Magliner CLK110FNG4 User Manual

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: [e-mail]

1

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

2

!

Caution !

Never make repairs to your Powered Stair Climber while battery is inserted.

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.

3

Control box

Round-up switch

Wheel guard

Small Gray
Wheels

Upper crossbar

Red Handle

Nose plate

Swing arm
Red Handle Grips
and O-Rings

B. Diagram

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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

5

!

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.

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 36.

6

Spring

Locking
Clip

Battery
Contacts

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

7

Tap in
direction
of arrow

Small plastic nubs

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

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

8

!

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.

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).

9

Connecting link

Sliding
Clutch

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

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Splice to disconnect

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

7. Electronic Card

Note – Powered Stair Climbers purchased AFTER December 2016 have the 0051491
electronic card and appropriate housing for the card and DO NOT need the adapter kit
spacer or extra wiring harness. Use these adapter items when replacing the electronic
card in Powered Stair Climbers purchased BEFORE December 2016.

Models Purchased AFTER December 2016

To replace the electronic card (part number 0051491) remove four bolts on the aluminum
motor cover with a 7mm socket with ratchet. Since removing this cover breaks the silicone
seal, scrape off old silicone and apply new silicone when reassembling.

Fig. 7.1a Fig. 7.1b

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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. 7.1d

Models Purchased BEFORE December 2016

To replace the electronic card (part number 0051491) remove four bolts on the aluminum
motor cover with a 7mm socket with ratchet. Since removing this cover breaks the silicone
seal, scrape off old silicone and apply new silicone when reassembling. See figures 7a and
7 b above.

Carefully remove the electronic card by unscrewing the 2 screws in the aluminum plate that
attaches to the circuit board with a 3mm Allen wrench. Mount the aluminum adapter inside
the motor power control housing using the countersunk-head screws provided in the kit.

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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.

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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

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Handle
bracket
screw

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. 8

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