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stertil-KONI ST 1055, Installation, Operation & Service Manual, Page: 1 / 50

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stertil-KONI ST 1055 Installation, Operation & Service Manual Download Page 1

 

 

Mobile Column Lifts 

 

 

ST 1055 
ST 1060 
ST 1072 

 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 

Installation - operation - service 

 

 

325-58-990A 

Summary of Contents for ST 1055

Page 1: ...Mobile Column Lifts ST 1055 ST 1060 ST 1072 Installation operation service 325 58 990A ...

Page 2: ......

Page 3: ... READ AND UNDERSTAND ALL INSTRUCTIONS IN THIS MANUAL BEFORE INSTALLING OPERATING OR MAINTAINING THIS LIFT DIRECTIONS ASSEMBLY AND SERVICING MANUAL FOR THE 10 000 16 000 LBS STERTIL KONI HYDRAULIC MOBILE COLUMN LIFTS MODEL ST 1055 ST 1060 ST 1072 Starting at Serial Number TN 72000 TH 49869 This document belongs with mobile column lift no TN TH Date first used Date 01 10 2003 ...

Page 4: ...d base leg length for recreational vehicles ST1055 RV The undersigned H Claus Director for this purpose authorised by Stertil BV hereby declares that the mobile column lift described above has been designed according to the Machines Directive and has been found to meet the fundamental safety requirements stipulated by this directive This Wheel Engaging Mobile Automotive Lifts are approved by Stert...

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Page 6: ...HEEL ADAPTERS 16 5 5 LENGTHENED WHEEL ADAPTERS 16 5 6 USING OUTDOORS 17 6 OPERATION 18 6 1 PREPARATION 18 6 2 RAISING AND LOWERING ALL LIFTING COLUMNS 18 6 3 RAISING AND LOWERING OF TWO LIFTING COLUMNS ONE VEHICLE AXLE PAIRED OPERATION 18 6 4 RAISING AND LOWERING A SINGLE LIFTING COLUMN 18 6 5 EMERGENCY RELEASE 18 7 INSPECTION AND MAINTENANCE 19 7 1 GENERAL 19 7 2 DAILY BY OPERATOR 19 7 3 MONTHLY ...

Page 7: ...60 HZ 32 FIG D HYDRAULIC CYLINDER 33 FIG E CONTROL BOX MASTER COLUMN 34 FIG F ELECTRICAL DIAGRAM CONTROLBOX PRIMARY 35 FIG G CONTROL BOX SECONDARY COLUMN 36 FIG H ELECTRICAL DIAGRAM SECONDARY COLUMN 37 FIG I CONNECTION CABLE 38 FIG J LABEL LOCATIONS 39 FIG K HYDRAULIC SCHEME 40 FIG L WHEEL ADAPTORS EXTENDED ARM OPTION ONLY ST 1055 ST 1060 41 FIG M DIMENSIONAL DRAWING 42 INSPECTION CHECK LIST 43 ...

Page 8: ...rator shall use all applicable safety features provided on the automotive lift and operate the lift in accordance with the instructions provided by Stertil Koni The lift operator or employer shall take all appropriate steps to follow the recommended inspection procedures of the lift manufacturer but in no event shall the lift operator fail to inspect or take notice of the following features on a d...

Page 9: ...per maintenance alteration improper fluid maintenance or other causes not the result of defective materials or workmanship Repair or replacement is the exclusive remedy for allegedly defective equipment under this warranty and Stertil KONI USA will not be liable for any consequential or incidental damages for breach of any express or implied warranty on this equipment Stertil KONI USA is not respo...

Page 10: ...phase 1x earth 1x phase 1x earth Mains fuse 3x208 230V 60 Hz 3x460V 60 Hz 3x575V 60 Hz 1x208 230V 60 Hz See Amperage Power Supply Consumption table 30 A slow 15 A slow 10 A slow 30 A slow See Amperage Power Supply Consumption table 30 A slow 15 A slow 10 A slow 30 A slow See Amperage Power Supply Consumption table 30 A slow 15 A slow 15 A slow 30 A slow Operational voltage 24 V 24 V 24 V Stroke 71...

Page 11: ...o contains important instructions to prevent accidents and serious damage prior to and during operation of the lifting system and it enables the product to perform as safely and flawlessly as possible Read this manual carefully before using the lifting system familiarize yourself thoroughly with the functioning and operation of the lifting system and strictly observe the directions given 2 2 LIABI...

Page 12: ...that lift inspectors are qualified and that they are adequately trained in the inspection of the lift The owner employer shall maintain the periodic inspection and maintenance records recommended by the manufacturer or ANSI ALI ALOIM American National Standard for Automotive Lifts Safety Requirements for Inspection and Maintenance and the employer shall ensure that lift inspectors are qualified an...

Page 13: ...s disconnect interconnecting cables and remove from vehicle travel path before moving vehicle Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by a qualified serviceman In case of using one or two lifting columns in paired operation be sure that this will not result in stability risks In case of doubt consult your superior Unsa...

Page 14: ...es that the columns are raised or lowered synchronically Each lifting column is equipped with a position sensor which transmits the height positions to the control system The control system controls and protects the lifting system during lifting or lowering as follows At a difference in height between the lifting columns of over 5 8 mm and less than 1 1 4 mm an extra adjustment valve in the hydrau...

Page 15: ...lic lifting cylinder provides the lifting capacity Control box The control box has all the functions controlling the use of the lifting column The control box of the primary column is provided with a three position switch allowing the lifting column to be used as a secondary column if necessary The control box components and functions have been specified in sections 5 and 6 Pallet jack mechanism T...

Page 16: ... the lifting column when it is suspended from the lifting equipment If it falls it will cause serious injury 3 Fasten a sling with a hoisting capacity of at least 480 kg 1065 lbs around the lifting column and lift the column from the crate see fig 4 1 Fig 4 1 4 Carefully lower the lifting column to the floor 5 Attach a hook to the lifting lug at the top of the column 6 Lift the column to the uprig...

Page 17: ...ting column s 2 SECONDARY COLUMN allows the primary column to be used as a secondary column if the mobile column lift has more than one primary column 3 UP button Controls the lifting of the columns 4 Ø DOWN button Controls the lowering of the columns 5 SET AXLE button This button serves to select the axle functions These functions are descibed in paragraph 5 3 6 6 Unlock button This button contro...

Page 18: ...se Lifting capacity in lbs Minimum number of primary columns Maximum number of secondary columns up to 40 000 up to 48 000 up to 64 000 1 5 40 000 to 80 000 48 000 to 96 000 64 000 to 128 000 2 2 sets required 10 80 000 to 120 000 96 000 to 144 000 128 000 to 192 000 3 3 sets required 15 120 000 to 160 000 144 000 to 192 000 192 000 to 256 000 4 4 sets required 20 etc etc etc etc etc 1 Phase Lifti...

Page 19: ...circuit can be selected at random primary columns or secondary columns can be positioned at any place provided the maximum lifting capacity of 40 000 64 000 is not exceeded as described in 5 2 A system must have at least one primary column single phase must have at least 2 primary columns The maximum number of lifting columns in a system is 32 single phase a max of 4 columns 2 With respect to all ...

Page 20: ...on one of the lifting columns belonging to the selected axle for approx 3 seconds The SET AXLE button will flash indicating that the setting procedure has been selected Within 30 seconds press the SET AXLE button of the control panel of the lifting column on the other side of the axle and also keep it pressed for 3 seconds The SET AXLE buttons of all lifting columns will go on indicating that pair...

Page 21: ... ST 1060 see fig L Special 8 longer wheeladaptors are available for in set wheels for RVs schoolbuses etc These longer adaptors can only be used together with wheelarm extensions for the column The lifting capacity will be reduced to 8 800 lbs see fig 5 3a The reduced capacity is clearly indicated on the sides of the longer wheel adaptors Please note that with the longer adaptors the lifting capac...

Page 22: ...s well as the weight of the vehicle When lifting large high sided vehicles the value for lighter vehicles must be used The operator must consider all factors when deciding if it is safe to use the lifting system If any doubt exists always use the lower wind speed Vehicle Type Weight empty metric tons lbs Max admissible wind speed mtr s on side of vehicle miles h Beaufort Light cars or lorries with...

Page 23: ...r 5 Make sure the main switch on the primary lifting column s control box is set to 0 OFF 6 Connect the connecting cable between the lifting columns in a closed circuit 7 Connect the power supply cable to the correct mains supply 8 Make sure that the Emergency Release buttons are unlocked on all the lifting columns 9 On the primary column control box set the main switch to position 1 ON 10 Push th...

Page 24: ...nded that the hydraulic oil be changed at least every 2 years irrespective of the amount of use to which the lift is subjected OIL CHANGING 1 Lower lift to fullest extent and drain all the oil 2 Refill with hydraulic oil UNIL HVC S15 filtered at 4 micron max Model ST 1055 ST 1060 ST 1072 Litre 7 Lubrication chart 7 2 DAILY BY OPERATOR Check for visible damage Check for oil leaks in the hydraulic u...

Page 25: ...y the service department of Stertil B V or by an agency approved by Stertil B V A maintenance contract can be arranged for this annual inspection with the Stertil B V Service Department If no maintenance contract is entered into the user himself should make an appointment each year for this inspection and servicing This inspection is recorded on the inspection checklist see page 43 or the ANSI ALI...

Page 26: ...the top of the lifting column remove the plastic cap and the nut and washer Lift the guide block to the maximum height and then lower it to the first catch position Push the SET REF and DOWN buttons to lower the cylinder It will take approximately 2 minutes for the cylinder to lower completely At the bottom of the cylinder release the hydraulic connection Lift the cylinder approximately 3 4 mm to ...

Page 27: ... non service department personnel the consequences of such repairs are entirely at the user s risk The term service department is the Stertil service department or a service department recognized by Stertil Two tables are provided to assist the service technician in locating faults in the lifting system The first table shows the faults indicated by the LEDs on the printed circuit see fig 8 1 and t...

Page 28: ...tons 3 4 and 6 will flash alternately The microprocessor board is equipped with 4 LEDs for indicating failures the order in which they are lit indicates the type of defect as described in 8 2 To see the LEDs open the control box cover Refer to fig E and H for identification of components Fig 8 1 Location of fault LED s MICROPROCESSOR BOARD ...

Page 29: ...ting of the system height differences of over 2 1 2 have occurred during operation Check the hydraulic system for leaks Check whether the load per lifting column is higher than 10 000 12 000 16 000 lbs Set the main switch to OFF and then again to ON press the SET REF button twice to make the system ready for operation again When the defect occurs again contact the service department A difference o...

Page 30: ...ected by a qualified electrician Catch not disengaged from locking system Raise column approximately 2 and then lower The electrically operated lowering valve on the hydraulic unit does not open No mains power for solenoid or lowering valve is faulty fault Have corrected by the Service Department Dirty lowering valve Have valve cleaned or replaced by service department Maximum height difference mo...

Page 31: ...4 S3 lifts the column and S4 lowers the column Operate the switches until the columns are synchronised If the fault occurs again contact the Service Department Lifting system may not be set up correctly Follow the procedures in sections 6 1 and 6 2 of this manual If the fault occurs again contact the Service Department LED defective Contact the service department Blown fuse Check the fuses F1 F2 a...

Page 32: ...hown below The label is located on the left side of the lifting column above the control box 9 LIST OF PARTS AND APPENDICES 9 1 PARTS LIST The titles of the columns on the parts list mean the following Index The numbers in this column refer to the numbers in the parts drawing Reference The numbers in this column are STERTIL KONI order numbers Please give these numbers when ordering Description Thi...

Page 33: ...t wider option 44 65 003 488 65 003 488 Bolt M14x30 DIN 933 12 325 56 075 325 56 075 Oil pipe 45 65 055 023 65 055 023 Washer M14 DIN 125A 13 See fig D See fig D Hydraulic cylinder 46 66 201 056 66 201 056 Spacer 6 3 15 15 14 See fig E F See fig E F Control box Prim 47 65 051 028 65 051 028 Locknut M6 14 See fig G H See fig G H Control box Sec 48 65 003 403 65 003 403 Bolt M10x20 DIN 933 15 See fi...

Page 34: ...29 FIG A ...

Page 35: ...03 Pin locking 18 325 56 218 Supporting base ITTD 118 60 1401 10 15 00 Steel ball 20 1038 40 04 50 Retaining ring DIN 471 61 325 56 261 Spring ITT 601 21 325 56 221 Bearing cover ITTD 121 62 325 56 262 Blade spring ITT 602 22 325 56 222 Bearing ITTD 122 63 325 56 263 Roller ITT 603 23 65 077 144 Roll pin 5x50 DIN 1481 64 65 077 101 Roll pin 4x30 DIN 1481 24 325 56 224 Dust cover ITTD 124 65 65 077...

Page 36: ...31 FIG B ...

Page 37: ...lve NC ex solenoid 7b 68 308 005 68 308 005 68 308 005 2 2 Valve NC ex solenoid incl manual lowering 8 68 510 124 68 510 124 68 510 124 O ring 12 42 x 1 78 9 69 481 501 69 481 501 69 481 501 Solenoid 24 VDC EC 30D 12 68 039 006 68 039 006 Pressure relief valve 220 bar 12 325 56 908 Pressure relief valve 265 bar 13 325 06 108 325 06 108 325 06 108 Half coupling pumpside 14 325 06 109 325 06 109 325...

Page 38: ...ing ring 6 68 515 402 O ring Ø40x2 7 340 06 828 325 06 825 Piston 8 340 06 801 325 06 800 Cylinder 9 340 06 826 Piston rod 9 68 500 501 Scraper 10 340 06 751 68 575 630 Bearing ring 11 65 263 006 65 261 068 Retaining ring 12 340 06 827 Piston cap 13 68 228 005 1003 91 80 38 Hose burst check valve 14 68 700 451 68 700 450 Union GE10 PSR 1 4 16 65 455 001 65 455 001 Copper sealing ring 17 68 900 000...

Page 39: ...A 69 153 002 Thermal relay 3x230V 21A 69 153 004 Thermal relay 3x575V 8 5A 8 01 615 655 Emergency stop button 9 01 615 656 Holder 3 SB 1902 1AC 10 69 120 010 NC contactor 3 SB 1400 0C 11 69 090 114 Connector 12 69 090 112 Connector internals male 13 69 090 111 Connector internals female 14 Cable gland UNI PG21 154uz20 15 Cable gland UNI PG13 5 152u9 16 Cable gland UNI PG13 5 152 um2x6 17 Cable gla...

Page 40: ...35 FIG F ELECTRICAL DIAGRAM CONTROLBOX PRIMARY ...

Page 41: ...2 006 Motor relay 8 01 615 655 Emergency stop button 9 01 615 656 Holder 3 SB 1902 1AC 10 69 120 010 NC contactor 3 SB 1400 0C 11 69 090 114 Connector 12 69 090 112 Connector internals male 13 69 090 111 Connector internals female 15 Cable gland UNI PG13 5 152 uz 13 16 Cable gland UNI PG13 5 152 um2x6 17 Cable gland UNI PG16 153 um2x8 21 69 900 131 Pushbuttonboard and flatcable 23 69 206 010 Fuse ...

Page 42: ...37 FIG H ELECTRICAL DIAGRAM SECONDARY COLUMN ...

Page 43: ...IG I CONNECTION CABLE INDEX REFERENCE DESCRIPTION ST 1055 ST 1060 ST 1072 1 325 57 150 Cable 39 9 assembly 2 69 090 111 Connector internals female 3 69 090 112 Connector internals male 4 69 090 113 Housing ...

Page 44: ...0 702 001 ALI member label 10 60 702 004 60 702 004 60 702 004 Uniform warning label 11 60 702 005 60 702 005 60 702 005 Caution label 12 60 702 006 60 702 006 60 702 006 Safety instruction label 13 60 700 146 60 700 094 60 700 094 Sticker AMPERAGE POWER SUPPLY CONSUMPTION 14 325 58 990 325 58 990 325 58 990 Service manual 15 60 702 002 60 702 002 60 702 002 Safety manual LIFTING IT RIGHT 16 60 70...

Page 45: ...40 FIG K HYDRAULIC SCHEME C Cylinder P Pump EV22 2 2 Valve T Tank VCDF Flow control valve O Safety pressure valve F Filter M Electr motor K Non return valve R Hose burst check valve ST 1055 1060 ST 1072 ...

Page 46: ... length 12 2 340 00 925 Extended adaptor 16 length 20 3 325 00 109 Shaft 4 340 00 920 Extention length 20 5 340 00 911 Wheel 6 340 00 912 Shaft 8 1038 34 02 40 Retaining washer A24 DIN6799 9 340 00 915 Arm extension 10 60 700 150 Label 8800 lbs 340 00 910 Arm extension set 2x item 4 2x item 5 2x item 6 4x item 8 2 item 9 2x item 10 ...

Page 47: ...42 FIG M DIMENSIONAL DRAWING ST 1072 ST 1055 ST 1060 ST 1072 V widened model 27 49 ...

Page 48: ...43 INSPECTION CHECK LIST Annual inspection as described under 7 Inspection and Maintenance Date Remarks Name of mechanic Initials of mechnicpass ...

Page 49: ......

Page 50: ...Manufactured by STERTIL B V P O Box 23 9288 ZG Kootstertille Holland Tel 31 0 512334444 Telefax 31 0 512334430 www stertil nl e mail info stertil nl ...

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