MARCOLIN Eletta User manual

®
COVERING SYSTEM FOR TIPPER TRUCKS
Installation Manual
English
- Translation of the original instructions in Italian language -

Marcolin Covering s.r.l.
Via O. Michelin, 3
33170 Pordenone (Italia)
Tel [phone]
Fax [phone]
www.marcolincovering.it
[e-mail]
Rev. 02
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 liability 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.
ELETTA

Installation manual - Eletta®- 3
SUMMARY
Summary ........................................................................................................................3
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Ch ha ap pt te er r 1 1Introduction ...................................................................................................5
1.1 Introduction .....................................................................................................................................................5
1.2 Commitments of the machinery deliverer to the end-user..............................................................................5
1.2.1 The teaching and training course for the end-user must include the following items: ............................................5
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Ch ha ap pt te er r 2 2The Eletta®Covering System .......................................................................6
2.1 Covering system components ........................................................................................................................6
2.2 Interventions and machine modifications .......................................................................................................7
2.3 Tipper body construction features for a good installation...............................................................................7
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Ch ha ap pt te er r 3 3Eletta®Covering System installation...........................................................8
3.1 Fitting the rear tensioning plate ......................................................................................................................8
3.1.1 Informations ...........................................................................................................................................................8
3.1.2 Fitting of the rear tension plate...............................................................................................................................8
3.2 Driving system installation - electric version...................................................................................................9
3.2.1 Versatility of the covering system...........................................................................................................................9
3.2.2 Processing and preparation of the cab guard ........................................................................................................9
3.2.3 Installation of the lateral driving units - electric version ........................................................................................10
3.2.4 Motor unit installation ...........................................................................................................................................11
3.2.5 Telescoping shafts installation .............................................................................................................................12
3.3 Driving system installation - hand-operated version.....................................................................................13
3.3.1 Versatility of the covering system.........................................................................................................................13
3.3.2 Processing and preparation of the cab guard ......................................................................................................13
3.3.3 Installation of the side transmission groups for hand-operated control ................................................................14
3.3.4 Telescoping shafts installation .............................................................................................................................15
3.4 Installation of steel cables ............................................................................................................................17
3.4.1 Positioning of the covering tarpaulin ....................................................................................................................17
3.4.2 Running of the left steel cable..............................................................................................................................17
3.4.3 Cable fastening ....................................................................................................................................................19
3.4.4 Running the right steel cable................................................................................................................................19
3.4.5 Steel cables tightening up ....................................................................................................................................20
3.5 Installation of the protective casings - electric version .................................................................................21
3.6 Installation of the protective casings - hand-operated version .....................................................................23
3.7 Fastening of the operating rod (hand-operated covering system) ...............................................................25
3.8 Tarpaulin fastening .......................................................................................................................................26
3.9 Lateral hooking system for the covering.......................................................................................................27
3.9.1 Standard closure with automatic “L” hooking system...........................................................................................27
3.9.2 Hermetic closure with elastic strings ....................................................................................................................29
3.10 Electrical wiring for Eletta®Covering System.............................................................................................30
3.10.1 Motor Control Unit models description ...............................................................................................................30
3.10.2 Installation of the electrical components ............................................................................................................31
3.11 Switch panel of the machine.......................................................................................................................32
3.11.1 Description of the Motor Control Unit .................................................................................................................32
3.11.2 Emergency pushbutton key, safety shutdown....................................................................................................33
3.11.3 Control switches of the Motor Control Unit for operators ...................................................................................33
3.11.4 Description of the radio control system ..............................................................................................................33
3.11.5 Unfold the Eletta® tarpaulin for covering the tipper body...................................................................................34
3.11.6 Interruption of machine operations.....................................................................................................................34
3.11.7 How do you stop the machine in case of emergency?.......................................................................................34
3.11.8 Restoring of standard operative conditions ........................................................................................................34
3.11.9 Machine stop in safety conditions ......................................................................................................................35
3.11.10 Retraction of the Eletta®tarpaulin for uncovering the tipper body....................................................................35
3.11.11 How do I interrupt the machine operations?.....................................................................................................35
3.11.12 How do I stop the machine in case of emergency?..........................................................................................35
3.11.13 Machine stop in safety conditions ....................................................................................................................35
3.11.14 In case of empty tipper body ............................................................................................................................35
3.12 What is to be done, when the electric operated handling system does not work? ....................................36
3.12.1 Replacement of the internal fuse in emergency situation...................................................................................36
3.12.2 Motor unlocking in emergency situation.............................................................................................................36

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Ch ha ap pt te er r 4 4Accessory equipment installation..............................................................37
4.1 Automatic rear closing system..................................................................................................................... 37
4.1.1 Installation of reinforcing brackets for automatic rear closing in case of lowered cables ..................................... 38
4.2 Quick cable release system......................................................................................................................... 39
4.2.1 Installation of the rear guide pulley ...................................................................................................................... 39
4.2.2 Tightening up system .......................................................................................................................................... 40
4.2.3 Automatic “Wheel-Hooking System”.................................................................................................................... 41
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Ch ha ap pt te er r 5 5Maintenance work of the Eletta®Covering System ..................................43
5.1 Bow replacement ......................................................................................................................................... 43
5.2 Tarpaulin replacement ................................................................................................................................. 44
5.3 Steel cable replacement .............................................................................................................................. 44
5.4 Extraordinary maintenance work –Annual operations to be carried out on the customer’s covering system45
5.4.1 General tightening up of the screw connections .................................................................................................. 45
5.4.2 Checking of the conservation status of metal structure and bows ....................................................................... 45
5.4.3 Checking of the tarpaulin conservation status ..................................................................................................... 45
5.4.4 Checking of the elastic strings or the automatic safety hooks (only if installed)................................................... 45
5.4.5 Checking of the contact plates (only if installed).................................................................................................. 45
5.4.6 Checking of the sliding conditions of the covering system................................................................................... 45
5.4.7 Thoroughly checking of the pulleys ..................................................................................................................... 45
5.4.8 Replacement of broken or damaged fastening hooks on the outer board wall .................................................... 45
5.4.9 Lubricate and grease thoroughly the covering system ........................................................................................ 46
5.4.10 Filling the machine control register .................................................................................................................... 46
5.5 Troubleshooting table for electrically operated covering system................................................................. 47
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Ch ha ap pt te er r 6 6Enclosures ...................................................................................................48
6.1 Reference diagram for electrical connections ............................................................................................. 48

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Ch ha ap pt te er r 1 1 INTRODUCTION
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 Eletta® 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 application and for keeping fully functional the Eletta®
Covering System through the planned periodic maintenance.
Thank you for having chosen the Eletta® Covering System of Marcolin Covering s.r.l. !
1.2 Commitments of the machinery deliverer to the end-user
As dealer of Marcolin Covering s.r.l. your company finalizes the sale, the installation, the delivery of the covering system to
the end-user and the customer service.
The handing over procedure of the machine to the end-user is an important happening both for the dealer and the user. For
this reason, it is relevant that the selling operation is carried out with mutual understanding and collaboration.
Following operations are mandatory for the machine deliverer:
•Carrying out the teaching and training course with final examination (in oral or written form at yours own discretion) to
pass by the machine operator.
The teaching and training course can be considered as passed when the machine operator has successfully answered your
questions and has personally performed several operating cycles on the machine.
•Issuing the own EC Declaration of Conformity.
•Handing over the own EC Declaration of Conformity to the end-user (not the one issued by Marcolin Covering s.r.l.,
because it doesn’t cover any civil and criminal responsibility arising from the installation and the start-up work of the
machine).
•Handing over the user manual and any other documentation received by Marcolin Covering s.r.l. together with the
covering system to the end-user.
1.2.1 The teaching and training course for the end-user must include the following items:
The end-user has to be informed about the great importance of the following operations:
•recognizing its own machine;
•knowing well the piece parts the machine is made of and their specific function and application.
The end-user has to receive an appropriate information about following items:
•machine’s risk and danger areas;
•actions which are absolutely forbidden;
•the permitted proper handling and the prohibited misuse of the machine;
•components regarding the operational security.
The end-user has to receive proper instructions about the following activities:
•turning on and off the control switches;
•the machine working by processing some operating cycles;
•the processing of the maintenance actions permitted by the manufacturer in safety conditions (fuse replacing);
•the processing of the ordinary maintenance of the machine;
•that it is mandatory to process EVERY YEAR at least one extraordinary maintenance at the manufacturer’s workshops
or at workshops authorised by the manufacturer;
•that the end-user must keep the maintenance check register updated.
It has to be repeated several times that:
•all the instructions given during the training course can be looked up in the user manual that has to be entirely read and
learnt by the end-user before using the machine for the first time.
•that in case of selling of the machine the end-user is obliged to:
ocarry out a teaching course to the new machine owner;
ohand over this installation manual and the EC Declaration of Conformity to the new machine owner.
It is mandatory to obtain from the receiver the signed declaration “ASSUMPTION OF RESPONSIBILITY BY
ACCEPTANCE OF THE MACHINE” to find under chapter 1.8.9 of the user manual, to make a copy of it and to send it to
Marcolin Covering s.r.l. as acknowledgement of acceptance and beginning of the term of guarantee.

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Ch ha ap pt te er r 2 2 THE ELETTA®COVERING SYSTEM
2.1 Covering system components
THE INSTALLER IS OBLIGED TO KNOW THE CONTENT OF THE MANUAL HANDED OVER TO THE OPERATOR
TOGETHER WITH EACH COVERING SYSTEM AND TO OBSERVE COMPLETELY PROHIBITIONS,
REGULATIONS AND ADVICES.
Before installing the covering system, it is essential to know well its characteristics and the various elements the system is
made of.
The figure below shows the main parts making up the system.
1 - Front covering driving system (hand or motor operated).
2 - Rear cable tensioning system.
3 - Tarpaulin of variable size according to tipper body length;
4 - Covering fastening system (depending on the model, it could be supplied with a hermetic closure with elastic strings).
5 - Folding and lifting system of the tarpaulin.

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2.2 Interventions and machine modifications
WARNING!
IT IS ABSOLUTELY FORBIDDEN TO MODIFY THE MACHINE!
Whoever modifies the machine becomes its manufacturer and assumes all civil and criminal liabilities
provided by law in force.
Whoever modifies the machine assumes the obligation to issue:
•a new CE marking,
•new installation and user manuals for the end-user,
•an own EC Declaration of Conformity.
The replacement of whatever is usually called spare part is not regarded as a modification.
2.3 Tipper body construction features for a good installation
Before installing the covering system check following items:
•The linearity of all the upper edge of the tipper body.
•The accuracy of flatness between the installation area of the covering (protrusion on the front side of the tipper body,
usually called cab guard) and the remaining part of the tipper body along which the covering should slide.
•The integrity of the upper edge of the tipper body.
•The absence of any projecting element all along the upper edge.
•The absence of any sharp edge.
NO!
YES!

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Ch ha ap pt te er r 3 3 ELETTA®COVERING SYSTEM INSTALLATION
IMPORTANT!
Before starting the installation process, check the covering model at your disposal and examine
carefully any particular case that can occur.
3.1 Fitting the rear tensioning plate
3.1.1 Informations
The following description of the rear tensioning plate installation concerns the standard covering systems; in case of:
•covering systems with cable’s quick-release system for three-sided tipper
please follow the described installation process for the specific case (paragraph 4.1.1 ).
3.1.2 Fitting of the rear tension plate
The installation of the rear tensioning plate requires a special attention in order to avoid to create any obstacle for mobile
elements (i.e. tailgate with lateral opening system).
The best installation position for the plate is the one as close as possible to the rear edge, but at a sufficient distance for
avoiding to be an obstacle for hinges
WARNING!
A wrong positioning of the tension plate could cause damages for the covering or for the tipper body.
If in doubt, carry out mobility trials of the rear mobile elements to avoid unpleasant surprises.
•Drill four M10 threaded holes on the side corresponding to the holes on the plate, at
the distances shown in the figure above.
•Fasten the plate using the M10x35 countersunk screws supplied, making sure that
the tensioning screw is directed towards the front of the vehicle.
•If proper threading is made difficult because of the thickness of the metal or the type
of material (e.g., aluminium body), drill Ø 10.5 through holes and fasten the
countersunk screws using UNI 7473 galvanized M10 self-locking nuts.
Note:
During its working life the structure is subject to vibrations and stress; therefore, it is recommended to apply a medium or
strong threadlocker Loctite® liquid.
•Repeat now the plate fastening operation on the opposite board wall.
Note:
The proper fitting of the rear plates is of primary importance since it is binding for the positioning of all the
subsequent element.

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3.2 Driving system installation - electric version
The covering handling system must be placed on the front side of the tipper body next to the cab guard.
3.2.1 Versatility of the covering system
In order to meet the various market requirements our covering system has been designed and manufactured for being
installed with every kind of tipper body.
The entire system is intended for fastening with screws (supplied). It is not necessary to weld any part to the tipper body,
allowing this way an easy maintenance in case of accidental breakage.
In this manual, reference will be made to standard assembly of the covering system.
3.2.2 Processing and preparation of the cab guard
•Drill the holes (Ø 9) of the fixing seats according to the dimensions shown in the following drawings:
Right view
Superior view
right side
Superior view
MR seat
Superior view
left side
•Drill the holes (Ø 9) of the seats for the front attachment of the coverage extendable and reductor carters, according to
the measurements shown in the following drawing:
Frontal view
At this point the cab guard is ready for housing the various components as indicated below.

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3.2.3 Installation of the lateral driving units - electric version
The first elements (1 per side) to be installed on the front cab guard are the side transmission groups right and left, to be
placed on the front of the tipper.
Side transmission group - right
Side transmission group - left
•Position the unit as in figure, by joining the support plate to the side of the cab guard of the vehicle and adjacent to the
front part.
•The unit is fastened laterally with 2 countersunk screws (A) and nuts. However, if there are impediments on the side to
the correct fastening, it can be made also with the seats positioned on the upper rear part (holes for hexagonal-head
screws B) or upper front (hole C).
•Proceed fastening the element to the cab guard using the screws, washers and self-locking nuts supplied, or
alternatively (if the thickness allows it) threaded M8 and tighten the screws, making sure to insert suitable thread locker
Note:
In this case we recommend to use oil tolerant Loctite 243 medium strength, or alternatively Loctite 262 medium
strength.
At this point the first lateral transmission assembly is fastened and it is possible to proceed with the fastening of the
second.
•Proceed fastening in the same way as the previous group, paying attention to the alignment of the two groups.