Conveyor 1MANUL010 REV 06

Transcription

1 Conveyor Belanger, Inc. P.O. Box 5470 Northville, MI Customer Service Phone (248) Fax (248) MANUL010 REV 06

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3 Belanger Equipment Owner s Manual DuraTrans XD Conveyor Copyright 2012 Belanger, Inc This manual and the accompanying equipment are protected by United States trademark, copyright, and patent laws. You may make one copy of this manual. Do not make additional copies of this manual or electronically transmit it in any form whatsoever, in whole or in part, without the prior written permission of Belanger, Inc. The registered trademarks used in this document are the property of their respective owners. The use of such trademarks is for reference purposes only and does not imply sponsorship or approval of Belanger, Inc. by these companies or any companies affiliated with their respective owners.

4 CURRENT REVISION LOG Trans XD Conveyor Rev Release Date Page Description 06 26OCT12 REV Added Revision Log TOC Consolidated Maintenance articles into one section 8 Removed paragraph 4 of rev 05, DuraTrans was Over/Under Conveyor in paragraph 5 of rev 05, updated image of conveyor assembly to reflect the current design. 9 Added data for 4-Wheel Roller (Standard) & Added Optional to 6-Wheel Roller data. 11 Updated conveyor section/assembly images to reflect the current design. 12 Added image of Standard 4-Roller Assembly & Updated the title of the 6- Roller Assembly to be Optional BIS-6 Roller Assembly. 16 Updated conveyor section/assembly images to reflect the current design. 18 Updated conveyor section/assembly images to reflect the current design. 21 Updated conveyor section/assembly images to reflect the current design. 23 Updated conveyor section/assembly images to reflect the current design. 24 Updated instructions and images to reflect 4-roller design (now standard) instead of 6-roller design (now optional). 25 Updated chart based on formulas given on the same page. 26 Updated instructions and images to reflect 4-roller design (now standard) instead of 6-roller design (now optional). 28 Conveyor Controller System was DCC. 29 Conveyor Controller System was DCC. 32 Conveyor Controller System was DCC. 36 Updated conveyor section/assembly images to reflect the current design. 37 Updated conveyor section/assembly images to reflect the current design. 45 Updated conveyor section/assembly images to reflect the current design. 47 Added first bullet on proper chain tension Updated Powder Coat article and consolidated it into the Maintenance section. Consolidated the HECO Hydraulic Gearbox article into the Maintenance section. For Part number DXD was DXB and updated conveyor section/assembly images to reflect the current design. 59 Updated conveyor section/assembly images to reflect the current design. 60 Updated conveyor section/assembly images to reflect the current design. 62 Updated conveyor section/assembly images to reflect the current design. 64 Updated conveyor section/assembly images to reflect the current design. 65 Updated conveyor section/assembly images to reflect the current design. 66 Updated conveyor section/assembly images to reflect the current design Removed part number from the title of the first image at the top of the page, added part number 1GEABX-AS971 to the Zone 1 image. Removed part number from the title of the first image at the top of the page, added part number 1GEABX-AS976 to the Zone 1 image. Added the Exploded View of Part Number and updated the exploded view of part number In the Entrance Section Replacement Part chart, the Part Number for the Prox Switch w/12 Cord was 1ELECT-SN357, now is 1ELECT-SN360. Added section 4 Roller for Standard Dollie & updated section BIS-6 Roller for Optional Dollie.

5 Table of Contents Belanger Incorporated Limited Warranty... 3 Operational Warning... 4 Important Safety Information... 5 Safety Symbols and Signal Words... 5 IMPORTANT Safety Information MUST READ... 6 Introduction... 8 Before You Get Started... 9 Available Sections Available Options Parts Identification Installation Overview Preparing the Pit Setting the Conveyor Permanently Welding the Conveyor into Place Installing the Electric Drive Unit Components (Exit Section) Electrical Prints Information Installing the Hydraulic Drive Unit (Exit Section) Optional Proximity Hub Assembly (Exit Section) Installing the Optional Exit Pulse Counting Proximity Mount and Sensor Securing Chain Links to Rollers How to Calculate Number of Rollers Required How to Calculate Chain Speed in Vehicles per Hour Assembling the Chain and Rollers Inserting the Chain and Rollers into the Conveyor Pneumatic Air Panel Placing the Floor Treadle Utility Connections Hydraulic Pump Schematic Fixed Displacement power unit with No Reversing Feature Variable Volume power unit with No Reversing Feature Fixed Displacement power unit with Reversing Feature Variable Volume power unit with Reversing Feature Installing the Plastic Guide Rail Optional Reversing Valve MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

6 Table of Contents Initial Startup...43 Air Panel Overview Initial Settings Operation...44 System Adjustments and Over-Rides Manual Roller-Up: Maintenance...46 Sprocket Torque Specifications Routine Procedures Trouble Shooting Powder Coating Maintenance Cleaning Procedure Powder Coating Repair HECO Hydraulic Gear Box Replacement Parts...58 Entrance Section Exit Section : Standard 4 Roller Replacement Assembly : BIS-6 Roller Replacement Assembly Replacement Chain Air Panel Guide Rail Floor Treadle Suggested Replacement Parts List Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

7 Belanger Incorporated Limited Warranty LIMITED WARRANTY: Equipment: Seller warrants to the original purchaser that the goods sold hereunder, which are fabricated by Seller, shall be free from defects in workmanship and material under normal use and service for a period of 1 year plus 30 days from the date of invoice - CAT Pumps will be warranted for 2 years from the date of invoice. All warranties, express, implied, or statutory, pertaining to Seller s machinery, parts, and equipment are fully set forth herein. This limited warranty applies to the original purchaser only and is not transferable. No addition to or modification of any of the provisions of this stated Limited Warranty shall be binding upon the Seller, unless made in writing and signed by a duly authorized employee of Seller. This warranty is subject to the following limitations: (1) This warranty shall be void if the factory specifications for operation and maintenance, found in original equipment manuals, and component manuals, are not followed, or if other than factory authorized erection, alterations or modifications are made to any parts or equipment; (2) Defective parts are warranted to the Purchaser for repair or replacement through an authorized distributor of Seller or direct with Seller for a period of 13 months from the date of invoice. Parts warranty excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation, omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. Purchaser agrees to submit to and assist Seller or its authorized distributor in conducting in-warranty inspections of the machinery and equipment including inspection of any part claimed to be defective by the Purchaser; (3) Labor to repair or replace parts is warranted to Purchaser during normal business hours through an authorized distributor of Seller or direct with Seller, for 120 days from date of invoice. Labor warranty excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation, and omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. Seller reserves the sole right to make determinations on the above stated limitation. All labor and service provided beyond the labor warranty period shall be subject to labor charges at the rates established by the local authorized distributor or direct with Seller; (4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, Sodium Hydroxide and Chlorinated Solvents. (5) Seller makes no warranty, express or implied, with respect to the design or operation of any entire system, in which Seller s goods sold hereunder are mere components. (6) In no event shall Seller be liable for any incidental, special, consequential or exemplary damages resulting from the furnishing, performance or use of any goods or services sold pursuant hereto, whether due to a breach of contract, breach of warranty, the negligence of Seller or to otherwise; not for loss of business; inconvenience, or property damage of any kind; not for any damages of whatever nature resulting in any way from the purchaser s selection and use of any chemicals not manufactured exclusively by seller but used with the purchased goods; or for any service not expressly provided herein related to or arising from the equipment or goods sold. This limitation of liability extends to purchaser s use of any engineering recommendations, sales representations, technical assistance, advice or data supplied by seller to purchaser in connection with the goods or services supplied, other than that information contained in Belanger manuals. Parts: Seller warrants to the original purchaser that the Replacement Parts sold hereunder, shall be free from defects in workmanship and material under normal use and service for a period of 30 days from the date of invoice. This limited warranty applies to the original purchaser only and is not transferable. (1) This warranty shall be void if the factory specifications for operation and maintenance are not followed; (2) Parts warranty excludes all claims for failure resulting from normal wear and tear to the depreciable parts, improper installation, omission of factory specified preventative maintenance, misuse, abuse, negligence, third party damages, or acts of God. (3) This warranty shall be void for all replacements parts failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger replacement parts will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, Sodium Hydroxide and Chlorinated Solvents. THIS LIMITED WARRANTY FOR EQUIPMENT AND REPLACEMENT PARTS IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, WHETHER STATUTORY OR OTHERWISE, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Copyright 2000 by Belanger, Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system, except as may be expressly permitted by the 1976 Copyright Act. Revised as of Belanger reserves the right to change or modify the Belanger Inc. Limited Warranty without notice. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

8 Operational Warning Formulations containing the chemicals listed below are particularly dangerous and should not be used even at low concentrations: Hydrofluoric Acid Ammonium Bi-flouride Bromic Acid Muriatic Acid Sulfonic Acid Phosphoric Acid Hydrogen Cyanide Hydrochloric Acid Chlorinated Solvents Belanger, Inc., does not endorse or condone the use of chemicals that are potentially dangerous to human health, the environment or property. Belanger recognizes that it is the right and sole decision of the end user operators of our equipment as to the type and dilution ratio of the chemicals used in their facilities. We strongly recommend that the end user does not select products containing any of the chemicals listed above as an ingredient in the wash solutions. The chemicals listed above are potentially dangerous to human health, and have a detrimental, deteriorating effect on the equipment and the facility. Be advised that a portion of, or all of your warranty will be voided if you determine to use any of the chemicals listed above as an ingredient in the wash solutions in conjunction with your Belanger automatic car wash equipment: Limitation (4), of Paragraph (8), Limited Warranty, of the Belanger Terms and Conditions of Sales describes the potential limitation of warranty due to your chemical selection: (4) This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process. The following list includes some, but not all, of the particularly corrosive chemicals that if used in conjunction with Belanger equipment will void the warranty: Hydrofluoric Acid, Ammonium Bi-flouride, Bromic Acid, Muriatic Acid, Sulfonic Acid, Phosphoric Acid, Hydrogen Cyanide, Hydrochloric Acid, and Chlorinated Solvents. The Purchaser also agrees to accept the responsibility and liability for the selection and use of any chemicals listed above; However, should the end user decide to use formulations containing any of the above ingredients, the end user should institute a comprehensive training program and implement detailed operational parameters within their organization for the proper handling and treatment of such products to minimize the potential dangers involved. Consult your chemical supplier for assistance in establishing operational guidelines in the use of their products. MSDS (Material Safety Data Sheet) should be obtained from the chemical supplier before using any chemical formulation. CAUTION During the installation process the installer is responsible for re-tightening ALL lugs, set screws and terminals located in the electrical panels. Components may vibrate loose during shipping. 4 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

9 Important Safety Information This section introduces the hazard and safety precautions associated with installing, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task may be found. Electrical shock could occur and cause death or serious injury if these safe service procedures are not followed. Safety Symbols and Signal Words Alert Symbol This safety alert symbol is used in this manual and on warning labels to alert you to precautions, which must be followed to prevent potential personal safety hazards. Obey safety directives that follow this symbol to avoid possible injury or death. Signal Words The signal words used in this manual and on warning labels tell you the seriousness of particular safety hazards. The precautions that follow must be followed to prevent death, injury or damage to the equipment. DANGER This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN DEATH OR SERIOUS INJURY This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR SERIOUS INJURY CAUTION This signal word designates a hazard or unsafe practice which MAY RESULT IN MINOR INJURY CAUTION When used by itself, CAUTION designates a hazard or unsafe practice which MAY RESULT IN PROPERTY OR EQUIPMENT DAMAGE Before You Begin Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain or service this equipment. Read the Manual Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand the procedure, call a Belanger, Inc. representative at It is imperative to your safety and the safety of others to understand the procedures before beginning work. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

10 Important Safety Information IMPORTANT Safety Information MUST READ Safety Warnings DISCONNECT THE MAIN POWER SUPPLY AND DISSIPATE ALL POTENTIALLY HAZARDOUS ENERGY SOURCES PRIOR TO SERVICING OR MAINTAINING EQUIPMENT Belanger recommends that all workers observe the OSHA (U.S. Department of Labor Occupational Safety & Health Administration) Lockout / Tagout procedure to dissipate all potentially hazardous energy sources (i.e. - electrical, mechanical, hydraulic, pneumatic, chemical, thermal, etc.) prior to performing service or maintenance on machinery and equipment. Note: Reference the OSHA standard for the Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of Federal Regulations (CFR) Part and the example provided in Appendix A for practices and procedures necessary to disable machinery or equipment, thereby preventing the release of hazardous energy while employees perform servicing and maintenance activities. The standard outlines measures for controlling hazardous energies electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources. Note: Reference the OSHA standard 29 CFR to 29 CFR for safe work practices to protect employees working on electrical circuits and equipment. This section requires workers to use safe work practices, including lockout and tagging procedures. These provisions apply when employees are exposed to electrical hazards while working on, near, or with conductors or systems that use electrical energy. Note: Both referenced OSHA standards can be found at the following website: Browse to the General Industry tab under the Find an OSHA Standard heading, scroll down to the link of interest and click on it. Doing so will prevent unexpected energization, startup, or release of hazardous energy while maintenance and servicing activities are being performed. 6 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

11 Important Safety Information Safety Warnings BE SURE TO OBSERVE OPERATING ENVELOPE. EQUIPMENT MAY START UNEXPECTICALLY. OVERHEAD, ROTATING AND/OR MOVING COMPONENTS COULD RESULT IN SERIOUS INJURY OR DEATH. BE AWARE OF FOREIGN OBJECTS IN THE AREA SURROUNDING A ROTATING PIECE OF EQUIPMENT. OBJECTS MAY BECOME TANGLED WITH EQUIPMENT AND COULD RESULT IN SERIOUS INJURY OR DEATH. CAUTION BE AWARE OF HAZARDS ASSOCIATED WITH EQUIPMENT INSTALLED ON THE FLOOR THAT MAY BE A TRIP HAZARD. It is imperative to your safety and the safety of others to always follow safe work procedures. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

12 Introduction Congratulations on your purchase of the Belanger, Inc. DuraTrans XD Conveyor. The purpose of this manual is to familiarize you with how the DuraTrans XD Conveyor is installed, how it operates, and how to maintain it after installation. The section called Installation will be used in conjunction with the location diagram, and the various DuraTrans XD Conveyor drawings. All of these combined are your guides to installation. The section entitled Maintenance will be used in conjunction with the section called Replacement Parts to make sure you can keep your car wash components looking and running like new. Read through the entire manual to familiarize yourself with the DuraTrans XD Conveyor before installation. When installation is completed, you will want to keep this manual as a guide to proper maintenance. 8 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

13 Introduction Before You Get Started Physical Features Dimensions and Weights (Packaging Extra) Item Description Weight Length Width Height Weight Length Width Height Lbs In In In Kg Cm Cm Cm Entrance Section /8 25 1/ Exit Section /8 25 1/ Center 10 Section /8 25 1/ Center 5 Section /8 25 1/ Wheel Roller (Standard) 6 7 3/ / Wheel Roller (Optional) 7 1/2 10 3/ X458 Chain, / / Sprockets, 4 Tooth 17 3/4 9 1/2 9 1/ Take-up w/sprocket /4 17 3/8 11 3/ Roller-Up Assembly 34 3/4 10 1/ / Guide Rail, /2 3 1/ Approximate Conveyor Weights (7 4 Roller Spacing Packaging Extra) Length Ft 60 Ft 80 Ft 100 Ft 120 Ft 140 Ft 160 Ft Weight Lb 4,350 5,695 7,040 8,385 9,730 11,075 Length M 18.3 M 24.4 M 30.4 M 36.5 M 42.6 M 48.7 M Weight Kg 1,978 2,589 3,200 3,812 4,423 5,035 Hydraulic Drive: Electrical Control, Hydraulic Power and Pneumatic Requirements Electrical Control 24 VDC (from Belanger DCC Panel) Contact Belanger for Other Voltages Hydraulic Power PSI (Contact Us) Bars (Contact Us) Pneumatic PSI (120 PSI maximum) Note: Entrance Sections Subjected to Temperatures Below 32 F Should Have A Compressor Auto-Drain Valve & Air Panel Coalescer for Air Supply Moisture Removal M Bars Note: Entrance Sections Operating at Temperatures Below 0 C Should Have A Compressor Auto-Drain Valve & Air Panel Coalescer for Air Supply Moisture Removal Electric Drive: Electrical Control, Hydraulic Power and Pneumatic Requirements Electrical Control 24 VDC (from Belanger DCC Panel) Contact Belanger for Other Voltages Electric Power Pneumatic 208 VAC / 230 VAC Hz 3 Phase 3 or 5 HP (20Amp) Minimum #12 Wire 460 VAC Hz 3 Phase 3 or 5 HP (10Amp) Minimum #14 Wire PSI (120 PSI maximum) Note: Entrance Sections Subjected to Temperatures Below 32 F Should Have A Compressor Auto-Drain Valve & Air Panel Coalescer for Air Supply Moisture Removal M Bars Note: Entrance Sections Operating at Temperatures Below 0 C Should Have A Compressor Auto-Drain Valve & Air Panel Coalescer for Air Supply Moisture Removal 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

14 Introduction Before You Get Started Tools Needed for Installation: Fork lift Hammer drill with 1/2 bit Tape measure (50 foot or greater) Pry bar Level Welder Disc grinder Shim plates C-clamps 50 foot extension cord Tin snips Safety glasses Work gloves Miscellaneous hand tools Torches Transit Hydraulic hand jack Chalk line Field Supplied Items Required: Steel grating to allow proper water drainage. Quantity is determined per specific installation DISCONNECT THE MAIN POWER SUPPLY, LOCKOUT ELECTRICAL POWER AND DISSIPATE ALL POTENTIALLY HAZARDOUS ENERGY SOURCES PRIOR TO SERVICING OR MAINTAINING EQUIPMENT! CAUTION Always wear safety glasses when performing maintenance on any equipment CAUTION It is recommended that a licensed electrician is contracted to perform all electrical installations. CAUTION A compressed Air System should be set correctly to support 90 PSI necessary to operate equipment, but should never be set to deliver more than 120 PSI air pressure to the Belanger specified equipment. 10 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

15 Introduction Available Sections 5 Foot Entrance 5 Foot Center 10 Foot Center 5 Foot Exit Above images shown with Single Guide Rail Available Options Single Guide Rail (driver side only) Double Guide Rail (both sides) Standard Finish (black) Premium Finish (green) 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

16 Introduction Parts Identification Standard 4 Roller Assembly Optional BIS-6 Roller Assembly Hydraulic Motor/Gearbox Assembly Electric Motor/Gearbox Assembly Tension Cylinder Assembly Take-Up Sprocket Assembly Roller-Up Ramp Assembly Roller-Up Ramp Cylinder Assembly Manual Roller-Up Lever Assembly Float Assembly Optional Exit Proximity Sensor 12 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

17 Installation Overview Overhead View with Conveyor in Place Motor/Gearbox Assembly Exit Door Direction of Travel Conveyor Surface Conveyor Pit Entrance Trap Door Correlator Y Section (sold separately) Correlator Assembly (sold separately) 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

18 Installation Preparing the Pit Objective Optimum placement of the conveyor is to be centered off the driver s side Correlator frame and straight throughout the building. The conveyor should be installed from the entrance to the exit on an incline of 1/4 inch per 10 ft, as should the concrete floor throughout the building. Note: This incline will keep pressure on the Rollers and keep the vehicles moving at a steady speed. The elevation of the top surface of the conveyor will change with the two different styles for running vehicles through the car wash. If the wash is setup to run the vehicles as a REAR TIRE PUSH the conveyor surface elevation will be 1 higher than the passenger side floor height. If the wash is setup to run vehicles as a FRONT TIRE PULL the conveyor top surface elevation will be 1 lower than the passenger side floor height. Understand the cement floor may have imperfections throughout the building and the elevation may require improvising slightly, to avoid radical rises and falls throughout the wash. The first sections of conveyor where the vehicles would be driven onto may not be as important as the rest of the conveyor. The total length of the pit should exceed the total length of the conveyor by 1 ft. the additional 1 ft will be split between each end of the conveyor (6 at entrance and 6 at the exit), that will allow adequate room for fabrication at the transition areas ON and OFF the conveyor. Read the Helpful Hints for techniques that have proven successful in such cases. 14 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

19 Installation Preparing the Pit 1) Clean out the pit. 2) Measure the total length of pit, it should be 1 FT longer than the total conveyor length. 3) Starting with the entrance section, place each conveyor section, except for the exit section, on the shelf of the pit. Note: Leave the exit section out so there is some room to work Overhead View of Conveyor Pit minus Exit Section Direction of Travel 4) Run a plumb line from the entrance to the exit over the top of the conveyor shelf. 5) Measure the distance from the pit wall or centerline of equipment to the centerline of the driver side Correlator frame and weld down pieces of round stock at the entrance side that are at least 5 high off the Conveyor surface. The 5 height is to allow adequate working space. 6) Go to the exit end of the tunnel. Measure then weld down round stock at least 5 high off the Conveyor surface at the exit end. Note: The measurement stated above is the same at the entrance and exit ends of the tunnel. Helpful Hint You can install a temporary anchor bolt in the floor just beyond the exit end of the pit to secure a plumb-line. This bolt MUST be removed once installation is complete. 7) Pull a plumb line from the entrance to the exit. This line should be the center of the conveyor. Note: The Driver side of the conveyor should be 1 away from the driver side pit wall. 8) Line the conveyor sections together and look to see if the pit wall prevents you from installing the conveyor on the centerline of the driver side Correlator main frame. Note: If the driver side of the conveyor makes contact with the pit wall you will have to move the conveyor away from that wall. 9) Looking down the tunnel, the conveyor should look to be straight through the building. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

20 Installation Preparing the Pit CAUTION If the passenger side floor varies from level more than 1/2" per 120 of tunnel distance, call your local distributor or a representative from Belanger sales department before going any further. Rear tire push conveyors should be 1 higher than the passenger side floor. Front tire pull conveyors should be 1 lower than the passenger side floor. 10) Setup transit so it is in view of the whole conveyor from entrance and exit. 11) Starting at the entrance of the conveyor pit. Take a reading of the floor elevation from both the centerline of the conveyor and 60 over on the passenger side floor (see image below and on following page). Examples Front Tire Pull Rear Tire Push 12) Record the two elevation dimensions on a map of the tunnel (see image on the next page). 13) Continue to take elevation readings at every seam on the surface of the conveyor sections and on the passenger side floor at 60 from the string-line (see dotted arrows above for reference). 16 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

21 Installation Preparing the Pit 14) As you move down the tunnel, you should be able to see the floor is poured with an upward pitch of 1/4 per 10 feet. Note: This will insure that the vehicle will travel through the wash with consistent pressure on the Rollers. If the floor varies more than 1/2 over 10 feet, call your local Belanger Representative or Belanger Technical Support. 15) At the exit end of the tunnel, take an elevation reading from both 60 over on passenger side floor and on the centerline of the conveyor on the concrete at the exit of pit. Transit 60 typical 60 typical Direction of Travel 16) With this information, you should be able to fill in the blanks on what would be the elevation of the conveyor sections as you move down the tunnel. Rear Tire push conveyor should be installed 1 higher than the passenger side floor. Front Tire pull conveyor should be installed 1 lower than the passenger side floor. 17) This map should give you a good idea of the lead ON at the entrance and the lead OFF at the exit. Helpful Hint There are two situations that have been known to add complexity to the Conveyor installation. One is when the pit floor is not completely flat such as having a slight hump along the path. Another is when the driver side pit wall is not totally flat and has a bow in it. Keep in mind that the goal is to install the Conveyor so all of the sections are perfectly aligned with smooth transitions from section to section and the surface of the Conveyor is at the correct incline from entrance to exit. For both of the scenarios the following are proven solutions. Bow in the Wall: Once all of the sections have been temporarily placed in the pit, butt them together and determine where the wall protrudes the most. Move the conveyor away from the wall until it can fit in the pit while remaining straight. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

22 Installation Preparing the Pit 18) The 1 higher and 1 lower dimensions should be held as possible. But DO NOT install a conveyor section going downhill. Note: If passenger side goes downhill, set that conveyor section level or just uphill a little from the elevation setting of the previous section. 19) This map should help you see the floor and conveyor layout throughout the tunnel. Setting the Conveyor 1) Starting with the entrance section, lift the section to the elevation that fits your application. With the transit check both sides of the tire track to insure the section is level. A small level may help. Note: The entrance section should be away from the entrance wall 6 inches, half of the 1 extra foot. 2) Insure that the section is on the string line, tack legs to the conveyor and down the angle on the shelf, in addition to the top of the driver sidewall. Note: Only tack-weld sections into place. 3) Move on to the next section and repeat steps 1 and 2 while making sure the string is still in place throughout the conveyor install. 4) Periodically, get out of the pit, look down the sections that have been tack-welded to insure the conveyor is straight. 5) When you get to the exit section remove the string and place the exit down into the pit and level it. Note: After the conveyor is tacked into place, the area for Grating can be measured and the Grating can be ordered or fabricated. An angle must be welded onto the passenger side of the conveyor sections to support the Grating.Grating is field supplied. 18 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

23 Installation Permanently Welding the Conveyor into Place 1) Weld a leg onto every leg of the conveyor. 2) Down the passenger side the legs are welded down the steel angle mounted into the floor. 3) On the driver side the legs will support the weight, but the conveyor should be welded to the top steel angle at all upright legs. 4) Confirm that the top, middle and lower levels of the conveyor are flush (straight and level). 5) Weld the seams of the top surface, inside and outside guide rails then weld the seams of the lower track. 6) Grind the welds smooth on the surfaces where the Rollers or tires ride. 7) Some fabrication will have to be done with the lead ON and OFF the conveyor. The Y- Section should be fabricated at this time. Note: All angle iron, ramps and legs stated in this section are field supplied. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

24 Installation Installing the Electric Drive Unit Components (Exit Section) If your conveyor is an electric drive system, it shipped with the motor/gearbox assembly already installed. Install the Electric Drive Float valve Assembly using the procedure below. 1) Locate the supplied Float valve Assembly and remove the fasteners and washers. You can discard the nut as it is only there to hold the fasteners in place during shipping. 2) Rotate the assembly to the orientation show below and secure it into place as shown. Before After Electrical Prints Information See the supplied electrical prints included with the electrical panel for connections. 20 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

25 Installation Installing the Hydraulic Drive Unit (Exit Section) Note: The Mounting Plates on both sides of the Exit Section are identical; allowing the Drive Unit to be installed on either side to best fit your application. 1) Remove the Sprocket from the Motor/Gearbox Assembly to allow installation of the Drive Unit. Sprocket Breather Plug- Facing Up Feeds-Facing Up Helpful Hint Drive Unit can be rotated to allow feeds to face either up, down, left or right. Breather Plug MUST face up. 2) Slide the gearbox onto the Exit Section Mounting Plate on the desired side (sprocket side first). Exit Section Mounting Plate (2) Sprocket Side of Gearbox Install from this direction 5/8-11 x 2-1/4 Bolts (4) 3) Replace the previously removed Sprocket. 5/8-11 Locking Nuts (4) Note: Procedures to secure the Sprocket are covered on the next page(s). 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

26 Installation Optional Proximity Hub Assembly (Exit Section) Parts Identification Proximity Hub Weldment Locking Nut CV Hub Nut Note: If you have purchased the optional Exit Proximity Sensor, follow steps 1 to 3 directly below. If not, proceed to step 4 on the next page. 1) Locate the Hub Assembly Kit. 2) Locate the supplied CV Hub Nuts from the kit. These nuts will replace the nuts that shipped on the unit and will hold the Sprocket in place. 3) Secure the Proximity Hub Weldment into place using the Locking Nuts from the kit as shown below. Sprocket/Proximity Hub Assembly Motor/Gearbox Assembly 22 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

27 Installation Installing the Drive Unit (Exit Section) 4) Secure the proximity hub using the supplied bolts, lock-washers and nuts then re-install the sprocket. The image below shows the Sprocket, Drive Unit and Proximity Hub in place. Installing the Optional Exit Pulse Counting Proximity Mount and Sensor The DuraTrans Conveyor monitors the distance that the Conveyor carries a vehicle using a Proximity Sensor that detects Target Bolts. Typical Target Bolt Proximity Sensor 1) The proximity switch and proximity mount are to be installed onto the opposite side that the gearbox was installed. LED Indicator lights when a target passes in front of the Proximity Sensor. The light goes ON when installed correctly, properly adjusted and in working order 2) Confirm that the Proximity Sensor is set a distance between 1/8 and 1/4 from the Target Bolts. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

28 Installation Securing Chain Links to Rollers Parts Identification Roller Link (1) Roller Pin (2) Green Middle Roller (2) Black Inner Roller (2) Side Plate (2) This link has a direction arrow on top that should point to the exit of the tunnel when facing up. These Rollers rides on the steel surfaces of all three level of the Conveyor. These Rollers correlate the Roller Assembly and Chain on all three levels of the Conveyor. It also makes contact with the tires. The DuraTrans-XD Rollers are factory-assembled and shipped with two X458 Side Plates and two X458 Roller Pins. Roller Top View Close-up of nut When installed correctly the nut should be on Driver Side when viewed from the top Helpful Hint A completely assembled Roller is equivalent to 8 of chain length. Follow the illustrated steps below to assemble the supplied chain pieces onto a Roller. Note: The Rollers must be installed forward (with the Side Plates and Roller Pins behind the Rollers) as shown below. 1. Locate the pieces below 2. Place one Pin and one Link as shown 3. Position the second Link on the first Pin 4. Make both Links parallel 5. Place the second Pin Note: The near Roller is the Passenger Side Roller. The bolt head, not the nut is visible. 24 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

29 Installation How to Calculate Number of Rollers Required Length of Conveyor x 2 Roller Spacing = Number of Rollers per Conveyor (round up to the next number) Example: 45 feet x 2 4 feet = 25.5 Rollers How to Calculate Chain Speed in Vehicles per Hour There are 3600 seconds in an hour The travel distance that is considered one vehicle is 20 feet. Number of Seconds 20 feet of Chain Travel = Chain Speed Example: 3600 Seconds in an Hour 70 Seconds for Chain to Travel 20 Feet = 52 Vehicles per Hour The following is to be used only as a guide. Actual spacing is typically site-specific. Conveyor Length (feet) Roller Spacing MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

30 Installation Assembling the Chain and Rollers 1) The Roller Assemblies must be installed forward as shown previously in Securing Chain Links to Rollers. 2) All the nuts on the Roller Assemblies should be on the driver side, looking down as shown previously in Securing Chain Links to Rollers. 3) Separate all of the chain into 10-0 sections and find the location of each Roller Assembly to verify that the Chain and Roller Assemblies shipped match the total ordered assembled chain length. 4) Starting with a Roller Assembly, install one set of the X458 Side Plates and a Roller Pin on the open side of the Roller Link, as shown previously in Securing Chain Links to Rollers. 5) Install a section of chain onto the exit end of that first Roller Assembly using the procedure shown previously in Securing Chain Links to Rollers. Note: A length of assembled chain, as shipped, may need to be separated in order to insert a Roller Assembly in the correct location, as shown previously in Securing Chain Links to Rollers. Helpful Hint Belanger Standard Spacing 4 Spacing Center to Center 7 4 Spacing Center to Center 14 Spacing Center to Center Chain is shipped in 10 foot sections with no Roller Assemblies installed. One link is 4 long. 6) Install the next Roller onto the end of the chain section as shown previously in Securing Chain Links to Rollers. 7) Repeat steps 4, 5 and 6 until there is a section of completely assembled chain that is approximately ) Build several of these sections of chain and Rollers as shown below. STANDARD 4 ROLLER DOLLIE 10 FOOT STRANDS OF X458 CHAIN -SHOWN WITH STANDARD 4 ROLLER DOLLIES ON 7-4 CENTERS STANDARD CHAIN MAY ALSO HAVE ROLLER ASSEMBLIES ON 4-0 OR 14-0 CENTERS Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

31 Installation Inserting the Chain and Rollers into the Conveyor 1) Remove the rubber entrance flap and let the Rollers down through the opening into the middle track. 2) As you start to pull the chain through the middle track connect a new chain assembly as the end of the previous section is installed as shown previously in Securing Chain Links to Rollers. 3) Install chain on to the lower track as well. 4) After the chain is installed as one full length make sure the entrance sprocket is pulled toward the exit as far as it can go. 5) Shorten the chain as much as possible, while still being able to join the two loose ends when the entire chain is installed. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

32 Installation Pneumatic Air Panel The Air-Panel has an Inlet Filter that feeds the first Regulator for the Roller-Up Cylinder (set between 70PSI 80PSI). The regulated air then feeds the 4-way electric valve. Two 1/4 airline runs from the 4-Way valve to the Roller-Up Cylinder (located on the entrance conveyor section). The regulated air runs through flow-controls that are installed into the ports on the Roller-Up Cylinder. The flow-controls on the Cylinder will control the Cylinder speeds. The second Regulator is for the Tension Cylinder (set between 70PSI 80PSI). This regulated air then feeds the 4-way manual valve. This valve has an outgoing port to the Tension Cylinder where there is a brass tee installed along with a pressure switch which is pre-set at 50PSI. The pressure switch will insure that if the chain has less than 50PSI the conveyor will not run. The pressure switch MUST be wired into the Low Air Fault on the Belanger Conveyor Controller System or in series with the E-Stop circuit using wires #1 and #3 from the pressure switch (normally open). Locate the supplied Pneumatic Air Panel and mount it to the wall in dry a location that will accommodate your airlines and is conveniently accessible. Main air supply 90-PSI minimum 120-PSI maximum 28 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

33 Installation Placing the Floor Treadle Locate the Floor Treadle Switch Assembly, Wire Chase, and its accessory bag. Secure the Treadle to the floor using the provided lag bolts according to the dimensions shown below. Feed the wire through the Wire Chase. Secure the Wire Chase to the floor using the provided lag bolts according to the dimensions shown below. Connect the Treadle wires to the Belanger Conveyor Controller System or the customer supplied control device per the system prints. Note: Dimensions shown for treadle placement are taken from the inside edge of the guide rail. The treadle is shown with the wire in place. It will be necessary to install wire separately. Overhead View 42 Dimension taken from inside edge of guide rail 42 Wire Chase 12 Floor Treadle Entrance Trap Door 12 Dimension taken from edge of rubber flap Note: Floor treadle switch placement is shown in Front Wheel Pull configuration and with the Correlator and Conveyor Y Section options. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

34 Installation Utility Connections Pneumatic Connections This Air-Panel ships with all DuraTrans XD Conveyors Entrance Section. The Filter feeds the system The Electric 4-Way Valve and the Roller-Up Regulator (pointed out below) feed the Roller-Up Cylinder The Tensioning Cylinder Regulator and the Manual 4-Way Valve s Low-Air Safety Switch will feed the Tensioning Cylinders. Run 1/4 air-line from the Air-Panel to the locations indicated (Air-line is field supplied). Air-Panel: Tensioning Cylinder Regulator Filter Electric 4- Way Valve (Roller-Up) Safety Switch Auto Drain Main air supply 90-PSI minimum 120-PSI maximum Roller-Up Regulator Roller-Up Retract Roller-Up Extend Manual 4- Way Valve (Chain Tension) To Retract Side of Tension Cylinder To Extend Side of Tension Cylinder 30 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

35 Installation Utility Connections Pneumatic Connections Tensioning Cylinder Assembly Cylinder Retract Cylinder Extend Main air supply 90-PSI minimum 120-PSI maximum Manual 4-Way Valve Roller-Up Cylinder Assembly Electric 4-Way Valve Main air supply 90-PSI minimum 120-PSI maximum Roller-Up Cylinder From Electric 4-Way Valve (retract side) Flow-Controls From Electric 4-Way Valve (extend side) 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

36 Installation Utility Connections Electrical Connections Electric Drive Motor/Gearbox Drive Motor: Wire the drive motor to the VFD per the supplied DuraTrans electrical drive wiring schematic. Note: Delta is low voltage and Wye is high voltage. Air-Panel Main air supply 90-PSI minimum 120-PSI maximum Belanger Conveyor Controller: #1 lead to terminal#338 #3 lead to PLC Input Other: In series with Hydraulic Low- Level or in series with E-Stop circuit NOTE: MUST HAVE LESS THAT A 5AMP DRAW Proximity Sensors 110VAC in from DCC or field supplied Roller-Up control unit This proximity switch 1ELECT-SN360 is a very versatile sensor depending on how it s wired it will either sink (NPN) N/O or N/C or source (PNP) N/O or N/C. Belanger DuraTrans XD with a Belanger DCC controller Roller Count Proximity Sensor (Belanger Conveyor Controller) Pulse Proximity Sensor (Belanger Conveyor Controller) Source N/C Black Wire +24DC #222 White Wire - Load # 11 on the Input Board Source N/O White Wire +24DC #222 Roller Count Proximity Sensor Sink N/C White Wire OVDC Black Wire Load #6 on the Input Board Black Wire Load (PLC Input) Pulse Proximity Sensor Sink N/O Black Wire OVDC White Wire - Load (PLC Input) Roller Count Proximity Sensor Pulse Counting Proximity Sensor 32 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

37 Installation Utility Connections Electrical Connections Floor Treadle Limit Switch 1) Remove the cover from the Treadle assembly. 2) Locate the limit switch and secure it into place while running the wire through the chase tube and out the other end. Limit Switch 3) Run the wire through the floor mounted Wire Chase (shown below) and to the appropriate INPUT Channel on your controller. Wire Chase Feed to controller From limit switch Hydraulic Connections Install hydraulic hoses from the hydraulic power pack to the Hydraulic Drive Unit as shown below (hydraulic hoses are field supplied). Helpful Hint Drive Unit can be rotated to allow feeds to face either up, down, left or right. Breather Plug MUST face up. Hydraulic Feeds Breather Plug Note: Procedures for securing the Sprocket into place are covered on the next page(s). 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

38 Installation Hydraulic Pump Schematic Note: See supplied electrical prints included with the electrical panel for connections Fixed Displacement power unit with No Reversing Feature Variable Volume power unit with No Reversing Feature Flow control Belanger part no. 1VALVE-HY472 Hydraulic supply feed IN Return back to tank Hydraulic supply feed Return back to tank IN CF EF Pressure compensated flow control Belanger part no. 1VALVE-HY413 OUT Hydraulic motor Hydraulic motor 34 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

39 Installation Hydraulic Pump Schematic Fixed Displacement power unit with Reversing Feature Variable Volume power unit with Reversing Feature Hydraulic supply feed Return back to tank Hydraulic supply feed Return back to tank IN Flow control Belanger part no. 1VALVE-HY472 CF IN EF OUT P T Pressure compensated flow control Belanger part no. 1VALVE-HY413 P T A B Manually operated reversing valve, center position in neutral A B Manually operated Reversing Valve, center position in neutral Hydraulic motor Hydraulic motor 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

40 Installation Installing the Plastic Guide Rail Helpful Hint The following procedure requires field fabrication 1) Locate the supplied Guide Rail FIXTURE CLAMP (part #102941) as shown below. 2) Slide the plastic guide rail onto the guide rail angle starting with a 10 FT section at the entrance. 5 foot Center Section shown above Note: This section will cover the 5 FT entrance and 5 FT of the next section. As you have a 5 FT center section installed, the plastic has to be cut down to 7 foot 6 inches. This will cover the exit end of the previous section and half or 2 foot 6 inches of that 5 FT section. 36 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

41 Installation Installing the Plastic Guide Rail 3) After all the plastic pieces are placed onto the guide rail angle, locate the supplied Guide Rail FIXTURE CLAMP (part #102941) as shown below. 4) Secure the clamp into the first hole position and drill down through the center hole on the fixture as shown below using a 13/32 (0.406) drill bit. This will produce properly aligned holes in the plastic for the supplied 3/8-16 x 1-1/4 button-head fasteners and 3/8-16 center-lock nuts on the underside of the guide rail. Install fasteners in sequence down the rail to prevent the plastic from moving on the angle and causing hole-misalignment. Drill down through hole here 1FSTNR-BH510: Button-Head Fastener 1NUT-CL375: Center-Lock Nut 5) Repeat this process until all plastic pieces are in place and secure. Tighten each nut and bolt down as you work your way down the conveyor. This will minimize bowing of the plastic due to temperature changes. Note: Make sure the seams are tight as you work your way down the conveyor. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

42 Installation Optional Reversing Valve Items Included with Kit Item Part No. Qty Hydraulic Reversing Valve 1VALVE-HY Elbow Fitting 1ELBOW-ST770 2 Straight Fitting 1MCONC-ST ELBOW-ST770 1MCONC-ST375 Specifications Before any work is performed, be sure to shut off ALL electrical disconnects for safety reasons. Make sure you have a qualified Plumber to perform install. 38 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

43 Installation Optional Reversing Valve Typical Hydraulic Circuit Filter Gauge Return Manifold Return Filter Hydraulic Motor/Pump Pressure Gauge Feed Manifold Hydraulic Oil Reservoir Site-Gauge Suction Filter Optional Reversing Valve Conveyor Motor / Gearbox 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

44 Installation Optional Reversing Valve Reversing Valve Overview Top View 1) Locate the Accessory Box labeled Reversing Valve Kit. 2) Verify that all the parts and components are present. 3) Install the four hydraulic fittings and the valve handle as shown below. Assembly Install both Straight Fittings here Install the Elbow Fittings in the IN and Out ports Secure handle into place using Cotter Pins NOTE: BE SURE TO INSTALL THE HANDLE IN THE SAME ORIENTATION AS SHOWN IN THE ABOVE IMAGE. IF DURING OPERATION THE HANDLE WILL NOT REST IN THE DETENT POSITION, IT IS LIKELY THAT THE HANDLE HAS BEEN INSTALLED BACKWARDS. 40 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

45 Installation Optional Reversing Valve Assembly 1) Secure the valve in a convenient location down in the conveyor trench (example shown below). Three possible mounting locations (Valves Not to Scale) 2) Remove and discard the caps and using two short hydraulic hoses (located in the Conveyor Accessory Box), connect all hydraulic hoses as shown below. Return line going to Hydraulic Filter/Tank Outgoing line going to Conveyor Motor Cap Cap Outgoing line going to Conveyor Motor Pressure line from Hydraulic Pump/Flow Control Valve on Conveyor 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

46 Installation Optional Reversing Valve Reversing Valve Operation When the valve handle is fully engaged in the detent position, the Conveyor Motor should turn counter clockwise (pulling vehicles from entrance to exit). If the motor rotation is incorrect, switch the hoses connected to ports A and B. When the valve handle is pulled from the previous position to the center position, the valve is now in a Neutral position. The Conveyor Motor will not turn. When the valve handle is pulled from the Neutral position to the Momentary position, the Conveyor Motor will now turn. Confirm that the Conveyor is moving from entrance to exit on the surface. The Conveyor will REVERSE. This valve position in momentary. Holding this position too long could result in Conveyor Jams. 42 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

47 Initial Startup Air Panel Overview Filter Main air supply 90-PSI minimum 120-PSI maximum Auto Drain Initial Settings Roller-Up Gauge: 70PSI to 80PSI Chain Tension Gauge: 70PSI to 80PSI 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

48 Operation System Adjustments and Over-Rides 4-Way Valves Roller-Up Over-Ride: (Push in and turn to the lock position to over-ride the coil which will extend the Roller-Up Cylinder) Manual Chain Tension Release: (Pull down to release chain / push back up to tighten chain back into operating mode) Regulators Chain Tension Adjustment: (Initially set to 70PSI 80PSI, Turn clockwise to decrease pressure, Turn counter-clockwise to increase pressure) Roller-Up Adjustment: (Initially set to 70PSI 80PSI, Turn clockwise to decrease pressure, Turn counter-clockwise to increase pressure) 44 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

49 Operation Manual Roller-Up: In situations where a Roller is needed to be manually activated, your DuraTrans Conveyor is equipped with a Manual Roller-Up lever (shown below). Simply pull on the lever and the next roller on the chain will come up and engage the vehicle. The Manual Roller-Up activation handle is removable to prevent unauthorized manual roller tasking. Pulling the handle shown above lifts the Roller Ramp, engaging a Roller. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

50 Maintenance Sprocket Torque Specifications 1SPROC410 and 1SPROC420 Assembly Note: Numbers in drawing show lug nut tightening sequence. Lug position number (typical) Exit: 1SPROC410 Entrance: 1SPROC420 Position 1 Position 2 Position 3 Position 4 Step 1 Finger tighten Finger tighten Finger tighten Finger tighten Step 2 25 foot pounds 25 foot pounds 25 foot pounds 25 foot pounds Step 3 50 foot pounds 50 foot pounds 50 foot pounds 50 foot pounds Step 4 80 foot pounds 80 foot pounds 80 foot pounds 80 foot pounds 46 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

51 Maintenance Routine Procedures Daily Verify proper chain tension. Note: The Tension Cylinder Assembly MUST NOT be at either extreme end of the cylinder stroke. Proper chain tension relies on free travel of the tension cylinders. Note: Due to natural wear of the chain, it will become necessary to remove chain link(s) in order to maintain proper tension. CAUTION CAUTION: LOOSE CHAIN CAN CAUSE SERIOUS DAMAGE. Make sure that all Rollers are turning freely To prevent the possibility of damage to tires, visually inspect plastic Roller rollers for damage. Check overall performance for any abnormalities on the first few vehicles washed each day. To keep your machine clean, nightly wash downs are recommended (with a water hose). This should be done while conveyor is running Weekly Inspect the idler sprocket slides for dirt build up and excess wear. Replace as required. Monthly Inspect chain for wear. The manufacturer pre-fills the HECO gearbox with EPPCO GL-5 85W 140 gear oil. It should be checked every month to be sure the proper amount of lubricant is maintained. To do this, unscrew the setscrew located half way up the side of the gearbox. The oil level should be up to this point (the set screw opening). If the level is lower, refill with EPPCO GL-5 85W 140 or equivalent gear oil. See information on HECO Gear Reducer. The manufacturer pre-fills the electric drive gearbox with ISO 220 mineral oil. It should be checked monthly to be sure the proper amount of lubricant is maintained. The oil should be visible at the site-gauge (pointed out below). The lube should be changed every 10,000 hours of service. Breather Element for ISO 220 Oil Breather Element for GW Gear- Lube (See HECO) Site-Gauge Oil Level Acceptable ISO 220 Mineral Oils AGIP Blasia 220 Shell Omala Oil 220 ESSO Spartan EP220 Mobil Mobilgear 630 Castrol Alpha Max 220 BP Energol GR-XP 220 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

52 Maintenance Trouble Shooting Problem Solution Conveyor Jams Check for fallen objects or obstructions on all tracks Rollers will not come up on demand Operates too slow Slows down during operation Vehicle jumps off track Check chain tension. CAUTION: LOOSE CHAIN CAN CAUSE SERIOUS DAMAGE As the chain wears and stretches due to normal operation, be sure to pay close attention to the Tension Cylinders stroke lengths. It is NOT to be fully extended. If it IS fully extended, remove chain links accordingly Check electrical circuit to 4-way solenoid valve Make sure 4-way solenoid valve is shifting Make sure ramp is free from obstructions and not jammed Check flow-controls on Roller-Up Cylinder Check air pressure Make sure hydraulic power unit is the correct size Check for hydraulic leaks Check for obstructions in hydraulic lines Check pressure at hydraulic power unit. (normal operating pressure is 1,000 PSI [68.9 BAR]) Check motor for leaks This condition usually is due to an incorrect installation. Consult installation manual, or call your local distributor, or a representative from Belanger, Inc. Customer Service Department Inspect plastic guide rail for damage and replace as needed CAUTION CAUTION: LOOSE CHAIN CAN CAUSE SERIOUS DAMAGE. 48 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

53 Maintenance Powder Coating Maintenance Just as washing your car is important for removing dirt and grime, your powder coated equipment needs to be given a regular wash to keep it looking good. In conjunction with a regular maintenance program, your powder coated equipment requires special care to maintain its durable finish, and is a smart way to protect your investment. The effects of atmospheric pollution, general dirt, grime and airborne salt deposits can all accumulate over time and should be removed at regular intervals. As a general rule powder coat cleaning should take place every six months. In areas where pollutants are more prevalent, cleaning programs should be carried out on a more frequent basis i.e. every three months. Cleaning Procedure Cleaning should start at the time the product is installed, ensuring that construction materials such as concrete, plaster and paint splashes are removed before they have a chance to dry. Failure to remove these materials at an early stage will require the use of aggressive cleaning materials and techniques with potential damage to the powder coated surface. The best method of cleaning is by regular washing of the coating using a solution of warm water and non-abrasive, ph neutral (ph 5-8) detergent solution. 1. Spray the powder coated surface with a garden hose to rinse off any loose dirt or debris. DO NOT use a power washer or high-pressure water as this can wear and cause harm to the powder coated surface. 2. Using a mild detergent and warm water clean the powder coat surface with a soft cloth, sponge, or a soft natural bristle brush. DO NOT use water heated to a temperature above 140 F, as this can wear and cause harm to the powder coated surface. 3. Rinse the sponge or soft brush as needed to prevent any abrasive debris from collecting on the cleaning surface. 4. Thoroughly rinse the powder coat surface with a garden hose after cleaning it to rinse off and remove all detergent residues. Tips & Warnings Over-cleaning or excessive rubbing can do more harm than good To prevent marring, make sure cleaning sponge, cloth, etc., are grit-free Abrasive materials such as steel wool, abrasive brushes, etc., can wear and harm finishes Do not scour painted surfaces Do not under any circumstances use strong solvents such as thinners, aggressive alkaline, acid or abrasive cleaners Do not use a power washer, high-pressure, or water heated above a temperature of 140 F, as these can wear and cause harm to the powder coated surface Always use a test surface first Use nothing stronger than white spirits to assist with stubborn stains. Cleaning with white spirits should be carried out in shade and during cooler temperatures using a soft cloth and gentle wiping only. It is also recommended that a small non-visible area be tested initially to ensure that no color change or damage will occur If you have any questions or concerns regarding how to clean powder coat equipment please call Belanger Technical Support / Aftermarket Group for additional assistance. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

54 Maintenance Powder Coating Repair Repair, fading, blemishes and light scratches, to powder coating. Repair faded powder coating Faded powder coating means, the surface of the coating has oxidized. This is usually only the surface (2-3 microns). By rubbing with cutting compound the oxidized surface will be removed and new paint exposed with its original color. However, if the original coating was a matte finish it will now have been polished to a gloss. Repair light scratches and blemishes to powder coating. Scratches may be deeper than 2-3 microns. Use cutting compound to remove the powder coating down to the level at the bottom of the scratch. A fine rubbing down paper may speed up the process (800 to 400 grit, no coarser), but the job will need to be finished with cutting compound to remove the fine scratches left by the rubbing down paper. Repair Powder Aerosol Cleaning prior to painting. The original paint needs to be clean prior to touch up, or touching in repainting. Indoor components may have been polished with polishes containing Silicone. Silicone will repel any further painting and must be removed from the local area. Clean the surface by washing it with a detergent and a non-scratch scrub sponge. Use a solution of warm water and non-abrasive, ph neutral (ph 5-8) detergent to clean material prior to painting. Thoroughly rinse and dry the surface. If solvents are needed to remove marks, a soft cloth dampened with Isopropyl Alcohol may be used. Solvents containing esters, ketones, or chlorinated solvents must not be used without consulting the paint manufacturer, as these are too aggressive and will melt the paint. A small discrete area should be tested first. Repair Powder The surface contaminants may need to be removed by abrading with fine rubbing down paper 400 grit. If the component has been damaged, causing chipping or cutting to the paint, the loose flakes should be removed. Ugly steps where the paint has been chipped need to be feathered. Coarse rubbing down paper 80 grit will do this faster, but it will leave noticeable scratches. Finer paper will produce better results, 250 grit paper is a good compromise, (this will wear smooth quickly, so replace it frequently). Primer preparation When the original paint edges have been rubbed down smooth and a step is not noticeable, remove the dust, apply a light coat of paint/primer, and allow it to dry. This will show how well the area has been prepared. Continue rubbing down and applying light coats, until the edges of the damaged paint have disappeared. Applied properly, at this stage all physical signs of repair can be lost. 50 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

55 Maintenance Powder Coating Repair Application technique for aerosol Apply three very light coats and allow each to dry. When the surface has been covered with the new paint, heavier coats may be applied. Do not rush, as this will produce runs; allow two minutes between each coat. The aerosol should never be nearer than 6 inches (150mm). Continue to move when spraying and keep the same distance from the work piece. Smooth strokes from side to side, covering the local area of damage. Start to move the aerosol before releasing the paint, and before the end of the stroke, stop releasing the paint. This should avoid ridges of paint at each end of the stroke. Patience On a warm day, if each coat has been allowed to dry before the next application, it should be possible to rub the paint down after about 30 minutes. If it starts to drag and ball the paint, leave it to dry further. It will now have to be rubbed right back to a smooth surface again, which may take another hour. More patience is required. (The thinner the coats of paint, the faster they will dry.) Types of paint The paint must have an aggressive solvent that will melt its way into the powder coating. An indication of suitability is the amount of time it takes to dry. Household polyurethane, which takes 24 hours to harden, is not suitable. This will sit on the powder, instead of melting its way into it. The result is that it will peel off. It is always a good practice to mechanically abrade a key by using rubbing down paper, or at least use a non-scratch scrub sponge. A small discrete area should be tested first. 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

56 HECO Hydraulic Gear Box Parts listing shown on following pages 52 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

57 Maintenance HECO Hydraulic Gear Box Lubricant Instructions HECO planetary speed reducers may be lubricated as a self-contained unit (standard hydraulic motor), or as an integral part of the hydraulic system (bearing less motor). SELF CONTAINED UNIT When installed as a self-contained unit, ensure adequate ventilation is provided to allow for lubricant expansion. In applications where the speed reducer is lubricated as a self-contained, horizontal unit, it is recommended that the unit be half-filled with EP oil (see the chart for the amount and proper grade of gear oil). Self-contained, vertical installations (output shaft down) require the unit to be filled to the centerline of the upper planetary gear train. For self-contained vertical installations (output shaft up) consult HECO. The oil should be changed after the first 50 hours and 100 hours of operation, and every 1000 hours thereafter. Oil should be drained while the unit is at operating temperature. The unit should be cleaned with flushing oil (use of solvents should be avoided). Note: The importance of a thorough gear case cleaning with flushing oil during the first lubricant change cannot be overemphasized. If the maximum oil operating temperature is exceeded, change oil immediately. INTEGRAL PART OF THE HYDRAULIC SYSTEM In applications where the speed reducer is lubricated by oil flow from the bearing less hydraulic motor, petroleum based hydraulic oil with EP additives should be used. Maintain a minimum oil flow of 2 GPM (7.6 liters per minute) Connect a separate case drain line connected directly from the top of the reducer (ensure the reducer remains full) to the oil reservoir. Note: For maximum cooling and lubrication the case drain should be connected to the drain port at the opposite end of the reducer from the hydraulic motor. Reducer case pressure must not exceed 20 PSI (1.4 BAR) with the standard shaft seal or 50 PSI (3.4 BAR) with the optionally available high-pressure seal installed. Note: Extreme Pressure Lubricants - These lubricants are petroleum base liquids with chemical additives, such as, sulfur phosphorous or similar materials or soluble compounds which produce a protective film to withstand high pressures. Horizontal Operation (1/2 full) Total Capacity Model oz. (6 dl.) 40 oz. (12 dl.) Oil Grade single reduction (RPM out) Oil Grade double reduction (RPM out) Maximum Oil Temperature 0-25 RPM - AGMA # RPM - AGMA #5 140 o F (60 o C) continuous HECO, Inc.: Phone (916) MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

58 Maintenance HECO Hydraulic Gear Box Replacement Parts Item # Part # Description Qty per Assembly * Cap Screw Shaft Seal (Not available in Viton) 3 Seal Carrier Standard High Pressure * Backup Ring (Not used on High Pressure Seal) * Quad Ring Quad Ring Viton High Pressure Lip Seal (Not available in Viton) * O Ring O Ring Viton 7 Output Shaft Straight Keyed Tapered T 8/16 Spline Bolt Flange (Includes Hub Stud) Hub Stud Bolt Flange (Includes Hub Stud) Hub Stud Thrust Plug Retaining Ring Cone Cup 2 12 Bearing Housing Front Flange Center Flange Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

59 Maintenance HECO Hydraulic Gear Box Replacement Parts Item # Part # Description Qty per Assembly Pipe Plug 3 * O Ring O Ring Viton Cup Cone Keyed Washer Lock Washer Lock Nut Planet Carrier Internal Gear 1 22 Motor Adapter SAE A 2-Bolt SAE B 2-Bolt SAE B 4-Bolt SAE C 2/4-Bolt Modified SAE A 4-Bolt Pipe Plug Bolt Stud - SAE C 2/4-Bolt Only Nut - SAE C 2/4-Bolt Only 8 25 Sun Gear Kit (Input Shaft Adapter) (See Separate Sheet for Kit Parts) 16B 16C 16D 16E 16F 7/8-13T Spline 1-15T Spline 1 Straight Keyed Char-Lynn 2000 Bearingless Char-Lynn 4000 Bearingless 1 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

60 Maintenance HECO Hydraulic Gear Box Replacement Parts Item # Part # Description 16 H 11/4 Straight Keyed 16I 16M 16O 16P 11/4-14T Spline 1 SAE 6B Spline 7/8 Straight Keyed 11/8 Straight Keyed Qty per Assembly Thrust Washer Planet Bearing Planet Gear Planet Pin Retaining Ring 6 31 Motor Seal/Gasket 32 Motor bolt and Seal Kit (Motor bolt and Seal Kits - Includes all Bolts, O Rings, Gaskets, etc. necessary to mount hydraulic motor to the gear reducers.) (See Parts Price List for Motor Bolt and Seal Kit Prices) BK16-0 BK16-2 BK16-4 BK16-5 BK Seal Kit - Buna Seal Kit - Viton High Pressure Seal Kit Note: * Items which are included in Seal Kits Note: Shaft seals may be replaced by removing the seal carrier from the shaft end of the unit. It is not necessary to disassemble unit to change the shaft seals unless the unit has a flanged output shaft. 56 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

61 DURATRANS XD CONVEYOR Maintenance HECO Hydraulic Gear Box NOTE: REPLACEMENT PARTS MUST BE PURCHASED DIRECTLY FROM PRINCE MANUFACTURING CORPORATION IN SIOUX CITY, IOWA. Reversing Valve Replacement Parts 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

62 Replacement Parts Entrance Section Overall Assembly Major Sub-Systems : DXD Take-Up Sprocket Assembly : Roller Up Ramp Assembly and Parts Identification (General) : 1/2 diameter : 1/2 diameter 1RETNR : 1/2 diameter : 3/4 diameter Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

63 Replacement Parts Entrance Section Frame Components 1PLSTC-EX100 (10 foot long stock length) 6921 (passenger side) 6993 (driver side) 6923 (4) Entrance Section Surface Pad Assembly 1WASHR-LC291 (6) 1FSTNR-HH288 (6) 1WASHR-FL498 (6) 6911 (2) 1RUBBR025 Roller Count Proximity and Clamp Assembly 1ELECT-SN360 1CLAMP301 1FSTNR-SH457 (2) 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

64 Replacement Parts Entrance Section The following assembly has been broken into sections to ease the parts identification process Complete: XD Take-Up Sprocket Assembly : Section 1 Quantities shown in parenthesis reflect only what is shown in the picture. There may be more of the stated parts on other sections of the Conveyor. 1FSTNR-HH571 (2) NUT-RG603 (2) 1WASHR-LC498 (2) WASHR-LC FSTNR-HH810 1FSTNR-HH594 (2) 1WASHR-FL706 (2) 1WASHR-LC498 (2) 60 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

65 Replacement Parts Entrance Section : Section 2 Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component FSTNR-HH460 (4) 1NUT-RG536 (4) 1WASHR-LC415 (4) 1FSTNR-HH270 (4) SPROC WASHR-LC291 (4) : Section 3 Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component. 1NUT-RG603 (4) 1WASHR-LC498 (4) 1FSTNR-HH558 (4) 1WASHR-LC291 (4) FSTNR-HH270 (4) (2) 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

66 Replacement Parts Entrance Section The following assembly has been broken into sections to ease the parts identification process : Complete: Roller-Up Ramp Assembly : Section 1 Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component. 1WASHR-LC291 (4) 1NUT-RG436 (4) 1FSTNR-HH783 1WASHR-LC FSTNR-SH822 (4) (3 per side) Details on next page 62 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

67 Replacement Parts Entrance Section : Roller-Up Cylinder Assembly CLAMP375 1TUBE015 1CLAMP NUT-JM043 1CYLND200 1VALVE-PN180 1VALVE-PN CYLND200 1VALVE-PN180 1CLAMP TUBE015 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

68 Replacement Parts Entrance Section and : Tension Cylinder Assemblies Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component. 1NUT-JM500 1CYLND ELBOW-ST212 1ELBOW-ST212 Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component. 1NUT-JM500 1CYLND FTTNG-SW302 (2) 1ELBOW-ST212 (2) 1ELBOW-PL666 (2) Hose and Fittings Exploded Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component. 1HOSE025 1ELBOW-ST212 1ELBOW-PL666 1FTTNG-SW302 1TEE-ST075 2 Hose Assemblies Required 64 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

69 Replacement Parts Entrance Section and : Transfer Ramp Assemblies Quantities shown in parenthesis reflect only what is shown in the picture. If the image shows partial components, be aware that the same quantity applies to the remainder of the total component NUT-RG469 1WASHR-LC FSTNR-HH WASHR-FL498 1RUBBR030 1FSTNR-HH270 1RUBBR (passenger side) 6993 (driver side) 6993 (driver side) 6921 (passenger side) : Manual Roller-Up Assembly FSTNR-HH FSTNR-SB MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

70 Replacement Parts Exit Section Overall Assembly RUBBR015 1NUT-TN313 1FSTNR-FH : Exit Flap Door Assembly Exit Section Surface Assembly 1WASHR-LC291 (4) 1FSTNR-FH626 (8) 1WASHR-FL498 (4) 1FSTNR-HH270 (4) RUBBR015 (2) 1NUT-TN313 (8) 66 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

71 Replacement Parts Exit Section DXD Exit Proximity Count Assembly: This plate not part of assembly 1CLAMP301 1NUT-RG670 (2) 1FSTNR-SH457 (2) 1ELECT-SN NUT-LC210 (2) 1FSTNR-HH680 (2) 1WASHR-LC581 (2) Hydraulic Drive and Gearbox Unit: and Mounting Plate not part of this assembly 1HYDRA-PR500 1MCONC-ST375 (2) 1FADAP-ST500 (2) 1SPROC410 1NUT-LC825 (4) 3023 (4) MOTOR-HY785: for MOTOR-HY835: for FSTNR-HH783 (4) FSTNR-HH478, Target Bolts (5) 1NUT-LC220 (4) NUT-LC HYDRA-PR500 1FADAP-ST500 1MCONC-ST375 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

72 Replacement Parts Exit Section DXD Electric Drive Float Valve Assembly: ELECT-FS176 1WASHR500 1ELECT-EN NUT-RG469 1WASHR-FL498 1WASHR-LC291 1FSTNR-HH252 1ELBOW-PL966 1REDUC-PL110 1ELECT-SW545 DXD Electric Drive and gearbox Components NUT-LC HYDRA-PR500 1FADAP-ST500 1ELBOW-ST Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

73 Replacement Parts Exit Section Electric 3HP Drive and Gearbox Unit: ZONE 2 ZONE 1 Electric Drive and Gearbox Unit: Zone 1 1WASHR-LC456 (4) 1FSTNR-HH171 (2) NUT-RG603 (4) 1WASHR-FL706 (4) *1GASKR320 (Includes O-Ring shown below) 1GEABX-AS /230/460V 1GEABX-AS /400/415V ZONE 3 1STEEL-KY200 (2) 1STEEL-KY NUT-LC220 (4) 1HYDRA-PR510 Electric Drive and Gearbox Unit: Zone 2 1PLUG500 1FSTNR-SH824 (8) REDUC-ST111 *1GASKR320 (Includes Ring shown above) *1GASKT320 (Includes Ring shown above) **1GEABX500 (Includes Gearbox shown below) Electric Drive and Gearbox Unit: Zone 3 1WASHR-FL706 (5) 1FSTNR-HH567 (4) 1FSTNR-HH783 (4) **1GEABX500 (Includes O-Ring and Plug shown above) 1SPROC410 1WASHR-LC498 (5) 1NUT-RG653 (4) 1NUT-LC220 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

74 Replacement Parts Exit Section Electric 5HP Drive and Gearbox Unit: ZONE 2 Electric Drive and Gearbox Unit: Zone 1 1WASHR-LC456 (4) 1FSTNR-HH171 (2) NUT-RG603 (4) ZONE 1 1WASHR-FL706 (4) *1GASKR320 (Includes O-Ring shown below) 1GEABX-AS /230/460V 1GEABX-AS /400/415V ZONE 3 1STEEL-KY200 (2) 1STEEL-KY NUT-LC220 (4) 1HYDRA-PR510 Electric Drive and Gearbox Unit: Zone 2 1PLUG500 1REDUC-ST111 1FSTNR-SH824 (8) 7908 *1GASKT320 (Includes Ring shown above) **1GEABX500 (Includes Gearbox shown below) Electric Drive and Gearbox Unit: Zone 3 1WASHR-FL706 (5) 1FSTNR-HH567 (4) 1FSTNR-HH783 (4) **1GEABX500 (Includes O-Ring and Plug shown above) 1SPROC410 1WASHR-LC498 (5) 1NUT-RG653 (4) 1NUT-LC Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

75 Replacement Parts Rollers : Standard 4 Roller Replacement Assembly 1WASHR-FL755 1WASHR-FL755 1NUT-JM333 1WASHR-FL810 (2) 1WASHR-LC ROLLR050 (2) 1FSTNR-HH925 1FORGE020 1ROLLR045 (2) : BIS-6 Roller Replacement Assembly 1NUT-CL500 1ROLLR-IL045 (2) 1ROLLR-IL050 (2) 1FORGE (2) 1ROLLR-IL040 (2) 6939(2) (2) 1FSTNR-HH672 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

76 Replacement Parts Replacement Chain 1CHAIN421 (Sold in 10 foot sections) 1FORGE010 1RETNR009 1RETNR Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

77 Replacement Parts Air Panel : Air Panel Assembly 1ELBOW-PL666 (8) 1FSTNR-HH027 (2) 871 1WASHR-LC125 (2) 1TEE-PL TEE-BR920 1ELECT-DN780 1FILTR780 1WASHR-LC115 (4) 1FSTNR-SH177 (4) 1VALVE- EL710 1ELECT-SW780 1VALVE- PN (2) 1GAUGE500 (2) 1RGLTR175 (2) 1FSTNR-SH406 (4) 1WASHR-FL332 (4) 1WASHR-LC125 (4) Individual Parts Shown on Next Page 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

78 Replacement Parts Air Panel : Air Panel Parts FILTR780 1GAUGE500 1RGLTR175 1VALVE-EL710 1TEE-BR920 1ELECT- SW780 1ELECT-DN780 1TEE-PL415 1VALVE-PN152 1DECAL-XD001 1DECAL-XD002 1DECAL-XD010 Guide Rail 1FSTNR-BH510 1PLSTC-EX100 (10 feet) 1FSTNR-BH510: Button-Head Fastener 1NUT-CL375: Center-Lock Nut 1NUT-CL : Guide Rail Fixture Clamp 74 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

79 Replacement Parts Floor Treadle TRD101775: Floor Treadle Assembly : Wire Chase : Treadle Weldment : Treadle Cover 1SPRNG436 Complete Assembly 1FSTNR-HH504 (2) 1WASHR-LC498 (2) 1WASHR-FL706 (2) 1FSTNR-SH236 (2) 1WASHR-LC115 (2) 1FSTNR-HH023 (2) 1ELECT-SW555 1ELECT-FS : Wand Holder 1384: 5/16 x 3 Wand 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

80 Replacement Parts Suggested Replacement Parts List Entrance Section Exit Section Part Number Description 6101 NON-DRIVEN BEARING WITHOUT STUDS 6918 DXD ENTRANCE TAKEUP ROLLER 6919 DXD TAKEUP JOURNAL END CAP 6920 DXD ENTRANCE TAKEUP SLIDER 6925 DXD DOLLIE UP JOURNAL BEARING 6928 DXD TAKEUP JOURNAL BEARING DXD MANUAL LIFT LEVER ASSEMBLY DXD DOLLIE UP BEARING ASSEMBLY DXD DOLLIE UP BUMPER ASSEMBLY DXD DRIVER SIDE TENSION CYLINDER ASSEMBLY DXD PASSENGER SIDE TENSION CYLINDER ASSEMBLY DXD DOLLIE UP CYLINDER ASSEMBLY : 1/2 Diameter DXD ENTRANCE RAIL PIN WELDMENT : 1/2 Diameter DXD ENTRANCE RAMP PIN WELDMENT : 1/2 Diameter DXD ENTRANCE CROSS PIN WELDMENT : 3/4 Diameter DXD ENTRANCE CYLINDER PIN WELDMENT * 1CLAMP301 STAUFF 30 mm CLAMP(FOR CONVEYOR PROX) 1CYLND200 1CYLND980 CYLINDER 1-1/8 BORE X 1" STROKE CYLINDER 3" BORE X 13" STROKE * 1ELECT-SN360 PROXIMITY SWITCH WITH12 CORD 1HOSE025 HOSE ASSEMBLY 1/4" INSTA-GRIP 8-1/2 LONG 8362 DXD 1/4" STAINLESS STEEL TENSION CYLINDER PIN 1RETNR445 STAINLESS STEEL HAIR PIN 1/8 X 1-15/16 1RUBBR025 1SPROC420 Part Number DXD ENTRANCE TRAP DOOR DXD 4 TOOTH ENTRANCE SPROCKET Description DXD EXIT FLAP DOOR ASSEMBLY * 1CLAMP301 STAUFF 30 mm CLAMP(FOR CONVEYOR PROX) * 1ELECT-SN357 PROXIMITY SWITCH WITH12 CORD 1FSTNR-FH626 5/16-18 X 3/4 FLAT HEAD SOCKET SCREW WITH ARMOR COAT 1NUT-TN313 4 PRONG T-NUT 5/16-18 X 3/4 1RUBBR015 DXD EXIT FLAP DOOR 76 Belanger, Inc. * PO BOX 5470 * Northville, MI * Ph (248) * Fax (248) MANUL010

81 Replacement Parts Suggested Replacement Parts List Miscellaneous Part Number MOTOR-HY785 1MOTOR-HY835 1SPROC410 1HYDRA-PR500 1NUT-JM333 1WASHR-LC830 1WASHR-FL755 Description Hydraulic Power Unit DXD HYDRAULIC DRIVE UNIT ASSEMBLY (LESS THAN 60 CARS PER HOUR) DXD HYDRUALIC DRIVE UNIT ASSEMBLY (MORE THAN 60 CARS PER HOUR) DXD HYDRAULIC MOTOR FOR CONVEYOR (LESS THAN 60 CARS PER HOUR) DXD HYDRAULIC MOTOR FOR CONVEYOR (MORE THAN 60 CARS PER HOUR) DXD 4 TOOTH EXIT SPROCKET HECO GEARBOX ADAPTER 1-3/8 BORE X 1/4" KEYWAY 4 Roller for Standard Dollie 3/4-10 JAM NUT WITH ARMOR COAT 3/4 LOCK WASHER WITH ARMOR COAT 2 OD X 1 ID X 1/8 THICK FLAT WASHER 8912 STANDARD DOLLIE ROLLER SLEEVE 1ROLLR045 1ROLLR050 1WASHR-FL810 1FSTNR-HH925 1FORGE020 1FSTNR-HH672 1NUT-CL500 STANDARD INNER BLACK ROLLER STANDARD URETHANE GREEN TWO PART ROLLER 1-1/2 OD X 3/4" ID FLAT WASHER WITH ARMOR COAT 3/4-10 X 7-1/2 HEX HEAD CAP SCREW WITH ARMOR COAT X458 CONVEYOR CHAIN CENTER LINK BIS-6 Roller for Optional Dollie 1/2-13 X 10 GR 5 HEX HEAD CAP SCREW WITH ARMOR COAT 1/2-13 CENTER LOCK NUT WITH ZINC PLATING 6939 BIS-6 OUTER JOURNAL ASSEMBLY 1ROLLR-IL040 BIS-6 YELLOW UHMWP OUTER ROLLER (2-15/16 OD) BIS-6 MIDDLE JOURNAL ASSEMBLY 1ROLLR-IL050 BIS-6 GREEN URETHANE MIDDLE ROLLER BIS-6 INNER JOURNAL ASSEMBLY 1ROLLR-IL045 1FORGE010 1PLSTC-EX100 1FSTNR-BH510 1NUT-CL375 BIS-6 BLACK UHMWP INNER ROLLER (3-15/16 OD) X458 CONVEYOR CHAIN CENTER LINK Plastic Guide Rail EXTERIOR YELLOW PLASTIC GUIDE RAIL-10' LONG 3/8-16 X 1-1/4 BUTTON HEAD CAP SCREW 3/8-16 CENTER LOCK NUT WITH ZINC PLATING DXD GUIDE RAIL FIXTURE CLAMP ASSEMBLY System Air/Basic Control Panel 1ELBOW-PL666 1FILTR780 1VALVE-EL710 1ELECT-SW780 1ELECT-DN780 1VALVE-PN152 ELBOW FOR 1/4 AIR LINE 1/4" NPT/40 MICRON FILTER WITH SERVICE INDICATOR AND AUTO DRAIN 4-WAY 120 VAC COIL VALVE SOLENOID AIR PRESSURE SWITCH DIN CONNECTOR FOR PART NUMBER 1ELECT-SW780 4-WAY MANUAL LEVER VALVE 1MANUL010 Belanger, Inc. * PO BOX 5470 *Northville, MI * Ph (248) * Fax (248)

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84 DuraTrans XD Conveyor 1MANUL010 Belanger, Inc. * P.O. Box 5470 * Northville, MI Customer Service Phone (248) * Fax (248)