PowerStak 62"NAS
Contents
1. 83 da DHddw NOILd 1H2530 TOHINOJ SHOLLI23HNO2 7800008 H CC onI 1102 O3 8002 Xx He e T 1073 ARX SAO LIWHA THROTTLE MODLILE ELECTRONIC POWER STAK Page 39 PRESTO OWNER S MANUAL ONIMVNOI S 1 NALLINM OL NOLLVWWOHNI ANVLATNdOYd ASN ON Y 76070008 QV3H 7410 215444 NNOD TA yt 78250008 m 0120 01049449 19245 3194 TZ 580111105 9IWONOONS NY RA acu ONITONVH TVIWSIVA SCIMCTIOM 1 I 01544 SHHONI NI SUY WI 181412445 85 10 557180 XX Sat l 900 XXX 011241094 INOOW 700813313 9014 4 amp LIHM 56070008 4 134 STINVH 5 RRR im 81048802 LON ALTHM V XOV1a MOTTA 9 LIS 8 SONVIO NMOUd 9079 10911 85 HS TI 15 YNId ul 1 NANO L Ng L 4014 76070008 g juesaJd o3 072 1snbny and d NAO MOTTE KOTIH MOTTHA MOTTA V 0 16 D NIRE O HONYYO 3079 TH LE 45 CR NO I NUD2. ONIAAVHG STALL SS3NHVH HIM XISMMd 9VIO NND2 13 BIZE DOB juesaJd 0 9002 J9quieAON A NS LT POWER STAK Page 44 PRESTO OWNER S MANUAL WW 16 STALL IT 01 LBEEDOOB gt BBZPOUOE SS3NHYH SHIM XISHMd 9710 09 73 _ im NOL eNO 58270008 JU S Jd 0 9002 J qUI AON 87 DANGLY POWER STAK Page 45 PRESTO OWNER S MANUAL HS DSA DNIAAVHG STALL HAYA Sn Wy Ue 343347 HALLEAN 0 060008 Ss3NHVH 15HMd 2710 13 M ir 8ZE 0DB 06570008 8 03 8002 6C IMIA POWER STAK Page 46 PRESTO OWNER S MANUAL Figure 30 Battery Connection MAIN BATTERY C HARG ER POSITIVE POSITIVE CABLE CABLE VOLT SYSTEM BATTERY C HARGER BATTERY CONNEC TING CABLE 120 VAC MAIN BATIERY CHARG ER NEGATIVE NEGATIVE CABLE BATIERY CABLE PRESTO OWNER S MANUAL Page 47 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 unauthori
3. t A EN ln IN f Asoyeg DE 2009 Wit 1112112 1021109 211129400 mi LOOS 511 OJ1UO 91119 1031009 sex ____ 5 DMI POWER STAK Page 34 PRESTO OWNER S MANUAL Figure 18 Electric Control Circuit 5455 56 S7 SB o9 N ES 5 5 gt 9 CV gt R 5 a a No Code cipi Mod DI NEN NN an Driving Motor 4 M2 Pump Motor CAT kw 5 4 _ Motor Controler DC24W 200A 6 4213 Driving Motor Contactor CAB DC24V 24A e exa Pump Circuit Fuse 2 ese 83 Urgent Reverse EMEN nz sa ppownSwich 13 56 Hom Switch 14 5758 X Down Swich E ____ ___ 16 L1 Magnetic Clutch DC24V 25W _ ret ee EE Ge 19 DC24V LX 5258 Dinda 4007 21 TSQ ETR711 DC24V PRESTO OWNER S MANUAL Page 35 POWER STAK Prior to November 2008 Figure 19 Wiring Connectors viewed from wire entry side I LL C
4. 101 103 1033 9 1034 J Q 2 Z ANN Eg 0 0 00 f ND 103 105 106 E 105 0e 2i 8000 1003 1005 PRESTO OWNER S MANUAL Page 18 POWER STAK Table 1 Prior to November 2008 Model PPS2200 62NAS Item Description aty 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 U 9 D O 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 gt lt Battery meter POWER STAK Figure 3 PPS2200 62NAS Exploded View November 2008 to Present PRESTO OWNER S MANUAL Page 20 POWER STAK Figure 4 Cylinder View PPS2200 62NAS Prior to November 2008 Mir E PRESTO OWNER S MANUAL Page 21 POWER STAK Figure 5 Cylinder View 52200 62 5 November 2008 to Present Item 5001 Fitting
5. A OPERATING INSTRUCTIONS 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 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 18 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 15 behind the pallet that you are lifting which may bend the tips of forks and overload the capacity of the stacker Travel Function 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 d
6. 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 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 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 A foot or hand caught between the stacker and a fixed object will be crushed or even cut off PRESTO OWNER S MANUAL 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 slipp
7. J 5002 ORing fj Nt 5006 URing 2 5007 Piston Jt 5008 Spacer 1 009 1 5010 PistonRod 1 5012 PRESTO OWNER S MANUAL Page 22 POWER STAK Figure 6 Prior to November 2008 Caster Wheel Assembly PPS2200 62NAS 2401 40 2403 2404 240 406 2410 241 2414 2412 240 410 249 2408 Item Description Oty Item Description Qty _ 2402 Springwasheri0 4 2411 Wheelframe __ 1 403 jNuM10 4 FN 2412 _ 5 fi 1 2405 Bearing 1 2406 Flatwasher 1 PRESTO OWNER S MANUAL Page 23 POWER STAK Figure 7 Caster Wheel Assembly November 2008 to Present PPS2200 62NAS 20 Description 4 1 2 2 1 1 PRESTO OWNER S MANUAL Page 24 POWER STAK Drive Wheel Assembly PPS2200 62NAS Figure 8 PRESTO OWNER S MANUAL Page 25 POWER STAK Figure 9 Control Pod PPS2200 62NAS Description Qty 103 Front Button ____ 1 _ 7106 teftHandleCover __ 1 7107 Upper Cover ____ 1 108 Spring 7109 Horn Button fi 7110 Button Group 1 7111 7112 BotM3x10 f2 7113 h 7114 Switch Cover PRESTO OWNER S MANUAL Page 26 POWER STAK Figure 10 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 10
8. PROCEDURE 1 PowerStak unit located on flat clean uniform surface unloaded forks raised a minimum of 1 off the floor 2 Determine the desired required straddle width dimension 2 inches greater than pallet width 1 on each side of the pallet or load up to a maximum of 50 inches inside width 3 Besure to fully loosen all bolts before moving stabilizing legs Adjust one stabilizer leg at a time using a pry bar pinch bar rubber mallet etc move the straddle leg out from the base tube to the desired position Do not move too far see picture below if the 1 4 wide painted White Line is visible the leg is pulled out too far Maxi mum movement 5 1 2 for each leg for 2200 pound units 4 Adjust second Straddle Leg using a pry bar pinch bar rubber mallet etc move the straddle leg out from inside the base tube to the desired straddle width position 5 Straddle Legs must be symmetrically adjusted both legs adjusted to the same extended dimension CRITICAL STRADDLE BOLT TIGHTENING SEQUENCE amp PROCEDURE Set up procedure for PowerStak Straddle legs with 3 or 4 Bolts Back off all bolts and follow steps First tighten Bolt 1 to 85 foot pounds NOTE Second tighten Bolt s 2 to 85 foot pounds When adjusted correctly white Third tighten Bolt 3 to 25 foot pounds NOT 85 line cannot be seen Last securely tighten all lock nuts PRESTO OWNER S MANUAL Page 11 POWER STAK SECTION 4 OPERATION
9. blinks 3 times in 5 seconds The output between charger 15 faulty loose bad connection 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 1s the general rule Charge Lamp Red Charger can charge normally The battery is less than 70 2 Orange charged 3 Green Battery 15 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 10 5 volts to initiate charge Battery is between 70 and 100 owners manual for charging instructions VOLTAGE 3 Approx 12 7 V Fully charged d Approx 12 2 V 1 2 charged gt RY eae Approx 12 0 V 1 4 charged Approx 11 6 V Discharged PRESTO OWNER S MANUAL Page 15 POWER STAK 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 Use only Hydraulic Oil AW32 or Dextron III in the hydraulic system not overload your lift Check brakes steering mechanisms and con trols before each use A WEEKLY OPERATIONS MAI
10. dIAVTO LIN A TIXSL 9XSL 9 21514 4638 12 S3IH3S IN 33825 YIL LdN 8 6 416 1305 3811 8 T 816 AEN XO 18 SZ Z X DHS MIYIS ASY Od INO ASSY d 05 lt GOW 6TSEW ASSY 3578 9007 J9qui9AON N SVNcC9 00ccSdd quiessy HUN J9MOd dad 2 _ lt 10 N Ajaj n N Y1OAY3SFY LN OHLIM NM ORS MAIA STI OH ONLLNNOW 8T 9T S Nd 55 ANN OY 9 INIVA 391353 9 IL 3SV8 T NIZOTO EE 91 1 e 5 u Cy RE Q h F j 00 T E INd1ZSZ 1590052 OUSV1d 2 9 AVS 81 91 6 E LH Od O AVS 81 91 6 108 4 POWER STAK Page 30 PRESTO OWNER S MANUAL Figure 14 November 2008 to Present Power Unit Assembly PPS2200 62NAS aii a qii PRESTO OWNER S MANUAL Page 31 POWER STAK Figure 15 Carriage Assembly PPS2200 62NAS PRESTO OWNER S MANUAL 1 4015 Page 32 Item Description Qty 4004 Middle Plate _ 4 4009 Forkshaft fi 40
11. 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 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 Remove the emergency stop button by unscrewing 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 17 POWER STAK Figure 2 PPS2200 62NAS Exploded View Prior to November 2008
12. 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 11 chains are in place and that the lift sys tem 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 bat tery charger as well as battery Figure 1 Operational buttons PRESTO OWNER S MANUAL I BELLY BUTTON SWITCH LIFT UP EE LIFT DOWN SPEED CONTROL DIRECTION CONTROL Page 10 POWER STAK CRITICAL PROCEDURE FOR PROPER WHEEL TRACTION Proper Drive Wheel traction is obtained for the PowerStak Straddle unit using this Procedure PowerStak Models are designed and intended to operate on an unfinished concrete floor surface If any PowerStak 15 operated on smooth or polished concrete sealed concrete epoxy sealed floor linoleum or other smooth surfaces Drive Wheel traction performance may be affected If traction issues are encountered Rubber Drive Wheels are available through special order Please contact Customer Service at Presto Lifts 1 800 343 9322 When any PowerStak is operated on a wet oily powdery sandy or non uniform liquid or granular surface Drive Wheel traction performance will be affected and loss of traction will occur SET UP PROCEDURE FOR POWERSTAK STRADDLE LEGS NOTE STRADDLE LEGS MUST BE ADJUSTED IN ACCORDANCE WITH THIS
13. 14 SnapRingM35 6 POWER STAK ings Warn ionary Labels amp Precauti Figure 16 OM 9 866001 8 ezescooily 39 ISNW 50951 0S 8XSC 100 01 ON 00 EX00 190 01 OIS33d 00 EX00 Z 1 128 07 v3 27 17798 3WSV OI O3aniOvJAnN VW 14 1 01 338 19912 v 83320 15 3WVMN 28 1 09 41 58 9 199 M0134 NO 31v 201 Dung LL Aiageq 53 p 558 Jo SIEG 8 afueuasic 32847 euo 1528 J0j puejs vc 591 0051 sz xo0z 159 91 v3 INIHDYW NO 31201 dO HVA 1D ALS SHO ONVLS LOW 04 331N32 OVO S41 005 9 2 4 EE EGRE LO S430 OW ONINSYM gt ISWW 40 3015 NO 3214 2 y s 9 NC PCT SLA S id POWER STAK Page 33 PRESTO OWNER S MANUAL Figure 17 Electric Control Parts Kiayeg YVOLIAZL UVOLIACL suopng 104002 bd
14. 18911 TT di ania H5 CZN di V ELECTRONC THROTTLE MODUL LIGHT GREEN T 27 AIS FUIN NONA AMATA SNOTLOANNOD POWER STAK Page 40 PRESTO OWNER S MANUAL NOTSTA JH LV 1 giZb UQDB 99270008 A juesaJd 0 9002 SOW ONIMVUG SIH L 2 8200008 SS3NHVH SHIM LSHMd 9910 02 73 pc POWER STAK Page 41 PRESTO OWNER S MANUAL 982600081 553 LSHMd 9910 NNOD 79 LLEE OQE 98270008 juesaJd 0 9002 J qUI AON Pore 6 WINS POWER STAK Page 42 PRESTO OWNER S MANUAL NOISIAAH LSOW DONIAViHG SIHL 1H3433H2w 01 411 11 18290008 MS AJA VJ 1903 NNOS NOILYNAOANI kHvL3IHd Hd 30 ISN 34 MIU 031312395 nn TASSE 593141 Take gu SNDILNIDS JIMONOD33 NY ALED repas e T Is3INM 141 1634 4 un ES 00 AAA HOT 1314 2590 SNDI LOU H MS 1 NN 253 499 18 5 INI a mu 9c JING 101 3N3I HOTLdTH43830 38 SMO L33HNO2 18570008 y juesaJd 0 9002 J9quieAON POWER STAK Page 43 PRESTO OWNER S MANUAL _ 88220008 88270008
15. 20 1021 1200 2 2 2 5 2 2 2 o o I O e lt PRESTO OWNER S MANUAL Page 27 POWER STAK Figure 11 Steering Assembly May 2007 to August 2008 52200 62 5 3100 3201 3202 3203 Pin Airspring _______ Air spring 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 28 POWER STAK 3204 2 o gt o I 2 O ex lt Figure 12 Steering Assembly August 2008 to Present PPS2200 62NAS 9 lt _ a 7029 7030 Wane connect ase 1 7031 1 7033 sensn 3 oinnes 1 7035 ve werte 3 Des 7037 sensus wea 1 e PRESTO OWNER S MANUAL Page 29 POWER STAK 0072149 14 d ASSY 13ddOd 31VIN v T OML 8 2QAvC 1102 000t L3ddOd ON dZ MZ 39dluluvo SH OMV9T TYLNI ASSY JAN vc LS 19 105 HOLIMS 1 9 SON1 M AJLVINSNI 318 V2 WYIL 24467 AZT IA YOLOW 1 4 1 ASAY YIS N ASY INHOM ISOH
16. INTENANCE CHECKS 1 Battery A Check for corroded and loose terminals A white powder substance will be present if there is any existing corrosion B Visually inspect for any cracks 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 PRESTO OWNER S MANUAL Page 13 POWER STAK DAILY OPERATOR CHECK LIST CHARGE CONDITION BATTERY CHECK LIST 1 Check Battery Discharge Indicator Fuel Gage and Hour Meter Be sure unit 18 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 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 d
17. MISHMd NNOJ 1051 0 58270008 8 SSINHYH 3HIM HLSHAd SSaNHVH OIM 98270008 a SSINYYH XISHMd jwvHH 18290008 8 MS A34 Y vo 1303 MISHMd A38 3979 1304 0000 88270008 8 3HIM XISHMd H311081N02 2518 69270008 8 SSINHYH JHIM WISHMd NNOJ INOJ 06200008 8 SSjNHTH JHIA XISHMd 53787 H3M d 30v IB 19 13 33397 1 MHSHITH ONY 209080 30 5 8 11935 547155309 803 SJIUN 0 8002 c 1081 11914539 20270008 V POWER STAK Page 38 PRESTO OWNER S MANUAL Wi telat LV ONIMVad STALL INJA OL 031111 MO IwWHIAN 30 351 SAHAN MI 387 WIO 131312345 yyy yarns j amp 1MH3HLLI S53 INN MER Wt SNOLLAIOS 91040559 ONY 9319 TWlH3IVW 301071904 157 01548 23193009 LON 931230002 1 BD 1134 NAH E EE T 9 jcH1AJdM m 23 l E E EEEE E jonvap 57 N18 1H511 X Sz a 16917 p IR a n m L HLINA Te 52 m 5 103d MAD z 5 FIN Td LIN338 TEE 4 DNS 11077 ESENIN 73079 l dil 1 917 A 1038 dn pl 3015 _____ _
18. NTENANCE 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 WHEELS AND CASTERS 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 PRESTO OWNER S MANUAL Page 16 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 arust 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 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 futur
19. ONNECTORS Moo WED FROM WIRE 2 ENTRY SIDE MEN z 2 ANA nus HANDLE CONTROL HEAD WIRING 5 11 6 2 F 16 18 UP po DOWN 1T 2 DOWN P l P HORN EMERGENCY REVERSE 19 13 19 ELECTRONIC THROTTLE MODULE PRESTO OWNER S MANUAL Page 36 POWER STAK Figure 20 Prior to November 2008 CONNECT IONS 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 5V SIGNAL ORWARD CONTACTOR DRIVER OUTPUT AIN CONTACTOR DRIVER OUTPUT 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 1 DI 93 MOVLVNADANE 31 89089 30 351 MI 39 MIU 031312345 351 1 5541 any qui c ATI ERZI OOO 45 3404 19 42530 am KALL ND Lu 820008 H 1810
20. Presio worldwide material handling and ergonomic solutions Power Stak PPS2200 62NAS FOR UNITS SHIPPED PRIOR TO MARCH 2014 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 September 2015 REV 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 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 15 required for warranty The ch
21. SI Standard Z535 4 indicates the relative seriousness of the hazardous situation DANGER indicates a hazardous situation which if not avoided A G E 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 Yellow Background NOTICE is used to address practices not related to personal NOTICE Blue Background SAFETY SAFETY INSTRUCTIONS or equivalent signs indicate safety INSTRUCTIONS related instructions or procedures Green Background CAUTION used with the safety alert symbol indicates a haz ardous situation which if not avoided could result in minor or moderate injury PRESTO OWNER S MANUAL Page 7 POWER STAK 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 oc cur 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 When servicing the unit Key should be in OFF position 2 E stop should be depressed 3 Disconnect the batteries at the terminals
22. UAL Page 4 POWER STAK 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 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 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 S or larger aisle These units not for personnel lifting PRESTO OWNER S MANUAL Page 5 POWER STAK Responsibility of Owners and Users Inspection and Maintenance The device shall be inspected and maintained proper working order in 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 li
23. and cables DO NOT use if any partis damaged worn or not work ing properly 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 PRESTO OWNER S MANUAL Page 9 POWER STAK 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 hydraulic power pack Check all electrical and hydraulic connec tions for tightness Remove back panel Turn key switch to OFF position 2 Push in E stop and unscrew the red knob 3 Lift off back panel Th
24. arge 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 resulting from noncompliance It is the dealer s responsibility to exercise this limited wa
25. e reference Electrical A Check batteries motors controllers limit switches electrical conductors and connec tions DO NOT USE LIFT IF IT IS NOT OPERATING PROPERLY OR APPEARS UNSAFE IN ANY WAY POWER STAK 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 terminals 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 e 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 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 dler wheel needs adjustment IDLER WHEEL ADJUSTMENT The following is a procedure for adjusting the
26. ere is enough wire to the key switch to allow the panel to be set aside Inspect for 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 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 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 standards have been met Visually inspect the stacker for damage Check for at tachments and accessories that may have been ordered If there is any damage or missing
27. ertify that you are qualified 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 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 Signal Words The meaning of different signal words as defined by AN
28. ery or uneven sur faces Do not run over objects on the floor e 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 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 Before you leave your stacker be sure to lower the forks to the floor Shut the stacker off with the key Page 8 POWER STAK 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 conditions of the stacker lift systems forks chains
29. irection 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 functions like a throttle When you release your hand from the but terfly control it automatically will resume to the neutral position and the speed of the stacker will slow down PRESTO OWNER S MANUAL Electric Brake Your stacker is equipped with an electric magnetic brake The brake is applied when the handle is in its vertical position 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 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 fork
30. isconnected 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 in 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 dou cd 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 14 POWER STAK 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 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 B 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 is not recommended Plug the charger into a 115 volt outlet Charge until the battery gauge indicator lights show fully charged app
31. ive Wheel Assembly isssescbkevePenceksenivesT xzizuP kia 25 Figure 9 Control 26 Figure 10 Steering Assembly Prior to May 200 27 Figure 11 Steering Assembly May 2007 to August 200 99 28 Figure 12 Steering Assembly August 2008 to esee eene eene 29 Figure 13 Power Unit Assembly Prior to November 2008 30 Figure 14 Power Unit Assembly November 2008 to 9 31 Figure 15 PPS2200 62NAS Carriage Assembly November 2008 to 32 Figure 16 Labels amp Precautionary duh 33 Figure 17 Electric Control Panel Prior to November 2008 34 Figure 18 Electric Control Circuit Prior to November 20080 eene 35 Figure 19 Wiring Prior to November 208 36 Figure 20 Wiring Diagram Prior to November 2008 a aaaaaaaaiaaaannannnnananununnnnannnnnunanannnutnnnnnnnanunannnnnannan 37 Figure 21 Wiring Diagrams November 2008 to Present aaaaaannaaaaannannnnnnnnnnnnnnnnnnannnnnnannnnnnannnnnnannannana 38 Figure 22 Wiring Diagrams November 2008 to July 2011 ren 39 Figure 23 Wiring Diagrams August 2011 to 40 Figure 24 29 Wiring Diagrams November 2008 to 41 46 Figure 30 Battery 47 PRESTO OWNER S MAN
32. nal 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 merchandise must arrive Free on Board at Presto Lifts facility or the shipment will be refused and returned to the sender 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 50 POWER STAK 2 Presio Call Presto Sales for stock or customized lift inquiries 800 343 9322 Email sales prestolifts com 5 PRESTO OWNER S MANUAL Page 51 POWER STAK
33. ncealed 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 condition 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 49 POWER STAK 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 Not all units are returnable Quantity orders and special designs cannot be returned under any circumstances Presto Cus tomer Service reserves the right for fi
34. nes damaged or malfunctioning controls or safety devices etc shall be removed from service until it is repaired to the original manufacturer s standards Repairs 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 e Read and or had explained and understood the manufacturer s operating instructions and safety rules e 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 AII items not 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 e 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 6 POWER STAK 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 c
35. r ranty This limited warranty is provided to the original purchaser defined as the original end user and 15 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 NES 2 OVC 1 NR TTC 5 Responsibility of Owners and US Ci 6 SECTION 2 EEES 7 9 Barely Alert Symbols and Es ed 7 SECTION 3 10 All 10 Kova ron SECRETO m 10 TOF cT 10 Wheel Traction and Siraddle Let 11 SECTION 4 852 12 A Operatme MUI PN 12 Daily Operations Maintenance l 13 Uc ste Daly Operator 14 SECTION 5 Battery 15 As UC Oe Cha
36. roximately 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 fol low all battery and battery manufacturer s specific pre cautions while working with and or charging batteries 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 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 quali fied electrician Improper connection can result in a risk of an electric shock 1 Disconnect the charger from the 115 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 Fault 1 Red light
37. s in lowered position Reversing Safety At the end of the handle there is a large red reversing bar belly button switch that 15 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 15 located on the top of the handle Page 12 POWER STAK 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 e Make sure load is evenly distributed not loose or unstable and 18 as far back on platform or forks as possible Do not pick up loads on tips or forks or edge of platform e For fork models adjust forks to the maxi mum practical 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 MA
38. se eT AY area 15 B 15 NEU 15 D Bitten aa aa E NOR 15 B MUI ME 12 6 IV UIE OEE E M __6_6_6_ _ _______ 16 A Weekly Operations Maintenance 16 B Monthly Operations Maintenance Checks d Okan kalan illa akal Dra Hilal 16 SECTION 7 a can dicU MEM 17 ORDERING REPLACEMENT PAR D asta r RRR 48 N 49 RETURN GOODS Fa OR ZA RRR RRR RRR RB AAVERE 50 LIST OF TABLES Table 1 PPS2200 62NAS Assembly Prior to November 2008 cesses eene 19 PRESTO OWNER S MANUAL Page 3 POWER STAK LIST OF FIGURES Figure 1 Operational 10 Figure 2 PPS2200 62NAS Exploded View Prior to November 2000 18 Figure 3 PPS2200 62NAS Exploded View November 2008 to Present 20 Figure 4 Cylinder View Prior to November 2008 21 Figure 5 Cylinder View November 2008 to 2 9 22 Figure 6 Caster Wheel Assembly Prior to November 2008 eene 23 Figure 7 Caster Wheel Assembly November 2008 to Present cesses 24 Figure 8 Dr
39. zed 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 warranty 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 15 30 days from date of shipment Parts replaced under warranty are on 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 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 48 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 co
Download Pdf Manuals
Related Search