Knowledge Hub

What Is a Thorough Examination?

A Thorough Examination is a legal safety inspection required for any lifting equipment — including forklifts, pallet stackers, and other materials-handling machinery.
Think of it as the MOT test for your forklift — confirming that every safety-critical component is in proper working condition and compliant with UK law.

These inspections are carried out under two key sets of regulations:

LOLER 1998 – Lifting Operations and Lifting Equipment Regulations
PUWER 1998 – Provision and Use of Work Equipment Regulations

What a Thorough Examination Covers

A Thorough Examination includes the inspection of all safety-critical parts such as:

Fork arms and carriage assemblies
Masts, lift chains, and hydraulic systems
Steering, braking, and control functions
Overhead guards and load backrests
Tyres, stabilisers, and overall structural integrity

A Thorough Examination is not the same as a routine service.
It is a legal safety inspection, not a mechanical tune-up, and must be completed by a qualified and independent examiner.

How Often Should a Thorough Examination Take Place?

The inspection interval depends on how the equipment is used:

Used to lift people: every 6 months
Used to lift goods only: every 12 months
Operated in harsh or exceptional conditions: as advised by the competent examiner
After installation, major repair, or accident: before being returned to service

These are the minimum legal requirements. Equipment used frequently or in demanding environments may need more frequent examinations.

Who Can Carry Out a Thorough Examination?

Only a competent person can legally perform a Thorough Examination — someone with the training, experience, and independence to properly assess the equipment’s safety.

Dyback recommends using CFTS-accredited examiners (Consolidated Fork Truck Services).
CFTS ensures compliance with both LOLER and PUWER, and all examiners work to a recognised national standard.

You can verify a registered examiner at www.thoroughexamination.org.

After the Examination

Once the inspection is complete, you will receive a Report of Thorough Examination (LOLER certificate) detailing:

Equipment make, model, and serial number
Examination date and next due date
Details of any defects or advisories

This report must be kept for at least two years and made available if requested by the HSE or your insurance provider.

Dyback’s Commitment to Safety

At Dyback Ltd, safety and reliability go hand in hand.
We provide nationwide Thorough Examination services through CFTS-accredited partners, ensuring every forklift remains safe, compliant, and performing at its best.

Every Dyback machine is supported with craftsmanship, reliability, and trust — from the workshop to the workplace.

Call: +44 (0)1242 374 354
Email: service@dyback.co.uk
Address: Dyback Ltd, Unit 7 Halfpenny Farm, Cold Pool Lane, Gloucestershire GL51 4UP

The Importance of Regular Forklift Servicing

Every forklift, no matter how robust, requires regular servicing to remain safe, efficient, and reliable.
Just like a car needs maintenance to stay roadworthy, a forklift must undergo routine checks to ensure it continues to perform safely in your workplace.

A forklift works under constant stress — lifting heavy loads, operating on uneven ground, and performing repetitive hydraulic movements.
Without regular servicing, wear and tear can go unnoticed, leading to breakdowns, unsafe operation, and costly downtime.

What Servicing Involves

A typical service includes inspection and maintenance of the following:

Engine or electric drive systems
Hydraulics, hoses, pumps, and cylinders
Brakes, steering, and tyres
Mast, chains, and lifting components
Electrical systems and batteries
Safety features, lights, alarms, and controls

Routine servicing ensures any worn, damaged, or unsafe components are replaced before they fail.
Preventive maintenance costs far less than emergency repairs and helps avoid unplanned downtime.

Safety and Legal Responsibility

Under the Provision and Use of Work Equipment Regulations (PUWER) 1998, employers must ensure that all work equipment — including forklifts — is maintained in an efficient state and good repair.

Failing to maintain a forklift properly can result in:

Accidents or injury to operators and staff
HSE enforcement actions or fines
Invalidated warranties or insurance

Regular servicing keeps your equipment legally compliant, your staff safe, and your operations running smoothly.

How Often Should a Forklift Be Serviced?

Service intervals depend on usage hours and working conditions, but as a general guide:

Light use (up to 10 hrs/week): every 12 months
Medium use (10–20 hrs/week): every 6 months
Heavy use (over 20 hrs/week or daily operation): every 3 months
After major repairs or long storage: before being returned to service

Most electric and diesel forklifts also require a Thorough Examination under LOLER every 6 to 12 months.
(See our Thorough Examination Guide for more details.)

Servicing Protects More Than the Machine

Regular maintenance benefits both performance and value:

Extends lifespan by reducing component wear
Improves lifting efficiency and energy use
Prevents costly breakdowns
Protects resale value
Keeps operators safe and confident

Dyback Service Support

At Dyback Ltd, we provide full UK service coverage — from routine maintenance to complete overhauls and CFTS-accredited Thorough Examinations.
Our engineers are trained to manufacturer standards and use genuine parts for every Dyback and Maximal model.

Reliable machinery starts with reliable maintenance — that’s the Dyback difference.

Call: +44 (0)1242 374354
Email: service@dyback.co.uk
Address: Dyback Ltd, Unit 7 Halfpenny Farm, Cold Pool Lane, Gloucestershire, GL51 4UP

HSE and Your Obligations When Using Forklifts

(Safety & Compliance – Dyback Knowledge Hub)

Understanding the HSE’s Role

The Health and Safety Executive (HSE) is the UK’s national regulator for workplace health and safety.
Its role is to set and enforce standards designed to prevent injuries and accidents at work — including those involving lifting equipment such as forklifts, pallet trucks, and stackers.

If you own, operate, or manage forklifts, you have legal obligations under the Health and Safety at Work Act 1974, LOLER 1998, and PUWER 1998 to ensure your equipment is safe and that all operators are trained and competent.

Your Key Legal Responsibilities

If your business owns or operates forklifts, you are legally required to:

Provide safe equipment – All forklifts must be kept in good working order and inspected regularly.
Carry out Thorough Examinations – Each forklift must have a valid LOLER certificate, completed by a competent person every 6 or 12 months.
Ensure operator training – All operators must be properly trained and certified by an accredited instructor.
Assess risks and working areas – Regularly evaluate operating zones, pedestrian areas, and loading points.
Maintain records – Keep service reports, inspection certificates, and examination documents up to date.
Report defects or incidents – Any equipment fault, near-miss, or injury must be reported and investigated.

Failure to comply can lead to HSE enforcement action, including improvement or prohibition notices, and potential prosecution.

The Main Regulations That Apply

The key UK regulations governing forklift safety are:

HSWA 1974 – Health and Safety at Work Act: outlines general duties for employers and employees.
LOLER 1998 – Lifting Operations and Lifting Equipment Regulations: covers safe lifting and Thorough Examinations.
PUWER 1998 – Provision and Use of Work Equipment Regulations: ensures all equipment is maintained and fit for purpose.
RIDDOR 2013 – Reporting of Injuries, Diseases and Dangerous Occurrences Regulations: sets out how workplace incidents must be reported.
WAHR 2005 – Work at Height Regulations: governs the safe use of platforms and people-lifting equipment.

Training and Competence

Only trained and authorised operators are permitted to use forklifts.
Training should cover:

Basic operation and safety awareness
Site-specific hazards such as ramps, gradients, and pedestrian areas
Regular refresher courses every few years

Recognised training bodies include RTITB, AITT, ITSSAR, and NPORS — all approved by the HSE.
Keep copies of all training certificates on file as part of your compliance evidence.

Maintenance and LOLER Inspections

Under PUWER and LOLER, forklifts must be:

Serviced regularly in line with the manufacturer’s recommendations
Inspected annually, or every six months for lifting equipment that carries people
Accompanied by valid LOLER Thorough Examination reports

How to Choose the Right Forklift

Choosing the right forklift means matching the truck to your environment, the loads you handle, and the type of power you need. The correct choice improves safety, efficiency, and long-term reliability.

1. Understand Your Working Environment

Different sites require different types of forklifts.
For smooth indoor floors, electric counterbalance trucks or pallet trucks work best because they’re quiet, clean, and manoeuvrable.
If your work takes you between indoor and outdoor areas, a semi-electric model like the Dyback QL1400 offers a balance of power, flexibility, and self-loading ability.
Rough or uneven yards call for diesel or rough-terrain forklifts with high ground clearance.
For tight aisles, a reach truck or three-wheel electric model gives tighter turning and extended reach.
In food or clean environments, AGM or lithium-powered units are ideal because they produce no emissions and require little maintenance.

2. Know Your Loads

Match the truck’s lifting capacity and height to the weight, size, and shape of your loads.
Always include packaging and pallet weight when calculating total capacity.
Attachments such as clamps or rotators may reduce a truck’s rated lifting ability.
A 1000 kg truck like the Dyback QL1400 is ideal for standard pallets and van loading.

3. Choose the Right Power Source

Electric forklifts are quiet, efficient, and best suited for indoor or light-duty work.
Semi-electric or self-loading models are compact, emission-free, and ideal for logistics and last-mile delivery.
Diesel and LPG trucks deliver higher power and longer run times, perfect for outdoor and heavy-duty applications.
Lithium-ion machines charge quickly and need minimal maintenance, making them ideal for multi-shift operations.

4. Priorities Operator Safety

Choose equipment that supports the operator through ergonomic controls, good visibility, overhead guards, and stable hydraulics.
Every Dyback QL1400 is built for safe, simple operation and proven reliability.

5. Check After-Sales Support

Even the best forklifts need professional maintenance.
Look for a supplier that offers local service coverage, genuine parts, CFTS-accredited Thorough Examinations, and clear warranty options.
Dyback provides full UK-wide service and support, ensuring complete confidence through the life of your equipment.

Quick Checklist

Before buying or hiring, make sure you’ve considered:

Load weight and height
Operating surface and environment
Indoor or outdoor use
Power type
Operator safety
Service and support availability