Kingpin Chain Breaker Instructions: Assembly, Disassembly and Precautions
These are the instructions T&D Machine includes with the Kingpin: how to remove a chain pin, how to install one, how to choose the push pin, spacers and pin cavity, and the precautions that apply every time. They're written for chain with a pin and a retainer, such as a cotter pin or pin lock, that falls within the tool's range.
Pin range: pin length 2.25 in. to 7.8 in. and pin diameter 1.125 in. or less.
Before you start
- Use the tool only on chain within range. Pin lengths between 2.25 in. and 7.8 in., and pin diameters not exceeding 1.125 in. Both limits apply.
- Wear safety glasses and gloves.
- Secure the chain. Lock out the drive, take tension off the take-up, and restrain the chain on both sides of the joint.
- Riveted (peened) pins must be ground off first. The Kingpin does not break rivets. See removing a seized conveyor chain pin.
- The Kingpin has no hazardous-location rating. Check your area classification and site rules first. See chain breaking in restricted hot-work areas.
Choosing the push pin, spacers and pin cavity
The Kingpin ships with 2 pin cavities, 4 push pins and 5 push pin spacers. Configure them for your chain.
- The tool should fit snugly around your chain.
- For either assembly or disassembly, choose the push pin, pin cavity and spacer(s) so there is minimal space between the push pin and the chain pin. A gap of about 1/8 in. (0.125 in.) between the push pin and the pin head is a good starting point.
- Set the pin cavity flush against the sidebar of the chain. All three walls of the cavity must contact the sidebar for the tool to work properly.
- Center the push pin on the chain pin.
Order along the cylinder: push pin spacer(s), then push pin, then the chain pin, then the pin cavity on the far side. The pin must be able to travel into the pin cavity as it comes out or goes in.
Chain disassembly: removing a pin
Follow all precautions below.
- Read and follow all precautions listed on the tool and on this page.
- Apply penetrating oil to the chain to cut friction from dirt or rust buildup.
- Choose the pin cavity, push pin and spacer(s) for your chain. The tool should fit snugly around the ends of the chain pin.
- Connect the pump hose to the cylinder by tightening the coupler.
- Remove the cotter pins or pin locks from the chain pin.
- Close the relief valve on the hand pump (clockwise).
- Position the tool above the chain and place the saddle on top of the chain roller. You may need to adjust the saddle height for the right location on the roller.
- Apply pressure by pumping the hand pump. Be sure the push pin is square on the end of the pin and that the pin's head end will clear the pin cavity on the opposite end.
- After the pin pops free of the sidebar press fit, release pressure by opening the pump relief valve.
- Remove the pin.
Chain assembly: installing a pin
Follow all precautions below.
- Read and follow all precautions.
- Grease the cotter side of the chain pin before assembling.
- Choose the pin cavity, push pin and spacer(s) for your chain (see the guide above).
- Connect the pump hose to the cylinder by tightening the coupler.
- Place the tool on top of the roller and position the saddle in the center of the roller.
- Close the relief valve on the hand pump (clockwise).
- Apply pressure by pumping the hand pump. Be sure the push pin is square on the head end of the pin and that the pin will clear the pin cavity on the opposite end.
- When the pin is flush with the sidebars, open the pump relief valve and let the cylinder return completely.
- If the chain does not flex freely, hit the pin's cotter end hard with a hammer to establish clearance.
Precautions
Chain disassembly
- Before disassembling, use penetrating oil on your chain to cut friction from buildup of dirt or rust.
- If you are pumping and the pin is not moving, stop pumping. With a mallet, strike the sidebar of the chain (not the tool). The shock travels through the chain and can loosen the pin so removal can continue.
Chain assembly
- Before assembling, grease the cotter side of the chain pin.
- Make sure the pin cavity sits flush on the sidebar. All three walls of the cavity must contact the sidebar for the tool to work properly.
- Align the push pin with the center of the chain pin.
Always
- Wear safety glasses and gloves.
- Secure the chain.
- Use the Kingpin only with chain within the recommended range: pin lengths between 2.25 in. and 7.8 in. and pin diameters not exceeding 1.125 in.
If your site restricts impact tools, such as in some combustible dust or vapor areas, check before using the mallet step.
Specifications
| Spec | Value |
|---|---|
| Hydraulic force | 15-ton cylinder, hand pump (foot pedal available) |
| Pin length | 2.25 in. to 7.8 in. |
| Pin diameter | 1.125 in. and below |
| Weight | 28 lb |
| Dimensions | 16.5 in. x 2.5 in. x 16 in. |
| Included | 2 pin cavities, 4 push pins, 5 push pin spacers |
| Made by | T&D Machine Corp, 5035 N. 124th St., Butler, WI 53007 |
| Phone | 262-781-3870 |
Troubleshooting
| Problem | Likely cause | What to do |
|---|---|---|
| Pin won't move | Pin binding from dirt or rust | Apply penetrating oil. Stop pumping, strike the chain sidebar (not the tool) with a mallet, then resume |
| Pin won't move | Cotter or pin lock still installed | Remove it and try again |
| Pin won't move | Riveted head still on the pin | Grind the rivet head off first. The Kingpin does not break rivets |
| Pin won't move | Pushing the wrong way, or the head end can't clear the cavity | Reposition so the head end clears the pin cavity on the opposite side |
| Push pin slips or the pin mushrooms | Push pin off-center or too much space between the push pin and the pin | Re-center the push pin and use spacers to minimize the gap |
| Tool rocks or loses seat | Pin cavity not flush against the sidebar | Reset it so all three walls touch the sidebar |
| Chain stiff after assembly | Joint not cleared after pressing | Hit the pin's cotter end hard with a hammer to establish clearance |
For help with a specific chain, call 262-781-3870.
FAQ
How do I use the Kingpin chain breaker?
Choose the pin cavity, push pin and spacers so the tool fits snugly around the pin ends. Remove the cotter or pin lock, close the relief valve, set the saddle on the chain roller, and pump until the pin pops free. Open the relief valve to retract the cylinder. The full steps are above.
What should I do if the pin stops moving while I'm pumping?
Stop pumping. Strike the sidebar of the chain, not the tool, with a mallet. The shock vibrates through the chain and can loosen the pin so you can keep pushing. If it still won't move, check for a retainer left in, an unground rivet head, or the wrong push direction.
Which push pin, pin cavity and spacers do I use?
The combination that fits snugly around the chain with minimal space between the push pin and the chain pin. A gap of about 1/8 in. (0.125 in.) between the push pin and the pin head is a good starting point. The cavity must sit flush on the sidebar, with the push pin centered on the pin.
Can the Kingpin remove riveted pins?
No. Riveted (peened) pins must have the rivet head ground off first. The Kingpin does not break rivets.
What size pins does the Kingpin handle?
Pin lengths from 2.25 in. to 7.8 in. and pin diameters of 1.125 in. or less. Both limits apply.
Is the Kingpin rated for hazardous locations?
No. It has no hazardous-location rating. It uses no flame or fuel gas, but check your area classification and your site's rules. See chain breaking in restricted hot-work areas.
How long does it take to remove a pin?
T&D Machine states about two minutes of press time per pin on pins within the advertised range when the tool is set up and used correctly. Allow extra for setup and for stubborn pins. For comparisons with other methods, see Torch vs. press: what a seized chain pin really costs.
Questions or need a quote? Call 262-781-3870 or request a quote. Include your chain type, pin diameter and pin length so we can confirm fit.
More guides: Resources. Product details: the Kingpin product page.
These instructions are general guidance for the Kingpin hydraulic chain breaker. Always follow your site's lockout, hot-work and safety procedures, and the chain manufacturer's instructions.