Operating manual Lifting device for standard removable versions Type 1889 haacon hilft heben haacon hebetechnik gmbh Josef-Haamann-Str. 6 D-97896 Freudenberg/Main Tel: +49 (0) 93 75/84-0 Fax: +49 (0) 93 75/84-66 e-mail: haacon@haacon.de Internet: www.haacon.de 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466
Content 1. Safety instructions...3 2. Technical data...5 3. General...6 4. Structure...6 5. Delivery...6 6. Mounting the lifting device...7 7. Operating...9 8. Servicing...9 9. Spare parts... 10 10. Electric drive unit for lifting device Type 1889 (optional)... 12 10.1 Technical data... 12 10.2 Structure... 12 10.3 Delivery... 13 10.4 Mounting... 14 10.5 Operating... 14 10.6 Spare parts... 15 This operating manual is to be kept on the lifting device. It must be ensured that everybody who must complete work on the lifting device can examine this operating manual at any time. In addition, the operating manuals described in the Safety of Work Law and the Equipment Usage Directive must be provided. All safety and operating notice signs on the machine are to be kept in a clearly legible condition at all times. Damaged or illegible signs are to be replaced immediately. 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 2
1. Safety instructions Duty of care of the operator The lifting device Type 1889 has been designed and built to after the careful selection of the harmonised standards with which it must comply and other technical specifications. It is therefore state of the art and offers maximum safety. However, this safety level can only be achieved in practice if all the action required for it is actually taken. It is a matter for the operator of the lifting device to plan this action and to check that it is implemented. The operating must in particular ensure that the lifting device is only used for the purpose for which it is design (see the section entitled General). the lifting device is only operated if it is in perfect working order and special safety equipment is checked regularly to ensure that it remains fully functional. the operating manual is available at the place of use of the lifting device at all times in legible condition. only suitably qualified and authorised personnel is allowed to operating, service and repair the lifting device. this personnel is instructed at regular intervals in all matters of industrial safety and environmental protection and that they are familiar with the operating manual and the safety instructions contained there in. all the safety and warning notices on the lifting device remain on the device and are kept in legible condition. nobody is on, in or under the container with the mounted lifting device during the lifting or lowering procedure. persons only enter the system if the distance between the bottom of the container and the ground is less than 400 mm or load holders are fitted to act as additional safety devices pursuant to VBG 14. exceed the maximum angle (see section entitled Other instructions). set up the device in wind speeds in excess of 64 kph. You must also ensure that if you wish to lift the maximum load the centre of gravity of the load is positioned as centrally as possible between the supports. Requirements on the operating personnel The lifting device Type 1889 may only be operated by people who have been trained, instructed and authorised to do so. These people must be familiar with the operating manual and act accordingly. The authority of the operating personnel must be defined clearly. Damage or defects on the lifting device are to be reported to the appropriate person without delay. Do not work with the lifting device until the damage or defect has been rectified. Servicing and repair work Servicing and repair work may only be completed by trained personnel. Do not make any unauthorised modifications to the lifting device for safety reasons this particularly applies to welding work on load-bearing parts. All planned modifications must be approved in writing by haacon hebetechnik gmbh. Only use original spare parts / original wear parts. These parts have been specially designed for the machine. If you use other parts it cannot be guaranteed that they are designed and built to withstand the stresses safely. Parts and special equipment that are not supplied by haacon hebetechnik gmbh have not been approved for use on the lifting device. The maintenance work set out in the operating manual (cleaning, lubrication, servicing, inspection, etc.) must be completed on schedule. Basic safety action To prevent damage and fatal injuries when operating the lifting device, do not exceed the maximum (see section entitled Technical data). allow people to ride on the device. work in, on or under the raised load if it exceeds the maximum height off the ground or load holders pursuant to VBG 14 are fitted. 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 3
Other instructions Important!. 2. 3. 4. 5. 6. Exercise great care when driving the carrier vehicle below the container. The lorry must not strike the container since otherwise there is a risk that the lifting device will bend. Have somebody guide the lorry! People must not be allow to stand in, on or under the container during the lifting and lowering procedure. People may stand on and in the raised container if it is no more than 400 mm off the ground or load holders pursuant to VBG 14 are fitted. The lifting device with a container must not be made to vibrate by means of crank impulses. The container may only be placed on solid ground by the lifting device. The area on which the container is placed or from which it is lifted must be as flat as possible. 7. The maximum angle of 2 applies to all types with a maximum load and at full lifting height. 8. If the site incline is greater than 2, all four supports must be loaded uniformly. the cab must be aligned horizontally. To eliminate the bending stress on the gear rack tubes, the stress must be removed form the supports individually. the sag of the gear rack tubes must be observed. It must be even. additional safety devices may be required if larger angles are used or the gear rack tubes are exposed to considerable sag. the centre of gravity of the container must be central. 9. Do not set up the device in storms. Length view Max. incline with a cab length, for example, of 4.25 m = 15 cm Side view Max. incline with a cab width, for example, of 2.2 m = 8 cm Figure 1-1 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 4
Technical instructions on the lifting device To prevent accidents and damage, notice signs (figure 1-2) are affixed to the landing gear (figure 1-3), and the instructions there on must be followed: figure 1-2 figure 1-3 All the safety signs and operating instruction signs on the lifting device are to be kept clearly legible at all times. Damaged or illegible signs are to be replaced without delay. 2. Technical data TYPE 1889.8 Maximum load / set t 8 Maximum load / support t 4 Weight / set approx. kg 445 Installation time / 2 men min. 10 Lifting time min. 20 Crank force / Support pair N 150 Lift / Turn of crank mm 2,82 Lift mm 1750 Design height mm 2330 Working temperature -33 C to +50 C *) Minimum design height with a lift of 1750 mm. 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 5
3. General The lifting device Type 1889 is designed to move and position containers with a maximum gross weight of 8 tonnes. It consists of four rack supports with spur gears and fold-out suspension unit. The support plate, top arm, crank handles and connection shafts are removable. To transport it the lifting device is removed and stowed in crates or in the container. The lifting device Type 1889 has a self-inhibiting spur gear, which holds the load securely at any height (you must nevertheless comply with the safety instructions). The rack supports form a stable unit with the container. The large support plates means that the device can be used anywhere in the open air where there is firm ground. The rack supports are connected using two telescoping connection shafts. They are driven in pairs using connecting crank handles. This operating manual applies to the removable standard lifting device Type 1889 for shelters and con-tainers with ISO corner fittings at the top and bottom. Supplementary operating manuals are available for these modified versions. 4. Structure The lifting device has a robust tubular steel construction. The gear rack support is a product that has proven its worth over many decades that offers a long service life and operational reliability. A removable connection shaft and a ratchet crank handle are sup-plied with each pair of supports. Accessories for retrofitting are available for all type 1889 lifting devices. The gear rack support complies with BGV D8 and the EC Machine Directive 98/37/EEC and subsequent directives. When the load holders (additional safety devices on the rack) are used with the device at a standstill the support complies with VBG 14. 5. Delivery 1 lifting device set Type 1889 consists of: 4 rack supports with fold-out suspension unit 4 top arms 4 support plates 2 telescoping connection shafts 2 Ratchet cranks 1 open-ended spanner, 30 mm Accessories (optional) Electric drive Winch Load holder VBG 14 Crank handle case extension 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 6
6. Mounting the lifting device 1. Take the crank out of its storage position and fit it on the gear. 2. Fit the top arm. 3. Align the supports individually, place them on the ground and unfold the suspension unit. 4. Support ready for mounting. 5. Raise the support until the top arm projects over the cabin. 094232_d_gb_hebvrr_s 6. Crank downwards until the journal engages in the top corner fitting and the arm sits on the cabin. haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466
7. Insert the locking bolt on the bottom support arm in the corner fitting, turn it through 90 and engage the locking lever in the mounting. 8. Turn the nut on to the locking bolt by hand and then tighten it with a 30 mm ring spanner. 9. Align the container with the crank handles until it is horizontal and insert the connection shaft. 10. Lifting device ready for use. Dismantle following the above procedure in reverse. Positioning plan connecting shaft Rear Plan view 2 1 2 1 Mark the bottom ISO corner fittings, supports and stowing device with numbers 1 and 2. Front of vehicle 1 1 direction of moving 2 2 Door side connecting shaft The positioning plan shows the numbering of supports 1 and 2 depending on the position of the ISO corner fittings on the container. The individual supports must be fitted in the order of these numbers. If the connection shaft is fitted along the longitudinal axis of the container rather than as shown on the position plan, no positioning is required. In this configuration all the supports are identical and can there-fore be interchanged. 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466
7. Operating To avoid danger for persons and the machine, before you lift a container it is essential to ensure the following The container has been released from the carrier vehicle. The rack supports have been mounted in their correct operating position. The lifting capacity has not been exceeded. Adequately compacted ground is available. To raise the container, first make sure that the gear rack supports are in contact with the ground using the ratchet cranks. Align the container by adjusting each support separately. Extend the supports with the inserted connection shafts in pairs and raise the container to the required height. 8. Servicing The lifting device Type 1889 is to be inspected by an expert at intervals that depend on the conditions in which it is used, but at least once per year (annual safety inspection pursuant to Accident Prevention Directive BGV D8, 23, Sub-Section 2). In addition to the annual inspection all the safety parts must be tested every ten years (including all gear parts such as the safety lock, etc.). We recommend that you have this safety check conducted by haacon hebetechnik gmbh. Experts are persons who, as a result of their training and experience, have adequate knowledge in the field of winches, lifting and towing equipment and are familiar with the relevant state industrial safety directives, regulations and generally acknowledged rules of engineering (for example DIN EN standards) so that they can assess the safe condition of winches, lifting and towing equipment. Servicing work Description Intervals Parts / Numbers Grease gear Depending on usage, at least every month Grease nipple Gleitmo 805 K Clean and grease gear rack Every month Steel brush,spray on Gleitmo 805 K Grease all the moving parts of the suspension construction Every quarter 55, 56, 57, 59, 69, 75 Gleitmo 805 K Fuchs Lubritech 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 9
1. Open the gear 1.1 Remove the screws (38-41) and take off the casing plate (28). 1.2 Remove the gear wheel (8), centre drive (14) and gear wheel (13). 1.3 Remove the complete crank drive (29-34). Ensure that the locking pawls (32) are installed again in the same position. 1.4 Remove the complete safety lock (19). 1.5 To remove the rack drive (7), pull out the rack to the end of the stroke since there is only a bevel on the top tooth on the rack, which allows the rack to be installed and removed. 2. Remove the rack (4) 2.1 Before pulling out the rack, remove the gear parts as described in 1.2 to 1.5. 3. Remove the arm and rack (53-67) 3.1 Drive out the clamp sleeve (68). 3.2 Remove the bolt (67). 3.3 Drive out the clamp sleeve (63). 3.4 Release the threaded hub (64). 3.5 The parts can now be removed. 4. Remove the locking bolt (36, 55-57) 4.1 Drive out the clamp sleeve (36). 4.2 Remove the handle (57). 4.3 Unscrew the nut (56). 4.4 The parts can now be removed. 5. Remove the connection shaft (110-121) 5.1 Knock out the heavy duty pins (111, 112, 114, 117, 120). 5.2 The remainder of the removal work is as shown in the exploded drawing. 9. Spare parts Only use original spare parts / original wear parts. These parts have been specially designed for the machine. If you use other parts it cannot be guaranteed that they are designed and built to withstand the stresses safely. Parts and special equipment that have not been supplied by us have not been approved by us for use on the lifting device. Please quote the following to order spare parts: Type: Factory No: Part No: Description: See model plate See model plate See spare parts list / drawing See spare parts list / drawing Spare parts list / drawing See attachments 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 0
Assemble the parts following the above instructions in reverse. 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466
10. Electric drive unit for lifting device Type 1889 (optional) Retrofit kit in the versions listed below Save time by using the motor drive unit. 20% reduced lifting times compared to manual drive. 10.1 Technical data Unit 24 V Direct current 230 V Alternating current 400 V Alternating current Rating W 2 x 700 2 x 750 2 x 750 Protection type IP 54 IP 54 IP 54 Ratio i 10 10 10 Drive speed *) min -1 140 140 140 Maximum load / set t 8 8 8 Lift / minute mm 406 406 406 Lifting time, approx. min 4:20 4:20 4:20 *) The drive speed of the electric drive unit is the same as the input speed of the lifting gear. 10.2 Structure Of the four rack support, two are powered electrically. The two passive supports can be connected mechanically using removable connection shafts in the same way as on the manual version. The container is to be raised evenly using this configuration. Control using the mobile controller. Connection for motors and limit switches The pin assignment of plug connectors A and B (connection between the controller and the support) is to be made as set out in the following table. 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 2
Unit 24 V Direct current 230 V Alternating current 400 V Alternating current Rating W 2 x 700 2 x 750 2 x 750 Protection type IP 54 IP 54 IP 54 Ratio i 10 10 10 Drive speed *) min -1 140 140 140 Maximum load / set t 8 8 8 Lift / minute mm 406 406 406 Lifting time, approx. min 4:20 4:20 4:20 The inputs for the limit switches are isolated in floating form by two optocouplers. For two of them the switch threshold can be set using trimmers. The monitor the motor temperature and thus allow PTC s to be used as a temperature sensors. If the system does not have a motor temperature monitor, pin B5 is to be connected in the plug with pin B1 (on the 230 V and 400 V version). Each motor has its own fuse. To protect the semi-conductors these fuses must only be replaced with equivalent types. On the 24 V direct current version: -10 x 38 mm, 25 A, GOULD series am for motor circuits - rated voltage 500 V, 120 ka switch rating On the 230 V alternating current version: -10 x 38 mm, 10 A, GOULD series am for motor circuits - rated voltage 500 V, 120 ka switch rating On the 400 V alternating current version: -10 x 38 mm, 6 A, GOULD series am for motor circuits - rated voltage 500 V, 120 ka switch rating The fuses for the limit switches are also inside the controller, they measure 5 x 20 mm, 1 A. The controller houses a 4-way DIP switch using which the direction of rotation of the motors can be changed if necessary. DIP 1 turns the first motor, DIP 2 the second. All the components in the controller are designed for operation in temperatures as low as - 33 C. Nevertheless in temperatures below - 20 C before you start work with the controller you should check that the joystick can be moved easily in all direction. 10.3 Delivery The electric drive unit for the lifting device Type 1889 consists of the following: 2 gear motors 1 control box 2 drive cables 2 limit switch cables 4 fitted limit switch casings 1 installation kit (connection flange, mounting bolts, etc.) 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 3
10.4 Mounting. 2. 3. 4. 5. 6. Connect the gear motors with a positive connection and so that they are protection from torsion by inserting the drive square into the mounting hole on the gear of the support marked 1 or 2. Secure the gear motors during the lifting process to prevent their coming away by inserting the locking spring in the stop bolt. Connect the connection cable for the gear motors to the corresponding connector on the support and secure it. Connect each pair of supports via a limit switch cable using a screw connector. Important: The cable ends have socket and plug connectors. Connect the drive cables to the supports marked 1 and 2 and secure them. Important: The cable ends have socket and plug connectors. Connect the drive cable to the control box and secure it. Important: Connect the drive cable from support 1 to connector 1 on the control box and connect the drive cable from support 2 to connector 2 on the control box. 10.5 Operating To avoid any risk to persons and the lifting device, before you raise the container ensure that The container has been released from the carrier vehicle. The rack supports have been correctly mounted in their operating positions. The control and power cables have been connected properly. The lifting capacity has not been exceeded. At the end of the lifting process or if it is interrupted, the main switch on the controller is always turned off. The adjustment to the ground conditions is conducted across the container by hand using the crank handle and along the container using the electric drive unit (see point 7). Do not operate the device without supervision. If the device is not in use cover the connectors with safety caps. Connect the extension cable (not supplied) for the power connection to the control box and to the power supply. Switch the main switch to "ON". You can now complete the following functions using the joystick. The operator must be positioned on the drive side of the container. Joystick up Joystick down Joystick up left downwards, or down right Joystick up right downwards, or down left Both supports move upwards. Both supports move downwards. Connection cable Locking spring Drive cable Drive square Limit switch cable The left support 2 moves upwards and the right support 1 moves the container rolls clockwise The right support 1 moves upwards and the left support 2 moves the container rolls anti-clockwise 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 4
The LED s on the control desk have the following functions GREEN Activation of the electric motors In addition on the 24 V version: If the power consumption rises to over 55 A per motor the LED will flash and the motor current will be electronically limited. ORANGE RED At least one limit switch on the supports has been tripped. Excess temperature on the power section in the controller. If the green LED is also lit, the drive has suffered an overload. 10.6 Spare parts Only use original spare parts / original wear parts. These parts have been specially designed for the machine. If you use other parts it cannot be guaranteed that they are designed and built to withstand the stresses safely. Parts and special equipment that have not been supplied by us have not been approved by us for use on the lifting device. Please quote the following to order spare parts: Type: See model plate Factory No: Part No: Description: See model plate See spare parts list / drawing See spare parts list / drawing Spare parts list / drawing See attachments 094232_d_gb_hebvrr_s haacon hebetechnik gmbh Phone +49 (0) 9375-84-0 Fax +49 (0) 9375-8466 5
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