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14 Chain Installation
It is vital to set up the drive or conveyor properly and install the chain correctly to get the longest
life and best performance from the chain. Almost all chain ratings are based on having sprockets
that are well aligned and not excessively worn. The ratings also require that the shafts and bearings
be rigidly mounted and in good condition. Also, the chain must be properly connected and mounted
with the right amount of slack. Failing to do any of these things can seriously reduce the life and
capacity of the drive or conveyor.

SAFETY PRECAUTIONS
Serious personal injury can result if safety rules are not followed. Observe the following safety
precautions when installing a chain.

• Shut off the power to the equipment and lock out the power switches before installing
chains.
• Always wear safety glasses to protect your eyes.
• Wear protective clothing, gloves, and safety shoes as appropriate.
• Support the chain to prevent uncontrolled movement of the chain or parts.
• Restrain shafts and sprockets from free rotation where such rotation could permit uncon-
trolled chain movement and cause personal injury or equipment damage.
• Use pressing equipment to remove or install press fit pins or link plates. Keep tooling
in good condition and use it properly. If pressing equipment is not available, contact the
chain manufacturer for additional guidance.
• Know and understand the chain construction, including the correct direction for pin
removal and insertion, before connecting or disconnecting a chain.

CHAIN GUARDING
Any chain can break in service from the effects of wear and exposure to the atmosphere. Sturdy
guarding should be furnished to prevent personal injury or property damage.
Persons often work near operating chain drives or conveyors. Guarding should be designed to
prevent persons from coming in contact with the chain and sprockets during normal operation.
If a chain breaks while operating on sprockets at speed, the chain can be thrown off the sprockets
with considerable force. Guarding should be strong enough to contain a broken chain that may be
thrown off the sprockets when operating at speed.
Sometimes a broken chain can release a load. If that is possible, a brake or other restraining
device should be furnished to stop and hold the load if the chain breaks.

INSTALLATION STEPS
The main steps for installing a chain on a drive or a conveyor include the following:

• Check the condition of all components.

• Align the shafts, sprockets, and ways.

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360 Standard Handbook of Chains

• Prepare the chain for installation.

• Install the chain on the drive or conveyor.
• Inspect the installation.
• Adjust the initial chain tension.
• Set up the lubrication system.
• Check the installation for proper function.
• Install guards.

CHECK THE CONDITION OF ALL COMPONENTS

Inspect the shafts, bearings, sprockets, and guards to ensure they are in good condition. Be sure
that none are excessively worn or damaged. Check all bearing mounts to be sure they are correctly
positioned and secure. If the chain is not new, be sure it is clean, well lubricated, and not excessively
worn or damaged. If the sprockets are not new, be sure they are not excessively worn or damaged.
Criteria for inspecting shafts and bearings should be obtained from the suppliers of those compo-
nents. Criteria for inspecting the chain and sprockets can be found in chapter 15.

ALIGN THE SHAFTS, SPROCKETS, AND WAYS

Align Shafts (Angular Alignment)

Figure 14-1 is a drawing that shows how to align the shafts. Carefully level each shaft with a
machinist’s spirit level set directly on the shaft. When multiple-strand sprockets are used, the level
may be set across the teeth.
Make the shafts parallel using a feeler bar. After setting to parallel, recheck the shaft levels.
Repeat the adjustments until both level and alignment are satisfactory.
Shafts should be aligned to within 0.050 in./ft, or 0.25 degrees for most single-strand roller
chain drives and conveyors. That same limit applies to most silent chain drives up to 1-in. wide.
A somewhat larger limit may be used for engineering steel drives.
High-speed, high-power, and multiple-strand roller chain drives should be aligned to the limit
obtained by Equation 14.1:

ø = 0.00133C/pn, (14.1)

where

ø is the maximum angular misalignment (in in./ft; 0.21 in./ft ≈ 1˚),

C is the drive center distance (in inches), p is the chain pitch (in inches), and
n is the number of strands.

Equation 14.1 also shows that angular alignment is more critical for short center distances. Consult
the silent chain, engineering steel chain, or flat-top chain manufacturer for angular misalignment
limits for those drives or conveyors.

Align Sprockets (Axial Alignment)

First, if a shaft can float axially, block the shaft in its running position before aligning the sprockets.
Also, be sure to secure the sprockets against axial movement by tightening the setscrews. When
preparing a conveyor with multiple strands of chain, make sure the sprockets are spaced correctly
on the shafts.
Figure 14-2 is a drawing that shows how to align the sprockets. The axial alignment of the
sprockets may be checked with a straightedge laid against the finished surfaces on the sides of the

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Chain Installation 361

FIGURE 14-1 Aligning shafts.

FIGURE 14-2 Aligning sprockets.

sprockets. Piano wire may be used if the center distance is too large to use a straightedge. Laser
instruments may also be used to check sprocket alignment. The latter are especially good for
checking the long center distances of conveyors.
The maximum amount of axial misalignment for roller chain drives and conveyors can be
obtained using Equation 14.2:

δ = 0.045p, (14.2)

where δ is the maximum axial misalignment (in inches). Consult the silent chain, engineering steel
chain, or flat-top chain manufacturer for axial misalignment limits for those drives or conveyors.

Align Ways or Wear Strips

When preparing a conveyor, carefully align the ways axially with the sprockets. This is so the chain
transfers from the ways to the sprocket smoothly without catching or binding. Most chain manu-
facturers can provide limits for axial alignment of the ways.
Conveyor ways must also be aligned vertically with the sprockets. In most cases, the pitch line
of the chain on the ways should be at or slightly above the pitch line of the chain on the sprockets
(Figure 14-3). Most chain manufacturers can provide limits for vertical alignment of the ways.

PREPARE THE CHAIN FOR INSTALLATION

Unroll or Uncoil the Chain and Lay It Out

Remove the chain from its packaging and unroll or uncoil the chain and lay it out on a bench or
on the floor. Use care to not twist or bend the chain.

Inspect the Chain

Compare the chain to the specifications to be sure that the chain matches what was ordered. Inspect
the chain to ensure that it has not been damaged in shipment or storage. Be sure that the attachments,

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362 Standard Handbook of Chains

FIGURE 14-3 Vertical sprocket alignment.

if any, are correctly positioned and aligned. Determine the correct direction of travel for offset
sidebar chains or multiple strands of chain with unsymmetrical attachments. If the chains are
matched in sets, be sure that the sections are placed in the correct position and sequence.

Disconnect or Connect to the Correct Length

If the chain is not purchased to a specific length from the factory, it usually must be disconnected
and/or connected to the needed length. Many chains come in a standard 10-ft lengths. This is
seldom the needed length for a drive or a conveyor, so often the chain must be disconnected to a
shorter length or connected to a longer length.
Very basic directions for disconnecting and connecting the several different types of chain
follow. More detailed guidance may be obtained from ACA publications or the chain manufacturer.
Disconnect and Connect Roller Chain
These directions cover only single-strand roller chains and connecting links with slip fit cover
plates. If the chain is multiple-strand roller chain or if the connecting link has a press fit cover
plate, see the ACA publication Connect and Disconnect Guide for ANS Roller Chains. Additional
information can also be obtained from the chain manufacturer.
Disconnect
If the chain is a riveted type, grind off the pin heads on one side of a pin link. If the chain is a
cottered type, remove the cotter, or cotters, in one pin link. Not doing this can damage the chain
bushings when the headed pins are pressed out.
If pressing equipment with appropriate tooling is available, mount the chain in a chain vise
(Figure 14-4). Then press the pins out of one pin link plate (Figure 14-5). If pressing equipment is
not available, the pins may be pressed out of the pin link plate with a pin extractor (Figure 14-6).
The pin links removed from the chain normally are not reusable.
Connect
Bring the end roller links of each section together. Inset the pins of the connecting link through
the bushings of the two roller links. Slide the cover plate on the ends of the connecting pins and
install the cotters or the spring clip. Then push the connecting pins back into the chain until the
cover plate is snug against the retainers. Referring to Figure 3-11 and Figure 3-16 will help the
user see how the connecting links go into the chain.

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Chain Installation 363

FIGURE 14-4 Roller chain in a chain vise.

FIGURE 14-5 Pressing pins out of a roller chain.

Install a spring clip with the closed (solid) end toward the direction of chain travel (Figure 14-7).
Spread the legs of the cotters to no more than a 90-degree angle (Figure 14-8). Spreading them more
than that can damage the cotter and result in early breakage. Be sure that the joint flexes freely after
the connection is finished.
Disconnect and Connect Silent Chain
These directions cover only silent chain with two pin joints and side guides, and using a connector
with a washer. For other types of joints and connectors, and for center guide chains, see the ACA
publication Connect and Disconnect Guide for Silent Chains. Additional information can also be
obtained from the chain manufacturer.
Disconnect
Grind off one pin head at a side link (Figure 14-9). Removing the pins without grinding off the
heads will damage the chain. Then remove both the long and short pins from the joint (Figure 14-10).

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364 Standard Handbook of Chains

FIGURE 14-6 Pressing a pin out of a roller chain with a pin extractor.

FIGURE 14-7 Direction to install spring clip.

FIGURE 14-8 Spread cotter.

Connect
Bring the two ends of the chains together. Be sure the holes in the link plates are aligned (Figure
14-11). Insert a drilled connecting pin through the holes in the link plates (Figure 14-12). Then
insert a short pin next to the drilled pin. Make sure the convex pin surfaces face each other (Figure
14-13).
Put a washer over the end of the drilled pin and secure it with a roll pin or a cotter
(Figure 14-14). If a cotter is used, spread the legs of the cotter to no more than a 90-degree

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Chain Installation 365

FIGURE 14-9 Grind off one pin head.

FIGURE 14-10 Remove both long and short pins.

FIGURE 14-11 Bring ends together and align holes.

angle. Spreading them more than that can damage the cotter and result in early breakage.
Be sure that the joint flexes freely after the connection is finished.
Disconnect and Connect Engineering Steel Chain
These directions cover only a few of the more common types of engineering steel chains and
connectors. For types of chain or connectors not listed here, see the ACA publication Connect and
Disconnect Guide for Engineering Steel and Cast Chains. Additional information can also be
obtained from the chain manufacturer.

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366 Standard Handbook of Chains

FIGURE 14-12 Insert drilled pin.

FIGURE 14-13 Insert short pin.

FIGURE 14-14 Put washer on pin and secure.

Many engineering steel chains are very large and the press fits of the pins in the sidebars are
very heavy. Connecting such chains into strands for installation must be carefully planned. This is
both for safety and to avoid damaging the chains. The forces needed to install the pins are so large
that pressing equipment is usually needed to disconnect and connect these chains.
Many different styles of pins are used in engineering steel chains (Figure 14-15). Be sure to
find out in which direction the pin may be pressed out of the chain before disconnecting a chain.

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Chain Installation 367

FIGURE 14-15 Styles of pins used in engineering steel chains.

FIGURE 14-16 Pressing pins out of straight sidebar engineering steel chain.

FIGURE 14-17 Pressing a sidebar onto the pins of a straight sidebar engineering steel chain.

Straight Sidebar Chain

Disconnect
If the chain is a riveted type, grind off the pin heads on one side of an outside link. If the chain
has retainers or cotter pins, remove the retainers or cotters in one outside link. Not doing this can
damage the chain bushings when the headed pins are pressed out. Support the top sidebar of the
outside link. Then press the pins out of the top sidebar (Figure 14-16).
Connect
If the sidebar that is furnished with the connecting link is a slip fit on the pins, the connecting link
can be assembled just like that for a roller chain. However, if the sidebar is a press fit on the pins,
the cover plate must be pressed onto the pins. The cover plate should be pressed equally onto both
pins at the same time (Figure 14-17). Then install the retainers into the connecting pins.
Sometimes, when the chain pitch is long, individual connecting pins are furnished for straight
sidebar engineering steel chain. When this is the case, place a drilled anvil under one hole of the

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368 Standard Handbook of Chains

FIGURE 14-18 Pressing a pin into a straight sidebar engineering steel chain.

FIGURE 14-19 Pressing a pin out of an offset sidebar engineering steel chain.

loose sidebar. Carefully align the holes in both sidebars and the inside link. Insert the pin by hand
as far as it will go. Carefully align any flats or keys on the pin with the corresponding recesses in
the sidebar holes. Press the pin into the holes of the sidebars (Figure 14-18). Repeat the procedure
at the other end of the sidebar. Finally, install the retainers into the connecting pins. Be sure that
the joint flexes freely after the connection is finished.
Offset Sidebar Chain
Disconnect
Usually only one pin must be pressed out of an offset sidebar chain because every link is the same.
If the pins are riveted or staked, grind the head off of one pin on the proper side of the chain. If
the chain has retainers or cotter pins, remove a retainer or cotter pin from the proper side of the
chain. Put a drilled anvil under the pin that is to be removed. Then press that pin out of the sidebars
(Figure 14-19).
Connect
Place a drilled anvil under the hole in the sidebar on the proper side of the chain. Carefully align
the holes in both sidebars and the narrow end of the next link. Insert the pin by hand as far as it
will go. Carefully align any flats or keys on the pin with the corresponding recesses in the sidebar
holes. Press the pin into the holes of the sidebars (Figure 14-20). Then install the retainers into the
connecting pin. Be sure that the joint flexes freely after the connection is finished.
Disconnect and Connect Flat-Top Chain
In many cases, the chain pin is also used as a connecting pin in flat-top chain. This is because the
pins are held in place by a press fit or knurl on one end of the pin. One must know the correct
direction for removing and inserting pins before disconnecting or connecting a flat-top chain.

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Chain Installation 369

FIGURE 14-20 Pressing a pin into an offset sidebar engineering steel chain.

FIGURE 14-21 Pressing a pin out of steel flat-top chain.

FIGURE 14-22 Pressing a pin into steel flat-top chain.

Disconnect
Steel Flat-Top Chain
Many steel flat-top chains have the pin press fitted in one curl. Determine which end of the pin is
in the press fit curl. Then press the pin out of the chain from the end with the press fit curl (Figure
14-21).
To connect steel flat-top chain, find if the chain has a press fit curl. If so, press the straight pin
into the chain from the end opposite the press fit curl (Figure 14-22). If all of the curls have the
same size hole, the chain will need a shouldered connecting pin. In this case, press the pin into the
chain with the smaller diameter leading (the same as for plastic chain as shown later). Be sure that
the joint flexes freely after the connection is finished.
Plastic Flat-Top Chain
Many plastic flat-top chains have the pin held in one barrel by a knurl on one end of the pin. Find
the end of the pin with the knurl. Then press the pin out of the chain from the end opposite the
knurled end (Figure 14-23).
Some plastic flat-top chains have a counterbored hole on one side. Find the correct direction to
insert the knurled pin, then press the pin into the chain with the knurled end trailing (Figure 14-24).
Be sure that the joint flexes freely after the connection is finished.

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370 Standard Handbook of Chains

FIGURE 14-23 Pressing a pin out of plastic flat-top chain.

FIGURE 14-24 Pressing a pin into plastic flat-top chain.

INSTALL CARRIERS, FLIGHTS, CROSS RODS, ETC.

If the chain is to be used in a conveyor, and there are no obstructions to prevent doing so, install
any carriers, flights, or cross rods on the chain now. Of course, if obstructions will not allow this,
any carriers, etc. will have to be installed after the chains are installed in the conveyor.

INSTALL THE CHAIN

When the chain is connected to the correct length, it is ready to be installed on the drive or
conveyor. All installations require three basic steps:

• Place the chain on the sprockets in a drive or thread the chain into its designed path and
over the sprockets in a conveyor. Make sure offset sidebar chains travel in the correct
direction.
• Make the final connection in the chain to make it endless.
• Inspect the installation to be sure that the installation is complete and that the chain path
is clear.

These three steps seem very simple, but there are many details to be considered in each one. The
details are covered in the following paragraphs.

Place the Chain on the Drive or in the Conveyor and Connect

Installation and Connection

Many roller and silent chains can be easily placed on the sprockets of a drive by hand. Pull the
ends of the chain together around one sprocket with the rollers seated in the sprocket teeth. Hold
the ends in place on the sprocket and connect the chain endless as described earlier. Figure 14-25
shows the final connection on a roller chain drive.
The general procedure is the same for installing larger chains on drives, but additional equipment
is often needed to install engineering steel chains, large roller chains, or very wide silent chains.
A hoist may be needed to lift the chain into place. A “come-along” may be needed to pull the ends
of the chain together on the sprocket. Planks or rods may be needed to support the chain between
the sprockets. And clamps may be needed to hold the chain in place while the final connection is
made.
NOTE: Carefully follow all of the manufacturers safety warnings when using a hoist or “come-
along.”
Normally, one should lay out and connect the sections of a chain for conveyors on a bench or
on the floor. If possible, install any flights or carriers at that time, then thread the chain into the

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Chain Installation 371

FIGURE 14-25 Final connection on a roller chain drive.

conveyor. If there is a catenary section just after the head shaft, it is often good to start feeding the
chain into the return run there. Be careful to pull the chain straight into the conveyor; do not twist
or camber the chain. Finally, pull the ends of the chain together on the head shaft sprocket and
connect the chain endless.
Just as for drives, additional special equipment is usually needed to install large heavy chains
on conveyors. A hoist may be needed to pull the chain into the conveyor, and clamps may be needed
to hold the chain in place while the final connection is made. In very large conveyors, the chain
sections may have to be connected as they are put into the conveyor, and carriers or flights may
have to be installed after the chain is in the conveyor.
A block and tackle or “come-along” is usually needed to pull the chain into a bucket elevator,
and the final connection is usually made at the tail shaft in a bucket elevator. This is because the
chain tension is lowest there. Ask the chain or machine supplier for advice on installing large chain
in a conveyor or bucket elevator.

DIRECTION OF TRAVEL
Offset sidebar chains should be installed to run in a given direction to obtain the least pin and
bushing wear. The basic idea is shown in Figure 14-26. The general rule for direction of chain
travel for offset sidebar chains is as follows. The narrow or roller end of the link in the tight strand
should always face the smaller sprocket. Regardless of whether it is a driver or a driven sprocket.
As a roller enters or leaves a sprocket, the chain joint articulates. The smaller the sprocket, the
larger the angle of articulation.
When the wide or pin end of the link faces the sprocket tooth, all of the sliding between the
pin and the bushing bore is under full load. Wear between the pin and the bushing bore is at a
maximum. Wear elongation is more rapid in this case, and the chain will need to be replaced more
often.
When the narrow end of the offset link faces the sprocket, sliding also takes place between the
pin and bushing bore, but the load quickly decreases between these parts as articulation starts. The
full load between the sprocket tooth and the tight-side strand is transferred from roller to bushing
to sidebar. Wear between the pin and the bushing bore is at a minimum. Wear elongation is less
rapid in this case and the chain will need to be replaced less often.
Wear elongation is probably the major reason to replace a chain. So the direction of travel that
gives the least amount of wear between the pin and bushing bore should be the correct direction.

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372 Standard Handbook of Chains

FIGURE 14-26 Proper direction of travel for offset sidebar chains.

When the drive ratio is not one-to-one, the narrow or roller end of the link in the tight strand should
face the smaller sprocket because the angle of articulation is larger. In this case, the greater the
difference in sprocket size, the more wear life may be increased.
The usual drive reduces the speed. That is, the drive sprocket is smaller and turns faster than
the driven sprocket. But there are many drives that increase the speed. Therefore, a rule based on
driver or driven sprockets cannot be used to determine the direction of chain travel.

INSPECT THE INSTALLATION

Inspect the newly installed equipment with care before applying power to it. This inspection should
include at least the following items:

• Chains must be in the proper position on the sprockets.

• The direction of chain travel and the direction of sprocket rotation must be correct.
• All chain connectors must be correctly installed.
• Any cotters, or other retainers, must be correctly in place and secure.
• All setscrews should be in place and tight.
• All bolts and nuts should be in place and nuts should be tight, with lock washers or other
retainers as needed.
• The chains, including any outboard rollers, should be lubricated as needed. Other bearings
related to the chain should be checked for proper lubrication.
• Any other factors that might hurt the operation of the chain should be checked and
corrected.

ADJUST INITIAL CHAIN TENSION

Drives

First, turn the sprockets opposite each other to put all of the slack in one span. Put a straightedge
between the two rollers that are first engaged on each sprocket in the slack span. This is the straight-
line distance between engagement points. Use a scale to measure the total midspan movement (AC)
in the slack span (Figure 14-27).

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Chain Installation 373

FIGURE 14-27 Adjusting initial tension in a chain drive.

FIGURE 14-28 Amount of chain sag in a horizontal catenary.

The total movement (AC) should be between 4% and 6% of the straight-line distance between
engagement points for drives that are horizontal or inclined up to 45 degrees from horizontal. In
a horizontal drive, the depth of sag is approximately 0.433 × AC. The total movement (AC) should
be only 2% to 3% of the straight-line distance between engagement points for drives that are vertical
or inclined more than 45 degrees from horizontal.

Conveyors

For horizontal conveyors, measure the sag in the catenary section shown in Figure 14-28. Put a
straightedge between the last roller engaging the sprocket and the first roller on the return support
(L). Then use a scale to measure the depth of sag (D).
Adjust the chain tension to give the amount of sag recommended by the chain manufacturer.
No sag is generally recommended for vertical conveyors and bucket elevators. Adjust the initial
chain tension to the amount, and using the method, recommended by the chain manufacturer.

SETUP LUBRICATION
Install and set up the lubrication system. Make sure that all reservoirs are filled. Make sure that
all lines are properly connected and clear, and make sure that the lubricant is directed onto the
chain as it was designed.

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CHECK CHAIN OPERATION AND RUN-IN

Turn the driveshaft slowly (preferably by hand) to see that the chain works as it should. Some large
machines may have to be jogged with the power on. When this is the case, be sure to follow all
safety rules to protect personnel and not damage the machinery. The chain should be pulled through
its path for at least one full cycle.
Make sure the chain works as it is supposed to through its entire path. Check carefully to ensure
that the chain works smoothly and does not catch or bind on the sprockets or in the tracks. It is
good to run the chain with no load for a few hours. This seats all of the bearing surfaces and gives
the lubricant an opportunity to penetrate all of the internal bearing surfaces.
After this run-in period, check and retighten any fasteners as needed. Also, check and readjust
the initial chain tension if needed.

INSTALL GUARDS
If the chain does not run in a casing, it should be enclosed in guards to prevent personnel from
being injured by coming in contact with the chain or sprockets. More information can be found in
the American National Standards, ASME B15.1 and ASME B20.1.
Before installing the guards, inspect them to ensure that they are not broken or damaged. Install
the guards, making sure that all fasteners are in place and secure. Make sure that any safety devices,
such as presence sensors and interlocks, are in the correct position and are working properly.

CONCLUSION
Most standard chain applications that are installed following the directions in this chapter will give
good service. However, improved methods and chains are constantly being developed. Contact your
chain and sprocket supplier to get the latest information.

© 2006 by American Chain Association