Free mobile crane annual inspection checklist

• The MapTrack mobile crane annual inspection checklist contains 25 checks across 5 sections. Sections covered: Carrier, tyres & outriggers, Slewing ring & slew drive, Boom, jib & ropes, Load moment indicator & limits, Brakes, cab & certification.
• 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.

Learn more about compliance and inspections in MapTrack.

• 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.

• 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.

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

7. 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.

Practical answers about the form, record keeping and using MapTrack.

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

• 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

• Model Codes of Practice (Safe Work Australia)
• Model WHS Regulations (Safe Work Australia)
• AS 1418 series, Cranes, hoists and winches (Standards Australia listing)
• AS 2550 series, Cranes, hoists and winches, safe use (Standards Australia listing)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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