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1. Grading Machinery Potting Machinery Quarries Radio Astronomy Roof Tile Manufacture e Rope Machinery Saw Mill Equipment Sewage Plants Shaker Conveyors e Ski Lifts Sluice Gates e Steel Making Sugar Factories Swarf Conveyors Textile Machinery Timber amp Woodworking Machines Tool Changer Tunnelling Machines Tyre Manufacture Washing amp Sterilising Machines e Water Treatment Wire Belts Lifting Chain e LH BL AL LL and Works Standard Chains Applications Bottle Washing Plants Cement Plants Chemical Counterbalance Sets Cranes e Dust Swarf Conveyors Elevators Food Processing Food Sterilisation Fork Lift Trucks Pipe Line Valves Taps Printing Machines Rock Drilling Straddle Carriers Sun Blinds Tail Lifts Renold Lifting Chain Manual 3 Table of Contents Lifting Chain Installation and Maintenance Introduction Types of Lifting Chain Chain Numbering Equipment Needed Preparation Checking Alignment Installation of Chain Test Run Maintenance Schedule Chain Protection Lubrication Environmental Factors To Measure Chain Wear Riveting Chain Chain Matching Repair and Replacement Disconnecting Chain Safety Warnings Safety Warning FLT Chain Modes of Failure Troubleshooting 11 13 OO Qo 0 0 dO 0uuuuudsil if m e O Special Applications 14 Lu em 9 J J cD Vi 4 Renold Lifting Chain Manual Chain Installation and Maintenance Int2. link plates The table below indicates the correct lubricant viscosity for various ambient temperatures Ambient Temperature Lubricant Rating Celsius SAE BS4231 5 to 5 20 46 to 68 5 to 40 30 100 40 to 50 40 150 to 220 50 to 60 50 320 For the majority of applications in the above temperature ranges a multigrade SAE 20 50 oil would be suitable Use of Grease As mentioned the use of grease is not recommended However if grease lubrication is essential it should be noted that applying normal greases to the outside surfaces of a chain only seals the bearing surfaces and will not work into them This causes premature failure Grease has to be heated until fluid and the chain immersed and allowed to soak until all air bubbles cease to rise If this system is used the chains need regular cleaning and regreasing at intervals depending on the loads in the lifting system Abnormal Ambient Temperatures For elevated temperatures up to 250 C dry lubricants such as colloidal graphite or MoS in white spirit or poly alkaline glycol carriers are most suitable Conversely at low temperatures between 5 and 40 C special low temperature initial greases and subsequent oil lubricants are necessary Lubricant suppliers will give recommendations Lubricating Methods There are two basic methods of lubricating lifting systems e TYPE 1 Manual Lubrication Cil is applied periodically with a brush or oil can preferably
3. Lifting Chain Maintenance Manual RENOLD Superior Chain Technology www renold com 2 Renold Lifting Chain Manual Renold Chain Product Range Roller Chain British ANSI API DIN ISO and Works Standard Chains Adapted Chains Extended Pitch Chains Hollow Pin Chains Polymer Block Chains e Made to Order Special Chains Side Bow Chains e Mini Pitch Chains e Stainless Steel Chains Nickel Plated Chains Oilfield Chains Plastic Bush Chains Power and Free Chains Applications e Abattoirs Air Conditioning Aircraft Civil amp Military Bakery Machines Battery Manufacturing e Brewing Canning Carpet Machines Chart Tables Marine Chocolate Manufacturing e Concrete Moulding Equipment Copying Machines Dairy Machinery Drying Machinery e Earth Moving Equipment Extrusion Machines Filtration Plants Food amp Drink Manufacture e Glass Manufacture Health Care Equipment Hydraulic Components Ice Cream Manufacture In flight Refueling Ingot Casting amp Scrap Metal Processing Latex Machinery Laundry Machinery e Lawnmower Manufacture Mill Machinery Mining MOT Brake Testing Machinery Nuclear Power e Off Road Vehicles Oil Industry Packaging Machines Paper amp Card Making E Paper Shredders e Plastic Machinery Potato Grading Machinery Power Generation Printing Machines Quarry Plant e Road Making amp Plant Machinery Robotic Systems Roof Tile M
4. anufacture Ship s Engines e Silkscreen Machinery Ski Lifts Soot Blowers Steel Making Straddle Carriers Sugar Beet Machines e Sun Blinds Telecommunications Textile Machinery Timber and Woodworking Machines e Tin Printer Ovens Tobacco Cigarette Machinery Tunnelling Machines TV and Audio Equipment e Tyre Manufacture Waste Handling X Ray Equipment Conveyor Chain British ISO and Works gt eee Ol ste Standard Chains Made to Order Specials Adapted Chains e Stainless Steel Chains e Agricultural Chains e Sugar Cane Chains e Bakery Chains e Zinc Plated Chains e Deep Link Chains Applications e Abattoirs Agricultural Machines Bakery Machines Bottle Washing Plants e Brick amp Tile Machinery OEM Car Plants Cement Plants Chemical Plants Chicken Process Equipment e Cigarette Tobacco Machinery Dust Filters Egg Sorting Conveyors Electrical Switchgears Escalators e Extrusion Machines Feed Mill Machines Feed Silo Equipment Fibreglass Industry Filtration Plants e Fish Conveyor Food Sterilisation Food Processing Freezing Equipment Freezing Tunnels Glass Manufacturing Grain Conveyor Harvesting Machines Ice Cream Machines Induction Furnaces Ingot Casting amp Scrap Metal Processing Mfr Latex Machinery Leisure Rides Luggage amp Parcel Handling e Machine Tools Mail Sorting Metal Casting Mushroom Compost Machinery Nuclear Ovens Provers e Potato
5. d with sprockets since there is no means of engagement Leaf chains have a greater strength weight ratio than Roller chains Roller Chain Conventional pin roller and bush construction normally used for transmission applications but easily adapted for lifting purposes Defined in ISO 606 latest edition Heavy duty ANSI chains with thick side plates are particularly suitable for lifting applications Bush Chain Identical to roller chain but with the omission of the roller The main disadvantage is that sprocket bush wear can be rapid in highly loaded applications For the use of roller or bush chains in lifting applications it is necessary to specify this in the order to ensure the specific CE mark will be given Chain Numbering Leaf Chain Renold chain conforms to International standards and can be ordered using the ISO or ANSI Part Number The letters prefixing the part number refer to the base chain standard as shown below LH Chain based on ISO4347 ANSI Chain BL Identical to LH North American terminology LL Chain based on ISO4347 European Type AL Obsolete standard No longer covered by ISO or ANSI standards Example BL646 or LH1246 The left hand numbers refer to the chain pitch size in 1 8 or 1 16 for LH inch units i e 3 4 pitch The numbers that follow the prefix refer to the number of plates in the outer and intermediate strands respectively In this example there ar
6. e four plates in the outer link and six intermediate plates Roller Chain The ANSI standard number system consists of at least two or three digits and possibly a suffix The left hand digit or digits refer to the pitch size in 1 8 inch units The right hand number refers to the chain style For multiple strand chains a dash and a number is added Example ANSI 60H i e 3 4 pitch roller chain heavy series The ISO standard number system consists of at least two or three digits and a suffix The digits refer to the pitch size in 1 16 inch units The right hand number refers to the chain style For example 1 Pitch ISO 16B European Type For Multiple Strand chains add a dash and the number of strands e g 16B 3 Equipment Needed The breaking of roller and bush chain can be achieved by using a Renold Chain Extractor these being 311015 for light industrial chains up to 0 5 pitch e 10101 for chains from 0 375 to 0 625 pitch 10102 for chains from 0 75 to 1 25 pitch European and 0 75 to 1 ANSI Pin heads will need to be removed using a hand grinder on all types of leaf chain and larger roller and bush chains For joining any chain up to 2 5 pitch a drift punch will be required Note however that it is not recommended that the user attempts to join lengths of FLT chain Erection of medium or heavy chain systems requires millwrighting equipment such as lifting tackle slings wedges packing e
7. e no embrittlement takes place Corrosion fatigue cracks are in appearance very similar to normal fatigue cracks Corrosion fatigue results from an aggressive environment combined with a cyclic stress Stress corrosion cracks are caused by a static stress Tensile Failure Fig 5 Tensile failure results from repeatedly loading the chain above its elastic limit Approximately 65 of breaking load Side plates appear stretched and distorted and plate holes often elongate and break out Tight Joints Tight joints do not rotate freely resulting in high friction This means that the lifting mechanism becomes less efficient and accelerates the onset of wear and fatigue related problems Fig 2 Chain Installation and Maintenance Troubleshooting Probable Cause solution O O Anchor fails Chain climbing or jumping off the sprocket or sheave Chain elongation A gradual increase over its life is normal Chain running hot Corrosion pitting Enlarged holes Excessive noise High overload Chain or sprockets worn Foreign build up in the tooth gap sprockets only Lubrication failure Overload conditions Lubrication method or type of lubrication is unsuitable for the operating speed and the load being transmitted Insufficient lubrication Chain continually hitting an obstruction Incorrect chain size selected for the speed and load Exposure to corrosive environment Chain misaligned Misa
8. eplace the entire chain Do not electroplate chain this can only be accomplished at the factory by plating individual components before assembly Post electroplated chain will fail due to hydrogen embrittlement Do not carry out welding operations on c chain Do not paint chain Do not anneal or otherwise heat chain above 2502C If a torch is used to cut chain the chain should be discarded Do not join lengths of chain together particularly in safety critical applications Note that the minimum tensile strength quoted in catalogues does not refer to the working load Designers generally use a factor of at least 5 1 on lifting applications 10 1 should be used on more safety critical applications un c 9 ren J cD an Lu Q UJ cD Vi 10 Renold Lifting Chain Manual Chain Installation and Maintenance Safety Warning FLT Chain Never use a connecting link in any lifting application to join leaf or roller chain lengths together in any manner that does not have the truck manufacturers approval Misuse of connecting links will render your chain warranty void and subject the user to a safety hazard Renold Distributors will not supply connecting links for this purpose When chains are sold as assemblies the connecting pins must be fitted to the chain anchor and chain using the approved method outlined by the truck manufacturer If you are unsure about the correct method contact your l
9. fastenings have been properly tightened Carry out any adjustment operations to ensure that all chains are equally loaded Test Run It is advisable to give the system a short test run for the following reasons To check for correct operation To ensure there is no cross binding and all chains are carrying an equal load To check for any unusual noise or vibration Renold Lifting Chain Manual 5 Maintenance Schedule un c 9 ren UJ o Vv Regular chain maintenance is important if maximum life is to be achieved In a correctly sized and installed system with adequate maintenance lubrication the chain is expected to last for approximately 6 000 hours or 3 years whichever is shorter The following maintenance schedule is suggested Regularly Check chain adjustment load sharing and rectify if necessary Check for smooth operation while under load in both lifting and lowering directions e Check for wear on side plates Max 5 of plate height e Check for evidence for twist or side bow Check for damaged or cracked plates Check for chain elongation Max 3 FLT chain 2 Roller chain Check for turned or protruding pins Check for cleanliness of components Check for shaft and sprocket or sheave alignment Check for wear on sprockets or sheaves Check the condition of the lubricant Relubricate if necessary Check the lubrication system if present The frequency of maintena
10. h should have a diameter slightly less than the pin link plate aperture Use a series of small blows rather than a few heavy ones Repeat the above steps with the other pin in the same link Chain Installation and Maintenance Disconnecting Roller Chain Renold Chain has end softened pins and for chain up to 1 pitch the pin may be removed using a suitable chain extractor Otherwise follow the above procedure In order to obtain the longest life from a leaf chain Renold recommends the following procedures for cutting short chain lengths from a new coil or shortening an existing leaf chain e Method 1 Grinding Two pins need to be removed Both pins should be in the same outer link plate With a grinding wheel grind the heads of both pins flush with the outer link plate This will ensure that the pin when pushed out will not damage the portion of the inner link plate holes noted in Fig B The joint may now be easily removed with a suitable hammer and punch If the chain is contaminated with grinding dust it should be cleaned and re lubricated before use Method 2 Pressing Two pins need to be removed Both pins should be in the same outer link plate Arrange the joint which is to be removed as shown in Fig A such that it is at r
11. i 8 Renold Lifting Chain Manual Chain Installation and Maintenance General A correctly installed chain will enhance service life and ensure safe operation When ordering replacement chains consult your operating service manual to ensure that the new chain or chains will be supplied to the correct size length and configuration Where a lift truck has a pair of chains a new pair should always be ordered and replaced The replacement of only one chain will lead to premature failure of both the new and used chain Sprockets Examination of the tooth faces will give an indication of the amount of wear which has occurred Fig A Under normal circumstances this will be evident as a polished worn strip about the pitch circle diameter on each of the sprocket teeth as shown If the depth of this wear X has reached an amount equal to 10 of the Y dimension then steps should be taken to replace the sprocket Running new chain on sprockets having this amount of tooth wear will cause rapid chain wear It should be noted that in normal operating conditions with correct lubrication the amount of wear X will not occur until several chains have been used Sheaves Check the running diameter and side faces of the flanges of sheaves There should be no evidence of side wear on the flanges indicating malalignment The sheave diameter should not be excessively worn Chain Chain repair should not as a rule be underta
12. ication shall constitute a part of any contract express or implied For more information or to contact your local sales team go to www renold com Whilst all reasonable care is taken in compiling the information contained in this brochure no responsibility is accepted for printing errors All information contained in this brochure is subject to change after the date of publication Renold Power Transmission 2013 Ref REN9 ENG 04 13 No QR reader Simply download one from your app store m en m r e s H Ti Want to find out more EN I yc ja Scan this QR code with your smartphone m pane JL Ip erior cnain Tecnno gy www renold com
13. ight angles to the line of the chain This will ensure that the riveted wedge of the pin head when pushed out will not damage the portion of the inner link plate holes noted in Fig B Push the pins directly through the inner link plates using a suitable hydraulic or manual press The movement of the pin through the outer link plate will tend to collapse the riveted end of the pin and allow it to pass freely through the inner link plate holes General When using either of the above methods ensure that The outer plates are not reused The portion of the inner link plate holes noted in Fig B are not damaged Pin removal To remove the pins position the chain on a solid support with a clearance hole corresponding to the pin positions Drive the pin through the first outer link plate using a suitable hammer and punch with a series of light blows rather than one heavy blow Method 1 or with a suitable hydraulic or manual press Method 2 Once the pin is clear of this outer link plate carry out the same operation on the second adjacent pin At this point the pins may be removed by hand or with minimal additional force and should pass unimpeded through the inner link plates If the pin has to be forced through the inner link plates due to Fig A Method 2 Pressing Renold Lifting Chain Manual 9 Fig B Pin removal insufficient collapse of the pin head or poor grinding excessive damage can occur to the holes
14. k on the chain components can cause microscopic cracking This can lead to progressive deterioration followed by dramatic failure Abrasives These will cause accelerated wear and is difficult to detect at an early stage Dynamic Shock Loads These can lead to early fatigue failure of pins and plates All of the above conditions make it very difficult to predict chain life It is therefore important to monitor chain performance closely until a proper schedule is established TYPE 2 Drip or Pressurised Lubrication Chain Installation and Maintenance To Measure Chain Wear Chain wear can be ascertained by length measurement as follows Lay the chain on a flat surface and after anchoring it at one end attach to the other end a turnbuckle and a spring balance suitably anchored Apply a tension load by means of the turnbuckle amounting to approximately 5 of the chain breaking load As an alternative to the use of turnbuckle and spring balance the chain may be measured in situ with a nominal weight in the lifting system Measure length M see Fig A in millimetres from which the percentage extension can be obtained from the following formula Percentage extension M X xP Xx P Where X number of pitches measured P pitch in mm x 100 As a general rule the useful life of the chain is terminated and the chain should be replaced when the percentage extension reaches 2 per cent 1 per cent in
15. ken A correctly selected and maintained chain should gradually wear out over a period of time but it should not fail A length extension check will give an indication of the service life remaining Fig A of wear Renold chain is prelubricated at the factory to ensure good corrosion resistance and wear properties If a chain is dry of this lubricant due to cleaning the chain must be relubricated before fitting to the system Other Points Before refitting the chain check that the chain anchors and sheaves are undamaged Broken damaged or worn out anchors and sheaves must be replaced before fitting the chain or chains Never fit a chain with a used anchor pin Pins may have been bent or damaged or have fatigue cracks that cannot be seen by the naked eye Your operating service manual will give full and detailed instructions on fitting and adjusting the chain Never paint chain or clean chain using steam or high pressure water jets If a lifting chain sustains damage due to an overload jam up or by riding over the sprocket teeth or sheave flanges it should be carefully removed from the drive and given a thorough visual examination Remove the lubricating grease and oil to make the task easier Depending on the damage it may be practicable to effect temporary repairs using replacement links It is not however a guarantee that the chain has not been overstressed and so made vulnerable to a future failu
16. lignment of sprockets sheaves Inadequate lubrication Worn or incorrectly fitted bearings Worn chain or sprockets sheaves Tight joints Heavy impulsive loads Obstruction in the chain path Renold Lifting Chain Manual 11 el c 2 a J o a Replace anchor and chain set Correct cause of overload Replace the chain and sprockets sheave if necessary Clean the sprocket teeth of all material so that the chain engages correctly Replace chain and sprockets or sheaves Check lubrication failure Check lubrication drive configuration and loadings Replace chain Increase the lubrication frequency and quantity Consider changing lubricant Increase the frequency oflubrication in line with good maintenance practice Remove the obstruction Check the chain selection as a larger pitch or multistrand chain of equivalent capacity may be required Replace chain set and protect from hostile environment Replace chain set and correct cause of overload Misalignment introduces abnormal loading and wear Recheck alignment to maintain normal drive conditions Improve the lubrication method to ensure the proper amount of lubrication is available in the bearing areas Replace or correct the bearings as these will malign the entire drive Replace the chain and where necessary the sprockets sheaves Replace chain set Reduce the load Remove the obstruction 12 Renold Lifting Chain Manual Chain Ins
17. ment rubbing on guides Check alignment and correct or pin heads el c 2 UJ o a 14 Renold Lifting Chain Manual Special Applications Section 1 Safety warning Outer Link for high speed drives or drives operating in arduous conditions a properly riveted outer link No 107 must always be used for optimum security in preference to any other form of chain joint The use of other connectors and cranked links No 12 and No 30 must always be restricted to light duty non critical applications in drives where an odd number of pitches is absolutely unavoidable Wherever possible drives should have sufficient overall adjustment to ensure the use of an even number of pitches throughout the useful life of the chain A cranked link joint should only be used as a last resort Health and Safety at work In the interests of safety customers are reminded that when purchasing any technical product for use at work or otherwise any additional or up to date information and guidance which it has not been possible to include in the publication should be obtained by you from your local sales office in relation to the suitability and the safe and proper use of the product All relevant information and guidance must be passed on by you to the person engaged in or likely to be affected by or responsible for the use of the product Chain performance The performance levels and tolerances of our product stated i
18. n damages the chain and should be corrected Cracked Plates Fig 1 Cracked plates can have a number of causes In any event any cracks discovered in a chain will render it unsafe Chain should be immediately replaced Reasons for Plate Cracking Fatigue cracks caused by cyclic loading beyond the chain s endurance limit which normally start at the plate hole point of highest stress and perpendicular to the chain pitch line There is no noticeable yielding stretch of the material Stress corrosion cracking Fig 2 due to the presence of harsh environmental conditions These also start at the plate hole but tend to extend in an arc like path between the plate holes More than one crack can often appear on a plate This can be caused by the presence of acid or caustic fluids or vapours in combination with Fig 1 Fig 4 NORMAL TURNED a static stress The interference fit between a pin and plate gives sufficient static stress This means that in the right environmental conditions the chain can crack even if under no load For example the presence of battery acid fumes in a warehouse could cause cracking in a chain stored on the shelf Never electroplate a chain or its components This process liberates hydrogen and hydrogen embrittlement cracks will appear These are similar in appearance to stress corrosion cracks Plated chains have to be produced by Renold Chain under controlled conditions which ensur
19. n this catalogue including without limitation serviceability wear life resistance to fatigue corrosion protection have been verified in a programme of testing and quality control in accordance with Renold independent and or international standard recommendations No representations or warranties are given that our product shall meet the stated performance levels or tolerances for any given application outside the performance levels and tolerances for the product s own specific application and environment Renold Lifting Chain Manual 15 Guidance notes Whilst all reasonable care in compiling the information contained in this catalogue is taken no responsibility is accepted for errors All information contained in this catalogue is subject to change without notice Illustrations The illustrations used in this catalogue represent the type of product described but the goods supplied may vary in some detail from those illustrated Specifications The right is reserved to make modifications to the product to meet manufacturing conditions and or developments for example in design or materials Renold Product can be supplied by Renold companies or representatives around the world on the standard terms and conditions of sale of the company or representative from which the product is purchased Copyright Copyright Renold Power Transmission Limited 2013 All rights reserved Nothing contained in this publ
20. nce checks depends upon environmental conditions such as presence of moisture temperature extremes corrosive atmospheres abrasive contamination etc The presence of shock or overloads will also reduce life expectancy and increase the requirement for regular checks At Least Every 6 Months Carry out the above checks and procedures on the entire chain If all parts of the chain cannot be accessed remove it and replace in accordance with manufactures instructions un 2 ud J cD Vi 6 Renold Lifting Chain Manual Chain Installation and Maintenance Chain Protection A new Renold chain should always be stored in its original packing until installation Renold chain is lubricated at the factory but this lubrication will not stand up to outdoor conditions for prolonged periods particularly where there is a salt water atmosphere Unprotected lubricated chains will become contaminated with grit and other materials which will harm the chain Lubrication Renold Chain should be protected against dirt and moisture and be lubricated with good quality non detergent petroleum based oil A periodic reoiling is desirable as already outlined Heavy oils and greases are generally too stiff to enter the chain working surfaces and should not be used Care must be taken to ensure that the lubricant reaches the bearing area of the chain This can be done by directing the oil into the clearances between the inner and outer
21. nt of similar clearance between outer and inner links as with the adjacent chain Still supporting the outer link No 107 rivet the bearing pin ends taking care to finish with a neat uniform spread having a similar appearance to the pins in the adjacent chain The force required to spread the pin end will vary with the pitch of the chain excessive riveting force should always be avoided Except where final chain joining in situ is necessary the work should be carried out on a bench Check that the newly fitted link articulates freely Incorrect riveting Correct riveting Chain Matching Any application in which two or more strands of chain are required to work side by side would benefit from special matching procedures These procedures only apply to roller chain and can be summarised as follows Length Matching Chains are accurately measured in handling lengths between 3m and 8m and selected to give overall length uniformity of two or more strands Pitch Matching Pitch matched chains are made from shorter subsections around 0 3 to 0 6m in length graded and joined to give even greater accuracy on both pitch to pitch dimensions and overall lengths Colour Coding The above two methods are factory applied It is also possible to receive chain coded to give a graded length tolerance within the normal manufacturing limits of 0 to 40 1526 Contact Renold Chain for further details Lu em 9 J J cD V
22. ocal Renold Chain Representative or the Truck Manufacturer direct The following notes highlight the common modes of failure in lifting chain Modes of Failure Normal Wear When the chain reaches the end of its normal wear life it should be replaced It is important to measure the chain in the section that moves over the sprockets or sheaves which do the greater amount of work Plate Edge Wear Fig 3 Plate edge wear occurs where the chain runs over the sheave This can be compared to a normal plate height by measuring an unworn portion Distorted or Damaged Plates These can cause tight joints and prevent chain articulation Turned or Protuding Pins Fig 4 Inadequately lubricated or highly loaded chain generates high frictional load between pin and plates In extreme cases the torque exceeds interference fit between the pin and the outer plates resulting in pin turning This ultimately causes the pin to screw out of the plates resulting in failure Fig 3 5 OF H The pin head rivets should be examined to determine if the VEE flats are still in correct alignment Chain with rotated displaced heads or abnormal pin protrusion should be replaced immediately Do not attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Wear on the Pin Heads Caused by chain misalignment This conditio
23. of the inner link plates Inner link plate holes should be visually checked on each cutting operation Excessively damaged holes will have one or more very discernible grooves running in the direction of the pin removal If excessive damage is noticed in the portion of the inner link plate holes noted in Fig B the chain should not be used Safety Warnings Health amp Safety Warning The following precautions must be taken before disconnecting and removing a chain from a system prior to replacement 1 Always isolate the power source from the drive or equipment 2 Always wear safety glasses 3 Always wear appropriate protective clothing hats gloves and safety shoes as warranted by the circumstances 4 Always ensure tools are in good working condition and used in the proper manner 5 Ensure there is no residual load in the system by supporting hung weights etc 6 Always support the chain to avoid sudden unexpected movement of chain or components 7 Never attempt to disconnect or reconnect a chain unless the correct procedure is fully understood 8 Ensure that directions for the correct use of any tools are followed 9 Never reuse individual components 10 Never reuse a damaged chain or chain part General Advice Never mix chain from various manufacturers Never build chain from individual components If a chain has been damaged it is likely that parts not obviously damaged are also affected R
24. once every 8 hours of operation Volume and frequency should be sufficient to just keep the chain wet with oil and allow penetration of clean lubricant into the chain joints Applying lubricant by aerosol can be satisfactory under some conditions but it is important that the aerosol lubricant is of an approved type for the application such as that supplied by Renold This type of lubricant penetrates into the pin bush roller clearances resisting both the tendency to drip or drain when the chain is stationary and dripping when the chain is moving TYPE 2 Drip or Pressurised Lubrication Oil drips or jets are directed between the link plate edges from a lubricator Volume and frequency should be sufficient to allow penetration of lubricant into the chain joints TYPE 1 Manual Lubrication Environmental Factors Effect of Temperature During operation an important factor to control in a drive system is the chain temperature Depending on the severity of the drive service continuity of use etc special attention to the lubrication method may be required Chain temperature above 100 C should be avoided if possible due to lubricant limitations although chain can generally give acceptable performance up to around 250 C in some circumstances Low temperatures reduce chain strength by embrittlement Going in and out of cold storage can result in moisture from condensation Chemical Solutions or Vapours Corrosive attac
25. oon as possible Clean chain and relubricate Check the safety factor to determine if the chain capacity has been exceeded Reduce high load condition Replace with chain of larger capacity Replace chain set immediately Ensure proper lubrication regime Replace chain set Remove several joints and check that the components are not severely damaged Replace chain and sprockets as necessary Improve lubrication method Replace chain and sheave Correct misalignment Check and adjust sprocket and shaft alignment Remove source of rubbing by removing the obstruction Replace chain at 5 wear Check alignment increase clearance Renold Lifting Chain Manual 13 Chain Installation and Maintenance Probable Cause solution O Side plate fails e Fatigue cracks due to high dynamic load Reduce loads e Stress corrosion due to severe rusting O or exposure to acidic or caustic medium Replace chain with higher capacity e Tensile failure due to high overload Replace chain set and protect from hostile environment Replace chain set and correct cause of overload Twisted chain e Lubrication failure Replace chain and sprockets or sheaves e Overload conditions Check lubrication failure Check lubrication drive configuration and loadings Replace chain Wear on the sides of the Drive misalignment Check and correct sprocket and sprocket teeth shaft alignment Worn surfaces on outside links Misalign
26. re The best policy therefore is to remove the source of trouble and fit a new chain Replacing Chain Sets When replacing chain in multiple point lifting systems the entire chain set should be replaced for the following reasons Used chain may have sustained fatigue cracking that will eventually cause failure Used chain may have elongated which will lead to a premature replacement of a new chain running in parallel Depth P The anchors holding the used chain may be at the limit of their adjustment causing misalignment of both the used and new chain Anew chain will have a lower rolling resistance than its mating chain causing stress on cylinder cross heads and sheaves The time and labour cost to change the second chain is minimal once the truck is stripped down ready Disconnecting Chain Disconnecting Leaf Chain Two pins need to be removed from one joint Both pins should be in the same outside plate With a grinding wheel grind the heads of both pins flush with the pin link plate This prevents scoring damage to inside link holes during disassembly If chain is exposed to grinding dust chain should be cleaned and relubricated Position a support ring in a clearance hole in the work surface The support ring serves to support the bottom pin link plate and avoid damage to chain components while driving the pin through the chain Drive the pin through the chain with a hammer and punch The punc
27. roduction Renold Chain has over 100 years experience in the operation and maintenance of lifting chain Involvement with designers manufacturers and users of all types of equipment has enabled Renold to develop this concise manual for chain lifting applications This definitive manual is designed to pass on the preferred methods of correct handling adjustment installation and maintenance of lifting chain systems resulting in maximum chain life The most common application for leaf chains is in the lifting equipment This manual has been written specifically for such applications Roller chains can also be used for lifting applications but this must always be referred in the order as a separate CE marking is required Renold also produces lifting chains for use in machine tools If you need chains for such an application please make sure that you indicate this clearly in your enquiry This is because for these chains additional specifications will also be required If further information is required please contact our technical sales staff Types of Lifting Chain There are three main categories of lifting chain covered by this guide Of these the most popular is leaf chain also referred to as Fork Lift Truck FLT chain since it is used in large quantities on this type of application Leaf Chain Made from interlaced plates connected with a hardened pin Defined in 1804347 latest edition These chains cannot be use
28. s the entire chain width and contributes substantially to maximum drive life Use a straight edge in several different positions if possible as a check against wobble A nylon or similar line is a good substitute for a straight edge particularly on longer centre distances Installation of Chain Should endwise float of shafts be present make due allowances so that alignment is correct at the mid position of float When alignment is correct within closest practical limits drive any keys home and take a final check When sheaves are used it should be checked that the chain sits comfortably between the flanges with equal clearance on both sides Pins should not rub on the sheave flanges Renold Chain should not be assembled into the system until attention has been paid to cleanliness of the sprocket teeth and sheave working area particularly if debris of an abrasive nature cement dust weld spatter etc has been prevalent whilst work was in progress Ensure the chain is clean and free from debris and place around the sprockets or sheave observing instructions where matched strands are involved Ensure that the strength of tackle is sufficient to hold the chain Chain weights are shown in the Renold catalogue Do not detach any tackle until the chain is completely assembled Never paint a chain since this will prevent the penetration of maintenance lubricant Adjustment After chain installation ensure that all
29. tallation and Maintenance Troubleshooting probable Cause Solution O el c 2 J o ua Heavy wear on sprocket teeth working faces a bright polished appearance is normal Kinks in chain Joints tight Pin fails Protruding or turned pins Rust present on chain Sheave worn Side plates are worn Poor lubrication Presence of abrasive Worn chain or sprockets sheaves Bent pins due to overload Chain corroded Peened plate edges Dirt or foreign substance in joints System loading is greater than the capacity of the chain Lack of lubrication High loads Inadequate lubrication This will also affect the joints which will be discoloured light to dark brown and could be rough grooved or galled Chain misaligned Wear on the inside of the plate is caused by sprocket misalignment Wear on the top of the side plate is caused by the chain rubbing against some obstruction Normal wear on leaf chain against sheave Abnormal wear on leaf chain rubbing against guides Improve the method of lubrication see lubrication section Check for presence of foreign materials and eliminate the source Replace sprockets and chain if necessary Replace chain sets and sprockets sheaves Check lubrication Correct overload condition replace chain set Clean chain with wire brush and relubricate Replace chain set as soon as possible Mechanical damage remove cause Replace chain set as s
30. tc Other Useful Equipment Measuring equipment straight edge calliper Spirit level e Plumb line Selection of hammers files key blanks etc Hand Grinding Machine Chain Installation and Maintenance Preparation Check equipment to ensure that general requirements are correct e g sprockets sheaves means of adjustment Check condition and rigidity of the shafts and bearings particularly if there has been considerable previous service Replace or rectify if necessary Drive headshaft sprockets should be checked to ensure they are level parallel and square with any slides or bearings Use a spirit level and adjustable comparator bar or micrometer between shafts at extreme points on each side of the drive Rectify any parallelism error present Place sprockets or respective shafts in approximate alignment and fit the keys in accordance with correct engineering practice Do not finally secure keys at this stage Care must be taken with sprockets of split design to ensure perfect abutting of the faces of each half Proceed with the key fitting after the halves are finally bolted together otherwise the key can prevent correct assembly and subsequently result in malgearing It should be verified that key heads will not project beyond the width of any cases guards or guides Checking Alignment Accurate alignment of shafts sheaves and sprocket tooth faces provides a uniform distribution of load acros
31. the case of extended pitch chains For drives with no provision for adjustment the rejection limit is lower dependent upon the speed and layout A usual figure is between 0 7 and 1 0 per cent extension It is not satisfactory to determine the elongation of a chain by checking its overall length against the nominal length of a new chain Worn chains must be examined over their full length and then measured on that portion of the chain which has obviously had the most wear Maximum wear occurs generally to those sections which articulate under load i e where the chain passes over a sprocket or sheave Renold Chain Wear Guide A simple to use chain wear guide is available from Renold for most popular sizes of chain pitch see Fig B Fig A Renold Lifting Chain Manual 7 e c 9 ren J cD uan Fig B When the pin centre comes to or past the indicated point the chain is worn out it is time to change the chain Hollow punch Bench or solid support Riveting Chain Roller Chains up to 63 5mm 2 5 Pitch Insert the bearing pins of the outer link No 107 through the inner links of the chain to be joined If multiplex chain assemble intermediate plates at the same time Provide support for the outer link No 107 while assembling the separate outer plate This has a force fit and is driven onto the bearing pins using a hollow punch alternatively on each pin The plate should be driven to the poi
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