Lifting Equipment Inspection Malaysia 2026: Certificate of Fitness Requirements for Cranes, Hoists & Forklifts

Disclaimer: This article provides general guidance on lifting equipment inspection requirements in Malaysia based on OSHA 1994 (Amendment 2022) and the Occupational Safety and Health (Plant Requiring Certificate of Fitness) Regulations 2024. Regulations may be amended. Always verify current requirements with DOSH or qualified professionals before making compliance decisions.

Since 1 June 2024, the old PMA (Perakuan Mesin Angkat) system for lifting equipment has been replaced by the Certificate of Fitness (CF) framework under new OSHA regulations. The penalty for operating lifting equipment without a valid CF is now up to RM 100,000 or 1 year imprisonment. For broader safety failures, fines reach RM 500,000 with director personal liability.

This guide covers the complete CF certification process, equipment classification, inspection requirements, load testing standards, operator competency rules, the penalty matrix, inspection costs, and how CF compliance connects to your insurance programme.

Which Equipment Requires a Certificate of Fitness

Not all lifting equipment requires a CF. DOSH classifies equipment based on whether it is a powered lifting machine capable of lifting and lowering loads. Understanding this classification prevents both non-compliance (missing a required CF) and wasted costs (certifying equipment that does not require it).

Equipment Type	CF Required	Common Locations	Notes
Overhead travelling crane (all powered)	Yes	Factories, warehouses, workshops	Includes single and double girder, gantry cranes
Jib crane and tower crane	Yes	Construction sites, shipyards, heavy engineering	Both fixed and mobile tower cranes
Mobile crane	Yes	Construction, oil and gas, heavy lifting	All types: truck-mounted, crawler, rough terrain
Electric wire rope hoist	Yes	Factories, workshops, loading bays	All powered hoists regardless of capacity
Electric chain hoist	Yes	Production lines, maintenance areas	All powered hoists regardless of capacity
Goods lift and passenger lift	Yes	Buildings, factories, warehouses	Both goods-only and passenger lifts
Powered monorail system	Yes	Automotive plants, heavy manufacturing	Powered transport and lifting systems
Fixed winch (powered)	Yes	Construction sites, mining operations	Powered winches used for lifting loads
Manual chain block	No	All industries	Not powered. Still requires regular inspection per manufacturer standards.
Manual monorail (4 tonnes or below)	No	Workshops, light manufacturing	Manual push trolley systems only
Forklift truck	No	Warehouses, logistics, manufacturing	Separate DOSH regulations apply. Requires operator Perakuan Kuasa, not CF.
Lifting accessories (slings, shackles, hooks)	No	All industries	Must be inspected and colour-coded quarterly. No CF required.

The forklift classification is a common source of confusion. Forklifts do not require a CF under lifting equipment regulations. They require a separate operator Perakuan Kuasa (competency certificate) and must comply with general OSHA 1994 safety requirements.

The Four-Stage CF Certification Process

CF certification follows a four-stage process from design through issuance. All stages are now managed through the MyKKP online portal (mykkp.dosh.gov.my). The total timeline for new equipment is typically 6 to 12 weeks.

Stage	Activity	Key Requirements	Timeline
Stage 1: Design Verification	Submit equipment designs to DOSH for review and approval	Design calculations, drawings, material certificates, compliance with BS/EN/AS/NZS standards	2 to 4 weeks (design approval valid 3 years)
Stage 2: Installation	Equipment installed by competent person or OEM	As-built documentation, installation certificate, foundation/structural verification	Variable (depends on equipment complexity)
Stage 3: Inspection and Load Testing	Full structural, mechanical, electrical inspection plus proof load test	DOSH officer or DOSH-licensed inspector conducts inspection. Test weights are owner's responsibility.	1 to 2 weeks
Stage 4: CF Issuance	CF issued through MyKKP portal after satisfactory inspection	All previous stages completed, no outstanding defects	1 to 2 weeks after inspection

The CF is valid for 15 months from the inspection date (not the issuance date and not the previous expiry date). There is no grace period. If your CF expires before the renewal inspection is completed, the equipment must be taken out of service immediately.

Load Testing Requirements

Load testing is the core of the CF inspection. It verifies that the equipment can safely handle its rated capacity with a safety margin. The test requirements differ between new installations and renewals.

Test Type	New Equipment	Renewal	Duration
Static proof load test	125% of Safe Working Load (SWL)	110% to 125% of SWL (inspector discretion based on equipment condition)	Minimum 10 minutes suspended static
Dynamic test	Full operational cycle at SWL	Full operational cycle at SWL	Complete lift, traverse, lower, and brake test cycle
Brake holding test	Load suspended at SWL	Load suspended at SWL	Minimum 10 minutes with zero drift permitted

Test weights are the equipment owner's responsibility, not the inspector's. This catches many companies off guard. You need to arrange test weight hire well in advance of the inspection date, especially for large cranes where certified test weights may need to be transported to site.

Inspection Checklist: What the Inspector Checks

Understanding the full scope of inspection helps you prepare equipment properly. Failed inspections cause delays, re-inspection costs, and production downtime.

Category	Items Inspected	Common Failure Reasons
Structural	Main structure, support beams, weld joints, connections, corrosion, deformation	Corrosion on runway beams, cracked welds, deformed structural members
Hook and block	Hook condition, safety latch, hook opening measurement, block sheaves	Hook opening exceeding 5% of original, missing safety latch, worn sheaves
Wire rope	Wire rope condition, broken wires, corrosion, kinking, terminations	Exceeding discard criteria (broken wires per lay length), visible corrosion, bird-caging
Electrical and mechanical	Motors, gearboxes, brakes (hoist, travel, slew), pendant/cabin controls, cabling	Brake wear beyond limits, damaged pendant cables, overheating motors
Safety devices	Overload protection, upper/lower limit switches, emergency stop, warning alarm/beacon	Overload device not calibrated or bypassed, limit switches not functioning, no emergency stop
Wheels and track	Wheel condition, track alignment, wheel flange wear, end stops	Worn wheel flanges, misaligned tracks causing crane skewing

The overload protection device is the single most commonly failed item. If the overload device is not calibrated, is bypassed (even temporarily), or does not trip at the correct load, the CF will not be issued until it is rectified.

Need Insurance Coverage for Your Lifting Equipment? Talk to Our Engineering Insurance Specialists.

CF Renewal Timeline and Preparation

CF renewal should begin 3 months before expiry. Starting late is the most common reason companies end up with expired CFs and equipment taken out of service.

Timeline Before Expiry	Action	Who Is Responsible
3 months	Begin planning. Review previous inspection findings. Identify outstanding repairs.	Maintenance manager
2 months	Complete all outstanding repairs. Schedule inspection with DOSH or licensed inspector.	Maintenance team
1 month	Conduct pre-inspection checks. Arrange test weights. Prepare all documentation.	Competent person
1 week	Final equipment verification. Documentation organised and ready. Test weights on site.	Maintenance supervisor
Inspection day	Equipment clean, accessible, and ready. All personnel available. Documentation complete.	All relevant personnel

Documentation Required for CF Renewal

Document	Purpose	Retention Period
Previous CF copy	Proves equipment was previously certified	Lifetime of equipment
Service and maintenance records	Shows equipment has been maintained per manufacturer requirements	Lifetime of equipment
Daily pre-use inspection checklists	Demonstrates daily monitoring between inspections	Minimum 3 years
Operator Perakuan Kuasa copies	Proves operators are competent and certified	3 years after employment ends
Modification records (if applicable)	Documents any changes to original design or capacity	Lifetime of equipment
Previous load test certificates	Historical test records for comparison	Lifetime of equipment
Incident reports (if any)	Documents any incidents involving the equipment	Minimum 7 years

Common CF Application Rejection Reasons

Understanding why CF applications get rejected helps you avoid the most common pitfalls. Each rejection means the equipment stays out of service until the issue is resolved and re-inspection is scheduled.

Rejection Category	Specific Issues	How to Prevent
Documentation	Missing or incomplete service records, expired operator certificates, incomplete MyKKP submission	Maintain continuous records. Renew operator certificates before expiry. Complete all MyKKP fields.
Wire rope	Broken wires exceeding discard criteria, visible corrosion, bird-caging, crushed sections	Quarterly wire rope inspection by competent person. Replace before discard criteria are reached.
Brakes	Excessive brake wear, slipping, inconsistent holding, contaminated brake pads	Monthly brake inspection. Replace pads per manufacturer wear limits. Test before inspection.
Overload device	Not calibrated, bypassed, trips at wrong load, not installed	Quarterly calibration check. Never bypass, even temporarily. Replace if faulty.
Safety devices	Limit switches not functioning, emergency stop not operational, warning devices failed	Include all safety devices in weekly inspection routine. Test before each shift for critical items.
Load test failure	Equipment cannot sustain proof load, structural deformation during test, excessive drift	Conduct internal load test before scheduling official inspection. Address structural issues early.

Operator Competency: Perakuan Kuasa

Every operator of CF-regulated lifting equipment must hold a valid Perakuan Kuasa (competency certificate) issued by a DOSH-recognised training centre. This is separate from and additional to the equipment CF itself.

Requirement	Detail
Issuing body	DOSH-recognised training centres only
Certification scope	Equipment-specific. Separate certificate required for each equipment type operated.
Assessment	Written examination and practical assessment
Validity	Typically 3 to 5 years depending on equipment type
Penalty for operating without	Fine up to RM 100,000 or 1 year imprisonment or both (both operator and employer liable)

A common compliance gap is operators holding a Perakuan Kuasa for one type of crane but operating a different type. An overhead crane operator certificate does not authorise operation of a mobile crane, and vice versa. Each equipment type requires a separate certificate.

Maintenance Schedule Between CF Inspections

The CF inspection happens once every 15 months. What happens between inspections determines whether your equipment passes the next one. A structured maintenance programme prevents surprise failures.

Frequency	Activities	Performed By
Daily (pre-use)	Visual inspection, control function test, safety device check, unusual noise or vibration	Equipment operator
Weekly	Wire rope inspection, hook condition check, limit switch test, brake inspection	Maintenance technician
Monthly	Lubrication, electrical connection checks, structural inspection, bolt tightness	Maintenance technician
Quarterly	Comprehensive inspection, overload device calibration, wire rope measurement, NDT if required	Competent person
Per manufacturer schedule	Full service per OEM specifications, component replacement per usage hours	OEM or qualified contractor

Penalty Matrix: Non-Compliance Consequences

Violation	Maximum Penalty	Who Is Liable
Operating equipment without valid CF	RM 100,000 fine or 1 year imprisonment or both	Equipment owner or occupier of premises
Failure to comply with safety notice	RM 500,000 fine or 2 years imprisonment or both	Owner, occupier, directors, and managers
Operating without qualified operator (no Perakuan Kuasa)	RM 100,000 fine or 1 year imprisonment or both	Employer and operator
Failure to ensure employee safety (Section 15)	RM 500,000 fine or 2 years imprisonment or both	Employer, directors, and managers
Continuing offence (per day of non-compliance)	RM 2,000 per day	Equipment owner or occupier
Using inspection results from unregistered inspector	Inspection invalidated (no CF issued, re-inspection required)	Equipment owner

Under Section 52 of OSHA 1994, directors and managers face personal prosecution if they gave consent to, connived at, or were negligent about a safety failure. Running a crane without CF because "the renewal is being processed" is not a defence. The equipment must be taken out of service.

Special Scheme of Inspection (SSI)

Companies with multiple pieces of lifting equipment and an established safety management system may qualify for the Special Scheme of Inspection (SSI). This provides longer inspection intervals and more scheduling flexibility.

Feature	Standard CF	SSI Class B
Validity period	15 months	Up to 60 months
Inspector	DOSH officer or licensed external inspector	Company's trained and approved inspection team
Scheduling	Dependent on DOSH or inspector availability	Self-scheduled by company
Scope	Individual equipment per inspection	All site lifting equipment under one scheme
Eligibility	All equipment owners	Established OSH management system, trained team, clean safety record
Application timing	Per equipment as needed	6+ months before current CF expiry

SSI is most beneficial for large factories or facilities with 10 or more pieces of lifting equipment. The upfront investment in building an approved inspection team is offset by reduced downtime, elimination of scheduling delays, and longer certification periods.

Protect Your Lifting Equipment Investment. Get the Right Engineering Insurance Coverage.

Inspection Cost Estimates

These are typical cost ranges for CF inspections in Malaysia. Actual costs vary based on location, equipment condition, and inspector availability. Budget for these costs in your annual maintenance plan.

Equipment Type	Inspection Fee Range	Additional Costs to Budget
Electric chain hoist (small)	RM 350 to RM 600	Test weights, minor maintenance items
Overhead crane (10 tonnes or below)	RM 600 to RM 1,200	Test weight hire, production downtime
Overhead crane (10 to 50 tonnes)	RM 1,000 to RM 2,000	Load cell hire, possible NDT testing
Tower crane	RM 1,500 to RM 3,000	Specialist load test setup, site coordination
Mobile crane	RM 1,200 to RM 2,500	Proof load weights, test area preparation
Passenger lift	RM 500 to RM 1,200	Governor and safety gear test costs
Goods lift	RM 400 to RM 800	Load test weights, interlock testing

The inspection fee is often the smallest cost. Production downtime during inspection and test weight hire for large cranes can exceed the inspection fee several times over. Plan inspections during scheduled shutdowns where possible.

Insurance Implications for Lifting Equipment

CF compliance directly affects multiple insurance policies in your programme. Expired or missing CFs can void coverage, and lifting equipment incidents generate some of the largest industrial insurance claims.

Insurance Type	Lifting Equipment Relevance	Impact of Non-Compliance
Machinery Breakdown	Covers sudden mechanical or electrical breakdown of cranes and hoists	Expired CF or non-compliance with manufacturer maintenance can void the claim
MLOP (Machinery Loss of Profits)	Covers revenue loss from crane downtime after breakdown	Same compliance requirements as machinery breakdown policy
Industrial Property (IAR)	Covers property damage from crane collapse, load drop, or structural failure	Pre-inception surveys check CF status. Non-compliance may result in exclusions or higher premiums.
CAR / EAR Insurance	Covers crane accidents during construction and erection projects	CAR policies require compliance with safety regulations. Operating without CF may void Section I and II claims.
Workmen Compensation	Covers worker injury from crane accidents (falling loads, collapse, entrapment)	Statutory cover is paid, but non-compliance strengthens employee negligence claim against employer.
CGL Insurance	Covers third-party injury and property damage from lifting operations	Non-compliance with statutory requirements weakens the employer's defence.

The most costly insurance consequence of expired CF is not claim denial. It is the loss of the statutory defence. If a crane without valid CF drops a load and injures a third party, the employer cannot argue that they complied with all legal requirements. This removes a key defence in both civil and criminal proceedings.

Get a Comprehensive Insurance Review for Your Factory Equipment. Contact Foundation Today.

Frequently Asked Questions

How often does a CF need to be renewed?

Every 15 months from the inspection date. Not from the issuance date and not from the previous expiry date. There is no grace period. If the CF expires, the equipment must be taken out of service immediately until a new CF is issued after satisfactory inspection.

Do forklifts need a Certificate of Fitness?

No. Forklifts are not classified as lifting machinery under the CF regulations. They require a separate operator Perakuan Kuasa (competency certificate) and must comply with general OSHA 1994 requirements and manufacturer maintenance standards. This is one of the most common compliance misunderstandings.

What happens if the crane fails the load test?

The equipment cannot operate. The inspector will document the failure, and the CF will not be issued. You must identify and rectify the defect (structural repair, component replacement, or derating), then schedule a re-inspection. The re-inspection includes a fresh load test. Production impact can be significant, which is why pre-inspection internal testing is strongly recommended.

Who can conduct CF inspections?

Only DOSH officers or DOSH-licensed external inspectors. Using an unlicensed inspector invalidates the inspection entirely, and the equipment owner bears the consequences. Verify your inspector's DOSH registration before scheduling the inspection. The MyKKP portal lists registered inspectors.

What changed on 1 June 2024?

The old PMA (Perakuan Mesin Angkat) system was replaced by the new CF regulations under the Occupational Safety and Health (Plant Requiring Certificate of Fitness) Regulations 2024. The MyKKP online portal became the standard submission channel. Penalties increased significantly: from RM 50,000 to RM 500,000 for serious breaches, with personal director liability under Section 52.

Can I operate the crane while waiting for CF renewal?

No. There is no grace period, no temporary permit, and no provision for continued operation with an expired CF. The equipment must be taken out of service the day the CF expires. This is why the 3-month preparation timeline is important. Late renewal planning is the most common reason companies end up with idle cranes.

What maintenance records do I need to keep?

Daily pre-use checklists (keep for minimum 3 years), maintenance and service records (keep for the lifetime of the equipment), operator training records (keep for 3 years after employment ends), and incident reports (keep for minimum 7 years). These records are required for both CF renewal and insurance claims.

Does machinery breakdown insurance cover cranes?

Yes, machinery breakdown insurance typically covers sudden and unforeseen mechanical or electrical breakdown of cranes and hoists. However, coverage is conditional on the equipment having a valid CF and being maintained according to manufacturer specifications. An expired CF at the time of breakdown can void the claim.

What is the penalty for operating without a valid CF?

Up to RM 100,000 fine or 1 year imprisonment or both for operating without CF. For broader safety failures connected to lifting equipment (Section 15 of OSHA 1994), the penalty increases to RM 500,000 or 2 years imprisonment. Directors and managers face personal prosecution under Section 52.

What is the difference between CF and SSI?

Standard CF requires inspection by a DOSH officer or licensed inspector every 15 months. The Special Scheme of Inspection (SSI) allows qualifying companies to conduct their own inspections with trained internal teams, with validity periods up to 60 months. SSI requires an established OSH management system, clean safety record, and DOSH-approved inspection team. It is most practical for facilities with 10 or more pieces of lifting equipment.

The CF system exists because lifting equipment failures produce some of the most catastrophic workplace incidents: dropped loads, crane collapses, structural failures. Every 15-month inspection cycle verifies that the equipment remains safe to operate.

The cost of maintaining CF compliance, including inspection fees, test weights, maintenance, and occasional downtime, is a fraction of what a single lifting accident costs in terms of worker injuries, property damage, regulatory penalties, and insurance consequences. Companies that treat CF as a box-ticking exercise rather than a genuine safety programme eventually learn the difference the hard way.