Fork and chain

Fork and Chain

Forks
• Types of Forks
• Fork Inspections
• Fork Failures
• Fork Use Guidelines
• Ordering Forks
• Freight Policy

Lift Chain
• Types of Lift Chain
• Chain Inspections
• General Cautions
• Ordering Chain
Fork Terminology

• Blade - The horizontal portion of the fork upon which the load is supported.
• Heel - The radiused portion of the fork connecting the blade to the shank.
• Shank – The upright (vertical) portion of the fork to which the supporting forks are
fixed.
• Hooks – Lugs attached to the shank to support and retain the fork on the carriage.
• Tube – The tube used for mounting forks onto shaft-type carriages.
• Tip – The free end of the blade.
• Positioning Lock – Device for locating the fork on the fork carriage.
• Flanks – The side faces of the blade and shank.
Types of Forks

The Promatch® parts program offers forks for

all makes and models of forklifts and other
industrial equipment.

Hook Style Forks

Hook style forks are separated into different
classes, depending on the size of the carriage.

The 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

All shaft forks are special sourced items and
must be ordered to customer specifications.
Types of Forks
Class II and III Carpet Poles
Designed to handle carpet rolls.
Coil Handling Forks
Blade is contoured to handle coils –
capacity is reduced according to the
size of the contour.
Class II and III Block Forks
Designed to handle bricks and blocks.
Folding Forks
Enables forklifts to maneuver in areas
where movement is restricted.
Fork Extensions
Extends the length of the fork blade.
Fork extensions should never exceed
1.5 times the length of the fork.
Lumber and Plywood Forks
Available in forged heel, square heel,
single taper, and double taper.
Spark Retardant Forks
For use in hazardous environments.
Most popular are covered in brass.
Tire and Drum Handling Forks
Designed to handle tires and drums.
Fork Tips

Fork tips and tip bevels are required for ease of

entry into load, depending on the application.

Standard
For most applications.

Tapered
For narrow pockets.

Square
Lumber forks and wide forks.

Round
Interchangeable with standard tip.
Fork Bevels

Bevels can be requested. There are four basic designs.

Fork Tapers

Fork tapers are required to enhance the ease

of travel of the fork when engaged into a load.

Standard
Common for pallet skids.

Full Taper Polish (FTP)

Easy to slide under objects on the floor and
used in lumber applications shorter than 72”.

Full Taper No Polish (FTNP)

For smaller, shorter pallet skids.
Fork Inspection and Repair

ANSI/ITSDF B56.1 – 2009

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 rating capacity of each fork shall be at least half the
manufacturer’s rated capacity of the truck, and at the rated load center
distance shown on the lift truck nameplate.
Fork Inspection and Repair

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)
Fork Inspection and Repair

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

The Promatch parts program

offers a Fork Inspection Report
(p/n - AEEP0012) 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.
Fork Wear Calipers

Fork wear calipers (p/n - A000025174)

are used to check for wear and distortion.

ANSI/ITSDF states “the fork blade and

shank shall be thoroughly checked for
wear, special attention being paid to the
vicinity of the heel. If the thickness is
reduced to 90% of the original thickness,
the fork shall not be returned to service.”
(B56.1d-2009 6.2.8.1)
Fork Wear Calipers

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).

Note: Wear calipers are not recommended for full taper or lumber forks.
Key Inspection Points

Fork wear calipers can also:

•Check fork heel angle
•Check the ITA hook for defects
•Measure bore on shaft/pin type forks

Make sure to inspect:

•Blade thickness
•Excessive fork angle
•Misaligned tips and hooks
•Permanent distortions
•Positioning lock
•Surface cracks
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
Fork Use Guidelines

To avoid potential damage and injury DO NOT:

• Carry full or partial loads on one fork.

• Change forks from one forklift to another, without knowing the

capacity of each.

• Overload forks beyond the rated capacity.

• Use a fork in an application for which it is not designed.

• Use fork extensions that exceed 1.5 times the fork blade length.

• Repair or modify forks in the field, especially by welding.

Welding destroys heat treat properties, making the fork brittle.

• Apply sideways pressure on forks, commonly called “side

loading,” as they are designed for vertical loading only.
Fork Use Guidelines

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 your fork wear cycle and replacement schedule for a

specific operation. Using larger forks in demanding applications
may extend fork life.

• Forks must be properly seated on the carriage and the lock pins
fully located in the carriage slot.
 Ordering Hook Style Forks

Critical
Ordering
Specification

Class I Class II Class III Class IV Class V

b dimension:
13.00” 16.00” 20.00” 25.00” 28.67”
Part Number Breakdown

1.5 x 4 x 42 (II)(FTP)

1.5” Thick 4” Width 42” Length Class Two Full Taper Polish
Hook Style Fork Specification Sheet

Ordering Hook Style Forks

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

Ordering Unusual or Special

Order Hook Style Forks
•Complete a hook fork specification
sheet. Fax the completed specification
sheet to our fork specialist.
Shaft Style Fork Specification Sheet

Ordering Shaft Style Forks

•Confirm fork capacity matches or is
greater than the forklift capacity.
•Consider forklift application.
•Be certain all measurements are
specific and accurate. Most shaft forks
are custom ordered, and our ability to
supply the correct fork depends on the
information provided.
•Select shaft style forks can be
ordered online.
•Complete a shaft fork specification
sheet for special order forks.
Fax the completed specification sheet
to our fork specialist.
Frequently Asked Questions

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 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 paragraph 7.23.7, except that the test
load shall correspond to 2.5 times the rated capacity marked on the fork.”

ANSI/ITSDF B56.1-2009 6.2.8.1 Repair and Testing

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

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
Fork Freight Policy

• Free freight on MCFNET® stock orders of 1 or more pairs

ordered from Indianapolis, Ontario, or York (no minimum
order fees apply).

• Free freight on 8 pairs (16 pieces) or more when ordered

from the Grand Rapids warehouse and shipped within the
contiguous U.S.
Chain

The Promatch® parts program offers

high quality, high performance roller
chain and leaf chain.

Chain is available in bulk spools or cut-

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

Leaf chains are generally used for load-

balancing lifting applications including
hoist chain, forklift mast chain, and
counter balance chain.

Leaf chains are made from interlaced

plates connected with a hardened pin and
cannot be used with sprockets, since
there is no means of engagement. Leaf
chains have a greater strength/weight
ratio than roller chain.
Leaf Chain

AL Series Chain
AL Series Leaf Chain is made for light-duty applications. Because of
the predominant use of heavier chain in new applications and a
common desire for simplification, AL series chain was eliminated
from ISO and ANSI standards.

• Pin diameter: 5/16”

BL Series Chain
BL Series Leaf Chain, our most popular chain, conforms to the
ASME/ANSI B29.8 Leaf Chain Standard.

• Pin diameter: 3/8”

 Leaf Chain Numbering

• The left-hand numbers refer to the chain pitch size in

1/8” inch units (i.e. – 6/8” = 3/4” pitch).

• The right-hand numbers refer to the chain lacing.

 Roller and Rollerless Chain

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 has a better wear resistance and may be
used at higher speeds.

Roller Chain
Roller chain consists of parallel pairs of flat links joined by
pins covered with rollers and engages with the teeth of
sprockets.

Rollerless Chain
Rollerless chain is roller chain without a roller and is the
only configuration for very small pitch chain. It is used for
light duty applications or those requiring direct pull.
Roller Chain Numbering

The ANSI numbering system works as follows:

• The left-hand numbers refer to the chain
pitch size in 1/8” inch units (i.e. – 10/8” = 1.25”
pitch).

• The right-hand number indicates that the

chain is a roller chain (0 = roller chain). A “5” instead of
a “0” indicates a rollerless chain.
Maintenance Schedule

Regular chain maintenance is important if maximum life is to be achieved. In a

correctly sized and installed system with adequate maintenance lubrication, the
chain is expected to last for approximately 6,000 hours or 3 years (whichever
is shorter).

The frequency of maintenance checks depends upon environmental

conditions such as:
•Presence of moisture
•Temperature extremes
•Corrosive atmospheres
•Abrasive contamination

The presence of shock or overloads will also reduce life expectancy and
increase the need for regular checks.
Periodic Inspections
At least every six months (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 (max 3% leaf, 2% roller). 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.
Edge Wear: Check the chain for wear on the
link plate edges caused by running over the
sheave (max 5% of chain height). This can be
compared to a normal link plate height by
measuring 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.
Periodic Inspections

Cracked Plates: Chain should be inspected, front and back as well as side to
side. If any crack(s) are discovered, the entire chain should be replaced, and the
cause of the crack should be determined.

• 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 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.
Periodic Inspections

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.

Chain adjustment: Check chain adjustment/load sharing and rectify if

necessary.

Lubrication: Check the condition of the lubricant. Re-lubricate if necessary.

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. 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
Chain Wear Gauge

A simple to use chain wear guide

(p/n - A000013600) is available from
the Promatch parts program for the
most popular sizes of chain pitch.
Chain Wear Gauge

Measuring Chain Elongation

1. Place a pin in the corner of the scale (as shown on the gauge).
2. Locate the correct series number (400 to 1200 on leaf, 40 to 200 on ANSI
roller chain, and 8 to 40 on BS roller chain).
3. If the line by the series number on the chain gauge is at or above the center
of the pin, the chain is stretched and must be replaced.
4. If the line is in the lower half of the pin, the chain is in good condition.
Troubleshooting Guide

Chain Wear Symptoms

• Worn Contour
• Worn Surfaces
• Tight Joints
• Missing Parts
• Abnormal Protrusions or Turned
Pins
• Cracked Plates
• Arc Like Cracked Plates
• Fractured Plates
• Enlarge Holes
• Corrosion Pitting
• Worn Connecting Clevis Pins
Please refer to our Fork and Chain Sales Manual
(p/n - CEGP0007) for our Troubleshooting Guide.
The guide is designed to help identify possible chain
wear causes and offer suggestions to reduce damage.
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 therefore
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.
Ordering Chain

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

Roller Chain
•Determine the size of chain needed.
•Find the matching Promatch part number
online or in our catalog.
Cut-To-Length Chain

Cut-to-length chain must be ordered by

the foot. With the exception of bulk
quantities, 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.

Example Two:
Quantity 1 BL534
Quantity 1 BL534
Quantity 1 BL534
You will receive (3) one-foot pieces.
Methods to Increase Sales
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.
Methods to Increase Sales

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.
Contact Information

You may contact our fork and chain

specialist for more information
including availability, pricing, and
specifications.

Promatch® Dealer Support

800.832.1275
616.647.2500

Thank You!

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