In the quest to keep your workplace safe and your operations going, there’s one thing you can’t afford to overlook: a forklift thorough examination. Whether you’re managing a warehouse, construction site, or distribution centre, forklifts are the backbone of your daily logistics. But just like any heavy machinery, they need regular checks to ensure they’re up to the job. That’s where a thorough examination comes in. It’s not just another maintenance task, but a legal requirement that could make all the difference between safe operation and a serious accident.
We break down everything you need to know about forklift thorough examination, including what it is, why it matters, and how to make sure you’re fully compliant.
What Exactly Is a Forklift Thorough Examination?
A thorough examination of a forklift is a systematic, detailed inspection. It’s carried out by a competent person to identify any defects that could make the forklift unsafe. Think of it as the forklift equivalent of an MOT for your car – except with potentially more serious consequences if it’s neglected.
The thorough examination goes beyond general maintenance. It focuses on the lifting components and safety-critical parts of the machine. This comprehensive check ensures that the forklift can continue to lift safely until the next examination.
Why Are Thorough Examinations Legally Required?
Forklift thorough examinations are mandated under the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) and the Provision and Use of Work Equipment Regulations 1998 (PUWER).
These regulations exist to prevent workplace accidents and injuries. Since forklifts lift heavy loads at height, any fault can be dangerous. That’s why the Health and Safety Executive (HSE) takes these checks seriously. Businesses that don’t follow the rules can face large fines.
LOLER forklift checks cover a lift truck’s lifting components, while PUWER addresses other safety aspects like brakes, steering, and overall condition. Both regulations work together to ensure comprehensive safety coverage.
How Often Should Thorough Examinations be Conducted?
Most forklifts need thorough examinations at least once every 12 months. However, this frequency increases in specific circumstances:
- Forklifts that lift people (with appropriate forklift attachments) require examinations every 6 months.
- Equipment used in challenging environments like corrosive or high-temperature settings may need more frequent checks.
- New or extensively refurbished equipment should have a thorough examination before first use.
Some industries may require more frequent examinations based on risk. CFTS (Consolidated Fork Truck Services) recommends following the manufacturer’s advice and thinking about how and where the forklift is used.
Who Can Perform a Thorough Examination?
Not just anyone can carry out a thorough examination. The inspection must be performed by a “competent person”. This is someone who knows how forklifts work, has hands-on experience, and can spot problems and judge how serious they are. Most importantly, they must be fair and independent when doing the check.
Many companies hire outside experts approved by groups like CFTS. Bigger businesses might have trained staff who can do it in-house. Either way, the person doing the check must have the right skills, training, and qualifications.
What Does a Thorough Examination Include?
During a thorough examination, the competent person will inspect numerous components and systems, including:
- Forks and carriage assembly
- Mast and chains
- Hydraulic systems and cylinders
- Braking systems
- Steering mechanisms
- Forklift tyres and wheels
- Safety features like overhead guards
- Warning devices and lights
- Structural components for damage or wear
The examination involves visual inspections, operational tests, and sometimes load testing to verify that all mechanical parts function correctly. The inspector will pay particular attention to safety-critical components that could cause accidents if they fail.
How Does a Thorough Examination Differ from Regular Maintenance?
Many businesses confuse thorough examinations with routine maintenance, but they serve different purposes:
Thorough Examination
A thorough examination is a legal safety check that looks for any faults in the forklift’s lifting parts and other key safety components. It must be done by a qualified person who helps ensure the forklift is safe to use.
Regular Maintenance
Regular maintenance is routine work that keeps the forklift running smoothly. This includes oil changes, replacing filters, and making small adjustments to prevent wear and tear.
Both are important and serve different purposes. A thorough examination doesn’t replace maintenance, and maintenance doesn’t count as a thorough examination. Your forklift needs both to stay safe and in good working order.
What Documentation Should You Receive?
Following a thorough examination, you should receive:
- A detailed examination report highlighting any defects found
- Recommendations for repairs or further actions
- A clear statement about the forklift’s safety status
- Timescales for addressing any issues
- Documentation to prove compliance with LOLER regulations
You must keep these records for at least two years and present them to authorities for inspection if requested. Proper documentation proves compliance and helps track your equipment’s condition over time.
What Happens If Defects Are Found?
If the examiner finds a serious problem during the check, they must tell you immediately and explain what’s wrong. They’ll suggest what needs fixing and how soon it should be done. If the issue is dangerous, they may put a “Do Not Use” notice on the forklift. In these cases, you must stop using it until it’s repaired. After major fixes, another check may be needed to make sure it’s safe again.
What Are the Consequences of Skipping Thorough Examinations?
Neglecting thorough examinations can lead to:
- Large fines and penalties from regulators
- Higher risk of accidents and injuries
- Equipment failure during important tasks
- Invalid insurance if something goes wrong
- Expensive emergency repairs that could have been avoided
- Shorter lifespan of your equipment
The small investment in regular thorough examinations is insignificant compared to these potential consequences.
How Can TAG Forklift Trucks Help with Thorough Examinations?
While TAG Forklift Trucks does not carry out forklift thorough examinations directly, we support your compliance needs through expert servicing, repairs, and refurbishment. Our team ensures your equipment is well-maintained and inspection-ready, helping you stay safe, efficient, and within legal requirements. We also supply genuine parts and accessories to keep your forklifts performing at their best.
If your equipment is no longer fit for purpose, we offer a wide range of new forklifts and used equipment from trusted brands, along with flexible hire options. Our certified operator training and fleet management solutions further support your operations, giving you the confidence that your team and equipment are fully prepared for everyday demands and safety checks alike.
Protect Your Workplace with Thorough Examinations
A thorough forklift examination is more than just a legal requirement. It’s essential for keeping your workplace safe and efficient. These checks ensure that all the important parts of your forklift are working properly, reducing the risk of accidents and costly downtime. While the process is simple, neglecting it can lead to severe consequences.
Get Thorough Support from TAG
If you need help keeping your forklifts in top shape, TAG Forklift Trucks is here for you. Contact us to learn how our expert servicing and equipment solutions can keep your forklifts running safely and efficiently.
Additional sources:
https://www.thoroughexamination.org/
