A detailed ELECTRIC HOIST MONTHLY preventive maintenance checklists
1. Safety Precautions
2. Visual Inspection
- Check for dents, scratches, or deformation.
- Look for any loose or missing components.
- Assess overall condition and functionality.
- Inspect welds and joints for integrity.
- Look for rust or paint peeling.
- Ensure structural components are secure.
- Check for signs of bending or twisting.
- Inspect hook latch functionality.
- Verify marking and load rating are visible.
- Look for broken strands in wire rope.
- Check for rust or discoloration on chain.
- Ensure proper lubrication is present.
- Check for fading or damage to decals.
- Verify compliance with safety regulations.
- Ensure placement is within operator's view.
- Look for exposed wires or insulation damage.
- Check connectors for corrosion or looseness.
- Ensure cables are properly secured and routed.
- Inspect for physical obstructions around switches.
- Test switch operation to confirm functionality.
- Ensure alignment with operational limits.
- Check buttons for responsiveness and damage.
- Inspect cord for fraying or breaks.
- Verify labeling is clear and intact.
- Check for oil leaks around seals.
- Inspect gearbox for unusual noises.
- Ensure motor mounting is secure.
- Check torque on critical fasteners.
- Inspect for signs of rust or degradation.
- Ensure no components are loose.
- Check connectors for oxidation or wear.
- Inspect circuit boards for corrosion.
- Ensure all electrical components are dry.
- Check for wear on pulley grooves.
- Inspect alignment with lifting mechanism.
- Ensure proper lubrication is applied.
- Inspect for rust or corrosion.
- Verify tightness of mounts and brackets.
- Check for any signs of structural failure.
- Check brake pads for thickness.
- Test braking functionality with load.
- Inspect for fluid leaks in hydraulic systems.
- Test emergency stop button operation.
- Verify visibility and accessibility.
- Inspect wiring for damage or wear.
- Check surrounding area for obstruction.
- Ensure floor is clean and clear.
- Verify that safety zones are established.
3. Mechanical Components
- Test brake engagement and release.
- Listen for unusual sounds during operation.
- Check for smooth operation without slipping.
- Inspect brake pads for wear.
- Ensure brake lever functions correctly.
- Check for signs of wear on gears.
- Ensure proper lubrication is applied.
- Inspect for any unusual noises.
- Look for loose or missing components.
- Verify that gears mesh correctly.
- Test limit switch activation points.
- Check that limit switches stop hoist correctly.
- Inspect wiring for wear or damage.
- Confirm safety devices are operational.
- Document any discrepancies noted.
- Inspect trolley wheels for wear or damage.
- Check for smooth movement along the rails.
- Lubricate wheels and rails as necessary.
- Look for debris obstructing movement.
- Ensure alignment is correct.
- Test brake engagement and release.
- Listen for unusual sounds during operation.
- Check for smooth operation without slipping.
- Inspect brake pads for wear.
- Ensure brake lever functions correctly.
- Check for signs of wear on gears.
- Ensure proper lubrication is applied.
- Inspect for any unusual noises.
- Look for loose or missing components.
- Verify that gears mesh correctly.
- Test limit switch activation points.
- Check that limit switches stop hoist correctly.
- Inspect wiring for wear or damage.
- Confirm safety devices are operational.
- Document any discrepancies noted.
- Inspect trolley wheels for wear or damage.
- Check for smooth movement along the rails.
- Lubricate wheels and rails as necessary.
- Look for debris obstructing movement.
- Ensure alignment is correct.
4. Electrical Components
- Check all terminals for secure connections.
- Look for discoloration or melted insulation.
- Use a torque wrench to ensure proper tightness.
- Document any loose or damaged connections.
- Inspect the cable for cuts, frays, or abrasions.
- Check for signs of exposure to heat or chemicals.
- Ensure there are no kinks or sharp bends.
- Document any damage and schedule replacement if needed.
- Activate each switch to confirm operation.
- Check for any sticky or unresponsive controls.
- Inspect the pendant for damage or wear.
- Document any switches that require attention.
- Listen for any grinding or rattling sounds.
- Check for excessive vibration during operation.
- Inspect motor mounts for stability.
- Document any irregularities and schedule repairs.
- Check all terminals for secure connections.
- Look for discoloration or melted insulation.
- Use a torque wrench to ensure proper tightness.
- Document any loose or damaged connections.
- Inspect the cable for cuts, frays, or abrasions.
- Check for signs of exposure to heat or chemicals.
- Ensure there are no kinks or sharp bends.
- Document any damage and schedule replacement if needed.
- Activate each switch to confirm operation.
- Check for any sticky or unresponsive controls.
- Inspect the pendant for damage or wear.
- Document any switches that require attention.
- Listen for any grinding or rattling sounds.
- Check for excessive vibration during operation.
- Inspect motor mounts for stability.
- Document any irregularities and schedule repairs.
- Test each breaker by toggling it on and off.
- Check for signs of tripping or failure.
- Ensure the breakers are correctly labeled.
- Document any breakers needing replacement.
- Check each fuse for visual signs of damage.
- Use a multimeter to test functionality.
- Replace any blown fuses with the correct rating.
- Document any fuse replacements.
- Inspect grounding connections for corrosion or damage.
- Use a multimeter to test grounding continuity.
- Ensure grounding meets local electrical codes.
- Document grounding status.
- Activate the emergency stop to verify it halts operation.
- Check that the system resets after release.
- Inspect the wiring to the emergency stop switch.
- Document any issues found.
- Test each limit switch for correct engagement.
- Adjust the position if they are misaligned.
- Inspect for wear or mechanical damage.
- Document any adjustments made.
- Check the panel for rust or corrosion.
- Inspect seals and gaskets for moisture intrusion.
- Ensure all components are clean and secure.
- Document any signs of corrosion.
- Test each indicator light for proper illumination.
- Replace any burnt-out bulbs with compatible types.
- Check for loose connections behind the panel.
- Document any lights that require replacement.
- Inspect all wiring for wear or damage.
- Look for exposed conductors that need insulation.
- Ensure all wires are properly routed and secured.
- Document any frayed wires.
- Simulate an overload condition to test the device.
- Check that it trips appropriately.
- Inspect for signs of wear or damage.
- Document any failures or required adjustments.
- Compare current schematics with previous versions.
- Note any changes or updates that need to be documented.
- Ensure all components are correctly represented.
- Document any discrepancies found.
5. Operational Test
- Attach a load that matches the rated capacity.
- Lift the load to the maximum height.
- Lower the load to the ground smoothly.
- Observe for any abnormal operation during the test.
- Engage the hoist at normal operating speed.
- Activate the emergency stop switch.
- Ensure the hoist stops immediately.
- Reset the emergency stop and check for normal operation.
- Operate the hoist in the upward direction.
- Operate the hoist in the downward direction.
- Test the trolley movement side to side.
- Check for smooth operation without hesitation.
- Attach a calibrated load to the hoist.
- Gradually lift the load to the rated capacity.
- Lower the load smoothly to the ground.
- Observe for any signs of strain or malfunction.
- Document the test results.
- Activate the hoist to a mid-range position.
- Press the emergency stop button immediately.
- Verify that all hoist functions cease instantly.
- Release the emergency stop and resume normal operation.
- Ensure the button resets properly.
- Operate the hoist to lift and lower a test weight.
- Move the trolley back and forth across its full range.
- Check for smoothness and responsiveness of each movement.
- Listen for any abnormal sounds during operation.
- Document any irregularities encountered.
- Manually raise the hoist to its upper limit.
- Confirm that the hoist stops automatically.
- Lower the hoist to its lower limit.
- Ensure it stops without exceeding the limit.
- Test both limits multiple times for reliability.
- Test each button on the pendant or remote.
- Observe the response of the hoist to each command.
- Check for any sticky or unresponsive buttons.
- Ensure clear communication between control and hoist.
- Document any faults or issues.
- Operate the hoist under normal load conditions.
- Listen for grinding, squealing, or rattling sounds.
- Feel for any excessive vibrations in the structure.
- Check for loose components or wear.
- Report any findings for further investigation.
- Lift a load to assess smooth operation.
- Evaluate the acceleration and deceleration.
- Check for consistent lifting speed.
- Ensure no stalling occurs during operation.
- Document the performance observations.
- Lift a test load and hold it for a few seconds.
- Release the control to simulate a power loss.
- Observe if the load remains suspended.
- Check for any slipping or descending of the load.
- Report any brake failures immediately.
- Gradually increase the load to the threshold limit.
- Observe if the hoist stops or alerts upon overload.
- Check for any warning indicators or alarms.
- Test the reset function of the protection device.
- Document the findings.
- Inspect the alignment of the hoist with the load.
- Ensure slings and hooks are properly positioned.
- Check for any twisting or misalignment during operation.
- Adjust as necessary to achieve optimal alignment.
- Document any discrepancies.
6. Lubrication and Maintenance
- Identify all moving parts.
- Select appropriate lubricant based on specifications.
- Apply lubricant evenly to each part.
- Avoid over-lubrication to prevent excess buildup.
- Ensure lubrication reaches all critical areas.
- Inspect gearbox lubricant levels.
- Use a dipstick or sight glass to check levels.
- Refer to manufacturer guidelines for lubricant type.
- Refill with recommended lubricant if low.
- Seal the gearbox securely after refilling.
- Locate all filters within the system.
- Inspect filters for signs of clogging or damage.
- Follow manufacturer guidelines for replacement frequency.
- Replace with OEM filters for compatibility.
- Dispose of old filters according to local regulations.
- Identify all designated lubrication points.
- Ensure that grease fittings are free from debris.
- Check for smooth operation without obstructions.
- Clear any blockages found during inspection.
- Document any issues for follow-up.
- Use a clean cloth or solvent for cleanup.
- Wipe down surfaces around lubrication points.
- Ensure no residue is left that could attract dirt.
- Inspect for any leaks that may have caused excess.
- Maintain cleanliness as part of routine check.
- Inspect each lubrication fitting for accessibility.
- Check for signs of wear or damage.
- Ensure that fittings are not obstructed.
- Replace any damaged fittings immediately.
- Confirm that fittings can be easily serviced.
- Inspect lubricant color and texture.
- Conduct a smell test for unusual odors.
- Use a sample for lab analysis if necessary.
- Replace any lubricant that appears degraded.
- Follow disposal guidelines for contaminated lubricants.
- Inspect seals and gaskets for wear or damage.
- Check for signs of leakage around joints.
- Replace any compromised seals immediately.
- Use manufacturer-approved replacements.
- Document any repairs made for future reference.
- Check bearings for smooth rotation.
- Listen for unusual noises indicating wear.
- Inspect for proper lubricant presence.
- Replace any bearings showing significant wear.
- Follow manufacturer guidelines for bearing specifications.
- Keep a log of lubricant types and quantities used.
- Record dates and conditions of lubricant application.
- Analyze trends for excessive usage or issues.
- Maintain logs in a centralized system.
- Review logs during each maintenance session.
- Review the manufacturer's lubrication schedule.
- Adjust schedules based on operational usage patterns.
- Document any changes made to the schedule.
- Communicate schedule to all relevant personnel.
- Ensure compliance with adjusted lubrication intervals.
- Check temperature gauges and indicators.
- Inspect lubrication lines for heat damage.
- Identify any sources of overheating.
- Implement corrective actions to resolve issues.
- Document findings and remedial actions taken.
- Select appropriate rust inhibitor or coating.
- Clean surfaces thoroughly before application.
- Apply evenly to all exposed metal areas.
- Follow drying times and manufacturer instructions.
- Re-inspect periodically for effectiveness.
Use in Manifestly