Vehicle loading cranes are fitted to service trucks, tyre handlers and field maintenance vehicles across every mine site, and are frequently the least-inspected lifting equipment in the fleet. The crane is only as sound as its mounting to the truck chassis, and knuckle and extension boom welds, slew columns and stabiliser legs all crack under repeated field service.
We inspect vehicle loading cranes to AS 2550.1 and AS 2550.11, including annual inspections, ten-year major inspections and post-installation inspections after a crane is fitted or moved to another truck.
Inspection checklist areas
- Boom, knuckle and extensions
- MT of main and knuckle boom welds, cylinder mounts and pivot bores, extension section wear pads and retention, pin and bush wear.
- Slew column and base
- Slew bearing or rack clearance, slew column welds, base frame welds, mounting bolts and torque evidence, sub-frame to chassis attachment and chassis reinforcement.
- Stabilisers
- Stabiliser beam and leg welds, extension locks and indication, pad condition, interlocks preventing operation without stabilisers deployed.
- Safety devices
- Rated capacity limiter or overload protection function and calibration, slew and boom limits, remote control emergency stop, stability system where fitted.
- Hydraulics
- Load-holding valves on lift and extension cylinders, hose condition and routing, PTO and pump, emergency lowering.
- Documentation
- Design registration for cranes of 10 metre-tonnes or more, log book, load charts and markings, previous inspection records.
Known failure modes
Boom and knuckle weld cracking
Fatigue at the knuckle joint, cylinder mounts and extension boom welds under repeated loading at reach.
Base mounting failure
Loose or fatigued mounting bolts, cracked sub-frame or chassis reinforcement, allowing the crane to separate from the truck.
Overturning
Operation without stabilisers fully deployed, on soft ground or with overload protection bypassed.
Uncontrolled boom lowering
Load-holding valve or hose failure on the lift cylinder circuit.
Slew column failure
Cracking of the slew column or rack housing under side-load.
Applicable standards and regulations
| Reference | Title | Relevance |
|---|---|---|
| AS 2550.1 | Cranes, hoists and winches — Safe use — General requirements | Inspection regime and records. |
| AS 2550.11 | Cranes, hoists and winches — Safe use — Vehicle loading cranes | Type-specific inspection and major inspection requirements. |
| AS 1418.11 | Cranes, hoists and winches — Vehicle loading cranes | Design basis, including stability and mounting requirements. |
| AS 1418.1 | Cranes, hoists and winches — General requirements | General design basis for structure and safety devices. |
| Model WHS Regulations, Schedule 5 | Plant requiring design and item registration | Vehicle loading cranes with a capacity of 10 metre-tonnes or more require design registration. |
Inspection intervals
- Annual inspection
- At intervals not exceeding 12 months by a competent person (AS 2550.1).
- Major inspection
- At ten years from manufacture under AS 2550.11, then at intervals determined by the competent person.
When to inspect
- Annual inspection due
- Crane reaching ten years of age
- After fitting to a new truck or chassis modification
- After overload, overturning or contact incident
- Before purchase or hire of a truck with a crane fitted
Frequently asked questions
Does the truck chassis form part of the crane inspection?
Yes. The sub-frame, chassis reinforcement and mounting bolts carry the crane's overturning moment into the truck and are inspected for cracking, deformation and bolt condition. A crane that has been moved between trucks needs a post-installation inspection.
Which vehicle loading cranes need design registration?
Under Schedule 5 of the model WHS Regulations, vehicle loading cranes with a capacity of 10 metre-tonnes or more require design registration. The inspection confirms whether registration applies and is held.
Is a remote-controlled crane inspected differently?
The remote control emergency stop, signal loss behaviour and control function are added to the scope. Otherwise the structure, stabilisers, safety devices and mounting are inspected in the same way.