If you work on a construction site, you already know that your passenger hoist is the lifeline of the project – it moves workers and materials safely, every single day. But like any machine that works this hard, it needs care to stay safe and reliable.
Think of it this way: a well-maintained hoist can easily last 20–30 years, while a neglected one might fail in less than a decade. That’s not just extra cost for repairs – it can mean project delays, compliance issues, and safety risks for your team.
At MKG, we’ve been designing and manufacturing hoists for over a decade, supporting real estate and infrastructure projects across India. We’ve seen one thing again and again regular maintenance is not optional. It’s what keeps your equipment running smoothly, prevents costly breakdowns, and keeps you on the right side of safety regulations like OSHA or Indian BIS standards.
In this guide, we’ll break down practical, step-by-step tips for keeping your passenger hoist in top condition – from daily checks to preventive servicing – so you can get the longest life and safest performance from your machine.
Daily & Weekly Inspections - Your First Defence Against Breakdowns
Your passenger hoist works hard every single day. If you don’t check it regularly, small problems can quickly turn into expensive breakdowns or safety hazards. That’s why daily and weekly inspections are not just “good practice” – they’re essential to keep your site safe and your project on schedule.
Think of it like health check-ups: skipping them might save you time today, but could cost you a lot tomorrow. Regular inspections reduce downtime, prevent accidents, and keep your hoist running smoothly for years.
Daily Pre-Use Checklist (Before Each Shift)
A quick 10-minute check before starting work can catch 80% of common issues:
Visual Check – hoist cage, Mast & Labels:
- Look for dents, cracks, loose bolts, or rust on the hoist cage, mast, and anchoring points. Make sure all safety labels (including load capacity) are readable.
- Why: Cracks and corrosion weaken the structure over time – early detection prevents accidents.
Doors & Safety Interlocks:
- Open and close every hoist cage and landing door. The hoist should not move unless gates are fully locked.
- Why: Faulty interlocks can lead to door-open movement, a major safety risk.
Electrical & Controls:
- Inspect power cables for cuts or frays. Test buttons (up, down, stop) and hit the emergency stop to confirm it works instantly.
- Why: Loose or damaged wiring can cause sudden stops or erratic movement.
Test Run Without Load:
- Run one cycle empty. Listen for grinding or jerky movement. Release the control button to check brakes stop the hoist cage smoothly with no excessive drift.
- Why: Noises and drift often signal early motor, brake, or alignment issues.
Weekly Inspection Checklist (More Detailed)
At the end of the week or during low-usage periods – go deeper:
Lubrication: Grease the rack & pinion, pulleys, and guide rollers with the recommended lubricant.
- Why: Proper lubrication cuts down friction, preventing overheating and premature wear.
Mast & Guide Rollers: Tighten loose bolts, check rollers for even wear and proper alignment.
- Why: Misaligned rollers cause jerky rides and damage mast sections.
Wire Ropes / Chains: Look for broken strands, rust, or kinks. Check that they are reeved correctly.
- Why: Damaged ropes are a top cause of hoist failures – replacing them early avoids accidents.
Safety Devices & Surroundings: Inspect the overspeed governor, limit switches, and barricades around the hoist base.
- Why: Safety devices are your last line of defence during an emergency – they must always be functional.
Keep It Clean & Rust-Free for Smooth Operation
Construction sites in India are full of dust, cement splatter, rain, and sometimes salty air (on coastal sites). These environmental stresses, if ignored, degrade your hoist faster than you think. Cleaning and rust prevention aren’t optional extras – they’re essential for safety, performance, and long life.
Deep Cleaning Routine
- Daily dust & debris wipe-down: At end of each shift, wipe down the hoist cage, platform floor, doors, and control panels using a dry or slightly damp cloth. Remove loose debris like dust, cement bits.
- Weekly or biweekly thorough clean: Clean mast sections, guide rails, rollers. Remove stubborn splatter or grime with non-abrasive cleaners. Use manufacturer-approved agents that do not damage paint or metal coatings.
- Protect electrical parts: Always switch off power before cleaning. Avoid spraying water near switches, motors, control panels. Moisture in electrical components is a common cause of short circuits or corrosion.
Rust & Corrosion Prevention
- Inspect for surface rust monthly (or more often in harsh conditions): Check bolts, frames, wire ropes for any rust, discoloration, or flaking. Even small spots matter.
- Apply protective coatings: If paint or galvanisation is chipped, restore it. Use anti-rust primer, rust-inhibiting sprays, or powder coatings. In monsoon or coastal locations, do this more often.
- Lubrication after cleaning: Once surfaces are clean and dry, apply recommended lubricants to gears, chains, wire ropes, bearings. Clean first so grease isn’t trapping dirt that causes abrasive wear.
- Store / cover correctly: When hoist is idle, especially during heavy rains or extended downtime, cover hoist components or position shelter to prevent water accumulation. Ensure drainage around the base so water doesn’t sit.
Seasonal Maintenance Tips
- Monsoon readiness: Before monsoon season, perform deep cleaning and rust checks. Repaint exposed metal parts, ensure seals and joints ar
- For coastal or humid sites: Increase frequency of rust inspections. Salt in air accelerates corrosion – so proactive rust protection here is not optional.
Load Management & Safe Operation
Load management and safe operation are absolutely key – not just for extending your passenger hoist’s lifespan, but for keeping everyone safe. Overloading, careless handling, and ignoring environmental stress can quickly damage parts (motors, brakes, cables) and lead to serious accidents.
What to Do (Best Practices)
Respect Load Capacity & Avoid Overloading
- Always check the hoist’s rated load capacity – typically displayed inside the hoist cage or on a nameplate. Know both weight limit and passenger/material limit.
- If your hoist has a Safe Load Indicator (SLI) or similar load display, use it. If the indicator warns you’re near the limit, do not push past it.
- Distribute load evenly. Don’t crowd everything to one side – weight imbalance stresses guide rollers, can twist the mast, and accelerate wear.
Train Operators on Smooth Operation
- Only trained and certified personnel should operate the hoist. They should know the manual, emergency features, safety warnings, and how to read the indicators.
- Use smooth starts/stops. Avoid jerky movements, which stress motors and mechanical parts.
- Communication is crucial – between operator, ground crew, and those entering/leaving the hoist. Miscommunication is a common source of accidents (e.g., someone stepping in before gate fully opens).
Factor in Harsh Environments
- In rainy or humid weather, or in coastal / saline air areas, corrosion and rust weaken parts. Reduce load if necessary and inspect more often.
- Dusty or muddy job sites can clog moving parts, affect rollers and guide rails – all of which can affect load handling.
- High winds or storms – sometimes hoists become less stable or parts like doors and gates may be stressed. Follow regulatory limits (e.g. OSHA standards limit operation above certain wind speeds). If unsure, suspend operation until conditions improve.
Electrical & Mechanical System Maintenance
Your hoist’s electrical and mechanical parts are its backbone. If they fail, everything else fails – loss of time, high repair cost, safety risks. If you keep them in shape, your hoist will work cleaner, safer, longer.
Electrical System Maintenance
- Wiring & Connections
Check all wiring, plugs, and terminals regularly. Look for fraying, chafing, loose screws, or corrosion. A loose or corroded connection can cause short circuits or power drop, risking operation failure or fire. - Motor & Brake System
Motors heat up when working hard. Feeling excess heat, or seeing burn marks / smells, are warning signs. Also check motor brushes (if applicable) and replace when worn. Brakes should act immediately when you release controls; any lag or slippage is dangerous – adjust or replace as needed. - Limit Switches, Interlocks & Safety Controls
These are the “stop-you-before-you-fail” parts. Test them regularly. Limit switches prevent overtravel. Interlocks ensure doors can’t open mid-travel. If any of these fail, shut down until fixed. - Control Panel, Emergency Stops, Alarms
Buttons should respond correctly. Emergency stop should cut power immediately. Alarms, lights, indicators (e.g. overload, door open) should be visible/audible and working. These give early warnings when something is wrong. - Grounding & Insulation
Ensure control panels and metallic components are properly grounded. Check the insulation of wires – cracked insulation allows moisture, which causes shorts and rust.
Mechanical System Maintenance
- Rack & Pinion, Gears, Drive Mechanisms
Make sure the rack (teeth on mast) and pinion (gear in hoist car) are clean, free from debris, properly aligned, and not worn. Worn or damaged teeth cause jerky movements, misalignment, and early failure. - Wire Ropes & Chains
Inspect ropes/chains for broken strands, kinks, stretch, corrosion. If ropes are damaged or exceed allowed wear, replace them immediately. Don’t wait until failure. - Overspeed Governor & Emergency Brakes
These are critical safety systems. The overspeed device should act if hoist goes past a safe speed; emergency brakes need to engage instantly. These must be tested (visually + functionally) on schedule by qualified technicians. - Guide Rollers & Guide Rails
Ensure rollers move smoothly; they should be well-aligned. Rails should be straight and free from dents or deformation. Misalignment causes vibration and spreads wear to other parts.
Structural & Frame Components
Check bolts, welds, frames, supports. Any crack, loose fastener, or deformation can make the whole structure unstable.
MKG’s Commitment to Long-Term Reliability
At MKG, we believe good equipment doesn’t just finish projects – it builds trust on your site. Our passenger hoists are designed, built, and serviced in India, using indigenous technology that meets global standards.
From high-rise housing to metro projects, our MKG Vimaan Passenger and Material hoists are made to handle Indian site conditions – dust, heat, rain, and heavy loads – day after day. And we don’t stop at manufacturing. Our trained service teams are here to help you with preventive maintenance plans, inspections, and genuine spare parts – so your hoist keeps working reliably for years.
A well-maintained hoist can last 20–30 years. we want to make sure you get that full value from your investment.
Talk to MKG’s service experts today to plan your next inspection or get guidance on preventive maintenance.
Email us at info@rajat-group.com or call +91 88899 00105 = let’s keep your project safe, efficient, and on schedule.
Frequently Asked Questions
1. How do I know if my passenger hoist needs major servicing or replacement?
If you notice frequent breakdowns, jerky movements even after lubrication, excessive noise, rust damage on mast sections, or worn wire ropes that require replacement too often, it may be time for a major service. If repair costs are rising close to 30–40% of the cost of a new hoist, consider replacement. A professional audit by your manufacturer or a certified service provider can give you a clear recommendation.
2. What is the average electricity consumption of a passenger hoist per day?
It depends on hoist capacity, motor power, and usage hours. For example, a 2-ton rack-and-pinion hoist with a 15 kW motor running 6–8 hours daily may consume roughly 90–120 kWh/day. You can reduce energy use by avoiding unnecessary trips, maintaining proper lubrication (reduces motor strain), and balancing loads.
3. Are there government regulations in India for hoist operator training?
Yes. As per Indian BIS and state factory inspectorate guidelines, hoist operators must be trained and certified for safe operation. Many large contractors follow international standards like OSHA 1926.552 and ANSI A10.4 for operator competence. Training should include emergency procedures, load management, and pre-use inspection protocols.
4. Can passenger hoists be used for material transport when not carrying people?
Yes, but capacity and speed may differ when in material-only mode. Ensure the hoist is rated for dual-mode use (personnel + material). MKG Vimaan hoists, for example, are available in configurations suitable for both passengers and construction material, but always follow the manufacturer’s mode-specific load limits.
