General Installation and Maintenance Instructions for

conveyor chains, roller chains, and Sprockets

Gelenkketten- und Kettenrderfabrik Werke in: Kckelheim und Sieperting Postfach 1164, D-59883 Eslohe-Kckelheim Tel.: 02973/801-0 Fax: 02973/801-228
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Conveyor Chain Tension Adjustment

Conveyor chain and roller chains wouldnt run smoothly if it is over-tightened or overslackened. Over-slackening of a conveyor chain, is especially to be avoided for it may cause the chain to ride over the sprocket and may as well cause troubles due to interference with rails etc. Hence be sure to check and adjust, if necessary, the chain tension from time to time.

Time of adjustment
Chain undergoes initial elongation for some time after the start of operation and its elongation gradually increases thereafter due to normal, natural wear even chains component parts are treated for surface hardening to resist wear. Therefore, periodic maintenance should include an inspection of wear of the chain. Inspection interval (8 hours/ day operation) 1 week after start of operation 1 month after start of operation Thereafter Daily Weekly Twice monthly

The above is, however, a rough guide, and the recommended times of inspection are to be further increased when the chain serves under continuous operation and/or under abrasive or corrosive conditions. Cautions Even when tension adjustment is made automatically by means of a weighttype or spring-type takeup, be sure to check to see it its function is properly operated. In the case the material conveyed is hot, be sure to chek the takeup at the time of start or stop of operation because the chain is subjected to marked expansion and contraction.

Adjustment of takeup is required to be done evenly on both sides and therefore preferably by a team of 2 men, one of them checking the chain tension and the other adjusting it. Adjustment is to be made while the conveyor is running, the left and right chains being tightened alternately little by little. One-sided overtightening is likely to cause trouble.
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Be sure to adjust the chain not to lean to the one side of sprocket teeth and the procedure is as follows.

Tighter the chain on the side there is a gap against the sprocket or loosen it on the side chain and sprocket are in contact.

Early adjustment of chain tension

The chain tension is normally adjusted by means of the takeup, but when the chain is elongated near to the adjustable limit of the takeup, some links of the chain are to be cut as soon as possible. Over- slackening of the chain is likely to cause trouble due to interference or contract with casing.

Check- point
Usually slack in the chain takes place only at one point, hence it is always advisable to confirm in advance, where or which part of the conveyor should be checked. Also, be careful to ensure safety at such predeterminded check-point. In the case of a conveyor which horizontally conveys materials with the upper or lower strand, slack is provided on the returning strand of the chain just or somewhat after the drive sprocket. In the case of a straight, inclined conveyor, the place where slack takes place depends on the inclination angle and/ or the kind of the conveyor. Follow to the operational manual etc. case by case. In the case of an L or S type conveyor, slack is to be provided in the vicinity of the bend case.
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Proper Sag
The proper tension is to be adjusted with the following in mind. The chain leaves from the sprocket smoothly. The chain as well as its attachment, pan etc. does not interfere with the rail or frame, enough space provided for that. Proper tension is provided not to cause surging.

In the case of a horizontal continuous conveyor, for example, the recommended sag is = 1/ 10 L 1/ 20 L.

In the following cases, the sag is to be decreased to = 1/ 15 L 1/ 25 L, i.e. the frequency of adjustment is to be increased accordingly.

When conveyor is stopped and restarted frequency. When the materials to be conveyed are hot. When the chain speed is high (more than 25 m/ min.) When the chain is heavy and large in size.

Shaft and Sprocket Alignment

Proper alignment of sprocket and shaft is essential for smooth operation of conveyors and greatly effects the life of conveyor chain and sprockets.. Even if they are set accurately at the time of installation, it is possible that they are disarranged in the course of operation due to vibration or subsidence of ground. Such disarrangement etc. are bound to be reflected in the wear of the side surface of sprocket teeth and chain linkplates, hence it is necessary to check from time to time for center deviation, shafts levelness, error etc.

Shafts levelness

Level the shaft by using a level. Angular alignment shall be adjusted within the gradient of 1/300.

Torsion of sprocket teeth with respect to conveyor center line

Be sure to adjust for minimizing torsion of sprocket teeth with respect to the conveyor center line.
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Alignment between sprockets

Align the shafts for parallelism using a straight edge or a scale. Tolerance for parallel alignment of shafts shall be within 1 mm. Adjust as follows for setting the drive and driven sprockets in the same plane. Flow conveyor: Bucket elevator: Long pan conveyor: Slat conveyor: = 1 mm max. = 2 mm max. = 1 mm max. = 1 mm max.

(The allowable misalignment for extra heavy duty type chains over 120 mm linkplate height is 3 mm max.) Fix each sprocket by a key. When two strands of chains are to run together, two sprockets must be matched.

Lubrication
Optimum conveyor operation and life are largely influenced by chain resistance depending mostly on all chain elements characteristics and constructive heat treatments but also on lubrication and maintenance. The lubricant used for chains must be of a grade capable of reaching the bearing surfaces between the bearing pin and bush, and between the bush and roller, and with adequate body to maintain an oil film over the whole of these surfaces as shown in Fig. Lub.1. It must also maintain its lubricating properties under operating conditions and be free from corrosive elements.

Lub.1 In all cases the lubricant should be applied immediately after the chain leaves the driving wheel and with the chain running. This is the point of least tension and the most likely position where the lubricant will reach the rubbing surfaces. Chains can be lubricated automatically with drip feed or oil mist spray lubricators or manually with a brush and lubricant. For normal conditions a good quality mineral base lubricant with a medium viscosity is recommended. Mineral base lubricants carbonise at about 140 C thus causing a build up of carbon between pin/ bush and bush/ roller. For temperateurs up to 300 C a colloidal graphite lubricant suspended in a volatile carrier should be used. Evaporation of the carrier (usually white spirit) leaves a film of graphite on the bearing surfaces but this will not be retained for a long period and must be reapplied at regular intervals.

Chains operating in abrasive conditions can also be lubricated with a dry lubricant but for extremely abrasive applications grease gun lubricated chain may be used. Grease lubrication through the pins (see fig. Lub.2) is normally possible with pin diameters over 12 mm. This pin design allow the grease to reach the surface between pin outer diameter and bush inner diameter, and when bushes are also provided with holes. The surface between the bush outer diameter and the roller inner diameter. Pins may also be provided with a longitudinal chamber as a grease reserve.

Lub.2

Different types of lubrication nipples:

The lubrication through the rollers is only possible when special rollers are adviced having those rollers are grease reserve chambers that supply grease through holes in the bush to all chain articulations. In those particular working conditions and when regular grease appliances are not easy, special greases are advised. For wet conditions, water repellent grease should be used, but this will not penetrate into the chain bearing surface and therefore additional application of oil is recommended.

Corrosive enviroment applications

Every application involving a hostile environment demands a clear appraisal of all factors so that the installation will work with reasonable durability with the most economic design. Where chains are in contact with pure water (pH value 7), town water or alkaline solutions (pH 8 to 14) at ambient temperatures and product contamination is not important then standard chains in normal materials are suitable. These have the advantage of low cost and ready availability. Where abrasion is present the harder surfaces obtained with case-hardened components, compared with the softer stainless materials give good abrasive resistance. To give reasonable life a higher strength of chain is often used compensating for the effects of corrosion, this being a more acceptable proposition compared with a chain made from stainless materials. To reduce the effects of corrosion, standard chains may be zinc or cadmium plated, but since these are toxic their contact with food should be prevented. Alkaline solutions produce a cleaning action which removes the lubricant from the chain. On these applications it is advisable to lubricate the chain with a de-watering oil. Where chains are in contact with acid solutions (pH 1 to 6) then it is generally necessary to use chain with components manufactured from corrosion resistant materials. For the majority of applications a stainless steel material is used with increase in chain coit.

Limit of Use for Conveyor Chain and Sprocket

Limit of use for individual components While in use, conveyor chain naturally and gradually deteriorate its performance due to wear, corrosion etc. depending on the conditions under which it is used and eventually reaches its life of limit. Limit of use for the individual components is as follows: Roller Until linkplate comes into contact with track rail due to wear of inner and outer peripheries of these rollers. Until protection rollers,either thereof, are cracked or worn out. Bushing Until it is worn out. Linkplate Plate thickness: Plate height: Until 2/3 the original plate thickness due to wear caused by mutual friction or by contact with rollers. When the linkplate slides directly on the liner, the plate height is reduced by wear. Usable limit is 1/8 of the original plate height.

Plate hole accommodating pin and bushing Pin and bushing are press-fitted to mating hole in linkplate lest they should turn, but after long period of use or when subjected to overload, there gradually results some looseness about the mating part of pin or bushing. The linkplate of which hole becomes loose in fitting with its mating pin or bushing is no longer usable. Wear elongation The chain is bent as it comes into engagement with the sprocket or as it passes a corner, and its overall length is increased due to mutual friction of pin and bushing. The chain which no longer comes into smooth engagement with the sprocket should be replaced to avoide possible trouble. Allowable limit for elongation of chain 1,5 to 2% max. of original length. Elongation is to be measured where the chain is subjected to tension. Normally the distance between pin heads of which distance is at least 4 pitches is to be measured with a tape measure.

Fatigue limit The chain component parts are subject to one complete load cycle in every periodic chain circulation and eventually reach the respective endurance limits of fatigue strength after long period of service
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Limit of use for sprocket

The wear of sprockets teeth appears to be generally made light of. This is presumably due to the difficulty in inspecting or measuring the amount of wear and also the difficulty in build up welding. It is, however, true that wear elongation of the chain is accelerated with the wear of sprockets teeth. Allowable limit for wear of sprocket teeth = 2% max. of nominal pitch length of the chain The sprocket which has reached the limit of use is either to remounted in the opposite sence or to replaced.

Maintenance Information
Connecting and Disconnecting Chain Introduction Chains are manufactured with connectors, either pins or rivets of various constructions depending upon the chain type, i.e., offset or straight sidebar, Roller Chain, Fabricated Steel Chain, Welded Steel Chain, Conveyor Chain, Combination Chain, etc. The particular connector link construction dictates the proper method and direction of connector insertion or removal from chain. The connectors can have uniform diameters, multiple stepped diameters, locking flats, various lead styles, riveted ends or various pinlocks (cotters, circlips etc.) A pin with either a flat on the head end, or a larger stepped diameter will not pass through the smaller cotter-side sidebar hole. Likewise, the round shank of a pin with locking flats on the cotter end will not pass through the slotted cotter-side sidebar hole. Field Repair When repairing chains in the field, the repair should be confined to replacement of complete links or sections. Replacement of individual components (bushings, rollers, etc.) is generally not recommended. Therefore, this connect- disconnect discussion has been limited to removal and replacement of connectors. Caution: Ketten Wulf does not recommend altering or rebuilding standard press-fit chains, or sub-assemblies especially the removal of press-fit components and their replacement with others. Such alterations destroys the integrity of the press-fits of the chain assembly.
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To Disconnect Chains on Sprockets 1. Decrease chain tension by loosening, take- ups, etc. 2. Restrain sprockets from rotating and secure chain on both sides of disassembly point. 3. Apply penetrating oil around connectors. 4. Remove where chain wraps over the sprockets. Support against removal force with heavy bar or tubing held against opposite side of the chain and sprocket. 5. Grind riveted end (if present) of connector flush with the sidebar. 6. Remove pinlocks or cut ends flush with outside diameter of pin. 7. Use press equipment to remove connectors, e.g., hydraulic press or jack, or arbor press.

IMPORTANT! SAFETY INSTRUCTIONS Follow safety guidelines on preceding Caution Tag. Dont heat or cut chain with torch unless absolutely necessary. Any links or pins heated by such a process should be replaced during reassembly. To Connect Chains on Sprockets 1. When connecting strand use sprocket for rigid support. Support against assembly force with heavy bar or tubing held against opposite side of chain and sprocket. 2. Grease or oil the connector before replacing it. 3. Check connectors to assure proper positioning of flats or cotter holes before assembly. 4. Use press equipment to insert connectors, e.g., hydraulic press or jack or arbor press. 5. Check to see that assembled joint (s) flex freely. If not, a light blow exerted on opposite end of connector (s) should free joint (s).

IMPORTANT! SAFETY INSTRUCTIONS Follow safety guidelines on preceding Caution Tag. Dont grind the circumference of the connector of the sidebar hole to ease insertion of the connector. Do not heat sidebars to ease pin insertion.

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Trouble Shooting Guide

Trouble Possible cause High speed running in excess of the allowable limit set for the chain and sprocket size Damage or breakage of pin, bushing or roller (Note) See the head "Form of breakage to each part of chain" Sudden, heavy shock load Inadequate lubrication Corrosion of chain Use of low- quality sprockets Foreign object being caught Under chain tension, too tight or too loose Misalignment of sprockets Excessive elongation from wear of chain, or excessive wear or breakage of sprocket Abnormal noise Setting fault of chain casing Removal Choose KW-chain higher in size or strength. Avoid impact load as far as possible. Apply proper lubricant periorically. Check the shop atmosphere and lubricating condition, and choose proper chain. Use quality sprockets of which specifications conform to the standard. Remove the foreign object and pay due attention to the shop atmosphere. Be always careful about the amount of chain sag, and adjust it properly in the way described above if necessary. Check alignment of both, drive and driven sprockets. Replace chain or sprockets without delay if it is found elongated or worn beyond the allowable limit. Repair without delay if the chain is in contact with the chain casing. Proper and periodical lubrication prevents rusting, and absorbs impact at at the time of sprocket-chain contact, being not only effective in preventing elongation of chain from wear, hence it is also effective in reducing noise. Pay due attention to the chain size and sprocket size in replacing the chain. Make sure that the sprocket size is matching the chain size, and vice versa. Replace chain. Excessive sag of chain causes over-riding of chain over sprocket to possibly cause damage to the tip of teeth thereof, hence be always sure to adjust it properly. Replace sprocket if its bottom diameter is not proper. Also, remove without delay if foreign objects should be deposited between teeth. Misalignment of drive and driven sprockets results in abnormal wear of the sides of linkplate and sprockets and shorting of the life thereof. Apply straight edge to the side faces of sprocket to check for misalignment. Adjust sag properly. Use idler of spring type, if necessary. If the chain quality is poor, ununiform wear of individual joints, so-called pitch uneveness, will result. Replace with a new, good chain, then. Eliminate the kinking part or replace the chain as a whole. Choose chain of larger allowable load from KW-range. If there is misalignment between sprockets, the force from either side of sprocket teeth causes opening of roller linkplates, this resulting in interference with pin linkplate to cause kinking of chain. Be sure to properly align both, drive and driven sprockets. When chain is left unoiled for a long time or in a corrosive atmosphere, resultant rusting interferes with smooth movement when it is used. Replace chain if it is corroded, and be sure to be oiling periodically. If chain motion is interfered with by foreign objects, it is likely to result in opening of linkplates. Be sure to remove them without delay, then. If sand or mud should get into joints, remove chain, wash and relubricate.

Inadequate lubrication

Inadequate chain or sprocket size Excessive elongation of chain from wear Chain over-riding sprocket Excessive sag of chain Sprocket defect or foreign object deposited between teeth Wear of sides of linkplate and sprocket Sprockets misalignment

Excessive sag of chain Vibration of chain (Whipping) Ununiform elongation from wear Kinking of chain Excessive load beyond allowable limit Sprocket misalignment

Kinking of chain

Corrosion of chain / Inadequate lubrication Interference between linkplate and foreign object Foreign objects in chain joints

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