Chain and Sprocket Fault Finding
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There can be many reasons why chain and sprocket installations of any type can give difficulties in service and we can only list a small number of suggestions when operating problems occur.
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FAULT |
CAUSE |
REMEDY |
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Fractured Chain Bush / Barrel |
Chain Speed too High |
Chain of Shorter Pitch but equivalent strength |
|
Heavy Shock Loads |
Investigate to reduce shock Loads |
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Corrosion Pitting |
Consider using special material or Improve Lubrication |
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Roller Flatting due to Skidding |
Too lightly loaded System |
Increase load within limit of chain |
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Heavy Load where Friction between bush and roller bore overcomes lever friction effect of friction at roller periphery |
Increase chain size if no reduction possible |
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Excessive lubricant on chain track |
Clean tracking |
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Canting Over of chain on Track |
Investigate |
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Tight Chain Joints |
Material packed in chain |
Clean & re- lube |
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Frozen / Seized Chain |
Clean & re- lube |
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Incorrect Lubricant |
Clean & re- lube |
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Corrosion |
Investigate |
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Mal-alignment |
Check structure |
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Fractured Chain Plates |
Overload above maximum Chain working capacity |
Investigate for foreign object causing construction. Check alignment between drive & tail sprockets |
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Protect with chain Overload Device |
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Check Power Consumption |
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Loose or Damaged Chain Attachments / Brackets |
High Unit Shock Loads |
Investigate |
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Incorrect Assembly of |
Re-align to ensure correct phasing |
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Twisted Chain causing Flexing and Cross Chain Loads |
Check for inaccuracies on assembly |
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Excessive Roller Bore Wear |
High Unit Load |
Distribute Load |
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Twisted Slats / Carriers |
Investigate, highlight, correct |
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Unsatisfactory Lubrication |
Improve Lubrication |
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Excessive Noise |
Mis-alignment of Chain Tracking |
Check all Structure Alignments |
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Too little or too much Chain Slack |
Re-tension chain |
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High Speed |
Use Shorter Chain Pitch Size |
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Chain Sprocket Wheels Worn |
Replace |
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In-effective Lubrication Damaged / Incorrectly positioned chain tracking |
Lubricate correctly Investigate and adjust as necessary |
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|
Uneven Running |
“Stick Slip” / Hunting |
See Roller Flatting. Check Drive for adequate capacity |
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Polygonal Action of closely spaced sprockets in a complex circuit |
Increase sprocket chainwheel centres or reposition wheels |
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High Friction at Idler Sprockets |
Lubricate or fit low friction bearings |
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Polygonal Action at Drive Chainwheel |
Use larger diameter sprocket |
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Chain Whip |
Excessive Slack |
Adjust correctly |
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Worn Tooth Form |
Replace Chainwheel |
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Long unsupported chain strands |
Fully guide return chain strand |
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Chain Clings to Sprocket Teeth |
Incorrect Tooth Form |
Replace |
|
Worn Tooth Form |
Replace |
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Heavy Tacky Lubricant |
Clean & re-lube |
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Stiff Chain Joints |
See chain assembly Procedures |
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Chain Climbs Sprocket Teeth |
Excessive Tooth Form Wear |
Replace |
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Build Up of Excessive Chain Slack |
Adjust Chain |
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Chain Elongation |
Replace Chain |
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Severe Overloads |
Investigate, highlight, correct |
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Material Packing between Chain and Tooth Root |
Remove obstruction Consider change to sprocket profile design |
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20.1 General Inspection Procedures
- Place spirit level on all shafts for accuracy of horizontal settings.
- Check visually for squareness.
- Rotate shafts through 90 degrees and inspect again.
- Release any chain tension weights or remove tension loads. Disconnect chain from head shaft sprockets. Place bar across chain sprocket tooth root and check alignment using a spirit level to sight against the shaft.
- Use diagonal cross wires to ensure squareness of twin chain strand sprockets.
- Record any rubbing marks made by the inside face of the chain side link plates on the sprocket tooth flanks. This indicates position and severity of misalignment.
- In twin strand chain systems, ensure that one tail shaft sprocket is free running to prevent chain “wind up”.
