Top Climbing System

Tower HD23
Maintenance
1 MAINTENANCE
1.1 GENERAL
1.2 REQUIREMENTS FOR THE SYSTEM MAINTENANCE
1.3 PRECAUTIONARY MEASURES
1.4 TOP CLIMBING UNIT COMPONENTS SUBJECT TO MAINTENANCE
1.5 ROUTINE MAINTENANCE
1.6 PERIODICAL INSPECTIONS
1.6.1 Daily inspections
1.6.2 Weekly inspections
1.6.3 Monthly inspections
1.6.4 Quarterly inspections
1.6.5 Six-monthly inspections
1.6.6 Annual inspections
1.7 SPECIAL MAINTENANCE
1.8 LUBRICATION AND OILS
1.8.1 Hydraulic systems (recommended oils)

Chapter 4
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 1 MAINTENANCE
1.1 GENERAL

Maintenance of the top climbing unit is an on-going process pursuing two basic aims: inspection
and repair.
Inspection consists of all the appropriate operations required to locate, identify and assess problems
which might weaken the safety and functionality of the system.
Repair is directly related to the inspection carried out and, resolving each detected deficiency,
restores the top climbing unit to its original configuration and state of operation.
The top climbing unit is equipped with some mechanical, hydraulic and electrical structural parts
which, being exposed to dynamic stresses or wear through their utilization, may suffer from
deterioration and/or failures.
These factors can lead to more serious malfunctions and jeopardize the operational safety of the
top climbing unit if they are not controlled.
The best way to manage these factors and minimize their negative effects is to cut down the risks
of failure and/or breakage respecting a maintenance program as prescribed by the Manufacturer.
Comedil has devised a detailed and rigid maintenance program tailored for the top climbing unit,
described hereunder, which has to be scrupolously observed by the User.
Maintenance requirements are divided into: routine maintenance and special maintenance.

ROUTINE MAINTENANCE: It covers most of the operations to be carried out by the

designated personnel.
These include: check of lubricating systems for delivery of
lubricant; most of the daily, weekly, monthly and annual
inspections; troubleshooting to determine any system
deficiencies; functional/operational checks; repair of
components, which does not require the services of
specialized technicians; replacement of parts within the
capabilities of local maintenance people.

SPECIAL MAINTENANCE:
These activities require the skill of highly trained and
experienced technicians to perform maintenance tasks not
normally accomplished by the top climbing unit operators or
their supervisors.
Special maintenance requirements include: assembly,
special operational checks and adjustments, electro-
mechanical failures repair and NDT testing (non-destructive
test) of structural members and critical components.

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 SPARE PARTS Use only Comedil original spare parts.

Using parts that do not meet the Manufacturer’s specifications

could be hazardous.
Such parts, exposed to stresses, could suddenly fail, thus resulting
in people’s injury and/or property damage.
Do not wait until the wearing out of the top climbing unit components
before replacing them. Replacing parts as they begin to show wear
gives longer service and avoids serious damages or delays thus
eliminating expense of special maintenance operations.

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 1.2 REQUIREMENTS FOR THE SYSTEM’S MAINTENANCE

TECHNICAL ASSISTANCE
The following inspection program has been studied to help people
in charge of the top climbing unit find possible structural defects
of the components, assembly defects and improper functioning
of the system.
Comedil has a world wide after-sales service network capable of
providing rapid assistance to resolve any use and maintenance
problems encountered with its cranes and equipments.

F
Crane owners shall designate the people responsible for performing routine maintenance of the
top climbing unit: normally, the crane operator or the job site supervisor.

In any case, people performing routine maintenance shall be thoroughly trained to accomplish
these tasks.

There are many inherent dangers associated with the top climbing unit operations and maintenance.
Inexperienced or untrained people shall not be entrusted to work on or operate a top climbing unit;
failing to comply with the rule could lead to serious injury to persons at the job site, death, and/or
equipment damage.

1.3 PRECAUTIONARY MEASURES

Before major adjustments or repairs are started with the top climbing unit assembled on the crane, the
following precautionary measures shall be taken.

A) Make sure that the crane is idle, that there is no load hanging from the hook and that the main
or emergency switch is open and locked in the open position, except for test purposes.
B) Warning or Out of Order signs shall be placed by appointed personnel.
C) Allow the motor to cool completely before starting maintenance on it.
D) Never disconnect or remove hydraulic system components when they are pressurized.
E) Always use proper maintenance equipment; ensure that the lifting capacity of the slings and
service winch is not exceeded when such devices are used for hoisting items.
F) Make sure that people appointed with maintenance are always equipped with the personal
safety equipment as required by the European Regulation 89/391/EEC.
G) After adjustments or repairs have been made, the crane shall not be returned to service until
all guards have been reinstalled, limit and protective devices reactivated and maintenance
equipment removed. Warning or Out of Order signs shall be removed by appointed personnel
only.

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1.4 TOP CLIMBING UNIT COMPONENTS SUBJECT TO MAINTENANCE

To facilitate the routine maintenance operations, the top climbing unit has been shared into two
main groups of intervention.
They associate several top climbing unit components and sub-groups in a manner which makes
them ideal for use as a checklist.

The groups: I) STRUCTURES

II) HYDRAULIC SYSTEM

Technicians should refer to these groups to carry out the daily, weekly, monthly and annual
inspections.

F If further details are needed to visualize and understand some maintenance/inspection

requirements, refer to the pictures contained in this manual and to the following tables, or contact
Comedil Engineering Department.

List of the top climbing unit groups subject to maintenance

I) STRUCTURES

A) Primary structures, such as frames, service trolley, service trolley rail guide, tie-ropes;

B) pins and bolts;

C) platforms, ladders and protections.

II) HYDRAULIC SYSTEM

A) Reservoir

B) Pump

C) Filter

D) Cylinder

E) Tubes

F) Electric motor

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 1.5 ROUTINE MAINTENANCE

Maintenance procedures consist of two phases: INSPECTION

REPAIR

This system guarantees that all potential top climbing unit deficiencies are identified and repaired.

Defects which cannot be solved during this phase will become part of the
“SPECIAL MAINTENANCE”.

INSPECTION PHASE: This preliminary maintenance phase includes check, troubleshooting

and methodical record of any top climbing system defects, deteriorations
and possible failures.
No repairs have to be performed during this phase.
In fact, only after a complete list of all problems and defects discovered
has been drawn up, the designated person can give a summary of the
top climbing unit’s general operation and reasonably schedule routine
and special maintenance repairs.
This phase permits to keep the crane’s “TEST RECORD BOOK”
updated.

REPAIR PHASE: It includes the following routine maintenance operations:

1) Repairs
2) Replacement
3) Lubrication
4) Painting

ATTENTION! Do not take the top climbing unit into operation until all deficiencies found
have been duly repaired.

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1.6 PERIODICAL INSPECTIONS

There are six routine inspections required for the top climbing unit:

1) Daily Inspections: to be performed before installing the top climbing unit and taking it in
operation;

2) Weekly inspections: to be performed every week on the same day.

Should the top climbing unit not be used for more than one week, then
carry out both weekly and daily inspections the day the top climbing
unit goes back into operation;

3) Monthly inspections: to be performed every month on the same day.

Should the top climbing unit not be used for more than one month,
then carry out monthly, weekly and daily inspections the day the top
climbing unit goes back into operation;

4) Three-monthly inspections: to be performed every three months on the same day.

Should the top climbing unit not be used for more than three months,
then carry out three-monthly, monthly, weekly and daily inspections
the day the top climbing unit goes back into operation;
5) Six-monthly inspections: to be performed every six months on the same day.
Should the top climbing unit not be used for more than six months,
then carry out six-monthly, three-monthly, monthly, weekly and daily
inspections the day the top climbing unit goes back into operation;
6) Annual Inspections: to be performed on their due date regardless of the top climbing unit
use over the year and with the equipment on the ground.

The inspection criteria and requirements listed hereon are enumerated under the two
systems/components breakdown groups outlined in para. 3.4.

1.6.1 Daily inspections

I) STRUCTURES

A) The operator, a qualified and trained person, is the appointed person for examination of any
deficiencies and for determination as to whether they constitute a hazard.
When installing the top climbing unit for use the first visual examination shall be performed
and the general conditions of the system inspected for possible deficiencies regarding the
structural, mechanical, electrical and hydraulic units.
B) Visually examine for proper connection the ladders, platforms, handrails, protections and special
devices provided for the operator’s safety.
C) Properly lubricate those mechanisms which need it.
D) Inspect the sliding rollers for correct operation.

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 II) HYDRAULIC SYSTEMS

A) Check the oil level of the resorvoir and its quality. Fill it up or replace it as necessary.
B) Check the hydraulic pipes for right connection and the seal gaskets for proper condition.

1.6.2 Weekly inspections

I) STRUCTURES

A) Make sure that all structural pin-connections are placed in the special housings and secured
with the relevant split pins.
B) Make sure that all bolt-connections are placed in the special housings, that they are secured
with the relevant nuts and properly tensioned as per Manufacturer’s recommended setting
torque.

II) HYDRAULIC SYSTEMS

A) Visually examine the electrical connections for proper condition.

1.6.3 Monthly inspections

I) STRUCTURES

A) Visually inspect all welds on the top climbing unit for visible cracks.
Examine closely welds that are rusted: rust is often a sign of crack in a structural weld.
B) Properly lubricate the pin connections as specified in the lubrication chart.

1.6.4 Quarterly inspections

They are part of the monthly inspections.

1.6.5 Six-monthly inspections

I) STRUCTURES
Visually inspect all welds on ladders, platforms and protections.

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1.6.6 Annual inspections

I) STRUCTURES

A) Perform non-destructive tests on structural welds of the top climbing unit.

B) Treat corrosion on and repaint all oxidized parts of the system.

C) Check the conditions of all the top climbing unit’s connecting systems: call Comedil’s technical
service for replacing any corroded, worn out or damaged pins, split pins, screws, nuts and
rollers.

II) HYDRAULIC SYSTEMS

A) Even if with the equipment out of operation, drain oil and flush reservoirs, clean and replace
filters. Replenish oil in the reservoirs as recommended at para. 1.8.1.
B) Properly set all devices and instruments of the hydraulic systems, as necessary.
C) Treat corrosion on all the hydraulic system components, replacing any corroded part.

Note:
Should extraordinary events happen, such as long periods of driving rain
with lightening striking near the crane, protracted work in a corroding
ambient or in particularly foul areas, etc. MORE FREQUENTLY AND
CAREFULLY INSPECT the electrical equipment for evident signs of wear.

1.7 SPECIAL MAINTENANCE

As indicated in section 1.1, special maintenance tasks shall be accomplished by skilled technicians
who have been properly trained and have the experience to accomplish these tasks.

F Specialists only shall be appointed to carry out the following operations:

A) Repairs of the electric motor;

B) Overhaul of pumps and adjustment of hydraulic devices;
C) Non-destructive testing for structural damage;
D) Repairs and replacement of top climbing unit’s structural parts.

1.8 LUBRICATION AND OILS

3$57672%(6(59,&(' /8%5,&$17
Pins Shield Fluid 3K

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 1.8.1 Hydraulic system (recommended oils)
RECOMMENDED OIL TYPE FOR AMBIENT TEMPERATURES FROM 0°C TO 40°C
(32°F TO 104°F)

The oil used shall be of suitable quality for hydraulic equipments, antifoaming, antioxidant,
anticorrosive and have such lubricating properties as to comply with the following standards:

ð FGZ TEST - 12° STAGE

ð DIN 51525 SPECIFICATION

ð VDMA 24317 STANDARD

We suggest to replace the hydraulic oil after 500 working hours and, in any case, every time it looks
not limpid or changes its colour.

Whenever replacing the oil, carefully clean the reservoir using by-products of petroleum such as
naftha or kerosene; do not use solvents.

At every oil change replace also the filter cartridge.

Protect the hydraulic equipment against bad weather.

Water is an oil’s enemy; small water quantities mixed with oil originate its polymerization. The
polymers so generated, because of their own consistency, cause the filter clog and can give rise to
cultures of bacteria compromising the lubricating quality.

Type Viscosity in °E at 50 °C (122 °F)

AGIP OSO 45 4°
BP ENERGON HPL 46 4.1°
CHEVRON HYDR. OILS EP 46 3.7°
ESSO NUTO H 46 3.9°
IP HYDRUS OIL 46 4°
MOBIL DTE OIL 25 3.9°
OLIMETE THF 40 4°
SHELL TELLUS OIL 46 4°
TOTAL AZOLLA 46 4°
VANGUARD SIRIO H OIL EP 46 4.3°

Remember that the hydraulic oil is highly polluting and toxic; therefore dispose of it adequately.

Avoid contact with the skin: in case of infection generously wash the exposed part with soap and
water. In case of contact with the eyes call immediately a doctor.

F When using the top climbing unit in an ambient with temperatures different form those considered,
consult Comedil’s Engineering Department.

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