Thrill Rider Service Manual (Preliminary).pub
Contents
1. FENCE SECTION 5 FENCE SECTION 6 FENCE SECTION 7 FENCE SECTION 8 TURNSTILE COVER PLATE TURNSTILE MOUNTING PLATE TURNSTILE BASE PLATE CL1213 SELECTOR ARM CL1214 LOCKOUT COIL ARM CL1218 LOCKOUT GEAR YOKE CL1220 LOCK KEY YOKE CL 1221 YOKE MOUNTING BRACKET CL1222 YOKE CL3001 SEAT CL3010 REAR FENDER LEFT SIDE CL301 1 REAR FENDER RIGHT SIDE CL3022 FRONT FENDER LEFT SIDE CL3023 FRONT FENDER RIGHT SIDE CL4001 BELLOWS CL4002X FLOOR MAT W ADHESIVE ELECIRONICS CL2002 TRANSFORMER CL2008 MOTOR LEESON DRIVE CL2008A GEARBOX LEFT HAND DRIVE CL2008B GEARBOX RIGHT HAND DRIVE CL2009 AMPLIFIER HIGH POWER THUMP CL2014 VIDEO PROJECTOR CL2020 MOTION SENSOR CL2027 BLOWER FAN CL2039X HOME SENSOR CL2040X BACKPLANE P C BOARD ASSY CL2041X MAIN CONTROLLER BOARD CL2042X FLASH MEMORY CARD CL2043X MOTOR CONTROLLER BOARD 20 CL7001 CL7002 CL7003 CL7004 CL7005 CL7006 CL7007 CL7008 CL7009 CL7010 CL701 1 CL7012 CL7014 CL7015 CL7016 CL7017 CL7018 CL7019 CL7027 CABINET LEFT SIDE DECAL CABINET RIGHT SIDE DECAL LEFT WHEEL DECAL RIGHT WHEEL DECAL STOP BUTTON DECAL REAR RIDE LOGO DECAL REAR LOGO DECAL SEAT DECAL THUNDERBOLT SELECT DECAL REAR LOWER DECAL PHOENIX SELECT DECAL CONTROL PANEL DECAL PHANTOM SELECT DECAL LEFT GRILL DECAL RIGHT GRILL DECAL WATCH YOUR STEP DECAL KEEP YOUR ARMS INSIDE DECAL TOP WARNING DECAL MARQUEE GRAPHICS PANEL ADDITIONAL PARTS AND INFORMATION CAN BE OBTA2. warranty OPERATION OF THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY THE MANUFACTURER MAY RESULT IN THE PROTECTION DEVICES NOT AFFORDING THE LEVEL OF SAFETY NORMALLY PROVIDED ONLY TRAINED PERSONNEL ARE ALLOWED TO MAINTAIN THE SYSTEM THE THRILL RIDER IS A DYNAMIC MOTION SIMULATOR RIDE ANYONE WHO IS PREGNANT OR THINK THEY MAY BE ARE SUBJECT TO MOTION SICKNESS HAVE BACK OR NECK PROBLEMS OR UNDER THE INFLUENCE OF ALCOHOL OR DRUGS HAVE EPILEPSY HAS A HEART COMPLAINT OR OTHER MEDICAL CONDITION OR IS OF A NERVOUS DISPOSITION SHOULD USE CAUTION WHEN USING THIS RIDE SMALL CHILDREN SHOULD BE SUPERVISED BY AN ADULT NOTICE Except as may be otherwise provided by contract this SERVICE MANUAL including the drawings and specifications are the property of INNOVATIVE CONCEPTS in ENTERTAIN MENT They are issued in strict confidence and shall not be reproduced copied or used as a basis for manufacture or sale of any apparatus SET UP AND ASSEMBLY INTRODUCTION Thank you for purchasing the THRILL RIDER coaster ride from I C E We have tried to make assembly of the THRILL RIDER as easy as possible Please follow the directions given below to be sure the coaster is assem bled properly and safely WARNING DO NOT TRY TO DEFEAT THE SAFETY SENSOR SYSTEM WITHIN THE FENCE AREA THIS IS NEEDED TO ENSURE THE SAFETY OF THE CUS TOMER LOCATION PREPARATION Be sure you have the space for the coaster ready before you unpackage th
3. NOT LOCKING GOING OUT OF THE RIDE IS NORMAL TURNSTILE SOLENOID BAD REPLACE SOLENOID TURNSTILE HARNESSING BAD OR DISCONNECTED CHECK HARNESSING FOR PROPER FUNCTION 14 QUICK TROUBLESHOOTING COASTER SOUND LOW OR SOME SOUND MISSING NO TRACK OR MUSIC SOUNDS EACH SOUND ON A DIFFERENT CHANNEL MAKE SURE BOTH ARE ON POWER AMP BAD OR DISCONNECTED CHECK OR REPLACE POWER AMP SPEAKERS OR HARNESSING BAD CHECK OR REPLACE SPEAKERS MEMORY CARD BAD CHECK OR REPLACE MEMORY CARD COASTER DOES NOT LEVEL AT END OF RIDE BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD BAD MOTOR DRIVER P C BOARD REPLACE MOTOR DRIVER P C BOARD BAD MOTOR REPLACE MOTOR BAD HOME SENSOR CHECK AND REPLACE HOME SENSOR IF NECESSARY BAD GEARBOX REPLACE GEARBOX NO VIDEO OR POOR QUALITY PICTURE NO POWER TO PROJECTOR CHECK POWER CORD AND BE SURE ON OFF SWITCH IS SET TO ON VIDEO CABLE BAD OR NOT FULLY PLUGGED IN CHECK OR REPLACE VIDEO CABLE AS NECESSARY PROJECTOR BULB BURNED OUT REPLACE BULB AS DESCRIBED IN OWNERS MANUAL PROJECTOR BULB OLD AND WORN OUT REPLACE BULB AS DESCRIBED IN OWNERS MANUAL PICTURE OUT OF FOCUS RE ADJUST FOCUS ON PROJECTOR PICTURE NOT CORRECT SIZE ADJUST ZOOM ON PROJECTOR PICTURE NOT CENTERED CORRECT BY ADJUSTING MOUNTING SHELF OR MOUNTING BRACKET PICTURE NOT SQUARE ADJUST KEYSTONE ADJUSTMENT AS DESCRIBED IN OWNERS MANUAL BAD MAIN P C BOARD REPAIR OR REPL
4. sections to the fence UE T supports 9 Square up all of the fence sections and tighten all of the hardware securely 11 Attach the Podium Turnstile assembly to the fence unit 10 Flip the podium Turnstile assembly up on its end and attach the Diamond Plate panel to the bottom using the supplied Flat head screws m SET UP AND ASSEMBLY 12 Attach the diamond plate panel to the short fence sec 16 Attach the other pole to the fence as shown tion using the supplied hardware t A ET n 17 Bolt the Marquee to the top of the attachment poles using the hardware supplied 13 Tighten the diamond plate and Podium Turnstile 18 Plug the power cord into the marquee and make sure that the power switch on the back of the marquee is turned on hardware securely 14 Run the Marquee power cord thru the mounting pole with the 3 pin connector running thru the slot in the pole 15 Attach the pole to the Podium Turnstile assembly while feeding the Marquee power cord thru the power cord hole SET UP AND ASSEMBLY HARNESSING ag WP din E ni ps nm h x E B E 4 28 mm e E z REFLECTOR 8 SENSOR LOCATIONS SET UP AND ASSEMBLY SAFETY SENSOR INSTALLATION 4 There are 4 long wires 1 for each of the sensors The longest wire goes to the sensor marked 2 This is the sensor located to your left as you walk into the fenced in OVERVIEW
5. to the coaster frame 2 Unzip the bellows to remove from the coaster the zipper is located on the side of the bellows facing the front 3 Re assemble in reverse order 4 Replace the adhesive Velcro strips on the base of the coaster if necessary ELECIRONICS ELECTRICAL REPAIR PROJECTOR SERVICING AND REPLACEMENT The projector used is a very reliable DLP system that requires very little service The advantages of this system over the traditional monitors are many The only necessary maintenance on this monitor is bulb replacement The average life of the bulb is around 4000 hours this averages out to around 1 year based on 11 hours of use per day DEIAILED REPAIR PROJECTOR REMOVAL 1 Remove the 3 security Allen head screws that secure the front access door 2 Tilt the door down for access to the Projector 3 Remove the 4 self locking nuts that secure the projector mounting bracket to the shelf 4 Remove the projector from the mounting bracket by removing the 3 screws that hold it in place DO NOT LOSE THE PLASTIC SPACERS PROJECIOR BULB REPLACEMENT WARNING WHEN CHANGING THE PROJECTOR BULB ALLOW SUFFICIENT TIME TO COOL THE BULB IS EXTREMELY HOT WHEN OPENING THE PROJECTOR TO CHANGE THE BULB BE VERY CAREFUL IN CASE THE BULB HAS BROKEN 5 Replace the bulb as per manufacturers directions provided in the projector owners manual PROJECTOR INSTALLATION ADJUSTMENT amp ALIGNMENT 1 Mount projec
6. ACE MAIN P C BOARD PROJECTOR SCREENS OR MIRRORS EXCESSIVELY DIRTY DISASSEMBLE SCREENS AND CLEAN MIRROR BROKEN THROUGH ACCIDENT OR ABUSE REPLACE MIRROR PROJECTOR NOT TURNED OFF LONG ENOUGH TURN OFF FOR AT LEAST 1 MIN THEN RESTART AIR BLOWERS DO NOT WORK PROPERLY BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD BAD BLOWER MOTOR REPLACE BLOWER MOTOR BAD BLOWER MOTOR RELAY CHECK AND REPLACE RELAY IF NECESSARY BAD BLOWER MOTOR HARNESSING CHECK AND REPAIR IF NECESSARY 15 DEIAILED REPAIR WARNING ALWAYS REMOVE POWER TO THE COASTER BEFORE ATTEMPTING ANY SERVICE UNLESS NEEDED FOR SPECIFIC TESTING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SERIOUS INJURY TO YOURSELF OR OTHERS TROUBLESHOOTING PHILOSOPHY To find problems with the coaster always first check what should be obvious See that the coaster is plugged in and that all of the fuses on the coaster are good This includes the fuse that is located INSIDE the power module Next check to see that all of the connectors are firmly seated and that none of the wires have pulled out of them When trying to find out if specific components are bad or not try swapping them with components from another player station to see if the problem moves with the component or stays where it was This will help you to know if you have a problem with a specific component or maybe a problem with either the wi
7. FOR INDOOR USE ONLY OWNERS AND SERVICE MANUAL INNOVATIVE CONCEPTS IN ENTERTAINMENT INC 10123 MAIN STREET CLARENCE NY 14031 SERVICE 1 716 759 0360 FAX 1 716 759 0884 E MAIL service icegame com WEBSITE www icegame com TABLE OF CONTENTS FOREN ORO Rm PAGE 3 SE FUP ASSEMBLY PAGE 4 9 INTRODUC ON 4 TRE Nr PAGE 4 UNPACKING PAGE 4 INSTALA TION ev PAGE 4 FENCE INSTALLATION pp PAGE 4 9 SAFETY SENSOR PAGE 10 SENG ae M PAGE 12 PETN ENE PAGE 13 QUICK 14 15 DETAILED rer PAGE 16 19 OPERATIONAL BACKGROUND TROUBLESHOOTING PHILOSOPHY MECHANICAL REPAIR PAGE 20 WARRANTY PAGE 21 22 ICEDOC CL9001 REVISION A 1 21 04 FOREWORD This Manual has been compiled to assist those whose task it is to set up operate and main tain the THRILL RIDER It is essential that all operating and maintenance staff responsible for the safe operation of the simulator completely understand and comply with information herein Further advice and field support is available from I C E SERVICE DEPARTMENT 716 759 0360 NORMAL BUSINESS HOURS ARE MONDAY FRIDAY 8 00 AM TO 5 00 PM Warnings Operation of the THRILL RIDER without the proper electrical requirements will void the
8. INED BY CONTACTING OUR SERVICE DEPARTMENT AT 716 759 0360 pA SE FRR __ ____________________________________________ __________ _________ 06 LUI WARRANTY ICE Inc warrants that all of its products will be free from defects in material and workmanship When placing a warranty request please be prepared to provide the following information serial Number of Game or Bill of Sale Machine Type A Detailed Description of the Equipment Fault Symptoms ICE product including Cromptons Sam s Billiards Uniana and Bell Fruit is warranted as follows 180 days on the Main PCB and Computers 90 days on all other components i e DBV s Ticket Dispensers etc 30 days on repaired items 3 years on all Crane Harnessing 9 Months on Printers ICE Inc shall not be obligated to furnish a warranty request under the following conditions Equipment has been subjected to unwarranted stress through abuse or neglect Equipment has been damaged as a result of arbitrary repair modification attempts Equipment that has failed through normal wear and tear ICE Inc will assume no liability whatsoever for costs associated with labor to replace defective parts or travel time associated therein All defective warranty covered components will be replaced with new or factory refurbished components equal to OEM specifications ICE Inc will cover all UPS ground or comparable shipping means freight costs during the warranty period Expedited ship
9. LECT OR EMERGENCY STOP SWITCHES DO NOT WORK PROPERLY BAD MICRO SWITCH OR HARNESSING REPLACE SWITCH OR HARNESSING BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD SWITCH ASSEMBLY POPPED OUT OF BUTTON HOUSING SNAP BACK INTO HOUSING SELECT OR EMERGENCY STOP SWITCHES DO NOT LIGHT OR FLASH BAD LIGHT BULB REPLACE BULB BAD BUTTON HARNESS REPAIR OR REPLACE BUTTON HARNESS BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD COASTER DOES NOT MOVE AT ALL BAD MAIN FUSE OR NO A C POWER CHECK FOR POWER AND GOOD FUSE BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD BAD MOTOR DRIVER P C BOARD REPLACE MOTOR DRIVER P C BOARD BAD MOTOR REPLACE MOTOR BAD OR MISALIGNED SAFETY SENSOR ALIGN OR REPLACE SAFETY SENSOR BAD OR DISCONNECTED SAFETY SENSOR HARNESSING CHECK HARNESSING BAD HOME SENSOR CHECK AND REPLACE HOME SENSOR IF NECESSARY BAD ON OFF SWITCH REPLACE ON OFF SWITCH COASTER MOVES IMPROPERLY BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD BAD MOTOR DRIVER P C BOARD REPLACE MOTOR DRIVER P C BOARD BAD MOTOR REPLACE MOTOR BAD POSITION ENCODER SENSOR CHECK FOR PROPER ALIGNMENT OR REPLACE SENSOR TURNSTILE DOES NOT LOCK DURING THE RIDE SHOULD ONLY LOCK GOING IN
10. TS THAT THE ADJUSTER FEET ON THE COASTER BASE FIT INTO Do one side of the coaster then tilt the other side of the coaster up and align the other side of the T supports with the adjuster feet 3 Check that the coaster sits firmly and evenly on the floor Rock the coaster back and forth to be sure the base of the coaster does not rock If the base rocks back and forth on the floor tilt the coaster up and screw or unscrew the adjuster feet until the base of the coaster is steady 4 Center the coaster The coaster will be very difficult to move once the fence sections are installed so now is a good time to make sure that the coaster will sit evenly to any walls or posts in the vicinity 5 It is now time to install the fence sections of the coaster together and to the fence T supports NOTE ALL FASTENING HARDWARE HAS BEEN PRE ATTACHED TO THE FENCE SECTIONS TO MAKE IT EASY TO DETERMINE WHERE THE PROPER HARD WARE GOES ASSEMBLE ALL SECTIONS LOOSELY THEN GO BACK AND TIGHTEN ALL BOLTS ONCE THE ENTIRE UNIT HAS BEEN ASSEMBLED 6 Fence sections are marked with numbers that match where the sections join together Working in a clockwise fashion join the sections together starting at 1 See illus tration 7 Continue to join the fence sections together until all of the fence is completed SEE PAGE 9 FOR FULL LAYOUT OF FENCE SECTION POSITIONS SET UP AND ASSEMBLY 8 Attach the bolts from the fence
11. There are 4 safety sensors that protect area See Fig 2 inside fence area of the coaster These are reflective optical sensors These sensors work by sending out a beam of infra red light bouncing it off a reflector and back to a receiver on the same sensor When the beam is broken a signal change is sent to the computer on the coaster and the coaster motion is stopped This prevents customers from being injured during the ride Each time the beam is broken motion for the game is stopped for a period of 5 seconds 5 Starting at this sensor insert the connector thru the slot in the sensor bracket as indicated Connect the long wire to the sensor Tuck the connector up into the sensor housing as shown See Fig 2 6 Run the long wire into the wire molding and snap the cover over the molding Run the wire thru the next section of wire molding and snap the cover on See Fig 3 NOTE FOR THE SENSORS AND COASTER TO FUNCTION PROPERLY IT IS NECESSARY FOR THE SENSORS TO BE ALIGNED PROPERLY IF THE SENSORS ARE MIS ALIGNED THE COASTER WILL NOT MOVE 1 Install the reflectors and sensors onto the fence in the positions indicated See Diagram on Page 9 There are numbers on the fence reflectors and sensors indicating the proper location for each Make sure everything is as straight as possible and fasten securely See Fig 1 7 Connect the next sensor Marked 4 in the same manor as above using the next longest wire 8 N
12. When you first turn the power to the coaster on the coaster may or may not have motion This is because the safety sensors need to be aligned properly for the coaster motion to work 1 BE SURE THE SENSORS ARE MOUNTED CORRECTLY Check to see that the sensor mounting brackets are mounted vertically If they lean forwards or backwards too far proper sensor alignment might not be possible If the brackets are not straight bend the bracket by hand until it appears to be straight up and down 2 SENSOR ALIGNMENT there is a small red pilot LED on the sensor that will light when the sensor is properly aligned The lenses on the sensor will rotate to allow for adjustment There is a screw between the 2 eyes on the sensor that secures the eyes in place Slightly loosen this screw and move the sensor around until the light comes on steadily BE SURE YOU RE NOT STANDING IN FRONT OF THE SENSOR OR IT WON T WORK 3 Once you think you have the sensor aligned properly wiggle the sensor and reflector brackets slightly to be sure you have the alignment in the sweet spot 4 Once all 4 of the sensors are aligned properly coaster motion will function properly as long as nothing is blocking the sensors NOTE DIRECT BRIGHT SUNLIGHT CAN AFFECT THE PROPER OPERATION OF THE SAFETY SENSORS WE RECOMMEND THAT DIRECT SUNLIGHT IS AVOIDED IF POSSIBLE 5 Install the sensor covers and check to make sure that the pilot LED s are still lit If you bloc
13. e cannot be responsible for the quality suitability or safety of any non l C E part or any modification including labor which is performed by such a distributor rmt rn pm ns prs pm n mmm gt pn mmm pr pr ens pm gene es memi ED IAS B s M 2 UJ Xa a D ss H E ar ssa seal kong se
14. e coaster Make sure there is an available 120 VAC outlet within 10 feet of the fence assembly You will need at least 10 amps of available current for the coaster but 15 amps of available current would be better Make sure you choose a spot with a relatively level sur face The flatter the better UNPACKING Carefully unpack the crating from around the coaster and remove from the skid Remove the fence sections podium and related parts from their packages Look for any loose hardware INSTALLATION FENCE INSTALLATION 1 Place the coaster into its permanent position POSITIONING TIPS a Make sure the coaster is at least 36 inches from any walls or pillars so there is room for the fence b Position the right hand side of the coaster where you want customers to enter and exit This is necessary since the podium and turnstile line up with the right hand side of the game See illustration for further explanation 2 Place the fence supports under the coaster feet The support with the longer legged T goes under the front of the coaster where the shorter legged T goes under the rear of the coaster LONG LEGGED T Y ADJUSTER FEET ADJUSTER FEET SHORT LEGGED T The easiest way to put the T fence supports under the coaster is to tilt the coaster up from the side and slide the t supports under the adjuster feet of the coaster NOTE THERE ARE LOCATING HOLES IN THE T SUPPOR
15. e into the hole on the front fence T support by the front right leg leveler as per the illustration FAILURE TO USE A PROPERLY GROUNDED OUTLET COULD VOID YOUR WARRANTY 2 Push the sensor wire out of the end of the T support and run wire into the bottom of the Turnstile WARNING BE SURE POWER IS OFF mo ON THE COASTER BEFORE PLUGGING IN BE SURE NO ONE IS INSIDE THE COASTER FENCE AREA BEFORE PLUGGING THE COASTER IN THE ON OFF SWITCH IS LOCATED UNDER THE COASTER NEAR THE RIGHT SIDE ENTRANCE TO THE COASTER AS ILLUSTRATED Turn the power to the game on 3 Insert the sensor wire into the access hole in the podium Turnstile assembly and connect to the sensor daisy chain harness 4 There is a 20 ft power cord for the Marquee that is supplied with the coaster Run the end with the 3 pin connector into the hole on the front fence T support by the front right leg leveler as per the illustration 5 Bring the marquee power cord back out of the hole that is located by the podium Turnstile assembly as per the illustration 6 Insert the marquee power cord into the access hole in the podium Turnstile assembly and connect to the marquee power cord that runs down thru the marquee pipe 7 RUNNING A C WIRING wrap a piece of supplied spiral wrap around the wiring where it comes out of the hole by the adjuster foot This will make for a neater appearance SET UP AND ASSEMBLY SENSOR ADJUSTMENT
16. e new gearbox into the coaster BE SURE TO USE THREAD LOCKING COMPOUND ON ALL BOLTS Torque the gearbox mounting bolts to 55 ft lb 12 Re install the swing arm Torque the swing arm pinch bolt to 55 ft Ib Torque the retaining bolt on the end of the gearbox shaft to 55 ft lb 13 Re install the transformer mounting plate and Torque the bolts to 55 ft lb The swing arm sensor mounting brackets get re attached under the mounting bolts NOTE THE END OF THE OPTO SENSOR SHOULD BE 1 8 TO 3 8 1 4 OPTIMAL FROM THE REFLECTIVE FOIL ON THE SWING ARM TO WORK PROPERLY 14 Re connect the sensor and transformer wiring 15 Install the motor onto the gearbox NOTE WHEN ORIENTING THE MOTOR TO THE GEARBOX BE SURE THAT THE WIRING BOX ON THE MOTOR FACES STRAIGHT DOWN 16 Re install the lock washers and bolts and Torque to 55 ft Ib 17 Re connect the encoder sensor to the harness 18 Re install the Power Supply or electronics whichever you removed to access the gearbox 19 Test for proper operation 20 Re install the bellows DEIAILED REPAIR SEAT REPLACEMENT NOTE ALL POWER CORDS MUST BE REMOVED FROM THE A C OUTLETS BEFORE PERFORMING THIS REPAIR FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY 1 Remove the nuts that secure the bellows to the top of the frame and lower the bellows The bellows does not have to be removed from the game 2 Unplug the speaker harnessing from the seat 3 Unbolt the seat retaining screw
17. est for proper operation 10 Re connect the bellows DEIAILED REPAIR GEARBOX REPLACEMENT NOTE ALL POWER CORDS MUST BE REMOVED FROM THE A C OUTLETS BEFORE PERFORMING THIS REPAIR FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY 1 Remove rear cover from game by removing the 2 Allen bolts that secure it to the frame 2 Remove the nuts that secure the bellows to the top of the frame and lower the bellows The bellows does not have to be removed from the game 3 Remove the Main control electronics box or power supply depending on which gearbox needs replacement to access the gearbox mounting bolts 4 Unplug the motor encoder sensor and motor power connector from the harness 5 Remove the bolts that hold the motor to the gearbox assembly and remove the motor 6 Remove the arm sensors and mounting brackets from the bottom of the transformer mounting pan 7 Remove the transformer harnessing and remove the transformer mounting pan from the bottom of the gearboxes 8 Remove the pinch bolt and safety bolt that connect the drive arm to the gearbox shaft NOTE WHEN THE SWING ARM IS REMOVED THE COASTER WILL FALL FORWARD GET SOMEONE TO HELP YOU TO MAKE SURE THE COASTER DOES NOT MOVE TOO QUICKLY THE COASTER IS VERY WELL BALANCED SO IT SHOULD BE EASY TO SET IT FORWARD 9 Carefully remove the bolts that hold the gearbox to the frame of the coaster 10 Remove the gearbox from the coaster 17 11 Install th
18. k the sensors with your hand the LED should go out and then come back on as soon as your hand is removed from the path of the beam 6 Re test the sensors by starting a coaster ride Once the ride starts carefully block each sensor one at a time You should notice that the coaster will stop moving immediately and will resume motion 5 seconds after beam interruption stops If the coaster does not work this way please call our service department for assistance WARNING DO NOT OPERATE THE COASTER IF THE SAFETY SENSORS DO NOT WORK PROPERLY IMPROPERLY WORKING SENSORS COULD CAUSE SERIOUS INJURY THE SYSTEM HAS BEEN DESIGNED TO SHUT THE COASTER DOWN BY DEFAULT IF A SENSOR PROBLEM IS DETECTED DO NOT TRY TO DEFEAT THE SENSOR SYSTEM IN THE EVENT OF A FAILURE SERIOUS INJURY COULD RESULT FOR INFORMATION ON PROGRAMMING YOUR COASTER SEE THE PROGRAMMING SECTION IF YOU HAVE ANY QUESTIONS OR COMMENTS REGARDING THE INSTALLATION OF THE COASTER PLEASE CONTACT OUR SERVICE DEPARTMENT AT 1 716 759 0360 QUICK TROUBLESHOOTING COASTER DOES NOT TAKE OR ADD MONEY CORRECTLY BAD COIN SWITCH REPLACE COIN SWITCH BAD COIN SWITCH HARNESSING REPAIR OR REPLACE HARNESSING BAD MAIN P C BOARD REPAIR OR REPLACE MAIN P C BOARD BAD BACKPLANE BOARD REPAIR OR REPLACE BACKPLANE BOARD GAME PROGRAMMING SET UP INCORRECTLY CHECK PROGRAMMING AND ADJUST IF NECESSARY BAD OR INCORRECTLY PROGRAMMED BILL VALIDATOR CHECK PROGRAMMING OR REPLACE SE
19. ments are available for an additional charge Defective parts are returned to ICE Inc at the customer s expense in a timely fashion ICE distributors are independent privately owned and operated In their judgment they may sell parts and or accessories other than those manufactured by ICE Inc We cannot be responsible for the quality Suitability or safety of any non ICE part modification including labor that is performed by such a distributor Parts Service Dept Innovative Concepts in Entertainment 10123 Main St Clarence NY 14031 Phone 716 759 0360 Fax 716 759 0884 M M B T jl ses er sn ee GEN m nml m aes EN FE ER FER aar meg TE ES KE KR quce SE NE amma FE ogni ES aer n ee SG m e Er SEAN ey pm mr rl pms mri gemens SS mp perm 21 Er d P V J P P fx Emend pen Er Fr Er ES es rmn penses FR kp ETP pr Fre gm rs peque EE sque er a es ess pnt warrants all components in the THRILL RIDER game to be free of defects in materials and workmanship for a period of 90 days from the date of
20. ow run the 2 wires into the wire molding and snap the cover on FA i Bb atA 2 Remove the covers from the sensors and set next to each sensor 3 Remove the snap on plastic covers for the wire molding and place by each fence section See Fig 2 9 Continue in this fashion with the rest of the sensor wiring SET UP AND ASSEMBLY 10 Once all of the wiring has been run insert all of the sensor wiring into the podium thru the access hole in the bottom NOTE ROUTING OF HARNESSING IN CORNERS i a 11 Connect all 4 sensor wires to the daisy chain adapter harness inside the podium turnstile assembly NOTE COVERS SHOULD LEFT OFF THE SENSORS UNTIL THEY ARE ADJUSTED AFTER THE INITIAL POWER UP SET UP AND ASSEMBLY FINAL WIRING 8 Determine where the coaster will be plugged in and run the power for the Marquee and coaster to the A C At this point the final wiring needs to be run from the Receptacle coaster and Podium Turnstile to the A C Outlet We have specifically kept the coaster and Marquee wired CAUTION USE ONLY A 110 120 VOLT V A C separately as this will allow the marquee to be plugged GROUNDED OUTLET FOR THIS PRODUCT into a separate circuit if necessary FAILURE TO USE A PROPERLY GROUNDED 1 Run the gray sensor wire from the coaster to the OUTLET COULD CAUSE SERIOUS BODILY INJURY Podium Turnstile assembly Do this by running the OR DAMAGE TO THE PRODUCT sensor wir
21. purchase Furthermore all MAIN P C BOARDS are warranted for 180 days This warranty does not cover items damaged due to normal wear and tear sub jected to abuse improperly assembled by the end user modified repaired or oper ated in a fashion other than that described in the service manual If your THRILL RIDER game fails to conform to the above mentioned warranty 5 sole responsibility shall be at its discretion to repair or replace any defective component with a new or remanufactured component of equal to or greater O E M specification will assume no liability whatsoever for costs associated with labor to replace defective parts or travel time associated therein 5 obligation will be to ship free of charge replacement parts by U P S Ground U S mail or other comparable shipping means Any express mail or over night shipping expense 15 at the cost of the purchaser Products will be covered under warranty only when The serial number of the game with the defective parts 15 given The serial number of the defective part if applicable is given Defective parts are returned to C E shipping pre paid in a timely fashion if requested by I C E A copy of the sales receipt is available as proof of purchase upon request of distributors are independent privately owned and operated In their judg ment they may sell parts or accessories other than those manufactured by LG E W
22. ring or the Main P C Board Use extreme caution when using probes or voltmeters if the game is powered up If doing continuity checks it is important to disconnect the harnessing at both as attached they may yield erroneous results If P C Boards are suspected as causing problems check to see that all of the I C chips are firmly seated on the boards If light bulbs are suspected swap them with one that is known to work to narrow the problem down to the bulb or P C Board 16 MECHANICAL REPAIR MOIOR GEARBOX REPLACEMENT MOTOR REPLACEMENT NOTE ALL POWER CORDS MUST BE REMOVED FROM THE A C OUTLETS BEFORE PERFORMING THIS REPAIR FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY 1 The motors can be removed and replaced without removing the gearboxes 2 Remove the nuts that secure the bellows to the top of the frame and lower the bellows The bellows does not have to be removed from the game 3 Unplug the motor encoder sensor and motor power connector from the harness 4 Remove the bolts that hold the motor to the gearbox assembly and remove the motor 5 Remove the sensor bracket and encoder wheel and install onto the new motor 6 Install the new motor onto the gearbox NOTE WHEN ORIENTING THE MOTOR TO THE GEARBOX BE SURE THAT THE WIRING BOX ON THE MOTOR FACES STRAIGHT DOWN 7 Re install the lock washers and bolts and Torque to 55 ft Ib 8 Re connect the encoder sensor to the harness 9 Re t
23. s from under the coaster 4 Assemble in reverse order PROJECTOR SCREEN REPLACEMENT There are 3 screen elements that make up the projector screen Fresnel Lens This lens re directs the light beams into a direction that is most advantageous for viewing this lens is mounted furthest to the inside with the smooth side facing out or away from the projector Diffuser Lens This lens is used to reduce the hotspots that would normally be visible if the diffuser were not used This is the screen very similar to that of a movie screen except this is used for back rather than front lighting This lens sits between the Fresnel lens and Cover it has no front or back orientation Cover This is a clear Scratch resistant plastic material that is used to protect the inner screens This can be replaced without removing the other screens 1 Remove the screws that secure the side retainer brackets 2 Remove the screws that secure the top retainer bracket 3 Remove the lenses as needed 18 BLOWER FAN REPLACEMENT 1 Remove the projector screen as indicated in the Projector Screen replacement section 2 Unplug the faulty blower fan and unbolt from the coaster 3 Re assemble in reverse order BELLOWS REPLACEMENT NOTE ALL POWER CORDS MUST BE REMOVED FROM THE A C OUTLETS BEFORE PERFORMING THIS REPAIR FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY 1 Remove the hardware that attaches the top of the bellows
24. tor to the projector mounting bracket 2 Use the spacers provided to mount to the bracket DO NOT OVER TIGHTEN THE SCREWS 3 Mount the projector to the mounting shelf in the coaster LEAVE THE MOUNTING NUTS LOOSE AT THIS TIME 4 Re connect the power and video cable the video cable uses the YELLOW INPUT 19 5 Turn the projector on and wait until the picture becomes visible 6 Once the picture becomes visible rotate the mounting bracket left or right until the picture is centered on the Screen 7 Adjust the focus and zoom to fully fill the screen with the picture 8 Once you are satisfied that the picture is the proper size and fits the screen properly tighten down the mounting bracket nuts NOTE IF YOU NEED TO MAKE ANY OTHER ADJUSTMENTS TO THE MONITOR REFER TO THE PROJECTOR OWNERS MANUAL MAIN P C BOARD DRIVER BOARD AND FLASH CARD REPLACEMENT 1 Remove all A C power to the coaster 2 Remove the rear access cover to the coaster 3 Remove the cover from the electronics box 4 Slide out and replace the appropriate card CL1060 CL1066 CL 1088 P500 CL1087 P500 CL 1090 P500 CL1091 P500 CL1092 P500 CL1093 P500 CL1094 P500 CL1095 P500 CL1096 P500 CL1097 P500 CL1210 P802 CL1211 CL1212 P903 PARTS LISTING DECALS AND GRAPHICS MECHANICAL PARTS U JOINT TIE ROD END REFLECTOR BRACKET MOTION SENSOR BRACKET FENCE ENTRANCE SECTION FENCE SECTION 2 FENCE SECTION 3 FENCE SECTION 4
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