Roller Chain Drives

Maintenance Recommendations
INSTRUCTIONS

WHEN DISASSEMBLING OR ASSEMBLING C. Installation of Spring Locks and

CHAINS: Cotterpins
WARNING - The components of a chain are After coversides have been installed, install
hardened parts. Striking these parts may cause metal spring locks or cotters (depending on chain
chips to break off from the chain or the tools used design). Avoid using bent or worn cotters or
resulting in personal injury. During all stages of chain spring locks. After spring locks (or cotters)
disassembly and assembly, wear safety glasses to are installed, lightly tap pin ends to position
prevent metal parts or chips from entering your eyes these parts snug against the coverside for
and have personnel in the immediate area do additional support.
likewise.
WHEN INSTALLING CHAIN DRIVES ON
A. Pin Removal EQUIPMENT:

1. If chain is of cotterpin-type construction, WARNING - You may be seriously

remove cotters. injured if you attempt to install chain on
equipment under power. Shut off power
2. It chain is riveted-type construction, grind pin and lock out gears and sprockets before
heads off so pin ends are flush with the
attempting installation.
linkplate.
3. Drive pins out of linkplate using a Diamond pin Once installed, the chain drive must be
extractor Model # 113 or 135. Some multiple guarded to prevent personal injury or
strand chains or large pitch models will require property damage in the event the chain
a hammer and punch or a press to remove the separates during operation. If chain drive is
pins. not guarded, contact equipment
manufacturer for recommendations on
B. Installation of Coversides guarding before using equipment.

Diamond coversides are manufactured three different Knowing more about how the chain is
ways: constructed may help in assembly and
disassembly.
1. Slip Fit
2. Modified Press Fit
3. Full Press Fit
Modified and Full Press Fits require some patience
and tools to assemble and/or disassemble.

All chain drives should receive regular 4. Check Sprocket Tooth Wear -
maintenance. Each drive should be inspected
after the initial 100 hours of operation. Check for roughness or binding when the
Thereafter, most drives may be inspected at 500 chain engages or disengages from the
hour intervals. However, drives subjected to sprocket. Inspect the sprocket teeth for
shock loads or severe operating conditions reduced tooth section and hooked tooth tips.
should be inspected at 200 hour intervals. If these conditions are present, the sprocket
teeth are excessively worn and the sprocket
At each inspection, the following items should
should be replaced. Do not run new chain on
be checked and corrected, if necessary.
worn sprockets as it will cause the new chain
 1. Check lubrication - to wear rapidly. Conversely, do not run a worn
chain on new sprockets as it will cause the
On slow speed drives, where manual new sprockets to wear rapidly.
lubrication is used, be sure the lubrication
schedule is being followed. If the chain is 5. Check Sprocket Alignment -
covered with dirt and debris, clean the
chain with kerosene and relubricate it. If there is noticeable wear on the inside
surface of the chain roller linkplates, the
WARNING! NEVER USE GASOLINE OR sprockets may be misaligned. Realign the
OTHER FLAMMABLE SOLVENTS TO sprockets as outlined in the installation
CLEAN A CHAIN. A FIRE MAY instructions to prevent further abnormal chain
RESULT. and sprocket wear.
If drip lubrication is used, check for 6. Check for Drive Interference -
adequate oil flow and proper application
to the chain. With bath or pump Check for interference between the drive and
lubrication, check oil level and add oil if other parts of the equipment. If there is any,
needed. Check oil for contamination and correct it immediately. Interference can cause
change oil if needed. Change oil after the abnormal and potentially destructive wear on
first 100 hours of operation and each 500 the chain or the interfering part. If the edges
hours thereafter. If pump lubrication is of the chain linkplates impact against a rigid
used, check each orifice to be sure it is part, linkplate fatigue and chain failure can
clear and is directing oil onto the chain result.
properly. Check for and eliminate any buildup of debris
2. Check Chain Tension - or foreign material between the chain and
sprockets.
Check chain tension and adjust as
needed to maintain the proper sag in the A RELATIVELY SMALL AMOUNT OF
slack span. If elongation exceeds the DEBRIS IN THE SPROCKET ROLL SEAT
available adjustment, remove two pitches CAN CAUSE TENSILE LOADS GREAT
and reconnect the chain. ENOUGH TO BREAK THE CHAIN IF
FORCED THROUGH THE DRIVE.
3. Check Chain Wear -
7. Check for Failure -
Measure the chain wear elongation and if
elongation exceeds functional limits or is Inspect the chain for cracked, broken or
greater than 3% (.36 inches in one foot) deformed parts. If any of these conditions are
replace the entire chain. Do not connect a found, REPLACE THE ENTIRE CHAIN, even
new section of chain to a worn chain though portions of the chain appear to be in
because it may run rough and damage good condition. In all likelihood, the entire
the drive. Do not continue to run a chain chain has been damaged.
worn beyond 3% elongation because the
chain will not engage the sprockets
properly and it may damage the
sprockets.

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Roller Chain Drives Lubrication Page 1 of 2

Roller Chain Drives

Lubrication - Part 1
Roller chain consists of a series of connecting traveling metallic Oil applied to rollers only cannot reach
bearings, which must be properly lubricated to obtain the pin-bushing joints, and therefore, cannot
maximum service life of the chain. Although many slow speed retard chain elongation due to wear. The
drives operate successfully with little or no lubrication beyond lengthening of chains in service results
the initial factory lubrication, proper lubrication will greatly from wear on pin and bushing surfaces,
extend the useful life of every chain drive. The chain drive not rollers.
requires lubrication for six purposes.
When lubricating multiple strand chain, it
1. To resist wear of the pin-bushing joint. is important that lubricant be directed to
2. To cushion impact loads. each row of chain linkplates.
3. To dissipate any heat generated.
4. To flush away foreign materials. In conveyor applications oil should be
directed between the rollers and
5. To lubricate chain-sprocket contact surfaces.
bushings as well as between the chain
6. To retard rust or corrosion.
linkplates.

A good grade of clean petroleum oil without additives, free

The following table indicates the
flowing at the prevailing temperatures, should be used. Some
lubricant viscosity recommended for
additives leave a varnish or gum deposit which prevents the oil
from entering chain joints. Heavy oils and greases are generally various surrounding temperatures:
too stiff to enter the chain joints and should not be used.
Recommended GradeTemperature, oF
SAE 5 -50 to + 50
With proper lubrication, a separating wedge of lubrication is
SAE 10 -20 to + 80
formed between the pins and bushings in the chain joints much
SAE 20 +10 to +110
like that formed in journal bearings. The viscosity of the
SAE 30 +20 to +130
lubricant greatly affects its film strength, and its ability to
SAE 40 +30 to +140
separate moving parts. The highest viscosity oil which will flow
SAE 50 +40 to +150
between the chain linkplates and fill the pin-bushing areas will
provide the best wear life. This is essential to minimize metal to
metal contact and, if supplied in sufficient volume, the lubricant There are three basic types of lubrication
also provides effective cooling and impact dampening at higher for roller chain drives. Close adherence
to the recommended type of lubrication
speeds. is essential to obtaining maximum
service life of a chain drive.
Note: Rotative speeds beyond the maximum
recommended for chain operation are indicated in the
The recommended type of lubrication as
horsepower rating tables with zero horsepower.
shown in the horsepower rating tables is
determined by the chain speed and the
Operation at these or higher speeds will result in amount of power transmitted.
excessing galling of the chain pins and bushings
regardless of the volume of oil applied.
Manual or drip lubrication. (Type A)
Chain drives should be protected from abrasive and corrosive
conditions, and the oil supply kept free of contamination. Oil should be applied periodically
Periodic oil change is desirable. between the chain linkplate edges with a
brush, spout can, or drip lubrication.

Oil bath or oil slinger. (Type B)

Note: Oil should be applied to
With bath lubrication the lower strand of
the lower span of chain on the
chain runs through a sump of oil in the
upper edges of linkplates since
drive housing. The oil level should reach
access of oil to pin-bushing joints
Roller Chain Drives Lubrication Page 2 of 2

is possible only through the the pitch line of the chain at its lowest
clearances between the roller point while operating. Only a short length
chain linkplates. of chain should run through the oil.

A typical drive arrangement for bath

lubrication is shown in the illustration
below.

Chain Cross-Section
Showing Exaggerated
Clearances

Drive arrangements which permit long

length of chain to travel through the oil
should be avoided as overheating or
foaming may result.

Part 2
Go to: Roller Chain Drives Lubrication

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Roller Chain Drives Troubleshooting Pg1 Page 1 of 4

Roller Chain Drives

Troubleshooting Guide

CONDITION/SYMPTOM POSSIBLE CAUSE WHAT TO DO

Tight Joints

z Dirt or foreign material in Clean and relubricate chain.

chain joints.

z Inadequate lubrication. Replace chain. Re-establish proper

lubrication.

z Misalignment. Replace sprockets and chain if

needed. Realign sprockets.

z Internal corrosion or rust. Replace chain. Eliminate cause of

corrosion or protect chain.

z Overload bends pins or Replace chain. Eliminate cause of

spreads roller. overload.

Rusted z Exposed to moisture. Replace chain. Protect from moisture.

Chain

z Water in lubricant. Change lubricant. Protect lubrication system from water.

Replace chain.

z Inadequate Provide or re-establish proper lubrication. Replace chain, if

lubrication. needed.

Turned Pins z Inadequate lubrication. Replace chain. Re-establish proper lubrication.

Enlarged Holes z Overload. Replace chain. Eliminate cause of overload.

Broken Pins z Extreme Replace chain. Replace sprockets if indicated. Eliminate

overload. cause of overload or redesign drive for larger pitch chain.
Roller Chain Drives Troubleshooting Pg1 Page 2 of 4

Broken Link Plates

Missing Parts z Missing at assembly. Replace chain.

z Broken and lost. Find and correct cause of damage. Replace chain.

Broken, Cracked or
Deformed Rollers

z Speed too high. Replace chain. Reduce speed.

z Sprockets too small. Replace chain. Use larger sprockets, or

possibly redesign drive for smaller pitch
chain.

z Chain riding too high Replace chain. Retension chain more

on sprocket teeth. often.

Pin Galling z Inadequate Reduce speed or load. Possibly redesign drive for smaller pitch
lubrication. chain. Provide or re-establish proper lubrication.

Chains Climbs Sprocket z Excess chain slack. Retension chain.

Teeth

z Excessive chain wear. Replace and retension chain.

z Excessive sprocket Replace sprockets and chain.

wear.

z Excessive overload. Replace chain. Eliminate cause or

overload.

Missing or Broken z Cotters installed Install new cotters per manufacturer's instructions.
Cotters improperly.
Roller Chain Drives Troubleshooting Pg1 Page 3 of 4

z Vibration. Replace chain. Reduce vibration. Use larger

sprockets.

z Excessively high Replace chain. Reduce speed. Redesign drive for

speed. smaller pitch chain.

Exposed Chain Surfaces z Exposure to corrosive Replace chain. Protect from hostile
Corroded or Pitted environment. environment.

Cracked Link z Exposure to corrosive environment Replace chain. Protect from

Plates combined with stress from press fits. hostile environment.
(Stress
Corrosion)

Cracked Link Plates z Loading greater than chain's Replace chain. Reduce dynamic loading or
(Fatigue) dynamic capacity. redesign drive for larger chain.

Battered Link Plate Edges z Chain striking an Replace chain. Eliminate

obstruction. interference.

Worn Link Plate z Chain rubbing on casing, Replace chain if 5% or more of height worn
Contours guide, or obstruction. away. Retension chain. Eliminate
interference.

Excessive z Chain striking an Replace chain. Eliminate interference.

Noise obstruction.

z Loose casing or shaft Tighten fasteners.

mounts.

z Excess chain slack. Retension chain..

z Excessive chain wear. Replace and retension chain.

 z Sprocket misalignment. Replace chain and sprockets, if needed. Realign
sprockets.

z Inadequate lubrication. Replace chain if needed. Re-establish proper

lubrication.

z Chain pitch too large. Redesign drive for smaller pitch chain.

z Too few sprocket teeth. Check to see if larger sprockets can be used. If not,
redesign drive.

Wear on Inside of Roller Link Plates z Sprocket Replace sprockets and chain if needed.
and one side of Sprockets. misalignment. Realign drive. Retension chain..

Chain Clings to z Excessive sprocket Replace sprockets and chain.

Sprocket wear.

z Sprocket Replace sprockets and chain if needed. Realign

misalignment. sprockets.

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