Achieving Precision in Belt Driven Machinery

Introduction

Belt drives represent a practical and economical means of transmitting power. Belt drives offer:
 Flexibility in drive design
 Speed ratio variation
 Clean, lubrication-free operation
 Ease of replacement
 Relatively high efficiency
Belt technology continues to evolve. The belt driven machine of today looks much different from a machine
built 20 years ago. Modern V-belt designs offer superior torque / horsepower handling capabilities with lower
bearing loads than their older counterparts, often with fewer belts and smaller pulleys. Synchronous belts
offer tremendous horsepower capacity in a small package, and are an excellent alternative to many gear and
chain drives.
Unfortunately, in many plants, belt maintenance practices have not evolved. Traditional maintenance
practices on belt-driven machinery have been, on average, poor to mediocre. While some plants have been
aggressively proactive with precision belt practices, many others accept poor maintainability and high
vibration and wear as “the nature of the beast.” A properly designed, installed, and maintained belt drive will
run as smoothly as any direct-coupled machine and will provide excellent life and service.

Chapter Objectives
The subjects covered in this chapter include:
 Description of common belt types and their application
 Description of sheaves / pulleys and shaft mounting methods
 Overview of belt and pulley selection based on application
 Belt tensioning methods
 Proactive belt installation and alignment
 Belt drive inspection and troubleshooting

V-Belts

V-Belts are the most commonly used belts in industrial drives today. Power is transmitted in a V-belt drive by
friction between the belt side surfaces and the corresponding surfaces on the sheave. The friction is a function
of:
 The belt and sheave materials
 The amount of wrap around the sheave
 The wedging action due to sidewall expansion of the belt when wrapped around the sheave
 The amount of tension
Critical factors for efficient operation are the condition of the belt sidewall surfaces and the condition of the
sheave walls, which directly affect the grip of the belt within the sheave. Proactive maintenance practices
have a direct impact on these critical factors and proper maintenance and installation practices can
dramatically improve system performance and reliability.
V-belt driven machinery design is relatively straightforward. Optimal designs can be determined from tables,
charts, and simple formulas. However, machinery in the field may not meet minimum criteria defined by belt
manufacturers and groups, such as the Rubber Manufacturer’s Association and the Mechanical Power
Transmission Association. Changes in sheave diameters to increase or decrease speeds, reengineering, or
poorly designed machines may create situations that adversely affect reliability. While the intention of this
course is not to teach machinery design, understanding minimum requirements enables mechanics to identify
potentially problematic machines, allowing alternative drives to be considered.
Even with increased belt load carrying capacities, many newer machines run with fewer and/or smaller belts
than their older counterparts with similar horsepower ratings and with lower belt tensions. When replacing
belts on an older machine, it is wise to re-evaluate belt and sheave requirements, as it may be possible to
replace old and worn components with less expensive components. Additionally, reduced bearing loads may
significantly improve the life of the driver and driven machine bearings and shafts.
With the advent of newer belts and the increasing number of machines utilizing metric belts, it is important
that the drive be thoroughly understood before belts or sheaves are replaced during normal or corrective
maintenance activities. The use of an incorrect belt or sheave can dramatically affect the life of the belt and
the efficiency of the drive. The following sections cover common belts used in industry.
Note on metric (SI) and inch-pound dimensions: Currently, V-belts are manufactured in metric (SI) and inch-
pound dimensions. The conversion between the two units of measurement presented herein represents the
standards developed by the power transmission industry. It should be noted that many dimensions are not
direct conversions. Since many belt dimensions are nominal, they fall within a tolerance range as specified
within a particular standard. Therefore, a 13 mm wide belt may actually be slightly wider or narrower than 13
mm. A direct conversion of 0.5” into metric units is 12.7 mm. For the sake of working with reasonable
numbers, 12.7 mm is rounded up to 13 mm. A review of belt dimension tables shows that an A Classical V-
belt with a nominal width of 0.5” is interchangeable with a 13C classical V-belt.
Classic V-belt lengths do not directly convert from metric to inch-pound units because the belt manufacturers
have adopted ISO standard 1081-1980 for metric dimension belts. This standard describes “effective”
dimensions. For example, the effective belt length is “the length of a line circumscribing a V-belt at the level
of the effective diameter of the measuring pulleys while the V-belt is at a prescribed tension.”
This method of dimensioning is very helpful to drive designers, but can be confusing to the end-user when
trying to determine what belt to use for replacement. It turns out that the effective length is very close to the
measured length of the outside of the belt. For example, a B-35 belt in the inch-pound system corresponds to
a 16C960 belt in the metric system. 960 mm converts to 37.79” rather than 35”. Use care when replacing
belts, and, when in doubt, work with the local belt distributor or the belt manufacturer to ensure that the
proper belt is selected.
A 13C belt can be replaced with an A belt in single belt applications, for example. However, for multiple V-
belt drives, belts should be either all metric, or all inch-pound dimensions. Belts from different manufacturers
having the same part number all have the same nominal dimensions. Due to differences in construction and
materials, all of the belts should be from the same manufacturer to ensure that they are properly and equally
tensioned.
There are many V-belt sizing standards throughout the world. For inch-pound measurement units, the US
standards are shown. For metric (SI), the RMA standards are used where applicable. The following chart
shows the belt interchange between major global standards.
 KS: Korean Industrial standards
 ISO: International Organization for Standardization
 DIN: Deutsche Industrie Norman
 JIS: Japanese Industrial Standard
 RMA: Rubber Manufacturers Association
 BS: British Standards
US KS ISO RMA JIS DIN BS
- M Z - M 10 Z
A/AP/AX A A 13C A 13 A
B/BP/BX B B 16C B 17 B
C/CP/CX C C 22C C 22 C
D/DP/DX D D 32D D 32 D
E/EP/EX E E - E 40 -
3V/3VX 3V SPZ 9N 3V SPZ SPZ
5V/5VX 5V SPB 15N 5V SPB SPB
8V/8VX 8V - 25N 8V - -
- - SPA - - SPA SPA
- - SPC - - SPC SPC
3L - - 3L - - -
4L - - 4L - - -
5L - - 5L - - -
International V-Belt Interchange.
Notice that for some V-belt types there is not an exact interchange. In these cases, it is important that only a
belt of the same type and standard be used. Alternatively, if it is difficult to source a particular belt, it may be
a good idea to simply install new sheaves and belts on the drive that meet the machine manufacturer’s
performance requirements. Use of an incorrect belt / sheave combination can lead to poor belt life, sheave
damage, inefficient operation, or excessive drive / bearing loads.

V-Belt Types

The three common types of V-belts used in industry are as follows:

 Classical, Standard, or Conventional V-belts
 Narrow or Wedge belts
 Fractional Horsepower (FHP) belts
Within these categories, are different belt constructions.

Classical V-belts
Classical V-belts offer a good compromise between load carrying capacity and cost, and are the most
common belts found on industrial machinery. Due to the nature of most loads, these belts are often installed
in multiple-belt configurations, either individually or in specially molded banded belts. The cross sections for
the Classic V-belts are 13C, 16C, 22C, and 32C, which correspond to the A, B, C, and D cross-sections in the
inch-pound (US) system as well as many international standards. The E cross-section belts are still available
for replacements from some manufacturers, but are not recommended for new designs. Belt profiles are
shown in Figure 1. Tables 2 and 3 list belt dimensions and minimum sheave diameters for standard single
belts. Joined or Banded V-belts are slightly thicker due to the band, but the cross-sections are the same as the
single belts.

CROSS- WIDTH THICKNESS OF MINIMUM

SECTION SINGLE SHEAVE
WRAPPED DIAMETER
BELT

13C 13 mm 8 80 mm
16C 16 mm 10 140 mm
22C 22 mm 13 224 mm
32C 32 mm 19 355 mm
Nominal Dimensions of Classical V-Belt Cross-Sections – metric.

CROSS- WIDTH THICKNESS OF MINIMUM

SECTION SINGLE SHEAVE
WRAPPED DIAMETER
BELT

A 0.5 (1/2) 0.31 (11/32) 3.0

B 0.66 0.41 (7/16) 5.4
(21/32)
C 0.88 (7/8) 0.53 (17/32) 9.0
D 1.25 0.75 (3/4) 13.0
(1-1/4)
E 1.5 1.0 21.6
(1-1/2)
Nominal Dimensions of Classical V-Belt Cross-Sections – inches.

Figure 1. Classical V-Belts.

Single belts are available with a fabric wrap or with rubber sided cogs. The fabric-wrapped belt, shown in
Figure 2, provides good wear and abrasion resistance, but the belts are relatively heavy and stiff (resistant to
bending), requiring a fairly large minimum pulley diameter to minimize belt bending stresses.
Figure 2. Wrapped Classic V-Belt.

The Cog V-belt has a molded or a machined rubber edge with cogs, as shown in Figure 3. These are also
referred to as raw edge belts. These belts are available in the 13C, 16C, and 22 C cross-sections (A, B, and C)
and are denoted by the addition of an X. For example, a 16CX belt indicates that the belt has a 16 mm cross-
section and is of cog construction. This design has an increased horsepower rating of approximately 30
percent over wrapped belts. Due to the raw edge construction, cog belts are more sensitive to misalignment
and slippage – extra care should be taken when aligning and tensioning drives utilizing these belts. The cog
design has greater flexibility and better heat dissipation than wrapped belts, and can run on smaller than
recommended pulleys, often with fewer belts than an equivalent Classical V-belt drive. The cog and standard
wrapped Classical V-belts may be interchanged, but on drives running two or more belts they must be of the
same construction. Cog belts should only be used on a drive originally designed for utilizing cog belts.
Consult the machine manufacturer or machine records to determine the proper belt rather than simply
replacing the belts with what came off of the machine. It is possible that the previous belts were incorrect for
the application.

Figure 3. Cog Belt.

Belt Dimensions

The advent of the metric system, changes in belt design, and slight differences between manufacturers has
created some confusion regarding belt lengths. Traditionally, Classic V-belts measurements were based on
the inside circumference of the belt. The part numbering system employed by belt manufacturers reflects this
value. However, from the design perspective, it is important to know the effective length of the belt. For a
number of years this was known as the pitch diameter, which is approximately at the center of the thickness of
the belt. As belts have evolved, the effective portion (the true pitch) of the belt has moved closer to the outer
diameter and no longer matches the older pitch diameter. Therefore, the Rubber Manufacturer’s Association
has changed the belt and sheave designation for Classic V-belts, which is also in accordance with ISO
standards. The old pitch diameter on sheaves now corresponds to what is referred to as the datum diameter.
The pitch diameter is now equal to the outside diameter on standard sheaves. The datum on the belt is the
point on the face that is coincident with the datum diameter on the sheaves. This is shown in Figure 4.
Figure 4. Sheave Dimensions.

While this may seem confusing, it aids in the design of modern belt systems as it reflects the true active radii
of the drive for load and speed / ratio calculations. In a belt catalog, you are likely to see the belt length listed
by part number, outside circumference / length, and datum circumference / length, as well as a metric
equivalent. The datum diameter is equal to the pitch diameter in older catalogs.
For metric belts, the effective belt length is expressed in millimeters (mm) and is shown following the belt
cross-section. For example, a 22C1830 belt indicates that the belt has a 22C cross-section with an effective
length of 1830 mm.
For example, a B35 V-belt would be listed as follows:
PART RMA OUTSIDE DATUM
NUMBER LENGTH CIRCUMFERENC LENGTH
(MM) E (IN) (IN)
B35 960 38 36.8
Sheave Belt Dimensions.
A modern B35 belt is a direct replacement for an old B35 belt. Belt lengths range from 710 mm to 12290 mm
(26” to 660”) depending on the cross section and the number of bands. For example, a 12290 mm (660”) belt
is only available in a 32C (D) cross-section.

Narrow V-Belts
Narrow V-belts represent an improvement over Classical V-belts. The smaller cross-section and revised
profile allow for smaller sheave diameters for a given application. Compared to a machine driven with
Classical V-belts, the Narrow V-belt machine will have smaller diameter, lighter weight sheaves; and a
properly designed drive will operate with lower bearing loads and shaft stresses. Narrow V-belt drives are
also capable of operating at higher speeds. When altering machine speeds on an existing drive or when
replacing worn components, a Narrow V-belt drive should be considered as a replacement. Narrow V-belt
sheaves are not interchangeable with Classic V-belt sheaves and the belts cannot be interchanged.
Belt cross-sections display in Figure 5. Tables 5 and 6 list belt dimensions and the minimum sheave
diameters for standard single belts. Joined or Banded V-belts are slightly thicker due to the band, but the
cross-sections are the same as the single belts. Cogged belts have slightly smaller minimum sheave
requirements.
Figure 5. Narrow V-Belts.

CROSS- WIDTH THICKNESS OF MINIMUM

SECTION SINGLE BELT SHEAVE
DIAMETER
9N 9 mm 8 mm 67 mm
15N 15 mm 13 mm 180 mm
25N 25 mm 23 mm 315 mm
Nominal Dimensions of Narrow V-Belt Cross-Sections – metric.
CROSS- WIDTH THICKNESS OF MINIMUM
SECTION SINGLE BELT SHEAVE
DIAMETER
3V 0.38 0.31 (5/16) 2.65
(3/8)
5V 0.62 0.53 (17/32) 7.1
(5/8)
8V 1.0 0.91 (7/8) 12.5
Nominal Dimensions of Narrow V-Belt Cross-Sections – inches.
The construction of Narrow V-belts is similar to Classical V-belts. They are available in wrapped or raw-
edged cog construction depending on belt width and manufacturer. 9N (3V) belts are generally of cog
construction. 15N (5V) and 25N (8V) belts are usually of cog construction up to 5000 mm (200”) in length,
and are of wrapped construction in lengths over 5000 mm (200”). Verify belt availability with specific
manufacturers. In most cases, cog belts can be substituted for wrapped belts, if more stringent alignment
practices are followed. However, wrapped belts should not be substituted on drives originally designed for
cog belts. When in doubt, refer to the machine manufacturer’s recommendations or machine records.
Belt Dimensions

Metric-dimension belt length is based on the effective length method and is measured in millimeters. A
9NX1080 belt indicates that the belt is a narrow V-belt with a 9N cross-section, ribbed construction (X), and
is 1080 mm in length.
For inch-dimension belts, a uniform identification system for Narrow V-belts has been adopted by all belt
manufacturers in the United States and Canada. The belt cross sectional width is measured in 1/8-inch
increments. The effective belt length is measured around the outer circumference of a tensioned belt in 0.1”
increments. For example, 3V1500 indicates that the belt is a narrow V-belt with a 3V (3/8”) cross-section,
and is 150” long.
The conversion between metric and inch lengths is rounded to the nearest whole number. For example, a
2540 mm belt is equal in length to a 100” belt.
Cog belts are designated with an X following the belt-type designator. For example, a 3VX440 indicates an
inch-dimension 3/8” wide cog belt that is 44 inches long.
Light-Duty (Fractional Horsepower) V-Belts
Light-duty or fractional horsepower (FHB) V-belts are used in smaller light-duty applications. These belts are
very flexible due to their lightweight construction and, therefore, can use smaller pulley diameters compared
to Classic V-belts. Light-duty belts are wrapped and generally have a single tension band. Cross-sections of
light-duty belts are shown in Figure 6.

Figure 6. Light-Duty Belt Cross-Sections.

It is important to note that 4L and 5L belts are dimensionally interchangeable with A and B Classic V-belts,
respectively. However, they have significantly lower horsepower ratings and will not last in service when
used in place of A or B belts. A and B belts used in FHP applications will not perform well due to their
increased bending stiffness and the likelihood that the light-duty sheave diameters will be too small.
Belt Dimensions

The Rubber Manufacturer’s Association has developed a uniform identification system for Light-duty belts
that has been adopted by all belt manufacturers in the United States and Canada. Belt cross-sectional width is
measured in 3.2mm (1/8”) increments. Belt length is measured around the outer circumference in 1/10-inch
increments. For example:

4L440
Identifies this belt as:
4 -13 mm (1/2”) wide
L - Light-duty
440 - 1120 mm (44”) long
There are currently no metric equivalent standards from the RMA.

V-belt Drives with Multiple Belts

Many drives require the use of multiple belts. Multiple belts provide a good compromise between belt sizes,
sheave size, and drive loads. When properly designed and installed, the load is shared equally by all of the
belts in the drive. For relatively short center distances, individual belts are often used of either cog or
wrapped construction. For longer spans, joined V-belts (often called banded belts) are often recommended as
they provide added stability.
Joined belts, as shown in Figure 7, are essentially individual belts that share a common backing. Because of
their construction, the belt lengths are equal and there is no concern over matching individual belts. Joined
belts are more expensive than an equal number of individual belts, and are not a solution to shoddy
maintenance practices. Alignment and tensioning are as critical when using joined belts, and joined belts do
not solve problems associated with poor sheave quality, or poor machine frame or foundation stiffness.
Generally, a drive is a good candidate for joined belts when the center span distances are large, where load
pulsations are present, or where the drive experiences large lateral forces.
Episodes of excessive belt whip, repeated belt overturning, or the throwing of belts when using individual
belts may indicate a need for joined belts, after the cause of the overturning has been determined. Joined belts
have a much higher lateral stiffness than individual belts and are far less sensitive to lateral and pulsating
loads. Joined V-belts are designated by the number of belt strands in the band followed by a slash. For
example, 3/5V650 indicates a joined Narrow V-belt with three elements, a 5V cross-section, and that is 65
inches long.

Figure 7. Banded Belts.

When using individual V-belts, they must be a matched set. In the past, that meant purchasing a set of belts
that had been measured and matched to within RMA guidelines. Matched belt sets can still be purchased, but
they are expensive. Over the last few decades, belt manufacturing technology has improved to the point that
for a given belt manufacturer and a given belt type and size, any new individual belts will meet or exceed
RMA recommendations for matching. However, belts from different manufacturers cannot be mixed, as they
will have unique belt stretch characteristics based on construction and materials. In addition, within a specific
manufacturer, the same belt type must be used. For example, cog and wrapped belts cannot be mixed.
When a single belt fails in a set, the entire set must be replaced to ensure that each belt is carrying the proper
load and that each belt is properly tensioned. Failure of a single belt often identifies an installation or
alignment problem, which must be addressed to prevent recurrence of the problem.

Sheaves

For proper operation, belts and sheaves must match, as premature wear or belt failure could result if the wrong
belt or sheave is used. By belt type, the following sheaves are used.

Classical V-belts
For metric belts:
13C - Accepts 13C and 13CX belts
16C - Accepts 16C and 16CX belts
13C/16C Combination - Accepts either 13C, 13CX, 16C or 16CX belts
22C - Accepts 22C or 22CX belts
32C - Accepts 32C belts
Sheave grooves are manufactured to RMA standards, a subset of which is shown in Table 7.

CROSS- DATUM GROOVE MINIMUM

SECTION DIAMETER ANGLE RECOMMENDE
(DEG.) D DIAMETER
(MM)
(MM)
13C, Up through 34 13C 80
13CX 125
Over 125 38 13CX 60
B, BX Up through 34 16C 140
195
Over 195 38 16CX 112
AB Up through 34 13C 80
185
Over 185 38 13CX 60
16C 140
16CX 112
C, CX Up through 34 22C 224
325
Over 325 38 22CX 180
D Up through 36 32C 355
490
Over 490 38
Classical V-Belt Sheave Dimensions – metric.
For inch-dimension belts:
A - Accepts A and AX belts and 4L Light-duty belts (in light-duty applications)
B - Accepts B and BX belts and 5L Light-duty belts (in light-duty applications)
AB - Accepts either A, AX, B, or BX belts
C - Accepts C or CX belts
D - Accepts D
Sheave grooves are manufactured to RMA standards, subsets of which are shown in Table 8.
CROSS DATUM GROOVE MINIMUM
SECTION DIAMETER ANGLE RECOMMENDE
(DEG.) D DIAMETER
(INCHES)
A, AX Up through 34 A 3.0
5.4
Over 5.4 38 AX 2.2
B, BX Up through 34 B 5.4
7.0
Over 7.0 38 BX 4.0
AB Up through 34 A 3.6
7.4
Over 7.4 38 AX 2.8
B 5.7
BX 4.3
C, CX Up through 34 C 9.0
7.99
7.99 through 36 CX 6.8
12.0
Over 12.0
38
D Up through 34 D 13.0
12.99
12.99 36
through 17.0
Over 17.0
38
Classical V-Belt Sheave Dimensions – inches.
Belts and sheaves must not be mixed. For example, an A belt in a B sheave will ride down at the bottom of
the groove and will not make proper sidewall contact. The exception is A or B belts with an AB sheave, as
shown in Figure 8. As long as the correct datum diameter corrections are used when determining drive ratios,
these sheaves can be stocked in place of separate A or B sheaves.

Figure 8. A and B Belts Shown in an AB Sheave.

As shown in Tables 7 and 8, sheave groove angles vary with the diameter of the sheave. As a belt is wrapped
around the sheave, the sidewalls bulge. The smaller the bend or wrapping radius, the greater the bulge.
Therefore, smaller diameter sheaves have slightly larger groove angles. When inspecting groove condition
with a gauge, ensure that the proper gauge has been selected for the belt type and the sheave diameter.

Narrow V-belts
Sheave groove standards for Narrow V-belts meet standards established by the RMA. Tables 9 and 10 list
subsets of the standards for these belts.
CROSS- EFFECTIVE GROOVE MINIMUM
SECTION DIAMETER ANGLE RECOMMENDE
(DEG.) D DIAMETER
(MM)
9N Up through 36 9N 67
90
9NX
Over 90 to 38 9NX 56
150
Over 150 to 40
300
Over 300 42
15N Up through 38 15N 180
250
15NX
Over 250 to 40 15NX 112
400
Over 400 42
25N Up through 38 25N 315
400
40
Over 400 to
42
560
Over 560
Narrow V-Belt Sheave Standards – metric.
CROSS- DATUM GROOVE MINIMUM
SECTION DIAMETER ANGLE RECOMMENDE
(DEG.) D DIAMETER
(INCHES)
3V Up through 36 3V 2.65
3.9
3VX
Over 3.9 to 38 3VX 2.2
6.0
Over 6.0 to 40
12.0
Over 12.0 42
5V Up through 38 5V 7.1
9.990
5VX
Over 9.99 to 40 5VX 4.4
16.0
Over 16.0 42
8V Up through 38 8V 12.5
15.99
Over 15.00 40
to 22.4
Over 22.4 42
Narrow V-Belt Sheave Standards.
Narrow V-belts and sheaves are not interchangeable. For example, a 3V belt cannot be used on a 5V sheave.
These belts and sheaves are also not compatible with any Light-duty or Classical V-belts. Always check the
driver and driven sheave types before installing a replacement belt.
Runout tolerances as recommended by the RMA are as follows:
Radial Runout (total indicator reading)
0,25 mm (0.010”) – for up to 250 mm (10.0”) outside diameter
0,01 mm (0.0005”) – add for each additional 25 mm (1”) of OD
Axial Runout (total indicator reading)
0,13 mm (0.005”) – for up through 125 mm (5.0”) outside diameter
0,03 mm (0.001”) – add for each additional 25 mm (1”) of OD
These values are suggested for the sheaves and do not reflect the total runout that may be seen when a sheave
is installed on a shaft. Attention to detail when installing sheaves will produce results similar to the RMA
values. Excessive axial or radial runout affects the ability to properly align the drive and will produce high
radial and axial forces on the bearings. In the next section, procedures are outlined to install sheaves with
minimal runout.
Sheave Mounting
In heavy-duty applications, most sheaves are attached with a tapered bushing, which may vary between
manufacturers. A typical bushing is shown in Figure 9.

Figure 9. Typical Sheave Bushing Arrangement.

Smaller and Light-duty sheaves may employ a straight bore with setscrews. These are available in standard
bores and can be bored to size. The installation of the sheave onto the shaft is important in order to preserve
the balance of the sheave, and to ensure that the grooves run true and concentrically. Orientation of the
sheave and the tapered bushing are also important to make sure the sheaves on both shafts line up properly,
and to minimize shaft loads. Preferably, the sheave should be placed as close as possible or practical to the
bearing. Flange-type bushings can be installed in two different ways to accommodate most applications, as
shown in Figure 10.

Figure 10. Sheave Mounting.

Balancing standards for sheaves from most manufacturers adhere to Mechanical Power Transmission
Association standards, which call for single plane balancing to ISO standard G26, which is a rough standard.
It is recommended that sheaves be balanced in two planes to ISO G6.3 or better to provide smoother operation
and lower bearing loads. These can be purchased directly from most manufacturers; but many plants balance
sheaves after the bushing has been sized in-house, or they send them out for precision balancing. It is
important to match-mark the sheaves and bushings when they are balanced to minimize axial runout. These
steps will preserve the balance of the sheave when installed on the machine. Belt design manuals generally
have a balancing chart indicating speed ranges for normal or special balancing. Proactive balancing practices
to ISO G6.3 will meet or exceed these values.
Synchronous and Timing Belt Drives

V-belt drives transfer power to the driven machine through friction created by the wedging action of the belt
in the sheave groove. Synchronous belts transmit power through positive engagement of the belt teeth in the
sprocket; therefore, there is no slip. Due to the thin profiles of synchronous belts, they operate on smaller
diameter sprockets than V-belts, which may be important in applications with limited space. Synchronous
belts are more efficient than V-belts (approximately 98 percent compared to 90 to 95 percent); and, as they do
not rely on tension to provide the frictional load, synchronous belts operate with lower bearing loads and shaft
stresses.
Several evolutions of synchronous belts are currently available; though not all belts are interchangeable
between manufacturers. The first generation, often-called timing or positive drive belts, have been available
for several decades and conform to RMA standard IP-24. These belts utilize a trapezoidal tooth design.
These belts use inch dimensions and are designated as MXL, XL, L, XH, and XXH, which correspond to the
belt tooth pitch or spacing. These belts have good registration (timing) characteristics and low to medium
load carry capabilities. The belt pitch and standard widths are as shown in Tables 11 and 12.
DESIGNATION DESCRIPTION BELT STANDARD
PITCH WIDTHS
(MM)

XL Extra light 5,080 9.7

L Light 9,525 12.7, 19.1,

25.4

H Heavy 12,7 25.4, 38.1,

50.8, 76.2

XH Extra Heavy 22,225 50.8,76.2,

101.6

XXH Double Extra 31,750 50.8, 76.2,

Heavy 101.6, 127.0

Synchronous Belt Standards – metric.

DESIGNATION DESCRIPTION BELT STANDARD
PITCH WIDTHS
(INCHES)

XL Extra light 0.20 .25, .38

L Light 0.375 .5, .75, 1.0

H Heavy 0.5 .75, 1.0, 1.5,

2.0, 3.0

XH Extra Heavy 0.875 2.0, 3.0, 4.0

XXH Double Extra 1.25 2.0, 3.0, 4.0,

Heavy 5.0

Synchronous Belt Standards – inches.

The belt pitch is the distance in inches between two adjacent tooth centers as measured on the belt’s pitch line.
The length of these synchronous belts is the circumference of the belt as measured on the pitch line, as shown
in Figure 11.

Figure 11. Dimensions.

Belts are designated by length (in inches) times ten, the belt pitch, and the width. For example:

770XL025
Identifies this belt as:
5080 mm (0.2”) pitch
1958 mm (77.0”) pitch length
9.535 mm (0.375”) wide
The next evolution in synchronous drives was the high torque belts and sprockets. These belts use a
curvilinear tooth profile and are capable of handling applications with higher horsepower / torque.
Dimensions for these belts and sprockets are in SI (metric) units. The RMA describes standard 8 and 14 mm
pitch drives, but the belt manufacturers produce belts with 5, 8, 14, and 20 mm tooth pitches. Within this
group of belts three tooth / groove profiles are designated as H, S, and R. Belt construction is similar to the
trapezoidal tooth synchronous belts. It consists of high tensile members with a neoprene backing and
neoprene teeth molded integrally with the backing. The wear surfaces of the belt are covered with nylon
facing, as shown in Figure 12.

Figure 12. Typical Synchronous Belt Construction.

Standard curvilinear tooth design belts with 8 and 14 mm tooth pitches conform to RMA standards and can be
interchanged between manufacturers. Generally, the 5 and 20 mm pitch belts can also be interchanged.
Belt manufacturers have embarked on improvements to the standard curvilinear tooth belts that offer
increased load capacities of 150 to 200 percent more than older designs. However, little or no standardization
on these “next generation” belts exist. These new-design belts offer increased speed capacity, lower noise,
lower bearing and shaft loads, and better registration (timing) than standard curvilinear belts. However,
unless clear cross-references exist, the belts and sprockets cannot be interchanged between manufacturers.
Goodyear, for example produces a belt with a herringbone design, a departure from the straight teeth that
most of the other manufacturers produce. In addition, a new generation belt may physically fit an older style
sprocket, but the sprocket may not be capable of handling the load for which the belt is designed. Meticulous
records of the components used on a machine help avoid errors when replacing worn belts or sprockets. It
may be beneficial to standardize on a particular manufacturer’s product line to ensure compatibility, and to
minimize spare parts stocking requirements. This also helps with specifications for newly purchased
machinery.

Curvilinear Tooth Belt Dimensions

Curvilinear tooth belt lengths are measured at the circumference of the belt pitch line in millimeters (mm).
Lengths range from 300 mm (11.81”) to 6860 mm (173.23”) depending on the belt pitch. Available belt
widths depend on the tooth profiles. Table 13 shows common belt widths for the R and H profiles.

DESIGNATIO BELT PITCH STANDARD WIDTHS

N (MM) (MM)
5M 5.0 9, 15, 25
8M 8.0 20, 30, 50, 85
14M 14.0 40, 55, 85, 115, 170
20M 20.0 115, 170, 230, 290, 340
Curvilinear Belt Dimensions
Belts are designated by pitch (mm), pitch length (mm), and the width (mm). For example:

2000-20M-230
Identifies this as a synchronous belt with:
20 mm pitch
2000 mm long
230 mm wide

Sprockets

The pulleys / sheaves for synchronous belts are referred to as sprockets, since they share many of the
characteristics of chain drives. Sprockets for the standard trapezoidal series of drives and the 8M and 14M
curvilinear belts are interchangeable between manufacturers, and adhere to RMA standards. The first
generation 5M and 20M curvilinear belts will more than likely interchange, but since there are no published
industry standards, it is best to check with the respective manufacturers before replacement.
As mentioned in the belt section, significant differences exist among manufacturers of the “new generation”
drives, so it is important that parts not be interchanged unless approved by the manufacturer.
Sprockets are mounted to shafts using the same method as V-belt sheaves. Configurations of the mounting
system vary depending on sprocket diameter and the width of the sprocket. When installing sprockets on a
machine, ensure that the sprockets are placed as close to the bearing on the shaft as possible to minimize shaft
deflections while allowing easy access to perform routine maintenance.
Balancing standards for sprockets also adhere to Mechanical Power Transmission Association standards. It is
recommended to either purchase sprockets balanced by the manufacturer to higher standards (e.g., ISO G6.3),
or to balance your sprockets in-house or with a reputable balancing shop for better performance and lower
vibration.
Sprockets are available with and without side flanges. The flanges prevent the belt from “walking” off the
flange. Most sprockets with 80 or fewer teeth come with flanges. In some drives, where there is limited
movement of the components for belt replacement, it is desirable to have one sprocket without side flanges to
facilitate belt changes. The following guidelines apply:
 Two sprocket drives – One of the sprockets must have flanges, or both sprockets must have one flange
mounted on opposite sides.
 Long centers – When the center distance is greater than eight times the smaller sprocket diameter, both
sprockets should be flanged.
 Vertical shafts – One sprocket should be flanged on both sides, and all other sprockets should have at
least one flange on the bottom side.
 Multiple sprocket drives (serpentine) – Every other sprocket should be flanged, and the remaining
sprockets should have alternating single flanges.

Belt Drive Design Considerations

When a new belt-driven machine is purchased, it is likely that the belts and sheaves are correct for the
application. This is an assumption. There may be instances where the drive is under or over-engineered to a
point that excessive maintenance results. However, the more likely candidate for improper or less than
optimal design is an existing machine in the plant. Over time, there may have been speed changes or
increases in load over the original design that has created a drive problem. Additionally, with the advent of
newer belt and sheave designs, it may be possible to upgrade a drive to significantly improve its efficiency,
maintainability, and durability.

Drive Selection
The selection of a drive is straightforward. Following the steps outlined in the manufacturer’s catalogs, a
number of combinations of drives can be easily identified. From there, a final drive can be selected that offers
the best combination of cost and loads. Additionally, these easy to use procedures can be used to evaluate an
existing design when troubleshooting a failure or high maintenance costs.
For example, a 10 hp induction motor is driving a centrifugal pump. It operates 24 hours per day. The motor
speed is 1750 and the desired pump speed is 1635 rpm. The center distance (distance between the centerlines
of the two shafts) is approximately 34 inches. V-belts will be used in the drive.
For every application, a service factor must be determined. This is a multiplier used to account for conditions
such as high starting torque, extended run times, shock loading, etc. For this application, a service factor of
1.2 is recommended. Therefore, the design horsepower for this example is 10 x 1.2, or 12 hp.
From the horsepower versus the speed of the fastest shaft chart supplied by one belt manufacturer, shown in
Figure 13, a 3VX cross-section belt is recommended

Figure 13. Belt Cross-Section Selection.

Next, the drive selection tables are referenced to determine the sheaves and belts required to provide the
correct speed and center distance. In this example, it is determined that a drive pulley of 5.6 inches in
diameter and a driven pulley of 6.0 inches provides the correct speed and meets the minimum sheave diameter
requirements recommended by NEMA. The ratio for the drive is 1:07 to one. The belt required is a 3VX750,
which is 75 inches long.
 The next step is to determine how many belts are needed. From the chart, it shows that for a 1750-rpm
application, the horsepower per belt is 7.09. Dividing the design horsepower by the horsepower per belt
(12.0/7.09) produces a value of 1.7. Therefore, two belts will be required. For very short center
distances, for example, a correction factor will actually reduce the horsepower per belt capacity of the
drive. This is due primarily to inadequate wrap (arc of contact) of the belt around the smaller of the two
sheaves. For example, if the wrap around the smallest sheave in a drive is only 90 degrees, the
horsepower rating for the drive is reduced by 30 percent. The length of the belt is also an important
consideration. Short belts are constantly being bent and have little time to cool between sheaves.
Therefore, the drive capacity is reduced by a length correction factor.
 Identify the part numbers for the appropriate 2-groove 3V sheaves.
 The next step is to determine the maximum and minimum deflection forces and deflection distances that
would be used to statically tension the drive. These can be determined from charts or equations.
 Based on the sheaves and tension, the shaft loads can be calculated.
Often, the selection of a drive is an repetitive process where different pulley diameters and center distances
are investigated to provide the most economical drive. To make this process easier, the various belt
manufacturers have produced drive selection computer programs that provide a number of drive alternatives
very quickly to the extent of displaying part numbers and list prices. Several of these programs also provide
belt tension information, shaft loads, and even anticipated noise levels for synchronous drives. They are
available through belt suppliers and many can be downloaded from company web sites.

Proactive Belt Installation and Maintenance

Proper belt drive installation and maintenance involves much more than prying belts back onto a sheave or
sprocket to get a machine back on line as quickly as possible. The steps are as detailed as a precision shaft
alignment or the proper installation of a rolling element bearing. When properly installed and maintained,
belt drives provide long life and smooth performance. Rough running belt driven machinery that crack
frames and foundations, and that vibrate across the floor are often accepted as “the nature of the beast” when,
in fact, they are simply examples of most often poor maintenance practices.
The following sections break down maintenance tasks to troubleshooting, inspection, installation, and
periodic maintenance / condition monitoring. Even when performing “routine” belt replacements, the full
approach should be followed to establish a maintenance pattern that becomes standard practice. The benefits
of following this sequence include potential correction of chronic problems along with prevention of future
problems through the identification of wear mechanisms, etc.

Troubleshooting and Inspection

Accurate machine history is important when trying to solve belt drive problems. From machine records,
identify the following:
 Original sheave / sprocket and belt specifications from the machine manufacturer including belt type and
length, and sheave pitch diameters. In addition, the speed and ratio values should be identified to verify
that the machine has or has not been altered.
 History of plant modifications to the drive, including belt or sheave reengineering, guarding changes, and
process changes. For example, the load on a blower drive that is operating above the original design
speed increases at a rate of the speed increase cubed. The old belts may be inadequate for the new
machine speed.
 History of machine frame or foundation changes, failures, or repairs including belt guard modifications.
 Motor or driver details such as frame size, horsepower, operating speed, and rotational direction, as well
as changes or modifications to the motor or motor platform.
 History of the frequency of belt or bearing failures.
 Previous attempts at problem correction.
 Tension data and notes from the previous repair / replacement.
Talk to the machine operators to obtain their opinions on potential problem sources and to determine if the
operation or process has changed, but not documented. Also, talk to any maintenance personnel who have
worked on the machine to identify problem areas.
For normal preventive belt replacement, many of these questions will not apply, however, at a minimum, the
original specifications should be obtained.

Running Inspection
If the machine is still running, perform a visual inspection of the machine checking the following:
 Overall machine condition / cleanliness. Inspect the machine frame and foundation for indications of
looseness or cracks. Check the belt guard to ensure it is properly mounted. If the guard is vented to
provide cooling to the belts, verify that screens and filters are clear of debris, grease, oil, etc. Make sure
the belt guard is properly mounted and all bolts are present. Check for any evidence of rubs against belts
or sheaves.
 Using a basic overall vibration instrument, perform a rough vibration test. Starting at the bearing
locations on the driver and driven shafts, compare the vibration at points on the framework of the
machine, ducting, conduit, etc. Pay close attention to changes in vibration across bolted or welded joints,
as this may indicate looseness or cracking. Note any areas that appear to have unusually high vibration
for possible further testing. If loose bolts are found, attempt to tighten them to determine if they have an
effect on the machine vibration.
 Note: A screwdriver or length of a wooden dowel can be used as a crude means of identifying any
unusual squeaks or bearing noise.
 If a temperature probe is available, measure the temperature of the bearing housings on both shafts. An
infrared probe can also be used to measure belt temperatures if there is a clear view of the belts through
the guard. Measure the ambient air temperature within the belt guard. Full belt life can be attained in
ambient air temperatures up to 30º C (85º F). Standard belts can operate safely in ambient temperatures
up to 60º C (140º F). Contact belt manufacturers for applications higher than 60º C. The RMA states
that for every 14º C (25º F) increase in ambient temperature, belt life is reduced by 50 percent. Actual
belt temperatures will be higher due to the constant bending around the sheaves / sprockets, and will be
significantly higher if there is slippage. For every 10º C (19º F) rise in the actual belt temperature, life is
reduced by 50 percent. Compare the as-found readings with temperatures after maintenance to identify
the quality of improvements.
 Under load, there should be a slight bow to the belt on the slack side of the drive as shown in Figure 14.
If the belt is straight, the tension is too high. Too much bow indicates inadequate tension.
Figure 14. Verifying Tension on the Slack Side of the Drive.

 If a strobe light is available, and if it is possible to see through or around the belt guard, inspect the belts
and sheaves / sprockets.
 The unaided eye can see approximately 0,25 mm (0.010”) of movement when a shaft or rotor is “slowed
down” with a strobe light. Set the strobe to a flash rate slightly slower or higher than shaft speed at the
first sheave / sprocket and check for excessive axial or radial runout. Find a fixed reference point to
compare the motion. If it is visible, it is probably excessive. Check the second sheave and note any
problems so runout can be checked during belt installation.
 Set the strobe light to a very high flash rate and watch to see how the belts enter / exit the sheaves on the
tension side. Angular or parallel misalignment often causes V-belts to ride up on the side of the sheave.
This is often visible when the machine is running.
 Decrease the flash rate of the strobe slowly and watch the belts for excessive whipping or movement on
the tension side. Resonance in a belt will often produce distinct waves. A change in tension may detune
the belt to minimize whip. One or more belts that appear to be moving much more than the others may
indicate unequal tensioning due to misalignment or mismatched belts. Some flutter is usually present on
the slack side of the drive and should not be a concern unless there is a significant difference between
belts.
 Slow the strobe light down to belt rotational speed. Inspect the belt or belts as they slowly rotate for any
signs of wear or damage. On multiple V-belt drives, attempt to determine if all of the belts are moving
together by watching markings on the belts. A slipping belt appears to rotate at a different speed. If the
drive can be shut down, spray a white stripe across the belts so that any relative movement is more
noticeable.
 If vibration equipment is available, record overall and spectrum readings at the bearings on both shafts in
the horizontal, vertical, and axial directions. Further testing by the vibration team may be necessary to
identify unusual vibration sources.
 Document the running amps and load / process information for comparison with post-maintenance
readings.
 Shut down the machine and observe any changes in vibration or noise as the machine coasts down.
 Follow plant safety procedures to lockout and tag-out the machine before any further work is performed.

Shutdown Inspection
The following steps should be followed once a machine has been taken out of service.
 Check the as-found alignment of the machine. Using a straight edge or piano wire, identify any
combinations of parallel or angular misalignment. Record any findings of excessive misalignment. If the
 shafts freely turn, rotate one sheave at a time by 90 degrees and check the alignment again. While not as
conclusive as a runout test, it will help to separate misalignment from runout as a problem source. Unless
the machine incorporates an idler pulley, the machine must be moved to remove and replace the belts.
Final alignment will be conducted as part of the installation process.
 If possible, pull the slack side and tension side belt(s) together and look for any noticeable movement of
the motor / driver or the frame. Weakness in the frame makes it difficult to properly tension the drive and
induces misalignment, especially when the drive is under load. High performance synchronous drives are
especially sensitive to driveline weakness.
 Check the seated position of the belt(s) within the groove. With the exception of a 13C belt running in a
13C/16C sheave (an A belt running in a AB sheave), a Classical V-belt should be even with the outside
diameter of standard sheaves, Figure 15. Narrow V-belts will actually sit slightly above the outside
diameter of the groove. Anything less may indicate sheave wear.

Figure 15. Groove Inspection.

 Slacken any hold down bolts as required to remove the belts from the drive. Inspect the belts, paying
close attention to any glazing, cracking, deterioration, etc. If any of the belts were broken and thrown
from the machine, look carefully at the break and several inches to each side of the break to identify any
pry marks from screwdrivers or other sharp objects. A diagonal line across the belt may indicate the belt
was pried or rolled over the sheave / sprocket. If the belt(s) is to be re-used, check the belt with a belt
gauge to identify any signs of wear and to verify that the belt is of the correct type. On applications with
multiple belts, verify that the belts are from the same manufacturer and have the same part number, if still
visible. If there are substantial differences in the condition of the belts within the set, it is wise to replace
all of the belts. Take extra care to identify any conditions that would cause unusual wear on one or two
belts of a set.
 Inspect the full circumference of all grooves to identify any burrs, nicks, rust, debris, oil, or other
contaminates. If abrasive material is present, check guarding and filters to ensure they are functional, or
make note of the condition for future corrective action. V-belts are somewhat tolerant of dirt as they are
essentially self-cleaning. Dirt that enters the sheave with the belt is ejected as the sheave rotates.
Synchronous belt drives, however, are very sensitive to debris that may become embedded in the belt or
the sprocket. For example, high debris environments such as saw mills may be better candidates for V-
belt drives because of unavoidable sawdust debris. Check the bottom of the groove for any signs of
rubbing or polishing which may be an indication of an incorrect belt or excessively worn groove
sidewalls. Use a sheave groove gauge to check all grooves on V-belt sheaves. Measure the outside
diameter of the sheaves to determine the proper groove gauge. Notice that the groove angle increases
 with diameter. The gap from groove wall wear should not exceed 0,8 mm (1/32”), as shown in Figure 16.
Any more than this and the proper wedging action will not be obtained and the belts may begin to ride on
the bottom of the groove. On lightweight / duty stamped steel sheaves, check the groove around the
entire circumference to ensure it is not bent and that the groove is uniform.

Figure 16. Use of Sheave Groove Gauge to Inspect Groove Walls for Excessive Wear.

The wear on multiple sheave grooves should be uniform or the belts will not operate with the same effective
radius, and one or more belts will continually be in slip. Replace any sheave that exhibits excessive wear.
Remove any burrs or rough spots on the face or rim of the sheave / sprocket that could damage the belt.
Proper belt installation and belt tensioning take-up requires that one or both machines be free to move in-line
with the line of action between the two shafts of a drive, as shown in Figure 17. Verify there is sufficient
allowable movement or that the drive is at one of the extremes of movement, which may indicate a belt that
was too long or too short was used. Belt design manuals contain charts for minimum take-up and installation
distances based on belt length. For example, a 2360 mm Classical V-belt with a 16C cross-section requires a
32 mm allowance for installation and 51 mm for take-up (initial tensioning and re-tensioning. A 90-inch
Classical V-belt with a B cross-section requires a 1.3-inch allowance for installation and 2.5 inches for take-
up). The drive may have to be modified if there is insufficient allowable movement. For example, if the
minimum installation distance is not met, it may be tempting to pry a belt onto the
sheave.
Figure 17. Two shafts of a Drive.

Proactive Sheave, Sprocket and Belt Installation

Throughout the installation / assembly of a belt drive, any errors will be compounded as the process
continues. For example, excessive shaft runout due to a bent shaft will create significant axial and radial
runout on the face and rim of a sheave. It is difficult to troubleshoot the perceived sheave problem when the
true source is the shaft. Therefore, follow each step, identify, and correct any problems as they are found.

Step 1 – Inspect the shaft

If the sheave / sprocket has been removed from the shaft, check the shaft for radial runout with a dial
indicator, preferable at three locations to separate shaft / bearing eccentricity from a bent shaft. Generally,
0,025 to 0,050 mm (0.001” to 0.002”) TIR (total indicator reading) is acceptable for most applications.
Inspect the condition of the shaft for evidence of burrs or other imperfections that would prevent the sheave /
sprocket or bushing from seating squarely on the shaft. The keyway should be clean and undamaged. Slight
imperfections can be removed with a machinist’s stone. Measure the shaft with a micrometer at a minimum
of three radial positions and two axial planes to verify that it is within specifications for the bushing to be
used, and that it is not tapered or out-of-round.
Clean the shaft with an approved solvent. Measure the length of the shaft and bushing keyways and make an
appropriate step key or cut the key to the correct length as shown in Figure 18.

Figure 18. Use the Correct Length Key for the Tapered Hub and Keyway.
Sheave / Sprocket Installation
If the old sheave or sprocket is to be re-used, inspect the bore, if it is a straight bore, or the bore of the bushing
for any damage. The outside of the tapered bushing should be free of any defects or corrosion. If the history
of the machine is unknown, check part numbers to confirm that it is the correct bushing for the mating parts.
Several types of tapered bushings are available from manufacturers. One common type is the QD bushing,
which typically has a side flange. The “Taper-Lock” bushing is a patented design that does not have a flange,
which allows for a more compact mounting. The assembly sequence shown below is for a QD type bushing.
Consult the technical manuals for your particular components for proper torque settings and other assembly
details.
A tapered bushing can be assembled two ways: insertion of the bolts through the bushing into tapped holes in
the sheave / sprocket, or insertion of the bolts through clearance holes in the sheave / sprocket into tapped
holes in the bushing, as shown in Figure 19.

Figure 19. Tapered Bushing Assembly Options.

The assembly sequence depends on the configuration of the shaft / machine and the axial position required to
mate with the sheave on the opposite shaft. When possible, mount the sheave / sprocket as close to the
bearing as possible to minimize shaft and bearing loading. Slide the sheave / sprocket on the shaft followed
by the bushing, or reverse the sequence depending on the mounting sequence. It may be necessary to spread
the split carefully with a screwdriver or other thin wedge. Some bushings are supplied with setscrews. The
setscrew can be lightly tightened to prevent excessive axial motion during assembly. If the bushing and
sheave sprocket are being installed on a vertical shaft, proper rigging must be used to ensure the assembly
does not shift or fall off the shaft until it has been fully tightened.
For safe installation, it is very important that no lubricants are used on the tapered surfaces of the bushing and
the mating sheave / sprocket. A lubricant will decrease the friction between the two surfaces allowing the
sheave / sprocket to be pulled up too far on the taper as the bolts are tightened. The result can be a cracked
sheave, or in a worst-case scenario, an explosion during operation. The excuse that if a lubricant is not used
disassembly will be difficult is an indication that the bushing bolts are being tightened too much. The safety
concerns of the use of lubricants outweigh any disassembly issues. The bushing bolts also should be clean
and free of any lubricants.
Insert the bushing bolts and hand-tighten the bolts. Push and pull lightly on the sheave / sprocket as the bolts
are snugged so it does not become wedged on the bushing. The bolts should be tightened with a torque
wrench in 40 percent, 90 percent, and 100 percent steps (note, other torque percentages will also work; these
are provided for guidance). Tighten to 40 percent of rated torque and measure axial and radial runout with a
dial indicator as shown in Figure 20. If the values exceed those shown in Tables 14 and 15, inspect the
bushing and shaft for fit. Occasionally, slight variations in tapers produce more axial runout depending on the
orientation of the bushing with respect to the sheave / sprocket. Sometimes, rotating the sheave / sprocket
clockwise or counterclockwise by one bolthole will significantly improve runout values.
Figure 20. Axial and Radial Runout Readings.

Confirm the axial position at this stage to ensure that there is sufficient movement to allow the drive to be
aligned axially (parallel alignment). Loosen the bushing, shift it axially if necessary, and then re-tighten to 40
percent. Do not tap on the shaft, bushing, or sheave / sprocket to move it as damage to bearings may result.
Use a puller or spread the bushing split so that it slides freely.
After tightening to 90 percent of the rated torque, check runout again. From this point, creative torque
techniques can be used to remove as much of the remaining runout as possible. For example, tighten the bolt
or bolts at the “high spot” identified with the dial indicator first and check the runout again. In no case should
the torque values recommended by the manufacturer be exceeded. Tables 14 and 15 lists common torque
values for inch and metric dimension QD bushings. Confirm these values with information provided for the
specific parts being used for exact values.
FT. – LBS.
SIZE & THREAD TO APPLY WITH
OF CAP SCREW TORQUE
WRENCH
1/4 x 1 9
No. 10 – 24 5
1/4 – 20 9
5/16 – 18 15
3/8 – 16 30
1/2 – 13 60
9/16 – 12 110
5/8 – 11 135
3/4 – 10 225
7/8 – 9 300
1–8 450
1-1/8 – 7 600
1-1/4 – 7 750
Typical QD Style Bushing Torque Values - inches.
 NEWTON METERS
SIZE & THREAD (FT. LBS.)
OF CAP SCREW TO APPLY WITH
TORQUE WRENCH
M6 x 1.0 12 (9)
M5 x 0.8 7 (5)
M6 x 1.0 12 (9)
M8 x 1.25 20 (15)
M10 x 1.5 41 (30)
M12 x 1.75 81 (60)
M16 x 2.0 149 (110)

M16 x 2.0 183 (135)

Typical QD Style Bushing Torque Values – metric.

A common assembly error is to wrestle a heavy sheave into position and to quickly tighten one of the bolts
first before inserting the other bolts. This technique usually results in a cocked sheave and one or more of the
bolts may be over-torqued as the remaining bolts are installed. Always follow a tightening sequence.
An alternative dial indicator method is to measure the runout perpendicular to one of the grooves if there is
sufficient room. This reading is effectively a combined axial and radial measurement. A reading of 0,18 mm
(0.007”) TIR is used for precision installations. It is suggested that the outermost groove be used as
machining forces occasionally produce some degree of distortion towards the center of a multiple V-sheave.
The desired condition is for the groove to be true and concentric to the shaft. On some sheaves, there may be
some discrepancies between the face and the grooves. Therefore, the runout as measured at the face may be
within specifications but the grooves may not be correct. The most appropriate action would be to reject the
components if they are new, or replace old parts, but this may not be practical, especially if there is pressure
to get the machine back on line. Make a note in the maintenance database so the parts can be replaced at a
future date.
Record the final runout results and document any problems encountered.

Belt Installation and Alignment

Move the machine to the install position or relax belt idlers on fixed center-distance drives and slip the belts
onto the sheaves / sprockets. Do not pry or roll the belts on. The sharp radius created at the local spot where
the belt is pried will damage the tension members inside the belt. The damage will not be readily apparent,
but the belt may fail in a very short period. Root cause failure analysis will usually reveal this installation
damage.
Confirm the belts are free of obstruction and move the machine to take up the slack in the belt(s). Confirm
that the sheaves / sprockets are in the correct axial position on the shaft. Loosen and correct if necessary, or if
required movements for the alignment will exceed bolthole or slot clearances.
There two fundamental forms of shaft misalignment in belt drives – parallel and angular. In most cases, there
will be a combination of both when dealing with a newly installed drive or when belts are being replaced, as
shown in Figure 21. Manufacturers provide guidelines for belt / sheave / sprocket alignment, but in most
cases these values should be used only as extreme limits and all attempts should be made to improve upon
them.

Figure 21. Belt / Shaft Alignment.

Belt misalignment terms are somewhat confusing. A pure parallel misalignment causes the belt to ride at an
angle as shown in the diagram on the left. The diagram on the right shows proper parallel alignment but the
lower shaft is misaligned at an angle. Proper alignment techniques will correct both of these conditions.
Total misalignment in a drive is expressed in degrees. For wrapped Classical V-belts and Narrow V-belts the
limit is 1/2 degree. This equates to 0,8 mm per 100 mm (0.1” per foot) of center distance. Synchronous belts
and ribbed V-belts must not exceed 1/4 degree, which is approximately 0,5 mm per 100 mm (.0625” per foot)
of center distance. It is obvious that 5 mm (0.2”) parallel offset on a V-belt drive with a 600 mm (24”)
distance span is quite large and can easily be improved upon. As a rule, angular misalignment is more
harmful to drives using synchronous belts, as it will create uneven wear. Parallel misalignment, on the other
hand, is more damaging to V-belts. However, every reasonable attempt should be made to remove angular
and parallel misalignment from any drive.
Alignment must actually be accomplished in two planes. On a horizontal drive, use a quality level to ensure
that both sheave / sprockets are parallel in the vertical plane. Hold the level vertically. This technique will not
work if the machine shafts are mounted directly above and below one another, as there is no convenient
reference for the horizontal portion of the alignment. A laser method or checking the alignment diagonally
across the sheaves after the vertical alignment has been achieved may improve the results on this type of
drive.
It is advisable to rotate the shafts 90 degrees when checking the level to make sure that axial runout is not
influencing the readings. When aligning critical drives, a method to remove the influence of runout is to
temporarily glue shim stock on to the face of the pulley at the low spot, as identified by the axial runout
readings. The shim stock will be 1/2 of the thickness of the TIR reading. This technique is also effective
when performing the face alignment with a straight edge or piano wire.
Drives with shaft center distances less than 300 mm (24”) can be aligned with a straight edge placed across
the faces of both sheaves / sprockets. Figure 22 shows angular misalignment between the two shafts. The
moveable machine would be adjusted so the space on both sides is equal, leaving only the parallel
misalignment to be corrected. Trying to fix a combination parallel and angular misalignment in one step may
prove difficult. Work to remove the angular misalignment first and the parallel problem will be easier to
correct.
Figure 22. Parallel Misalignment.

Parallel misalignment is shown in Figure 22. The parallel offset can be removed by repositioning the
moveable machine or by adjusting the axial position of one or both of the sheaves / sprockets on the shaft.
For machines with longer center distance spans, a length of piano wire can be stretched across the faces of the
drives as shown in Figure 23. Piano wire tends to provide a better reading than string.

Figure 23. The Use of Piano Wire to Measure Belt Alignment.

Avoid the errors shown in Figure 24 when checking the alignment.

Figure 24. Potential Errors When Checking Alignment.

Final checks can be made by rotating one shaft by 90 degrees and comparing the results. Return the drive to
the original position and rotate the opposite shaft 90 degrees and check it again. Repeat these steps for 180-
degree rotation of both shafts. Significant changes indicate there is axial runout out in one or both of the
sprockets / sheaves. Check the runout and correct if necessary before accepting the alignment. On drives that
have experienced long belt life and low levels of vibration, these checks may not be necessary, but they are
essential when trying to solve problems on troublesome drives.
After alignment and tensioning of a synchronous drive, the alignment can be checked by pushing the belt
against the flanges on one side of the drive. Slowly rotate the shaft in one direction by hand and watch for
belt movement across the sprockets. It should take several turns for the belt to traverse across the sheave.
The better the alignment, the more turns required (if the belt does not move initially, reverse the rotation).
Next, reverse the rotation. If the belt moves back across the sprockets, the angular alignment is correct. If the
belt continues to move in the same direction as it did initially, the system has angular misalignment that
should be corrected. Synchronous belts move towards the direction of least tension. Therefore, it is easy to
determine the appropriate corrections.
On V-belt sheaves, it is important to align the grooves rather than the faces of the sheaves. A possible error
may occur if the two sheaves in the drive have a different face-to-groove distance as shown in Figure 25. A
technique that references off the groove, such as some laser systems, may improve results. Another method to
overcome this problem is to simply measure the difference between the two sheaves and account for the
difference when using the straight edge or piano wire.

Figure 25. Sheaves with Different Face-to-Groove Distances.

Laser alignment systems are becoming more widely used on belt drives. Two laser designs widely in use are
face-mounted systems as shown in Figure 26 and groove-mounted systems as shown in Figure 27. A laser
beam is pointed at one or more targets on the opposite shaft. The position and angle of the beam on the
targets indicates the amount and type of misalignment. Care should be exercised when using the face-
mounted device on sheaves with different face-to-groove widths.

Figure 26. Face-Mounted Laser Alignment Device.

Figure 27. Groove-Mounted Laser Alignment System.
Belt Tensioning
Belt tension affects many aspects of belt performance. Excessive tension produces:
 Excessive belt temperatures
 Accelerated wear of belts and sheaves / sprockets
 High shaft bending loads
 High bearing loads
 Potential misalignment due to frame distortion
 High energy bills
 Belt whip if tuned to an excitation frequency in the machine
 High noise in synchronous drives
 Accelerate belt tooth and sprocket tooth wear
 Drives are often over-tensioned due to lack of proper tools, inexperience, or attempting to make up for
parts such as worn sheave grooves. Inadequate tension is equally harmful, producing:
 Slippage resulting in sheave and belt wear
 High belt temperatures
 Excessive belt whip that can throw belts or turn them over
 High noise in synchronous drives
 Accelerated belt tooth and sprocket tooth wear
Proper belt tension is essential and is easily accomplished if all of the previous precision installation steps
have been followed. There are several methods of setting belt tension. Given drive specifications, it is
possible to mathematically determine the correct “take-up” in the shaft center distances. The static belt
deflection from a force applied at the center of the span between sheaves / sprockets can be calculated based
on drive details, which are referred to as the force deflection method. For “unusual” drives such as variable
speed drives and spring-loaded idlers, or critical applications, these methods are recommended because they
may require higher or lower tensions than “standard” values. Another method that is gaining popularity is
tuning the belt to a predetermined frequency. Belt tension is set and the belt is plucked to determine its
natural frequency. Special measuring devices or even a vibration spectrum analyzer can be used to measure
the frequency. The measured frequency is compared to the desired frequency and the drive is adjusted. The
exact frequency ranges must be supplied by each belt manufacturer since slight variations in belt construction
will affect the frequency. For mass production, this method would be especially valuable.
A less complicated method is based on the deflection of the belt at the center of the span for a given force
determined from a belt-tensioning chart. This method will work well in 90 percent of applications and is
much better than any attempts to tension by “feel.”
First, measure the free span of the belt between sheaves / sprockets as shown in Figure 28.
Figure 28. Span Length for Force Deflection Method.

Divide the span, in mm, by 100. This is the deflection value in mm/100 mm to be used for tensioning, or 1
mm per 100 mm of span. In inches, divide the span by 64. This gives a deflection value of 1/64” per inch of
span.
Next, refer to the chart supplied by the belt manufacturer’s catalog for the force values (in Newtons or
pounds) for the belt type on the drive. These will vary, so it is important not to use a single chart for all
drives. The values are based on new designs. If used on older machines, over-tensioning may result. Older
drives used larger and potentially more belts than equivalent drives of more modern design. A typical chart is
shown in Table 16.
Force Values Based on Belt Type and Drive Details.
Use a force deflection gauge as shown in Figure 29 and push on the belt to a distance equal to the
predetermined deflection value. Push at the center of the belt span and at the center of the belt width. For
wide belts or banded belts, use a strip of steel or wood across all of the belts. For single belts on a multiple
belt drive, the belts can be checked individually. This is a good idea as any unequal tension due to
misalignment will be evident. Ensure that at least one sheave / sprocket is free to turn as the force is applied.
Look at the o-ring on the force scale and compare it to the chart. Increase or decrease tension as required.
Notice that the chart provides a used belt and new belt value. The tension on a new belt will decrease quickly
over the first 24 hours of operation as the belt seats in the sheave. Set the tension to the new belt value. Over
the first 24 hours, check the belt often. If it begins to slip, re-tension immediately. Shut down the machine
after 24 hours and check the tension again. If it falls between the used and new belt values, do not re-tension.
If the tension has fallen below the used belt value, tension to that value and restart the drive.
Periodic inspection of the drive and drive tension is recommended as part of a preventive maintenance
program. With experience and history, the frequency of inspections can be adjusted to avoid excessive
maintenance at one extreme and unexpected failure at the other.
Figure 29. Force Deflection Gauge.

If unfamiliar with the machine, check the alignment of the shafts after tensioning to determine if there is any
deflection in the frame or structure. The machine may have to be offset before tensioning to achieve proper
alignment. This is symptomatic of a weak frame, and, under load, the drive will deflect even more.
Document the frame weakness when closing out the work order, and on the belt drive checklist.

Inspection after Startup

It is recommended that the drive be inspected when the machine is restarted to ensure proper operation. The
running inspection steps outlined above can be followed to check the drive. Pay close attention to any
unusual noise or vibration and check bearing temperatures after the machine has reached steady state
operation. Compare observations with the as-found conditions on the drive. Do not hesitate to shut the
machine down if problems are identified to prevent damage to the belts or sheaves / sprockets.