PDL Series Dock Lift
Contents
1. Da 4 LIFTS Pres worldwide material handling and ergonomic solutions Dock Lift Model PDL60 60 Installation Operation and Service Manual Model Number Serial Date Placed in Service IMPORTANT READ CAREFULLY BEFORE INSTALLING OR OPERATING LIFT Part orders are subject to a 50 minimum charge September 2015 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 DOCK LIFT Contents INTRODUCTION 4 RESPONSIBILITY OF OWNERS AND 0 5 SAFETY ALERT SYMBOLS AND SIGNAL WORDS 6 SAFE SERVICING OF THE LIFT nnne 7 vilgiibd 8 INSTALLATION INSTRUCTIONS eere 8 Prepatation M 8 Positioning the ded victus 9 Hydraulic Connections 9 Electrical COhfie CHONG rue aqu 10 j 10 Completing Installation 1 2 eerte tor netten LO OPERATING INSTRUCTIONS 11 Operating Procedure n 11 MAINTENANCE 13 Ses corset TE E E E A E A ES 13 Routine P2. TROUBLESHOOTING Troubleshooting Check List All servicing should be done by qualified personnel Qualified personnel should be able to read and understand wiring and hydraulic diagrams They should be able to troubleshoot live electrical circuits safely and in accordance with accepted practice For safety s sake if in doubt please contact your dealer or the Service Department at Presto Lifts at 800 343 9322 Before servicing the lift read and understand this entire section and the section entitled Operating Instructions Before working underneath the lift always raise the lift and insert the maintenance chocks as shown in Figure 1 Failure to do so may result in damage to the lift and severe personal injury If the lift will not raise ACAUTION Do not continue to hold the up button for more than 2 or 3 seconds You may damage the pump Check the actual weight of the load The rated capacity of the lift is shown on the table skirt PRESTO OWNER S MANUAL Page 14 This power unit contains a hydraulic pump that is capable of developing excessive pressure A pressure relief valve is used to set the pressure at the desired level Tampering with adjusting modifying or removing the relief valve is extremely dangerous and is not recommended Only a trained hydraulics technician using a calibrated hydraulic pressure gauge to assure the proper pressure setting is achieved should make the adjustments to
3. od pesa DU UE 21 Table 1 Electrical Interface Supplied by Customer 21 Table 2 Hydraulic Oil Specifications 21 PRESTO OWNER S MANUAL Page 3 DOCK LIFT SECTION 1 INTRODUCTION The PDL series includes Presto Lifts Dock Lift scissor table The basic PDL series lift may be modified in many ways to meet special requirements for load capacity vertical travel table size power source and other characteristics PDL lifts can also be fitted with many optional accessories and modifications to suit the customer s needs This manual contains information to acquaint you with the safe and proper installation use and upkeep of an PDL series lift table You should ensure that this manual is available to personnel working with and on the lift table and require its use by these personnel PDL lift tables are designed for lifting and vertical positioning of equipment and materials in a wide variety of industrial settings The instructions set forth in this manual are not necessarily all inclusive as Presto Lifts cannot anticipate all conceivable or unique situations In the interest of safety please read all of this manual carefully and be familiar with its contents before you install use or service the PDL Lift Table If you have any questions about any of the instructions in this manual please contact your dealer or Presto Lifts Presto s product warranty 1s shown on the back cover of this
4. If the lift will be used at normal ambient temperatures Presto supplies the unit with CONOCO Ecoterra 32 biode gradeable oil do not substitute NOTICE This lift is supplied with Conoco Ecoterra 32 Hydraulic Oil Do not substitute It is very important to keep the hy draulic oil free of dirt dust metal chips water and other contami nation Most of the problems with hydraulic systems are caused by contamination in the oil Ecoterra Hydraulic oil is not compatible with oils containing Zinc Mixng will result in poor machine performance could damage hydraulic compoentns adn will lessen the envi ronmental beneits gained by using Ecoterra Hydraulic Oil Tank to be full only when cylinders are fully retracted PRESTO OWNER S MANUAL Page 21 DOCK LIFT 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 t
5. Be careful Each cylinder 1 heavy Figure 8 shows the parts inside a J style cylinder At the upper end of the cylinder remove the large snap ring Pull the rod and piston all the way out of the cylinder This assembly is heavy Be careful not to drop it as it comes free Look for deformation around the hole at the clevis end of the cylinder rod If necessary clean up the rod diameter with a file to allow the rod bearing to slide off without damage Fig 7 Parts Identification lift Shown without precautionary labels for clarity Throw aver plate Hydraulic cylinder assembly Lower roller assembly Roller retainers PRESTO OWNER S MANUAL m lj J Page 16 Remove the plastic rod bearing from the cylinder rod Observe how the wiper ring sits in the rod bearing Remove the wiper ring and the O ring from the rod bearing Do not try to remove the aluminum piston from the cylinder rod as this will damage the assembly Loosen the small snap ring Remove the poly U cup from the piston Check the vent plug and clean it 1f it appears dirty While reassembling it is very important to keep all of the parts free of dirt dust metal chips water and other contamination Most of the problems with hydraulic systems are caused by contamination in the oil Clean the piston surfaces and install a new fiber wear ring Install a new poly U cup seal with the open part of the seal facing down Clean all of the
6. and you may be hurt Operate the lift Press and hold the up button to raise the lift and down to lower it Release the button when the lift reaches the limit of travel If the lift does not operate within 2 or 3 seconds turn off the lift and call a qualified maintenance worker If you hear a squealing noise from the pump the pressure relief valve is operating Do not continue to use the lift The pump will overheat very quickly and may be permanently damaged The relief valve is included to protect the machine operators don t change the relief pressure setting Wait until the lift table has stopped Unload the lift The warning labels on the lift are there for your safety If you find that the labels are worn or missing or have been painted over ask Maintenance to replace the labels before you use the lift The labels are shown in Figure 7 PRESTO OWNER S MANUAL Page 12 DOCK LIFT MAINTENANCE All servicing should be done by qualified personnel Qualified personnel should be able to read and understand wiring and hydraulic diagrams They should be able to troubleshoot live electrical circuits safely and in accordance with accepted practice For safety s sake if in doubt please contact your dealer or Presto Lifts Service Department at 207 878 0700 or 800 743 1000 Before servicing the lift read and understand this entire section and the section entitled Operating Instructions Hazards T
7. Figure 6 If you are standing too close to the lift when it is moving your arm or leg may be caught in the moving parts and you may be hurt Stay away from the pinch points when the lift is moving Completing Installation If your lift is mounted in a pit align the unit with the sides of the pit Once you are sure the lift is positioned correctly mark the locations of the lag holes in the base frame and drill the holes If necessary insert metal shims to level the base of the lift Insert and tighten the lag bolts to secure the lift Grout under the base rails to prevent vibration and distortion of the base frame as shown in Figure 2 If the lift is lowering too quickly or too slowly you can change the down speed by adjusting the flow control The flow control may be mounted either internally at the base of the cylinders or on the external power unit When adjusting the flow control always raise the lift table and insert the maintenance chocks as shown in Figure 1 Do not try to adjust the flow control while pressing the down button If you try this the lift table may drop suddenly and you may be hurt It is important that you follow these steps when adjusting the flow control DOCK LIFT OPERATING If you want the lift to lower more slowly turn the control clockwise up to 1 4 turn at a time If you want the lift to Raise the lift table and insert the maintenance chocks as shown in Figure 1 INSTRUC TI
8. handrails Through out this manual the handrails have been omitted for clarity Use lag bolts to hold the unit down unless it is mounted on casters If necessary insert shims to level the lift Mount the lift on a firm level surface Fig 2 Mount the Lift Securely PRESTO OWNER S MANUAL Page 8 Grout or shim the area under each side rail with cement The side rails must be supported Lag plates DOCK LIFT Fig 3 Using Lifting Eyes Ta Ae lt Protect the power unit from rain or moisture If the electrical parts in the power unit get wet workers may be hurt by electrical shock The electrical parts may fail if they are wet The electric motor in the lift can create sparks Don t install the power unit in an area where flammable gases may be present If the power unit is mounted within the lift internal power unit you will need these tools Acrane or lift truck that can lift the unit safely e Shims and lag bolts see the pit plan if the lift will be mounted in a pit Amasonry drill and bit to drill the holes for the lag bolts Apower supply with the specified voltage including fuses or circuit breakers as specified in Figures 12 13 and 14 If the power unit will be mounted away from the lift external power unit you will also need Acompressed air source for clearing the hydraulic lines Extra hydraulic oil for flushing the underground lin
9. storage location and place it them into the engaged position as shown in Figure 1 Note further information may be useful here to provide additional instructions as to the location and method of storage and engaged positions 4 Lower the lift until it makes complete contact with the maintenance device s Re check to ensure that all provided devices are fully and securely engaged If the device s is are not fully engaged the lift could fall unexpectedly resulting in permanent damage to the device s or the lift PRESTO OWNER S MANUAL Page 7 Rotate the chocks into position Working position position Storage position Figure 1 Safe Servicing of Lift FEES If for any reason you are unable to lower the lift com pletely onto the maintenance device s stop immedi ately and consult the factory Failure to properly use the factory approved maintenance device s could result in severe injury or death For single acting hydraulic and pneumatic lifts Once the maintenance device s is are properly and securely engaged continue to press the down button valve or switch for an additional 5 10 seconds to relieve all pres sure in the operating system add more specifics here as required for pneumatic lifts AN Failure to relieve operating system pressure could result in the sudden and unexpected release of high pressure fluids or air during maintenance and or repair of the lift and result in sever
10. surfaces on the rod bearing Install a new O ring and wiper Replace the rod bearing assembly on the rod CAUTION Be careful not to install the wiper backwards The lip on the wiper should point upwards as shown in the detail in Figure 8 Clean the bore of the cylinder tube thoroughly s Upper hinge pin amp Sores bushing Upper roller assembly y r A gd y Fo joy i my P in A C _ ju Ec n F F j T f mam f fag 4 foe i N J n j i T i af Vg p i 4 n2 p 2 mud ncc fi E Pinus Hn J i Lag points DOCK LIFT Adjustable flow control Down valve amp coil Breather vent Terminal strip Fig 8 Standard 3 2 HP Power Unit 8 2 WAY VALVE SOLENOID CAVITY WITH 1 313 SPOTFACE lt BL T IDENTIFICATION C BORES 7 NVALVE FOR THRU BLOTS 2 5 16 18 SHCS A 51 j gt 1 a Qu MTE PUMP ASSEMBLY OS 500 IDENTIFICATION C BORES FOR THRU BLOTS Fig 9 Hydraulic Pump and Down Valve PRESTO OWNER S MANUAL Page 17 DOCK LIFT Electrical Connections for Single Phase AC Enclosure with contactor T see detail below Up limitswitch optional wired normally closed Ground Red Black Pushbutton or footswitch E Circuit breaker or a 20A time delay fuse 227 White installed by user 120
11. the relief valve Ifthe motor is not running check the main disconnect switch the fuse s and the wiring to the motor Using an external lifting mechanism such as a crane or fork lift raise the lift and insert the maintenance chocks as shown in Figure 1 Be sure to lift the hinged end of the table top The hydraulic oil level may be low When the lift is raised as far as possible the oil should be about 3 4 inch above the bottom of the tank The exact level varies with different models especially on models with tanks that tip as the lift elevates Use a dipstick to check the oil level If your lift has an optional up limitswitch the lift may have reached this upper limit If the switch is out of adjustment the lift may not be able to raise completely Readjust the switch if necessary Do not disconnect the up limitswitch Instead loosen the adjusting screw and change the position of the arm If you do disconnect the switch when the lift platform moves up it may not stop at the correct point If the platform rises above the normal stopping point the frame of the unit may be damaged People working nearby may be hurt Ona lift with a three phase motor the motor may be running backwards If the motor has been wired correctly the lift should start moving 2 or 3 seconds after you press the up button If it does not try reversing any two electrical leads On a lift with a three phase motor the motor may be sin
12. D nv kid LTo pushbutton amp limit switch _ Jumper Motor contactor 2 90 Down valve White solenoid Indicates terminal on the contactor X Indicates wire connection in the enclosure Fig 13 Wiring Diagram LIfts Wired for Single Phase AC with limitswitch Main power Tank Filler unit Pump Down m Motor valve Filter and suction line Fig 14 Hydraulic Connections Connectors near lift table external power units only Flow control down speed control Hydraulic cylinder GN e Hydraulic supply line Vent return line Hydraulic cylinder Connectors near main power unit external power units only Page 20 DOCK LIFT PRESTO OWNER S MANUAL lt DOWN VALVE ELECTRIC STEEL LINES DOWN SPEED FLOW CONTROL ADJUSTABLE PREASURE COMPENSAT LIFT CYLINDERS HOSE i ALL PART OF PUMP ASSY VELOSITY FUSES SYSTEM RELIEF ADJUSTABLE Fig 15 Hydraulic Diagram Table 1 Electrical Interface Supplied by Customer Motor Required Fuse Required Fuse Required Fuse Wire Voltage 1 0 HP Motor 3 2 HP Motor 5 0 HP Motor Gauge 120 1 60 20 AMP 12 AWG 208 1 60 20 AMP 12 AWG 230 1 60 20 AMP 12 AWG 208 3 60 10 AMP 12 AMP 20 AMP 14 AWG 230 3 60 10 AMP 12 AMP 20 AMP 14 AWG 460 3 60 9 AMP 6 AMP 10 AMP 14 AWG 575 3 60 9 AMP 9 AMP 7 5 14 Table 2 Hydraulic Oil Specifications
13. ONS Operating Procedure lower more quickly turn the control counterclockwise Before operating the lift read and understand this entire up to 1 4 turn Don t move the control more than 1 4 turn section at a time Remove the maintenance chocks and check the descent speed Every time you want to change the adjustment again raise the table again and insert the maintenance chocks as shown in Figure 1 Test the lift with the rated load If the lift does not rise and you hear a loud squealing noise the pressure relief valve is operating Contact Presto Lifts for instructions Don t continue to use the lift if this happens The A DANGER The lift may use a power supply of up to 575 Volts AC This voltage can kill Do not work with the electrical parts unless you are a qualified electrician Locate the lift on a firm flat surface as shown in Figure 2 Stationary lifts should be lagged to the floor If you place the lift on a soft surface it may tip over especially when it is loaded or raised Someone may be hurt and the lift and load may be damaged pump will overheat very quickly and may be Load the lift correctly permanently damaged Do not try to adjust the relief valve If you change the setting on the relief valve you may overwork the lift This can cause the lift to fail suddenly and you may be hurt As a final step clean up all spilled hydraulic fluid Spilled hydraulic oil is slippery and may presen
14. VAC in Ground Power cord Receptacle NEMA 5 15R installed by user Tank Motor Down and pump valve Fig 10 Electrical Connections Lifts Wired for Single Phase AC If your lift has a dual voltage motor determine the correct voltage and make the connections as shown on the nameplate Connections shown above are for lifts operating on 120 VAC For lifts operating on 230 VAC a NEMA L6 15R receptacle 15 required The pump motor and down valve may be mounted on the lift unit itself internal power unit or in a separate location external power unit The pump has a built in relief valve and check valve The down speed control is pressure compensated Down valve m Fused disconnect 17 by ics _ her ki ie 15 230 dE HM Green Hydraulic IPH Ground lt i607 p 77407 7077 4 MTR power unit Power Hh motor cor ct Receptadle E To pushbutton amp limit switch Block Red Black Whit ILI White Up ies Black Uplimit o oper E contactor e rf if d or footswitch 7 i own Mie Bok 98 Don valve Contactor White solenoid Note Entry locations may differ from those shown Indicates terminal on the contactor Ground connections although not shown are required X Indicates wire connection in the enclosure Motor Enclosure Fig 11 Wiring Diagram LIfts Wired for Single Phase AC wi
15. bols 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 ANSI Standard Z535 4 indicates the relative seriousness of the hazardous situation DANGER indicates a hazardous situation which if not avoided A N G R will result in death or serious injury Red Background WARNING indicates a hazardous situation which if not avoided could result in death or serious injury Orange Background CAUTION used with the safety alert symbol indicates a haz ardous situation which if not avoided could result in minor or moderate injury Yellow Background NOTICE Blue Background SAFETY SAFETY INSTRUCTIONS or equivalent signs indicate safety INSTRUCTIONS related instructions or procedures Green Background NOTICE is used to address practices not related to personal injury PRESTO OWNER S MANUAL Page 6 DOCK LIFT SAFE SERVICING OF THE LIFT A Only authorized personnel should perform inspec tion or mainte
16. c Maintenance Every month Visually inspect the leg rollers center pivot bushings and pins cylinder clevis pins and bushings and the leg hinge pins and bushings for signs of wear Contact Presto for instructions for repair of the center pivot pins and bushings If you are going to repair the center pivot pins and bushings you must support the lift table in a special way Each set leg plates on both sides of the unit must be clamped together firmly using large C clamps You cannot use the chocks shown in Figure 1 With the pivot pins removed they will not support the table top If you do not support the lift table correctly the top may drop suddenly when you remove the pivot pins Please contact Presto for instructions Apply oil or WD 40 to the parts listed in the last step NOTE Although the bearings are lifetime lubricated their performance may be extended by additional periodic lubrication Check the level and appearance of the hydraulic fluid First raise the lift and insert the maintenance chocks as shown in Figure 1 On most models when the lift is fully elevated the oil should be about 3 4 inch above the bottom ofthe tank Use a dipstick to check the oil level and add oil as necessary Change the oil if it has darkened or feels gritty or sticky It is important to use hydraulic fluid with the correct grade and properties See the hydraulic oil specification in this manual Table 2 Every six months o
17. cks and check the speed as the table lowers Every time you want to change the adjustment again raise the table again and insert the maintenance chocks as shown in Figure 1 A DANGER Do not try to adjust the flow control while pressing the down button If you try this the lift table may drop suddenly and you may be hurt If the steps listed above do not solve the problem please call the Service Department at Presto Lifts at 800 343 9322 DOCK LIFT the lift and use it immediately A supply of new hydraulic oil Contaminated oil may damage the new packing e A container to catch the used oil Aclean place to work Choose a place which will not be damaged if you spill some oil Raise the lift and insert the maintenance chocks as shown in Figure 1 Turn off electrical power at the main disconnect or circuit breaker or unplug the machine This will prevent the lift from moving accidentally while you are working on it Disconnect the cylinder supply line at the pump and place the end into a container to collect the used oil Disconnect the vent line s at the cylinder s At the top end of the cylinder rod remove the keeper and drive out the clevis pin Push the rod back into the cylinder to drive the hydraulic fluid out through the hose into the container You may use air pressure at the vent hole to do this Disconnect the hydraulic line s from the cylinder s Lift the cylinder s out of the lift
18. e injury or death 6 Follow OSHA electrical lock out tag out procedures Disconnect and tag all electrical and or other power sources to prevent an unplanned or unexpected actua tion of the lift 7 Once inspection or work is complete reverse the perfor mance of the steps above to raise the lift off the main tenance device s and place the device s back into its their designated storage position s A FIXES HIGH VOLTAGE Disconnect and or lock out the electrical supply to the power unit prior to any installation or maintenance being performed DOCK LIFT SAFETY The safety of all persons operating maintaining repairing or in the vicinity of the PDL lift table is of paramount concern to Presto Lifts The lift table is a powerful machine with moving parts and is capable of causing personal injury if proper precautions are not taken Therefore throughout this manual Presto Lifts has identified certain hazards which may occur in the use of the lift table and provided appropriate instructions or precautions which should be taken to avoid these hazards In some cases Presto Lifts has also pointed out the consequences which may occur if Presto s instructions or precautions are not followed Presto Lifts uses the following system of identifying the severity of the hazards associated with its products Immediate hazard which will result in severe personal injury or death WA Hazard or unsafe practic
19. e which could result in severe personal injury or death CAUTION Hazard or unsafe practice which could result in minor personal injury or property damage Please read and follow this instruction manual including all safety instructions and precautions carefully and completely INSTALLATION INSTRUCTIONS Preparation Before you start to install the lift check for local codes and ordinances which may apply It is your responsibility to obtain any necessary permits Read all of these installation instructions carefully Be sure to read and understand all of the warnings If your unit is designed to be installed in a pit check the pit before you start to install the lift Measure the length and width of the lift table then measure the pit and be sure the pit allows adequate clearance Does the pit have 90 angles at each corner To check measure across the opposite corners of the pit The measurement on each diagonal should be the same within 1 2 inch The walls ofthe pit should be vertical Check with a carpenter s square If the power unit will be mounted away from the lift external power unit check the mounting arrangement for the power unit The power unit should be sheltered from the weather It should be mounted within 30 feet of the lift to minimize the pressure drop in the hydraulic system Be sure the hydraulic lines have been installed properly Note Certain PDL models including dock lifts require
20. eriodic Maintenance 13 TROUBLESHOOTING tart tr anm dest 14 Troubleshooting Check List 14 Electrical Connections for Single Phase AC 18 Electrical Connections for Three Phase AC 19 Ordering Replacement Parts remisit tans 22 RESTOCKING POLICY 00 0 cc cccccsccceessensceesesssccceeeeessccsseeesessesseenss 23 b Uis nghe 24 List of Figures Pig Safe Servicing pog otis Codi cups Ea 5 Fis 2 Mount the Lift Securely issivisassneasnisacsdweesinoasiunasucnsdeccassasveats 8 Fig 3 Using Lifting Eyes CREE Fig 4 Center the Load cs scscscacisessenssnccticccesoresssencdarmsddennnsastiardnoncen 11 Fig 5 Secure the Logd iind l1 Fig 6 Pinch Points 12 Fig 7 Parts AMO 16 Fig 8 Standard 3 2 HP Power Unit 17 Fig 9 Hydraulic Pump and Down Valve 17 Fig 10 Electrical Connections Lifts Wired for Single Phase AC 18 Fig 11 Wiring Diagram Lifts Wired for Single Phase AC without limitswitch 18 Fig 12 Electrical Connections Lifts Wired for Three Phase 19 Fig 13 Wiring Diagram Lifts Wired for Single Phase AC with limitswitch 20 Fig 14 Hydraulic Connections sss 20 Fig 15 Hydraulic Diagram
21. es and refilling the tank See Table 2 for the oil specifications Positioning the Lift Remove the shipping material and unskid the lift On the front of this manual confirm the model number serial number and date the lift is placed in service You can find the model number and serial number on the name plate The name plate is located on the crossbar at the base of the cylinders PRESTO OWNER S MANUAL Page 9 Chain spreader bar be Captive nut yu Base nut Move the lift into position supporting the base of the lift If the lift has a hinged throwover plate set the lift in position so the plate is in the appropriate orientation Install the lift as shown in Figure 2 Unless the lift is mounted on casters lag the lift to the floor Do not hang the lift from the table top This can damage the lift If the lift is mounted on an unstable surface it may tip over when it is in use You may be hurt and the lift and load may be damaged If your lift has lifting eyes as shown in Figure 3 use these when you move the lift It is best to use a chain spreader so the chain sections pull straight up You must supply the chain and spreader Remove the lifting eyes once you have moved the lift Hydraulic Connections External Power Units Only If Internal Power Unit proceed to step 10 Install the power unit Install the hydraulic line between t
22. g Presto Lift Cylinders If the lift fails to lower 1 Raise the lift and insert the maintenance chocks as shown in Figure 1 Failure to chock the legs may result in damage to the lift and severe personal injury PRESTO OWNER S MANUAL Page 15 The down valve may be de energized When the lift 15 lowering the down valve should be energized and fully open Check the solenoid in the valve with a volt meter The valve must also be clean and free to operate Remove the solenoid then the down valve Look for contamination which could block the valve action Clean the valve plunger with kerosene then blow it clean with compressed air The strainer screen over the lower part of the plunger must be clean See Figure 11 Before reassembling depress the plunger manually several times to be sure it moves freely The expansion nut which holds the solenoid should be finger tight only The flow control may need to be adjusted The flow control must be partially open to allow the oil to return from the cylinder s It is important that you follow these steps when adjusting the flow control Raise the lift and insert the maintenance chocks as Shown in Figure 1 e If you want the lift to lower more slowly turn the control clockwise up to 1 4 turn at a time If you want the lift to lower more quickly turn the control counterclockwise up to 114 turn Do not move the control more than 1 4 turn at a time Remove the maintenance cho
23. gle phasing When this happens the motor hums but does not turn If this 1s the case one lead of the three phase line has been interrupted Check the motor wiring and line fuses The motor voltage may be too low Check the voltage at the starter when the motor is under load The supply voltage should be within 10 of the rating On a lift with an external power unit the tank vent may be plugged You must remove the solid plug from the tank and insert the vented plug The vent line must be clear The suction filter may be clogged Clean the suction filter as described in the section on Periodic Maintenance A vacuum leak may be allowing air into the suction line DOCK LIFT causing cavitation loss of suction in the pump Check all fittings in the suction line and repair as necessary If cavitation is allowed to continue the pump may be damaged and may have to be replaced For the lift to raise the down valve must be de energized and fully closed Check for a problem with the wiring to the down valve Check the solenoid in the valve with a volt meter The valve must be clean and free to operate To check this remove the solenoid and then the valve Look for contamination which could block the valve action Clean the valve plunger with kerosene then blow it clean with compressed air The expansion nut which holds the solenoid should be finger tight only If the pump has been changed the coupling may not have been in
24. handise 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 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 23 DOCK LIFT Presto Lifts Limited Warranty Policy Presto Lifts warrants all of its products against defects in the welded structural frame and if ap plicable scissor legs from faulty material and workmanship for a period of five 5 years from the date of invoice other components have a limited warranty against defects in faulty material and workmanship for a two 2 year period from the date of invoice date of invoice and 30 day limited warranty on labor Please note that prior authorization from Presto Lifts 1s required on all warranty work There are no implied warranties of any kind more specifically there are no warranties of mer chantability 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 compo nents should become defective within the limited warranty period Proof of purchase 15 required for warranty The charge for sh
25. he power unit and the lift as shown on the pit plan Blow out the hydraulic line with compressed air before DOCK LIFT connecting it to the lift table Replace the solid plug on the hydraulic fluid tank with the vented plug supplied then attach the vent line to the vented plug Be sure that the hydraulic line will not be pinched by the lift as it raises or lowers If you allow the line to be pinched the lift may not work properly A hose may break the lift table may drop suddenly and someone may be hurt It is very important to keep the hydraulic oil free of dirt dust metal chips water and other contamination Most of the problems with hydraulic systems are caused by contamination in the oil Be sure to flush all hydraulic lines before connecting remote power units If you do not install the vented plug in the tank the pump may be damaged Electrical Connections A DANGER The lift may use a power supply of up to 575 Volts AC This voltage can kill you Do not work with the electrical parts unless you are a qualified electrician Make temporary electrical connections to the lift as shown in Figure 13 through 15 This temporary set up will allow you to raise the lift The fusing requirements are shown in Table 1 To avoid fire danger follow these requirements On a lift designed for three phase AC you must be sure the pump motor is turning in the right direction The lift table should start to move quickly whe
26. he 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 e The warranty for repair parts is 30 days from date of shipment Parts replaced under warranty are on a charge credit basis We will invoice you when we ship the replacement part then credit you when you return the worn or damaged part and we verify that it is covered by our warranty Labor is not covered under warranty for Parts orders Presto Lifts Parts Department 50 Commerce Way Norton 02766 Telephone 800 343 9322 FAX 888 788 6496 Email Service g PrestoLifts com www PrestoLifts com PRESTO OWNER S MANUAL Page 22 DOCK LIFT RESTOCKING POLICY PARTS Standard parts may be returned with a 23 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 1s 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 merc
27. here are several hazards you should be aware of as you service the lift A DANGER The lift may use a power supply of up to 575 Volts AC This voltage can kill Do not work with the electrical parts unless you are a qualified electrician As the lift moves up and down pinch points are formed as shown in Figure 6 Keep hands feet and loose clothing away from these pinch points If your hand or arm or a part of your clothing is caught you may be hurt A falling lift can cause severe personal injury Before working under the lift raise the lift and insert the maintenance chocks as shown in Figure 1 Do this every time you work under the lift Do not change the setting on the relief valve If you do change the setting this may cause a hydraulic part to fail The hydraulic components in the lift are designed to handle a certain amount of pressure If the relief valve does not open this pressure may be exceeded The lift may drop suddenly Someone may be hurt and the lift and load may be damaged Release of fluids under high pressure can cause personal injury Before you open any part of the hydraulic system be sure to release the hydraulic pressure The warning labels on the lift are there for the safety of the operators See Figure 7 e If the labels are worn or missing or have been painted over replace them before releasing the lift for operation PRESTO OWNER S MANUAL Page 13 Routine Periodi
28. ion 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 1n 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 5 DOCK LIFT SAFETY ALERT SYMBOLS AND SIGNAL WORDS The safety of all persons operating maintaining repairing or in the vicinity of this equipment 15 of paramount concern This is a powerful machine with moving parts and 1 capable of causing personal injury if proper precau tions 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 sym
29. ipping the defective component is the responsibility of the buyer and must be accompanied with an RMA number The shipping charge to return the component to the buyer 1 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 ap plicable use of product while charger is plugged into an AC outlet or failure to follow operating 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 warranty Th
30. is 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 PRESTO OWNER S MANUAL Page 24 DOCK LIFT MANY NEEDS REQUIRE MANY OPTIONS Call Presto Sales for stock or customized lift inquiries 800 343 9322 Email sales prestolifts com
31. manual This instruction manual is not intended to be or to create any other warranty express or implied including any implied warranty of merchantability or fitness for a particular purpose all of which are hereby expressly excluded As set forth more specifically in the product warranty Presto s obligation under that warranty is limited to the repair or replacement of defective components which shall be the buyer s sole remedy and Presto Lifts shall not be liable for any loss injury or damage to persons or property nor for any direct indirect or consequential damage of any kind resulting from the PDL lift table PRESTO OWNER S MANUAL Page 4 DOCK LIFT Responsibility of Owners and Users Inspection and Maintenance The device shall be inspected and maintained in 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 lines damaged or malfunctioning controls or safety devices etc shall be removed from service until it 1 repaired to the original manufacturer s standards Repairs All repairs shall be made by qualified personnel in conformance with Presto s instructions Operators Only trained personnel and authorized personnel shall be permitted to operate PowerStak Before Operat
32. n you press the up or down button If the lift table does not move in 2 or 3 seconds do not try to operate the lift Exchange any two of the three phase leads If this does not correct the problem see the troubleshooting instructions at the end of this manual If you have a unit designed for three phase AC and you connect the power so the motor runs backwards the lift will not operate and you may damage the pump Do not operate the lift for more than 2 or 3 seconds if you think the motor might be turning backwards PRESTO OWNER S MANUAL Page 10 Raise and chock the lift as shown in Figure 1 Make the permanent electrical connections as shown in Figure 10 through 12 Check the level of the hydraulic fluid On most models when the lift is fully elevated the oil should be about 3 4 inch above the bottom of the tank Use a dipstick to check the oil level and add oil as necessary Testing Clear the area around the lift Remove any loose wires lumber or other materials which might get in the way of the lift as it raises or lowers Remove the maintenance chocks and warn others to stay away from the lift Operate the lift through its full range of travel The lift should rise smoothly with a quiet humming sound and lower smoothly and quietly Raise and lower the lift a few times to check the clearances around the lift table As the lift table moves up and down pinch points are created at the places shown in
33. nance and service procedures Unau thorized personnel attempting these procedures do so at the risk of severe injury or death A rum Failure to properly adhere to lift blocking procedures is to risk the sudden and uncontrolled descent of the lift during maintenance or inspection A falling lift can cause severe injury or death This procedure describes the only factory approved method of working under a lift Follow these instructions EVERY time you plan to reach or crawl beneath the lift to perform service or maintenance no matter how momentary that might be If the factory provided maintenance device is damaged or missing stop immediately and consult the factory for as sistance The manufacturer is not liable for your failure to use the approved maintenance device s and procedures that have been provided 1 Any load must be removed from the lift prior to engaging the maintenance device s These devices are designed to support an unloaded lift only Failure to remove the load from the lift prior to blocking could cause the failure of the maintenance device s and allow the lift to fall unexpectedly This can result in personal injury or death or permanent damage to the maintenance device s and or the lift 2 Raise the lift to its fully raised position If you do not the maintenance device s may not be able to be placed properly in its their designed blocking position 3 Remove the maintenance device s from its their
34. r 500 hours of operation whichever comes first Raise the lift and insert the maintenance chocks as shown in Figure 1 Check all of the hydraulic fittings and hoses and repair the connections as necessary Occasionally the fittings can be worked loose by the vibrations from the power unit If a hydraulic fitting becomes loose or if a hydraulic hose breaks the hydraulic fluid DOCK LIFT may escape from the system under pressure If the lift is raised when this happens it can drop quickly Someone may be hurt or the lift or load may be damaged The clear plastic vent line and the cylinder rod s should be free of hydraulic fluid If you find much fluid in either place the cylinder seals may be leaking Disassemble the down valve as shown in Figure 11 Blow the valve plunger clean with compressed air Reassemble and reinstall Drain and discard the hydraulic fluid The suction filter is in the tank at the point where the suction line runs out to the pump Unscrew the hydraulic filter Blow the filter clean Reinstall the filter the tank and reassemble the hydraulic line Refill the tank with new hydraulic fluid If you continue to use fluid after it has worn out the moving parts in the system will wear more quickly Be sure all of the warning labels are in position and legible The warning labels are intended to protect your workers If the labels are missing or if they have been painted over replace them
35. stalled See the pump assembly in Figure 11 If the lift elevates but fails to hold a load Raise the lift and insert the maintenance chocks as shown in Figure 1 Failure to chock the legs may result in damage to the lift and severe personal injury The check valve may be leaking Dirt on the valve seat will prevent the valve from closing fully The check valve is mounted in the base of the pump housing as shown in Figure 11 Remove the check valve cap and inspect the valve for contamination which may be preventing it from closing You may be able to restore the seal by lightly rapping the ball into the seat using a 1 4 diameter rod and a small hammer The down valve may be energized While the lift is holding a load the down valve should be de energized and fully closed Check the solenoid in the valve with a volt meter The valve must also be clean and free to operate To check this remove the solenoid and then the valve Look for contamination which could block the valve action Clean the valve plunger with kerosene then blow clean with compressed air The expansion nut which holds the solenoid should be finger tight only The cylinder s may be leaking Look for oil on the cylinder rod s and in the vent line This may also occur if the oil tank has been overfilled If you find much oil in either place and the tank is not overfilled the cylinder s need to be repacked See the instructions in this manual on Repackin
36. t a fire hazard Always place the load in the center of the lift table Fig 4 Center the Load PRESTO OWNER S MANUAL Page 11 Besure that the load weighs no more than the maximum rated for the lift The maximum rated load 1 shown on the platform skirt Do not try to lift a load that exceeds the maximum rating If you try this the lift may fail suddenly Someone may be hurt and the If the load can roll or move insert chocks or fasten the load down Fig 5 Secure the Load DOCK LIFT Fig 6 Pinch Points lift and load may be damaged Place the load in the center of the lift table as shown in Figure 4 Do not try to load the lift while the lift table is moving f you are lifting pipes or other objects which may be able to roll or move fasten them down or chock them as shown in Figure 5 Be sure all workers are clear of the lift Remove any lumber or other material which may fall onto the lift Do not use the unit to lift people unless it has been specially equipped for this purpose A specially equipped lift will include operator protection and an excess flow protector to keep the lift from dropping suddenly if a hydraulic line is damaged Retrofit kits are available if you want to add these features to your lift As the lift table moves up and down pinch points are created as shown in Figure 6 Stay away from these pinch points Part of your body or clothing may become caught
37. thout limitswitch PRESTO OWNER S MANUAL Page 18 DOCK LIFT Electrical Connections for Three Phase AC CONTRGL PANEL 2408 2 30 4o90V 1P4 BOHZ SUPPLY VOLTAGE FRUM FUSED DISCONNECT 1 Li 12 L CONNECT THES LEAD TU THE CORREC SUPPLY TAGE JUMPER TRANSFORMER CONNECTIONS ARE SHOWN FOR 115 CONTROL FOR 24V CONTROL USE TERMINAL X2 INSTEAD OF X1 NOTE GAOUND CONNECTIONS SHOWN FOR GROUND CONNECTIONS USE SUPPLIED GROUNDING TERMINAL GROUNDING TERMINAL 3 BL es Oo E UPPER TRAVEL LIMIT SWITCH 1 5 NOTE TZRED M S WHITE m PUSHALT TON OR FBOTSWITEH Figure 12 Electrical Connections Lifts Wired for Three Phase AC Connect the power and control wiring to the proper terminals located in the control panel The pump motor and valve may be mounted on the lift unit itself 1nternal power unit or in a separate location external power unit The control panel may be wall mounted If on power up the motor rotates in the wrong direction don t continue to operate the lift You may damage the pump To correct the problem interchange any two of the motor leads T T or T PRESTO OWNER S MANUAL Page 19 DOCK LIFT Enclosure Note Entry locations may differ from those shown Ground connections although not shown are required Fused disconnect by customer m d nsn 0 1 lt PI Ground saki OH
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