FEDERATION EUROPEENNE DE LA F.E.M.

MANUTENTION 1.007
SECTION I
November 2003
HEAVY LIFTING APPLIANCES

RE COMMANDATIONS

TO MAI NTAIN TOWER C RANES

I N S AFE COND ITIONS

This edition is also available in French and German

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 FEM 1.007

Recommendations to maintain tower cranes

in safe condition

CONTENT

I SCOPE 3

2 INSPECTIONS 3

2.1 Daily inspections 3

2.1.1 General 3
2.1.2 Content 3
2.1.3 Results 4

2.2 Frequent inspections 4

2.2.1 General 4
2.2.2 Content 4
2.2.3 Periodicity 5
2.2.4 Results 5

2.3 Periodic inspections 5

2.3.1 General 5
2.3.2 Content 5
2.3.3 Periodicity 6
2.3.4 Results 7

2.4 Thorough inspections 7

2.4.1 General 7
2.4.2 Content 7
2.4.3 Periodicity 8
2.4.4 Results 8

ANNEX A SYNTHESIS OF THE RECOMMENDED INSPECTIONS 9

ANNEX B LIST OF THE PERIODIC INSPECTIONS TO BE PERFORMED 12

ANNEX C VERIFICATION OF THE HOOKS 13

ANNEX D EXAMPLE OF REPORT FOR PERIODIC AND THOROUGH INSPECTIONS 14

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1 Scope
The aim of this recommendation is to identify the different operations (content and periodicity)
needed to maintain tower cranes in a safe condition.

It gives also guidance for detection of defects and actions to be taken.

This recommendation should be used in absence of manufacturer's requirements or national

regulations. It can also be a guidance for the manufacturer to establish his requirements.

The manufacturer's instructions have priority over this recommendation.

National regulations shall also be considered.

2 Inspections
To maintain tower cranes as a whole and/or its components in a safe working condition they shall
be submitted to the following inspections:

Daily inspections
Frequent inspections;
Periodic inspections;
Thorough inspections (special assessment).

Note : This recommendation deals only with recurrent inspections, not with the inspection after the
first erection of the tower crane.

Furthermore tower cranes shall be used and maintained in accordance with the manufacturer's
instructions.

Annex A summarises the recommended inspections (periodicity, content, persons in charge,

results and reports).

2.1 Daily inspections

2.1.1 General
Daily inspections shall comprise a visual inspection (in general no dismantling is required) and
functional tests as defined hereafter and shall be carried out by a designated person (e.g. the
crane driver).

2.1.2 Content
The inspections before each start shall contain :

a) functioning of mechanisms, in particular the brakes (generally without load);

b) functioning of limiting and indicating devices;

c) observation of conspicuous defects including ropes.

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2.1.3 Results
Any defect shall be pointed out to a person who can take a suitable decision (to leave the tower
crane in use, repair, thorough inspection of a part of the tower crane or the whole tower crane,
limitation of use).

The causes of these defects shall be searched depending on the type of component and the
criticized defect.

The record book shall be updated (date of the repair, method)

2.2 Frequent inspections

2.2.1 General
Frequent inspections are inspections made with a periodicity as indicated in clause 2.2.3.

They shall comprise visual inspections ( in general no dismantling is required) as described in 2.2.2.
and functional tests listed in 2.1.2.

They shall be carried out by a designated person (e.g. experienced technician, see ISO 9927-1).

2.2.2 Content

a) Level of lubricants
leak of lubricants, greasing;

b) Hydraulic equipment
leakage;

c) Hooks and latches

visible deformation, cracks, wear;

d) Connections, joints
corrosion, visual inspection;

e) Wearing of the brakes

thickness of brakes linings, adjustment, noise, etc.;

f) Hydraulic and pneumatic hoses

in particular those which are bent during operations;

g) Electrical installation
state, signs of deterioration, moisture accumulation;

h) Anchorage
braces or guys supporting cranes (condition);

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2.2.3 Periodicity

The periodicity of the frequent inspections has to be determined taking into account the real use of
the tower crane and the environment in which the tower crane is working.

The minimum periodicity is

a) For clauses a) to d) of 2.2.2 monthly;

b) For clauses e) to h) of 2.2.2 twice a year.

2.2.4 Results

Any defect shall be pointed out to a person who can take a suitable decision (to leave the tower
crane in use, repair, thorough inspection of a part of the tower crane or the whole tower crane,
limitation of use).

The causes of these defects shall be searched depending on the type of component and the
criticized defect.

The record book shall be updated (date of the repair, method).

2.3 Periodic inspections

2.3.1 General
Periodic inspections are inspections made periodically as indicated in clause 2.3.3.

Periodic inspections shall comprise visual inspections (in general no dismantling is required),
functional tests with and without load as defined below.

They shall be carried out by a competent person (e.g. an experienced technician , see ISO 9927-1).

The competent person shall have

the report of the previous inspections and
> the automatic registered data, where available, (cycles, hours, days, loads...) permitting to
know the service time of the components for which data exist.

2.3.2 Content
The periodic inspections shall include the content of frequent inspections (see clause 2.2.2) and
the following points.

The functional tests for all components shall be performed in the most unfavourable position for
these components.

a) Verification of the tower crane's identification and plates;

b) Presence of the instruction handbook;

c) Verification of the records of maintenance

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 d) Verification of the components, equipment and steel structure
compare the component installed on the tower crane with the component listed in the
documentation

e) Consideration of the condition of equipment which warn on damages

the gear or it's components are leak;

visible couplings between particular components (e.g. motor, gear, brakes, drums)
show wear or damages;

unusual noise is noticed;

unusual high temperature is noticed;

fastening bolts are loose, fissured or defect;

brake linings are worn or damaged;

the general condition (corrosion, dirt) is to criticize;

the electrical installation (cable entries, cable attachments) shows damages;

ropes in accordance with ISO 4309;

hooks (see Annex C).

f) functional tests
functioning and efficiency, with the rated load, of
- mechanisms, in particular the brakes;

- limiting and indicating devices;

g) Steel structure and rails

Welding, corrosion, remaining deformation, cracks

h) Support of the tower crane/crane track

As an example , Annex B gives a list of components to be checked (identical to Annex A of ISO

9927-1).

2.3.3 Periodicity
Tower cranes shall be inspected at least each year and after each re-erection.

Note 1 : Some verifications can be performed when the tower crane is dismantled.

Note 2 : Changing of the pulley block or addition of a jib extension or tower section are not
considered as dismantling and re-erection.

Note 3 : After folding and unfolding of a self erecting tower crane, the inspection is limited to
points b), c), f), g) and h) of clause 2.3.2.

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2.3.4 Results
Periodic inspections shall be recorded. This report shall indicate the components verified and
remaining defects. An example for such report is given in Annex D.

The report shall be given to a person who can take a suitable decision (to leave the tower crane in
use, repair, thorough inspection of a part of the tower crane or the whole tower crane, limitation of
use).

The causes of these defects shall be searched depending on the type of component and the
criticized defect.

The record book shall be updated (date of the repair, type, etc.).

2.4 Thorough inspections

2.4.1 General
Thorough inspections are detailed inspections made with a periodicity as defined in clause 2.4.3 or
following a detected serious defect.

They shall be performed by an expert who has a competence which permits him to define the
actions to be taken depending on the results of these inspections (e.g. an expert engineer, see ISO
9927-1).

The expert shall have

the report of the previous inspections and
the automatic registered data, where available, (cycles, hours, days, loads...) permitting to
know the service time of the different components for which data exists

2.4.2 Content
The thorough inspections shall comprise at least all the elements of the periodic inspections.

The thorough inspection could need non destructive tests and/or dismantling if it is justified
considering
- the content of the previous verifications (daily, frequent periodic or thorough),
- the results of the current tests,
- the result of the current visual checks.

When dismantling, special care has to be taken to avoid mistake or wrong operation following the
maintenance instructions. If they are not available, the manufacturer of the tower crane or of the
component should be contacted for assistance.

During the thorough inspection, a particular attention shall be taken for the following:
vibration;
unusual noise or temperature;
poor general condition, corrosion;
alignment of machinery, motors and gears, rails, wheels, shafts;
brakes;
connections, bolts, pins.

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2.4.3 Periodicity

2.4.3.1 Periodicity for tower cranes or components for tower cranes with no automatic
registration on use
Thorough inspection of a component or the tower crane is recommended at periodic intervals as
follows:

4 years
8 years
10 years
12 years
14 years
every year after 14 years
after detection of a serious defect or substantial modification

Modification is substantial for example in case of increase of the rated capacity, change of the
mechanisms, transfer of the control station, change of power, change of the design of the load
bearing structure, welding on the load bearing structure, modification of the control system or
change of the operating condition relative to the class of utilisation and the load spectrum.

2.4.3.2 Periodicity for tower cranes or components for tower cranes with automatic
registration of data on use

The instruction handbook should contain the periodicity of the thorough inspection of the crane and
of the corresponding components based on the registered data, at least the intervals as given in
2.4.3.1.

In addition to the periodicity, the manufacturer should give guidance to reinitialise the value of the
parameter (return to zero, keep the value as new origin...).

2.4.4 Results
The report of the thorough inspections shall contain the result of the inspection made by the expert
as well as his conclusions and recommendations including the delay for the next thorough
inspection.
An example of such report is given in Annex D.
When the tower crane or a component is not used as classified or in a condition which seems to be
hazardous, the expert (see clause 2.4.1 above) will recommend accordingly.

The causes of defects shall be searched depending on the type of component and the criticized
defect.

The record book shall be updated (date of the repair, type, etc.).

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 Annex A Synthesis of the recommended inspections

Daily inspection Frequent inspection Periodic inspection Thorough inspection

When - before each start up of the tower - monthly or every six months - at a determined period (legal, - after finding a fundamental failure
crane and/or according to the given by the manufacturer or a
(Periodicity) manufacturer's recommendation) - at a determined period either

- after dismantling/re-erection - Legal

- Given by the
manufacturer
- Given by
recommendation
following a report
(frequent or periodic
inspection),
- Given by this
recommendation
What (content) Clause 2.1.2 Clause 2.2.2 Clause 2.3.2 Clause 2.4.2

How - Visual inspections Visual inspections - Visual inspections including the - Same as for the periodic
reading of recording instruments inspection
- Functional tests - Functional tests
- Functional tests (loaded and -If necessary with dismantling or
unloaded) measurement (play) or specific
tests on all or part of the tower
Without dismantling Without dismantling Without dismantling if not otherwise crane.
required by the manufacturer

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 Daily inspection Frequent inspection Periodic inspection Thorough inspection

By who Designated person (e.g.crane Designated person (experienced Competent person (experienced Expert (expert engineer)
driver) technician) technician)

Inspection - OK or, - OK or, - OK or, - date of the next inspection

results
- request for repair if fault found or, - request for repair if fault found or, - request for repair if fault found or, - partial or total changes 1 or

- can give rise to a request for a - can give rise to a request for a - can give rise to a request for a - scrapping or
thorough inspection (repetitive thorough inspection (repetitive thorough inspection (repetitive
cases, major fault, etc.) cases, major fault, etc.) cases, major fault, etc.) - request for repair

- can give rise to a request for a - can give rise to a request for a - can give rise to a request for a - can give rise to a request for a
training action (driving, instructions, training action (driving, instructions, training action (driving, instructions, training action (driving, instructions,
limit of use, etc.) limit of use, etc.) limit of use, etc.) limit of use, etc.)

Report Not systematic Not systematic The report shall include a check list The report shall contain the findings
of the points checked and a of the expert as well as his
summary of the detected defects. conclusions, for instance, the list of
repairs, period before the next
thorough inspection, tests to be
performed, proposal for general
overhaul...

Maintenance Updating the maintenance book if Updating the maintenance book Updating the maintenance book Updating the maintenance book
book repair is involved with reports on maintenance work, with reports on maintenance work, with reports on maintenance work,
defects, damages, repairs... defects, damages, repairs... defects, damages, repairs...

1 Systematic changes of certain parts can be recommended by the manufacturer or by way of recommendations .

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 Annex B List of the periodic inspections to be performed
Identical to Annex A of ISO 9927-1

Element Verification to be made

1 Components and mechanical equipment

1.2 Access ladders and walkways

Steps, rungs, beams, covering of walkways, Installation, condition
platforms, etc.
Protective guarding (railing, intermediate bars,
hoop guard, toe guards)
Information labels and boards marking
hazardous areas
1.3 Crane and trolley tracks
Travel rails, runway stops Installation and condition, track gauge, span, deformation
Locking and latching devices Condition, function
1.4 Crane structure (bridge, portal mast, jib, tower)
Girders, bars, connections, buffers, end stops, Cracks, deformation, wear, fastening elements, condition,
bracing alignment
1.5 Trolley structure (structure, jib)
Girders, bars, connections, slewing rims Condition

1.6 Assemblies
Travel wheels, shafts, couplings, drums, sheaves,
Fitting and securing of removable parts, condition
compensating sheaves with pins
Gear wheels, worm gears Function
Screws, nuts, wedges Support
Hydraulic and pneumatic components Protection of assembly
Mechanical warning devices, limit stop devices, Condition, function
overload protection

1.7 Brakes
Discs, shoes, belts, levers, release units, weights, Condition, function, brake test with load (test load in the
pins, springs capacity range)

1.8 Lubrication
Lubrication systems and lubrication points Sufficient filling, accessibility, identification

1.9 Clearances Compliance, also with regard to subsequently added

elements

1.10 Foundations anchorage Condition and installation

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 ANNEX C Verification of the hooks

This annex gives an example for the verification of the hooks

To apply the following method , the initial dimensions of the hooks need to be known.
They are available near the manufacturer of the tower crane of the hook.

Deformation
If the opening "a" and "y" have widened more than 10%, which is the max.
permissible limit, replace the load hook.
Surface fissures
Damage and surface fissures may be removed notch-less, provided that the
permissible tolerance levels are not exceeded.
Wear
Wear on single or twin hooks may not be greater than 5% of the height "h". It is
not permitted to carry out welding work on load hooks, e.g. to compensate for
wear.
Hook neck shaft
Cracks

Marking Marking

Reference values for "a", "h" and "y" are to be taken form the instruction manual. If they are
not available, the manufacturer of the tower crane or of the hook shall be contacted.

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 Annex D Example of report for periodic and thorough inspections

Company: Date:

Crane type: Serial No.:

Manufacturer: Year of construction:

Address of customer/hirer:

Construction site: Stock number:

Examiner: Signature:

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 re-examination
oE

part to be checked ; 12 Q necessary carried out

Z r c a
yes no date
+ _ + + -
signature

Crane book
C_
Instruction handbook
r 96 spare parts lists

Substructure horizontal
Substructure able to take the loads

Length of sleepers

Condition of sleepers
0
t Distance of sleepers

Gauge
Inner radius of curved rail
10
Rail dimensions

Rail fixings
Rail joints/joint plates

Running-up key for travelling limiter

Travel limits

Type plate
Signs
Warning signs

Safety distances

to
to
Y
to

to
barriers

met = x not met = - not necessary = 0

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 2,
F oo a a
n y o 1, E re-examination

z Jmp part to be checked xE =.E E ^ necessary carried out

yes no date
signature
Free of cracks
Outrigger arm support

Outrigger arm lock

Rail wheels
Wheel flanges

's Travelling gears

0 Travelling brakes (travelling test)

Guarding of danger spots

m Devices to limit fall due to wheel failure

-0
E 1
Rail clamps
Track clearer

Supporting devices
Transport safety retainer removed

F
Clearance of the slewing ring

Fastening of the slewing ring

Test run of the slewing ring

oao Slewing gear pinion

Fastening of the gear

1!) Slewing gear brake

Free jib slewing

Guarding of danger spots

Coupling
Changing gear
Interlock of changing gear
Rope drum mounting
-
(D Fastening of the hoisting winch
Clearance of brake linings
Brake disk

Brake release unit

Springs

met = x not met = - not necessary = 0

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 T

oE re-examination
0
part to be checked 0 2 2 necessary ca
carried out
z
yes no date
+ - + - + - + -
signature
Brake test

Lowering without power

F Rope fastening
CIO
2 safety turns

Coupling

Changing gear
Interlock of changing gear
Rope drum mounting
Fastening of the luffing winch

Clearance of brake linings

Brake disk
N. Brake release unit

Springs
Brake test
Lowering without power
Rope fastening

2 safety turns

Coupling
Changing gear
Interlock of changing gear
Rope drum mounting
Fastening of the auxilary winch

Clearance of brake linings

Brake disk

Brake release unit

Q Springs
X

Brake test
Lowering without power
Rope fastening

2 safety turns

F
met = x not met = - not necessary = 0

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 T

y
8 g E re-examination
Z part to be checked 12 necessary carried out
Cc
+ - + - + - + - yes no date
signature
Rail wheels

Rope pulleys

Wheel flanges / guide rollers

'E Trolley travelling limiter

4, Coupling
i=
Fastening of the trolley travelling drum
Rope fastenings
V
Limit stops
9 2 safety turns
Fetch back of the maintenance cage

Ballast

Loose ballast (weight)

Fixed ballast (weight)

Secured against moving
Secured against falling down
Slinging points

Welds free of cracks

Comer posts
tff Diagonals
2
; Bolt connections
Pin connections
Towerjoints

Welds free of cracks

Upper and lower chords

Diagonals

4.
L, Bolt connections
C
Pin connections
Jib joints

F
met = x not met = - not necessary = 0

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 T
p Q p f} w 0
E re-examination
a o
E
part to be checked P'& necessary carried out

- yes no date
+ - + - + - +
signature
Welds free of cracks

Counter jib chords / girder

Diagonals
Bolt connections
Pin connections
U
Counter jib joints

Ladders

Hoop guards
E
E
Personal protective equipment against
falls from a height
Walkways

Platforms

Safety device against falling down

Walls

Windows
Floor
Entrance
Doors
Seat

T Y
Ventilation

Heating

a Electric Installation
a
U
Windscreen wiper

Side protection

Actuating devices
Signs and warnings

Radius indicator

U` Indicators

met = x not met = - not necessary = 0

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 T
7E
O t c p
re-examination
.E
part to be checked necessary carried out
z R E3 E,
- yes no date
+ - + - + - +
signature
Groud fault protection system
Feed line

Cable drum

Crane switch
No-volt release

Deadman 's switch (movable control)

Electric installation
t
j-
w Strain reliefs
Lighting

I F
Hoisting rope
Luffing rope

Jib tie(s)
Trolley travel rope(s)
Erection rope(s)

Rope pulleys

Rope hoop guard

a
ca CL Rope guides
.I Rope en d t erm i na ti ons
43
a Other rope connections
or Pendant ropes
Other pendants
Locating points of ropes

I F
Fastening at hoisting rope

Wear of the hook

Deformation of the hook

Surface cracks

Load hook's nut safety catch

Hook catch

Hook block

met = x not met = - not necessary = 0

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 T
8V c a-
08 0
OE re-examination
S' E GU
part to be checked $ 2a necessary carried out
z x
w3 a o

yes no date
+ - + - + - + -
signature
Travelling limiter
Hoisting limiter

Lowering limiter
Derricking limiter up
Derricking limiter down
o
Trolley travelling limiter forward

CI4 Trolley travelling limiter reverse

Max. load limiter

Load moment limiter

Slewing limiters

a
a
Cc

y N
E
N 0 ,1
ws
rt

t U

met =x not met = - not necessary = 0

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