Free crane inspection checklist
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Free crane inspection checklist for mobile and overhead cranes. structural, wire ropes, hooks, brakes and load testing. PDF or digital with MapTrack.
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See the first part of the crane inspection checklist below. Download the full version above.
What is a crane inspection checklist?
A crane inspection checklist is a structured form used to inspect and document the condition of a crane at regular intervals. It covers all safety-critical components, including structural members, wire ropes, hooks, sheaves, brakes, controls, safety devices, load indicators and electrical systems. The checklist ensures that cranes are safe to operate, identifies defects before they cause failures, and provides documented evidence of compliance with Australian WHS regulations and AS 2550 standards.
Cranes are classified as high-risk plant under Australian WHS legislation, meaning they are subject to strict registration, licensing and inspection requirements. A documented inspection program is essential to meet these obligations. The checklist applies to all crane types, including mobile cranes, tower cranes, overhead bridge cranes, gantry cranes, jib cranes, crawler cranes and vehicle-loading cranes. Using a consistent inspection form across your fleet ensures every safety-critical component is checked to the same standard regardless of which operator or inspector performs the work. Under WHS Regulations 2011 and AS 2550 (Cranes, hoists and winches), the PCBU must ensure that cranes are inspected at prescribed intervals and maintained by competent persons. Failing to detect a mechanical defect before a lift can lead to load drops, structural collapse or fatalities, making documented pre-use and periodic inspections a non-negotiable obligation for every crane operator and site supervisor.
Learn more about compliance and inspections in MapTrack.
Benefits of using this crane inspection checklist
- Safety: identify worn or damaged components before they cause a failure or incident.
- Compliance: documented inspections to meet WHS and AS 2550 requirements.
- Reduced downtime: catch issues during scheduled inspections rather than mid-lift.
- Insurance requirements: many insurers require documented inspection records for crane cover.
- Liability protection: demonstrated inspection history provides a defence in incident investigations.
- Component tracking: monitor wear trends on wire ropes, brakes and structural members over time.
Benefits of digitising forms in MapTrack
When you digitise crane checklists in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- 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.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Escalate critical hazards instantly to safety managers via push notification.
- Maintain an auditable safety register that satisfies WHS regulator requests.
- Correlate incident trends across sites with built-in safety analytics.
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What to include in a crane inspection checklist
This crane inspection checklist covers 13 key areas:
- Crane details: type, make/model, serial number, SWL/WLL, registration, site location.
- Inspection details: date, inspector name, inspection type, hours/cycles.
- Structural: boom, jib, mast, turntable, outriggers, chassis, welds, pins, bolts.
- Wire ropes and chains: diameter, lay length, broken wires, corrosion, lubrication, terminations.
- Hooks: throat opening, twist, wear, safety latch, markings.
- Sheaves and pulleys: groove wear, bearings, guards, alignment.
- Brakes: hoist, slew, travel, emergency, adjustment, wear.
- Controls: levers, pedals, switches, cab instruments, load moment indicator.
- Safety devices: anti-two-block, load indicator, limit switches, anemometer, level indicator.
- Electrical: motors, contactors, wiring, pendant, collector bars, earthing.
- Load testing: proof load, functional test, SWL verification.
- Defect register: item, severity, action required.
- Sign-off: inspector, crane supervisor.
How to use this crane inspection checklist
- Record crane details and current hours/cycles.: Note the crane type, make, model, serial number, registration, SWL/WLL, site location, current run hours or lift cycles and the date of next scheduled service. This information ties the inspection to the specific asset and its maintenance history.
- Conduct visual inspection with crane powered off.: Walk around the crane and inspect the boom, jib, mast, turntable, outriggers, chassis, welds, pins and bolts for cracks, corrosion, deformation or missing components. Check all guards and covers are secure and that safety signage and load charts are legible.
- Inspect wire ropes, hooks and structural members in detail.: Measure wire rope diameter and check for broken wires, corrosion, kinking, birdcaging and correct lubrication. Inspect hooks for throat opening, twist, wear and safety latch operation. Examine all sheaves and pulleys for groove wear, bearing play and guard condition.
- Power up and test all controls, brakes and safety devices.: Start the crane and test each control function: hoist up and down, slew, travel, boom raise and lower. Test all brakes under load. Verify anti-two-block device, load moment indicator, limit switches, anemometer and level indicator are functioning correctly.
- Record all defects with severity ratings.: For each defect found, record the component, the nature of the fault and a severity rating (critical, major or minor). Critical defects require the crane to be immediately taken out of service. Major defects must be rectified before the next scheduled use.
- Sign off, tag crane status and update the service record.: Record the overall inspection result (pass or fail), sign and date the form. Attach a green (serviceable) or red (out of service) tag to the crane. Update the asset service record with the inspection outcome and any outstanding work orders.
In MapTrack, you can digitise safety inspections and compliance forms. Each submission is stored as a timestamped PDF against the asset record.
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Back to download formHow often should you complete this checklist?
Crane inspections follow a tiered schedule. Daily pre-operational checks are performed by the operator before each shift. Monthly inspections cover major components (wire ropes, hooks, brakes, safety devices). Quarterly inspections include detailed structural and rope assessments. Annual major inspections are comprehensive and should be performed by a competent person or licensed assessor. Cranes in high-use or harsh environments may require more frequent inspections. Ten-year major inspections typically involve non-destructive testing of structural members. After any incident, overload event or significant modification, the crane must be re-inspected before returning to service. In MapTrack, you can schedule each inspection tier and track compliance across your entire crane fleet.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 2550 - Cranes, hoists and winches (safe use)
- AS 1418 - Cranes, hoists and winches (design and manufacture)
- WHS Regulations 2011 - Chapter 5, Part 5.1 (registration and inspection of plant)
- Safe Work Australia - Code of Practice: Managing risks of plant in the workplace
Need to digitise safety inspections and compliance forms?
Register every crane in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.
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