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DiamondOil Field PRoduct GuideMaintenance Guide

Table of Contents

Installation 4

Lubrication 5-6

Inspections 7

ElongationLimits 8

Troubleshooting 9-10

Instructions 11

Every Calling is Great, When Great ly Pursued. OLIVER WENDELL HOLMES

AttheDiamondChainCompany,thecallingtodesignandmanufacturetheworld’shighest-performingrollerchainisgreatlypursuedeverydaybyteamsofpassionatetechnicalexpertswhohavemadeyoursuccesstheirlife’swork.It’sthatintensityoffocusthatsomeoftheworld’sgreatestinventorstrustedtoprovidethedrivechainstheyneededtotransformtheworld.FromtheWrightBrothers,toHenryFord,tothegloballeadersofourtime,Diamond®chainistherollerchainmosttrustedtoperform,whenperformancemattersmost.

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Toobtainmaximumservice-lifeandefficiencyfromachaindrive,itisnecessarythatcertainprecautionsininstallationbetaken.Chaindriveinstallationisrelativelysimpleandgoodresultsmaybeobtainedwhenthefollowingconditionsaremet:

1.Therollerchain,sprockets,andothercomponentsareingoodcondition.2.Thesprocketsareproperlyaligned.3.Provisionismadeforadequatelubrication.4.Thechainiscorrectlytensioned.

CONDITION OF COMPONENTSShafting,bearings,andfoundationsshouldbesupportedrigidlytomaintaintheinitialalignment.Rollerchainshouldbefreeofgritanddirt.Washchaininkerosenewhenrequiredandthenre-lubricate.

DRIVE ALIGNMENTMisalignmentresultsinunevenloadingacrossthewidthofthechainandmaycauserollerlinkplateandsprockettoothwear.Drivealign-mentinvolvestwothings:parallelshaftalignmentandsprocketaxialalignment.

2.Sprocketaxialalignmentcanbecheckedwithastraightedgewhichwillextendacrossthefinishedsidesofthetwosprockets.Normally,itisgoodpracticetoalignthesprocketsasclosetotheshaftbearingaspossible.Forlongcenterdistances,useatautcord,orwirelongenoughtoextendbeyondeachofthesprockets.Themaximumallowableamountofaxialmisalignmentisobtainedfromthefollowingformula:

Max.Offset=0.045PininchesormmwhereP=chainpitchininchesormm.Thisformulaappliestobothsingleandmultiplestrandchains.

INSTALLING THE CHAINRe-checkallprecedingadjustmentsforalignmentandmakecertainallsetscrews,boltsandnutsaretight.Fitchainaroundbothsprocketsandbringthefreeendstogetherononesprocketforconnection.Thesprocketteethwilllocatethechainendlinks.Installtheconnectinglinkandconnectinglinkcoverplate,andthespringcliporcotterpins.Onlargerpitchorheavymultiplestrandchains,itmaybenecessarytolockthesprocketsforthisoperation.Whenpressfitcoverplatesareused,becarefulnottodrivetheplateonsofarastogriptherollerlinks.Stiffjointscanresultifthisisdone.Ondriveswithlongspans,itmaybenecessarytosupportthechainwithaplankorbarastheconnectionismade.

CHAIN TENSIONCheckchaintensiontobecertaintheslackspanhas4-6%mid-spanmovementinhorizontaldrivesand2-3%inverticaldrives.Pleasereferencethetablebelow.

1. Shaftsshouldbeparallelandlevel.Thisconditionmaybereadilycheckedbytheuseofafeelerbar,andamachinist’slevel.Ifthereisaxialmovementoftheshaft(asinthecaseofanelectricmotor),locktheshaftinthenormalrunningpositionbeforealigningthesprockets.

Mostsinglestranddriveswillperformacceptably if theshaftsareparalleland in thesameplanewithin.050in/ft(4.2mm/m)or1/4°.However,highspeed,highhorsepower,ormulti-plestranddrivesshouldbealignedwithinthetoleranceobtainedfromthefollowingformula:

INSTALLATION

Tolerance=.00133C(in/ft),or.111C(mm/m)PnPn

TAUT SPAN

CBA

AC = Total Possible Mid-Span Movement

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Where:C=centerdistance,ininchesormm.P=chainpitch,ininchesormm.n=numberofchainstrands.

LUBRICATIONRollerchainconsistsofaseriesofconnectedtravelingmetallicbearingswhichmustbeproperlylubricatedtoobtainthemaximumservicelifeofthechain.Althoughmanyslowspeeddrivesoperatesuccessfullywithlittleornolubricationbeyondtheinitialfactorylubrication,properlubricationwillgreatlyextendtheusefullifeofeverychaindrive.Thechaindriverequireslubricationforsixpurposes:

1. Toresistwearofthepin-bushingjoint.2.Tocushionimpactloads.3.Todissipateanyheatgenerated.4.Toflushawayforeignmaterials.5.Tolubricatechain-sprocketcontactsurfaces.6.Toretardrustorcorrosion.

Agoodgradeofcleanpetroleumoilwithoutadditives,freeflowingattheprevailingtemperatures,shouldbeused.Someadditivesleaveavarnishorgumdepositwhichpreventstheoilfromenteringchainjoints.Heavyoilsandgreasesaregenerallytoostifftoenterthechainjointsandshouldnotbeused.

Withproper lubrication,aseparatingwedgeof lubrication is formedbetweenthepinsandbushings inthechain jointsmuch likethatformedinjournalbearings. Theviscosityofthelubricantgreatlyaffectsitsfilmstrength,anditsabilitytoseparatemovingparts. Thehighestviscosityoilwhichwillflowbetweenthechainlinkplatesandfillthepin-bushingareaswillprovidethebestwearlife.Thisises-sentialtominimizemetaltometalcontactand,ifsuppliedinsufficientvolume,thelubricantalsoprovideseffectivecoolingandimpactdampeningathigherspeeds.

Oilappliedtorollersonlycannotreachpin-bushingjoints,andtherefore,cannotretardchainelongationduetowear.Thelengtheningofchainsinserviceresultsfromwearonpinandbushingsurfaces,notrollers.Whenlubricatingmultiplestrandchain,itisimportantthatlubricantbedirectedtoeachrowofchainlinkplates.Inconveyorapplications,oilshouldbedirectedbetweentherollersandbushingsaswellasbetweenthechainlinkplates.

Roller

Roller Link Plate

Pin Link Plate

Bushing

Pin

The table indicates the lubricant viscosity recommended for varioussurroundingtemperatures:

Therearethreebasictypesoflubricationforrollerchaindrives.Closeadherence to the recommended type of lubrication is essential toobtainingmaximumservicelifeofachaindrive.

The recommended type of lubrication as shown in the horsepowerrating tables is determined by the chain speed and the amount ofpowertransmitted.

Note: Speeds beyond the maximum recommended for chain operation are indicated in the horse-power rating tables with zero horsepower. Operation at these or higher speeds will result in excessive galling of the chain pins and bushings regardless of the volume of oil applied.

Chaindrivesshouldbeprotectedfromabrasiveandcorrosiveconditionsandtheoilsupplykeptfreeofcontamination.Periodicoilchangesareencouraged.

Note: Oil should be applied to the lower span of chain on the upper edges of linkplates since access of oil to pin-bushing joints is possible only through the clearances between the roller chain linkplates.

5

Recommended Grade Temperature,˚F

SAE5

SAE10

SAE20

SAE30

SAE40

SAE50

Operating Temperature oC

-46TO+10

-29TO+27

-12TO+43

-7TO+54

-1TO+60

+4TO+65

Sight FeedLubricator

Wick PackedDistributing Pipe

MANUAL OR DRIP LUBRICATION (TYPE A)Oilshouldbeappliedperiodicallybetweenthechainlinkplateedgeswithabrush,spoutcan,ordriplubrication.

OIL BATH OR OIL SLINGER (TYPE B)

Withbathlubrication,thelowerstrandofchainrunsthroughasumpofoilinthedrivehousing.Theoillevelshouldreachthepitchlineofthechainatitslowestpointwhileoperating.Onlyashortlengthofchainshouldrunthroughtheoil.

Drivearrangementswhichpermitlonglengthofchaintotravelthroughtheoilshouldbeavoidedasoverheatingorfoamingmayresult.

Withslingerdisclubrication,thechainoperatesabovetheoillevel.Thediscpicksupoil from the sump and deposits it into the chain, usually by means of a trough. Thediameterof thediscshouldproducerimspeedsbetween183Meters/Min.minimumand2438Meters/Min.maximum.Acollectorplateisusuallyrequiredtodirecttheoiltothechainlinkplates.

OIL STREAM LUBRICATION (TYPE C)

Thistypeoflubricationisrequiredforlargehorsepower,highspeeddrives.Anoilpumpshouldbeprovidedtospraytheoilacrossthelowerspanofchaininacontinuousstream.Orificesshouldbeplacedsothatoilissprayedacrosseachstrandofthechain.Thistypeoflubricationmaybeuseduptothemaximumspeedsshowninthehorsepowerratingtablesforeachsizeofchain,exceptwheretheratingiszero.

OIL LEVEL

OILLEVEL

Limiting Chain Speed for Various Types of Lubrication (Chain Speed in Meters/Minute)

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TypeA

TypeB

TypeC

LUBRICATIONINSPECTIONSAllchaindrivesshouldreceiveregularmaintenance.Eachdriveshouldbeinspectedaftertheinitial100hoursofoperation.Thereafter,mostdrivesmaybeinspectedat500hourintervals.However,drivessubjecttoshockloadsorsevereoperatingconditionsshouldbeinspectedat200hourintervals.

Ateach inspection,thefollowingitemsshouldbecheckedandcor-rected,ifnecessary:

1.Checklubrication—Onslowspeeddrives,wheremanuallubricationisused,besurethelubricationscheduleisbeingfollowed.Ifthechainiscoveredwithdirtanddebris,cleanthechainwithkeroseneandre-lubricate it.

WARNING!NEVERUSEGASOLINEOROTHERHIGHLYFLAMMABLESOLVENTSTOCLEANACHAIN.AFIREMAYRESULT.

Ifdriplubricationisused,checkforadequateoilflowandproperap-plicationtothechain.Withbathorpumplubrication,checkoillevelandaddoilifneeded.Checkoilforcontaminationandchangeoilifneeded.Changeoilafterthefirst100hoursofoperationandeach500hoursthereafter.Ifpumplubricationisused,checkeachorificetobesureitisclearandisdirectingoilontothechainproperly.

2.CheckChainTension—Checkchaintensionandadjustasneededtomaintainthepropersagintheslackspan.Ifelongationexceedsthe available adjustment, remove two pitches and reconnect thechain.

3.CheckChainWear—Measurethechainwearelongationandifelongationexceedsfunctionallimitsorisgreaterthan3%(.001mminonemeter)replacetheentirechain.Donotconnectanewsectionofchaintoawornchainbecauseitmayrunroughanddamagethedrive. Donotcontinuetorunachainwornbeyond3%elongationbecausethechainwillnotengagethesprocketsproperlyanditmaydamagethesprockets.

NOTE: Diamond Chain wear gauges are available to monitor chain elongation.

4. Check SprocketToothWear — Check for roughness or bindingwhenthechainengagesordisengagesfromthesprocket. Inspectthesprocketteethforreducedtoothsectionandhookedtoothtips.If these conditions are present, the sprocket teeth are excessivelywornandthesprocketshouldbereplaced.Donotrunnewchainonwornsprocketsasitwillcausethenewchaintowearrapidly.Con-versely,donotrunawornchainonnewsprocketsasitwillcausethenewsprocketstowearrapidly.

5.CheckSprocketAlignment—Ifthereisnoticeablewearontheinside surface of the chain roller linkplates, the sprockets may bemisaligned. Realign the sprockets as outlined in the installationinstructionstopreventfurtherabnormalchainandsprocketwear.

6.CheckforDriveInterference—Checkforinterferencebetweenthedriveandotherpartsoftheequipment.Ifthereisany,correctit immediately. Interference can cause abnormal and potentiallydestructivewearonthechainortheinterferringpart.Iftheedgesofthechainlinkplatesimpactagainstarigidpart,linkplatefatigueandchainfailurecanresult.

NOTE: Check for and eliminate any buildup of debris or foreign material between the chain and sprockets. A RELATIVELY SMALL AMOUNT OF DEBRIS IN THE SPROCKET ROLL SEAT CAN CAUSE TENSILE LOADS GREAT ENOUGH TO BREAK THE CHAIN IF FORCED THROUGH THE DRIVE.

7. Check for Failure — Inspect the chain for cracked, broken, ordeformedparts.Ifanyoftheseconditionsarefound,REPLACETHEENTIRE CHAIN, even though portions of the chain appear to be ingoodcondition.Inalllikelihood,theentirechainhasbeendamaged.

For additional technical assistance, please contact Diamond Chain at +44-191-414-8822 or at www.diamondchain.co.uk.

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ELONGATION LIMITS

FOR REFERENCE ONLY

3.0%Max.ElongationAdjustableCenterDistanceDrives

1.5%Max.ElongationFixedCenterDistanceDrives

NOTE: Chain Wear Scales are available free from any Diamond Sales Representative.

8

MeasuringLength

80#12Pitches

TROUBLESHOOTING GUIDE

9

CONDITION/SYMPTOM POSSIBLE CAUSE WHAT TO DOTightJoints Dirtorforeignmaterialinchainjoints. Cleanandre-lubricatechain.

Inadequatelubrication. Replacechain.Re-establishproperlubrication.

Misalignment. Replacesprocketsandchainifneeded.Realignsprockets.

Internalcorrosionorrust. Replacechain.Eliminatecauseofcorrosionorprotectchain.

Overloadbendspinsorspreadsrollerlinkplates. Replacechain.Eliminatecauseofoverload.

RustedChain Exposedtomoisture. Replacechain.Protectfrommoisture.

Waterinlubricant. Changelubricant.Protectlubricationsystemfromwater.Replacechain.

Inadequatelubrication. Provideorre-establishproperlubrication.Replacechainifneeded.

TurnedPins Overload. Replacechain.Eliminatecauseofoverload.

Inadequatelubrication. Replacechain.Re-establishproperlubrication.

EnlargedHoles Overload. Replacechain.Eliminatecauseofoverload.

BrokenPinsBrokenLinkplates

ExtremeOverload. Replacechain.Replacesprocketsifindicated.Eliminatecauseofoverloadorredesigndriveforlargerpitchchain.

Broken,Cracked,orDeformedRollers Speedtoohigh. Replacechain.Reducespeed.

Sprocketstoosmall. Replacechain.Uselargersprockets,orpossiblyredesigndriveforsmallerpitchchain.

Chainridingtoohighonsprocketteeth. Replacechain.Re-tensionchainmoreoften.

PinGalling Speedorloadtoohigh. Reducespeedorload.Possiblyredesigndriveforsmallerpitchchain.

Inadequatelubrication. Provideorre-establishproperlubrication.

ChainClimbsSprocketTeeth Excesschainslack. Re-tensionchain.

Excessivechainwear. Replaceandre-tensionchain.

Excessivesprocketwear. Replacesprocketsandchain.

Excessiveoverload. Replacechain.Eliminatecauseofoverload.

CONDITION/SYMPTOM POSSIBLE CAUSE WHAT TO DOMissingorBrokenCotters Cottersinstalledimproperly. Installnewcotterspermanufacturer’sinstructions.

Vibration. Replacechain.Reducevibration.Uselargersprockets.

Excessivelyhighspeed. Replacechain.Reducespeed.Redesigndriveforsmallerpitchchain.

ExposedChainSurfacesCorrodedorPitted

Exposuretocorrosiveenvironment. Replacechain.Protectfromhostileenvironment.

CrackedLinkplates(StressCorrosion)

Exposuretocorrosiveenvironmentcombinedwithstressfrompressfits.

Replacechain.Protectfromhostileenvironment.

CrackedLinkplates(Fatigue) Loadisgreaterthanchain’sdynamiccapacity. Replacechain.Reducedynamicloadingorredesigndriveforlargerchain.

BatteredLinkplateEdges Chainstrikinganobstruction. Replacechain.Eliminateinterference.

WornLinkplateContours Chainrubbingoncasing,guide,orobstruction. Replacechainif5%ormoreofheightwornaway.Re-tensionchain.Eliminateinterference.

ExcessiveNoise Chainstrikinganobstruction. Replacechain.Eliminateinterference.

Loosecasingorshaftmounts. Tightenfasteners.

Excesschainslack. Re-tensionchain.

Excessivesprocketwear. Replaceandre-tensionchain.

Sprocketmisalignment. Replacechainandsprockets,ifneeded.Realignsprockets.

Inadequatelubrication. Replacechainifneeded.Re-establishproperlubrication.

Chainpitchtoolarge Redesigndriveforsmallerpitchchain.

Toofewsprocketteeth. Checktoseeiflargersprocketscanbeused.Ifnot,redesigndrive.

WearonInsideofRollerLinkplatesandOneSideofSprockets

Sprocketmisalignment. Replacesprocketsandchainifneeded.Realigndrive.Re-tensionchain.

ChainClingstoSprocket Excessivesprocketwear. Replacesprocketsandchain.

Sprocketmisalignment. Replacesprocketsandchainifneeded.Realignsprockets.

TROUBLESHOOTING GUIDE

10

5% of H

H

WHEN DISASSEMBLING OR ASSEMBLING CHAINS:WARNING—Thecomponentsofachainarehardenedparts.Strikingthesepartsmaycausemetalchipstobreakofffromthechainorthetoolsusedresultinginpersonalinjury.Duringallstagesofchainassemblyanddisassembly,wear safety glassestopreventmetalpartsorchipsfromenteringyoureyesandhavepersonnelintheimmediateareadolikewise.

A. Pin Removal1)Ifchainisofcotterpin-typeconstruction,removecotters.2)Ifchainisriveted-typeconstruction,grindpinheadsoffsopinendsareflushwiththelinkplate.3)DrivepinsoutoflinkplateusingaDiamondpinextractorModel#113or#135.Somemultiplestrandchainsorlargepitch modelswillrequireahammerandpunchorapresstoremovethepins.

B. Installation of CoversidesDiamondcoversidesaremanufacturedthreedifferentways:(1)SlipFit,(2)ModifiedPressFit,and(3)FullPressFit.Modifiedandfullpressfitsrequiresomepatienceandtoolstoassembleand/ordisassemble.

Full Press-Fit and Modified Press-Fit Coversides Toassemblethepress-fitcoversides: 1.Insertthe“MasterLink,”theportionofthelinkthatcontainsthepins,andprovidesupportorbackingtoresisttheforces neededtodrivethecoversideon. 2.Placethepress-fitcoversideovertheexposedpinendsandensurethatitisalignedproperly. 3.Drivethecoversideonuntilitisflushwiththeendsofthepins. 4.Obtainahollowpunch(perhapsasmallpieceofpipeoradiscardedchain’sroller)andlocateitover/aroundtheflushpinend. 5.Alternatelyfromonepitchholetotheother,continuetodrivetheendsofthelinkplateontothepinsuntilitisclearofthe springclipgrooveorcotterhole.Careshouldbetakennottodrivetheplateonsofarastosqueezeagainstorpinchtheroller links.Thiswillresultinstifforbindingjoints. 6.Installtheretainingdevice,eitherspringcliporcotter. Caution: Never drill out or enlarge the pitch holes of a press-fit coverside to make the installation easier. This will lower the integrity of the link.

Slip-Fit Coversides Toassembletheslip-fitcoversides: 1.Insertthe“MasterLink,”theportionofthelinkthatcontainsthepins,intothechain. 2.Slidetheplateoverthepinendstoalocationwhichclearseitherthespringclipgrooveorcotterhole 3.Installtheretainingdevice,eitherspringcliporcotter. Note: When a slip-fit coverside is used, a chain’s working capacity can be reduced as much as 30%.

C. Installation of Spring Clips and CotterpinsAftercoversidehasbeeninstalled,installspringclipsorcotters(dependingonchaindesign).Avoidusingbentorworncottersorspringclips.Afterspringclips(orcotters)areinstalled,lightlytappinendstopositionthesepartssnugagainstthecoversideforadditionalsupport.

WHEN INSTALLING CHAIN DRIVES ON EQUIPMENT:WARNING —Youmaybeseriouslyinjuredifyouattempttoinstallchainonequipmentunderpower.Shutoffpowerandlockoutgearsandsprocketsbeforeattemptinginstallation.

Onceinstalled,thechaindrivemustbeguardedtopreventpersonalinjuryorpropertydamageintheeventthechainseparatesduringoperation.Ifchaindriveisnotguarded,contactequipmentmanufacturerforrecommendationsonguardingbeforeusingequipment.

INSTRUCTIONS

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DIAMOND® CHAIN COMPANY

nothing outlasts a diamond®©TheDiamondChainCompany2012DC-MG11

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