Mechanical Drives 2 Lap 2

MECHANICAL
LEARNING
DRIVES 2 ACTIVITY
PACKET
V-belt selection
and maintenance
TM
B503-XC
LEARNING ACTIVITY PACKET 2
V-BELT SELECTION AND MAINTENANCE
INTRODUCTION
In this last LAP in the v-belt series, you will learn how to identify, specify, and select
sizes of v-belts and their drive components. This is an important skill for either replacing
components on older drives or selecting components while designing new ones.
Also, you will learn how to maintain and troubleshoot v-belt drives. If v-belts are
properly maintained, they will give long, trouble-free service.
ITEMS NEEDED
Needed Amatrol Supplied
Items
950-ME1 Mechanical Drives 1 Learning System

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

Assorted Hand Tools
Felt-Tip Pen
String
FIRST EDITION, LAP 2, REV. B

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered
trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their
respective companies.
Copyright © 2006, 2005 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any
means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying,
recording or any information storage and retrieval system, without written permission of the copyright owner.
Amatrol,Inc., P.O. Box 2697, Jeffersonville, IN 47131 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com
B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Copyright  2006 Amatrol, Inc. 2
TABLE OF CONTENTS
SEGMENT 1 V-BELT SIZE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OBJECTIVE 1 Describe how v-belts are specified
OBJECTIVE 2 Describe three methods of identifying belt size and type
OBJECTIVE 3 Describe the function and operation of v-belt match codes
SKILL 1 Use a belt code to determine the size and type of a v-belt
SEGMENT 2 V-BELT COMPONENT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SKILL 2 Use a belt gage to determine belt cross section size
SKILL 3 Use measurement to determine the size and type
OBJECTIVE 4 Describe how bushings are specified
OBJECTIVE 5 Describe how sheaves are specified
SKILL 4 Use a sheave gage to identify a sheave size
SKILL 5 Identify size and type of a sheave and bushing given a sample
SEGMENT 3 V-BELT DRIVE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

OBJECTIVE 6 Describe how to select bushings, sheaves, and a v-belt for an application
SKILL 6 Select bushings, sheaves, and a v-belt for a given application
SEGMENT 4 V-BELT MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 66

OBJECTIVE 7 Describe preventive maintenance
OBJECTIVE 8 Describe nine preventive maintenance steps for v-belt drives
OBJECTIVE 9 Describe how to troubleshoot a v-belt drive system
SKILL 7 Troubleshoot a v-belt drive system

SEGMENT 1
V-BELT SIZE SPECIFICATION
OBJECTIVE 1 DESCRIBE HOW V-BELTS ARE SPECIFIED
dT
his V-belts are specified by their type, cross sectional size or belt
Rea
section, and their length. The three main types of v-belts (FHP,
conventional, and wedge) are all specified in a similar manner. A typical
belt code is shown in figure 1.
The letter or a number that precedes the letter identifies the type and
size of the belt’s cross section. The number that comes after the letter
identifies the nominal length of the belt.
In many cases, the exact length of a particular belt varies a little from
the nominal length. If the belt is to be used in a multiple belt set, it is
very important that the belts be of exactly the same length. To assist this,
a match code may also be printed on the belt, as shown in figure 1. This
tells you how much the belt length varies from the nominal length.
B40 GOODYEAR 52
NOMINAL MATCH
SIZE AND LENGTH CODE NUMBER
MANUFACTURER'S NAME
Figure 1. Typical V-Belt Code
With advancing technologies, many manufacturers are able to

manufacture belts that are all of the same size, without any variance. In
these cases, a match code is not needed. When using multiple belt sets,
always check with the supplier to determine if the brand you are using
uses match codes.

FHP Belt Specification
The specific codes used for the various sizes of FHP belts are shown
in figure 2. FHP belts are identified by the letter L. There are 4 sizes of
FHP belts, the smallest of which is the 2L and the largest being the 5L.
As you can see, this size refers to both the thickness and the width. For
example, the 4L belt is 1/2 inch wide and 5/16 inches thick. All 4L belts
will have this same cross-section, no matter what their length. When
specifying v-belts, the code that refers to the cross-section of the belt is
often called the belt section.
FRACTIONAL HORSEPOWER
BELT SIZES
WIDTH
SIZE
1/4
2L 5/32 HEIGHT
3/8
3L 7/32
1/2
4L 5/16
21/32
5L 3/8
ALL DIMENSIONS IN INCHES
Figure 2. FHP V-Belt Cross Section Size Codes
The number that precedes the letter L in the FHP belt specification
indicates the width of the belt in eighths of an inch. For example, the 4L
belt is 4 eighths of an inch wide or 1/2 inch wide.
The number that follows the letter L in the FHP belt code is a
number that represents the nominal length of the belt in tenths of an inch.
The nominal length of an FHP belt is the outside length of the belt. For
example, a typical FHP belt might be 4L450. This is belt with a 4L belt
section and whose outside length is 45 inches long.

Classical (Conventional) Belt Specification
The belt section of a conventional v-belt is specified with just a
letter. As figure 3 shows, there are five sizes of conventional v-belts,
ranging from the letters A to E. Unlike FHP belts, conventional belts do
not use a number that precedes the letter.
CONVENTIONAL BELT SIZES
SIZE DIMENSIONS
WIDTH HEIGHT
1/2
A 5/16
21/32
B 13/32
7/8
C 17/32
1-1/4
D 3/4
1-1/4
E 29/32
Figure 3. Conventional V-Belt Section Codes

The number that follows the belt section code of a conventional
v-belt specifies its nominal length. This number represents the nominal
length in inches, not tenths of an inch. For example, an A40 is an ‘A’
size belt that has a nominal length of 40 inches. The nominal length of a
conventional belt is measured along the inside length of the belt, as
shown in figure 4. This is different from the FHP belt, which uses
outside length.
INSIDE LENGTH
OF BELT
(CONVENTIONAL BELTS)
OUTSIDE LENGTH
OF BELT
(FHP BELTS)
Figure 4. Inside Length vs. Outside Length

Wedge Belt Specification
Wedge belts are specified using a code that is similar to the FHP
belts. The cross-sectional size is identified by a number, followed by a
V. As shown in figure 5, there are 3 sizes of wedge belts that follow the
sizes of the FHP belts. They are 3V, 5V, and 8V.
WEDGE BELT SIZES

SIZE DIMENSIONS
3/8
3V 5/16
5/8
5V 17/32
8V 7/8
Figure 5. Wedge Belt Section Codes

The nominal length of wedge belts is measured in tenths of an inch
along the pitch line of the belt, as shown in figure 6. This is different
from both the FHP and conventional belt. For example, a 5V850 wedge
belt has a nominal length of 85 inches.
PITCH
LENGTH
(WEDGE BELTS) INSIDE LENGTH
OF BELT
(CONVENTIONAL BELTS)
OUTSIDE LENGTH
OF BELT
(FHP BELTS)
Figure 6. Pitch Length vs. Inside and Outside Length
Any of the three types of v-belts can have a notched or cog design that
allows the belt to be used in small diameter sheaves, as shown in figure 7.
Figure 7. A Typical Cog Type V-Belt
To designate this, the letter X is added to the belt section code. For
example, a B60 becomes a BX60 or a 5V600 becomes a 5VX600. Note
the addition of the X to the belt code when specifying cog type v-belts.

OBJECTIVE 2 DESCRIBE THREE METHODS OF IDENTIFYING
BELT SIZE AND TYPE
dT
his The size and type of V-belt can be identified in one of three ways:
Rea • Reading the code printed on the outside of the belt

• Using a belt gage
• Measuring with a rule and comparing to a reference chart
Belt Section Identification

Reading the belt code that is printed on the belt is the easiest way to
determine the belt section and type. However, after the belt has been
used, this code may get worn off.
The next easiest method to determine the belt section is to use a belt
gage, as shown in figure 8. The belt gage allows you to quickly
determine the cross sectional size of the belt by simply sliding the belt
into the gage and reading the belt size closest to the top of the belt. For
example, the belt shown below is an 8V belt.
SHEAVE GROOVE GAGE
1" 8V
5/8" 5V
3/8" 3V
BELT GAGE
Figure 8. Belt Gage

The last method that is used to determine the belt section is by
measurement. You can measure the width and the height of the belt. The
belt section and type can then be determined by locating these values in a
table, similar to the one shown in figure 9.
FRACTIONAL
CONVENTIONAL WEDGE
HORSEPOWER
SIZE DIMENSIONS SIZE DIMENSIONS SIZE DIMENSIONS
1/4 WIDTH HEIGHT

2L 5/32 1/2
3/8
A 5/16
3L 7/32 3/8
1/2 21/32
3V 5/16
B 13/32
4L 5/16
21/32
7/8
5L 3/8
5/8
C 17/32
5V 17/32
1-1/4
D 3/4
1
1-1/4
8V 7/8
E 29/32
Figure 9. Belt Types and Sizes

The dimensions of the wedge belts, conventional, and FHP belts are
different, except in the cases of the 4L and 5L belts, which can be
interchanged with the A and B belts. In these cases, you would normally
replace these belts with the ‘A’ and ‘B’ belts, because 4L and 5L are
being phased out of production. Distinguishing between the two is not
important.
Most manufacturers have or are planning to phase out the 4L and 5L
belts in favor of the A and B belts, because they are interchangeable in
size and not much different in cost to make. In fact, if you look at the A
and B size belts used on the Amatrol trainer, you will notice that the
belts show both the conventional and FHP belt codes, e.g. B40 (5L430).
Also, notice that the belt length for the two codes are different because
they measure nominal length differently.

Belt Length Identification
When reading belt lengths directly from the belt code printed on the
belt is not possible, the belt length can be determined by measuring the
length with a piece of string, as shown in figure 10.
POINT OF OUTSIDE
OVERLAP OF BELT
STRING
Figure 10. Measuring Belt Length with String
For FHP belts, you should measure the outside length. To do this,
first wrap a string around the belt and mark its ends, as shown in figure
10. Then unwrap the string and measure the distance between marks with
a tape measure.
In a similar manner, the nominal length of a conventional belt is
measured along the inside of the belt.

Wedge belts, are measured along their pitch line. The pitch line is
approximately equal to the line made by the cording in the belt, as shown
in figure 11. Since it is hard to measure this, an easier way is to measure
outside length and then look up in a catalog table of standard belt
lengths, the nearest belt length that is shorter than your measurement.
PITCH
LENGTH
(WEDGE BELTS)
Figure 11. Approximate Pitch Line

OBJECTIVE 3 DESCRIBE THE FUNCTION AND OPERATION OF V-BELT
MATCH CODES
dT
his The belt match code is used to make sure that all belts which are
Rea
used in a multiple belt drive are of the exact same length. As you learned
in an earlier LAP, this is important in order to keep the same tension on
each belt and therefore evenly divide the load among each of the belts.
The match code tells you how much the belt length varies from the
nominal value. This code is a 2-digit number that comes after the belt
code, as shown in figure 12. If the belt length is exactly the same as the
nominal length value, the match code given is a 50. For each 1/10 of an
inch longer than the nominal value, the number of the match code is
increased by 1 over 50. For each 1/10 inch shorter than the nominal
value, the match code is decreased by 1 from 50.
For example, the belt shown in figure 12 has a match code of 52.
This means that it is 2/10 of an inch over the nominal value, which is 40
inches. The belt is therefore 40.2 inches long. In a similar manner, a belt
which has a match code of 47 makes it 3/10 inch shorter than the
nominal value, or 39.7 inches long.
B40 GOODYEAR 52
NOMINAL MATCH
SIZE AND LENGTH CODE NUMBER
MANUFACTURER'S NAME
Figure 12. Multiple Belt Match Code

All belts used on the same drive should ideally have the same
nominal length code as well as have the same match code. In many
cases, you can purchase belts in sets that have already been matched for
you. If matching belts are not available, a multiple belt drive will still
work well if the variation is kept to the limits shown in figure 13. This
means, for example, that belts having lengths less than 100 inches must
have match codes that vary by no more than one digit, e.g. 51 and 52.
BELT LENGTH
MATCHING LIMIT
(inches)
Up to 100 Use only 1 number
100 to 200 Within 2 consecutive numbers
500 and up Within 6 consecutive numbers

Match number 50 indicates a belt of nominal length. Numbers 51, 52, and 53
are successively longer belts, and numbers 49, 48, and 47 are progressively
shorter belts.
Figure 13. Limits of Match Codes
All manufacturers do not use match codes. In many cases, belt

manufacturing tolerances have become so small that some manufacturers
are able to guarantee that all belts are close enough to the nominal size
that match codes are not needed.

SKILL 1 USE A BELT CODE TO DETERMINE THE SIZE AND TYPE OF
V-BELT
Procedure Overview
In this procedure, you will be given a variety of v-belt
size codes including the belts used on your trainer and will
be directed to interpret the size and type of v-belt.
This ❑ 1. Perform the following substeps to identify the size and type of the
Do
belt given by the following belt size code.

Belt Size Code: 4L360 49
A. Identify the type of belt and record it.
Belt type: ____________________(FHP/Conventional/Wedge)
The first letter in the belt size code indicates the type of belt,
and is given by the following code:
(L) = FHP v-belt
(V) = Wedge v-belt
(A, B, C, or D) = Conventional v-belt
If there is a (X) next to the belt type letter, the belt also has a
cog design.
You should find this to be a FHP v-belt.
B. Identify the cross-sectional dimensions of the belt.
Cross-sectional dimensions:
Width: ______________________________________(in/mm)
Height: _____________________________________(in/mm)
The first portion of the belt size code indicates the belt section
of a v-belt. The following table can be used to identify the size
of the belt, based on the belt size code.
FHP V-BELT CONVENTIONAL V-BELT WEDGE V-BELT
Code Width Height Code Width Height Code Width Height
2L 1/4 5/32 A 1/2 5/16 --- --- ---
3L 3/8 7/32 B 21/32 13/32 3V 3/8 5/16
4L 1/2 5/16 C 7/8 17/32 --- --- ---
5L 21/32 3/8 D 1-1/4 3/4 5V 5/8 17/32
8L 1 7/8 E 1-1/2 29/32 8V 1 7/8
All Dimensions in inches
You should have found the cross-sectional dimensions to be

1/2 inch wide x 5/16 inch tall.

C. Identify the nominal length of the belt.
Nominal Length: ______________________________(in/mm)
The last few numbers in the belt size code indicate the nominal
length of the belt. In FHP and wedge v-belt codes, the length is
given in tenths of an inch. The code for conventional belts
gives the inside length in inches.
You should have found the nominal length of the belt to be 36
inches.
D. Identify the match code and determine the actual length of the
belt
Match Code: ________________________________________
Actual Length: ________________________________(in/mm)

The match code is a two-digit number that follows the belt size
code. Some manufacturers guarantee that their belts are exactly
equal to the nominal size, so there may not be a match code.
You should have found the match code to be 49. This means
the belt is one-tenth of an inch shorter than its nominal length,
or 35.9 inches.
❑ 2. Perform the following substeps to identify the size and type of the
belt given by the following belt size code.
Belt Size Code: 3VX400 55
A. Identify the type of belt and record it.
Belt type: ____________________(FHP/Conventional/Wedge)
You should find this to be a cog type, wedge v-belt.
B. Identify the cross-sectional dimensions of the belt.
Width: ______________________________________(in/mm)
Height: ______________________________________(in/mm)
You should have found the cross-sectional size to be 3/8 inch
wide x 5/16 inch tall.
C. Identify the length of the belt.
Nominal Length: ______________________________(in/mm)
You should have found the length of the belt to be 40 inches.

D. Identify the match code and determine the actual length of the
belt
Match Code: ________________________________________
Actual Length: ________________________________(in/mm)

You should have found the match code to be 55. This means
the belt is one-half of an inch longer than its nominal length, or
40.5 inches.
❑ 3. Identify the size and type of the belt given by the following belt
size code.
Belt Size Code: CX60 50
Belt type: _______________________(FHP/Conventional/Wedge)
Width: _________________________________________(in/mm)
Height: _________________________________________(in/mm)
Nominal Length: _________________________________(in/mm)
Match Code: ___________________________________________
Actual length: ___________________________________(in/mm)

You should have found the belt to be a cog type, conventional
v-belt whose size is 7/8 inch x 17/32 inch. Its nominal length is 60
inches and it has a match code of 50, giving an actual length of 60
inches.
❑ 4. Obtain the A belt from your Amatrol 950-ME trainer.
❑ 5. Identify the size and type of the belt.
Width: _________________________________________(in/mm)
Height: _________________________________________(in/mm)
Match Code: ___________________________________________
Actual Length:___________________________________(in/mm)
You should have found the belt to be a conventional v-belt whose
size is 1/2 inch x 5/16 inch. It is 36 inches long and does not have
a match code.
❑ 6. Obtain a wedge v-belt from the Amatrol trainer.

Width: _________________________________________(in/mm)
Height: _________________________________________(in/mm)
Match Code: ___________________________________________
You should have found the belt to be a wedge v-belt whose size is
3/8 inch x 5/16 inch. It is 36 inches long and has no match code.
❑ 8. Obtain the BX belt from the Amatrol trainer.
Width: _________________________________________(in/mm)
Height: ________________________________________(in/mm)
Match Code: ___________________________________________
You should have found the belt to be a cog type conventional
v-belt whose size is 21/32 inch x 13/32 inch. It is 40 inches long
and has no match code.

SEGMENT 1
SELF REVIEW
r This
we
Ans
1. V-belts are specified by their type, cross-sectional size, and
____________.
2. The three main types of v-belts are FHP, classical, and

__________.
3. The belt section of a conventional v-belt is specified by just

a __________.
4. FHP belts are specified by the letter ___ in the belt size
code.
5. ___________ belts are specified by the letter V in the belt

size code.
6. The number that follows the belt section code of a

conventional v-belt specifies its nominal _________.
7. A wedge belt size code of 8V1180 indicates a nominal

length of ______ inches.
8. The size and type of a v-belt can be determined by using

a(n) _________ ________.
9. A __________ should be used to measure the outside length

of a v-belt.
10. A match code of 48 indicates that the actual length of a

v-belt is 1/5 of an inch ____________ than its nominal
length.

SEGMENT 2
V-BELT COMPONENT IDENTIFICATION
SKILL 2 USE A BELT GAGE TO DETERMINE BELT

CROSS SECTION SIZE
Procedure Overview
In this procedure, you will use the belts in the Amatrol
trainer to develop your skill using a belt gage to identify the
size and type of v-belt.
This ❑ 1. Locate the belt/sheave gage from the Amatrol trainer, as shown in
Do
figure 14. It is located on the Belt Drive Panel 1.
Figure 14. Belt/Sheave Gage
e This NOTE
tic
No
The belt/sheave gage is a two-in-one tool that is also a

sheave gage.

❑ 2. Pick up one of the six v-belts supplied with your trainer and place
its cross section into the gage, as shown in figure 15.
Figure 15. Measuring Belt Section with a Belt Gage
❑ 3. Read the belt size on the gage that is closest to the top of the belt,
as shown in figure 15. Record the belt type and size in the first row
of the table below.
BELT TYPE SECTION CODE

1
2
3
4
5
6
NOTE
e This
tic There are two leaves in the belt gage, one for conventional
No
v-belts and the other for wedge v-belts. Sometimes a belt may
seem to fit both gages. Select the gage that gives the best fit.

❑ 4. Repeat steps 2-3 in a similar fashion for the other five v-belts.
❑ 5. You should find the following belts in the 950-ME trainer.
TYPE SECTION CODE

FHP or Conventional A or 4L
FHP or Conventional A or 4L
FHP or Conventional B or 5L
FHP or Conventional B or 5L
Wedge 3V
FHP Cog Type BX
❑ 6. Return the belt gage to Belt Panel 1.

❑ 7. Leave the six belts on the work surface and continue on to the next
skill.

SKILL 3 USE MEASUREMENT TO DETERMINE BELT SIZE AND TYPE
Procedure Overview
In this procedure, you will identify the size and type of
each v-belt in the Amatrol trainer by measuring its
dimensions. This is a skill often used on the job site to
identify used belts when the codes are worn off and there
is not a belt gage available.
This ❑ 1. Locate the following items:

Do
• (6) V-belts (950-ME1 trainer)

• Machinist’s rule
• Tape measure
• Felt-tip pen
• String
❑ 2. Select one of the belts.
❑ 3. Measure the width of the top of the belt and its height, as shown in
figure 16. Record your results in row 1 of the table below.
100
90
80
70
60
50
40
30
HEIGHT
20
10
WIDTH HEIGHT BELT LENGTH FULL BELT

BELT # (in) (in) CODE (in) SPECIFICATION
1
2
3
4
5
6
Figure 16. Measuring the Width and Height of a V-Belt

❑ 4. Perform the following substeps to determine the size and type of
belt you just measured.
A. In the table below, locate the width and height of the belt
measured in step 3. Then determine the belt code (e.g. B, C,
4V, etc.) of your belt. Record this code in the table of Step 2.
e This NOTE
tic
No
You may find that your measurements can be seen in two

places in the table below. This is because of the
interchangeability between 4L & A and 5L & B v-belts.
FHP V-BELT CONVENTIONAL V-BELT WEDGE V-BELT

Width Height Width Height Width Height
Code Code Code
(in) (in) (in) (in) (in) (in)
2L 1/4 5/32 A 1/2 5/16 2V --- ---
3L 3/8 7/32 B 21/32 13/32 3V 3/8 5/16
4L 1/2 5/16 C 7/8 17/32 4V --- ---
5L 21/32 3/8 D 1-1/4 3/4 5V 5/8 17/32
8L 1 7/8 E 1-1/2 29/32 8V 1 7/8
B. Use a length of string to measure the belt’s nominal length and

mark the position where the string intersects itself with a felt tip
pen.
The nominal length of the belt is measured in different places,
depending on the type of belt. Perform your measurements
according to the following guide:
• FHP Belt - Measure the outside circumference.
• Conventional Belt - Measure the inside circumference.
• Wedge Belt - Measure the pitch line.
NOTE
This
tic
e Measuring the pitch line of a wedge belt is very difficult to do.
No
Therefore, it is easier to measure its outside circumference and

round down to the nearest inch. This is fairly accurate since the
pitch line of a v-belt is very close to its outside edge.

C. Stretch the string across the work surface so that it forms a
straight line.
D. Measure the distance from the end of the string to the mark you
just made, as shown in figure 17. This is the nominal length of
the belt. Record your result in the table of Step 2 under Length.
TAPE MEASURE
1 2 3 4 5 6 7 8 9 10 11 12
LENGTH
END STRING END
Figure 17. Measuring the Mark on the String to Determine the Length of
a Belt
E. You now have enough information to complete the belt size

code for this belt. Write the belt size code in the last column of
the table.
❑ 5. Repeat Steps 3 and 4 in a similar fashion for the rest of the belts.
You should have the table from Step 2 completely filled out.
❑ 6. Check your answers with the answer guide given below.
ACTUAL VALUES
WIDTH HEIGHT LENGTH BELT SIZE
BELT # TYPE
(In) (In) (In) CODE
1 21/32 3/8 5L or B 43 or 40 5L430 or B40
2 21/32 3/8 5L or B 43 or 40 5L430 or B40
3 3/8 5/16 3V 35.5 3VX400
4 21/32 3/8 5LX or BX 43 or 40 5LX430 or BX40
5 1/2 5/16 4L or A 36 or 34 4L360 or A34
6 1/2 5/16 4L or A 60 or 58 4L600 or A58
❑ 7. Store all materials.

OBJECTIVE 4 DESCRIBE HOW BUSHINGS ARE SPECIFIED
his
dT All of the types of bushings are specified by either a one, two, or
Rea
four digit code. This code will tell you the type of bushing and its
dimensions.
The specific details of the specifications for each of the 3 major
types of bushings are explained as follows.
QD Bushing Specification
There are twelve different sizes of QD bushings designated by one or
two letter codes. These codes are listed below, along with the dimensions
of the bushing they specify. Refer to figure 18 for each dimension.
A
B
BORE
SIZE
BASIC SPECIFICATIONS AND DIMENSIONS

BUSHING A B C
CODE (in) (in) (in)
JA 2 1.375 11/16
SH 2-11/16 1.871 7/8
SDS 3-1/8 2.1875 7/8
SD 3-1/8 2.1875 1-3/8
SK 3-7/8 2.8125 1-3/8

SF 4-5/8 3.125 1-7/16
E 6 3.834 1-7/8
F 6-5/8 4.4375 2-3/4
J 7-1/4 5.1484 3-1/2

M 9 6.494 5-1/2
N 10 6.992 6-5/8
P 11-3/4 8.242 7-5/8
Figure 18. QD Bushing Dimensions
The specification of a QD bushing also has a bore size attached to it.

For example, a specification of SK x 1-1/8 signifies an SK sized QD
bushing with a 1-1/8 inch bore.

Split Taper Bushing Specification
A one letter or a one letter and one number code specify split taper
bushings. As with QD bushings, this code indicates the dimensions of
the split taper bushing. There are twenty types of split taper bushings.
Their code and dimensions are given in figure 19 below.
A
B
BUSHING SPECIFICATIONS
BUSHING A B (in)
C (in)
CODE (in) LARGE END SMALL END
G 2 1.172 1.133 5/8
H 2-1/2 1.625 1.570 7/8
P1 3 1.9375 1.8555 1-5/16
P2 3 1.9375 1.7930 2-5/16
P3 3 1.9375 1.6993 3-13/16
B 3-11/16 2.625 2.5567 1-3/16
Q1 4-1/8 2.875 2.7657 1-3/4
Q2 4-1/8 2.875 2.7032 2-3/4
Q3 4-1/8 2.875 2.6094 4-1/4
R1 5-3/8 4.000 3.8750 2
R2 5-3/8 4.000 3.7500 4
S1 6-3/8 4.625 4.4180 3-5/16
S2 6-3/8 4.625 4.2696 5-11/16
U0 8-3/8 6.000 5.7656 3-3/4
U0 8-3/8 6.000 5.7656 3-3/4
U1 8-3/8 6.000 5.6485 5-5/8
U2 8-3/8 6.000 5.4610 8-5/8
W1 12-1/2 8.500 8.1016 6-3/8
W2 12-1/2 8.500 7.9141 9-3/8
Y0* 16-1/2 12.000 11.4688 8-1/2
Figure 19. Split Taper Bushing Dimensions
Notice that none of these codes are the same as the codes for the QD
bushings. That is how you can tell a QD specification from a split taper
bushing. To determine the dimensions of a split taper bushing, you only
need to look up its specification in a manufacturer’s catalogue. The
specification for a split taper bushing may also have the bore size
attached to it. For example, a specification of U0 x 1-1/16 signifies a U0
sized split taper bushing with a 1-1/16 inch bore.

Taper Bore Bushing Specification
The last type of bushing, taper lock or taper bore, is specified by a
TB followed by a four-digit number. This makes it easy to distinguish a
taper bore specification from the other two types of bushings.
There are fifteen different codes for taper bore bushings that indicate
the size of the bushing. These codes and their dimensions are listed in
figure 20.
B A
BUSHING SPECIFICATIONS AND DIMENSIONS (in)

BUSHING NO. A B C
1008 1-25/64 1-21/64 7/8
1108 1.511 1-29/64 7/8
1210 1-7/8 1-3/4 1
1215 1-7/8 1-3/4 1-1/2
1610 2-1/4 2-1/8 1

1615 2-1/4 2-1/8 1-1/2
2012 2-3/4 2-5/8 1-1/4
2517 3-3/8 3-1/4 1-3/4

2525 3-3/8 3-1/4 2-1/2
3020 4-1/4 4 2
3030 4-1/4 4 3
3535 5 4.83 3-1/2

4040 5-3/4 5.54 4
4545 6-3/8 6.13 4-1/2
5050 7 6.72 5
Figure 20. Taper Bore Bushing Dimensions
The specification for a taper bore bushing may also have the bore
size attached to it. For example, a specification of TB3030 x 1-7/16
indicates a 3030 sized taper bore bushing with a 1-7/16 inch bore.

OBJECTIVE 5 DESCRIBE HOW SHEAVES ARE SPECIFIED
his
dT Sheaves are specified by a code in much the same way v-belts are.
Rea
Even though not all manufacturers use a standardized code, they all have
five features in common. They are:
• Number of grooves
• Belt size and type
• Material
• Sheave diameter
• Bushing type and size
4 B 3.4 SH
SIZE SH BUSHING
3.4 INCH DIAMETER
B TYPE BELT (CONVENTIONAL)
FOUR GROOVE
Figure 21. A Typical Sheave Specification
Number of Grooves
The first one or two digits of the sheave specification code indicate
the number of grooves on a sheave. For example, the specification
shown above indicates a sheave with four grooves. As you have already
learned, sheaves with multiple grooves are used in multiple belt drive
systems. If the number of grooves is not indicated in the sheave
specification code, then it is understood to be a single groove sheave.
Belt Size and Type

The next digit or two of the sheave specification code indicates the
size and type of belt that the sheave is designed to carry. The
specification in figure 21 is a four-groove sheave with a B-size belt
section. These digits are identical to the belt size and type codes that you
learned about earlier in this LAP.

Material
Some manufacturers use a one-letter code to indicate the material
from which the sheave is made. Usually you will see only a K for cast
iron sheave or an S for a pressed steel sheave. Whether or not this is
included in the sheave specification code depends on the manufacturer.
Sheave Diameter
Sheave diameter specification can mean either pitch diameter or
outer diameter, depending on whether it is FHP, conventional, or wedge
belt sheave. With FHP and wedge sheaves, the sheave diameter
specification is the outer diameter of the entire sheave. For conventional
sheaves, the diameter specification is the pitch diameter, as shown in
figure 22.
FHP AND WEDGE SHEAVES CONVENTIONAL SHEAVES
O.D. P.D.
Figure 22. Sheave Diameter Specifications for Each Type of Sheave
The sheave diameter specification is given by the next two or three

digits in the sheave specification code. These digits give the sheave
diameter in hundredths of an inch. For example, a sheave specification of
23V320 indicates a sheave whose outer diameter is 3.2 inches.
e This NOTE
tic
No
Even though the sheave specification code gives either the

pitch diameter or the outer diameter, both are listed in a
manufacturer’s catalogue.
Bushing Type and Size

Bushing size is indicated by the same code that is assigned to the
bushing itself. This is the same code that you learned about earlier in this
LAP. If there is no bushing code, then the sheave has a finished bore and
only the bore size is specified. A typical sheave specification with a
bushing would be: AK250SDS x 1-1/8.

SKILL 4 USE A SHEAVE GAGE TO IDENTIFY A SHEAVE SIZE
Procedure Overview
In this procedure, you will use the sheaves in the
Amatrol trainer to develop your skill in using a sheave
gage to identify the size and type of sheave.
This ❑ 1. Locate the belt/sheave gage and the sheaves from the Amatrol
Do
trainer’s Belt Drive Panels 1 and 2. Place them on the work

surface.
❑ 2. Perform the following substeps to measure the sheave with the
sheave gage.
A. Select the first leaf of the sheave gage and insert one of its tips
into the sheave, as shown in figure 23.
Figure 23. Measurement with a Sheave Gage
B. If the tip doesn’t fit properly, try the other tip on the same leaf.
C. Keep trying tips on successive leaves until a proper fit is found,
as shown in figure 24.

NOTE
e This There may be two or more sheave gage tips that seem to fit.
tic
No
Remember that you are looking for the best fit. Although some
tips may fit fairly well, there will be one that fits better than the
others.
.4
O
42 .
22
V
O.D 22.4
.0 O.D °
ER
40
.
°
HRU
T
16
8V
UP TO 16.00
O.D.
38°
SHEAVE GROOVE GAGE
Figure 24. The Proper Fit of a Sheave Gage
D. When the proper leaf and tip are found, enter the sheave size in
the table below next to the part number of the sheave you
measured. The part number is stamped on the sheave gage.
BELT
SHEAVE SECTION
AK22
AK32
AK44
1B34SH
1B44SH
2BK36H
2BK55H
13V265-1108
13V450-1610

❑ 3. Repeat Step 2 in a similar manner to measure the other sheaves
from the trainer. Enter these results in the table as well.
❑ 4. Compare your results to the answer guide given below.
BELT
SHEAVE SECTION
AK22 A
AK32 A
AK44 A
1B34SH B
1B44SH B
2BK36H B
2BK55H B
13V265-1108 3V
13V450-1610 3V
❑ 5. Retain all materials and continue with the next skill.
SKILL 5 IDENTIFY SIZE AND TYPE OF A SHEAVE AND BUSHING

GIVEN A SAMPLE
Procedure Overview
In this procedure, you will identify the size and type of
the sheaves and bushings from the Amatrol trainer by
measurement. This is a skill you will often use on the job
site to identify replacement sizes.
This ❑ 1. Locate the dial caliper and place it on the work surface. You
Do
should already have the Belt Drive Panels 1 and 2. If not, locate
them and place them on the overhead portion of the trainer.
❑ 2. Perform the following substeps to identify the size and type of the
bushing and sheave.
A. Remove the sheave from Belt Drive Panel 1 that is labeled FHP
SHEAVE 3PD.
B. Identify whether or not it has a bushing. If so, remove the
bushing according to the procedures you learned in the
previous LAP. Record your answer in the following table.

FHP FHP 1 GROOVE 2 GROOVE WEDGE
SHEAVE SHEAVE SHEAVE SHEAVE SHEAVE SHEAVE
3 PD 4 PD 3.4 PD 3.4 PD 2.65 PD
Bushed (yes/no)
# of grooves
Belt Section
Material Code
Outer Diameter (in)
Part Number
Bushing Code
(If Bushed)
Bore Diameter (in)
Specification
This is a finished bore sheave. Therefore, it does not have a

bushing.
C. Count and record the number of grooves on the sheave in the
same table.
You should find that this sheave has one groove.
D. Use the sheave gage to measure and record the belt section
(size) of the sheave, as shown in figure 25. Record your result
in the table of substep B.
“A” SECTION
BELT
Figure 25. Measuring the Belt Section of the Sheave
You should find this sheave to have an A size belt section.

E. This sheave is made of cast iron. Record the code for cast iron
in the next row of the table.

F. Measure and record the outer diameter of the sheave in the
table of substep B.
You should find the outside diameter to be 3.25 inches.
G. Use the information taken from sheave catalogues to determine
the sheave part number that corresponds to the sheave
description and outside diameter. Record the catalogue part
number in the table of substep B.
CAST IRON SHEAVES CAST IRON SHEAVES

Single Groove Sheaves for “A” Single Groove Sheaves for “B”
Belts Belts
Catalogue Part Outside Catalogue Part Outside
Number Diameter (in) Number Diameter (in)
AK20 2.00 1B34SH 3.40
AK22 2.20 1B36SH 3.60
AK30 3.05 1B38SH 3.80
AK32 3.25 1B40SH 4.00
AK34 3.45 1B42SH 4.20
AK44 4.25 1B44SH 4.40
AK46 4.45 1B46SDS 4.60
AK56 5.45 1B48SDS 4.80
Double Groove Sheaves for “B” Single Groove Sheaves for “3V”
Belts Belts
2BK34H 3.55 112124 2.65
2BK36H 3.75 112126 3.60
2BK40H 3.95 112175 3.35
2BK50H 4.75 112176 3.65
2BK55H 5.25 112177 4.12
2BK57H 5.45 112178 4.50
2BK60H 5.75 112180 5.00
2BK70H 6.75 112183 6.00
Figure 26. Catalogue Sheave Listing
You should find the part number to be AK32, which is the part
number shown on the sheave.

H. Measure and record in the table the diameter of the bore of the
bushing or the sheave, as shown in figure 27.
You should find the bore diameter to be 5/8 in.
Figure 27. Measuring the Bore Diameter
I. Write the entire specification for the sheave in the last column
of the table.
You should find the entire sheave specification to be AK32 -
5/8.
❑ 3. Perform the following substeps to determine the specification of a
sheave by measurement. Record your results in the appropriate
column of the table.
A. Obtain the 2 groove 3.4 PD sheave from Belt Drive Panel 2.
B. Identify whether or not it has a bushing. If so, remove the
bushing according to the procedures you learned in the
previous LAP.
This sheave does have a bushing.
C. Count and record the number of grooves on the sheave.
You should find that this sheave has two grooves.
D. Using the sheave gage, measure and record the belt section
(size) of the sheave.
You should find this sheave to have a B size belt section.
E. This sheave is made of cast iron. Record the code for cast iron
in the next row of the table.
The code for cast iron is K.
F. Measure and record the outer diameter of the sheave.
You should find the outside diameter to be 3.75 inches.

G. Using the table shown in figure 28, locate the outside diameter
column. Move down that column until you reach the diameter
you just measured. Just to the left of that, in the part number
column, is the part number of your sprocket. Record the part
number below.
Part Number: ________________________________________

Single Groove Sheaves for “A” Single Groove Sheaves for “B”
Belts Belts
AK20 2.00 1B34SH 3.40
AK22 2.20 1B36SH 3.60
AK30 3.05 1B38SH 3.80
AK32 3.25 1B40SH 4.00
AK34 3.45 1B42SH 4.20
AK44 4.25 1B44SH 4.40
AK46 4.45 1B46SDS 4.60
AK56 5.45 1B48SDS 4.80
Double Groove Sheaves for “B” Single Groove Sheaves for “3V”
Belts Belts
2BK34H 3.55 112124 2.65
2BK36H 3.75 112126 3.60
2BK40H 3.95 112175 3.35
2BK50H 4.75 112176 3.65
2BK55H 5.25 112177 4.12
2BK57H 5.45 112178 4.50
2BK60H 5.75 112180 5.00
2BK70H 6.75 112183 6.00
Figure 28. Catalogue Sheave Listing
You should find the part number to be 2BK36H.

H. Determine what type of bushing was attached to the sheave.
Bushing Type:_______________________________________
Based on bushing types that you learned about in the previous
LAP, you find this to be a split taper bushing.

I. Measure and record dimensions A, B, and C, of the bushing, as
shown in figure 29.
Dimension A: _________________________________(in/mm)
Dimension B: _________________________________(in/mm)
Dimension C: _________________________________(in/mm)
B A
Figure 29. Dimensions of a Split Taper Bushing
You should have found the following dimensions:

Dimension A: 2-1/2 inches
Dimension B: 1-5/8 inches
Dimension C: 7/8 inches

J. Use the table in figure 19 to locate the bushing code number
which has the dimensions that most closely matches the
dimensions you just measured.
Bushing Code:_______________________________________
You should find this to be an H size bushing.

K. Measure and record the diameter of the bore, as shown in
figure 30.
Bore Diameter: ________________________________(inches)
You should find the bore diameter to be 5/8 of an inch.
Figure 30. Measuring the Bore Diameter

L. Write the entire specification for the sheave and the bushing in
the following blank.
Specification: _______________________________________
You should find the entire sheave and bushing specification to
be 2BK36H - 5/8.
❑ 4. Perform the same procedures as Step 3 to determine the entire
specification of the 1 groove 3.4 PD sheave and bushing from Belt
Drive Panel 2. Record all results in the table of substep 2B.
tic
e This NOTE
No
You will need the tables shown in figure 28 to complete this

step.
You should have found the sheave and bushing specification to be

1B34SH - 5/8.
❑ 5. Perform the same procedures as Step 3 to determine the entire
specification of the 2.65 PD wedge, sheave and bushing.
Use figures 20 and 28.
tic
e This NOTE
No
You will need the tables shown in figure 28 to complete this

step. Also, the material code is not required in this step.
Specification: _______________________________________
You should have found the sheave and bushing specification to be
13V265-1108 - 5/8.

SEGMENT 2
SELF REVIEW
r This
we
Ans
1. There are _________ different sizes of QD bushings
designated by one or two letter codes.
2. A QD bushing specification of SK x 1-1/8 signifies a QD

bushing with a 1-1/8 inch _________.
3. A bushing code of SDS indicates a _____ type bushing.
4. _________ of the split taper bushing codes are the same as

the codes for the QD bushing.
5. A bushing code of Q1 indicates a _______________type

bushing.
6. The taper bore bushing is specified by a ________ followed

by a four-digit number.
7. The first number in a sheave specification indicates the

number of __________ on the sheave.
8 A sheave specification of AK250SDS indicates a bushing

having a diameter of ____ inches.

SEGMENT 3
V-BELT DRIVE SELECTION
OBJECTIVE 6 DESCRIBE HOW TO SELECT BUSHINGS, SHEAVES,

AND A V-BELT FOR AN APPLICATION
his
dT In some cases, you might have to design a v-belt drive system. This
Rea
can be easily done by using a the following ten-step procedure:

1. Determine the design power
2. Determine the v-belt section
3. Determine the drive ratio
4. Select the sheave diameter
5. Determine the number of grooves required
6. Determine the belt length
7. Determine the corrected power per belt
8. Determine the corrected total power
9. Compare the corrected drive power to design power
10. Select the sheave and bushing sizes
Each of these steps is explained as follows:
Step 1. Determine the Design Power

The first step in designing a v-belt drive is to determine the design
horsepower. The design horsepower is simply the rated horsepower of
the driving unit times a service factor. This service factor is used to
account for extreme working conditions to which the drive might be
subjected.
Design Power = Rated Power × Service Factor
The service factor is determined by using the chart shown in figure
31.

TYPES OF DRIVING UNITS
AC Motors, High Torque, High Slip

AC Motors; Normal Torque, Squirrel Repulsion-Induction, Single Phase,
Cage, Synchronous and Split Phase. Series Wound and Slip Ring.
DC Motors; Shunt Wound, Multiple DC Motors; Series Wound and
TYPES OF DRIVEN MACHINES Cylinder Internal Combustion Engines. Compound Wound, Single Cylinder
Internal Combustion Engines.
Line Shafts. Clutches.
Intermittent Normal Continuous Intermittent Normal Continuous

Service (3-5 Service (8-10 Service (16-24 Service (3-5 Service (8-10 Service (16-24
Hours Daily Hours Daily) Hours Daily) Hours Daily Hours Daily) Hours Daily)
or or Seasonal)
Agitators for Liquids

Blowers and Exhausters
Centrifugal Pumps and Compressors 1.0 1.1 1.2 1.1 1.2 1.3
Fans up to 10 HP
Light Duty Conveyors
Belt Conveyors For Sand, Grain, etc.

Dough Mixers
Fans Over 10 HP
Generators
Line Shafts
Laundry Machinery
Machine Tools 1.1 1.2 1.3 1.2 1.3 1.4
Punches-Presses-Shears
Printing Machinery
Positive Displacement Rotary Pumps
Revolving and Vibrating Screens
Speed Reducers, All Types
Brick Machinery
Bucket Elevators
Exciters
Piston Compressors
Conveyors (Drag-Pan-Screw)
Hammer Mills
Paper Mill Beaters 1.2 1.3 1.4 1.5 1.5
Piston Pumps
Positive Displacement Blowers
Pulverizers
Saw Mill and Woodworking Machinery
Textile Machinery
Crushers (Gyratory-Jaw-Roll)
Mills (Ball-Rod-Tube)
Hoists 1.3 1.4 1.5 1.5 1.6 1.8
Rubber Calendars-Extruders-Mills
A minimum Service Factor of 2.0 is suggested for equipment subject to choking.*
Figure 31. Service Factor Chart

Step 2. Determine the V-Belt Section
The next step is to determine what belt size and type to use. Most
manufacturers publish a table such as the one shown in figure 32 that
helps you to determine the belt size to use. This decision is based on the
design power of the drive.
The design power is the power of the prime mover that drives the
system times a service factor. If this has not yet been chosen, calculate
the power needed using the speed and torque of the driven shaft using
the formula given below. Then round up to the nearest motor size.
Always round up, even if your calculation is only slightly above the
nearest motor size.
FORMULA: POWER
English Units:
T×S
P =
5252
Where: P = Output Power (Hp)
out
T = Torque (ft-lbs)
S = Speed (RPM)
S.I. Units:
T × S
P =
out
9549
Where: Pout= Output Power (kW)
T = Torque (N-m)
S = Speed (RPM)

The selections for each power size are shown in a series of columns
with the preferred selection in the left-most column and the least
preferred in the right-most column. Normally, you would choose the belt
size that is shown in the first column. If this one is not practical because
of availability of parts or some other reason, use the one shown in the
next column.
BELT SECTION SELECTION CHART

DESIGN HP BELT SECTION
1/2 A AX
3/4 A AX
1 A AX
1-1/2 A AX
2 A AX
3 AX A BX
5 BX AX B A
7-1/2 BX AX B 3VX
10 BX B AX 3VX
15 BX 3VX AX B
20 BX 3VX B
25 5VX, 5V 3VX B
30 5VX, 5V 3VX B
40 5VX, 5V B 3VX
50 5VX, 5V BX B CX
60 5VX, 5V BX B CX
75 5VX, 5V CX BX C
100 5VX, 5V CX C
125 5VX, 5V CX C
150 5VX, 5V CX C
200 5VX, 5V CX
250 5VX, 5V CX
Figure 32. Belt Section Selection Chart
Step 3. Determine the Drive Ratio

The drive ratio can be easily calculated by knowing how fast the
driver shaft rotates and how fast you want the driven shaft to rotate.
Drive ratio is given by the following formula:
Rotational speed of driver shaft
Drive ratio =
Rotational speed of driven shaft
tic
e This NOTE
No
Remember that in most industrial applications, the driver

sheave is the smaller of the two sheaves in a belt drive system.

Step 4. Select the Sheave Diameter
Next, another table is used to determine the appropriate size smaller
sheave, as shown in figure 33. The larger sheave is then found by using
the drive ratio. From this table, you must find a sheave that meets all of
the following criteria:
• A sheave that is both strong enough and large enough to meet the
horsepower requirements.
• Uses the fewest number of grooves possible.
• Uses the smallest diameter sheave that will meet each of these
requirements.
SHEAVE DIAMETER SELECTION CHART BY HORSE POWER
“B” SECTION V-BELTS
RPM SHEAVE DIAMETERS

of
Smaller
Sheave 3.00 3.20 3.40 3.60 3.80 4.00 4.20 4.40 4.60 4.80 5.00 5.20 5.40 5.60 5.80 6.00 6.20 6.40 6.60
1450 1.49 1.88 2.26 2.63 3.01 3.37 3.74 4.10 4.55 5.01 5.47 5.93 6.38 6.82 7.27 7.71 8.14 8.58 9.00
1750 1.58 2.03 2.47 2.91 3.34 3.77 4.19 4.61 5.10 5.64 6.16 6.69 7.21 7.72 8.22 8.72 9.22 9.71 10.19
2900 1.54 2.19 2.82 3.45 4.06 4.65 5.23 5.80 6.35 6.99 7.70 8.38 9.04 9.69 10.31 10.31 11.50 12.06 12.60
3500 1.28 2.01 2.72 3.40 4.06 4.70 5.32 5.92 6.48 7.03 7.69 8.38 9.04 9.67 10.26 10.26 11.34 11.82 12.27
400 ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** **
600 ** ** ** ** ** ** ** ** ** ** ** ** ** ** 3.71 3.92 4.13 4.35 4.56
800 ** ** ** ** ** ** ** 2.73 3.00 3.28 3.56 3.84 4.12 4.39 4.67 4.94 5.21 5.48 5.75
1000 ** ** ** 2.11 2.39 2.66 2.93 3.19 3.53 3.87 4.21 4.55 4.88 5.21 5.54 5.87 6.20 6.53 6.85
1200 1.39 1.72 2.04 2.36 2.68 3.00 3.31 3.62 4.01 4.41 4.80 5.19 5.58 5.97 6.35 6.73 7.11 7.49 7.86
1400 1.48 1.85 2.22 2.58 2.94 3.30 3.66 4.01 4.45 4.90 5.34 5.79 6.23 6.66 7.09 7.52 7.95 8.37 8.79
1600 1.54 1.96 2.37 2.78 3.18 3.58 3.97 4.36 4.84 5.34 5.83 6.32 6.81 7.29 7.76 8.24 8.70 9.16 9.62
1800 1.59 2.05 2.50 2.95 3.39 3.82 4.26 4.68 5.18 5.73 6.27 6.80 7.33 7.85 8.37 8.88 9.38 9.88 10.37
2000 1.62 2.12 2.61 3.09 3.57 4.04 4.51 4.97 5.49 6.07 6.65 7.23 7.79 8.35 8.90 9.44 9.97 10.50 11.01
2200 1.63 2.17 2.69 3.21 3.72 4.23 4.73 5.22 5.74 6.37 6.98 7.59 8.19 8.78 9.35 9.92 10.48 11.02 11.56
2400 1.62 2.20 2.76 3.31 3.85 4.39 4.91 5.43 5.95 6.61 7.26 7.90 8.52 9.13 9.73 10.32 10.89 11.45 12.00
2600 1.60 2.21 2.80 3.38 3.96 4.52 5.07 5.61 6.13 6.81 7.48 8.14 8.78 9.41 10.03 10.63 11.21 11.78 12.33
2800 1.56 2.20 2.82 3.43 4.03 4.61 5.19 5.74 6.29 6.94 7.64 8.32 8.98 9.62 10.24 10.85 11.43 12.00 12.54
3000 1.50 2.17 2.82 3.46 4.08 4.68 5.27 5.84 6.40 7.03 7.74 8.43 9.09 9.74 10.36 10.97 11.55 12.10 12.63
3200 1.43 2.12 2.80 3.45 4.09 4.72 5.32 5.90 6.47 7.05 7.77 8.46 9.13 9.78 10.39 10.99 11.55 12.08 12.59
3400 1.34 2.05 2.75 3.43 4.08 4.72 5.33 5.92 6.49 7.04 7.74 8.43 9.09 9.73 10.33 10.90 11.44 11.94 12.41
3600 1.23 1.96 2.68 3.37 4.04 4.68 5.30 5.90 6.46 7.00 7.63 8.32 8.97 9.58 10.16 10.70 11.20 11.67 12.09
3800 1.10 1.85 2.58 3.29 3.97 4.62 5.24 5.83 6.39 6.92 7.46 8.13 8.75 9.34 9.88 10.39 10.84 11.26 _
4000 0.95 1.72 2.47 3.18 3.86 4.51 5.13 5.71 6.26 6.77 7.25 7.85 8.45 9.00 9.50 9.95 10.35 _ _
4200 0.78 1.57 2.32 3.04 3.72 4.37 4.97 5.54 6.07 6.56 7.01 7.49 8.05 8.55 9.00 _ _ _ _
4400 0.60 1.39 2.15 2.87 3.55 4.18 4.78 5.33 5.84 6.29 6.71 7.07 7.55 7.99 _ _ _ _ _
4600 0.39 1.19 1.95 2.67 3.34 3.96 4.54 5.06 5.54 5.96 6.33 6.64 _ _ _ _ _ _ _
4800 0.16 0.97 1.72 2.43 3.09 3.69 4.25 4.74 5.18 5.56 5.88 _ _ _ _ _ _ _ _
5000 _ 0.72 1.47 2.16 2.80 3.39 3.91 4.37 4.76 5.09 _ _ _ _ _ _ _ _ _
6000 _ _ _ 0.30 0.77 1.14 _ _ _ _ _ _ _ _ _ _ _ _ _
Figure 33. Sheave Diameter Selection Chart
Part of this step is to also calculate the size of the larger sheave. This
is done by multiplying the small sheave diameter by the Drive Ratio
calculated in Step 3.

Step 5. Determine the Number of Grooves Required
The number of sheave grooves can be determined by using the
following simple formula:
Design Horsepower
# of grooves =
Horsepower of the selected sheave
Remember to always round up. Even if the result is very close to one
number like 1.01. In this case, you should round up to 2.
Step 6. Determine the Belt Length

Belt length is determined by using the following formula:
FORMULA: BELT LENGTH

(D − d) 2
L = 2C + 1.57 (D + d) +
4C
Where:
L= Pitch length of the belt
C= Distance between shaft centers
D= Pitch diameter of large sheave
d= Pitch diameter of small sheave
If you are designing a belt drive system that has adjustable shaft
centers, use the center distance when the shafts are at the middle of their
adjusted range.
Step 7. Determine the Corrected Power per Belt

The horsepower that a single v-belt can handle is called its
horsepower rating. This value is determined by the strength of the belt.
But, there are other factors which must be taken into account such as:
sheave ratio, belt length, and loss in arc of contact. Each of these is
explained as follows:
SHEAVE RATIO
One of the factors that affects the amount of power a v-belt can
apply is the ratio of the sheaves. This is because the sheave ratio
determines the speed at which the belt travels around the drive. And, as
you have already learned, speed and horsepower are directly
proportional. That means, the faster a belt travels, the more horsepower it
is capable of transmitting. For this reason, a correction factor must be
added to the rated power of the v-belt.
To add the sheave ratio correction to the basic horsepower rating,
you must first locate the correction factor using the chart shown in figure
34.
This value is then added to the basic horsepower rating of the
sheave.

DRIVE RATIO CORRECTION CHART
“B” SECTION V-BELTS
“Drive Ratio Correction” Must Be ADDED to Sheave HP Rating
RPM DRIVE RATIO CORRECTION

of
Smaller 1.02- 1.04- 1.07- 1.09- 1.13- 1.17- 1.23- 1.33- 1.51-
Sheave 1.03 1.06 1.08 1.12 1.16 1.22 1.32 1.50 & UP
1450 0.08 0.16 0.24 0.32 0.40 0.48 0.56 0.64 0.72
1750 0.10 0.19 0.29 0.39 0.49 0.58 0.68 0.78 0.88
2900 0.16 0.32 0.48 0.64 0.81 0.97 1.13 1.29 1.45
3500 0.19 0.39 0.58 0.78 0.97 1.17 1.36 1.56 1.75
400 0.02 0.04 0.07 0.09 0.11 0.13 0.16 0.18 0.20
600 0.03 0.07 0.10 0.13 0.17 0.20 0.23 0.27 0.30
800 0.04 0.09 0.13 0.18 0.22 0.27 0.31 0.36 0.40
1000 0.06 0.11 0.17 0.22 0.28 0.33 0.39 0.44 0.50
1200 0.07 0.13 0.20 0.27 0.33 0.40 0.47 0.53 0.60
1400 0.08 0.16 0.23 0.31 0.39 0.47 0.54 0.62 0.70
1600 0.09 0.18 0.27 0.36 0.44 0.53 0.62 0.71 0.80
1800 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90
2000 0.11 0.22 0.33 0.44 0.56 0.67 0.78 0.89 1.00
2200 0.12 0.24 0.37 0.49 0.61 0.73 0.86 0.98 1.10
2400 0.13 0.27 0.40 0.53 0.67 0.80 0.93 1.07 1.20
2600 0.14 0.29 0.43 0.58 0.72 0.87 1.01 1.16 1.30
2800 0.16 0.31 0.47 0.62 0.78 0.93 1.09 1.25 1.40
3000 0.17 0.33 0.50 0.67 0.83 1.00 1.17 1.33 1.50
3200 0.18 0.36 0.53 0.71 0.89 1.07 1.24 1.42 1.60
3400 0.19 0.38 0.57 0.76 0.94 1.13 1.32 1.51 1.70
3600 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80
3800 0.21 0.42 0.63 0.84 1.06 1.27 1.48 1.69 1.90
4000 0.22 0.45 0.67 0.89 1.11 1.33 1.55 1.78 2.00
4200 0.23 0.47 0.70 0.93 1.17 1.40 1.63 1.87 2.10
4400 0.24 0.49 0.73 0.98 1.22 1.47 1.71 1.96 2.20
4600 0.26 0.51 0.77 1.02 1.28 1.53 1.79 2.05 2.30
4800 0.27 0.53 0.80 1.07 1.33 1.60 1.87 2.13 2.40
5000 0.28 0.56 0.83 1.11 1.39 1.67 1.94 2.22 2.50
6000 0.33 0.67 1.00 1.33 1.67 2.00 2.33 2.67 3.00
Figure 34. Drive Ratio Correction Chart
BELT LENGTH
The length of the belt also effects its rated power. As a rule, the
longer the belt, the greater its power capacity. This is because the longer
belt has more area over which to distribute the stresses of the drive.
The correction factor for belt length is found by using another chart,
which is shown in figure 35.
This correction factor is multiplied by the result obtained from the
drive correction ratio.

CONVENTIONAL V-BELTS
Nominal Nominal
A B C A B C D E
Length Length
26 .81 - - 90 1.06 1.00 .91 - -
31 .84 - - 93 - 1.01 - - -
32 .85 - - 96 1.08 1.02 .92 - -
33 .86 - - 97 - 1.02 - - -
34 .86 - - 99 - 1.02 - - -
35 .87 .81 - 100 - 1.03 - - -
36 .87 - - 103 - 1.03 - - -
37 .88 - - 105 1.10 1.04 .94 - -
38 .88 .83 - 108 - 1.04 - - -
42 .90 .85 - 109 - - .94 - -
43 .90 - - 110 1.11 - - - -
46 .92 .87 - 112 1.11 1.05 .95 - -
48 .93 .88 - 115 - - .96 - -
50 - .89 - 116 - 1.06 - - -
51 .94 .89 .80 120 1.13 1.07 .97 .86 -
52 - .89 - 124 - 1.07 - .87 -
53 .95 .90 - 128 1.14 1.08 .98 - -
54 .95 .90 - 133 - 1.08 - - -
55 .96 .90 - 136 1.15 1.09 .99 - -
56 .96 .90 - 144 1.16 1.11 1.00 .90 .88
58 .97 .91 - 150 - 1.12 1.01 - -
59 - .91 - 158 1.17 1.13 1.02 .92 -
60 .98 .92 .82 162 - 1.13 1.03 .92 -
61 - .92 - 173 1.18 1.15 1.04 .93 -
62 .99 .93 - 180 1.19 1.16 1.05 .94 .91
63 - .93 - 195 - 1.18 1.07 .96 .92
64 .99 .93 - 210 - 1.19 1.08 .96 .94
65 - .94 - 225 - 1.20 1.09 .98 .95
66 1.00 .94 - 240 - 1.22 1.11 1.00 .96
67 - .94 - 255 - 1.23 1.12 1.01 -
68 1.00 .95 .85 270 - 1.25 1.14 1.03 .99
70 1.01 .95 - 285 - 1.26 1.15 1.04 -
71 1.01 .95 - 300 - 1.27 1.16 1.05 1.01
75 1.02 .97 .87 315 - 1.28 1.17 1.06 -
77 - .98 - 330 - - 1.19 1.07 1.03
78 1.03 .98 - 345 - - 1.20 1.08 -
79 - .98 - 360 - 1.31 1.21 1.09 1.05
80 1.04 .98 - 390 - - 1.23 1.11 1.07
81 - .98 .89 420 - - 1.24 1.12 1.09
82 - .99 - 480 - - - 1.16 1.12
83 - .99 - 540 - - - 1.18 1.14
85 1.05 .99 .90 600 - - - 1.20 1.17
88 - 1.00 -
WEDGE V-BELTS
Cross Section Cross Section

Belt Belt
Length Length
3V 5V 8V 3V 5V 8V
25.0 .83 - - 112.0 1.11 .98 .88

26.5 .84 - - 118.0 1.12 .99 .89
28.0 .85 - - 125.0 1.13 1.00 .90
30.0 .86 - - 132.0 1.14 1.01 .91
31.5 .87 - - 140.0 1.15 1.02 .92
33.5 .88 - - 150.0 - 1.03 .93
35.5 .89 - - 160.0 - 1.04 .94
37.5 .91 - - 170.0 - 1.05 .95
40.0 .92 - - 180.0 - 1.06 .95
42.5 .93 - - 190.0 - 1.07 .96
45.0 .94 - - 200.0 - 1.08 .97
47.5 .95 - - 212.0 - 1.09 .98
50.0 .96 .85 - 224.0 - 1.09 .98
53.0 .97 .86 - 236.0 - 1.10 .99
56.0 .98 .87 - 250.0 - 1.11 1.00
60.0 .99 .88 - 265.0 - 1.12 1.01
63.0 1.00 .89 - 280.0 - 1.13 1.02
67.0 1.01 .90 - 300.0 - 1.14 1.03
71.0 1.02 .91 - 315.0 - 1.15 1.03
75.0 1.03 .92 - 335.0 - 1.16 1.04
80.0 1.04 .93 - 355.0 - 1.17 1.05
85.0 1.06 .94 - 375.0 - - 1.06
90.0 1.07 .95 - 400.0 - - 1.07
95.0 1.08 .96 - 425.0 - - 1.08
100.0 1.09 .96 .87 450.0 - - 1.09
106.0 1.10 .97 .88 -
Figure 35. Correction Factor for Belt Lengths

LOSS IN ARC OF CONTACT
Because a v-belt drive works by friction, the more sheave groove
area a belt is in contact with, the more power that belt is able to transmit.
This is affected by the arc of contact, as shown in figure 36.
Unfortunately, when using drives whose sheaves are very different
in size, the amount of contact between the small sheave and the belt is
reduced, as shown in figure 36. This is called a loss in arc of contact.
ARC OF CONTACT = 180°
ARC OF CONTACT = 150°
Figure 36. Loss in Arc of Contact
For this reason, a correction factor for loss in arc of contact must be
applied. To do this, first use the following formula to determine the loss
in arc of contact.
FORMULA: LOSS IN ARC OF CONTACT

(D − d) × 57
Loss in arc of contact =
C
Where:
D = Diameter of large sheave
d = Diameter of small sheave
C = Distance between shaft centers

The result of this calculation is then used to find the correction factor
in the chart shown in figure 37.

Loss in Arc Correction Loss in Arc Correction
of Contact Factor of Contact Factor
0° . . . . . . . . . . . . . . . . . . . . . 1.00 50° ..................... .86
5° . . . . . . . . . . . . . . . . . . . . . .99 55° ..................... .84
10° . . . . . . . . . . . . . . . . . . . . . .98 60° ..................... .83
15° . . . . . . . . . . . . . . . . . . . . . .96 65° ..................... .81
20° . . . . . . . . . . . . . . . . . . . . . .95 70° ..................... .79
25° . . . . . . . . . . . . . . . . . . . . . .93 75° ..................... .76
30° . . . . . . . . . . . . . . . . . . . . . .92 80° ..................... .74
35° . . . . . . . . . . . . . . . . . . . . . .90 85° ..................... .71
40° . . . . . . . . . . . . . . . . . . . . . .89 90° ..................... .69
45° . . . . . . . . . . . . . . . . . . . . . .87
Figure 37. Correction Factor for Loss in Arc of Contact
Once all of the above factors have been applied to the belt’s rated
power, you have the corrected horsepower per belt.
BELT VELOCITY
The last thing you need to check is the belt velocity. This substep is
needed to make sure that you don’t end up with dangerously high belt
velocities. In this substep you can calculate the belt velocity with the
following formula:
Belt velocity (FPM) = Pitch Diameter of smaller sheave × 0.2618 ×
RPM of smaller sheave
All that you need to do is verify that this result is less than 6500
FPM. If the result that is greater than 6500, you will need to contact a
manufacturer to determine which products can safely be operated at
those extremely high speeds.
Step 8. Determine the Corrected Total Power

The corrected total power of the belt drive system is simply the
corrected horsepower of each belt times the total number of belts used in
the system.
Step 9. Compare the Corrected Total Power to the Design

Horsepower
In this step, you must verify that the corrected total horsepower is
greater than the design horsepower you found in step 2. If it is not, the
drive must be redesigned using larger sheaves.

Step 10. Select the Sheave and Bushing Sizes
This final step is to make a list of all of the components that will be
required to make the drive system. This includes the two sheaves, any
bushings that might be needed to mount the sheaves, and the v-belts.
Most manufacturers provide a series of tables that can be used to
determine the part numbers of their components. One such table is
shown in figure 38.
“A” and “B” SECTION SHEAVES
SHEAVE OVER
TO 10 HP
DIAMETERS 10 HP
“A” “B”
AS AK AKH BS BK BKH QD
Belts Belts
1.25” - AS15 - - - - - -
1.5 - AS17 AK17* - - - - -
1.8 2.0 AS20 AK20* - BS24 BK24* - -
1.9 2.3 AS21 AK21* - BS25 BK25* - -
2.0 2.4 AS22 AK22* - BS26 BK26* - -
2.1 2.5 AS23 AK23* - BS27 BK27* - -

2.2 2.6 - - - BS28 BK28* - -
2.3 2.7 AS25 AK25* - - - - -
2.4 2.8 AS26 AK26* - BS30 BK30* BK30H -
2.5 2.9 AS27 AK27* - - - - -
2.6 3.0 AS28 AK28* - BS32 BK32* BK32H -

2.8 3.2 AS30 AK30* AK30H BS34* BK34 BK34H -
3.0 3.4 AS32 AK32* AK32H BS36* BK36 BK36H 1B34SH
3.2 3.6 AS34 AK34* AK34H BS40* BK40 BK40H 1B36SH
3.4 3.8 - - - - - - 1B38SH
3.5 3.9 AS39* AK39 AK39H BS45* BK45 BK45H -

3.6 4.0 - - - - - - 1B40SH
3.7 4.1 - AK41 AK41H - BK47 BK47H -
3.8 4.2 - - - - - - 1B42SH
4.0 4.4 AS44* AK44 AK44H BS60* BK50 BK50H 1B44SH
4.2 4.6 - AK46 AK46H - BK52 BK52H 1B46SDS

4.4 4.8 - - - - - - 1B48SDS
4.5 4.9 AS49* AK49 AK49H BS55* BK55 BK55H -
4.6 5.0 - - - - - - 1B50SDS
4.7 5.1 - AK51 AK51H - BK57 BK57H -
4.8 5.2 - - - - - - 1B52SDS

5.0 5.4 AS54* AK54 AK54H BS60* BK60 BK60H 1B54SDS
5.2 5.6 - AK56 AK56H - BK62 BK62H 1B56SDS
5.4 5.8 - - - - - - 1B58SDS
5.5 5.9 - AK59 AK59H - BK65 BK65H -
5.6 6.0 - - - - - - 1B60SDS
5.7 6.1 - AK61 AK61H - BK67 BK67H -
5.8 6.2 - - - - - - 1B62SDS
6.0 6.4 AS64* AK64 AK64H BS70* BK70 BK70H 1B64SDS
6.2 6.6 - AK66 AK66H - BK72 BK72H 1B66SDS
6.4 6.8 - - - - - - 1B68SDS
6.5 6.9 - AK69 AK69H - BK75 BK75H -
6.6 7.0 - - - - - - 1B70SDS
6.7 7.1 - AK71 AK71H - BK77 BK77H -
7.0 7.4 AS74* AK74* AK74H BS80* BK80 BK80H 1B74SDS
7.5 7.9 - AK79* AK79H - BK85 BK85H -
7.6 8.0 - - - - - - 1B80SDS
8.0 8.4 AS84* AK84* AK84H BS90* BK90 BK90H -
8.2 8.6 - - - - - - 1B86SDS
8.5 8.9 - AK89* AK89H - BK95 BK95H -
8.6 9.0 - - - - - - -
9.5 9.9 - AK99* AK99H - BK105 BK105H -
10.0 10.4 AS104* AK104* AK104H BS110* BK110 BK110H -
10.5 10.9 - AK109* AK109H - BK115 BK115H -
10.6 11.0 - - - - - - 1B110SDS
11.0 11.4 AS114* AK114* AK114H - BK120 BK120H -
13.0 13.4 - AK134 AK134H - BK140 BK140H -
13.2 13.6 - - - - - - 1B136SDS
14.0 14.4 - AK144 AK144H - - BK150H -
15.0 15.4 - AK154 AK154H - BK160 BK160H 1B154SK
15.6 16.0 - - - - - - 1B160SK
18.0 18.4 - AK184 AK184H - BK190 BK190H 1B184SK
19.5 20.0 - - - - - - 1B200SK
22.9 23.4 - - - - - - -
24.5 25.0 - - - - - - -
27.3 27.8 - - - - - - -
29.5 30.0 - - - - - - -
37.5 38.0 - - - - - - -
Figure 38. Stock Sheave Listings

SKILL 6 SELECT BUSHINGS, SHEAVES, AND A V-BELT
FOR A GIVEN APPLICATION
Procedure Overview
In this procedure, you will use the 10-step procedure to
select the sizes of the components for a v-belt drive
application. In the first step, you will be lead through an
example. In the next steps, you will do it on your own.
This ❑ 1. Perform the following substeps to select the sizes of the

Do
components for a v-belt drive system.

A. Examine the information about a v-belt drive application.
FEATURE SPECIFICATION
Motor Size 2 hp
Motor Shaft Size 5/8 in.
Driven Shaft Size 5/8 in.
Distance between centers 20 in.
Application Type Machine Tool under normal use
Driver Shaft Speed 1800 RPM
Driven Shaft Speed 1000 RPM +- 5%
B. Determine the rated power of the system.

Rated Power: ________________________________(Hp/KW)
This can be determined by looking at the given information in
substep A. In this case, it is easy because the motor size is
given. The rated power is therefore 2 Hp.
C. Determine the service factor using figure 31.
Service Factor: ______________________________________
You should find that the service factor for a machine tool under
normal service is 1.2.
D. Calculate the design horsepower.
Design Horsepower: __________________________(Hp/KW)
The design horsepower is found by multiplying the rated power
of the driver by the service factor that was found in substep C.
You should find a design horsepower of 2.4Hp (2Hp x 1.2).

E. Select the belt section.
Belt Section: ________________________________________
The belt section is found by locating the design power in the
table of figure 39.
BELT SECTION SELECTION CHART

DESIGN HP BELT SECTION
1/2 A AX
3/4 A AX
1 A AX
1-1/2 A AX
2 A AX
3 AX A BX
5 BX AX B A
7-1/2 BX AX B 3VX
10 BX B AX 3VX
15 BX 3VX AX B
20 BX 3VX B
25 5VX, 5V 3VX B
30 5VX, 5V 3VX B
40 5VX, 5V B 3VX
50 5VX, 5V BX B CX
60 5VX, 5V BX B CX
75 5VX, 5V CX BX C
100 5VX, 5V CX C
125 5VX, 5V CX C
150 5VX, 5V CX C
200 5VX, 5V CX
250 5VX, 5V CX
Figure 39. Belt Section Selection Chart
You should select a belt with an AX belt section.

F. Determine the drive ratio.
Drive Ratio:_________________________________________
As you have already learned, the drive ratio is simply the speed
of the driver shaft divided by the speed of the driven shaft.
Both of these values are given in substep A.
In this case, the drive ratio is 1.8 (1800/1000RPM).

G. Select the sheave diameters.
Small sheave diameter: _________________________(in/mm)
Large Sheave Diameter:_________________________(in/mm)

To find the diameter of the small sheave, use the table shown in
figure 40.
SHEAVE DIAMETER SELECTION CHART BY HORSE POWER
“A” SECTION V-BELTS
RPM SHEAVE DIAMETERS

of
Smaller
Sheave 2.00 2.10 2.20 2.40 2.60 2.80 3.00 3.20 3.40 3.50 3.70 3.80 4.00 4.20 4.40 4.50 4.70 4.80 5.00
1160 ** ** ** ** ** ** 1.68 1.94 2.19 2.32 2.57 2.69 2.94 3.19 3.43 3.55 3.80 3.92 4.16
1450 ** ** ** 1.27 1.49 1.71 1.96 2.27 2.58 2.73 3.04 3.19 3.49 3.78 4.08 4.23 4.52 4.66 4.95
1750 0.90 1.03 1.17 1.43 1.69 1.95 2.23 2.59 2.95 3.13 3.48 3.66 4.00 4.35 4.69 4.86 5.20 5.36 5.69
2900 1.10 1.30 1.50 1.90 2.28 2.66 3.03 3.49 4.02 4.28 4.79 5.04 5.54 6.02 6.50 6.73 7.19 7.41 7.85
3500 1.14 1.37 1.60 2.05 2.49 2.92 3.34 3.78 4.37 4.66 5.22 5.50 6.04 6.56 7.07 7.32 7.80 8.03 8.49
600 ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** **
800 ** ** ** ** ** ** ** ** ** ** ** ** ** ** 2.55 2.64 2.81 2.90 3.08
1000 ** ** ** ** ** ** ** ** ** 2.07 2.29 2.40 2.62 2.84 3.05 3.16 3.37 3.48 3.69
1200 ** ** ** ** ** ** 1.72 1.99 2.25 2.38 2.63 2.76 3.02 3.27 3.53 3.65 3.90 4.02 4.27
1400 ** ** ** ** 1.46 1.67 1.92 2.22 2.52 2.66 2.96 3.11 3.40 3.69 3.97 4.11 4.40 4.54 4.82
1600 ** ** 1.11 1.35 1.59 1.83 2.10 2.44 2.77 2.93 3.26 3.43 3.75 4.07 4.39 4.55 4.86 5.02 5.33
0.91 1.05 1.45 1.72 1.98 2.27 2.64 3.00 3.19 3.55 3.73 4.09 4.44 4.79 4.96 5.30 5.47 5.81
1800 1.19 6.26
2000 0.96 1.11 1.26 1.55 1.84 2.13 2.42 2.82 3.22 3.42 3.82 4.01 4.40 4.78 5.16 5.34 5.71 5.90
1.00 1.16 1.64 1.95 2.26 2.57 3.00 3.43 3.64 4.07 4.27 4.69 5.10 5.50 5.70 6.10 6.29 6.68
2200 1.32 7.06
2400 1.03 1.21 1.38 1.72 2.06 2.39 2.71 3.16 3.62 3.85 4.30 4.52 4.96 5.39 5.82 6.03 6.45 6.65
1.06 1.25 1.80 2.15 2.50 2.85 3.30 3.79 4.03 4.51 4.74 5.66 6.11 6.33 6.77 6.98 7.40
2600 1.43 5.21 7.71
2800 1.09 1.28 1.48 1.86 2.24 2.61 2.96 3.43 3.95 4.20 4.70 4.95 5.43 5.91 6.38 6.60 7.06 7.28
1.11 1.32 2.32 2.71 3.09 3.55 4.09 4.35 4.87 5.13 6.13 6.61 6.85 7.31 7.54 7.99
3000 1.52 1.93 5.64 8.22
3200 1.12 1.34 1.56 1.98 2.40 2.80 3.20 3.65 4.21 4.49 5.03 5.29 5.82 6.32 6.82 7.06 7.53 7.77
1.13 1.36 2.46 2.88 3.29 3.74 4.32 4.60 5.16 5.44 6.49 7.00 7.24 7.72 7.95 8.41
3400 1.59 2.03 5.97
1.14 1.38 2.52 2.96 3.38 3.81 4.41 4.70 5.28 5.56 6.63 7.14 7.39 7.87 8.11 8.56
3600 1.61 2.07 6.10 8.66
3800 1.14 1.39 1.63 2.11 2.57 3.02 3.46 3.88 4.48 4.78 5.37 5.65 6.21 6.74 7.26 7.50 7.98 8.22
1.14 1.39 2.61 3.07 3.52 3.95 4.54 4.84 5.44 5.73 6.82 7.34 7.58 8.06 8.28 8.72
4000 1.64 2.13 6.29 8.69
4400 1.11 1.38 1.65 2.17 2.67 3.15 3.62 4.06 4.59 4.91 5.51 5.80 6.36 6.89 7.39 7.63 8.08 8.29
1.07 1.36 2.70 3.20 3.67 4.57 4.88 5.49 5.77 6.83 7.30 7.52 7.93 8.12 8.46
4800 1.64 2.18 4.11 6.32 _
5200 1.01 1.31 1.60 2.16 2.69 3.19 3.67 4.11 4.51 4.77 5.36 5.64 6.16 6.63 7.05 7.24 7.59 _
0.93 1.23 2.65 3.15 3.62 4.43 4.60 5.13 5.39 6.28 6.64 _ _ _ _
5600 1.53 2.11 4.04 5.84 _
6000 0.82 1.14 1.44 2.02 2.56 3.06 3.51 3.91 4.27 4.43 4.78 5.02 5.43 _ _ _ _ _
0.66 0.98 2.40 2.88 3.30 3.96 4.08 4.28 4.37 _ _ _ _ _ _
6500 1.29 1.87 3.66 _ _
7000 0.46 0.79 1.09 1.66 2.17 2.62 2.99 3.29 3.51 3.60 _ _ _ _ _ _ _ _ _
7500 0.23 0.55 0.85 1.40 1.87 2.27 2.58 2.80 _ _ _ _ _ _ _ _ _ _
_ 0.27 1.50 1.83 _ _ _ _ _ _ _ _ _
8000 0.56 1.07 2.06 _ _ _ _
Figure 40. Sheave Diameter Selection Chart
In the first column, locate the rotational speed of the small

sheave. Move across that row until your finger reaches the first
value that is equal to or greater than the design horsepower. In
this case, you would stop at 2.64 Hp. Now, move straight to the
top of that column. There you will find the diameter that should
be used on the small sheave. In this case, you should find a
small sheave diameter of 3.20 inches.
The large sheave diameter is found by multiplying the small
sheave diameter by the pulley ratio found in substep D. Here
you should have found the diameter of the large sheave to be
5.76 inches (3.20 inches x 1.8).

H. Determine the number of grooves required.
Number of Grooves Required: __________________________
The number of grooves required is found by dividing the
design horsepower of substep C by the maximum horsepower
of the small sheave, which was the 2.64 you stopped at in the
table of substep E.
In this case, the number of grooves required is 1
(2.4Hp/2.64Hp) = 0.91. Remember to always round up!
I. Determine the belt length.
Belt Length: __________________________________(in/mm)
The belt length can be calculated using the belt length formula.
You should use the following values:
C = Center distance. Specification given in substep A
D = Pitch diameter of large sheave. Value calculated in
substep F (5.70 in)
d = pitch diameter of small sheave. Value calculated in
substep F (3.2 in)
In this case, you should find a belt length of 55 inches as
follows.
L = 2 (20 inches) + 1.57 (5.70 inches + 3.2 inch)
(5.70 inches − 3.2 inches) 2
+ = 54.05 inches » 55 inches
4 (20 inches)
J. Determine the corrected power per belt.
Corrected Power per Belt: ______________________(Hp/KW)
The corrected power per belt is found by first using the table
shown in figure 41 to determine the correction factor for the
pulley ratio.

DRIVE RATIO CORRECTION CHART
“A” SECTION V-BELTS
“Drive Ratio Correction” Must Be ADDED to Sheave HP Rating
RPM DRIVE RATIO CORRECTION

of
Smaller 1.02- 1.04- 1.07- 1.09- 1.13- 1.17- 1.23- 1.33- 1.51-
Sheave 1.03 1.06 1.08 1.12 1.16 1.22 1.32 1.50 & UP
11.60 0.03 0.06 0.09 0.12 0.14 0.17 0.20 0.23 0.26
1450 0.04 0.07 0.11 0.14 0.18 0.22 0.25 0.29 0.32
1750 0.04 0.09 0.13 0.17 0.22 0.26 0.30 0.35 0.39
2900 0.07 0.14 0.22 0.29 0.36 0.43 0.50 0.58 0.65
3500 0.09 0.17 0.26 0.35 0.44 0.52 0.61 0.70 0.78
600 0.01 0.03 0.04 0.06 0.07 0.09 0.10 0.12 0.13
800 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18
1000 0.02 0.05 0.07 0.10 0.12 0.15 0.17 0.20 0.22
1200 0.03 0.06 0.09 0.12 0.15 0.18 0.21 0.24 0.27
1400 0.03 0.07 0.10 0.14 0.17 0.21 0.24 0.28 0.31
1600 0.04 0.08 0.12 0.16 0.20 0.24 0.28 0.32 0.36
1800 0.04 0.09 0.13 0.18 0.22 0.27 0.31 0.36 0.40
2000 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45
2200 0.05 0.11 0.16 0.22 0.27 0.33 0.38 0.44 0.49
2400 0.06 0.12 0.18 0.24 0.30 0.36 0.42 0.48 0.54
2600 0.06 0.13 0.19 0.26 0.32 0.39 0.45 0.52 0.58
2800 0.07 0.14 0.21 0.28 0.35 0.42 0.49 0.56 0.63
3000 0.07 0.15 0.22 0.30 0.37 0.45 0.52 0.60 0.67
3200 0.08 0.16 0.24 0.32 0.40 0.48 0.56 0.64 0.72
3400 0.08 0.17 0.25 0.34 0.42 0.51 0.59 0.68 0.76
3600 0.09 0.18 0.27 0.36 0.45 0.54 0.63 0.72 0.81
3800 0.09 0.19 0.28 0.38 0.47 0.57 0.66 0.76 0.85
4000 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90
4400 0.11 0.22 0.33 0.44 0.55 0.66 0.77 0.88 0.99
4800 0.12 0.24 0.36 0.48 0.60 0.72 0.84 0.96 1.08
5200 0.13 0.26 0.39 0.52 0.65 0.78 0.91 1.04 1.16
5600 0.14 0.28 0.42 0.56 0.70 0.84 0.97 1.12 1.25
6000 0.15 0.30 0.45 0.60 0.75 0.90 1.04 1.20 1.34
6500 0.16 0.32 0.49 0.65 0.81 0.97 1.13 1.29 1.46
7000 0.17 0.35 0.52 0.70 0.87 1.05 1.22 1.39 1.57
7500 0.19 0.37 0.56 0.75 0.93 1.12 1.31 1.49 1.68
8000 0.20 0.40 0.60 0.80 1.00 1.20 1.39 1.59 1.79
Figure 41. Drive Ratio Correction
In the first column, locate the rotational speed of the small

sheave. Then move across that row until you reach the column
of the pulley ratio. The value indicated by the intersection of
these two values is the correction factor. In this case, it is 0.40.
Add this value to the rated horsepower of the sheave to obtain
3.04Hp (2.64Hp + 0.40Hp).
Next, you need to apply the correction for belt length. This is
done by locating the belt length, which was calculated in
substep H, in the first column of the table in figure 42.

CONVENTIONAL V-BELTS
Nominal Nominal
A B C A B C D E
Length Length
26 .81 - - 90 1.06 1.00 .91 - -
31 .84 - - 93 - 1.01 - - -
32 .85 - - 96 1.08 1.02 .92 - -
33 .86 - - 97 - 1.02 - - -
34 .86 - - 99 - 1.02 - - -
35 .87 .81 - 100 - 1.03 - - -
36 .87 - - 103 - 1.03 - - -
37 .88 - - 105 1.10 1.04 .94 - -
38 .88 .83 - 108 - 1.04 - - -
42 .90 .85 - 109 - - .94 - -
43 .90 - - 110 1.11 - - - -
46 .92 .87 - 112 1.11 1.05 .95 - -
48 .93 .88 - 115 - - .96 - -
50 - .89 - 116 - 1.06 - - -
51 .94 .89 .80 120 1.13 1.07 .97 .86 -
52 - .89 - 124 - 1.07 - .87 -
53 .95 .90 - 128 1.14 1.08 .98 - -
54 .95 .90 - 133 - 1.08 - - -
55 .96 .90 - 136 1.15 1.09 .99 - -
56 .96 .90 - 144 1.16 1.11 1.00 .90 .88
58 .97 .91 - 150 - 1.12 1.01 - -
59 - .91 - 158 1.17 1.13 1.02 .92 -
60 .98 .92 .82 162 - 1.13 1.03 .92 -
61 - .92 - 173 1.18 1.15 1.04 .93 -
62 .99 .93 - 180 1.19 1.16 1.05 .94 .91
63 - .93 - 195 - 1.18 1.07 .96 .92
64 .99 .93 - 210 - 1.19 1.08 .96 .94
65 - .94 - 225 - 1.20 1.09 .98 .95
66 1.00 .94 - 240 - 1.22 1.11 1.00 .96
67 - .94 - 255 - 1.23 1.12 1.01 -
68 1.00 .95 .85 270 - 1.25 1.14 1.03 .99
70 1.01 .95 - 285 - 1.26 1.15 1.04 -
71 1.01 .95 - 300 - 1.27 1.16 1.05 1.01
75 1.02 .97 .87 315 - 1.28 1.17 1.06 -
77 - .98 - 330 - - 1.19 1.07 1.03
78 1.03 .98 - 345 - - 1.20 1.08 -
79 - .98 - 360 - 1.31 1.21 1.09 1.05
80 1.04 .98 - 390 - - 1.23 1.11 1.07
81 - .98 .89 420 - - 1.24 1.12 1.09
82 - .99 - 480 - - - 1.16 1.12
83 - .99 - 540 - - - 1.18 1.14
85 1.05 .99 .90 600 - - - 1.20 1.17
88 - 1.00 -
WEDGE V-BELTS
Cross Section Cross Section

Belt Belt
Length Length
3V 5V 8V 3V 5V 8V
25.0 .83 - - 112.0 1.11 .98 .88

26.5 .84 - - 118.0 1.12 .99 .89
28.0 .85 - - 125.0 1.13 1.00 .90
30.0 .86 - - 132.0 1.14 1.01 .91
31.5 .87 - - 140.0 1.15 1.02 .92
33.5 .88 - - 150.0 - 1.03 .93
35.5 .89 - - 160.0 - 1.04 .94
37.5 .91 - - 170.0 - 1.05 .95
40.0 .92 - - 180.0 - 1.06 .95
42.5 .93 - - 190.0 - 1.07 .96
45.0 .94 - - 200.0 - 1.08 .97
47.5 .95 - - 212.0 - 1.09 .98
50.0 .96 .85 - 224.0 - 1.09 .98
53.0 .97 .86 - 236.0 - 1.10 .99
56.0 .98 .87 - 250.0 - 1.11 1.00
60.0 .99 .88 - 265.0 - 1.12 1.01
63.0 1.00 .89 - 280.0 - 1.13 1.02
67.0 1.01 .90 - 300.0 - 1.14 1.03
71.0 1.02 .91 - 315.0 - 1.15 1.03
75.0 1.03 .92 - 335.0 - 1.16 1.04
80.0 1.04 .93 - 355.0 - 1.17 1.05
85.0 1.06 .94 - 375.0 - - 1.06
90.0 1.07 .95 - 400.0 - - 1.07
95.0 1.08 .96 - 425.0 - - 1.08
100.0 1.09 .96 .87 450.0 - - 1.09
106.0 1.10 .97 .88 -
Figure 42. Belt Length Correction Factor

Once the belt length is found in the first column, move across
that row until you are in the column of the type of belt you are
using, which was found in substep B. Where the two values
intersect, is the correction factor. Multiply this value by the
result of the drive ratio correction. In this case, you should find
a result of 2.92Hp (0.96 x 3.04Hp).
Next, you need to apply a correction factor for the Loss in arc
of contact. To do this, you must first calculate the loss of arc of
contact, which is given by the following formula:
(D − d) × 57
Loss in arc of contact =
C
This formula should give you a result of 7.125. Locate this
value in the table of figure 43.

Loss in Arc Correction Loss in Arc Correction
of Contact Factor of Contact Factor
0° . . . . . . . . . . . . . . . . . . . . . 1.00 50° ..................... .86
5° . . . . . . . . . . . . . . . . . . . . . .99 55° ..................... .84
10° . . . . . . . . . . . . . . . . . . . . . .98 60° ..................... .83
15° . . . . . . . . . . . . . . . . . . . . . .96 65° ..................... .81
20° . . . . . . . . . . . . . . . . . . . . . .95 70° ..................... .79
25° . . . . . . . . . . . . . . . . . . . . . .93 75° ..................... .76
30° . . . . . . . . . . . . . . . . . . . . . .92 80° ..................... .74
35° . . . . . . . . . . . . . . . . . . . . . .90 85° ..................... .71
40° . . . . . . . . . . . . . . . . . . . . . .89 90° ..................... .69
45° . . . . . . . . . . . . . . . . . . . . . .87
Figure 43. Loss of Arc Correction Factor
This table will give you the correction factor to apply, which is
0.99. Multiplying this value by the result of the belt length
correction should give you a corrected belt horsepower of
2.89Hp (0.99 x 2.92Hp).
Finally, once the corrected power per belt has been found, you
should check to make sure that the belt velocity isn’t
dangerously high. To do this, simply use the following
formula:
Belt velocity (FPM) = Pitch diameter × 0.2618 × RPM
In this case, you should find a belt velocity of 1508 FPM (3.2
inches x 0.2618 x 1800 RPM). As long as this value is less than
6400 FPM, the drive system will be safe.

K. Determine the corrected total power.
Corrected Total Power: ________________________(Hp/KW)
The corrected total power is simply the corrected power of each
belt times the total number of belts. In this example, you should
find the corrected total power to be 2.89Hp (2.89Hp x 1 belt).
L. Compare the corrected total power to the design horsepower.
In this substep, simply verify that the corrected total
horsepower of the design belt drive system is greater than the
design horsepower you found in substep C. In this example it is
(2.89Hp vs. 2.4Hp).
M. Select the sheave and bushing sizes.
Small Sheave: _______________________________________
Small Sheave Bushing: ________________________________
Large Sheave: _______________________________________
Large Sheave Bushing: ________________________________
Belt:_______________________________________________
In this final substep, you will use a manufacturer’s table to
determine the part numbers of the components required to build
the belt drive system. One such table was shown in figure 38.
First, use the column of the belt section that you chose in
substep E. Move down that column until you find the diameter
of that sheave. Then move across that row until you are in the
column of the type of sheave you wish to use. In this, and all
other steps of this skill, you will choose a sheave that uses
some type of a bushing.
Repeat this procedure to find the part number of the large
sheave you wish to use. Make sure that you include the shaft
sizes for the sheaves that you wish to use. For this example,
you should have found the following part numbers:
Small sheave: AK34H
Small sheave bushing: H - 5/8-inch bore
Large sheave: 1B62SDS
Large sheave bushing: SDS - 5/8-inch bore
Belt: A55
tic
e This NOTE
No
According to the manufacturer’s note in figure 40, you can use

A size belts with a B size sheave.

❑ 2. Select the sizes of the components for a v-belt drive system given
the information shown.
A. Examine the information about a v-belt drive application.
Motor Size 1.5 hp
Motor Shaft Size 5/8-inch
Driven Shaft Size 5/8-inch
Distance between centers Adjustable: 18-24 inches
Application Type Fan, continuous operation
Driven Shaft Speed 1000 RPM +- 5%
B. Determine the rated power of the system.

Rated Power: ________________________________(Hp/KW)
You should find a rated horsepower of 1.5Hp.
C. Determine the design horsepower of the system.
Design Horsepower: __________________________(Hp/KW)
Remember to use the service factor correction table in figure
31. You should find a design horsepower of 1.95Hp (1.5Hp x
1.3).
D. Determine the drive ratio.
Drive Ratio:_________________________________________
You should find a drive ratio of 1.75 (1750RPM/1000RPM).
E. Select the belt section.
Belt Section: ________________________________________
Use the table in figure 39.
You should find an A size belt section.
F. Select the sheave diameters.
Small sheave diameter: _________________________(in/mm)
Large Sheave Diameter:_________________________(in/mm)

Remember to use the horsepower ratings table shown in figure
40 for the small sheave and the drive ratio for the large sheave.
You should find a small sheave diameter of 2.80 inches and a
large sheave diameter of 4.90 inches.

G. Determine the number of grooves required.
Number of Grooves Required:___________________(grooves)
You should find the number of grooves required to be 1
(1.95Hp/1.95Hp).
H. Determine the belt length.
Belt Length: __________________________________(inches)
In this case, you should find a belt length of 55 inches.
I. Determine the corrected power per belt.
Corrected Power per Belt: ______________________(Hp/KW)
Remember to use all of the same tables and procedures of
substep H in Step 1. You should find a corrected power per belt
of 2.22Hp.
J. Determine the corrected total power.
Corrected Total Power: ________________________(Hp/KW)
You should find a corrected total horsepower of 2.20Hp
(2.20Hp x 1 belt).
K. Compare the corrected total power to the design horsepower.
Is corrected total horsepower greater than the design
horsepower: _________________________________(Yes/No)
You should find that the corrected total horsepower is greater
than the design horsepower.
L. Select the sheave and bushing sizes.
Small Sheave: _______________________________________
Small Sheave Bushing: ________________________________
Large Sheave: _______________________________________
Large Sheave Bushing: ________________________________
Belt:_______________________________________________
Remember to use the stock sheave listing table in figure 38 and
to choose sheaves that use some sort of bushings.
Small sheave: AK30H
Small sheave bushing: H - 5/8-inch bore
Large sheave: AK54H
Large sheave bushing: H - 5/8-inch bore
Belt: A55

❑ 3. Select the sizes of the components for a v-belt drive system given
the information shown.
Motor Size 10 hp
Motor Shaft Size 1 inch
Driven Shaft Size 1-1/8 inches
Distance between centers Adjustable: 18-24 inches
Application Type Sawmill, intermittent service
Driven Shaft Speed 1750 RPM
Belt Section Type:____________________________________
Belt Length: __________________________________(in/mm)
Driver Sheave Pitch Diameter: ___________________(in/mm)
Driven Sheave Pitch Diameter: ___________________(in/mm)
No. of Grooves: ______________________________(grooves)
Driven Bushing Size and Type: _________________________
Drive Bushing Size and Type: __________________________

❑ 4. Compare your results to the following answer guide.
Belt Section Type: BX
Belt Length: 74 inches
No. of Grooves: 1 groove
Driver Sheave Part Number: 1B66SDS
Driven Sheave Part Number: 1B136SDS
Driven Bushing Size and Type: SDS - 1.0 inch bore
Drive Bushing Size and Type: SDS - 1-1/8 inches bore

SEGMENT 3
SELF REVIEW
r This
we
Ans
1. The process used to design a v-belt drive system is a _____
-step process.
2. In the formula used to determine belt length, the variable

____ is used to identify the distance between shaft centers.
3. The v-belt _________ that should be used mostly depends

on the horsepower of the driver.
4. The design horsepower is simply the horsepower of the

driver times a __________ factor.
5. The corrected total power is the corrected power per belt

times the ___________ of ___________.
6. The corrected total power must be ___________ than the

design horsepower.

SEGMENT 4
V-BELT MAINTENANCE AND TROUBLESHOOTING
OBJECTIVE 7 DEFINE PREVENTIVE MAINTENANCE AND

EXPLAIN ITS IMPORTANCE
his
dT Machine downtime can be very expensive because it means
Rea
production has been halted and machine components that have failed
must be replaced. To reduce down time and save money, many industries
perform preventive maintenance on all of their equipment. Preventive
Maintenance is the periodic inspection and servicing of equipment in
order to predict, prevent, or identify possible failures. Preventive
maintenance usually includes the following activities:
• Inspection
• Lubrication
• Cleaning
• Replacing consumable components
• Testing components
OBJECTIVE 8 DESCRIBE NINE PREVENTIVE MAINTENANCE STEPS

FOR V-BELT DRIVES
his
dT While v-belt drives require very little maintenance, they should be
Rea
inspected on a periodic basis to determine if a problem of some type

exists. If a problem does exist, then it should be corrected before a
failure occurs.
There are nine preventive maintenance steps that should be
performed regularly on a belt drive system. These steps should all be
performed with the following frequency:
• First inspection: After 8 hours of operation following any

performed maintenance
• Second inspection: After 24 - 48 hours of operation
• Third inspection: After 100 hours of operation
Inspections should also be conducted periodically thereafter.

The nine maintenance steps for v-belts are described as follows:
Step 1. Check for Sheave Groove Wear

All v-belt sheaves will wear under use. As a sheave becomes worn, a
belt will ride lower and lower in the groove. Replace any sheave whose
belts ride lower than 1/16 of an inch below the edge of the groove or
where the groove bottom has been polished from contact with the belt, as
shown in figure 44.
The sidewalls of the sheave will also become worn and dished out.
Replace any sheaves whose sidewalls are dished out by more than 1/32
of an inch, as is also shown in figure 44.
GROOVE BOTTOM
1/32" MAX. SHINY FROM
DISHED-OUT WEAR BELT CONTACT
1/16" MAX
1/32” MAX
Figure 44. Wear Limits of a Sheave

Step 2. Check for Sheave Run-Out
You do not need to setup a dial indicator for this step. Simply watch
the sheave while you rotate it by hand. If run-out is excessive, it can
easily be seen by visual inspection.
Step 3. Inspect for Heat Buildup and Proper Ventilation

Check the belts for excessive heat buildup. The surface temperatures
of the belt or sheaves should not get above 180°F. Check the belt and
sheave surfaces with a contact thermometer immediately after stopping
the drive. If there is a heat problem, make sure that the drive is properly
ventilated.
Step 4. Clean Belts and Sheave Grooves

Inspect all of the belts and sheaves for dirt, oil, or grease buildup. If
there is any, it should be removed with detergent and water. A product
known as belt dressing should not be applied as it actually accelerates
v-belt decay.
Step 5. Check Belt Tension

The belt tension should be checked with a belt tension tester. As you
have already learned, the proper amount of tension can be calculated or
found in a manufacturer’s tables.
Step 6. Check Sheave Alignment

You have already learned how to check the alignment of sheaves.
This can be performed with a straight edge or a string.
Step 7. Check for Mismatched Belts

To check for mismatched belts in a multiple belt drive, simply check
the tension in the drive. The tension in all of the belts should be uniform.
Step 8. Check All Sheave and Bushing Set-Screws

Check to make sure that all sheave and bushing set-screws are set to
the proper torque. Retighten them if necessary.
Step 9. Check for Damaged or Worn Belts

Belt damage and wear can come in many forms. The most common
problems are shown in the following figures.
A v-belt should be replaced if any of these conditions are found to
exist.

COMMON V-BELT FAULTS
Figure 45. Figure 46.

SYMPTOM: Belt is swollen, soft, and seam has opened up. SYMPTOM: Weathering or “crazing”.
FAULT: Excessive exposure to oil or grease. FAULT: Caused by the elements and aggravated by small
CORRECTIVE ACTION: Provide splash guards, do not over sheaves.
lubricate, clean belts and sheaves with gasoline. CORRECTIVE ACTION: Provide protection for the drive and
replace belt or belts.

SYMPTOM: Cut bottom and sidewall. SYMPTOM: Severe localized wear.
FAULT: Belt was pried over sheave and damaged during FAULT: Caused by a frozen or locked driven sheave.
installation. CORRECTIVE ACTION: Determine that the drive components
CORRECTIVE ACTION: Be sure to use proper length belt and turn freely and tighten belt, if necessary.
move tensioning all the way “in” when installing belt.

SYMPTOM: Badly worn and torn belt sides. SYMPTOM: Belt covering worn in uneven pattern.
FAULT: Constant slippage caused by insufficient tension in FAULT: Rough sheave sidewalls.
belt. CORRECTIVE ACTION: File or machine out the rough spot on
CORRECTIVE ACTION: Tension drive in accordance with the the sheave groove. If beyond repair, replace the sheave.
recommendations of the equipment manufacturer and this
manual.

SYMPTOM: Belt has evenly spaced deep bottom cracks. SYMPTOM: Ply separation.
FAULT: Use of a substandard backside idler. FAULT: Caused by substandard sheave diameter.
CORRECTIVE ACTION: Replace backside idler with the CORRECTIVE ACTION: Redesign drive to use proper size
minimum size recommendation. sheaves.

SYMPTOM: Split on side at the belt pitch line. SYMPTOM: Pinching or narrowing of belt.
FAULT: Use of a sheave with a substandard diameter. FAULT: The load carrying member has been broken by a
CORRECTIVE ACTION: Redesign drive to utilize proper size shock load or damage during installation.
sheaves.

SYMPTOM: Tensile break. SYMPTOM: Backside of belt is worn.
FAULT: Can be caused by high shock loads, foreign object FAULT: Back of the belt has been rubbing on a belt guard or
between the bottom of the sheave and the bottom of the belt or other appurtenance.
damage during installation. CORRECTIVE ACTION: Provide adequate clearance between
CORRECTIVE ACTION: Maintain proper drive tension and belt and guard or any appurtenances.
installation procedures. Provide guard to keep foreign material
from coming in contact with the drive.
Figure 57.
SYMPTOM: Severe envelope wear and early belt failure.
FAULT: Excessive dust and rough sheaves.
CORRECTIVE ACTION: Maintain sheave condition, alignment
and attempt to protect drive from excessive dust exposure.

Step 10. Observe the Operation of the Drive
After all of the inspections and checks are completed, the v-belt
drive should be observed while it is operating. You should look and
listen for excess belt noise, belt whipping, or belt turn over. If any of
these problems exist, it will need to be corrected.
OBJECTIVE 9 DESCRIBE HOW TO TROUBLESHOOT A V-BELT

DRIVE SYSTEM
dT
his Problems with a v-belt drive may be observed either during a routine
Rea
preventive maintenance inspection or when the system breaks down. In

either case, the source or cause of the problem must be found. The
process of isolating the cause is known as troubleshooting.
Most v-belt drive manufacturers provide tables to aid in
troubleshooting. The tables are broken up into two categories: inspection
faults and operating faults. Inspection faults are faults that are found
during routine preventive maintenance inspections, such as the ones that
are part of the maintenance steps you just learned about. An operating
fault is indicated by any changes in the operation of the belt drive. These
tables list faults, along with each fault’s probable causes and the
corrective action required by each probable cause.
To troubleshoot a malfunctioning v-belt drive you should use the
following four-step process.
Step 1. Identify the Type of Fault and its Symptoms

The cause of a drive malfunction is called a fault. Faults can cause a
drive to do many things. For example, a fault can cause a v-belt drive to
squeal, whip, or slip. The type of malfunction you observe is called the
symptom.
All troubleshooting starts with identifying the symptom or
symptoms. What follows is a methodical troubleshooting process to find
the cause as quickly as possible and fix it.
Step 2. Look Up the Probable Causes

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

Step 3. Determine the Actual Cause
Sometimes there may be several probable causes of a fault. You
must then isolate which of them is the actual cause, either by verifying
one cause as the actual cause or by eliminating all possibilities but one. If
only one probable cause is listed in the table, it must be the actual cause.
Step 4. Perform the Corrective Action

For each probable cause, a corrective action is listed. Once you have
determined the actual cause, the corrective action that should be taken is
listen in the Corrective Action column just to the right of the actual fault.
The two charts are shown below. You will be using these in the next
skill.
INSPECTION FAULTS
FAULT PROBABLE CAUSES CORRECTIVE ACTION
Short belt life • Belt slips and burns under stalled • Set belt to proper tension
load conditions or when starting
• Gouges or extreme wear from belt • Eliminate obstructions
rubbing on obstructions
• High ambient temperatures • Use cog type belts. Provide
ventilation. Shield belt from high
temperatures
• Grease or oil eating belt • Clean belts and sheaves. Check
for leaking components
• Poorly designed drive • Redesign drive
• Worn sheaves • Replace sheaves
Belt stretch beyond idler • Worn sheaves • Replace sheaves

• Adjustable centers slipped • Reposition adjustable centers
• Drive excessively tensioned • Properly tension belt
• Damaged cord section during • Replace belt and properly install it
installation
Belt too long at installation • Insufficient adjustable centers • Use shorter belts
• Drive improperly set up • Check and correct improper set up
• Improper size belt • Use correct belt size
Belt too short at installation • Insufficient adjustable centers • Use longer belts
• Drive improperly set up • Check and correct improper set up
• Improper size belt • Use correct belt size
Belts mismatched after service • Old and new belts used on the • Replace with all new belts
same drive
• Belts from different manufacturers • Replace with all belts from same
manufacturer
• Shafts not parallel • Realign drive
• Belt cord section damaged at • Replace belts and properly install
installation
Excessive stretch • Worn sheaves • Replace sheaves

• Excessive tension • Properly tension the belt

OPERATING FAULTS
FAULT PROBABLE CAUSES CORRECTIVE ACTION
Belt squeal • High starting load. Excessive • Redesign and replace drive
overload
• Improper tension • Properly tension the belt
• Insufficient arc of contact • Increase center distance or use
cog type belts
Belt breakage • Foreign material in drive • Provide drive guard

• Belt damaged at installation • Replace and properly install belt
• Shock or extreme overload • Eliminate cause of overload or
redesign drive
Belt turns over in groove • Damaged cord section. Frayed or • Replace belts
gouged belts
• Excessive vibration • Properly tension the belt. Use cog
type belts
• Idler pulley misaligned • Realign idler pulley
• Worn sheaves • Replace sheaves
• Sheave misalignment • Realign sheaves
Excessive vibration • Damaged cord section • Replace belt

• Belt improperly tensioned • Properly tension the belt
• Shaft centers too far apart • Install an idler pulley
SKILL 7 TROUBLESHOOT A V-BELT DRIVE SYSTEM
Procedure Overview
In this procedure, you will be listing the probable
causes for a given fault. You will also give the actual fault
for a few of the exercises and give the corrective action
that should be taken.
This ❑ 1. Perform the following substeps to determine the probable causes

Do
of the following fault.

Symptom: A v-belt drive excessively vibrates under normal
operation.
A. Determine whether this is an inspection fault or an operating
fault
Type of fault: _____________________(Inspection/Operating)
You should have found this to be an operating fault.
B. Using the table of the type of fault that you determined in the
previous substep, locate the Excessive vibration fault in the
Faults column.
C. In the same row as the fault, move over one column to the
Probable Causes column.

D. List below the probable causes from the table.
Probable causes:
You should have found the following probable causes:
Damaged cord section
Belt improperly tensioned
Shaft centers too far apart
❑ 2. Perform the following substeps to determine the probable causes

of the following fault.
Symptom: While inspecting a multiple v-belt drive system, you
find all of the belt to be mismatched despite having correct match
codes.
A. Determine whether this is an inspection fault or an operating
fault.
Type of fault: ______________________(Inspection/operating)
You should have found this to be an inspection fault.
B. Using the table of the type of fault that you determined in the
previous substep, locate the Belts mismatched after service
fault in the Faults column.
C. In the same row as the fault, move over one column to the
Probable Causes column.

D. List below the probable causes from the table.
Probable causes:
Old and new belts used on the same drive
Belts from different manufacturers
Shafts not parallel
Belt cord section damaged at installation
❑ 3. Determine the probable causes of the following fault.
Symptom: While inspecting a v-belt drive system, you find the

belt to be excessively stretched.
Probable causes:
Worn sheaves
Excessive tension
Poorly designed drive

❑ 4. Perform the following substeps to determine the actual fault of the
following scenario.
Symptom: While inspecting a v-belt drive system, you find the
belt to be excessively stretched. Under further inspection you find
the sheaves to be in excellent condition, but the tension seems to
be firm to the touch.
A. Determine all probable causes of the fault listed below.
Probable causes:
Worn sheaves
Excessive tension
Poorly designed drive
B. Look once again at the given scenario. From it you should be

able to eliminate two of the probable causes.
C. List the remaining probable cause as the actual cause.
Actual cause: ________________________________________
You should have determined the actual cause of the fault to be
that the drive is under excessive tension.

❑ 5. Perform the following substeps to determine the actual fault of the
following scenario.
Scenario: While operating a newly installed v-belt drive with an
idler, you notice that the belt inverts itself as it goes around one of the
pulleys. There is no vibration to speak of, and you know the sheaves
are properly aligned. Both the sheaves and the belts are brand new,
and you were very careful not to damage the belts at installation.
A. Determine all probable causes of the fault listed below
Probable causes:
Damaged cord section. Frayed or gouged belts.
Excessive vibration
Idler pulley misaligned
Worn sheaves
Sheave misalignment
B. Look once again at the given scenario. From it you should be

able to eliminate all but one of the probable causes.
C. List the remaining probable cause as the actual cause
Actual cause: ________________________________________
You should have determined the actual cause of the fault to be
that the idler pulley is misaligned.
D. Go back to the listing of the probable faults in the appropriate
table. Next to the actual fault that you determined in the previous
substep, locate the corrective action that should be taken. This is
located in the Corrective Action column of the table.
Corrective Action:____________________________________
You should have determined that the corrective action to take is
to realign the idler pulley.
❑ 6. Use the photos of common v-belt faults to identify the missing
element, either Symptom, Fault, or Corrective Action.

SYMPTOM: ________________________________________ SYMPTOM: Tensile breaks.
FAULT: ___________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
FAULT: Substandard backside idler. __________________________________________________
CORRECTIVE ACTION: Replace backside idler with the __________________________________________________
minimum size recommendation.
CORRECTIVE ACTION: Maintain proper drive tension and
installation procedures. Provide guard to keep foreign material
from coming in contact with the drive.

SYMPTOM: Badly worn and torn belts. SYMPTOM: Weathering or “crazing”.
FAULT: ___________________________________________ FAULT: Caused by the elements and aggravated by small
sheaves.
__________________________________________________
CORRECTIVE ACTION: ______________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
CORRECTIVE ACTION: Tension drive in accordance with the
recommendations of the equipment manufacturer and this
manual.
Figure 62.
SYMPTOM: Pinching or narrowing of belt.
FAULT: ___________________________________________
__________________________________________________
__________________________________________________
CORRECTIVE ACTION: Maintain proper tensioning and
observe proper installation procedures.

SEGMENT 4
SELF REVIEW
r This
we
Ans
1. There are ______ basic steps to v-belt maintenance.
2. Oil and grease are not good things to have on a v-belt drive
because they _________ the belt.
3. Sheave _________ can be seen with the naked eye.
4. Using old belts with new belts or using belts from different
manufacturers on a multiple belt drive is likely to cause
excessive belt __________________.
5. Having foreign material in the belt drive, damaging the belt

at installation, or having extreme overloads is likely to cause
belt _____________.


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MECHANICAL

V-BELT SELECTION AND MAINTENANCE

950-ME1 Mechanical Drives 1 Learning System

Amatrol or School Supplied

FIRST EDITION, LAP 2, REV. B

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

SEGMENT 1 V-BELT SIZE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 2 V-BELT COMPONENT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SEGMENT 3 V-BELT DRIVE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SEGMENT 4 V-BELT MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 66

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

OBJECTIVE 1 DESCRIBE HOW V-BELTS ARE SPECIFIED

Figure 1. Typical V-Belt Code

With advancing technologies, many manufacturers are able to

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

ALL DIMENSIONS IN INCHES

Figure 2. FHP V-Belt Cross Section Size Codes

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

CONVENTIONAL BELT SIZES

ALL DIMENSIONS IN INCHES

Figure 3. Conventional V-Belt Section Codes

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Figure 4. Inside Length vs. Outside Length

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

WEDGE BELT SIZES

ALL DIMENSIONS IN INCHES

Figure 5. Wedge Belt Section Codes

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Figure 6. Pitch Length vs. Inside and Outside Length

Figure 7. A Typical Cog Type V-Belt

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Rea • Reading the code printed on the outside of the belt

Belt Section Identification

SHEAVE GROOVE GAGE

Figure 8. Belt Gage

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

1/4 WIDTH HEIGHT

ALL DIMENSIONS IN INCHES

Figure 9. Belt Types and Sizes

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Figure 10. Measuring Belt Length with String

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Figure 11. Approximate Pitch Line

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Figure 12. Multiple Belt Match Code

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Up to 100 Use only 1 number

100 to 200 Within 2 consecutive numbers

200 to 300 Within 3 consecutive numbers

300 to 400 Within 4 consecutive numbers

400 to 500 Within 5 consecutive numbers

500 and up Within 6 consecutive numbers

Figure 13. Limits of Match Codes

All manufacturers do not use match codes. In many cases, belt

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

belt given by the following belt size code.

You should have found the cross-sectional dimensions to be

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Actual Length: ________________________________(in/mm)

B503-XC LAP 2 V-BELT SELECTION AND MAINTENANCE

Actual Length: ________________________________(in/mm)

Belt type: _______________________(FHP/Conventional/Wedge)

Nominal Length: _________________________________(in/mm)

Match Code: ___________________________________________