Any manufacturing, warehouse, or construction worker understands the importance of maintaining the equipment on their worksite, ensuring safety and productivity. Forklifts and their accessories are no different. It may be common practice to maintain and inspect the forklift itself, but did you know that forklift arms also need to be replaced? Forklifts are arguably the most versatile and necessary pieces of equipment on any worksite, and not only can the metal forks take on damage from day-to-day use, but sometimes accidents happen. Fork arms are the heavy lifters on the forklift, and ensuring they are in top condition will keep you and your industry moving forward.
Fork arms are ICHINEN USA’s specialty. We take great pride in manufacturing top-tier forklift arms and accessories, and in our time working with various industries, we’ve learned quite a bit about the implications of worn fork arms. Damaged or compromised fork arms can cause load instability, accidents, and fork breakage. Additionally, even slightly worn fork arms can reduce lifting capacity, cause difficulty handling loads, and increase the chances of dropped or damaged products.
Regular inspection and worker training are critical to ensuring your worksite is safe and avoiding common forklift safety violations. However, knowing when to identify that you need to replace your fork arms will protect you, your product, and your enterprise.
We put together this list of 5 signs that your forklift arms may need to be replaced. Let’s take a look.
#1: Visible Wear and Damage
The Occupational Safety and Health Administration requires all forklift operators to perform a daily pre-operation inspection before using the truck for the day. This inspection is the perfect opportunity for forklift operators to inspect the fork arms themselves for visible wear and damage.
Operators should look for these signs that the fork arms may need to be replaced:
- Surface cracks or fractures
- Significant bending or twisting
- Visible metal fatigue (look for the distinct ‘clamshell’ appearance in the metal)
- Heel wear (from contact with the ground or other surfaces) that exceed manufacturer specifications
#2: Decreased Load Capacity Performance
Another sign that your forklift arms may need replacing is if you are experiencing decreased load capacity. A forklift with a decreased load capacity may lift a load slowly or unevenly, have difficulty reaching full height, and exhibit a decrease in lifting power, noticeable to operators.
Safety Tip: This may not be noticed until the forklift is in operation, so remember to report any anomalies in performance and discrepancies immediately to the appropriate people within your organization.
Keep an eye out for these indicators that your fork arms may need replacement:
- Difficulty handling rated loads
- Uneven lifting
- Signs of strain under normal operating conditions
#3: Thickness Reduction
As forklifts maneuver about a worksite, lifting or carrying their loads, fork arms drag along the ground, shelves, and the product they lift. This friction slowly wears down the metal, making it thinner and thinner over time. The industry standards for the minimum thickness of fork arms vary, and fork arm thickness is chosen based on the forklift’s load capacity and handling needs. Any fork arm wear over 10% of the total thickness indicates it is time to replace your fork arm.
Knowing how to measure your fork arm’s thickness is necessary to ensure your forklift operates at its peak. Three measurements are essential to record. Using a caliper, capture the following measurements:
- Width: Measure the blade from side to side
- Length: Measure from the shank to the tip
- Thickness: Measure the blade from the thickest part, bottom to top
#4: Uneven Fork Arms
Fork arms are manufactured close to a 90-degree angle. However, wear-and-tear and minor worksite accidents can sometimes cause fork arms to be bent upwards or downwards, causing the two arms to be uneven. This imbalance can make lifting loads of any size dangerous and cause the forklift to become out of balance enough to tip. Replacing uneven fork arms in pairs is vital, preventing any further misalignment.
Keep an eye (and ear!) out for these clues that your fork arms are uneven:
- Look for bulges or bents in the shake or blade
- Check for cracks, especially near the heel
- Measure the angle and replace fork arms with bends that exceed 93 degrees
- Listen for strain in the fork stanchions
#5: Age and Usage Hours
Sometimes, the most significant indicator that your fork arms should be replaced is that they have been used for a long time. Every fork arm manufacturer recommends replacement intervals, so checking with your manufacturer for their best practices is key. However, if your enterprise has not replaced its fork arms in some time, consider replacing them as a preventative measure.
Forklift maintenance is a daily, weekly, monthly, and annual commitment. Tracking the use of your forklift and documenting its functionality is necessary to understand the lifespan of your equipment and will help prevent the extended costs of forklift failure. Check your operations records to verify that your machines are being regularly serviced and to ensure there have not recently been any minor accidents that could have damaged your fork arms.
These less common signs may be an indicator that your regularly maintained forklift arms may need replacing:
- Damage to the positioning lock
- Excessive fork hook wear or deformation
- Fractures or unevenness in arm tips
- Fork arm documentation is unavailable
Never Settle for Less than Exceptional
Knowing when to replace your forklift fork arms is key to keeping your lifting operations on the move, and preventative replacement can prevent unwanted accidents or downtime.
At ICHINEN USA, we are passionate about providing you with the highest quality, 100% heat-treated standard and premium forks and fork arm accessories. We work hard to help our customers stay safe in their day-to-day operations.
If you’d like to learn more about forklift arms or how we can help you determine the perfect fork arm and fork arm accessories for your lifting needs, contact us today!
