Presto Lifts PPS1100-62-CB Setup guide

Counter Balance
Stacker
Model PPS1100-62-CB
Installation, Operation
and Service Manual
Model Number ___________________
Serial # _________________________
Date Placed in Service _____________
IMPORTANT: READ CAREFULLY
BEFORE INSTALLING OR OPERATING LIFT
Part orders are subject to a $50 minimum charge.
JAN 2014

PRESTO OWNER’S MANUAL Page 2 COUNTER BALANCE STACKER
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.
Presto Lifts Limited
Counter Balance 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 specically; there are no warranties of merchant-
ability 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 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 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 (dened as the original end user)
and is nontransferable. This constitutes the complete and nal agreement involving Presto Lifts and
limited warranty obligations for products.

PRESTO OWNER’S MANUAL Page 3 COUNTER BALANCE STACKER
TABLE OF CONTENTS
S E C T I O N 1:
Limited Warranty ...............................................................................................................................2
Introduction .......................................................................................................................................4
S E C T I O N 2:
Safety................................................................................................................................................4
S E C T I O N 3:
Installation.........................................................................................................................................5
A. Inspection ..................................................................................................................................5
B. Removing from Pallet .................................................................................................................5
C. Preparation for Use ....................................................................................................................6
S E C T I O N 4:
Operation ..........................................................................................................................................6
A. Operating Instructions..................................................................................................................6
B. Daily Operations Maintenance Checks........................................................................................7
Suggested Daily Operator Checklist .................................................................................................8
S E C T I O N 5:
Battery Maintenance .........................................................................................................................9
A. Preparing to Charge a Battery ....................................................................................................9
B Charging the battery ....................................................................................................................9
C. Warnings and Battery Information ...............................................................................................9
D. Battery maintenance....................................................................................................................9
D. Charger Operation.......................................................................................................................9
S E C T I O N 6:
Maintenance......................................................................................................................................9
A. Weekly Operations Maintenance Checks..................................................................................10
B. Monthly Operations Maintenance Checks ................................................................................10
S E C T I O N 7:
Troubleshooting............................................................................................................................... 11
ORDERING REPLACEMENT PARTS...........................................................................................................26
RESTOCKING POLICY.................................................................................................................................27
RETURN GOODS AUTHORIZATION POLICY .............................................................................................28
LIST OF FIGURES & TABLES :
Figure 1: Operational Buttons...........................................................................................................................................6
Figure 2: PPS1100-62-CB .............................................................................................................................................. 12
Figure 3: Exploded View.................................................................................................................................................13
Figure 4: Steering System.............................................................................................................................................. 14
Figure 5: Control Pod .....................................................................................................................................................15
Figure 6: Wiring Diagram................................................................................................................................................ 16
Figure 7: Wiring Diagram (August 2011 to Present)....................................................................................................... 17
Figure 8: Fork & Carriage System..................................................................................................................................18
Figure 9: Fork & Carriage System..................................................................................................................................19
Figure 10: Mast Assembly .............................................................................................................................................. 20
Figure 11: Drive Unit.......................................................................................................................................................21
Figure 12: Power Unit Assembly .................................................................................................................................... 22
Figure 13: Cylinder Assembly......................................................................................................................................... 23
Figure 14: Chain Wheel Assembly ................................................................................................................................. 24
Figure 15: Labels & Precautionary Warnings ................................................................................................................. 25

PRESTO OWNER’S MANUAL Page 4 COUNTER BALANCE STACKER
CAREFULLY READING THIS MANUAL. In order
to provide for the safe operation of these stackers,
Presto Lifts Inc. has identied 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 pos-
sibility 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 responsibil-
ity 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
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,
Counter Balance Stacker. It is important that all per-
sonnel involved with the installation, maintenance or
operator of the stacker read this manual. Additional
manuals are available upon request or at www.Presto-
Lifts.com.
Each Presto stacker is equipped with nameplate, serial
number and model identications. Please refer to these
numbers when ordering parts or requesting further
information.
The Presto stackers are designed for lifting, lower-
ing 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. These units are not for
personnel lifting.
S E C T I O N 2
SAFETY
You must be trained and certied to operate this
powered stacker. Federal law states that only prop-
erly trained operators are permitted to operate a
powered industrial stacker and that your employer
must train you and certify that you are qualied.
(OSHA 1910.178 29QFR-7-1-06 Edition)
Presto lifts does not offer operator training. Op-
erator 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

PRESTO OWNER’S MANUAL Page 5 COUNTER BALANCE STACKER
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. Per-
form all stacker movements smoothly and at a
speed that will give you time to react in an emer-
gency.
•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.
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 condi-
tions 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 com-
pletely 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/hy-
draulic power pack.
•Check all electrical and hydraulic connec-
tions for tightness.
•Remove back panel.
•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-lb. capacity. The nylon sling will not do any dam-
age 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