Instruction- and Maintenance Manual
Super Boom Lift

Document Number:
ED.03622.00.001.R03.ENG
Status:
Final
Original instructions

SBL1100 / SBL900
1068 / 915 metric ton
hydraulic portal lift system

www.enerpac.com

Revisions
Rev

Description

Date

AuthorCheckedApprovedby00

Initial version

23 March 2017

D. RosierTh. Westerhof
B. Geerdink
A. Holterman

R. Broenink

9 May 2017

D. RosierR. Bosman
R. Corbeek

R. Broenink

19 July 2017

D. Rosier

13 March 2018

R. Corbeek

R. Broenink

R. Broenink

15 March 2018

R. Corbeek

R. Broenink

R. Broenink

01

02

03

04

Added:
Transporting frame
Index table
Document lined up with other Gantry manuals:
Pictures and illustrations
Standardized texts
ASME B30 implemented
On request of Reinder Hilarius:
Safety sheets should be of the same
manufacturer as the type of hydraulic oil(Shell)Add safety data sheets for all other prescribedlubricants (Kroon oil)On request of Ruben Bosman: minimum operating
temperature set to -10 degrees
Changed the extending time during lifting andadded the retracting time during lowering of
the load.
New front page.
Remote control: explanation arrows.
Editorial changes.
Safety data sheet HF95 hydraulic oil.
Added Section 7.2 Warning Signs-

Tracks alignment requirements changed.
Additional lubrication of the runningsurfaces of the booms within the chapter“maintenance”.

R. Broenink

Preface
Dear customer,
This is the manual for assembling, using and maintaining of both the SBL1100 and the SBL900Super Boom Lift systems. In this manual, those machines are referred to by the term “System”.
The manual is meant to be used by operators and by maintenance engineers.

x
x

x
x
x

)

It is essential that the user reads this manual completely before start working
with the System.

All information, illustrations and technical data in this manual are applicable to the System as it
was at the time of issuing of this manual.
We continuously 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. Nevertheless,when the system is improved due to serious safety issues, you as a customer will be
informed.
If this manual becomes unreadable, in whole or in part, you can order a copy by providing us
the number given on the front cover.
Despite the fact that this manual has been drafted with great care, we cannot guarantee thatit does not contain any errors.
The use and interpretation of all information in this manual and the possible consequences
through improper use of the system are wholly the responsibility of the user. Enerpac shallunder no circumstances accept any responsibility for such improper use.

Pictures and illustrations in this manual may differ from reality.
Within this document use is made of structured text. The following conventions are applied:-

Procedural steps are numbered. Execute the steps sequentially. Do not skip any step.
Responses of the system are written on the next line in italic font
Choices are indicated with bullets.

Example:1. Press the button
The indicator turns green
2. Click on the square icon
The system starts moving
3. Select one of the following options:x Click the red icon for liftingx Click the green icon for loweringx Click the blue icon for ending the operation© All rights reserved. Nothing in this publication may be duplicated, stored in an automateddatabase 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 this manual will help you to use the System properly.
Enerpac.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 3

Contents
Preface _______________________________________________________________________ 3
Contents ______________________________________________________________________ 4
1.

2.

3.

4.

Introduction ________________________________________________________________ 7
1.1.

Manufacturer address __________________________________________________________ 7

1.2.

Declaration ___________________________________________________________________ 7

1.3.

Referenced documents__________________________________________________________ 7

1.4.

Identification__________________________________________________________________ 7

1.5.

Liability ______________________________________________________________________ 8

1.6.

Intended use __________________________________________________________________ 8

1.7.

Modifications _________________________________________________________________ 8

1.8.

Personnel and obligations _______________________________________________________ 9

1.9.

Lifetime _____________________________________________________________________ 13

1.10.

Warning symbols used within this document _____________________________________ 14

General safety aspects ______________________________________________________ 15
2.1.

Mandatory protective gear _____________________________________________________ 15

2.2.

General safety regulations ______________________________________________________ 16

2.3.

Symbols applied to the System __________________________________________________ 17

2.4.

Welding work ________________________________________________________________ 19

2.5.

Working on the electrical system _________________________________________________ 19

2.6.

Working on the hydraulic system ________________________________________________ 19

2.7.

Fire_________________________________________________________________________ 19

2.8.

Working with hazardous substances ______________________________________________ 20

2.9.

Assembly and disassembly ______________________________________________________ 23

2.10.

Transport, loading and unloading of the System __________________________________ 23

System Overview ___________________________________________________________ 24
3.1.

General _____________________________________________________________________ 24

3.2.

System specifications __________________________________________________________ 30

3.3.

System configurations _________________________________________________________ 33

3.4.

Service conditions _____________________________________________________________ 35

Plan a lifting operation ______________________________________________________ 36
4.1.

Ground bearing pressure calculation ______________________________________________ 37

4.2.

Check the lifting capacity of the System ___________________________________________ 44

4.3.

Side shift units and lifting lugs ___________________________________________________ 48

4.4.

The bearing capacity of the header beam __________________________________________ 49

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 4

4.5.

5.

Side load ____________________________________________________________________ 51

Install the System __________________________________________________________ 53
5.1.

How to hoist parts of the System _________________________________________________ 53

5.2.

Place the Skid Tracks __________________________________________________________ 57

5.3.

Put the units upon the skid tracks ________________________________________________ 61

5.4.

Connect the power cables ______________________________________________________ 62

5.5.

Put the boom in upright position _________________________________________________ 63

5.7.

Mount the header beams _______________________________________________________ 66

5.8.

Put the side shifts on the header beams ___________________________________________ 68

5.9.

Mount the longitudinal beams___________________________________________________ 71

5.10.

Check the stroke sensor ______________________________________________________ 71

5.11.

Install the remote control console (RCC) _________________________________________ 72

5.12.

Perform an all-over visual inspection of the System ________________________________ 77

6.

How to control the System ___________________________________________________ 78
6.1.

The Emergency buttons ________________________________________________________ 78

6.2.

The Control Panel of the unit ____________________________________________________ 79

6.3.

The remote control console (RCC) ________________________________________________ 81

7.

Execute a lifting operation ___________________________________________________ 87
7.1.

Risks and Warnings ____________________________________________________________ 87

7.2.

Warning signs on the System ____________________________________________________ 88

7.3.

Suspend the load _____________________________________________________________ 89

7.4.

Lift the load __________________________________________________________________ 90

7.5.

Move the load in longitudinal direction ___________________________________________ 92

7.7.

Move the load in transversal direction ____________________________________________ 94

7.8.

Tilt the load __________________________________________________________________ 95

8.

Solve problems ____________________________________________________________ 97
8.1.

Main problem localization procedure _____________________________________________ 97

8.2.

List of problems and solutions ___________________________________________________ 98

9.

Storage__________________________________________________________________ 100

10.

Maintenance ___________________________________________________________ 101

10.1.

Mechanical _______________________________________________________________ 102

10.2.

Hydraulic _________________________________________________________________ 112

10.3.

Electrical _________________________________________________________________ 119

11.

Quality ________________________________________________________________ 120

12.

Recycling the machine ____________________________________________________ 120

13.

Index __________________________________________________________________ 121

Appendices __________________________________________________________________ 123

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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A. Checklist for planning a lifting operation _______________________________________ 123
B.

Checklist for installing the System ____________________________________________ 124

C.

Final checks ______________________________________________________________ 126

D. Recording a lifting operation ________________________________________________ 128
E.

Recording maintenance ____________________________________________________ 130

F.

Drawings for the skid tracks _________________________________________________ 133

G. Drawing of the units _______________________________________________________ 135
H. Drawings of the side shift units ______________________________________________ 137
I.

Drawings of the lifting lug __________________________________________________ 139

J.

Hydraulic fluid safety information ____________________________________________ 140

K.

Kroon Oil Multi purpose grease 3 _____________________________________________ 144

L.

Torque settings ___________________________________________________________ 150

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 6

1. Introduction
1.1. Manufacturer address
Enerpac Heavy Lifting Technology B.V
Spinelstraat 15, 7554 TS
Hengelo
The Netherlands
Tel.
+31 74 242 20 45
Fax.
+31 74 243 03 38
Email:
info.hengelo@enerpac.com
Website:www.enerpac.com

1.2. Declaration
Declaration of Conformity according to machine Directive 2006/42/EC.
For the EC Declaration of Conformity reference is made to ref [6] “EC Declaration ofconformity” which is part of the product delivery.

1.3. Referenced documents
Ref
Name
1. Operation of electricalinstallations - Low voltage
2. Operation of electricalinstallations
3. General rules and safety
requirements for systems
and their components
4. USB stick Wind calculations
5. Technical handbook
6. EC Declaration ofconformity
7. ASME B30.1-2015

Identification
NEN 3140

Manufacturer
NEN

NEN-EN 50110-1

NEN

NEN-EN-ISO 4413

NEN

Enerpac
Enerpac
EnerpacJacks, Industrial
Rollers, Air Casters,and Hydraulic Gantries.
(Safety Standard for Cableways, Cranes, Derricks,

AmericanSociety of
MechanicalEngineers

Hoists, Hooks, Jacks and Slings)

1.4. Identification
Each main component is fitted with a name plate as shown below.

)

The name plates are official documents. Altering or rendering them is illegible.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 7

1.5. Liability
x
x
x

x

x

Personnel as well as other people involved in the usage of the System are expected tohave read and understood this manual.
In cases of doubt about the use or application of this machine, always contact with
Enerpac for advice and recommendations.
Unauthorised alterations to the machine may have a deleterious effect on thecharacteristics of the machine and may disrupt the control functions. Unauthorised
alterations therefore annul any resultant damage claims against the manufacturer.
The risk analysis conducted by Enerpac, intended usage and reasonably foreseeable
incorrect usage of the System were assessed. The instructions in this manual weredrawn up based on this analysis.
Unauthorised modifications to the machine may adversely affect its properties or
disrupt normal functioning. Therefore, the manufacturer shall not be liable for any
claims resulting from unauthorised modifications.

1.6. Intended use
The System is intended to move a load in vertical, longitudinal and transverse direction.
The definition of 'intended use' excludes any and all uses which do not meet the descriptions,
including use that exceeds the machine's technical limitations. The manufacturer shall not
accept any liability for damage resulting from use that is not in accordance with the machine's
intended use. The user shall bear any and all risks. The definition of 'intended use' also
includes strict compliance with the instructions in the user manual and assumes that theequipment is inspected and maintained at the indicated times.
x
x
x

x
x
x

The System should only be used in the intended manner as described in the
instructions in this manual, in particular listed in section 3.3. “System configurations”.
The System should only be operated by operators with full knowledge of theapplicable safety regulations and the hazards which may arise during use.
The System was developed and built according to the officially recognised safety
regulations. However, if the machine is not used as intended:o This may pose a risk to the health and lives of operators and bystanders.
o The System may not function properly or may create hazardous situations.
The System should only be used if the machine is in perfect technical condition.
Faults which may result in hazardous situations must be resolved immediately.
The machine must not be used in potentially explosive environments.

1.7. Modifications
Never make any modifications or additions which could have an adverse impact on safety
without prior approval from the manufacturer. This also applies to the installation andadjustment of safety devices and valves and welding work on the System.
Spare parts must always meet the technical specifications given by Enerpac in theconstruction file and the component construction lists for the machine. It is recommended touse original spare parts. In cases of doubt, please contact Enerpac.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 8

1.8. Personnel and obligations
x
x
x
x
x

x
x
x
x

Only qualified personnel are allowed to operate the System.
Qualified personnel are those who have followed the official Gantry training of Enerpac
and have obtained the Certificate.
Only qualified personnel are allowed to maintain the System.
Qualified personnel are those who have certified main education for the jobs they have
perform, either mechanical, hydraulically or electrical.
Qualification of the personnel is a responsibility of the customer.
Always comply with legal minimum age stipulations.
The System should only be used, maintained and repaired by properly instructed andtrained personnel. Clearly describe the qualifications of the relevant employees withregard to use, commissioning, assembly, disassembly and all maintenance and repair
work. If must be performed by third parties, they must receive clear instructions so boththe client and the contractor are up-to-date on the agreements reached.
The supervisor and operator are authorized to refrain from following any instructions
from third parties that may pose a risk to the machines or bystanders.
Personnel who have not been fully trained and instructed in the use of the machine,or personnel who have only received general training, may only perform work on the
System under continuous supervision of a qualified person.
Work on the electrical and the hydraulics systems must be performed by competent,
qualified personnel, or by trained personnel under the direct supervision of qualified
personnel, in compliance with all applicable rules and regulations.
Assembly and disassembly may only be performed by trained installers under thesupervision of an authorized person who has adequate knowledge of the System.

The responsibilities are conform the standard as referred to in Ref [7] ASME B30.1-2015
x In some situations, the owner and the user may be the same entity and is therefore
accountable for all of the following responsibilities a listed in this chapter.
x In other cases, the user may lease or rent the system from the system without
supervisory, operational, maintenance, support personnel, or services from the systemowner. In these situations the following sections apply.

1.8.1.

The owner of the system

The responsibilities of the owner of the system are:a) make sure the system meets the requirements as given in this manual as well as specificjob requirements defined by the user.
b) make sure the system and all necessary components, specified by the manufacturer,
meet the user's requested configuration and capacity.
c) providing the applicable capacity charts to the user.
d) providing this manual to the user to enable correct assembly, disassembly, operation andmaintenance information.
e) make sure all inspections and maintenance activities are performed.
f) designating personnel for maintenance, repair, transport, assembly, and disassembly.
g) designating personnel for inspections as required in the applicable chapters.

1.8.2.

The user of the system

The responsibilities of the user of the system are:a) complying with the requirements of this manual and all regulations applicable at the work
site.
b) using supervisors for activitiesc) ensure that the system is in proper operating condition, prior to initial use by
x verifying that the Owner has provided this manual.
x verifying that a frequent inspection has been performed.

Document number: ED. 03622.00.001.R04.ENG
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Page 9 of 151

Page 9d) verifying that the system has the necessary capacity to perform the proposed operations in
the planned configuration.
e) ensuring the assigned operators have has been notified of adjustments or repairs thathave not yet been completed, prior to commencing operations.
f) designating personnel for inspections as required in the applicable chapter.
g) designating personnel for maintenance, repair, transport, assembly, and disassembly.
h) ensuring that all personnel involved in maintenance, repair, transport, assembly,
disassembly, and inspection are aware of their responsibilities, assigned duties, and theassociated hazards.
i) ensuring that the inspection, testing, and maintenance programs specified by owner are
followed.

1.8.3.

The site supervisor

In some cases the site supervisor and the system director may be the same person.
The responsibilities of the site supervisor shall include the following:a) ensuring that the system meets the requirements prior to initial site usage.
b) determining if additional regulations or requirements are applicable.
c) ensuring that a qualified person is designated as the system director.
d) ensuring that the operations are coordinated with other jobsite activities that will beaffected by or will affect the operations.
e) ensuring that the area for the system is adequately prepared. The preparation includes,
but is not limited to, the following:
1. access for the system and associated equipment.
2. sufficient room to assemble and disassemble the system.
3. an operating area that is suitable for the system with respect to levelness, surface
conditions, support capability, proximity to power lines, excavations, slopes,
underground utilities, subsurface construction, and obstructions to operation.
4. traffic control as necessary to restrict unauthorized access to the system's working
area.
5. ensuring that work involving the assembly and disassembly of system is supervised bya qualified person .
6. ensuring that operators meet the physical, knowledge, and skill requirements as
described in this manual.
7. ensuring that conditions that may adversely affect the operations are addressed. Such
conditions include, but are not limited to, the following:
x poor soil or support conditions
x wind velocity or gusting winds
x weather conditions
x extreme temperaturesx inadequate lighting
x operating surface conditions
x excessive noise proximity to energized sources (e.g., power lines, pressurizedlines)
x ensuring that work performed by the rigging crew is supervised by a qualified
personx ensuring that maintenance is performed by a designated person

1.8.4.

The system director

The system Director's responsibilities shall include the following:a) being present at the job site during the operations.
b) stopping the operations if alerted to an unsafe condition.
c) ensuring that the preparation of the area needed to support the operation has been
completed before the operation starts.
d) ensuring necessary traffic controls are in place to restrict unauthorized access to thesystem's work area.
Document number: ED. 03622.00.001.R04.ENG
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Page 10 of 151

Page 10e) ensuring that personnel involved in the operations understand their responsibilities,
assigned duties, and the associated hazards.
f) addressing safety concerns raised by the system operator or other personnel andbeing responsible if he decides to overrule those concerns and directs the operation tocontinue. In all cases the manufacturer's criteria for safe operation and therequirements of this manual shall be followed.
g) designating the signal person(s) and conveying that information to the system operator.
h) evaluating the operation in proximity to energized sources.
i) ensuring precautions are implemented when hazards associated with special load
handling operations are present. Such operations may include, but are not limited to,the following:x multiple types of system used simultaneously
x shifting centre(s) of gravity or lifting below the centre or gravity
x shifting, inclined, or moving surfaces
x operating bargesj) informing the system operator of the weight and planned movement of the loads to behandled.
k) obtaining the system operator's verification that this weight does not exceed thesystem's rated load.
l) ensuring that load rigging personnel have been designated for the system.
m) ensuring that the load is properly rigged and stable.

1.8.5.

The operators

The system Operator shall be responsible for the following listed items.
The system Operator shall not be responsible for hazards or conditions that are not under his
direct control and that adversely affect the system operations.
Whenever the system Operator has doubt as to the safety of operation, the system Operator
shall stop the system functions in a controlled manner. System operations shall resume only
after safety concerns have been addressed and the continuation of the operation is directed by
the system Director.
The system Operator's responsibilities shall include the following:a) reviewing the requirements for the system with the Director before the operations.
b) knowing what types of site conditions could adversely affect the operation of thesystem and consulting with the system Director concerning the possible presence of
those conditions.
c) understanding and applying the information contained in this manual.
d) understanding the system's functions and limitations as well as its particular operating
characteristics.
e) using the system's load/capacity chart(s) and diagrams and applying all notes andwarnings related to the charts to confirm the correct system configuration to suit theload, site, and load handling conditions.
f) refusing to operate the system when any portion of the load or the system could be
adversely affected by proximity to energized sources until evaluated and approved by aqualified person.
g) performing inspections as specified in the applicable chapter.
h) promptly reporting the need for any adjustments or repairs.
i) following applicable lock out/tag out procedures,j) not operating the system when physically or mentally unfit.
k) ensuring that all controls are in the off or neutral position and that all personnel are in
the clear before energizing the system.
l) not engaging in any practice that will divert his attention while actually operating thesystem controls.
m) testing the system function controls that will be used and operating the system only if
those function controls respond properly.
n) operating the system's functions, under normal operating conditions, in a smooth andcontrolled manner.
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Page 11o) knowing and following the procedures specified by the system manufacturer orapproved by a qualified person for assembly, disassembly, and setting up the system.
p) knowing how to travel the system, if applicable.
q) ensuring that the load and rigging weight(s) have been provided.
r) calculating or determining the rated load for all configurations that will be used andverifying, using the capacity chart(s), that the system has sufficient capacity for the
proposed operation.
s) considering all factors known that might affect the system capacity and informing thesystem Director of the need to make appropriate adjustments.
t) knowing the standard and special signals as specified in the applicable chapter andresponding to such signals from the signalperson. When a signalperson is not required,
the system Operator is then responsible for the movement of the system. However, thesystem Operator shall obey a stop signal at all times, no matter who gives it.
u) understanding bask load rigging procedures. For responsibility of rigging the load andensuring that the load is rigged properlyv) if power fails during the operations
x set all locking devices
x move all power controls to the OFF or neutral positionx secure and stabilize the load, if practicalw) before leaving the system unattended
x secure and stabilize the load
x set all locking devices
x put the system controls in the OFF or neutral position
x turn off the system power source
x follow the recommendations as given in this manual or given by a qualified
person for securing the system

1.8.6.

Hand signals

The following hand signals are applicable when using the system:
RAISE.

LOWER.

With forearm
vertical, forefinger
pointing up, move
hand in small
horizontal circle.

With arm extended
downward, forefinger
pointing down, move
hand in small
horizontal circle.

GANTRYTRAVEL.

SIDE SHIFT.

Arm extended
forward, handopen and slightly
raised, makepushing motion in
direction of travel.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Palm up,fingers closed, thumbpointing in directionof motion, jerk handhorizontally.

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STOP.
Arm extended,palm down, movearm back and forthhorizontally.

END
EVERYTHING.
Clasp hands infront of body.

EMERGENCY
STOP.
Both arms extended,
palms down, movearms back and forthhorizontally.

INDIVIDUAL LEGS.
Hold up:one finger for leg
marked: "1,"
two fingers for leg
marked "2”.
Regular signals
follow.

1.9. Lifetime
No lifetime of the System is specified, since its safe and effective lifetime strongly depends onx the intensity of the use,x the quality of the maintenance,x the service conditions in which the System is applied, like wet or salty environments,
x and the masses of the loads to which the System is exposed.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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1.10. Warning symbols used within this document
This manual uses warnings and symbols to draw your attention to important safety information.
The table below indicate the most common used labels in industrial documents.

)

NB‘NB’ is used to highlight important work activities andfor additional information
Caution'Caution' is used if failure to heed the given instructions may resultin damage to the system.

Attention
General warning to the operator of potential damage to equipment and theenvironment.

HazardDraws the user's attention to potential hazards to personnel if work
instructions are not followed precisely.

Document number: ED. 03622.00.001.R04.ENG
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2. General safety aspects
Subjects that must be followed are covered not only in this chapter; also in other chapters are
specific safety directions that must be read and followed.

2.1. Mandatory protective gear
While using the System ensure that the applicable safety regulations are observed.
Make sure that all people on the working place observe the following safety regulations:
Always wear • safety goggles
and a safety helmet

Always wear • safety footwear
Wear safety gloves.
But we strongly advise not to wear them when
operating handheld control consoles
Wear a safety harness when working at heights
more than 2 meters

Document number: ED. 03622.00.001.R04.ENG
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2.2. General safety regulations
Special safety regulations are given in the relevant national legislations or company
regulations for accident prevention. Compliance with these rules and regulations is a legal
requirement and a condition of employment. In addition to the safety regulations set out under
the law, also observe the following points:x

Keep the worksite clean.

x

Before every start-up, always check that there are no persons in an unsafe situation or
position with respect to the System. Stop working if, despite warnings, there are still
employees in an unsafe situation.

x

Only use the System on an adequately stable and robust subsurface.

x

Keep all equipment out of the area of above-ground power lines.

x

The coverings must be closed (this does not apply to the covering on control panels).

x

The operator must switch off the System before leaving it unattended.

x

Use all required Personal Protection Equipment (PPE).

x

Do not wear any loose clothing or jewelry. Long hair must be tied back.

x

Tools and equipment, necessary for (dis-)assembly of the System, as well as formaintenance has to be in good condition. Badly maintained equipment can cause time
wastage and lead to permanent damage to the equipment and/or it surroundingsx

Keep the hydraulic and moving equipment of the System clean to prevent it fromjamming or causing damage to itself or other equipment.

x

Do not use the System, whether loaded or not, while unauthorized people are in its
vicinity. The System can be operated remotely.

x

Maintain concentration during the work. Carelessness may result in serious injuries.

x

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

x

Inspect the condition of the System before every individual start-up, given the fact thatthe slightest defect may have severe consequences.

Enerpac is not liable for improper use of accessories in combination with the System.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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2.3. Symbols applied to the System
The System is labelled withx warning symbols
x symbols with mandatory directions.
The table below show the most common used warning symbols.

Danger of contact with moving machine parts

DangerLethal voltage in the control panels

Danger of parts of hands getting trapped/caught

Danger of parts of feet getting trapped/caught

Danger of falling

DangerExercise extreme attention and caution when under moving loads.

Danger of getting trapped/caught between moving parts.

Document number: ED. 03622.00.001.R04.ENG
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The table below shows the most commonly symbols with mandatory directions in industrial
environments:

Read the instruction manual.

Wear gloves to prevent injury from and/or exposure to chemicals.

Wear safety glasses to prevent eye injuries.

Wear safety shoes to prevent injuries caused by falling objects and/or feetgetting caught in machinery.

Wear hearing protection.

Wear a safety helmet to prevent injuries caused by falling objects.

Wear a safety harness))

The stickers on the machine are official documents and it is not permitted toalter them or render them illegible.
It is strictly obligatory to observe the warning symbols and the mandatory
symbols applied to the machine.

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2.4. Welding workxx

Welding, cutting and grinding work on the System is only permitted with the priorwritten consent of the manufacturer. Welders must be properly qualified and musthave a valid welding certificate.
If welding work needs to be performed on the System theno Switch the machine off
o Disconnect all power cables and communications cableso Connect the system to a direct earth line.

)

Welding, cutting or grinding work on the System is not permitted without the
manufacturer's prior written permission.

2.5. Working on the electrical system
x
x

x

x
x

In the event of an electrical fault in the electric control system, you must bring all
connected device into a safe condition. Switch off the System.
Work on the electrical system must be performed by a competent, qualified
electrician or by trained personnel under the direct supervision of a qualified
electrician, in compliance with all applicable rules and regulations such aso Ref 1 “Operation of electrical installations - Low voltage”
o Ref 2 “Operation of electrical installations”
Switch the power off before inspection, maintenance or repair of the System.
Make certain that the relevant parts are no longer receiving power. If necessary,connect the machine to earth. Insulate any adjacent components that are still receiving
power.
Check and inspect the electrical system of the System at regular intervals.
Problems, such as loose connections and damaged or stuck wiring, must be resolved
immediately. Only use original fuses and circuit breakers with the correct current value.
If work does need to be performed on components receiving power, then cordon off
the work zone and only use certified and properly insulated tools.

2.6. Working on the hydraulic system
x

x
x
x
x

Work on the hydraulics system or other components in a pressurized system must be
performed by a competent, qualified installer or by trained personnel under the directsupervision of a qualified installer, in compliance with all applicable rules andregulations.
Check all pipes, hoses, quick-release couplings and screw joints regularly for leaks
and visible external damage. Repair damage immediately. Pressurized hydraulic fluid
leaks may cause serious injury, and it may cause fire and damage to the environment.
If parts need to be removed from the hydraulic system, the hydraulic pressure must
be released according to the instructions in this manual before beginning work.
Expand and install pressurized hydraulic pipes, tubes and lines in accordance withprofessional standards.
Make certain that no ports have been switched.

All parts and the length and quality of hoses meet the requirements of Ref 3 “General rules
and safety requirements for systems and their components”.

2.7. Fire

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The course of action in the event of an emergency is determined by the rules and regulations
applicable on the worksite. Every company has its own special rules. So make certain you are
up-to-date on these rules.
In any case, the following actions are necessary in the event of a fire:x Keep calm.
x Report the emergency to the employee responsible for in-house emergency services(IHES).
Tell who you are, where you are located and describe the emergency situation.
(The IHES employee will notify external emergency services.)
x Warn your colleagues.
x Switch off the electrical power supply.
x Extinguish the fire if it is still in its early stage, using the extinguishing means available
onsite.
x Leave the scene of the emergency situation and report to the rendez-vous point.

Caution: Never use water to put out an electrical fire or a fluid fire.

2.8. Working with hazardous substances
It is thought that special first aid procedures are required in cases of accidents with chemicals.
But in cases of small quantities, standard measures suffice:- rinse thoroughly with water- wash with soap
- provide fresh air- remove any contaminated clothing
In common the following rules are applicable:
x Contact with the skin:o rinse thoroughly with watero remove any contaminated clothingo wash the relevant body parts with soap.
x Contact with the eyes:o rinse thoroughly with water (5 minutes) using eye wash fountaino consult a doctor.
x Ingestion:o rinse the mouth out with water.
o If necessary, dilute the substance by drinking water.
o If a corrosive substance has been ingested, do not induce vomiting. This is toprevent the substance coming into contact with the sensitive oesophagus again.
o If the victim is unconscious, never attempt to induce vomiting or have the victim
drink anything.
Using a ‘neutralizing solution’ (such as a base for an acid) can actually make the situation
worse.
In addition to this, it is advisable to consult the safety information (TREMCARD book, safety
information sheets and the catalogue) and report everything that is relevant to the accident toa doctor.

When work has to be done in confined spaces:
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x Wear personal protection equipmentx ventilate according to the relevant regulations
x Ask a colleague to remain by the entrance in order to provide assistance in the event of an
emergency.
x You are legally required to be familiar with the potential hazards of the product.
The safety information sheets are intended to provide adequate, correct and up-to-date
information on all substances used on the worksite.
x Relevant safety information sheets are given in Appendix J Hydraulic fluid safety
information of this manual.

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During maintenance, you may work with substances fitted with GHS symbols.
These GHS symbols are explained in the next below.1

SymbolGeneral hazard indication

Possible precautionary measures

May cause an allergic reaction on theskin.

Contaminated work clothing must notleave the workspace.

Harmful to aquatic organisms, withlong term effects

Do not discharge into theenvironment.

Causes serious eye injury and/or
damage to the skin.

Wear eye protection and skinprotection (such as protective
gloves).

Fire hazard when heated and/or inpresence of sparks.

Keep away from heat, sparks, open
flames and/or hot surfaces. No
smoking!

May cause fire (oxidising agent).

Take the necessary precautionary
measures to prevent mixture withflammable substances.

Toxic in cases of ingestion and/or
skin penetration

Do not eat, drink or smoke whenusing this product.

May cause hypersensitivity of the
airways or heritable mutations in male Apply a strict hygiene/health policy
reproductive cells, is a potential
and wear suitable personal protection
carcinogen and/or is toxic to humanequipment.
reproduction
Keep away from heat, sparks, open
Explosion hazard when heated and/or
flames and/or hot surfaces. No
in presence of sparks
smoking!
Contains a gas under pressure. May
explode if heatedKeep out of sunlight. Store in a wellventilated space.

1 CLP is the Regulation on Classification, Labelling and Packaging of substances and mixtures (EC No

1272/2008). This regulation brings European legislation on the classification, labelling and packaging ofchemical substances into accordance with the GHS (Global Harmonised System for classification andlabelling of chemical substances).The GHS is a United Nations system used to identify chemical
substances and inform users of their hazards using standard symbols and phrases on labels, packaging
and Safety Information Sheets (SIS).

Document number: ED. 03622.00.001.R04.ENG
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Page 22

2.9. Assembly and disassembly
x
x
x
x

x
x

Assembly and disassembly of the System has to be performed by properly trained
operators
Only use certified lifting and hoisting equipment.
Check the validity of these certificates and qualifications.
Only use lifting and hoisting equipment with suitable capacity for the loads in question.
Before commissioning, any parts that were disassembled for transport must be reassembled, re-installed, checked and approved by personnel which is trained andqualified for the job. Use checklist B “Checklist for installing the System”.
Make sure that the instructions in this manual have been followed precisely before
commissioning the System.
Lift loads as described in the user manual (connection points for lifting hooks) andobserve the professional standards.
Caution: Any components that are blocked or stuck in any way (and any partsconnected to these components) will be under mechanical tension. If you
release these parts, they could change position suddenly and injure you(seriously).

2.10. Transport, loading and unloading of the System
x
x
x
x
x

x
x
x

Loading and unloading has to be performed by properly trained operators
Only use lifting and hoisting equipment with suitable capacity for the loads in question.
Lift loads as described in the user manual (connection points for lifting hooks) andobserve the professional standards.
Only use suitable containers with adequate load-bearing capacity for transport
purposes.
Secure the load properly using suitable connection points and twist locks (for thecontainers). When using twist locks secure them properly and check that the locking
mechanism is working correct.
Disconnect all electrical and hydraulic connections when the System has to be moved,
even if it is for only a short distance.
To avoid damage during transport, use timbers, gummies and plastic packaging toprevent this.
Containers may be used for transport, since they provide rigid protection against andavoid weather influences. Make sure that all parts are secured against sliding around.

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3. System Overview
This chapter describes the main functions and components of the System.

3.1. General

Side Shift unit

Lifting lug
Header beam

Boom

Unit

Skid track

Remote control console(RCC)

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The System is a four point lifting system which can move a heavy load inthree directions:x Upwards by extending the booms
x In longitudinal direction by moving the units along the skid tracks
x In transversal direction by moving the side shift units (if applied)along the header beams
Some more properties:
x The System can put the boom in upright position hydraulicallyx The System is provided with on-board hydraulic power. No hydraulic hoses have to be
used on the working scene. Only connecting electric power is required.

3.1.1.

The Unit

Boom

SwivelStroke sensor
orTilting cylinders

Electrical cabinet
net

Roller tracks
x
x
x

x

The units can be controlled:o Individually, using the control panel on the electrical cabinets
o Individually and simultaneously by the remote control console (RCC).
The tilting cylinders can put the boom in upright position.
In order to synchronize travelling of all units, each unit is provided with a travelling distancemeasuring device which runs on the skid track.

The swivel enables flexible mounting of the header beam

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Page 25xx

x

The boom consists of a telescopic cylinder system:o the SBL900 extends in two stageso the SBL1100 extends in three stages
The boom is provided with guiding pads at the inner side, whicho centralise the stages of the boomo enable smooth moving of the stages into each other

The guiding pads are adjustable in order to centralise the stages precisely. Since theguiding pads are made of plastic material, they are subject to wear.
In order to synchronise the lifting heights of all units, each unit is provided with a stroke
sensor. The sensor is provided with a wire which is attached to the top of the boom.

Each unit is provided with a control panel which is used for local control of the unit itself(not of other units).

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Page 26

3.1.2.

The Skid track

The skid tracks form a railway on which the System runs.
x Skid tracks spread the pressure on the ground.
x Skid tracks guide the units. Therefore, the skid tracks are provided with a ridge on top.

3.1.3.

The Header beam

The header beams across the top of the units create a portal.
Two types of header beams can be applied:x Integral header beams of various lengths

xModular header beams composed out of more sections to construct various lengths.

Header beams of foreign make may be applied if
x they have equal material properties
x their flange dimensions match with the Enerpac beams

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3.1.4.

The side shift units

The load can be affixed to the header beams by side shift units.
Two types of side shift units can be applied:

HBS3000xxxx

HBS6000

Side shift units enable moving of the load in transversal direction. Therefore, each side
shift unit is provided with an electro motor which propels rollers. The rollers run on theheader beams.
Side shift units have only one single speed.
Side shifts units can be controlled
o by the RCCo by the control panel on the electrical cabinet.
Optionally a transportation frame may be delivered for transporting and storage of theside shift unit:

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3.1.5.

The Lifting lugs

The load can be affixed to the header beams by lifting lugs. Unlike side shift units, lugs cannot
move the load aside.

Depending on the mass of the load to be lifted you can apply lifting lugs
x in double-plate configuration
x in single-plate configuration

3.1.6.

The Remote control console (RCC)The RCC enables the operator
x to control the system on a safe distancex to control all units simultaneously and synchronised

The RCC can be connected to the system
x by radio
x by wire

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3.2. System specifications
3.2.1.

Main specifications

The specifications listed below are valid both for the SL900 and the SL1100 system.

Specification of the power source
Voltage

360 to 480 V AC/ 3-phase
The units feature automatic phaseselection according to the rotation
direction of the electric motors
16 A per unit
50-60 Hz7.5 kW per unit
32A
5 pinsCurrent
Frequency
Power
Fuse
Plug
Temperatures
Minimum operating temperature of the machine

Maximum operating temperature of the machine
Minimum storage temperature of the machine
Maximum storage temperature of the machine
Minimum storage temperature of the RCC
Maximum storage temperature of the RCC
Noise pressure
Measured at ear height at nominal loading one metre
away from any Unit’s electric motor(The C-weighted instantaneous sound pressure of 130
dB is never exceeded)-10°C
The battery of the RCC will only
have half capacity
50°C
-25°C
60°C
x 20°Cx
0°C While charging the battery
x 60°Cx 45°C While charging the battery
77 dB(A)Caution: There is a risk of ice accretion at temperatures below 0ºC. If ice has
accreted on machine components, they cannot be used because since they may
lock up.

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3.2.2.

Operational specifications

Moving directions of the load
Horizontally

Transverse direction
Longitudinal direction

Vertically

By moving the side shifts
By moving the units along the skid tracks
By extending the booms

Velocities of the units and the side shifts
Unit

Side shift

SBL900 / 1100

Travelling speed
Extending time @ 40 Hz(during lifting a load)
Retracting time @ 20 Hz(during lowering a load)

HBS3000
HBS6000-Mk1

18 meter/hour
Approx.60 minutes
Approx.28 minutes
90 cm / minute
90 cm / minute

Bearing capacities of units, side shifts, lifting lugs and beams
Unit

SBL900Stage 1
Stage 2
Stage 1
Stage 2
Stage 3700 kN
5060 mm – 8372 mm
500 kN
8372 mm – 11360 mm
2621 kN 4409 mm – 7060 mm
SBL1100
1689 kN 7060 mm – 9724 mm
945 kN 9724 mm – 12016 mm
750 kNSide shift
HBS3000
1500 kN
HBS6000-Mk1
1250 kN
Lifting lug
LLSBL250
Single plate configuration
2500 kN
Double plate configuration
Header beams are optional parts.
Header beams
For bearing capacities reference is made to Ref 5 “Technicalhandbook”.

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Page 313.2.3.

Dimensions

The following information of the main parts of the system is available in Appendixes:
x Dimensions
x Weights
x Technical drawings
Part
Appendix
Skid tracks
Appendix F “Drawings for the skid tracks”
Units
Appendix G “Drawing of the units”
Side shift
Appendix H “Drawings of the side shift unit”
Lifting lugs
Appendix I “Drawings of the lifting lug”
For technical details of the header beams reference is made to Ref 5 “Technical handbook”.
The weights of the main parts of the system:
Type
Weight [kg]11950 (incl oil)Unit
814 kgSide shift
HBS3000
1544 kg
unit
HBS6000 MK-1
600 kgLifting lug
Double plate configuration
220 kgSingle plate configuration

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3.3. System configurations
3.3.1.

Header beam configurations

Header beams are optional parts. For technical information reference is made to Ref 5“Technical handbook”.
Proposed configurations of the System are:x

Classic configuration.
Two header beams, each ofthem connecting two units. Lateral stability isprovided by the beams, and the Units contribute to
the longitudinal stability.

x

Configuration with a single longitudinal header beam.:x

Configuration with double longitudinal header beams:

)

x
x
x
x

If you want to use other configurations than the depicted make sure the correct
calculations are made. Enerpac may advise.
Enerpac cannot be held responsible for application of other configurations thanthe proposed.
Configurations in which non-Enerpac equipment such as strand-jacks andskidding systems is applied, is allowed as long as all static requirements withreference to strength, deflections and stability are fulfilled.
The use of non-Enerpac header beams is allowed as long as those are used inaccordance with their own specifications.

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3.3.2.

Side shift units

The side shift unit described in Appendix H “Drawings of the side shift unit” can be applied toboth the SBL1100 and the SBL900 systems.

3.3.3.

)

Position of the loadx

The System can lift loads while the load issuspended from the header beams.

x

The System can tilt a load.

x

If you want to put the load on top of theheader beams, contact Enerpac.

x

The system is exclusively suitable forlifting with four booms.

Call Enerpac for advice when you want to position the load differently.

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Page 34

3.4. Service conditions
xx

The System is intended for hoisting loads.
Do not use the System for any other purpose.
No alterations may be made to the System.
Only use the System as it was delivered.

)

The System is explicitly not intended for transporting people.

Attention: Lifting operations with less than four units is strictly prohibited
Hazard: Lifting a load with only two units is a high risk operation,
hazardous and therefore prohibited:
The System with its load can tip-over completely, due tox out of centre of gravity
x swinging of the load
x large sling angles.
Such an operation may lead to an accident which causes damage to thex machine itself
x objects and goods in its vicinity or mounted to the machine
People in the immediate area may get severely injured.

Document number: ED. 03622.00.001.R04.ENG
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4.

Plan a lifting operation

In this chapter, the planning activities for a lifting operation are described.
1. Record your planning activities in the checklist given in Appendix A “Checklist for planninga lifting operation”.
2. Make sure the following information is available:
x Mass of the loadx Centre of gravity of the loadx Dimensions of the loadx Allowable ground bearing pressure
3. Determine the lifting height
4. Consider the following subjects:
x Lifting capacity of the most heavily loaded unit
x Lifting capacity of the side shift
x Lifting capacity of the header beams
x Bearing capacity of the groundIs additional foundation underneath the skid tracks necessary?
x The wind load)

It is of the utmost importance to perform all steps described in this section
carefully, before starting the lifting operation.

Hazard : Failure to prepare a lifting operation correctly may result in loss of
System stability during use.

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4.1. Ground bearing pressure calculation
Skid tracks can be put
x directly on the ground , if the bearing capacity of the ground is sufficient.
x on a foundation:o to compensate unevenness in the groundo to reduce the bearing pressure. Use is made of the effect that pressure spreads
down in an angle of 450, as shown below. So the higher the foundation, thelower the ground bearing pressure.

Skid track(side view)

Bearing ground
Bearing surface

Foundation

The bearing surface is extended
with 1 * height at both sides

The following sections describe how the bearing pressure can be calculated.
Feel free to apply your own calculation methods.

)

The pressure on the ground is inverse proportional with the height of the
supporting material.

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4.1.1.

No foundation applied

The dimensions of the bearing surface are as follows:

Skid height

Skid width

To calculate the bearing pressure, you may use the following procedure:
Parameter
Unit

LengthOwn mass
Skid track
HeightWidth
Auxiliary material (beams, shackles etc)
Safety factor
Maximum force on one unit which can occur during
the operation

1.

Abbrev
Unit length
Unit mass
Skid height
Skid width
Aux massS

Value
2.76 m12 metric tons
0.3 m
0.3 m
20 metric tons
1.7

F

t.b.s.

Bearing surface, including the
spreading effect in length
direction, of one unit
Unit length +2 * Skid height

Skid width

Bearing_surface =2 tracks * [(Unit length + 2 * Skid height) * Skid width]2.

Pressure on the ground[metric tonnes / m2]

V

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

F / 4  Unit _ mass  Aux _ mass / 4*S
Bearing _ surface

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Page 38

Example:
Load to be lifted

1068 metric tons

Ground pressureV)1068 / 4  12  20 / 4* 1.7 = 241 metric tons / m2
2.0Complete the checklist in appendix A “Checklist for planning a lifting operation”
with the calculated bearing pressure.

Attention: the exerted ground pressure may never exceed the maximum
allowed ground bearing pressure.

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4.1.2.

Foundation applied

Timbers of Azobé hard wood can be used as foundation material.
Steel plates have to be mounted between the timbers and the skid tracks.
The dimensions of the bearing surface are determined as follows:x

The width of one footprint:

Timber height

Skid width

Width = Skid width + 2 * Timber heightx

The length of one footprint:

Skid height

Timber height

Unit length
Length = Unit length + 2 * (Skid height + Timber height)

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To calculate the bearing pressure, you may use the following procedure:
Parameter
Unit

LengthOwn mass
Skid track
HeightWidth
Auxiliary material (beams, shackles etc)
Safety factor
Maximum force on one unit which can occur
during the operation
Timbers
Width
HeightGap between the timbers

1.

Surface of one footprint =width * length

Abbrev
Unit length
Unit mass
Skid height
Skid width
Aux massS

Value
2.76 m12 metric tons
0.3 m
0.3 m
20 metric tons
1.7

F

Depends on the operation

Timber width
Timber height
Timber gap

Depend on the applied
timbers(Skid width + 2 * Timber height) *[ Unit length + 2 * (Skid height + Timber height) ]2.

Surface on which the pressure isexerted for one unit = 2 * footprint

2 * footprint

LengthWidth3.

Support ratio, to correct for the gaps
between the timbers

Support_Ratio =Timber width / (Timber width + Timber gap)

4.

Pressure on the ground[metric tonnes / m2 ]Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

V

F  Unit _ mass  Aux _ mass / 4*S
Surface * SupportRatio

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Example:
Load to be lifted
Timbers:
Width
HeightGap

1068 metric tons
0.10 m0.10 m0.03 mMeasure of one footprint:
Width:

Skid width + 2 * Timber height = 0.3 + 2 * 0.1 = 0.5

Length: Unit length + 2 * (Skid height + Timber height) = 2.76 + 2 * (0.3 + 0.1) = 3.56 m
L * W:

0.5 * 3.56 = 1.78 m2

Two footprints :2 * 1.78 = 3.56 m2

Support ratio:

0.10 / (0.10 + 0.03) = 0.77

Ground pressure)V1068 / 4  12  20 / 4*1.7
3.56 * 0.77
= 176 metric tons /m2

Complete the checklist in appendix A “Checklist for planning a lifting operation”
with the calculated bearing pressure.

Attention: the exerted ground pressure may never exceed the bearing capacityof the ground.

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4.1.3.

Requirements for foundation material

The foundation material has to meet the following requirements:

Timber height

Steel width
Steel thickness
T min

S min

Timber length

Steel length

Parameter
Timber length
Timber width
Timber gap
mechanical compressive strength

Timbers

Requirement
>
Tmin
<
612mm
>
Timber height<
Timber width>
25 N/mm² without occurrenceof deflection
to 30N/mm², preferably) adhering
Azobé wood
Enerpac strongly recommends

Steel length
Steel width
Steel thickness
mechanical compressive strength

Steel plates

Mounting

)

x
x

>
=
>
>

Smin
Timber width
15 mm
30 N/mm² without occurrenceof deflection
properly secured

Wood is a natural product: its quality is not assured. In order to guarantee
quality, test the timbers on 125% of the expected load.
For your planning keep in mind that suitable wood may not always be available
immediately.

Hazard: Use of other wood types such as plywood, multiply, pine and compressedwood is explicitly prohibited.

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4.2. Check the lifting capacity of the System
The capacities and dimensions of the units, the side shifts, and skid tracks are given in section
3.2.2 “Operational specifications”. Use this information to determine the feasibility of your lifting
operation.

Caution: though all limits for the capacity, lifting height, skew and environmental
influences are either calculated or tested by the Enerpac consciously, duringlifting operations these parameters may interfere with each other in a negative
way. Test situations differ from real life situations!

4.2.1.

Maximum load

The bearing capacity of the System depends on the degree of extension of the beams:
the more extension, the less bearing capacity will be.

Stage 1

Stage 2

Stage 3

SBL900,
SBL1100

SBL900,
SBL1100

SBL1100

Complete the checklist in Appendix A “Checklist for planning a lifting operation”, under “Stageof Extension”.
The maximum load per Unit
The bearing capacity per Stage is given in the table of section 3.2.2 “Operational specifications”
on page 31.

)

The capacity of a System is four times the maximum load on one unit.

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Page 44The effect of eccentricity of the Centre of Gravity on the capacity of the System
When the Centre of Gravity (COG) is not in the centre of the System, the capacity of the
System will decrease. The figures below give the principle of it. The numbers are fictitious.
Assume:x a load of 1000 kNx a bearing capacity per unit of 250 kN
x stage 2 used
Centre of Gravity in the centre

Centre of Gravity eccentric

COG
COG

The load is spread equally over the units:
All Units bear 1000 / 4 = 250 kN
The system is loaded to its limits, but none of
the units is overloaded.

)

The load is spread unequally over the units.
The load on the ‘green unit has increased
significantly and exceeds 250 kN
The green unit is overloaded!
The system cannot lift the 1000 kN anymore
but less, to prevent overload in the green unit.
The capacity of the system has decreased
due to eccentricity of the load.

The more the COG of the load deviates from the centre of the System, the lessthe capacity will be.

The capacity charts on the next pages show the bearing capacity of the system in relation to
the position of the load. The coloured cells in that capacity chart correspond with the units
in the figure above.
COG

Use the capacity chart as follows for your side
shift operations:x Locate the position of the COG in thecapacity chart, as shown at the right Æ
x The data on that spot shows the total
capacity (4 units) of the system.

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Page 45

Capacity chart of SBL1100 (metric version) ED.03622.70.001.R00.ENG

Document number: ED. 03622.00.001.R04.ENG
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Capacity chart SBL900 (metric version)

Document number: ED. 03622.00.001.R04.ENG
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ED.03454.70.001.R00.ENG

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4.2.2.

Minimum load

When the load is only little, the motion of the stages of the booms may not be smooth, due tox friction in the hydraulic cylinders
x friction in the booms
To ensure smooth motion, the units have to be loaded with at least 50 kN. In most cases themass of the header beams is sufficient.
Enter the minimum load in the checklist given in Appendix A “Checklist for planning a lifting
operation”. Do such for the unit which is bearing the lightest load only.

4.3. Side shift units and lifting lugs
4.3.1.

Side shift units

When you want to move the load in transverse direction then you have to apply side shift units.
xx

Check the capacity of the side shift units, using the information in section 3.2.2“Operational specifications”.
Enter the load in the checklist given in Appendix A “Checklist for planning a lifting
operation”.

)
4.3.2.

Always determine the force on the side shift units, even for relatively lightloads. In case of any doubt, consult Enerpac.
Attention:
The force on the side shift units shall never exceed their bearing capacity.

Lifting lugs

If there is no need to move the load in transverse direction then simple lifting lugs can beapplied, rather than the more complicated side shift units.
x Choose single- or double plated lifting lugs, depending on the mass of the load
x Check the capacity of the lifting lugs, using the information in section 3.2.2 “Operational
specifications”.
x Populate the checklist given in Appendix A “Checklist for planning a lifting operation”
with the mass of the load to be lifted.

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4.4. The bearing capacity of the header beam
The bearing capacity (allowable load) of the header beams depends on the position of thesuspension of the load. The closer the load is suspended to the centre of the beam, the lessbearing capacity.
The relation between the positions of the suspensions (anchor points) and the allowable load
is given in capacity charts. For the capacity charts of Enerpac header beams reference ismade to Ref 5 “Technical handbook”.

Allowable load

Example how to determine the allowable load of the header beam for two anchor points.
Loads within the green area are allowed.

Distance between the anchor points
The distance between the anchor points is (1250 + 1250) mm,
so the maximum allowable load is 520 kN per anchor point.

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When only one anchor point is applied then the allowable load can be determined as follows:
1. Read the value of the allowable load from the capacity chart
2. Calculate the distance between the top of the capacity chart and that value
3. Add half of that distance to the indicated allowable load.
Example:1. Assume the anchor is located in centre of the header beam.
For that location the capacity chart shown below indicates an allowable load of 300.
2. The distance between the top of the capacity chart and the curve is (900 – 300) = 600
3. The allowable load is 300 + 600/2 = 600

Allowable load

Example how to determine the allowable load of the header beam for one anchor point.
Loads within the green area are allowed.

One anchor point
The allowable load is 550 + (900 – 550) / 2 = 725
Enter the allowable load on the header beam in the checklist given in Appendix A “Checklist
for planning a lifting operation”.
Caution: The force on each anchor point shall not increase the capacity of theheader beam.

)x
x

Earlier purchased Enerpac / Hydrospex header beams may be applied if theircapacity is sufficient.
Header beams of foreign make can be applied if their capacity is sufficient, but
Enerpac will not take any responsibility for it.

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4.5. Side load
Side load may endanger the stability of the System. It can be caused byx windx skid tracks not levelx system not mounted plumbx slings or shackles not plumb
During activities in the open air, wind exerts may put force on the lifted object.
Therefore, for every lifting operation the maximum permissible side load has to be calculated.
The permitted side-load on the System is 1.5% of the actual load.
Enter the max expected side-load Appendix A “Checklist for planning a lifting operation”.
The side load caused by wind depends onx the size of the object
x the wind speed
x the height of the header beams (lifting height).
To calculate the permissible wind speed you may apply the provided calculation program; see
Ref 4 “USB stick Wind calculations”. The program calculates the permissible wind speeds inboth directions under different circumstances.
The used parameters are indicated in the illustration below.

Load length

Document number: ED. 03622.00.001.R04.ENG
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Total lifting height

Header width

Load height

Slinglength

Header height

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Example of a completed form:
Load Properties
Load width
4 m
5 m
Load length
Load height
3 m

Operational parameters
Total lifting height
7.0 m
0.5 m
Sling length1250 kN

Load weight

Header geometry
Header width
0.33 mHeader length
6.00 mHeader height
0.40 mWind parameters
Max. wind velocity X-direction
Max. wind velocity Y-direction

Cross Beam parameters
Beam width
0.33 mBeam length
6.00 mBeam height
0.40 m17.8 m/sec
15.6 m/sec

The calculation program takes the dimensions of the foot of the System in account. Thosedimensions are implemented as fixed parameters and cannot be altered.

)xx

Always assume the most adverse situation
Populate the checklist in Appendix A “Checklist for planning a lifting
operation” with the maximum permissible wind speed.

Hazard:x Under no circumstances whatsoever lifting operations may be carriedout when the wind speed is exceeds the permissible values
x When lifting, assume a worst-case scenario. Wind is unpredictable andmay quickly change speed and direction.

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5. Install the System
This chapter describes how to install the System, including the preparation of the working
location.
For torque settings reference is made to Appendix L.

)

Enerpac only guarantees System integrity when exclusively Enerpac products areapplied.

5.1. How to hoist parts of the System
5.1.1.

Hoisting units

Pre-conditions for moving a unit:
x no header beams are mounted
x no load is attached
x the boom is in horizontal position
The units can be moved in two ways:
A. Using a forklift truck.
Use the fork holes of the unit.
In order to prevent damage to the wheels of the units:
x keep the bottom of the unit at a height of at least 300 mm
x the unit should not lean backB. Using a crane.
Use the lifting eyes of the unit.
Attention: always use both lifting eyes

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Lifting eyes

Fork holes)

Always keep the unit in vertical position

5.1.2.

Hoisting the Skid tracks

The skid tracks can be hoisted:
x by a forklift truck.
Use the fork holes
x by a crane.
Use the two lifting eyes.

5.1.3.

Hoisting the header beams

Header beams are provided with lifting eyes.
Lifting eyes

Fork holes (> 8m header beams only)

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5.1.4.

Hoisting the side shift unit

To hoist the side shift units regard the following.
The descriptions are given for the HBS6000 only, but are valid for the HBS3000 as well.

The side shift units shall only be hoisted using the lifting eyes. When not in use then put theside shift units down horizontally. Put them on timbers.

Optionally, transportation frames may be delivered for transporting and storage.

Locking pin
AdjustableheightForklift hole
Lifting eyeeyes for strapping down
Forklift hole
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To get the side shift unit out of the transportation frame proceed as follows:
1. Put the transportation frame next to the gantry.
Preferable apply a forklift. Eventually you can
use a crane and use the lifting eyes.
2. At delivery, the side shift units are strapped tothe strap-down eyes. Remove those straps.
3. Remove the locking pin

4. Store the locking pin in one of the pipes

5. For HBS6000: remove the locking plates.

6. Hoist the side shift unit out of the transportation
frame. Use all four lifting eyes.
For storing the side shift units in the transportation units, proceed in reverse order.
Pay attention to the following:x The height of the transportation frame is adjustable. Make sure the height is set in sucha way that the side shift units cannot touch the ground.
x Strap the side shift units to the strap-down eyes.

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5.2. Place the Skid Tracks
Correct positioning of the skid tracks insures that the System is put level on the ground.
When the ground is not flat then grade it in advance, to create a solid foundation on which thesystem can operate safely.
Attention: creating a proper foundation has to be performed with utmost care, as itis the system's primary safety issue. The foundation of the Skid tracks is the
exclusive responsibility of the user.

5.2.1.

Build the foundation

For building the foundation, proceed as follows:
Install the foundation material as you determined; see section 4.1. “Ground bearing pressure
calculation”.
Regard the following aspects:
x If the diameter of the timbers is not square then put them in flat position.

x

If you stack timbers then leave no slack in between, to avoid risk of spring.

x

Put the timbers horizontally, not vertically.

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5.2.2.

Put the skid tracks in place

For putting the skid tracks in place, proceed as follows:
Put the skid tracks on the foundation and mount them together.
Regard the following aspects:x

Put steel plates between the timbers and the skid tracksx

Make sure no slack is left between the foundation and the skid tracks.
Eventually use shims.

x

Put foundation material directly underneath the couplings of the skid tracks:

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5.2.3.

Align the skid tracks

Align the Skid tracks according to the following requirements:

Front view

Side view

Nr Alignment requirement

1

The skid tracks shall be in parallel

Tolerance

13 mm(top view)
2

The skid tracks shall be aligned from the start to the end

12 mm(top view)

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3

The skid tracks shall have now skew

0.25°

(front view of one skid track)4

The skid tracks shall not incline

0.2°(side view of one skid track)5

The skid tracks shall be flat

8 mm over 3
meter(side view of one skid track)6

The surfaces of the segments of the skid tracks shall be well aligned.
Use shims if necessary-(side view of one skid track)

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5.3. Put the units upon the skid tracks
To put the units upon the skid tracks proceed as follows:
1.

2.

Put the units on the skid tracks
x

Regard the hoisting instructions as given inparagraph 5.1.1 “ Hoisting units”.

x

Put all units with the electro cabinet towards
the outside.

x

The grooves in the roller tracks have tomatch with the ridges on the skid tracks.

Set the moving direction of all units in such a
way that they travel in the same direction.
Use [5] on the control panel; see section 6.2.1“The switches and indicators”.
(Do this after the power has been connected)

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5.4. Connect the power cables
Connect the power cables to units. Use the sockets on the electrical cabinet.

Don’t bother the phase of the power since the units feature automatic phase detection. Thisassures the correct rotation direction of the electro motors.
There are two options for connecting the units:
x connect each unit individually to the main power.

Main powerx

connect the units two-by-two to the main power.

Main power
The two power sockets of a unit are functional equal: both can be used for power input andpower output.
Do not interconnect more than two units.

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Page 625.5. Put the boom in upright position
For putting the boom in upright position the system is operated local control. So, use is madeof the buttons on the control panel; see section 6.2.1 “The switches and indicators”.
The unit has to be connected to electric power.
Attention:
Never put the boom in upright position or lower it
x when something is attached to it.
The tilting cylinders are not designed to bear additional weight.
x while the boom is extended.
The unit might tumble due to the different centre of gravity
Proceed as follows:
1.

Remove the three lifting shafts from theframe:x Remove the spring clips from the three
shaftsx

Pull the three indicated shafts out until the
red indicators)

Leave the fourth shaft (notprovided with a clip) in place; it
serves as the axe for the rotationof the boom.

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2.

Check:xx
x

3.

nobody is close to the unit
no cables can be pinchednothing is attached to theboom

Use the buttons on the control panel to raise
the boom; see section 6.2. “The Control
Panel of the unit”.

The tilting cylinders extend.

The boom gets in upright position.

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4.

Put the shafts back into position and lockthem with the spring clips.
Play with the buttons on the control panel forfine-positioning, to enable restoring of the
shafts.
Hazard:A missing shaft may result inan unstable unit foot and thus
also an unstable system.

5.

Decompress the tilting cylinders by retracting
them slightly, using the buttons on the control
panel.
Keep an eye on the pressure gauge; there
should not be pressure built up.

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5.7. Mount the header beams
5.7.1.

Assemble the modular beam

When you apply the modular header beam then construct it as follows:
1. Put two sections male / female
together and align the holes

2. Mount the connection bolt

3. Mount the flanges of theconnection bolt

4. Tighten the bolts according to thetable in Appendix 0 “
Torque settings”.

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5.7.2.

Mount the header beam on top of the boom

To mount the header beams on top of the boom proceed as follows:
1.
2.

Remove the six bolts at the top of the swivel
plate
Remove the locking strips.

Locking strips
bolt
bolts

Swivel plate3.

Put the header beam on top of the swivel.

4.

Clamp the header beam to the swivel using
the distance strips and the locking strips.

Distance
strips

Wide:
Note that two types of beams can be mounted:
x Wide (480 mm)
x Narrow (300 mm)
Set the locking strips of the swivel according
to the applied type.

5.
6.

Narrow:

Level the beam. Use [1] of the control panel(see page79).
Tighten the bolts according to the table inAppendix 0 “
Torque settings”.

)

xx

Make sure that all bolts aretightened properly.
Always apply all bolts

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5.8. Put the side shifts on the header beams
To put the side shifts to the header beams, proceed as follows:1.

Mount the cable-guiding wheel at theheader beam.

2.

Hoist the side shift unit out of thetransportation frame.
Both types of side shift units are depicted.

Remove the locking pins.

3.

Put the side shift on the header beam.

)Preferably put the side shiftunits with their chain-boxes atthe same side of the header
beam. This makes setting of
the running direction of the side
shift units more logical.

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4.

Place the anchor block.

5.

Lock the bolts with the locking pins

6.

When you’re going to apply slings thenmount the sling tool.

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7.

Connect the cable on the cable reel withthe side shift

Ensure that the cable ismounted in such a way thatit cannot get pinched.

8.
9.

Mount the other side shift similarly.
Set the moving direction in such a waythat side shift units will move in the same
direction. Use [5] on the control panel; seesection 6.2.1 “The switches andindicators”.
(This may be done in a later phase when theunits have been provided with electric power,e.q. section 7.7. “Move the load in transversal
direction”).

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5.9. Mount the longitudinal beams
When you apply longitudinal beams, make sure those longitudinal beams are securely
fastened to the header beams.
For header beam configurations reference is made to section 3.3.1 Header beam
configurations”.

)

Enerpac provides a solution for mounting longitudinal beams.
Contact Enerpac if you want to apply longitudinal beams

5.10. Check the stroke sensor
Though the wire of the stroke sensor is not a removable part, its presence and the correct
mounting has to be checked due to its vulnerability.
Proceed as follows:1.

Verify that the wire is connected to thestrip on top of the boom

2.

Verify that the wire is attached to theelectrical box and follows the guiding
wheels in as indicated.

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5.11. Install the remote control console (RCC)The RCC can communicate with the units:
x wireless, using radiox wired, using data cables

5.11.1.

Wireless communication

The RCC enables wireless on a radio frequency of 2.4 GHz.
No cables have to be connected.
BUT:
The wireless communication may be disturbed.
If so, a report is given on the LCD per Unit: ”*** Communication-time-out ***”The disturbance may be caused by radio reflections or ‘dead’ area’s. Walking to anotherposition may help
Connection-fail measures:x If the communication fails for 2 seconds then all movements of the units and the side
shifts are stopped.
x If the communication fails for 10 seconds then the system makes an Emergency stop.
For recovering from this situation reference is made to section 6.1. “The Emergency
buttons”.

5.11.2.

Wired communication

Wired communication is preferable when the radio link is disturbed.
To enable wired communication between the RCC and the four units, the following
configuration has to be set up:
Dongleremote control console

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Proceed as follows:
1.
2.
3.

Make sure the RCC is switched off
Make sure the power of all units is switched off
Connect the data cable to the RS-485 socket of the
RCC.

4.

Connect the data cable to one of the units.
Each units are provided with two RS485 sockets. Use
one of them; the sockets are functionally identical.
Connect another data cable to the other socket of theunit and connect it to the next unit.
Carry on connecting until all units are connected.
The sequence in which you interconnect the units does
not matter since the units will identify themselvesautomatically.

5.
6.

7.

Provide the unused socket of the last connected unit
with the Dongle

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5.11.3.

Set up the communication

To set up the communication between the RCC and the four Units to work, proceed as follows.
Reference is made tox the controls on the RCC as “RCC[x]”.
The layout of the RCC is given on page 81.
x the Control Panels of the units as “UNIT[x]”.
The layout of the control panel is given on page 79.
1.
2.

Connect data cables or do not so.
The system will automatically detect their presence.
Ensure that the “Emergency stop” button on the RCC
is in the non-activated position.

3.

Switch the main power switches on the control panelsof all units to “on”.
The “power on” indicator on the control panel of theUnits will be lit.

4.

Make sure that the “Emergency stop” buttons on allunits’ are in the non-activated position.
The blue indicator should be dimmed.

5.

Switch the unit to Remote

6.

Select the Units you want to operate with.
The RCC can now detect the units.
If the connection with a unit is fine than the“emergency active” indicator on the control panel ofthat unit is dimmed.

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7.

Switch the same switches to off again

8.

Switch the RCC off and on
As soon as the communication is established:x the text “Engine still” is displayed
x an asterisk is displayed
If the RCC detected data cables then the wirelessmeans are switched off.
Now it is possible to control the units.

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5.11.4.

Reprogram the communication

Each RCC is provided with a unique code. This code is known by the receivers of the units, sothey can recognize their Master’s Voice.

)

Enerpac has set this communication configuration initially.
The setting is persistent and remains after switching off the power.
Only when the RCC or one of the units was replaced, reprogramming is required.

Reprogramming has to be performed for each unit individually.
Proceed as follows:1.
Make sure the battery of the RCC is charged
2.
Switch the units off.

3.

Use the switches to deselect all units.

4.

Switch the unit which has to be programmed on.

5.

Select the concerned unit

6.

Open the electro cabinet of the unit.
Look for the receiver..

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7.

Press “LEARN” for two seconds
When the tekst “NO ANSWER” disappears from thedisplay of the RCC, the RCC and the unit areconnected.

8.
9.

Eventually repeat [2] .. [7] for the other units
Verify that the number on the RCC match with thenumbers on the units, by travelling with the units
individually.

5.12. Perform an all-over visual inspection of the System
Inspect the System visually.
Enter the result of the inspection in the checklist given in Appendix B “Checklist for installing
the System”.

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6. How to control the System
6.1. The Emergency buttons
The system is provided with emergency buttons.
x

On the control panels of all four units.

When the button is pressed:o the unit is switched offo the blue button “Emergency active” is lit
o if the unit is in Remote Control then other units which are in Remote Control too
are switched off as well.
To recover the system from an Emergency situation:o investigate why the button was pressedo turn and pull the emergency buttono press the blue buttonx

On the RCC.

When the button is pressed:o all units which are in remote control are switched off
To recover the system from an Emergency situation:o investigate why the button was pressedo switch off the main power of all units for at least 20 seconds
o restart the system

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6.2. The Control Panel of the unit
6.2.1.

The switches and indicators

1. Extend and lower
the boom

2. Tilt and lower theboom

3. Move the units
4. Move the side shifts

5. Set the moving
direction of the unit
and the side shifts.
If “0” then they will
not move.

6. Switch the unit toremote control (theunit is controlled by
RCC) or to local
control (the unit iscontrolled by the
buttons on thiscabinet)7. It lit when the
power is connected
8. It lit when
failure of themotor

9. It lit when amotor of a side
shift fails. All side
shift motors stop.
10. Is lit when any
emergency button of
one of the connectedunits was pressed.
Press to reset the
emergency.
11. To set the travelling
speed and the lifting
speed *)
12. Emergency
switch. If pressed
then all movements of
the unit stop.
If [6] = Remote thenall other units which
are switched in
Remote stop too.

13. To switch the unit
on and off.
If switched on thenindicator [7] it lit.

14. To switch main
power.

*) Ad [11]: If the system detects a load > 10% of the maximum load or the boom is extended
for more than one stage then the speed is automatically set to Low, regardless the system
is in Local control or Remote control.

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6.2.2.

Local control mode

The control panel of a unit enables the operator to control only the unit on which it is mounted.
Other units cannot be controlled.
Let’s call this mode “Local Control”.
Local control is meant to be used during the setting-to-work phase of the System:x to manoeuvre the units into position
x to put the booms in upright position
x to manoeuvre the side shifts into position
x to set the positive running directions of the unit and the side shift.
For Local Control proceed as follows:
1. Switch the unit on; use [14] and [13].
Verify that [7] is lit, and [8] and [9] are dimmed
2. Use [6] to enable Local Control
In local control the following operations can be executed:x Set the positive running direction of the unit;
x Set the positive running direction of the Side Shift;x Extend or lower the boom;x Travel the units forward and backward;
x Move the side shift towards the left and the right;
x Put the boom in upright position;use [5]use [5]use [1]use [3]use [4]use [2]

Attention:
Never use local control when header beams are mounted, since:x In local control the units are not controlled simultaneously.
x In local control no load detection is performed.

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6.3. The remote control console (RCC)The RCC enables the operator
x to execute a lifting operation on a safe distancex to control all units simultaneously
Let’s call this mode “Remote control”.
Applying the RCC ensures thatx the moving speeds of the units is synchronized
x the heights of the booms during a lift operation are kept equal within a tolerance of 24mm.
The RCC cannot control the tilting cylinders, used for putting the boom in upright position.

)

System start up is faster when the RCC is switched on before the units are
switched on.

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6.3.1.

The controls

1 Display:load per lifting foot,lifting height per foot,error messages…

2 Connection for fixed wiring(RS845). Also used to charge thebatteries.

3 Emergency stop.
When pressed, all Units which are in
Remote are switched off. (The Units haveto be reactivated using their own Control
Panels.)4 Switches toactivate anddeactivate Units.
(A Unit may bedeactivatedtemporarily .
Useful during
installation phase.)

5 Switch:
Power of theconsole6 Switch:
Driving speedof the Units
fast/slow

7 Switch:lift or lower theload

8 Switch:
Move Unit

9 Switch:move SideShift

10 Button: reset theheight measurement of allactivated Units.

ad [6]:The system can operate in “fast” (which is valid for lifting,/lowering and travelling) whenx The load on all units < 45 kN
x The cylinders are not extended in stage 2
Otherwise the system automatically operates in “Slow”

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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6.3.2.

The display

A. Absolute height ofthe cylinders

D. Height of the cylinders
w.r.t. “zero lift”).

B. Total load on
the System

C. Direction of the arrow
Direction of arrow within the remotecontrol display:
Up: Lifting
Down: Lowering
Right or Left: Travelling direction
Diagonal: Side shifting

E. The load per cylinder

F. Power status of
the battery

The following values are displayed on the screen:x Tot.
The total load on the selected units
x Position
The height per cylinder
x Lift
The height with reference to the zero lift position
x LoadThe load per cylindero The load is a calculated value, based on the position.
Changes in the indicated position may cause a jump in the load indication.
o The values indicated for the non-selected cylinders are invalid.
x Warnings and errors are displayed on the top line:

A list of possible errors and warnings is given in Paragraph 8.2. “List of problems andsolutions” under “Reports on the display of the Intellilift Console”.
When communication with the Units is OK, an asterisk is shown behind the Lift value.

xx

The display 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.
Emergency pressed
The report ““***Emergency pressed***” is shown:o When the emergency button on the remote control console was pressed

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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When the emergency button on a unit was pressed, but only when that unit wason Remote control. Reference is made to section 6.1. “The Emergency buttons”.
Battery levelox

The display shows the power level of the battery.
The console can operate approximately 8 hours on a fully charged battery.
Switch the console off after use and connect it with the 12V loader.

)

Only apply the delivered loader.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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6.3.3.

Calibrate the stroke sensor

This paragraph describes how to calibrate the stroke sensor, which measures the height of theboom.
Reference is made to the layout of the remote control console on page 82.

)

Calibration has to be performed when stroke sensors were changed, so calibration
is not part of the daily routine.

Proceed as follows:
1. Preconditions:x RCC switched off
x Units switched off.
2. Set “Speed” on the RCC to the ‘hare’ (high speed)3.

Press “Zero lift” and keep it pressed while you
switch the console on.
Keep “Zero lift” pressed until the message “System
not ready” is shown

4.

Release the “Zero lift” button.
The RCC is now in calibration mode.
The “Calibration mode” message appears on thedisplay.

5.

Switch the unit which you want to calibrate on andstart its motor.

6.

Select the unit on the RCC

7.

Retract the cylinders to the very minimum position

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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8.

Extend the cylinders to the very maximum position

9.

Deselect the unit
The stroke sensor has been calibrated.
The message “Calibration succeeded” is shown.
10. Switch the RCC off.
11. Switch the RCC on.
12. Verify the displayed position.
It should be the maximum position.
13. Retract the cylinder to the very minimum position.
14. Verify the displayed position.
It should be approx. 0.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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7. Execute a lifting operation
This chapter describes how to perform a lifting operation.

7.1. Risks and Warnings
Good operation of the System is essential for safety. Therefore, address the following
subjects:
Attentionx It is of the utmost importance to read this manual carefully before setting
up the machine. Failure to prepare correctly for a lifting operation may result
in total loss of machine stability during use.
x Adhere to the checklists during all work activities: during preparation forthe lifting operation, system construction, and for lifting the load.
x A unit is only part of the central emergency stop system if the control
selector switch is in the remote position.
x Ensure that the load avoids contact with a leg, header beam, othercomponents of the system or any obstructions while lifting, side shifting, ortraveling.
x The operator should have an unobstructed view of the system and load
during operation of the system. If this is not possible, a signalperson shallbe used with an effective means of communication to provide directions to
the operator.
x Communication among personnel involved in the operation shall bemaintained continuously during all movement of the load. If at any timecommunication is disrupted, the operator shall stop all movements until
communication is restored.
x Signals to the operator should be in accordance with the standards
prescribed in section 1.8.6 “Hand signals”. If special signals are required,
they shall be agreed upon by the operator and support personnel prior to
the lifting operation. Signals shall be discernible or audible at all times. No
action shall be taken unless signs are clearly understood.
x Load handling personnel shall obey any stop signal.
Hazardx Improper use of the machine or failure to take the changes indicated in thismanual 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, andpossibly even death.
x Adhere to the checklists during all work activities: during preparation forthe 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.
x Do not extend booms when a person is close to.
x Local control is only permitted if there is no header beam attached to theunit. A unit is only part of the central emergency stop system if the control
selector switch is in the remote position.
Cautionx 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'!
x Never extend or lower booms to which something is attached since theextension cylinders are not designed to bear additional weight.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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)

NB
Follow the instructions on labels applied to the system, without question.

HazardDespite all inherent safe design measures, safeguarding and complementary
protective measures, there will always be the residual risk of tumbling of thesystem.

7.2. Warning signs on the System
The following signs are applied to the system:

The legend of the symbols is given in section 2.3. “Symbols applied to the System”.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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7.3. Suspend the load
For suspending the load regard the following subjects:

1. The anchors on the header beam
have to be in line with the hoisting
points of the load.
Hazard: if the anchors
are not in line with the
hoisting points, the load
will sway as soon as it gets freefrom the ground. The resulting
lateral force may endanger thestability of the System.

(front view)

2. Keep the lifting straps as short as
possible.
Hazard: long slings may
enable swinging of theload, causing dangerous
lateral forces.
(front view)
3. The header beam has to be kept
level at any time, with a toleranceof 0.2°.
Level the header beam atinstallation time.
During operation the header beam
is kept level automatically.

(front view)

4. Lifting slings have to be plumbwithin a tolerance of 0.2°.
This is especially applicable fortilting operations; see section 7.8.
“Tilt the load”.

Hazard: exceeding thelimit of 0.2° will cause
dangerous lateral forces.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG(side view)

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7.4. Lift the load
This section describes how to lift the load.
In the procedure below reference is made tox the controls on the RCC: “RCC [number of the control as given on page 81].
E.q. RCC[5] means: press the Speed button on the RCC.
x the Control Panels of the Units: “UNIT [the number of the control as given on page 79].
Proceed as follows:
1.
2.

3.

4.

5.

Record all activities during the operation using the form
given in Appendix D “Recording a lifting operation”
Verify that the checklists given in:a. Appendix A Checklist for planning a lifting
operation”
b. Appendix B “Checklist for installing the System”
c. Appendix C “Final checks “are completed and signed off.
Switch the RCC on.
The RCC starts up.
The software version number is displayed
Verify the battery of the RCC is fully charged
The battery status is shown at the display.
A full battery has a capacity of approximately 8 hours.
Switch all four Units on.
Indicator UNIT [7] (power) lit .
Indicators UNIT [8] and UNIT[8] (failure motor, side shift
failure) should bedimmed

6.

Activate all four units.

7.

Switch the units to Remote

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 908.

9.

Reset the measured heights of all units by pressing “zerolift”.
The current heights of the cylinders will be taken as the newreference points.
The height counters [D] on the display will start counting
from zero.
Select the travelling speed.
Select “low” if the system is carrying a load.
If the system detects a load or the units are extended formore than the first stage then “Low” is selected
automatically.

10. Lift the load using RCC[7].
While lifting, monitor the display (shown below).
x Monitor the lifting heights.
The heights of the cylinders are measured continuously;
see [A].
The RCC automatically levels the heights of the fourcylinders within a bandwidth of 24 mm.
o When the height of one cylinder differs more than
12 mm from the others, its lifting speed (or thelifting speeds of the other beams) is slowed down
until all heights are within a bandwidth of 6 mm.
o When the difference of height exceeds 24 mmthen system stops moving the load. Technicalinvestigations of the problem have to be made.
Follow the main problem solving procedure as
described in 8.1. “Main problem localization
procedure”.
x Monitor the individual loads on the units [E]x Monitor the total load on the system [B]x Monitor the direction of vertical movement [C]x Monitor the power status of the battery [F]11. Switch the unit off
12. Switch the RCC off

A. Absoluteheight (mm)of the cylinders

B. Total load on
the System

D. Relative height of the cylinders
w.r.t. “zero lift”).

E. The load per cylinder

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

C. Direction of the verticalmovement of the load.
(When not moving,no arrow is shown)

F. Power status of
the battery

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7.5. Move the load in longitudinal directionx

For travelling all four units simultaneously and synchronised, apply the RCC.
See section 6.3.1 “The controls”.

x

To move one single unit individually, you can use
x local control; see section 6.2.2 “Local control mode”
x the RCC;see section 6.3.1 “The controls”.

7.5.1.

Move the units

To move all units synchronously, proceed as follows:
1. Apply the RCC; see page 82.
2. Verify that all checklists have been completed and signed
off:
x Appendix A Checklist for planning a lifting
operation”
x Appendix B “Checklist for installing the System”
x Appendix C “Final checks “
3. Verify the power status of the battery of the RCC
4. Select the travelling speed [6].
Select “tortoise” if the system is carrying a load
If the system detects a load or the cylinders are extended
for more than the first stage, tortoise is selected
automatically.

5. Enable all units; use the buttons [4] “Ram select”.

6. Use [8] “Travel” to move the units
Attention:
When you have stopped the systemfour times then you have tosynchronize the positions of the units.
Synchronisation is described in thenext section.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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7.5.2.

Synchronize the positions of the units

The system keeps the relative positions of the units lined-up automatically.
Use is made of a travelling distance measuring device which runs on the skid track.

The measuring starts counting at zero every start. Due to the limited resolution of themeasuring device, the positions of the units may get out of rectangular formation when thesystem has stopped moving several times.
Unit which is out of position

The following procedure can be applied to synchronise the positions of the units.
1.

The units are in rectangular formation if
x B1 = B2
x A1 = A2.
To measure the positions of the units you might apply
x a tape-measurex optical measuring means, if you want to stay awayfrom the System while it is bearing a load
Feel free to apply your own measuring methods.

2.

If you detect misalignment then move the concerned
unit (or units) to restore the rectangular formation.
Apply local control or remote control to move the unit.
Attention:
To prevent worsening the situation:
x make sure you move the correct
Unit(s)x make sure you move it in the correct
direction
The stability of the system is at stake!

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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7.7. Move the load in transversal direction
For moving the load in transversal direction the moving capability of the side shift is applied.
To operate the side shifts simultaneously, proceed as follows:
1. Apply the RCC
2. Verify that all checklists have been completed andsigned off:
x Appendix A “Checklist for planning a lifting
operation”
x Appendix B “Checklist for installing the
System”
x Appendix C ”Final checks”.
3. Verify the power status of the battery [F]; see thefigure below.
4. Enable all units; use the buttons [4] “Ram select”.

5. Use [9] “side shift” to move the selected side shiftunits simultaneously.



Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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7.8. Tilt the load
It is possible to perform tilt operations with the System.
activepassive

Note the following aspects:xxx

Unlike the normal lifting operations, here the slings should be kept as long as possible,
to minimize lateral forces.
Always apply four units.
Only move two units at a time.
The other two units are kept passive.
In the illustration above the red unit is the active one: it moves towards the blue unit.
The blue unit is passive and stands still.

Hazard: This operation has an increased risk of dangerous lateral forces.

)

If you want to perform a tilting operation, first contact Enerpac.

An illustrative video of a tilting operation is available on
https://www.youtube.com/watch?v=rC1toW6ECfU.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 95 of 151

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To tilt a load, proceed as follows.
In the procedure below, the controls of the RCC are indicated like “[x]”.
For the layout of those controls see page 81.
1.
2.
3.

4.

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Apply the RCC
Record all activities during the operation using the form given in Appendix D “Recording a
lifting operation”.
Verify that all checklists have been completed and signed off:
x Appendix A “Checklist for planning a lifting operation”
x Appendix B “Checklist for installing the System”
x Appendix C ”Final checks”.
Select the two ‘passive’ units on the RCC

Manoeuvre the header beam of the units attached to the (future) bottom of the load rightabove the load.
Attach the bottom of the load to the header beam.
De-select the passive units on the RCC
Select the two ‘active’ units on the RCC
Manoeuvre the header beam of the active units right upon the (future) top of the load.
Attach the header beam to the load.
Extend the cylinder for 5 cm.
Let the units travel towards the passive units in such a way that the lifting eyes of the load
are once again directly underneath the header beam.
Verify that the lifting eyes are straight underneath the header beam with in toleranceof 0.2°. Use a plumb line, a laser or a theodolite.
Repeat the steps 8 .. 10 until the load has been tilted completely.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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8. Solve problems
This chapter describes localization and solving of problems.
x A main problem localization procedure is given.
x A list of possible problems is given, together with causes and possible solutions.

8.1. Main problem localization procedure
When during lifting or other use of the System problems occur, follow the steps below to solve
the problem.
Verify that no Emergency button is activated:
x Is indicator [10] on the control panel lit?
(Emergency active)
Is there an overload problem?
x Check the displayed Loads on the RCC [E] (see page 82).
x Check the heights displayed on the RCC [A], [D] (see 82)
Is there a technical problem in one of the units?
Check the Control Panel of all units (see page 79):
x indicator [7] should be lit(power on)
x indicator [8] should be dimmed(motor failure)x indicator [9] should be dimmed(side shift overload)
Are hydraulic leakages visible?
Are there any mechanical obstructions?
Solve the problem accordingly.
Call Enerpac if you need assistance

1.
2.

3.

4.
5.
6.

.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 97 of 151

Page 978.2. List of problems and solutions
The table below lists a number of errors and problems which may appear during the use of the
System, together with possible causes and solutions.

Symptom

Possible cause

What to do…

Faulty or loose wiring

Check the wiring
Call Enerpac-

Main problems
Load value “–300” displayed(large negative)
All units selected, but none
moves up

Cylinder at end position?

One of the hydraulic motors stopped Press the START button [10] on
the Control Panel to restart
Emergency pressed?
Reset the Emergency
All units selected, but only one
moves up
After switching on the Control
Panel of a Unit, the error“communication timeout” isdisplayed on the RCC
No display indication afterswitching on the RCC

Height measurement was not
zeroed.
This is normal behaviour due to timeneeded by the starting-up
processes.

Zero the height measurements
using [10] of the RCC.
Wait for approximately 30
seconds

Battery is low

Charge the battery for at least 4
hours

Reports on the display of the RCC“Emergency pressed”“Communication timeout”“*” visible behind the RAMs”“System not ready”“Stroke measurement out ofrange”“Load measurements out ofrange”“Drive sensor error”(All Units stop driving)“Engine still”

An Emergency button was pressed,
either on one of the unit or on the
RCC.
Radio disturbed
No problem

Use cable connection
Appears when the cableconnection is used
Initiation message
Wait a 20 seconds
Measurement counter defectReplace the device
Fault in the wiring
Repair the wiring
Height measurement cable snapped Check the cable
Sensor defectReplace the sensor orcontact Enerpac.
Fault in the wiring
Check the wiring
One of the travelling distance
Change the sensor ormeasuring devices defectcontact Enerpac.
If you do not have aspare sensor, you
might remove all
driving sensors of all Units. The
System will be operational again,
BUT WITHOUT DRIVINGSAFETY! IT IS ON YOUR OWN
RISK.
Too long misalignment between the The sensor itself slips.
Units
One of the Units is obstructedElectro motor of the indicated unit is Push [4] on the Control Panel of
not running
the Unit

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Reset the emergency

Page 98 of 151

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SymptomPossible cause

What to do…

“Overload”

Too much weight on one of thebooms

If on one boom: the load is notdivided properly over the System.
Else: reconsider your lifting
operation w.r.t. the weight of the
Load

Mechanical and electrical problems
The System does not travel

The System does not lift
The cylinders raise unequally
The System cannot lower theload
The Side Shift does not move

The two Bolts of the driving motors Fasten the boltsof the Units are loose
One of the hydraulic valves is defect Repair the valve;
Contact Enerpac.
Hydraulic valve defectCall Enerpac
unit is switches off
Use [4] to switch the unit on
Problem with oil flow or leakage.
Contact Enerpac
Problem with oil flow or leakage.
Contact Enerpac
Side shift not connected
Thermic safety relays has tripped

Indicator “Invertor Failure” on
the Electrical Cabinet is lit

Indicator “Side Shift Overload”
on the Electrical Cabinet is lit)

Connect the Side Shift
Open the Electrical Cabinet andreset the relays indicated with
10QF2. See the picture below.
If not successful thenContact Enerpac.
Try to start the motor, use [4]If not successful the open theElectrical Cabinet and reset therelays indicated with 11QF2; see
the figure below.
If not successful thenContact Enerpac.
Try to start the motor, use [4]If not successful the open theElectrical Cabinet and reset therelays indicated with 10QF2; see
the figure below.
If not successful thenContact Enerpac.

The table is meant as a first aid kit. Contact Enerpac if you need assistance.

Hazard:Performing repairs on the System may cause dangerous effects when not
executed by well-skilled personnel.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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9. Storage
Requirements for storage of the System:x During short-term storage, especially in the open air, cover the units with a tarpaulin inorder keep electrical and other moisture-sensitive components dry.
The tarpaulin is not included in the delivery, but can be added as an option.
x Long-term storage:
For long-term storage a dry and closed space is recommended.
Make sure the electrics are kept dry. Pay special attention tox the stroke sensor and thex travelling distance measuring device
since they are vulnerable parts.
Stroke sensor

Travelling distance measuring device

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 100

10. Maintenance
Keep the machine in good condition
x to obtain optimum performance from your machine
x to guarantee the safety of the users, it is important to.
This chapter describes
x the maintenance jobs to be carried out
x the required skills for the maintenance jobs
x the time-intervals the jobs have to be performed.
The intervals are based on regular use of the System; which is approximately one
lifting operation per month. When the System is intensively or less intensively used,
the maintenance intervals will change accordingly.

)

x
x
x
x

Only perform maintenance on the units if they are not under load
Only perform maintenance on the units if no header beams are mounted
Maintenance which is not described in this section can only be performedby or in consultation with Enerpac.
Only apply spare parts provided by Enerpac. If parts of foreign make areapplied, all guarantees will be void.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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10.1. Mechanical

1. Main construction
1.1. Main construction

1.2. Test the oil of the
gearboxes
1.3. Replace the oil ofthe gearboxes
1.4. Adjust the guiding
pads
1.5. Lubricate theswivelVisual check of all weldings
Visual check painting
Visual check on corrosion and damages
Check all bolts.
Visual check of the lifting lugs
Inspect the readability of the warning signs.
Clean if obscured by dirt.
Restore if damaged or even no longer present
Test the oil of the gearboxes;
see section 10.1.5 “Replace the oil of the gearbox”
Test the oil of the gearboxes;
see section 10.1.5 “Replace the oil of the gearbox”
Adjust the guiding pads;
see section 10.1.7 “Adjust the guiding pads”
Lubricate the swivel;see section 10.1.6 “Lubricate the swivel”

O
O
O
O
O

x
x
x
x
x
x

O
x

O

x

O
EE
O

x
x

x
x

2. Chain of the units
2.1. Lubricate thechain

Lubricate the driving chainssee section 10.1.1 “Lubricate the driving chains”

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

O

Page 102 of 151

Page 102x

Remarks

10000 hours
Every 10 year

2000 hours
Every 2 years

O (owner)
EE (Enerpac expert)

Each 500
hours
Each year

Person40 hours
WeeklyAction

8 hours Daily

Subject

First 40 hours

Perform maintenance on the mechanical part according to the list as shown below.
Record all activities in Appendix E “ Recording maintenance”.

2.2. Tension the chain
2.3. Tension the roller
chainsTension the driving chainssee section 10.1.2 “Tension the driving chains”
Tension the roller chain
see section 10.1.3 “Tension the roller chains”

x

O

x

O

3. Side shift unit
3.1. Lubricate thechain

Lubricate the chain
see section10.1.4 “Lubricate the side shift units”

xO

4. Booms / guiding pads
4.1. Adjust the guiding
pads
4.2. Booms

Adjust the guiding pads.
࢚࣮ࣛ! ཧ↷ඖࡀぢࡘ࠿ࡾࡲࡏࢇࠋ”.
See section “࢚Lubricate the booms on the running surface of the guidepads with synthetic motor oil for instance 10W40.
See section “Booms / guiding pads”.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

O/EE
O/EE

Page 103 of 151

Page 103

x

x
x

x

10.1.1.

Lubricate the driving chains

Chains connect the gearboxes with the driving shafts.
To lubricate the chains proceed as follows:1.
2.

Make sure the power supply has beenswitched of
Unlock the front doors and open them

doors

3.

Visually inspect the chains and the gears
chains

4.
5.
6.
7.

Clean the chains
Lubricate the chain with Kroon Oil multipurpose grease 3
Close the front doors and lock them
Verify that the wheel of the travelling
distance measuring device runs fineDocument number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 104 of 151

Page 10410.1.2.

Tension the driving chains

1. Perform steps [1] .. [3] from section 10.1.1“Lubricate the driving chains”.
x The gearbox is affixed to the frame of
the unit with 6 bolts which can move inslotted holes.
x

shaft

gearbox

The bearings of the intermediate shaft
are affixed to the frame of the unit with
6 bolts, which can move in slotted holes

2. Loosen the bolts of the shaft
3. Tension the lower chain.
The slack in the middle of the chain shall be
10 mm. Use hand power.
4. Tighten the bolts of the shaft
5. Loosen the bolts of the gearbox
6. Tension the upper chain until the slack is 10
mm in the middle of the chain. Use hand
power.
7. Tighten the bolts of the gearbox
Caution: tensioning the chains
too tight might harm thedriving mechanism

8. Close the front door

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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10.1.3.

Tension the roller chains

To tension the roller chains proceed as follows:
HazardDuring the adjustment, you are underneath the unit. Use lawful hoisting
and lifting equipment.
1.
2.

3.

Make sure the power supply has beenswitched of
Lift the unit.

Verify the slack between the upside of the
middle roller and the frame of the unit.
If the clearance exceedes 10 mm thencontinue with the next steps.
Max 10mm

4.

Unscrew the four bolts [1] at the rear side of
the unit (so the side of the stairs) …

… both at the left- and the right hand sideof the track. So, eight bolts in total.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 106 of 151

Page 106

5.

Tension the chains by turning the bolts.
Use hand power.
Make sure the shaft is kept parallel.

Carry on turning until the top of the roll isflush with the frame

6.

CautionTensioning the chain too tightmight harm the driving
mechanism
Tighten the bolts.

7.

Inspect the roller chain:
x Check he bolts on damage
x Make sure the bolts of the chain aretightened (45 Nm)

10.1.4.

Lubricate the side shift units

Clean the chains of the side shift units, and lubricate them.
Use “Kroon Oil multi-purpose grease 3”. This is valid for both types of side shift units.

(The bearings of the side shift units were greased for lifetime.)

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 107 of 151

Page 10710.1.5.

Replace the oil of the gearbox

1. Perform a purity test on the oil of the
gearboxes

Gear
boxes

2. Change the oil of the gearbox
x If the yearly purity test points out,orx at least every 10 years
Use 2.6 litres of oil type “ISO VG 320
Mineral oil”.

10.1.6.

Lubricate the swivel

1. Lubricate the nipples of the swivel; two atboth sides.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 108 of 151

Page 10810.1.7.

Adjust the guiding pads

The guiding pads of the booms have to be adjusted
x periodically, due to wear
x after replacement
The guiding pads are located in the booms on each stage Æ,
so for the SBL100 on three spots, for the SBL900 on two spots.
At each stage, the inner side of the boom is provided with four sets of steel
plates on which guiding pads are mounted:
sets of plates

One set of steel plates consists of a two plates which abut against each other.
x Two guiding pads are mounted on the inner plate: one on the top and one on thebottom.
x The distance between the inner- and the outer plate can be adjusted by adjusting bolts.
Those bolts can be reached through holes in the boom.
x The plates are affixed to the boom by a mounting element.

Inner plate
Outer plate

Mounting element

Adjustingg bolts

Outer plate
Inner plate
e

holes

Guiding pad

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 109 of 151

Page 109Adjusting the guiding pads is done stage by stage, by tensioning the adjusting bolts.
The procedure has to be executed preferably by two persons.

)This accurate job should preferably be executed by Enerpac people.

To adjust the guiding pads proceed as follows:
1. Position yourself close to top of the unit.
Use the platforms or your own means.
HazardWear a safety harness. You’re
working at height.

2. Extend the boom until the four holes for theupper bolts and the lower bolts are visible
3. The adjusting bolts of the guiding pads arelocated behind the holes in the boom.
Loosen the 8 upper bolts and the 8 lower bolts ofthe four sides by turning them clockwise.
Turn them as far as possible.

Upper bolts
Lower bolts

4. Turn only a half turn counter clockwise:
1.
2.
3.
4.

the two upper bolts of side one
the two upper bolts of side two
the two upper bolts of side three
the two upper bolts of side four

Use little force. Turn the bolts simultaneously.
(Therefore, two persons are required.)
5. Repeat step [4] until 100 Nm is reached
6. Turn only a half turn counter clockwise:
1. the two lower bolts of side one
2. the two lower bolts of side two
3. the two lower bolts of side three
4. the two lower bolts of side four
7. Repeat step [6] until 100 Nm is reachedThe inner beam is now centred inside the outerbeam without being clamped
8. Extend the boom until the four holes of the next
section are visible
9. Repeat the steps [2] .. [8] for the new stages

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG(top view)

Page 110 of 151

Page 11010.1.8. Booms / Guiding pads
Procedure:x Saturate a rag and lubricate the booms on their running surfaces (mating surface of theguide pads) with synthetic motor oil for instance 10W40.
Remarks:x In case of vibration of the booms during operation, execute this procedure also.
x In case of contamination of the running surface(s) by for instance sand, clean therunning surfaces and lubricate the booms again.
In case of new guiding pads, execute this procedure also. But before installing the new pads,
make sure to ‘activate’ the pads by rubbing them with a rag saturated with synthetic oil too.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 111

10.2. Hydraulicxxxx

All inspections up to yearly have to be performed if the system has been idle for atleast 12 months.
For repairs reference is made to section 2.6. “Working on the hydraulic system”.
The system shall only be returned to service when approved by a qualified person as
described that section.
All replacement parts including the ram, hoses, couplings, seals, valves, and caps shallmeet or exceed the original equipment manufacturer's specifications.

Hydraulic jacks shall be removed from service if damage such as the following is present:a) excessively worn, scored, cracked, bent, or broken ramb) cracked or broken jack housing or cylinderc) internal or external hydraulic fluid leakd) damaged seals or valvese) excessive pitting or corrosionf) excessive nicks or gougesg) missing or illegible identificationh) indications of structural damage due to heat, or evidence of unauthorized weldingi) improperly functioning or damaged load cap or integral auxiliary load pointj) loose structural bolts or rivetsk) worn or damaged load-bearing threadsl) damaged or improperly assembled accessory equipmentm) missing relief valve for double-acting jackn) damaged or severely worn hoses or couplingso) contaminated hydraulic fluidp) other conditions including visible damage that cause doubt as to the continued use of
the hydraulic jackDocument number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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)

Enerpac strongly advises to apply parts as bought from Enerpac.
HazardApplying parts which to not apply to the specifications may cause hazards topersonnel and the system

1. Electro motor, tank and cooler
1.1. Motor

1.2. Hydraulic tank

1.3. Valves

1.4. Manifolds

Check on oil leakage, damages and paint work
Check if the bolts are still tightened
Check on damages
Wipe it clean and free from dust
Check on oil leakage, damages and paint work
Check if the bolts are still tightened
Replace all seals
Replace the level gauges
Drain the tank (water and sludge)
Exchange the filler cap (which contains a filter)
Check on oil leakage and damages
Check if the bolts are still tightened
Replace all seals
Check all valve settings
Check on oil leakage and damages
Check if the bolts are still tightened

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

O
O

O
O
EE
EE
EE
O
O
O
EE
O
O
O

Page 113 of 151

Page 113

x
x

x
x
x
x

x

x
x
x
x
x

x

x
x

x
x
x
x
x

Remarks

10000 hours
10 years

2000 hours
2 years

O (Owner)
EE (Enerpac expert)

500 hours
yearlyPerson40 hours
WeeklyAction

8 hours
Daily

Subject

First
40 hours

Perform maintenance on the mechanical part according to the list as shown below.
Record all activities in Appendix E “ Recording maintenance”.
For hydraulic fluid safety information sheet, see Appendix J “Hydraulic fluid safety information”.

1.5. Oil

Take an oil sample to analyze
Replace the hydraulic oil.
See section 10.2.1 “Drain the oil” andSection 10.2.2 “Filling the tank”
Check the oil level

x

EE

x
EE
O

x

1.6. Hydraulic filter

1.7. Breathers
1.8. Bellhousing

1.9. Cooler

Change oil ifnecessary
Or after 2000
running hoursx
Check and replace the filter element.
See section 10.2.3 “Replace the filter element”.

EE

Replace the seals of the filter housing
Replace the breather
Check on damages
Check if the bolts are still tightened
Replace motor pump coupling
Check on oil leakage and damages
Check if the bolts are still tightened
Clean the cooler
Measure pressure difference “delta p” at the cooler

EE
EE
O
O
EE
O
O
O
EE

x

x
x
x
x

x
x
x

x

x
x
x

2. Hydraulic connections
2.1. Pipes, hoses andbrackets

2.2. Couplings andquick-screw
couplings
2.3. Gauges,
measurement
sensors

Check on oil leakage and damages
Check if the couplings are tightened well.
Replace all seals within the piping (Waldform)
Replace all hoses
Replace all plastic brackets
Check on oil leakage and damages
Check if the couplings are tightened well.
Replace all seals of the couplings
Replace fast couplings and screw couplings
Check on damages

O
O
EE
EE
EE
O
O
EE
EE
O

Check the tightening bolts, nuts and components

O

Replace all seals

EEx

Replace all gauges

EE

xDocument number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 114 of 151

Page 114

x
x

x
x
x
x
x
x

x
x
x

x
x

x

And ifindicated by
the clogging
indicator

3. Housing
3.1. Common

Check on damages and paint
Check if the bolts are still tightened
Replace all seals, door seals and inspection hatches
Grease the hinges and locks
Replace engine feet

O
O
EE
O
EE

Check on leakages
Check if the bolts are still tightened
Replace all seals
Grease the bearings

O
O
EE
EE

x
x

x
x
x
x

4. Cylinders
4.1. Common

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 115 of 151

Page 115

x
x

x
x
x

10.2.1.

Drain the oil

The oil in the sump has either to be refreshed or a purity test has to be performed.
The minimum requirement is that the purity of the medium is in accordance with class 7 of
NAS 1638.
Proceed as follows:
1. Ensure that the cylinder is completely pulled in
2. Disconnect the hose from to the ball valve

3. Connect your own hose to the ball valve
4. Drain the oil.
While draining, keep an eye on the oil level gauches

5.
Attention
Dispose the oil responsibly

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 116

10.2.2.

Filling the tank

To fill the tank, proceed as follows:
1. Make sure the cylinder of the unit is fully pulled in
2. Use the fill/bleed opening to fill the tank with oil.
Use oil type “Shell Tellus T32 or Shell Tellus Artic”.

Filler cap

Caution
Do not fill the tank over the maximum.

3. Make sure that the oil is free of air by circulating the oil
through the system.
Just start the System and let it run for 10 minutes.

10.2.3.

Replace the filter element

The return filter cleans the oil that flows back into the tank.
Due to contamination of the oil, the permeability of the filter will decrease, which causes araise of the pressure of the return flow of the oil. The pressure is shown on the clogging
indicator:

Clogging indicatorx
x
x

Green: the pressure is 0 .. 2 bar
The filter is fine.
Yellow: the pressure is 2..3 bar
The filter is still working, but has to be replaced as soon as possible.
Red: the pressure is over 3 bar.
Oil is no longer filtered.
Replace the filter element immediately.

The filter element has to be replaced
x when the oil is refreshed
x when the clogging indicator shows yellow or redx according to the maintenance scheme

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 117

To replace the filter element, proceed as follows:
1.
2.
3.

Unscrew the return filter cap
Remove the internal filter element
Put a new filter element.
To ensure correct operation, only replace with an element with equal brand and type.
Use Hydac return filters. The exact type is listed on the parts list of the machine.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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10.3. Electrical

1. Electro motor
1.1. General

Check on damages
Wipe it clean and free from dust

O
O

x
x

x

2. Cables and connectors
2.1. General

Check on damages

Ox

3. Devices and cabinets
3.1. General

3.2. Main switch
3.3. Remote control

Check on damages
Check if the bolts and nuts are still tightened
Replace all seals
Replace the main switch
Replace the battery

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

O
O
EE
EE
O

Page 119 of 151

Page 119

x
x

x
x
x
x
x

Remarks

10000 hours
Every 10 year

2000 hours
Every 2 years

O (owner)
EE (Enerpac expert)

Each 500 hours
Each year

Person40 hours
WeeklyAction

8 hours
Daily

Subject

First 40 hours

Perform maintenance on the electrics of the system according to the list below.
Record all activities in Appendix E “ Recording maintenance”.

11. Quality
Not applicable

12. Recycling the machine
To recycle the machine at the end of its lifetime, proceed as follows:x Drain and collect the hydraulic oil and other fluids separately, if applicable.
x Remove the batteries.
x Remove the electric components and electric wiring.
x Remove the metal components.
Separate all metals and liquids for recycling purposes and bring it to a recycling company.

Attention:
Dispose all material in a responsive way.

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 120 of 151

Page 120

13. IndexA
accident, 16, 20, 35
accretion, 30
acid, 20
active, 74, 78, 95, 96,
97
address, 7, 87
adjustment, 8, 106
agent, 22align, 66
allergic, 22
alterations, 8, 35
anchor, 50, 122anchors, 89, 126
approval, 3, 8
aquatic, 22
assembling, 3assistance, 21, 97,99
attached, 26, 53, 63,
64, 71, 87, 96
authorized, 9automatic, 30, 62

Bbandwidth, 91
batteries, 119battery, 30, 76, 83,
84, 90, 91, 92, 94, 98,
118, 123, 131beam, 25, 27, 33, 49,
50, 66, 67, 68, 69, 71,
87, 89, 96, 110, 122,
123, 126
beams, 25, 27, 28, 29,
31, 32, 33, 34, 36, 38,
41, 44, 48, 49, 50, 51,
53, 54, 67, 68, 71, 80,
91, 101, 123
bearing, 23, 31, 37,
38, 39, 40, 41, 42, 44,
45, 48, 49, 50, 51, 93
brackets, 29, 113,130
breather, 113, 130C
cable, 68, 70, 73, 98
cable-guiding, 68
cables, 19, 62, 64, 72,
74, 75, 124
calculate, 38, 41,51
calculated, 37, 39,
42, 44, 51, 83
calculation, 37, 51,
52, 57
calculations, 7, 33, 51

calibrate, 85
calibration, 85
capability, 94
capacities, 31, 44
capacity, 23, 30, 36,
37, 39, 42, 44, 45, 48,
49, 50, 90, 122
carcinogen, 22
certificate, 19
certified, 9, 19, 23
chain, 68, 102, 103,
104, 105, 107, 129
chains, 102, 103, 104,
105, 106, 107, 129
charging, 30
chart, 45, 46, 47
checked, 23, 71
checklist, 23, 36,
39, 42, 44, 48, 50, 52,
77
checks, 90, 92, 94, 96,
125, 127
chemicals, 20
circulating, 116
clothing, 16, 20, 22
competent, 9, 19
configuration, 29,
31, 32, 33, 72, 76
console, 25, 29, 72,
81, 83, 84, 85, 131
contamination,
116
conventions, 3cooler, 112, 113, 130
cordon, 19, 125
corrosion, 102, 129
corrosive, 20
cover, 3, 100
covering, 16
coverings, 16
crane, 53, 54, 56
cylinder, 26, 83, 86,
91, 96, 115, 116
cylinders, 25, 48,
63, 64, 65, 81, 82, 83,
85, 86, 87, 91, 92, 99

Ddamage, 8, 14, 16, 19,
22, 23, 35, 53, 87,107damaged, 19, 102, 124,
125, 129
damages, 102, 112,
113, 114, 118, 129,
130, 131
dangerous, 89, 95,
99
deflections, 33deleterious, 8

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

device, 19, 25, 26, 93,
98, 100, 104dimensions, 27, 38,
40, 44, 52
direction, 8, 25, 28,
30, 31, 38, 48, 52, 61,
62, 68, 70, 80, 87, 91,
92, 93, 94, 122, 123
draining, 115
driving, 98, 99, 102,
103, 104, 105, 107,
123, 129E
earth, 19
eccentric, 45
eccentricity, 45
education, 9electric, 19, 25, 30,
63, 70, 119
electrical, 7, 9, 19, 20,
23, 25, 28, 62, 71, 99,
100, 124
electrician, 19
emergency, 20, 21,
74, 78, 83, 84, 87, 98
employee, 20
environment, 14, 19,
22
environmental, 44
environments, 8, 13
explode, 22
explosive, 8extinguishing, 20eye, 20, 22, 65, 115

F
failure, 14, 87, 90,
97
familiar, 21
filter, 112, 113, 116,
117, 130
filters, 117
flames, 22
flammable, 22
fluid, 19, 20, 21, 112foot, 52, 65
footprint, 40, 41
footwear, 15
forklift, 53, 54, 56
fuses, 19Ggauges, 112, 113, 130
gear, 15, 16, 104
gearbox, 102, 105,
108
gloves, 15, 22
goggles, 15

gravity, 35, 36, 63
grease, 104, 107, 149
grinding, 19
grooves, 61
ground, 16, 38, 39, 41,
42, 51, 56, 57, 89
guarantee, 3, 43,101

H
handbook, 7, 31, 32,
33, 49handheld, 15
hands, 17
harness, 15, 110
hazard, 22, 149
hazardous, 8, 20, 35
hazards, 8, 14, 21, 22
hose, 115
hoses, 19, 25, 113,130
hydraulic, 16, 19,
23, 25, 48, 97, 98, 99,
111, 112, 113, 119,
124, 125, 130
hydraulically, 9,25
hydraulics, 9, 19
hypersensitivity,
22

I
ice, 30
injure, 23
injured, 35
injuries, 16, 87
injury, 19, 22, 87
inspection, 19, 77,
114, 124, 131
install, 19, 53
installation, 8, 89
installing, 23, 77,
90, 92, 94, 96, 123,
125
insulated, 19Llaser, 96
lateral, 89, 95
leakage, 99, 112, 113,
130
lean, 53
legal, 9, 16
legally, 21
legislations, 16
liability, 8
lifetime, 13, 107,
119

Page 121 of 151

Page 121

lift, 34, 45, 81, 83,
85, 90, 91, 99, 125
lifting, 3, 16, 23, 25,
26, 29, 31, 32, 34, 36,
39, 42, 44, 48, 50, 51,
52, 53, 54, 55, 56, 63,
81, 82, 87, 89, 90, 91,
92, 94, 95, 96, 97, 99,
101, 102, 106, 122,
123, 126, 127, 129,138
limitations, 8
limits, 44, 45, 122loading, 23, 30
lock, 30, 65, 104
locking, 23, 56, 67,
68
locks, 23, 114, 131
longitudinal, 8, 25,
33, 71, 92, 122
lubricate, 104, 107lug, 31, 32, 138Mmaintain, 9
maintaining, 3maintenance, 3, 9,
13, 16, 19, 22, 101,
102, 112, 116, 118,
129
manual, 3, 8, 14, 19,
21, 23, 87, 123
mass, 29, 38, 41, 48
measure, 93
measurement, 98,
113, 130
measures, 20, 22, 72,85
motor, 28, 30, 85, 90,
97, 98, 99, 112, 113,
118, 130, 131
mouth, 20
moved, 23, 53
movement, 91
moves, 95, 98
moving, 3, 16, 17, 25,
26, 28, 31, 53, 61, 70,
81, 91, 93, 94

N
NEN-EN, 7
NEN-EN-ISO, 7O
operate, 9, 57, 74, 82,
84, 94operating, 15, 30
operation, 3, 35, 36,
38, 39, 41, 42, 44, 48,
50, 51, 52, 81, 87, 89,
90, 92, 94, 95, 96, 99,
101, 117, 122, 123,
127
operational, 98
operations, 35, 44,
45, 52, 80, 89, 95
operator, 9, 14, 16,
29, 80, 81
operators, 3, 8, 23
original, 8, 19

P
paint, 112, 114, 130,131
people, 8, 15, 16, 35,
87, 110, 125, 149
permeability, 116
permissible, 51, 52,122
persistent, 76
person, 9, 87
personal, 21, 22
planning, 36, 39, 42,
43, 44, 48, 50, 51, 52,
90, 92, 94, 96, 122,
123
plywood, 43
preparation, 53, 87
prepare, 36, 87
pressure, 19, 22, 27,
30, 36, 37, 38, 39, 41,
42, 65, 113, 116, 122,
130
pressurized, 19Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

protection, 21, 22,
23
protective, 15, 22

Rradio, 29, 72
railway, 27
recycling, 119Ssafe, 13, 19, 29, 81
safety, 3, 7, 8, 14, 15,
16, 19, 20, 21, 57, 87,
99, 101, 110, 112
secure, 23, 43
secured, 23, 43
securely, 71
sensor, 26, 71, 85, 86,
98, 100
setting, 68, 76, 80,
87
shackles, 16, 38, 41,
51
shaft, 63, 65, 105,
107
shims, 58, 60
side-load, 51, 125
smoke, 22
software, 90
stage, 20, 45, 79, 82,
91, 92, 109, 110, 122
subsoil, 27, 36, 37,
39, 42, 57, 122
substance, 20
subsurface, 16
supervision, 9, 19
synchronise, 26, 93
synchronously, 92

Ttank, 112, 113, 116,130
tarpaulin, 100
temperature, 30
tension, 23, 106

tensioning, 105,
110
theodolite, 96
timbers, 23, 40, 41,
43, 55, 57, 58
torque, 53, 123, 149
tortoise, 92
toxic, 22
track, 25, 27, 38, 41,
60, 93, 106
tracks, 25, 27, 31, 32,
36, 37, 38, 40, 44, 54,
57, 58, 59, 60, 61,123, 124, 125, 132
trained, 9, 19, 23
training, 9transport, 23transporting, 28,
35, 55transversal, 25, 28,
70, 94, 122transverse, 8, 48

U
USB, 7, 51

Vventilate, 21
vicinity, 16, 35, 87
victim, 20
voltage, 7, 17, 19

W
wheel, 68, 104
wind, 36, 51, 52, 87,122wireless, 72, 75

Zzero, 60, 83, 91, 93
zone, 19, 125Page 122 of 151

Page 122

AppendicesA. Checklist for planning a lifting operation
1. Project

Project
Customer
LocationDate
2. Operation typeLift / lower
Move in longitudinal direction
Move in transversal direction

3. Ground bearing pressureAllowable ground bearing pressure (σ toe)….. Tonne/ m²

4. Capacity










Mass of the load
Lifting height….
Stage of Extension
Capacity in highest stage….
Allowable load:....
The mass of the load does not exceed the allowable load
Minimum force per unit is sufficient….
Maximum force per anchor point does not exceed the….
capacity of the side shift (if applicable)
The force on the applied header beam does not exceed the limits
Maximum permissible wind speed
X-direction.…
Y-direction.…
The side load does not exceed 1.5 % of the vertical load

mm
1 / 2
kN
kN
kN
kN

m/sec
m/sec

5. Commitment
Planning by:

Date:

Signature:
Approved by:Date:

Signature:

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Page 123 of 151

Page 123

B. Checklist for installing the System
1. Project
Project
Customer
Location
Date

2. PlanningChecklist A “Checklist for planning a lifting operation” was completed and signed off

3. Foundation
Foundation underneath skid tracks has been put in accordance with the instructions in thismanual. If foundation is applied

4. Skid tracks

Skid tracks placed according to instructions in manual
Skid tracks connected according to instructions in manual.
Skid tracks aligned according to instructions in manual.

Move all units forwards and backwards over a short distance using the RCC, to ensure you
have set the positive driving direction correctly.
Slide all beams in and out over a short distance.
(This assures the communication functions properly.)
Check the battery status of the RCC
The stroke sensors are undamaged

5. Units

6. Header beamBolts on the swivel tightened to torque in accordance with instructions in manual
Beam is horizontal (level) on the two units

7. Side shiftsSide shift units mounted in accordance with instructions in manualMove the side shift units to the right and the left over a short distance, to ensure you have
set the positive driving direction correctly.

page 1/2

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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page 2/2
8. Visual inspection







Visual inspection: no excessive rust.
Visual inspection: no parts of the system are damaged
Visual inspection of the hydraulic components: no oil leakages
Running surfaces of the skid tracks are clean.
(Dirt may cause the units slip)
The units can run freely and are not obstructed.
Inspection of the electrics:
electrical cables are undamaged
electrical cables cannot be pinched

9. Applied equipment
What
Lifting
strapsChains
Other

LengthCapacity

Mass

10. Commitment
Installed by:Date:

Signature:
Approved by:Date:

Signature:

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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C. Final checks
1. Project
Project
Customer
Location
Date
2. Installation


Checklist B “Checklist for installing the System” was completed and signed off

3. Inspect the System








No parts of the portal lift are damaged
No leakages of the hydraulic components
Drop-zone is cordoned off.
No people are inside the unsafe zone.
Barriers and tape are used.
Running surfaces of the skid tracks are clean.
The units can run freely and are not obstructed.
The weight of the load is indicated on the RCC correctly.
The side-load does not exceed 1.5 % of the vertical load

Part 1/2

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Part 2/2

4. Check the suspension of the load
The anchors on the header beam
are in line with the hoisting points of
the load.
(front view)
The lifting straps are short.

(front view)
The header beam are level(front view)
Lifting slings are plumb.

(side view)

5. Commitment
Inspected by:Date:

Signature:
Approved by:Date:

Signature:

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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D. Recording a lifting operation
1. Project
Project
Customer
Location
Date

2. Recording of activities
Activity
The checklists have been completed and are signed off:Appendix C “Final checks” has been completed and signed off

Time

1
2

3

4

5

6

7

8

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Part 2/3

Activity

Time

9

10

11

12

13

15

16

17

18
3. Commitment
Executed by:Date:

Signature:
Approved by:Date:

Signature:

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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E.

Recording maintenanceUse the table below for recording all maintenance activities,
accordance with section 10. “Maintenance”.

a. Mechanical:

Subject

ActionPersonDate

1. Main construction
1.1. Main construction

1.2. Test the oil of the
gearboxes
1.3. Replace the oil of the
gearboxes
1.4. Adjust the guiding
pads

2.

Test the oil of the gearboxes
Replace the oil of the gearboxes
Adjust the guiding pads

Chain of the units

2.1. Lubricate the chain
2.2. Tension the chain
2.3. Tension the roller
chains3.

Visual check of all weldings
Visual check painting
Visual check on corrosion and damages
Check all bolts.
Visual check of the lifting lugs
Inspect the readability of the warning signs.
Clean if obscured by dirt.
Restore if damaged or even no longer present

Lubricate the driving chains
Tension the driving chains
Tension the roller chains

Side shift unit

3.1. Lubricate the chain

Lubricate the chain

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Page 130b. Hydraulical:

Subject

ActionPersonDate

1. Electro motor, tank and cooler
1.1. Motor

1.2. Hydraulic tank

1.3. Valves

1.4. Manifolds
1.5. Oil1.6. Hydraulic filter
1.7. Breathers
1.8. Bellhousing

1.9. Cooler

Check on oil leakage, damages and paint work
Check if the bolts are still tightened
Check on damages
Wipe it clean and free from dust
Check on oil leakage, damages and paint work
Check if the bolts are still tightened
Replace all seals
Replace the level gauges
Drain the tank (water and sludge)
Exchange the filler cap (which contains a filter)
Check on oil leakage and damages
Check if the bolts are still tightened
Replace all seals
Check all valve settings
Check on oil leakage and damages
Check if the bolts are still tightened
Take an oil sample to analyze
Replace the hydraulic oil.
Check the oil level
Replace the filter element.
Replace the seals of the filter housing
Replace the breather
Check on damages
Check if the bolts are still tightened
Replace motor pump coupling
Check on oil leakage and damages
Check if the bolts are still tightened
Clean the cooler
Measure pressure difference “delta p” at thecooler

2. Hydraulic connections
2.1. Pipes, hoses
and brackets

2.2. Couplings andquick-screw
couplings
2.3. Gauges,
measurement
sensors

Check on oil leakage and damages
Check if the couplings are tightened well.
Replace all seals within the piping (Waldform)
Replace all hoses
Replace all plastic brackets
Check on oil leakage and damages
Check if the couplings are tightened well.
Replace all seals of the couplings
Replace fast couplings and screw couplings
Check on damages
Check the tightening bolts, nuts and components
Replace all seals
Replace all gauges

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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3. Housing
3.1. Common

Check on damages and paint
Check if the bolts are still tightened
Replace all seals, door seals and inspection
hatches
Grease the hinges and locks
Replace engine feet

4. Cylinders
4.1. Common

Check on leakages
Check if the bolts are still tightened
Replace all seals
Grease the bearingsc. Electric:

Subject

ActionPersonDate

1. Electro motor
1.1. General

Check on damages
Wipe it clean and free from dust

2. Cables and connectors
2.1. General

Check on damages

3. Devices and cabinets
3.1. General
Check on damages
Check if the bolts and nuts are stilltightened
Replace all seals
3.2. Main switch
Replace the main switch
3.3. Remote Control
Replace the battery
consoleDocument number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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F. Drawings for the skid tracks

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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G. Drawing of the units

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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H. Drawings of the side shift units

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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I.

Drawings of the lifting lug

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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J. Hydraulic fluid safety information

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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K. Kroon Oil Multi purpose grease 3

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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L. Torque settings
Inspect all bolt joints which may pose a hazard to people and machines at fixed intervals andcheck their torque. Apply the torque values unless indicated otherwise on the drawing.

Course pitch[Nm]
Nominal
size

M4

M5

M6

M7

M8

M10

M12

M14

M16

M18

M20
M22

(CopperStrength grease)
class
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8

0.08
2.2
3.2
3.8
4.3
6.3
7.4
7.4
10.9
12.5
12.0
17.5
20.5
18
26
31
36
52
61
61
90
105
97
145
165
145
215
250
210
300
350
300
420
500
400

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

Fine pitch[Nm](Coppergrease)
0.08

19
28
32
37
55
64
63
93
109
103
150
175
155
225
270
230
330
380
320
460
530
430

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Course pitch[Nm]
Nominal
size

M24

M27

M30

M33

M36

M39

(CopperStrength grease)
class

Fine pitch[Nm](Coppergrease)

10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9
12.9
8.8
10.9

0.08
570
670
510
730
850
750
1070
1250
1000
1450
1700
1400
1950
2300
1750
2500
3000
2300
3300

0.08
610
710
640
900
1060
920
1310
1530
1280
1820
2130
1700
2430
2840
2230
3170
3710
2850
4050

12.9

3800

4740

Document number: ED. 03622.00.001.R04.ENG
ED.02518.00.001.R08.ENG

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