Pre-Operational Inspection, Function Checks and Fault Reporting
Before each shift the operator performs a pre-start inspection and function check; more thorough inspections occur at defined intervals (weekly, monthly, after erection, after modification, after a repair, and after a significant event such as an overload or lightning strike). The purpose is to detect defects before they become failures, and to create a record that the duty of care was met.
A practical inspection sequence walks the crane from the ground up. Ground level: foundation condition, ballast security, rail condition and stops for travelling cranes, earth stakes, fencing, access ladders and gates. Mast: bolts, pins, splits, corrosion, plumb. Slewing: ring bolts, backlash, lubrication, brake. Jib and counter-jib: pins, tie bars, walkway, counterweight security. Trolley and hoist: rope condition (broken wires, kinks, corrosion, termination), sheave wear, hook block and hook latch, brake function. Cab: controls, indicators, load moment limiter display, anemometer, two-way radio, fire extinguisher, emergency lowering provisions. Then function checks: hoist up and down, brake hold, trolley in and out, slew both directions, limit switches, emergency stop, and the moment limiter readout against a known load where permitted.
Fault reporting: any defect affecting safe operation must be reported immediately, recorded, and the crane taken out of service until repaired and re-checked by a competent person. Traps include: continuing to operate with a defective limit switch because 'the operator can watch it'; assuming a visual check replaces a function test; failing to record a verbal report; and returning a crane to service without verification after repair.
Rule of thumb: if a safety device is not working, the crane is not working.