Thorough Examination: an interactive guide

Beware: not every Examination is truly Thorough. CFTS is the only standard guaranteed to fulfil your obligations under LOLER 98 & PUWER 98.

Some so-called "Thorough" Examinations only cover a fork truck's lifting mechanism, doing the minimum to meet LOLER 98 (in blue, below); but you also have a duty under PUWER 98 to ensure equipment is safe to use - and that requires a much more detailed test (also including the items in red). Only CFTS Thorough Examination is certain to cover both parts.

Hover your mouse over an item to see more detail... and think: would you want to use a truck that hadn't had its brakes checked?

 
 
A truly Thorough Examination should include all the following...


Forks

Fork arms must be of the correct capacity, and need to be inspected for signs of wear (meeting ISO 5057), cracks and deformation. The means of fork location and end stops are also checked.

Carriage

The fork arm carrier must be checked for distortion or cracking, along with the mounting and soundness of any load backrest extension. If a side shift is fitted, it must move in a controlled, even manner.

Attachments / side shift (if fitted)

Permanently fitted attachments and side shifts can be included in the truck’s usual Thorough Examination interval. If removable, they must be checked at least twice a year. To ensure safety, they must be free from distortion or cracks, mounted securely, and operable in a smooth, even manner throughout their full range of movement.

Load Guard

The load guard should be inspected to ensure it is structurally sound and securely mounted.

Chains

Sudden lift chain failure is potentially lethal. Careful inspection is required to rule out chain wear, elongation or corrosion – we well as checking chain anchors and pulleys.

Mast

The mast, or telescopic boom on a telehandler, must be inspected throughout its full range of extension and movement. Hydraulic systems are also carefully checked and tested.

Tilt mechanism

The tilt must move in a controlled, even manner with no signs of damage or scoring. Hydraulic cylinders, hoses and piping are also inspected.

Hydraulic Systems

Hydraulic cylinders, reservoir, hoses and pipes must be checked carefully, as sudden loss of pressure can be catastrophic. Filters can be checked for signs of debris, and load handling parts should be subjected to a prolonged load test to rule out unacceptable descent.

Rating Plate

Capacity data plates must be securely attached, legible and have the capacity rating for the truck and any attachments fitted. If a load capacity indicator is fitted, the information should be clearly visible to the operator.

Controls

All controls, cables and linkages should be checked for correct operation, corrosion, damage and signs of potential failure. They must be securely mounted, and their function clearly marked.

Brakes

All service and parking brake systems must operate as expected. Inspection should also cover hydraulics/pneumatics, mountings, cables, linkages, pedals levers and controls.

* Note: Brakes might NOT be checked under a non-CFTS examination *

Chassis

Where possible, the chassis should be inspected for signs of damage and cracking in welds.

* Note: Chassis might NOT be checked under a non-CFTS examination *

Wheels & tyres

Wheels and their assemblies should be in sound condition and securely fixed. Tyres must be checked for specification, wear, damage and bonding failure. Wheel bearings also need particular attention.

* Note: Wheels and tyres might NOT be checked under a non-CFTS examination *

Seat mountings

The mounting must be secure, along with the panel to which it is attached. Any operator restraint (e.g. seat belt) or anti-vibration mounting is also checked for signs of damage.

* Note: Seat mountings might NOT be checked under a non-CFTS examination *

Steering

All mechanical and hydraulic components must be inspected for damage, excessive wear, signs of failure or corrosion. The truck is also manoeuvred at low speed to check steering response and operation.

* Note: Steering might NOT be checked under a non-CFTS examination *

Overhead guard or cab

The structure must be sound and securely mounted. Any transparent screens must be clear and undamaged.

* Note: Overhead guards are often NOT be checked under non-CFTS examinations *

Safety Equipment

All safety systems should function properly – including visible & audible warning devices, capacity/data plates and safety interlocks such as seat switches.

* Note: Safety equipment might NOT be checked under a non-CFTS examination *

Seat Restraint

Any operator seat restraint (including seatbelts and other devices designed to keep the operator safely seated in the event of a tipping accident) should be securely mounted, and free from damage.

Traction system

The prime mover and transmission are checked, along with the exhaust system and emissions on IC engine (diesel and LPG) trucks, and battery connections on electric trucks.

* Note: The traction system might NOT be checked under a non-CFTS examination *

Counter weight

The fastening must be inspected to ensure it is secure and undamaged. Other structural components and mountings, such as for fluid containers, axles and batteries, should be checked in the same way.

* Note: The counter weight might NOT be checked under a non-CFTS examination *

 
 
 
NB: this basic interactive guide is for explanatory purposes only. The full CFTS Thorough Examination procedure, GN28, is available for purchase from BITA.
Read more about CFTS, the Industry Standard for Thorough Examination, here.