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Counterbalance Forklift: An Interactive Guide

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Home » Thorough Examination » Thorough Examination Guide » Thorough Examination Counterbalance

Counterbalance Forklift Interactive Thorough Examination Guide

LOLER 1998, which covers lifting equipment, and PUWER 1998, which deals with other components such as brakes, steering and tyres, are both elements of Thorough Examination guidelines and health and safety legislation that must be adhered to when a counterbalance or telehandler forklift is being inspected.

The inspection will cover every component of the machinery to look for faults or malfunctions that may not be noticeable during forklift operation. To give you an indication of what kinds of things will be checked, we’ve created this interactive guide that explains the different parts of your counterbalance forklift, the potential damage they can incur and what legislation the product has to meet to be deemed safe for use. Simply click on a part to find out more.

We also have interactive guides for other forklift trucks including man-up, telehandler, reach and rough terrain forklifts. If you need to book a Thorough Examination for your forklift, call our team today.

LOLER (Lifting Parts)
PUWER (Other Parts)

1 Mast

The mast or telescopic boom will be fully inspected to ensure it is moving in its full range of extension and the hydraulic systems are also checked for functionality.
2 Chains

Wear, corrosion or elongation of chains is a very gradual but potentially lethal change. A Thorough Examination will take three measurements to rule out any signs of damage - a change of just 3% means that the chain must be replaced. The chain anchors and pulleys are also carefully inspected.
3 Load Backrest

The load backrest will be verified as securely attached and structurally sound.
4 Tilt Mechanism

The tilt will be inspected to ensure it moves in a controlled, smooth motion and is free from any signs of damage, such as scoring. The other components such as hoses, piping and the hydraulic cylinders will also be checked to ensure they are in good condition.
5 Attachments | Side Shift (If Fitted)

If your forklift has a permanently attached fixture or side shift then they will be inspected for distortion, cracks or other signs of damage. The mounting of the attachment will also be inspected, and it must move in a smooth, controlled way through its full range of movement.
6 Forks

Fork arms should be free from abrasions, cracks, splaying and other signs of stress, as laid out in ISO 5057. Fork location and end stops should also be checked.
7 Carriage

The fork arm carrier and mounting is inspected for signs of distortion or cracking and the load backrest extension and side shift, if applicable, are inspected for security and control over movement.
8 Hydraulic System

All components of the hydraulic system such as the cylinders, reservoir hoses and pipes are checked for signs of damage and to evaluate their condition. The filters are also checked for debris which can impede functionality. Load handling parts may also undergo a prolonged load test.
9 Rating Plate

The rating plate will be checked to ensure that all information is legible and visible. They must be securely attached to the forklift and any other attached fixtures.
10 Controls

Controls, cables and linkages will be inspected for signs of corrosion, damage or any other indicators that the controls will not be able to function correctly.

1 Overhead Guard or Cab

Your overhead guard or cab must be securely attached and any screens must be clear and undamaged, offering an unhindered view out.
2 Steering

All mechanical and hydraulic elements of the steering will be checked for any signs of damage or corrosion and the forklift will be driven slowly to check for steering response times.
3 Safety Equipment

All safety systems, including sound and light alarms or warning devices, capacity/data plates and safety interlocks are thoroughly scrutinised for signs of damage or wear that can prevent them from keeping both the operator and passersby safe.
4 Seat Restraint

Seat restraints such as seat belts will be checked for strength of mounting and any signs of damage that could hinder their performance.
5 Seat Mountings

Seat mountings and the panel they are attached to will be inspected to ensure they are secure and free from damage. If an anti-vibration mounting is used, that will also be inspected.
6 Traction System

All elements of the tractions system such as the prime mover, transmission, exhaust system, battery and connections (whichever are applicable) are thoroughly checked for corrosion or signs of damage.
7 Counterweight

Counterweights must have a very strong and secure fastening and the fluid containers, axles and batteries must be free from damage and operating correctly.
8 Wheels & Tyres

Wheels should be strong, secure and free from damage, with particular attention paid to the wheel bearings. Tyres should be inflated to the correct capacity and will be inspected for signs of damage and bonding failure. Composite tyres should be suitable for use on the truck, given its application.
9 Chassis

The chassis will be inspected for damage or cracks in welds.
10 Brakes

A slow drive test will be conducted to check the brakes reaction times. Hydraulics, mountings, cables, linkages, pedals, levers and controls will be inspected for any signs of corrosion, damage or malfunction that can prevent the brakes reacting as they should.

General FAQs

More FAQs

Do trucks have to be inspected daily?

Will one certificate cover an operator for all trucks?

Will the certification cover our company for Health and Safety and insurance purposes?

Is there an age requirement for forklift operators?

Do operators need a car driving licence?

Help & Advice

More Resources

Short-term vs Long-term Forklift Hires

How to Transport a Forklift

East Midlands Forklifts

Tweets by EMForklifts

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Counterbalance Forklift Interactive Thorough Examination Guide

1 Mast

2 Chains

3 Load Backrest

4 Tilt Mechanism

5 Attachments | Side Shift (If Fitted)

6 Forks

7 Carriage

8 Hydraulic System

9 Rating Plate

10 Controls

1 Overhead Guard or Cab

2 Steering

3 Safety Equipment

4 Seat Restraint

5 Seat Mountings

6 Traction System

7 Counterweight

8 Wheels & Tyres

9 Chassis

10 Brakes

General FAQs

Do trucks have to be inspected daily?

Will one certificate cover an operator for all trucks?

Will the certification cover our company for Health and Safety and insurance purposes?

Is there an age requirement for forklift operators?

Do operators need a car driving licence?

Help & Advice

Short-term vs Long-term Forklift Hires

How to Transport a Forklift

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