Daily Inspection Procedures
2 hours
Learning Objectives
- •Conduct a pre-shift crane inspection following the OSHA 1926.1412 competent-person checklist
- •Identify wire rope removal-from-service conditions under OSHA 1926.1413
- •Explain the three-tier inspection system: pre-shift, monthly (qualified person), and annual
- •Distinguish between conditions requiring immediate removal from service and those requiring monitoring
Topics Covered
- •OSHA 1926.1412(d): pre-shift inspection — 15-item competent-person checklist
- •Control mechanisms: do all controls respond correctly and return to neutral?
- •Drive systems: hydraulic leaks, unusual sounds, smooth boom extension and retraction
- •Pressurized lines: no bulges, abrasions, or leaks in hoses and fittings
- •Hydraulic fluid level: check sight glass or dipstick before start
- •Hooks and latches: latch closes fully; hook not cracked, twisted, or opened beyond 15% of throat
- •Wire rope: inspect per OSHA 1926.1413 — broken wires, corrosion, kinking, diameter reduction
- •Electrical apparatus: warning lights, anti-two-block alarm, LMI display, backup alarm functional
- •Tires (if on rubber): pressure, sidewall condition, lug nut torque
- •Ground conditions and equipment level: re-check every shift if conditions change
- •Operator cab: clean windows, all controls labeled and readable, fire extinguisher present
- •Operational aids: anti-two-block device tested, LMI configured for today's boom length and configuration
- •Monthly inspection: qualified person (more detailed, documented, 3-month retention)
- •Annual inspection: disassembly as needed, functional testing, 12-month retention
- •Removal-from-service tags: use a DO NOT OPERATE tag visible to all potential operators
Resources
Self-Check Questions
Question 1: During a pre-shift wire rope inspection, you find six randomly distributed broken wires in one rope lay. What action is required under OSHA 1926.1413?
- A. Document the finding and monitor for additional breaks over the next three shifts
- B. Remove the wire rope from service immediately — six random breaks in one lay is a removal-from-service condition(correct)
- C. Reduce the lift capacity by 50% and continue operating until end of shift
- D. Apply wire rope lubricant and re-inspect after 100 cycles
Show Explanation
Explanation:
Under OSHA 1926.1413, six randomly distributed broken wires in one rope lay (or three in one strand per lay) on a running rope is a Category II removal-from-service condition. Stop operations and replace the rope — broken wires indicate fatigue that will accelerate rapidly under continued loading.
Question 2: You find a hook whose throat opening has spread from the manufacturer's specified dimension by 20%. What does this mean?
- A. The hook has stretched within acceptable limits — continue operating with extra caution
- B. The hook has been permanently deformed and must be removed from service; hooks must be replaced when throat opening exceeds 15%(correct)
- C. Apply a correction factor to the load chart and reduce lifts by 20%
- D. The hook needs lubrication at the swivel — this is a normal wear condition
Show Explanation
Explanation:
A hook whose throat has opened more than 15% beyond its original dimension has been overloaded and permanently deformed. It must be removed from service immediately. A distorted hook can allow rigging to slip out under load — a catastrophic failure mode.
Question 3: Who must perform the pre-shift inspection required by OSHA 1926.1412(d)?
- A. A qualified person (engineer or manufacturer's representative)
- B. The operator or a competent person designated by the employer(correct)
- C. Any crew member present at the start of the shift
- D. A certified crane inspector holding an ASME B30.5 qualification
Show Explanation
Explanation:
OSHA 1926.1412(d) requires the pre-shift inspection to be performed by a competent person — someone who can identify hazards and has authority to correct them. This is typically the crane operator or a designated competent person on the crew. The monthly inspection requires a qualified person.
Question 4: You discover a kink in the hoist wire rope during pre-shift inspection. What is the correct action?
- A. Straighten the kink with pliers and lubricate the affected section before operating
- B. Tag the machine out of service — kinking is a Category I removal-from-service condition(correct)
- C. Reduce the load by 25% and monitor the kink throughout the shift
- D. Cut out the kinked section and re-splice the rope
Show Explanation
Explanation:
Kinking is a Category I removal-from-service condition under OSHA 1926.1413. A kink permanently distorts the wire rope's internal structure, causing stress concentrations that can cause sudden failure under load. The rope must be replaced — never attempt to straighten a kinked wire rope and return it to service.
Question 5: The anti-two-block alarm sounds during a pre-shift function test but the automatic stop device does not cut power to the hoist. What must you do?
- A. The alarm working is sufficient — the automatic stop device is a Category II aid with a 30-day repair window
- B. Reduce hoist speed and use the cable-marking alternative measure; repair within 7 days(correct)
- C. Continue operating — the audio alarm alone provides adequate warning to the operator
- D. Tag the crane out of service if the automatic stop device cannot be repaired today
Show Explanation
Explanation:
For telescopic-boom cranes built after February 28, 1992, the anti-two-block device is a Category I operational aid. If the automatic stop function fails, OSHA 1926.1416 requires implementing the temporary alternative measures (marking the cable, using a spotter) and the device must be repaired within 7 calendar days — not 30.
Question 6: Which of the following is NOT typically included in a pre-shift crane inspection under OSHA 1926.1412?
- A. Hydraulic fluid level check
- B. Wire rope condition inspection
- C. Load cell calibration against a certified test weight(correct)
- D. Hook latch condition and throat opening measurement
Show Explanation
Explanation:
Load cell calibration against certified test weights is part of an annual/comprehensive inspection by a qualified person — not a pre-shift check. Pre-shift inspections cover visual and functional items a competent person can assess without test equipment: fluid levels, hose condition, hook condition, wire rope, and operational aid function tests.