Service Manual for Quikstak 'smart-stackers'
Contents
1. De 19 20 Lift Ram removal service amp replacement n MI 21 22 Rear Wheel Assembly Park Brake m 22 23 Electronic Drive Unit and Wiring Diagrams 7 usse 24 30 General Items ssesssssesenneee enean r 31 32 Spare Parts LiSt cierre racine pestes deest dead oic ia AANST ARTE 33 35 TJ PDF Lifters Stackers QS Service Manual 2012 Page 2 of 34 e C G PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU T PDF Lifters Stackers QS_Service Manual_2012 Page 3 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Emai INDUSTRIES Pt WWW SPACEPAC COM AU Ltd General Description of QUIKSTAK Smart Stackers QUIKSTAK stackers are battery powered non counter balanced forklifts having outriggers going forward either straddling or underneath the load QUIKSTAKS are available as either pushed versions or self propelled walk behind and are available in a range of lift heights and weight capacities Lifting force comes from a single displacement type hydraulic ram Models with less than 1 5m lift height usually have a direct acting ram those with higher lift use the more conventional arrangement with lift chains passing2. Battery monitor Manual switch Cut if time delay fitted Optional Q time delay unit Potentiometer 250k ohms Auto switch Nine way connector Battery charger Lowering cutout T PDF Lifters Stackers QS_Service Manual_2012 Page 13 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 3 0 Hydraulic Power Pack Service QUIKSTAK stackers use top quality European powerpacks which have proved to be very reliable and long lasting and require no regular maintenance Hidroirma brand powerpacks were used up until approximately early 2003 after this mostly Oil Sistem brand units were used though some Hidroirma units were used With the Hidroirma powerpacks the hydraulic hose connects into the rear vertical face of the main block on Oil Sistem units the hose connects into the top face see photo below All powerpacks have a pressure compensating lowering speed valve this automatically regulates the lowering speed regardless of the weight on the forks The powerpacks also have a check valve solenoid lowering valve pressure relief valve and oil filter suction type on Oil Sistem units return type on Hidroirma 3 1 To Remove the Powerpack 1 Ensure the forks are fully lowered 2 Us
3. To Remove 1 Undo the grubscrew holding the adjusting knob on 2 Disconnect the plug that connects the sensor to the main loom 3 Undo the 3 screws holding the aluminium bracket to the front panel and slide the shaft out of the top support bracket 4 Lift the assembly out Refitting is the reverse of the above procedure Adjustment of chain tension The bottom sprocket is mounted on an eccentric spacer Turn the spacer using a 13mm spanner to tighten or loosen the chain tension This should only be done when the assembly is mounted in the machine The chain should be tight enough to ensure the sensor does not fall under its own weight T PDF Lifters Stackers QS_Service Manual_2012 Page 30 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 8 2 Fibreglass Cover If the fiberglass cover needs to be removed for any reason the best way is to punch the plastic clips right through with a 6mm punch and fit new clips when refitting the cover Cracks and other damage can be repaired by the manufacturer or by any qualified fiberglass company 8 3 Polycarbonate Screen To Remove Undo the M5 screw in the centre at the bottom and slide the screen up and out of the channels Replacement panels are available if the existing one is scratched or damaged 8 4 Outrigger Mounting The outri
4. Faulty Charger relay 1 4 3 8 Broken or loose wires Emergency Stop switch not working 1 8 9 2 LED s glowing but no response when switches operated Possible Causes Refer to Section Page Charger relay not working 1 4 3 8 Broken or loose wires Emergency Stop switch not working 1 8 9 Raise Lower switches not working 1 6 1 7 9 Faulty raise solenoid motor relay 1 1 3 3 7 14 Top microswitch sticking on 2 0 9 Faulty motor 2 4 10 3 Forks go up on Manual but not on Automatic Possible Causes Refer to Section Page Faulty infra red sensor 1 3 7 Faulty Auto switch or wiring 1 7 9 Object being detected by sensor 4 Forks go up on Automatic but not on Manual Possible Causes Refer to Section Page Faulty Manual switch or wiring 1 6 9 TJPDFi Lifters Service Manual 2012 Page 5 of 34 INDUSTRIES Pty Ltd WwW SPACEPAC COM AU If the forks will not come down 5 Forks will not go down in Manual or Automatic Possible Causes Refer to Section Lowering valve not working 1 2 3 5 Lowering solenoid coil faulty 1 2 3 5 Wires to lowering solenoid broken or loose Mast blocks tight in mast 4 2 Forks jammed against top stop blocks 2 0 Lift Ram sticking 5 2 Pressure compensating valve blocked 3 7 6 Forks come down in Manual but not Automatic Possible Causes Refer to Section Lower microswitch jammed 2 1 Faulty sensor Auto switch or wiring 1 3 1 7 7 Forks come down in Automatic but not Manual Possibl
5. in the masts Ideally there should be 1 2mm of free play at the bottom and at the height of the top blocks The free play can be adjusted by adding or removing 1 x 1 16 flat washers under the plastic blocks If adjustment is required remove the forks add or subtract washers to the relevant blocks and refit the forks Recheck the clearance When satisfied replace the circlip and the 2 M10 bolts Raise the fork fully and check that the top microswitch works properly Check also that the forks go down without sticking T PDF Lifters Stackers QS_Service Manual_2012 Page 18 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Models with Compound Ram 4 3 Removal 1 Lower the forks onto a support block approx 50mm high then press the ram down while holding the Down switch to take the tension off the chains 2 Remove the spring clips on the connecting links holding the chain to the adjusting bolts and remove the connecting links 3 Remove the circlips securing the chain rollers onto the shaft on top of the ram slide the chain rollers off and drape the chains over the front of the fork back plate Remove the 2 M10 stop bolts and spring washers from the 100 x 50 RHS cross member 5 Carefully lift the forks up and out of the masts preferably using another forklift so the forks ar
6. over rollers on top of the ram Lifting force is provided by a 24 volt hydraulic power pack this is an complete unit comprising the motor pump oil tank all control valves check valve pressure relief valve solenoid lowering valve pressure compensating lowering speed valve and oil filters Two deep cycle gel batteries are connected in series to provide 24 volts for the motor and control circuit The fully automatic battery charger is mounted internally the machine may be used while the charger is connected but the charger is automatically disconnected when the forks are being raised Almost all QUIKSTAK stackers are fitted with a patented infra red height sensing function which automatically adjusts the fork height up or down to maintain a constant working level as product is loaded or unloaded The infra red sensor is a retro reflective type that emits an infra red beam and receives a reflected signal from any object within its range The sensor s range is adjustable up to 700mm out from the fork backplate and height is adjustable between 750mm and 1000mm from the floor In some applications particularly in the woodworking industry it is desirable to have a delay between when the product is detected by the sensor and when the forks actually move Fixed and variable delays are available to suit most applications Self propelled QUIKSTAKS have a large single rear wheel with a 1200 watt motor and gearbox mounted in the hub An ele
7. 2 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 2 Remove the cap screws holding the filter remove and clean it carefully with petrol Clean the body also of all traces of foreign matter using compressed air 3 Reassemble carefully Cleanliness is essential the pump must be fitted the correct way around and all screws tightened firmly and evenly 4 When refitting the tank ensure that the o ring is correctly seated in it s groove and do up the hose clamp directly over the o ring The filler cap should be on the opposite side to the lowering valve Refill the tank with clean hydraulic oil ISO 32 viscosity Test the machine with a full load and check carefully to ensure there are no oil leaks Oil tem If necessary the filter may be unscrewed and cleaned with degreaser and compressed air 3 9 Oil Leaks If an oil leak is suspected check the following 1 There is a hose clamp around the plastic tank where it joins onto the body of the power pack Occasionally if this clamp is not tight enough a small amount of oil can seep out of the tank The clamp screw can normally be easily accessed by moving the batteries apart do it up as tight as possible Any oil sitting on the chassis should be wiped up in view of confirming that the leak has stopped 2 Ensure that the fitt
8. 63444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 5 0 Lift Ram Removal Service and Replacement 5 1 Removal Direct Acting Types Ensure the forks are fully lowered Disconnect one battery cable for safety Remove the circlip on top of the centre member of the forks Raise the forks fully using any available form of lifting device Do not use the stacker s powerpack 1 2 3 4 Pull the base of the ram forward sufficiently to undo the hydraulic hose fitting 11 16 spanner 5 Remove the ram 6 Plug the end of the hose to prevent contamination Compound Acting Types with chains and rollers Raise the forks fully and support them firmly so they cannot fall Press the Manual Lower switch and hold until the ram has fully retracted Disconnect one battery cable for safety Remove the access panel undo both bolts holding the top bracket to the front panel Pull the base of the ram forward sufficiently to undo the hydraulic hose fitting 11 16 spanner Remove the ram zogen SE cU ee cbe Plug the end of the hose to prevent contamination 5 2 Service The rams fitted to QUIKSTAK stackers are of the displacement type and only have a head seal sealing on the chromed spear There is no piston nor any internal means of preventing the spear from coming out of the ram body Once the ram and forks are assembled in the stacker the spear cannot come out In p
9. If not check the charger See section 1 4 Subject to conditions of use 2 5 3 To Test Batteries 1 Using a multimeter check the voltage of each battery with the charger disconnected If below 12 volts even after having been charged the battery is probably faulty and should be replaced 2 Ifthe voltage is OK when at rest but a fault is still suspected check again while raising a load on the forks Depending on the load the voltage of each battery may drop down to 10 11 volts If lower than this replace the battery 2 5 4 Battery Replacement 1 Always replace with 2 batteries of the same type 2 Ensure that they are installed the right way around and that the cables are connected correctly Red lead to positive black lead to negative Gel batteries should be installed with the positive terminals to the left When installing gel batteries put the right hand battery in first connect the black battery cable and then slide it as far as possible to the right Then install the left hand battery connect the red battery cable and the joiner cable from the negative of the left battery to the positive of the right one TJ PDF Lifters Stackers QS Service Manual 2012 Page 12 of 34 e C P AC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Standard Wiring Diagram Emergency Sop 4 Raise cutout
10. RCE 3 Ensure the solenoid is correctly oriented before replacing the powerpack Hidroirma 4 The orange and grey wires can go on either of the motor relay terminals 5 Obtain replacement plastic retaining clips from Simpro tap in to hold the fibreglass cover 6 After refitting check carefully all functions and check that there are no oil leaks 3 3 To Replace the Motor Relay with the powerpack in place 1 Remove the access panel batteries and battery support frames 2 Remove the 2 switching wires battery cable and motor cable from the relay terminals 3 Undo the 2 securing screws and remove the relay On machines with Oil Sistem powerpacks it may be easiest to remove the entire fibreglass cover as detailed above Section 3 1 steps 2 4 4 Fitting the new relay is a reversal of the above procedure 3 4 To Replace the Lowering Solenoid Coil Hidroirma Brand 1 Remove the powerpack as described in section 3 1 2 Remove the screw holding the plug onto the solenoid and remove the plug 3 Fit the plug to the new solenoid 4 Reassemble with attention to notes in section 3 2 Oil Sistem Brand 1 Remove the fibreglass cover as detailed in section 3 1 steps 2 4 2 Undo the knurled nut holding the solenoid onto the valve 3 When refitting ensure there is an o ring each side of the coil and do up the nut finger tight only 3 5 To Remove the Lowering Valve 1 Remove powerpack as described in section 3 1 2 Hold the p
11. SP AC E P AC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Service Manual for Quikstak smart stackers T PDF Lifters Stackers QS_Service Manual_2012 Page 1 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WwW SPACEPAC COM AU Index Section Page General Description e Rec enema tede tote ra pects eats EB see EUIS 2 3 Trouble ShootingGuide Forks Willi NOEGO UP P 4 Forks willl pat come dOWID ueieto eis niacin AAR 5 Other Electrical problems rre eiecit o eiiis etc rer EHE REESE 5 Nonc electrical probleitris eiecti Peter rete crat ete totis b tar erret ena becr ue 6 Electrical Fault Finding iisisso ius ina eres PORA aer RE RES GR GIO KY REM EA EEX ME RES OO E ERE eSES 6 Raise Relay Lowering Solenoid Infra red sensor Battery Charger Contrtol circuit f se ettet cnttotetnnin t Switches and lights eene 1 6 2 2 comes 9 10 Battery Care and Service sss v P 11 Wiring Diagrams sse 2 iO 12 Hydraulic Power Pack Removal amp refitting of forks
12. SW 2500 Phone 1300763444 Fax 61 2 4226 2208 INDUSTRIES Pty Ltd WwW SPACEPAC COM AU 1 5 To Replace the Control Circuit Fuse Remove the access panel The main control fuse is in an in line case just above the batteries and just to the left of centre If it has blown replace with an 8 amp standard automotive type fuse 4 x 1 Control Switches and lights 1 6 Manual Raise Lower Rocker Switch Cole Hersee 58027 11 This is a 3 position 2 pole switch with spring return to centre The actual switch cavity is sealed however over time dust or moisture can penetrate the seal and prevent an effective contact The switch clips into a rectangular cut out in the fibreglass cover To remove firstly remove the access panel reach up inside squeeze the clips on the ends of the switch and push it out If any of the wires are removed they must be replaced in the same position 1 7 Automatic Raise Lower Rocker Switch Cole Hersee 58027 07 This is very similar to the manual switch above except that it stays in any of the 3 positions If this switch is left in the Auto Down position when the machine is not in use it can cause the lowering solenoid to energise If this happens the batteries will become drained fairly quickly 1 8 Emergency Stop Switch Schneider ZB5 AS54 It is more difficult to disengage the lower portion of the Schneider switches a small flat screwdriver must be inserted as shown arrow and
13. VER CONTACTOR DRIVER COIL SHORTED CONTACTOR CLOSED TH PROTECTION o 00 32 BATTERY LOW Email sales spacepac com au ABN 98 002 454 462 WWW SPACEPAC COM AU ZAPI Controller Notes Problem with Logic or Line Contactor Logic board and or software failure Problem with EEPROM or Logic Starting sequence for travel not correct Double running requests Problem in Power Block Problem with Chopper Problem with Field Voltage Potentiometer Wiper Pedal Wire not OK Field wiring not OK or field current Sensor not OK Field wiring not OK or field current Sensor not OK High current at the stand by sensor of Armature current not OK No current sensor of armature current Not OK Contactor Driver not OK Coil contactor shorted Line Contactor contact not OK Temperature too high 709C or low 109C Battery too low 7 3 To Replace motor brushes Disconnect one of the battery cables from one battery Remove the fibreglass cover over the wheel and motor Unclip the band at the end of the motor Undo the screws securing the wires lift the springs to one side and remove the brushes Fit new brushes replace springs and screw wires tightly Qv uv de qu qu ipe Replace band and fibreglass cover taking care that the cables to the brake are correctly positioned TJ PDF Lifters Stackers QS Service Manual 2012 Page 25 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Ema
14. ackers QS_Service Manual_2012 Page 17 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 4 0 Removal and Refitting of Forks Models with Direct acting Ram 4 1 Removal Fully lower the forks Remove the circlip securing the top of the ram to the centre post of the fork back plate Remove the 2 M10 bolts 16mm spanner one each side of the top of the front panel or cross member on models lifting higher than 1 metre Note the way the flat washer s and spring washer are fitted to ensure correct reassembly 4 Lift the forks out using another forklift chain block or other safe approved method to support them evenly NOTE Just as the top plastic blocks come out of the mast the ram will come out of the centre post and should be carefully rested against one mast 4 2 Refitting 1 Ensure the four blocks are correctly positioned on the fork spigots Raise the forks then carefully lower them into the masts ensuring they are held level at all times Just before the top blocks enter the masts hold the ram upright so that it enters the hole at the bottom of the forks Take special care that the top microswitch roller does not get damaged or bent by the forks Lower the forks fully making sure the spigot on top of the ram passes through the hole Check the side to side clearance of the forks
15. ax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pt WWW SPACEPAC COM AU J Ltd If the mast blocks are badly worn the trigger plates can try to bypass the stop bolts generally when this happens the chrome bar comes past the seal in the head of the ram and some oil leaks out If this does occur the forks must be forced back down while the Manual Lower switch is operated so the chrome bar can re enter the seal Again the microswitch must be repaired or adjusted before using again The mast blocks should also be replaced section 4 5 2 1 Lower Microswitch This is mounted near the lower left hand corner of the front panel Its purpose is to cut out the AUTO DOWN function when the forks are approximately 200mm off the floor to prevent a pallet accidentally being lowered onto the operator s feet It needs to be adjusted accurately in order to work properly If it jams in the Auto down function will not work but Manual Down will work as usual If this occurs free the roller and bend it so that it is just triggered by the trigger plate 2 2 Battery Monitor Panel Quikstak stackers have a single battery status LED with 3 states Green steady OK for use Red steady recharging recommended and Red flashing recharge as soon as possible During recharging the LED will remain red until the batteries have been recharged to approximately 90 then it will turn green 2 3 Charger Soc
16. bar Align the shaft so the spring hook on the top disc is opposite the brake pedal and tighten the grub screws Refit the wheels 7 Remount the complete assembly onto the machine 6 3 To Adjust the Height of the Rear Wheel Assembly 3 Remove and dismantle as described in section 6 2 1 3 If rear of machine needs to be raised add 625mm flat washers to the desired thickness under the thrust bearing and then reassemble Note that raising the rear of the machine only will tend to tip the machine and forks slightly forward This can be counteracted to some degree by shifting the outrigger wheels to the lower holes If the whole machine is raised the forks will be slightly higher off the floor If this is a problem please contact the manufacturer 6 4 To Remove and Refit the Outrigger Wheels Support the front of the outriggers on 25mm high packers Using a 3 8 diameter shaft drive the roll pin axles out If refitting the wheels using the lower holes raise the outriggers another 15mm Sr es Tap the roll pin through one side of the carrier bracket with the slot down Insert the wheel and tap the roll pin right through T PDF Lifters Stackers QS_Service Manual_2012 Page 22 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 7 0 Electronic Drive Units for Self Propelled stacke
17. ce QUIKSTAK stackers use 2 deep cycle batteries linked in series to give 24 volts Before mid 2005 most machines were fitted with 2 lead acid batteries which require regular maintenance and care From mid 2005 on machines have generally been supplied with sealed maintenance free gel batteries Simpro recommends that gel batteries are fitted whenever the original batteries become unserviceable If batteries are sourced from a supplier other than Simpro they must have a maximum depth front to back of 135mm and ideally should be approximately 50amp hr 2 5 2 Battery Life Depending on the level of usage lead acid batteries typically give 2 3 years of use before requiring replacement Maximum life is obtained by frequent charging without letting the batteries get deeply discharged As the charger is automatic there is no risk of overcharging the batteries Gel batteries should give up to 5 years of use before requiring replacement The batteries should be replaced when the useful life of a charge gets too low or if a faulty battery is suspected NOTE If the batteries do not give much use from a charge check that this is not resulting from a short circuit or the AUTO DOWN switch being left on When the machine is at rest there should be no current draw Also check that the charger is working by reading the voltage across both batteries when off charge then plugging the charger in The voltage should immediately start to rise
18. ck O negative to park brake switches brake coil on 5 Yellow I positive when key on tiller handle in operating position 6 Black O negative at all times 7 Red Black O positive supply to contactor switches in handle and tiller position switches 8 I Hard amp Soft switch not used Plug B 6 pin Input Output 1 Green O Potentiometer wiper terminal 2 Black I Potentiometer negative 3 Orange I Potentiometer positive 4 Yellow Black I positive from reverse command 5 Grey I positive from rapid inversion belly switch 6 Blue Black I positive from forward command Plug C 3 pin Input Output 1 O positive supply to Speed Limits 1 and 2 2 I positive when speed switch is set to medium 3 I positive when speed switch is set to low If a Zapi Diagnostic Console is available this can be used to check all faults and the current status of all Switches If necessary a console may be loaned from Simpro or an agent SP controller showing diagnostic unit plugged in m PDF Lifters Stackers QS Service Manual 2012 Page 24 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 INDUSTRIES Pt Diagnostic LED flash codes No of Messages Flashes LOGIC FAILURE 1 WATCH DOG EEPROM KO INCORRECT STARTS FORW BACK CAPACITOR CHARGE VMN NOT OK VFIELD NOT OK VACC NOT OK PEDAL WIRE KO NO FIELD CUR UR OB UU UONM MG Re 5 HIGH FIELD CUR 5 STBY 1 HIGH 5 1 0 E
19. contact your supplier or the manufacturer To replace a gold charger reconnect positive and negative output connectors mains input lead to socket and add earth from socket to frame To replace a YK charger connect output leads direct to positive and negative of d owertech silver batteries in series using leads supplied 24v charger with eyes Care must be taken when replacing fuses only a registered electrician may open and service chargers 1 4 2 Diode Check the diode very small square electronic component mounted just to the left of the relay If it appears to be heat damaged replace it Using a multimeter hold the red probe on the positive battery terminal and the black probe on the right leg of the diode should be 26 29VDC when the charger is plugged in Then put the black probe onto the left leg of the diode If the voltage here is more than 1 6 volts lower than the other side the diode should be replaced 1 4 3 Charger relay With YK chargers the charger relay 24VDC should click every time the charger is plugged in or unplugged If there is no click check the input and output fuses on the charger Check also the relay automotive type mounted just to the left of the charger With Powertech chargers the relay should click only when the raise switch is pressed T PDF Lifters Stackers QS_Service Manual_2012 Page 9 of 34 c C PAC PO Box 1468 Auburn St Wollongong N
20. ctronic controller regulates direction speed and power according to the position of a thumb operated control on the handle head Various parameters in the controller can be altered to achieve the optimum performance for each application The controller also has a self diagnostic function and will report faults by a series of coded flashes on an LED Pushed versions have two large diameter wheels on a common axle which can rock a little to allow for uneven floors When the park brake is applied a bar locks into grooves machined around the inner rim of both wheels holding the machine firmly regardless of the condition of the floor The forks slide in the masts on specially shaped blocks of self lubricating nylon Although they have a little more friction than rollers the contact surface is many times larger allowing much higher loads to be put on the masts without deformation Replacement and adjustment of the mast blocks is also very easy TJ PDF Lifters Stackers QS Service Manual 2012 Page 4 of 34 sales spacepac com au ABN 98 002 454 462 SPAC PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300 763 444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WwW SPACEPAC COM AU Trouble Shooting If the forks will not go up 1 No power at all no LED s glowing no response Possible Causes Refer to Section Page Batteries discharged 2 5 11 Control circuit fuse blown 1 5 8
21. developed Early machines had a 12v system and a single Arlec charger 24v systems pre 2003 were fitted with a simple open auto charger 24v systems between 2003 and 2006 had a YK2408 3 stage aluminium body charger From late 2006 to mid 2010 a Powertech gold charger was used and a Powertech silver is used currently To check the battery charger measure the battery voltage with the charger unplugged then again with the charger plugged in If the voltage does not increase with the charger plugged in check the following The power outlet wall socket is actually live The charger is switched on The charging lead is not damaged The input and output fuses on the charger have not blown The bullet connectors on the red and black wires from the charger are connected properly The wires to the charger are connected to the terminals on the inside of the charging socket The YK and Powertech type chargers can be very simply removed for checking simply disconnect the 2 bullet connectors cable clips and slide the charger up out of the mounting rails The YK chargers have two fuses on the top of the unit the Powertech gold chargers have a single internal fuse and the Powertech silver units are all electronic and have no fuses Note only Powertech silver chargers are now available If you are unsure of which model of charger you have or any details regarding its repair or replacement please
22. e supported flat 4 4 Refitting 1 Refitting is a reversal of the above procedure take special care that the top microswitch roller does not get damaged or bent during refitting Check and adjust the mast block clearance as described in section 4 2 It is essential that the chain adjustment bolts are adjusted correctly to ensure that both chains are taking an equal share of the load With the forks right down pull the long portion of both chains forward and adjust the Nylock nuts until they both pull forward evenly 4 Refit the 2 M10 stop bolts then raise the forks fully to check that the top microswitch works correctly and that the forks go down smoothly without sticking 4 5 Mast Blocks The mast blocks are made from a special oil impregnated nylon material that combines exceptional strength with good wear properties and minimal friction Generally they will give years of service without needing replacement if one side of the blocks does wear they can be rotated 180 to extend their life The lower blocks tend to wear at the back and the upper ones at the front To rotate or replace the blocks follow the steps in section 4 2 Note that although most machines have tapered flange channel masts some have parallel flange channel masts Please specify when ordering replacement mast blocks T PDF Lifters Stackers QS_Service Manual_2012 Page 19 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 13007
23. e Causes Refer to Section Faulty manual switch or loose wire 1 6 Other Electrical Problems 8 Battery Charger Not Charging Possible Causes Refer to Section Power socket not live blown fuse 1 4 Faulty charging lead 1 4 Input or output fuses in charger blown 1 4 Faulty diode 1 4 2 Charger cut out relay not working 1 4 3 Faulty charger 1 4 2 ervice Manual 2012 TJPDFi Lifters SPAC PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 Page 7 15 7 15 19 21 16 Page 10 7 9 Page Page Page 6 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC IE PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WwW SPACEPAC COM AU 9 Other Fault Possible cause Page Short Battery Charge life Batteries need replacing 11 Batteries go flat overnight or when machine is not in use Auto Down switch left on 9 Note For all problems relating to the drive system on Self Propelled machines refer to Section 7 Non Electrical Problems i Fault Possible cause Page mE Band clamp around tank is not tight 18 Hose fittings not tight 18 Cil leaks Leaking ram seal 18 Oil level in tank too high 18 Oil getting hot 18 m Sensor slowly dropping Chain tension insufficient 31 nd Excessive free play in fork frame Mast block
24. ection 2 0 page 15 then check 2 and 3 below If the relay clicks but the motor does not run short across the 2 large terminals with a screwdriver if the motor runs now the relay contacts are probably faulty and the relay should be replaced 2 Test for a positive signal at the orange wire when the Manual Up switch is pressed 3 Test for a negative signal at the grey wire when the Manual Up switch is pressed If either wire is not giving the correct signal check the wiring and switches for breaks or poor connections If both signals are present but the relay does not click its internal coil is probably faulty To remove see section 3 3 page 22 1 2 To check the Lowering Solenoid 1 The lowering solenoid should make a faint click when the Manual Down switch is pressed If not check 2 and 3 below If it clicks but the forks do not come down the problem will probably either be hydraulic section 3 or mechanical refer to section 4 2 Check for a positive signal at the blue wire on the centre pin of 9 pin plug at far left of the machine 3 Check for a negative signal at the white wire on the bottom cut out microswitch at the lower left of machine If either of these wires is not giving the correct signal check the wiring and switches for breaks or poor connections If both signals are present but the solenoid does not click the coil may be faulty To gain access to the coil it is necessary to remove the fibregla
25. ee of the wheels in OFF position and securely locks both wheels in ON position TJ PDF Lifters Stackers QS Service Manual 2012 Page 21 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 6 2 To Replace the Spindle Bearings 1 Raise the rear of the machine and undo the 4 bolts holding the rear wheel assembly to the chassis Loosen the 2 M8 grub screws part way up the hexagonal bar The 25mm bar to which the top disc is screwed and which goes down through the spindle bearings and into the hex bar can now be extracted It may be a tight fit in the hex bar but generally once it has moved a little it should come out easily If necessary try driving a screwdriver between the square plate on the top of the hex bar and the thrust bearing at the bottom of the spindle 4 When the hex bar is removed the 25 bar can be driven back through the spindle bearings Ensure the thrust bearing is kept clean 5 Ifthe spindle bearings need replacing drive them out from the opposite end with a suitable bar Fit new bearings available from Simpro or any bearing supplier The top bearing is a 6005 2RS and the lower one is a 30205 tapered roller bearing Early machines have a 6005 2RS bearing and a 51305 thrust bearing at the bottom 6 Reassemble the shaft through the bearings and the hex
26. ggers fit into channels welded to the bottom of the main frame Straddle type outriggers have a brace with a tongue that slips into a pocket welded to the masts When fitting outriggers to a machine it should be raised ideally about 1 metre Sling off the lifting brackets welded to the top of the masts Insert the tongue into the pocket and then insert the outrigger into the channel Ensure that the outriggers are fully inserted if possible use a clamp or put a spacer cut to the correct width between the outer end of the outriggers and put a load binder around the outriggers near the main frame With pressure on them tap them with a hammer and piece of wood Insert the 2 countersunk bolts each side and tighten to the recommended torque setting see table below Bolt Size Torque Setting 1000kg 10 x 100 80ft Ibs 110 NM 1500kg 12 x 100 100ft Ibs 140NM 2500kg 16 x 130 120ft Ibs 170 NM Ensure that the outriggers are parallel and square off the machine If not contact the manufacturer T PDF Lifters Stackers QS_Service Manual_2012 Page 31 of 34 e PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 EMail sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Spare Parts for Quikstak smart stackers August 2010 Description Part 24 volt charger 19150H eB og Replaces all previous models requi
27. handle is pulled down If it does not open the right hand door to gain access to the controller and see if the red LED is flashing If it is the number of flashes in each series indicates the type of fault see the following chart for details 4 The park brake coil should click when the forward reverse control is moved If it does not check the electrical connection to the brake 24V when tiller is in operating position If an electrical signal is getting through but it still doesn t click the electromagnetic coil could be faulty or the brake lining may be frozen onto the disc 5 If all of the above checks show OK the fault will almost certainly be either in the handle head wiring or between the handle head and controller As the Zapi brand is the most common type we only give here information relating to that brand Please contact Simpro for details about the Reghel brand T PDF Lifters Stackers QS_Service Manual_2012 Page 23 of 34 e C P AC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Fault Finding Zapi Controller Check the voltages at the plugs as shown below Plug A 8 pin Input Output 1 O positive to hour meter not used 2 White Blue I positive signal into controller from key switch 3 Black O negative to main contactor switches contactor on 4 Red Bla
28. il sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 7 4 To adjust the park brake 1 Remove the fibreglass wheel cover 2 Pull the rubber cover off the brake assembly If fitted 3 At rest there should be a clearance of 2 0mm between the steel disc next to the electromagnetic coil and the coil itself all around the disc 4 To adjust the clearance loosen the 3 cap screws holding the coil on turn the hexagon adjusting bolts Looking at the end of the brake turning the nuts clockwise increases the gap Turn them evenly and check the gap beside each adjuster When correct tighten the cap screws 5 The actual spring pressure applied to the brake disc can also be adjusted by turning the disc at the centre of the coil Turning clockwise increases the brake pressure generally unless a loaded machine is to be parked on a ramp fairly light spring pressure is best 7 5 To remove the park brake assembly Remove the fibreglass wheel cover Disconnect the wires to the brake coil Undo the 3 cap screws holding the brake on and remove the coil The friction disc can now be removed from the splined shaft a a E et To remove the steel disc from the coil undo the 3 adjusting bolts Mark the position of the disc for correct reassembly Remove the 3 outer and 4 inner springs and 4 small spacers from the coil 6 Clean all parts check the amps draw of the coil if any fault is suspected should be app
29. ing a sharp knife inserted between the fibreglass cover and the steel frame cut the black plastic retaining clips 3 on each side 3 on top 3 Undo the grubscrew holding the sensor adjusting knob onto the shaft and remove the knob 4 Pull the cover out a little remove the 3 wires from the charger socket and separate the 2 halves of the wiring loom plug Lift the cover away 5 Undo the battery cables remove the batteries and support frame s 6 Undo the hydraulic hose connection using an 11 16 spanner and tape or plug the end of the hose to prevent contamination 7 Remove the orange and grey wires from the motor relay 8 Remove the 2 bolts holding the motor clamp bracket 9 Carefully raise the powerpack Hidroirma brand only until the lowering solenoid is in view Undo the knurled nut securing the solenoid and remove it along with the outer o ring Lay the solenoid on the chassis and remove the powerpack T PDF Lifters Stackers QS_Service Manual_2012 Page 14 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pt WWW SPACEPAC COM AU Ltd 3 2 To Install the Powerpack Installation is a reversal of the above procedure with attention to the following points 1 Ano ring goes each side of the solenoid on the valve stem 2 The knurled nut should be only tightened by hand DO NOT USE EXCESSIVE FO
30. ings at both ends of the hydraulic hose are tight While extremely rare it is possible for the hose itself to leak If this is suspected wipe all oil off the machine then leave the machine standing with weight on the forks for several hours If more oil leaks out try replacing the hose only a genuine part should be used available from Simpro or an agent 3 A further possibility is that the oil could be foaming and coming out the filler breather on the tank This can happen if very heavy loads are being picked up and the oil is bypassing through the pressure relief valve This generates a lot of heat and makes the oil foam causing the tank to overflow If the loads being raised are more than the rated capacity of the machine either the weight of the loads should be reduced or a higher capacity machine used If the loads are within the rated capacity but the relief valve is still blowing it can be adjusted by authorized persons only The oil level in the tank can be lowered a little in many cases to help prevent overflowing With the forks fully raised there should be a minimum of 20mm oil across the bottom of the tank If more than this try pumping out some of the surplus 4 If the top cut out switch when the forks are fully raised fails to work oil can leak from the top of the ram This will normally be obvious by oil running down the ram body If this occurs check and adjust the top cut out switch T PDF Lifters St
31. ket The charger socket may occasionally break or crack if the charging lead is pulled at an angle To replace it drill out the securing rivets and disconnect the wires from the inside terminals The new socket can be riveted in or screwed if this is easier The brown wire must connect to the top terminal green to centre and blue to the bottom terminal From 2004 on a metal support plate was fitted inside the fibreglass cover to provide extra reinforcement This plate can be retrofitted to older models if desired Please contact Simpro to obtain a plate 2 4 24VDC Motor The motors are permanent magnet type with 900 watts output They are generally very reliable and long lasting There are 4 brushes which do gradually wear down as these are difficult to replace it is generally more economical to fit a complete new motor To do this the entire powerpack must be removed section 3 1 The motor is held on to the main block with 2 cap screws When installing a new motor take care to engage the motor shaft with the coupling correctly and ensure that it is correctly oriented The motor relay may be swapped over from the old motor if it is still serviceable T PDF Lifters Stackers QS_Service Manual_2012 Page 11 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Battery Care and Servi
32. levered Once the lower portion is disengaged the nut on the inside can be unscrewed and the upper portion removed Note that a metal plate is fitted between the nut and the fibreglass to prevent the switch from turning 1 9 Emergency Battery Lockout Switch From mid 2010 the Quikstak has been fitted with a battery lockout key switch which cuts the power supply from the batteries in case of an emergency It is not recommended to use unless necessary This can be retro fitted to a machine if required 2 0 Upper Microswitch ore nu A microswitch is mounted either at the top right hand corner of the front panel 1 metre lift machines or 9 inside the cross member on machines with greater than 1 metre lift height This microswitch is triggered by a plate welded to the back of the fork upright member and cuts the power to the motor relay when the forks reach maximum height If the roller arm becomes bent or is not adjusted correctly it may not stop the motor when the forks reach the top When this happens the trigger plates welded to the back of the forks come up against 2 stop bolts which stop the forks going any higher If this happens press the Emergency Stop immediately and fix or adjust the microswitch before using again TJ PDF Lifters Stackers QS Service Manual 2012 Email sales spacepac com au ABN 98 002 454 462 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 F
33. o aw E E Hn RB S u 25 9 z mo S le Ez a 2 3 a 2 ra QuVMO4 3NIVO3N Aa 3401 ISYY Siva Ava 3AUV93N l A LT g 2 5 8 D amp ES E ATI38 Ao e vv T PDF Lifters Stackers QS_Service Manual_2012 Page 27 of 34 SPACEPAC INDUSTRIES Pty Ltd PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 WWW SPACEPAC COM AU Self Propelled Quikstak with ZAPI Controller Circuit Diagram 24v DC Raise relay Charger cutout relay TJ PDF Lifters Stackers QS Service Manual 2012 Beom sensor contclor 00 Top cutout microswitch Bottom cutout mierosuatch Manual lower Manual raise To other drive and contro switches Page 28 of 34 S PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 a EMail sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Self Propelled Quikstak Smart Stacker Controller Motor and Battery Wiring ZAPI brand controller TJ PDF Lifters Stackers QS Service Manual 2012 Page 29 of 34 e PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 8 General Items 8 1 Sensor mounting bracket
34. owerpack vertically in a vice and unscrew the valve from the main body using a 15 16 spanner 3 Clean the valve carefully with compressed air Ensure that the centre poppet can move freely and that it seals firmly on the valve seat when released Clean the valve orifice before refitting the valve 5 Reassemble with attention to notes in section 3 2 TJ PDF Lifters Stackers QS Service Manual 2012 Page 15 of 34 c C PAC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Emai INDUSTRIES Pt WWW SPACEPAC COM AU JLtd 3 6 Pressure Relief Valve Setting NOTE The relief valve is set at the factory so the stacker can lift just more than it s rated capacity Increasing the pressure setting without calibration equipment is dangerous and will void the warranty If the stacker will not lift it s rated capacity first lubricate the masts and check the mast blocks for wear Also check the battery voltage and motor condition If all of these are OK contact the manufacturer see page 44 3 7 To Remove Pressure Compensating Lowering Speed Valve PCLSV Hidroirma Brand 1 Remove the powerpack as described in section 3 1 2 Hold the powerpack vertically in a vice and remove the BSP fitting from the pressure port using a 9 16 spanner 3 The PCLSV is right at the bottom of the pressure port and can be unscrewed using a 10mm wide flat screwdriver Clean the valve carefully using comp
35. ractice the rams have proved very reliable and service if necessary is very simple 1 Hold the ram in a vice with the port up and the port end slightly lower than the open end 2 Carefully grip the end of the chrome spear and pull it right out of the ram body Lay on clean rags or paper and take special care that it does not receive any knocks which may damage the surface Drain and dispose of the oil in the ram body 4 To replace the seal pick the old one out from it s groove just below the top of the ram and replace with an identical seal Clean the inside of the ram thoroughly 6 Smear oil around the inside of the head and seal and replace the chrome bar The air should be removed from the ram by holding it upside down and pumping oil in through the port then retracting the ram until no air comes out Alternatively hold the ram in a vice with the port at the top and the port end of the ram slightly higher Connect a hose to the port and dip the end into a container of clean hydraulic oil Pull the chrome bar out a little then slowly push back Repeat until no more air comes out 5 3 Replacement 1 Replacement is a reversal of the process described in section 5 1 Ensure the hose connection is tight 2 Test run and check carefully for oil leaks TJ PDF Lifters Stackers QS Service Manual 2012 Page 20 of 34 S C P AC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com a
36. res plate below New charger mount plate to suit above d 24 volt ISKRA motor 38724IS ip 24 volt contactor 18224 qu 24 volt power pack 12 volt DEN vitiis C91255 T PDF Lifters Stackers QS_Service Manual_2012 Page 32 of 34 18112 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 EMail sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Charging Lead 19129 GE Chassis socket 39116 v 24 volt Battery status LED 19158 an Emergency stop switch 19127 Infra red sensor 19126 Auto on Indicator 19120 24vdc lowering solenoid coil 18200 Microswitch 19123 Battery lock out switch 19149 Auto 19125 Manual 19124 Outrigger wheel 2100mm 13108 OS raise lower switch E TJ PDF Lifters Stackers QS Service Manual 2012 Page 33 of 34 e PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Rear tiller wheel 200mm 16130 Brake kit pedal 16110 spring 16111 8mm pin 16112 Tiller handle 16122 Tiller handle spring 16127 Sensor knob 10136 Mast sliding block 10110 1 5 Ram seal 141506 T PDF Lifters Stackers QS_Service Manual_2012 Page 34 of 34
37. ressed air Ensure the port is clean before refitting Tighten the valve firmly at the bottom of the orifice Use Ceelon tape or similar sealant only where the elbow fitting screws into the power pack body Do Not use sealant on the hydraulic hose connection Oil Sistem Brand 1 Remove the Lowering valve as described in section 3 5 2 The PCLSV is in the same orifice just below the lowering valve Using a pair of long nose pliers grip the cross pin and pull the PCLSV out with a twisting motion 3 Clean carefully then replace Reassembly is a reversal of the above procedure 3 8 To Clean the Tank and Oil Filter NOTE Hidroirma powerpacks have a return line filter Oil Sistem units have a suction strainer which is easy to remove and clean once the tank is removed 1 Remove the power pack as described in section 3 1 2 Hold the power pack vertically in a vice remove the hose clip and the clamps holding the tank onto the main body Use a 5mm Allen Key 3 Pull the main body up off the tank and lay carefully on it s side Dispose of the old oil clean the tank thoroughly Hidroirma only 1 Hold the power pack upside down in a vice Mark the pump to ensure correct reassembly then undo the 4 cap screws holding the pump to the body In particular note the 2 small rings that ensure the pump locates accurately onto the body cont d TJ PDF Lifters Stackers QS Service Manual 2012 Page 16 of 34 sales spacepac com au ABN 98 002 454 46
38. roximately 1 amp at 24VDC 7 Reassemble carefully in reverse order and then adjust the clearance as described in section 7 4 To select a different tone on the horn 1 Open the right hand door 2 The sounder is the red box mounted just above the controller The outer section is clipped onto the base section carefully prise it off 3 32 different sounds are available by altering the position of the five small switches located inside A chart showing the range can be supplied if desired 4 Clip the cover back on ensuring the o ring is in place To replace the gas strut TJ PDF Lifters Stackers QS Service Manual 2012 Page 26 of 34 S C P AC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU 1 Near the ends of the gas strut is a small slide out wedge of plastic Once this wedge is pulled out a little the strut can be pulled off its mounting pins 2 The strut must be fitted with a body uppermost Clip it back onto its mounting pins and then push the wedges in Traction Control Wiring ZAPI Brand Controller co gt co ces EERE Red Black Ea Block E E E es z E E 2 8 g r e E 2 2 2 L a m z g E B 3 e E e lo 2330 El oR E 3 ms c Der 7 a ES lene B gE mx yo o
39. rs Self propelled QUIKSTAK stackers have either a Reghel early models or a Zapi drive unit Both types comprise a single drive wheel with motor and gearbox mounted in the hub electronic control box and handle head A plug in calibration unit allows various parameters to be set e g acceleration rate speed limits and maximum power and on the Zapi unit the calibration unit can also display faults current status of switches and hours of use Both types signal faults via a series of coded flashes on a LED The electronic controller is very sensitive and moisture in the handle head switches can cause it to shut down A sequence must also be followed when using the machine or it will not operate 7 1 Fault Finding If the machine will not move work through the following check list 1 It will not move if e the charger is plugged in e The emergency Stop button is pressed in e The key switch is not ON e The tiller is not held in the correct position e The incorrect start sequence is followed The correct start sequence is e Turn the key on wait for 1 2 seconds for the controller to do a self diagnosis e Pull the tiller handle down Operate the forward reverse control Check all the above If it still will not move check the following items 2 Check that the batteries are charged and connections to the controller and motor are secure 3 The main line contactor should click when the tiller
40. s worn 20 f Wheel bearings rusty j Machine difficult to move Outriggers not parallel 32 Electrical Fault Finding Procedure for Checking Electrical Components To carry out the following checks it may be necessary to remove both batteries place them on the ground to the left of the rear wheels and reconnect the cables When testing for current the easiest tool to use is a test probe with a clip on a lead a light glows when the probe is touched onto anything that completes the circuit For example when testing for a positive signal on a certain wire connect the lead onto the negative battery terminal and touch the probe onto the wire Alternatively use a good quality multimeter in 0 30VDC mode To test for a positive signal hold the black probe on the negative battery terminal and the red probe on the wire or terminal to be tested To test for a negative signal hold the red probe on the positive battery terminal and the black probe on the wire or terminal to be tested TJPDF Lift Manual 2012 Page 7 of 34 c PO Box 1468 Auburn St Wollongong NSW 2500 PAC E PAC Phone 1300763444 Fax 61 2 4226 2208 Email sales spacepac com au ABN 98 002 454 462 INDUSTRIES Pt WWW SPACEPAC COM AU Ltd 1 1 To Check the Raise Relay 1 The motor should normally run when the Manual Up switch is pressed If the motor does not run first check that the upper microswitch has not jammed in see s
41. ss cover section 3 1 1 4 1 3 To check the Infra red Sensor If the automatic height sensing function is not working and a faulty sensor is suspected check the following 1 Turn to Auto Up the green LED on the sensor should come on and the forks should raise when something is held in front of the sensor the red LED should also come on and the forks stop Test again in Auto Down the forks should go down when an object is in front of the sensor and stop when it is removed If the LED s don t come on check that the brown wire to the sensor has a positive signal Auto Up or Down switch on and the blue white wires have a negative signal If the signals are correct but the LED s do not turn on the sensor is probably faulty 2 Ifthe LED s come on but the forks do not go up and down correctly check the grey wire for a negative signal when the sensor is at rest and the black wire for a negative signal when an object is detected If either one is incorrect the sensor s internal relay is probably faulty and the sensor will need to be replaced TJ PDF Lifters Stackers QS Service Manual 2012 Page 8 of 34 S C P AC PO Box 1468 Auburn St Wollongong NSW 2500 Phone 1300763444 Fax 61 2 4226 2208 1 4 Email sales spacepac com au ABN 98 002 454 462 NDUSTRIES Pty Ltd WwW SPACEPAC COM AU To check the Battery Charger The chargers in the Quikstaks have been upgraded as new and better technology has been
42. u ABN 98 002 454 462 INDUSTRIES Pty Ltd WWW SPACEPAC COM AU Rear Wheel Assembly Park Brake To Dismantle and Reassemble the Park Brake 1 Raise the rear of machine slightly off the ground and pack under the back upright member so the wheels are clear of the ground 2 Press the brake pedal down then remove the circlip from one side of the wheel axle remove the wheels and axle 3 To remove the brake pedal the domed star lock washer on one end of the pivot shaft will have to be destroyed Tap one side with a hammer until the shaft comes free of the star lock remove the shaft and pedal 4 If pedal spring is to be replaced pull the end out of the slot in the roll pin flip the brake pin around and remove the screw holding the spring to the pin 5 If the brake pin is to be replaced remove the spring as described above then slide the pin out through the slot 6 To reassemble insert the pin into the slot screw the spring on with an M4 x 8 screw using Loctite retaining compound Ensure the spring is on the correct side of the pin Insert the other end of the spring into the slot of the roll pin 7 Smear a little grease on the part of the pedal that pushes against the brake pin then replace the pedal pass the shaft through and gently tap on a new 8mm domed star lock washer 8 Lock the pedal down then reassemble the wheels and axle ensuring that a flat washer is put each side of the wheels 9 Test that the brake is fr
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