PPS2200-62NAS - Cisco
Contents
1. m _ _ nus HANDLE CONTROL HEAD WIRING BEN i 16 18 UP DOWN 17 P DOWN gt HORN i l EMERGENCY REVERSE 19 13 19 ELECTRONIC THROTTLE MODULE PRESTO OWNER S MANUAL Page 38 POWER STAK Figure 25 Prior to November 2008 CONNECTIONS VIEWED FROM WIRE SIDE EMERGENCY REVERSE FORWARD INPUT MODE SELECTIO PUT REVERSE INPUT BRAKE INPUT KEYSWITCH INPUT REVERSE CONTACTOR THROTTLE POT LOW DRIVER OUTPUT THROTTLE 0 5 SIGNAL FORWARD CONTACTOR DRIVER QUTPUT AIN CONTACTOR DRIVER QUTPUT CONNECTOR UNIT UP CONTACTOR HYDRAULIC POWER DOWN VALVE SOLENOID CONTACTORS WRAP EACH END OF ALL WIRES WITH IDENTIFYING NUMBER LABEL PRESTO OWNER S MANUAL Page 39 POWER STAK En NOISIAHM LV 38 STALL 015 WviSHdMDd T3 540111105 2JIW NMOSH3 INY Tv H31vM 30 LAO THOM ON 820008 8 9820008 8 7 7 942500 8 1880008 8 882v0008 8 68200008 8 06250008 8 SS JNHVH SS WS ASH Y V2 55 55 JNHYH SS JNHVH 1 ONY 209080 30 juesaJd 01 8002 Jequie2. 12 Monthly Operations Maintenance Checks 12 SECTION 7 DIS 13 ORDERING REPLACEMENT PAR 50 RESTOCEING POLI Y YT 51 LIST TABLES Table 1 PPS2200 62NAS Assembly Prior to November 2008 RN 16 Table 2 Drive Wheel Description Prior to November 200 24 Table 3 Recommended Spare Parts List PPS2200 62NAS 49 PRESTO OWNER S MANUAL Page 3 POWER STAK LIST OF FIGURES Figure 1 Operational 7 Figure 2 PPS2200 62NAS Prior to November 2008 14 Figure 3 PPS2200 62NAS Exploded View Prior to November 2008 15 Figure 4 PPS2200 62NAS November 2008 to 17 Figure 5 PPS2200 62NAS Exploded View November 2008 to Present 18 Figure 6 Cylinder View Prior to November 2008 19 Figure 7 Cylinder View November 2008 to 9 9 7 20 Figure 8 Caster Wheel Assembly Prior to November 2008 21 Figure 9 Caster Wheel Assembly November 2008 to 22 Figure 10 Drive Wheel Assembly Prior to November 2008 23 Figure 11 Drive Wheel Assembly November 2008 to 25 Figure 12 Handle Assembly Prior to November 2008 26 Figu
3. LA INNS 01 008 SS SHIM 15 9910 NNO 13 Lt 22020002 J 1 1 1 68270008 A juesaJd 01 8005 CE INSI POWER STAK Page 47 PRESTO OWNER S MANUAL L 1520008 LV ONIMVad STALL 2820008 acci tici LTI 143493499 O 06220008 553NHYH SHIM XISuMd 9910 NND2 13 AAW LID Hct juesaJd 03 8002 INSI POWER STAK Page 48 PRESTO OWNER S MANUAL Table 3 RECOMMENDED SPARE PARTS LIST PPS2200 62NAS 4 I I I 1 PRESTO OWNER S MANUAL Page 49 POWER STAK Ordering Replacement Parts Presto Lifts has carefully chosen the components in your unit to be the best available for the purpose 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 Part
4. 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 personnel involved with the installation maintenance or operator of the stacker read this manual Additional manuals are avail able upon request or at www PrestoLifts com Each Presto stacker is equipped with nameplate serial number and model identifications Please refer to these Specifications numbers when ordering parts or requesting further information The Presto stackers are designed for lifting lower ing 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 Lifting speed empty Lifting speed loaded 7 Lowering speed loaded Aisle Spacing Travel with 28mh 00000 Lowering speed 3 3 Travel speed w o load 34mh 6 Overall height Overall length 5 Overall width Usage for all 4 6 hrs per 8 hr shift 2200 lbs Adjustable straddle legs OD 46 58 Adjustable straddle legs ID 38 50 Lifting height Gradient performance w o load
5. 8 9 6 5 9 IL 3SV8 OUMW3HOS z NIZOLO lt 3850 I9 1 m Y 5 nAd9o0z 1 d y e ISd 0052 uva 5md gt 5 9 AVS 81 91 6 4 130415 JAY 9 SVS 81 91 6 1 LINO M LI JINSIA POWER STAK Page 31 PRESTO OWNER S MANUAL Figure 18 November 2008 to Present Power Unit Assembly PPS2200 62NAS 017 0015 2 C a gid 90113 PRESTO OWNER S MANUAL Page 32 POWER STAK Figure 19 4001 4002 4003 Prior to November 2008 Carriage Assembly 52200 62 5 4004 4005 4006 4007 4008 1009 Description Qty 4008 Washer35 PRESTO OWNER S MANUAL Page 33 POWER STAK Figure 20 Carriage Assembly PPS2200 62NAS November 2008 to Present m An eu are 0 Item Description Qy 4004 Middle Plate 4 4009 Fork shaft fi 4013 WheelSleeve f4 4014 SnapRingM35 6 406 Fork f PRESTO OWNER S MANUAL Page 34 POWER STAK ings Warn ionary Labels amp Precauti Figure
6. Ix 13783 81242 NAOH MAH 034133NND2 LON E 2 0008 9 SS3HHVH 5 143345 MUTTA LENS 1035 pg ps d 122 NOTI3A PIDE lags 398 98670008 juesaJd 01 8005 LEM LANI d 11509 33111 113018 JANI d B BOODDA 284 1 TILLER HANDLE NEXT 3015 FSPZRO N S 043 038114 SNOJLOSNNOD 55 54011934405 6Z POWER 5 43 PRESTO OWNER S MANUAL hae HARANIN eee ju343342 01 0311817 y SSINAVH YLSHMd 9910 T3 30 351 5jH2H 34 11290008 7 131412145 3JS RH3HID 5531 TM THE 1111056 21NDMDOJ3 ONY 00061 HA 7 emu 12 pace SNITONYH 1218319W 3018017808 141 1 384 des E 16 Al T aaa ON 01101 2530 Wald z j W m SS H 123NNU 3 H1 E i I 11 2 AH3llVvH 3 3l N3349 ma ER _ i 1134 MOTTI P m m 35 9 WY OSL 01 931104109 DHdNY2 01 1BZPDODS d 34008 01 HJL MS 134 QNS 55jMHVH T33HM 93150 3095 7914 l E NAI N TO 401 010
7. Description 1009 NutC Grade m12 4 1010 Bot PRESTO OWNER S MANUAL 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040 1041 1042 1043 1044 1045 1046 1047 1048 1049 1050 1051 1052 1053 1054 1055 1056 1057 1058 1059 1060 e lt Page 16 Description Bearing 6006 Washer Washer 30 chain wheel top base Chain LH1234 Bolt M6x25 Flat washer 4 Spring washer 4 H bolt M4x12 Nut M10 Nut M10 Flat washer 10 Cylinder hoop Vertical mast cover Battery B pin 8x40 Pin 2 5x12 Chain pole Pin 2 5x25 Flat washer 16 Nut M16 Battery cover Nut M6 Spring washer 6 Bolt M6x25 Bolt M6x35 Spring washer 6 Flat washer 5 Cover lock plate Round cover Bolt M5x10 Flat washer 5 E Stop Key Switch Battery meter POWER STAK Figure 4 PPS2200 62NAS November 2008 to Present PRESTO OWNER S MANUAL Page 17 POWER STAK Figure 5 PPS2200 62NAS Exploded View November 2008 to Present PRESTO OWNER S MANUAL Page 18 POWER STAK Figure 6 Cylinder View PPS2200 62NAS Prior to November 2008 ip SG PRESTO OWNER S MANUAL Page 19 POWER STAK 7 Cylinder View PPS2200 62NAS November 2008 to Present Item 5001 Fitting J 5002 ORing fj 5006 URing 2 5007 Piston fj 5008 Spacer ft _ 009 1 5010 PistonRod 1 5012 PRESTO OWNER S MANUAL Page 20 POWER STAK 8 Prior to Novembe
8. Presio worldwide material handling and ergonomic solutions Power Stak PPS2200 62NAS Installation Operation and Service Manual Model Number Serial IMPORTANT READ CAREFULLY BEFORE INSTALLING OR OPERATING LIFT Part orders are subject to a 50 minimum charge DECEMBER 2011 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 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 t
9. 005 PRESTO OWNER S MANUAL 1006100 0009 SIIB d 941007 211392919 w s CN 19104409 134301 1006 8002 49QUJ9AON 03 201 Figure 23 Electric Control Circuit Prior to November 2008 t ircul Electric Control C 5 St S 54 Description 12V 70Ah Motor Controller 4 X PumpMotor 1 5 Jt Pump Motor Controller DC24V 200 6 J243 Driving Motor Contactor DC88 DC24V 24A 8 BX2 PumpCircuitFuse 0OC24Vi50A 9 BX3 Controller Circuit Fuse FS 10DC24VA0A 10 82 MagneticCiutch 11 S3 JjUrgentReveseSwith S4 S5 UpDownSwth 2 13 Se HomS Swih 4 57 58 A DownSwth 15 S9 A PowerSwth 250 16 MagneticCluth 1 DC24V 25W BNm Magnetic Come Valve DC 24V 46W eS 19 MC 0 120 D2D6 1 Diode NAOT 21 v Tinng ETR711 DC24V PRESTO OWNER S MANUAL Page 37 POWER STAK Prior to November 2008 Figure 24 Wiring Connectors viewed from wire entry side I LL CONNECTORS II eee WED FROM ENTRY SIDE
10. DO NOT use on ramps or inclines Only smooth level surfaces 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 position DO NOT handle tall unsecured or unstable loads that could fall DO NOT allow people to stand or pass under forks or platform 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 SECTION 3 INSTALLATION A INSPECTION Upon receipt of the stacker inspect the equipment com pletely to determine if there is any shipping damage and that the lift is complete Presto tests and inspects every piece of equipment 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 hy draulic power pack e Check all electrical and hydraulic connec tions for tightness e 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
11. Gradient performance with load Short term gradient performance w o load Short term gradient performance witah load PRESTO OWNER S MANUAL Page 5 POWER STAK 2 SAFETY You must be trained and certified to operate this powered stacker Federal law states that only prop erly 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 Op erator training programs may be offered by your local Presto Lifts dealer or obtained online Enter powered industrial truck operator training into a search engine The battery operated stackers are very powerful lifts capable of doing large amounts of work DO NOT OPERATE THESE LIFTS WITHOUT CAREFULLY 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 maintenance 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 pos sibility of injury WARNING 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 platfo
12. 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 OWNER S MANUAL Page 51 POWER STAK m Presio Call Presto Sales for stock or customized lift inquiries 800 343 9322 Email sales prestolifts com
13. 21 159123 L6COVOOT NSSTO 8 86 00T LL86 001 9 86 00 ON YACNN AWVes ALVIO1 x ONO 40 AWS EA REED EL LEER 00 3719039 LUN LON 09 54301 ONINSVM V SLA 1 ao Unna Spend SHIAQIN 30 Hv312 Ppp Gunes SWHO3 ONVLS LON apu gane pinay ua ung ON DON US De pott Duo ape WHE Canela JS VW 3GIM d Vd SS Ou NO QNV S3NIH O VIN 1S VIN Odd VN NA OHS SV WLS Od 3L V2OI 3 A POWER STAK Page 35 PRESTO OWNER S MANUAL Electric Control Parts Figure 22 4191138 pem Ais 1 6 s Un 1664 uo POWER STAK Page 36 X _ a 4008 JE NN M Coy WOH 9009 1112112 1011002 9119914 EF esnj 9009 V091 9514 7009 Jojoejuo
14. stop button down 3 Remove the 2 screws from the main orange cover that covers the unit 4 Remove the emergency stop button by unscrew ing 5 Slide the main cover up and place the block of wood under the right hand side to hold open exposing the idler wheel and adjusting the screw 6 With the adjustable wrench loosen the jam nut on the idler wheel adjusting screw 7 Loosen the adjusting screw until you have no ten sion between the adjusting screw and idler wheel You will have some play between the idler wheel and the left front wheel 8 Now tighten the screw until you just make contact with the idler wheel Continue adjusting until the idler wheel just touches the floor 9 Tighten jam nut You may have a slight rocking back and forth from the left front to right rear idler wheel but this is not uncommon 10 Now remove the wooden block and lower the cover back into place inserting the 2 screws and tighten Screw the E stop button back on 11 Your adjustment is complete If the wheel is worn replace wheel Page 13 POWER STAK Figure 2 PPS2200 62NAS Prior to November 2008 POWER STAK Page 14 PRESTO OWNER S MANUAL Figure 3 1028 107 1026 Prior to November 2008 PPS2200 62NAS Exploded View er BA f of AK lt POWER 5 15 PRESTO OWNER S MANUAL Table 1 Prior to November 2008 Model PPS2200 62NAS
15. 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 put 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 DAM AGE TO LOAD AND EQUIPMENT Inspect the lift for damaged or worn parts Do not use if not in safe operating condition e Use lift on hard level surfaces only Make sure load is evenly distributed not loose or uns
16. 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 in 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 traveling 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 func tions like a throttle When you release your hand from the butterfly control it automatically will resume to the neutral position and the speed of the stacker will slow down PRESTO OWNER S MANUAL To Brake Your stacker is equipped with a magnetic brake The brake 15 applied when the handle is in its vertical po sition between 10 15 degrees and lowered position between 80 90 degrees The brake could be released when you pull down the handle at any point between 15 80 degrees Always make sure the brake is re leased 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
17. 034 1055 Jie 7036 y i 7037 AN PRESTO OWNER S MANUAL Steering Assembly PPS2200 62NAS 9 lt eei Treas a Des 7030 connect ase 1 Des 1 3 rose oin i 7035 ome werte 1 Des sr sensu wea 1 e Page 30 POWER STAK 002 Wd9 14 dIND d ASSY 134404 AVL 31VIN 8 2QAvC 1102 00 L3ddOd ON dZ MZ JOCINLYVD SH 1 1 2 ASSY DAA vc 15 HLI 19 10S HOLIMS 1 9 Stt SONT M GALVINSNI 319VI C AZT 2 YOLOW vI v 1 y3HJV3yg ASAY YIS ASY u v39 INHOM ISOH 2 LIN A LIXS 9X8 79 21614 4638 TONS 531835 33825 c 8002 O01 SVNcC9 00ccSdd quiessy dad lt _ eo 8 8 416 1206 H 8 T YLS 3gni Pals XO 119 4 7 X Oc v T DHS 7443825 ASY 219 5 INO ASSY d 15 GOW 6TSEW ASSV ASV f COlalals 5 LN OHLIM NM OHS MAIA
18. 31 TH BOTA 1134 1 311 1 11 13 0 gee 3541438 3 1 E 2 1 E L NI HACHE T L1IN33H9 1 011 ND A 3179 2 1 T A 1033 dl 3015 OFVIH 109 LT POWER STAK Page 41 PRESTO OWNER S MANUAL 8250008 ONT MALE SNOILNTOS JIWONOONS 0120 019421331 329145 D ONITONVH TWIMSLYA SOIMTTION SLAIT OLSHud 9 0008 8 1731 01141 2591 1011 AS Cni 720008 juesaJg 01 15 28 KG MOTTA amg LHOIT 18 YLIN m AS qa N 2 L NATH 5 AINAIYANA 8Z dINSI IULOYHL 240412313 9413 99 LIGHT T POWER STAK Page 42 PRESTO OWNER S MANUAL DSW STALL UUP 01 MOLIYNMO4N 30 351 SAHIN 389 UN 319 OYE 540111705 21WDNDOH3 ONY SS ro MEN 3N TIONYH WlH31VW 301MC 140M 015384 107 L H cat Go XXX ON 1499 01 19135530
19. 43105 15 21044 30 l 4 FBZBO JHIA WOH OH A awa Ld H33 ns SSSNH H H H M 54011 98 r0008 H juesaJd 01 8002 J9quieAON 0g POWER STAK 44 PRESTO OWNER S MANUAL NOISIA TM 38 LSOW DNIAVHG SIHL 1H3433H5v GL d311H11 WS ASX Y v9 1903 WNILSHMd 9910 MN S 30 ISN SHON 3dY MIU 31319345 Di 5 55 ut DS J INDNOSH3 ee CF STONY 1411 0156384 D x 15142530 279 rm zs Igas LOW NH MOTTE 4 TT 5 j x mana N JOH 03H wW WE WANS 3915 420 1 4530 3 SMO 1234403 18220008 y i ju8saJg 01 8002 J9quiaAoN POWER STAK Page 45 PRESTO OWNER S MANUAL HALLEAN 01 987000081 SSINHYH ZMIM XISMMd 9910 73 BIZEDUOB 141015334 88270008 f juesaJd 01 8005 5 LV 1521 O gt Te ZE POWER STAK Page 46 PRESTO OWNER S MANUAL ONIMVU STALL
20. ASTERS Check for wear and that they are turning smoothly LIFT CHAINS Check to see that they are in place and not loose FORKS Check that they are not bent or cracked BRAKES Ensure brakes work properly CABLES WIRES Check that there are no loose cables or wires LABELS Ensure all 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 Lubricate chain with 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 assem bly 3 Frame Assembly A Clean and lubricate all roller bearings cam followers 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 connec tions CAUTION DO NOT USE LIFT IF IT IS NOT OPERATING PROPERLY OR APPEARS UNSAFE IN ANY WAY Page 12 POWER STAK ECTION 7 TROUBLESHOOTING Before starting the troubleshooting you have to A Put the truck on an even and solid su
21. AoN OM 0 POOOg HOT 191 d 3530 1594 Sud A StMd 35 8 Wldds TALI WR 3409 Z 5141 0153849 m url iz SNOLLOVHS amj j 1 CIRES Es JJNMUJ 34918 1919 d Jav saAvisgiMDd 903 10 Ld l 3553 333uog DI MOILYNADJHMI 30 sJH2N 3dY MIU 031312345 3J5TWH3HID ss3Nn 0 221084 E t 500 LE NU SS JNHVH 1M AJH 35 1303 v OSTA INO A 38 3 53 1992 9c POWER STAK Page 40 PRESTO OWNER S MANUAL ON 199 LX H G82 pODOS 3371111 3 1 10111105 JIWONOSHS 1v H31VM 30180 1808 I 113ill te 78250008 H011d 42530 Jig LHS 7 45 1 11 col co de d 455445 Mad L 431 0 1 34 2 d3LJ3HN03 LOW 4H d 119 L41805 38 LSOIN ONIAAVHG Pe HLONJ tw HLJNJ jd 07 8002 DL 0311411 MOlISWHOJNI AuwIJ Bd ud 30 5n SIHIN MI SHY 091 4193d5 35 MY 3HLO 553 33 01123 TINY DHE pe 129 EC ggg F XXX ALE TRONIC THROTTLE n 13
22. 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 dam age to the steel construction of stacker Pick the unit up On conventional masts use the top crossmember of the lift On narrow masts the cover must be removed to access lifting equipment Be careful of the stacker swinging once fully lifted off the pallet or skid Have Figure 1 Operational buttons EN PRESTO OWNER S MANUAL 7 BELLY BUTTON SWITCH Lt LIFT UP LIFT DOWN HORN SPEED CONTROL DIRECTION CONTROL Page 7 POWER STAK all personnel completely cleared from the area Pick the unit up approximately six inches above the pal let 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 standards have been met Visually inspect the stacker for damage Check for at tachments an
23. ction 2 Red light blinks 5 times in 5 seconds The tempera ture 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 charged 3 Green BAttery is at 100 Fully charged 4 No light The charger can not charge the battery Voltage of the battery may be too low to cause the char ger to start It must be at 9 volts to initiate charge Battery is between 70 and 100 SECTION 6 MAINTENANCE Operation of Presto Power Stak is very simple as is their construction They require very little maintenance Reasonable 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 e Use only Hydraulic AW32 or Dextron III in the hydraulic system not overload your lift Check brakes steering mechanisms con trols before each use A WEEKLY OPERATIONS MAINTENANCE CHECKS DAMAGE Check for bent dented worn or broken parts 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 LEAKS Check hydraulic system for leaks and hydru alic oil level PRESTO OWNER S MANUAL WHEELS AND C
24. d 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 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 Set up procedure for Power Stak Straddle legs with 3 Bolts Straddle Leg Bolt Tightening Procedure 1 Pre tighten all bolts to the bottom but not too tight Fully tighten bolt 1 Next tighten bolt 3 Last tighten bolt 2 Tighten all bolts to 85 foot pounds PRESTO OWNER S MANUAL NOTE The Straddle legs must be adjusted to the procedure below 1 Determine the required straddle leg dimension 2 Relieve any weight from the legs This may need to be done one side at a time 3 Adjust the legs and ensure both legs are positioned equally 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 mark ing wheel Note The travel speed is preset at the factory For travel speed adjustment please contact customer service at Presto Lifts 1 800 343 9322 Set up procedure for Power Stak Straddle legs with 4 Bolts FZ gt Straddle Le
25. ed 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 cur rent Owner s Manuals to print PRESTO OWNER S MANUAL Page 2 POWER STAK TABLE OF CONTENTS SECTION 1 ET 2 M 5 PP isuu uuu E ni ncaa vnc DCN III cb nC ets des E elena vended done 5 SECTION 2 IE 6 7 3 7 is 1 Emo trom Pallet 7 8 En 8 4 9 Operati e EE RD IRL MT 9 B Daily Operations Maintenance Checks 11 Sussested Daily Operator Chee ESL 10 SECTION 5 Daters c MN 11 A Piepari e 10 Charre aA Dallepy 11 D ha EU 11 11 IP NECI NIIS DUI ee RM 11 Re 11 12 6 hA EUIS NN T 12 A Weekly Operations Maintenance Checks
26. g Bolt Tightening Procedure 1 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 8 POWER 5 SECTION 4 OPERATION OPERATING INSTRUCTIONS Operational Speeds the Presto Power Stak is designed to operate at the following speeds Rise speed empty 24fpm Rise speed loaded 17fpm Lowering speed empty 13fpm Lowering speed loaded 31fpm 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 15 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 been stacked safely on the pallet Also make sure that the length of the forks corresponds to the length of the pal let 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
27. he 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 any way with those codes it shall not be considered a defect of materials or workmanship Presto Lifts shall 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 provid
28. r 2008 Caster Wheel Assembly PPS2200 62NAS 0401 40 243 2404 2405 406 16 5 240 MO NINOS 2408 Description Description 2402 Springwasheri0 4 2403 fa FN 1 245 Bearing J1 24066 Flatwasher 1 PRESTO OWNER S MANUAL Page 21 POWER STAK Figure 9 Caster Wheel Assembly November 2008 to Present 52200 62 5 m Description 4 1 1 2 2 2 1 PRESTO OWNER S MANUAL Page 22 POWER STAK Figure 10 Drive Wheel Assembly PPS2200 62NAS Prior to November 2008 PRESTO OWNER S MANUAL Page 23 POWER STAK Table 2 Drive Wheel Description Prior to November 2008 PPS2200 62NAS Description Item Description 3001 3017 bearing 6006 3002 3018 Plug 3003 3019 5 6 15 3004 3020 _ Screw M6x20 3005 3021 Screw M6x60 3006 3022 Gear 3007 3023 Spring washer 15 3008 3024 _ Bearing 80102 3009 3010 3026 Clutch plate 3011 3027 Clutch gear 3012 3028 _ Spring washer 14 3013 3029 Scraping plate 3014 3030 Clutch fold DC 24V 16W 3015 3031 Screw M5x50 3016 WIRE IO lt PRESTO OWNER S MANUAL Page 24 POWER STAK juesaJd 01 8005 SVNcC9 00ccSdd quiassy 99uM POWER STAK Page 25 PRESTO OWNER S MANUAL Prior to November 2008 Figure 12 Handle A
29. r into a 115V outlet Charge until the battery gauge indicator lights show fully charged approximately 6 8 hours C WARNINGS AND BATTERY INFORMA TION 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 folow all battery and battery manufacturer s specific precautions while working with and or charging bat teries 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 the previous 30 minutes DANGER Never alter the cord or plug provided If it will not fit outlet have proper outlet installed by a quali fied electrician Improper connection can result in a risk of an electric shock 1 Disconnect the charger from the 110 volt wall out let 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 normally Charger will operate 2 Red Bad connection or bad battery Page 11 POWER STAK Fault 1 Red light blinks 3 times in 5 seconds The output between charger is faulty loose or bad conne
30. re 13 Control Pod November 2008 to Present 27 Figure 14 Steering Assembly Prior to May 200 28 Figure 15 Steering Assembly May 2007 to August 2008 29 Figure 16 Steering Assembly August 2008 to 30 Figure 17 Power Unit Assembly Prior to November 2008 31 Figure 18 Power Unit Assembly November 2008 to 2 32 Figure 19 PPS2200 62NAS Carriage Assembly Prior to November 2008 33 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 PPS2200 62NAS Carriage Assembly November 2008 to 34 Labels amp Precautionary 5 35 Electric Control Panel Prior to November 2008 a 36 Electric Control Circuit Prior to November 2008 ener nenne 37 Wiring Parto November 2008 uy Gusan 38 Wiring Diagram Prior to November 205 39 Wiring Diagrams November 2008 to 40 Figure 27 Wiring Diagrams November 2008 201 nennen 41 Figure 28 Wiring Diagrams August 2011 to Present 42 Figure 29 34 Wiring Diagrams November 2008 to Present a 43 48 PRESTO OWNER S MANUAL Page 4 POWER STAK
31. re is any existing corrosion B Visually inspect for any cracks or damage to the casing C Check for loose battery tie downs 2 Charger A Inspect wire connections B Check power cord for nicks damage C Check power charger for proper mounting 3 Hydraulic System D Inspect pump and cylinder for oil leaks E Check hydraulic oil level Check hydraulic fittings and hoses G Check ram for nicks damage 4 Frame Assembly A Check chain roller assembly connections B Check for any worn or damaged parts SECTION 5 BATTERY MAINTENANCE A PREPARING TO CHARGE A BATTERY 1 Always turn off E stop and key switch before work ing with the batteries 2 sure the area around the stacker and the battery VOLTAGE 12 7 Fully charged 12 2 1 2 charged BA M E d Approx 12 0 V 1 4 charged T 11 6 Discharged PRESTO OWNER S MANUAL is well ventilated while battery is being charged 3 The battery terminals connections and wiring connections should be clean and free of corrosion When cleaning any of these components wear a face shield or other suitable protective eyewear BATTERY CHARGING Charging must be performed with the charger that is provided with or prewired into the machine During charging the temperature in the battery must not exceed 120 F Charging simultaneously with truck operation 15 not recommended Plug the charge
32. rface B Turn off key switch or disconnect the battery terminals 1 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 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 e Chain or roller bound e Check oil level 2 Forks will not lower Look for binding in chains or rollers 3 No electrical power Dead Batteries Keyswitch 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 contactor Faulty contactor PRESTO OWNER S MANUAL 4 No Traction Idler wheel needs adjustment IDLER WHEEL ADJUSTMENT The following is a procedure for adjusting the idler wheel on the Presto PowerStak Under normal condi tions this should not be necessary becaus the idler wheel has been adjusted at the factory Tools Needed Phillips head screw driver Medium crescent wrench 1 block of wood 2 x 4 Place unit on a flat surface 2 Turn key to the OFF position and push emergency
33. rm 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 motion Do not put hands or feet under the forks or platform Do not stand underneath the forks or plat form 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 PRESTO OWNER S MANUAL WARNING 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 on the stacker It is your responsibil ity 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 e Watch your hands and feet 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 sur faces Do not run over objects on the floor e Perform all stacker mo
34. s 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 warranty Freight collect for truck except parts covered by warranty Freight prepaid and invoice for small parcel shipments except parts covered by warranty 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 Presto Lifts Parts Department 21 Park Street Attleboro MA 02703 Telephone 800 343 9322 FAX 888 788 6496 Email Service PrestoLifts com www PrestoLifts com PRESTO OWNER S MANUAL Page 50 POWER STAK RESTOCKING POLICY PARTS Standard parts may be returned with a 20 restocking fee Modified or custom engineered parts are not returnable Unfortunately due to potentially concealed damage all sales of electrical 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 condition
35. ssembly B Q Q e Q lt lt i c O 3 100 101 102 103 104 10 10 5 9 110 111 112 113 3114 6 3 107 1 3108 10 3 3 3 POWER STAK Page 26 PRESTO OWNER S MANUAL Figure 13 Control Pod 52200 62 5 PRESTO OWNER S MANUAL November 2008 to Present Page 27 101 103 Front Button 1 Description Qty 114 Switch Cover 1 POWER STAK Figure 14 Steering Assembly Prior to May 2007 PPS2200 62NAS Description 1100 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1200 B S e c I r r N r IO EF lt PRESTO OWNER S MANUAL Page 28 POWER STAK Figure 15 Assembly 2007 to August 2008 PPS2200 62NAS 3100 3201 3202 3203 Pin Airspring Air spring 3204 3205 3206 3207 3208 3209 3210 3211 3212 3213 3214 3215 3216 3217 3218 3219 3220 3221 3222 3223 3224 3225 3226 3227 3228 3229 3230 3000 PRESTO OWNER S MANUAL Page 29 POWER STAK I lt Figure 16 August 2008 to Present 7002 1005 7025 Ta 7027 7004 1028 7005 7 uc 7006 7030 7007 E 7008 7009 7032 035 1
36. table and is as far back on platform or forks as possible Do not pick up loads on tips or forks or edge of platform Page 9 POWER STAK SUGGESTED DAILY OPERATOR CHECKLIST WALK AROUND INSPECTION 1 Check general condition of lift loose or broken parts etc 2 Check for dented or scratched panels 3 Look for broken or cracked welds broken or worn rollers and chains Check for loose pins or fasteners 4 Ensure condition of wheels are not flat spotted or chunked out 5 Check for hydraulic leaks 6 Make sure all precautionary labeling 1s 1n place and legible 7 Check for hydraulic leaks FUNCTIONAL INSPECTION 1 Check for proper operation of UP DWN FOR REV controls 2 Check operation of brake system 3 Check for locations of belly button switch and horn 4 Check for hydraulic leaks OPERATOR ID DATE DO NOT USE LIFT IF NOT OPERATING PROPERLY OR IF LIFT APPEARS UNSAFE IN ANY WAY REPORT CONCERNS TO SUPERVISOR IMMEDIATELY PRESTO OWNER S MANUAL Page 10 POWER STAK e For fork models adjust forks to maxi mumpractical width Pick up loads on both forks Do not overload Check load center and load weight capacities on the nameplate e Make sure travel and work area is clear of obstructions Check overhead clearance before lifting loads or transporting B DAILY OPERATIONS MAINTENANCE CHECKS 1 Battery A Check for corroded and loose terminals A white powder substance will be present if the
37. vements smoothly 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 e 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 trailers are chocked e Travel with the load or forks close to the ground Watch for overhead obstructions Per form all stacker movements smoothly and at a speed that will give you time to react in an emer gency Keep your hands and feet away from all mov ing parts such as masts chains forks or wheels e 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 e Before you leave your stacker be sure to lower the forks to the floor Shut the stacker off with the key Page 6 POWER STAK WARNINGS 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 instructions DO NOT exceed load center or load weight capacities check capacity plate DO NOT operate until you have checked the condi tions of the stacker lift systems forks chains and cables DO NOT use if any part is damaged worn or not work ing properly
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