Symptom Appearance Probable cause Correction
Worn contour leaf-chain-worn-plate-contour Normal wear on sheave

Abnormal wear rubbing on guides
Replace leaf chain when 5% worn

Check Leaf chain alignment or increase clearance
Worn surfaces on outer plates or pin heads

worn-leaf-chain-surfaces-on-outer-plates-or-pin-heads

Misalignment, rubbing on side flanges Check leaf chain alignment and correct clearance as necessary
Tight joints tight joints on fork lift leaf chain Dirt or foreign substance
packed in joints
or
corrosion or rust
or
bent pins
Clean & re-lubricate leaf chain

Replace leaf chain

Replace leaf chain
Missing parts leaf chain missing parts at original assembly Missing at original assembly Replace leaf chain
Abnormal protrusion or turned pins abnormal protrusion of pins in leaf chain link plates or turned pins in lift chain Excessive internal friction
caused by high loading and
inadequate lubrication
Replace leaf chain, improve
lubrication and eliminate
overload conditions
Cracked plates (fatigue)

crack from aperture of leaf chain link plate going out towards edge of linkplate caused by fatigue resulting in cracked plates

Crack from aperture towards edge of linkplate at 90º to line of pull. Note there is no linkplate distortion.

Loading beyond chain's
dynamic capacity (above fatigue endurance limit)
Replace chain with leaf chain
of larger dynamic
capacity or eliminate
high load condition or
dynamic (impulse)
overloading

 

Symptom Appearance Probable cause Correction
Fractured plates
(tension mode)

fractured plates due to high over load fractured leaf chain and material distortion

Note material distortion

High overload Replace leaf chain and correct cause of overload
Arc like cracked plates
(stress corrosion)
stress corrosion causing arc like cracked plates to chain plates Severe rusting or exposure to acidic or caustic medium, plus static pressure at press fit (between pin and pin linkplate). No cyclic stress is necessary for this phenomenon to occur. Replace leaf chain and protect from hostile environment.
Enlarged holes enlarged holes leaf chain caused by high overload High overload Replace leaf chain and correct cause of overload
Corrosion pitting   Exposure to corrosive environment Replace leaf chain and protect from hostile environment.
Worn leaf chain anchor bolt connecting pin   Normal wear Replace worn leaf chain components and always when fitting new leaf chains