Power Stak
PPS2200-62NAS
This manual covers PowerStak units with frame
numbers starting with GC stamped into the mast
and shipped March 2014 and after.
Installation, Operation
and Service Manual
Model Number ___________________
Serial # _________________________
Date Placed in Service _____________
IMPORTANT: READ CAREFULLY
BEFORE INSTALLING OR OPERATING LIFT
JUNE 2015
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 specically; there are no warranties of merchantability or tness for any particular purpose. Presto Lifts’ sole warranty shall be as set forth in this
limited warranty. Presto Lifts will elect to repair or replace a defective component without charge,
if any components should become defective within the limited warranty period. Proof of purchase is
required for warranty. The charge for shipping 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 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 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 nancial 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 war-
ranty. This limited warranty is provided to the original purchaser (dened as the original end user)
and is nontransferable. This constitutes the complete and nal 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 nd a complete list of cur-
rent Owner’s Manuals to print.
PRESTO OWNER’S MANUAL Page 2 POWER STAK
TABLE OF CONTENTS
S E C T I O N 1:
Limited Warranty ................................................................................................................................................2
Wheel Traction and Straddle Leg Set-Up ...........................................................................................................4
Introduction .........................................................................................................................................................5
Responsibility of Owners and Users ...................................................................................................................6
S E C T I O N 2:
Certied Operator Training .................................................................................................................................7
Safety .................................................................................................................................................................7
S E C T I O N 3:
Installation ...........................................................................................................................................................9
A. Inspection ....................................................................................................................................................9
B. Removing from Pallet ..................................................................................................................................9
C. Preparation for Use .......................................................................................................................................9
S E C T I O N 4:
Operation ...........................................................................................................................................................10
A. Operating Instructions .................................................................................................................................10
B. Daily Operations Maintenance Checks .......................................................................................................11
Suggested Daily Operator Checklist .................................................................................................................12
S E C T I O N 5:
Battery Maintenance .........................................................................................................................................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
ORDERING REPLACEMENT PARTS ...........................................................................................................................29
RESTOCKING POLICY ..................................................................................................................................................30
RETURN MATERIALS AUTHORIZATION .................................................................................................................31
LIST OF FIGURES:
Figure 1: Operational Buttons......................................................................................................... 7
Figure 2: Stacker Body Components............................................................................................ 16
Figure 3: Control Pod ................................................................................................................... 17
Figure 4: Steering Component ..................................................................................................... 18
Figure 5: Drive Unit....................................................................................................................... 19
Figure 6: Carriage Assembly ........................................................................................................ 20
Figure 7: Mast Components ......................................................................................................... 21
Figure 8: Power Unit ..................................................................................................................... 22
Figure 9: Hydraulic System .......................................................................................................... 23
Figure 10: Hydraulic Schematic.................................................................................................... 24
Figure 11: Control Panel ............................................................................................................... 25
Figure 12a & b: Electrical Schematic Diagram ........................................................................ 26-27
Figure 13: Battery Connection ...................................................................................................... 28
PRESTO OWNER’S MANUAL Page 3 POWER STAK
CRITICAL PROCEDURE FOR PROPER WHEEL TRACTION
Proper Drive Wheel traction is obtained for the PowerStak Straddle unit using this Procedure
All PowerStak Models are designed and intended to operate on an unnished concrete oor surface. If any
PowerStak is operated on smooth or polished concrete, sealed concrete, epoxy sealed oor, linoleum or
other smooth surfaces Drive Wheel traction performance may be affected; If traction issues are encountered
Rubber Drive Wheels are available through special order. Please contact Customer Service at Presto
Lifts 1-800-343-9322
When any PowerStak is operated on a wet, oily, powdery, sandy or non-uniform liquid or granular surface
Drive Wheel traction performance will be affected and loss of traction will occur.
SET-UP PROCEDURE FOR POWERSTAK STRADDLE LEGS
NOTE: STRADDLE LEGS MUST BE ADJUSTED IN ACCORDANCE WITH THIS PROCEDURE
1. PowerStak unit located on at, clean uniform surface, unloaded, forks raised a minimum of 1” off the oor
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 stabilizing legs. Adjust one stabilizer leg at a time – using a pry
bar, pinch bar, rubber mallet etc. move the straddle leg out from the base tube to the desired position. Do not
move too far, see picture below, if the ¼” wide painted White Line is visible the leg is pulled out too far; Maximum movement 5 ½” for each leg for 2200 pound units.
4. Adjust second Straddle Leg – using a pry bar, pinch bar, rubber mallet etc. move the straddle leg out from inside
the base tube to the desired straddle width position.
5. Straddle Legs must be symmetrically adjusted, both legs adjusted to the same extended dimension!
CRITICAL – STRADDLE BOLT TIGHTENING SEQUENCE & PROCEDURE
Set up procedure for PowerStak Straddle legs with 5 Bolts:
1020 REF.
BOLTS 2BOLTS 2
BOLT 3
BOLT 1
1270 MAXIMUM
Back off all bolts and follow steps.
BOLT 4BOLT 4
WHITE LINE
JUST SHOWING
First - tighten Bolt 1 to 85 foot pounds
Second - tighten Bolts two (2) to 85 foot pounds
Third - tighten Bolt 3 to 85 foot pounds
Fourth – tighten Bolt 4 to 25 foot pounds - NOT 85 foot pounds!
Last - securely tighten all lock nuts
PRESTO OWNER’S MANUAL Page 4 POWER STAK
NOTE:
When adjusted correctly, white
line cannot be seen.
S E C T I O N 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 is equipped with nameplate, serial
number and model identications. 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 designed for inplant/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 the Control Pod
Handles
The Control Pod and steering arm should
only be moved side to side when the
machine is under power
The Control Pod and steering arm should
be lowered to the drive position and power,
Forward or Reverse, is engaged by moving
the thumb wheel in the direction of desired
travel then the steering arm can be moved
side to side for directional steering.
Pushing or pulling on the Control Pod
Handles when the unit is not powered can
lead to damage and/or breakage
PRESTO OWNER’S MANUAL Page 5 POWER STAK
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 is repaired to the original manufacturer’s standards.
Repairs
All repairs shall be made by qualied personnel in conformance with Presto’s instructions.
Operators
Only trained personnel and authorized personnel shall be permitted to operate PowerStak.
Before Operation
Before using the device, the operator shall have:
• 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 qualied person as to whether it constitutes a hazard. All
items not in conformance with Presto’s specication shall be corrected before further use of the
PowerStak.
During Operation
The device shall only be used in accordance with this owner’s manual.
• Do not overload.
• Ensure that all safety devices are operational and in place.
Modications or Alterations
Modications or alterations to any Presto industrial positioning equipment shall be made only with
written permission from Presto.
PRESTO OWNER’S MANUAL Page 6 POWER STAK
S E C T I O N 2
CERTIFIED OPERATOR TRAINING
You must be trained and certied to operate this powered stacker. Federal law states that only properly
trained operators are permitted to operate a powered industrial stacker and that your employer must train
you and certify that you are qualied. (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.
SAFETY ALERT SYMBOLS AND SIGNAL WORDS
The safety of all persons operating, maintaining, repairing, or in the vicinity of this equipment is of paramount
concern. This is a powerful machine with moving parts, and is capable of causing personal injury if proper precautions
are not taken. Therefore, throughout this manual, certain hazards have been identied which may occur in the use
of the machine, and there are appropriate instructions or precautions which should be taken to avoid these hazards.
In some cases, there are consequences which may occur if instructions or precautions are not followed. Below are
the symbols and signal words along with their denitions 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 hazards. 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 dened 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.
(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 hazardous situation which, if not avoided, could result in minor or
(Yellow Background)
moderate injury.
(Blue Background)
A. SAFETY
B. INSTRUC-
TIONS
(Green Background)
PRESTO OWNER’S MANUAL Page 7 POWER STAK
NOTICE is used to address practices not related to personal
injury.
SAFETY INSTRUCTIONS (or equivalent) signs indicate safetyrelated instructions or procedures.
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 identied certain hazards 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.
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 motion.
• Do not put hands or feet under the forks or
platform.
• Do not stand underneath the forks or plat-
form.
• Do not stand in front of the stacker while in
motion.
• Do not stand, sit or climb on the lift.
• Do not use the lift on soft, uneven or unstable
surfaces.
• Do not exceed the load center or capacity.
WARNING!
You or others around you can be seriously injured
or even killed if you don't use this stacker correctly.
Read and obey all warnings and instructions in this
manual and on the stacker. It is your responsibility before starting work to make sure it is in good
working order.
caught between the stacker and a xed object will
be crushed or even cut off.
• If traveling forks rst, 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 oor.
• Perform all stacker movements smoothly and
at a speed that will give you time to react if an
emergency occurs.
Tipovers and falls are very serious accidents; you can
be crushed or even killed. To prevent injury, know
where you are at all times and follow the rules of safe
stacker operation.
• Be careful when working around docks,
dockboards and trailers. Stay away from the
edge of docks and ramps. Check to make sure the
wheels of truck or trailers are chocked.
• Travel with the load or forks close to the
ground. Watch for overhead obstructions. Perform all stacker movements smoothly and at a
speed that will give you time to react in an emergency.
• Keep your hands and feet away from all mov-
ing 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 oor. Shut the stacker off
with the key.
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 xed object such
as a wall or post.
• Watch your hands and feet. A foot or hand
PRESTO OWNER’S MANUAL Page 8 POWER STAK
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
instructions.
DO NOT exceed load center or load weight capacities
(check capacity plate).
DO NOT operate until you have checked the conditions
of the stacker: lift systems, forks, chains, and cables.
DO NOT use if any part is damaged, worn or not work-
ing properly.
DO NOT use on ramps or inclines. Only smooth level
surfaces.
DO NOT use for lifting or carrying people.
DO NOT handle unbalanced, unstable or loosely
stacked loads.
DO NOT travel with forks or platform in an elevated
position.
DO NOT handle tall, unsecured or unstable loads that
could fall.
DO NOT allow people to stand or pass under forks or
platform with or without load.
DO NOT operate when parts of anyone’s body may be
close to mast structure or any moving parts.
DO NOT drop loads on platform or forks.
DO NOT alter or modify this stacker in any way.
S E C T I O N 3
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 equipment prior to shipment. If damage
is apparent, a freight claim must be led with the freight
company. Do not use the stacker if there appears to be
any damage. With the stacker in a lowered position,
check the following:
• Check for signs of damage especially to the
back cabinet that houses the battery, electrical/
hydraulic power pack.
• Check all electrical and hydraulic connec-
tions for tightness.
• Remove back panel.
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
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 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-lb. capacity. The nylon sling will not do any damage to the steel construction of stacker. Pick the unit
up. On conventional masts use the top crossmember of
the lift. On narrow masts the cover must be removed
to access lifting equipment. Be careful of the stacker
swinging once fully lifted off the pallet or skid. Have
all personnel completely cleared from the area.
Pick the unit up approximately six inches above the
pallet or skid. Once raised, remove the pallet or skid
from below the lift. Do not move the lift around in the
air. Lower the stacker on the ground.
C. PREPARATION FOR USE
PowerStak left our factory in new condition. It has been
inspected and weight tested to assure all performance
standards have been met.
Visually inspect the stacker for damage. Check for attachments 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 is in working order. Inspect for oil leaks.
Connect battery cable. Check cables and wires on battery charger as well as battery.
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 9 POWER STAK
S E C T I O N 4
OPERATION
A. OPERATING INSTRUCTIONS:
To Raise and Lower:
There are two buttons located on both sides of the
handle. The inside one is for lowering the forks. The
outside one is for raising the forks. When operating,
always make sure the load being lifted is within the
loading capacity of your stacker and the load has been
stacked safely on the pallet. Also, make sure that the
length of the forks corresponds to the length of the 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.
forks rst direction. When rotating the buttery 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
in either direction; it functions like a throttle. When you
release your hand from the buttery control, it automati-
cally will resume to the neutral position and the speed
of the stacker will slow down, and come to a stop
Turtle Speed Travel:
When the buttery control is engaged forward (toward
the forks) or reverse (toward the operator if the operator 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 buttery forward with the
right hand and engage the turtle speed button with the
left hand.
The operator can engage the buttery forward with the
left hand and engage the turtle speed button with the
right hand.
Travel Function:
To travel, rotate the buttery controls throttle on the upper part of the handle. When rotating the buttery con-
trol towards the forks, the stacker runs forwards in the
Figure 1: Operational buttons
Control Pod Top
The reverse operation is also controlled with either hand.
The turtle speed is maintained only when the turtle speed
button is engaged. When the turtle speed button is not
engaged the unit will operate at full speed. The turtle
speed button is a maintained contact operation.
Turtle Speed
Control Pod Bottom
PRESTO OWNER’S MANUAL Page 10 POWER STAK
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