GA1 Inspections for Telehandlers and Forklifts: What's Checked and Why

Telehandlers and forklifts are the workhorses of Irish sites and yards — and two of the most common machines we examine. Both need a GA1 thorough examination at least every 12 months (every 6 months if fitted with a man basket or otherwise used to lift people). Here is what actually happens during the examination, and what most often fails.

Why these machines are in scope

Both are lifting equipment under the General Application Regulations 2007: they lift and lower loads, their failure modes are serious, and their load-bearing parts wear in ways a walk-around check won't reveal. A pre-shift check by the operator and a weekly GA2 on site are essential — but neither replaces the periodic thorough examination by a competent person.

What the competent person examines

Forks and carriage. Fork heel wear is measured — worn heels quietly reduce capacity well below the rated load. Cracks, bends, uneven fork height and worn hooks or locking pins are checked, along with the carriage and side-shift mechanism.

Chains and mast (forklifts). Lift chains are examined for elongation, corrosion, tight links and worn pins — chain stretch is one of the most common defects we find, and it is invisible from the seat. Mast channels, rollers and welds are inspected for wear and cracking.

Boom and structure (telehandlers). Boom sections, wear pads, pivot pins and bushes, chassis welds and stabiliser structures are examined for cracking, distortion and excessive play.

Hydraulics. Cylinders, hoses and fittings are checked for leaks, scoring and creep — a load that drifts down under its own weight is a failed check, not a quirk of the machine.

Safety devices. Load charts present and legible, rated capacity/load moment indicators functioning, stabiliser interlocks, horns, beacons and seat switches all working as the manufacturer intended.

Identification. Serial number, capacity plate and markings must be present and match the machine — a machine that can't be identified can't be certified against its rated capacities.

The defects we find most often

Across telehandler and forklift examinations, the recurring failures are: worn fork heels, stretched lift chains, hydraulic leaks and drift, missing or unreadable load charts and capacity plates, damaged tyres affecting stability, and non-functioning warning devices. Most are inexpensive to fix when caught — and expensive when they aren't. See our post on the 10 most common GA1 defects.

Pass, defect, or fail — what happens next

If the machine is sound, the GA1 report is issued with the next due date. Where defects are found, the report states exactly what they are and what must happen: a defect that is a danger to persons means the machine does not lift again until it is put right and re-examined; lesser items are recorded with timescales. Either way, you know precisely where the machine stands — which is the entire point.

Attachments change the rules

Fit a man basket to a telehandler and the combination is now lifting people — a 6-month examination regime, plus requirements on the basket itself. Fork extensions, jibs, and lifting hooks are lifting accessories with their own 6-monthly examination requirement. Tell your inspector about every attachment the machine uses; certifying the base machine alone leaves gaps.

Book your fleet in

L&M Plant & Inspection Services Ltd. examines telehandlers, forklifts and their attachments in a single visit, on your site, with reports issued on completion. Call 083 870 5355 to book.