CEMA Std.

601-2019 - Draft 3
Revision of CEMA Std. 601-1995
Approved: XXXX

9
01
/21
/1
-6
OVERHEAD TROLLEY CHAIN CONVEYORS

N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
tH
ni
-U
w
ie

Unit Handling Conveyors

ev
R
A
EM
rC
Fo

Conveyor Equipment Manufacturers Association

 CEMA Std. 601 - 2019

DISCLAIMER

The information provided herein is advisory only.

These recommendations provided by CEMA are general in nature and are not intended as a substitute for professional
advice. Users should seek the advice, supervision and/or consultation of qualified engineers, safety consultants,
and other qualified professionals.

9
Any use of this publication, or any information contained herein, or any other CEMA publication is made with the

01
agreement and understanding that the user and the user’s company assume full responsibility for the designs, safety,

1/2
specifications, suitability and adequacy of any conveyor system, system component, mechanical or electrical device

/1
designed or manufactured using this information.

-6
N
O
The user and the user’s company understand and agree that CEMA, its member companies, its officers, agents and

TI
employees are not and shall not be liable in any manner under any theory of liability to anyone for reliance on or use

U
IB
of these recommendations. The user and the user’s companies agree to release, hold harmless and indemnify and

TR
defend CEMA, its member companies, successors, assigns, officers, agents and employees from any and all claims

IS
of liability, costs, fees (including attorney’s fees), or damages arising in any way out of the use of this information.

D
R
CEMA and its member companies, successors, assigns, officers, agents and employees make no representations

FO
or warranties whatsoever, either expressed or implied, about the information contained herein, including, but not

ED
limited to, representations or warranties that the information and recommendations contained herein conform to

IZ
any federal, state or local laws, regulations, guidelines or ordinances.
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
tH
ni
-U
w
ie
ev
R
A

EM

Conveyor Equipment Manufacturers Association

rC

5672 Strand Ct., Suite 2

Fo

Naples, Florida 34110-3314

www.cemanet.org

Copyright © 2019
All rights reserved.
ISBN - 1-891171-50-X

2 of 40
 CEMA Std. 601 - 2019

TABLE OF CONTENTS

Section Page
I INTRODUCTION 4
II DEFINITIONS FOR TROLLEY CHAIN CONVEYORS 7
III CONVEYOR COMPONENTS 10
Rivetless Chain Dimensions - Drop Forged 10

9
01
Trolley Dimensions 11

/2
Vertical Bolts 11

1
/1
Horizontal Bolts 13

-6
N
For X-228 Chain 15

O
TI
Trolley Attachments Dimensions - Vertical Bolts 16

U
Trolley Attachments Dimensions - Horizontal Bolts 18

IB
TR
Roller Turn Dimensions 20

IS
Traction Wheel Turn Dimensions 21

D
R
IV DESIGN PROCEDURE AND ENGINEERING DATA 22

FO
Overhead Trolley Conveyor Symbols - Plan View 22

ED
Typical Trolley Conveyor Installation 23

IZ
Design Steps 24
R
O
Conveyor Drives 29
TH

Types of Drives 29
AU

Standard Drive Speed Ranges 29

T
O

Guards - Typical Sections 32

-N

V VERTICAL CURVE DATA 33

ee
itt

Vertical Curve Beam Radii for Overhead Conveyors as Related to Trolley Spacing 33
m
om

Compound Vertical Curve 34

C

VI TROUBLESHOOTING, LUBRICATION GUIDE AND INSPECTION CHECKLIST 37

g

Troubleshooting Guide 37
in
dl

Lubrication Guide for Overhead Monorail Conveyors 39

an
H

Equipment, Maintenance and Services 40

t
ni

Suggested Inspection Checklist for Trolley Conveyor Systems 40

-U
w
ie
ev
R
A
EM
rC
Fo

3 of 40
 CEMA Std. 601 - 2019

SECTION I - INTRODUCTION

Overhead Monorail Conveyor

The overhead trolley chain conveyor is an extremely flexible material handling means. This is due in part because
its design is based upon a single rail from which the conveying means and the product is suspended, normally over
other work areas. It can be installed to follow almost any path, changing direction vertically or horizontally. Using
multiple drives, a single path can be typically several 1000 ft long.

9
Although monorail conveyors are most commonly thought of in relation to automotive or appliance

01
manufacturing, they are used in practically every industry worldwide. Moving product through processes, conveying

1/2
finished goods to staging or shipping and returning of fixtures are normal applications.

/1
-6
N
In certain environments, humans cannot survive or human health is endangered, yet conveying means are

O
essential. Under many conditions, other types of conveyors are not practical or would not have acceptable life

TI
U
expectancy. The overhead monorail conveyor combines its directional flexibility (horizontal and vertical curve

IB
movement) with its tolerance to adverse environments to broaden its applications to user requirements.

TR
IS
Beyond warehouse and material transportation in ambient indoor or outdoor environments, other industrial

D
applications for product processing include:

R
FO
• Washing/cleaning/finishing

ED
• Phosphatizing or similar treatments

IZ
• Solvent degreasing O
R
• Paint stripping
TH

• Baking/drying
AU

• Prime and finish painting

• Freezing
T
O

• Cooling
-N

• Clean room
ee

• Food and pharmaceutical handling

itt
m

• Other selection tote return

om

• Irradiation
C
g

Product carriers are especially designed to suit secure handling while providing ease in loading and unloading,
in
dl

whether this is done manually, semi-automatically, or automatically. Further design considerations are required
an

where the product is processed and not merely transported.

H
t
ni

With adequate part (or carrier) clearance within recommended allowable loading, any type of product may
-U
w

be transported. Carriers may be in the form of hooks, slings, boxes, fixtures, racks, trays, baskets, or one of other
ie

numerous configurations designed to suit the application requirement.

ev
R

The preferred conveyor system uses standard components wherever possible in the principal interest of
A
EM

economics (minimum cost). Countless specially designed components are available and are used where required.
rC

In this event, it is recommended that the manufacturer be consulted. While this standard relates to continuous
powered chain monorail conveyors, overhead monorail conveyors fall into four main classifications:
Fo

• Horizontal manual push monorail conveyor

• Continuous powered (chain/cable) monorail conveyor
• Power and free monorail conveyor
• Electrified monorail conveyor

Typically each of these classifications relies upon a track section that is either floor supported or is suspended

4 of 40
 CEMA Std. 601 - 2019

with "hanging steel" from the building structure. Under-guarding is required in areas below the conveyor path
anywhere that area is accessible to people. The under-guarding must be properly labeled cautioning against its use
as service access and should not be accessible to any but maintenance personnel.

Horizontal Manual Push Monorail Conveyor

Horizontal Manual Push Monorail Conveyors generally utilize either an “I” beam track with wheeled trolleys
running on the beam flanges or they utilize a box formed, tubular or fabricated “enclosed “track with internal trolleys
running on the inside track flanges. Products, or carriers designed to support the product can be suspended from

9
one or more trolleys dependent upon capacity and curve clearance requirements. Because trolleys are independent

01
of each other, and rely on an operator to move the trolley, manual push monorail conveyors can be very flexible and

/2
are not restricted to only straight line or circular paths, layouts can also provide for change of carrier direction. The

1
/1
layout can include not only curved track sections but also track switches and spurs, trolley escapements and stops

-6
N
and also trolley turntables. In more sophisticated arrangements, gravity flow of carriers on pitched track sections

O
can be included. However, keep in mind that in gravity applications, the carrier either manually or with a powered

TI
assist, must be returned to the higher track elevations, a version of Power and Free Monorail. (Inverted “T” section

U
IB
tracks and light tubular tracks are offered by some manufacturers for very light duty applications).

TR
IS
Continuous Powered (chain/cable) Monorail Conveyor

D
Continuous Powered (chain/cable) Monorail Conveyors, similarly, utilize both the “I” beam track and the

R
FO
enclosed track configurations. With the “I” beam track, intermittently spaced trolleys are connected in series, to
each other, by rivetless chain, coil chain or cable depending upon the manufacturer’s design. Enclosed track designs

ED
for powered monorail, typically integrate both horizontal guide wheels and vertical load carrying wheels into the

IZ
interconnecting chain (not an independent trolley) which then runs within the enclosed track. As with the manual
O
R
push monorail, the powered variant utilizes a box formed, tubular or fabricated enclosed track section. Product or
TH

carriers designed to support the product are suspended from one or more attachments/pendants extending below
AU

the track. On the “I” beam track variant, the attachment/pendant is bolted into and between the trolley halves,
while with the enclosed track variant the attachment/pendant mounts onto an axle within the chain. (Inverted “T”
T
O

section tracks and light tubular tracks are offered by some manufacturers for very light duty applications).
-N
ee

Power and Free Monorail Conveyor

itt
m

Power and Free Monorail conveyors, combine the best features of both non-powered/manual push, and powered
om

conveyors. These conveyors offer the directional flexibility and manual interaction of the manual push systems, but
C

also can incorporate the powering of product carriers to multiple destinations.

g
in
dl

Most power and free designs consist of two parallel tracks either configured as “side by side” or “over/under”.
an

These arrangements, which vary by manufacturer, provide for one of the tracks to support the load bearing trolley/
H

trolleys and carrier/load bar from which the product and/or carrier is suspended. The parallel powered track
t
ni

incorporates drive mechanism and the power chain that provides the motive force. Most often, a chain/trolley
-U

attachment (pusher dog assembly) attached to the chain on the power track latches onto a mating provision on
w
ie

the load bearing trolley. This latching feature can be released or reengaged to allow for mechanical control and in
ev

the “side by side” configuration can reroute to move the power interface to the other side of the carrier/load bar.
R
A
EM

Product carriers may be tracked/routed thru the system by several control methods or even by creating and
rC

utilizing a carriers’ unique “bar code” or "license plate” identity. At decision points within the system, carriers can
be “actively” accumulated, diverted into spur sections, and stopped and/or positioned for automated interface. This
Fo

can also allow for real time management updates of process elements. Other complex actions such as automatic
carrier loading/unloading and carrier rotation can be incorporated into the design. More costly than a straight power
overhead monorail conveyor, power and free conveyors incorporate significantly more sophisticated hardware,
controls, software, and installation elements but can also provide for a controllable process and reporting system.

Electrified Monorail Conveyor

An Electrified Monorail Conveyor (EMC) is an overhead or inverted conveyor where each carrier is self-powered

5 of 40
 CEMA Std. 601 - 2019

via individual electrical gear motors and controls. Typically, conductor bars are mounted to a single track supplying
the electrical power, control and communication to the individual carriers.

EMC systems are well suited to flexible production systems. The conveyor has the ability to operate at a wide
range of speeds from creep to over 300 fpm, along with acceleration, deceleration and precise braking functions.
Transport/Delivery and Assembly are ideal applications for an EMC because of the increased speed and control
flexibility capabilities. Another good application for EMC can be long delivery buffer and storage systems. However,
the relative high cost of individual motorized carriers, compared with the cost of the product, the product they are

9
carrying could offset this advantage.

01
1/2
There are several key elements that contribute to the flexibility of an EMC system layout. Switches of the sliding

/1
or rotating type allow for carriers to transfer horizontally from one monorail and/or process to another. Vertical

-6
N
drop/lift stations or incline and decline rails are other key elements that makes EMC a versatile system.

O
TI
U
Because of its high speed and positioning capabilities and flexibility the EMC is compatible with a variety

IB
of manufacturing processes from storage/delivery systems to automated build lines to sortation systems. The

TR
EMC interface/transit time in/out requirements is relatively low, thus minimizing transfer time in and out of the

IS
manufacturing process.

D
R
FO
Specific Safety Standards (Reference ANSI B20.1)
Safety Considerations

ED
a) In areas where the parted chain, cable, or other linkage would permit a runaway condition on an inclined or

IZ
declined section, and where personnel are present, anti-runaway devices shall be provided. The conveyor
O
R
path may be arranged so that travel of the uncontrolled conveyor will be arrested before it enters an area
TH

where personnel are present.

AU

b) In areas where personnel perform work of a moving conveyor and guards would impair the workers'
performance, the load shall be cradled, hooked, bolted, or otherwise attached to the carrier.
T
O
-N

Guarding
ee

a) Nip points occur at traction wheels, sprockets, caterpillar drives, and roller turns and shall be guarded unless
itt
m

guarded by location.
om

b) The telltale effect of the moving conveyor components serves as a warning device and permits unguarded
C

nip or shear points at heights of less than 2.44 m (8 ft).

g

c) Automatic stops or closures shall prevent a trolley or trolleys from moving off the track during the portion
in
dl

of a cycle when any track end is not aligned with its mating member.
an

d) Hoisting equipment for lift sections or drop sections or both shall stop or control the vertical motion in the
H

event of power failure.

t
ni

e) On inclined or declined conveyors or sections, where personnel are present and there may be an occurrence
-U
w

of uncontrolled movement of a free trolley, arresting devices shall be provided. A rigid pusher dog on the
ie

power chain with positive carrier engagement shall be considered and acceptable means, or the conveyor
ev

path may be arranged so that travel of the uncontrolled free trolley, carrier, or load, or combination thereof,
R

will be arrested before it enters the personnel area.

A
EM

f) Guards shall be provided to restrict unauthorized personnel from entering hazardous loading, unloading,
rC

and transfer areas. When guarding is not feasible, clear and legible warnings shall be provided.
g) Access to lift or drop sections shall be guarded to prevent unauthorized personnel from entering the area.
Fo

Warning signs shall be posted where guarding is not feasible, unless access to lift or drop sections is guarded
by location.
h) Where conveyors are located above personnel, and the possibility exists that the transported product may
fall off for any cause, guards (spill guards) shall be provided.

6 of 40
 CEMA Std. 601 - 2019

SECTION II - DEFINITIONS FOR TROLLEY CHAIN CONVEYORS

Adjustable Speed Drive - A type of drive designed with a speed changing device by which the speed of the conveyor
can be changed.

Air-operated Take-up - A take-up mechanism where adjustments are made automatically by an air cylinder.

Antibackup - See Backstop.

9
01
Antirunaway - A safety device to stop a declining conveyor and thus prevent running away in event of an electrical

/2
or mechanical failure.

1
/1
-6
N
Automatic lubricator - A device used to lubricate the chain, trolley wheels, or other conveyor components

O
automatically as they pass.

TI
U
IB
Automatic Take-up - A take-up mechanism where adjustments are made automatically.

TR
IS
Backstop - A mechanical device to prevent reversal of a loaded conveyor under action of gravity when forward

D
travel is interrupted.

R
FO
Backup Bar - A metal bar used to back up the caterpillar chain of a drive to hold the drive chain dogs in proper

ED
contact with the conveyor chain.

IZ
R
O
Backup Rollers - Series of rollers so mounted as to back up the conveyor chain to hold it in proper relation to the
TH

caterpillar chain dogs.

AU

Balanced Drives - Drives so designed that two or more such drives on a single conveyor may be synchronized to
T
O

pull predetermined shares of the load.

-N
ee

Beam Clamp - A device for gripping the flange of supporting beams or trusses for the purpose of suspending from
itt
m

same a structure such as a conveyor frame or track.

om
C

Bracing - Diagonal or horizontal members used to prevent swaying in conveyor supporting structure.
g
in
dl

Caterpillar Chain - A short endless chain on which dogs or teeth are spaced to mesh with and move, or be moved
an

by, a conveyor chain.

H
t
ni

Caterpillar Chain Dog - A dog or tooth attached to a caterpillar drive chain to provide the driving contact with the
-U

conveyor chain.
w
ie
ev

Caterpillar Drive - A drive equipped with a caterpillar chain to engage with, and provide the propelling force to the
R

conveyor chain.
A
EM
rC

Caterpillar Chain Take-up Sprocket - The non-driving sprocket of a caterpillar drive, adjustable for proper tensioning
of the caterpillar chain.
Fo

Center Link - The loop-shaped link of rivetless chain which provides the bearing surfaces for the pins and permits
passage of the trolley load support members through the chain.

Chain Pin - The pin that is used to connect succeeding links of a chain about which the links pivot.

Change of Elevation - Vertical distance between the upper horizontal track of a vertical curve to the corresponding

7 of 40
 CEMA Std. 601 - 2019

point on the lower horizontal track.

Compound Vertical Curve - An assembly of two single vertical curves with necessary connecting track to accomplish
a change in elevation.

Conveyor Guard - A structure mounted below the conveyor path to protect personnel and equipment below.

Counterweighted Take-up - A take-up mechanism where the adjustment is made automatically by the potential

9
energy of weights.

01
/2
Drive Frame - The structure which supports the drive shaft assembly and machine parts and which contains or

1
/1
supports the motive power or supports the assembly to which the motive power is connected.

-6
N
O
Drive Shaft - Main driving shaft on which the conveyor sprocket is mounted.

TI
U
IB
Drive Sprocket - Sprocket of a caterpillar drive or of a sprocket drive.

TR
IS
Drop - The vertical distance from the bottom of the track to centerline of the chain.

D
R
FO
Finger Guard - Enclosure around trolleys and chain to protect personnel nip/pinch points.

ED
Hanger Steel - Angles or rods by which a conveyor is hung from supports above.

IZ
R
O
Link - A chain unit of one pitch length.
TH
AU

Load Bar - A device to distribute a load over two or more trolleys.

T
O

Machinery Guard - A covering or barricade for safety purposes such as gear, chain, and V-belt guards.
-N
ee

Multiple Drives - Two or more motorized and load-sharing drives applied to a single conveyor for the purpose of
itt
m

reducing the chain tension over the entire conveyor length.

om
C

Rivetless Chain - A completely forged, heat-treated chain comprised of pins, side links, and center links which can
g

be assembled or disassembled without the use of tools.

in
dl
an

Roller Turn - A series of vertical rollers mounted in a frame to guide a conveyor chain around a horizontal curve.
tH
ni

Roller Turn Roller - The vertical roller with integral bearings as used in the roller turn.
-U
w
ie

Screw Take-up - A take-up mechanism having provision for manual adjustment by one or more screws.
ev
R

Side Link - That portion of the chain which longitudinally connects joint portions at each end of the center link
A
EM

with chain pins.

rC

Single Vertical Curve - A section of track bent in a desired curve to change the direction of a conveyor in the vertical
Fo

plane.

Spring Take-up - A take-up mechanism where adjustments are made automatically by the potential energy of springs.

Sprocket Drive - A conveyor chain driving unit using a sprocket to transmit power to the chain, located at a turn of
approximately 90° or more.

8 of 40
 CEMA Std. 601 - 2019

Superstructure - Members to which the hanger steel is connected and which transfer the load to the building
members or floor support columns.

Take-up - The assembly of the necessary structural and mechanical parts which provides the means to adjust the
conveyor length to compensate for chain stretch, shrink, or wear and to maintain proper tension.

Track - The I-beam section on which trolley wheels roll while being propelled.

9
Traction Wheel - A smooth, straight face wheel without dogs or teeth.

01
1/2
Traction Wheel Turn - See Wheel Turn.

/1
-6
N
Trolley - An assembly of two half-trolleys (each with wheel, bearing, and bracket) and an attachment. It is used to

O
support and move suspended loads and to carry the load connecting and conveying chain.

TI
U
IB
Trolley Attachments - Trolley attachment configurations vary depending on the product being transported.

TR
• "B" Bolt Attachment - A trolley attachment having a threaded rod projection for attaching a load bar or various

IS
objects.

D
• "H" Clevis Attachment - A forked or clevis type trolley attachment

R
FO
• "I" Idler Attachment - An attachment used to complete the assembly of a non-load carrying trolley.
• "C" Pendant Attachment - A single bar trolley attachment projecting through the chain having a single hole for

ED
supporting loads.

IZ
R
O
Trolley Brackets - Drop forged, cast, or pressed steel members to which the trolley wheels are attached with
TH

provision for connecting to the chain.

AU

Trolley Conveyor - A series of trolleys supported from an overhead track and connected by an endless propelling
T
O

chain with load usually suspended from the trolley. Trolley conveyors may be designed for single or multiple plane
-N

operation.
ee
itt
m

Trolley Wheel - The wheel with integral bearing mounted to the trolley bracket.
om

• Full Complement - Maximum number of balls without a retainer.

C

• Retainer - Balls are separated by a retainer for low friction.

g
in
dl

Wheel Turn - A horizontal turn employing a traction wheel which guides the conveyor chain around a horizontal curve.
an
tH
ni
-U
w
ie
ev
R
A
EM
rC
Fo

9 of 40
 CEMA Std. 601 - 2019

SECTION III - CONVEYOR COMPONENTS

Rivetless Chain Dimensions - Drop Forged

9
01
1/2
/1
-6
N
O
TI
U
IB
TR
G H I

IS
D E
B C Min. Min. Min.

D
A* Height of Max. F
Height of Max. Length Length Inside

R
Chain Nominal Center Overall Diameter

FO
Center Width of of Pin of Flat on Width of
Type Pitch Link at Length of of Pin
Link Chain Between Center Center

ED
[in (mm)] Flat Pin [in (mm)]
[in (mm)] [in (mm)] Heads Link Link
[in (mm)] [in (mm)]

IZ
[in (mm)] [in (mm)] [in (mm)]
R
O
X-228 0.47 0.69 0.38 1.13 0.25 0.83 1.06 0.31
2 (50.8)
TH

(X-50-6) (11.91) (17.46) (9.53) (28.57) (6.35) (21.03) (26.99) (7.94)

AU

X-348 0.75 1.09 0.5 1.84 0.5 1.28 1.63 0.56

3 (76.2)
(X-75-13) (19.05) (27.78) (12.7) (46.83) (12.7) (32.54) (41.28) (14.29)
T
O

X-458 1 1.41 0.63 2.25 0.63 1.63 2.25 0.69

-N

4 (101.6)
(X-100-16) (25.4) (35.72) (15.88) (57.15) (15.88) (41.28) (57.15) (17.46)
ee
itt

X-678 1.28 2 0.81 3.13 0.88 2.25 3.38 0.97

6 (152.4)
m

(X-150-22) (32.54) (50.8) (20.64) (79.38) (22.23) (57.15) (85.73) (24.61)

om

* Actual pitch varies from nominal.

C
g
in

Average Length of Production Chain

dl
an
H

Average Length of
Chain Assembled Weight
t

Nominal 10 ft Strand
ni

Type [lbs/ft (kg/m)]

-U

[in (mm)]
w

X-228
ie

120.60 (3063.24) 0.75 (1.12)

(X-50-6)
ev
R

X-348
120.60 (3063.24) 2.10 (3.13)
A

(X-75-13)
EM

X-458
rC

120.80 (3068.32) 3.10 (4.61)

(X-100-16)
Fo

X-678
120.90 (3070.86) 6.10 (9.08)
(X-150-22)

10 of 40
 CEMA Std. 601 - 2019

Trolley Dimensions - Vertical Bolts (most common)

9
01
1/2
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
J K Min.
L Max.
H Max. Centerline of Minimum

ED
Overall
Width of Lubrication Distance

IZ
Chain Drop Width of
I-Beam Size Trolley R Fitting to Between
Type [in (mm)] Trolley
O
Bracket Bottom of Wheel Inside
Assembly
TH

[in (mm)] Beam Faces

[in (mm)]
AU

[in (mm)] [in (mm)]

3 in @ 5.7 lbs/ft X-348
T

2.5 (63.5) 1.63 (41.28) 1.44 (36.51) 0.63 (15.88) 4.25 (107.95)
O

(76.2 mm @ 8.48 kg/m) (X-75-13)

-N

3.19 (80.96) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.38 (136.53)
ee

4 in @ 7.7 lbs/ft X-458

(101.6 mm @ 11.45 kg/m) (X-100-16) 4 (101.6) 2.25 (57.15)
itt

1.88 (47.63) 0.63 (15.88) 5.5 (139.7)

m

6 in @ 12.5 lbs/ft X-678

om

4 (101.6) 3.38 (85.73) 2.69 (68.26) 0.75 (19.05) 7.63 (193.68)

(152.4 mm @ 18.60 kg/m) (X-150-22)
C
g
in

P Min.
dl

M Max.
an

N O Interface of
Clearance Q Max.
H

Centerline Centerline Dimension

Width of Centerline
t

of Chain to of Chain to from

ni

Chain Trolley of Chain to

-U

I-Beam Size Centerline Centerline Centerline

Type Bracket at Bottom of
w

of Upper of Lower of Chain

Lubrication Bracket
ie

Bolt Hole Bolt Hole to Trolley

ev

Fitting [in (mm)]

[in (mm)] [in (mm)] Bracket
R

[in (mm)]
[in (mm)]
A
EM

3 in @ 5.7 lbs/ft X-348

3.81 (96.84) 1 (25.4) 0.88 (22.23) 1.06 (26.99) 1.31 (33.34)
rC

(76.2 mm @ 8.48 kg/m) (X-75-13)

Fo

4 in @ 7.7 lbs/ft X-458 4.63 (117.48) 1.31 (33.34) 0.81 (20.64) 1.25 (31.75) 1.31 (33.34)
(101.6 mm @ 11.45 kg/m) (X-100-16) 4.63 (117.48) 1.31 (33.34) 0.81 (20.64) 1.25 (31.75) 1.31 (33.34)
6 in @ 12.5 lbs/ft X-678
7.63 (193.68) 1.63 (41.27) 1.13 (28.58) 1.56 (39.69) 1.75 (44.45)
(152.4 mm @ 18.60 kg/m) (X-150-22)
NOTE: P Min. is measured vertically at outside edge of chain.

11 of 40
 CEMA Std. 601 - 2019

T Min.
S
R Slope of
Diameter of
Thickness of Wheels
I-Beam Size Chain Type Mounting
Attachments from the
Bolts
[in (mm)] Vertical
[in (mm)]
[deg.]
3 in @ 5.7 lbs/ft X-348
0.25 (6.35) 0.31 (7.94) 1
(76.2 mm @ 8.48 kg/m) (X-75-13)

9
4 in @ 7.7 lbs/ft X-458 0.38 (9.53) 0.38 (9.53) 1

01
(101.6 mm @ 11.45 kg/m) (X-100-16)

/2
0.38 (9.53) 0.38 (9.53) 1

1
/1
6 in @ 12.5 lbs/ft X-678
0.5 (12.7) 0.5 (12.7) 1

-6
(152.4 mm @ 18.60 kg/m) (X-150-22)

N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
t H
ni
-U
w
ie
ev
R
A
EM
rC
Fo

12 of 40
 CEMA Std. 601 - 2019

Trolley Dimensions - Horizontal Bolts

9
01
1/2
/1
-6
N
O
TI
U
IB
TR
IS
J K Min.

D
L Max.
H Max. Centerline of Minimum

R
Overall

FO
Width of Lubrication Distance
Chain Drop Width of
I-Beam Size Trolley Fitting to Between

ED
Type [in (mm)] Trolley
Bracket Bottom of Wheel Inside
Assembly

IZ
[in (mm)] Beam Faces
R [in (mm)] [in (mm)]
[in (mm)]
O
TH

4 in @ 7.7 lbs/ft X-458 3.81 (96.84) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.38 (136.53)
AU

(101.6 mm @ 11.45 kg/m) (X-100-16) 4 (101.6) 2.25 (57.15) 1.88 (47.63) 0.63 (15.88) 5.5 (139.7)
T

6 in @ 12.5 lbs/ft X-678

O

4 (101.6) 3.38 (85.73) 2.69 (68.26) 0.75 (19.05) 7.63 (193.68)

(152.4 mm @ 18.60 kg/m) (X-150-22)
-N
ee
itt

P Min.
m

M Max.
N Interface of
om

Clearance
Centerline Dimension S
Width of R
C

of Chain to from Diameter of

g

Chain Trolley Thickness of

in

I-Beam Size Centerline Centerline Mounting

Type Bracket at Attachments
dl

of Upper of Chain Bolts

an

Lubrication [in (mm)]

Bolt Hole to Trolley [in (mm)]
H

Fitting
[in (mm)] Bracket
t

[in (mm)]
ni

[in (mm)]
-U

4.94 (125.41) 1.88 (47.63) 1.25 (31.75) 0.63 (15.88) 0.38 (9.53)
w

4 in @ 7.7 lbs/ft X-458

ie

(101.6 mm @ 11.45 kg/m) (X-100-16) 4.75 (120.65) 2 (50.8) 1.25 (31.75) 0.63 (15.88) 0.38 (9.53)
ev
R

6 in @ 12.5 lbs/ft X-678

7.63 (193.68) 2.5 (63.5) 1.56 (39.69) 0.88 (22.23) 0.5 (12.7)
A

(152.4 mm @ 18.60 kg/m) (X-150-22)

EM

NOTE: P Min. is measured vertically at outside edge of chain

rC
Fo

13 of 40
 CEMA Std. 601 - 2019

W
T Min.
Distance
Slope of
Chain Between
I-Beam Size Wheels from
Type Centerline of
the Vertical
Bolt Holes
[deg.]
[in (mm)]
4 in @ 7.7 lbs/ft X-458 2 1.38 (34.93)
(101.6 mm @ 11.45 kg/m) (X-100-16) 2 1.38 (34.93)

9
01
6 in @ 12.5 lbs/ft X-678
2 2 (50.8)

/2
(152.4 mm @ 18.60 kg/m) (X-150-22)

1
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
t H
ni
-U
w
ie
ev
R
A
EM
rC
Fo

14 of 40
 CEMA Std. 601 - 2019

Trolley Dimensions - For X-228 Chain

9
01
1 /2
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
J K Min.
L Max.
H Max. Centerline of Minimum

IZ
Overall
Width of R Lubrication Distance
Chain Drop Width of
O
I-Beam Size Trolley Fitting to Between
Type [in (mm)] Trolley
TH

Bracket Bottom of Wheel Inside

Assembly
AU

[in (mm)] Beam Faces

[in (mm)]
[in (mm)] [in (mm)]
T
O

2 in @ 3.76 lbs/ft X-228

-N

1.88 (47.63) 1 (25.4) 0.56 (14.29) 4.69 (119.06) 3.5 (88.9)

(50.8 mm @ 5.59 kg/m) (X-50-6)
ee
itt
m

P Min.
om

M Max.
N O Interface of
Clearance Q Max.
C

Centerline Centerline Dimension

Width of Centerline
g

of Chain to of Chain to from

in

Chain Trolley of Chain to

dl

I-Beam Size Centerline Centerline Centerline

Type Bracket at Bottom of
an

of Upper of Lower of Chain

Lubrication Bracket
H

Bolt Hole Bolt Hole to Trolley

Fitting [in (mm)]
t
ni

[in (mm)] [in (mm)] Bracket

[in (mm)]
-U

[in (mm)]
w

2 in @ 3.76 lbs/ft X-228

ie

0.75 (19.05) 1.91 (48.42) 0.97 (24.61) 3.41 (86.52) 0.25 (6.35)
ev

(50.8 mm @ 5.59 kg/m) (X-50-6)

R

NOTE: P Min. is measured vertically at outside edge of chain

A
EM

T Min.
rC

S
R Slope of
Fo

Diameter of
Thickness of Wheels
I-Beam Size Chain Type Mounting
Attachments from the
Bolts
[in (mm)] Vertical
[in (mm)]
[deg.]
2 in @ 3.76 lbs/ft X-228
0.19 (4.76) 1.03 (26.19) 5.5
(50.8 mm @ 5.59 kg/m) (X-50-6)

15 of 40
 CEMA Std. 601 - 2019

Trolley Attachment Dimensions - Vertical Bolts (Most Common)

9
01
1 /2
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
N U
TH

Centerline R S Width of
V
AU

I-Beam Size of Chain to Thickness Diameter of Opening

Chain Width of
Centerline of Mounting Between
T

Type Attachment
O

of Bolt Attachment Bolts Assembled

-N

[in (mm)]
Holes [in (mm)] [in (mm)] Clevis Halves
ee

[in (mm)] [in (mm)]

itt
m

3 in @ 5.7 lbs/ft X-348

1 (25.4) 0.25 (6.35) 0.31 (7.94) 0.56 (14.29) 1.5 (38.1)
om

(76.2 mm @ 8.48 kg/m) (X-75-13)

C

4 in @ 7.7 lbs/ft X-458

1.31 (33.34) 0.38 (9.53) 0.38 (9.53) 0.69 (17.46) 2.13 (53.98)
g

(101.6 mm @ 11.45 kg/m) (X-100-16)

in
dl

6 in @ 12.5 lbs/ft X-678

an

1.63 (41.28) 0.5 (12.7) 0.5 (12.7) 0.81 (20.64) 3 (76.2)

(152.4 mm @ 18.60 kg/m) (X-150-22)
t H
ni
-U

X
W Y
w

Centerline Centerline Z
Distance AA
ie

of Chain to of Load Hole

ev

Between Diameter of
Chain Centerline Mounting Diameter
R

I-Beam Size Centerlines Rod on Bolt

Type of Load Hole to for Load
A

of Bolt Attachment
EM

Mounting Bottom of Mounting

Holes [in (mm)]
Hole Attachment [in (mm)]
rC

[in (mm)]
[in (mm)] [in (mm)]
Fo

3 in @ 5.7 lbs/ft X-348

1.88 (47.63) 3.13 (79.38) 0.63 (15.88) 0.5 (12.7) 0.5 (12.7)
(76.2 mm @ 8.48 kg/m) (X-75-13)
4 in @ 7.7 lbs/ft X-458
2.13 (53.98) 2.88 (73.03) 0.75 (19.05) 0.5 (12.7) 0.63 (15.88)
(101.6 mm @ 11.45 kg/m) (X-100-16)
6 in @ 12.5 lbs/ft X-678
2.75 (69.85) 3.63 (92.08) 1.13 (28.58) 0.75 (19.05) 0.88 (22.23)
(152.4 mm @ 18.60 kg/m) (X-150-22)

16 of 40
 CEMA Std. 601 - 2019

AD
Centerline AE
AC
AB of Load Centerline
Overall
Thickness Mounting of Chain
Chain Length of
I-Beam Size of Clevis Hole to to Bottom
Type Rod on Bolt
Half Inside Bend of Bolt
Attachment
[in (mm)] Line of Clevis Attachment
[in (mm)]
Attachment [in (mm)]
[in (mm)]

9
01
3 in @ 5.7 lbs/ft X-348

/2
0.13 (3.18) 1.81 (46.04) 1 (25.4) 4.25 (107.95)
(76.2 mm @ 8.48 kg/m) (X-75-13)

1
/1
4 in @ 7.7 lbs/ft X-458

-6
0.19 (4.76) 2.13 (53.98) 1 (25.4) 4.94 (125.41)
(101.6 mm @ 11.45 kg/m) (X-100-16)

N
O
6 in @ 12.5 lbs/ft X-678

TI
0.25 (6.35) 3 (76.2) 1.13 (28.58) 6.13 (155.58)
(152.4 mm @ 18.60 kg/m) (X-150-22)

U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
t H
ni
-U
w
ie
ev
R
A
EM
rC
Fo

17 of 40
 CEMA Std. 601 - 2019

Trolley Attachment Dimensions - Horizontal Bolts

9
01
1 /2
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH

N U
AU

Centerline R S Width of
V
T

of Chain to Thickness Diameter of Opening

Chain Width of
O

I-Beam Size Centerline of Mounting Between

-N

Type Attachment
of Bolt Attachment Bolts Assembled
ee

[in (mm)]
Holes [in (mm)] [in (mm)] Clevis Halves
itt

[in (mm)] [in (mm)]

m
om

4 in @ 7.7 lbs/ft X-458

2 (50.8) 0.63 (15.88) 0.37 (9.53) 0.69 (17.46) 2.25 (57.15)
C

(101.6 mm @ 11.45 kg/m) (X-100-16)

g

6 in @ 12.5 lbs/ft X-678

in

2.5 (63.5) 0.88 (22.23) 0.5 (12.7) 0.88 (22.23) 3.38 (85.73)
dl

(152.4 mm @ 18.60 kg/m) (X-150-22)

an
H

X Y
t
ni

W
Centerline Centerline Z
-U

Distance AA
of Chain to of Load Hole
w

Between Diameter of
ie

Chain Centerline Mounting Diameter

ev

I-Beam Size Centerlines Rod on Bolt

Type of Load Hole to for Load
R

of Bolt Attachment
Mounting Bottom of Mounting
A

Holes [in (mm)]

EM

Hole Attachment [in (mm)]

[in (mm)]
[in (mm)] [in (mm)]
rC

4 in @ 7.7 lbs/ft X-458

Fo

1.38 (34.93) 3 (76.2) 0.75 (19.05) 0.56 (14.29) 0.63 (15.88)

(101.6 mm @ 11.45 kg/m) (X-100-16)
6 in @ 12.5 lbs/ft X-678
2 (50.8) 3.63 (92.08) 1 (25.4) 0.81 (20.64) 1 (25.4)
(152.4 mm @ 18.60 kg/m) (X-150-22)

18 of 40
 CEMA Std. 601 - 2019

AD
AE AN
AC Centerline of
AB Centerline Centerline of
Overall Load Mounting
Thickness of Chain Load Mounting
Chain Length of Hole to Inside
I-Beam Size of Clevis to Bottom Hole to Bottom
Type Rod on Bolt Bend Line
Half of Bolt of Pendant
Attachment of Clevis
[in (mm)] Attachment Attachment
[in (mm)] Attachment
[in (mm)] [in (mm)]
[in (mm)]

9
4 in @ 7.7 lbs/ft X-458

01
0.31 (7.94) 4 (101.6) 1.81 (46.04) 4.63 (117.48) 0.81 (20.64)
(101.6 mm @ 11.45 kg/m) (X-100-16)

1/2
6 in @ 12.5 lbs/ft X-678
0.25 (6.35) 3.25 (82.55) 1.69 (42.86) 6.16 (156.37) --

/1
(152.4 mm @ 18.60 kg/m) (X-150-22)

-6
N
O
AP AR

TI
U
Bolt Thickness

IB
Diameter of Pendant
Chain

TR
I-Beam Size for Pendant Load
Type

IS
Load Mounting

D
Mounting Boss

R
[in (mm)] [in (mm)]

FO
4 in @ 7.7 lbs/ft X-458
0.81 (20.64) 0.5 (12.7)

ED
(101.6 mm @ 11.45 kg/m) (X-100-16)

IZ
6 in @ 12.5 lbs/ft X-678
(152.4 mm @ 18.60 kg/m) (X-150-22)
-- -- R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
t H
ni
-U
w
ie
ev
R
A
EM
rC
Fo

19 of 40
 CEMA Std. 601 - 2019

Roller Turn Dimensions

9
01
1 /2
/1
-6
N
O
TI
U
IB
Drop AL Min. Degrees of Turn

TR
Bottom of Beam Bottom of Nominal

IS
Chain
I-Beam Size to Centerline of Beam to Top Radius

D
Type 30 45 60 90 180
Chain of Roller Hub [in (mm)]

R
FO
[in (mm)] [in (mm)]
18 (457.2)     

ED
24 (609.6)     

IZ
3 in @ 5.7 lbs/ft X-348
2.5 (63.5) R
1.44 (36.51) 30 (762)     
O
(76.2 mm @ 8.48 kg/m) (X-75-13)
TH

36 (914.4)     
AU

48 (1219.2)     
18 (457.2)
T

    
O

24 (609.6)
-N

    
ee

30 (762)     
itt

3.19 (80.96) 1.94 (49.21) 36 (914.4)     

m
om

48 (1219.2)     
C

60 (1524)     
g
in

4 in @ 7.7 lbs/ft X-458 72 (1828.8)     

dl

(101.6 mm @ 11.45 kg/m) (X-100-16)

an

18 (457.2)     
H

24 (609.6)     
t
ni

30 (762)     
-U

4 (101.6) 2.75 (69.85) 36 (914.4)

w

    
ie

48 (1219.2) 
ev

   
R

60 (1524)     
A

72 (1828.8) 
EM

   
24 (609.6)     
rC

30 (762)
Fo

    
6 in @ 12.5 lbs/ft X-678 36 (914.4)     
4 (101.6) 2.44 (61.91)
(152.4 mm @ 18.60 kg/m) (X-150-22) 48 (1219.2)     
60 (1524)     
72 (1828.8)     
 Standard Size

20 of 40
 CEMA Std. 601 - 2019

Traction Wheel Turn Dimensions

9
01
1/2
Drop AF Min. AL Min. Degrees of Turn

/1
-6
Bottom of Height of Bottom
Nominal

N
Chain Beam to Traction of Beam

O
I-Beam Size Diameter
Type Centerline Wheel to Top of 30 45 60 90 180

TI
[in (mm)]
of Chain Rim Roller Hub

U
IB
[in (mm)] [in (mm)] [in (mm)]

TR
18 (457.2)     

IS
24 (609.6)     

D
R
30 (762)     

FO
3 in @ 5.7 lbs/ft X-348
2.5 (63.5) 2 (50.8) 1.44 (36.51) 36 (914.4)     
(76.2 mm @ 8.48 kg/m) (X-75-13)

ED
42 (1066.8)  

IZ
48 (1219.2)  
R
O
60 (1524)  
TH

18 (457.2)    
AU

24 (609.6)     
T
O

30 (762)     
-N

3.19 36 (914.4)     
ee

1.94 (49.21)
(80.96) 42 (1066.8)
itt

 
m

48 (1219.2)  
om

60 (1524)  
C
g

4 in @ 7.7 lbs/ft X-458 72 (1828.8)  

in

2.5 (63.5)
dl

(101.6 mm @ 11.45 kg/m) (X-100-16) 18 (457.2)    

an

24 (609.6)     
H t

30 (762)     
ni
-U

36 (914.4)     
w

4 (101.6) 2.75 (69.85)

ie

42 (1066.8)  
ev

48 (1219.2)  
R

60 (1524)
A

 
EM

72 (1828.8)  
rC

24 (609.6)   
Fo

36 (914.4)     
6 in @ 12.5 lbs/ft X-678 42 (1066.8)     
4 (101.6) 3 (7.62) 2.44 (61.91)
(152.4 mm @ 18.60 kg/m) (X-150-22) 48 (1219.2)     
60 (1524)  
72 (1828.8)  
 Standard Size

21 of 40
 CEMA Std. 601 - 2019

SECTION IV - DESIGN PROCEDURE AND ENGINEERING DATA

Overhead Trolley Conveyor Symbols - Plan View

HORIZONTAL STRAIGHT CONVEYOR VERTICAL CURVE

9
01
/2
DIRECTION OF TRAVEL

1
EL

EL

/1
-6
N
O
TI
U
IB
TR
CATERPILLAR DRIVE

IS
D
R
FO
ED
ROLLER TURN TRACTION WHEEL SPROCKET DRIVE

IZ
R
O
ROLLER TURN TAKE-UP
TH

CONVEYOR GUARD
AU
SPREAD

T
O
-N
ee
itt
m
om
C

TRACTION WHEEL TAKE-UP

g

OVEN, WASHER, OR SPRAY

in

BOOTH ENCLOSURE
dl

SPREAD
an
DIA

OVEN
H

TEMP.
t
ni
-U
w
ie
ev
R

EXPANSION JOINT ANTI-BACKUP ANTI-RUNAWAY

A
EM

EL
EL
EL
EL
rC

UP DOWN
Fo

22 of 40
 Fo Typical Trolley Conveyor Installation
rC
EM
A
R
ev
ie
w
-U
ni
t H
an
dl
in
g
C
om
m
itt
ee
-N
O
T

23 of 40
AU
TH
O
R
IZ
ED
FO
R
D
IS
TR
IB
U
TI
O
N
-6
See Guards at the /1
end of this section 1/2
for more information 01
9
CEMA Std. 601 - 2019
 CEMA Std. 601 - 2019

Design Steps

Metric Conversion: Calculations may be performed in the English system, as shown, or in metric.

The following steps will assist you in designing an Overhead Trolley Conveyor System:

Step A. Draw Plant Layout

1. Draw Layout to largest practical scale. For example: 1/4 in =1 ft or 1/8 in = 1 ft (50:1 or 100:1)
2. Make a plan view of plant area in which the conveyor is to be erected. Show dimensioned column or

9
01
bay lines. Indicate “North” direction relative to building.

/2
3. Locate and label all obstructions which affect the path of the conveyor, such as columns, walls, machinery,

1
/1
work areas, and aisles on the plan view.

-6
N
O
Step B. Design a Carrier

TI
1. Determine number of parts to be placed on each carrier and their relative position on carrier. Make the

U
IB
carrier as compact as possible.

TR
2. Design carrier to permit easy loading and unloading of parts.

IS
3. Design the carrier to carry loads within the rated capacity of the trolley. Trolley capacities are listed in

D
this section.

R
4. Design carrier bracket to fit a trolley attachment to which the load or carrier can most easily be attached,

FO
keeping within the load ratings.

ED
5. Standard trolley attachments can be selected from the data and illustrations in this section.

IZ
Step C. Determine Conveyor Size R
O
TH

1. Select a trolley arrangement, either a single trolley with attachment or double trolley with load bar, in
AU

this section that has a capacity rating exceeding the total weight of the carrier designed in Step B and
the carried load.
T
O

2. The trolley size will determine the size of the conveyor in the average conveyor application. However,
-N

the chain pull, as calculated in Step N, must not exceed the recommended capacity for the selected size
ee

chain as shown in this section.

itt
m
om

Step D. Determine Track Elevations

C

1. Elevations are measured from floor line to top of I-beam track.

g

2. At loading, unloading, and manual operating stations, the conveyor height must permit an operator to
in
dl

access the carrier easily.

an

3. The conveyor height over work areas and aisles must allow traffic to pass freely conveyor under guards.
H

4. Indicate the elevation at all vertical curves. See typical conveyor layout at beginning of this section.
t
ni
-U

Step E. Determine Material flow

w
ie

1. On plant layout, locate all load and unload points and, also, any processing stations that will be served
ev

by the conveyor. Typical stations: Dip tanks, paint booths, bake ovens (indicate temperature).
R

2. Draw conveyor route so that it connects all areas in their proper work sequence with the most practical
A
EM

path for the system, using standard components where possible. Keep parallel conveyor routes as closely
spaced as possible to reduce the amount of supporting members and guards required.
rC

3. Be sure the path of conveyor does not interfere with any machine operations or work areas.
Fo

4. Indicate location of drive, take-up, vertical curves, and horizontal turns relative to column lines. Refer
to typical layout and conveyor symbols and glossary at beginning of this section.

Step F. Select Vertical Curves

1. For increased conveyor life, use the largest recommended radius possible for vertical curves in your
layout. Use minimum radius vertical curves only in conveyor areas where necessary. See vertical curve
radii chart, section V.

24 of 40
 CEMA Std. 601 - 2019

2. Select a load spacing.

3. Using Figure 9, select a degree of incline for vertical curves that will provide a clearance between carriers,
or load silhouette when they are moving on the incline. To assure clearance between carriers, dimension
“A” must be greater than carrier length.
4. Because of carrier sway, clearance must be provided between top of carrier and conveyor chain.
5. Indicate on layout drawing the horizontal length (tangent to tangent) of each vertical curve, its radius
and degree.
6. Locate each vertical curve relative to some adjacent component, as shown on typical conveyor layout

9
at beginning of this section.

01
/2
1
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH
AU
T

Figure 9.
O
-N

Step G. Select Horizontal Turns

ee

1. Make a plan view layout of horizontal turn, as shown in Figure 10. Clearance between adjacent carriers
itt
m

or maximum load silhouette while they are negotiating turns will determine the minimum horizontal
om

turn radius.
C

2. For increased conveyor life, use the largest standard radius possible for horizontal turns in your layout.
g

Select the horizontal turns best suited to your requirements from Section III, Conveyor Components.
in
dl

3. Provide for one (1) 180° horizontal turn in your layout, as near as possible on the output side of the drive
an

unit, for use as a slack chain take-up. If possible, place this take-up at the bottom of a vertical curve.
H
t
ni
-U
w
ie
ev
R
A
EM
rC

CLEARANCE
Fo

Figure 10. Plan View Layout of Horizontal Turn

Step H. Determine Guard Requirements

1. For standard guard methods, refer to the end of this section.
2. Select type of conveyor guard best suited to your requirements and which meets all safety specifications.

25 of 40
 CEMA Std. 601 - 2019

3. Be sure loaded carriers will clear all guards. 6 in clearance on each side is usually sufficient. It is especially
important to check clearances on horizontal and vertical curves. Carrier templates can be used for this
purpose. If maintenance access is required from inside the conveyor guard, increase clearance on one
side by a minimum of 24 in.
4. Locate each guard relative to some adjacent conveyor component or column line as shown on typical
conveyor layout at beginning of this section.

Step I. Determine Trolley Spacing

9
1. To determine the trolley spacing, refer to Step F, Numbers 3, 4 and 5, then go to Step G, Number 1.

01
Note the carrier spacing selected for proper clearances. Refer to Table 4 and note the recommended

1 /2
spacing for trolleys. If your required carrier spacing is greater than the recommended trolley spacing,

/1
intermediate trolleys are required.

-6
N
2. When laying out the conveyor path, a distance equal to the maximum trolley spacing selected should

O
be allowed between tangent lines of vertical curves and horizontal turns.

TI
U
IB
Step J. Determine Maximum Conveyor Speed

TR
1. A speed of 50 to 70 fpm is normally considered as maximum. However, 30 fpm usually allows easy

IS
loading and unloading and assures longer conveyor life. Lowest possible speeds are recommended to

D
suit required production. Required conveyor speed in fpm is equal to the number of carriers per minute

R
FO
multiplied by carrier spacing in ft.
2. To illustrate this formula:

ED
a. Assume your production rate is 1,200 parts per hour.

IZ
b. Assume each carrier holds four (4) parts. O
R
c. Required number of carriers per hour equals 1,200 divided by 4 or 300 carriers.
TH

d. Required number of carriers per minute is 300 divided by 60 or 5 carriers.

AU

e. Assume a carrier spacing of 24 in or 2 ft.

f. Five (5) carriers per minute multiplied by carrier spacing of 2 ft equals a conveyor speed of 10 fpm.
T
O

3. To allow for variation in production requirements, it is advisable to set a maximum speed of about two
-N

times that calculated. A variable speed drive with a speed range of about 3 to 1 is the most common.
ee

a. The maximum speed is 20 fpm or 2 x 10 fpm.

itt
m

b. Using a 3 to 1 ratio variable speed drive would give you a speed range of 6.6 fpm to 20 fpm.
om
C

Step K. Determine Conveyor Length

g

1. Obtain the sum of all straight track dimensions.

in
dl

2. Obtain the sum of all arc lengths on the horizontal turns.

an

3. Obtain the sum of all arc lengths on the vertical curves by using the vertical curve charts in Section V,
H

Vertical Curve Data.

t
ni

4. The total length of the conveyor is equal to the sum of steps 1, 2, and 3.
-U
w
ie

Step L. Determine Moving Load

ev

1. The moving load on a conveyor is equal to the sum of the weights of all moving parts—chain, trolleys,
R

carriers, and loads.

A
EM

2. Establish distances from loading to unloading points and determine the number of loaded and empty
rC

carriers in the system during maximum loading of conveyor.

3. The following example illustrates the procedure for determining moving load assuming the conveyor is
Fo

300 ft long, carriers are at 2 ft centers, and distance from loading to unloading points is 250 ft.
300 ft X-458 chain with trolleys at 2 ft centers at 7.1 Ibs/ft = 2,130 Ibs
125 loaded carriers at 250 Ibs each = 31,250 Ibs
25 empty carriers at 20 Ibs each = 500 Ibs
The total moving load is 33,880 lbs

26 of 40
 CEMA Std. 601 - 2019

Step M. Determine Lift Load

1. The lift load is the amount of force required to pull the moving load upward along the vertical curves
in the entire system.
2. To calculate this force, determine the net difference in elevation of all the loaded vertical curves (inclines
and declines) in the system. This net vertical rise or fall (ft) will be considered the total lifting height of
the conveyor.
3. The lift load or chain pull for the elevation changes of the conveyor is equal to the total lift height (ft)
multiplied by the individual load weight (lbs), then divided by the load spacing (ft).

9
01
Example: Assume that the net elevation change of all loaded vertical curves results in a total rise or

/2
1
lifting height of 12 ft, the load on each carrier is 230 Ibs, and the carriers are on 2 ft centers.

/1
-6
N
12 ft x 230 lbs

O
Lift Load = = 1,380 lbs
2 ft

TI
U
IB
The chain, trolleys, and carriers are excluded from the calculations because they are balanced by the

TR
portion of the system that moves down the vertical curves.

IS
D
NOTE: If the net difference of elevation in the system is negative due to greater elevation change as a

R
FO
result of loaded declines, the lift load resultant will be negative.

ED
Step N. Determine Chain Pull

IZ
1. Chain pull is the effort necessary to maintain the normal operating speed of a conveyor under a rated
R
O
capacity load. To arrive at this final driving effort, it is necessary to add the lift load and the friction
TH

factors, expressed as a small percentage of the moving load, which act as resistance to the progress of
AU

the conveyor. The moving load and the lift load were calculated in Steps L and M.
T

2. Frictional resistance is found in the bearings of the trolley wheels, roller or traction wheel turns, vertical
O

curves, and the drive unit itself. This friction figure is represented as a small percentage and is listed
-N

in the table below for each conveyor size. It should be noted that these percentages are for average
ee
itt

conveyors which travel under normal conditions.

m

3. Select from Table 1 the friction factor indicated for your conveyor size.
om

NOTES:
C

- A large number of vertical and horizontal curves will create slightly higher friction.
g
in

- The conveyor manufacturer should be consulted for specific information on friction factors.
dl
an

Table 1. Friction Factors

tH

Ball Bearing Trolleys

ni
-U

Operating Conditions (in)

w

2 3 4 6
ie
ev

32°F to 250°F (0°C to 121°C) - Average Good Conditions 2.5 2 1.75 1.5
R

250°F to 375°F (121°C to 191°C) - Auto Oil Lubrication 3.5 3 2.5 2

A
EM

For adverse environmental conditions and temperature

-- -- -- --
over 375°F (191°C), consult manufacturer
rC
Fo

4. To determine chain pull due to friction, multiply total moving load by selected friction factor. Using
figures from previous examples, the following illustrates proper procedure:
Total moving load (from Step L) = 33,880 lbs
Multiply by friction factor (Table 1) = 0.025
Friction chain pull = 847 Ibs
5. Add lift load to friction chain pull to obtain total chain pull:
Friction chain pull = 847 Ibs

27 of 40
 CEMA Std. 601 - 2019

Lift load (from Step M) = 1,380 lbs

Total chain pull = 2,227 Ibs
6. Refer to Table 3 and determine if chain size selected has sufficient capacity for required chain pull.
7. Consult conveyor manufacturer to obtain a drive of sufficient size for the calculated chain pull.
NOTE: Above method of calculating chain pull is an approximation to determine drive size or number of
drives required. When adverse environmental conditions exist (such as high temperature, caustic solutions,
excessive dust, corrosive solutions) or the conveyor is abnormally long or complex (1,000 ft; 20 changes
of direction), a progressive chain pull computation is necessary where the friction losses are progressively

9
calculated and accumulated through the path along the conveyor.

01
1/2
Step O. Locate Drive

/1
1. Locate the drive so it will apply a pulling force on the most heavily loaded portion of the system.

-6
N
2. For best results, locate the drive at some high point in the conveyor system and place the take-up just

O
after the drive at a lower point.

TI
U
3. Locate drive on conveyor layout. Relate location to some adjacent component, as shown in Typical

IB
Conveyor Layout at beginning of this section.

TR
IS
Step P. Summarize

D
1. For quick and easy reference, make a legend on your layout covering the following subjects (Refer to

R
FO
Typical Conveyor Layout):
a. Speed of conveyor. Mark direction of travel.

ED
b. Length of conveyor

IZ
c. Trolley spacing O
R
d. Carrier spacing
TH

e. Weight of empty carrier

AU

f. Maximum weight of loaded carrier

T

g. Total moving load

O

h. Maximum lift load

-N

i. Maximum chain pull

ee

j. Type of drive (caterpillar or sprocket); electrical specs

itt
m

k. Cross section of guard with dimensions

om
C

Step Q. Safety Codes (Reference current ANSI B20.1)

g
in

Safety Considerations
dl

a) In areas where the parted chain, cable, or other linkage would permit a runaway condition on an inclined
an

or declined section, and where personnel are present, anti-runaway devices shall be provided. The
H

conveyor path may be arranged so that travel of the uncontrolled conveyor will be arrested before it
t
ni

enters an area where personnel are present.

-U
w

b) In areas where personnel perform work of a moving conveyor and guards would impair the workers'
ie

performance, the load shall be cradled, hooked, bolted, or otherwise attached to the carrier.
ev
R
A

Guarding
EM

a) Nip points occur at traction wheels, sprockets, caterpillar drives, and roller turns and shall be guarded
rC

unless guarded by location.

Fo

b) The telltale effect of the moving conveyor components serves as a warning device and permits unguarded
nip or shear points at heights of less than 2.44 m (8 ft).
c) Automatic stops or closures shall prevent a trolley or trolleys from moving off the track during the portion
of a cycle when any track end is not aligned with its mating member.
d) Hoisting equipment for lift sections or drop sections or both shall stop or control the vertical motion in
the event of power failure.
e) On inclined or declined conveyors or sections, where personnel are present and there may be an
occurrence of uncontrolled movement of a free trolley, arresting devices shall be provided. A rigid pusher

28 of 40
 CEMA Std. 601 - 2019

dog on the power chain with positive carrier engagement shall be considered and acceptable means,
or the conveyor path may be arranged so that travel of the uncontrolled free trolley, carrier, or load, or
combination thereof, will be arrested before it enters the personnel area.
f) Guards shall be provided to restrict unauthorized personnel from entering hazardous loading, unloading,
and transfer areas. When guarding is not feasible, clear and legible warnings shall be provided.
g) Access to lift or drop sections shall be guarded to prevent unauthorized personnel from entering the
area. Warning signs shall be posted where guarding is not feasible, unless access to lift or drop sections
is guarded by location.

9
h) Where conveyors are located above personnel, and the possibility exists that the transported product

01
may fall off for any cause, guards (spill guards) shall be provided

1 /2
/1
Conveyor Drives

-6
N
The most important component of the conveyor system is the drive. The drive gives the conveyor motion and

O
controls conveyor speed.

TI
U
IB
Types of Drives

TR
Two Standard types of drives (caterpillar and sprocket) are available for overhead trolley conveyor systems.

IS
A caterpillar drive uses a chain made of precision steel rollers with driving dogs that mesh with the links of the

D
conveyor chain to deliver driving force. A sprocket drive makes use of a sprocket whose teeth mesh with the links

R
FO
of the conveyor chain to deliver driving force.

ED
Standard Drive Speed Ranges

IZ
All drives are furnished with either constant or variable speeds. Variable speed drives allow flexible production
O
R
schedules. Variable speed drives are commonly 3:1. Greater speed variations are available. VDF drives and Inverter
TH

Duty Motors are now commonly available from various manufacturers for speed change needs.
AU
T
O

Idler/Caterpillar Chain
-N

Take-up Sprocket
ee

Drive Sprocket
itt
m
om
C
g
in
dl
an

Chain Travel for Right

H

Hand Drive
t
ni
-U

Figure 11. Plan View of Drive Frames Indicating Hand of Drive

w
ie

To determine the hand of the drive, look in the direction of the chain travel (the chain is moving away from
ev

you). If the drive is to be placed on the right side of chain, it is a right hand drive. If it is on the left side of chain, it
R

is a left hand drive.

A
EM

NOTE: Overload protection shall be provided on all drives. Overload protection is typically set at 150% of rated
rC

drive capacity.
Fo

29 of 40
 CEMA Std. 601 - 2019

Table 2. Combined Chain and Trolley Weights per Foot of Conveyor for Uniform Trolley Spacing
Trolley Spacing Combined Chain and Trolley Weights
I-Beam Size Chain Type
[in (mm)] [lbs/ft (kg/m)]
6 (152.4) 8.3 (12.35)
12 (304.8) 5.3 (7.87)
3" @ 5.7 lbs/ft X-348
18 (457.2) 4.3 (6.40)
(76.2 mm @ 8.48 kg/m) (X-75-13)
24 (609.6) 3.8 (5.64)

9
30 (762) 3.5 (5.22)

01
8 (203.2) 15.1 (22.47)

1 /2
4" @ 7.7 lbs/ft X-458 16 (406.4) 9.1 (13.55)

/1
-6
(101.6 mm @ 11.45 kg/m) (X-100-16) 24 (609.6) 7.1 (10.56)

N
O
32 (812.8) 6.1 (9.09)

TI
12 (304.8) 25.7 (38.25)

U
6" @ 12.5 lbs/ft X-678

IB
24 (609.6) 16.2 (24.11)

TR
(152.4 mm @ 18.60 kg/m) (X-150-22)
36 (914.4) 12.5 (18.60)

IS
D
R
Table 3. Recommended Maximum Allowable Chain Pull on Drop Forged Rivetless Chain (Heat Treated)

FO
Maximum Chain Pull
Chain Type

ED
[lbs (kg)]

IZ
X-348
1500 (680)
(X-75-13) R
O
TH

X-458
3000 (1360)
(X-100-16)
AU

X-678
T

5500 (2500)
(X-150-22)
O
-N
ee

Table 4. Minimum Recommended Radius and Diameter Turns for Various Trolley Spacings
itt
m

Traction Wheel Roller Turn

Trolley Spacing
om

Chain Type Diameter Radius

[in (mm)]
[in (mm)] [in (mm)]
C
g

Up to 18 (457.2) 24 (609.6)
in

X-348
dl

24 (609.6) 30 (762) 18 (457.2)

an

(X-75-13)
30 (762) 36 (914.4)
tH

X-458 Up to 24 (609.6) 30 (762)

ni

24 (609.6)
-U

(X-100-16) 32 (812.8) 36 (914.4)

w
ie

12 (304.8) 36 (914.4)
ev

X-678
24 (609.6) 42 (1066.8) 36 (914.4)
R

(X-150-22)
A

36 (914.4) 48 (1219.2)
EM
rC
Fo

30 of 40
 CEMA Std. 601 - 2019

Table 5. Approximate Allowable Suspended Load on Single Trolley

Maximum Load Capacity
I-Beam Size
[lbs (kg)]
3" @ 5.7 lbs/ft
200 (90)
(76.2 mm @ 8.48 kg/m)
4" @ 7.7 lbs/ft
400 (180)
(101.6 mm @ 11.45 kg/m)
6" @ 12.5 lbs/ft

9
1200 (540)

01
(152.4 mm @ 18.60 kg/m)

/2
Load Capacity = Two times single trolley = in (mm)

1
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
Figure 12. Dual Trolley With Load Bar

IZ
R
O
TH

Guards
AU

Conveyor guards are recommended where loaded conveyors pass over aisles, work stations, machinery, or where
T

work carriers are not permanently fastened to conveyor, to prevent injury or damage from falling parts. Dimensions
O
-N

of guards are determined by the size of loaded carriers. 6 in minimum clearance on each side is required. Vertical
ee

height should permit loaded carriers to clear a fallen part lying on the bottom of the guard. Check all pertinent
itt

safety codes for specific requirements.

m
om

A wide variety of materials is available for guard construction, including woven wire mesh, expanded metal, and
C

sheet steel. Size and weight of the part being handled determine the correct choice. Support steel and headers are
g
in

usually structural angles.

dl
an
H

Typical Sections
t
ni

• Sheet Metal Type: Sheet metal guards are often used after dip tanks or washes, where dripping may be
-U
w

problem, and on conveyors carrying small or fine materials that would pass through expanded metal or
ie

wire mesh.
ev
R
A
EM
rC
Fo

31 of 40
 CEMA Std. 601 - 2019

• Expanded Metal or Wire Mesh Type: Conveyor guards are fabricated from heavy gauge expanded metal
or wire mesh and welded to angle iron frames.

9
01
/2
1
/1
-6
N
O
TI
U
IB
• Multiple Run: If several runs of loaded conveyors can be routed close together, a single wide guard will

TR
serve more than one conveyor.

IS
D
R
FO
ED
IZ
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
H
t
ni
-U
w
ie
ev
R
A
EM
rC
Fo

32 of 40
 CEMA Std. 601 - 2019

SECTION V - VERTICAL CURVE DATA

Table 6. Vertical Curve Beam Radii for Overhead Conveyors as Related to Trolley Spacing.
Minimum and Recommended Radius of Vertical Curve Beams
Radius of vertical Curve
Trolley Spacing [in (mm)]
Chain Type
[in (mm)]
Minimum Recommended
8 (203.2) 24 (609.6) 48 (1219.2)

9
01
12 (304.8) 36 (914.4) 48 (1219.2)
X-228

/2
16 (406.4) 48 (1219.2) 48 (1219.2)

1
(X-50-6)

/1
20 (508) 72 (1828.8) 72 (1828.8)

-6
24 (609.6) 96 (2438.4) 96 (2438.4)

N
O
12 (304.8) 48 (1219.2) 60 (1524)

TI
U
18 (457.2) 60 (1524) 78 (1981.2)

IB
X-348

TR
24 (609.6) 78 (1981.2) 96 (2438.4)
(X-75-13)

IS
30 (762) 92 (2336.8) 120 (3048)

D
36 (914.4) 108 (2743.2) 144 (3657.6)

R
FO
8 (203.2) 36 (914.4) 72 (1828.8)
16 (406.4) 66 (1676.4) 96 (2438.4)

ED
X-458
X-100-16 24 (609.6) 84 (2133.6) 120 (3048)

IZ
32 (812.8) R
108 (2743.2) 144 (3657.6)
O
TH

12 (304.8) 72 (1828.8) 144 (3657.6)

X-678
AU

24 (609.6) 132 (3352.8) 180 (4572)

X-150-22
T

36 (914.4) 192 (4876.8) 240 (6096)

O
-N
ee

NOTE: Minimum radii to be used only when absolutely required and only after considering chain pull, imposed load on trolley, beam wear,
itt

and possibility of surge.

m
om
C
g
in
dl
an
tH
ni
-U
w
ie
ev
R
A
EM
rC
Fo

33 of 40
 CEMA Std. 601 - 2019

Compound Vertical Curve

9
01
1/2
/1
-6
N
O
TI
U
IB
TR
IS
D
R
FO
ED
IZ
R
O
TH

For vertical drop greater than shown subtract drop "D" of appropriate degree and radius in Table 7 from actual drop
AU

"D" and use the remainder to compute "S" and "L" dimensions as shown below:
T

For 15° Curves:

-N
ee

S = Remainder X 3.864
itt

L = Remainder X 3.732 + "L" from Table 7

m
om

For 20° Curves:

C

S = Remainder X 2.924
g
in

L = Remainder X 2.7475 + "L" from Table 7

dl
an

For 30° Curves:

tH

S = Remainder X 2
ni
-U

L = Remainder X 1.732 + "L" from Table 7

w
ie

For 45° Curves:

ev
R

S = Remainder X 1.414
A

L = Remainder + "L" from Table 7

EM
rC
Fo

34 of 40
 CEMA Std. 601 - 2019

Example: 96 in radius, 30° curve, 60 in drop, vertical curve

Total Drop = 60 in
Chart Drop = 25.75 in
Remainder = 34.25 in

S = 34.25 in X 2 = 68.5 in
L = 34.25 X 1.732 + 96 =155.321 in

9
01
To calculate the arc length of any curve, horizontal or vertical, for use in determining the total chain length the

1/2
following formula can be used:

/1
-6
3.1416 x Arc Radius x Arc Degree

N
Arc Length =

O
180

TI
U
IB
Example: Find the arc length of an 10 in radius, 45° horizontal turn.

TR
IS
3.1416 x 18 in x 45°

D
Arc Length = = 14.137
180

R
FO
ED
IZ
R
O
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
Ht
ni
-U
w
ie
ev
R
A
EM
rC
Fo

35 of 40
 CEMA Std. 601 - 2019

Table 7. Compound Vertical Curve Table

Radius Drop L A Angle
[in (mm)] [in (mm)] [in (mm)] [in (mm)] [Deg.]
3.25 (82.55) 24.88 (631.82) 12.56 (319.09) 15
48 5.81 (147.64) 32.81 (833.44) 16.75 (425.45) 20
(1219.2) 12.88 (327.03) 48 (1219.2) 25.13 (638.18) 30
28.13 (714.38) 67.88 (1724.03) 37.69 (957.26) 45

9
4.06 (103.19) 31.06 (788.99) 15.69 (398.46) 15

01
60 7.25 (184.15) 41.06 (1042.99) 20.94 (531.81) 20

/2
1
(1524) 16.06 (407.99) 60 (1524) 31.44 (798.51) 30

/1
-6
35.13 (892.18) 84.88 (2155.83) 47.13 (1196.98) 45

N
O
4.94 (125.41) 37.25 (946.15) 18.88 (479.42) 15

TI
8.69 (220.66) 49.25 (1250.95) 25.13 (638.18) 20

U
72

IB
(1828.8) 19.31 (490.54) 72 (1828.8) 37.69 (957.26) 30

TR
42.19 (1071.56) 101.81 (2586.04) 56.56 (1436.69) 45

IS
D
5.31 (134.94) 40.38 (1025.53) 20.44 (519.11) 15

R
78 9.44 (239.71) 53.38 (1355.73) 27.25 (692.15) 20

FO
(1981.2) 20.88 (530.22) 78 (1981.2) 40.81 (1036.64) 30

ED
45.69 (1160.46) 110.31(2801.94) 61.25 (1555.75) 45

IZ
6.5 (165.09) 49.69 (1262.06)
R 25.13 (638.18) 15
O
96 11.63 (295.28) 65.69 (1668.46) 33.5 (850.9) 20
TH

(2438.4) 25.75 (654.05) 96 (2438.4) 50.25 (1276.35) 30

AU

56.25 (1428.75) 135.75 (3448.05) 75.38 (1914.52) 45

T
O

8.19 (207.96) 62.13 (1577.98) 31.44 (798.51) 15

-N

120 14.5 (368.29) 82.06 (2084.39) 41.88 (1063.63) 20

ee

(3048)
itt

32.13 (815.98) 120 (3048) 62.81 (1595.44) 30

m

70.31 (1785.94) 169.69 (4310.06) 94.25 (2393.95) 45

om

9.81 (249.24) 74.56 (1893.89) 37.69 (957.26) 15

C
g

144 17.38 (441.33) 98.5 (2501.9) 50.25 (1276.35) 20

in
dl

(3657.6) 38.56 (979.49) 144 (3657.6) 75.38 (1914.52) 30

an

84.38 (2143.13) 203.63 (5172.08) 113.13 (2873.38) 45

t H

12.25 (311.15) 93.19 (2366.96) 47.13 (1196.98) 15

ni
-U

180 21.69 (550.86) 123.13 (3127.38) 62.81 (1595.44) 20

w

(4572) 48.25 (1225.55) 180 (4572) 94.25 (2393.95) 30

ie
ev

105.44 (2678.11) 254.56 (6465.89) 141.38 (3590.93) 45

R

16.38 (415.93) 124.25 (3155.95) 62.81 (1595.44) 15

A
EM

240 28.94 (735.01) 164.19 (4170.36) 83.75 (2127.25) 20

rC

(6096) 64.31 (1633.54) 240 (6096) 125.63 (3190.88) 30

Fo

140.56 (3570.29) 339.44 (8621.71) 188.5 (4787.9) 45

36 of 40
 CEMA Std. 601 - 2019

SECTION VI - TROUBLESHOOTING, LUBRICATION GUIDE AND INSPECTION CHECKLIST

Table 8. Troubleshooting Guide

Problem Possible Causes Remedy
Lack of lubrication. Lubricate chain.
Sluggish or frozen trolley
1. Excessive chain wear. See #1 under "trolleys".
wheels.
(NOTE: The chain will
Roller turn roller frozen. See #1 under "Roller Turns".

9
elongate due to wear; this

01
is normal wear and is no Remove obstruction and remove and

/2
Obstruction in chain path.
replace chain if damaged.

1
fault of the system)

/1
Conveyor should not be loaded

-6
Chain Conveyor Overloaded.
beyond its designated capacities.

N
O
Chain growth through Adjust take-up and, if necessary,

TI
normal wear. remove links in chain.

U
2. Excessive slack chain.

IB
Maintenance schedule not

TR
Reinstitute maintenance.
adhered to.

IS
Same as #1 above. Also see

D
3. Surging chain. Same as #1 above. Also see "Drive".
"Drive".

R
FO
Remove from conveyor and clean.
Residue accumulated from
Remove welsh plug to clean and

ED
over lubrication.
press on new plug with blunt tool.

IZ
R
Bearing corroded or worn
Replace trolleys.
O
1. Sluggish or frozen trolley out.
TH

wheels.
Lack of lubrication. Lubricate chain.
AU

Trolleys Incorrect lubrication. Verify lubricant: replace if necessary.

T
O

Maintenance schedule not

Reinstitute maintenance.
-N

adhered to.
ee

Remove obstruction and replace

itt

Damaged in jam or by damaged trolley bracket with

m

2. Bent trolley brackets.

om

obstruction. new bracket. (Do not attempt to

straighten bent brackets)
C
g

Clean thoroughly or replace

in

Dirt or grease residue. if bearings are damaged. See

dl
an

Lubrication Guide.
H

1. Sluggish or frozen roller Lack of lubrication. Lubricate roller.

Roller Turns
t

turn rollers.
ni

Incorrect lubrication. Verify lubricant: replace if necessary

-U
w

Maintenance schedule not

Reinstitute maintenance.
ie

adhered to.
ev

1. Excessive wear or
R
A

peening of flanges at Excessive chain tension. See #1 under "Chain".

EM

I-Beam vertical curves.

rC

2. Excessive wear on I-Beam Bent trolley brackets. See #2 under "Trolleys".

Fo

web. Eccentric loading. Load carriers symmetrical.

37 of 40
 CEMA Std. 601 - 2019

Table 8. Troubleshooting Guide (cont.)

Trouble Possible Causes Remedy
Spring compression, air
Reduce the spring, air or counterweight
pressure or counterweight
loading.
1. Floating frame load too great.
Take-up movement sluggish or Dry or damaged expansion Lubricate if dry and replace with new
frozen. joints. expansion joints if damaged.
Guide wheels worn or

9
Clean thoroughly or replace if worn.

01
frozen.

/2
Adjust belt by loosening bolts on motor

1
Belt slippage.

/1
and pull back until belt is snug.
1. Decrease in conveyor

-6
Set screws on pulley are

N
speed.

O
loose and causing pulley to Align pulley and tighten set screws.

TI
rotate on shaft.

U
IB
Conveyor chain pull is
2. Drive stops. See #1 under "Chain".

TR
excessive.

IS
Fill reducer with oil to oil level plate; or
Lack of lubrication.

D
if needed change oil. Grease all fittings.

R
Tighten all grease fittings and pipe

FO
3. Excessive noise in reducer. Oil leak. plugs, clear breather tube opening and

ED
add lubricant.

IZ
Worn or broken gear or Disassemble reducer and replace
Drive bearing. R damaged part.
O
TH

Conveyor chain pull excessive. See #1 under "Chain".

4. Motor running above
AU

Electrical. Inspect electrical wiring and controls.

normal temperature.
T

Bearing failure. Inspect and replace motor.

O
-N

Adjust drive take-up until chain is snug.

ee

Chain too loose. (Do not remove any links of caterpillar

5. Slapping or pulsating
itt

chain or dogs).
m

caterpillar chain.
Conveyor chain or caterpillar
om

Replace.
chain worn beyond use.
C

Remove obstruction and repair or

g

Obstruction.
in

6. Floating frames sluggish replace any damaged equipment.

dl
an

or frozen. Guide wheels worn or frozen

Clean thoroughly or replace if worn.
H

with dirt or grease residue.

t
ni
-U
w
ie
ev
R
A
EM
rC
Fo

38 of 40
 CEMA Std. 601 - 2019

Table 9. Lubrication Guide for Overhead Monorail Conveyors

Lubricants at Temperature
Inspection Interval
Component Part to 250°F (121°C)
(See Note #1)
(See Note #2)
Open Race 30 days Oil = ISO 15-150
Trolley Wheels
Closed 30 days Grease = NLGI #2
Chain Pins -- 30 days Oil = ISO 15-150
Roller Chain 30 days Oil = ISO 15-150

9
01
Caterpillar Drive
Dogs 30 days Grease = NLGI #2

1 /2
Back-up Rollers -- 30 days Grease = NLGI #2

/1
-6
Back-up Bar -- 30 days Grease = NLGI #2

N
Anti-friction 30 days Grease = NLGI #2

O
TI
Traction Wheels Carbon 30 days None

U
IB
Graphite 30 days None

TR
Anti-friction 30 days Grease = NLGI #2

IS
Roller Turns Carbon 30 days None

D
R
Graphite 30 days None

FO
Floating Frame Wheels -- 30 days Grease = NLGI #2

ED
Take-up Frame Wheels -- 30 days Grease = NLGI #2

IZ
30 days
Track -- R
(Inspect for wear)
None
O
TH

Reducer Bearings 30 days

See Manufacturer's
AU

Gear Box 30 days Nameplate for lubrication

Drive
T

Idler Sprocket 30 days requirements on reducer

O

and motor
-N

Motor 30 days
ee
itt

NOTE #1: The inspection interval and lubrication frequency should be adjusted according to the application; i.e.: Elevated temperatures
m

and/or process conditions.

om
C

NOTE #2: Consult conveyor manufacturer or lubrication specialists for lubricant recommendations specific to each application especially for
g
in

those above 250°F (121°C).

dl
an
tH
ni
-U
w
ie
ev
R
A
EM
rC
Fo

39 of 40
 CEMA Std. 601 - 2019

Equipment, Maintenance and Services

Automated equipment for precise delivery of lubricants to conveyor wear points, cleaning equipment, and
maintenance services are available to the users of conveyors. Consult with the conveyor manufacturer or the
providers of these products and services for application assistance.

Suggested Inspection Checklist for Trolley Conveyor Systems

9
Check for:

01
1. Chain: Lubrication, excessive wear, slack chain.

1/2
2. Trolleys: Lubrication, sluggish or frozen wheels, bent bracket, loose bracket bolts.

/1
3. I-Beam: Wear and peening on flanges at vertical curves; wear on web at load or unload points, horizontal

-6
N
and vertical curves; obstacles on track interfering with trolley path.

O
4. Roller Turns: Lubrication, roller bearing wear, roller face wear, loose roller bolts, loose brackets bolts.

TI
U
5. Traction Wheels: Lubrication, bearings, rim wear, loose hub bolts, alignment.

IB
6. Take-up: Lubrication, roller bearing wear, roller face wear, loose roller bolts, loose bracket bolts,travel

TR
remaining, spring (screw) adjustment; expansion joint conditions (lubrication, wear, free movement); ease

IS
of floating frame travel.

D
7. Drive: Lubrication (cat chain, machinery components, bearings, oil level in reducer), wear (cat chain, back-

R
FO
up bar, back-up rollers, cat unit sprockets), adjustments (cat unit take-up, cat chain should be tight; back-up
bar; limit switch cut-off tripper bar), overload condition (chain pull indicator reading in overload zone, motor

ED
or reducer running at excessive temperature), belt drive condition (pulleys are aligned and set screws are

IZ
tight, belts are in good condition and are not slipping), excessive oil leakage from reducer, loose mounting
O
R
bolts, ease of floating frame travel.
TH
AU
T
O
-N
ee
itt
m
om
C
g
in
dl
an
H
t
ni
-U
w
ie
ev
R
A
EM
rC
Fo

40 of 40