CTT “City”

General Information
1 INFORMATION ABOUT THE MANUAL
1.1 FOREWORD
1.2 GENERAL
1.3 PURPOSE AND CONTENTS OF THE MANUAL
1.4 CARE OF THE MANUAL
1.5 REVISION OF THE MANUAL
1.6 USER’S RESPONSABILITIES
1.7 ACCIDENT PREVENTION STANDARDS OBSERVED AND TO BE COMPLIED WITH
1.8 GUARANTEE
1.9 MANUFACTURER’S RESPONSABILITIES
1.10 OPERATOR’S QUALIFICATIONS
1.11 TECHNICAL ASSISTANCE
1.12 SPARE PARTS
1.13 TABLES
1.13.1 Crane identification plate
1.13.2 Crane noise level markings
1.13.3 Other plates
2 SAFETY WARNINGS
2.1 WARNINGS TO THE JOB SITE MANAGEMENT
2.2 WARNINGS TO THE OPERATOR
2.3 GENERAL COMMUNICATION PROVISIONS
2.3.1 Voice communication
2.3.2 Hand signals
2.3.3 Signal-man’s equipment
2.3.4 Usual hand signals
2.3.4.1 Enclosure IX to Directive 92/58/EEC
2.3.4.2 ASME B 30.3-96
2.4 ACCIDENT PREVENTION SIGNS
3 USE
3.1 PLACING THE CRANE IN SERVICE
3.2 TAKING THE CRANE OUT OF OPERATION
3.3 CHANGING FROM 4-PART LINE TO 2-PART LINE AND VICE VERSA
3.4 AUTHORIZED AND UNAUTHORIZED CRANE OPERATIONS
4 ALLOWED LOADS
5 HOISTING LOAD-HANDLING DEVICES
5.1 UNAUTHORIZED HOIST LOAD-HANDLING DEVICES
5.2 LOAD STABILITY AND SLING PROCEDURES
5.3 CAPACITY OF THE SLINGS
6 INHERENT RISKS AND EMERGENCY SITUATIONS
7 STAFF TRAINING
8 FINAL DISMANTLING OF THE CRANE

Chapter 1
1_2_001_e
1 INFORMATION ABOUT THE MANUAL

1.1 FOREWORD

Comedil’s CTT “City” series tower

cranes are manufactured and tested
in accordance with the machine’s
safety provisions outlined in
98/37/EC standard and following
revisions.

The instructions in this manual may

integrate the laws and safety
regulations in force in the country
where the crane is used. However,
they do not take precedence of them.

An original signed “Declaration of

Conformity” to the Standard
accompanies each crane. This
document shall be maintained in a
legible state by the crane owner and
shown on request to the legal
Authorities.

The “ Declaration of Conformity”

forms integral part of the crane and
shall have to be delivered to the new
owner upon its transfer.

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 A copy of this manual shall be
available at the job site.

A ll the safety and accident

prevention precautions contained in
the 89/391/EEC standard and
revisions thereafter shall be
observed and scrupulously adhered
to while operating or servicing the
crane.

Provisions in this manual pertain to

crane owners, job site supervisors,
assemblers, operators and
engineers performing maintenance
on CTT “City” series Tower Cranes.

Should there be uncertainties about

any of the provisions contained in
this manual, contact the
Manufacturer or the authorised
service centre for clarifications.When
doing so, please refer to the section
number of the matter in question.

Complete or partial printing, translation or copying of this manual is

subject to Comedil’s written authorization.

Technical information, drawings and specifications contained in

this manual are not to be divulged.

1_2_001_e General Information CTT “CITY” Page 4/44

1.2 GENERAL

Do not operate the crane if the instructions and procedures outlined in the manual are not clearly
understood. Should there be any doubt, ask for the intervention of Comedil’s technical service.
Comedil reserves the right to make changes to specifications or to modify the crane at any time
without notice.

WARNING INDICATIONS AND SYMBOLS

The following designations or symbols are employed in the manual for particularly important
indications:

F NOTE: Special indications concerning the efficient application of

the crane

CAUTION: Special indications of instructions/prohibitions for damage

prevention

WARNING: Indications of instructions/prohibitions for the prevention of

personal injury or extensive material damage.

INTENDED CONDITIONS OF USE

Comedil CTT “City” hoisting machines are high-level slewing tower cranes. They are devised only
and exclusively for lifting, level luffing and lowering loads as described and specified at para. 4.

F
The use and configurations of the crane described in this manual are the only ones approved by
the Manufacturer: the crane shall only be used according to the instructions herein.
The intended uses of the crane can be assured only if its structural and mechanical components
are properly maintained and all systems are working well.

MANDATORY AND ADVISORY RULES

Mandatory rules of this volume are carachterized by use of the word shall. If a provision is of an
advisory nature, it is indicated by use of the word should and is a recommendation to be considered,
the advisability of which depends on the facts in each situation.

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 1.3 PURPOSE AND CONTENTS OF THE MANUAL

PURPOSE The purpose of this manual is to assist the user, and especially the operator of
the crane, in taking all precautions and means materially or humanly available for
the correct, safe and long-lasting use of the crane.
CONTENT All the information necessary for the installation, assembly, use and maintenance
of the CTT “City” tower crane series is contained in this manual.
By closely observing the cautions, procedures, and maintenance requirements
contained herein, you will be guaranteed the highest degree of safety and
operational efficiency throughout the life cycle of the crane.

F Should there be any doubts about the contents of this manual, contact the Manufacturer.

1.4 CARE OF THE MANUAL

CARE AND CONSULTING The manual shall be kept in a dry and protected place by the person in
charge of the job site. The operators and the assemblers shall be able to
consult it.
The instructions, procedures, and maintenance requirements contained in
this manual are in effect an integral part of the crane and shall be kept for
continuous reference until the final crane disassembly has been carried out.

DETERIORATION OR LOSS If necessary, ask for another copy from the Manufacturer.

CRANE TRANSFER Should the crane be transferred, the present operations manual shall
accompany it.
Should the crane be transferred to a buyer in a country where another
language is spoken, whoever sells the crane shall enclose a copy of this
manual correctly translated into the language of the country where the crane
is going to be operated (Operations manuals translated into many foreign
languages are available at and can be purchased from Comedil).

1_2_001_e General Information CTT “CITY” Page 6/44

1.5 REVISION OF THE MANUAL

This manual is an integral part of the crane. It reflects the state of art technology of the machine
when it was introduced into the market.
Modifications, changes or the application of new technology on subsequently commercialized cranes
do not constitute cause for the Manufacturer to consider cranes currently present in the market or
their technical documentation to be obsolete.

1.6 USER’S RESPONSABILITIES

INFORMATION In making inquiries to the Manufacturer about the crane, refer to its serial number
and other information listed in the “INDEX OF REVISIONS” page of this manual.

RESPONSABILITY Upon receipt of this manual by the crane owner, Comedil declines any
responsability either civil or criminal for accidents due to the total or partial
non-observance of the specifications stated herein.
Furthermore, Comedil declines any responsability for damages caused by
improper use of the crane or unauthorized use by untrained people; by
unauthorized modifications or repairs; or by not using original spare parts or
spare parts specific for this crane model.

CRANE TRANSFER Should the crane be sold, the seller shall inform the Manufacturer about the
address of the new buyer so that the latter can be advised of changes,
modifications or other up-to-date information concerning the crane.

SPECIAL MAINTENANCE The special maintenance operations shall have to be carried out
under the supervision of qualified people.

F RESPONSABILITY OF WORKS
AT THE JOB SITE
The user of the crane is responsible for all work at the job site.
The user shall therefore make sure that the ground on which the
crane is installed and the methods adopted for its installation are
suitable and safe.

USE Any use of this machine shall be made in conformity with the safety standards
dictated by the specific laws in force in the country where the crane is installed,
as well as with the provisions stated in this manual.

Page 7/44 General Information CTT “CITY” 1_2_001_e

 1.7 ACCIDENT PREVENTION STANDARDS OBSERVED AND TO BE COMPLIED WITH

A) 98/37/EC directive: “Regarding the standardizing of the laws of the Member States
concerning the machines”.

B) 89/391/EEC directive: “Enforcement of provisions for the improvement of safety and health
standards for workers on the job.”

C) 92/58/EEC directive: “Provisions for the minimum safety and/or health warning signs that
must be posted at the job site.”

D) 92/57/EEC directive: “Minimum safety and health provisions to be enforced in mobile or

temporary job sites”.

1.8 GUARANTEE

To take advantage of the Manufacturer’s warranty, the user shall scrupulously observe the
instructions stated in this manual and in particular:
- always perform operations that are within the capacities and limits specified for the equipment;
- perform routine maintenance as indicated in this manual;
- verify that the equipment is only used by competent and skilled people, who have been specifically
trained for this purpose.
Failing to follow the instructions given in this manual will void the crane’s warranty.

1.9 MANUFACTURER’S RESPONSIBILITIES

F The Manufacturer declines any direct or indirect public and criminal liability due to:
- any use that does not comply with the laws and regulations in force in the country where the
crane is installed;
- non-observance of the instructions stated in the manual;
- use by unauthorized and/or untrained people;
- use that does not comply with safety regulations;
- unauthorized modifications and repairs of the crane;
- use of spare parts which are not original or specific for the crane model concerned;
- preparation of a job site which is not in accordance with 92/57/EEC regulation, “Temporary
Building Yards”, or not compatible with the specifications and characteristics of the crane;
- unsuitable ground condition;
- lack of maintenance;
- force majeure events.
The transfer of the crane to a third party automatically revokes the Manufacturer’s responsibility to
the buyer with the exception of the provisions specified in 85/374/EEC standard
(“Manufacturer Design Defects”).

1_2_001_e General Information CTT “CITY” Page 8/44

1.10 OPERATOR’S QUALIFICATIONS

F The operator of the crane shall be a responsible adult who does not have any physical defects.
Likewise, he shall be of a sound state psychologically and possess the knowledge required for
operating the crane, the know-how to perform routine maintenance and have a thorough
understanding of the crane’s mechanical and electrical components.

1.11 TECHNICAL ASSISTANCE

Comedil can solve any problem regarding the use and maintenance of its cranes.
Authorized service centers are located both in Italy and abroad.

1.12 SPARE PARTS

F Use only original spare parts.

Do not wait for the components to wear out before replacing them.
When the component is replaced at the right time, accidents due to sudden breakage of the parts,
which might seriously injure persons and equipments, can be esasily avoided.

F Scheduled maintenance inspections shall be carried out as recommended in this manual at the
following chapters:
08_“GENERAL MAINTENANCE”
09_“HOISTING DRIVE UNIT”
10_“TROLLEY DRIVE UNIT”
12_“TRAVELLING DRIVE UNIT”
13_“SLEWING DRIVE UNIT”
of the crane’s operations manual.

Page 9/44 General Information CTT “CITY” 1_2_001_e

 1.13 TABLES

1.13.1 Crane identification plate

An identification plate as indicated in picture 1.13.1, is placed on the base mast section of the
tower, which shows the data relative to the crane specifications including the Manufacturer, serial
number and marking.

9,$6(*,',2$)217$1$)5(''$31,7$/,$7(/)$;

*587,32&5$1(7<3( 15',6(5,(6(5,$/180%(5 $112<($5

*58(7<3(.5$17<3 180(52'(6(5,(6(5,(115 $11((-$+5

202/2*$=,21(7
h9157h97<3($33529$/ 1250$7,9$&/$66(67$1'$5'6&/$66

+202/2*$7,217
h9127h97<335h)81*15 1250(&/$661250./$66(

&DULFRPD[6EUDFFLR &2175$33(62&2817(5:(,*+7
6%5$&&,25$1*(3257
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%5$&&,2 &KDUJHPD[L3RUW
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)/(&+( %UDFFLR-LE
$86/(*(5 W P )O FKH$XVOHJHU W

%5$&&,2 75$6/$=,21(
-,% 75$9(//,1*
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$86/(*(5 W P )$+5:(5.
N:

1P

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USP

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7,32',7255(('(//$/81*+(==$'(/ )81=,21('(/7,32',7255(('(//$ +2,67,1*
/81*+(==$'(/%5$&&,2&2168/7$5( /(9$*( N:
%5$&&,2&2168/7$5(,/0$18$/(
,6758=,21, ,/0$18$/(,6758=,21, +8%:(5.
)250$;,080+(,*+76$1'%$6(
)250$;,080+(,*+76$&&25',1* %$//$67$&&25',1*727+(72:(5
PPLQ W
727+(72:(57<3($1'7+(-,% 7<3($1'7+(-,%/(1*7+6((7+(
/(1*7+6((7+(23(5$7,210$18$/ 23(5$7,210$18$/

3285+$87(8560$;,0$/(6(7/(67'(
3285+$87(8560$;,0$/(66(/21 %$6(6(/217<3('$0Ç785((7 PPLQ W
7<3('$0Ç785((7/21*8(85)/ &+( /21*8(85)/ &+(&2168/7(5/(
&2168/7(5/(0$18(/'
,16758&7,216 0$18(/'
,16758&7,216
)h50$;,0$/(+g+(181' 327(1=$727$/(5,&+,(67$
)h50$;,0$/(+g+(1*(0b‰78507<3 =(175$/%$//$67*(0b‰78507<381' 5(48,5('(/(&75,&32:(5
$86/(*(5/b1*(6,(+( 38,66$1&(727$/(1(&(66$,5( N9$
81'$86/(*(5/b1*(6,(+(
%(75,(%6$1/(,781* %(75,(%6$1/(,781* %(1g7,*7(*(6$07/(,6781*
/$*58'(9((66(5(87,/,==$7$&21)250(0(17($//(,6758=,21,'(/&267587725( $/,0(17$=,21(
7+(&5$1(6+$//%(23(5$7('675,&7/<,1&203/,$1&(:,7+7+(0$18)$&785(5
6',5(&7,216 6833/<0$,16
/$*58('2,7 75(87,/,6 (&21)250(0(17$8;',5(&7,9(6'8&216758&7(85 $/,0(17$7,21 9 +]
'(5.5$1,67(17635(&+(1''(1%(75,(%6$1:(,681*(1'(6+(567(//(56=8%(1
h7=(1 675209(5625*81*

Picture 1.13.1

1_2_001_e General Information CTT “CITY” Page 10/44

 U.S. Customery Units

9,$6(*,',2$)217$1$)5(''$31,7$/,$7(/)$;

*587,32&5$1(7<3( 15',6(5,(6(5,$/180%(5 $112<($5

*58(7<3(.5$17<3 180(52'(6(5,(6(5,(115 $11((-$+5

202/2*$=,21(7
h9157h97<3($33529$/ 1250$7,9$&/$66(67$1'$5'6&/$66

+202/2*$7,217
h9127h97<335h)81*15 1250(&/$661250./$66(

&DULFRPD[6EUDFFLR &2175$33(62&2817(5:(,*+7
6%5$&&,25$1*(3257
e ($86/$'81*>IW@ 0D[/RDG5DQJH &2175(32,'6*(*(1*(:,&+7
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7,32',7255(('(//$/81*+(==$'(/ )81=,21('(/7,32',7255(('(//$ +2,67,1*
/81*+(==$'(/%5$&&,2&2168/7$5( /(9$*( N:
%5$&&,2&2168/7$5(,/0$18$/(
,6758=,21, ,/0$18$/(,6758=,21, +8%:(5.
)250$;,080+(,*+76$1'%$6(
)250$;,080+(,*+76$&&25',1* %$//$67$&&25',1*727+(72:(5
IWPLQ OEV
727+(72:(57<3($1'7+(-,% 7<3($1'7+(-,%/(1*7+6((7+(
/(1*7+6((7+(23(5$7,210$18$/ 23(5$7,210$18$/

3285+$87(8560$;,0$/(6(7/(67'(
3285+$87(8560$;,0$/(66(/21 %$6(6(/217<3('$0Ç785((7 IWPLQ OEV
7<3('$0Ç785((7/21*8(85)/ &+( /21*8(85)/ &+(&2168/7(5/(
&2168/7(5/(0$18(/'
,16758&7,216 0$18(/'
,16758&7,216
)h50$;,0$/(+g+(181' 327(1=$727$/(5,&+,(67$
)h50$;,0$/(+g+(1*(0b‰78507<3 =(175$/%$//$67*(0b‰78507<381' 5(48,5('(/(&75,&32:(5
81'$86/(*(5/b1*(6,(+( $86/(*(5/b1*(6,(+( 38,66$1&(727$/(1(&(66$,5( N9$
%(75,(%6$1/(,781* %(75,(%6$1/(,781* %(1g7,*7(*(6$07/(,6781*
/$*58'(9((66(5(87,/,==$7$&21)250(0(17($//(,6758=,21,'(/&267587725( $/,0(17$=,21(
7+(&5$1(6+$//%(23(5$7('675,&7/<,1&203/,$1&(:,7+7+(0$18)$&785(5
6',5(&7,216 6833/<0$,16
/$*58('2,7 75(87,/,6 (&21)250(0(17$8;',5(&7,9(6'8&216758&7(85 $/,0(17$7,21 9 +]
'(5.5$1,67(17635(&+(1''(1%(75,(%6$1:(,681*(1'(6+(567(//(56=8%(1
h7=(1 675209(5625*81*

Page 11/44 General Information CTT “CITY” 1_2_001_e

1.13.2 Crane noise level markings

CTT crane series conforms to the LW limit sound power level provided in the European directives
98/37/EC <Machinery directive> and 2000/14/EC <Noise emission in the environment by
equipment for use outdoors>. This value is indicated on two plates positioned on the main electrical
box door and at the crane tower bottom respectively (picture 1.13.2).

F The maximum outdoors sound level varies according to the hoist winch the crane is equipped
with. Anyhow it never exceeds the value of 100 dB(A) [stage I of the 2000/14/EC directive as from
3rd January 2003] or 98 dB(A) [stage II of the 2000/14/EC directive as from 3rd January 2006].

Picture 1.13.2

F As regards the Lp sound pressure value measured at the crane’s workstation, it does not exceed
70 dB(A).

1.13.3 Other plates

FALLING HAZARD FROM HIGH PLACE ATTACH SAFETY BELT

Code 850100037 Code 850100038

1_2_001_e General Information CTT “CITY” Page 12/44

 CURRENT HAZARD
Code 833699001

TENSION-ON
Code 850100039

NO ENTRY
Code 850100040

Page 13/44 General Information CTT “CITY” 1_2_001_e

 2 SAFETY WARNINGS

2.1 WARNINGS TO THE JOB SITE MANAGEMENT

- The instructions stated in this manual shall have to be observed.

- The instructions and warnings shown on the crane note plates shall have to be observed.

- The note plates placed on the crane are accident prevention devices and shall have to be
perfectly legible at all times. Should they be damaged, replace them by asking the Manufacturer
for the original spare part.

- Prior to operation, perform a visual examination at least daily on any externally perceptible
defects and flaws, as recommended in chapter 8 - “General maintenance” of the
crane operation manual.

- Follow the routine and special maintenance program scrupulously.

- In the event of malfunctioning, signs of damage, anomalous performance or strange noises,

stop the crane immediately.

- Accident prevention signs and/or advertising posters can be posted on the counterjib structure
of the crane.
For dimensions and placing of signs, look at the following two indications:

a×b×c£X a×b£Y

1_2_001_e General Information CTT “CITY” Page 14/44

 &5$1(PRGH O
-LE [ (max.) < (max.)
(m) IW 2  2 
(m ×m) IW îIW (m ) IW 

)/$772372: (5&5$1(6

CTT161 60  35  6 

CTT161 55  30  5 
CTT161 50  24  5 
CTT161 45  19  4 
CTT161 40  15  4 
CTT161 35  10  3 
CTT161 30  5  2 
CTT141 60  32  6 
CTT141 55  28  5 
CTT141 50  24  5 
CTT141 45  19  4 
CTT141 40  14  4 
CTT141 35  9  3 
CTT141 30  6  2 
CTT121 57,5  29  5 
CTT121 55  27  5 
CTT121 50  22  5 
CTT121 45  18  4 
CTT121 40  14  4 
CTT121 35  10  3 
CTT121 30  6  2 
CTT61 45  10  3 
CTT61 40  8  3 
CTT61 35  6  3 
CTT61 30  5  2 
CTT61 25  4  2 
CTT51 40  7  3 
CTT51 35  5  2 
CTT51 30  4  2 
CTT51 25  3  2 
CTT51 20  3  2 

F For special problems, consult the Manufacturer.

- Advertising boards placed on cab tower section are intended as a protection. Therefore, they
shall be considered an integral part of the structure and never be removed.
- It is compulsory to stop working when the wind reaches a speed of 72 km/h (45 mph) or when
weather conditions are adverse.
- An anemometer installed at an appropriate location is the safest way to determine the wind
speed.
- The weight of the load-handling devices shall be added to the actual weight of the load to be
lifted when calculating the maximum allowable working load.
- The use of load load-handling devices which can cause dynamic overstresses, or accidental
overloads, or which can limit the free movement of the load is not permitted.
- Do not use jumper wires or uninsulated wiring on the crane’s electrical system.
- Do not use the crane tower as a mean of support or anchorage of any kind.

Page 15/44 General Information CTT “CITY” 1_2_001_e

 - Some electronic parts the crane may be equipped with contain back-up batteries.
Radio controls, instead, contain feeding batteries.
Lead and lead compounds are chemicals known to cause cancer and reproductive harm.
Wash hands after handling.

2.2 WARNINGS TO THE OPERATOR

- Always use the available individual safety devices and other means of protection.

- Prior to operation, make yourself familiar with the construction site conditions. This also applies
to any obstructions within the working and traffic area and the required safety measures in
respect of public traffic.

- Carry out all daily inspections recommended in chapter 8 - “General maintenance”

of the crane’s operations manual prior to operation.

- Give the appropriate signal before initiating any maneuver.

- Check all limit switches and braking devices prior to starting the work shift. Notify, without
delay, the person responsible for the crane in the event of any defects.

- The employer, managers or supervisors shall have to be immediately informed about any
defects detected in components, safety and protection devices, as well as any other dangerous
conditions.

- In case of emergency, intervene immediately within the limits of your own experience, possibility
and responsability to eliminate or minimize inefficiencies and risks.

- Never use the crane if the limit switches are out of operation.

- Never use the crane with defective brakes or worn out brake pads.

- Never use the crane with damaged control units or control units with electrical cables that are
worn or have no insulation.

- Should even one of the safety devices need to be calibrated or not be operating, the crane
shall have to be taken out of operation and such condition indicated by posting appropriate
warning signs.

- Ensure that the slings of the load are properly secured on the hook and pull them taut by
hoisting with a slow and careful maneuver.

- Starting, stopping and any other maneuver shall have to be carried out gradually.

- During the normal operation of the crane, do not use the emergency braking device to stop it.

- All the limit switches and stops are safety devices: do not use them to stop motion during the
normal crane operation. Remember that the best limit switch is the eye of the operator.

- Before reversing any movement, make sure that the crane has come to a stop.

1_2_001_e General Information CTT “CITY” Page 16/44

 - Be attentive and careful when dangerous works are being carried out.

- Never lift a load that exceeds the crane rated load or that is not well slung. As for the capacities,
refer to the tables shown in chapter 2 - “Technical Specifications” of the crane
operation manual.

- Not less than three wraps of rope shall remain on the winch drums under any working condition.

- Avoid hoisting maneuvers and movements of a load above working and transit areas. Should
this not be possible, give appropriate warnings both at the starting of the maneuver and at the
time the load passes over the zone.

- Avoid oscillating the load, especially when lowering it to areas which are not in a direct vertical
position.

- Avoid oblique or sideload hoisting and lowering of loads and dragging maneuvers.

- When lowering a load, keep the rope taut with the weight of the hoist block, thus preventing
irregular spooling of the rope on the winch drum or slippage of the cable off the sheaves,
which could result in the rope breakage or in serious damages to other mechanical parts.

- When the crane is not operating, hoist the hook (unloaded) to the maximum height, trolley all
the way in and release the slewing brake to allow the jib to weathervane.

- Once the work shift is over, always release the slewing brake so that the jib can weathervane.

- Before leaving the crane unattended, disconnect power, place all controls in the off or neutral
position and land any load.

- If adjustments or repairs are necessary, report the condition promptly to the appointed person
and notify the next operator.

- Never leave tools or loose objects on the service catwalks. Keep the control free from dirt and
do not leave any flammable materials inside it.

- With the crane out of service, due to repairs or maintenance, the main switch shall be
disconnected.

- Never open switches and connectors until the electric power is off.

- Never carry out the “Unauthorized Crane Operations” shown at para. 3.4;

- Never move “Not allowed loads” as shown at para. 4.

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 2.3 GENERAL COMMUNICATION PROVISIONS

Audible and/or hand signals shall be used by the technicians responsible of the erection and by the
crane operator in accordance with the provisions stated in attachments VIII and IX to 92/58/EEC
standard.

2.3.1 Voice communications

Voice communications shall have to be concise, simple and clear.

The technician who receives information, and the person who communicates it, shall be certain to
understand each other perfectly.
Should the working place be noisy, the use of a radio equipment is suggested.
Should the use of a radio be unsatisfactory for the comprehension of commands and
communications, hand signals shall be utilized.

2.3.2 Hand signals

Hand signals shall be used whenever the operator cannot hear clearly the voice communications
of the signalman.
Rules of action:
A) the person who gives the signals, called the “Signal-man”, shall provide, by means of hand
signals, the maneuvering instructions to the person operating the crane, called the “Operator”;
B) the signal-man shall be able to constantly observe the crane maneuvers without being exposed
to any risk;
C) the signal-man shall devote his attention completely and exclusively to the signals necessary
for the maneuvers and the safety of the workers in the immediate area;
D) when the conditions called for in para. C) cannot be met, one or more auxiliary signal-men are
required;
E) when the operator is not able to carry out the instructions received by the signal-man with
regard to safety, he shall suspend the operation in progress and ask for alternative instructions.

2.3.3 Signal-man’s equipment

The signal-man shall be easily recognizable by the operator:

A) he shall wear or hold one or more items which identify him as a signal-man, such as jacket,
safety helmet, protecting gloves, signalling devices, etc.
B) the devices shall have a bright colour, preferably a colour used exclusively by the signal-man.

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2.3.4 Usual hand signals

Below find the hand signals to be used according to enclosure IX to Directive 92/58/EEC. Different
hand signals in force over the European Community or specific to the various Countries can still be
used.

2.3.4.1 Enclosure IX to Directive 92/58/EEC

START

Attention / Maneuver starting

The two arms are open horizontally with the

palms of the hands turned forward.

ALT

Interruption / Movement ending

The right arm is turned upward with the palm of

the right hand turned forward.

END

Interruption of the operations

The two hands are joined at the height of the

chest.

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 VERTICAL MOVEMENTS

LIFTING

The right arm, turned upward with the palm of

the right hand turned forward, slowly makes a
circular movement.

LOWERING

The right arm, turned downward with the palm

of the right hand towards the body, slowly makes
a circular movement.

VERTICAL DISTANCE

The hands show the distance.

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 HORIZONTAL MOVEMENTS

MOVING FORWARD

Both arms are bent, the palms of the hands are

turned upward; the forearms make slow
movements in the direction of the body.

MOVING BACKWARD

Both arms are bent, the palms of the hands are

turned forward; the forearms make slow
movements which move away from the body.

TO THE RIGHT

As regards to the signalman

The right arm, stretched out horizontally, with
the palm of the right hand turned downward,
makes small, slow movements.

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 TO THE LEFT

As regards to the signalman

The left arm, stretched out horizontally, with the
palm of the left hand turned downward, makes
small, slow movements.

HORIZONTAL DISTANCE

The hands show the distance.

DANGER

Halt or emergency stop

Both arms are stretched upward; the palms of
the hands are turned forward.

QUICK MOVEMENT

The usual signs previously described are performed more rapidly.

SLOW MOVEMENT

The usual signs previously described are performed very slowly.

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2.3.4.2 ASME B 30.3-96

TOWER TRAVEL
Arm extended forward, hand open and
slightly raised, make pushing motion in
direction of travel.

HOIST LOWER
With forearm vertical, forefinger pointing With arm extended downward, forefinger
up, move hand in small horizontal circle. pointing down, move hand in small
horizontal circles.

TROLLEY TRAVEL STOP EMERGENCY STOP

Palm up, fingers closed, thumb pointing in Arm extended, palm down, move arm back Both arms extended, palms down, move
direction of motion, jerk hand horizontally. and forth. arm back and forth.

SWING MOVE SLOWLY DOG EVERYTHING

Arm extended, point with finger in direction Use one hand to give any motion signal Clasp hands in front of body.
of swing of boom. and place other hand motionless in front
of hand giving the motion signal.
(Hoist slowly shown as example)

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 2.4 ACCIDENT PREVENTION SIGNS

The job site supervisor shall post the mandatory safety and prohibitory signs shown below when
the crane is present on the job site. For example (valid for EEC):

MANDATORY SIGNALS PROHIBITORY SIGNALS

No thoroughfare or standing
Protective gloves within the crane’s working
area

Protective shoes No thoroughfare

Safety belt Working on running parts

forbidden

Safety helmet Removal of protective and

safety devices forbidden

Antifall individual safety Use by unauthorized persons

harness forbidden

Protective overalls No maneuvering

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 DANGER SIGNALS

Suspended loads

Falling materials

Electrocution

Danger

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 3 USE
3.1 PLACING THE CRANE IN SERVICE

F Prior to operation, perform a visual examination of any externally perceptible defects and flaws of
the crane as recommended in chapter 8 - “General maintenance” of the crane operation
manual.

- Move the lever of the main switch (1) on

“QEL” electrical box at the bottom of the crane
tower to “ON-I” position (picture 3.1.1). 1

F Refering to chapter 6A - “Standard and

optional controls” of the crane operation
manual.
- Make sure that “STOP” push button on the
activated control station is released;
- Insert “ON” key (cab control or remote
control station) or, with the key on “I”
position, press “START” push button (radio
control).
Picture 3.1.1

F The control becomes uneffective with the hand levers not in the neutral “0” position.
- Engage the slewing brakes operating one “slewing” right or left movementy by “Trolley traversing-
slewing” left joystick .
- Perform functional motion tests without load to verify the crane efficiency.
In particular, check that:
. the directions of the motions are correct;
. the hoist limit switch is operative;
. the “trolley traversing inward” limit switch is operative;
. the “trolley traversing outward” limit switch is operative;
. the horn is operative.

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3.2 TAKING THE CRANE OUT OF OPERATION

Stop work immediately and take the crane out of operation:

- at the end of every working day;

- if wind speed exceeds 20 m/s (72 km/h - 45 mph) even in gusts;
- when a rain storm is about to start;

Refer to chapter 6A - “Standard and optional controls” of the crane operation manual
and procede as follows to stop and secure the crane:

- Lift the hoist block all the way up by “Hoisting-Travelling” right joystick;
- trolley in to the minimum hook position by “Trolley traversing-Slewing” left joystick;
- If the crane is travelling on rail tracks, move it to the special out-of-service parking area by
“Hoisting-Travelling” right joystick and secure it to the tracks through the special anchor clamps;
- Release the slewing brakes keeping the special “Slewing brake off” push button pressed for
about 3 seconds. A rapid and discontinuos audio signal shall advise of the positive conclusion
of the operation and “Slewing brake off” push button can be released.
- Press “STOP” push button on the activated control station;
- With “ON” key in neutral position, extract it from the activated control station.

Now the crane is out of service.

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F
Should it not be possible to carry out the electrical release of the slewing brakes, once pressed the
“STOP” push button on the activated control station, operate the manual release as per directions
given hereinafter.

Manual release

F Carry out this operation on each slewing motor equipped with brake.
1) Move lever (5) on the slewing brake to position (1) (picture 3.2.1);
2) Press push button (6) in the direction of arrow (2);
3) Release lever (5) keeping push button (6) pressed;
4) Release push button (6).

Picture 3.2.1

6
3
1 2 4

F Should some utilities on the crane upper part (such as job site lights, obstruction lights, cab air
conditioning or other electric equipment) need to be still energized, keep the lever of the main
switch (1) on the (QEL) electrical box at the bottom of the crane tower to “ON-I” position (picture
3.1.1).
Otherwise, move it to “0-OFF” position.

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3.3 CHANGING FROM 4-PART LINE TO 2-PART LINE AND VICE VERSA

Passing from 4-Part Line to 2-Part Line

F For detailed information on the controls refer to chapter 6A - “Standard and optional
controls ” of the crane operation manual.

1) lower the hoist block to the ground;

2) remove the “M” 35×245 pin connecting the

two hoist blocks;

3) pulling back “Hoisting-Travelling” right

joystick operate “LOAD LIFTING” and
slowly raise the 4-part line hoist block until
it engages the special housing on the trolley
and the 2-part line hoist block is off the
ground

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 Passing from 2-Part Line to 4-Part Line

F For hook heights exceeding the rated ones, consult Comedil Technical Department.

F For detailed information on the controls refer to chapter 6A - “Standard and optional
controls ” of the crane operation manual.

1) Pulling back “Trolley traversing-Slewing” left

joystick on the activated control station, trolley
in to the minimum hook position;

2) lower the 2-part line hoist block to the ground

and with “Hoisting-Travelling” right joystick
still forward, lower also the 4-part line hoist
block to the ground;

3) connect the two hoist blocks together by pin

“M” 35×245 and relevant split pin;

4) lift the hoist blocks.

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3.4 AUTHORIZED AND UNAUTHORIZED CRANE OPERATIONS

The crane shall be operated only by skilled workers (preferably by licenced workers).
The operator is authorized to carry out only the operations described below observing the relative
instructions.
As the crane can perform more than one movement at a time, it’s upon the operator to control
these functions according to the visibility of the suspended load.

F The operator shall be able to follow the trajectory of the moving loads at any moment.
If not, he shall take precautions. In particular, he shall be assisted by other people who, with voice
and/or hand signals, provide him with all the information necessary to work in safety.
For a correct use of the crane, the operator shall observe the crane maintenance rules and carry

F out periodical inspections of the whole system as described in chapter 8 “General

maintenance” of the crane operation manual.
The use of Comedil parts or parts recommended by Comedil is critical to the correct use of the
crane.
Any subsidiary material necessary to the job site, such as buckets, belts, etc. and belonging to the
buyer should be suitable for the correct use of the crane and in conformity with the local regulations
in force.

- All national and local safety standards must be adhered to.

- Do not use the crane with a wind speed exceeding 20 m/s (72 km/h - 45 mph).

If so, release the slewing brake or brakes to enable the jib to weathervane.

- Do not carry out any slewing, crane

travelling, trolley traversing movement or
engage the maximum hoist speed with
loads laying on the ground.

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 - Do not use the emergency stop button to interrupt any motion during the normal crane operation.
Use it only in case of emergency situations that may endanger the operator, other people or
the equipment.

- The crane cannot be used by persons who have not been authorized by the job site foreman.

- Do not tamper or modify any crane component.

- Do not leave the crane unattended unless you have first released the slewing brake, anchored
it to the rail track (where a traveling crane is used) and disconnected the electrical power.

- Do not use the crane for demolitions.

- Do not carry out tilted tractions and towing

operations of the load.

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 - Do not hoist loads set onto the ground
(uprooting of trees, poles, pile shoes, forms
used for pouring concrete, etc.).

- Do not lift loads which may be anchored to the ground by ice.

- Do not unload suspended items being hoisted rapidly (using load-handling devices that permit
an immediate release of the load, non-homologated buckets or self-dumping buckets, or cutting
the sling, etc.).

- Do not lower the load abruptly using the highest lowering speeds.

- Do not lift the load if it is placed on unstable and/or not well balanced planes, load placed on
dangerous scaffoldings, watercrafts, etc.

- Do not lift loads which are hooked off center

or unbalanced.

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 - Do not oscillate the suspended load to lay it
down in a position out of the crane working
radius.

- Do not lay the hoist block on the ground.

- Do not move the load over people.

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 - Do not carry out any maneuver if the load
cannot be seen.

“X” kg/lbs

- Do not lift loads which exceed the rated

capacity shown in the load chart.
“X + 1100” lbs
“X + 500” kg

- Do not lift or lower the load running the risk of collision with obstacles of any nature.

- Do not leave any load suspended when the crane is out of service (small loads with ristricted
surface exposed to the wind can be an exception, when used to keep the rope properly
tensioned).

- Do not activate the countermaneuver function (do not start any maneuver until the dynamic
effects of the opposite previous maneuver are stopped).

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 - Do not place on the crane signs or other objects which may increase the surface exposed to
the wind and the crane’s own weight.
For special problems, contact Comedil Engineering Department.

- Do not tamper, modify or make any change to the crane structural, electrical and mechanical
parts without informing the Manufacturer.
Should this not be done, the crane warranty and the Manufacturer’s responsabilities will be
automatically voided.

F - Do not lift loads having a surface exposed to the wind greater than the allowed
(refer to chapter 2 “Technical specifications” of the crane operation manual).

- Do not use the crane if it is not operating correctly.

- Do not use the limit switches as maneuvering mechanisms to systematically stop the load in
predetermined positions.

- Do not go on lifting loads close to the maximum allowed working capacity, if this repeatedly
actuates the limiters.

- Do not lift containers with liquids, unless they are properly sealed and filled up. The movement
of the liquid, in fact, could result in dangerous oscillations of the load, maybe even in its flowing
off (if it is an open top container).

- Never disengage the “dead-man-control”

safety device (1) of the control unit.

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  4 ALLOWED LOADS
The dimensions and shape of the loads shall be suitable for the place where they are going to be
moved and for the crane used.
The weight of the loads shall be clearly marked. Their dimensions shall not exceed those allowed,
according to the wind speed they could be exposed to.
ALLOWED LOADS

F
Loads equipped with proper load-lifting attachments (picture 4.4).
Loose loads placed in suitable containers equipped with proper load-lifting attachments, which
prevent them from coming out (picture 4.2).
Loads which cannot change their physical configuration during the travelling and/or hoisting
operations.
NOT ALLOWED LOADS
Loads whose weight, including the eventual load-handling device, exceeds the crane rated capacity.
Loads that are classified as dangerous for their features (flammable, explosive, toxic materials, etc.).
Liquids put in open top containers (picture 4.12) or liquids put in sealed containers, which are not
properly filled up (picture 4.13).
Loads that are not properly secured to the load-handling device (picture 4.1).
Particular attention must be paid to asymmetric and/or unstable loads which can turn or move
when being hoisted (picture 4.5 - 4.6).
Particular attention must also be paid when placing the loads on the ground: put shims, boards,
wedges, etc. for the stability of the load, thus preventing it from falling or turning over when
released from the hoist block (picture 4.9 - 4.10). 

Picture 4.1  Picture 4.2  Picture 4.3 

Picture 4.4 Picture 4.5 Picture 4.6

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 Picture 4.7  Picture 4.8 Picture 4.9

Picture 4.10   Picture 4.11  Picture 4.12 

People in charge of hoisting and handling shall strictly Picture 4.13 

observe the following general rules:

- defend other people’s safety by sending the unauthorized

persons away and preventing them from entering the working
area.
- prevent any suspended load from being moved over people
(picture 4.1); if not, signal the manoeuver, thus allowing them
to leave the area.
- do not carry out tilted tractions of the load (picture 4.3).
- check the efficiency of ropes and chains.
- locate the sling points, thus allowing the correct distribution of the load.
- NEVER exceed the maximum capacity of the crane.
- interpose rags, wood, rubber, etc. in case of load with projecting parts or sharp edges, which
can damage cables or chains (picture 4.9 - 4.10).
- never get onto unstable load hanging from the hook or cling to it, in order to balance it
(picture 4.5 - 4.6).
- never lift man-holder baskets or keep them suspended as working stations (picture 4.11).

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 5 HOISTING LOAD-HANDLING DEVICES

Comedil supplies as an integral part of the crane hoist and movement wire ropes together with the
safety hook. Ropes for the load slinging are not supplied.
All these components comply with safety requirements equal to or higher than the ones stated in
98/37/EC standard.
To assist the user in choosing the slinging or hoisting accessories, below is a summary of the
standard itself.

F The dimensional specifications of the slinging accessories must be established basing upon operating
cycles, stress and wear factors the accessories will be subject to.
Furthermore:
a) The coefficient of utilization of the metal cable and terminals should guarantee an appropriate
safety level. This coefficient is generally equal to 5. The cables shall not contain any interlacement
or rings different from that found at the ends.
b) Should welded link chains be used, they shall be short link type. The coefficient of utilization of
the chains, apart from the type, shall guarantee an appropriate safety level. This coefficient is
generally equal to 4.
c) The coefficient of utilization of the cables or belts made of textile fibers depends on the material,
manufacturing process, dimensions and use. This coefficient is chosen to guarantee an
appropriate safety level. Should the materials be of high quality and the manufacturing process
controlled to ensure that the lifting straps meet the specifications for the intended loads for
which they will be used, then the coefficient is generally equal to 7. If this is not the case, it is
necessary to upgrade the coefficient to guarantee an appropriate safety level.
The cables or belts made of textile fibers must not have knots, splices or connections, aside
from the ones placed on the ends of the straps.
d) The coefficient of utilization of all the metal components of a sling or used with a sling, is
chosen to guarantee an appropriate safety level. This coefficient is generally equal to 4.
e) The maximum capacity of utilization of a strand sling is established bearing in mind the maximum
capacity of utilization of the weakest strand, number of strands and reduction factor which
depends on the type of sling.
f) To check that the appropriate coefficient of utilization has been reached, the manufacturer or
his agent named by the Community should carry out the tests fitted for each type of component
as described at points a), b), c) and d).

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 5.1 UNAUTHORIZED HOISTING LOAD-HANDLING DEVICES

a) Improvised hooks which do not guarantee

the safe transportation of the load.
b) Accessories which transmit dynamic
stress onto the crane due to their own
features.

The hoisting hooks must be equipped with safety latches and show their maximum capacity
(raised or engraved) (picture 5.1.1).

Picture 5.1.1

The capacity shown on the slinging devices shall be strictly observed.

F The hoisting load-handling devices should be inspected every three months under the employer’s
responsability by skilled personnel of his own or chosen by him.

5.2 LOAD STABILITY AND SLING PROCEDURES

With two tie-ropes crossed on the same hook (picture 5.2.2), only one works but both wear out on
the cross point. A correct sling shall see the two tie-ropes placed in parallel on the hook (picture 5.2.1).

Picture 5.2.1 Picture 5.2.2

YES NO
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5.3 CAPACITY OF THE SLINGS

F ATTENTION: - The sling angle is a crucial factor for the resistance of the cable or of the chain.
- The maximum capacity is achieved with cables or chains in vertical position
(angle 0°).
- As a angle increases, the capacity decreases (picture 5.3.1).

Picture 5.3.1 

ATTENTION: Sling angles exceeding 90° are not allowed: they would increase the stress
on cables or chains.

Picture 5.3.2

Picture 5.3.2 shows how the capacity varies according to the sling angle, namely how it decreases
as the sling angle increases.

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 6 INHERENT RISKS AND EMERGENCY SITUATIONS
The crane is intended only for its specified technical use. In spite of the efforts made by the designer
and Manufacturer to develop a safe product, it still has certain inherent risks which could not be
removed throughout the design, manufacturing and accident prevention process.

Some of the risks are due to:

- projecting and/or sharp-cornered parts;
- suspended loads;
- presence of feeding electrical cables;
- storage of electrostatic energy;
- thermal features (for example, warmed up electric motors, etc.);
- moving mechanical parts;
- presence of grounding plates;
- lack of maintenance;
- falling objects from the structure.

If the crane is correctly used as stated in the operations manual, the operator and the crane will
never be in danger.
However, particular emergency conditions can occur. Only the competence and experience of the
operator can solve the problem without jeopardizing his safety and the safety of others by careless
maneuvers.

These situations can be for example:

- unsafe loads due to faulty slingings;
- sudden obstacles which are not seen at the beginning of the maneuver;
- unexpected indisposition of the crane operator (for this reason, it is strictly forbidden to
the operator to disconnect the safety mechanism placed on the control unit);
- unexpected mechanical failures, etc.

F The immediate stop of all movements can only be insured by pressing the “STOP” push button
(see chapter 6A - “Standard and optional controls” of the crane operation manual),
anyhow, the operator is free to carry out any other movement necessary to prevent an emergency
from becoming an accident.
Should the operator be in the control cab, he shall have to be able to communicate with the operators
working on the ground in case of dangerous situations.
If the emergency has been caused by electrical or mechanical failures, which cannot be solved by
the operator, call Comedil’s nearest service center.

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 7 STAFF TRAINING

The training of the operators should comply with UNI-ISO 9926/1 and UNI-ISO 9926/3 standards.

The person responsible for the job site is fully responsible for assigning only and exclusively skilled
operators to use the crane or allowing specialized personnel to perform maintenance operations.

All personnel who operate or service the crane should be trained on the safety requirements contained
in the new EEC standard.

All items contained in 89/391/EEC standard and revisions thereafter should be explained to the
operator teaching how to use the crane with the greatest degree of safety.

The operator should be trained on all the technical and operational provisions to get the greatest
productivity and efficiency from the machine.

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 8 FINAL DISMANTLING OF THE CRANE

Complying with all special and routine maintenance requirements and a continuous correct
operational use of the crane facilitate a possible use of the machine after the general testing of the
structure and drive systems, which is usually carried out on the tenth year.

The test shall certify if the crane is suitable for the use with reduced capacities or if it is to be
definitely taken out of operation and destroyed.

The authorities in charge shall determine and confirm the above.

The crane shall be dismantled by the owner separating all the materials according to the typology
(structure and mechanism, electric parts, plastic materials, lubricants). But only authorized firms
shall be trusted for the crane elimination.

The crane dismantling could be assigned also to a third party, if authorized for the salvage and
elimination of the materials concerned.

WARNINGS: The elimination of the materials and any report of elimination shall comply with the
standards in force in the country where the crane is working.

IMPORTANT: Never leave the crane in a place which is not a restricted area.

Leaving the crane in a free-admittance area would constitutes a serious danger to

people.

The owner of the crane shall always be responsible for any injury or damage to
people.

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