QTEK Design GS 2 pallet stacker Operations & Service Manual
DStacker GS GS2 is a pallet handling system with a vertical reach of 12 feet. It can be used in warehouses for loading and unloading pallets using a forklift. The machine has a safety feature to prevent the pallet stack from falling forward when loading. It also has a priming switch to lower the pallet stack to the floor, and a photo eye to sense when a pallet has been dispensed. The GS2 is designed for use in a variety of industrial and warehouse environments, and is capable of handling pallets up to 5000 lbs. It also includes a variety of safety features, such as photo eyes and a lock-out lanyard to prevent accidents.
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QTEK Design
441 Industrial Road
London, Ontario Canada N5V 1T6
sales@qtekdesign.com
877-453-1880 Fax: 519-451-3124
www.qtekdesign.com
Operations & Service
Manual
DStacker GS2
DStacker GS2
Part #: Serial #:
Production Code:
Manufacture Date:
QTEK Design
441 Industrial Road
London, Ontario Canada N5V 1T6
sales@qtekdesign.com
877-453-1880 Fax: 519-451-3124
www.qtekdesign.com
Operations & Service
Manual
DStacker GS2
DStacker GS2
Part #: Serial #:
Production Code:
Manufacture Date:
441 Industrial Road, London, Ontario L5V 1T6 Canada
Service@qtekdesign.com www.qtekdesign.com
Page 2 of 2M000001-‐ar1 QTEK DStacker GS2 – Operations & Service Manual May 2015
SITE REQUIREMENTS
FACILITY SUPPLIED:
1) Electrical Requirements: 120VDC or Solar Option Pneumatic Requirements: None
2) The installation site must have a level concrete surface otherwise the machine’s functionality
could be compromised.
3) The site will require a minimum headroom clearance of 16 feet from the floor.
4) The machine will require a minimum clearance around the unit as follows;
Left side, right side and rear of unit – 24” minimum
Front access clearance – 96” minimum
5) A forklift (minimum 5000 lbs lifting capacity) with a vertical reach of 12 feet”.
TOOLS REQUIRED:
Hammer drill with a 3/4” & 5/8” drill bit capable of drilling a minimum depth of 6”
Heavy hammer
Set of wrenches (1/2", 9/16” and 3/4")
Utility knife
Step Ladder – 6 ft.
Service@qtekdesign.com www.qtekdesign.com
Page 2 of 2M000001-‐ar1 QTEK DStacker GS2 – Operations & Service Manual May 2015
SITE REQUIREMENTS
FACILITY SUPPLIED:
1) Electrical Requirements: 120VDC or Solar Option Pneumatic Requirements: None
2) The installation site must have a level concrete surface otherwise the machine’s functionality
could be compromised.
3) The site will require a minimum headroom clearance of 16 feet from the floor.
4) The machine will require a minimum clearance around the unit as follows;
Left side, right side and rear of unit – 24” minimum
Front access clearance – 96” minimum
5) A forklift (minimum 5000 lbs lifting capacity) with a vertical reach of 12 feet”.
TOOLS REQUIRED:
Hammer drill with a 3/4” & 5/8” drill bit capable of drilling a minimum depth of 6”
Heavy hammer
Set of wrenches (1/2", 9/16” and 3/4")
Utility knife
Step Ladder – 6 ft.
441 Industrial Road, London, Ontario L5V 1T6 Canada
Service@qtekdesign.com www.qtekdesign.com
M000001 QTEK DStacker GS2 -‐ INSTALLATION OPERATIONS MANUAL May 2015 Page 3 of 3
MACHINE ASSEMBLY
ASSEMBLY SEQUENCE:
1) The DStacker GS will arrive on one skid containing two main sections -‐ the machine base and
the middle pallet magazine section bolted together with the upper magazine section being
nested inside the base. The pallet will also contain the additional installation components
which include:
a) GS2 Front Latch Assembly
b) All machine hardware plus ten (10) floor anchors
c) Two (2) Front mesh guards
d) Two (2) safety bollards
e) Spare Parts – 4 springs, Battery
f) Operations and Service Manual
2) Move the complete GS2 Dstacker shipping assembly to installation area accessing the heavier
black base end of the shipping skid with a forklift.
3) Remove the lag bolts used to secure machine and components to wooden shipping skid.
Remove bollard and guarding off the shipping skid.
4) Remove upper pallet magazine from shipping skid: using the forklift, insert forks under the
wooden shipping brace at the top of the upper pallet magazine; place upper pallet magazine on
floor; remove wooden shipping brace.
5) Install upper pallet magazine onto middle pallet magazine: using forklift put 5 pallets into upper
pallet magazine then lift upper pallet magazine and align onto middle pallet magazine. Install all
connecting fasteners.
6) Position Dstacker: using the forklift lift complete assembly with 5 pallets 3” off the shipping
skid. Slide the shipping skid out of place, move the GS2 Dstacker onto the floor, placing it in the
final installation location. Level the 2 sides to each other by shimming the front of one side.
7) Install the GS2 Front Latch Assembly. Remove the front corner covers and install the GS2 Front
Latch Assembly with the four (4) 3/8-‐16 cap screws and lock nuts. Reinstall the front corner
covers
8) Secure the machine to the floor by bolting the four corners of the base using the 3/4” anchor
bolts supplied by QTEK.
9) Remove counter weight shipping support. Remove equipment access plate and access the
shipping support. Cut tie wraps and remove all shipping material. Reinstall equipment access
plate after inspecting area for any shipping debris.
10) Install the two (2) mesh guards and braces with 3/8-‐16 cap screws
11) Secure the two (2) Bollards to the floor by bolting the base using the 5/8” anchor bolts supplied
by QTEK.
12) Install the photo eye reflector to the mesh guards.
13) Plug in 12 VDC battery
14) Remove all shipping material and clean work site.
Service@qtekdesign.com www.qtekdesign.com
M000001 QTEK DStacker GS2 -‐ INSTALLATION OPERATIONS MANUAL May 2015 Page 3 of 3
MACHINE ASSEMBLY
ASSEMBLY SEQUENCE:
1) The DStacker GS will arrive on one skid containing two main sections -‐ the machine base and
the middle pallet magazine section bolted together with the upper magazine section being
nested inside the base. The pallet will also contain the additional installation components
which include:
a) GS2 Front Latch Assembly
b) All machine hardware plus ten (10) floor anchors
c) Two (2) Front mesh guards
d) Two (2) safety bollards
e) Spare Parts – 4 springs, Battery
f) Operations and Service Manual
2) Move the complete GS2 Dstacker shipping assembly to installation area accessing the heavier
black base end of the shipping skid with a forklift.
3) Remove the lag bolts used to secure machine and components to wooden shipping skid.
Remove bollard and guarding off the shipping skid.
4) Remove upper pallet magazine from shipping skid: using the forklift, insert forks under the
wooden shipping brace at the top of the upper pallet magazine; place upper pallet magazine on
floor; remove wooden shipping brace.
5) Install upper pallet magazine onto middle pallet magazine: using forklift put 5 pallets into upper
pallet magazine then lift upper pallet magazine and align onto middle pallet magazine. Install all
connecting fasteners.
6) Position Dstacker: using the forklift lift complete assembly with 5 pallets 3” off the shipping
skid. Slide the shipping skid out of place, move the GS2 Dstacker onto the floor, placing it in the
final installation location. Level the 2 sides to each other by shimming the front of one side.
7) Install the GS2 Front Latch Assembly. Remove the front corner covers and install the GS2 Front
Latch Assembly with the four (4) 3/8-‐16 cap screws and lock nuts. Reinstall the front corner
covers
8) Secure the machine to the floor by bolting the four corners of the base using the 3/4” anchor
bolts supplied by QTEK.
9) Remove counter weight shipping support. Remove equipment access plate and access the
shipping support. Cut tie wraps and remove all shipping material. Reinstall equipment access
plate after inspecting area for any shipping debris.
10) Install the two (2) mesh guards and braces with 3/8-‐16 cap screws
11) Secure the two (2) Bollards to the floor by bolting the base using the 5/8” anchor bolts supplied
by QTEK.
12) Install the photo eye reflector to the mesh guards.
13) Plug in 12 VDC battery
14) Remove all shipping material and clean work site.
441 Industrial Road, London, Ontario L5V 1T6 Canada
Service@qtekdesign.com www.qtekdesign.com
M000001 QTEK DStacker GS2 -‐ INSTALLATION OPERATIONS MANUAL May 2015 Page 4 of 4
OPERATING INSTRUCTIONS:
A) PRIMING THE PALLET MAGAZINE:
Priming the pallet magazine will occur when initially loading the DStacker or when a previous
pallet issue has necessitated the removal of the entire pallet stack.
1) Using a forklift, place one (1) pallet on top of the forks and go into the DStacker from the
bottom. From the underside raise the pallet until the front and rear latches flip up past the top
board. The latches drop inside the pallet’s opening between the top and bottom boards. Do
not raise the pallet beyond this point. WARNING: Contacting the front two latches with the
forklift during this step can result in damage and render the machine inoperable.
2) Using a forklift, pick up one (1) pallet with the forks and place on top of the installed pallet
3) Next, load a straightened stack of ten (10) pallets into the magazine making sure to raise the
pallet stack above the black base pallet guides when entering the unit. WARNING: To prevent
damage to the DStacker and to eliminate dispensing problems, forklift operators must ensure
the pallet stacks are vertically aligned and straightened prior to being loaded into the machine.
4) The yellow Pallet Containment Mechanism (PCM), located on each side along the leading edge
of the upper pallet magazine, will pivot back out of the way once contacted by the entering
pallet stack. The PCM is designed to prevent the pallet stack from falling forward once it is
loaded into the pallet magazine. Ensure the 10-‐pallet stack is touching the back wall before
lowering them onto the pallets currently resting on the latches.
5) Move the forklift back clear of the Dstacker and not allowing access to the pallets. Hold down
the priming switch for 3 seconds, the pallet stack will start to slowly descend to the floor. Once
the stack is on the floor, the latches will release the bottom pallet, rise up and be reinserted
into the front and rear openings of the second pallet. The Dstacker is now in a safe operable
state.
6) Operator should finish filling the rest of the pallet magazine until it reaches the “Pallet Height
Limit” indicator at the top of the machine. Do not overfill machine. The pallet magazine must
not exceed the maximum number of pallets as indicated. The DStacker is now ready to
operate. WARNING: Operators must be certain the pallets do not touch upper support cross
braces at the top of the magazine during the loading process.
7) Since the DStacker requires a minimum number of six (6) pallets to operate, the pallet
magazine should be reloaded before reaching this minimum number in the machine.
B) DISPENSING PALLETS WITH WALKIE RIDER:
1) Check to see the lifting frame is in dispensing position (latches are in the second pallet.)
2) Drive walkie rider into bottom pallet until the backrest is 1/2” from the pallet stack.
3) Raise walkie rider to its full height, which will lift the entire pallet stack.
4) Lower walkie rider forks until the bottom pallet is approximately 1” off the floor.
5) Back out of the DStacker to dispense the pallet. Once the pallet has passed the photo eye the
pallet magazine will descend and set the pallet stack on the ground. It will reset the position of
the latches into the openings of the next pallet. It is now ready to repeat the process.
6) Replenish the pallet magazine anytime. Do not allow remaining pallet stack to go below the top
of the black base.
Service@qtekdesign.com www.qtekdesign.com
M000001 QTEK DStacker GS2 -‐ INSTALLATION OPERATIONS MANUAL May 2015 Page 4 of 4
OPERATING INSTRUCTIONS:
A) PRIMING THE PALLET MAGAZINE:
Priming the pallet magazine will occur when initially loading the DStacker or when a previous
pallet issue has necessitated the removal of the entire pallet stack.
1) Using a forklift, place one (1) pallet on top of the forks and go into the DStacker from the
bottom. From the underside raise the pallet until the front and rear latches flip up past the top
board. The latches drop inside the pallet’s opening between the top and bottom boards. Do
not raise the pallet beyond this point. WARNING: Contacting the front two latches with the
forklift during this step can result in damage and render the machine inoperable.
2) Using a forklift, pick up one (1) pallet with the forks and place on top of the installed pallet
3) Next, load a straightened stack of ten (10) pallets into the magazine making sure to raise the
pallet stack above the black base pallet guides when entering the unit. WARNING: To prevent
damage to the DStacker and to eliminate dispensing problems, forklift operators must ensure
the pallet stacks are vertically aligned and straightened prior to being loaded into the machine.
4) The yellow Pallet Containment Mechanism (PCM), located on each side along the leading edge
of the upper pallet magazine, will pivot back out of the way once contacted by the entering
pallet stack. The PCM is designed to prevent the pallet stack from falling forward once it is
loaded into the pallet magazine. Ensure the 10-‐pallet stack is touching the back wall before
lowering them onto the pallets currently resting on the latches.
5) Move the forklift back clear of the Dstacker and not allowing access to the pallets. Hold down
the priming switch for 3 seconds, the pallet stack will start to slowly descend to the floor. Once
the stack is on the floor, the latches will release the bottom pallet, rise up and be reinserted
into the front and rear openings of the second pallet. The Dstacker is now in a safe operable
state.
6) Operator should finish filling the rest of the pallet magazine until it reaches the “Pallet Height
Limit” indicator at the top of the machine. Do not overfill machine. The pallet magazine must
not exceed the maximum number of pallets as indicated. The DStacker is now ready to
operate. WARNING: Operators must be certain the pallets do not touch upper support cross
braces at the top of the magazine during the loading process.
7) Since the DStacker requires a minimum number of six (6) pallets to operate, the pallet
magazine should be reloaded before reaching this minimum number in the machine.
B) DISPENSING PALLETS WITH WALKIE RIDER:
1) Check to see the lifting frame is in dispensing position (latches are in the second pallet.)
2) Drive walkie rider into bottom pallet until the backrest is 1/2” from the pallet stack.
3) Raise walkie rider to its full height, which will lift the entire pallet stack.
4) Lower walkie rider forks until the bottom pallet is approximately 1” off the floor.
5) Back out of the DStacker to dispense the pallet. Once the pallet has passed the photo eye the
pallet magazine will descend and set the pallet stack on the ground. It will reset the position of
the latches into the openings of the next pallet. It is now ready to repeat the process.
6) Replenish the pallet magazine anytime. Do not allow remaining pallet stack to go below the top
of the black base.
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Key Features
- Vertical reach of 12 feet
- Priming switch and photo eye
- Load capacity of 5000 lbs
- Lock-out lanyard safety feature
Related manuals
Frequently Answers and Questions
What is the maximum load capacity of the DStacker GS GS2?
The DStacker GS GS2 has a maximum load capacity of 5000 lbs. as per the manual.
How do I prime the pallet magazine?
To prime the pallet magazine, you need to load one pallet on top of the forks of a forklift and raise it until the front and rear latches flip up past the top board. Then load a straightened stack of 10 pallets into the magazine, making sure to raise the pallet stack above the black base pallet guides. Next, move the forklift back clear of the DStacker and hold down the priming switch for 3 seconds. The pallet stack will then slowly descend to the floor. Once the stack is on the floor, the latches will release the bottom pallet, rise up, and be reinserted into the front and rear openings of the second pallet. The DStacker is now in a safe operable state.
What do I do if a pallet jams in the DStacker GS GS2?
If a pallet jams in the DStacker GS GS2, you can remove the pallet stack, except for the bottom two pallets, which should be left in the machine. If the latches are still caught in the bottom-most pallet, lift the second pallet up and out of the machine. Next, lift the bottom pallet straight up slowly, making sure the latches flip upward, releasing the pallet. Clean the area and repeat the loading process. If the problem persists, contact QTEK Design Service at 519-453-1880.
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