Common defects and potential outcomes that our engineers find when examining equipment

Lifting Plant

2 post - excessive movement in support arm locks exceedingly more the one diameter of the pad width
2 post - load pads damaged / missing should be replaced before use to reduce the likelihood of vehicle movement / instability
2 & 4 post - excessively worn or damaged ropes, lift ropes should be monitored regularly and regardless of their apparent condition replaced at least every 6 years or 9000 cycles
2 & 4 post - loose floor bolts, potentially leading to the vehicle hoist becoming unstable when the vehicle is lifted
2 & 4 post - damaged / distorted columns resulting in loss of strength and stability

Worn load chains – load chains have a maximum wear of 3% and should be replaced before this limit is reached
Fork heels excessively worn – fork heels have a maximum wear of 10% and should be replaced before this limit is reached
Handbrake effectiveness - forklifts can be used on inclines or uneven ground which increases the importance of the effectiveness of the brakes, on every thorough examination carried out by CTS Safety comprehensive brake test is carried out and reported to the contact so any remedial action can be carried out
Horn / warning devices inoperable – these are critical devices used by the operator to warn other persons of their presence
Seat belt / seat damaged – a poorly maintained seat can lead to operator injury; a faulty seat belt may not restrain the operator in the event of an overturn

Safe load indicator not functioning - the safe load indicators purpose is to the tell the operator the exact load can be safely lifted at any given extension and radius and is critical to the stability and safety of the machine
Wear in hydraulic ram pins – due to being a moving part if regular maintenance is not carried out, the pins could wear and this should be regular monitored and then changed as required
Damaged or incomplete load chart - the load chart in the cab is used by the operator to plan safe lifting operations and must be available
Steering linkages excessively worn resulting in poor control of machine
Tyres damaged or incorrect inflation pressures – due to the machines versatility to move over a variety of terrain whilst carrying out tasks there is a high chance of the tyres wearing or becoming damaged which could result in their structural integrity compromising the overall stability, tyre pressures must also be maintained at the manufacturers recommended pressures to ensure machine stability

Access gate not closing / latching - access gate on to the platform should be self-closing and open inwards this is to stop the potential of workers falling through the opening of the platform.
Dead man switch disconnected or inoperable – this has the potential for the machine to be operated in an unsafe condition
Stability sensor disconnected / over-ridden / faulty – using a machine without a fully functioning stability sensor can lead to instability and machine overturn
Leaks from hydraulic system – this can cause poor machine control and may lead to component failure
Control markings not legible / operators’ instructions not available on machine – it is critical that operators’ instructions are provided and that all controls are clearly marked to ensure that the operator can use the machine safely

Excessive movement or cracking in kingpost area – this area is key to the overall strength of the crane and any defects must be addressed immediately
Main lift ram creep rate on a dynamic test exceeds the figure stated in the British Standard
Boom sections damaged / distorted / cracked – issues of this type can lead to catastrophic failure
Hook safety catch - safety catch missing on the hook stops any accessory attached potentially becoming detached from the hook
Oil leak at outrigger rams – oil leaks have the potential ability to create instability of the lorry due to loss of pressure to a stabiliser leg or the oil could become a slip hazard to the operator or persons within the vicinity

Hoist rope is excessively worn or damaged – potential to fail under load
Safe working load (SWL) not clearly marked SWL should be clearly visible to any operator to prevent overloading
Emergency stop button on pendant inoperable – this button is required to stop the machine instantly in an emergency
Control button markings missing / not legible – operators need to be able to understand all control button functions to prevent operational errors
Control pendant wire broken – pendants are suspended from a support cable, so the electrical cable is not taking any weight of the controls, it is imperative that the control wiring cable is not pulled out of the control boxes

Load bed damaged - any damage to the load bed has the potential to affect the structural integrity therefore its ability to safely hold the load whilst the platform id being raised.
Load bed stops seized / inoperable – these stops prevent any load shifting or falling from the platform as it is being lifted
Worn load chain – the chain supports the load the same as a forklift and as such is subject to the same wear limits
Guides bent / twisted – distortion to the guides can result in the platform becoming jammed and then releasing resulting in the load becoming unstable
Signage illegible – signage is important to allow the operator to move the platform safely within its limits. It is also important to warn the public of the potential hazard and the additional space which will be required.

Tear in the outer cover of a round sling – any tears in the outer cover would be an automatic discard due to the core being exposed
Cut in a webbing belt – major cuts compromise the strength of the belt and would be subject to discard
Identification label missing or damaged – all equipment should have a unique identification number and the safe working load should be clearly visible or it should be discarded. It is not suitable to write the details directly on to the sling material
Eye bolt shank damaged or twisted – this reduces the structural integrity and strength of the eye bolt
Lifting accessories such as shackles, eyebolts or swivel hooks etc worn and the material loss exceeds 10 % should be removed from service immediately and destroyed.