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StakCat

OPERATORS GUIDE AND


MAINTENANCE REFERENCE GUIDE

Version 1 and 2.0

Version 1 Version 2
INDEX

PAGE

3 - INTRODUCTION

3 - SAFETY WARNINGS

4 – RECEIVING AND UNCRATING STAKCAT

5 - OPERATIONAL CHECK

5 - BASKET AND DOLLY ALIGNMENT

6 - MAINTENANCE

6 - GENERAL OPERATING PROCEDURES

15 – V1 FACT SHEET

17 – V2 FACT SHEET

APENDIX

19 - A) PRE-USE CHECKLIST

20 - B) MAINTENANCE PM CHECKLIST

22 - C) TROUBLESHOOTING

30 - D) 1575 RETRO FIT WINCH KIT INSTALLATION GUIDE

53 - E) COMPONENTS

58 - F) PARTS LIST

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INTRODUCTION:
The StakCat basket lifting device was designed to enhance productivity,
maximize cubing space for transportation and create a safer work
environment for the user.
DESCRIPTION:
The StakCat Basket Stacking Equipment consists of a non-motorized
hand cart with stabilizing outrigger arms that surround a dolly/stack
securely to facilitate raising/lowering the stack so that baskets can be
added /removed as needed to increase or decrease stack heights.

The StakCat V1 and 2.0 utilizes an Electric Winch system to raise or


lower stacks of product. Operating the StakCat is accomplished by
manually pressing the “UP” / “DOWN” foot pedal control switch in order
to physically raise or lower the feature arms.

The StakCat system is designed to be operated by one person, with


minimal effort, and eliminate the need for step stools or ladders to reach
MAX Cube efficiency. StakCat creates higher than standard basket
stack heights while improving ergonomic conditions, dramatically
reducing the need to manually handle baskets above shoulder height
and increase productivity of employees.

SAFETY HAZARDS:
• Sprains/Strains from incorrect body mechanics
• Contusions/lacerations/fractures from striking framework of
equipment, catching hands/fingers between descending baskets,
free-wheeling stacks, raised stack falling
• Injury from not avoiding noted pinch-points
• Electrical hazard from electrical cord damage on 110V unit.
• Trip hazard from power cord not being properly routed to unit
• Trip hazard from out rigger legs of an empty unit
• Struck by falling objects with the items raised above the head.
• Potential for injury to individuals standing below or in the path of
baskets when being lowered to the ground level.
• Possible tipping of basket stacks if the Feature Arms of the StakCat
are not fully engaged into the basket handles prior to lifting the load.

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• When working with double dollies it is highly recommended that two
people operate the lift in order to ensure the lifting arms are fully
engaged into the basket handles prior to lift the stack.
• Always ensure the dolly is fully engaged with the dolly stops before
lowering a raised stack of product onto the dolly.
• When adding the second stack of product to a double dolly use extra
caution not to make contact between the first and second stack of
baskets. If contact is made there is a potential for the feature arms to
become disengaged and the stack could fall.

PERSONAL PROTECTIVE EQUIPTMENT RECCOMENDATIONS:


o Safety Glasses
o Work Gloves
o Bump Cap

RECEIVING NEW STAKCAT:

o Uncrate the StakCat:


– Cut away the Plastic cover sheet
– Cut the Zip Tie straps that hold the lift arms in shipping position.
– Cut the Zip Tie that holds the power cord in place.
– Cut the Metal Tie straps that hold the lift to the shipping pallet.
– Open the plastic bag which contains the Foot Control Pedal.
– Hang the Foot Control Pedal from the bracket located on the side
of the lift on the left side.
– Remove the 9/16 attachment bolts from the Outrigger arms.
– Install plastic plugs into the holes where the hold down bolts were
removed
– To remove lift from the shipping pallet simply apply up pressure
from the rear handles and push forward at the same time and the
StakCat will slide off the front of the pallet and roll onto the ground.
– Remove the wire ties that hold the power cables for the pedal
control and the 110volt converter.

o Operational Check:
– Inspect the lift prior to putting the lift into service.

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– Visually inspect the power cables for proper connection or
potential damage.
– Visually inspect the Lifting Arms, Outriggers and Frame for any
damage received during shipping.
– Turn the power switch to the ON position. A Red light will appear
next to the switch and the cooling fan will turn on.
– With the power switch on Check the 12volt battery by raising and
lowering the arms using the foot pedal control pedals.
– With the power switch on plug in the 110volt converter and
perform the following:
– Press the Right foot pedal (UP) and Raise the arms.
– Press the Left foot pedal (DOWN) and Lower the arms.

o Check the dolly and basket alignment:


– With the lifting arms in the full down position. Roll a dolly with two
baskets in between the lifting arms to the full rear position.
– The dolly and baskets will contact the two guide bars and the
lifting arms will close.
– The tabs on the lifting arms will insert themselves into gaps and
the handle of the basket.
– With the dolly and baskets inserted in between the lifting arms
check the dolly stop bolts for a slight gap of approximately 3/16”
between the dolly and the bolt head.
– With the lifting arms fully engaged around the baskets press the
right foot pedal and raise the baskets off the dolly until the red
guide arms are above the dolly.
– Push the dolly against the stop bolts.
– Lower the baskets back onto the dolly. The vertical guide arms
should not hit the back of the dolly when lowering. If the bottom
tip of the guide arms contacts the dolly the stop bolts may need to
be extended until the guide bars clear the dolly.
– Next check the stacking alignment with a full stack of baskets.
– Insert a full stack of baskets part way into the lift.
– Raise the arms until they are approximately mid-way of the full
stack.

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– Insert the stack of baskets into the lift until the arms fully engage
with the baskets.
– Lift the upper portion of the baskets from the lower half.
– Remove the lower half of baskets and reinsert the stack into the
lift. Lower the upper section back onto the lower stack of baskets.
The upper and lower stack should align and the lift arms will
disengage from the baskets. Adjusting the dolly stop bolts will fine
tune the basket alignment.

MAINTENANCE:

o Users shall perform daily inspections to ensure equipment is working


properly. (Appendix A)
o Preventative Maintenance checks need to be performed monthly to
ensure safe operation of the equipment. (Appendix B)
o Trouble Shooting StakCat issues can be found in (Appendix C)

Safety Devices:

o The V1 and V2 StakCat has a Safety Break that will assist in the
event the lifting cable breaks and the raised feature arms begin to fall.
o There are three (3) limit switches that stop the motor in the event:
o The lifting cable starts to de-spool from the winch assembly.
o The Upper travel limit is reached.
o The lower travel limit is reached.
o Batteries are a Lead Acid, Maintenance Free, Explosion Proof, Leak
Free type.

PROCEDURE:

General Operation:

o Prior to daily use perform a pre-use inspection of the StakCat by


using the inspection list in Appendix A.

o StakCat is a tool designed to up stack, down stack and assist in the


removal of broken baskets / dolly’s with minimal physical effort by the
operator.

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o The control switch is an up and down foot switch that is capable of
being placed on either side of the StakCat. To operate, depress the
right foot pedal to raise the lift arms. Depress the left foot pedal to
lower the lift arms.

o Lifting arms are designed to engage, or


disengage, when a stack of baskets is properly
inserted or removed from the StakCat.

o The StakCat is a mobile device which allows


the operator to position the unit close to the
work area.

o Unit should only be powered when an operator is present.

o A counter is attached to the unit for maintenance purposes. On the


V1 the counter is activated each time the Feature Arms reach the full
down position. The V2 counter is activated each time the “UP” pedal
is pressed.

Step 1: Lifting a Stack of Baskets and Removing the Dolly

o Orientate a stack of baskets so the handholds of the baskets are


facing left and right in comparison to the stacker.
o Approach the unit “squarely” pushing the dolly/stack straight into the
space between the outrigger arms firmly.
▪ It is advisable to put “toe” pressure on the dolly to ensure the
stack is fully inserted into the unit

o The basket support arms will close as the basket stack is pushed fully
into the lift device.

o The large tabs attached to each of the arms will fit into the handholds
on each side of the basket.

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o The smaller tabs fit into the basket cutouts to provide forward and
back stability.

o Visually check the basket support arms to ensure they are fully closed
onto the sides of the basket before engaging the lift. Use hand
pressure to hold the support arms in place to ensure the handles
completely seat in the basket handholds when the “Up” pedal is
pressed.

INCORRECT CORRECT

o Depress and hold the right foot pedal to raise the stack of baskets
approximately 6-10 inches off the dolly

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o With the stack of baskets suspended remove the dolly from beneath
the stack. Reuse this dolly for the next stack or neatly stack the dolly
away from the basket stacker.

Step 2: Up Stacking half stacks of Baskets

o Follow Step 1 to ensure a stack of baskets is properly inserted in the


StakCat and Dolly removed prior to performing Up-Stacking of half
stacks of baskets.

o Depress and hold the right foot pedal switch to raise the stack of
baskets until you reach the desired height so a second stack can be
inserted below.

o Ensure the baskets are properly orientated to meet either the high
stack (Bread Position) or the low stack (Bun Position) prior to pushing
the stack into the StakCat.

o Approach the unit “squarely” pushing the dolly/stack straight into the
space between the outrigger arms and into position beneath the
raised stack.

o Raise the first partial stack at least 1 inch


above the top of the stack to be inserted.
When the lower stack is inserted the top
basket will match up with the basket alignment
bars and ensure the baskets will nest properly
into each other.

o Visually check to ensure the alignment of the raised basket meets the
grooves of the baskets inserted below before lowering the lift.

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This shows

Proper Stack

Alignment

o Slowly depress the left foot pedal to lower the raised stack.
Depressing the left foot pedal in short increments
will help control the lowering of the stack.

➢ Safety Caution: Do not put your hands or


other body parts between the baskets when
lowering a raised stack onto a lower stack.

o After the stacks are securely settled into each other continue to jog
the left foot pedal until the lifting arms become disengaged from the
basket handles.
▪ If the lift arms stop lowering, simply press the “UP” foot pedal
until the arms begin to raise. Check the surrounding area for
any item that may be preventing the arms from lowering.
o Once lifting arms are free pull the stack of baskets out of the lift by
pulling the stack from between the outrigger legs.
▪ Grab the stack from the front center at chest height to easily remove it
from the unit.

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NOTE: THIS NEXT STEP IS CRITICAL

o After the stack is removed lower the lifting arms to the full down
position in order to accept the next stack.

Step 3: Down Stacking Baskets

o Orientate a stack of baskets so the handholds of the baskets are


facing left and right in comparison to the stacker.
o Adjust the lifting arms to the desired basket you wish to lift to split the
stack. Use the foot control pedal to raise or lower the lifting arms.
o Approach the unit “squarely” pushing the dolly/stack straight into the
space between the outrigger arms.
▪ You may have to JOG the lift by tapping the foot pedals
up or down to find the correct alignment.
▪ If this position is used frequently you can place a mark on
the lift framework to easily find the position next time.
▪ When approached “squarely” the basket support arms will
automatically close as the basket stack is pushed fully into the
lift.
▪ It is advisable to put “toe” pressure on the dolly to ensure
the stack is fully inserted into the unit
▪ Visually check the basket support arms to ensure they are fully
closed onto the sides of the basket before lifting.
▪ The large tabs attached to each of the arms will fit into the
handholds on each side of the basket.
▪ The smaller tabs fit into the basket cutouts to provide
forward and back stability.

➢ Caution: It is highly recommended to manually hold the arms


into position as you begin to raise the arms by pressing the
“UP” pedal. If using double dollies, it is also recommended to
use a person on each side of the lift to ensure the arms are fully
engaged prior to raising the lift arms.

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o Depress and hold the right foot pedal to raise the stack of baskets a
few inches off the stack.
o With the partial stack of baskets suspended remove the lower stack of
baskets from the lift.
o Lower the suspended baskets to 10 – 12 inches off the ground.
o Insert a new dolly into the lift by placing it on the ground in front of the
outrigger arms and pushing it in place against the dolly stop bolts.
▪ It is advisable to put “toe” pressure on the dolly to ensure the
dolly is fully inserted into the unit

➢ Caution: do not place your any part of your body beneath a


suspended stack of baskets.

o Depress and hold the left foot pedal to continue to lower the stack of
baskets on to the dolly.
▪ If the lift arms stop lowering, simply press the “UP” foot pedal
until the arms begin to raise. Check the surrounding area for
any item that may be preventing the arms from lowering.
o When the lifting arms are in the full down position the arms will
disengage with the basket stack and the motor will stop running.
o Once lifting arms are free pull the stack of baskets out of the lift by
pulling the stack from between the outrigger legs.
▪ Grab the stack from the front center at chest height or below to
easily remove it from the unit.

Step 4: Removing Baskets from a stack

o Orientate a stack of baskets so the handholds of the baskets are


facing left and right in comparison to the stacker.
o Adjust the lifting arms to the desired basket above the one(s) you wish
to remove by using the foot control pedal to raise or lower the lifting
arms.
▪ You may have to JOG the lift by tapping the foot pedals up or
down to find the correct alignment.
▪ If this position is used frequently you can place a mark on the
lift framework to easily find the position next time.

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o Approach the unit “squarely” pushing the dolly/stack straight into the
space between the outrigger arms.
▪ When approached “squarely” the basket support arms will close
as the basket stack is pushed fully into the lift device.

o Visually check the basket support arms to ensure they are fully closed
onto the sides of the basket before lifting. Use hand pressure to hold
the support arms in place to ensure the handles complete seat in the
basket handholds when the Up pedal is pressed.

INCORRECT CORRECT

▪ The large tabs attached to each of the arms will fit into the
handholds on each side of the basket.
▪ The smaller tabs fit into the basket cutouts to provide forward
and back stability. (See Picture above)

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o Depress and hold the right foot pedal to raise the partial stack of
baskets a few inches off the stack.
o Create enough clearance and remove the baskets you need to
remove.
o Pull the lower stack out an inch or two prior to lowering upper stack to
avoid contact with the stack alignment bars.
o Slowly depress the left foot pedal switch to lower the raised stack to
within 1 to 2 inches of the lower stack.
o Push the lower stack back into the unit until they make contact with
the alignment bars.
▪ It is advisable to put “toe” pressure on the dolly to ensure the
dolly is fully inserted into the unit
o Depress the left foot pedal in short increments to control the lowering
of the stack.

➢ Safety Caution: Do not put your hands or other body parts between
the baskets when lowering a raised stack onto a lower stack.

o After the stacks are securely settled into each other continue to jog
the left foot pedal until the lifting arms become disengaged from the
basket handles.
▪ If the lift arms stop lowering, simply press the “UP” foot pedal
until the arms begin to raise. Check the surrounding area for
any item that may be preventing the arms from lowering.
o Once the basket lifting arms are free pull the stack of baskets out of
the lift by pulling the stack out from between the outrigger legs.
▪ Grab the stack from the front center at chest height to easily
remove it from the unit.

Reposition lifting arms to the desired position in order to accept the next
stack.

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Appendix A

Operator pre-use Inspection

• Visually Check cable for fray


• Move the Arms in and out and check for smooth operation
• Ensure the Stabilizing crank and foot pad is down and in contact with
the floor. The rear foot pads under the outrigger legs should not be off
the ground when the Stabilizing Crank and foot pad is in the down
position.
• Ensure the 110-power cord is plugged in and the cable is out of the
way. If using 12volt power and not 110-volt inverter power ensure the
power cord is moved out of the way and secured to the lift to prevent
a tripping hazard.
• Power on the unit and check the following:
– Check the Upper Limit Switch: Raise the cradle and arms by pressing the UP
pedal. While the cradle/arm assembly is raising press and hold the upper
limit switch. The cradle should stop. Release the up selector pedal.
– Check the Lower Limit Switch; Lower the Cradle/Arm assembly by pressing
the down pedal. While the cradle/arm assembly is moving down press and
hold the lower limit switch. The cradle/arm assembly should stop. Release
the down selector pedal.
– Raise and lower the cradle and arm assembly by pressing and Up and Down
foot pedals to ensure the winch motor is operating smoothly.

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Appendix B

Maintenance PM Procedures

Version 1 StakCat Version 2 StakCat

• Check Upper Pulley for play and cable for fray or wear.
• Ensure the inside tracks of guide rails are lightly lubed.
• Visually Check Cradle guide bushings for wear.
• Swing the Arms in and out and check for smooth operation.
• V1 - Check the four foot pads under the left and right outriggers for condition.
– Check the Stabilizing crank and foot pad for condition.
• V2 – Check wheel lock pads for condition and proper operation.

• Remove the rear guard to expose the battery and inverter to check the following:
– 110v wall plug and cable for good condition
– Foot pedal power cable for good condition
– With the StakCat unplugged from wall power Check the 4 – 40 amp Fuses on the 110 volt
invert to ensure they have not failed.

• Power on the unit and check the following:


• Ensure the Battery is plugged in correctly.
– Check the battery by unplugging the lift from the 110v wall outlet power, turn the on / off
switch to the on position and press the up pedal. The cradle should raise. Press the down
pedal and lower the cradle to the full down position.
– Check the Inverter by unplugging the battery, plug the StakCat into 110volt wall power.
Press the Up Pedal to raise Cradle/Arm assembly, press the down Pedal to lower the
Cradle/Arm assembly.
• If the Inverter does not power the lift check the 4 – 40 amp fuses on the Inverter to
make sure they have not failed.
– Check the Upper Limit Switch: Raise the cradle and arms by pressing the UP pedal. While
the cradle/arm assembly is raising press and hold the upper limit switch. The cradle should
stop. Release the up selector pedal.
– Check the Lower Limit Switch; Lower the Cradle/Arm assembly by pressing the down pedal.
While the cradle/arm assembly is moving down press and hold the lower limit switch. The
cradle/arm assembly should stop. Release the down selector pedal.
– Check the De-spooling limit switch; with the cradle raised about waist high, hold the arms
to prevent the cradle from lowering. Press and hold the down pedal, the motor should
momentarily run and then shutoff.

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• Caution: after performing this check if you release the arm and cradle assembly before
pressing the up pedal the cradle/arm assembly may go down as it takes up the slack in
the cable. Make sure to press the up pedal until the cradle/arm assembly begins to
move up.
– Check the Anti-Fall brake; visually check to ensure the pads on the end of the Anti-Fall Brake
arms are in good condition.
– Ensure the winch motor is operating smoothly.
• Loud noise from the motor may indicate lack of grease.
• Heavy grinding noise may indicate the 8 tooth Pinion Gear may need to be replaced.
• Large amount of black powder residue may indicate brush wear.
– Add High Temperature/ High Lubricant Thermo-Plex Grease to the Winch Motor Gearbox
assembly, add 5 to 10 pumps of grease from a standard handheld grease gun, disconnect the
grease gun from the motor, press the up or down pedal and let the motor run a few
revolutions. Attach grease gun once again and add an additional 5 – 10 pumps of grease. Run
the motor a second time with the grease gun disconnected. The motor should run more
smoothly and with less noise. StakCats under heavy use, or under extreme heat conditions,
will require additional grease more frequently.

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(Appendix C)

TROUBLE SHOOTING:

Winch motor does not run -Make sure the On/Off switch is turned on
-Ensure the battery is fully charged and connected
-Ensure the 110v Inverter is plugged into an active 110v outlet.
-Check each of the 40 amp fuses on the top of the 110v invert to
ensure they have not failed.
-Remove rear guard and check the Anti-Spool limiter switch.
Make sure the limiter switch is not making contact with the spool
drum.
Check to ensure the limiter switch is tight and not moving in position

-Check the Automatic Reset Circuit Breaker. Connect a jumper wire


across the terminals of the Automatic Reset Circuit Breaker. Press
the Up or Down Foot Pedal control switch.
If the motor works; replace the Auto Reset Circuit Breaker

If the motor does not work or works intermittently check the


Reverse Contact Relay Switch:
Jump test of the motor:
-Disconnect the battery and 110V Inverter by unplugging the wall
plug to the inverter and disconnect the plug between the battery
and the power switch.
-Disconnect the wire leads from the winch motor terminals.
-Connect one end of a jumper cable to the negative side of the
battery and the other to one of the terminals of the Winch Motor.
-Connect a second jumper cable to the positive end of the battery.
-Touch the other end of the second jumper to the second post of the
Winch motor. The motor should engage and rotate the drum, swap
the jumper cables on the motor post and the drum should change
direction.

If the Motor turns when performing the jump test replace the
Reverse Contact Rely Switch.
If the Motor does not turn over the motor brush set is worn out and
needs to be replaced or replace the motor assembly.

Winch Motor makes a loud


noise.

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-If the Winch begins to make a louder than normal noise the general
cause is due to lack of grease in the gearbox assembly. Add high
temperature grease to the gearbox through the Grease fitting that is
inserted at the end of the winch gearbox shaft.
-If the Winch continues to make excessive noise after greasing the
pinion gear inside of the gearbox is worn and should be replaced.
How to replace the pinion gear:
- Remove the front and rear guard that covers the winch
motor assembly.
- Lower the fork back arms by pressing the down pedal on the
foot control switch, just prior to the arms reaching the full
down position grab onto the arms and stop them for going
full down. Continue to hold the down pedal of the foot
control switch and allow the cable to de-spool and trip the
anti-spool switch that lays across the cable spool.
- Unplug the battery quick disconnect and the 110 volt power
supply for the wall.
- Remove the anti-spool cable guard by removing two of the
screws from one side and pushing the remainder of the
bracket out from under the cable spool.
- Remove the two 9/16 mounting bolts that mount the winch
assembly to the StakCat cross-member.
- Once the Winch Motor Assembly is free rotate the assembly
90 degrees so the bottom of the mount bracket is exposed.
- Remove the two (2) T40 torque screws from the bottom of
the mounting plate.
- With the torque screws removed the motor/gearbox will
separate from the cable spool section of the assemble.
- Remove the plastic spacer that separates the cable spool
and the head of the pinion gear.
- Remove the transition gear assembly.
- The pinion gear is single 10 tooth gear that transfers drive
power from the motor to the transition gear assembly.
- Remove pinion gear by simply pulling on it.
- Remove the washer and place it on the new pinion gear.
- Add a small amount of high temperature grease to the shaft
of the pinion gear before inserting it back into the housing.
This will help lubricate the needle bearing in the gearbox
housing.
- Add high temperature grease to the gear teeth of the pinion
gear and the gearbox housing.
- Pack the transfer gear assembly with high temp grease and
reinstall assembly over pinion gear. Note: make sure the
plastic spacers are installed on both sides of the transfer
gear assembly before installing.
- When the transfer gear assembly is installed correctly the
pinion gear will be centered between the gears of the

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transfer assembly and slide into the teeth of the gearbox
housing.
- Install the spool spacer over the end of the pinion gear with
the raised portion of the spacer facing the pinion gear.
- Slide the cable spool with mount bracket back onto the
gearbox housing assembly.
- Install the two (2) T40 torque screws and tighten.
- Remount the winch motor assembly to the StakCat cross-
member frame with the 9/16 bolts with the head of the
bolts on top. Align the flat sides of the bolt head to allow
the slot of the anti-spool bracket to slide over.
- Install anti-spool bracket.
- Reconnect battery/110 power.
- Guide the cable from above the upper cross-member
bracket while pressing the UP pedal of the foot control
switch to re-spool the cable. Caution: do not hold the cable
directly above the winch spool to avoid getting your hand
caught between the cable and spool.
- Install anti-spool bracket.
- Use a grease gun and add additional approximately 10 to 20
pumps of additional grease to the gearbox through the
grease fitting at the end of the winch assembly shaft.
- Run a functional check to make sure the anti-spool limit
switch is working properly.
- Install both front and back guards.
Lift arms will rise when the Up
Foot Control is pressed, but not
lower when the Down Foot
Control Switch is pressed. -Anti Fall brake could be activated.
To disengage Anti Fall Brake press the UP foot control Pedal and
allow the Winch motor to spool the cable back around the spool. As
the cable tightens the anti-fall brake arms will retract and disengage
the brake.

-Check the Down Limit Switch for proper operation:


-Check the wire connection to the Down Limit Switch. Look for loose
wires leading into or out of the quick disconnect.
-Bypass down limit switch to check operational status of the switch:
Disconnect the power source cable connector to the down limit
switch. Insert a jumper wire between the two terminals of the
power source cable. Press the down foot control pedal: If the motor
lowers the control arms the Lower Limit Switch needs to be
replaced.

If the Motor does not lower:


-Reconnect the Power Source Cable to the Lower Limit Switch.
-Remove the Guard from the back of the lift.

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-Connect a jumper wire across the terminals of the auto-reset circuit
breaker.
-Press the Down Foot Pedal control.
If the Motor works – replace the auto-reset circuit breaker.

If the Motor does not work check the Down Foot Pedal Contact
switch:
-Remove the screws from the bottom of the foot pedal control unit
and remove the cover.
-Use a jumper wire to complete connection between the terminals
of the Down Foot Pedal control switch.
If the Motor begins to work the foot pedal contact switch needs to
be replaced.

If the Motor does not work check the Contact Relay Switch:
-Disconnect the battery connector plug.
-Run a jumper wire from the negative side of the battery to one of
the wire terminals of the Motor.
-Run a second jumper wire from the Positive side of the Battery
Terminal to opposite wire terminal of the Winch motor.
- If the Winch motor moves up rather than down, swap the wires on
the Winch terminals. If the Winch begins to lower the Contact Relay
Switch is not work and needs to be replaced.

Lift arms will lower when the


Down Foot Control Switch is -Check the up Limit Switch for proper operation: Make sure the
pressed, but not raise when the plunger pin on the switch moves in and out freely when the contact
Up Foot Control is pressed. arm is engaged.
-Check the wire connection to the Up Limit Switch. Look for loose
wires leading into or out of the quick disconnect.
-Bypass Up limit switch to check operational status of the switch:
Disconnect the power source cable connector to the Up limit switch.
Insert a jumper wire between the two terminals of the power source
cable. Press the Up foot control pedal. If the motor raises the
control arms the upper Limit Switch needs to be replaced.

If the Motor does not lower:


-Reconnect the Power Source Cable to the Upper Limit Switch.
-Remove the Guard from the back of the lift.
-Connect a jumper wire across the terminals of the Automatic Reset
circuit breaker.
-Press the Up Foot Pedal control.
If the Motor works – replace the Automatic Reset circuit breaker.

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If the Motor does not work check the Up Foot Pedal Contact switch:
-Remove the screws from the bottom of the foot pedal control unit
and remove the cover.
-Use a jumper wire to complete connection between the terminals
of the Up Foot Pedal control switch.
If the Motor begins to work the foot pedal contact switch needs to
be replaced.

If the Motor does not work check the Contact Relay Switch:
-Disconnect the battery connector plug.
-Run a jumper wire from the negative side of the battery to one of
the wire terminals of the Motor.
-Run a second jumper wire from the Positive side of the Battery
Terminal to opposite wire terminal of the Winch motor.
- If the Winch motor moves down rather than up, swap the wires on
the Winch terminals. If the Winch begins to raise the Contact Relay
Switch is not work and needs to be replaced.

Winch Motor does not always


activate when the Foot Pedal
Control pedal is pressed. Check the Reverse Contact Relay Switch for proper operation:
Jump test of the motor:
-Disconnect the battery and 110V Inverter by unplugging the
connect plug between the battery and the power switch and
disconnecting the wall plug from any outlet.
-Disconnect the wires from the end of the Winch motor.
-Connect one end of a jumper cable to the negative side of the
battery and the other to one of the terminals of the Winch Motor.
-Connect a second jumper cable to the positive end of the battery.
-Touch the other end of the second jumper to the second post of the
Winch motor.
If the Motor runs normally when performing the jump test replace
the Contact Rely Switch.

If the Motor does not turn over the motor is defective, replace the
motor.

Battery will not charge.


- Unplug battery and try to run the StakCat on 110v Inverter power
only. If lift does not work check the 4 – 40 amp fuses on top of the
inverter. If fuses are in good order;

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- Check the voltage coming out of the inverter. Voltage should show
approximately 14.5 volts. If no reading or low reading the inverter is
bad and needs to be replaced.

Inverter works correctly:


-Visually check the battery for bulging.
-Check voltage of battery to ensure cells are producing correct
voltage 13.5 to 14volts. If low voltage then replace the battery.
How to replace the Winch
Motor without the Cable and
Cable Drum assembly. -Unplug power cable.
-Remove rear guard from lift.
-Disconnect Connector between Battery and Power Cable.
-Remove the two terminal nuts and electrical connections from the
Winch motor.
-Remove the two attachment bolts that go through the back of the
motor housing to the cable drum.
-Separate the motor assembly from the cable drum by gently pulling
on the motor casing.
-Be sure to retain the metal and fiber washer that is located on the
end of the motor shaft that goes into the Cable Drum.

-Install the washers on the shaft end of the new motor. Make sure
the washers are placed in the proper order during reassembly.
-To install new motor follow the steps above in the reverse order.

Replace the Winch, Cable and


Drum assembly Removal:
-Unplug power cable.
-Remove rear guard from lift.
-Disconnect Connector between Battery and Power Cable.
-Remove the two terminal nuts and electrical connections from the
Winch motor.
-Disconnect the Cable from the Anti-Fall Brake by removing the
cotter Pin and sliding the washers and cable from the mounting pin.
-Remove the Cable Pulley at the top of the lift by removing the
Cotter Pin and sliding the Pulley Axle Pin from the mount bracket
and pulley.
-Remove the two Winch Motor/ Cable Drum mount bolts located
beneath the motor mount brace and above the 110v Inverter.
-Pull the cable and Winch motor/ cable drum assembly from the lift.

Installation:

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-The new Winch motor should come with a new cable and drum
assemble already assembled.
-Place the new Winch motor assembly on the mounting bracket just
above the 110v invert.
-Install the two mounting bolts from underneath the Winch motor
mounting plate.
-Thread the lifting cable through hole above the cable drum to the
top of the lift and over the guard and out to the front of the lift.
-Place the cable over the pulley and insert the pulley into the upper
mounting bracket.
-Insert the pulley axle pin through the mounting bracket and pulley.
-Place washer over the exposed end of the pulley axle pin and insert
cotter pin.
-Attach cable end to Anti Fall brake assembly, install washer and
cotter pin.
-Check the Anti-Spool limit switch arm for a small amount of
clearance between the arm and the cable drum.
-Attach wire connectors to the Winch motor.
-Reconnect power cables from battery.
-Before installing guard test the Winch motor assembly:
-Turn on power switch.
-Pull excess cable through the pulley toward the front of the lift.
-Press and release the “UP” Foot Control Pedal and see if the Winch
motor runs in the right direction. If the motor is running in the
wrong direction simply reverse the wires attached to the Winch
motor.
-If the Winch motor is running in the right direction. Continue to
press down on the “UP” Foot Control Pedal and wined the excess
cable onto the cable drum.
-Continue to raise the Arm Assembly to the top. Ensure the Cable
spools smoothly on the drum collar and does not make contact with
the two guide bracket mounted on either side of the drum spool.
-Press the “Up” Foot Control Pedal and raise the Arm Assembly to
ensure the upper limit switch is adjusted and working properly.
-Check the anti-spooling limit switch: press the Down Foot Control
pedal and hold the Arm Assembly to prevent it from lowering.
-The Cable will loosen around the drum and trip the anti-spool limit
switch within a few seconds. Adjust the limit switch as needed to
prevent the cable from becoming too loose around the cable drum.
-With the cable loose the anti-fall brake will engage. To disengage
the brake press the Up Foot Control Pedal until the cable tightens up
and disengages the brake mechanism.

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-Continue lowering the Arm Assembly down and check the lower
limit switch.
-In the full down position, the Arm Assembly should be resting
lightly on the bottom stop and making contact with the lower limit
switch enough to shut the motor off.
-Install the Rear-Guard plate.

Replace Winch Cable Removal:


-Lower the Arm Assembly to the full down position.
-Unplug power cable.
-Remove rear guard from lift.
-Disconnect Connector between Battery and Power Cable.
-Disconnect the Cable from the Anti-Fall Brake by removing the
cotter Pin and sliding the washers and cable from the mounting pin.
-Remove the attachment bolt that mounts the cable end to the
Cable Drum.
-Disconnect the cable from the spool drum.
-Pull the cable by the looped end through the pulley guide bracket.

-Remove the Cable.

To Install the new Cable, follow the instructions above in the reverse
order.

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(Appendix D)
#1575 Electric Winch Retro-Fit Kit, for V1 and V2 StakCat CHANGEOUT

Old style X2 Superwinch

#1575 Electric Winch Retro-Fit Kit

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Version 1 Version 2

This guide will provide you with the necessary steps to remove the Super Winch
X1/X2 style assemblies from the Version 1 and Version 2 StakCats and install the
new electric winch assembly. There are many upgrades and modifications made
to the new assembly that will help to increase performance, reliability and reduce
overall decibel noise level.

New Components included with the kit are:

- Winch Assembly with new cooling fan, heat sink, thermal switch and
anti-spool contact switch mount
- Winch Cable
- De-spooler guide
- Wire connectors for the Winch Motor power leads
- New Replacement Wire for Winch Motor
- New wire for thermal switch to master switch

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- New wire for cooling fan to reverse contact switch
- Winch Mount Bolts

Tools Required to perform this task will include:

- #2 Phillips Screwdriver or Drill with #2 bit


- #2 Flat Tip Screwdriver
- 7/32 Allen Wrench
- 5 mm Allen Wrench
- 5/16 Open/Box end Wrench
- ½” Open/Box end Wrench
- 9/16 Open/Box end Wrench
- 9/16 Socket (3/8” Drive deep well preferred)
- Ratchet ¼” and 3/8” drive
- ¼” and 3/8” extension
- 1/8” Allen Wrench (Long Allen type with handle preferred)
- 7/16” x ¼” Deep well Socket
- 7/16” Nut Driver
- 3/8” Nut Driver
- 10 MM Open End wrench
- 10 MM deep well socket, ¼” drive
- Wire cutters
- Wire Crimpers
- Needle Nose Pliers

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Removal of the X1/X2 Winch Assembly:

Step 1: Place the StakCat in well illuminated work


area and secure the lift to prevent it from moving
while performing this task.

Step 2: Remove the front and back guards from the


StakCat.

Step 3: Raise the Lifting arms high enough to be


able to remove the Cotter Key from the Lift Cable
Attachment point but not high enough that it will
be in the way when removing the winch motor.

Version 2 StackCat

Version 1 StakCat

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Step 4: Place an object under the lifting arms to
prevent the lifting arms from going down when the
down pedal is pressed.

Caution: In the next steps use caution and keep


your hands and other materials away from the
Winch Speed Spool. Items or hands could get
caught in between the cable and the speed spool
which will cause severe injury. Recommend the
use of leather gloves to prevent the possibility of
cuts from frayed wire on the lifting cable.

Step 5: Press the down pedal to allow the lifting


arms to rest on the vise grips or the object placed
under the lifting arms and allow the cable to de-
spool. Keep a small amount of tension on the cable
by pulling on the cable as it de-spools.

Step 6: De-spool the cable completely off the


Winch Speed Spool. Stop de-spooling when the
lifting cable retaining bolt is accessible.

Step 7: Disconnect the Battery and unplug the 110v


Convert from wall outlet.

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Step 8: Disconnect the Power Leads from the
Winch Motor.

Step 9: Remove the Cotter Key from the Lifting


Cable/ Emergency Brake Retaining Pin.

Step 10: Remove the Lifting Cable/ Emergency


Brake Retaining Pin and disconnect the cable end
from the brake.

Step 11: Remove the Allen Head Retaining Bolt


from the Winch Spool Drum.

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Step 12: Disconnect the lifting cable from the
Winch Drum and remove the lifting cable from the
StakCat.

Step 13: Use a Phillips #2 Screw Driver or Electric


Drill with #2 bit to remove the cable de-spooler
guide from the winch assembly.

Version 2

Step 14: Use the 9/16” Wrench and Socket to


remove the 2 Mount bolts that holds the Winch
Assembly to the StakCat crossmember shelf.

Step 15: Remove the Old Winch Assembly and


clean the StakCat crossmember shelf from old
grease and dirt in preparation of installing new
winch assembly.

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Page | 37 revised 7-2021 Escalera, Inc – 530-673-6318
Installing the new Winch Assembly:

Step 1: There are minor differences when installing the new Winch assembly to a
Version 1 and Version 2 StakCat. Although they are minor in nature ensure to
follow the proper steps for the specific lift type you are working on.

Version 1 Version 2

Step 2: Version 1 - Replace the wire


terminal leads with the larger loop
connectors on each of the power supply
electrical wires that will connect to the
winch motor.

Version 1

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Version 2 – Use the Black Wire that is
provided to replace the power supply wire
that runs from the top right terminal (see
arrow) of the reverse contact switch to the
winch motor top terminal (Red); replace
the terminal lead of the second wire with
the larger loop connector that connects to
the winch motor bottom terminal.

Version 2

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Step 3: Version 1 and Version 2– Connect
the new Red Cooling Fan wire to the
Reverse Contact Switch terminal where the
battery/converter wires attach.

Step 4: Version 1 and Version 2- Connect


the new Black wire from the thermal switch
to the left terminal of the Master Switch.

Step 5: Version 1 only – Remove the black


rubber pad from the winch assembly
mounting shelf. The newly installed red and
black wire will run under this rubber pad
once the winch is installed. Some Version 1
lifts do not have the rubber pad, in this type
the wire will run under the shelf through a
hole in the shelf plate.
Version 2 – run the new black and
red wire through the access hole in the
winch mounting shelf.

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Step 6: Disconnect the De-Spooler contact
switch from the mount bracket and discard
the bracket. Save the screws and nuts so
they can be used to remount the contact
switch to the new winch assembly.

Note: Version 1 mount brackets are


welded in place and must be cut away or
broken off using vice grips or some other
tool to slowly bend the bracket back and
forth until the weld breaks.

Step 7: Version 1 only – Remove the power


cable from the De-Spooler contact switch to
the 12v junction box and install the new 16
x 2 power cable provided.

Remove the rear plate of the switch to


expose the wire connectors.

Disconnect the wires and remove the old


wire from the switch body.

Install the new wire into the switch.

Thread the new wire through the Winch


Assembly mounting deck and replace the

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remaining section of old wire with the new
one. The old harness was a 2 piece
assembly. Replace both sections with the
new one-piece wire harness from the De-
Spooler Contact Switch. Connect the wires
to the 12v junction box in the same manner
as the ones removed.

Step 8: Place the new Winch Assembly


onto the Crossmember shelf of the StakCat.

Step 9: Connect the electrical leads to the


Winch Motor Terminals.
Note: Before securing the power leads to
the terminal it is a good practice to test the
motor to ensure the wires are connected
properly. With the power leads loosely
connected to the winch motor, reconnect
the battery and quickly press the up or
down pedal to note the direction the winch
drum rotates. If the winch drums rotate in
the wrong direction, then simply swap the
power supply wires to the opposite
terminal and test again. Once complete
disconnect the battery.

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Step 10: Align the Winch Assembly with the
mounting bolt holes in the StakCat
crossmember shelf.

Step 11: Insert the two 3/8” bolts with flat


washer into the holes.

Step 12: Attach Flat Washer, Lock Washer


and 3/8” nut to mount bolts from the
bottom of the crossmember shelf.

Note: When tightening the bolts ensure


the bolt head stays directionally aligned
with the frame of the winch assembly. This
will allow the cable guide to slide smoothly
over top of the bolts heads when installed.

Step 13: Use the 9/16” Open/Box end


wrench to hold the bolt head and tighten
the nuts using the ratchet and 9/16”
Socket.

Step 14: Connect the newly installed black


wire coming from the left terminal of the
Master Switch to the Thermal Switch
mounted on the Winch Assembly casing.

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Step 15: Connect the newly installed Red
Wire from the Reverse Contact Switch to
the Winch Motor Cooling Fan red lead.

Step 16: Insert the 1/8” Allen Head wrench


into the small hole on top of the Speed
Collar and insert it into the Allen Head set
screw. You will not be able to see the set
screw so this will be completed by feel.

Step 17: Connect the new lifting cable to


the lifting arm assembly. Install the
retaining pin through one of the emergency
brake arms, through the eyelet of the cable
and then through the second emergency
brake arm.

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Step 18: Thread the new lifting cable
through the pulley at the top of the lift and
down through the openings in the StakCat
Crossmember shelves to the Winch
Assembly.

Step 19: Insert the end of the cable into


the Winch Assembly Drum and Speed Spool
until the Red section of the cable is fully
inserted. If the cable does not fully inset
into the Speed Spool you may need to
unscrew the set screw with the 1/8” Allen
wrench until the cable fully inserts.

Fully inserted cable

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Step 20: Tighten the Set Screw with the
1/8” Allen Wrench.

Step 21: Tighten the four bolts that hold


the Speed Collar in place. Use a Crisscross
pattern to tighten the bolts, this will ensure
a uniform fit of the Speed Collar. The 7/16”
x 1/4” Drive Deep Well and the 7/16” nut
driver work best to accomplish this task.

Note: Connect the battery and rotate the


drum to access all bolts by pressing the Up
Pedal. Do not fully spool the cable around
the drum or you will not be able to tighten
the bolts of the Speed Collar.

Step 22: Install the De-Spooler Cable


Guide. The slot in the cable guide faces
down and rides over the top of the mount
bolt heads. The slot is offset to one side of
the block. Make sure the Wide section of
the block is on the same side as where the
cable inserts into the Winch Drum.

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Step 23: Once the Cable Guide is installed
the Cable can be wound around the Winch
Drum and Speed Collar. Using leather
gloves, old onto the lifting cable with light
pressure and align the cable with the
groove in the Speed Collar. Press the UP
Pedal and allow the cable to feed onto the
Speed Collar.

Caution: Keep your Hands and other


objects clear of the Speed Collar while
spooling up cable. Severe Injury can occur
if hands or other objects become entangled
with the cable and spool.

Step 24: Install De-Spool Limit Switch to


the mount plate on the Winch Assembly.
The Limit Switch will lay on its side and the
spring arm will lay over the top of the Drum
and Speed Spool above the flapper plate.
Use the two original screws and nuts to
install the switch.

Step 25: With the guards removed, run the


lift up and down for several minutes to
make sure everything is running correctly.
As the motor heats up the cooling fan will
turn on automatically. Once the fan turns
on, turn off the master switch and the fan
should continue to run. If the Winch
Mounted Cooling fan turns off when the
master switch is turned off the new Black
Wire for the thermal switch is mounted to
the wrong terminal of the master switch.

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Simple move it to the opposite terminal and
the fan should start running with the
master switch in the off position once the
winch motor become warm. The fan should
continue to run until the winch motor
cools.

Step 26: Use wire ties to bundle any loose


hanging wires to ensure they do not
become accidentally entangled with other
components.

Step 26: Re-Install Guards

Page | 48 revised 7-2021 Escalera, Inc – 530-673-6318


#1575 Electric Winch Retro-Fit Kit Component List:
ITEM No. Description

1575 Winch Assembly Complete Retro-


fit Kit - StakCat V1, V2

9826 Winch Assembly with Thermal


Switch

9537 Cable, StakCat

1572 Wire Assy, Thermal Switch - Fan

1570 Wire Assy, Thermal Switch –


Master Switch (hot)

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1571 Wire Assy, Fan – Reversing
Contactor

9561 80mm Fan Guard

9560 Electric Fan, 12v, 80mm

9727 Machine Screw #8-32 1 ½ , Phillips,


pan Head
0526 Flat Washer, #6
0246 Nylon Insert Lock Nut, #8-32

8900 Spool Spacer Speed Collar Kit,


StakCat

8871 Bracket, Fan, Winch Motor

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8872 Bracket, Limit Switch, De-Spooler
(Retro)

1573 Heat Sink, 4” for Winch Motor

0553 (2x) Hex Bolt, 3/8" -16 x 1-1/4"


0294 (4x) Flat Washer, 3/8" USS
0554 (2x) Washer, Split Lock, 3/8"
0558 (2x) Hex Nut, 3/8"-16UNC

0450 Cotter Pin, 1/8" x 1", Zinc

0542 (2x) Terminal, 12-10 AWG, 1/4"


Ring

8726 De-Spooler Kit

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9456 Wire Segment, 16/2 AWG, Main
Spool Limit Switch

1569 Wire Assy, Winch Motor -


Reversing Contactor

518 Wire Ties

8917 Despooler Trigger Plate

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Appendix E

ELECTRICAL COMPONENTS:

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Electrical Diagram

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Page | 57 revised 7-2021 Escalera, Inc – 530-673-6318
Appendix F

Common Replacement Parts List


Contact Escalera Directly via Email or Phone to order parts:

o Escalera, Inc. PO Box 1359, Yuba City, CA 95992


o Office (530)-673-6318 or 800-622-1359
o Fax 530-673-6376 ; email : (info@escalera.com)

Model 1512 - Version 1 StakCat


Model 1519 - Version 2 StakCat

PART # StakCat MODEL NOMENCLATURE NOTE:


1575 1512 & 1519 Electric Winch Retro Fit Kit, StakCat V1, V2
9826 1512 & 1519 Electric Winch Assembly with Thermal Switch,
Trigger Plate
0364 1512 & 1519 Motor, Electric Winch Compatible with
winch model: 9826
(retro-fit)
9537 1512 & 1519 Cable, StakCat: Comes preassembled with cable
loop.
8951 1512 & 1519 Assembly, Fork Arm
call 1512 & 1519 Basket Arm Bracket – Left and Right Contact Escalera for
compatible part
number
call 1512 & 1519 Feature Plate, Basket – Left and Right Contact Escalera for
compatible part
number
8726 1512 & 1519 De-Spooler Kit
8900 1512 & 1519 Assembly, Spool Spacer Speed Collar Compatible with
winch model: 9826
(retro-fit)
9415 1512 & 1519 Circuit Breaker, 10 amp auto reset
9416 1512& 1519 Converter, 110 VAC - 12 VDC 120 amp: Includes 4 -
40 amp blade style fuses
9424 1512 & 1519 Foot Pedal, Double Heavy Duty

1563 1512 & 1519 Cable Connector, Strain Relief, StakCat Pedal

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9426 1512 Counter, Mechanical
9428 1512 & 1519 Switch, Battery Master
9449 1512 & 1519 Pulley, 3" Steel with Bearings: Comes with Cotter
Pin
9666 1512 Fan Retro Kit includes Fan and Mount Bracket for
Version 1 StakCat
9490 1512 & 1519 Electric Fan With Connectors
9561 1512 & 1519 Guard, Electric Fan 80mm
8871 1512 & 1519 Fan Mount Universal Bracket
9494 1519 Counter, Electric
9536 1512 & 1519 Battery, StakCat: 12 Volt, Maintenance Free, Acid,
Explosion Proof
9538 1512 & 1519 Reversing Contactor Kit: Comes with electrical
connector ends, black jump wire, mounting
bolts/nuts/washers and spacers.
9539 1512 & 1519 Brake Pad Kit, Bimbo: Kit Contains Rubber pads and
replacement nuts/bolts
9556 1512 & 1519 Limit Switch Kit, Roller
9557 1512 & 1519 Limit Switch Kit, Coil Spring Wobble
9558 1512 Limit Switch Kit, Plunger
9594 1512 & 1519 Grease, Thermo-Plex #2
9699 1519 Caster, 360 degree Total Locking
9680 1519 Front Wheel Brake Kit
9535 1512 & 1519 UHMW Guide Strip with Hardware: Attaches to the
guides on the outrigger legs to align the dolly into
position between the out-rigger
1514 1512 Big Wheel Attachment

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