What does LOLER Regulation 9 require for forklift examinations?

LOLER Regulation 9 requires that forklift trucks, as lifting equipment, undergo thorough examination by a competent person at prescribed intervals. For forklifts used to lift goods, the examination must occur at least every twelve months or at the intervals specified in an examination scheme drawn up by a competent person. For forklifts used to lift persons (with a work platform), the interval is at least every six months. The thorough examination must assess whether the forklift is safe for continued use and the results must be documented in a written report before the forklift is returned to service.

How often should a forklift be thoroughly examined under LOLER?

A forklift used for lifting goods must be thoroughly examined at least every twelve months. If the forklift is fitted with a work platform for lifting persons, the maximum interval is six months. The competent person may recommend shorter intervals based on the operating conditions, usage intensity, environment (outdoor, cold store, corrosive atmosphere) and the age and condition of the forklift. Daily pre-use checks and periodic maintenance inspections supplement but do not replace the statutory thorough examination.

Who is a competent person for LOLER forklift thorough examinations?

A competent person under LOLER is someone with sufficient practical and theoretical knowledge and experience of the equipment to detect defects and assess their significance. For forklift thorough examinations, this is typically an engineer employed by an independent inspection body, such as an insurance company engineering surveyor or a specialist forklift examination company. The competent person must be independent and impartial, with no conflict of interest regarding the equipment. The duty holder is responsible for appointing a suitably qualified competent person.

What is the difference between a LOLER thorough examination and a forklift service?

A LOLER thorough examination is a statutory inspection conducted by a competent person to determine whether the forklift is safe for continued use. It focuses on structural integrity, safety-critical components and compliance with the regulations. A forklift service is a maintenance activity conducted by a service engineer to restore or maintain the operational condition of the forklift, including oil changes, filter replacements, brake adjustments and wear part replacements. Both are necessary, but a service does not satisfy the LOLER thorough examination requirement and vice versa.

When must fork blades be replaced on a forklift?

Fork blades must be withdrawn from service if the blade thickness at the heel has worn to 90% of the original manufactured thickness. This is typically measured using an ultrasonic thickness gauge or vernier callipers at the thinnest point of the heel section. Forks must also be replaced if cracks are detected at the heel, the blade or shank, if the fork tip height difference between paired forks exceeds 3% of the blade length, if the fork angle has deformed beyond 93 degrees from the original 90 degrees, or if the surface shows significant pitting or corrosion that reduces the load-bearing cross-section.

What happens if a defect is found during a LOLER forklift examination?

If the competent person finds a defect that presents an existing or imminent danger, the forklift must be taken out of service immediately and the duty holder notified in writing. Under LOLER Regulation 10, the competent person must send a copy of the report to the relevant enforcing authority (HSE or local authority) as soon as practicable. For defects that do not present immediate danger but require attention, the report must specify a timeframe within which the repairs must be completed. The forklift must not be used until all safety-critical defects have been rectified and, where necessary, a further examination has confirmed it is safe.

Is this LOLER forklift examination checklist free?

Yes. Download and use this LOLER forklift thorough examination checklist at no cost. Open the file in your browser and use Print then Save as PDF for a paper copy. No MapTrack account is required. If you want digital forklift examinations on mobile with photo capture, automatic defect escalation, LOLER certificate expiry tracking and compliance dashboards per asset, MapTrack can do that. Book a demo to see how it works.

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Free LOLER forklift thorough examination checklist for Regulation 9. Covers mast, forks, chains, hydraulics, brakes and certification. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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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 that all lifting equipment undergoes thorough examination by a competent person at prescribed intervals. For forklift trucks, which are classified as lifting equipment because they raise and lower loads, this examination covers the mast assembly, forks, lift chains, hydraulic system, braking system, steering, tyres, operator restraint and all safety devices.

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) and INDG457 (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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Generate region-specific compliance reports that match local regulator expectations.
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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 any defect presents an existing or imminent danger, the forklift must be taken out of service immediately and the duty holder notified in writing. Under LOLER Regulation 10, defects involving existing or imminent danger must be reported to the relevant enforcing authority (HSE or local authority). Sign the report, issue the examination certificate and record the next thorough examination due date in the equipment register.

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How often should you complete this checklist?

LOLER 1998, Regulation 9 sets the thorough examination intervals for lifting equipment. Forklift trucks used solely for lifting goods must be thoroughly examined at least every twelve months, or at shorter intervals if specified in 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 significant repair, modification or event that may have affected the forklift integrity (such as a collision, tip-over or overload), a thorough examination must be carried out before the forklift is returned to service.

Frequently asked questions

What does LOLER Regulation 9 require for forklift examinations?: LOLER Regulation 9 requires that forklift trucks, as lifting equipment, undergo thorough examination by a competent person at prescribed intervals. For forklifts used to lift goods, the examination must occur at least every twelve months or at the intervals specified in an examination scheme drawn up by a competent person. For forklifts used to lift persons (with a work platform), the interval is at least every six months. The thorough examination must assess whether the forklift is safe for continued use and the results must be documented in a written report before the forklift is returned to service.
How often should a forklift be thoroughly examined under LOLER?: A forklift used for lifting goods must be thoroughly examined at least every twelve months. If the forklift is fitted with a work platform for lifting persons, the maximum interval is six months. The competent person may recommend shorter intervals based on the operating conditions, usage intensity, environment (outdoor, cold store, corrosive atmosphere) and the age and condition of the forklift. Daily pre-use checks and periodic maintenance inspections supplement but do not replace the statutory thorough examination.
Who is a competent person for LOLER forklift thorough examinations?: A competent person under LOLER is someone with sufficient practical and theoretical knowledge and experience of the equipment to detect defects and assess their significance. For forklift thorough examinations, this is typically an engineer employed by an independent inspection body, such as an insurance company engineering surveyor or a specialist forklift examination company. The competent person must be independent and impartial, with no conflict of interest regarding the equipment. The duty holder is responsible for appointing a suitably qualified competent person.
What is the difference between a LOLER thorough examination and a forklift service?: A LOLER thorough examination is a statutory inspection conducted by a competent person to determine whether the forklift is safe for continued use. It focuses on structural integrity, safety-critical components and compliance with the regulations. A forklift service is a maintenance activity conducted by a service engineer to restore or maintain the operational condition of the forklift, including oil changes, filter replacements, brake adjustments and wear part replacements. Both are necessary, but a service does not satisfy the LOLER thorough examination requirement and vice versa.
When must fork blades be replaced on a forklift?: Fork blades must be withdrawn from service if the blade thickness at the heel has worn to 90% of the original manufactured thickness. This is typically measured using an ultrasonic thickness gauge or vernier callipers at the thinnest point of the heel section. Forks must also be replaced if cracks are detected at the heel, the blade or shank, if the fork tip height difference between paired forks exceeds 3% of the blade length, if the fork angle has deformed beyond 93 degrees from the original 90 degrees, or if the surface shows significant pitting or corrosion that reduces the load-bearing cross-section.
What happens if a defect is found during a LOLER forklift examination?: If the competent person finds a defect that presents an existing or imminent danger, the forklift must be taken out of service immediately and the duty holder notified in writing. Under LOLER Regulation 10, the competent person must send a copy of the report to the relevant enforcing authority (HSE or local authority) as soon as practicable. For defects that do not present immediate danger but require attention, the report must specify a timeframe within which the repairs must be completed. The forklift must not be used until all safety-critical defects have been rectified and, where necessary, a further examination has confirmed it is safe.
Is this LOLER forklift examination checklist free?: Yes. Download and use this LOLER forklift thorough examination checklist at no cost. Open the file in your browser and use Print then Save as PDF for a paper copy. No MapTrack account is required. If you want digital forklift examinations on mobile with photo capture, automatic defect escalation, LOLER certificate expiry tracking and compliance dashboards per asset, MapTrack can do that. Book a demo to see how it works.

Applicable regulatory standards

This template aligns with the following regulations and standards:

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER), Regulation 9 (Thorough examination and inspection)
LOLER 1998, Regulation 10 (Reports and defects)
Provision and Use of Work Equipment Regulations 1998 (PUWER), Regulation 6 (Inspection)
Health and Safety at Work etc. Act 1974 (General duties)
HSE L117 (Rider-Operated Lift Trucks: Operator Training and Safe Use)
HSE INDG457 (Thorough Examination of Lifting Equipment)

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