Presto Lifts Power Stak PPS3000-125AS Installation, Operation And Service Manual Download

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Power Stak

PPS3000-125AS

Installation, Operation

and Service Manual

Model Number _____________________________________

Serial # ____________________________________________

Date Placed in Service _____________

IMPORTANT: READ CAREFULLY
BEFORE INSTALLING OR OPERATING LIFT

MARCH 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 PPS3000-125AS

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

Page 2: ...ility 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 rea...

Page 3: ...13 A Preparing to Charge a Battery 13 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 Troubleshooting Check List 16 21 ORDERING REPLACEMENT PARTS 35 RESTOCKING POLICY 36 LIST OF FIGURES Figur...

Page 4: ... PROCEDURE FOR POWERSTAK STRADDLE LEGS NOTE 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 ...

Page 5: ...g a wide variety of loads WHERE UNIQUE SITUATIONS ARISE WHICH ARE NOT COVERED IN THIS MANUAL CALL PRESTO LIFTS FOR FURTHER INSTRUCTIONS The battery operated stackers are designed for in plant non hazardous locations only They can be used in a 8 or larger aisle These units are not for personnel lifting This machine is designed for powered travel and should not be manually moved by applying force to...

Page 6: ...all 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 instruc tions and safety rules Inspected the device for proper operation and condition Any suspect item shall be carefully examined and a determination made by a qualified person as to whether it constitutes a hazard All items ...

Page 7: ...kground 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 will result in death or serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious ...

Page 8: ...d object will be crushed or even cut off If traveling forks first keep both hands on the control handle and be careful when changing direction of travel Keep your feet clear of the 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 sur faces Do not run over objects on the floor Perform all stacker movemen...

Page 9: ...conventional masts use the top crossmember of the lift On narrow masts the cover must be removed to access lifting equipment Be careful of the stacker swinging once fully lifted off the pallet or skid Have all personnel completely cleared from the area Pick the unit up approximately six inches above the pallet or skid Once raised remove the pallet or skid from below the lift Do not move the lift a...

Page 10: ...tor if the opera tor simultaneously engages the turtle speed button the forward and or reverse speed is limited to 50 of full speed or turtle speed The operator can engage the butterfly forward with the right hand and engage the turtle speed button with the left hand The operator can engage the butterfly forward with the left hand and engage the turtle speed button with the right hand The reverse ...

Page 11: ... LOAD AND EQUIPMENT Inspect the lift for damaged or worn parts Do not use if not in safe operating condition Use lift on hard level surfaces only Make sure load is evenly distributed not loose or unstable and is 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 maxi mum practical width Pick up loads on both fo...

Page 12: ...al condition of Stacker loose or broken parts oil dangling wires dents cracked covers etc 2 Check metal frame mast carriage and font load supports for cracked welds worn or flat rollers loose or 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...

Page 13: ...omponents wear a face shield or other suitable protective eyewear Read understand and fol low all battery and battery manufacturer s specific pre cautions while working with and or charging batteries 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 prov...

Page 14: ...e that they are in place and not loose FORKS 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 Hyd...

Page 15: ...ump contactor to pump motor Burned out brushes in pump motor Low hydraulic pressure caused by Pressure relief valve needs adjustment Pump check valve stuck open Faulty solenoid valve Faulty wiring from lift switch to solenoid Faulty lift contactor Defective control circuit fuse Chain or roller bound Check oil level 2 Forks will not lower Look for binding in chains or rollers 3 No electrical power ...

Page 16: ...emp Shutdown Motor Shutdown Main Contactor Shutdown EM Brake Shutdown Throttle Full Brake Shutdown Pump 1 See Monitor menu Controller Temperature 2 Controller is operating in an extreme environment 16 Controller Severe Overtemp Shutdown Motor Shutdown Main Contactor Shutdown EM Brake Shutdown Throttle Full Brake Shutdown Pump 1 See Monitor menu Controller Temperature 2 Controller is operating in a...

Page 17: ...supply pin 26 is too low 2 See Monitor menu outputs 5 Volts and Ext Supply Current 26 Digital Out 6 Overcurrent Digital Output 6 driver will not turn on 1 External load impedance on Digital Output 6 driver pin 19 is too low 27 Digital Out 7 Overcurrent Digital Output 7 driver will not turn on 1 External load impedance on Digital Output 7 driver pin 20 is too low 28 Motor Temp Hot Cutback Reduced d...

Page 18: ... phase is open 2 Bad crimps or faulty wiring 38 Main Contactor Welded Shutdown Motor Shutdown Main Contactor Shutdown EM Brake Shutdown Throttle Full Brake Shutdown Pump 1 Main contactor tips are welded closed 2 Motor phase U or V is disconnected or open 3 An alternate voltage path such as an external precharge resistor is pro viding a current to the capacitor bank B connection terminal 39 Main Co...

Page 19: ...n has concluded but the throttle forward and reverse inputs and interlock have not been returned to neutral 49 Parameter Change Fault Shutdown Motor Shutdown Main Contactor Shutdown EM Brake Shutdown Throttle Full Brake Shutdown Pump 1 This is a safety fault caused by a change in certain parameter settings so that the vehicle will not operate until KSI is cycled For example if a user changes the T...

Page 20: ...Mode changed to LOS Limited Operating Strategy 1 Stalled motor 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Problems with power supply for the motor encoder 5 See Monitor menu Motor Motor RPM 74 Fault On Other Traction Controller Dual Drive fault see Dual Drive manual 75 Dual Severe Fault Dual Drive fault see Dual Drive manual 87 Motor Characterization Fault Shutdown Motor Shutdown Main...

Page 21: ...3 Encoder LOS Limited Operating Strategy Enter LOS control mode 1 Limited Operating Strategy LOS control mode has been activated as a result of either an Encoder Fault Code 36 or a Stall Detect Fault Code 73 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Vehicle is stalled 94 Emer Rev Timeout Shutdown EM Brake Shutdown Throttle 1 Emergency Reverse was activated and concluded because the E...

Page 22: ... Spindle 4 28 Seat Auxiliary Wheel 2 51 Bolt 4 9 Bearing 8 29 Screw 4 52 Screw 2 10 Load Wheel 4 30 Controller Assembly 1 53 Charger 1 11 Bracket Load Wheel 2 31 Washer 8 54 Battery 2 12 Bushing 4 32 Bolt 4 55 Separator Battery 1 13 Load Wheel Assembly 2 33 Suspension Drive 1 56 Display Unit 1 14 Straddle Leg Right Hand 1 34 Link Shock Absorbing 1 57 Lock 1 15 Spindle Load Wheel 2 35 Washer 6 58 S...

Page 23: ...Qty 1 Lifting Switch 2 2 Lowering Switch 2 3 Running Switch 1 4 Emergency Reverse Switch 1 5 Horn Button 1 6 Control Pod Bottom 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 Control Pod ...

Page 24: ...ssembly Suspension 1 32 Snap Ring 2 5 Cushion 3 19 Screw 4 33 Bushing 2 6 Spring 3 20 Cover Steering Arm 1 34 Screw 2 7 Cover Spindle 3 21 Screw 1 35 Nut 2 8 Washer 3 22 Air Spring 1 36 Suspension Assembly 1 9 Spring Washer 3 23 Screw 3 37 Spring Washer 6 10 Bolt 3 24 Control Handle 1 38 Screw 6 11 Bolt 2 25 Anchor Handle 1 39 Screw 6 12 Spring Washer 2 26 Steering Arm 1 40 Screw 6 13 Fixing 1 27 ...

Page 25: ...ing 1 15 Screw 6 27 Plate 1 4 Screw 8 16 Helical Gear Axis 1 28 Friction Disk 1 5 Connecting Flange 1 17 Bearing 2 29 Friction Cover 1 6 Nut 1 18 Baffle Ring 1 30 Three Jaw 1 7 Gear 1 19 Framework Seal 1 31 Motor 1 8 Helical Gear Axis 1 20 Shaft Steering Wheel 1 32 Speed Sensor 1 9 Bearing 2 21 Wheel 1 33 Key 1 10 Casing 1 22 Bolt 5 34 Nut 1 11 Washer 1 23 Plug Screw 1 35 Gear 1 12 Lock Washer 1 2...

Page 26: ...Page 26 POWER STAK Carriage Assembly Item Description Qty 1 Fork 2 2 Snap Ring 2 3 Nut 2 4 Bolt 2 5 Roller Main 4 6 Screw 8 7 Spring Washer 8 8 Side Roller 4 9 Washer 8 10 Spacer 16 11 Load Bracket Assembly 1 12 Feed Shaft 1 ...

Page 27: ...r 2 2 Spring Washer 2 11 U Bolt 2 20 Screw 2 3 Washer 2 12 Seat Limit Switch 1 21 Outer Mast 1 4 Inner Mast 1 13 Washer 2 22 Screw 6 5 Spacer 16 14 Spring Washer 2 23 Washer 6 6 Main Roller 4 15 Screw 2 24 Net Cover 1 7 Side Roller 4 16 Micro Switch 1 25 Washer 2 8 Spring Washer 8 17 Cylinder 2 26 Slip Assembly 2 9 Bolt 8 18 O Ring 2 27 Chain Assembly 2 ...

Page 28: ...O OWNER S MANUAL Page 28 POWER STAK Lift Cylinder Assembly Item Description Qty 1 Lift Cylinder 1 2 Piston Rod 1 3 Baffle Ring 1 4 Ring Back Up 1 5 Plug 1 6 Cylinder Block 1 7 Ring 1 8 U Seal 1 9 Ring Dust 1 ...

Page 29: ...1 6 Motor 1 11 Tank Plastic 1 1C Unilateral Valve 1 6A Switch 1 11A Bolt with Spring Washer 4 2 Throttle Valve 1 7 O Ring 1 11B Nut 4 3 Solenoid Valve 1 8 Gear Pump 1 11C Cover Oil Tank 1 4A Screw Plug Metal 1 8A Bolt with Spring Washer 2 12 Clamp 1 4B Screw Plug Plastic 1 9 Oil Hose Suction 1 4C Screw Plug Metal 1 9A Oil Hose Return 2 Hydraulic Power Unit Assembly ...

Page 30: ...PRESTO OWNER S MANUAL Page 30 POWER STAK Hydraulic System Assembly Item Description Qty 1 Bolt 2 2 Spring Washer 2 3 Washer 2 4 Hydraulic Assembly 1 5 Oil Hose 1 6 O Ring 1 7 L Adaptor 1 ...

Page 31: ...PRESTO OWNER S MANUAL Page 31 POWER STAK PPS3000 125AS Velocity Fuse Velocity Fuse Hydraulic Schematic ...

Page 32: ...E A PHASE B 5 100mA 2 J1 21 J1 34 start 80 80 100 BATTERY FUEL GAUGE INPUT 120 1 60 OUTPUT 24VDC 15A REVISIONS REV DESCRIPTION DATE REVISED BY ECO DWG NO SHEET 1 OF 2 50 Commerce Way Norton MA 02766 STATUS Released 3RD ANGLE PROJECTION EL POWER STAK ELEC DIAG 24VDC SYSTEM 8 80006862 0 00 LB PRESTO LIFTS 80007376 1 1 REV DWG NO B SIZE TITLE FRACTIONS 1 XXX 005 XX 01 ANGLES 5 USE OF PROPRIETARY INFO...

Page 33: ...IN5408 DIODE 2 IN5408 DIODE 1 IN5408 HANDSET 16 16 DOWN VALVE SOLENOID 2 2 7 8 3 0 4 5 7 6 J13 J6 J1 5 J1 1 J1 10 J1 12 J1 24 J1 33 J1 22 ACCELERATOR J7 J29 J28 J25 MC 7 7 7 7 UNSWITCHED POWER FROM KEY SWITCH 3 7 DWG NO 50 Commerce Way Norton MA 02766 STATUS Released 3RD ANGLE PROJECTION EL POWER STAK ELEC DIAG 24VDC SYSTEM 8 80006862 0 00 LB PRESTO LIFTS 8000 1 1 DWG NO B SIZE TITLE FRACTIONS 1 X...

Page 34: ...DERS 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 LOCATE ON COVER BELOW BDI LOCATE 1 ON EACH SIDE OF WIDE MAST LOCATE 1 ITEM 6 ON MACHINE FRAME UNDER COVER 5 5 LOCATE ON FORK CARRIAGE DATE DATE DAP MODEL PROJECT C D B A 4 3 2 1 D C B A 3 1 2 4 SHEET 1 OF 1 12 05 14 SIZE TITLE USE OF PROPRIETARY INFORMATION PROJECTION LD LABEL DIAGR...

Page 35: ...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 36: ...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 in spection and testing The carrier of choice has signed for and accepted the product in new working condition The customer should inspect to...

Page 37: ...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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