Pre-operational Checks, Inspection and Maintenance
Why checks matter
Pre-operational checks catch faults before they become incidents. They are required by the WHS Regulations and by the manufacturer's manual, and must be recorded. Checks are not a substitute for scheduled maintenance; they are a daily verification that the crane is fit for use.
What to check
- Visual: wire rope for broken wires, kinks, corrosion and bird-caging; chain for stretch and wear; hook for cracks, throat opening and latch operation; slings and shackles for tags and damage.
- Structure: bridge and runway for cracks, loose bolts, corrosion; rails for alignment and obstructions; end stops and buffers.
- Controls: pendant and buttons function correctly; emergency stop works; limit switches operate; brakes hold; alarms and lights work.
- Safety devices: overload protection, anti-collision, rail clamps, warning devices.
- Environment: walkway clear, lighting adequate, no people in the area.
Traps
Questions often ask what to do when a fault is found. The answer is: isolate and tag out, report, record, and do not operate until repaired and verified. A minor defect is still a defect. Do not "test" a faulty brake by lifting a load.
Maintenance and records
Maintenance follows the manufacturer's schedule and is performed by competent people. Records include pre-start checks, maintenance logs, inspection reports and repair records. These support due diligence and are audited after incidents.
Worked example
During a pre-start check you find two broken wires in a running rope and a slow-responding brake. You stop, lock out, tag the crane, notify the supervisor, and record the fault. The crane stays out of service until repaired and re-inspected.
Rule of thumb
If in doubt, tag it out. A crane that is not proven safe is not safe.