stertil-KONI ST1075-FBF Installation, Operation And Maintanance Instructions

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Mobile column lift

ST1075-FBF

Installation, operation

and

maintenance instructions

Page 2

PLEASE DELIVER TO THE LIFT ALL OPERATION, INSPECTION AND MAINTENANCE MANUALS, AND ALL OTHER INSTRUCTIONAL 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

Operating instructions (Version 0) 2 ST 1075

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Contents

Statement of conformity - - - - - - - - - - - - - - - - - - - - - 7

Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

1.1 Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

1.2 Limitations of the document - - - - - - - - - - - - - - - - - - - 11

1.3 Intended readership - - - - - - - - - - - - - - - - - - - - - - - 11

1.4 Scope of this manual - - - - - - - - - - - - - - - - - - - - - - 12

1.5 Symbols in the text - - - - - - - - - - - - - - - - - - - - - - - 12

1.6 Manufacturer's details - - - - - - - - - - - - - - - - - - - - - - 13

1.7 Guarantee and liability - - - - - - - - - - - - - - - - - - - - - - 13

1.8 Environmental aspects- - - - - - - - - - - - - - - - - - - - - - 13

1.8.1 Information about REACH - - - - - - - - - - - - - - - - 13

1.9 Disposal of the 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 Hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - 24

3.6 Column, lifting cylinder and guide block - - - - - - - - - - - - - 25

3.7 Control box - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

3.8 Pallet lifting mechanism - - - - - - - - - - - - - - - - - - - - - 25

3.9 Locking feature - - - - - - - - - - - - - - - - - - - - - - - - - 25

4 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

4.1 Unpacking and setup - - - - - - - - - - - - - - - - - - - - - - 26

Operating instructions (Version 0) 3 ST 1075

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4.2 Linking the column lifts- - - - - - - - - - - - - - - - - - - - - - 29

4.3 Safety when hoisting- - - - - - - - - - - - - - - - - - - - - - - 29

4.4 Traverse beam (option) - - - - - - - - - - - - - - - - - - - - - 32

4.5 Testing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

5 Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

5.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33

5.2 Control box - - - - - - - - - - - - - - - - - - - - - - - - - - - 34

5.2.1 Emergency shutdown button - - - - - - - - - - - - - - - 34

5.2.2 Starting and identification - - - - - - - - - - - - - - - - 34

5.2.3 Raising - - - - - - - - - - - - - - - - - - - - - - - - - 37

5.2.4 Lowering - - - - - - - - - - - - - - - - - - - - - - - - 37

5.2.5 Slow lowering - - - - - - - - - - - - - - - - - - - - - - 37

5.2.6 Lowering in the safety locks - - - - - - - - - - - - - - - 37

5.2.7 Information screen- - - - - - - - - - - - - - - - - - - - 38

5.3 Setting the columns - - - - - - - - - - - - - - - - - - - - - - - 39

5.3.1 Operating system - - - - - - - - - - - - - - - - - - - - 39

5.3.2 Pair operation - - - - - - - - - - - - - - - - - - - - - - 39

5.3.3 Operation of a single column- - - - - - - - - - - - - - - 39

5.4 Operating 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 Lubrication program - - - - - - - - - - - - - - - - - - - 45

6.3.2 Hydraulic oil - - - - - - - - - - - - - - - - - - - - - - - 45

6.3.3 Checking the safety battery capacity - - - - - - - - - - - 46

6.3.4 Checking the emergency shutdown mechanism - - - 47

6.3.5 Checking the safety locking feature - - - - - - - - - - - 47

6.3.6 Maintenance switches - - - - - - - - - - - - - - - - - - 48

6.3.7 Batteries - - - - - - - - - - - - - - - - - - - - - - - - 49

7 Service and troubleshooting - - - - - - - - - - - - - - - - - - 50

7.1 General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50

7.2 Emergency lowering procedure - - - - - - - - - - - - - - - - - 50

Operating instructions (Version 0) 4 ST 1075

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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

8 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

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

A.1 Summary column lift - - - - - - - - - - - - - - - - - - - - - - 76 A.2 Hydraulic unit - - - - - - - - - - - - - - - - - - - - - - - - - - 78

Operating instructions (Version 0) 5 ST 1075

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A.3 Hydraulic scheme - - - - - - - - - - - - - - - - - - - - - - - - 80 A.4 Hydraulic cylinder - - - - - - - - - - - - - - - - - - - - - - - - 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

Operating instructions (Version 0) 6 ST 1075

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Statement of conformity

Statement of conformity with the European Machinery Directive (2006/42/EC) and with the ANSI/ALI ALCTV 2006 and UL 201 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

Operating instructions (Version 0) 7 ST 1075

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The manufacturer is authorized to constitute the technical documentation.

The undersigned, U. Bijlsma, General Manager, authorized for this purpose by Stertil B.V., hereby declares that the mobile column lift described above conforms with the fundamental safety requirements set down in:

• 2006/42/EC Machinery Directive EN 61508 (SIL1), EN 1493, EN 418, 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 Telephone: 607-753-6711 Fax.: 607-756-9891 WEB: www.intertek-etlsemko.com Under report no.: 3107897CRT-001

Stertil B.V. Kootstertille

U. Bijlsma General Manager

Signature:

Date: 01 January 2013

Operating instructions (Version 0) 8 ST 1075

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Preface

Prior to the operation of your Stertil Koni mobile lift, make sure that you read the instructions thoroughly. These instructions are found in this manual. Please note that your warranty can be voided if you do not read the manual and understand its contents

If you have any questions concerning operation, safety or application of your mobile lift, please contact Stertil Koni USA at the following toll free number: 800 336 6637 or call 410 643 9001. The address for Stertil Koni USA Inc. is 200 Log Canoe Circle, Stevensville, Maryland 21666.

The operator shall have certain qualifications before he/she can safely operate a Stertil Koni mobile lift and these include ability in written or oral communications as demonstrated by either a high school diploma or certificate of equivalency, aptitude test or job experience. He/she must also have the ability to understand the mathematical, mechanical and electrical principles of automotive lifts as demonstrated by one of, or a combination of aptitude test, training program, technical vocational school or job experience.

The owner/employer of the Stertil Koni mobile lift must ensure that the operator of the mobile lift must be instructed and trained in the safe use and operation of 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 conspicuous location in the lift operating area.

The owner or employer shall appropriately document operator training by completing an operator-training log, which shall be part of the management documentation.

The operator shall operate the automotive lift only after being properly instructed or trained in accordance with manufacturer supplied instructions found in the 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 operator fail to inspect or take notice of the following features on a daily basis.

1. Accessibility and readability of the operating procedures, safety tips and generic safety material.

2. Accessibility and readability of safety warning labels.

3. Readability of the rated load capacity of the lift.

4. Proper operation of the lift controls, restraints and locking devices.

Operating instructions (Version 0) 9 ST 1075

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5. Deformation or excessive wear of any of the lift structural components.

6. Deformation or excessive wear of other components such as hoses, electrical wires.

7. Evidence of hydraulic leaks.

8. Unusual noises.

If any of the conditions described above are observed before, during or after operation of the lift, the operator shall stop using the lift and report the condition to the supervisor, employer or owner. If any of the conditions listed above are observed, then the lift shall not be used until the cause of the problem has been determined and the appropriate repairs made by qualified Stertil Koni service authorized personnel. In order to ensure that the lift is not used until the repairs have been affected, the lift shall be locked out or tagged in accordance with ANSI/Z244.1

1982.

Note

n ‘Trained lift service personnel’ refers to personnel of the Stertil-Koni service

department or another servicing agency recognized by Stertil-Koni, both 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 out for in this manual or in this notice.

Please note that there shall be no modifications or reconstruction made to the Stertil Koni mobile lift without the express written permission of the manufacturer.

Please make sure that caution labels are not frayed and are on the lift. Please call the manufacturer if these caution labels have been removed or through age are no longer on the lift.

Please read and understand the attached Statement of Warranty for the Stertil Koni mobile lift.

Thank you for the purchase of your Stertil Koni product.

Please contact Stertil Koni USA for the location of authorized Service Centers throughout the United States.

Stertil 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

Operating instructions (Version 0) 10 ST 1075

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1 General

1.1 Copyright

All rights reserved worldwide. No part of this publication, including drawings and diagrams, may be reproduced and/or published, whether by printing, photocopying, microfilm or by any other means whatsoever, without the prior written permission of Stertil B.V.

1.2 Limitations of the document

Stertil B.V. reserves the right to modify the construction and/or configuration of its products at any time without any obligation to modify products which have been previously supplied. The data provided in this manual is based on the most recent information. This data may be subject to change at a later date, without prior notification. For information regarding adjustment, maintenance or repair which is not described in this document, please contact the customer service department of Stertil B.V.

The information in this document concentrates solely on 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 other than the order confirmation.

This manual contains useful and important information on the correct operation and proper maintenance of the product. Furthermore, the manual also contains important instructions for installing the product and instructions for preventing possible accidents and serious injury while the machine is running. We have taken all possible steps to make this manual as correct and as complete as possible. Should you discover any errors or omissions, please bring this to the attention of our service manager, so that we can make amendments. This will enable us to improve our documentation.

1.3 Intended readership

This manual is intended for users, fitters and service engineers for mobile column lifts of type ST 1075.

Operating instructions (Version 0) 11 ST 1075

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Persons who are not familiar with the operation and installation of type ST 1075 mobile column lifts are advised to read the following chapters thoroughly and to follow the instructions given exactly.

Persons who are familiar with the operation and installation of type ST 1075 mobile column lifts can use this manual as a reference. The table of contents and the index can be used to search for the information required.

1.4 Scope of this manual

This manual contains important information about the operation, installation and servicing of type ST 1075 mobile column lifts.

For information 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 followed, otherwise the machine or materials may

be damaged. Follow the procedure exactly.

Warning

w Indicates a procedure or action which, if performed incorrectly, can lead to personal

injury or may cause damage, or otherwise indicates a prohibited action. Ignoring the warning can lead to accidents, personal injury or serious damage to the machine.

Notations between <> such as e.g. <DOWN> indicate the control buttons of the column lift.

Operating instructions (Version 0) 12 ST 1075

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General

1.6 Manufacturer's details

Stertil B.V. P. O . B o x 2 3 9288 ZG Kootstertille Telephone (international): +31(0)512 334 444 Telephone (national): (0)512 334 441 Fax: +31(0)512 332 638 E-mail: [email protected] Website: www.stertil.nl

1.7 Guarantee and liability

Please refer to the delivery terms and conditions, and the order confirmation.

1.8 Environmental aspects

The owner and/or user of the mobile column lifts is responsible for the disposal of waste materials (oil, etc.) in accordance with the applicable local laws or regulations.

1.8.1 Information about REACH

The REACH regulation entered into force 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 materials and substances used in our products.

Your local dealer will provide relevant information e.g. Material Safety Data Sheet (MSDS) on request.

1.9 Disposal of the column lifts

Once the mobile column lifts have reached the end of their operational lives, the owner and/or user is responsible for the safe disassembly of the mobile column lift and for the disposal of the components, in accordance with applicable local laws or regulations.

Operating instructions (Version 0) 13 ST 1075

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2 Safety

2.1 Introduction

Our safety requirements may under no condition conflict with the statutory requirements and rules that apply to the safety of the mobile lift. Whenever one of the warnings or safety requirements conflicts with existing local legislation, the most stringent rule will always take precedence. Our mobile lifts type ST 1075 are protected in accordance with the rules for this type of equipment.

It is not permissible to carry out any changes to the mobile lift without our written consent. If any damage to persons or property is caused as a consequence of not complying with this requirement, Stertil B.V. will accept no liability for such damage.

The manager of the 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 symbols and arrangements that the user needs to understand. For the indications in the text, see 1.5 ’Symbols in the

text’ on page 12.

2.3 Safety instructions

Read all instructions. The mobile lift is provided with safety and protection features. Even so, caution is required when using the mobile lift

Work safely!

Stertil B.V. has made every effort to inform you as correctly and completely as possible on any dangers associated with operation of the mobile lift. You must ensure and are responsible for compliance with these behavioral guidelines.

Operating instructions (Version 0) 14 ST 1075

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The buyer/user is obliged to familiarize operating, cleaning and maintenance personnel with these instructions.

Upon their arrival, check deliveries for:

• Any damage and/or missing parts due to transport. Make sure that the carrier

draws up a transport damage report on the spot.

• Correctness and completeness; have all parts (additionally) and or accessories

ordered been supplied?

In the event of damage always contact Stertil B.V. or the supplier.

All worn or broken parts need to be replaced with genuine lift manufacturer supplied parts.

Safety

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 to pull the plug from the outlet. Grasp plug and pull to disconnect.

• Let equipment cool completely before putting

away. Loop cord loosely around equipment when storing.

• To reduce the risk of fire, do not operate

equipment in the vicinity of open containers of flammable liquids (gasoline).

• Provide adequate ventilation when working on

internal combustion engines.

Operating instructions (Version 0) 15 ST 1075

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• 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

eyeglasses only have impact resistant lenses they are not safety glasses.

• Use by 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,

ensure that the mobile lift is disconnected from the power supply.

• Take care as burns can occur from touching hot

parts.

• Prevent damage to the power feed cables on

account of driving over or heavy or falling objects.

Operating instructions (Version 0) 16 ST 1075

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Safety

• Do not operate equipment with a damaged cord or

if the equipment has been dropped or damaged until it has been examined by a qualified serviceman.

• In case of using one or two lifting columns (in

paired operation), be sure that this will not result in stability risks. In case of doubt, consult your superior. 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 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 track width and/or wheel base.

• Use the lifting columns only on a hard and level

floor with sufficient bearing capacity, see the specifications for floor pressure and floor load in

Table 3.1 ’Specifications’ on page 22.

• Whenever a vehicle is raised on the lift, always

raise the mobile column lifts to at least above the first safety lock.

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• Always lower the mobile column lifts into the

safety lock before starting any work on the vehicle or leaving the vehicle unattended.

FOR YOUR AND OTHER PEOPLES SAFETY: SAVE THESE INSTRUCTIONS.

Warning

w All accessories supplied with this lift are to be used on this lift only.

Accessories from other lifts are not acceptable and could result in injury to the user.

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 Requirements for Operation Inspection and Maintenance; ALI/WL Series, ALI Uniform Warning Label Decals/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 the inspection of the lift.

• Maintain the periodic inspection and maintenance records recommended

by the manufacturer or 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 the inspection of the lift.

• Display the lift 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 Requirements for Operation Inspection and Maintenance; in a conspicuous location in the lift area convenient to the operator.

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• Provide necessary lockout/tagout means for energy sources per ANSI

Z244.1-1982 (R1993), Safety Requirements for the Lockout/Tagout of Energy Sources, before beginning any lift repairs.

• Not modify the lift in any manner without the prior written consent of the

manufacturer.

Safety

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 the mobile column lifts have been damaged.

2.5.2 Safety features

The mobile column lifts have a control and monitoring 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 disabled,

• the lowering action stops 12’’ above the floor; if the <DOWN> and <UNLOCK>

buttons are pressed again, the column will be lowered further with an accompanying acoustic signal; this option (foot protection) can be enabled or disabled; by default it is disabled,

• lifting is halted when the highest position is reached (height safeguard),

• the lifting columns cannot be operated if one or more of the columns are lifted

using the pallet lifting mechanism.

• lowering is mechanically blocked in the event of loss of control power or leakage

from the cylinders.

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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

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Safety

Figure 2.2 Safety and warning labels

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3 Specifications

3.1 General

The general specifications are also printed on the type plate on the mobile column lift.

Table 3.1 Specifications

Model ST 1075-FBF

Lifting capacity 16,500 lbs Pressure relief valve 3,800 psi (sealed with plastic cap ex-

Maximum lifting height 69"

works)

Electric power rating 4HP Mains power

(battery charger) Motor 24VDC 130Amps Charging current

Charger type

Charging time when 70% discharged

Number of complete lifting actions (fully charged batteries)

Main fuse 24VDC 200A (slow-blow) Control voltage 24VDC Raising/lowering time 75 / 55 s Noise level Max. 73 dB(A) Installation Inside Weight 1250 lbs Maximum distance between two column

lifts

115 VAC / 60Hz/7A 230 VAC / 50Hz/3A

24VDC/10,5A (20 min) / 24VDC/6,25A (continuous)

Automatic charger; can remain connected during use and in storage.

9 hours 22 (fully loaded)

33 (half loaded)

approx. 29' - 6"

Maximum floor surface pressure 7500 psi

(per front wheel)

Maximum floor loading 6300 lbs

(per front wheel)

Operating temperature 5 to 122

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3.2 Lifting capacity

See Table 3.1 for specifications of the maximum lifting capacity. The overpressure safeguard in the hydraulic unit has been preset so that the lift can never raise more than the specified weight +10%.

The design is calculated for a maximum load of 16,500 lbs on any one column.

3.3 Lifting system

This mobile column lift is an electrically driven hydraulic column lift 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.

Specifications

1. Column

2. Potentiometer

3. Locking pawl

4. Hydraulic unit

5. Control box

6. Electrical connector

Figure 3.1 Main components of a mobile column lift

The columns have an integrated power supply (batteries with charger).

Operating instructions (Version 0) 23 ST 1075

7. Main switch

8. Automatic battery charger

9. 200A fuse holder

10.Batteries

11.Pallet lifting mechanism

12.Guide block

13.Lifting fork

14.Wheel adapter (option)

15.Cylinder

16.Fixed wheels

Page 24

The columns are coupled together by an identification procedure (with an ID key). The control signals that ensure synchronised movement of the columns, are transmitted through the air.

3.4 Control system

The control system on the columns ensures that raising and lowering of the column lifts is simultaneous and synchronised, independent of the load distribution on the columns.

Each column lift has a potentiometer that detects the height position and passes it on to the control system. The control system controls and protects the lifting system during raising and lowering in the following manner:

• When there is a elevation difference of more than 5/8" and less than 1 1/4", an

extra correction valve in the hydraulic system opens until the elevation difference between the column lifts is eliminated.

• Lowering will be interrupted when the 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 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 33).

Warning

w Controlling individual column lifts and/or pairs of axles is exceptionally hazardous.

Refer to 4.3 Safety when hoisting on page 29.

The control is equipped with a number of programmable settings; see 7.3 Programmable settings on page 51

3.5 Hydraulic unit

The hydraulic power unit comprises an electrically powered pump, flow control valves, control valves and a fluid reservoir.

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Specifications

3.6 Column, lifting cylinder and guide block

The column and lifting cylinder together form the most important part of the mobile column lift. A guide block with rollers is located within the U-shaped profile of the column. The rollers enable the guide block to move up and down the entire length of the column. The lifting force is supplied by the hydraulic lifting cylinder.

3.7 Control box

The control panel on the front of the control box has all functions necessary to control the operation of the column lift. An emergency stop switch is also located on the control 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 raises the rear of the column off the floor so that it can be moved more easily.

3.9 Locking feature

If the hydraulic pressure fails while a vehicle is being raised, lowered or standing still above the first safety lock on the lifting system, a mechanical safeguard will ensure that the vehicle cannot fall.

The characteristic clicking sound indicates that the locking pawl is active. When lowering, the pawl is retracted by a solenoid.

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4 Installation

4.1 Unpacking and setup

Proceed as described below when unpacking and setting up each column.

Warning

w Only use proper lifting equipment to move the column lift. Lift the column only at the

points intended for this. Failure to relocate the column lift in the right manner can cause damage to the column lift and/or personal injury.

1. Transport the column lift to the location where 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 ).

Hoisting belt

Crate or pallet

Figure 4.1 Lifting the column

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. Attach a hoisting belt to the top of the column.

6. Raise the column until it is upright.

7. Remove the hoisting belt.

8. The control cabinet assembly can now be put together (if delivered separately).

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9. Hang the entire assembly for the control cabinet on the bracket on the column.

10. Remove the two M6 bolts and open the door.

11. Fix the frame in place with the four M6 bolts.

12. Attach the potentiometer (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

Installation

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) from the motor to the negative terminal of the bottom battery.

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1. Control box

2. Relay (24V/150A)

3. Battery charger

4. Main switch

5. Fuse holder

6. 200A main fuse

8. Charging cable connector

9. Charging cable

10. Relay-motor cable

11. Switch-fuse cable

12. Pos. battery terminalswitch cable

13. Neg. battery terminal-pos. battery terminal cable

14. Neg. battery terminal-moto cable

7. Battery

Figure 4.2 Connections

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18. Also attach the negative cable (3) from the battery charger to the negative terminal of the bottom battery.

19. Connect the positive of the black connector cable (13) to the positive of the battery.

20. Place the top battery with the negative terminal on the same side as the battery charger.

21. Connect the red positive cable (12) to the positive terminal of the top battery.

22. Also connect the red positive cable from the battery charger (3) to the positive terminal of the top battery.

23. Connect the negative of the black connector cable (13) to the negative of the top battery.

24. Connect the RF-module.

25. Connect the safety swich according to the electrical drawing.

26. Remove the stopper from the filler opening and attach the air bleed cap.

27. Close the door and fix it in place with the two M6 bolts.

28. Check for oil leaks.

Installation

4.2 Linking the 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 capacity for the ST 1075 model is 16,500 lbs per column; a set of 4 can therefore lift 66,000 lbs (max.).

Note

n By default, the operating system will only accept an even number of columns.

This helps avoid situations where a column is not properly registered or missed out accidentally while columns are being linked. After the link procedure, the number of columns found is reported and this is continually visible on the screen. In specific cases, the service team can disable this additional check.

4.3 Safety when hoisting

In principle, the individual and per-axle control over the column lifts is intended to enable the vehicle to be raised horizontally, or alternatively to be lowered onto axle supports.

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Safety guidelines:

• When operating an individual column 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.

16,500 lbs

Centre of gravity of the

16,500 lbs

vehicle 66,000 lbs

16,500 lbs

Figure 4.3 Centre of gravity and weight distribution

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If one of the columns is lowered too far, it can have the following consequences:

• No load on that particular column.

• No load on the column diagonally opposite.

• Double load on the remaining columns.

Installation

33,000 lbs

Example: this column is too low

No load

Centre of gravity of the vehicle 66,000 lbs

33,000 lbs

No load

Figure 4.4 Overloading of 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 ).

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Figure 4.5 Hoisting floating axles

4.4 Traverse beam (option)

For the lifting and lowering of trailers on a set of mobile lifting columns, a special Stertil-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.

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5Operation

5.1 General

The mobile column lifts are designed to provide maximum flexibility and ease of use. A lifting system may consist of 2 to 8 columns in total.

The following possibilities are available within the control 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 needing to set any selector switches.

Figure 5.1 Control box connection

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5.2 Control box

All functions of the lifting system are controlled from the control box on the column lift (see Figure 5.2 ).

1. Emergency stop button

2. Information screen

3. UP button

4. DOWN button

5. <SELECT> button

6. UNLOCK button

Figure 5.2 Control box

Note

7. Slow lowering selection button

8. <FAULT> indicator

9. <ALL> indicator

10. <SINGLE> indicator

11. <PAIR> indicator

12. ID key reader (antenna)

13. ID key

14.Interconnection cables

n Operate the panel only with your fingertips. Pressing the buttons using sharp objects

(such as screwdrivers) can damage the equipment and cause errors.

5.2.1 Emergency shutdown button

If the emergency shutdown switch 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.

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To start the mobile lift (see Figure 5.2 ):

• Select an (even) number of columns (2-8) that are jointly to define a set.

• Check that all the emergency stop switches are unlocked.

• Place the columns with the forks around the wheels of the vehicle.

• Check that interconnection cables have formed a closed loop.

• Set the main switch of each column to <1> (ON) and follow the on-screen instructions.

CABLED V3.22

Figure 5.3 Startup screen

Operation

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.

START-UP

HOLD ID-KEY IN FRONT OF

ANTENNA SYMBOL

Figure 5.4 instructions on the screen

START-UP

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2. The columns are now linked. This is shown by: <4 COLUMNS FOUND>.

STARTUP COMPLETED

COLUMNS FOUND

Figure 5.5 instructions on the screen

and then immediately afterwards, <READY>.

READY

Figure 5.6 instructions on the screen

The mobile lift is now ready for use.

Note

n The ID key allows any random set from a number of columns to be linked together.

It is therefore practical to give all the engineers their own ID keys, so that they can link columns together themselves as needed.

Note

n The ID keys have unique individual identification codes, so that different keys can

be used to start 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 with the other columns with the same ID number. If another column from the same selection is selected once again with the ID key, then there is a possibility of two random sets being created.

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Operation

5.2.3 Raising

To raise the column lifts, press the UP button (3). There is an arrow pointing up beside this button.

5.2.4 Lowering

Operate button (6) simultaneously with button (4) to lower the column lifts. There is an arrow pointing down next to button (4).

Note

n If the foot protection has been enabled, the lowering action will be interrupted at

approx. 12’’ above the floor. The column will be lowered further, with an acoustic signal, when button (6) and button (4) are pressed again simultaneously.

Warning

w If problem situations arise during raising or lowering, release the control buttons or

press the emergency stop.

5.2.5 Slow lowering

1. Press the <SLOW LOWERING> button (turtle symbol). This function is activated if the LED in the button is illuminated.

2. Press the button again to deactivate the function.

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. Once the elevation difference has been levelled, the column will again be lowered.

5.2.6 Lowering in the safety locks

For lowering on the safety locks, simply press the DOWN button (4). The column lifts will then lower no more than 1 3/8”, until the safety pawls engage the teeth in the safety lock profile. The drop-safeguard pawls can then no longer be released. If the UNLOCK button (6) is now pressed, there will be no sound of the pawls being released. Raise the column lifts again (to relieve the safety lock) so that the column lifts can resume lowering.

Warning

w Always lower the column lifts in the safety locks before carrying out any work on the

vehicle.

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The buttons for raising, normal lowering and lowering in the safety locks are of the "dead man" type (hold to run). Operation continues as long as the button remains pressed, and stops immediately once the button is released.

Note

n In the event of malfunction, consult the troubleshooting section

(see 7.5 "Troubleshooting" on page 58).

5.2.7 Information screen

The information screen informs the user about various operational statuses.

1. Operating symbols

234

(e.g. lowering and locking)

2. Work timer

3. Set size

4. Column number

5. Lifting height

6. Battery meter

Figure 5.7 Information screen

Battery meter:

indicates the charge level of the batteries - see also 6.2.1 "Daily checks by the 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 timer stops again as soon as the mobile lift is lower than 2 inches. This can be seen by the fact that the colon is shown continuously. This time can be used to determine how long the work on the vehicle took.

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Operation

5.3 Setting the columns

5.3.1 Operating system

1. Link the columns - see 5.2.2 "Starting and identification" on page 34.

2. All system functions are now available (the default is <ALL> all columns):

- button 3 = all columns will be raised,

- button 4 = all columns will be lowered into the safeguard,

- buttons 6 and 4 = all columns will be lowered.

5.3.2 Pair operation

Note

n Setting to the pair operation (only possible when you have an even number of

columns):

1. Select the 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 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: Set of 4: select 1 pair and the remaining columns automatically become a pair. Set of 6: select 2 pairs and the remaining columns automatically become a pair. Set of 8: select 3 pairs and the remaining columns automatically become a pair.

5.3.3 Operation of a single column

1. Press <SELECT> until the <SINGLE> light has been activated.

2. Press button 3 to raise the single column or press button 4 to lower the single column.

Note

n An acoustic signal will be emitted when “SINGLE” UP and DOWN are operational,

because this is an unusual situation.

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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.

1 2

Lever

Drawbar

Figure 5.8 Pallet lifting mechanism

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 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,

Figure 5.9 Bay size

• the maximum load on each column will not exceed 16,500 lbs,

• the lifting system is perfectly vertical, when viewed both from the front and the

side,

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• the pallet lifting mechanism is set to the bottom position.

5.5.1 Preparation

1. Fit wheel adapters to the forks of the column lifts if necessary.

2. Set up 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 mains switch on the control box of the column(s) is set to 0 (OFF).

6. Link the columns - see 5.2.2 "Starting and identification" on page 34.

7. Check the mechanical safeguard by pressing the UNLOCK button (6) a few times. You should clearly hear the noise of the pawls.

5.5.2 System functions

Operation

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> (button 5) and <PAIR> (light 11) and <DOWN> (button 4)

one axle is lowered (2 column lifts).

<SELECT> (button 5) and <SINGLE> (light 10) and <UP> (button 3)

one column lift is raised

<SELECT> (button 5) and <SINGLE> (light 10) and <DOWN> (button 4)

one column lift is lowered.

<TURTLE> (icon) and <DOWN> (button 4)

columns are lowered slowly. This works for <ALL>, <PAIR> and <SINGLE>.

Note

n Lower the column lifts into the safety locks and set the mains switch to 0 (OFF) once

the desired height has been reached.

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Note

n Turn the main switch off when the columns are not in use.

The (slight) power consumption of the controller can discharge the batteries, so that raising and lowering become impossible. The system switches itself off complete discharge is imminent.

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 column lifts manually. Manual lowering may only be carried out by an authorized technician.

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6 Inspection and maintenance

6.1 General

Always completely lower the column lifts and switch off the mains power switch (position 0) during inspection and maintenance.

The power may be only temporarily switched on, and the lift placed in a higher position, when required for performing certain checks and adjustments.

Warning

w When the column lifts are in a raised position, always lower them into the safety lock.

Once a year, the column lifts must be subjected to a thorough check by a technical 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 "Checking

the safety locking feature" on page 47.

Note

n If this does not function correctly, consult the technical service.

2. Check the emergency shutdown mechanism as described in § 6.3.4 "Checking the

emergency shutdown mechanism" on page 47.

3. Carry out the monthly lubrication programme as set out in Table 6.1 "Lubrication

program" on page 45.

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6.2.3 Annual maintenance by trained lift service personnel only

The user must have the column lifts inspected once a year by the Stertil technical service or another technical service authorized by Stertil (both hereafter referred to as the technical service). A maintenance subscription can be taken out with the technical service for this annual inspection. In the event that no maintenance subscription has been taken out, the user must make an appointment each year for this inspection and servicing.

This inspection is signed off on the inspection checklist (see appendix A of the Operating Instructions.)

The following tasks must be carried out:

1. Inspection as described under daily and monthly.

2. Check oil level. Check the oil level in the tank 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.

Caution

c ANY DIRT OR CONTAMINATION WHICH IS FOUND IN 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 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 for leakage from the cylinders. If oil is leaking from one of the cylinders, the seals and the guide rings must be replaced.

7. Check for leakage from the hydraulic system. If the column lift sinks back down by more than 6mm per hour, then the system must be inspected for external (hoses, couplings) and internal (valves) leakage. Defective parts must be replaced.

8. General inspection for damage. If cracks have appeared in structural components, then the parts in question must be replaced. Immediately repair or replace all parts which could cause hazardous situations.

9. Perform all lubrication tasks set out in Table 6.1 "Lubrication program" on page 45.

Operating instructions (Version 0) 44 ST 1075

Page 45

Inspection and maintenance

For additional details, see chapter 7 "Service and troubleshooting" on page 50.

Table 6.1 Lubrication program

Every 2

years

(technical

service)

Maintenance tasks Description Monthly

Cylinder Lubricate piston rod if

Annual

(technical

service)

dry (machine oil)

Check oil level in tank Top up (only with

x column lifts fully lowered)

Various pivot points Lubricate x

Hydraulic oil in the tank Replace (2.6 gallon) x

Suction filter Clean or replace x

Safety lock Check and clean if

required

Safety lock Disassemble, clean

x and (if necessary) replace and adjust (see § 6.3.5)

6.3 Maintenance procedures

6.3.1 Lubrication program

The column lifts must be serviced regularly in accordance with the lubrication program.

6.3.2 Hydraulic oil

Replace the hydraulic oil in the tank approximately once every 2 years.

Note

n This oil change must take place as scheduled, even 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.

Operating instructions (Version 0) 45 ST 1075

Page 46

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.

6.3.3 Checking the safety battery capacity

The battery capacities must be checked daily.

The battery capacity can be read off on the left of the screen.

Battery meter (full)

READY

Figure 6.1 battery capacity

When the batteries get low, the following warnings are issued:

ARNING 5

Weak battery. Lowering and shortly up possible

Figure 6.2 Warnings

It is recommended that the batteries should be recharged when the capacity has dropped to half (just three markers remaining). Under normal conditions, the batteries need to be recharged after 26 cycles (ST 1060) or 22 cycles (ST 1073) under full load.

Recharging an empty battery takes 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 batteries are being charged. Green signs that the batteries are charged sufficiently to work properly.

Low battery. No more movements possible

ARNING 6

If the green sign is blinking while the charger is connected, this means that the charger is charging by small portions. This is a normal situation and is to prevent self-discharge of the battery.

Operating instructions (Version 0) 46 ST 1075

Page 47

If the columns are not going to be used for a lengthier period (2 or 3 weeks), the charger can remain connected to the mains. The columns have an automatic charger, so there is no possibility of the batteries being overloaded.

Note

Inspection and maintenance

n Turn the main switch off when the columns are not in use.

The (slight) power consumption of the controller can discharge the batteries, so that raising and lowering become impossible. The system switches itself off complete discharge is imminent.

Warning

w Do not use an external battery charger (booster) to charge the batteries. Only use

the built-in Stertil-Koni battery charger. Loading the batteries with a standard charger can cause explosive gases to be produced.

6.3.4 Checking the emergency shutdown mechanism

1. Press the emergency shutdown button on the auxiliary boxes while the column lifts are moving. All column lifts must 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 are under very high pressure, and failure or malfunction could result in personal injury and failure of hydraulic components. Consult your authorized representative for proper fittings, hoses, or repairs.

6.3.5 Checking the safety locking feature

1. Raise the lift to the first locking position above the floor and lower it into the 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”.

Operating instructions (Version 0) 47 ST 1075

Page 48

5. Adjust the top position end stop as follows: move the column lifts to its lowest position and look at the display. If the height is not 0", then the potentiometer rod must be adjusted. This is only possible at the highest position. The highest position can only be reached by using the maintenance switches at the rear side of the electrical panel (see section 6.3.6 "Maintenance switches" on page 48. For instance, when the value is 1/2", then move the potentiometer rod 1/2" down.

READY

at least1/8"

Figure 6.3 Adjusting the safety lock

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 system. These switches can be used to check whether the lowering valve, the unlocking solenoid and the hydraulic power unit are functioning properly.

Operating instructions (Version 0) 48 ST 1075

Page 49

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 Maintenance switches

Switch Description Function

<UP> Lifting Operates the relay for the electric

<MS> Main relay This operates the main relay.

<DWN> Lowering and unlocking Controls the lowering valve and

Inspection and maintenance

motor of the lifting column controlled by this switch. Has to be activated together with <MS> to raise the lifting column.

the solenoid for unlocking the column on which this switch is operated. Has to be activated together with <MS> to lower the lifting column.

6.3.7 Batteries

The batteries are maintenance-free and do not require additional attention when used normally. Clean the battery terminals if necessary and tighten 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.

Operating instructions (Version 0) 49 ST 1075

Page 50

7 Service and troubleshooting

7.1 General

Faults in the column lifts can have simple causes. Check the installation for the possible causes indicated.

If troubleshooting as described below fails to correct the malfunction, please contact technical services.

Most errors can be corrected without having to remove the vehicle from the column lifts. However, it is strongly recommended that you remove the vehicle, if the column lifts are completely lowered.

When troubleshooting or repairing the column lifts, set them to the lowest position. If the malfunction makes this impossible, then ensure that all pawls are engaged in the safety locks (lower without unlocking).

Turn off 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 service is taken to mean either the Stertil technical service or another

technical service authorized by Stertil.

The following troubleshooting guide can be used to identify possible defects. If in doubt, contact technical services.

7.2 Emergency lowering procedure

In emergency situations, when it is not possible to lower the column lifts from the control box, the column lifts can be lowered manually.

Warning

w The emergency lowering procedure must only be performed by persons who are

trained in this procedure.

Operating instructions (Version 0) 50 ST 1075

Page 51

Service and troubleshooting

7.3 Programmable settings

Pressing <SELECT> and <SLOW LOWERING> (turtle) continuously for 2 seconds activates the service menu.

The screen looks like this:

SERVICE MENU

Height limit OFF Unlock during up OFF Crush limit ON Height diff.guard ON Height guard ON Odd nr of columns OFF

Figure 7.1 Service menu

The functions can be selected using the <UP> and <DOWN> buttons:

Height limit Height dimension Weight category Unlock during up Language Motor type Crush limit Motor run hrs Footguard Height diff.guard System run days Height guard ZB:Long distance Odd nr of columns Weight dimension

The <SELECT> button enables or disables a function.

The <SLOW LOWERING> (turtle) button confirms the choice and exits the service menu.

7.3.1 Height limit

If this function is <OFF>, the mobile lift stops in the highest position at the fixed value set in the software. The height limit can be programmed as follows:

1. Position the column at the required height.

2. Lower the column lift into the pawls and 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 other columns can have a height limit that differs from the height limit for the column that it was set from.

Operating instructions (Version 0) 51 ST 1075

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7.3.2 Unlock during up

This option is available so that the pawls are operated when the UP button is operated. This will suppress the clicking noise while raising.

This function has no effect on the safety of the column lift. The pawl will be pulled in again when the <UP> button is released. "Unlock during up" is active when the function is <ON>.

7.3.3 Crush limit

A height of approximately 12 inches is set when using a remote control, beneath which the lowering function will no longer function. This function is enabled by default. This function must only be disabled during maintenance work on the column.

7.3.4 Height difference guard

This option ensures that the column can operate outside the cutoff limits (3/4" when being lowered and 2 3/8" when being raised). This can be used to level the lift outside the safe limits. Height difference guard 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 be switched back <ON> again from the service menu. This setting is not stored in memory, so height difference guard is always switched <ON> after the system is switched off and on again.

7.3.5 Height monitoring

This option ensures that the value at the potentiometer input is replaced by a constant value. The column will function normally without the height differences being corrected. This can be used to check whether the potentiometers (for height measurement) are working properly. Height guard must then be switched <OFF>.

If the height differences between the columns become larger during raising and lowering, there may be problems in the hydraulic circuit or other mechanical faults.

Operating instructions (Version 0) 52 ST 1075

Page 53

The screen shows the messages <Warning 15> and <Height 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 2 minutes and the height difference guard is then

automatically switched back <ON> again. The height difference guard can be switched back <ON> again from the service menu. This setting is not stored in memory, so height monitoring is always switched <ON> after the 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.

Service and troubleshooting

7.3.7 Height dimension

This setting can modify how the height is read on the screen.

You can choose between centimeters <cm> or inches <">.

7.3.8 Language

This setting allows the language used on the screen to be selected. There is a choice of:

Table 7.1 Language settings

Setting Language

NED Dutch ENG English DEU German FRA French ESP Spanish POL Polish POR Portugese ITA Italian

Operating instructions (Version 0) 53 ST 1075

Page 54

7.3.9 Motor run time hours

This shows the time (in hours and minutes) that the motor has run for. The time is stored by the controller and cannot be reset. If a new PCB is fitted, though, the measurement will start at zero again.

7.3.10 System run time

This shows the time (in days and hours) that the controller has run for. The time is stored by the controller and cannot be reset. If a new PCB is fitted, though, the measurement will start at zero again.

7.3.11 Long distance

This function is disabled <OFF> by default.

This is the recommended position for indoor use.

For long distance 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 uA)

The load is derived from the hydraulic pressure in the lifting cylinder.

Note

n If the lifting fork is resting on the pawl, the pressure drops and the load indicator

shows 0 lbs.

7.3.13 Weight category (optional)

In order for the weight to be displayed correctly, the correct type of vehicle lift must be entered:

• 082 = ST1082 (cylinder diameter. 70 mm)

• 073 = ST1073 (cylinder diameter. 63 mm)

• 060 = ST1060 (cylinder diameter. 55 mm)

Operating instructions (Version 0) 54 ST 1075

Page 55

7.3.14 Motor type

This setting is used to select the type of motor.

• DC = standard direct current motor with brushes (no speed controller).

• AC = low voltage (3x24V) three-phase motor and motor controller (Curtis) with

speed regulation.

For this lift the DC motor type must be selected.

7.3.15 Footguard

This function is disabled <OFF> by default.

When switching this function <ON>, the lowering function will be interrupted at a height of about 30 cm above the floor. Pressing again on the buttons <UNLOCK> and <LOWER>, lowering is continued with an acoustic signal.

7.4 Error messages

Service and troubleshooting

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 lowering motion stops and the message <Down stop limit exceeded> appears on the screen.

WARNING 1

Down stop limit exceeded

Figure 7.2 Warning while lowering

A height difference of 12 inches has arisen between the columns during lowering. Raise the columns approximately 4 inches and remove any obstacles. The column lifts can now be lowered further. Do not forget to press the UNLOCK button first.

Operating instructions (Version 0) 55 ST 1075

Page 56

When raising: The raising motion stops and the message <Maximum height reached> appears on the screen.

WARNING 2

Maximum height reached

Figure 7.3 Warning while raising

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.

Operating instructions (Version 0) 56 ST 1075

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7.4.1 Service sticker

Service and troubleshooting

Figure 7.4 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.

Operating instructions (Version 0) 57 ST 1075

Page 58

7.4.2 Electrical diagram for control box

For an overview of the electrical components and the electrical diagram, refer to section A.6 "Electrical diagram control box" on page 86.

7.4.3 Hydraulic components

For an overview of the hydraulic components and the hydraulics diagram, refer to section A.3 "Hydraulic scheme" on page 80.

7.5 Troubleshooting

7.5.1 Warnings

Various functions can be locked out when there is a warning. This is shown on the screen as follows:

WARNING 1

Down stop limit exceeded

Figure 7.5 Warning

The table indicates how the system can then be brought back to its normal status.

Table 7.2 Warnings

Code Screen text Possible cause Solution

01 02

Down stop limit exceeded

Maximum height reached.

Maximum programmed height reached.

Obstacle under the columns

One of the columns has reached its highest position.

One of the columns has reached the highest position as defined in the software.

Raise a little and remove obstacle

System can be lowered normally.

Operating instructions (Version 0) 58 ST 1075

Crush limit reached.

Lowering to below

2.5" is not possible with a remote control.

Can be lowered further by using the buttons on the column.

Page 59

Table 7.2 Warnings

Code Screen text Possible cause Solution

Service and troubleshooting

Weak battery. Lowering and shortly up possible.

Low battery. No more movements possible.

Very low battery. No more movements possible.

Other column in service menu.

Battery has not been recharged for a while.

More than 15 movements on a single battery charge. If this happens during lifting, the motor continues to run.

More than 15 raise actions on a single battery charge.

The service menu is open on one of the other columns.

Set the system charging.

Quit the service programme by pressing the <SLOW LOWERING> button (tortoise).

Height difference guard is off.

Height guard is off.

Setting in the service menu.

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7.5.2 Error reports

When there is an error, further operations are locked out. This is shown on the screen as follows:

ERROR 5

Other column has an error/failure

Figure 7.6 Error report

The error has to be cancelled first.

Pressing <SELECT> and <UNLOCK> continuously for 2 seconds resets the system.

Table 7.3 Troubleshooting

Code Screen text Possible cause Solution

07 08

Column software version too low.

Other column has an error/fault.

Status error on another column.

Output UP too long activated.

Output DOWN too long activated.

Output UNLOCK too long activated.

Another PCB is installed.

Another column has a problem.

Only occurs on column 1: other column(s) are not carrying out instructions.

UP button stuck. Check the push button.

DOWN button stuck. Check the push button.

UNLOCK button stuck.

Fit a PCB with the right software.

Check the screens on the other columns.

Restart the system. If the fault occurs again, contact technical services.

Check the push button.

10 -

Turn off limit columns 1 to 8.

Operating instructions (Version 0) 60 ST 1075

Hydraulic leak in one of the columns: this can be recognized by one of the columns lagging behind when raising.

Cancel the fault by pressing <SELECT> and <UNLOCK> for 2 seconds.

Page 61

Table 7.3 Troubleshooting

Code Screen text Possible cause Solution

Service and troubleshooting

Potentiometer short circuit or loose.

Main relay driver.

Motor relay driver.

Lowering valve driver.

Correction valve driver.

Unlock magnet driver

The potentiometer's slider is loose or causing a short circuit.

Main relay defective or wires have come loose.

Motor relay defective or wires have come loose.

Solenoid coil defective or wires have come loose.

Solenoid coil defective or wires have come lose.

Check the potentiometer wiring.

Check the wiring to the main relay.

Check the wiring to the motor relay.

Check the wiring to the lowering valve.

Check the wiring to the correction valve.

Check the wiring to the unlock magnet.

30 31

32 33

Potentiometer power supply.

Motor relay active.

Motor relay not active.

Main relay active.

Main relay not active.

Internal main relay active or MS button pressed.

The supply voltage for the potentiometer is too low/too high.

The motor relay may have stuck.

The motor relay does not switch on, despite receiving a control voltage.

The main relay may have stuck.

The main relay does not switch on, despite receiving a control voltage.

The main relay on the PCB has stuck or the MS button has been pressed.

Cancel the fault by pressing <SELECT> and <UNLOCK> for 2 seconds. If the fault occurs again, contact technical services.

Replace the motor relay.

Replace the main relay.

Replace the PCB.

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Table 7.3 Troubleshooting

Code Screen text Possible cause Solution

Internal main relay not active or emergency loop open.

Emergency loop open.

Odd number of columns.

The main relay on the PCB is not switching.

One of the emergency stop switches has been pressed.

An odd number of columns has been selected.

Check whether the emergency stop switches are unlocked; otherwise replace the PCB.

Check whether all the emergency stop switches are unlocked.

Reboot with an even number of columns, or change in the service menu.

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7.5.3 Fault messages

If there is a fault, the radio network will be cancelled and a red light (FAULT) will be continuously illuminated on the front panel. On the screen, it looks like this:

FAILURE 71

No communication with the master column

Figure 7.7 Fault message

Before the system can be restarted (see 5.2.2 "Starting and identification" on

page 34), the fault must be cancelled.

Table 7.4 Fault messages

Code Screen text Possible cause Solution

Service and troubleshooting

No communication with the master column.

No communication with a slave column.

Front key. A push button was

Distance between the columns too great; time interval between messages too great.

being pressed during startup.

Reboot the system. If the fault occurs again, contact technical services.

Reboot.

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Page 64

Table 7.4 Fault messages

Code Screen text Possible cause Solution

Hardware failure:

internal RAM.

Hardware failure:

external watchdog.

Hardware failure:

EPROM.

Hardware failure:

external RAM.

Hardware failure:

EEPROM.

Software failure:

Illegal state.

An error has occurred on the PCB.

Reboot the system. If the fault occurs again, contact technical services.

Operating instructions (Version 0) 64 ST 1075

Page 65

Service and troubleshooting

7.5.4 Troubleshooting overview

Table 7.5 The column lift cannot be raised

Cause Solution

No battery power. Check the main fuse above the batteries. Have

the batteries checked by a battery specialist.

Oil level too low (but motor running). Top up; see Table 6.1 "Lubrication program"

on page 45.

There is air in the hydraulic pump (only possible if the tank has been empty).

Select <SINGLE> operation and press the UP button until the column lift rises (max. 1 minute).

The pressure relief valve has not been correctly adjusted.

Contact technical services to have the valve 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 battery specialist.

The pawl does not retract from the safety lock. First raise the column lift about 35mm and then

lower it.

The electrically operated lowering valve on the hydraulic unit will not open.

There is no voltage on the lowering valve or the lowering valve is faulty. Have technical services solve the problem.

Contaminated or damaged lowering valve. Have the lowering valve cleaned or have it

replaced by technical services.

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Table 7.6 The column lift cannot be lowered

Cause Solution

The maximum elevation difference (more than 1 1/4") has been exceeded.

Press <UP> until the height difference has been levelled out. If lifting is not required, you can press the <SELECT> button three times. Then you can lower. The difference of 30mm remains. If this occurs regularly, contact technical services.

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.

The highest position is virtually the same as the highest locking position.

Have the height set again by technical services.

Table 7.7 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 correction valve.

Have the valve cleaned or have it replaced by technical services.

Table 7.8 The column lift is not raised far enough

Cause Solution

Oil level in the tank is too low. Top up with oil as described in 6.3.2 "Hydraulic

oil" on page 45.

Pump is drawing air. Tighten or crimp the suction filter attachment.

The steel plug has not been replaced by the air

Fit the air bleed cap.

bleed cap.

The air bleed cap is blocked. Clean the air bleed cap.

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Table 7.9 No battery power

Cause Solution

No battery power. Charge the batteries using the mains cable

The main fuse has blown. Check the main fuse above the batteries.

The mains switch is OFF. Set the mains switch to ON.

Indicator lights and/or screen defective. Contact technical services.

Table 7.10 No control voltage

Cause Solution

Service and troubleshooting

supplied. DO NOT USE AN EXTERNAL BOOSTER CHARGER.

Have the batteries checked by a battery specialist.

Indicator lights and/or screen defective. Lifting system functioning normally.

The lifting system may not be set up properly. Follow the procedures in 5.5 "Operating

A fuse has cut power to the controller. The controller has multi-fuse circuit breakers.

The mains switch is OFF. Set the mains switch to ON.

Note

Contact technical services.

procedure" on page 40. If the fault occurs

again, contact technical services.

After they have cooled down, they switch back on again automatically. If the fault occurs again, contact technical services.

n In the event of malfunctions other than those described here, always consult

technical services.

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7.6 Maintenance procedures

7.6.1 Removal and installation of the lifting cylinder

Proceed as follows to remove the cylinder:

1. Remove the bolt and the retaining tube at the bottom of the guide block.

2. Press the <SELECT> button until the <SINGLE> button is illuminated. Then press the <DOWN> button to lower the cylinder. It will take approximately 2 minutes before the cylinder is fully lowered.

3. Uncouple the hydraulic coupling at the bottom of the cylinder.

4. Lift the cylinder about 3/4" to withdraw it from its seating on the bottom end.

5. Pull the cylinder forwards.

Proceed as follows to install the cylinder:

1. Place the cylinder 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 the <DOWN> button to lower the cylinder.

6. Press the <UP> button and open the bleed valve until a continuous flow of oil appears.

7. Close the bleed valve and fit the cap.

7.6.2 Adjustment of the pallet lifting mechanism

1. With the lever in position 3 (see Figure 7.8 ), move the drawbar up and down. If the adjustment is correct, the cylinder should now give about 8mm lift per stroke.

Lever plate (C)

Nut 1

Chain

Lever

Adjusting screw

1 2

Drawbar

Figure 7.8 Pallet lifting mechanism

Operating instructions (Version 0) 68 ST 1075

Page 69

2. Set the lever to position 2 and move the drawbar up and down; the cylinder will now not lift if the setting is 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 until the movements at each lever position are correct.

7. Once 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.

Service and troubleshooting

No. Total number of parts in the column lift.

Reference The numbers in this column are Stertil B.V. order numbers.

Please specify these numbers when ordering.

Description This column contains the name of the parts.

7.8 Replacement parts

You can order replacement parts from Stertil B.V. - see 1.6 "Manufacturer's details"

on page 13 for address details.

When ordering replacement parts, please supply the following information:

Column lift type: ST 1075.

Serial number: See the type plate on the column lift.

Reference no.: See List of Parts.

Operating instructions (Version 0) 69 ST 1075

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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 procedure may only be performed by persons who are

trained in this procedure.

Operating instructions (Version 0) 70 ST 1075

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8Options

8.1 Wheel adapters

The mobile column lifts may be used to hoist vehicles with a wheel diameter ranging from R12 (20") to R22.5 (45"). Wheel adapters must be used for certain wheel diameters (see Figure 8.1 ).

Figure 8.1 Wheel adapters

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.

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8.1.1 Longer wheel adapters

Special 6 inches longer wheel adapters (see Figure 8.2 ) can be supplied for hoisting vehicles with double wheels such as trucks, buses, etc. and for vehicles with an overhanging body (camper vans, etc.).

Figure 8.2 Longer wheel adapters

Warning

w These longer wheel adapters may only be used in 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 16,500 lbs. When this is the case, the column foot extensions may remain fitted (see Figure 8.2 ).

Operating instructions (Version 0) 72 ST 1075

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8.2 Traverse beam

For the lifting and lowering of trailers on a set of mobile lifting columns, a special Stertil-Koni traverse beam is available.

8.2.1 Before you start working

Check both the maximum lifting capacity of the traverse beam and the maximum lifting capacity of a set of two mobile columns.

If there is a difference in the maximum lifting capacity of the traverse beam and the set of two mobile columns, the lowest maximum lifting capacity is always

leading.

Caution

c This can be a potential hazardous situation.

The traverse beam can be overloaded without warning.

8.2.2 User instruction

Options

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.

Figure 8.3 Pickup points of the traverse beam

4. Operate the mobile lifting columns as described in section 5.5 Operating procedure

on page 40.

8.2.3 Tilting of the traverse beam with king pin adapter

For some trailer models, a traverse beam with a king pin adapter must be used.

Due to the design of the suspension of trailers, some models will move horizontally when the wheels are touching the ground again.

Operating instructions (Version 0) 73 ST 1075

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During this horizontal movement, it is possible that the traverse beam starts to tilt, as shown in Figure 8.4 .

Figure 8.4 Tilted traverse beam

Caution

c Tilting 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 .

Operating instructions (Version 0) 74 ST 1075

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A List of parts and appendices

The following sections will give an overview of the main assemblies and their 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.

Operating instructions (Version 0) 75 ST 1075

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A.1 Summary column lift

See

Figure A.2

Figure A.1 Column lift

See

Figure A.2

Operating instructions (Version 0) 76 ST 1075

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List of parts and appendices

Table A.1 Column lift

Index No. Reference Description Remarks

1 1 See Figure A.5.1 Cover / Control Box 2 1 30501003 Packing ring 3 1 34200116 Locking bush 4 4 1020.50.00.30 Roller 5 1 32700101 Angle support 6 2 32500116 Wheel 7 1 34500150 Column 8 1 34200117 Plate 9 2 32500109 Shaft 10 1 34500200 Guide block 11 1 69090050 Grommet No. 2790 type 2 12 1 32706075 Oil pipe 13 1 See Figure A.4 Hydraulic cylinder 14 1 68700450 Straight adaptor GE 10-PS 16 1 32736150 Hydraulic hose 17 4 30001006 Slide plate 18 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 4 Washer M16 DIN125A 35 4 Bolt M16x25 DIN 933 Tightening Torque 110-

155 lbs.ft 36 1 Set screw M5x12 DIN 916 37 2 Bolt M10x20 DIN 933 50 1 32700300 Balancer 51 1 32550103 Shaft 52 2 66201055 Spacer 12.8-18-15 53 1 32700120 Cap 54 1 Adjusting screw M8x8 DIN 916 55 1 Nut M8 DIN 439B 56 2 60203002 Gas spring 57 4 60203003 Clamp 58 2 Retaining ring No.9 DIN 6799 59 1 32550102 Shaft

Operating instructions (Version 0) 77 ST 1075

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A.2 Hydraulic unit

Figure A.2 Hydraulic unit

Operating instructions (Version 0) 78 ST 1075

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List of parts and appendices

Table A.2 Hydraulic unit

Index No. Reference Description Remarks

68038427 Hydr.unit 1.2cc 24V 265 Bar 1 1 68039011 Tank plastic 9 liter 3 1 68510911 O-ring 110.72x3.53 mm 4 1 32506103 Suction filter D.62 dia. 3/8" 5 1 32006254 Return filter 10 micron 6 1 32516105 Pump 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)

Tightening torque 22 lbf ft

(incl. manual lowering) 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 Check valve Tightening torque 16.5 lbf ft 17 1 68039004 Breather cap 18 1 Seal cap 19 1 32556903 Flow control valve 6 L/min. 20 1 32556902 Flow control valve 2 L/min. 21 1 Transport plug

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A.3 Hydraulic scheme

6 L/min

Index Description

C Cylinder EV22 2/2 Valve VCDF Flow control valve FFilter K Non return valve PPump T Tank O Safety pressure valve M Electric motor R Hose burst check valve

X psi

Figure A.3 Hydraulic scheme

3,850 psi

Operating instructions (Version 0) 80 ST 1075

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List of parts and appendices

A.4 Hydraulic cylinder

Figure A.4 Hydraulic cylinder

Operating instructions (Version 0) 81 ST 1075

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Table A.4 Hydraulic cylinder

Index No. Reference Description Remarks

34400600 Cylinder (assembly) 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 71 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

Operating instructions (Version 0) 82 ST 1075

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A.5 Control box

List of parts and appendices

Figure A.5.1 Control box

Figure A.5.2 Control box

Operating instructions (Version 0) 83 ST 1075

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Table A.5 Control box

Index No. Reference Description Remarks

1 1 32739100 Control box wireless

(incl. cables) 2 2 68039013 Motor relays 24Vcc 150A 3 1 69500104 Battery charger

230/115V 24V 10.5A 4 1 69120026 Battery switch 5 1 69206403 Fuse holder 6 1 69206102 Fuse 200A 300V A3T200 7 2 69302016 Battery

12V/104Ah VDC31M VMF 8 1 32739160 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 contactor 20 1 69202009 Acoustical alarm 21 1 Cable gland M25x1.5 22 3 Cable gland M20x1.5 23 1 Cable gland M25x1.5 24 1 32730300 Cover 25 1 69004002 Charging cable No standard delivery

Operating instructions (Version 0) 84 ST 1075

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List of parts and appendices

Figure A.5.3 Control box

Operating instructions (Version 0) 85 ST 1075

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A.6 Electrical diagram control box

Figure A.6 Electrical diagram control box

Operating instructions (Version 0) 86 ST 1075

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List of parts and appendices

A.7 Pallet jack mechanism

Figure A.7 Pallet jack mechanism

Operating instructions (Version 0) 87 ST 1075

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Table A.7 Pallet jack mechanism

Index No. Reference Description 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

Operating instructions (Version 0) 88 ST 1075

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List of parts and appendices

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)

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A.9 Label locations

Figure A.9 Label locations

Operating instructions (Version 0) 90 ST 1075

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List of parts and appendices

Table A.9 Label locations

Index No. Reference Description Remarks

1 1 60700268 User instruction sticker 2 1 1005.01.01.92 Type plate 3 1 60700189 Sticker "Oil dry piston rod…." 4 2 60700061 Large sticker "STERTIL/KONI" 5 1 60700092 Sticker "CAUTION" 6 1 60700331 Capacity sticker "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 American Nat. Standard 20 1 60700134 Label “Do not use.../Ne pas...” 21 1 60702010 ALI/ETL/CSA label standard

201 22 1 60700193 Sticker "SAFETY

INSTRUCTIONS"

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A.10 Dimensional drawing

Figure A.9 Dimensional drawing ST 1075-FBF

Operating instructions (Version 0) 92 ST 1075

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B List 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.

Operating instructions (Version 0) 93 ST 1075

Page 94

B.1 Wheel adaptors and column extensions

Figure 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.

Operating instructions (Version 0) 94 ST 1075

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List of parts - Options

Table B.1 Wheel adaptor and extended arm

Index No. Reference Description Remarks

1aR 1 32700920 Wheel adaptor 14" Right

(length = 350 mm / 14")

1aL 1 32700925 Wheel adaptor 14" Left

(length = 350 mm / 14")

2R 1 34200930 Longer wheel adaptor 16" Right

Max. 8,800 lbs

(length = 500 mm / 20")

2L 1 34200935 Longer wheel adaptor 16" Left

Max. 8,800 lbs

(length = 500 mm / 20")

3bR* 1 34400930 Longer fork adaptor Right

Max. 12,000 lbs

(length = 500 mm / 20")

3bL* 1 34400935 Longer fork adaptor Left (length =

Max. 12,000 lbs

500 mm / 20") 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 65055040 Spacer M36 10* 2 60700206 Label 5500 kg/12,000 lbs * 1 34400915 Extension set (item 3bR, 3bL, 4,

Max. 12,000 lbs

6, 7, 8, 9, 10 and 4x item 6)

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B.2 Traverse beam

Type: 32591100

65432

A - A (1:10)

Figure B.2.1 Traverse beam

Table B.2.1 Traverse beam

MIN. 1000

7,2T

BELASTINGSGRAFIEK BELASTUNGSSCHEMA DIAGRAMME DE CHARGE

LOAD GRAPH

Index No. Reference Description Remarks

32591100 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

Operating instructions (Version 0) 96 ST 1075

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DRSN.A-A

List of parts - Options

Type: 32591500

3 4

16 5

Figure B.2.2 Traverse beam

Table B.2.2 Traverse beam

Index No. 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)

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Type: 3259200

3,4

Figure B.2.3 Traverse beam

87125

Table B.2.3 Traverse beam

Index No. Reference Description 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

Operating instructions (Version 0) 98 ST 1075

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C Inspection check list

Annual inspection as described in the installation and service manual.

Date Remarks Name of mechanic Initials of mechanic pass

Operating instructions (Version 0) 99 ST 1075

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Date Remarks Name of mechanic Initials of mechanic pass

Operating instructions (Version 0) 100 ST 1075