Magliner Powered Stair Climber Operating instructions

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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: [phone]
Web: www.magliner.com
E-mail: [email protected]

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Table of Contents
A. Introduction...............................................................................................................................3
B. Diagram .....................................................................................................................................4
1. Battery........................................................................................................................................5
2. Battery Clamp............................................................................................................................7
3. Control Box................................................................................................................................7
4. Crossbars ..................................................................................................................................8
5. Drive Chain ................................................................................................................................9
6. Drive Motor ..............................................................................................................................10
7. Electronic Card........................................................................................................................11
8. Gray End Cap...........................................................................................................................15
9. Handles ....................................................................................................................................16
10. Lifting Unit .............................................................................................................................16
11. Main Wiring Harness.............................................................................................................17
12. Microswitch............................................................................................................................20
13. Nose Plate..............................................................................................................................20
14. Round up Switch...................................................................................................................21
15. Safety Flap.............................................................................................................................22
16. Small Gray Wheel..................................................................................................................23
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
26. Schematics for Additional Reference..................................................................................36

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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:
A troubleshooting guide
Detailed directions to make each repair on your own
Assembly drawings to help locate and describe parts
A replacement parts list
The following are the tools needed to properly service the Powered Stair Climber:
#1 Phillips screwdriver
#2 Phillips screwdriver
Flat screwdriver
3mm Allen wrench
5mm Allen wrench
6mm Allen wrench
8mm Allen wrench
13mm Allen wrench
7mm socket with ratchet
13mm socket with ratchet
T-40 Torx®wrench
T-30 Torx®wrench
We sincerely appreciate your purchase of this exciting product. We hope this manual is
helpful. However, if you have questions please do not hesitate to call our customer service
department at 1-800-MAGLINE (624-5463) or 989-512-1000.
!
Caution !
Never make repairs to your Powered Stair Climber while battery is inserted.

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

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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 fuse for continuity with a MultiMeter or similar. If it reads OL (digital)
or ∞(analog), change the 30 Amp fuse by pulling the old one out by hand and inserting
the new one.
Fig. 1d Fig. 1e

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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.
Reconnect bottom wires into the new battery cells. Gently reposition into the battery
case and reconnect the top wires. Use page 33 as a guide when reconnecting.
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 and
symbols to indicate reversed polarity. Correct polarity by ensuring the battery wires are
connected exactly as shown on page 33.
!
Caution !
Avoid touching battery contact points together.
!
Caution !
Inserting a battery with reversed polarity on the Powered Stair Climber will cause
a short circuit in the electronic card and may cause overheating and potential
damage to the DC charger.

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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
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.
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.
Fig. 3a Fig. 3b Fig. 3c
Spring
Locking
Clip
Battery
Contacts

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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. 4a
To replace the bottom cross bar (part number 030034), make sure the battery is not
inserted. Unplug the main wiring harness from the control box (see Figure 3c), and then
remove safety flap (see page 19), remove left wheel (see page 22), and remove right and
left battery clamps (see page 7). Remove the red plastic cover on bottom of crossbar
stabilizer arm by prying at the top in the middle with a small flat screwdriver, and then pry
each side at the bottom. Be careful to not break the two small plastic nubs on the bottom.
Fig. 4b Fig. 4c
Tap in
direction
of arrow
Small plastic nubs

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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.
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. 5a
Next, check the chain to ensure none of the links are broken. If necessary, replace the
chain (part number 005627).
!
Caution !
Tapping the LEFT side of the side rail will damage the main wiring harness.
!
Caution !
Do not run Powered Stair Climber without the plastic safety cover securely in
place.

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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
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. 6a
* Drive Motor part numbers:
-010123 for the SAL 110 model
-010124 for the SAL 140 model
-010137 for the SAL 170 model
Connecting link
Sliding
Clutch