Home

PowerStak PPS2200 101AS Oct11.indd - Cisco

1. N l res LER m PRESTO OWNER S MANUAL Page 12 POWER STAK PPS2200 101AS Figure 3 PPS2200 101AS Exploded V Prior to November 2008 _ 8000 POWER STAK 52200 101 5 Page 13 PRESTO OWNER S MANUAL Table 1 PPS2200 101AS Assembly November 2008 to Present Description Description Flat washer 10 Battery B Pin 8x40 Pin 2 5x12 Chain pole Pin 21 5 25 Flat washer 16 Nut M16 Battery Cover Nut M6 Spring washer 6 Bolt M6x35 Spring washer 6 2300 2400 3000 3100 3200 4000 5000 6000 7000 8000 9000 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1030 1035 1036 1037 1040 1041 1042 2043 1044 1045 1046 1047 1048 1049 1051 1052 1054 1055 1056 1057 1058 1059 1060 1061 1062 1063 1064 1065 1066 1067 1068 1069 1070 1071 1072 1073 1074 1075 1076 1077 Cylinder Rear wheel Drive wheel assembly Handle assembly Steering assembly Lifting mechanism Electric system Power unit Battery charger Body weld Inner mast Drive wheel cover Rear box cover Nut M6 Bolt M6x25 Spring washer 6 Bolt M12x50 Nut C grade M12 Leg assembly Nut C grade M12 Bolt
2. 24 20 02 06 1 407 ___ 21 750 ETH711 DC24V PRESTO OWNER S MANUAL Page 35 POWER STAK PPS2200 101AS Figure 26 Wiring Connectors viewed from wire entry side gt CONNECTORS VIEWED FROM WIRE SIDE Prior to November 2008 O O REVERSE 19 5 MANUAL 5 S F DOWN DOWN HORN I I ELECTRONIC THROTTLE MODULE Page 36 POWER STAK PPS2200 101AS Figure 27 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 FORWARD CONTACTOR DRIVER OUTPUT AIN CONTACTOR DRIVER OUTPUT THROTTLE 0 5V SIGNAL 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 37 POWER STAK PPS2200 101AS November 2008 to Present Figure 28 _ 181 ER 1H3433H5v DI 4311017 0157
3. RIDERS DO LIFT PEOPLE DO NOT STAND UNDER FORKS STAY CLEAR OF MOVING PARTS LOCATE ON MACHINE LIFTS 10039876 10039877 10039878 C155N 10040297 C165L LD TAG Lift manufactured to ASME B56 1 2 BK LD TAG 3 50x 1 87 Stacker Name Plate 4 PBKiDDCLI200x300 Presto Alpha 6 Page 33 POWER STAK PPS2200 101AS Figure 24 Electric Control Parts Priorto November 2008 Electric Control Parts 1 w Electric control circuit it j Lontactor j orn 5001 controller 1 5002 Contactor F R 1 5003 Hydraulic Contactor 1 5004 Fuse 150 2 5005 Fuse 5A 1 5006 1 5007 Horn 1 PRESTO OWNER S MANUAL Page 34 POWER STAK PPS2200 101AS Figure 25 Electric Control Circuit 12074 4104 MY 170 M Wn I 4 Code Description q J4DR Driving Motor 12V 70Ah 2 Ka Motor Controller 12074 4102 DC24V 250A M2 DC24V 13Kw bui 6 i le 87 9 i 1 53 UrgentReverseSwich 12 5455 Up DownSwich A X J 13 S6 j 15 S9 PowerSwtch 202 16 Li MagneticClutch DC24V 25W Magnetic Somoutete Valve Da tied ircle 18 Di Diode 1 1 548 Prior to November 2008 19 MC
4. pad D ONITONVH OLSHud 091412845 01141 2594 qx NASD OTT Wild 9119 LWIT 05 MS Ct 15 Id 1 ana 76570008 4 juesaJg 01 10z 15 NaH MOTTAL vig GH amm 18011 XR 19 m AS qi N 1 1 WNId 5 AONAD MANA NaOH r o O N MEM NAT 911nsrq 1 sis qas 70004 IULOYHL 20313313 9213 d LIGHT GREEN T S S SS ELECTRONC THROTTLE MODLL POWER STAK PPS2200 101AS Page 40 PRESTO OWNER S MANUAL NOPTAAY LV SIH L 2 GBZPO008 SS3NHVH 3MIM XLSHMd 9910 NNDD 73 DIDA 01 812 0008 58270008 A PETE 1 5 44 018002 J9QUI9AON PPS2200 101AS 41 PRESTO OWNER S MANUAL v _ 98090008 SS3NUVH 3NIM 915844 9710 NNDD 13 112 000 gt 98270008 p juesaJd 01 8002 JequieAoN lt POWER STAK 52200 101 5 Page 42 PRESTO OWNER S MANUAL tw SIHL SNOLINTDS ALNOMOSS3 NY THOM NOT 1d 835 30 M5 183382 1035 10H WOT TE 421 18 N 19220008 y
5. 3222 Bearingsleeve ___ 1 3223 Aflatkey 845 i _ 3224 Steeringweldbase 3225 Washer f 3226 Springwasher6 ____ 2 3227 612 J2 3228 30212 f 3229 BolM10GO fja 3230 Springwasher10 4 _ 3000 Drive wheel 7000 1 PRESTO OWNER S MANUAL Page 27 POWER STAK PPS2200 101AS Figure 18 Steering Assembly August 2008 to Present PPS2200 101AS em Deco a 7013 7003 S Pe 7016 Va 7018 7006 h An NO 0 ON 7021 7008 mn 7009 ee SS NN 7023 9 lt PRESTO OWNER S MANUAL Page 28 POWER STAK PPS2200 101AS Figure 19 Prior to November 2008 OUTLET PORT 9 16 18 SAE 6 REF OUTLET PORT 9 16 18 SAE 6 PLASTIC PLUG 172 BAR 9500PS V 7 57 LPM 1 200 GPM E I F 21 67 CCIREV L 0 1021N_ REV 5 ISCHEMATIC r 1 BASE 11763 RELIEF VALVE GROUND SC REW HOLE 5 16 18 UNC 2B VIEW SHOWN WITHOUT RESERVOIR DRAIN HOLE REF Power Unit Assembly Q PPS2200 101AS TUBE RIN STR 3 8 NPT NYLON i TUBE STR 3 8 NPr NYLON i SCREEN Msemessuc a RES 6756751 O N CLAMP
6. q Presto S worldwide material handling w s and ergonomic solutions p Power Stak F PPS2200 101AS p Installation Operation and Service Manual Model Number Serial If you are not satisfied in any way contact _ 4 7 Date Placed Service IMPORTANT READ CAREFULLY BEFORE INSTALLING OR OPERATING LIFT Part orders are subject to 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 wit
7. 1015 1016 1017 1018 1019 1020 1021 1200 EF lt PRESTO OWNER S MANUAL Page 26 POWER STAK 52200 101 5 Figure 17 2007 to August 2008 Steering Assembly PPS2200 101AS Description 3100 3201 Handle pipe weld 3202 3203 Ly 3204 Ai 3205 Cover lock plate 3206 Bolt M6x25 6 3205 3207 3208 3209 3211 3212 3213 3214 3215 3216 3217 3218 3219 3220 Travel switch Flat washer 4 Bolt M4x25 Round nut M52x1 5 Lock washer 52 Handle base weld Round nut M56x2 Lock washer 56 Press cover 3221 Bearing 6212 3222 Bearing sleeve 3223 3224 3225 3226 3227 3228 3229 3230 3000 Steering weld base Spring washer 6 Bolt M6x12 Bearing 30212 Bolt M10x30 Spring washer 10 Drive wheel 700W Item Description 3100 3201 Handlepipeweld i 3202 Washer8 h 3203 pin 3204 Aisping fJ 3205 Coverlockplate 1 _ 3206 Bot 625 3207 Sprimgwasher ___ 2 3208 washers 2 3209 nume 2 3210 Nutma _ 3211 Travelswitch 3212 Flatwasher4 2 _ 3213 4 25 f2 3214 Shortthread screw 2 3215 _ Round nut M52x1 5 1 _ 3216 lockwashers2 1 3217 Handlebaseweld ___ 1 __ 3218 RoundnutM56Q ___ 1 3219 lockwashers 1 3220 Presscover j _ 3221 BearingG212 1
8. 2008 to 19 D Removine irom Pallet 6 Fig 10 Caster Wheel Assembly Prior to Nov 2008 20 Preparation for 6 Fig 11 Caster Wheel Assembly Nov 2008 to Present 21 Fig 12 Drive Wheel Assembly Prior to Nov 2008 21 SECTION 4 Fig 13 Drive Wheel Assembly Nov 2008 to Present 23 Opera 7 9 Fig 14 Control Pod Prior to Nov 2008 24 A Operating Instructions y Fig 15 Control Pod Nov 2008 to 25 B Daily Operations Maintenance Checks 8 Fig 16 Steering Assembly Prior to May 2007 26 Suggested Daily Operator Checklist 8 Fig 17 Steering Assembly Prior to May 2007 Aug 2008 27 Fig 18 Steering Assembly August 2008 to 28 Fig 19 Power Unit Assembly Prior to Nov 2008 29 Battery Maintenance 9 Fig 20 Power Unit Assembly Nov 2008 to 30 A Preparing to Charge a Battery 9 U B Chaieine uuu uuu uuu 9 Fig en i C Warnings and Battery Info 9 Fig 22 Carriage
9. juesaJd 01 8002 POLED WW 34049 Z l Ld 85533 LINJ ddai DI 11411011 dIHd Hd 30 53H2N MI 131313451 5131 015344 400 TT LE 5 13784 WHIA 08 9 405 INGA w 3015 54011934405 351MH3HIU 5531 digne DE L 1 3818 Q3N 3 POWER STAK 52200 101 5 Page 43 PRESTO OWNER S MANUAL VW LV 1 sos SlHllOIS33d 88270008 A juesaJd 01 8002 987900081 SS3NHVH 34IM XLSMMd 9710 NNDD 73 NO END ONIAAVHG HALLEAN 01 POWER STAK 52200 101 5 Page 44 PRESTO OWNER S MANUAL NOISIAT I LV 38 L 58270008 juesaJd 01 8005 _ 6820008 SS3NHVH 3MIM XISHMd 9910 NNDD T3 LNA SOA ONIMVUd 01 JINSIA POWER STAK 52200 101 5 Page 45 PRESTO OWNER S MANUAL V LV LSOW ONIAAVHG STALL HAAN dc 93433497 HALLEAN 01 Q3LIBI Ss3NHVH SHIM xISHMd 2710 13 mE NDIIVNHDJH LuvIJIHdON JD 357 B 2000002 40 5 a TEXT ani 05270008 A 1 95 14 0198004 0 POWER STAK 52200 101 5 Page
10. 46 PRESTO OWNER S MANUAL RECOMMENDED SPARE PARTS LIST 52200 101 5 PRESTO OWNER S MANUAL Page 47 POWER STAK PPS2200 101AS ORDERING REPLACEMENT PARTS Presto Lifts has carefully chosen the components In your untt to be the best avallable 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 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 Invotce 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 T
11. Assembly Nov 2008 to Be D Battery uu u LUIS 9 Fig 23 Labels amp Precautionary Warnings 33 Fig 24 Electric Control Panel Prior to Nov 2008 34 SECTION 6 Fig 25 Electric Control Circuit Prior to Nov 2008 35 Maintenance 10 FIG 26 WINAG 27070402008 unsi inu tra tti eet 36 Weekly Operations Maintenance Checks 10 Fig 27 Wiring Diagram Prior to Nov 2008 37 B Monthly Operations Maintenance Checks 10 Fig 28 Wiring Diagrams Nov 2008 to Present 38 Fig 29 Wiring Diagrams Nov 2008 to July 2011 39 SECTION 7 Fig 30 Wiring Diagrams August 2011 to Present 40 11 Fig 31 36 Wiring Diagrams Nov 2008 to Present 41 46 ORDERING REPLACEMENT PARTS 48 RESTFOCKINCG POLIC etei 48 LIST OF TABLES Table 1 52200 101 5 Assembly November 2008 to 14 Table 2 Drive Wheel Description Prior to November 2008 22 Table 3 Recommended Spare Parts List 47 PRESTO OWNER S MANUAL Page 3 POWER STAK PPS2200 101AS 1 INTRODUCTION This manual attempts to provide all of the Information nec
12. RESULT IN INJURY AND OR DAMAGE TO LOAD AND EQUIPMENT SUGGESTED DAILY OPERATOR CHECKLIST WALK AROUND INSPECTION Check general condition of lift loose or broken parts etc Check for dented or scratched panels Look for broken or cracked welds broken or worn rollers and chains Check for loose pins or fasteners Ensure condition of wheels are not flat spotted or chunked out Check for hydraulic leaks Make sure all precautionary labeling is in place and legible Check for hydraulic leaks FUNCTIONAL INSPECTION 1 Check for proper operation of UP IDWN 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 YOUR CONCERNS TO SUPERVISOR IMMEDIATELY PRESTO OWNER S MANUAL Page 8 POWER STAK PPS2200 101AS 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 15 as far back on platform or forks as possible Do not pick up loads on tips or forks or edge of platform For fork models adjust forks to the maximum practi cal width Pick up loads on both forks e Do not overload Check load center and load weight capacities on the nameplate e Make sure travel
13. and work area is clear of obstruc tions Check overhead clearance before lifting loads or trans porting B DAILY OPERATIONS MAINTENANCE CHECKS 1 Battery A Check for corroded and loose terminals white powder substance will be present if there is any existing corrosion 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 F 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 BATTERY I 271 VOLTAGE Approx 12 7 Fully charged Approx 12 2 V 1 2 charged Approx 12 0 V 1 4 charged Approx 11 6 Discharged PRESTO OWNER S MANUAL Page 9 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 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 B
14. marking 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 PRESTO OWNER S MANUAL Page 7 Set up procedure for Power Stak Straddle legs with 4 Bolts Straddle Leg Bolt Tightening Procedure 1 Pre tighten all bolts to the bottom but not too tight 2 Fully tighten bolt 1 3 Next tighten bolt 3 4 Next tighten bolt 4 5 Last tighten bolt 2 6 Tighten all bolts to 85 foot pounds ECTION 4 OPERATION A OPERATING INSTRUCTIONS Operational Speeds the Presto Power Stak is designed to operate at the follow ing 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 is for lowering the forks When operating always make sure the load being lifted 1s 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 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 lifti
15. 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 PRESTO OWNER S MANUAL Page 10 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 Battery maintenance free A Clean terminals B Clean battery compartment area if there are signs of corrosion 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 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 Electrical A Check batteries motors controllers limit switches electrical conductors and conne
16. xvISHdMUd 94 13 NOILYNAOANI JO 351 S3H2H 34 MIU 74445444 031312345 js1MH3H1U 55371Nf ih 7105 13 ugogs Lpy1222 5 3409 Par QNITONYH WIH3LVM 30IMQTHOM 6141 01S33d xo Xe 2 9 p ARA OM 1999 NDI 14142530 SHDI LOS 43 82 0008 8 1812 WISHMd DVIO JH 0 3 1031403 58220008 SSINHYH JHIA wISMMd 9910 NNO Ju 2 SS3NHVH OIM 9820008 8 SS3NUVH 3HIM 1549 9910 NNOJ Ju 19 9 2920008 19 5 A3y 9 1303 91544 Ju A39 3099 1313 88090004 8 SS3NHYH 3H M 158 4 4311081409 2SINW 69270008 8 SS3NUVH SHIM XISuMd 9910 NNOJ Ju 3 INOJ 06200008 8 SSINHVH JHIA WISHMd Ji 53787 H3M d 30v IB 19 13 33397 1 4JHJIH ONY 609080 JU 5 171435 11 5 27159 803 SION M Ld 855343 20270008 V POWER STAK PPS2200 101AS Page 38 PRESTO OWNER S MANUAL LW 1412 X3ISHMd SY10 NNOJ 13 78200008 0 1102 018002 ul kl iin L 2d 141 11 12H44 1713 1 IM 12 Lid T STALL 62 POWER STAK 52200 101 5 Page 39 PRESTO OWNER S MANUAL HHYH 6652 0008 190 SHHONI NI SHY MIQ SNOILATOS 21 0 0943 NY ua W
17. 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 115V outlet Charge until the battery 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 the previous 30 minutes DANGER 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 110 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 POWER STAK
18. Bolt M20x65 Nut C grade M20 Upper fix plate Cover lock plate Round cover Bolt M5x10 Flat washer 5 E Stop Key Switch Battery meter Bolt M5x25 Safety net Safety net lock plate Bolt M4x10 Bolt M10x40 Nut C grade M10 Press plate U bolt Bolt M10x10 Idler wheel Flat washer 16 Ring 16 Lubricate bearing no oil Spring sleeve Spring Front wheel axle Washer 20 Bearing 6204 Front wheel Flat washer 12 Spring washer 12 Bolt M12x25 Battery lock plate Chain LH 1233 Nut M10 Nut M10 Idler wheel axle Nut M12 Adjustable bolt Flat washer 6 5 N N N 5 P I gt Ir IO et lt et lt PRESTO OWNER S MANUAL Page 14 POWER STAK PPS2200 101AS Figure 4 52200 101 5 November 2008 to Present PRESTO OWNER S MANUAL Page 15 POWER STAK PPS2200 101AS Figure 5 PPS2200 101AS Exploded View November 2008 to Present PRESTO OWNER S MANUAL Page 16 POWER STAK PPS2200 101AS Figure 6 9001 9002 9003 9004 9005 52200 101 5 Mast 9008 Description 9004 Chain wheel protect plate 9005 Chain wheel frame weld 9006 Chain wheel special bearing Prior to November 2008 Item Description _ Qty 9007 Washer 30 PRESTO OWNER S MANUAL Page 17 9013 35 4 _ POWER STAK PP
19. Gear 1 3023 Springwasher15 1 3024 BearingS0102 1 3025 Ring 2 1 3026 j 3027 Clutchgear 1 3028 14 1 3029 Scraping plate __ 1 __ 3030 Clutch fold Dc 24v 16w 1 3031 Screw 5 3 s P I loo PRESTO OWNER S MANUAL Page 22 POWER STAK PPS2200 101AS juesaJd 01 8005 SV L0L 00ccSdd quiossy 99uM 1081 4 POWER STAK 52200 101 5 23 PRESTO 5 MANUAL Figure 14 Prior to November 2008 Control Pod PPS2200 101AS Description 3106 Lefthandlecover ft 3107 Handlecover 1 3108 Spring 3109 Horn button fj 3110 Butongroup 3111 Righthandlecover ft _ 3112 BoltM3x0 fJ 3113 Washer hP 3114 Switch covert PRESTO OWNER S MANUAL Page 24 POWER STAK PPS2200 101AS Figure 15 November 2008 to Present Control Pod PPS2200 101AS FrontButton 1 small 7106 1 Handle Cover 1 7107 7108 Spring 109 HornButon fi 7110 ButtonGroup ____ 1 7111 7112 10 f2 7113 Washer 2 7114 SwitchCover ____ 1 7115 Swith f Description PRESTO OWNER S MANUAL Page 25 POWER STAK PPS2200 101AS Steering Assembly Prior to May 2007 PPS2200 101AS 1100 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014
20. HOSE WORM GEAR RSV M SER PLUG RESV BREATHER FILL 3 4 14 0 MOTOR DC 12V 4 5 2 TERM 1 gt SWITCH SOL ACT MTR ST 24 VDC WIRE ASSY CNTRL 16AWG HS RING UJ CABLE INSULATED W LUGS 46 6 L 4 CARTRIDGE 2W 2P NC POPPET 4000 5 COIL 24VDC 8 TWO 1 4 MALE TAB 16 POPPET ASSY P CMP FL GPM 2 00 gt PRESTO OWNER S MANUAL Page 29 POWER STAK PPS2200 101AS Figure 20 November 2008 to Present Power Unit Assembly PPS2200 101AS PRESTO OWNER S MANUAL Page 30 POWER STAK PPS2200 101AS Figure 21 PE Prior to November 2008 Carriage Assembly PPS2200 101AS n NE x I b 7 E i Y JEN i i i lj ul 7498 WM 100 7 4001 Liftingframe fi __ 4008 Washer3s POWER STAK 52200 101 5 Page 31 PRESTO OWNER S MANUAL Figure 22 November 2008 to Present Carriage Assembly PPS2200 101AS A 02 40 Description 4009 ForkShaft fi 4010 iframe ___ 1 4013 jWheelSleve 4 _ 4014 SnapRing35 _ 6 PRESTO OWNER S MANUAL Page 32 POWER STAK PPS2200 101AS Figure 23 Labels Precautionary Warnings Power Stak LOCATE POWER 5 LABEL AS SHOWN FOR NARROW MAST MACHINESAND THE UPPER C ROSS BAR FOR WIDE MAST MACHINES Presi PRESTO OWNER S MANUAL
21. PPS2200 101AS CHARGER OPERATION Power Lamp 1 Green Connection correct Charger will operate nor mally 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 is between 70 and 100 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 charger to start It must be at 9 volts to initiate charge SECTION 6 MAINTENANCE Operation of Presto Power Stak is very simple as 15 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 Oil AW32 Dextron III in the hydraulic system Do not overload your lift Check brakes steering mechanisms and controls be fore each use A WEEKLY OPERATIONS MAINTENANCE CHECKS 1 DAMAGE Check for bent dented worn or broken parts 2 LIFT SYSTEM Check to assure that there is
22. S2200 101AS Figure 7 52200 101 5 Mast November 2008 to Present Flat Washer 8 Spring Washer 8 Description item _ PRESTO OWNER S MANUAL Page 18 POWER STAK PPS2200 101AS Figure 8 Prior to November 2008 Cylinder View PPS2200 101AS Figure 9 November 2008 to Present Cylinder View 500 PPS2200 101AS m 5001 Fitting J 5002 ORing fj 003 5007 Piston Jt 5008 Spacer 1 009 ORng J 010 PistonRod ____ 1 _ 5011 PRESTO OWNER S MANUAL Page 19 POWER STAK PPS2200 101AS Figure 10 Prior to November 2008 Caster Wheel Assembly PPS2200 101AS 401 40 243 2404 2405 406 240 410 809 2408 2409 Wheel 128x55 2401 Bolt M10x35 2410 Bearing 6004 2402 Spring washer 10 2411 Wheel frame 2403 Nut M10 Description Description PRESTO OWNER S MANUAL Page 20 POWER STAK PPS2200 101AS 412 _ 1415 1 Figure 11 November 2008 to Present Caster Wheel Assembly PPS2200 101AS Description 2008 Wheel _ 2009 Seeve fi Figure12 Drive Wheel Assembly PPS2200 101AS Prior to November 2008 PRESTO OWNER S MANUAL Page 21 POWER STAK PPS2200 101AS Table 3 Prior to November 2008 Drive Wheel Description PPS2200 101AS Description item Description 3018 2 1 _ 3017 Screw 5 h 3020 ScrewM6x20 3 _ 3021 ScrewM x60 3 3022
23. acker 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 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 hands 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 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 in structions DO NOT exceed load center or load weight capacities check ca
24. ch 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 Figure 1 Operational buttons PRESTO OWNER S MANUAL tion of stacker Pick the unit up On conventional masts use the top cross member 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 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 ha
25. ctions CAUTION DO NOT USE LIFT IF IT IS NOT OPERATING PROPERLY OR APPEARS UNSAFE IN ANY WAY POWER STAK PPS2200 101AS ECTION 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 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 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 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 Idler wheel needs adjustment PRESTO OWNER S MANUAL Page 11 IDLER WHEEL ADJUSTMENT The following is a procedure for adjusting the idler wheel on the Presto PowerStak Under normal conditions t
26. elephone 800 343 9322 FAX 888 788 6496 Email Service PrestoLifts com www PrestoLifts com PRESTO OWNER S MANUAL Page 48 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 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 POWER STAK PPS2200 101AS Presio W mm w Fratris O gt 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 49 POWER STAK PPS2200 101AS
27. essary 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 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 not for personnel lifting 2 SAFETY You must be trained and certified to operate this powered stacker Federallaw 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 1910 178 29QFR 7 1 06 Edition Presto lifts does not offer operator training Operator training programs 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
28. hin 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 shall not be held liable for any damages resulti
29. his should not be necessary because 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 1 Place unit on a flat surface 2 Turn key to the OFF position and push emergency stop button down 3 Remove the 2 screws from the main orange cover that covers the unit 4 Remove the emergency stop button by unscrewing 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 tension 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 POWER STAK PPS2200 101AS Figure 2 Prior to November 2008 PPS2200 101AS 1 LT HS i L
30. l down the handle at any point between 15 80 degrees Always make sure the brake 15 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 opera tor 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 im mediately 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
31. 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 haz ards 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 possibility of injury PRESTO OWNER S MANUAL Page 4 POWER STAK PPS2200 101AS AWARNING To avoid bodily injury read UP TO 7 UP TO 8 understand and follow all instructions before operating this machine 2 200 LBS 1 800 LBS E Ratings based on 24 Load Center See Owner s Manual Tor details ionis AWARNING itar us Maximum Lifting Capacity To avoid bodily injury read UPTO UP TOR ur ro10 UP TO 12 instructions before 2200 LBS 1 300 LBS 1 500 LES 1 200 LBS operating this machine Ratings based on 24 Load Center Sen Owner s Manual for details vins LIFTING CAPACITY ABOVE 7 IS LIMITED Maximum Lifting Capacity To avoid bodily injury read 223 UPTO TN 2 200 LBS 1 800 LBS 1 500 LBS Ratings based an 24 Load Center Seo Owner Manual for detail operating this machine SECTION 1 IN WARNING When servicing
32. ng 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 PPS2200 101AS TABLE CONTENTS LIST OF FIGURES Fig 1 Operational Buttons 6 SECTION 1 Fig 2 PPS2200 101AS Prior to Nov 2008 12 SEO Nr 2 Fig 3 PPS2200 101AS Exploded View Prior to Nov 2008 13 lili ID u 4 Fig 4 PPS2200 101AS Nov 2008 to 15 ONG uu 4 Fig 5 PPS2200 101AS Exploded View Nov 2008 10 16 Fig 6 PPS2200 101AS Inner Mast Prior to Nov 2008 17 4 5 Fig 7 PPS2200 101AS Inner Mast SECTIONS NOW 2008 0 uuu ainei a 18 Isa ET EE ERES ER 6 a As uuu u u 6 Fig 9 Cylinder View Nov
33. ng 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 POWER STAK PPS2200 101AS Travel travel rotate the butterfly controls throttle 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 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 release 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 1s equipped with a magnetic brake The brake is applied when the handle is in its vertical position between 10 15 degrees and lowered position between 80 90 de erees The brake could be released when you pul
34. pacity 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 PPS2200 101AS SECTION 3 INSTALLATION A INSPECTION Upon receipt of the stacker inspect the 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 e 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 e Remove back panel 1 Turn key swit
35. 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 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 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 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 PRESTO OWNER S MANUAL Page 5 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 st
36. ve 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 Check to see if chains are in place and that the lift system 15 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 1 BELLY BUTTON SWITCH LIFT UP Le LIFT DOWN HORN SPEED CONTROL DIRECTION CONTROL POWER STAK PPS2200 101AS Page 6 Set up procedure for Power Stak Straddle legs 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 Please refer to diagram below otraddle Leg Bolt Tightening Procedure 3 Bolt Vl 1 Pre tighten all bolts to the bottom but not too tight 2 Fully tighten bolt 1 3 Next tighten bolt 3 4 Last tighten bolt 2 5 Tighten all bolts to 85 foot pounds 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

PowerStak PPS2200 101AS Oct11.indd - Cisco

Contents

Download Pdf Manuals

Related Search

Related Contents