Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
1
OPERATING & MAINTENANCE MANUAL
SwingLift
KJ, ML, F500, FV500, CC, MC, GBC
Page 1: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 1 OPERATING MAINTENANCE MANUAL SwingLift KJ ML F500 FV500 CC MC GBC...
Page 2: ...mounted and operated by hold to run controls with all functions being protected by inbuilt overload features and powered by the vehicle s battery We strongly recommend that an operator of any crane i...
Page 3: ...ontract 16 Typical Wiring Layout 17 Overload Setting 17 EC Declaration of Conformity 18 SwingLift Knuckle Joint Range 19 KJ250 1 Exploded View 20 KJ250 1 Parts List 21 KJ250 1 5 2 Exploded View 22 KJ2...
Page 4: ...commended Lubricants 42 Electrical Hydraulic Operation 43 Electrical Schematic 44 Hydraulic Schematic 45 Technical Data 46 Terminal Disposal 46 Fault Finding 47 SwingLift MC250 48 MC250 Parts list 49...
Page 5: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 5 Safety Warning...
Page 6: ...ent Do not interfere with the factory settings Do not modify or re install the crane without seeking guidance from Penny Hydraulics Ltd Only use correct and certified lifting accessories Any lifting o...
Page 7: ...ments are valid and up to date Ensure that the report of thorough examination does not exceed 12 months for the crane and 6 months for the associated lifting accessories 3 Ensure the vehicle is on fir...
Page 8: ...on with the rope attached to the retaining eye and all the locking devices firmly secured 15 Ensure the support leg s is withdrawn and secured and detach any controls and store securely Fault Finding...
Page 9: ...d conform to LOLER Please see the Service Contract enclosed The following Planned Maintenance schedule is to ensure the continued safe working order of the crane and includes a thorough examination by...
Page 10: ...off paying particular attention to the slew areas required for dynamic testing On receipt of a new crane and before it is put into service check that there is no transit damage or evidence of mishand...
Page 11: ...the vehicle in a safe working area with the support leg firmly set if necessary Cordon off the area with appropriate barriers and work in progress signs 2 Prepare the required test weight equal to th...
Page 12: ...he crane is fitted to a new or modified structure After any modifications have been carried out to the crane or support structure Following any incident which may have caused damage to the crane or it...
Page 13: ...gh Examinations should be conducted at least every 12 months A thorough examination will also be required If the lorry loader is involved in an accident or dangerous occurrence After a significant cha...
Page 14: ...r inspections and report any faults found The standard contract provides for an annual service and an interim six monthly inspection or for total piece of mind we offer a Fully Comprehensive option In...
Page 15: ...unit or part has been repaired or adjusted other than by an authorised engineer Normal service repairs carried out by authorised engineers are supported by their own warranty Warranty does not extend...
Page 16: ...ion can be taken by us There will be no charge for the call out or for labour unless the problem is due to abuse or misuse Parts may be added to the next invoice due The customer will be invoiced foll...
Page 17: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 17 Typical Wiring Layout Overload Setting...
Page 18: ...rmonised Standards EN 12100 2010 Safety of Machinery General Principles for Design BS 7121 Parts 1 2 and 4 BS EN 982 Safety of Machinery EN 50081 1 1997 Electromagnetic Compatibility General Standard...
Page 19: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 19 SwingLift Knuckle Joint Range...
Page 20: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 20 KJ250 1 Exploded View 29...
Page 21: ...0033 Remote Connector Tail 1 13 108 000001 Anderson Power Connector 50A 1 14 035 000056 Joint Bearing Assembly 1 15 713 200005 Disc Spring Assembly 1 16 200 000009 Shoulder Bolt Assembly 1 17 a 077 00...
Page 22: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 22 30 011 000509 Anti luce Bracket 1 KJ250 1 5 2 Exploded View...
Page 23: ...x Caution Label 1 11 547 000033 Remote Connector Tail 1 12 108 000001 Anderson Power Connector 50A 1 13 713 200008 Anti slew Tensioner Assembly 1 14 173 000006 Rubber Holder Male Female Assembly 1 15...
Page 24: ...y Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 24 30 079 000050 Rope Hook Bulkhead Mounted Assembly 1 31 039 000002 Flanged Bush 2 KJ250 2 RPT Exploded V...
Page 25: ...y 1 11 035 000056 Joint Bearing Assembly 1 12 713 200005 Disc Spring Assembly 1 13 200 000009 Shoulder Bolt Assembly 1 14 a 077 000024 Winch Assembly 12V Left Hand LH 1 b 077 000023 Winch Assembly 12V...
Page 26: ...ithin a 15 minute period for both 12 Volt and 24 Volt winches Typical Weights SwingLift KJ250 32 5kg 100kg subject to specification including winch unit Maximum Working Load Each SwingLift KJ250 is ma...
Page 27: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 27 SwingLift Mini Loader Range...
Page 28: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 28 ML250 Assembly view...
Page 29: ...Pulley Assembly 1 7 022 000002 Ball Weight Assembly Drilled Painted 1 8 654 000008 Rope Assembly 15 4 5m x 5mm 1 9 195 000012 Solenoid Box Harness Assy 12v 1 10 077 000087 Winch Assembly Inc Motor Mi...
Page 30: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 30 ML500 Assembly view...
Page 31: ...nc Yellow 4 17 760 000033 M20 Nylon Washer 4 18 539 000091 Pin 3 4 x 4 5 Long 2 19 253 080802 M8 Nyloc Grade 8 BZP 2 20 539 000043 Lynch Pin 6mm x 45 1 21 413 060252 M6 x 25 Slotted Cheese Hd Screw 4...
Page 32: ...tion Winch Operating Temperature A range of 5 C to 30 C for both 12 Volt and 24 Volt winches Winch Duty Cycle 1 minute of continuous running within a 15 minute period for both 12 Volt and 24 Volt winc...
Page 33: ...ics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 33 Penny hydraulics will remove and dispose of the entire crane in an environmentally sound manner when required Sw...
Page 34: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 34...
Page 35: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 35 F500 Exploded View 24...
Page 36: ...Assembly 1 11 539 000145 Boom Pin Assembly Foldaway 500 1 12 539 000130 Extension Locking Pin Assembly 1 13 555 000018 Pulley Wheel Axle Assembly 1 14 077 000024 Winch Assy Inc Microswitch 12V L H 1 1...
Page 37: ...Volt and 24 Volt winches Typical Weights Standard SwingLift F500 83KG subject to specification including winch unit Maximum Working Load Each SwingLift F500 is marked individually with its maximum wor...
Page 38: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 38 FV500...
Page 39: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 39 FV500 Exploded view 68 69 69 70 70 67...
Page 40: ...r Flange 1 15 415 060252 M6 x 25 Hex Skt Hd Cap Screw 2 16 418 060202 M6 x 20 Hex Skt Csk Hd Screw 3 17 035 000067 Motor Flange Bush 2 18 770 06SC02 M6 Spring Washer 6 19 002 000152 Lift Ram Assy 1 20...
Page 41: ...S P Bonded Seal 2 52 303 08081L 8L Standpipe 90deg Swivel Elbow 2 53 309 000004 8L Compression Nut 4 54 045 000194 Return Pipe DCV to Power Pack 1 55 045 000193 Feed Pipe Power Pack to DCV 1 56 301 20...
Page 42: ...Recommended Lubricants Description Part No Qty Rope Hook Assembly As Specified 2 Solenoid As Specified 1 Handset Plug Assembly As Specified 1 Rope Pulley 555 000001 1 Wear Pad 057 000055 2 DUTY LUBRIC...
Page 43: ...k to start and stop with a signal from each individual button The main power supply to the power pack is controlled by a solenoid sited on the power pack Pressure to the hydraulic lift ram is adjusted...
Page 44: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 44 Electrical Schematic...
Page 45: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 45 Hydraulic Schematic...
Page 46: ...oth 12 Volt and 24 Volt winches Typical Weights Standard SwingLift FV500 85kg subject to specification Maximum Working Load Each SwingLift FV500 is marked individually with its Maximum Working Load No...
Page 47: ...Clean All Earth Terminals Crane will slew and lower but will not lift Crane overloaded Remove some of load Clicking sound from Power Pack compartment but no hydraulics working As above Faulty Power P...
Page 48: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 48 SwingLift MC250...
Page 49: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 49 MC250 Exploded view...
Page 50: ...ted Cheese Hd Screw 4 8 BZP 4 16 770 06SC02 M6 Spring washer BZP 4 17 555 000001 Pulley 70 x 42 x 17 1 18 539 000131 Pulley Axle 5 8 BSW x 3 25 BZP 1 19 760 000002 M16 Nylon Washer 2 20 250 000001 5 8...
Page 51: ...running within a 15 minute period for both 12 Volt and 24 Volt winches Typical Weights Standard SwingLift crane 60kg subject to specification including winch unit Maximum Working Load Each CC MCC is m...
Page 52: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 52 SwingLift Gas Bottle Crane...
Page 53: ...104 Service Kit Support Bearings 1 4 085 000026 Flipper Arm 1 5 692 000005 Limit Switch Long Lever 1 6 654 000021 Rope Assembly 15 x 5mm Special 1 7 123 000068 Cover Micro Switch Gas Bottle Cane 1 8 0...
Page 54: ...running within a 15 minute period for both 12 Volt and 24 Volt winches Typical Weights Standard SwingLift crane 60kg subject to specification including winch unit Maximum Working Load Each GBC is mark...
Page 55: ...ng the use of work equipment have received adequate training in method risk and precautions Penny Hydraulics offers nationwide training by qualified instructors for the full range of lifting equipment...
Page 56: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 56 Work Record Date Work Done remarks Engineer Company...
Page 57: ...Penny Hydraulics Ltd Operating Maintenance Manual VME SwingLift Cranes KJ ML F500 FV500 CC MC GBC 57...
