Date Maintenance Check list The inspection and preventive maintenance schedule of the Power Stow Rollertrack is as follows: Daily (10 hrs), Weekly (50 hrs.), every 6 months ( hrs.), yearly (1 hrs.) and every 2 nd year (3000 hrs). Maintenance refers to a time span. The operation hours are shown on the Power Stow Display. Below scheme is clarified in detail 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 10 50 1.10 1.20 First operations inspection (by user) Empty FOD tray Special Attention to: Remove FOD tray, empty and clean 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 14487 Phillips Screwdriver 5 min. Maintenance scheme 700-729 Page 1 of 32
Init. Date. Operation Hours* Hint Drawing reference 1.30 1.40 1.50 2.10 2.20 2.30 2.40 Clean and lubricate chain drive Lubrication the flexramp axle Check for any loose bolts and nuts at the console 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 Lubricate the chain, slide edge and drive pins with Penetro 90 spray 2 lube points Tighten all retaining bolts between console and boom All 6 mm nuts are tightened to 12.5 ft-lbs (17 Nm) All 8 mm nuts are tightened to 22 ft-lbs (30 Nm) Lubricate all pivot points on each link 14487 11685 12530 11679 Required tools Phillips Screwdriver Required Spare parts and estimated duration: Lubrication: Schaeffer Penetro 90 spray 5 min. Grease 2 min. 11685 20 min. 11691 11691 11691 3570 3975 3578 3570 3975 3578 Torx T20 Screwdriver Torx T20 T40, T45 10mm socket 13mm wrench 6 mm Allen wrench 13 mm wrench 2459 2 min. each link Special Power Stow tools available 60 min. Lubrication: Schaeffer Penetro 90 spray 10 min 13984 1747 2 min. each damaged roller. Maintenance scheme 700-729 Page 2 of 32
Init. Date. Operation Hours* Hint Drawing reference 2.50 2.60 3.10 3.25 3.20 4.10 4.20 Change damaged skate wheels 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. The swivel wheels on the first 4 links must also be checked 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. General cleaning Lubricate Ball bearing seat of the wheels Lubricate all moving parts of the safety stop linkage 3570 3975 3578 Required tools 10 mm wrench 11691 10 min 11218 11218 11219 1893 Wooden dummy Test function of safety stop main belt, and lubricate all pivot points. Lubricate all moving parts of the safety stop linkage 11681 3535 Wooden dummy Required Spare parts and estimated duration: 1743 2115 1740 2 min. each damaged wheel. 13907 30 min. Lubrication: Schaeffer Penetro 90 spray 12949 2 min. 3218 Grease 5 min. 5 min Schaeffer Penetro 90 spray 12949 5 min Schaeffer Penetro 90 spray 12949 Maintenance scheme 700-729 Page 3 of 32
Init. Date. Operation Hours* Hint Drawing reference 1 1 1 4.30 4.40 4.50 5.00 6.10 6.20 6.30 Test the function of the emergency stops Test the sensor and function of Autolevel Test of retraction error sensor in the Flexramp Test 12V Batteries (2pcs) Change Hydraulic Pressure filter Tighten chain drive if necessary Fatigue inspection Test all 7 emergency stops, one at the time, followed by a restart each time. Check that the Autolevel will adjust the boom height when the flexramp is raised or lowered Check that the retraction error sensor of the Flexramp is working when the Rollertrack comes out of track. Always replace batteries in pairs Do not overtighten filter housing. Adjust clearance to be within 0.8 1.0 Inch (20 25 mm) under load (while extending the Rollertrack by the hand wheel) Examine all critical parts, chassis and lifting devices for metal fatigue failure 14412 11221/11220 12901/8944 9990/9991 11676 9704 10702 Required tools Battery Tester 14141 13 mm wrench Required Spare parts and estimated duration: 8614, 8615, 8616 5 min. 9704 6303 6308 5 min 10709 15 min. 2114 5 min. 14411 20 min Maintenance scheme 700-729 Page 4 of 32
Init. Date. Operation Hours* Hint Drawing reference 1 1 3000 6.40 6.50 7.00 Clean suspension rails under the belt boom Function check of load control valves, lift rams Check condition and wear on brushes in chain drive motor Remove the covers and scrape/ clean with compressed air or vacuum cleaner Verify that the load control valves of front and rear lift rams are tight Verify the wear on brushes Replace before min. length: 12 mm Length, new brush: 22,5 mm Date:. 14807 11150/9764 Required tools Compressor, Vacuum cleaner Required Spare parts and estimated duration: 13995 13000 (C.F.R.) *PLC running time Maintenance inspection carried out by:. Maintenance scheme 700-729 Page 5 of 32
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 are turned off Auto level function is off Automatically retraction of the Rollertrack (the last 4 inches (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 700-729 Page 6 of 32
1.10 Daily maintenance: Inspection during the first operation Operator while using Hints: 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 700-729 Page 7 of 32
1.20 Monthly maintenance: Cleaning in chain drive area: Hints: 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. 14487 Maintenance scheme 700-729 Page 8 of 32
1.30 Lubrication of chain drive: Hints: Lubrication of chain and drive pins. Lubricate the drive pins (1), chain (2) and the slide edge for the drive pins (on points, top and bottom) (3) with Payback Penetro spray (on points, top and bottom). Tools: Phillips Screwdriver Material: Lubrication: (1), (2) and (3) Schaeffer Penetro 90 spray. Illustration: Power Stow Drawing No. 14487 3 3 Maintenance scheme 700-729 Page 9 of 32
1.40 Lubrication of the flexramp axle: Hints: A total of 2 Lubrication points must be lubricated Material: Grease Illustration: Power Stow Drawings No. 12530, 11679 Maintenance scheme 700-729 Page 10 of 32
1.50 Check for any loose bolts and nuts at the console Hints: Tools: Verify / retighten the bolts attaching the console to the boom. 19 mm and 24 mm Spanner 2.10 Change bungees on sides of the links: Hints: Can be done on the ramp Tools: Material: Screwdriver Torx T20 Cutting pliers Power Stow spare part No. 2459, 6 mm bungee Illustration: Power Stow Drawing No. 11691 Maintenance scheme 700-729 Page 11 of 32
2.20 Check for any loose bolts and nuts on the Rollertrack: Hints: Tools: Just retighten bolts that are starting to come loose. 13 mm wrench, Torx T40 and 10mm socket (special Power Stow tools available under P/N 9485, 9575, and 9590) Material: Illustration: Power Stow Drawing No. 11691 and 3570 Maintenance scheme 700-729 Page 12 of 32
2.30 Lubrication of Rollertrack links: Hints: Material: Lubricate all pivot points on each link Lubrication: Schaeffer Penetro 90 spray Illustration: Power Stow Drawing No. 11691 and 3570 Maintenance scheme 700-729 Page 13 of 32
2.40 Replace damaged horizontal rollers: Hints: Tools: The horizontal rollers are self-lubricating 6 mm Allen key and 13mm wrench Material: Power Stow spare part No. 1747 and 13984 Illustration: Power Stow Drawing No. 3570 13984 To horizontal rollers and screws of the rear links are accessed through a removable part of the rails behind the cover. Remove the cover as shown Maintenance scheme 700-729 Page 14 of 32
Extend the Rollertrack until the P3 junction box is aligned with the inspection opening as shown. Disconnect the power and remove the start key. IMPORTANT! When the inspection part is removed NEVER operate the Rollertrack electrically - Inch the Rollertrack by the hand knob on the worm gear only! Loosen the 8 bolts securing the removable inspection part Lower the removable part of the rail to gain access to To the rear links horizontal rollers and screws for maintenance. After maintenance of each individual link, it is Inched inwards by turning the hand knob Anti- Clockwise. Ensure that the horizontal rollers will enter properly into the rails again as the hand knob is turned. Once the inspection and maintenance is complete the parts are assembled in reversed order again. Maintenance scheme 700-729 Page 15 of 32
2.50 Replace damaged skate wheels: Hints: Tools: Remember, that the 4 links at front 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 3975 Maintenance scheme 700-729 Page 16 of 32
2.60 Inspection of the Rollertrack for damages: Hints: 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, then do the same thing in on loading direction. Illustration: Power Stow Drawing No. 11691 Maintenance scheme 700-729 Page 17 of 32
3.10 Functional test / visual inspection of loading head: Hints: 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 700-729 Page 18 of 32
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 700-729 Page 19 of 32
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 700-729 Page 20 of 32
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 700-729 Page 21 of 32
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 does not interrupt with the belt. Replacement part: 5089 Left, 1953 Right The correct gap is 0.08 inches (0.2mm) or the thickness of a sheet of paper. Maintenance scheme 700-729 Page 22 of 32
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 has to be between 1.2 1.6 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 in 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 700-729 Page 23 of 32
3.20 Lubrication of bronze bearings under the loading- / unloading head: 3.25 Lubrication of the wheels under the loading head E F Lubrication of the bronze bearings F on the loading head Material: Lubrication: Payback Penetro spray 12949 Lubricate Ball bearing seat of the wheels E. Material: Grease Illustration: Power Stow Drawing No. 11218 Maintenance scheme 700-729 Page 24 of 32
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. 1893 Lubricate all pivot points on both sides. Arrow= Schaeffer Penetro 90 spray Maintenance scheme 700-729 Page 25 of 32
4.20 Test function of safety stop main belt: Hints: While belt and rollers are running, push the big transition roller forward, 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. 11681, 3535 Lubricate pivot point on both sides. Arrow= Schaeffer Penetro 90 spray Maintenance scheme 700-729 Page 26 of 32
4.30 Test function of emergency stop: Hints: 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. 14412, 11221/11220, 9990/9991, 8944, 12901 4.40 Test the function of Autolevel Hints: Park the vehicle and lift the front of the boom until the flexramp set at about shoulder height. Engage the parking brake and set the forward/reverse selector at neutral. Lift the flexramp off the bumper and above level. Verify that Autolevel will re-adjust the height to level when the flexramp is raised and lowered. If not adjust the level sensor until it will adjust the flexramp to level, or replace the sensor unit if the sensor fails. Material: 11676, 9704 Maintenance scheme 700-729 Page 27 of 32
4.50 Test the function of Retraction error sensor Hints: Verify that the Retraction error sensor will trigger a retraction error alarm In the event that the roller track will come out of the tracks while retracting. The roller track should not retract more than max.8 inches (20 cm) since latest pulse. Reset the alarm by extending the Rollertrack by 12 inches (30 cm) again. Illustration: 11861 5.50 Test of 12V batteries Hints: Tools: Test the 2x12V batteries voltage under load. Test the batteries individually. If one battery is weak, always replace both at the same time. Battery tester Maintenance scheme 700-729 Page 28 of 32
6.10 Change Hydraulic Pressure filter: Hints: Lower the conveyor completely, 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. Tools: 30 mm wrench Material: Filter element Power Stow No. 10709 Illustration: Power Stow Drawing No. 10702 Maintenance scheme 700-729 Page 29 of 32
6.20 Tighten chain drive: Hints: Measure the gap between edge and drive block to be within 0.8-1.0 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. 14141 6.30 Examine the vehicle for metal fatigue failure: Workshop 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. Illustration: Power Stow Drawing No. 14302 0.8 1.0 Inch 20-25 mm Maintenance scheme 700-729 Page 30 of 32
6.40 Cleaning of Rollertrack suspension rails Remove all cover panels under the boom, lift the rear, and lower the front ends to extend the entire Rollertrack on the floor. Scrape dirt and dust away and blow the rails clean by compressed air. Alternatively, a vacuum cleaner may be used. In very dusty environments it may be necessary to carry out this cleaning at each maintenance inspection. If the rails are packed with dust it will prevent the Rollertrack from extending or retracting properly Illustration: Power Stow Drawing No. 14215 6.60 Function check of Load control valves, lift rams Verify that the load control valves are working properly. Lift the belt boom of its rest front and rear. Power off the vehicle. Draw a small line with a speed marker at a distance of 0.4 inch (10 mm) from the base. Leave the vehicle standing for 1 hour. During this time the hydraulic ram positions should remain unchanged. Adjust/replace as required. Maintenance scheme 700-729 Page 31 of 32
7.00 Check condition and wear on brushes in chain drive motor Hints: Parts: Check the condition and wear of the brushes inside the chain drive motor. The brushes must be renewed before they have reached half-length of new, and as long as the springs are still able to apply pressure at the brushes. Minimum length: 0,47 Inch (12 mm). Length of a new brush is 0.89 inch (22,5 mm) For access to the brushes, unlock the clip and remove the cover. P/N 13000 (C.F.R.) Maintenance scheme 700-729 Page 32 of 32