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
4
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
5
Safety Warning

Penny Hydraulics Ltd
Operating & Maintenance Manual – VME - SwingLift Cranes KJ, ML, F500, FV500, CC, MC & GBC
6
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
7
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
8
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
9
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
10
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.