Forklifts are so common that their inspection is often left to the pre-start check. The components that actually fail — fork arms worn thin at the heel, lift chains stretched past their limit, mast rollers and carriage welds — need measurement, not a glance. AS 2359.2 requires inspection and maintenance in accordance with the manufacturer, and ISO 5057 gives the fork arm criteria used across Australian industry.
We inspect counterbalance, rough-terrain and reach forklifts in warehouses, workshops and on site, with a scope built around the load-handling components and the operator protection systems.
Inspection checklist areas
- Fork arms
- Blade and shank thickness at the heel compared with original (withdraw at 10 percent wear), heel and hook crack inspection by MT, tip height difference (limit 3 percent of blade length), blade straightness and hook wear, positioning lock and identification markings, to ISO 5057.
- Mast and carriage
- Mast channel wear and roller clearance, carriage and fork bar welds, tilt cylinder mounts and pins, mast mounting trunnions, side-shift and attachment mountings.
- Lift chains and cylinders
- Chain elongation measurement against the manufacturer's discard limit, anchor pins and adjusters, chain lubrication and corrosion, lift cylinder drift and hose condition.
- Attachments
- Rotators, clamps, jibs and work platforms, with matching capacity plates and de-rated load charts, attachment locking and hydraulic connections.
- Brakes, steering and tyres
- Service and park brake function, steering play and cylinder condition, tyre condition including solid and pneumatic tyres, wheel nuts and rims.
- Operator protection and markings
- Overhead guard and load backrest condition and unauthorised modification, seat belt, horn and lights, capacity plate legibility and match to configuration, hour meter and previous records.
Known failure modes
Fork arm failure
Cracking at the heel or hook, usually preceded by wear beyond 10 percent of original thickness or prior heating and straightening.
Lift chain failure
Chain elongated beyond its discard limit, corroded or with cracked plates, dropping the carriage and load.
Overturning
Lateral tip-over from cornering with an elevated or off-centre load, or longitudinal tip from overload at height.
Mast and carriage cracking
Fatigue at carriage welds, tilt cylinder mounts and mast trunnions.
Load falling onto the operator
Damaged or removed load backrest or overhead guard.
Applicable standards and regulations
| Reference | Title | Relevance |
|---|---|---|
| AS 2359.1 | Powered industrial trucks — General requirements | General design and safety requirements for forklifts. |
| AS 2359.2 | Powered industrial trucks — Operation | Requires inspection and maintenance in accordance with the manufacturer, and safe operating practices. |
| ISO 5057 | Industrial trucks — Inspection and repair of fork arms in service on fork-lift trucks | Fork arm wear, crack, straightness and tip height criteria used for inspection. |
| AS 2359.6 and AS 2359.13 | Powered industrial trucks — Safety code; Fork arms — Technical characteristics and testing | Safety requirements and the original fork arm specification against which wear is assessed. |
| Model WHS Regulations | High risk work — Forklift operation | Licensing context for forklift operation, referenced for site compliance. |
When to inspect
- Annual or manufacturer-specified inspection interval
- Fork arms showing heel wear, bending or after impact
- Before fitting a new attachment or work platform
- After tip-over, collision or load drop
- Before purchase, hire or introduction to site
Frequently asked questions
When must fork arms be withdrawn from service?
Under ISO 5057, when the blade or shank thickness at the heel has worn by 10 percent or more of the original, when the difference in tip height between the two forks exceeds 3 percent of the blade length, when cracks are found at the heel or hooks, or when the blade is bent or twisted beyond the permitted deviation. Fork arms must not be repaired by heating or welding except by the manufacturer or a competent person to a documented procedure.
How is lift chain wear checked?
Chain elongation is measured over a set number of pitches and compared with the manufacturer's discard limit, commonly around 3 percent for leaf chain. Chains are also inspected for corrosion, cracked or turned plates, and worn or protruding pins.
Do forklift attachments change the rated capacity?
Yes. Any attachment moves the load centre and reduces the rated capacity. Each attachment must have a capacity plate or de-rated chart for the truck it is fitted to, which the inspection checks against the truck's capacity plate.