Electric Hoist Inspection Checklist: Annual vs. Daily Self-Check
Periodic Inspection vs. Routine Self-Inspection Periodic inspection is a statutory requirement (performed by an approved inspection body every 2 years) that determines whether the equipment may remain in service. Routine self-inspection, on the other hand, is an internal practice organized by the user unit (daily, monthly, or annually). The two cannot replace each other. Annual inspections are carried out in accordance with Appendix A of TSG Q7015-2016 and cover six categories of inspection items: metal structure, hoisting mechanism, travel mechanism, safety devices, electrical system, and protective devices. All inspection records must be kept on file for review.
Many user units confuse periodic inspection with annual inspection, assuming that completing an annual check eliminates the need for a statutory periodic inspection—or that passing the periodic inspection exempts them from annual checks. Both assumptions are incorrect. Periodic inspection and routine self-inspection (which includes annual, monthly, and daily checks) are fundamentally different in nature, with distinct distinctions in legal effect, executing body, inspection interval, depth of examination, and consequences of non-compliance. This article systematically clarifies the differences and relationships between the two, based on TSG Q7015-2016 Rules for Periodic Inspection of Lifting Appliances and the Rules for the Management of Special Equipment Use (TSG 08-2017).
1. Key Differences Between the Three Inspection Types
Periodic Inspection: Conducted by an approved special equipment inspection body every 2 years. The inspection includes a 125% static load test and a 110% dynamic load test, along with functional verification of all safety devices. Upon successful completion, a legally binding Periodic Inspection Report for Lifting Appliances is issued. The inspection conclusion determines whether the equipment may continue operating—equipment that fails must be taken out of service and rectified, or the user unit faces legal liability. Periodic inspection is the "legal health check."
Annual Inspection: Performed by the user unit's safety management personnel or an authorized maintenance contractor, once per year. The inspection covers the visual condition of the metal structure, functional testing of safety devices, wear on key components, and the condition of the electrical system. Results are recorded in the Annual Inspection Record for Lifting Appliances and kept on file. Equipment that fails the annual inspection must also be taken out of service, but the inspection itself carries no statutory enforcement power—it is primarily a safety management responsibility of the user unit.
Monthly/Daily Inspection: Performed by the operator, either daily or monthly. Daily inspections are conducted before the equipment is started, focusing on safety-critical components such as the brake, limit switch, wire rope, and emergency stop button. Monthly inspections are more comprehensive and are led by the equipment supervisor. Any issues found during routine inspections must be rectified immediately; major hazards must be reported to the safety officer and the equipment must be taken out of service.
2. Annual Inspection Items Explained
Annual inspections are carried out in accordance with Appendix A of TSG Q7015-2016, covering 27 items across 6 categories: I. Visual quality inspection (corrosion/deformation/cracks in the metal structure, weld seam appearance, anti-corrosion coating); II. Safety device inspection (functional testing of limit switches, overload limiter, anti-collision device, and emergency stop button); III. Key component inspection (wire rope wear, wire breaks, diameter reduction, brake clearance/friction lining, pulley wear, crane wheel wear); IV. Electrical system inspection (insulation resistance ≥1MΩ, grounding resistance ≤4Ω, cable condition); V. Protective device inspection (walkway guardrails, toe boards, warning signs); VI. Operational inspection (no-load test run of all mechanisms).
3. Inspection Comparison Table
| Aspect | Periodic Inspection | Annual Inspection | Monthly/Daily Inspection |
|---|---|---|---|
| Executing Body | Approved special equipment inspection body | User unit safety personnel or authorized maintenance contractor | Operator (daily); equipment supervisor (monthly) |
| Inspection Interval | Every 2 years | Once per year | Daily before startup; monthly comprehensive check |
| Legal Effect | Legally binding; determines continued use | No statutory enforcement; internal safety management responsibility | No statutory enforcement; operational safety practice |
| Inspection Content | 125% static load test, 110% dynamic load test, functional verification of all safety devices | Metal structure appearance, safety device function, component wear, electrical system condition (27 items in 6 categories per TSG Q7015-2016 Appendix A) | Brake, limit switch, wire rope, emergency stop button (daily); broader mechanism checks (monthly) |
| Consequence of Failure | Equipment must cease use; rectification required before re-inspection | Equipment must cease use; rectification required | Immediate rectification; major hazards reported and equipment taken out of service |
| Documentation | Periodic Inspection Report (legally binding) | Annual Inspection Record kept on file | Inspection records kept on file |
| Item | periodic inspection | annual inspection | Monthlyinspection |
|---|---|---|---|
| Executing Entity | inspection body | user unit/Maintenance Unit | operator/Equipment Supervisor |
| Frequency | Per2Year | Annually | Daily/Monthly |
| legal effect | Yes(Statutory) | No(Archived for Reference) | No(Archived for Reference) |
| load test | 125%static load+110%dynamic load | 100%rated load | No-load |
| Reporting Format | Formalinspection report | inspection records Form | Daily Record Log |
Electric Hoist FAQ: Inspection & Maintenance
Q: How often should an electric hoist be self-inspected?
A: Once an electric hoist is installed on a crane, the user unit must carry out daily inspections (visual checks before each shift plus monthly functional tests), annual inspections (once per year, performed by safety management personnel or a maintenance contractor, item-by-item per TSG Q7015-2016 Appendix A), and periodic inspections (every 2 years, performed by an inspection body). Daily and annual inspections do not replace the periodic inspection, but combining them significantly reduces the risk of failing the periodic inspection. Kelude offers annual inspection training services for customers.
Q: How should an electric hoist be maintained?
A: Electric hoist maintenance is organized into five levels: shift maintenance (cleaning + visual inspection), weekly maintenance (brake gap adjustment + wire rope lubrication + crane rail bolt tightening), monthly maintenance (gearbox oil level check + motor bearing greasing + electric control cabinet dusting), quarterly maintenance (radiator cleaning + limit switch accuracy verification), and annual maintenance (gearbox oil replacement + weld inspection + main girder deflection measurement). Annual maintenance should be scheduled to coincide with the periodic inspection.
Q: What does an electric hoist annual inspection cover?
A: The annual inspection (periodic inspection) is performed on-site by an inspection body and covers: ① Technical documentation review — verifying the inspection report, maintenance records, and usage logs; ② Metal structure — camber of main girder L/1000~L/800, end carriage diagonal difference, and weld seam appearance; ③ Hoisting mechanism — brake gap 0.5~1.5mm, brake slip distance S≤v/100, wire rope wear and wire break; ④ Safety devices — functional testing of limit switches, overload limiter, and emergency stop button; ⑤ Electrical system — insulation resistance ≥1MΩ, grounding resistance ≤4Ω; ⑥ Load test at 100% rated load over the full lifting stroke.
Q: What is the difference between the annual inspection and routine self-inspection?
A: The annual inspection (periodic inspection) is a legally mandated examination carried out by a certified inspection body every 2 years. It produces a formal report, and any non-conformities must be rectified within 30 days. Routine self-inspection, on the other hand, is an internal maintenance duty organized by the user unit, including visual checks before each shift, monthly functional tests, and an annual inspection, with records kept on file for review. The key differences: the annual inspection is a regulatory enforcement action, while self-inspection is a safety management obligation; equipment that fails the annual inspection can be ordered out of service, whereas issues found during self-inspection can be addressed by the user unit's own maintenance team.
Kelude offers annual inspection training services to help user units establish a standardized daily inspection routine. Refer to the earlier article Which Electric Hoists Require Mandatory Inspection to determine whether your equipment falls under special equipment regulation.
