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Magliner Powered Stair Climber User Maintenance Manual

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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.com
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Summary of Contents for Magliner Powered Stair Climber

  • Page 1 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.com...

  • Page 2: Table Of Contents

    17. Swing Arm Assembly ......................24 18. Wheel ............................25 19. Wheel Bracket ........................27 20. Wheel Guard .......................... 27 22. Powered Stair Climber Warranty and Liability ..............30 23. Design Protection by Patents....................31 24. Trouble-Shooting Directions ....................31 25. Maintenance Schedule ......................33...

  • Page 3: Introduction

    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. This Maintenance Manual contains: ...

  • Page 4: Diagram

    B. Diagram Red Handle Grips and O-Rings Control box Round-up switch Red Handle Upper crossbar Wheel guard Nose plate Small Gray Wheels Swing arm...

  • Page 5: Battery

    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.
  • Page 6 DC charger. Before inserting this battery on your Powered Stair Climber, test the battery for reverse polarity by connecting your battery to a charger. Display will alternately blink symbols to indicate reversed polarity.

  • Page 7: Battery Clamp

    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. Gently pry the control box from the frame with a flat screw driver. Use both hands to disconnect the control box from the rest of the Powered Stair Climber wiring harness.

  • Page 8: Crossbars

    4. Crossbars To replace top two crossbars (kit number 030024K) remove screws in side rails using a T- 40 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.

  • Page 9: Drive Chain

    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.

  • Page 10: 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).

  • Page 11: Electronic Card

    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.
  • Page 12 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.
  • Page 13 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.
  • Page 14 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. 7.2g Fig. 7.2h Fig. 7.2i...

  • Page 15: Gray End Cap

    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.

  • Page 16: Handles

    10. Lifting Unit With the battery in place, position the swing arm out of way so the bolts are easily reached (see Fig. 6a). Then, remove the battery from the Powered Stair Climber so no power can get to the unit.

  • Page 17: Main Wiring Harness

    -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).
  • Page 18 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).
  • Page 19 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.

  • Page 20: 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.

  • Page 21: Round Up Switch

    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.

  • Page 22: Safety Flap

    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.

  • Page 23: Small Gray Wheel

    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.

  • Page 24: Swing Arm Assembly

    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.

  • Page 25: Wheel

    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;...
  • Page 26 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.

  • Page 27: Wheel Bracket

    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.
  • Page 28 930085 Noseplate G 16.5" x 13.4" 930003 Noseplate LH 18.4" x 10.9" 930002 Noseplate Bolt Kit 030634K Wheels 1-Puncture Proof Wheel 930148 1-Red Hub 4-ply Pneumatic Wheel 030245 Tube only (used with Powered Stair Climber wheels) 121060T Wheel Bearing 030642...
  • Page 29 004123 Battery Harness 004129 Lower Battery Case Assembly 004233 Electrical - Powered Stair Climber Chargers Battery Holder with DC Charger, Powered Stair Climber 930114 AC Battery Charger Kit with bag 930602 Cable and plug adapter for USA, AC charger 930624...

  • Page 30: Powered Stair Climber Warranty And Liability

    Modifications to the Powered Stair Climber or its accessories  Liability Magline Inc. as distributor of the Powered Stair Climber is not responsible for the safety of the Powered Stair Climber if: The Powered Stair Climber is used for purposes other than those for which it is intended ...

  • Page 31: Design Protection By Patents

    I. Inspect the electronic card for any water or cracks (see page 11). For more assistance, call Magline customer service at 1-800-MAGLINE (624-5463). 24.2 My Powered Stair Climber turns on, but will not run A. Is the battery charged? When charging with DC charger (part number 930114), be sure the main switch on battery is in the on position (see Fig.
  • Page 32 B. Be sure no more than capacity is loaded on the Powered Stair Climber. C. Make sure the battery contacts on both the Powered Stair Climber and the battery (part numbers 004120 & 004121) are clean. It may be necessary to replace if corroded beyond what can be cleaned.

  • Page 33: Maintenance Schedule

    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.
  • Page 34 25.2 Eighteen Month Recommended Maintenance Date Page Completed Part # 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 030640 Replace hub caps if missing.
  • Page 35 25.3 Thirty Month Recommended Maintenance Date Page Completed Part # Tasks Apply thin film of anti-seize to threads of nose bolts. Remove wheels and apply thin film of anti-seize to mounting flange. 930030 Replace nose. 030023 Replace gray end cap on top of side rails if missing. 30024K Replace any cracked crossbars.

  • Page 36: Schematics For Additional Reference

    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...
  • Page 37 26.2 Electrical Components- Ergo 0051491 Apply electrical grease to the locations indicated by red arrows.
  • Page 38 26.3 Electrical Components- Folding 0051491 Apply electrical grease to the locations indicated by red arrows.
  • Page 39 26.4 Electrical Components- Uni 0051491 Apply electrical grease to the locations indicated by red arrows.
  • Page 40 26.5 Frame- Ergo and Uni 030 039 030 039...
  • Page 41 26.6 Frame- Folding 030 083 030 039 030 039...
  • Page 42 26.7 Handle- Ergo 030 083...
  • Page 43 26.8 Handle- Folding...
  • Page 44 26.9 Handle- Uni...
  • Page 45 26.10 Hinged Nose Bracket – Units built prior to November 2016 Apply Anti-seize to these five locations indicated by red arrows. Apply to inside of mounting flange on both sides of the unit. Standard Fixed Nose – units built prior to November 2016...
  • Page 46 26.11 Hinged or Fixed Nose – units built after April 2017 Apply Anti-seize to these five locations Apply to inside of indicated by red arrows. mounting flange on both sides of the unit. Please note – for units with serial number 201633806 through 201735490, the 930197 hinged-to-fixed exchange kit must be ordered if the nose plate is being changed from hinged to fixed.
  • Page 47 26.12 Lifting Unit Sal 110: 005037 Sal 140: 005020 Sal 110: 010123 Sal 140: 010124 Sal: 170: 010137...
  • Page 48 26.13 Lifting Unit Assembly Apply Anti-seize grease to the exterior of shaft. Sal 110: 005133 Sal 140: 005134 Sal 170: 005146...
  • Page 49 26.14 Swing Arm .020” .080” .004” Note: To replace oil in part number 005124, use 1.75 oz. of SAE 90W Gear Lube.
  • Page 50 26.15 Wheel U.S. Patents 6,386,552; 6,616,174 LIFTKAR® is a registered trademark of SANO Transportgeräete GmbH. Copyright 2005-2017 Magline, Inc. REV 07/17 B8145...

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