Is Disassembly Required for Crane Inspections?
Is Disassembly Required
For Overhead Crane Inspections?
Or
When is Enough…Enough?
One of the most common questions I am asked is, “How much teardown of gearboxes, motor brakes, etc., is needed to meet the requirements for routine OSHA overhead crane inspections?”
For this paper, I will reference three primary sources and one trump card. The sources regarding overhead crane authority are:
A) OSHA- (a Federal Law)
OSHA 1910 General Industry in general and specifically OSHA 1910.179 Overhead & Gantry Cranes.
B) ASME B30- (a series of US Consensus Standards)
Specifically, ASME/ANSI B30.2: Overhead and Gantry Cranes (Top Running Bridge,Top Running Trolley Hoist), ASME/ANSI B30.16: Overhead Underhung and Stationary Hoists and ASME/ANSI B30.17: Cranes and Monorails (With Underhung Trolley or Bridge).
C) CMAA- (the Crane Manufacturers’ Association of America specification)
Specifically, CMAA 78: Standards for Overhead Crane Services.
D) The Manufacturer’s Owner’s Manual
In all cases, the fine print in generic documents, including OSHA, B30, and CMAA, states that the manufacturer’s guidelines take precedence over them all.
A quick overview of these documents indicates that routine overhead crane inspections generally do not require a complete teardown or disassembly of major components, such as hoists, gearboxes, or motor brakes. The inspection mainly involves visual and auditory evaluations. The exact phrases, “visual and auditory,” are used throughout all the relevant B30 specifications as shown below;
ASME/ANSI B30.2: Overhead and Gantry Cranes
- B30.2-2.1.2 Initial Inspection
- B30.2-2.1.3 Functional Test Inspection (Pre-shift/Daily Inspection)
- B30.2-2.1.4 Frequent Inspection
- B30.2-2.1.5 Periodic Inspection
ASME/ANSI B30.16: Overhead Underhung and Stationary Hoists
- B30.16-2.1.2 Initial Inspection
- B30.16-2.1.2 Initial Inspection
- B30.16-2.1.3 Functional Test Inspection (Pre-shift/Daily Inspection)
- B30.16-2.1.4 Frequent Inspection
- B30.16-2.1.5 Periodic Inspection
ASME/ANSI B30.17: Cranes and Monorails (With Underhung Trolley or Bridge)
- B30.17-2.1.2 Initial Inspection
- B30.17-2.1.3 Functional Test Inspection (Pre-shift/Daily Inspection)
- B30.17-2.1.4 Frequent Inspection
- B30.17-2.1.5 Periodic Inspection
Let’s examine the details of this issue.
Part 1: INSPECTION CATEGORIES AND REQUIREMENTS---
Frequent Inspections (Daily to Monthly)
According to each of the source documents listed above, these inspections are mainly visual and observational, conducted during crane operation [2]. As per CMAA Specification #78 and ASME B30.2, regular inspections include:
Visual checks of hooks, wire rope, chains, and controls
Operational testing of brakes and limit switches
Observation for oil leakage, unusual sounds, and proper operation
No documentation requirement for most items
Periodic Inspections (Quarterly to Annually)
Periodic inspections are more comprehensive but still primarily visual reviews of components in their installed positions. These include:
Structural members (girders, end trucks, trolley frames)
Wear patterns on brakes, gears, bearings, and shafts
Electrical apparatus condition
Sheaves, drums, and transmission components[2]
Part 2: COMPONENT DISASSEMBLY---
CASE-BY-CASE BASIS
The need for disassembly depends on performance and the specific situation[3]. According to OSHA's interpretation of 29 CFR 1910.179(j)(3):
"It is the responsibility of the employer to assess and determine during frequent and periodic inspections...whether 'disassembly and/or more advanced examination methods than visual inspections' are required. If the employer can assure that any defects are detectable through visual inspection, then that would meet the intent of the standard. If not, disassembly of some components may be necessary."[3]
Gearbox Inspections
Routine periodic inspections can include opening inspection covers to visually check gear teeth, lubrication levels, and wear patterns if there has been a visual or audible reason to suspect performance.
Advanced gear case inspections with complete disassembly are performed only when specific concerns are identified or as part of major overhauls, not as routine practice[6]
Many modern inspections employ endoscopes to examine internal components without the need for full disassembly[6]
Motor Brake Inspections
Pre-shift/Daily or Frequent inspections verify brake operational function without disassembly [8].
Periodic inspections may involve removing covers to visually inspect brake linings and measure wear [9][10][11].
Adjusting brakes can often be done without disassembly, using access covers[9][10].
Complete disassembly for brake lining replacement is only necessary when wear limits are exceeded, not as a routine procedure.[11]
Part 3: KEY STANDARDS REQUIREMENTS---
OSHA 1910.179 specifies periodic inspection items, including "worn, cracked or distorted parts such as pins, bearings, shafts, gears" [13], but does not require routine disassembly.
ASME B30.2 defines periodic inspection as requiring examination to "determine their condition," but emphasizes that this is primarily achieved through visual inspection with components in place [3].
ASME B30.16 provides additional insight by the following wording of the Periodic Inspection.
16-2.1.5 Periodic Inspection
(a) A periodic inspection is a visual and audible examination of the hoist and may be performed with the hoist at its normal location. Periodic inspections do not require the hoist to be disassembled.
CMAA Specification #78 recommends opening gearbox inspection covers to "check for gear teeth wear and proper lubrication" during periodic inspections, indicating limited access rather than a full teardown.
Part 4: WHEN DISASSEMBLY IS REQUIRED---
Component disassembly becomes necessary when:
Defects are discovered during visual inspection that require detailed examination[3].
Components fail or show signs of imminent failure.
Extensive repairs are needed (which then trigger operational and rated load testing).
Visual/audible inspection cannot adequately assess a suspect component condition[3].
Manufacturer recommendations specify disassembly intervals for specific components[2].
Part 5: A POTENTIAL “BELT AND SUSPENDERS” SOLUTION
First of all, there is no absolute answer to this or any other OSHA question. All you can do is make sure you have crossed your “t’s” and dotted your “i’s” to put yourself in the best possible position.
It has been my experience that both OSHA and the law give credence to planned actions before the event over serendipitous happenstance discovered after the event. With this in mind, assemble a group of qualified individuals and commit a plan to paper. However, it is critical to understand that your work is not over with the creation of a plan. You then document your strict adherence to that plan.
Here are a couple of critical things to understand:
- If you don’t have the qualified personnel to put the plan together in-house, consider hiring a crane inspection company for a day of consulting to assist.
- Ensure that you document the qualifications of all individuals involved with designing the plan, particularly the outside expert. Just because they are in the business does NOT make them qualified. Insist on proof of their formal training. A plan put together will unqualified people will be more trouble than no plan at all.
CRITICAL WARNING
Once you put a plan in writing, you must execute it. OSHA will treat it as the “law of the land,” just as if it were written in 1910.179. In other words:
SAY WHAT YOU'RE GOING TO DO AND THEN DO WHAT YOU SAID!!!
Let me put this another way. You can be issued an OSHA violation for not following a rule that, even if not in 1910.179, is a company rule you have agreed to. Your “house rules” hold the same weight and requirements as OSHA 1910 in the eyes of the OSHA inspector!!!
Some suggested points to include in your Overhead Crane Safety Program;
- Appointing a Qualified Person
o It is essential for the company to appoint a “designated qualified person” (DQP)
o Designating an individual is a management obligation.
o Ensure that you document the process used to select this person and include a detailed list of their qualifications.
o List the DQP’s name, title, and contact information at the beginning of your Overhead Crane Safety Manual.
o Post the DQP’s name and contact details in a suitable public location.
o Provide third-party crane inspectors with the DSP’s name and contact information and insist it be included in their reports.
- Inspection Basic Parameters
o Establish that all crane inspections will be conducted as visual and audible inspections.
o No hand tools are to be used for disassembly during the initial inspection.
o If, during inspection, an audible or visual concern is identified, it shall be documented in the inspection report. The inspector shall discuss the issue with the DQP immediately upon discovery.
o The review meeting must be recorded in writing.
- An Inspection Log
o A simple “minimalist” logbook should be created. The log’s columns should include;
§ Date of inspection
§ Which crane was inspected?
§ Inspection type (Frequent or Periodic)?
§ Who performed the inspection?
§ Was this a “zero event” (clean inspection) Y/N
§ If Yes, was it reviewed with the DQP with review date?
§ Was further action determined necessary?
§ Inspectors initials and date
§ DQP’s initials and date
- The DQP’s responsibilities
o The qualified person will explain the problem, and then decide if further inspection or disassembly is needed.
o Only qualified persons can decide whether the crane should be immediately tagged “out of service” for further attention or can be returned to regular service.
o If it is determined that the issue is significant but does not require removing the crane from service, the requirement for future maintenance shall be documented in the report.
o The DQP shall provide a written record of both the issue and the decision regarding whether to remove the crane from service, along with any necessary subsequent maintenance requirements for the crane.
o The DQP shall prepare the written report and store it in the designated file location for the duration of the equipment's lifetime.
IMPORTANT DEFINITIONS:
These definitions were taken directly from OSHA documentation. It is essential to understand the difference and the reason why both are necessary designations.
Designated Person
Means selected or assigned by the employer or the employer's representative as being qualified to perform specific duties. (§1910.179(a)(35), .180(a)(21), .181(a))16), .184(b)]
Qualified Person
Qualified employee (qualified person)
Any worker who, by reason of his training and experience, has demonstrated his ability to safely perform his duties. [§1910.268(s)(33)].
In other words, the Designated Person has the authority to act, but not necessarily the knowledge. Conversely, the Qualified Person knows but not the authority. A Designated Qualified Person possesses both the authority conferred by management and the knowledge demonstrated in their resume.
SUMMARY
Routine overhead crane inspections primarily involve visual and operational checks that do not require disassembly. Although inspection covers may be removed to examine internal parts, complete disassembly of hoists, gearboxes, and motor brakes is not usually part of standard or periodic inspections.
If the inspector identifies a questionable issue, decisions to disassemble are made on a case-by-case basis by qualified personnel when visual inspection methods cannot identify potential hazards or when specific problems are detected.
SOURCES
[1] How to Make Your Overhead Crane Inspection Program OSHA ... https://www.mazzellacompanies.com/learning-center/how-to-make-your-overhead-crane-inspection-program-osha-compliant/
[3] Clarification of Overhead and Gantry Cranes definition of OSHA http://www.osha.gov/laws-regs/standardinterpretations/2003-08-28-0
[5] How to Inspect a Gearbox - Machinery Lubrication https://www.machinerylubrication.com/Read/28765/how-to-inspect-a-gearbox-
[6] Crane & Hoist Gear Case Inspection Services - Konecranes https://www.konecranes.com/en-us/service/crane-inspections-and-preventive-maintenance/crane-and-hoist-gear-case-inspection
[8] Proper Hoist Brake Inspections are Critical | Crane1 2023 https://crane1.com/proper-hoist-brake-inspections-are-critical/
[9] Brake Adjustment & Replacement for the Main Motor on Demag P type hoist ... https://www.youtube.com/watch?v=XLK9w6LCrYs
[10] Brake Adjustment for the Main & Microspeed Motors on Demag P Hoist https://www.youtube.com/watch?v=xdQqpTslbU4
[11] Inspecting and Changing the Brake Lining on a Demag KB Motor https://www.youtube.com/watch?v=Hcc7jkcKfMk
[13] OSHA Periodic Inspection Policy and Procedures - Konecranes https://www.konecranes.com/en-us/safety/crane-safety-inspections/osha-periodic-inspections
[14] Overhead And Gantry Inspections 101: Learn The Basics https://www.overheadlifting.org/overhead-and-gantry-inspections-101-learn-the-basics/
[15] Crane Inspections: A Guide to OSHA Requirements [Free Checklist] https://www.corfix.com/blog/crane-inspections-requirements-osha/
[16] Inspection and Maintenance Needs for Cranes - Bobcat Contracting https://bobcatcontracting.com/crane-repair-service-experts-explain-inspection-maintenance-requirements/
[17] Ensure Safety with OSHA Frequent Crane Inspections - Konecranes https://www.konecranes.com/en-us/safety/crane-safety-inspections/osha-frequent-inspections
[18] How to Conduct Thorough Visual Inspections of Overhead Cranes https://crane1.com/conduct-thorough-visual-inspections-of-overhead-cranes/
[19] What to Expect from an Overhead Crane Inspection https://www.tmcranes.com/what-to-expect-from-an-overhead-crane-inspection/
[20] 1926.1412 - Inspections. | Occupational Safety and Health OSHA http://www.osha.gov/laws-regs/regulations/standardnumber/1926/1926.1412
[21] 1910.179 - Overhead and gantry cranes. - OSHA http://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.179
[22] Tips for Maintaining and Repairing Overhead Cranes - SISSCO Hoist https://www.sisscohoist.com/tips-for-maintaining-and-repairing-overhead-cranes/
[23] 49 CFR Part 396 -- Inspection, Repair, and Maintenance - eCFR https://www.ecfr.gov/current/title-49/subtitle-B/chapter-III/subchapter-B/part-396
[24] 1926.1404 - Assembly/Disassembly--general requirements ... - OSHA http://www.osha.gov/laws-regs/regulations/standardnumber/1926/1926.1404
[25] Overhead Crane Inspection Checklist for Preparedness https://crane1.com/overhead-crane-inspection-checklist/
[26] [PDF] Part 18. Overhead and Gantry Cranes - State of Michigan https://www.michigan.gov/leo/-/media/Project/Websites/leo/Documents/MIOSHA/Standards/General_Industry/GI_18/GI_18__02-02-2018.pdf
[27] OSHA Guidelines for Overhead Crane Inspection https://www.gohispeed.com/proper-overhead-crane-inspection-schedule-osha-guidelines/
[28] A Brief Guide to Crane Maintenance - Spanco, Inc. https://www.spanco.com/blog/overhead-cranes-daily-inspection-and-maintenance-requirements/
[29] Maintenance and Inspection Practices for Tower Cranes - ihurmo https://ihurmo.com/tower-crane/maintenance-and-inspection-practices-for-tower-cranes/
[30] [PDF] CRANE AND HOIST SAFETY PROGRAM https://safety.caltech.edu/documents/13973/Crane_and_Hoist_Safety_Program.pdf
[31] [PDF] Rigging Gear Inspection Web-Based Training Student Guide NCC ... https://ncc.navfac.navy.mil/Portals/73/Documents/NCC/Main/Training/WBT%20Student%20Guides/17_08_23_RGI_SG_Rev04.pdf?ver=VL-WZJNuNNhVwcTTgNmq1Q%3D%3D
[32] Crane Inspection & Maintenance | Pre-Check, Records ... - YouTube https://www.youtube.com/watch?v=Cg6845Vnz0g
[33] [PDF] ASME-B30.2 Overhead And Gantry Cranes 2011 https://americancraneschool.com/wp-content/uploads/2025/05/Taiwan_Crane_Regulations_ASME-B30.2-OverHead-And-Gantry-Cranes-2011.pdf
[34] Crane inspections: tips and tricks | igus® Engineer's Toolbox https://toolbox.igus.com/9534/crane-inspections-a-comprehensive-guide
[35] [PDF] Lenze BFK458 Brake Adjustment Instructions https://rmhoist.com/sites/default/files/public_files/lenze_bfk458_brake_adjustment_instructions2019.pdf
[36] ASME B30.2-2022: Overhead And Gantry Cranes - The ANSI Blog https://blog.ansi.org/ansi/asme-b30-2-2022-overhead-gantry-cranes/
[39] Overhead Crane Inspection App - InspectAll https://www.inspectall.com/overhead-cranes
[40] Opening The Operator's Eyes: Internal Inspections For Overhead ... https://www.manufacturing.net/operations/article/13056977/opening-the-operators-eyes-internal-inspections-for-overhead-lifting-equipment
[41] CM Lodestar Brake Adjustment - YouTube https://www.youtube.com/watch?v=ilckELdlm-A