Powered Stair Climbing Hand Truck Maintenance Manual Magline, Inc. 1205 W. Cedar Street Standish, MI 48658 1-800-MAGLINE (624-5463) Outside US and Canada: 989-512-1000 Fax: 989-803-5941 Web: www.magliner.com E-mail: customerservice@magliner.
Table of Contents A. Introduction ............................................................................................................................... 3 B. Diagram ..................................................................................................................................... 4 1. Battery ........................................................................................................................................ 5 2. Battery Clamp ..................................
A. Introduction Please read the Operator’s Manual thoroughly to become familiar with the operation and controls of the Powered Stair Climber. The Powered Stair Climber has been designed specifically for serviceability so components can be easily replaced.
B.
1. Battery Make sure the battery is properly engaged into the spring-loaded battery clamps. Turn on the main switch. Fig. 1a Fig. 1b Depress the ascend / descend button to initially turn on the Powered Stair Climber and to toggle between the ascending and descending modes. The green light should be on. Fig. 1c If not, the fuse (part number 004607) for the battery may need changing. Remove the battery cover by unscrewing the eight screws with a #1 Phillips screwdriver. Remove the fuse.
Test the battery pack for voltage with a MultiMeter or similar. A good battery should read 24-26 volts (VDC). If the MultiMeter reads 12-15 volts (VDC), one battery cell needs replacing. Check each cell separately to determine which battery cell needs replacing. Fig. 1f To replace battery cells, remove battery cover with a #1 Phillips screwdriver. Remove fuse and unplug top wires and tilt entire battery case 45 degrees to allow cells to gently fall out of case. Unplug bottom wires.
2. Battery Clamp Remove right battery clamp (part number 004120) and left battery clamp (part number 004121) by unscrewing the three screws in the side rail with a #1 Phillip screwdriver. If springs or locking clips are noticeably worn, replace the battery clamp. Fig. 2a Fig. 2b Spring Locking Clip Battery Contacts 3. Control Box To change the control box (part number 030220), remove the setscrew located on the inside of the Powered Stair Climber frame side rail using a #1 Phillips screwdriver.
4. Crossbars To replace top two crossbars (kit number 030024K) remove screws in side rails using a T40 Torx wrench. Loosen RIGHT side of bottom crossbar with a T-40 Torx wrench. Gently tap the side rail with a soft rubber mallet to break the seal. Fig. 4a Tap in direction of arrow To replace the bottom cross bar (part number 030034), make sure the battery is not inserted.
Remove screws in side rail with a T-40 Torx wrench. Lightly tap the RIGHT side (when standing behind Powered Stair Climber) of the side rail with a soft rubber mallet. ! Caution ! Tapping the LEFT side of the side rail will damage the main wiring harness. Fig. 4d 5. Drive Chain Be sure battery is not inserted. To inspect the drive chain, remove the left wheel (see page 22) and safety flap (see page 19). Pop off and rotate the plastic safety cover out of the way with a flat screwdriver. Fig.
If links are broken, replace chain by disconnecting the connecting link. Remove old chain and put the new chain in place with a new connecting link. Fig. 5b Sliding Clutch Connecting link 6. Drive Motor With the battery in place, position the swing arm out of way so the bolts are easily reached. Then, remove the battery from the Powered Stair Climber so no power can get to the unit. To replace the drive motor*, remove both wheels (see page 22) and safety flap (see page 19). Fig.
Remove swing arm assembly (see page 21). Rotate the chain guard out of the way. Locate and remove the connecting link so chain comes off (see page 10). Using a 5mm Allen wrench, remove the three bolts that hold the motor on from the inside. Fig. 6b Find where the motor wires come in at the bottom of the main panel and disconnect at the splice. The drive motor should come off easily. Fig. 6c Splice to disconnect 7.
Silicone seal around edge Carefully remove the electronic card by unscrewing the two screws in the aluminum plate that attaches to the circuit board with a 3mm Allen wrench. Note the location of connections and arrangement of all wires for reassembly. Disconnect wires and remove electronic card by gently prying each side of the electronic card up with a small flat screwdriver. Reconnect wires to the new electronic card and reposition. Fig. 7.1c Fig. 7.
Fig. 7.2a Connect the adapter cable with the cable harness of the machine as shown in the following pictures. Fig. 7.2b Fig. 7.2c Fig. 7.2d Assemble the electronic card to the aluminum adapter, using the two screws previously removed from damaged electronic card.
Fig. 7.2e Connect the cabling with the motor power control assembly (MESAL, p/n 0051491) as shown in the following pictures. Fig. 7.2f Fig. 7.2h Fig. 7.2g Fig. 7.
Fig. 7.2j After arranging the cables as shown above, apply new silicone to the aluminum cover and reinstall the cover (see Figures 7.1a through 7.1d). 8. Gray End Cap To replace gray end cap (part number 030023) use flat screwdriver to pry the end cap out of side rail. Push new one into side rail. Fig.
9. Handles To replace red handles (see pages 39-41 for part numbers) pull out and unplug the round up switch (see page 18). Then, remove the screws in the red handle with a #2 screwdriver. Fig. 9 Remove the right handle bracket screw (see Fig. 8 on page 12) with a T-30 Torx wrench. Pull handle apart while being careful to not damage the main wiring harness that runs to the round-up switch. Remove old red plastic handles and cut off old O-rings.
-005146 for the SAL 170 model Remove the aluminum motor cover with a 7mm socket wrench (see Fig. 7a). Since removing this cover breaks the silicone seal, scrape off old silicone and apply new silicone when reassembling. Unhook the main wiring harness from the electronic card (see Fig. 11d). Pull out both grommets that run the wires through to the electronic card by working side to side. Fig. 10b 11. Main Wiring Harness Be sure the battery is removed.
Remove handle brackets to the frame with a T-40 Torx wrench. Remove handle and gently pull the wires through. Fig. 11b Remove nose plate (see page 17). Remove wheels (see page 22). Remove all screws in the left, side rail. Remove left wheel guard (see page 24). Remove both wheel brackets (see page 24). Remove left battery clamp (see page 7). Remove safety flap (see page 19). Carefully pull wires one at a time through the frame at the hole above the wheels and remove the side rail. Fig.
Unhook the main wiring harness from the electronic card. In Fig. 11e, the main wiring harness is the plug that has all the colored wires. The green plastic plug will unhook from the white plastic terminal. Do not unplug by pulling on the wires as this will damage the wires. If necessary, gently pry the green plug loose using a flat screwdriver. Fig. 11d Fig.
12. Microswitch To inspect the microswitch (part number 005136), be sure battery is removed from your Powered Stair Climber. Remove aluminum motor cover (see Fig. 7a on page 11). Since removing this cover breaks the silicone seal, scrape off old silicone and apply new silicone when reassembling. The microswitch should make a soft clicking sound when depressed. To inspect the microswitch, use an Ohm Meter. It should read near 0.4 when depressed.
14. Round up Switch Be sure battery is removed from unit so no power goes to the Powered Stair Climber. Remove the round up switch (part number 030148) by popping out of handle hole with a flat screwdriver. Unplug the switch from the main wiring harness. Fig. 14a Fig. 14b Test the round up switch with a MultiMeter by touching each prong to each connection. When button is not depressed, the display should read OL (digital) or ∞ (analog). Depress the button and the display should read near 0.3.
15. Safety Flap To inspect the safety flap (part number 005025), remove the left wheel, when standing behind the unit (see page 22). Pry the black cap off with a flat screw driver. Using an 8mm Allen wrench, remove the bolt holding the safety flap in place. Fig. 15a Fig. 15b X Press on X during reassembly Apply anti-seize grease to the safety flap shaft before reassembly (see Fig. 15c). The spring must be “loaded” prior to assembly.
If safety flap shaft has some corrosion, clean with 320 grit emery cloth. If safety flap shaft is corroded beyond cleaning as shown on the right in Fig. 15e, replace. Fig. 15e Non-corroded Corroded 16. Small Gray Wheel To replace the small gray wheel (part number 005120) on the support arm, remove bolt with a 3mm Allen wrench. The outer assembly of the small gray wheel will pull right off. Fig.
Apply anti seize grease to bearing flange and locking bolt. Position as shown below for reassembly. Place a quarter inch wide piece of masking tape on the bottom portion to hold pins and springs in place while sliding bearing assembly over the small pins and small springs. Be sure to remove tape before operating your Powered Stair Climber. Use snap ring pliers to put snap ring back on. Fig. 16c Apply anti-seize grease here Lock bearing housing in place by inserting a 2.
Fig. 17a Fig. 17b Unscrew so it is secured by approximately three threads only. Gently pound on the head of the screw with a hammer to move the bushing out just enough to move the swing arm. Repeat on the other side. Work swing arm assembly back and forth to remove. To change oil, remove piston rod and drain oil completely; replace with 1.75 ounces of SAE 90W Gear Lube. ! Caution ! When removing piston rod, do so carefully because oil will flow out once removed. 18.
Fig. 18c Fig 18d Then, replace the plastic hubs making sure both grooves for the valve stem are lined up properly. Fig. 18e Valve Stem Grooves Before reattaching the wheel, apply a thin film of anti seize grease to the 1/8 inch lip on the mounting flange. Fig.
19. Wheel Bracket Remove wheel (see page 22) and wheel guard (see below) on the same side as the wheel bracket (part number 030037) you are replacing. Remove nose plate (see page 17). Remove thru rod with a 13mm Allen wrench. Remove 2 bolts on nose plate bracket with a 13mm Allen wrench using a second wrench at the other end to hold in place while loosening. Gently tap out of place with a soft rubber mallet. Fig. 19 For reassembly, loosely attach the wheel guard.
21. Replacement Parts List Description Part # Service Kit Dealer Service Kit - includes Crossbar Kit, Noseplate Kit, Round "Up" Switch, and Red Control Switch.
Black Wheel Cap Small Grey Wheel Small wheel hardware pack 030640 005121 005638K Shoulder Bolt Axle 030645 Red Wheel Guard - each 030077 Right wheel bracket 030036 Left wheel bracket 030037 Securing Devices 1" x 56" Strap with buckle 930006 1" x 100" Strap with buckle Keg Hook 930007 930108 Electrical - Powered Stair Climber Battery Parts Complete Powered Stair Climber Battery 004210 Battery cell (each); 12v gel cell Battery Cover Grey Lower Battery Housing Handle for battery unit red Bolt M
Motor Components Motor Safety Cover Motor mount bushing - 27mm 005025 005028 Drive Motor Sal 110 Drive Motor Sal 140 010123 010124 Drive Motor Sal 170 Motor Safety Cover Spring, Powered Stair Climber Rod, lifting unit mount 010137 005033 030132 Lifting Unit Sal 110 Lifting Unit Sal 140 Lifting Unit Sal 170 Drive Chain Bushing, Pivot Shaft Bushing, LH Motor Mount Black Plastic Cap for Safety Flap Safety Flap Shaft Nut M8, motor mount 005133 005134 005146 005627 005610 005027 005632 005031 005611 22.
23. Design Protection by Patents US. Patents 6,386,552; 6,616,174 24. Trouble-Shooting Directions 24.1 My Powered Stair Climber does not turn on A. Is the main switch turned on (see Fig. 1b on page 5)? B. Is the battery charged? When charging with DC charger (part number 930114), be sure the main switch on battery is in the on position. C. Is the battery in complete contact with the spring-loaded battery clamp? Disengage and re-engage the battery to be sure (see Fig. 1a on page 5). D.
If the motor can be heard running but the swing arm with support wheels does not move, inspect the drive chain (see page 9). If the drive chain is in place, then the sliding clutch must be re-adjusted. (see Fig. 5b on page 10) 24.3 My Powered Stair Climber Will Not Lift Full Capacity A. Charge the battery fully. When charging with DC charger (part number 930114), be sure the main switch on battery is in the on position (see Fig. 1b on page 5). B.
25. Maintenance Schedule The following section is the recommended maintenance for your Powered Stair Climber. Directions to complete each individual task can be found on the page indicated. Magline would be happy to do this maintenance. Call our customer service department at 1-800-MAGLINE (624-5463) or (989) 512-1000 for more information. 25.
25.2 Eighteen Month Recommended Maintenance Date Completed Page # 17 22 22 22 8 12 11 Part # 030640 30024K 030023 20 7 004120 21 5 19 20 004011 19 19 5 33-36 005632 Tasks Apply thin film of anti-seize to threads of nose bolts. Remove wheels and apply thin film of anti-seize to mounting flange. Verify air pressure in wheels is correct. 45-50 psi Replace hub caps if missing. Replace any cracked crossbars. Replace gray end caps on top and bottom of side rails if missing.
25.3 Thirty Month Recommended Maintenance Date Completed Page # 17 22 17 Part # Tasks 930030 Apply thin film of anti-seize to threads of nose bolts. Remove wheels and apply thin film of anti-seize to mounting flange. Replace nose. 12 8 030023 30024K Replace gray end cap on top of side rails if missing. Replace any cracked crossbars. 14 18 030126 Replace main wiring harness. 030148 004120 Replace round up switch. Replace right and left battery clamps.
26. Schematics for Additional Reference Assembly drawings in this section are for reference only and should not be used to modify any original Magliner equipment. Drawings may not be to scale. 26.1 Battery 004 129 Apply electrical grease to the locations indicated by red arrows.
26.2 Electrical Components- Ergo 0051491 Apply electrical grease to the locations indicated by red arrows.
26.3 Electrical Components- Folding 0051491 Apply electrical grease to the locations indicated by red arrows.
26.4 Electrical Components- Uni 0051491 Apply electrical grease to the locations indicated by red arrows.
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26.11 Hinged or Fixed Nose – Units from Serial No. 201737030 Apply Anti-seize to these five locations indicated by red arrows. Apply to inside of mounting flange on both sides of the unit. Fixed Please note: To change from hinged to fixed nose configuration on Powered Stair Climbing units before Serial No. 201737030, please order 930104K nose kit and 930197K fixed hardware kit.
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26.13 Lifting Unit Assembly Apply Anti-seize grease to the exterior of shaft.
26.14 Swing Arm .020” .080” .004” Note: To replace oil in part number 005124, use 1.75 oz. of SAE 90W Gear Lube.
26.15 Wheel www.maglner.com/patents LIFTKAR® is a registered trademark of SANO Transportgeräete GmbH. Copyright 2005-2018 Magline, Inc.
