Mechanical Drives 2 Lap 1

MECHANICAL
LEARNING
DRIVES 2 ACTIVITY
PACKET
HEAVY DUTY V-BELT DRIVES
TM
B503-XC
LEARNING ACTIVITY PACKET 1
HEAVY DUTY V-BELT DRIVES
INTRODUCTION
In this first LAP of Mechanical Drives Course Level 2, Model 95-ME2, you will
continue the study of v-belt drives you began in Level 1 by learning about the operation
and installation of conventional belts and wedge belts, both in single and multiple
configurations. These types of belts are more often used in industry than FHP belts
because of their ability to handle higher operating speeds and loads.
You will also learn how to install drives which use bushings. Bushings are
commonly used in industrial drives in place of the finished bore mounting method. There
are three types of bushings commonly used. In this LAP, you will learn to install each of
them.
ITEMS NEEDED
Needed Amatrol Supplied
Items
950-ME1 Mechanical Drives 1 Learning System

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

Assorted Hand Tools
FIRST EDITION, LAP 1, REV. C

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 1 HEAVY DUTY V-BELT DRIVES

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

OBJECTIVE 1 Describe the function of a bushing and list three types
OBJECTIVE 2 Describe the construction and operation of a QD bushing and give an advantage
OBJECTIVE 3 Describe the construction and operation of a Conventional V-Belt Drive
SKILL 1 Install and align a conventional v-belt drive system with a QD bushing
SEGMENT 2 MULTIPLE V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

OBJECTIVE 4 Describe the construction and operation of a multiple belt v-belt drive
OBJECTIVE 5 Describe the construction and operation of a split taper bushing and give an advantage
SKILL 2 Install and align a multiple belt v-belt drive system with a split taper bushing
SEGMENT 3 WEDGE V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

OBJECTIVE 6 Describe the construction and operation of a wedge v-belt drive
OBJECTIVE 7 Describe the construction and operation of a taper lock bushing and give an advantage
SKILL 3 Install and align a wedge v-belt drive system with a taper lock bushing
OBJECTIVE 8 Describe the construction and operation of a notched v-belt and give an advantage
SKILL 4 Install and align a notched v-belt drive system
SEGMENT 4 VARIABLE SPEED V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

OBJECTIVE 9 Describe the operation of a variable speed v-belt drive system and give an application
OBJECTIVE 10 Describe how to install and align a variable speed v-belt drive system
SKILL 5 Install and align a variable speed v-belt drive system
SEGMENT 5 V-BELT CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

OBJECTIVE 11 Describe four v-belt configurations and give an application of each
OBJECTIVE 12 Describe the function of a belt idler pulley and give an application
OBJECTIVE 13 Describe the operation of three types of belt idler pulley configurations
SKILL 6 Install and adjust a backside v-belt idler
SKILL 7 Install and adjust a kiss v-belt idler

SEGMENT 1
CONVENTIONAL V-BELT DRIVES
OBJECTIVE 1 DESCRIBE THE FUNCTION OF A BUSHING

AND LIST THREE TYPES
dT
his A bushing is a component that attaches the driver and driven sheaves
Rea
to their respective shafts. The bushing serves several purposes:

• It allows the sheave to be quickly removed
• The same sheave can be used with more than one size of shaft
• It allows the sheave to be mounted closer to a bearing
BUSHING
SHEAVE
Figure 1. Sheave Bushing

Most conventional and wedge v-belt drives use bushings as well as
chain sprockets, couplings and other types of hubs. The three main types
of bushings used in industrial applications are:
• QD
• Split Taper
• Taper Lock
All three of these bushings use some type of tapered bore design.
Each has unique advantages that make it better in some applications than
the others, but in many cases, any of the three will do well. The QD is
the most widely used mainly because it has been around the longest.
OBJECTIVE 2 DESCRIBE THE CONSTRUCTION AND OPERATION OF

A QD BUSHING AND GIVE AN ADVANTAGE
dT
his The quick detachable bushing, or QD bushing as it is commonly
Rea
known, is the most widely used of all types of tapered bore bushings.
Originally developed by Worthington, the QD bushing has a tapered
barrel and a flange, both of which are split along their entire length.
The QD bushing is attached to the sheave by 3 pull-up bolts that
draw the tapered barrel into the sheave hub. The split feature of the
bushing allows it to contract as its tapered barrel is drawn into the hub.
This creates the effect of a press fit onto a shaft, which gives the QD
bushing very good holding power. It is further attached to the shaft by a
key fastener and set-screw on the flange, as shown in figure 2.
SPLIT
(3) THREADED
HOLES
(3) THRU HOLES
(3) THRU HOLES
(3) THREADED
HOLES
PULL-UP
BOLTS
KEY
FLANGE
SET
SHEAVE SCREW
Figure 2. QD Bushing Assembly

One advantage of the QD bushing is that it can be mounted on the
sheave in 2 ways. The standard mounting has the bolts passing through
the bushing and threaded into the sheave with the flange turned either
towards or away from the shaft. The most common mounting is with the
flange turned towards the shaft, as shown in figure 3.
SHEAVE
QD
BUSHING
SHAFT
BUSHING SHEAVE
THRU THREADED
HOLE HOLE
Figure 3. The Forward Method of Installing a Bushing
The other method of mounting a QD bushing is to pass the bolts

through the sheave and thread them into the bushing, as shown in figure
4. This reverse method can also be mounted so the flange is turned either
towards or away from the shaft.
SHEAVE
QD
BUSHING SHAFT
SHEAVE BUSHING
THRU THREADED
HOLE HOLE
Figure 4. The Reverse Method of Mounting a Bushing
With the extra holes provided in the QD bushing, the bolts can be
inserted from either side.

Another advantage of the QD bushing is its flange. The flange
allows a bearing or gear puller to be used to remove the bushing from the
shaft. This is very useful in applications where there is rusting or
corrosion. For this reason, many industries such as the oilfield equipment
industry have standardized on the QD bushing.
The third advantage of the QD bushing is that it has a set-screw in
the flange to secure the key to the shaft. This feature gives the QD
bushing good holding power for heavy-duty applications.

A CONVENTIONAL V-BELT DRIVE
dT
his The conventional v-belt drive operates in a similar manner to the
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FHP v-belt drive, except that it is made for heavy-duty service. It is

designed for higher power levels and harsher operating conditions than
the FHP drive. It also is designed for continuous operation while the
FHP drive is not. As a result, the conventional v-belt is the type you will
normally see in industry.
The belt used on the conventional v-belt drive, as well as most other
belt types, consists of a neoprene envelope, polyester or some other
textile-based cording, and rubber filler compound, as shown in figure 5.
The conventional v-belt has more cords than the FHP v-belt to give it
higher strength.
FABRIC OR
NEOPRENE
COVER
TENSION
SECTION
POLYESTER
CORDS
COMPRESSION SECTION
Figure 5. Typical Conventional V-Belt Construction

The sheaves used for conventional v-belt drives are usually made of
cast iron to give them greater strength and durability. They are usually
attached with a bushing but can also be supplied with a finished bore.
These sheaves are made with either a single groove or multiple grooves
and can have either solid construction or spokes.
CAST IRON SHEAVE
Figure 6. Typical Sheave Construction for a Conventional V-Belt Drive
The conventional v-belt is also called a standard multiple belt

because it is most often used in multiple belt sets. However, it also used
in single belt applications. Another name for this type of belt is a
classical v-belt.

SKILL 1 INSTALL AND ALIGN A CONVENTIONAL V-BELT DRIVE
SYSTEM WITH A QD BUSHING
Procedure Overview
In this procedure, you will install a conventional v-belt
sheave that uses a QD bushing. This drive will use
sheaves with only one groove, so most of the installation
will be similar to the FHP installation except for the QD
bushing.
This ❑ 1. Perform the following safety checkout to prepare for working with
Do
power transmission equipment. Make sure that you are able to

answer yes to each item before proceeding.
YES/NO SAFETY CHECKOUT

Wearing safety glasses
Wearing tight fitting clothes
Ties, watches, rings, and other jewelry are removed
Long hair is tied up or put in a cap or under shirt
Wearing heavy duty shoes
Wearing short sleeves or long sleeves are rolled up
Floor is not wet
❑ 2. Perform a lockout/tagout on the Motor Control Unit’s safety

switch.

❑ 3. Locate Belt Drive Panel 2 and Shaft Panel 1 and place them on the
overhead rack.
❑ 4. Perform the following substeps to mount the adjustable mounting
base.
A. Position the adjustable mounting base over the set of holes in
the 950-ME Trainer’s work surface shown in figure 7.
Notice the flange of the adjustable base that has the narrow
offset.
The outlines of the positions of the other components to be
mounted are also shown.
4.4 PD
SHEAVE
NARROW
FLANGE
MOTOR
3.4 PD
SHEAVE
Figure 7. Positioning of Motor on 950-ME Work Surface
B. Locate four bolts with the specification of 3/8-16UNC-2A x 2

Hex Head, along with the compatible flat washers, lock
washers, and nuts.
C. Fasten the mounting base to the work surface by assembling
the bolts, washers, and nuts.
Use a criss-cross sequence.

❑ 5. Perform the following substeps to mount and level the motor on
the adjustable mounting base.
A. Position the motor over the set of studs in the adjustable
mounting base.
B. Locate four hex nuts with the specification of 5/16-18UNC-2B,
along with compatible flat washers and lock washers.
C. Fasten the motor to the adjustable mounting by assembling the
nuts and washers.
Remember to place the lock washer between the flat washer
and the hex nut.
D. Check the shaft for run-out. Record below the amount of
run-out.
Run-out: _____________________________________(in/mm)
The run-out should be less than 0.002 inches.
E. Check for motor shaft end float.
End Float ____________________________________(in/mm)
It should be less than 0.002 inches.
F. Check the level of the motor shaft. Shim the motor feet as
needed.
Feeler Gauge Leaf Thickness_____________________(in/mm)
Effective Level Length _________________________(in/mm)
Mounting Bolt Distance_________________________(in/mm)
Shim Ratio _________________________________________
Shim Thickness _______________________________(in/mm)

❑ 6. Perform the following substeps to mount the shaft and pillow
block bearings.
A. Select four Bearing Standoffs from Shaft Panel 1.
B. Make sure that the standoffs, pillow block mounting surface,
and mounting area of the work surfaces, shown in figure 7, are
free of dirt, rust and burrs.
C. Place the four standoffs on the 950-ME work surface.
D. Remove two pillow block bearings from Belt Drive Panel 1
having a bore size of 1-inch.
E. Place the pillow block bearings on the standoffs.
F. Locate four bolts with the specifications of 3/8-16UNC-2A x
4-1/2 Hex Head, along with the compatible flat washers, lock
washers, and nuts.
G. Fasten the pillow block bearings and the standoffs to the work
surface by assembling the bolts, washers, and nuts.
Hand tighten only.
H. Select an 8-inch long shaft from Belt Drive Panel 1 having a
1-inch diameter and 5/8-inch ends.
I. Slide the shaft through the two pillow block bearings. Position
it as shown in figure 7.
J. Tighten the set screws on each bearing to lock the bearing to
the shaft.
K. Tighten the pillow block bearing mounting bolts.
L. Turn the shaft by hand to make sure it turns freely.
If not, loosen the bolts and adjust the positions of the bearings.
M. Check the driven shaft for run-out.
Run-out: _____________________________________(in/mm)
The shaft should have no more than 0.002 inches run-out.
N. Level the driven shaft. Shim the bearing standoffs as needed.
Place the shims between the work surface and the standoffs.
Feeler Gauge Leaf Thickness_____________________(in/mm)
Effective Level Length _________________________(in/mm)
Mounting Bolt Distance_________________________(in/mm)
Shim Ratio _________________________________________
Shim Thickness _______________________________(in/mm)

❑ 7. Obtain the following two sheaves from Belt Drive Panel 2.
• 1 Groove 3.4 PD Sheave with QD bushing
• 1 Groove 4.4 PD Sheave with QD bushing
❑ 8. Perform the following substeps to mount the 3.4-inch PD sheave
onto the driver shaft using the QD bushing.
A. Use a rag to wipe off any oil or lubrication from the sheaves
and bushings.
Any lubrication on the bushing or sheave may result in the
bushing moving too far into the sheave when it is tightened.
This can cause the sheave to break.
B. Locate the set screw hole that is drilled into the flange of the
QD bushing, as shown in figure 8.
QD BUSHING
SET SCREW
Figure 8. Set Screw on QD Bushing

C. Use an allen wrench to back out the set screw so that it is not
extending into the keyseat.
D. Clean the shaft keyseat and the sheave keyseat with a wire
brush to make sure that no dirt or burs are in the keyseat. File
away any burs if necessary.
E. Select a 3/16-inch square x 1-inch key from your key stock.
F. Slide the key into the keyseat of the shaft. It should slide in
without forcing it and have no play.
If not, try another key.

G. Remove the key from the shaft keyseat and insert it into the QD
bushing keyseat. It should also slide in without forcing it and
have no play.
H. Remove the key from the QD bushing and insert it into the
motor shaft keyseat. Line it up flush with the end of the shaft.
I. Locate the 3 pull-up bolts and lock washers that will be used to
mount the sheave.
The manufacturer of the bushings recommends that your first
choice be to use the bolts that are supplied with the sheave. If
these are not available, use the bolts that are supplied with the
QD bushing.
e This NOTE
tic
No
Manufacturers of QD bushings refer to the sheaves,

sprockets, and other types of hubs which mount to the shaft with
a QD bushing as the QD product.
J. Insert the bolts with lock washers through the 3 thru-holes

(unthreaded holes) of the bushing, as shown in figure 9.
THRU-HOLES
Figure 9. Thru-Holes of the Bushing

K. Slide the bushing into the hub of the sheave from the side
where the hub is indented into the sheave, as shown in figure
10.
Figure 10. Bushing Inserted into Hub of Sheave
L. Rotate the sheave so that the bolts line up with the threaded
holes on the sheave. Then use your fingers to screw the bolts
into the sheave just enough to engage the threads.

M. Align the bushing keyseat with the key and keyseat of the
motor shaft then slide the loosely assembled sheave and
bushing onto the shaft, as shown in figure 11.
NOTE
e This The bushing can be positioned on the shaft in any location
tic
that serves the needs of the application. If the sheave is not to
No
be located between two bearings (i.e. an overhung shaft), it is

best to locate the bushing as close as possible to the nearest
bearing. This will reduce bearing load.
Figure 11. Bushing Assembled on Motor Shaft

N. Tighten the set screw onto the shaft key using the set-screw
torque level shown in the following table for the particular size
bushing, which is an SH size.
BUSHING BOLT TORQUE SET-SCREW TORQUE

SIZE (in-lb) (ft-lb) (in-lb)
JA 60 5 —
SH 108 9 87
SDS 108 9 87
SD 108 9 87
SK 180 15 87
SF 360 30 165
E 720 60 290
F 900 75 290
G 1620 135 290
M 2700 225 290
N 3600 300 620
P 5400 450 620
O. Use a wrench to tighten each of the bushing’s roll-up bolts

alternately and evenly. Tighten to the torque specification listed
for the SH bushing in the table shown above.
CAUTION
tion
Do not tighten the bolts any tighter than the recommended
u
Ca
CAUTION
level. This can cause the bushing or sheave to crack. Notice that
the torque is given in inch-pounds and foot-pounds (ft/lbs).
As the bolts are tightened, the bushing will remain in place and
the sheave will be pulled closer to the flange of the bushing.
When the bushing and sheave are fully tightened, there should
be a small gap between the flange and the sheave. Do not
attempt to tighten the bolts until the bushing flange is flush
with the hub.
❑ 9. Repeat Step 8 in a similar manner to mount the 4.4 PD sheave
using a QD bushing onto the driven shaft.
❑ 10. Perform the following substeps to align the sheaves.
A. Check the sheave alignment by placing a straight edge flush
against the driven sheave face. Then check the position of the
face of the driver sheave. This is the same procedure you used
to align FHP sheaves and roller chain sprockets.
If the face of the driver sheave is also flush against the straight edge, the
sheaves are aligned. Proceed directly to step 11. If one or both edges are
not flush, go to substep B to align the sheaves.

B. Loosen all 4 bolts which fasten the mounting base to the work
surface.
C. Move the motor base to a position where all 4 edges of the
sheaves are touching the straight edge.
D. Tighten the bolts in a criss-cross pattern until the bolts are tight.
E. Recheck the alignment with the straight edge after the bolts are
tightened. Repeat the alignment steps if necessary.
❑ 11. Perform the following substeps to mount the belt.
A. Obtain a 40 inch belt from the storage unit. It is labeled B37.
B. Loosen the locking nuts holding the motor on the adjustable
base approximately 1 turn.
C. Use a wrench to rotate the lead screws until the belt begins to
feel springy when pushed on.
D. Tighten the locking nuts holding the motor to the base.
E. Check the sheave alignment with a straight edge to make sure it
is still aligned.
If the straight edge shows no light, the sheaves are aligned and this skill
is complete. You can now proceed to the next objective.
If the straight edge shows some light, the sheaves are not
aligned. Loosen the motor’s bolts and adjust the appropriate
lead screw to realign the sheaves. Then, retighten the motor’s
bolts.
❑ 12. Perform the following substeps to tension the belt.
A. Determine the allowable belt deflection force range for the
application. Use the table in figure 12 and the following
information to determine the minimum belt deflection force.
Minimum Belt Deflection Force: ____________________(lbs)
FEATURE SPECIFICATION
Belt Size B
Sheave Pitch Diameter 3.4 inches
Operating Speed 1725 RPM
Belt Age New
B. Calculate the upper limit belt deflection force (minimum belt

deflection force x 1.5).
Upper Limit Belt Deflection Force : __________________ (lb)
Belt Deflection Force Range ________________________(lbs)

You should find the belt deflection force range to be 7.1 to
10.65 lbs.

Table No. 1 Sheave Diameter - INCHES Minimum Deflection Force - LBS
Belt Deflection Force
Smallest Super Gripbelts and Gripnotch Belts and

Sheave Unnotched Gripbands Notched Gripbands
Cross Diameter RPM
Section Range Range Used Belt New Belt Used Belt New Belt
A, AX 2.0 - 2.8 1000 - 2500 3.0 4.5 3.4 5.4
2501 - 4000 2.1 3.9 2.9 3.5
3.0 - 3.6 1000 - 2500 3.7 5.5 4.1 6.1
2501 - 4000 2.8 4.2 3.4 5.0
3.8 - 4.8 1000 - 2500 4.5 6.8 5.0 7.4
2501 - 4000 3.8 5.7 4.3 6.4
5.0 - 7.0 1000 - 2500 5.4 8.0 5.7 9.4
2501 - 4000 4.7 7.0 5.1 7.6
B, BX 3.4 - 4.2 860 - 2500 4.2 7.1 4.9 7.2
2501 - 4000 3.4 6.3 4.2 6.2
4.4 - 5.6 860 - 2500 5.3 7.9 7.1 10.5
2501 - 4000 4.5 6.7 7.1 9.1
5.8 - 8.6 860 - 2500 6.3 9.4 8.5 12.6
2501 - 4000 6.0 8.9 7.3 10.9
C, CX 7.0 - 9.0 500 - 1740 11.5 17.0 14.7 21.8
1741 - 3000 9.4 13.8 11.9 17.5
9.5 - 16.0 500 - 1740 14.1 21.0 15.9 23.5
1741 - 3000 12.5 18.5 14.6 21.6
D 12.0 - 16.0 200 - 850 24.9 37.0 31.9 47.2
851 - 1500 21.2 31.3 26.8 39.7
18.0 - 20.0 200 - 850 30.4 45.2 38.4 56.8
851 - 1500 25.6 38.0 32.3 47.8
3V, 3VX 2.2 - 2.4 1000 - 2500 2.7 3.8 3.3 4.9
2501 - 4000 2.3 3.3 2.9 4.3
2.65 - 3.65 1000 - 2500 3.6 5.1 4.2 6.2
2501 - 4000 3.0 4.4 3.8 5.6
4.12 - 6.90 1000 - 2500 4.9 7.3 5.3 7.9
2501 - 4000 4.4 6.6 4.9 7.3
5V, 5VX 4.4 - 6.7 500 - 1749 8.9 13.2 10.2 15.2
1750 - 3000 7.7 11.4 8.8 13.2
3001 - 4000 4.9 7.2 5.6 8.5
7.1 - 10.9 500 - 1740 12.7 18.9 14.8 22.1
1741 - 3000 11.2 16.7 13.7 20.1
11.8 - 16.0 500 - 1740 15.5 23.4 17.1 25.5
1741 - 3000 14.6 21.8 16.8 25.0
Figure 12. Belt Deflection Force Table
C. Loosen locking nuts holding the motor approximately 1 turn.

D. Use a wrench to rotate the lead screws approximately 2 full
turns to tighten the belt.
E. Retighten the locking nuts on the motor.
F. Check the sheave alignment again with a straight edge.
If there is any misalignment, adjust the alignment using the
lead screws.

G. Use the 36-inch rule to measure the belt span.
The belt span is measured between the points where the belt
first touches the sheaves.
Belt Span ____________________________________(in/mm)

H. Calculate the amount of deflection for your v-belt drive.
Deflection distance: ___________________________(in/mm)
The amount of deflection is 1/64 of the belt span.
I. Use a tension tester and a straight edge to measure the force
deflection.
Force scale reading: ____________________________(lbs./N)
J. Compare your force reading with the force range you
calculated in substep B.
Readjust the tension if necessary until the force reading is
between the minimum force and 1.5 times the minimum.
❑ 13. Perform the following substeps to connect and start the motor.
A. Make sure that the Motor Power switch is in the OFF or down
position.
B. Connect the Constant Speed Motor’s power cord to the Motor
Control Unit.
C. Make sure that the Motor Control Unit’s power cord is plugged
into a wall outlet.
D. Install the guard.
WARNING
ning
ar Do not operate the mechanical drive system without the guard
W
in place. Also, do not attempt to open or bypass the guard at

any time during operation. Performing any of these actions will
create a hazardous situation.
E. Remove the lockout/tagout.

F. Turn on the safety switch.
The Main Power Indicator on the Motor Control Unit should
turn on.
G. Make sure that no one is near the motor.
H. Turn on the Constant Speed Motor by moving the Motor Power
Switch to the ON or up position.
The motor should accelerate to full speed quickly and run at a
constant speed. Run the motor for 1 minute to allow the belt to
seat.
❑ 14. Turn off the motor and allow it to coast to a stop.
❑ 15. Perform a lockout/tagout and remove the guard.

❑ 16. Repeat Step 12 again to test and adjust the tension of the belt.
Record your reading.
Force scale reading: _______________________________(lbs/N)
Once the belt tension is correct, you have completed the
installation of the v-belt drive, except for retensioning the drive
after 24-48 hours of operation.
❑ 17. Install the guard.
❑ 18. Remove the lockout/tagout.
❑ 19. Restart the motor and observe the drive.
The v-belt drive should run smoothly with no belt squeaking.
❑ 20. Turn off the motor.
❑ 22. Remove the belt, being careful not to force the belt.
tic
e This
NOTE
No
Remember to loosen the motor locking nuts before adjusting

the motor’s position.
❑ 23. Perform the following substeps to disassemble and remove the

driver sheave and QD bushing.
A. Loosen and remove the 3 pull-up cap screws from the driver
sheave and bushing assembly.
B. Install the 3 screws into the threaded holes on the same side of
the bushing from which they were removed.
In this case, this means that you should insert them into the
threaded holes on the bushing. If you were using the reverse
method, you would use the threaded holes on the sheave.

C. Use a wrench to turn the bolts alternately and evenly until the
sheave breaks loose from the bushing.
The bolts act as jackscrews to push on the sheave, breaking the
grip of the bushing. Once the sheave is off of the bushing,
remove the bushing by hand or with a gear puller.
❑ 24. Repeat Step 23 in a similar manner to remove the driven sheave
and bushing.
❑ 25. Leave the motor, mounting base, and shaft/pillow block assembly
in place. You will use them in the next skill.
Figure 13. Current Setup

SEGMENT 1
SELF REVIEW
r This
we
Ans
1. The __________ v-belt drive is designed for higher power
levels and harsher working conditions than the FHP v-belt
drive.
2. A component that attaches the sheaves to their respective

shafts is called a __________.
3. There are ___ main types of bushings used in industrial

applications.
4. The most widely used type of bushing is called the

____________ ____________ or QD bushing.
5. The ________ feature of the QD bushing allows it to

contract as its tapered barrel is drawn into the hub.
6. The ____________ of a QD busing allows the bushing to be

removed from the shaft using a bearing or gear puller.
7. Along with the clamping power of the tapered surface, a QD

bushing also uses a _____________ and set-screw to mount
the bushing to the shaft.

SEGMENT 2
MULTIPLE V-BELT DRIVES

A MULTIPLE BELT V-BELT DRIVE
dT
his V-belt drives are often designed to use more than one belt to transmit
Rea
the power. This method allows the drive to transmit a great deal of power
using low cost components. In fact, the standard-multiple v-belt is called
standard because it is so frequently used in multiple belt sets.
Multiple v-belt drives use either conventional or wedge type v-belts.
These are the same belts used in single belt drives; there are just more of
them. The sheaves are usually made of cast iron and attached to their
shafts using either a finished bore or one of the 3 types of bushings. The
number of grooves in the sheaves for multiple belts is often 2 to 4, but
can be even higher.
PUMP
(DRIVEN)
ELECTRIC MOTOR
(DRIVER)
MULTIPLE V-BELT DRIVE
Figure 14. Multiple Belt Drive

When installing or replacing multiple belt drives, it is important to
realize that the belts of the same nominal size aren’t all exactly the same
length. The lengths of belts vary due to variations that occur in the
manufacturing process. This is not a problem for single belt drive
because the sheaves can be adjusted to compensate. However, it is a
problem for multiple belt drives because it means that the belts cannot be
tensioned the same and therefore the load will not be evenly divided
among the belts. Uneven belt loads in a multiple belt drive can cause
belts to break.
Therefore, the belts used in a multiple belt application must be of the
same length. To achieve this, many manufacturers place an additional
code on the belt called a match code, as shown in figure 15. This code
tells you how the belt length varies from the nominal value. All belts
used on the same drive should have the same match code. In many cases,
you can purchase belts in sets which have already been matched for you.
B40 GOODYEAR 49
NOMINAL MATCH
SIZE AND LENGTH CODE NUMBER
Figure 15. Multiple Belt Match Code
This
NOTE
e
tic
Some belt manufacturers produce all belts to a close
No
tolerance so that match codes are unnecessary. Check with your

belt supplier on match code requirements.

OBJECTIVE 5 DESCRIBE THE CONSTRUCTION AND OPERATION OF A
SPLIT TAPER BUSHING AND GIVE AN ADVANTAGE
dT
his
The split taper is another type of bushing that is used to attach
Rea
sheaves and sprockets to shafts. Originally developed by Browning, it
differs from the QD bushing in that its barrel has a higher degree of
taper, it is split in two places on the barrel, and only the barrel is split,
not the flange. This gives the split taper bushing a better grip on the
shaft. In fact, you can actually remove the bolts from the bushing and it
will still hold.
Some of the larger split taper bushings have a double key locking
system (one on the outside of the bushing and one on the inside) to give
them even more holding power.
The disadvantage of the split taper bushing is that it can only be
installed in one direction.
NON-THREADED
HOLES
THREADED
HOLE
Figure 16. Split Taper Bushing

SKILL 2 INSTALL AND ALIGN A MULTIPLE BELT V-BELT DRIVE
SYSTEM WITH A SPLIT TAPER BUSHING
Procedure Overview
In this procedure, you will set up a v-belt drive that
uses multiple belts and a split taper bushing. These steps
are similar to the steps you used in the last skill except for
the split taper bushing. Although the split taper bushing is
being used in this skill to attach a multiple belt drive, it can
be used to attach any other type of hub as long as the hub
is designed for the split taper.
Do


Floor is not wet

switch.

❑ 3. Perform the following substeps to set up the drive.
A. Continuing from the last skill, the motor and driven shaft
should still be set up, as shown in figure 17. If not, repeat Steps
4-6 in the last skill to do so.
B. Obtain the following sheaves from Belt Drive Panel 2.
• 2 Groove 3.4 PD Sheave
Figure 17. Motor and Driven Shaft Setup
❑ 4. Perform the following substeps to mount the 3.4 PD to the motor

shaft sheave using the split taper bushing.
A. Clean the shaft keyseat and the bushing keyseat with a wire
brush to make sure that no dirt, paint, or burs are in the
keyseats. File away any burs if necessary. Clean off any oil or
grease as well.
B. Select a 3/16-inch square x 1-inch key from your key stock.
C. Slide the key you selected into the bushing’s keyseat. It should
slide in without forcing it and have no play.
tion CAUTION
u
Ca
CAUTION Do not lubricate the bushing taper, the cap screws, the
sheave’s taper, or the threaded holes. This can cause the
sheave to break.
D. Remove the key from the bushing and insert it into the shaft
keyseat. It should also slide in without forcing and have no
play.
E. Line up the key so that it is flush with the end of the shaft.
F. Locate the 2 pull-up bolts and lock washers that will be used to
mount the sheave.
The manufacturer of the bushings recommends that your first
choice be to use the bolts that are supplied with the sheave. If
these are not available, use the bolts that are supplied with the
bushing.
G. Insert the bolts with lock washers through the 2 thru-holes
(unthreaded holes) of the bushing, as shown in figure 18.
STEP G: BOLTS INSERTED STEP H: BUSHING

IN THRU HOLES ATTACHED TO SHEAVE
LOCK WASHER
THREADED
HOLES
THRU
HOLES
Figure 18. Bushing Inserted Into the Hub of the Sheave

H. Slide the bushing into the hub of the sheave from the side
where the hub extends from the sheave, as shown in figure 18.

I. Rotate the sheave so that the bolts line up with the threaded
holes on the sheave. Then use your fingers to screw the bolts
into the sheave just enough to engage the threads.
J. Pick up the sheave/bushing assembly and slide it onto the
motor shaft. Be careful to line up the bushing keyseat with the
key on the shaft as you do this.
NOTE
e This
tic
The bushing can be positioned on the shaft in any location
No
that serves the needs of the application. If the sheave is not to

be located between two bearings (i.e. an overhung shaft), it is
best to locate the bushing as close as possible to the nearest
bearing. This will reduce bearing load.
K. Use a wrench to tighten each bolt alternately and evenly.

Tighten to the torque specification listed for the H size bushing
in the table below.
tion CAUTION
u
Ca
CAUTION Do not tighten the bolts any tighter than the recommended
level. This can cause the bushing or sheave to crack.
BOLT TORQUE
BUSHING SIZE (in-lbs)
G 95
H 95
P 197
Q 348
R 348
S 840
U 1780
W 3000
❑ 5. Repeat Step 4 in a similar manner to mount the 4.9 PD sheave onto

the driven sheave, except mount the bushing on the side where the
hub is indented.
❑ 6. Use a straight edge to check the sheaves’ alignment. Use the lead
screws to adjust as needed.

❑ 7. Perform the following substeps to mount the two belts.
A. Select two 40-inch “B” belts from the storage unit. They are
labeled B37.
B. Adjust the position of the motor so that it is close enough to be
able to put the belts on without having to force them past the
sheaves.
C. Place one belt on the inner grooves of the sheaves and another
belt on the outer grooves.
D. Move the motor away from the driven shaft until it lightly grips
the belts, as shown in figure 19.
Figure 19. Multiple Belt Drive Assembly

❑ 8. Perform the following substeps to tension the belts.
A. Calculate the allowable belt deflection force range for the
application. Use the table in figure 12.
Total Deflection Force Range:_____________________(lbs/N)
Belt Size B
Sheave Diameter 3.4 inches
Belt Age New
You should find the belt deflection force range to be 7.1 to

10.65 lbs.
B. Loosen the locking nuts holding the motor approximately 1
turn.
C. Use a wrench to rotate the lead screws approximately 2 full
turns to tighten the belt.
D. Retighten the locking nuts on the motor.
E. Check the sheave alignment again with a straight edge.
If there is any misalignment, use the lead screws to correct it.
The belt span is measured between the points where the belt
first touches the sheaves.
F. Use the 36-inch rule to measure the belt span.
Belt Span ____________________________________(in/mm)
G. Calculate the amount of deflection for your v-belt drive.
H. Use a tension tester and a straight edge to measure the force
deflection of each belt. Record it.
Belt 1 Force scale reading: _______________________(lbs/N)
Belt 2 Force scale reading: _______________________(lbs/N)

I. Compare your force reading with the force range you
calculated.
Readjust the tension if necessary until the force readings of
both belts is within the force range.
A. Connect the Constant Speed Motor’s power cord to the Motor
Control Unit.
B. Make sure that the Motor Control Unit’s switch power cord is
plugged into a wall outlet.

C. Make sure that the Motor Power switch is in the OFF or down
position.
WARNING
ning
W
in place. Also, do not attempt to open or bypass the guard at any
time during operation. Performing any of these actions will create
a hazardous situation.

turn on.
H. Turn on the Constant Speed Motor by moving its power switch
to the ON or up position.
constant speed. Allow the motor to run for about 1 minute to
allow the belts to seat.
❑ 12. Repeat Step 8 again to test the tension of the belts. Record your
reading.
Belt 1 Force scale reading: __________________________(lbs/N)
Belt 2 Force scale reading: __________________________(lbs/N)

Once the belt tensions are correct, you have completed the
installation of the multiple v-belt drive, except for retensioning the
drive after 24-48 hours of operation.
The multiple v-belt drive should run smoothly with no belt
squeaking.
❑ 17. Perform a lockout/tagout.
❑ 18. Remove the guard.
❑ 19. Remove the belts, being careful not to force them.

❑ 20. Perform the following substeps to disassemble the sheaves and the
split taper bushings.
A. Loosen and remove the 2 pull-up bolts from the motor sheave
and bushing assembly.
B. Install the 2 bolts into the threaded holes on the same side of
the assembly from which they were removed, as shown in
figure 20.
LOCK WASHER
THREADED
HOLES
THRU
HOLES
Figure 20. Threaded Holes for Removal of Sheave and Bushing

C. Use a wrench to turn the bolts alternately and evenly until the
sheave breaks loose from the bushing.
The bolts act as jackscrews to push on the sheave, breaking the
grip of the bushing. The bushing and sheave can now be
removed from the motor shaft.
❑ 21. Perform Step 20 in a similar manner to remove the driven sheave
and bushing.
Remove the driven sheave and bushing.
in place. You will use them in the next skill. Return all other
components to their proper storage.

SEGMENT 2
SELF REVIEW
r This
we
Ans
1. V-Belts can transmit more power by simply using
___________ belts.
2. Multiple belts use either the _____________ or the

____________ belts.
3. It is very important that every belt in a multiple belt system

be of the same _________.
4. Manufacturers use a ________ _________ to make sure that

all belts used in a multiple belt system have the same length.
5. A __________ __________ bushing differs from a QD

bushing in that it has a higher degree of taper than the QD
bushing.
6. The disadvantage of a split taper bushing is that it can only

be installed in one ___________.

SEGMENT 3
WEDGE V-BELT DRIVES

A WEDGE V-BELT DRIVE
his
dT The wedge v-belt design is a type of belt that is designed to transmit
Rea
the same or more power in a 40% smaller cross section than a

conventional v-belt. Designed in 1958 by Gates Rubber and Dodge, the
wedge belt is very popular because it allows smaller sheaves to be used.
This permits higher operating speeds, lower cost components, and
increased efficiency. The wedge belt can also be used for higher power
applications than the other belts, which extends the range over which
belts can be used. Wedge belts are also called a narrow-series or
heavy-duty belts.
The increased power of the wedge belt comes mainly from a stronger
internal belt design which uses stronger tensile cords, and more of them,
as shown in figure 21.
The wedge belt also has a smaller tensile groove angle, which
increases the friction between the belt and sheave walls. This increase in
friction means that larger loads can be applied to the same size belts.
NEOPRENE
ENVELOPE
CORDING
RUBBER COMPOUND
CONVENTIONAL BELT WEDGE BELT
Figure 21. Typical Wedge V-Belt Construction

The wedge belt operates in a similar manner to the FHP and
conventional v-belt drives, and is designed for continuous operation.
The sheaves used for narrow-series v-belt drives are made of cast
iron and are often used with a bushing. These sheaves can also be
supplied with either a single groove or multiple grooves and can have
either solid construction or spokes.
Figure 22. Typical Sheave Construction for a Narrow V-Belt Drive
Wedge type v-belts are designated by a ‘V’ in their part number.

You will learn more about belt and sheave designations in the next LAP.

A TAPER LOCK BUSHING AND GIVE AN ADVANTAGE
dT
his The taper lock bushing, or taper bore as it is also known, is the third
Rea
type of tapered bore bushings. Originally developed by Dodge, the taper
lock bushing has a tapered barrel that is split but has no flange.
The taper lock bushing has semi-circular holes that match with
semi-circular holes in the hub. Two of the bushing’s holes are
unthreaded, but their counterparts in the hub are, as shown in figure 24.
This configuration forces the split in the bushing to close when
tightened, giving it strong holding power as clamps onto a shaft.
The other hole(s) in the bushing are threaded, whereas their
counterpart is not. These holes are used to remove the bushing.
NON-THREADED
HOLES
THREADED
HOLE
Figure 23. Taper-Lock Bushing

The split feature of the taper lock bushing allows it to contract as its
tapered barrel is drawn into the hub by set-screws as they are driven into
the unthreaded holes of the bushing. This creates the effect of a press fit,
which gives the bushing very good holding power on the shaft, like the
QD bushing. The difference is in how the taper lock bushing is drawn
into the hub.
The advantage of the taper lock bushing is that it fits flush with the
hub. The disadvantage is that it is easy to install it incorrectly. The
common mistake is to try to align the threaded hole of the bushing with a
threaded hole in the hub. There is only one arrangement where all holes
line up, preventing this mistake.
TAPER BORE SHEAVE

BUSHING
THREADED
SET SCREW 1/2 HOLE
NON SHAFT
THREADED
1/2 HOLE
TAPER
LOCK
BUSHING
Figure 24. Taper Lock Bushing Assembly

SKILL 3 INSTALL AND ALIGN A WEDGE V-BELT DRIVE SYSTEM
WITH A TAPER LOCK BUSHING
Procedure Overview
uses the wedge belt and a taper lock bushing.
These steps are similar to the steps you used in the
last skill, except for the split taper bushing. Although the
taper lock bushing is being used in this skill to attach a
wedge belt drive, it can be used to attach any other type of
hub as long as the hub is made for the taper lock.
This
❑ 1. Perform the following safety checkout to prepare for working with
Do


Power is off to machines in work area
Floor is not wet

switch

❑ 3. Perform the following substeps to set up the trainer.
should still be set up, as shown in figure 26. If not, repeat Steps
4-6 in Skill 1 to do so.
• 2.65 PD Wedge Sheave
• 4.45 PD Wedge Sheave
tion CAUTION
u
Ca
CAUTION Do not lubricate the bushing taper, the cap screws, the
sheave’s taper, or the threaded holes. This can cause the
sheave to break.
❑ 4. Perform the following substeps to mount the 2.65 PD wedge

sheave to the motor shaft using the taper lock bushing.
A. Clean the shaft key seat and bushing keyseat with a wire brush
to make sure that no dirt, paint, or burs are in the keyseats. File
away any burs if necessary. Clean off any grease as well.
B. Select a 3/16-inch square x 1-inch key from your key stock.

C. Slide the key into the bushing’s inner keyseat. It should slide in
without forcing it and have no play.
D. Remove the key from the bushing and insert it into the shaft
keyseat. It should also slide in without forcing it.
E. Line up the key so that it is flush with the end of the shaft.
F. Locate the 2 hex socket set screws that will be used to mount
the sheave.
G. Place the bushing into the sheave hub and align the threaded
sheave holes with the non-threaded bushing holes, as shown in
figure 26.
NON-THREADED
BUSHING HOLES
THREADED
BUSHING HOLE
Figure 26. Alignment of Threaded and Non-Threaded Holes
H. Insert the two set screws into the two holes where the bushing
is non-threaded and the hub is threaded, as shown in figure 26.
I. Tighten the set screws just enough to engage the threads.
J. Hold the assembly so that the set screws are facing towards you
and align the loosely assembled sheave and bushing with the
motor shaft and key.
K. Slide the assembly onto the shaft until the shaft is flush with
the bushing.

L. Use an Allen wrench to tighten the set screws to the
recommended level, as given by the following table.
tion CAUTION
u
Ca
CAUTION
Do not tighten the bolts any tighter than the recommended
level. This can cause the bushing or sheave to crack.
SET SCREW TORQUE

BUSHING NUMBERS (in-lb)
1008, 1108 55
1210,1215,1310 175
1610,1615 175
2012 280
2517, 2525 430
3020, 3030 800
3535 1000
4040 1700
4545 2450
5050 3100
6050, 7060, 8080 7820
10086, 12010 13700
❑ 5. Repeat Step 4 in a similar manner to mount the 4.45 PD sheave to

the driven shaft.
❑ 6. Use a straight edge to check the sheaves’ alignment. Use the lead
screws to adjust as needed.
❑ 7. Select the wedge belt. It is labeled 3V 355 or 3V X355.
❑ 8. Move the motor towards the driven shaft until the wedge belt can
be placed on the sheaves.

Belt Deflection Force Range ______________________(lbs/N)
Belt Size 3V
Belt Age New
You should have calculated a belt deflection force range of

5.1-7.65 lbs.
B. Loosen the locking nuts holding the motor to the base.
C. Use a wrench to rotate the lead screws until the belt is springy
when struck.
D. Retighten the locking nuts.
E. Check the sheave alignment again with a straight edge.
Use the lead screws to correct any misalignment.
F. Use the 36-inch rule to measure the belt span.
Belt Span ____________________________________(in/mm)
G. Calculate the amount of deflection for your v-belt drive.
H. Use a tension tester and a straight edge to measure the force
deflection. Record it.
Force scale reading: ____________________________(lbs./N)
I. Compare your force reading with the force range you
calculated in substep A.
within the range you calculated.

A. Connect the motor’s power cord to the Motor Control Unit.
B. Make sure that the Motor Control Unit’s power cord is plugged
into a wall outlet.
position.
WARNING
ning
W


turn on.
H. Turn on the Constant Speed Motor by moving the power switch
allow the belts to seat.
❑ 14. Repeat step 9 again to test the tension of the belt. Record your
reading.
after 24-48 hours.
❑ 20. Remove the belt, being careful not to force it.

❑ 21. Perform the following substeps to disassemble the motor shaft’s
sheave and taper lock bushing.
NON-THREADED
BUSHING HOLE
THREADED
BUSHING HOLE
Figure 27. Threaded Holes for Removal of Sheave and Bushing
A. Loosen and remove the set screws from the bushing.

B. Install one set of the set screws into the threaded hole on the
bushing side.
C. Use the hex key to turn the set-screw until the sheave breaks
loose from the bushing.
The set screw acts as a jackscrew to separate the bushing and
the sheave. The bushing and the sheave can now be removed
from the motor shaft.
D. Replace the set screws in the bushing before returning it to the
storage panel.
❑ 22. In a similar manner, remove the driven sheave and bushing.
❑ 23. Leave the motor, mounting base, and shaft/ pillow block assembly

A NOTCHED V-BELT AND GIVE AN ADVANTAGE
dT
his The three types of v-belts (FHP, conventional, and wedge) were
Rea
originally designed with a smooth surface that is completely covered by
the exterior covering, usually neoprene. This design is still used, but
another option called a notched belt, or cog belt, is now becoming more
popular. The cog belt design uses notches in the bottom on the belt with
exposed rough edges on the sides, as shown in figure 28.
COGGED, RAW-EDGE BELT
TENSION
SECTION
POLYESTER
CORDS
RAW-EDGE
SIDEWALLS
COMPRESSION SECTION COGS
Figure 28. Notched Belt Design with Rough Edge

The notches allow the belt to better transfer heat, which makes them
last longer and handle higher loads. The notches also allow the belt to
bend around smaller sheaves, thus allowing them to be used with higher
pulley ratios.
The rough edge design creates more gripping force, which when
combined with the notch design, enables this belt to handle
approximately 30% more power than a classical v-belt.
All three types of v-belts are available with the cog design. They use
the same sheaves as non-cog v-belts. Cog belts also use the same parts
numbering systems with the addition of an “X” in the designation.
Another variation of the cog belt is to use a kevlar wrap on the
outside of the belt instead of an exposed rough edge. The rough texture
of the kevlar also helps grip the sheave.
At this point, you may be wondering why anyone would use the
smooth classical v-belt. One reason is that it may be used on other
machines in the plant and the company is keeping them for their
compatibility and versatility. Another reason is the smooth feature of the
classical belt causes the belt to slip if the load gets too high. This can be
used as an overload safety. This is not a recommended method, but some
people use it anyway.

SKILL 4 INSTALL AND ALIGN A NOTCHED V-BELT DRIVE SYSTEM
Procedure Overview
uses a notched v-belt. You will see that this belt operates
in a similar manner to the smooth belts.
Do


Floor is not wet

switch
should still be set up. If not, repeat Steps 4-6 of Skill 1 to do
so.
• 1 Groove 3.4” PD Sheave
• 1 Groove 4.4” PD Sheave
❑ 4. Assemble the 3.4 PD sheave onto the motor shaft using the QD
bushing.
❑ 5. Assemble the 4.4 PD sheave onto the driven sheave using the QD
bushing.

❑ 6. Use a straight edge to check the alignment of the sheaves.
If necessary, loosen the bolts on the motor mount and readjust the
position.
This
tic
e
NOTE
No
The cog belt uses the same sheaves as does a smooth belt.
❑ 7. Obtain the cog belt from the storage unit. It is labeled BX36.
❑ 8. Move the sheave centers together using the adjustable mount, and
mount the cog belt loosely on the sheaves.
Belt Size B
Belt Age New
Minimum Belt Deflection Force Range______________(lbs/N)

B. Adjust the motor’s position on the adjustable mounting base
until the belt tension appears to be springy when you strike it
with your hand.
C. Check the sheave alignment again with a straight edge.
If there is any misalignment, use the lead screws to correct it.
D. Use the 36-inch rule to measure the belt span.
E. Calculate the amount of deflection for your v-belt drive.
F. Use a tension tester and a straight edge to measure the force
Force scale reading: ____________________________(lbs/N)
G. Compare your force reading with the force range you
within the allowable range.
Control Unit.
B. Make sure that the Motor Control Unit’s power cord is plugged
into a wall outlet.

position.
WARNING
ning
W
in place. Also, do not attempt to open or bypass the guard at any
time during operation. Performing any of these actions will create
a hazardous situation.

turn on.
H. Turn on the Constant Speed Motor by moving its power switch
allow the belt to seat.
❑ 14. Repeat Step 9 again to test the tension of the belt. Record your
reading.
❑ 20. Adjust the position of the motor so that the belt is loose on the
sheaves.
❑ 22. Disassemble the sheaves and QD bushings.

SEGMENT 3
SELF REVIEW
r This
we
Ans
1. The wedge v-belt is designed to transmit equal power as the
conventional belt, but does it with a belt with a _____ %
smaller cross sectional area.
2. A wedge v-belt system allows smaller __________ to be

used.
3. The advantages of a wedge v-belt system are that it permits

_________ operating speeds, __________ cost components,
and better efficiency.
4. A tapered bushing that has no flange on it is called a

_________ _________ bushing.
5. One advantage of a taper lock bushing is that is fits

__________ with the hub.
6. V-belts can have __________ in them that allow the belt to

be use on smaller sheaves and higher pulley ratios.
7. _____________ v-belts are v-belts that have a notched

surface.
8. One advantage of a notched v-belt is that it _____________

heat better than regular belt.

SEGMENT 4
VARIABLE SPEED V-BELT DRIVES
OBJECTIVE 9 DESCRIBE THE OPERATION OF A VARIABLE SPEED V-BELT

DRIVE SYSTEM AND GIVE AN APPLICATION
his
dT A variable speed drive is a type of v-belt drive whose speed is varied
Rea
by changing the pitch diameter of one or both of the sheaves. The

changing of the pitch diameter of the sheaves is accomplished by a
specially designed sheave, similar to the one shown in figure 29.
THREADED HUB
1/2 OF SHEAVE
(MALE)
1/2 OF SHEAVE
(FEMALE)
Figure 29. A Typical Variable Pitch Sheave
Usually, a variable pitch sheave is made of two halves, as shown in

figure 29. One half threads onto the other by using male and female
threaded counterparts. The distance between the two sheave halves is
adjusted by turning one sheave half either clockwise or
counterclockwise. This either increases or decreases the pitch diameter
of the sheave.

Another variation of the variable pitch sheave is shown in figure 30.
This design changes the pitch diameter of the driven sheave by pulling
the sheave centers apart, forcing the spring loaded sheave to spread out.
SPRING LOADED
DRIVEN SHEAVE
LOW SPEED HIGH SPEED
DRIVER SHIFTING
SHEAVE MECHANISM
Figure 30. Increasing and Decreasing the Pitch Diameter of a Variable

Pitch Sheave
As you have already learned, the speed and torque of a v-belt drive
depends on the ratio of the driver and driven pitch diameters. By
changing the pitch diameter of one or both of the sheaves, you can
change the speed and torque characteristics of the drive without having
to completely change the sheaves themselves.
Variable speed v-belt drives can be used on most any machinery that
uses a belt drive system. But, they are most often used in fan systems to
change the speed in which the fan operates to match seasonal conditions.
They are also used in conveyor belt systems to either increase or
decrease the output of the conveyor.
For most variable speed applications, a single variable speed sheave
is suitable, but both sheaves can be variable when a wider range of
speed and torque is required.

OBJECTIVE 10 DESCRIBE HOW TO INSTALL AND ALIGN A VARIABLE SPEED
V-BELT DRIVE SYSTEM
his
dT The installation of a variable speed v-belt drive system is much the
Rea
same as that of any other v-belt drive, with a minor change in the
alignment procedure. To install a variable speed v-belt drive, you should
follow the same step-by-step procedure you did for the installation of all
of the other v-belt drives until you reach step 4.
Step 1. Mount the motor and the driven components, level their
shafts, and check for run-out
• The motor is mounted and its shaft is leveled
• The driven shaft is mounted and leveled
• Both shafts are checked for run-out
Step 2. Inspect the sheaves for cleanliness and wear. Clean or

replace if necessary.
• The sheaves are inspected to determine if they are suitable for use
• Damaged sheaves, which can harm belts, are discarded
• Any dirt, oil, or grease is removed from the sheaves
Step 3. Mount the sheaves onto the shafts.

• The sheaves are mounted to the shafts
• They are checked for run-out
e This NOTE
tic
No
The next step is where the installation procedure of a variable

speed v-belt drive differs from that of any other v-belt drive.

Step 4. Align the sheaves
The alignment of the sheaves in a variable speed v-belt drive differs
from the alignment of any other v-belt drive because of the special
sheaves. In most v-belt drives, the sheaves are matched with each other.
In variable speed drives, the sheaves may or may not be matched with
each other, as shown in figure 31.
W1 VARIABLE
PITCH SHEAVE
100
90
80
70
60
50
40
30
MOTOR
20
10
W2 FIXED
SHEAVE
Figure 31. A variable pitch sheave may not match its counterpart
To align a variable speed drive, you should first align the drive as
you have before, as shown in figure 31.
Next, move the straight edge to the opposite side of the sheaves, and
measure the distance G, that the sheaves are offset.
MOTOR
Figure 32. The First Stage in Aligning a Variable Speed V-Belt Drive

Lastly, adjust the position of the driver sheave so that the offset G is
divided equally on both sides of the narrower sheave as shown in figure
33. Shift the driver sheave by moving the motor the appropriate amount,
and in the appropriate direction, by loosening the motor’s mounting
bolts.
MOTOR
G/2 G/2
Figure 33. The Second Stage in Aligning a Variable Speed V-Belt Drive
e This
tic NOTE
No
The rest of the variable speed v-belt drive installation is the

same as before.
Step 5. Mount the belt

• The belt is mounted to the sheaves. This is usually accomplished
by moving the sheaves close together so the belt can be slipped
over them.
• Once the belt is mounted, the sheaves can then be moved apart
from each other.
Step 6. Apply initial tension to the belt

• The amount of tension required by the drive is calculated.
• The tension is adjusted to the result of the calculation.
• The tension is measured with a belt tension tester.
Step 7. Run the motor briefly to seat the belts

• New belts quickly stretch. Briefly running the drive stretches the
belt, allowing for more accurate tension measurements.
• Briefly running the drive allows the belt to settle into the sheaves.

Step 8. Stop the motor and retighten the belt to the correct
tension
• The now settled belt can be accurately tensioned.
Step 9. Retension the belt after 24 to 48 hours of operation

• After 24 to 48 hours of operation, the belt may need retensioning.
Step 10. Adjust the speed of the drive as it is needed

• When the application requires it, the speed of the variable speed
drive can be adjusted by adjusting one or both of the variable
speed sheaves.
• The motor must be secured. The belt is removed and the sheave is
adjusted as needed.
• The adjustment requires that the alignment procedure be
re-performed.
• The belt is installed and the drive put back into service.
SKILL 5 INSTALL AND ALIGN A VARIABLE SPEED V-BELT

DRIVE SYSTEM
Procedure Overview
In this procedure, you will install and align a v-belt drive
system that has a variable pitch sheave. You will also
change the pitch of the sheave and measure how it affects
the output speed of the drive.
Do


Floor is not wet

switch.
A. Continuing from the last skill, make sure that the trainer is set
up as shown in figure 34. If it is not, perform Steps 4 - 6 of
Skill 1 to make it so.
B. Obtain the following sheaves.

• Variable Speed Sheave (Belt Drive Panel 3)
• FHP 4.0 PD Sheave (Belt Drive Panel 1)

❑ 4. Inspect the fixed sheave and the variable pitch sheave for dirt, oil,
rust, or grease. If you find any foreign material on sheaves, clean
them.
❑ 5. Perform the following substeps to mount the variable sheave onto
the motor shaft.
These steps are the same steps you used to install the fixed bore
sheaves in a belt drive system.
A. Locate the two set screw holes which are drilled into the side of
the hub of the variable pitch sheave, as shown in figure 35. One
set screw is to secure the sheave to the shaft, the other set screw
secures the sheave halves together once the pitch has been
adjusted.
SET SCREW SET SCREW
Figure 35. The Set Screws of a Variable Pitch Sheave
B. Loosen the set screw that secures the sheave halves until the
two halves rotate freely with each other.

C. While holding one half of the sheave, turn the other half
clockwise until it comes to a stop. Then turn it
counterclockwise until the set screw is aligned with the first of
the two voids, as shown in figure 36.
VOID
Figure 36. The Voids for the Set Screw
CAUTION
tion Never tighten the set screw down onto the threads. This will
u
Ca
CAUTION destroy the threads, preventing the sheave from being

adjustable. There are two voids where the setscrew can safely
be tightened onto, as shown in figure 36.
D. Tighten the set screw to secure the two sheave halves together.
E. Use a hex key wrench to back out the hub set screw so that it is
not extending into the shaft hole.
F. Clean the motor shaft’s key seat and the sheave’s hub’s key
seat with a wire brush to make sure that no dirt or burrs are in
the keyseats.
G. Select a 3/16 square x 1 inch key from your key stock.
H. Slide the key into the keyseat of the motor shaft.
I. The key should fit into the keyseat without forcing it. If it is too
tight, take it out and measure it to see which part is out of
tolerance. Select another key from your stock and try it.
J. Check the key for play when it is in the keyseat by wiggling it.
K. There should be no play. If there is play, replace the key.

L. Remove the key from the shaft keyseat and insert it into the
sheave hub keyseat. It also should slide in without forcing it
and have no play.
M. Remove the key from the sheave hub and reinsert into the shaft
keyseat. Line it up flush with the end of the shaft just as you
did while mounting the brake drum.
N. Pick up the sheave and line it up in front of the motor shaft so
that the hub’s key seat is in line with the key on the shaft.
O. Then slide the sheave hub onto the motor shaft until the end of
the hub is flush with the end of the shaft, as shown in figure 37.
The hub should slide on without using tools. If it doesn’t, pull
it off and check the dimensions.
P. Tighten the set screw onto the key.
Figure 37. Position of the Sheave on the Drive Shaft

❑ 6. Mount the single groove 4.0 PD sheave to the driven shaft.
❑ 7. Perform the following substeps to align the two sheaves.
A. Place the straight edge across the fronts of the sheaves and
align them as you have done in previous skills.
B. Move the straight edge to the backside of the sheaves.
C. Using a machinist’s rule, measure and record the total offset, as
shown in figure 32.
Total Offset: __________________________________(in/mm)
D. Divide the total offset you measured in the last substep by 2.
The result is the amount the driver sheave needs to be shifted to
align the sheaves.
E. Shift the driver sheave the required amount.
❑ 8. Perform the following substeps to mount the belt.
❑ 9. Calculate the allowable belt deflection force range for the
Belt Deflection Force Range _________________________(lbs/N)
Belt Size A
Belt Age New
❑ 10. Tension the belt.

❑ 11. Check the sheave alignment again with a straight edge.
If there is any misalignment, loosen the belt and adjust the motor
position to correct it.
❑ 12. Use the 36-inch rule to measure the belt span.
❑ 13. Calculate the amount of deflection for your v-belt drive.
Deflection distance: ______________________________(in/mm)
❑ 14. Use a tension tester and a straight edge to measure the force
❑ 15. Compare your force reading with the force range you calculated in
Step 9.
Readjust the tension if necessary until the force reading is within
the allowable range.

Control Unit.
B. Make sure that the safety switch power cord is plugged into a
wall outlet.
position.
WARNING
ning
W


turn on.
❑ 17. Use the tachometer to measure the output speed of the drive.
Record the result in the blank below.
Output speed: _____________________________________RPM
❑ 19. Perform a lockout/tagout on the safety switch and remove the
guard.
❑ 20. Perform the following substeps to change the pitch of the variable
pitch sheave.
A. Loosen and remove the belt.
B. Loosen the set screw that secures the two sheave halves
together.
C. Rotate the loosened sheave half three complete turns,
counterclockwise.
D. Make sure that the set screw is positioned over one of its voids,
then tighten the set screw to secure the sheave halves together.
E. Repeat Step 7 to align this new sheave arrangement.
❑ 21. Reinstall the belt and check its tension.

❑ 24. Start the motor and observe the drive.
❑ 25. Use the tachometer to measure the output speed of the drive and
record the result below.
Output speed: _____________________________________ RPM
You should see that the output speed has changed.

❑ 27. Perform a lockout/tagout on the safety switch and remove the
guard.
❑ 28. Perform the following substeps to change the pitch of the variable
pitch sheave again.
A. Loosen and remove the guard.
B. Loosen the set screw that secures the two sheave halves
together.
C. Rotate the loosened sheave half three more complete turns,
counterclockwise.
D. Make sure that the set screw is positioned over one of its voids
then tighten the set screw to secure the sheave halves together.
E. Repeat Step 7 to align this new sheave arrangement.
❑ 29. Reinstall the belt and check its tension.
❑ 33. Using the tachometer to measure the output speed of the drive and
record the result below.
Output speed: _____________________________________RPM
❑ 36. Compare the three output speeds that you recorded in the previous
steps to see how the variable pitch sheave varies the output speed
of a v-belt drive system.
❑ 37. Adjust the position of the mounting base so that the belt is loose on
the sheaves.
❑ 38. Remove the belt and both sheaves and store them.

in place, as shown in figure 38. You will use them in the next skill.
Return all other components to their proper storage.
Figure 38. Current Arrangement of the Mechanical Trainer

SEGMENT 4
SELF REVIEW
r This
we
Ans
1. A ________________ v-belt drive is one that uses one or
two variable pitch sheaves.
2. Changing the __________ ___________ of one or both of

the sheaves can change the speed and torque of a drive.
3. Turning one of the sheave halves ________________

increases the pitch of a variable pitch sheave.
4. You should never tighten the set-screw that secures the two
sheave halves onto the ___________ of the sheave.
5. The proper alignment of a variable speed drive is when the

offset is _____ of the total offset between the sheaves.

SEGMENT 5
V-BELT CONFIGURATIONS
OBJECTIVE 11 DESCRIBE FOUR V-BELT CONFIGURATIONS

AND GIVE AN APPLICATION OF EACH
dT
his The v-belt configuration describes the orientation of the two sheaves
and how power is transferred. Four of the types of configurations you
Rea
will encounter are shown in figure 39.
ANGLE
OPEN
SERPENTINE
QUARTER TURN
Figure 39. Types of V-Belt Configurations

Each of these configurations is described as follows:
Open Configuration
The open configuration is the one you have already used. In this
configuration, the shafts are parallel with each other. The open
configuration is the most common, and is used in nearly any application
that a v-belt drive can be used for. A simple fan system is one of the
many applications in which the open configuration is used.
Quarter Turn Configuration

In this configuration, the driven shaft is turned 90 degrees to the
driver shaft. This allows the power to be transferred to a vertical shaft.
These types of configurations are often found in conveyor systems.
Angle Drive
The angle drive uses two idler pulleys to turn the belt so that the
driven shaft is turned 90 degrees and in a different horizontal plane to the
driver shaft. These types of configurations are often found in complex
conveyor systems and in farm equipment.
Serpentine Configuration
In this configuration, the belt turns more than one driven sheave.
This requires that it actually reverse itself to go around an idler pulley,
which maintains tension on the belt. It also requires the use of a special
belt that has a v-shape on both sides, as shown in figure 40. This is called
a hex belt or double v-belt.
The serpentine configuration is found on most automobile engines.
Figure 40. Hex Belt Cross Section

OBJECTIVE OBJECTIVE 12 DESCRIBE THE FUNCTION OF A BELT IDLER PULLEY
AND GIVE AN APPLICATION
dT
his
An idler pulley, or idler wheel, is a third pulley that is used in a
Rea
v-belt drive to either add tension to the belt, keep long belts from
whipping, or automatically adjust tension under varying loads.
Idler pulleys are used to add tension when the driver and driven
sheaves do not have adjustable mounts. This is not recommended,
however, because it adds stress to the belt which will cause it to wear
more quickly. Its more common application is to reduce vibration and
whipping with long belts.
FLANGED
BEARING
IDLER
PULLEY
Figure 41. Idler Pulley and Bearing

OBJECTIVE 13 DESCRIBE THE OPERATION OF THREE TYPES OF
BELT IDLER PULLEY CONFIGURATIONS
his
dT
Idler pulleys are used in three configurations:
Rea
• Inside Idler
• Backside Idler
• Kiss Idler
An idler pulley configuration describes the position and the amount
of tension placed on the belt by the idler. In all three cases, the idler
pulley is mounted between the driver and driven sheaves on some type of
adjustable height mount. This gives it the ability to have its position
relative to the belt adjusted to change the tension, as shown in figure 42.
The idler pulley is usually made with a roller bearing built into its
hub so that it can turn freely. It is mounted using an adjustable bracket or
arm of some type. The idler pulley does not drive a shaft.
IDLER
PULLEY
Figure 42. Pulley and Bracket

In most cases, it is recommended that the idler pulley be mounted to
the slack side of the belt. This is the side that is connected to the point
where the belt leaves the driver pulley, as shown in figure 43. The
opposite side is the tension side.
SLACK IDLER
SIDE
DRIVER
TENSION SIDE
DRIVEN
Figure 43. Idler Pulley Mounted to Slack of Belt
The details of each configuration are explained as follows:
Inside Idler
The inside idler is designed to add tension to the belt by placing the
idler on the inside of the belt, as shown in figure 44. Tension is added by
positioning the pulley so that it pushes out on the belt.
INSIDE IDLER PULLEY
Figure 44. Inside Idler

The inside idler is placed near the larger sheave, so that it does not
reduce the arc of contact with the smaller sheave. The idler pulley is
sized so that it the same size or larger than the smaller sheave.
Backside Idler
The backside idler is designed to add tension to the belt by placing
the idler on the outside of the belt, as shown in figure 45. Tension is
added by positioning the pulley so that it pushes in on the belt.
BACK SIDE IDLER
Figure 45. A Backside Idler Configuration
The backside idler pulley is placed near the smaller sheave because it
increases the arc of contact. This helps keep it from slipping on the
smaller sheave. The disadvantage of this method is that is creates a
reverse bend on the belt, which can cause it to wear out more quickly.
The design of the sheave for a backside idler uses a non-grooved
pulley because it is in contact with the flat side of the belt. It is sized to
be 1.5 times the diameter of the smaller sheave.

Kiss Idler
The design of the kiss idler is similar to the backside idler in that it is
placed on outside of the belt, as shown in figure 46. The difference is
that the kiss idler does not deflect the belt to create tension. Instead, it is
gently contacts the belt along it normal path so that any vibration or
whipping of the belt is reduced.
BACK SIDE IDLER
Figure 45. A Backside Idler Configuration
Like the backside idler, the kiss idler has a non-grooved surface and
is chosen to be 1.5 times the diameter of the smaller sheave. Its
placement, however, is usually near the middle of the belt instead of near
one of the sheaves.
Because the kiss idler does not place tension on the belt, it does not
cause high wear and is therefore recommended for any application that
uses long belts.

SKILL 6 INSTALL AND ADJUST A BACKSIDE V-BELT IDLER
Procedure Overview
In this procedure, you will install a backside idler pulley
to a belt drive. This will show you an alternate method of
tensioning the belt.
This
Do


Floor is not wet

switch.

should still be set up, as shown in figure 47.

❑ 4. Mount the 3.4 PD sheave on the motor shaft and 4.4 PD sheave on
the driven shaft.

❑ 5. Locate Chain Drive Panel 2 and place it on the overhead rack. This
panel contains the idler stand used to mount both the chain and
belt idlers.
❑ 6. Perform the following substeps to assemble and mount the
backside idler
A. Mount the idler pulley to the idler bracket, as shown in figure
49. Use the large screw and T-nut to secure it to the bracket.
1/4-20 ADJUSTMENT SCREW
FLANGED BUSHING
IDLER
PULLEY
T-NUT
5/8-11 SOCKET HEAD

CAP SCREW
IDLER BRACKET
Figure 49. Backside Idler Assembly

The assembled backside idler should appear as shown in figure
50.
IDLER
PULLEY
Figure 50. Backside Idler

B. Position the idler bracket assembly over the holes in the
950-ME trainer work surface, as shown in figure 51.
C. Locate two 3/8-16 x 1-1/2 hex head cap screws and compatible
flat washers, lock washers, and nuts.

D. Attach the idler bracket to the work surface by assembling the
fasteners. Hand tighten only. Leave the idler pulley at its lowest
position.
Figure 51. Idler Pulley Mounted to Work Surface
E. Use a straight edge to align the idler pulley with the belt
sheaves. Center it with the other pulleys.
F. Once the idler pulley is aligned, finish tightening its mounting
bolts.

❑ 7. Obtain the B belt from the storage unit. It is labeled B37.
❑ 8. Place the belt onto the sheaves, as shown in figure 52.
Figure 52. Belt Installed with Backside Idler
❑ 9. Adjust the adjustable motor mount until the distance between

centers is 12-3/4 inches. Then lock the base in place by tightening
the setscrews.
A. Calculate the belt deflection distance.
Deflection distance _______________________________ (in)
B. Use figure 12 to calculate the belt deflection force range.
Belt deflection force range _______________________ (lbs/N)
C. Use a 7/16 wrench to raise the idler pulley until the belt is
properly tensioned.

Control Unit.
wall outlet.
position.
WARNING
ning
W


turn on.
The motor should coast to a stop.
❑ 14. Repeat step 10 again to test the tension of the belt. Record your
reading. Adjust the belt tension, if necessary, using the backside
idler.
❑ 20. Loosen the set-screws on the adjustable mounting base and adjust
the position so that the belt is loose on the sheaves.

❑ 22. Leave the remaining components assembled. You will use them in
the next skill.
SKILL 7 INSTALL AND ADJUST A KISS V-BELT IDLER
Procedure Overview
In this procedure, you will install and align a power
transmission system using a long v-belt to observe
whipping of the v-belt during operation. You will then
adjust the kiss idler pulley to eliminate the whipping of the
This power transmission equipment. Make sure that you are able to
Do


Floor is not wet
switch
❑ 3. Disassemble the adjustable motor mount/motor assembly and the
driven shaft assembly from the trainer work surface.

❑ 4. Position the adjustable motor mount assembly and the driven shaft
assembly over the holes in the work surface as shown in figure 53.
Note that the narrow flange on the motor mount assembly is
nearest the edge of the trainer worksurface.
NARROW FLANGE
MOTOR
❑ 5. Level both shafts and check for run-out. Make adjustments as

necessary.
❑ 6. Install a 2.0 PD FHP sheave on the driver shaft and a 4.0 PD FHP
sheave on the driven shaft. Then align the sheaves using the
straight edge.
If necessary, loosen the bolts on the motor’s mounting base and
readjust the position.

❑ 7. Install the prony brake, as shown in figure 54.
MOTOR
HUB
PRONY BRAKE
Figure 54. Prony Brake Installation
❑ 8. Obtain the 58-inch “A” belt from the storage unit. It is labeled A58
(4L600).

❑ 9. Move the sheave centers together and mount the 58-inch belt
loosely onto the sheaves, as shown in figure 55.
MOTOR
Figure 55. V-Belt Installation
❑ 10. The installation should now appear, as shown in figure 56.
Figure 56. V-Belt Installation

application shown in figure 57.
Belt Size A
Belt Age New
Figure 57. Belt Application
Use the Belt Deflection Force Table in figure 12 to determine

the allowable belt deflection force range.
Belt Deflection Force ____________________________(lb/N)

B. Turn the screws on the adjustable mounting base until the belt
tension appears to be springy when you strike it with your
hand.
C. Check the sheave alignment again with a straight edge.
If there is any misalignment, loosen the belt to correct it.
D. Use the 36-inch rule to measure the belt span.
E. Calculate the amount of deflection for your v-belt drive.
F. Use a tension tester and a straight edge to measure the force
Force scale reading: _____________________________(lbs/N)
G. Compare your force reading with the force range you
between the minimum force and 1.5 times the minimum.
Control Unit.
wall outlet.
position.
turn on.

I. Adjust the prony brake to 56 ounces.
The motor should coast to a stop.
❑ 14. Perform lockout/tagout and install the guard.
❑ 15. Repeat Step 14 again to test the tension of the belt. Record your
reading.
after 24-48 hours.
You should observe that the belt whips. This shows the need for a
kiss idler for longer belts.
❑ 20. Assemble the kiss idler assembly as shown in figure 58.
1/4-20 ADJUSTMENT SCREW
FLANGED BUSHING
IDLER
PULLEY
T-NUT
5/8-11 SOCKET HEAD

CAP SCREW
IDLER BRACKET
Figure 58. Kiss Idler Assembly

❑ 21. Install the kiss idler assembly on the trainer work surface as shown
in figure 59. Note that the position of the kiss idler assembly is
raised using two stacks of two pillow block bearing standoffs and
two 3/8-16 x 7 hex head bolts.
MOTOR
TWO
STANDOFFS
Figure 59. Kiss Idler Installation
❑ 22. Use the straight edge to align the idler pulley with the drive
sheave. Lock the idler pulley into its position.
❑ 23. The installation should now appear as shown in figure 60.
Figure 60. Kiss Idler V-belt Installation

❑ 24. Use a 7/16 wrench to adjust the height of the idler pulley so that it
contacts the belt but does not apply much pressure.
WARNING
ning
W ar Do not operate the mechanical drive system without the guard

❑ 27. Turn on the motor and observe the drive.
You should observe that the belt does not whip.
❑ 30. Adjust the position of the mounting base so that the belt is loose on
the sheaves.
❑ 32. Disassemble the sheaves.
❑ 33. Remove all components from the work surface and return them to
their proper storage areas.

SEGMENT 5
SELF REVIEW
r This
we
Ans
1. There are ____ basic types of v-belts configurations.
2. The ________ configuration is when the two shafts are

parallel, as you have worked with throughout this LAP.
3. The quarter turn configuration allows the driven shaft to be

turned _____ degrees to the driver shaft.
4. A variation of the quarter turn drive that uses two idler

pulleys to enable the driven shaft to be in a different plane
than the driven shaft is called a(n) _________ drive.
5. A _____________ configuration allows more than one

driven sheave to be operated by one belt.
6. A type of pulley that adds tension to a belt is called a(n)

___________ pulley.
7. Belt idler pulleys can be used in ______ basic types of

configurations.


Mechanical Drives 2 Lap 1

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MECHANICAL

HEAVY DUTY V-BELT DRIVES

HEAVY DUTY V-BELT DRIVES

950-ME1 Mechanical Drives 1 Learning System

Amatrol or school Supplied

FIRST EDITION, LAP 1, REV. C

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

SEGMENT 1 CONVENTIONAL V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SEGMENT 2 MULTIPLE V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SEGMENT 3 WEDGE V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SEGMENT 4 VARIABLE SPEED V-BELT DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SEGMENT 5 V-BELT CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

OBJECTIVE 1 DESCRIBE THE FUNCTION OF A BUSHING

to their respective shafts. The bushing serves several purposes:

Figure 1. Sheave Bushing

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

OBJECTIVE 2 DESCRIBE THE CONSTRUCTION AND OPERATION OF

Figure 2. QD Bushing Assembly

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Figure 3. The Forward Method of Installing a Bushing

The other method of mounting a QD bushing is to pass the bolts

Figure 4. The Reverse Method of Mounting a Bushing

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

OBJECTIVE 3 DESCRIBE THE CONSTRUCTION AND OPERATION OF

FHP v-belt drive, except that it is made for heavy-duty service. It is

Figure 5. Typical Conventional V-Belt Construction

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

CAST IRON SHEAVE

Figure 6. Typical Sheave Construction for a Conventional V-Belt Drive

The conventional v-belt is also called a standard multiple belt

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

power transmission equipment. Make sure that you are able to

YES/NO SAFETY CHECKOUT

❑ 2. Perform a lockout/tagout on the Motor Control Unit’s safety

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Figure 7. Positioning of Motor on 950-ME Work Surface

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

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Effective Level Length _________________________(in/mm)

Mounting Bolt Distance_________________________(in/mm)

Shim Ratio _________________________________________

Shim Thickness _______________________________(in/mm)

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Feeler Gauge Leaf Thickness_____________________(in/mm)

Effective Level Length _________________________(in/mm)

Mounting Bolt Distance_________________________(in/mm)

Shim Ratio _________________________________________

Shim Thickness _______________________________(in/mm)

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Figure 8. Set Screw on QD Bushing

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Manufacturers of QD bushings refer to the sheaves,

J. Insert the bolts with lock washers through the 3 thru-holes

Figure 9. Thru-Holes of the Bushing

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

Figure 10. Bushing Inserted into Hub of Sheave

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

be located between two bearings (i.e. an overhung shaft), it is

Figure 11. Bushing Assembled on Motor Shaft

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

BUSHING BOLT TORQUE SET-SCREW TORQUE

O. Use a wrench to tighten each of the bushing’s roll-up bolts

B503-XC LAP 1 HEAVY DUTY V-BELT DRIVES

4. Manufacturers use a _ to make sure that

5. A bushing differs from a QD