Regular inspection keeps an overhead crane safe and avoids unplanned stops. This checklist covers the checks that operators and maintenance staff make most often.
Always follow the manufacturer’s manual and your local rules. They set the exact intervals and who may carry out each inspection.
Before each shift: operator checks
- Test the controls and the emergency stop.
- Check that the limit switches stop the movement.
- Look at the hook and the safety latch.
- Look at the rope or chain for visible damage.
- Listen for unusual noise and look for oil leaks.
- Make sure the area around the crane and the runway is clear.
Periodic inspection: maintenance staff
- Structure: girders, end carriages and welds, for cracks, deformation and corrosion.
- Wheels, rails and runway: wear, alignment and fixings.
- Hoist: rope or chain condition, drum or chain wheel, hook block and hook.
- Brakes: wear, adjustment and holding.
- Gearboxes and motors: oil level, leaks, noise and temperature.
- Electrics: cables, conductor bar or festoon, contactors, drives and connections.
- Safety devices: overload protection, limit switches and emergency stops.
- Labels: rated capacity and warning signs are readable.
Records
Keep a log of every inspection, repair and part replacement, with dates and names. Records show how the crane is ageing and are often required by local rules.
When to take a crane out of service
- A defective brake, limit switch or overload protection.
- A damaged or worn rope, chain or hook.
- Cracks in the structure or welds.
- Any damage after an overload or a collision.
Tag the crane as out of service and repair it before use.
After repairs
After a major repair or a modification, the crane should be inspected and load-tested before it returns to service.
Training
Only trained operators should use the crane. Give them the manual, and make sure they know how to report a fault.
Scheduled maintenance items
The CESAN operating manual for hoists lists the checks below. It sets daily, three-monthly, annual and longer intervals, and says the intervals must be shortened for higher duty groups or abnormal conditions.
- Brake function, and brake adjustment so that the load cannot slip.
- Limit switch function, and cleaning and lubricating the limit switch rod.
- Rope damage and fraying of fine wires, rope fixing points and rope fittings.
- Rope and rope drum condition and greasing.
- Oil level, with a top-up when needed, and gearbox oil change.
- Connection bolts and welds.
- Current collectors, electric cables and the pushbutton.
- Wear of crane and trolley wheels.
- Hook: cracks and deformation.
- Couplings: listen for abnormal noise.
- Seals: check for oil leaks.
Safe operation rules
- Keep at least two turns of rope on the drum at all times.
- Do not distract the operator.
- Check the hook latch, slings and every hook attachment before lifting.
- Lift vertically and keep the rope in the drum groove.
- Make sure the load is attached securely and balanced.
- Never use the rope as a welding earth.
- Make no changes or repairs to the hoist without approval.
- Do not leave a load hanging on the hoist.
- Check that the limit switches work, and never use them for normal stopping.
- Do not run the crane while people are on the runway or the service platform.
- Check that the hook and limit switches move in the direction shown on the pendant.
- Pull the empty hook slowly, without swinging it.
- Never remove or cover labels and plates.
Common operating mistakes
- Slack rope. The rope must stay tensioned, loaded or not. Slack can damage the rope, make it jump out of the rope guide or break the guide.
- Cross-pulling. Lift directly under the hoist. The allowed angle is only 3 degrees, and a side pull loads the rope guide and can break it.
- Swinging pendant. Leave the pendant hanging still, so that it is not knocked and damaged.
- Uncontrolled lifting. Watch what the load could touch. Keep a clear approach distance of at least half a metre.
- Standing under a load. Never stand, walk or work under a lifted load.
- Unbalanced loading. It puts people and the crane at risk.
- Lifting without seeing the load. The operator must not lift, lower or travel unless the load is fully visible.
How CESAN can help
CESAN supplies spare parts and modernizes existing cranes. If an inspection shows worn or outdated parts, send us the nameplate data and a description, and our engineers will recommend a solution.
Why choose CESAN
- Turkish manufacturer since 1976. CESAN designs and builds overhead, gantry and jib cranes and hoists in its own factory in Turkey, with engineering, sales and after-sales in one country.
- Projects in more than 52 countries. Experience with different standards, climates and site conditions.
- A full range. Single girder cranes up to 32 t, double girder cranes up to 250 t and gantry cranes up to 500 t, plus jib cranes, hoists, transfer carts and attachments.
- Recognized standards. Design to FEM 1.001, EN 13001 and ISO 4301, CE marking, and ISO 9001 and TSE certificates for the company.
- Installation and commissioning on site. CESAN handles installation, commissioning and the load test in any country.
- Factory acceptance test (FAT). The complete crane system is tested before delivery, and customers or third parties can witness the tests.
- 24-month warranty, with the terms stated in each quotation.
- An office in Dubai for Gulf customers.
Send us your requirements
To help with spare parts or modernization, send the nameplate data, photos and a short description of the problem. Send them through the enquiry form and our engineers will reply with a technical and budgetary assessment.
See our overhead cranes and the guide crane modernization and spare parts.