Free checklist · Aerial & lifting
Overhead crane daily inspection checklist (free, printable)
This overhead crane daily checklist covers the frequent-inspection items OSHA lists in 29 CFR 1910.179(j), checked before the first lift of the shift: hook and latch, hoist rope or chain, load block, pendant and emergency stop, the upper limit switch tried with no load, brakes, bridge and trolley travel, the warning device and the floor under the runway. Free to print or use by QR code.
- How often
- Before each shift
- The rule
- OSHA 29 CFR 1910.179(j)
- Items
- 21 checks
- Takes
- About 6 minutes
By the CheckBadges team · Updated
Layout
Overhead crane daily inspection checklist
Before each shift
| Item | OK | Problem | N/A |
|---|---|---|---|
| From the floor (before power-up) | |||
| Area under the craneFloor clear; nothing stored in the bridge or trolley path; nobody under | |||
| Out-of-order tagsNo warning or out-of-order sign on the crane, hook or main switch | |||
| Rated load markingCapacity marked on the crane and hoist, readable from the floor | |||
| HookNo cracks or nicks; not opened up or twisted; swivels freely | |||
| Hook latchPresent, springs closed across the throat, not bent | |||
| Load blockNot cracked or damaged; sheave guards in place | |||
| Wire ropeNo kinks, crushing, birdcaging, broken wires or corrosion | |||
| Rope reevingRope seated in the drum and sheave grooves; parts not twisted together | |||
| Hoist chainNo stretched, twisted, gouged or worn links; end connections secure | |||
| Air or hydraulic linesNo leaks or damage on lines, tanks or valves | |||
| Pendant and cableCase not cracked; buttons and labels readable; strain relief intact | |||
| Function tests (no load) | |||
| Emergency stopPendant or remote stop cuts power to all motions | |||
| Control buttonsEach button runs the motion marked and stops when released | |||
| Upper limit switchEmpty block inched up stops before it reaches the trolley | |||
| Hoist and brakeRaises and lowers smoothly; stops and holds with no drift | |||
| Trolley travelSmooth both ways; stops when released; no grinding | |||
| Bridge travelSmooth with no skewing, binding or wheel noise; stops properly | |||
| Warning deviceBell, horn or light works when the bridge travels | |||
| Noise, smell and vibrationNothing unusual from motors, gearboxes, brakes or wheels | |||
| Radio remoteStop button works; labels readable; strap or holder OK | |||
| Below-the-hook gear | |||
| Slings and lifting devicesInspected today; tags readable; no visible damage | |||
Problems found and action taken:
If anything is a problem, don't use the machine: tag it out and report it. Free checklist from checkbadges.com — put it on a QR sticker and operators can fill it in on their phone.
What to check on an overhead crane, item by item
From the floor (before power-up)
- Area under the crane — Floor clear; nothing stored in the bridge or trolley path; nobody under
- Out-of-order tags — No warning or out-of-order sign on the crane, hook or main switch
- Rated load marking — Capacity marked on the crane and hoist, readable from the floor
- Hook — No cracks or nicks; not opened up or twisted; swivels freely
- Hook latch — Present, springs closed across the throat, not bent
- Load block — Not cracked or damaged; sheave guards in place
- Wire rope — No kinks, crushing, birdcaging, broken wires or corrosion
- Rope reeving — Rope seated in the drum and sheave grooves; parts not twisted together
- Hoist chain — No stretched, twisted, gouged or worn links; end connections secure
- Air or hydraulic lines — No leaks or damage on lines, tanks or valves
- Pendant and cable — Case not cracked; buttons and labels readable; strain relief intact
Function tests (no load)
- Emergency stop — Pendant or remote stop cuts power to all motions
- Control buttons — Each button runs the motion marked and stops when released
- Upper limit switch — Empty block inched up stops before it reaches the trolley
- Hoist and brake — Raises and lowers smoothly; stops and holds with no drift
- Trolley travel — Smooth both ways; stops when released; no grinding
- Bridge travel — Smooth with no skewing, binding or wheel noise; stops properly
- Warning device — Bell, horn or light works when the bridge travels
- Noise, smell and vibration — Nothing unusual from motors, gearboxes, brakes or wheels
- Radio remote — Stop button works; labels readable; strap or holder OK
Below-the-hook gear
- Slings and lifting devices — Inspected today; tags readable; no visible damage
How often an overhead crane has to be inspected
Some parts of an overhead crane must be checked every day, others monthly, and the whole crane every 1 to 12 months. OSHA's overhead and gantry crane standard, 29 CFR 1910.179(j), splits inspections into "Frequent inspection—Daily to monthly intervals" and "Periodic inspection—1 to 12-month intervals", and marks some frequent items as daily.
| What | How often | Written record |
|---|---|---|
| Functional operating mechanisms, for maladjustment | Daily | Not required |
| Air and hydraulic systems, for leaks and deterioration | Daily | Not required |
| Hooks | Visual daily; full inspection monthly | Monthly certification record |
| Hoist chains | Visual daily; full inspection monthly | Monthly certification record |
| Running ropes | Thorough inspection at least monthly | Monthly certification record |
| Upper limit switch | Tried with no load at the start of each operator's shift | Not required |
| Whole crane (periodic) | Every 1 to 12 months, by use, severity and environment | Not specified |
The limit switch line comes from 1910.179(n)(4)(i): "At the beginning of each operator's shift, the upper limit switch of each hoist shall be tried out under no load." A crane idle for a month or more needs a frequent-style inspection before it goes back into service. Many crane inspectors also work to ASME B30.2, the consensus standard for overhead and gantry cranes. More in crane inspection requirements.
How to do the check
Look from the floor first, then power up and test every motion with no load on the hook.
- Check the area. Clear floor under the runway, nothing in the bridge or trolley path, and no out-of-order tag on the crane, hook or main switch.
- Look at the hook and block. Cracks, a throat that's opened up, twist, a missing or bent latch, sheave guards.
- Look at the rope or chain. Kinks, crushing, broken wires, corrosion, stretched or worn links, and rope seated in its grooves.
- Check the pendant or remote. Case, cable, buttons and labels.
- Power up and test the emergency stop.
- Run each motion. Hoist up and down, trolley and bridge both ways, listening for grinding and watching for drift when you stop.
- Try the upper limit switch. Inch the empty block up slowly until the switch trips. Never use the limit switch to stop the hoist in normal work; OSHA says it "shall never be used as an operating control."
- Record and report.
Brakes get an extra test in use: OSHA requires the operator to test them "each time a load approaching the rated load is handled", by raising the load a few inches and applying them (1910.179(n)(3)(vii)).
The defects that take an overhead crane out of service
Any unsafe condition found in the daily inspection keeps the crane out of use until it's corrected.
| Defect | Why it matters |
|---|---|
| Hook cracked, throat opened more than 15%, or twisted more than 10° | OSHA says hooks with these defects must be discarded (1910.179(j)(2)(iii), (l)(3)(iii)) |
| Upper limit switch doesn't trip | The block can be pulled into the trolley and the rope or chain can part |
| Broken wires, kinks, crushing or birdcaging in the rope | The rope has lost strength and can fail under load |
| Stretched, twisted or worn chain links | The chain can break or jam |
| Hoist brake slips or the load drifts | A load can drop |
| Emergency stop fails or a button sticks | A motion can't be stopped |
| Damaged pendant case or cable | Shock risk and unreliable controls |
What to do when something fails
Park the crane where it's out of the way, switch it off and report it; don't lift with it. OSHA says "Any unsafe conditions disclosed by the inspection requirements of paragraph (j) of this section shall be corrected before operation of the crane is resumed," and adjustments and repairs "shall be done only by designated personnel" (1910.179(l)(3)(i)). Before repairs start, the main or emergency switch must be "open and locked in the open position", and warning or "out of order" signs placed on the crane and on the floor beneath or on the hook (1910.179(l)(2)).
An out-of-service tag on the pendant works for the operator's end. For the steps after that, see what to do when equipment fails inspection.
Keeping the record
The daily check doesn't have to be written down, but the monthly hook, chain and rope inspections do. OSHA requires a certification record for each with "the date of inspection, the signature of the person who performed the inspection" and an identifier for the hook, chain or rope inspected. The standard doesn't set a retention period; keep them where appointed personnel can get to them. A dated daily record is still your proof the frequent inspection happened. See equipment inspection record keeping.
Doing it on a phone
Put a QR sticker on the pendant or the column next to the crane, and whoever runs it first that shift scans it with their own phone and works through this list in the browser. A problem emails you with photos and is shown to the next operator who scans. See QR code equipment checklists.
Skip the clipboard
Put this overhead crane inspection checklist on a QR sticker.
- Operators scan the sticker with their own phone's camera. No app, account or password.
- Anything marked Problem emails you right away, with photos, and warns the next operator.
- Every check is saved by machine with who did it and when. Print one or export a CSV.
Free for 3 machines. Every item above is already filled in — edit anything. No card.
Overhead crane 1
Overhead crane inspection checklist
Frequently asked questions
How often does OSHA require overhead crane inspections?
Some items daily, some monthly, and a periodic inspection every 1 to 12 months. Under 29 CFR 1910.179(j), operating mechanisms and air or hydraulic systems are checked daily, hooks and hoist chains get a daily visual check and a monthly inspection, running ropes a monthly thorough inspection, and the upper limit switch is tried at the start of each operator's shift.
Does the daily overhead crane inspection have to be documented?
No. OSHA requires written certification records for the monthly hook, chain and rope inspections, not the daily checks. A dated daily record is still the only way to show the frequent inspection was done.
How do you test the upper limit switch on an overhead crane?
With no load on the hook, inch the block up slowly, or run it in at slow speed, until the limit switch stops the hoist. OSHA requires this at the start of each operator's shift (1910.179(n)(4)(i)). If it doesn't trip, stop and tell the appointed person immediately.
When must a crane hook be taken out of service?
When it's cracked, its throat has opened more than 15 percent beyond normal, or it's twisted more than 10 degrees from the plane of the unbent hook. OSHA says hooks with those defects shall be discarded, and that repairs by welding or reshaping are not generally recommended (1910.179(l)(3)(iii)).
Who is allowed to operate an overhead crane?
Only designated personnel (1910.179(b)(8)): people the employer has chosen and trained to run that crane. Adjustments and repairs must also be made by designated personnel. The operator usually does the daily checks; periodic inspections are normally done by a crane service technician.
Keep reading
- Crane inspection requirementsOSHA crane inspections: shift checks by a competent person, documented monthly inspections kept 3 months, and annual ones by a qualified person kept 12 months.
- Rigging and sling inspection checklistFree rigging and sling inspection checklist: wire rope, chain and synthetic slings, shackles, hooks and eyebolts, with OSHA 1910.184 removal criteria.
- Mobile crane inspection checklistFree mobile crane shift inspection checklist built on OSHA 1926.1412(d): controls, hydraulics, hooks, wire rope, tires, ground, level, cab and safety devices.
- ManufacturingMachine pre-use checklists for manufacturing: a QR sticker on each press, saw, crane and forklift. Operators scan with their phone; problems alert you at once.
- Equipment inspection appAn equipment inspection app where operators scan a QR sticker on any machine and do its check in the browser. No app or login. Instant alerts, history per machine.
- Scissor lift inspection checklistFree scissor lift pre-use inspection checklist: guardrails, gate, controls, emergency stop and lowering, pothole guards, tilt alarm and tires. Print or use QR.
Do your overhead crane checks by QR code.
Stick a QR code on every machine and operators do the pre-use check on their own phone — no app, no login. Free for up to 3 machines; try it with your real machines before you sign up.