Common Defects Found on Fork Lift Trucks
Fork lift trucks are essential pieces of equipment in warehouses, factories, and distribution centres, but they can also present serious safety risks if they are not properly maintained. Regular inspections and thorough examinations are vital to ensure forklifts remain safe, reliable, and compliant with workplace safety regulations. Below are some of the most common defects found on fork lift trucks and why they must be addressed promptly.
1. Elongated Load Chains
One of the most critical defects involves load chains that have elongated beyond acceptable limits, typically more than 2%–3%. Load chains elongate over time due to wear, heavy use, and inadequate lubrication. Excessive elongation weakens the chain, reducing its ability to safely lift loads and increasing the risk of sudden failure. If left unchecked, elongated chains can lead to dropped loads, equipment damage, and serious injuries. Regular measurement and timely replacement are essential to maintain lifting safety.
2. Wear To Fork Arm Heels
Excessive wear on fork arm heels, especially when wear exceeds 10% of the original thickness, is a serious structural defect. The heel of the fork arm carries the majority of the load stress, and wear in this area significantly reduces the safe working load of the forklift. Fork arms with excessive heel wear may look serviceable at a glance but can fail without warning. Regular measurement and replacement of worn forks are crucial to prevent catastrophic failures.
3. Hydraulic Leaks
Hydraulic leaks are another common defect and should never be ignored. Leaks can occur in hoses, seals, cylinders, or connectors and may result in reduced lifting capability or uncontrolled movements of the mast. In addition to performance issues, hydraulic leaks create slip hazards and can lead to environmental contamination. Even small leaks often indicate underlying problems that can worsen over time if not repaired.
4. Damaged Tyres
Damaged or worn tyres are another frequently identified issue. Forklift tyres
may suffer from chunking, splitting, flat spots, or excessive wear, particularly in harsh operating environments. Defective tyres reduce stability, traction, and braking efficiency, making the truck harder to control—especially when carrying loads or operating on uneven surfaces. Poor tyre condition can also increase the likelihood of tip-overs, which are among the most dangerous forklift accidents.
5. Ineffective Brakes
Finally, ineffective or poorly performing brakes pose an immediate and severe safety risk. Forklift brakes must be capable of stopping the truck safely under load and holding it stationary when parked. Worn brake components, hydraulic issues, or poor adjustment can lead to longer stopping distances or complete brake failure. Faulty brakes greatly increase the risk of collisions, especially in busy workplaces with pedestrians and other vehicles.
Summary
In conclusion, many forklift defects develop gradually and may go unnoticed without proper inspection routines. Issues such as chain elongation, tyre damage, fork wear, hydraulic leaks, and brake failures all have the potential to cause serious accidents. Regular pre-use checks, planned maintenance, and statutory thorough examinations are essential to keep forklift trucks safe, compliant, and fit for purpose.
Fork Lift Defect And Inspection FAQ's
Our Engineer Surveyors use an array of guidance and standards when examining any item of plant, the main pieces of guidance when examining Fork Lift Trucks and their load chains are as follows;
SAFed Guidance LG 4 Issue 03 – Lifting – Guidelines for the safe management and the thorough examination of lift trucks.
SAFed Guidance MLCC 01 Issue 5 – Fork Lift Truck / Order Picker – Leaf Chain Elongation Rejection Criteria.
Our Engineer Surveyors use an array of guidance and standards when examining any item of plant, the main pieces of guidance when examining Fork Lift Trucks and their load chains are as follows;
SAFed Guidance LG 4 Issue 03 – Lifting – Guidelines for the safe management and the thorough examination of lift trucks.
BS ISO 5057:2022 – Industrial Trucks. Inspection and repair of form arms in service on forklift trucks.
The periodicity of which your lift truck requires examining, all depends on it’s usage and environment. In some instances, if your lift equipment is used in extreme conditions (cold store, or a particularly corrosive environment), the competent person may wish to reduce the periodicity of which your equipment is examined. Your equipment could be placed on an examination scheme, however, under normal circumstances, the following applies;
- 6 monthly intervals if man riding operations are taking place. Man riding operations means when a person is hoisted up during normal operation (on an order picker for example), or the lift truck is used to raise persons with a lifting attachment (man riding basket).
- 12 monthly when used for lifting loads on, and no persons are raised or lowered using the machine.
