MAINTENANCE INSTRUCTIONS

GIROTEC RD 1800 Version G0701

GIROTEC PL 2000 Version G0801

GIROTEC ST 1800/2000 Versions G1201/G1001

GIROTEC WT2 2000 Version 1301

GIROTEC WT3 2000 Version G1501

MAINTENANCE INSTRUCTIONS Table of contents 1. Machine Construction / General parts in all Girotec models……………………………………………………………… 2 2. Maintenance of Driving Unit………………………………………………………………………………………………… 3 2.1 General maintenance actions………………………………………………………………………………………………. 3 2.2 Check list…………………………………………………………………………………………………………………… 3 2.3 Removing the cover of driving unit…………………………………………………………………………………….….. 4 2.4 Tensing the toothed belt………………………….……………………………………………………………………..….. 4 2.5 Replacing the toothed belts……………………………………………………………………………………………..….. 5 3. Maintenance of film distributor……………………………………………………………………………………………… 7 3.1 General maintenance actions……………………………………………………………………………….......................... 7 3.2 Check list……………………………………………………………………….……………………………….………....... 7 3.3 Replacing the tensioning spring and brake plate……………………….................………………………..….……………. 8 4. Maintenance of guiding unit……………………………………………………………………………………….…….….... 9 4.1 General maintenance actions……………………………………………………………………………………….………. 9 4.2 Check list…………………………………………………………………………………………………………..……….. 9 4.3 Removing cover of guiding unit…………………………………………………………………………………..………… 10 4.4 Lubricating the sliding pieces………………………………………………………………………………………….…… 10

4.5 Replacing the lifting belt set……………………………………………………………………………………….……….. 11 5. Machine type orientated maintenance…………………………………………………………………………………...…… 12 5.1 Girotec RD / Pallet truck…………………………………………………………………………………………….………. 12 6. Maintenance table……………………………………………………………………………………………………..……….. 14

1. Machine construction / General parts in all Girotec models

1. DRIVING UNIT

2. FILM DISTRIBUTOR

3. GUIDING UNIT

3 1

2

2

2. Maintenance of driving unit Always switch off the machine before any maintenance act

2.1 General maintenance actions

- Remove the red plastic cover (see page 4) - Vacuum all dust and dirt - Tight the toothed belt if necessary (see page 4)

2.2 Check list

- Toothed belts (1) - Collector ring (2) and carbon brushes (3) - Lamp 24V (4) - Proximity switches and cables (Arm home proximity (5) & pulse proximity (6)) Correct distance between pulse proximity and toothed wheel = 4mm

3

2

5

3

4

1

6

2.3 Removing the cover of driving unit

- Open the screws (1) around the cover (2) and lift cover up to remove it.

2.4 Tensing the toothed belt

It is possible to tense only the belt attached to rotation main axis (3).

Loosen the motor frame fastening screws (4). Loosen the nut (5). Tense the belt by turning adjustment screw (6) to clockwise direction (turning it to anticlockwise directions will loosen the belt) Tight the nut and all screws when the belt is tense

2

3

1

4

6 pci

5

6

4

2.5 Replacing the toothed belts

Loosen the fastening screws of rotation motor (1) and bearing unit (2). This can give little loose to the belt.

Open the fastening screws of the upper transmission toothed wheel (3). Lift off the upper transmission wheel.

You can now replace the other toothed belt (4). If you are replacing both belts, please continue with following steps:

Remember to SWITCH OFF THE MACHINE !!

Remove the cable tie (5) and twist off the carbon brushes like shown in picture 6. MARK CAREFULLY WHICH BRUSH BELONGS TO WHICH SLIP RING !!

Open the fastening screw of brush holder plate (7), and move it aside like shown in the picture 8.

You can now replace the other belt (9) too. Note:

If the belt (9) is too tense, and it is impossible to remove it, please see page 4, where are instructions to loosen the belt.

1

32

5

6

7 8

9

4

5

Both toothed belts ready to be replaced

6

3 Maintenance of film distributor Always switch off the machine before any maintenance act

3.1 General maintenance actions

- Wipe off dust using clean, dry cloth - Clean the surface of the folding roller (1) using cloth with cleaning spray

- Lubricate the brake roller bushing (2)

BE CAREFUL THAT LUBRICANT DOES NOT REACH THE SURFACE BETWEEN BRAKE PLATE AND BRAKE ROLLER (3)!!

3.2 Check list

- Film distributor fastening screws (4) 4pc (Connection between film distributor and guiding unit)

- Folding roller fasteners and bearings - Film reel holder (5) and plastic bushing (6) - Brake roll (7)

- roll surface - brake plate - tensioning spring

- releasing system - Photocell and cable (8)

4

5 6

7

8

2

1

7

2 3

3.3 Replacing the tensioning spring and brake plate

- Remove the tension adjustment nut by turning it to anticlockwise direction like shown in picture 1.

You can now lift off all parts above film distributor frame. These parts are shown in picture 2. Replace the tension spring if necessary.

- Open the brake roller fastening screw (3) and twist out the brake roller from carriage frame.. You can now replace the brake plate if necessary.

1

2

3

8

4 Maintenance of guiding unit Always switch off the machine before any maintenance act

4.1 General maintenance actions - Remove the cover of Guide Unit (See page 10) - Wipe off all dust and dirt - Use silicon spray to lubricate guide profile and sliding pieces

(See page 10)

4.2 Check list

- Lifting belt set (Toothed belt & Cable wire) (1) - Sliding pieces (2) 4pc - Spring of lifting system (3) - Limit switches and cables (4) - Lifting motor and cable (5) - Energy transfer chain (6)

1

2

6

3

4

5

9

4.3 Removing cover of guiding unit - Open the fastening screws (1) of cover and remove cover by twisting it out from the profile. Disconnect the Safety Edge connector (2)

4.4 Lubricating the sliding pieces

- Clean the path (3) of sliding pieces in aluminium profile using e.g. compressed air.

- Use silicon spray to lubricate the sliding pieces and path.

1

2

3

10

4.5 Replacing the lifting belt set (Set = Toothed belt & Cable wire) Remove the both ends of the spring (1) Open the fastening screws of bracket (2). Use your other hand to keep film distributor still, while opening screws When screws are open, let the film distributor down slowly. Pull out the lifting belt set If the distance between toothed wheel and guiding profile is too small to pull out the belt set, then Loosen the motor bed fastening screws (3) so that you can move the system aside to remove the lifting belt set. PLEASE MARK EXACT POSITION OF THE MOTOR BED PLATES BEFORE LOOSENING THE SCREWS !! (Dashed lines in picture 3)

2

1

1

3

11

5 Machine type orientated maintenance 5.1 Girotec RD / Pallet truck Once in the month, check: - Hydraulic system (1) - Lifting leverage (2) - Links, bushings - Function

- Rollers and bearings Removing cover:

Open two fastening screws (3) Twist and pull cover out from system (4)

Pallet Truck

2

1

3

4

12

Once in the month, lubricate: - Lifting leverage links and bushings (1)

- Controlling mechanism of hydraulics (2) 1

1

1

2 2

13

6 Maintenance table

14