How to use this checklist
Build a traceable crane inspection record that shows the applicable crane standard, current duty, each inspection tier, major-inspection trigger and wire-rope discard basis before the crane is accepted for continued use.
Use it when
- Auditing a crane inspection and maintenance program.
- Checking whether monthly/quarterly/annual tasks are actually defined for the specific crane.
- Reviewing design working period and a proposed or completed major inspection.
- Examining wire rope records, damage and discard decisions.
Do not use it to
- Assuming every crane has the same daily/monthly/quarterly/annual calendar.
- Treating 10 years as an automatic reset period after a major inspection.
- Using one broken-wire count or diameter-reduction percentage for every rope construction and function.
- Replacing the applicable AS 2550 part, crane manufacturer instructions, regulator requirements or competent-person scope.
Stop and escalate when
These conditions deserve an explicit competent-person decision rather than being treated as routine checklist gaps.
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A safety-related defect, crack, overload event or uncontrolled motion is reported.
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The crane's inspection history, age, duty or design working period cannot be reconstructed.
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A major inspection is due/overdue or its scope departed from manufacturer instructions without a documented basis.
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Wire rope has broken wires, significant diameter loss, corrosion, deformation, heat damage or termination defects approaching the applicable discard basis.
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A crane has been modified, re-rated, repaired after major damage or used outside the original duty basis.
03
Working checklist
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1. Identify the crane, applicable parts and duty basis
The correct inspection pathway depends on crane type and use. Start by identifying the exact standards, manufacturer documents and design/duty information that apply.
Identify crane type, make/model, serial number, rated capacity and registration status where applicable.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forNameplate, crane register, registration record and current configuration.Typical gapInspection reports use a fleet number but omit the manufacturer serial or configuration.Escalate whenThe inspected crane cannot be uniquely matched to the report.Source basisApplicable AS 1418 crane part, AS 2550 safe-use part and regulatory plant records.Identify the applicable AS 1418 design part and AS 2550 safe-use/inspection part for this crane type.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forInspection plan listing editions/parts and any project or regulator basis.Typical gapA generic crane checklist is used across mobile, bridge, tower and vehicle-loading cranes.Escalate whenThe applicable part cannot be established.Source basisAS 1418 series design scope and AS 2550 series safe-use/inspection scope.Collect manufacturer inspection, maintenance and major-inspection instructions.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forControlled manual/service bulletins and current OEM inspection criteria.Typical gapThe site relies only on an Australian Standard summary and misses model-specific dismantling or inspection requirements.Escalate whenManufacturer criteria are unavailable, ignored or contradicted by the current inspection scope.Source basisRegulator crane guidance and AS 2550/OEM inspection hierarchy.Record current duty: operating hours/cycles, load spectrum, environment, travel duty and abnormal events.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forData logger, logbook, lift history, operator records and environment/service description.Typical gapAge is known but accumulated duty is not.Escalate whenSevere duty, overload, corrosive environment or unknown history may shorten inspection/major-inspection timing.Source basisAS 1418 duty classification context, AS 2550 DWP assessment and regulator guidance.02
2. Check pre-operational and shift inspection
The operator-level check should identify obvious conditions that make the crane unsafe before work starts and ensure defects enter a controlled close-out process.
Confirm a documented pre-operational/shift inspection is defined for the specific crane.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forCurrent operator checklist and completed sample records.Typical gapA generic checklist omits model-specific limiting devices, ropes or outriggers.Escalate whenNo pre-use check exists or the checklist does not cover critical safety features.Source basisSafe Work Australia and regulator crane inspection guidance; applicable AS 2550 part.Check visible structure, hooks, ropes/chains, sheaves, drums, controls, brakes, leaks and safety devices before use.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forCompleted checklist with defect notes, not just a signature.Typical gapEvery box is pre-ticked or repeated defects are never raised.Escalate whenCrack, deformation, uncontrolled leakage, damaged rope or failed safety device is found.Source basisCrane pre-operational inspection guidance and OEM instructions.Confirm defects found during pre-use checks are graded, controlled and closed before continued operation where necessary.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forDefect register, isolation/restriction record and repair close-out.Typical gapOperator writes a defect in the logbook but no work order is created.Escalate whenA safety-related defect remains open without an explicit competent-person decision.Source basisCrane risk-control and defect-management requirements.Check operator familiarisation and access to load charts/operating limits for the exact crane configuration.
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forTraining/familiarisation record and current load charts/manuals.Typical gapExperienced operator is assumed familiar with a new model or attachment.Escalate whenConfiguration-specific limits are unavailable or misunderstood.Source basisRegulator crane operation guidance and manufacturer instructions.03
3. Check routine inspection and maintenance tiers
Weekly, monthly and quarterly tasks may be appropriate for a particular crane, but they are not universal labels. The site schedule should be derived from the applicable part, manufacturer instructions, operating hours and duty.
Confirm the routine schedule identifies every required calendar- or operating-hour-based task.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forMaintenance matrix showing weekly/monthly/quarterly/hour-based tasks where applicable.Typical gapThe CMMS has a monthly service but omits an OEM 250-hour task or quarterly safety-device check.Escalate whenRequired tasks cannot be mapped to a source basis.Source basisApplicable AS 2550 part, manufacturer instructions and regulator guidance.Verify routine inspections cover wear components, lubrication, adjustments, brakes, ropes, sheaves, hooks and safety devices relevant to the crane.
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forTask sheets with actual measurements/observations and defect results.Typical gapService record proves attendance but not what was inspected.Escalate whenCritical components have no defined inspection task.Source basisApplicable AS 2550/OEM routine inspection and maintenance requirements.Check inspection frequency has been adjusted for severe duty, environment, repeated defects or abnormal events where needed.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forCompetent-person/OEM decision and revised schedule.Typical gapSame interval is used for indoor light duty and corrosive continuous duty.Escalate whenDamage trend suggests the current schedule is not detecting deterioration early enough.Source basisDuty- and condition-responsive crane maintenance principles.Confirm replacement, adjustment and repair records are linked back to the inspection that found the defect.
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forWork orders, parts records and post-repair verification.Typical gapA component is replaced but the reason, measured condition and recurring trend are lost.Escalate whenRepeated failures occur without root-cause review.Source basisCrane lifecycle inspection/maintenance record requirements.04
4. Check annual/periodic competent-person inspection and DWP review
The periodic inspection should do more than repeat routine maintenance. It should examine condition, safety devices, structural/wear components and accumulated duty as required for the crane type.
Confirm the annual/periodic inspection scope includes manufacturer requirements and all applicable routine items.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forControlled inspection procedure and completed report.Typical gapAnnual certificate is issued from a short visual checklist with no component detail.Escalate whenCritical inspection criteria from the manufacturer are omitted.Source basisApplicable AS 2550 part and regulator crane guidance.Check limiting, indicating and safety devices are function-tested and calibrated where required.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forTest/calibration results and defect close-out.Typical gapDevice powers up but accuracy and trip performance are not verified.Escalate whenA capacity, motion or safety limit is unreliable.Source basisRegulator annual crane inspection guidance and applicable AS 2550/OEM requirements.Check structural and wear components receive detailed visual/tolerance examination and crack-prone areas are addressed.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forMeasurements, NDT where specified, photographs and comparison with limits.Typical gapReport says 'structure OK' without recording critical areas or wear measurements.Escalate whenCrack-like indications, distortion or wear near limits are found.Source basisRegulator annual inspection guidance; manufacturer and applicable AS 2550 scope.Record crane duty and assess design working period/remaining design life where applicable.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forDWP calculation/assessment using operating data, load spectrum and stated assumptions.Typical gapThe crane receives annual inspection for years but accumulated duty is never assessed.Escalate whenHistory is incomplete, severe duty is evident or the assessment approaches/exceeds the design basis.Source basisAS 2550 DWP concept and regulator guidance on duty recording/assessment.05
5. Check the major-inspection trigger and scope
Ten years is not a universal reset clock. Major inspection is tied to design life, manufacturer instructions, duty/condition and regulatory requirements; 10 years can be a fallback maximum in specific regimes.
Identify the manufacturer-recommended design life and major-inspection trigger for the crane and major components.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forOEM manual, design documentation or formal manufacturer advice.Typical gapThe site assumes every crane automatically reaches major inspection at exactly 10 years.Escalate whenDesign-life information is missing or the crane has exceeded it.Source basisApplicable AS 2550/OEM major-inspection framework and regulator requirements.Where manufacturer design life is unavailable, document the competent-person basis used to determine the major-inspection timing and scope.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forEngineering assessment addressing age, duty, environment, damage history and technical standards.Typical gapA calendar date is selected with no assessment of accumulated duty or condition.Escalate whenHistory is insufficient to support the proposed deferral/scope.Source basisRegulator major-inspection framework and competent-person requirements.For registered mobile cranes in Queensland, check the regulatory fallback pathway where design-life information cannot practicably be used.Escalation-sensitive
Current Queensland guidance requires major inspection at manufacturer design life, or a competent-person equivalent basis; where neither is reasonably practicable, at least every 10 years from first commissioning/registration.Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forCommissioning/registration date and documented trigger basis.Typical gapThe 10-year number is applied as though it overrides manufacturer criteria or accumulated duty.Escalate whenThe statutory trigger is due/overdue or the basis cannot be demonstrated.Source basisQueensland Mobile Crane Code of Practice 2024 and WHS Regulation pathway.Confirm the major-inspection scope follows manufacturer criteria as a minimum where available.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forScope matrix comparing OEM criteria with work completed, including dismantling where required.Typical gapA DWP calculation is used to justify omitting manufacturer-required dismantling or internal examination.Escalate whenCritical OEM inspection criteria were not completed.Source basisQueensland regulator guidance following major-inspection failures.Do not assume completion of a major inspection gives every component another guaranteed 10-year life.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forPost-major-inspection report stating next inspection/maintenance basis by component and condition.Typical gapThe major inspection date becomes the only future control until the next decade.Escalate whenKnown wear, corrosion or fatigue-sensitive items lack more frequent follow-up.Source basisSafe Work Australia and Queensland regulator major-inspection guidance.06
6. Check wire rope identity, examination and discard basis
Wire rope discard is construction- and service-specific. Do not apply one broken-wire count or diameter-loss percentage to every rope.
Identify each rope by function, construction, nominal diameter, grade, lay, length and certificate/installation date.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forRope certificate, crane rope register and drum/reeving identification.Typical gapInspector records '16 mm rope' but not construction or function, making the discard table impossible to select.Escalate whenRope identity cannot be established.Source basisApplicable AS 1418/AS 2550 requirements, rope certificate and examination/discard standard such as ISO 4309 where applicable.Record measured diameter at repeatable locations and compare with the applicable discard basis.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forDiameter readings, locations, instrument and nominal/reference diameter.Typical gapOne reading is taken at the easiest point with no trend or local minimum search.Escalate whenDiameter reduction approaches/exceeds the applicable limit or is strongly localised.Source basisApplicable rope examination/discard standard, OEM and rope manufacturer criteria.Count broken wires over the reference lengths required by the applicable rope discard basis.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forBroken-wire map showing count, distribution, reference length and rope construction.Typical gapReport says 'three broken wires' without the length, location or whether breaks are clustered.Escalate whenCount/distribution approaches the applicable discard criterion or localised concentration is present.Source basisApplicable AS 2759/ISO 4309/OEM/rope-manufacturer discard criteria; exact limits depend on rope and function.Inspect for crown and valley breaks, corrosion/fretting, wear, waviness, kinks, birdcaging, crushing, heat damage and other deformation.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forClose photographs and condition map along the rope and at high-duty zones.Typical gapInspection focuses only on visible broken wires.Escalate whenAny severe deformation, heat damage or internal deterioration indication is found.Source basisRope examination/discard standards and manufacturer criteria.Inspect terminations, dead ends, sockets, wedges, clips and local high-stress zones separately.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forDetailed photographs, dimensions and condition record at each termination.Typical gapMain rope body is examined while the termination assembly is not dismantled or closely inspected where required.Escalate whenMovement, corrosion, broken wires or locking defects are found at a termination.Source basisApplicable crane/rope standards, manufacturer instructions and recent regulator incident guidance.Record the exact document and criterion used for the keep/monitor/discard decision.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forReport cites applicable edition/table/criterion, OEM or rope manufacturer instruction.Typical gapDecision says 'within standard' with no identified standard or rope category.Escalate whenNo valid discard basis can be matched to the rope.Source basisTraceable rope examination/discard decision practice.07
7. Check records, defects and return to service
An inspection program is only as strong as its defect history and close-out trail.
Keep complete pre-operational, routine, periodic/annual and major-inspection records as distinct tiers.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forIndexed crane history with report dates and next due actions.Typical gapA service invoice is treated as both routine maintenance and annual competent-person inspection.Escalate whenA required tier cannot be demonstrated.Source basisCrane regulator and safe-use inspection record framework.Link defects to restrictions, repairs, testing and authorised close-out.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forDefect register, work order, repair report and post-repair verification.Typical gapInspection findings disappear once a work order is raised.Escalate whenSafety-related defect remains open without explicit operating restrictions or competent-person acceptance.Source basisCrane defect-management and return-to-service requirements.Record overloads, collisions, severe duty, unusual vibration and other abnormal events in the crane history.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forIncident/event records and resulting inspection/assessment.Typical gapAn overload trip is reset without considering whether inspection scope or DWP assessment should change.Escalate whenEvent could have impaired structure, rope, mechanisms or safety devices.Source basisCondition- and event-responsive crane inspection principles.After major repair or modification, confirm the crane remains within its design limits and required verification/testing is complete.Escalation-sensitive
Add measurement, evidence or notes
Inspection guidance and source basis
Evidence to look forEngineering assessment, repair drawings, NDT, load/function tests and acceptance.Typical gapRepair restores appearance but not the original design detail or fatigue basis.Escalate whenLoad path, rated capacity, structural detail or safety function changed.Source basisAS 1418 design basis, AS 2550 safe-use requirements and regulator repair guidance.Overall notes
Record the final screening context
Note operating restrictions, missing documents, work orders, competent-person decisions or assumptions that affect the result.
Minimum useful attachment pack
The checklist is most useful when the evidence can travel with the request.
Five questions before you call it complete
1Can we show why this crane has this inspection schedule rather than a generic monthly/annual calendar?
2Does the annual/periodic inspection include accumulated duty and DWP assessment where applicable?
3Is the major-inspection trigger based on manufacturer design life, duty/condition and regulatory requirements rather than age alone?
4Can every wire-rope accept/discard decision be traced to the exact rope construction and applicable criterion?
5Do defects remain visible from first detection through repair, verification and return to service?
Common gaps and weak evidence
Daily/monthly/quarterly/annual tasks exist, but no one can show which AS 2550 part, OEM instruction or duty condition requires them.
A major inspection is completed and the next decade is assumed safe, despite component condition and more frequent inspection needs.
Accumulated-duty calculations are used to narrow scope even when manufacturer criteria require dismantling or examination.
Broken wires or diameter loss are judged against a remembered number without identifying rope construction, reference length or applicable discard basis.