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How Often Should an Overhead Crane Be Serviced?

Author:
Granada Cranes
Crane Servicing & Maintenance

One of the most common questions we receive at Granada Cranes is about service frequency. How often should you service your overhead crane? What’s the legal minimum? And what do we actually recommend for safe, reliable operation?

The answer depends on several factors – but let’s start with the essentials you need to know.

Quick Answer
Under UK law (LOLER), overhead cranes must have a thorough examination at least every 12 months. Lifting accessories (chains, slings, shackles) require examination every 6 months. However, for optimal safety and reliability, we recommend servicing every 6–12 months depending on usage.

Keep reading to understand the difference between legal requirements and best practice maintenance.

Understanding the Legal Requirements

In the UK, overhead crane maintenance and inspection is governed primarily by two regulations:

  • LOLER – Lifting Operations and Lifting Equipment Regulations 1998
  • PUWER – Provision and Use of Work Equipment Regulations 1998

LOLER sets out the requirements for thorough examination of lifting equipment, while PUWER requires that all work equipment is maintained in safe working order. Together, they establish your legal obligations as an employer or equipment owner.

LOLER Thorough Examination Requirements

Equipment Type Examination Frequency Examples
Lifting equipment (not for lifting people) Every 12 months Overhead cranes, hoists, runway beams
Lifting accessories Every 6 months Chain slings, wire rope slings, shackles, hooks, eyebolts, lifting beams
Equipment for lifting people Every 6 months Man-riding baskets, access platforms
After installation or relocation Before first use New installations, cranes moved between sites
Important Distinction

A LOLER thorough examination is a legal inspection, not a service. It checks whether equipment is safe to use—it doesn’t include maintenance tasks like lubrication, adjustment, or preventive repairs. You need both: regular servicing and thorough examinations.

Thorough Examination vs Preventive Maintenance

Many crane owners confuse thorough examination with servicing. They’re related but serve different purposes:

Aspect Thorough Examination Preventive Maintenance Service
Purpose Assess safety and identify defects Maintain condition and prevent failures
Legal requirement? Yes (LOLER) Yes (PUWER requires maintenance)
Frequency specified? Yes (6 or 12 months) No – “as necessary”
What happens Inspection and report Inspection, lubrication, adjustments, minor repairs
Output Report of Thorough Examination Service report with recommendations
Who does it? Competent person (often insurance engineer or specialist) Crane service engineer

Think of it like your car: the MOT (thorough examination) confirms it’s roadworthy at a point in time, but regular servicing keeps it running reliably between MOTs.

Recommended Service Frequency

While LOLER sets minimum examination intervals, the ideal service frequency depends on how your crane is used. A crane sitting idle in a maintenance bay has very different needs to one running continuous shifts in a steel foundry.

Legal Minimum

12 Months
Thorough Examination

Required by LOLER for all overhead cranes. This is an inspection, not a service – it identifies defects but doesn’t prevent them.

Best Practice

6–12 Months
Preventive Service

Includes lubrication, brake adjustment, limit testing, and visual inspection. Frequency depends on duty cycle and environment.

6 Months
Accessory Examination

Legal requirement for all lifting accessories – chains, slings, shackles, hooks, and below-the-hook equipment.

Daily
Pre-Use Checks

Visual checks by the operator before each shift. Quick but essential for catching obvious issues early.

Service Frequency by Duty Cycle

The FEM/ISO duty classification of your crane is a good indicator of how often it should be serviced:

Duty Class Typical Use Recommended Service Interval
M3–M4 (Light) Occasional use, maintenance tasks, light workshops Annually (combined with LOLER)
M5 (Medium) Regular use, general manufacturing, warehousing Every 6–12 months
M6 (Heavy) Intensive use, steel fabrication, foundries Every 6 months
M7–M8 (Very Heavy) Continuous severe service, steel mills Quarterly or more frequent
Environment Matters Too

Cranes operating in harsh environments – dusty, humid, corrosive, or extreme temperatures – typically need more frequent servicing regardless of duty cycle. A lightly used crane in a coastal facility may need more attention than a busy crane in a clean, dry workshop.

What Does a Crane Service Include?

A comprehensive preventive maintenance service covers far more than a visual check. Here’s what our engineers typically inspect and maintain:

Hoist Unit

Brake adjustment, rope condition, drum inspection, gearbox oil, motor checks, limit switches

Crane Motions

Cross-travel and long-travel motors, brakes, wheels, gearboxes, drive alignment

Electrical Systems

Contactors, pendant controls, radio controls, festoon/conductor systems, isolators

Safety Devices

Overload limiter calibration, limit switches, emergency stops, warning devices

Structural Components

Bridge girders, end carriages, runway beams, supporting structure, bolted connections

Hook & Block

Hook wear and deformation, safety catch, swivel bearing, sheave condition

What Gets Lubricated

Proper lubrication is essential for crane longevity. During a service, we typically lubricate:

  • Wire rope (where applicable)
  • Wheel bearings
  • Gearbox oil top-up or change
  • Hook swivel bearing
  • Guide rollers and trolley wheels
  • Any grease points on the structure

The Complete Maintenance Schedule

A well-maintained crane requires attention at multiple intervals. Here’s a practical schedule:

  • Daily / Each Shift
    Pre-Use Operator Checks

    Visual inspection of hook, rope/chain, controls, warning devices. Listen for unusual noises. Test brakes. Check the area is clear. Takes 2–5 minutes.

  • Weekly / Monthly
    Routine Inspections

    More detailed visual checks by trained personnel. Inspect rope for wear, check oil levels, look for loose fixings, test all motions. Document any concerns.

  • 6–12 Months
    Preventive Maintenance Service

    Comprehensive service by qualified engineer. Includes lubrication, brake adjustment, electrical checks, safety device testing, and detailed inspection. Service report provided.

  • 6 Months
    Lifting Accessory Examination

    LOLER thorough examination of all slings, chains, shackles, hooks, and below-the-hook equipment. Legal requirement.

  • 12 Months
    Crane Thorough Examination

    LOLER thorough examination of the complete crane system. Statutory Report of Thorough Examination issued. Legal requirement.

Daily Pre-Use Checks: What Operators Should Do

Daily checks by the crane operator are your first line of defence against problems. They take just a few minutes but can prevent accidents and catch issues early.

Daily Operator Checklist
  • Check the hook for wear, cracks, or deformation—and ensure the safety catch works
  • Inspect wire rope or chain for visible damage, kinks, or bird-caging
  • Test all controls function correctly (up, down, travel motions)
  • Check brakes hold when tested under light load
  • Listen for unusual noises during operation
  • Verify warning devices (horn, lights) are working
  • Check the runway and travel path are clear of obstructions
  • Ensure emergency stop is accessible and functional
  • Report any concerns to your supervisor immediately
Stop If You Find a Problem

If a daily check reveals any issue—unusual noise, sticking controls, rope damage, or anything else concerning – stop using the crane and report it. Don’t assume it will be fine. What seems minor can quickly become dangerous or lead to a costly breakdown.

Benefits of Regular Servicing

Beyond legal compliance, there are compelling business reasons to maintain a proper service schedule:

Why Regular Service Pays Off
  • Reduced downtime: Planned maintenance prevents unexpected breakdowns that halt production
  • Lower repair costs: Catching problems early avoids expensive emergency repairs
  • Extended lifespan: A well-maintained crane lasts significantly longer than a neglected one
  • Safer operation: Regular checks catch wear before it becomes dangerous
  • Insurance compliance: Many policies require evidence of regular maintenance
  • Better performance: Properly adjusted brakes and drives operate more smoothly and precisely

The cost of a planned service visit is typically a fraction of an emergency callout – and nothing compared to the production losses when a crane is out of action unexpectedly.

What Happens If You Don’t Service Your Crane?

Neglecting crane maintenance doesn’t just risk breakdowns – it has serious legal and safety implications:

  • HSE enforcement: The Health and Safety Executive can issue improvement notices, prohibition notices, or prosecute for LOLER/PUWER breaches
  • Insurance issues: Claims may be rejected if maintenance records are inadequate
  • Accelerated wear: Components wear faster without proper lubrication and adjustment
  • Cascading failures: One worn component puts stress on others, causing multiple failures
  • Safety incidents: Undetected defects can lead to dropped loads or crane failures
  • Unexpected downtime: Breakdowns always happen at the worst possible time
The Real Cost of Neglect

We’ve seen cranes that were “fine” according to their owners need complete hoist rebuilds because worn brakes went unadjusted for years. The repair cost was 10x what regular servicing would have been – plus weeks of lost production while parts were sourced.

Granada Cranes Service Packages

We offer flexible service arrangements to suit different needs:

  • Planned Preventive Maintenance (PPM): Scheduled service visits at agreed intervals, typically combined with LOLER examinations for efficiency
  • LOLER Thorough Examinations: Statutory inspections by our competent engineers, with Reports of Thorough Examination issued
  • Reactive Repairs: Callout service for breakdowns and urgent repairs
  • 24/7 Breakdown Cover: Priority response for service contract customers

Most customers find that combining their annual service with their LOLER examination provides the best value – one visit covers both requirements, minimising disruption and cost.

Need Your Crane Serviced?

Our service engineers cover the whole of the UK. Whether you need a one-off service, LOLER examination, or ongoing maintenance contract, we can help.

Request a Service Quote

Or call us on 0800 376 27 27

Frequently Asked Questions

What’s the legal minimum for crane inspections in the UK?

Under LOLER, overhead cranes must have a thorough examination by a competent person at least every 12 months. Lifting accessories (chains, slings, etc.) require examination every 6 months. These are legal minimums – you may need more frequent attention depending on usage.

Can I do crane maintenance myself?

Daily pre-use checks should be done by trained operators. However, preventive maintenance and thorough examinations must be carried out by competent persons with appropriate training and experience. For complex systems like overhead cranes, this typically means specialist crane engineers.

What’s the difference between a service and a LOLER inspection?

A LOLER thorough examination is a safety inspection that assesses whether equipment is safe to use and identifies defects. A service includes maintenance tasks – lubrication, brake adjustment, testing, and minor repairs – that keep the crane in good working order. You need both.

How much does crane servicing cost?

Costs vary depending on crane size, complexity, location, and the scope of work needed. A straightforward service on a small single-girder crane might be a few hundred pounds; larger or more complex systems cost more. We provide fixed quotes before any work begins – contact us for a specific price.

What records do I need to keep?

You must keep Reports of Thorough Examination until the next report is issued (or for 2 years for accessories). We recommend also keeping service reports, daily check records, and any repair documentation for the life of the equipment. These demonstrate compliance and help track the crane’s history.

My crane is rarely used – does it still need annual inspection?

Yes. LOLER requires thorough examination regardless of how often equipment is used. In fact, infrequently used cranes can develop issues from standing idle – seized brakes, corroded components, or deteriorated lubricants. A pre-use inspection is also required if the crane has been out of service for an extended period.

What happens if a defect is found during inspection?

If a thorough examination identifies a defect that poses an immediate danger, the competent person must notify the employer and the HSE immediately. The crane cannot be used until the defect is rectified. Less urgent defects will be noted in the report with recommended timescales for repair.

Can you service cranes from other manufacturers?

Yes. Granada Cranes services all makes and models of overhead crane, not just those we’ve supplied. Our engineers are experienced with equipment from all major manufacturers and can source parts for most systems.

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