NAFLIC

National Association For Leisure Industry Certification

Standards & Related Documents Committee

TECHNICAL BULLETIN – October 2015

395. Zamperla service bulletin re Crazy Bus/Crazy Sub/Crazy Plane/Fire Chief

Zamperla has issued a service bulletin relating to the above mentioned devices regarding the
installation of a redundant chain system to prevent the arms going out of sync should the
drive mechanisms fail. This issue has been discussed in previous TBs. There are two different
systems to install depending on the type of drive installed on the device. The solution for both
types appears to be the attachment of an additional sprocket onto the slewing ring and
connecting the two sprockets with a chain. This has the potential to introduce an additional
hazard, however, that of an unguarded chain. IBs and controllers are reminded that
implementation of this modification will require a design review of the safety critical
modification to be carried out.

The information contained within is that of the manufacturer and not NAFLIC. When
following the advice from the manufacturer, you are reminded of your duties and
responsibilities under HSG175 regarding modifications.

Committee Members: Mr. D Dadswell (Chairman), Mr. A Mellor (Secretary), Mr. P Smith, Mr. J Green,
Mr. D Cox, Mr. M Thirkettle, Mr. I Davies, Mr. J Shilling & Mr. D Inman

www.naflic.co.uk
Ride distributed by: Bulletin No: 2014 CB01
Zamperla, Inc. ® Release Date: October 1, 2014
49 Fanny Road Effective Date: October 1, 2014
Boonton, New Jersey 07005 Supersedes: n/a
USA Completion Date: Prior to 2015 Operation
Phone: 973 334 8133 Fax: 973 334 6880 Page: 1 of 2

SERVICE BULLETIN
Ride Manufacturer: A. Zamperla SpA Affected Production Dates: ALL
Ride Name: Crazy Bus, Crazy Sub, Crazy
Plane, Fire Chief Affected Serial Nos.: ALL
Model Number: Crazy Bus, Crazy Sub, Crazy Plane, Fire Chief
Abstract Of Issue:
Installation of the redundancy kit.

Reason For Release:

To introduce a redundant system to the drivetrain.

Action To Be Taken:
Use the attached page to determine the version of your ride. Contact Zamperla Inc. (973 334 8133) to
obtain the correct version redundancy kit (provide serial number). Follow the procedure to install the
redundancy kit on your ride. Procedure will be provided with kit.

Detail Of Issue:
Determine the version of ride (refer to page 2 of 2).
Follow procedure to install the redundancy kit, which will be provided with the kit when it is delivered.

Future Action To Be Taken:

Daily:
- Inspect chain is intact and shows no signs of damage or wear.
- Visually inspect torque stripes.
- Verify tensioner is adjusted properly.
Weekly
- Grease chain.
Service Bulletin 2014 CB01 Page 2

How to determine the version of my ride?

Horizontal Motor “drive belts”
Requires Redundancy Kit 9369232000A

___________________________________________________
Vertical Motor “no drive belts”
Requires Redundancy Kit 9369235000A

Issued by: Zamperla, Inc.

 Procedure  to  install  the  chain  redundancy  kit,  part  number  
9369232000A,  on  the  Crazy  Bus  ride

“Horizontal  Motor”  Version

Note:    There  may  be  some  slight  varia3ons  in  design  from  ride  to  ride.  If  you  encounter  a  
problem  installing  this  kit,  please  contact  Zamperla  at  973  334  8133.  Please  have  the  serial  
number  of  the  ride  available.

The  kit  contains  all  the  components  required  to  perform  the  installa3on.  The  kit  consists  of  two  
half  moon  sprockets,  two  half  moon  reinforcement  plates  and  hardware.  The  sprockets  form  a  
circle  against  the  boom  flange  that  mates  to  the  ring  gear.  The  reinforcement  plates  form  a  
circle  that  bridges  the  joint  of  the  sprockets.  The  ride  must  be  rotated  several  3mes  during  the  
installa3on  to  allow  access  to  the  socket  head  bolts  that  secure  the  ring  gear.  These  bolts  are  
systema3cally  replaced  with  the  new  hardware  supplied  in  the  kit.  Refer  to  drawing  
9369232000A  for  complete  bill  of  material  of  kit.

1. Remove  the  ring  gear  covers  that  conceal  the  two  rotary  ring  gears.

2. Remove  six  consecu3ve  bolts  of  the  ring  gear  and  replace  them  with  the  longer  
M12x100  bolts,  washers  and  nuts  supplied  (Fig.  1).  ATach  the  first  half  moon  sprocket  
(they  are  in  matched  sets)  to  these  six  bolts.  The  end  of  the  half  moon  sprocket  must  not  
land  concealed  behind  the  steel  of  the  boom.  Posi3on  it  so  that  the  sprocket  ends  land  
outside  this  concealed  space.  The  sprocket  must  rest  flush  against  the  boom  flange.  If  
there  is  some  interference,  carefully  clean  or  grind  the  material  away  to  allow  a  correct  
ma3ng  of  the  sprocket  to  the  flange  (Fig.  2).  Tighten  these  bolts  (do  not  torque  to  the  
final  value)  (Fig.  3).

Fig.  1 Fig.  2
 Fig.  3 Fig.  4

3. Remove  the  remaining  six  original  bolts  from  the  ring  gear  and  replace  them  with  the  
longer  M12x100  bolts,  washers  and  nuts  supplied.  ATach  the  second  half  moon  sprocket  
(they  are  in  matched  sets)  to  these  six  bolts  (Fig.  5,  6).  The  two  sprockets  should  now  
form  a  360  degree  circle  (Fig.  7).  Tighten  these  bolts  (do  not  torque  to  the  final  value).

Fig.  5 Fig.  6

Fig.  7
4. Remove  three  nuts  from  the  first  half  moon  sprocket  and  three  nuts  from  the  second  
half  moon  sprocket.  Install  the  first  half  moon  reinforcement  plate  to  span  across  the  
two  sprocket  halves  (Fig.  8).  Install  the  supplied  hardware  (M12x25  bolts  with  washers)  
through  the  holes  in  the  reinforcement  plate  and  into  the  threaded  holes  of  the  
sprockets  (Fig.  9).  Tighten  all  hardware.

Fig.  8 Fig.  9
5. Remove  the  remaining  nuts  and  install  the  second  half  moon  reinforcement  plate.  The  
two  reinforcement  plates  should  now  form  a  360  degree  circle  (Fig.  10).  Tighten  these  
bolts  and  nuts.

Fig.  10
6. Inspect  the  sprocket  joints.  If  the  joint  does  not  meet  correctly  (Fig.  11),  use  a  punch  to  
mate  the  joint  so  that  the  chain  will  rest  correctly  in  the  teeth  of  the  sprocket  (Fig.  12,  
13).
 Fig.  11 Fig.  12

Fig.  13

7. Use  a  torque  wrench  to  apply  84  NM  of  torque  to  the  nuts  of  the  sprocket  (Fig.  14)  and  
torque  stripe.  Snug  3ght  the  small  bolts  of  the  reinforcement  plates  (Fig.  15,  16).

Fig.  14 Fig.  15

 Fig.  16 Fig.  17

8. AYer  performing  the  sprocket  /  reinforcement  plate  installa3on  on  the  other  boom,  the  
chain  can  be  installed.

9. Lay  the  chain  over  one  sprocket.    Push  and/or  pull  the  arms  of  the  ride  to  allow  a  3ght  
slack  free  chain  tension.  The  chain  may  be  joined  with  the  full  or  half  master  link  
supplied  with  the  chain.  A  link  of  the  chain  may  be  removed  if  necessary  (Fig.  17).

10. The  upper  and  lower  chain  should  be  aligned  with  liTle  or  no  slack  (Fig.  18,  19).  Refer  to  
View  X  on  drawing  9369232000A  for  tolerance.

Fig.  18 Fig.  19

11. Install  the  chain  tensioner.    Refer  to  Chain  Tensioner  Installa3on  Procedure  to  properly  
install  the  chain  tensioner.

12. Inspect  the  counterweight  hinge  pin  to  ensure  that  it  will  clear  the  chain  when  the  boom  
is  rotated  (Fig.  20).  If  required,  cut,  grind  or  re-­‐drill  the  arc  clip  hole  to  provide  adequate  
clearance  between  the  hinge  pin  and  chain  (Fig.  21,  22,  23).
 Fig.  20 Fig.  21

Fig.  22 Fig.  23

13. Apply  good  quality  chain  grease  to  the  chain.

14. The  ring  gear  covers  may  be  discarded  or  modified  to  be  reinstalled.  You  will  need  to  
custom  cut  and  fit  them  for  remoun3ng.

15. Test  the  ride  slowly  at  first  increasing  speed  to  normal  opera3ng  speed  (Fig24).

Fig.  24
NOTE:  THE  ABOVE  PHOTOS  ARE  FOR  GENERAL  REFERENCE  ONLY.    DEPENDING  ON  YOUR  MODEL,  THE  
INSTALLATION  MAY  VARY  FROM  THE  ABOVE  PHOTOS.  
 12 11 10 9 8 7 6 5 4 3 2 1

H B-­B  (  1:5  ) C-­C  (  1:10  ) 2 H

2800 1
e  =  16 355
1 36,1 REGOLAZIONE  TENDITORE D-­D  (  1:10  )
B Z=80,  PITCH  1"  (25.4  mm)  
5 SPROCKET  ADJUSTMENT 15
18 124,6 355 Z=80,  PITCH  1"  (25.4  mm)
12 50 11 C
12 N . 1 -  1
D
3
1 13
6
10
G G
16 D 11
C
6 14
10
10 5
(2)         2
MAGLIE:    N .  301  +  FALSAMAGLIA
LINKS:  N .  301  +  MASTER  LINK 400
400 VIEW  -­  Y
F
(2)         B IL  TENDITORE  VA  INSTALLATO  QUANDO  LA  DISTANZA  E'  SUPERIORE  AI  30  mm.
F
SPROCKET  MUST  BE  INSTALLED  IF  THE  DISTANCE  IS  MORE  THAN  30  mm TABELLA  COPPIA  SERRAGGIO
2806 TORQUE  TABLE
6 COPPIA COPPIA
TORQUE A TORQUE B
VITERIA  NON  LUBRIFIC. VITERIA  LUBRIFICATA
COEFF.  ATTRITO=  0.14 COEFF.  ATTRITO=  0.10
>30   NON  LUBRICATED  BOLTS LUBRICATED  BOLTS
647

FRICTION  COEF.=  0.14 FRICTION  COEF.=  0.10

RIFERIMENTO
REFERENCE  TO  

16,2
647 N  m lbf  ft N  m lbf  ft
2 (2)         1 25 18 18 13

2 84 62 61 45
1 41.3
3 56 40 20.5
E E
IL  PRODOTTO  USATO  PER  LA  LUBRIFICAZIONE
DELLE  VITI  E'  PASTA  "MOLYKOTE  HSC"  
LUBRICATING  PRODUCT:  "MOLYCOTE  HSC"  PASTE
2794

A  (  1  :  5  )
VIEW  -­  X
1
5 FARE  RIFERIMENTO  ALA  PROCEDURA  DI  INSTALLAZIONE  PER  L'ASSEMBLAGGIO.
REFER  TO  INSTALLATION  PROCEDURE  FOR  PROPER  ASSEMBLY.

D 6 D

4 N . 1 -  1 AGGIUNTO  SISTEMA  TENDICATENA  (OTT_2013_LM)

ADDED  KIT  CHAIN  TENSIONER  (OTT_2013_LM)

3 16 4 1070917   ROSETTA  D.  8.4x17x1.6  -­  140HV  UNI6592PLAIN  WASHER 0

15 2 1070834   DADO  AUTOBL.  M8  NORM.  -­  8  UNI7473 SELF  LOCKING  HEX.  NUT 0
10 14 2 107041605   VITE  TCCE  M8x70  -­  8.8  UNI5391 HEX.  SOCKET  SET  SCREW 0
13 4 107018494   VITE  TE  M12x260  -­  8.8  UNI5737 HEX.  HEAD  SCREW 0,2
12
12 1 9369232004 A PIASTRA  FISSAGGIO FIXING  PLATE 4,2
5 11 1 10501801890 A TENDICAT.  TENBLOC  TBB-­RR40  (1"X17.02)  SPROCKET  TENBLOC  TBB-­RR40   1
C C
(1"X17.02)  
10 1 9369232003 A SUPPORTO  TENDICATENA CHAIN  THIGHTENER  SUPPORT 4,6
9 2 005014245   FALSA  MAGLIA  CATENA  ISO  16B-­1  1"X17,02   DUMMY  JERSEY  CHAIN  ISO  16B-­1   0
7 SEMPL 1"X17,02  SIMPL
8 1 005014242   GIUNTO  CATENA  ISO  16B-­1  1"X17,02  SEMPLICE JOINT  CHAIN  ISO  16B-­1  1"X17,02   0
SIMPLE
7 24 1070162   VITE  TE  M12x25  -­  8.8  UNI5739 HEX.  HEAD  SCREW 0
6 28 1070840   DADO  AUTOBL.  M12  NORM.  -­  8  UNI7473 SELF  LOCKING  HEX.  NUT 0
5 56 1070922   ROSETTA  D.  13x24x2.5  -­  140HV  UNI6592 PLAIN  WASHER 0
(3)         4 24 10704410   VITE  TCCE  M12x100  -­  8.8  UNI5931 HEX.  SOCKET  SET  SCREW 0,1
11 3 4 9369232001 A SPESSORE  RINFORZO REINFORCEMENT  PLATE 3,8
A 2 4 9369232002 A LAVORAZIONE  CORONA  SINGOLA  1"-­17.02  Z=80 MACHINED  GEAR  CROWN  SINGLE   7,8
B CHAIN  1"-­17.02  Z=80 B
1 1 005014241   CATENA  ISO  16B-­1  1"X17,02  SIMP ROLLER  CHAIN  ISO  16B-­1   86,6
1"X17,02  SIMPLE
Pos Q.ty Codice  /  Code Rev. Descrizione Description  Mass  Kg
 A  TERMINI  DI  LEGGE  LA  ZAMPERLA  S.p.A.  CONSIDERA  QUESTO  DOCUMENTO  COME  SEGRETO  AZIENDALE  CON  DIVIETO  PER  CHIUNQUE
 DI  RIPRODURLO  E/O  DI  RENDERLO  COMUNQUE  NOTO,  IN  TUTTO  O  IN  PARTE,  A  TERZI,  OVVERO  A  DITTE  CONCORRENTI,  SENZA
 SPECIFICA  AUTORIZZAZIONE  SCRITTA  DELLA  DIREZIONE  ZAMPERLA.
 ACCORDING  IN  LAW  ZAMPERLA  S.p.A.  CONSIDERS  THIS  DOCUMENT  TO  BE  A  COMPANY  SECRET  AND  THEREFORE  PROHIBITS
 ANY  PERSON  TO  REPRODUCE  IT  KNOWN  IN  WHOLE  OR  IN  PART  TO  OTHER  PARTIES  OR  TO  COMPETITORS  WITHOUT  SPECIFIC  WRITTEN
 AUTHORIZATION  OF  ZAMPERLA'S  MANAGEMENT.

 Data:
 09/11/2011
(1)          Date
 Firma:
 Signature:  LM
   Via  Monte  Grappa,  15-­17  -­  36077  ALTAVILLA  VICENTINA  (VI)  -­  ITALIA
   Tel.  +39.0444.998400  -­  Fax  +39.0444.573720
   e-­mail:  zamperla@zamperla.it  -­  http://www.zamperla.com  Disegnato  /  Drawn  Controllato  /  Checked  Approvato  /  Approved
 SIMBOLI  SALDATURE  SECONDO  EN  22553
 Macchina:  QUOTE  SENZA  TOLLERANZE  SPECIFICHE:  WELDING  SYMBOLS  ACCORDING  TO  EN  22553
 CARPENTERIA:  EN  ISO  13920  Cl.  A-­E
 Assembly  machine: CRAZY  BUS  LAVORAZIONI  MECCANICHE:  EN  22768  Cl.  m-­k  PREPARAZIONE  DEI  LEMBI  DA  SALDARE
 DIMENSION  WITHOUT  SPECIFIC  TOLERACES:  SECONDO  ISO  9692
 Gruppo:  STEEL  STRUCTURE:  EN  ISO  13920  Cl.  A-­E
TRASMISSIONE  JOINT  PREPARATIONS  TO  WELD  ACCORDING
 MACHININGS:  EN  22768  Cl.  m-­k  TO  ISO  9692
 Unit: TRASMISSION
A  Denominazione: ASSIEME  MONTAGGIO  KIT  CATENE  Materiale:  Massa  -­  Unit: A
 Name: CHAINS  SYSTEM  KIT  ASSEMBLY  Material:   148.76  kg
 N  disegno:  Mod.:  Foglio:  Scala:  Proiezione:  Formato:
 drawing  Nr: 9369232000A  Mod.: 1  Sheet: 1  di  1    Scale: 1:10  Projection:  Format: A1
12 11 10 9 8 7 6 5 4 3 2 1