Chain drive fault finding chart

A chain drive fault finding chart is a useful tool for diagnosing common issues in chain drive systems, such as those found in machinery, vehicles, or conveyors. When using a fault finding chart, it’s important to check each symptom carefully, observe the chain system in operation, and refer to the manufacturer’s guidelines for specific tolerances and maintenance procedures. Below is an example of how such a chart might look, including the symptoms, possible causes, and solutions for each issue:

Symptom	Possible Causes	Solutions
Excessive noise or vibration	- Worn chain	- Replace the chain.
	- Improper chain tension	- Adjust the chain tension to specifications.
	- Misaligned sprockets	- Realign the sprockets to ensure they are parallel.
	- Inadequate lubrication	- Lubricate the chain properly.
Slipping or poor engagement	- Loose or worn chain	- Tighten or replace the chain.
	- Incorrect sprocket size or tooth wear	- Replace sprockets if worn or mismatched.
	- Insufficient or improper lubrication	- Apply the correct lubricant to the chain and sprockets.
Chain elongation or stretching	- Excessive load on the chain drive	- Reduce the load or install a chain with higher load capacity.
	- Worn or poorly maintained chain	- Replace the chain if it has reached the maximum allowable elongation.
	- Poor lubrication or lack of maintenance	- Perform regular maintenance, including lubrication.
Sprocket wear or damage	- Misalignment of sprockets	- Align sprockets properly.
	- Incorrect chain tension	- Adjust chain tension as required.
	- Inadequate lubrication	- Regularly lubricate the chain and sprockets.
Overheating	- Insufficient lubrication	- Check and improve lubrication.
	- High load or excessive speed	- Reduce load or speed to prevent overheating.
	- Friction due to misalignment or dirt buildup	- Clean the chain and sprockets, and ensure proper alignment.
Broken chain	- Overload or shock loading	- Avoid shock loads, and ensure the correct chain size.
	- Manufacturing defect or material fatigue	- Replace the chain.
	- Inadequate maintenance or poor lubrication	- Lubricate and inspect the chain regularly.