stertil-KONI ST1075-FBF Installation, Operation And Maintanance Instructions Download Page 5

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Operating instructions (Version 0)

ST 1075

7.3

Programmable settings - - - - - - - - - - - - - - - - - - - - - 51
7.3.1

Height limit - - - - - - - - - - - - - - - - - - - - - - - 51

7.3.2

Unlock during up - - - - - - - - - - - - - - - - - - - - 52

7.3.3

Crush limit- - - - - - - - - - - - - - - - - - - - - - - - 52

7.3.4

Height difference guard - - - - - - - - - - - - - - - - - 52

7.3.5

Height monitoring - - - - - - - - - - - - - - - - - - - - 52

7.3.6

Odd number of columns - - - - - - - - - - - - - - - - - 53

7.3.7

Height dimension - - - - - - - - - - - - - - - - - - - - 53

7.3.8

Language - - - - - - - - - - - - - - - - - - - - - - - - 53

7.3.9

Motor run time hours- - - - - - - - - - - - - - - - - - - 54

7.3.10 System run time - - - -  - - - - - -  - - - - - -  - - - - -  54
7.3.11 Long distance - - - - - - - - - - - - - -  - - - - - - - -  54
7.3.12 Weight dimension (optional)  - - - -  - - - - - -  - - - - -  54
7.3.13 Weight category (optional) - - - - - - - - - - - - - - - -  54
7.3.14 Motor type- - - - - -  - - - - - - - - - - - - - - - - - -  55
7.3.15 Footguard - - - - - - - - - - - - - - - - - - - - - - - -  55

7.4

Error messages - - - - - - - - - - - - - - - - - - - - - - - - - 55
7.4.1

Service sticker- - - - - - - - - - - - - - - - - - - - - - 57

7.4.2

Electrical diagram for control box- - - - - - - - - - - - - 58

7.4.3

Hydraulic components - - - - - - - - - - - - - - - - - - 58

7.5

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - 58
7.5.1

Warnings - - - - - - - - - - - - - - - - - - - - - - - - 58

7.5.2

Error reports- - - - - - - - - - - - - - - - - - - - - - - 60

7.5.3

Fault messages - - - - - - - - - - - - - - - - - - - - - 63

7.5.4

Troubleshooting overview - - - - - - - - - - - - - - - 65

7.6

Maintenance procedures- - - - - - - - - - - - - - - - - - - - - 68
7.6.1

Removal and installation of the lifting cylinder - - - - - - 68

7.6.2

Adjustment of the pallet lifting mechanism - - - - - - - - 68

7.7

List of parts - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

7.8

Replacement parts - - - - - - - - - - - - - - - - - - - - - - - 69

7.9

Emergency lowering facility - - - - - - - - - - - - - - - - - - - 70

Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71

8.1

Wheel adapters - - - - - - - - - - - - - - - - - - - - - - - - - 71
8.1.1

Longer wheel adapters - - - - - - - - - - - - - - - - - 72

8.2

Traverse beam - - - - - - - - - - - - - - - - - - - - - - - - - 73
8.2.1

Before you start working - - - - - - - - - - - - - - - - - 73

8.2.2

User instruction - - - - - - - - - - - - - - - - - - - - - 73

8.2.3

Tilting of the traverse beam with king pin adapter - - - - - 73

List of parts and appendices - - - - - - - - - - - - - - - - - - 75

A.1

Summary column lift - - - - - - - - - - - - - - - - - - - - - - 76

A.2

Hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - 78

Summary of Contents for ST1075-FBF

Page 1: ... 2013 Stertil B V 34508860 0 Mobile column lift ST1075 FBF Installation operation and maintenance instructions ...

Page 2: ... MATERIAL FURNISHED WITH 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 1075 FBF Capacity 16 500 lbs Starting at Serial Number UK 184100 ...

Page 3: ... column lifts 13 2 Safety 14 2 1 Introduction 14 2 2 Safety indications 14 2 3 Safety instructions 14 2 4 Manufacturers instructions to the lift owner employer 18 2 5 Safety measures 19 2 5 1 Emergency stop 19 2 5 2 Safety features 19 2 6 Safety instructions caution and warning labels 20 3 Specifications 22 3 1 General 22 3 2 Lifting capacity 23 3 3 Lifting system 23 3 4 Control system 24 3 5 Hydr...

Page 4: ... the pallet lifting mechanism 40 5 5 Operating procedure 40 5 5 1 Preparation 41 5 5 2 System functions 41 5 5 3 Unblocking in case of emergency 42 6 Inspection and maintenance 43 6 1 General 43 6 2 Maintenance schedule 43 6 2 1 Daily checks by the user 43 6 2 2 Monthly maintenance by the user 43 6 2 3 Annual maintenance by trained lift service personnel only 44 6 3 Maintenance procedures 45 6 3 1...

Page 5: ...r 57 7 4 2 Electrical diagram for control box 58 7 4 3 Hydraulic components 58 7 5 Troubleshooting 58 7 5 1 Warnings 58 7 5 2 Error reports 60 7 5 3 Fault messages 63 7 5 4 Troubleshooting overview 65 7 6 Maintenance procedures 68 7 6 1 Removal and installation of the lifting cylinder 68 7 6 2 Adjustment of the pallet lifting mechanism 68 7 7 List of parts 69 7 8 Replacement parts 69 7 9 Emergency...

Page 6: ...nder 81 A 5 Control box 83 A 6 Electrical diagram control box 86 A 7 Pallet jack mechanism 87 A 8 Connection cable 89 A 9 Label locations 90 A 10 Dimensional drawing 92 B List of parts Options 93 B 1 Wheel adaptors and column extensions 94 B 2 Traverse beam 96 C Inspection check list 99 ...

Page 7: ... 2 nd edition Manufacturer Stertil B V Postbus 23 9288 ZG Kootstertille Nederland Machine Hydraulic mobile column lifts Trademark STERTIL KONI Serial Numbers Date first used Model ST 1075 FBF Version Mobile column lifts with fixed wheels and fixed forks Control with battery power Options Wheel adapters Extended wheel adapters column foot extensions Various accessories Traverse beams ...

Page 8: ...EN 954 1 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 2006 and UL201 2 nd edition CAN CSA C22 2 No 68 92 These Wheel Engaging Mobile Automotive Lifts are approved by ALI Testing and evaluation has been performed by INTERTEK TESTING SERVICES NA Inc 3933 US Route 11 Cortland NY 13045...

Page 9: ...e 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 conspic...

Page 10: ...so 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 out f...

Page 11: ...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 12: ...ation about spare parts for these column lifts please refer to the attached ST 1075 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 procedures that must be ...

Page 13: ... 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 ...

Page 14: ...rkshop 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 symbo...

Page 15: ...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 16: ...y untrained people could result in serious 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 Danger of getting injured by electrical shock Care must be taken as burns can occur from touching hot parts Only remove the covers to carry out maintenance ens...

Page 17: ...applications The positioning of the lifting system must be done in a way that a safe working area will be obtained thereby creating escape paths for emergency situations leave passageways of at least 24 For important vehicle technology see section 4 3 Safety when hoisting on page 29 If a vehicle is in the lifted position its air suspension system may not be used in a view of possible change of tra...

Page 18: ...Placards SAE J2184 Vehicle Lift Points for Service Garage Lifting Establish procedures to periodically inspect the lift in accordance with the lift manufacturers instructions ANSI ALI ALOIM 2008 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 trained in t...

Page 19: ... system which ensures that the guide blocks always stay at an equivalent height within the control limits lowering is halted in the event that obstacles cause an elevation difference to occur the control circuit is interrupted in the event the height difference between the guide blocks exceeds a pre defined value operation via the push buttons on the mobile column lift control boxes is then disabl...

Page 20: ...Operating instructions Version 0 20 ST 1075 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 21: ...Safety Operating instructions Version 0 21 ST 1075 2 Figure 2 2 Safety and warning labels ...

Page 22: ...r 24VDC 130Amps Charging current Charger type Charging time when 70 discharged 24VDC 10 5A 20 min 24VDC 6 25A continuous Automatic charger can remain connected during use and in storage 9 hours Number of complete lifting actions fully charged batteries 22 fully loaded 33 half loaded Main fuse 24VDC 200A slow blow Control voltage 24VDC Raising lowering time 75 55 s Noise level Max 73 dB A Installat...

Page 23: ...for lifting heavy vehicles A minimum of two column lifts is needed to lift a vehicle The number of column lifts required depends on the weight of the vehicle and the number of axles Four lifting columns are normally used The columns are all identical The columns have an integrated power supply batteries with charger Figure 3 1 Main components of a mobile column lift 1 Column 2 Potentiometer 3 Lock...

Page 24: ...he elevation difference is more than 1 1 4 and less than 2 3 8 A lifting fork may be blocked The cause of the fault must then be traced You can still lift and the correction valve in the hydraulic system will open until the elevation difference has been synchronized When the elevation difference exceeds 2 3 8 the control voltage will be cut off causing all movement to stop The cause of the fault m...

Page 25: ...panel The components of the control panel and their functions are described in chapter 5 Operation on page 33 3 8 Pallet lifting mechanism The pallet lifting mechanism is fitted with two wheels and is used for relocating the column lift Mounted at the rear these safeguard the column lift against toppling over when it is being relocated When relocating the column lift the pallet lifting mechanism r...

Page 26: ... 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 carefully to the floor 5 Att...

Page 27: ...PTM plug 13 Connect the locking magnet VLM plug 14 Remove the stoppers and connect up the hydraulic hose 15 Check that the main switch is OFF 16 Place the bottom battery in the cabinet with the negative terminal on the charger side Note n The cables can only be connected one way The cable clamps are marked with a and a and only fit onto the corresponding terminals 17 Attach the black mini cable 14...

Page 28: ...24V 150A 3 Battery charger 4 Main switch 5 Fuse holder 6 200A main fuse 7 Battery 8 Charging cable connector 9 Charging cable 10 Relay motor cable 11 Switch fuse cable 12 Pos battery terminal switch cable 13 Neg battery terminal pos battery terminal cable 14 Neg battery terminal motor cable ...

Page 29: ... column lifts Sets comprising 2 to 8 columns can be put together using interconnection cables The linked columns are referred to as a set Several sets can be used next to one another in the same area A maximum of 60 columns can be used The columns are absolutely identical The columns work independently of the mains supply The mains supply is only required for loading the batteries The lifting capa...

Page 30: ...umn 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 of the vehicle 66 000 lbs 16 500 lbs 16 500 lbs 16 500 lbs 16 500 lbs ...

Page 31: ...maining columns Note n Columns 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 Figure 4 4 Overloading of columns Centre of gravity of the vehicle 66 000 lbs Example this column is too low...

Page 32: ...il Koni traverse beam is available For the operating procedures and safety precautions of the traverse beam see 8 2 Traverse beam on page 73 4 5 Testing Once all the installation work has been completed and all adjustments and checks have been performed the lifting system must be tested under full load using a typical vehicle Figure 4 5 Hoisting floating axles ...

Page 33: ...ol system operating all column lifts simultaneously operating one pair of column lifts 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 n...

Page 34: ...itch is pressed all movements are immediately halted raising or lowering 5 2 2 Starting and identification Each of the columns has a main switch This switch has two positions 0 OFF This interrupts the power supply to the column lift 1 ON This switches on the power supply to the column lift Figure 5 2 Control box 1 Emergency stop button 2 Information screen 3 UP button 4 DOWN button 5 SELECT button...

Page 35: ...e formed a closed loop Set the main switch of each column to 1 ON and follow the on screen instructions Note n The current software version may be different from the version shown in the picture 1 HOLD THE ID KEY IN FRONT OF THE ANTENNA SYMBOL See Figure 5 2 item 13 Hold the ID key in front of the antenna symbol 12 this is acknowledge with a single bleep and the green light starts blinking Figure ...

Page 36: ...art up multiple sets simultaneously with no problems Warning w After the STARTUP COMPLETED message the same ID key can be used to link another set of columns If the same ID key is used during the CONNECTING step a set can be produced at random Warning w Only a single column from those selected using the ID key can be selected again using the same ID key This master column will form a set together ...

Page 37: ...If the SLOW LOWERING function has been activated the lowering speed of the column lifts will be reduced to 1 3 of the normal speed This can be used when building out gearboxes or to allow the vehicle to carefully be lowered onto an axle support Caution c A column lift may come to a standstill when lowering columns if the SLOW LOWERING function has been activated to even out elevation differences O...

Page 38: ... user on page 43 Operating symbols The screen shows which buttons are pressed Lifting Height Shows the current height that the column is raised to Column number Shows the number of the column Set size Shows the number of columns in this set Work timer This timer is reset and starts to run as soon as the mobile lift is 2 inches from the ground This can be seen by a blinking colon character The time...

Page 39: ...SELECT until the PAIR light is continuously lit Now the pair has been selected 4 Press button 3 to raise the pair of columns Press button 4 to lower the pair of columns Note n An acoustic signal will be emitted when PAIR UP and DOWN are operational because this is an unusual situation When setting up pair operation the last two remaining columns will automatically be defined as a pair This means S...

Page 40: ... the lever to the neutral position 2 whenever the column lift is to be used to hoist a vehicle 5 5 Operating procedure Before using the column lift make certain that the floor where the column lifts are set up is capable of supporting the setup and the vehicle the installation has taken account of the need for an escape route at least 24 wide on all sides of the setup the maximum load on each colu...

Page 41: ... few times You should clearly hear the noise of the pawls 5 5 2 System functions All system functions see Figure 5 2 Control box on page 34 are now available by pressing UP button 3 all columns are raised DOWN button 4 lower into the safety locks UNLOCK button 6 and DOWN button 4 all column lifts are lowered SELECT button 5 and PAIR light 11 and UP button 3 one axle is raised 2 column lifts SELECT...

Page 42: ...ent When using just one or two column lifts when operating in pairs make certain that there is no possible danger of instability see also 4 3 Safety when hoisting on page 29 If in doubt ask your supervisor Warning w Unsafe hoisting can lead to serious injuries and damage to the lifting system and the vehicles 5 5 3 Unblocking in case of emergency In emergency situations it is possible to lower the...

Page 43: ...ical service recognized by Stertil B V see section 6 2 3 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 3 Check the battery capacity 6 2 2 Monthly maintenance by the user 1 Check the operation of the safety locking feature as described in 6 3 5 Che...

Page 44: ... THE HYDRAULIC RESERVOIR SHALL BE REMOVED AT ONCE This dirt could get into the cylinders and DAMAGE OR DESTROY the seals resulting in a POTENTIALLY SERIOUS SAFETY HAZARD Clean the hydraulic reservoir thoroughly and replace only with approved oil Contact your Authorized Service Representative if further assistance is required 3 The hydraulic oil to be used is UNIL HVD S15 ISO VG15 with an absolute ...

Page 45: ...ven when the column lifts are not in continuous use When changing the hydraulic oil proceed as follows 1 Fully lower the column lifts and drain off the oil 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 in tank Top up only with column lifts fully lowered ...

Page 46: ...akes about 9 hours Each column has its own battery charger This can be connected up to the mains with a standard cable and an IEC plug a computer cable 115V 60Hz 6Amps The charger works independently of the operating system This means that the main switch can be at 0 OFF while the charger is connected to the mains A gauge glass is situated at the right hand side of the box Red signs that the batte...

Page 47: ...ust immediately come to a standstill 2 Turn the emergency stop knob anti clockwise to release it 3 Press SELECT and the release button 6 simultaneously for 2 seconds the emergency stop situation is cancelled and the system is ready to be used again 4 Check the system for signs of age or damage Warning w Any hose which shows signs of age damage or distress must be replaced at once Hydraulic hoses a...

Page 48: ...n 6 3 6 Maintenance switches on page 48 For instance when the value is 1 2 then move the potentiometer rod 1 2 down 6 Check for oil leaks damage and wear and tear Check electrical cables and connectors for damage 7 If dry lubricate piston rod with machine oil 6 3 6 Maintenance switches Switches can be found in the control panel that can be operated by the fitter during maintenance to the lifting s...

Page 49: ...them Warning w Only replace the batteries with original Stertil Koni batteries Universal car batteries can produce explosive gases during normal charging Recharging defective or totally discharged batteries can cause explosive gases to be produced Table 6 2 Maintenance switches Switch Description Function UP Lifting Operates the relay for the electric motor of the lifting column controlled by this...

Page 50: ...ff the mains switch at the control box Turn the main switch to the 0 position to do this 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 Note n Technical ...

Page 51: ...then raise it approx 1 inch to be sure that the highest position is well above the locking position 3 Switch the function ON and exit the service menu Note n The setting is switched ON by all the columns in the set Each column sets the current height is set as the limiting height even if the current height has been raised or lowered with the SINGLE or PAIR functions This therefore means that the o...

Page 52: ...uard must then be switched OFF The screen shows the messages Warning 14 and Height difference guard is off There is also an acoustic signal when raising or lowering to alert the operator to the fact that this servicing operation is enabled Note n This setting is active for 10 minutes and the height difference guard is then automatically switched back ON again The height difference monitoring can b...

Page 53: ...system is switched off and on again 7 3 6 Odd number of columns This option allows odd numbers of columns to be accepted too By default Odd number of columns is OFF This helps avoid situations where a column is not properly registered or missed out accidentally while columns are being linked This setting can only be switched ON in specific cases and when expressly requested by the customer 7 3 7 H...

Page 54: ...ce between columns enabling it ON is recommended In contrast to the other service settings this particular setting must be made for each column individually 7 3 12 Weight dimension optional This setting shows the representation of the weight on the screen The choices are kg kilograms lbs pounds bar kg cm2 system pressure uA microamps the measurement range of the pressure transmitter is 0 to 20 000...

Page 55: ...ntinued with an acoustic signal 7 4 Error messages A red light FAULT will be continuously lit on the front panel when a fault occurs The screen provides information about the fault that has occurred See 7 5 Troubleshooting on page 58 for possible problems The system may also stop without an error having occurred This is reported on the screen the red lamp FAULT is not lit When lowering The lowerin...

Page 56: ...on stops and the message Maximum height reached appears on the screen One of the columns has reached its highest position The column lifts can be lowered normally Do not forget to press the UNLOCK button first Figure 7 3 Warning while raising WARNING 2 Maximum height reached ...

Page 57: ... Version 0 57 ST 1075 7 7 4 1 Service sticker The service sticker is behind the control box The items stated on the sticker include the type of main fuse used and how the various components on the controller PCB are connected Figure 7 4 Service sticker ...

Page 58: ...as follows The table indicates how the system can then be brought back to its normal status Figure 7 5 Warning Table 7 2 Warnings Code Screen text Possible cause Solution 01 Down stop limit exceeded Obstacle under the columns Raise a little and remove obstacle 02 Maximum height reached One of the columns has reached its highest position System can be lowered normally 03 Maximum programmed height r...

Page 59: ...ing the motor continues to run Set the system charging 07 Very low battery No more movements possible More than 15 raise actions on a single battery charge Set the system charging 09 Other column in service menu The service menu is open on one of the other columns Quit the service programme by pressing the SLOW LOWERING button tortoise 14 Height difference guard is off Setting in the service menu ...

Page 60: ... has a problem Check the screens on the other columns 06 Status error on another column Only occurs on column 1 other column s are not carrying out instructions Restart the system If the fault occurs again contact technical services 07 Output UP too long activated UP button stuck Check the push button 08 Output DOWN too long activated DOWN button stuck Check the push button 09 Output UNLOCK too lo...

Page 61: ...d coil defective or wires have come lose Check the wiring to the unlock magnet 29 Potentiometer power supply The supply voltage for the potentiometer is too low too high Cancel the fault by pressing SELECT and UNLOCK for 2 seconds If the fault occurs again contact technical services 30 Motor relay active The motor relay may have stuck Replace the motor relay 31 Motor relay not active The motor rel...

Page 62: ...tches are unlocked otherwise replace the PCB 37 Emergency loop open One of the emergency stop switches has been pressed Check whether all the emergency stop switches are unlocked 50 Odd number of columns An odd number of columns has been selected Reboot with an even number of columns or change in the service menu Table 7 3 Troubleshooting Code Screen text Possible cause Solution ...

Page 63: ...Fault message Table 7 4 Fault messages Code Screen text Possible cause Solution 71 No communication with the master column Distance between the columns too great time interval between messages too great Reboot the system If the fault occurs again contact technical services 72 No communication with a slave column Distance between the columns too great time interval between messages too great Reboot...

Page 64: ... the PCB Reboot the system If the fault occurs again contact technical services 82 Hardware failure external watchdog 83 Hardware failure EPROM 84 Hardware failure external RAM 85 Hardware failure EEPROM 86 Software failure Illegal state Table 7 4 Fault messages Code Screen text Possible cause Solution ...

Page 65: ...e correctly adjusted The pump s capacity is inadequate Replace the pump The maximum height difference more than 2 1 2 has been exceeded Cancel the fault by pressing SELECT and UNLOCK for 2 seconds If the fault occurs again contact technical services Table 7 6 The column lift cannot be lowered Cause Solution No battery power Check the main fuse above the batteries Have the batteries checked by a ba...

Page 66: ... 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 correction valve Have the valve ...

Page 67: ...FF Set the mains switch to ON Indicator lights and or screen defective Contact technical services Table 7 10 No control voltage Cause Solution Indicator lights and or screen defective Lifting system functioning normally Contact technical services The lifting system may not be set up properly Follow the procedures in 5 5 Operating procedure on page 40 If the fault occurs again contact technical ser...

Page 68: ... inside the guide block and ensure that it drops into the seating in the plate below the cylinder 2 Fit the hydraulic coupling at the bottom of the cylinder 3 Press the UP button to raise the cylinder Release the button as soon as the cylinder begins to raise the guide block the head of the cylinder must protrude through the hole in the top plate 4 Fit the bolt and the retainer tube 5 Then press t...

Page 69: ...e the adjustments are correct re tighten nut 1 7 7 List of parts See appendix A List of parts and appendices on page 75 and appendix B List of parts Options on page 93 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 c...

Page 70: ...ower 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 procedure may only be performed by persons who are trained in this procedure ...

Page 71: ...ging 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 72: ... combination with the column foot extensions The lifting capacity will be restricted to 12 000 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 with the longer wheel adapters Check the maximum weight carefully before lifting The lifting capacity with removed wheel adapters is ...

Page 73: ...ion 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 col...

Page 74: ...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 75: ...ir components A 1 Summary column lift on page 76 A 2 Hydraulic unit on page 78 A 3 Hydraulic scheme on page 80 A 4 Hydraulic cylinder on page 81 A 5 Control box on page 83 A 6 Electrical diagram control box on page 86 A 7 Pallet jack mechanism on page 87 A 8 Connection cable on page 89 A 9 Label locations on page 90 A 10 Dimensional drawing on page 92 ...

Page 76: ...Operating instructions Version 0 76 ST 1075 A 1 Summary column lift Figure A 1 Column lift See Figure A 2 See Figure A 2 ...

Page 77: ...1 30007400 Potentiometer unit 19 1 See Figure A 2 Hydraulic unit 20 1 See section A 7 Pallet jack mechanism 21 1 32700122 Pawl 22 2 Nut M4 DIN 934 23 1 30001004 Clamp 24 2 66201085 Buffer 25 1 69451400 Lifting magnet 26 1 Bolt M10x25 DIN 912 28 5 Bolt M6x10 DIN933 29 12 Washer M6 DIN125A 30 4 Washer M4 DIN 125A 31 4 Screw M4x10 DIN 7985 32 4 Retaining washer A24 DIN 679 33 2 Washer M10 DIN 127B 34...

Page 78: ...Operating instructions Version 0 78 ST 1075 A 2 Hydraulic unit Figure A 2 Hydraulic unit ...

Page 79: ...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 lowering Tightening torque 22 lbf ft 8 4 68510124 O ring 12 42 x 1 78 mm 9 2 69481501 Solenoid 24 VDC EC 30D 12 1 68039043 Pressure relief valve 265 bar Tightening torque 18 5 lbf ft 13 1 68039015 Half coupling pump side 15 1 68039014 Electric motor 3kW 24VDC 3300 rpm 16 1 32006261...

Page 80: ... 3 Hydraulic scheme Figure A 3 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 3 850 psi 6 L min ...

Page 81: ...List of parts and appendices Operating instructions Version 0 81 ST 1075 A A 4 Hydraulic cylinder Figure A 4 Hydraulic cylinder ...

Page 82: ...ssembly 1 1 Cylinder bottom 2a 1 O ring Ø56 74x3 53 2b 1 Backup ring 3 1 Retaining ring 4 1 Piston seal 5 1 Bearing ring 6a 2 O ring Ø34x3 6b 2 Backup ring 7 1 Piston 8 1 Cylinder 9 1 Piston rod 10 1 Guide post 11 1 Bearing ring 12 1 Piston cap 13 1 68228005 Hose burst check valve 14 2 68700451 Union GE 10 PSR 1 4 32599000 Seal kit ...

Page 83: ...List of parts and appendices Operating instructions Version 0 83 ST 1075 A A 5 Control box Figure A 5 1 Control box Figure A 5 2 Control box ...

Page 84: ...60 Connector PX0580 63 9 1 32737160 Connecting cable See A 8 10 2 32737175 Cable relays motor L 30 11 1 32737165 Cable switch fuse L 16 12 1 32737165 Cable battery switch L 16 13 1 32737180 Cable battery battery L 24 14 1 32737185 Cable battery motor L 40 15 1 69004002 Mains cable 16 1 69900160 PCB 17 1 32739050 Foil covered switch panel 18 1 69120018 Emergency stop button 19 2 69120020 NC contact...

Page 85: ...List of parts and appendices Operating instructions Version 0 85 ST 1075 A Figure A 5 3 Control box ...

Page 86: ...Operating instructions Version 0 86 ST 1075 A 6 Electrical diagram control box Figure A 6 Electrical diagram control box ...

Page 87: ...List of parts and appendices Operating instructions Version 0 87 ST 1075 A A 7 Pallet jack mechanism Figure A 7 Pallet jack mechanism 8 3 2 7 1 ...

Page 88: ...ks 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 ...

Page 89: ...0 89 ST 1075 A A 8 Connection cable Figure A 8 Connection cable Table A 8 Connection cable Index No Reference Description Remarks 1 1 32737160 Cable 39 9 assembly 2 2 69090106 Housing 3 1 69090108 Connector internals female 4 1 69090109 Connector internals male ...

Page 90: ...Operating instructions Version 0 90 ST 1075 A 9 Label locations Figure A 9 Label locations ...

Page 91: ...icker 16 500 lbs 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 14 1 60700238 Sticker SCHEMATIC DIAGRAM 15 1 60702002 Safety manual LIFTING IT RIGHT 16 1 60702003 Card SAFETY TIPS 17 1 60700131 Sticker CAUTION ATTENTION 19 1 60702008 Ameri...

Page 92: ...Operating instructions Version 0 92 ST 1075 A 10 Dimensional drawing Figure A 9 Dimensional drawing ST 1075 FBF ...

Page 93: ...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 1075 and their components B 1 Wheel adaptors and column extensions on page 94 B 2 Traverse beam on page 96 ...

Page 94: ...heel 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 95: ...s 2L 1 34200935 Longer wheel adaptor 16 Left length 500 mm 20 Max 8 800 lbs 3bR 1 34400930 Longer fork adaptor Right length 500 mm 20 Max 12 000 lbs 3bL 1 34400935 Longer fork adaptor Left length 500 mm 20 Max 12 000 lbs 4 2 32550915 Column extension 5 2 34400916 Shaft 6 4 1038 34 02 40 Retaining washer A24 DIN6799 7 2 65003530 Bolt M16x40 8 8 DIN 933 8 2 1037 07 50 16 Nut M16 DIN 439B 9 2 6505504...

Page 96: ...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 3 2 1 A A ...

Page 97: ...Reference 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 98: ...592000 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 99: ...C Operating instructions Version 0 99 ST 1075 C Inspection check list Annual inspection as described in the installation and service manual Date Remarks Name of mechanic Initials of mechanic pass ...

Page 100: ...Operating instructions Version 0 100 ST 1075 Date Remarks Name of mechanic Initials of mechanic pass ...

Page 101: ...sh limit 52 D Daily maintenance 43 Declaration of conformance 7 E Emergency lowering Procedure 50 Emergency lowering facility 70 Emergency shutdown button 34 Emergency stop 19 Error messages 55 63 G Guarantee 13 H Height difference guard 52 Height dimension 53 Height limit 51 Height monitoring 52 Hydraulic oil 45 I Inspection 43 Installation 26 K King pin adapter 73 L Language 53 Liability 13 Lift...

Page 102: ...mechanism 40 procedure 40 raising 37 system functions 41 Options longer wheel adapters 72 wheel adapters 71 P Pallet lifting mechanism adjustment 68 operation 40 Procedures maintenance 68 R REACH regulation 13 Replacement parts explanation 69 S Safety 14 emergency lowering 50 emergency stop 19 features 19 measures 19 when hoisting 29 Safety features 19 Safety indications 14 Service 50 Specificatio...

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