Replacement bushing Grade 100

steelalloyrepair

Product Overview
The Grade 100 Bushing & Pin Repair Kit provides precision replacement bushings and pins for maintaining Grade 100 short-link lifting chains. Components are machined and heat-treated to match original material and mechanical properties, restoring chain geometry and certified working load limits where repair is appropriate.

Key Benefits

• Restores chain pitch and geometry for correct sprocket engagement
• Recovers certified working load limit (WLL) when replacement is within allowed repair practices
• Extends component service life and reduces downtime versus full-chain replacement when feasible
• All components individually proof-load tested and dimensionally verified for interchangeability

Why Bushings and Pins Fail

• Increased pitch tolerance: link spacing grows, impairing sprocket meshing
• Surface degradation: hardened contact surfaces wear, reducing load distribution
• Pin wear: cylindrical wear and micro-fractures on pin surface
• Loss of rotational freedom: binding increases localized stress and accelerates fatigue

The Solution: Precision Replacement Components
The kit includes bushings and pins produced from the same alloy formulation and subjected to comparable quench-and-temper cycles as original Grade 100 chain parts. Each piece is precision-machined, finished to specified tolerances and individually proof-load tested to ensure safe interchangeability.

Material Composition & Manufacturing
Components are manufactured from fully killed, fine-grain alloy steel to DIN 17115. Typical chemical and process parameters: C 0.35–0.45%, Cr 0.5–0.8%, Ni 0.3–0.6%, Mo 0.15–0.25%; S, P ≤ 0.035%; Al deoxidation; controlled quench and temper to achieve ~45–50 HRC surface hardness.

Installation & Maintenance Guidance

• Inspect the entire chain: cracked, bent or heavily corroded links require chain replacement
• Remove worn bushing and pin using a proper chain breaker to avoid link damage
• Clean link cavity of debris, rust and corrosion before assembly
• Fit new bushing fully seated and aligned with the link plate
• Insert new pin ensuring smooth fit; do not force; verify full seating and alignment
• Manually articulate the chain to confirm free rotation and absence of binding or abnormal noise
• Monitor initial operation, apply appropriate lubrication (avoid over-lubrication), and document inspections

Available Sizes (table format)
Chain Size | Chain Diameter (in) | Bushing Diameter (in) | Pin Diameter (in) | Kit Weight (lbs) | Typical WLL (lbs) | Standard Designation
9/32 | 0.281 in | 0.375 in | 0.250 in | 0.5 | 5,400 | CBHW7
5/16 | 0.313 in | 0.438 in | 0.281 in | 0.5 | 7,100 | CBHW8
3/8 | 0.375 in | 0.500 in | 0.313 in | 0.5 | 10,200 | CBHW10
1/2 | 0.500 in | 0.625 in | 0.375 in | 0.5 | 14,400 | CBHW13
5/8 | 0.625 in | 0.750 in | 0.438 in | 0.5 | 22,600 | CBHW16
3/4 | 0.750 in | 0.875 in | 0.500 in | 0.5 | 32,400 | CBHW19/20
7/8 | 0.875 in | 1.000 in | 0.563 in | 0.5 | 44,100 | CBHW22
1 in | 1.000 in | 1.125 in | 0.625 in | 0.75 | 58,000 | CBHW26

Material Specifications (table format)
Property | Specification | Test Method
Material Grade | Alloy Steel (DIN 17115) | Material Certification
Carbon Content | 0.35–0.45% | ASTM E1019
Chromium Content | 0.5–0.8% | ASTM E1019
Nickel Content | 0.3–0.6% | ASTM E1019
Molybdenum Content | 0.15–0.25% | ASTM E1019
Sulfur Content | ≤ 0.035% | ASTM E1019
Phosphorus Content | ≤ 0.035% | ASTM E1019
Surface Hardness (Bushing) | 45–50 HRC | ASTM E18
Surface Hardness (Pin) | 45–50 HRC | ASTM E18
Tensile Strength | ≥ 1,800 MPa (260 ksi) | ASTM E8
Yield Strength | ≥ 1,400 MPa (200 ksi) | ASTM E8
Elongation | ≥ 8% | ASTM E8
Impact Toughness | ≥ 40 J (30 ft-lbs) at 0°C | ASTM E23

Dimensional Specifications (table format)
Dimension | Tolerance | Measurement Method
Bushing Outer Diameter | ±0.01 in (±0.25 mm) | Micrometer
Bushing Inner Diameter | ±0.005 in (±0.13 mm) | Micrometer
Bushing Length | ±0.01 in (±0.25 mm) | Caliper
Pin Diameter | ±0.005 in (±0.13 mm) | Micrometer
Pin Length | ±0.01 in (±0.25 mm) | Caliper
Chamfer Angle | 45° ± 5° | Visual Inspection
Surface Finish (Bushing/Pin) | Ra 0.4–0.8 µm | Surface Profilometer

Performance Characteristics (table format)
Characteristic | Specification | Basis
Load Capacity Retention | ≥ 95% of original chain WLL | EN 818-7 Section 5.2
Pitch Accuracy | ±0.02 in (±0.51 mm) per 10 links | EN 818-7 Section 5.3
Rotational Resistance | ≤ 5% increase vs. new chain | ISO 1149
Wear Rate | Comparable to original chain | ASTM G65
Corrosion Resistance | Zinc-plated finish (optional), ASTM B117 (500+ hours) | ASTM B117
Temperature Range | -20°C to +80°C (-4°F to +176°F) | Material Specification
Service Life | 5–10 years (typical use, application dependent) | Field Data

Kit Contents

• Replacement bushings: quantity varies by chain size (typically 4–10 per kit)
• Replacement pins: quantity varies by chain size (typically 4–10 per kit)
• Installation instructions with alignment guidance
• Material certification to DIN 17115
• Test report / proof-load test documentation

Standards & Compliance

• ASTM A952 — Chain, Welded, Double Loop, Alloy Steel, for Lifting
• EN 818-7 — Short Link Chain for Lifting Purposes, Fine Tolerance Hoist Chain
• DIN 17115 — Steel for Welded Round Steel Link Chains
• EN 818-1 — General Conditions of Acceptance for Short Link Chain
• Proof load testing and full material certification provided

Certification & Testing
Each bushing and pin is individually proof-load tested (example proof load = 2.5 × chain WLL for the corresponding chain size). Dimensional verification is performed with micrometers, calipers and surface profilometers; hardness and mechanical properties are documented in supplied test reports.

Features / Technical Specifications

• Product: Grade 100 Bushing & Pin Repair Kit
• Material: Alloy steel to DIN 17115, fully killed fine-grain
• Surface Hardness: ~45–50 HRC (bushing and pin)
• Tensile Strength: ≥ 1,800 MPa (260 ksi)
• Yield Strength: ≥ 1,400 MPa (200 ksi)
• Elongation: ≥ 8%
• Impact Toughness: ≥ 40 J at 0°C
• Dimensional tolerances: bushing OD ±0.01 in, ID ±0.005 in, pin dia ±0.005 in
• Typical WLL coverage: 5,400–58,000 lbs depending on chain size
• Proof Load Testing: 100% per component
• Optional finish: zinc-plated for enhanced corrosion resistance
• Operating temperature range: -20°C to +80°C