MARCOLIN Sigillo User manual

COVERING SYSTEM FOR TIPPER TRUCKS
User Manual with Maintenance Register
English
- Translation of the original instructions in Italian language -

Marcolin Covering s.r.l.
Via Orefici Michelin, 3
33170 Pordenone (Italy)
Tel. [phone]
e-mail: [email protected]
www.marcolincovering.it
Rev. 09
The translation, reprinting, digital storage or any other type of storage and diffusion, even in excerpts, of this manual and its content are strictly forbidden.
Marcolin Covering s.r.l. reserves the right to make changes at any time without notice.
All mentioned product names and trademarks are exclusively owned by the respective holder.
Marcolin Covering s.r.l. took great care in editing this manual, however, the company denies responsibility for errors and omissions, if present, and for
personal and animal injuries as well as for material and environmental damages as a consequence of the application of the manual’s instructions.
This manual has been edited in accordance with the Machinery Directive 2006/42/CE.
SIGILLO

User Manual - Sigillo®- 3
SUMMARY
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Su um mm ma ar ry y . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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Ch ha ap pt te er r 1 1I In nt tr ro od du uc ct ti io on n a an nd d i in nf fo or rm ma at ti io on ns s. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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1.1 Introduction ......................................................................................................................................................................6
1.2 Explanatory convention....................................................................................................................................................6
1.3 Information on the use of the machine.............................................................................................................................6
1.3.1 Restrictions of use on the Motor Control Unit..........................................................................................6
1.4 Product warranty..............................................................................................................................................................6
1.5 Declaration of Conformity and Manufacturer’s CE Mark ..................................................................................................6
1.5.1 Facsimile of EC Declaration of Conformity..............................................................................................7
1.5.2 Facsimile of Manufacturer’s CE Marking Plate .......................................................................................8
1.6 Prohibition of putting into service .....................................................................................................................................8
1.7 General Directions ...........................................................................................................................................................8
1.8 The importance of the manual .........................................................................................................................................9
1.8.1 Adequateness..........................................................................................................................................9
1.8.2 Conservation............................................................................................................................................9
1.8.3 Comprehension .......................................................................................................................................9
1.8.4 Illustrations...............................................................................................................................................9
1.8.5 If the Manual is Lost ................................................................................................................................9
1.8.6 Conveying notions and manual, information. ..........................................................................................9
1.8.7 How do I convey notions in the correct way? ..........................................................................................9
1.8.8 How can I demonstrate that the notions have been conveyed? .............................................................9
1.8.9 Forms for conveying notions and manual .............................................................................................10
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Ch ha ap pt te er r 2 2S Si ig gi il ll lo o®
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Co ov ve er ri in ng g S Sy ys st te em m, , d da an ng ge er ro ou us s s si it tu ua at ti io on ns s
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.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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2.1 Covering System functions ............................................................................................................................................13
2.2 Covering System movements ........................................................................................................................................13
2.3 Covering System main components ..............................................................................................................................13
2.4 Danger zone, exposed person, operator: definitions .....................................................................................................13
2.5 Situations of risk and dangers for people’s health .........................................................................................................14
2.5.1 Danger of slipping and falling ................................................................................................................14
2.5.2 Danger of limb crushing and/or shearing injuries ..................................................................................14
2.5.3 Danger of crushing ................................................................................................................................15
2.5.4 Danger of crushing from the automatic rear closing system (optional) .................................................15
2.5.5 Danger of snagging and consequent danger ........................................................................................15
2.5.6 Danger of detachment and covering’s projection ..................................................................................16
2.6 Environmental and operative situations that can damage the covering .........................................................................16
2.6.1 Danger of unloading material with the covering not completely folded on the front..............................16
2.6.2 Danger of bows bending........................................................................................................................16
2.6.3 Danger of ice forming ............................................................................................................................16
2.6.4 Wind dangers.........................................................................................................................................17
2.7 What has not to be done with the covering ....................................................................................................................17
2.8 Residual risk ..................................................................................................................................................................18
2.9 Safety services and documentation provided to the user...............................................................................................18
2.9.1 Training course ......................................................................................................................................18
2.9.2 User manual delivery .............................................................................................................................18
2.9.3 Safety signs and signals on the machine ..............................................................................................18
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Ch ha ap pt te er r 3 3O Op pe er ra at ti io on n o of f t th he e m ma ac ch hi in ne e . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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3.1 Manually-operated version.............................................................................................................................................20
3.1.1 Unfolding the Sigillo®for covering the tipper body ................................................................................20
3.1.2 Folding the Sigillo® for uncovering the tipper body...............................................................................20
3.1.3 In case of empty tipper body .................................................................................................................20
3.2 Electrical-operated version ............................................................................................................................................21
3.2.1 Description of the Motor Control Unit (MCU).........................................................................................21
3.2.2 Emergency pushbutton key, safety shutdown.......................................................................................21

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3.2.3 Control switches of the Motor Control Unit for operators ..................................................................... 21
3.2.4 Description of the radio remote control................................................................................................. 22
3.2.5 Unfolding the Sigillo®covering for covering the tipper body................................................................. 22
3.2.6 Interruption of machine operations ....................................................................................................... 22
3.2.7 How do I stop the machine in case of emergency?.............................................................................. 23
3.2.8 Restoring of standard operative conditions .......................................................................................... 23
3.2.9 Machine stop in safety conditions......................................................................................................... 23
3.2.10 Folding of the Sigillo®tarpaulin to uncover the tipper body ................................................................ 23
3.2.11 How do I interrupt the machine operations?....................................................................................... 24
3.2.12 How do I stop the machine in case of emergency?............................................................................ 24
3.2.13 Machine stop in safety conditions....................................................................................................... 24
3.2.14 In case of empty tipper body............................................................................................................... 24
3.3 Using the optional accessories (if installed)................................................................................................................... 24
3.3.1 Automatic rear closing device............................................................................................................... 24
3.3.2 Steel cable quick release device .......................................................................................................... 24
3.4 What has to be done if the covering does not work electrically? ................................................................................... 25
3.4.1 Check and replacement of the internal fuse in emergency case.......................................................... 25
3.4.2 Unlocking the motor in an emergency situation.................................................................................... 26
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Ch ha ap pt te er r 4 4M Ma ai in nt te en na an nc ce e w wo or rk k o of f t th he e S Si ig gi il ll lo o®
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C Co ov ve er ri in ng g S Sy ys st te em m . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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4.1 Introduction.................................................................................................................................................................... 27
4.2 Safety Norms................................................................................................................................................................. 27
4.3 Instructions on washing the machine............................................................................................................................. 27
4.4 Ordinary maintenance ................................................................................................................................................... 28
4.4.1 General tightening up of the screw connections................................................................................... 28
4.4.2 Check the conservation status of metal structure and bows ................................................................ 28
4.4.3 Check the tarpaulin conservation status............................................................................................... 28
4.4.4 Check the cables’ tensioning and conservation status......................................................................... 28
4.4.5 Lubricate and grease ............................................................................................................................ 29
4.4.6 Check the elastic strings with hooks or the automatic lateral hooks (only if installed) ......................... 30
4.4.7 Replacement of broken or damaged fastening hooks on the outer board wall (only if installed) ......... 30
4.4.8 Check the contact plates (only if installed) ........................................................................................... 30
4.4.9 Check the sliding paths of the covering................................................................................................ 30
4.4.10 Check the pulleys ............................................................................................................................... 31
4.5 Ordinary maintenance that can be carried out exclusively by operators equipped with the installer’s manual .............. 32
4.5.1 Bow replacement .................................................................................................................................. 32
4.5.2 Tarpaulin replacement .......................................................................................................................... 33
4.5.3 Steel cables replacement ..................................................................................................................... 34
4.5.4 Repositioning the covering ................................................................................................................... 41
4.6 Troubleshooting table for electrically operated covering system ................................................................................... 42
4.7 Extraordinary maintenance work ................................................................................................................................... 43
4.8 Important information for the machine management ..................................................................................................... 43
4.8.1 Machine disassembly and demolition................................................................................................... 43
4.8.2 Machine noisiness ................................................................................................................................ 43
4.8.3 Vibrations .............................................................................................................................................. 43
4.8.4 Modifying the machine.......................................................................................................................... 43
4.8.5 Transporting the covering ..................................................................................................................... 43
4.8.6 Maintenance register, maintenance tables........................................................................................... 43
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Ch ha ap pt te er r 5 5M Ma ac ch hi in ne e m ma ai in nt te en na an nc ce e r re eg gi is st te er r . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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5.1 Introduction to the maintenance register ....................................................................................................................... 44
5.2 Ordinary maintenance register ...................................................................................................................................... 44
5.2.1 List of operations .................................................................................................................................. 44
5.2.2 Register of the maintenance intervention carried out on the machine ................................................. 44
5.3 Yearly extraordinary maintenance register .................................................................................................................... 46
5.3.1 Authorised workshops, retail outlets, spare parts, customer assistance and installation .................... 46
5.3.2 List of operations to be carried out by the authorised workshop .......................................................... 46
5.3.3 Register of annual checks carried out .................................................................................................. 47
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Ch ha ap pt te er r 6 6E En nc cl lo os su ur re es s . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
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User Manual - Sigillo®- 5
6.1 Reference diagram for electrical connections ................................................................................................................48
6.2 Printouts for certifying the training course completion ...................................................................................................49

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Ch ha ap pt te er r 1 1 INTRODUCTION AND INFORMATIONS
1.1 Introduction
Load securing, for example of aggregates, during the freight transport on road is required by law.
Marcolin Covering s.r.l. has developed and patented the Sigillo® Covering System, which fulfils the legal obligation and
satisfies practical and functional needs of its user.
This manual provides all the necessary instructions for a safe use and for keeping fully functional the Sigillo®Covering
System.
Thank you for having chosen the Sigillo®Covering System of Marcolin Covering s.r.l.!
1.2 Explanatory convention
When equipped with the electric device with radio remote control, the covering becomes a “machine” moved by a different
energy than the human force. For exposition convenience, all along this manual the synonym “machine” refers to the Sigillo®
Covering System.
1.3 Information on the use of the machine
The machine was built for operating in environmental temperatures between –10° C and + 40° C. For any other climatic
condition, ask the manufacturer for instructions. The machine’s operational function is confined to cover the tipper body to
prevent material from falling out during road travel.
The covering equipped with electric driving system has to be powered up only when the vehicle is stationary.
1.3.1 Restrictions of use on the Motor Control Unit
WARNING!
It is absolutely forbidden to use the Motor Control Unit when the vehicle is moving.
The constructor declines any responsibility.
Any other use is defined as “IMPROPER USE”. The machine’s “lifecycle” depends on the frequency of its use and the
preservation status in which it is maintained.
1.4 Product warranty
The covering is supplied according to the contractual warranty conditions stipulated at the time of purchase. The warranty
consists in supplying and replacement of components that cannot be used because of an ascertained material’s flaw and the
repairing of those pieces that are defective: the examination of the defects and their causes it is exclusively carried out by
the manufacturer.
The component’s replacement is made by using exclusively original spare parts.
Any delays do not give the buyer the right to claim for damages, nor to extend the warranty. The warranty ceases if the
machine is used in a manner not conform to these conditions or to the manufacturer’s instructions and if parts are
disassembled, repaired or replaced without the manufacturer’s authorisation.
The manufacturer is exempt from all responsibility and obligation for any accident or damage to people, objects, animals and
environment which could occur for or during the use of the vehicle supplied for installation, that is, also during testing and
even if the accident was caused by a fault in building or materials.
1.5 Declaration of Conformity and Manufacturer’s CE Mark
In compliance with the Machinery Directive 2006/42/EC, which, in Annexes IIA and III, contemplates the declaration of
conformity and the CE marking of the machine, here follows the facsimiles of the EC Declaration of Conformity and the CE
marking plate attached to the machine.
The Declaration of Conformity signed by the legal representative of the MARCOLIN COVERING s.r.l. is handed over
conjointly with the machine.

User Manual - Sigillo®- 7
1.5.1 Facsimile of EC Declaration of Conformity

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1.5.2 Facsimile of Manufacturer’s CE Marking Plate
As provided by the Machinery Directive 2006/42/EC, the machine
displays in a visible, legible and indelible way an affixed plate with
the following data:
•Name and address of the manufacturer.
•CE Marking (according to the Machinery Directive, annex III).
•Label of the machine’s type and serial number.
•Year of manufacturing.
1.6 Prohibition of putting into service
The machine cannot be put into service after being subjected to constructive modifications or component’s additions not
concerning the planned or extraordinary maintenance, if not declared in conformity with the 2006/42/EC Machinery Directive
and the other applicable EC directives.
WARNING!
IT IS ABSOLUTELY FORBIDDEN TO MODIFY THE MACHINE!
Whoever modifies the machine becomes its manufacturer and assumes all civil and criminal liabilities
provided for by law in force.
Whoever modifies the machine assumes the legal obligation of issuing a new CE Marking, new
installation manual and user manual for the end user and an own EC Declaration of Conformity.
The replacement of whatever is usually called spare part is not considered as a modification.
1.7 General Directions
WARNING!
It is forbidden for personnel unable to absorb and understand the contents of this manual to
operate the machine.
Before working with the machine, operators, maintenance personnel and those authorised to use it are required to know the
contents of this manual.
•The owner of the machine is committed to personally check that people in charge are adequately trained.
•The owner of the machine is committed to make sure that the above instructions are applied.
•Personnel in charge of operating and maintaining the machine must be equipped with clothing that is suited to the
operations that needs to be carried out.
•Personnel are committed to observing any warning, danger and obligation signs on the machine.
•Personnel must reflect physical and moral qualities such to gain the employer’s full trust for taking the responsibility of
using the machine and must not partake of drugs, alcohol or medicine which could cause drowsiness, slow reflexes or
loss of balance.
•The machine must only be used for the operations for which it was designed and built for. The manufacturer declines all
responsibility for any different use than what described in this manual, both during the warranty than afterwards.
•Personnel must not tamper with protections and safety devices.
•For the machine to work at is best and for the longest time, the user must make sure that maintenance is carried out at
the intervals shown in the specific sections of this manual and record the maintenance done in the respective tables of
the maintenance register. If the machine works in extreme conditions or is subjected to work overloads, intervals
between maintenance must be reduced.
•Adjustments and repairs must only be carried out by qualified personnel.

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1.8 The importance of the manual
1.8.1 Adequateness
The manufacturer always tend to improve the product; it is therefore possible that a component in your machine may be
changed in future machines. This does not lead to your machine’s operating system to become inadequate; you may ask for
adaptation to the manufacturer only in case of inconsistency. In all other cases, the manufacturer is not obliged to update
plants or manuals.
At the precise historical-technical moment of the machine’s construction, the installed operating and safety systems, the CE
Certification and Marking ensure the respect of the directions of the MACHINE DIRECTIVE.
1.8.2 Conservation
The manual has to be kept in a protected dry area, away from atmospheric agents (water, sun) or worse, fire. The manual is
an integral part of the machine; it must be easily found for immediate consultation when necessary.
1.8.3 Comprehension
In case of doubt or difficulty in interpreting the subject matter of this manual, the machine does not have to be used; ask for
an explanation on the matter and, when still in doubt, attend a brief training course at the manufacturer’s premises.
1.8.4 Illustrations
Some of the illustrations in this publication may show components or accessories that are different from those assembled on
your machine: this is due to the product’s continuous improvement. In the illustrations, protections and covers may be
removed to help clarify communication. The MANUFACTURER reserves the right to carry out changes to the machine and
the contents of this manual without prior notice.
1.8.5 If the Manual is Lost
Given its importance to operational safety, in our opinion the manual should be kept constantly inside the machine. If the
manual is lost, the operator is obliged to notify the safety manager immediately, who will then request a copy from the
manufacturer.
1.8.6 Conveying notions and manual, information.
We would like to inform the user that one of the main causes of accidents at work is the lack of information on the machine
that the new operator is about to run. This manual must always be with the covering and its contents must be illustrated
when the operator changes and when the vehicle onto which the covering is installed is sold.
1.8.7 How do I convey notions in the correct way?
For a proper transfer of notions:
•Instruct the new operator (or the new owner, in the case of sale) on all aspects concerning operations;
•Specifically highlight the components relative to operational safety;
•Carefully notify them the machine’s dangers;
•Hand the manual over to the new operator (or new owner), highlighting the contents in detail;
•In the event of yield to the new owner, also hand over the Manufacturer’s Declaration of Conformity and highlight the
presence of the plate with the marking;
•Make sure that the new operator (or owner) has completely understood the instructions and that there are no doubts on
how the machine works.
1.8.8 How can I demonstrate that the notions have been conveyed?
Considering the great importance of assuming adequate knowledge of the machine and that the operator is no longer
responsible for it in the instant that they cease to operate it, we considered worthwhile to insert some forms drawn up in a
suitable manner and aimed at witnessing the occurrence of and correct withdrawal of the machine at the manufacturer’s
premise (declaration of responsibility) and of the conveyance carried out between operators and owners (declaration of
training course completion –see paragraph 6.2).

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1.8.9 Forms for conveying notions and manual
DECLARATION OF ASSUMPTION OF RESPONSIBILITY
WHEN TAKING POSSESSION OF THE MACHINE
The undersigned Mr./Mrs: ......................................................................................................................................
resident in: ..................................................................
postcode: ...........................
address: .....................................................................
no.: .......................................
phone / mobile: ..........................................................
fax / e-mail: ......................................................
AS:
❑OWNER OF THE VEHICLE
❑OPERATOR AUTHORIZED BY THE OWNER OF THE VEHICLE
❑DEALER (OR SALESMAN)
❑FINANCIAL DELEGATE
❑...................................................................................
DECLARES, UNDER ITS OWN RESPONSIBILITY:
to have received and understood enough instructions on the functioning of the machine;
to have received and took the instruction manual and to commit himself to understanding its contents before using
the machine for the first time;
by the manufacturer of the Covering System mod.:
company Marcolin Covering s.r.l.
COMMITS HIMSELF ALSO TO THE CONVEYING OF NOTIONS
AND TO THE DELIVERY OF THE MANUAL TO HIS SUCCESSOR OR NEW OWNER.
IN WITNESS
IN WITNESS
MARCOLIN COVERING S.r.l.
The legal representative
Who is taking possession of the machine
...........................................................................
Date: ......................................