stertil-KONI ST 1082-FS Installation, Operation And Maintanance Instructions Download Page 5

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Operating instructions (Version F)

ST 1082 & ST 1100

7.2

Emergency lowering procedure - - - - - - - - - - - - - - - - - 47

7.3

Programmable settings - - - - - - - - - - - - - - - - - - - - - 48

7.4

Error messages - - - - - - - - - - - - - - - - - - - - - - - - - 51

7.5

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - 53
7.5.1

Troubleshooting overview - - - - - - - - - - - - - - 57

7.6

Maintenance procedures- - - - - - - - - - - - - - - - - - - - - 60
7.6.1

Removal and installation of the lifting cylinder - - - - - - 60

7.6.2

Adjustment of the pallet lifting mechanism - - - - - - - - 61

7.6.3

Adjustment of the retractable front wheels
(RS models) - - - - - - - - - - - - - - - - - - - - - - - 62

7.7

List of parts - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

7.8

Replacement parts - - - - - - - - - - - - - - - - - - - - - - - 63

7.9

Emergency lowering facility - - - - - - - - - - - - - - - - - - - 63

Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64

8.1

Wheel adapters - - - - - - - - - - - - - - - - - - - - - - - - - 64
8.1.1

Longer wheel adapters (only FS models) - - - - - - - - - 65

8.2

Traverse beam - - - - - - - - - - - - - - - - - - - - - - - - - 66
8.2.1

Before you start working - - - - - - - - - - - - - - - - - 66

8.2.2

User instruction - - - - - - - - - - - - - - - - - - - - - 66

8.2.3

Tilting of the traverse beam with king pin adapter - - - - - 66

List of parts and appendices - - - - - - - - - - - - - - - - - - 68

A.1

Summary column lift - - - - - - - - - - - - - - - - - - - - - - 69

A.2

Mobile column lift - - - - - - - - - - - - - - - - - - - - - - - - 72

A.3

Hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - 74

A.4

Hydraulic scheme - - - - - - - - - - - - - - - - - - - - - - - - 76

A.5

Hydraulic cylinder - - - - - - - - - - - - - - - - - - - - - - - - 77

A.6

Control box (master column) - - - - - - - - - - - - - - - - - - 79

A.7

Electrical diagram control box (master column) - - - - - - - - - - 81

A.8

Control box (secondary column) - - - - - - - - - - - - - - - - - 82

A.9

Electrical diagram control box (secondary column) - - - - - - - - 84

A.10

Connection cable - - - - - - - - - - - - - - - - - - - - - - - - 85

A.11

Pallet jack mechanism - - - - - - - - - - - - - - - - - - - - - 86

A.12

Label locations - - - - - - - - - - - - - - - - - - - - - - - - - 88

A.13

Dimensional drawing - - - - - - - - - - - - - - - - - - - - - - 90

List of parts - Options - - - - - - - - - - - - - - - - - - - - - 92

B.1

Wheel adaptors and column extensions - - - - - - - - - - - - - 93

B.2

Traverse beam - - - - - - - - - - - - - - - - - - - - - - - - - 95

Inspection check list - - - - - - - - - - - - - - - - - - - - - - 98

Summary of Contents for ST 1082-FS

Page 1: ... 2011 Stertil B V 32708980 F Mobile column lift ST 1082 FS ST 1100 FS ST 1082 RS ST 1100 RS Installation operation and maintenance instructions ...

Page 2: ...H THE LIFT TO THE LIFT OWNER USER EMPLOYER PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS IN THIS MANUAL BEFORE INSTALLING OPERATING OR MAINTAINING THIS LIFT Installation operation and maintenance instructions for the Stertil Koni hydraulic mobile column lifts ST 1082 FS ST 1100 FS ST 1082 RS ST 1100 RS Capacity 18 000 lbs 22 000 lbs Starting at Serial Number EN 159487 UA 157657 ...

Page 3: ...mn lifts 12 2 Safety 13 2 1 Introduction 13 2 2 Safety indications 13 2 3 Safety instructions 13 2 4 Manufacturers instructions to the lift owner employer 17 2 5 Safety measures 18 2 5 1 Emergency stop 18 2 5 2 Safety features 18 2 6 Safety instructions caution and warning labels 19 3 Specifications 21 3 1 General 21 3 2 Lifting capacity 22 3 3 Lifting system 23 3 4 Control system 24 3 5 Hydraulic...

Page 4: ... 5 3 3 Operation of one single column 39 5 4 Operating the pallet lifting mechanism 39 5 5 Operating procedure 40 5 5 1 Preparation 40 5 5 2 System functions 41 5 5 3 Unblocking in case of emergency 41 6 Inspection and maintenance 42 6 1 General 42 6 2 Maintenance schedule 42 6 2 1 Daily checks by the user 42 6 2 2 Monthly maintenance by the user 42 6 2 3 Annual maintenance by trained lift service...

Page 5: ...el adapters only FS models 65 8 2 Traverse beam 66 8 2 1 Before you start working 66 8 2 2 User instruction 66 8 2 3 Tilting of the traverse beam with king pin adapter 66 A List of parts and appendices 68 A 1 Summary column lift 69 A 2 Mobile column lift 72 A 3 Hydraulic unit 74 A 4 Hydraulic scheme 76 A 5 Hydraulic cylinder 77 A 6 Control box master column 79 A 7 Electrical diagram control box ma...

Page 6: ...rk STERTIL KONI Serial Numbers Date first used Model ST 1082 FS ST 1100 FS ST 1082VFS ST 1100VFS ST 1082 RS ST 1100 RS Version Mobile column lifts with fixed wheels and fixed forks Mobile column lifts with fixed wheels and fixed forks widened version Mobile column lifts with retractable wheels and fixed forks Options Adjustable forks only ST1082 Wheel adapters Extended wheel adapters column foot e...

Page 7: ... EN 60204 1 1999 5 EC R TTE Directive EN 301 489 01 EN 301 489 02 EN 61000 3 2 EN 61000 3 3 2006 95 EC Low Voltage Directive EN60950 1 IEC60335 2 29 ANSI ALI ALCTV 2008 and UL201 2 nd edition CAN CSA C22 2 No 68 92 These Wheel Engaging Mobile Automotive Lifts are approved by INTERTEK TESTING SERVICES NA Inc 3933 US Route 11 Cortland NY 13045 Telephone 607 753 6711 Fax 607 756 9891 WEB www intertek...

Page 8: ...f the lift using the manufacturer provided instructions and warning labels and the Automotive Lift Institute Publications Lifting It Right and Safety Tips The lift that has been delivered to you contains the supply of operating instructions general safety information safety tips and warning labels on the control post As an owner or employer it is requested that you display these materials in a con...

Page 9: ...h also designated as service department The consequences of all repairs carried out on the vehicle lift by non trained lift service personnel are entirely at the user s risk The owner or employer shall establish a periodic preventive maintenance procedure in accordance with the recommendations listed in this manual Stertil Koni USA shall not be responsible for any actions not specifically called o...

Page 10: ...n use of the product as intended by the manufacturer In the event that the products parts of the products or procedures are applied in any way other than that described in this manual then confirmation must be obtained as to the correctness and suitability of that use No rights may be derived from this manual or from the documentation supplied with the product Supplier is bound by no agreement oth...

Page 11: ... lifts For information about spare parts for these column lifts please refer to the attached ST 1082 ST 1100 List of Parts and Appendices 1 5 Symbols in the text The following notation styles are used in this manual Each style has its own significance Text printed in bold is intended to emphasise something Note n Indicates an important aspect of the text Read the text carefully Caution c Indicates...

Page 12: ...on 1st June 2007 Regarding human health and environment the target is to manufacture and to use only safe chemical substances inside the EU Considering the terms of the regulation Stertil manufactures articles and is downstream user of chemical substances Stertil has the intention to fully comply to REACH regulation and checked his suppliers to make sure they comply to REACH requirements for all m...

Page 13: ...e workshop or business should ensure that all safety instructions that apply within the business are strictly observed Warning w Physical injury and damage to the machine can result by not following the safety instructions Ensure that you become familiar with the operation and control of the machine Follow the instructions exactly 2 2 Safety indications This document contains a number of special s...

Page 14: ...anufacturer supplied parts Important safety instructions Read all instructions If an extension cord is necessary use a cord with a current rating equal to or more than the equipment Cords rated for less current than the equipment may overheat Take care to arrange the cord so that it will not be tripped over or pulled Always unplug equipment from electrical outlet when not in use Never use the cord...

Page 15: ...rious injury and or damage Only authorized persons should operate the mobile lift These persons are in any case familiar with the operating instructions of the lift Do not use the lifting system outdoors if the wind velocities mentioned in section 4 5 Outdoor use on page 31 are exceeded If the lifting system is used outdoors do not leave the vehicles unattended in the lifted position The wind spee...

Page 16: ...ting columns in paired operation be sure that this will not result in stability risks In case of doubt consult your superior Unsafe lifting can result in serious injury and damage to the lifting system and or vehicles This mobile lift 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 ...

Page 17: ...er 2 4 Manufacturers instructions to the lift owner employer The owner employer shall Ensure that lift operators are qualified and that they are trained in the safe use and operation of the lift using the manufacturers operating instructions ALI SM 01 1 ALI Lifting it Right safety manual ALI ST 90 ALI Safety Tips card ANSI ALI ALOIM 2008 American National Standard for Automotive Lifts Safety Requi...

Page 18: ...y lift repairs Not modify the lift in any manner without the prior written consent of the manufacturer 2 5 Safety measures 2 5 1 Emergency stop Set the rotary switch on the main control box to 0 or press the emergency button on the auxiliary control box if an emergency arises All movements of all column lifts will stop If the emergency stop has been used check whether any person is trapped whether...

Page 19: ...erating instructions Version F 19 ST 1082 ST 1100 2 2 6 Safety instructions caution and warning labels The following safety and warning labels may be used on the mobile lift Figure 2 1 Safety and warning labels ...

Page 20: ...Operating instructions Version F 20 ST 1082 ST 1100 Figure 2 2 Safety and warning labels Figure 2 3 Safety and warning labels ...

Page 21: ...Hz 3x575V 60Hz 1x208 230V 60Hz 3x phase 1x earth 3x phase 1x earth 3x phase 1x earth 1x phase 1x zero 1x earth 3x phase 1x earth 3x phase 1x earth 3x phase 1x earth 1x phase 1x zero 1x earth Mains fuse See amperage power supply consumption table Figure 2 3 on page 20 See amperage power supply consumption table Figure 2 3 on page 20 Control voltage 24VDC 24VDC Lifting speed 3 phase 1 phase 44 min 2...

Page 22: ...ad of 18 000 lbs on any one column Lifting column interconnection cable length 39 4 39 4 Maximum distance between two column lifts approx 29 6 approx 29 6 Maximum floor surface pressure 900 psi per front support ST 1082 RS 7000 psi per wheel ST 1082 FS 900 psi per front support ST 1100 RS 7000 psi per wheel ST 1100 FS Maximum floor loading 7000 lbs per front support 7000 lbs per front support Oper...

Page 23: ...re normally used The columns are all identical The power supply is connected to the master column All power requirements and control signals are fed via the connecting cables The cables for the slave columns are connected directly to the control box on the master column Figure 3 1 Main components of a mobile column lift 1 Locking feature behind 2 Guide block 3 Lifting fork 4 Wheel adaptor 5 Cylind...

Page 24: ... 3 8 the control voltage will be cut off causing all movement to stop The cause of the fault must then be traced Note n Height differences may be caused by oil leakage in cylinders or valves The control system is also designed so that Any column lift can be controlled individually Any pair of axles can be controlled individually for an explanation see chapter 5 Operation on page 34 Warning w Contr...

Page 25: ...ated When relocating the column lift the pallet lifting mechanism raises the rear of the column off the floor so that it can be moved more easily 3 9 Retractable wheels RS models The front wheels are controlled simultaneously with the lifting and lower of the pallet lifting mechanism 3 10 Locking feature If the hydraulic pressure fails while a vehicle is being raised lowered or standing still abov...

Page 26: ... it will be used 2 Remove the lid of the crate or the straps on the transport pallet 3 Attach a hoisting belt rated at a minimum of 1100 lbs around the column lift and raise it out for the crate see Figure 4 1 Warning w Do not enter the area below the column lift while it is suspended from the lifting equipment If it should fall it could cause serious injury 4 Lower the column lift carefully to th...

Page 27: ...g capacity for the ST 1100 model is 22 000 lbs per column a set of 4 can therefore lift 88 000 lbs max For higher lifting capacities sets must be combined in a column ring according to the next mentioned tables Warning w If you want to lift the maximum weight with a set of 6 two main columns with two power supplies must be used because otherwise the current will be too high Main columns are positi...

Page 28: ...lbs 1 5 88 000 to 176 000 lbs 2 2 sets required 10 176 000 to 264 000 lbs 3 3 sets required 15 etc etc etc Table 4 4 Lifting capacities ST 1100 1 phase ST 1100 1 phase Lifting capacity Minimum number of main columns Maximum number of auxiliary columns up to 88 000 lbs 2 2 Figure 4 2 Linking columns Max lifting capacity ST 1082 72 000 lbs ST 1100 88 000 lbs Max lifting capacity ST 1082 72 000 lbs S...

Page 29: ... lift the maximum permissible elevation difference is 2 inches When operating two column lifts per axle control the maximum permissible elevation difference between the front and rear axles is 6 inches With a tandem axle at the rear of the vehicle the maximum permissible elevation difference between both rear axles is 2 inches Figure 4 3 Centre of gravity and weight distribution Centre of gravity ...

Page 30: ...used for extremely rigid vehicles aircraft towing vehicles trains will quickly overload if a single column is lowered 0 5 to 2 inches Warning w Lifting one wheel of a floating axle will result in a dangerous horizontal displacement of the column see Figure 4 5 on page 31 Figure 4 4 Overloading of columns Centre of gravity of the vehicle 72 000 88 000 lbs Example this column is too low No load No l...

Page 31: ...r the operating procedures and safety precautions of the traverse beam see 8 2 Traverse beam on page 66 4 5 Outdoor use When the lifting system is used outdoors you must take account of the maximum permissible wind speeds Maximum permissible wind speeds for various types of vehicles are given in Table 4 5 Note n The values in the table are averages and may only be used as a guideline Figure 4 5 Ho...

Page 32: ...ibed in chapter 2 4 6 Adjustable forks option for ST 1082 The mobile column lifts can be used for lifting vehicles with a wheel diameter of R10 17 to R22 5 45 The forks can be adjusted as follows to obtain the required wheel diameter also see Figure 4 7 Wheel positioning on page 33 1 Pull the T shaped handle up to unlock the fork 2 Slide the fork to the side Use both hands Table 4 5 Wind speeds an...

Page 33: ... the centre of the column 4 Position the forks in such a way that they just touch the tyre at a floor height to ensure the rim does not sink through when the tyre has a puncture 5 Lock the fork by pushing the T shaped handle again downwards in one of the holes check this Figure 4 7 Wheel positioning Same lengths Right Right Right Wrong Wrong Wrong ...

Page 34: ...s per vehicle axle referred to as operating in pairs operating a single column lift Warning w Operating a single column lift or one pair of column lifts can be extremely hazardous Refer to 4 3 Safety when hoisting on page 29 These possible modes of operation are available on every one of the column lifts without needing to set any selector switches 5 2 Control box All functions of the lifting syst...

Page 35: ...mergency shut down button If the emergency shut down switch main box is set to 0 or the emergency shut down switch auxiliary box is pressed all movements lifting and lowering will be immediately stopped 5 2 2 Starting The mains switch 2 controls the power supply to the column lifts This switch has two positions 0 OFF This will interrupt the power supply to the column lift s 1 ON This will activate...

Page 36: ...button 4 Warning w If problem situations arise during raising or lowering release the control buttons or press the emergency stop 5 2 5 Slow lowering Press the SLOW LOWERING button tortoise symbol This function is activated if the LED is lit in the button 1 Press the button again to deactivate the function If the SLOW LOWERING function has been activated the lowering speed of the column lifts will...

Page 37: ...e the button is released Note n In the event of malfunction consult the troubleshooting section see section 7 5 Troubleshooting on page 53 5 3 Setting the columns 5 3 1 Control system Set the control system of the mobile column lift as follows 1 Configure the column lifts in a full circuit as specified in Figure 4 2 Linking columns on page 28 The column sequence in this circuit is random master co...

Page 38: ...eration only possible when you have an even number of column lifts 1 Select the master columns at one axle to set this function for example the front wheel axle 2 Press the SELECT button until the PAIR light starts to flash Next select the other column of the pair 3 Go to the other column of the pair and press SELECT until the PAIR light is continuously lit Now the pair has been selected 4 Press b...

Page 39: ...ause this is an exceptional situation 5 4 Operating the pallet lifting mechanism 1 Set the lever to position 3 and make a pumping movement with the drawbar to raise the column lift with the pallet lifting mechanism The column lift can then be relocated 2 Pull the lever to position 1 to lower the column lift to the floor 3 Set the pallet lifting mechanism in the lowest position and the lever to the...

Page 40: ... to the forks of the column lifts Or slide the forks to the correct distance see section 4 6 Adjustable forks option for ST 1082 on page 32 2 Setup the required number of column lifts 3 Ensure that the fork of each column lift is extended as far as possible under the wheel 4 Lower the pallet lifting mechanism by pulling on the lever that is located on the inside of the drawbar 5 Ensure that the ma...

Page 41: ...SINGLE light 10 and DOWN button 4 one column lift lowers TORTOISE icon and DOWN button 4 columns lower slowly This works for ALL PAIR and SINGLE Note n Lower the column lifts in the safety locks and set the mains switch to 0 OFF once the desired height has been reached When using just one or two column lifts when operating in pairs make certain that there is no possible danger of instability see a...

Page 42: ...ognized by Stertil B V see section 6 2 3 Annual maintenance by trained lift service personnel only on page 43 6 2 Maintenance schedule 6 2 1 Daily checks by the user 1 Inspect the column lifts for visible damage 2 Check whether there has been any oil leakage from the hydraulic unit the hoses or the cylinder 6 2 2 Monthly maintenance by the user 1 Check the operation of the safety locking feature a...

Page 43: ...ank of the hydraulic unit only with the column in the highest position The oil level must be above the minimum oil level line but not more than 1 1 4 above this line 3 The hydraulic oil to be used is UNIL HVD S15 ISO VG15 with an absolute filtering at 4 microns 4 When the oil level is too low always perform the leak checks described later in this chapter 5 Inspection of all safety features 6 Check...

Page 44: ... proceed as follows 1 Fully lower the column lifts and drain off the oil 2 Fill the tank with UNIL HVD S15 ISO VG15 hydraulic oil filtered at maximum 4 microns Quantity of hydraulic oil in the tank 2 6 gallon Table 6 1 Lubrication program Maintenance tasks Description Monthly Annual technical service Every 2 years technical service Cylinder Lubricate piston rod if dry machine oil x Check oil level...

Page 45: ...e safety locks 2 Check whether the adjusting nut of the solenoid of the mechanical safety lock have a clearance of 1 8 5 32 If not adjust the nut at the rear side of the solenoid to get within this clearance range 3 Raise the lift to the highest position and lower it into the locks 4 Check but do not adjust the clearance of the nut at the back of the solenoid This clearance should be at least 1 8 ...

Page 46: ... to check whether the lowering valve the unlocking solenoid and the hydraulic power unit are functioning properly As soon as the switches are pressed the system produces an error Pressing SELECT and UNLOCK continuously for 2 seconds resets the system The switches can be used to check that the lowering valve the unlocking solenoid and the hydraulic power unit are functioning properly Table 6 2 Main...

Page 47: ...ains switch at the control box Turn the main switch to the 0 position to and pull the plug from the mains Never loosen or remove any part of the hydraulic system without first placing the column lifts in the lowest position or in the safety locks Note n All repairs carried out on the column lifts by persons other than technical services and consequences thereof are entirely at the user s own risk ...

Page 48: ...iting elevation 2 Lower the column lift in the pawls and then raise it approx 1 to be sure that the highest position is well above the locking position 3 Next activate program 60 code must be lit continuously If the currently set limiting elevation is not high enough then first deactivate the current elevation limitation Warning w The height of the column on which programming is taking place is us...

Page 49: ...am 65 active in each column to be able to operate a column set outside the safe limits Program 66 Potentiometers OFF check of the potentiometer operation This option is available so that the value on the potentiometer input is replaced by a constant value The column will function normally without the elevation difference being corrected This setting is active during 10 minutes and then the safe li...

Page 50: ...xit the programming mode by switching off the main switch and switching it back on again 8 Start the system by pressing the Select button 9 Lower all column lifts completely until they have attained the lowest position 10 Switch off the main switch and switching it back on again 11 Start the system again by pressing the Select button The height reference values will be automatically set Note n If ...

Page 51: ...ops and the red light FAULT on the front panel flashes then a difference of 1 1 4 has occurred between the columns during lowering Raise the columns approximately 4 and remove the obstacle if any The column lifts can now again be lowered Do not forget to first press the UNLOCK button When rising If the rising movement stops and the red light FAULT on the front panel is lit continuously then it may...

Page 52: ... FAULT will be lit on the front panel when a phase error occurs The microprocessor card has a 2x7 segment display which specifies a fault the related code specifies the type of fault see Table 7 1 Error codes on page 53 Open the front panel of the control box to see the 2x7 segment display Figure 7 1 Location on the display which specifies an error or fault ...

Page 53: ...ift has not risen within 5 seconds when the UP button was operated Check the main fuse when the motor fails to run Check the lowering valve for leaks The pressure relief valve will open Check whether the vehicle lift has not been loaded too heavily Check whether all three phases have been connected correctly 07 2 1 2 tilt Elevation differences of more than 2 1 2 have occurred since the last zero s...

Page 54: ...ELECT button to ensure the system can again be used If the fault occurs again contact the technical service 11 Potentiometer circuit fault Fault in the potentiometer cabling Check the potentiometer cabling Turn OFF and ON on the main switch s and press the SELECT button to ensure the system can again be used If the fault occurs again contact the technical service 16 Potentiometer not calibrated Po...

Page 55: ...n drop safeguard unlocking solenoid Check the circuit of the unlocking solenoid 33 Output correction valve fault Broken wire short circuit in the correction valve Check the circuit of the correction valve 35 Motor relay fault Broken wire short circuit in the motor relay Check the cabling to A1 and A2 of the motor relay 36 Output power supply fault Defective power supply to outputs Set the main swi...

Page 56: ...rn OFF and ON on the main switch s and press the SELECT button to ensure the system can again be used Replace the PCB if required 83 EPROM write fault 91 Watchdog fault 93 General CAN error 94 95 CAN time out Table 7 1 Error codes Error code Code label Possible cause Solution ...

Page 57: ...lt occurs again contact the technical service The maximum elevation difference more than 2 1 2 has been exceeded Set the main switch to OFF and ON Press twice the SELECT button to ensure the system can again be used If the fault occurs again contact the technical service The phases have not been correctly connected The red light FAULT is continuously lit Exchange the two phases in the plug on the ...

Page 58: ...e Table 7 4 The column lift lowers all by itself Cause Solution The cylinder seal is damaged oil is leaking continuously Have technical services replace the cuff or the cylinder Leak in the oil line couplings Tighten the couplings or union nuts Contaminated or damaged non return valve Have the non return valve cleaned or have it replaced by technical services Contaminated or damaged lowering corre...

Page 59: ...The mains switch is OFF Set the mains switch to ON Faulty LEDs Contact the technical service Table 7 8 No control voltage Cause Solution Faulty LEDs Lifting system functioning normally Contact the technical service A fuse has been tripped Check the F2 and F3 fuses Replace the fuse s in the control box if necessary If the fault occurs again contact the technical service The mains switch is OFF Set ...

Page 60: ...e elastic ring from the head of the cylinder Proceed as follows to install the cylinder 1 Place the elastic ring on the head of the cylinder 2 Place the cylinder inside the guide block and ensure that it drops into the seating in the plate below the cylinder 3 Make the hydraulic coupling at the bottom of the cylinder 4 Press the SELECT button and the UP button to raise the cylinder Release the but...

Page 61: ... correct 3 If the cylinder lifts loosen nut 1 and turn the adjusting screw clockwise 4 If the cylinder sinks down turn the adjusting screw anti clockwise until the cylinder no longer sinks Raise the cylinder to the top position and set the lever to position 1 the cylinder should now be lowered 5 If it does not lower or only does so slowly tighten the adjusting screw a little 6 Repeat these steps u...

Page 62: ...f parts See appendix A List of parts and appendices on page 68 and appendix B List of parts Options on page 92 Explanation of the titles of the columns in the parts list Fig index Fig refers to the related group on the parts drawing Index to the section in this group No Total number of parts in the column lift Reference The numbers in this column are Stertil B V order numbers Please specify these ...

Page 63: ...llowing information Column lift type ST 1082 ST 1100 Serial number See the type plate on the column lift Reference no See List of Parts 7 9 Emergency lowering facility If there is a power failure you will be unable to use the control buttons to lower the lift In such a case it is possible to let the lift down manually Please contact technical services in this case Warning w The emergency lowering ...

Page 64: ... ranging from R12 20 to R22 5 45 Wheel adapters must be used for certain wheel diameters see Figure 8 1 For tyre sizes R12 20 to R15 26 two adapters are needed For tyre sizes R15 26 to R17 36 one adapter is needed For tyre sizes R17 36 to R22 5 45 adapters are not needed For smaller wheel diameters 20 special adapters are available Figure 8 1 Wheel adapters ...

Page 65: ...sed in combination with the column foot extensions The lifting capacity will be restricted to 12 000 lbs 8 800 lbs see Figure 8 2 The restricted lifting capacity is also clearly indicated on the sides of the longer wheel adapters Note n The lifting capacity will still be 12 000 lbs 8 800 lbs with the longer wheel adapters Check the maximum weight carefully before lifting The lifting capacity with ...

Page 66: ...on The traverse beam can be overloaded without warning 8 2 2 User instruction 1 Position the vehicle on the desired location 2 Place the traverse beam with the optional pick up pads on the correct lifting position under the vehicle 3 Position the mobile lifting columns in such a way that the forks of the columns fully support the pickup points of the traverse beam 4 Operate the mobile lifting colu...

Page 67: ...lting of the traverse beam is a potential hazardous situation Whether this situation will occur depends on the specific design of the trailer To prevent this dangerous situation 1 Always connect the brake air pressure to the trailer from an external source 2 Make sure the brakes are released to allow rotation of the wheels while lifting and lowering Figure 8 4 Tilted traverse beam ...

Page 68: ... A 3 Hydraulic unit on page 74 A 4 Hydraulic scheme on page 76 A 5 Hydraulic cylinder on page 77 A 6 Control box master column on page 79 A 7 Electrical diagram control box master column on page 81 A 8 Control box secondary column on page 82 A 9 Electrical diagram control box secondary column on page 84 A 10 Connection cable on page 85 A 11 Pallet jack mechanism on page 86 A 12 Label locations on ...

Page 69: ...List of parts and appendices Operating instructions Version F 69 ST 1082 ST 1100 A A 1 Summary column lift Figure A 1 Column lift See Figure A 3 See Figure A 3 ...

Page 70: ...See Figure A 5 Hydraulic cylinder 14 1 See Figure A 6 Control box 15 1 See Figure A 10 Connection cable Item not shown on figure 16 1 32556150 Hydraulic hose 17 4 30001006 Slide plate 18 1 30007400 Potentiometer unit 19 1 See Figure A 3 Hydraulic unit 20 1 See Figure A 2 Pallet jack mechanism 21 1 32700122 Pawl 22 1 32700134 Support 23 1 30001004 Clamp 24 6 66201085 Buffer 25 1 69451400 Solenoid 2...

Page 71: ...08 Cable support 44 4 65003488 Bolt M14x30 DIN 933 45 4 65055023 Washer M14 DIN 125A 46 6 66201056 Spacer 6 3 15 15 47 4 65051028 Locknut M6 48 2 65003403 Bolt M10x20 DIN 933 49 2 65058028 Washer M10 DIN127B 51 1 68700450 Straight adaptor GE 10 PS 53 1 66201039 Nut cap M20 0342044 54 1 69090050 Grommet No 2790 type 2 56 4 65870011 Locking ring special M6 57 2 65050124 Nut M4 DIN 934 Table A 1 Colu...

Page 72: ...Operating instructions Version F 72 ST 1082 ST 1100 A 2 Mobile column lift Figure A 2 Mobile column lift P6 Locked with loctite 542 sealant Note Adjustable forks only possible on ST 1082 models ...

Page 73: ...tractable models 15 2 65025007 Bolt M10x30 ISO 7380 Only retractable models 16 1 32700200 Torsion bar Only retractable models 17 2 32700121 Shaft All models 18 2 1038 66 04 24 Roll pin 6x30 DIN 1481 All models 19 1 32706200 Jack assembly All models 20 1 65214358 Adjusting screw M8x8 DIN 916 All models 21 1 1037 07 50 08 Nut M8 DIN 439B All models 22 1 32550103 Shaft All models 23 1 32700120 Cap Al...

Page 74: ...Operating instructions Version F 74 ST 1082 ST 1100 A 3 Hydraulic unit Figure A 3 Hydraulic unit ...

Page 75: ...1 2 CM3 REV Tightening torque 16 5 lbf ft 7a 1 68308013 2 2 Valve NC ex solenoid Tightening torque 22 lbf ft 7b 1 68308005 2 2 Valve NC ex solenoid incl manual Tightening torque 22 lbf ft 8 4 68510124 O ring 12 42 x 1 78 9 2 69481501 Solenoid 24 VDC EC 30D 10 1 68039019 Valve block assembly 11 2 68512140 O ring 14x1 78 12 1 68039007 Pressure relief valve 3800 psi Tightening torque 18 5 lbf ft 12 1...

Page 76: ...ydraulic scheme Figure A 4 Hydraulic scheme Index Description C Cylinder EV22 2 2 Valve VCDF Flow control valve F Filter K Non return valve P Pump T Tank O Safety pressure valve M Electric motor R Hose burst check valve X psi ST 1082 3800 psi ST 1100 4200 psi ...

Page 77: ...List of parts and appendices Operating instructions Version F 77 ST 1082 ST 1100 A A 5 Hydraulic cylinder Figure A 5 Hydraulic cylinder ...

Page 78: ...g ring 2 2 Backup ring 3 2 O ring 4 1 Bearing ring 5 1 Piston seal 6 1 O ring 7 1 Backup ring 8 1 Piston cap 9 1 68700450 Straight adaptor 10 1 1003 91 80 38 Hose burst check valve 11 1 68900000 Air bleeding nipple 12 1 Cylinder 13 1 Piston rod 14 1 Piston 15 1 Gate 16 1 Retaining ring 17 1 65263009 Spring ring 18 1 Cylinder bottom 32706900 Seal kit ST1082 ...

Page 79: ...s 32707100 Primary control box 3x460V incl cables 32707200 Primary control box 3x208 230V incl cables 32707920 Primary control box 3x575V incl cables 32707950 Primary control box 1x208 230V incl cables 1 1 32707125 Box 2 1 69900135 PCB 3 1 69500007 Trafo 4 1 69152006 Motor relay 5 1 32707050 Foil covered switch panel 6 1 69154001 Main safety relay 7 2 69156009 Safety relays 9 1 69141050 Main switc...

Page 80: ...n 23 2 69206010 Fuse 125 mAT 250V F3 24 2 69206012 Fuse 3 15 AT 24V F2 26 1 69202008 Acoustical alarm 27 1 69153003 Thermal relay 3x460V 1x230V See Figure A 7 27 1 69153002 Thermal relay 3x220V See Figure A 7 27 1 69153004 Thermal relay 3x575V See Figure A 7 32 1 Cable power supply 34 1 Motor cable 35 1 Cable lowering valve 36 1 Cable correction valve 37 1 Cable unlocking solenoid 38 1 Cable poten...

Page 81: ...List of parts and appendices Operating instructions Version F 81 ST 1082 ST 1100 A A 7 Electrical diagram control box master column Figure A 7 Electrical diagram control box master column ...

Page 82: ...ription Remarks 32707300 Secondary control box 3x208 230 460 575V incl cables 1 1 32707125 Box 2 1 69900135 PCB 3 1 69500007 Trafo 4 1 69152006 Motor relay 5 1 32707050 Foil covered switch panel 6 1 69141061 Emergency stop 7 2 69141041 NC contactor 10 2 69090114 Connector 11 1 69090112 Connector internals male 12 1 69090111 Connector internals female 16 1 Cable gland M20x1 5 22052um2x6 ...

Page 83: ...gland M20x1 5 22052u11 green 23 2 69206010 Fuse 125 mAT 250V F3 24 2 69206012 Fuse 3 15 AT 24V F2 26 1 69202008 Acoustical alarm 34 1 Motor cable 35 1 Cable lowering valve 36 1 Cable correction valve 37 1 Cable unlocking solenoid 38 1 Cable potentiometer Table A 8 Control box secondary column Index No Reference Description Remarks ...

Page 84: ...Operating instructions Version F 84 ST 1082 ST 1100 A 9 Electrical diagram control box secondary column Figure A 9 Electrical diagram control box secondary column ...

Page 85: ...ble Figure A 10 Connection cable Table A 10 Connection cable Index No Reference Description Remarks 1 1 32707150 Cable 39 9 assembly Standard 1 1 32557150 Cable 39 9 assembly With steel protection option 2 1 69090111 Connector internals female 3 1 69090112 Connector internals male 4 2 69090113 Housing ...

Page 86: ...Operating instructions Version F 86 ST 1082 ST 1100 A 11 Pallet jack mechanism Figure A 11 Pallet jack mechanism 8 3 2 7 1 ...

Page 87: ...tion Remarks 1 32706200 Pallet jack assembly All models 1 1 32706205 Hydraulic valve assembly 2 1 32706210 Spring cover assembly 3 1 32706215 Pump piston assembly 4 1 32706220 Lowering valve assembly 5 1 32706225 Lowering screw assembly 6 1 32706230 Safety valve assembly 7 1 32706235 Pump unit 8 1 32706240 Handle assembly 1 32706245 Seal kit ...

Page 88: ...Operating instructions Version F 88 ST 1082 ST 1100 A 12 Label locations Figure A 12 Label locations ...

Page 89: ...ity sticker 22 000 lbs ST 1100 7 1 60700093 Sticker WARNING 8 1 60700090 Address sticker STERTIL KONI USA 9 1 60702001 ALI member label 10 1 60702004 Uniform warning label 11 1 60702005 Caution label 12 1 60702006 Safety instruction label 13 1 60700198 Sticker AMPERAGE POWER SUPPLY 14 1 32708980 Service manual 15 1 60702002 Safety manual LIFTING IT RIGHT 16 1 60702003 Card SAFETY TIPS 19 1 6070200...

Page 90: ...ing instructions Version F 90 ST 1082 ST 1100 A 13 Dimensional drawing Figure A 13 1 Dimensional drawing ST 1082 ST 1082 FS with fixed forks ST 1082VFS widened model 27 1 2 49 ST 1082 RS with adjustable forks ...

Page 91: ... parts and appendices Operating instructions Version F 91 ST 1082 ST 1100 A Figure A 13 2 Dimensional drawing ST 1100 ST 1100 FS with fixed forks ST 1100VFS widened model 27 1 2 49 ST 1100 RS with fixed forks ...

Page 92: ...st of parts Options The following sections will give an overview of the main assemblies of the variants and options of the Mobile column lifts ST 1082 ST 1100 and their components B 1 Wheel adaptors and column extensions on page 93 B 2 Traverse beam on page 95 ...

Page 93: ... ST 1100 B B 1 Wheel adaptors and column extensions Warning w Longer wheel adaptors may only be used in combination with column extensions See the attached label on longer wheel adaptors for the maximum allowed capacity Figure B 1 Wheel adaptors and column extensions ...

Page 94: ...00935 Longer wheel adaptor 16 Left length 500 mm 20 Max 8 800 lbs all models 3R 1 34400930 Longer fork adaptor Right length 500 mm 20 Max 12 000 lbs all models 3L 1 34400935 Longer fork adaptor Left length 500 mm 20 Max 12 000 lbs all models 4 2 34400916 Column extension FS models 5 2 34400916 Shaft FS models 6 4 1038 34 02 40 Retaining washer A24 DIN6799 FS models 7 2 65003530 Bolt M16x40 8 8 DIN...

Page 95: ...0 Traverse beam 1 1 32591054 Traverse beam support 2 4 66002015 Wheel 3 2 60700164 Capacity sticker See Figure B 2 1 4 4 65003408 Hex cap screw M10x35 8 8 DIN 933 GV 5 4 65058028 Circlip M10 DIN127B GV 6 4 65050134 Hex nut M10 8 DIN934 GV 7 2 32591020 Adapter adjustable 8 2 32591051 Adapter low A A 1 10 MIN 1000 7 2T 7 2T BELASTINGSGRAFIEK BELASTUNGSSCHEMA DIAGRAMME DE CHARGE LOAD GRAPH 8 7 6 5 4 ...

Page 96: ...e Description Remarks 32591500 Traverse beam 1 1 32591510 Traverse beam support 2 2 32591020 Adapter adjustable 3 2 1020 50 00 30 Wheel 4 2 1038 40 04 00 Retaining ring A40 DIN471FF 5 2 1005 01 01 49 Stertil Koni sticker 6 2 60700127 Capacity sticker 14400 kg 32 000 lbs 7 2 60700102 Stertil Koni sticker medium 7 DRSN A A 3 4 A A 1 6 5 2 ...

Page 97: ...ption Remarks 32592000 Traverse beam 1 1 32592010 Traverse beam support 2 1 32592020 King pin support 3 2 32500116 Wheel 4 2 1038 34 02 40 Retaining ring No 24 DIN6799 GV 5 1 4310 09 00 10 Pin with clip 6 1 32592005 Reducing bush 3 5 to 2 7 2 60700102 Stertil Koni sticker 8 2 60700075 Capacity sticker 7200 kg 9 2 60700076 Capacity sticker 16000 lbs 9 6 8 7 1 2 5 3 4 ...

Page 98: ... Operating instructions Version F 98 ST 1082 ST 1100 C Inspection check list Annual inspection as described in the installation and service manual Date Remarks Name of mechanic Initials of mechanic pass ...

Page 99: ...Inspection check list Operating instructions Version F 99 ST 1082 ST 1100 C Date Remarks Name of mechanic Initials of mechanic pass ...

Page 100: ...ure 47 Emergency lowering facility 63 Emergency shut down button 35 Emergency stop 18 Error messages 51 F Forks adjust 32 G Guarantee 12 H Hydraulic oil 44 I Inspection 42 Installation 26 K King pin adapter 66 L Liability 12 Lifting capacity 22 Lifting cylinder maintenance 60 Lifting system 23 List of Parts explanation 62 Lubrication programme 44 M Maintenance 42 annual 43 daily 42 hydraulic oil 4...

Page 101: ...t lifting mechanism adjustment 61 operation 39 Procedures maintenance 60 R REACH regulation 12 Replacement parts explanation 63 Retractable front wheels adjustment 62 S Safety 13 emergency lowering 47 emergency stop 18 features 18 measures 18 when hoisting 29 Safety features 18 Safety indications 13 Service 47 Specifications 21 Starting 35 System functions 41 T Traverse beam 31 tilting 66 user ins...

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stertil-KONI ST 1082-FS, Installation, Operation And Maintanance Instructions

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