Maintenance & Troubleshooting Guide: Sprocket & Gear, Inc
Maintenance & Troubleshooting Guide: Sprocket & Gear, Inc
Maintenance & Troubleshooting Guide: Sprocket & Gear, Inc
MAINTENANCE &
TROUBLESHOOTING
GUIDE
WARNING & SAFETY REMINDER
Safety must be considered a basic factor in machinery operation at all times. Most accidents are the
results of carelessness or negligence. All rotating power transmission products are potentially dan-
gerous and must be guarded by the contractor, installer, purchaser, owner,
and user as required by applicable laws, regulations, standards, and good safety practice. Additional
specific information must be obtained from other sources including the latest
editions of American Society of Mechanical Engineers; Standard A.N.S.I. B15.1. A copy
of this standard may be obtained from the American Society of Mechanical Engineers at
345 East 47th Street New York, NY 10017 (212705-7722).
It is the responsibility of the contractor, installer, purchaser, owner, and user to install, main-
tain, and operate the parts or components manufactured and supplied by Sprocket & Gear,
Inc., in such a manner as to comply with the Williams-Steiger Occupational Safety
Act and with all state and local laws, ordinances, regulations, and the American National Standard
Institute Safety Code.
CAUTION
Guards, access doors, and covers must be securely fastened before operating any equipment.
If parts are to be inspected, cleaned, observed, or general maintenance performed, the motor dri-
ving the part or components is to be locked out electrically in such a manner that it cannot be
started by anyone, however remote from the area. Failure to follow these instructions may result in
personal injury or property damage.
WARNING
NOTE: CATALOG DIMENSIONS
Every effort is made to keep all catalog dimensions and styles current; however, from time to time, it
is necessary because of manufacturing changes to alter stock products dimensionally.
If any stock product dimension or style shown in this catalog is critical to your application please
consult factory for certification.
INDEX
Introduction to Sprocket & Gear
Indexed Troubleshooting Guide
Lubrication — Type A Manual Lubrication, oil applied periodically brush or spout can.
Drip lubrication, oil applied between link plates edges from a drip lubricator.
Lubrication — Type B Oil bath or oil slinger, oil level maintained in casing at predetermined height.
Lubrication — Type C Oil stream, oil supplied by circulating pump inside chain loop on lower span.
Check for Chain Stretch If elongation is in excess of 3%, replace with new chain. Check length after first
1,000 hours.
Check Sprocket If teeth have a hooked appearance, replace. Initial inspection 24 hours,
second 100 hours, third 500 hours. Periodically thereafter, check chain length, may
be elongated.
Check Alignment If wear is apparent on inner surface of roller link side-bars and on sides of sprocket
teeth, there is misalignment. Realign sprockets.
Wear on Sprockets or Rollers Realigning nonparallel shafts or shafts not in same plane.
Nonsymmetrical Shafts might be bent, or shaft bearings worn.
Wear on Side of Sprocket Teeth or Inside Sprockets are offset or not parallel and should be realigned.
of Roller Plates
Wear on Tips of Sprocket Teeth Chain elongation is excessive and chain should be replaced.
Chain Climbs Sprocket Chain does not properly fit sprocket. Check sprocket bottom diameters and replace
if necessary. Chain may be stretched more than 3%.
If sprocket worn, replace chain and sprocket or replace chain if worn.
Redesign drive for more teeth in contact if insufficient chain wrap. Or use
chain tighteners. Should have at least 17 teeth in small sprocket.
Provide cover for chain drive when material builds up in the tooth pocket of the
sprocket. Or "mud reliefs" may be helpful.
Excessive Noise Check sprocket alignment. Lubricate chain and sprocket drive.
Replace chain and/or sprocket(s) if worn. Driver should have hardened teeth.
Tighten and align supports, casing, and chain when moving parts contact
stationary parts.
Excessive Vibration Possible broken or missing roller. Replace or repair chain. Check shaft
bearing supports, bearings may be worn or broken.
1
GEAR DRIVES
Type Maintenance What To Do
Inspect for Wear and Alignment Initial inspection 24 hours, second 100 hours, third 500 hours. Once a year there-
after. Check tooth contact pattern for full face contact.
Excessive Drive Noise Check gear set for proper backlash. Adjust as necessary.
Misaligned drive.
Worn gears, replace as necessary.
Drive speed too high, check pitch line velocity.
Gear Breakage Eliminate overload or shock load conditions. Replace drive with wider gears or 20°
P.A. gears.
Provide adequate cover for environmental material surrounding drive.
Disfiguration of Gear Tooth Remove overload condition. Replace with hardened gears or wider gears.
CHAIN COUPLINGS
Type Maintenance What To Do
Lubrication Check after initial 100 hours for leakage. Change lubricant once per year thereafter.
Check Alignment Disassemble after initial 100 hours, check for excessive wear. If misaligned, wear
patterns will appear very uneven. If necessary, realign shafts and replace worn cou-
pling parts.
Chain Breakage Provide adequate lubrication, provide with sealed cover for longer life. Check for
excessive radial misalignment and/or excessive end float. Realign shafts
to eliminate most of misalignment. If not provided with cover, check for
foreign objects near or in coupling, provide with cover. Check for sudden shock
loads, if present go to larger coupling or go to more flexible type
couplings such as "Q.D." Flex or Quadra-Flex.
Excessive Noise Check chain and sprockets to make sure not worn, or have broken pin link. Replace
if necessary, chain may be striking inside of cover.
2
JAW COUPLINGS
Type Maintenance What To Do
Jaw Breakage Buna-N Insert failed causing metal to metal contact. Replace with hytrel or urethane
spiders. Hytrel withstands oil products better than urethane or
Buna-N. Hytrel will not withstand hot water. Urethane withstands water better.
Eliminate overload or shock load conditions. Replace drive with new MS jaw cou-
pling. Carries approximately 20% higher capacity.
Rubber Element Failure Buna-N insert failed due to horsepower applied to coupling greater than
insert can withstand. Replace with Hytrel spider, which can withstand 3 times
Buna-N horsepower capacity.
Check misalignment. Coupling can only handle up to 1° angular misalignment.
Excessive Drive Noise Check jaw set for proper fit. May have wrong insert in coupling.
Misaligned drive.
Worn couplings, replace as necessary.
Drive speed too high, check shaft rpm.
QUADRA-FLEX COUPLINGS
Type Maintenance What To Do
Element Failure Check for alignment. Can handle up to 1° angular and up to .062 parallel
offset misalignment.
Check for proper installation. May be installed in an application not suited
for the coupling; i.e., an internal combustion engine, reciprocating pump,
compressor, or fan and propeller blades.
Teeth Worn on One or Both Sides of Sleeve Caused by excessive misalignment. Realign coupling.
Improper service factor. Check design, go to larger coupling.
Crack in Sleeve at 45° Caused by flex fatigue. Normal mode of failure, if premature use a larger
coupling.
Sleeve Thrown Out of Coupling Caused by shock load. Unjam machine, check for misalignment.
Caused by overspeed. Reduce speed of coupling.
Element Deteration TPR (Thermo-Plastic Rubber) can operate in conditions of extreme temperatures -
50°F to +250°F and in oily or wet conditions.
Neoprene can operate in temperatures of 0°F to +250°F.
Hytrel can operate in temperatures of -65°F to +250°F and oily conditions. Hytrel will
not withstand hot water.
If elements are deteriorating due to heat or solvents check sleeve chemical resistance
from table in catalog #1090 page C8.
3
SYNCHRONOUS DRIVES
HTS DRIVES
Type of Failure Probable Cause Corrective Action
Excessive Edge Wear Misalignment or nonrigid centers. Check alignment and/or reinforce mounting.
(Exposed Tensile Member) Bent flange. Straighten flange.
Jacket Wear on Pressure-Face Excessive overload and/or Reduce installation tension and/or increase drive
Side of Belt Tooth excessive belt tightness. load-carrying capacity.
Excessive Jacket Wear Between Belt Excessive installation tension. Reduce installation tension.
Teeth (Exposed Tension Members)
Cracks in Neoprene Backing Exposure to excessive low temperature Eliminate low temperature condition or
(below 30°F). consult factory for proper belt construction.
Softening of Neoprene Backing Exposure to excessive heat (+200°F) Eliminate high temperature and oil condition or
and/or oil. consult factory for proper belt construction.
Tensile or Tooth Shear Failure Small or sub-minimum diameter Increase pulley diameter of use next
pulley. smaller pitch with same P.D.
Indicating Corrosion of Tension Extreme humidity. Eliminate humidity or refer to factory for
Member (rust) belt construction.
Acid or caustic atmosphere. Refer to factory for belt
construction.
Excessive Pulley Tooth Wear Excessive overload and/or excessive Reduce installation tension and/or
(On Pressure-Face and/or O.D.) belt tightness. increase drive load-carrying capacity.
Insufficient hardness of pulley Surface-harden pulley or use harder
material. material.
Tooth Shear Less than 6 teeth in mesh (TIM). Increase TIM or use next smaller pitch with same
P.D.
Excessive load. Increase drive load-carrying capacity.
Apparent Belt Stretch Reduction of center distance or Retension drive and/or reinforce mounting.
nonrigid mounting.
Cracks or Premature Wear Improper pulley groove top Regroove or install new
at Belt Tooth Root radius. pulleys.
Note: When HP rating is adequate, using multiple belts in matched sets rather than a single wide belt will reduce sound emission.
Effective noise reduction for power transmission drives can be accomplished by incorporating a flexible noise-absorbing material
such as acoustical-grade glass fiber with the protective guard. The guard design must allow a cooling air passage on the top and
bottom to prevent overheating the drive.
4
SYNCHRONOUS DRIVES
TIMING BELT DRIVES
Type of Failure Probable Cause Corrective Action
Teeth Wearing Unevenly Shafts might not be parallel causing belt to Check alignment of shafts.
pull one side. Abrasion material may be on
teeth or enmeshed into belt.
Belt Breakage Improper sized for torque loading. Check proper sizing procedures.
Too much load. May be severe shock load, may need to go to
chain drive instead of belt drives.
Underdesigned drive. Redesign drive.
Sharp bend damaged tensile cord. Follow proper storage and handling
procedures.
Belt was pried or forced on the drive. Follow proper installation procedures.
Foreign object in drive. Shield drive.
Belt runs onto pulley flange. Align pulleys.
Apparent Belt Stretch Reduction of center distance or nonrigid Retension drive and/or reinforce mounting.
mounting.
Pulley teeth poorly machined or worn. Replace pulleys. Install cover if drive is dusty.
Sudden equipment stops. Increase deceleration time or redesign drive.
Belt does not engage pulley teeth. Retension drive.
Tooth Shear Less than 6 teeth in mesh. Redesign drive, install back side idler, or use
next smaller pitch.
Excessive load. Redesign drive.
Tensile or Tooth Shear Failure Pulley diameter too small. Increase pulley diameter or use next smaller
pitch.
Exposure to acid or caustic Protect drive or ask about special
atmosphere. construction belt.
Excessive Pulley Tooth Wear Drive overload and/or excess belt Reduce installation tension and/or increase
(On Pressure Face and/or O.D.) tension. drive load carrying capacity.
Insufficient hardness of pulley material. Use harder material or surface-hardened pulley.
Excessive Jacket Wear Between Excessive installation tension. Reduce installation tension.
Teeth, Exposed Tensile Cord
Cracks in Belt Backing High temperatures. Improve ventilation, remove heat source, or
check with for special construction belt.
Softening of Backing Excess heat (over 200°F) and/or oil. Lower ambient temperature, protect from oil, or
ask about special belt construction.
Excessive Edge Wear Misalignment or nonrigid centers. Realign drive and/or reinforce mounting.
Bent flange. Straighten flange.
5
V-BELT DRIVES
Type of Failure Probable Cause Corrective Action
Rapid Failure With No Worn sheave grooves ( Use groove gauge Replace sheaves.
Visible Reason to check ).
Tensile cord damage through improper Replace all belts with a new set, check for proper
installation. installation.
Drive is underdesigned. Redesign drive.
Wrong type or cross section belt. Replace all belts with correct type, check for
proper installation.
Sheave diameter too small. Redesign drive.
Foreign substance caught between belts Shield the drive with drive guard.
and sheave.
Soft, Sticky, Swollen Sidewalls Oil or grease on belt or sheave. Clean belts and sheave with degreasing agent or
Low Adhesion Between Plies detergent and water. Remove source of oil or
grease.
Dry, Hard Sidewalls. Use Low Excessive high temperature. Remove heat source. Improve ventilation.
Adhesion Between Plies. Cracked Belt
Bottom
Deteration of Rubber Belt dressing being used. Don't use belt dressing. Clean belts and sheaves
with degreasing agent or detergent and water.
Tension belts properly.
Broken Belts Foreign object in drive. Shield drive with drive guard.
Spin Burns Belts slip under starting or stalling load. Check belt tension — retension drive if
necessary.
Sheave diameter too small. Redesign drive.
Load miscalculated — Redesign drive.
drive underdesigned.
Cut Bottom Improper installation. Replace all belts with a new set, check for prop-
erly installation.
Foreign object in drive. Shield drive with drive guard.
Belt was run off sheave. Check for proper tension and alignment.
Cracked Bottom Excessive high temperature. Remove heat source. Improve ventilation.
Back side idler too small. Replace with an inside idler on slack side, or
redesign.
Sheave diameter too small. Redesign drive. Use cogged belts.
Slippage. Retension drive.
Extreme Cover Wear, Sheaves rusted, sharp corners or burrs on Repair or replace sheaves.
Worn Corners sheaves.
Dirt on belt. Clean belt, shield drive.
Sheaves misaligned. Realign sheaves.
Belts rub against guard or other Remove obstruction or check drive alignment.
obstruction.
Improper tension. Retension drive.
6
V-BELT DRIVES
Type of Failure Probable Cause Corrective Action
Belts Stretch
Belts Stretch Equally Overloaded or under-designed drive. Redesign drive.
Insufficient take-up allowance. Check take-up and follow guidelines.
Belts Stretch Unequally Tensile cord broken from improper Replace all belts with a new set, check for proper
installation. installation.
Misaligned drive. Realign drive.
Installation Problems
Belts Too Long or Short at Design and/or belt selection error. Check catalog for proper design and selection.
Installation
Belts Mismatched at Installation Worn sheave grooves. Replace sheaves.
Mixed used and new belts. Replace all belts with new belts.
Mixed belts from different manufac- Replace belts from the same manufacturer.
turers.
Hot Bearings
Drive Overtensioned Worn sheave grooves, belts bottom out. Replace sheaves.
Sheave Diameter Too Small Design error. Redesign drive.
Sheaves Too Far Out On Shaft Design error or obstruction. Place sheaves as close to bearing as possible.
7
SCREW CONVEYOR
Type of Failure Probable Cause Corrective Action
Premature Trough Failure Gauge too light. Increase thickness. Consult catalog mate-
rials table/component series for recommendation.
Eliminate excessive deflection. Consult cat-
Screw deflection. alog for calculation procedure to determine proper
pipe size and screw length.
Straighten or replace. Check before operation.
Bent screw.
Accelerated Flight Tip Wear Gauge too light. Increase thickness. Consider hardfacing.
RPM too high. Slow conveyor down. Consult catalog
engineering section to determine proper trough
loading.
Coupling Shaft Breakage Torque capacity insufficient. Increase torque capacity or use larger shaft.
Check motor amp demand for torque require-
ments.
Motor/Heaters Overload Amp. demand excessive for motor. Recheck horsepower calculations. Check material
characteristics. Check capacity. Regulate feed.
Inlet Trough End Bearing Failure Material getting into bearing. Add or upgrade seal to keep material out of bear-
ing. Change to outboard bearing.
Insufficient lubrication. Lubricate properly.
Shaft slope. Align screw. Check for excessive screw deflection
and for bent screw.
Discharge Trough End Bearing Failure Material getting into bearing. Add or upgrade seal.
Change to outboard bearing.
Cut off flight at center of discharge.
8
SPROCKET & GEAR, INC.
3100 Sprocket Drive • Arlington, Texas 76015-0088
Phone: 817-2 5 8-3000 • FAX: 817-258-3333