Enerpac SBL1100 Instruction Manual

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Instruction Manual

M ANU AL

Super Boom Lift

SBL1

SBL1100

- 1100 Sh. Te Hydraulic Gantry -

100

Document number ED.02518.001.R03.ENG Issued Revision No. 3 Revision Date 27-06-2011

23-12-2010

Dear customer,

This is the manual for the Enerpac product you have purchased.

This manual contains important information for the correct use and safe operation of the machine.

If this manual should become wholly or partly unusable, you can order a new replacement copy of it, making reference to the number shown on the cover.

Enerpac reserves the right to modify this manual at any time, at its discretion or according to its advancing insight.

ED.02518.00.001.R03.ENG

Page 2

Contents

Contents ______________________________________________________________________ 3

Introduction ___________________________________________________________________ 5

1. General Information _________________________________________________________ 7

1.1. General _______________________________________________________________________ 7

1.2. Manufacturer’s address __________________________________________________________ 7

1.3. Declaration ____________________________________________________________________ 7

1.4. Identification __________________________________________________________________ 7

1.5. Liability _______________________________________________________________________ 8

1.6. Appropriate use ________________________________________________________________ 8

1.7. Application limits _______________________________________________________________ 8

1.8. The basic principle ______________________________________________________________ 9

1.9. General Specifications ___________________________________________________________ 9

1.10. Machine overview ___________________________________________________________ 10

2. Safety ____________________________________________________________________ 11

2.1. Mandatory protective gear while working with or on the system _______________________ 12

2.2. Explanation of symbols in this manual _____________________________________________ 12

2.3. Explanation of symbols on the machine ____________________________________________ 13

3. Preparation for a lifting operation _____________________________________________ 14

3.1. Lifting capacity of the units ______________________________________________________ 15

3.2. Capacity of the Side shift or Lug __________________________________________________ 18

3.3. Capacity of the Header beam ____________________________________________________ 19

3.4. Surface loading for full support of the skid tracks ____________________________________ 19

3.5. Surface load with filler material under the skid tracks ________________________________ 21

3.6. Maximum permissible wind loading _______________________________________________ 23

4. Explanations of Methods ____________________________________________________ 24

4.1. Storage ______________________________________________________________________ 24

4.2. Handling _____________________________________________________________________ 25

4.3. Placement of the skid tracks _____________________________________________________ 29

4.4. Placement of the unit __________________________________________________________ 36

4.5. Connection of power cable ______________________________________________________ 36

4.6. Erect the mast ________________________________________________________________ 37

4.7. Mounting the header beams _____________________________________________________ 40

4.8. Mounting the side shift _________________________________________________________ 41

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5. Before raising the load ______________________________________________________ 42

6. Checklists _________________________________________________________________ 44

6.1. Preparation for a lifting operation ________________________________________________ 44

6.2. Setting up the portal system _____________________________________________________ 45

6.3. Before raising the load __________________________________________________________ 45

7. The operation of the machine _________________________________________________ 46

7.1. The control panel on the unit ____________________________________________________ 47

7.2. The Intellilift control panel ______________________________________________________ 49

7.3. Manual control ________________________________________________________________ 50

7.4. Intellilift control _______________________________________________________________ 50

7.5. Mechanical locking ____________________________________________________________ 62

8. Special applications _________________________________________________________ 64

8.1. Tilting a load __________________________________________________________________ 64

9. Maintenance ______________________________________________________________ 67

9.1. Lubrication Points _____________________________________________________________ 68

9.2. Maintenance of the hydraulic system _____________________________________________ 69

9.3. Adjust guides _________________________________________________________________ 72

9.4. Lubricating the rams ___________________________________________________________ 76

9.5. Roller Chain __________________________________________________________________ 78

Appendices ___________________________________________________________________ 80

Appendix A Checklist for work preparation ______________________________________________ 80

Appendix B Checklist for setting up the machine __________________________________________ 82

Appendix C Checklist for lifting the load _________________________________________________ 83

Appendix D Hydraulic fluid safety information sheet ______________________________________ 85

Appendix E Skid track requirements ____________________________________________________ 90

ED.02518.00.001.R03.ENG

Page 4

Introduction

Dear customer,

In purchasing the SBL portal lift system, you have bought a quality product from the Enerpac company. We thank you for the confidence you place in us by your purchase of this portal lift system.

Operating an SBL system is only permitted if you are certified by Enerpac as an authorised operator.

In order to be able to use the portal lift safely, we urgently request you to read this manual thoroughly before you start working with the machine.

The manual is made up in such a way that you are comprehensively provided with information during the course of the working situation. The whole consists of comprehensive directions and instructions about maintenance, safe use, safe practices and specific safety instructions. It is necessary, important and advantageous to the proper function and reliability of your SBL portal lift system, and to maintain its value, to take these directions and instructions into account.

Note:

In the rest of this manual, the portal lift is also referred to by the term “Machine”.

NOTE:

This manual is part of the machine.

Only operate the machine after you have been trained, and taking this manual into account.

Follow the safety instructions exactly!

Also observe the applicable directions to prevent accidents and the generally recognised safety regulations, as well as the health and safety inspectorate’s regulations.

All information, illustrations and technical data in this manual are applicable to the situation existing at the time of publication.

We strive continuously to improve our products and therefore reserve the right to implement improvements and changes whenever it is necessary and possible to do so, without any obligation to apply improvements or changes to models purchased previously.

If this manual should become wholly or partly unusable, you can order a new replacement copy of it, making reference to the number shown on the cover.

This manual is continually updated. We welcome suggestions which make the reading of this manual or the use of the SBL system easier or safer.

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even death.

Introduction

Despite the fact that this manual has been drafted with great care, we cannot guarantee that it does not contain any errors. The interpretation and use of that described in this document and possible consequences through improper use of the system are wholly the responsibility of the user. Enerpac shall under no circumstances accept responsibility for such improper use.

Improper use of the machine or failure to take the changes indicated in this manual into consideration may result in accidents causing damage not only to the machine itself, but also to objects and goods in its vicinity or mounted to the machine, as well as injuries to people in the immediate area, and possibly

All rights reserved. Nothing in this publication may be duplicated, stored in an automated database or made public in any form or in any manner, whether electronic, mechanical, by photocopying, recording or any other means, without prior written approval by Enerpac.

We hope you find your Enerpac machine very useful.

Enerpac.

ED.02518.00.001.R03.ENG

Page 6

General Information

Enerpac Integrated Solutions B.V.

1. General Information

The manual contains fundamental instructions that must be taken into consideration in preparing for a lifting operation, and for assembly, use and maintenance. For this reason it is essential that the user read this manual before working with or on the machine, and it must always be available for reference.

Points that must be followed are mentioned, not only in the safety chapter; in other chapters too there are specific directions that must be read and followed.

1.1. General

This manual applies to a complete SBL1100 system.

1.2. Manufacturer’s address

Enerpac Integrated Solutions B.V. Opaalstraat 44 7554 TS Hengelo The Netherlands Tel. +31 - 74 - 242 20 45 Fax. +31 - 74- 243 03 38 E-mail: info.hengelo@Enerpac.com

1.3. Declaration

EC Conformity declaration according to Directive.

1.4. Identification

Each unit; header beam, side shift and skid track is provided with a type plate as illustrated below.

The type plates are official documents and must not be altered or made

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illegible!

Page 7

General Information

1.5. Liability

In the risk analysis conducted by Enerpac, intended usage and reasonably foreseeable incorrect usage of the SBL portal lift system were assessed. The instructions in this manual came into being based upon this analysis.

It is expected of the user of the SBL portal lift system that he or she has read and understood this manual.

In cases of doubt about the use or application of this machine, always make contact with Enerpac for advice and recommendations.

Unauthorised alterations to the machine may have a deleterious effect on the characteristics of the machine and may disrupt the control functions. Unauthorised alterations therefore annul any resultant damage claims against the manufacturer.

1.5.1. Limitations of liability:

We accept no liability whatsoever:

- for damage as a result of this equipment;

- to objects and third party equipment;

- to vehicles;

- for personal injury.

1.6. Appropriate use

The SBL1100 hydraulic portal lift is a four point lifting system. All four units must always be used when lifting or transferring various objects. The centre of gravity (C.O.G.) of the load must always remain within the four feet and under the header beam.

The machine has been designed to be controlled using the associated Intellilift remote control. Using this, the user can and must remain outside the range of the machine while working with it.

Additional possible applications for the machine with the associated warnings are to be found in Chapter 8, “special applications”.

The machine must not be used in potentially explosive environments.

1.7. Application limits

The application limits for the capacity, lifting height, skew, wind and environmental influences are the maxima either calculated or tested by the manufacturer. During practical applications, you must bear in mind that, through influences these characteristics may exercise on each other, they may reinforce each other, and must then be appropriately altered. Enerpac can advise you on this point.

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General Information

(1)

(2)

used because they may lock up.

1.8. The basic principle

Each lifting unit consists of a basic frame with its own drive and octagonal telescopic masts. In each telescopic mast there is an extending hydraulic ram.

The internal propulsive force is provided by a hydraulically driven roller track system. This reduces the basic loading in comparison with conventional wheels. Moreover, the resistance when bridging rail systems is reduced. It is impossible for wheels to slip through!

One of the unique characteristics of the SBL1100 portal lift is the integration of the power source into the basic frame. In contrast to conventional systems, this means no separate power source and no hoses or data cables between power source and units.

The beams across the top of the units create a portal. The load is affixed to the beam by means of a side shift module or lifting anchor.

1.9. General Specifications

Each separate unit has a load carrying capacity of 2,670 kN. The exact permissible loading is described in detail in Chapter 3. The hydraulic pumps have a fixed stroke capacity. The machine's speed is variable thanks to the built-in frequency controller.

Specification of the power source:

Voltage.......................................................................... :360 to 480 V AC/ 3-phase

Current.......................................................................... :16 A per unit

Frequency...................................................................... :50-60 Hz

Power............................................................................ :7.5 kW per unit (10 hp)

The units feature automatic phase selection according to the rotation direction of the electric motors.

Noise pressure................................................................ :77 dB(A)

Temperatures

Minimum operating temperature of the machine.................. :-25°C

Maximum operating temperature of the machine................. :50°C

Minimum storage temperature of the machine.................... :-25°C

Maximum storage temperature of the machine................... :60°C

Minimum storage temperature of the Intellilift control panel.. :20°C/0°C Maximum storage temperature of the Intellilift control panel. :60°C/45°C

(1)

measured at ear height at nominal loading one metre away from any unit’s

electric motor

(2)

While charging the battery.

NOTE:

ED.02518.00.001.R03.ENG

There is a risk of ice accretion at temperatures below 0ºC. If ice has accreted on machine components, they cannot be

Page 9

1.10. Machine overview

General Information

1) Skid track Required

2) Lift unit Required

3) Header beam* Required

4) Side shift unit** Required

*The figure shows a 10-metre beam. Beam dimensions and material may vary from customer to customer. ** The figure shows an HBS6000 Side Shift unit. It is also possible to opt for a different type of side shift, or fixed anchors.

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Safety

2. Safety

Points that must be followed are covered not only in this chapter; in other chapters too there are specific safety directions that must be read and followed.

It is very important to inspect the condition of the SBL system before every individual start-up, given the fact that the slightest defect may have disastrous, and in some cases fatal, consequences.

Keep your equipment clean. Badly maintained equipment can cause time wastage and lead to permanent damage to the equipment and/or it surroundings.

Do not use equipment, whether loaded or not, while people are in the vicinity of the equipment or object. The SBL series has been designed for used without manpower inside the range of the portal lift, and must be operated according to the instructions.

Only operate the SBL system if you have been certified by Enerpac as an authorised operator.

Only use original Enerpac spares to repair machine faults.

Maintain concentration during the work. Carelessness may result in serious injuries to others, and possibly even death.

Additional lifting gear and accessories such as hawsers, shackles etc. must comply with the legal requirements imposed in the country of use.

Enerpac is not liable for improper use of such accessories in combination with the SBL system.

Adhere to the checklists during all work activities: during preparation for the lifting operation, system construction, and for lifting the load. Failure to adhere to the checklists may result in serious injury to the user, possibly even death.

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Safety

2.1. Mandatory protective gear while working with or on the system

Ensure that you and other people in the vicinity and during the operation of the portal lift wear a safety helmet and that the applicable safety regulations are observed. Wear safety footwear, safety goggles, and, when not using the remote control, safety gloves*.

*We strongly advise against wearing safety gloves while using the Intellilift remote control.

2.2. Explanation of symbols in this manual

The following symbols are used in this design manual to elucidate the various specific instructions.

Indicates to the user that something needs to be filled in on the checklist.

Gives the user hints and tips on simple control procedures and work activities

General warning to the operator for possible damage to equipment and to the environment in general.

Draws the user's attention to risks to personnel if work instructions are not followed precisely

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Safety

4 stickers (On protective caps)

2.3. Explanation of symbols on the machine

Instructions on labels applied directly to the machine must be followed without question, and always be kept in a fully and properly legible condition.

1. Risk of trapping parts of the hand

2. Risk of trapping parts of the foot

3. Risk of falling

4. Risk from electricity

4 stickers (Around the bottom ram)

2 stickers (visible from stage)

2 stickers (On motor and Switchbox)

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Preparation for a lifting operation

3. Preparation for a lifting operation

In this chapter, the essential preparations for a lifting preparation are comprehensively described. Before this preparation can be started, certain information must be known:

• Mass of the load.

• Centre of gravity of the load.

• Dimensions of the load.

• Maximum lifting height.

• Allowable pressure on the subsoil before subsidence happens.

First, the position of the load’s centre of gravity within the units should be determined. Then the maximum lifting height is determined.

Thereafter, it is checked whether the following details are adequate:

• Lifting capacity of the most heavily loaded unit.

• Capacity of the side shift.

• Capacity of the header beams.

• Load capacity of the subsoil.

Finally, the maximum acceptable wind speed should be calculated.

This preparation results in: A checklist for use while setting up the machine. A checklist the operator must follow during use of the machine.

It is of the utmost importance to read this whole chapter carefully before setting up the machine.

Failure to prepare correctly for a lifting operation may result in total loss of machine stability during use.

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Preparation for a lifting operation

⋅

3.1. Lifting capacity of the units

Determine the maximum for the lifting height needed for your lifting operation.

3.1.1. Maximum load

The portal lift system comprises four units. Given the fact that each unit is provided with a telescopic hydraulic ram, the capacity varies according to the phase. The working pressure for each step is around 350 bar. This results in the following lifting capacities:

stage: 2670 kN, → lifting height: 0 mm to 2934 mm

stage: 1750 kN, → lifting height 2934 mm to 5698 mm

stage: 1000 kN, → lifting height: 5698 mm to 7632 mm

Theoretically, this means that the maximum loading is this is only applicable if the load is evenly distributed over the portal lift. In other words, if the centre of gravity is positioned in such a way that each lifting units carries exactly the same load. This is naturally a situation that never arises in practice. In order to prevent overloading of the portal lift, the loading table must be used.

Dimensions of the units, beams, side shift, and skid tracks. may be found in Appendix D to G. This information can be used to determine the required lifting height.

Fill the maximum lifting height into the checklist in appendix A

1068026704

kN. But

The figure shows the orientation of the table with respect to the portal lift.

The coloured cells in the load chart correspond to the lifting units in the figure

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The stability of the system is such that if the COG is positioned in the centre of the machine, then any movement of the COG out of the ideal centre will result in reduced stability of the overall system.

The table on the next page should always be used before and during side-shift operations. During this kind of work, the load's centre of gravity (COG) shifts from one point to another. After this kind of shift, one or two units will bear more of the load, and the other two will bear less of it. In order to ensure that the maximum permissible load is not exceeded for any of the units, it is necessary to consult the table before each operation.

Use the load chart to fill the maximum force per unit occurring during the lifting operation into checklist A

(Only for the unit under the heaviest load)

Preparation for a lifting operation

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Preparation for a lifting operation

This table must always be used for side shift operations. During this kind of work, the load's centre of gravity (COG) shifts from one point to another. After this kind of shift, one or two units will bear more of the load, and the other two will bear less of it. In order to ensure that the maximum permissible load is not exceeded for any of the units, it is necessary to consult the table before each operation.

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Preparation for a lifting operation

3.1.2. Minimum load

Due to friction in the hydraulic cylinders, it is possible that the extension order of the first and second step may not be followed properly, due to insufficient loading of the units. In other words, the units also have a minimum lifting capacity. The total minimum loading is 50 kN. In most cases, the header beams’ own weight is sufficient.

3.2. Capacity of the Side shift or Lug

The force on each anchor point cannot under any circumstances be greater than the capacity of the side shift unit or lug. The capacity of the side shift or lug is indicated on the documentation provided on delivery.

Use the load chart to fill the minimum force per unit occurring during the lifting operation into checklist A

(Only for the unit under the lightest load)

Always determine the force on each anchor point. Even for relatively light loads. This can be done using a centre of gravity calculation.

The preparer is expected to possess this skill. In case of doubt,

Fill the maximum anchor load into the checklist in appendix A

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Preparation for a lifting operation

3.3. Capacity of the Header beam

The force on each anchor point may not in any case be greater than the capacity of the header beam. The capacity of the header beams is shown in the beam load chart.

3.4. Surface loading for full support of the skid tracks

If it is not possible to have the underside of the skid tracks 100% supported, Azobé wood and steel plates must be installed under the skid track – see section

3.5.

The surface load is defined as follows: the load due to the weight exerted on the subsoil by the guide rails.

Fill the maximum permissible beam load into the checklist in appendix A

If the following requirements cannot be met: then the skid tracks must be set up using filler materials. In this case, the force on the subsoil is determined in chapter

3.5.

The rails may not be skewed in side view. The angle from the horizontal plane must be less than 0.2° in both axes.

0 ,

2 °

0 ,

2 °

2 ,

The incline angle of the running surface must not be more than 0.2°.

The surface loading is dependent on the type of guide rails used.

The height h is indicated on the drawing provided with the skid tracks.

The surface loading may be calculated by means of the formulae below; a small extra safety factor is already included in these formulae.

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Preparation for a lifting operation

1380

⋅

33.54

⋅

1380

400

1380

⋅

33.54

⋅

Metric system Imperial system

5000100

σ = surface load, [metric tonnes/m2] σ = surface load, [short tonnes/ft2] F = load on a particular foot, [kN] F = load on a particular foot, [kips] h = rail height, [mm] h = rail height, [inches]

The load F is the maximum load on one particular lifting foot. This is the force determined in section 3.2 and indicated as the maximum force per unit occurring during the lifting operation.

Replace parameter F in the formula with this maximum load to determine the maximum surface load during the lifting work.

Examples:

Metric: The expected maximum load on one of the feet is 1200 kN. The height of the rail is 400 mm. The resulting maximum surface loading is then:

5000100

7.1*

50001200100

1197.1*

metric Te/m2, or

11.2079.1

1.19

N/mm2.

7.1*

Imperial: The expected maximum load on one of the feet is 350 kips. The height of the rail is 15”. The resulting maximum surface loading is then:

11.2079.1

7.1*

The surface load occurring with complete underfilling of the skid tracks must always be less than the permissible surface load.

The height of the skid tracks is indicated on the drawing provided with the skid tracks

Fill the maximum surface load into the checklist in appendix A

11.2035079.1 9,157.1*

sh. tonnes/ft2.

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Preparation for a lifting operation

*.*6.

3.5. Surface load with filler material under the skid tracks

If it is necessary to use Azobé wood under the rails to compensate for unevenness in the subsoil, or to create a lower surface loading, then a number of matters must be borne in mind!

The points of attention are dealt with in this chapter and in the chapter “Explanations of Methods”. The preparer must also go through and understand section 4.3.

Geometrical requirements for the Filler material:

Only use filler materials in accordance with section 4.3.2 Read section 4.3.2 before proceeding any further in this section.

In case of doubt, consult Enerpac

Description Parameter Requirements Comment

Length of the filler material L > L Min. Max. 914mm Length between plates M > M Min. Width of the filler material B > H and > 250 mm Space in between S < 250 mm

The surface loading may be calculated by means of the formulae below; a small extra safety factor is already included in these formulae.

Length measurements in metres

Description Formulas

O = filler material ratio

O+=

L net. = Effective Length

Please Note: L net can never be greater than 0.914 m

σ = surface load, [metric tonnes/m2]

F = load on a particular foot, [kN]

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HLnet *23.0.

100

7.1*

OLnet

Preparation for a lifting operation

25.04.

*.*6.

61.0*9.0*6.33

The load F is the maximum load on one specific lifting foot; this is the force specified in section 3.2, defined as the maximum force arising during the lifting operation.

Example:

The expected maximum load on one of the feet is 1200 kN. B= 400mm  0.40m H= 300mm  0.30m S= 250mm  0.25m

The resulting maximum surface loading is then:

O+=



61.0+=

HLnet *23.0.



100

7.1*



OLnet

The actual surface load must always be less than the permissible surface load.

The formulas in this section are based on the Enerpac Rollertrack

4.0

3.0*23.0.9.0

/120

=mton

1001200

7.1*

Fill the maximum surface load, the L, W, H and the S from the checklist in appendix A

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Preparation for a lifting operation

3.6. Maximum permissible wind loading

Another factor that must be taken into account when lifting is the sidewards loading. During activities in the open air, the wind exerts a certain force on the object lifted by the portal, which directly results in a sidewards loading. The permissible sidewards loading is dependent upon a number of factors, namely the size of the object, the wind speed and the height of the top beams (lifting height). This means that, before every lifting operation, it must be checked that the wind does not present danger.

The maximum wind speed is calculated in accordance with a calculation form for loads; this form can be found on the CD-ROM supplied. The form shows the maximum permissible wind speed in both directions under different circumstances. Under no circumstances whatsoever may lifting operations be carried out when the wind speed is greater than the values given on the form.

On the left, you will find an example of a fully completed form:

Only certain parameters have to be entered. Enter the dimensions referred to as the outline dimensions of the object. These are the x-y-z dimensions of the outline of the beams and load. The foot dimensions of the portal lift are already entered and cannot be changed. Always start from the most adverse situation.

Do not forget that the wind speed and direction may change during lifting.

When lifting, always assume a worst-case scenario. The wind can be unpredictable, quickly changing speed and direction. Do not take any chances: if the wind is strong, that means it's a 'no go'!

Fill the maximum permissible windspeed into the checklist in appendix A

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Explanations of Methods

4. Explanations of Methods

This chapter provides detailed information about putting the SBL1100 system into use. The preparations to be made for the working location, the portal lift etc. are described here.

4.1. Storage

In storing the SBL system, you should distinguish between temporary storage and storage for a long period. If you intend to store the system for a longer period, a dry and preferably closed space is recommended.

During short-term storage, especially in the open air, cover the units with a tarpaulin in order keep electrical and other moisture-sensitive components dry.

During storage in the open air, cover the units with a tarpaulin in order keep electrical and other moisture-sensitive components dry.

If the stroke meter gets wet, its functioning may be impaired. So pay special attention to the encoder box.

The tarpaulin is not included in the delivery, but can be added as an option.

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Explanations of Methods

4.2. Handling

Each unit is fitted with four lifting eyes, as shown in the figure below:

Always use all four of the lifting eyes

The lower section of the base is provided with two lifting openings for a forklift truck:

Lifting eyes can only be used when the mast is in retracted position (horizontal position). Use of the forklift trucks is permitted in both positions. Please note that when using the forklift truck with the mast in extended position, the centre of gravity (COG) of the unit is considerably higher, and therefore less stable.

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Explanations of Methods

In extended position, only use the fork openings

In this setup, it is possible to use both the lifting eyes and the fork openings.

In order to prevent damage to the wheels, all movements, in any direction, must be executed at a height of 300 mm off the ground.

In order to prevent damage to the wheels, all movements, in any direction, must be executed at a minimum height of 300 mm off the ground.

• The unit can only be moved if the telescopic cylinder is

fully retracted.

• Movement of the unit is not permitted with the top beams

mounted on the top plates.

for lifting trucks to move the units.

Hold the mast of the lifting truck upright. Leaning it too far back may cause damage to the roller tracks.

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Explanations of Methods

4.2.1. Skid tracks

The skid tracks may be moved in two ways:

1. With a forklift truck. For this, the skid tracks are fitted with fork holes

2. Using a crane. For this, the skid tracks are fitted with 2 lifting eyes.

See illustration below:

Lifting

Fork holes

4.2.2. Header beam

The header beams may be moved in two ways:

1. With a forklift truck; the header beam is provided with fork openings for

this

2. Using a crane; for this, the header beam is provided with four lifting eyes.

See illustration below:

Lifting

Fork holes

Always use all four lifting eyes

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Explanations of Methods

4.2.3. Side shift

The side shift may only be moved using the lifting eyes. Once the side shift is off the beam, it must be laid down flat as shown in the illustration below:

In order to place the side shift on the beam, it is provided with lifting eyes. During assembly, always work with two or three lifting chains; in this way the side shift always remains horizontal during lifting. See illustration:

In this case, set a filling block for lifting.

Always set a filling block between the roller bearings first before raising the side shift. This is to prevent damage to the shift shift motor.

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Explanations of Methods

4.3. Placement of the skid tracks

In order to ensure proper functioning, the system should be set up level on the ground. In many cases, the subsoil is not flat and must be graded to create a good solid foundation on which the system can work safely.

The definition of a good supporting surface is: a properly graded base that cannot be deformed by transverse forces under load or overloading.

Guide rails have two functions:

• The use of guide rails reduces the basic loading

• They guide the portal lift over their length, so that the possible danger of

misalignment is avoided.

Creating a proper foundation must be handled with the utmost of care, as it is the system's primary safety issue.

Failure to use the guide rails may result in improper alignment.

Unstable surfaces cause instability.

Concrete is not a suitable foundation for wheels.

4.3.1. Requirements for the skid tracks

Permissible skid tracks are:

1. The skid tracks manufactured by Enerpac, supplied with the machine.

2. Additional skid tracks supplied by Enerpac.

3. Skid tracks that comply with the following requirements: a. Prescribed material and the dimensional tolerances specified on the

drawing in Appendix F and in Chapter 4.3.2.

b. The materials used must be accompanied by materials certificates

type 3.1.B.

c. The skid track must be tested statically before use to an overloading

of 125% of the maximum capacity; during this a notified body must have been present. The said notified body must issue a certificate for this.

d. At an overloading of 125%, the stresses in the material must remain

below 60% of the yield point.

e. All welding work must be executed according to EN-ISO 15614-1. f. The quality of the welding processes must comply with EN729. g. The welding must be approved and in this comply with EN-ISO 5817

class B. Check of the skid tracks before use

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Explanations of Methods

4.3.2. Check the skid tracks for damage before installation.

Several minimum requirements are listed below. Pay special attention to the welds: Pay special attention to the welds. There should be no fissures in them.

Enerpac can provide you with skid tracks: the wide range of available lengths is listed in appendix G. These skid tracks are hot-dip galvanized and meet all of Enerpac's requirements for skid tracks.

The flatness tolerance of the running surface is 5 mm over 3 m (1/5” over 10’).

The rails may not be skewed in side view. The angle from the horizontal plane must be less than 0.2° in both axes.

2 ,

0 ,

2 °

0 ,

2 °

° 2

, 0

The incline angle of the running surface must not be more than 0.2°.

Never use rails which do not meet the above requirements.

4.3.3. Requirements for the filler material

The filler material must be stacked contiguously so that there is no risk of spring action!

Minor deformations in filler material or subsoil may result in strong internal transverse forces or diagonal or longitudinal movements of the load or masts.

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Permitted filler materials:

1. Hard wood with a mechanical compressive strength of at least

25 N/mm² without occurrence of deflection However, Enerpac strongly recommends adhering to 30N/mm². Preferably Azobe. The minimum hard wood thickness is 50 mm and the maximum thickness is 150 mm.

NOTE:

Use of other wood types such as plywood, multiply, pine and compressed wood is expressly prohibited.

Wood is a natural product, which means its quality is not standardly assured. In order to guarantee quality an appropriate test must be conducted before use to verify that the material meets the set requirements.

2. Steel filler plates, provided they are properly secured with a

mechanical compressive strength of at least 30 N/mm² without occurrence of deflection.

Use of other materials is not permitted!

In case of doubt, consult Enerpac

For your planning, please bear in mind that the ideal wood is not only hard to the touch; it is also hard to acquire.

Explanations of Methods

4.3.4. Placement of the filler material

If it has become apparent from Chapters 3.4 and 3.5 that it is necessary to install filler material under the skid tracks, this must be implemented as prescribed in Chapter 3.5. The parameters L, H, B and S are listed in the checklist in Appendix A.

When laying the filler material, always consult with the person who performed the calculation in section 3.5. This is necessary to prevent excessive surface loading.

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Explanations of Methods

Standard geometrical requirements for the filler material:

Parameter Requirements

L > L Min. (to 914mm) M > M Min. B > H and > 250mm S < 250 mm

1. Install the filler material as determined by the preparer.

Pay attention in this to the following points:

Filler material must be laid with the largest surface on the horizontal zone.

Track couplings must always be fully supported.

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Always put filler material under the ribs in the skid track!!

Explanations of Methods

Always place a steel plate with a minimum thickness of 15 mm between the skid track and the filler material at the joint. At least 150 mm of each skid track must be on the steel plate.

Steel plate width at least 300 mm + 2x the thickness of the plate

2. Next, place the skid tracks on the filler material.

3. Align the guide rails

4. Ensure that the rails run parallel to each other:

A maximum deviation of ½’’ (~12 mm) in the alignment is permissible:

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Explanations of Methods

5. Ensure that no clearance is left between the filler material and skid

tracks.

Before the units are placed on the skid tracks, these must comply with the following requirements!

Ensure that no clearance is left between the filler material and skid tracks.

For filler material requirements, see section 4.3.2.

Enerpac can provide you with additional skid tracks or advise you on an appropriate design for your application during the planning phase.

The flatness tolerance of the running surface is 5 mm over 3 m (1/5” over 10’).

The rails may not be skewed in side view. The angle from the horizontal plane must be less than 0.2° in both axes.

2 ,

0 ,

2 °

0 ,

2 °

° 2

, 0

The incline angle of the running surface must not be more than 0.2°.

Ensure that the running surfaces of the rails are aligned. Otherwise, use shims to align the surfaces. Ensure that the angle of incline created is less than

0.2°.

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Check that the skid tracks meet all requirements and fill this in on the checklist in appendix B.

Explanations of Methods

Connect the rails or plates together under tension. Gaps between the surfaces may cause dislocation of the lifting foot and thus of the load.

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Explanations of Methods

4.4. Placement of the unit

After the rails have been correctly aligned and connected, the lifting feet may be placed on to the rails. The groove in the wheels must engage with the guide ridge on the rails.

Check that the units are on the rails properly and fill this in on the checklist in appendix B.

4.5. Connection of power cable

Once the units are in position, the power cable can be connected. Each unit must be connected separately to the electricity supply. Connect the power cables to each of the units’ power connections:

Specification of the power source: Voltage :360 to 480 V AC/ 3-phase Current :16 A per unit Frequency :50-60 Hz Power :7.5 kW per unit (10 hp)

The units feature automatic phase selection according to the rotation direction of the electric motors.

Once the power supply has been connected, the masts can be set upright.

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Explanations of Methods

4.6. Erect the mast

Once the rails have been installed, the lifting feet brought into position and the cables connected, the SBL1100 is ready for use. The masts can now be extended.

Mast extension is a manual operation and is performed on the electrical control panel of the SBL1100.

Never attempt to extend or retract masts to which something is attached or which are fitted with a buffer beam. The extension cylinders are not designed to bear additional weight.

Do not attempt to erect or retract an extended mast. The upright structure has a very different centre of gravity (COG). This will damage critical structural components.

Do not extend masts when a person is too close to the masts.

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Explanations of Methods

Remove the three lifting shafts from the frame. To do so, first remove the spring clips. Pull the shafts out until there is no connection between the mast and the frame (approximately 80%). The fourth shaft is locked and serves as a point of rotation. This shaft cannot be removed, except during maintenance.

Check that there is no one within the range of the lifting foot. Check that no cables are pinched and that there is no load on the masts. Use the switch on the front panel to extend the masts.

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Explanations of Methods

When the masts are in vertical position, put the shafts into position and lock them with the spring clips:

After setting and locking all pins, decompress the extension cylinders by retracting them slightly. Keep an eye on the pressure gauge: there should not be any pressure buildups.

Always put all three shafts into position. The portal lift is designed to distribute weight across the shafts. A missing shaft may result in an unstable foot and thus also an unstable system.

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4.7. Mounting the header beams

In order to mount the header beams on the units, the six bolts on the top of the swivel plate must first be removed. Remove the locking strips.

Place the header beam on top of the swivel.

Replace the strips and the six bolts (M20 St8.8 Elvz.). Adjust the beams to be level before the beam is fixed to the lift. In this way, a fixed connection between the unit and the beam is achieved. (For the operation of the machine, see Chapter 7.)

Tighten the bolts to 370Nm

Always install all six bolts. The header beam may shift slightly, which will exert a considerable amount of force on the bolts. If all bolts are not used, the structure may get damaged.

Check that the beam is level and that all bolts are tightened properly. Fill this in on the checklist in appendix B.

Explanations of Methods

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4.8. Mounting the side shift

Place the side shift on the beam as shown in the illustration alongside. See section 4.2.4 for how to lift the side shift.

Place the lifting beam as illustrated alongside:

Explanations of Methods

Feed the cable through the guide roller. Fix the cable into the connector and attach the strain relief to the eye provided.

Ensure that the cable is mounted in such a way that it cannot get pinched.

Fit the locking strip as shown in the illustration next to this text. Tighten the bolts (M12) to 60 Nm.

Check that the side shift is on the beam properly and that the lifting beam is set and locked. Fill this in on the checklist in appendix B.

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Before raising the load

5. Before raising the load

Before using the portal lift, certain matters must be checked.

1) Check whether the checklist in Appendix B has been fully completed and

signed.

2) Carry out a visual inspection of all lifting feet. Assure yourself that there are

no signs of excessive rust and that no parts of the portal lift are damaged. Rust means a weaker structure.

3) Carry out a visual inspection of all hydraulic components.

Assure yourself that there are no signs of wear or damage. Oil leakage may indicate wear or damage to the system.

4) Define what is known as a defined drop zone. This is the area outside of

which you and all bystanders and goods on the site are safe, if anything should go wrong. Cordon off this area using barriers, tape etc., in such a way that no one can enter the area.

5) Ensure that the running surfaces of the skid tracks are clean and that the

unit cannot slip or be obstructed.

6) Check whether all wedges have been removed from the rams.

See Chapter 7.4.

7) Slide all masts in and out a little to check that all communication functions

are working properly.

8) Drive the units forwards and backwards a short distance.

9) If applicable, do the same for the Side Shift units.

10) Check whether the correct load is indicated. This is of course the

weight of the beams and the internal resistance of the feet themselves. The load must only be raised after all preparatory measures have been implemented and the system is fully ready for use.

Always check the points given in this section before beginning to move with a load.

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Before raising the load

11) Check before raising loads that the load anchorages are in line with

the fixing points on the load:

Use a plumb line, a laser, or a theodolite. If the anchors are not in line with the fixing point, the load will start to sway as soon as it comes off the ground. This causes a huge transverse load on the portal lift, and might even lead to the portal lift tipping over. Such accidents have happened in the past, and were attributable to carelessness on the part of the operators.

12) Always keep lifting straps as short as possible. With long lifting

strops, the load will always have the tendency to start swinging during travelling or sidewards movement. This can also cause unexpected sidewards loading of the portal lift:

13) The beam must remain level at all times, with a tolerance of ± 0.2°.

This section is associated with the checklist in appendix C

The load cannot be moved until the checklist in appendix C has been completed in full and signed.

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Checklists

6. Checklists

The checklists have been drafted to ensure safety before and during the lifting operation.

The checklists have been prepared in chronological order in order to keep their completion as simple as possible.

Only once all checklists have been fully completed, and all the requirements in the checklists have been fulfilled, may the load be raised.

Always have the checklist verified and signed in approval by a second person authorised by the machine’s owner. The objective of this is to create extra certainty that the checks have been correctly executed.

Work exclusively according to the checklists: during preparation for the lifting operation, system construction, and for lifting the load. Failure to adhere to the checklists may result in serious injury to users and bystanders, and possibly even death.

6.1. Preparation for a lifting operation

The checklist for preparation may be found in Appendix A. Make a copy of the list, or print one out from the CD-ROM supplied.

The checklist during preparation is to check:

• The machine is able to carry the load.

• The foundation can carry the load.

• To establish how high the wind speed may be during the operation.

Various pieces of information that are important during setting up the machine are entered in this list during the work preparation. It is therefore important that this list is continuously available during setting up the machine.

It is only permitted to start setting up the machine once the checklist is fully completed and if all the requirements stated in this manual are fulfilled.

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Checklists

6.2. Setting up the portal system

The checklist for erection is to be found in Appendix B. Make a copy of the list, or print one out from the CD-ROM supplied.

The checklist during erecting the machine is to check:

• The machine is erected according to the directions in the manual.

• The machine is erected according to the data upon which the calculations

during preparation were based (Appendix A).

This checklist has been drafted in chronological order. Therefore, it is necessary to go through this list point-by-point from top to bottom. During checking, as well as during construction.

If it is necessary to use lifting strops, chains or other accessories, this should also be noted on the checklist.

6.3. Before raising the load

The checklist for during lifting is to be found in Appendix C. Make a copy of the list, or print one out from the CD-ROM supplied.

The checklist for raising the load serves to check that:

• The machine is not damaged and shows no signs of wear

• The machine’s functions are correct and all work in the right direction

• That the machine is correctly situated above the load.

This list must be completed by the operator of the machine during the lift operation.

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Working with the machine

7. The operation of the machine

The portal lift may be used in two ways:

• Manual operation, known as “local control”.

• Using the Intellilift, known as “Remote control”.

Once the header beams have been installed on the units, the machine may only be operated using the Intellilift control panel. Manual control should only be used during installation.

Before the machine can be operated, the user must read and understand the manual in its entirety.

In case of doubt, consult Enerpac.

Local control us only permitted if there is a beam attached to the unit.

A unit is only part of the central emergency stop system if the control selector switch is in the remote position.

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controller is

controller is not

active

the lifting cylinder

remote control

7.1. The control panel on the unit

Local control of the travel motors and

Switches to tilt the mast

Move side shift to the left and right

Switch to equalize the travel direction

Working with the machine

Switching voltage present

Motor for hydraulic pump running

Frequency

Switch to equalize the side shift direction

Speed selection for local control

Toggle switch between local and

Button to switch unit on/off

Frequency

Side shift overload protection signal

Emergency switch NOTE: this only works on other units if they also work on remote control

Emergency stop signal active.

An emergency stop switch is active or there is no connection with the Intellilift panel.

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Main power switch

Page 47

The direction of the side shift and travel depends on the “travel direction” and “side shift direction” selector switches Before the shaft between the side shift units is coupled, the direction of the side shifts must be checked.

Working with the machine

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The RS845 connection. Connection

Display. Displays basic

Emergency stop switch. When activated,

Fast/slow

rse

7.2. The Intellilift control panel

Working with the machine

information, such as load per lifting foot, lifting height per foot, and messages

Cylinder selection. Activates and deactivates individual lifting feet. Useful

for fixed wiring. This connection is also used to charge the batteries.

power is cut to all power cables. They must be reactivated manually for each lift component.

Power

Lift Lift/lower

Travel

Forward/reve

Side shift

Left/right

Zero lift switch. Resets the lift counters of the activated lifting feet to 0.

Always select "tortoise mode" on the speed selector switch when working with a load on the machine.

Only one function can be active at a time!

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Working with the machine

7.3. Manual control

Local control is useful during assembly of the machine. It may be used to put the separate units into the correct position.

During local control, no detection of the load or hysteresis takes place. In other words: manual control is unsafe control, and must only be used during installation of the units and as long as no beams have been mounted on the units.

This is how you work with a unit manually:

1. Ensure that the main switch on the control panel of the unit in question is

set to 'on'.

2. In order to raise a lifting foot manually, the control switch on the unit

should be set to ‘local’.

3. Switch the unit on using the operation switch on the unit’s control panel.

4. The desired speed can be selected using the speed selection switch on the

control panel.

5. The following functions may be controlled via the control panel on the unit: a. The ram can be extended and retracted. b. The unit can be made to travel. c. The mast can be tilted. d. The side shift can be controlled.

Important: only for maintenance purposes.

7.4. Intellilift control

7.4.1. About Intellilift

The Intellilift control system has been developed to allow loads to be raised and lowered under control. The control system ensures that the units remain within a hysteresis of 24mm. For this, it is necessary that the Intellilift is set up correctly. See section 7.4.3.2

The emergency stop system will not work if the control valves are not calibrated by Intellilift.

7.4.2. Communication

7.4.2.1. Cordless

Intellilift uses cordless communication. This means that communication with the lifting units takes place via radio waves.

The frequency of the cordless communication is 2.4 gigahertz.

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Working with the machine

Dongle

7.4.2.2. Data cables

In places where the use of radio waves is not allowed, data cable communication may be used.

See section 7.4.4.3 for how to switch between cordless and data cable control.

For a wired connection of the lifting feet, the data cables are connected together using RS-485 connection, in such a way that the following network arises:

Intellilift control panel

The use of a network requires a closed circuit. Connect a dongle (terminator) to the last unit in the circuit. It is not important which cable is in which connector as long as the circuit is terminated. The same applies to the dongle. The right- and left-hand connectors are identical.

Switchbox, nothing connected.

Switchbox, with connections from one unit to the next

Connected switchbox, end of the ring network.

Dongle

7.4.3. Normal operation

1. Switch the Intellilift control panel on by setting the “power” switch to “on”.

2. The Intellilift control panel will now start up; during start-up, the software

version number is displayed.

3. Before using, check that the control panel battery is fully charged.

This is to prevent problems due to a flat battery during the lifting operation. A full battery has a capacity of around 8 hours.

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Working with the machine

See section 7.4.7 for charging the battery.

(full battery on the display)

4. Ensure that the “Emergency stop” button on the Intellilift control panel is in

the non-activated position.

5. Switch the main power switches on the control panels on the units to “on”.

If the power supply is in order, the “power on” indicator on the control panel of the unit in question will light up green.

6. Ensure that the “Emergency stop” buttons on the units’ control panels are in

the non-activated position.

7. Switch the local/remote selector switches on the units’ control panels to the

‘rem.’ position.

The “emergency active” indicator on the control panel of the unit in question will light up blue.

8. Switch the “RAM SELECT” switches of the units you wish to operate to the

“on” position.

The units required can now be detected by the Intellilift control panel. If the

connection is in order, the “emergency active” indicator on the control panel of the unit in question will go out.

9. As soon as the “emergency active” indicator has gone out, the unit can be

activated.

10.It is now possible to use the following functions: Lift, Travel, and Side shift. A unit may be deactivated temporarily using the ram selection switches.

Only one function can be operated at a time.

Level indicator

7.4.3.1. Lift

If you want to start lifting or lowering, first check the values indicated on the lift counter on the display.

Remember that the control unit keeps the lifting height of all units selected using “ram select” within a hysteresis of 24 mm.

You can reset the values on the lift counter using the ZERO LIFT button. By pressing this button, the current, absolute position is set as start point, so that all lift counters indicate zero.

When you start the lifting or lowering action, the unit stops a ram as soon as the lifting position exceeds the range by too much (more than the hysteresis of 20 mm).

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Working with the machine

Once the position is back to within half of the hysteresis, the movement is restarted.

Besides this, you may during lifting put the ‘speed’ switch into the “hare” position to increase the speed while working without load. Whenever one single ram is extended too far in comparison with the others (more than half of the hysteresis), the movement is slowed until all the other rams are within a quarter of the hysteresis range.

After repositioning the skid tracks, the beams must be levelled. After this, give the zero lift command.

Always select "tortoise" mode on the "speed" selector switch when working with a load on the machine.

7.4.3.2. Travel

The SBL system is a self-driven system. Each unit is provided with two hydraulically-driven travel motors. These motors are connected via chains to the roller tracks under the frames.

If the direction of one or more units does not match, this can be changed using the “direction travel” selector switch on the control panel of the relevant unit.

Only use the "travel direction" selector switch after the machine has come to a complete standstill.

Travel motor

Roller track

Travel motor

The synchronous travel of the four SBL units is realised using what are known as pulse counters that are fitted on the output shaft of the travel motors:

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Working with the machine

Pulse

Pulse gear

The pulses from each SBL unit are counted by the Intellilift remote control unit. Whenever, on one unit, four pulses more than on the other three units are counted, the drive to the unit concerned is briefly interrupted, until four more pulses are added for the other three units. Then, the stopped SBL unit continues travelling.

This four-pulse discrepancy is equivalent to a 15.4 mm difference in distance for the SBL units. In other words, the maximum discrepancy between the four units is

15.4 mm. This is a standard setting that cannot be changed.

You may during travelling put the ‘speed’ switch into the “hare” position to increase the speed while working without load.

Always select "tortoise" mode on the speed selector switch when working with a load on the machine.

Every time the travel function is used, the synchronization is reset. Therefore, use this function until the lift is in the desired position. If the machine comes to a complete standstill during travel: check that there is nothing blocking the unit. Position the individual units correctly before travelling further with multiple units.

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Working with the machine

7.4.3.3. Side shift

Each side shift is provided with an electrical drive. This drive has a single speed.

There is no equal-travel regulation, although the drive roller is provided with knurling for sufficient traction on the beam. The side shifts on the same beam can be coupled together mechanically with a coupling rod.

If the direction of one or more side shifts does not match, this can be changed using the “side shift direction” selector switch on the control panel of the relevant unit(s).

7.4.4. LCD screen

The LCD screen is provided with background lighting. In order to extend the battery life, the background lighting is switched off if no changes are detected for a period of 15 seconds.

Only use the "side shift direction" selector switch after the machine has come to a complete standstill.

7.4.4.1. Level indicator

The following values are displayed on the screen:

• The total load on the selected units: “Tot”

• The absolute “position” for each unit

• The “lift” position with respect to the zero lift position

• The “load” on each unit

You can read the load on each selected cylinder separately from the control panel. The values indicated for the non-selected cylinders are invalid! The load indicated is calculated using the value from the pressure sensor and the ram range. Given that the cylinder has multiple stages, the conversion factor changes from stage to stage. Enerpac has configured the position where the factor change ought to take place. Small errors in the position indication may cause a ‘jump’ in the load indication at a switch point.

If an incorrect factor is used on the second or third stage, then an overload message may be displayed. There is however no actual physical overload! This can be resolved by recalibrating the position measurement, or by slightly reducing the switchover point (please contact Enerpac for this).

Due to the nature of the hydraulic system, the load value is only valid in static situations!

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Working with the machine

7.4.4.2. Overload warning

If the calculated load is above the maximum value, an asterisk appears before and after the load value (*900*).

Once this indication appears, it is not possible to extend the unit in question any further.

7.4.4.3. Communication timeout

When it becomes difficult to communicate with a certain unit, a message like this appears: Communication-time-out.

Try moving to a different position – this usually helps. (The fault may be caused by reflections in areas known as reception dead areas.) Also check that the unit in question is still receiving power.

Switching to data cable control (RS485 mode)

If you experience many problems in cordless mode, as a result of external influences or a fault, you may use wired mode.

• Switch off the Intellilift control panel and the main power switches on the

units.

• Connect the communications cable between the Intellilift panel and the

units.

o First switch all units on according to steps 5 to 8

in section 7.4.3.

• Switch on the Intellilift panel with all selection switches in the OFF position;

if communication is working properly, a star will be displayed after the lift value – see illustration

• The LCD display indicates that the control has been switched to wired and

the cordless control is deactivated until you switch the control panel off and back on again (without cables connected).

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Working with the machine

7.4.5. Emergency stop system

If the emergency stop button on the control panel is pressed, the message “***Emergency pressed***” appears on the display. This message also appears when the emergency stop button on one of the units is pressed, but only if that unit's cylinder was selected!

The display also shows which unit caused the emergency switch-off. In such cases, the main motors for all cylinders are stopped.

The system may be started up again by going through steps 6 to 8 in section

7.4.3.

7.4.6. Switching off the control panel

When the control panel is switched off, you can no longer control the units.

If the units receive no signals for 2 seconds, all outputs switch to a stand-by condition.

If the ram receives no messages for 10 seconds, the main motor is also switched off.

After the connection is restored, the system may be started up again by going through steps 6 to 8 in section 7.4.3.

If the control panel is switched off during an emergency situation, the main power supply to all units must be switched off for at least 20 seconds before the system can be restarted.

7.4.7. Charging the battery

There is a lithium ion battery in the control unit. The battery has a capacity of around 8 hours in normal operating mode. In order to extend the battery life, the background lighting is switched off if no changes are detected for a period of 15 seconds. After completing a lifting operation, connect the charger to the control panel (set the power switch to the OFF position). The display shows the current battery level and charging status. A fully charged battery should read 8.4 V. The charger feeds the circuit a controlled 12.0V power supply.

Do not use any other voltage levels, as this may damage the circuit! Do not charge the battery at temperatures below 0ºC (32º Fahrenheit) or above 45ºC.

Only use the adapter provided with the equipment to charge the batteries.

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Working with the machine

7.4.8. Settings

7.4.8.1. Learning a replacement Intellilift control panel

Each control panel has a unique code. In order to make control possible, you must match the separate receivers with the control panel. This has usually already been done by the programmers at Enerpac. But in the case of a serious fault, it may be necessary to reprogram the panel. This is also true when the old panel is replaced with a new one. The matching remains valid, even after switching off the power. Steps to reprogram the panel:

1. Check that the battery is fully charged

2. Switch off all ram selection switches on the control panel

3. Switch on the control panel

4. Switch on the unit to be ‘matched’

5. Put the RAM SELECT SWITCH 1 (on the control panel) to ON

6. On cylinder 1, press and hold the ‘LEARN’ button for about half a second

(and then release it)

7. As soon as the NO ANSWER message disappears, set the RAM SELECT

SWITCH back to OFF

8. Repeat steps 5 to 7 for cylinders 2, 3 and 4

If the control panel is switched on first, then the system will start up faster during power up.

Always ensure that you match RAM 1 with selection switch 1, given that the settings are individually calibrated!

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Working with the machine

7.4.8.2. Recalibration procedure

This subsection describes how to reset the masts to zero position:

Step 1: Set all cylinders to the minimum position

Step 2: Deselect all cylinders

Step 3: Switch off the power supply to the remote control unit

Step 4: Switch the “Speed switch” to the ‘hare’ symbol (high speed) and press the “Zero lift” button.

Step 5: Keep the “Zero lift” button pressed and switch on the power supply to the remote control.

Step 6: Keep the “Zero lift” button pressed until the message “System not ready” appears on the remote control unit display

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Working with the machine

Step 7: Release the “Zero lift” button and the “Calibration mode” message will appear on the display

Step 8: Now select the cylinder you wish to calibrate, wait for about 5 seconds and then deselect the cylinder.

Step 9: Thereafter the power supply to the remote control unit should be switched off. The cylinder position is now calibrated and the position on the display is around 0 mm

If the calibration proceeded successfully, this message appears: “Calibration succeeded”.

If there was poor communication during the calibration, causing it to fail, the following message appears: ”Calibration failure”.

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Working with the machine

communication timeout to

7.4.9. Correction of faults

Here you find a short list of possible faults, their causes and solutions:

Symptom

Load value –300 (large negative value)

Large negative position value

All units selected, but none move up

All units selected, but only one moves up

After switching on the control panel, it will take a moment for the

disappear. No display indication after switching on the control unit Communication problems when you place your hand on the top right corner of the control panel

Possible cause

Faulty wiring or loose connector on the LED indicator Faulty wiring, loose sensor wire

Possible solution

Check the wiring, measure the current (should be 4 - 20mA) Check the position reading for the physical cable, check the position

sensor One of the main motors has stopped, is outside of

Press the START button

to restart the motor the lifting hysteresis Lifting value was not reset, only the unit with the lowest lifting value moved up This is normal – the receivers continuously

First reset the lift

counters (even if you

have switched off the

control panel)

Wait approximately 30

seconds scan the various RF channels when they cannot find a control unit Battery is low Charge the battery for at

least 4 hours

This is where the internal aerials are located.

Do not place your hands

on this area.

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Working with the machine

7.5. Mechanical locking

The SBL1100 is provided with a mechanical locking system. This system may only be used when the portal lift is under load and must remain in this position for a longer period.

The system is based on a wedge-locking system that is mounted on both sides and on each phase of the mast.

The system must be controlled manually, and can only be unlocked by means of an extra extension stroke. It is therefore necessary to check in advance whether such an extra extension stroke is possible, from the position where you want to activate the mechanical locking. When the cylinders are locked in fully extended position, the system can no longer be unlocked because the wedges will not release.

How to do this: The SBL1100 is provided with a ladder for access to the top of the frame. It is possible to activate the grips from the landing. These grips serve a safety function. They provide a mechanical locking system for the booms. The locking mechanism is controlled by inserting the wedges or by removing them manually.

The wedges can be inserted as shown here

Here, the wedges are in their correct position

The grips can only be enabled during a lifting stroke. When the cylinder needs to be retracted, the grips will have to be disabled or else the grips will take hold and lock the booms to one another.

To use the grips for locking a load to a certain position, a so-called ‘load-transfer’ will have to take place. During this transfer the load is shifted from the cylinder to the grips. To make this load transfer the cylinder must make a small retracting stroke. The load will then be transferred. This also means that when the cylinder

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Working with the machine

has to pick up the load again, it first needs to make a small extending stroke. The load will then be transferred back to the hydraulic cylinder. Hereafter the wedges can be disabled again and the cylinder can be retracted. Keep in mind that the cylinder needs to extend a little to transfer the load from the wedges to the cylinder. This means that during long-term storage of a load where the safety grips are used, the cylinder should never reach the end of its stroke. Always keep an additional distance of 100 mm.

7.5.1. Use of wedges

The wedges serve as a safety precaution when the load has to be supported for a longer period. Firstly, the load has to be put into the correct position, and only after this may the wedges be inserted. During long-term storage of a load, there is always a small risk that the rams leak a little. If this happens, the wedges take the weight over and prevent the load dropping. The wedges must never be inserted during lifting. This is only allowed once the load is hanging at the correct height and the system is ready to be switched off.

Before the hydraulic portal lift has taken over the full load, removal of the wedges under load is impossible. Due to the compressibility of the hydraulic oil, the oil column in the ram is compressed immediately upon transfer of the load to the portal lift. The compressibility of the oil is around 1% for each 100 bar of pressure (1450 psi). Thus, when the ram extends to 100” (2540 mm) and the load transfer occurs on the top of the portal lift, and the resulting pressure is 100 bar, the oil column is compressed by around 1" (25.4 mm). This means that the height of the portal lift is also reduced by around 1”, with the result that the wedges receive the pressure exerted by the load. Only after removal of this load can the wedges be deactivated.

Normally, the rams are extended at low pressure until the portal lift takes over the load. The pumps remain in operation and the pressure in the hydraulic system is built up. This ensures an immediate compression of the oil. Because the pump remains in operation, this compression process is not noticeable. When the entire load is taken over by the portal lift, the compression is at its maximum and the pump pumps compressed oil. It is now easy to deactivate the handles and to reactivate them.

Never use a full stroke when the safety grips are operational. Only a slight extension of the cylinder is necessary to transfer the full load from the grips to the cylinder.

Never use grips before the full load has been taken over by the hydraulic portal crane.

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8. Special applications

Special applications

8.1. Tilting a load

It is possible to tilt a load with an SBL lift. This is in fact a risky operation, because incorrect control can lead to sidewards forces arising.

Normally speaking, Enerpac recommends keeping the slings or lifting strops as short as possible, but when tilting a load, longer slings or lifting strops should be used. In this way, the sidewards forces are kept to a minimum and the sidewards resultant force is no longer directly observable.

During tilting, it is only permissible to work with two units. The units attached to the top of the load in the lain-flat situation (the blue units in the illustrations) may not be operated during tilting.

Tilting of a load must only happen in the following way:

1. The units which are attached to the top of the load in the lain-flat situation

must be placed in the desired position

2. Thereafter, these units must not be used any more during the tilting of the

load. These units must also not be switched to the neutral setting, if present. (the blue units)

3. The other two units are now extended a little. Next, travel them a short

distance towards the other units so that the lifting eyes are once again directly under the header beam. (the red units)

4. This sequence should be repeated until the load has been tilted.

Make small movements of no more than 5 centimetres, both in lifting and travelling.

Check continuously that the lifting eyes are vertically under the beam: a tolerance of ±0.2° applies here. Make use of a plumb line, a laser or a theodolite for this.

5. Now all units should be selected and the command “zero lift” should be

given.

6. The lift can now be operated in the normal way.

Procedures described in this section should only be performed by experienced operators and only in the manner described in this section.

Before starting any special applications, contact Enerpac before hand.

All the other requirements mentioned in this manual continue to be applicable.

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The slings or lifting straps must remain completely vertical at all times. If they do not, this will result in lateral forces. These, in turn, may cause the lift to loose stability.

Special applications

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Special applications

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Maintenance

9. Maintenance

In order to obtain optimum performance from your machine and to safeguard the safety of the users, it is important that your machine remains in good condition.

In order to achieve this, it is strongly recommended to remove dirt from the machine after every lifting operation, and to check the machine for damage. Pay special attention here to the hydraulic and electrical components.

Remember that maintenance must only be carried out by skilled personnel. Damage to components, particularly the rams, can have serious consequences.

Hydraulic fluid safety information sheet, see Appendix I

Maintenance should only be performed by qualified personnel.

Only perform maintenance on the SBL units if they are not under load and if all lifting beams have been removed.

Any maintenance procedures not detailed in this section can only be performed by or in consultation with Enerpac.

Periodic maintenance intervals:

Interval Description Product Volume

Every 50 hours, and at least once every 6 months Every 50 hours, and at least once every 6 months Every 50 hours, and at least once every 6 months Every 50 hours, and at least once every 6 months Once every 5 years* Every year Inspection of the

Lubricate swivel, 4 nipples per unit

Lubricate side shift 8 nipples per unit

Kroon Oil multi purpose grease 3

+chain

Lubricate guide Shell ultragel 2

Adjust guide

Replace Oil filter + Refresh or change oil

Shell Tellus T32 or Shell Tellus Artic

roller chain

10 strokes nipple

5 drops per nipple

410 litres

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Maintenance

* For normal use. If in doubt, contact Enerpac.

9.1. Lubrication Points

9.1.1. The swivel

There are four lubrication points on the swivel. These must be supplied with 10 strokes of Kroon Oil multi-purpose grease 3 every 50 lifting hours, or at least once a year.

9.1.2. Side shift

The side shift is fitted with 4 grease nipples per unit. These must be supplied with 5 strokes of Kroon Oil multi-purpose grease 3 every 25 lifting hours, or at least once a year.

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Maintenance

Oil level indicator

indicator

cap

filter

Ball valve suction

port

Oil level indicator

The chain in the drive must be lubricated with Kroon Oil multi-purpose grease 3 at the same intervals.

9.2. Maintenance of the hydraulic system

Once every 2 years, or once a year for intensive use, the oil in the sump should be changed completely and replaced with fresh oil, or alternatively a purity test should be performed. The minimum requirement is that the purity of the medium is in accordance with class 7 of NAS 1638.

9.2.1. Draining Oil

Ensure that the ram is completely retracted. When changing the oil, use the large ball valve on the side of the sump to drain it. Remove the filler cap while draining the oil to allow air to flow into the tank. Keep an eye on the oil level indicator.

If the oil is below the level, then the power supply must be disconnected.

Now remove the strip that holds the oil sump in the frame. Remove the sump from the frame on the forks of the forklift truck or similar machine.

There are two caps on the tank cover, one fill/bleed cap and one return filter. The fill/bleed filters filter the air that is drawn into the sump when the oil flows out of the tank. The used oil can now be drained through the ball valve. Dispose of the oil responsibly.

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Fill/bleed

Return

Contamination

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Maintenance

9.2.2. Filling with oil

The sump can be filled using the fill/bleed opening. Ensure that the ball valve is tightly fitted on the bottom of the tank, thus avoiding leaks. Fill the tank up via the filling cap on the top until the oil level is 50 mm below the top of the tank. This only applies if a cylinder is fully retracted.

9.2.3. Return filter

The return filter filters the oil that flows back into the reservoir from the whole system. The filter will become blocked over time (depending on oil usage) and the oil will cease to be filtered. Keep an eye on the filter’s contamination indicator.

If the indicator is within the green zone, the filter is working correctly. If the indicator is within the yellow zone, the filter is still working, but must be replaced as soon as possible. If the indicator is in the red zone, the oil is no longer being filtered. Replace the filter element immediately. To do this, unscrew the return filter cap. The internal filter element can now be removed. Replace the element only with one of the same brand and type, so that correct operation is ensured. The portal lift uses Hydac return filters, type see the parts list provided with the machine

Replace the filter every year in any case.

Immediately replace filter element Over 3 bar

Replace ASAP 2-3 bar

Normal operation 0-2 bar

Do not use other filter elements, with the exception of previously installed elements.

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Maintenance

After maintenance, put the sump back in its frame. Check that it is secure by screwing the strip back into position. Reattach the hoses, open the ball valves, and, if necessary, fill the oil sump. Before you use the portal lift, make certain that the system is free of air and oil by pumping oil through the system for several minutes.

When refreshing oil, use the fill/bleed opening to top the oil up. The sump has a capacity of 410 litres. See Appendix D for the applicable Material Safety Data Sheet.

Do not use other filter elements, with the exception of previously installed elements.

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Appendices

Allen key 12

4 wedges

1 2

9.3. Adjust guides

Every 50 hours, at least once a year in any case, the ram guides must be adjusted.

9.3.1. Requisites

Torque wrench with 12mm allen

9.3.2. Adjustment

Ensure that the lift is standing on a flat, level surface ±0.2°. The lift is fully extended during adjustment. Therefore, make certain that you are in an adequate workspace.

Adjustment is carried out for each stage. Each stage has adjustment bolts for this. The adjustment order is important. The numbering is given in the illustration below. The order is explained in the table.

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It is not permitted to operate the lift on the platform or when people are present on the platform.

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Appendices

1. Ensure that the lift is completely retracted.

2. Loosen all 12 adjustment bolts on the painted ram by half a turn.

Turn Adjustment Bolt 1A manually with an allen key until resistance is felt. Certainly do not turn any further!

Now tighten bolt 3A to 40 N*m

Now tighten bolt 1A to 40 N*m

Turn Adjustment Bolt 2A manually with an allen key until resistance is felt. Certainly do not turn any further!

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Appendices

Now tighten bolt 4A to 40 N*m

Now tighten bolt 2A to 40N*m

Repeat steps A to F for adjustment bolts B1, B3, B2 and B4, following the same order as in steps A to F.

Repeat steps A to F for adjustment bolts C1, C3, C2 and C4, following the same order as in steps A to F.

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The guide in the painted ram has now been adjusted. Next extend the lift until the guide bolts in the second stage are accessible.

Page 74

Appendices

Now the wedges must be inserted so that the second stage cannot be retracted any further. Always insert all four wedges.

Then the lift must be retracted by a further metre; as the wedges are inserted in the second stage, the first stage will retract.

Next the guide in the second stage must be adjusted (see illustration for step I) according to steps A to H.

The lift must now be extended by a couple of centimetres, so that the wedges are unloaded and may be removed.

Important: only remove the wedges after the second stage has been extended a little. It is possible that the first stage extends first.

After the wedges have been removed, the lift must be extended further until the bolts for the third stage guide become accessible.

Now, the wedges must be inserted so that the third stage cannot be retracted any further.

Always insert all four wedges.

Then the lift must be retracted by a further metre; as the wedges are inserted in the third stage, the second stage will retract.

Now, the guide in the third stage must be adjusted (see illustration at step I) according to steps A to H.

The tightening torque is 20 N*m this time rather than 40 N*m

L The lift must now be extended by a couple of

centimetres, so that the wedges are unloaded and may be removed.

Important: only remove the wedges after the third stage has been extended a little. It is possible that the first and/or third stage will extend first.

M This unit has now been adjusted. Next the rams must be lubricated according

to the section “Lubricating rams”.

This sequence must be followed for all units.

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Appendices

9.4. Lubricating the rams

Every 50 hours, but in any case at least every six months, the rams must be lubricated with Shell Ultragel 2.

It is not permitted to operate the lift on the platform or when people are present on the platform.

Before new grease may be applied to the guide, the old grease must be removed:

First remove the old grease. for example with a filling knife.

Make certain that no grease residue falls into the guide.

Once all remaining grease has been removed, degrease the ram with cleaning spirit.

The fluid may be applied for example using a spray bottle.

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Appendices

Once the grease residue has been dissolved in the solvent, the rams must be polished dry.

Use a lint-free cloth.

Once the rams are clean, fresh grease can be applied.

The grease may be applied for example with a paintbrush. Ensure that the grease layer is applied over the whole surface.

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Appendices

9.5. Roller Chain

The SBL1100 is moves on a roller chain. In normal use a yearly inspection of the chain tension is sufficient

The SBL1100 unit must be lifted for inspection of the roller chain tension.

This is possible with a forklift or crane. See section “handeling” for more information and tips.

During the adjustment, you are under a lifted machine, so use only lawful hoisting and lifting equipment.

When the SBL's 1100 unit is lifted, the tension of the roller chain can be read based on the level of bending of the chain under the machine.

When the distance between the top of the middle roller and the frame is more than 10mm the chain must be tensioned

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Max 10mm

Page 78

Appendices

For tensioning the chain, the end bearings must be transferred The bolts 1 (M16 St8.8 Elvz ) (8x per side)must be unscrewed. Now the chain can shall be tightened by tightening the bolts 2.

Tighten the chain on both sides evenly until the top of the middle roll is flush with the plate edge (See below)

Now the bolts (1) must be tightened on 180N* m Now the chain is properly adjusted.

Tension the chain definitely not too tight this can cause major damage to the machine.

Repeat for all Roler chains

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Take the opportunity to inspect the roller chain.

The bolts deserve special attention. Check the bolts (M10x16 St8.8 Elvz.) on damage Make sure the bolts are tightened (45 N*m).

Good maintenance prevents downtime at work!

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Appendices



Appendices

Appendix A Checklist for work preparation

Project data

Project:

Customer:

Location:

Lifting

Skid track

date:

Load

Description:

Weight:

COG: Symmetrical/

centre distance

Operation type

Lift/lower Lift/lower + move Lift/lower + lateral movement Lift/lower + move + lateral movement

Subsoil

Type:

Allowable pressure on the subsoil before subsidence happens.

(σ toe)

Source:

Capacity

 Use of extension tubes

Maximum lifting height mm Maximum force per unit occurring during the lifting operation:…

….kN

Under the capacity of the unit in the maximum stage.

Minimum force per unit occurring during the lifting operation:… ….kN

Sufficient

Maximum force per anchor point: …

.kN

Less than the capacity of the side shift The beam load is still less than the permissible beam load.

Stage In maximum stage

Skid tracks

Maximum surface load:…… … . Tonne/m²

asymmetrical

…………Tonne/ m²

Capacity:………..kN

Page 1/2 Wind loading

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Less than σ toe Filler material under skid tracks required

Material: Maximum height of filler : H mm Maximum clearance (see manual) :

S Minimum width of filler material : B mm

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Appendices

Dimensions of the load

Preparations by

Signature

Height mm

Length (in line with skid tracks) mm Width mm

Maximum permissible windspeed m/s

: Date: :

Approved by

: Date:

Signature

Page 2/2

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Appendices



Appendix B Checklist for setting up the machine

Project data

Project:

Customer:

Location:

Lifting

Skid track

date:

Load

Description:

Weight:

COG: Symmetrical/

centre

asymmetrical

distance

Checks while setting up the machine

Appendix A Checklist for work preparation filled out in full and signed.

Filler material under skid tracks has been laid in accordance with the instructions in this manual and the values in appendix A.

If filler material applicable

Skid tracks placed at centre distance as indicated in appendix A Skid tracks aligned according to instructions in manual. Skid tracks connected according to instructions in manual. Skid track units are on the skid tracks in accordance with instructions in manual Units are in parallel in accordance with instructions in manual Bolts on Extension tubes tightened to torque in accordance with instructions in

manual Beam is horizontal (level) on the two units

Attachment bolts on the beam tightened to torque in accordance with instructions in manual. Side shift mounted in accordance with instructions in manual

Other equipment

What Length Capacity according to

Unladen weight

prescriptions

Lifting straps Chains Other

Constructed by

: Date:

Signature

Approved by

: : Date:

Signature

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Appendices



Appendix C Checklist for lifting the load

Project data

Project:

Customer:

Location:

Lifting

Skid track

date:

Load

Description:

Weight:

COG: Symmetrical/

centre

asymmetrical

distance

Checks for raising the load

Appendix A Checklist for work preparation filled out in full and signed. Appendix B Checklist for setting up the machine

Carry out a visual inspection of all lifting feet. Assure yourself that there are no signs of excessive rust and that no parts of the portal lift are damaged. Rust means a weaker structure.

Carry out a visual inspection of all hydraulic components. Assure yourself that there are no signs of wear or damage. Oil leakage may indicate wear or damage to the system. Define what is known as a defined drop zone. This is the area outside of which you and all bystanders are safe, if anything should go wrong. Cordon off this area using barriers, tape etc., in such a way that no one can enter the area. Check whether all wedges have been removed from the rams. See Chapter 7.4. Check if the masts are in and out of test hours

Check that all units travel forward and in reverse. Pay attention to the correct direction. Check that the side shifts are functioning correctly. Pay attention to the correct direction. Check whether the correct load is indicated. This is initially the weight of the beams and the internal resistance of the feet themselves. Check before raising loads that the load anchorages are in line with the fixing points on the load:

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Page 1/2

Page 83

Appendices



Running surfaces of the skid tracks are clean Always keep lifting straps as short as possible. With long lifting strops, the load

will always have the tendency to start swinging during travelling or sideways movement. This can also cause unexpected lateral loads on the portal lift:

The beam must remain level at all times, within a tolerance of ± 0.2°.

Windspeed lower than permissible limit

Checked by

Signature

: Date: :

Approved by

: Date:

Signature

Page 2/2

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