Presto Lifts Power Stak PPS2200-62NAS Installation, Operation And Service Manual
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
December 2018
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 warranty.
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 current Owner’s Manuals to print.
Page 2 PRESTO POWER STAK PPS2200-62NAS
TABLE OF CONTENTS
Limited Warranty ....................................................................................................................................................2
Wheel Traction and Straddle Leg Set-Up ...............................................................................................................4
S E C T I O N 1:
Introduction ............................................................................................................................................................. 5
Responsibility of Owners and Users.......................................................................................................................6
Safety Alert Symbols and Signal Words ................................................................................................................7
S E C T I O N 2:
Certied Operator Training .....................................................................................................................................8
S E C T I O N 3:
Installation ..............................................................................................................................................................9
A. Inspection ........................................................................................................................................................ 9
B. Removing from Pallet ....................................................................................................................................... 9
C. Preparation for Use ........................................................................................................................................ 10
S E C T I O N 4:
Operation .............................................................................................................................................................. 10
A. Operating Instructions ..................................................................................................................................... 10
B. Daily Operations Maintenance Checks ........................................................................................................... 12
Suggested Daily Operator Checklist.....................................................................................................................13
S E C T I O N 5:
Battery Maintenance.............................................................................................................................................14
A. Preparing to Charge a Battery .......................................................................................................................14
B Charging the Battery .......................................................................................................................................14
C. Warnings and Battery Info ..............................................................................................................................14
D. Battery maintenance ....................................................................................................................................... 14
E. Charger Operations.........................................................................................................................................15
S E C T I O N 6:
Maintenance ......................................................................................................................................................... 16
A. Weekly Operations Maintenance Checks .......................................................................................................16
B. Monthly Operations Maintenance Checks .....................................................................................................16
S E C T I O N 7:
Troubleshooting ....................................................................................................................................................17
Ordering Replacement Parts ................................................................................................................................ 33
Restocking Policy .................................................................................................................................................34
Return Materials Authorization ............................................................................................................................. 35
Figure 1: Operational Buttons............................................................................................................................... 11
Figure 2: Stacker Body Components....................................................................................................................18
Figure 3: Control Pod ...........................................................................................................................................19
Figure 4: Steering Component .............................................................................................................................20
Figure 5: Drive Unit...............................................................................................................................................21
Figure 6: Carriage Assembly ................................................................................................................................22
Figure 7: Mast Components .................................................................................................................................23
Figure 8: Power Unit ............................................................................................................................................. 24
Figure 9: Hydraulic System ..................................................................................................................................25
Figure 10: Hydraulic Schematic............................................................................................................................26
Figure 11: Control Panel .......................................................................................................................................27
Figure 12a & b: Electrical Schematic Diagram, before 11/17 ..........................................................................28-29
Figure 12c & d: Electrical Schematic Diagram, after 11/17 .............................................................................30-31
Figure 13: Battery Connection .............................................................................................................................. 32
PRESTO POWER STAK PPS2200-62NAS Page 3
LIST OF FIGURES:
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 is-
sues 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
BOLT 4BOLT 4
WHITE LINE
JUST SHOWING
Back off all bolts and follow steps.
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
Page 4 PRESTO POWER STAK PPS2200-62NAS
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 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 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 POWER STAK PPS2200-62NAS Page 5
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.
Page 6 PRESTO POWER STAK PPS2200-62NAS
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.
4.11 Safety Alert Symbols: A symbol that indicates a hazard. It is composed of an equilateral triangle surrounding
an exclamation mark. The safety alert symbol is only used on hazard alerting signs. It is not used on safety notice and safety
instructions signs.
A): for use with DANGER signal word; (safety white triangle, safety red exclamation mark, safety red background)
B): for use with WARNING signal word; (safety black triangle, safety orange exclamation mark)
C): for use with CAUTION signal word; (safety black triangle, safety yellow exclamation mark)
D) and E): for use with DANGER, WARNING, or CAUTION signal word; (D: is a safety yellow triangle with a
black border and safety black exclamation mark; E: is a safety yellow triangle with a safety black exclamation mark and a
safety yellow border around a safety black band)
NOTE: D and E are provided to allow for consistency with certain ISO standards such as ISO 3864-1 and ISO 3864-2.
4.14 Signal Words: The words used in the signal word panel. The signal words for hazard alerting signs are “DANGER,”
“WARNING,” and “CAUTION.” Safety notice signs use the signal word “NOTICE.” Safety instruction signs use signal words that
are specic to the 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 injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE is used to address practices not related to physical injury.
SAFETY INSTRUCTIONS (or equivalent) signs indicate specic safety-
related instructions or procedures.
NOTE: DANGER, WARNING or CAUTION should not be considered for property damage accidents unless personal injury risk
appropriate to these levels is involved.
PRESTO POWER STAK PPS2200-62NAS Page 7
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.
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 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 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.
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 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 surfaces. 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.
Tip overs 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.
Page 8 PRESTO POWER STAK PPS2200-62NAS
• 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 oor. 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 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 working 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 connections 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.
PRESTO POWER STAK PPS2200-62NAS Page 9
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
Chain adjustment must not be made to allow the forks to have a lowered height greater than 2
customer service at Presto Lifts 1-800-343-9322
¾ inches. This measurement is from the oor, to the top of the front tip of the forks. If higher
fork adjustment is needed or if there are questions contact Presto Customer Service at 800-
343-9322.
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.
Travel Function:
To travel, rotate the buttery controls throttle on the upper part of the handle. When rotating the buttery control towards the forks, the stacker runs forwards in the forks rst direction. When rotating the
buttery towards the operator, the stacker runs in the reverse direction. Always make sure the stack-
er 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 automatically 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.
Page 10 PRESTO POWER STAK PPS2200-62NAS
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.
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.
Figure 1: Operational buttons
Turtle Speed
Control Pod Top
Electric Brake:
Your stacker is equipped with an electric magnetic brake. The brake is applied when the handle is
in its vertical position between 10 – 15 degrees and lowered position between 80 – 90 degrees. The
brake could be released when you pull down the handle at any point between 15 – 80 degrees. Always make sure the brake is 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 low-
est position. Or, to turn the buttery controls in the opposite direction, the change in direction of the
motor will slow down, stop, and reverse the direction of stacker. When parked, the handle will spring
back to 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 backwards, and the end of the
handle comes in contact with the operator’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, immediately release your hands from the buttery 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.
Control Pod Bottom
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.
PRESTO POWER STAK PPS2200-62NAS Page 11
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