Crane Maintenance Checklist Template - Free PDF

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Crane maintenance checklist

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Use this template with Lumiform

The Lumiform application helps frontline teams uphold internal standards effortlessly.

Customize this template or build your own
Fill out templates via mobile app
Assign and track corrective actions
Get reports and analyse your data

Prices start from ░░░ per month

Book a demo

Learn more

The crane maintenance checklist helps you systematically inspect and maintain all critical crane components to prevent equipment failures and ensure workplace safety. This comprehensive template covers structural elements, mechanical systems, electrical components, and safety devices—addressing the specific requirements outlined by OSHA standards.

When your team identifies a worn wire rope during a routine inspection using this checklist, you can immediately tag the equipment out of service and schedule repairs before a catastrophic failure occurs. According to the Bureau of Labor Statistics, crane-related accidents cause over 70 fatalities annually in the US, making regular maintenance not just a regulatory requirement but a critical safety practice.

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Preview of the template

Page 1

General Inspection

Crane model and serial number

Date of inspection

Operator name

Any visible damage or wear?

Comments on visible damage or wear

Structural Inspection

Check boom, jib, and mast for cracks, bending, or other damage

Comments on boom, jib, and mast condition

Check all structural connections and bolts

Comments on structural connections and bolts

Check for excessive wear on pivot pins and bearings

Comments on pivot pins and bearings condition

Mechanical Inspection

Check all hydraulic hoses and fittings for leaks

Comments on hydraulic system condition

Check all wire ropes for wear, kinking, or damage

Comments on wire rope condition

Check all sheaves and pulleys for wear and proper lubrication

Comments on sheaves and pulleys condition

Safety Systems

Check all safety devices (e.g. limit switches, anti-two block, etc.)

Comments on safety device condition

Check emergency stop button/switch

Comments on emergency stop condition

Check all warning labels and placards

Comments on warning labels and placards

Electrical Inspection

Check all electrical connections and wiring

Comments on electrical connections and wiring

Check functionality of all instruments and indicators

Comments on instrument and indicator condition

Check battery and charging system

Comments on battery and charging system

Frequently asked questions

How often should different parts of a crane be inspected according to regulations?

OSHA classifies crane inspections as “frequent” (daily to monthly) and “periodic” (1-12 months). Daily inspections cover operating mechanisms, while monthly checks examine components like hydraulic systems and hooks. Periodic inspections assess overall wear on parts like sheaves and brakes. Cranes in normal service require less frequent inspections than those in heavy or severe service conditions.

What documentation should I maintain with my crane maintenance checklist?

Maintain comprehensive records of all inspections including dates, inspector names, identified issues, and corrective actions taken. Document both frequent and periodic inspections, load tests, and any repairs or modifications. Keep equipment specifications, manufacturer guidelines, and operator certifications. These records demonstrate regulatory compliance and provide valuable maintenance history during audits or investigations.

What should I do if I find a major issue during a crane inspection?

If you discover a major issue during inspection, stop using the crane immediately to avoid accidents. Report the issue to your maintenance team, document the problem with photos, and assign a repair task. Prioritize critical repairs, especially those related to safety, and schedule downtime for immediate fixes as needed.

What are the most critical safety components to check on a crane?

The most critical safety components include the braking system, wire ropes, hooks, load-bearing mechanisms, limit switches, and safety devices. Pay special attention to components that could fail catastrophically, such as load-sustaining structural elements and hoisting equipment. Also verify that warning devices, emergency controls, and operator protection systems function properly to prevent accidents.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.