PowerStak PPS2200-150AS Dec11.indd - Cisco
Contents
1. 21 12 Labels amp Precautionary Warnings 22 13 Electric Control Panel Prior to Nov 2008 23 14 Electric Control Circuit Prior to Nov 2008 24 15 Wiring Prior to Nov 2008 25 16 Wiring Diagram Prior to Nov 2008 26 17 Wiring Diagrams Nov 2008 to Present 27 18 Wiring Diagrams Nov 2008 to July 2011 28 19 Wiring Diagrams August 2011 to Present 29 20 25 Wiring Diagrams Nov 2008 to Present 30 35 POWER STAK PPS2200 150AS 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 available upon request or at www PrestoLifts com Each Presto stacker 15 equipped with nameplate serial number and model identifications Please refer to these numbers when ordering parts or requesting further information The Presto stackers are designed for lifting lowering and positioning a wide variety of loads WHERE UNIQUE SITUATIONS ARISE WHICH ARE NOT COVERED IN THIS MANUAL CALL PRESTO LIFTS FOR FURTHER INSTRUCTIONS The battery operated stackers are de2. Presto S worldwide material handling w s and ergonomic solutions p Power Stak F 26 52200 150 5 RL Installation Operation and Service Manual Model Number Serial If you are not Satisfied in any way contact 4 7 Date Placed Service IMPORTANT READ CAREFULLY BEFORE INSTALLING OR OPERATING LIFT Part orders are subject to a 50 minimum charge DECEMBER 2011 Presto Lifts Limited Power Stacker Warranty Policy Presto Lifts warrants the Power Stacker against defects on the mast fork carriage chains pumps DC motors controllers cylinders and wiring harnesses from faulty material and workmanship for a period of one 1 year from the date of invoice All wear items such as batteries wheels motor brushes seals bearings hydraulic hoses all switches battery chargers and forks have a limited warranty against defects in faulty material and workmanship for a ninety 90 day period from the date of invoice and 30 day limited warranty on labor Please note that prior authorization from Presto Lifts is required on all warranty work There are no implied warranties of any kind more specifically there are no warranties of merchant ability or fitness for any particular purpose Presto Lifts sole warranty shall be as set forth in this limited warranty Presto Lifts will elect to repair or replace a defective component without charge if any components should become defectiv
3. 20270008 V POWER STAK PPS2200 150AS Page 27 PRESTO OWNER S MANUAL LW 1812 5158 4 2810 NNOJ 13 78200008 A II0c f 03 800Z ul kl iin L 2d 14 11 12H44 s 1 1 IM 12 Lid T LY STALL 81 POWER STAK PPS2200 150AS Page 28 PRESTO OWNER S MANUAL HHYH 6652 0008 190 SHHONI SHY MIQ SNOILATOS 21 0 00 NY cozzo W D ONITONVH SQIMTTIOA SLAIT 015444 81419845 14150584 qx 01181 Wild 9119 15 084 MS Ct 145 Id 1 ana 76570008 q juesaJg 01 10z i iSnDnv NaH MOTTAL vig GH amm 18011 XR 19 m AS qi N 1 FONAN 854414 AONSONSNH NaOH r o MEM NAT 6 1 sis qas 70004 31110881 20313313 9213 d LIGHT GREEN T S S ELECTRONC THROTTLE MODUL POWER STAK PPS2200 150AS Page 29 PRESTO OWNER S MANUAL 920008 f juesaJd 01 8002 V NOISIA TI LV 1 g ZEDUDE 2 GBZPO008 SS3NHYH 3818 XLSHMd OVIO NNDD 73 DIDA DONIAAVHCG SIH L Ol 0c 91nsrq POWER STAK PP
4. 31fpm To Raise and Lower There are two buttons located on both sides of the handle The inside one is for raising the forks The outside one is for lowering the forks When operating always make sure the load being lifted 15 within the loading capacity of your stacker and the load has been stacked safely on the pallet Also make sure that the length of the forks corresponds to the length of the pallet In this way the load rollers will place themselves in the opening at the end of the pallet so that when you raise the forks you will not break the bottom boards of the pallet Always make sure that when entering the pallet that the forks are in the fully lowered position Be careful when lifting pallets that are too short or too long for the stacker It might destroy your pallet by breaking the bottom boards and if the forks project through the end of the pallet the tips of fork may go into the next pallet that is behind the pallet that you are lifting which may bend the tips of forks and overload the capacity of the stacker POWER STAK PPS2200 150AS Travel travel rotate butterfly controls throttle the upper part of the handle When the butterfly control CW towards the forks the stacker runs forwards in the forks first direction When rotating the butterfly CCW towards you the stacker runs backwards in the handle first direction Always make sure the stacker clears any obstruction when travel ing
5. DO NOT USE LIFT IF NOT OPERATING PROPERLY OR IF LIFT APPEARS UNSAFE IN ANY WAY REPORT YOUR CONCERNS TO SUPERVISOR IMMEDIATELY PRESTO OWNER S MANUAL Page 8 POWER STAK PPS2200 150AS Inspect lift for damaged or worn parts Do not use if not in safe operating condition Use lift on hard level surfaces only Make sure load is evenly distributed not loose or un stable and 15 as far back on platform or forks as possible Do not pick up loads on tips or forks or edge of platform For fork models adjust forks to the maximum practi cal width Pick up loads on both forks Do not overload Check load center and load weight capacities on the nameplate e Make sure travel and work area is clear of obstruc tions e Check overhead clearance before lifting loads or trans porting B DAILY OPERATIONS MAINTENANCE 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 or damage to the casing C Check for loose battery tie downs 2 Charger A Inspect wire connections B Check power cord for nicks damage C Check power charger for proper mounting 3 Hydraulic System D Inspect pump and cylinder for oil leaks E Check hydraulic oil level F Check hydraulic fittings and hoses G Check ram for nicks damage 4 Frame Assembly A Check chain roller assembly connections B Check for
6. Figure 1 Operational buttons PRESTO OWNER S MANUAL tion of stacker Pick the unit up On conventional masts use the top cross member of the lift On narrow masts the cover must be removed to access lifting equipment Be careful of the stacker swinging once fully lifted off the pallet or skid Have all personnel completely cleared from the area Pick the unit up approximately six inches above the pallet or skid Once raised remove the pallet or skid from below the lift Do not move the lift around in the air Lower the stacker on the ground C PREPARATION FOR USE This stacker left our factory in new condition It has been inspected and weight tested to assure all performance stan dards have been met Visually inspect the stacker for damage Check for attach ments and accessories that may have been ordered If there is any damage or missing parts report it to your carrier and your Presto dealer immediately Remove all metal plastic bands cardboard and other material used for shipping purposes Check to see if chains are in place and that the lift system 15 in working order Inspect for oil leaks See instructions for removing back panel on pg 5 Connect battery cable Check cables and wires on battery charger as well as battery 1 BELLY BUTTON SWITCH LIFT UP Le LIFT DOWN HORN SPEED CONTROL DIRECTION CONTROL POWER STAK PPS2200 150AS Page 6 Set up procedure for Power Stak Straddle
7. and that your path of travel is clear of people Never carry loads above the loading capacity of the stacker It is suggested that when traveling without a load the forks be in the lowered position The speed of the stacker is increased by the degree of the rotation in either direction it functions like a throttle When you release your hand from the butterfly control it automatically will resume to the neutral position and the speed of the stacker will slow down To Brake Your stacker 1s equipped with a magnetic brake The brake is applied when the handle is in its vertical position between 10 15 degrees and lowered position between 80 90 de erees The brake could be released when you pull down the handle at any point between 15 80 degrees Always make sure the brake 15 released before operating the stacker When the stacker is running you could brake the stacker by raising the handle to its vertical position or lowering the handle to its lowest position Or to turn the butterfly controls in the opposite direction the change in direction of the motor will slow down stop and reverse the direction of stacker When parked always put the handle in the full vertical position with the brake applied and the forks in lowered position Reversing Safety At the end of the handle there is a large red reversing bar belly button switch that is designed to protect the operator from injury When the operator runs the stacker backwa
8. Load Center See Owner s Manual Tor details ionis AWARNING 222751 11 1245 Maximum Lifting Capacity To avoid bodily injury read UPTO UP TOR ur ro10 UP TO 12 instructions before 2200 LBS 1 300 LBS 1 500 LES 1 200 LBS operating this machine Ratings based on 24 Load Center Sen Owner s Manual for details vins LIFTING CAPACITY ABOVE 7 IS LIMITED Maximum Lifting Capacity To avoid bodily injury read 223 27705 2 200 LeS 1 800 LBS 1 500LBS Ratings based an 24 Load Center Seo Owner Manual for deiaila operating this machine WARNING When servicing the unit 1 Key should be in OFF position 2 E stop should be depressed 3 Disconnect the batteries at the terminals Do not perform any repair work on lifts if there is a load on the forks or platform Do not perform any repair work if the forks or platform is in the raised position All personnel must stand clear of the lift while in mo tion Do not put hands or feet under the forks or platform Do not stand underneath the forks or platform Do not stand in front of the stacker while in motion Do not stand sit or climb on the lift Do not use the lift on soft uneven or unstable surfaces Do not exceed the load center or capacity WARNING You or others around you can be seriously injured or even ki
9. PRESTO OWNER S MANUAL Page 20 POWER STAK PPS2200 150AS Figure 11 Carriage Assembly November 2008 to Present PPS2200 150AS 4 Middle Plate 4 idler Wheel Wheel Sleeve 4 rok Description PRESTO OWNER S MANUAL Page 21 POWER STAK PPS2200 150AS Figure 12 Labels amp Precautionary Warnings Power Stak LOCATE POWER STAK LABEL AS SHOWN FOR NARROW MASTMACHINES AND ON THE UPPER CROSS BAR FOR WIDE MAST MACHINES Presi PRESTO OWNER S MANUAL NO RIDERS DO LIFT PEOPLE DO NOT STAND UNDER FORKS STAY CLEAR OF MOVING PARTS LOCATE ON MACHINE LIFTS 10039876 10039877 10039878 C155N 10040297 C165L LD TAG Lift manufactured to ASME B56 1 2 BK LD TAG 3 50x 1 87 Stacker Name Plate 4 PBKiDDCLI200x300 Presto Alpha 6 Page 22 POWER STAK PPS2200 150AS Figure 13 Electric Control Parts Priorto November 2008 Electric Control Parts 1 w Ih Electric control circuit xl j j orn 5001 MOSFET controller 1 5002 Contactor F R 1 5003 Hydraulic Contactor 1 5004 Fuse 150A 2 5005 Fuse 5A 1 5006 Horn 1 5007 Horn 1 PRESTO OWNER S MANUAL Page 23 POWER STAK PPS2200 150AS Figure 14 Electric Control Circuit 12074 4104 11 17 1 l 4 No Code
10. any worn or damaged parts BATTERY 5 121 VOLTAGE Approx 12 7 Fully charged Approx 12 2 V 1 2 charged Approx 12 0 V 1 4 charged Approx 11 6 V Discharged PRESTO OWNER S MANUAL Page 9 SECTION 5 BATTERY MAINTENANCE A PREPARING TO CHARGE A BATTERY 1 Always turn off E stop and key switch before working with the batteries 2 sure the area around the stacker and the battery is well ventilated while battery is being charged 3 The battery terminals connections and wiring connec tions should be clean and free of corrosion When clean ing any of these components wear a face shield or other suitable protective eyewear B 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 115V outlet Charge until the battery gauge indicator lights show fully charged approximately 6 8 hours C WARNINGS AND BATTERY INFORMATION Avoid use of open flame near batteries At temperatures around freezing point battery capacity 15 reduced by 30 The battery terminals connections and wiring should be clean and free of corrosion When cleaning any of these components wear a face shield or other suitable protective eyewear Read understand and follow all battery and ba
11. A SOA ONIMVUd SIH L 01 5 52200 150 5 34 PRESTO 5 MANUAL LSOW ONIAAVHG STALL HAAN Mv dc 93433497 HALLEAN 01 Q3LIBI 00680008 Ss3NHVH SHIM 515484 213 mE NDIIVNHDJH LuvIJIHdON JD 357 5 1222 1201 ios 40 91 34 1 a TEXT ani 05270008 A juesaJd 03 8002 J9quieAoN 67 POWER STAK PPS2200 150AS Page 35 PRESTO OWNER S MANUAL RECOMMENDED SPARE PARTS LIST PPS2200 150AS PRESTO OWNER S MANUAL Page 36 POWER STAK PPS2200 150AS ORDERING REPLACEMENT PARTS Presto Lifts has carefully chosen the components In your untt to be the best avallable for the purpose Replacement parts should be identical to the original equipment Presto Lifts will not be responsible for equipment failures resulting from the use of incorrect replacement parts or from unauthorized modifications to the unit Presto Lifts can supply all replacement parts for your lift With your order please include the model number and the serial number of the unit You can find these numbers on the name plate This plate is located within the cabinet or the angle iron cylinder cross support To order replacement parts please call the Presto Parts Department Parts are shipped subject to the following terms FOB factory Returns only with the approval of
12. Description q J4DR Driving Motor 12V 70Ah 2 Ka Motor Controller 1207 4102 DC24V 250A M2 PumpMotor DC24V 13Kw E3 bui 6 i le 87 9 i 1 53 UrgentReverseSwich 12 5455 Up DownSwich A X J 13 S6 j I J 15 S9 A 250 J Li MagneticClutch DC24V 25W Magnetic Somoutete Valve Da tied ircle 181 Di 1 5408 Prior to November 2008 19 MC j __BatteryMeter DC24V 20 02 06 1 4007 21 150 Timing 11 0 24 PRESTO OWNER S MANUAL Page 24 POWER STAK PPS2200 150AS Figure 15 Wiring Connectors viewed from wire entry side gt CONNECTORS VIEWED FROM WIRE SIDE Prior to November 2008 O O EMERGENCY REVERSE 19 PRESTO OWNER S MANUAL 5 S F DOWN DOWN HORN 4 I ELECTRONIC THROTTLE MODULE Page 25 POWER STAK PPS2200 150AS Figure 16 Prior to November 2008 CONNECTIONS VIEWED FROM WIRE SIDE EMERGENCY REVERSE FORWARD INPUT MODE SELECTIO PUT REVERSE INPUT BRAKE INPUT KEYSWITCH INPUT REVERSE CONTACTOR THROTTLE POT LOW DRIVER OUTPUT FORWARD CONTACTOR DRIVER OUTPUT AIN CONTACTOR DRIVER OUTPUT THROTT
13. LE 0 5V SIGNAL CONNECTOR UNIT UP CONTACTOR HYDRAULIC POWER DOWN VALVE SOLENOID CONTACTORS WRAP EACH END OF ALL WIRES WITH IDENTIFYING NUMBER LABEL PRESTO OWNER S MANUAL Page 26 POWER STAK PPS2200 150AS November 2008 to Present Figure 17 _ LY 15114 VIG ER 1H3433H2v DI 4311017 015 xvISHdMUd 94 ld NOILYNAOANI 3491 31 X ISN S3H2H 34 MIU 74445444 031312345 115310 js1MH3H1U 55371Nf c ih 7105 143 WW 0 114 17144415 5484 Par QNITONYH WIH3LVM 30IMQTHOM 6141 01S33d xo Xe DE BU F2 9 p ARA OM 1999 NDI 14142530 up LOS H 82 0008 8 1812 WISHMd DVIO NNOJ JH l 1031403 58220008 8 SSINHYH JHIA 15 9910 NNO Ju 2 SS3NHVH OIM 9820008 8 SS3NUVH 3HIM 51584 9910 NNOJ Ju 1 18220008 8 854319 1303 515880 Ju A39 9 3099 1303 000 88080008 8 SS3NHYH 3818 158 4 43911081409 2SINW 69270008 8 SS3NUVH JHIA 515884 9910 NNOJ Ju 9 INOJ 06880008 8 SSINHVH JHIA WISHMd 531842 H3M d wSd LJ3NMUS 30v IB Iv 13 13881 ONT 609080 JU 5 8 191845 11 SA3vISHiMDd 903 SJIUN M Ld 855343
14. S PRESTO OWNER S MANUAL Page 5 SECTION INSTALLATION A INSPECTION Upon receipt of the stacker inspect the equipment completely to determine if there is any shipping damage and that the lift is complete Presto tests and inspects every piece of equip ment prior to shipment If damage is apparent a freight claim must be filed with the freight company Do not use the stacker if there appears to be any damage With the stacker in a lowered position check the following Check for signs of damage especially to the back cabinet that houses the battery electrical hydraulic power pack Check all electrical and hydraulic connections for tightness e Remove back panel 1 Turn key switch to OFF position 2 Push in E stop and unscrew the red knob 3 Lift off back panel There is enough wire to the key switch to allow the panel to be set aside Inspect for any bent or damaged parts B REMOVING FROM PALLET Each of the Presto stackers is shipped out on a pallet or skid Prior to removing the unit from the pallet or skid remove all tie down straps and packaging Visually inspect the unit as Closely as possible With an overhead hoist or forklift carefully pick up the unit taking into consideration the center of gravity of the unit If you choose to pick the unit with an overhead hoist use a nylon sling and hoist with a minimum of 2 000 Ib capacity The nylon sling will not do any damage to the steel construc
15. S2200 150AS Page 30 PRESTO OWNER S MANUAL 2 _ 98090008 SS3NHYH 3818 ISHMd 9710 NNDD 13 14 08 gt 98270008 juesaJd 01 8002 JequieAoN c POWER STAK PPS2200 150AS Page 31 PRESTO OWNER S MANUAL tw 18118 SIH L SNOLINTDS ALNOMOSS3 NY THOM NOT 14142530 1485 13389 14501 100 WOT TE 421 18 N 19200008 juesaJd 01 8002 JequieAoN POLED WW 89445 34049 18 18145534 LINJ ddai DI 411111 dIHd Hd 40 451 53H2N MI MIU 131313451 5131 015344 2 TT LE 5 12984 WHIA I0 8 8 3015 54011934405 351MH3HIU 563 digne DE L 1 3818 Q3N 3 CC POWER STAK PPS2200 150AS Page 32 PRESTO OWNER S MANUAL LV 1 22000002 SlHllOIS33d 88270008 A juesaJd 01 8002 _ 88280008 SS3NHYH 34IM XLSMMd 9710 NNDD 73 NO END ONIAAVHG HALLEAN 01 POWER STAK PPS2200 150AS Page 33 PRESTO OWNER S MANUAL LV 38 1 58270008 juesaJd 01 8005 2 6820008 3 SS3NHVH 3MIM XISHMd 9410 NNDD T3 NOL LN
16. d at a speed that will give you time to react in an emergency Keep your hands and feet away from all moving parts such as masts chains forks or wheels Never stand on or under the forks or allow anyone else to stand on or under them Never ride on the stacker or allow anyone else to ride There is no safe place to sit or stand Before you leave your stacker be sure to lower the forks to the floor Shut the stacker off with the key WARNINGS DO NOT use this stacker until you have been trained and authorized to do so DO NOT operate until you have read all warnings and in structions DO NOT exceed load center or load weight capacities check capacity plate DO NOT operate until you have checked the conditions of the stacker lift systems forks chains and cables DO NOT use if any part is damaged worn or not working properly DO NOT use on ramps or inclines Only smooth level sur faces DO NOT use for lifting or carrying people DO NOT handle unbalanced unstable or loosely stacked loads DO NOT travel with forks or platform in an elevated posi tion DO NOT handle tall unsecured or unstable loads that could fall DO NOT allow people to stand or pass under forks or plat form with or without load DO NOT operate when parts of anyone s body may be close to mast structure or any moving parts DO NOT drop loads on platform or forks DO NOT alter or modify this stacker in any way POWER STAK PPS2200 150A
17. ders are determined to be complete based upon Presto Lift Inc inspection sheets and carrier shipping weights POWER STAK PPS2200 150AS m Presio W I w enam O 2 LET PRESTO MEET THOSE NEEDS Call Presto Sales for stock or customized lift inquiries 800 343 9322 Email sales prestolifts com n PRESTO OWNER S MANUAL Page 38 POWER STAK PPS2200 150AS
18. e within the limited warranty period Proof of purchase is required for warranty The charge for shipping the defective component is the responsibility of the buyer and must be accompanied with an RGA number The shipping charge to return the component to the buyer is the responsibility of Presto Lifts Inc This limited warranty does not cover labor expense for removal or reinstallation of components after thirty days This limited warranty shall not cover among other things damages resulting from foreign matter or water failure to provide reasonable and necessary maintenance and if applicable use of product while charger is plugged into an AC outlet or failure to follow operat ing instructions The limited warranty is not valid for damage resulting from negligence accident unreasonable use abuse or misuse exceeding data plate capacities or altering the product without Presto Lifts authorization Presto Lifts expressly disclaims and excludes any liability for consequential incidental indirect or punitive damages or financial loss to people or property resulting from any breach of warranty or the operation or failure of this product Presto Lifts makes no representation that this product complies with local state or federal safety product standards codes Should this product fail to comply in any way with those codes it shall not be considered a defect of materials or workmanship Presto Lifts shall not be held liable for any damages re
19. etween the idler wheel and the left front wheel 8 Now tighten the screw until you just make contact with the idler wheel Continue adjusting until the idler wheel just touches the floor 9 Tighten jam nut You may have a slight rocking back and forth from the left front to right rear idler wheel but this is not uncommon 10 Now remove the wooden block and lower the cover back into place inserting the 2 screws and tighten Screw the E stop button back on 11 Your adjustment is complete If the wheel is worn replace wheel POWER STAK PPS2200 150AS Figure 2 PPS2200 150AS November 2008 to Present PRESTO OWNER S MANUAL Page 12 POWER STAK PPS2200 150AS Figure 3 PPS2200 150AS Exploded View November 2008 to Present 0020 0022 1111 11115111 11101111 iiu i TT 111111 111111 3000 10041 0042 POWER STAK PPS2200 150AS Page 13 PRESTO OWNER S MANUAL Figure 4 Inner Mast PPS2200 150AS November 2008 to Present Description 10 Description 6015 InnerMastWeld 1 6016 MastBottomBeam 1 6017 BoltMiOQ5 f2 6018 ldlerWheelCover 14 6019 Bearing 307 4 6020 SnapRing3S 4 j C PRESTO OWNER S MANUAL Page 14 POWER STAK PPS2200 150AS Figure 5 November 2008 to Present Cylinder View PPS2200 150AS m Description Qy 5001 Fitting J 5002 OR
20. ing fj 003 004 Nt URs 2 007 Piston 1 _ 008 Spacer 1 ORng 1 010 PistonRod 1 5011 Wearable Ring 5012 Direction Sleeve 5013 Dustproof Ring PRESTO OWNER S MANUAL Page 15 POWER STAK PPS2200 150AS 6 November 2008 to Present Caster Wheel Assembly PPS2200 150AS 11 Description Qty 2003 2004 WheelFrame 006 2007 BearingRing 2 2009 Sleeve fji 6 2010 Bearing 2 PRESTO OWNER S MANUAL Page 16 POWER STAK PPS2200 150AS juesaJd 01 8002 SV0SL 00ccSdd quiessy o9uM L dans POWER STAK PPS2200 150AS Page 17 PRESTO OWNER S MANUAL Figure 8 November 2008 to Present Control Pod PPS2200 150AS FrontButton fi small 7106 Left Handle Cover 1 7107 7108 Spring 109 Horn Button fi 7110 Button Group 1 7111 7112 Boltm3x10 f2 7113 Washer _ h 7114 SwitchCover 1 7115 switch Description PRESTO OWNER S MANUAL Page 18 POWER STAK PPS2200 150AS Figure 9 Steering Assembly August 2008 to Present PPS2200 150AS em Deco a 7013 7003 S AS Z 7016 Wo 7018 7006 h 7 An m ON 7021 7008 mn 7009 7023 9 lt PRESTO OWNER S MANUAL Page 19 POWER STAK PPS2200 150AS Figure 10 November 2008 to Present Power Unit Assembly PPS2200 150AS
21. legs NOTE The Straddle legs must be adjusted to the procedure below 1 Determine the required straddle leg dimension 2 Relieve any weight from the legs This may need to be done one side at a time 3 Adjust the legs and ensure both legs are positioned equally Please refer to diagram below otraddle Leg Bolt Tightening Procedure 3 Bolt 1 Pre tighten all bolts to the bottom but not too tight 2 Fully tighten bolt 1 3 Next tighten bolt 3 4 Last tighten bolt 2 5 Tighten all bolts to 85 foot pounds Note The Power Stak is meant to operate on a non slip floor or surface If traction is needed Presto Lifts offers an optional rubber wheel or a non marking wheel Note The travel speed is preset at the factory For travel speed adjustment please contact customer service at Presto Lifts 1 800 343 9322 PRESTO OWNER S MANUAL Page 7 Set up procedure for Power Stak Straddle legs with 4 Bolts Straddle Leg Bolt Tightening Procedure 1 Pre tighten all bolts to the bottom but not too tight 2 Fully tighten bolt 1 3 Next tighten bolt 3 4 Next tighten bolt 4 5 Last tighten bolt 2 6 Tighten all bolts to 85 foot pounds ECTION 4 OPERATION A OPERATING INSTRUCTIONS Operational Speeds the Presto Power Stak is designed to operate at the follow ing speeds Rise speed empty 24fpm Rise speed loaded 17fpm Lowering speed empty 13fpm Lowering speed loaded
22. lled if you don t use this stacker correctly Read and obey all warnings and instructions in this manual and on the stacker It is your responsibility before starting work to make sure it is in good working order Always be alert to the area around you and watch where you are walking Be careful that you don t get pinned or crushed between the stacker and a fixed object such as a wall or post Watch your hands and feet A foot or hand caught between the stacker and a fixed object will be crushed or even cut off f traveling forks first keep both hands on the control handle and be careful when changing direction of travel Keep your feet clear of the stacker Keep the stacker under control at all times Operate at a speed that allows you to stop safely Be even more careful on slippery or uneven surfaces Do not run over objects on the floor Perform all stacker movements smoothly and at a speed that will give you time to react if an emergency occurs Tipovers and falls are very serious accidents you can be crushed or even killed To prevent injury know where you are at all times and follow the rules of safe stacker operation Be careful when working around docks dockboards and trailers Stay away from the edge of docks and ramps Check to make sure the wheels of truck or trail ers are chocked Travel with the load or forks close to the ground Watch for overhead obstructions Perform all stacker movements smoothly an
23. osion Hydraulic System A Clean and inspect hydraulic cylinder B Lubricate chain with a rust inhibitive lubricant light machine oil C Check chain tension It should be even on both chains The chain should be tight enough so that it does not come off of the roller assembly Frame Assembly A Clean and lubricate all roller bearings cam fol lowers and all moving parts B Clean and inspect all welds C Check wheels for wear and damage D Inspect nameplate for legibility Place the serial and model number shown on the nameplate on the cover of the manual for future reference Electrical A Check batteries motors controllers limit switches electrical conductors and connections CAUTION DO NOT USE LIFT IF IT IS NOT OPERATING PROPERLY OR APPEARS UNSAFE IN ANY WAY POWER STAK PPS2200 150AS ECTION 7 TROUBLESHOOTING Before starting the troubleshooting you have to A Put the truck on an even and solid surface B Turn off key switch or disconnect the battery termi nals 1 Unit will not lift motor does not run Faulty wiring from fuse to lift switch in handle Faulty lift switch Faulty wiring from battery positive terminal to pump contactor to pump motor Burned out brushes in pump motor Low hydraulic pressure caused by Pressure relief valve needs adjustment Pump check valve stuck open Faulty solenoid valve Faulty wiring from lift switch to solenoid Faulty lift contacto
24. our Parts Department Credit cards preferred except parts covered by war ranty Freight collect for truck except parts covered by warranty Freight prepaid and invoice for small parcel shipments except parts covered by warranty Parts replaced under warranty are on a charge credit basis We will invoice you when we ship the replacement part then credit you when you return the worn or damaged part Presto Lifts Parts Department 21 Park Street Attleboro MA 02703 Telephone 800 343 9322 FAX 888 788 6496 Email Service PrestoLifts com www PrestoLifts com PRESTO OWNER S MANUAL Page 37 PARTS Standard parts may be returned with a 20 restocking fee Modified or custom engineered parts are not returnable Unfortunately due to potentially concealed damage all sales of electrical assemblies are final QUALITY ISSUES Should you feel there is a quality problem please contact the seller to ask questions and gather information on how to rectify the issue Presto Lift Inc reserves the right to determine potential credits as a result of factory defects based on its inspection of the merchandise GENERAL All products shipped from our factory have passed Quality Assurance inspection and testing The carrier of choice has signed for and accepted the product in new working condi tion The customer should inspect to ensure it is not received damaged has no concealed damage or is not incomplete Parts or
25. r Defective control circuit fuse Chain or roller bound Check oil level 2 Forks will not lower Look for binding in chains or rollers 3 No electrical power Dead Batteries Key switch on OFF position E stop button depressed Loose or dirty battery connections Blown fuse s Faulty wiring from fuse to travel control switch Faulty control switch Faulty wiring from travel control switch direction con tactor Faulty contactor 4 No Traction 9 Idler wheel needs adjustment PRESTO OWNER S MANUAL Page 11 IDLER WHEEL ADJUSTMENT The following is a procedure for adjusting the idler wheel on the Presto PowerStak Under normal conditions this should not be necessary because the idler wheel has been adjusted at the factory Tools Needed Phillips head screw driver Medium crescent wrench 1 block of wood 2 x 4 1 Place unit on a flat surface 2 Turn key to the OFF position and push emergency stop button down 3 Remove the 2 screws from the main orange cover that covers the unit 4 Remove the emergency stop button by unscrewing 5 Slide the main cover up and place the block of wood under the right hand side to hold open exposing the idler wheel and adjusting the screw 6 With the adjustable wrench loosen the jam nut on the idler wheel adjusting screw 7 Loosen the adjusting screw until you have no tension between the adjusting screw and idler wheel You will have some play b
26. rds and the end of the handle comes in contact with the opera tor s body the stacker will automatically reverse direction and travel away from the operator When the reversing safety bar comes in contact with your body during operation im mediately release your hands from the butterfly control and put the handle up to its vertical position or down to its lowest position and the brake is on The reversing safety bar will automatically resume to its original position after being activated Horn As standard equipment a horn that is located on the top of the handle AUTHORIZED OPERATORS SHOULD READ AND UNDERSTAND ALL INSTRUCTIONS PRECAUTIONS AND WARNINGS IMPROPER USE OF THIS LIFT TRUCK COULD RESULT IN INJURY AND OR DAMAGE TO LOAD AND EQUIPMENT SUGGESTED DAILY OPERATOR CHECKLIST WALK AROUND INSPECTION Check general condition of lift loose or broken parts etc Check for dented or scratched panels Look for broken or cracked welds broken or worn rollers and chains Check for loose pins or fasteners Ensure condition of wheels are not flat spotted or chunked out Check for hydraulic leaks Make sure all precautionary labeling is in place and legible Check for hydraulic leaks FUNCTIONAL INSPECTION 1 Check for proper operation of UP IDWN FOR REV controls 2 Check operation of brake system 3 Check for locations of belly button switch and horn 4 Check for hydraulic leaks OPERATOR ID DATE
27. ry Info D Battery SECTION 6 NENNEN 10 Weekly Operations Maintenance Checks 10 B Monthly Operations Maintenance Checks 10 SECTION 7 Trouble S DOO IE uu uuu uuu asas 11 ORDERING REPLACEMENT PARTS 37 RESTOCKING 37 LIST OF TABLES Table 1 Recommended Spare Parts List 36 PRESTO OWNER S MANUAL Page 3 Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig LIST OF FIGURES 1 Operational Buttons 6 2 PPS2200 150AS Nov 2008 to Present 12 3 PPS2200 150AS Exploded View Nov 2008 io Present u u uu u exc 13 4 PPS2200 150AS Inner Mast Nov 2008 to Presenb 14 5 Cylinder View Nov 2008 to 15 6 Caster Wheel Assembly Nov 2008 to 16 7 Drive Wheel Assembly Nov 2008 to Present 17 8 Control Pod Nov 2008 to 18 9 Steering Assembly August 2008 to Present 19 10 Power Unit Assembly Nov 2008 to 20 11 PPS2200 150AS Carriage Assembly Nov 2008 to
28. signed for in plant non hazardous locations only They can be used in a 8 or larger aisle These units are not for personnel lifting SECTION 2 SAFETY You must be trained and certified to operate this powered stacker Federallaw states that only properly trained operators are permitted to operate a powered industrial stacker and that your employer must train and certify that you are qualified OSHA 1910 178 29QFR 7 1 06 Edition Presto lifts does not offer operator training Operator training programs may be offered by your local Presto Lifts dealer or obtained online Enter powered industrial truck operator training into a search engine 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 haz ards that may occur during the maintenance and use of these lifts For safety reasons these units are designed to be serviced or repaired in the fully lowered position If performed properly this will greatly reduce the possibility of injury PRESTO OWNER S MANUAL Page 4 POWER STAK PPS2200 150AS AWARNING 12121 138112 Maximum Lifting Capacity To avoid bodily injury read understand and follow all instructions before operating this machine UP TO 7 UP TO 8 2 200 LBS 1 800 LBS E Ratings based on 24
29. sulting from noncompliance It is the dealer s responsibility to exercise this limited war ranty This limited warranty is provided to the original purchaser defined as the original end user and is nontransferable This constitutes the complete and final agreement involving Presto Lifts and limited warranty obligations for products This manual was current at the time of printing To obtain the latest most updated version please contact the Customer Service Department or go to our website www PrestoLifts com you will find a complete list of current Owner s Manuals to print PRESTO OWNER S MANUAL Page 2 POWER STAK PPS2200 150AS TABLE OF CONTENTS SECTION 1 inte f Pure s MTM SECTION 2 SECTION 3 Jats j 2106 Rest te ete As B Removing from Pallet gt Preparation Tor SECTION 4 7 9 A Operating Instructions Daily Operations Maintenance Checks Suggested Daily Operator Checklist SECTION 5 Battery uuu u u rd avevo squid A Preparing to Charge Battery B Charging the battery C Warnings and Batte
30. t It must be at 9 volts to initiate charge SECTION 6 MAINTENANCE Operation of Presto Power Stak is very simple as is their construction They require very little maintenance Reason able care will result in excellent trouble free performance The Power Stak is designed for one man operation and ease of performance Grease floor wheels and casters at least once a month Use only Hydraulic Oil AW32 or Dextron III in the hydraulic system Do not overload your lift Check brakes steering mechanisms and controls be fore each use A WEEKLY OPERATIONS MAINTENANCE CHECKS 1 DAMAGE Check for bent dented worn or broken parts 2 LIFT SYSTEM Check to assure that there is no bind ing or excessive play in the forks Check for quiet and smooth operation of the lift cylinder Check all moving parts and linkage 3 LEAKS Check hydraulic system for leaks and hydraulic oil level 4 WHEELS AND CASTERS Check for wear and that PRESTO OWNER S MANUAL Page 10 they are turning smoothly LIFT CHAINS Check to see that they are in place and not loose FORKS Check that they are not bent or cracked BRAKES Ensure brakes work properly CABLES WIRES Check that there are no loose cables Or Wires LABELS Ensure all precautionary labels and guards are in place B MONTHLY OPERATIONS MAINTENANCE CHECKS Battery maintenance free A Clean terminals B Clean battery compartment area if there are signs of corr
31. ttery manufacturer s specific precautions while working with and or charging batteries D BATTERY MAINTENANCE To measure the voltage use a digital voltmeter DC on the battery poles The truck must not have been in use for the previous 30 minutes DANGER Never alter the AC cord or plug provided If it will not fit outlet have proper outlet installed by a qualified elec trician Improper connection can result in a risk of an electric shock 1 Disconnect the charger from the 110 volt wall outlet once the indicators read fully charged Note The batteries are designed for intermittent use Continual usage will wear the battery out and charging will be required POWER STAK PPS2200 150AS E OPERATION Power Lamp 1 Green Connection correct Charger will operate nor mally 2 Red Bad connection or bad battery Fault 1 Red light blinks 3 times in 5 seconds The output between charger is faulty loose or bad connection 2 Red light blinks 5 times in 5 seconds The temperature is too hot for the charger to operate 3 Building power is not compatible too low or too high 10 is the general rule Charge Lamp 1 Red Charger can charge normally The battery is less than 70 2 Orange Battery is between 70 and 100 charged 3 Green Battery is at 100 Fully charged 4 No light The charger can not charge the battery Voltage of the battery may be too low to cause the charger to star
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