Sprocket Replacement Tutorial

Tools Needed: 

• Safety glasses
• Cut-proof gloves
• 9/16” wrench
• 9/16” socket
• Crowbar/pole for belt
• Small flathead screwdrivers
• Hammer
• Channel locks
• Needle nose pliers
• Impact driver
• 13/16” impact socket and extension
• Adjustable wrench
• Ratchet straps
• Standard and metric Allen key sets
• 7/16” deep socket and extension
• Anti-seize

Parts Needed:

• (10) 17 Tooth Machined White Sprockets - P-C2262
• (2) 3/4" X 3" Square Shaft Keys - P-C2121-3
• (2) 2-15/16" Chain Coupling Flanges - P-C2163-3
• (2) Split Collar Sprocket Retainers - P-C2162
• (2) 2-15/16" Pillow Block Bearings - P-C2119
• (5) Conveyor Belt Connecting Pins - P-C2191
• (1) 2-15/16" Square Belt Drive Shaft - P-C2130-S-3
• (1) Belt Conveyor Coupling Chain - P-C2123
• (5) 1/4" Round U-Bolts - P-C2129

Procedure: 

1. First, it is important that you put in the wash stop and set the Conveyor to “OFF” in the setup menu as to avoid accident.
2. Next, remove the exit transfer plate.
3. Slide your crowbar/pole under the belt at the second or third set of blowers to create slack on top.
4. This will then allow you to disconnect the belt at the second or third set of blowers by opening the banana clips and removing the dowel pin. Allow the belt to fall into the pit below the sprockets.
5. Next, you can begin removing the chain coupling. You will then want to loosen the 9/16” bearing set screw and remove the bearing bolts.
6. Wrap the ratchet straps around each end of the driveshaft assembly. Remove the driveshaft/sprocket assembly and then directly after remove the bearing shims from the red iron.
7. Loosen the Allen set screw and remove the chain coupler sprocket and keyway from the driveshaft. Then, remove the bearings from the driveshaft as well.
8. Next, loosen the center sprocket spacer on the driveshaft. This will allow you to remove the old sprockets and center spacer and permit you to install the new sprockets on the driveshaft. Make sure to take note of the arrow directions on the driveshaft and ensure that every sprocket is oriented the same.
9. Loosely install the center sprocket spacer around the 5th sprocket.
10. Apply anti-seize to the ends of the driveshaft assembly, as well as the new bearings which can then be installed on the driveshaft. Do not tighten the set screws during this process.
11. Then, apply anti-seize to the end of the gear box stub shaft and to the new chain coupler sprocket and keyway, which can then also be installed on the gearbox. Again, make sure not to tighten the set screws during this process.
12. Wrap the ratchet straps around each end of the new driveshaft assembly. Lower the driveshaft/sprocket assembly back onto the red iron while lining up bearings to bolt holes so you can loosely install the bearing bolts.
13. Lift up on the driveshaft while bolts/nuts are in place and install the bearing shims as well.
14. Adjust the driveshaft within the bearings to line up with the chain coupling sprocket. Then, install the new chain coupling.
15. Ensure the sprockets are evenly spaced and centered on the assembly. If needed, tighten the center sprocket spacer around the driveshaft.
16. Also ensure that the driveshaft/sprocket assembly is aligned properly and is perfectly parallel to the welded transfer plate.
17. Once everything looks set in place, tighten the other bearing bolts, as well as the 9/16” set screws against the side of the bearing whilst also double-checking sprocket alignment.
18. On the driver side, install a proximity collar on the end of the driveshaft, ensuring proper alignment with the proximity sensor.
19. Pull the belt up and around the sprockets as much as possible, ensuring all drive pockets are aligned and engaging with sprockets.
20. To disengage the wash stop, three team members will be required.
21. First, set the belt speed to negative five in the setup menu.
22. Team members One and Two will need to pull the back belt on both the passenger and driver side. If only one side has been disconnected, you must still pull both sides to avoid the belt bunching up at the sprocket/transfer plate.
23. While this is happening, Team Member Three must start the belt manually.
24. Team Members One and Two will then pull back the belt until it can be reconnected, which then the third team member will turn the belt off.
25. Now, engage the wash stop and reconnect the belt with a dowel pin. Reinstall the transfer plate and check for clearance issues with the belt.
26. Once this is completed, you can disengage the wash stop and clean the area. Run the belt and listen for noises while checking the alignment, sprockets, under rollers, belt tension, and proximity sensor.
27. Run a test vehicle to ensure proper operation of all functions, and if everything appears to be working fine, you have successfully conducted your sprocket/driveshaft assembly maintenance.

Instructional Video: