Survey of HAMMAR crane models

Transcription

1 USER MANUAL

2 Survey of HAMMAR crane models User Manual / 167 / Page 1

3 Survey of HAMMAR crane models User Manual Page 2

4 Survey of HAMMAR chassis models User Manual S-chassis C-chassis F-chassis A-chassis E-chassis T-chassis GOOSENECK-chassis FIX-chassis D-chassis Page 3

5 CONTENTS User Manual 1 GET TO KNOW YOUR HAMMAR SIDELOADER MAIN WIRE TERMINAL CRANE TERMINOLOGY SURVEY OF MODEL SERIES SERIES SERIES SERIES SERIES SERIES SERIES SERIES LEG AXLES LEAF SPRING SUSPENSION AIR SUSPENSION SAFETY WARNING NOTICES SAFETY CONTROL OTHER COUPLING UNCOUPLING / PARKING PARKING LEGS BRAKES SERVICE BRAKE / PARKING BRAKE BEFORE HANDLING POSITIONING OPERATION CONTROL SYSTEM / OPERATING DEVICE WIRED REMOTE CONTROL RADIO REMOTE CONTROL DIRECT CONTROL WITH VALVE BLOCK LEVERS (EMERGENCY OPERATION) CONTROL SYMBOLS / TABLE OF SYMBOLS ENGINE CRANE MODEL OVERRIDE ENGINE STOP ADJUSTMENT TO DIFFERENT CONTAINER SIZES S-CRANE SLIDE E-TAIL C-COMBI F-FLEXIBLE T-TROMBONE A-ADVANCED D-DOUBLE GOOSENECK CLIP ON-FRAME PARK THE CLIP-ON SUBFRAME COUPLE THE CLIP-ON SUBFRAME HANDLING THE CLIO-ON SUBFRAME WITH FORKLIFT LIFTING PLACING OF STABILIZER LEGS PLACING ON GROUND TRANSFERRING Page 4

6 6.1.3 MODEL 155-MEGA TRANSFER MODEL HAMMAR SAFETY HOOK ATTACHING THE HOOKS LOADING CONTAINER (WITH CHAINS) UNLOADING CONTAINER (WITH CHAINS) SPREADER LOADING CONTAINER (WITH SPREADER) UNLOADING CONTAINER (WITH SPREADER) STACKING OF CONTAINERS TIPS FOR LOADING IN A SLOPE TWIST LOCKS OPTIONS AUTOMATIC TWIST LOCKS EXTRA STABILIZERS FAST ACTING STABILIZER LEGS AUFB EXTENSION HIGH CUBE STACKING HAMMAR MEGA REACH PARALLEL SLIDE X20' TWINLOCK SHORTENING HOOK CARRIAGE OF DANGEROUS GOODS HAMMAR SAFETY HAMMAR SAFETY+ DISPLAY LAYOUT NON LIFTING SIDE SAFETY HOPE CAMERA(S) TAILGUARD POWER PACK AXLE LIFT SELF-STEERING AXLE POWER STEERING HYDRAULIC POWER STEERING ELECTRO-HYDRAULIC POWER STEERING LOAD INDICATION SYSTEM AXLE PRESSURE MANOMETER SMARTBOARD CENTRAL LUBRICATION RETRACTABLE UNDERRUN BAR EXTENDABLE UNDER RUN BAR DRAWBAR COUPLING Hammar Maskin AB reserves the right to vary specifications and equipment and amend service and maintenance instructions without prior notification. Page 5

7 1 GET TO KNOW YOUR HAMMAR 1.1 SIDELOADER 1. Chassis 6. Flashing beacon 2. Front crane 7. 2x20' Beam 3. Rear crane 8. Central box 4. Parking leg 9. Underrun bar 5. Side protection MAIN WIRE TERMINAL The main wire terminal is located inside the central box. 1. Main wire terminal 2. Indication crane electricity 3. Switch Work light 4. Contact radio/wired remote control In some markets the HAMMAR is equipped with lighting that shall be switched on when parking in the dark. In such cases the switch is located on the main wire terminal. Page 6

8 1.2 CRANE User Manual 1. Upper crane arm 7. Container stops 2. Load axle 8. Extra stabilizing leg 3. Lifting chains with HAMMAR safety hooks 9. Twist lock 4. Work light* 10. Crane base 5. Lower crane arm 11. Stabilizer leg 6. Hydraulic valve block 1.3 TERMINOLOGY Hammar HAMMAR Container, 8'6" High Cube Container 9'6" Hammar Maskin, Hammar subsidary, Hammar representative One complete unit, chassis with cranes. ISO container, height 2590 mm ISO container High Cube, height 2896 mm Page 7

9 1.4 SURVEY OF MODEL SERIES User Manual SERIES The HAMMAR 110 series has stabilizer legs that can be used in two ways depending on lifting situation. Either similar to HAMMAR 155 and reach across an adjacent trailer, vehicle or railway wagon so that the stabilizer feet are situated on the far side of the chassis or like the HAMMAR 160 model to obtain a faster handling procedure SERIES The HAMMAR 130 series is a light lifting model, SWL 16 metric ton. The 130 series is equipped with three cranes on one chassis, it makes it possible to handle two 20 containers individual. It is also possible to lift 40 containers as the middle crane is fully folded down in its transport position. The folding version of the crane 130 can also be mounted at the rear of the trailer, container doors can then be opened backwards and goods can be loaded or unloaded against a loading dock SERIES The HAMMAR 140 series is a light lifting model, up to 16 metric ton. The stabilizer legs are of the telescopic type and are extended diagonally downwards. The 140 series can be mounted on different types of chassis or on a clip-on subframe. By default the 140 series is equipped with radio remote control, Hammar Safety+ and has its own power source with gasoline engine and hydraulic pump. Page 8

10 When handling empty containers is it with the 140 series possible to lift the container outside the support legs position, see the load chart of the crane SERIES The HAMMAR 150 series has telescopic stabilizer legs as standard which can be angled freely from the horizontal to vertical position. The legs may be supported against the ground, a trailer, a railway wagon or a loading platform. The legs may also be placed beneath other vehicles, making it possible to get very close to the load and thus ensure safe and rapid lifting. 151, the standard machine in the 150 series. 155 has stabilizer legs which reach across an adjacent trailer, vehicle or railway wagon so that the stabilizer feet are situated on the far side of the chassis; alternatively, the stabilizer legs may be placed directly on the adjacent trailer SERIES Page 9

11 The HAMMAR 160 series stabilizer legs are aligned with the crane arms, and this makes the entire structure compact. The stabilizer legs are placed on the ground or on the adjacent vehicle SERIES The HAMMAR 180 series is a fixed 20' model for mounting on the truck chassis. The stabilizer legs are of the telescopic type and extend diagonally downwards SERIES The HAMMAR 190 series has stabilizer legs comprising a telescopic inner leg and an outer leg which can be inclined. It can be angled freely from the horizontal to the vertical position LEG The HAMMAR 17-leg is a stabilizer leg with low outreach which enables it to get under railway wagons, trailers and lorries. Page 10

12 1.5 AXLES Most HAMMAR side loaders are equipped with three axles. This may vary according to customer requirements, legislation and so forth. Information regarding lubrication, spare parts, service etc. can be found in accompanying documents from the axle manufacturer LEAF SPRING SUSPENSION This suspension normally consists of parabolic springs. The suspension may also consist of a spring unit comprising leaves (multi-leaf springs). The multi-leaf springs are normally fitted when the machine is delivered to areas with poor road conditions, or if specifically requested by the customer, for example for the purpose of off-road driving AIR SUSPENSION The air suspension system is supplied with compressed air from a compressor on board the truck. The compressed air first of all fills the air reservoirs which form part of the braking system. One of these has an overflow valve set at 5.5 bar. When the pressure in the brake tanks exceeds this value, the air bellows in the air suspension system start to fill up. Air pressure may also be used for other functions on the HAMMAR. The air pressure in the air bellows is determined on the basis of the vehicle s payload. This is controlled by a valve which ensures that the height between the axle and the chassis is always the same (provided that that there is sufficient pressure in the air bellows). 2 SAFETY Page 11

13 The HAMMAR may only be operated by a driver who has received training from Hammar Maskin AB, or from Hammar-approved personnel. Information regarding the precise lifting capacity of your particular HAMMAR can be found on the sheet entitled Your HAMMAR. The handling of such large loads calls for extreme caution and for the safety instructions to be rigorously observed incorrect handling may lead to serious personal injury and material damage. A HAMMAR may only be used by trained personnel. It is not allowed to use the HAMMAR in any other way than what it is intended for. The HAMMAR must always be coupled to a truck when handling a load. Keep out of the working area during handling. Always make sure that no-one is within the working area during handling. Never walk or stand under a suspended load. Never handle a load closer than 10 metres to a high-voltage power line. Never lift a container which has cracks or defective corner fittings. Page 12

14 The load on the HAMMAR must not be used as a counterweight when lifting another container. Never climb on the HAMMAR during lifting. Exercise extreme caution when lifting in strong winds, risk of overturning. The stabilizer legs are only to be used when the HAMMAR is lifting. The stabilizer legs should not be burdened in other ways e.g. shove loads on ground. The extra stabilizers shall not be used for lifting the HAMMAR, their only purpose is to be extra support while lifting load. o Keep distance to hydraulic hoses, tubing and fittings, these may become hot during operation. Can cause burns if touched. o Hot oil at high pressure can cause injury if a line fail. Pay attention to the load shift during lifting. This is especially important in the handling of tank containers. 2.1 WARNING NOTICES Warning notices on the HAMMAR, and their approximate positioning. Variations occur when this is a specific requirement for the HAMMAR in question. Page 13

15 Working area and safe distance for the HAMMAR. Indicates a potential crush hazard. In addition to those places indicated by notices, there is also a risk of crushing by other moving parts on the HAMMAR. Load chart, showing the load capacity of the HAMMAR in relation to the position of the stabilizer legs and crane arms. Page 14

16 A fixed emergency stop button is provided at the rear of the HAMMAR. 2.2 SAFETY CONTROL Daily inspection of the equipment contributes to increased safety and correct functioning. Check: o That the king pin is correctly attached to the fifth wheel. o That container hooks, chains and twist locks are undamaged and functioning correctly. o That operating levers on the crane control valve block move easily and automatically return to neutral position. o That hydraulic system hoses, fittings and components are not leaking oil. o The hydraulic oil level in the tank. o The tyres, for damage and abnormal wear. o The functioning of the braking system. o That the lighting is working. o At risk of sub-zero temperatures, drain the HAMMAR air tanks, unless automatic venting valves are fitted. o That the HAMMAR is not damaged in a way that may cause personal injury or material damage. Page 15

17 o That the emergency stops is functioning correctly. User Manual If any shortage detected at inspection, this must be corrected before the HAMMAR is put into use. This is only a daily function and safety check. For a more detailed description of periodic maintenance, see the separate service manual. For lubrication and care of axles, suspension and brakes, see accompanying service documents from each manufacturer respectively. 2.3 OTHER If you are experiencing problems with the HAMMAR unit, particularly ones which you believe may affect safety, we urge you to contact Hammar immediately. In all guarantee related matters, Hammar must always be contacted before any measure is taken. All repairs should be carried out by personnel who are either trained by Hammar or are acting on direct instructions from Hammar. In order to avoid corrosion of piston rods, each cylinder must be fully retracted at least twice a week. Page 16

18 In order to ensure that the machine is in a safe and in operational condition it should undergo regular service, see the separate service manual. 3 COUPLING It is recommended that brake adjustment is carried out between truck and trailer before the HAMMAR is put into service. This is to ensure a uniform braking effect and thereby extend the service life of the braking system. The upper part of the fifth wheel should always be well lubricated before the HAMMAR is connected. Reverse the truck and check that the king pin engages and is correctly positioned. During transportation of the HAMMAR the brake couplings should always be connected. In addition, statutory electrics (lighting) and ABS contacts shall be connected. Always check that all lighting, such as indicators and brake lights, are functioning correctly. If anything is found to be not working it should be attended to as soon as possible. Always check that the cranes are fully closed before transporting the HAMMAR. Check that the HAMMAR parking legs are fully cranked up. Make sure that the parking brake is released before driving away; the pressure in the air tanks must be approximately 5 bar for the brakes to be released. Location and appearance of the couplings varies depending on the market, below is an example. Note, some fittings are optional. 1. Return line, hydraulic system pin contact Page 17

19 2. Pressure line, hydraulics, front and rear crane 8. Duo Matic (brake) 3. Brake, supply 9. VBG contact (electric) 4. Brake, control 10. Two 7 pin contacts 5. Hose holder 11. Heavy current contact 6. ABS User Manual 3.1 UNCOUPLING / PARKING Park in a suitable location on level ground and apply the parking brake. All contacts, air and hydraulic connections between the HAMMAR and the truck shall be disconnected. Crank down the parking legs until the HAMMAR almost lifts from the fifth wheel. If the ground is soft, support pads should be used. Release the lock on the fifth wheel and carefully drive the truck away. 3.2 PARKING LEGS The parking legs are of telescopic design. They are provided with two gears - a working gear with a high degree of efficiency and a fast gear with a high gear ratio. The fast gear is used when the legs are cranked down to the ground or raised up from the ground. The working gear is used to adjust the height when there is load applied. 4 BRAKES The HAMMAR is equipped with brakes approved for country of operation; it may be drum brakes or disc brakes. Information about service and maintenance can be found in a separate manual available from the axle manufacturer. Page 18

20 4.1 SERVICE BRAKE / PARKING BRAKE If the air supply to the trailer is disconnected or if the supply line is broken, the brake valve pressure decreases, and this turns on full pressure to the brake cylinders so that the vehicle brakes will be applied (emergency brake). When the HAMMAR is uncoupled from the truck the trailer is emergency braked; this applies only as long as there is air in the HAMMAR air reservoirs. If the air pressure is lost the parking brake (spring brake) will automatically be applied. Depending on the market of operation the brakes function can differ from what is described here. 5 BEFORE HANDLING o The vehicle s parking brake shall be applied while the cranes is manoeuvred. o Take note of the surroundings. Make sure that no obstacles or persons are within the HAMMAR working area. o Never lift a container which shows signs of cracks or has damaged corner fittings. o Never handle a load closer than 10 metres to a high voltage power line. o Recommendations from Hammar regarding placement must be followed to ensure safe handling. If deviations made from these recommendations, a risk assessment shall be made in each case before operation. Page 19

21 o Use caution at slippery ground, the vehicle can slide sideways when lifting. 5.1 POSITIONING When lifting, a distance of 0.4 m between the HAMMAR and the container is recommended, as this will enable you to take advantage of the HAMMAR s full lifting capacity. The HAMMAR should stand on firm, level ground. If the ground is not sufficiently firm, support pads of appropriate size and strength should be placed beneath the stabilizer legs. The ground should be horizontal, the recommendation for maximum inclination is: Longitudinal inclination of chassis, ±1cm/m Longitudinal inclination of underlying ground, ±2cm/m Transverse inclination, ±5cm over width of trailer. Chassis Underlying ground Page 20

22 When handling a container in a slope, the driver should ensure that the sideloader remains steady without any possibility whatsoever of slipping lengthwise or sideways. If the HAMMAR is equipped with a RAISE/LOWER function, this should be used in order to make the chassis as horizontal as possible. In situations deviating from the recommendations above, a risk assessment should be made incorrect handling may lead to serious material damage and personal injury. For more information about handling of containers in a slope see separate Chapter. Also ensure that the crane's position along with the trailer is correct in relation to the container size. 5.2 OPERATION When the HAMMAR is in operation, position yourself in such a way that you have a good overall view of the working area. Normally, the best place to stand is behind the rear end of the HAMMAR CONTROL SYSTEM / OPERATING DEVICE The HAMMAR control system is an electro-hydraulic system, which ensures smooth movement of the cylinders, and thus also of the cranes. In order to extend the service life of the cylinders it is recommended to use low speed when they are being run to their end positions. The respective sections of the valve block have one or two pressure limiting valves. These limit the pressure for each function, so that the HAMMAR cannot be overloaded. Page 21

23 For each load-bearing cylinder there is an OC (over-centre) valve, which ensures smooth operation and also has the function of a load-holding valve which prevents the load from falling in case of a hydraulic hose failure WIRED REMOTE CONTROL Wired remote control is used as the main operating device or as a supplement to radio remote control. The wired remote handset is equipped with two joysticks, one of which controls the cranes and the other the stabilizer legs. The handset is also provided with switches/buttons which control various functions, depending on the type of equipment your HAMMAR includes; see Table of Symbols. The HAMMAR has two speeds: high speed for rapid handling and low speed for precision operation. In order to switch between these modes use the button on the left side of the handset. This button must be depressed, in order to enable you to operate the HAMMAR (dead man s switch). When the button is released, all functions will stop. Button is not activated: Activated for first stage: Activated for second stage: No operation is possible. All functions come to a standstill. Low speed High speed Both cranes are operated simultaneously; however, it may in certain circumstances be necessary to operate each crane separately. By using the switch on the top of the handset it is possible to select to manoeuvre the front and rear crane, either separately or together. The control handset is also provided with an emergency stop button. Page 22

24 5.2.3 RADIO REMOTE CONTROL User Manual Radio remote control gives the driver greater freedom to move around the container and the sideloader. The radio remote control system comprises a transmitter, which is either a button transmitter or a joystick transmitter, and a receiver mounted on the HAMMAR. Information on how the radio transmitter is used can be found in the accompanying manual DIRECT CONTROL WITH VALVE BLOCK LEVERS (EMERGENCY OPERATION) If a critical situation arises and the HAMMAR electrical system has faild, one may resort to emergency operation via the valve block levers. Please note that, on emergency operation, all safety systems are overridden and the operator needs to be within the working area. Emergency operation means that use of the machine is restricted to: o Lifting the container down to the ground only, never lifting it up onto the chassis. o Finding a way out of a dangerous situation. o Avoiding an emergency in which there is a risk of serious damage or injury. o Exiting from a lifting sequence when normal control equipment has stopped working. In order to facilitate emergency operation it is necessary to bypass the valve block relief valve. This relief valve is situated on the inlet side of the valve block, and in order to bypass this, one has to press, and hold down, the relief valve button whilst at the same time using the valve block levers. The valve block levers only control the crane to which they are fitted, so it is only possible to manoeuvre one crane at a time. Page 23

25 See the lever symbols for each function respectively. Crushing risk! Please note that, on emergency operation the operator is near the cranes moving parts CONTROL SYMBOLS / TABLE OF SYMBOLS SYMBOL FUNCTION SYMBOL UPPER ARM OUT UPPER ARM IN LOWER ARM OUT LOWER ARM IN STABILIZER LEG OUT STABILIZER LEG IN STABILIZER LEG DOWN Page 24

26 STABILIZER LEG UP 160 STABILIZER LEG UP AND DOWN MIDDLE LEG UP AND DOWN HOOK LEG OUT AND IN CRANE SLIDE OUT CRANE SLIDE IN EXTRA STABILIZER LEG DOWN EXTRA STABILIZER LEG UP EXTRA STABILIZER LEG OUT EXTRA STABILIZER LEG IN FRAME SLIDE / UNDERRUN BAR EXT. FRAME SLIDE / UNDERRUN BAR RETR. Page 25

27 FRAME LOCK LOCKED FRAME LOCK OPEN CRANE FRONT CRANE REAR POWER STEERING FRONT AND MID CRANE ACTIVE MID AND REAR CRANE ACTIVE ENGINE CRANE MODEL 140 Use of hearing protection is recommended since noise level of the engine is high. Page 26

28 1. Main circuit-breaker 4. Control box, Engine 2. Accelerator, max 3000rpm 5. Switch, work light 3. Choke 6. Ignition key For details on operation, service and maintenance, please refer to the attached material from the engine manufacturer OVERRIDE ENGINE STOP At emergency operation of the motor the function, engine stop must be overridden. This is done by holding in the key for two seconds. The text Engine Stop Override now appears in the display and you can start the engine as normal. A short press on key removes the text and the engine stop is activated again. 5.3 ADJUSTMENT TO DIFFERENT CONTAINER SIZES The HAMMAR can be adjusted in various ways depending upon the cranes, trailer and extra equipment. Certain models are equipped with movable cranes which can be slid lengthwise on the chassis for the handling of differing container sizes. During adjustment, the cranes shall be fully closed, and no load of any kind should be suspended from the cranes. Never run the cranes towards end stop at high speed, as this may damage the equipment. Page 27

29 Make sure that there is no-one within the HAMMAR working area when adjustment of the cranes/trailer is being carried out S-CRANE SLIDE A HAMMAR with an S-trailer has a fixed length chassis and movable cranes. Depending upon the design, an S- trailer can handle containers from 20' up to 40' and 45' in length. The trailer may also be equipped with 2x20' capacity, and it can then handle two 20' containers at the same time with an total weight of 28 metric ton. (Maximum of 14 metric ton per container.) The cranes are moved lengthwise along the chassis by hydraulics, see symbols on your control device. For a description of the symbols see the Table of Symbols. When the trailer has to be adjusted for a 20' container, the cranes are moved towards the middle of the chassis until they encounter the inner fixed stops. The longest possible position is achieved by running the cranes outwards to the outer fixed stops. The trailer may have a number of positions adjusted to customer requirements, and the procedures whereby these positions are attained also vary. One of the cranes may for example be moved to the corresponding outer fixed stop whilst the other is moved to a removable stop. Alternatively, both cranes may be moved to removable stops. Always use the stops in order to ensure that the cranes are in the correct position E-TAIL On this model the rear crane extends to the rear of the trailer frame to achieve the 45' position. When this is done the HAMMAR rear underrun bar must also be extended (legal requirement). The rear underrun bar shall remain retracted in 20' or 40' position. For more information see separate Chapter, Extendable under run bar C-COMBI Adjustment between different container sizes is done by hydraulically lengthening /shortening of the two-part telescopic chassis and by moving the cranes. Page 28

30 When adjusting the chassis, the frame locks must always be unlocked first. Never run at high speed when the frame locks are close to their locking position. User Manual Ensure that the chassis is correctly locked on both sides before the HAMMAR is driven away F-FLEXIBLE A three-part telescopic chassis with front crane movable, the rear crane placed on an extendable tail, and the axles being fitted in the central section of the chassis. Adjustment between the various positions is carried out in the same way as for the C-trailer. Ensure that the chassis is correctly locked on both sides before the HAMMAR is driven away T-TROMBONE Telescopic chassis with fixed cranes. Adjustment between the various positions is carried out by lengthening and shortening the chassis. Ensure that the chassis is correctly locked on both sides before the HAMMAR is driven away A-ADVANCED A three-part chassis where both cranes are movable, which makes it possible to optimize the load distribution on the HAMMAR. Adjustment between the various positions is carried out in the Page 29

31 same way as for the C-trailer. User Manual Ensure that the chassis is correctly locked on both sides before the HAMMAR is driven away D-DOUBLE A HAMMAR with the designation D has a fifth wheel at the rear in order to enable it to tow a trailer. On some markets the trailer is equipped with a lamp located on the side protection which indicates that the rear fifth wheel is in locked or unlocked position. When required this model is equipped with an extendable underrun bar - more information about this can be found in a separate Chapter GOOSENECK Page 30

32 A HAMMAR may be built with a gooseneck chassis, in various models, in order to minimize the height when high-cube containers are being transported. A Gooseneck HAMMAR is equipped with detachable twist lock towers which can be fitted to the fixed mounted twist locks in order to facilitate the transportation of containers without a gooseneck tunnel. 20 'high-cube containers can be placed behind the trailer neck. The twist lock towers may be of right-hand or left-hand design. The rear tower has a screw type twist lock, whilst the front crane is secured to the load with cotters. Tower, front crane. Tower, rear crane CLIP ON-FRAME A subframe with clip-on design consists of two fixed cranes and a frame. The unit can be placed on all kinds of vehicles equipped with 20 twist locks. The cranes and subframe can be adjusted 200mm lengthwise to fit the carrier vehicle. The clip-on subframe can be removed and put on hold when it doesn't carry any load. Page 31

33 The subframe is also provided with forklift pockets, this makes it able for a forklift to handle the unit. The subframe and its cranes is designed so that the lifting side can be right or left depending on how the unit is mounted. This makes it easy to change the lifting side by rotating the complete unit 180. o Regularly check the attachments of the subframe to the carrier vehicle, that the twist locks is undamaged and in locked position. o Also check that the twist lock brackets on the subframe is mounted correctly PARK THE CLIP-ON SUBFRAME o The clip-on subframe may only be parked when it is unloaded, nor to be subjected to load when it is parked. o Use extreme caution when parking and assembling the unit. o The unit may only be used for lifting when it is mounted on a carrier vehicle. o The clip-on subframe shall be parked on firm, level ground. If the ground is not sufficiently firm support pads is to be used. o The ground/underlay may not be slippery. o Never climb on the unit when it is parked, nor go underneath it. o Park the vehicle, disengage the twist locks that hold the subframe at its place. Page 32

34 o Mount the parking legs and adjust the height of them. The parking legs are in their transport position secured by a cotter provided with chain, this cotter is also used to lock the legs in the parking position. o Run the cranes support legs down to the ground. o Raise the clip-on subframe gradual, support leg/ parking leg, until chassis/truck is free to drive away. If the carrier vehicle is equipped with air suspension this can be used to lower the vehicle until it is free to drive away COUPLE THE CLIP-ON SUBFRAME o Place the carrier vehicle in position under the clip on subframe. o Check that the attachment on the subframe is in right position in relation to the twist locks on the carrier vehicle. o Lower the subframe gradually, support leg/ parking leg. If the carrier vehicle is equipped with air suspension this can be used to raise the vehicle. o Engage the container twist locks when the subframe is stable on the carrier vehicle. o Remove the parking legs and place them in their transport position. o Retract the cranes support legs. If the unit been parked for a longer period it is recommended to make an inspection of frame, cranes and lifting equipment before use HANDLING THE CLIO-ON SUBFRAME WITH FORKLIFT The clip-on subframe is provided with forklift pockets to enable handling of it with a forklift. It is at this occasions important to use a forklift that safely can handle the load of the unit. Page 33

35 With a forklift truck the subframe can be lifted off the carrier vehicle and then be parked or placed on a other vehicle. Parking can be performed by mounting the parking legs and run down the support legs or by placing the subframe directly on the ground. 6 LIFTING 6.1 PLACING OF STABILIZER LEGS For the safe handling of loads it is important that the stabilizer legs are correctly placed. On the HAMMAR there is a load chart showing what the correct position of the stabilizer legs should be in relation to the maximum payload. Pay attention to this to avoid tipping accidents. The load chart shall always be observed. Example of load chart - see your HAMMAR for specific chart. Note that when the lower arm leaves its closed position the stabilizer legs cannot be retracted. This does not apply if the HAMMAR is equipped with SAFTY + or AUFB. Page 34

36 6.1.1 PLACING ON GROUND The stabilizer legs shall be extended as far as possible until they rest firmly on level ground. If necessary - use support pads. The legs must be pressed down towards the ground to make the safety sensors located on the outer leg come in contact with the inner leg. This is not applicable on model 160 and 155, the support leg on these models must instead be folded out to a certain angle. Otherwise it will not be possible to perform the lift. Caution! Do not press the stabilizer onto the ground to hard. When the twistlock closest to the stabilizer have been raised approx. 2cm (one inch) is it normally enough. Page 35

37 6.1.2 TRANSFERRING When transferring, the trailer to/from which the lift shall be performed must be coupled to a truck. The stabilizer legs must rest firmly on the trailer/railway wagon without the possibility of slipping off or in any other way moving out of position. It is also of the greatest importance that the trailer/wagon structure is strong enough to carry the extra load from the HAMMAR stabilizer legs MODEL 155-MEGA TRANSFER As an option model 15 can be equipped with the Mega Transfer leg on one of the cranes or both. The Mega Transfer allows loading and unloading while the trailer which the container shall be transferred to/from, is still attached to the truck. Page 36

38 The Mega Transfer consists of two parts, Middle leg and Hook leg. This design allows the Mega Transfer to reach the ground on the other side of the trailer that shall be loaded/unloaded. For safety reasons, the Mega Transfer is equipped with two proximity switches (sensors) that ensure that both Middle Leg and Hook Leg is extended before lifting commences. If there isn t enough space or if it for other reasons is unsuitable to let the leg rest on the ground, the Mega Transfer can rest on a trailer chassis (or railway wagon) instead. This means that the Hook leg is still closed when the lifting maneuver is about to start. Also when putting down a container towards a wall it is not possible to fully extend the Mega Transfer Leg. To be able to continue the lifting maneuver in these situations, the leg sensors have to be overridden. To do this, follow the procedure below: Hammar standard: Extend the Mega Transfer until it rests safely. On the non-lifting side of the crane base, there is a switch to override the leg sensors, making it possible to proceed with the lifting maneuver. Hammar Safety+: Extend the Mega Transfer until it rests safely. In the rear aluminum compartment, push down button 4 for 2 seconds to override the leg sensors. Button 4 will high light and the display indicates SF (support leg front) and/or SR (support leg rear) when it is ok to proceed with the lifting maneuver. Page 37

39 SF= Support leg Front, OK SR= Support leg Rear, OK 4= Push for 2s to override leg sensors The override mode resets automatically when retracting the stabilizers, or when the power is shut off. To reactivate the override mode, push the button again. Note that the lifting capacity is reduced depending on how far from the side loader the leg is supported when resting on a trailer. See lifting diagram placed on rear crane. Hook Leg Override switch (Hammar std) Middle Leg Override button (Hammar Safety+) Override to proceed with the lifting manoeuvre in shadowed position or when resting on another trailer. Note the reduced lifting capacity depending on how far out the hook leg is supported. Page 38

40 Crushing risk when retracting the hook leg. Do not enter the handling area while the side loader is powered. Tip over risk. Ensure that the Mega Transfer rests safely before overriding the leg sensors. Beware that the Mega Transfer leg has a different movement pattern compared to a standard support leg. If the side loader is equipped with two different leg types in front and rear, be careful when operating both legs at the same time. Meaning of symbols on handheld controls when manoeuvring the Mega Transfer (std Stabilizer leg in parenthesis.) MEGA TRANSFER Hook leg out (STABILIZER LEG Extend) MEGA TRANSFER Hook leg in (STABILIZER LEG Retract) MEGA TRANSFER Middle leg up (STABILIZER TILT Raise) MEGA TRANSFER Middle leg down (STABILIZER TILT Lower) MODEL 110 Page 39

41 Model 110 consist of two parts, middle leg and hook leg. The design allow the stabilizer legs to be used in two ways. The Mega Transfer usage allows the stabilizer legs to reach the ground on the other side of the trailer/rail wagon that shall be loaded/unloaded. For safety reasons, the Mega Transfer is equipped with two proximity switches (sensors) that ensure that both Middle Leg and Hook Leg is extended before lifting commences. The Mega Transfer allows loading and unloading while the trailer which the container shall be transferred to/from, is still attached to the truck. If there isn t enough space or if it for other reasons is unsuitable to use the stabilizer legs in a Mega Transfer position can stabilizer legs be used as model 160 stabilizer legs. No action is needed from operator to switch between these two alternatives. Safety system recognize stabilizer legs position and allow lifting behavior according to situation. Note that the lifting capacity is reduced depending on usage of stabilizer leg and how far from the side loader the leg is supported. See lifting diagram placed on rear crane. Page 40

42 Crushing risk when retracting the hook leg. Do not enter the handling area while the side loader is powered. Beware that the Mega Transfer leg has a different movement pattern compared to a standard support leg. If HAMMAR is equipped with two different models of stabilizer legs use caution when both stabilizer legs is manoeuvred simultaneously. 6.2 HAMMAR SAFETY HOOK The HAMMAR safety hook is designed in such a way that it always hangs backwards when it is not attached to any corner fitting. This prevents it from accidentally hooking onto the trailer frame, for example. The hook has a right-hand and left-hand design, and is so small that it is possible to handle containers standing only 75 mm apart. The lifting capacity per hook is 12.5 metric ton maximum ATTACHING THE HOOKS Be careful not to mix up right-hand and left-hand hooks the lifting chains must not be twisted in any way. For shortening of the chain, only shortening hooks specially designed for the purpose shall be used. Page 41

43 The chains must be well protected against sharp objects. Emergency stop must be activated if attaching hooks under hanging crane parts. Attach the hooks to the container as shown in the figure below. 6.3 LOADING CONTAINER (WITH CHAINS) Never lift the container beyond the container stop on the nonlifting side. Never lift a platform or container further out from the HAMMAR than necessary. In order to reduce the stresses in the cylinder and avoid unnecessary swaying when the container is being lifted alongside the HAMMAR, consider not running out the lower arm completely. o Ensure that all container locks are in unlocked position. o Extend the support legs. o Extend the lower arm so that the load axle is placed in front of the center of the container. o Attach the container hooks, using the holes on the ends of the container. o Retract the lower arms and extend the upper arms until all chains are equally stretched. This prevents the container from being pulled sideways on the ground when lifting commences. Observe the load chart. o Lift the container with the upper arms and the lower arms alternately. o Retract the lower arms so that the container hangs approximately 0.2 m directly above the HAMMAR twist locks. Let the container rest against the container stops on the non-lifting side. o Lower the container onto the twist locks using the upper arms and the lower arms. In some situations the operation may proceed more smoothly if one crane is operated at a time, so that for example the container is first placed on the rear container locks and then on the front ones. Page 42

44 o Fold the upper and lower arms completely. o Retract the stabilizer legs completely. o Lock the container locks. User Manual When the lift is performed the crane arms and legs should be in its transport position, then the HAMMAR is ready to go. Ensure that the chain or hook does not get pinched when the crane folds. This is especially important on the crane 130 that folds much. Utmost caution UNLOADING CONTAINER (WITH CHAINS) o Park the HAMMAR next to the place, trailer or railway carriage where/on which the container is going to be unloaded. o Check that the ground is suitable. If required, use support plates. o Unlock the container locks and make sure that the HAMMAR hooks are correct. o Run out the support legs so that they stand firmly on the ground. o Raise the lower arms slightly and then the upper arms until the container is lifted up on the lifting side. o Run out the lower arms until the container is hanging completely away from the HAMMAR, maximum distance between the HAMMAR and the container 0.4 m. o Lower the container by lowering the upper arms and extend the lower arms. o When the container has reached the ground, trailer or railway carriage, extend the lower arms completely. o Detach the HAMMAR hooks by dragging the chains against the containers outer edge. o Fold the upper and lower arms completely. o Retract the stabilizer legs to its transport position. o Place the HAMMAR hooks on their holders. o The HAMMAR in now ready for new assignments. If the cargo is unloaded from the HAMMAR with other lifting equipment, make sure that container locks is unlocked and the Hammar safety hooks is uncoupled. Ensure that the chain or hook does not get pinched when the crane folds. This is especially important on the crane 130 that folds much. Utmost caution 6.4 SPREADER With a spreader the container is lifted by its upper corner fittings. Page 43

45 The correct position of the spreader on the container is given by four sensors; unless all four sensors are activated, the spreader twist locks cannot be locked/unlocked. An indicating flag is fitted to each of the twist locks so that the driver can see whether they are open or locked. The flag points in the direction of travel of the vehicle when the twist locks are open. In its transport position the spreader must be secured with the chain provided. 6.5 LOADING CONTAINER (WITH SPREADER) The spreader in its transport position. The spreader in its position for uncouple/couple the suspension chain. o Extend the support legs. o Release the spreader from the suspension chain by extending the upper arm cylinder, until the spreader hangs horizontally. Uncouple the suspension chain, front and back. Hang the chains on the upper arms of the HAMMAR. o Extend the lower arms so that the load axle is in front of the centre of the container. The spreader should rest on the container and the spreader twist locks should be in the corner fittings. o Lock the twist locks and check thoroughly that all are in fact locked. The lift is performed in the same way as with chains, see previous section. When the lift is performed the crane arms and legs should be in its transport position, then the HAMMAR is ready to go. Page 44

46 6.5.1 UNLOADING CONTAINER (WITH SPREADER) User Manual o Park the HAMMAR next to the place, trailer or railway carriage where/on which the container is going to be unloaded. o Check that the ground is suitable. If required, use support plates. o Unlock the container locks on the trailer. o Make sure that the spreaders container locks is in locked position. The lift is performed in the same way as with chains, see previous section. o When the container has reached the ground, trailer or railway carriage. Unlock the container locks on the spreader. o Raise the upper arms so that the locks on the spreader are free from the container. o Fold the lower arms completely. o Attach the spreader to the upper arms with the suspension chains o Fold the upper arms until the spreader is in its transport position. o Retract the stabilizer legs to its transport position. o The HAMMAR in now ready for new assignments. 6.6 STACKING OF CONTAINERS A HAMMAR equipped with stacking capability is designated H in the model number. Stacking of one container on top of another may only be performed with a HAMMAR which bears this designation. When stacking, the permitted lifting capacity is reduced. Always use the extra stabilizer leg on the side opposite to lifting when stacking. Extreme caution must be taken when stacking as the container may easily start swaying. For safer handling when stacking, we recommend that stacking twist locks are placed on the lower container. Put the container down directly over the lower container, with the corresponding corner fittings directly over each other. On delivery of a HAMMAR with stacking capability a ladder is always included. Use this when necessary for attaching container hooks etc. Page 45

47 Always use extra stabilizer legs when stacking. 6.7 TIPS FOR LOADING IN A SLOPE For information regarding the maximum permitted inclination see separate Chapter. When loading a container in a slope, the container slopes towards the crane which stands lowest. In order to get in between the cranes, that side of the container which is lowest must be lifted first. Follow the section on loading of containers together with the following additional advice. o When the bottom of the container is level with the HAMMAR twist locks, retract the lower arm of the crane which stands lowest in order to move the end of the container in over the HAMMAR. o If the container still slopes towards the crane standing lowest and it is not possible to move the container in above the HAMMAR, raise the upper arm of that crane which stands highest. o When the container is turned to the extent that it may pass the lower crane, both cranes shall be operated until half the container is positioned over the HAMMAR. o Then operate only the lower arm of the crane which stands highest until the container hangs parallel to the HAMMAR. o Carefully lower it onto the twist locks. Use the same procedure in reverse when unloading in a slope. Something to consider when operating in a slope, particularly when handling tank containers, is that the displacement of the load may start the container swinging. Also, pay attention to the chains on the lowest standing crane and make sure that they do not become caught in any way. 6.8 TWIST LOCKS When the lifting operation is completed it is most important to remember to check the twist locks. Get into the habit of checking Page 46

48 these in a particular sequence, otherwise there is a considerable risk that one of them might be overlooked. This check should be carried out in all cases of lifting, both before and after. 7 OPTIONS 7.1 AUTOMATIC TWIST LOCKS With the automatic twist locks option, the locks are operated by air cylinders and opened automatically when the PTO (the power take off) is engaged, and are locked when the PTO is disconnected. If the HAMMAR is provided with the PowerPack option, the locks are opened and closed when its ignition is turned on and off. For more information about operating the PowerPack see separate Chapter. If the PowerPack is started via remote control, the automatic container locks are opened when the remote is turned on, and are locked when it is shut off. 7.2 EXTRA STABILIZERS The two extra stabilizer legs on the side opposite to lifting are fully hydraulic and controlled from the handset. Extra stabilizers shall always be used when stacking and can also be used in other situations to increase stability. Page 47

49 The extra stabilizers shall not be used for lifting the HAMMAR, their only purpose is to be extra support while lifting load. 7.3 FAST ACTING STABILIZER LEGS Certain models can be equipped with fast acting stabilizer legs. Regenerative operation of the hydraulic system increases the speed of the functions up to 50%. 7.4 AUFB In order to facilitate attachment of the Hammar hooks, the HAMMAR may be equipped with AUFB. This is a safety system that monitors the load suspended in the crane arms, and allows the crane arms to be operated unloaded without the stabilizer legs being on the ground. 7.5 EXTENSION With this option the HAMMAR is provided with a extension of the upper arms. The outreach and the handling area are thereby increased. Use of the extension reduces the lifting capacity. 7.6 HIGH CUBE STACKING The HAMMAR is supplied with a stacking capacity and is capable of stacking High Cube containers (9 6, 2896 mm). Option available on certain models. 7.7 HAMMAR MEGA REACH The HAMMAR is provided with a extension of the upper arms, in order to be able to place one or two containers in a second row, that is to say behind the first row of containers. In the first row, two fully-loaded high cube containers can be stacked one on top of the other. In the second row, two empty high cube containers can be stacked one on top of the other. Page 48

50 The lifting capacity is restricted by the safety system when using the extension, and decreases successively down to 5.5 metric tonnes. 7.8 PARALLEL SLIDE The cranes may be moved in parallel along the chassis with a loaded container in order to achieve optimized weight distribution. The function parallel slide shall not be activated while lifting, it can cause the cranes to move uneven X20' This option makes it possible to handle two 20' containers in the same operation. The beam comes in different designs, depending on model and other geometry of the HAMMAR. Container's maximum weight must not exceed 14 metric tonnes each. Page 49

51 The beams have four twist locks for securing containers during transport TWINLOCK Twinlock is used for coupling together two containers for a combined lift. The prerequisites are a maximum weight per container of 14 metric tonnes (total weight 28 metric tonnes) and a minimum container height of 8'6". For a 2x20' lift always use Twinlock on both sides of the containers. Page 50

52 7.10 SHORTENING HOOK The shortening hook is used when it is necessary to shorten the lifting chains. The chains must not be shortened in any other way CARRIAGE OF DANGEROUS GOODS European Agreement Concerning the International Carriage of Dangerous Goods by Road - ADR. HAMMARN comply with the laws relating to the carriage of dangerous goods ADR in Europe. To run ADR goods the combination must have ADR approval, even the tractor. On other markets the HAMMAR can be adapted to local regulations regarding transport of dangerous goods HAMMAR SAFETY+ HAMMAR Safety+ is an advanced PLC-monitored safety system, which further enhances safety when lifting. The mass and position of the load in relation to the trailer and stabilizer legs are continuously calculated. This prevents the development of a lifting situation which may put driver or machine of harm. If the load gets into a position in which danger may arise, the driver is only permitted to return the load to a safe position. The main features of HAMMAR Safety+ may be divided into three different areas: Page 51

53 1. Positioning of the stabilizer legs in relation to the mass and position of the load: the system automatically stops the operator from exceeding the permitted loading. This means that the operator cannot use functions which may result in the HAMMAR overturning. 2. Restriction of the HAMMAR handling area: for example, the system prevents stacking if the load mass exceeds the maximum permitted weight for stacking. The system also prevents handling in areas which may be dangerous, for example handling on the nonlifting side of the HAMMAR. 3. Weight indication: the approximate weight of the load is used to prevent overloading of the HAMMAR. The margin of error for weight indication is ±400kg. The system is equipped with a display, where a number of different variables may be read off: weight of load, distribution of weight between front and rear crane, position of load and of stabilizer legs, the total number of working hours, the number of lifts and the system voltage. The display is normally located in the HAMMAR central box. The symbols SF (Support leg Front), ESF (Extra Support leg Front), SR (Support leg Rear), ESR (Extra Support leg Rear) illuminates when the sensors on the support legs are activated. SF= Support leg Front, OK ESF= Extra Support leg Front, OK SR= Support leg Rear, OK ESR= Extra Support leg Rear, OK By using the display buttons, various pieces of information can be obtained. Not all information is available to the operator certain information is only intended for service and maintenance purposes. This button is used for accessing error messages from the front and rear crane. When the button is depressed for 3 seconds, the operator is asked: "Do you want to reset all errors?" If the answer is YES, press the OK button and the errors will be reset. If there is still an error, then an Page 52

54 error message will appear again within 10 seconds. For further fault diagnosis see the service manual. This button is used for accessing the menu system, where the current information etc. from HAMMAR may be viewed. Use this button to go back one or more steps in the menu. OK: this button is used for accepting marked menu items or selections. Use the arrows to navigate through the menu system. NEVER change any variables, unless instructed to do so by authorized Hammar personnel. Page 53

55 The central to HAMMAR Safety + is mounted in the HAMMAR central box. The operating device is connected to the socket marked Normal Use. If a critical situation arises and the HAMMAR PLC system has failed, one may resort to emergency operation. This is done by breaking the seal on the connector marked For Emergency Use ONLY and move the cable of the operating device to it. Emergency operation is just for getting out of a dangerous situation, afterward the HAMMAR shall be taken to service for troubleshooting and to restore the connector seal. Please note that, on emergency operation, all safety systems are overridden HAMMAR SAFETY+ DISPLAY LAYOUT Page 54

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57 7.13 NON LIFTING SIDE SAFETY User Manual Safety against lifting the load past the trailer center. If the load pass the center of the trailer the cranes will automatically stop, then it is only possible to run the cranes towards the lifting side HOPE HAMMAR Optical Positioning Equipment (HOPE) is an optical system which senses whether the HAMMAR is in the correct position for lifting in relation to a container standing on the ground. The accuracy is ±2cm. HOPE consists of photoelectric cell/cells and an indicator lamp, which are located on the lifting side of the HAMMAR. The sensing range of the photoelectric cells is up to approximately 6m. This range is adjustable and can if necessary be adjusted, contact Hammar in this case. The range is also dependent upon whether the target sensing area of the cell is light or dark. In a lighter area the cell can "see" further. The indicator lamp is located so that the driver can see it in his/her rear view mirror, and it switches off to on when the HAMMAR is in the correct position beside the container CAMERA(S) The HAMMAR may be fitted with one or two cameras: a rear camera and/or a side camera to find the correct position in relation to the container TAILGUARD The TAILGUARD consists of rear sensors connected to the braking system. The sensors are activated when the trucks reverse gear is engaged. They sense both moving and stationary objects, and the system automatically brakes the trailer when something is in the way. Page 56

58 7.17 POWER PACK User Manual Use of hearing protection is recommended since noise level of the engine is high. As an alternative to PTO the HAMMAR can be equipped with its own power supply. This includes a diesel engine that runs the hydraulic pump, a control box for the engine and a combined tank for hydraulic oil and diesel. The engine is placed either beside or in between the frame beams. 1. Engine 8. Ignition key 2. Main circuit-breaker 9. Hour counter 3. Battery 10. Charging 4. Tank 11. High water temperature 5. Tank filler cap, Hydraulic oil 12. Oil pressure 6. Tank filler cap, Diesel 13. Control box, Engine, Hammar Australia 7.Control box, Engine Engine start and engine stop are also possible as functions of the radio remote control system. Page 57

59 Engine start symbol Engine stop symbol For details on operation, service and maintenance, please refer to the attached material from the engine manufacturer AXLE LIFT With air suspension, axle lift can be provided on any axle. Axle lift permits the lifting of an axle when the trailer is unloaded or carries low weight SELF-STEERING AXLE If your HAMMAR has a self-steering axle, this is provided with a locking device which can lock the axle in its central position (straight ahead). In its locked position the self-steering axle may be considered as a fixed axle. Locking of the axle is activated when reverse gear is engaged (normally activated when the HAMMAR reverse lights are switched on). In certain cases it is also possible to lock the axle with a separate switch, which in such cases is located in the truck cab. In order to be able to lock the self-steering axle it must be in line with the trailer. Drive first of all straight ahead in order to get the axle in line, then activate the lock POWER STEERING Power steering offers considerable advantages, for example when reversing, as it enables the driver to steer into confined spaces. When the power steering is not in use, the axle works as a normal self-steering axle. The axle is power-steered via radio remote control system, at speeds <10 km/h. Page 58

60 HYDRAULIC POWER STEERING User Manual With hydraulic power steering of the self-steering axle, hydraulic oil pressure is taken from the truck s pumping equipment and via the valve block on the HAMMAR. PTO (power take-off) must be engaged on the truck ELECTRO-HYDRAULIC POWER STEERING With electro-hydraulic power steering of the self-steering axle, an electrically powered hydraulic pump provides the pressure for power steering. The oil in the equipment must have purity of 18/14 (ISO standard) or better LOAD INDICATION SYSTEM Equipment for monitoring the weight of the load that the HAMMAR is handling. The installed display shows the weight for front and rear crane separately, as well as the total weight. Measuring accuracy ± 400 kg AXLE PRESSURE MANOMETER With air suspension it is possible to measure the load on the axles. Since the bellows pressure is proportional to loading of the axle, the pressure is measured with a manometer graduated in metric ton SMARTBOARD SmartBoard is an option which is installed and connected directly to the trailer s braking system and air suspension. This provides access to information such as mileage, axle loads etc. See manual from manufacturer for more information. Page 59