OSHA Compliant Electric Hoist Inspection Checklist

This checklist will help you stay compliant with OSHA standards (primarily 1910.179) et, more importantly, keep your workplace safe.

Why Regular Hoist Inspections Are Non-Negotiable

Before we dive into the checklist, remember: failures of overhead lifting equipment can lead to catastrophic injury, property damage, and costly downtime. OSHA mandates three levels of inspection:

• 1. Daily/Pre-Use Inspection: A visual check performed by the operator at the start of each shift.
• 2. Frequent Inspection: Conducted monthly or as per manufacturer guidelines (often based on usage), by a designated competent person.
• 3. Periodic Inspection: Conducted annually or semi-annually, by a certified inspector.

The Ultimate Electric Hoist Inspection Checklist

Use this comprehensive checklist to guide your inspections. Always refer to the hoist’s manufacturer manual for specific requirements.

Pre-Use / Daily Visual Inspection (By the Operator)

• 1. Work Area: Check for clear, unobstructed paths and adequate lighting.
• 2. Controls: Test all functions (up, down, left, right) on the pendant control station. Ensure buttons are clearly labeled and work correctly without sticking.
• 3. Wire Rope/Chain:
  • (Wire Rope) Look for kinks, birdcaging, corrosion, broken wires, or significant wear.
  • (Chain) Look for stretching, twisting, cracks, gouges, or excessive wear on links.
• 4. Hook: Inspect for deformation, cracks, or throat opening. Ensure the safety latch is present, not damaged, and functions properly (springs back into place).
• 5. Load Block: Check for cracks, deformation, or other damage.
• 6. Limit Switches: Perform a functional test of the upper limit switch by raising the hook block to activate it (ensure it stops automatically).
• 7. General Condition: Look for obvious signs of damage, leaks (oil, grease), or loose/missing parts on the hoist body.

Action: If any defect is found, TAKE THE HOIST OUT OF SERVICE IMMEDIATELY and report it to a supervisor. Tag it with a “DO NOT OPERATE” label.

Frequent / Monthly Inspection (By a Competent Person)

Includes all items from the Daily Inspection, plus:

• 1. Bolts, Nuts, Rivets: Check for looseness or shearing.
• 2. Brakes: Test the holding brake by lifting a light load a short distance and checking for drift or creep.
• 3. Electrical Components: Look for signs of overheating, damaged wiring, or corrosion on connectors. Check for frayed cords on the pendant.
• 4. Lugging / Mounting: Ensure the hoist is securely mounted to its trolley or beam and that all hardware is tight.
• 5. Hook Rotation: Check that the hook swivels freely.
• 6. Labels: Verify all warnings and capacity labels are legible and present.

Periodic / Annual Inspection (By a Certified Inspector)

Includes all items from the Frequent Inspection, plus:

• 1. Load Test: Perform a formal load test to 125% of rated capacity (unless documented test exists) to verify structural integrity and brake performance.
• 2. Disassembly: Open gear covers to inspect gears for wear, pitting, or misalignment.
• 3. Internal Brakes: Inspect brake components for wear, proper adjustment, and contamination.
• 4. Electrical Systems: Thoroughly check contactors, relays, and overload protection for proper operation.
• 5. Wear Parts: Measure hook throat opening and rope/chain diameter to compare against manufacturer’s discard specifications.
• 6. Documentation: Record all findings in the inspection log. This is a critical OSHA requirement.

Documentation: Your Proof of Compliance

OSHA requires you to keep records of periodic inspections. Your log must include:

• 1. Date of inspection

• 2. Name and signature of the inspector

• 3. Serial number or identifier of the hoist

• 4. A record of any deficiencies found and corrective actions taken

A checklist is only effective if used consistently and correctly. Empower your operators to stop work if something seems wrong. Invest in training to ensure everyone understands the “why” behind these rules.

Disclaimer: This checklist is a general guide. Always prioritize the specific inspection procedures outlined by your hoist’s manufacturer and the latest OSHA regulations. When in doubt, consult with a qualified hoist inspector or service professional.