Pre-Operational Inspection, Maintenance and Defect Reporting
Why it matters
Pre-start inspection catches the failures that cause incidents: hydraulic leaks, damaged tyres, faulty interlocks, worn twistlocks, cracked welds. It is a documented, systematic check, not a glance.
What to check
- Fluids and leaks: engine oil, coolant, hydraulic oil; look for weeping cylinders and hoses.
- Tyres and wheels: pressure, cuts, chunking, loose nuts.
- Structure: boom, spreader, welds, pins, cracks.
- Safety devices: load moment indicator, interlocks, horn, lights, reversing alarm, fire extinguisher, seat belt.
- Brakes and steering: function test.
- Attachments: twistlock operation, spreader condition.
Defect reporting
The chain is: identify → assess → tag out if unsafe → report in writing → record. A defect that affects safe operation means the machine is out of service until repaired and re-inspected. Never "operate carefully" around a safety-critical defect.
Traps
- Questions test whether you know a defect must be recorded, not just mentioned verbally.
- A minor cosmetic defect may allow operation; a safety-critical one (brakes, load moment indicator, structural crack) does not.
- Maintenance records are part of the plant register and must be retained.
Rule of thumb
If the defect could cause a load to fall, the machine to overturn, or a person to be struck, it is safety-critical: tag out, report, do not operate.