Crane 10-Year Major Inspection Checklist

Estimated duration: 5 - 15 days • Required at 10 years for mechanical components, 25 years for structural

Important: The crane cannot legally be operated once mechanical components reach the 10-year mark without a completed major inspection per AS 2550.1. NDT must be performed by AINDT-certified technicians. The inspection must be supervised by a professional engineer experienced with this crane type.

Equipment and Inspection Details

Make / Model

Serial Number

Fleet / Asset ID

Year of Manufacture

Crane Type

SWL / Rated Capacity

Max Radius

Boom Length

Registration Number

Inspection Start Date

Inspection End Date

Inspecting Engineer

Engineer Reg. Number

#	Inspection Item	Method
1. Pre-Inspection Documentation
1	Serial number verification against registration records	VERIFY
2	Maintenance history review, service records and defect log	INSPECT
3	Registration with WHS regulator confirmed current	VERIFY
4	Manufacturer's manual and critical component list available	VERIFY
5	Previous major inspection report reviewed	INSPECT
6	Operating hours and duty cycle classification confirmed	VERIFY
2. Structural Assessment
7	Main boom sections, visual and dimensional inspection	INSPECT
8	Jib / fly jib structural integrity and pin connections	INSPECT
9	Chassis / carrier frame, corrosion and cracking assessment	INSPECT
10	Turntable and slewing ring wear, backlash and bolt torque	MEASURE
11	Outrigger beams, cylinders and pads condition	INSPECT
12	Counterweight mounting and securing hardware	INSPECT
13	NDT all critical structural welds (boom, chassis, turntable)	NDT
14	NDT boom foot pins and major structural pins	NDT
15	Structural bolted connections torque check	MEASURE
3. Mechanical Components
16	Wire ropes, broken wires count, corrosion, diameter reduction	MEASURE
17	Sheaves and pulleys, groove wear, cracking, bearing play	MEASURE
18	Hook block, throat opening, twist, NDT, swivel, safety latch	NDT
19	Brakes (hoist, slew, travel), lining, adjustment, holding test	TEST
20	Gearboxes, oil analysis, bearing condition, gear wear	INSPECT
21	Slewing ring gear teeth, wear patterns and backlash	MEASURE
22	All bearings (slew, hoist drum, boom pivot, sheave)	INSPECT
23	Hoist drum wear, cracking, groove condition	INSPECT
4. Hydraulic System
24	Hydraulic cylinders, scoring, seal leaks, rod condition	INSPECT
25	System pressures (main pump, pilot, brake release)	TEST
26	Hoses, fittings and tubing, condition and age	INSPECT
27	Hydraulic oil condition and contamination testing	TEST
28	Control valves, function and leakage check	TEST
29	Filter condition and differential pressure	INSPECT
5. Electrical and Control Systems
30	Wiring, connectors and junction boxes condition	INSPECT
31	Control circuits and operator controls function test	TEST
32	Slip rings and collector brushes (tower / overhead cranes)	INSPECT
33	Lighting, warning devices and alarms	TEST
34	Power supply cables and cable reeling (overhead / gantry)	INSPECT
6. Safety Devices and Instrumentation
35	RCI / LMI accuracy and calibration verification	TEST
36	Limit switches (hoist upper/lower, boom angle, slew, trolley)	TEST
37	Anti-two-block device function and trip test	TEST
38	Emergency stops, all stations confirmed operational	TEST
39	Anemometer / wind speed indicator (tower cranes)	TEST
40	Overload protection and automatic cut-out	TEST
41	Boom backstop and derricking limiters	TEST
7. Load Testing
42	Proof load test at rated capacity	LOAD
43	Load chart accuracy verified at multiple radii	LOAD
44	Structural deflection measured under load	MEASURE
45	All motions under load (hoist, lower, slew, derricking, travel)	LOAD
8. Final Assessment and Certification
46	Comprehensive engineering report completed	VERIFY
47	NDT results documented with technician certifications	VERIFY
48	Risk assessment and recommendations issued	VERIFY
49	Certification of continued serviceability issued	VERIFY
50	Logbook and registration records updated	VERIFY

Inspection Item

Method

P / F

Notes / Measurements

1. Pre-Inspection Documentation

Serial number verification against registration records

VERIFY

Maintenance history review, service records and defect log

INSPECT

Registration with WHS regulator confirmed current

VERIFY

Manufacturer's manual and critical component list available

VERIFY

Previous major inspection report reviewed

INSPECT

Operating hours and duty cycle classification confirmed

VERIFY

2. Structural Assessment

Main boom sections, visual and dimensional inspection

INSPECT

Jib / fly jib structural integrity and pin connections

INSPECT

Chassis / carrier frame, corrosion and cracking assessment

INSPECT

Turntable and slewing ring wear, backlash and bolt torque

MEASURE

Outrigger beams, cylinders and pads condition

INSPECT

Counterweight mounting and securing hardware

INSPECT

NDT all critical structural welds (boom, chassis, turntable)

NDT

NDT boom foot pins and major structural pins

NDT

Structural bolted connections torque check

MEASURE

3. Mechanical Components

Wire ropes, broken wires count, corrosion, diameter reduction

MEASURE

Sheaves and pulleys, groove wear, cracking, bearing play

MEASURE

Hook block, throat opening, twist, NDT, swivel, safety latch

NDT

Brakes (hoist, slew, travel), lining, adjustment, holding test

TEST

Gearboxes, oil analysis, bearing condition, gear wear

INSPECT

Slewing ring gear teeth, wear patterns and backlash

MEASURE

All bearings (slew, hoist drum, boom pivot, sheave)

INSPECT

Hoist drum wear, cracking, groove condition

INSPECT

4. Hydraulic System

Hydraulic cylinders, scoring, seal leaks, rod condition

INSPECT

System pressures (main pump, pilot, brake release)

TEST

Hoses, fittings and tubing, condition and age

INSPECT

Hydraulic oil condition and contamination testing

TEST

Control valves, function and leakage check

TEST

Filter condition and differential pressure

INSPECT

5. Electrical and Control Systems

Wiring, connectors and junction boxes condition

INSPECT

Control circuits and operator controls function test

TEST

Slip rings and collector brushes (tower / overhead cranes)

INSPECT

Lighting, warning devices and alarms

TEST

Power supply cables and cable reeling (overhead / gantry)

INSPECT

6. Safety Devices and Instrumentation

RCI / LMI accuracy and calibration verification

TEST

Limit switches (hoist upper/lower, boom angle, slew, trolley)

TEST

Anti-two-block device function and trip test

TEST

Emergency stops, all stations confirmed operational

TEST

Anemometer / wind speed indicator (tower cranes)

TEST

Overload protection and automatic cut-out

TEST

Boom backstop and derricking limiters

TEST

7. Load Testing

Proof load test at rated capacity

LOAD

Load chart accuracy verified at multiple radii

LOAD

Structural deflection measured under load

MEASURE

All motions under load (hoist, lower, slew, derricking, travel)

LOAD

8. Final Assessment and Certification

Comprehensive engineering report completed

VERIFY

NDT results documented with technician certifications

VERIFY

Risk assessment and recommendations issued

VERIFY

Certification of continued serviceability issued

VERIFY

Logbook and registration records updated

VERIFY

NDT Methods Record

Dye Penetrant (DP)

Magnetic Particle (MPI)

Ultrasonic (UT)

Radiographic (RT)

NDT Technician Name

AINDT Certification No.

NDT Cert. Standard

NDT Report Reference

Load Test Record

SWL / Rated Capacity

Proof Load Applied

Test Radius

Boom Angle / Config

Hold Duration

Deflection Measured

Weights Calibration Cert.

Result

Defects, Recommendations and Component Replacements

Next Major Inspection Due

Next Mechanical Insp.

Next Structural Insp.

Estimated Date

Conditions / Limitations

Inspecting Engineer

Name

Registration No.

Signature

Date

Owner / Fleet Manager

Name

Organisation

Signature

Date