Mechanical Drives 2 Lap 7

MECHANICAL
LEARNING
DRIVES 2 ACTIVITY
PACKET
HEAVY-DUTY CHAIN DRIVES
TM
B503-XC
LEARNING ACTIVITY PACKET 7
HEAVY-DUTY CHAIN DRIVES
INTRODUCTION
In the Mechanical Drives 1 course, you were introduced to chain drives and their
basic operation, particularly roller chain drives. In this LAP, you will learn about two
more types of chain drives commonly used in industry: silent chain drives and multiple
strand chain drives.
You will also learn how a particular chain drive is selected based on the application
and how to lubricate and maintain a chain drive system.
ITEMS NEEDED
Needed Amatrol Supplied
Items
950-ME1 Mechanical Drives 1 Learning System

95-ME2 Mechanical Drives 2 Learning System
Amatrol or School Supplied

Assorted Hand Tools
FIRST EDITION, LAP 7, 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
means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying,
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
B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Copyright  2006 Amatrol, Inc. 2
TABLE OF CONTENTS
SEGMENT 1 SILENT CHAIN DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe the operation of four types of sprockets and give an application of each
OBJECTIVE 2 Describe the operation of a silent chain drive
OBJECTIVE 3 Describe how to install and align a silent chain drive system
SKILL 1 Install and align a silent chain drive system
SEGMENT 2 MULTIPLE STRAND SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

OBJECTIVE 4 Describe the operation of a multiple strand chain drive
OBJECTIVE 5 Describe how to install and align a multiple strand chain drive system
SKILL 2 Install and align a multiple strand chain drive system using a taper lock bushing
SEGMENT 3 CHAIN SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

OBJECTIVE 6 Define chain pitch and pitch length of a chain drive and explain their importance
OBJECTIVE 7 Describe how chains are specified
OBJECTIVE 8 Describe how sprockets are specified
SKILL 3 Identify the size and type of a chain and sprocket given a specification
OBJECTIVE 9 Describe how to identify the size and type of chain and sprocket given a sample
SKILL 4 Identify the size and type of chain and sprocket given a sample
OBJECTIVE 10 Describe how to select the type and size of chain and sprocket for a given application
SKILL 5 Select a chain and sprocket for a given application
SEGMENT 4 CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

OBJECTIVE 11 Describe four types of chain lubrication methods
OBJECTIVE 12 Describe how to select a lubrication system for a chain drive system
SKILL 6 Select a lubrication system for a chain drive system
OBJECTIVE 13 Describe how to select a type of lubricant for a chain drive system
SKILL 7 Lubricate a chain drive system using the manual lubrication method
SEGMENT 5 CHAIN MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 76

OBJECTIVE 14 Describe ten maintenance steps for chain drives
OBJECTIVE 15 Describe how to troubleshoot a chain drive system
SKILL 8 Check a chain for elongation
SKILL 9 Troubleshoot a chain drive system
OBJECTIVE 16 Describe the operation of a chain breaker
SKILL 10 Cut a chain using a chain breaker

SEGMENT 1
SILENT CHAIN DRIVES
OBJECTIVE 1 DESCRIBE THE OPERATION OF FOUR TYPES OF SPROCKETS

AND GIVE AN APPLICATION OF EACH
his
dT There are four basic types of sprockets commonly used in chain
Rea
drive systems. They are:

• Type A: No Hub
• Type B: Single Hub
• Type C: Double Hub
• Type D: Detachable Hub
Each of these is described as follows:
Type A: No Hub Sprocket

No Hub, or hub-less, sprockets are the most simple and inexpensive
type of sprocket. They consist of a flat plate with a hole cut in the center
to accommodate a shaft, as shown in figure 1.
Figure 1. Type A Sprocket

A common method of mounting these types of sprockets is to weld
them directly to the shaft. This makes replacement of the sprocket very
difficult. Another method used is to attach it to a collar that is mounted
to the shaft, as shown in figure 2.
Figure 2. Type A Sprocket Mounted to a Shaft Using a Collar
Type A sprockets are generally used in low-speed, low-load

applications. This is the type of sprocket found on bicycles.

Type B: Single Hub Sprocket
Single hub sprockets have an integral, or built in, hub as shown in
figure 3.
Figure 3. A Typical Type B Sprocket
Type B hubs allow for a more secure attachment to a shaft than the
hub-less sprockets. Consequently, they can be used for heavier-duty and
higher speed applications than can hub-less sprockets.

Type C: Double Hub Sprocket
Type C sprockets have two integral hubs, one on each side, as shown
in figure 4.
Figure 4. A Typical Type C Sprocket
This arrangement allows for the greatest amount of stability under

very heavy loads and high speeds. Double hubs are only used on larger
sprockets for extreme load and high speed application.
Type B and C sprockets are commonly mounted with bushings.
Type D: Detachable Hub Sprocket

A sprocket that has a detachable hub is simply a two-piece sprocket
whose hub is attached by several bolts, as shown in figure 5.
Figure 5. A Typical Type D Sprocket
This arrangement makes it very easy to remove and replace

sprockets. Type D sprockets are used in applications where a high rate of
wear requires frequent sprocket replacement. They are not used as often
as the other three types.

OBJECTIVE 2 DESCRIBE THE OPERATION OF A SILENT CHAIN DRIVE
his
dT Silent chain consists of a series of leaf links connected together
Rea
side-by-side much like a leaf chain, as shown in figure 6. Each leaf has
two teeth that are oriented upside down, which is why silent chain is also
called inverted tooth chain. Further, the leaves are designed so that some
teeth on each row have leading teeth and others have trailing teeth, as is
also shown in figure 6. This causes the chain to maintain continuous
contact with the sprocket, thereby reducing noise. In fact, the silent chain
is 35% quieter than roller chain.
SPROCKET
Figure 6. Silent Chain Design

Silent chain sprockets look more like a gear than a sprocket because
of their width and tooth shape, as shown in figure 7. The chain’s teeth
are designed to contact the sprocket similar to the way a gear rack
contacts a spur gear. The biggest difference you will notice is the silent
chain will often have a groove which runs down the middle of the teeth,
as shown in figure 7. This groove provides a means of guiding the chain
so it doesn’t fall off the sprocket.
GROOVE
Figure 7. Silent Chain Sprocket
The sprocket shown in figure 7 is called a single center guide which

is used with the guide on the silent chain, shown in figure 8. Silent chain
sprockets are available with either a finished bore or bushing mounting.
GUIDE
Figure 8. Silent Chain Guide Methods

OBJECTIVE 3 DESCRIBE HOW TO INSTALL AND ALIGN A SILENT CHAIN
DRIVE SYSTEM
his
dT The installation of a silent chain drive system is very similar to the
Rea
installation of a roller chain drive system. The steps involved in
mounting a silent chain drive system are as follows:
Step 1. Mount the Motor and the Driven Component, Level their
Shafts, and Check for Run-Out
• The motor and driven shafts are mounted, leveled and checked for
run-out.
Step 2. Inspect the Sprockets for Cleanliness and Wear. Clean

or Replace if Necessary
• The sprockets are inspected to determine if they are suitable for
use.
Step 3. Mount the Sprockets onto the Shafts

• The sprockets are mounted to the shafts and checked for visible
run-out.
Step 4. Mount the Chain

• The chain is mounted to the sprockets.
• The chain guides are aligned with the grooves in the sprocket.
• Silent chains can be mounted by using a connecting link in a
similar fashion as roller chains. The construction of a silent chain
link, however, is quite different from that of a roller chain, as
shown in figure 9.
Figure 9. A Silent Chain Connecting Link

• Silent chain connecting links are installed by interlocking the two
end links together, then inserting the two rocker joints. These
joints are held in place by the small cotter pins.
Step 5. Align the Sprockets

• Alignment of the sprockets is checked using either the straight
edge or string method.
Step 6. Apply Initial Tension to the Chain

• Chain sag is calculated and chain tension is adjusted using a
straight edge and machinist’s rule.
Step 7. Lubricate the Drive System

• The chain is lubricated either by hand or by the drive’s permanent
lubrication system.
Step 8. Run the Motor Briefly to Test the Drive

• Operation of the drive is carefully observed. If there are any
problems with the drive, it is stopped and the problem is corrected.
If not, the drive can continue running.
Step 9. Retest the Chain Sag after 24 Hours of Operation

• The chain sag is inspected after 24 hours of operation and
periodically thereafter.
Chain Removal
• Chain removal is accomplished by either moving the shaft centers
close together or by removing a connecting link.

SKILL 1 INSTALL AND ALIGN A SILENT CHAIN DRIVE SYSTEM
Procedure Overview
In this procedure, you will install and align a silent
chain drive system. This installation process is similar to
installing a roller chain drive system.
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. Locate Shaft Panel 1 and Chain Drive Panel 2 and place them on
the overhead rack.

❑ 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 Trainer’s work surface shown in figure 10.
The outlines of the positions of the other components to be
mounted are also shown.
Notice the side of the adjustable base that has the greater offset.
SILENT
CHAIN
MOTOR
ADJUSTABLE
BASE
Figure 10. 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.
❑ 5. Perform the following substeps to mount and level the motor on
the adjustable mounting base.
A. Position the motor over the set of holes in the adjustable
mounting base.
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
washers and nuts.
D. Lock the set screws of the adjustable base to lock the motor in
position. This will create a rigid setup.

E. 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.
F. Check for motor shaft end float.
End Float ____________________________________(in/mm)
It should be less than 0.002 inches.
G. 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 10, are
free of dirt, rust and burrs.
C. Place the four standoffs on the 950-ME work surface.
D. Remove two pillow block bearings from Shaft Panel 1 that
have a bore size of 1-inch.
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 an 8-inch long shaft from Shaft Panel 1 that has a 1-inch
diameter and 5/8-inch ends..
I. Slide the shaft through the two pillow block bearings. Position
it as shown in figure 10.
J. Tighten the set screws on each bearing collar 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. Select the two silent chain sprockets from Chain Drive Panel 2.
These sprockets are the same size. Therefore the sprocket ratio is
1:1.
❑ 8. Inspect the two silent chain sprockets for dirt or rust.
If you find any foreign material on sprockets, clean it.
❑ 9. Perform the following substeps to mount the drive sprocket.
These steps are the same steps you used to install the fixed bore
sprocket shaft drive system.
A. Locate the setscrew hole which is drilled into the side of the
hub of one of the silent chain sprockets, as shown in figure 11.
SET SCREW
Figure 11. Set Screw on Hub
B. Use a hex key wrench to back out the set screw so that it is not
extending into the shaft hole.
C. Clean the motor shaft’s key seat and the sprocket’s hub’s key
seat with a wire brush to make sure that no dirt or burs are in
the keyseats.
D. Select a 3/16 square x 1 inch key from your key stock.

E. 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.
F. 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.
G. Remove the key from the sprocket hub and reinsert into the
shaft keyseat. Line it up flush with the end of the shaft just as
you did while mounting the brake drum.
H. Pick up the sprocket with 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.
I. Then slide the sprocket hub onto the shaft, as shown in figure
12.
NOTE
tic
e This The hub of the silent chain sprocket is so long that the
No
sprocket will not sit flush with the motor shaft. When you come
across a situation like this, simply slide the component onto the
shaft or for as will go. You must, however, make sure that the
setscrew engages the key.
The hub should slide on without using tools. If it doesn’t, pull

it off and check the dimensions.
J. Tighten the setscrew onto the key.
Figure 12. Position of the Sprocket on the Drive Shaft

❑ 10. Repeat Step 9 in a similar manner to mount the other sprocket to
the driven shaft.
The setup should look like figure 13 at this time.
Figure 13. Current Setup
❑ 11. Place a straight edge against the two sprockets to check for alignment.
If the face of the driver sprocket is flush against the straight edge,
the sprockets are aligned and you can proceed to Step 13.
If, however, only one or no points of the driver sprocket is
touching the straight edge, the shafts are not parallel, and you
should perform Step 12 to align the sprockets.

❑ 12. Perform the following substeps to ensure the sprockets are
properly aligned.
A. Slightly loosen all four bolts that fasten the motor to the
adjustable mounting base.
B. Move the motor to a position where all four edges of the
sheaves are touching the straight edge.
C. Tighten the bolts in a criss-cross pattern until they are tight.
D. Recheck the alignment with the straight edge after the bolts are
tightened. Use the leadscrews to adjust if necessary.
Figure 14. Straight Edge Check for Sprocket Alignment

❑ 13. Perform the following substeps to mount the silent chain.
A. Make sure the locking nuts on the motor are loose, then turn
the lead screws on the adjustable mounting base so that the
motor is moved closer to the driven shaft. Position it close
enough to be able to put the chain on, as shown in figure 15.
Figure 15. Positioning of Motor Base
B. Place the chain over the sprockets, making sure that the chain
guides fall into the grooves of the sprockets.
C. Turn the motor base’s lead screws so that the motor moves
away from the driven shaft and lightly grips the chain.
The chain should straighten out, as shown in figure 16, but it
should not have any tension in it yet. This will just hold the
chain in place.
Figure 16. Motor Base Positioned to Hold the Chain

❑ 14. Calculate the allowable range of mid-span movement and chain
sag for this application.
Mid-span Movement Range: ________________________(in/mm)
Chain Sag Range: ________________________________(in/mm)
Remember, midspan movement is 4 to 6% of the chain span for
horizontal drives.
❑ 15. Turn the lead screws on the adjustable mounting base until the
chain has the proper amount of chain sag, as shown in figure 17.
❑ 16. Tighten the motor’s locking nuts.
Figure 17. Adjusting Chain Sag
❑ 17. Place a cloth under the chain and spray the Teflon lubricant onto
the chain until it is coated.

❑ 18. Perform the following substeps to start the motor.
A. Make sure that the safety switch power cord is plugged into a
wall outlet.
B. Connect the constant speed motor’s power cord to the Motor
Control Unit.
C. Make sure that the Constant Speed Motor switch is in the OFF
or down position.
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 than 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.
You should notice that this silent chain drive is quieter than the
roller chain drives you have used in previous skills.
❑ 19. Turn off the motor and allow it to coast to a stop.
❑ 20. Perform a lockout/tagout and remove the guard.
❑ 21. Adjust the position of the mounting base so that the silent chain is
loose on the sprockets.
❑ 22. Remove the chain and both sprockets and return them to their
storage locations.

❑ 23. Leave the motor, mounting base, and shaft/pillow block assembly
in place, as shown in figure 18. You will use them in the next skill.
Figure 18. Current Set-Up

SEGMENT 1
SELF REVIEW
r This
we
Ans
1. The type of sprocket that is most often welded to a shaft is
called a ______ ________ sprocket.
2. _______________ hubs are usually only found on larger

sprockets.
3. Roller chain drives are very __________ due to the rollers

colliding with the sprocket teeth.
4. Another name for silent chain is ___________ tooth chain.
5. A silent chain drive system usually produces ____% less

noise than a standard roller chain drive.
6. A silent chain must have a(an) __________ to keep the

chain from rotating off of the sprockets.

SEGMENT 2
MULTIPLE STRAND SYSTEMS
OBJECTIVE 4 DESCRIBE THE OPERATION OF A MULTIPLE-STRAND

CHAIN DRIVE SYSTEM
dT
his The multiple-strand chain is constructed of one or more widths of
Rea
standard roller chain which have been joined together side-by-side, as

shown in figure 19.
Figure 19. Typical Multiple-Strand Chain

Multiple-strand chain has the advantage of being able to carry much
heavier loads than single-strand chain because the load is distributed
across each of the strands, rather than one strand having to carry the
entire load by itself.
Multiple-strand chain drive sprockets are constructed of one or more
single sprockets that have been joined together side-by-side as well, as
shown in figure 20.
Figure 20. Typical Multiple-Strand Chain Sprockets
Multiple-strand chain drive systems work just like any other chain
drive systems. The teeth of the driver sprocket engage with the links of
the multiple-strand chain. This transfers power from the driver shaft to
the chain, which then applies its power to the driven shaft, as shown in
figure 21.
Figure 21. The Operation of a Multiple-Strand Chain Drive

OBJECTIVE 5 DESCRIBE HOW TO INSTALL AND ALIGN A
MULTIPLE-STRAND CHAIN DRIVE SYSTEM
dT
his The installation of a multiple-strand chain drive system is very
Rea
similar to the installation of most other chain drive systems. The steps
involved in mounting a multiple-strand chain drive system are as
follows:
Step 1. Mount the Motor and the Driven Component, Level their
Shafts, and Check for Run-Out
• The motor and driven shafts are mounted, leveled and checked for
run-out.
Step 2. Inspect the Sprockets for Cleanliness and Wear. Clean

or Replace if Necessary
• The sprockets are inspected to determine if they are suitable for
use.
Step 3. Mount the Sprockets onto the Shafts

• The sprockets are mounted to the shafts and checked for visible
run-out.
Step 4. Mount the Chain

• The chain is mounted to the sprockets.
• The chain guides are aligned with the grooves in the sprocket.
Step 5. Align the Sprockets

• Alignment of the sprockets is checked using either the straight
edge or string method.
Step 6. Apply Initial Tension to the Chain

• Chain sag is calculated and chain tension is adjusted using a
straight edge and machinist’s rule.
Step 7. Lubricate the Drive System

• The chain is lubricated either by hand or by the drive’s permanent
lubrication system.
Step 8. Run the Motor Briefly to Test the Drive

• Operation of the drive is carefully observed. If there are any
problems with the drive, it is stopped and the problem is corrected.
If not, the drive can continue running.

Step 9. Retest the Chain Sag after 24 Hours of Operation
• The chain sag is inspected after 24 hours of operation and
periodically thereafter.
Chain Removal
• Chain removal is accomplished by either moving the shaft centers
close together or by removing a connecting link.
SKILL 2 INSTALL AND ALIGN A MULTIPLE-STRAND CHAIN DRIVE

SYSTEM USING A TAPER LOCK BUSHING
Procedure Overview
In this procedure, you will install and align a
multiple-strand chain drive system. This installation
process is similar to installing a roller chain drive system.
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 dry
❑ 2. Perform a lockout/tagout on the Motor Control Unit’s safety

switch.

❑ 3. Continuing from the last skill, the motor and driven shaft should
still be set up, as shown in figure 22. If not, repeat Steps 4-6 in the
last skill to do so.
❑ 4. Select the following sprockets from Chain Drive Panel 2.

• 15 Tooth double row sprocket
• 23 Tooth double row sprocket
❑ 5. Inspect the sprockets for dirt or grease.
If you find any foreign material on the sprockets, clean it.
❑ 6. Perform the following substeps to mount the 15 tooth sprocket on
the motor shaft.
This sprocket uses a taperlock bushing.
A. Clean the motor shaft’s key seat and the bushing keyseat of the
15 tooth sprocket with a wire brush to make sure that no dirt or
burs are in the keyseats.
B. Select a 3/16 square x 1 inch key from your key stock.
C. Slide the key into the keyseat of the motor shaft.
The key should fit into the keyseat without forcing it and have
no play. If so, replace the key.
D. Remove the key from the shaft keyseat and insert it into the
bushing keyseat of the 15 tooth sprocket. It also should slide in
without forcing it and have no play.
E. Remove the key from the bushing and reinsert into the shaft
keyseat. Line it up flush with the end of the shaft just as you
did while mounting the brake drum.

F. Place the sprocket, without the bushing, onto the shaft and let it
hang there.
G. Hold the bushing so that the printing is facing away from you
and align the bushing keyseat with the key on the motor shaft.
H. Then slide the bushing onto the shaft until the end of the hub is
flush with the end of the shaft, as shown in figure 23.
The bushing should slide on without using tools. If it doesn’t,
pull it off and check the dimensions.
Figure 23. Position of the Bushing on the Drive Shaft
I. Now, carefully slide the tapered bore sprocket onto the bushing
making sure the three holes are lined up. The sprocket does not
have to, and probably will not, slide until it is entirely flush
with the bushing.
This
tic
e
NOTE
No
If you apply too much pressure to the bushing it will move. Be

very careful.
J. Insert the two setscrews into the holes directly adjacent to the
split.
K. Tighten the setscrews until they are snug and the sprocket
comes flush with the bushing.

❑ 7. Repeat Step 6 in a similar manner to mount the 23 tooth sprocket
to the driven shaft.
The setup should look like figure 24 at this time.
Figure 24. Current Setup
❑ 8. Perform the straight edge check for sprocket alignment.

If the face of the driver sprocket is flush against the straight edge,
the sprockets are aligned and you can proceed to Step 9.
If, however, only one or no points of the driver sprocket are
touching the straight edge, the shafts are not parallel. You must
then align the sprockets by loosening the motor mounts and
adjusting the motor until the sprockets are aligned.

❑ 9. Perform the following substeps to mount the chain.
A. Select the 1/2-inch pitch multiple strand chain from the storage
unit.
B. Turn the leadscrews on the adjustable mounting base so that the
motor is moved closer to the driven shaft. Position it close
enough to be able to put the chain on, as shown in figure 25.
Figure 25. Positioning of Motor Base
C. Place the chain over the sprockets. Make sure that the multiple
strands of the chain match up with the multiple sprockets.

C. Turn the motor base’s adjustment screw so that the motor
moves away from the driven shaft and lightly grips the chain.
The chain should straighten out, as shown in figure 26, but it
should not have any tension on it yet. This is used to hold the
chain in place.
Figure 26. Motor Base Positioned to Hold the Chain
❑ 10. Calculate the allowable range of mid-span movement and chain

sag for this application.
Mid-span Movement Range: ________________________(in/mm)
Chain Sag Range: ________________________________(in/mm)
❑ 11. Turn the screw on the adjustable mounting base until the chain has
the proper amount of chain sag, then lock it in place.
❑ 12. Place a cloth under the chain and spray the Teflon lubricant onto
the chain until it is coated.
❑ 13. Perform the following substeps to start the motor.
A. Make sure that the safety switch power cord is plugged into a
wall outlet.
B. Connect the constant speed motor’s power cord to the Motor
Control Unit.
C. Make sure that the Constant Speed Motor switch is in the OFF
or down position.

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 than 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. Allow it to run for a few minutes.
Observe the operation of the multiple strand chain drive.
❑ 13. Turn off the motor and allow it to coast to a stop.
❑ 14. Perform a lockout/tagout and remove the guard.
❑ 15. Leave the trainer in this current set-up. You will need this
arrangement for a later skill.
Figure 27. Current Arrangement of the Mechanical Trainer

SEGMENT 2
SELF REVIEW
r This
we
Ans
1. A special type of chain drive that has two or more strands of
chain affixed side-by-side and is used on _________ -duty
machinery is called a(an)__________ - __________ chain
drive.
2. A multiple-strand drive system can carry heavier loads due

to its increased __________ _____.
3. Multiple-strand chain drives are just like several standard

____________ chain drives side-by-side.
4. The taper design of a taper lock bushing causes the bushing

to _________ down onto the shaft.

SEGMENT 3
CHAIN SELECTION
OBJECTIVE 6 DEFINE CHAIN PITCH AND PITCH LENGTH OF A CHAIN DRIVE

AND EXPLAIN THEIR IMPORTANCE
dT
his The chain pitch and pitch length are important concepts in chain
Rea
drives because they are used to specify chains.

Each of these is described as follows:
Chain Pitch
Unlike v-belt drives, pitch has a specific meaning in a chain drive.
The pitch of a chain is the distance between the center of one pin of a
chain link and the corresponding center of the pin of the next link, as
shown in figure 28.
Chain pitch is important because it specifies both chain size and
length.
CHAIN PITCH
Figure 28. Chain Pitch

Pitch Length
The pitch length of a chain drive is the total length of the chain
measured along the centerline of the pins, as shown in figure 29.
PITCH LENGTH
Figure 29. Pitch Length of a Chain Drive
You may also hear of chain length being measured by its number of
pitches. This means that the number of links in the chain gives the chain
length. To determine the pitch length of a chain in this case, simply
multiply the total number of pitches in the chain by the pitch (length of a
single link).
Pitch length is used to specify the length of a chain.

OBJECTIVE 7 DESCRIBE HOW CHAINS ARE SPECIFIED
his
dT Roller Chain Link Specification
Rea
Roller chain links are specified by a numbering code that is defined
by the ANSI Standards B29.1 and B29.3. These standards describe the
specific dimensions to which manufacturers should manufacture chains.
This assures interchangeability between manufacturers. A typical code
for a roller chain is shown in figure 30.
12 0
CHAIN CHAIN
PITCH DESIGN
Figure 30. Typical Roller Chain Code
The leftmost one or two digits describe the pitch of the chain in
eighths of an inch. For example, a chain code of 120 means that the
chain pitch is 12 eighths of an inch, or 1.5 inches. A code of 60 means
that the chain pitch is 6 eighths of an inch, or 0.75 inches.
The next digit to the right of the one or two-digit pitch code
describes the chain design. It can either be a 0 for standard roller chain, a
1 for lightweight roller chain, or a 5 for rollerless bushing chain.
For heavy series chain, an H, as shown in figure 31 follows these
two or three digits. This type of chain has links that have a plate
thickness which is equal to the next larger pitch size of standard chain.
Standard roller chain will not have letters in its code. For example, a
120H is a heavy-duty roller chain, while a 120 is a standard roller chain.
12 0 H
CHAIN PITCH HEAVY

AND DESIGN CHAIN
Figure 31. Heavy Chain Specification

If the chain is made of multiple strands, the chain code will end with
a hyphen and a number that specifies the number of strands. For
example, a 120-4 is a standard roller chain with four strands.
Finally, adding 2000 to the single pitch chain code specifies chains
that have a double pitch. For example, a chain code of 2120-2 is a double
pitch chain with a 3-inch pitch (2 times the single pitch of 12 eighths)
and is double stranded.
Some more examples of common chain sizes are shown in figure 32.
CHAIN SIZE CODE PITCH (inches) TYPE OF ROLLER CHAIN

25 1/4 Rollerless Links
30 3/8 Standard Links
35 3/8 Rollerless Links
41 1/2 Narrow, light-duty links
61 3/4 Narrow, light-duty links
80 1 Standard Links
100 1-1/4 Standard Links
160 2 Standard Links
240 3 Standard Links
Figure 32. Common Roller Chain Size Codes

Special Chain Link Specifications
Silent chain link sizes are also defined by an ANSI Standard and
specified in a similar manner to roller chains. A typical code is shown in
figure 33. As you can see, the code starts with an SC which designates
that it is a silent chain. The next digit identifies the pitch in eighths of an
inch and the last two digits identify the width of the chain in fourths of
an inch. For example, the chain code in figure 33, SC-612, is a silent
chain with a 0.75 inch pitch (identified by a 6) and is three inches wide
(identified by a 12).
SC - 6 12
SILENT CHAIN CHAIN

CHAIN PITCH WIDTH
Figure 33. Silent Chain Size Code
Notice that this size code uses only 1 digit for the pitch, meaning that
the greatest pitch specified by the code is 1 inch. This is because silent
chains are used on smaller power applications below 50 Hp. Their main
advantages are high-speed capability and quiet operation.
High Velocity Heavy Duty chain, or simply HV chain, is specified in
a similar manner as silent chain. The only difference is the chain pitch is
preceded by the letters HV.
Chain Length
The length of all types of chains is specified either by the number of
pitches (links) or the pitch length. Chain comes in standard lengths that
are in turn cut to the length needed for the application. This is done by
separating one of the links with a tool of some type.

OBJECTIVE 8 DESCRIBE HOW SPROCKETS ARE SPECIFIED
dT
his Sprockets are specified in much the same way as chains are. That’s
Rea
because the sprocket must exactly match the chain that it is being used to
drive.
To specify a sprocket, you must know:
• Number of Strands
• Chain Type and Size
• Bushing Type and Size / Bore Size
• Number of Teeth
A typical sprocket specification is shown in the figure below.
D60 C 35
SPROCKET
# OF PITCH # OF
ROLLER
STRANDS TEETH
CHAIN
SPROCKET
TYPE
Figure 34. The Sprocket Designation Code
Number of Strands
The first digit in the code is a letter indicating the number of strands
of the sprocket. The letters are given under the following code:
Blank = single strand
D = Double or two strands
T = Triple or three strands
F = Four strands
Chain Size and Type

The next digits are the pitch and chain type, which is once again
measured in eighths of an inch. The specification in figure 34, for
example, shows a #60 chain which has a 3/4 inch pitch and is a standard
roller chain.
After the pitch comes the type of sprocket hub (A, B, C, or, D).
Bushing Type and Size/Bore Size

The next one or two digits describe how the sprocket is mounted. If
the sprocket does not use a bushing, these digits aren’t used. If the
sprocket is bushed, the bushing size and type codes that you learned
about in a previous LAP are used here.
Number of Teeth
Finally, the number of teeth on the sprocket is indicated by the last
few digits in the code.
For example, a sprocket specification code of D60BTB35 is the
specification of a sprocket that has 2 strands, a pitch of 3/4 inch, it is a
Type B sprocket with a tapered bore, and it has 35 teeth.
Another example, a sprocket specification code of 80C40 is the
specification of a single strand sprocket with 1 inch pitch that has a Type
C hub with a finished bore, and has 40 teeth.
SKILL 3 IDENTIFY THE SIZE AND TYPE OF A CHAIN AND SPROCKET

GIVEN A SPECIFICATION
Procedure Overview
In this procedure, you will first identify the
characteristics of chains and sprockets given their
specification codes.
This ❑ 1. Identify the size and type of chain given the following
Do
specification:
Chain Specification: SC-608
Pitch: __________________________________________(in/mm)
Chain Type: ___________________________________________
Chain Width: ____________________________________(in/mm)
The pitch of the above chain specification is 6 eighths or 3/4 of an
inch. It is a silent chain (SC) that is 8/4 or 2 inches wide.
❑ 2. Identify the size and type of chain given the following
specification:
Chain Specification: 50-4
Pitch: __________________________________________(in/mm)
Chain Type: ___________________________________________
Chain Width: ___________________________________(strands)
The pitch of the above chain is 5/8 of an inch long. It is a multiple
strand roller chain which is four strands wide.

specification.:
Chain Specification: 2040
Pitch: __________________________________________(in/mm)
Chain Type: ___________________________________________
The pitch of the above specification is twice the 4 eighths or 1 inch
since it is a double pitch chain.
specification:
Chain Specification: 61
Pitch: __________________________________________(in/mm)
Chain Type: ___________________________________________
The pitch of the above specification is 6 eighths or 3/4 of an inch
long. The 1 indicates that this is a narrow, light-duty chain.
specification:
Chain Specification: HV-820
Pitch: __________________________________________(in/mm)
Chain Type: ___________________________________________
Chain Width: ____________________________________(in/mm)
The pitch of the above specification is 8 eighths or 1 inch. It is a
high-velocity, heavy-duty (HV) chain that is 20/4 or 5 inches wide.
❑ 6. Identify the characteristics of the sprocket in the blanks below
given the following sprocket specification:
Sprocket Specification: F50B12
Pitch: __________________________________________(in/mm)
Sprocket Type: __________(No-Hub, Single, Double, Detachable)
Sprocket Width: _________________________________(strands)
Number of Teeth: __________________________________(teeth)
Bore: ___________________________________(finished/bushed)
The pitch of the above specification is 5/8 of an inch. It is a single
hub sprocket with four strands. Each of the strands has 12 teeth
and the sprocket has a finished bore.

given the following sprocket specification:
Sprocket Specification: D80D35
Pitch: __________________________________________(in/mm)
Bore: ___________________________________(finished/bushed)
The pitch of the above specification is 8 eighths or 1 inch. It is a
detachable hub type sprocket that is two strands wide. Each strand
has 35 teeth and the hub has a finished bore.
given the following sprocket specification
Sprocket Specification: 60C80:
Pitch: __________________________________________(in/mm)
Bore ___________________________________(finished/bushed)
The pitch of the above specification is 6 eighths or 3/4 of an inch
long. It has a double hub and is only one strand wide. It has 80
teeth and uses an SDS size QD bushing.
OBJECTIVE 9 DESCRIBE HOW TO IDENTIFY THE SIZE AND TYPE OF CHAIN

AND SPROCKET GIVEN A SAMPLE
his
dT Sometimes it may be necessary to identify the size and type of a
Rea
sprocket whose part number can’t be determined. In this case, you can do
so by making a few measurements.
To determine a sprocket specification you need to determine the
following:
• Type of Chain
• Number of Strands
• Pitch
• Sprocket Type
• Number of Teeth
• Bushing Type/Bore Size

Type of Chain
You first need to determine the type of chain for which that the
sprocket is designed for. Here, a quick glance at the chain or the shape of
the sprocket teeth will tell you if it is a roller chain sprocket or silent
chain, HV chain, or multiple strand chain sprocket.
Number of Strands
Next, you need to determine the number of strands that the sprocket
has.
Pitch
The pitch of the sprocket can be determined by measurement. Using
a machinist’s rule, measure the distance between two successive sprocket
teeth, as shown in figure 35. Don’t forget to translate this number into
the chain pitch code.
Figure 35. Measuring Sprocket Teeth
Sprocket Hub Type

Determine whether the sprocket hub is type A, B, C, or D.
Number of Teeth
The number of teeth are counted.
Bushing Type/Bore Size

Determine whether or not the sprocket has a bushing. You can
determine its type by measuring its dimensions and locating them in a
manufacturer’s catalog. The bushing code may also be printed on the
bushing itself.
You should also measure the bore of the sprocket or bushing. You
can measure the bore of a finished bore sprocket with a dial caliper. If it
is a bushed sprocket, measure the bore of the bushing.

Construct the Sprocket Specification
You now have all of the information you need to construct the
sprocket specification code. Use the information you learned earlier in
the previous objective to do so.
Chain Specification
You can determine the size and type of chain in much the same way
as was done for sprockets. To identify the size and type of chain, you
need to determine the following:
• Type of chain
• Pitch
• Number of strands
• Number of links
• Construct the chain specification
Type of Chain
Here a quick glance is all that is needed to determine the type of
chain used on the drive. You then use the following numbers in the chain
code.
0 Standard Roller Chain
1 Lightweight Chain
5 Rollerless Chain
20 Double Pitch Chain
Pitch
The pitch can be measured using a machinist’s rule. Measure the
distance between successive pins on the chain. Don’t forget to translate
this value in to the chain pitch code.
Number of Strands
Determine how wide the chain is by counting its number of strands.
Number of Links
You will want to replace an existing chain with one that is the same
length. Do not measure an old chain. Remember, it can stretch under use.
The length of a chain is determined by counting its number of links.
Construct the Chain Specification

You now have enough information to construct the chain
specification. Use the information you learned earlier in this LAP to do
so.

SKILL 4 IDENTIFY THE SIZE AND TYPE OF CHAIN AND SPROCKET
GIVEN A SAMPLE
Procedure Overview
In this procedure, you will examine chains and
sprockets in order to identify their specifications. This skill
may be useful in the event you have to identify a drive
component whose specification isn’t available.
This ❑ 1. Obtain the following items from the 950-ME trainer and place
Do
them on the work surface.

• Machinist’s rule
• Dial caliper
• All sprockets from chain drive panels 1 and 2
• All chains from the storage unit
tic
e This NOTE
No
The trainer should still be set up with the multiple strand chain
drive. You do not have to disassemble this set-up for this skill.
❑ 2. Select one of the sprockets.

❑ 3. Perform the following substeps to identify its characteristics. Write
your results in the table below:
Sprocket No. 1 2 3 4 5 6 7
Drive Type
No. of Strands
Pitch
Sprocket Type
No. of Teeth
Mounting
Bore
Specification
A. Identify the type of chain for which the sprocket is designed.

Identify whether the chain that the sprocket is designed for is a
roller, rollerless, double pitch, silent, or multiple strand
sprocket. Enter your choice in the drive type row of column 1
of the table in substep A.

B. Count the number of strands of the sprocket and enter the
number in the No. of strands row of the table.
C. Measure the pitch of the sprocket.
Use the machinist’s rule to measure the pitch of the sprocket.
Write the pitch code in the pitch row of the table
D. Identify whether the sprocket is type A, B, C, or D. Enter this
into the table.
E. Count the number of teeth of the sprocket and enter the result
in the No. of teeth column of the table
F. Determine whether the sprocket is bushed or has a finished
bore and write the result in the table.
G. Measure the bore of the sprocket/bushing and write the result in
the Bore Diameter row of the table.
H. Write the sprocket specification code in the bottom row of the
table.
❑ 4. Perform Step 3 in a similar manner to determine the specifications
of the remaining sprockets. Enter the data for each sprocket into
one of the columns in the table.
❑ 5. Compare your answers with the answer guide shown below.
e This NOTE
tic
No
The sprockets in the answer guide are presented in no

particular order. Only verify that your answers are correct.
Sprocket No. 1 2 3 4 5 6 7
Drive Type Roller Roller Roller Multiple Multiple Silent Silent
No. of Strands 1 1 1 2 2 1 1
Pitch 40 40 40 40 40 40 40
Sprocket Type B B B B B B B
No. of Teeth 30 20 15 23 15 17 17
Mounting Finished Finished Finished Bushed Bushed Finished Finished
Bore (inches) 5/8 5/8 5/8 5/8 5/8 5/8 5/8
Specification 40B30 40B20 40B15 D40BTL23 D40ATL15 SC404-17 SC404-17

❑ 6. Locate one of the chains from the trainer.
❑ 7. Perform the following substeps to identify its characteristics. Write
your results in the table below:
Chain No. 1 2 3
Drive Type
No. of Strands
Pitch
No. of Pitches
Specification
A. Identify the type of drive of the chain.

Identify whether the drive that the chain is designed for is a
roller, rollerless, double pitch, silent, or multiple strand
sprocket. Enter your choice in the drive type row of the table
shown above.
B. Count the number of strands of the chain and enter the number
in the No. of strands row of the table.
C. Measure the pitch of the chain.
Use the machinist’s rule to measure the pitch of the chain.
Write the pitch code in the pitch row of the table.
D. Count the number of pitches of the chain and enter the result in
the No. of Pitches column of the table.
E. Write the chain specification code in the bottom row of the
table.
❑ 8. Perform Step 7 in a similar manner to determine the specification
of each of the remaining chains.
❑ 9. Compare your answers with the answer guide shown below.
Chain No. 1 2 3
Drive Type Roller Silent Multiple
No. of Strands 1 3 2
Pitch 40 40 40
No. of Pitches 80 74 76
Specification SC-403 w/74 40-2 w/76

40 w/80 pitches pitches pitches
❑ 10. Return all materials to their proper storage locations..

OBJECTIVE 10 DESCRIBE HOW TO SELECT THE TYPE AND SIZE OF CHAIN
AND SPROCKET FOR A GIVEN APPLICATION
his
dT Most chain and sprocket manufacturers provide a step-by-step
Rea
process that can be used to determine the necessary chain drive, as
shown below:
1. Determine the Design Power
2. Approximate the Chain Pitch and the Size of the Smaller
Sprocket
3. Verify that the Small Sprocket is Large Enough for its Shaft
4. Compute the Size of the Larger Sprocket
5. Approximate the Length of Chain
6. Select Sprocket and Bushing Sizes
This process is described as follows:
Step 1. Determine the Design Power

The first step in designing a chain drive is to determine the design
power. This is similar to what you did in designing v-belts and
synchronous belt drives. The design power is the rated power of the
driving unit times a service factor. This service factor can be found in a
manufacturer’s table and is used to account for extreme working
conditions.
Step 2. Approximate the Chain Pitch and the Size of the Smaller
Sprocket
The power and the rotational speed of the smaller sprocket determine
chain pitch. Pitch is most often calculated by using a table similar to the
one shown in figure 36.

NUMBER OF
STRANDS
1
0
24
0
20
0
18
0
16
0
14
0
12
0
10
80
DESIGN HORSEPOWER
60
50
40
35
25
Figure 36. Chart Used to Select Chain Pitch

The number of teeth used on the small sprocket is given by speed
and chain pitch. Many chain and sprocket manufacturers provide a table
that recommends the appropriate number of teeth based on chain pitch
and design power, as shown in figure 37.
HORSEPOWER RATINGS STANDARD SINGLE STRAND ROLLER CHAIN - NO. 60 - 3/4” PITCH
No. of REVOLUTIONS PER MINUTE - SMALL SPROCKET
Teeth
Small 10 25 50 100 150 200 300 400 500 600 700 800 900 1000 1100 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500
Spkt.
12 0.20 0.45 0.85 1.58 2.28 2.95 4.25 5.51 6.74 7.94 9.12 10.3 11.4 12.6 13.7 13.5 10.7 8.77 7.35 6.28 4.49 3.42 2.71 2.22 1.86
13 0.22 0.50 0.92 1.73 2.49 3.22 4.64 6.01 7.34 8.65 9.94 11.2 12.5 13.7 14.9 15.2 12.1 9.89 8.29 7.08 5.06 3.85 3.06 2.50 0
14 0.24 0.54 1.00 1.87 2.69 3.49 5.02 6.51 7.96 9.37 10.8 12.1 13.5 14.8 16.2 17.0 13.5 11.1 9.26 7.91 5.66 4.31 3.42 2.80 0
15 0.25 0.58 1.08 2.01 2.90 3.76 5.41 7.01 8.57 10.1 11.6 13.1 14.5 16.0 17.4 18.8 15.0 12.3 10.3 8.77 6.28 4.77 3.79 3.10 0
16 0.27 0.62 1.16 2.16 3.11 4.03 5.80 7.52 9.19 10.8 12.4 14.0 15.6 17.1 18.7 20.2 16.5 13.5 11.3 9.66 6.91 5.26 4.17 3.42 0
17 0.29 0.66 1.24 2.31 3.32 4.30 6.20 8.03 9.81 11.6 13.3 15.0 16.7 18.3 19.9 21.6 18.1 14.8 12.4 10.6 7.57 5.76 4.57 3.74 0
18 0.31 0.70 1.31 2.45 3.53 4.58 6.59 8.54 10.4 12.3 14.1 15.9 17.7 19.5 21.2 22.9 19.7 16.1 13.5 11.5 8.25 6.28 4.98 4.08 0
19 0.33 0.75 1.39 2.60 3.74 4.85 6.99 9.05 11.1 13.0 15.0 16.9 18.8 20.6 22.5 24.3 21.4 17.5 14.6 12.5 8.95 6.81 5.40 4.42 0
20 0.35 0.79 1.47 2.75 3.96 5.13 7.38 9.57 11.7 13.8 15.8 17.9 19.8 21.8 23.8 25.7 23.1 18.9 15.8 13.5 9.66 7.35 5.83 0
21 0.36 0.83 1.55 2.90 4.17 5.40 7.78 10.1 12.3 14.5 16.7 18.8 20.9 23.0 25.1 27.1 24.8 20.3 17.0 14.5 10.4 7.91 6.28 0
22 0.38 0.87 1.63 3.05 4.39 5.68 8.19 10.6 13.0 15.3 17.5 19.8 22.0 24.2 26.4 28.5 26.6 21.8 18.2 15.6 11.1 8.48 6.73 0
23 0.40 0.92 1.71 3.19 4.60 5.96 8.59 11.1 13.6 16.0 18.4 20.8 23.1 25.4 27.7 29.9 28.4 23.3 19.5 16.7 11.9 9.07 7.19 0
24 0.42 0.96 1.79 3.35 4.82 6.24 8.99 11.6 14.2 16.8 19.3 21.7 24.2 26.6 29.0 31.3 30.3 24.8 20.8 17.8 12.7 9.66 7.67 0
25 0.44 1.00 1.87 3.50 5.04 6.52 9.40 12.2 14.9 17.5 20.1 22.7 25.3 27.8 30.3 32.7 32.2 26.4 22.1 18.9 13.5 10.3 8.15 0
26 0.46 1.05 1.95 3.65 5.25 6.81 9.80 12.7 15.5 18.3 21.0 23.7 26.4 29.0 31.6 34.1 34.2 28.0 23.4 20.0 14.3 10.9 8.65 0
28 0.50 1.13 2.12 3.95 5.69 7.37 10.6 13.8 16.8 19.8 22.8 25.7 28.5 31.4 34.2 37.0 38.2 31.3 26.2 22.4 16.0 12.2 0
30 0.54 1.22 2.28 4.26 6.13 7.94 11.4 14.8 18.1 21.4 24.5 27.7 30.8 33.8 36.8 39.8 42.4 34.7 29.1 24.8 17.8 13.5 0
32 0.57 1.31 2.45 4.56 6.57 8.52 12.3 15.9 19.4 22.9 26.3 29.7 33.0 36.3 39.5 42.7 46.7 38.2 32.0 27.3 19.6 14.9 0
35 0.63 1.44 2.69 5.03 7.24 9.38 13.5 17.5 21.4 25.2 29.0 32.7 36.3 39.9 43.5 47.1 53.4 43.7 36.6 31.3 22.4 17.0 0
40 0.73 1.67 3.11 5.81 8.37 10.8 15.6 20.2 24.7 29.1 33.5 37.7 42.0 46.1 50.3 54.4 62.5 53.4 44.7 38.2 27.3 0
45 0.83 1.89 3.53 6.60 9.50 12.3 17.7 23.0 28.1 33.1 38.0 42.0 47.7 52.4 57.1 61.7 70.9 63.7 53.4 45.6 32.6 0
Type A Type B Type C
Figure 37. Table Used to Determine Number of Teeth on the Small Sprocket
Step 3. Verify that the Small Sprocket is Large Enough for its
Shaft
Sprockets have a limit the size of the bore that can be drilled into
them. In this step, the sprocket size that was approximated in step 2 is
looked up in the manufacturer’s catalog to verify that it can handle the
diameter of the shafts. If not, the smallest sprocket that will
accommodate the shaft is used.
Step 4. Compute the Size of the Larger Sprocket

The size of the driven sprocket can easily be determined by using the
speed ratio. Recall that speed ratio is:
Rotational Speed of Driven Shaft
Speed Ratio =
Rotational Speed of Driver Shaft
We can rearrange this equation to find the size of the driven sprocket
as:
# of teeth of Driver sprocket
# of teeth of Driven sprocket =
Speed Ratio

Step 5. Approximate the Length of Chain
Chain length (in pitches) can be approximated by a simple
calculation as shown below.
FORMULA
S
Length = 2C +
2
Where:
C = distance between centers of the sprockets measured
in chain pitches
S = total number of sprocket teeth in entire system
If this result yields an even number of links, then one link is added.
This is because chains are made of two types of links. Using chains with
an odd number of pitches ensures that the two end links are roller links
and a connecting link can be used to complete the chain.
Step 6. Select Sprocket and Bushing Sizes

In this final step, all of the components required for the application
are listed by their specifications.

SKILL 5 SELECT A CHAIN AND SPROCKET FOR
A GIVEN APPLICATION
Procedure Overview
In this procedure, you will design a chain drive system
for a given application, using the process you’ve just
learned about. You will then be given a real application to
select the appropriate drive system.
This ❑ 1. Perform the following substeps to select the sizes of the

Do
components for a chain drive system given the information shown

in substep A.
A. Examine the information about a chain drive application
FEATURE SPECIFICATION
Motor Size 12 hp
Motor Shaft Size 1/2 inch
Driven Shaft Size 1/2 inch
Distance between centers 24 inches
Application Type Centrifugal fan
Driver Shaft Speed 600 RPM
Driven Shaft Speed 300 RPM
B. Determine the rated power of the system.

Rated Power:_________________________________(Hp/kW)
This can be determined by looking at the given information in
substep A. In this case, it is easy because the motor size is
given. The rated horsepower is therefore 12 Hp.

C. Use figure 38 to determine the service factor.
Service Factor: ______________________________________
SERVICE FACTORS
DRIVEN EQUIPMENT Input Power

Electric motor
or turbine
Agitators, liquid stock. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Beaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Blowers, centrifugal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Boat propellers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Compressors
centrifugal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
reciprocating, 3 or more cylinders . . . . . . . . . . . . . . . 1.3
reciprocating, singular, 2 cylinders . . . . . . . . . . . . . . . 1.5
Conveyors
uniformly loaded or fed. . . . . . . . . . . . . . . . . . . . . . . . 1.0
not uniformly loaded or fed. . . . . . . . . . . . . . . . . . . . . 1.3
reciprocating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Cookers, cereal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Crushers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Elevators, bucket
uniformly loaded or fed. . . . . . . . . . . . . . . . . . . . . . . . 1.0
not uniformly loaded or fed. . . . . . . . . . . . . . . . . . . . . 1.3
Fans, centrifugal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Feeders
rotary table 1.0
apron, belt, screw, rotary vane . . . . . . . . . . . . . . . . . . 1.3
reciprocating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Generators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Grinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Hoists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Kettles, brew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Kilns and dryers, rotary . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Lineshafts
light or normal service . . . . . . . . . . . . . . . . . . . . . . . . 1.0
heavy service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Machinery
uniform load, nonreversing. . . . . . . . . . . . . . . . . . . . . 1.0
moderate pulsating load, nonreversing . . . . . . . . . . . 1.3
severe impact or variable load, reversing. . . . . . . . . . 1.5
Mills
ball, pebble and tube . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
hammer, rolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Pumps
centrifugal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
reciprocating, 3 or more cylinders . . . . . . . . . . . . . . . 1.3
Screens, rotary, uniformly fed . . . . . . . . . . . . . . . . . . . . . 1.3
Basic for service factors: Uniform load . . . . . . . . . . . . . . 1.0
Basic for service factors: Moderate shock load . . . . . . . . 1.3
Basis for service factors: heavy shock load . . . . . . . . . . . 1.5
Figure 38. Service Factors for Chain Drive Systems
You should find that the service factor for a centrifugal fan is
1.0.

D. Calculate the design power.
Design Power:________________________________(Hp/kW)
The design horsepower is found by multiplying the rated power
of the driver by the service factor that was found in substep C.
You should therefore find a design power of 12 Hp (12 Hp x
1.0).
E. Approximate the chain pitch.
Chain Pitch ____________________________________(code)
NUMBER OF
STRANDS
1
0
24
0
20
0
18
0
16
0
14
0
12
0
10
80
DESIGN HORSEPOWER
60
50
40
35
25
Figure 39. Chain Pitch Selection Table

Using the table in figure 39, move down the horsepower
column until you reach the design power calculated in substep
D. Read across the top row until you find the RPM of the
smaller sprocket. These two values should intersect in a field
that indicated the approximate chain pitch that should be used.
You should choose a #60 chain.
F. Approximate the size of the smaller sprocket.
Small Sprocket Size:_____________________________(teeth)
Teeth
Small 10 25 50 100 150 200 300 400 500 600 700 800 900 1000 1100 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500
Spkt.
12 0.20 0.45 0.85 1.58 2.28 2.95 4.25 5.51 6.74 7.94 9.12 10.3 11.4 12.6 13.7 13.5 10.7 8.77 7.35 6.28 4.49 3.42 2.71 2.22 1.86
13 0.22 0.50 0.92 1.73 2.49 3.22 4.64 6.01 7.34 8.65 9.94 11.2 12.5 13.7 14.9 15.2 12.1 9.89 8.29 7.08 5.06 3.85 3.06 2.50 0
14 0.24 0.54 1.00 1.87 2.69 3.49 5.02 6.51 7.96 9.37 10.8 12.1 13.5 14.8 16.2 17.0 13.5 11.1 9.26 7.91 5.66 4.31 3.42 2.80 0
15 0.25 0.58 1.08 2.01 2.90 3.76 5.41 7.01 8.57 10.1 11.6 13.1 14.5 16.0 17.4 18.8 15.0 12.3 10.3 8.77 6.28 4.77 3.79 3.10 0
16 0.27 0.62 1.16 2.16 3.11 4.03 5.80 7.52 9.19 10.8 12.4 14.0 15.6 17.1 18.7 20.2 16.5 13.5 11.3 9.66 6.91 5.26 4.17 3.42 0
17 0.29 0.66 1.24 2.31 3.32 4.30 6.20 8.03 9.81 11.6 13.3 15.0 16.7 18.3 19.9 21.6 18.1 14.8 12.4 10.6 7.57 5.76 4.57 3.74 0
18 0.31 0.70 1.31 2.45 3.53 4.58 6.59 8.54 10.4 12.3 14.1 15.9 17.7 19.5 21.2 22.9 19.7 16.1 13.5 11.5 8.25 6.28 4.98 4.08 0
19 0.33 0.75 1.39 2.60 3.74 4.85 6.99 9.05 11.1 13.0 15.0 16.9 18.8 20.6 22.5 24.3 21.4 17.5 14.6 12.5 8.95 6.81 5.40 4.42 0
20 0.35 0.79 1.47 2.75 3.96 5.13 7.38 9.57 11.7 13.8 15.8 17.9 19.8 21.8 23.8 25.7 23.1 18.9 15.8 13.5 9.66 7.35 5.83 0
21 0.36 0.83 1.55 2.90 4.17 5.40 7.78 10.1 12.3 14.5 16.7 18.8 20.9 23.0 25.1 27.1 24.8 20.3 17.0 14.5 10.4 7.91 6.28 0
22 0.38 0.87 1.63 3.05 4.39 5.68 8.19 10.6 13.0 15.3 17.5 19.8 22.0 24.2 26.4 28.5 26.6 21.8 18.2 15.6 11.1 8.48 6.73 0
23 0.40 0.92 1.71 3.19 4.60 5.96 8.59 11.1 13.6 16.0 18.4 20.8 23.1 25.4 27.7 29.9 28.4 23.3 19.5 16.7 11.9 9.07 7.19 0
24 0.42 0.96 1.79 3.35 4.82 6.24 8.99 11.6 14.2 16.8 19.3 21.7 24.2 26.6 29.0 31.3 30.3 24.8 20.8 17.8 12.7 9.66 7.67 0
25 0.44 1.00 1.87 3.50 5.04 6.52 9.40 12.2 14.9 17.5 20.1 22.7 25.3 27.8 30.3 32.7 32.2 26.4 22.1 18.9 13.5 10.3 8.15 0
26 0.46 1.05 1.95 3.65 5.25 6.81 9.80 12.7 15.5 18.3 21.0 23.7 26.4 29.0 31.6 34.1 34.2 28.0 23.4 20.0 14.3 10.9 8.65 0
28 0.50 1.13 2.12 3.95 5.69 7.37 10.6 13.8 16.8 19.8 22.8 25.7 28.5 31.4 34.2 37.0 38.2 31.3 26.2 22.4 16.0 12.2 0
30 0.54 1.22 2.28 4.26 6.13 7.94 11.4 14.8 18.1 21.4 24.5 27.7 30.8 33.8 36.8 39.8 42.4 34.7 29.1 24.8 17.8 13.5 0
32 0.57 1.31 2.45 4.56 6.57 8.52 12.3 15.9 19.4 22.9 26.3 29.7 33.0 36.3 39.5 42.7 46.7 38.2 32.0 27.3 19.6 14.9 0
35 0.63 1.44 2.69 5.03 7.24 9.38 13.5 17.5 21.4 25.2 29.0 32.7 36.3 39.9 43.5 47.1 53.4 43.7 36.6 31.3 22.4 17.0 0
40 0.73 1.67 3.11 5.81 8.37 10.8 15.6 20.2 24.7 29.1 33.5 37.7 42.0 46.1 50.3 54.4 62.5 53.4 44.7 38.2 27.3 0
45 0.83 1.89 3.53 6.60 9.50 12.3 17.7 23.0 28.1 33.1 38.0 42.0 47.7 52.4 57.1 61.7 70.9 63.7 53.4 45.6 32.6 0
Figure 40. Sprocket Selection Table
Using figure 40, locate the speed of the small sprocket in the
top row. Read down this column until you reach the first power
rating that will satisfy the design power. Read left across this
row until you reach the first column. The size of the small
sprocket is indicated here. In this case, you should use a
sprocket with 18 teeth, which is rated for 12.3 horsepower.

G. Verify the size of small sprocket.
Maximum Bore Size: ___________________________(inches)
STOCK STEEL SPROCKETS

Catalog Diameters No. Stock Bores Marked “X” inches
No. Teeth
Outside Pitch 3/4 1 1-1/8 1-1/4 1-1/2
609 2.50” 2.193” 9 X X - - -
6010 2.76 2.427 10 X X X X -
6011 2.96 2.662 11 X X X X -
6012 3.25 2.898 12 X X X X -
6012W 3.25 2.898 12 - - - X -
6013 3.45 3.134 13 X X X X X

6014 3.74 3.371 14 X X X X X
6015 3.98 3.607 15 X X X - -
6015 3.98 3.607 15 - - - X X
6016 4.22 3.844 16 - X X - -
6016 4.22 3.844 16 - - X X X

6017 4.46 4.082 17 - X - - -
6017 4.46 4.082 17 - - - X X
6018 4.70 4.319 18 - X - - -
6018 4.70 4.319 18 - - X X X
6018W 4.70 4.319 18 - - - X -

6019 4.95 4.557 19 - X - - -
6019 4.95 4.557 19 - - - X -
6020 5.19 4.794 20 - X - - -
6020 5.19 4.794 20 - - - X X
Figure 41. Sprocket Dimension Table
H. Once the driver sprocket size has been determined, you must
see if it can be mounted to the shaft. Next to the sprocket size
in figure 41, is the maximum size bore that the sprocket can
accommodate. Record this value in the blank below.
Max. Bore Size ___________________________________(in)
You should have found a maximum bore size of 2.5 inches.
This number is greater than the motor shaft size.
I. Determine the drive ratio
Speed Ratio: ________________________________________
As you have already learned, the speed ratio is the speed of the
driven shaft divided by the speed of the driver shaft. Both of
these values are given in substep A.
In this case, you should find a speed ratio of 0.5 (300 rpm/600
rpm).

J. Compute the size of the larger sprocket.
Large Sprocket Size:_____________________________(teeth)
The size of the large sprocket is found by dividing the size of
the small sprocket by the speed ratio found in substep H. Here
you should find the size of the large sprocket to be 36 teeth.
K. Approximate the length of the chain.
Approximate Chain Length: _____________________(pitches)
The chain length can be approximated by the formula you
learned earlier. Here you should find the chain to have 91
pitches.
S 2 (24) (18 + 36)
Length of Chain = 2C + = +
2 0.75 2
Length of chain = 91 pitches.
Then, add 1 connecting link to make it an even 92 pitches.
L. Select sprocket and bore sizes.
Assume all sprockets are to be type B with a finished bore.
Small Sprocket: ______________________________________
Large Sprocket: ______________________________________
Chain: _____________________________________________
Connecting Link: ____________________________________
You should have the following list:
• 1 x 60B18 w/ 1/2 inch bore
• 1 x 60B36 w/ 1/2 inch bore
• 1 x chain no. 60 w/ 91 pitches
• 1 x no. 60 connecting link
❑ 2. Perform the following sub-steps to select the sizes of the
components for a chain drive system given the information shown
below.
A. Examine the information about a chain drive application.
Motor Size 2 hp
Motor Shaft Size 5/8 inches
Driven Shaft Size 3/4 inches
Application Type Centrifugal compressor

B. Determine the rated power of the system.
Rated Power:_________________________________(Hp/kW)
The rated power is 2 Hp.
C. Use figure 38 to determine the service factor.
Service Factor: ______________________________________
You should find that the service factor for a propeller type fan
is 1.3.
D. Calculate the design power.
You should find a design power of 2.6 Hp (2 Hp x 1.3).
E. Approximate the chain pitch.
Chain Pitch ____________________________________(code)
Using the table in figure 39, you should find an approximate
pitch of 60.
F. Approximate the size of the smaller sprocket. Use figure 40.
You should use a sprocket with 19 teeth, which is rated for 2.60
horsepower.
G. Verify size of small sprocket.
Maximum Bore Size: ___________________________(inches)
Using figure 41, you should have found a maximum bore size
of 2.688 inches. This number is greater than the motor shaft
size.
H. Determine the speed ratio.
Drive Ratio:_________________________________________
In this case, you should find a speed ratio of 0.75 (75 rpm/100
rpm).
I. Compute the size of the larger sprocket.
Here you should find the size of the large sprocket to be 26
teeth.
J. Approximate the length of the chain.
Approximate Chain Length: _____________________(pitches)
Here you should find the chain to have 71 pitches.
S  18  (19 + 26)
Length of chain = 2C + = 2×  + = 70.5 or 71
2 0.75  2
Then add 1 connecting link to make it an even 72 inches.

K. Select sprocket and bore sizes.
Assume all sprockets are to be type B with a finished bore.
Small Sprocket: ______________________________________
Large Sprocket: ______________________________________
Chain: _____________________________________________
Connecting Link: ____________________________________
You should have the following list:
• 1 x 60B19 w/ 5/8 inch bore
• 1 x 60B26 w/ 3/4 inch bore
• 1 x chain no. 60 w/ 71 pitches
• 1 x no. 60 connecting link
❑ 3. Select the sizes of the components for a chain drive system given
the information shown below. Use figures 38-41.
Motor Size 1 hp
Motor Shaft Size 5/8 inches
Driven Shaft Size 3/4 inches
Application Type Crusher
Chain Pitch: ___________________________________(code)
Chain Length: ________________________________(pitches)
❑ 4. Compare your results to the following answer guide.
Design Horsepower: 1.5
Chain Pitch: 25
Small Sprocket Size: 12 teeth
Large Sprocket Size: 27 teeth
Chain Length: 212 (211 pitches + 1 connecting link)

SEGMENT 3
SELF REVIEW
r This
we
Ans
1. The first two or three digits of the chain sizing code reveal
the __________ of the chain.
2. A 20 in front of the chain code indicates the chain is a

__________ - _________ chain.
3. Narrow chain is indicated by a ____ within the pitch code.
4. Rollerless chain is indicated by a ____ within the pitch code.
5. A chain code of 60-4 indicates a ______ inch pitch chain

that is _____ strands wide.
6. Silent chain is indicated by ________ while high-velocity,

heavy-duty chain is indicated by _______.
7. The width of a multi-strand sprocket is indicated by a

____________ in its specification.
8. A Type ____ sprocket has a double-hub.
9. A Type ____ sprocket has no hub.
10. Sprockets with a(an) _____________ hub is a Type D hub.

SEGMENT 4
CHAIN LUBRICATION
OBJECTIVE 11 DESCRIBE FOUR TYPES OF CHAIN LUBRICATION METHODS
his
dT There are four methods used to apply lubrication to a chain drive
Rea
system. They are comprised of the same methods you learned about in a
previous LAP. The only difference is the bath and slinger disk methods
have been combined into one. Hence the four methods are:
• Manual Method
• Drip Cup Method
• Bath or Disc Method
• Forced or Stream Method
Each of these methods and the applications in which they are used is
described as follows:
Manual Method
In this method, lubricants are periodically applied with a brush or oil
can, as shown in figure 42. This method requires that the machinery be
shut down for safety.
Figure 42. Chains are Periodically Lubricated by Hand

The manual method is used in low speed applications where the
equipment can be periodically shut down.
The manual method of lubrication requires the shutdown of
equipment. It also requires an employee to remember to perform the
lubrication. For these reasons, other methods of lubrication are used
more often than manual lubrication.
Drip Cup Method

This method uses gravity to slowly drip lubricant onto the required
areas, as shown in figure 43. A reservoir holds a small volume of oil
which is allowed to slowly drip out of a port in the reservoir.
OIL CUP
DRIPS ON
DRIVE
Figure 43. The drip method uses gravity to supply oil to mechanical components.

Bath or Disc Method
In the bath method, the chain drive is partially submerged in a bath
of oil. As the components are rotated, the lubricant is applied to all of the
necessary parts, as shown in figure 44.
OIL LEVEL
Figure 44. The drive is partially submerged in oil.
The disc method uses a slinger wheel that dips into a pool of oil. As
the slinger is rotated, it scoops up a small amount of oil and slings it
against a collection plate and trough, as shown in figure 45. The trough
then directs the flow of oil to where it is needed.
COLLECTION
PLATE
SLINGER
OIL LEVEL
Figure 45. A slinger slings oil onto a collection plate and trough.

Forced Oil Stream Method
The forced oil stream method uses a pump and hose to distribute and
spray the oil onto the surfaces where it is needed, as shown in figure 46.
Figure 46. A pump and hose spray oil onto machinery components.

OBJECTIVE 12 DESCRIBE HOW TO SELECT A LUBRICATION SYSTEM
FOR A CHAIN DRIVE SYSTEM
dT
his The lubrication system that is eventually used for a chain drive
Rea
system depends primarily on the speed and load requirements of the
drive system.
The oil lubrication systems that you have just learned about are
grouped into three types, called Type A, B, and C. Type A consists of the
manual and gravity drip lubrication methods. Type B consists of the
slinger disk and the oil bath method. The oil stream method is Type C
lubrication. Each of the lubrication system types are shown in figure 47.
TYPE A TYPE B TYPE C
Figure 47. Type A, B and C Lubrication Systems

In most cases, chain manufacturers provide tables that can be used to
determine the type of lubrication system used. Often, this information
can be found on the same table that was used to verify the power limit of
a sprocket, as shown in figure 48.
Teeth
Small 10 25 50 100 150 200 300 400 500 600 700 800 900 1000 1100 1200 1400 1600 1800 2000 2500 3000 3500 4000 4500
Spkt.
12 0.20 0.45 0.85 1.58 2.28 2.95 4.25 5.51 6.74 7.94 9.12 10.3 11.4 12.6 13.7 13.5 10.7 8.77 7.35 6.28 4.49 3.42 2.71 2.22 1.86
13 0.22 0.50 0.92 1.73 2.49 3.22 4.64 6.01 7.34 8.65 9.94 11.2 12.5 13.7 14.9 15.2 12.1 9.89 8.29 7.08 5.06 3.85 3.06 2.50 0
14 0.24 0.54 1.00 1.87 2.69 3.49 5.02 6.51 7.96 9.37 10.8 12.1 13.5 14.8 16.2 17.0 13.5 11.1 9.26 7.91 5.66 4.31 3.42 2.80 0
15 0.25 0.58 1.08 2.01 2.90 3.76 5.41 7.01 8.57 10.1 11.6 13.1 14.5 16.0 17.4 18.8 15.0 12.3 10.3 8.77 6.28 4.77 3.79 3.10 0
16 0.27 0.62 1.16 2.16 3.11 4.03 5.80 7.52 9.19 10.8 12.4 14.0 15.6 17.1 18.7 20.2 16.5 13.5 11.3 9.66 6.91 5.26 4.17 3.42 0
17 0.29 0.66 1.24 2.31 3.32 4.30 6.20 8.03 9.81 11.6 13.3 15.0 16.7 18.3 19.9 21.6 18.1 14.8 12.4 10.6 7.57 5.76 4.57 3.74 0
18 0.31 0.70 1.31 2.45 3.53 4.58 6.59 8.54 10.4 12.3 14.1 15.9 17.7 19.5 21.2 22.9 19.7 16.1 13.5 11.5 8.25 6.28 4.98 4.08 0
19 0.33 0.75 1.39 2.60 3.74 4.85 6.99 9.05 11.1 13.0 15.0 16.9 18.8 20.6 22.5 24.3 21.4 17.5 14.6 12.5 8.95 6.81 5.40 4.42 0
20 0.35 0.79 1.47 2.75 3.96 5.13 7.38 9.57 11.7 13.8 15.8 17.9 19.8 21.8 23.8 25.7 23.1 18.9 15.8 13.5 9.66 7.35 5.83 0
21 0.36 0.83 1.55 2.90 4.17 5.40 7.78 10.1 12.3 14.5 16.7 18.8 20.9 23.0 25.1 27.1 24.8 20.3 17.0 14.5 10.4 7.91 6.28 0
22 0.38 0.87 1.63 3.05 4.39 5.68 8.19 10.6 13.0 15.3 17.5 19.8 22.0 24.2 26.4 28.5 26.6 21.8 18.2 15.6 11.1 8.48 6.73 0
23 0.40 0.92 1.71 3.19 4.60 5.96 8.59 11.1 13.6 16.0 18.4 20.8 23.1 25.4 27.7 29.9 28.4 23.3 19.5 16.7 11.9 9.07 7.19 0
24 0.42 0.96 1.79 3.35 4.82 6.24 8.99 11.6 14.2 16.8 19.3 21.7 24.2 26.6 29.0 31.3 30.3 24.8 20.8 17.8 12.7 9.66 7.67 0
25 0.44 1.00 1.87 3.50 5.04 6.52 9.40 12.2 14.9 17.5 20.1 22.7 25.3 27.8 30.3 32.7 32.2 26.4 22.1 18.9 13.5 10.3 8.15 0
26 0.46 1.05 1.95 3.65 5.25 6.81 9.80 12.7 15.5 18.3 21.0 23.7 26.4 29.0 31.6 34.1 34.2 28.0 23.4 20.0 14.3 10.9 8.65 0
28 0.50 1.13 2.12 3.95 5.69 7.37 10.6 13.8 16.8 19.8 22.8 25.7 28.5 31.4 34.2 37.0 38.2 31.3 26.2 22.4 16.0 12.2 0
30 0.54 1.22 2.28 4.26 6.13 7.94 11.4 14.8 18.1 21.4 24.5 27.7 30.8 33.8 36.8 39.8 42.4 34.7 29.1 24.8 17.8 13.5 0
32 0.57 1.31 2.45 4.56 6.57 8.52 12.3 15.9 19.4 22.9 26.3 29.7 33.0 36.3 39.5 42.7 46.7 38.2 32.0 27.3 19.6 14.9 0
35 0.63 1.44 2.69 5.03 7.24 9.38 13.5 17.5 21.4 25.2 29.0 32.7 36.3 39.9 43.5 47.1 53.4 43.7 36.6 31.3 22.4 17.0 0
40 0.73 1.67 3.11 5.81 8.37 10.8 15.6 20.2 24.7 29.1 33.5 37.7 42.0 46.1 50.3 54.4 62.5 53.4 44.7 38.2 27.3 0
45 0.83 1.89 3.53 6.60 9.50 12.3 17.7 23.0 28.1 33.1 38.0 42.0 47.7 52.4 57.1 61.7 70.9 63.7 53.4 45.6 32.6 0
Figure 48. Table for Determining the Type of Lubrication System Required
You may have noticed several jagged lines running down the table.
These lines indicate the ranges for each type of lubrication system should
be used.
To determine the type of lubrication system required for an
application, locate the sprocket size in the left-hand column of figure 48.
Then move across the table to the rotational speed of the sprocket. The
type of lubrication system that should be used is indicated at the bottom
of the table.
For example in figure 48, a number 60 chain drive system whose
smaller sprocket has 26 teeth and rotates at 1100 RPM would require a
Type B lubrication system. If it is rotated at 1200 RPM, it would require
a Type C lubrication system.

SKILL 6 SELECT A LUBRICATION SYSTEM FOR A CHAIN DRIVE
SYSTEM
Procedure Overview
In this procedure, you will use several tables of
different sized chain drives to determine the lubrication
system required by a particular application.
This ❑ 1. Perform the following sub-steps to determine the appropriate

Do
lubrication system for the following application.

Lubrication system: Type _________________________________
Pitch: 40
Small Sprocket Speed: 1750 RPM
HORSEPOWER RATINGS STANDARD SINGLE STRAND ROLLER CHAIN - NO. 40 - ½” PITCH
Teeth
Small 10 25 50 100 200 300 400 500 700 900 1000 1200 1400 1600 1800 2100 2400 2700 3000 3500 4000 5000 6000 7000 8000
Spkt.
12 0.06 0.14 0.25 0.47 0.88 1.27 1.65 2.01 2.73 3.42 3.76 4.43 5.09 5.74 5.31 4.22 3.45 2.89 2.47 1.96 1.60 1.15 0.87 0.69 0.57
13 0.06 0.15 0.28 0.52 0.96 1.39 1.80 2.20 2.97 3.73 4.10 4.83 5.55 6.26 5.99 4.76 3.89 3.26 2.79 2.21 1.81 1.29 0.98 0.78 0.64
14 0.07 0.16 0.30 0.56 1.04 1.50 1.95 2.38 3.22 4.04 4.44 5.23 6.01 6.78 6.70 5.31 4.35 3.65 3.11 2.47 2.02 1.45 1.10 0.87 0.71
15 0.07 0.17 0.32 0.60 1.12 1.62 2.10 2.56 3.47 4.35 4.78 5.64 6.47 7.30 7.43 5.89 4.82 4.04 3.45 2.74 2.24 1.60 1.22 0.97 0.79
16 0.08 0.19 0.35 0.65 1.20 1.74 2.25 2.75 3.72 4.66 5.13 6.04 6.94 7.83 8.18 6.49 5.31 4.45 3.80 3.02 2.47 1.77 1.34 1.07 0.87
17 0.08 0.20 0.37 0.69 1.29 1.85 2.40 2.93 3.97 4.98 5.48 6.45 7.41 8.36 8.96 7.11 5.82 4.88 4.17 3.31 2.71 1.94 1.47 1.17 0.96
18 0.09 0.21 0.39 0.73 1.37 1.97 2.55 3.12 4.22 5.30 5.82 6.86 7.88 8.89 9.76 7.75 6.34 5.31 4.54 3.60 2.95 2.11 1.60 1.27 0
19 0.09 0.22 0.42 0.78 1.45 2.09 2.71 3.31 4.48 5.62 6.17 7.27 8.36 9.42 10.5 8.40 6.88 5.76 4.92 3.91 3.20 2.29 1.74 1.38 0
20 0.10 0.24 0.44 0.82 1.53 2.21 2.86 3.50 4.73 5.94 6.53 7.69 8.83 9.96 11.1 9.07 7.43 6.22 5.31 4.22 3.45 2.47 1.88 1.49 0
21 0.11 0.25 0.46 0.87 1.62 2.33 3.02 3.69 4.99 6.26 6.88 8.11 9.31 10.5 11.7 9.76 7.99 6.70 5.72 4.54 3.71 2.66 2.02 1.60 0
22 0.11 0.26 0.49 0.91 1.70 2.45 3.17 3.88 5.25 6.58 7.23 8.52 9.79 11.0 12.3 10.5 8.57 7.18 6.13 4.87 3.98 2.85 2.17 1.72 0
23 0.12 0.27 0.51 0.96 1.78 2.57 3.33 4.07 5.51 6.90 7.59 8.94 10.3 11.6 12.9 11.2 9.16 7.68 6.55 5.20 4.26 3.05 2.32 1.84 0
24 0.13 0.29 0.54 1.00 1.87 2.69 3.48 4.26 5.76 7.23 7.95 9.36 10.8 12.1 13.5 11.9 9.76 8.18 6.99 5.54 4.54 3.25 2.47 1.96 0
25 0.13 0.30 0.56 1.05 1.95 2.81 3.64 4.45 6.02 7.55 8.30 9.78 11.2 12.7 14.1 12.7 10.4 8.70 7.43 5.89 4.82 3.45 2.63 0
26 0.14 0.31 0.58 1.09 2.04 2.93 3.80 4.64 6.28 7.88 8.66 10.2 11.7 13.2 14.7 13.5 11.0 9.23 7.88 6.25 5.12 3.66 2.79 0
28 0.15 0.34 0.63 1.18 2.20 3.18 4.11 5.03 6.81 8.54 9.39 11.1 12.7 14.3 15.9 15.0 12.3 10.3 8.80 6.99 5.72 4.09 3.11 0
30 0.16 0.37 0.68 1.27 2.38 3.42 4.43 5.42 7.33 9.20 10.1 11.9 13.7 15.4 17.2 16.7 13.6 11.4 9.76 7.75 6.34 4.54 3.45 0
32 0.17 0.39 0.73 1.36 2.55 3.67 4.75 5.81 7.86 9.86 10.8 12.8 14.7 16.5 18.4 18.4 15.0 12.6 10.8 8.64 6.99 5.00 0
35 0.19 0.43 0.81 1.50 2.81 4.04 5.24 6.40 8.66 10.9 11.9 14.1 16.2 18.2 20.3 21.0 17.2 14.4 12.3 9.76 7.99 5.72 0
40 0.22 0.50 0.93 1.74 3.24 4.67 6.05 7.39 10.0 12.5 13.8 16.3 18.7 21.1 23.4 25.7 21.0 17.6 15.0 11.9 9.76 6.99 0
45 0.25 0.57 1.06 1.97 3.68 5.30 6.87 8.40 11.4 14.2 15.7 18.5 21.2 23.9 26.6 30.5 25.1 21.0 17.9 14.2 11.7 0
Figure 49. Power Ratings Table
A. This application uses a chain number 40 drive. Using figure 48,

locate the size of the smaller sprocket in the left-hand column.
B. Move across the table until you are in the rotational speed of
that sprocket. This is the power limit of the sprocket at that
speed.
C. Locate the lubrication system range marks. These are the
jagged lines that run through the table.

D. The lubrication system that should be used is indicated at the
bottom of the table. Record the lubrication type in the blank
below.
You should have found that a Type B lubrication system should
be used.
❑ 2. Using figure 50, determine the appropriate lubrication system for
the following application.
Pitch: 40
HORSEPOWER RATINGS STANDARD SINGLE STRAND ROLLER CHAIN - NO. 40 - ½” PITCH
Teeth
Small 10 25 50 100 200 300 400 500 700 900 1000 1200 1400 1600 1800 2100 2400 2700 3000 3500 4000 5000 6000 7000 8000
Spkt.
12 0.06 0.14 0.25 0.47 0.88 1.27 1.65 2.01 2.73 3.42 3.76 4.43 5.09 5.74 5.31 4.22 3.45 2.89 2.47 1.96 1.60 1.15 0.87 0.69 0.57
13 0.06 0.15 0.28 0.52 0.96 1.39 1.80 2.20 2.97 3.73 4.10 4.83 5.55 6.26 5.99 4.76 3.89 3.26 2.79 2.21 1.81 1.29 0.98 0.78 0.64
14 0.07 0.16 0.30 0.56 1.04 1.50 1.95 2.38 3.22 4.04 4.44 5.23 6.01 6.78 6.70 5.31 4.35 3.65 3.11 2.47 2.02 1.45 1.10 0.87 0.71
15 0.07 0.17 0.32 0.60 1.12 1.62 2.10 2.56 3.47 4.35 4.78 5.64 6.47 7.30 7.43 5.89 4.82 4.04 3.45 2.74 2.24 1.60 1.22 0.97 0.79
16 0.08 0.19 0.35 0.65 1.20 1.74 2.25 2.75 3.72 4.66 5.13 6.04 6.94 7.83 8.18 6.49 5.31 4.45 3.80 3.02 2.47 1.77 1.34 1.07 0.87
17 0.08 0.20 0.37 0.69 1.29 1.85 2.40 2.93 3.97 4.98 5.48 6.45 7.41 8.36 8.96 7.11 5.82 4.88 4.17 3.31 2.71 1.94 1.47 1.17 0.96
18 0.09 0.21 0.39 0.73 1.37 1.97 2.55 3.12 4.22 5.30 5.82 6.86 7.88 8.89 9.76 7.75 6.34 5.31 4.54 3.60 2.95 2.11 1.60 1.27 0
19 0.09 0.22 0.42 0.78 1.45 2.09 2.71 3.31 4.48 5.62 6.17 7.27 8.36 9.42 10.5 8.40 6.88 5.76 4.92 3.91 3.20 2.29 1.74 1.38 0
20 0.10 0.24 0.44 0.82 1.53 2.21 2.86 3.50 4.73 5.94 6.53 7.69 8.83 9.96 11.1 9.07 7.43 6.22 5.31 4.22 3.45 2.47 1.88 1.49 0
21 0.11 0.25 0.46 0.87 1.62 2.33 3.02 3.69 4.99 6.26 6.88 8.11 9.31 10.5 11.7 9.76 7.99 6.70 5.72 4.54 3.71 2.66 2.02 1.60 0
22 0.11 0.26 0.49 0.91 1.70 2.45 3.17 3.88 5.25 6.58 7.23 8.52 9.79 11.0 12.3 10.5 8.57 7.18 6.13 4.87 3.98 2.85 2.17 1.72 0
23 0.12 0.27 0.51 0.96 1.78 2.57 3.33 4.07 5.51 6.90 7.59 8.94 10.3 11.6 12.9 11.2 9.16 7.68 6.55 5.20 4.26 3.05 2.32 1.84 0
24 0.13 0.29 0.54 1.00 1.87 2.69 3.48 4.26 5.76 7.23 7.95 9.36 10.8 12.1 13.5 11.9 9.76 8.18 6.99 5.54 4.54 3.25 2.47 1.96 0
25 0.13 0.30 0.56 1.05 1.95 2.81 3.64 4.45 6.02 7.55 8.30 9.78 11.2 12.7 14.1 12.7 10.4 8.70 7.43 5.89 4.82 3.45 2.63 0
26 0.14 0.31 0.58 1.09 2.04 2.93 3.80 4.64 6.28 7.88 8.66 10.2 11.7 13.2 14.7 13.5 11.0 9.23 7.88 6.25 5.12 3.66 2.79 0
28 0.15 0.34 0.63 1.18 2.20 3.18 4.11 5.03 6.81 8.54 9.39 11.1 12.7 14.3 15.9 15.0 12.3 10.3 8.80 6.99 5.72 4.09 3.11 0
30 0.16 0.37 0.68 1.27 2.38 3.42 4.43 5.42 7.33 9.20 10.1 11.9 13.7 15.4 17.2 16.7 13.6 11.4 9.76 7.75 6.34 4.54 3.45 0
32 0.17 0.39 0.73 1.36 2.55 3.67 4.75 5.81 7.86 9.86 10.8 12.8 14.7 16.5 18.4 18.4 15.0 12.6 10.8 8.64 6.99 5.00 0
35 0.19 0.43 0.81 1.50 2.81 4.04 5.24 6.40 8.66 10.9 11.9 14.1 16.2 18.2 20.3 21.0 17.2 14.4 12.3 9.76 7.99 5.72 0
40 0.22 0.50 0.93 1.74 3.24 4.67 6.05 7.39 10.0 12.5 13.8 16.3 18.7 21.1 23.4 25.7 21.0 17.6 15.0 11.9 9.76 6.99 0
45 0.25 0.57 1.06 1.97 3.68 5.30 6.87 8.40 11.4 14.2 15.7 18.5 21.2 23.9 26.6 30.5 25.1 21.0 17.9 14.2 11.7 0
Figure 50. Power Ratings Table for No. 40 Chain
You should have found that a Type C lubrication system should be

used.

Pitch: 40
You should have found that a Type A lubrication system should be
used.
Pitch: 80
HORSEPOWER RATINGS STANDARD SINGLE STRAND ROLLER CHAIN - NO. 80 - 1” PITCH

Teeth
Small 10 25 50 100 150 200 300 400 500 600 700 800 900 1000 1100 1200 1400 1600 1800 2000 2200 2400 2700 3000 3400
Spkt.
12 0.47 1.06 1.98 3.69 5.32 6.89 9.93 12.9 15.7 18.5 21.3 24.0 26.2 22.3 19.4 17.0 13.5 11.0 9.25 7.90 6.85 6.01 5.04 4.30 0
13 0.51 1.16 2.16 4.03 5.80 7.52 10.8 14.0 17.1 20.2 23.2 26.2 29.1 25.2 21.8 19.2 15.2 12.5 10.4 8.91 7.72 6.78 5.68 4.85 0
14 0.55 1.25 2.34 4.36 6.29 8.14 11.7 15.2 18.6 21.9 25.1 28.4 31.5 28.2 24.4 21.4 17.0 13.9 11.7 9.96 8.63 7.57 6.35 5.42 0
15 0.59 1.35 2.52 4.70 6.77 8.77 12.6 16.4 20.0 23.6 27.1 30.6 34.0 31.2 27.1 23.8 18.9 15.4 12.9 11.0 9.57 8.40 7.04 6.01 0
16 0.63 1.45 2.70 5.04 7.26 9.41 13.5 17.6 21.5 25.3 29.0 32.8 36.4 34.4 29.8 26.2 20.8 17.0 14.2 12.2 10.5 9.25 7.76 6.62 0
17 0.68 1.55 2.88 5.38 7.75 10.0 14.5 18.7 22.9 27.0 31.0 35.0 38.9 37.7 32.7 28.7 22.7 18.6 15.6 13.3 11.5 10.1 8.49 7.25 0
18 0.72 1.64 3.07 5.72 8.25 10.7 15.4 19.9 24.4 28.7 33.0 37.2 41.4 41.1 35.6 31.2 24.8 20.3 17.0 14.5 12.6 11.0 9.25 7.90 0
19 0.76 1.74 3.25 6.07 8.74 11.3 16.3 21.1 25.8 30.4 35.0 39.4 43.8 44.5 48.6 33.9 26.9 22.0 18.4 15.7 13.6 12.0 10.0 8.57 0
20 0.81 1.84 3.44 6.41 9.24 12.0 17.2 22.3 27.3 32.2 37.0 41.7 46.3 48.1 41.7 36.6 29.0 23.8 19.9 17.0 14.7 12.9 10.8 0
21 0.85 1.94 3.62 6.76 9.74 12.6 18.2 23.5 28.8 33.9 39.0 43.9 48.9 51.7 44.8 39.4 31.2 25.6 21.4 18.3 15.9 13.9 11.7 0
22 0.90 2.04 3.81 7.11 10.2 13.3 19.1 24.8 30.3 35.7 41.0 46.2 51.4 55.5 48.1 42.2 33.5 27.4 23.0 19.6 17.0 14.9 12.5 0
23 0.94 2.14 4.00 7.46 10.7 13.9 20.1 26.0 31.8 37.4 43.0 48.5 53.9 59.3 51.4 45.1 35.8 29.3 24.6 21.0 18.2 15.9 13.4 0
24 0.98 2.24 4.19 7.81 11.3 14.6 21.0 27.2 33.2 39.2 45.0 50.8 56.4 62.0 54.8 48.1 38.2 31.2 26.2 22.3 19.4 17.0 14.2 0
25 1.03 2.34 4.37 8.16 11.8 15.2 21.9 28.4 34.7 40.9 47.0 53.0 59.0 64.8 58.2 51.1 40.6 33.2 27.8 23.8 20.6 18.1 15.1 0
26 1.07 2.45 4.56 8.52 12.3 15.9 22.9 29.7 36.2 42.7 49.1 55.3 61.5 67.6 61.8 54.2 43.0 35.2 29.5 25.2 21.8 19.2 16.1 0
28 1.16 2.65 4.94 9.23 13.3 17.2 24.8 32.1 39.3 46.3 53.2 59.9 66.7 73.3 69.0 60.6 48.1 39.4 33.0 28.2 24.4 21.4 0
30 1.25 2.85 5.33 9.94 14.3 18.5 26.7 34.6 42.3 49.9 57.3 64.6 71.8 78.9 76.6 67.2 53.3 43.6 36.6 31.2 27.1 23.8 0
32 1.34 3.06 5.71 10.7 15.3 19.9 28.6 37.1 45.4 53.5 61.4 69.2 77.0 84.6 84.3 74.0 58.7 48.1 40.3 34.4 29.8 26.2 0
35 1.48 3.37 6.29 11.7 16.9 21.9 31.6 40.9 50.0 58.9 67.6 76.3 84.8 93.3 96.5 84.7 67.2 55.0 46.1 39.4 34.1 0
40 1.71 3.89 7.27 13.6 19.5 25.3 36.4 47.2 57.7 68.0 78.1 88.1 98.0 108 117 103 82.1 67.2 56.3 48.1 20.0 0
45 1.94 4.42 8.25 15.4 22.2 28.7 41.4 53.6 65.6 77.2 88.7 100 111 122 133 123 98.0 80.2 67.2 54.1 0
Figure 51. Power Ratings Table for No. 18 Chain
You should have found that a Type A lubrication system should be

used.

Pitch: 80
You should have found that a Type B lubrication system should be
used
OBJECTIVE 13 DESCRIBE HOW TO SELECT A TYPE OF LUBRICANT

FOR A CHAIN DRIVE SYSTEM
his
dT Most chain drive systems used in industry are lubricated with oil. A
Rea
mineral oil with a viscosity or S.A.E. rating of 30 is suitable for most

chain drives operating at room temperature. For operation at different
temperatures, oils with higher or lower viscosities should be used. Figure
52 shows the proper viscosity rating for given temperature ranges.
RECOMMENDED OIL VISCOSITIES FOR VARIOUS TEMPERATURES
Recommended Grade Temperature, °F (Temperature, °C)
SAE 5 -50 to + 50 (-46 to +10)
SAE 10 -20 to + 80 (-29 to +27)
SAE 20 +10 to +110 (-12 to +43)
SAE 30 +20 to +130 (- 7 to +54)
SAE 40 +30 to +140 (- 1 to +60
SAE 50 +40 to +150 (+ 4 to +66)
Note: When the temperature range permits a choice, the heavier grade should be used.
Figure 52. Oil Viscosities that Should Be Used for a Given Temperature
The above figures only contain recommended oils for a certain

temperature. They do not take into account other important operating
conditions of the mechanical system, such as: environmental conditions,
extreme loads and pressures, and speed conditions. These conditions are
generally accounted for in the type of lubrication system used, as you
learned how to select in the previous skill.

SKILL 7 LUBRICATE A CHAIN DRIVE SYSTEM USING THE MANUAL
LUBRICATION METHOD
Procedure Overview
In this procedure, you will use the manual method of
lubrication to apply lubricant to a chain drive system.
This ❑ 1. Continuing from an earlier skill, the motor trainer should still be
Do
set up, as shown in figure 53. If not, repeat Steps 4-11 in Skill 2 to
make it so.

❑ 2. Locate the oil can and a large clean rag.
❑ 3. Spread the large clean rag over the trainer table, directly under the
chain, as shown in figure 54.
Figure 54. Place the rag under the chain.
❑ 4. By inverting the oil can and pressing on the bottom, oil is forced
through the tube and out of the tip.

❑ 5. Perform the following substeps to lubricate the chain drive system.
A. Perform a lockout/tagout.
B. Place a drop or two of oil on the upper side of the lower portion
of the chain drive in the locations indicated by figure 55.
Notice that each of these points is where rollers, bushings, and
side plates come into contact with each other.
INSIDE THE ROLLER
BETWEEN THE SIDE

BARS TO THE PIN
ROLLER CHAIN
Figure 55. Important Chain Lubrication Points
C. With your hand rotate the chain drive until the next link is
positioned where the last one was lubricated.
D. Repeat substep A to lubricate this link, and then substep B to
move to the next link.
E. Repeat this process until the entire chain has been lubricated.
❑ 5. Once the entire chain has been lubricated, inspect it for any links
that you may have missed.
❑ 6. Continuously rotate the chain by hand, listen for any squeaks, and
look for stiff or frozen links which could indicate links that were
not properly lubricated.
❑ 7. Clean up any spilled oil with the clean rag.
❑ 8. Return the oil can to its proper place and dispose of the rag in
accordance with your instructor.

SEGMENT 4
SELF REVIEW
r This
we
Ans
1. To lubricate a chain by using an oil can or by removing the
chain and dipping it into an oil bath is called the
__________ method of lubrication.
2. The ___________ method of lubrication uses a pump to

force lubricant onto the chain.
3. The bath method of lubrication is where a chain in an

enclosed case is __________ into a bath of oil.
4. The lubrication method that is required by a particular

application depends primarily on the ___________ and the
_________ of the application.
5. Chain drives are lubricated by liquid lubricants called

________.
6. Chain drive lubricants vary in their thickness, which is

called ____________.

SEGMENT 5
CHAIN MAINTENANCE AND TROUBLESHOOTING
OBJECTIVE 14 DESCRIBE TEN MAINTENANCE STEPS FOR

CHAIN DRIVES
his
dT Just like proper eating habits and getting plenty of exercise will help
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you to live a longer, healthier life, proper preventive maintenance will

extend the service life of any drive system. Preventive maintenance
ensures that all is going well with the drive system and helps to locate
minor faults before they become a major problem. There are ten
maintenance steps that should regularly be performed on a chain drive
system. They are as follows:
Step 1. Lubricate the system

All chain drive systems require lubrication to run properly. As you
have already learned, there are three types of lubrication systems. The
type that is used depends on the operating speeds and loads that the drive
system is required to handle.
Manually lubricated drives should be lubricated every eight hours of
operation. Other types are automatically lubricated. Therefore, only the
oil level and/or flow needs to be periodically checked.
Step 2. Check oil level

Type B and Type C lubrication systems will not function properly if
they are allowed to run out of lubricant. For this reason, one of the
maintenance steps is to periodically check the amount of oil that is
present in the system. Checking oil level is often accomplished through
the use of a sight gage or dipstick, as shown in figure 56. The oil level in
these systems should be checked often enough to ensure it never runs too
low.

Figure 56. Oil level can be checked by using a sight gage.
Step 3. Check the oil flow

Type C lubrication is subject to clogging due to a number of causes.
If this happens, the chain drive system will not receive the proper
lubrication and will quickly wear out. Step 3 of chain drive maintenance
is to periodically check to see if the oil is flowing through the system
properly. These types of lubrication systems often have pressure gages or
flow sensors to assist you, as shown in figure 57.
Figure 57. Oil flow can be monitored by using a pressure gage.

Step 4. Change Oil
From time to time, a lubricant simply breaks down due to the
mechanical stresses on it and temperature. Lubricants can also loose their
effectiveness due to dirt and mineral buildup. For these reasons, a
lubricant should periodically be replaced to keep the components of the
chain drive system protected. The oil should be changed after every 2500
hours of operation.
Step 5. Check All Setscrews and Bushing Cap-Screws

The continous vibrations created by a mechanical system can cause
screws and bolts to become loosened. They should be checked
periodically to make sure that they have not loosened.
Step 6. Check Chain Sag

Even under normal operating conditions a chain will stretch. This
stretching will increase the amount of sag that is present in a chain drive
system. Other operating conditions may even reduce the amount of sag
in a chain. Because of this, chain sag should be checked and adjusted if
necessary.
Step 7. Clean the Chain

Normally the lubrication of a chain will keep it clean, but sometimes
a chain drive system may not be operating in the cleanest of
environments. In these instances, dirt and grime can get into the chains
and sprockets, creating excess wear and preventing proper lubrication.
When a chain drive system is operating in an unclean environment, it
should frequently be removed and thoroughly cleaned. Once clean, the
chain is then dipped in hot oil before being reinstalled.
Step 8. Check the Chain for Elongation and Wear

As you have already learned, a chain stretches over time. But, there
is a limit to how much the chain can stretch before it causes excessive
wear to the sprockets and becomes dangerously weak. That limit is about
3% of the chain’s original length.
After a chain’s first 1000 hours of operation, and periodically
thereafter, remove the chain and measure it to determine if it is still
within its stretch limit. To do this, calculate the maximum allowed length
of the chain by counting its pitch length then multiplying that by its pitch
and by 1.03. For example, a size 40 chain hose pitch length is 80 pitches,
has a maximum allowable length at 41.2 inches (80×0.5×1.03) 41.2).

Step 9. Check the Sprockets for Wear
A sprocket, when worn, can cause chains to wear out and fail before
their time. A worn sprocket is also inefficient and subject to failure.
Periodically inspect the sprockets for hooked teeth which indicates wear,
as shown in figure 58.
Figure 58. The Hooked Tooth Profile of a Worn Sprocket
The limits of wear for a sprocket is not nearly as well defined as the
wear limits of a chain. You should, however, look for reduced tooth
thickness and hooked teeth. If any of these conditions exist, the sprocket
is worn and should be replaced. Some other types of normal sprocket
wear are shown in figure 59.
Figure 59. Normal Wear of Sprocket Grooves and Teeth Types

One variation of sprocket wear is when the roll seats are flared, as
shown in figure 60. This type of wear indicates an overloaded drive. This
drive should be redesigned.
Figure 60. The Flared Tooth Profile of a Worn Sprocket in an Overloaded

Drive
CAUTION
tion
It is very important when replacing any component of a chain
u
Ca
CAUTION
drive system to replace both sprockets and chain. Mixing new
components with old ones will only cause premature failure of
the new components.
Step 10. Check the Alignment of the Sprockets

The alignment of a chain drive system should often be checked to
ensure proper operation.

OBJECTIVE 15 DESCRIBE HOW TO TROUBLESHOOT A CHAIN DRIVE SYSTEM
his
dT You will notice the failure of a chain drive, as well as any other
Rea
mechanical system, at one of two times: either during a routine
inspection or when the system breaks down. Because of the inherent
danger of a mechanical failure and the resultant down time of the
machine while it is in repair, it is best to find a fault during periodic
inspections.
Troubleshooting, determining the cause of the fault, should be
performed when a fault is found. Most chain drive manufacturers
provide tables, similar to the one shown below, to aid in troubleshooting.
Troubleshooting with tables is a four-step process:
Step 1. Identify the Type of Fault

Identify the fault and determine whether it is an inspection fault or
an operating fault.
Step 2. Look up the Probable Causes

Look up the fault in the Fault column of the appropriate table. The
probable causes of that fault are listed in the Probable Causes column
just to the right of the fault.
Step 3. Determine the Actual Cause

Sometimes there may be several probable causes of a fault. You
must then isolate which of them is the actual cause, either by verifying
one cause as the actual cause or by eliminating all possibilities but one. If
only one probable cause is listed in the table, it must be the actual cause.

Step 4. Perform the Corrective Action
For each probable cause, a corrective action is listed. Once you have
determined the actual cause, the corrective action that should be taken is
listen in the Corrective Action column just to the right of the actual fault.
The two charts are shown below. You will be using these in the next
skill.
INSPECTION FAULTS
FAULT PROBABLE CAUSES CORRECTIVE ACTION
Wear on sides of chain or on sides • Shafts not parallel or sprockets • Remove the chain and properly
of sprocket teeth not in the same plane align the sprockets and shafts,
replace worn components
Broken chain parts • Chain speed too high for sprocket • Use a sprocket with more teeth
(pins, rollers, bushings, link plates) size and pitch and a chain of shorter pitch
• Sudden impact loads • Reduce the impact load, or
• Buildup of deposits in sprocket redesign drive
teeth • Clean sprockets
• Improper lubrication • Apply proper lubrication system
• Sprocket or chain corrosion • Protect from corrosive
• Excessive sprocket wear environments
• Check for wear, replace if
necessary
Stiff chain • Dirt or debris in chain joints • Cover drive to protect it from dirt
• Improper lubrication and debris, clean and relubricate
• Shafts not parallel or sprockets chain
not in the same plane • Apply proper lubrication system
• Chain corrosion • Remove the chain and properly
• Bent pins or flattened rollers due align the sprockets and shafts
to overload • Protect from corrosive
environments, replace chain if
necessary
• Replace chain, reduce load or
redesign drive
Broken sprocket teeth • Sprockets made of inferior • Replace with steel sprockets
materials • Reduce the impact load or
• Sudden impact loads redesign the drive, replace the
• Shafts not parallel or sprockets sprockets
not in the same plane • Remove the chain, replace and
• Foreign material in the drive properly align the sprockets and
shafts
• Remove the foreign material,
replace the sprockets
Uneven wear on the sprocket • Shafts not parallel or sprockets • Remove the chain and properly
not in the same plane align the sprockets and shafts,
• Chain overly elongated replace the sprockets if necessary
• Replace the chain
Premature chain elongation • Improper lubrication • Apply proper lubrication system

(less than 100 hours of operation) • Drive overload • Redesign the drive
Rusted chain • Exposed to corrosive environment • Protect form corrosive

• Water in lubricant environments, replace chain
• Improper lubrication • Protect lubrication from water and
change lubricant, replace chain
• Apply proper lubrication system,
replace chain

Link retainers fall off or broken and • Cotter pins improperly installed • Properly install new pins
missing cotter pins • Excessive vibration • Reduce vibration or redesign drive
• Speed too high for drive with larger sprockets
• Retainer striking obstruction • Reduce speed or redesign drive
• Retainer improperly installed with smaller pitch
• Eliminate obstruction or use
riveted chain
• Properly install retainer
Chain pins are turned • Improper lubrication • Apply proper lubrication system,
• Overload replace chain
• Reduce load or redesign drive with
larger sprockets, replace chain
Enlarged pin holes • Overload • Reduce load or redesign drive with

larger sprockets, replace chain
Battered or worn link plates • Obstruction interfering with chain • Eliminate interference, replace
chain
Wear on tips of sprocket teeth • Chain overly elongated • Replace chain
OPERATING FAULTS
FAULT PROBABLE CAUSES CORRECTIVE ACTION
Chain drive overheats • Drive speed too high • Reduce speed or redesign drive
• Improper lubrication with smaller pitch
• Speed too fast for bath lubrication • Apply proper lubrication system
• Drive component striking an and lubricant
obstruction • Use Type C lubrication system
• Eliminate interference
Excessive noise • Excessive chain or sprocket wear • Replace chain, replace and realign
• Chain overly elongated or has sprockets
excess sag • Replace chain if elongated, adjust
• Improper lubrication sag otherwise
• Drive component striking an • Apply proper lubrication system
obstruction • Eliminate obstruction
• Too few sprocket teeth • Redesign drive with larger
• Chain pitch too large sprockets
• Loose casing or component • Redesign drive with smaller chain
mounts pitch
• Shafts not parallel or sprockets • Tighten all fasteners
not in the same plane • Remove the chain and properly
align the sprockets and shafts
Chain climbs sprockets • Sprockets excessively worn • Replace and realign sprockets
• Shafts not parallel or sprockets • Remove the chain and properly
not in the same plane align the sprockets and shafts
• Chain does not fit sprocket • Make sure sprocket and chain are
• Buildup of deposits in sprocket of the same pitch
• Overload • Reduce load or redesign drive with
larger sprockets

Chain sticks to sprockets • Excessively worn sprockets or • Replace worn components, realign
chain drive
• Improper lubrication • Apply proper lubrication system
• Buildup of deposits in sprocket and proper lubricant
• Shafts not aligned or sprockets • Remove the chain and properly
not in the same plane align the sprockets and shafts
Chain whips • Overly elongated chain or • Replace chain or properly adjust

excessive sag sag
• Pulsating overloads • Reduce load or redesign drive with
• Distance between centers too larger sprockets
great • Install an idler or other tensioning
• Stiff chain links component
• Clean and relubricate chain,
replace chain if necessary
Excessive vibration • Broken or missing rollers • Repair or replace chain
SKILL 8 CHECK A CHAIN FOR ELONGATION
Procedure Overview
In this procedure, you will measure a standard roller
chain to determine if it is still suitable for use due to
elongation.
This ❑ 1. Obtain the following items and lay them on the work surface.
Do
• Standard roller chain

• Tape measure.
❑ 2. Perform the following substeps to determine the maximum
allowable chain length.
A. Remove the master link.
B. Count and record the pitch length of the chain.
Pitch Length: __________________________________Pitches
C. Multiply the number of pitches by the pitch of the roller chain
to obtain nominal length of the chain.
Nominal Length: __________________________________(in)
As you have already learned, this chain has a pitch code of 40,
giving it a pitch of 1/2 of an inch. The nominal length should
therefore be 35 inches (71 links × 1/2 inch/link).

D. Multiply the nominal length of the chain by 1.03 to obtain the
maximum allowable chain length.
Maximum Allowable Chain Length:___________________(in)
You should find a maximum allowable chain length of 36.0
inches (35 inches × 1.03).
❑ 3. Use a tape measure to measure and record the actual length of the
chain.
Actual Length: ___________________________________(inches)
This measurement should be taken from the centers of the first and
last roller link rollers, as shown in figure 61.
1 2 3
Figure 61. Measuring the Nominal Length of a Chain
❑ 4. If the actual nominal length measured in Step 3 is less than the

maximum allowable chain length, the chain is suitable for use. If
not, it should be replaced.
❑ 5. Return all materials to their proper storage.

SKILL 9 TROUBLESHOOT A CHAIN DRIVE SYSTEM
Procedure Overview
In this procedure, you will list the probable causes for a
given fault. You will also give the actual fault for a few of
the exercises and give the corrective action that should be
taken.
This ❑ 1. Perform the following substeps to determine the probable causes

Do
of the fault given below.

Fault: A silent chain drive gets too hot after being in operation for
only a few hours.
A. Determine whether this is an inspection fault or an operating
fault.
Type of fault: ______________________(Inspection/operating)
You should have found this to be an operating fault.
B. Using the table of the type of fault that you determined in the
previous substep, locate the Chain drive overheats fault in the
Faults column.
C. In the same row as the fault, move over one column to the
Probable Causes column.
D. List the probable causes form the table, below.
Probable causes:
You should have found the following Probable causes:
Drive speed too high
Improper lubrication
Speed too fast for bath lubrication
Drive component striking an obstruction

❑ 2. Perform the following sub-steps to determine the probable causes
of the fault given below.
Fault: While inspecting a roller chain drive, you find the links to
be very stiff.
A. Determine whether this is an inspection fault or an operating
fault.
Type of fault: ______________________(Inspection/operating)
You should have found this to be an inspection fault.
B. Using the table of the type of fault that you determined in the
previous substep, locate the Stiff chain fault in the Faults
column.
C. In the same row as the fault, move over one column to the
Probable Causes column.
D. List the probable causes from the table, below.
Probable causes:
Dirt or debris in chain joints
Shafts not parallel or sprockets not in the same plane
Chain corrosion
Bent pins or flattened rollers due to overload

❑ 3. Determine the probable causes of the fault given below:
Fault: While inspecting a multiple-strand chain drive, you find
most of the chain to be rusted.
Probable causes:
Exposed to corrosive environment
Water in lubricant

❑ 4. Perform the following substeps to determine the actual fault of the
scenario given below:
Fault: While inspecting a multiple-strand chain drive, you find
most of the chain to be rusted. Further inspection shows that the
chain is well lubricated and that there is no water in the chain.
A. Determine all probable causes of the fault listed below.
Probable causes:
Exposed to corrosive environment
Water in lubricant
B. Look once again at the given scenario. From it you should be

able to eliminate two of the probable causes.
C. List the remaining probable cause as the actual cause.
Actual cause: ________________________________________
You should have determined the actual cause of the fault to be
that the drive is exposed to a corrosive environment.

❑ 5. Perform the following substeps to determine the actual fault of the
scenario given below:
Fault: While operating a newly installed roller chain drive, you
notice that the chain whips violently. The drive system is unloaded
and has a brand new chain. The tension of the chain is set
perfectly.
A. Determine all probable causes of the fault listed below.
Probable causes:
Overly elongated chain or excessive sag
Pulsating overloads
Distance between centers is too great
Stiff chain links
B. Look once again at the given scenario. From it you should be

able to eliminate all but one of the probable causes.
C. List the remaining probable cause as the actual cause.
Actual cause: ________________________________________
You should have determined the actual cause of the fault to be
that the distance between sprocket centers is too great.
D. Go back to the listing of the probable faults in the appropriate
table. Next to the actual fault that you determined in the
previous substep, locate the corrective action that should be
taken. This is located in the Corrective Action column of the
table.
Corrective Action:____________________________________
You should have determined that the drive requires an idler or
other tensioning device.

OBJECTIVE 16 DESCRIBE THE OPERATION OF A CHAIN BREAKER
dT
his Roller chain is supplied by distributors in standard lengths. Once it is
Rea
received in the plant it must often be cut to length. A chain breaker is the
tool used to accomplish this.
A chain breaker is a tool that is designed strictly for removing a link
from a chain. Figure 62 shows a picture of a typical chain breaker.
PLUNGER
JAWS
Figure 62. A Typical Chain Breaker

To remove a link using a chain breaker, the plunger is first retracted
until it is flush with the upper base of the tool by rotating the upper
handle counterclockwise, as shown in figure 63.
PLUNGER
JAWS
Figure 63. Retracting the Plunger
The two handles are then squeezed together to open the jaws of the
chain breaker, which can then be placed around the roller of a chain link,
as shown in figure 64.
Figure 64. Placing the Jaws Around the Roller of a Chain Link

Releasing the handles will close the jaws and they will lock around
the chain link. Then the upper handle is rotated in a counterclockwise
direction. This brings the plunger down on the pin of the chain link and
pushes it out, as shown in figure 65.
Figure 65. The plunger pushes the pin out of a chain link.
Once the pin is removed, the tool can be taken off the chain link and
the chain can be disassembled.
NOTE
e This
tic Often, the pin being pushed out by the chain breaker will only
No
bend the opposite link plate. When this happens, simply remove
the chain puller, spin the now empty link plate out of the way,
and apply the chain breaker to the other side of the chain.

SKILL 10 REMOVE A CHAIN USING A CHAIN BREAKER
Procedure Overview
In this procedure, you will remove a link from a scrap
length of chain. This skill will familiarize you with the
operation of the chain breaker.
This ❑ 1. Obtain the chain breaker and a scrap length of chain. The chain
Do
must have at least two links in it.

❑ 2. Perform the following substeps to remove a link from the chain.
A. Hold the tool in one hand and rotate the upper handle until the
plunger is flush with the upper base of the tool, as shown in
figure 66.
PLUNGER
JAWS
Figure 66. Retracting the Plunger

B. Squeeze the two handles together to open the jaws of the chain
breaker.
C. Place the last link of the scrap chain into the jaws of the chain
breaker, as shown in figure 67.
Figure 67. Placing the Chain Link in the Jaws of the Chain Breaker
D. Slowly rotate the upper handle and observe the plunger as it

comes into contact with the pin.
Make sure the plunger tip contacts the center of the pin.
E. Continue rotating the upper handle until the plunger tip extends
into the link plate.
F. If the pin slid out of the opposite side without trouble, grasp it
with a pair of pliers and disassemble the link in much the same
way you would a master link and continue with step 3.
G. If the pin only bent the opposite link plate, squeeze the handles
of the chain breaker to release the chain link.
H. Rotate the link plate that the pin was just pushed out of to move
it out of the pin’s way.
I. Flip the chain over.
J. Apply the chain breaker to this side. With the link plate on the
opposite side out of the way, the pin can easily be removed.
K. Disassemble the broken link in much the same way as you
would a master link
❑ 3. Return the chain breaker and scrap chain to their proper locations.

SEGMENT 5
SELF REVIEW
r This
we
Ans
1. Chain drive systems that are ____________ lubricated
should have their oil levels checked often enough to make
sure that they never run dry.
2. Manually lubricated chains should be lubricated every

_________ hours of operation.
3. The oil flow of a Type _____ lubrication system should

periodically be inspected to make sure that the oil flowing
through the system properly.
4. Normal wear for a sprocket is considered excessive when the

teeth take on a _________ shape.
5. Roller seat wear on a sprocket is indicative of an

_________-designed chain drive.
6. Troubleshooting a chain drive system involves determining

the ________ cause of a fault and taking corrective action.
7. When replacing any component of a chain drive system, you

should replace the sprockets as well as the __________. This
prevents you from mixing old components with new ones.


Mechanical Drives 2 Lap 7

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MECHANICAL

HEAVY-DUTY CHAIN DRIVES

HEAVY-DUTY CHAIN DRIVES

950-ME1 Mechanical Drives 1 Learning System

Amatrol or School Supplied

FIRST EDITION, LAP 7, REV. B

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

SEGMENT 1 SILENT CHAIN DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 2 MULTIPLE STRAND SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SEGMENT 3 CHAIN SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SEGMENT 4 CHAIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

SEGMENT 5 CHAIN MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 76

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

OBJECTIVE 1 DESCRIBE THE OPERATION OF FOUR TYPES OF SPROCKETS

drive systems. They are:

Type A: No Hub Sprocket

Figure 1. Type A Sprocket

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 2. Type A Sprocket Mounted to a Shaft Using a Collar

Type A sprockets are generally used in low-speed, low-load

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 3. A Typical Type B Sprocket

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 4. A Typical Type C Sprocket

This arrangement allows for the greatest amount of stability under

Type D: Detachable Hub Sprocket

Figure 5. A Typical Type D Sprocket

This arrangement makes it very easy to remove and replace

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 6. Silent Chain Design

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 7. Silent Chain Sprocket

The sprocket shown in figure 7 is called a single center guide which

Figure 8. Silent Chain Guide Methods

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Step 2. Inspect the Sprockets for Cleanliness and Wear. Clean

Step 3. Mount the Sprockets onto the Shafts

Step 4. Mount the Chain

Figure 9. A Silent Chain Connecting Link

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Step 5. Align the Sprockets

Step 6. Apply Initial Tension to the Chain

Step 7. Lubricate the Drive System

Step 8. Run the Motor Briefly to Test the Drive

Step 9. Retest the Chain Sag after 24 Hours of Operation

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

power transmission equipment. Make sure that you are able to

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

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 10. Location of Components on 950-ME Work Surface

B. Locate four bolts with the specification of 3/8-16UNC-2A x 2

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

Figure 11. Set Screw on Hub

B503-XC LAP 7 HEAVY-DUTY CHAIN DRIVES

The hub should slide on without using tools. If it doesn’t, pull

Figure 12. Position of the Sprocket on the Drive Shaft