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stertil-KONI ST 1082-F/BAT Installation, Operation And Service Manual Download Page 5

 

1

 
Contents   

 

 

 

 

 

 

 

 

   

 

 

 

Page 

 

PREFACE ............................................................................................................................................................................. 3

 

1.

 

GENERAL ................................................................................................................................................................. 5

 

1.1

 

MANUFACTURER'S INFORMATION..................................................................................................................... 5

 

1.2

 

SPECIFICATIONS ....................................................................................................................................................... 5

 

2.

 

DIRECTIONS ........................................................................................................................................................... 6

 

2.1

 

SCOPE............................................................................................................................................................................ 6

 

2.2

 

GUARANTEE AND LIABILITY ................................................................................................................................ 6

 

2.4

 

SAFETY MEASURES .................................................................................................................................................. 7

 

3.

 

DESCRIPTION OF THE LIFTING SYSYEM .................................................................................................... 11

 

3.1

 

STRUCTURE OF THE COLUMN LIFT ................................................................................................................. 12

 

4.

 

INSTALLATION .................................................................................................................................................... 13

 

4.1

 

UNPACKING AND HANDLING THE LIFTING COLUMN ................................................................................ 13

 

5.

 

GENERAL USE ...................................................................................................................................................... 14

 

5.1

 

CONTROL ................................................................................................................................................................... 14

 

5.2

 

CONNECTING LIFTING COLUMNS..................................................................................................................... 14

 

5.3

 

DESCRIPTION OF THE MOBILE COLUMN LIFT SYSTEM............................................................................ 14

 

5.4

 

WHEEL ADAPTERS (OPTIONAL) ......................................................................................................................... 16

 

5.5

 

LONGER WHEELADAPTORS (OPTIONAL ONLY ON ST 1082-F) ................................................................. 16

 

5.6

 

ADJUSTABLE FORKS (OPTION)........................................................................................................................... 17

 

5.7

 

OPERATING THE PALLET LIFTING MECHANISM......................................................................................... 18

 

5.8

 

USING OUTDOORS................................................................................................................................................... 18

 

5.9

 

VEHICLE TECHNOLOGY ....................................................................................................................................... 19

 

6.

 

OPERATION .......................................................................................................................................................... 20

 

6.1

 

PREPARATION .......................................................................................................................................................... 20

 

6.2

 

RAISING AND LOWERING ALL LIFTING COLUMNS ..................................................................................... 20

 

6.3

 

RAISING AND LOWERING OF TWO LIFTING COLUMNS............................................................................. 20

 

6.4

 

RAISING AND LOWERING A SINGLE LIFTING COLUMN............................................................................. 20

 

6.5

 

EMERGENCY RELEASE ......................................................................................................................................... 21

 

7.

 

INSPECTION AND MAINTENANCE ................................................................................................................. 21

 

7.1

 

GENERAL ................................................................................................................................................................... 21

 

7.2

 

DAILY (BY OPERATOR).......................................................................................................................................... 21

 

7.3

 

MONTHLY (BY OPERATOR) ................................................................................................................................. 22

 

7.4

 

ANNUALLY (BY SERVICE DEPARTMENT)........................................................................................................ 23

 

7.5

 

MAINTENANCE SWITCHES................................................................................................................................... 24

 

7.6

 

REMOVAL/INSTALLATION OF THE LIFTING CYLINDER ........................................................................... 24

 

7.7

 

 

ADJUSTING THE PALLET JACK MECHANISM ............................................................................................... 25

 

7.8

 

 

ADJUSTING RETRACTABLE FRONT WHEELS ............................................................................................... 25

 

8.

 

SERVICE ................................................................................................................................................................. 26

 

8.1

 

GENERAL ................................................................................................................................................................... 26

 

8.2

 

TROUBLE-SHOOTING............................................................................................................................................. 28

 

8.3

 

IDENTIFICATION ..................................................................................................................................................... 31

 

9.

 

LIST OF PARTS AND APPENDICES ................................................................................................................. 31

 

9.1

 

PARTS LIST ................................................................................................................................................................ 31

 

9.2

 

ORDERING SPARE PARTS ..................................................................................................................................... 31

 

FIG. A - MOBILE LIFTING COLUMN ........................................................................................................................... 32

 

FIG. B - MOBILE LIFTING COLUMN ........................................................................................................................... 34

 

FIG. C – HYDRAULIC UNIT ............................................................................................................................................ 36

 

FIG. D – HYDRAULIC CYLINDER ................................................................................................................................. 37

 

FIG. E - CONTROL BOX

 

.................................................................................................................................................. 38

 

FIG. F – SCHEMATIC DIAGRAM................................................................................................................................... 40

 

Summary of Contents for ST 1082-F/BAT

Page 1: ...Mobile Column Lifts ST 1082 F BAT ST 1082 R BAT Installation operation service 32738980 A ...

Page 2: ......

Page 3: ... PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS IN THIS MANUAL BEFORE INSTALLING OPERATING OR MAINTAINING THIS LIFT DIRECTIONS ASSEMBLY AND SERVICING MANUAL FOR THE 18 000 LBS STERTIL KONI HYDRAULIC MOBILE COLUMN LIFTS MODEL ST 1082 F BAT ST 1082 R BAT Starting at Serial Number TM 139067 This document belongs with mobile column lift no TM Date first used Date 12 04 2007 ...

Page 4: ...red Options Adjustable forks Wheel adaptors Longer extensions and wheel adaptors The undersigned U Bijlsma Director for this purpose authorized by Stertil BV hereby declares that the mobile column lift described above has been designed according to the Machines Directive ANSI ALI ALCTV 1998 and UL201 and has been found to meet the fundamental safety requirements stipulated by these directives This...

Page 5: ...LOGY 19 6 OPERATION 20 6 1 PREPARATION 20 6 2 RAISING AND LOWERING ALL LIFTING COLUMNS 20 6 3 RAISING AND LOWERING OF TWO LIFTING COLUMNS 20 6 4 RAISING AND LOWERING A SINGLE LIFTING COLUMN 20 6 5 EMERGENCY RELEASE 21 7 INSPECTION AND MAINTENANCE 21 7 1 GENERAL 21 7 2 DAILY BY OPERATOR 21 7 3 MONTHLY BY OPERATOR 22 7 4 ANNUALLY BY SERVICE DEPARTMENT 23 7 5 MAINTENANCE SWITCHES 24 7 6 REMOVAL INSTA...

Page 6: ...2 FIG G CONNECTION CABLE 41 FIG H PALLETJACK SERVICE KITS 42 FIG I LABEL LOCATIONS 43 FIG J WHEEL ADAPTORS EXTENDED ARM OPTION 44 FIG K DIMENSIONAL DRAWING 45 INSPECTION CHECK LIST 46 ...

Page 7: ...e with manufacturer supplied instructions found in this manual The operator 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 op...

Page 8: ...tertil Koni USA Inc 200 Log Canoe Circle Stevensville Maryland 21666 tel 00 1 410 643 9001 fax 00 1 410 643 8901 Toll free number 800 336 6637 Column Serial Numbers _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ ___________________________________________...

Page 9: ... plastic cap Electrical power 24vdc 4HP Mains supply bat charger 1x115V 60 Hz 2A 1x phase 1x zero 1x earth Main battery fuse 200 AT Operational voltage 24 V Stroke 69 Lifting speed 44 min Lifting lowering time 94 sec 68 sec Noise level max 73 dB A Set up Indoors outdoors Weight 1250 lbs Lifting column interconnection cable length 39 4 Maximum distance between lifting columns 29 6 Maximum floor suf...

Page 10: ...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 GUARANTEE AND LIABILITY See the terms of d...

Page 11: ...Series ALI Uniform Warning Label Decals Placards The owner employer shall establish procedures to periodically inspect the lift in accordance with the lift manufacturers instructions ANSI ALI ALOIM 2000 American National Standard for Automotive Lifts Safety Requirements for Inspection and Maintenance and the employer shall ensure that lift inspectors are qualified and that they are adequately trai...

Page 12: ...hould be provided when working on internal combustion engines Keep hair loose clothing fingers and all parts of the body away from moving parts To reduce the risk of electrical shock do not use on wet surfaces or expose to rain Use only as described in this manual Use only manufacturers recommended attachments ALWAYS WEAR SAFETY GLASSES Everyday eyeglass only have impact resistant lenses they are ...

Page 13: ...and damage to the lifting system and or vehicles This lifting system should only be used for lifting of vehicles and not for other applications The positioning of the lifting system must be done in a way that a safe working area will be obtained above and around the lifting columns thereby creating escape paths for emergency situations leave passageways of at least 24 For important vehicle technol...

Page 14: ...10 ...

Page 15: ...onnecting cables Each column has a mains connection for the integrated battery charger The control system on the lifting columns ensures 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 follo...

Page 16: ...to move along the full length of the column The hydraulic lifting cylinder provides the lifting capacity Control box The control box has all the functions controlling the use of the lifting column A battery condition meter is integrated in the control panel The control box components and functions have been specified in sections 5 and 6 Battery power system The battery system consists of two batte...

Page 17: ...ls it will cause serious injury 3 Fasten a sling with a hoisting capacity of at least 1100 lbs around the lifting column and lift the column from the crate see fig 4 1 4 Carefully lower the lifting column to the floor 5 Attach a sling at the top of the column 6 Lift the column to the upright position 7 Remove the sling from column For transport the complete assembly incl hydraulic unit is taken fr...

Page 18: ...are described in paragraph 5 3 5 8 Mains voltage indication light This will go on when the internal control voltage relay is switched on 1 Battery condition meter 2 Emergency release knob 3 Lifting 4 Lowering 5 SET AXLE button 6 Unlock button 7 SET REF button control voltage indication 8 Control power indicator light 5 2 CONNECTING LIFTING COLUMNS A fully closed ring circuit consists of a minimum ...

Page 19: ...e primary columns at one axle to set this function e g the front wheel axle Press the SET AXLE button 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 kee...

Page 20: ...ER WHEELADAPTORS OPTIONAL ONLY ON ST 1082 F Special 6 longer wheel adaptors fig 5 5 are available for in set wheels for RVs school buses etc WARNING These longer adaptors can only be used together with wheel arm extensions for the column The lifting capacity will be reduced to 12 000 8 800 lbs see attached label fig 5 5a The reduced capacity is clearly indicated on the sides of the longer wheel ad...

Page 21: ...ect dimension 1 Lift T handle to unlock the fork fig 5 6 a 2 Use both hands to slide the fork sideways 3 Adjust both forks so that they are equally spaced in relation to the centre of the column 4 Adjust so that the forks at floor height just fit around the tire to prevent the rim falling through when tire becomes deflated 5 Make sure that the T handle locks in Fig 5 6 a Fig 5 6 b ...

Page 22: ...wind speeds for different types of vehicle are shown in the table below The values in the table are average values and should only be used as a guide The admissible wind speed is dependent on the type as 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 l...

Page 23: ...rence between front and rear axle is 6 inches In case of a tandem axle on the rear the maximum allowed height difference between both rear axles is 2 inches Lowering one column too far will cause No load at all on this specific column No load on diagonal opposite column Double load on the remaining columns Columns used for very rigid vehicles airplane tugs trains will be overloaded when lowering o...

Page 24: ...g the lever inside the tow bar 5 Make sure the main switch on the lifting columns is set to 0 OFF 6 Connect the connecting cable between the lifting columns in a closed circuit 7 Make sure that the Emergency Release buttons are unlocked on all the lifting columns 8 Set the main switch to position 1 ON on ALL columns 9 Push the SET REF button Make sure the control voltage and the main supply light ...

Page 25: ...round level only X Several pivot points Grease X HYDRAULIC OIL It is strongly recommended that the hydraulic oil be changed at least every 2 years irrespective of the amount of use to which the lift is subjected Quantity of oil 2 6 gallon OIL CHANGING 1 Lower lift to fullest extent and drain all the oil 2 Refill with hydraulic oil UNIL HVC S15 ISO VG 15 filtered at 4 micron max 7 2 DAILY BY OPERAT...

Page 26: ...eed replacement only use the original equipment from Stertil KONI Universal car type batteries may release highly explosive gasses under normal charging conditions Replacement of batteries must be done by skilled service people 7 3 MONTHLY BY OPERATOR Check hydraulic fluid level and replenish as necessary Remove the cover from the hydraulic unit Ensure that the column is in its lowest position and...

Page 27: ... 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 ALOIM and should include at least the following checks Daily and Monthly checks Check the gas spring for its...

Page 28: ...f the interconnecting black cable Turn on the main switch 7 6 REMOVAL INSTALLATION OF THE LIFTING CYLINDER To remove the cylinder At 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 c...

Page 29: ...usting screw must be turned anti clockwise until the cylinder does not come down any further Bring the cylinder in its highest position and set the lever to position 1 now the cylinder should come down When it comes down slowly or not at all the adjusting screw must be slightly tightened Repeat the aforementioned steps until all movements are normal When the settings are right nut 1 can be tighten...

Page 30: ...subject to failure faults are indicated by means of 4 LED s see sticker fig 8 1 in the control box and table on page 31 Remove the two bolts on the left side to open the hinged cover To open the control box remove the four bolts inside the cover so that the inside of the box can be reached from the opening in the back Remarks Danger of getting injured by high amperage and when used inexpertly Only...

Page 31: ...27 MICROPROCESSOR BOARD Fig 8 1 Location of fault indication LED s ...

Page 32: ...nt defect in the 24V outputs Set the main switches to OFF Check and if necessary replace fuse F2 3 15 A Turn the control boxes on to ON according to normal procedure When this defect occurs repeatedly contact the service department Since the last zero setting of the system height differences of over 2 1 2 have occurred during operation Check the hydraulic system for leaks Check whether the load pe...

Page 33: ...er Catching pawl 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 Have fault corrected by the Service Department Dirty lowering valve Have valve cleaned or replaced by service department Maximum height difference more than 1 1 4 exceeded...

Page 34: ... Columns lift at different heights Control system not working correctly Use internal switches S3 and S4 S3 lifts the column and S4 lowers the column Operate the switches until the columns are synchronized 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 ...

Page 35: ...tion label 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 Index The numbers in this column refer to the numbers in the parts drawing Reference The numbers in this column are STERTIL KONI part numbers Please give these numbers when ordering Description This column gives the name of the parts 9 2 ORDERING SPARE PARTS Re...

Page 36: ...5024 Washer M16 DIN125A 8 32700117 Plate 35 65003526 Bolt M16x25 DIN 933 9 32500109 Shaft 36 1036 46 03 45 Set screw M5x12 DIN 916 10 32702100 Guide block ST 1082 F 37 65003403 Bolt M10x20 DIN 933 32741125 Guide block ST 1082 F V 11 69090050 Grommet No 2790 type 2 12 32706075 Oil pipe 13 See fig D Hydraulic cylinder 14 68700450 Straight adaptor GE 10 PS 15 See fig G Connection cable 16 32736150 Hy...

Page 37: ...33 FIG A ...

Page 38: ...t All models 18 1038 66 04 24 Roll pin 6x30 DIN 1481 All models 19 32706200 Jack assembly All models 20 65214358 Adjusting screw M8x8 DIN 916 All models 21 1037 07 50 08 Nut M8 DIN 439B All models 22 32550103 Shaft All models 23 32700120 Cap All models 24 32700250 Balancer Only ST 1082 R BAT 24 32700300 Balancer Only ST 1082 F BAT 25 32550102 Shaft All models 26 60203002 Gas spring All models 27 6...

Page 39: ...35 FIG B Item 6 locked with loctite 542 sealant ...

Page 40: ...lenoid Tightening torque 22 lbf ft 7b 68308005 2 2 Valve NC ex solenoid incl manual ering Tightening torque 22 lbf ft 8 68510124 O ring 12 42 x 1 78 mm 9 69481501 Solenoid 24 VDC EC 30D 12 32556908 Pressure relief valve 265 bar 3800 psi Tightening torque 18 5 lbf ft 13 68039015 Half coupling pump side 15 68039014 Electric motor 4HP 24VDC 3300 rpm 16 32556904 Check valve Tightening torque 16 5 lbf ...

Page 41: ...5702 Oring Ø70x2 5 3 Retaining ring 4 Piston seal 5 6 68515402 Oring Ø50x2 7 Piston 8 Cylinder 9 Piston rod 10 Bearing ring 11 Retaining ring 12 Piston cap 13 1003 91 80 38 Hose burst check valve 14 68700450 Union GE10 PSR 1 4 16 65455001 Copper sealing ring 17 68900000 Air bleeding nipple 32706900 Seal kit ST 1082 ...

Page 42: ...38 FIG E CONTROL BOX ...

Page 43: ...se L 15 400mm 12 32737165 Cable battery switch L 13 350mm 13 32737180 Cable battery battery L 27 700mm 14 32737185 Cable battery motor L 51 1300mm 15 69900230 PCB 16 69900220 Adapter PCB 17 69203001 Battery condition meter 18 69900131 Pushbutton board and flat cable 19 69141061 Emergency stop button 20 69141041 NC contactor 3 SB 3400 0C 21 69090107 Connector 22 69090109 Connector internals male 23...

Page 44: ...40 FIG F SCHEMATIC DIAGRAM ...

Page 45: ...41 FIG G CONNECTION CABLE INDEX REFERENCE DESCRIPTION REMARKS 1 32737160 Cable 39 9 assembly 2 69090106 Housing 3 69090108 Connector internals female 4 69090109 Connector internals male ...

Page 46: ...ON REMARKS 1 32706205 Hydraulic valve ass y 2 32706210 Spring cover ass y 3 32706215 Pump piston ass y 4 32706220 Lowering valve ass y 5 32706225 Lowering screw ass y 6 32706230 Safety valve ass y 7 32706235 Pump unit 8 32706240 Handle ass y 32706245 Seal kit ...

Page 47: ...IL KONI USA 9 60702001 ALI member label 10 60702004 Uniform warning label 11 60702005 Caution label 12 60702006 Safety instruction label 13 60700218 Sticker FAULT INDICATION 14 60700219 Sticker SCHEMATIC DIAGRAM 15 60702002 Safety manual LIFTING IT RIGHT 16 60702003 Card SAFETY TIPS 17 60700131 Sticker CAUTION ATTENTION 19 60702008 American Nat Standard 20 60700134 Label Do not use Ne pas 21 60702...

Page 48: ... Only for ST 1082F fixed wheels 6 1038 34 02 40 Retaining washer A24 DIN6799 Only for ST 1082F fixed wheels 7 65003530 Bolt M16x40 8 8 DIN 933 Only for ST 1082F fixed wheels 8 1037 07 50 16 Nut M16 DIN 439B Only for ST 1082F fixed wheels 9 66700206 Label 5500 kg 12 000 lbs Only for ST 1082F fixed wheels 10 66700150 Label 4000 kg 8 800 lbs Only for ST 1082F fixed wheels 32550910 Extension set 2x it...

Page 49: ...45 FIG K DIMENSIONAL DRAWING ST 1082 F BAT with fixed forks ST 1082 R BAT with adjustable forks option ST 1082 F V BAT widened model 27 49 ...

Page 50: ...INSPECTION CHECK LIST Annual inspection as described under 7 Inspection and Maintenance Date Remarks Name of mechanic Initials of mechnicpass ...

Page 51: ......

Page 52: ...Manufactured by STERTIL B V P O Box 23 9288 ZG Kootstertille Holland Tel 31 0 512334444 Telefax 31 0 512334430 www stertil nl email info stertil nl ...

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