Free overhead crane monthly inspection procedure
Jump to download form ↓Enter your email below to download this overhead crane monthly inspection procedure as a ready-to-use PDF.
Free overhead crane monthly inspection checklist (PDF-ready). Wire ropes, hook, brakes, limit switches, controls and lubrication checks. Download free.
Commercial Director
How to use: download the PDF, print or complete digitally on any device.
- ✓PDF format, ready to print or fill on screen
- ✓Use as-is or customise to suit your operation
- ✓Go digital in MapTrack for photos, alerts and audit trails
Download free PDF template
Trusted by teams across Australia and New Zealand
We respect your privacy. Unsubscribe anytime.
Preview the template
See the first part of the overhead crane monthly inspection procedure below. Download the full version above.
What is a overhead crane monthly inspection procedure?
A monthly inspection is a scheduled preventive maintenance check for overhead cranes, bridge cranes and gantry cranes. It is performed every month by a competent person and covers operational testing, visual inspections and lubrication. The procedure includes checking wire ropes for broken wires, corrosion and kinks, inspecting chains for stretch and wear, verifying hook condition (throat opening and safety latch), testing hoist and travel brakes under load, testing all limit switches (upper, lower hoist and travel), checking pendant or radio controls and emergency stops, inspecting electrical systems (collector bars or festoons, motors), inspecting runway beams and rails, and greasing all specified bearings. Unlike a daily pre-use check (which confirms the crane is safe to operate), the monthly inspection involves detailed functional testing and documented results. It is typically performed by a qualified crane technician or maintenance fitter.
Regular monthly inspections are a key component of a crane's ongoing maintenance programme and are required under AS 2550.1 and AS 1418. In Australia, the PCBU has a duty under the WHS Regulations 2011 to ensure that plant is inspected at intervals recommended by the manufacturer or a competent person. Monthly inspections catch developing issues between annual services, preventing costly unplanned breakdowns and reducing the risk of load drops or structural failure.
Learn more about maintenance and work orders in MapTrack.
Benefits of using this overhead crane monthly inspection procedure
- Reduced breakdowns: regular brake, rope and limit switch checks catch wear before it causes unplanned downtime in production.
- Extended component life: correct lubrication and early detection of wear on wheels, bearings and ropes extends the service life of expensive crane components.
- Operator safety: testing brakes, limit switches and emergency stops at regular intervals reduces the risk of dropped loads or crane collisions.
- Compliance: documented monthly inspections demonstrate compliance with AS 1418, AS 2550 and WHS regulations. Records support insurance and audit requirements.
- Lower repair costs: a monthly inspection costs a fraction of an emergency breakdown repair. Identifying worn brake linings or fraying wire ropes early prevents cascading damage.
- Production continuity: in manufacturing and warehousing environments, crane downtime directly impacts production throughput. Scheduled inspections keep cranes available.
Benefits of digitising forms in MapTrack
When you digitise overhead crane service procedures 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).
- Trigger work orders automatically when a fault is logged during an inspection.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
Book a demo to see how MapTrack handles overhead crane service procedures.
Try MapTrack free for 30 days
Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.
- No credit card required
- 30 days free trial
- Cancel anytime
What to include in a overhead crane monthly inspection procedure
This overhead crane monthly inspection procedure covers 8 key areas:
- Wire ropes and chains: inspect wire ropes for broken wires, corrosion, kinks and diameter loss; inspect chains for stretch, wear and twist.
- Hook and attachments: check hook throat opening, safety latch and swivel bearing.
- Brakes: test hoist brake (hold rated load), test cross-travel and long-travel brakes.
- Trolley and travel: inspect trolley wheels and rail for wear and alignment.
- Controls and safety: check pendant or radio controls, test upper and lower hoist limit switches, test travel limit switches, test emergency stop at all stations, check warning horn and lights.
- Electrical: inspect collector bars or festoon system, check motor condition (noise, heat, vibration).
- Structural: inspect runway beams and rails for alignment, wear and clips.
- Lubrication: grease hoist drum bearing, sheave bearings, trolley wheel bearings and long-travel wheel bearings.
How to use this overhead crane monthly inspection procedure
- Isolate the crane from operation. Ensure the area below is clear and barricaded if required. Confirm the crane is in a safe position with the hook at rest.: Coordinate with production to take the crane out of service. Isolate the main power supply and apply a lockout/tagout if working on the crane structure. Barricade the area below with cones or barriers and post warning signage to prevent foot traffic during the inspection.
- Record the equipment details, crane identification (make, model, serial, SWL, span) and site/building/bay at the top of the inspection form.: Capture the crane make, model, serial number, SWL rating, span measurement, hoist classification and the building or bay location. Accurate identification ensures the inspection record is filed against the correct asset in your maintenance system.
- Start with wire ropes and chains: visually inspect for broken wires, corrosion, kinks and abnormal wear. Check chains for stretch and twist.: Run the wire rope through its full travel while visually inspecting for broken wires, flattening, birdcaging, corrosion and kinks. Pay particular attention to areas where the rope contacts sheaves and the drum. For chain hoists, measure chain link pitch and compare to the manufacturer nominal to check for stretch. Look for twisted or distorted links.
- Inspect the hook: check throat opening measurement, safety latch operation and swivel bearing condition.: Measure the hook throat opening using a calliper and compare to the manufacturer original dimension. An increase of 15 percent or more from the original indicates the hook should be replaced per AS 2759. Confirm the safety latch snaps closed automatically and the swivel bearing rotates freely without roughness.
- Test brakes: engage the hoist brake with a rated load to confirm it holds. Test cross-travel and long-travel brakes for stopping distance and holding.: Lift a load at or near the rated capacity to a height of approximately 300 mm and release the hoist control. Confirm the brake holds the load without any drift. Test cross-travel and long-travel brakes by driving at normal speed and releasing, measuring the stopping distance and confirming it is within the manufacturer specification.
- Test all limit switches: upper and lower hoist limits, travel limits. Test emergency stop at every station (pendant, remote, wall-mounted).: Operate the hoist upward slowly until the upper limit switch activates and stops the motion. Repeat for the lower limit. Test cross-travel and long-travel limit switches if fitted. Press each emergency stop button (pendant, remote, wall-mounted) and confirm the crane stops all motion immediately and requires a deliberate reset to restart.
- Check pendant or radio controls: test all functions in both directions. Verify warning horn and lights operate correctly.: Test every pendant or radio control function (hoist up, hoist down, cross-travel left, cross-travel right, long-travel forward, long-travel reverse, speed selection) and confirm the crane responds correctly. Verify that the motion matches the label on the control. Test the warning horn and any warning beacons or lights.
- Inspect electrical systems: check collector bars or festoon system for damage. Listen for abnormal motor noise and check for excessive heat or vibration.: Visually inspect collector bars for wear, arcing damage and loose connections. For festoon systems, check cable carriers for cracked rollers, stretched cables and sagging. Run each motor and listen for grinding, whining or knocking. Place a hand on the motor housing to feel for excessive heat or abnormal vibration.
- Inspect runway beams and rails: check alignment, wear patterns and rail clips.: Walk the full length of the runway and inspect beams for cracking, corrosion and deflection. Check rails for wear patterns on the running surface, flange wear from crane skewing and loose or missing rail clips. Misaligned rails cause accelerated wheel wear and increased risk of derailment.
- Lubricate all specified points: hoist drum bearing, sheave bearings, trolley wheel bearings and long-travel wheel bearings with EP2 grease.: Pump EP2 lithium complex grease into each fitting until fresh grease appears at the seal. Cover all specified lubrication points: hoist drum bearings, upper and lower sheave bearings, trolley wheel bearings and long-travel wheel bearings. Wipe excess grease to prevent accumulation of dirt and debris.
- Record any defects or recommendations in the notes section. Set the next inspection date and sign off.: Document all findings, measurements and defects. Assign a severity to each defect (critical, major, minor) and specify recommended corrective actions. Set the next monthly inspection date and obtain the inspector and maintenance manager signatures. Critical defects must be reported immediately and the crane taken out of service until repaired.
In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.
Get the free template
Enter your email above to download the full overhead crane monthly inspection procedure as a PDF.
Back to download formHow often should you complete this service procedure?
Monthly inspections should be performed every calendar month for cranes in regular service. Cranes that are used infrequently (less than once per month) should be inspected before each use. High-duty cycle cranes in steel mills, foundries or container terminals may require fortnightly or weekly operational checks in addition to the monthly inspection. The annual service adds wire rope measurement, brake overhaul, structural NDT, rated capacity load testing and certification per AS 1418 and AS 2550. Daily pre-use checks by the operator should cover wire rope condition, hook, brakes and controls before every shift.
Monthly inspections should be performed by a competent person with knowledge of overhead crane systems and the relevant Australian Standards. For cranes in high-utilisation environments, consider increasing the frequency to fortnightly. In MapTrack, recurring inspection schedules can be configured for each crane with automatic reminders and a compliance dashboard.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS 1418 Cranes, hoists and winches
- AS 2550 Cranes, hoists and winches - Safe use
- AS 2759 Steel wire rope - Use, operation and maintenance
- OSHA 29 CFR 1910.179 Overhead and gantry cranes
Need to schedule and track maintenance digitally?
Register every overhead crane in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.
Maintenance and work orders · All templates · Pricing · Book a demo