Common Failures in LOLER Examinations of Counterbalance Forklifts

Ensuring the safety and compliance of counterbalance forklifts is critical in any industrial or warehouse setting. The Lifting Operations and Lifting Equipment Regulations (LOLER) mandate that lifting equipment, including counterbalance forklifts, undergo regular examinations to identify and rectify potential safety hazards. Understanding the most common failures observed during LOLER examinations can help you maintain your equipment better and ensure a safe working environment. In this blog post, we will discuss the typical issues found during LOLER inspections of counterbalance forklifts and provide tips on how to prevent them.

Importance of LOLER Examinations

LOLER examinations are essential for several reasons:

1. Safety: Identifying and addressing potential hazards can prevent accidents and injuries.

2. Compliance: Adhering to LOLER regulations is a legal requirement in the UK. Non-compliance can result in severe penalties.

3. Operational Efficiency: Well-maintained forklifts reduce the risk of breakdowns, ensuring smooth and uninterrupted operations.

4. Insurance: Compliance with LOLER regulations is often a prerequisite for insurance coverage. Regular inspections help avoid disputes in the event of an accident.

Common Failures in LOLER Examinations of Counterbalance Forklifts

1. Worn or Damaged Forks

• Issue: Forks can become worn or damaged due to regular use, collisions, or improper handling of loads.

• Impact: Worn or damaged forks can lead to load instability, increasing the risk of accidents.

• Prevention: Regularly inspect forks for signs of wear, cracks, or distortion. Replace them as needed and avoid overloading the forklift.

1. Hydraulic System Leaks

• Issue: Leaks in the hydraulic system can result from worn seals, damaged hoses, or loose fittings.

• Impact: Hydraulic leaks can cause a loss of lifting power and pose a slip hazard.

• Prevention: Regularly check the hydraulic system for leaks and ensure that all components are in good condition. Replace any damaged parts promptly.

1. Mast and Lift Chains

• Issue: The mast and lift chains can become worn, rusted, or damaged over time.

• Impact: Damaged or poorly maintained chains can fail, leading to load drops and potential injuries.

• Prevention: Regularly inspect the mast and lift chains for wear and damage. Lubricate and adjust the chains as needed and replace them if necessary.

1. Braking System Issues

• Issue: The braking system can become less effective due to worn brake pads, damaged brake lines, or low brake fluid levels.

• Impact: Ineffective brakes can lead to accidents, especially in environments where precise handling is required.

• Prevention: Regularly test the brakes and inspect all components. Replace worn brake pads, repair damaged lines, and ensure brake fluid levels are adequate.

1. Tire Wear and Damage

• Issue: Tires can wear out or become damaged due to heavy use, poor driving habits, or rough terrain.

• Impact: Worn or damaged tires can affect the stability and maneuverability of the forklift.

• Prevention: Regularly check tire pressure and inspect tires for signs of wear, cuts, or punctures. Replace tires as needed and ensure proper driving practices.

1. Operational Controls

• Issue: Faulty or unresponsive operational controls, such as steering, throttle, and lift controls, can occur due to wear or electrical issues.

• Impact: Malfunctioning controls can lead to operator errors and accidents.

• Prevention: Regularly test all operational controls and ensure they are responsive. Address any issues promptly and conduct routine maintenance.

1. Overloading and Load Handling

• Issue: Overloading the forklift or improper load handling can cause undue stress on the equipment and increase the risk of tipping.

• Impact: Overloading can lead to equipment failure and accidents, endangering operators and bystanders.

• Prevention: Adhere to the manufacturer's load capacity guidelines and ensure operators are trained in proper load handling techniques.

How OR Group LTD Can Help

At OR Group LTD, we specialize in conducting thorough LOLER examinations to ensure your counterbalance forklifts are safe and compliant. Our comprehensive inspection process includes:

• Initial Assessment: Reviewing maintenance records and previous inspection reports.

• Visual Inspection: Identifying signs of wear, damage, or defects.

• Functional Testing: Assessing the performance of the forklift under normal operating conditions.

• Load Testing: Verifying that the forklift can handle its maximum rated load safely.

• Detailed Reporting: Providing a comprehensive report detailing our findings and recommendations.

• Compliance Certification: Issuing a LOLER compliance certificate once the forklift passes the inspection.

Conclusion

Understanding the common failures in LOLER examinations of counterbalance forklifts and taking proactive measures to address them can significantly enhance safety and compliance in your workplace. By partnering with OR Group LTD, you can ensure that your forklifts are thoroughly inspected and maintained, reducing the risk of accidents and improving operational efficiency.

For more information or to schedule a LOLER inspection, contact us today at 0330 043 4773 or visit our website at www.orgroupltd.com.

Stay safe, stay compliant.