Installation and Operations Manual

Installation and Operations Manual 990155 ENTRANCE SECTION 990089 CENTER SECTION (5') 990091 CENTER SECTION (10') 990084 EXIT SECTION (D88K CHAIN) 990086 EXIT SECTION (X458 CHAIN) Model No.: UENTTUF, UEXT88, UEXT45, UC05, UC10 Part No.: 990155, 990084, 990086, 990089, 990091 Description: Ultimate Conveyor Entrance, Center & Exit Section Revision Date: June 15, 2017 Released Date: September 23, 2007 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 1 of 37

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

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

Description PECO ULTIMATE CONVEYOR v.2 1.0 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 10 750 (341 kg) 18.5 (247mm) 120 (3.04m) 26 (660mm) Center Section 5 375 (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 3-6 10.5 (4.7 kg) 2.75 (70mm) 41.74 (25.4mm) 1 (25.4mm) D88k Chain 7-4 22 (10 kg) 2.75 (70mm) 86.10 (25.4mm) 1 (25.4mm) D88k Chain 6-6 19.5 (8.8 kg) 2.75 (70mm) 75.66 (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 lpm) @ 1,000 psi (6.9 Mpa) Pneumatics: 40 psi (0.27 Mpa) Roller Up Solenoid 15-20 psi (0.1-0.13 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 / 460 @ 60Hz FLA 24.2 / 22 / 11 VOLT 200 / 400 @ 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

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 [1219.20] 43.0 [1092.20] 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

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 990091AY52 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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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 1 2 3 4 5 6 7 8 9 10 11 VEHICLE TRAVEL 481350AY72M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 8 of 37

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

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

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

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 028092AY51 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 12 of 37

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 20-40 PSI (0.13-0.26 MPa) ROLLER UP CONTROL SCHEMATIC 990155AY53 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 13 of 37

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

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

PULSE FLAG *901190 (4 MAGNET) *901187 (2 MAGNET) SPROCKET *170084 (D88K CHAIN) SPROCKET - 4 TOOTH *269912 (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 990155AY51 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

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.2 990155AY54 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 17 of 37

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

Electrical Connection Information: MOTOR SPECIFICATIONS: VOLTAGE (VAC) FREQ (Hz) POWER (HP) MOTOR RPM AMPS SPROCKET RPM CHAIN SPEED VEHICLES PER / HR 200 50 5 1455 14.8 10.76 28.7FT/MIN 75 400 50 5 1455 7.4 10.76 28.7FT/MIN 75 208 60 5 1760 13.4 13.0 34.7FT/MIN 90 230 60 5 1760 12.6 13.0 34.7FT/MIN 90 460 60 5 1760 6.3 13.0 34.7FT/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

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

Recommended Replacement Parts List Part Number Description Comments 164220 TD-ENTRANCE, COMPLETE BELTED PECO (DLX/ULT) 164205 TD-EXIT,COMPLETE BELTED, PECO (DLX/ULT) 027805 CYLINDER, 1-1/16 BORE x 2 STROKE 510236 CN-LIFT ARM-ALUM, ULT-TUF 007981 MOTOR-HYD CONSULT FACTORY 170084 CN-SPROCKET, 2-1/4 12T FOR 88K CHAIN 269912 CN-SPROCKET, 2-1/4 4T FOR X458 CHAIN 000185 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

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

Replacement Parts List UENTTUF 990155 ITEM NAME DESCRIPTION QTY 1 164220 TD-ENTRANCE, COMPLETE BELTED PECO (DLX/ULT) 1 2 164221 TD-PLATE-PAINTED, ENT BOLT/WELD DOWN 1 3 510500 CN-MODULE, ULTIMATE ENTRANCE W/TUFF 1 4 510530 CN-FRAME-PAINTED, ULT ENTRANCE (TUFF) 1 5 510212 CN-CENTER ANGLE-UHMW, ULT ENTERANCE P/S 1 7 510078 CN-PLATE-PAINT, ULTIMATE ENTRANCE (CAUTION) 1 8 950407 CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) 2 9 015602 WASHER-LOCK-PLT, 1/2 8 10 510215 CN-CENTER ANGLE-UHMW, ULT ENTERANCE D/S 1 11 016063 NUT-HEX-PLT, 1/2-13 8 12 017167 BOLT-FLAT HD-PLT, 1/2-13 x 2 8 13 510080 CN-PLATE-PLASTIC, YELLOW SINTRA 3MM x 8-1/2" x 10" 1 14 600001 BOLT-HEX-SS, 1/4-20 x 3/4 4 15 600022 BOLT-HEX-SS, 1/2-13 x 1-3/4 8 16 600134 NUT-NYLON INSERT-SS, 1/2-13 8 17 015537 WASHER-FLAT-PLT, 1/2 USS 8 18 017856 BOLT-SOCKET, 1/2-13 x 1 FLAT SCREW 2 19 600147 WASHER-FLAT-SS, 1/4 SAE 4 20 600135 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

Replacement Parts UENTTUF 990155 8 4 3 10 11 9 17 5 12 990155AY55 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 24 of 37

14 19 7 20 1 16 15 13 13 2 18 990155AY56 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 25 of 37

Replacement Parts List Take Up Module 510500 ITEM NAME DESCRIPTION QTY 1 055260 CN-SPRING, ULT 6-3/4 x 26 TAKE-UP 1 2 001658 STREET ELL-BRASS, 3/8 NPT (45 DEGREE) 2 3 801272 NOZZLE-BRASS-3/8, 6530 VEEJET 2 4 600036 BOLT-HEX-SS, 3/8-16 x 2 8 5 600160 NUT-NYLON INSERT-SS, 3/8-16 16 6 510214 CN-DRUM-PAINT, ULT TAKE-UP 1 7 510213 CN-CAGE-PAINT, ULT TAKE-UP DRUM 1 8 510254 BUSH-UHMW, ULT SLIDE INSERT (YELLOW) 24 9 600023 BOLT-HEX-SS, 1/2-13x2 8 10 600134 NUT-NYLON INSERT-SS, 1/2-13 8 11 600135 WASHER-FLAT-SS, 1/2 SAE 16 12 010375 BRG-4B-2 3/16, STD 2 13 510216 CN-RAIL-SS, ULT SLIDE 1 14 510225 CN-SLIDE-PAINT, ULT-TUF D/S FORK 1 15 510226 CN-SLIDE-PAINT, ULT-TUF P/S FORK 1 16 510217 CN-FORK-PAINT, ULT-TUF 1 17 228536 STOP-RUBBER, 1-1/2 DIA x 1-1/4 LONG (1/2-13 x 2-1/2 BOLT) 2 18 027805 CYLINDER-ARO, 1-1/16 BORE x 2 STROKE 1 19 027804 CYLINDER-BUMPER, 3/4 x 5/8 x 5/16-24 NEOPRENE 1 20 510236 CN-LIFT ARM-ALUM, ULT-TUF 2 21 510234 CN-LIFT BKT-PAINT, ULT-TUF 1 22 510235 CN-LIFT ROD-PAINT, ULT-TUF 1 23 510202 CN-HFRAME-PAINT, ULT SLIDE RAIL SUPPORT 1 24 510228 CN-REST BLOCK-PAINT, ULT-TUF 2 25 600186 NUT-NYLON INSERT-SS, 1/4-20 2 26 510244 BRG-BUSH-UHMW, ULT FORK (YELLOW) 4 27 019762 SET COLLAR-SS, 7/8 2PC SPLIT W/SET SCREW 8 28 600033 BOLT-HEX-SS, 3/8-16x2-1/2 6 29 600133 WASHER-FLAT-SS, 3/8 SAE 12 30 001928 ELBOW-PLASTIC, ML SWIVEL (3/8 TUBE - 1/8 NPT) 2 31 510242 CN-TAKE UP STOP-UHMW, 5" ENTRANCE ULT-TUF 2 32 510243 CN-TAKE UP STOP-UHMW, 3" EXIT ULT-TUF 2 33 600153 WASHER-LOCK-SS, 1/2 2 34 600000 BOLT-HEX-SS, 1/4-20 x 1 2 35 600035 BOLT-HEX-SS, 3/8-16 x 1-3/4 2 36 016346 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

ITEM NAME DESCRIPTION QTY 37 600147 WASHER-FLAT-SS, 1/4 SAE 4 38 600142 NUT-HEX-SS, 1/2-13 2 39 600019 BOLT-HEX-SS, 1/2-13 x 1 2 40 002023 KEY STOCK-PLN, 1/4 x 1/4 (12" LENGTH) 1 41 510201 CN-HFRAME-PAINT, ULT SLIDE/SPRING SUPPORT 1 Replacement Parts Take Up Module 510500 37 25 34 41 5 22 29 28 26 16 21 20 12 40 5 4 14 27 13 1 9 11 10 7 8 6 23 510500AY55 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 27 of 37

40 35 20 19 36 18 30 15 39 33 41 17 2 3 38 31 24 32 510500AY55 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 28 of 37

Replacement Parts List UC10 990091 ITEM NAME DESCRIPTION QTY 1 510250 CN-FRAME-PAINTED, ULT 10' CENTER 1 2 510249 CN-CENTER ANGLE-UHMW, ULT 10' 2 3 017167 BOLT-FLAT HD-PLT, 1/2-13 x 2 12 4 015537 WASHER-FLAT-PLT, 1/2 USS 12 5 016287 NUT-NYLON INSERT-PLT, 1/2-13 (MFG ONLY) 12 6 015602 WASHER-LOCK-PLT, 1/2 12 7 950407 CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) 2 8 880004 ANGLE, 1-1/2 x 1-1/2 x 1/4 1 Replacement Parts UC10 990091 7 1 2 5 6 4 3 990091AY51 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 29 of 37

Replacement Parts List UC05 990089 ITEM NAME DESCRIPTION QTY 1 510248 CN-CENTER ANGLE-UHMW, ULT 5' 2 2 510255 CN-FRAME-PAINTED, ULT 5' CENTER 1 3 015537 WASHER-FLAT-PLT, 1/2 USS 6 4 015602 WASHER-LOCK-PLT, 1/2 6 5 016063 NUT-HEX-PLT, 1/2-13 6 6 017167 BOLT-FLAT HD-PLT, 1/2-13 x 2 6 7 950407 CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) 1 8 880004 ANGLE, 1-1/2 x 1-1/2 x 1/4 1 Replacement Parts UC05 990089 2 7 5 4 3 6 1 990089AY51M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 30 of 37

Replacement Parts List UEXT88 990084 ITEM NAME DESCRIPTION QTY 1 510240 CN-FRAME-PAINTED, ULT EXIT 1 2 600020 BOLT-HEX-SS, 1/2-13 x 1-1/4 4 3 017168 SET SCREW-PLT, 1/2-13 x 1-1/4 SQ HD 2 4 002019 KEY STOCK-PLT, 1/2 x 1/2 1 5 184698 ADAPTER-PLT, 7/16 STRAIGHT THRD O-RING x 1/4 NPT 1 6 001980 PLUG-PLT, 1/4 NPT SOCKET HD 1 7 017490 BOLT-HEX-PLT, 1/2-13 x 2-1/4 GR5 8 8 600153 WASHER-LOCK-SS, 1/2 8 9 170084 CN-SPROCKET, 2-1/4" 12T 1 9 269912 CN-SPROCKET, 2-1/4" 4T 1 10 007762 GEAR BOX-HECO, 2-1/4 SHAFT KEYED 5-1 RATIO CF HYD DR 1 11 510015 CN-HANG DOWN-RUBBER, PECO EXIT 1 12 510081 CN-PLATE-PAINTED, PECO EXIT BASE 1 13 164205 TD-EXIT,COMPLETE BELTED, PECO (DLX/ULT) 1 14 510246 CN-TOP ANGLE-GALV, ULTIMATE EXIT 2 15 510017 CN-CUSHION-RUBBER, PECO EXIT ROLLER 1 16 016287 NUT-NYLON INSERT-PLT, 1/2-13 (MFG ONLY) 8 17 016295 NUT-NYLON INSERT-PLT, 5/8-11 4 18 017582 BOLT-HEX-PLT, 5/8-11 x 2-1/2 4 19 017167 BOLT-FLAT HD-PLT, 1/2-13 x 2 10 20 017210 BOLT-HEX-PLT, 5/16-18 x 1 GR5 6 21 015420 WASHER-FLAT-PLT, 5/16 SAE 6 22 016063 NUT-HEX-PLT, 1/2-13 10 23 600019 BOLT-HEX-SS, 1/2-13 x 1 4 24 510245 CN-TOP ANGLE-UHMW, ULTIMATE EXIT (YELLOW) D/S-P/S 2 25 510238 CN-CENTER ANGLE-UHMW, ULT EXIT P/S 1 26 001391 ADAPTER-PLT, 7/8" STRAIGHT THRD O-RING x 1/2" NPT FM 2 27 001550 ELBOW-PLASTIC, 3/8 TUBE x 3/8 NPT (90 DEGREE)PUSHLOCK 1 28 007763 GEAR KIT-HECO, SUN 1 28 007759 HECO SUN GEAR & GEAR BOX (E-DRIVE) 1 29 007981 MOTOR-HYD, 106-1012 CHAR-LYNN 1 29 000185 MOTOR-ELECTRIC 1785 RPM (E-DRIVE) 1 30 016154 NUT-NYLON INSERT-PLT, 5/16-18 6 31 015537 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

ITEM NAME DESCRIPTION QTY 32 510239 CN-CENTER ANGLE-UHMW, ULT EXIT D/S 1 33 950407 CN-DECAL, "CAUTION / DANGER" CONVEYOR LABEL (LAMINATED) 1 34 880591 PLATE-A36, 3/8 x 12 x 18 (DRIVE OFF PLATE) 1 35 990084 ANGLE, 1-1/2 x 1-1/2 x 1/4 1 Replacement Parts UEXT88 990084 33 1 990084AY51M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 32 of 37

31 22 25 19 32 990084AY52M Replacement Parts UEXT88 990084 13 7 8 12 23 31 14 24 4 3 9 16 9 5 27 28 10 11 30 20 21 20 21 30 29 26 2 8 17 18 990084AY53M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 33 of 37

30 20 11 21 990084AY54M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 34 of 37

Replacement Parts List Entrance Trap Door 164220 ITEM NAME DESCRIPTION QTY 1 164223 FLAT, 1/4 x 1-1/4 1 2 164224 TD-PLATE-PAINTED, ENT. TOP 1 3 164225 FLAT, 1/4 x 1-1/4 1 4 510098 TD-RUBBER, PECO ENTRANCE REPLACEMENT 1 5 015537 WASHER-FLAT-PLT, 1/2 USS 2 6 016279 NUT-NYLON INSERT-PLT, 1/2-13 JAM 5 7 600015 BOLT-FLAT HD-SS, 1/2-13 x 1 SOCKET (MFG ONLY) 2 8 600020 BOLT-HEX-SS, 1/2-13 x 1-1/4 5 Replacement Parts Entrance Trap Door 164220 7 1 5 6 8 3 2 4 164220AY50M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 35 of 37

Replacement Parts List Exit Trap Door 164205 ITEM NAME DESCRIPTION QTY 1 164206 TD-PLATE-PAINTED, EXIT MAIN TOP 1 2 164207 TD-PLATE-PAINTED, EXIT SQUEEZE 1 3 164208 TD-PLATE-PAINTED, EXIT HOLD DOWN 1 4 177873 TD-EXIT WHEEL-STL 1 5 510096 TD-RUBBER, PECO EXIT REPLACEMENT 1 6 510097 TD-PAD, EXIT CUSHION (REPLACEMENT) 2 7 177881 TD-EXIT WHEEL SHAFT-STL 1 8 600133 WASHER-FLAT-SS, 3/8 SAE 2 9 600132 NUT-NYLON INSERT-SS, 3/8-16 JAM 2 10 017162 SCREW-MACH-SS, 1/4-20 x 3/4 FLT HD 4 11 600034 BOLT-HEX-SS, 3/8-16 x 1-1/4 2 12 600015 BOLT-FLAT HD-SS, 1/2-13 x 1 SOCKET (MFG ONLY) 10 Replacement Parts Exit Trap Door 164205 1 11 4 3 8 7 10 12 5 2 9 6 164205AY50M 06/15/17 T:\Engineering Doc's\Manuals & Packing Lists Combined\Conveyor Item\Ultimate Conveyor\990155ML UENTUFF.doc Page 36 of 37

Packed By: Date: / / Inspected By: Date: / / Serial # Packing List UENTTUF 990155 ENTRANCE ULTIMATE TIP UP FORK PAINTED SECTION Part Number Description Qty. Shipped 990155AY ULTIMATE ENTRANCE TUF SECTION ASSEMBLED 1 880004 ANGLE-STL, 1-1/2 X 1-1/2 X ¼ 1 990155ML MANUAL, UENTTUF 1 ***** OPTIONAL EQUIPMENT ***** 990095 CONVEYOR HYDRAULIC TAKE-UP ASSIST 1 028092 4WM 4-WAY MANUAL VALVE 1 990096 FWP FRONT WHEEL PULL 1 990078 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