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Free mobile crane annual inspection checklist
Free mobile crane annual inspection checklist (PDF-ready). Structural NDT, ropes, LMI, outriggers, brakes and assessor sign-off: AS 2550.1, AS 2550.5.
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25 checks · 5 sections · Sign-off
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The fields in the printable form, in a view that fits your screen.
- Crane serial / model
- Registration number
- Capacity (tonnes)
- Boom length (m)
- Hours at inspection
- Crane type
- Assessor name and licence
- Date and certificate number
Carrier, tyres & outriggers
Slewing ring & slew drive
Boom, jib & ropes
Load moment indicator & limits
Brakes, cab & certification
Declaration & Sign-Off
I confirm that all items have been inspected/completed as indicated above. Any defects or concerns have been noted and reported.
Completed By
Printed name · Signature · Date
Reviewed / Approved By
Printed name · Signature · Date
The MapTrack mobile crane annual inspection checklist contains 25 checks across 5 sections.
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Short answer
A mobile crane annual inspection checklist records a competent person's inspection of the crane's structure, mechanical systems and safety devices, such as the boom, slewing ring, outriggers, ropes, LMI and brakes, with defects and test results. Regulation 213 of the model WHS Regulations requires inspection following the manufacturer's recommendations, else a competent person's; annual inspection applies only where neither is reasonably practicable.
Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates
Key takeaways
- 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.
- Regulation 213 sets annual inspection only where neither manufacturer nor competent person recommendations can be followed; otherwise the 12-month cycle comes from the manufacturer or practice.
- A registered mobile crane needs records of its tests, inspections, maintenance and alterations (reg 237).
- The annual is not the major inspection: reg 235 sets that at the manufacturer's design life end, else as a competent person advises, else every 10 years.
- AS 2759 Sections 13 and 14 set in-service wire rope inspection and discard criteria; record rope condition and changes against the crane.
- Inspect again before lifting after any overload, impact, hire return or rope change.
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 (annual) 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 the WHS Regulations 2011, a mobile crane with a rated capacity greater than 10 tonnes is item-registered plant (Part 5.3 and Schedule 5), and the person with management or control of it must keep a record of its tests, inspections and maintenance for as long as the crane is used or until they relinquish control of it (regulation 237). AS 2550.1 and AS 2550.5 set the safe-use requirements, and AS 1418.5 covers design. The annual inspection is not the major inspection: under regulation 235, a registered mobile crane needs a major inspection at the end of the design life recommended by the manufacturer, or as a competent person recommends, or otherwise every 10 years from first commissioning or registration, and Safe Work Australia's guide notes that an annual inspection may be less comprehensive than a major inspection. Wire rope inspection follows AS 2759, and regulation 213 requires maintenance and inspection by a competent person following the manufacturer recommendations. 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.
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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.
- Safe-use reference: The form lists the crane areas the annual inspection covers, for the assessor to check against AS 2550.1, AS 2550.5 and the manufacturer manual before sign-off.
- 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.
What to include in a mobile crane annual inspection checklist
- 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.
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How often should you complete this checklist?
The manufacturer manual and the safe-use standards (AS 2550.1 and AS 2550.5) shape 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 inspection by a competent person or licensed assessor covers the full crane including structural NDT, LMI calibration, hook proof load and brake tests. The separate major inspection under regulation 235 falls at the end of the design life recommended by the manufacturer, or as a competent person recommends, or otherwise every 10 years from first commissioning or registration, and examines every critical component of the boom, chassis and slewing ring, stripping the crane down where necessary. 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.
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Frequently asked questions
Practical answers about the form, record keeping and using MapTrack.
AS 2550.1 (general requirements) and AS 2550.5 (mobile cranes) cover safe use, and AS 1418.5 covers design. AS 2759 covers the hoist, luffing and pendant ropes. Under the WHS Regulations, regulation 213 requires maintenance and inspection by a competent person following the manufacturer recommendations; for a registered mobile crane (over 10 tonnes), regulation 237 requires records of its tests, inspections and maintenance to be kept while the crane is used or until control is relinquished, and regulation 235 sets the separate major inspection. Most insurers and head contractors also require the annual inspection certificate to be current.
Link to this answerThe annual inspection should be done by a competent person, which in Australian practice means a licensed crane assessor, an OEM-trained technician or an engineer experienced in mobile crane inspection. The separate regulation 235 major inspection must be done by, or under the supervision of, a competent person who has the skills and is a registered professional engineer, or is determined by the regulator. Daily pre-start checks remain with the licensed operator (the high-risk work licence for the crane class: non-slewing over 3 tonnes, slewing up to 20, 60 or 100 tonnes or over 100 tonnes, or vehicle loading crane of 10 metre tonnes and above), and monthly and quarterly inspections are done by a trained technician working to the OEM procedure.
Link to this answerA proof load is not required at every annual inspection. It is required after major structural repair, after a hook or rigging-attachment change, after relevant boom or jib work, and where the manufacturer or state regulator specifies it. Where a proof load is performed, it is done at the test load the manufacturer or engineer specifies, with the test recorded against the hook block or attachment and signed by the assessor.
Link to this answerThe load moment indicator is typically recalibrated at every annual inspection, and a functional test is done at every quarterly inspection. The calibration must be done per the OEM procedure with calibrated test weights, and the certificate is kept with the crane file. After any LMI sensor change, controller update or boom-section change, an additional calibration is required before the crane returns to lifting work.
Link to this answerA hire crane needs a current annual inspection certificate, a current state plant registration, the most recent rope and hook records, the current LMI calibration certificate and a pre-mobilisation pre-start by the licensed operator. Most Tier 1 head contractors also require a site-specific risk assessment and verification at the gate, with the inspection records attached to the crane file in the site management system.
Link to this answerYes. This mobile crane annual inspection checklist is completely free to download and use, and it downloads as a ready-to-print PDF. No MapTrack account is required. It suits licensed crane assessors, OEM-trained technicians and hire-fleet owners carrying out the 12-monthly inspection. If you later want to move off paper and spreadsheets, MapTrack turns this into a live digital inspection: the annual certificate, NDT results, LMI calibration certificate and rope retirement log all stored against each crane serial, defects raised with photos, and automated reminders for the daily, monthly, quarterly and annual tiers with a complete timestamped audit trail, so nothing slips through across your fleet. Start free at maptrack.com/free-trial or book a demo.
Link to this answerApplicable regulatory standards
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.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| Model Work Health and Safety RegulationsCompetent-person inspection per the manufacturer, the separate major inspection, and records for registered cranes. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| Cranes, hoists and winches - Safe use, Part 5: Mobile cranesMobile crane maintenance, inspection and repair, and the limiting and indicating devices such as the LMI. | AS 2550.5:2016 |
| Standards AustraliaSold by the publisher |
| Cranes, hoists and winches - Safe use, Part 1: General requirementsGeneral crane inspection and records, and the major assessment of a crane for continued use. | AS 2550.1-2011 |
| Standards AustraliaSold by the publisher |
| Steel wire rope - Use, operation and maintenanceIn-service wire rope inspection and discard criteria. | AS 2759-2004 |
| Standards AustraliaSold by the publisher |
| Cranes, hoists and winches, Part 5: Mobile cranes (EN 13000:2010, MOD)Mobile crane design standard; the safe-use side is AS 2550.5. | AS 1418.5-2013 | Whole instrument | Standards AustraliaSold by the publisher |
| Guide to inspecting and maintaining cranesSafe Work Australia guidance on crane inspection and maintenance; practical advice, not law. | December 2015 | Whole instrument | Safe Work Australia |
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 inspection per the manufacturer, the separate major inspection, and records for registered cranes.
- 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.
- Schedule 5: Plant requiring registration: plant designs (Part 1) and items of plant (Part 2), such as boilers and tower cranes.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
Cranes, hoists and winches - Safe use, Part 5: Mobile cranes
Edition: AS 2550.5:2016
Mobile crane maintenance, inspection and repair, and the 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 inspection and records, and the major assessment of a crane for continued use.
- Section 7: Maintenance, inspection and repair of cranes, hoists and winches.
- 7.3: Inspection of cranes, hoists and winches.
- 7.5: Records of maintenance, inspection and repair.
- Section 9: Major assessment of a crane for continued use or changed operation.
Standards AustraliaSold by the publisher
Steel wire rope - Use, operation and maintenance
Edition: AS 2759-2004
In-service wire rope inspection and discard criteria.
- Section 13: Inspection of steel wire ropes in service.
- Section 14: Criteria for discarding steel wire ropes.
Standards AustraliaSold by the publisher
Cranes, hoists and winches, Part 5: Mobile cranes (EN 13000:2010, MOD)
Edition: AS 1418.5-2013
Mobile crane design standard; the safe-use side is AS 2550.5.
Standards AustraliaSold by the publisher
Guide to inspecting and maintaining cranes
Edition: December 2015
Safe Work Australia guidance on crane inspection and maintenance; practical advice, not law.
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
- 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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The MapTrack mobile crane annual inspection checklist contains 25 checks across 5 sections.
- Short attribution
- MapTrack Mobile Crane Annual Inspection Checklist, https://www.maptrack.com/templates/mobile-crane-annual-inspection-checklist
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- MapTrack. (2026). Mobile Crane Annual Inspection Checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/mobile-crane-annual-inspection-checklist
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<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 Annual Inspection 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;">Crane identity: serial number, model, capacity, registration and current Lloyds/RIMS plate.</li>
<li style="margin:4px 0;">Chassis and carrier: frame, suspension, tyres or tracks, steering and driveline.</li>
<li style="margin:4px 0;">Slewing ring: bolt torque pattern, axial and radial play, grease and gear teeth.</li>
<li style="margin:4px 0;">Boom and jib structure: chord and lattice NDT, weld inspection, pin and pin-keeper inspection.</li>
<li style="margin:4px 0;">Outriggers and stabilisers: cylinders, pads, float plates, level indicators and emergency lowering.</li>
<li style="margin:4px 0;">Hoist drums and reeving: drum condition, spooling, brake and gearbox oil.</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/mobile-crane-annual-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Mobile Crane Annual Inspection Checklist</a> by MapTrack</p>
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About the author
Co-Founder & Commercial Director
Jarrod has spent over a decade in technology consulting and asset management, including roles at Accenture (mining and heavy industry) and CGI as an Asset Management Consultant. He co-founded MapTrack and built and scaled its original platform, then rebuilt it with Lachlan and Alex from thousands of customer conversations and 300+ user research sessions with field teams. His consulting background gives him deep insight into the operational and compliance challenges facing asset-intensive Australian businesses.
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