Manual for equipment of amusement parks

Type of attraction: BALLOON FLIGHT

USE AND MAINTENANCE MANUAL

Instructions for use and maintenance

Directions for safety

OPERATING MANUAL

WARNING :
Before working on the ride the staff must know the operative instructions and the directions for
safety contained in the manual and its enclosures.

No part of this manual can be reproduced and/or spread by any means or in any form, modified or
integrated without the Manufacturer’s previous written authorisation.

The Manufacturer reserves to defend his rights and interests in case of unauthorised reproduction
or spreading.
No modification or integration of this manual can be carried out without the Manufacturer’s
authorization.

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MANUAL INDEX

MANUAL INDEX..................................................................................................................................... 2

1. IDENTIFICATION ........................................................................................................................... 5

2. INTRODUCTION ............................................................................................................................. 6
2.1. Guide to consultation ....................................................................................................................... 6
2.2. General warnings ............................................................................................................................. 6

3. SAFETY RULES .............................................................................................................................. 7

3.1. Anti-accident instructions during setting up .................................................................................... 7
3.2. Anti-accident instructions during operation .................................................................................... 7
3.3. General safety rules ......................................................................................................................... 8

4. CONSERVATION OF THE MANUAL.................................................................................................. 9

5. DESTINATORS OF THE INSTRUCTIONS AND THEIR TASKS ............................................................ 10

5.1. Supervisor ...................................................................................................................................... 10
5.2. Operator ......................................................................................................................................... 11
5.3. Assistant ......................................................................................................................................... 11
5.4. Specialized technician .................................................................................................................... 11
5.5. Public ............................................................................................................................................. 11
5.6. Things not to do: ............................................................................................................................ 12

6. INDICATIONS AND INSTRUCTIONS ON THE RIDE .......................................................................... 13

6.1. Indications and instructions for the operators ............................................................................... 13
6.2. Indications and instructions for the public .................................................................................... 13

7. SAFETY ....................................................................................................................................... 14
7.1. Safety precautions .......................................................................................................................... 14
7.2. General precautions ....................................................................................................................... 15
7.2.1. General safety precautions in the using phases of the ride ........................................................................... 16
7.2.2. Before starting the journey (in the case of ride built on vehicles) ................................................................. 16
7.2.3. During the journey (in the case of ride built on vehicles) ............................................................................. 16
7.3. Assembly and disassembly of the ride ............................................................................................ 17
7.4. Connections .................................................................................................................................... 19
7.4.1. Connection to the electric supply system ....................................................................................................... 19
7.4.2. Connection to the pneumatic/hydraulic supply system .................................................................................. 19
7.5. For the public’s safety.................................................................................................................... 20
7.6. General maintenance ..................................................................................................................... 22
7.7. Assistance ....................................................................................................................................... 22
7.8. Repairing........................................................................................................................................ 22
7.9. Atmospheric conditions limiting operation .................................................................................... 23
7.9.1. Recognizing wind speed ................................................................................................................................. 24
7.10. Residual risks ................................................................................................................................. 25
7.11. Guide notes of anti-fire precautions .............................................................................................. 25
7.12. The operators’ training .................................................................................................................. 28
7.12.1. Aptitudes and knowledge...................................................................................................................... 28
7.12.2. Aims of the training .............................................................................................................................. 29
7.12.3. Content of the training ......................................................................................................................... 29
7.12.4. Theoretical programme ........................................................................................................................ 30
7.12.5. Practical programme ........................................................................................................................... 31
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8. PLAN OF THE ATTRACTION ......................................................................................................... 32

9. SAFETY INSTRUCTIONS DURING TRANSPORT AND INSTALLATION ............................................... 33

9.1. Handling , shipping and transport of the ride totally/partly built on vehicles ............................... 34
9.2. General criteria for the matching and use of vehicles ................................................................... 34
9.2.1. Fixing of moving/removable parts during the running of the vehicle ............................................................ 35
9.2.2. Check of the requirements and conditions for installation ............................................................................ 35
9.2.3. Placing and installation of the attraction ...................................................................................................... 36
9.2.4. Characteristics of the ground ........................................................................................................................ 37
9.2.5. Characteristics of the supports on the ground ............................................................................................... 38

10. USE OF THE ATTRACTION........................................................................................................ 42

10.1. Checks and advise before every starting ........................................................................................ 42
10.2. Starting ........................................................................................................................................... 44
10.3. Electric connections ....................................................................................................................... 44
10.4. Starting ........................................................................................................................................... 45
10.5. Adjustments and regulations .......................................................................................................... 47
10.6. General working anomalies ........................................................................................................... 47

11. EMERGENCY SITUATIONS........................................................................................................ 48

11.1. The passengers’ evacuation ........................................................................................................... 49
11.2. Out of order .................................................................................................................................... 49

12. REPAIRS .................................................................................................................................. 50

13. STRUCTURAL MODIFICATIONS ................................................................................................ 51

14. MAINTENANCE ....................................................................................................................... 52

14.1. Ordinary maintenance ................................................................................................................... 52
14.2. Extraordinary maintenance ........................................................................................................... 54
14.3. Periodical maintenance ................................................................................................................. 56
14.3.1. Transmission ........................................................................................................................................ 56
14.3.2. Sprocket bearing .................................................................................................................................. 58
14.3.3. Electric motor ...................................................................................................................................... 59
14.3.4. Hydraulic motor ................................................................................................................................... 62
14.3.5. Hydraulic pump.................................................................................................................................... 63
14.3.6. Heat exchanger .................................................................................................................................... 64
14.3.7. Maintenance of the braking system (ONLY FOR TRAILER MOUNTED VERSION) ........................................ 65
14.3.8. Maintenance of the electric system ...................................................................................................... 69
14.3.9. Maintenance of the hydraulic system ................................................................................................... 70
14.4. Lubrication ..................................................................................................................................... 72
14.4.1. Characteristics of lubricants to use ..................................................................................................... 73
14.4.2. Comparing chart of lubricants ............................................................................................................. 75

15. STRUCTURES ........................................................................................................................... 76

15.1. General instructions for the use and maintenance of structures.................................................... 76
15.2. Checking to carry out periodically on structures........................................................................... 76
15.3. Connections through steel bolts and nuts ...................................................................................... 77
15.3.1. General information ............................................................................................................................. 77
15.3.2. Resistance class.................................................................................................................................... 77
15.3.3. Tightening ............................................................................................................................................ 78
15.4. Connections through pins .............................................................................................................. 79
15.4.1. General information ............................................................................................................................. 79
15.4.2. Checking on connections through pins ................................................................................................ 80

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15.5. Cracks and breaks .......................................................................................................................... 81

16. CHECKING: WAYS OF OPERATION ........................................................................................... 82

17. INACTIVITY ............................................................................................................................. 84

17.1. Preparation to stop ........................................................................................................................ 84
17.1.1. First cleaning ....................................................................................................................................... 84
17.2. Restarting ....................................................................................................................................... 85

18. TECHNICAL DATA.................................................................................................................... 86

19. ENCLOSURES .......................................................................................................................... 87

19.1. Hydraulic system view.................................................................................................................... 87
19.2. Declaration form of manual delivery ............................................................................................. 91
19.3. Explanations request form ............................................................................................................. 92
19.4. Reparations – interventions request form ...................................................................................... 93
19.5. Mistakes and inaccuracies form in the use and maintenance manual ........................................... 94

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1. IDENTIFICATION

Identification of the document:

• Type of document: USE AND MAINTENANCE MANUAL

• Document code: 22700AA5200
• Revision indication: 00
• Document edition: 07/2003
• Copy number: 01

Identification of the ride:

• Type of ride: Trailer mounted

• Name: Balloon Flight
• Serial number: RS/227
• Model (or short description): Family ride
• Year of manufacture:

Identification of the manufacturer:

• Name: SARTORI GROUP

• Address: ZONA IND. – 35044 MONTAGNANA (PD) ITALY
• Telephone number: +39-0429-800222
• Fax number: +39-0429-800333
• E-mail: [email protected]

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2. INTRODUCTION
2.1. GUIDE TO CONSULTATION
2.2. GENERAL WARNINGS

The whole staff will make every effort to understand the nature of the attraction they are responsible for,
including, where necessary, reading and discussing the relevant operating instructions and inspection
reports.

The safety of an attraction can be achieved by means of:

- the understanding of one’s own duties and general responsibilities;
- the execution of periodical checks;
- safe operation;
- proper surveillance;

WARNING:
BEFORE CARRYING OUT ANY OPERATION ON THE AMUSEMENT DEVICE, THE OWNER,
THE CONTROLLER, THE OPERATORS, THE COMMON MAINTENANCE STAFF AND THE
ENGINEERS MUST CAREFULLY READ THE INSTRUCTIONS OF THIS MANUAL (and relevant
enclosures) AND FOLLOW THEM WHILE CARRYING OUT THE OPERATIONS.

They provide important information regarding:

- the safety of the people in charge of transport, packing, installation, assembly and disassembly,
operation, use and maintenance;
- the safety and the efficiency of the amusement device;
- the public’s safety;

WARNING:
All safety-related notices are referred to and/or repeated in the points of the manual where they
need to be used.
If those operating the amusement device do not believe they are able to operate correctly in spite
of reading the instructions in the manual, they must ask the manufacturer, the supplier or the
authorised servicing centre for the explanations they need.

THIS MANUAL IS NOT THE ONLY DOCUMENT SUPPLIED WITH THE RIDE.
In case of modifications, repairs, thorough inspections, and so on, it is necessary to consult and to refer to
other documents such as:
- Design calculations;
- Construction methods;
- Reports and drawings of structures and systems;
- Inspections and approvals;

THIS MANUAL PROVIDES SAFETY REGULATIONS FOR THE USE AND MAINTENANCE OF THE
AMUSEMENT DEVICE. THESE REGULATIONS NEITHER NULLIFY NOR REPLACE THE MANDATORY
ONES OF THE PUBLIC AUTHORITY OF THE COUNTRY WHERE THE ATTRACTION IS INSTALLED AND
USED.
The Manufacturer reserves the right to communicate at any time all information considered useful, necessary
or that has become compulsory, concerning the attraction.
Such information in the form of modification, updating or addition will be considered in all respects as an
integral part of this manual.
The Manufacturer reserves the right to introduce, without notice, all those modifications he considers suitable
both technical and concerning the instructions of this manual.
This manual has been carefully checked, however any responsibility for possible mistakes and/or omissions
is declined.

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3. SAFETY RULES
3.1. ANTI-ACCIDENT INSTRUCTIONS DURING SETTING UP

Before setting up the ride, the operator/s has to know the following safety rules.
The operator must keep in mind that if he uses the ride improperly and neglects any safety rule he could
cause serious damages to people and the ride structures.
Our Company provides the following instructions to be observed:

Before setting up, make sure that in the surrounding area there are no elements which could make the
assembling or the working of the ride dangerous, as well as the passengers’ safety;

During setting up, unauthorized people must not be in the working area;

Assembling must be done by qualified personnel;

Take care to hanging loads and before operating make sure that each load to lift up is properly fixed to the
manoeuvring equipment.

3.2. ANTI-ACCIDENT INSTRUCTIONS DURING OPERATION

As to the accident-prevention rules to be followed during operation, our Company provide the following
prescriptions and restrictions:

People attending to the ride must be adult , qualified and know everything written in this manual as well as
evaluate the danger of the different situations;

Before opening the ride to visitors, the operator will make the ride turn idly for some minutes so to check if
all safety devices are efficient;

Check if START-STOP-EMERGENCY devices work properly;

In no case the operator must leave the power switchboard unattended when the ride is working.

When leaving it, he must be replaced by qualified personnel;

Before every ride, make sure that nobody stops or gets closer to the operating zone of the ride.

Do not tamper with or take away possible seals.

If during operation some passenger tried to get down from the vehicle in motion or others tried to go up,
block immediately the ride through the Emergency button.

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3.3. GENERAL SAFETY RULES

The ride cannot be used by:

-disabled children
-children under the age of 4 or shorter than 1 mt. (40 in) except when accompanied by their parents.
-children with frequent symptoms of nausea;
-children with serious back problems;
-children with serious health problems;
-children with serious psychological problems;
-children with serious illnesses, even if temporary;
-children with such body dimensions that the adopted safety rules cannot be applied.

Besides these prescriptions, the operator must pay attention to the following ones about passengers:
-no-smoking on the ride;
-any object which could fall down during operation ( i.e. bags, rucksacks, mobiles) must be left at the
cashier’s desk. For this purpose expose a warning notice at the entry;
-do not make get on the ride drunk/drugged people.
Pay attention to all those safety rules imposed by the country where the ride will operate. It is anyway the
operator’s responsibility to evaluate and decide which persons to make get on the ride, evaluating every time
the passengers’ conditions.

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4. CONSERVATION OF THE MANUAL

WARNING:
The use and maintenance instructions are safety measures. The manual, which contains them, is
an integral part of the attraction with safe intentions.
IT IS THEREFORE COMPULSORY TO KEEP THIS MANUAL, AND ALL THE ENCLOSED
DOCUMENTS , IN AN EASILY ACCESSIBLE PLACE , ON THE ATTRACTION, AND FAMILIAR
TO ALL THE OPERATORS AND TO THE PERSONNEL IN CHARGE OF MAINTENANCE.

The Controller, the operators, those in charge of the ride should be able to consult very quickly, in any
situation, the manual and its enclosures.

THE MANUAL AND ALL THE ENCLOSED DOCUMENTS ARE AN INTEGRANT PART OF THE
ATTRACTION WITH SAFETY AIMS , AND FOR THIS REASON:

• they must be kept with care, intact (in all their parts), in an environment protected from excessive
humidity and heat;

• they must accompany the attraction in all its passages till demolition (also in case of displacements,
sale or assignment to a third party for any reason, like loan, hiring, rent, etc....);

• they must be kept updated;

• they must cite any modification of the attraction;

• handle the manual with care, with clean hands and avoiding to put it on dirty surfaces.

• Do not tear, remove or modify , for any reason, parts of the manual.

• The Manufacturer, on the client’s request, can provide further copies of the manual.

• In case of damage or loss of the manual, a new copy must be asked for, with reference to the
attraction serial number.

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5. DESTINATORS OF THE INSTRUCTIONS AND THEIR TASKS

To improve comprehension and avoid mistakes of interpretation, find below the people who will enter in
relation, for any reason, with the attraction and the duties they have to carry out.
The tasks related to the user of the instructions (supervisor, operator, assistant, ordinary maintenance men)
can be carried out by a narrower number of people, provided that they have the professional competence for
the operations to perform.

WARNING:
We remind you that all those operating on the attraction must own all the authorizations and
permissions, administrative too (if required)

5.1. SUPERVISOR

The SUPERVISOR is the person in charge of carrying out, under his/her direct responsibility, the direction,
the supervision and the control of the following operations:
- transport;
- assembly and disassembly;
- starting and operation with or without the public;
- maintenance;
- periodical controls and inspections;
- repairs and interventions on the attraction (only those provided for and allowed by this manual).

The SUPERVISOR is responsible for the running of the attraction, and must have the necessary
administrative authorizations which let him practise his/her own activity.
He has to respect and to make respect all the instructions and recommendations of this manual.

The SUPERVISOR can be also identified as OPERATOR when he has to carry out some of the operations
which are going to be defined below.

WARNING:
The assignation of tasks and competences to the operators, assistants and maintenance men has
to be made only by the SUPERVISOR.

The SUPERVISOR must:

 make sure that all the instructions (text and images) contained in this manual and those given by him
to carry out them, are clearly understood by the operators and assistants in charge of operating on
the attraction;
 assure an adequate practical training and make sure, through trials, that the operators are able to
use in a proper and safe way the attraction, both in normal situations and in emergency situations;
 check that those in charge of maintenance are able to intervene in a correct and safe way, and that
know the way to ask for the authorizations expected by the working procedures inside the
SUPERVISOR ’s organization .

For this reason he/she has to make sure that they have at least the following characteristics:
 sufficient general and technical knowledge to understand the content of the manual in those parts
concerning them and to interpret properly designs and schemes, symbols and signs and video
messages;
 knowledge of the main hygienic, anti-accident and technological rules;
 general knowledge of the ride and of the location of the escape routes, of the safety systems, etc. ;
 a detailed experience in the management of the rides and of the amusement parks;
 capacity of operating in any emergency, of finding the means of individual protection, the fire means
and of using them properly.

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5.2. OPERATOR

The OPERATOR is the person in charge of carrying out the following operations concerning the ride:
- transport;
- assembling and disassembling;
- starting and operation with or without the public;
- some interventions of ordinary maintenance expected in the manual;
- cleaning.

These functions have to carried out with the SUPERVISOR’ s direct control (if they are different vehicles).

5.3. ASSISTANT

The ASSISTANT is the person in charge of carrying out some tasks when the attraction is open to the
public.

He has to carry out on time all the instructions given to him by the SUPERVISOR and the OPERATOR.

5.4. SPECIALIZED TECHNICIAN

The SPECIALIZED TECHNICIAN is the specialized, professionally qualified, trained person authorized to
carry out interventions of extraordinary maintenance, repairs, replacements, revisions, which demand a
particular knowledge of the techniques and of the methods of interventions.
(He acts according to the Manufacturer’s instructions or of the authorized service centre.)

Authorized operations by Sartori Company by request of authorization:

- interventions of repair of electrical and/or mechanical failures;
- replacement of broken or damaged parts;
- replacement of safety components;
- any electrical interventions (necessary only in case of failure);
- all the interventions typical of the conductors and of those in charge of ordinary maintenance.

5.5. PUBLIC

In this manual are cited the instructions concerning the public, standing out, in this field, two figures:

SPECTATORS: they are the people who, as to the ride, are in the position and condition of assisting to the
operation of the ride or are waiting for using the ride as passengers.

PASSENGERS: they are the people who use the ride placing themselves in the suitable places, such as
vehicles, seats, corridors, platforms, walkways, etc. ... , and who are in active or passive conditions ,
depending to the moving characteristics of the ride, for enjoyment, emotion or fun.

The public’s indications and instructions are given by:

- the operators and/or assistants ;
- the notices and/or signs on the ride.

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5.6. THINGS NOT TO DO:

 To introduce structural changes of any type;

 To introduce changes to hydraulic, pneumatic or electric installations;

 To change the operating speed of the attraction;

 To remove or break any seals;

 To change the safety limits;

 To change or remove safety-guaranteeing devices or systems;

 To change or remove control mechanisms;

 To change or remove the holding structures (gates, bulkheads, etc.) supplied with
the attraction;

 To install fixed devices inside the attraction without previous authorization of Sartori
Company’s technicians.

If the owner and/or supervisor of the attraction provides directly or through third parties for the
execution of any variation of the structures and/or installations without any previous approval of
Sartori Company, he will be responsible for any harmful consequence which could occur to people
and/or structures being the attraction stationary or in motion.

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6. INDICATIONS AND INSTRUCTIONS ON THE RIDE

The attraction is handed over equipped with metallic plates and/or sticky labels with indications important for
assembly and disassembly, operation, safety systems, instructions for the operators and the public.
These indications do not replace the prescriptions contained in this manual and the other documents
equipping the attraction and supplied by the Constructor.
They therefore cannot be considered the only rules to observe, but they have to be considered as an
integration of the directions of this manual.

WARNING:
The SUPERVISOR has to make respect, both by those in charge and the public, all the warnings
on the notices on the ride, to keep them always legible, to replace them (with others identical or
asked to the Manufacturer) in case of loss or damage.

WARNING:
The information cited directly on the attraction has to be legible, visible and kept clean for all the
lifetime expected for the attraction.
It is not allowed to remove and/or damage the plates.
In case of damage it is necessary to replace immediately the plate with a new one citing the same
instructions of the old one.

6.1. INDICATIONS AND INSTRUCTIONS FOR THE OPERATORS

In the components reachable for the starting/maintenance operations the safety instructions and the cares
which have to be scrupulously observed by the personnel in charge and by anyone intending to enter these
components for any reason are mentioned.

6.2. INDICATIONS AND INSTRUCTIONS FOR THE PUBLIC

The notices point out those people who are forbidden to use the attraction (for example: people with heart
troubles, pregnant women, children without an adult , people altered by alcohol or narcotics, people shorter
than ... cm, etc. ... ).

In no case no changes can be made to the notices to the public concerning:

- the passengers' proper placement on the ride ;
- the operation and the control of the safety systems;
- the behaviour to keep not to endanger themselves or the others.

WARNING:
The multilingual indications and/or signs are not supplied with the attraction as they have to be
personalized according to the country of destination and the environment where the attraction is
introduced.

Other instructions for the public will be charged to the administrators or those in charge of the attraction.

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7. SAFETY
7.1. SAFETY PRECAUTIONS

The public using the attraction is right to expect a high safety level, in particular when the possible risk
situations are out of one’ control ( for example those coming from the machines, the electrical components ,
etc. ...).
It is therefore necessary to keep this safety level, carefully observing the instructions of this manual, and
making them follow by their receivers : safety, in fact, does not realize by itself, but demands everyone’s
engagement, the personnel’s and also, as far as is due to him, the public’s.
In this chapter is given general information in order to inform the controller, the operator, and the assistants
about the precautions, the cautions and the particular attentions to adopt in the use (in a wide sense) of the
attraction.
There are also indicated the particular precautions to observe and to make respect to the public and the
passengers, to avoid the arising of dangerous situations, or to eliminate and neutralize particular risks.

WARNING:
SOME PICTURES OF THE MANUAL REPRESENT THE ATTRACTION, OR PARTS OF IT,
WITHOUT SAFETY LOCKS OR WITH THE NON-INDICATED, REMOVED SAFETY
EQUIPMENT OR WITHOUT PROTECTION DEVICES, GATES, SHELTERS, SUPPORTS, ETC.
... THIS HAS BEEN MADE ONLY FOR NEEDS OF ILLUSTRATION OR EXPLANATION
ABOUT OPERATIONS WHICH CAN CONCERN EVERY COMPONENT.

IT IS ALWAYS FORBIDDEN TO USE THE ATTRACTION WITHOUT LOCKS, SAFETY

DEVICES, PROTECTIONS IN GENERAL, WHICH ARE CITED IN THIS MANUAL AND IN THE
PROJECT, CALCULATION AND MANAGEMENT DOCUMENTS OF THE ATTRACTION

WARNING:
This manual contains safety regulations for the use and maintenance of the attraction. When
selling and/or using the attraction out of the territory of the Italian Republic, you will observe the
accident-prevention, safety, industrial hygiene, fire-fighting, performance safety and public safety
dispositions in force in the country where the attraction will be used.

In Italy these regulations have to be fulfilled observing the safety rules against industrial accidents provided
for in the D.P.R. 27 April 1955 N. 547 and so as modified and integrated by the D. Lgs. 19 September 1994
N.626, and successively by the D. Lgs. 19/3/96 N.242, and also observing all the accident-prevention,
safety, industrial hygiene, fire-fighting dispositions (D. Lgs. 19 August 1996 N.149), provided for in the laws
in force in Italy and which will be issued by the authority afterwards.

As information, we remind you that in the EU countries these regulations must be brought about in the
observance of the following instructions and rules:
- 89/391/EEC "Measures to promote the improvement of the workers’ safety and health during their work";
- Particular instructions according to the art. 16 par. 1 of the Directive 89/391/EEC

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7.2. GENERAL PRECAUTIONS

The owner and/or supervisor of the attraction will have to provide for a proper training of the personnel in
charge (operators, assistants and anyone operates on the attraction) about the operating system and the
working of the attraction, the safety devices, the risks from noise emissions, respecting all the accident-
prevention, safety and industrial hygiene, fire-fighting and public safety regulations provided for in the law in
force in the country of installation and use of the attraction.

The operators and the assistants will have to follow the regulations of this manual , and those given by the
supervisor, besides the rules cited above, in force in the country of installation and use of the attraction.

They have in any case to fulfil these obligations:

• to know the characteristics of the attraction, above all in relation to one’s tasks;
• to use the attraction only for the purpose it is assigned for and in the respect of the regulations contained
in this manual;
• to know perfectly the position and the working of all the controls of the attraction, none excluded;
• to operate always in the safety zones indicated in the manual;
• do not remove nor disactivate protection carters, safety devices, locks, mechanical, electric or other
protections, except at the conditions provided for in the manual;
• do not lubricate, repair, register members in motion;
• do not go near members in motion or at high temperatures;
• do not introduce parts of the body through slits or holes of the attraction;
• do not leave the attraction unattended when it is operating or it can operate;
• to pay attention to the safety notices mentioned in various parts of the manual and on the attraction;
• to know and follow the using procedures in the public’s presence (spectators and passengers);
• to demand from the public the respect of the safety indications and the notices on the attraction and the
rules of normal prudence;
• to know and follow the emergency procedures;
• to follow the instructions of the manual and the controller’s;
• do not do operations which are not perfectly known;
• to behave so that not to put into danger one’s and other’s safety.

The explanations concerning the safety systems have to be perfectly understood since:
• they identify the risks and their causes;
• they point out the consequences for the persons and/or the things;
• they explain the correct behaviours to eliminate or neutralize the dangers and/or the risks discovered;
• they illustrate the safety behaviours, the safety devices and their correct use.

WARNING:
ANY INTERVENTION ON THE ELECTRIC OR MECHANICAL PARTS MUST BE DONE BY
SPECIALIZED TECHNICAL PERSONNEL KNOWING THE SYSTEMS ON THE ATTRACTION.

WARNING:
If, during any using phase of the attraction (transport, assembly, disassembly, use, maintenance,
etc. ...), for any reason, there is only the simple suspect of incorrect or unsafe operation of the
attraction, anyone is operating must immediately interrupt any activity, so that not to jeopardize
anyone’s safety, till the complete putting back in operation of the safety conditions..

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7.2.1. General safety precautions in the using phases of the ride

• The attraction must be always used, assembled and disassembled by qualified and suitably trained
personnel.

• Before starting the attraction make sure that there are no persons in the dangerous zones and/or they are
not doing any cleaning or maintenance operations.

7.2.2. Before starting the journey (in the case of ride built on vehicles)

• Check that all the fasteners and the precautionary measures, in particular those of the opening parts, are
inserted.

• Check the proper operation of the brakes and their correct connection.

• Check the proper operation of the lighting and visual signalling devices.

• Check the state of the tyres.

• Check that the loading is within the lawful gauge.

• Do not overcharge the vehicle beyond the expected testing limits.

7.2.3. During the journey (in the case of ride built on vehicles)

• Respect speed limits.

• Make bends, especially if at narrow radius, adopting a moderate speed.

• Respect the highway code in force in the country using the attraction.

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7.3. ASSEMBLY AND DISASSEMBLY OF THE RIDE

• Follow always the instructions purposely supplied by the Manufacturer in this manual and during the
owner’s and/or supervisor’s training course.

• Follow a safe working system as established by the laws in force.

• Pay a lot of attention to moving the vehicles within the place destined to the installation of the attraction.
Do not move them if in the area there are persons from the public or children. Look always for somebody
else’s help when going into reverse, unless you are not sure that there are no risks for people and/or
things.

• Do not assemble/disassemble the attraction in case of unfavourable weather conditions (wind, rain, snow,
fog, ice, etc. ...).

• During the assembly and disassembly of the attractions, use all the temporary guys, the props, the
supports and the fixing devices necessary to avoid damages caused by the fall of parts of the attraction.

• Check that all the parts to assemble do not have any signs of break, tear, rust, etc..., checking in
particular the safety critical components (safety locks, cables for electric connections, etc. ...).

• Cylinders, tubes, exhaust valves of the hydraulic and pneumatic installation do not have to be damaged,
degraded, crushed.

• It is not allowed the presence of unauthorized people : if necessary install barriers and warning notices.

• Make sure that the ground is free from obstacles, is solid and no foot, or support on the ground , is
placed on drains, underground pipes, electric cables, or unsuitable ground for the characteristics of the
attraction.

• The ground must allow an adequate water draining.

• Do not work under hanging parts.

• The personnel must keep at safety distance and out of the sliding, going up and coming down trajectories
of the moving parts.

• Before every motion, check that the personnel are at safety distance and give suitable advance notices
(acoustic and/or visual).

• Adopt all the precautions to avoid the dangers a super-elevated electric line can cause to personnel or
public.

• The attraction must be mounted so that to:

• respect the safety distances among the various attractions and/or pavilions;
• allow the public’s safe entry and exit;
• allow the intervention of the rescue means.

• Check at the end of assembly that tools which could cause incidents and/or breaks have not been
forgotten.

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• Once completed the assembly the supervisor must verify that all the important safety elements (structural
elements, connecting parts, closing parts, safety devices, electric installation, etc. ...) have been properly
installed and correspond to the official book of the construction.

• Lighting must be sufficient and suitable to the assembly and disassembly operations so that they may be
carried out in a safe and correct way.

• Suitable tools and utensils must be used, in particular those to lift up loads.

• Respect the accident-prevention rules, in force in the destination countries, and use the individual
protection devices (safety belts, helmets, etc...).

• When it is necessary to work in height supply yourself’ with anti-falling devices.

• Emergency equipment must be pointed out by special signs.

• Do not ever keep lowered the hydraulic jacks to support the operating attraction, use the suitable feet and
stabilizing foot-straps.

• In some attractions with raised platforms, under the platform there can be a dangerous area. Do not allow
the entrance to these areas, in particular if the attraction is installed on a sloping ground.

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7.4. CONNECTIONS
7.4.1. Connection to the electric supply system

• The installation works concerning the electric connection must be done by competent and suitably
trained personnel.

• Use tools protected from shock risks (electrocution).

• Before carrying out any maintenance, cleaning, adjustment intervention on the electric board it is
necessary to stop the attraction, to put it in maintenance state and adopt the protecting devices required
by the operation.

• The lighting accessories and eventual heaters must be placed respecting the fire-fighting dispositions
and rules.

• The boxes and the electrical devices must be opened by qualified personnel (maintenance electrician).

• If supply cables are on the ground, must be placed suitable barriers or other means to avoid dangers to
the people who:
• assemble or disassemble;
• work;
• pass by vehicles or on foot;
• use the attraction.

• If the supply cables are underground pay attention they are not hit by poles or stakes or mining works.

• Pay particular attention to the earthing of the attraction. The earth resistance and the dispersors must be
of suitable sizes in accordance with the laws in force in the installation country of the attraction.

7.4.2. Connection to the pneumatic/hydraulic supply system

• Before intervening on any pneumatic and/or hydraulic element it is necessary to isolate the circuit from
the supply source and discharge completely the pressure from the circuit and the various components of
the pneumatic and/or hydraulic system.

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7.5. FOR THE PUBLIC’S SAFETY

• Avoid the public’s presence in the zones where the attraction is being assembled or disassembled, or you
are operating on it. If necessary, the checker or the authorized person must use every means to avoid the
public’s entrance.

• Block or reduce the public’s presence inside the passengers loading and unloading zones, avoiding
crowds.

• Keep free, dry, clean and in order the zones around the emergency exits to allow a rapid flow if
necessary.

• Keep free, dry, clean and in order the walking ways, the flights and the ladders to avoid falling risks to the
public and the operators in charge.

• Supply the attraction with fire-fighting extinguishers according to the laws of the country where the
attraction will be used.

• These regulations, as all the others concerning the passengers contained in the manual, are meant also
valid for the Service Personnel when these, for any reason, occupy positions normally destined to the
passengers and/or public, or way-outs.

• A person’s exclusion for health and safety reasons is not a discrimination.

• Considering the characteristics of the attraction, going up is not allowed to:

• children with an age lower than the minimum admitted according to the characteristics of the
attraction;
• drunk or drugged people;
• pregnant women;
• people with heart problems or precarious health conditions;
• people with such physical and/or psychological handicaps that they cannot be sufficiently
fastened by the passengers’ holding devices.
• people with such body dimensions that they do not permit a proper and comfortable use of the
passengers’ holding devices ( handles, etc. ...).

• On the attraction the passengers cannot eat and/or drink, smoke, bring animals, umbrellas, sticks, bulky
pointed objects or that in any case can become blunt dangerous instruments.

• The passengers must in any case behave not to put in danger their own and others’ safety, for example
by creating crowds, leaning out, standing up, eluding the safety devices , etc. ... .

• Clothes must not be any danger for the public. In particular scarves, foulards, etc…must be avoided
because they can get entangled in fixed or moving parts. Unworn clothes cannot be taken on the
attraction.
• Avoid wearing parts and personal objects which could be lost during operation.

• Check that all the components of the passengers’ holding system included seats, bars, belts, slings,
hand holds, foot-rests, locks, bolts, hinges and all the other fixing points are submitted to a suitable
maintenance and properly adjusted so that to be safe and minimize the public’s consequences caused
by the movement of the attraction. Do not let the passengers use any part of the attraction whose holding
system is faulty.

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• Train, instruct and request that the operators and the working personnel take reasonable measures,
included the stop of the attraction if necessary, to avoid that the passengers :
• intentionally abuse the equipment provided for their safety ;
• behave imprudently;
• ignore in a deliberately imprudent way every clear reasonable instruction.

• These regulations must be made respect by the Personnel in Service also through suitable clearly visible
signs. When, for the presence of ethnic minorities or tourists, it is probable that there are passengers
unable to understand the national language, it is highly recommended the use of multilingual signals.

• Except for particular agreements, the public’s and passengers’ signals are at the expense of the owner of
the attraction. The used signals will have to consider the laws and/or prescriptions of the authorities of the
country where the attraction will be used.

• Shifts must not be tiring, considering the type of attraction and the functions the operators and/or
assistants have to carry out. An excessive weariness can reduce concentration and create dangerous
situations because of a larger facility of error. It could be necessary to divide the periods of greater
crowding in more shifts.

• Make sure that all the personnel of the attraction can be easily identified, wearing easily recognizable
clothes (for example: hats, uniforms, bands at the arm, etc. ...).

• The Manufacturer of the attraction has not any elements to fix, in this manual, the length of the shifts for
every possible situation. It’s the Supervisor’s concern to estimate, case after case, the real working
conditions and establish length and rotation of the shifts.

• However, it is useful to state some criterions of evaluation (as a non-exhaustive example) :

- the public’s crowding ;
- kind of public (more or less disciplined) ;
- part of the day (morning, afternoon or evening) ;
- climatic conditions ;
- limits and rules imposed by the legislation in force;
- operators’ and assistants’ personal health conditions;
- etc. ... .

• Do not allow that smoke, lighting effects or of other kind stop or reduce visibility.

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7.6. GENERAL MAINTENANCE

A correct, efficient and periodical maintenance assures a longer service life to all the structures and
mechanisms and reduces the danger of accidents. Submit the attraction to an accurate maintenance
according to the programme specified in this manual.

• Check periodically:
• the structures;
• the tightening of the bolts;
• the state of the joints and the welds;
• the state of the mechanical safety devices;
• the lifting, sliding, working members by promptly replacing those worn or damaged;
• the safety devices.

• Eliminate quickly any beginning of rust.

• Check the good state of the wooden supports which do not have to have any cracks or other damages.

• Use always the Manufacturer’s original spare parts.

• Check that tools for maintenance operations have not been forgotten.

7.7. ASSISTANCE

• Assistance intervals recommended by the Manufacturer must never be exceeded.

• If it is necessary to use spare parts different from those specified by the Manufacturer, these changes
have to be considered as variations and need the written authorization of the Manufacturer and the
Authority in charge of the periodical controls.

7.8. REPAIRING

• The repairing of damaged parts must be done cautiously, because this could move from the documents
of the original project. For example, the stiffening or reinforcing of a component can produce greater
tensions in the nearby components, which then by turn break down. Changes of this type must be
considered variations and therefore need the written authorization of the Manufacturer and the Authority in
charge of the periodical controls.

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7.9. ATMOSPHERIC CONDITIONS LIMITING OPERATION

• We recommend to use particular caution in case of strong wind.

• Do not assemble or disassemble the attraction in case of wind.

• Do not use the attraction with adverse atmospheric conditions.

• The attraction has not been calculated for snow loading, and so any snow has to be quickly cleared.

• The attraction must not operate when the following atmospheric conditions take place:

• rain, snow, hail or fog;

• storms with lighting danger ;

• wind with a speed higher than the greatest authorized in the planned documents of calculation
and management of the attraction.

• Because of precipitations, the carrying capacity of the ground could vary: after rain or snow we
recommend to keep particularly controlled the levelling of the attraction and the state of the
wooden supports.

In case of humid places (fogs, etc. ...) or precipitations, some parts of the attraction can become more
slippery : therefore remove the deposits of water and frequently drain the interested areas.

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7.9.1. Recognizing wind speed

It is important to recognize the wind speed and direction and the effects it produces on the structures.
For want of suitable measuring instruments (for example anemometers) which give precise numeric
information, it exists a visual method which permits a general estimate of speed.

The table in this paragraph supplies this guide.

We recommend an extremely prudent use, being subjective estimates the operators in charge must do in
presence of wind, mainly going by their own experience.

DENOMINATION, SPEED AND IDEAL PRESSURES TABLE CORRESPONDING TO THE WIND

N° Wind Corresponding wind Dynamic Remarks

denomination pressure
in km/h in m/sec in kg/m2
0 Calm 1,08 0,3 0,006 Calm : smoke rises vertically
(Perfect calm) 3,60 1,0 0,0086
1 Puff of wind 6,12 1,7 0,25 Wind direction indicated by the smoke deviation,
(light breeze) but not the wind sleeve
7,20 2,0 0,34
2 Mild breeze 11,16 3,1 0,82 Wind felt on face; the leaves rustle; a normal wind
(Mild breeze) sleeve is moved by the wind.
14,40 4,0 1,37
3 Stiff breeze 17,28 4,8 1,97 Leaves and branches move constantly; wind
(Light wind) spreads out light flags
21,60 6,0 3,08
4 Moderate wind 24,12 6,7 3,84 It raises dust and pieces of paper; small branches
(Moderate wind) move
28,80 8,0 5,48
5 Tense wind 31,68 8,8 6,64 Small trees begin to sway
(Fresh wind) 36,00 10,0 8,56
6 Fresh wind 38,52 10,7 9,81 Big branches in motion; it is difficult to use
(Strong wind) umbrellas
43,20 12,0 12,32
7 Strong wind 46,44 12,9 14,25 All the trees are in motion; it is difficult to walk
(Very strong wind) against the wind
50,40 14,0 17,68
8 Storm 55,44 15,4 20,30 The branches are torn up from the trees; it
(Stormy wind) generally hinders from walking
61,20 17,0 24,75
9 Strong storm 64,80 18,0 27,70 Light structural damages are recorded (tiles and
(Tempest) chimney-covers are swept away from the roofs)
72,00 20,0 34,25
10 Tempest 75,60 21,0 37,70 It rarely happens in the hinterland, uprooted trees,
(Strong tempest) serious structural damages are recorded
82,80 23,0 45,30
11 Violent tempest 86,40 24,0 49,00 It happens very rarely; accompanied by structural
(Storm) damages in the whole interested area
108,00 30,0 77,00
12 Hurricane 144,00 40,0 140,00
(Hurricane) 180,00 50,0 214,00
nc Unclassified 181,00 50,60 220,00
188,00 52,15 235,00
193,00 53,66 245,00
198,00 55,00 260,00
204,00 56,50 275,00

Denomination, speed and ideal pressures table corresponding to the wind

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7.10. RESIDUAL RISKS

When the operations to carry out imply residual risks for the operators, that is risks which cannot be totally
eliminated, in the related instructions are given the:
- instructions related to these risks;
- methods to reduce them;
- eventual protections to adopt.

7.11. GUIDE NOTES OF ANTI-FIRE PRECAUTIONS

These guide notes refer both to fixed attractions and to moving ones. They contain practical suggestions
about anti-fire safety but do not supply an authoritative interpretation of the rules and laws for the fire safety.
For further information about how to comply with the legal requisites it is necessary that the operators
contact the competent authorities.

The anti-fire procedures vary according to the laws in force in the country of installation and use of the
attraction and have to be agreed with the anti-fire service or the fire brigade.
The checker, the operators and the personnel in charge of the attraction have to be instructed on the anti-fire
procedures.
A notice about the anti-fire procedures must be exposed in a position agreed with the anti-fire service. This
notice must also quote the number and the means that have to be used to call the anti-fire service itself.

The extinguishers must be placed where they are visible at once and easily accessible. They must be
marked by notices in accordance with the rules in force in the country where the attraction will be used.
Arrange with the anti-fire service or the local authorities the number and the placing of the extinguishers. In
zones with electric boards or anyway with electric dangers special extinguishers are used and signs
highlighting the electric danger.

DANGER OF FIRE PRACTICAL PRECAUTIONS

1. Presence of combustible 1. Reduce to a minimum the combustible materials and if possible keep
materials, in particular : them safe; observe in particular what follows :
a) Furnishing. a) Make sure that furnishings are supplied with suitable resistance to fire.
b) Combustible materials, b1) Do not store more combustible than what is necessary or allowed.
including inflammable b2) Keep the inflammable liquids, such as petrol, in suitable closed
liquids and GPL. containers and clearly marked to indicate the content.
b3) Keep the containers in a safe way in order to prevent the access to
unauthorized people. Do not place them under lorries, near cables
or other electric equipment.
c) Rubbish. c1) Supply with fireproof containers for rubbish and empty them
regularly.
c2) Prearrange the regular collecting of the rubbish left on the ground.
c3) If it is not possible to get immediately rid of rubbish, keep it away
from lighting sources, the other inflammable materials, etc and keep
it safe.
d) Vegetation. d1) Keep grass short and the GPL depots free from weeds.
d2) Water vegetation during dry season.

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DANGER OF FIRE PRACTICAL PRECAUTIONS

2. Misuse of equipment which 2. Check regularly the conditions and the use of equipment, including
use solid, liquid or what follows :
gaseous combustibles.
Misuse includes what follows :
(TYPICAL EXAMPLES …….)
a) Lack of maintenance. a) Make sure that they are subjected to maintenance according to the
Manufacturer’s instructions. It could be necessary to rely on a
competent person to check and carry out maintenance.

b) Dangerous places. b1) Do not use free fires near combustible materials.
b2) Do not use free fires inside the structures and in the public’s
presence. If they are used in other moments, keep the equipment
constantly checked and take them to a safe place with the fire out
before the public’s admittance.

c) Obstruction of ventilation. c) Check there is a proper ventilation to :

c1) Permit a correct combustion and a safe leak of the products of
combustion ;
c2) Avoid overheating the equipment.

d) Refuelling. d) Refuel the combustible tank, or change the gas cylinders, in the open
air or in a well ventilated area far from lighting sources. Do not refuel
when the engine or the generator are working.

e) Restarting. e) Do not try to restart a discarded oil heater while the heater is still hot.

3. Abuse of electric 3. Visual regular checks with checking and testing by a competent
equipment, including what person.
follows :

a) Inadequate installation,
cables passing in unsuited
zones, etc. ...

b) Lack of maintenance.

c) Unauthorized and
temporary repairs, incorrect
connectors, badly
dimensioned cables and
fuses, etc. ...

d) Overload.

e) Equipment left on when

unused.

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DANGER OF FIRE PRACTICAL PRECAUTIONS

4. Smoking or abuse of 4.1) Do not allow smoking in dangerous areas, particularly near
smoking materials (for combustible materials and tented, inflated or similar structures.
example matches). 4.2) Where smoking is allowed supply with ashtrays, etc.

5. Contractors and 5.1) Clearly explain what they can and cannot do.
maintenance workers’ 5.2) Acquaint them with every particular fire risk and your own safety
behaviour : policy and the relative precautions.
- welding jets ; 5.3) Regularly check their work.
- hot metal.

6. Unauthorized 6.1) Make all the personnel conscious of the importance of the protection
access/arson. of the installations.
6.2) Keep very few inflammable materials and in the most protected way.
6.3) Regularly check the installation place of the attraction.

Guide notes of anti-fire precautions

Note: This list is not exhaustive but should help to identify the main dangers and the related
precautions to take. The fire brigade, present in the installation and working place of the attraction,
can supply with much more detailed suggestions, especially about problems like the safe
conservation of inflammable materials.

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7.12. THE OPERATORS’ TRAINING

The information contained in this paragraph is a help for the people in charge of the attraction who have to
train the employed personnel.
The specific training on every single attraction is agreed with the Manufacturer.

The running of the attractions must consider the safety of the people and goods situated in their field of
action
The attractions are often machines of considerable value and occupy a key position in the amusement
parks.
The operators have therefore to be attentively selected and have to receive a basic training of specialized
experts.
It is also important that people who make part of the assembling team receive a suitable training.

It is recommended to keep a record of all the given training and of all the tests made to verify the
understanding of the operators in charge of the attraction.

The personnel will regularly have to follow training and refreshing courses, especially after changes caused
by a variation related to safety, or a change of the way with which the public is handled. If the lighting system
is changed, smoke is introduced or the points of access to a device are changed, it will be necessary to
evaluate these effects and if the procedures have to be changed.

7.12.1. Aptitudes and knowledge

The operators must have at least the minimum age provided in the laws in force.
They must be recognized fit from the medical point of view for practising.
Moreover, the following aspects must be considered:

a) Physical:
- sight and hearing;
- lack of dizziness when operating at a certain height;
- lack of disturbs and incapacitating illnesses for the expected tasks;
- lack of disturbs due to drug or alcohol.

b) Psychological:
• behaviour under tension states;
• mental equilibrium;
• sense of responsibility.

You can carry out some tests to determine the operators’ attitude ( manual ability, attention, good sense,
self-control, calm, accuracy, coordination of movements and reflexes).

The operators have to be able to understand and read the language in which the documents and the
information plates of the attractions and the passengers units are written.

If the operators have to move the attraction on road, they have to know the related laws and have the
necessary documentation and own the authorisation to drive if requested by the local legislation.

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7.12.2. Aims of the training

The aims of the training are:

a) to supply with the complete knowledge of the rules applicable to the attractions and their environment, to
put them on duty , out of order and to use them in safety;

b) to supply with the knowledge of the hand signals, radio communications, equipment and sufficient
technique for loading and assembling move so that the operator:
- carries out the operations efficaciously and without danger for himself and the others;
- is able to carry out normal and emergency operations;

c) to supply with the technical knowledge of the attractions, the passengers units, their characteristics, their
usage, the mechanisms and the safety devices, sufficient to:
- drive different attractions of the same type;
- make optimal use of their characteristics;
- identify their defects;
- do controls and inspections;
- know how to use their documentation;

d) the acquisition of the management and usage ability related to:

- working instructions;
- passengers’ evaluation and selection;
- optimal use of the control devices and the equipment providing the attraction;
-
e) to supply with the knowledge of the first aids interventions to give to the passengers and the public in
case of illnesses and/or accidents.

7.12.3. Content of the training

The content of the training programme is the essential factor to reach the aims.
It must include, besides the programme, the control requirements.

The control requirements, for every vehicle, must define what follows:
a) the knowledge level the operator/assistant must reach;
b) teaching methods, means, supports and recommended means of information.

Being general instructions, these matters have not been developed in this manual.

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7.12.4. Theoretical programme

The programme is the list of what have to be taught. It is given below per arguments and not chronologically.

a) The operator:
- his aptitudes and responsibilities;
- his role and his tasks in the various living phases of the attraction (assembling, use, inspection, etc.)

b) Technology of the equipment for amusement parks:

- terminology and characteristics;
- types of attractions;
- engines (running principles);
- mechanisms (cinematic chain, running principle and suitable order);
- brakes, moving limiters and speeds (operating principles and tests);
- electric equipment for distance order (operating principle, safety functions: tests and assembling);
- hydraulic and pneumatic ordering equipment (operating principle, safety functions: tests and assembling);
- safety devices (operating principle: tests and assembling ).

c) Starting and out of order:

- connection and supports on the ground (stabilizers, anchor systems );
- specific assembling (with lifting self-assembling devices );
- auxiliary assembling devices and accessories (generator groups, etc. ...);
- electric power (dangers, protection systems);
- hydraulic and pneumatic systems, fuels (dangers and precautions);
- assembling, starting, tests, disassembling, maintenance operations;
- transfer of the attraction to a square or on the road .

d) Moving parts of the attraction during assembling:

- slinging equipment (instructions for use);
- equipment for lifting loads (instructions for use);
- instructions for moving hand loads;
- loads (evaluation, gravity centre, balance, influence of the wind);
- normal moving operations (preparation of a load);
- a load moving with a lifting equipment;
- transport of the personnel

e) Use of the attractions and safety rules:

- passengers’ disposition, charging and discharging (choice of procedures for optimal use);
- activation and check of the safety and passengers’ keeping devices;
- indications and limitations for the public;
- stability of the attraction;
- influence of weather and environmental conditions (for example low temperatures, fog, wind, storm,
lightning, dust, smoke, corrosive atmosphere);
- attraction areas and related instructions (tension lines, other lines, prohibited and dangerous areas, other
attractions, radio transmitters, air traffic, noise/pollution limit);
- start/stop procedures;
- prohibited/dangerous operations;
- use limits of the attraction;
- specific instructions concerning the attraction or the used place;
- intervention procedures (in normal and emergency conditions).

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f) Operation:
- the operator’s cabin (access, safety and characteristics contributing to the operator’s comfort);
- control instruments and equipment;
- helps for driving (indicators and signs);
- appropriate use of motions and their combinations;
- appropriate effectiveness of the various mechanisms for the proper and safe operation.

g) Communication:
- hand signals (direct or release signals);
- radio communication;
- control through television circuit.

h) Inspection, maintenance:
- use of documentation;
- regular inspections and inspections before using;
- reports about bad operation;
- interventions in case of bad operation or lack of energy for operation.
-

7.12.5. Practical programme

Besides what follows below, the practical programme includes the visualization of the components, the
devices and the equipment mentioned in the theoretic programme.

a) Operative exercises:
- use of commands, operative helps and control instruments;
- operation without passengers and with ballasts;
- automatic and manual operation;
- preparation of the attraction for removal on road.

b) Assembly/disassembly exercises:
- load moving
- moving of parts of the attraction;
- moving of loads with big horizontal surface;
- moving of loads with big vertical surface;
- moving of self-assembling parts;
- sling exercises of load and driving;
- communication exercises through hand/radio signals.

c) Exercises in the use, tests, maintenance, and emergency situations:

- stabilization and supports of the attraction;
- starting/stop procedure;
- regular inspections (brakes, safety devices, etc. ...);
- lubrication/level control;
- emergency procedures.

Continuation of the instruction:

The described training is intended only to give the operator the necessary knowledge and ability for
an appropriate and safe use of the attraction. The operator’s capacity can be developed only
through the experience obtained by working in real conditions and under suitable control. For these
reasons, it can be useful to record chronologically on a training paper all the acquired experiences
acquired on different types of attraction. It is also necessary to plan sessions to update the
operator’s knowledge to re-educate those who have temporarily stopped the activity and give the
operators an up-to-date training in conformity to the occurred technical changes and improvements.

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8. PLAN OF THE ATTRACTION

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9. SAFETY INSTRUCTIONS DURING TRANSPORT AND INSTALLATION

WARNING:

The raising, moving, transport operations of the attraction and of its components have to be
exclusively entrusted to personnel expert in these operations.

During the operations the personnel have to wear means of individual protection expected by the
laws in force in the country of installation and use of the attraction (for example: helmets, gloves,
safety shoes, overalls, etc. ... ).

The personnel have to respect, among the others , the following general rules:
- get away from loads before raising and lowering;
- do not stop under hanging loads ;
- keep away unauthorized people.
If the charge has to be driven during the raising , use suitable equipment to keep the safety
distances from the raised part or component.
If the bulk of the raising load does not allow a sufficient visibility to the operator, the presence of
an assistant is necessary.

For information about the coding of the notices and the equipment used by the assistant on the
ground during the moving phase, it is necessary to refer to the rules in force.

People and things can be damaged by neglecting these precautions.

Also the transport has to be carried out by trained authorized staff.

On the transport means (lorry boxes or railway carriages or containers), the attraction or its parts
have to be fixed by bands or other suitable means to avoid their overturn.

If the manuals are put into the packaging, it is necessary to give the operators in charge of
transport an extract with the information of this chapter regarding them.
The extract can be enclosed to the packaging in an envelope accessible from outside or
delivered together with the travelling documents.

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9.1. HANDLING , SHIPPING AND TRANSPORT OF THE RIDE TOTALLY/PARTLY BUILT ON VEHICLES
9.2. GENERAL CRITERIA FOR THE MATCHING AND USE OF VEHICLES

• For semi-trailers, the maximum values of the drawing relation refer to the relation between the
maximum mass on the ground axes of the semi-trailer and the tare of the tractor plus the maximum
load on the fifth wheel. Towing mass of the tractor stands for the whole mass with a full load of the
semi-trailer.

• The vehicle group must be equipped with approved pulling members both on the tractor and on the
trailer or semi-trailer. The approval derives from the stamping on the member itself showing the
Manufacturing Company and the details of the approval.

• The towing members of the vehicles and their braking devices have to be compatible between them
for structural and functional characters.

• The vehicle body has to be inscribed in the curve of minor radius described by the tractor vehicle.

• The vehicle body, not to have particular circulation problems , should be inscribed in the circular
crown (encumbrance sector) with a 12,50 m external ray and a 5,30 m internal ray ( regulation
encumbrance sector used in the E.U. countries).

• The attack systems of the joints of the lighting and braking devices must be compatible among them.

• There must be no interference between the two vehicles of the complex when it runs on altimetrical
bends of the road surface.

• All the obligations fixed by the rules in force in the country of destination and/or use of the attraction
must be observed.

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9.2.1. Fixing of moving/removable parts during the running of the vehicle

Clamps are:
- usable without using specific equipment (extractors, special tools, etc. ...);
- placed in easily surveying positions;
- easily inserted/removed by generic operators (without particular specializations);
- suitable to block between them the bearing structures of the fixed parts with those of the moving/removable
parts.

9.2.2. Check of the requirements and conditions for installation

The checks to carry out are the following:

- simple inspections to point out for example : state and levelling of the ground, rainwater flow , etc. ... ;
- simple documentary inspections (with maps) to survey for example: sewers, cables, etc. ...;
- instrumental surveys (for pipes, etc. ...).

Places of the surveys:

- ground (manholes, asperities, consistency, etc. ... );

- underground (pipes, canals, sewers, etc. ...);
- topsoil (obstacles for the attraction and the public, aerial conduits, etc. ...);
- adjacent places (buildings, stores of particular or dangerous materials).

Operators and competences:

Checks must be carried out by the supervisor of the attraction.

Checking operations:

- Mechanical dangers (settling, sinking, knocks, collisions, etc. ...).

Electrical dangers (aerial electrical lines, etc. ...).

- Emission dangers (noise, vibrations, smokes, steams, electromagnetic troubles due to high-tension lines).

- Check the ground characteristics, to verify the conformity to the rules in force in the country of installation
and to the Manufacturer’s instructions.

- Check the particular conditions of the ground and of the loading points, with reference to the rules ( and the
Manufacturer’s instructions) for the placing of the attraction.

- Check the conditions and the placing of other attractions and/or structures or fixed objects, free necessary
spaces, access of the rescue means, etc. ... .

- Check the presence and the displacement of the fire-fighting means and their easy access as regards the
installation of the attraction.

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9.2.3. Placing and installation of the attraction

The attraction must be installed in an area without obstacles, to safely allow the normal operations of use
and maintenance.

Choose the position and the orientation of the ride checking in particular:
- the position of the other attractions already present in the amusement park area;
- that there will be no dangerous lifting caused by the strength of the wind (funnel effect );
- that the public can safely enter the entering/leaving points of the attraction;
- that in an emergency the way outs are easy and practicable;
- that there are sufficiently wide spaces to allow the rescue operations by ambulances, firemen and other
rescue means;
- that the placing of the fixed and/or mobile hydrants and of the other fire-fighting means gives a good
visibility and an easy access in an emergency;
- that there exist places suitable for the working/command positions;
- the possibility of realizing the connections to the feeding nets (electrical, water, etc. ...);
- the requirements of the underground and therefore the possibility of building foundations, floors,
underground lines, etc. ...;
- the possibility of opening doors, protectors, covers, etc. ... .
- that the chosen place for installation is neither near stores of solvents, nor places with manufacturing
which can create inflammable or explosive atmospheres;
- that the flow of rainwater is such that it does not provoke stagnation in the supporting points of the
attraction, reducing the carrying capacity of the ground.

WARNING:
Pay a lot of attention to the super-elevated power supply lines. Check if there are sufficient spaces
to operate completely safe. In presence of high tension cables there exists the danger of electric
arcs, above all with particular atmospheric conditions (fog etc. ...).

WARNING :
The areas around the attraction where it is not allowed the transit of people and/or means of
motion ,must be identified and delimited with systems like:
- barriers;
- chains;
- other means provided for by the law in force in the country of installation.

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9.2.4. Characteristics of the ground

Note: The following instructions are used in case of travelling attractions.

Arrived on the place where the attraction will operate, first of all it is necessary to make an accurate control of
the ground.
This control must be periodically repeated to check that its capacity of carrying the load is not deteriorated, in
particular when there are bad weather conditions.

It is useful to know everything about the ground and the area where the attraction will operate.
Previous uses for travelling shows or similar activities allow a better evaluation in the choice of the area
suitable to install the attraction.

The ground must not have such slopes or irregularities to compromise the assembling and the operation of
the attraction in safety.

There must be such a flow and drainage of the rainwater and/or of drain that there will be no stagnations
which reduce the ground carrying capacity.

If the installation takes place on a ground with non-optimum consistency, it is necessary to arrange boards
and wooden caps to share the pressure and limit the yielding of the loading points.

It is very important to know the carrying capacity of the place where the attraction will be installed.
If the real carrying capacity of the ground, expressed as admissible pressure on the ground, is not known, it
must be established by specialized technicians or asked to the competent authorities and to those in charge
of the park.

Carefully examine the ground or the square so that no stabilizer cylinder or supporting foot will be on
manholes, sewers, water mains or electrical cables etc. ... , which could yield under the weight of the
structures.

The supervisor, by checking, has to identify the sources of danger present in the area (on the ground, in the
underground and on the topsoil) and evaluate the resulting risks:
- for the authorized people, in particular during the phases of the vehicle motion, assembly, disassembly,
adjustments, tests and maintenance;
- for those in charge and/or for the public during operation;
- for those in charge and/or for the public and/or for a third party, when they pass by or stop, on vehicles or
on foot, through the amusement park;
- for the personnel in charge of rescue functions.

For every risk, measures suitable for preventing accidents or damages to the health or things must be
adopted.

Before installing the attraction it is necessary to verify that there are no super-elevated or underground
services which could be dangerous. If necessary, ask the various competent authorities (present in the place
of installation and use of the attraction) all the necessary information to adopt the suitable precautions to
avoid accidents or interferences with the safe operation of the attraction.

WARNING:
Pay a lot of attention to the aerial electrical lines. Check if there are enough spaces to operate in
complete safety.

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9.2.5. Characteristics of the supports on the ground

The wooden supports are the transmission points to the ground of the forces due to its own weights, the
operational loads, the wind pressure and the movements themselves of the attraction. They must have such
a surface that they do not charge excessively the ground, so that they do not fall down compromising the
stability of the attraction itself.

The wooden supports are therefore very important for the stability and the safety of the attraction and have
to:
• be properly prepared in advance for the assembly of the attraction;
• be frequently controlled.

If the acceptable pressure of the ground is less than the indicated one, it is necessary to widen the
supporting surface till a lower pressure than the acceptable one on the ground itself is reached.

Keeping in mind that pressure is transferred with a 45° angle, as a general rule the minimum acceptable
thickness "B" must be higher than the projection "A" of the wooden loading point compared to the
supporting plate.

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If the supports are not supplied or it is necessary to increase the size of the supplied ones , it is necessary to
set up safe steady supports for the attraction, according to the following rules:
- make sure that the ground is sufficiently horizontal, regular, uniform and dry;
- choose the supporting surfaces avoiding irregular, non homogeneous and loose areas (see pict. below;
- use wood of good quality;
- dispose with contiguity and at crossed layers the wooden boards, so that to obtain a steady support, with
previously calculated dimensions;
- avoid irregular , asymmetrical, improvised or made up with unsuitable materials supports;
- avoid in any case too high supports (horizontal forces due to extreme conditions could cause an overturn of
the support);
- avoid supports of structural parts with points or with small contact areas directly on the wooden supports,
if necessary arrange metallic sharing plates covered with non-slip rubber;
- when expected, pose through the levelling hydraulic cylinders the attraction on the supports, checking that
its basement is levelled both horizontally and vertically, using the levels.

The wooden supports must be made up of good seasoned wood, fir, larch or oak, without defects, such as:
- cracks for ice or lightings;
- damages caused by insects and in particular woodworm hollows;
- lichen infestation ;
- ring shakes;
- fungus attacks.

WARNING:
Fir wood is not recommended for supports of dynamic attractions and huge loads.

The wood, scarcely knotty, must be in the shape of:

- joists with dimensions not less than 8x8 cm, with increasing section with the length;
- boards, with section increasing with the length and the section of the board not less than 30x 8 cm;
- boards cut by fibres lengthwise.

Note: Wood with less thickness can be used only for supports of small dimensions (lower than 30 x
30 cm) and not under main structures.
In any case do not use thicknesses lower than 3,2 cm.

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MAXIMUM PRESSURES ADMISSIBLE ON THE WOOD

(in the most unfavourable direction of the fibres)

FIR (conifer)
LARCH (conifer) 20 from N/cm2
OAK

Maximum pressures admissible on the wood

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The dimensions of the supports vary with the admissible pressure on the ground.
Some indicative data about the admissible pressures on the ground and usable supports are mentioned
below.
These data do not exempt from verifying the effective carrying capacity of the ground where the attraction is
assembled.

TYPE OF SOIL
Soil in general Gravelly Asphalt Cement
Admissible pressures 1 from N/cm2 3 from N/cm2 6 from N/cm2 20 from N/cm2
Supports dimension (with
32x32 cm 20x20 cm 13x13 cm 8x8 cm
load 1.000 kN)
Supporting surface (with
40x40 cm 23x23 cm 16x16 cm 9x9 cm
load 1.500 kN)
Supports dimension (with
45x45 cm 26x26 cm 19x19 cm 10x10 cm
load 2.000 kN)
Supporting surface (with
50x50 cm 30x30 cm 21x21 cm 12x12 cm
load 2.500 kN)

Dimensions of the supports in relation to the type of soil

The rectangular/square wooden supports must respect the limits mentioned in the above table .
.
Dimensions must be such as to guarantee a supporting surface at least like the expected one.

Proportions between dimensions are the following:

- side "b" is bigger than side "a" in case of rectangular supports (only for explanation reasons) ;
- side "b" cannot be longer than 3 times side "a" ;
- height "h" must not be bigger than 2,5 times side "a" (shorter side in case of rectangular support).

WARNING:
Do not use fragile materials in presence of dynamic stresses and/or vibrations

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10. USE OF THE ATTRACTION

10.1. CHECKS AND ADVISE BEFORE EVERY STARTING

Before each use, check always the proper earthing set of all the carrying and supporting structures.

Before starting, check if the ground-wire is placed, do not give power to the board if it is not placed.
The ground-wire placement must be done by qualified personnel and follow the rules in force.

Before every opening to the public make the attraction turn idly for a few minutes to check that every device
works properly and there are no situations which could make the ride dangerous for the public.

We recommend to check, before operating, all safety and operation buttons ( START, STOP,
EMERGENCY). If a device does not work, do not open the ride to the public before adjusting it.

Check that all male/female plugs of the electric installation are properly connected and in a perfect state.

Check if all safety pins have their safety split pins and are properly fixed in their seats (see picture below).

ACCEPTABLE UNACCEPTABLE
A

B
B
A

PROPER SETTING UP WRONG SETTING UP

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Make sure that all safety pins are in a good state, otherwise replace them.

Grease where structure requires it.

Before placing the ride at the public’s disposal for the first time (or all the times it were necessary for the
authorities’ request), the owner has to make carry out all the testing operations by qualified and independent
technicians, according to the laws and rules of the local bodies in charge.
These technicians will have to check the proper operation of all safety devices and that these agree with the
rules in force, as well as the good efficiency of all the structural, mechanical and installing parts.

Do not make operate the ride at full load when weather conditions are not good. The highest value of the
wind speed, beyond which it is not advisable to keep operating the attraction, is equal to 70 Km/h.
With these characteristics of wind, and naturally with higher speeds, it will be advisable to remove all the
scenographic parts which could be damaged.

IMPORTANT

FOR SAFETY OF PASSENGERS AND RIDE STRUCTURES, IT IS ADVISABLE TO CHECK EVERY 7 DAYS THE
MAINTENANCE OF THE ELEMENTS OF THE RIDE. ANY ANOMALY MUST NOT BE NEGLECTED, CHECK
CAREFULLY THE CAUSES OF THIS ANOMALY, AVOIDING TO MAKE THE RIDE WORK IF BEFORE ANY
DANGEROUS CONDITION HAS NOT BEEN ELIMINATED.

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10.2. STARTING
10.3. ELECTRIC CONNECTIONS

WARNING: The connection of the electric power, the adjustments, the test circuits, the working
testing, the verifications must be carried out:
- by experienced, trained, authorized and qualified staff observing the regulations in force in the
Country where the attraction is installed and used;
- observing the instructions supplied by the Manufacturer of the attraction contained in this
manual, in the enclosures (including manuals of the commercial groups) and on the notices
placed directly on the attraction or on its components.

WARNING :
Check that the values of the frequency and the tension of the system correspond to the supply
values of the ride marked on the signs.

Earlier protections

The electrical supply lines which are not directly supplied by the Manufacturer must be realized according to
the laws in force in the country of installation and use of the attraction and must anyway be:
- realized with cables of section suitable to the total power absorbed by the attraction and to the length of the
line;
- supplied with an efficient grounding system;
- supplied with devices of sectioning and of automatic protection against dispersions, discharges on the
earth, short-circuits.

The supply line of the electric board must be protected through fuses

WARNING: Before giving voltage to the attraction it is necessary to:

- check that the cables and connections have not been damaged during assembling;
- check that all the electric connections have been made properly;
- remove any block and do some tests idly.

DANGER OF ELECTROCUTION.
The parts marked by this symbol remain in tension even when the general switch is on "0":

WARNING: At the end of the installation, check the efficiency of the attraction earthing

Before starting the ride you must do some controls necessary to start.
Check the three-phase + neutral supply and that all the closing devices work properly.

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10.4. STARTING

Once the above safety conditions are verified, start the ride.

Pull the motive power general switch, the services control switch and the line switches.

To make rotate the ride press the START button and the ride will immediately begin to rotate clockwise.
To lift the arm turn the selector in the CLIMB position and press the PUMP button which puts on the
hydraulic pump and lets the arm raise (to raise the arm keep pressed the button ).; to make descend the arm
turn the selector in the DESCENT position.
To operate the TIMER to program the total time of the turn set the timer in the desired time and move
upwards the TIME switch.

In case of immediate danger there is a red emergency button which pressed completely block the ride.
To re-establish the operation of the ride it is necessary first to rotate the emergency button clockwise (arrow).
The control board is supplied with a BELT button which lets the operator inform of the beginning of the turn.
To totally stop the ride (the end of work), to carry out with still ride, press the STOP button, lower the line
switches.

FOR ANY ANOMALY OF THE RIDE OR ANY PASSENGER’S STRANGE BEHAVIOUR PRESS THE “
EMERGENCY” BUTTON, THE ATTRACTION WILL STOP IMMEDIATELY AND THE OPERATOR WILL
HAVE TO CHECK HOW TO GO ON BY ALWAYS GUARANTEEING THE PASSENGERS’ GREATEST
SAFETY.
TO RESET THE BUTTONS TURN THE EMERGENCY BUTTON CLOCKWISE.

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Emergency button

The pressure of the emergency button stops the operation of the attraction, so that to take it to the rest/stop
state, in the shortest time, and maintaining the safety conditions for the passengers and for the ride
structure, compatibly with the effects of the risky/dangerous situation provoked by the event which caused
the emergency.

WARNING:
It is not allowed to use the emergency buttons to carry out the normal service stop.
Remove in the shortest time the cause of the stop, not to damage mechanical parts blocked in
positions different from the resting ones.

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10.5. ADJUSTMENTS AND REGULATIONS

10.6. GENERAL WORKING ANOMALIES

For all the working anomalies of the ride we remind you that every repairing must be done by competent and
qualified personnel.
You will find below some inconveniences which could occur on the attraction and the relative remedies to
take for every part in question.

The attraction does not respond to the ignition controls

Cut off tension from the line and check all the fuses of the general board. If they were damaged, replace
them.
Check also the electric connections on the control board.

The lights do not work

Check in this case the fuses inside the electronic flashing box of the lights by also checking all the lights off,
replacing those damaged. Check the proper operation of the manifold inside the centre piece.

The intermittent lights work irregularly or do not work

Check the fuses of the electronic flashing box under the “centre piece”.
Moreover, if some light does not work check if it is burnt and replace it.

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11. EMERGENCY SITUATIONS

In the following paragraphs the emergency situations, some general warnings and the behaviour ways to
adopt in the different situations are summed up and pointed out.

GENERAL WARNINGS

WARNING:
In the amusement parks a serious and imminent danger can arise due to:
- fire ;
- extreme weather conditions;
- other events, for example criminal behaviour.

In an emergency situation, besides the general precautions, other elements will be taken into
consideration, for example :
- the passengers’ reactions who can be children, young/old people or disabled ;
- the other spectators’ behaviour (some of whom can be the passengers’ relatives and for this
reason anguished) ;
- the personnel’s behaviour in charge of the attraction.

WARNING:
To avoid emergency situations or limit the consequences in case of incidents it is necessary:
- to carry out a frequent and accurate cleaning of the operational zones of the attraction;
- to keep in good state all the members of the attraction respecting the maintenance times;
- to keep always efficient, and in a position easily reachable by the operators, the fire means;
- to keep up to date all the operators about the evacuation/ rescue procedures.

The personnel in charge of the attraction must be instructed about the procedures to take and to
follow in case of emergency.
It is advisable to carry out, in the public’s and the passengers’ absence, some simulations of the
emergency situations to check the correctness of the intervention procedures and the training of
the executive people.
In the operator’s box in charge of the attraction operation must be stuck up one ore more signs
quoting:
- the references of the first aid, the firemen, the police, etc. ... ;
- the main instructions for the emergency situations.

Train the personnel so that they personally and immediately relate any possible accident causing
personal injuries or damages, including menaces or violent acts. Take care first of all of the
injured, but relate what happened after the accident.

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11.1. THE PASSENGERS’ EVACUATION

If the attraction is blocked in positions different from those expected in the normal working, the operator must
immediately tell the passengers to keep calm and that they will evacuated in the shortest time. To do this he
/she can use the loudspeakers or get closer to any passenger.

The operator takes the passengers to the zone allowing them to leave the attraction.

The passengers must flow with calm to avoid panic situations which could cause accidents.

The attraction must be supplied with stairs or evacuation systems allowing to reach the passengers in case
of stopping, different from those of rest.
These stairs or evacuation systems will be charged to the buyer.

WARNING:
The stairs and/or the evacuation devices must correspond to the safety rules in force in the
country where the attraction is to be installed and used.

11.2. OUT OF ORDER

To put the attraction out of order it is necessary:

- to isolate the attraction from its external power sources (electric, pneumatic, oil-pressure, .....);
- to isolate the attraction from the autonomous circuits;
- to block in “off” position the cut and sectioning devices ( through key blocks, safety codes, etc. ...);
- to dissipate the remaining energy of the following fixtures and/or fittings:
- to insert the following mechanical blocks (bolts, props, etc. ...) to avoid unattended and dangerous
movements of members.

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12. REPAIRS

WARNING:

Repairs are operations directed to re-establishing the operation of the components of the
attraction, through a repair or substitution of the piece, which are necessary because of a break or
a malfunction of parts of the attraction, provoked either by natural causes, or human facts, or by
both.

Through a repair you get the reintegration of the component in its original characteristics of
composition, dimensions, capacity, resistance, and fitness for the use of the function it is destined
to.

The repair which does not observe this principle is a variation and cannot be carried out, except in
the way described below.

The repair of a damaged component must be carried out by the Manufacturer or by specialized
personnel authorized by the Manufacturer him/herself.

In carrying out these repairs, qualitatively adequate materials must be used; when substituting,
only components supplied by the Manufacturer or authorized by him/herself must be employed.
.

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13. STRUCTURAL MODIFICATIONS

WARNING:

Modifications are changes to the original condition of the attraction or of its components, thus
creating a difference between the new configuration and that intended by the Manufacturer.

The modifications of the attraction or of its parts are not allowed, and they can affect the correct
operation of the ride, its safety and its preservation.

If modifications of the attraction are necessary, these shall be agreed with the Manufacturer, who
will also supply the technical documents related to the modification.

Before carrying out the modification it will be necessary to verify:

- the qualitative standards to be used;
- the observance of the limits and conditions established by the Manufacturer;
- the adequacy of the overall/particular safety of the ride.

The Manufacturer is empowered to refuse to carry out the required modification, if this does not
observe the established criteria.

If the owner and/or controller of the attraction carries out the modification directly or by means of a
third party, he will be in any case responsible for the eventual detrimental consequences and for
any incorrect operation or use of the attraction which could arise from the modification.

Safety critical modification

A modification includes any change to :

• loading (e.g. changing seating arrangements, assembling heavier passenger units);

• speed of operating cycle ;

• range (e.g. lifting height ) ;

• safety limits ;

• safety-critical components, devices or systems;

• structural and mechanical components ;

• drive mechanisms;

• control mechanisms (e.g : brakes, vibration dampers, speed limiters, etc. ...) ;

• passenger containment (including fencing and barriers);

• passengers’ height restrictions;

• installation of a fixed device in a different location.

This list is not exhaustive. If in doubt, it should be assumed that every modification is safety-critical and
contact the Manufacturer in conformity with the instructions cited above.

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14. MAINTENANCE
14.1. ORDINARY MAINTENANCE

The ordinary maintenance of the attraction includes the interventions of checking, operation check,
inspections, greasing, replacements of normally wearable parts which do not demand interventions on the
structures or mechanisms, normal setting-up of mechanical and/or electrical parts, etc. ... , which are
necessary due to the normal use of the attraction itself.

The instructions allowing to carry out properly the ordinary maintenance interventions are cited in this
manual. The owner and/or controller can directly carry out and/or have these interventions carried out,
following the instructions of the manual.

If the owner and/or checker do not think to be able, despite the instructions received, to go on with the
ordinary maintenance interventions, they have to ask the Manufacturer or an authorized service centre.

General instructions

WARNING:

The attraction must be submitted to periodical checks and maintenance interventions to keep in a
good state its original technical/operational/safety conditions.
In this chapter will be given some information about the interventions to carry out and the methods
to adopt.

Maintenance/ greasing/ cleaning interventions are not allowed on:

- the working attraction;
- the devices on;
- installations under pressure or hot.

Before starting any maintenance/greasing/cleaning intervention, it is necessary to adopt the

individual protection means required by the operation and to set the attraction in safety conditions.

The key/padlocked blocks, on switches and taps, have been installed to:
- avoid unexpected starting of the attraction during the interventions;
- avoid unexpected movements of mechanical members;
- eliminate the risk of discharges and electrocutions by electric energy;
- prevent operators or unauthorized people from carrying out starting interventions, during
maintenance operations.

When necessary, interpose safety mechanical blocks, like supporting blocks etc. . .
In the instructions for the maintenance interventions will be indicated when this procedure should
be adopted.

Some pictures of the manual represent the attraction or parts of it without safety blocks,
protections or deactivated protections.
IT IS NOT ALLOWED TO USE THE ATTRACTION WITHOUT BLOCKS, SHELTERS OR
PROTECTIONS OR DEACTIVATED PROTECTIONS.
By ignoring this prohibition, serious accidents could be caused.

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WARNING:
THE NEGLECT OF THESE PRECAUTIONS CAN DAMAGE PEOPLE, THE ATTRACTION AND
THE THINGS.

IF THOSE OPERATING ON THE RIDE DO NOT THINK TO BE ABLE TO OPERATE

PROPERLY, DESPITE THE MANUAL INSTRUCTIONS, THE MANUFACTURER MUST BE
ASKED TO GET THE NECESSARY EXPLANATIONS

The protections and the safety devices, present on the attraction, can be removed only for work
necessities (maintenance). If they have to be removed it is necessary to adopt immediately
measures to point out and reduce to the possible lowest limit the danger and the risk which could
derive. The protections and the safety devices have to be put to their place again as soon as fail
the reasons which made necessary their temporary removing and in any case before re-starting
the attraction..

DURING MAINTENANCE OPERATIONS THE PUBLIC’S PRESENCE IS NOT ADMITTED.

Technical instructions for a good maintenance

For a good maintenance:

• Use only original spare parts, tools suitable to the aim and in good state.

• Respect the intervention frequencies cited in the manual.

• Apart from the maintenance prescriptions, the ordinary maintenance operations must be carried out
whenever it is necessary.

• A good preventive maintenance demands constant attention and continuous watch of the attraction.
Promptly check the cause of any anomaly such as excessive noise, overheating, fluid leakages,
etc...and intervene.

• If you are in doubt, contact either the Manufacturer or the authorized service centre.

General instructions after maintenance operations

WARNING:
After maintenance works and before re-starting the attraction, it is always necessary to check:
- that the pieces eventually replaced and/or the tools used for the maintenance intervention have
been removed from the attraction;
- that all the shelters and the protections eventually dismounted during the intervention have
been mounted, positioned, regulated properly and are working;
- that all the connections (fluid and electric) have been carried out properly;
- the efficiency of the safety devices.

Only after the intervention and the checks the working conditions will be restored.

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14.2. EXTRAORDINARY MAINTENANCE

In conditions of normal operation of the attraction, regulations and interventions different from those
indicated and expected in the manual as ordinary maintenance are not demanded.

All the maintenance interventions unexpected in this manual have to be considered "Extraordinary
maintenance", as they require a deep specialized knowledge of the attraction.

WARNING:
In no case the owner and/or the controller will provide directly or through his own persons in
charge.
The extraordinary maintenance interventions are reserved exclusively to the Manufacturer or to
suitable specialized technicians, or to personnel explicitly authorized by the Manufacturer himself.

Besides, exceptional unexpected events caused by human/natural facts can occur, which are the cause of
incidents and damages to every component, the structures and/or the attraction as a whole.

Due to these exceptional events, “Extraordinary maintenance” operations will be carried out. It consists
therefore of all those operations demanding:
• repairs to structures;
• repairs to mechanical parts;
• repairs to the electric parts of the attraction;
• changes even partial of members failed due to break or accident ;
• new-regulations of the system ;
• repairs become necessary for damages caused by incidents occurred during the use, mounting and
dismounting, transport, etc. ..., of the attraction.

Also the revisions envisaged by the Manufacturer are to be considered "Extraordinary Maintenance" .

In any case the owner and/or controller must promptly communicate the Manufacturer the happening of the
event which makes necessary the intervention of extraordinary maintenance, indicating the causes and the
effects, so that to let the Manufacturer do a correct evaluation of the damages of the attraction.

The Manufacturer will indicate the most suitable interventions for the restoration (repairs or changes) of the
damaged parts, reserving to send his own personnel, to arrange the re-entry of the attraction by the
manufacturing Company or an authorized centre, or to adopt or make adopt the most suitable solutions for
the intervention itself.

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WARNING

FOR SAFETY OF PASSENGERS AND RIDE STRUCTURES, WE ADVISE YOU TO CHECK EVERY 7
DAYS THE MAINTENANCE STATE OF THE INSIDE ELEMENTS , WITH PARTICULAR CARE WHEN
CHECKING ALL THE WELDS, IN ANY CASE MAKE SURE THAT THERE ARE NO ANOMALIES IN THE
STRUCTURE OR OF ANY OTHER ORIGIN.
POSSIBLE ANOMALIES MUST NOT BE IGNORED, CHECK CAREFULLY THE CAUSES FOR SUCH
ANOMALIES AND DO NOT MAKE THE ATTRACTION OPERATE UNTIL ANY DANGER IS REMOVED.

CHECK DAILY:

The oil level inside the tank;

to clean the heat exchanger.

CHECK EVERY 15/20 DAYS:

The wear state of the sprocket bearings and the traction pinions, this coupling must be always greased both
externally on the teeth and internally through the proper greasers.
Grease through the proper greasers the lifting rolls of the arm.
Grease through the proper greasers the hinge of the eccentric arm.

Greasing must be carried out using grease of the type listed in the table in chapter 14.4.1 (Characteristics of
lubricants to use)

WARNING

AFTER THE FIRST THIRTY (30) WORKING HOURS, CHECK AND FIX ALL THE BOLTS ON THE RIDE.

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14.3. PERIODICAL MAINTENANCE

The operator must pay particular attention to all the maintenance operations of the ride to get a good
operation at the lowest running cost.
The parts of the ride which are going to be treated in this chapter are:
• Transmission
• Sprocket bearing
• Electric motor
• Hydraulic motor
• Hydraulic pump
• Heat exchangers
• Electric system
• Hydraulic system
• Braking system
• Vehicle

14.3.1. Transmission

With regard to the maintenance of all the transmission components, we advise you to follow the following
programme and before every maintenance intervention, make sure that the supply board of the ride is not in
tension. By neglecting this instruction, you could provoke serious damages to people.

Pinion and
Sprocket bearing

Lifting roll

Hydraulic motor

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Electric motor Hydraulic pump

Elettrico

Heat exchanger

Check the perfect state of the pinion and the sprocket bearing.
Check there are not any oil leaks in the hydraulic motor.
Weekly check the good state of all the pipes.
Check the proper operation of the hydraulic motor.
Weekly grease the external teeth of the pinion.

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14.3.2. Sprocket bearing

Maintenance of bearings is very important.

For this reason, you must follow some rules concerning the type/quantity of grease to use and in case of
substitution of one or more bearings, the type to use.
We remind that maintenance operations on the motor must be done with no power.
During greasing operation, an excessive quantity of grease must not be injected on the bearing as it could
produce an anomalous heating of the bearing itself.
Greases suitable to be used are:
Shell Alvania 2 e Shell Alvania 3
Esso Beacon 2 e Esso beacon 3
BP Energrease L52 e BP Energrease L53
Mobilux Grease 2 e Mobilux Grease 3.
Lithium-based greases with small additions of calcium are strongly recommended as they are water
repellent.

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14.3.3. Electric motor

Maintenance activities must be carried out by qualified personnel only after having disconnected the system
or the motor from the line and that any charge is applied to the motor shaft. Find below a list of the activities
which have to be performed periodically to assure a correct operation of the motor.
The frequency of the checks depends on the particular application of the motor (environmental conditions,
number of starting, applied inertia moment, etc.).
- check periodically the motor works properly without anomalous noises or vibrations and that the
openings for the ventilation air are not blocked.
- check with annual periodicity the correct tightening of the supply cables to the terminal board of the
motor and the earthing conductor to the chassis of the motor.

WARNING:
Keep the motor spaces clean and dry and the ventilation openings clear of obstacles which could
compromise the cooling of the motor with consequent risk of fire because of overtemperature.

Keep readable, by accurate cleaning, the identifying plates and the arrows showing the way of
rotation of the motors.

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THREE-PHASE MOTOR

PROBLEM CAUSE REMEDY

The motor does not start, the
Interruption of at least two phases, Check all the protection elements,
characteristic starting noise is
lack of power. supply lines and terminals.
not heard
Locate the interrupted phase,
check the fuses, replace those
A phase is interrupted.
The motor does not start, a damaged.
There is scrubbing between rotor
strong hum is heard. Check the bearings, check the
and lamellar parcel.
connection and the correct tension
of the belt.
The motor does not start under
Check the joined machine, disjoin
load, but the magnetic hum is The resistant torque is too high
the motor and try it idly.
regular. A too low system voltage.
Measure the voltage.

The motor runs idly and does

Interruption of a phase after
not arrive to the regular number Check the supply line.
starting.
of turns. For any damage of the rotor,
The ammeter in the stator circuit
Loss of speed, hum contact a specialist
signals periodic variations.
Wrong connection of the stator
Check and set the connections in
winding, for ex.: instead of the star
accordance with the diagram.
The motor heats already during connection there is a triangle
Check the voltage and the idle
the idling. connection.
current
A too high voltage.
Clean the ventilation canals.
Insufficient cooling because of
the blocked ventilation canals.
Measure the current intensity.
Measure both the voltage and the
Load is too high. Voltage is either
The motor heats too much under current.
too low or too high. The supply line
load. Check the voltage line.
has got an interrupted phase. The
Locate the interrupted phase.
rotor touches against the stator.
Check the connection and the
correct tension of the belt.

They are defects in the electric

part, the noises disappear when
you disconnect the motor ; in case
The motor has got anomalous
Mechanic or electric causes. of defects of the mechanical part
noises.
noises often are lower with the
reduction of the turn number..
Contact the manufacturer.
The motor at commutable poles
Check the connections and set
turns with a wrong number of Connection mistake
them properly.
turns.
One or more lines or connections
The motor at commutable poles
between terminals and pole Check the connections between
turns only with a number of
inverters are defective or terminals and line.
turns.
interrupted.

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ONE-PHASE MOTOR

PROBLEM CAUSE REMEDY

The motor does not start, the
Interruption of the line, lack of Check all the protection elements,
characteristic starting noise is
power. supply lines and terminals.
not heard

The motor does not start under The resistant torque is too high Check the joined machine, disjoin
load, but the magnetic hum is The ammeter in the stator circuit the motor and try it idly.
regular. signals periodic variations For any damage of the rotor,
contact a specialist

The motor already heats during Insufficient cooling because of the Clean the ventilation canals.
the idling. blocked ventilation canals.

Load is too high.

Check the connection and the
Voltage is either too low or too
The motor heats too much under correct tension of the belts.
high.
load. Measure the current intensity.
The rotor touches against the
Contact the manufacturer.
stator.

They are defects in the electric

part, the noises disappear when
you disconnect the motor; in case
The motor has got anomalous of defects of the mechanical part
Mechanic or electric causes.
noises. noises often are lower with the
reduction of the turn number.
Contact the manufacturer.

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14.3.4. Hydraulic motor

Maintenance activities have to be carried out by qualified personnel only after having previously excluded the
motor from the supply system and made sure the pump is not working. Find below the activities which have
to be carried out periodically to assure the proper operation of the motor.
The frequency of inspections depends on the particular use of the motor (room conditions, number of
startings, applied moment of inertia, etc.).
- periodically check that the motor works properly without noises or anomalous vibrations and that
there are no leaks of the system near the motor or leaks of the motor itself.
- annually check the proper tightening of supply pipes and the fixing of the motor itself to the chassis
of the ride.
- check the good state of pipes.
- after a change of oil check at first starting that motor is completely filled with oil and there are no air
bubbles.
- at first starting, after a change of oil, make turn the motor empty for 20-25 min, paying attention to
possible oil leaks.

WARNING:
Keep controlled the level of oil in the tank, if level were lower than the minimum fill it up, with oil
with equal characteristics.

Keep readable, by accurate cleaning, the identifying plates and the arrows showing the way of
rotation of the motors.

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14.3.5. Hydraulic pump

WARNING:
Keep the spaces where the attraction is placed clean and dry and the ventilation openings free
from obstacles which could jeopardize the cooling of the pump.

Keep readable, by accurate cleaning, the identifying plates and the arrows showing the turning
direction of the pump.

The pump does not need particular maintenance interventions; but pay attention that:
- the external part of the pump is not dirty with oil;
- there are no big leaks of oil near the pump;
- the screws firmly fixing the pump to the motor are not loose or missing;
- there is not an excessive overheating of the pump;
- the pump works properly without noises or anomalous vibrations and there are no leaks in the
system near the motor or leaks of the motor itself.

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14.3.6. Heat exchanger

WARNING:
Keep the space where the heat exchanger is placed clean and dry and the ventilation openings
free from obstacles which could jeopardize the cooling of the oil.

Keep readable, by accurate cleaning, the identifying plates and the temperatures marked on the
adjusting thermostat of temperature.

The heat exchanger does not need particular maintenance interventions; but pay attention that:
- the external part of the heat exchanger is not dirty with oil;
- there are no big leaks of oil nearby;
- the screws firmly fixing the heat exchanger to the structure are not loose or missing;
- there is not an excessive overheating of the external structure and so of the heat exchanger itself;
- there are no noises or anomalous vibrations.

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14.3.7. Maintenance of the braking system (ONLY FOR TRAILER MOUNTED VERSION)

LIST OF MAINTENANCE INTERVENTIONS

OPERATIONS FREQUENCY
• Brakes checking • Before starting
• Wheels tightening • After 150 Km
• Tightening of the nuts of the U-bolts • After 1500 Km
leaf springs • Every 3 months
• The locks of leaf springs support with • After every wheel removing
prescribed tightening couples • After an eventual brakes overhauling
• Lubrication camshaft bushes and
• Every 3 months
brake lever (*)
• Overhauling and complete
• Every year
maintenance of the brakes. (*)
• Every 3 months check the oil level
(only for oil bath axles)
• Inspection of the hub and bearings • Every year, with lubricant check
• Every 2 years (or 300.000 Km) replace
the lubricant (*)
• Check the braking system, clean the
filters, the tubes and discharge the
condensation from the valve under the
• Every 5.000 Km
tanks.
• Grease all the points supplied with
greaser.
• Check the valves of the system (*) • Every 50.000 Km (or once a year)

Maintenance interventions

Note: Checks marked by an asterisk (*) have to be carried out in a car repairs shop or by qualified
personnel.

WARNING:
Maintenance operations have to be carried out at regular time intervals (i.e.: after the first month,
every 3 - 6 -12 months,, etc. ...) even if the expected kilometric distance has not been covered.

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RECOMMENDED LUBRICANTS

Lubricant for axles

BRAND GREASE OIL

MERITOR Hub grease blue
Lithium EP2
SHELL Retinax “A” Spirax EP90
MOBIL Mobilgrease M.P. Mobilube GX90
BURMAH CASTROL Spheerol EPL2/Castrol LM
TEXACO Marfak All Purpose Multigear EP85W/90
TOTAL Multis EP2 Total EP90
B.P. L.S. EP2 Gear oil 90EP
ESSO Beacon EP2 GX 85/90

Lubricant for camshafts bushes and brakes components

- Meritor High Performance Brake Lubricant, or

- Total Extemp, or
- Equivalent grease

Lubrication wheel axes

At the first dismounting of the group hub-bearings we advise you to apply a thin layer of Optimol Optimoly
White Paste T on the bearing housings to prevent the formation of oxide by rubbing and facilitate the
following dismountings.

QUANTITY OF LUBRICANT

Quantity
Location
(g)
Hub hollow 325-375
Inside bearing 50-60
Outside bearing 35-40
Hubcap 150

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BRAKES

We advise you the checking period of the thickness of the gaskets through the porthole on the cover. If the
thickness is less than 8 mm we advise you to replace the gasket. It is important to use original spare parts
not to alter the characteristics and the performance of the brakes.
When replacing the brake washers, we advise to clean properly the shoes and to repaint with antitrust.

Check of the components of the brake

Check the anchorage pins, the OR rings and the bushes; if worn or damaged replace them.
Check the rolls of the bush; if worn or damaged replace them. Every time you remove the rolls from the
shoes the rollstop fasteners have to be replaced.
Check if the shoes are worn in correspondence of the pins and the rolls, in this case replace them.
Check the camshaft; if it is worn or damaged just next to the cam contour or on the grooves (where the brake
lever is mounted) it has to be replaced.
Check the brake drum.
If it has got cracks or chaps it means that the brake has worked at excessive temperatures.

By mounting a new drum you do not eliminate the problem whose possible causes are:
• Too high adjustment of the predominant valve of the drawing vehicle;
• Detective/ badly-adjusted brake lever;
• You ONLY use the trailer brakes to reduce the vehicle speed on long distances;
• Use of non original sealing washers;
• A failure in the pneumatic operating system;
• Discalibration of the servodistributor and/or the corrector and/or eventual limiting valves.
• Too high pressure of the system (max 7.5 bar according to the EEC directions).

The drums which have got chaps due to overheating of the drum itself or any other damages (i.e. rivet
grooving , etc.) have to be changed.

Replace the jaws springs when changing the brake washers.

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Checks to carry out periodically

a) Check the wear of the friction gaskets.
b) Check the free rotation of the cam pin.
c) Check the operation of the brake lever.
d) Check eventual leakages of the brake system and the air springs.
e) Check the piston of the air springs.
f) Check the deterioration of the airbags of the air springs and in case make it free from dirt.
g) Check the corrosion/wear state of the leaf springs.
h) Check the wear state of the tyres.
i) Check the right working height of the pneumatic suspension.
j) Check the air pressure in the brake system.

WARNING:
If the vehicles are used in conditions of particular strain, the maintenance intervals have to be
reduced.

Note: The checks (b), (e),(f) have to be carried out in a car repairs shop.

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14.3.8. Maintenance of the electric system

COMPETENCES

WARNING:
The maintenance interventions on the electric parts and the electric system have to be entrusted
to the various people in charge respecting their competences.

PERIODICAL CHECKS ON ELECTRIC SYSTEM

List expected checks:

Operations to carry out every day:
- Check that all plugs are properly connected.
- Check that all the cables supplying the different lights of the attraction are in good state.
- Check the correct fixing of the wires of the main supply.
- Check the correct fixing of the grounding.

Operations to carry out every week:

- efficiency of the emergency stops;
- check the proper operation of the lights, if some were burnt or broken replace it.

Operations to carry out every 6 months:

- check accurately the good state of all electrical cables.

WARNING:
Before intervening on the electric system it is necessary to:
- put the attraction in maintenance state ;
- wear the individual protection means (d.p.i.) required in the operation ;
- have obtained the necessary authorizations by the owner and/or supervisor ;
- use tools protected from shock risks.

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14.3.9. Maintenance of the hydraulic system

WARNING:
The maintenance interventions on the hydraulic parts and the hydraulic system have to be always
entrusted to the various people in charge respecting their competences.
Maintenance has to be done with the ride still and with oil at room temperature.

PERIODICAL CHECKS ON THE HYDRAULIC SYSTEM

List expected checks:

Operations to carry out every day:

- check that the various taps are properly positioned before operating the attraction.
- check the oil level.
- check that the oil breather is clean.
- check that the oil exchanger is clean.

Operations to carry out every week:

- check the oil level in the tank
- check that in general there are not any leaks in the system.

Operations to carry out every month:

- after the first operating month substitute the oil filter, then substitute it once a year;
- check the proper operation of the emergency hand pump.

Operations to carry out every 3 months:

- clean the oil filter.

Operations to carry out every 6 months:

- accurately clean the heat exchanger (if the working environment is too dirty, anticipate the cleaning
of the filter at once a month.)

Operations to carry out every year:

- after 3.000/4.000 working hours or once a year change the hydraulic oil;
- before pouring in the new oil clean the inside of the tank with detergent liquid suitable for the
purpose and advised by the manufacturer of the lubricants ;

DEFECT CONTAMINATION POSSIBLE CAUSE

Overheating, change of fluid not
Dark coloration Products of oxidation carried out (ev. penetration other
fluid)

Milky turbidity Water or foam Water and air penetration.

Water
Water separation Water penetration, for. ex.. coolant

Air bubbles Air Air penetration, for example

because of insufficient fluid or an
unsealed suction pipe
Suspending or deposited Abrasion material, dirt, ageing
Solid outside particles
impurities. products.

Smell of burnt oil Ageing products. Overheating

Check of the oil state inside the tank

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Vehicles

In the vehicles the parts to be checked are mainly listed below.

We remind you that maintenance of the vehicle has to be done by qualified personnel.

 grease periodically all the moving mechanisms, such as : levers, pins, blockings, etc.
 check the perfect contact of the electric connections.
 check before every starting of the ride the proper fixing of the vehicles to their respective arms.

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14.4. LUBRICATION

General safety instructions, precautions and warnings when lubricating

Do not oil and/or grease the parts and the moving elements of the attraction, if not requested by
particular technical exigencies. In this case suitable means must be adopted to avoid any danger.

When using lubricants follow the Manufacturer’s instructions (contained in the safety forms supplied with the
lubricant itself).
.
BEFORE OPERATING FOLLOW THESE GENERAL RULES OF BEHAVIOUR:

DO NOT SMOKE

DO NOT USE FIRE

SUPPLY YOURSELF WITH MEANS OF INDIVIDUAL PROTECTION:

WEAR GLOVES

WEAR PROTECTIVE GLASSES

WEAR A MASK

For a good lubrication:

- do not use old/badly-kept oils;
- do not mix different oils among them;
- use clean cans and tools.
Dispose of worn out lubricants and cans according to the regulations in force in the country where the
attraction is going to be set up and used.

WARNING: Do not make fall down any lubricant on floors, passages, etc. ... , to avoid staining
which could cause risks of falls to the operators and/or the public.
Clean properly the zones which could get dirty.

Being an attraction with particular constructive technologies and complex movements, we remind you that for
safety reasons all blocking parts must be checked: bolts, pins and split pins.

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14.4.1. Characteristics of lubricants to use

a) Hydraulic oil

Brand Used oil Mass of a Viscosity Viscosity Index of Inflam. Sliding

volume unit at 40°C viscosity point
at 20 °C

Kg/dm3 cSt °E °C °C
TAMOIL Tamhydro HVI 0.868 45 170 198 -33

Characteristics of oil lubricants

b) OIL FOR GEAR-BOXES

For the gear-boxes on the attraction we advise the following oils, in conformity with use and temperatures :

Operating from 0 °C to 20 °C from 20 °C to 40 °C

temperature
Oil Mineral oil Synthetic oil Mineral oil Synthetic oil

Medium load ISO VG 150 ISO VG 150 ISO VG 320 ISO VG 220

Heavy load ISO VG 220 ISO VG 220 ISO VG 460 ISO VG 320

The attraction is supplied with the following type of oil:

Brand Used oil Mass of a Viscosity at Viscosity Index of Infiam. Sliding

volume 40°C viscosity point
unit at 20
°C

Kg/dm3 cSt °E °C °C
VALVOLINE GEAR EP 0.868 209 100 238 -12

Characteristics oils for gear-boxes

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c) OIL FOR HYDRAULIC JOINTS

For the hydraulic joints we advise the following oils (choose among those listed below):

Brand Oil

AGIP OSO 35
BP ENERGOL HL 65
MOBIL ATF 200
SHELL TELLUS OIL 29
CASTROL HYSPIN AWH 46
CHEVRON OC TURBINE OIL 11
FINA HYDRAN 31
ARAL E 100 EXTRA
GULF PARAMOUNT 35

Characteristics oils for hydraulic joints

d) GREASE FOR SUPPORTS WITH BEARING

For supports with bearing we advise types of grease belonging to the class NLGI 2 (choose among those
listed below ):

Brand Grease

SHELL ALVANIA R2
MOBIL MOBILIX 2
ESSO BEACON 2
CASTROL SPHEEROL AP2
GRIPPA 33S

Characteristics grease for supports with bearing

e) LUBRICANTS FOR BRASSES, PINS, ETC. ...

We advise types of grease belonging to the class NLGI 2 (choose among those listed below ):

Brand Grease

SHELL ALVANIA R2
MOBIL MOBILIX 2

ESSO BEACON 2

Characteristics lubricants for brasses, pins, etc. ...

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14.4.2. Comparing chart of lubricants

In the following chart are reported the lubricants equivalent to the advised product:

Brand Oil Grease

VANGUARD GEARING EP 150 LLZ 10 / 2

AGIP BLASIA 150 GR LP / 2
BP GR XP 150
CASTROL ALPHA SP 150 UNDERWATER 4
ESSO SPARTAN EP 150
MOBIL MOBILGEAR 629
SHELL OMALA 150
TOTAL CARTER EP 150 MARINGREASE 3

Comparison of lubricants

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15. STRUCTURES

All steel structures of the ride have been planned, calculated and built to perform their function.

To get a greater duration and a good operation of the ride, some main rules must be observed.

15.1. GENERAL INSTRUCTIONS FOR THE USE AND MAINTENANCE OF STRUCTURES

 Avoid damaging the structures through an improper use, exposing them to unexpected loads,
carrying out wrong assembly/disassembly/transport operations.

 Do not alter the functionality of the structures through welding, holes, structural incisions and any
other operation which could jeopardize their integrity.

 Expose structures to careful checking and a periodical maintenance, avoiding the forming of rust
through regular painting.

 Check that infiltrations and water stagnations do not form inside the structures, or that there is no
intervention of corrosive agents, by keeping any openings sealed and the drainage holes free.

15.2. CHECKING TO CARRY OUT PERIODICALLY ON STRUCTURES

A visual periodical checking, for safety reasons, is absolutely necessary and determining for structures.

Checking must be carried out:

 frequently;
 following the instructions mentioned below:

Instructions to carry out checks on structures:

 Remove all the parts which could block the entrance to the structures to check.

 Clean carefully all the structures to check, removing any trace of grease or rust which could impede
the checking or make it difficult to understand.

 Observe carefully all different parts constituting the structure to check, paying particular attention to
any deformation, dent, folding, incision and crack.

 Examine with attention the structure, especially next to weldings, ribs, connections, changes of
section and discontinuities in general. These are zones where cracks and/or breaks can more easily
occur, provided they are continuously submitted to maintenance.

 Pay particular attention to the paint condition. If paint presents rust leakages, the underlying material
may begin to crack. In this case it will be necessary to intervene immediately to restore the original
state of the damaged element.

 If the visual exam gives doubtful results and there remains the suspect of possible cracks or
something else, contact the Manufacturer or Companies specialized in non-destructive checking and
carry out deeper tests.

 If cracks were discovered, stop immediately all operations and contact the Manufacturer or one of
his/her authorized service centre.

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15.3. CONNECTIONS THROUGH STEEL BOLTS AND NUTS

15.3.1. General information

Screw connections, both those manufactured in factory and that can be dismantled except for maintenance
or repair, and those that must be restored at every assembly of the attraction, are among the most
important elements for the reliability and the safety of the attraction.

15.3.2. Resistance class

On the attractions are generally used commercial high-resistance screws of the classes 8.8 and 10.9.
Use nuts with resistance class compatible with the resistance class of the screws to which they couple.
For 8.8-class screws use nuts class 8 EN 20898 (ISO 898).
For 10.9-class screws use nuts class 10 EN 20898 (ISO 898).
The resistance class is easily identifiable since screws and nuts are marked by initials

In particular cases can be mounted special screws, expressly produced for the attraction.
In this case there can be no stamping of the resistance class.
The special screws can be considered spare parts, then ordered exclusively from the Manufacturer, and
cannot be replaced by different screws.

WARNING: When replacing you HAVE TO use screws and nuts of the same resistance class
respectively of the original screws and nuts.
Therefore, YOU MUST NOT use screws and nuts with a different material from the original one or
with different characteristics.

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15.3.3. Tightening

Screws proper tightening is fundamental for a safe operation of the connection.

A too strong tightening (over-tightening) can in fact involve permanent plastic deformations which will
endanger the solidity of the connection.
A too loose tightening (under-tightening) can instead involve:
- settlings for strain;
- loosening;
- sliding of the connected parts and cut of the bolt;
- vibrations and shakings of the connected parts.

In the case of bolts, the correct tightening must be carried out through the rotation of the nut and not of the
screw head.

WARNING: SELFBRAKING NUTS SUBJECT TO DISASSEMBLY MUST BE REPLACED AT

EVERY SETTING UP.

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15.4. CONNECTIONS THROUGH PINS

15.4.1. General information

They are mainly used in connections frequently disassembled and may be used as follows:
- connections where there is not any relative motion between the parts;
- connections where there is an occasional relative motion;
- connections where the relative motion is frequent.

Avoid damaging these connections with an improper use, exposing them to unexpected loads, carrying out
forced assembly and/or disassembly operations.

WARNING:

DO NOT alter the functionality of the connection carrying out welding of any type, by modifying or
rendering inefficient the safety connection devices, heating the connection members, making
holes, structural incisions and anything else which could compromise its integrity.

The connection MUST be periodically maintained to avoid seizures and corrosions.

ALL PINS MUST BE SUPPLIED WITH SAFETY PINS.

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15.4.2. Checking on connections through pins

The connections made through pins or similar must be regularly checked.

Wear, deformations, corrosion

At every disassembly you must verify that the material is intact and does not present any deformations or
crushing which reduce its resistance.
If necessary, the damaged parts must be promptly replaced.
The connections in question, with or without relative motion, are generally subject to wear, and more rarely
to deformations or corrosive phenomena.
Wear, so as the other cited phenomena, can occur on the pin, the holes or the eventual interposed bearings.
If contained within certain limits, they can be considered harmless for the good operation of the connection.
You will find below the general criteria of evaluation of these phenomena, while in some particular cases will
be given more detailed indications necessary in relation to specific use situations of the connections.

The control of the connection must, in general, assure that:

a) The play between pins and holes has not become excessive. If the values of the highest acceptable play
are not indicated, an excessive play is a play meant anomalous by sufficiently trained personnel
considering: the type of connection, its dimensions and its operation.

TABLE of the INDICATIVE PLAYS according to the DIAMETER of the pins

without relative motion between the parts and for static applications
PIVOT Ø TILL 20 mm MAX. PLAY 1 mm
PIVOT Ø BEYOND 20 mm TILL Ø 24 mm MAX. PLAY 1,5 mm
IVOT Ø BEYOND 24 mm MAX. PLAY 2 mm

b) The pin MUST not present form alterations or sensible dimensional variations such as:
ovalizations, deformations, heading, steps, seizures, pitting, and/or other corrosive attacks.

Form defects of the pin

c) The hole must not have similar defects on the inner surface

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15.5. CRACKS AND BREAKS

The elements of the connections, and in particular the pins, have to be carefully checked to make sure that
there are no breaks (generally due to hard work but also to incorrect use).

This phenomenon consists in the creation of a small crack which, under the action of variable loads applied
all along, grows until the complete destruction of the part.
These fatigue cracks have generally origin in discontinuities such as:
(1) diameter changes;
(2) slots for seeger rings or tangs;
(3) slots for devices to impede the rotation or the coming out of the pin.

The control must be carried out after having removed dirt, grease and whatever could stop a correct
checking.

WARNING:
If there are any doubts about the integrity and the connection seal DO NOT use the attraction in
the public’s presence.
Contact the Manufacturer before any operation.

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16. CHECKING: WAYS OF OPERATION

If during the checking some anomalies are found, the checking must be extended to all the other parts of the
same kind, identical or not.
You must also check any anomaly transmitted by the damaged parts to other nearby/connected members.

Non-destructive checking and tests

The term non-destructive test includes a range of techniques studied to find defects which cannot be
discovered by a visual checking without instruments. The aim is to discover if a structure or a component is
so deteriorated they do not satisfy the original specifications.

Besides revealing the defects which can be safety-significant, it is probable that also the non-destructive test
will reveal other defects which are not safety-important. It is therefore important that the expert, who carries
out the non-destructive tests, is able to distinguish between real defects and other indications.

The operating manual specifies which non-destructive tests are required during the service according to the
duration of use of the device.

The periodical non-destructive checking and tests must be carried out as further deepened checking of the
state of structures and mechanical parts.

The non-destructive tests do not replace the visual checks, which anyway have to be carried out with the
greatest care and frequently.

The non-destructive checks must be done by competent, authorized and adequately trained personnel.

a) VISUAL CHECKING
It indicates a general particular checking of a single element or a group. It must be very accurate and
can require the disassembly of parts reducing the access or the inspection to the elements or the
groups to check.

b) INSTRUMENTAL CHECKING
It must carried out in the same way of the visual checking and with the help of instruments of
measure and/or survey adequate to quantify wear, plays, tolerances, etc.

c) CHECKING OF PROPER OPERATION

Functional checking of an element or a group. It includes the visual checking and repeated tests to
verify that the different parts or the single elements work properly, that there are no loosening, wear,
deformations which could compromise their performance.

d) CHECKING OF CORRECT FIXING

Checking of the general state of a connection made with bolts, screws, pins, wedges, etc. ... .
- In the bolted/ screwed connections without indicating the tightening couple, the checking has to
verify a normal tightening through manoeuvring keys.
- In the bolted/screwed connections, with indication of the tightening couple, checking must be
carried out by means of a dynamometric key proportional to the expected tightening couple.
- In bolts the correct tightening must be carried out by rotating the nut, not the screw head.
- In all the connections, all the safety elements (washers, pins, safety pins, etc.) must be present,
intact and efficient.

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The following non-destructive tests must be carried out by specialized personnel, for example personnel with
PCN qualification (personal certificate for non-destructive tests), which is a training plan recognized all over
the world.

The Manufacturer can prescribe one or more non-destructive periodical controls on important or more
stressed parts.
Because of inspections pointing out defects or doubts about the integrity of the surveyed particulars, contact
the Manufacturer to arrange the non-destructive checking to be carried out.

The records and the reports of the carried out checks must be kept inside the manual.

e) MAGNETOSCOPIC CHECKING

The magnetoscopic checking makes you notice surface discontinuities or sub-surface defects, which
cannot be noticed through a visual checking.

WARNING:
DO NOT carry out the magnetoscopic checking with electrical push rods as some steels,
used for mechanical structures or parts, can create undesired hardening if exposed to
quick heating/cooling cycles.

f) MAGNETIC DUST CHECKING

It is limited to ferromagnetic materials.

g) CHECKING WITH PENETRATING LIQUIDS

Checking must be carried out on parts of the structure having cracks in the paint with rust leakages.

h) CHECKING AT PASSIVE CURRENTS

It is not recommended to check attractions and passenger units.

i) CHECKING WITH ULTRASOUNDS

It allows to calculate the thickness of the structural elements. It is also used to point out breaks in
welded joints, bolts, pins, mechanical particulars subject to fatigue.

j) RADIOGRAPHIC CHECKING

It is particularly adequate to find out defects such as porosity, slags and lack of penetration in the
welding.

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17. INACTIVITY
17.1. PREPARATION TO STOP

We remind you that all the operations we are going to treat must be carried out with no tension and
by competent and qualified personnel.

Before stopping the ride for a long period, a general control of all structures must be done along with a
cleaning work of all those points subject to intense operation.
It is particularly important to clean and later grease the main transmission.
We recommend to clean properly the particulars of the structures where any dirt or encrustations are
present.

17.1.1. First cleaning

GENERAL WARNINGS

WARNING:
Before cleaning, you must follow the same procedures and precautions described for
maintenance.

If for cleaning chemical products dangerous for the operators’ health are used, these have to protect
themselves with means of individual protection (gloves, masks, glasses) adequate to the danger of the
product used.
Furthermore, observe the instructions supplied by the manufacturer of the product itself.
When cleaning operations require the use of inflammable materials, it is necessary to comply with all the
precautions indicated in the safety cards of the product used.

AS GENERAL PRECAUTIONS:

No smoking

Fire forbidden

Gloves compulsory

Respiration mask compulsory

Wait for the complete cooling of hot parts before operating.

FIRE AND/OR BURN DANGER.

When you clean zones subject to heating it is always necessary to wait for their complete cooling
before operating with cloths soaked with inflammable substances.

WARNING : The material used to clean the attraction must be disposed of according to the rules
in force in the country where the attraction is going to be set up and used.

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FIRST CLEANING

Interventions necessary for a first cleaning:

a) Painted parts:
clean carefully, using a normal liquid for domestic cleaning (do not use any solvents on the painted parts),
removing dust and fat.
b) Unpainted parts:
clean carefully removing any protective materials, using cleansing substances harmless for health and not
damaging the other surfaces.
c) Parts covered with protective grease or oil:
remove the protective substances through solvents allowed by the law in force.

17.2. RESTARTING

Restarting the ride after a long inactivity period demands an accurate check of the particulars subject to an
early wear, replacing them if necessary.
Check the condition of all electric connections and the general electric board.
Check the correct operation of all safety devices.
Once checking operation is over, go on by assembling the different structures and test the ride. However, we
remind you to follow all the safety rules mentioned above in this manual.

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18. TECHNICAL DATA

Model : Trailer mounted

Dimensions: m Ø7.5x5 h

Lighting: 10 KW approx.

Lighting voltage: 220 Volt

Motive power: 6 KW approx.

Motive power voltage : 380 Volt

Vehicles : n° 08

Seats: n°32 children or 8 adults and 16 children

Hourly capacity : 600 people approx.

Rotation speed: 5 rpm

Weight: kg. 2.700 approx. – 5.955 LBS

Transmission: hydraulic

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19. ENCLOSURES
19.1. HYDRAULIC SYSTEM VIEW

01 02

06
04

01

10
07

09

04 08

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01 03 02

04 05

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11

12 12

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Components list

1. Manometer Ø63 mm 0 … 400 bar “ADAMI”

2. Electric valve “ARON” cod. AD. 3.E 04 EC P1 20
3. Electric connector for electric valves
4. Base with max. Valve ES 38 3X 3F “F.T.”
5. Maximum valve
6. One-way flux regulator RFU 38
7. Electric valve “HYTOS” cod. RPE3 – 062H 11 – 01200E1 484-0705 0305/01
8. Descent control valve VOC 45/1 BI CH 2AY 03B
9. Double hydraulic pump
10. Heat exchanger
11. Closing tap in case of maintenance
12. 5 – bar set Valve.

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19.2. DECLARATION FORM OF MANUAL DELIVERY

______________

Attraction type:_________________________
Model:________________________________
Serial no:______________________________

The undersigned _________________________ herewith states

to have received a copy of the Use and Maintenance Manual.

The undersigned also declares:

To acknowledge all rules mentioned in it;
To ask for further explanations if instructions are not clearly
understood;
To inform Sartori Group about mistakes or inaccuracies in the
manual;
To avoid any divulgation, reproduction, transfer, sale or donation
of the present manual.

Signature

______________________

NOTE: Please make a photocopy of the form and send back a signed copy to SARTORI GROUP.

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19.3. EXPLANATIONS REQUEST FORM

EXPLANATIONS REQUEST FORM

USE AND MAINTENANCE MANUAL

Attraction type:_________________________
Model:______________________________
Serial no:____________________________

The undersigned _________________________ requires some

explanations on the following parts of the manual

CHAPTER:
PARAGRAPH:
PAGE:
EXPLANATION REQUIRED:

NOTE: Please make a photocopy and send it by fax to Manufacturer

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19.4. REPARATIONS – INTERVENTIONS REQUEST FORM

REPARATIONS AND/OR INTERVENTIONS REQUEST FORM

Attraction type:_________________________
Model:______________________________
SERIAL NO:____________________________

DESCRIPTION:

 FAILURE

 BREAKING

The following part needs intervention :

 MECHANICAL

 HYDRAULIC

 ELECTRICAL

 ELECTRONICAL

 PNEUMATIC

 OTHER

Description:

NOTE: Please make a photocopy and send it by fax to Manufacturer

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19.5. MISTAKES AND INACCURACIES FORM IN THE USE AND MAINTENANCE MANUAL

MISTAKES AND INACCURACIES FORM IN THE USE

AND MAINTENANCE MANUAL
Attraction type :_________________________
Model:______________________________
Serial no:____________________________

SARTORI GROUP thank for the kind cooperation shown for

improving the quality of their manufactures.

We found a/an:

 MISTAKE

 INACCURACY

in the Use and Maintenance Manual, and more precisely:

CHAPTER:

PARAGRAPH:

PAGE:

DESCRIPTION:

NOTE: Please make a photocopy and send it by fax to Manufacturer

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