Maintenance and modernization
In short: A good maintenance plan includes regular checks set according to how intensively the crane is used, a record of every job, critical spare parts kept ready and statutory inspections done on time. The aim is to prevent failures, not wait for them.
Maintenance and periodic inspection are not the same
Periodic inspection is the examination and reporting, by a competent person at defined intervals, of whether work equipment is safe to use. In Türkiye, under Occupational Health and Safety Law No. 6331 and the regulation on the safe use of work equipment, lifting equipment such as cranes must be inspected at the intervals set in the regulation (for cranes at least once a year). Other countries have similar statutory inspection requirements.
Maintenance is the lubrication, adjustment, cleaning, measurement and part replacement that keep the crane working safely. Inspection does not replace maintenance; a crane without regular maintenance can fail within months of passing an inspection.
What determines maintenance frequency?
- Duty class and intensity of use (see the duty class guide)
- Environment: dust, humidity, temperature, chemicals and outdoor use
- Age and history of the crane
- Manufacturer instructions for gearbox oil, brakes and rope criteria
As a rule of thumb, a thorough service every 3 months for cranes in normal one-shift use and monthly for intensive or heavy use is a good starting point.
Example maintenance plan
| Frequency | By | Main checks |
|---|---|---|
| Start of every shift | Operator | Test motions and brakes without load, upper limit, emergency stop, controls, warning; visible damage on rope and hook; obstacles on the runway |
| Weekly | Operator / maintenance | Rope lubrication and visual check, hook safety latch, pendant cable and radio remote batteries |
| Monthly | Maintenance team | Brake air gap and noise, limits tested under load, festoon system, visual check of wheels and buffers |
| Every 3 months | Maintenance team | Rope measurement (diameter, broken wires), hook opening and wear, gearbox oil level and leaks, brake lining, wheel flanges, bolted connections, panel and terminal tightness, overload test |
| Every 6 months | Maintenance team | Insulation measurements, motor and brake electrical checks, runway and rail alignment visual check, paint and corrosion |
| Annually | Competent person + maintenance | Documented periodic inspection, load tests, thorough mechanical and electrical examination, review of the maintenance plan |
This table is a template; adapt it to your crane’s use and the manufacturer’s instructions.
Rope, hook and wheels: the most often skipped checks
- Rope: broken wires, crushing, birdcaging, corrosion and diameter loss are measured and assessed against standards and manufacturer values. See steel core wire rope.
- Hook: increased throat opening, cracks, a working safety latch and free rotation of the hook block.
- Wheels: flange wear and irregular treads usually indicate runway misalignment; replacing wheels without fixing the cause does not solve the problem.
Why keep records?
Every maintenance job should be recorded with date, technician, findings, actions and replaced parts. Records support the employer at inspections and in accident investigations and reveal recurring faults. Paper forms get lost; digital crane records accessible by QR code on each crane make this much easier.
Spare parts and readiness
Where downtime is expensive, keeping critical parts in stock is part of the plan: brake linings and coils, contactors, limit switches, pendant or spare radio remote, fuses and rope. Which parts to stock follows from fault records and lead times. See crane spare parts.
General overhaul timing
Each mechanism has a safe working period determined by its duty class (FEM 9.755). If operating hours and loads are recorded, the used portion can be calculated; as it nears the limit the mechanism should be overhauled or replaced. Maintenance records and operating data are the soundest basis for this decision.
7 steps to set up the plan
- Inventory every crane: capacity, type, serial number, location, age, manufacturer.
- Define use: shifts, daily operating time, load intensity, environment.
- Mark critical cranes whose stoppage halts production.
- Assign intervals by adapting the table above.
- Prepare checklists so the same items are checked in the same order.
- Define responsibilities of operators, in-house team and external service.
- Review records at least annually and update the plan.
Is maintenance working?
| Indicator | What it shows |
|---|---|
| Unplanned failures | Falling numbers mean effective maintenance |
| Downtime per failure | Spare part readiness and response speed |
| Repeat failures | Root cause not solved |
| Planned jobs done on time | Feasibility of the plan |
| Non-conformities at periodic inspection | Whether the maintenance scope is sufficient |
Safety during maintenance
- Isolate the crane at the main switch, lock and tag it.
- Protect against collision if other cranes run on the same runway.
- Use suitable platforms, harnesses and anchor points when working at height.
- Never work under a suspended load or while slackening a loaded rope.
- Test all safety functions before returning the crane to service.
Outsourcing maintenance: what the contract should include
- Cranes covered and service frequency (e.g. quarterly, semi-annual, annual)
- Work performed at each service and the service report
- Response time for breakdowns
- How parts and consumables are charged
- How records and reports are delivered
See our periodic maintenance service.
Need support?
If you need help on site with the topics in this guide, the Aylen team is available 24/7. We inspect your crane, take measurements and provide recommendations in a written report. Quotation and service request form
FAQ
How often should a crane be serviced?
A thorough service every 3 months for normal one-shift use and monthly for intensive or heavy use is a good start; operator checks are done at the start of every shift.
Does a periodic inspection replace maintenance?
No. A periodic inspection examines and reports whether the equipment is safe to use; it does not replace lubrication, adjustment and part replacement.
How should maintenance records be kept?
Each job should be recorded with date, technician, findings, actions and replaced parts; QR-coded digital crane records make them instantly accessible on the crane.