Fork and Chain

Sales Manual
Table of Content Fork and Chain Sales Manual

Why Focus on Fork and Chain?..................................... 1

Forks
Types of Forks............................................................... 2
Fork Tapers, Tips and Tip Bevels................................... 4
Fork Extensions............................................................ 6
Fork Inspection and Repair........................................... 7
Fork Use Guidelines.................................................... 11
Fork Failures............................................................... 11
Ordering Forks............................................................ 11
Shaft Fork Specification Sheet.................................... 13
Hook Fork Specification Sheet................................... 14
Frequently Asked Questions...................................... 15

Chain
Roller and Rollerless Chain......................................... 16
Leaf Chain....................................................................17
Chain Inspection......................................................... 18
Ordering Chain........................................................... 23

Dealer Operations
Methods to Increase Sales......................................... 24

Promatch® Dealer Support

800.832.1275
616.647.2500
Why Focus on Fork and Chain? Fork and Chain Sales Manual

Two essential parts on a forklift, forks and chain, are commonly neglected.
Lifting heavy or uneven loads, running into stationary objects, or driving with the
carriage too low can damage forks.

When forks and chain wear, the lifting ability of a powered industrial truck is jeopardized. This
puts your customers’ employees in danger. One of the keys to safer forklift operation is routinely
inspecting your forks and lift chain for wear and damage. Since forks and chain bear the full load
weight, OSHA has enacted strict regulations to help increase safety awareness and compliance.

Worn forks and chain are missed opportunities for providing excellent customer service and
generating revenue. Your customers will be thankful for your complete inspection, and grateful
for the potential fines you eliminate from their future. Have your sales representatives and
technical personnel study this manual, and send them out with fork calipers and chain gauges –
you most certainly will see the benefits.

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Types of Forks Fork and Chain Sales Manual

Hook Style Forks

Hook style forks are separated into different classes, depending
on the size of the carriage. Be sure to have the appropriate
carriage size information to make certain you order the correct
forks. Carriage size is measured from the top to the bottom of
the carriage.

• Class II–16” Carriage (2,000–5,500 lbs)

• Class III–20” Carriage (6,000–10,000 lbs)
• Class IV–25” Carriage (10,000–17,500 lbs)
• Class V–28.67” Carriage (18,000–24,000 lbs)

Shaft Style Forks

Shaft forks are used as an alternative to hook forks. They are
also referred to as pin type forks. Shaft forks are more readily
found on larger forklifts, although there are a number of small
forklifts with a pin type carriage. There are a large variety of
sizes of shaft forks found in the materials handling industry.
All shaft forks are special sourced items and must be ordered
to customer specifications.

Class II and III Block Forks

Block forks are primarily used for lifting concrete or cement
blocks. They can be ordered in sets as required, depending on
the load-width, configuration, and weight.

Class II and III Carpet Poles

• Designed to handle carpet rolls.
• The load capacity at 72” is 1,200 pounds.
• A lock pin helps prevent lateral movement.
• Carpet poles are available by special order.

Tire and Drum Handling Forks

Tire handling forks are used for lifting tires of all sizes.
The blade can be custom shaped (profiled) for the variety of
sizes (radius) of tires on the market. Drum handling forks are
designed to lift one or two drums at the same time. These fork
can be supplied with either one or two cut-outs.

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Types of Forks Fork and Chain Sales Manual

Two-Stage Lumber Taper Forks

• A two-stage taper is factored into the blade design.
• Short and durable slim tip for easy entry into the stack.
• 10% of the blade near the inside of the heel is at full
thickness, providing increased rigidity.
• 20% from the tip of the fork is now 50% of the full thickness
of the blade, thus reducing fork deflection.
• The top of the blade can be polished to reduce friction when
engaging a load.
• This design is recommended on forks 72” and longer.
• Lumber forks are available by special order.

Spark Retardant Forks

Spark retardant forks are used on forklifts operating
in hazardous locations. This includes chemical plants,
grain elevators, mines, paint plants, munitions, arsenal
manufacturing, and storage facilities.

The most popular spark retardant fork is covered in ASTM B36

alloy 6 brass that is 0.125” thick (except rear of upright and
hooks) and brazed 100% along all seams.

Similarly coated forks (using stainless steel) are also available for
the food industry though these are not spark retardant.

Coil Handling Forks

Chamfered or radiused coil handling forks are used to move
steel coils, reels, etc. when straddling the load is desired. Other
products, such as concrete pipes, can also be moved with this
type of fork. The blade is contoured to handle coils – capacity is
reduced according to the size of the contour.

Folding Forks
Folding forks are designed to fold at the heel on a pin, allowing
the blade to be placed in a vertical position, and secured with
a chain. Folding forks are often necessary when operating in a
confined and restricted work environment and for forklifts that
are transported to different work sites on trailers.

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Fork Tips, Tapers and Bevels Fork and Chain Sales Manual

Fork tapers are required to enhance the ease of travel of the fork when engaged into a load. Fork tips and tip bevels are required
for ease of entry into a load, depending on the application. These three features should be carefully selected when deciding on
how the tip of the fork will engage into a specific load.

No. 1 No. 3

R16 (Typ.)

W B C
100 50 38 90°
R200 (Typ.) W 125 80 38
150 90 50
C
180 90 82
B R25 (Typ.) W=100 to 300
REF.

Standard Taper–No Bevel Standard Taper–with Bevel

10±6

10±3 3±1.5
10±3

Standard–Full Taper with Top or Bottom Bevel Chisel Tip

45±6 45±6

+0.0
10±3 3 10±3 1.5 Max.
–1.5

Features
1. Careful choice of a tip configuration will enhance the fork's functionality.
2. There are 2 commonly requested top tip profiles: No. 1 and No. 3 (refer to diagram).
3. Tips can be ordered with or without a bevel.
4. Bevels can be requested. There are 4 basic designs (refer to diagram).
5. Tapers can be ordered as required. There are 4 basic designs.
6. A selection of the variables above can be custom ordered, recommended, or come standard with a specific fork requirement.

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Fork Tips, Tapers and Bevels Fork and Chain Sales Manual

Fork Tips
No. 1 No. 2 No. 3

General Notes:
No. 1 tip is standard on forks up to and including 7" (180 mm).
No. 2 tip is standard on Block Handling Forks.
No. 3 tip is standard on forks wider than 7" (180 mm).

Chisel and Bevel Options

Standard Taper, No Bevel Full Taper and Polish Full Taper and Polish
with Bottom Bevel with Top Bevel

Tapers
Standard Taper Full Top Taper and Polish Full Bottom Taper and Polish Two-Stage Taper and Polish

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Types of Forks Fork and Chain Sales Manual

Fork Extensions
• Fork Extensions must not exceed 150% of fork length.
• DO NOT load extension at tips. Loads must be uniformly distributed over the length of the
extensions.
• DO NOT use fork extensions to chisel under loads.
• DO NOT use fork extensions to push loads sideways using the tips.
• DO NOT suspend chains, cables slings or other lifting devices from fork extensions.
• DO NOT use forward tilt if load is raised or is forward on fork extensions.
• DO NOT stand or walk under forks or a load. Falling forks or objects can cause injury or death.
Always use supports or blocks to prevent forks and carriage from falling.
• DO NOT stand or ride on forks, fork extensions or pallets. STAY OFF all load carrying devices.
Lifting personnel requires use of a properly designed work platform as per OSHA 1910.178 and
ASME B56.1.

How To Install Fork Extensions:

• Raise forks approximately 4-6 inches off ground.
• Slide fork extension heel loop over the fork tip. Open side of extension is toward the fork.
• Slide heel loop behind the bend of the fork and lower the extension onto the fork.
• Check that the heel loop has engaged the fork by pulling forward on the extension.
• Check that the distance of extension is not more than 50% of fork length.
• Check to see that the extension lies flat on the fork blade.

DO NOT USE IF:

• The extension is greater than 50% longer than the fork.
• The heel loop is not fully engaged with the fork heel.
• The heel loop is bent or damaged or welds are cracked or broken.
• The extension is warped or twisted or shows signs of stress or fatigue such as buckled or
dented sides.
• The extensions are not level at the tips. Extensions may be bent or the forks may be uneven,
requiring replacement.

Capacity Rating Of Fork Extensions:

• ANSI/ITSDF B56.1-2012 (Sec. 7.39.1) Fork extensions must not be longer than 150% of fork’s
length.
• ANSI/ITSDF B56.1-2012 (Sec. 7.39.3) For purpose of rating, the rated load center of the fork
extension should be at 50% of the fork extension load supporting length.
• ANSI/ITSDF B56.1-2012 (Sec. 7.39.4) “Extension shall be clearly stamped with its individual
load rating and supporting fork size…”

The following chart shows the recommended fork thickness and width for each extension size
and the load rating of each individual extension of that size:

Width Thickness Load Rating

4” (104 mm) 1.75” (45 mm) 2,750 lbs (1250 kg)

5” (127 mm) 2.00” (50 mm) 5,000 lbs (2,270 kg)

6” (152 mm) 2.50” (65 mm) 8,750 lbs (3,975 kg)

Example of rated capacity stamping for a 4” wide fork extension 60” long (FE112-60): Metric:
1250/765-45 x 104 x 1070. Imperial: 2750/30-1.75 x 4 x 42. Meaning (Imperial): Fork extension
capacity 2,750 lb at 30” load center, recommended fork 1.75” thick x 4” wide minimum
length 42”. The addition of any attachment to a forklift requires the remarking of the truck in
accordance with 29 CFR 1910.178(a)(5).

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Fork Inspection Fork and Chain Sales Manual

ANSI/ITSDF B56.1 – 2012

6.2.8 Inspection and Repair of Forks in Service on Forklift Trucks
(a) Forks in use shall be inspected at intervals of not more than 12 months (for single shift
operations) or whenever any defect or permanent deformation is detected. Severe applications
will require more frequent inspection.

(b) Individual Load Rating of Forks. When forks are used in pairs (the normal arrangement), the
rated capacity of each fork shall be at least half of the manufacturer’s rated capacity of the
truck, and at the rated load center distance shown on the lift truck nameplate.

6.2.8.1 Inspection
Fork inspection shall be carried out carefully by trained personnel with the aim of detecting
damage, failure, deformation, etc., which might impair safe use. Any fork that shows such a
defect shall be withdrawn from service, and shall not be returned to service unless it has been
satisfactorily repaired in accordance with para. 6.2.8.2.

(a) Surface Cracks

(b) Straightness of Blade and Shank
(c) Fork Angle (upper face of blade to load face of the shank)
(d) Difference in Height of Fork Tips
(e) Positioning Lock (when originally provided)
(f) Wear
• Fork Blade and Shank
• Fork Hooks (when originally provided)
(g) Legibility of Marking (when originally provided)

6.2.8.2 Repair and Testing

(a) Repair. Only the manufacturer of the fork or an expert of equal competence shall decide if a
fork may be repaired for continued use, and the repairs shall only be carried out by such parties.

It is not recommended that surface cracks or wear be repaired by welding. When repairs
necessitating resetting are required, the fork shall subsequently be subjected to an appropriate
heat treatment, as necessary.

(b) Test Loading. A fork that has undergone repairs other than repair or replacement of the
positioning lock and/or the marking, shall only be returned to service after being submitted to,
and passing, the tests described in para. 7.27.3*, except that the test load shall correspond to 2.5
times the rated capacity marked on the fork.

*Para 7.27.3 reflects manufacturing standards.

Fork Inspection Report

Part Number: AEEP0012

The Promatch parts program offers a Fork Inspection Report designed for your technicians
to use during a routine fork inspection. The form alerts your customers of any forks that are
in need of repair. The burden of responsibility then becomes the end-user’s to see that their
unit(s) comply.

Do not threaten your customer with OSHA regulations. Make sure they are informed of
possible fines for non-compliance. Your responsibility is to make them aware of the ANSI/ITSDF
standards and provide the customer with a resource for inspections.

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Fork Inspection Fork and Chain Sales Manual

Checking for Thickness Wear

The best method is to use a fork caliper, which is a type of adjustable go/no go gauge.
The calipers measure the thickness of the fork arm shank (A) then automatically indicate what a
10% wear factor would be when the calipers are applied to the blade cross section (B). Calipers
are not recommended for full taper or lumber forks.

• Set the front teeth of the jaws by measuring the thickness of the shank (in an area of little or
no wear) ensuring that the caliper is square across the shank.
• Carefully remove the caliper from the shank and position the jaws over the fork arm blade
approximately 2" out from the heel.
• If the inside teeth of the caliper hit the fork blade it has less than 10% wear and can be
returned to service.
• If the inside teeth pass freely over the blade, the fork has 10% wear and 20% reduction in
capacity. Remove the fork from service.

Failure to properly inspect forks on powered industrial trucks, in some circumstances, may
be a recognized hazard and therefore warrant the use of the OSHA general duty clause in
enforcement.

Diagram A Diagram B

Fork Arm Shank Fork Arm Blade

Cross Section Cross Section
100% 90%

Checking the Fork Heel Angle

• Open the calipers to approximately 90° and place the calipers in the top inside heel area of the
fork (on top of the blade).
• Ensure that the two lower pieces on the horizontal leg are both touching the top of the blade.
• Move the calipers towards the upright. Ensure that the caliper arms are both parallel to the
blade and to the upright.
• Open/close the calipers so that the two similar extruding pieces on the vertical leg of the
calipers both touch the upright/shank of the fork.
• When you are sure that all four points are simultaneously in contact with the fork, gently
remove the calipers and look at the indicator lines found at the top of the hinge pin.

If the line on the horizontal leg (that points vertically) is found to lie beyond either the 93° or
87° indicator line, the forks should be marked to be checked for either permanent deformation,
possible stress cracks or any other defect that could impede the safe use of the fork.

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Fork Inspection Fork and Chain Sales Manual

Checking the Hook for Defects

Select the correct ITA caliper-gauge for the appropriate ITA hook.

• Insert the caliper up into the hook recess with the corresponding 20° angle of the fork.
• Press the vertical face flat against the fork upright/shank and move the caliper up into the
hook recess. The caliper must be held at 90° to the hook.
• If the (lower) horizontal face of the caliper can go up high enough to make contact with the
lower lip surface on the hook, this would indicate that the 20° angle of the hook is worn or
deformed, and therefore the fork hook welds and fork heel area should be checked for cracks.

Measuring the Bore on Shaft/Pin Type Forks

Insert the reversed caliper inside the eye of the tube (see diagram 1) opening the teeth until both
sides of the teeth come in contact with the inside wall of the tube. Pull the caliper out and
measure the distance from tip to top (see diagram 2).

Diagram 1 Diagram 2

Measure the distance from tip to tip.

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Fork Wear Calipers Fork and Chain Sales Manual

Fork Wear Caliper–Series II

Part Number: A000002638

This fork wear caliper provides a simple “ACCEPT” or “REJECT” comparison of the fork arm’s critical load bearing areas with user
FORK ARM SAFETY STANDARDS. The calipers are supplied in a wallet which also contains a steel rule and instruction booklet on
their use of information on the care, maintenance, and operation of fork arms. The calipers measure hook/shaft wear, arm wear,
and fork angle.

General Arrangement Set the Calipers Check the Blade

Check the Fork Angle Check Retaining Face Check Suspension Face

Internal Diameters External Diameters

Class I, II, and III

Model Range

Cascade Fork Wear Caliper

Part Number: A000025174

10
Guidelines, Fork Failures, and Ordering Fork and Chain Sales Manual

Fork Use Guidelines

To avoid potential damage and injury:
• Do not carry full or partial loads on one fork.
• Do not change forks from one forklift to another, without knowing the capacity of each.
• Do not overload forks beyond the rated capacity.
• Do not use a fork in an application for which it is not designed for.
• Do not use fork extensions that exceed 1.5 x’s the fork blade length.
• Do not repair or modify forks in the field, especially by welding. Welding destroys heat treat
properties, making the fork brittle.
• Do not apply sideways pressure on forks, commonly called “side loading,” as they are designed
for vertical loading only.

To ensure efficient operation:

• Inspect forks regularly, using an inspection log for recording data.
• Make sure the capacity meets or exceeds the forklift rating and load weight.
• Obtain written approval from the fork manufacturer prior to making fork modifications.
• Determine fork wear cycle and replacement schedule for a specific operation. Larger forks for
demanding applications may extend fork life.
• Properly seat forks on the carriage and fully locate the lock pins in the carriage slot.

Fork Failures
How damage and wear occur:
• Application environment
• Improper chain adjustments
• Normal wear from extended use
• Operator error or abuse
• Tire wear
• Used beyond rated load capacity

Statistics
• Nearly 25% of all forks currently in operation fail to meet
safety criteria.
• Outdoor applications are the most detrimental.
• Cracked heels, worn heels, and unauthorized welds are the
most common failures.
• Nearly 70% of unauthorized welds are cracked.

Ordering Shaft Style Forks

• Confirm the fork capacity matches or is greater than the
forklift capacity.
• Consider the forklift application.
• Complete a shaft fork specification sheet.
• Fax the completed specification sheet to our fork specialist.
• Select shaft style forks can be ordered online.

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Ordering Forks Fork and Chain Sales Manual

Ordering Hook Style Forks

• Determine fork dimensions.
• Confirm the fork capacity matches or is greater than the forklift capacity (see below).
• Consider the forklift application.
• Verify Promatch part number.
• Place your order by phone, fax, online or contact our fork specialist.

Hook style forks are separated into different classes, depending on the size of the carriage.
Be sure to have the appropriate carriage size information to make certain you order the
correct forks. Carriage size is measured from the top to the bottom of the carriage.

• Class II–16” Carriage (2,000–5,500 lbs)

• Class III–20” Carriage (6,000–10,000 lbs)
• Class IV–25” Carriage (10,000–17,500 lbs)
• Class V–28.67” Carriage (18,000–24,000 lbs)

Ordering Unusual or Special Order Hook Style Forks

Complete a hook fork specification sheet.
Fax the completed specification sheet to our fork specialist.

Hook Style Fork Part Number Breakdown

1.5 x 4 x 42 (II)(FTP)

1.5” Thick 4” Width 42” Length Class Two Full Taper Polish

Front Carriage View

Critical Ordering
b
Specification

Class I Class II Class III Class IV Class V

b dimension
13.00” 16.00” 20.00” 25.00” 28.67”

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Shaft Fork Specification Sheet Fork and Chain Sales Manual

Contact Forklift Make

Dealer Name Forklift Model
Dealer Code Capacity
Address Number of Pieces
Phone PO Number
Fax

Tapers (Choose One) Tips (Choose One)

Standard Tip
Standard Taper

Tapered Tip

Full Taper

Square Tip

Full Taper Polish

Round Tip

Shaft Type Forks

A To Center Line of Tube
B Inset
Choose
C Offset
One
D Inline
E Thickness
F Width
G Length
OD Outside Diameter
IS Inside Diameter
SD Shaft Diameter
*Clearance must exist between shaft and tube ID.

Tube Specifications
H Angle of Slot
I Depth of Slot
J Location of Slot
K Slot Width
L Tube Length
If there is no slot in the tube, only the Dim. L is required.

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Hook Fork Specification Sheet Fork and Chain Sales Manual

Contact Forklift Make

Dealer Name Forklift Model
Dealer Code Capacity
Address Number of Pieces
Phone PO Number
Fax

Tapers (Choose One) Tips (Choose One)

Standard Tip
Standard Taper

Tapered Tip

Full Taper

Square Tip

Full Taper Polish

Round Tip

Hook Type Forks (20° Rear Slope on Carriage)

(M) Distance Between Hooks Class Carriage Height

M = 12.09” I 13.00”

M = 15.07” II 16.00”

M = 18.82” III 20.00”

M = 23.59” IV 25.00”

N Thickness
O Width
P Length

Non-Standard Hook Forks (Square Carriage)

W Y1
T W1
BL W2
BH X1
b X2
h1 Z1
h2 Z2

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Frequently Asked Questions Fork and Chain Sales Manual

Question:
If the blade thickness is at 90% or less, can I place the fork on a lesser capacity unit?

Answer:
Yes. If the fork is load tested and re-stamped with the new capacity. “A fork that has undergone repairs other than repair or re-
placement of the positioning lock and/or the marking, shall only be returned to service after being submitted to and passing, the
tests described in paragraph 7.23.7, except that the test load shall correspond to 2.5 times the rated capacity marked on the fork.”

ANSI/ITSDF B56.1-2012 6.2.8.1 Repair and Testing

90% of forks that are worn at least 10% in the blade usually have cracks in the heel or the welds and are rejected.

Question:
Will the capacity decrease or increase when the load center is increased or decreased?

Answer:
Yes. To determine load capacity for load centers other than 24” use the following formula:

Known Capacity x Known Load Center

New Load Center

15
Roller Chain Fork and Chain Sales Manual

Roller and rollerless chains can be used for lifting and moving purposes and have the advantage
over leaf chain in that they may be geared into a suitable driving sprocket.

Roller Chain
Roller chain consists of parallel pairs of flat links joined by pins covered with rollers and engages
with the teeth of sprockets. Roller chain has a better wear resistance than leaf chain and may be
used at higher speeds.

Rollerless Chain
Rollerless chain is simply roller chain without a roller and is the only design configuration
possible on very small pitch chain, such as 4 mm and ANSI 25 or 1/4 inch pitch. Rollerless chain is
used for lightly loaded applications or those requiring only direct pull.

Operating Speed
Applications should not normally exceed a maximum chain speed of 148 feet/min
(45 meters/min).

Standards organizations (such as ANSI) maintain standards for design, dimensions, and
interchangeability of transmission chains. For example, the following Table shows data from
ANSI standard B29.1-2011 (Precision Power Transmission Roller Chains, Attachments, and
Sprockets) developed by the American Society of Mechanical Engineers (ASME).

100R
R – Rivet
C – Cotter Pin
x 1/8”
0 – Roller
1 – Light Weight
5 – Rollerless

The ANSI numbering system works as follows:

• The pitch is the distance between roller centers. The width is the distance between the link
plates (i.e. slightly more than the roller width to allow for clearance).
• The right-hand digit of the standard denotes 0 = normal chain, 1 = lightweight chain, 5 =
rollerless bushing chain.
• The left-hand digit denotes the number of eighths of an inch that make up the pitch.
• An “H” following the standard number denotes heavyweight chain. A hyphenated number
following the standard number denotes double-strand (2), triple-strand (3), and so on. Thus
60H-3 denotes number 60 heavyweight triple-strand chain.

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Leaf Chain Fork and Chain Sales Manual

Leaf chain is generally used for load-balancing lifting applications including hoist chain, forklift
mast chain, and counter balance chain. Generally, leaf chain has greater strength than roller
chain and runs over sheaves.

AL Series Leaf Chain

AL Series Leaf Chain is made for light-duty applications. The ANSI standard organization
discontinued the AL series and thus these chains may become more difficult to obtain in
the future.

BL Series Leaf Chain

BL Series Leaf Chain is crafted for moderate- to heavy-duty lifting applications and conforms
to the ASME B29.8 Leaf Chain Standard. Pins and link plates of the BL series are made one size
larger than the corresponding ANSI chain to allow for operation in moderate–to heavy load
applications.

Operating Speed
Applications should not exceed a maximum chain speed of 98 feet/min (30 meters/min).

BL634 Inner Plates

BL – Heavy Duty
AL – Light Duty
x 1/8”
Outer Plates

Leaf Chain Lacing Leaf Chain Lacing

2x2 4x6

2x3
6x6

3x4

8x8
4x4

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Chain Inspection Fork and Chain Sales Manual

Environmental Conditions
Environments in which material handling and lifting mechanisms operate can vary widely, from
outdoor moisture to mildly corrosive industrial atmospheres.
Some effects can be:

Moisture
Corrosive rusting reduces strength by pitting and cracking.

Temperature
Low temperature reduces chain strength by embrittlement. Going in and out of cold storage
can result in moisture from condensation.

Chemical Solutions or Vapors

Corrosive chemicals can attack the chain components and/or the mechanical connections
between the chain components. Cracking can be (and often is) microscopic. Propagation to
complete failure can either be abrupt or may require an extended period of time.

Abrasives
Exposure to abrasives, such as sand and grit, can lead to accelerated wearing and scoring of
the articulation members of the chain (pins and plates), with a corresponding reduction in
chain strength. Due to the inaccessibility of bearing surfaces (pin surfaces and plate
apertures), wear and scoring are not readily noticeable to the naked eye.

Each application should be evaluated based on the degree of exposure and the areas of possible
operation. A chain replacement schedule should be established to prevent chain failure. The
schedule can be established by frequent inspection. Based on the observations, the frequency
of inspection can be adjusted. Chain should be considered an expendable item and a safe chain
replacement schedule established.

Dynamic Impulse/Shock Loads

Dynamic shock loading can impose abnormal loads above the endurance limit of leaf chain. The
following examples make it impossible to predict chain life. It is therefore necessary to conduct
frequent inspections until replacement life can be predicted.

• High velocity movement of load, followed by sudden, abrupt stops.

• Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes
and rough terrain.
• Attempting to “inch” loads which are beyond the rated capacity of the handling
or lifting mechanism.

Lubrication
In order to get satisfactory service life, periodic lubrication must be provided. Like all bearing
surfaces, the precision-manufactured, hardened steel, joint-wearing surfaces of leaf chain require
a film of oil between mating parts to prevent accelerated wear. Chain should be protected against
dirt and moisture and lubricated with good quality, non-detergent petroleum-based oil. Heavy
oils and greases are generally too stiff to enter the chain working surfaces and should not be
used. Maintaining a lubricant film on all chain surfaces will:

• Minimize joint wear

• Improve corrosion resistance
• Reduce the possibility of pin turning
• Minimize tight joints
• Promote smooth, quiet action
• Lower chain tension by reducing internal friction in the chain system

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Chain Inspection Fork and Chain Sales Manual

Periodic Inspections
After each 30 days of operation (more frequently in hostile environments), leaf chain should be
inspected and lubricated. The inspection should focus on the following:

Elongation
Chain life expectancy can be expressed as a maximum percent of elongation, which is
generally 3%. It is important to measure chain in the section that moves over the sheaves
because it receives the most frequent articulation. Measuring chain near its clevis terminal
could give an erroneous reading, as it would not have flexed as frequently, if at all, near the
middle of the assembly.

Edge Wear
Check the chain for wear on the link plate edges caused by running over the sheave. The
maximum reduction of material should not exceed 5%. This can be compared to a normal
link plate height by measuring a portion of chain that does not run over the sheave.

Turning or Protruding Pins

Highly loaded chain, operating with inadequate lubrication, can generate abnormal frictional
forces between pin and link plates. When chain is allowed to operate in this condition, a
pin, or series of pins, can begin to twist out of a chain, resulting in failure. Chain with rotated,
displaced heads or abnormal pin intrusion should be replaced immediately.

Cracked Plates
There are various types of cracks, depending on the application or atmosphere. Chain should
be periodically inspected, front and back as well as side to side, for any evidence of cracked
plates. If any crack(s) are discovered, the chain should be replaced in its entirety. It is
important to also determine the cause of the crack before installing new chain.

Fatigue Cracking
Fatigue cracks are a result of repeated cyclic loading between the chain’s endurance limit
and are often microscopic in their early state.

Stress Corrosion Cracking

The outside link plates, which are heavily press fitted to the pins, are particularly susceptible
to stress corrosion cracking. Stress corrosion is an environmentally assisted failure. Two
conditions must be present: a corrosive agent and static stress.

Corrosion Fatigue
These cracks are very similar to normal fatigue cracks in appearance. They generally begin at
the aperture and propagate to the chain pitch line. Corrosion fatigue is the combined action
of an aggressive environment and a cyclic stress.

Ultimate Strength Failure

This failure is caused by overloads far in excess of the design load.

Tight Joints
All joints should flex freely. Tight joints resist flexure and increase internal friction, thus
increasing chain tension required to lift a given load. Increased tension accelerates wear and
fatigue problems.

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Chain Inspection Fork and Chain Sales Manual

Chain Wear Gauge

Part Number: A000013600

A simple to use chain wear gauge is available from the Promatch parts program.

Measuring Elongation
1. Determine if the chain is roller or leaf and locate the correct side of the gauge. Most leaf
chain has the chain series imprinted on the side of the leaf, designating it as AL (light duty) or
BL (heavy duty) which is the most common. If the series is not imprinted, it can be
determined by measuring the pitch (distance from one pin center to the next pin center).
Pitch is measured in 1/8” increments and the nominator, multiplied by 100, is the series
number. For example a pitch of 5/8” is a 500 series and a pitch of 1/2” is a 400 series
(1/2 = 4/8 = 400 series).
2. To measure chain wear, place a pin in the corner of the scale (as depicted on the gauge).
3. Locate the correct series number (400 to 1200 on leaf, 40-200 on roller chain, and 08 to 40 on
BS roller chain).
4. If the line by the series number on the chain gauge is at or is above the center of the pin, the
chain is elongated and must be replaced.
5. If the line is in the lower half of the pin, the chain is in good condition. Ideally, the line will be
at the bottom of the pin.

Good Replace

BL534 Chain

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Chain Inspection Fork and Chain Sales Manual

Troubleshooting Guide

Appearance and/or Symptom Probable Cause Correction

Worn Contour Normal wear on sheave bearing area Replace chain when 5%

Abnormal wear rubbing guides Check alignment

Increase clearance
H

5% of H

Worn surfaces on outside links or pins. Misalignment rubbing on guides Check alignment to correct clearance

Tight Joints Dirt or foreign substance is packed in Clean and lubricate chain
the joints

Corrosion and rust Replace chain

Bent pins Replace chain

Missing Parts Missing at original assembly Replace chain

Abnormal Protrusion or Turn Pins Excessive friction by high loading and Replace chain
inadequate lubrication Improve lubrication
Normal Turned Eliminate overloading conditions

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Chain Inspection Fork and Chain Sales Manual

Troubleshooting Guide

Appearance and/or Symptom Probable Cause Correction

Cracked Plates (Fatigue) Loading beyond chain’s Replace chain with chain of larger
dynamic capacity dynamic capacity or eliminate high
load condition or dynamic (impulse)
overloading.

Crack – from aperture toward edge of link

plate 90° to line of pull.
Arc Like Cracked Plates (Stress Corrosion) Severe rusting or exposure to acidic Replace chain
or caustic medium, plus static press at Protect from hostile environment
press-fit (between pin and plate) (no
cyclic stress necessary)

Fractured Plates (Tensions Mode) High overload Replace chain

Correct cause of overload

Enlarged Holes High overload Replace chain

Correct cause of overload

Replace chain
Corrosion Pitting Exposure to corrosive environment Protect from hostile environment

Worn Connecting Clevis Pins Normal wear Replace worn components

General Cautions
• Use lengths of factory assembled chain. Do not build lengths from individual components.
• Do not attempt to rework damaged chains by replacing only the faulty components. The entire
chain should be discarded.
• Never electroplate assembled chain or its components. Plating will result in failure from
hydrogen embrittlement.
• Welding should not be performed on chain or component. Welding spatter should never be
allowed to come in contact with chain or components.
• Chains are manufactured exclusively from heat treated steels and must not be heated.
• The practice of joining chain lengths is not recommended.
• Minimum Ultimate Strength means the minimum load at which it will break when subjected to
a destructive tensile test. It does not mean working load.

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Ordering Chain Fork and Chain Sales Manual

How to Order Chain

To determine the type of chain that you need to order please
refer to the following:

For Leaf Chain:

• Verify if AL or BL series chain is needed.
• Establish the pitch (distance between centers of pins).
• Determine leafing system required.
• Find corresponding Promatch part number on DealerNet
or in our catalog.

For Roller Chain:

• Determine size of chain needed.
• Find corresponding Promatch part number on DealerNet
or in our catalog.

How to Order Cut-to-Length Chain

Cut-to-length chain must be ordered by the foot. With
exception of bulk chain, the quantity entered represents the
number of feet ordered. Each separate piece of chain must be
entered as a separate line item.

Example One:
Quantity 3 BL534

You will receive (1) three-foot piece of BL534.

Example Two:
Quantity 1 BL534
Quantity 1 BL534
Quantity 1 BL534

You will receive (3) one-foot pieces of BL534.

Save Time and Money

Cut-to-length chain eliminates the cost of unusable,
left-over sections, cutting time, and inventory expense.

23
Methods to Increase Sales Fork and Chain Sales Manual

Service Technicians
Train all service technicians how to properly use fork wear
calipers and chain wear gauges. It is imperative to have these
tools on all service calls, and when they are performing PMs.
Spend a few minutes inspecting forks and chain to increase
potential sales.

Sales Personnel
When visiting an existing customer, inspect forks and chain and
suggest worn products be replaced. Train your customers to
perform fork and chain inspections. For potential customers,
offer a free fork and chain inspection. Chances are they will not
turn you away. Any potential OSHA fines you can alert them to
will almost certainly turn into purchase orders.

Waiver Form
If you notify an existing customer that their equipment is
below OSHA regulations, and they do not want to replace
the worn parts, require them to sign a wavier form. When a
customer notices that you want to be waived of all liability,
they might reconsider not replacing the parts.

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 CEGP0007
05/17

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