Enerpac SBL1100 Instructions for use

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
Author
Checked
Approved
by
00
Initial
version
2
3 M
arch 2017
D.
Rosier
Th. Westerhof
B. Geerdink
A. Holterman
R. Broenink
01
Added:
-
Transporting frame
-
Index table
- Document lined up with other Gantry manuals:
-
Pictures and illustrations
-
Standardized texts
- ASME B30 implemented
9
May 2017
D. Rosier
R. Bosman
R. Corbeek
R. Broenink
02
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
prescribed
lubricants (Kroon oil)
19 July 2017
D. Rosier
R. Broenink
On request of Ruben Bosman: minimum operating
temperature set to -10 degrees
03
- Changed the extending time during lifting and
added 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
13 March 2018
R. Corbeek
R. Broenink
R. Broenink
04
- Tracks alignment requirements changed.
-
Additional lubrication of the running
surfaces of the booms within the
chapter
“maintenance”.
1
5
March 2018
R. Corbeek
R. Broenink
R. Broenink

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ED.02518.00.001.R08.ENG Page 3
Preface
Dear customer,
This is the manual for assembling, using and maintaining of both the SBL1100 and the SBL900
Super 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.
)
It is essential that the user reads
this manual completely before
start working
with the System.
xAll information, illustrations and technical data in this manual are applicable to the System as it
was at the time of issuing of this manual.
xWe 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.
xIf this manual becomes unreadable, in whole or in part, you can order a copy by providing us
the number given on the front cover.
xDespite the fact that this manual has been drafted with great care, we cannot guarantee that
it does not contain any errors.
xThe 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 shall
under 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:
xClick the red icon for lifting
xClick the green icon for lowering
xClick the blue icon for ending the operation
© All rights reserved. Nothing in this publication may be duplicated, stored in an automated
database or made public in any form or in any manner, whether electronic, mechanical, by
photocopying, recording or any other means, without prior written approval by Enerpac.
We hope this manual will help you to use the System properly.
Enerpac.

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Contents
Preface _______________________________________________________________________ 3
Contents ______________________________________________________________________ 4
1. 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
2. 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
3. System Overview ___________________________________________________________ 24
3.1. General _____________________________________________________________________ 24
3.2. System specifications __________________________________________________________ 30
3.3. System configurations _________________________________________________________ 33
3.4. Service conditions_____________________________________________________________ 35
4. 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

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4.5. Side load ____________________________________________________________________ 51
5. 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

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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

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1. Introduction
1.1. Manufacturer address
Enerpac Heavy Lifting Technology B.V
Spinelstraat 15, 7554 TS
Hengelo
The Netherlands
Tel. [phone]
Fax. [phone]
Email: [e-mail]
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 of
conformity”which is part of the product delivery.
1.3. Referenced documents
Ref
Name
Identification
Manufacturer
1. Operation of electrical
installations - Low voltage
NEN 3140
NEN
2. Operation of electrical
installations
NEN-EN 50110-1
NEN
3. General rules and safety
requirements for systems
and their components
NEN-EN-ISO 4413
NEN
4. USB stick Wind calculations
Enerpac
5. Technical handbook
Enerpac
6. EC Declaration of
conformity
Enerpac
7. ASME B30.1-2015
Jacks, Industrial
Rollers, Air Casters,
and Hydraulic Gantries.
(
Safety Standard for Cableways, Cranes, D
erricks,
Hoists, Hooks, Jacks and Slings)
American
Society of
Mechanical
Engineers
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.

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1.5. Liability
xPersonnel as well as other people involved in the usage of the System are expected to
have read and understood this manual.
xIn cases of doubt about the use or application of this machine, always contact with
Enerpac for advice and recommendations.
xUnauthorised alterations to the machine may have a deleterious effect on the
characteristics of the machine and may disrupt the control functions. Unauthorised
alterations therefore annul any resultant damage claims against the manufacturer.
xThe risk analysis conducted by Enerpac, intended usage and reasonably foreseeable
incorrect usage of the System were assessed. The instructions in this manual were
drawn up based on this analysis.
xUnauthorised 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 the
equipment is inspected and maintained at the indicated times.
xThe 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”.
xThe System should only be operated by operators with full knowledge of the
applicable safety regulations and the hazards which may arise during use.
xThe System was developed and built according to the officially recognised safety
regulations. However, if the machine is not used as intended:
oThis may pose a risk to the health and lives of operators and bystanders.
oThe System may not function properly or may create hazardous situations.
xThe System should only be used if the machine is in perfect technical condition.
xFaults which may result in hazardous situations must be resolved immediately.
xThe 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 and
adjustment of safety devices and valves and welding work on the System.
Spare parts must always meet the technical specifications given by Enerpac in the
construction file and the component construction lists for the machine. It is recommended to
use original spare parts. In cases of doubt, please contact Enerpac.

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1.8. Personnel and obligations
xOnly 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.
xOnly 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.
xQualification of the personnel is a responsibility of the customer.
xAlways comply with legal minimum age stipulations.
xThe System should only be used, maintained and repaired by properly instructed and
trained personnel. Clearly describe the qualifications of the relevant employees with
regard to use, commissioning, assembly, disassembly and all maintenance and repair
work. If must be performed by third parties, they must receive clear instructions so both
the client and the contractor are up-to-date on the agreements reached.
xThe supervisor and operator are authorized to refrain from following any instructions
from third parties that may pose a risk to the machines or bystanders.
xPersonnel 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.
xWork 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.
xAssembly and disassembly may only be performed by trained installers under the
supervision 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
xIn 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.
xIn other cases, the user may lease or rent the system from the system without
supervisory, operational, maintenance, support personnel, or services from the system
owner. 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 specific
job 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 and
maintenance 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 activities
c) ensure that the system is in proper operating condition, prior to initial use by
xverifying that the Owner has provided this manual.
xverifying that a frequent inspection has been performed.

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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 that
have 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 the
associated 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 be
affected 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 by
a 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:
xpoor soil or support conditions
xwind velocity or gusting winds
xweather conditions
xextreme temperatures
xinadequate lighting
xoperating surface conditions
xexcessive noise proximity to energized sources (e.g., power lines, pressurized
lines)
xensuring that work performed by the rigging crew is supervised by a qualified
person
xensuring 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 the
system's work area.