Mechanical Drives 1 Lap 5

MECHANICAL
LEARNING
DRIVES 1 ACTIVITY
PACKET
Introduction
to chain drives
TM
B502-XC
LEARNING ACTIVITY PACKET 5
INTRODUCTION TO CHAIN DRIVES
INTRODUCTION
This LAP will begin your study of another method of adjacent shaft-to-shaft power
transfer, the chain drive. Along with the belt drive, the chain drive is also common in
industry because it is more efficient than the v-belt. A chain drive can handle higher
power loads than a v-belt, and it does not slip.
While there are many types of chain drives, the most widely used type is the roller
chain drive. This is the type you will learn about in this LAP.
ITEMS NEEDED
Needed Amatrol Supplied
Items
950-ME1 Mechanical Drives 1 Learning System
Amatrol or School Supplied

Assorted Hand Tools
FIRST EDITION, LAP 5, REV. B

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered
trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their
respective companies.
Copyright © 2006, 2005 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any
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recording or any information storage and retrieval system, without written permission of the copyright owner.
Amatrol,Inc., P.O. Box 2697, Jeffersonville, IN 47131 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com
B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Copyright  2006 Amatrol, Inc. 2
TABLE OF CONTENTS
SEGMENT 1 CHAIN DRIVE CONCEPTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe the function of the three basic components of a chain drive
OBJECTIVE 2 Describe how to calculate sprocket ratio and explain its importance
SKILL 1 Calculate sprocket ratio
OBJECTIVE 3 Describe how to calculate shaft speed and torque of a chain drive system
SKILL 2 Calculate the shaft speed and torque of a chain drive system
SEGMENT 2 CHAIN DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

OBJECTIVE 4 List four types of chain drives and give an application of each
OBJECTIVE 5 List four types of roller chain drives and give an application of each
OBJECTIVE 6 Describe the operation of a single-strand roller chain drive
OBJECTIVE 7 Describe how to install, align, and remove a roller chain drive system with adjustable centers
SKILL 3 Install and align a roller chain drive system with adjustable centers
SEGMENT 3 CHAIN TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

OBJECTIVE 8 Describe how to determine allowable chain sag for a given application
SKILL 4 Determine allowable chain sag for a given application
OBJECTIVE 9 Describe two methods used to adjust chain sag
SEGMENT 4 CHAIN TENSION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

OBJECTIVE 10 Describe how to measure chain sag
SKILL 5 Use a rule and a straight edge to measure chain sag
SKILL 6 Adjust chain sag to a specified amount using adjustable centers
Activity 1 Roller chain drive analysis
SEGMENT 5 FIXED CENTER CHAIN INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

OBJECTIVE 11 Describe the function and operation of a master link
OBJECTIVE 12 Describe two methods of installing a lightweight chain which uses a master link
SKILL 7 Install and remove a chain with a master link using sprocket teeth
OBJECTIVE 13 Describe the operation of a chain puller
SKILL 8 Install and remove a chain with a master link using a chain puller

SEGMENT 1
CHAIN DRIVE CONCEPTS
OBJECTIVE 1 DESCRIBE THE FUNCTION OF THE THREE BASIC

COMPONENTS OF A CHAIN DRIVE
his
dT As shown in figure 1, a chain drive consists of three basic
Rea
components:
• Chain - The chain is a continuous loop of links, usually having
steel rollers, which is wrapped around two toothed wheels called
sprockets. The chain transmits speed and torque between the two
sprockets.
• Driver Sprocket - A sprocket is a disk-shaped component with
teeth which is mounted to the shaft of the driver or prime mover.
When the driver shaft turns, the driver sprocket turns, applying its
speed and torque to the chain and causing it to move.
• Driven Sprocket - The driven sprocket is a sprocket which is
mounted to the driven shaft. It turns when the chain moves and in
turn causes the driven shaft to rotate.
DRIVEN SPROCKET
DRIVER SPROCKET
CHAIN
Figure 1. The Three Basic Components of a Chain Drive

The relative number of teeth between the driven sprocket and the
driver sprocket determine the speed and torque of the driven shaft. The
ratio of the teeth of the two sprockets can be selected to either increase or
decrease the speed or torque delivered to the driven shaft.
OBJECTIVE 2 DESCRIBE HOW TO CALCULATE SPROCKET RATIO

AND EXPLAIN ITS IMPORTANCE
dT
his The speed and torque that are transmitted to the driven shaft of a
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chain drive can be calculated by using the sprocket ratio, as was done
with the pulley ratio of belt drives.
The sprocket ratio is the ratio of teeth of the driven and driver
sprockets, as the following formula shows:
FORMULA: SPROCKET RATIO

No. of Teeth of Driven Sprocket
Sprocket Ratio =
No. of Teeth of Driver Sprocket
At first glance, you might think that you could use the sprocket pitch
diameters to determine sprocket ratio as you did to determine pulley ratio
for a belt drive. This is not the case. In a belt drive, the belt rides along a
sheave through the pitch circle at all times, allowing pitch diameters to
be used.
The chain does not ride along the pitch line because each link is a
rigid bar that cannot bend around a circular path. Instead, the links of a
chain move around a circle in a series of straight lines, as shown in
figure 2. This is called chordal action. Chordal action is very similar to
the motion a train makes as its straight cars move around a turn.
CHORD
DIRECTION
OF CHAIN TRAVEL
PITCH
CIRCLE
Figure 2. Chordal Action of a Drive

SKILL 1 CALCULATE SPROCKET RATIO
Procedure Overview
In this procedure, you will determine the sprocket ratio
of a number of chain drive applications. This is a simple
skill but you will use it in the next skill to calculate the
speed and torque of chain drive shafts.
This ❑ 1. Calculate the sprocket ratio of the chain drive shown in figure 3.
Do
Sprocket Ratio: ____________
DRIVEN SPROCKET
18 TEETH
DRIVER SPROCKET
36 TEETH
Figure 3. Chain Drive Application
In this case, the number of teeth of the driver sprocket is 36 and

the number of teeth of the driven sprocket is 18. The ratio is
therefore 0.5 or 1:2 (SR=18/36= 0.5).

❑ 2. Calculate the sprocket ratio of the chain drive shown in figure 4.
Sprocket Ratio: ____________
DRIVER SPROCKET
8 TEETH
DRIVEN SPROCKET
24 TEETH
In this case, the number of teeth of the driver sprocket is 8 and the
number of teeth of the driven sprocket is 24. The ratio is therefore
3 or 3:1 (SR=24/8=3).

❑ 3. Calculate the sprocket ratio of the chain drive shown in figure 5.
Sprocket Ratio: ____
DRIVER
SPROCKET
16 TEETH
DRIVEN SPROCKET 96 TEETH
In this case, the number of teeth of the driver sprocket is 16 and

the number of teeth of the driven sprocket is 96. The ratio is
therefore 6 or 6:1 (SR=96/16= 6).

OBJECTIVE 3 DESCRIBE HOW TO CALCULATE SHAFT SPEED
AND TORQUE OF A CHAIN DRIVE SYSTEM
his
dT The speed of the driven sprocket is determined by the sprocket ratio.
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This is because the rate at which the teeth of the driven sprocket engage
the chain is the same as the rate at which the driver sprocket teeth
disengage the chain. If the sprockets have different numbers of teeth, the
driven shaft’s rotational speed (RPM) will be different than the driver
shaft’s rotational speed. The shaft with the sprocket having more teeth
will have a slower rotational speed than the shaft with the sprocket
having fewer teeth.
DRIVEN SPEED
500 RPM
DRIVER SPEED
1000 RPM
20 TEETH
40 TEETH
Figure 6. Effect of Relative Numbers of Sprocket Teeth on the Speed of

the Driven Shaft
The relationship between numbers of sprocket teeth and shaft speeds

of a chain can be expressed in the following formula:
FORMULA: CHAIN DRIVE SPEED

Driver Rotational Speed (RPM) No. of Teeth of Driven Sprocket
=
Driven Rotational Speed (RPM) No. of Teeth of Driver Sprocket
As you can see by the formula, the shaft speeds are inversely
proportional to the number of teeth. This means that an increase in
sprocket size (number of teeth) causes the speed to decrease. Also, notice
that the right hand side of the formula is actually the sprocket ratio, so
the formula can also be stated as follows:

FORMULA: CHAIN DRIVE SPEED
Driver Rotational Speed (RPM)
= Sprocket Ratio
Driven Rotational Speed (RPM)
In a similar manner to speed, sprocket ratio also affects the torque

transmitted to the driven shaft. This is because the number of teeth
relates directly to the radius of the sprockets. This means a larger driven
sprocket creates more torque on its shaft.
DRIVEN TORQUE
1200 in-lbs
DRIVER TORQUE
600 in-lbs
20 TEETH
40 TEETH
Figure 7. Effect of Sprocket Ratio on Torque of Driven Shaft
The calculation of shaft torque is performed using a formula that is

similar to the shaft speed formula, except that the torque is directly
proportional to the number of teeth. The torque formula is therefore as
follows:
FORMULA: CHAIN DRIVE TORQUE

Driven Rotational Torque No. of Teeth of Driven Sprocket
=
Driver Rotational Torque No. of Teeth of Driver Sprocket
As with the speed formula, the torque formula can be modified to

use the sprocket ratio as follows:
FORMULA: CHAIN DRIVE TORQUE

Driven Rotational Torque
= Sprocket Ratio
Driver Rotational Torque

SKILL 2 CALCULATE SHAFT SPEED AND TORQUE
OF A CHAIN DRIVE SYSTEM
Procedure Overview
In this procedure, you will use the formulas just
described to determine speed and torque of either the
driver or the driven shaft. On the job, you will sometimes
know the driver data and will need to determine the driven
data. In other cases, it will be the reverse.
This ❑ 1. Calculate the driven shaft speed of the chain drive system shown
Do
in figure 8.
Driven Shaft Speed:________________________________(RPM)
DRIVER SPEED 600 RPM

DRIVER TORQUE 500 in-lbs
35 TEETH
DRIVEN SPROCKET
70 TEETH
DRIVER SPROCKET
The driven shaft speed is 1200 RPM

❑ 2. Calculate the driven shaft torque of the chain drive shown in figure
8.
Driven Shaft Torque: __________________________(in-lbs/N-M)
The driven shaft torque is 250 in-lbs.

❑ 3. Calculate the driven shaft speed and torque of the chain drive
system given the following information.
Given:
Driver Speed = 1600 RPM
Driver Torque = 500 in-lbs
Driver Sprocket = 10 teeth
Driven sprocket = 20 teeth
The driven shaft speed is 800 RPM.
Given:
Given:

SEGMENT 1
SELF REVIEW
r This
we
Ans
1. Two __________ and a __________ are the three basic
components of a chain drive system.
2. ___________ action is caused by straight chain links

moving about a circular sprocket.
3. In a chain drive ___________ ratio cannot be determined by

the pitch diameters of the sprockets.
4. __________ ratio is the ratio of the number of teeth of the

__________ sprocket divided by that of the __________
sprocket.
5. The speed and __________ of a driven sprocket can be

determined from those same values of the driver sprocket
and the __________ ratio.

SEGMENT 2
CHAIN DRIVE OPERATION
OBJECTIVE 4 LIST FOUR TYPES OF CHAINS

AND GIVE AN APPLICATION OF EACH
his
dT Chains are popular for a large number of industrial applications. The
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four types of chains you will most often encounter are:

• Roller chain
• Rollerless chain
• Silent chain
• Leaf chain
Each of these is described as follows:
Roller Chain
The roller chain is the most common type of chain used for
mechanical drives. It has rollers mounted on pins and bushings, as shown
in figure 9. These rollers roll over the teeth of the sprocket to minimize
the friction and increase the efficiency of the drive.
PINS
ROLLER
BUSHING
Figure 9. The Construction of a Standard Roller Chain

Roller chains can be found on machinery drives, conveyor systems,
robot drives, and timing drives.
Rollerless Chain
Rollerless chains have nearly the same construction as roller chains
except that they have no rollers, as shown in figure 10.
PINS
BUSHINGS
Figure 10. The Construction of a Rollerless Chain
Rollerless chains are used in light-weight, low-speed, mechanical

drive applications where the friction between the chain and sprocket
would cause little wear. They are also used in very dirty applications that
would cause roller chain bushings to wear out too quickly if the chain
had rollers.
Examples include hoisting chains or drives in small cranes.

Silent Chain
The silent chain uses what is called an inverted tooth design which is
designed to reduce the noise created by the engagement and release of
the sprocket teeth to the chain.
CHAIN LOAD
PINS
FLAT
LINKS
SPROCKET
ROTATION
Figure 11. The Engagement and Release of a Silent Chain
Silent chains are also more efficient, last longer, and can operated at
higher speeds than roller chain. The disadvantage with silent chains is
that they are much more expensive.
Silent chain is also used in mechanical drive applications such as
industrial pumps, fans, and other heavy machinery.

Leaf Chain
Leaf chains are made up of many plates held together by pins, as
shown in figure 12. They have no rollers and aren’t usually used in chain
drive applications.
But leaf chains are normally used in forklift or other hoisting
applications. Leaf chains with extended pins are also used on chain
wrenches, as shown in figure 13.
Figure 12. The Construction of a Leaf Chain
Figure 13. Leaf chains are used for forklifts and chain wrenches.

OBJECTIVE 5 LIST FOUR TYPES OF ROLLER CHAIN DRIVES
AND GIVE AN APPLICATION OF EACH
his
dT As you have already learned, the roller chain is the most common
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type of chain used in industrial chain drive systems. There are four basic
types of roller chains:
• Single strand chain
• Multiple strand chain
• Double pitch chain
• Offset chain
Each of these is described as follows:
Single Strand Chain

This is the type of chain with which you are most familiar. The
single strand chain is made up of a single row of rollers with plates on
each side, as shown in figure 14.
Figure 14. Single Strand Chain
Single strand roller chain is used for most general-purpose

applications of low-to-medium power transmissions. This type of chain
is also found on bicycles.

Multiple Strand Chain
For applications that transmit a great deal of power, multiple strand
chains can be used. Multiple strand chains are made up of two or more
single strand chains, as shown in figure 15. The chains used in multiple
strand chain drives are the same as those used in single strand drives.
They are merely joined to create multiple rows.
Figure 15. Multiple Strand Chain

Multiple strand chain is used in applications with much heavier loads
and higher speeds than a single strand chain can handle.

Double-Pitch Chain
Double pitch chain has the same construction as standard roller chain
except that the length of its links are twice that of the single-pitch chain,
as shown in figure 16. Double pitch chain is normally used when trying
to save money and the application has low loads and speeds. They are
also used in conveyor drives.
DOUBLE PITCH
Figure 16. Double-Pitch Roller Chains

Offset Chain
Standard roller chain is made up of two different links that mate with
each other. Offset chain, sometimes called cast chain, is made up of a
single kind of link, as shown in figure 17.
Figure 17. Offset Chain Links
Offset chain can come with or without rollers. Because of its offset
design, this type of chain doesn’t require a connecting link, which is
usually weaker than the rest of the chain. For this reason, offset chain is
normally made out of high strength steel to be used in heavy-load, low
speed applications.

OBJECTIVE 6 DESCRIBE THE OPERATION OF A SINGLE-STRAND
ROLLER CHAIN DRIVE
his
dT Roller chain is made up of two types of links: pin links and roller
Rea
links, as shown in figure 18.
ROLLER LINK PIN LINK ASSEMBLED LINKS
Figure 18. Roller Chain is Made of Pin Links and Roller Links
The two types of links are alternately assembled to form a complete

link. These links mesh with the driver and driven sprockets so speed and
torque can be transmitted between the two.

The two types of links are described as follows:
Pin links are made of two side plates separated by two pins, as
shown in figure 19.
Roller links are similar to pin links, but are made of two side plates
that are separated by bushings, as shown in figure 20. These bushings
support the rollers that are mounted to them.
PIN LINK
PINS
SIDE PLATES
ROLLER LINK
BUSHINGS
ROLLERS
SIDE PLATES
Figure 19. The Construction of a Roller Chain Pin and Roller Link

The two links form an assembly as shown in figure 20.
The jointed link design allows the chain to flex at the junction
between links. It also allows the rollers to freely roll, which reduces
friction between the chain and the sprocket.
EXPLODED LINK ASSEMBLY
PIN
BUSHING
ROLLER ROLLER ROLLER

LINK LINK
SIDE PLATES
ASSEMBLED LINKS
Figure 20. Roller Chain Link Assembly

The single-strand roller chain, as well as other types of chains,
transmits power by rotating the driver sprocket so that its teeth engage
the roller links and pull the chain around it. This in turn causes the chain
to pull on driven sprocket teeth, causing it to rotate, as shown in figure
21.
CHAIN PULLS THE

DRIVEN SPROCKET
DRIVER PULLS
THE CHAIN
SPEED AND TORQUE

ARE TRANSMITTED TO
THE DRIVEN SPROCKET
Figure 21. Operation of a Roller Chain Drive
Unlike the v-belt drive, the chain drive does not depend on friction
between the sprocket and chain to drive it. Instead, the chain drives use
the engagement or interlocking of the sprocket teeth and chain, which
creates a positive drive.
This means that chain tension does not have to be as high as v-belt
tension, which is one reason why a chain drive is more efficient. The
chain tension only needs to be high enough to keep the chain from flying
off the sprocket during operation.

It is worthwhile to note, however, that chain drives still have some
losses due to friction between the sprocket and the chain. This is because
of the chordal action of the chain links. As the roller link contacts the
sprocket, it initially rises up the tooth. Then, as it is wound around the
sprocket it slides down the tooth, as shown in figure 22. This action
repeats itself as each link contacts the sprocket, creating a certain amount
of friction. It is small, however, because the frictional contact is reduced
by the a rolling action of the chain’s rollers.
It is also worthwhile to note that this rising and falling of the links
causes a slight speed variation in the chain drive. Even though the driver
sprocket’s speed is constant, the driven sprocket speed oscillates. The
amount of oscillation depends on the number of teeth. If the number of
teeth is greater than 25, the oscillation is less than 1% and is usually
disregarded.
B A
Figure 22. Chordal Action
Chain sprockets are normally made of strong, high carbon steel.

They can be attached to shafts using an integral hub with a keyseat, or
with a bushing.

OBJECTIVE 7 DESCRIBE HOW TO INSTALL, ALIGN, AND REMOVE A ROLLER
CHAIN DRIVE SYSTEM WITH ADJUSTABLE CENTERS
his
dT Chain drives are easy to install but it is important to do it correctly in
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order to achieve the maximum life. Regardless of the type of chain you
are using, the installation steps are similar. These steps are as follows:
Step 1. Mount and Level the Motor and the Driven Component
Leveling the shafts is actually part of the alignment of the sprockets,
which is step 5 of this process. However, it is easier to place a level on
the shaft before the sprockets are attached.
As part of this process the motor and driven component should also
be checked for a soft foot condition and excessive run-out. The shaft
run-out should be no more than 0.002 inches.
Step 2. Inspect the Sprockets for Cleanliness and Wear. Clean

or Replace if Necessary
If the sprockets have nicks, burs, gouges, or missing teeth, replace
the sprocket. This can cause the chain to fail.
At the same time the sprockets should be checked for wear. If the
sprocket is excessively worn, replace it.
Make sure that the sprocket does not have any dirt or rust on it. Dirt
and rust can cause the chain to wear quickly. Use a stiff brush to remove
any dirt and rust.

Step 3. Mount the Sprockets on the Shafts
The sprockets should be attached to the shafts using either a fixed
bore hub or a bushing. Bushings are commonly used on industrial chain
drives.
Figure 23. Installation of a Single-Strand Sprocket
After you install the sprockets, make sure that they don’t wobble by
rotating the shafts and observing the motion of the sprockets. If they do,
reinstall them or use other sprockets.
Step 4. Mount the Chain

If the chain drive has movable centers, adjust the driver shaft
towards the driven shaft. This will reduce the center distance between the
two sprockets so that the chain can be slipped loosely over the sprockets
without forcing it. Next place the chain over the sprockets.
If the drive system does not have movable centers, the chain can be
connected and disconnected using a special link, called a master link.

Step 5. Align the Sprockets
Just as with couplings and belt drives, it is important to align the
sprockets. Misaligned sprockets will cause the chain and the bearings to
wear quickly. This misalignment can appear in several ways, as shown in
figure 24. The goal of aligning sprockets is to avoid twisting or applying
excessive forces on the chain.
ANGULAR SPROCKET PARALLEL

MISALIGNMENT MISALIGNMENT MISALIGNMENT
Figure 24. Types of Misalignment

The sprockets can be aligned by first leveling the two shafts using a
spirit level. If this has already been done as part of mounting the motor,
you can skip this substep and go to the next one.
The next step is to place a straight edge against the faces of the
sprockets to align the sprocket teeth and check the parallelism of the
shafts, as shown in figure 25.
The faces of the sprockets should be made so that they are flush
against the straight edge. This means that the shafts are parallel and the
sprocket teeth are aligned.
STRAIGHT
EDGE
4 CORNERS OF SPROCKETS
Figure 25. Alignment of Sprockets with Straight Edge
If you do not have a straight edge or the distance between sprocket

centers is too great, you can use a string, just as described in the previous
LAP for v-belt sheaves.
Step 6. Apply Tension to the Chain

The proper chain tension is very important to the life of the drive.
Some slack is necessary for the chain drive to function properly. If the
tension is too little, the chain will fly off the sprocket. If the tension is
too high, the bearings and the chain will wear very quickly.
Tensioning the chain is a 3-step process:
• Determine the sag needed
• Apply tension to the chain
• Measure the sag

Step 7. Apply Lubrication to the Chain
Before the chain can be run, it must be lubricated. In many cases, a
new chain will come with suitable lubrication for temporary operation,
but in some cases it may not. The easiest way to lubricate a chain is to
dip it in an oil bath before installing it. If a bath is not available, simply
oil the chain while it is on the sprockets with an oil can. Other types of
chain drives may have a continuous means of lubrication.
Step 8. Run the Motor Briefly to Test the Drive

Briefly run the motor and observe the operation of the drive. It
should run smoothly and be fairly quiet. If so, continue running. If not,
stop the drive and check for the problems.
Step 9. Recheck the Chain Sag

After the first 24 hours of operation, the tension in the chain should
be rechecked to verify that the chain sag is still adjusted properly. If the
chain tension is still as it should be, the drive system can be operated full
time. If the chain tension is incorrect, it could indicate that something is
wrong with the chain drive system. Chain sag should also be checked at
100 hours and every 500 hours of operation thereafter.
Step 10. Chain Removal

To remove a chain from a drive system with adjustable centers,
simply move the two shafts closer together. This will create enough slack
in the chain so that it can easily be lifted off of the sprockets, as shown in
figure 26.
If the drive does not have adjustable centers, the master link can be
disconnected to allow removal of the chain.
CENTERS
MOVED
CLOSER
OPERATING
CENTER
DISTANCE
Figure 26. Moving the Sprockets Close Together Makes Chain Removal
Simple

SKILL 3 INSTALL AND ALIGN A ROLLER CHAIN DRIVE SYSTEM
WITH ADJUSTABLE CENTERS
Procedure Overview
In this procedure, you will perform steps 1-5 of the
chain drive installation procedure for a system with
adjustable centers. You will complete the installation
procedure in a later skill in this LAP.
This ❑ 1. Perform the following safety checkout to prepare for working with
Do
power transmission equipment. Make sure that you are able to

answer yes to each item before proceeding.
YES/NO SAFETY CHECKOUT
Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put it in a cap or under shirt
Wearing heavy duty shoes
Wearing short sleeves or long sleeves are rolled up
Floor is not wet
❑ 2. Perform a lockout/tagout on the Motor Control Unit’s safety

switch.

❑ 3. Place the adjustable mounting base and Constant Speed Motor on
the work surface.
❑ 4. Perform the following substeps to mount the adjustable mounting
base.
A. Position the adjustable mounting base over the set of holes in
the 950-ME Mechanical Drives System’s work surface shown
in figure 27.
The outlines of the positions of the other components to be
mounted are also shown.
PRONY PRONY
1-INCH DIAMETER BRAKE BRAKE
5/8-INCH ENDS HUB
SHAFT
30 TOOTH
SPROCKET
1-INCH
BORE
BEARINGS
CHAIN
15 TOOTH MOTOR
SPROCKET
ADJUSTABLE
BASE
Figure 27. Location of Components on 950-ME Work Surface

B. Locate four bolts with the specification of 3/8-16UNC-2A x 2
Hex Head, along with the compatible flat washers, lock
washers, and nuts.
C. Fasten the mounting base to the work surface by assembling
the bolts, washers, and nuts.
Use a criss-cross sequence.
D. Adjust the lead screws to place its mounting studs in the center
position.
This will allow adjustments in either direction.
❑ 5. Perform the following substeps to mount and level the motor on
the adjustable mounting base.
A. Place the motor on top of the adjustable mounting base’s studs.
B. Locate four hex nuts with the specification of 5/16-18UNC-2B,
along with compatible flat washers and lock washers.
C. Fasten the motor to the adjustable mounting by assembling the
bolts washers and nuts.
tic
e This NOTE
No
Make sure that the lock washer is between the nut and the flat
washer.
D. Fasten the mounting base to the work surface by assembling

the bolts, washers, and nuts.
Use a criss-cross sequence.
E. Tighten the nuts to lock the motor in position. This will create a
rigid setup.
F. Check the shaft for run-out. Record below the amount of
run-out.
Run-out: _____________________________________(in/mm)
The run-out should be less than 0.002 inches.
G. Check for motor shaft end float.
End Float ____________________________________(in/mm)
It should be less than 0.002 inches.
H. Check the level of the motor shaft. Shim the motor feet as
needed.
Feeler Gage Leaf Thickness______________________(in/mm)
Effective Level Length _________________________(in/mm)
Mounting Bolt Distance_________________________(in/mm)
Shim Ratio _________________________________________
Shim Thickness _______________________________(in/mm)

❑ 6. Perform the following substeps to mount the shaft and pillow
block bearings.
A. Select four Bearing Standoffs from Shaft Panel 1.
B. Make sure that the standoffs, pillow block mounting surface,
and mounting area of the work surfaces, shown in figure 27, are
free of dirt, rust and burrs.
C. Place the four standoffs on the 950-ME work surface.
D. Remove two pillow block bearings with 1-inch diameter boxes
from Shaft Panel 1.
E. Place the pillow block bearings on the standoffs.
F. Locate four bolts with the specifications of 3/8-16UNC-2A x
4-1/2 Hex Head, along with the compatible flat washers, lock
washers, and nuts.
G. Fasten the pillow block bearings and the standoffs to the work
surface by assembling the bolts, washers, and nuts.
Hand tighten only.
H. Select a 8-inch long shaft from Shaft Panel 1 that has a 1-inch
diameter with 5/8-inch diameter ends.
I. Slide the shaft through the two pillow block bearings. Position
it as shown in figure 27.
J. Tighten the set screws on each bearing to lock the bearing to
the shaft.
K. Tighten the pillow block bearing mounting bolts.
L. Turn the shaft by hand to make sure it turns freely.
If not, loosen the bolts and adjust the positions of the bearings.
M. Check the driven shaft for run-out.
Run-out: _____________________________________(in/mm)
The shaft should have no more than 0.002 inches run-out.
N. Level the driven shaft. Shim the bearing standoffs as needed.
Place the shims between the work surface and the standoffs.
Feeler Gage Leaf Thickness______________________(in/mm)
Effective Level Length _________________________(in/mm)
Mounting Bolt Distance_________________________(in/mm)
Shim Ratio _________________________________________
Shim Thickness _______________________________(in/mm)
❑ 7. Install the prony brake on the shaft and work surface in the
location shown in figure 27.
This brake will be used in later skills to demonstrate how the
torque is affected by a sprocket ratio.
❑ 8. Locate the 15 and 30 tooth sprockets from Chain Drive Panel 1.

❑ 9. Perform the following substeps to mount the 15-tooth drive
sprocket to the motor shaft.
These steps are the same steps you used to install the sheaves in a
belt drive system.
A. Inspect the 15-tooth drive sprocket.
B. Locate the set-screw hole which is drilled into the side of the
hub of the 15-tooth sprocket.
C. Use a hex key wrench to take out the set screw and verify that
it is tipped with brass.
This will prevent damage to the shaft.
D. Clean the motor shaft’s key seat and the sprocket’s hub key
seat with a wire brush to make sure that no dirt or burs are in
the keyseats.
E. Select a 3/16 x 1 inch square key from your key stock.
F. Slide the key into the keyseat of the motor shaft.
Make sure it isn’t too tight or too loose. If so, replace the key.
G. Remove the key from the shaft keyseat and insert it into the
sprocket hub keyseat.
It also should slide in without forcing it and have no play.
H. Remove the key from the sprocket hub and insert into the shaft
keyseat. Line it up flush with the end of the shaft.
I. Pick up the sprocket with your hand and line it up in front of the
shaft so that the hub’s key seat is in line with the key on the shaft.
Orient the sprocket so that the hub points toward the motor.

J. Then slide the sprocket hub onto the shaft until the end of the
hub is flush with the end of the shaft, as shown in figure 28.
The hub should slide on without using tools. If it doesn’t, pull
it off and check the dimensions.
Figure 28. Sprocket Hub Attached to Motor Shaft
K. Tighten the setscrew onto the key to lock the sprocket in

position.
❑10. Repeat Step 9 in a similar manner to mount the 30-tooth driven
sprocket onto the driven shaft.
The setup should look like figure 29 at this time.
Figure 29. Current Setup

❑11. Check the sprocket alignment by placing the long straight edge (a
36-inch steel rule) flush against the driven sprocket face. Then
check the position of the face of the driver sprocket, as shown in
figure 30.
The driver sprocket must be adjusted to align with the driven
sprocket.
If the face of the driver sprocket is also flush against the straight
edge, the sprockets are aligned and the shafts are parallel. This
means that the sprockets are aligned and you can proceed to step
13.
If, however, only one point or no points of the driver sprocket
touch the straight edge, the shafts are not parallel. Proceed to step
12 to correct this.
Figure 30. Straight Edge Check for Sprocket Alignment
❑12. Perform the following substeps to align the sprockets.

A. Slightly loosen the 4 bolts that fasten the adjustable mounting
base to the work surface.
B. Move the motor base to a position so that all 4 edges of the
sprockets touch the straight edge.
C. Tighten the bolts in a criss-cross pattern until the bolts are tight.
D. Recheck the alignment with the straight edge after the bolts are
tightened. Repeat the alignment steps if necessary.

❑13. Perform the following substeps to mount the chain.
A. Loosen the locknuts on the motor and move the motor toward
the driven shaft by rotating the lead screws.
Position it close enough to be able to put on the chain, as
shown in figure 31.
Figure 31. Positioning of Motor Base

B. Place the chain over the sprockets.
C. Move the motor until the chain does not touch the worksurface,
as shown in figure 37.
D. You will learn exactly how much sag should be in the chain
later in this LAP.
E. Tighten the locknuts against the motor.
Figure 32. Motor Base Positioned Until a Small Amount of Sag is Left
❑14. Rotate the driven shaft by rotating the prony brake drum with your
hand.
Observe the meshing that occurs between the sprocket and the
chain, and how motion is transmitted through out the entire
system.
You should be able to hear the clicking as the links strike the
sprocket teeth. See if you can observe the chordal action.
❑15. Leave the setup as it is. You will need this same arrangement in
the next skill.

SEGMENT 2
SELF REVIEW
r This
we
Ans
1. __________ chains are similar in construction to a roller
chain except they have no __________.
2. __________ chains create less noise than standard chains

because of their tooth-shaped design.
3. Chains that are made up of a series of plates held together by

pins are called __________ chains.
4. __________ strand chains are similar to standard chains, but

they have two or more widths.
5. The interlocking between chain and sprocket prevent the

chain from ________ when a load is applied to the sprocket.
6. Power is __________ from one shaft to another via a

__________.

SEGMENT 3
CHAIN TENSIONING
OBJECTIVE 8 DESCRIBE HOW TO DETERMINE ALLOWABLE CHAIN SAG

FOR A GIVEN APPLICATION
dT
his In order for a chain to function properly its tension must be high
Rea
enough to enable it to stay on the sprockets. It must also not be too tight
or the drive will quickly wear and fail. For this reason, a chain must have
some slack in it, which is called sag. Chain tension is determined by how
much sag is in the chain, as shown in figure 33.
DRIVEN SPROCKET DRIVER SPROCKET
SAG
Figure 33. Chain Sag

When a chain is under load, it will have a taut side and a slack side.
The taut side is the side of the chain that is being pulled by the driver
sprocket. The slack side comes from the effect of the driver sprocket
‘pushing’ the chain, as shown in figure 34.
DRIVEN
TAUT SIDE
DRIVER
SLACK SIDE
Figure 34. The Taut Side and Slack Side of a Chain

Chain sag is measured by rotating the sprockets so that there is little
or no chain sag in the taut side and then measuring the sag in the slack
side. Chain sag is measured at the middle of the span between the two
sprockets, which is why it often called the mid-span sag.
Another term that is often used is the mid-span movement, which is
the movement of the sag in both directions, as shown in figure 35.
Mid-span movement is always two times the mid-span sag.
MID-SPAN
MOVEMENT
Figure 35. Mid-Span Movement

The amount of sag a chain drive should have depends on the
application for which the drive system is being used. The two
applications are:
• Vertically oriented chain drives
• Horizontally oriented chain drives
A vertically oriented chain drive is defined as a drive where the
angle between the line going through the centers of the two sprockets
and a horizontal line is greater than 45 degrees, as shown in figure 36. A
horizontally-oriented drive is one in which the angle is less than 45
degrees.
VERTICAL
LINE
90º
VERTICAL DRIVES
45º
HORIZONTAL
DRIVES
0º
Figure 36. Vertical and Horizontal Chain Drive
The allowable mid-span movement of a vertical chain drive is 2 or 3

percent of the distance between sprocket centers. For example, a
vertically oriented chain drive whose distance between centers is 24
inches has an allowable mid-span movement of about 0.6 inch. This
corresponds to a mid-span sag of 0.3 inch.
The allowable mid-span movement for a horizontal chain drive is 4
to 6 percent of the distance between sprocket centers. For example, a
horizontal chain drive whose distance between centers is 24 inches has
an allowable mid-span movement of 1 inch. This corresponds to a
mid-span sag of 0.5 inch.

SKILL 4 DETERMINE ALLOWABLE CHAIN SAG
FOR A GIVEN APPLICATION
Procedure Overview
In this procedure, you will determine the allowable
chain sag for a given application. This will include both
vertical and horizontal chain drives. To begin, you will be
lead through the steps. Then, you will do it yourself.
This ❑ 1. Perform the following substeps to determine the allowable

Do
mid-span movement and chain sag for the application shown in

figure 37.
A. Determine whether the drive system is a vertical or horizontal
type.
Orientation: ________________________(Vertical/Horizontal)
This application is horizontally oriented. This means that the
allowable mid-span movement should be 4-6 percent.
B. Locate the distance between centers of the drive system
30”

Distance between centers: _______________________(in/mm)
The distance between centers of this application is 30 inches.
C. Calculate the allowable mid-span movement of the chain drive
system.
Mid-Span Movement Range: _____________________(in/mm)
To determine the lower limit of the range, multiply 0.04 (4%)
times the distance between centers. To determine the upper
limit of the range, multiply 0.06 (6%) times the distance
between centers. This is as follows:
Minimum Movement = 0.04 x 30 = 1.2 inches
Maximum Movement = 0.06 x 30 = 1.8 inches
You should find a mid-span movement range to be 1.2 inches
to 1.8 inches.
D. Divide the mid-span movement by 2 to determine the allowable
sag of the system.
Chain Sag Range:______________________________(in/mm)
You should find a chain sag of 0.6 to 0.9 inches.

❑ 2. Determine the allowable mid-span movement and chain sag for the
application shown in figure 38.
Mid-Span Movement Range: _______________________(in/mm)
Chain Sag Range: ________________________________(in/mm)
”
20
30°
You should find a mid-span movement range of 0.8 to 1.2 inches

and a chain sag range of 0.4 to 0.6 inches.
application given the following information.
Given:
Drive Angle = 60 degrees from horizontal
Center Distance = 50 inches

You should find a mid-span movement range of 1 to 1.5 inches

application given the following information.
Given:
Drive Type: Vertical
Center Distance: 80 inches

You should find a mid-span movement range of 1.6 to 2.4 inches
OBJECTIVE 9 DESCRIBE TWO METHODS USED TO ADJUST CHAIN SAG
his
dT
During installation and later, after the chain has become worn, the
Rea
chain sag will need to be adjusted. There are two basic methods used to
adjust chain sag:
• Adjustable Centers
• Idler
You have already learned about adjustable centers. When the sag of
a chain needs to be adjusted, the centers of the drive system can be
moved either further apart or closer together, as shown in figure 39.
Figure 39. Adjusting Chain Sag by Using Adjustable Centers

Another method that is used to adjust chain sag is a device called a
chain idler, as shown in figure 40. A chain idler is a mechanism that has
a small sprocket attached to an arm which may or may not be spring
loaded. The spring-loaded feature automatically keeps constant tension
in the chain drive via the sprocket.
If a spring-loaded arm is not used, the idler sprocket must be
manually adjusted using a slot on the arm or by some other means.
Figure 40. Typical Chain Idler
It is important to understand that the adjustment of the chain tension

after the drive has been in use for a time is not done because the chain
has stretched. Chains do not stretch. They become longer because they
wear. Specifically, the bushings inside the roller links wear. As these
bushings wear, they become smaller and the length of the chain gets
longer. This makes it look as if the chain is stretching.
This wear feature is actually a benefit of a chain drive because it
allows the chain to be used for a longer time than other types of drives
and it makes it easy to determine when to replace the chain by measuring
its length. A chain should be replaced when its length becomes 3%
longer than the original length.

SEGMENT 3
SELF REVIEW
r This
we
Ans
1. The two methods commonly used to adjust chain centers are
__________ centers and by using a(n) __________
2. The allowable mid-span movement of a horizontally

oriented chain drive is ___ to ___ percent.
3. The allowable mid-span movement of a vertically oriented

chain drive is ___ to ___ percent.
4. Dividing the mid-span movement by ___ will give you the

chain ______.
5. If chain tension is too ________ the chain will wobble off of

the sprockets during operation.

SEGMENT 4
CHAIN TENSION MEASUREMENT
OBJECTIVE 10 DESCRIBE HOW TO MEASURE CHAIN SAG
dT
his Before the chain drive is put into operation, the chain sag must be
Rea
adjusted. This requires that you measure the actual chain sag. This is
easy to do using a straight edge and a rule.
To measure chain sag, one sprocket is rotated while the other is held
in place. This causes the sag to be on one side of the drive. A straight
edge is then laid across the sprockets on the side with sag. Midway
between the sprockets, the end of a rule is placed on the chain. The sag
in the chain is then read off of the rule where it crosses the straight edge.
CHAIN SAG
1
8
16
READING
Figure 41. Measuring Chain Sag

SKILL 5 USE A RULE AND A STRAIGHT EDGE
TO MEASURE CHAIN SAG
Procedure Overview
In this procedure, you will perform the next step of the
chain drive installation procedure by measuring the chain
sag of the chain drive you set up in the previous skill.
This ❑ 1. Perform the following safety checkout to prepare for working with
Do
power transmission equipment. Make sure that you are able to

answer yes to each item before proceeding.
YES/NO SAFETY CHECKOUT
Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put it in a cap or under shirt
Wearing heavy duty shoes
Wearing short sleeves or long sleeves are rolled up
Floor is not wet
❑ 2. Make sure the lockout/tagout is still in place. If not, make it so.

❑ 3. Make sure that the chain drive is still set up as it was in Skill 3, as
shown in figure 42. If not, repeat Skill 3 to do so.
Figure 42. Current Arrangement

❑ 4. Using one hand, turn the driven sprocket in a clockwise direction
while holding the other sprocket fixed in your hand.
This puts the slack in the upper side of the chain drive and makes
the lower side taut.
❑ 5. Perform the following substeps to measure the sag in the chain.
A. Lay a straight edge across the top of the sprockets, as shown in
figure 43.
Figure 43. Measuring Chain Sag
B. Press a rule into the sagging chain, as shown in figure 43.

C. Read the rule where it comes into contact with the underside of
the straight edge. Write your result in the blank below.
Rule Measurement: ____________________________(in/mm)
This value is the mid-span sag. It can be anything, depending
on how you adjusted the chain back in skill 3.
❑ 6. Leave the mechanical drives system setup in place and continue
directly to the next skill.

SKILL 6 ADJUST CHAIN SAG TO A SPECIFIED AMOUNT
USING ADJUSTABLE CENTERS
Procedure Overview
In this procedure, you will perform the last steps of the
chain drive installation and alignment procedure, which is
to adjust the tension to the correct amount. You will then
operate the drive.
This ❑ 1. Continuing from the last skill, make sure the lockout/tagout is still
Do
in place. Also, make sure the drive setup is still in place.

❑ 2. Perform the following substeps to calculate the allowable chain
sag.
A. Adjust the adjustable mounting base until the chain is taut.
B. Using a tape measure, determine the distance between shaft
centers.
Write the result in the blank below.
Center Distance _______________________________(in/mm)

C. Calculate the allowable mid-span movement.
Mid-Span Movement Range: ____________________(in/mm)
D. Calculate the allowable mid-span sag.
Mid-Span Sag Range: __________________________(in/mm)
❑ 3. Use the adjustable mounting base to position the driver sprocket so
that the chain sag is set to the midpoint of the range you calculated
in the previous step.
You may have to recheck the sag several times as you move the
mounting. Recheck the sag by repeating Steps 4 and 5 of the
previous skill. Lock the adjustable mount in place by tightening
the motor locknuts.
❑ 4. Lightly coat the chain with teflon lubricant.
Congratulations! You have completely installed, adjusted, and
aligned a roller chain drive system.

❑ 5. Perform the following substeps to start the motor.
A. Make sure that the safety switch power cord is plugged into a
wall outlet.
B. Make sure the Constant Speed Motor switch is in the OFF or
down position.
C. Connect the motor’s power cord to the Motor Control Unit.
D. Install the guard.
WARNING
ning Do not operate the mechanical drive system without the guard
ar
W
in place. Also, do not attempt to open or bypass the guard at any

time during operation. Performing any of these actions will create
a hazardous situation.
E. Remove the lockout/tagout.

F. Turn on the safety switch.
The Main Power Indicator on the Motor Control Unit should
turn on.
G. Make sure that no one is near the motor.
H. Turn on the Constant Speed Motor by moving its power switch
to the ON or up position.
The motor should accelerate to full speed quickly and run at a
constant speed.
❑ 6. Allow the motor to run for a few minutes while you observe the
operation of the drive.
You should notice that it is significantly louder than the v-belt
drive. This is one of its disadvantages.
❑ 7. Turn off the motor.
The motor should coast to a stop.
❑ 8. Perform a lockout/tagout.
❑ 9. Remove the guard.
❑10. Recheck the chain tension.
Chain Sag: ______________________________________(in/mm)
You should find that chain sag will not change after the operation
of the motor because a chain will not stretch like a v-belt does.
❑11. Replace the guard.
❑12. Leave your setup in place and go directly to the next activity to
operate the drive and analyze its operation.

Activity 1. Roller Chain Drive Analysis
Procedure Overview
In this activity, you will continue from the previous skill
to measure the torque and speed output of the chain drive
to prove that the formulas you learned in Segment 1
actually work.
This ❑ 1. Continuing directly from the previous skill, perform the following
Do
substeps to start the motor.

A. Verify that the guard is installed.
B. Remove the lockout/tagout.
C. Turn on the safety switch.
The Main Power Indicator on the Motor Control Unit should
turn on.
D. Make sure that no one is near the motor.
E. Turn on the Constant Speed Motor.
The motor should accelerate to full speed quickly and run at a
constant speed.
❑ 2. Measure the speeds of the motor shaft and the driven shaft using
the tachometer. Record your readings.
Driver Shaft Speed ________________________________(RPM)
Driven Shaft Speed ________________________________(RPM)
The unloaded speed of the motor shaft should be close to 1750
RPM. Since the sprocket ratio is 2 (30/15), the speed of the driven
shaft speed should be about 875 RPM.
This type of drive, where the speed of the driven shaft is lower
than the driver shaft, is called a speed-down drive. This is the more
commonly used configuration.
❑ 3. Now measure the motor’s electrical input current for each of the
prony brake load settings listed in the following table.
Scale Reading Motor Current Torque

(Ounces) (Amps) (In-Ounces)
24
30

❑ 4. Reduce the load on the motor to zero by turning the load nut
counterclockwise until the scale reads zero.
❑ 5. Turn off the electric motor.
❑ 6. Calculate the torque value for each scale reading in the table of
Step 3. Record your calculations in column 3 of the table in Step 3.
Use a value of 6.0 inches (15.24cm) for the torque radius of the
prony brake to do your calculations.
❑ 7. Compare the electrical current readings in the table Step 3 to the
electrical current readings you measured in LAP 2, when the motor
was directly coupled to the prony brake.
You should find that the current required for a given prony brake
load is lower than the current measured in LAP 2 because the
sprocket ratio is (30/15). The speed decreased and the torque
delivered increased. This means that the torque input required to
deliver the given torque is less.
❑ 8. Perform a lockout/tagout.
❑10. Perform the following substeps to partially disassemble the chain
drive.
A. Loosen the motor’s locknuts and position the motor close
enough to the driven shaft to make the chain loose.
B. Carefully pull the chain off the sprockets. Make sure that you
do not have to use force to remove the chain. Move the motor
closer to the driven shaft if necessary.
C. Use a hex key wrench to loosen the set screw on the hub of the
driven sprocket.

D. Carefully pull the sprocket off the driven shaft, as shown in
figure 44.
If the sprocket is stuck, use a small punch and tap the key out
of the keyseat, or use a gear puller.
This will break the sprocket loose to make it easier to remove.
Figure 44. Removal of Sprocket
E. Remove the motor sprocket using the same steps used to

remove the driver sprocket.

❑11. Reassemble the drive with the sprockets reversed, so that the large
sprocket is on the driver (motor) shaft and the small sprocket is on
the driven shaft, as shown in figure 45.
❑12. Adjust the chain sag to the same amount you did in the last skill.
Then, lock the motor’s locking nuts.
This configuration is called a speed-up drive. This is the least
common configuration of the chain drive, because many driven
components operate at lower speeds than typical motor speeds and
need higher torque.
Figure 45. Reversed Sprocket Configuration
❑13. Install the guard.

❑14. Remove the lockout/tagout.
❑15. Turn on the motor and allow it to accelerate to full speed.
❑16. Measure the speeds of the motor shaft and the driven shaft using
the tachometer. Record your readings.
The unloaded speed of the motor should be close to 1750 RPM.
Since the sprocket ratio is now 15:30, the speed of the driven shaft
speed should be about 3500 RPM.

❑17. Now measure the motor’s electrical input current for each of the
prony brake load settings listed in the following table.
Scale Reading Motor Current Torque

(Ounces) (Amps) (In-Ounces)
24
30
❑18. Reduce the load on the motor to zero and turn off the electric
motor.
❑19. Perform a lockout/tagout.
❑20. Remove the guard.
❑21. Calculate the torque value for each scale reading in the table of
Step 14. Record your calculations in column 3 of the table in step
14.
❑22. Compare the electrical current readings in the table of Step 14 to
the electrical current readings you measured in LAP 2, when the
motor was directly coupled to the prony brake.
You should find that the current required for a given prony brake
load is higher than the current measured in LAP 2 because the
sprocket ratio is 0.5. The speed at the driven shaft increased and
the torque delivered decreased. This means that more input torque
is required.
❑23. Perform Steps 10-15 in a similar manner to determine a chain
drive’s output speed and torque when the driver sprocket is a
20-tooth and the driven sprocket is a 30-tooth type.

❑24. Perform the lockout/tagout.

SEGMENT 4
SELF REVIEW
r This
we
Ans
1. Chain sag can be measured using a __________ edge and a
_________.
2. On a horizontally oriented drive, it is very important for the

sag to be on the __________ strand.
3. Shaft speed is measured using a _____________.
4. Shaft torque can be determined by using a ___________

brake and a(n) __________.
5. A chain that has too little sag can ___________ the

efficiency of the drive system and can cause excess
________.

SEGMENT 5
FIXED CENTER CHAIN INSTALLATION
OBJECTIVE 11 DESCRIBE THE FUNCTION AND OPERATION

OF A MASTER LINK
his
dT In some mechanical applications, the machine’s design does not
Rea
permit the driver shaft or the driven shaft to be moved in order to remove
and install a chain. For these cases, a continuous chain loop must be
separated so it can be installed and removed.
One way to separate and reconnect a chain is to use a special chain
link called a master link. Master links are similar in construction to a
standard chain link, but one of its side plates can be removed, as shown
in figure 46.
With the side plate removed, a master link can be put into a chain or
removed from it. This allows the chain to be installed onto sprockets and
the master link reinstalled to form a continuous chain.
The side plate of a master link can be held onto the two pins by using
either a cotter pin, or a locking spring clip.
Figure 46. Master Link

OBJECTIVE 12 DESCRIBE TWO METHODS OF INSTALLING
A LIGHTWEIGHT CHAIN WHICH USES A MASTER LINK
his
dT There are two main methods used to install chains which have a
Rea
master link: using the sprocket teeth mesh or a chain puller.
The simplest of these methods is to use the sprocket teeth mesh. This
method is accomplished by engaging one end of the chain with one of
the sprockets. The teeth of the sprocket will hold that end in place while
the rest of the chain is wrapped around the other sprocket and back to the
original end, as shown in figure 47.
When the two ends of the chain are next to each other, the master
link can then be installed.
ENDS OF CHAIN
MESHED IN
SPROCKET
TEETH
Figure 47. Using Sprocket Teeth to Install a Chain

In some cases, the chain is too heavy to lift the chain ends onto
adjacent sprocket teeth, or the sprockets have a protective shield over
them. In cases like these, a chain puller is used.
A chain puller is a tool that is used to hold the two ends of a chain
together while the master link is installed, as shown in figure 48.
CHAIN
PULLER
MASTER LINK
Figure 48. A Chain Puller Holds the Ends of a Chain Together

SKILL 7 INSTALL AND REMOVE A CHAIN WITH A MASTER LINK
USING SPROCKET TEETH
Procedure Overview
In this procedure, you will install a roller chain onto two
sprockets using a master link. You will use the teeth of the
sprocket to help you to hold the chain ends together while
the master link is assembled.
This ❑ 1. Make sure the lockout/tagout is still in place.

Do
If not, make it so.

❑ 3. Make sure that the drive assembly is still setup as it was in the
previous skill, as shown in figure 49. If they are not, repeat Steps
2-13 of Skill 3 to make it so.
Figure 49. Current Arrangement
❑ 4. Using the straight edge, adjust the motor mount until the distance
between the shaft centers is approximately 12-3/4 inches. Then
lock the motor in place.
tic
e This NOTE
No
Don’t forget to loosen the locking nuts before attempting to

move the motor.
This distance will simulate a fixed center chain drive setup.

❑ 4. Locate the chain’s master link, as shown in figure 50.
Figure 50. The Master Link
❑ 5. Perform the following substeps to disassemble the master link.

A. The locking clip is split at one end. Using your fingernails, you
should be able to lift one prong of the locking clip over the
grooved pin, as shown in figure 51.
If you are unable to do this with your fingernails, needle-nose
pliers may be used. If you do use the pliers, please be careful
not to damage or lose the locking clip.
REMOVABLE
SIDE PLATE
LOCKING
CLIP
LIFT HERE
Figure 51. Lifting Prongs or the Locking Clip

B. Once one prong is lifted over the pin, the other prong can easily
be lifted in the same manner.
C. Slide the locking clip until the split end is on the other pin, as
shown in figure 52.
SPLIT END
Figure 52. Slide the Split End to the Other Pin
D. The locking clip can now be removed by lifting the prongs as

was done for substeps A and B.
E. Once the locking clip is removed, slip the link’s side plate off
of the pins as well.

F. Slide the rest of the master link out from the other side of the
chain, as shown in figure 53, and remove the chain.
Be careful not to lose any of the pieces.
Figure 53. Removing the Master Link
❑ 6. Perform the following substeps to install the chain.

A. Place the chain over the sprockets, as shown in figure 54.
You should be able to get both ends of the chain into adjacent
sprocket teeth, as shown in the figure. The teeth will help hold
the chain ends for the next substep.
Figure 54. Installing the Chain

B. Install the master link by running the part with the pins into the
ends of the chain, as shown in figure 55.
Figure 55. Installing the Master Link
C. Slip the removable side plate onto the pins protruding from the
other side of the chain as shown in figure 56.
D. Then press the split part of the locking clip onto one of the pins
until the clip fits into one of the groove of that pin, as shown in
figure 56.
The locking clip can only be pressed onto a pin at the point of
the split.
REMOVABLE
SIDE PLATE
Figure 56. Assembling the Master Link

E. Position the clip so that the split is on top of the next pin.
F. Push the clip forward so that it fits into the groove of this pin,
as shown in figure 57.
Figure 57. Master Link Installed
G. Pull outward on the removable plate to make sure that it is

pressing up against the locking clip and not the chain bushings.
This allows the panels to freely rotate.
e This
tic NOTE
No
It is important that the clip not rub against the bushings.
❑ 7. Rotate the prony brake drum to make sure that the chain moves
freely.
❑ 8. Rotate the chain drive until the master link is once again
positioned on the sprocket where it was assembled.
The sprocket will hold the chain in place while you remove the
master link.
❑ 9. Disassemble the master link as you have before, and remove the
chain.
❑10. Leave the drive assembly setup for the next skill.

OBJECTIVE 13 DESCRIBE THE OPERATION OF A CHAIN PULLER
dT
his A chain puller operates by pulling the two ends of the chain together
Rea
with its jaws. The jaws are opened and closed by the dial on top of the
tool. When the jaws are opened far enough, each jaw is inserted into the
ends of the chain, as shown in figure 58.
Once the jaws are inserted into the ends of the chain, the chain puller
is then tightened by turning the dial until the chain ends are close enough
to allow the master link to be installed.
CHAIN
PULLER
MASTER LINK
Figure 58. A Chain Puller Holds the Ends of a Chain Together

SKILL 8 INSTALL AND REMOVE A CHAIN WITH A MASTER LINK
USING A CHAIN PULLER
Procedure Overview
In this procedure, you will use the chain puller to hold
the ends of the chain together.
This ❑ 1. Make sure the lockout/tagout is still in place.

Do
If not, make it so.

❑ 2. Continuing from the previous skill, make sure the mechanical
drives system is set up as in the previous skill. If it is not, make it
so.
❑ 3. Perform the following substeps to install the chain using a chain
puller.
A. Drape the chain over the two sprockets, as shown in figure 59.
Figure 59. Chain Draped Over Two Sprockets
B. Obtain the chain puller from Chain Drive Panel 1.

C. Open the jaws of the chain puller as far as they will go by
rotating the dial counterclockwise.
D. Insert each of the jaws into the ends of the chain, as shown in
figure 60.
Figure 60. Insert the Jaws into the Ends of the Chain
E. Tighten the chain puller by rotating the dial clockwise.

This will close the jaws of the chain puller, which will bring the
ends of the chain together.
F. When the ends of the chain are close enough together, install
the master link as you did in the previous skill.
❑ 4. After the master link has been installed, slightly open the jaws of
the chain puller and remove it from the chain.
❑ 5. Make sure that the sprockets are still aligned.
❑ 6. Perform the following substeps to make sure that your installation
is correct.
A. Make sure that the master link is firmly held in place by its
locking clip.
B. Then, rotate the drive by hand until the master link travels
completely around the drive. Carefully observe it as you do as
to make sure the master link functions as it should.
❑ 7. Disassemble the setup and store components.
❑ 8. Remove the lockout/tagout.

SEGMENT 5
SELF REVIEW
r This
we
Ans
1. The easiest drive system to install a chain on is one with
__________ centers.
2. A chain can be disconnected and reconnected at one point

through the use of a __________ ______
3. A _______ __________ is used to pull the loose ends of a

chain together.
4. The __________ alignment can be checked with a straight

edge.


Mechanical Drives 1 Lap 5

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Mechanical Drives 1 Lap 5

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MECHANICAL

INTRODUCTION TO CHAIN DRIVES

950-ME1 Mechanical Drives 1 Learning System

Amatrol or School Supplied

FIRST EDITION, LAP 5, REV. B

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

SEGMENT 1 CHAIN DRIVE CONCEPTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 2 CHAIN DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SEGMENT 3 CHAIN TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SEGMENT 4 CHAIN TENSION MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SEGMENT 5 FIXED CENTER CHAIN INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

OBJECTIVE 1 DESCRIBE THE FUNCTION OF THE THREE BASIC

Figure 1. The Three Basic Components of a Chain Drive

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

OBJECTIVE 2 DESCRIBE HOW TO CALCULATE SPROCKET RATIO

FORMULA: SPROCKET RATIO

Figure 2. Chordal Action of a Drive

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Sprocket Ratio: ____________

Figure 3. Chain Drive Application

In this case, the number of teeth of the driver sprocket is 36 and

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Figure 4. Chain Drive Application

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

DRIVEN SPROCKET 96 TEETH

Figure 5. Chain Drive Application

In this case, the number of teeth of the driver sprocket is 16 and

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Figure 6. Effect of Relative Numbers of Sprocket Teeth on the Speed of

The relationship between numbers of sprocket teeth and shaft speeds

FORMULA: CHAIN DRIVE SPEED

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

In a similar manner to speed, sprocket ratio also affects the torque

Figure 7. Effect of Sprocket Ratio on Torque of Driven Shaft

The calculation of shaft torque is performed using a formula that is

FORMULA: CHAIN DRIVE TORQUE

As with the speed formula, the torque formula can be modified to

FORMULA: CHAIN DRIVE TORQUE

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

DRIVER SPEED 600 RPM

Figure 8. Chain Drive Application

The driven shaft speed is 1200 RPM

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

2. ___________ action is caused by straight chain links

3. In a chain drive ___________ ratio cannot be determined by

4. __________ ratio is the ratio of the number of teeth of the

5. The speed and __________ of a driven sprocket can be

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

OBJECTIVE 4 LIST FOUR TYPES OF CHAINS

four types of chains you will most often encounter are:

Figure 9. The Construction of a Standard Roller Chain

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Figure 10. The Construction of a Rollerless Chain

Rollerless chains are used in light-weight, low-speed, mechanical

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Figure 11. The Engagement and Release of a Silent Chain

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Figure 12. The Construction of a Leaf Chain

B502-XC LAP 5 INTRODUCTION TO CHAIN DRIVES

Single Strand Chain

Figure 14. Single Strand Chain

Single strand roller chain is used for most general-purpose