Hydraulic & mechanical lock grip pullers long jaws (2 pages)
Summary of Contents for Enerpac SBL500
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Instruction- and Maintenance Manua SUPER BOOM LIFT Document Number: SBL500 ED.03906.00.001.ENG rev01 SBL900 Status: Final SBL1100 Original instructions www.enerpac.com...
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Revisions Description Date Author Checked Approved by First release This document is a merge of the manuals of the SBL500, SBL900 and the SBL1100. New developments are integrated: • Top swivel 03 Feb 2020 Rosier Jansen Broenink • Free wheel •...
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Preface Dear customer, This is the manual for assembling, operating and maintaining the Super Boom Lifts SBL500, SBL900 and the SBL1100. Differences between the are indicated clearly, if applicable. Within this manual, the machines are referred to by the term “System”.
Contents INTRODUCTION ..........................8 ......................8 ANUFACTURER ADDRESS ..........................8 ECLARATION ......................8 EFERENCED DOCUMENTS ........................... 9 DENTIFICATION ............................. 9 IABILITY ..........................9 NTENDED USE ......................... 10 ODIFICATIONS .................... 10 ERSONNEL AND RESPONSIBILITIES 1.8.1 ......................... 10 HE OWNER OF THE SYSTEM 1.8.2 ........................
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PLAN AN OPERATION ........................41 ................42 EARING GROUND PRESSURE CALCULATION 4.1.1 ....................42 ALCULATIONS FOR UNITS WITH WHEELS 4.1.2 ..................47 ALCULATIONS FOR UNITS WITH ROLLER TRACKS 4.1.3 ..................52 EQUIREMENTS FOR FOUNDATION MATERIAL ................53 HECK THE LIFTING CAPACITY OF THE SYSTEM 4.2.1 ...........................
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EXECUTE A LIFTING OPERATION ..................... 105 ........................105 AIN DIRECTIONS 7.1.1 ........................105 ISKS AND ARNINGS 7.1.2 ......................106 ARNING SIGNS ON THE YSTEM ....................106 OCAL CONTROL OF ONE UNIT ......................... 108 USPEND THE LOAD 7.3.1 ...................... 108 IDE SHIFT UNITS OR LIFTING LUGS 7.3.2 ...........................
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CHECKLIST FOR PLANNING ...................... 155 CHECKLIST FOR INSTALLING THE SYSTEM ................157 FINAL CHECKS ..........................159 RECORDING A LIFTING OPERATION ..................160 LOGGING MAINTENANCE ......................162 WEAR OF THE PADS ........................165 HYDRAULIC FLUID SAFETY INFORMATION ................166 TORQUE SETTINGS........................174 COMPATIBILITY OF SYSTEM PARTS ..................
Personnel as well as other people involved in the usage of the System are expected to have read and understood this manual. • In cases of doubt about the use or application of this machine, always contact Enerpac for advice and recommendations. •...
1.7 Modifications Never make any modifications or additions which could have an adverse impact on safety without prior approval from Enerpac. This also applies to the installation and adjustment of safety devices and valves and welding work on the System.
g) and to designate 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) to comply with the requirements of this manual and all regulations applicable at the work site, b) to use supervisors for activities, c) to ensure that the system is in proper operating condition, prior to initial use at the worksite by •...
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 the system's work area. e. ensuring that personnel involved in the operations understand their responsibilities, assigned duties, and the associated hazards.
calculating or determining the rated load for all configurations that will be used and verifying, 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 the system Director of the need to make appropriate adjustments.
END EVERYTHING. INDIVIDUAL BOOMS. Clasp hands in front Hold up: of body. one finger for boom marked: "1," two fingers for boom marked "2”. Regular signals follow. 1.10 Lifetime No lifetime of the System is specified, since its safe and effective lifetime strongly depends on •...
Remove loose tools or components from the load or the System if the load will be moved as they might fall down during moving, which can lead to fatal accidents. Enerpac is not liable for improper use of accessories in combination with the System. Page 15 of 182...
2.3 Symbols applied to the System The System can be labelled with • warning symbols, • mandatory signs. The table below shows the most commonly used warning symbols in industrial environments: Danger of contact with moving machine parts Danger of lethal voltage in the control panels Danger of parts of hands getting trapped/caught Danger of parts of feet getting trapped/caught Danger of falling...
• Connect the system to a direct earth line. NB: welding, cutting, grinding or any other structural adjustment work on the System is not permitted without Enerpac’s prior written permission. 2.5 Working on the electrical system • In the event of an electrical fault in the electric control system, you must bring all connected devices into a safe condition.
In any case, the following actions are necessary in the event of a fire: • Keep calm. • 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.) •...
Symbol General hazard indication Possible precautionary measures Contaminated work clothing must not May cause an allergic reaction on the skin. leave the workspace. Harmful to aquatic organisms, with long term Do not discharge into the environment. effects Causes serious eye injury and/or damage to Wear eye protection and skin protection the skin.
• Only use suitable containers with adequate load-bearing capacity for transport purposes. • Secure the load properly using suitable connection points and twist locks (for the containers). When using twist locks secure them properly and check that the locking mechanism is working correctly. •...
2.11.2 Main procedure for connecting hoses Inspect the couplings. Clean the coupling if dirty. Replace the coupling if damaged. Clean the inner and outer side of the couplings before they are mounted; dirt might get in the system causing damage. Use degreaser.
3 System Overview This chapter describes the main functions and components of the System. 3.1 General The System is intended to move a heavy load: • In vertical direction by extending the booms. • In longitudinal direction by travelling along tracks. •...
3.2 Main parts NB: Pictures may differ for the different systems. Header beam Boom unit Remote control console Skid track The system is a four-point lifting system which can move a heavy load in three directions: • Vertical direction, by extending the four booms. The booms move computer controlled and are synchronized.
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Different types of side shift units are available. SSU150 SSU300 SSU600 Optionally, the side shift units can be provided with • A top swivel. This enables mounting header beams on top of the side shift units. • A rotation anchor.This enables rotating the load by manpower while the load is lifted. •...
• The HPU powers the lifting cylinder and wheel drives. • The boom consists of a telescopic cylinder system, extending in two (SBL900) or three (SBL500, SBL1100) stages • Each unit is provided with a sensor which measures the travelling distance. The sensor is located at the axis of the unit.
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• The boom consists of a telescopic cylinder system, extending in two (SBL900) or three (SBL1100) stages 3.2.1.3 Commonalities SBL500, SBL900, SBL1100 • The units have to be provided with electrical power. • The swivel enables flexible mounting of the header beam.
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Using the buttons and controls of the control panel, the unit can be controlled locally. Other units cannot be controlled by the control panel. Local control is intended for installation and maintenance purposes only. SBL500 SBL900, SBL1100 •...
• flange dimensions match with the Enerpac beams Attention: Header beams of foreign make can be applied if their capacity is sufficient, but Enerpac will not take any responsibility for it. Page 28 of 182...
The Skid tracks form a railway on which the system travels. Skid tracks are provided with a longitudinal ridge to guide the units while travelling. ridge Attention: Skid tracks of foreign make can be applied if their capacity is sufficient, but Enerpac will not take any responsibility for it. 3.2.4 Side shift units The load can be affixed to the header beam by means of side shift units.
3.2.4.2 Type SSU300 Electro motor Rollers 3.2.4.3 SSU600 3.2.5 Options for side shift units 3.2.5.1 Transporting frames Frames for transport and storage are available for all types of side shift units. SSU150 SSU300 SSU600 Page 30 of 182 Document number: ED.03906.00.001.ENG rev01...
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3.2.5.2 Sling anchors Sling anchors enable usage of slings for lifting. The sling anchors are positioned over the anchor plate of the side shift unit. Sling anchors are available for all types of side shift units. SSU150, SSU300 SSU600 3.2.5.3 Extended anchor plates Anchor plates with extended length are available for all types of side shift units.
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3.2.5.5 Rotation anchor The rotation anchor is a device which enables you to rotate a heavy load. It is attached to a side shift unit, which on its turn is attached to a gantry system. The rotation anchor is a passive device; it does not contain any electrics or hydraulics. Rotation is done by hand force.
Depending on the mass of the load to be lifted you can apply lifting lugs • in double-plate type • in single-plate type Attention: Lifting lugs of foreign make can be applied if their capacity is sufficient, but Enerpac will not take any responsibility for it. Page 33 of 182 Document number: ED.03906.00.001.ENG rev01...
3.2.7 The remote-control console The remote-control console enables the operator to control the complete system (all four units simultaneously) on a safe distance. Connection with the system can be made either by a radio link or by wire. The remote-control console enables the operator to control the system on a safe distance. The device is able to control •...
Caution: There is a risk of ice accretion at temperatures below 0ºC. If ice has accreted on machine components, they cannot be used since they may lock up NB: Consult Enerpac if you want to apply the system by other temperatures. Page 35 of 182...
3.4 System configurations 3.4.1 Header beam configurations Commonly used configuration. Two header beams are applied, each of them connecting two units. Transverse stability is provided by the beams. The units contribute to the longitudinal stability. Configuration with two header beams and one longitudinal beam.
NB: Observe the following: • The use of other components than purchased by Enerpac is possible as long as those components are used in accordance with their own specifications. • When you deviate from the configurations as proposed, make sure the correct calculations are made.
Hazard: Using the system with only two legs may cause instability. NB: Enerpac can advise you when you want to use the System in other configurations than the proposed ones. 3.6 Service conditions • The System is intended for hoisting loads.
4 Plan an operation In this chapter, the planning activities for a lifting operation are described. Record the preparation in the checklist given in Appendix A “Checklist for planning”. • Type of operation Lift / lower Move in longitudinal direction Move in transversal direction •...
4.1 Bearing ground pressure calculation For bearing ground calculations use is made of the effect that pressure spreads down in an angle of 45 The calculations are different for units with wheels (SBL500) and for units with roller tracks (SBL900, SBL1100). 4.1.1...
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4.1.1.1 No foundation applied The dimensions of the bearing surface are as follows: Skid height Footprint 2 * Skid height Skid width To calculate the bearing pressure, you might use the following procedure: Parameter Abbrev Value Skid track height Skid height 0.2 [m] width Skid width...
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Example: Load to be lifted 125 metric tons 125/4+2.13+15/4 = ∗ 1.65= 191.5 metric tons / m Ground pressure 0.32 NB: Complete the checklist in appendix A “Checklist for planning”. Attention: the exerted ground pressure may never exceed the bearing capacity of the subsoil. Page 44 of 182 Document number: ED.03906.00.001.ENG rev01...
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4.1.1.2 Foundation applied In order to reduce the bearing ground pressure, timbers of hard wood can be applied as foundation material. Steel plates have to be mounted on top of the timbers. The dimensions of the bearing surface are as follows: Footprint 2 * (Skid height + Timber height) Skid width + 2 * Timber height...
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Surface of one footprint = (Skid width + 2 * Timber height) * width * length [ 2 * (Skid height + Timber height )] The bearing surface of one Unit is formed by four footprints Support ratio, to correct for the gaps between the timbers Support_Ratio = Timber width / (Timber width + Timber gap)
4.1.2 Calculations for units with roller tracks Skid tracks can be put • directly on the ground, if the bearing capacity of the ground is sufficient. • on a foundation: • to compensate unevenness in the ground • to reduce the bearing pressure. Use is made of the effect that pressure spreads down in an angle of 450, as shown below.
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4.1.2.1 No foundation applied The dimensions of the bearing surface are as follows: Skid height Unit length + 2 * Skid height Skid width To calculate the bearing pressure, you may use the following procedure: Parameter Abbrev Value Length Unit length 2.76 m Unit Own mass...
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Example: Load to be lifted 1068 metric tons Ground pressure = 241 metric tons / m NB: Complete the checklist in appendix A “Checklist for planning”. Attention: the exerted ground pressure may never exceed the bearing capacity of the subsoil. 4.1.2.2 Foundation applied Timbers of Azobé...
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• The length of one footprint: Skid height Timber height Unit length Length = Unit length + 2 * (Skid height + Timber height) To calculate the bearing pressure, you may use the following procedure: Parameter Abbrev Value Length Unit length 2.76 m Unit Own mass...
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Pressure on the ground [metric tonnes / m Example: Load to be lifted 1068 metric tons Timbers: Width 0.10 m Height 0.10 m 0.03 m Measure 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:...
Caution: though all limits for the capacity, lifting height, skew and environmental influences are either calculated or tested by the Enerpac consciously, during lifting operations these parameters may interfere with each other in a negative way. Test situations differ from real life situations! 4.2.1...
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4.2.1.2 Use of load charts When the centre of gravity 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 • a load of 1000 kN •...
Enter the load in the checklist given in Appendix A “Checklist for planning”. NB: Always determine the force on the side shift unit, even for relatively light loads. In case of any doubt, consult Enerpac. Attention: the force on the side shift units shall never exceed their lift capacity.
4.4 The bearing capacity of the header beams The bearing capacity of the main header beams depends on position of the load: the closer to the centre, the less the capacity of the header beam. The capacities of the header beams in relation to the position of the load are given in the load charts in Ref 5 “Technical handbook”.
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Earlier purchased Enerpac / Hydrospex Header Beams may be applied if their capacity is sufficient. • Header beams of foreign make can be applied if their capacity is sufficient, but Enerpac will not take any responsibility for it. Page 57 of 182...
4.5 Side load Side load may endanger the stability of the System. Side load can be caused by • Wind: • Size of the object • Windspeed • Height of the header beams • Lifting height • Bearing ground not levelled out •...
5 Install the System This chapter describes how to install the System as well as the preparations which have to be made for the working location. Fully complete the checklist as given in Appendix A “Checklist for planning”. Verify the lifting capacity of your lifting means with reference to the weight of the parts to be hoisted. The weights are given in Ref 5 “Technical handbook”.
Lifting eyes Fork holes Transporting a unit in vertical position can be performed by • Using a forklift truck. Use the fork holes of the unit. Attention: In order to prevent damage to the wheels of the units: keep the bottom of the unit at a height of at least 300 mm the unit should not lean back •...
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Loosen and remove the four bolts of the wheel cover plate. Then remove the cover plate. Attention: once the screws are loose, the cover can fall out Remove the eight head bolts which are positioned circular in the top ring. Hoist the swivel and the top ring from the telescopic tubes.
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Make sure the side hole is positioned right above the electric box. Attach the lock plate to the long edges of the lowest tube. Ensure that the hole in the lock plate is positioned in line with the side hole of the lifting yoke. The lock plate is attached with rods: •...
Attention: Only rotate the unit in this way, to prevent the unit from tumbling. 5.1.3 Hoisting skid tracks The skid tracks can be hoisted: • by a forklift truck. Use the fork holes • by a crane. Use the two lifting eyes. Lifting eyes Forklift holes (not present in all systems) 5.1.4...
5.1.5 Hoisting a side shift unit To hoist the SSU130 and the SSU300 side shift unit, observe the following. 5.1.5.1 SSU300 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.
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5. Store the locking pin in one of the pipes 6. Hoist the side shift unit out of the transportation frame. Use all lifting eyes. For storing the side shift units in the transportation units, proceed in reverse order. Attention: •...
Locking pin of frame Locking pin of side shift unit Forklift hole To take 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.
Lifting holes 5.2 Place the skid tracks Correct positioning of the skid tracks ensures 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 the system can operate safely.
• If you stack timbers then leave no slack in between, to avoid risk of spring. • Put the timbers horizontally, not vertically. 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.
• Support the locations where the skid tracks are attached to each other. • The gap between the timbers shall be smaller than the width of the timbers. gap width 5.2.3 Align the skid tracks Align the Skid tracks according to the following requirements: Front view Side view Alignment requirement...
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(top view) The skid tracks shall have no skew 0.2° (front view of one skid track) The skid tracks shall not incline 0.2° (side view of one skid track) The skid tracks shall be flat 5 mm over 3 meter (side view of one skid track) The surfaces of the segments of the skid tracks shall be well aligned.
5.3 Put the units upon the skid tracks To put the units upon the skid tracks proceed as follows: 1. Make sure the travelling distance sensor is in transport position. 2. Put the units on the skid tracks • Observe the hoisting instructions as given in section 5.1.1 “Transporting a unit”.
5.4 Connect the power cables Connect the power cables to units. Use the sockets on the electrical cabinet. The male-type power socket is for power input, the female type for power output. Power-in/out There are two options for connecting the units. Pick one, according to your own demands. •...
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Attention: Never put the boom in upright position or lower it • when something is attached to it since the tilting cylinders are not designed to bear additional weight. • while the boom is being extended, since the unit might tumble due to the different centre of gravity Proceed as follows: Remove the three shafts from the frame:...
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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. Put the shafts back into position. Play with the buttons on the control panel for finepositioning the boom, to enable restoring of the shafts.
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. 5.6 Mount the header beams 5.6.1 Assemble the modular beam Modular beams are optional. When you apply the modular header beam then assemble it as follows: Put two sections male / female together and align the holes...
Tighten the bolts according to the table in Appendix H “Torque settings”. 5.6.2 Mount the lifting lugs Lift the header beam on top of two supports. Put the lifting lugs over the header beam symmetrically. Page 76 of 182 Document number: ED.03906.00.001.ENG rev01...
5.6.3 Mount the header beam on top of the cylinders To mount the Header Beams on top of the Units proceed as follows: Remove the six bolts at the top of the swivel plate Bolts Locking strips Remove the locking strips. Swivel Distance plate...
When you apply longitudinal beams (see section 3.4.1 “Header beam configurations”), make sure that those longitudinal beams are securely fastened to the header beams. Enerpac provides a solution for mounting the longitudinal beams. Contact Enerpac if you are going to use longitudinal beams.
5.7.2 Mount the rotation anchor If you apply the rotation anchor, then proceed as follows: Use the locking pins and the safety clips to attach the rotation anchor to the side shift unit. Locking pin and safety clip Use the lifting hole to suspend the load to the rotation anchor.
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Put the side shift over the header beam. NB: Preferably put the side shift units with their chain-boxes at the same side of the header beam. This makes setting of the running direction of the side shift units more logical. Place the anchor block Lock the anchor with the locking strips or locking pins.
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Remove the locking pins on both sides If you’re going to apply a rotation anchor, then mount the rotation anchor If you’re going to apply slings then mount the sling anchor. If you’re going to apply a top swivel kit then mount the kit.
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10. Remove pins before use. Otherwise the system cannot hinge around the anchor plate pins. Attention: ensure that the cable is mounted in such a way that it cannot get pinched. See section 5.1.5 “Hoisting a side shift unit” 11. Hoist the side shift unit out of the transportation frame.
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13. Place the anchor bloc. 14. Lock the anchor with the locking strips or locking pins. Page 83 of 182 Document number: ED.03906.00.001.ENG rev01...
5.7.4 Mount the SSU600 1. If you want to apply the top swivel: 1. Unscrew the top plates from the side shift unit and remote the top plates. 2. Put the top swivel on top of the unit and fix the bolts. Use the lifting lugs of the top swivel to hoist.
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4. Put the side shift on the header beam. NB: Preferably put the side shift units with their chain-boxes at the same side of the header beam. This makes setting of the running direction of the side shift units more logical. 5.
5.7.5 Connect the cable of the side shift unit 1. Connect the cable on the cable reel with the side shift. 2. Connect the cable on the cable reel with the side shift. Connection eye Connect the strain relief of the cable to the connection eye Attention: ensure that the cable is mounted in such a way that it...
3. Feed the cable it through the guiding guide. Use the provided strain relief. Cable guide Attention: ensure that the cable is mounted in such a way that it cannot get pinched. Cable reel 5.7.6 Set the moving direction 1. Set the moving direction in such a way that side shift units will move in the same direction.
5.8 Install the rotation anchor If you apply the rotation anchor, then proceed as follows: Use the locking pins and the safety clips to attach the rotation anchor to the side shift unit. Locking pin and safety clip Use the lifting hole to suspend the load to the rotation anchor.
5.9 Install the sling guides To install the sling guides, proceed as follows. Hazard: fingers and hands can be crushed between sling guide and header beam. Remove the cleats and shimming plates from the sling guide. Position the sling guide on top of the header beam.
5.10 Install the remote-control console The remote-control console can communicate with the units: • Wireless, using radio connection. No cables have to be used on the working area, but the radio communication can be disturbed. • Wired, using data cables. Preferable when the radio link is disturbed.
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 the unit and connect it to the next unit. Carry on connecting until all units are connected.
5.10.4 Set up the communication for wireless and for wired connection To set up the communication between the remote-control console and the four units to work, proceed as follows. Reference is made to • the controls on the remote-control console. The layout of the remote-control console is given in section 6.3 “The remote-control console”.
Each remote-control console is provided with a unique code. This code is known by the receivers of the units, so they can recognize their Master’s Voice. NB: Enerpac has set this communication configuration initially. The setting is persistent and remains after switching off the power.
Deselect all units. Switch the unit which has to be programmed on. Select the concerned unit Open the electro cabinet of the unit. Look for the receiver. Press “LEARN” for two seconds When the text “NO ANSWER” disappears from the display of the remote-control console, the remote- control console and the unit are connected.
6 How to control the System 6.1 The emergency buttons The system is provided with emergency buttons. Press an emergency button when you want to stop all movements of the system immediately. Available emergency buttons: • on the control panels of all four units. Indicatior Emergency button When the emergency button is pressed:...
6.2 The control panel of the unit The control panel of each unit is provided with controls and indicators. Using the controls, the unit can be operated. Other units cannot be controlled. This mode is called ‘local control’. Local control is meant to be used during the setting-to-work phase of the system. You use local control: •...
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Schneider [8] it lit. *) ad 2: Applicable for SBL500 and SBL1100 only. *) ad 11: The button is only effective when the unit is in local control. When a load is detected of when the cylinders are extended in more than one stage, the speed is set to low automatically.
6.3 The remote-control console The remote-control console enables the operator • to execute a lifting operation on a safe distance • to control all units simultaneously This mode is called “Remote-control”. Applying the remote-control console ensures that • the moving speeds of the units is synchronized •...
6.3.2 The display A. Height of the cylinders B. Load on the complete C. Direction of the arrow: : Lifting, lowering system with reference to the unit. → : Travelling direction : Side shift Tot. 4614 kN Ram_1 Ram_2 Ram_3 Ram_4 Position mm 6285 ...
The mechanical locking system provides additional safety by preventing unintended lowering. The mechanical locking system is available for SBL500, SBL900 and SBL1100. The system makes use of wedges, which are mounted on each stage of the boom. The wedges are mounted manually.
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Proceed as follows: Lower the gantry for 100 mm. The top sections lower. NB: The 100 mm space is used to enable releasing the wedges afterwards. Caution: If there is not enough space is left for extension, the wedges cannot be released anymore.
6.5 Rotate the load using the rotation anchor Attention: Rotating the load is a potentially dangerous operation, due to the fact that the load is suspended to one single point. Hazard: Not following the rules given in this section may cause damage to the lifting system and to the load.
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• Preferably put the load in low position while it is rotated. • Make sure the centre of gravity of the load is perpendicular underneath the lifting hole of the rotation anchor, in order to prevent swinging of the load while it comes free from the ground. Page 103 of 182 Document number: ED.03906.00.001.ENG rev01...
• Be aware that wind may rotate the load if the centre of gravity of the load is not at the same position as its geometrical centre. 6.6 Limiting devices • When the system is in remote-control, it will stop moving when the difference of height of the cylinders exceeds 24 mm.
Precondition is, that the system has been set to work completely, and that you are familiar with the operation if the system. NB: Operation of the system is only allowed for personnel certified by Enerpac as authorised operator. 7.1 Main directions 7.1.1...
personnel prior to the lifting operation. Signals shall always be visible or audible. No action shall be taken unless signs are clearly understood. • Load handling personnel shall obey any stop signal. NB: Pay attention to the “Hydraulic fluid safety information” as listed in Appendix G “Hydraulic fluid safety information”.
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Verify that power on is lit, and motor failure and side shift overload are dimmed. Set the unit to Local Control Select the required speed Perform the operation you want to: • Extend or retrack the cylinder • Move the unit •...
7.3 Suspend the load 7.3.1 Side shift units or lifting lugs To suspend the load, use side shift or lifting lugs. Attention: Do no place the sling directly over the header beam. (front view) 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 free from the ground.
(side view) Lifting slings have to be plumb within a tolerance of 0.2°. This is especially applicable for tilting operations; see section 7.9 “Tilt the load”. Hazard: exceeding the limit of 0.2° will cause dangerous lateral forces. 7.3.2 Sling guides To suspend the load using sling guides, proceed as follows: Position the slings over the sling guides.
7.4 Lift the load This section describes how to lift the load. In the procedure below reference is made to • the controls on the remote-control console; see section 6.3 “The remote-control console”. • the controls and indicators of the units; see section 6.2 “The control panel of the unit”. Proceed as follows: Record all activities during the operation using the form given in Appendix D “Recording a lifting operation”.
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Activate all four units on the remote-control console. Reset the measured heights of all units by pressing “zero lift”. The current heights of the cylinders will be taken as the new reference points. The height counters on the display will start counting from zero.
7.5 Move the load in longitudinal direction To move the load, all units travel synchronously. The remote-control console is to be used. Proceed as follows: Record all activities during the operation using the form given in Appendix D “Recording a lifting operation”.
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Activate all four units on the remote-control console. Select the travelling speed of your choice. Select “low” if the system is carrying a load. If the system detects a load, or if the units are extended for more than the first stage then “Low” is selected automatically.
7.6 Synchronize the positions of the units While the units travel, their relative positions are kept constant automatically by regulating their individual travelling speeds. Use is made of a sensor which measures the travelling movements of the unit. sensor The sensor starts measuring from zero every start. Therefore, a unit may get out of rectangular position when the system has stopped moving several times.
7.7 Move the load in transversal direction For moving the load in transversal direction, the moving capability of the side shift is applied. Caution: Side shift is a separate system. Side shifting will not stop when overload in one of the units occurs.
Activate all four units on the remote-control console. Move the selected side shift units. 10. Switch the unit off 11. Switch the remote-control console off 7.8 Rotate the load Be sure all personnel is outside the declared safety zone. Lift the load using the gantry system. Make sure stop-guide wires are in place and manned.
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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. NB: 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 To tilt a load, proceed as follows: Record all activities during the operation using the form given in Appendix D “Recording a lifting...
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Set all units to Remote-control Set the speed on the remote-control console to slow. Select the two ‘passive’ units on the remote- control console 10. Manoeuvre the header beam of the units attached to the (future) bottom of the load right above the load.
Main problems Load value “–300” displayed Faulty or loose wiring Check the wiring (large negative) Call Enerpac All units selected, but none Cylinder at end position? moves up One of the hydraulic motors stopped Press the START button on the...
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Height measurement cable snapped Check the cable “Load measurements out of Sensor defect Replace the sensor or range” contact Enerpac. Fault in the wiring Check the wiring “Drive sensor error” One of the travelling distance Change the sensor or contact (All Units stop driving) measuring devices is defect.
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Hazard: Performing repairs on the system may cause dangerous effects when not executed by well- skilled personnel. NB: The table is meant as a first aid kit. Contact Enerpac if you need assistance. Page 121 of 182 Document number: ED.03906.00.001.ENG rev01...
8.3 Repair the wire stroke sensor If the wire has to replaced, the stroke sensor has to be calibrated as well. This section describes both activities. NB: The wire is mounted permanently. The procedure is only applicable for reparation purposes. After the wire was mounted, the system has to be calibrated.
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To calibrate, proceed as follows: Preconditions: • The remote-control is switched off • All units are switched off. Switch the remote-control console on. Set “Speed” on the remote-control console to the ‘hare’ (high speed) Press “Zero lift” and keep it pressed while you switch the remote-control console on.
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Extend the cylinders to the very maximum position 10. Deselect the units. The stroke sensors have been calibrated. The message “Calibration succeeded” is shown. Attention: If communication was poor during calibration, the following message appears: ”Calibration failure”. If so, then restart the procedure. 11.
9 Storage 9.1 System When the system is stored then retract all jacks. Requirements for storage of the System: • During short-term storage, especially in the open air, cover the units with a tarpaulin in order keep electrical and other moisture-sensitive components dry. The tarpaulin is not included in the delivery, but can be added as an option.
>200 mm 9.3 Remote-control unit Store the remote-control with a maximum charged battery in case of storage for more than one month. After six months of storage the battery will still be charged for approximately 40% in case of an ambient temperature of 25°C.
Enerpac. • Only apply spare parts provided by Enerpac. If non-Enerpac parts of are applied, all guarantees will be void. NB: If the system has been idle for more than 12 months than it shall be inspected prior to use completely.
Only perform maintenance work after the powerpack has been shut down. Before starting maintenance, make sure the powerpack is secured against unauthorized use. Put up warning signs. Make certain that the hydraulic system is not under pressure. Use the manometer. If maintenance has to be executed while the system is running then a person has to be present to supervise, and to stop the machine if needed.
10.3 Mechanical Perform maintenance on the mechanical part according to the list as shown below. Record all activities in Appendix E “Logging Maintenance”. Subject Action 1. Main construction 1.1. Main construction Visual check of all welding Visual check painting Visual check on corrosion and damages Check all bolts.
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1.8. Stroke sensor Check the stroke sensor. See section 10.3.9 “Check the stroke sensor”. 1.9. Replace the oil of the Replace the oil fo the gearboxes. See section 10.3.11 “Replace the oil of the gearboxes”. gearboxes 2. Chain of the units 2.1.
10.3.1 Lubricate the driving chains 10.3.1.1 SBL500 The chain connects the gearbox with the driving shafts. To lubricate the chains proceed as follows: Make sure the power supply has been switched of Unlock the front doors and open them Visually inspect the chains and the gears...
Verify that the wheel of the travelling distance measuring device runs fine 10.3.2 Tension the driving chains 10.3.2.1 SBL500 The motor is mounted on a subframe which can move in slotted holes. Slotted hole To tension the chain, proceed as follows: Page 132 of 182...
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1. Loosen the four bolts of the subframe 2. Tension the chain by moving the subframe. The slack in the middle of the chain shall be 10 mm. Use hand power. Caution: tensioning the chains too tight might harm the driving mechanism 3.
10.3.2.2 SBL900, SBL1100 To tension the drive-chain, proceed as follows: • The gearbox is affixed to the frame of the unit with 6 bolts which can shaft gearbox move in slotted holes. • The bearings of the intermediate shaft are affixed to the frame of the unit with 6 bolts, which can move in slotted holes Loosen the bolts of the shaft...
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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 then continue with the next steps. Max 10mm Unscrew the four bolts [1] at the rear side of the unit (so the side of the stairs) …...
Tighten the bolts. Inspect the roller chain: • Check he bolts on damage • Make sure the bolts of the chain are tightened (45 Nm) 10.3.4 Lubricate the side shift units The side shift units are provided with chains, which have to be lubricated. Use “Kroon Oil multi-purpose grease 3”.
10.3.5 Lubricate the swivel Lubricate the nipples of the swivel; two at both sides. Use 10 strokes of Kroon Oil multi-purpose grease 3. 10.3.6 Lubricate the booms Perform this procedure: • At the regular maintenance intervals • In case of vibration of the booms during operation. •...
Remove dirt. You might apply a filler knife. Clean the ram with cleaning spirit Wipe the ram dry. Use a lint free cloth. Saturate a rag and lubricate the booms on their running surfaces (the mating surface of the guide pads) with synthetic motor oil, for instance 10W40. 10.3.7 Measure the wear of the guiding pads Guiding pads are mounted inside the booms.
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The principle of measuring and adjusting is as follows: • The pads are fixed to the fixing plate. • As the pads wear, you have to move the fixing plate inwards by turning the adjusting bolts. In this way the pads stay in touch with the inner boom. •...
2. Enter the result of the inspection in the checklist given in F “Wear of the pads”. 3. Continue for the pads of the other sections 4. When the pads are worn out, replace them. See also section 10.3.6 “Lubricate the booms”. 10.3.8 Adjust the guiding pads Guiding pads are of plastic fabric and are subject to wear.
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Adjusting the guiding pads is done stage by stage, by tensioning the adjusting bolts. The procedure has to be executed preferably by two persons. NB: This accurate job should preferably be executed by Enerpac people. 1. Put the unit horizontally with a tolerance of 0.2 2.
9. Repeat the steps [2] .. [8] for the new stages 10. Repeat the steps [1] .. [9] for all units NB: Mounting, adjusting and dismounting of the guiding pads should preferably be done by Enerpac people. Caution: Incorrect mounting or adjusting of the guiding pads may cause severe risks for the stability of the System.
2. Verify that the wire is attached to the electrical box as indicated. 3. Check whether the wheels run fine. No dirt? No rust? 10.3.10 Tension the chain of the side shift units Tension of the side shift units. NB: The following procedure describes tensioning of the chain of the SSU150. Tensioning of the SSU600 and SSU600 is similar.
Tension the chain by turning the tensioning bolts or moving the gearbox backwards. Tighten the bolts of the gearbox and clamping ring according to Appendix H “Torque settings”. Keep the gearbox level. 10.3.11 Replace the oil of the gearboxes Perform a purity test on the oil of the gearbox. Change the oil of the gearbox If the yearly purity test points out or with a periodicity as given in the maintenance table.
All replacement parts including the ram, hoses, couplings, seals, valves, and caps shall meet or exceed the original equipment manufacturer's specifications. NB: Enerpac strongly advises to apply parts as bought from Enerpac. Hazard: Applying parts which to not apply to the specifications may cause hazards to personnel and the system...
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Perform maintenance on the hydraulics of the system according to the list below Record all activities in Appendix E “Logging Maintenance”. Subject Action 1. Hydraulic pump and tank 1.1. Pump Check on oil leakage Check if the bolts are still tightened Check on damages.
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1.8. Bellhousing Check on damages Check if the bolts are still tightened Replace motor pump coupling 2. Hydraulic connections 2.1. Pipes, hoses and Check on oil leakage and damages brackets Check if the couplings are tightened well. Replace all seals within the piping (Walform) Replace all hoses Replace all plastic brackets 2.2.
The oil in the sump has either to be refreshed or a purity test has to be performed. For minimum requirements reference is made to section 3.3.1 “Main specifications”. 10.4.1.1 SBL500 Proceed as follows: Ensure that the cylinder is completely pulled in Disconnect the hose from to the ball valve ...
While draining, keep an eye on the oil level gauches. Attention: Dispose the oil responsibly 10.4.2 Fill the tank 10.4.2.1 SBL500 To fill the tank, proceed as follows: 1. Make sure • the cylinder of the unit is fully pulled in •...
3. Fill the tank until the maximum level of 50mm below the top of the tank is reached. Use oil type “Shell Tellus T32 or Shell Tellus Artic”. Attention: Do not fill the tank over the maximum. 4. 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.
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• when the clogging indicator shows yellow or red • according to the maintenance scheme 10.4.3.1 SBL500 Clogging indicator To replace the filter element, proceed as follows: Unscrew the return filter cap Remove the internal filter element Put a new filter element.
10.5 Electrics Perform maintenance on the electrics of the system according to the list below. Record all activities in Appendix E “Logging Maintenance”. Subject Action 1. Electro motor 1.1. General Check on damages Wipe it clean and free from dust 2.
11 Quality Not applicable. 12 Dismantling the system To dismantle the system at the end of its lifetime, proceed as follows: • Drain the fluids like: hydraulic oil, lubricating oil, coolant, fuel. • Remove the batteries. • Dismount the electric components and electric wiring. •...
Appendices Checklist for planning Project Project Customer Location Date 2. Planning operation Type of operation Lift / lower Move in longitudinal direction Move in transversal direction The system Lifting capacity of the most heavily loaded unit ...
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Stage extension 1 / 2 / 3 Capacity in highest stage … kN The environment Bearing capacity of the subsoil ….. Tonne/ m² Is additional supporting material under the skid tracks necessary? … m/s Maximum permissible wind speed X-direction ...
Checklist for installing the System 1. Project Project Customer Location Date 2. Planning Checklist A “Checklist for planning” is completed and signed off. 3. Foundation Foundation underneath skid tracks has been put in accordance with the instructions in this manual. If foundation is applied 4.
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8. Visual inspection Visual inspection: no excessive rust. 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 to slip) ...
Final checks Project Project Customer Location Date 2. Checks Checklist B “Checklist for installing the System” is completed and signed off. No parts of the portal lift are damaged No leakages of the hydraulic components are visible ...
Recording a lifting operation 1. Project Project Customer Location Date 2. Recording of activities Activity Time The checklist in Appendix A “Checklist for planning” has been completed and signed off Checklist B “Checklist for installing the System” completed and ...
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Activity Time 3. Commitment Date: Executed by Signature Date: Approved by Signature Page 161 of 182 Document number: ED.03906.00.001.ENG rev01...
E. Logging Maintenance Hydraulics Subject Action Person Date 1. Hydraulic pump and tank 1.1. Pump 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 1.2.
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4. Cylinders 4.1. Common Check on leakages Check if the bolts are still tightened Replace all seals Grease the bearings Mechanical Person Date Subject Action 1. Main construction 1.1. Main construction Visual check of all welding Visual check painting Visual check on corrosion and damages Check all bolts.
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Subject Action Person Date 1. Cables and connectors 1.1. General Check on damages 2. Devices and cabinets 2.1. General Check on leakages and damages Check if the bolts and nuts are still tightened Replace all seals 2.2. Main switch Replace the main switch 2.3.
F. Wear of the pads NB: To be able to calculate the wear of the pads, measure their thickness: • before first use of the System • when new pads are mounted. • Attention: Replace the pads when the wear exceeds 1.5 mm. All units in [mm] Boom 1 Boom 2...
Hydraulic fluid safety information SAFETY DATA SHEET According to EC No 1907/2006 as amended as at the date of this SDS Shell Tellus S4 VE 46 Version 1.2 Revision Date 02.01.2020 Print Date 03.01.2020 Identification of the substance/mixture and of the company/undertaking 1.1.
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Composition/information on ingredients 3.1. Mixtures Chemical nature Blend of polyolefins and additives Hazardous components Chemical name CAS-No. EC-No. Registration Classification Concentration [%] number (REGULATION (EC) No 1272/2008) Distillates (Fischer - 848301-69-9 Asp. Tox.1; H304 85- 95 Tropsch), heavy, C18- 482-220-0 50 –...
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Methods for cleaning Slippery when spilt. Avoid accidents, clean up immediately. Prevent from spreading by making a barrier with sand, earth or other containment material. Reclaim liquid directly or in an absorbent. Soak up residue with an absorbent such as clay, sand or other suitable material and dispose of properly 6.4.
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washed and dried thoroughly. Application of a non-perfumed moisturizer is recommended. For continuous contact we recommend gloves with breakthrough time of more than 240 minutes with preference for > 480 minutes where suitable gloves can be identified. For short-term/splash protection we recommend the same but recognize that suitable gloves offering this level of protection may not be available and in this case a lower breakthrough time maybe acceptable so long as appropriate maintenance and replacement regimes are followed.
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11.1. Information on toxicological effects Basis for assessment Information given is based on data on the components and the toxicology of similar products. Unless indicated otherwise, the data presented is representative of the product as a whole, rather than for individual component(s). Information on likely routes of Skin and eye contact are the primary routes of exposure although exposure may occur exposure...
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12.2. Persistence and degradability Product: Remarks: Not readily biodegradable., Major constituents are inherently Biodegradability biodegradable, but contains components that may persist in the environment. 12.3. Bioaccumulative potential Product: Remarks: Contains components with the potential to Bioaccumulation bioaccumulate. Partition coefficient: n- log Pow: >...
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Not applicable for product as supplied. MARPOL Annex 1 rules apply for bulk shipments by sea. 15. Regulatory information 15.1. Safety, health and environmental regulations/legislation specific for the substance or mixture REACH - List of Product is not subject to Authorisation under REACH substances subject to authorisation (Annex XIV)
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NOEC/NOEL No Observed Effect Concentration / No Observed Effect Level OE_HPV Occupational Exposure - High Production Volume PBT = Persistent, Bioaccumulative and Toxic PICCS Philippine Inventory of Chemicals and Chemical Substances PNEC Predicted No Effect Concentration REACH Registration Evaluation And Authorisation Of Chemicals Regulations Relating to International Carriage of Dangerous Goods by uail SKIN_DES Skin Designation...
Torque settings Inspect all bolt joints which may pose a hazard to people and machines at fixed intervals and check their torque. Apply the torque values unless indicated otherwise on the drawing. Course pitch Fine pitch [Nm] [Nm] (Copper- (Copper- Nominal Strength grease)
For Ga-drawing and Load chart is made to Ref 5 “Technical handbook”. Pitch of Lifting Article Height Capacity GA Drawing Load chart wheels unit number [mm] [kN] [mm] 8618 1300 SBL500 03451.01.00.00 03451.50.00.00 03451.70.001 11306 2244 SBL900 03623.01.00.00 03623.50.00.00 03623.70.001 12202 2621 SBL1100 03622.01.00.00 03622.50.00.00 03622.70.001 b.
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Special beams (not in catalogue; maybe extended delivery time): Article Height Width Headerbeam GA Drawing Load chart Length [m] number [mm] [mm] 1025 Connectable 03672.01.00.00 03672.50.00.00 ED.03672.70.118 Obsolete beams: Article Height Width Headerbeam GA Drawing Load chart Length [m] number [mm] [mm] HBSL 125-6...
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Header beam Capacity per sling Sling guide Article number GA Drawing width [mm] guide [kN] 300 – 310 mm HBHSG 03893.01.00.00 03893.50.00.00 480 mm 2500 HBBSG 03892.01.00.00 03892.50.00.00 2. Compatibility of system parts Legend Compatible Not Compatible a. Gantries and header beams All gantries and header beams are compatible to each other.
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d. Lifting lugs with header beam type wide / narrow Header beam type Lifting lugs Narrow Wide LL200 03889.01.00.00-01 LL500 03890.01.01.00-01 LL1000 03890.01.01.00 LLSL200-8 03817.01.00.00-03 LLSL125-10 03647.01.00.00-03 LLSL125-12 03648.01.00.00-03 LLSBL125 02940.01.02.00-01 LLSBL250 02940.01.02.00 e. Headerbeams with side shift units Header beam Side Shift Unit SSU150 03842.01.00.00...
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f. Top swivel kit and side shift unit Side shift unit Top swivel kit TSK150 03842.01.04.00 TSK300 03636.01.10.00 TSK600 03530.01.11.00 g. Side shift sling guide with side shift unit Side shift unit Side shift Sling Guide SSG150 03842.01.03.00 SSG300 03636.01.11.00 SSG600 03530.01.05.00 Page 181 of 182...
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h. Rotation anchor kit and side shift unit Side shift unit Rotation Anchor Kit RAK300 03636.01.12.00 i. Header beams and sling guides Header beam Sling guide HBHSG 03893.01.00.00 NC NC NC NC NC NC NC NC HBBSG 03892.01.00.00 NC NC NC NC NC NC Page 182 of 182 Document number: ED.03906.00.001.ENG rev01...
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