KNOW YOUR FORKLIFT WEAR LIMITS

Safe operation starts with proper inspections. Wear on forks, chains, tires, and brakes can create serious safety risks and costly repairs if left unchecked. Don’t just look—measure. A quick inspection helps identify problems early, keeps equipment operating safely, and supports OSHA compliance. Knowing your forklift wear limits helps protect operators, equipment, and your operations.

WORN FORKS SILENTLY REDUCE CAPACITY

When a fork wears to 90% of its original thickness, its load capacity drops by approximately 20%. A 5,000 lb. forklift can effectively become a 4,000 lb. forklift. Use a caliper and perform daily inspections to identify unsafe wear before it leads to accidents, OSHA violations, or costly downtime.

CHECK >>> Use a caliper to check fork heel wear against the original shank thickness. Replace forks if wear exceeds 10% or if cracks, bends, or other damage are present. Inspect heels, tips, blade angles, and fork hooks for compliance with manufacturer specifications. TMHS stocks a wide range of replacement forks for quick replacement.

STRETCHED CHAINS INCREASE RISK OF SUDDEN FAILURE

Inspect mast chains at the start of every shift. Chain wear and elongation can weaken lifting performance and lead to sudden failure. If chain elongation exceeds 3%, replace the chain immediately. Any signs of stretch, damage, corrosion, or abnormal wear should be inspected by a qualified technician.

CHECK >>> Use a chain gauge to check lift chain wear and elongation against manufacturer specifications. Replace chains with more than 3% elongation. Lift chain inspection is a key part of TMHS’ Planned Maintenance (PM) program and helps ensure safe, reliable forklift operation.

TIRES ARE THE FORKLIFTS’ SUSPENSION

Unlike automobiles, forklifts do not have a traditional suspension—the entire weight of the truck and its load is supported by the tires. Worn or damaged tires can reduce stability, affect load handling, and increase operator fatigue and safety risks. Regular inspections help keep your forklift safe and productive.

CHECK >>> Inspect tires during your pre-shift check. Replace them immediately when they reach the manufacturer’s wear line or show chunking, tearing, flat spots, or other damage. Worn tires reduce stability and increase safety risks. TMHS offers mobile tire service with quality tires, including Camso Solideal.

FORKLIFT BRAKES ARE A CRITICAL SAFETY ITEM

A forklift cannot stop on a dime—it can take approximately three truck lengths to come to a complete stop under normal travel conditions, and even longer when carrying a load or operating on slippery, uneven, or congested surfaces.

CHECK >>> Inspect brakes before every shift. Check for leaks, damaged hoses, worn components, and loose hardware. The brake pedal should feel firm and never sink to the floor. Test the parking brake to ensure it holds the truck on a 15% grade. If the brakes fail inspection, remove the forklift from service immediately and contact TMHS for prompt repair and service.

Don’t wait for a failure to reveal a problem. Inspect critical wear items daily, measure them against manufacturer specifications, and remove unsafe forklifts from service immediately. Need help? TMHS’ factory-trained technicians can perform Planned Maintenance (PM) inspections and repairs before wear leads to accidents, OSHA violations, truck damage, downtime, and lost productivity.

Contact us today to let our Planned Maintenance (PM) Agreements “inspect, measure and protect” your fleet; and keep your organization safe, compliant, & operating at peak performance.

OSHA 1910.178 requires daily/pre-shift forklift inspections. Wear limits shown are based on ANSI/ITSDF B56.1 standards, manufacturer recommendations, and industry best practices. Always follow your forklift manufacturer’s inspection/replacement criteria; and refer to the truck’s data plate for capacity information.