PennyHydraulics SwingLift KJ Installation and operation manual

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

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
2
Welcome
Thank you for purchasing a Penny Hydraulics crane. This is a unique design that is built in
our factory to your specification. Each crane is tailor-made, and we trust that it meets with
your approval and provides you with a safe, efficient and trouble-free means of moving
goods for many years.
This manual explains what you need to know about the crane’s operation together with
some useful guidance on safety and general care. It also explains the servicing requirements
and the availability of a service agreement should you wish to take advantage of it. We have
our own engineers around the country lead by our Central Service Department to give an
exceptional after-sales service.
The crane will normally be vehicle 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 is trained in its use and has read all
the details set out in this booklet.
Accessories
We provide a range of lifting accessories and we can make bespoke items to suit your exact
requirements. Replacement parts if required can be purchased direct from our website –
Always confirm model and serial number when ordering spare parts.
https://shop.pennyhydraulics.com
Service
Our service contract will ensure continued, safe, reliable use of the equipment and full
compliance with current legislation. We provide a combined maintenance and statutory
inspection regime which saves time and money. With our team of service engineers across
the UK we have vans well stocked with spares enabling most visits to be a first-time fix
reducing downtime to a minimum. We understand that safe and reliable equipment is
essential to your business.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
3
Table of Contents
Welcome .................................................................................................................................................2
Table of Contents.................................................................................................................................... 3
Safety Warning........................................................................................................................................6
Method of Operation.............................................................................................................................. 7
Fault Finding............................................................................................................................................8
Maintenance ...........................................................................................................................................9
Planned Maintenance Schedule ...........................................................................................................10
Load Test Procedure .............................................................................................................................11
Commissioning......................................................................................................................................12
Penny Hydraulics Limited Warranty Policy ...........................................................................................15
Service Contract.................................................................................................................................... 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
KJ250/ 1.5&2 Parts List .....................................................................................................................23
KJ250/2 RPT – Exploded View........................................................................................................... 24
KJ250/2 RPT – Parts List ....................................................................................................................25
Technical Data – KJ Series................................................................................................................. 26
SwingLift Mini-Loader Range ................................................................................................................27
ML250 - Exploded view.....................................................................................................................28
ML250 - Parts List..............................................................................................................................29
ML500 - Exploded view.....................................................................................................................30
ML500 - Parts List..............................................................................................................................31
Technical Data – ML Series ...............................................................................................................32
SwingLift F500 .......................................................................................................................................33
F500 – Exploded View....................................................................................................................... 35
F500 Parts List................................................................................................................................... 36
Technical Data – F500 .......................................................................................................................37
FV500 ....................................................................................................................................................38

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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FV500 – Exploded view .....................................................................................................................39
FV500 – Parts List..............................................................................................................................40
Pendant Control – Standard Model ..................................................................................................42
Recommended spares ......................................................................................................................42
Recommended 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
MC250 – Exploded view.................................................................................................................... 50
Technical Data – Corner Crane Series...............................................................................................51
SwingLift Gas Bottle Crane....................................................................................................................52
GBC – Exploded View........................................................................................................................53
GBC – Parts List .................................................................................................................................53
Technical Data – Gas Bottle Crane....................................................................................................54
Training Register ................................................................................................................................... 55
Work Record ......................................................................................................................................... 56

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Safety Warning

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Safety Warning
-In the interest of safety, all personnel involved in the operation of the
crane must read and understand this manual. The personnel must be
trained and competent in the safe use of the crane. A training register is
included at the back of this manual.
-The crane must not be used for man-riding.
-Do not use the crane if not supported with valid documentation
recording a thorough examination and certificate of test, carried out by
a competent person within the last 12 months.
-The crane should be inspected every six months and serviced annually
by a competent person. See “Maintenance” in this manual for full
statutory responsibilities.
-The crane should not be overloaded. Refer to the safe working load signs
attached to the equipment.
-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 or securing attachments must be formally certified by
thorough examination every 6 months.
-Only use genuine parts and accessories.
-During the operation of the crane, access to the area should be
restricted to those personnel essential to the operation only.
-Do not leave any load suspended between lifting/lowering operations.
-All safety notes must be read and adhered to at all times.
-Keep the crane properly maintained by a competent person. See the
“Maintenance” section in this manual.
-Do not allow any person beneath a suspended or moving load.
-Isolate, immobilize and lock off the equipment before commencing any
maintenance routine. Please note that any control panel may remain
live, even when the motor is not running.
-Never interfere with the unit. It should run smoothly at all times. If in
doubt call the helpline telephone number 01246 811475.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Method of Operation
Warning, read all safety warnings and instructions carefully. Failure to do so
may result in serious injury or death.
Standard operation is via a single hold to run control station. Ensure the
person in control of the crane is in a safe position and no one should pass
them while in operation. The operation can be stopped at any time by
releasing the hold to run control.
1. Before operation, clear the operating area of any unnecessary
obstructions. Ensure that all operating instructions are read
and understood.
2. Check and ensure that the necessary documentation for the crane and
lifting attachments 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 firm and level ground with the handbrake
applied and wheel chocks deployed where necessary.
4. Before operating check for potential hazards such as: overhead electric
wires, nearby structures, public roads or paths, railways or rivers. Also
pay attention to any underground services, e.g. gas, electric, drainage.
5. Wear any PPE equipment required or stipulated by your employer
or the risk assessment.
6. Extend the support legs (if required) and adjust to ground level using a
suitable spreader pad if necessary.
7. Check the power connector from the vehicle is firmly in place. Plug in
the pendant control to the control box if button operated.
8. Check for any visual signs of defects or malfunction.
The Crane is now ready for use.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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9. Using the hold to run controls, lower the rope and release the hook from
the retaining eye. Release any other stowage catches and deploy the
crane.
10. Attach the load to the hook using suitable certified attachments only.
11. Carefully manoeuvre the load into position remaining alert at all times.
12. Keep clear of the suspended load as much as practically
possible, but do not leave the load suspended or attached
unattended.
13. Do not drive the vehicle with a suspended load or drive with
the support legs in the down position.
14. On completion of the operation ensure the crane is folded into the
travelling position 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
FAULT
CAUSE(S)
REMEDY
No response when
operating controls
for the crane.
A. No power from battery.
B. Faulty earth connection.
C. Faulty or low vehicle battery.
A. Check supply fuse and
replace if necessary. Check all
cable connections are safe
and sound.
B. Check, clean and secure all
earth points.
C. Re-charge or replace vehicle
battery.
Crane will not lift
but will lower.
A. Crane overload.
B. Rope bunched on pulley
or winch.
C. Broken brake spring.
D. Faulty solenoid.
A. Remove excessive load.
B. Ensure that the rope is free
to travel.
C. Call service engineer.
D. Call service engineer.
Crane will not slew
freely.
A. Bearings seized.
B. Slew lock in place.
A. Call service engineer to
loosen clean and lubricate
bearings.
B. Undo slew lock.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Maintenance
It is the employer’s legal responsibility to ensure the lift is maintained in
accordance with the manufacturer’s specification.
Your Swing lift vehicle mounted crane is subject to the LIFTING OPERATIONS
AND LIFTING EQUIPMENT (LOLER) Regulations 1998. These are statutory
requirements and need to be recorded on a formal document governing the
safe working condition of the crane, attachments and mounting structure.
Penny Hydraulics Ltd. Support team offers a service package to meet customer
requirements and 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 a
competent person as required by LOLER. LOLER also requires that a thorough
examination is carried out following any exceptional circumstances that may
affect the safety of the equipment.
Any defects found whilst carrying out the thorough examination must be
reported and recorded, and if necessary, the equipment taken out of operation
until appropriate action is undertaken. In certain circumstances it may be
necessary to report the unsafe condition to the enforcing authorities.
The planned maintenance schedule may require the use of parts and
consumables. A list of recommended spares and lubricants is attached.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Planned Maintenance Schedule
Before any work is undertaken, ensure the site supervisor is informed and
that all local safety precautions are observed and adhered to. Pay attention
to site specific safety and PPE requirements.
Unless dynamic checks, tests or setting up procedures are being carried out,
always isolate the machine from the power supply. An assistant is
recommended to be on call if required, when carrying out dynamic tests.
Ensure the working area is clean, ensure the work area is cordoned 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 mishandling. Install and carry out a
commissioning test.
Levels of Maintenance.
Always Before Use.
-Check visually for signs of external damage.
-Check all guards are securely in place.
-Check for loose or missing nuts, bolts and fasteners.
-Check the hoist rope for kinks, broken strands or corrosion.
-Check the lifting hook and connection to the rope.
-Check for damage to electrical cables and connectors.
-Check all safety notices and MWL stickers are in place.
6 Monthly.
-Carry out checks as above.
-Thoroughly examine the support structure and sub frames for soundness
and signs of deflection.
-Thoroughly inspect all welds.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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-Thoroughly check the security of all fixings on the main body and sub
frames.
-Thoroughly examine all pivot points for excessive play. Remove the pivot
pins and thoroughly inspect the condition of the pins and bushes and
replace where necessary.
-Thoroughly examine all electrical components, cables and connectors.
12 Monthly.
-Check all as for before use and 6 Monthly.
-Carry out a full load test as set out in the Load test procedure.
-Carry out a statutory examination as required by LOLER.
Load Test Procedure
1) Prepare 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 the maximum permissible load
for the crane.
3) Deploy the crane.
4) Without load, manoeuvre the crane through all extents to ensure the
correct operation.
5) Lower the rope and attach the hook to test the weight.
6) Raise the load clear of the ground.
7) Check for signs of excessive flexing, structural deformation, paint flaking
and excessive play in the joints.
8) Rotate the crane through its maximum swing and repeat the checks in
#7 above.
9) Remove the weight and stow the crane and any legs.
On completion of the test, restore the vehicle to its normal driving position,
restore the working area and complete the documentation.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Commissioning
A commissioning test involves a 25% (50% if manual) static overload test and,
as elements of the crane’s safety features may have to be overridden, it must
only be carried out by a trained and competent person.
It is a legal requirement that a commissioning test must be carried out:
-Before being put into use for the first time.
-If the 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
its supporting structure.
The Association of Lorry Loaders, Manufacturers and Importers, (ALLMI), also
recommend that on commissioning a 10% dynamic over-load test is conducted
by a trained and competent person through full slewing arc.
In severe or extreme conditions, it is recommended that commissioning is
incorporated into the annual load test of the crane and its supporting
structure.
Please contact Penny Hydraulics Ltd. for further information.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Thorough Examination
The Lifting Operations and Lifting Equipment Regulations (LOLER) replaced
the legal requirement for the four yearly Overload Test with the annual
Thorough Examination and Inspection, and made it the responsibility of the
Competent Person to determine if and when an Overload Test should be
carried out, on the grounds that “the design of certain lifting equipment is
such that damage may be caused by conventional Overload Tests”. Loader
cranes do not fall into this category, as witnessed by the fact that BS7121
Part 2 has an entire section devoted to the testing of loader cranes. Load
Testing is a requirement of ALLMI and BS7121 Parts 2 and 4.
Inspection of the lorry loader by a competent person to determine if it is safe
for continued use until the next thorough examination is due. Thorough
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 change in conditions of use.
•After long periods out of use.
•At shorter intervals as determined by the Competent Person.
Please note that in addition to the above, lifting equipment for lifting persons
or an accessory for lifting, must be thoroughly examined at least every six
months.
BS7121 Part 2
Occasion
Minimum test and thorough
examination
Before being first taken into service
Full test including 25% overload
Annually after being first put into service
Proof load test of rated capacity +10% at
full radius and through the full slewing
arc, and a Thorough Examination
4 years after first being put into service
Full test including 25% overload
8 years after first being put into service
Non-destructive test of structure
After each structural repair or component
change
Full test including 25% overload
When chassis is changed
Full test including 25% overload
Is removed and refitted
Full test including 25% overload

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Lorry Loader Servicing
Penny Hydraulics Limited manufactures a range of Swinglift Cranes, Taillift,
Steplift, Loadlift and Tyre Press products, which are supported by a fleet of
dedicated service vans fully stocked with original equipment spares and
manned by trained engineers.
Current legislation requires that each item of lifting equipment must be
thoroughly examined at least once in every period of twelve months by a
competent person. Additionally, the lifting equipment must be inspected at
suitable intervals between thorough examinations. Our service contract will
ensure continued safe, reliable use of the equipment and full compliance with
current legislation.
The operator is required to carry out regular 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 all cases a test certificate will be issued with a copy being left on site
and a further copy sent together with our invoice. We will also keep a copy for
our records that can be forwarded to enforcing authorities on your behalf as
necessary.
Our database of all equipment ensures that statutory inspections are kept up
to date and can help customers with many items of equipment to predict
forthcoming servicing budgets.
A Help Line telephone number is provided with each service contract for the
operators to seek assistance directly from our Service Department. There is no
call out or labour charge for help required in-between scheduled visits and any
parts used will be charged on the next invoice.
Should this be of interest then in the first instance please contact the Service
Department on 01246 810403.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Penny Hydraulics Limited Warranty Policy
This policy is intended to provide our customers with the best possible support
to ensure trouble free use of their new Penny Hydraulics lifting equipment.
Products sold by the company are guaranteed to be free from defective
material and workmanship for the period of one year from the date of invoice
or from the date of the commissioning certificate.
This warranty applies only under the following conditions:
-The unit or part must not have been subject to neglect or abuse or
operated under abnormal conditions or in an unapproved application.
-The responsibility of the company is restricted to what is, in their
judgement an adequate repair or replacement of the company’s
product.
-An authorised engineer must carry out a six-monthly inspection.
-The warranty is void if examination reveals that the 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 to consumable items requiring replacement
due to normal wear and tear.
UK Mainland
We will normally have one of our own engineers based around the country visit
the site to rectify the problem. This policy may be varied at our discretion but it is
our aim to give the best possible response to minimise the product’s downtime
and inconvenience to the end user.
Other Locations
Warranty is limited to a parts only service but in certain areas we have service
partners who may be able to assist. Any defective item should be returned to
Penny Hydraulics Ltd for inspection and any valid warranty claim will include
reasonable carriage costs both ways. A replacement part will then be sent to the
customer.
No variation of the warranty as stated in the company’s standard terms and
conditions of sale is authorised unless agreed in writing by a Director of the
company. This is the only warranty given and the company accepts no other
responsibility.

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Service Contract
Date ……………………………..
Crane Serial Number ……………………………..
Vehicle Registration ……………………………..
Vehicle Make/Model ……………………………..
Penny Hydraulics Ltd agrees to carry out one annual service and one interim
inspection on the crane in any 12-month period. A test certificate will be left
on site and a copy sent with invoice.
In the event of a problem arising in-between scheduled visits, the customer
should telephone the HELPLINE on 01246 811475 as soon as possible so that
the appropriate action 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 following each visit and by signing this document
agrees to make full payment within 30 days of the invoice date in accordance
with the agreed scale of charges, which may vary from time to time.
Signed ………………………………………… Print Name …………………………………
Position ……………………………………….. Order Number ……………………………
More details are available online. Please fax, post or email this form to the office below.
Penny Hydraulics Ltd
Tel [phone]
Fax [phone]
Email – [e-mail]
Web – www.pennyhydraulics.com
Crane Location …………………………………………………
Post Code …………………………………………………
Contact …………………………………………………
Telephone …………………………………………………
Email …………………………………………………
Invoice Address …………………………………………………
Post Code …………………………………………………
Contact …………………………………………………
Telephone …………………………………………………
Email …………………………………………………

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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Typical Wiring Layout
Overload Setting

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
18
EC Declaration of Conformity
This declaration relates exclusively to the machinery in the state in which it
was supplied, and excludes components, which are added, and/or operations
carried out subsequently by the final user.
Penny Hydraulics Limited hereby declare that the products listed below:
Models
SwingLift KJ, ML, F500, FV500, CC, MCC & GBC
Serial Number(s)
050 000 to 999 999
Conforms to the essential requirements of 2006/42/EC machinery directive of
the European community.
Applied Harmonised 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
Radiated RF Emissions Class B (30MHz-300MHz)
BS 2573 Rules for design
Other Technical standards and specifications
DIN 15018 Steel Structures - Cranes
Supply of Machinery Safety Regulations 2008
Electrical Equipment (Safety) Regulations 1994
European Council EMC Directive 89/336/EEC
The Lifting Operations and Lifting Equipment Regulations 1998
The Provision and Use of Work Equipment Regulation 1998
Penny Hydraulics Limited, Station Road Industrial Estate, Station Road, Clowne, S434AB
Place
Penny Hydraulics Limited
Signature
Date
15/3/2019
Full Name
Robin Penny
Position
Managing Director

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
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SwingLift Knuckle Joint Range

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
20
KJ250/1 – Exploded View
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