Catch Forklift Wear & Tear Before it Erodes Your Equipment Budget
Moving, lifting, and stacking thousands of pounds of inventory every day puts a tremendous amount of strain on forklift equipment, particularly the forklift forks and chains. Although they are designed to take a certain amount of wear and tear, it’s important to conduct a daily inspection and schedule regular vehicle maintenance to keep performance at peak levels and extend their operational life. An ounce of prevention is a significant cost-saver when you can avoid costly downtime, major repairs and accidents.
The good news is that the problems that affect these critical parts of your forklift are usually predictable and can be mitigated with regular inspection and preventative maintenance. With that in mind, here are some helpful insights for proper assessment of forklift forks and chains.
Inspecting Forklift Forks to Ensure Proper Function
Bent, damaged or misaligned forks are a common cause of falling loads. OSHA requires forklift inspections at least once per day and those used around the clock should be checked every shift. Here are some of the critical areas on which to focus during a routine fork inspection.
- Rated Load Capacity – A forklift’s rated load capacity has as much to do with weight distribution as it does with load weight and size. Forklifts are designed to carry a capacity load at a standard load center, typically 24″, i.e., the load centered, and weight distributed evenly across the forks. A pallet of 4500 lbs. may be within the rated capacity if it is evenly distributed. If it is irregularly shaped, unbalanced, or placed closer to the fork tip, the same 4500 lbs. could exceed the rated load capacity. The rated capacity should appear on the forklift’s data plate. For more information – see OSHA Guidelines on forklift load composition.
- Surface Cracks and Breaks – Inspect each fork, top and bottom, for surface cracks. Pay close attention to the heel area and the welds to the hook areas that attach the forks to the lift truck. These areas are most likely to develop cracks. If a crack is found, the fork must be replaced before the lift truck is put back into service. OHSA does not permit a damaged fork to be repaired.
- Blade and Shank Straightness – Damaged or bent blades and shanks can have serious consequences and lead to accidents. It’s critical that bent blades or shanks, no matter how minor, are replaced before the vehicle is placed back into operation. If the shank and blade angle exceeds 93 degrees, the fork must be replaced before the lift truck is put back into service.
- Check the Positioning Lock – The positioning lock on a forklift holds the forks in position and prevents sliding of the forks and loss of the load. If the positioning lock is damaged or broken, it can lead to intense and immediate strain on the fork and cause loads to fall. Broken positioning locks will need to be replaced before further use.
- General Wear and Tear – The heal and the blade on forklifts tend to wear out most quickly. Use calipers to measure these components. Once heel and blade wear reaches 10 percent, the fork must be replaced. Ten percent wear results in a 20 percent reduction in rated fork capacity and represents a significant exposure for accidents.
Tips for Inspecting Forklift Chains
Forklift chains are built to last anywhere from three to five years. It’s important to inspect chains on new forklifts and older models for general wear and tear and environmental factors, like dirt, rain, and industrial chemicals. Here are some tips to remember when inspecting your forklift chains.
- Elongation – You can use a chain gauge to measure the elongation of your forklift chain. Elongation of more than three percent indicates a 15 percent reduction in strength and means the chain should be replaced. It’s best to have an experienced and certified professional assess and repair chain elongation.
- Corrosion and Rust – Rust and corrosion can quickly erode the integrity of your forklift chain and put your operators at risk. These factors generally worsen over time but can still affect newer models through exposure to chemicals, moisture, or extreme temperatures. Chains showing any rust or corrosion should be replaced. For maximum protection, chains must always remain lubricated.
- Cracks in the Plates – Corrosion and rust can lead to cracks in the plates. Plate cracks signify a severe deficit in the chain’s strength and stability and should be inspected closely and replaced if necessary.
- Protruding or Turned Pins – Lack of lubrication results in friction between the plates and the pin, causing the pins to twist and turn out of position, resulting in chain failure.
- Misalignment – Misalignment can be identified through several indicators, including holes on the outside of the side links due to worn-down pinheads. Address misalignment immediately to prevent one-sided wear and tear and eventual chain failure.
Be sure to check anchors and sheaves for misalignment and undue wear and tear. When identified, these parts must be replaced immediately.
Let Apex Guide You Toward Proper Forklift Inspection
Apex Companies is a national leader in forklift sales, maintenance, and repair. We’re ready to help you ensure your forklifts are running on all cylinders so you can maximize their longevity. We also offer certified driver training including daily vehicle inspection criteria. Contact the Apex team today to learn more about what we can do for you.