Pre-Operational Inspection and Equipment Condition
Inspections are scheduled, not optional
OSHA 1926.1412 requires a shift inspection before each shift by a competent person, plus monthly, annual, post-assembly, after repair, after modification, and after severe service. The shift inspection is a visual and functional check: fluid levels and leaks, tires, outriggers and floats, hooks and latches, wire rope and end connections, sheaves and guards, brakes, clutches, horns, lights, swing and travel alarms, load chart in the cab, control labeling, fire extinguisher, seat belt, and the load moment indicator and anti-two-block devices. Deficiencies that create a safety hazard must be corrected before use; document the inspection and the repair.
Functional tests matter
Do not just look. Test the horn, the anti-two-block alarm and stop, the LMI display, the swing brake, and the travel alarm. Check that the load chart matches the crane's current configuration. Verify that safety devices are not disabled, bypassed, or missing.
Worked example
A 3/4 in nominal running rope measures 0.700 in. The permitted diameter reduction for rope up to 3/4 in is 3/64 in, or 0.047 in. The measured reduction is 0.050 in, so the rope is removed from service even though it looks clean. The reasoning is based on loss of cross-section and strength, not appearance.
Traps
Visual-only inspections, ignoring a missing hook latch, assuming an annual inspection covers the shift, operating with an expired or uncalibrated LMI, and failing to document are frequent failures. A defect that affects safety is not a 'note it for later' item.