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Free overhead crane annual service procedure

Free overhead crane annual service checklist (PDF-ready). Wire rope measurement, brake overhaul, load test, NDT and AS 1418 certification. Download free.

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Updated 26 Oct 2026

Overhead Crane Annual Service Procedure

Annual service - overhead crane, bridge crane and gantry crane (AS 1418 / AS 2550)

Live form
0 of 12 checks

Wire Rope Measurement

1Wire rope measurement (diameter at 3 points, broken wires per lay length - compare to rejection criteria AS 2759)

Brake Overhaul

2Full brake overhaul (hoist, travel - reline linings if worn, adjust torque)

Structural Inspection

3Structural inspection (main beams, end carriages, connection welds, runway beams)
4NDT of critical welds (if due per manufacturer or 10-year schedule)

Load Testing

5Rated capacity load test (SWL with calibrated weights)

Electrical

6Electrical insulation resistance test (all motors, contactors)

Gearbox and Drivetrain

7Inspect hoist gearbox oil (sample or change)
8Replace worn trolley wheels and travel wheels

Runway and Alignment

9Check runway rail alignment (survey)

Overload Protection

10Recalibrate overload protection (if fitted)

Certification

11Update compliance sticker and logbook
12Certification per AS 1418 / AS 2550

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Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:Crane inspections →Maintenance and work orders →Best CMMS software →MapTrack vs MaintainX →

Short answer

An overhead crane annual service procedure records the yearly service of a bridge or gantry crane: every monthly item plus wire rope measurement, brake overhaul, structural and runway checks, electrical testing and overload device checks. The 12-month interval is common practice. AS 2550.3:2025 Section 14 covers maintenance, inspection and repair of bridge and gantry cranes, and Section 16 covers crane runways.

Checked against AS 2550.3:2025 on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack overhead crane annual service procedure contains 12 checks across 9 sections. Sections covered: Wire Rope Measurement, Brake Overhaul, Structural Inspection, Load Testing, Electrical, Gearbox and Drivetrain, Runway and Alignment, Overload Protection, Certification.
  • AS 2550.3:2025 Section 14 covers maintenance, inspection and repair of bridge and gantry cranes; Section 16 covers runway inspection.
  • The 12-month interval is common practice; regulation 213 follows the manufacturer's recommendations, then a competent person's, and annually only if neither is practicable.
  • Check wire ropes against the AS 2759 Section 14 discard criteria and record measured diameters and broken wire counts.
  • AS 1418 is the design series; in-service inspection sits in the AS 2550 safe-use series.
  • Keep the crane out of service when a brake, limit switch or overload device fails, until a competent person repairs it.

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Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is an overhead crane annual service procedure?

An annual service is the most comprehensive scheduled maintenance event for an overhead crane, bridge crane or gantry crane. It is performed every 12 months by a competent person and includes all monthly inspection items plus additional tasks that require extended downtime, specialist equipment or certification authority. The annual service adds wire rope measurement against AS 2759 rejection criteria, full brake overhaul (relining if worn), structural inspection of main beams, end carriages and connection welds, NDT of critical welds (if due), rated capacity load test with calibrated weights, electrical insulation resistance testing, hoist gearbox oil inspection or change, wheel replacement assessment, runway rail alignment survey, overload protection recalibration, and certification per AS 1418 / AS 2550. This is a carry-forward service: it includes every task from the monthly inspection, so both are completed in a single visit.

In Australia, the design of a bridge crane with a safe working load greater than 10 tonnes, or a gantry crane greater than 5 tonnes, must be registered with the regulator (WHS Regulations 2011, Part 5.3 and Schedule 5, Part 1), as must the design of any bridge or gantry crane built to handle molten metal or Schedule 11 hazardous chemicals; the crane itself is not an item of plant that must be registered. AS 2550.1 sets out the inspection, testing and maintenance of cranes in use, and AS 1418 covers crane design. The annual service is the primary compliance event, and keeping the completed report for the life of the crane is good practice. Insurance policies for lifting equipment typically require evidence of annual inspections by a competent person.

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Benefits of using this overhead crane annual service procedure

  • Regulatory compliance: annual servicing with certification per AS 1418 / AS 2550 satisfies WHS obligations, insurance requirements and audit expectations.
  • Structural integrity: NDT of critical welds and structural inspection of beams and carriages identifies fatigue cracks before they become safety risks.
  • Load capacity assurance: rated capacity load testing with calibrated weights confirms the crane can safely handle its SWL, protecting operators and loads.
  • Extended component life: brake overhaul, wheel replacement and gearbox oil service prevent premature failure of expensive drivetrain components.
  • Reduced unplanned downtime: comprehensive annual servicing catches issues that monthly inspections may miss, reducing the risk of mid-production breakdowns.
  • Documentation trail: a completed annual service record with certification provides an auditable compliance history for each crane.

Benefits of digitising forms in MapTrack

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

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  • 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.

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What to include in an overhead crane annual service procedure

This overhead crane annual service procedure covers 10 key areas:

  • Wire rope measurement: diameter at 3 points, broken wires per lay length, compared to AS 2759 rejection criteria.
  • Brake overhaul: full overhaul of hoist and travel brakes, reline linings if worn, adjust torque.
  • Structural inspection: main beams, end carriages, connection welds, runway beams.
  • NDT: non-destructive testing of critical welds (if due per manufacturer or 10-year schedule).
  • Load testing: rated capacity load test (SWL) with calibrated weights.
  • Electrical testing: insulation resistance test of all motors and contactors.
  • Gearbox and drivetrain: inspect or change hoist gearbox oil, replace worn trolley and travel wheels.
  • Runway alignment: runway rail alignment survey.
  • Overload protection: recalibrate overload protection (if fitted).
  • Certification: update compliance sticker and logbook, certification per AS 1418 / AS 2550.

How to use this overhead crane annual service procedure

  1. Complete the full monthly inspection procedure first. All monthly items carry forward into the annual service.: Work through every item on the monthly inspection checklist, including wire rope visual inspection, hook condition, brake testing, limit switch testing, controls, electrical systems, runway inspection and lubrication, before beginning the annual-only tasks.
  2. Isolate the crane from production. Ensure the area below is clear, barricaded and locked out. Arrange for calibrated test weights to be available.: Coordinate with production to schedule the crane out of service. Isolate the main power supply and apply a lockout/tagout. Barricade the area below the crane and post warning signage. Arrange for NATA-calibrated test weights equal to the crane rated capacity to be delivered to site.
  3. Measure wire rope diameter at 3 points along its length. Count broken wires per lay length and compare to AS 2759 rejection criteria. Record all measurements.: Use a wire rope calliper to measure the rope diameter at three evenly spaced points along its working length. Count the number of broken wires visible in any single lay length and compare to the rejection criteria in AS 2759. Record all measurements and compare to previous annual readings to track the rate of deterioration.
  4. Perform a full brake overhaul: strip, inspect and reline hoist and travel brake linings if worn. Adjust brake torque to manufacturer specification.: Remove the hoist and travel brake covers, strip the brake assemblies and measure lining thickness. Replace linings if worn to or below the manufacturer minimum. Inspect brake drums or discs for scoring and heat damage. Reassemble and adjust brake torque using a torque wrench to the manufacturer specification.
  5. Conduct a structural inspection of main beams, end carriages, connection welds and runway beams. Arrange NDT of critical welds if due per the manufacturer's schedule or 10-year interval.: Visually inspect the main beams, end carriages and all connection welds for cracks, corrosion, distortion and paint failure. Check bolted connections for looseness. If NDT is due, engage a qualified NDT technician to perform magnetic particle or ultrasonic testing on critical welds identified in the manufacturer inspection plan.
  6. Perform a rated capacity load test using calibrated weights at SWL. Verify the crane holds the load with correct brake operation, no structural deflection beyond limits and all safety devices functioning.: Attach the calibrated test weights to the hook and lift to a height of approximately 300 mm. Hold the load for a minimum of 10 minutes and observe for any drift, brake slip or abnormal deflection. Test all safety devices (overload, limit switches, emergency stop) with the load applied. Record the test weight, hold time and results.
  7. Test electrical insulation resistance on all motors and contactors. Record readings and compare to acceptable limits.: Isolate each motor from the drive and apply a 500 V or 1,000 V megger test to each winding phase to ground. Record the megaohm readings. Test contactor coils for insulation resistance. Compare all readings to the manufacturer minimum acceptable values and flag any readings showing a declining trend.
  8. Inspect or change hoist gearbox oil (sample for analysis or drain and refill). Replace worn trolley and travel wheels if required.: Check the hoist gearbox oil level and condition. Either take a sample for laboratory analysis or drain and refill with the manufacturer-specified oil. Inspect trolley and travel wheels for flat spots, flange wear and bearing condition. Replace any wheels that exceed the manufacturer wear limits.
  9. Survey runway rail alignment. Recalibrate overload protection (if fitted).: Use a laser alignment tool or steel tape to survey the runway rails for straightness, gauge and levelness. Record deviations and compare to AS 1418 tolerances. Recalibrate the overload protection system using calibrated weights, confirming it activates at the correct percentage of SWL as specified by the manufacturer.
  10. Update the compliance sticker and logbook. Complete certification per AS 1418 / AS 2550. Sign off and set the next service dates.: Apply a new compliance sticker showing the inspection date, next due date and inspector details. Update the crane logbook with all measurements, test results and any corrective actions. Issue the annual certification per AS 1418 and AS 2550. Obtain inspector, maintenance manager and site manager signatures.

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How often should you complete this service procedure?

The annual service must be performed every 12 months and is typically combined with the periodic inspection described in AS 2550.3 for bridge and gantry cranes. Monthly inspections should continue between annual services, covering operational testing, brake checks, limit switch testing and lubrication. Daily pre-use checks by the operator should confirm wire rope condition, hook safety latch, brakes and controls before each shift. High-duty cycle cranes in steel mills, foundries or container terminals may require more frequent comprehensive inspections based on duty classification.

Bridge and gantry cranes need design registration above set capacities but are not items of plant requiring registration under Schedule 5 of the model WHS Regulations, so time the annual service to your maintenance calendar or any state registration date that applies. For cranes in high-utilisation environments, consider supplementing the annual service with quarterly structural inspections. In MapTrack, calendar-based triggers ensure every crane receives its annual service on time, with digital records that satisfy regulatory and insurance requirements.

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Frequently asked questions

An overhead crane annual service includes all monthly inspection items plus 12 additional actions: wire rope diameter measurement at 3 points and broken wire count per lay length (compared to AS 2759 rejection criteria), full brake overhaul (hoist and travel brakes with lining replacement if worn), structural inspection of main beams, end carriages and connection welds, NDT of critical welds (if due per manufacturer or 10-year schedule), rated capacity load test with calibrated weights, electrical insulation resistance testing of all motors and contactors, hoist gearbox oil inspection or change, replacement of worn trolley and travel wheels, runway rail alignment survey, overload protection recalibration, compliance sticker update and certification per AS 1418 / AS 2550. It takes approximately 4 to 8 hours.

Carry-forward (or cumulative) servicing means that each higher-level service includes all tasks from the level below. The annual service includes all monthly inspection items. This ensures that when the annual service is performed, the crane also receives a full monthly inspection as part of the same procedure. The annual service adds wire rope measurement, brake overhaul, structural NDT, load testing, electrical testing and certification on top of the standard monthly checks.

Overhead cranes in Australia are governed by AS 1418 (Cranes, hoists and winches) and AS 2550 (Cranes, hoists and winches - Safe use). Wire rope rejection criteria are covered by AS 2759. Check AS 2550.3:2025 for its periodic inspection requirements (clause 14.3). The annual service also typically requires a rated capacity load test with calibrated weights. State WHS regulations may impose additional requirements. Always ensure services are performed by a competent person as defined by the relevant legislation.

An overhead crane annual service typically takes 4 to 8 hours depending on the crane size, SWL, number of hoists and whether NDT is required. The load test alone can take 1 to 2 hours including setup and weight positioning. Planning for a full day of crane downtime allows adequate time for thorough inspection, measurement, testing and documentation without rushing safety-critical tasks.

Yes. This overhead crane annual service checklist is completely free to download and use. It downloads as a ready-to-print PDF. No account or sign-up is required. If you want to digitise inspections with automatic scheduling, photo capture and compliance dashboards, MapTrack can help. Book a free demo to see how it works for your operation.

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 3: Bridge, gantry, portal (including container cranes), jib cranes and monorail beams

    Edition: AS 2550.3:2025

    Safe-use standard for bridge, gantry and jib cranes: maintenance, inspection and repair, and crane runway inspection.

    • Section 14: Maintenance, inspection and repair of bridge, gantry, portal and jib cranes.
    • Section 16: Inspection and maintenance of crane runways.

    Standards AustraliaSold 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 to the manufacturer's recommendations, and registration of the crane designs Schedule 5 lists. Model law.

    • 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.
    • Part 5.3: Registration of plant designs and items of plant with the regulator.
    • 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 1: General requirements

    Edition: AS 2550.1-2011

    General crane safe use: maintenance and inspection, records, and the major assessment for continued use.

    • Section 7: Maintenance, inspection and repair 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

    Inspection of 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, hoists and winches, Part 3: Bridge, gantry, portal (including container cranes) and jib cranes

    Edition: AS 1418.3:2024

    Design standard for bridge and gantry cranes; it is not an in-service inspection standard.

    Standards AustraliaSold by the publisher

  • 29 CFR Part 1910, Occupational Safety and Health Standards

    Edition: Current eCFR text, up to date as of 2026-10-22 (read 2026-10-26)

    US rule for overhead and gantry cranes, including frequent and periodic inspections. Applies in the US only.

    • 1910.179: Overhead and gantry cranes: design, initial, frequent and periodic inspections, testing, maintenance, ropes and operation.

    US Occupational Safety and Health Administration (text via eCFR)

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

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  <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;">Overhead crane annual service procedure</p>
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    <li style="margin:4px 0;">Wire rope measurement: diameter at 3 points, broken wires per lay length, compared to AS 2759 rejection criteria.</li>
    <li style="margin:4px 0;">Brake overhaul: full overhaul of hoist and travel brakes, reline linings if worn, adjust torque.</li>
    <li style="margin:4px 0;">Structural inspection: main beams, end carriages, connection welds, runway beams.</li>
    <li style="margin:4px 0;">NDT: non-destructive testing of critical welds (if due per manufacturer or 10-year schedule).</li>
    <li style="margin:4px 0;">Load testing: rated capacity load test (SWL) with calibrated weights.</li>
    <li style="margin:4px 0;">Electrical testing: insulation resistance test of all motors and contactors.</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/overhead-crane-annual-service" style="color:#071D49;font-weight:600;text-decoration:none;">Overhead crane annual service procedure</a> by MapTrack</p>
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The MapTrack overhead crane annual service procedure contains 12 checks across 9 sections.

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