TUV SOUTHWEST

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PROCEDURE FOR INSPECTION AND

CERTIFICATION OF

FORKLIFT

Prepared By: M.Hamza

Reviewed By: Mohd. Usman

Authorized By: Waqas Arshad

Procedure Ref #.: SW/TIP-FL/001 Rev. 02 Issue Date: 05/06/2018

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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I. Objective:

To define and outline the responsibilities, sequence and procedural requirements for
Forklift Inspection in accordance with International Standards mentioned below.

II. Scope:

This procedure covers all Inspection bodies in all areas.

III. Duties / Responsibilities:

 The Inspector assigned for the job has to be a competent person with
sufficient experience and knowledge in the inspection/ test of lifting
equipment.
 Lifting head is responsible for the review of this Procedure.
 Lifting head is responsible for the preparation and revision of this
procedure.
 The dept manager is responsible for the review of the procedure and
General Manager is responsible for the Approval.

IV. Relevant Standards and Code of Practice

Sr. No Applicable Standards Title Identifier

Rough-terrain trucks. Safety requirements and
1
BS EN 1459-1:2017 verification. Variable-reach trucks

Rough-terrain trucks. Safety requirements and

2
BS EN 1459-2:2015+A1:2018 verification. Slewing variable-reach trucks

Rough-terrain trucks. Safety requirements and

3 verification. Interface between the variable-reach truck
BS EN 1459-3:2015
and the work platform

4 Industrial trucks. Verification of stability. General

BS ISO 22915-1:2016
Industrial trucks. Safety requirements and verification.
5 Self-propelled industrial trucks, other than driverless
BS EN ISO 3691-1:2015
trucks, variable-reach trucks and burden-carrier trucks

Industrial trucks. Safety requirements and verification.

6
BS EN ISO 3691-2:2016 Self-propelled variable-reach trucks

Industrial trucks. Safety requirements and verification.

Additional requirements for trucks with elevating
7
BS EN ISO 3691-3:2016 operator position and trucks specifically designed to
travel with elevated loads

Industrial trucks. Safety requirements and verification.

8
BS EN ISO 3691-5:2015 Pedestrian-propelled trucks

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Industrial trucks. Safety requirements and verification.

9
BS EN ISO 3691-6:2015 Burden and personnel carriers

Industrial trucks. Verification of stability. Single-side-

10
BS ISO 22915-5:2014 loading trucks

Fork-lift trucks. Fork arms. Technical characteristics and

11
BS ISO 2330:2002 testing

Fork-lift trucks. Hook-on type fork arms and fork arm

12
BS ISO 2328:2011 carriages. Mounting dimensions

Industrial trucks. Verification of stability.

13
BS ISO 22915-2:2018 Counterbalanced trucks with mast

Industrial trucks. Inspection and repair of fork arms in

14
BS ISO 5057:1993 service on fork-lift trucks

Federal Ministry of Law and Social Affairs, 10.1.83 -

15 UAE. Federal Ministry of Law
10.1.83 M.O. No: 32 – Article 20

16 Trakhees Regulation IO-11 EHS Lifting Equipment Protocol

OSHAD Code of Practice 34
17 Safe Use of Lifting Equipment and Lifting Accessories
v3.0-2016
Note:
1. Also, considerations and reference to the standard /code to which the equipment has been built has
to be given due attention.
2. Related reference standard may also be referred during inspection / test.
3. In addition to requirements stipulated in this document, Project site/ Client specific requirements are
applied and shall be followed all the time.

V. Overview of the Procedure for Thorough Examination:

Subsequent to client request, the unit has to be thoroughly examined visually

for all its sections i.e. hooks, wire ropes, supporting structures, winches, control
panel, safe load indicator/over load cut off device. Then test the Crane functionally
prior to any loading. Apply applicable codes/standards to evaluate any discontinuities
either as Satisfactory OR Unsatisfactory with any part or function.

Also inspect the Ground should be well consolidated and capable of

withstanding the loads that will be applied on it. Confirm with the client if there are
any doubt

This ensures that there are no visible discontinuity/s that may be detrimental
during a lift later.

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VI. The Documents to be reviewed prior to examination are:

 Record of Pre use & in-services check lists

 Previous Reports of thorough examination
 Safe Working Load clearly marked on the truck and duty charts fixed to it
 Lifting attachments marked with their safe working load
 Individual Certifications of personnel involved
 Maintenance records
 Prior to performing any tests loads, the manufacturer’s instructions should be
obtained or alternatively, a referenced authority on the design and construction of
the truck. The said Information should be consulted, understood and implementation
prior to test load

VII. Procedure Instructions:

A. Site Conditions

 Ground should be well consolidated and capable of withstanding the loads that will
be applied on it. Confirm with the client if there are any doubt
 Make a general observation to ensure that there are no dangers such as cable ducts,
drains, backed filled areas, power lines etc.,
 Test should not be performed over any high risk areas e.g. public highway, occupied
building where people are working within the vicinity.
 It should be remembered that test are performed to ensure forklift can withstand the
desired loading. A forklift can fail under at any time, so remember, all - essential
personnel should be removed from the area and the crane inspector should stand in
a position where he is unlikely to be injured in the event of tipping or structural.
 Fire extinguisher & first aid box should be nearby.

B. Toolbox Meeting & General Risk Assessment

Before proceeding in any kind of job, test or inspection, a Toolbox Meeting should be
conducted that focuses on safety topics related to the specific job, such as workplace
hazards and safe work practices.

C. Test weights

Test weights used should be:

 Weights of proven accuracy to within ± 2%
 Weights proven on weighbridge, valid 12 months calibration certificate required.
 Weights suspended from calibrated weighing device, 12 month calibration certificate
required.

D. Preparation of PPE & Tools:

The inspector should ensure that:

 Personal safety equipment that is appropriate for the conditions of the location is
available, such as helmets, safety spectacles, fall protection equipment, safety boots,
ear defenders and life jackets or other buoyancy aids;
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 Equipment is inspected before and after use and maintained in good working order
 Ensure all the equipment used during inspection/test i.e caliper, Spirit Level,
measuring tape, Load cell etc shall be in good condition and shall be certified where
ever applicable.

E. Thorough Examination:

Fork lift trucks must have a valid Load Test and Thorough Examination certificate
prior to entering service by the manufacturer, or after substantial repairs or
alterations. Thereafter, a thorough examination will take place at yearly intervals.

Note - Forklift arms can be interchanged. Therefore, a Certificate of Test and

Thorough Examination should be available for each pair of forklift arms.

 Load Chain Examination

 Load chains which appear suspect must be removed from the truck. Removal
should be carried out in accordance with the manufacturer’s manual.

 Note: Adequate safety precautions shall be taken to ensure that the forks are
independently supported to allow sufficient slackening in the chain to enable
removal.

 Wash chain thoroughly using a suitable safety cleaning fluid. Ensure that
supply cable to the remote indication unit is not cut or damaged such as to
prevent correct operation.
 Each chain shall be checked for wear, stretch and seized links over its full
length.
 Particular attention should be paid to the chain at the load carriage which is
subject to most strain. Chain extensions/stretch should not exceed 2% of its
full length.
 Chain shall be checked for wear on the link plate edges. The maximum
allowable reduction in the link plate edge shall not exceed 5% of the total
plate depth. Maximum chain wear is normally confined to sections of the
chain which articulates under load, i.e. over a pulley.
 Chain should be rejected if they contain fractured links, or damage/wear on
the end of bearing pins, or links that have elongated such that there is a
danger of the link running over the rivet head.
 Examine chain for signs of corrosion damage.
 Chains that are satisfactory shall then be refitted and lubricated in accordance
with the manufacturer’s instructions.

 Forklift arms and attachments examination:

 Examine fork lifting arms and attachments for wear, distortion, surface cracks
or damage. Particular attention should be paid to fork arm blade.
 Forks shall be inspected, if considered suspect, for cracking by means of MPI
over 100% of the surface. This shall also apply to any welded attachments.
 Check for distortion or permanent deformation using steel straight edges
along the lifting surfaces, with the forks in an upright position on a level
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surface and adjacent to each other. In addition, check right angles using a set
square.
 If the section thickness of the lifting forks or attachments are reduced to 90%
of the original thickness it should be withdrawn from use.
 The angle between the upper face of the blade and the front face shall not
exceed 93 degrees.
 Straightness of the blade and the shank shall not deviate by more than 0.5%
of the length of the blade and/or the height of the shanks.
 The difference in tip height, i.e. difference in height on the fork carrier shall
not exceed more than 3% of the blade length.
 It shall be confirmed that the positioning lock is in good condition and in
correct working order.
 Ensure that the extensions are the correct type for the truck and such that the
truck cannot be overloaded and are in accordance with the rating plate.

 Truck Examination:

 Inspect steering for excessive play and wear on track rod ends. In addition,
examine track rods and steering arm for possible misalignment, fracture and
mechanical defects.
 Examine wheel retaining bolts and tyre tread/wall for possible
fractures/damage, or excessive wear.
 Wheel bearings and stud axle shall be examined for wear and/or damage.
 Check for brake servo and parking brake for correct operation.
 Steering column shall be examined for side play, end float, cracks and
possible damage.

Note: Play in steering wheel shall not exceed 1/5 of the diameter.

 Drivers seat should be checked for adequate fixing, adjustment and general
condition.
 Windscreen shall be examined for visibility/cracks. Check that wipers are
present and function correctly.
 Horn should be present and operational.
 All controls should operate correctly and be adequately labeled.
 Check that the SWL ratings are clearly marked together with
distinguishing/serial numbers on the plate.
 Head guard will be examined for distortion, cracks, damage and fixing.
 Inspect for hydraulic/oil/water leaks. Particular attention should be made to
the top seal and main seal for possible hydraulic leak.
 Ensure tilt arms operate equally.
 Examine general condition of floor plates, side panels and general body work,
ensuring adequate shielding for moving parts.
 Check engine for excessive smoke emission.
 Engine mountings shall be checked for excessive wear, fixings, distortion and
other defects.
 Fuel tank system shall be examined for leakage and general condition. Filling
cap shall be fitted to fuel tank intake.
 Examine general condition and adequate insulation of the electric wiring.

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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F. LOAD TEST:

 100 % Load test according to manufacturers recommendations of rated lifting

capacity of the truck.
 With the mast vertical and a test load operate lift slowly. Measure/mark the
lifting height of the fork.
 During this operation, observe the forks for any signs of excessive bending or
erratic behavior.
 Check the movement between the carriage and the sliding surfaces for
excessive wear.
Note : Proof load test according to manufacturer’s Instructions shall be carried out at the
time of Initial Inspection, Major Inspection, Major Repair/alternation.

G. REPORTING

 On completion, record examination details and issue report to OIM or

designated Supervisor.
 If a Forklift is considered unsafe for continued service, a copy of the
Examination Report must be sent to the company safety officer within 7 days

VIII. Certification:

 A test certificate shall be issued as per company procedure that indicates

compliance to appropriate regulations.
 Test certificates should be supported with necessary information to ensure that
there is no doubt as to crane rigging at the time of test.
 Should the inspector consider it necessary to restrict the use of the crane or
equipment, (e.g. site limitations prevent the testing of the full range of duties of the
machine) then the restrictions should be noted on the certificate and the use of the
crane should be subject to these restrictions.
 A notice of these restrictions should be posted in the crane.
 Where the inspector feels it necessary to change the safe working load (SWL), the
markings and tables of the SWL on the machine should be amended to reflect the
restrictions and recorded on the test certificate.

IX. RECORDS:

SN Control Name Retention Period Document No.

1 Inspection Report or Certificate of Inspection 3 years FL/02
2 Filled-up Inspection Checklist / Rough Reports 1 years FL/02

This is an official document of TUV South West. Printed copies without the original seal of the company is “Uncontrolled Copy”.
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