BRITISH INDUSTRIAL TRUCK ASSOCIATION

GUIDANCE NOTE GN15 Rev 4

INDUSTRIAL TRUCK LEAF CHAINS, MAINTENANCE

September
AND INSPECTION 2019

Page 1 of 6
IMPORTANT NOTICE

PLEASE READ CAREFULLY

(a) The recommendations and advice contained in this Guidance Note are based on specifications,
procedures and other information which have been collected by the British Industrial Truck
Association Limited (“BITA”) from its members. They represent what is, so far as BITA is aware,
the best available data at the time of publication on the construction and use of industrial trucks
in the general conditions described, and are intended to provide guidance for such use.
(b) However, there are a wide variety of situations in which industrial trucks may be used,
consequently in all cases the suitability and safety of this Guidance Note must be determined by
the person seeking to apply it on the basis of his own judgement, in the light of the conditions in
which use is envisaged and subject to all relevant statutory requirements.
(c) BITA accepts no responsibility for the recommendations, advice, statements, opinions and
conclusions expressly or by implication set out below and gives no warranty or representation of
assurance in respect of the accuracy or validity of the same.

1. INTRODUCTION

1.1 Lift chains by their very function are subject to considerable stress. When abused or incorrectly
used and improperly maintained and protected, especially in hostile environments, chains can
suffer from decreased service life.
1.2 Observance of the guidance notes detailed below for maintenance inspection and examination
should help eliminate failures in lift chains when working in normal conditions and ensure
optimum chain life. Manufacturer’s maintenance advice should be followed.

2. MAINTENANCE & INSPECTION

2.1 Chains should be kept free of dirt and debris.

2.2 At intervals as recommended by the truck manufacturer and with the chains in situ in a slack
condition, or removed from the truck, chains, anchors and pins should be cleaned if necessary,
and lubricated as recommended in the operating handbook.
2.3 After a chain has been removed for cleaning or inspection it must be refitted in exactly the same
working position as before. The chain and anchor pins should be marked prior to disassembly
to ensure that the correct working position is maintained. Refitting and adjusting must be done
as recommended by the truck manufacturer.
2.4 Only lubricants approved the truck manufacturer/supplier or their equivalent should be used.
2.5 The lubricant provides wear and corrosion protection. The method of lubricant application must
ensure that all required surfaces over the entire length of the chain, including internal bearings
surfaces and between inner and outer plates, are sufficiently coated.
2.5 For applications where chains are subjected to condensation, etc, (e.g. cold store), lubrication
may be required at more frequent intervals, as specified by the truck manufacturer/supplier.
2.6 For applications in hostile or hazardous/aggressive environments, such as fertiliser plants,
chemical factories or cement works, etc. consult the truck manufacturer/supplier.

© Published by: BRITISH INDUSTRIAL TRUCK ASSOCIATION

5 - 7 High Street, Sunninghill, Berkshire, SL5 9NQ
 BRITISH INDUSTRIAL TRUCK ASSOCIATION
GUIDANCE NOTE GN15 Rev 4

INDUSTRIAL TRUCK LEAF CHAINS, MAINTENANCE

September
AND INSPECTION 2019

Page 2 of 6
3. EXAMINATION FOR DEFECTS AND MEASUREMENT OF WEAR
3.1 Examination
3.1.1 The chain(s) should be sufficiently cleaned on their external surfaces to facilitate the
examination.
3.1.2 In preparation for the examination, and if deemed necessary, clean the chains sufficiently using
a suitable proprietary chain cleaner (e.g. a paraffin derivative) in accordance with the
manufacturer’s guidance. DO NOT USE CHEMICAL SOLVENTS. Generally, steam cleaning
should be avoided as this will remove the lubricant on the internal bearing surfaces and may
leave water droplets between the link plates and pins. Unless the chain is thoroughly dried and
fully re-lubricated, ensuring full lubricant penetration to all internal surfaces, the service life of
the chain(s) will be seriously reduced, and mid pin failure may occur.
3.1.3 If it is possible to examine the entire chain, the procedures detailed below can be carried out in
situ. Where this is not possible chains should be removed from the truck and examined/re-
lubricated and replaced in accordance with the manufacturers/suppliers of the industrial truck
instructions. The chain should be examined in a slack condition.
For heavy chains assistance must be sought when removing or refitting.
3.1.4 Visually examine the chain(s) and all associated components for:
(a) Evidence of pitting due to rust or corrosion
(b) Tight chain joints
(c) Missing link plates
(d) Cracked or fractured link plates
(e) Loose pins with enlarged pin holes
(f) Protruding, buried or turned pins
(g) Worn surfaces on the chain outer links or worn, damaged or misaligned pin heads
(h) Missing or damaged anchor pin locking device (e.g. split pins etc.)
(i) Anchor pin locking mechanism integrity
(j) Wear and corrosion of the anchor pin, clevis (including integral anchor clevises) and
fixings
(k) Wear on link plate edges – i.e. that caused by running over the chain pulleys (subject to
3.2.1 below)
(l) Wear between the pin and the plate and/or associated components – i.e. chain
elongation (subject to 3.2.6 below)
If any of the above defects are found, the chain(s) and/or associated components must be
replaced within a period specified by the competent person.
If the competent person judges that the chain(s) and/or associated components may not remain
safe to use, then faulty items must be RENEWED IMMEDIATELY and the lift truck removed
from service until these parts have been replaced.
3.1.5 Chain anchors are not routinely changed when chains are replaced. It is for this reason, that in
addition to the visual inspection, the thorough examination of chain anchors shall include Non-
Destructive Testing (NDT) where appropriate (e.g. after an incident where severe shock
loadings have been applied to the lifting mechanism). When chains are replaced the chain
anchors should be removed from the truck, cleaned and examined, particularly in the areas
most likely to fail including the thread, shank and changes in section.
3.1.6 Pulley wheels should rotate freely, the edges should be undamaged and the chain running
surface free of damage and wear marks.

© Published by: BRITISH INDUSTRIAL TRUCK ASSOCIATION

5 - 7 High Street, Sunninghill, Berkshire, SL5 9NQ
 BRITISH INDUSTRIAL TRUCK ASSOCIATION
GUIDANCE NOTE GN15 Rev 4

INDUSTRIAL TRUCK LEAF CHAINS, MAINTENANCE

September
AND INSPECTION 2019

Page 3 of 6

3.2 Measurement for Wear

3.2.1 If the examination shows no defects, measure and record the wear of the plate depth (h 3). This
reduction should not be more than 5% of the original dimension. Chain(s) that have plates worn
in excess of 5% must be RENEWED IMMEDIATELY and the lift truck removed from service
until the chain has been replaced.

3.2.2 The unworn h3 dimension may be ascertained by measuring a portion of the chain that does
not run over the pulley, e.g. near the chain anchor. If in doubt contact must be made with the
manufacturer/supplier of the industrial truck or chain.

(Fig 1)

3.2.3 Before measuring chain extension (elongation due to wear) it is essential to take up any slack
that may exist in the chain. For chains that are not removed the weight of the fork carriage or
mast will be sufficient. Should the chain(s) be removed from the truck, the chain(s) must be
pulled taut for measurement (e.g. 5% of rated load).

3.2.4 Identify the most worn sections of chain, typically those which regularly runs over the pulley(s).
Measurement for chain elongation must then be made in at least three separate locations on
these worn sections. The measurement should be carried out using a Vernier caliper, chain
gauge, or other suitable measuring instrument, over a whole number of pitches giving a
measuring length of 200 to 400 mm (see note 1).

The measured dimension should then be compared with the chain’s original nominal length
measurement and an assessment made on the suitability for continued service as shown in
3.2.5 (see note 2).

Note 1: Chain wear guides/checkers may be used to measure elongation. If these devices indicate
elongation close to the rejection limit the elongation shall be confirmed by an accurate
measuring device (e.g. Vernier calipers).
Tape measures should not be used due to the difficulty in obtaining consistently accurate
results.

Note 2: Chains other than BL series may have an actual pitch slightly shorter than the nominal pitch
and it is necessary to check that the actual ‘as new’ chain pitch is the same as the nominal
pitch. This can be verified by measuring an unworn length of chain which does not pass over
the pulley. Chain wear is relative to the actual ‘as new’ pitch, where this is different from the
nominal pitch table 3.2.5 must be amended accordingly. If in doubt, consult the manufacturer.

© Published by: BRITISH INDUSTRIAL TRUCK ASSOCIATION

5 - 7 High Street, Sunninghill, Berkshire, SL5 9NQ
 BRITISH INDUSTRIAL TRUCK ASSOCIATION
GUIDANCE NOTE GN15 Rev 4
September
INDUSTRIAL TRUCK LEAF CHAINS, MAINTENANCE
AND INSPECTION 2019
Page 4 of 6
3.2.5 The following table provides a guide for measuring chain elongation. The nominal and actual
pitch should be confirmed by measuring chain on a section which does not move.
Chain Pitch Measured Number Nominal length of Measured Measured
pitches of n pitches of new length when 2% length when 3%
pins chain worn worn
inch mm n inch mm inch mm inch mm
3/8" 9.525 40 41 15.00'' 381.0 15.30” 388.6 15.45” 392.4
1/2" 12.7 30 31 15.00'' 381.0 15.30” 388.6 15.45” 392.4
5/8" 15.875 24 25 15.00'' 381.0 15.30” 388.6 15.45” 392.4
3/4" 19.05 20 21 15.00'' 381.0 15.30” 388.6 15.45” 392.4
1" 25.4 15 16 15.00'' 381.0 15.30” 388.6 15.45” 392.4
1 1/4" 31.75 12 13 15.00” 381.0 15.30” 388.6 15.45” 392.4
1 1/2" 38.1 10 11 15.00'' 381.0 15.30” 388.6 15.45” 392.4
1 3/4" 44.45 8 9 14.00” 355.6 14.28” 362.7 14.42” 366.3
2" 50.8 7 8 14.00'' 355.6 14.28” 362.7 14.42” 366.3
2 1/2" 63.5 6 7 15.00'' 381.0 15.30” 388.6 15.45'' 392.4
3" 76.2 5 6 15.00'' 381.0 15.30'' 388.6 15.45'' 392.4
3.2.6 When examining lift truck chains, the criteria for rejection of chains due to excessive elongation
should be made in accordance with the manufacturer’s recommendations and on the following
basis, considering the maximum elongation value measured:
Up to 2% Elongation
On recently supplied chains, excessive deterioration compared with service history may be an
indicator of manufacturing defects or unforeseen operating conditions. Under these conditions
the competent person needs to make a judgement on the rate of deterioration which could lead
to failure and advise on appropriate timescales for replacement of the chain.
>2% but <3% Elongation
Between these elongation limits a judgement needs to be made by a competent person on
whether or not the chain can continue to be used safely up to the next thorough examination.
Account should be taken of at least the following factors:
- date of next thorough examination
- elongation measured
- rate of deterioration since the last thorough examination
- general condition of chain, including distribution of lubricant
- significance of any local damage or wear
- quality and frequency of maintenance
- whether the truck is frequently working at maximum capacity
- condition of the travelling surface over which the truck normally operates
- working environment, e.g. wet, humid, dry, dusty, hot, cold, abrasive, corrosive
If the competent person judges that the chain may not remain safe to use up to the next
scheduled examination, they must recommend replacement within a specified time limit again
based on the factors above.
Note: Where chains are elevating persons refer to manufacturer’s recommendations;
Manufacturer’s may specify replacement at 2% elongation in these applications.
≥3% Elongation
Chains with a measured elongation of 3% or more must be RENEWED IMMEDIATELY and the
lift truck removed from service until the chain has been replaced.

© Published by: BRITISH INDUSTRIAL TRUCK ASSOCIATION

5 - 7 High Street, Sunninghill, Berkshire, SL5 9NQ
 BRITISH INDUSTRIAL TRUCK ASSOCIATION
GUIDANCE NOTE GN15 Rev 4

INDUSTRIAL TRUCK LEAF CHAINS, MAINTENANCE

September
AND INSPECTION 2019

Page 5 of 6

4. SERVICE LIFE

4.1 Hostile and Aggressive Environments

For trucks operating in Hostile and Aggressive Environments irrespective of the results of the
inspection, chains and anchor pins should be replaced after a period not exceeding 4000
operating hours or two years, whichever is the shorter. Where the lifting mechanism employs
a single chain (e.g. free lift section), chain anchors of the free movement design should also be
replaced.

Industrial trucks operating in the following examples fall into this category:
i) Marine environments
ii) Corrosive chemical environments
iii) Metal manufacturing or processing
iv) Cement/aggregate processing or where abrasive particulates are present
v) Brine processes
vi) Cold stores
Note: This list is not exhaustive.

The competent person shall make a judgement based on the operating conditions and then
decide if replacement is necessary on a case by case basis

5. REPLACEMENT AND SHORTENING OF CHAINS

5.1 In no circumstances are chains to be lengthened by joining together (this action would invalidate
the chain certification).

5.2 It is not recommended but should a chain require shortening, it is essential that the
manufacturer/supplier of the industrial truck or chain be consulted.

5.3 Where a mast is fitted with pairs of chains, they must be replaced together and adjusted to have
equal tension in each chain.

5.4 Only fit replacement chains, chain anchors, anchor pins and integral anchors as specified and
approved by the truck manufacturer/supplier.

5.5 In all circumstances new anchor pins/end connecting links with new split pins must be used
when replacing chain(s).

5.6 Where chains are replaced as a result of breakage, the cause of the breakage should be
established. If the circumstances of a chain breakage have involved severe shock loadings,
chain anchors of the free movement design shall also be replaced. Welded chain anchors shall
be thoroughly examined, including NDT, to establish their suitability for continued safe use.

© Published by: BRITISH INDUSTRIAL TRUCK ASSOCIATION

5 - 7 High Street, Sunninghill, Berkshire, SL5 9NQ
 BRITISH INDUSTRIAL TRUCK ASSOCIATION
GUIDANCE NOTE GN15 Rev 4

INDUSTRIAL TRUCK LEAF CHAINS, MAINTENANCE

September
AND INSPECTION 2019

Page 6 of 6

6. THOROUGH EXAMINATION AND INSPECTIONS

6.1 Periodic thorough examination and inspection of lifting equipment is covered by LOLER 98,
regulations 9, 10 and 11. Frequency of THOROUGH EXAMINATION and the competence of
persons carrying out this task is critical, see BITA guidance GN28.

6.2 Examination for defects and measurement of wear shall be carried out by competent persons
who shall have appropriate qualifications and training to carry out the examination and have
sufficient theoretical knowledge and practical experience to assess the importance of defects
or weaknesses

7. BIBLIOGRAPHY

L113* Health & Safety Executive, Safe use of lifting equipment, Lifting operations and
lifting equipment regulations 1998. Approved code of practice and guidance.

L22* Health & Safety Executive, Safe use of work equipment, Provision and use of
work equipment regulations 1998. Approved code of practice guidance.

INDG422* Health & Safety Executive, Thorough examination of lifting equipment. A simple
guide for employers.

BITA GN28 Thorough Examination and Safety Inspections of Industrial Lift Trucks

* Documents free to download from www.hse.gov.uk

© Published by: BRITISH INDUSTRIAL TRUCK ASSOCIATION

5 - 7 High Street, Sunninghill, Berkshire, SL5 9NQ