What should a hoist inspection checklist cover?

A hoist inspection checklist should cover the load chain or wire rope (wear, elongation, lubrication, terminations), hook and block (latch, throat opening, twist, wear), brakes and clutch (holding test, adjustment, wear indicators), limit switches and controls (upper and lower limits, pendant or remote controls, emergency stop), electrical components (power supply, wiring, motor condition), and structural items (frame, mounting bolts, trolley, beam clamps, load rating plate). The checklist confirms the hoist is safe to operate before each use.

How often should a hoist be inspected?

Hoists should receive a visual inspection before each use or shift. Monthly inspections should cover deeper items such as brake adjustment, chain or wire rope measurement, and limit switch testing. Annual inspections, often called thorough examinations, should be performed by a competent person in accordance with AS 1418 and AS 2550. High-use hoists or those in harsh environments may require more frequent inspections. Follow the manufacturer recommendations and your site requirements.

Who can inspect a hoist?

Daily pre-use visual inspections can be completed by any trained and competent operator. Monthly and periodic inspections should be conducted by a competent person with knowledge of hoist mechanics and relevant Australian Standards (AS 1418, AS 2550). Annual thorough examinations are typically done by qualified inspectors or engineers. Always check your state or territory WHS requirements for specific competency obligations.

What are common hoist defects that require immediate action?

Common defects that require immediate removal from service include chain elongation exceeding the manufacturer discard criteria (typically 3% to 5%), hook throat opening beyond the rejection limit, hook twist exceeding 10 degrees, brake slippage or failure to hold a load, non-functional limit switches, cracked or damaged load-bearing components, and an illegible or missing safe working load plate. Any of these defects can lead to dropped loads and must be rectified before the hoist is returned to service.

Is this hoist inspection checklist free to download?

Yes, this hoist inspection checklist is completely free to download as a PDF. No account or signup is required. For teams wanting to move beyond paper forms, MapTrack offers a digital version that automates scheduling, sends overdue alerts, and stores completed records in the cloud for instant retrieval during audits.

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Free hoist inspection checklist (PDF-ready). Covers chain or wire rope, hooks, brakes, limit switches, controls and load rating. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

Also see:Compliance and inspections →Best inspection software →MapTrack vs SafetyCulture →

Updated 3 May 2026

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What is a hoist inspection checklist?

A hoist inspection checklist is a structured form used to inspect a chain hoist, wire rope hoist or electric hoist before it is used for lifting. It covers the load chain or wire rope, hook and block assembly, brakes and clutch, limit switches and controls, electrical components, and structural items including the frame, trolley and beam clamps. Hoists are used across construction, manufacturing, warehousing and maintenance operations. A thorough inspection helps confirm the hoist is safe, identifies chain wear, hook deformation or brake faults before they cause dropped loads, and provides documented evidence of compliance with Australian Standards (AS 1418 and AS 2550) and WHS regulations.

Hoist failures can result in dropped loads, serious injury or fatality, and significant property damage. Regular inspections are required under Australian WHS legislation and the relevant standards to ensure hoists remain safe for their rated capacity. The inspection follows a tiered approach: a visual check before each use or shift, a more detailed monthly inspection covering mechanical and electrical components, and an annual thorough examination by a competent person. Documented inspection records provide an audit trail for safety regulators, insurers and site safety audits, and demonstrate that the organisation is meeting its duty of care obligations for lifting equipment.

Learn more about compliance and inspections in MapTrack.

Benefits of using this hoist inspection checklist

Load safety: verify chain or wire rope condition, hook integrity and brakes before lifting loads.
Dropped load prevention: catch chain elongation, hook deformation and brake wear before they cause failures.
Standards compliance: documented inspections meet AS 1418, AS 2550 and WHS obligations for lifting equipment.
Reduced downtime: identify electrical faults, limit switch failures, lubrication needs and mechanical wear before they cause unplanned breakdowns and production delays.
Worker confidence: operators can trust the hoist has been checked and cleared before each lifting task.
Audit trail: maintain a verifiable history of inspections for each hoist, supporting safety audits, incident investigations and regulatory compliance reviews.

Benefits of digitising forms in MapTrack

When you digitise hoist checklists in MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Set recurring audit schedules with automatic reminders and escalation.
Produce regulator-ready PDF compliance packs in one click.
Track corrective actions from finding to close-out with full audit trail.

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What to include in a hoist inspection checklist

This hoist inspection checklist covers 9 key areas:

Hoist details: type (chain/wire rope/electric/manual), make/model, serial/asset number, SWL (safe working load).
Inspector details: name, inspection date, inspection type (daily/monthly/annual).
Load chain or wire rope: wear, elongation, kinks, lubrication, terminations.
Hook and block: safety latch, throat opening, twist, wear, block sheave.
Brakes and controls: brake holding test, upper and lower limit switches, pendant or remote controls, emergency stop.
Electrical: power supply, wiring condition, motor, isolator.
Structure: frame and housing, mounting bolts, trolley wheels, beam clamps, load rating plate.
Defect register: item, description, action required.
Sign-off: inspector and supervisor.

How to use this hoist inspection checklist

Record hoist details including type, make/model, serial number and SWL.: Confirm the hoist identity against your plant register. Note the hoist type (chain, wire rope, electric or manual), rated safe working load and the inspection type being performed (daily, monthly or annual).
Visually inspect the load chain or wire rope for wear, kinks, elongation and proper lubrication.: Run the chain or wire rope through its full travel and inspect each section. Check chain links for stretch, gouging or corrosion. For wire rope, count broken wires per lay length and check for kinking or bird-caging.
Check the hook: safety latch closes fully, no throat opening beyond limits, no twist or cracks.: Measure the hook throat opening against the manufacturer specification. Check for twist exceeding 10 degrees from the plane of the hook body. Inspect for cracks, gouges or signs of overloading at the bend.
Test the brakes with a light load. Confirm the hoist holds without drift.: Lift a light test load a short distance and hold for at least one minute. Observe for any drift or creep. If the brake slips or the load drops, the hoist must be taken out of service immediately.
Test upper and lower limit switches, pendant or remote controls, and emergency stop.: Slowly raise and lower the hook to confirm both limit switches activate and stop the hoist at the correct positions. Test all pendant or remote control buttons for correct function and verify the emergency stop halts all movement.
Check the structure: frame, mounting bolts, trolley wheels and beam clamps for damage or looseness.: Inspect the hoist housing, trolley wheels and beam clamps for cracks, wear or loose fixings. Confirm the load rating plate is legible and the mounting is secure with no excessive movement or vibration during operation.
Record any defects and report per your site procedures. Tag out the hoist until safety defects are rectified.: Document each defect with a description, location and severity. Apply a tag-out or lock-out to the hoist if any safety-critical defect is found. Notify the site supervisor and arrange repair before the hoist is returned to service.
Sign off, date the form and save as PDF.: The inspector and supervisor should both sign the completed checklist. File the record in the lifting equipment register and schedule the next inspection based on the applicable frequency under AS 1418.

In MapTrack, you can automate compliance tracking and audit trails. Each submission is stored as a timestamped PDF against the asset record.

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How often should you complete this checklist?

Complete a visual inspection before each use or at the start of each shift. Monthly inspections should cover deeper items such as chain or wire rope measurement, brake adjustment, limit switch function testing and electrical component checks. Annual thorough examinations should be performed by a competent person in accordance with AS 1418 and AS 2550, covering structural integrity, load testing and full component assessment. In MapTrack, you can schedule each inspection tier and track compliance across all your hoists and lifting equipment.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 1418
AS 2550
LOLER 1998
WHS Regulations 2011, Chapter 5

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