Do your truck’s forks

meet safe operational

standards?
We make checking simple.
 Reduce “Workload”.
Check your truck’s forks
regularly.

There is a lot resting on the safe operation of your forklift Who performs the inspections?
truck forks. The forks are the main load carrier and it is a They may only be performed by competent engineers.
pre-requisite that they are given a full inspection on a
regular basis to ensure availability for day to day opera- ISO standard 5057:
tion. Inspections must be performed regularly. At least every
12 months or at least every 1,500 operating hours. Fork
Our simple check procedure will confirm the forks meets truck operators / owners are also required to conduct
all safety parameters prior to operation. regular visual inspections.

Good Practice
“Employees must immediately report to their employer or 6
responsible supervisor any significant concerns that may
affect health and safety issues discovered during inspec-
tions.” 8 2

5
Employers’ Liability
4
“The operator must ensure that defects which impair
1 3
safety are remedied before continuing operation.”
2
7

2
Our wear measuring card
will make it easy for you to
check fork wear.

General instructions for safe operation of forks

1. Always lift the load with both forks, never a single 9. When the truck is in operation the fork locks must
fork (either partial or full load). always be engaged to prevent the forks moving to the
side. Otherwise there is the potential of fork slide.
2. Conduct regular visual inspections. If damage is
discovered, take the forks out of operation 10. Do not lift loads with only the fork tip or with the tilt
immediately. cylinder. Danger of overload!

3. Note the capacity and load centre distance. Using the 11. Have the required statutory accident prevention
forks up to the tipping point of the truck is not inspections (including crack check) performed
permitted and is dangerous. regularly (by our safety service, for example).

4. Forks are not designed for lateral forces. Avoid entering 12. Forks with a longer length must generally be of a
at an angle or pushing from the side. higher specification, as there is a danger of overload.
Ask our Area Sales Manager for advice.
5. Due to the danger of breakage, never use the forks as
reverse forks with the blade pointing up. Reverse forks 13. Do not make any changes or modifications yourself.
are availabe as specially designed units.
14. Welding and heat treatment can destroy the material
6. Do no allow any loads to fall on the forks. structure, resulting in breakage.

7. Do not transport any molten materials. 15. Do not weld worn forks (ISO 5057).

8. Do not carry people.

3
 16. Drilled holes can weaken the fork, the result is the
forming of cracks.

17. Do not straighten bent forks yourself.

1. Determine the nominal
thickness “N” of the fork with a
18. Even if only one fork is damaged, you should still scale (in the rear part of the
examine both forks for possible damage and if fork, as illustrated.).

necessary replace both to ensure uniformity.

19. Measure wear regularly. When 10 % of the original

nominal thickness has worn off, the forks must be 2. Place the opening assigned to
replaced (ISO 5057). Just 10 % wear reduces capacity nominal fork thickness “N” (for
example “N 40” for a nominal
by about 20 %. thickness of 40 mm) in the
area of the greatest wear
(often in the formed area).

3. If the opening of the relevant

measuring card can be
pushed onto the fork, the fork
must be replaced. The wear
Measuring card has already exceeded 10 % of
Order no. the nominal thickness.
51073378

All illustrations and graphics in this brochure are schematic diagrams. Subject to technical modifications as part of technological progress and product
optimisation. The illustrations in this brochure are not part of any contract. Errors excepted.

The measuring tool for checking angles and measuring wear is merely an aid. It is not certified legal for trade, it cannot be calibrated and it is not a
precision measuring instrument. Using it does not relieve the user of his obligation to exercise due care.

4
Checklist.
Visual inspection and intensive check in accordance
with ISO standard.
Mark the horizontal / vertical distance at 500 mm.
1 5
n Fork wear generally occurs in the
outer bend area.
Diagonal dimension d: Ideal condition 90°:
d = 707 mm
Acceptable tolerance: d = 695–713 mm

500

d
Straighten fork: d = 714–730 mm
Replace fork: d > 730 mm
Wear range Note: Occasionally forks are used for special
“n”– 10 % = replace forks! applications with different angular dimensions.
500 Please check before inspection.

1 Wear 5  Angular dimension

Just 10 % wear of the fork means that capacity has been reduced Forks are at an angle of 90° as supplied. They are designed so
by about 20 %. The original nominal thickness (N) of the fork is that no permanent bending will occur even if three times the
the starting point for the wear measurement. With a nominal normal load is applied. Overload or misuse can result in perma-
thickness of 40 mm, for example, the wear limit is 36 mm. nent bending.
ISO standard 5057 prescribes that a fork must be replaced if the
wear of the fork exceeds 10 %.

2 6
Fork hook

Inner bend

2  Surface cracks 6 Locks

Critical areas: Fork inner edge and welding on carriers – The locks prevent unwanted slipping on the fork carriage. Use of
test procedures: Magnetic powder crack inspection /  the truck with damaged or missing locks is not permitted.
dye penetration method.

3 Forks 7

1 2
h

For approximate values see table on page 6.

3  Differences in height 7  Damage / wear on the tip

The difference in height between the forks on the tip must not Forks that are worn or too thin pose a risk of injuries and could
be more than 1.5 % of the blade length. damage goods. Replace or shorten fork!
Acceptable: h = max. L*
66
Straighten fork: h = L* to L*
66 33
Replace fork: h = more than L*
33

4 Straight edge
8 Bending up

k
Bending point

4  Deflection of the blade 8  Bending up of the fork hook

Acceptable: k = max. L* Lateral forces and extended operating time can cause fork
66
hooks to bend laterally. This results in limited directional
Straighten fork: k = L* to L*
66 33 stability.­If fork hooks are significantly bent or worn they must
Replace fork: k = more than L* be reforged or replaced.
33
* L = blade length (mm)
5
 Your reference values for items
3 and 4 in the checklist.

Fork length Acceptable value Straighten fork Fork Alignment

(mm) (mm) (mm) (mm)
800 to 12 12 to 24 24
900 to 14 14 to 27 27
1,000 to 15 15 to 30 30
1,100 to 17 17 to 33 33
1,200 to 18 18 to 36 36
1,300 to 20 20 to 39 39
1,400 to 21 21 to 42 42
1,500 to 23 23 to 45 45
1,600 to 24 24 to 48 48
1,700 to 26 26 to 52 52
1,800 to 27 27 to 55 55
1,900 to 29 29 to 58 58
2,000 to 30 30 to 61 61
2,100 to 32 32 to 64 64
2,200 to 33 33 to 67 67
2,300 to 35 35 to 70 70
2,400 to 36 36 to 73 73

6
Template for copying

Inspection record.
Forks for trucks and construction machines.
Condition Findings
1 Wear n

Nominal thickness “N” – 10 % ➞ Replace • In good condition

• Not in good condition
Wear range Comments:
“n”– 10 % = replace forks!

2  Surface cracks • In good condition

Fork hook
Signs of cracks ➞ Replace • Not in good condition
Comments:
Inner bend

3  Differences in height at fork tip

• In good condition
Acceptable: h = max. L* Forks
66 • Not in good condition
1 2
Straighten fork: L* to L*
h = 66
33
Comments:
h

Replace fork: h = more than L*

33

4  Deflection of the blade

Acceptable: k = max. L* • In good condition
Straight edge
66
• Not in good condition
Straighten fork: L* to L*
k = 66 k

33 Bending point Comments:

Replace fork: k = more than L*
33

5  Angular dimension • In good condition Occasionally forks are used for

special applications with
Ideal condition 90°: d = 707 mm • Not in good condition different angular dimensions.
Please check before inspection.
500

Acceptable tolerance: d = 695–713 mm Comments:

d

Straighten fork: d = 714–730 mm

Align fork: d > 730 mm 500

6 Locks • In good condition

• Not in good condition
Comments:

7  Damage / wear on the tip • In good condition

• Not in good condition
Comments:

8  Bending up of the fork hook Bending up

• In good condition
• Not in good condition
Comments:
* L = blade length (mm)
Findings

Fork dimensions:
• Fork in good condition
• Fork not in good condition Width (mm) Blade length (mm)
➞ Scrap / replace Thickness (mm) Suspension
➞ Repairs
Forks should always be replaced in pairs, This is because if one fork is
Type of fork lift truck
damaged it may be assumed that its counterpart will exhibit similar
damage. Serial no.

Inspected by Date Signature

 4424.COM.08.2013.r.r.s · Technical modifications reserved.
Jungheinrich
Plants, Sales and
Services Europe
ISO 9001/ ISO 14001

Jungheinrich trucks
conform to the European
Safety Requirements.

Jungheinrich
Vertrieb Deutschland AG & Co. KG

Am Stadtrand 35
22047 Hamburg
Germany
Telephone +49 40 6948-0
Telefax +49 40 6948-1777

[email protected]
www.jungheinrich.com