Wilorton Holding MK-C-10-BM SERIES User manual

OPERATION & MANUAL
MOBILE WASHERS
MK-C-10-BM SERIES
Live Line Insulator Washing Unit Model MK-C-10-BM
Wilorton Holding Inc.
Mail Address: c/o Fiam SA Mercurio Bldg., 4th Floor, P.za Col. Bernasconi, nr 5 - 6830 Chiasso - Switzerland
T.+41(0)91 695 1070 - F.+41(0)91 682 6672
Email: [email protected]o - web: http://www.wilorton.com
1
MK-C-10-BM-317.1/1-EM

MK-C-10-BM
2
2
MK-C-10-BM-317.1/1-EM

LIST
OPERATION & MANUAL
1. TRUCK ASTRA HD 9 E64.42 6X4........................................................PAG 4
2. CRANE PM 15523.................................................................................PAG 6
3. REMOTE CONTROLLER RC400.........................................................PAG 150
4. BASKET TWO PEOPLE FIBER GLASS..............................................PAG 188
5. DIESEL ENGINE VM-D703TEO-F3S...................................................PAG 205
6. PUMP TMA 50-8/5-C/RA......................................................................PAG 287
7. JUNCTION BOX 00BBJBXA01...........................................................PAG 296
9. CONTROL PANEL BOARD CEP-461.................................................PAG 306
10. MAGNETIC LEVEL TOR B..................................................................PAG 315
11. HOSE REELS EP6030-23-24 .............................................................PAG 325
12. GENERATOR HONDA EU30is...........................................................PAG 328
13.
LIGHT TOWER....................................................................................PAG 400
14.
CONDUCTIVITY PEN PT1...................................................................PAG 392
8. JUNCTION BOX A9011030.................................................................PAG 304
3
MK-C-10-BM-317.1/1-EM

1.TRUCK
ASTRA HD 9 E64.42 6X4
4
MK-C-10-BM-317.1/1-EM

SEE
THE MANUAL OF THE TRUCK
UNDER
PASSENGER SEAT
5
MK-C-10-BM-317.1/1-EM

2.CRANE
PM 15523
6
MK-C-10-BM-317.1/1-EM

SERIE 15.5
- G129 -
Realised by Unistudio - Modena
Valid for models:
PM 15521
PM 15522 - PM 15522 LC
PM 15523 - PM 15523 LC
PM 15524 - PM 15524 LC
PM 15525
INSTRUCTION AND WARNINGS
Valid with the serial number
Code number: 4.150.915
Edition: 02/2013
G.129.0001
Original instructions in English
7
MK-C-10-BM-317.1/1-EM

GENERAL INDEX
1 General information .................................................................................................................................................... 1.1
1.1 - Purpose of the manual.................................................................................................................................................. 1.1
1.2 - Manufacturer’s details and machine identification data................................................................................................. 1.1
1.3 - Symbology .................................................................................................................................................................... 1.2
1.4 - Technical service........................................................................................................................................................... 1.3
1.5 - Enclosed documentation............................................................................................................................................... 1.3
1.6 - Disclaimer ..................................................................................................................................................................... 1.3
2 Technical information ................................................................................................................................................. 2.1
2.1 - Description of the crane ................................................................................................................................................ 2.1
2.1.1 - Basic crane main parts ................................................................................................................................................. 2.1
2.1.2 - Basic crane LC main parts............................................................................................................................................ 2.3
2.2 - Conditions of use .......................................................................................................................................................... 2.5
2.2.1 - Designated use ............................................................................................................................................................. 2.5
2.2.2 - Inadmissible uses.......................................................................................................................................................... 2.5
2.3 - Control and limiting devices .......................................................................................................................................... 2.6
2.3.1 - Momentum limiting device............................................................................................................................................. 2.6
2.3.2 - Rotation locking and limiting device .............................................................................................................................. 2.6
2.3.3 - Load support valves...................................................................................................................................................... 2.7
2.3.4 - Stabiliser valve .............................................................................................................................................................. 2.7
2.3.5 - Emergency stop device................................................................................................................................................. 2.7
2.3.6 - Load gauge ................................................................................................................................................................... 2.8
2.3.7 - Signal lamp and buzzer................................................................................................................................................. 2.8
2.3.8 - Stabilisation controller ................................................................................................................................................... 2.9
2.3.9 - Locking devices for transit on the roads........................................................................................................................ 2.10
2.4 - Safety recommendations and information..................................................................................................................... 2.11
2.5 - Accessories................................................................................................................................................................... 2.15
2.5.1 - Additional crossmember................................................................................................................................................ 2.15
2.5.2 - Manual extensions .............................................................................................................................................. 2.17
2.5.3 - Raised control station.................................................................................................................................................... 2.19
2.5.4 - Winch ............................................................................................................................................................................ 2.20
2.6 - Noise level..................................................................................................................................................................... 2.25
2.7 - Vibrations ...................................................................................................................................................................... 2.25
2.8 - Gas emissions............................................................................................................................................................... 2.25
2.9 - Electromagnetic compatibility........................................................................................................................................ 2.25
2.10 - Residual dangers .......................................................................................................................................................... 2.25
8
MK-C-10-BM-317.1/1-EM

3 Safety ........................................................................................................................................................................... 3.1
3.1 - Safety regulations ......................................................................................................................................................... 3.1
3.2 - Operator’s qualifications and behaviour ........................................................................................................................ 3.8
4 Handling, lifting and fitting......................................................................................................................................... 4.1
4.1 - Handling and lifting........................................................................................................................................................ 4.1
4.1.1 - Lifting the crane with a hook ......................................................................................................................................... 4.2
4.1.2 - Locking devices............................................................................................................................................................. 4.2
4.2 - Storage.......................................................................................................................................................................... 4.3
4.3 - Fitting ............................................................................................................................................................................ 4.3
4.4 - Fitting the manual extension ......................................................................................................................................... 4.4
4.5 - Fitting the hook.............................................................................................................................................................. 4.5
4.6 - Tackle installation .......................................................................................................................................................... 4.6
4.6.1 - Fitting the tackle on the crane ....................................................................................................................................... 4.6
5 Information about adjustments ................................................................................................................................. 5.1
6 Usage instructions...................................................................................................................................................... 6.1
6.1 - Controls......................................................................................................................................................................... 6.1
6.1.1 - Crane control symbols .................................................................................................................................................. 6.1
6.1.2 - Controls and signals/gauges located in the truck cab................................................................................................... 6.3
6.2 - Radio control ................................................................................................................................................................. 6.4
6.2.1 - "SCANRECO MINI" radio control.................................................................................................................................. 6.4
6.2.2 - HETRONIC radio control............................................................................................................................................... 6.8
6.2.3 - Radio control operation check....................................................................................................................................... 6.12
6.2.4 - Radio control stop due to power failure......................................................................................................................... 6.12
6.2.5 - Radio control maintenance ........................................................................................................................................... 6.12
6.3 - Work sectors ................................................................................................................................................................. 6.13
6.3.1 - Electrical and mechanical rotation control devices ....................................................................................................... 6.14
6.3.2 - Stabilisation control device (TYPE 1)............................................................................................................................ 6.15
6.3.3 - Stabilisation control device (TYPE 2)............................................................................................................................ 6.16
6.3.4 - Stabilisation control device (TYPE 3)............................................................................................................................ 6.17
6.3.5 - Stabilisation control device (TYPE 4)............................................................................................................................ 6.19
6.3.6 - Stabilisation control device (TYPE 5)............................................................................................................................ 6.21
6.3.7 - Raised control station control device ............................................................................................................................ 6.23
6.4 - Crane stabilisation......................................................................................................................................................... 6.24
6.4.1 - Stabilisation procedure.................................................................................................................................................. 6.24
9
MK-C-10-BM-317.1/1-EM

GENERAL INDEX
6.4.2 - Stabilisation controls ..................................................................................................................................................... 6.25
6.4.3 - Manual adjustable stabiliser.......................................................................................................................................... 6.26
6.4.4 - Hydraulic adjustable stabiliser....................................................................................................................................... 6.27
6.5 - Working position of the crane........................................................................................................................................ 6.28
6.6 - Checking the efficiency of the control and limiting devices ........................................................................................... 6.29
6.6.1 - Checking the emergency stop button............................................................................................................................ 6.29
6.6.2 - Checking the hydraulic moment limiter ........................................................................................................................ 6.29
6.6.3 - Checking the rotation limiter (fig. 6.6.2)......................................................................................................................... 6.30
6.6.4 - Checking the rotation block (fig. 6.6.2) .......................................................................................................................... 6.30
6.6.5 - Checking the rotation limiter with stabilisation control device ....................................................................................... 6.30
6.6.6 - Checking the load maintenance valve........................................................................................................................... 6.31
6.7 - Lifting and moving the load ........................................................................................................................................... 6.31
6.8 - Crane resting position ................................................................................................................................................... 6.32
6.9 - Crane destabilisation and circulation on the roads ....................................................................................................... 6.33
6.9.1 - Crane destabilisation..................................................................................................................................................... 6.33
6.9.2 - Circulation on the roads ................................................................................................................................................ 6.33
6.10 - Lock situations and manoeuvres permitted................................................................................................................... 6.34
6.10.1 - Crane lock due to momentum limiting device trigger .................................................................................................... 6.34
6.10.2 - Winch lock..................................................................................................................................................................... 6.34
6.11 - Failure situations ........................................................................................................................................................... 6.35
6.11.1 - Momentum limiting device failure .................................................................................................................................. 6.35
6.11.2 - Hydraulic power failure.................................................................................................................................................. 6.35
6.11.3 - Electric power failure..................................................................................................................................................... 6.35
6.11.4 - Radio control failure ...................................................................................................................................................... 6.36
6.12 - Use of the load limiter for manual extensions ............................................................................................................... 6.36
7 Maintenance ................................................................................................................................................................ 7.1
7.1 - Regular checks ............................................................................................................................................................. 7.1
7.2 - Checking the condition of the hoses ............................................................................................................................. 7.2
7.3 - Checking the hosing guards.......................................................................................................................................... 7.2
7.4 - Checking for oil leaks from the hydraulic system .......................................................................................................... 7.3
7.5 - Checking the hydraulic oil level ..................................................................................................................................... 7.3
7.6 - Structure inspection ...................................................................................................................................................... 7.4
7.7 - Pulley check .................................................................................................................................................................. 7.4
7.8 - Cable check .................................................................................................................................................................. 7.4
7.9 - Cable lubrication ........................................................................................................................................................... 7.4
10
MK-C-10-BM-317.1/1-EM

7.10 - Checking the pin locks .................................................................................................................................................. 7.4
7.11 - Checking the anchorage stay rods................................................................................................................................ 7.5
7.12 - Checking the jack sliding blocks.................................................................................................................................... 7.5
7.13 - Checking the supplementary crossmember.................................................................................................................. 7.5
7.14 - Filters ............................................................................................................................................................................ 7.6
7.15 - Lubrication of the crane arms and stabilisers ............................................................................................................... 7.6
7.16 - Cleaning the machine ................................................................................................................................................... 7.7
7.17 - Long periods of machine inactivity................................................................................................................................ 7.7
7.18 - Starting the machine up again ...................................................................................................................................... 7.7
7.19 - Scrapping and disposal................................................................................................................................................. 7.7
7.20 - Oils and lubricants......................................................................................................................................................... 7.8
7.20.1 - Lubricant comparison table........................................................................................................................................... 7.8
7.21 - Greasing and lubrication diagrams ............................................................................................................................... 7.9
8 Fault, cause, remedy................................................................................................................................................... 8.1
9 Spare part replacement .............................................................................................................................................. 9.1
9.1 - Hose replacement ......................................................................................................................................................... 9.1
9.2 - Fuse replacement ......................................................................................................................................................... 9.1
9.2.1 - Connector block fuse replacement................................................................................................................................ 9.1
9.2.2 - Radio receiver fuse replacement .................................................................................................................................. 9.2
9.3 - Filters replacement........................................................................................................................................................ 9.3
9.3.1 - Replacing the exhaust filter........................................................................................................................................... 9.3
9.3.2 - Delivery filter replacement............................................................................................................................................. 9.3
Enclosures ................................................................................................................................................................................. A.1
- Overall dimensions ............................................................................................................................................................... A.1
- Overall dimensions standard machine and LC machine ....................................................................................................... A.2
- Specifications and performances PM 15521 - PM 15521 LC................................................................................................ A.3
- Capacities diagram PM 15521 - PM 15521 LC ..................................................................................................................... A.4
- Specifications and performances PM 15522 - PM 15522 LC................................................................................................ A.5
- Capacities diagram PM 15522 - PM 15522 LC .................................................................................................................... A.6
- Specifications and performances PM 15523 - PM 15523 LC................................................................................................ A.7
- Capacities diagram PM 15523 - PM 15523 LC ..................................................................................................................... A.8
- Specifications and performances PM 15524 - PM 15524 LC................................................................................................ A.9
- Capacities diagram PM 15524 - PM 15524 LC ..................................................................................................................... A.10
- Specifications and performances PM 15525 - PM 15525 LC................................................................................................ A.11
11
MK-C-10-BM-317.1/1-EM

GENERAL INDEX
- Capacities diagram PM 15525 - PM 15525 LC ..................................................................................................................... A.12
- “CE” declaration of conformity of the machine ...................................................................................................................... A.13
- Register of the periodic technical inspections of the control and limiting devices ................................................................. A.14
- EXTRAORDINARY MAINTENANCE check register ............................................................................................................. A.19
- CABLES AND CHAINS quarterly check register................................................................................................................... A.25
- Maintenance intervention confirmation.................................................................................................................................. A.30
12
MK-C-10-BM-317.1/1-EM

1.1
GENERAL INFORMATION
01-GB-A1-274FI
1
1General
information
1.1 - Purpose of the manual
The instructions manual contains information which is es-
sential for the correct use of the crane (1) (hereinafter also
referred to as the machine).
Its purpose is to inform the operator (2) of the instructions to
follow and the fundamental criteria to apply in all machine use
or maintenance operations.
Before starting up the machine for the first time, the operator
must have read and understood the instructions contained in
this manual, in particular those highlighted with the various
symbols.
The manual is an integral part of the machine and must be
kept, for future reference, until the machine is scrapped.
If the machine is resold, the seller is bound to provide the new
owner with the manual.
The information contained herein is arranged in chapters, in
a sequential order according to subject matter.
The indexes, both alphabetic or analytic, allow the user to
refer to the different subjects quickly and easily.
The original instructions are supplied by the manufacturer in
english language.
- Manufacturer’s details
PM Group S.p.A.
Via Verdi, 22
41018 San Cesario sul Panaro - Modena (Italy)
tel. [phone]
fax. + 39 059 936800
e-mail: [e-mail]
1.2 - Manufacturer’s details and machine
identification data
(1) The term “crane” refers to the trade name given to the machine (from the
crane series) stated on the title page.
(2) The term “operator(s)” refers to the person(s) possessing the necessary
expertise to use, inspect and carry out routine maintenance on the machine.
To fulfil legal or commercial requirements, the original instruc-
tions may be supplied by the manufacturer in other languag-
es.
It is strictly forbidden to use the manual for anything other
than the machine’s use and maintenance.
13
MK-C-10-BM-317.1/1-EM

UN01-2756FI
G.XXX.XXXX
a
b
c d
1.2.1
1.2
- Machine identification data
Plate details
a= Crane model
b= Serial number
c= Year of manufacture
d= Conformity "CE" stamp
Punching
WARNING !
This indicates information or procedures which, if not com-
plied with exactly, could cause death or serious injuries.
CAUTION !
This indicates information or procedures which, if not com-
plied with exactly, could cause slight injuries or damage to
the machine.
Information
This indicates useful and important information or proce-
dures.
1.3 - Symbology
This indicates information or procedures which, if not com-
plied with exactly, cause death or serious injuries.
HAZARD !
The symbols used in this manual are intended to highlight
potentially hazardous operations.
To guarantee safe working conditions, the instructions high-
lighted by these symbols must always be followed.
14
MK-C-10-BM-317.1/1-EM

1.3
GENERAL INFORMATION
01-GB-A1-274FI
1
Technical service requests must be addressed to the man-
ufacturer’s Technical Assistance Service (T.A.S.) or to the
nearest Authorised Workshop.
- "EC" conformity declaration
- Warranty booklet
- Machine certificate of origin (only for markets requiring it).
1.4 - Technical service
1.5 - Enclosed documentation
WARNING !
For the sake of clarity when outlining procedures to carry
out, some illustrations show the machine with the guards,
casings or panels removed.
Never use the machine without all the casings and guards
in place.
1.6 - Disclaimer
The manufacturer cannot be held responsible for any occur-
rence arising from the following:
- total or partial failure to comply with instructions herein;
- misuse of the machine;
- unauthorised alterations or work carried out on the ma-
chine;
- failure to comply with the highway code and regulations
concerning transportation when moving the machine from
one site to another;
- lack of maintenance;
- use of non-original spare parts or those which are not de-
signed specifically for the model;
- exceptional weather conditions.
15
MK-C-10-BM-317.1/1-EM

2.1
UN01-2243CD
F L1 L2 L3 L4 L5
M1 M2 M3 M4 M5 M6
H
AC
EG
NNC
DBBD
2.1.1
TECHNICAL INFORMATION
01-GB-A2-298BL
2
2.1 - Description of the crane
The crane is composed of a base inside
which there is a rotating column with a
system of articulated arms at its end.
The crane is driven by hydraulic energy
generated by a motor and a pump.
This crane series is available in vari-
ous models, which differ mostly in the
number of extendable arms.
There is also the LC version, which has
a shorter secondary arm.
2.1.1 - Basic crane main parts
2Technical
information
16
MK-C-10-BM-317.1/1-EM

2.2
Ref.Part 15521 15522 15523 15524 15525
ABase •••• •
B Stabiliser arm •••• •
C Stabiliser jack •••• •
D Rotation jack •••• •
EColumn •••• •
F Main arm •••• •
G Main jack •••• •
H Secondary jack •••• •
L1 1st arm extension jack •••• •
L2 2nd arm extension jack • • • •
L3 3rd arm extension jack • • •
L4 4th arm extension jack • •
L5 5th arm extension jack •
M1 Secondary arm •••• •
M2 1st hydraulic extension arm •••• •
M3 2nd hydraulic extension arm • • • •
M4 3rd hydraulic extension arm • • •
M5 4th hydraulic extension arm • •
M6 5th hydraulic extension arm •
NStabiliser arm extension jack •••• •
Key to the main parts
17
MK-C-10-BM-317.1/1-EM

2.3
UN01-2244CD
F L2M1 L3 L4 L5
M2 M3 M4 M5 M6
HL1
AC
EG
NNC
DBBD
2.1.2
TECHNICAL INFORMATION
01-GB-A2-298BL
2
2.1.2 - Basic crane LC main parts
Key to the main parts - basic crane LC
Ref.Part 15522 LC 15523 LC 15524 LC
ABase •••
BStabiliser arm •••
CStabiliser jack •••
DRotation jack •••
EColumn •••
FMain arm •••
GMain jack •••
HSecondary jack •••
18
MK-C-10-BM-317.1/1-EM

2.4
Ref.Part 15522 LC 15523 LC 15524 LC
L1 Secondary arm extension jack •••
L2 1st arm extension jack •••
L3 2nd arm extension jack • •
L4 3rd arm extension jack • •
L5 4th arm extension jack •
M1 Cover •••
M2 Secondary arm •••
M3 1st hydraulic extension arm •••
M4 2nd hydraulic extension arm •••
M5 3rd hydraulic extension arm • •
M6 4th hydraulic extension arm •
NStabiliser arm extension jack •••
19
MK-C-10-BM-317.1/1-EM

2.5
TECHNICAL INFORMATION
01-GB-A2-298BL
2
2.2.1 - Designated use
2.2 - Conditions of use
The crane is designed for the vertical lifting, handling and po-
sitioning of free loads (3), in compliance with the values given
in the capacities diagram and handling speeds not exceeding
the maximum prescribed limits (see specifications).
The cranes are designed in compliance with harmonised
standard EN 12999, class H1-B3, which provides for non-
continuous use, with a hook, for a maximum of 400 lifting
cycles per week and a load equalling 3/4 of the load indicated
in the relative diagram.
To use the machine with loads other than those for which it
is designed, it is the user’s responsibility to first contact an
authorised workshop to check whether a downgrade is nec-
essary.
It is forbidden to use the machine in areas where there is a
risk of fires or explosions.
It is forbidden to use the crane to pull out poles, uproot trees
and lift fixed loads.
It is forbidden to use the machine to lift people, with the
exception of cases in which the crane is fitted with a specially
designed operator’s platform approved by the manufacturer.
It is forbidden to use the crane with fixed load-hoisting ac-
cessories such as hooks, bucket, grabs etc unless the acces-
sories are authorised by the manufacturer.
It is forbidden to use the machine as a recovery means for
towing broken-down vehicles.
It is forbidden to drag or push loads.
Before performing a rotation manoeuvre, the load must be
lifted off the ground.
It is forbidden to lift the base truck with the stabilisers to
change the tyres.
It is forbidden to lift the base truck with the stabilisers in or-
der to move the vehicle if stuck in areas of loose ground.
It is forbidden to fit removable clamping accessories such as
jibs, manual extensions etc if:
they are not approved by the manufacturer;
they are not designed specifically for the model in ques-
tion.
2.2.2 - Inadmissible uses
(3) The term “free load” means loads whose movement is not limited.
20
MK-C-10-BM-317.1/1-EM