stertil-KONI ST 1082-F/BAT, ST 1082-R/BAT Installation, Operation And Service Manual

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Mobile Column Lifts

ST 1082-F/BAT ST 1082-R/BAT

Installation - operation – service

32738980-A

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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

DIRECTIONS ASSEMBLY AND SERVICING MANUAL

FOR THE 18,000 LBS STERTIL-KONI HYDRAULIC MOBILE COLUMN LIFTS

MODEL

ST 1082-F/BAT ST 1082-R/BAT

Starting at Serial Number

TM 139067

This document belongs with mobile column lift no.:

TM...................

Date first used:

……………….

12-04-2007

Date:

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EC DECLARATION OF CONFORMITY in application of the European 'Machines' Directive (98/37/EC) ALI DECLARATION OF CONFORMITY in application of the ANSI\ALI ALCTV-1998 and UL201

Manufacturer : Stertil B.V., Postbox 23, 9288 ZG

KOOTSTERTILLE Holland

Machine : Hydraulic mobile column lifts Make : STERTIL-KONI

The undersigned U.Bijlsma, Director, for this purpose authorized by Stertil BV, hereby declares that the mobile column lift described above, has been designed according to the 'Machines' Directive, ANSI\ALI ALCTV-1998 and UL201 and has been found to meet the fundamental safety requirements stipulated by these directives.

This Wheel Engaging Mobile Automotive Lifts are approved by: Stertil, Kootstertille INTERTEK TESTING SERVICES NA. Inc. U.Bijlsma 3933 US Route 11. Cortland, NY 13045 Director Telephone: 607-753-6711 Fax: 607-756-9891 Signature: WEB: www.intertek-etlsemko.com Date: 01-05-05 Under report no J99024825-003

Model : ST 1082-F/BAT Fixed wheels and fixed forks : ST 1082-R/BAT Retractable wheels and fixed

forks

: ST 1082-F/V/BAT Widened model with fixed

wheels and fixed forks

Version : Battery powered Options : Adjustable forks : Wheel adaptors

: Longer extensions and wheel adaptors

ST 1082-F/R

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Contents Page

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

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

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

1.2 SPECIFICATIONS ....................................................................................................................................................... 5

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

2.1 SCOPE............................................................................................................................................................................ 6

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

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

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

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

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

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

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

5.1 CONTROL................................................................................................................................................................... 14

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

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

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

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

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

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

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

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

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

6.1 PREPARATION.......................................................................................................................................................... 20

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

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

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

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

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

7.1 GENERAL ................................................................................................................................................................... 21

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

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

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

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

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

7.7

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

7.8

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

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

8.1 GENERAL ................................................................................................................................................................... 26

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

8.3 IDENTIFICATION..................................................................................................................................................... 31

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

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

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

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

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

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

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

FIG. E - CONTROL BOX .................................................................................................................................................. 38

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

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FIG. G - CONNECTION CABLE...................................................................................................................................... 41

FIG. H - PALLETJACK SERVICE KITS ........................................................................................................................ 42

FIG. I - LABEL LOCATIONS ........................................................................................................................................... 43

FIG. J - WHEEL ADAPTORS & EXTENDED ARM (OPTION) ................................................................................. 44

FIG. K - DIMENSIONAL DRAWING .............................................................................................................................. 45

INSPECTION CHECK LIST............................................................................................................................................ 46

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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 content

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.

An automotive lift 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 operating instructions, general safety information, safety tips and warning labels on the master control console. 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 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

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 effected, the lift shall be locked out or tagged in accordance with ANSI/Z244.1-1982.

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.

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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

Column Serial Numbers: _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________ _______________________

___________________________________________________________________________________________ Signature Date

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1. GENERAL

1.1 MANUFACTURER'S INFORMATION

Stertil BV Kootstertille (NL) Westkern 3, 9288 CA Telephone 31(0)512334444

Postbus 23, 9288 ZG Telefax 31(0)512334430 E-mail: [email protected] Website: www.stertil.nl

1.2 SPECIFICATIONS

Also see type plate on the mobile column lift.

Model

Capacity

Pressure relief valve

Electrical power 24vdc

Mains supply (bat. charger)

1x115V 60 Hz 2A

Main battery fuse

Operational voltage

Stroke

Lifting speed

Lifting/lowering time

Noise level

ST 1082-F/BAT ST 1082-R/BAT

18,000 lbs

3,800 psi (sealed ex-works with plastic cap)

4HP

1x phase, 1x zero, 1x earth

200 AT

24 V=

69”

44"/min

94 sec/68 sec

max 73 dB(A)

Set-up

Weight Lifting column interconnection

cable length Maximum distance between

lifting columns Maximum floor suface

pressure Maximum floor load

Operation temperature

Indoors / outdoors

1250 lbs

39' - 4"

29' - 6" 900 psi (per front support) – ST 1082-R/BAT

7000 psi (per wheel) – ST 1082-F/BAT 7000 lbs (per front support)

5 to 122° F (-15 to +50°C)

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2. DIRECTIONS

2.1 SCOPE

This manual refers to the Mobile Column Lift.

This manual contains useful and important information for proper functioning and maintenance of the lifting system. It

also contains important instructions to prevent accidents and serious damage prior to and during operation of the lifting

system, and it enables the product to perform as safely and flawlessly as possible. Read this manual carefully before using

the lifting system, familiarize yourself thoroughly with the functioning and operation of the lifting system and strictly

observe the directions given.

2.2 GUARANTEE AND LIABILITY

See the terms of delivery and order conformation.

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2.4 SAFETY MEASURES

The lifting system is provided with safety and protection features. Even so, caution is required when using the lifting

system.

Work safely!

Stertil B.V. has made effort to inform you about possible dangers associated with operation of the lifting system.

You must ensure and are responsible for compliance with these behavioral guidelines.

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.

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 93-1, ALI Lifting it Right safety

manual; ALI/ST-90, ALI Safety Tips card; ANSI/ALI ALOIM-2000, American National Standard for

Automotive Lifts-Safety Requirements for Operation Inspection and Maintenance; ALI/WL Series, ALI

Uniform Warning Label Decals/Placards.

The owner/employer shall establish procedures to periodically inspect the lift in accordance with the lift

manufacturers instructions; ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety

Requirements for Inspection and Maintenance; and the employer shall ensure that lift inspectors are qualified and

that they are adequately trained in the inspection of the lift.

The owner/employer shall maintain the periodic inspection and maintenance records recommended by the

manufacturer or ANSI/ALI ALOIM-2000, American National Standard for Automotive Lifts-Safety

Requirements for Inspection and Maintenance; and the employer shall ensure that lift inspectors are qualified and

that they are adequately trained in the inspection of the lift.

The owner/employer shall display the lift manufacturers operating instructions; ALI/SM-01, ALI Lifting it Right

safety manual; ALI/ST-90, ALI Safety Tips card; ANSI/ALI ALOIM-2000, American National Standard for

Automotive Lifts-Safety Requirements for Operation Inspection and Maintenance, Vehicle Lift Points for

Service Garage Lifting; ANSI/SAE J2184-may00 in a conspicuous location in the lift area convenient to the

operator.

The owner/employer shall provide necessary lockout/tagout means for energy sources per ANSI Z244.1-1993,

Safety Requirements for the Lockout/Tagout of Energy Sources, before beginning any lift repairs.

The owner/employer shall not modify the lift in any manner without the prior written consent of the manufacturer.

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IMPORTANT SAFETY INSTRUCTIONS

- Read all instructions.

- If an extension cord is necessary, a cord with a current rating equal to or more than the equipment must be used. Cords rated for less current than the equipment may overheat. Care should be taken 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 the 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).

- Adequate ventilation should be provided when working on internal combustion engines.

- Keep hair, loose clothing, fingers and all parts of the body away from moving parts.

- To reduce the risk of electrical shock, do not use on wet surfaces or expose to rain.

- Use only as described in this manual. Use only manufacturers recommended attachments.

- ALWAYS WEAR SAFETY GLASSES. Everyday eyeglass only have impact resistant lenses, they are not safety glasses.

- Use by untrained people could result in serious injury and/or damage.

- Do not use the lifting system outdoors if the wind velocities mentioned in paragraph 5.5 are exceeded

- If the lifting system is used outdoors do not leave the vehicles unattended in the lifted position. The wind speed may change and exceed the safety limits.

- Danger of getting injured by electrical shock.

- Only remove the covers to carry out maintenance, ensure that the lifting system is disconnected from the power supply.

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- Care must be taken 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.

- Do not drive over interconnecting cables. Always disconnect interconnecting cables and remove from

vehicle travel path before moving vehicle.

- Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by a qualified serviceman.

- In case of using one or two lifting columns (in paired operation), be sure that this will not result in stability risks. In case of doubt, consult your superior. Unsafe lifting can result in serious injury and damage to the lifting system and/or vehicles.

- This lifting system should only be used for lifting of vehicles and not for other applications. The positioning of the lifting system must be done in a way that a safe working area will be obtained above and around the lifting columns, thereby creating escape paths for emergency situations (leave passageways of at least 24").

- For important vehicle technology see 5.7.

- 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 1.2 Specifications for floor pressure and floor load.

- Once desired height has been reached, it is recommended but not required that the lift be lowered into the mechanical locks.

SAVE THESE INSTRUCTIONS

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3. DESCRIPTION OF THE LIFTING SYSYEM

For the hydraulic system diagram see figure L.

The mobile column lift is a movable electrically driven hydraulic column lift used for lifting heavy vehicles. At least two lifting columns are required for lifting a vehicle. The number of lifting columns required depends on the weight of the vehicle and the number of axles.

The main components of the mobile column lift are shown below:

1. Column

2. Potentiometer

3. Mechanical lock

4. Hydraulic unit

5. Control box

6. Electrical connector

7. Main switch

8. Automatic battery charger

9. Fuseholder 200A

10. Batteries

11. Pallet jack

12. Guide block

13. Lifting fork

14. Wheel adaptor (option)

15. Cylinder

16. Fixed wheels (model ST 1082-BAT/F)

17. Adjustable forks (option)

18. Retractable wheels (model ST 1082-R/BAT

Fig. 3

Usually, a set of four lifting columns is used

Each lifting column has a lifting capacity of 18,000 lbs. Consequently, four columns have a total lifting capacity of 72,000 lbs. The total lifting capacity can be increased by adding more lifting columns.

The columns are interconnected so as to form a ring circuit. All the control signals are through the connecting cables. Each column has a mains connection for the integrated battery charger.

The control system on the lifting columns ensures that the columns are raised or lowered synchronically. Each lifting column is equipped with a position sensor which transmits the height positions to the control system. The control system controls and protects the lifting system during lifting or lowering as follows:

- At a difference in height between the lifting columns of over 5/8" and less than 1 1/4"mm, an

extra adjustment valve in the hydraulic system opens and remains open until the difference has been cancelled out.

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- At a difference in height of over 1 1/4" and less than 2 3/8", lowering is interrupted. A lifting

fork may be blocked; the cause of the failure must then be traced first. Lifting is still possible, the adjustment valve in the hydraulic system will open and remain open until the difference has been cancelled out.

- At a difference in height of over 2 3/8" mm, the control voltage is switched off, thus blocking all

movements. The cause of the failure can then be traced.

In addition, the control system has been designed so that:

- Each lifting column can be operated separately

- Any pair of axles can be handled separately

Also see section 6, Operation

3.1 STRUCTURE OF THE COLUMN LIFT

Each lifting column consists of (see figure 3):

- a column and a lifting cylinder

- a hydraulic unit

- a control box

- battery power system

- a pallet jack lifting mechanism

- a mechanical safety lock

- two fixed or adjustable forks (option)

- two fixed or retractable wheels (option)

• Hydraulic unit

The hydraulic system consists of an electrically driven pump, flow control valves, control valves and a oil reservoir.

• Column and lifting cylinder

The column and lifting cylinder form the major part of the mobile column lift. In the U-section of the column are a guide block and rollers. The rollers enable the guide block to move along the full length of the column. The hydraulic lifting cylinder provides the lifting capacity.

• Control box

The control box has all the functions controlling the use of the lifting column A battery condition meter is integrated in the control panel.

The control box components and functions have been specified in sections 5 and 6.

• Battery power system

The battery system consists of two batteries, main switch to power the control box and hydraulic unit, a heavy duty

fuse, a battery charger and a battery condition meter.

• Pallet jack mechanism

The two-wheel pallet jack mechanism serves to move the lifting column. The two wheels protect the lifting column from being turned over at the back when it is moved. The pallet jack mechanism lifts the column off the floor so that the column can be easily moved.

The pallet jack mechanism is operated by means of the handle bar and the lever inside the bar. (see fig. 7.7) The lever can be set in three positions:

1. When the lever is set in the upper position, the pallet jack mechanism is lowered.

2. The middle setting is the neutral position; the column can be moved without the system being lifted or lowered.

3. When the lever is in the lower position, the pallet jack mechanism can be raised by moving the handle bar up and down.

• Retractable wheels model ST 1082-R/BAT only.

When the pallet jack mechanism will be operated the retractable wheels are in this system also engaged by lifting/lowering the front wheels of the column.

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• Mechanical safety lock

If the hydraulic pressure fails while a vehicle is on the lifting system or is lifted or lowered, a mechanical safety lock ensures that it cannot drop.

The characteristic clicking of the safety lock when lifting, indicates that it is activated. During lowering the pawl is retracted by a solenoid.

• Adjustable forks (option) The forks can be adjusted manually to accommodate a wide range of tire sizes. A mechanical lock prevents the

forks from moving sideways under load.

4. INSTALLATION

Remark: Only move the lifting column with the correct type of lifting equipment. Only raise the lifting column at the correct points. Damage to lifting column and/or injury to

persons may occur if the lifting column is not moved in the correct manner.

4.1 UNPACKING AND HANDLING THE LIFTING COLUMN

1. Transport the lifting column to the place of use.

2. Remove the cover from the crate or, when using a stand, remove the straps.

Remark: Do not stand under the lifting column when it is suspended from the lifting equipment. If it falls it

will cause serious injury.

3. Fasten a sling with a hoisting capacity of at least 1100 lbs around the lifting column and lift the column from the crate (see fig. 4.1).

4. Carefully lower the lifting column to the floor.

5. Attach a sling at the top of the column.

6. Lift the column to the upright position.

7. Remove the sling from column.

For transport the complete assembly (incl. hydraulic unit)

is taken from the column.

8. The assembly can be lifted by two man, and can be hung on the existing bracket for the hydraulic unit on the column.

9. Remove the two bolts on the left side to open the hinged cover.

10. Fix the frame with 3x M6 bolt to the column.

11. Reconnect potentiometer plug.

12. Reconnect unlock solenoid plug.

13. Reconnect hydraulic hose (bleed air later on top of cylinder, if req'd).

14. Position batteries with + connection to the right when looking into the door (see picture page 38).

15. Make sure main switch is off and connect batteries.

16. Use the threaded bar to retain the batteries and to line-up the M6 holes for closing the cover.

17. Connect columns with cables.

18. Remove the plug from the fill opening and install the breather cap. Close the hinged cover.

19. Check for oil leakage.

20. Repeat the procedure for each column.

Fig. 4.1

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5. GENERAL USE

5.1 CONTROL

All functions of the lifting system are controlled from the control panel on the column. The main switch is positioned on the right side of the cover.

The functions of the switches, buttons and knobs on the primary control panel are described below (see Fig. 5.1).

1. Battery condition meter showing the capacity of the batteries. Lifting is disabled when the battery capacity is below

20%.

2. Emergency release button; Pressing this, all movements (lifting or lowering) are immediately stopped.

3.  (UP) button; Controls the lifting of the columns.

4.  (DOWN) button; Controls the lowering of the columns.

5. “SET AXLE” button. This button serves to select the axle functions. These functions are described in paragraph

5.3.6.

6. Unlock button. This button controls, in combination with the lowering button, the lowering of the columns.

7. “SET REF” button. This button has several functions. These are described in paragraph 5.3.5.

8. Mains voltage indication light. This will go on when the internal control voltage relay is switched on.

1. Battery condition meter

2. Emergency release knob

3. Lifting 

4. Lowering 

5. “SET AXLE”-button

6. Unlock button

7. “SET REF”-button/control voltage

indication.

8. Control power indicator light.

5.2 CONNECTING LIFTING COLUMNS

A fully closed ring circuit consists of a minimum of two and a maximum of 28 lifting columns

A set can consist of 2, 3, 4, 5 or 6 etc. up to 28 lifting columns

5.3 DESCRIPTION OF THE MOBILE COLUMN LIFT SYSTEM

The mobile column lifts are designed in such a way as to offer maximum flexibility and convenience. A lifting system can consist of a minimum of 2 and a maximum of 28 lifting columns. The control system is equipped with the following features:

- simultaneous operation of all lifting columns

- operation of one pair of lifting columns (per vehicle axle): the so-called paired operation

- operation of one lifting column

Each lifting column is provided with these control functions without selector switches having to be set.

Fig. 5.1, Control box

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The control system of the mobile column lift is set-up as follows:

1. Connect the lifting columns in a full circuit as indicated in 5.2, Connecting Lifting Columns.

- The column sequence in this circuit can be selected at random columns can be positioned at any place, provided the maximum lifting capacity of 72,000 lbs is not exceeded as described in

5.2.

- The maximum number of lifting columns in a system is 28

2. With respect to all columns:

- Set main switches to 1 (ON).

3. Take care that the emergency stop button of each lifting column has been released.

4. Press the "SET REF" button. The light in button 8 (control power) will come on indicating that:

- the system control has been checked for its proper functioning

- the sequence of all lifting columns has been stored in the system memory

- the primary column in the system has been connected to the mains.

5. Press the "SET REF" button again. The light in this button will come on indicating that:

- the height position of each lifting column has been stored in the system.

- the lifting columns can now be activated. All functions are possible now except paired operation.

6. Setting paired operation (only possible with an even number of lifting columns):

- Select the primary columns at one axle to set this function (e.g. the front wheel axle).

- Press the "SET AXLE" button on one of the lifting columns belonging to the selected axle for approx. 3 seconds.

- The "SET AXLE" button will flash indicating that the setting procedure has been selected.

- Within 30 seconds press the "SET AXLE" button of the control panel of the lifting column on the other side of the axle and also keep it pressed for 3 seconds. The "SET AXLE" buttons of all lifting columns will go on indicating that paired operation has been set.

When setting paired operation, the other pairs of axles in the control system are automatically selected as pairs. This only works satisfactorily if all lifting columns have been connected in a closed circuit as described in 5.2.

All system functions are now available by pressing:

- button 3 ⇑, all columns are raised;

- button 4 ⇓, lowered and locked;

- buttons 6 and 4 ⇓, all columns are lowered;

- buttons 5 (SET AXLE) and 3 ⇑, one axle is raised (2 lifting columns);

- buttons 5 (SET AXLE) and 4 ⇓, one axle is lowered (2 lifting columns);

- buttons 7 (SET REF) and 3 ⇑, one column is raised;

- buttons 7 (SET REF) and 4 ⇓, one column is lowered.

Note: 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. (see also 5.8)

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5.4 WHEEL ADAPTERS (OPTIONAL)

The mobile lifting columns can be used to lift vehicles with a wheel diameter of R12 (500 mm, 19 ¾”) to R22.5 (1140 mm, 45”). Wheel adapters (fig. 5.4) are required for use with different wheel diameters. Two adapters are required for tire size of R12 (500 mm, 19 ¾") to R15 (650 mm, 25 ½"). One adaptor is required for tire size R15 (650 mm, 25½") to R17 (900 mm, 35½"). No adaptors are used for tire size R17 (900 mm, 35 ½") to R22.5 (1140 mm, 45"). There are special adapters for smaller wheel diameters (< 500 mm, 19 ¾").

5.5 LONGER WHEELADAPTORS (OPTIONAL ONLY ON ST 1082-F)

Special (6” longer) wheel adaptors (fig. 5.5) are available for in-set wheels (for RVs, school buses etc).

WARNING: These longer adaptors can only be used together with wheel arm extensions for the column.

The lifting capacity will be reduced to 12,000/8,800 lbs (see attached label fig. 5.5a). The reduced capacity is

clearly indicated on the sides of the longer wheel adaptors.

Please note that with the longer adaptors, the lifting capacity still remains 12,000/8,800 lbs, check the maximum load that has to be lifted carefully. The capacity with removed wheel adaptors is 18,000 lbs; the lower wheel arm extensions do not have to be removed (see fig. 5.5.b).

Fig. 5.4

Fig. 5.5a Fig. 5.5b

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5.6 ADJUSTABLE FORKS (OPTION)

The mobile lifting columns can be used to lift vehicles with a wheel diameter of R10 (450 mm, 17 ¾”) to R22.5 (1140 mm, 45”). The forks can be slided to the correct dimension:

1. Lift T-handle to unlock the fork. (fig. 5.6-a

2. Use both hands to slide the fork sideways.

3. Adjust both forks so that they are equally spaced in relation to the centre of the column.

4. Adjust so that the forks at floor height just fit around the tire (to prevent the rim falling through, when tire becomes deflated)

5. Make sure that the T-handle locks-in.

Fig. 5.6-a

Fig. 5.6-b

Page 22

5.7 OPERATING THE PALLET LIFTING MECHANISM

1. Set the lever to position (3) and make a pumping movement with the drawbar, to raise the column lift with the pallet lifting mechanism. The column lift can then be relocated.

2. Pull the lever to position (1) to lower the column lift to the floor.

3. Set the pallet lifting mechanism in the lowest position, and the lever to the neutral position (2), whenever the column lift is to be used to hoist a vehicle

5.8 USING OUTDOORS

When using the lifting system outdoors you must be aware of the admissible wind speed. The admissible wind speeds for different types of vehicle are shown in the table below.

The values in the table are average values and should only be used as a guide.

The admissible wind speed is dependent on the type as well as the weight of the vehicle. When lifting large high-sided vehicles, the value for lighter vehicles must be used.

The operator must consider all factors when deciding if it is safe to use the lifting system If any doubt exists, always use the lower wind speed.

Vehicle Type

Light cars or lorries with long swop bodies.

Buses

Lorries and Heavy vehicles

Weight (empty)

metric tons

lbs

4.5 - 10

10,000 - 22,000

10 - 15

22,000 - 33,000

>> 10

>> 22,000

Fig 5.7 Pallet lifting mechanism

Max. admissible wind speed mtr/s on side of vehicle

miles/h

Beaufort

WARNING: Do not expose to rain, see also important safety

instructions.

Page 23

Lifting on one wheel of a swing axle will create

a horizontal displacement of the lifting

5.9 VEHICLE TECHNOLOGY

IMPORTANT:

Basically single and paired operation are only meant for levelling a vehicle and/or in combination with axle stands. Safety guideline parameters:

- For single operation the maximum allowed

height difference is 2 inches.

- For paired operation the maximum

allowed height difference between front and rear axle is 6 inches.

- In case of a tandem axle on the rear the

maximum allowed height difference between both rear axles is 2 inches.

Lowering one column too far will cause:

- No load at all on this specific column!

- No load on diagonal opposite column!

- Double load on the remaining columns!

Columns used for very rigid vehicles (airplane tugs, trains) will be overloaded when lowering one column ½”to 2”.

Fig. 5.8-a

Fig. 5.8-c

Fig. 5.8-b

Swing axle:

column. (see fig. 5.8-c)

Page 24

6. OPERATION

The assembled lifting system must be checked for correct working and adjustments and a complete operational test should be carried out by using a typical vehicle.

Remarks:

- When using this lifting system leave a space for a 24" wide passage around the lifting system which can serve as

escape route.

- Before using the Mobile Lifting Columns, ensure that the maximum load for each lifting column is not more

than 18,000 lbs.

- Ensure that before use, the lifting system is placed vertically seen from the sides as well as from the front.

- Refer to section 5.7 for lifting system wind speed limits.

- Refer to section 5.8 for vehicle technology.

- Make sure that the pallet jack mechanism it is fully lowered before lifting a vehicle.

6.1 PREPARATION

1. Adjust the forks to the required distance, See section 5.6. (Only adjustable forks)

2. Place the required number of lifting columns.

3. Ensure that the fork of each lifting column is slid around the wheel as far as possible.

4. Lower the pallet jack mechanism by lifting the lever inside the tow bar.

5. Make sure the main switch on the lifting columns is set to 0 (OFF).

6. Connect the connecting cable between the lifting columns in a closed circuit.

7. Make sure that the Emergency Release buttons are unlocked on all the lifting columns.

8. Set the main switch to position 1 (ON), on ALL columns

9. Push the “SET REF”-button. Make sure the control voltage and the main supply light are on.

10. Check the mechanical safety lock.

11. Once desired height has been reached, it is recommended but not required that the lift be lowered into the mechanical

locks.

12. Once desired height has been reached turn main switches to 0 (OFF)

WARNING: Turn off the main switch when the columns

are not used. If not, the control system will slowly drain the batteries completely, resulting in damaged or defective batteries

6.2 RAISING AND LOWERING ALL LIFTING COLUMNS

See section 5, paragraph 5.3: Description of the mobile column lift system.

6.3 RAISING AND LOWERING OF TWO LIFTING COLUMNS

(ONE VEHICLE AXLE); PAIRED OPERATION

See section 5, paragraph 5.3: Description of the mobile column lift system.

6.4 RAISING AND LOWERING A SINGLE LIFTING COLUMN

See section 5, paragraph 5.3: Description of the mobile column lift system.

Page 25

6.5 EMERGENCY RELEASE

In emergency situations it is possible to lower the lifting columns manually. Manual lowering must only be performed by a qualified engineer.

7. INSPECTION AND MAINTENANCE

7.1 GENERAL

All maintenance on the lifting equipment must be performed only by trained lift service personnel.

During inspection and maintenance the columns should be in the lowest position and the main switch should be turned off. This means that the main switch should be turned to the 0 position and is to be secured with a padlock.

The current should be turned on again only for the adjustments and checks that require it.

The columns must be regularly serviced as listed. Once a year the lift must be subjected to a highly detailed check and inspection. You can have the car lift professionally checked by STERTIL mechanics by entering into a maintenance contract.

Maintenance and inspection

Cylinder

Check oil level in reservoir

Several pivot points

HYDRAULIC OIL

It is strongly recommended that the hydraulic oil be changed at least every 2 years, irrespective of the amount of use to which the lift is subjected.

Quantity of oil: 2.6 gallon

OIL CHANGING

1. Lower lift to fullest extent and drain all the oil.

2. Refill with hydraulic oil UNIL HVC S15 (ISO VG 15), filtered at 4 micron max.

7.2 DAILY (BY OPERATOR)

- Check for visible damage.

- Check for oil leaks in the hydraulic unit, lines and cylinder. Check battery capacity on the battery condition meter

Since this is a battery operated system, the battery capacity will have to be checked on a daily basis. When the main switch is ON (1) the capacity is monitored by the battery condition meter. It is advised to recharge the batteries when they are below the ½ full indication. Under normal conditions batteries need to be recharged after 12 to 15 full load cycles. Recharging an empty battery will take 12 to 16 hours.

Each column is provided with with an automatic battery charger . the charger can beconnected to mains by means

of the universal IEC connection on the front. (115V/60Hz/ 2Amp)

The charger is independent of the control system. This means that the main switch can be turned off while charging.

Lubrication chart

Description

Lubricate dry piston rod (machine oil) Top up (with car lift at ground level only)

Grease

Monthly yearly

Page 26

WARNING: Turn off the main switch when the columns

are not used. If not, the control system will slowly drain the batteries completely, resulting in damaged or defective batteries. Recharging defective batteries may result in the release of highly explosive gasses.

When the columns are not used for a longer time (2 or 3 weeks) it is advised to keep the battery charger connected to the mains. Since the battery charger will automatically stop charging when the batteries are full, there is no risk of overcharging.

Batteries are deep cycle (semi-traction) maintenance free enclosed type. They cannot be refilled with water. Pressure release is only opened when the batteries are overcharged .

WARNING: Use only the charger supplied with columns to

recharge the batteries, charging batteries with a standard type charger may result in the release of highly explosive gasses from the battery.

If batteries need replacement only use the original

equipment from Stertil-KONI. Universal car type batteries may release highly explosive gasses under normal charging conditions. Replacement of batteries must be done by skilled service people.

7.3 MONTHLY (BY OPERATOR)

Check hydraulic fluid level, and replenish as necessary.

- Remove the cover from the hydraulic unit. Ensure that the column is in its lowest position and check the oil level in

the plastic tank; the level must between the two horizontal marks.

- Fill up with UNIL HVC S15 (ISO VG 15), filtered on 4 microns, up to the end of the marks.

Check the emergency release mechanism.

- Push the emergency stop button when the columns are moving. All the columns should stop immediately.

- To release the emergency stop button turn it counter-clockwise, set the main switch(es) to O and then to 1 and

press the "SET REF"-button to restore control power.

- Check the functionality of the mechanical safety locks.

- Examine the lifting system for fluid leaks and signs of damaged or worn parts.

- Examine the electrical cables and connectors for signs of damage.

- Oil the dry piston shaft.

Page 27

7.4 ANNUALLY (BY SERVICE DEPARTMENT)

Check the mechanical safety lock (see fig. 7.1).

The lifting system must be inspected once a year by the service department of Stertil B.V. or by an agency approved by Stertil B.V. A maintenance contract can be arranged for this annual inspection with the Stertil B.V. Service Department. If no maintenance contract is entered into, the user himself should make an appointment each year for this inspection and servicing. This inspection is recorded on the inspection checklist (see page 43 or the ANSI/ALI ALOIM) and should include at least the following checks.

- Daily and Monthly checks.

- Check the gas spring for its proper functioning.

approximately 4".

- Check the general operation of the lifting columns.

- Take the locking device apart, clean its components, put it back and adjust as required.

- Check the hydraulic oil level.

- Every two years the hydraulic oil must be changed, even if the lifting system has not been used regularly.

- Set the lifting column at its lowest position. Remove the drain plug, from the bottom of the tank, and drain the oil. Install the drain plug.

- Fill the system (capacity 2.6 gallons) with UNIL HVC S15 (ISO VG 15) filtered at 4 microns max.

- Check the battery and battery cable connections, clean if necessary

Fig. 7.1, Mechanical safety lock adjustment

- With the pallet mechanisms in the highest position, lift a vehicle of 8,800 lbs, or more,

- Then check if the column rest on the floor.

• Set the lifting columns in the lowest

the internal switch SET+ and SET- in the control box).

• Raise the lifting columns to the first locking position and then

lower into it. Check whether the adjusting nut of the solenoid has a clearance of 1/8" - 5/32".

• If not, adjust the adjusting nut at the back of the solenoids to

become 1/8" - 5/32" clearance.

• Raise the lifting columns to the highest position and during

raising check clearance.

• Lower the lifting columns form their highest position in the

safety lock and check for 1/8" - 5/32" clearance; adjust, if necessary.

• Adjust the highest position stop, by means of the set pin of the

potentiometer, so that the guide block is placed 68 1/2" to 69 1/4" above bottom plate (see fig. 7.1)

position (if necessary, use

Page 28

7.5 MAINTENANCE SWITCHES

Maintenance switches are located inside the control box to assist the technician when servicing the lifting system (see fig. 8.1). These switches can be used to check the correct functioning of the lowering valve, unlock solenoid and the hydraulic unit. As long as the control system is still functional, the switches can also be used to check the safety margins for control.

7.6 REMOVAL/INSTALLATION OF THE LIFTING CYLINDER

Switch

DOWN * Lower and unlock.

UP *

SET+

SET -

* To make the use of “UP” and “DOWN” possible the MS relais (see page 38) must be bypassed. Turn-off the main switch and reconnect the red cable coming from the 200 AMP fuse to the other side of the relays. (under the nut of the interconnecting black cable) Turn on the main switch.

To remove the cylinder:

- At the top of the lifting column, remove the plastic cap and the nut and washer.

- Lift the guide block to the maximum height and then lower it to the first catch position.

- Push the SET REF and ⇓ (DOWN) buttons to lower the cylinder. It will take approximately 2 minutes for the cylinder to lower completely.

- At the bottom of the cylinder, release the hydraulic connection.

- Lift the cylinder approximately 3/4" to release the bottom of the cylinder from the notch. Pull the cylinder forward and away from the guide block.

- Remove the elastic ring from the cylinder head.

To install the cylinder:

- Place the elastic ring on the cylinder head

- Position the cylinder inside the guide block and engage the notch in the hole in the bottom plate of the cylinder.

- At the bottom of the cylinder, connect the hydraulic connection.

- Push the SET REF and the ⇑ (UP) buttons to lift the cylinder.

- Release the buttons when the cylinder starts to lift the guide block (the cylinder head must be positioned through the hole in the head plate).

- Press SET REF and the ⇓ (DOWN) buttons to lower the guide.

- Mount the nut and the washer.

- Push the SET REF and the ⇑ (UP) buttons and open the air bleed until a continuous flow of oil appears. Close the air bleed and install the cap.

Description

Lifting.

Lifting without safety limits

Lowering without safety limits.

Function Operates the lowering valve and the

unlock solenoid on the lifting column at which the switch is operated.

Operates the electric motor on the lifting column at which the switch is operated (lifting column raises).

These switches lift and lower all the lifting columns in the loop. The safety margins of 1 1/4" and 2 1/2" will be ignored. The system will control the heights of the guide blocks so they become level.

Page 29

7.7 ADJUSTING THE PALLET JACK MECHANISM

When moving the handle bar up and down, with the lever in position 3 (see fig. 7.7), the cylinder should at the correct setting be raised approx. 5/16" per stroke. Set the lever to position 2 and move the handle bar up and down; at a correct setting the cylinder will not be raised now. When the cylinder is raised, nut 1 must be loosened and the adjusting nut be turned clockwise. When the cylinder comes down, the adjusting screw must be turned anti-clockwise until the cylinder does not come down any further. Bring the cylinder in its highest position and set the lever to position 1; now the cylinder should come down. When it comes down slowly or not at all, the adjusting screw must be slightly tightened.

Repeat the aforementioned steps until all movements are normal. When the settings are right, nut 1 can be tightened.

Fig. 7.7, Adjusting the pallet jack mechanism

7.8 ADJUSTING RETRACTABLE FRONT WHEELS

Adjustment of the front wheels must be done with the pallet jack mechanism in the highest position. Adjust the ground clearance at 1 ¼” by turning the adjusting nut. (see fig. 7.8)

Fig. 7.8

Page 30

8. SERVICE

8.1 GENERAL

Attention: All repairs carried out on the lifting system by non-service department personnel, the consequences of

such repairs are entirely at the user's risk.

The term 'service department' is the Stertil service department or a service department recognized by Stertil.

Two tables are provided to assist the service technician in locating faults in the lifting system . The first table shows the faults indicated by the LED’s on the microprocessor board (see fig. 8.1) and the second table shows possible mechanical faults. When a fault occurs, the "SET REF" light on the control panel will go out. On the box where the fault has occurred the "SET REF" light will start flashing. When serious failures occur, e.g. height differences of over 2 1/2” between columns will create an emergency stop, both the "SET REF" light and the mains power light will go out. In the box subject to failure faults are indicated by means of 4 LED’s (see sticker (fig. 8.1) in the control box and table on page 31). Remove the two bolts on the left side to open the hinged cover. To open the control box , remove the four bolts inside the cover, so that the inside of the box can be reached from the opening in the back.

Remarks:

- Danger of getting injured by high amperage and when used inexpertly .

- Only open the covers to carry out maintenance. In this case make sure that the lifting system is disconnected from the electrical power supply.

- Faults can be released by holding the “SET REF” button pressed for 2 seconds until control light is on.

If the fault cannot be released, check the trouble shooting list in 8.2. Turn ALL main switches OFF(0) before turning them ON (1) again. Press “SET REF” two times to start the system again.

The microprocessor board is equipped with 4 LED’s for indicating failures; the order in which they are lit indicates the type of defect as described in 8.2.

To see the LED’s open the control box cover.

Refer to fig. E and H for identification of components.

Page 31

MICROPROCESSOR BOARD

Fig. 8.1, Location of fault indication LED’s

Page 32

8.2 TROUBLE-SHOOTING

LED

INDICATION

Potentiometer Fault

Communication Fault

Hardware fault in the communication circuit.

A defect in the control system

defect in the 24V outputs

Since the last zero setting of the system, height differences of over 2 1/2" have occurred during operation.

A difference of 2 3/4" or over has occurred during standstill.

Emergency stop

Fault in the unlocking solenoid circuit

Fault in lowering valve circuit Fault in adjusting valve circuit

POSSIBLE FAULT

REMEDY

Check the wiring to the potentiometer. Hold “SET REF” button for 2 sec until control light is on. If the fault occurs again, contact the Stertil B.V. Service Department.

Check the connecting cables between the boxes. Connect one auxiliary box to the main box using - preferably - new cables. Start the system according to the standard procedure. Continue extending the system by one auxiliary box until the defective cable or box has been traced. If necessary, replace the connecting cable or have the microprocessor board replaced by the service department.

Check if all wires in the box and the communication cable are connected. If the fault occurs again, contact the Stertil B.V. Service Department

Set all main switches to OFF and then again to ON and press the "SET REF" button twice. If the defect occurs again, contact the service department.

Set the main switches to OFF. Check and if necessary replace fuse F2 (3, 15 A).. Turn the control boxes on to ON according to normal procedure. When this defect occurs repeatedly, contact the service department.

Check the hydraulic system for leaks. Check whether the load per lifting column is higher than 18,000 lbs Hold “SET REF” button for 2 sec until control light is on. When the defect occurs again, contact the service department.

Check whether the hydraulic system is leaking. Hold “SET REF” button for 2 sec until control light is on. When the defect occurs again, contact the service department.

Check the emergency stop switches and release them if necessary. Hold “SET REF” button for 2 sec until control light is on.

Check the wiring and coil for short-circuits or damage and repair if necessary. Hold “SET REF” button for 2 sec until control light is on. If necessary contact the service department.

Page 33

FAULT POSSIBLE CASE REMEDY

Column does not lift.

No battery power.

Oil level too low.

Air in hydraulic pump (only possible after the tank has been empty).

Safety valve not properly adjusted

Pump has insufficient yield.

Maximum height difference (more than 2 1/2") exceeded.

Check main fuse above batteries inside cover. Have batteries tested by qualified battery supplier

Add oil as necessary, refer to lubricating instructions on lifting column.

Press the ⇑ (UP) and SET REF buttons until the lifting column rises (max. 1 minute).

Have valve adjusted, contact Service Department to check the valve.

Replace the pump.

Hold “SET REF” button for 2 sec until control light is on. If the defect occurs again, contact the service department.

Column does not lower.

No battery power.

Catching pawl not disengaged from locking system.

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

Dirty lowering valve.

Maximum height difference (more than 1 1/4") exceeded.

Maximum height difference (more than 2 1/2") exceeded.

Check main fuse above batteries inside cover. Have batteries tested by qualified battery supplier

Raise column approximately 2" and then lower.

No mains power for solenoid or lowering valve is faulty. Have fault corrected by the Service Department.

Have valve cleaned or replaced by service department.

Press lifting button until the height difference has been cancelled out. If lifting is not desired, the "SET REF" button can be pressed once. Following, lowering can be activated. The difference of 1 1/4" will be maintained. If the defect occurs again, contact the service department.

Hold “SET REF” button for 2 sec until control light is on. If the defect occurs again, contact the service department.

Highest position stop practically nearly equal to highest locking position stop.

Slightly raise the ramp by touching S2. Then set highest position stop (see fig. 8.1)

Page 34

FAULT POSSIBLE CASE REMEDY

Column lowers by itself.

Column does not lift properly.

The cylinder seal is damaged, oil leaks continually.

Leaks in the oil line couplings.

Dirty or damaged non-return valve.

Dirty or damaged lowering or correction valve.

Oil level in tank too low.

Pump drawing-in air.

Have seals or cylinder replaced by service department.

Tighten couplings and coupling nuts.

Clean the filter and the ball behind the filter.

Clean or replace valve.

Add oil as necessary, refer to lubricating instructions on lifting column.

Tighten the suction filter fastening or crimp tighter.

Columns lift at different heights.

No control power (control power indicator is OFF, mains power indicator is ON).

The steel plug has not been replaced by the breather cap

Breather cap blocked.

Control system not working correctly.

Lifting system may not be set up correctly.

LED defective.

Blown fuse.

Main switch OFF.

Broken cable or loose connector. Check cable and connector.

Install the breather cap

Clean breather cap.

Use internal switches S3 and S4. S3 lifts the column and S4 lowers the column. Operate the switches until the columns are synchronized. If the fault occurs again, contact the Service Department.

Follow the procedures in sections 6.1 and 6.2 of this manual. If the fault occurs again, contact the Service Department.

Contact the service department.

Check the fuses F1, F2 and F3. If necessary, replace the fuse(s) in the control box. If fault occurs again, contact the Service Department.

Set main switch ON.

The emergency stop button has not been unlocked.

Release the button. Hold “SET REF” button for 2 sec until control light is on.

Page 35

FAULT POSSIBLE CASE REMEDY

No mains power (control power indicator and mains power indicator are off)

Push button indicator (LED) flashes when the ⇑ (UP) button is pressed.

8.3 IDENTIFICATION

The lifting system has an identification label. The label is located on the left side of the lifting column, above the control box.

9. LIST OF PARTS AND APPENDICES

9.1 PARTS LIST

Index: The numbers in this column refer to the numbers in the parts drawing. Reference: The numbers in this column are STERTIL-KONI part numbers.

Description: This column gives the name of the parts.

9.2 ORDERING SPARE PARTS

Replacement parts can be ordered from Stertil, for addresses see §1.1. The following information should be given when ordering spare parts:

Type of lifting system : ST 1082-F/BAT, ST 1082-F/V/BAT or ST 1082-R/BAT Serial number : see preceding or identification label on lifting column. Reference nr. : see fig. A t/m K.

No mains supply.

Mains fuse blown.

Mains switch OFF.

LED’s faulty.

The column has reached the maximum height.

Please give these numbers when ordering.

Have fault corrected by qualified electrician.

Replace fuse.

Set mains switch ON.

Contact the service department.

The column will function normally if the ⇓ (DOWN) button is pressed.

Page 36

FIG. A

- MOBILE LIFTING COLUMN

INDEX REFERENCE DESCRIPTION INDEX REFERENCE DESCRIPTION

ST 1082-BAT ST 1082

1 See fig. E/F Cover / Control Box 27 65050144 Nut M20 DIN934 2 30501003 Packing ring 28 1035.38.04.11 Bolt M6x10 DIN933 3 66201039 Nut cap M20 0342044 29 65055015 Washer M6 DIN125A 4 32700104 Roller 30 65055013 Washer M4 DIN 125A 5 32700101 Angle support 31 65034219 Screw M4x10 DIN 7985 6 32500116 Wheel 32 65062041 Retaining washer A24 DIN 679 7 32711050 Column (ST 1082-F) 33 65058028 Washer M10 DIN 127B

32741100 Column (ST 1082-F/V) 34 65055024 Washer M16 DIN125A 8 32700117 Plate 35 65003526 Bolt M16x25 DIN 933 9 32500109 Shaft 36 1036.46.03.45 Set screw M5x12 DIN 916

10 32702100 Guide block (ST 1082-F) 37 65003403 Bolt M10x20 DIN 933

32741125 Guide block (ST 1082-F/V)

11 69090050 Grommet No. 2790 type 2 12 32706075 Oil pipe 13 See fig. D Hydraulic cylinder 14 68700450 Straight adaptor GE 10-PS

**15 See fig. G Connection cable

16 32736150 Hydraulic hose 17 30001006 Slide plate 18 30007400 Potentiometer unit 19 See fig. C Hydraulic unit 20 See fig. B Pallet jack mechanism 21 32700122 Pawl 22 65050124 Nut M4 DIN 934 23 30001004 Clamp 24 66201085 Buffer 25 69451400 Solenoid 26 65058044 Spring ring M20 DIN 127B

** Item not shown on figure.

See fig. B for retractable wheels and adjustable forks

Page 37

FIG. A

Page 38

FIG. B - MOBILE LIFTING COLUMN

INDEX REFERENCE DESCRIPTION REMARKS

1 32701050 Column Only ST 1082-R/BAT 2 32700111 Shaft Only ST 1082-R/BAT 3 66103909 Ball bearing 60052RSR Only ST 1082-R/BAT 4 32700105 Wheel Only ST 1082-R/BAT 5 32700110 Wheel shaft Only ST 1082-R/BAT 6 65725009 Bolt M10x20 DIN 7984 Only ST 1082-R/BAT 7 32700170 Hinge ass’y Only ST 1082-R/BAT 8 66103908 Bush bearing GFM-1214-10 Only ST 1082-R/BAT 9 32700160 Pull rod Only ST 1082-R/BAT 10 65051036 Locknut M12 DIN 985 Only ST 1082-R/BAT 11 32700225 Hinge tube Only ST 1082-R/BAT 12 32700128 Push plate Only ST 1082-R/BAT 13 65062028 Retaining ring Nr. 12 DIN 6799 Only ST 1082-R/BAT 14 32700129 Axle Only ST 1082-R/BAT 15 65025007 Bolt M10x30 ISO 7380 Only ST 1082-R/BAT 16 32700200 Torsion bar Only ST 1082-R/BAT 17 32700121 Shaft All models 18 1038.66.04.24 Roll pin 6x30 DIN 1481 All models 19 32706200 Jack assembly All models 20 65214358 Adjusting screw M8x8 DIN 916 All models 21 1037.07.50.08 Nut M8 DIN 439B All models 22 32550103 Shaft All models 23 32700120 Cap All models 24 32700250 Balancer Only ST 1082-R/BAT 24 32700300 Balancer Only ST 1082-F/BAT 25 32550102 Shaft All models 26 60203002 Gas spring All models 27 60203003 Clamp All models 28 65762024 Retaining ring Nr. 9 DIN 6799 All models 29 32700150 Front support Only ST 1082-R/BAT 30 32700131 Plastic cover Only ST 1082-R/BAT 31 66201102 Handle Option adjustable forks 32 60201703 Spring Option adjustable forks 33 32700118 Pin Option adjustable forks 34 32702000 Guide block for adjustable forks Option adjustable forks 35 32702085 Adjustable fork (right) Option adjustable forks 36 32702075 Adjustable fork (left) Option adjustable forks 37 65760012 Retaining ring a12 DIN 471 Only ST 1082-R/BAT 38 66201055 Spacer 12.8-18-15 All models

For other parts see FIG. A

Page 39

FIG. B

Item 6 locked with loctite 542 sealant

Page 40

FIG. C – HYDRAULIC UNIT

INDEX REFERENCE DESCRIPTION REMARKS

68038427 Hydr. unit 1.2cc, 24V 265 bar/3800 psi

1 68039011 Tank plastic 10 liter/2.64 gallon 3 68510911 O-ring 110.72x3.53 mm 4 32506103 Suction filter D.62 dia. 3/8" 5 32006254 Return filter 10 micron 6 32516105 Pump 1.2 CM3/REV Tightening torque 16.5 lbf ft 7a 68308013 2/2 Valve NC (ex. solenoid) Tightening torque 22 lbf ft 7b 68308005 2/2 Valve NC (ex. solenoid) (incl. manual ering) Tightening torque 22 lbf ft 8 68510124 O-ring 12.42 x 1.78 mm 9 69481501 Solenoid 24 VDC EC 30D 12 32556908 Pressure relief valve 265 bar/3800 psi Tightening torque 18.5 lbf ft 13 68039015 Half coupling pump side 15 68039014 Electric motor 4HP 24VDC 3300 rpm 16 32556904 Check valve Tightening torque 16.5 lbf ft 17 68039004 Breather cap 18 Seal cap 19 32556902 Flow control valve 2 Ltr. 20 32556903 Flow control valve 6 Ltr. 21 Transport plug

Hydraulic scheme

Page 41

FIG. D – HYDRAULIC CYLINDER

INDEX

1 2 68515702 * 3 * 4 * 5 6 68515402 7 8 9 * 10 11 12 13 1003.91.80.38 14 * 16 17 68900000 * 32706900 Seal kit (ST 1082)

REFERENCE DESCRIPTION

ST 1082

32706800

68700450 65455001

Cylinder (assembly) Cylinder bottom Oring Ø70x2.5 Retaining ring Piston seal

Oring Ø50x2 Piston Cylinder Piston rod Bearing ring Retaining ring Piston cap Hose burst check valve Union GE10 PSR 1/4" Copper sealing ring Air bleeding nipple

Page 42

FIG. E - CONTROL BOX

Page 43

FIG. E - CONTROL BOX

NDEX REFERENCE DESCRIPTION

1 32737100 Control box (incl. cables) 2 68039013 Motor relays 24Vcc 150A 3 69500104 Battery charger Mean Well 230/110V 24V 10.5A 4 69120026 Battery switch PN 9006 5 69206403 Fuse holder 5007 Class T 110-200A 6 69206102 Fuse 200A 300V A3T200 7 69800001 Battery 12V/104Ah VDC31M VMF 8 69302016 Connector PX0580/63 9 69004002 Mains cable 10 32737190 Cable relays - +motor L=41 ½” (1050mm) 11 32737170 Cable switch – fuse L=15 ½” (400mm) 12 32737165 Cable +battery – switch L=13 ½” (350mm) 13 32737180 Cable –battery - +battery L=27 ½” (700mm) 14 32737185 Cable –battery - -motor L=51” (1300mm) 15 69900230 PCB 16 69900220 Adapter PCB 17 69203001 Battery condition meter 18 69900131 Pushbutton board and flat cable 19 69141061 Emergency stop button 20 69141041 NC contactor 3 SB 3400-0C 21 69090107 Connector 22 69090109 Connector internals (male) 23 69090108 Connector internals (female) 24 69141115 Pushbutton 25 69141011 Multiled yellow 26 69141120 Lamp socket 27 Cable gland M20x1.5 22052um2x6 28 Cable gland M20x1.5 22052u11 29 Cable gland M25x1.5 22553um2x8 30 3501.50.90.08 Fuse 5 AT 31 69206004 Fuse 200 mAT

ST 1082-BAT

Page 44

FIG. F – SCHEMATIC DIAGRAM

Page 45

FIG. G

- CONNECTION CABLE

INDEX REFERENCE DESCRIPTION

1 2 3 4

32737160 Cable (39’ – 9’’) assembly) 69090106 Housing 69090108 Connector internals (female) 69090109 Connector internals (male)

REMARKS

Page 46

FIG. H - PALLETJACK SERVICE KITS

INDEX REFERENCE DESCRIPTION

1 2

32706205 32706210

Hydraulic valve ass’y

Spring cover ass’y 3 32706215 Pump piston ass’y 4 32706220 Lowering valve ass’y 5 32706225 Lowering screw ass’y 6 32706230 Safety valve ass’y 7 32706235 Pump unit 8 32706240 Handle ass’y * 32706245 Seal kit

REMARKS

Page 47

FIG. I - LABEL LOCATIONS

INDEX REFERENCE DESCRIPTION

1 2 3

10 11 12 13 14 15 * 60702002 16 * 60702003 17 19 * 60702008 20 21 22 26 * 32738980

ST 1082

60700224

1005.01.01.92 60700189 60700061 60700092 60700203 60700093 60700090 60702001 60702004 60702005 60702006 60700218 60700219

60700131

60700134 60702010 60700193

* Item not shown on figure

User instruction sticker Type plate Sticker “Oil dry piston rod….” Large sticker "STERTIL/KONI" Sticker "CAUTION" Capacity sticker "18.000 lbs" Sticker "WARNING" Address sticker "STERTIL KONI USA" ALI member label Uniform warning label Caution label Safety instruction label Sticker “FAULT INDICATION” Sticker “SCHEMATIC DIAGRAM” Safety manual “LIFTING IT RIGHT” Card “SAFETY TIPS” Sticker "CAUTION/ATTENTION" American Nat. Standard Label Do not use.../Ne pas... ALI/ETL/CSA label standard 201 Sticker “SAFETY INSTRUCTIONS”. Service manual

Page 48

4x item 5)

may only be used with arm

FIG. J - WHEEL ADAPTORS & EXTENDED ARM (OPTION)

INDEX REFERENCE DESCRIPTION REMARKS

1 32503050 2

34000930 Wheel adaptor 16" (length = 500 mm / 20") Only for ST 1082F (fixed wheels) Max. 8,800 lbs

*3 32550905 Longer wheel adaptor (length = 500 mm / 20") Only for ST 1082F (fixed wheels) Max. 12,000 lbs *4 32550915 Arm extension Only for ST 1082F (fixed wheels) *5 32500109 Shaft Only for ST 1082F (fixed wheels) *6 1038.34.02.40 Retaining washer A24 DIN6799 Only for ST 1082F (fixed wheels) *7 65003530 Bolt M16x40 8.8 DIN 933 Only for ST 1082F (fixed wheels) *8 1037.07.50.16 Nut M16 DIN 439B Only for ST 1082F (fixed wheels) *9 66700206 Label 5500 kg/ 12,000 lbs Only for ST 1082F (fixed wheels) 10 66700150 Label 4000 kg/ 8,800 lbs Only for ST 1082F (fixed wheels)

* 32550910

Wheel adaptor 16" (length = 300 mm / 12") All models

Extension set (2x item 2, 3, 4, 6,7 and 8

Only for ST 1082F (fixed wheels)

WARNING: Longer wheel adaptors

extensions!! See attached label on longer wheel adaptors for max. usable capacity.

Page 49

FIG. K - DIMENSIONAL DRAWING

ST 1082-F/BAT (with fixed forks) ST 1082-R/BAT (with adjustable forks option)

ST 1082-F/V/BAT (widened model)

* 27 ½ ” ** 49 ”

Page 50

INSPECTION CHECK LIST

Annual inspection as described under 7, "Inspection and Maintenance".

Date

Remarks

Name of mechanic

Initials of mechnicpass

Page 51

Page 52

Manufactured by:

STERTIL B.V.

P.O. Box 23, 9288 ZG Kootstertille (Holland) Tel. 31(0)512334444. Telefax 31(0)512334430.

www.stertil.nl email: [email protected]