📋 UKMHA GN28

0. SCOPE

The purpose of this guidance note is to identify the statutory duties of the duty holder and the Competent Person for Thorough Examinations under LOLER 98 and safety inspections under PUWER 98. Guidance is provided on what should be included in schemes of Thorough Examination and inspection. This guidance applies to industrial and rough-terrain, masted and variable-reach trucks and their attachments.

Purpose of Thorough Examination and Safety Inspection

The thorough examination and safety inspection is intended to:

• Verify that the truck is operating as it is intended to when lifting and travelling
• Identify defects which could compromise the safe use of the truck
• Specify the time-scales within which identified defects or weaknesses need to be rectified
• Assess the correct function of all safety devices
• Check that warning notices are correctly fixed and legible
• Where necessary specify any limitations on the use of the truck

NOTE: Low lift (pallet) trucks that lift to not more than 300mm from the ground do not require Thorough Examination under LOLER 98 regulation 9. They do, however, need periodic safety inspections under PUWER 98, regulation 6.

1. LEGISLATION

The requirements for work equipment and equipment for lifting are implemented in UK law by two Statutory Instruments:

• SI 1998 No. 2306- The Provision and Use of Work Equipment Regulations 1998 (PUWER 98)
• SI 1998 No. 2307 – The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER 98)
• SI 2002 No. 2776- The Dangerous Substances and Explosive Atmospheres Regulations 2002

Approved Codes of Practice and Guidance

• L22- Safe use of work equipment – PUWER 1998
• L113- Safe use of lifting equipment – LOLER 1998
• L117- Rider-operated lift trucks – Operator training and safe use

Available to download free from www.hse.gov.uk

2. REQUIREMENTS FOR COMPETENT PERSONS

Only Competent Persons shall carry out Thorough Examinations and safety inspections. A Competent Person is defined as a person who, based on their education, training and professional experience, has sufficient practical and theoretical knowledge in the technology of industrial trucks to evaluate the safety of an industrial truck.

The Competent Person shall be sufficiently independent to reach an unbiased judgement. Where the Examination is carried out by a person who is servicing/maintaining the equipment, the servicing/maintenance should be carried out after the Examination.

3. FREQUENCY OF EXAMINATION

Standard Intervals

• 12 months- Standard interval for trucks working up to 40 hours per week
• 6 months- Trucks working 40-80 hours per week, OR any truck used for elevating persons
• 4 months- Trucks working over 80 hours per week, OR working in arduous environments (marine, corrosive, cold stores below -10°C, etc.)
• 6 months- Removeable attachments and accessories (even if mounted on a truck with longer interval)

NOTE: Additional examinations required after any exceptional event (overloading, accidents, incidents, impacts).

4. GENERAL REQUIREMENTS

• Truck should be cleaned prior to examination
• Adequate lighting and safe working area must be provided
• Equipment must be operational with sufficient fuel/battery power
• Access to inspection compartments must be available
• Operating manual should be available on request

5. CONTENT OF EXAMINATION

5.1 LOAD HANDLING MECHANISM [LOLER]

5.1.1 Lift Chains

Visually inspect for cracked or missing link plates, elongated holes, loose or worn pins, corrosion, chain elongation, chain anchors and pulleys (per BITA GN15).

5.1.2 Mast/Telescopic Boom

Inspect at maximum lift height/extension. Operate throughout full range including tilt. Check for damage or scoring.

5.1.3 Hydraulic Cylinders

Inspect lift, tilt and reach cylinders for leakage and mounting security. Check hoses and piping for damage, exposed braiding, bulges, kinks and corrosion.

5.1.4 Fork Arms

Verify combined stamped capacity (S.W.L) meets truck capacity. Check for cracks, deformation or excessive wear (per BITA GN62). Verify fork location means and end stops are satisfactory.

5.1.5 Attachments

Inspect for distortion, cracks and security. Check hydraulic components for leaks. Operate through full range to ensure controlled movement.

5.1.6 Load Handling Testing

Lifting system – load descent:

• Masted trucks ≤10,000 kg: max 50mm in 5 minutes
• Masted trucks >10,000 kg: max 100mm in 5 minutes
• Telescopic boom trucks: max 75mm in 5 minutes at maximum reach

Tilt system – forward tilting:

• Masted trucks: max 5° rotation in 10 minutes (load at 2500mm or max height)
• Telescopic boom trucks: max 5° rotation in 10 minutes at maximum load

5.2 BRAKING SYSTEMS [PUWER]

• Inspect hydraulic/pneumatic hoses and piping for leaks, corrosion and damage
• Check cables and linkages for damage and wear
• Check mechanical condition of pedals and levers
• Test operational performance of service and parking brakes

5.3 STEERING SYSTEMS [PUWER]

• Inspect mechanical components (cables, chains, belts, linkages, ball joints)
• Inspect hydraulic components (unit, pump, cylinders, hoses)
• Manoeuvre truck in figure of eight to check response

5.4 TRACTION SYSTEM [PUWER]

• Inspect prime mover and transmission for leaks and damage
• Check controls, cables and linkages
• Inspect exhaust system and emissions (IC engines)
• Check battery cell connectors and cables
• Inspect tyres for wear, damage and bonding failure
• Drive truck forward and reverse - check for smooth operation
• Check LPG systems for deterioration, corrosion and leaks

5.5 SAFETY SYSTEMS [PUWER]

• Test visual and audible warning devices (horn, alarms, lights, indicators)
• Check safety interlocks (seat switch, starter inhibitor, micro switches)
• Test pedestrian control machines (tiller return, anti-pinning device)
• Check cutback speeds on rider pallet trucks
• Test side arms on stacker machines (lift inhibit at 1800mm)
• Inspect electrical circuits - no components bridged or bypassed
• Verify capacity/data plates are secure, legible and accurate [LOLER]
• Check function labelling is clear and secure
• Test road lights, wipers, mirrors where fitted
• Check wire guidance systems and aisle interlocks
• Inspect escape harness (expiration date, mounting, condition)
• Test operator assistance systems (cameras, detection systems)

5.6 GENERAL STRUCTURE [PUWER]

• Inspect chassis/frame for damage and weld cracking
• Check roll-over protective structure/overhead guard for damage and mounting (BITA GN65)
• Inspect load backrest extension for security and soundness
• Check all fastenings securing structural members
• Inspect seat mountings, operator restraint (seat belt) for damage and wear

NOTE: Seat belt must be fitted on seated counterbalance lift trucks up to 10 tonne capacity (does not apply to reach trucks).

5.7 PROTECTED TRUCKS IN EXPLOSIVE AREAS

Competent Person must have additional training on Ex equipment and protection concepts. Detailed inspection requirements depend on protection type used and are outside scope of this guidance.

6. ON CONCLUSION OF EXAMINATION

6.1 Report Preparation

Competent Person shall prepare a report (paper or electronic) identifying:

• Defects presenting danger to persons
• Requirements to remove equipment from service
• Items requiring replacement/rectification with timescales
• Items requiring monitoring
• Observations, recommendations and comments

Original report given to user within 28 days. Reports kept minimum 2 years.

6.2 Serious Defects - Reporting Requirements

If existing or imminent risk of serious injury, Competent Person shall immediately recommend withdrawal from service.

Under LOLER: Any existing defect or imminent failure of safety critical lifting elements must be reported to relevant Enforcement Authority:

• HSE- lease/rental trucks, factories, manufacturing sites
• Local Authority- retail, warehousing, distribution (except lease/rental)

Reportable issues include: Chain or fork wear beyond limits, missing or defaced capacity/data plate.

6.3 Labelling

Recommended to apply label indicating:

• Examined and inspected per BITA GN28 and LOLER Regulation 9
• Next safety inspection required date
• Date repairs must be completed (if applicable)

7. BIBLIOGRAPHY

Reference	Title
BITA GN15	Industrial truck leaf chains; Maintenance and inspection
BITA GN50	Tyre tread wear
BITA GN62	Maintenance, Inspection and Repair of Fork Arms & Attachments
BITA GN65	Overhead guard (FOPS) damage
PM28	Working platforms on forklift trucks - www.hse.gov.uk/pubns/pm28.pdf
INDG422	Thorough Examination guide - www.hse.gov.uk/pubns/indg422.pdf