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Tower Crane Intermediate Service Inspection
Tower Crane Intermediate Service Inspection
Jerome Guillermo

Tower Crane Intermediate Service Inspection

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Free Tower Crane Intermediate Service Inspection Checklist

Use this Template

Title Page

  • Site conducted

  • Document No.

  • Plant Number (eg. TC 1)

  • Serial Number

  • Crane Model

  • Tower Crane Intermediate Maintenance Report

  • Client / Site

  • Service conducted on:

  • Technician

  • Location

  • Time of arrival at site

Site information

  • Have I completed a site induction or partial induction?

  • Have I been briefed on any known issues on the cranes?

  • Have I been briefed on emergency response situations

General Condition of structures, fasteningss and machinery

  • The technician will survey the crane from base to top of the crane ensuring all tower connections are checked (Pins, bolts, connections, anticlimb system) for security or looseness. Approach the slew ring and check all the bolts are tight and secure. On the crane superstructure check all connection pins for the A-frame and counterweights. Also, check all the sheave jumper protection bars. The condition of all connected joints are to be checked such as the platforms and gratings. Pins along to the boom are also to be checked for security and secondary retention.

  • I, as the technician, have performed the above sequence of works

  • Condition check: Fixing or Ballast blocks and counterweights

  • Reason or recomendation

  • Add media

  • Condition check: Structural elements

  • Reason or recomendation

  • Add media

  • Condition check: presence and condition of fastenings - particularly pins of frames and masts

  • Reason or recomendation

  • Add media

  • Condition check: lubrication of articulated connection in operation (Slew ring, sheaves, heel pins)

  • Reason or recomendation

  • Add media

  • Condition check: lubrication of articulated connection in operation (Slew ring, sheaves, heel pins)

  • Reason or recomendation

  • Add media

  • Condition check: Assembly if access equipment (Platforms, ladders, trap doors, guard rails and hook guards etc

  • Reason or recomendation

  • Add media

  • Condition check: Fixing of accessories (Advertising signs, wind plates, navigation lights, jib angle-distance indication plates)

  • Reason or recomendation

  • Add media

  • Condition check: boom connection pins and heel pins for security, including secondary retention systems.

  • Reason or recomendation

  • Add media

  • Condition check: Condition of machinery and their fixings

  • Reason or recomendation

  • Add media

Test the crane in operation with the crane driver

  • All functions and systems are to be checked physically throughout tests in particular the emergency or secondary devices.

  • I, as the technician, have performed the above sequence of works

  • Check the operation of all machinery (Hoisting, luffing - trolley, slewing)

  • Reason or recomendation

  • Add media

  • Check the condition and operation of alarms (warning lights, horn and flash lamp)

  • Reason or recomendation

  • Add media

  • Check the condition and operation of indicators (load, moment, distribution, anemometer etc)

  • Reason or recomendation

  • Add media

  • Check the condition and operation of motion limiters (limit switches, slow speed etc)

  • Reason or recomendation

  • Add media

  • Check condition and operation of cab accessories (Windscreen wiper, heater, seat, lighting etc)

  • Reason or recomendation

  • Add media

Check Brakes

  • Check the presence of manual release system

  • Reason or recomendation

  • Add media

  • Check the lining and gap of machinery brakes (excluding travelling machine)

  • Reason or recomendation

  • Add media

  • Check the operation of the weathervaning system

  • Reason or recomendation

  • Add media

  • Check the presence of manual release system (free slew)

  • Reason or recomendation

  • Add media

Checking the Machinery

  • During the machinery checks, the technician will coordinate with the operator to do the following.
    - Lubrication of the slew ring shall take place with the crane rotating using the slew, this will allow uniform and ubiquitous lubrication of the gear. This allows for detailed inspection of the teeth.
    - Inspection of sheaves is to be performed while on the boom, checking for lubrication, bearing operation and general condition of sheave to be inspected

  • I, as the technician, have performed the above sequence of works

  • Check the condition and operation of the roller path

  • Reason or recomendation

  • Add media

  • Check the greasing of the ring and its external teeth

  • Reason or recomendation

  • Add media

  • Check the oil level of the reduction gears

  • Reason or recomendation

  • Add media

  • Check the oil level of the hydraulic units and circuits for leaks

  • Reason or recomendation

  • Add media

  • Does the crane have a belt drive on any of its systems?

  • Check the condition and operation of belt transmissions

  • Reason or recomendation

  • Add media

  • Check the belt tension

  • Reason or recomendation

  • Add media

Does the crane have a Parking Weights Device?

  • Check the Parking weights Device

  • Check the Parking Weights Lifting Eye/Lifting Tackle

  • Parking Weights Serial Number and Weight

Check the control gear

  • Additional checks are to be performed on the electrical systems these are:
    -Ensure water ingress to the cabinets is controlled by seals
    -Ensure all electrical items are grouded correctly.
    -Damage to cables (particularly high voltage) are checked for safety.

  • I, as the technician, have performed the above sequence of works

  • Check the condition of cabling and electrical components ( Particularly the vertical column)

  • Reason or recomendation

  • Add media

  • Check the operations and adjustment of heating in the electrical cabinets

  • Reason or recomendation

  • Add media

  • Check the condition and operation of the isolating switch (including ESD) and/or general circuit breaker

  • Reason or recomendation

  • Add media

  • Check the condition and operatoin of contactors and control switches

  • Reason or recomendation

  • Add media

  • Check the internal cleanliness of the electrical cabinets (check the condition of any vents and filters including water tightness)

  • Reason or recomendation

  • Add media

Check the safety devices

  • Check the condition of safety gear (moment, motion and load limiting devices etc)

  • Reason or recomendation

  • Add media

Check wire ropes (Hoist, luffing, trolley ropes) and related devices

  • The technician will lubricate and inspect the wire ropes as follows:
    - Hoist rope: the crane operator will assign a safe spot to lower the block to just above ground level, this operations will be performed at a maximum speed second gear, where the technician will spray lubricant on the wire as he is inspecting it for damage. Rope discard criteria is to be folowed as per British Standards recomendation.
    -Luffing rope: The crane shall travel to minimum radius and at a slow speed lower the jib to maximum radius as the technician lubricates and inspects the wire rope for damage.
    -Trolley ropes: the technician will coordinate with the crane operator to allow the trolley to travel from minimum radius to maximum radius at a maximum speed of gear 2 to allow for lubrication to be applied and and damage inspection to take place.

  • I, as the technician, have performed the above sequence of works

  • Check the condition of the distribution trolley (structure, straining screw, saber, wheels, fall protection etc)

  • Reason or recomendation

  • Add media

  • Check the condition of wire ropes and routing (pulley, bearings and cable guides amongst others)

  • Reason or recomendation

  • Add media

  • Check the condition and operation of the sliding pulley mechanism

  • Reason or recomendation

  • Add media

  • Check the greasing of the sliding pulley mechanism

  • Reason or recomendation

  • Add media

  • Check the winding of wire ropes on the drums (correct spooling of all winches)

  • Reason or recomendation

  • Add media

  • Check the condition of wire ropes and their attacahments (swivels, rope anchor backs [wedge and socket], bulldog grips)

  • Reason or recomendation

  • Add media

  • Check the condition and operation of the hook block (hook, safety catch, SM/DM locking, thrust ball bearing)

  • Reason or recomendation

  • Add media

Documentation and markings

  • Check that the documention is present (instruction manual, certificates of conformity, maintenance log)

  • Reason or recomendation

  • Add media

  • Check that warning signs are present.

  • Reason or recomendation

  • Add media

Conclusion of visit

  • Final report

  • Is the crane safe to continue work?

    • Yes
    • No
    • Yes - With time limited actions

  • Reason and actions/recommendations

  • Materials needed to correct defects reported

  • Consumables used (if any)

  • Finish time

  • Technician Signature

  • Site representative Signature

Tower Crane Intermediate Service Inspection
Jerome Guillermo

Tower Crane Intermediate Service Inspection

Use this Template
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