Installation and Operations Manual

Transcription

1 Installation and Operations Manual ENTRANCE SECTION CENTER SECTION (5') CENTER SECTION (10') EXIT SECTION (D88K CHAIN) EXIT SECTION (X458 CHAIN) Model No.: UENTTUF, UEXT88, UEXT45, UC05, UC10 Part No.: , , , , Description: Ultimate Conveyor Entrance, Center & Exit Section Revision Date: June 15, 2017 Released Date: September 23, /15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 1 of 37

2 General Warning READ ENTIRE MANUAL CAREFULLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THE PECO Equipment. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMATION AND ADDITIONAL INSTRUCTIONS INCLUDED WITH THIS EQUIPMENT. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE! Product Description & Specification System Description: The PECO Ultimate Conveyor is designed specifically for the car wash industry to provide safe conveyance of any automobile through the car wash tunnel. This conveyor is a three-tier design, allowing the operator to call a roller when the automobile is in position. This is known as Roller-On-Call. Once the roller is activated, it will engage the tire and will push the vehicle through the wash tunnel. The rollers otherwise will remain on the middle tier until they are raised. The conveyor can be set to engage the front tire or the rear tire. The Ultimate Conveyor is comprised of four basic elements: Entrance Section, Center Section, Exit Section and Chain with Rollers. The conveyor is constructed of a rugged three-tier steel frame with driver-side UHMW plastic guide rail. The middle tier has a Patented UHMW Internal Plastic Guide System. The roller assemblies are attached to the chain, which revolves in a circle about the middle and bottom tier. The top tier is used to convey the vehicle; middle tier is used for rollers not conveying; and the bottom tier is used for the return trip to the entrance section. The Ultimate Conveyor features heavy-duty entrance and exit rubber trap doors. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 2 of 37

3 General Safety Information All WARNINGS, CAUTIONS, AND SAFETY TIPS below concern the safe installation, operation, and service of your PECO Equipment. Please abide by this information; it is listed for you protection. Review thoroughly with all personnel working on or near this machine. NEVER ATTEMPT TO WORK ON THE EQUIPMENT WHILE IT IS RUNNING. DISCONNECT ALL HYDRAULIC POWER TO THIS DEVICE BEFORE SERVICING THIS MACHINE. DISCONNECT ALL ELECTRICAL POWER TO THIS DEVICE BEFORE SERVICING THIS MACHINE. RISK OF ELECTRICAL SHOCK AND DEATH HAZARD IF IMPROPERLY SERVICED. PERSONNEL MUST BE TRAINED IN SAFE OPERATING PROCEDURES. ALL PERSONNEL SHOULD REVIEW THIS MANUAL PERIODICALLY. EMERGENCY STOP BUTTONS MUST BE WELL MARKED AND THEIR LOCATION AND OPERATION REVIEWED WITH ALL PERSONNEL. MAINTENANCE OR REPAIR WORK ON EQUIPMENT MUST BE PERFORMED ONLY BY TRAINED EMPLOYEES ASSIGNED BY THE CAR WASH OPERATOR. DO NOT WEAR LOOSE FITTING CLOTHING WHEN WORKING ON OR AROUND EQUIPMENT. ALL CAR WASHES SHOULD HAVE A HORN OR ALARM THAT SOUNDS PRIOR TO EQUIPMENT STARTING. NO UNAUTHORIZED INDIVIDUALS SHOULD BE PERMITTED NEAR THE EQUIPMENT AT ANY TIME. CLEAR THE AREA OF PEOPLE AND ANY LOOSE DEBRIS PRIOR TO STARTING THE WASH. DO NOT OPERATE EQUIPMENT IF ANY COMPONENT MALFUNCTION IS FOUND. DO NOT OPERATE EQUIPMENT WITHOUT GUARD(S). DO NOT OPERATE EQUIPMENT FOR ANY OTHER PURPOSE THAN EXPRESSED IN SYSTEM DESCRIPTION SECTION AT THE BEGINNING OF THIS GUIDE. LOCK OUT THE AIR SUPPLY TO THE MACHINE PRIOR TO SERVICING THIS UNIT. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 3 of 37

4 Description PECO ULTIMATE CONVEYOR v Specification Weights and Physical Specifications Approximate Shipping Weight Unit W X L X H Width Length Height Entrance Section 925 (420 kg) 24.5 (622mm) 120 (3.04m) 26 (660mm) Exit Section 975 (443 kg) 27.5 (247mm) 120 (3.04m) 26 (660mm) Center Section (341 kg) 18.5 (247mm) 120 (3.04m) 26 (660mm) Center Section (170 kg) 18.5 (247mm) 60 (1.52m) 26 (660mm) PECO Roller 12 (5.5 kg) 10 (254mm) 10 (254mm) 3.6 (91.4mm) PECO 8-Wheel Roller 10 (4.5 kg) 10 (254mm) 10 (254mm) 3.75 (95.2mm) PECO 4-Wheel Roller 12 (5.5 kg) 9.75 (247mm) 10 (254mm) 3.5 (89mm) D88k Chain (4.7 kg) 2.75 (70mm) (25.4mm) 1 (25.4mm) D88k Chain (10 kg) 2.75 (70mm) (25.4mm) 1 (25.4mm) D88k Chain (8.8 kg) 2.75 (70mm) (25.4mm) 1 (25.4mm) Examples of Conveyor Weights Description Total Weight in Pounds 60 Conveyor 6,000 (2727 kg) 80 Conveyor 7,750 (3522 kg) 100 Conveyor 9,000 (4091 kg) 120 Conveyor 11,500 (5227 kg) 140 Conveyor 13,000 (5909 kg) Hydraulics/Pneumatics/Pit/Electrical Requirements Hydraulics: 10 gpm (45.4 1,000 psi (6.9 Mpa) Pneumatics: 40 psi (0.27 Mpa) Roller Up Solenoid psi ( Mpa) Hydraulic Take Up Assist Pit: Minimum Shelf Depth: 19 (483 mm) REAR WHEEL PUSH / 21 (533 mm) FRONT WHEEL PULL Standard Trench Width: 48 (1219 mm) See Conveyor Trench Schematic for detailed specifications Motor Information for Electric (e-drive) Option: 7.5HP (5.6 kw) RPM 1760 / 1455 FREQ 60 / 50 VOLT 208 / 230 / 60Hz FLA 24.2 / 22 / 11 VOLT 200 / 50Hz FLA 24 / 12 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 4 of 37

5 2.0 Prerequisite for Installation In order to plan an installation, the following items should be known prior to the construction of conveyor trough. 1. Length of conveyor. 2. Rear Wheel Push or Front Wheel Pull operation. 3. Location of hydraulic power pack and roller up controls. 4. Three Phase and Control Voltage at site. 5. Finish grade. 6. Sewer location and elevation. 7. Correlator location 8. Reclaim tank location 2.1 Installation of Conveyor Sections Place all sections on the conveyor shelf, starting with the entrance section. After all sections have been placed in position, there should be approximately 1 (305 mm) of space left at the exit end. This will accommodate the 1-6 (457 mm) drive off plate. Cut drive off plate to size if necessary. Once all the sections have been placed, you must establish the CENTERLINE OF THE EQUIPMENT in the building tunnel. This centerline is typically the center of the entrance and exit doors. All conveyor sections are set off this centerline. Once the center of the equipment has been established, set the inside guard rail 26-½ (673 mm) off this centerline of the equipment. C L 48.0 [ ] 43.0 [ ] 5.0 [127.00] 26.5 [673.10] DRIVER SIDE TUNNEL FLOOR PASSENGER SIDE TUNNEL FLOOR CONVEYOR LEDGE *C1 *C1-19" [483.0] REAR WHEEL PUSH 21 [533.0] FRONT WHEEL PULL 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 5 of 37

6 Next, level each section of the conveyor perpendicular to the travel of the vehicle. It is recommended that you start leveling the sections at the entrance and work towards the exit. All sections have to be leveled from driver s side to passenger s side. The entire conveyor must be straight and free of any humps, dips, or bends. All tiers must be accurately aligned at the joints. These are CRITICAL adjustments that must be made to ensure the proper operation of the conveyor. To adjust, shim any legs that do not touch the floor. NOTE: FRONT WHEEL PULL Front wheel pull conveyor passenger side slab concrete elevation is to be 1 (25 mm) HIGHER than the tire rolling surface of the conveyor. NOTE: REAR WHEEL PUSH Rear wheel pull conveyor passenger side slab concrete elevation is to be 1 (25 mm) LOWER than the tire rolling surface of the conveyor. Once leveling is complete, tack-weld the conveyor into place. After the conveyor has been leveled and tack welded into place, take a break! Stand back, take a look down the conveyor and see how it looks. If you are satisfied that all the tiers match and are level, weld completely. It is recommended that you weld a piece of flat stock between the driver s side conveyor section and the imbedded angle along the driver side trench wall. Make this connection at each conveyor section. Once the conveyor is welded in place, you can weld the angle for the grates on to the conveyor. Place the angle on the conveyor at a height to ensure a level grate installation. WELD CONVEYOR SECTIONS TOGETHER AT THESE LOCATIONS WELD A STEEL PLATE TO THE CONVEYOR SECTION & THE TRENCH ANGLE FOR LATERAL STABILITY 3" +/- 1 2" BEAD LENGTH AY52 WELD CONVEYOR SECTION TO THE CONVEYOR SHELF 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 6 of 37

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8 2.2 Chain and Roller Installation D88K Chain and Rollers The chain length is predetermined at the factory along with the number of pieces required for your conveyor. Place one roller between each piece of chain. When assembling the chain sections, you must make sure that the rollers are in the correct direction and that they are right side up. Attach a roller to each piece of chain. Note that the connecting pin has a notch. It will fit only one way into the chain link. Installation of the chain must ensure the sprocket teeth engage the chain surface and not the chain pins. Feed all the pieces into the conveyor. The last connecting piece of the chain should be pinned and cottered. Tighten the chain with a Come-Along. The Take-Up Drum can move ten inches (254mm). X458 Chain and Rollers X458 Chain requires no tools for assembly. The chain is shipped in 10 (3.04 m) sections. You will need to place a roller at specific chain increments depending on the roller spacing desired. 23 Chain Increments for 7-4 (2.23 m) Roller Spacing (23 increments between rollers) 19 Chain Increments for 6-4 (1.93 m) Roller Spacing (19 increments between rollers) 11 Chain Increments for 3-8 (1.11 m) Roller Spacing (11 increments between rollers) Tighten the chain with a Come-Along. The Take-Up Drum can move ten inches (254mm). 3-8 ROLLER SPACING EXAMPLE TD45P TD45P VEHICLE TRAVEL AY72M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 8 of 37

9 Chain and Rollers Care and Maintenance Maintenance of the chain and rollers is crucial to the operation of the conveyor. Once a day, call the rollers up and power-wash them to flush out all the dirt and sand. Less grime on the rollers and chain will promote longer life of all the conveyor components. Keep the conveyor shelf clean to extend the life of the chain, rollers, and sprocket. Dirt and sand is the chain and rollers worst enemy. The life expectancy of the chain and rollers depends on how clean you keep your conveyor, the number of revolutions that the conveyor makes is only a small factor in the life expectancy. NEVER APPLY OIL OR GREASE TO THE CHAIN OR THE ROLLERS. OIL AND GREASE WILL ATTRACT THE SAND AND DIRT AND ACCELERATE THE WEAR. CHECK THE DRIVE SPROCKET FOR WEAR ONCE A MONTH. A WORN DRIVE SPROCKET WILL CAUSE ACCELERATED CHAIN WEAR AND BREAKAGE. Once a year, the rollers should be removed in order to flip the chain over. This will help maximize the chain life. Now is a good time to closely examine your chain, rollers, and sprocket for wear. When replacing a roller on the conveyor you do not have to take the chain apart. Remove the idler shaft and the roller will come off the chain. Refer to the Roller Installation and Operations Manual. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 9 of 37

10 CHAIN TRAVEL ENTRANCE END D88K CHAIN EXIT END CHAIN TRAVEL D88KAY50 CHAIN TRAVEL ENTRANCE END X458 CHAIN EXIT END CHAIN TRAVEL X458AY50 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 10 of 37

11 2.3 Hydraulic Power Pack / Roller-Up Control Place hydraulic power pack in equipment room. Hydraulic power pack is required to operate the conveyor. See the Installation and Operations Manual for your specific hydraulic unit. Mount Roller-Up 4W1 4-Way Valve Solenoid in equipment room. If your conveyor has the optional Hydraulic Take-Up Assist, mount the 4WM 4-Way Manual Valve in the equipment room. 3.0 Entrance Section General Features The Entrance section is comprised of three basic elements: 1. Take Up Assembly 2. Fork Assembly 3. Roller Control 4. Optional Hydraulic Take-Up Assist. The Take-Up assembly is designed to provide chain tension for the conveyor. The fork assembly lifts a roller to the conveyor s top tier. The entrance section can have an optional Hydraulic Take-Up Assist. This option is highly recommended on conveyors of 150 ft (45m) and longer. 3.1 TAKE-UP ASSEMBLY The Take-Up Assembly is comprised of a drum, slide rails, spring, and hydraulic take-up assist (optional). This assembly will apply tension to the chain. The Take-Up Assembly has 10 inches (254mm) of travel. Over time, as the chain wears and becomes loose, you must remove some of the chain links. Closely monitor the chain tension the first few weeks. Remove chain sections as required. After this initial break-in period, check the chain tension weekly and adjust as required. There are two bearings that support the drum shaft. These bearings should be greased every day. The bearings are located on the inside surface of the take-up drum mounting plate. Take care not to blow out the bearing seals. Slowly apply a small amount of grease through the fittings on the bearings. The Hydraulic Take-Up Assist is comprised of a cylinder, fluid reservoirs, and a 4WM (Manual 4-Way Valve). Installation of the unit: 1. Mount the 4WM in the equipment room. 2. Attach the Air-Oil reservoirs to the entrance conveyor section (inboard side). 3. Run 3/8 (10 mm) poly flow hose between the 4WM and the ports on the reservoirs. 4. Fill the reservoirs with hydraulic oil. Once installation is completed, turn air on. Adjust the operating pressure to no more than 20 psi. WARNING: 1. DO NOT EXCEED 20 PSI (0.13 Mpa) 2. PURGE ALL AIR LINES BEFORE PERFORMNING ANY MAINTENANCE. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 11 of 37

12 CLEAN, DRY AIR FROM COMPRESSOR 4WM AIR FEED LINES USE 3/8" POLY FLOW HOSE DO NOT EXCEED 20 PSI HYD CYLINDER AIR / OIL RESERVOIRS AY51 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 12 of 37

13 3.2 FORK ASSEMBLY PECO ULTIMATE CONVEYOR v.2 The fork assembly is made up of: a fork, couplings, pneumatic cylinder actuator and a manual actuator. This assembly will call up rollers to the top tier. When the air pressure is forced into the ports of the pneumatic cylinder, it will cause the shaft to lift, causing the fork to rotate up and raise a roller at your command. Manual actuator: This actuator is provided to be able to rotate the forks up in case there has been a failure with the roller call pneumatic cylinder (examples: air compressor failure, supply line failure, cylinder failure, computer output failure, etc.). This actuator should only be used temporarily. When using the manual actuator you must disconnect all air pressure to the Conveyor Roller-Up Four Way Valve. Raise the fork by stepping on the foot pedal. This procedure should be supervised with a manager or owner who is familiar with this procedure. Improper use of manual actuator could result in injury. 3.3 ROLLER CONTROL The Tunnel Controller sends a signal to the 4W1 Valve. This Solenoid Valve assembly sends air to the cylinder on the conveyor. The cylinder shaft extends and lifts the fork into position to raise the roller to the top deck of the conveyor. COIL EXHAUST TUBE A B P AIR REG 3/8" (10 mm) POLY FLOW TUBING CLEAN, DRY AIR FROM COMPRESSOR CLEAN, DRY AIR PROMOTES LONGER CYLINDER LIFE. 4W1 VALVE ADJUST TO PSI ( MPa) ROLLER UP CONTROL SCHEMATIC AY53 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 13 of 37

14 3.0a EXIT SECTION HYDRAULIC DRIVE The exit section is comprised of two basic elements: (1) Hydraulic Drive System (2) Separate Hydraulic Power Pack The exit conveyor section houses the hydraulic drive motor and gearbox. 1.1 HYDRAULIC DRIVE SYSTEM The Hydraulic Drive System is comprised of a gearbox, hydraulic motor and sprocket. This system drives the conveyor chain and rollers. Installation of the hydraulic system: (1) Place sun gear into the Char Lynn motor; be sure that the brass ring is on. (2) Now place the Char Lynn motor into the HECO gearbox tighten the bolts. (3) Fill HECO gearbox with hydraulic oil. Then place plug into the drain port on the gearbox. (4) Install the F x M swivel to the Motor case-drain. Also install the adapters to the motor. (5) Connect two ½ (12 mm) hydraulic hoses to the hydraulic motor. Run the feed and return lines to the hydraulic pumping station. The hose must meet or exceed 2000 psi (13.8 Mpa) rating. (6) Use ¾ (19 mm) hydraulic hose if distance between hydraulic pumping station and hydraulic motor exceeds 35 ft. (10.6 m) (7) Run a 3/8 (12 mm) hose from the motor case drain to the hydraulic pumping station. This line is to be attached to the port on the top plate of the Conveyor Hydraulic Power Pack. 1.2 HYDRAULIC POWER PACK The Hydraulic Power Pack is comprised of a vane pump, a motor, a reservoir tank, and a priority valve. This unit will supply hydraulic oil to the motor on the exit conveyor section. Installation of the unit: (1) Place the hydraulic power pack in the equipment room. (2) Lag unit to the floor. (3) Run the hydraulic lines to the hydraulic drive system at the exit conveyor section. (4) Place the hydraulic oil into the hydraulic tank. (5) Have a qualified electrician wire the unit. Have the electrician install a horn or alarm. Refer to the Installation & Operations Manual of the Hydraulic Power Pack. DO NOT USE GALVANIZED PIPE FOR THE HYDRAULIC LINES. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 14 of 37

15 PECO Recommedation on Hyraulic Fluids for Hydraulic Power Packs Use a Premium quality, anti-wear type hydraulic oil with a viscosity of not less than 70 SUS at operating temperature. Oil Viscosity Recommendations: Crankcase Oil--- Hydraulic System Operating Temp. Range: -10 C to 99 C(14 F to 210 F) SAE Viscosity Designation: 20-20W Antiwear Hydraulic Oils--- Hydraulic System Operating Temp. Range: -9 C to 88 C(15 F to 190 F) ISO Viscosity Grade: 46 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 15 of 37

16 PULSE FLAG * (4 MAGNET) * (2 MAGNET) SPROCKET * (D88K CHAIN) SPROCKET - 4 TOOTH * (X458 CHAIN) * DENOTES PECO PART NUMBER (VERIFY WITH FACTORY) BASE PLATE ON EXIT CONVEYOR SECTION GEAR BOX FILL PORT HYDRAULIC RETURN LINE HYDRAULIC FEED LINE HYDRAULIC MOTOR MOTOR CASE DRAIN BACK TO HYDRAULIC TANK DRIVE SECTION - HYDRAULIC MOTOR ILLUSTRATION AY51 PECO ULTIMATE CONVEYOR v.2 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 16 of 37

17 MICRO SWITCH PLACEMENT DIAGRAM 1/4" TO 3/8" PULSE FLAG MICRO SWITCH LINE UP TARGET AREA ON MICRO SWITCH WITH ROTATING MAGNET GEAR BOX ASSEMBLY PECO ULTIMATE CONVEYOR v AY54 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 17 of 37

18 3.0b EXIT SECTION ELECTRIC DRIVE The exit section is comprised of two basic elements: (1) Electric Drive Motor / Gearbox (2) Variable Frequency Drive The exit conveyor section houses the electric drive motor and gearbox. The unit is installed at the PECO factory. *** The gearbox must be filled with2 ½ Quarts (2.4 l) of 85W-140EP Rated Gear Oil before operating. BREATHER PORT (1) OIL FILL PORT (2) OIL FILL PORT (3) Note: Gearbox should always be oriented with worm gear in the highest horizontal position (as shown) How to Fill 1. Place gearbox on a level surface and remove plug from Breather Port (1) and Oil Fill Port (2) 2. Fill unit with 2 1/2 quarts of gear oil* via Oil Fill Port (2) 3. Replace plug in Breather Port (1) and Oil Fill Port (2) 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 18 of 37

19 Electrical Connection Information: MOTOR SPECIFICATIONS: VOLTAGE (VAC) FREQ (Hz) POWER (HP) MOTOR RPM AMPS SPROCKET RPM CHAIN SPEED VEHICLES PER / HR FT/MIN FT/MIN FT/MIN FT/MIN FT/MIN 90 FINAL DRIVE RATIO 135:1 DRIVE CONTROL REQUIREMENTS: Use a Variable Frequency Drive (VFD) with the capability of producing the correct output voltage and power listed above. The VFD must have a programmable relay output that de-energizes when the drive trips or power is removed. Set Ramp-Up Time for 3 to 5 seconds. WIRING REQUIREMENTS BETWEEN VFD & MOTOR: Shielded Motor Cable must be used between the VFD and the Motor. Follow the VFD manufacturer s wiring diagram for proper motor lead, shield and grounding terminations. Enter through the underside of the junction box with the shielded motor cable. Terminate the motor leads to the motor terminal according to the diagram inside the junction box cover. Use Split Bolt fasteners to terminate the motor leads. Use a water tight connection to accommodate the motor cable. Water leaking into the motor will damage the unit. Water damage is not covered under warranty. Never run 3-Phase wires in the same conduit or chase with tunnel controller input, output, or communication wires. Voltage drop between the motor starter and the 3-Phase motor must never exceed 2%. Ensure the motor cable is routed safely and securely. Do not let the motor cable to drag or rub on the equipment. A float switch must be used to detect high water in the conveyor trench. This float switch must be wired into the conveyor enable circuit or interlock. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 19 of 37

20 Operation Adjustments 1. HYDRAULIC DRIVE: At initial Start-Up, have conveyor power pack set to the lowest speed. Slowly increase hydraulic oil flow to increase speed. Make sure chain and rollers are moving in the correct direction. Swap feed and return lines to change conveyor travel direction if necessary. 2. ELECTRIC DRIVE: At initial Start-Up, ensure the VFD is set to a low speed (30Hz). The Ramp-Up Time should be set between 3 and 5 seconds. Make sure the chain and rollers are moving in the correct direction. Swap any two electric motor leads at the motor junction box to reverse the observed chain direction if necessary. 3. Tighten chain by using a come-along to collapse the chain. Remove the necessary number of chain links. Maintenance Schedule Maintenance Performed Daily Weekly Monthly 6-Months Yearly Flush Conveyor, Chain, and Rollers with water. Grease Take-Up Drum Bearings on Entrance Section Inspect Entrance and Exit Trap Doors for function and wear. Ensure there are no loose bolts on Exit Trap Door Roller. Check Chain Tension Inspect Cotter Pins on D88K Chain for wear Remove and flip Chain and Rollers to extend the life of the Chain Check Drive Sprocket, Chain, and Rollers for wear Check oil level in Electric Drive Gearbox Replace oil in Electric Drive Gearbox X X X X X X X X X X X 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 20 of 37

21 Recommended Replacement Parts List Part Number Description Comments TD-ENTRANCE, COMPLETE BELTED PECO (DLX/ULT) TD-EXIT,COMPLETE BELTED, PECO (DLX/ULT) CYLINDER, 1-1/16 BORE x 2 STROKE CN-LIFT ARM-ALUM, ULT-TUF MOTOR-HYD CONSULT FACTORY CN-SPROCKET, 2-1/4 12T FOR 88K CHAIN CN-SPROCKET, 2-1/4 4T FOR X458 CHAIN MOTOR- ELECTRIC 1785 RPM (E-DRIVE) CONSULT FACTORY 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 21 of 37

22 Trouble Shooting Chart Trouble Possible Cause Probable Remedy Conveyor motor does not run. Chain and Rollers Jamming when raising the forks. Chain is rubbing on conveyor. Rollers not coming up to top tier when called upon. Chain Breaking Excessive Drive Sprocket Wear Hydraulic Float Switch opened. Emergency Stop Button Engaged Low Air Pressure VFD Overload Trip MCC Overload Protection Tripped. Forks not lifting completely. Chain tension is low. Not enough air pressure. Debris in air line to actuator cylinder. Actuator cylinder failure Roller Up Control Valve not functioning. Worn out Chain Pressure too high on Hydraulic Take-Up Assist Regulator Worn 4 tooth Sprocket Conveyor components not getting cleaned and flushed regularly. Pressure too high on Hydraulic Take-Up Assist Regulator Check Hydraulic Oil Level in Power Pack. Add oil if necessary. Check Tunnel Controller Pilot Light. Check all emergency stop buttons. Check Tunnel Controller Pilot Light. Check Tunnel Controller Pilot Light. Check VFD Parameters. Check Electric Motor. Check MCC Panel for tripped Overload Fault. Increase air pressure at the Roller-Up Control Valve. Increase Chain tension by removing links. Increase air pressure at the Roller-Up Control Valve. Check and clean air line. Recommended to always use a dryer on air compressor. Check air line connections at actuator cylinder. Tighten if necessary. Repair or replace cylinder. Check valve for operation. Manual fire this solenoid through the tunnel controller. Replace Chain and Roller if necessary Set Air Pressure at 15 to 20 psi on Hydraulic Take-Up Assist. Replace Chain and Drive Sprocket in necessary. Replace chain and sprocket Flush Chain and Rollers with water every day. Set Air Pressure at 15 to 20 psi on Hydraulic Take-Up Assist. Replace Chain and Drive Sprocket in necessary. 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 22 of 37

23 Replacement Parts List UENTTUF ITEM NAME DESCRIPTION QTY TD-ENTRANCE, COMPLETE BELTED PECO (DLX/ULT) TD-PLATE-PAINTED, ENT BOLT/WELD DOWN CN-MODULE, ULTIMATE ENTRANCE W/TUFF CN-FRAME-PAINTED, ULT ENTRANCE (TUFF) CN-CENTER ANGLE-UHMW, ULT ENTERANCE P/S CN-PLATE-PAINT, ULTIMATE ENTRANCE (CAUTION) CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) WASHER-LOCK-PLT, 1/ CN-CENTER ANGLE-UHMW, ULT ENTERANCE D/S NUT-HEX-PLT, 1/ BOLT-FLAT HD-PLT, 1/2-13 x CN-PLATE-PLASTIC, YELLOW SINTRA 3MM x 8-1/2" x 10" BOLT-HEX-SS, 1/4-20 x 3/ BOLT-HEX-SS, 1/2-13 x 1-3/ NUT-NYLON INSERT-SS, 1/ WASHER-FLAT-PLT, 1/2 USS BOLT-SOCKET, 1/2-13 x 1 FLAT SCREW WASHER-FLAT-SS, 1/4 SAE WASHER-FLAT-SS, 1/2 SAE 16 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 23 of 37

24 Replacement Parts UENTTUF AY55 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 24 of 37

25 AY56 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 25 of 37

26 Replacement Parts List Take Up Module ITEM NAME DESCRIPTION QTY CN-SPRING, ULT 6-3/4 x 26 TAKE-UP STREET ELL-BRASS, 3/8 NPT (45 DEGREE) NOZZLE-BRASS-3/8, 6530 VEEJET BOLT-HEX-SS, 3/8-16 x NUT-NYLON INSERT-SS, 3/ CN-DRUM-PAINT, ULT TAKE-UP CN-CAGE-PAINT, ULT TAKE-UP DRUM BUSH-UHMW, ULT SLIDE INSERT (YELLOW) BOLT-HEX-SS, 1/2-13x NUT-NYLON INSERT-SS, 1/ WASHER-FLAT-SS, 1/2 SAE BRG-4B-2 3/16, STD CN-RAIL-SS, ULT SLIDE CN-SLIDE-PAINT, ULT-TUF D/S FORK CN-SLIDE-PAINT, ULT-TUF P/S FORK CN-FORK-PAINT, ULT-TUF STOP-RUBBER, 1-1/2 DIA x 1-1/4 LONG (1/2-13 x 2-1/2 BOLT) CYLINDER-ARO, 1-1/16 BORE x 2 STROKE CYLINDER-BUMPER, 3/4 x 5/8 x 5/16-24 NEOPRENE CN-LIFT ARM-ALUM, ULT-TUF CN-LIFT BKT-PAINT, ULT-TUF CN-LIFT ROD-PAINT, ULT-TUF CN-HFRAME-PAINT, ULT SLIDE RAIL SUPPORT CN-REST BLOCK-PAINT, ULT-TUF NUT-NYLON INSERT-SS, 1/ BRG-BUSH-UHMW, ULT FORK (YELLOW) SET COLLAR-SS, 7/8 2PC SPLIT W/SET SCREW BOLT-HEX-SS, 3/8-16x2-1/ WASHER-FLAT-SS, 3/8 SAE ELBOW-PLASTIC, ML SWIVEL (3/8 TUBE - 1/8 NPT) CN-TAKE UP STOP-UHMW, 5" ENTRANCE ULT-TUF CN-TAKE UP STOP-UHMW, 3" EXIT ULT-TUF WASHER-LOCK-SS, 1/ BOLT-HEX-SS, 1/4-20 x BOLT-HEX-SS, 3/8-16 x 1-3/ NUT-NYLON INSERT-PLT, 5/8-18 JAM (MFG ONLY) 1 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 26 of 37

27 ITEM NAME DESCRIPTION QTY WASHER-FLAT-SS, 1/4 SAE NUT-HEX-SS, 1/ BOLT-HEX-SS, 1/2-13 x KEY STOCK-PLN, 1/4 x 1/4 (12" LENGTH) CN-HFRAME-PAINT, ULT SLIDE/SPRING SUPPORT 1 Replacement Parts Take Up Module AY55 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 27 of 37

28 AY55 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 28 of 37

29 Replacement Parts List UC ITEM NAME DESCRIPTION QTY CN-FRAME-PAINTED, ULT 10' CENTER CN-CENTER ANGLE-UHMW, ULT 10' BOLT-FLAT HD-PLT, 1/2-13 x WASHER-FLAT-PLT, 1/2 USS NUT-NYLON INSERT-PLT, 1/2-13 (MFG ONLY) WASHER-LOCK-PLT, 1/ CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) ANGLE, 1-1/2 x 1-1/2 x 1/4 1 Replacement Parts UC AY51 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 29 of 37

30 Replacement Parts List UC ITEM NAME DESCRIPTION QTY CN-CENTER ANGLE-UHMW, ULT 5' CN-FRAME-PAINTED, ULT 5' CENTER WASHER-FLAT-PLT, 1/2 USS WASHER-LOCK-PLT, 1/ NUT-HEX-PLT, 1/ BOLT-FLAT HD-PLT, 1/2-13 x CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) ANGLE, 1-1/2 x 1-1/2 x 1/4 1 Replacement Parts UC AY51M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 30 of 37

31 Replacement Parts List UEXT ITEM NAME DESCRIPTION QTY CN-FRAME-PAINTED, ULT EXIT BOLT-HEX-SS, 1/2-13 x 1-1/ SET SCREW-PLT, 1/2-13 x 1-1/4 SQ HD KEY STOCK-PLT, 1/2 x 1/ ADAPTER-PLT, 7/16 STRAIGHT THRD O-RING x 1/4 NPT PLUG-PLT, 1/4 NPT SOCKET HD BOLT-HEX-PLT, 1/2-13 x 2-1/4 GR WASHER-LOCK-SS, 1/ CN-SPROCKET, 2-1/4" 12T CN-SPROCKET, 2-1/4" 4T GEAR BOX-HECO, 2-1/4 SHAFT KEYED 5-1 RATIO CF HYD DR CN-HANG DOWN-RUBBER, PECO EXIT CN-PLATE-PAINTED, PECO EXIT BASE TD-EXIT,COMPLETE BELTED, PECO (DLX/ULT) CN-TOP ANGLE-GALV, ULTIMATE EXIT CN-CUSHION-RUBBER, PECO EXIT ROLLER NUT-NYLON INSERT-PLT, 1/2-13 (MFG ONLY) NUT-NYLON INSERT-PLT, 5/ BOLT-HEX-PLT, 5/8-11 x 2-1/ BOLT-FLAT HD-PLT, 1/2-13 x BOLT-HEX-PLT, 5/16-18 x 1 GR WASHER-FLAT-PLT, 5/16 SAE NUT-HEX-PLT, 1/ BOLT-HEX-SS, 1/2-13 x CN-TOP ANGLE-UHMW, ULTIMATE EXIT (YELLOW) D/S-P/S CN-CENTER ANGLE-UHMW, ULT EXIT P/S ADAPTER-PLT, 7/8" STRAIGHT THRD O-RING x 1/2" NPT FM ELBOW-PLASTIC, 3/8 TUBE x 3/8 NPT (90 DEGREE)PUSHLOCK GEAR KIT-HECO, SUN HECO SUN GEAR & GEAR BOX (E-DRIVE) MOTOR-HYD, CHAR-LYNN MOTOR-ELECTRIC 1785 RPM (E-DRIVE) NUT-NYLON INSERT-PLT, 5/ WASHER-FLAT-PLT, 1/2 USS 26 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 31 of 37

32 ITEM NAME DESCRIPTION QTY CN-CENTER ANGLE-UHMW, ULT EXIT D/S CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) PLATE-A36, 3/8 x 12 x 18 (DRIVE OFF PLATE) ANGLE, 1-1/2 x 1-1/2 x 1/4 1 Replacement Parts UEXT AY51M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 32 of 37

33 AY52M Replacement Parts UEXT AY53M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 33 of 37

34 AY54M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 34 of 37

35 Replacement Parts List Entrance Trap Door ITEM NAME DESCRIPTION QTY FLAT, 1/4 x 1-1/ TD-PLATE-PAINTED, ENT. TOP FLAT, 1/4 x 1-1/ TD-RUBBER, PECO ENTRANCE REPLACEMENT WASHER-FLAT-PLT, 1/2 USS NUT-NYLON INSERT-PLT, 1/2-13 JAM BOLT-FLAT HD-SS, 1/2-13 x 1 SOCKET (MFG ONLY) BOLT-HEX-SS, 1/2-13 x 1-1/4 5 Replacement Parts Entrance Trap Door AY50M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 35 of 37

36 Replacement Parts List Exit Trap Door ITEM NAME DESCRIPTION QTY TD-PLATE-PAINTED, EXIT MAIN TOP TD-PLATE-PAINTED, EXIT SQUEEZE TD-PLATE-PAINTED, EXIT HOLD DOWN TD-EXIT WHEEL-STL TD-RUBBER, PECO EXIT REPLACEMENT TD-PAD, EXIT CUSHION (REPLACEMENT) TD-EXIT WHEEL SHAFT-STL WASHER-FLAT-SS, 3/8 SAE NUT-NYLON INSERT-SS, 3/8-16 JAM SCREW-MACH-SS, 1/4-20 x 3/4 FLT HD BOLT-HEX-SS, 3/8-16 x 1-1/ BOLT-FLAT HD-SS, 1/2-13 x 1 SOCKET (MFG ONLY) 10 Replacement Parts Exit Trap Door AY50M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 36 of 37

37 Packed By: Date: / / Inspected By: Date: / / Serial # Packing List UENTTUF ENTRANCE ULTIMATE TIP UP FORK PAINTED SECTION Part Number Description Qty. Shipped AY ULTIMATE ENTRANCE TUF SECTION ASSEMBLED ANGLE-STL, 1-1/2 X 1-1/2 X ¼ ML MANUAL, UENTTUF 1 ***** OPTIONAL EQUIPMENT ***** CONVEYOR HYDRAULIC TAKE-UP ASSIST WM 4-WAY MANUAL VALVE FWP FRONT WHEEL PULL URG INSIDE RAIL ROLLER GUIDE 1 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 37 of 37