Free mobile crane annual inspection checklist
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Free mobile crane annual inspection checklist (PDF-ready). Structural NDT, ropes, LMI, outriggers, brakes and assessor sign-off per AS 2550.1 and AS 1418.5.
Commercial Director
Updated 24 May 2026
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What is a mobile crane annual inspection checklist?
A mobile crane annual inspection checklist is the structured record used by a competent person, licensed crane assessor or OEM-trained technician to carry out the 12-monthly major inspection on a mobile crane. It applies to all-terrain, rough-terrain, truck-mounted, crawler and hiab/loader cranes that operate on Australian construction, infrastructure, ports, mining and energy projects. Unlike the daily pre-start that the operator runs at the start of each shift, the annual inspection is a thorough strip-and-check that confirms the structural, mechanical, hydraulic, electrical and load-control systems are still within tolerance, and that the crane can stay registered for another year of work. It covers chassis and carrier, slewing ring, boom and jib including pin and chord NDT, outriggers and stabilisers, hoist drums and ropes, hook block proof load, load moment indicator (LMI) calibration, anti-two-block test, hydraulic pressure tests, brake test, cab and visibility, and the registration plate and inspector sign-off.
Under WHS Regulations 2011 (Chapter 5, Part 5.1), a mobile crane with a rated capacity over a state threshold is item-registered plant and the PCBU must keep an inspection and maintenance history for the life of the crane. AS 2550.1 sets the safe-use baseline including the major annual inspection, and AS 1418.5 governs design and manufacture. Wire rope inspection follows AS 2759, and the Safe Work Australia mobile crane Code of Practice ties the regulatory duty into practical inspection requirements. Most insurers, hire-fleet owners and Tier 1 head contractors require the annual inspection certificate to be on the crane before the rear-steer wheels hit the site gate. A printed checklist supports the assessor on the day; a digital record in MapTrack ties the inspection to the crane serial, the LMI calibration certificate, the rope retirement log and the next service due date.
Learn more about compliance and inspections in MapTrack.
Benefits of using this mobile crane annual inspection checklist
- Assessor accountability: The annual inspection is signed against a licensed crane assessor or OEM-trained technician, not a generic supervisor signature.
- AS 2550.1 alignment: Each section maps to the safe-use standard so insurers, hire customers and head contractors accept the certificate without follow-up.
- LMI and rope traceability: The LMI calibration certificate, hook proof load and wire rope retirement log all attach to the inspection record.
- Defect routing: Issues raised on slewing ring, hydraulics or electronics become work orders against the crane, not isolated paper jobs.
- Hire-fleet readiness: A clean annual inspection means the crane is ready to mobilise to the next site without delay at the gate.
- Registration support: The inspection record supports state plant registration renewal and Lloyds or RIMS plate validation.
- Lifecycle records: NDT results on boom pins, slewing ring bolt torque and rope changes sit against the crane for its full life.
Benefits of digitising forms in MapTrack
When you digitise mobile 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.
Book a demo to see how MapTrack handles mobile crane checklists.
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What to include in a mobile crane annual inspection checklist
This mobile crane annual inspection checklist covers 14 key areas:
- Crane identity: serial number, model, capacity, registration and current Lloyds/RIMS plate.
- Chassis and carrier: frame, suspension, tyres or tracks, steering and driveline.
- Slewing ring: bolt torque pattern, axial and radial play, grease and gear teeth.
- Boom and jib structure: chord and lattice NDT, weld inspection, pin and pin-keeper inspection.
- Outriggers and stabilisers: cylinders, pads, float plates, level indicators and emergency lowering.
- Hoist drums and reeving: drum condition, spooling, brake and gearbox oil.
- Wire ropes: hoist, luffing and pendant ropes per AS 2759 including diameter, broken wires and termination.
- Hook block: throat wear, safety latch, sheaves, bearings and swivel, plus proof load record.
- Load moment indicator (LMI): calibration certificate, sensor function and load-chart validation.
- Anti-two-block and overload: functional test on every reeving configuration and warning device.
- Hydraulic system: pressure tests, hose condition, accumulator and oil sample if due.
- Brakes and steering: service brake, park brake, swing brake stopping distance and steering lock-to-lock.
- Cab, controls and visibility: labelling, e-stops, mirrors, camera, audible warning and seatbelt.
- Registration and documentation: state plant registration, RIMS or Lloyds plate, load chart, manuals and assessor sign-off.
How to use this mobile crane annual inspection checklist
- Plan the inspection and gather records.: Confirm the licensed assessor or OEM-trained technician, pull the previous annual inspection, the LMI calibration history, the rope retirement log, the maintenance history and the state plant registration. Book the crane out of service for the day, organise a clear hardstand and a calibrated test weight if a proof load is planned.
- Inspect chassis, carrier and outriggers.: Walk the chassis, suspension, tyres or tracks, driveline and steering. Extend each outrigger to full stroke, inspect cylinders, pads and float plates and confirm the level indicator and emergency lowering function. Note any oil leak, loose fastener or paint loss at a weld.
- Inspect slewing ring, superstructure and boom.: Rotate the upper on the chassis. Check slewing-ring bolt torque in the documented star pattern. Measure axial and radial play. NDT the boom chord welds and pin bores per the OEM annual procedure, inspect pin keepers and confirm pin condition.
- Inspect ropes, hook block and reeving.: Inspect the hoist, luffing and pendant ropes per AS 2759, including diameter, broken-wire count per lay length, lubrication and the termination at the drum and the hook block. Inspect the hook block, throat, safety latch, sheaves and swivel. Record the most recent hook proof load.
- Test the load moment indicator and safety devices.: Recalibrate the LMI per the OEM procedure. Function-test the anti-two-block on every reeving configuration. Confirm the overload warning trips at the setpoint, the audible warning is clear in the cab and the override key is controlled.
- Test hydraulics, brakes and a function lift.: Run hydraulic pressure tests on the boom hoist, telescope and winch circuits. Test service brake, park brake and swing brake. With the area clear, run a no-load function test of all motions, then a test lift at SWL where required by the inspection plan, watching for unusual noise, drift or pressure loss.
- Record defects, sign off and update the crane record.: Photograph every defect, rate severity and raise a corrective action. Issue the annual inspection certificate with the assessor name and licence number. Update the crane history, the LMI certificate file and the registration record. In MapTrack the certificate, NDT results and rope retirement log all attach to the crane.
In MapTrack, you can digitise safety inspections and compliance forms. 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 annual inspection checklist as a PDF.Back to download formHow often should you complete this checklist?
AS 2550.1 and the Safe Work Australia mobile crane Code of Practice set the inspection tiers a fleet should follow. The licensed operator runs a daily pre-start at the start of every shift. A monthly inspection covers ropes, brakes, limits and visible structure. A quarterly inspection adds slewing ring, hydraulic system and load moment indicator function. The 12-monthly annual major inspection by a competent person or licensed assessor covers the full crane including structural NDT, LMI calibration, hook proof load and brake tests. A 10-yearly or major periodic inspection (often called the design-life inspection) reviews structural and fatigue life of the boom, chassis and slewing ring. Any incident, overload, impact, hire return or rope change triggers an out-of-cycle inspection before the crane returns to lifting work. In MapTrack each tier is scheduled per crane serial and reminds the right person ahead of time.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 2550.1 - Cranes, hoists and winches (Safe use - General requirements - Mobile cranes)
- AS 1418.5 - Cranes, hoists and winches (Mobile cranes - Design and manufacture)
- AS 2759 - Steel wire rope - Use, inspection and discard criteria
- WHS Regulations 2011 - Chapter 5, Part 5.1 (Registration and inspection of plant)
- Safe Work Australia - Code of Practice: Mobile cranes
Need to digitise safety inspections and compliance forms?
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