ASSEMBLY INSTRUCTIONS, USE AND MAINTENANCE — technical document
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ASSEMBLING, OPERATING AND MAINTEINANCE
INSTRUCTIONS FOR LIGHTING MAST WITH MOBILE
CROWN
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SUMMARY
1. INTRODUCTION 3
2. GENERAL DESCRIPTION OF THE MAST 3
3. PRELIMINARY DRAWING WITH DIMENSIONS AND WEIGHT 4
4. TRANSPORT, UNLOADING AND STORAGE OF THE LIGHT MAST 5
5. BOLTS, NUTS AND MATERIAL NECESSARY FOR THE ASSEMBLING 6
6. ASSEMBLY OF THE SECTIONS 7
7. ASSEMBLY OF TRAILING HEAD AND MOBILE CROWN 8
8. LIFTING AND CENTERING OF THE SHAFT 14
9. FIRST OPERATION OF THE MAST 19
10. INSTALLATION OF BRACKETS FOR FLOODLIGHTS AND ACCESSORIES 20
11. WIRING AND GROUND TEST OF FLOODLIGHTS 21
12. ROPES ADJUSTMENT 22
13. FIRST HOOKING OPERATION-SWITCH LIMITER ADJUSTMENT 24
14. PUT INTO SERVICE THE BRAKE SYSTEM 26
15. OPERATING INSTRUCTIONS 27
16. WARNINGS 28
17. DISMANTLING OF THE LIGHTING MAST 28
MANUAL MAINTENANCE 29
MAINTENANCES BOOK 36
INFORMATION NOTE 43
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1. INTRODUCTION
This manual contains the instructions for the assembling, operation and maintenance of the lighting
masts with mobile crown. IN ADDITION TO THIS INSTRUCTIONS, YOU ALWAYS HAVE
TO REFER TO THE WORKSHOP DRAWINGS PROVIDED AT TIME OF ORDER THAT
COULD INCLUDE ADDITIONAL INFORMATION ABOUT PARTICULAR CASES
2. GENERAL DESCRIPTION OF THE MAST
The lighting mast with mobile crown, it is a steel structure composed of:
Monotubolar shaft tapered shaped with polygonal cross section, made of hot dip galvanized steel, composed of
two or more sections to be joined at site by forced overlapping (slip on joint). Manufactured by cold forming of
steel plate and subsequent external longitudinal welding carried out by automatic an approved process.
The anchorage to the base can be either by direct burying the foundation plinth or by base plate and anchor bolts.
The shaft is equipped at the base of grounding connection, reinforced door for access to the internal equipment
and, in the case of direct burying, a slot for cable entry. At the top it is provided with a flange for fixing the trailing
head.
The trailing head made of hot galvanized steel, consisting of a 3-arms arranged at 120 ° housing the lifting cables
and / the cord / the electric, designed for attachment to the stem by means of flange and bolts. The bracket is
completely covered to grant the protection of the movement devices composed of polyamide pulleys 6.6 mounted
on self-lubricated bushes and inox steel pivots. A system which prevents the hoisting and electric cable to go out
of their groove is provided. The brackets of the ropes are provided with hooking and centering system of the
mobile crown.
The trailing head is supplied assembled and completed with the lifting ropes (dimensioned with a minimum safety
coefficient equal to 6 and / of the cable / the electric for feeding the floodlights.
The trailing head is supplied assembled and completed with the lifting ropes (dimensioned with a minimum safety
coefficient equal to 6 and / of the cable / the electric for feeding the floodlights.
The wiring ropes and the power cables are fixed at one end to the connection cylinder (distributor), while the other
end is passed on relative arms and subsequently anchored to the mobile crown.
Mobile crown made of hot, dip galvanized steel profiles composed of two concentric rings connected by three ribs
at 120 °. On each rib is fixed the elastic hooking system composed of stainless-steel pivots and double steel metal
foils; This enables the crown to be firmly attached to the trailing head completely releasing the hosting ropes from
any load during normal operation of the mast. Upon request the safety brake system can be installed, that locks the
mobile crown to the shaft in the case of failure of the lifting ropes or the hoist chain.
It is provided an anti-rotation system that prevents the movement on the horizontal plane of the crown.
The floodlights and related boxes are mounted on special brackets made of hot galvanized steel and are fitted to be
fixed to mobile crown by bolts.
Electrical-system
The electric cable for the power supply of the floodlight is of self-supporting type having adequate section for the
power to be installed. At the base of the mast (nearby the connecting drum) the cable is provided with CEE plug
for connection to the interlocked socket fixed nearby the door, while on the top ends inside the junction box it is
fixed to the mobile crown. The junction box, completed with pre-wired terminal board, is equipped with socket
watertight provided for the ground test using a purpose made extension with EEC plugs.
Electric hoist with suitable bearing capacity to the loads to be lifted required by the project; the mast can be
provided with integrated version (the hoist is placed inside of the shaft) or trolley mounted (the hoist is mounted in
a separate structure from the mast).
The protection of the surface is obtained by hot dip galvanizing. The thickness of the zinc layer will be according to
UNI EN ISO 1461.
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3. PRELIMINARY DRAWING WITH INDICATION OF DIMENSIONS AND
WEIGHT
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4. TRANSPORT, UNLOADING AND STORAGE OF THE LIGHTING MAST
TRANSPORT
The lighting mast is provided to be assembled in the following packages:
− N.1 bundle for each section
− N.1 bundle for the trailing head
− N.1 bundle for the mobile crown
− N.1 bundle for electric hoist and driving whirl, if any
− N.1 bundle for the bracket for floodlight supports and ballasts if any, bolts nuts, distribution
box and door.
During transport, care should be taken to ensure the mast in such a way as to prevent damage (such
as crushing and / or distortion) of the most breakable parts (the trailing head, crown, door) due to
the heavier parts (shaft).
UNLOADING
The unloading must be carried out with suitable means to lift the weights indicated in the previous
chapter, slinging the section with suitable strips or chains arranged in such a way that the sections
are balanced as shown in the photo below.
STORAGE
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the storage of the shaft, the mobile crown and the trailing head can be done outside avoiding the
direct contact with the ground; to this purpose it is useful to arrange the material on some raised
supports.
The trolley mounted hoist, the door, the distribution box and bolts and nuts must be kept in a
covered and dry place.
5. BOLTS AND MATERIAL NECCESSARY FOR THE ASSEMBLING
Description Q.ty aim Type of Given
mast with the
supply
Screws M18x60 TF
Hooking of the trailing head to the
completed with 2 middle 6 All YES
top plate of the shaft
nut M18
Screws M16x40 TF Fastening of the hoist support to the
2 Integrated YES
complete plane washer shaft
Screw M18x90 TF
Fastening hoist support to the mast
complete with even 1 Integrated YES
shaft
washer
(*) Fasten the electrical cable to the
Blocks for cable fixing All YES
mobile crown
2 Overlap the section composing the
Tir-for All NO
shaft
pilot probe having length Facilitate the insertion of a rope
at least equal to the 1 within the shaft used for the insertion All NO
height of the shaft of the distributor
Ropes having at least a
Facilitate the lowering of the mobile
length equal to the height 2 All NO
crown during the adjusting phase
of the shaft
(*) The number of the pairs of cable clamp blocks is a function of the number of the present electrical cables. It is provided a pair of blocks for each
electrical cable.
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6. ASSEMBLY OF THE MASTS
Put the masts on wooden edges in such a way that the longitudinal welding line of each shaft
coincides with that of the next one.
The door opening of the base section must be turned upwards, NEVER downwards. The mark made
on the top plate must be in axis with the door (see figure below). Before proceeding with the
assembly, you need to be sure that the overlapping areas are free from gravel pebbles or dirt (which
may be enter during unloading / handling / storage phases) that can cause problems during the
forced overlapping phases.
TOP VIEW
The assembly of the masts is made by using 2-tir (pull and lifting machines) hooked to the ends of
the sections, starting, in the case of mast in 3 or more elements, to assemble the base section with
the next one and proceeding gradually up to the top section. THE MASTS MUST BE
OVERLAPPED TO REFUSAL.
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7. ASSEMBLING OF THE TRAILING HEAD AND MOBILE CROWN
Before to assemble the trailing head and the mobile crown is necessary to put the mast in sloped
positions raising the top end around 1m above the ground; if the shaft is composed in 3 or more
sections it is better to arrange a support in the central part of the shaft to avoid that the tower can
flex. Moreover, if it is possible, it’s good to put the shaft in proximity to the foundation block in
order to reduce to a minimum the handling operations with the mast suspended during the lifting
operations.
Then proceed with the following steps:
- Make sure that the lock crown devices are fixed to outermost position.
- Place the crown on the top of the tower in such a way that the centering pivots are toward
the top of the shaft
- Insert the driving probe from the top of the mast and leave it sliding inside the mast until it
can be seen from the door; connect the rope to the end of the driving probe which exit from
the top of the shaft. Then pull the driving probe (to the base of the shaft) so that the rope
enters inside the shaft. Release the driving probe.
- Put the trailing head near the top of the shaft unrolling the cable and ropes along the axis of
the mast.
- Fix the trailing head to the top plate with N. 6 screws TE M18x60 TF and nuts and washers
included in the supply
- Insert the distributor within the tower (by pulling the free end of the rope) taking care not to
damage the wire ropes and the power cables, stopping it when it appears on the door at the
base.
- Fasten the trailing head-to-head with plate TF 6 TE M18x60 screws and nuts included in the
supply.
NOTE: On the trailing head there is a mark “SIDE DOOR"; such mark must be the axis with the
door at the base of the mast.
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- Pass the cables inside the centering sleeves as shown in figure
- Hook the crown to the trailing head locking it with 3 edges so that it doesn’t unhook
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- [Only for the integrated version] Fix the hoist support (and the integrated hoist) using the two
M18x90 TF screws and move the distributor so that its distance from the limit switch is 500mm as
shown in picture. Lock the distributor with the safety chain supplied
.
- [Just for the trolley mounted version] Insert and secure the driving whirl from the purpose
made on the side of the shaft and move the distributor so that its distance from the limit switch is
500mm as shown in picture. Lock the distributor with the safety chain supplied.
- Pull the wire ropes and electric cable until they are under tension, then marking them with a
marker in the way indicated below:
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STANDARD MOBILE CROWN
-The wire ropes must be marked at the end of the tubular
-The electric cable must be marked in center line of the connection point for fastening cables blocks
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MOBILE CROWN WITH SAFETY BRAKE SYSTEM (IF REQUIRED)
- Spin the rope around the pulley of the brake and mark it at the center of the thimble attached to the
tie rod of rope adjuster
-The electrical cable must be marked in the center line of the connection of cables blocks
- Unhook the distributor and move it to the upper edge of the door, then lock it in this new position. Pull the
ropes again to the top so they exit from the centering pivots. Cut the ropes at 23 cm away from the mark.
Fold the ropes on the thimble of the tie rod of the wire adjuster (in case You have the brake system) or ropes
adjuster blocks (for mast without brake system) nearby the mark and use the U bolts (3 per rope) for their
fixing.
CAUTION!!! The fixing of the rope with 4 clamps must be done as shown in the drawing below. This operation is
among the most important one and delicate because if it isn’t done properly, it can result with the time being, in
loosening and sliding of the rope preventing the unhooking of the mobile crown. To obtain the maximum efficiency it is
recommended to place the clamps in the way shown in the picture (the incorrect assembly of the attack decreases the
efficiency of 60% with respect to the breaking load of the rope).
− Unhook the mobile crown from the trailing head.
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− Fix the power cable on the mobile crown by means of the purpose made block cable devices
− Fix the 2 ropes having length suitable to the shaft, to the outer circle of the mobile crown
close to the connecting rods.
BEFORE LIFTING THE MAST MAKE SURE THAT THE DISTRIBUTOR IS
FIXED TO THE BASE OF THE MAST BY MEANS OF THE SAFETY
CHAIN INCLUDED IN THE SUPPLY.
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8. LIFTING AND CENTERING OF THE SHAFT
To lift the mast, it is necessary to use a crane of suitable capacity (refer to the table of weights in
drawings) which secure the shaft about 3/4 of its height.
Secure the mast about 3/4 of its height taking care to insert, in
the harness itself, a steel cable 16 (minimum) whose other end
is fixed to the earthing device of the shaft. The rope will
prevent the harness to climb due to the effect of the conicity of
the shaft
N.B.: For safety reasons it is good that within range of the
crane there is only people and means concerned to the
assembling of the lighting mast.
Hereby You can find the operation to be taken to lift the mast
either in case of direct burying and with base plate and anchor
bolts
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MAST TO BE BURIED INTO THE FOUNDATION BLOCK
Following the below operations to plumb the mast:
− With the bracket of the crane put the mast inside the
foundation block, as much as possible to the vertical
position
− Put around the mast sand (or even better broken
pebbles) up to a height of approx. 50 cm and press
properly
− Insert 4 wooden edges (better if knots) around the mast
and forced them so that the mast cannot move
anymore
− Let the crane free
− Act on 4 edges to plumb the mast
Pass the tube for the cable through the suitable slot on the
mast; filled with sand (or broken pebbles) the place around the
mast and press it until 2/3 of the height. Close with cls as the
same type as that used to make the foundation block
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MAST WITH BASE PLATE AND ANCHOR BOLTS
Following the below operations to plumb the mast:
− Tight the lower nuts and insert washers on the anchor bolts
− Low down the mast on the anchor bolts
− Insert the washers and tight the upper nut on the anchor bolts
− Let the crane free
− Acting on the lower and upper nuts plumb the mast
− Tight the nuts and lock them
N.B.: Clean well with the brush the threaded part of anchor
bolts before tightening the nuts and grease it
ALSO, WE RECOMMEND to perform the sealing of base
plate using expansive mortar taking care to protect the threaded
zone of anchor bolts with bituminous painting. As alternative
performed a concrete collar to cover completely either base
plate and anchor bolts
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INFORMATION NOTE
CLARIFICATION ON THE APPLICATION OF TIGHTENING TORQUE
The tightening torque is needed to give a force to the bolt in order to prevent the sliding between the
two parts to be joined making thus a friction union; this force, as it is suggested from the D.M.
17/01/2018 “technical standard for constructions”, is assumed equal to 70% of the ultimate
resistance to traction of the bolts according to the formula:
f ⋅A
F p ,Cd = 0.7 ⋅ th res
γ M7
To which it is associate a tightening torque equal to:
M = k ⋅ d ⋅ F p ,Cd
where:
f th = resistance to traction of the bolt
Ares = resisting area of the bolts (reduced of the threaded part)
γ M 7 = safety coefficient (equal to 1.1 for high resistance bolts prestressed)
k = safety coefficient given by the producer
d = nominal diameter of the bolt
The scope of the friction union is that on to bring to contact the two parts to be joined so that they
do not slide one on the other, causing as a consequence a traction stat on the shaft of the bolt until to
reach values near to the yield point. In fact, considering a bolt class 8.8 [yield point 640 MPa,
braking load 800MPa], the pre stressing force is equal to:
f th ⋅ Ares f yh Ares
Fp ,Cd = 0.7 ⋅ = 0 .7 ⋅ ⋅ ≅ 0.8 ⋅ f yh ⋅ Ares
γM7 0 .8 1 .1
where f yh = resistance to the yield point
We reach therefore values near to the 80% of the yield point
In case of structures with base plate the connection between plate and foundation block isn’t a
friction bolted union working with prestress, therefore the verification of the tightening torque by
means of a dynamometric key. In fact, the task of the anchor bolts is to transfer the stresses deriving
from the upper structure to the foundation block, that is to maintain the structure in its place
avoiding the overturning.
Furthermore, we underline that to apply a tightening torque to the anchor bolts can be
counterproductive because You will pre stress the anchor bolts with a force equal already to the
80% of the yield point (maintaining only 20% as reserve for the external actions).
For the above-mentioned reasons MUST NOT BE APPLIED THE TIGHTENING TORQUE
PRELOAD the nuts of bolts or bolts in general of our products (unless explicitly stated otherwise
reports on the drawings).
THE NUTS AND BOLTS TO BE TIGHTING WITH NORMAL MARKETING KEYS
AVAILABLE, WITHOUT EXTENSION OR SIMILAR DEVICES, USING FORCES
DEVELOPABLE FROM A NORMAL PERSON.
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You can define approximately the applied torque values, according to the following assumptions:
− Considering that bolted joints must not be subjected to preload
− Considering that simply tightening the bolts forced with the normal human strength
− Considering that the maximum stress that a normal man can exercise safely, is defined in
25kg (Decree Law 81/08 - ISO 11228)
− Considering the length of the standard fork key
T the approximate value of the tightening torque can be defined by the formula:
M = F ⋅L
where F = applied force (max 25 kg ~ 245 N)
L = length of the key
In the following page there is a table referred to the fork spanner which can usually be found in
commerce.
Forchetta a
chiave
semplice
a L
Misura
[mm] [mm]
10 26 120
13 32 145
17 40 160
19 44 175
21 44 175
22 50 196
24 50 196
26 54 216
27 54 216
30 58 240
32 68 270
35 80 300
36 80 300
38 80 300
41 93 340
42 93 340
45 100 376
46 100 376
50 105 420
55 113 450
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9. FIRST MOVING THE TOWER
Proceed as follow:
- give power to the electric hoist by
plugging it into the socket.
- Check the correct sequence of steps:
BUTTON UP the chain enter inside
the hoist.
BUTTON DOWN the chain comes
out of the hoist
THE SWITCH LIMITER ROD
WORKS ON THE RAISING
PHASE, SO FOLLOW THE STEPS
UP/DOWN
Fix the hoist to the distributor
- put in tension the chain of the hoist
until you loosen the security chain.
- Remove safety chain.
- bring down the mobile crown,
(Since there are no weight mounted
on the crown you may need to take
action on the ropes to lower the crown
down).
CAUTION DURING THE
LOWERING CHECK THAT CHAIN
OF THE HOIST IS ALWAYS
UNDER STRESS.
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10. INSTALLATION OF CROSSBARS, FLOODLIGHTS AND ACCESSORIES
− Lower the Crown Mobile helping it, if necessary, pulling the three ropes tied to it.
− Secure the floodlights supports brackets on the mobile crown and then fix the floodlights on the
brackets (following the indications of any lighting project out of scope of supply)
FI SSAGGIO SU CORON A M OBI LE
− If included in delivery, fix the brackets for ballasts support to the mobile crown and 2 ballasts for
each bracket. Be careful that if the bracket for ballasts is turned upwards you have to bear in
mind the overall dimensions of the trailing head in such a way that the brackets and the ballasts
do not go to bump the trailing head itself
− Fix the junction box to the mobile crown nearby to the power cables.
− Before securing the power cable to the cable blocks of the mobile crown, you must tighten the
cable as much as possible. At this point the wiring of the floodlights can be done and insert the
lamps.
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11. WIRING AND TESTING GROUND OF FLOODLIGHTS
The floodlights are powered by one or more lines five-cores. The junction box (usually one for each
line) is provided with an EEC plug connected upstream of the terminal block; in normal operation
to it is connected the socket referred to the power cable.
To carry out the "GROUND TEST " of the floodlights take off the plug and connect it to the socket
at the base of the shaft by means of the purpose made extension included in the supply.
N.B.: ALL THE OPERATIONS OF SWITCH OFF AND SWTICH ON THE ELECTRICAL
ACCESSORIES TO CARRY OUT THE GROUND TEST, MUST BE CARRIED OUT WITH
THE SWITCH JACK OF THE SOCKET IN ZERO (0) POSITION, THAT IS WITHOUT
POWER.ONCE THE CONNECTIONS ARE ESTABLISHED, AND ONLY THEN, YOU CAN
PUT THE SWITCH IN WORKING POSITION (1).
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12. ROPES ADJUSTMENT
Mark on each cable with a permanent marker the position where to place the rope adjuster that
is about 80 cm from the base of the centering sleeve.
Raise the mobile crown until you see the
distributor appearing on the door
(WARNING: the Mobile Crown must not
hook to the trailing head) When You see the
distributor the rope adjuster stroke on the
grooves of the centering pivots of the trailing
head. Continue for approx. another 10cm.
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Lower the mobile crown and measure the distance between the rope adjuster and the base of the
centering pivot of the three wires ropes.
The differences in measure recorded are going to
be even out screwing (or unscrewing) the nuts of
the mobile crown.
Repeat the operations described above for all the 3
ropes; in detecting the new measures no difference
should be found. Otherwise, it levels it again.
Remove 3 rope adjuster (it is important not to leave
them attached to ropes in order to not affect the
operation of the mobile crown).
REGULATION EXAMPLE
− Rope “A”: 43 cm
− Rope “B”: 45 cm
− Rope “C”: 46 cm
Act on the tightener until you bring the ropes “A”
and “C” at 45 cm
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13. FIRST HOOKING AND SWITCH LIMITER ADJUSTING
These operations concern the hooking and unhooking
phases of the mobile crown to the trailing head.
Mount the switch limiter rod and the switch limiter as
in the photo (switch limiter in the low position).
Once the 3 ropes adjuster are removed raise the crown
with a continuous action. When the distributor comes
close to the top of the switch limiter rod, pass from a
continuous raising to an intermittent (strokes) until you
hear the click of the connecting rods on the trailing
head (see photo below).
At this point give an extra raise lightly of about 1cm to
be sure that all the 3 connecting rods have passed the
labyrinth.
Bring the switch limiter placed to the distributor until it intervenes; You should hear a click sounds
made from the switch limiter.
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Tighten the screw and the nuts on the switch limiter rod.
Press the DOWN button on the push button and go on in
lowering until the chain of the hoist is release.
(MECHANICAL HOOKING IS DONE).
To release the crown, proceed with the following steps:
Press up on the push button (the distributor will come
down) until the switch limit intervenes.
CAUTION!!!!! DURING THE RAISE KEEP
BUTTON PRESSED, BECAUSE IT IS THE
SWITCH LIMIT WHICH LOCK THE RAISSE
ITSELF.
At this point press the DOWN button to lower the crown.
Repeat HOOKING AND UNHOOKING 2/3 TIMES.
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14. PUT INTO SERVICE OF THE BRAKE SYSTEM (IF ANY)
Once the proper working of the movement has been checked with guide / brake units completely
open towards the outside of the Mobile Crown, we start to put into service the brake system. To do
this it is necessary to make the trolley with the drive / brake assembly working by inserting the
supplied springs in their seats (as shown in the drawing below). For each trolley 2 springs must be
mounted. By now, the three trolleys will drive the raising and lowering, expanding and clinging
following the diameter of the shaft.
In case of failure of the wire ropes or the lifting chain the braking element acts on the latching of 3
trolleys racks. The fall of the Mobile Crown will therefore be prevented due to the increase of the
section of the shaft.
The brake system does not require any special care, only checking of the springs, the
driving rolls and a greased of driving lanes, racks and springs themselves.
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15. OPERATING RULES
− Power the tower from the general board
− Open the door, unplug from the socket the CEE plug that powers the floodlights and insert it into
the distributor
− Power the lifting unit by inserting the CEE plug on the interlocked socket
− To carry out subsequent operations, take out of range of the Mobile Crown and carry on the
following operations to unhook and lower the Mobile Crown:
Press the "UP" button on the push button of the hoisting unit until the intervention of
the switch limiter, which lock the hoist
Press "DOWN" to lower the Mobile Crown
− To perform maintenance and ground testing of the floodlights, use the electrical cable attached to
the junction box fixed to the crown.
− Once maintenance has been carried out, perform the following operations to attach the Mobile
Crown:
Press the "UP" button until you see the distributor appearing on the door
From now on proceed in the raising “by shots" until the distributor arrives at about
10cm of the switch lever
Proceed then with a continuous raising until the intervention of the switch limiter
(which coincides with the click of the connecting rods that reach their grooves)
which blocks the electrical units
Press the "DOWN” to hook the Mobile Crown on the trailing Head
Once the crown is attached:
− Pass the passive safety chain through the distributor and secure it to the appropriate connections
welded inside the tower
− Disconnect the power plug of the electric unit (hoist) and, in the case of a trolley-mounted hoist,
remove it from the mast
− Power the floodlights by inserting the CEE plug into the interlocked socket and close the switch
− Close the door
IN CASE ALL 3 RODS DO NOT HOOK, WHEN YOU PRESS THE BUTTON "DOWN" TO
HOOK THE MOBILE CROWN, SINCE ONE OR MORE' ROPES ARE NOT RELIEVED FROM
THE WEIGHT OF THE CROWN ITSELF, THE DISTRIBUTOR WILL TILT TOWARDS THE
CABLE/S STILL UNDER TENSION. WE HAVE THEREFORE TO ACT WITH BUTTONS
"UP" AND "DOWN" TO UNHOOK THE ROD STILL HOOKED.
LOWER THE CROWN AND REPEAT THE ADJUSTMENT OF THE ROPES. IF THE HOOK
HAS NOT OCCURRED 'THIS IS DEFINITELY DUE TO WRONG ADJUSTMENT OF THE
ROPES
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16. WARNING
− Do not stand under the Mobile Crown during the raising and lowering of the same
− Mark out the area where you will carry on the maintenance operations with appropriate
barriers or tape
− Carry out hooking / unhooking of the Mobile Crown at least 2 times a year (every 6 months)
− Record all maintenance in the relevant register hereby enclosed
− the maintenance of the floodlights must always be combined with a check of the ropes and
tightening of all bolts and nuts
− Once a year schedule a checkup of the electric hoist as described in the maintenance manual
of the hoist
− The chain supplied with the electric unit must always be lubricated
− If for lighting needs a different aiming of the floodlights, you must repeat the adjustment
operations of the ropes
− The maintenance operations must be performed in favorable weather conditions (no wind)
− The operator performing maintenance of the mast/s must be aware of the operating
instructions contained in this manual
17. DISMANTLING OF THE HIGH MAST
Given the peculiarities of the structures and equipment required to carry out the dismantling of the
masts with Mobile Crown, it is better that in case it is required the dismantling of a mast this
activity is carried out by specialized personnel, authorized and instructed by this company.
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MANUAL MAINTENANCE
HIGH MAST WITH
MOBILE CROWN
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MAINTENANCE
Introduction:
The maintenance on the lighting mast, must be performed by authorized personnel for this purpose,
who has to know the operating instructions as well as our handling system.
In the case you have to substitute some elements, they must be original spare parts.
The maintenance of the electric hoist must be carried out according to what is mentioned the
instruction manual and safety that is always included in the delivery.
Maintenance:
In order to ensure the proper functioning of the lighting mast, a MAINTENANCE SCHEDULE has
been worked out. three key periods for maintenance have been defined, as following:
- annual maintenance (TYPE A) which consists of a check - up of the mobile crown brought to
ground level, of all the elements that constitute it, as well as a control of the electrical components,
and a check of what is placed inside the shaft.
- maintenance to 5 year (TYPE B) which includes all the maintenance operation TYPE A, and
also requires careful control of the at the top of the stem parts.
- maintenance to 10 years (TYPE C) which incorporates all of the maintenance operation TYPE
A and TYPE B, as well as a tree control (rod, any base plate) in order to check its status and to
check the condition of the protective coating (galvanizing).
ALL THE OPERATIONS OF MAINTENANCE AND CONTROL WILL BE RECORDED IN THE FORMS
ATTACHED TO THIS FILE.
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MAINTENANCE PROGRAM
TABLE FIRST MAINTENANCE
FIRST CHECK TYPE A TYPE B TYPE C
Check that the earth connection is connected to the structure and is efficient YES YES YES
Check that the door’s locking device is efficient YES YES YES
Make sure the safety chain is positioned as per instructions and not too tight YES YES YES
Check the efficiency of the electrical connections at the base of the mast YES YES YES
Check that the phase sequence is such that the lifting unit works with the correct YES YES YES
logic (You can verify it feeding the lifting units)
Check the efficiency of the safety switch limiter (connecting the lifting unit and YES YES YES
verifying that acting on the rod at the bottom it does not work in UP)
Check the condition of the wire ropes and the electric cables on the distributor which YES YES YES
must not be pulled (with mobile crown hooked)
Check the tightening of the clamps on the ropes (on the distributor) YES YES YES
MAINTENANCE TABLE OF THE MOBILE CROWN
WITH CROWN LOWERED: TIPO A TIPO B TIPO C
Make sure the sheath of the ropes, as well as electric /s cable/s is intact YES YES YES
Check the tightening condition of all bolts and nuts YES YES YES
Check the tightening conditions of the clamps on the ropes YES YES YES
Check the condition of elastic plates of the elastic coupling system (rods) YES YES * YES *
Check that the brackets for floodlights and ballasts support are securely fastened to YES YES YES
the mobile crown
Check that electrical cables are in good condition and that wiring in boxes, on
floodlights, and ballasts (on ballasts and floodlights are optional but recommended) YES YES YES
do not present oxidations such as to compromise the functionality of the lighting
system.
Check that the distribution boxes always ensure the protection degree stated and that YES YES YES
the connection with EEC accessories doesn’t present oxidation such as to
compromise the functionality of the lighting system
Check the correct balancing of the mobile crown YES YES YES
Check the operation of the floodlights (ground test) YES YES YES
WITH THE MOBILE CROWN IN SERVICE POSITION: TYPE A TYPE B TYPE C
Check that the hooking and unhooking operations of the mobile crown to the trailing YES YES YES
head occur regularly
Make sure that the safety switch limiter is positioned correctly YES YES YES
MAINTENANCE OF THE MOBILE CROWN (at ground) TYPE A TYPE B TYPE C
Check the condition of the springs YES YES * YES *
Check the condition of the polyamide wheels YES YES YES
* it is advisable to replace the material.
MAINTENANCE TABLE OF THE TRAILING HEAD
MAINTENANCE TRAILING HEAD TYPE A TYPE B TYPE C
Check tightening of bolts and nuts securing the trailing head to the shaft NO YES YES
Check conditions of carpentry NO YES YES
Check condition of polyamide pulleys, pivots NO YES YES
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TABLE FOR STRUCTURE MAINTENANCE
STRUCTURE MAINTENANCE TYPE A TYPE B TYPE C
Check condition of the structure and galvanization. NO NO YES
MAINTENANCE TABLE FOR HOISTING UNIT
MAINTENANCE OF HOISTING UNIT TYPE A TYPE B TYPE C
Please refer the operator to verify the instructions in the user manual and safety of the / / /
hoist included in to the supply.
The maintenance program reported concerns a normal environment, which may be a road
interchange, parking etc. For special environments, the maintenance program should be
implemented together with the designer - customer, considering the toughest aspects under which
the facility will operate.
Furthermore, if the timing established by Pali Campion Srl turns out to be characterized by too long
periods or too short for those who in the future will manage the facility, subject to our authorization
they may be revised and adapted to the actual system requirements.
Any replacement of parts which prove worn or otherwise not suitable to secure the safe and proper
operation of the lighting mast, will be done only and exclusively with original spare parts.
If not, so legal guarantees will fail.
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CONTROL PROCEDURES:
TYPE OF COMPONENT TO BE METHOD OF CONTROL NORMAL CONDITION REMEDY
MAST CONTROLLED
C.M
ALL THE SOCKET Check the Integrity of the The peculiarity of the In the case the conditions
MODELL external structure lock socket is that it listed left do not occur
Check operation by doesn’t allow the plug to replace the socket with
performing a number of open slip out when the circuit one having the same
/ close circuit tests is closed (position I), as characteristics.
well as the circuit cannot
be closed t (transition
from 0 to I) if a suitable
plug it is not inserted
before
ALL THE STEEL ROPES Check integrity of the sheath, The cable must have If you found loss on the
MODELL POLYPROPYLENE the tightening of the clamps at perfect sheath all over sheathing, and
SHEATHED the ends of the cables and its length, without consequent worn ropes,
threaded tightener fraying, obvious signs of they t be checked by a
bending. technician to assess the
Clamps must be well true extent of the
made and regularly damage and then if it
checked. needs replacement of the
cable / s
ALL THE ELECTRIC CABLE Check the Integrity of the The cable must have a If You found that the
MODELL sheath perfectly intact sheath insulation is damaged it
and when the crown is need to be checked by a
lowered it has not to be technician to assess the
stretched but very soft. true extent of the
damage and then if it
needs replacement / the
cable / s.
If you found that when
the crown is lowered the
cable is tight, loosen it by
acting on the cable stop
blocks fixed on the
mobile crown
ALL THE ELECTRICAL Check the conditions of all All electrical connections Should you note any
MODELL CONNECTIONS electrical wiring. must be perfectly done connections not well
executed or that are worn
out with the time being,
make new connections
replacing electric cables,
if any
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TYPE OF COMPONENT TO BE METHOD OF CONTROL NORMAL CONDITION REMEDY
MAST CONTROLLED
C.M
ALL THE BRACKETS FOR Check the straightness of the The brackets for Mount the expected
MODELS FLOODLIGHT brackets and check the floodlight support must number of floodlight (if
SUPPORT AND ballast support to be be straight also after one floodlight for each
BALLASTS orthogonal, check tightening being loaded with the bracket is foreseen do
SUPPORT of the coupling bolts with the floodlights. not put two floodlights.
mobile crown, as well as the The same applies to the Observe the executive
tightening of the floodlight. brackets for ballasts design in order not to
support. install floodlight with
different weights, which
could create stress
conditions on carpentry
ALL THE HOOKING ELASTIC Check feature of the The structure must IT IS 'THE MOST'
MODELS SYSTEM connecting rods. appear intact, you don’t IMPORTANT PART OF
have to find bent parts, THE HANDLING
and the operating parts SYSTEM
(elastic plates) if Any sign that could be
stressed will have to related to stressful
create the vibration of situations or non-
the overlying part alignment with the trailing
(connecting rod). head should immediately
be noticed for
replacement.
Should some elastic
plates had lost their
elastic characteristic it is
possible to replace them
without changing the
whole system.
If necessary, it is
advisable to replace all
three systems, and
repeat the test for
adjustment of the ropes
and the safety switch.
Limiter
ALL THE BOLTS AND NUTS Check tightening of the bolts The bolts must be If the bolts and nuts are
MODELSL perfectly tightened not well tightened, make
the tightening once again
ALL THE POLYAMIDE Check the wearing conditions The pulleys must not If the conditions reported
MODELL PULLEY AND of the pulleys wiring ropes show signs of wearing are not observed the
PIVOTS and cables, the respective that can affect the replacement of worn
pivots on the trailing head, the sliding of the rope (on parts must be foreseen
pivots supporting the elastic the trailing head) and
hooking system (connecting the chain (driving whirl).
rods), on the mobile crown, as The pivot must be
well as the driving whirl and undamaged and self-
respective pivot inside the lubricating bushings free
base section for the shaft. to rotate.
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TYPE OF COMPONENT TO BE METHOD OF CONTROL NORMAL CONDITION REMEDY
MAST CONTROLLED
C.M
ALL THE SAFETY SENSOR Check that the switch limiter HOOKING MOBILE If during the phases
MODELS (SWITCH LIMITER) intervenes correctly in the CROWN HOOKING –
hooking and unhooking The switch limiter UNHOOKING of mobile
phases of the mobile crown to intervenes at the point crown to the trailing head
the trailing head. where the connecting it occurs that the engine
rod entered into the clutch intervenes before
labyrinth of the trailing the switch limiter, the
head, is free, and then it status of the electrical
makes a step forward, contacts of the same
then, with a descent it must be checked; also,
leans against the seat of the status of the switch
the labyrinth in the limit rod that may not be
working position. well-placed must be
RELASE MOBILE checked. If the suitability
CROWN of the switch limiter is
The switch limit rod verified, its position on
intervenes at the point the adjustment rod must
where the piston rod be modified to re-
exits from the labyrinth, establish the correct
and then from the operation of movmejment
coupling seat. system (which must hook
At this point, the crown and uunhook without the
can be lowered intervention of any
(DOWN). security of the electric
The intervention of the motor).
switch limit prevents that If ion the contrary
the clutch. intervenes encounter any problems
into the hoist on the rod or on electrical
contacts, the switch
limiter must be promptly
replaced.
ALL THE CONNECTION TO Check existence of the The earth conductor If it is not connected,
MODELS THE GROUND metallic mass connection to must be connected to restore the connection
RING the earthing system the appropriate immediately.
connections on the shaft
ALL THE ELECTRIC HOIST Check tyre pressure The trolley t must have If the wheels are inflated
MODELL the 2 wheels at a inflate them, while if they
suitable pressure to are perforated the must
allow the easy handling be repaired or replaced
at site.
ALL THE ELECTRIC HOIST the operator has to refer to
MODELS the vision of USER AND
SECURITY electric hoist
supplied with the delivery
ALL THE CHAIN the operator has to refer to
MODELS the vision of USER AND
SECURITY electric hoist
supplied with the delivery
NOTE: At the end of the product's life cycle, the owner of the good shall dispose the material in
accordance with current environmental regulations. The shaft, crown, trailing head and distributor
are made of fully recyclable steel.
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MAINTENANCE REGISTER
FOR HIGH MAST WITH
MOBILE CROWN
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ANNUAL MAINTENANCE (TYPE A) MAST CM
DATE OPERATION RESULT SIGNATURE NOTE
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ANNUAL MAINTENANCE (TYPE A) MAST CM
DATE OPERATION RESULT SIGNATURE NOTE
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5° YEAR MAINTENANCE (TYPE B) MAST CM
DATE OPERATION RESULT SIGNATURE NOTE
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5° YEAR MAINTENANCE (TYPE B) MAST CM
DATE OPERATION RESULT SIGNATURE NOTE
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10° YEAR MAINTENANCE (TYPE C) MAST CM
DATE OPERATION RESULT SIGNATURE NOTE
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10° YEAR MAINTENANCE (TYPE C) MAST CM
DATE OPERATION RESULT SIGNATURE NOTE
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NOTICE
The civil and criminal liability in case of accident or damage caused by a failure on maintenance of the roads or its
accessories (among the we can find the hypothesis of a lighting plant) will be in charge of the owner of them.
Especially as far as the criminal liability is concern, i twill be in charge of the person that, at the moment of the
accident, will be recognised as holder of the legal duty to grant the perfect maintenance of the above plant.
In order to clarify better, in case of accident caused by a lack of, or to a bad maintenance of the high mast located in
centre of a town, the legally liable person will be identified by the legal representative of the municipality, because he is
owner and responsible of the above-mentioned structure.
Criminal Responsibility
The art. 35 paragraph 4 of D.Lgs. 626/94, provides that: “the employer implements and organise the suitable technical
measures in order to reduce to the minimum the risk connected to the use of the devices so that they are:
a) installed according to the manufacturer’s instructions;
b) properly employed;
c) they are subjected to a suitable maintenance in order to grant, with the time being, that they comply to the safety
requests ".
Failure to comply with the obligations imposed by the above standards, exposes the owner of the high mast to the risk
of application of penalties, as expressly provided for by art. 89 D.Lgs. 626/94
Furthermore, according to art. 589 e 590 C.P, the owner of the lighting plants with high masts, may be considered
criminal liable, in case that he is not able to prove that he has duly carried out the checking and surveillance on the
plants of his property, having put in act all actions and measures at his disposal, to keep the plant in good conditions,
carrying out regular maintenance
Civil liability
Art. 2043 C.C. contents the principle that “any intentional or negligent did, which causes unjust damage to others,
obliges the one who committed it to pay damages ", underlying that the fact which is source of this responsibility may
also consist of an omission
It is also established by the following articles of the Civil Code:
- art.1669 “The manufacturer is liable for damaged to others caused by sever defects of workmanship, for a period of 10
years from the date of manufacturing”
- art. 2050 "Anyone who cause a damage to others during an activity which is dangerous itself or it is dangerous
because of the means used for it, is liable to pay damages unless he can prove which he has undertaken all the steps to
avoid the damage";
- art.2051 "each one is responsible for the damage caused by things under his care unless he can prove that it was and
accidental event ";
- art.2053 "The owner of a building or other constructions is liable of damages caused by their decay unless he can
prove that it is not due to a lack of maintenance or manufacturing defect ".
In case of accident, the owner must provide evidence that he has organised all the activities taking all the precautions
that seemed suitable to avoid the damage, give evidence that the damage occurred was unpredictable, and consequently
he has to identify the cause of the damage or the proof that the responsibility of the damage itself can be in charge of
others persons
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