02 Falcone HD23 CTL 400-CTT Soprael 003 e

Top Climbing System
HD23 Tower
Top Climbing
1 HD23 TOWER - TOP CLIMBING
1.1 INTRODUCTION
1.2 WIND SPEED LIMIT
1.3 TOP CLIMBING UNIT COMPOSITION
1.4 TOP CLIMBING UNIT GROUND ASSEMBLY
1.4.1 Preassembling
1.4.2 Assembling the upper and intermediate platforms, the lower platforms and ladders
1.4.3 Pin connection of supports P1 and P2 to the top climbing unit
1.5 ASSEMBLING THE TOP CLIMBING UNIT ON THE CRANE
1.5.1 Assembling service trolley CS and service trolley rail guide RC on the top climbing unit
1.5.2 Adjusting spacers (1) and (2) of mobile sleeper TR, front-back guide rollers R1 and
side rollers R2
1.5.3 Connecting the top climbing unit to the lower slewing ring support PI
1.6 PREPARING FOR TOP CLIMBING
1.6.1 CTL 400 HD23
1.6.2 CTT 331 and CTT 561 HD23
1.7 TOP CLIMBING
1.8 TOP CLIMBING DOWN
1.9 HYDRAULIC POWER PACK
1.9.1 Hydraulic power pack failure
1.9.2 Hydraulic power pack calibration
1.9.3 Recommended oil for ambient temperatures within -15° and +40°
1.10 HYDRAULIC SYSTEM
Chapter 2
2_F_HD23_003_e
2 HD 23 TOWER TOP CLIMBING
1.1 INTRODUCTION
Having to increase the height of a stationary or travelling base crane without removal of the
superstructure, this may be accomplished by means of a top climbing unit (telescoping section)
and special jacking equipment.
The top climbing unit assembly and the tower raising operations are quite complex and dangerous.
Therefore, they shall be performed exclusively by Comedils own skilled technicians or other
technicians authorized by Comedil.
F Any intervention of unauthorized personnel will make any Comedils public and criminal liability
automatically void, as far as possible damages to persons and equipment caused by accidents
due to any operation or intervention carried out by such unauthorized technicians is concerned.
1.2 WIND SPEED LIMIT

The maximum wind speed allowed at the crane rotating upper part level when top climbing varies
according to the crane model and the specific jib configuration (see table below):
-LE :LQGVSHHG
&UDQH OLPLW
PRGHO
P IW NPK PSK

&77

&77 Table 1.2.1

&7/$

Do not top climb if weather is expected to get worse.

Do not stop top climbing prior to completing any partial raising of the tower.
TRANSPORT
When transporting the top climbing unit assembled, attention to the side C (picture 1.2.1) and
sleeper TV (picture 1.3.1) which shall also be assembled to make the unit stiff enough.
Picture 1.2.1
Page 3/56 Tower - Top Climbing 2_F_HD23_003_e

1.3 TOP CLIMBING UNIT COMPOSITION
The top climbing system includes:
1) the top climbing unit: which is made of four frames A,B,C and D,
supports P1 and P2 connecting it to the lower slewing
ring support PI and of sleeper TV (picture 1.3.1);
2) Upper platforms A1, A2 DX, A2 SX; intermediate platforms B1, B2 DX, B2 SX;
lower platform C1 and ladders S1 and S2 (picture 1.3.2);
3) service trolley CS, servic trolley rail guide RC, sleeper AC, platform for service trolley rail
guide B3 and rail guide holding tie-ropes (picture 1.3.3);
4) the hydraulic jacking equipment: which is made of hydraulic power pack CN, hydraulic jack
MP, mobile sleeper TR, hydraulic jack support SM
and pawls SR (picture 1.3.4);
2_F_HD23_003_e Tower - Top Climbing Page 4/56

P2
TV
P1
Picture 1.3.1

A2 SX
A1
A2 DX
S2
B2 SX
B1
B2 DX
S1
C1 Picture 1.3.2

1 Washer Ø 60 - Thickness 6
2 Rope Ø 16
3 Pin T 25 × 75
4 Rope tensioner 7/8"
5 Thimble 5/8"
6 Clamp 5/8"
7 Spring washer M16
8 Screw TEIF M16 × 30
4
3
5
6 5
1
7 8
AC
B3 CS
RC
Picture 1.3.3

C1
CN
SR
SR
SM MP
TR
190
310
Picture 1.3.4

1.4 TOP CLIMBING UNIT GROUND ASSEMBLY (PICTURE 1.4.1)
1) place hydraulic jack support SM on hydraulic jack MP; secure the unit to frame A with
the special screws (picture 1.4.2);
2) place pawls SR on the proper housings on frame A and secure them with the special
slides and pins (picture 1.4.3);
3) place mobile sleeper TR on hydraulic jack MP (picture 1.4.4);
4) place front-back guide rollers R1 (picture 1.4.5) on frames A - C and sleeper TV
(picture 1.4.7); place side guide rollers R2 (picture 1.4.6) on frames B - D (picture 1.4.7).
5) join together frames A - B - C - D and sleeper TV with threaded pins and bolts
(pictures 1.4.7, 1.4.8, 1.4.9, 1.4.10);
6) fix the nameplate on mobile sleeper TR with M4 screws.

1.4.5
re
1.4.6 Pictu
e ì
ctur TV
ìP
i
1.4.7
e
D
ictur
ìP
1.4.8
re
Pictu
ì
1.4.8
e
ictur
ìP
A
C
1.4.9
e
ictur
ìP
0
1.4.1
e
tur
1.4.3 ìP
ic
e
ictur
ìP .4.2
1
ctur
e
1.4.9
i re
ìP Pictu
ì
1.4.4
e
ictur B
ìP
Picture 1.4.1

Picture 1.4.2 Picture 1.4.3
A
A
screw TEIF M30 × 90
mean nut M30
screw TEIF M20 × 40 SR

SM
pin lock
DIN 15058
pin Ø 120 × 290

pin Ø 20 × 185
split pin D6
MP slide
MP
pin Ø 120 × 270

split pin 16 × 140
TR
Picture 1.4.4

front-back guide rollers
Picture 1.4.5
pin Ø 30 × 210
(no. 12 pcs.)
R1
pin lock DIN 15058
tower stanchion
5 mm (0.2 inch.)
side guide roller

(no. 12 pcs.)
pin Ø 60 × 194 R2
lock pin DIN 15058

tower stanchion
5 mm (0.2 inch.)
Picture 1.4.6

D
mean nut M36
Picture 1.4.7
washer 90 × 37 × 10
threaded pin Ø 65 × 336
R2
A TV
R1 R1
washer 90 × 37 × 10
R2
mean nut M36
Picture 1.4.8
washer 90 × 37 × 10
mean nut M36 B

D mean nut M36
Picture 1.4.9
washer 90 × 37 × 10
R2
R1 R1
washer 90 × 37 × 10
R2
mean nut M36
Picture 1.4.10 D
mean nut M30
A C
washer 90 × 37 × 10
mean nut M36 B

1.4.1 Preassembling service trolley CS and service trolley rail guide RC
(picture 1.4.11)
1) Using sleeper (3) join together service trolley frames (1) and (2) ;
2) using sleeper (6) join rail guides (4) and (5) ;
3) secure platform B3 to the rail guide with four supports (7) and two supports (8). Install the
platform safety rails only after placing the rail guide on the top climbing unit;
4) attention that assembly of connection rod AC on service trolley CS shall be carried out
when moving inward the tower section placed on it.

AC tall nut M20
screw screw TEIF M20 × 55

TEIF M20 × 40 tall nut M20
2
3
5 6
pin Ø 20 × 87
split pin D4
7
4
7 screw TEIF M18 × 50

dtall nut M18
washer M18
7
8
7
B3
Picture 1.4.11

1.4.2 Assembling the upper and intermediate platforms, the lower platform and ladders
(picture 1.4.12)
1) Connect all platform foot-boards to the top climbing unit by pins and split pins;
2) Secure ladders and safety rails by screws and nuts;
3) Join the platform foot-boards together by screws and nuts;
4) Place the safety rails in the special housings on the platforms. Secure them by split pins;
5) Connect the safety rails with brackets (1). Secure them by screws and nuts.

tall nut M10
washer M10
A2 SX
A2 DX
A1
bracket (1)
S2
B2 SX
B2 DX
B1 screw TEIF M18 × 50

tall nut M18
washer M18
S1

tall nut M12
split pin D6 washer M12
C1
pin C25 × 115

screw TEIF M18 × 50 split pin D6
tall nut M18
washer M18
Picture 1.4.12

1.4.3 Pin-connection of supportsP1 and P2 to the top climbing unit (picture 1.4.13)
P2
pin Ø 65 × 220
split pin 13 × 110
P1
p
sp in Ø
lit p 6
A in 1 5 × 2
3× 20
110
Picture 1.4.13

1.5 ASSEMBLING THE TOP CLIMBING UNIT ON THE CRANE
The top climbing unit shall be assembled on the crane following one of the two different procedures
outlined below:
1) during the crane erection by mobile crane:
- Top lower the top climbing unit to the crane tower prior to the slewing unit assembly
(minimum crane height required for the operation 13 m / 42.65 ft, equal to three 6 m / 19.69 ft
-tower sections);
- Move pawls SR close to the tower and engage them on lugs H, thus holding the
top climbing unit (picture 1.5.1 - detail K);
2) with the crane erected:
- Place P1 and P2 supports on the lower slewing ring support. Secure them by screws
and nuts (picture 1.5.2);
- Sling the top climbing unit on points (1) - (1). Lift it by the crane hoist block (4-part line)
(picture 1.5.3);
- Connect the top climbing unit to the tower with (2) - (2) ropes equipped with
BRI-HIT (rope-through pulling jack) to facilitate its positioning inside the mast
(picture 1.5.3);
- Move pawls SR close to the tower and engage them on lugs H, thus holding the top
climbing unit (picture 1.5.1 - detail K);
- Place sleeper TV (picture 1.4.7) and frame C (pictures 1.4.9 - 1.4.10). Secure them
by threaded pins and bolts.

WEIGHT OF THE UNIT
14500 kg (31973 lbs)
top climbing unit
tower
SR
SR
tower
SR
DETAIL K
Picture 1.5.1

Screw TEPF M20 × 100
(Torque wrench setting 520 Nm / 384 lbsft)
Tall nut M20
Washer M20
P2
P1
s
e
sid
ction
Ere
Picture 1.5.2

WEIGHT OF THE UNIT
hoist block 13500 kg (29768 lbs)
TV
top climbing unit
tower
SR
SR
Picture 1.5.3

1.5.1 Assembling service trolley CS and service trolley rail guide RC on the top
climbing unit
1) Place service trolley CS on service trolley rail guide RC. Secure it by four pins Ø 20 × 87
and split pins D4.
Connect preassembled rail guides RC to the top climbing unit by threaded pins Ø 30 × 82
(picture 1.5.4);
2) Connect the rail guide holding pendants to the top climbing unit. Place the rail guide in horizontal
position by means of rope tensioners (4) (picture 1.3.3), thus making the service trolley
traversing easier.
CS
pin
Ø 20
× 87
RC
B3
RC
spacer Ø 40 × 11
tall nut M24
washer D6
Picture 1.5.4

1.5.2 Adjustinf spacers (1) and (2) of mobile sleeper TR and front-back guide rollers
R1 and side guide rollers R2.
1) On positioning power pack CN on platform B1 and connecting it tp hydraulic jack MP,
before mobile sleeper TR engages lugs H on the tower, adjust spacers (1) and (2) as per
table 1.5.1 and picture 1.5.5;
2) adjust the clearnace between front-back guide rollers R1, side guide rollers R2 and the
tower stanchion by M36 × 200 adjusting screws (picture 1.4.5 and 1.4.6).
TR
SPACER
Picture 1.5.5

+'72:(5 ; ; < <

7<3( >PP@ >LQFK@ >PP@ >LQFK@
TR 18.6 75 100
22.6 55 80
26.6 30 remove UHPRYH
Table 1.5.1
tower stanchion HD
H
2 ATTENTION!
Failing to get the proper contact between

X spacer (2) and the tower stanchion, use
one of the two extra spacers supplied with
the mobile sleeper with y measuring
1 split pin D8 70 mm and 90 mm respectively.
Y
pin Ø 40 × 110

1.5.3 Connecting the top climbing unit to the lower slewing ring support
1) The top climbing unit is hold by pawls SR engaged on the tower lugs H (picture 1.5.6)
2) move mobile sleeper TR close to the tower operating joystick C1 on power pack CN
(picture 1.3.4); raise pressure to hydraulic jack MP thus allowing mobile sleeper TR
engage lugs H (picture 1.5.9);
3) extend the stem of hydraulic jack MP thus releasing pawls SR from lugs H
(picture 1.5.7); extend the stem of hydraulic jack MP further until the top climbing unit
matches the lower slewing ring support;
4) connect the top climbing unit to the lower slewing ring support with supports P1 and P2
(pictures 1.4.13 and 1.5.2).

tower tower
SR SR
H H
MP MP
H H
TR TR

1.6 PREPARING FOR TOP CLIMBING
Attain to the following procedure to raise the tower by the top climbing unit.
1.6.1 CTL 400 HD23
1) Place all tower sections PR to be installed on the ground as close as possible to the tower
(service trolley CS side), on a level and clear area (picture 1.6.1).
Clean the connecting surfaces.
2) Prepare a load Z for the crane balancing. Its weight shall vary depending on the jib length
used (see table 1.6.2).
Note
The tower sections shall be preassembled on the
CS ground.
Refer to chapter 4B Tower erection of
the crane operation manual.
PR
Picture 1.6.1
Z
3) Disconnect cam no. 1 (jib luffing angle 84°) and no. 2 (jib luffing angle 80°) of the rotating luffing
limit switch placed on the luffing winch (picture 1.6.2 and 1.6.3).
A
B
1
2
3
4

4) Set the mechanical luffing limit switch II (jib luffing angle 85°) placed on the A-frame
(picture 1.6.4) according to the jib length used (see table 1.6.1).
II
Picture 1.6.4
-LE $QJOH a
>P@ >IW@ >@

D Table 1.6.1
Note
a = jib angle
PR = Tower section HD23 22.6
Z = Weight
F Theoretical calculation (absence of wind)
PR
Z
Picture 1.6.5

5) Sling tower section PR in the special eyebolts (picture 1.6.6).
Tower section HD23 22.6 (4823 kg / 10635 lbs)

ë total no.2 eyebolts placed on the opposite
stanchions
Tower section HD23 26.6 (6473 kg / 14273 lbs)

ë total no.4 eyebolts placed on four stanchions (all
to be used, always and in any case)
Picture 1.6.6
Lift tower section PR and place it on service trolley CS, which was secured to rail guide
RC with pins Ø 20 × 87 (picture 1.6.7).
Picture 1.6.7
PR
CS
PR
Z
Turn tower section supports S inside the tower itself.

Place sleeper AC ans secure it with screw TEIF M20 × 40 (picture 1.6.8).

S
P
CS
RC
Screw TEIF M20 × 40 AC Pin Ø 20 × 87
Picture 1.6.8
Pin Ø 20 × 87
6) Position the tower section on service trolley CS.

Hang Z weight to the hook and lift it, thus balancing the crane.
Make sure the jib luffing angle keeps within the limits stated in table 1.6.2.
Note
Picture 1.6.9 a = jib angle
PR = Tower Section HD23 22.6
Z Z = Weight
D
F Theretical calculation (absence of wind)
-LE $QJOH a 35 =
PR >P@ >IW@ >@ >NJ@ >OEV@ >NJ@ >OEV@

PR

Table 1.6.2
7) Repeat the operation until all tower sections have been assembled.

1.6.2 CTT 331 and CTT 561 HD23
1) Place all tower sections PR to be installed on the ground as close as possible to the tower
(service trolley CS side), on a level and clear area (picture 1.6.10).
Clean the connecting surfaces.
2) Prepare a load Z for the crane balancing. Its weight shall vary depending on the jib length
used (see tables 1.6.3 -1.6.4 - 1.6.5).
Note
The tower sections shall be preassembled on the
ground.
CS
Refer to chapter 4B Tower erection of
the crane operation manual.
Picture 1.6.10
PR
Z
3) From the cab keep push-button Trolley coupling pressed, thus preventing the trolley limit
switch from intervening and trolley all the way in.
4) If the crane is CTT 561-20 model (with double jib trolley), connect the hook to the hoist block of
the jib-foot trolley and work with 2-part line engaged (picture 1.6.11).
Picture 1.6.11
do not use this bracket

5) Lift tower section PR by special triangular handling device B (see picture 1.6.12) diagonally
connecting it to two of the tower section stanchions with M36 × 520 threaded bars.
threaded bar M36×520
Picture 1.6.12
Position tower section PR on service trolley CS, which was secured to rail guide RC
with Ø 20 × 87 pins (picture 1.6.13).
PR
CS
PR
Z
Picture 1.6.13

Turn tower section supports S inside the tower itself.
Place sleeper AC and secure it with TEIF M20 × 40 screw (picture 1.6.14)
CS P
RC
AC Pin Ø 20 × 87
Screw TEIF M20 × 40
Pin Ø 20 × 87
Picture 1.6.14
6) Hook Z weight (see tables 1.63 - 1.64 - 1.6.5) and balance the crane just trolleying in and out
as necessary.
PR Z
PR
Picture 1.6.15
Note
PR = Tower section HD23 22.6
Z = Weight
F Theretical calculation (absence of wind)
7) Repeat the operation until all tower sections have been assembled

&77 &77 &77
-LE E 35 = -LE E 35 = -LE E 35 =
>P@ >P@ >NJ@ >NJ@ >P@ >P@ >NJ@ >NJ@ >P@ >P@ >NJ@ >NJ@

Table 1.6.3 Table 1.6.4 Table 1.6.5
U.S. Customery Units
&77 &77 &77

-LE E 35 = -LE E 35 = -LE E 35 =
>IW@ >IW@ >NJ@ >NJ@ >IW@ >IW@ >NJ@ >NJ@ >IW@ >IW@ >NJ@ >NJ@


1.7 MAST RAISING
Warning!
While raising the mast it is severely forbidden:

- to carry out any slewing maneuver;
- to carry out any hoisting maneuver;
- to carry out any travelling maneuver.
Should any of the above operations be absolutely

required, the top climbing unit shall be lowered
and the lower slewing ring support pin-connected
to the tower (picture 1.7.1).
Picture 1.7.1
1) Unscrew the nuts of the high strength bolts connecting lower slewing ring support PI to
tower T about 20 mm / 0.79 inches (picture 1.7.2)
LOWER
SLEWING RING
SUPPORT PI
P1
20 mm
P2
High strength bolt
Nut
TOWER T
TOP CLIMBING
UNIT
Picture 1.7.2

2) Using joystick" C1" on power pack CN (picture 1.7.3) raise enough pressure to hydraulic
jack "MP".
C1
Picture 1.7.3
CN
Extend the stem of hydraulic jack MP about 10 mm / 0.39 inches further by mobile sleeper
TR (already engaged on lugs H), thus allowing lower slewing ring support PI to detach
from tower T (picture 1.7.4).
LOWER
SLEWING RING
SUPPORT PI
0.39 inch.
P1
10 mm/
P2 High strength bolt
Nut
0.39 inch.
10 mm/
TOWER T
TOP CLIMBING
UNIT
Picture 1.7.4

3) Make sure there is the same gap among the lower slewing ring support PI and the four tower
T stanchions, thus resulting in the crane balancing. If not, properly increase or decrease a
angle of the jib through slight movements (picture 1.6.9).
4) Check the distance between front-back guide rollers R1, side guide rollers R2 and the
tower stanchions (the gap shall be 5 mm / 0.20 inches on each side, equal to total 10 mm /
0.39 inches between the guide rollers and the tower - pictures 1.4.5. and 1.4.6).
5) Remove the 16 high strength bolts connecting the lower slewing ring support to the tower
T (picture 1.7.5).
LOWER
SLEWING RING
SUPPORT PI
10 mm / 0.39 inch.
P1
P2
Picture 1.7.5
TOWER T
TOP CLIMBING
UNIT
Move pawls SR away from the tower, thus preventing them from interfering with the
upper lugs H when top climbing (picture 1.5.7).
6) 1st raising phase: on removing the high strength bolts, extend the stem of hydraulic jack
"MP" to stroke end (during the operation, always keep control of the crane balancing). This
will produce a gap L between lower slewing ring support "PI" and the tower T (picture
1.7.6).
A telescoping action of the right height needed to insert a 6 m / 19.69 ft tower section requires
four 1500 mm / 59.06 inches strokes of hydraulic jack "MP". So, the complete operation
consists of four raising phases, as called for at next para. 7.

SR
PI
H
L
H
MP
T
H
T
Picture 1.7.6
H
TR
7) Close pawls SR to the tower until they engage the upper lugs H.
Retract the stem of hydraulic jack MP until mobile sleeper "TR" clears the lower lugs H
(picture 1.7.7).
Retract the stem of hydraulic jack MP to stroke end. Make sure mobile sleeper "TR" does
not interfere with lugs H (picture 1.7.8).
Move mobile sleeper "TR" close to the tower. Raise pressure to hydraulic jack MP and
make sure it perfectly engages lugs H.
Move pawls SR away from tower T, thus preventing them from interfering with the
upper lugs H when top climbing (picture 1.7.9).

SR SR SR
H H H
MP MP
H H H
MP
H H
TR TR
T
T
H
TR
Picture 1.7.7

Extend the stem of hydraulic jack "MP" to stroke end.
The gap between lower slewing ring support PI and tower Tshall be now equal
to gap L + 1500 mm / 59.06 inches (picture 1.7.10)
Repeat the operations in sequence another three times.
PI
SR
L + 1500 mm / 59.06 inch.

H
H
MP
T
H
T
Picture 1.7.10
H
TR

2nd raising phase: The gap between lower slewing ring support "PI" and tower "T" shall
be now equal to gap L + 3000 mm / 118.11 inches (picture 1.7.11).
PI
SR
H
L + 3000 mm / 118.11 inch.

H
MP
T
H
T
H
Picture 1.7.11
TR

3rd raising phase: The gap between lower slewing ring support "PI" and tower "T" shall
be now equal to gap L + 4500 mm / 177.17 inches. (picture 1.7.12).
PI
SR
H
L + 4500 mm / 177.17 inch.

H
MP
H
T
T
H
Picture 1.7.12
TR

4th raising phase: The gap between lower slewing ring support "PI" and tower "T" shall
be now equal to gap L + 6000 mm / 236.22 inches (picture 1.7.13) and
allow the insertion of the tower section.
PI
SR
H
L + 6000 mm / 236.22 inch.

H
MP
H
T
T
H
TR
Picture 1.7.13

8) Prior to the insertion of tower section PR, place no. 4 high strength bolts (1) with special nut
(3) and joint plate (2) on the lower stanchions (lugs H side). Make sure they come out
100 mm / 3.94 inches maximum from the lower edge of the tower section itself (picture 1.7.14).
H PR
max. 100 mm / 3.94 inch.
Picture 1.7.14
3
2
1

9) Remove the four pins Ø 20 × 87 securing service trolley CS to rail guide RC.
Let the tower section on service trolley CS go inside the tower until the lower mounts of the
tower section stanchions line up with the upper mounts of the tower (picture 1.7.15).
PR
AC
CS
RC
Pin Ø 20 × 87
see picture 1.7.14
TOWER Picture 1.7.15

10) With the tower section perfectly aligned with the tower, make sure the mounting holes are
clean and free from paint, dirt, etc.
Then place the remaining twelve high strength bolts (1) with special nut (3) and joint plate (2).
Activate hydraulic jack MP and lower the top climbing unit with the tower section until its
lower mounts match the upper mounts on the tower (picture 1.7.16).
R1 - R2
a
AC
2
3
R1 - R2
b
Picture 1.7.16
R1 - R2
c

11) Retract the stem of hydraulic jack MP and lower the top climbing unit with service trolley
CS, thus releasing tower section supports S.
Turn supports S towards rail guide RC; loosen screw TEIF M20 × 40 screw and withdraw
sleeper AC (picture 1.7.17).
PR
S
Screw TEIF M20 × 40
CS
RC
AC
Picture 1.7.17
Now push service trolley CS outside the top climbing unit and secure it to rail guide RC
with Ø 20 × 87 pins (picture 1.6.8).

12) Tensioning of the tower high strength bolts
Tension high strength bolts M45 (HD 23 22.6 tower sections) and M52 (HD23 26.6 tower
sections) as stated below:
High strength bolts M45 10.9 Tensioning = 896 kN ( 201394 lbs)
High strength bolts M52 10.8 Tensioning = 1196 kN (268826 lbs)
The tensioning order shall be as follows:
a) Tension high strength bolts (1) and (2) on hydraulic jack MP and tower lugs H side
(picture 1.7.18);
b) Retract the stem of hydraulic jack MP and lower the top climbing unit with lower slewing
ring support PI about 30 mm / 1.18 inches off tower section PR, thus granting the
necessary space for tensioning of the remaining high strength bolts by the special tool
(picture 1.7.19);
c) Tension high strength bolts (3), (4), (5), (6), (7) and (8) (picture 1.7.18).
1 5 8 3 Respecting the tensioning order of picture 1.7.18

1 5 8 3 releases the user from tensioning the high
strength bolts again after the crane erection is
finished.
Hydraulick jackMP
The non-observance of the recommended

procedure might result in an irregular
2 7 6 4 tensioning of the 16 high strength bolts:
2 7 6 4 dangerous!
PI
Picture 1.7.18
30 mm
PR
Picture 1.7.19

Important advise
When top climbing, the top climbing unit shall move along the tower (made from tower sections
PR of different type: 18.6 / 22.6 / 26.6) with the crane perfectly balanced. To this purpose, attain
strictly to the directions given below:
1) Adjust gap L between R1 - R2 guide rollers (pos. a of pictures 1.7.16 and 1.7.20) and the
stanchions of tower section PR by M36 special screws (pictures 1.4.5, 1.4.6 and table 1.7.1).
2) Extend the stem of hydraulic jack MP until R1 - R2 guide rollers (pos. b of pictures 1.7.16
and 1.7.20) are close to the smaller sized (thinner) tower section. Adjust gap L between
them and the stanchions as indicated at point 1) (pictures 1.4.5, 1.4.6 and table 1.7.1).
3) On positioning R1 - R2 guide rollers (pos. c of pictures 1.7.16 and 1.7.20) close to the
smaller sized (thinner) tower section, adjust gap L between them and the stanchions as
indicated at point 1) (pictures 1.4.5, 1.4.6 and table 1.7.1).
L 5 mm /
0.20 inch.
R1 a
R2
L 5 mm /
0.20 inch.
Picture 1.7.20
22.6 18.6
R1 b
R2
P P
5 mm /
0.20 inch.
26.6 22.6
R1 c
R2
/
5 5
3 5 )5 2 1 7%$ & . 6 ,' (
72 : ( 5 * 8 , ' ( 5 2 / / ( 5 6 * 8 , ' ( 5 2 / / ( 5 6
6 ( &7,2 1
>P P @ >LQFKH V@ >P P @ >LQFKH V@

Table 1.7.1


Important advise
Prior to positioning the following tower section on service trolley CS you shall:
1) lower the top climbing unit with lower slewing ring support PI until the proper connections
with the tower are made (picture 1.7.22);
2) place two high strength bolts (4) on each tower stanchion and tension them half the setting
values called for at para.12);
3) lower balancing weight Z to the ground (picture 1.6.9).
LOWER
SLEWING RING
SUPPORT PI
P1
High strength
P2
bolt (4)
Nut
TOWER T
TOP CLIMBING
UNIT
Picture 1.7.22
(4) (4)
Hydraulic jack MP
(4) (4) Picture 1.7.23

For the installation of the remaining tower sections, repeat the raising phases called for at
para. 1.6.
On achieving the tower height required, connect lower slewing ring support PI to the tower T by
16 high strength bolts and tension them as indicated at para. 12).
On completing the tower raising, lower the top climbing unit as far as it can go (tower height usually
restricted by the undercarriage struts or tie-in assemblies).
Failing to take this precaution, the surface exposed to the wind would make the stormy thrust not
only heavy but, in certain circumstances, even unbearable.
Lowering the top climbing unit
1) Remove the four Ø 65 × 220 pins connecting the top climbing unit to supports P1 and P2 of
lower slewing ring support PI.
2) Lower the top climbing unit following one of the two recommended procedures below:
a) reversing the raising procedure;
b) hooking the top climbing unit to the hoist rope and guiding it along the tower to the ground
with care.
3) On completing the operation, set cam no. 1 (jib luffing angle 84°) and no. 2 (jib luffing angle
80°) of the rotating luffing limit switch placed on the luffing winch (pictures 1.6.2 and 1.6.3). Set
also the mechanical luffing limit switch II (jib luffing angle 85°) placed on the A-frame
(picture 1.6.4).
1.8 TOP CLIMBING DOWN
For the tower sections dismantling, reverse the sequence of the tower raising operations previously
set out.
In particular, while lowering the top climbing unit, adjust the position of guide rollers R1 - R2, thus
preventing them from interfering with the bigger sized (thicker) tower section (pictures 1.7.20
and 1.7.21).
Note
Having to stop raising the tower (maybe, at the end of a working day or due to bad weather), lower
the top climbing unit and place the 16 high strength bolts (picture 1.7.1).

1.9 HYDRAULIC POWER PACK
1.9.1 Power Pack Failure to start
In case of hydraulic power packs failure to start proceed as follows:
a) Check the motor rotating direction: it shall be left to right, and slewing therefore be clockwise.
b) Check theres enough oil in the reservoir for the operation: the minimum level admitted is
130 mm / 5.12 inches (measured from the bottom of the reservoir).
c) Check there is no foam on the oil surface: foaming causes cavitation which generates
excessive noise from the power pack; oil shall always be transparent and have a pale
yellow colour: if not, replace it.
In case of foaming inspect the suction filter: if it looks slightly squashed (this means the
filter is obstructed), replace it.
Do not clean it by compressed air. Remember that the filter flow rate must be 3-4 times the
pump delivery and the minimum required filtering power is 60 µm.
d) Check for leakages inside the power pack as follows:
1) start the power pack;
2) remove the oil filler plug;
3) pull back the distributor lever.
The oil surface should remain motionless. If not, it means there is a leakage inside. Maybe due
to a pipe not properly tightened, or to the extrusion of the O-ring of the pump connecting flange.
If there is no spare O-ring available, temporarily use that of the suction flange.
To replace the electric motor make sure the rubber flexible coupling is not compressed between
the motor and pump sides of the joint. To make the assembly of the flexible coupling easier,
grease the joint surfaces.
Never force the motor through the coupling flange: axial thrusts demage the pump irreparably.

1.9.2 POWER PACK CALIBRATION
Calibrate the power pack separately. Make sure, therefore, it is not connected to the cylinder during
this phase.
Operating instructions:
a) Check that there is oil inside the power pack.
b) Check that the motor turns left-to-right. Turning right-to-left more than one minute might result
in an irreparable damage to the pump.
c) Unloose lock nut (2) on the valve using a 13 mm / 0.51 inches wrench (picture 1.9.1).
d) Pull lever C1 close towards you and slowly turn clockwise the adjusting screw (1) using a
5 mm / 0.20 inches setscrew wrench.
Read the pressure value achieved on the pressure gauge. Never exceed the pressure value
of 250 bar.
e) On calibrating the valve, secure lock nut (2).
C1
Picture 1.9.1
CN
2

1.9.3 RECOMMENDED OIL FOR AMBIENT TEMPERATURES WITHIN -15°C + 40°C.
The oil used shall be of suitable quality for hydraulic equipments. Namely, it shall be antifoaming,
antioxidant, anticorrosive and have such lubricating properties as to comply with the following
standards:
à FGZ TEST - 12° STAGE
à DIN 51525 SPECIFICATION
à VDMA 24317 STANDARD
AGIP OSO 45
BP ENERGOL HPL 46
CHEVRON HYDRAULIC OIL EP 46
ESSO NUTO H 46
IP HYDRUS OIL 46
MOBIL DTE OIL 25
OLIMETE THF 40
SHELL TELLUS OIL 46
TOTAL AZOLLA 46
VANGUARD SIRIO H OIL EP 46
We suggest to replace the hydraulic oil after 500 working hours and, in any case, every time it looks
not clear 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 the filter cartridge, as well.
Protect the hydraulic equipment against bad weather.
Water is an oils 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.
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.
Keep the system in a dry site.

1.10 HYDRAULIC SYSTEM
OP1 Pump 2D 30 RO OZ6 Gauge - Scale 0-400 AR 1/4

OM1 Multitension motor 11kW 4P B3 B5 OZ7 Distributor SD 11/1N (3 kg / 7 lbs) 28L
OV1 Valve VBSO DE NBA 12 OZ8 Flexible pipe SAE R9 L=5000 F.3/4
OZ1 Reservoir 150 l 420×1100×400 OZ9 Quick joint 3/4
OZ2 Oil level indicator 127 l M12 1A Cylinder T. DE 300 × 180 × 1675
OZ3 Oil filler plug TMDA 114
OZ4 Oil drain filter RFM 25.MS1.B510
OZ5 Gauge disconnecting device FT 294 1/4

02 Falcone HD23 CTL 400-CTT Soprael 003 e

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

02 Falcone HD23 CTL 400-CTT Soprael 003 e

Enviado por

Direitos autorais:

Formatos disponíveis

Top Climbing System

1.2 WIND SPEED LIMIT

&7/$    

Do not top climb if weather is expected to get worse.

Page 3/56 Tower - Top Climbing 2_F_HD23_003_e

The top climbing system includes:

2_F_HD23_003_e Tower - Top Climbing Page 4/56

Page 5/56 Tower - Top Climbing 2_F_HD23_003_e

2_F_HD23_003_e Tower - Top Climbing Page 6/56

Page 7/56 Tower - Top Climbing 2_F_HD23_003_e

2_F_HD23_003_e Tower - Top Climbing Page 8/56

3) place mobile sleeper TR on hydraulic jack MP (picture 1.4.4);

6) fix the nameplate on mobile sleeper TR with M4 screws.

Page 9/56 Tower - Top Climbing 2_F_HD23_003_e

2_F_HD23_003_e Tower - Top Climbing Page 10/56

screw TEIF M30 × 90

mean nut M30

screw TEIF M20 × 40 SR

pin Ø 120 × 290

pin Ø 120 × 270

Page 11/56 Tower - Top Climbing 2_F_HD23_003_e

side guide roller

lock pin DIN 15058

screw TEIF M36 × 200

2_F_HD23_003_e Tower - Top Climbing Page 12/56

threaded pin Ø 65 × 336

mean nut M36

threaded pin Ø 65 × 336

mean nut M36 B

threaded pin Ø 65 × 295

Page 13/56 Tower - Top Climbing 2_F_HD23_003_e

threaded pin Ø 65 × 336

mean nut M36

threaded pin Ø 65 × 336

mean nut M30

mean nut M36 B

threaded pin Ø 65 × 295

2_F_HD23_003_e Tower - Top Climbing Page 14/56

2) using sleeper (6) join rail guides (4) and (5) ;

Page 15/56 Tower - Top Climbing 2_F_HD23_003_e

screw screw TEIF M20 × 55

7 screw TEIF M18 × 50

2_F_HD23_003_e Tower - Top Climbing Page 16/56

2) Secure ladders and safety rails by screws and nuts;

3) Join the platform foot-boards together by screws and nuts;

Page 17/56 Tower - Top Climbing 2_F_HD23_003_e

B1 screw TEIF M18 × 50

screw TEIF M12 × 35

pin C25 × 115

2_F_HD23_003_e Tower - Top Climbing Page 18/56

Page 19/56 Tower - Top Climbing 2_F_HD23_003_e

1) during the crane erection by mobile crane:

2) with the crane erected:

2_F_HD23_003_e Tower - Top Climbing Page 20/56

top climbing unit

Page 21/56 Tower - Top Climbing 2_F_HD23_003_e

2_F_HD23_003_e Tower - Top Climbing Page 22/56

top climbing unit

Page 23/56 Tower - Top Climbing 2_F_HD23_003_e

tall nut M24

2_F_HD23_003_e Tower - Top Climbing Page 24/56

+'72:(5 ; ; < <

TR 18.6 75  100 

22.6 55  80 

&7/$

3) place mobile sleeper TR on hydraulic jack MP (picture 1.4.4);

6) fix the nameplate on mobile sleeper TR with M4 screws.

TR 18.6 75 100

22.6 55 80

26.6 30 remove UHPRYH

Turn tower section supports S inside the tower itself.

6) Position the tower section on service trolley CS.

&77 &77 &77

P2 High strength bolt

H H H

H H H

L + 1500 mm / 59.06 inch.

L + 3000 mm / 118.11 inch.

L + 4500 mm / 177.17 inch.

L + 6000 mm / 236.22 inch.

TOWER Picture 1.7.15