Presto Lifts Power Stak PPS2200-125AS Installation, Operation And Service Manual Download

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Power Stak

PPS2200-125AS

Installation, Operation

and Service Manual

Model Number _____________________________________

Serial # ____________________________________________

Date Placed in Service _____________

IMPORTANT: READ CAREFULLY
BEFORE INSTALLING OR OPERATING LIFT

JUNE 2015

This manual covers PowerStak units with frame

numbers starting with GC stamped into the mast

and shipped March 2014 and after.

Summary of Contents for Power Stak PPS2200-125AS

Page 1: ...________________ Serial ____________________________________________ Date Placed in Service _____________ IMPORTANT READ CAREFULLY BEFORE INSTALLING OR OPERATING LIFT JUNE 2015 This manual covers PowerStak units with frame numbers starting with GC stamped into the mast and shipped March 2014 and after ...

Page 2: ...ed 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...

Page 3: ...B Charging the battery 13 C Warnings and Battery Info 13 D Battery maintenance 13 E Charger Operations 13 S E C T I O N 6 Maintenance 14 A Weekly Operations Maintenance Checks 14 B Monthly Operations Maintenance Checks 14 S E C T I O N 7 Troubleshooting 15 ORDERING REPLACEMENT PARTS 30 RESTOCKING POLICY 31 LIST OF FIGURES Figure 1 Operational Buttons 7 Figure 2 Stacker Body Components 16 Figure 3 ...

Page 4: ...E STRADDLE LEGS MUST BE ADJUSTED IN ACCORDANCE WITH THIS 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 Be sure to fully loosen all bolts before moving stabi...

Page 5: ...HER INSTRUCTIONS The battery operated stackers are designed for in plant non hazardous locations only They can be used in a 8 or larger aisle These units are not for personnel lifting WARNING Maximum Lifting Capacity UP TO 7 2 200 LBS UP TO 8 1 800 LBS UP TO 10 1 500 LBS Ratings based on 24 Load Center See Owner s Manual for details 10055256 This machine is designed for powered travel and should n...

Page 6: ...and authorized personnel shall be permitted to operate PowerStak Before Operation Before using the device the operator shall have Read and or had explained and understood the manufacturer s operating instructions and safety rules 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 cons...

Page 7: ... 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...

Page 8: ...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 If traveling forks first keep both hands on the control handle and be careful when changing direction of travel Keep your f...

Page 9: ...he key switch to allow the panel to be set aside Inspect for any bent or damaged parts B REMOVING FROM PALLET PowerStak 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 gr...

Page 10: ...terfly towards the operator the stacker runs in the reverse 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...

Page 11: ...g 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 Inspect the lift for damaged or worn parts Do not use if n...

Page 12: ...r 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 disconnected 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 1 Check ...

Page 13: ... suitable protective eyewear Read understand and fol low all battery and battery manufacturer s specific pre cautions 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 p...

Page 14: ...RKS Check that they are not bent or cracked BRAKE Ensure the brake works properly CABLES WIRES Check that there are no loose cables or wires LABELS Ensure all precautionary labels and guards are in place B MONTHLY OPERATIONS MAINTENANCE CHECKS 1 Battery maintenance free A Clean terminals B Clean battery compartment area if there are signs of corrosion 2 Hydraulic System A Clean and inspect hydraul...

Page 15: ...ure caused by Pressure relief valve needs adjustment Pump check valve stuck open Faulty solenoid valve Faulty wiring from lift switch to solenoid Faulty lift contactor Defective control circuit fuse Chain or roller bound 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 ...

Page 16: ... 10 8 Bolt 10 9 Bolt 2 10 Seat 1 11 Drive Wheel Cover 1 12 Rear Cover 1 Item Description Qty 13 Screen 1 14 Straddle Leg RH 1 15 Screen 1 16 Top Cover 1 17 Stacker Body Assembly 1 18 Screw 14 19 Caster Assembly 1 20 Bolt 4 21 Spring Washer 4 22 Nut 4 23 Bracket 4 24 Bolt 4 PRESTO OWNER S MANUAL Page 16 POWER STAK PPS2200 125AS ...

Page 17: ...witch 1 4 Emergency Reverse Switch 1 5 Horn Button 1 Figure 3 Control Pod Item Description Qty 1 Lifting Switch 2 2 Lowering Switch 2 3 Butterfly Switch 1 4 Belly Button Stop Switch 1 5 Horn Button 1 6 Turtle Speed Switch 1 6 Control Pod Bottom PRESTO OWNER S MANUAL Page 17 POWER STAK PPS2200 125AS ...

Page 18: ...13 Bolt 2 14 Collar Spindle 2 15 Lock Nut 1 Item Description Qty 16 Seat Connection 1 17 Bolt 2 18 Anchor Spindle Cover 1 19 Lock Washer 1 20 Nut 1 21 Spindle Cover 1 22 Screw 2 23 Spring Washer 2 24 Nut 2 25 Micro Switch 1 26 Bolt 2 27 Snap Ring 1 28 Spindle Collar 2 29 Air Spring 1 30 Fixing Shaft 1 31 Control Handle 1 32 Anchor Handle 1 33 Control Pod 1 34 Bolt 3 35 Flat Key 1 PRESTO OWNER S MA...

Page 19: ...1 8 Electric Brake 1 9 Bearing 1 10 Key 2 11 C Clip 1 12 Gear 1 13 Screw 4 14 Flange 1 Item Description Qty 15 Screw 3 16 Bearing 1 17 Seal 1 18 Ring Gear 1 19 Wheel 1 20 C Clip 1 21 Seal 1 22 Ring 1 23 Traction Motor 1 24 Dust Ring 1 25 Screw 10 26 Screw 3 27 Spacer 1 28 Panel 1 PRESTO OWNER S MANUAL Page 19 POWER STAK ...

Page 20: ...tion Qty 1 Block 4 2 Roller 4 3 Washer 4 4 Bolt 4 5 Fixed Pin Chain 1 6 Load Bracket Assembly 1 7 Snap Ring 2 8 Feed Shaft 1 9 Bolt 2 10 Nut 2 11 Fork Assembly 2 12 Cotter Pin 2 13 Nut 4 PRESTO OWNER S MANUAL Page 20 POWER STAK PPS2200 125AS ...

Page 21: ...ty 13 Spring Pin 2 14 Chain Wheel Cover 1 15 Bolt 1 16 Spring Washer 1 17 Washer 1 18 Chain Wheel 2 19 Snap Ring 2 20 Chain Wheel Seat 1 21 Rubber Spacer 1 22 Lift Cylinder 1 23 Bolt 2 24 Spring Washer 2 Item Description Qty 25 Washer 2 26 Plug 2 27 Bearing 2 28 Dust Cover 2 29 Spacer 2 30 Chain Assembly 1 31 Nut 4 32 Bolt 1 33 Nut 4 34 Orientation Piece 1 35 Nut 1 PRESTO OWNER S MANUAL Page 21 PO...

Page 22: ... Bolt Spring Washer 4 12B Cover Oil Tank 1 STACKER BODY COMPONENTS PPS2200 62NFO 21 Item Description Qty Item Description Qty 1A Valve Block 1 6C Bolt Spring Washer 2 1B Relief Valve 1 7 O Ring 1 1C Unilateral Valve 1 8 Gear Pump 1 2 Throttle Valve 1 8A Bolt Spring Washer 4 3 Solenoid Valve 1 9 Oil Hose Return 1 4A Screw Plug Metal 1 10 Oil Hose Suction 1 4B Screw Plug Plastic 1 11 Oil Filter 1 5 ...

Page 23: ...daptor 1 5 O ring 1 6 Oil Hose 1 7 Adaptor 1 HYDRAULIC SYSTEM PPS2200 62NAS Item Description Qty 1 Screw 2 2 Washer 2 3 Hydraulic Assembly 1 4 L Adaptor 1 5 O ring 1 6 Oil Hose 1 7 Adaptor 1 Figure 9 Hydraulic System PRESTO OWNER S MANUAL Page 23 POWER STAK PPS2200 125AS ...

Page 24: ...Figure 10 Hydraulic Schematic PRESTO OWNER S MANUAL Page 24 POWER STAK PPS2200 125AS ...

Page 25: ...oller 1 2 Fuse 1 3 Fuse 1 4 Travel Contactor 1 5 Lifting Contactor 1 Item Description Qty 1 Controller 1 2 Fuse 1 3 Fuse 1 4 Travel Contactor 1 5 Lifting Contactor 1 Figure 11 Control Panel PRESTO OWNER S MANUAL Page 25 POWER STAK PPS2200 125AS ...

Page 26: ...Figure 12a Electric Schematic Diagram 24 Volt System Two 12 Volt Batteries Connected in Series PRESTO OWNER S MANUAL Page 26 POWER STAK PPS2200 125AS ...

Page 27: ...Figure 12b Electric Schematic Diagram 24 Volt System Two 12 Volt Batteries Connected in Series PRESTO OWNER S MANUAL Page 27 POWER STAK PPS2200 125AS ...

Page 28: ...HERWISE 80006 5 0 00 LB 1 1 DIMENSIONS ARE IN LIMITED TO WRITTEN AGREEMENT DR PowerStak TITLE SIZE CK A DWG NO FRACTIONS 1 XXX 005 XX 01 ANGLES 3RD ANGLE v 14 B CHARGER BATTERY CHARGER CONNECTING BATTERY BATTERY CHARGER 120 VAC 24 VOLT SYSTEM 1 NEGATIVE CABLE B POSITIVE CABLE 2 B CABLE BATTERY REVISIONS REV DESCRIPTION DATE REVISE MAIN POSITIVE BATTERY CABLE MAIN NEGATIVE BATTERY CABLE B Figure 13...

Page 29: ...B 10040297 4 1 EA BK LD DCL 12 00X3 00 PRESTO ALPHA C155N 3 2 EA BK LD DCL 3 00X3 00 NO RIDERS 10039878 2 1 EA BK LD DCL 3 00X20 00 POWER STAK 10039877 1 1 EA BK LD DCL 2 25X8 50 WARNING USERS MUST 10039876 PROJECT C D B A 4 3 2 1 D C B A 3 1 2 4 SHEET 1 OF 1 DWG NO 80006773 50 Commerce Way Norton MA 02766 STATUS MODEL PROJECTION LD KIT LOC DIAG PWD STACKER 8 80003413 0 LB 80006773 REV DWG NO C SI...

Page 30: ...e 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 part...

Page 31: ...er information on how to rectify the issue Presto Lift Inc reserves the right to determine potential credits as a result of factory defects based on its inspection of the merchandise GENERAL All products shipped from our factory have passed Quality Assurance inspection and testing The carrier of choice has signed for and accepted the product in new working condition The customer should inspect to ...

Page 32: ...LET PRESTO MEET THOSE NEEDS MANY NEEDS REQUIRE MANY OPTIONS Call Presto Sales for stock or customized lift inquiries 800 343 9322 Email sales prestolifts com ...

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