Pre-Use Checks, Routine Maintenance and Defect Reporting
Pre-use checks are a legal duty under PUWER and an operator's first line of defence. A structured walk-round check before each shift should cover fluid levels (engine oil, coolant, hydraulic oil, fuel, AdBlue where fitted), leaks under the machine, tyre condition and pressure, wheel nuts, boom wear pads and rams for damage or weeping seals, the attachment and quick-hitch, seat belt and operator restraint, lights, beacons, horn, mirrors, the RCI and its calibration, the load chart in place and legible, fire extinguisher, and the condition of the forks (heel wear, cracks, bent tines). The operator should also check the machine's thorough examination certificate and any previous defect log. On start-up, test the controls, brakes, steering, parking brake and the RCI self-test before moving off.
Question traps: candidates think pre-use checks are a 'tick-box' formality or can be skipped when the machine was checked yesterday. They should understand that defects must be reported to a responsible person and recorded, and that a defect affecting safety means the machine is taken out of service until rectified - not 'used carefully'. Another trap is confusing routine maintenance (oils, greasing, filters) with statutory thorough examination (by a competent person). Operators should not carry out maintenance beyond their competence or training.
Worked example: if a fork heel is worn beyond the manufacturer's limit (often around 10% of original thickness), the fork must be withdrawn from service - a worn heel reduces strength and can fail under load. Record it, tag it, report it.
Rule of thumb: if in doubt, stop, report and record - a machine out of service is safer than a machine in use with a known defect.