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Common Defects Found on Fork Lift Trucks
Fork lift trucks are critical to day-to-day operations in warehouses, factories, and distribution centres across the UK. When properly maintained, they are safe and reliable. When defects are missed or ignored, however, they can present serious risks to operators, pedestrians, and property.
Based on inspection findings commonly identified during LOLER thorough examinations and PUWER inspections, this article outlines some of the most frequent defects found on fork lift trucks, explains why they matter, and highlights the importance of early detection and corrective action.
1. Elongated Load Chains
Elongation of lift chains is one of the most serious defects found on fork lift trucks. Over time, chains stretch due to repeated loading, wear between pins and links, inadequate lubrication, and harsh operating environments. Once elongation exceeds accepted limits—typically 2–3% depending on manufacturer guidance—the chain’s strength and ability to lift safely are significantly reduced.
Excessively elongated chains increase the risk of:
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Sudden chain failure
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Dropped or unstable loads
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Mast misalignment and uneven lifting
Because chain elongation is gradual, it is rarely obvious without accurate measurement during a thorough examination. Chains that exceed allowable limits must be replaced promptly to maintain lifting safety and compliance.
2. Excessive Wear to Fork Arm Heels
Wear to the heel of the fork arms is another commonly identified defect and one that is often underestimated. The heel area bears the highest stress during lifting, and excessive wear here directly reduces the fork’s load-carrying capacity.
As a general rule, heel wear exceeding 10% of the original fork thickness is considered a serious defect and typically requires fork replacement. Forks with excessive wear may still appear usable, but their structural integrity can be compromised, increasing the risk of sudden failure under load.
Regular inspection, measurement, and comparison against original fork specifications are essential to ensure forks remain fit for purpose.
3. Hydraulic Leaks and System Defects
Hydraulic systems are central to forklift operation, controlling lifting, lowering, and mast movement. Leaks from hoses, seals, cylinders, or fittings are frequently identified during inspections and should never be dismissed as minor issues.
Hydraulic defects can result in:
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Reduced or uneven lifting performance
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Uncontrolled or jerky mast movement
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Increased risk of load instability
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Slip hazards and environmental contamination
Even small leaks often indicate underlying deterioration that can worsen quickly if not addressed. Prompt repair helps maintain control, reliability, and safety.
4. Damaged or Worn Tyres
Forklift tyres play a crucial role in stability, traction, and braking performance. Common tyre defects include chunking, splitting, flat spots, uneven wear, or excessive degradation caused by rough surfaces or poor housekeeping.
Damaged tyres can:
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Reduce truck stability, especially when carrying loads
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Increase stopping distances
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Make steering unpredictable
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Increase the risk of tip-overs
Because forklift overturns are among the most serious workplace accidents, tyre condition should be monitored closely as part of routine checks and planned inspections.
5. Ineffective or Poorly Maintained Brakes
Brake defects present an immediate safety risk. Forklift braking systems must be capable of safely stopping the truck under load and holding it stationary when parked, including on gradients where applicable.
Common brake-related issues include:
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Worn brake components
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Poor adjustment
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Hydraulic faults
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Reduced braking efficiency
Faulty brakes significantly increase the risk of collisions with pedestrians, racking, and other vehicles, particularly in busy operational environments. Brake performance should be assessed during inspections and addressed without delay.
Why These Defects Matter
Many forklift defects develop gradually and silently, making them easy to miss without structured inspection and examination regimes. Defects such as chain elongation, fork wear, hydraulic leaks, tyre damage, and brake failure are among the most common contributors to serious forklift incidents.
Regular:
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Pre-use checks by operators
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Planned maintenance
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PUWER inspections
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LOLER thorough examinations
are essential to identify defects early, manage risk, and ensure ongoing legal compliance.
Final Thoughts
Fork lift trucks are safety-critical pieces of work equipment. Identifying and addressing common defects promptly not only protects operators and pedestrians but also helps organisations meet their legal duties and avoid costly downtime, enforcement action, or accidents.
A proactive approach to inspection, maintenance, and examination is one of the most effective ways to ensure forklift trucks remain 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.
Load chain elongation weakens the chain and reduces its ability to lift loads safely. When elongation exceeds acceptable limits, typically around 2–3% depending on manufacturer guidance, the risk of sudden chain failure and dropped loads increases significantly.
As a general rule, wear to the heel of a forklift fork arm should not exceed 10% of the original thickness. Excessive heel wear reduces the fork’s load-carrying capacity and can lead to unexpected failure, even if the forks appear visually serviceable.
Damaged or worn forklift tyres reduce stability, traction, and braking efficiency. This increases the risk of loss of control or tip-over incidents, particularly when operating with loads or on uneven surfaces.
