Forklift chains are critical safety components responsible for bearing the weight of the load and transmitting lifting force from the hydraulic system to the mast mechanism. Understanding chain types, specifications, and maintenance requirements is essential for safe and efficient forklift operation.
Types of Forklift Chains
There are three primary types of forklift chains, each serving different applications.
Leaf Chains
Leaf chains are the most common type used in forklift mast systems. They consist of interleaved metal plates resembling a leaf spring, connected by pins without rollers. Leaf chains are designed purely as tensile members—carrying load through the chain links rather than transmitting rotary motion. They are optimized for vertical load transmission and lifting at relatively low speeds.
Leaf chains are manufactured according to international standards including ISO4347, DIN8152, ANSI B29.8, and NFE26107. The three main leaf chain series are:
Series Description
AL Standard leaf chain series
EL-LL European standard leaf chain (ISO 606 Series B)
BL-LH Heavy-duty leaf chain constructed from specific leaf chain components; the most common chain used for forklift trucks
Leaf chains are identified by a number that refers to the pitch and lacing of the links. Pitch sizes range from 1/2" to 2-1/2", with lacing patterns including 2x2, 2x3, 3x4, 4x4, 4x6, 6x6, and 8x8.
Roller Chains
Roller chains consist of cylindrical rollers connected by pins and held together by side plates. They are designed for transmitting rotary motion using shaft-mounted sprockets. While less common in mast lifting applications, roller chains are used in other forklift drive and power transmission systems.
Block Chains
Block chains are composed of rectangular blocks held together by pins. They represent the strongest type of forklift chain and are typically used in heavy-duty forklifts that need to lift extremely heavy loads.
Leaf Chain Specifications – BL434 Example
The BL434 leaf chain is a representative example of a heavy-duty forklift chain:
Specification Metric Imperial
Pitch (P) 12.70 mm 1/2"
Pin Diameter (A) 5.08 mm 0.200"
Plate Thickness (B) 2.08 mm 0.082"
Plate Depth (C) 12.00 mm 0.472"
Pin Length (D) 17.20 mm 0.677"
Weight 1.09 kg/m 0.733 lbs/ft
Breaking Strength 3,750 kg 8,265 lbs
Tensile Strength 36.78 kN —
Source: Leafchain.com
Maintenance and Inspection
Daily Inspection
Forklift chains should be inspected at the start of every shift. Operators should check for:
Worn contours – Replace leaf chain when worn down 5%
Worn surfaces on outer plates or pinheads – Check alignment and correct clearance
Tight joints – Clean and re-lubricate or replace
Missing parts – Replace chain completely
Protruding or turned pins – Replace chain, improve lubrication, eliminate overload
Cracked or fractured plates – Replace with larger dynamic capacity chain
Rust and corrosion – Replace chain and protect from hostile environment
Wear Limits and Replacement
Wear Indicator Action Required
Chain elongation ≥ 3% Replace immediately
Chain elongation ≥ 2% Replace (UK and Netherlands standard)
Worn down 5% Replace leaf chain
Any cracks detected Replace before returning to service
Chain elongation of 3% represents a decrease of approximately 15% in chain strength, risking breakage and potential danger to the operator and workplace.
Lubrication and Cleaning
Lubricate chains sufficiently to prevent corrosion and keep pins and plates in place
Clean chains with steam or solvents, ensure degreasing, and avoid detergents that can corrode the chain
Dry with compressed air after cleaning
Inspection Frequency
Interval Action
Every shift Visual inspection
Every 500 hours Detailed inspection
Every 1,000 hours Lubrication and thorough inspection
Every 6,000 hours or 3 years Recommended replacement interval
Annually Professional assessment
Chain Length Measurement
To determine the correct chain length:
Count the outer plates (marked in red)
Multiply the number of outer plates × 2
Add 1
Multiply this result by the pitch in mm
Divide by 1000
Formula: (((# outer plates × 2) + 1) × pitch) / 1000 = chain length in meters
Note: This formula can only be used for chains ending in inner plates.
Chain Life Expectancy
In a single-shift operation working on flat, even surfaces, chains can last 3–5 years. In harsh environments, chains may need to be replaced much sooner.
Where to Buy Forklift Chains
Forklift chains are available through multiple channels:
OEM Dealers – Toyota, Caterpillar, Hyster, and other manufacturers supply genuine chains
Aftermarket Suppliers – Companies like TVH, Intella Parts, and Fast Lift Parts offer replacement chains
Online Marketplaces – Made-in-China, Vander Haag's, and other platforms list new and used chains
Specialty Chain Manufacturers – Tsubaki, Laclede Chain, and Wippermann produce leaf and roller chains
Brand-Specific Chain Components
Brand Part Number Examples
Toyota 13506-78150-71, 00591-61730-81, 13506-78001-71
Hyster/Yale 1481258, 0322607, 4014712, 356917, 1651357, 3116089
Key Safety Reminders
Leaf chains are safety components; their reliability is directly related to property safety and personal safety
Always replace the chain wheel (sprocket) when replacing the lift chain
If budget constraints require staggered replacement, inspect the sprocket tooth profile against OEM wear limit gauge
Replace worn chain anchor bolts and components when fitting new leaf chains
Schedule professional assessments at least once a year