Free LOLER forklift thorough examination checklist
Free LOLER forklift thorough examination checklist for Regulation 9. Covers mast, forks, chains, hydraulics, brakes and certification. Download free.
Updated 26 Sept 2026
LOLER Forklift Thorough Examination
Thorough examination of forklift truck per LOLER 1998 Regulation 9.
Mast, Chains & Forks
Hydraulic System
Safety Devices
Load Rating Plate & Markings
Tyres & Wheels
Operator Controls & General Condition
Competent Person Sign-off
Signature
Print name
Date & time
Duty Holder / Site Manager Acknowledgement
Signature
Print name
Date
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Short answer
A LOLER forklift thorough examination checklist records a competent person's examination of a lift truck's mast, chains, carriage, forks and tilt, plus the PUWER inspection of brakes, steering and tyres. Regulation 9(3) of LOLER 1998 requires lifting equipment exposed to deteriorating conditions to be examined at least every 12 months, or every 6 months when it lifts people, unless an examination scheme sets other intervals.
Checked against LOLER 1998 (Current revised version as at 2026-10-26 (legislation.gov.uk, no outstanding effects listed)) on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack LOLER forklift thorough examination checklist contains 25 checks across 6 sections. Sections covered: Mast, Chains & Forks, Hydraulic System, Safety Devices, Load Rating Plate & Markings, Tyres & Wheels, Operator Controls & General Condition.
- Unless an examination scheme sets other intervals, a forklift in deteriorating conditions needs a thorough examination every 12 months, or every 6 months if it lifts people.
- Examine it again whenever exceptional circumstances liable to jeopardise its safety occur, such as a tip-over or overload (reg 9(3)(a)(iv)).
- After the examiner reports a defect that is or could become dangerous, the truck is not used until it is fixed, or past any repair deadline set.
- Keep each periodic report until the next one is made or for two years, whichever is later (LOLER reg 11).
- A service is not a thorough examination: the examiner judges continued safe use and reports to the Schedule 1 content.
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What is a LOLER forklift thorough examination checklist?
A LOLER forklift thorough examination checklist is a structured document used to record the thorough examination of forklift trucks and other powered industrial trucks as required by the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). Regulation 9 requires lifting equipment exposed to conditions that could cause dangerous deterioration to be thoroughly examined by a competent person at set intervals or under an examination scheme. For forklift trucks, which are classified as lifting equipment because they raise and lower loads, the LOLER examination covers the lifting parts, such as the mast, chains, carriage, forks and tilt mechanism. HSE notes it can be combined with the PUWER inspection of non-lifting parts such as brakes, lights and fall-over protection, and this checklist covers both, including the hydraulic system, steering and tyres.
Forklift trucks are involved in a significant number of workplace injuries and fatalities in Great Britain each year. The Health and Safety Executive (HSE) publishes guidance on forklift safety through documents including L117 (Rider-Operated Lift Trucks: Operator Training and Safe Use), INDG457 (Use lift trucks safely) and INDG422 (Thorough examination of lifting equipment). A thorough examination under LOLER is more detailed than a daily pre-use check or a routine maintenance service. It is a statutory inspection conducted by a competent person who assesses the structural integrity, mechanical condition and safety of the forklift to determine whether it is safe for continued use. Without documented thorough examinations, duty holders risk enforcement action from the HSE, including improvement notices, prohibition notices and prosecution.
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Benefits of using this LOLER forklift thorough examination checklist
- LOLER compliance: documented thorough examinations satisfy Regulation 9 and provide evidence for HSE inspectors during workplace visits or following an incident.
- Defect detection: systematic checks of the mast, forks, chains, hydraulics, brakes and safety devices catch wear, damage and deterioration before a critical failure occurs.
- Fork integrity verification: measuring fork blade thickness, checking for cracks at the heel and verifying the fork retaining mechanism prevents fork failures that can drop loads onto workers.
- Reduced downtime: early identification of worn components allows planned replacement during scheduled maintenance windows rather than emergency breakdown repairs.
- Audit trail: completed examination reports create a permanent record that can be cross-referenced with the equipment register, maintenance log and operator training records.
- Consistent standards: a standardised checklist ensures every competent person examines the same critical points regardless of forklift type, manufacturer or workplace location.
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- Set each asset's inspection interval to match the rule where it works.
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What to include in a LOLER forklift thorough examination checklist
This LOLER forklift thorough examination checklist covers 10 key areas:
- Forklift identification: unique asset number, manufacturer, model, serial number, year of manufacture, rated capacity, mast type and maximum lift height.
- Examination details: date of examination, name and employer of the competent person, LOLER regulation reference (Reg 9), examination scheme reference and previous examination date.
- Mast and carriage assembly: visual and operational inspection of mast channels, rollers, carriage plate, side shift mechanism (if fitted), tilt cylinder pins and bushes, and chain anchor points.
- Forks and attachments: measurement of fork blade thickness at the heel (discard if worn to 90% of original), check for cracks, straightness, locking pin engagement and wear on mounting hooks.
- Lift chains and hydraulic system: chain wear measurement, elongation check (discard at 3% elongation), hydraulic cylinder condition, hose integrity, valve operation and leak inspection.
- Braking system: service brake and parking brake function test under load, brake pad or shoe condition, hydraulic brake fluid level and handbrake hold test on an incline.
- Steering and tyres: steering play, power steering operation, tyre condition (pneumatic inflation, solid tyre wear indicators, chunking and flat spots) and wheel nut torque.
- Safety devices: operator restraint system (seatbelt or operator presence system), overhead guard integrity, load backrest condition, horn, lights, reversing alarm and any fitted camera systems.
- Defect register: description of each defect found, risk rating, whether the forklift may continue in use or must be withdrawn, and corrective action required with timeframe.
- Overall result and certification: Pass or Fail declaration, next thorough examination due date, competent person signature and report reference number.
How to use this LOLER forklift thorough examination checklist
- Record the forklift identification details including asset number, manufacturer, model, serial number, rated capacity and mast type.: Verify the data plate is legible and securely attached to the forklift. Cross-reference the asset number against the lifting equipment register to confirm the examination is due. Record the examination scheme reference and the regulation under which this thorough examination is conducted (LOLER 1998, Regulation 9). Note the operating environment (indoor warehouse, outdoor yard, cold store) as this affects the examination scope.
- Conduct a visual inspection of the mast assembly, carriage, overhead guard, load backrest and chassis for cracks, corrosion, deformation and weld integrity.: Examine the mast channels for wear, scoring and straightness. Check rollers for flat spots and free rotation. Inspect the carriage plate for cracks, particularly at weld points. Verify the overhead guard is securely mounted with no cracked or missing members. Check the chassis and counterweight mounting bolts. On reach trucks and articulated forklifts, inspect the reach mechanism and articulation joints for excessive play.
- Measure fork blade thickness at the heel, check for cracks using visual or dye penetrant methods, and verify the fork retaining mechanism operates correctly.: Forks must be withdrawn from service if the blade thickness at the heel has worn to 90% of the original manufactured thickness. Measure both forks at the thinnest point using a calibrated ultrasonic thickness gauge or vernier callipers. Inspect the top and bottom surfaces of each fork for cracks, paying particular attention to the heel radius. Confirm the fork locking pins engage fully and the positioning mechanism allows adjustment without binding.
- Function test the lift chains, hydraulic system, brakes, steering, tyres and all safety devices under operational conditions.: Raise and lower the mast through its full travel with and without a test load, observing chain movement for stiff links, uneven tension and abnormal noise. Check hydraulic cylinders for drift by holding a raised load for a timed period (typically two minutes). Test the service brake stopping distance, parking brake hold on an incline and brake balance. Verify steering response and power steering operation. Check tyre condition, inflation pressures and wheel nut torque. Test the seatbelt, horn, lights, reversing alarm and operator presence system.
- Complete the defect register, record the overall result (Pass or Fail), sign the report and set the next thorough examination due date.: List every defect found with a risk rating and recommended corrective action. If a defect presents an existing or imminent danger, the forklift must be taken out of service immediately. The competent person must tell the duty holder straight away of any defect that is or could become a danger and, where it involves an existing or imminent risk of serious personal injury, send a copy of the report to the relevant enforcing authority (HSE or the local authority) under LOLER Regulation 10. Sign the report, issue the examination certificate and record the next thorough examination due date in the equipment register.
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LOLER 1998, Regulation 9 sets the thorough examination intervals for lifting equipment. Where a forklift truck used solely for lifting goods is exposed to conditions causing deterioration that is liable to result in dangerous situations, it must be thoroughly examined at least every twelve months, or at the intervals set by an examination scheme drawn up by a competent person. If a forklift is used to lift persons (for example, with a work platform attachment), the interval reduces to at least every six months.
In addition to the statutory thorough examination, forklift trucks should receive a daily pre-use check by the operator before each shift, a weekly or monthly maintenance inspection depending on usage intensity and a full service at manufacturer-recommended intervals. After any exceptional circumstances liable to jeopardise the forklift safety (such as a collision, tip-over or overload), a thorough examination must be carried out before the forklift is returned to service.
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Frequently asked questions
Applicable regulatory standards
This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| The Lifting Operations and Lifting Equipment Regulations 1998Thorough examination (6 or 12 monthly, by scheme, or after exceptional circumstances), inspections between, defect reporting, report contents and retention (next report or two years, whichever later). | Current revised version as at 2026-10-26 (legislation.gov.uk, no outstanding effects listed) |
| legislation.gov.uk (The National Archives) |
| The Provision and Use of Work Equipment Regulations 1998Maintenance of work equipment and competent-person inspection of non-lifting parts such as brakes, steering and lights. | Current revised version as at 2026-10-26 (legislation.gov.uk, no outstanding effects listed) |
| legislation.gov.uk (The National Archives) |
| Thorough examination of lifting equipment: A simple guide for employersHSE's plain guide to thorough examination of lifting equipment for employers. | INDG422, first published 06/08 | Whole instrument | Health and Safety Executive (HSE) |
| Rider-operated lift trucks. Operator training and safe use. Approved Code of Practice and guidanceApproved Code of Practice for rider-operated lift trucks; it absorbed HSG6 guidance on maintenance and thorough examination. | L117, revised edition published 2013 | Whole instrument | Health and Safety Executive (HSE) |
| Health and Safety at Work etc. Act 1974General duty of employers, so far as reasonably practicable, that sits behind the LOLER and PUWER duties. | Current revised version as at 2026-10-26 (legislation.gov.uk) |
| legislation.gov.uk (The National Archives) |
The Lifting Operations and Lifting Equipment Regulations 1998
Edition: Current revised version as at 2026-10-26 (legislation.gov.uk, no outstanding effects listed)
Thorough examination (6 or 12 monthly, by scheme, or after exceptional circumstances), inspections between, defect reporting, report contents and retention (next report or two years, whichever later).
- reg 9: Thorough examination before first use, after installation and periodically, plus inspection between examinations where appropriate.
- reg 9(3)(a)(i): Equipment for lifting persons and lifting accessories exposed to deteriorating conditions must be thoroughly examined at least every 6 months, unless an examination scheme applies.
- reg 10: Examiners must notify and report defects; equipment must not be used until a defect is fixed, or past the deadline set for a defect that could become dangerous.
- reg 11: Requires keeping of declarations of conformity and reports of thorough examination for set periods.
- Sch 1: Lists the information a report of thorough examination must contain.
- reg 9(3)(a)(ii): Other lifting equipment exposed to deteriorating conditions must be thoroughly examined at least every 12 months, unless an examination scheme applies.
- reg 9(3)(a)(iv): Lifting equipment exposed to deteriorating conditions must also be thoroughly examined each time exceptional circumstances liable to jeopardise its safety have occurred.
- reg 9(3)(b): Where appropriate, a competent person inspects lifting equipment exposed to deteriorating conditions at suitable intervals between thorough examinations.
- reg 11(2)(a)(iv): Information in a report of a reg 9(3) thorough examination is kept available until the next report or for two years, whichever is later.
The Provision and Use of Work Equipment Regulations 1998
Edition: Current revised version as at 2026-10-26 (legislation.gov.uk, no outstanding effects listed)
Maintenance of work equipment and competent-person inspection of non-lifting parts such as brakes, steering and lights.
- reg 5: Work equipment must be maintained in an efficient state, in efficient working order and in good repair, with any maintenance log kept up to date.
- reg 6: Inspection by a competent person where safety depends on installation or equipment is exposed to deteriorating conditions, with results recorded.
Thorough examination of lifting equipment: A simple guide for employers
Edition: INDG422, first published 06/08
HSE's plain guide to thorough examination of lifting equipment for employers.
Rider-operated lift trucks. Operator training and safe use. Approved Code of Practice and guidance
Edition: L117, revised edition published 2013
Approved Code of Practice for rider-operated lift trucks; it absorbed HSG6 guidance on maintenance and thorough examination.
Health and Safety at Work etc. Act 1974
Edition: Current revised version as at 2026-10-26 (legislation.gov.uk)
General duty of employers, so far as reasonably practicable, that sits behind the LOLER and PUWER duties.
- s 2: General duty of employers to ensure, so far as reasonably practicable, the health, safety and welfare at work of their employees.
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
LOLER forklift thorough examination checklist preview
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
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<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Forklift identification: unique asset number, manufacturer, model, serial number, year of manufacture, rated capacity, mast type and maximum lift height.</li>
<li style="margin:4px 0;">Examination details: date of examination, name and employer of the competent person, LOLER regulation reference (Reg 9), examination scheme reference and previous examination date.</li>
<li style="margin:4px 0;">Mast and carriage assembly: visual and operational inspection of mast channels, rollers, carriage plate, side shift mechanism (if fitted), tilt cylinder pins and bushes, and chain anchor points.</li>
<li style="margin:4px 0;">Forks and attachments: measurement of fork blade thickness at the heel (discard if worn to 90% of original), check for cracks, straightness, locking pin engagement and wear on mounting hooks.</li>
<li style="margin:4px 0;">Lift chains and hydraulic system: chain wear measurement, elongation check (discard at 3% elongation), hydraulic cylinder condition, hose integrity, valve operation and leak inspection.</li>
<li style="margin:4px 0;">Braking system: service brake and parking brake function test under load, brake pad or shoe condition, hydraulic brake fluid level and handbrake hold test on an incline.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/loler-forklift-thorough-examination" style="color:#071D49;font-weight:600;text-decoration:none;">LOLER forklift thorough examination checklist</a> by MapTrack</p>
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The MapTrack LOLER forklift thorough examination checklist contains 25 checks across 6 sections.
- Short attribution
- MapTrack LOLER forklift thorough examination checklist, https://www.maptrack.com/templates/loler-forklift-thorough-examination
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- MapTrack. (2026). LOLER forklift thorough examination checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/loler-forklift-thorough-examination
Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/loler-forklift-thorough-examination.
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