Safety Operating Guide for Factory Electric Hoists: Upholding the First Line of Defense in Lifting Operations

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Release time:

26-08-21

In daily production operations within factory workshops and warehouse facilities, electric hoists are among the most widely used lifting devices. They are easy to operate and offer flexible handling, making them indispensable for material handling, equipment loading and unloading, and workpiece relocation—key tools for enhancing productivity and quality. However, convenience does not equate to safety. Most lifting accidents stem from operators’ complacency, non‑compliant practices, inadequate equipment maintenance, and perfunctory inspections. Overloading, crooked or angled lifting, personnel standing beneath suspended loads, and operating equipment with known defects—each seemingly minor violation can trigger serious safety incidents, such as falling objects, equipment damage, or casualties.

There are no small matters when it comes to workplace safety; proactive prevention is key. Today, we will comprehensively review the safety operating procedures for electric hoists in factory buildings across five dimensions—pre-job inspections, standardized operations, prohibited red‑line practices, routine maintenance, and personnel management—thereby establishing a robust safeguard for safe production in the workshop.

1. Conduct a comprehensive pre-job inspection to ensure that no equipment is operated while faulty.

Equipment hazards are the primary cause of safety incidents. Before each start-up and operation, a comprehensive inspection must be rigorously carried out; skipping steps or conducting perfunctory checks is strictly prohibited. Work may only commence after confirming that the equipment is in proper working condition.

1. Mechanical Structure Inspection

Focus inspections on critical components such as the hook, wire rope/chains, drum, and brakes. Verify that the hook is free of cracks and deformation, with an opening no greater than the specified limit, and that the anti‑disengagement device is intact and functional; ensure the wire rope shows no broken wires, broken strands, corrosion, kinking, or excessive wear, and that the chains are free of binding, deformation, or excessive wear; confirm that the wire rope is neatly arranged on the drum, and that when the hook is lowered to its lowest position, at least two safety turns remain on the drum. Also inspect the machine’s outer casing for damage or deformation, and ensure all connecting bolts are securely tightened with no signs of loosening.

2. Electrical System Inspection

Inspect power and control cables for damage, aging, or exposed conductors; ensure that the grounding and earthing protection system is secure and reliable to eliminate the risk of electrical leakage. Verify that operating buttons and remote controls are responsive and functional, with indicator lights displaying normally. Confirm that limit switches and emergency stop devices are accurate and sensitive, capable of promptly cutting off the equipment’s power supply to ensure emergency braking in unforeseen situations. In wet working environments, perform additional tests on the equipment’s insulation performance to mitigate the risk of electric shock.

3. No-Load Trial Run Inspection

Prior to formal lifting operations, a 3–5 minute no‑load trial run must be conducted, during which the equipment’s lifting and traveling functions are fully tested. Verify that operation is smooth with no jerking, unusual noises, abnormal vibrations, or overheating; ensure the braking system is responsive and free of hook slippage or hook creep. Only after confirming that all functions are operating normally may the equipment be put into service under load.

II. Adhere to standardized operating procedures during work and strictly comply with safety regulations.

Electric hoists are classified as special‑purpose equipment, and compliance with operating procedures directly determines operational safety. Operators must be certified and assigned to specific roles, strictly adhere to standardized work processes, and eliminate all habitual violations.

1. Strictly control the load and prohibit overloading during operations.

Strictly in accordance with the specifications indicated on the equipment nameplate. Rated load During operations, strictly prohibit overloading and luffing‑off‑center lifting; it is also forbidden to lift materials of unknown weight, items buried underground, or objects adhered to the ground. In addition, rigorously control the frequency of operation: the number of circuit‑breaker closing cycles per hour must not exceed 120, to prevent overheating of the motor and premature aging or damage to components caused by frequent starts and stops.

2. Standardize lifting operations; prohibit slinging and hoisting at an angle.

During operations, heavy loads must be lifted vertically; it is strictly prohibited to lift them at an angle or drag them diagonally. Oblique lifting can cause the wire rope to become misaligned and unevenly load the equipment’s tracks, greatly increasing the risk of the rope slipping off the sheave or breaking, as well as causing the load to swing and fall. At the same time, such practices accelerate wear on the machine body and tracks, significantly raising the likelihood of equipment failure. When lifting, maintain the load in a stable position, raise and lower it slowly, and move it at a steady speed; abrupt lifting, lowering, stopping, or turning is forbidden.

3. Control the site and strictly enforce the no‑entry zone for operations.

The lifting operation area must remain clear; personnel and obstacles within the working radius shall be removed in advance, and a warning zone shall be established. It is strictly prohibited for any personnel to linger, walk, work, or pass under suspended loads, nor is it permitted for loads to pass over the heads of workers. During lifting operations, operators must never place their hands between the sling and the load to prevent crushing injuries. The use of electric hoists to carry or transport personnel is forbidden.

4. Operate smoothly and mitigate unexpected risks.

During lifting operations, the load should not be raised excessively above the ground; maintain a clearance sufficient to clear obstacles and minimize risks associated with high‑altitude hoisting. During breaks in work, it is strictly prohibited to leave suspended loads hanging for extended periods. If the equipment is temporarily stopped, the load must be lowered to the ground and the power supply disconnected. Should any abnormal conditions arise during operation—such as unusual noises, jamming, brake failure, or electrical leakage—immediately stop the machine, disconnect the power, evacuate personnel, and investigate the fault. Operating under such conditions is strictly forbidden.

III. Keep the safety red lines firmly in mind; the following behaviors are strictly prohibited.

Based on high-frequency accident cases in the workshop, we have compiled ten strict red‑line prohibitions for electric hoist operations, which all employees must memorize and strictly adhere to:

It is strictly prohibited to operate equipment without proper certification or for personnel who are not authorized to do so.

Overloading, exceeding the prescribed number of operations, and operating beyond capacity are strictly prohibited.

It is strictly prohibited to lift loads at an angle, drag materials along the ground, or forcibly hoist loads.

It is strictly prohibited to use limit switches or extreme position switches as the standard means of stopping the machine.

It is strictly prohibited to have personnel standing beneath suspended loads or to allow anyone to pass through the hazardous area of lifting operations.

It is strictly prohibited to operate equipment while it is faulty or to force operations when malfunctions have not been rectified.

It is strictly prohibited to leave your post without authorization or to leave suspended loads unattended during operations.

Open-air operations are strictly prohibited under adverse weather conditions such as strong winds, heavy rain, and dense fog.

It is strictly prohibited to dismantle, modify, or disable the equipment’s safety protection devices without authorization.

It is strictly prohibited to lift materials that are loose, improperly secured, or have an unstable center of gravity.

IV. Routine Maintenance and Overhaul to Extend Equipment Lifespan

Maintaining equipment in good working condition is the foundation of safe operations. Electric hoists must adhere to a standardized management approach that integrates daily inspections, regular maintenance, and specialized overhauls, while strictly complying with industry standards such as GB/T 3811-2008 and JB/T 9008.1-2014, thereby preventing equipment failures at their source.

1. Routine Maintenance

After completing daily operations, clean dust and oil from the equipment’s surface to keep the machine body clean and tidy; inspect the lubrication condition of wire ropes and chains, and replenish lubricant as needed; upon completion of work, raise the hook to a safe height, return the control handle to its neutral position, switch off the main power supply, and maintain accurate operation records.

2. Regular Maintenance

A comprehensive, specialized inspection is conducted weekly, focusing on tightening connection bolts, assessing brake wear, testing limit switch sensitivity, and identifying potential risks associated with aging wiring. Each month, in-depth maintenance is performed on critical components such as the drive mechanism, bearings, and drum, with worn parts replaced promptly when wear exceeds allowable limits. Annually, inspections are carried out in coordination with a qualified professional agency to ensure compliance with special‑equipment annual certification; only after passing these inspections may the equipment remain in service.

3. Fault Management

Establish a maintenance log for equipment malfunctions. Upon detecting issues such as hook slippage, abnormal noises, brake failure, limit switch malfunction, or electrical leakage, immediately shut down the equipment, tag it out, and prohibit its use. Arrange for qualified personnel to perform repairs, and strictly forbid unauthorized disassembly, modification, or operation while faulty. After completion of repairs, conduct no‑load and loaded trial runs for acceptance; only resume operation once all potential hazards have been confirmed to be eliminated.

V. Strengthen personnel management and fortify the ideological defense against safety risks.

Equipment-related hazards can be identified and addressed, but human‑induced risks are the most difficult to prevent. In the vast majority of lifting‑related accidents, the root causes are weak safety awareness among personnel and non‑compliant operating practices.

Enterprises are required to conduct regular specialized safety training on electric hoists, covering operating procedures, hazard identification, and emergency response protocols, and to organize警示教育 (educational sessions) based on accident case studies, ensuring that operators fully understand the risks associated with non‑compliant operations. Furthermore, the certification‑required‑for‑work policy must be strictly enforced, and personnel without the requisite qualifications are absolutely prohibited from operating such equipment.

At the same time, implement a job‑specific safety responsibility system, clearly defining the duties of operators, maintenance personnel, and management staff, ensuring that “whoever operates is responsible, and whoever manages is responsible,” thereby eliminating complacency and carelessness and making compliant operating procedures an ingrained work habit.

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