PowerStak 3000
Contents
1. 12 D Battery maintenance 12 E Charger ee 12 SECTION 6 Maintenance 12 13 A Weekly Operations Maintenance Checks 13 Monthly Operations Maintenance Checks 13 SECTION 7 DOWD 15 ORDERING REPLACEMENT PARTS 30 RES TOCKING POLICY u uuu u l uu 30 RETURN GOODS AUTHORIZATION 3 PRESTO OWNER S MANUAL Page 3 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig LIST OF FIGURES 1 Operational Buttons 9 2 Straddle Leg 4 Bolt Tightening 10 9000 125 nenn 14 4 PPS3000 125FS Exploded View 15 5 PPS3000 125FS Mast Assembly 16 6 PPS3000 125FS Cabinet Assembly 17 7 PPS3000 125FS Carriage Assembly 18 8 PPS3000 125FS Leg Assembly 19 9 PPS3000 125FS Caster Wheel Assembly 20 10 PPS3000 125FS Steering Assembly 21 11 PPS3000 125FS Handle Assembly 22 12 PPS3000 125FS Drive Wheel Assembly 29 13 PPS3000 125FS Cylinder Assembly 24 14 PPS3000 125FS Power Unit Assembly 25 15 PPS3000 125FS Hydraulic Schematic 26 16 PPS3000 125FS Labels and Warnings 27 17 PPS3000 125FS Wiri2. m I Parts No y 9 2103 Parts Description Qt No POWER STAK PPS3000 125FS Page 16 PRESTO OWNER S MANUAL Figure 6 PPS3000 125FS Cabinet Assembly PRESTO OWNER S MANUAL No 6 1202 Coverholder M 8 124 Chargerholder 9 1301 Charger Cd Page 17 POWER STAK PPS3000 125FS Figure 7 PPS3000 125FS Carriage Assembly No Snap ring 235 MM PRESTO OWNER S MANUAL Page 18 POWER STAK PPS3000 125FS Figure 8 PPS3000 125FS Leg Assembly PRESTO OWNER S MANUAL No 6 4203 Frontwheel C 2 19 POWER STAK PPS3000 125FS Figure 9 PPS3000 125FS Caster Wheel Assembly m No 10 PRESTO OWNER S MANUAL Page 20 POWER STAK PPS3000 125FS Figure 10 PPS3000 125FS Steering Assembly 39 38 l 00 35 34 33 32 3l cl 28 No 26 7001 Handlepipeweld EM 0 T 12 3 Parts Description Qty 4 5 Handle base 16 Round nut stop washer 052 MM 17 17015 Bearing 33013 18 7036 A flatkey 8X45 MM 1 7028 Round nut M52X1 5 7027 Bolt M4X25 2 19 17016 Bolt M10X30 20 7017 Spring washer O10 MM 4 7025 Flat washer 04 MM 7023 hP 7022 NutM6 hR 22 23 24 7034 Greasezerk M8X1 I 25 7033 Ballbearing61812 ___ 1 Spring washer 26 MM 26 7019 __ 6 25 2 27 Cover holder 21 7200 Drive wheel 1200W 1 7024 Limit s
3. Low hydraulic pressure caused by Pressure relief valve needs adjustment Pump check valve stuck open Faulty solenoid valve Faulty wiring from lift switch to solenoid Faulty lift contactor Defective control circuit fuse Chain or roller bound Check oil level 2 Forks will not lower Look for binding in chains or rollers 3 No electrical power Dead Batteries Key switch on OFF position E stop button depressed Loose or dirty battery connections Blown fuse s Faulty wiring from fuse to travel control switch Faulty control switch Faulty wiring from travel control switch direction con tactor Faulty contactor 4 No Traction Check to insure base legs are torqued properly POWER STAK PPS3000 125FS 53000 125 5 Figure 3 5 53000 125 5 14 PRESTO OWNER S MANUAL PPS3000 125FS Exploded View Figure 4 LTTE ET ONT JII Item 6 700 _ Gearassembly 1 _ 8 900 Powerunt 1 Page 15 POWER STAK PPS3000 125FS PRESTO OWNER S MANUAL PPS3000 125FS Mast Assembly Figure 5 _ nner mast Chain wheel protective assembly 6 2203 Guide roller shafi 4 _ 8 2205 Snap ring 230 1 gt gt EE D gt gt c lt sS 5 ni MN Q om
4. Presto CI worldwide material handling FEF ASSN and ergonomic solutions Power Stak lt PPS3000 125FS gt ax FOR UNITS SHIPPED PRIOR TO MARCH 2014 Installation Operation and Service Manual Model Number Serial If you are not satisfied in any way contact 4 amp Date Placed in Service IMPORTANT READ CAREFULLY BEFORE INSTALLING OR OPERATING LIFT Part orders are subject to a 50 minimum charge September 2015 Presto Lifts Limited Power Stacker Warranty Policy Presto Lifts warrants the Power Stacker against defects on the mast fork carriage chains pumps DC motors controllers cylinders and wiring harnesses from faulty material and workmanship for a period of one 1 year from the date of invoice All wear items such as batteries wheels motor brushes seals bearings hydraulic hoses all switches battery chargers and forks have a limited warranty against defects in faulty material and workmanship for a ninety 90 day period from the date of invoice and 30 day limited warranty on labor Please note that prior authorization from Presto Lifts is required on all warranty work There are no implied warranties of any kind more specifically there are no warranties of merchant ability or fitness for any particular purpose Presto Lifts sole warranty shall be as set forth in this limited warranty Presto Lifts will elect to repair or replace a defective component without charge
5. if any components should become defective within the limited warranty period Proof of purchase is required for warranty The charge for shipping the defective component is the responsibility of the buyer and must be accompanied with an RGA number The shipping charge to return the component to the buyer is the responsibility of Presto Lifts Inc This limited warranty does not cover labor expense for removal or reinstallation of components after thirty days This limited warranty shall not cover among other things damages resulting from foreign matter or water failure to provide reasonable and necessary maintenance and if applicable use of product while charger is plugged into an AC outlet or failure to follow operat ing instructions The limited warranty is not valid for damage resulting from negligence accident unreasonable use abuse or misuse exceeding data plate capacities or altering the product without Presto Lifts authorization Presto Lifts expressly disclaims and excludes any liability for consequential incidental indirect or punitive damages or financial loss to people or property resulting from any breach of warranty or the operation or failure of this product Presto Lifts makes no representation that this product complies with local state or federal safety product standards codes Should this product fail to comply in any way with those codes it shall not be considered a defect of materials or workmanship Presto Lifts s
6. 015444 ON LUVd 01141 25 4 WALI oS 10 500 H INTER NALLIUM OL 04107 NOLLYMAOANI ANVISTUdONd 40 ASN SAHONI NI AAV MIG 181412445 ASIMNAHLO SSH INN NY QE 2 gt SNOLLOVUA 96070008 4 LXEN GTONYH Ya TILL 100 08108 00 LON ALIHM Yovig HOTTE 1 MOTTA YNId arg 1011 Ce HS CEN us s INT 45 INId CINIAW DNI 1 4014 311004 FULOYHL 70412713 9413 92 MOTH ALIHM anid MOTTH MOTTA HAS 1 NANO 1 NANO 19911 LIGHT GREEN T ELECTRONC THROTTLE MODUL HIS ANIM HONA CAMATA SNOTLOANNOD 76070008 g o3 TLOZ 1snbny LT SAS POWER STAK PPS3000 125FS Page 28 PRESTO OWNER S MANUAL Figure 18 Battery Connection MAIN BATIERY CHARGER POSITIVE POSITIVE CABLE BATTERY CABLE 24 VOLT SYSTEM BATIERY CHARGER BATIERY CONNECTING CABLE 120 VAC BATTERY B NEGATIVE NEGATIVE CABLE CABLE PRESTO OWNER S MANUAL Page 29 POWER STAK PPS3000 125FS ORDERING REPLACEMENT PARTS Presto Lifts has carefully chosen the components in your unit to be the best available for the purpo
7. 2100 LBS operating this machine Ratings based 24 Load Center See Owner s Manual for details 10059665 Y BLACK BACK GROUND WHITE BACK GROUND amp WHITE PRINTING amp BLACK PRINTING T PRESTO OWNER S MANUAL Page 4 POWER STAK PPS3000 125FS Responsibility of Owners and Users Inspection and Maintenance The device shall be inspected and maintained proper working order accordance with Presto s owner s manual Removal from Service Any device not in safe operating condition such as but not limited to excessive leakage missing rollers pins or fasteners any bent or cracked structural members cut or frayed electric hydraulic or pneumatic lines damaged or malfunctioning controls or safety devices etc shall be removed from service until it 1s repaired to the original manufacturer s standards Repairs All repairs shall be made by qualified personnel in conformance with Presto s instructions Operators Only trained personnel and authorized personnel shall be permitted to operate PowerStak Before Operation Before using the device the operator shall have Read and or had explained and understood the manufacturer s operating instructions and safety rules Inspected the device for proper operation and condition Any suspect item shall be carefully ex amined and a determination made by a qualified person as to whether it constitutes a hazard All items not
8. OWNER S MANUAL Page 10 POWER STAK PPS3000 125FS DAILY OPERATOR CHECK LIST CHARGE CONDITION BATTERY CHECK LIST 1 Check Battery Discharge Indicator Fuel Gage and Hour Meter Be sure unit 15 showing proper Charge Level before operating unit 2 Check to be sure Charging Cord is Unplugged and properly stowed before operat ing unit 3 Inspect Battery Wire Connections All connections should be tight with No Corro sion white powder showing at the Battery Terminals 4 Inspect Battery Case There should be no cracks or visible damage to the Battery Case WALK AROUND INSPECTION 1 Check general condition of Stacker loose or broken parts oil dangling wires dents cracked covers etc 2 Check metal frame mast carriage and font load supports for cracked welds worn or flat rollers loose or disconnected chains loose pins missing snap rings and loose or missing hardware bolts nuts washers etc 3 Check for evidence of hydraulic leaks 4 Make sure all precautionary labeling is place and legible FUNCTIONAL INSPECTION Check Drive Forward and Reverse Function Check Lift Up and Down Function Check Function for Belly Button Reverse Check Horn Function Check Brake Function o OPERATOR ID DATE DO NOT USE OR OPERATE STACKER IF ANY FUNCTION IS NOT OPERATING PROPERLY OR IF STACKER APPEARS UNSAFE IN ANYWAY REPORT CONCERNS TO SUPERVISOR IMMEDIATELY PRESTO OWNER S MANUAL Page 11 POWER STAK PPS3000 125
9. STAK PPS3000 125FS Labels amp Precautionary Warnings Figure 16 ON tava wa 9186500 8 __39 LSNW 4351 ONINSVM iOS 9XSZ Z 100 V3 SLA 4866001 8 AVIS YIMOd 00 0ZX00 100 MO138 33AOO NO JIVDOT 84865001 EX00 vz zje 615 8 OiS344 00 EX00 T1 7120 V3 L 7 260001 v 2 99 3WSV OL OJANIOVINNVW OVL 338 z S WERL e o ho M 16915 VIS 31770 SWWN 28 LXOS E OVI 07 8 Z 9 JI Joyeo puj 90785001 1 591 0006 ALIDVdVO STEX00Z 100 1 V3 1 Z au YOBYD nou euo 15681 JE 10 04615 DU 59965001 DNINAVM 00 7X00 10 91 V3 1 8 iv 9521900 13O3VH2 OL N3HM JOON 00 X00 12 6 041 ONIAOW 30 9312 AVLS 33AOO YANN WA 3NIHOYW NO JIVDOT IONN GNV1S LON OQ _ JOVIAAVO A303 31v2O1 AJINJO QVO Wo sg1 000 AllOVdVv2O SLYVd 30 319 AVLS 71303 H30NN GNVLS LON 00 314039 1111 LON 3341 ON ONINEVM V Page 27 POWER STAK PPS3000 125FS PRESTO OWNER S MANUAL ASA AIMAN SNIMVSG S TILIL V 76270008 OH TAL 215444 NNOO T4 y 78270008 DNA JAR HTVIS SNOLLNTOS DIMONOSMA NY nn XI 80 62 01 ONTTANYH TVDISLV SLH I
10. be removed to access lifting equipment Be careful of the stacker swinging once fully lifted off the pallet or skid Have all personnel completely cleared from the area Pick the unit up approximately six inches above the pallet or skid Once raised remove the pallet or skid from below the lift Do not move the lift around in the air Lower the stacker on the ground C PREPARATION FOR USE This stacker left our factory in new condition It has been inspected and weight tested to assure all performance stan dards have been met Visually inspect the stacker for damage Check for attach ments and accessories that may have been ordered If there is any damage or missing parts report it to your carrier and your Presto dealer immediately Remove all metal plastic bands cardboard and other material used for shipping purposes PRESTO OWNER S MANUAL Page 8 Check to see if chains are in place and that the lift system is in working order Inspect for oil leaks See instructions for removing back panel on pg 5 Connect battery cable Check cables and wires on battery charger as well as battery SECTION 4 OPERATION A OPERATING INSTRUCTIONS To Raise and Lower There are two buttons located on both sides of the handle The inside one is for raising the forks The outside one is for lowering the forks When operating always make sure the load being lifted is within the loading capacity of your stacker and the load has bee
11. in conformance with Presto s specification shall be corrected before further use of the PowerStak During Operation The device shall only be used in accordance with this owner s manual Do not overload Ensure that all safety devices are operational and in place Modifications or Alterations Modifications or alterations to any Presto industrial positioning equipment shall be made only with written permission from Presto PRESTO OWNER S MANUAL Page 5 POWER STAK PPS3000 125FS ECTION 2 SAFETY You must be trained and certified to operate this powered stacker Federal law states that only properly trained operators are permitted to operate a powered industrial stacker and that your employer must train you and certify that you are qualified OSHA 1910 178 29QFR 7 1 06 Edition Presto lifts does not offer operator training Operator training programs may be offered by your local Presto Lifts dealer or obtained online Enter powered industrial truck operator training into a search engine SAFETY ALERT SYMBOLS AND SIGNAL WORDS The safety of all persons operating maintaining repairing or in the vicinity of this equipment is of paramount concern This is a powerful machine with moving parts and is capable of causing personal injury if proper precautions are not taken Therefore throughout this manual certain hazards have been identified which may occur in the use of the machine and there are appropriate instructions or
12. precautions which should be taken to avoid these hazards In some cases there are consequences which may occur if instructions or precautions are not followed Below are the symbols and signal words along with their definitions referenced from ANSI Z535 4 Product Safety Signs and Labels Safety Alert Symbols These are the safety alert symbols They are used to alert you to potential physical injury haz ards Obey all safety messages that follow this symbol to avoid possible injury or death For use with DANGER signal word Red Background For use with WARNING signal word Orange Background For use with CAUTION signal word Yellow Background gt P Sienal Words The meaning of different signal words as defined by ANSI Standard Z535 4 indicates the relative seriousness of the hazardous situation DANGER indicates a hazardous situation which if not avoided A D A G F R will result in death or serious injury Red Background WARNING indicates a hazardous situation which if not avoided could result in death or serious injury Orange Background CAUTION used with the safety alert symbol indicates a haz ardous situation which if not avoided could result in minor or moderate injury Yellow Background NOTICE is used to address practices not related to personal Blue Background SAFETY SAFETY INSTRUCTIONS or equivalent signs indicate safety INSTRUCTIONS related instructions or pro
13. the previous 30 minutes NOTICE When to charge the battery Allow the machine to stand idle for at least one hour Check the Battery Discharge Indicator If 6 bars or less are lit it is time to charge the battery 388 owner s manual for charging instructions v a VOLTAGE Approx 12 7 V Fully charged Approx 12 2 V 1 2 charged Approx 12 0 V 1 4 charged Approx 11 6 Discharged BATTERY ex 21 Die PRESTO OWNER S MANUAL Page 12 Never alter the AC cord or plug provided If it will not fit outlet have proper outlet installed by a qualified elec trician Improper connection can result in a risk of an electric shock 1 Disconnect the charger from the 115 volt wall outlet once the indicators read fully charged Note The batteries are designed for intermittent use Continual usage will wear the battery out and charging will be required E CHARGER OPERATION Power Lamp 1 Green Connection correct mally Charger will operate nor 2 Red Bad connection or bad battery Fault 1 Red light blinks 3 times in 5 seconds The output between charger is faulty loose or bad connection 2 Red light blinks 5 times in 5 seconds The temperature is too hot for the charger to operate 3 Building power is not compatible too low or too high 10 is the general rule Charge Lamp 1 Red Charger can charge normally The battery is less than 70 2 Orange Battery i
14. FS SECTION 5 BATTERY MAINTENANCE A PREPARING TO CHARGE A BATTERY 1 Always turn off E stop and key switch before working with the batteries 2 Be sure the area around the stacker and the battery is well ventilated while battery is being charged 3 The battery terminals connections and wiring connec tions should be clean and free of corrosion When clean ing any of these components wear a face shield or other suitable protective eyewear BATTERY CHARGING Charging must be performed with the charger that 1s provided with or prewired into the machine During charging the temperature in the battery must not exceed 120 F Charging simultaneously with truck operation is not recommended Plug the charger into a 115 volt outlet Charge until the bat tery gauge indicator lights show fully charged approximately 6 8 hours C WARNINGS AND BATTERY INFORMATION Avoid use of open flame near batteries At temperatures around freezing point battery capacity is reduced by 30 The battery terminals connections and wiring should be clean and free of corrosion When cleaning any of these components wear a face shield or other suitable protective eyewear Read understand and follow all battery and battery manufacturer s specific precautions while working with and or charging batteries D BATTERY MAINTENANCE To measure the voltage use a digital voltmeter DC on the battery poles The truck must not have been in use for
15. ID of the legs does not exceed 50 powder substance will be present if there is any and each leg should be inserted into the holder evenly existing corrosion B Visually inspect for any cracks or damage to the 2 Relieve any weight from the legs This may need to be done casing one side at a time C Check for loose battery tie downs 3 Adjust the legs and ensure both legs are positioned equally 2 Charger Please refer to diagram below A Inspect wire connections B Check power cord for nicks damage C Check power charger for proper mounting 3 Hydraulic System Set up procedure D Inspect pump and cylinder for oil leaks for PowerStak E Check hydraulic oil level Straddle legs with F Check hydraulic fittings and hoses 4 Bolts G Check ram for nicks damage 4 Frame Assembly A Check chain roller assembly connections B Check for any worn or damaged parts Figure 2 Straddle Leg Bolt Tightening Procedure Pre tighten all bolts to the bottom but not too tight Fully tighten bolt 1 Next tighten bolt 3 Next tighten bolt 4 Last tighten bolt 2 Tighten all bolts to 85 foot pounds En S ee Note The Power Stak is meant to operate on a non slip floor or surface If traction is needed Presto Lifts offers an optional rubber wheel or a non marking wheel Note The travel speed is preset at thefactory For travel speed adjustment please contact customer service at Presto Lifts 1 800 343 9322 PRESTO
16. Not all units are returnable Quantity orders and special designs cannot be returned under any circumstances Presto Cus tomer Service reserves the right for final judgment on all product returns The RGA number must appear on the outside of any packaging material for a return to be ac cepted and processed by Presto Lifts Customers shipping returns from the Continental US Canada or Mexico have thirty 30 days from date of RGA issue to have the product arrive at Presto Lifts facility All merchandise must arrive Free on Board at Presto Lifts facility or the shipment will be refused and returned to the sender All credits are issued less restocking and refurbishing charges regardless if the merchandise was damaged in transit Return addresses please refer to your RMA for the address to which your product should be returned Presto Lift Inc 715 Highway 77 Manila Arkansas 72442 Telephone 800 343 9322 Fax 888 788 6496 PRESTO OWNER S MANUAL Page 31 POWER STAK PPS3000 125FS 2 Presio RC a ss J B e r ij i LET PRESTO MEET THOSE NEEDS Call Presto Sales for stock or customized lift inquiries 800 343 9322 Email sales prestolifts com PRESTO OWNER S MANUAL Page 32 POWER STAK PPS3000 125FS
17. ands and feet away from all moving parts such as masts chains forks or wheels Never stand on or under the forks or allow anyone else to stand on or under them Never ride on the stacker or allow anyone else to ride There is no safe place to sit or stand Before you leave your stacker be sure to lower the forks to the floor Shut the stacker off with the key DO NOT use this stacker until you have been trained and authorized to do so DO NOT operate until you have read all warnings and in structions DO NOT exceed load center or load weight capacities check capacity plate DO NOT operate until you have checked the conditions of the stacker lift systems forks chains and cables DO NOT use if any part is damaged worn or not working properly DO NOT use on ramps or inclines Only smooth level sur faces DO NOT use for lifting or carrying people DO NOT handle unbalanced unstable or loosely stacked loads DO NOT travel with forks or platform in an elevated posi tion DO NOT handle tall unsecured or unstable loads that could fall DO NOT allow people to stand or pass under forks or plat form with or without load DO NOT operate when parts of anyone s body may be close to mast structure or any moving parts DO NOT drop loads on platform or forks DO NOT alter or modify this stacker in any way POWER STAK PPS3000 125FS SECTION 3 INSTALLATION A INSPECTION Upon receipt of the stacker inspect th
18. cedures Green Background PRESTO OWNER S MANUAL Page 6 POWER STAK PPS3000 125FS The battery operated stackers are very powerful lifts capable of doing large amounts of work DO NOT OPERATE THESE LIFTS WITHOUT CARE FULLY READING THIS MANUAL In order to provide for the safe operation of these stackers Presto Lifts Inc has identified certain hazards that may occur during the mainte nance and use of these lifts For safety reasons these units are designed to be serviced or repaired in the fully lowered position If performed properly this will greatly reduce the possibility of injury When servicing the unit 1 Key should be in OFF position 2 E stop should be depressed 3 Disconnect the batteries at the terminals Do not perform any repair work on lifts if there is a load on the forks or platform Do not perform any repair work if the forks or platform is in the raised position All personnel must stand clear of the lift while in mo tion Do not put hands or feet under the forks or platform Do not stand underneath the forks or platform Do not stand in front of the stacker while in motion Do not stand sit or climb on the lift Do not use the lift on soft uneven or unstable surfaces Do not exceed the load center or capacity You or others around you can be seriously injured or even killed if you don t use this stacker correctly Read and obey all warnings and instructions in this manual and o
19. e equipment completely to determine if there is any shipping damage and that the lift is complete Presto tests and inspects every piece of equip ment prior to shipment If damage is apparent a freight claim must be filed with the freight company Do not use the stacker if there appears to be any damage With the stacker in a lowered position check the following Check for signs of damage especially to the back cabinet that houses the battery electrical hydraulic power pack e Check all electrical and hydraulic connections for tightness Remove back panel 1 Turn key switch to OFF position 2 Push in E stop and unscrew the red knob 3 Lift off back panel There is enough wire to the key switch to allow the panel to be set aside Inspect for any bent or damaged parts B REMOVING FROM PALLET Each of the Presto stackers is shipped out on a pallet or skid Prior to removing the unit from the pallet or skid remove all tie down straps and packaging Visually inspect the unit as Closely as possible With an overhead hoist or forklift carefully pick up the unit taking into consideration the center of gravity of the unit If you choose to pick the unit with an overhead hoist use a nylon sling and hoist with a minimum of 2 000 Ib capacity The nylon sling will not do any damage to the steel construc tion of stacker Pick the unit up On conventional masts use the top cross member of the lift On narrow masts the cover must
20. hall not be held liable for any damages resulting from noncompliance It is the dealer s responsibility to exercise this limited war ranty This limited warranty is provided to the original purchaser defined as the original end user and is nontransferable This constitutes the complete and final agreement involving Presto Lifts and limited warranty obligations for products This manual was current at the time of printing To obtain the latest most updated version please contact the Customer Service Department or go to our website www PrestoLifts com you will find a complete list of current Owner s Manuals to print PRESTO OWNER S MANUAL Page 2 POWER STAK PPS3000 125FS TABLE OF CONTENTS SECTION 1 Limited Warranty 2 PROC 4 Responsibility of Owners and Users 5 SECTION 2 sri 6 7 SECTION 3 O unu uu 8 N uuu u uuu 8 B Removing from 8 Prepatation for 8 SECTION 4 ODAO 8 A Operating Instructions 8 B Daily Operations Maintenance Checks 10 Suggested Daily Operator Checklist 11 SECTION 5 Battery Maintenance ascen tea u Prts 12 A Preparing to Charge a Battery 12 B Charging the battery 12 C Warnings and Battery Info
21. lectrical assemblies are final QUALITY ISSUES Should you feel there is a quality problem please contact the seller to ask questions and gather information on how to rectify the issue Presto Lift Inc reserves the right to determine potential credits as a result of factory defects based on its inspection of the merchandise GENERAL All products shipped from our factory have passed Quality Assurance inspection and testing The carrier of choice has signed for and accepted the product in new working condi tion The customer should inspect to ensure it is not received damaged has no concealed damage or is not incomplete Parts orders are determined to be complete based upon Presto Lift Inc inspection sheets and carrier shipping weights Presto Lifts Parts Department 50 Commerce Way Norton MA 02766 Telephone 800 343 9322 FAX 888 788 6496 Email Service PrestoLifts com www PrestoLifts com PRESTO OWNER S MANUAL Page 30 POWER STAK PPS3000 125FS RETURN GOODS AUTHORIZATION POLICY Presto Lifts provides the Return Goods Authorization RGA Policy for specific models as a courtesy to our distributors in the event they do not receive what they ordered If a customer wishes to return a Presto Lifts product please contact the Customer Service Department and request an RGA number This request must be made on or before the fifteenth calendar day following the date of Presto Lifts invoice for the merchandise
22. n the stacker It is your responsibility before starting work to make sure it is in good working order Always be alert to the area around you and watch where you are walking Be careful that you don t get pinned or crushed between the stacker and a fixed object such as a wall or post Watch your hands and feet A foot or hand caught between the stacker and a fixed object will be crushed or even cut off If traveling forks first keep both hands on the control handle and be careful when changing direction of travel Keep your feet clear of the stacker Keep the stacker under control at all times Operate at a speed that allows you to stop safely Be even more careful on slippery or uneven surfaces Do not run over objects on the floor Perform all stacker movements smoothly and at a speed that will give you time to react if an emergency occurs Tipovers and falls are very serious accidents you can be crushed or even killed To prevent injury know where you are at all times and follow the rules of safe stacker operation PRESTO OWNER S MANUAL Page 7 Be careful when working around docks dockboards and trailers Stay away from the edge of docks and ramps Check to make sure the wheels of truck or trail ers are chocked Travel with the load or forks close to the ground Watch for overhead obstructions Perform all stacker movements smoothly and at a speed that will give you time to react in an emergency Keep your h
23. n stacked safely on the pallet Also make sure that the length of the forks corresponds to the length of the pallet In this way the load rollers will place themselves in the opening at the end of the pallet so that when you raise the forks you will not break the bottom boards of the pallet Always make sure that when entering the pallet that the forks are in the fully lowered position Be careful when lifting pallets that are too short or too long for the stacker It might destroy your pallet by breaking the bottom boards and if the forks project through the end of the pallet the tips of fork may go into the next pallet that is behind the pallet that you are lifting which may bend the tips of forks and overload the capacity of the stacker To Travel To travel rotate the butterfly controls throttle on the upper part of the handle When rotating the butterfly control CW towards the forks the stacker runs forwards the forks first direction When rotating the butterfly CCW towards you the stacker runs backwards in the handle first direction Always make sure the stacker clears any obstruction when travel ing and that your path of travel is clear of people Never carry loads above the loading capacity of the stacker It is suggested that when traveling without a load the forks be in the lowered position The speed of the stacker is increased by the degree of the rotation in either direction it functions like a throttle When you relea
24. ng Aug 2011 to present 28 18 PPS3000 125FS Battery Connection 29 POWER STAK PPS3000 125FS ECTION 1 INTRODUCTION This manual attempts to provide all of the information necessary for the safe and proper installation operation and maintenance of Presto Lifts Inc battery operated Power Stak It is important that all per sonnel involved with the installation maintenance or operator of the stacker read this manual Additional manuals are available upon request or at www PrestoLifts com Each Presto stacker 1s equipped with nameplate serial number and model identifications Please refer to these numbers when ordering parts or requesting further information The Presto stackers are designed for lifting lowering and positioning a wide variety of loads WHERE UNIQUE SITUATIONS ARISE WHICH ARE NOT COVERED IN THIS MANUAL CALL PRESTO LIFTS FOR FURTHER INSTRUCTIONS The battery operated stackers are designed for in plant non hazardous locations only They can be used in a 8 or larger aisle These units are not for personnel lifting BLACK TRIANGLE BLACK LETTERS SODA Hau r amp ORANGE ORANGE BACK GROUND __ ________ __________________ AN WARNING LIFTING CAPACITY ABOVE 5 IS LIMITED Maximum Lifting Capacity M To avoid bodily injury read understand and follow all 5 UPTO7 UPTO8 UP TO 10 3 instructions before 3000 LBS 2600 LBS 2400 LBS
25. precautionary labels and guards are in place B MONTHLY OPERATIONS MAINTENANCE CHECKS 1 Battery maintenance free A Clean terminals B Clean battery compartment area if there are signs of corrosion 2 Hydraulic System A Clean and inspect hydraulic cylinder B Lubricate chain with a rust inhibitive lubricant light machine oil C Check chain tension It should be even on both chains The chain should be tight enough so that it does not come off of the roller assembly 3 Frame Assembly A Clean and lubricate all roller bearings cam fol lowers and all moving parts B Clean and inspect all welds C Check wheels for wear and damage D Inspect nameplate for legibility Place the serial and model number shown on the nameplate on the cover of the manual for future reference 4 Electrical A Check batteries motors controllers limit switches electrical conductors and connections DO NOT USE LIFT IF IT IS NOT OPERATING PROPERLY OR APPEARS UNSAFE IN ANY WAY PRESTO OWNER S MANUAL Page 13 SECTION 7 TROUBLESHOOTING Before starting the troubleshooting you have to A Put the truck on an even and solid surface B Turn off key switch or disconnect the battery termi nals Unit will not lift motor does not run Faulty wiring from fuse to lift switch in handle Faulty lift switch Faulty wiring from battery positive terminal to pump contactor to pump motor Burned out brushes in pump motor
26. s between 70 and 100 charged 3 Green Battery is at 100 Fully charged 4 Nolight The charger can not charge the battery Voltage of the battery may be too low to cause the charger to start It must be at 10 5 volts to initiate charge SECTION 6 MAINTENANCE Operation of Presto Power Stak is very simple as 1s their construction They require very little maintenance Reason able care will result in excellent trouble free performance The Power Stak is designed for one man operation and ease of performance Grease floor wheels and casters at least once a month Use only Hydraulic AW32 or Dextron III in the hydraulic system Do not overload your lift Check brakes steering mechanisms and controls be fore each use POWER STAK PPS3000 125FS A WEEKLY OPERATIONS MAINTENANCE CHECKS 1 DAMAGE Check for bent dented worn or broken parts 2 LIFT SYSTEM Check to assure that there is no bind ing or excessive play in the forks Check for quiet and smooth operation of the lift cylinder Check all moving parts and linkage 3 LEAKS Check hydraulic system for leaks and hydraulic oil level 4 WHEELS AND CASTERS Check for wear and that they are turning smoothly 5 LIFT CHAINS Check to see that they are in place and not loose 6 FORKS Check that they are not bent or cracked 7 BRAKKS Ensure brakes work properly 8 CABLES WIRES Check that there are no loose cables or wires 9 LABELS Ensure all
27. se Replacement parts should be identical to the original equipment Presto Lifts will not be responsible for equipment failures resulting from the use of incorrect replacement parts or from unauthorized modifications to the unit Presto Lifts can supply all replacement parts for your lift With your order please include the model number and the serial number of the unit You can find these numbers on the name plate This plate is located within the cabinet or the angle iron cylinder cross support To order replacement parts please call the Presto Parts Department Parts are shipped subject to the following terms FOB factory Returns only with the approval of our Parts Department Credit cards preferred except parts covered by war ranty Freight collect for truck except parts covered by warranty Freight prepaid and invoice for small parcel shipments except parts covered by warranty The warranty for repair parts is 30 days from date of shipment Parts replaced under warranty are on a charge credit basis We will invoice you when we ship the replacement part then credit you when you return the worn or damaged part and we verify that it is covered by our warranty Labor is not covered under warranty for Parts orders PARTS Standard parts may be returned with a 20 restocking fee Modified or custom engineered parts are not returnable nfortunately due to potentially concealed damage all sales of e
28. se your hand from the butterfly control it automatically will resume to the neutral position and the speed of the stacker will slow down To Brake Your stacker is equipped with a magnetic brake The brake is applied when the handle 1 in its vertical position between 10 15 degrees and lowered position between 80 90 de grees The brake could be released when you pull down the POWER STAK PPS3000 125FS handle at any point between 15 80 degrees Always make sure the brake is released before operating the stacker When the stacker is running you could brake the stacker by raising the handle to its vertical position or lowering the handle to its lowest position Or to turn the butterfly controls in the opposite direction the change in direction of the motor will slow down stop and reverse the direction of stacker When parked always put the handle in the full vertical position with the brake applied and the forks in lowered position Reversing Safety At the end of the handle there is a large red reversing bar belly button switch that is designed to protect the operator from injury When the operator runs the stacker backwards and the end of the handle comes in contact with the operator s body the stacker will automatically reverse direction and travel away from the operator When the reversing safety bar comes in contact with your body during operation immediately release your hands from the butterfly control and pu
29. t the handle up to its vertical position or down to its lowest position and the brake is on The reversing safety bar will automatically resume to its original position after being activated Horn As standard equipment a horn that is located on the top of the handle AUTHORIZED OPERATORS SHOULD READ AND UNDERSTAND ALL INSTRUCTIONS PRECAUTIONS AND WARNINGS IMPROPER USE OF THIS LIFT TRUCK COULD RESULT IN INJURY AND OR DAMAGE TO LOAD AND EQUIPMENT Figure 1 Operational buttons SQ Page 9 PRESTO OWNER S MANUAL Inspect the lift for damaged or worn parts Do not use if not in safe operating condition Use lift on hard level surfaces only Make sure load is evenly distributed not loose or un stable and is as far back on platform or forks as possible Do not pick up loads on tips or forks or edge of platform Do not overload Check load center and load weight capacities on the nameplate Make sure travel and work area is clear of obstruc tions Check overhead clearance before lifting loads or trans porting 1 BELLY BUTTON SWITCH LIFT UP i urrpom SPEED CONTROL DIRECTION CONTROL POWER STAK PPS3000 125FS B DAILY OPERATIONS MUAAS AUN ANCES A KS Set up procedure for PowerStak 1 Battery Fixed Removable straddle legs 1 Install both legs into the leg cup holders evenly on both sides A Check for corroded and loose terminals A white ofthe lift Check to insure the
30. witch TM1703 PRESTO OWNER S MANUAL Page 21 POWER STAK PPS3000 125FS Figure 11 PPS3000 125FS Handle Assembly No No 9 7109 Hombuton M 6 7106 Left handle cover 1 8 7108 Spring 0 2 PRESTO OWNER S MANUAL Page 22 POWER STAK PPS3000 125FS Figure 12 PPS3000 125FS Drive Wheel Assembly No No 6 706 Ga 8 728 Washers 9 7209 Ball bearing 6002 2LS P6 1 PRESTO OWNER S MANUAL Page 23 POWER STAK PPS3000 125FS Figure 13 PPS3000 125FS Cylinder Assembly fy e s 4 Y m bw 3 4 9 7 0 _ x 7 S lt 10 2 ls 4 PS No 6 _ 8206 Pison 1 8 908 Guidebush U 9 8209 Wiper seals SFMHW 45 53 5 6 MM 1 PRESTO OWNER S MANUAL Page 24 POWER STAK PPS3000 125FS Figure 14 Parts Description No m 6 ss Block IET MM _ 7 sor row control vave s sos 9 so me PRESTO OWNER S MANUAL 7 Page 25 PPS3000 125FS Power Unit Assembly Q tem ty Parts Description No sns Reservoir 5L 1 POWER STAK PPS3000 125FS 12 13 14 15 16 17 18 19 20 21 2 2 Figure 15 PPS3000 125FS Hydraulic Schematic Solenoid valve DC24V B Flow conrol valve Check valve A X Y 16Mpa E DC24V 3 Okw Relief valve MC 2 Tml r Li PRESTO OWNER S MANUAL Page 26 POWER
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