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Euro-Rock System Portable Climbing & Eurobungee Wall

Operations Manual REVISION 07/14/11

Extec Gear, 420 Industrial Ct W, Villa Rica, GA 30180 Phone: (770) 257-7518, Webpage: www.etgear.com,

Email: sales@etgear.com

Welcome Thank you for purchasing your Extec Engineering’s Extec Gear “Euro-Rock” system, a remanufactured rock climbing wall with eurobungee conversion. Your wall system has been rebuilt and certified to meet or exceed original standards and enhanced to improve operating life and safety. We are confident that through the experience and advanced safety systems utilized in building our climbing walls you will find it a rewarding and profitable purchase meeting your equipment quality and safety needs. Your climbing wall has been remanufactured from the following equipment base:

TRAILER: DAR MDG24 7000# S/N: #1S9BD24282C685409

WALL BODY: DROP A ROCK 01048 S/N: #2409

AUTO-BELAYS: 4 x SPECTRUM-MOBILE S/N: N/A 3-PERSON 4-PERSON And has been assigned the following remanufactured equipment identification:

WALL SYSTEM: EXTEC EUROROCK-24 S/N: 11ER0701

Company Overview

Extec Engineering is a manufacturer, rebuilder and distributor of commercial interactive sports and amusement equipment and parts. Designed for fun, safety and profit, Extec Gear products provide maximum income and years of safe and exciting entertainment for your customers. Our mission includes:

• Commitment to quality, safe and profitable equipment design • Continuous customer service support • Manufacturing to "ASTM F-1159-97a" safety standards for the amusement industry • Cycle time that generates high profits

Confidentiality Agreement

This manual contains proprietary information belonging to Extec Engineering and Extec Gear. This manual and its content are for the exclusive use and operation of an Extec portable climbing wall by its owner and those authorized operators, marketing and service personnel of the owner or Extec Gear. This manual is designed to provide accurate and authoritative information in regard to the subject matter covered, however, is not warranted as to accuracy or reliability. This manual may not be reproduced in whole or part without the prior written consent of Extec Gear.

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Revision & Disposition

Extec Gear may make periodic revisions to this manual. The owner agrees to keep this manual up to date, reflecting all updates currently in use. This manual remains the property Extec Gear and must be returned or shredded upon receipt of an updated version.

Receipt and Acknowledgment

This Training/Operations Manual is an important document intended to help you become acquainted with the portable climbing wall, Extec Gear and guidelines as to safe and recommended operation.

Please read the following statement and sign below to indicate your receipt and acknowledgment of the portable climbing wall/ Extec Gear Training Manual.

Receipt and Acknowledgment And Warranty Registration - - - - - - - - - PLEASE FILL IN, SCAN AND EMAIL TO: warranty@etgear.com. I have received and read my copy of the Extec Gear Euro-Rock Operations Manual. I understand that the information outlined in this manual are subject to change at the sole discretion of Extec Gear at any time. It is further understood that the owner of the portable climbing wall has the responsibility to ensure the correct and latest version of the manual is being used. As an owner of the portable climbing wall or authorized representative, it is my responsibility to keep this manual up-to-date with any chances that are made by Extec Gear. I understand that my signature below indicates that I have received the portable climbing wall/ Extec Gear Training Manual and that I have read it.

Owner’s Business Name: ________________________________________________________________

Authorized Representative:______________________________________________________________

Printed Name and Title: ________________________________________________________________

Date: ____/____/20____

VIN Number: ________________________________

Date Purchased: ____/____/20____

The signed original copy of this agreement will be held in the Extec Gear Corporate Offices. - - - - - - - - -

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Training Overview This training course is an introduction to the portable climbing wall and its operation. The purpose of this manual is to provide a compilation of information that will assist you in proper and safe operation. This manual is designed to aid in your training for safe climbing wall operation. Sections are prerequisite to each other. In other words, the information in section one pertains to the information in section two. The philosophy of Extec Gear is centered on a commitment to excellence in meeting the needs of its customers and associates by providing them with the enclosed information. This manual is designed to provide the wall owner with the information, tips, and techniques that will help the employees and owner operate the wall as effectively and safely as possible. It is no way a total representation of all facts. Safe operation of this wall is the sole responsibility of the wall owner/operator. Good and reasonable judgment must be used when traveling, promoting and/or operating the wall.

Training Objectives Upon reviewing this training, you will be able to complete the following:

• Understand the process for proper set-up of the portable climbing wall • Identify and understand the inspection points for day-to-day maintenance. • Understand the replacement of wear dated parts • Define and understand the safe operation of the portable climbing wall. • Identify and explain the rules for safe usage of the portable climbing wall.

Portable Climbing Wall Through an analysis of portable climbing wall history, Extec Gear's portable climbing wall provides a new level of safety through a layer of redundancy and back up of potential fail points. Designed to meet “ASTM F-1159-97a” standards for the Amusement Industry, its fully automatic, redundant hydraulic belays to protect the climber rather than a human holding a rope. Extec Gear’s climbing wall provides a higher degree of safety than may be found in climbing gyms or in nature and with the auto-belays doing the work and ensuring safety, person(s) operating the wall act more like a coach offering encouragement and direction. Physical Dimensions. The portable climbing wall meets all requirements for physical size as outlined by the Department of Transportation. The dimensions of the portable climbing wall are:

Specifications. 3 and 4-person portable climbing wall trailer:

• Width – 7’6” to 8' 0" • Height – 8'6" to 9'6" • Length – 28'0" • Weight – 3,140 lbs

Mechanical Engineering Approval. The portable climbing wall has been designed and reviewed by engineers that stand behind the portable climbing wall design. Components (or equivalents) have tested in actual field use for over a decade.

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The "Auto-Belay” (“A-B”) In traditional rock climbing, the belay is the climber’s safety line and person holding it. If the climber falls or needs lowered back down after completing the climb, the belay safely does this at a rate that is not too fast or too slow. If the belayer fails to continuously hold the rope, the climber may fall to the ground.

Extec Gear uses a pressurized air & oil hydraulic system to automatically belay each of 3 climbers on the portable climbing wall. No human is needed to hold the line and the much stronger 4,200# load cable steel cables that are used instead of ropes. A 4,200# test roller-bearing swivel prevents cable twisting or binding as the autobelay (“A-B”) system pulls in the slack at the climber ascends and safely controls the rate of descent when a climber falls or chooses to come down.

We know of no other organization taking such steps to assure and backup safety on their wall.

A-B Function. Approximately 20 lbs of upward pull is continuously exerted on the climber’s safety cable by the A-B system. As a climber ascends the wall, his weight is taken off the cable and the A-B system pulls up the slack. What happens is the positive air pressure in the hydraulic system forces hydraulic oil into the then twin pistons, causing the cable pulleys to retract and take up the cable slack. The sequence is reversed for the controlled decent of the climber. A-B Safety. While failures on a well maintained auto-belay (“A-B”) climbing wall are very rare, the primary fail points reported in the national database “RideAccidents.com” relate to the hydraulic cylinders, cable-to-user and cable-to-wall connections. Redundant Cylinders. Extec Gear’s portable climbing wall has with two parallel hydraulic cylinders (pistons) for each climber. One cylinder alone can handle a climber’s needs so redundant safety is provided.

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Cable-to-User Backup. While a single cable crimp fitting can properly fasten a cable, Extec Gear’s climber cables use three on each cable-to-user end. Two are placed next to the swivel connection and a third about 2 feet back up the cable for triple redundancy. In addition, a shoulder strap using 9/16”+ tubular webbing (with 1,500+ lbs. nominal breaking strength) is added using a prussic knot to the climber’s cable immediately above the 3rd cable crimp. A slip ball allows this webbing to be placed snuggly under the climbers arms without being so loose as to get in the climber’s way or allow the climber to fall through the loop should it ever be needed. This shoulder strap protects against any unforeseen failure of the swivel, carabineer, climber’s harness and even the triple crimps creating a new level of protection not available through other manufacturers.

Note: The Cable-to-User Backup is a back up of the primary climber safety equipment provided on an A-B system. It is not intended to and should never be used by itself. The components should be replaced immediately if wear is noted or at each A-B cable replacement.

Cable-to-Wall Backup. The climber’s cable is looped through a welded fitting on the climbing wall to securely attach that end. Extec Gear adds two crimps to fasten the cable instead of one and adds a second, normally non-load bearing, cable to loop around the frame should the first loop or welded fitting every fail. 3X safety factor. The impact force on the catastrophic failure of parts protected by the Cable-to-User Backup is calculated at 500 lbs, based on a 250 lb person falling a maximum two feet (2’) before the redundant devices engage. Using the webbing’s 1,500+ lbs nominal breaking strength, a 3X safety factor is provided. Disclaimer. Even with redundant safety devices all rock climbing has inherent risks. A climber using an A-B system can be injured or killed. Even though automated, a responsible person must be assigned to ensure that the portable climbing wall is mechanically sound and operating properly. As an owner of the portable climbing wall it is your responsibility to make sure constant care and supervision is taken regarding its maintenance, operation and use.

WARRANTIES. Extec Gear (“Seller”) warrants that from the date of invoice or cash sale all Goods shall be free of initial defects in material and workmanship and that portable climbing wall products have a limited one-year warranty on the climbing wall systems including the frame, trailer, climbing panels, handholds and auto-belays. Warranty does not include consumables (including harnesses, handholds, cables, pulleys, batteries and tires) although the individual manufacturer’s warrantees may cover these). Seller provides a 90-day warranty on electronics. This warranty does not apply towards normal wear and tear on products nor does it apply towards misuse on products. Warning. Rock climbing is a dangerous sport. Whether one is climbing outdoors, on a portable product or in a gym, all are dangerous without the proper training and safety practices. The purchasers and users of any Extec Gear products are completely liable for and accept full responsibility for any and all damages or injury, which may result from the use and/or misuse of any products. The Seller makes no warranties, expressed or implied, except as specifically stated above. SUCH WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, WRITTEN OR ORAL, STATUTORY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SELLER SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES OF ANY NATURE, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. The Seller shall only be obligated to repair a defective item. If the item(s) cannot be repaired, the Seller shall only be obligated to pay damages up to an amount equal to the sale price of the item(s).

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EURO-ROCK SUMMARY. Safety Summary. Extec Gear’s portable climbing wall locks hydraulically in the raised position with two-doubled 1-ton manual cam tie-downs providing 3+ tons of backup safety. Four load jacks keep the rock wall leveled while in use. For climber safety there are fully automatic climber belays (A-B systems) that require no human rope handlers. These auto-belays have dual redundant hydraulic/pneumatic load handling systems and use 4,200# load cable with an anti-binding, roller-bearing 4,000# swivel. On the wall end of the load cable there is a 4,200# backup cable to wall connector and on the climber end there is a 1,000# chest strap backing up the swivel, auto-locking 4,000# carabineer and harness. This system provides a 2 points connection of the climber to the load cable.

Transportation. The portable climbing wall travels on the road in the closed (down) position. Because of its hollow, aerodynamic shape towing is usually easier than with an enclosed trailer. Please follow all local traffic laws and requirements. Required Personnel. One lead operator can operate the euro-rock wall in sparsely attended events. A good rule of thumb is one operator for each two participants using the wall at the same time. The required duties of the operators are: (1) the wall attendant who acts as the activity coach, double checking the harness before a participant begins, connecting and disconnecting the climber to the safety systems and supervising the participants as they use the wall. The coach offers encouragement and most importantly watches the cables to see that no excess slack occurs and that the user does not go beyond the top of the wall; and (2) the harness fitter who helps put on and removing the harness from the participant, double checking the harness to ensure it is worn correctly and obtaining a hold harmless signature (from a parent if the participant is a minor). Hitch and Wiring. To pull the portable climbing wall you will need a 2-inch ball and a Class II or better hitch. To use the trailer’s electric brakes, the tow vehicle must be outfitted with an electric brake controller and a circular 6-prong receptacle. The portable climbing wall also has a flat 4-prong receptacle for towing by a vehicle that does not need the trailer’s electric brakes. Your receptacle must be equipped with a 12-volt positive feed if you want the portable climbing wall’s dedicated battery to charge as you are towing the unit. Absolutely no use should be allowed: (1) on any route that does not have a fully functioning safety system or (2) if wind speeds exceed 30 mph. It is the responsibility of the operator, climbing coach, owner, or other responsible party to be aware of weather conditions and make the appropriate call for closure of the wall if necessary. When closure of the wall is necessary, put the wall in the down position. The Euro-Rock System can be setup in three different forms, which will be discussed separately. Use in any of the three forms is encouraged to maximize the value and use of the equipment.

1. Portable Climbing Wall

2. Eurobungee

3. Portable Climbing Wall with Eurobungee

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1. PORTABLE CLIMBING WALL SETUP The order shown below is important, please follow it closely. While the climbing wall can be set and used without a tow vehicle attached, it is recommended (but not mandatory) that the tow vehicle be left in place for added stability when possible. 1. Pull portable climbing wall trailer into final position and keep it attached to the tow vehicle. Insure a level

position has been selected with AT LEAST 28-feet of overhead clearance. STAY AWAY from power lines. 2. If back-end wall trailer storage box is attached, remove cam lever strap then remove both the snap

locking pin and the padlock from the hitch bolt installed in box attach point. Lift box safely out of the way. Move the box to near the middle of the passenger side of the wall trailer and reinsert it into the side-hitch mount located there. Re-install the hitch bolt; snap locking pin and padlock so the storage box cannot be removed. Store the cam lever straps nearby so they can be used to secure the wall once it is raised (a few minutes from now).

3. Inspect each of the auto-belay climber cables. Do not use any cable that has a loosened crimp connector or shows fraying, kinking or penetrating rust. Lock out any such cable and report condition.

4. At the top of the lowered wall (inside the "tunnel" near the hitch), find and remove the cam lever strap from the wall lay-down "Y" support. The strap is hooked on the front metal tie loops attached to the trailer. Save the cam lever strap for use in securing the wall once it is raised.

5. Rear the bottom of the wall, find the rear leveler jacks. If the jacks have horizontal extension arms, pull the pins holding them in place, but do not extend the arms yet.

6. At the top of the lowered wall (inside on the support beams), find and turn on the horn switch. 7. Attach "UP/DOWN" (“RAISE/LOWER”) control box wire to the round quick connect located on the

driver's side near the back end of wall trailer. 8. Have a second person put tow vehicle into neutral (engine does not need to be on) and then stay in

the driver’s seat to make sure the vehicle does not roll until the wall pulls it backwards. The first person then presses the "UP" button to raise wall to full upright position. Once the wall touches the ground (it will not yet be straight up), stop raising the wall and extend the rear leveler jacks horizontally, but do not yet lower the jacks against the ground. Next continue to raise the wall. As the wall pushes against the ground, it will pull the tow vehicle backwards a few feet. The person in the driver’s seat should allow this to happen – carefully releasing the brakes so that the vehicle moves backwards (but not forwards). If breaks are applied instead, wall will dig into the ground (or pavement) and scrape it. When the wall is fully raised, the sound of the hydraulic motor will change (to more of a struggling sound). Do not continue to operate hydraulic motor once wall is fully raised. • DO NOT PUSH AND RELEASE THE CONTROL BUTTON MULTIPLE TIMES WHILE RAISING OR

LOWERING THE WALL. Hold the button in continuously until the wall is upright (or lowered). • Make sure that only the metal frame is resting on the ground. If there is an obstacle or high point

on the ground, you will break the wall’s fiberglass. As an option, if only a portion of the metal wall frame is resting on the ground, shim up the portion of the wall base not touching the ground with wood or metal shims. Shim only the metal frame!

9. Put tow vehicle into park. Remove control box and store in safe location in tow vehicle. Remove keys. Open the tow hitch locking mechanism and lower the front tongue jack until the tow vehicle disconnects. Move the tow vehicle and park it elsewhere.

10. Install a tongue lock to secure the trailer from theft or misuse. 11. Lower the two rear leveling jacks until trailer is off the ground enough for the middle jacks to be

lowered into vertical position. Lock middle jacks into vertical position. Lower the rear jacks and the front tongue jack until the trailer is level and trailer tires remain off the ground..

12. WALL LOCKING STRAPS. Find the cam lever straps removed earlier above. On each side of the wall (behind the climbing surface) do the following: (1) Each strap has two hooks; hook both ends into the

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eyebolt at the bottom of the wall. (2) Run the long end (the piece without the cam lock) around the upright behind the taillight (look for the labeling "STRAP -->" to show where to run it). (3) Loop the strap securely around the upright for extra support. (4) Thread the long end through the cam lock and use the cam lever to tighten firmly. Do this on both sides of the wall. This is redundant safety to secure the raised wall in the upright position and is recommended, but not required.

13. Remove rope stands and barrier rope from the black Integral Storage Box (“ISB”) mounted near the front of the trailer. Rope off area. Leave space for two 6'-8’ tables to be located ~20' in front of wall and entry-exit space next to tables. Set up tables at front of roped area. Remove literature, business cards, waiver forms & pen-clip boards & holders from the ISB and set up on 1st table. Remove yellow rope from ISB and layout on ground halfway between wall and tables. This is the "do not cross until it’s your turn" line for those that are harnessed up and ready to climb.

14. Remove the universal harnesses from the ISB. Do not lay harnesses on ground – dirt is not good! Inspect the harnesses to make sure harnesses loops are not inside out and straps are properly tied through and back over buckles. Red marking on buckle should not be seen if strapped correctly.

15. Unlock chain holding auto-belay cables. Do not let go of cables or you will have to either climb (if one auto-belay is available) or lower wall to retrieve them. (Remember to remove the WALL LOCKING STRAPS if used, when you must lower the wall.)

16. When the wall is raised, inspect the hydraulic fluid levels in each A-B cylinder. Oil should be visible in oil eye/lens. Re-fill as needed with ISO 32 hydraulic oil, such as Wal-Mart Super Tech R and O Hydraulic Oil is needed.

17. "Pump" each of the A-B cables individually by pulling down 3-4 feet 5 or 6 times on each. This removes air that may be trapped in the auto-belay system.

18. An operator on the front of the wall is to manually, quickly raise each individual A-B cable to arm’s length while he and a second person behind the wall inspects the retraction of the cable to ensure there is smooth operation with NO SLACK.

19. Attach one auto-locking carabineer and one swivel (or a combination carabineer-swivel) to the climber end of each auto-belay cable. To avoid metal to metal contact, use a short climbing sling or similar to attach the carabineer to the wall if possible. This is a non-load bearing location but metal to metal contact should be avoided.

20. Inspect the air pressure on the hydraulic reservoir should be between 85-90 psig. If less than 85 psig, fill to 90 psig using a compressor. It is recommended a 12-volt mini compressor be stored in the ISB. Attach the compressor’s alligator clips to the wall trailer’s 12-volt battery – red to positive and black to negative. Do not overpressure system.

21. Lay out “crash pads”, gym mats or similar in front of each belay station. This will help prevent ankle and other injuries should a climber come down incorrectly. Crash pads are a redundant safety feature that is recommended, but not required.

WALL USE

1. Have climbers step into a harness that is near their size. It is OK to loosen straps, but do not allow climbers to pull the straps out of the buckles. It is unnecessary, will create a lot of work for you to re-thread them through the buckles and can lead to potentially dangerous mistakes.

2. Do not allow waiting participants to approach closer than 15-ft from the wall. Only the wall attendant(s) should clip climbers into the wall. Do not allow climbers to clip or unclip. Clip the auto-locking carabineer onto a climber by pushing in on the locking button while twisting the locking mechanism and pushing the carabineer gate open. Clip onto the rappel loop on the front of the harness.

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3. Place the chest loop (attached to the auto-belay cable) over the climber’s head and have them bring their arms up through the loop. Tighten the loop loosely high on the climber’s chest (right under their armpits is best) by pulling the plastic binder circle down to the climber.

4. If the climber weighs less than 40 pounds, a pull-down strap should be attached to the back of their harness and allowed to trail behind them as they climb. If they are too light for the auto-belay, a wall attendant can help pull them down with the strap.

5. Allow the climber to climb. Typically, if the climber falls from higher than the 1st wall section (about 8’) if counts as a climb, otherwise the climber may make one more attempt before the turn is up. Climbers should not attempt to climb outside their section (left–middle–right) this will interfere with other climbers and can lead to dangerous swings if they fall. If a climber reaches the top, they can press the horn button at the top of each section to signal their accomplishment.

6. When a climber is ready to come down, tell them to simply lean back and walk down the wall with their legs shoulder width apart. Trying to climb down or coming down with their body vertical does not work well at all.

7. If allowing two climbs per admission, when the climber’s first turn is up they may choose to climb the same section again or go to the back of one of the other lines inside the roped climbing area. Once they have completed 2 climbs, they must go to the end of the line – outside the roped climbing area and wait for another turn. If there are not enough harnesses to handle those waiting in line, the climber will have to remove the harness and place on the harness table before leaving the roped climbing area.

8. Have the climber wait for a wall attendant to unclip them. The wall attendant can then clip in the next person in that line or clip the auto-belay to the cable holding loop for that section, located near the bottom of the wall.

Absolutely no climbing should be allowed: (1) on any route that does not have a fully functioning auto-belay or (2) if wind speeds exceed 30 mph. It is the responsibility of the operator, climbing coach, owner, or other responsible party to be aware of weather conditions and make the appropriate call for closure of the wall if necessary. When closure of the wall is necessary, put the wall in the down position. WALL DIFFICULTY. Facing the wall, the middle section is the easiest. The left side is more difficult and the right side is the most difficult. Routes can be changed by relocating hand-holds as best suits your needs.

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2. EUROBUNGEE SETUP The order shown below is important, please follow it closely. While the eurobungee can be set and used without a tow vehicle attached, it is recommended (but not mandatory) that the tow vehicle be left in place for added stability when possible. 22. Pull portable climbing wall trailer into final position and keep it attached to the tow vehicle. Insure a level

position has been selected with AT LEAST 28-feet of overhead clearance. STAY AWAY from power lines. 23. If back-end wall trailer storage box is attached, remove cam lever strap then remove both the snap

locking pin and the padlock from the hitch bolt installed in box attach point. Lift box safely out of the way. Move the box to near the middle of the passenger side of the wall trailer and reinsert it into the side-hitch mount located there. Re-install the hitch bolt; snap locking pin and padlock so the storage box cannot be removed. Store the cam lever straps nearby so they can be used to secure the wall once it is raised (a few minutes from now).

24. Inspect each of the auto-belay climber cables. Do not use any cable that has a loosened crimp connector or shows fraying, kinking or penetrating rust. Lock out any such cable and report condition.

25. At the top of the lowered wall (inside the "tunnel" near the hitch), find and remove the cam lever strap from the wall lay-down "Y" support. The strap is hooked on the front metal tie loops attached to the trailer. Save the cam lever strap for use in securing the wall once it is raised.

26. Rear the bottom of the wall, find the rear leveler jacks. If the jacks have horizontal extension arms, pull the pins holding them in place, but do not extend the arms yet.

27. At the top of the lowered wall (inside on the support beams), find and turn on the horn switch. 28. Attach "UP/DOWN" (“RAISE/LOWER”) control box wire to the round quick connect located on the

driver's side near the back end of wall trailer. 29. Have a second person put tow vehicle into neutral (engine does not need to be on) and then stay in

the driver’s seat to make sure the vehicle does not roll until the wall pulls it backwards. The first person then presses the "UP" button to raise wall to full upright position. Once the wall touches the ground (it will not yet be straight up), stop raising the wall and extend the horizontal rear leveler jacks (if so equipped), but do not yet lower the jacks to level against the ground. Next continue to raise the wall. It will pull the tow vehicle backwards a few feet. The person in the driver’s seat should allow this to happen – if he uses the breaks at this time the wall will dig into the ground (or pavement) and scratch it up a bit. When the wall is fully raised, the sound of the hydraulic motor will change (to more of a struggling sound). Do not continue to operate hydraulic motor once wall is fully raised. • DO NOT PUSH AND RELEASE THE CONTROL BUTTON MULTIPLE TIMES WHILE RAISING OR

LOWERING THE WALL. Hold the button in continuously until the wall is upright (or lowered). • Make sure that only the metal frame is resting on the ground. If there is an obstacle or high point

on the ground, you will break the wall’s fiberglass. As an option, if only a portion of the metal wall frame is resting on the ground, shim up the portion of the wall base not touching the ground with wood or metal shims. Shim only the metal frame!

30. Put tow vehicle into park. Chock trailer wheels. Remove control box and store in safe location in tow vehicle. Remove keys and lock tow vehicle or disconnect tow vehicle and park it elsewhere.

31. If the tow vehicle is removed, lower the front tongue jack until the hitch is level. Attach the ball-hitch ball lock, the ball-hitch lever lock and the wheel and axle chain and lock to secure the trailer from theft or misuse.

32. Lower the two rear leveling jacks and level the back portion of the trailer. Lower the two mid-front leveling jacks and level the front portion of the trailer. You do not need to raise the trailer tires off the ground, although most of the trailer weight should be on the leveling jacks.

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33. WALL LOCKING STRAPS. Find the cam lever straps removed earlier above. On each side of the wall (behind the climbing surface) do the following: (1) Each strap has two hooks; hook both ends into the eyebolt at the bottom of the wall. (2) Run the long end (the piece without the cam lock) around the upright behind the taillight (look for the labeling "STRAP -->" to show where to run it). (3) Loop the strap securely around the upright for extra support. (4) Thread the long end through the cam lock and use the cam lever to tighten firmly. Do this on both sides of the wall. This is redundant safety to secure the raised wall in the upright position and are recommended, but not required.

34. Remove rope stands and barrier rope from the black Integral Storage Box (“ISB”) mounted near the front of the trailer. Rope off area. Leave space for two 6'-8’ tables to be located ~20' in front of wall and entry-exit space next to tables. Set up tables at front of roped area. Remove literature, business cards, waiver forms & pen-clip boards & holders from the ISB and set up on 1st table. Remove yellow rope from ISB and layout on ground halfway between wall and tables. This is the "do not cross until it’s your turn" line for those that are harnessed up and ready to climb.

35. Remove the universal harnesses from the ISB and place on 2nd table. Do not lay harnesses on ground – dirt is not a good thing! Inspect the harnesses to make sure harnesses loops are not inside out and straps are properly tied through and back over buckles. Red marking on buckle should not be seen if strapped correctly.

36. Unlock chain holding auto-belay cables. Do not let go of cables or you will have to either climb (if one auto-belay is available) or lower wall to retrieve them. (Remember to remove the WALL LOCKING STRAPS if used, when you must lower the wall.)

37. When the wall is raised, inspect the hydraulic fluid levels in each A-B cylinder. Oil should be visible in oil eye/lens. Re-fill as needed with ISO 32 hydraulic oil, such as Wal-Mart Super Tech R and O Hydraulic Oil is needed.

38. "Pump" each of the A-B cables individually by pulling down 3-4 feet 5 or 6 times on each. This removes air that may be trapped in the auto-belay system.

39. An operator on the front of the wall is to manually, quickly raise each individual A-B cable to arm’s length while he and a second person behind the wall inspects the retraction of the cable to ensure there is smooth operation with NO SLACK.

40. Attach one auto-locking carabineer to the end of each auto-belay cable. To avoid metal to metal contact, use a short climbing sling or similar to attach the carabineer to the wall if possible. This is a non-load bearing location but metal to metal contact should be avoided.

41. Inspect the air pressure on the hydraulic reservoir should be between 85-90 psig. If less than 85 psig, fill to 90 psig using a compressor. It is recommended a 12-volt mini compressor be stored in the ISB. Attach the compressor’s alligator clips to the wall trailer’s 12-volt battery – red to positive and black to negative. Do not overpressure system.

42. Lay out “crash pads”, gym mats or similar in front of each belay station. This will help prevent ankle and other injuries should a climber come down incorrectly. Crash pads are a redundant safety feature that is recommended, but not required.

EURO-BUNGEE USE

9. Have climbers step into a harness that is near their size. It is OK to loosen straps, but do not allow climbers to pull the straps out of the buckles. It is unnecessary, will create a lot of work for you to re-thread them through the buckles and can lead to potentially dangerous mistakes.

10. Do not allow waiting participants to approach closer than 15-ft from the wall. Only the wall attendant(s) should clip climbers into the wall. Do not allow climbers to clip or unclip. Clip the auto-locking carabineer onto a climber by pushing in on the locking button while twisting the locking mechanism and pushing the carabineer gate open. Clip onto the rappel loop on the front of the harness.

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11. Place the chest loop (attached to the auto-belay cable) over the climber’s head and have them bring their arms up through the loop. Tighten the loop loosely high on the climber’s chest (right under their armpits is best) by pulling the plastic binder circle down to the climber.

12. If the climber weighs less than 40 pounds, a pull-down strap should be attached to the back of their harness and allowed to trail behind them as they climb. If they are too light for the auto-belay, a wall attendant can help pull them down with the strap.

13. Allow the climber to climb. Typically, if the climber falls from higher than the 1st wall section (about 8’) if counts as a climb, otherwise the climber may make one more attempt before the turn is up. Climbers should not attempt to climb outside their section (left–middle–right) this will interfere with other climbers and can lead to dangerous swings if they fall. If a climber reaches the top, they can press the horn button at the top of each section to signal their accomplishment.

14. When a climber is ready to come down, tell them to simply lean back and walk down the wall with their legs shoulder width apart. Trying to climb down or coming down with their body vertical does not work well at all.

15. If allowing two climbs per admission, when the climber’s first turn is up they may choose to climb the same section again or go to the back of one of the other lines inside the roped climbing area. Once they have completed 2 climbs, they must go to the end of the line – outside the roped climbing area and wait for another turn. If there are not enough harnesses to handle those waiting in line, the climber will have to remove the harness and place on the harness table before leaving the roped climbing area.

16. Have the climber wait for a wall attendant to unclip them. The wall attendant can then clip in the next person in that line or clip the auto-belay to the cable holding loop for that section, located near the bottom of the wall.

Absolutely no bungying should be allowed: (1) on any route that does not have a fully functioning auto-belay or (2) if wind speeds exceed 30 mph. It is the responsibility of the operator, climbing coach, owner, or other responsible party to be aware of weather conditions and make the appropriate call for closure of the wall if necessary. When closure of the wall is necessary, put the wall in the down position.

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WALL TAKE DOWN.

1. Disconnect any live 120 VAC power. Reverse each step used for wall setup. Remove and store equipment, parts, cords, harnesses and literature in the ISB.

2. Be sure to remove the auto-locking carabineers and swivels and store in the ISB. Thread the locking chain through the loop end of each auto-belay cable. Thread the chest webbing of each auto-belay cable onto the locking chain. Make sure this is done in such a way the plastic quick adjust ball on the chest webbing can not fall off when the trailer is transported. Lock the locking chain into the middle climb’s retainer strap.

3. Store any other loose items that will not be needed in the ISB. Close the ISB fully. Remove the cam lever straps connecting each side of the upright wall frame to the trailer frame and set aside for use in a few minutes.

4. Raise and lock into the transportation position both the two rear leveling jacks and the two front leveling jacks. Re-attach the tow vehicle completely, if it was removed earlier. (If you did remove the tow vehicle, you must remove the ball-hitch ball lock, the ball-hitch lever lock and the wheel and axle chain and lock.) Raise the front hitch tongue jack fully.

5. Attach yellow "UP/DOWN" (“RAISE/LOWER”) control box wire to the round quick connect located on the driver's side near the back end of wall trailer.

6. Remove wheel chock blocks if used from the wall trailer wheels. Remove the wheel chain lock if used and store all in the ISB. Put tow vehicle into neutral (engine does not need to be on). Press "DOWN" button to lower wall to full lowered position. Have everyone stand back during this operation; the wall comes down fairly hard. It is best not to stop the lowering until complete. Do not continue to operate hydraulic motor once wall is fully lowered. Put tow vehicle into park.

7. At the top of the lowered wall (inside on the support beams), find and turn off the horn switch. At the top of the lowered wall (inside the "tunnel" near the hitch), reinstall the cam lever strap around the wall lay-down "Y" support. Loop the strap twice around the wall beam and hook the straps into the red colored metal tie loops on each side of the trailer. Use the cam lever to firmly securing the strap.

8. If back-end wall trailer storage box needs to be attached, remove hitch bolt from box attach point and lift box back onto wall trailer brackets. Re-install the hitch bolt with both the snap pin and padlock. Install the cam tie-down strap by hooking the long strap to the eyebolt at the bottom right side of the box. Run this up through the eyebolt on bottom right hand side of the backside of the wall. Continue running strap through the eyebolt on the bottom left hand side of the backside of the wall. Attach the short cam lever strap to the eyebolt on the bottom left of the box. Thread the long strap through the cam lever and tighten firmly. (Note: If the box does not need to be re-attached, save the strap with the yellow UP/DOWN control box inside the tow vehicle.)

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TRANSPORTATION.

1. Connect the wall trailer wiring harness to the tow vehicle wiring harness. Verify lights, break lights and turn signals are working properly.

2. Check the wall trailer tires to insure they are properly inflated. Verify the crank-down lifting mechanism near the trailer tongue is fully retracted. Verify that the wall trailer ball connector release is PADLOCKED in the closed position. Verify that the 2 safety chains are properly attached. If back-end wall trailer storage box is attached, verify the hitch bolt with both snap pin and padlock are installed. Insure cam tie-down strap is installed to help lift weight of box.

3. Wall trailer will tow similar to a large boat. At higher speeds, when being passed by large vehicles or in windy conditions, the trailer may begin to sway. Slow down to correct this condition. Remember to allow extra stopping distance due to the weight you are towing.

4. Do not tow with a cover on the portable climbing wall or trailer. The wind will damage it.

5. Be sure the ball-hitch lever is down and the ball-hitch lever lock is in place whenever the trailer is being towed.

STORAGE.

Install the ball-hitch ball lock, the ball-hitch lever lock and the wheel and axle chain and lock to help protect your investment from theft or misuse.

SLACKLINE USE ON ROCKWALL TRAILER.

The Extec Gear portable climbing wall can be used as one base for a slackline. While the slackline manufacturer’s instructions must be followed completely, these additional instructions must be added:

1. Remove slackline kit from ISB. Mount the ratchet end onto one of the metal tie-down loops near the wall "Y" support at the front of the wall trailer.

2. Mount the long end to an available tree, vehicle or other structure on site. Run slackline over a grassed area for soft dismounts. If onsite mounts not available install portable webbing supports (also stored in the ISB). This requires installing the 3 welded-loop ground anchors with equalization webbing and the 30” tripod for webbing height support. The tripods can be installed in any setup to standardize the slackline height. Carefully follow the tripod set-up and anchoring instructions per the manufacturer’s requirements.

3. To better protect against injuries, line the ground under the slackline with the 4 or more crash pads.

Follow the manufacturer’s slackline setup instructions to complete a proper setup.

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RULES AND SAFETY TIPS Wall attendant double-checks the climber’s harness, clips the climber on and off the belay cable and properly instructed the climber on the climbing rules; which are:

1. Climbers stay within the respective climbing route (left, middle or right side). The four-foot area directly under the belay cable outlines the climbing zone up the wall.

2. No swinging from side to side. 3. No stepping on the belay cable. 4. No climbing if cable does not retract. 5. Communications with the climbing coach only, no distracting other climbers with idle conversation. 6. When rappelling, keep the kick-off distance to a minimum (approximately. 2 - 3 feet from the wall). 7. DO NOT allow a climber to climb beyond the wall top. A climber should never climb higher than chest

high to the top of the wall. 8. The weight range for the wall is 40-250lbs. Minimum height 42”. It is possible for a child weighing

less than 40 lbs. to climb the wall as long as the climbing harness is properly fitted and a pull-down rope is attached to the child's harness so the child can be pulled down after the climb if needed.

9. Do not allow someone to sit and bounce on the belay cable when finished rappelling. Have them rappel onto their feet.

10. Climbing helmets are not required however they are provided and we strongly recommend their use.

Entertainment Tips Your Euro-Rock wall is a fun attraction and will draw attention. Use this unique feature to book company picnics, birthday parties, corporate promotion events, special events, public attractions, fairs and festivals. The wall can be equipped for corporate advertising to generate additional revenue. The belay coach should be someone who enjoys people and has a positive rapport with people making your attraction fun for the entire family. Euro-Rock walls are not necessarily designed for climbers – instead they are more for those who have always wanted to give rock climbing or a euro-bungee a try. Your portable wall is a product designed for fun!

Accident Report Form We anticipate that you never will have to use this form, however in the unlikely event of an accident, please email the following details to Extec Gear as soon as possible:

• Date of accident • Place of accident • Time of accident • Name of injured person • Address of injured person • Phone of injured person • Was 911 called (attach a coy of the report) • Extent and nature of injury • What caused the accident

• Was the person intoxicated or under the influence of alcohol or drugs

• Were Extec Gear’s safety rules posted • Was your staff properly trained in the operation

of the wall • Was the wall shut down for inspection after the

accident occurred • Name of person signing the report • Signature

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Inspections and Preventive Maintenance FORM-CWINSP1 (“24’ 3-Autobelay portable Climbing Wall Set-up, Preventative Maintenance and Inspection Log”, included with this document) should be completed prior to each day’s use of the portable climbing wall. Keep these records for at least one year or longer (check your State and local records requirements to assure compliance). With all parts supplied from manufacturers other than Extec Gear (i.e. harnesses, Carabiner's, swivels) make sure to read and understand their respective warnings and instructions. WEAR DATED ITEMS Below is a list of wear-dated items along with suggested guidelines for replacement. Please contact Extec Gear for replacements. Replace annually or sooner:

• Cables. Replace annually or every 10,000 cycles whichever comes first regardless of condition. Replace if cable or crimps show signs of deterioration or being frayed, rusted or kinked.

Replace when any malfunction or damage noted:

• Carabineers, swivels, pulleys, harnesses and handholds. These items deteriorate progressively with use. Metal-to-metal contact, surface damage, cuts, tears, corrosion, loose stitching, mechanical wear or impairment is easily observed. Replace when any malfunction, impairment or damage noted.

• Harnesses - Replace when the fabric has visible cuts, tears, abrasion and/or damage caused by use, heat chemicals etc. The stitching is cut, tom worn or loose threads. Or, when the buckles are not functioning properly

Trouble Shooting Guide Wall won't rise. If NO: • Is the hydraulic motor getting power? o Check battery voltage and connections. o Check hand control connections.

Wall won't go down. • Is the hydraulic motor getting power? IF NO: o Check battery voltage and connections. o Check hand control connections.

If YES:• Has the tie downs been removed. • Check hydraulic fluid level.

IF YES • Make sure wall is raised of the ground

Auto belay cable will not retract when wall is vertical. • Check air tank pressure is between 35-40 psig. • Check for air leaks using soapy water • Check cable routing for obstructions • Check that pulleys are rotating freely • Check ram alignment

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24’ Euro-Rock Portable Wall Set-up, Preventative Maintenance and Inspection Log

Inspection Date: Inspected by:

PASS

FAIL Trailer VIN #:

Last Cable Change: Owner:

BEFORE TAKING TRAILER ON ROAD: Verify wall battery disconnect is set to DISCONNECTED. Check tires for proper pressure. Use 12V wall air compressor or other air source to adjust. Check axles for proper alignment and grease. Adjust or add grease as needed. Connect trailer to tow vehicle. Verify trailer lighting working correctly. Replace any failed bulbs. Verify electrical breaks are working correctly. Adjust as needed.

BEFORE RAISING WALL AT EACH SET-UP: Set wall battery disconnect to CONNECTED. Check auto-belay (“A-B”) cable. Lock out for replacement if frayed or rusted. Check both A-B cable ends. Lock out for replacement if any broken strands by crimp or if any crimp loose. Check A-B cables are tracking along pulleys without restriction. Lock out for maintenance if not. Check A-B cables-to-frame back-up loop clamp to verify tight attachment. Adjust or lock out for maintenance if not. Inspect hydraulic cylinders for rusting. Clean any rust with fine steel wool then wipe down with clean cloth. Lock out if excessive pitting. Inspect pulleys to verify proper function. Lock out for maintenance if worn or not functioning properly. Inspect trailer frame and pulley beams for proper attachment and weld condition. Lock out for maintenance if any cracks or concerns. Inspect hydraulic hoses for road damage and proper function. Minor weepage permitted. If observable leaks, lock out for maintenance. Verify hydraulic fittings are tight. Tighten any loose fittings/connections. Turn ON switch for climber route completion horn.

AFTER RAISING WALL AND BEFORE USE AT EACH SET-UP: Verify there is no A-B cable slack in front or behind the wall. “Pump” each A-B system 3-4 times to remove any air pockets by raising cable 3-4 feet and then pulling down on it. Verify A-B cables operate without excess slack. Test cable to ensure proper A-B function. Lock out any system that fails. Check A-B cable climber chest harness. Repair, replace or lock out if webbing frayed or tightening ball missing or frayed. Verify that the hydraulic oil level is at least 3 inches in the tank and not over 6” deep with all cables at the top. Verify hydraulic oil level is between the upper and lower marks on the reservoir with all cables in ready position.

Verify harness stitching. If stitching is pulling apart label “DO NOT USE – REPAIR” and place in storage away from usable harnesses. Verify Air Tank Pressure Gauge reads between 35-40 psig. Use wall’s 12V air compressor to adjust as needed. Install & inspect auto-locking carabineers. If not positively locking, sticking open or showing wear - replace immediately or lock out. Inspect cable swivels and verify each turns freely. Inspect handholds on the wall to insure they are tight. If any of the handholds spin or are loose, tighten or replace them.

FAILURE CORRECTIVE ACTIONS TAKEN (detail all corrections to failures noted above):

FORM-CWINSP1

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AUTO-BELAY CABLE REPLACMENT PACK Part #06-001 While failures on a well-maintained auto-belay climbing wall are very rare, the primary fail points reported in the national database “RideAccidents.com” relate to the cable-to-user and cable-to-wall connections. The Onsite Challenge update pack is designed not only to meet OEM standards, but to exceed them by backing up these potential fail points based on the design and structural criteria stated below: REPLACEMENT CABLE: Each pack contains 80 feet of prime quality 0.250” diameter, 4,200-lb test, 7x19 galvanized aircraft cable, swages and thimbles.

USER END. The user (climber) end is threaded into a roller bearing swivel through a galvanized wire rope thimble and into an aluminum swage sleeve forced against the thimble to tightly hold the cable. The swage is then crimped at three points with in excess of 2-tons force to securely connect the end. This holding force of this swage exceeds the 4,200 lb test of the cable. Extec Gear goes significantly further, using another 2-ton, 3-point crimped swage immediately adjacent to the first more than doubling the holding power. Twenty-one inches of cable extends beyond these first two swages and a third 3-ton, 3-point crimp is installed on the end of this cable. The combined holding force of these 3 swages exceeds the 4,200-lb test of the cable by 150%. A 1-1/4” I.D. rubber tube is slipped over the

swages and cable to protect the user’s hands when climbing or lowering. This tube can be quickly slipped up the cable and out of the way for inspection of the fittings underneath.

CABLE-TO-USER BACKUP. The cable end, swages, thimble, swivel, locking carabineer and user’s harness are backed-up using a loop of 1,500-lb test tubular webbing that a slip ball has been added and the webbing connected in one flat, non-twisted loop using a non-slip webbing knot. The webbing is attached to the belay cable immediately above the 3rd swage using a modified self-tightening prussic knot. Any downward pressure causes the knot to tighten around the cable and hold firm. The 3 layers of swages each act as a positive barrier to further prevent slippage. This loop is placed over the user’s head and under his/her shoulders then loosely tightened using the slip ball the webbing is treaded through. In the event of a catastrophic failure of any downstream component, this chest harness will handle the load while the user is safely lowered to the ground. At all other times the chest harness handles no load and does not interfere with mobile climbing wall use.

• SAFETY FACTOR: Based upon a 250 lb person falling a maximum 2-feet, the impact force of a catastrophic failure of any part protected by the Cable-to-User Backup is 500-lbs. This provides a 3X safety factor based upon the 1,500-lb webbing test strength.

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• NOTE: The Cable-to-User Backup is a back up of the primary climber safety equipment provided on an A-B system. It is not intended to and should never be used by itself. The components should be replaced immediately if wear is noted or at each A-B cable replacement.

• USE: To use the CABLE-TO-USER BACKUP simply have each climber place their head and arms through the webbing loop and tighten loosely under their armpits using the tie-ball. Reverse the process to remove at the end of each climber’s turn.

WALL END. The wall (auto-belay) end of the 4,200-lb test aircraft cable is attached to the integral wall anchor through a galvanized wire rope thimble and into an aluminum swage sleeve forced against the thimble to tightly hold the cable. The swage is then crimped at four points using a portable long-handle swage-crimping tool capable of providing in excess of 2-tons force on the swage to securely connect the end. The holding force of this swage exceeds the 4,200-lb test of the cable. Again, this alone conforms to most OEM specifications. The Onsite Challenge system goes significantly further, using another 2-ton, 4-point crimped swage against the first more than doubling the holding power. A final malleable galvanized wire rope clips is installed after the 2nd swage to complete the connection. The combined holding force of these 3 swages exceeds the 4,200-lb test of the cable by 100% or more.

CABLE-TO-WALL BACKUP. The wall end cable attachment is backed up using a 3’ piece of 4,200-lb test aircraft cable by looping the cable over a horizontal wall support beam near the integral wall anchor. Both ends of the backup cable are attached to the belay cable using two (2) malleable galvanized wire rope clips so that there is normally a slight amount of play in the back-up loop. • SAFETY FACTOR: The holding power of the Cable-to-Wall Backup matches the original integral wall

anchor provided the double cable is double looped around a support beam equal to that supporting the integral wall anchor.

• NOTE: The Cable-to-Wall Backup is a back up of the primary Cable-to-Wall connection provided on a mobile climbing wall system. It is not intended to and should never be used by itself. The components should be replaced immediately if wear is noted and at each cable replacement.

CABLE REPLACEMENT Disconnect the user end of the old cable and connect the user end of the new cable to it. Cut the end off the old cable and use electrical tape to tape the wall end of the new cable end-to-end to the user end of the old cable. Disconnect the wall end of the old cable and carefully pull the new cable into place by pulling out the old cable. Once the cable is in place, complete the “WALL END” efforts listed above. Cut off any excess cable (if long enough, this can be used in the “CABLE-TO-WALL BACKUP” also listed above).

INSPECTION Before each use, inspect each auto-belay cable system. Lock out any cable for replacement if it shows kinks, frays or rust. Lock out any cable for replacement if the cable end shows broken strands by a swage or if any swage is loose. Lock out for maintenance any cable that is not tracking along pulleys without restriction. Lock out for maintenance any cable that the “CABLE-TO-WALL BACKUP” shows kinks, frays, rust, loose fittings or improper attachment. Lock out for maintenance any cable that the “CABLE-TO-USER BACKUP” shows frays, loose webbing knot or improper attachment.

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Manufacturer Certification AUTO-BELAY CABLE INSPECTION & SERVICE PACK Part #06-001

Quantity: |______| Date: |___|___|20___|

• Inspection and service pack application required every 100 use-days or annually, whichever is sooner.

Design, Inspection and Service Criteria

REPLACEMENT CABLE: 80-feet, 0.250-inch diameter, 4,200-lb test, 7x19 galvanized aircraft cable. Inspection to Casar Wire Rope Inspection and Examination Standards. Passed cable exterior metal surface treatment of iron oxide to magnetite. Failed cable replaced.

USER END: Roller bearing swivel, galvanized wire rope thimble, 3 x ¼-inch malleable swage sleeves or rope clips (3 point, 3+ tons holding force). Slip tube installed on end: 1-1/4” I.D. x 24” polymer tube. Inspection for corrosion and fracture. Passed end exterior metal surface treatment of iron oxide to magnetite. Failed end replaced.

CABLE-TO-USER BACKUP. 1,500-lb test tubular webbing w/slip ball. Non-twisted loop w/non-slip webbing knot attached w/modified self-tightening prussic knot. Inspection for wear and tear. Failed backup replaced.

WALL END. Galvanized wire rope thimble, 3 x ¼-inch malleable swage sleeves or rope clips (3 point, 2+ tons holding force). Total holding force: 5+ tons. Inspection for corrosion and fracture. Passed end exterior metal surface treatment of iron oxide to magnetite. Failed end replaced.

CABLE-TO-WALL BACKUP. 3-ft, 0.250-inch dia., 4,200-lb test, 7x19 galv. aircraft cable, 2 x ¼-inch malleable swage sleeves or wire rope clips. Inspection to Casar Wire Rope Inspection and Examination Standards. Passed end exterior surface treatment of iron oxide to magnetite. Failed backup replaced.

Manufacturer Certification: ___________________________________________

Installer Certification Quantity: |______|

Inspection and Installation Date: |___|___|20___|

Installer Certification: ___________________________________________

Extec Gear 420 Industrial Ct W, Villa Rica, GA 30180 (770) 257-7518, Email: sales@etgear.com