Thorough examination · 15 items

LOLER Thorough Examination
condition checks

What the competent person is looking at when lifting equipment goes for its 6- or 12-monthly thorough examination, and what fails it.

Every item below says what good looks like, when it passes, the regulation or manufacturer's standard it rests on and the defects that usually fail it. That guidance is the difference between a tick and a check.

  1. 1.
    Structural integrity — no cracks, distortion, or excessive wear
    What to look forExamine all primary structural members — main beam(s), boom sections, jib, mast, chassis, A-frame. Look for cracks (especially at welds, plate corners, pin bores), distortion (twist, bend, kink), and excessive wear (pin bores ovalled, plate sections thinning). Visual examination supplemented by NDT (MPI/UT) at known high-stress points where the scheme of examination requires it.
    Acceptable whenNo detectable cracks. No measurable permanent distortion (verify with reference dimensions where suspect). Wear at pin bores / sliding surfaces within manufacturer's tolerance. NDT findings within acceptance criteria.
    StandardLOLER 1998 reg.9 & reg.10, Schedule 1. BS 7121 (cranes). BS 7212 (lift trucks). BS EN 280 (MEWPs). Manufacturer's scheme of examination. ISO 9927 (cranes – inspection).
    Common defectsHairline crack at boom-section weld toe — propagates rapidly under fatiguePin bore ovalled — pin no longer carries load on full circumferencePlate corrosion at base of mast where water has pooledTwist in chassis from a poor lift / poor recoveryRepaired weld done without procedure — usually visible by appearance and lack of records
  2. 2.
    Wire ropes / chains — condition, lubrication, terminations
    What to look forWire rope: broken wires (count and distribution), corrosion, kinks, birdcaging, diameter reduction, lubrication. Chain: stretched links (gauge), nicks, twist, weld undercut. Terminations: swaged ferrules, wedge sockets, eye splices, rope-end covers — all to manufacturer / standard.
    Acceptable whenWire rope discard criteria per BS ISO 4309 (e.g. <5 broken wires in 6× rope diameter on a 6×36 IWRC); diameter reduction <7%. Chain links wear ≤10% of nominal. Terminations correctly assembled.
    StandardLOLER 1998 reg.9. BS ISO 4309. BS EN 818 (chain). BS EN 13414 (wire rope slings). LEEA COPSULE. BS 7121-2.
    Common defectsCluster of broken wires at a fixed termination — high-stress zoneBirdcaging from a snatch lift — internal damageWedge socket installed upside downChain link stretched — gauge failsDry rope, surface rust — overdue lubrication
  3. 3.
    Hooks — safety catch, throat opening, straightness
    What to look forHook free of cracks (visual + MPI per scheme). Throat opening within reject limit (typically 10–15% over nominal). Twist <10° from plane. Safety catch (mousing) springs closed and seats positively against the tip. Wear at the saddle within tolerance.
    Acceptable whenNo cracks (NDT confirmed). Throat ≤10% over nominal. Twist <10°. Catch closes and stays closed under spring. SWL plate legible.
    StandardLOLER 1998 reg.9. BS EN 1677. Manufacturer's reject criteria. LEEA TSP guidance.
    Common defectsThroat stretched from a snatch lift — discardCatch missing or wired openTwist visible from side load — discard, do not straightenWear flat at saddle — sling sits on the bendCrack only visible after MPI at the inner radius
  4. 4.
    Sheaves / pulleys — condition, bearings, rope tracking
    What to look forSheave groove profile (gauge against rope diameter — should support ⅓ to ⅖ of rope circumference, not pinch or be over-wide). Bearings rotate without rumble or play. No corrugation or chipping in the groove. Rope tracking centred, not riding up the flange.
    Acceptable whenGroove profile matches the rope diameter per manufacturer's gauge. Bearings smooth, no axial/radial play. No groove corrugation. Rope tracks in the centre of the groove on all positions of the boom.
    StandardLOLER 1998 reg.9. BS 7121-2. BS ISO 4309. Manufacturer's sheave wear criteria.
    Common defectsGroove worn oversize — rope flattens and crushesBearing rumbling — pre-failure, replaceSheave seized — rope drags rather than rolls, accelerated rope wearRope tracking off the flange — fleet angle exceeded or bent guardCracked flange from a side load — replace
  5. 5.
    Brakes — holding capacity, wear, adjustment
    What to look forHoist, slew, luff brakes engage on release of control lever and hold a known load without drift. Brake pads/discs within wear limits (gauge or visual against witness mark). Brake fluid (where hydraulic) clean and at correct level. Spring-applied / hydraulically released brakes — releasing pressure correct.
    Acceptable whenBrakes hold rated load without drift for ≥10 minutes (or per manufacturer's test). Pad/disc wear within limits. No glazing or contamination. Adjustment within spec.
    StandardLOLER 1998 reg.9. BS 7121-2. EN 13000. Manufacturer's brake test procedure.
    Common defectsHoist brake drift — pad worn or seal failure on hydraulic releaseSlew brake fade as drum heats — overdue overhaulBrake glazed from contaminated pad — needs replacementAdjustment slipped — pedal travel excessive before biteCracked disc from heat cycling
  6. 6.
    Safety devices — limit switches, overload protection, emergency stop
    What to look forEach device tested through its trigger condition: hoist-up limit, hoist-down limit, slew limits, anti-two-block, overload (SLI/RCI/RCL) at 90% pre-warning and 100% lockout, all E-stops at every station. Override mechanism (where fitted) requires a deliberate action and is logged.
    Acceptable whenAll devices trigger before mechanical hard stop. Overload calibration in date. SLI configuration matches the rigging. E-stops effective. Overrides not engaged in normal operation.
    StandardLOLER 1998 reg.9. BS 7121-2. EN 13000. EN ISO 13849 (safety-related parts). Manufacturer's test procedure.
    Common defectsAnti-two-block weight tied up — limit defeatedSLI calibration drift — pre-warning at wrong thresholdOverride key left in — bypass activeLimit switch electrically OK but mechanically jammedE-stop wired through a relay that doesn't kill the fuel solenoid
  7. 7.
    Controls — operation, labelling, emergency functions
    What to look forEach control labelled per manufacturer (icon and direction), no missing or replaced placards. Joysticks self-centre cleanly, no creep on neutral. Pedals proportional. Emergency functions (descent valves, hand pumps) labelled and accessible. No make-do controls fitted.
    Acceptable whenControls labelled per OEM. Self-centring and proportional. Emergency descent / pump operates and is labelled. No unauthorised modifications.
    StandardLOLER 1998 reg.9. PUWER 1998 reg.14, reg.17. BS 7121-2. ISO 10968.
    Common defectsDecals worn off — operator memorises rather than readsJoystick creep — gimbal wearFoot pedal sticking partly on — return spring corrodedAux circuit added without a proper labelled switchEmergency descent valve hidden behind a non-OEM panel
  8. 8.
    Load bearing components — pins, bolts, welds, structural connections
    What to look forPin bores: no ovalling, pins straight and not corrugated, retainers (bolts, R-clips, circlips) present. Bolted connections: torqued to spec, witness marks intact (no movement marks). Welds: no undercut, cracking, or porosity at primary load paths. NDT at critical points per scheme.
    Acceptable whenPins, bolts, and retainers present and as designed. Torque marks unbroken. Welds free of cracks and undercut. NDT findings within the scheme of examination acceptance criteria.
    StandardLOLER 1998 reg.9. BS 7121-2. BS EN ISO 9606 (welder qualification — for repairs). Manufacturer's torque schedule. ISO 9927.
    Common defectsPin retainer replaced with a non-spec boltWitness paint mark broken — bolt has moved, retorque and investigateCrack at weld toe of a primary load path — refer for engineer assessmentPin corrugated from poor lubrication — bore wears rapidlyRepair weld done without procedure — visible inconsistency
  9. 9.
    Hydraulic / pneumatic systems — hoses, cylinders, valves, leaks
    What to look forHoses: no chafing, kinks, blisters; fittings dry. Cylinders: rod surface clean and undamaged, no weeping at gland, no drift. Valves: response sharp, no internal leakage causing creep. Reservoir level, fluid colour, breather clean.
    Acceptable whenNo external leaks or weeping. No drift on a known load (cylinder seal test). Hoses within service life (typically 5 years). Fluid colour amber, free of moisture, contamination class within manufacturer spec.
    StandardLOLER 1998 reg.9. PUWER 1998 reg.5/6. BS 7121-2. ISO 4413 (hydraulic system safety). ISO 4414 (pneumatic).
    Common defectsHose chafing through outer cover, braid showingRod with corrosion pitting — accelerated seal failureCylinder drift under load — internal valve or seal failureMilky fluid — water ingressReservoir breather blocked — vacuum on retract, foaming
  10. 10.
    Electrical systems — cables, connections, earthing, isolation
    What to look forCables: insulation intact, no crushing, no UV cracking, glands tight. Connections: terminals clean, torqued, no corrosion. Earthing: continuity to chassis at all bonding points. Isolators: function as designed and lockable for maintenance.
    Acceptable whenNo insulation damage. Continuity from chassis to earth at all required points (≤0.1 Ω). Insulation resistance per spec. Isolators lockable.
    StandardLOLER 1998 reg.9. Electricity at Work Regs 1989. BS 7671. BS EN 60204-32 (electrical equipment of hoisting machines). IET Code of Practice.
    Common defectsCable trapped at a hinge — insulation crushedEarth bonding broken at a bolted joint covered in paintJunction box ingress — water insideIsolator broken handle — locked-off check impossibleIR test failed — winding insulation degraded
  11. 11.
    Outriggers / stabilisers — condition, operation, locking
    What to look forEach leg extends/retracts smoothly, locks at intended positions, pad firm to ground, no creep when set under load (≥30 min hold test). Limit switches register the actual position selected on the SLI. Locking pins / latches engaged.
    Acceptable whenNo creep over hold-test period. Position feedback to the SLI matches the actual setting. Pads in good condition, mats sized for ground bearing pressure.
    StandardLOLER 1998 reg.9. BS 7121-2/3. EN 13000. Manufacturer's GBP data.
    Common defectsPilot-operated check valve leaking — leg creeps inLimit switch out of adjustment — false position reading on SLILocking pin missing, replaced with a boltPad cracked from point loadingMat too small for the load case
  12. 12.
    Rated capacity indicator / SLI — functionality, calibration
    What to look forPower-on self-test passes. Configuration matches the rigging (boom length, jib, counterweight, outrigger spread, mode). Calibration sticker in date. Test load (where part of scheme) registers within ±5%. Pre-warning at 90%, lockout at 100%.
    Acceptable whenCalibration in date (typically 12-month). Test load reads within ±5% of true. Pre-warning at 90% audible and visual. Lockout at 100% inhibits motions toward worse condition. Override logged.
    StandardLOLER 1998 reg.9. BS 7121-2. EN 13000. ISO 11662 (mobile cranes — load indicator). Manufacturer's commissioning spec.
    Common defectsConfiguration set to "no jib" when the jib is rigged — false high capacityCalibration drift — pre-warning at 95% instead of 90%Length sensor cable damaged, frozen readingOverride key permanently in — lockout always available to bypassAudible buzzer disconnected — visual warning only
  13. 13.
    Guards and protective devices — condition, fitment
    What to look forAll guards (drum guard, fan guard, drive guard, slew ring guard, pinch-point guards) present and secured with the correct fasteners. Interlocked guards cut drive/power when opened. No removed or modified guards.
    Acceptable whenAll guards as drawing. Interlocks functional. Fasteners correct (e.g. shoulder bolts, captive screws). No modifications.
    StandardLOLER 1998 reg.9. PUWER 1998 reg.11. BS EN ISO 14120. Manufacturer's drawings.
    Common defectsDrum guard left off after rope inspectionInterlock bridged with a magnetFan guard substituted with non-OEM mesh, gaps too wideCable-tied guardSlew ring guard cracked from impact
  14. 14.
    Markings and identification — SWL plates, serial numbers, CE marks
    What to look forManufacturer's plate present, legible, with model, serial, year, SWL/WLL, mass, electrical/hydraulic data. CE/UKCA mark. SWL/load chart inside the cab (or in clear view), legible. Identification on lifting accessories matching the register.
    Acceptable whenManufacturer's plate, CE/UKCA, SWL plate(s), and load chart all legible and applicable. Serial number traceable on records.
    StandardLOLER 1998 reg.7 & reg.9 (information of safe use). Supply of Machinery (Safety) Regs 2008. BS 7121.
    Common defectsPlate painted over after refurb — illegibleLoad chart laminate yellowed and unreadableCE plate riveted from a different machine — non-compliantNo accompanying load chart for the optional fly jib in useSerial number ground off (suggests theft or substitution)
  15. 15.
    Previous defects — have they been rectified?
    What to look forCross-reference the previous thorough examination report and any defect notifications. Each defect either rectified (with evidence — repair records, parts, sign-off) or item taken out of service.
    Acceptable whenAll previously raised defects either evidenced as rectified or item formally withdrawn. Repair documentation traceable. No "rolled-over" open defects without action.
    StandardLOLER 1998 reg.10 & reg.11 (information from examination, action). Schedule 1.
    Common defectsDefect rolled over from previous report — never closed outRepair done but no records — competent person can't accept"Rectify before next exam" deadline passed without actionDifferent repair done than was specifiedItem passed off as different equipment to dodge an open defect

Questions people ask

What is a LOLER thorough examination?

A detailed examination of lifting equipment by a competent person, under the Lifting Operations and Lifting Equipment Regulations 1998 (regulation 9). Equipment for lifting people and lifting accessories are examined at least every 6 months, other lifting equipment at least every 12 months, or to a written scheme of examination, and after installation or anything exceptional that could affect its safety. The examiner writes a report to Schedule 1. Guidance, not legal advice.

Who counts as a competent person?

Someone with enough practical and theoretical knowledge and experience of the equipment to find defects and judge how serious they are, and independent enough to give an honest report. Often the insurer's engineer surveyor or a specialist inspection firm. Not the operator and not the fitter who maintains it, where that can be avoided.

How is this different from the daily pre-use check?

The pre-use check is the operator's own look before every shift: fluids, guards, controls, obvious damage. The thorough examination is the periodic deep look, by a competent person, at structure, mechanisms, safety devices and documents. You need both. One does not replace the other.

What happens when the report finds a defect?

The competent person tells the employer straight away. Where the defect is, or could become, a danger to people, the report says what needs doing and by when, and the equipment does not lift until it is done. Where there is an imminent risk of serious personal injury, the competent person also sends a copy of the report to the enforcing authority. Guidance, not legal advice.

How long do I keep the reports?

Reports of thorough examination are kept until the next report is made or for two years, whichever is later, and made available to the enforcing authority on request (regulation 11). A report that is on a phone and in the job file is one you can produce; one in the cab door pocket is not.

Keep the examination reports where you can find them

SiteLynx holds every item of plant with its LOLER dates, thorough examination reports and daily pre-use checks in one register, and warns you before a certificate lapses. 14 days free.

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