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Inspection template in the LeanSuite app

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Overhead crane inspection checklist

Operator inspection of an overhead crane or hoist before use.

Use this template in LeanSuitePrintable version (PDF)

The full question list

The 34 questions in the inspection

Every question is answered Yes, No or N/A. Each No is flagged and asks for a photo and a comment, so the finding arrives with its evidence.

Operator pre-shift check: Before first use each shift, no load on the hook

  1. 1Rated load is marked on the crane and on each hoist or load block, and can be read from the floor [(b)(5)]
  2. 2No out-of-order or warning sign on the crane, the hook or its disconnect, and the travel path is clear [(l)(2)(i)]
  3. 3Pendant or cab controls: function labels readable, and buttons or levers return to off when released [(g)(1)(v), (g)(3)]
  4. 4Hoist, trolley and bridge each run in the direction marked, smoothly and with no unusual noise [(j)(2)(i)]
  5. 5Upper hoist limit switch stops the empty block when it is inched slowly into the limit; if it does not, tell the appointed person at once [(n)(4)(i)]
  6. 6Brakes stop each motion, and the hoist brake holds with no drift [(j)(2)(i), (f)]
  7. 7Hook: no visible crack, bend or twist; safety latch closes, if one is fitted [(j)(2)(iii)]
  8. 8Hoist rope or chain, as far as it can be seen: no kinks, broken wires, crushing, twisted parts or stretched links, and seated in the drum grooves and sheaves [(j)(2)(iv), (m)(1), (n)(2)(i)]
  9. 9Air or hydraulic hoists: no leaks from lines, tanks or valves [(j)(2)(ii)]
  10. 10Warning signal sounds, on cranes with powered travel that are not floor-operated [(i)]

Frequent inspection: Daily to monthly by a designated person, with the checks above; hooks, chains and ropes need a signed monthly record

  1. 11Operating mechanisms adjusted so they work properly, with no excessive wear on their parts [(j)(2)(i), (j)(2)(vi)]
  2. 12Air and hydraulic systems: lines, tanks, valves and drain pumps not leaking or deteriorated [(j)(2)(ii)]
  3. 13Hooks: no cracks or deformation; throat opening no more than 15% over normal and twist under 10 degrees, or the maker's tighter limit; hook serial number recorded [(j)(2)(iii)]
  4. 14Hoist chain and end connections: no excessive wear, twist or distorted links, stretch within the maker's limit; chain ID recorded [(j)(2)(iv)]
  5. 15Rope reeving matches the crane maker's instructions [(j)(2)(vii)]
  6. 16Running ropes, full length: diameter not reduced below nominal, broken outside wires counted and located, outside wires not worn [(m)(1)(i) to (iii)]
  7. 17Rope ends and damage: no corroded or broken wires at end connections, end fittings sound and correctly applied, no severe kinking, crushing, cutting or unstranding; rope ID recorded [(m)(1)(iv) to (vi)]
  8. 18Each deficiency judged for whether it is a safety hazard; if it is, the crane is not used until it is corrected [(j)(2), (l)(3)(i)]

Periodic inspection: A complete inspection every 1 to 12 months, set by use, service and environment; includes every frequent check

  1. 19Structural members: none deformed, cracked or corroded [(j)(3)(i)]
  2. 20Bolts and rivets: none loose [(j)(3)(ii)]
  3. 21Sheaves and drums: none cracked or worn [(j)(3)(iii)]
  4. 22Pins, bearings, shafts, gears, rollers, and locking and clamping devices: none worn, cracked or distorted [(j)(3)(iv)]
  5. 23Brake linings, pawls, ratchets and other brake parts: no excessive wear [(j)(3)(v)]
  6. 24Load, wind and other indicators read correctly over their full range [(j)(3)(vi)]
  7. 25Power plant (electric, gasoline, diesel or other) performs properly and meets its safety requirements [(j)(3)(vii)]
  8. 26Chain drive sprockets not excessively worn, and drive chain not stretched [(j)(3)(viii)]
  9. 27Electrical apparatus: no pitting or deterioration of controller contactors, limit switches and pushbutton stations [(j)(3)(x)]

Other conditions the standard sets: From other paragraphs of 1910.179, checked at the periodic inspection

  1. 28Trolley stops, and bridge and trolley bumpers, in place and secure [(e)(1) to (e)(3)]
  2. 29Rail sweeps on the bridge trucks reach below the top of the rail in front of the wheels [(e)(4)]
  3. 30Guards on gears, chains, sprockets and other exposed moving parts secure; rope guards where ropes could foul or chafe [(e)(5), (e)(6)]
  4. 31Sheave guards in place on the bottom block and where ropes can go slack [(h)(1)(ii), (h)(1)(iii)]
  5. 32At least two wraps of rope left on the drum with the hook at its lowest point, and the rope end anchored by a clamp or approved socket [(h)(2)(iii)]
  6. 33Runway conductor disconnect can be locked open, the crane's own disconnect works, and the hoist has an upper overtravel limit switch [(g)(5)]
  7. 34Ladders, footwalks and cab: access clear, handrails and toeboards in place, no loose tools or articles in the cab [(c), (d), (o)(2)]

When to use it

  • Every day, before first use or at the start of the shift.
  • The person responsible for the area or equipment answers each question on the spot.

How it is scored

The template is built with points per answer and a pass mark of 90. In this library every audit is set to pass at 80 and every inspection at 90. Each submitted inspection shows its score and pass or fail, and every No is flagged with its photo and comment.

Change the points or the pass mark after you clone it. How rules and scoring work.

Read and print

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Use this template in LeanSuite

It is ready in the Template Marketplace inside Lean Creator as “Overhead Crane Inspection”. Clone it into your plant, change any question, then schedule it to a person, role or asset with reminders. Auditors complete it on a phone or tablet, with photo evidence where required.

Not on LeanSuite yet? On a 90-day pilot our team sets up your account and digitizes the forms and checklists you use today, this one included.

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