The Ultimate Guide to Roller Chain Removal

Important Safety & PPE Use Note Before You Start

Mandatory Training Requirement

Before undertaking any work like chain removal, you must ensure you have received proper training and the required qualifications. Although these instructions are comprehensive, they do not substitute for professional training. We cannot be held responsible if you inflict any injury to people or equipment due to lack of proper training.

Chain Removal Safety Measures

Safety measures are crucial when working with roller chains, especially when removing them from drives. In addition to common industrial workplace risks, removing a chain, particularly if it has heat-treated parts or has been exposed to overheating, carries the risk of material breakage. If a metal particle chips away and becomes airborne, it may strike the operator or damage equipment.

Chain removal safety has three key elements/requirements:

• Use personal protective equipment (PPE). When removing a chain, you must protect your eyes with safety glasses. Protective clothing, gloves, and footwear are also recommended.
• Electrical shock protection. Turn off the power supply to the equipment and restrict access to the power switches with locks.
• Use appropriate and intact tools. Ensure the tools you are using are in good condition and used properly as designated. Do not use inappropriate tools when the right tool is unavailable. Obtain the right tools for the job if you do not have them.

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Step 1: Get Access to the Chain & Drive

First, you need to gain access to the chain itself as you will be working directly with it. If your equipment has safety guarding that covers the drive, remove it to access the chain. If any presence sensor devices obstruct the chain removal process, remove them as well. Ensure no foreign objects that could create process disruptions are present in the work area.

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Step 2: Determine the Chain Type and Understand Its Construction

Understand the chain's construction, including the side plate fastening method, before disconnecting it. This crucial step determines the approach to chain removal. It will also dictate the necessary preparation actions, measures to undertake, tools to use, and effort required to support the chain and secure the drive parts.

The three most common chain types that substantially affect how you remove the chain are:

• A chain with a master link
• A cottered chain without a master link
• A riveted chain without a master link

Knowing the specific chain type you are working with is essential for determining the appropriate removal approach.

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Step 3: Prepare Tools & Equipment

Depending on the chain type, you may need different sets of equipment. Its identification at the previous steps will determine the specialty tools, supporting devices, and pressing equipment that may be needed for its removal.

Here are some typical tools and equipment used for removing the three types of chain:

In order for the chain removal process to be safe and efficient all tools and equipment should be properly sized to the chain.

Ensure you have the appropriate tools and equipment based on the chain type and size before proceeding to the next step.

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Step 4: Restrain Uncontrolled Chain Drive Movement

Before chain disassembly, support the chain and restrain the drive parts from free rotation:

• Restraining shafts and sprockets prevents the drive parts from uncontrolled movement that may cause equipment damage or operator injury.
• Supporting the chain itself is also important to prevent any uncontrolled motion, especially after the chain loop is disconnected.

The goal here is to ensure that when you disconnect the chain, it does not engage in any dangerous movement that may damage the equipment or jeopardize the safety of the operator. For heavier chains that may create these risks, we recommend using a pulley support system like a block and tackle.

To provide safety during the chain removal process, chains with master links and cottered chains typically require less support and movement restriction. However, a riveted chain may need additional support for safely grinding off the pin rivets.

The tools you use to drive out the link pins will also affect the level of desired movement restriction you’ll need. Pressing equipment like chain breaker tools may require minimal support, while driving the pins out of the link with a hammer and punches is not possible without securing the chain in a more stable position.

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Step 5: Remove a Link From the Chain

To remove a roller chain from the drive, you need to disconnect it at the position of the master link or one of the pin links. Specific instructions for removing a link to disconnect the chain loop depend on the chain's construction type and whether the side plate is press-fit or slide-fit (less common). We discussed the importance of determining the chain type by the pin fastening method in earlier steps, as this creates the most significant difference in this step.

The link removal process usually involves two major steps:

• First, you need to remove the fastening that holds the link side plate in place. This can be a spring clip, cotters, or rivets, depending on the chain type.
• Second, remove the side plate of the link from the pins. This can be done by sliding the link out of the roller link in the case of a split-fit construction or by driving the pins out from the side plate if they are press-fit. Since removing a split-fit side plate is a simple process, we will only review this part of the process for press-fit chain link construction.

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1. Removing a Chain with a Master Link

Locate the Master Link and Determine Its Type

In the best-case scenario, your chain will have a master link that connects its two ends. Once you locate the master link on the chain, you need to determine the type of fastening. Master links typically use one of the following three fastening methods:

• Spring clip
• Single Cotter key
• Double Cotter key

For specific guidance on removing each of the types of master link fasteners, see our comprehensive chain link removal guide.

Remove a Master Link

• Rotate the drive sprockets to move the position of the master link where the most access is provided for its removal, typically in the middle of the chain strand between the sprockets, often the upper (slack) strand.
• For additional support, you may rotate the sprockets in opposite directions from the link to tension the chain and provide more stability in the working area.
• While not required, you can achieve maximum stability by clamping the part of the chain with the master link to one of the sprockets (see instructions for riveted pin link chain removal).
• Use specialty tools or pliers and a flat-head screwdriver to unclasp the spring clip or pull the cotters out of the chain link pin holes.
• Push the pins out with a roller chain breaker tool or other pressing equipment. For more detailed information about cutting the chain with a roller chain breaker, check out this guide "How to Cut Roller Chain the Right Way".

2. Remove a Chain Without a Master link

2.1. Remove a Pin Link From a Cottered Chain

On a cottered chain, every pin link has its side plate secured on the pins with removable cotters. These chains don't have a specific link designated as a master link. However, they should not be confused with a riveted roller chain without a master link, as the methods of link removal differ entirely. Removing a pin link from a cottered roller chain is similar to removing a chain with a master link. The main difference is that you don't need to locate a specific link and may choose virtually any link unless some links require replacement due to wear.

The process is as follows:

• Choose the pin link that offers the most access for the removal job.
• Remove the pin cotters using pliers and a flat-head screwdriver. Optionally, you may use specialty pliers and cotter pin removal tools.
• Push the pins out of the side plate with a roller chain breaker tool or other pressing equipment. For more detailed information about cutting the chain with a roller chain breaker, check out this guide - "How to Cut Roller Chain the Right Way".

2.2. Remove a Riveted Chain

Removing a link from a riveted chain includes these steps:

• Identify the pin link you will be removing and rotate the sprocket you will use as support for grinding off link rivet heads until the chosen link is in the uppermost position.
• Secure the chain on the sprocket with C-clamps for stability.
• Protect equipment from debris generated by using the grinder.
• Grind off the pin rivet heads with an angle grinder, flush to the side plate.
• Unclamp the chain from the sprocket.
• Rotate the sprockets to move the chain into a position where the link you are removing will be accessible for using the chain breaker tool. This would typically be in the middle of the upper strand.
• Push the pins out with a roller chain breaker tool or other pressing equipment. For more detailed information about cutting the chain with a roller chain breaker, check out this guide - "How to Cut Roller Chain the Right Way".

Be sure to read our guide on link removal for different types of chains here - How to Remove a Chain Link. Focus on the parts of the guide that discuss disconnecting the chain on the drive or conveyor instead of on the bench.

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Step 6: Unclamp the Chain & Remove It From the Drive

Once the link is removed and the chain loop is disconnected, you are ready to remove it from the drive.

• Start releasing all clamping devices you used to restrain its free movement on the drive.
• If you used any equipment to support the chain from falling off the drive under its own weight, do not remove it just yet. This goes in the last turn.
• Carefully guide the chain out of the drivetrain. If necessary, assist the process by slowly rotating the sprockets

After these steps the chain is ready for serving, repair or replacement.

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Before You Put the Chain Back on the Drive or Stow it Away

Preparing for Storage

If the equipment is going to be out of service and the chain will not be reinstalled, you need to ensure proper chain storage. Clean the chain, cover it with grease, wrap it in grease-resistant paper, and place it in a moisture-free storage space. Make sure to thoroughly remove the grease when it will be taken out of storage for installation.

Preparing for Installation

Ensure comprehensive cleaning and re-lubrication of both the chain and sprockets before reinstalling. This is particularly important for riveted chain installation if you used a grinder to previously disconnect it. During grinding, the grind dust gets inside the chain assembly and will create more wear on the chain parts if the chain is not cleaned properly.

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