Skip to main content
MapTrack
Book a demo
Skip to download form

Free mobile crane 2000 hour service checklist

Free mobile crane 2000 hour service checklist covering engine, hydraulics, slew bearing, LMI calibration and wire rope discard per AS 2550.1 and AS 2759.

Updated 2 Oct 2026

Mobile Crane 2000 Hour Service Checklist

Major service | Per AS 2550.1, AS 1418.1, AS 2759 and ISO 4309

Live form
0 of 36 checks

Engine

1Oil and filter change to OEM spec
2Valve clearance check and adjustment
3Fuel filters and water separator renewal
4Air cleaner element and restriction gauge
5Coolant condition and freeze-point test
6Belt, hose, turbo and exhaust mounting check

Hydraulic system

7Full system flush 300 to 500 litres
8Return and pressure filter change
9ISO 4406 cleanliness sample to target code
10Accumulator pre-charge test and re-gas
11Suction strainer clean and main pump inlet check

Slewing ring & slew gearbox

12Slewing ring bolt torque audit (random sample)
13Slewing gearbox oil drain and refill
14Slewing ring grease re-charge all nipples
15Hoist drum gearbox oil drain and refill
16Brake pack thickness and dust inspection

Boom, sheaves & wear pads

17Boom-tip sheave bearing inspection and grease
18Telescope wear pad measurement
19Side-thrust pad check
20Extension cable and hose festoon inspection
21Jib lattice section bolt torque check

Wire rope measurement

22Broken wires per lay count
23Diameter loss measurement
24Lay-length growth check
25Corrosion and birdcaging visual
26Discard rope marked and quarantined

Safety systems & load moment indicator

27LMI calibration with certificate issued
28Anti-two-block weight and switch function test
29Emergency stop function on all stations
30Load chart current revision check
31RCL hour meter cross-reference to service log

Certification & records

32Service book stamped by licensed fitter
33LMI and rope inspection certificates filed
34Fluid sample report attached
35Function test under load completed
36Next 250, 500, 1000 and 2000 hour dates set in MapTrack

How to use: download the PDF, print or complete digitally on any device.

  • PDF format, ready to print or fill on screen
  • Use as-is or customise to suit your operation
  • Go digital in MapTrack for photos, reminders and audit trails

Download free PDF template

Use in MapTrack →
FreePDFUpdated Oct 2026

Get your free template

Enter your email to download the mobile crane 2000 hour service checklist as a free PDF. No sign-up required to use it.

G2 rating 4.9 out of 5
Capterra rating 5.0 out of 5GetApp rating 5.0 out of 5Software Advice rating 5.0 out of 5
All MapTrack reviews
Your info is secure. No spam, ever.

These templates are free general guides provided as-is. They do not constitute legal, safety or compliance advice. You are responsible for ensuring any form meets your specific workplace obligations, industry standards and applicable regulations.

G2 rating 4.9 out of 5
Capterra rating 5.0 out of 5GetApp rating 5.0 out of 5Software Advice rating 5.0 out of 5
All MapTrack reviews

Trusted by teams across Australia and New Zealand

We respect your privacy. Unsubscribe anytime.

Or set it up in MapTrack

  • Fill it in on a phone, attach photos to any check
  • Automatic reports and audit trails
  • Upload the PDF and MapTrack drafts the form for you

Free trial. No credit card. Personal email accepted.

Don't just download it - use it live. Start a free workspace, upload this mobile crane 2000 hour service checklist and MapTrack drafts it as a form your crew can run from a phone.

Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 2 October 2026
Also see:Maintenance and work orders →Best CMMS software →MapTrack vs MaintainX →

Short answer

A mobile crane 2000 hour service checklist records the major workshop service: every 250, 500 and 1000 hour task plus slew ring bolt torque, hydraulic flush, gearbox oil changes, sheave bearings, anti-two-block and LMI calibration and wire rope assessment. It falls due at the hour and calendar limits in the crane model's service manual. AS 2550.5:2016 Section 7 covers mobile crane maintenance, inspection and repair.

Checked against AS 2550.5:2016 on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack mobile crane 2000 hour service checklist contains 36 checks across 7 sections. Sections covered: Engine, Hydraulic system, Slewing ring & slew gearbox, Boom, sheaves & wear pads, Wire rope measurement, Safety systems & load moment indicator, Certification & records.
  • AS 2550.1-2011 clause 7.5 covers records of maintenance, inspection and repair; keep the signed service sheet and calibration records with the crane.
  • Registered mobile cranes need a major inspection at the manufacturer's design life end, else on competent advice, else every 10 years (reg 235).
  • Regulation 237: keep records of tests, inspections, maintenance and alterations for plant that must be registered.
  • Assess every wire rope against AS 2759 Section 14 and ISO 4309:2017 discard criteria, and record the result for each rope.
  • A competent person signs off the service and the LMI calibration; the operator's daily checks do not replace them.

Enter your email below to download this mobile crane 2000 hour service checklist as a ready-to-use PDF.

Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is a mobile crane 2000 hour service checklist?

A 2000 hour service is the major and extended tier of scheduled preventive maintenance for a mobile crane such as a CAT, Tadano, Liebherr, Grove or Manitowoc machine. It rolls every task from the 250, 500 and 1000 hour intervals into one workshop visit and then layers on the high-hour work that only falls due every second year of typical hire-fleet duty. That extended scope includes engine valve clearance check and adjustment, slewing ring bolt torque audit and grease re-charge, full hydraulic system flush of 300 to 500 litres on larger lattice and all-terrain cranes, boom-tip sheave bearing inspection, slewing gearbox and hoist drum gearbox oil change, anti-two-block circuit calibration, load moment indicator certification and a full wire rope retirement assessment against AS 2759 and ISO 4309.

Service-record audit requirements for registered cranes make this tier especially significant. A 2000 hour visit is where SafeWork inspectors, finance auditors and incoming hire-customer engineers expect to see a fully documented major service stamped by a licensed fitter, with LMI and anti-two-block certificates attached. AS 2550.1 sets the safe-use framework for cranes in service, AS 1418.1 covers the original design baseline, and the WHS Regulations 2011 Chapter 5 place a duty on the PCBU to maintain plant in line with the manufacturer schedule. A skipped or unsigned 2000 hour service is one of the fastest paths to a prohibition notice on a yellow registered crane.

Learn more about maintenance and work orders in MapTrack.

Get the free template

Enter your email above to download the full mobile crane 2000 hour service checklist as a PDF.

Download free PDF

Benefits of using this mobile crane 2000 hour service checklist

  • Major fault interception: catches gearbox swarf, bearing play and ring-bolt loosening before they cause boom drop, slew lock-up or crown wheel failure in service
  • Wire rope retirement evidence: documents broken-wire count, diameter loss and lay-length growth against AS 2759 and ISO 4309 for every reeved rope on the machine
  • LMI and anti-two-block certification: produces the calibration certificate that hire customers and lift supervisors expect before the crane is dispatched to site
  • Hydraulic fluid contamination reset: a 300 to 500 litre system flush restores ISO cleanliness codes and extends pump, swivel and main control valve life by tens of thousands of hours
  • Insurance and finance protection: maintains an unbroken stamped service record that protects residual value at trade-in and underpins warranty claims against the OEM dealer network
  • Workshop scheduling discipline: a fixed 2000 hour milestone forces fleet managers to plan a 12 to 16 hour workshop slot rather than letting the crane drift into reactive failures on hire
  • Hire readiness and utilisation: a current 2000 hour major with LMI, anti-two-block and wire-rope certificates attached means the crane clears an incoming customer pre-mobilisation check first time, so it stays on hire instead of sitting in the yard waiting on paperwork

Benefits of digitising forms in MapTrack

When you digitise crane service procedures in MapTrack, you get:

  • Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
  • Email the right people when a form is submitted, with an automation you set up.
  • File every completed form against the asset, location or person it covers.
  • Download any completed form as a PDF, with failed answers listed at the top.
  • Fill in forms offline; they upload when the device is back online.
  • Build conditional logic (show or hide questions based on answers).
  • Take pictures or attach photos. Not possible with a paper-based form.
  • Electronic signatures.
  • Edit forms later without reprinting.
  • Set who can view, fill in or edit forms with user roles.
  • Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
  • Raise a work order from a submitted form with an automation you set up.
  • Track service intervals by hours, kilometres or calendar date in one place.
  • Attach supplier invoices and parts receipts to each maintenance record.

Book a demo to see how MapTrack handles crane service procedures.

Try MapTrack free

Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.

Start free trial
  • No credit card required

1-2 days/week saved

“Bloody amazing! We used to spend 1-2 days a week tracking and managing our generators alone.”
Saunders International

Steve McAllister

Asset Coordinator, Saunders International

What to include in a mobile crane 2000 hour service checklist

This mobile crane 2000 hour service checklist covers 10 key areas:

  • Engine system: oil and filter change, valve clearance check, fuel filter and water separator renewal, air cleaner element, coolant condition test, belt and hose inspection, turbo and exhaust mounting check
  • Hydraulic system: full system flush of 300 to 500 litres, return-line and pressure filter change, kidney-loop sample to ISO 4406, suction strainer clean, accumulator pre-charge test
  • Slewing system: slewing ring bolt torque audit on random sample, internal and external gear inspection, grease re-charge through all nipples, slewing gearbox oil drain and refill, brake pack inspection
  • Hoist and winch system: hoist drum gearbox oil change, brake disc thickness check, drum anchor pin inspection, free-fall clutch test, anti-two-block weight and switch function
  • Boom and sheave system: boom-tip sheave bearing inspection and grease, telescope wear pad measurement, side-thrust pad check, extension cable and hose festoon inspection
  • Wire rope assessment: every reeved rope inspected for broken wires, diameter loss, lay-length growth, corrosion and birdcaging against AS 2759 and ISO 4309 discard criteria
  • Safety and control systems: LMI calibration with certificate, anti-two-block circuit test, emergency stop function on all stations, load chart current revision check, RCL hour-meter cross-reference
  • Electrical and structural: alternator output and battery load test, slip ring brush inspection, structural weld visual on main boom pins and outrigger boxes, jib lattice section bolts torque check
  • Outrigger and chassis: outrigger cylinder leak test, beam wear pad inspection, pad and float condition, transport lock function, suspension lockout test for pick-and-carry duty
  • Tyres and brakes: tyre depth and pressure record, service brake stroke check, park brake hold-on-grade test, axle and differential oil samples

How to use this mobile crane 2000 hour service checklist

  1. 1. Plan and quarantine the machine: book a 12 to 16 hour workshop slot, lock out the ignition, fit a danger tag, position the crane on level ground with outriggers retracted, decommission load and run engine to operating temperature for accurate fluid drains and torque checks
  2. 2. Document the starting state: photograph hour meter, LMI display, defect log and any leak points before work begins, scan tyre depths and pressures, and capture any operator notes from the most recent pre-start and weekly inspections for the fitter to action
  3. 3. Drain and sample fluids: collect engine oil, hydraulic oil, slewing gearbox oil and hoist gearbox oil samples into labelled bottles before any new product goes in, ship to a fluid lab for elemental and ISO 4406 cleanliness analysis to spot wear trends across the fleet
  4. 4. Complete the engine work: change oil and filters, renew fuel filters and water separator, check valve clearances against OEM specification, inspect belts, hoses and turbo mounts, test coolant freeze point and inhibitor, replace air cleaner if differential gauge has tripped
  5. 5. Flush and refill hydraulics: drain the full 300 to 500 litre hydraulic charge, change return and pressure filters, refill with OEM-spec fluid, run the kidney loop until the ISO sample meets target, test accumulator pre-charge and re-gas if low
  6. 6. Service slewing and drivelines: torque-audit a random sample of slewing ring bolts to OEM pattern, drain and refill the slewing gearbox, re-grease the slewing ring through every nipple, drain and refill the hoist drum gearbox and check the brake pack for thickness and dust
  7. 7. Inspect ropes and reeving: run every wire rope through the discard criteria of AS 2759 and ISO 4309 covering broken wires per lay, diameter loss, lay-length growth, corrosion and core protrusion, mark any rope that meets a discard threshold and quarantine until replaced
  8. 8. Test and certify safety circuits: calibrate the LMI against a certified test load, function-test the anti-two-block circuit on every reeving configuration, issue calibration certificates and load them against the crane record before the machine leaves the workshop
  9. 9. Walk the structure: visually inspect main boom pins, outrigger boxes, jib lattice sections, slewing platform welds and main equaliser pivots, torque-check the listed structural fasteners against the OEM table, photograph and quarantine any crack indication for NDT follow up
  10. 10. Function-test under load: re-erect the crane, drive a function test through full boom telescope, hoist up and down at every drum layer, slew full revolution under load and exercise the outriggers, confirm LMI cutout and anti-two-block trip operate cleanly before signing off
  11. 11. Close the record: stamp the service book, load the LMI certificate, fluid sample report, wire-rope inspection sheet and structural torque sheet against the asset in MapTrack, set the next 250, 500, 1000 and 2000 hour service dates and dispatch the crane back to allocation

In MapTrack, you can schedule and track maintenance digitally, by date or meter reading. Each submission is stored as a timestamped PDF against the asset record.

Get the free templateEnter your email above to download the full mobile crane 2000 hour service checklist as a PDF.Back to download form

How often should you complete this service procedure?

A 2000 hour service is due every 2000 engine hours or every 24 months, whichever comes first. For a typical hire fleet machine that turns 800 to 1000 hours a year on tower and infrastructure work, that means a major service every second calendar year. Cranes on heavy lift, port or wind farm duty often hit 2000 hours inside 18 months and the service is then triggered by hour meter rather than the calendar. Cranes in low-utilisation standby fleets still need the 2000 hour tasks completed on the calendar because seals, fluids, ropes and rubber components deteriorate in storage. Set the trigger on whichever clock arrives first, schedule the workshop window 30 days in advance and protect the slot from hire pressure so the work is done in one disciplined visit.

Try MapTrack free

Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.

Start free trial
  • No credit card required

Frequently asked questions

The 2000 hour service is due every 2000 engine hours or every 24 months, whichever comes first. Hire-fleet cranes on infrastructure or tower work usually hit the calendar trigger first at 24 months, while cranes on heavy lift, port loading or wind farm duty often reach the hour trigger inside 18 months. Cranes in low-utilisation standby fleets still need the 2000 hour tasks completed on the calendar because seals, fluids, ropes and rubber components deteriorate in storage. Set both triggers in MapTrack and schedule the workshop window 30 days in advance.

Plan for 12 to 16 hours of workshop time for a typical all-terrain or rough-terrain crane in the 50 to 100 tonne class. Larger lattice or heavy lift cranes can stretch to 20 to 24 hours, mostly because the hydraulic flush volume runs to 500 litres and the wire rope assessment covers multiple reeved ropes. The LMI and anti-two-block calibration usually adds another 2 hours on top of the mechanical work. Booking the crane out of allocation for two full workshop days is more realistic than trying to compress the work into a single shift.

The 2000 hour service must be carried out and signed off by a competent person (regulation 213), such as a qualified plant fitter or mechanical engineer, working to the OEM service schedule, not by the crane operator. Operators are responsible for the daily pre-start and weekly inspection layers, which feed defects into the workshop for action. The LMI calibration certificate and the wire-rope retirement assessment must be signed by competent persons named on the service record. MapTrack stores the fitter trade certificate number against the asset so audit trails always link the signature back to a verified competency.

The four anchor standards are AS 2550.1 for safe use of cranes in service, AS 1418.1 for the original design baseline of the crane, AS 2759 for wire ropes in service and ISO 4309 for wire rope discard criteria. The WHS Regulations 2011 Chapter 5 place a duty on the PCBU to maintain plant in line with the manufacturer schedule, which is what a documented 2000 hour service record evidences. The OEM service manual is the primary task list and the standards above sit over the top as the technical benchmark, while the WHS Regulations set the legal floor.

Yes, the mobile crane 2000 hour service checklist is free to download as a PDF and free to use across your fleet. MapTrack publishes the checklist as a stand-alone working document with no signup required. When you are ready to schedule the 250, 500, 1000 and 2000 hour services across multiple cranes, attach LMI and rope inspection certificates against each asset and trigger work orders from hour meter or calendar, the digital version inside MapTrack handles the cadence and audit trail for you.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Cranes, hoists and winches - Safe use, Part 5: Mobile cranes

    Edition: AS 2550.5:2016

    Maintenance, inspection and repair of mobile cranes, and their limiting and indicating devices such as the LMI.

    • Section 7: Maintenance, inspection and repair of mobile cranes.
    • Section 8: Limiting, indicating and data recording devices on mobile cranes.

    Standards AustraliaSold by the publisher

  • Cranes, hoists and winches - Safe use, Part 1: General requirements

    Edition: AS 2550.1-2011

    General crane maintenance, inspection and repair, records of that work, and inspection of ropes and hooks.

    • Section 7: Maintenance, inspection and repair of cranes, hoists and winches.
    • 7.5: Records of maintenance, inspection and repair.
    • Section 8: Inspection of ropes, hooks and lifting gear.

    Standards AustraliaSold by the publisher

  • Steel wire rope - Use, operation and maintenance

    Edition: AS 2759-2004

    Inspection of steel wire ropes in service and the criteria for discarding them.

    • Section 13: Inspection of steel wire ropes in service.
    • Section 14: Criteria for discarding steel wire ropes.

    Standards AustraliaSold by the publisher

  • Cranes - Wire ropes - Care and maintenance, inspection and discard

    Edition: ISO 4309:2017 (Edition 5)

    International care, inspection and discard criteria for crane wire ropes.

    International Organization for Standardization (ISO)Sold by the publisher

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Competent-person maintenance, major inspection of registered mobile cranes, and records for registered plant. Model law: check your state's version.

    • reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
    • reg 235: Registered mobile and tower cranes need a major inspection at the manufacturer's design life end, else per competent person advice, else every 10 years.
    • reg 237: Records of tests, inspections, maintenance and alterations must be kept for plant required to be registered.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Guide to inspecting and maintaining cranes

    Edition: December 2015

    Safe Work Australia guide to inspecting and maintaining cranes. Guidance, not law.

    Safe Work Australia

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

Check the current source

Mobile Crane 2000 Hour Service Checklist preview

Mobile Crane 2000 Hour Service Checklist template preview showing fields and layout

The numbers behind this mobile crane 2000 hour service checklist

The pages below gather the figures behind this kind of check. Each figure on them carries its source and date, so you can quote it in a toolbox talk, a budget case or a board paper without chasing the original report.

Get the free template

Enter your email above to download the full mobile crane 2000 hour service checklist as a PDF.

Download free PDF

Embed this free template on your website

Run an industry blog, trade association site, or training resource? Drop a preview of this free mobile crane 2000 hour service checklist straight into your page. The snippet is self-contained, needs no scripts, and links readers back to the full free template.

<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Mobile Crane 2000 Hour Service Checklist</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Engine system: oil and filter change, valve clearance check, fuel filter and water separator renewal, air cleaner element, coolant condition test, belt and hose inspection, turbo and exhaust mounting check</li>
    <li style="margin:4px 0;">Hydraulic system: full system flush of 300 to 500 litres, return-line and pressure filter change, kidney-loop sample to ISO 4406, suction strainer clean, accumulator pre-charge test</li>
    <li style="margin:4px 0;">Slewing system: slewing ring bolt torque audit on random sample, internal and external gear inspection, grease re-charge through all nipples, slewing gearbox oil drain and refill, brake pack inspection</li>
    <li style="margin:4px 0;">Hoist and winch system: hoist drum gearbox oil change, brake disc thickness check, drum anchor pin inspection, free-fall clutch test, anti-two-block weight and switch function</li>
    <li style="margin:4px 0;">Boom and sheave system: boom-tip sheave bearing inspection and grease, telescope wear pad measurement, side-thrust pad check, extension cable and hose festoon inspection</li>
    <li style="margin:4px 0;">Wire rope assessment: every reeved rope inspected for broken wires, diameter loss, lay-length growth, corrosion and birdcaging against AS 2759 and ISO 4309 discard criteria</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/crane-2000-hour-service" style="color:#071D49;font-weight:600;text-decoration:none;">Mobile Crane 2000 Hour Service Checklist</a> by MapTrack</p>
</div>

Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.

Cite this template

Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.

The MapTrack mobile crane 2000 hour service checklist contains 36 checks across 7 sections.

Short attribution
MapTrack Mobile Crane 2000 Hour Service Checklist, https://www.maptrack.com/templates/crane-2000-hour-service
Reference list
MapTrack. (2026). Mobile Crane 2000 Hour Service Checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/crane-2000-hour-service

Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/crane-2000-hour-service.

Need to schedule and track maintenance digitally, by date or meter reading?

Register every crane in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.

Start free trialBook a demo

Maintenance and work orders · All templates · Pricing · Book a demo