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1 Date Maintenance Check list This document describes the inspection and maintenance of the Power Stow Rollertrack. Maintenance refers to a time span. The operation hours are shown on the Power Stow Display Below scheme is completed later in this chapter. Power Stow number: _ Unit number: _ Hour meter PLC Loading Offloading Loading Offloading Rollertrack Compressor dd.mm.yy H. H. Pcs. Pcs. H. H. Meters H. Init. Date. Operation Hours* Hint Drawing reference First operations inspection (by user) Empty FOD tray Clean and lubricate chain drive Special Attention to: Remove FOD tray, empty and clean Lubricate the chain with Penetro 90 spray and grease the slide edge for the drive dogs , Maintenance scheme Page 1 of Required tools Required Spare parts and estimated duration: - Damages to the loading head - Unusual noises - Hampered functions - In case of doubt, contact responsible workshop 5 min Phillips Screwdriver Phillips Screwdriver 5 min. Lubrication: Schaeffer Penetro 90 spray 5 min.

2 Init. Date. Operation Hours* Hint Drawing reference Check for any loose bolts and nuts at the console Lubrication the flexramp axle Change broken bungees on sides of the links. Check for any loose bolts and nuts on the Rollertrack Lubrication of Rollertrack Links Change damaged horizontal rollers Change damaged skate wheels 2 lube points All 6 mm nuts are tighten with 17 Nm. All 8 mm nuts are tighten with 30 Nm. Lubricate all pivot points on each link The swivel wheels on the first 4 links must also be checked Required tools min Torx T20 Screwdriver Torx T20 T40, T45 10mm socket 13mm wrench 6 mm Allen wrench 13 mm wrench 10 mm wrench Required Spare parts and estimated duration: Grease 2 min min. each link Special Power Stow tools available 60 min. Lubrication: Schaeffer Penetro 90 spray 10 min min. each damaged roller min. each damaged wheel , Maintenance scheme Page 2 of 25

3 Init. Date. Operation Hours* Hint Drawing reference Inspection of the Rollertrack for damages Functional test / visual inspection of loading head Lubrication of the bronze bearings on the loading head Lubricate wheels on loading head Test function of safety stop Rollertrack, and lubricate all pivot points. Test function of safety stop main belt, and lubricate all pivot points. Test the function of the emergency stops Fully extract the Rollertrack, and visually inspect for damage or fatigue damage. Must be checked: under rollers Wear and tension on the belt (not too tight) Adjustment of belt alignment Lubricate Ball bearing seat of the wheels Required tools min Wooden dummy Wooden dummy Test all 7 emergency stops / / Required Spare parts and estimated duration: min. Lubrication: Schaeffer Penetro 90 spray min Grease 5 min. 5 min Schaeffer Penetro 90 spray min Schaeffer Penetro 90 spray , 8615, min , Maintenance scheme Page 3 of 25

4 Init. Date. Operation Hours* Hint Drawing reference Test 12V Batteries (2pcs) Change Hydraulic Pressure filter Tighten chain drive if necessary Fatigue metal crack examination Always replace batteries in pairs Adjust gap between chain and edge to be within Inch (20 25 mm) Examine all critical parts and lifting devices for metal fatigue failure Date: _ Required tools Battery Tester mm wrench Required Spare parts and estimated duration: 5 min min min min *PLC running time Maintenance inspection carried out by: _ , Maintenance scheme Page 4 of 25

5 Service mode: To enter service mode: Set the service mode toggle switch in the control cabinet (P1) in on position. Then SERVICEMODE will show on the display, on this model protective fender and flexramp is optional and are not in use. This function should only be used by trained workshop personnel. When Service mode is on: Soft start/confirmation start of the belt and rollers are off. (Belt and rollers starts by one click on one of the toggle switches). All alarms is turned off Auto level function is off Automatically retraction of the Rollertrack (the last 100mm) is off The counter stops the belt and rollers after one minute is off While the system is in service mode, the warning light on the dashboard for extracted Rollertrack always lights. To go out of service mode: Set the service mode toggle switch in the control cabinet in off position. Attention: By re-entering operational mode, all functions above will be back in operation mode , Maintenance scheme Page 5 of 25

6 1.10 Daily maintenance: Inspection during the first operation Operator while using Special attention during first operation as for: - Damages to loading- / off-loading head - Unusual noises - Hampered functions - If in doubt contact responsible workshop , Maintenance scheme Page 6 of 25

7 1.20 Monthly maintenance: Cleaning in chain drive area: Can be done on the ramp Tools: The main belt boom is raised and the system is set in service mode (see above). Extract the protective fender (if the unit is equipment with a protective fender) Release screws on the cover Open cover Remove foreign objects; Leave no FOD s on the ramp Inspect the drive Close cover Tighten screws on the cover NB: Exit out of service mode when finished Phillips Screwdriver Illustration: Power Stow Drawing No , Maintenance scheme Page 7 of 25

8 1.30 Lubrication of chain drive: Can be done on the ramp. Lubrication of chain and drive pins Lubricate the chain (2) with IWIS chain spray and the slide edge for the drive chain (3) with grease (on points, top and bottom). Tools: Phillips Screwdriver Material: Lubrication: (2) and (3) Schaeffer Penetro 90 spray. Illustration: Power Stow Drawing No , Maintenance scheme Page 8 of 25

9 1.40 Lubrication of the flexramp axle: A total of 2 Lubrication points must be lubricated Material: Grease Illustration: Power Stow Drawings No , Maintenance scheme Page 9 of 25

10 2.10 Change bungees on sides of the links: Tools: Can be done on the ramp Screwdriver Torx T20 Cutting pliers Material: Power Stow spare part No. 2459, 6 mm bungee Illustration: Power Stow Drawing No Check for any loose bolts and nuts on the Rollertrack: Tools: 13 mm wrench, Torx T40 and 10mm socket (special Power Stow tools available) Material: Illustration: Power Stow Drawing No and , Maintenance scheme Page 10 of 25

11 2.30 Lubrication of Rollertrack links: Material: Lubricate all pivot points on each link Lubrication: IWIS chain spray Illustration: Power Stow Drawing No and , Maintenance scheme Page 11 of 25

12 2.40 Replace damaged horizontal rollers: Tools: The horizontal rollers are self-lubricating 6 mm Allen key and 13mm wrench Material: Power Stow spare part No and 1748 Illustration: Power Stow Drawing No , Maintenance scheme Page 12 of 25

13 2.50 Replace damaged skate wheels: Tools: Remember, that the 4 frontal links are equipped with swivel wheels 10 mm wrench Material: Power Stow spare part No. 1743, 2115 and 1740 Illustration: Power Stow Drawing No. straight wheels: 3570, Swivel wheels , Maintenance scheme Page 13 of 25

14 2.60 Inspection of the Rollertrack for damages: By fully extracted Rollertrack. Manipulate links so that the fixation of the Rollertrack in all directions can be verified. Check for possible damage visually. Activate conveying in loading direction verify that all rollers and belt are rotating, and then do the same thing in on loading direction. Illustration: Power Stow Drawing No , Maintenance scheme Page 14 of 25

15 3.10 Functional test / visual inspection of loading head: Must be checked: Clean under Rollers Wear on belt Adjustment of belt alignment Lubricate the bronze bearings For inspection of the lower rollers, please open the pivoting plate. If the head is locked, the plate is opened as illustrated below. Use a screw driver to loosen the spring lock. When the spring lock has been loosened, pull out the axle by means of a bolt. When the axle at both sides has been pulled out, the pivoting plate can be opened , Maintenance scheme Page 15 of 25

16 3.10 Clean the rollers if they are coated. This is done easily if they are demounted. It is possible to demount the rollers without touching the belt adjustment. Demount roller no. 1 first and then roller no. 2. When remounting the rollers, roller no. 2 has to be mounted first and then roller no. 1. The diameter of the roller will increase, if the rollers are coated and finally this coating will cause that there is not enough space for the belt resulting in an overstrain of the motor roller which will then be disconnected as if the belt was blocked , Maintenance scheme Page 16 of 25

17 3.10 Mounting new gas spring When mounting a new gas spring A first screw the rod into the fork B. the release pin at the end of the rod pushes the brass pin C inside the fork. This pin then pushes the release plate D. A B E C D The point where the brass pin and the release plate meet must intersect the axis of which the fork is hinged. See X The meeting point is correct when the release plate does not move while the fork is moved up and down making it turn around the axis where it is hinged. The bearing in the top of the release plate is mounted in such a way that the plate pushes the brass pin 1mm. This is done to avoid slag in the handle F. The mechanical stop E protects the handle from going to far up X F , Maintenance scheme Page 17 of 25

18 3.10 Lubrication of the nose roller on the loading- / unloading head: Power Stow recommends that for every belt change on a Power Stow loading head, a complete refill of grease on nose roller assembly, and this will significantly improve life span on the roller bearings. Power Stow recommends Molycote 33 medium (Power Stow art.nr 8621), it has low friction even in low temperature, and that makes the motor roller run on a low ampere consumption Remove end screw, to relief air pressure when assembly Fill cavity with grease, before assembly Remove end screw, to relief air pressure when assembly Fill cavity with grease, before assembly After assembly, insure to fill up with grease gun and tighten screw , Maintenance scheme Page 18 of 25

19 3.10 Adjustment of rear protection cover Black adjustment bracket in both sides Rear protection cover Gap 0.2mm between cover and belt The Rear protection cover can be adjusted forward and backwards by loosen the 2 bolts each side on the black adjustment bracket then take a blade screwdriver and set between belt and protection cover to have the right distance, then tighten the bolts on each of the black adjustments brackets. Verify when tilting the plate up and down that protection cover do not interrupt with the belt. Replacement part: 5089 Left, 1953 Right The correct gap is 0.2mm or the thickness of a sheet of paper , Maintenance scheme Page 19 of 25

20 3.10 Adjustment of belt A B Before adjusting of the belt is possible the lock bolts A in each side has to be loose, and make sure that the adjustable bracket (see below) is mounted so that the bracket is centred C D Feel the tightness of the belt by sticking a hand under the middle of belt in each side. The hand should be able to go in to the knuckles. Then measure ampere consumption, it have to be between amp. Make sure the belt is equally tight in both sides (motor should align with belt cassette). Lock screw in A in each side is tightened to prevent adjusting screws from turning when motor is running. Start the belt in off loading direction C and turn speed up to maximum. If entire belt cassette is removed just supply with 24V. If the belt moves to one side away from center, tighten belt in this side, or loosen in opposite side. The belt will always move to where it is loosest. When the belt is running in the centre of the belt cassette and has done so for 10 min. change direction to loading. D. Once more make it run at maximum speed. If the belt runs off centre it can be adjusted by moving the rear under roller. Adjusting the Belt with this Roller only works when the belt is running in loading direction D. In one side of the roller the bracket can move back and forth, use a screwdriver for this. If the belt runs towards the adjustable bracket then move the under roller/bracket back towards the motor roller to make the belt run back to centre. If the belt runs off centre away from the bracket move the under roller/bracket forward/away from the motor roller, to make the belt run back to centre , Maintenance scheme Page 20 of 25

21 3.20 Lubrication of the wheels and bronze bearings on the loading- / unloading head: Lubricate Ball bearing seat of the wheels E. Material: Grease E F Illustration: Power Stow Drawing No Lubrication of the bronze bearings F on the loading head Material: Lubrication: Schaeffer Penetro 90 spray , Maintenance scheme Page 21 of 25

22 4.10 Check function of safety stops: Hint: During retraction of the Rollertrack lift the transition roller, or engage one of the rubber fenders at each side then the retraction of the Rollertrack will stop. Safety stop, Rollertrack is shown in the display. To reset the safety stop, extract the Rollertrack for more than 0.5 seconds, and resume the retraction again. Tools: Wooden dummy or similar without sharp edges Illustration: Power Stow Drawing No Lubricate all pivot points on both sides. Arrow= Schaeffer Penetro 90 spray , Maintenance scheme Page 22 of 25

23 4.20 Test function of safety stop main belt: While belt and rollers are running, push the big transition roller forward, and then the main belt and rollers will stop. The display says Safety stop Main belt. When the roller is back in its normal resting position, the operation can be restarted by activating toggle switch. Tools: Wooden dummy or similar without sharp edges Illustration: Power Stow Drawings No , 3535 Lubricate pivot point on both sides. Arrow= Schaeffer Penetro 90 spray , Maintenance scheme Page 23 of 25

24 4.30 Test function of emergency stop: Press all emergency Stops individually; Each of them must shot down all functions including the engine. The Power Stow can only be restarted when all emergency stops are reset, and ignition are turned off and on. An activated emergency stop is indicated on the dashboard control lamp as well as on the Power Stow display Material: Power Stow spare part No. 8614, 8615, 8616 Illustration: Power Stow Drawing No , 11221/11220, 9990/9991, Change Hydraulic Pressure filter: Tools: Lower the conveyor completely, and then the hydraulic circuit pressure is automatically relieved. Unscrew the filter housing, change filter element. Install filter housing again. System is automatically vented after filter change. Check hydraulic oil level and top up. 30 mm wrench Material: Filter element Power Stow No Illustration: Power Stow Drawing No , Maintenance scheme Page 24 of 25

25 6.20 Tighten chain drive: Measure the gap between edge and drive block to be within Inch (20-25 mm when chain is loaded (while extending the Rollertrack by turning the knob at the worm gear) Adjust as required. Tools: 13 mm wrench Illustration: Power Stow Drawing No Examine the vehicle for metal fatigue failure: Workshop Inch mm Tips: Examine the entire vehicle for fatigue failure in welding and joints. Pay special to the front of the belt boom, fastening spots of the hydraulic cylinders onto the belt boom and chassis as well as the axle suspension on the chassis. The hydraulic cylinders and lifters front and rear should be examined carefully as well , Maintenance scheme Page 25 of 25