Users’ Manual

SL60:
Super Lift
- 60 Metric Tonne Hydraulic portal lift system

ED.03098.00.001.R00.ENG
Dear customer,

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

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

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

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

ED.03098.00.001.R00.ENG Page 2
1. Contents

1. CONTENTS ........................................................................................................................................... 3
PREFACE ....................................................................................................................................................... 5
1. GENERAL INFORMATION ............................................................................................................... 7
1.1. GENERAL ......................................................................................................................................... 7
1.2. MANUFACTURER'S ADDRESS........................................................................................................... 7
1.3. DECLARATION ................................................................................................................................. 7
1.4. IDENTIFICATION .............................................................................................................................. 7
1.5. LIABILITY ........................................................................................................................................ 8
1.5.1. Limitations of liability: ............................................................................................................... 8
1.6. APPROPRIATE USE ........................................................................................................................... 8
1.7. APPLICATION LIMITS ....................................................................................................................... 8
1.8. THE BASIC PRINCIPLE ...................................................................................................................... 9
1.9. GENERAL SPECIFICATIONS .............................................................................................................. 9
1.10. MACHINE OVERVIEW .................................................................................................................... 10
2. SAFETY ............................................................................................................................................... 11
2.1. MANDATORY PROTECTIVE GEAR WHILE WORKING WITH OR ON THE SYSTEM ............................. 12
2.2. EXPLANATION OF SYMBOLS IN THIS MANUAL .............................................................................. 12
2.3. EXPLANATION OF SYMBOLS ON THE MACHINE ............................................................................. 13
3. PREPARATION FOR A LIFTING OPERATION.......................................................................... 14
3.1. LIFTING CAPACITY OF THE UNITS .................................................................................................. 15
3.1.1. Minimum load ........................................................................................................................... 18
3.2. CAPACITY OF THE SIDE SHIFT OR LUG ........................................................................................... 18
3.3. CAPACITY OF THE HEADER BEAM ................................................................................................. 19
3.4. SURFACE LOADING FOR FULL SUPPORT OF THE SKID TRACKS ...................................................... 19
3.5. SURFACE LOAD WITH FILLER MATERIAL UNDER THE SKID TRACKS ............................................. 21
3.6. MAXIMUM PERMISSIBLE WIND LOADING ...................................................................................... 23
4. EXPLANATIONS OF METHODS.................................................................................................... 24
4.1. STORAGE ....................................................................................................................................... 24
4.2. HANDLING ..................................................................................................................................... 25
4.2.1. Unit ........................................................................................................................................... 25
4.2.2. Skid tracks ................................................................................................................................ 26
4.2.3. Header beam............................................................................................................................. 26
4.2.4. Side shift ................................................................................................................................... 27
4.2.5. Single lifting anchor ................................................................................................................. 28
4.3. PLACEMENT OF THE SKID TRACKS ................................................................................................ 29
4.3.1. Requirements for the skid tracks .............................................................................................. 29
4.3.2. Check of the skid tracks before use........................................................................................... 30
4.3.3. Requirements for the filler material ......................................................................................... 31
4.3.4. Placement of the filler material ................................................................................................ 32
4.4. PLACEMENT OF THE UNIT .............................................................................................................. 36
4.5. CONNECTION OF POWER CABLE .................................................................................................... 36
4.6. MOUNTING THE HEADER BEAMS ................................................................................................... 37
4.7. MOUNTING THE SIDE SHIFT ........................................................................................................... 38
5. BEFORE LIFTING THE LOAD ....................................................................................................... 39
6. CHECKLISTS ..................................................................................................................................... 41
6.1. PREPARATION FOR A LIFTING OPERATION .................................................................................... 41
6.2. SETTING UP THE PORTAL SYSTEM ................................................................................................. 42
6.3. BEFORE LIFTING THE LOAD ........................................................................................................... 42

ED.03098.00.001.R00.ENG Page 3
7. THE OPERATION OF THE MACHINE ......................................................................................... 43
7.1. THE CONTROL PANEL ON THE UNIT ............................................................................................... 44
7.2. THE INTELLILIFT CONTROL PANEL ................................................................................................ 45
7.3. MANUAL CONTROL ....................................................................................................................... 46
7.4. INTELLILIFT CONTROL ................................................................................................................... 46
7.4.1. About Intellilift.......................................................................................................................... 46
7.4.2. Communication......................................................................................................................... 46
7.4.3. Normal operation ..................................................................................................................... 47
7.4.4. LCD screen ............................................................................................................................... 50
Emergency stop system .......................................................................................................................... 52
7.4.5. Switching off the control panel ................................................................................................. 52
7.4.6. Charging the battery ................................................................................................................. 52
7.4.7. Settings ..................................................................................................................................... 53
7.4.8. Correction of faults................................................................................................................... 56
7.5. INCLINATION SENSORS *OPTIONAL .............................................................................................. 57
8. SPECIAL APPLICATIONS ............................................................................................................... 58
8.1. TILTING A LOAD ............................................................................................................................ 58
8.2. LIFTING WITH TWO UNITS ............................................................................................................. 60
9. MAINTENANCE................................................................................................................................. 62
9.1. LUBRICATION POINTS ................................................................................................................... 63
9.1.1. Side shift ................................................................................................................................... 63
9.2. MAINTENANCE OF THE HYDRAULIC SYSTEM ................................................................................ 64
9.2.1. Draining oil .............................................................................................................................. 65
9.2.2. Filling with oil .......................................................................................................................... 65
9.3. CHAIN DRIVE ................................................................................................................................. 66
9.3.1. Lubricating the chains .............................................................................................................. 66
9.3.2. Tensioning the chains ............................................................................................................... 67
APPENDICES .............................................................................................................................................. 70
APPENDIX A CHECKLIST FOR WORK PREPARATION ................................................................................. 70
APPENDIX B CHECKLIST FOR SETTING UP THE MACHINE ......................................................................... 72
APPENDIX C CHECKLIST FOR LIFTING THE LOAD ..................................................................................... 73
APPENDIX D HYDRAULIC FLUID SAFETY INFORMATION SHEET ........ ERROR! BOOKMARK NOT DEFINED.
APPENDIX E SKID TRACK REQUIREMENTS ............................................................................................... 75

ED.03098.00.001.R00.ENG Page 4
Preface

Preface

Dear customer,

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

Operating an SL system is only permitted if you are certified by Enerpac as an

authorized operator.

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

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

Please note:
In the rest of this manual, the portal lift is also referred to by the term
"Machine".

Note:

This manual is part of the machine.

Only operate the machine after you have been trained, and taking this manual into
account.
Follow the safety instructions exactly!
Also observe the applicable directions to prevent accidents and the generally
recognised safety regulations, as well as the health and safety inspectorate’s
regulations.
All information, illustrations and technical data in this manual are applicable to the
situation existing at the time of publication.
We strive continuously to improve our products and therefore reserve the right to
implement improvements and changes whenever it is necessary and possible to do
so, without any obligation to apply improvements or changes to models purchased
previously.
If this manual should become wholly or partly unusable,
you can order a new replacement copy of it, making reference to the number shown
on the cover.
This manual is continually updated. We welcome suggestions which make the reading
of this manual or the use of the SL system easier or safer.

ED.03098.00.001.R00.ENG Page 5
Preface

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

Improper use of the machine or failure to take the changes

indicated in this manual into consideration may result in
accidents causing damage not only to the machine itself, but also
to objects and goods in its vicinity or mounted to the machine, as
well as injury to people in the immediate area, and possibly even
death.

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 the
prior written approval of Enerpac.

We hope you find your Enerpac machine very useful.

Enerpac Integrated Solutions B.V.

ED.03098.00.001.R00.ENG Page 6
General Information

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

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

1.1. General
This manual applies to a complete SL60 system.

1.2. Manufacturer's address

Enerpac Integrated Solutions B.V.

Opaalstraat 44 7554 TS
Hengelo Netherlands
Tel. +31 - 74 - 242 20 45
Fax. +31 - 74- 243 03 38
Email: [email protected]

1.3. Declaration
EC Declaration of Conformity according to Directive.
See inside of title page.

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

Enerpac Integrated Solutions B.V.

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

ED.03098.00.001.R00.ENG Page 7
General Information

1.5. Liability

In the risk analysis conducted by Enerpac, intended usage and reasonably

foreseeable incorrect usage of the SL portal lift system were assessed. The
instructions contained in this manual have been drawn up in accordance with the
assessment findings.

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

If there is any doubt about the use or application of this machine, please contact
Enerpac for advice and recommendations.

Unauthorized alterations to the machine may have a detrimental effect on the

characteristics of the machine and may disrupt the control functions. Unauthorized
alterations shall therefore result in any consequential claims against the
manufacturer being rendered null and void.

1.5.1. Limitations of liability:

We accept no liability whatsoever for damage arising from:

- this equipment;
- items and equipment owned by third parties;
- vehicles;
- personal injury.

1.6. Appropriate use

The SL60 hydraulic portal lift is a four point lifting system. All four units must always
be used when lifting or transferring various objects. The centre of gravity (C.O.G.) of
the load must always remain within the four feet and under the header beam.

The machine has been designed to be controlled using the associated Intellilift
remote control. This will ensure that the user stays out of reach of the machine whilst
it is in operation.

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

The machine must not be used in potentially explosive environments.

1.7. Application limits

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

ED.03098.00.001.R00.ENG Page 8
General Information

1.8. The basic principle

Each lifting unit consists of a base frame with its own drive and hydraulically operated
telescopic masts.

The internal propulsive force is provided by a set of hydraulically driven wheels.

One of the unique characteristics of the SL60 portal lift is the integration of the power
source into the base frame. In contrast to conventional systems, this means no
separate power source and no hoses or data cables between power source and units.

The beams across the top of the units create a portal.

The load is affixed to the beam by means of a side shift module.

1.9. General specifications

Each separate unit has a load carrying capacity of 150kN.
The exact permissible loading is described in detail in Chapter 3.

The hydraulic pumps have a fixed stroke volume; due to the built-in frequency
regulator, the machine possesses several speeds.

Specification of the power source:

Voltage :360 to 480 V AC/ 3-phase
Current :7.5 A per unit
Frequency :50-60 Hz
Power : 2.2 kW per unit
The units feature automatic phase selection according to the rotation direction of the
electric motors.

Noise pressure: 77 dB(A) measured at ear height at nominal loading one metre
away
from any unit’s electric motor.
Temperatures
Minimum operating temperature of the machine: - 25°C
Maximum operating temperature of the machine: 50°C
Minimum storage temperature of the machine: - 25°C
Maximum storage temperature of the machine: 60°C
Minimum storage temperature of the Intellilift control panel: -20°C/0°C*
Maximum storage temperature of the Intellilift control panel: 60°C/45°C*

*While charging the battery.

Note:
There is a risk of ice accretion at temperatures below 0ºC.
If ice has accreted on machine components, they cannot be
used because they may lock up.

ED.03098.00.001.R00.ENG Page 9
General Information

1.10. Machine overview

4
3
3

2 1
2

2
1

1) Skid track Required

2) Lift unit Required
3) Header beam Required
4) Lifting lug Optional
5) Side shift unit Optional

ED.03098.00.001.R00.ENG Page 10
Safety

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

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

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

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

Only operate the SL system if you have been certified by Enerpac as an authorized
operator.

Only use original Enerpac spares to repair machine faults.

Maintain concentration during the work. Inattention may cause serious injury to
yourself or others, or even a fatal accident.

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

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

Work exclusively according to the checklists: during preparation

for the lifting operation, system construction, and for lifting the
load.
Failure to adhere to the checklists may result in serious injury to
the user, possibly even death.

ED.03098.00.001.R00.ENG Page 11
Safety

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

Ensure that you and other people in the vicinity and during the operation of the portal
lift wear a safety helmet and that the applicable safety regulations are observed.
Wear safety gloves*, safety footwear and safety glasses.

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

2.2. Explanation of symbols in this manual

The following symbols are used in this manual to indicate various specific
instructions.

 Indicates to the user that something needs to be filled in on the

checklist.

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

General warning to the operator of possible damage to

equipment and to the environment in general.

Draws the user's attention to risks to personnel if work

instructions are not followed precisely.

ED.03098.00.001.R00.ENG Page 12
Safety

2.3. Explanation of symbols on the machine

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

1. Risk of pinching to parts of the hand

3 stickers (around the cylinder + chain)

2. Risk of trapping parts of the foot

4 stickers (on protective caps)

3. Risk of electric shock

2 stickers (on motor and switch box)

ED.03098.00.001.R00.ENG Page 13
Preparation for a lifting operation

3. Preparation for a lifting operation

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

 Mass of the load.

 Center of gravity of the load.
 Dimensions of the load.
 Maximum lifting height.
 Allowable pressure on the subsoil before subsidence happens.

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

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

 Lifting capacity of the most heavily loaded unit.
 Capacity of the side shift or lugs
 Capacity of the header beams.
 Load capacity of the subsoil.

Finally, the maximum acceptable wind speed should be calculated.

This preparation results in:

A checklist for use while setting up the machine.
A checklist the operator must follow during use of the machine.

It is of the utmost importance to read this whole chapter

carefully before setting up the machine.

Failure to prepare correctly for a lifting operation may

result in total loss of machine stability during use.

ED.03098.00.001.R00.ENG Page 14
Preparation for a lifting operation

3.1. Lifting capacity of the units

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

Dimensions of the units, beams, side shift, and skid tracks

are shown in the various drawings supplied with the machine.
This information can be used to determine the required lifting
height.

 Fill the maximum lifting height into the checklist in appendix A.

The portal lift system comprises four units. Given the fact that each unit is
provided with a telescopic hydraulic ram, the pressure varies according to the
phase. The capacity for each phase is 150 kN. This results in the following
pressures:
1st stage: 75 bar, → lifting height: 0 mm to 1400 mm
2nd stage:133 bar, → lifting height: 1400 mm to 2959 mm

Theoretically, this means that the maximum loading is 4  150kN  600 kN.
However, this only applies when the load is distributed evenly, i.e. when the COG
is positioned such that each lifting unit carries exactly the same load. This is
naturally a situation that never arises in practice. In order to prevent overloading
of the portal lift, the loading table must be used.

The figure shows the orientation of the table with respect

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

ED.03098.00.001.R00.ENG Page 15
Preparation for a lifting operation

The stability of the system is such that if the COG is positioned in

the centre of the machine, then any movement of the COG out of
the ideal centre will result in reduced stability of the overall
system.

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


Use the load chart to fill the maximum force per unit occurring
during the lifting operation into checklist A
(Only for the unit under the heaviest load)

ED.03098.00.001.R00.ENG Page 16
Preparation for a lifting operation

ED.03098.00.001.R00.ENG Page 17
Preparation for a lifting operation

3.1.1. Minimum load

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


Use the load chart to fill the minimum force per unit occurring
during the lifting operation into checklist A
(Only for the unit under the lightest load)

3.2. Capacity of the side shift or lug

The force on each anchor point cannot under any circumstances be greater than
the capacity of the side shift unit or lug. The capacity of the side shift and lug is
shown on the set of drawings supplied with the machine. The corresponding
drawing is indicated by the number on the type plate on the side shift or lug.

Always determine the force on each anchor point. Even for

relatively light loads. This can be done using a centre of gravity
calculation. The preparer is expected to possess this skill. In case
of doubt, please contact Enerpac.

 Fill the maximum anchor load into the checklist in

appendix A

ED.03098.00.001.R00.ENG Page 18
Preparation for a lifting operation

3.3. Capacity of the header beam

The force on each anchor point may not in any case be greater than the capacity
of the header beam. The capacity of the header beams is shown in the load chart
supplied with the beam. The number on the load chart corresponds to the number
on the type plate.

 Fill the maximum permissible beam load into the checklist

in appendix A

3.4. Surface loading for full support of the skid tracks

If it is not possible to have the underside of the skid tracks 100% supported,
Azobé wood and steel plates must be installed under the skid track – see section
3.5.
The surface loading may be defined as the loading on the subsoil, exerted by the
guide rails.

If the following requirements cannot be met, then the skid tracks

must be set up using filler materials.
In this case, the force on the subsoil is determined in section 3.5.

The rails may not be skewed in side

view. The angle from the horizontal
plane must be less than 0.2° in both
axes.

The incline angle of the running surface

must not be more than 0.2°.

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

The default height h is 133mm and is already incorporated in the formulas
The surface loading may be calculated by means of the formulas below; a small
extra safety factor is already included in these formulas.
ED.03098.00.001.R00.ENG Page 19
Preparation for a lifting operation

Metric system
F 9
 *1.7
3,0968
σ = surface load, [metric tonnes/m2]
F = load on a particular foot, [kN]

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

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

The surface load occurring with complete under-filling of the skid

tracks must always be less than the permissible surface load.

The height of the skid tracks may be found in appendix G

 Fill the maximum surface load into the checklist in

appendix A

ED.03098.00.001.R00.ENG Page 20
Preparation for a lifting operation

3.5. Surface load with filler material under the skid tracks
If it is necessary to under-fill
the rails to compensate for
unevenness in the subsoil, or to
create a lower surface loading,
then a number of matters must
be borne in mind!

The points of attention are

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

Only use filler materials in accordance with section 4.3.2

Read section 4.3.2 before proceeding any further in this chapter.
In case of doubt, please contact Enerpac

Geometrical requirements for the filler material:

Description Parameter Requirements Comment

Length of the filler material L > L Min. Max. 629mm
Length between plates M > M Min.
Width of the filler material B > H and > 250 mm
Space in between S < 250 mm

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

ED.03098.00.001.R00.ENG Page 21
Preparation for a lifting operation

Length measurements in metres

Description Formulas
O = filler material ratio B
O
BS
L net. = Effective Length
Please Note: L net can never be greater than 0.629 m Lnet.  0.14  2 * H
2
σ = surface load, [metric tonnes/m ] F  10
 *1.7
F = load on a particular foot, [kN] 26 * L min* O

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

Example:

The expected maximum load on one of the feet is 150 kN.

B= 400mm  0.40m
H= 200mm  0.20m
S= 250mm  0.25m

The resulting maximum surface loading is then:

B 0.4
O  0.615 
BS 0.4  0.25

L min  0.14  2 * H  0.54m.  0.14  2 * 0.2

F  10 150  10
 *1.7  31.75ton / m 2  *1.7
26 * L min* O 26 * 0.54 * 0.61

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

The formulas in this section are based on the

the Enerpac Rollertrack

 Fill the maximum surface load, the L, W, H and the S from

the checklist in appendix A

ED.03098.00.001.R00.ENG Page 22
Preparation for a lifting operation

3.6. Maximum permissible wind loading

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

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

On the left, you will find an example

of a fully completed form:

Only certain parameters have to be

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

Do not forget that the wind speed

and direction may change during
lifting.

When lifting, always assume a worst-case scenario. The wind can

be unpredictable, quickly changing speed and direction. Do not
take any risks: if the wind is too strong, that means it's a 'no go'!

 Fill the maximum permissible wind speed into the checklist in

appendix A

.
ED.03098.00.001.R00.ENG Page 23
Explanations of Methods

4. Explanations of Methods

This chapter provides detailed information about putting the SL60 system into
use. It will describe the preparations to be made at the working site, on the portal
lift, etc.

4.1. Storage

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

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

If the stroke encoder gets wet, it may not function correctly, so

pay special attention to the encoder box.

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

an option.

ED.03098.00.001.R00.ENG Page 24
Explanations of Methods

4.2. Handling

4.2.1. Unit

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

fully retracted.
 Movement of the unit is not permitted with the top beams
mounted on the top plates.

In order to prevent damage to the wheels, all movements, in any

direction, must be executed at a minimum height of 300 mm off
the ground.

Each unit is fitted with

two lifting eyes, as shown
in the illustration below:

Always use both lifting eyes.

ED.03098.00.001.R00.ENG Page 25
Explanations of Methods

4.2.2. Skid tracks

1. Skid tracks can be moved by using a crane and attaching it to the two
lifting eyes fitted.

See illustration below.

Lifting eyes

4.2.3. Header beam

The header beams can be moved in two ways:
1. With a forklift truck; the header beam is provided with fork openings for
this.
2. Using a crane; for this, the header beam is provided with four lifting eyes.
See illustration below.

Lifting eyes

Fork holes

Always use all four lifting eyes

ED.03098.00.001.R00.ENG Page 26
Explanations of Methods

4.2.4. Side shift

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

In order to place the side shift on the beam, it is

provided with lifting eyes.
During assembly, always work with two lifting
chains; in this way the side shift always remains
horizontal during lifting. See illustration:

In this case, set a filling

block for lifting.

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

ED.03098.00.001.R00.ENG Page 27
Explanations of Methods

4.2.5. Single lifting anchor

The single lifting anchor system consists of a propelled unit of the HBS4500-SP
connected to the single lifting Anchor.
If the single lifting anchor is used on a 300mm wide beam, then the guide strips
should be installed as shown in the illustration below.

Guide strips

ED.03098.00.001.R00.ENG Page 28
Explanations of Methods

4.3. Placement of the skid tracks

To ensure proper operation, the system must be installed level on the ground; in
many cases the surface is not flat, and it must be graded to create a good solid
base on which the system can work safely.

The definition of a good supporting surface is:

a properly graded base that cannot be deformed by transverse forces under load
or overloading.
The utmost care must be taken in achieving a proper foundation, as
this forms the basis of the system's safety.

Guide rails have two functions:

 The use of guide rails reduces the basic loading
 They also guide the portal lift over their length, thus avoiding the risk of
misalignment.

Failure to use the guide rails Unstable surfaces cause instability. Concrete is not a suitable
may result in misalignment. foundation for wheels.

4.3.1. Requirements for the skid tracks

Permissible skid tracks are:
1. The skid tracks manufactured by Enerpac, supplied with the machine.
2. Additional skid tracks supplied by Enerpac.
3. Skid tracks that comply with the following requirements:
a. Prescribed material and the dimensional tolerances specified on the
drawing in appendix E and in section 4.3.2.
b. The materials used must be accompanied by materials certificates
type 3.1.B.
c. The skid track must be tested statically before use to an overloading
of 125% of the maximum capacity; during this a notified body must
have been present. The said notified body must issue a certificate
for this.
d. At an overloading of 125%, the stresses in the material must remain
below 60% of the yield point.
e. All welding work must be executed according to EN-ISO 15614-1.
f. The quality of the welding processes must comply with EN729.
g. The welding must be approved and in this comply with
EN-ISO 5817 class B.

Enerpac can supply skid tracks.

These skid tracks are hot-dip galvanized and meet all of
Enerpac's requirements for skid tracks.

ED.03098.00.001.R00.ENG Page 29
Explanations of Methods

4.3.2. Check of the skid tracks before use

Check the skid tracks for damage before installation.
Several minimum requirements are listed below.
Pay special attention to the welds, there must be no cracks in them.

The flatness tolerance of the running

surface is 5 mm over 3 m (1/5” over
10’).

The rails may not be skewed in side

view. The angle from the horizontal
plane must be less than 0.2° in both
axes.

The incline angle of the running surface

must not be more than 0.2°.

Never use rails which do not meet the above requirements.

ED.03098.00.001.R00.ENG Page 30
Explanations of Methods

4.3.3. Requirements for the filler material

The filler material must be stacked contiguously so that there is no

risk of spring action!

Minor deformations in filler material or subsoil may result in strong

internal transverse forces or diagonal or longitudinal movements of
the load or masts.

Permitted filler materials:

1. Hard wood with a mechanical compressive strength of at least
25 N/mm² without occurrence of deflection
However, Enerpac strongly recommends adhering to
30N/mm². Preferably Azobe.
The minimum hardwood thickness is 50 mm and the
maximum thickness is 150 mm.
Note:
Use of other wood types such as plywood, multiply, pine
and compressed wood is expressly prohibited.
Wood is a natural product, which means its quality is not standardly
assured. In order to guarantee quality an appropriate test must
be conducted before use to verify that the material meets the set
requirements.

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

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

r Use of other materials is not permitted!

In case of doubt, please contact Enerpac

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

ED.03098.00.001.R00.ENG Page 31
Explanations of Methods

4.3.4. Placement of the filler material

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

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

Standard geometrical requirements for the filler material:

Parameter Requirements
L > L Min. (to 629mm)
M > M Min.
B > H and > 250mm
S < 250 mm

ED.03098.00.001.R00.ENG Page 32
Explanations of Methods

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

Pay attention in this to the following points:

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

Track couplings must always be fully supported.

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

Always place a steel plate with

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

Steel plate width at least 300

mm + 2x the thickness of the
plate

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

3. Align the guide rails

ED.03098.00.001.R00.ENG Page 33
Explanations of Methods

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

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

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

Ensure that no clearance is left between the filler material and

skid tracks.

For filler material requirements, see section 4.3.2.

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

ED.03098.00.001.R00.ENG Page 34
Explanations of Methods

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

The flatness tolerance of the running

surface is 5 mm over 3 m (1/5” over
10’).

The rails may not be skewed in side

view. The angle from the horizontal
plane must be less than 0.2° in both
axes.

The incline angle of the running surface

must not be more than 0.2°.

Ensure that the running surfaces of the

rails are aligned. Otherwise, use shims
to align the surfaces. Ensure that the
angle of incline created is less than
0.2°.

Connect the rails or plates together

under tension. Gaps between the
surfaces may cause dislocation of the
lifting foot and thus of the load.

 Check that the skid tracks meet all requirements and

fill this in on the checklist in appendix B.

.
ED.03098.00.001.R00.ENG Page 35
Explanations of Methods

4.4. Placement of the unit

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

 Check that the units are on the rails properly and

fill this in on the checklist in appendix B.

.
4.5. Connection of power cable

Once the units are in position, the power

cable may be connected. Each unit can be
connected separately to the power supply.
No more than one unit should be
connected via the multiple socket.
Connect the power cables to each of the
units’ power connections:

Specification of the power source:

Voltage :360 to 480 V AC/ 3-phase
Current :7.5 A per unit
Frequency :50-60 Hz
Power :22 kW per unit
The units feature automatic phase selection according to the rotation direction of
the electric motors.

ED.03098.00.001.R00.ENG Page 36
Explanations of Methods

4.6. Mounting the header beams

In order to mount the header

beams on the units, the six bolts
on the top of the swivel plate
must first be removed. Remove
the locking strips.

Place the header beam on top of

the swivel.

Replace the strips and the six

bolts (M12). Adjust the beams to
be level before securing the
beam to the lift.
In this way, a fixed connection
between the unit and the beam
is achieved. (For the operation of
the machine, see Chapter 7.)

Tighten the bolts to 79 Nm

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

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

.
ED.03098.00.001.R00.ENG Page 37
Explanations of Methods

4.7. Mounting the side shift

Place the side shift on the beam as shown in the

illustration. See section 4.2.4 for how to lift the side
shift.

Place the lifting beam as illustrated:

Fit the locking strip as shown in the illustration

next to this text. Tighten the bolts (M12) to
60 Nm.

Feed the cable through the guide

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

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

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

.
ED.03098.00.001.R00.ENG Page 38
Raising the load

5. Before lifting the load

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

Always check the points given in this section before beginning to

move a load.

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

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

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

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

4) Define what is known as a 'declared drop zone'. This is the area outside of
which you and all bystanders and goods on the site are safe, if anything
should go wrong. Cordon off this area using barriers, tapes etc., and in
such a way that no-one can enter the area.

5) Ensure that the running surfaces of the skid tracks are clean and that the
unit cannot slip or be obstructed.

6) Check whether all wedges have been removed from the rams.
See section 7.4.

7) Slide all masts in and out a little to check that all communication functions
are working properly.

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

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

10) Check whether the correct load is indicated. This is of course the weight of
the beams and the internal resistance of the feet themselves. The load
must only be hoisted after all preparatory measures have been
implemented and the system is fully ready for use.

ED.03098.00.001.R00.ENG Page 39
Raising the load

11) Before hoisting loads, check that the load anchorages are in a line with the
fixing points on the load:

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

12) Always keep lifting straps as short as possible. With long lifting straps, the
load will always have the tendency to start swinging during travelling or
sidewards movement. This can also cause unexpected lateral loading of
the portal lift:

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

 This chapter is associated with the checklist in appendix C.

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

ED.03098.00.001.R00.ENG Page 40
Checklists

6. Checklists

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

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

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

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

Work exclusively according to the checklists: during preparation

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

6.1. Preparation for a lifting operation

The checklist for preparation may be found in Appendix A.

Make a copy of the list, or print one out from the CD-ROM supplied.

The checklist during preparation is to check:

 the machine is capable of bearing the load;
 The subsoil can carry the load.
 To establish how high the wind speed may be during the operation.

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

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

ED.03098.00.001.R00.ENG Page 41
Checklists

6.2. Setting up the portal system

The checklist for erection is to be found in Appendix B.

Make a copy of the list, or print one out from the CD-ROM supplied.

The checklist for the construction is for confirming that:

 the machine has been set up in accordance with the instructions in the
manual;
 The machine is erected according to the data upon which the calculations
during preparation were based (Appendix A).

This checklist has been drafted in chronological order. Therefore, it is

necessary to go through this list point-by-point from top to bottom. During
checking, as well as during construction.

If it is necessary to use lifting straps, chains or other accessories, this should

also be noted on the checklist.

6.3. Before lifting the load

The checklist for during lifting is to be found in Appendix C.

Make a copy of the list, or print one out from the CD-ROM supplied.

The checklist for use before lifting the load is for confirming that:
 The machine is not damaged and shows no signs of wear.
 the machine's functions are working correctly and all work in the right
direction;
 The machine is correctly situated above the load.

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

ED.03098.00.001.R00.ENG Page 42
Working with the machine

7. The operation of the machine

The portal lift may be used in two ways:

 Manual operation, known as “local control”.
 Using the Intellilift, known as “Remote control”.

Once the header beams have been installed on the units, the machine may only
be operated using the Intellilift control panel.
Manual operation is reserved for Enerpac technicians.

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

In case of doubt, please contact Enerpac.

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

unit. And only after approval by Enerpac.

A unit is only part of the central emergency stop system if the

control selector switch is in the remote position.

ED.03098.00.001.R00.ENG Page 43
Working with the machine

7.1. The control panel on the unit

Side shift overload Emergency stop

Switching voltage
protection signal signal active
present
active
*An emergency stop
has been operated.
Motor for
hydraulic pump Motor overload *No connection with the
running protection signal Intellilift panel.
active

Main Unit ON Emergency

switch RS485 and stop
OFF button
Note: this only
works on other
units if they
Side shift direction Local/remote are also
identical selector control selector working on
remote
control.

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

ED.03098.00.001.R00.ENG Page 44
Working with the machine

7.2. The Intellilift control panel

Display. Displays basic The RS845 connection. Connection Emergency stop switch. When activated,
information, such as load per for fixed wiring. This connection is power is cut to all power cables.
lifting foot, lifting height per also used to charge the batteries. They must be reactivated manually for each
foot, and messages. lift component.

Cylinder
selection.
Activates and
deactivates
individual lifting
feet. Useful
during
installation.

Power

N.A. for SL60 Lift Travel Side shift Zero lift switch. Resets the
Lift/lower Forward/reverse Left/right lift counters of the
activated lifting feet to 0.

Always select "tortoise" mode on the speed selector switch when

working with a load on the machine.

Only one function can be active at a time!

ED.03098.00.001.R00.ENG Page 45
Working with the machine

7.3. Manual control

Local operation is reserved for Enerpac personnel

7.4. Intellilift control

7.4.1. About Intellilift

The Intellilift control system has been developed to allow loads to be raised and
lowered under control.
The control system ensures that the units remain within a hysteresis of 20mm.
For this, it is necessary that the Intellilift is set up correctly.
See section 7.4.3.1.

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

7.4.2. Communication

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

The frequency of the cordless communication is 2.4 gigahertz.

ED.03098.00.001.R00.ENG Page 46
Working with the machine

7.4.2.2. Data cables

In places where the use of radio waves is not allowed, data cable communication
may be used.
See section 7.4.4.3 for how to switch between cordless and data cable
control.

For a wired connection of the lifting feet, the data cables are connected together
using an RS485 connection, in such a way that the following network arises:

Dongle

Intellilift control
panel

Dongle

The use of a network requires a closed circuit. Connect a dongle (terminator) to

the last unit in the circuit.
It is not important which cable is in which connector as long as the circuit is
terminated. The same applies to the dongle. The right- and left-hand connectors
are identical.

Switch box, nothing Switch box, with connections Connected switch box, end
connected from one unit to the next of the ring network

7.4.3. Normal operation

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

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

3. Before using, check that the control panel battery is fully charged.
This is to prevent problems due to a flat battery during the lifting operation.
A full battery has a capacity of around 8 hours.

ED.03098.00.001.R00.ENG Page 47
Working with the machine

See section 7.4.7 for battery charging.

Level indicator
(full battery on the display)

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

5. Switch the main power switches on the control panels on the units to “on”.
If the power supply is in order, the “power on” indicator on the control
panel of the unit concerned will light up green.

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

7. Switch the local/remote selector switches on the units’ control panels to the
‘rem.’ position.
The “emergency active” indicator on the control panel of the unit concerned
will light up blue.

8. Switch the “RAM SELECT” switches of the units you wish to control to the
“on” position.

The units required can now be detected by the Intellilift control panel. If the
connection is in order, the “emergency active” indicator on the control panel
of the unit concerned will go out.

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

10.You can now control the following functions: Lift, Travel and Side Shift.
A unit may be deactivated temporarily using the ram selection switches.
Only one function can be operated at a time.

7.4.3.1. Lift
If you want to start LIFTING or LOWERING, first check the values indicated on the
lift counter on the display.

Remember that the control unit keeps the lifting height of all units selected using
“ram select” within a hysteresis of 20mm.

ED.03098.00.001.R00.ENG Page 48
Working with the machine

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

When you start the lifting or lowering action, the unit stops a ram as soon as the
lifting position exceeds the range by too much (more than the hysteresis of
20mm).
Once the position is back to within half of the hysteresis, the movement is
restarted.

After repositioning the skid tracks, the beams must be levelled.

After this, give the zero lift command.

7.4.3.2. Travel
The SL system is a self-driven system. Each unit is provided with a hydraulically-
driven travel motor. The motor is connected via chains to the wheels under the
frames.

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

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

7.4.3.3. Side shift

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

There is no equal-travel regulation, although the drive roller is provided with

knurling for sufficient traction. The side shifts on the same beam may be coupled
together mechanically with a link rod.

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

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

ED.03098.00.001.R00.ENG Page 49
Working with the machine

7.4.4. LCD screen

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

7.4.4.1. Level indicator

The following values are displayed on the screen:
 The total load on the selected units: “Tot”
 The absolute position for each unit: “position”
 The position with respect to the zero lift position: “lift”
 The load per unit: “load”

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

If an incorrect factor is used for the second or third phase, you may receive an
overload notification, although there is in fact no question of physical overloading!
This can be resolved by recalibrating the position measurement, or by slightly
reducing the switchover point (please contact Enerpac for this).

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

7.4.4.2. Overload warning

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

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

7.4.4.3. Communication timeout

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

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

ED.03098.00.001.R00.ENG Page 50
Working with the machine

Switching to data cable control (RS485 mode)

If you experience many problems in cordless mode, as a result of external
influences or a fault, you may use wired mode.
 Switch off the Intellilift control panel and the main power switches on the
units.
 Connect the communications cable between the Intellilift panel and the
units.
o First switch all units on according to steps 5 to 8
in section 7.4.3.
 Switch on the Intellilift panel with all selection switches in the OFF position;
if communication is working properly, a star will be displayed after the lift
value – see illustration

 The LCD indicates that the control has been switched to wired and the
cordless control is deactivated until you again switch the control panel off
and on (without cables connected).

ED.03098.00.001.R00.ENG Page 51
Working with the machine

Emergency stop system

If the emergency stop button on the control panel is pressed, the message
“***Emergency pressed***” appears on the display.
When the emergency stop button on one of the units is pressed, you also receive
such a message, but only if the cylinder was selected!

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

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

7.4.3.

7.4.5. Switching off the control panel

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

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

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

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

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

7.4.6. Charging the battery

There is a lithium ion battery in the control unit. The battery has a capacity of
around 8 hours in normal operating mode. In order to increase the battery life,
the background lighting is switched off if no changes have been detected for a
period of 15 seconds.
After completing a lifting operation, connect the charger to the control panel. (Put
the power switch to OFF.) A fully charged battery should read 8.4 V. A fully-
charged battery should indicate 8.4 V. The charger supplies the circuit with a
regulated voltage of 12.0 V.

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

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

ED.03098.00.001.R00.ENG Page 52
Working with the machine

7.4.7. Settings

7.4.7.1. Learning a replacement Intellilift control panel

Each control panel has a unique code. In order to make control possible, you must
match the separate receivers with the control panel. This has usually already been
done by the programmers at Enerpac. But in the case of a serious fault, it may be
necessary to reprogram the panel. This is also true when the old panel is replaced
with a new one. The matching remains valid, even after switching off the power.
Steps to reprogram the panel:
1. Check that the battery is fully charged
2. Switch off all cylinder selection switches on the control panel
3. Switch on the control panel
4. Switch on the unit to be ‘matched’
5. Put the RAM SELECT SWITCH 1 (on the control panel) to ON
6. On cylinder 1, press and hold the ‘LEARN’ button for about half a second
(and then release it)

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

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

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

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

ED.03098.00.001.R00.ENG Page 53
Working with the machine

7.4.7.2. Recalibration procedure

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

Step 1: Set all cylinders to the minimum position

Step 2: Deselect all cylinders

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

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

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

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

ED.03098.00.001.R00.ENG Page 54
Working with the machine

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

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

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

If the calibration proceeded successfully, this message appears:

“Calibration succeeded”.

If there was poor communication during the calibration, causing it to fail,

the following message appears:
”Calibration failure”.

ED.03098.00.001.R00.ENG Page 55
Working with the machine

7.4.8. Correction of faults

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

Symptom Possible cause Possible solution

Load value –300 (large Faulty wiring or loose Check the wiring,
negative value) connector on the LED measure the current
indicator (should be 4 - 20mA)
Large negative position Faulty wiring, loose Check the position
value sensor wire reading for the physical
cable, check the position
sensor
All units selected, but One of the main motors Press the START button
none move up has stopped, is outside of to restart the motor
the lifting hysteresis
All units selected, but Lifting value was not First reset the lift
only one moves up reset, only the unit with counters (even if you
the lowest lifting value have switched off the
moved up control panel)
After switching on the This is normal – the Wait approximately 30
control panel, it will take receivers continuously seconds
a moment for the scan the various RF
communication timeout to channels when they
disappear cannot find a control unit
No display indication after Battery is low Charge the battery for at
switching on the control least 4 hours
unit
Communication problems This is where the internal Do not place your hands
when you place your aerials are located. on this area.
hand on the top right
corner of the control
panel

ED.03098.00.001.R00.ENG Page 56
Working with the machine

7.5. Inclination sensors *optional

The gantries are equipped with inclination sensors. These sensors help to establish
if the gantry is level or not while lifting a load. With this sensor the gantry will
issue a warning when not level. The sensors have no effect on the functionality of
the gantry system.
The value of the sensors is only shown on the electrical cabinet of the gantry. The
value is not displayed on the Intellilift remote control.

The inclination sensors are mounted on the base frame behind the electrical
cabinet.

Whenever the inclination sensor value exceeds 0.2, the red light on the gantry will
flash, giving the operator the opportunity to decide whether to stop or proceed
with the lift. The gantry will not stop automatically.

ED.03098.00.001.R00.ENG Page 57
Special applications

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

Before attempting any special applications, please contact

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

8.1. Tilting a load

Laying a load flat and bringing it upright are possible actions with an SL lift. This is
in fact a risky operation, because incorrect control can lead to sidewards forces
arising.

In general, Enerpac recommends keeping the slings or lifting straps as short as

possible, but when tilting a load, longer slings or lifting straps should be used. In
this way, the sidewards forces are kept to a minimum and the sidewards resultant
force is no longer directly observable.

During tilting, it is only permissible to work with two units.

The units attached to the top of the load in the lain-flat situation (the blue units in
the illustrations) may not be operated during tilting.

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

1. The units which are attached to the top of the load in the lain-flat situation
must be placed in the desired position (the blue units).
2. Thereafter, these units must not be used any more during the tilting of the
load. These units must also not be switched to the neutral setting, if
present.
3. The other two units are now extended a little. Next, travel them a short
distance towards the other units so that the lifting eyes are once again
directly under the header beam (the red units).
4. This sequence should be repeated until the load has been tilted.
Make small movements of no more than 5 centimetres, both in lifting and
travelling.
Check continuously that the lifting eyes are vertically under the
beam: a tolerance of ±0.2° applies here.
Make use of a plumb line, a laser or a theodolite for this.
5. Now all units should be selected and the command “zero lift” should be
issued.
6. The lift can now be operated in the normal way.

ED.03098.00.001.R00.ENG Page 58
Special applications

The slings or lifting straps must remain completely vertical at all

times. If they do not, this will result in lateral forces. These, in
turn, may cause the lift to loose stability.

ED.03098.00.001.R00.ENG Page 59
Special applications

8.2. Lifting with two units

The SL lift has been designed to lift with four units at all times, and with the load’s
centre of gravity always inside the units.

In exceptional cases, it is possible to lift with two units; this option may be
chosen, taking into account the considerations mentioned in this chapter. All the
other requirements mentioned in this manual continue to be applicable.

Note:
Lifting with two units makes heavy demands of the operator; for this
reason, such an operation must be carried out by experienced operators
only.

Points of attention:
1. Before raising the load, its centre of gravity must be positioned immediately
under the centre line of the beam. This prevents the load from swinging
when it is raised.
2. The straps and chains must be made to the correct length in advance, so
that the load can be lifted horizontally in one go, and it cannot swing.
3. The load’s centre of gravity must remain at all times under the centre line
of the beam; a tolerance of ±0.2° applies here. This can be checked using,
for example, a theodolite. See also section A-A.
4. Slight swinging of the load could cause the lift to topple over.

Carelessness during preparation and/or lifting may have serious

consequences.

ED.03098.00.001.R00.ENG Page 60
Special applications

This page was intentionally left blank

ED.03098.00.001.R00.ENG Page 61
Maintenance

9. Maintenance

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

In order to achieve this, it is strongly recommended to remove dirt from the

machine after every lifting operation, and to check the machine for damage.
Pay special attention here to the hydraulic and electrical components.

Remember that maintenance must only be carried out by skilled personnel.

Damage to components, particularly the cylinders, can have serious
consequences.
Hydraulic fluid safety information sheet, see Appendix D

Maintenance should only be performed by qualified personnel.

Only perform maintenance on the SL units if they are not under

load and if all lifting beams have been removed.

Any maintenance procedures not detailed in this section can only

be performed by or in consultation with Enerpac.

Periodic maintenance intervals:

Interval Description Product Volume
Every 50 hours, Lubricate side shift Kroon-Oil multi purpose 5 strokes per
and at least 8 nipples per unit grease 3 nipple
once every 6 +chain
months
Every 50 hours, Lubricate chain Kroon-Oil multi purpose
and at least grease 3
once every 6
months
Every 50 hours, Tension chain
and at least
once every 6
months
Every 5 years* Change oil Shell Tellus T32 or Shell 55 liter
Tellus Artic
Every 5 years Change reduction ISO VG 320 Mineral oil 2.6 liter
chamber oil

* For normal use. In case of doubt, please contact Enerpac

ED.03098.00.001.R00.ENG Page 62
Maintenance

9.1. Lubrication Points

9.1.1. Side shift

The side shift is fitted with 4 grease nipples per unit.

These must be supplied with 5 strokes of Kroon-Oil multi purpose grease 3 every
25 lifting hours, or at least once a year.
The chain in the drive must be lubricated with Kroon-Oil multi purpose grease 3 at
the same intervals.

ED.03098.00.001.R00.ENG Page 63
Maintenance

9.2. Maintenance of the hydraulic system

Every five years, the oil in the reservoir must be completely replaced with new oil,
or a purity test must be conducted. In this, the minimum requirement is that the
purity of the medium complies with class 7 in accordance with NAS 1638.

The reservoir has a capacity of 55 litres and is filled with Shell Tellus 32.
See Appendix D for the applicable Material Safety Data Sheet.

Electric motor

Manifold

Filler cap

Oil level and temperature indicator

ED.03098.00.001.R00.ENG Page 64
Maintenance

9.2.1. Draining oil

Ensure that the cylinder is completely retracted.
Drain the oil from the tank via the filler cap, making sure that the drain pipe is
located beneath the tank.

When the oil is below the required level, disconnect the power
supply.

9.2.2. Filling with oil

After draining the tank completely of oil, it should be refilled using 55 liters of
fresh oil. Keep a close eye on the level indicator. Never fill the tank over the
maximum.

This only applies if the cylinder is completely retracted.

ED.03098.00.001.R00.ENG Page 65
Maintenance

9.3. Chain drive

The SL60 is fitted with three chains. One connecting the reduction chamber to the
distributor shaft and the other two connecting the distributor shaft to each wheel.

Distributor shaft

Reduction chamber

The guards should only ever be removed after disconnecting the

power supply to the machine and ensuring that the machine is on
level ground so that it cannot roll.

9.3.1. Lubricating the chains

Remove the protective caps as shown in the illustration above.
Visually inspect the chains and chain wheels. Then lubricate the chains. The
protective caps can now be replaced.

ED.03098.00.001.R00.ENG Page 66
Maintenance

9.3.2. Tensioning the chains

Remove the protective caps (see 9.3.1) and loosen the four securing bearing nuts
on the distributor shaft by one turn. See illustration below.

Securing nuts

The four uppermost nuts used to secure the reduction chamber should be rotated
15 mm upwards. See illustration below

The chains connecting the distributor shaft to the wheels can now be tensioned by
tightening the clamping bolts (see illustration below). When doing this, ensure
that the distributor shaft remains as level as possible with the machine.

ED.03098.00.001.R00.NL Page 67
Maintenance

The chain is tensioned correctly when there is 10mm play at its mid point (see
illustration below). The four bearing nuts should now be re-tightened to 75 Nm.
Re-check the chain tension.

ED.03098.00.001.R00.NL Page 68
Maintenance

Now the chain connecting the reduction chamber to the distributor shaft should be
tensioned. This is done by adjusting the securing nuts on the reduction chamber.
Adjust the chain in such a way that the play at its mid point does not exceed 10
mm. Make sure that the chain wheels are in a straight line.
This can be checked by holding a straight ruler alongside the chain wheels.

Now the nuts have to be secured by turning them in opposite directions to 75 Nm.

Finally, replace the protective caps.

ED.03098.00.001.R00.NL Page 69
Appendices

Appendices

Appendix A Checklist for work preparation

Project data Load

Project: Description:
Client:
Weight:
Location: CoG: Symmetrical /
asymmetrical
Lifting Skid track
date: centre mm
distance

Operation type Subsoil

 Lift/lower Type:
 Lift/lower + move Allowable pressure
on the subsoil
 Lift/lower + lateral movement
before subsidence ………tonne/m²
 Lift/lower + move + lateral movement
happens.
(σ toe)

Source:
Capacity
 Use of extension tubes
Maximum lifting height Stage In maximum stage
mm Capacity:………..kN
Maximum force per unit occurring during the lifting operation:… ….kN

 Under the capacity of the unit in the maximum stage.

Minimum force per unit occurring during the lifting operation:… … .kN
 Sufficient
Maximum force per anchor point: … .kN
 Less than the capacity of the side shift
 The beam load is still less than the permissible beam load.

Skid tracks
Maximum surface load:…… … . Tonne/m²
 Less than σ toe
 Filler material under skid tracks required
Material:
Maximum height of filler material : H mm
Maximum play (see manual) :S mm
Minimum width of filler material :B mm

Page 1/2

ED.03098.00.001.R00.ENG Page 70
Appendices

Wind loading
Dimensions of Height mm
the load Length (in line with skid tracks) mm
Width mm
Maximum permissible wind speed m/s

Prepared by: Date:

Signature:

Date:
Approved by:

Signature:

Page 2/2

ED.03098.00.001.R00.ENG Page 71
Appendices

Appendix B Checklist for setting up the machine

Project data Load

Project: Description:
Client:
Weight:
Location: CoG: Symmetrical /
asymmetrical
Lifting Skid track
date: centre mm
distance

Checks while setting up the machine

 Appendix A Checklist for work preparation filled out in full and
signed.
 Filler material under skid tracks has been laid in accordance with the
instructions in this manual and the values in appendix A.
If filler material applicable
 Skid tracks placed at centre distance as indicated in appendix A.
 Skid tracks aligned according to instructions in manual.
 Skid tracks connected according to instructions in manual.
 Skid track units are on the skid tracks in accordance with instructions in
manual.
 Units are in parallel in accordance with instructions in manual.
 Bolts on Extension tubes tightened to torque in accordance with instructions in
manual if applicable.
 Beam is horizontal (level) on the two units.
 Attachment bolts on the beam tightened to torque in accordance with
instructions in manual.
 Side shift mounted in accordance with instructions in manual.

Other equipment
What Length Capacity according to Unladen weight
prescriptions
Lifting straps
Chains
Other
Date:
Constructed by:

Signature:

Approved by: Date:

Signature:

ED.03098.00.001.R00.ENG Page 72
Appendices

Appendix C Checklist for lifting the load

Project data Load

Project: Description:
Client:
Weight:
Location: CoG: Symmetrical /
asymmetrical
Lifting Skid track
date: centre mm
distance

Checks before lifting the load

 Appendix A Checklist for work preparation filled out in full and
signed.
 Appendix B Checklist for setting up the machine
 Carry out a visual inspection of all lifting feet. Assure yourself that there are no
signs of excessive rust and that no parts of the portal lift are damaged. Rust
means a weaker structure.

 Carry out a visual inspection of all hydraulic components.

Assure yourself that there are no signs of wear or damage.
Oil leakage may indicate wear or damage to the system.
 Define what is known as a 'declared drop zone'. This is the area outside of
which you and all bystanders are safe, if anything should go wrong. Cordon off
this area using barriers, tapes etc., and in such a way that no-one can enter the
area.
 Check whether all wedges have been removed from the rams.
See section 7.4.
 Check if the masts are in and out of test hours.
 Check that all units travel forward and in reverse. Pay attention to the correct
direction.
 Check that the side shifts are functioning correctly. Pay attention to the correct
direction.
 Check whether the correct load is indicated. This is initially the weight of the
beams and the internal resistance of the feet themselves.
 Before hoisting loads, check that the load anchorages are in a line with the
fixing points on the load:

Page 1/2

ED.03098.00.001.R00.ENG Page 73
Appendices

 Running surfaces of the skid tracks are clean

 Always keep lifting straps as short as possible. With long lifting straps, the load
will always have the tendency to start swinging during travelling or sideways
movement. This can also cause unexpected sidewards loading of the portal lift:

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

 Wind speed lower than permissible limit

Checked by: Date:

Signature:

Date:
Approved by:

Signature:

Page 2/2

ED.03098.00.001.R00.ENG Page 74
Appendix E Skid track
requirements

Appendix E Skid track requirements

ED.03098.00.001.R00.ENG Page 75