How do you know when it's time to replace your forklift tires? Wait too long and you're looking at reduced productivity, safety hazards, and potential damage to your equipment. Replace too early and you're throwing money away.
The good news? Your tires will tell you exactly when they need to go—if you know what to look for. Here are the five telltale signs that it's time to swap out those worn treads.
1. The "50% Wear Line" Is Visible
Most forklift tires come with a wear line molded into the rubber—a visual indicator that shows when you've hit the 50% mark. Once you can see this line clearly, you're on borrowed time.
What to look for: Check the sidewall of the tire for numbers, letters, or a visible line that wasn't there when the tire was new. On press-on tires, the wear line is typically a different color layer that becomes visible as rubber wears away.
Pro tip: Don't wait until you hit the wear line to start shopping. Lead times on specialty sizes can run 2-3 weeks, so order replacements when you're at 60% wear.
2. Chunking and Tearing
If chunks of rubber are missing from your tire, you've got a problem. Chunking happens when tires are pushed beyond their limits—whether from overloading, excessive speed, or running on debris-covered floors.
Common causes:
- Overheating: High-speed operation or heavy loads generate heat that breaks down rubber compounds
- Chemical exposure: Oils, solvents, and certain cleaning chemicals attack tire material
- Debris damage: Metal shavings, glass, or sharp objects tear chunks from the tread
- Age: Old tires become brittle and prone to cracking
Once chunking starts, it accelerates quickly. A small missing piece becomes a big missing piece within days of continued operation.
3. Flat Spots
Flat spots are exactly what they sound like—worn flat areas on the tire surface that should be round. You'll feel them as vibration or "thumping" when the forklift moves.
Causes of flat spots:
- Spin-outs: Aggressive acceleration or braking on smooth floors
- Locked brakes: Skidding when stopping under load
- Stationary loading: Repeatedly picking up or setting down heavy loads in the same spot
Flat spots can't be repaired. Once they develop, the tire will continue to wear unevenly, creating more vibration and potentially damaging bearings and axle components.
4. Cracking and Dry Rot
Even if your tires have plenty of tread left, age catches up eventually. Rubber compounds break down over time, especially when exposed to UV light, ozone, or temperature extremes.
Where to check: Look closely at the sidewalls and in the tread grooves. Small surface cracks are early warning signs. Deep cracks that expose the tire's internal structure mean replacement is urgent.
Timeline: Most forklift tires should be replaced after 5-7 years regardless of wear, depending on operating conditions. Outdoor operation and extreme temperatures accelerate aging.
5. Reduced Traction and Performance
Sometimes the signs aren't visible—you feel them. If operators are reporting that the forklift handles differently, takes longer to stop, or slips more than it used to, worn tires are likely the culprit.
Performance symptoms to watch for:
- Longer stopping distances
- Difficulty climbing ramps or grades
- Slipping during turns
- Increased operator fatigue from fighting vibration
- More frequent battery drain (on electric forklifts) due to increased rolling resistance
Trust your operators. They spend hours on these machines every day and notice changes long before they become obvious to a visual inspection.
When in Doubt, Measure
The most reliable way to assess tire wear is measurement. Press-on tires typically have a usable rubber thickness of 1-2 inches. When you're down to less than half an inch of rubber above the band, it's replacement time.
For pneumatic and solid pneumatic tires, measure tread depth at multiple points around the tire. Uneven wear patterns indicate alignment or load distribution issues that should be addressed when installing new tires.
Ready to Replace?
Don't wait for a blowout or breakdown to address worn tires. Browse our complete selection of forklift tires including press-on, pneumatic, and solid options for all major brands. Need help finding the right size? Submit a parts inquiry or call us at (562) 693-7748 for expert recommendations.