Forklift, Telehandler and Industrial Truck Inspection and Load Testing

Forklifts and telehandlers are used harder than almost any other lifting equipment on a site, by more operators and with less downtime for maintenance. They are also the machines most often modified in service: an attachment fitted, a mast changed or a counterweight altered changes the rated capacity and invalidates the plate on the machine. itmad inspects and load tests forklifts, telehandlers and related industrial trucks. itmad operates across the Middle East, Asia and Europe. Last reviewed: October 2026.

Equipment covered

Counterbalance forklifts, whether diesel, LPG or electric; reach trucks and narrow aisle equipment; telehandlers, rough terrain handlers and rotating telehandlers; container handlers and reach stackers; side loaders and multi-directional trucks; order pickers and stacker trucks; powered and manual pallet trucks; attachments such as clamps, rotators, jibs and man cages; and tow tractors and platform trucks.

Mast, chains and lifting

Mast channels, rollers and bearings are examined for wear, distortion and cracking. Lift chains are measured for elongation against the manufacturer's discard limit, which is the check most often skipped and the one most likely to drop a load, and chain anchors, sheaves and equaliser condition are checked, together with the carriage, fork carrier and backrest. Forks are examined for heel wear, blade thickness, cracks at the heel and the angle between blade and shank, because forks are consumable and worn ones are routinely left in service, and fork locking pins and retention are checked. Lift, tilt and reach cylinders are checked for leakage and creep under a held load, along with hoses, fittings and the hydraulic system.

Capacity plate and attachments

The rated capacity of a truck depends on the mast, the load centre, the lift height and any attachment fitted. Where an attachment has been added or a mast changed, the original plate no longer applies, and a truck operating to a plate that does not match its configuration is operating outside its rating whatever the operator believes. itmad verifies that the capacity plate matches the machine as configured, that any attachment is approved by the truck manufacturer for that model, and that the derated capacity with the attachment fitted is marked and known to the operator.

Chassis, drive and stability

The chassis and overhead guard are examined for cracking, distortion and impact damage, and counterweight security and correct mass are verified. Tyres, wheels and rims are checked for condition, wear and the correct type for the surface and duty, and the steer axle, pivot and stability arrangement are examined. Service and parking brakes are tested for stopping and for holding on a gradient, transmission, drive and engine condition are checked, and electric trucks have battery condition, restraint and charging arrangements examined, while gas trucks have LPG cylinder mounting, hoses and shut-off checked.

Telehandler-specific checks

On telehandlers, itmad examines the boom sections, wear pads and extension and retraction under load, and function tests the longitudinal load moment indicator against known loads at radius. Stabilisers and frame levelling are checked where fitted, including deployment interlocks, and the load chart for each attachment and configuration must be present in the cab and correct. Rotating machines have their slew mechanism and lock checked, and where the machine is used to lift persons, the man cage, its interlocks and the reduced rated capacity that applies are inspected.

Controls and operator safety

Controls, the deadman, the seat switch and the emergency stop are tested, together with operator restraint, seat belt and overhead guard. Visibility, mirrors, camera systems, lights and travel alarms are checked, as are the horn, indicators and warning devices, the legibility of the capacity plate, decals and safety markings, and access steps, handholds and platform condition.

Load testing

Proof load testing is carried out on new machines, after structural repair, after a mast or attachment change, and at the intervals that the client's specification requires. The load is applied at the rated capacity and load centre with the machine in the configuration in which it will be used, and stability, brakes, hydraulic holding and structural condition are verified during and after the test.

Standards applied

Inspection follows the standard that the contract or governing authority specifies, commonly ASME B56.1 for low and high lift trucks, ASME B56.6 for rough terrain trucks, EN 1459 for rough terrain telehandlers and the ISO 3691 series for industrial trucks. The manufacturer's inspection and maintenance schedules are applied alongside, since they set the chain elongation limits, fork wear criteria and service intervals that no general standard specifies.

When inspection is required

Inspection is needed periodically, at the interval that the governing authority sets; before a machine is released for use on a new site; after fitting or changing an attachment or altering the mast; after structural repair or impact damage; after an overload, tip-over or collision; before hire out or on acceptance of a hired machine; and, where the machine is used to lift persons, at the shorter interval that applies. Where a fleet is spread across locations, inspection is scheduled to cover it in one programme.

What the client receives

An inspection certificate in the format that the governing authority requires, and a report that identifies each machine by make, model, serial number and capacity. The report includes chain elongation and fork wear measurements against the discard limits and confirmation that the capacity plate matches the configuration as found. Findings are recorded component by component with photographic evidence, defects are classified by severity, load test results are included where load testing was carried out, and machines are tagged on site and the fleet register updated.

Frequently asked questions

Why is the capacity plate checked?

Because rated capacity depends on the mast, load centre, lift height and any attachment, and an attachment or mast change makes the original plate invalid. A truck operating to a plate that does not match its configuration is operating outside its rating.

What is the most often skipped forklift check?

Measuring lift chain elongation against the manufacturer's discard limit. It is the check most likely to drop a load, and itmad records the measurement in the report.

How are forks inspected?

For heel wear, blade thickness, cracks at the heel and the angle between blade and shank, and the locking pins are checked. Forks are consumable, and worn ones are routinely left in service.

What extra checks apply to telehandlers?

The boom sections and wear pads, a function test of the load moment indicator against known loads at radius, stabilisers and their interlocks, and the load chart for each attachment. Where the machine lifts persons, the man cage, interlocks and reduced capacity are inspected.

Which standards apply?

Commonly ASME B56.1 for low and high lift trucks, ASME B56.6 for rough terrain trucks, EN 1459 for rough terrain telehandlers and the ISO 3691 series. The manufacturer's schedules are applied alongside.

When must a forklift or telehandler be inspected?

Periodically, before release for use on a new site, after an attachment or mast change, after structural repair or impact, after an overload, tip-over or collision, and before hire out or acceptance of a hired machine. Where the machine lifts persons, the shorter interval applies.