Very Latest Wave Swinger NDT and Maintenance
Contents
1. seat hanger 042 30 27 27 27 Y10 Bi or B2 042 30 28 or B3 or D F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 3 von 13 Karussell und Spezial Legend of Time code maschinenbau GmbH D daily W weekly W2 every two weeks M monthly M6 every six month Y yearly Y2 every two years Y10 first time after ten years and then every four years Legend of Test method code A1 examination by manufacturer A2 examination by specialized company A3 accredited laboratory B1 magnaflux testing MT B2 paint penetration testing PT B3 ultrasonic testing UT B4 X ray testing RT C1 Visual inspection by an expert C2 Visual inspection by an experienced qualified maintenance staff D replacement Remark Above chart is a general valid chart for the Wave Swinger Ride There might be some slight differences to your Wave Swinger model Detected broken worn or cracked parts have to be replaced and or repaired immediately by a qualified worker or company The test results are to be documented in detail and comprehensibly These test results along with evaluations and statements are to be presented to the local safety authorities responsible for the safety of Amusement Rides In order to avoid doubts as to their proper identification the examined structural components should be marked distinctively e g punch marks etc Additionally to our Wear insp2. the seat chains They have to be replaced when the wear measures 1 5mm 2 0 mm 1 1 1 3 S Hooks 1 1 1 3 1 Maintenance Replacement of S hooks The S hook is a special product manufactured and supplied only by ZIERER Karussell u Fahrzeugbau GmbH For safety reasons it is absolute necessary to follow the instructions of the manufacturer regarding maintenance and or replacement Subsequent treatment of the S hooks by a third party is not permitted Especially surface welding of the unit moulds radius leads to embrittlement of the material and can cause fractures The S hook has to be replaced if the wear measures more than 1 5 2 0 mm more on the unit moulds 1 1 1 4 Spreader Bars Examine together with the chains The spreader bar needs to be exchanged if the maximum allowed wear of 1 5 2 0mm at the boreholes for the shackles is reached Also check the polyamide bushing in the center for cracks and to replace it if necessary 1 1 1 5 Lifting Cables i In accordance with DIN 15 020 and TUV Bayern both sets of lifting cables have to be magnaflux tested or have to be replaced at least every two years of operation In addition these cables have to be checked daily over the entire length for wire breaks corrosion abrasion structural abnormalities or deformation and may have to be replaced at even shorter intervals if necessary F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 7 vo
3. cessible when the carrousel is lifted The lubrication nipples can then be reached from below through the guide channel of the mast The lubrication takes place daily Lift cable shoes F en Picture 28 1 2 4 Guide Rail Surface The blank spots of the surfaces of the guide rail along the mast are to be greased weekly using a brush A F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 11 von 13 1 2 5 Sheaves At the tip of the mast are two lubricating nipples one inside one outside for greasing the axles of the sheaves They have to be lubricated daily Inner Sheave Outer Sheave 29 1 2 6 Lower ball bearing slewing rim The Lower ball bearina slewing rim is greased through six lubricating nipples located all arour Toothing to grsase the toothing around the ball bearing slewing A FR gt Ei 5 x M z rn u er rm J u S a CF j 2 Grease nipple Picture 30 1 2 7 Slide channels of mast decoration and joints of the S Hooks Grease from time to time with spray grease to avoid unpleasant noise and premature wear F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 12 von 13 F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 13 von 13
4. e thorough lubrication of the rotating parts and contacting parts except the slip ring assembly To efficiently lubricate these parts raise the carrousel about 2m to make the points of lubrication accessible F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 9 von 13 1 2 1 Slewing Ring in the Basket lt is lubricated weekly at the 6 lubricating nipples below the basket The teeth of the ring gear are greased with a brush A through the oval shaped opening in the basket from above Attention Danger Slip rings are live Switch off power supply first Grease nipple Picture 25 Toothing Picture 26 F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 10 von 13 1 2 2 Guide Rollers The guide rollers 4 rollers running inside along the guide rail of the mast on the upper basket 2 pieces and the lower basket 2 pieces are to be greased daily through the lubricating nipples extending to the outside of the inner basket The guide rollers 4 pieces running outside along the guide rail of the mast are to be greased daily through lubricating nipples positioned on one side of the guide rollers Inner Guide Rollers gt Outer Guide Rollers A Picture27 1 2 3 Lift cable shoes The lift cable shoes 2 pieces running inside the guide rail along the mast and their lubrication nipples are ac
5. ecial tool 4 Remove the top dome the cover plate on the side of the mast and the safety clip above the pulleys F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 8 von 13 5 The cross brace inside the mast is now accessible The cable attachment bolts may now be removed 6 Now the pulleys can be removed For easier lifting and disassembly an eyebolt can be inserted into the borehole on the pulleys Pull out the center pins a Picture 24 Special care must be taken of the nylon washers between the pulleys and the walls 7 Now the cables can be exchanged When inserting the new cables make sure they are not twisted 8 Installment is in reverse order to the sequence of disassembly Make sure all safety plates and safety pins are put back in place 1 1 1 6 Sheaves Every time the lifting cables are replaced the rib treads of the sheaves have to be inspected with a radius gauge r 9 5mm using the light gap method When a rib tread deviates from the contour of the radius gauge the respective sheave must be replaced as well Tolerances are not permissible since these can again cause deformation of the new wire rope and lead to wire breaks at an accelerated rate 1 2 Maintenance of Mechanical Parts Maintenance of mechanical parts is limited to closely checking for wear and tear and the examination of the primary connecting components with their safety backups as well as th
6. ection and NDT requirements the requirements of your local safety institutions have to be followed The replacement of components can sometimes be more cost efficient than expensive test procedures The check interval dates of replaced components change based on the date they were exchanged Same type components or component assemblies are subject to random check with at least 20 but no less than two components being examined A defect in any of these components requires a thorough check of all similar components F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 4 von 13 for completeness pls See hereunder an extract from the service manual Maintenance Checklist To increase safety and extend the life of each component as well as the reliability of the whole construction the persons responsible for maintenance and attendance of the ride must be instructed to regularly and carefully inspect and maintain the entire ride according to the following check list For any problems you cannot solve contact the address below Before contacting make sure all errors which caused the breakdown are written down Did you notice any irregularities prior to this breakdown Who is the person to contact Under which phone number can he be reached An address to which spare parts may be shipped if required would be very helpful as well Contact address Zierer Karussell und Spezialmaschinenbau GmbH Moos
7. ength is 6 0mm 1mm wear or less Terminal link 1 1 1 1 1 Visual Inspection Look for external failures deformation cracks wear and corrosion pits If necessary clean the chains before visual inspection Only use cleaning agents which do not affect the material of the chain 1 1 1 1 2 Replacement Elongation caused plastic deformation When the outside length of a chain link terminating link has exceeded 3 of the nominal dimension 29 35mm due to plastic deformation the chain or the terminating link has to be exchanged 1 1 1 1 3 Checking for Flaws The chains have to undergo a special examination after maximum 3 years The chains can be examined either by using the crack detection method magnetic crack detection or dye penetration test or a load test with subsequent visual inspection This load test is to be performed with 1 5 times the load capacity Subsequent to the load test the chains have to undergo another visual inspection If deformed and damaged links are detected the respective chain has to be replaced F Compag Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 6 von 13 ESSENTIAL INFORMATION FOR THE USE OF CHAINS MADE OF STAINLESS STEEL Improper treatment of stainless steel chains will lead to loss of rust protection If the protective layer on the chain surface is damaged the chain is no longer protected against corrosion Please follow the instructions below to avo
8. gasse 4 94560 Neuhausen Offenberg Phone 49 991 9106 0 Germany Fax 49 991 9106 84 1 1 1 Wear Limits and Non Destructive Testing Material wear of 3 is to be reported to the manufacturer components showing a material wear of 5 should be replaced However this is only a rough guideline and the system must be inspected and maintained on a regular basis Unusual noises or instability occurring during operation should be reported to the manufacturer in order to make necessary adjustments or to even replace components before they reach the wear limit At the end of each season but at least once a year all structural components such as sweeps basket and mast base along with any attachments and fasteners have to be inspected thoroughly After 3 to 5 years or when cracks in material or in welding seams appear the components should undergo non destructive material tests 1 1 1 1 Seat Chains Seat Chain Terminal Links and Chain Shackles After a maximum of 1200 hours of operation or semi annually a thorough check of chains and suspension has to be carried out Chain Chain links and terminal links worn down to a remaining strength of shackle 3 5mm must be exchanged The measurement has to be taken at those links which show the most wear It is the responsibility of the ride owner to see to these inspections being carried out Chain shackles should be inspected together with the seat chains en and have to be replaced if the remaining str
9. id loss of rust protection e Do not drag the chains along steel or metal parts during installation e Do not do any grinding using an angle grinder for instance or welding jobs near the chains Sparks too will damage the chain surface e Do not use tools which are normally used for working on untreated steel for example wire brushes grinding wheels e Always remove industrial dust by cleaning the chains regularly e Tempering colors as caused by welding for instance will also result in corrosion if the stains are not thoroughly removed from the chains NOTE Any corrosive material touching stainless steel chains may cause deterioration of the chains rust protection That means only correct treatment of the chains will guarantee rust free chains Improper handling and disregarding the above guidelines will probably lead to strong corrosion of stainless steel chains within only one year Neither Zierer nor the chain manufacturer will grant any warranty in case of improper treatment of stainless steel chains Therefore please check every new stainless steel chain for any damages immediately when receiving it Later complaints cannot be considered since inexpert treatment and handling of the chains must be assumed The above guidelines for proper treatment also apply to all stainless steel parts that have been installed in attractions and ride manufactured by Zierer 1 1 1 2 Shackles The shackles have to be checked when inspecting
10. ing girder of base frame te a a strut and the binding girder of base frame or B3 Joint weld at the boundaries of the diagonals 042 30 19 Ci or C2 at the base frame Joint weld at the boundaries of the diagonals 042 30 19 Y10 B1 or B2 at the base frame or B3 Welding seams at the bushing of the 042 30 20 B1 or B2 attachment pin Welding seams at the lower and upper 042 30 21 21 Y Ci or C2 polygon ring Welding seams at the lower and upper 042 30 21 Y10 B1 or B2 polygon ring or B3 Joint weld at the boundaries of basket and 042 30 22 C1 or C2 polygon ring as well as welding seams in the area of the slew ring connection Joint weld at the boundaries of basket and 042 30 22 22 Y10 B1 or B2 polygon ring as well as welding seams in the or B3 area of the slew ring connection Welding seams at the lattice girder Sweep 30 23 e or C2 locations Y Q locations X Q or B3 i a cylinder attachments or B3 Circulating welding seam at the upper mast 042 30 25 B1 or B2 base or B3 F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 2 von 13 maschinenbau GmbH Stabilization Cables 042 30 26 SZ J oooO ees a a eS OOOO 042 30 27 C1 or C2 Check for cracks Seat frame 042 30 27 27 Y10 Bi or B2 Check for cracks or B3 or D Chains shackles spreader bar bolts for seat 042 30 27 27 28 M Ci orC2 Check for cracks wear and deformation hangers 042 30 28 Shackle spreader bar bolts for
11. m ZIERER Karussell und Spezialmaschinenbau GmbH Josef Wallner Str 10 D 94469 Deggendorf Karussell und Spezial maschinenbau GmbH Versand Lieferanschrift Delivery Address Neuhausen Moosgasse 4 D 94560 Offenberg Telefon 49 991 91060 49 991 910638 Telefax 49 991 910684 49 991 910683 49 991 910624 Zentrale Service Verkauf Sales Service Technik Engineering E Mail info zierer rides de service zierer rides de Ihre Nachricht vom Ihre Zeichen Unser Zeichen Tel Durchwahl Datum Internet Your message dated Your reference Our reference Direct Line Date www zierer rides de Wm 49 991 9106 40 05 08 2004 Non destructive testing Wave Swinger Ride To whom it may concern We would like to inform that there is a new German TUV regulation on older amusement rides which requires a special examination on safety relevant parts To ensure the safety of the ride we highly recommend to perform this as requested Attached please find a Wear inspection Non destructive testing chart for the Wave Swinger ride This testing requirement is restricted to dynamic high stress structural components whose breakdown could endanger the passengers It is meant to be an addition to the required regular safety checks and maintenance check list and it is by no means a complete inspection program The testing results are to be documented in detail and comprehensible These testing results are
12. n due to fretting pits and reduction of the metallic cross section The wire cable has to be replaced if anywhere along the cable the cable diameter is decreased by 10 compared to the nominal size even though there are no visible wire breaks 1 1 1 5 4 Structural Changes Strain on the wire rope during operation causes structural changes which will reduce the rope diameter The cable must be replaced when over a longer stretch the cable diameter has decreased by 15 compared to the nominal size even though there are no visible wire breaks 1 1 1 5 5 Deformation Deformations of the wire rope are visible changes in the rope structure Deformation usually generates a destabilization of the rope structure at least near the deformed area When a wire rope is visibly deformed an exchange of the lift cable sets is recommended as the destabilization of the rope structure also means increased abrasion The consequential damage leads to an accelerated rate of wire breaks which are crucial for the replacement state of wear Please proceed as follows to exchange the cables 1 Bring the ride to its load unload position 2 For manual lowering use the setup unit see function description of hydraulic system 4 3 5 the carrousel is lowered until it comes to rest on the basket stops and the lift cables become slack 3 Slide up securing pins The pins attaching the cables to the basket may now be removed through the basket openings by using the sp
13. n 13 1 1 1 5 1 Wire Breaks Wire breaks initially occur after a certain running period and then continue to occur after increasingly shorter time periods a a The wire rope is to be replaced when the number of breaks and the wear increases to 10 and more within 0 5 meters anywhere along the cable b The wire rope is to be discarded immediately when wire break clusters appear c The wire rope is to be discarded immediately when a wire strand is fractured 1 1 1 5 2 Corrosion Corrosion occurs particularly in corrosive environment e g sea climate Wire ropes stored outdoors for longer periods will also corrode Corrosion of the outer wires can easily be noticed by visual inspection Corrosion of wires not visible from the outside is difficult to detect Both the static breaking strength as well as the stability of the wire rope will be reduced by corrosion due to corrosion pits and reduction of the metallic cross section The cable must be replaced when the cable diameter in any given spot has decreased by 10 compared to the nominal size even though no wire breaks are visible 1 1 1 5 3 Abrasion Wire abrasion occurs as internal abrasion due to the movements of strands and wires against each other by bending the wire rope and as external abrasion due to movement between wire rope and pulley A dusty environment increases the abrasion Both the static breaking strength as well as the stability of the wire rope becomes reduced by abrasio
14. omponents Time code method Attachment pin basket to cable attachment 042 30 04 04 Y10 B1 or B2 or B3 or D ema e A block or B3 or D Cable block of lifting cables n a 042 30 06 Cable attachment ie 042 30 07 i i 0 7 or B2 5 B3 or D Cable attachment 042 30 07 Check for play aaa a or B3 or D Sheave pins S 02 30 08 O Ne _ Ae attachement as well as pins of cable or B3 or D attachments Pins of outriggers 042 30 10 B1 or B2 or B3 or D Pins at the locations R S T Z of the lattice 042 30 11 11 Y10 B1 or B2 girder sweep or B3 or D Pins at the locations Y Q of the lattice girder sweep B1 or B2 or B3 or D cal een fe f gh pa attachment or B3 Upper mast base in the area of the circulating 042 30 13 welding seam F Compaq Laptop 0406_Wearoutinspectionchart_WS 0406_Wearoutinspectionchart_WS doc 27 10 05 Seite 1 von 13 maschinenbau GmbH Lower mast base in the area of the transversal 042 30 14 14 Y10 welding seams at the 12 Gussets Cross bar in the area of welding of the seat 042 30 15 15 Y10 Bi or B2 attachment or B3 S hook for the chain attachment 042 30 16 16 Y10 B3orD TP EEE Oe ES Or ae Joint weld at the boundaries of U 220 at 042 30 17 17 Y C1 or C2 bottom boom and joint weld at the boundaries at the bottom boom of the IPB220 Joint weld at the boundaries of U 220 at 042 30 17 17 Y10 B1 or B2 bottom boom and joint weld at the boundaries or B3 at the bottom boom of the IPB220 strut and the bind
15. to be presented to the local safety authorities responsible for the safety of Amusement Rides along with evaluations and statements If doubts about their clear identification exists the examined structural components are to mark distinctively e g punch marks etc in order to avoid confusion by further prospective testings Attached Wear inspection Non destructive testing chart is based on the assumption that the ride is not modified and still original Remark The replacement of components can sometimes be more cost efficient than expensive test procedures For questions or assistance on site regarding the examination and or assembling disassembling work as well for spare parts please don t hesitate to contact us ZIERER Karussell und Spezialmaschinenbau GmbH Martin Weichselgartner Tel 49 991 9106 40 Fax 49 991 9106 83 E mail m weichselgartner zierer rides de ZIERER Karussell und Spezialmaschinenbau GmbH Firmensitz Josef Wallner Str 10 D 94469 Deggendorf Tel 49 991 31090 Fax 49 991 310920 Gesch ftsf hrer Norbert Polkehn e Rupert Baur Registergericht Deggendorf HRB 2432 Ust ID Nr DE813372843 FA Straubing Bank HypoVereinsbank Deggendorf Kto 335 610 482 BLZ 741 200 71 SWIFT HYVEDEMM415 maschinenbau GmbH Wear inspection Non destructive testing Addition to the maintenance checklist see manual and daily lubrication schedule Facility Wave Swinger Park Road Model C
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