 15 CREATIVE ENGINEERING INCI I PCl 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 LOAD SERVED DINlNG RCm E1 ERGENCY LIGHTS BL Gl AL R1 CURTAIN COOROL CENTER Pl A TF...

Page 319: ... p Je t 5 o35 Tro t oNttt r t i f 0 5 2 03 Mo U lJin If o zo 005 LineCoid j 0 0 OO l Bed X 1 o tr 35 Sirq n T et J 3 a 11___Jt f l t CovER Stee Jin3 useJ o All were Moniter IAPPROVED BY 3 fOO O DRAWN BY car DRAWING NUMaER Ll 0 I Ll ...

Page 320: ...R BL ACK Ll PARTS LIST DI 02 IN 4002 OR EQUfV Tl SIGNAL 241 3 12 PI MOLE X 03 06 1031 L I LINE CORD 0161 KEY 2 56C BOX BUD CU 2 0J 8 NOTE LEAD HEIGHT OF DIODES 3 8 BETWEEN DIODES 3 8 ADD SLEAVING TO DIODES LEGS 5 076 ...

Page 321: ... C2 11 I I I tN O _c 1 23i R elctys P puDA but tcm _Tit T ime r Re Q r O L ewer Ie1 o d cc u coontet ClocK w e c c Cloc K i Tt N c C3 7 CREATIVE c tiw W 0 ENGINEERING wc APPROVED BY JDAT E IDRAWN BY I DATE CHK D BY X _ J ITEM Curtl o to v CoYl t f O 6 TR e I I 6 Box r lc l LQyov t Ot J k G C4 lf 4E is L Y it Swi tc h Tl TS I I I 1_ 1 TB T2 c c w 0 I ...

Page 322: ...5 Bodine or MDL 10 Dayton TR input 9 Bl n o Al n o n c 1 Bodine Tl Red Black open limit B2 6 5 g T4 Black Red Tr Red Yel Tr TS Blue Xel Tr Brown 1 8 11i e _ urtll iV Motor CohtYol Pre 1 S3 5hows 5 078 T8 TS Tl T3 T2 T4 2 2 2 ...

Page 323: ...11 E f wderllt 0 CW C IDC K wise PRoDucTtoNAPP DATE ENG INEE RING c 1 DEBURR AND ectAl ou nte r C IDc twl REVISIONs a c APPROVAL DATE a ANERs REV IDATE I BY 010 IDATE ICHK D BY I L DRAWN BY SCALE I ITEM UNTOLEAANCED DIM I I J L v t 1 C e o L V f t Sw liC FAACT L EC MA o o 020 XXII 005 V Lo y t Jvr Pr e j Q z S f 1DRAw NUMBER VJ V Cit V5 ...

Page 324: ...24 I 16 I 01 2 2N 3904 01 2 IN 4002 vee PIN 14 ORO PIN 7 24 luf 5 cl U9 10 11 STAGE R U5 6 7 CENTER STAGE U1 2 3 STAGE L I 0 U8 18 BIT INVERTER co ALL STAGES 0 I Ln C2 L I I u f __STAG _L _T_j t rE OPN I I I I L N R J F a f i J OPNJ I I I 7 c__ ______________STAG T K CLS ...

Page 325: ... l s f F I I t l f I E L J i 3 w ll tt it s T L TM lAIIlT c i II I a f II Ill I 0 6 5 081 I It r w L 0 N T z t 2 l 2 2 Ml li fil Ht Hl L ML ...

Page 326: ...0 000000 3 PIN MALE G YELLOW 7 GREEN B BROWN 9 VIOLET 10 GRAY 0 t J _________ c REO 3 O NOT USED I WHITE 2 RED 3 BLACK PROCEDURE ATTACH THE 3 CONDUCTOR CABLE CUT TO 3 LENGTH DUAL VALVE BANK CABLE TO THE 10 CONDUCTOR CABLE OF THE PROPS VALVE BANK T OFF BOTH WIRES OH d VALVE OF VALVE BANK 5 082 7 21 83 ...

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