Please contact us today and allow us to show you how we can help you with your material handling.

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2 LOADING AUTOMATION, INC. Automated Shipping and Receiving Systems LOADING AUTOMATION, INC is proud to announce they are now the exclusive suppliers of the Hydraroll roller track and power systems throughout North America. The Hydraroll product line has long been associated with quality and reliability in the material handling industry. Specializing in the air cargo, automotive, food and beverage, and other palletized product lines, their products will be an asset to the already impressive line of material handling systems available through Loading Automation, Inc. Please contact us today and allow us to show you how we can help you with your material handling. Sincerely, William M. Witwer William M. Witwer Director of Sales Loading Automation, Inc. My office phone & fax number: Please visit our web-site at: P.O. BOX 4820, WILMINGTON, NC Tel Fax

3 SLIPCHAIN SYSTEMS TABLE OF CONTENTS: *DESCRIPTION *PAGE NUMBER EQUIPMENT SPECIFICATIONS 4 -EQUIPMENT SPECIFICATIONS 5 -ROUTINE MAINTENANCE 8 -TROUBLE SHOOTING 14 -WARRENTY 16 -HEALTH & SAFETY 17 SERIES 4/5 1/2 PITCH SLIPCHAIN SYSTEMS 19 -SERIES SERIES 5 24 SERIES 6/6A 5/8 PITCH SLIPCHAIN SYSTEMS 36 -SERIES SERIES 6A 39 CONTACT INFORMATION 58 * TO VIEW A SPECIFIC TOPIC. CLICK ON THE DESCRIPTION OR PAGE NUMBER OF THE RESPECTIVE TOPIC.

4 SLIPCHAIN SYSTEM SERIES 4, 5, 6 & 6A EQUIPMENT SPECIFICATIONS Sold and Serviced by: LOADING AUTOMATION, INC. WILMINGTON, NC (910) FAX (910)

5 COMMON COMPONENTS SLIPCHAIN SYSTEM Sold and Serviced by: LOADING AUTOMATION, INC. WILMINGTON, NC (910) FAX (910)

6 EQUIPMENT SPECIFICATION Section 1 General Description of System 1. Slipchain Track The track is made from Aluminium alloy extrusions with a low friction slide for the chain. The sections consist of a main channel and a bridge section which encloses the air tube, and a steel channel which supports the slide. The space below the bridge forms a return tunnel for the chain which runs along the top of the track on the slide and returns around the idler sprockets at each end of the track, returning to the drive unit mounted below the track. The complete track system is made up of standard sections, air inlet sections and end sections, the combinations of which are manufactured to suit customers requirements. Each section is nominally 2m long and has nine steel guide pins evenly distributing the upwards thrust of the air tube, through the bridge section of the main channel. The chain is contained within a channel shaped UHMW profile, with side guide flanges. This eliminates the possibility of the chain wearing the steel support channel, especially where side movement of the chain occurs through pallet drift (or fork lift truck operations on flat bed trailers). 2. Drive Unit This is a robust steel welded fabrication containing drive and idler sprockets running on shafts mounted in grease lubricated plummer block bearings. The unit is fitted with integral chain tensioners with a self-adjusting slack take up facility preventing the chain jumping the drive sprocket as chain stretch takes place. Initial chain tension requirement is reduced and can be accurately applied by compressing the tensioner springs to a predetermined length. 3. Power Unit The power unit is typically a 4KW a.c. motorised gear unit with twin output shafts centrally positioned to drive two Slipchain track drive units via chain couplings. Output speed is nominally 31 rpm giving a linear speed to the chain, depending on drive sprocket size, within the range 6-10m/min. Where required, separate hydraulic drive motors may be specified for each track. The motorised gear unit is pre-filled with a synthetic oil lubricant to provide improved starting characteristics in cold weather temperatures down to -25 C, yet providing good lubrication qualities at up to +80 C.

7 EQUIPMENT SPECIFICATION Section 1 4. Track End Idlers A robust but compact idler sprocket assembly is fitted at both ends of the Slipchain track. These have 16 teeth for normal applications, but may have 14 teeth where the chain is required to be lower when retracted to minimise the chance of damage when pallets are loaded onto the vehicle from the side. 5. Lubrication The Slipchain track system requires lubrication at a total of 20 positions. Although accessible, these points can be connected to an automatic lubrication unit arranged to pump accurate amounts of grease to each point during operation of the Slipchain system, or a centralised system which reduces the number of greasing points to Control Raising and lowering of the Slipchain track is effected by pneumatic controls. These can be either manually operated or automatically/ remotely operated with an optional manual override. Air is supplied from the vehicle s own system, which is protected against depressurisation by an automatic valve to an air reservoir. From here it is supplied via pressure regulators to the control valves. A variety of options for emergency charging, stand by supply and air shut-off is available. Power for the Slipchain drive is supplied from the dock or warehouse via a plug and socket. Control of the drive may be either manual via a pendant or control box, or automatic, including PLC control, and may be dock or vehicle mounted. All control systems are supplied to customer requirements.

8 ROUTINE MAINTENANCE Section 2 To be carried out by customer or maintenance contractor. SLIPCHAIN General Notes Ensure that systems are disconnected from electrical power supply before commencing any repair or maintenance work. Ensure air systems are isolated from supply and that system pressures are released before disconnecting any air equipment. Repace all covers and guards after inspection. 1st and 2nd weeks of Service 1. Check tension of chains daily and adjust as necessary - see Chain Tensioning Procedure. 2. Carry out weekly checks. 3rd and 4th weeks of Service, by customer or maintenance contractor 1. Check tension of chains and adjust as necessary - see Chain Tensioning Procedure. 2. Carry out weekly checks. Weekly checks by customer 1. Ensure that vehicle/dock floor, associated roller tracks, Slipchain tracks and track end sprockets are free from dirt and debris. Blow out debris with air line as necessary. 2. Ensure that Slipchain drive units are free from debris. 3. Wipe clean electronic sensors if fitted, taking care not to damage sensor face. 4. Check that Slipchain system operates freely in both forward and reverse directions, and in both the raised and lowered mode. Investigate any extraneous noises from the system. 5. Drain water from air reservoir and from filter regulator filter bowls. 6. Check air regulator pressures are to original settings and adjust if necessary.

9 ROUTINE MAINTENANCE Section 2 Monthly checks by customer or maintenance contractor 1. Check chains for damage/wear. Replace part section or completely as necessary. 2. Check UHMW slide blocks for wear and replace as necessary. 3. Check Slipchain drive unit sprockets and end of track sprockets for damage/wear. Replace as necessary. 4. Check for leaks at all air line connections and control equipment connections and repair as necessary. 5. Ensure pressure protection valve is operating correctly - see PPV Checking Procedure. 6. Check tension of Slipchains and adjust as necessary - see Chain Tensioning Procedure. 7. Lubricate Slipchains lightly with chain oil spray. Vegetable oil may be substituted for mineral oil where the latter is unacceptable. Clean away any surplus oil form chain. 8. Re-grease all Slipchain drive unit and track end bearings - see Lubrication Diagram. Alternatively, if an automatic lubrication system is fitted, top up reservoir with grease and check system is functioning correctly. Re-filling the grease reservoir is achieved through a standard grease nipple situated on the side of the pump, by means of a grease gun or filler pump. Clean away any surplus grease from components. 9. Check lubricant level in motorised gear unit and top up if necessary. Visually check for leaks at shaft seals. 10. Check hydraulic system for leaks, tightening connections where necessary or refitting. Carry out maintenance of hydraulic power pack and top up hydraulic reservoir - see Power Pack Installation and Maintenance Instructions. Check operation of power pack and operating pressures. 11. Ensure Slipchain system is disconnected from electrical power source and check that all electrical connections are free from corrosion and provide good contact. 12. Wipe clean electrical control panels and ensure switches/push buttons are operating correctly and indicator lamps are working. 13. Check status of batteries and recharge as necessary. 14. Carry out weekly checks.

10 ROUTINE MAINTENANCE Section 2 Half-Yearly Checks by customer or maintenance contractor 1. Release chain tension and split chain. Note: Care must be taken when adjusting nuts are removed as springs may still be in compression. Lift out Slipchain inner channels and clean system thoroughly. 2. Carry out maintenance to motorised gear unit - see Operations and Maintenance Instructions. 3. Check the air bag for damage and leaks. 4. Re-assemble Slipchain and tension chain. 5. Remove drive coupling guards, check coupling components, lubricate and replace guards. 6. Check security of all system components. 7. Carry out monthly checks.

11 ROUTINE MAINTENANCE Section 2 Chain Tensioning Procedure Introduction Chain tensioning is necessary to prevent slippage between the chain and the drive sprocket during operation. The tension in the chain is indicated by the length to which the springs beneath the Slipchain drive units are compressed. Retensioning is necessary because the chain stretches. This stretch is relatively large during a chain s early life whilst the minute surface irregularities of the chain components wear and bed in. Initial Tensioning 1. Assemble the tensioners in the drive unit with the compression springs and setting tubes in position, and the M24 adjusting nuts just on the ends of the tensioner rods by 2 or 3 threads. 2. Thread the chain through the drive unit and bring ends together but do not join at this stage. 3. Using a spring compressor or jacking equipment, compress the spring until it and its setting tube is clamped tightly to the underside of the drive unit. 4. Pull together the ends of the chain and join with a connector link, making the chain as tight as possible. Several links may have to be removed from the chain to accomplish a degree of chain tightness. This action will have the effect of pulling the tensioner units until the M24 adjusting nuts are against the underside of the compressed springs. 5. Release the compression springs, then tighten the M24 locknut compressing the springs until there is a 1mm gap between the setting tube and the thrust bearing face. Check this using a 1mm feeler gauge. 6. The correct tension in the chain should now have been achieved, and the distance between the underside of the tensioner cradle and the top surface of the drive unit bottom-mounting plate should measure approximately 100mm. If the distance is less than 100mm, then it will be necessary to release the tension in the chain, split the chain and remove more links. The chain can then be retensioned as before. 7. Refit all components and tighten the M24 locknuts against the adjusting nuts before starting the Slipchain.

12 ROUTINE MAINTENANCE Section 2 Retensioning Retensioning of the chain should be carried out when, with the Slipchain stationary, the springs have extended by 20mm. To retension the chain, loosen the M24 locknuts on the tensioner rods beneath the Slipchain drive units, and turn the M24 adjusting nuts compressing the springs, back to the original setting of a 1mm gap between the setting tube and the thrust bearing face. Retighten the locknuts against the adjusting nuts before restarting the Slipchain. Should retensioning be required more than twice in succession, then it will be necessary to remove one or two links from the chain. To achieve this, loosen and remove the locknuts, loosen the adjusting nuts to the ends of the tensioner rods, and repeat the procedure for initial tensioning. Note: Care must be taken when loosening the adjusting nuts as the springs may still be partially compressed. Refit all components and retighten the locknuts against the adjusting nuts before restarting the Slipchain.

13 ROUTINE MAINTENANCE Section 2 Motorised Gear Unit Oil Level Checking Procedure Introduction The motorised gear unit used to drive the Slipchain system requires an oil quantity of 9.1 litres. When cold, the level of this oil quantity does not reach the level plug, and an oil level check using the level plug is not possible. During running, the oil in the gear unit warms and is aerated, and thus increases in volume to such an extent that the apparent oil level reaches the plug. Checking Procedure 1. Run the system to warm and aerate the oil. 2. Remove the oil level plug and check that the oil level is at or slightly below the plug aperture. 3. Top up as necessary with clean oil and refit the filler plug. 4. Re-run the system and re-check the level allowing excess oil to drain from the level point into a suitable receptacle. 5. Refit the oil level plug. Note: See also Geared Motors and Gearboxes Operating and Maintenance Instructions.

14 TROUBLESHOOTING Section 3 Slipchain Symptom Diagnosis Remedy No movement of chain Mains isolator off Switch on ELCD tripped Power circuit fault Press reset button on ELCD. If ELCD continues to trip, check electrical system. Reset overload relays. Test fuses and replace, if necessary. Check cable connections at motor and start. Check contactors and repair/replace as necessary. Pendant or control circuit fault. Test fuses and replace, if necessary. Check cable connections. Check relays and control equipment and repair/replace as necessary. Cabling fault. Check security and continuity of power cabling and control cabling. Chain movement in one direction only. Power circuit fault Check cable connections at starter. Check contactors and repair/replace as necessary. Pendant or control circuit fault Cabling fault Check cable connections. Check relays and control components and repair/replace as necessary. Check security and continuity of power cabling and control cabling. Slipchain movement on one side only. Coupling fault Check coupling chain and replace as necessary. Check coupling keys and replace as necessary.

15 TROUBLESHOOTING Section 3 Slipchain Symptom Diagnosis Remedy Sprocket fault Check sprocket and replace as necessary. Check sprocket keys and replace as necessary Chain breakage Check chain for the damage and reconnect using spare chain and/or chain links as necessary, or replace chain. Slipchain jumping sprocket Chain too slack Retension chain Sprocket worn Replace as necessary No lift on Slipchains No mains air supply to regulators Open supply valves or switch on compressor. Check supply pressure is adequate. Check pipe and connections for leaks. No air supply to control valves Check regulator setting and operation and repair/replace as necessary. Check pipe and connections for leaks; repair/replace as necessary. No air supply to air bags Check control valve operation; repair/replace as necessary. Check pipe and connections for leaks; repair/replace as necessary Damaged air bag Replace as necessary.

16 Joloda /Hydraroll Limited C/o Loading Automation, Inc. Wilmington, NC, USA Ph: Fx: Website: 7 YEAR LIMITED WARRANTY ON HYDRAROLL PNEUMATIC ROLLER TRACK SYSTEMS JOLODA/HYDRAROLL warrants each system sold to the first customer and installed in the original truck body or trailer for a period of seven (7) years after installation to be free from defects in material and workmanship when properly installed, maintained, and used in normal service, in accordance with HYDRAROLL recommended operation and maintenance procedures. HYDRAROLL is not responsible for service interruptions caused by improper installation or operation of system. HYDRAROLL will warrant parts for seven (7) years; however, the customer MUST FIRST SECURE APPROVAL from HYDRAROLL OR THEIR AUTHORIZED REPRESENTATIVE (LOADING AUTOMATION, INC.) before any repairs are made to system. Upon request, all parts replaced under warrantable conditions must be returned to HYDRAROLL within fourteen (14) days of repair. HYDRAROLL shall not be liable, under any circumstances, for any loss of profits, or any other contingent, consequential or special damages. Unless specifically stated otherwise, HYDRAROLL shall not be responsible for the cost of removal of the product, damages due to removal, or any other costs incurred in shipping the product to and from the plant of manufacture, or incurred in the installation of the repaired or replaced product. 1 YEAR LIMITED WARRANTY ON HYDRAROLL POWERED CONVEYOR SYSTEMS All information as described above applies, but for a period of one (1) year after installation. The one (1) year warranty applies to the power system components and not the roller track: parts one year, limited labor 90 days from inservice date. system as follows Purchased components including power-pak, air system valves, and electrical components carry the warranty of the manufacturer with their associated terms and conditions. Liability under this warranty is limited to the repair or replacement, at HYDRAROLL S option, of the products determined to be defective upon examination and to be within the warranty period. DISCLAIMER WARNING ---The specifications/application date shown in our catalogs and data sheets are intended only as a general guide for the product described. Any specific application should not be undertaken without independent study, evaluation and testing for suitability. Exceeding the specifications could result in equipment malfunction, property damage, serious injury or death Warranty Document 21 May 2002

17 HEALTH & SAFETY SECTION 6 CAUTION CAUTION WARNING DANGER DANGER DANGER CAUTION Do not walk on chains. Serious injuries may occur from slipping or tripping on equipment installed in this system. Do not maintain this equipment unless technically qualified. Risk of damage to equipment and possible minor intermediate personal injury. Do not insert fingers into chain sprockets when system is in operation. The result could be minor intermediate injuries. Check that the system is clear of personnel before operating the system. Death or serious injury may result from being crushed between loads. Ensure that the system is isolated from electrical supply before commencing repair or maintenance work. Death or serious injury may result from electrocution or system starting automatically. Before commencing repair or maintenance work on the power chain system, ensure all the tension in the chain and coil springs is released. Serious injury may result from unreleased energy still in the coil springs. All guards must be replaced before re-energizing the system. Serious injury many result from being caught up in the chain drive.

18 HEALTH & SAFETY SECTION 6 HEALTH & SAFETY 1. Trailer driver must make sure that the access to docking the trailer is clear or personnel and equipment. 2. Before initiating loading of the trailer, make sure there are no personnel inside the trailer and not maintenance work is being carried out on or near the system. 3. Keep the area clear of personnel during automatic operation. 4. All guard must be replaced before re-energizing the system. 5. This manual MUST be read before any maintenance work is carried out on the system and all safety warning noted. 6. All personnel working on or near the system must perform their respective duties in accordance with the information given on all the warning labels.

19 SLIPCHAIN SYSTEM SERIES 4 & 5 (1/2 PITCH CHAIN) Sold and Serviced by: LOADING AUTOMATION, INC. WILMINGTON, NC (910) FAX (910)

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36 SLIPCHAIN SYSTEM SERIES 6 & 6A (5/8 PITCH CHAIN) Sold and Serviced by: LOADING AUTOMATION, INC. WILMINGTON, NC (910) FAX (910)

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60 Loading Automation Contacts Wade Shanklin President William Witwer Director of Sales Rob Fornnarino Engineering Manager Rick Little Customer Service Manager Bill McClanahan Engineering Technician David Sullivan Service Manager LOADING AUTOMATION, INC. P.O. Box 4820 Wilmington, NC Fax

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