2K STAK SYSTEM Installation & Operation Manual

2K STAK SYSTEM Installation & Operation Manual PG08-7-200-038-12 Rev C 6/30/11 PCR 110511-001

The STAK System is: Foreword A sturdy, captive mast with a fork lifting/handling mechanism for up to 2,000 pounds or 1,000 kg. Space-optimizing modular racking that accepts/stores pallets on tight 3-7/8 or 98 mm increments. Removable, positive-fork entry pallets with optional add-on features and capacity of 2,000 pounds or 1,000 kg uniformly distributed static load. Together, the STAK System components provide a preengineered, integrated storage/retrieval system that reduces labor time, frees up forklift trucks, and safely stores valuable tools, parts, and other bulky items off the floor. This manual provides important information necessary for the proper installation, operation, and maintenance of your Stanley Storage Systems STAK System. Carefully study the entire contents of the manual and the prints before attempting to install the STAK System. PAY CLOSE ATTENTION TO THE INSTRUCTIONS GIVEN IN THE TEXT. ONLY CAREFUL AND EXACT ASSEMBLY WILL RESULT IN A PROPERLY FUNCTIONING SYSTEM. A copy of this manual is included with every Stanley Storage Systems STAK System. Please record the information below as soon as you receive the STAK System. After assembly of the STAK System, carefully file this manual for future reference. STAK System Serial Number: Number of Bays: Hoist Serial Number: Pallet Size : Electrical Specifications : Installation Date:

Contents Section Page A. Storage Rack Assembly 2 A.1. Site Preparation 2 A.2. Section Erection 5 A.3. Bay Spacer Installation 11 A.4. Cantilever Overhang Installation 12 A.5. Preliminary Leveling Operation 15 A.6. Anchoring 16 A.7. Final Leveling 18 B. Rail Assembly 19 C. Conductor Installation 20 C.1. Conductor Installation 20 C.2. SAF-T-BAR Conductor Assembly 21 D. Bridge & Trolley Installation 22 E. Mast Installation 23 F. Hoist Installation 24 G. Canopy & Trolley Stop Installation 25 H. Window Installation 25 J. Fork Installation 26 K. Electrification 27 L. Free-Fall Prevention Device 28 M. Lubrication & Maintenance 29 N. Operation 30 O. Trouble Shooting 31 P. Pallet Assemblies 32 R. Additional Instructions 33 R.1. Column Sleeves 33 R.2. Column Indicator Strips 33 Illustrations Figure A-1 Overall STAK System View 3 A-2 Chalk Markings 4 A-3 Starter Section Erection 5 A-4 Top Frame Assembly 6 A-5 Individual Column Erection 7 A-6 Top View 8 A-7 Bar Spacer & Vertical Guard 9 A-8 Brace Configurations 10 A-9 Bay Spacer Installation 11 A-10 Cantilever Overhang Installation 13, 14 A-11 Preliminary Leveling Operation 15 A-12 Anchoring Hardware 16 A-13 Anchoring Layout 17 A-14 Shimming 18 B-1 Rail Assembly 19 C-1 Conductor Installation 20 C-2 SAF-T-BAR Conductor Assembly 21 D-1 Bridge & Trolley 22 E-1 Mast 23 E-2 Mast Assembly Raising 23 F-1 Hoist Installation 24 G-1 Canopy & Trolley Stop Installation 25 J-1 Fork Installation 26 K-1 Collector Pivot 27 L-1 Free-Fall Prevention Device 28 P-1 Pallet Tub Assembly 32 R-1 Column Sleeve Installation 33 R-2 Column Indicator Strip Installation 33 1 Section A

Storage Rack Assembly A. Storage Rack Assembly A.1. Site Preparation 1. Prior to Delivery The site preparation should be done prior to delivery of the STAK System. The area in which the STAK System will be erected must be clear and free of obstructions. Check to make certain overhead clearance is sufficient to provide the overall height of the STAK System (Dimension F in Figure A-1) and allow at least 6 or 152 mm additional vertical for maintenance. The highest elevation point and the lowest elevation point on the floor where the STAK System will be erected must be determined. This may be done using a transit or a dumpy level and a measuring rod. The difference between the highest and lowest elevation will determine the thickness of shimming material required to level the STAK System. A nominal amount of shims are included. If additional shims are needed, this information should be transmitted to the Stanley Storage Systems STAK Sales Engineer. Also, if height difference is greater than 1 1/4 or 32 mm, it will be necessary to obtain anchor bolts longer than those normally supplied. IMPORTANT: FOLLOW RECOMMENDED UNLOADING PROCEDURES INCLUDED WITH YOUR STAK SYSTEM DELIVERY 2. At Delivery Before assembling your STAK System, unpack the entire system. Separate the Storage Rack components (pictured in Figures A-3 through A-14) and the Stacking System components (usually painted safety yellow and pictured in Figures D-1 through L-1). Inspect all components to familiarize yourself with the system. Should any parts be missing, notify Stanley Storage Systems, Inc., Allentown, PA 18103 immediately. Should any parts be damaged, notify the freight carrier immediately. When referring to your STAK System, always use the serial number located directly beneath the handle support on the Mast Assembly. CAUTION: DO NOT DROP MAST ASSEMBLY ON BEARING PLATE EDGE. HANDLE ALL COMPONENTS WITH CARE. 2 Section A

Storage Rack Assembly NOTES: 1. Floor length of the STAK System is determined by multiplying the G dimension (pallet width plus 5 or 127 mm) by the number of bays and adding 8 or 203 mm to the total. EXAMPLE: 10 Bay 52 X 42 STAK System 10 Bay 132.1 X 106.7 STAK System Floor Length = 10 X 57 + 8 Floor Length = 10 X 144.8 + 20.3 = 578 or 48-2 = 14.68 m 2. Rack height and overall height are prior to leveling (does not include shims). 3. Rail length equals the number of bays times the G dimension (pallet width plus 5 or 127 mm) plus the appropriate T- Rail overhang dimension from the chart in Section B on Page 19. EXAMPLE: 10 Bay 52 X 42 STAK System 10 Bay 132.1 X 106.7 STAK System with (1) 4 Cantilever with (1) 1.22 m Cantilever Rail Length = 10 X 57 + 53 1/2 + 4 Rail Length = 10 X 144.8 + 135.9 + 10.2 = 627 1/2 or 52-3 1/2 = 15.94 m 4. Standard STAK overall length equals Rail Length (see Note 3) plus 4 or 102 mm (2 or 51 mm for each rail stop). 5. Motorized bridge STAK overall length equals Rail Length (see Note 3). 6. Dimensions shown are for 7 Bay standard height STAK System. 3

Section A Storage Rack Assembly 3. After Delivery The outside floor perimeter of the STAK System (Dimensions A and B from Figure A-1) and the inside edge of the aisle column base-to-column base (Dimension C from Figure A-1) must be marked on the floor along with equal spaced cross marks along the Aisle Chalk Line to show the location of each front column. This work may by done with a chalk line or marking pen, and tape rule. Figure A-2 shows chalk lines and where front columns will be located. The first cross mark (1st Column Centerline) is located 4 or 102 mm from the Floor Length perimeter line. The second cross mark (2nd Column Centerline) is located from the first cross mark at G distance (from Figure A-1). To prevent column centerline tolerance build-up, always start measuring from the first cross mark (1st Column Centerline). Example: When locating the 3rd Column Centerline, multiply G (from Figure A-1) by 2 and measure from the 1st Column Centerline. For the 4th column, multiply G by 3 and measure from the 1st Column Centerline. For the 5th column, multiply G by 4... Etc. Figure A-2 4 Section A

Storage Rack Assembly A.2. Section Erection 1. Starter Section Erection NOTE: If optional column indicator strips are needed, installation may be easier while columns are laying on the floor (see Section R2). 1. Lay one Vertical Column in a horizontal position on the floor as shown in Figure A-3. Position the Vertical Column so that it rests on the rear column (wider column), with the base plates on the bottom end adjacent to their final position. If there is insufficient room to lay the assembly as shown, lay the Vertical Column in another direction and rotate it to a proper orientation after the assembly is raised to the vertical position. 2. Place a second Vertical Column in the same relative position- parallel to the first Vertical Column and parallel to the direction in which the assembly will progress as shown in Figure A-3. Figure A-3 5 Section A

Storage Rack Assembly 3. Position the Top Frame between the top ends of the two Vertical Columns. The narrow width of the Top Frame goes between the two wide rear columns that are resting on the floor (see Figure A-3). 4. Connect the Top Frame to the Vertical Column as shown in Figures A-4 and A-6. The top frame rear member attachment tab goes outside the rear column flange whereas the top frame front member goes inside the front column flange. Use the hardware as indicated in Figure A-4 at the four corners of each Top Frame and tighten securely. 5. Raise the entire section assembly into a vertical position as shown in Figure A-3 and place in its approximate final position. Figure A-4 6 Section A

Storage Rack Assembly 2. Additional Section Erection 1. Place the third Vertical Column horizontally on its side on the floor, with the base plates resting adjacent to their final position as shown in Figure A-5. 2. Attach a Front Spacer to the top of the Vertical Columns as shown in Figure A-5. The Front Spacer attachment tab goes inside the front column flange as shown in Figure A-6. Use hardware as shown in Figure A-4 at each end of the Front Spacer. 3. Raise this assembly into position next to the previously raised Vertical Columns as shown in Figure A-5. 4. Attach the Front Spacer to the top of the previously raised Vertical Column per the instructions in Step A2.2.2 above. Figure A-5 7 Section A Storage Rack Assembly

Figure A-6 5. Repeat steps A2.2.1 through A2.2.4 until all Vertical Columns (except the last Vertical Column) have been raised and placed in their approximate positions as shown by the markings on the floor (from Section A1.3). 6. Attach a Top Frame to the last Vertical Column as shown in Figures A-4 and A-6. Use the hardware as shown in Figure A-4. 7. Raise this last assembly into position. 8. Attach the Top Frame to the top of the previously raised Vertical Column. Use the hardware as shown in Figure A-4. IMPORTANT: Make sure the four corner sections of the STAK System have Top Frames installed. 8 Section A Storage Rack Assembly

Figure A-7 3. Bar Spacer and Vertical Guard Erection 1. When the entire row of Vertical Columns is erected, attach the Bar Spacers to the bottom, middle, and top of the rear columns as shown in Figure A-7. Use hardware as shown in Figure A-7. DO NOT TIGHTEN AT THIS TIME. 2. Attach one Vertical Guard to the middle rear of each section, making attachment to the Bar Spacers with the same hardware as shown in Figure A-7. DO NOT TIGHTEN AT THIS TIME. 9 Section A Storage Rack Assembly

4. Cross Brace Configuration NOTICE: The Cross Brace configurations are different based on the pallet widths of the STAK System (26 1/2 X 30, 36 X 30, Etc.). Follow the appropriate drawing in Figure A-8. 1. Attach one Cross Brace to the center slot at the top position adjacent to the top Bar Spacer on the end Vertical Column where shown in Figure A-8. Project the brace downward at a 45 degree angle so that it intersects the center slot in the next-in-line Vertical Column*. Use hardware as listed in Figure A-8. DO NOT TIGHTEN AT THIS TIME. 2. Attach one or two Cross Braces to the center slot at the bottom position adjacent to the bottom Bar Spacer on the Vertical Column(s) where shown in Figure A-8. Project the brace(s) upward at a 45 degree angle so that it(they) intersect(s) the center slot in the next-in-line Vertical Column*. DO NOT TIGHTEN AT THIS TIME. 3. For intermediate Cross Braces which do not begin at either the top or bottom of a Vertical Column, locate by approximately centering between Cross Braces above and below* (as shown in Figure A-8, 16 /5m height and 26-1/2 /673mm or 36 /914mm wide). DO NOT TIGHTEN AT THIS TIME. 4. Repeat steps A2.4.1-3 for each of the four ends of the STAK System. * If any interference is encountered with other parts or hardware when making connections, shift crossbracing left or right one slot as needed until attachment may be made. Figure A-8 10 Section A Storage Rack Assembly

A.3. Bay Spacer Installation 1. Connect the front columns at both ends of the STAK System by installing the Bay Spacers to the second hole at both ends as shown in Figure A-9. DO NOT TIGHTEN AT THIS TIME. Figure A-9 11 Section A Storage Rack Assembly

A.4. 48 (1.22 m) Cantilever Overhang Installation (optional) 1. Attach one (1) Top Channel (Item 1 in Figure A-10), with the flanges facing outward, to the last two Vertical Columns using hardware shown in Detail C. DO NOT TIGHTEN AT THIS TIME. On older STAK Systems, it may be necessary to drill one (1).562 or 15 mm diameter hole in each of the last Vertical Columns on each side of the storage rack as shown in Detail C. 2. Attach one Diagonal Support (Item 4 or 5) to the last Vertical Column, Top Channel (Item 1), and Back Up Channel (Item 6) with hardware as shown in Detail D. DO NOT TIGHTEN AT THIS TIME. 3. Repeat Steps A.4.1 and A.4.2 on opposite storage rack. 4. Assemble the left hand and right hand Aisle Spacer Weldments (Items 2 and 3) to dimensions comparable with your STAK System using hardware shown in Detail B. NOTE: Field drilling of left hand and right hand Aisle Spacer Weldments (Items 2 and 3) will be required for installation on STAK Systems with special widths. 5. Raise the assembly from Step A.4.4 into position at the ends of the Top Channels (Item 1) and fasten to the Top Channels (Item 1) and Diagonal Supports (Items 4 and 5) using hardware shown in Detail A. 6. Attach two (2) Rail Supports (Item 7) to the left hand and right hand Aisle Spacers (Items 2 and 3) using hardware shown in Detail A. 7. Mount the Conductor Adaptor Bracket (Item 8) on the electrical supply side of the STAK System and attach it to the Rail Support Weldment (Item 7) using hardware shown in Detail A. Attach the Conductor Bracket (see Figure C-1) to the Conductor Adaptor Bracket as in Section C. 12 Section A Storage Rack Assembly

Figure A-10 13 Section A Storage Rack Assembly

Detail A Detail B Detail C Detail D 14 Section A Storage Rack Assembly

A.5. Preliminary Leveling Operation 1. Using a transit or dumpy level, verify that the highest column is at the point where the floor is marked (from Section A1.1). A folding rule or flexible tape rule taped to a pipe or rod will serve as a measuring stick. Position the rule with the zero (0) point toward the bottom of the rod, similar to a standard surveyor s rod. Mark the column that rests on the highest point on the floor with a zero (0), denoting that it is the highest column. Mark the elevation reading from the tape, as viewed through the transit, on this column in inches and the nearest fraction of 1/16 or in mm. Move the measuring rod to each column (both front and rear) and rest it on the floor near the base plate. Note the elevation reading in inches or mm and subtract it from the elevation on the (0) column. Mark this difference figure on each column (see Figure A-11). This dimension is the thickness of the shims required to bring the column bases to the same elevation as the highest column. The columns will be raised to their proper heights after the Anchor Bolts are installed. The Anchor Bolts supplied will handle approximately 1 1/4 or 32 mm difference in column base elevations. If the elevation difference is greater than 1 1/4 or 32 mm, it will be necessary to obtain longer Anchor Bolts than those normally supplied. Figure A-11 15 Section A Storage Rack Assembly

A.6. Anchoring IMPORTANT: Position each Vertical Column before drilling any anchor holes. 1. The vertical columns MUST be located in their correct positions before anchoring. Each column should be close to its marked position on the Aisle Chalk Line (from Section A1.3). 2. Starting with the front column of the first Vertical Column, and making certain it is in the correct position, drill two (2) 1/2 or 13 mm diameter holes for insertion of two (2) Expansion Anchors. Use the two (2) unthreaded holes in the base plate as the template. The depth of the drilled hole is determined by the amount of shimming required (as determined in Section A5). If the base plate rests on the floor, the hole depth must be approximately 3 1/4 or 83 mm. Reduce the depth of the drilled hole by approximately the thickness of the shimming required at each column. The depth of the drilled hole may never be less than 2 1/4 or 57 mm. Insert the Expansion Anchors and install the washers and nuts supplied with the anchors. Turn the nuts down to a position just below the machined head on the stud. DO NOT TIGHTEN AT THIS TIME. Thread the Leveling Screw (1/2-13 X 2 Hexagonal Head Machine Screw) into the threaded hole in the column base plate (see Figure A-12). 3. Using the appropriate column center-to-center spacing (Dimension G from Figure A-1), position the next front column along the Aisle Chalk Line. After the vertical column is in the correct position, drill the anchor holes and install Expansion Anchors, washers, nuts, and Leveling Screws to each successive front column base plate. DO NOT TIGHTEN AT THIS TIME. Figure A-12 16 Section A Storage Rack Assembly

Figure A-13 4. Place the rear column of the first Vertical Column on the same front-to-back centerline as its mating front column and anchor following the same procedure described in Section A6.2. The Bar Spacer previously installed between the rear columns will approximately space the rear of the Vertical Columns. Do not allow tolerance build-up to create a problem as the rear columns are anchored. Check by making certain each rear column remains on the same front-to-back centerline with its mating front column. Install Expansion Anchors, washers, nuts, and Leveling Screws to each successive rear column base plate. DO NOT TIGHTEN AT THIS TIME. 5. Repeat steps A6.2, A6.3, and A6.4 for the Vertical Columns on the opposite side of the aisle. 17 Section A Storage Rack Assembly

A.7. Final Leveling Figure A- 14 NOTE: SECTION A.7. FINAL LEVELING REVISED ON 6/30/2011 AS SHOWN BELOW. 1. Using the inch or mm figures noted on the columns (from Section A5.1), make shim pack heights where required. Position each correct shim pack in front of the column where it is to be used. 2. Turn the Leveling Screw at the base plate of each column to raise the column and slip the shim pack into place (see Figure A-14). Back off the Leveling Screw to allow the column to rest on the shim pack. 3. Using a hammer, drive each Expansion Anchor (installed in Section A6) down until the nut and washer bottom on the base plate of the column or the anchor bottoms in the hole. Turn the 1/2 nuts on the Expansion Anchors finger tight. Complete this operation for all columns. 4. Using the transit or dumpy level and the measuring stick, check the zero (0) column that designated the highest column for the elevation reading. Move the measuring stick to each column and check to see that each reading is approximately the same, within + or -1/16 or 2 mm. Further adjustment may be made by adding or removing shims if necessary. 5. After leveling, check to make certain all front columns are vertical. Place a 5 or 1.5 m carpenters level approximately half way up the front column and check the bubble level indicator. Corrections may be made by adjusting the shimming at the mating rear column. A final check on the vertical plumb may be done by stretching a string at about the 6 or 2 m height across each row of front columns. Any column that is out of line or elevation may be easily seen and the proper adjustment made. 6. Completely tighten all hardware, previously left loose, starting with the Expansion Anchors. After the Expansion Anchors have been tightened, completely tighten the attachment hardware for the Cross Braces, Bar Spacers, Vertical Guards, and Bay Spacers. 18 Section B Rail Assembly

B. Rail Assembly 1. Raise the T-Rails into position and attach one to each storage rack as shown in Figure B-1. Use hardware as shown in Figure B-1. The two T-Rails must be positioned parallel with a center-to-center distance for the appropriate STAK System size (see chart with Figure B-1) and must be straight and parallel within + or -1/8 or 3 mm. Use a string line to insure straightness of the rails. Tightly stretch a string on the top surface of one rail and move the rail where necessary to position it in a straight line. Position the opposite T-Rail at the proper distance from the previously set T-Rail at each end and position the remainder of the rail in a straight line according to the string. 3. Securely attach the Wheel Stops to the ends of each T-Rail as shown in Figure B-1. Use the hardware as shown in Figure B-1. 4. Join T-Rails with Rail Splice Assembly and hardware as shown in Figure B-1. Figure B-1 19 Section C Conductor Installation

C. Conductor Installation C.1. Conductor Installation 1. Mount and connect the Conductor Brackets as shown in Figure C-1. Use the hardware as shown in Figure C-1. The Conductor Brackets may be located on either side of the storage rack, depending on the location of the electric supply source. 2. Mount the four (4) Conductors on the Conductor Bracket as shown in Figure C-1 using Hanger Clamps. See additional information and instructions in Section C2 (SAF-T-BAR Conductor Assembly). 3. Remove the pre-assembled Collector Shoe Assembly from the bridge. This assembly consists of four (4) Collectors, two (2) Tow Wires, and two (2) S Hooks. Disconnect the three (3) black wires and one (1) green wire. Disconnect the S Hook (taped end) from the Collector Bracket. Slide the Collectors into the end of the Conductors. This unit will be reconnected when the bridge is installed. Figure C-1 20 Section C Conductor Installation

C.2. SAF-T-BAR Conductor Assembly Figure C-2 1. Joining Conductor Sections The joint splice assembly connects and aligns standard 10 or 3 m conductor lengths. The joint clip is furnished in place on one end of the conductor. The end of the adjacent conductor slides into the joint clip and is pulled together tightly with a joint tool. A 4 or 102 mm joint cover slides over the exposed joint area to complete the insulation. The joint cover locks in place by means of indents and is formed of the same materials as the insulating conductor cover. 2. Power Feed A terminal lug with insulating cover is provided as a feed which clamps onto a 3/4 or 19 mm length of bare conductor. 3. End Cover The end cover required to complete the insulation of the conductor is a sleeve extending 1/2 or 13 mm over the end of the bar. 21 Section D Bridge & Trolley Installation

D. Bridge & Trolley Installation Figure D-1 CAUTION: Serious injury and damage may result from attempts to lift the Bridge Assembly without first blocking the Trolley. The Trolley is blocked before the Bridge Assembly is shipped (Figure D-1). CHECK AND DO NOT REMOVE BLOCKING UNTIL ASSEMBLY IS COMPLETE. Also make certain the Collector Ring Assembly is secured so it will not hang or fall to the floor during lifting. 1. Place the Bridge Assembly on the T-Rails by lifting with a forklift truck or by hoisting from the building s structural system. The forklift truck must have a minimum lifting capacity or 2500# or 1134 kg. The forklift truck must also have a minimum reach of 13 or 4m for STAK Systems of 13 or 4m height or less and 16 or 5m for STAK Systems of 13-16 or 4-5m height. The end of the Bridge Assembly that holds the Collector Shoe Assembly must be adjacent to the Conductors. 2. Remove the Trolley factory clamps. Check for free motion of the Bridge Assembly along the entire length of the T-Rails. The double-flanged wheels must run freely along the rails without the flanges scuffing or binding on the side of the T-Rails. 3. Re-attach the Collector Shoe Assembly to the Collector Bracket with the S Hooks. Close the open end of the S Hooks with pliers. Reconnect the four (4) electrical connectors. 22 Section E Mast Installation

E. Mast Installation 1. Lay the Mast Assembly flat on the floor with the fork mounting assembly down and the handle side up and with the top end (round plate) directly under the clearance hole in the Trolley. Temporarily remove the nameplate attached to the second crossbrace from the top (see Figure E-1). Figure E-1 2. Use a forklift truck as shown in Figure E-2 with the forks brought together so they are approximately 8 or 200 mm apart. Slide the forks on the floor under the Mast Bearing Plate until the plate is near the heel of the forks and the tips of the forks are past the second crossbrace but not past the third crossbrace. Place a safety chain or rope around the Mast Assembly and forks. Secure the top end of the Mast Assembly to the fork mast with the chain or rope to prevent the Mast Assembly from sliding toward the tips of the forks as the Mast Assembly is raised. Slowly raise the top end with the forks and allow the end resting on the floor to slide forward. As the top end is raised, guide the tips of the forks under the second crossbrace. When the forks have passed under the second crossbrace, the chain or rope securing the mast to the forks may be removed. Do not remove the remaining tie-down until the Mast Assembly has reached at least 45 degrees. Continue raising the Mast Assembly until it is entirely supported on the second crossbrace and in an upright position. 3. Maneuver the Mast Bearing Plate directly beneath the bearing under the Trolley and raise the Mast Assembly until it meets the bottom of the bearing. 4. Align the mounting holes and install the hardware from below as shown in Figure F-1 (detail). Tighten the bolts in a star pattern and torque them to 150 ft.-lbs or 204 Nm. 5. Reinstall the nameplate on the second crossbrace from the top. Figure E-2 23 Section F Hoist Installation

F. Hoist Installation 1. Install the Hoist Mounting Weldment with hardware as shown if Figure F-1. 2. Lift the hoist to the top of the Trolley and Mast Assembly and align the Hoist so that the lifting chain is on the side of the Hoist away from the chain bucket. Place the free chain loop in the chain bucket. 3. Raise the Hoist and slide the Hoist Mounting Lug between the two (2) horizontal hoist supports. Secure with hardware shown in Figure F-1. Torque the nuts to 250 ft.-lbs or 339 Nm. Do not connect plugs at this time. Figure F-1 24 Section G & H Canopy & Window Installation

G. Canopy & Trolley Stop Installation 1. Reposition the Canopy to the Mast Assembly as shown in Figure G-1. 2. Reposition the Trolley Stop at the top of the Mast Assembly as shown in Figure G-1. Figure G-1 H. Window Installation 1. Slide the window completely into the channels on the Mast Assembly until it fits against the opposite side. 2. Bend the metal tab at the end of each channel to secure the window in place. 25 Section J Fork Installation

J. Fork Installation 1. Fork Installation 1. Loosen the socket head set screws holding the Fork Mounting Shaft in place. Slide the Fork Mounting Shaft to the side and install one fork. Slide the Fork Mounting Shaft to the opposite side to install the second fork. Center the Fork Mounting Shaft again and retighten the set screws. Figure J-1 2. Fork Setting and Adjustment 1. The forks on the STAK System are factory set so that the forks tips are approximately 1 or 25 mm higher than the heel carrying no load. The 1 or 25 mm setting is for maximum loading and should allow the fork tips to be slightly higher than the heel when carrying a maximum load. To adjust the level of the fork blade, a 1/2 hex head adjusting bolt is located on the back side of the vertical portion of the fork. Turn this bolt in or out to lower or raise the tip of the fork accordingly so that it is always higher than the heel when carrying your average load. The tip height above the heel should be no more than necessary to maintain a level load since the higher the tip of the fork, the less clearance is available to enter the fork openings in the pallet. 2. Position each fork so that the pallet is level when an average load is carried. Turn the adjusting bolts to raise the fork pitch as necessary. 3. Place a carpenters level across the tips of the forks to check that both forks are at equal elevations. Use the adjusting bolts to level the forks. 26 Section K Electrification

K. Electrification 1. Complete wiring schematics for the different systems are included at the end of this manual. 2. The Collector Ring Assembly and Post Weldment are pre-assembled with the Collector Pivot Weldment. Fasten the Collector Pivot Weldment to the Lock Arm Collector (welded to the Trolley base) using the hardware shown in Figure K-1. Fasten the Collector Ring Assembly and Post Mounting Plate to the Post Weldment located on top of the Hoist Mounting Weldment. The square hole in the bottom of the Collector Ring Assembly must pass over the shoulder bolt mounted on the Lock Arm Collector before the fastening is done. 3. Mount the Collector Ring Cover Assembly over the Collector Ring Assembly and fasten with hardware shown in Figure K-1. Figure K-1 Wiring Connections 1. Connect the matching male and female pairs of 4 contact-480 V connectors and 2 contact-120 V connectors. All are located at the top of the Mast Assembly. 2. Wire the conductors to a disconnect box (supplied by the customer) located at a convenient location next to the STAK System per code requirements. 27 Section L Free-Fall Prevention Device

L. Free-Fall Prevention Device 1. After proper connections have been made, lower the hoist chain and secure the hook to the pin. Position the hook with the latch visible to the operator as shown in Figure L-1. 2. Inspect the free-fall prevention device at least once a month. Raise the Fork Mounting Plate by hand at least 3 or 80 mm and release. If the Fork Mounting Plate remains in the released position, the device is functioning. Push the UP button and raise the Fork Mounting Plate with the hoist to reactivate the free-fall prevention device. 3. Check periodically that the bolt head at the end of the support is snug against the side roller mount. IMPORTANT: The free-fall prevention device is set at the factory. When the free-fall prevention device is activated, the knurled, hardened steel rollers instantly grip the guide bar in a wedging action. DO NOT GREASE THE GUIDE BARS INSIDE THE MAST ASSEMBLY CHANNELS. Figure L-1 28 Section M Lubrication & Maintenance

M. Lubrication & Maintenance 1. The Hoist is lubricated at the factory. Lubricate as scheduled in the Hoist Maintenance Manual. The Hoist manufacturer maintains service centers throughout the United Stated for fast service and parts replacement. Consult the Hoist service list located within the Hoist Maintenance Manual. 2. The four (4) bridge wheels are greased at the factory. Service at least every six months with a light duty lubricating grease. 3. The four (4) trolley wheels are permanently greased and require no further lubrication. 4. The four (4) fork mounting bearings located on the rear of the Fork Mounting Plate are greased at the factory. Service at least every six months with a medium duty grease. 5. The rotary bearing on the Mast Assembly is lubricated at the factory. Service at least every six months with Mobilux EP #2. Under extremely dusty or dirty conditions, add sufficient grease to flush out contaminated grease. Under less severe conditions, add grease until it appears at the seal. 6. The (8) cam followers ((4) in the fork mounting assembly and (4) in the trolley) are permanently greased and require no further lubrication. IMPORTANT: DO NOT grease the guide bars inside the Mast Assembly channels (Figure L-1). 29 Section N Operation

N. Operation 1. Turn on power. Lights turn on automatically. 2. Push the Mast Assembly to the desired location. 3. Raise or lower the forks to the desired pallet location by depressing the push buttons marked UP and DOWN as necessary, 4. Align the forks so they are directly in front of and aligned with the pallet fork openings. 5. Insert the forks until they fully engage the pallet. 6. Lift the pallet until it clears the front and rear hooks. Be careful that any load protrusion clears the pallet above it. 7. Pull the loaded Mast Assembly straight out until the pallet clears the rack. 8. Lower the load below eye level. Turn the mast and push in the desired direction. 9. When placing pallets in the storage rack, make certain the front angle supports rest in the notches in the front columns. This will insure the pallet is completely and properly inserted. Push your foot on the foot guide plate located at the bottom of the Mast Assembly to insure proper pallet installation. 10. DO NOT exceed the STAK System s 2,000 pound or 1,000 kg maximum rated load. Continued overloading for extended periods of time may damage the hoist motor. CAUTION: DO NOT jog the control buttons rapidly when raising or lowering a load. This may damage the hoist. Raise and lower loads in one smooth operation. 30 Section O Trouble Shooting

O. Trouble Shooting Trouble Possible Cause Remedy 1a. T-rails out of alignment 1. Bridge moves with difficulty (usually noted by scuffing of wheel flanges on T-rail sides) 2. Trolley base moves with difficulty 3. Difficulty rotating Mast (up to approximately 40 ft-lbs or 54 Nm of torque is normal) 1b. Bridge wheel bearings bad 2a. Dirt on flange of bridge channels or running surface of wheels 2b. Trolley guide bearings bad 2c. Bridge not level 1a. Check for straightness and proper spacing of the T-rails (Section B) 1b. Raise end of bridge and check for free-spinning wheels 2a. Clean bridge channels and wheels 2b. Check wheel bearings 2c. Level bridge 3. Torquing not even 3. See Section E, para. 4 4. Hoist Difficulties 4. Consult trouble-shooting section in Hoist Manual 5. No electrical power 5a. Fuse blown 5b. Wire leads disconnected 5c. Collector Shoes 5d. Collector Ring 5a. Check/replace fuses in main disconnect 5b. Check/reconnect leads 5c. Check/replace worn shoes 5d. Check/replace worn brushes 6. Lights do not illuminate 6a. Bulb blown 6b. Fuse blown 7. Difficulty engaging pallet inrack 8. Free-Fall Device not activating 7a. Forks not set properly 7b. Rack columns not level/aligned 8. Free-Fall Devise not set properly 6a. Check/replace bulbs 6b. Check/replace fuse inside transformer cover 7a. Set forks per Section J.2 7b. Check levels/alignment of vertical columns per Section A7 8. See Figure L-1, remove screw attaching operating cable to lever, roate cable counter-clockwise to lengthen cable, reattach and test. Continue process one revolution at a time until device activates. * NOTE: If problem persists, contact STAK System distributor or Sales Engineer. 31 Section P Pallet Assemblies

P. Pallet Accessories 1. Optional Tub Kit Installation 1. Arrange various add-on accessories by category (all sidewalls, all front and back walls, all corner brackets, Etc.). 2. Place a rear wall (flange in) over the series of small holes on the pallet surface. Connect the wall using the screws provided and a hex head driver or a slotted screwdriver. 3. Take one corner bracket and slide it onto one end of one sidewall. 4. Slide the sidewall end (flange in) with the corner bracket onto the installed rear wall. Tighten. 5. Repeat Steps P.1.3 and P.1.4 for the remaining front wall and sidewall. 6. Slide the last remaining corner bracket onto the open ends of the sidewall and rear wall. Figure P-1 2. Partition & Divider Installation 1. Place two (2) clips onto the slots located in the middle of the rear wall. 2. Repeat Step P.2.1 using two (2) clips for the front wall. 3. Slide the front-to-back partition into place and screw down tightly. 4. Place two (2) clips each into the sidewalls and the front-to-back partition. 5. Slide each divider into place. 32 Section R

Additional Instructions Additional Instructions R.1. Column Sleeves Figure R-1 1. Install (1) 8 or 2.4 m long rubber Column Sleeve onto each unused front column flange, typically on either side of the aisle at each end of the STAK System, to prevent snags during travel around the corners of the STAK System. Fit each Column Sleeve around the bottom of the front column flange and the support teeth above as in Figure R-1. R.2. Column Indicator Strips Figure R-2 1. Install optional Column Indicator Strip as shown in Figure R-2 from the base of each front column. 2. Install upper Column Indicator Strip above lower Column Indicator Strip on 13-16 or 4-5m STAK Systems as shown in Figure R-2 if necessary. 3. Cut excess Column Indicator Strip off above the top position of each front column if necessary. 33