MAINTENANCE

MANUAL
Synchronous & V-Belts

www.megadynegroup.com/usa
 Founded in 1957 in
Mathi, Italy, Megadyne
is a manufacturer of
industrial belting for
power transmission,
product handling and linear positioning
applications.
Founded in 1958 in Fairfield, NJ, Jason
Industrial quickly gained a solid reputation as a
go to source for both industrial hose and power
transmission belts. Products, supported by
reliable stocks and knowledgeable customer
care quickly enabled Jason to become well
recognized as a solid partner to distributors
across the States. In 2007 Jason Indsutrial was
acquired by the Megadyne Group.
In 2018, the Megadyne Group joined with
Ammeraal Beltech to create AMMEGA.

AMMEGA – We Make Your Business Move.

WARNING: This document is recognized as a Maintenance Manual with its main
intent to be product application/installation/trouble-shooting use training. While this
is not a selling document, we do recognize some items include chemicals that are
on the California Prop 65 list. The chemicals identified within rubber v and timing
belts described through this manual include carbon black chemical ingredient
within the belt material. Additionally references to metal pulleys could include
lead. Both materials are identified in the California Prop 65 list effective August
30, 2018. For more information on CA Prop 65 visit www.P65Warnings.ca.gov.
For specific warnings related to the identified chemical refer to the shipping label
accompanying receipt of this product. Always wash your hand after handling belts,
pulleys and sheaves.

The following trademarks are registered in the United

States Patent and Trademark Office by their owners:
HTB® and Accu-Link® are registered trademarks of Jason Industrial
(Megadyne Group)
RPP® is a registered trademark of the Timken company (formerly Carlisle)
Poly Chain® and HTD® are registered trademarks of the Gates Corporation
ISORAN® is a registered trademark of Dayco Europe S. R. L.

B
 TABLE OF CONTENTS

Foreword

Why Preventive Maintenance is Important

Safety

Belt Storage

Best Practices

Using the Tension Tester Gauge

Belt Installation Checklist

Tensioning & Installation - V-Belts

Troubleshooting V-Belt Drives

Tensioning & Installation – Isoran RPP Synchronous Belts

Tensioning & Installation – Platinum Synchronous Belts

Troubleshooting Synchronous Belts

Flange Requirements – Synchronous Belts

Idler Usage – Synchronous Belts

Alignment

Belt Guard Design

Failed Belt Analysis – V-Belts

Failed Belt Analysis – Synchronous Belts

Ultimate Solution - Belt Drive Data Sheet

1
FOREWORD

FOREWORD
The implementation of a The majority of power
preventative maintenance transmission drive
program including proper problems are attributed to
belt drive installation, improper installation and
tensioning procedures maintenance. This manual
and best practices will is intended to provide
increase productivity, guidance in avoiding
reduce downtime and yield drive problems, extending
the additional benefit of drive life and maximizing
improved workplace safety. performance while
maintaining a safe working
environment.

NOTE:
The metal components used with v-belt and synchronous
belts are commonly referred to as pulleys. Where it’s
necessary to distinguish between the two, we refer to
v-belt pulleys as “sheaves” and synchronous pulleys as
“sprockets”. Where the information is the same for both
the term “pulleys” will be used.

2
 WHY PREVENTIVE MAINTENANCE

WHY PREVENTIVE MAINTENANCE

IS IMPORTANT
When compared to the cost drives” that are a constant
of production downtime and headache, requiring frequent
the labor costs associated attention and replacement.
with a belt failure, the cost
of a belt is relatively insignif- Additionally, it’s not uncom-
icant. Generally speaking, mon for a large industrial
at any given production fa- facility to spend thousands
cility, 80% of the downtime of dollars annually to deter-
related to power transmis- mine what type of replace-
sion belts can be found on ment belt is needed for a
20% of the drives in the particular drive. Worn belts
plant. In other words 80% are often difficult to identify
of the drives are working as their part numbers some-
fine, day in and day out. The times become impossible to
remaining 20% are “problem read after lengthy service.

LET US TROUBLE-SHOOT YOUR

PROBLEM DRIVES
Megadyne is uniquely Whether you have a
positioned to partner with low or high temperature
you to keep production at application, a need for
a maximum and “problem non-marking compound,
drives” at a minimum. electrical conductivity or
Megadyne is at your service resistance, silicone-free
to offer drive designs to product, special backings,
eliminate the problem chemical resistance or
drives in your facility. We ultra-high torque power
offer one of the widest transmission capability,
selections in the industry Megadyne can provide
of power transmission and a belt that will improve
product handling belts. performance on your
We can provide a vast application.
array of synchronous and
non-synchronous product Contact your Megadyne
in rubber or polyurethane. sales representative to work
Additionally, we can with you to trouble-shoot
customize belts for any your problem drives.
application imaginable.

3
SAFETY

WARNING: Failure to follow these

instructions may result in personal
injury or death!
Power transmission products are potentially dangerous.
Failing to follow recommended application information
and procedures for installation, care, maintenance and
storage of products may result in serious bodily injury or
death. Make sure that product selected for any application
is recommended for that service. Always follow the
recommendations of the original equipment manufacturer.
Contact Megadyne for specific information.

• Before doing any maintenance work on power

drives, ALWAYS switch off the power and lock-
out the drive. A tag should be attached stating
– Danger – DO NOT OPERATE.

• One should ALWAYS try to operate the

equipment after shutdown to make sure you
have locked-out the proper switchbox, ensuring
that the switchbox is operating properly and
also to release any stored energy.

• Use belt guards to provide protection for

personnel from contact with drive components.
NEVER test or operate belt drives without
guards in place.

• ALWAYS wear gloves to protect from sharp

edges and hot surfaces.

• NEVER wear loose or bulky clothing in close

proximity to an unguarded drive where it could
become entangled in the drive and cause injury
to personnel.

4
 SAFETY

WARNING: Failure to follow these

instructions may result in personal
injury or death!

• ALWAYS be aware of pinch points where hands

and fingers can be injured, especially where the
belt enters the sheave or sprocket.

• ALWAYS keep the area around the drive free of

clutter and debris.

• NEVER re-use damaged pulleys. They should

be replaced if not repairable.

• ALWAYS use static dissipating belts in

conjunction with industry approved methods to
dissipate electrical charges on drives used in
hazardous atmospheres.

• NEVER use Megadyne belts for aircraft

applications. Megadyne belts are not designed for
or intended for use on aircraft propellers, rotors
or accessory drives. Do not use on helicopters
or private, commercial, ultralight or any other
airborne aircraft application.

5
BELT STORAGE

BELT STORAGE
Proper belt storage is with protection from light,
the first step for good dirt and dust. Avoid high
performance and long ozone concentrations,
drive life. When belts are moisture, chemicals,
improperly stored they can solvents, fuels, lubricants,
be damaged and reduce and acids.
performance and product
life before they are even Ensure that belts are stored
installed. Properly stored in a stress-free way without
belts will not undergo excessive tension, pressure
significant changes in or other deformation
properties for several as this could result in a
years. However, exposure permanent deformation or
to extreme environmental the occurrence of cracks.
conditions will have a Belts must not be bent to
negative effect. Belts should avoid damage to the internal
be stored in dry conditions tensile reinforcements.

BELTS MUST BE STORED:

• In an environment between 40°F & 86 °F (5°C/30°C).
Extreme temperatures, in particular higher temperatures
can cause damage to the belt due to the deformation of
the superficial structure. These effects can lead to reduced
performance. Belts could swell and not run straight and
smooth. Lower temperatures are also not suggested and
cause an undesirable increase in stiffness of the belt.

• Away from equipment generating ozone, such as high

voltage electrical machines or fluorescent light sources. Also
combustion gases and vapors that can cause ozone should
be avoided.

• In a dry place. Storage rooms must be kept free from

moisture. The humidity must not exceed a maximum of
50%. Polyurethane and rubber belts have hygroscopic
properties and will absorb moisture. This can cause
deterioration of the compound and oxidation of steel tensile
cord. Storage in excessively high humidity will reduce belt life.

6
 BELT STORAGE

BELTS MUST BE STORED:

• With original packaging intact until the belt is ready to be
used. The packaging delivered by Megadyne is designed to
provide protection from environmental conditions.

• In a way that protects against light, particularly against

direct sunlight and artificial light with a high ultraviolet
concentration.

• To ensure they are not crimped or bent in handling or

storage. Belt damage occurs when bent to a diameter
smaller than the minimum recommended pulley diameter for
a particular belt. Use a crescent shaped saddle rather than
a peg or hook to lessen the amount of bend when hanging
v-belts from walls. Synchronous timing belts should never be
hung from a peg. They are best stored laid flat on a shelf.

7
BEST PRACTICES

INSPECT PULLEYS
A stiff brush can be used to
remove rust and dirt. Use a
soft cloth to wipe off oil and
grease.

For the sprockets used

on synchronous timing
belt drives the tolerance is
normally minus zero, plus a
few thousandths of an inch.
If you can visually detect
or feel any wear, it is worn
beyond the tolerance range
and should be replaced.

SHEAVE GAUGES/INSPECTION
For V-belts select the proper As a general rule, the worn
sheave groove gauge and sheave will most likely be
template for the sheave the smallest sheave in the
diameter. Insert the gauge drive. This is referred to as
in the groove and look for the “critical” sheave, the
gaps that indicate dishing or most likely to slip. All life
other abnormal wear. calculations and total drive
performance is based on the
• You should not see a gap critical sheave. On a typical
between the belt sidewall speed reduction two sheave
and the sheave sidewall. drive, the driver (critical)
sheave will be replaced
• If more than a 1/32” gap is many more times than the
present the sheave should driven sheave.
be replaced. (This is 1/64”
for banded belts.)

LIKE THIS NOT THIS

.0
Ov FD
38

°
17

36
er
°

to
17

FD

.0

Standard
.0

13

Section

FD
12.0 to 12.99
34°

8
 BEST PRACTICES

IDENTIFY THE CORRECT BELT

V-Belt - Always select the correct cross section of v-belt
to match sheave grooves. Use a sheave groove gauge to
determine the correct belt cross section. Use a v-belt gauge
to verify v-belt cross section and length when markings are no
longer legible on the belt back.
0.66”
0.50”
0.38”
4L 5L
3L

0.41”
0.31”
0.22”

40° 40° 40°

1.50”
1.25”
0.66” 0.88”
0.50” E
D

1.00”
C

0.75”
A B
0.53”
0.41”
0.31”

40° 40° 40°

40° 40°

0.88”
0.66”
0.50”
CX
BX

0.53”
0.41”

AX
0.31”

40° 40°
40°

1.00”
0.63”
0.38”
8V
5V
0.88”

3V
0.53”
0.31”

38° 38°
38°

0.63”
0.38”

5VX
0.53”

3VX
0.31”

38° 38°

Part Number Approximate

V-Belt Type Identified By Example Outside Length
Fractional HP (FHP) Effective Length 4L500 =
Standard Length
Classical Multi-Plus A48 =
Designation
Fractional HP Effective Length 5L500 =
Classical Multi-Plus
Standard Length
Designation
B47 = 50"
Standard Length
Classical Cogged AX48 =
Designation
Narrow Deep Wedge/
Effective Length 5V500/5VX500 =
Cogged
NOTE: Length information values in the above table are approximate. Industry
standards require that to accurately measure a belt, it must be installed on a fixture with
two pulleys of prescribed dimension and tensioned to a specific value. Accurate values
cannot be measured by hand on a free length of belt.

9
BEST PRACTICES

SYNCHRONOUS BELT
Confirm that belt pitch (distance between the teeth) and belt
tooth profile (shape of the belt tooth) are compatible with
those of the corresponding sprocket.

Trapezoidal Parabolic Curvilinear

Synchronous Belt Identification

Tooth Belt
in or Pitch Sprocket
Belt Type / Pitch Code Service Duty Height Height
mm (P) Compatibility
(ht) (H)
Trapezoidal
mini-extra standard
MXL in 0.080 0.020 0.045
light timing
standard
XL extra light in 0.200 1/5 0.050 0.094
timing
standard
L light in 0.375 3/8 0.075 0.140
timing
standard
H heavy in 0.500 1/2 0.090 0.173
timing
standard
XH extra heavy in 0.875 7/8 0.250 0.448
timing
extra extra standard
XXH in 1.250 1-¼ 0.375 0.600
heavy timing
Parabolic

RPP 3®
high torque mm 3 1.15 2.40 RPP® / HTD®

RPP® 5 high torque mm 5 2.00 3.80 RPP® / HTD®

RPP® 8 high torque mm 8 3.20 5.40 RPP® / HTD®

RPP® 14 high torque mm 14 6.00 9.70 RPP® / HTD®

RPP® Silver2 extra high

mm 8 3.20 5.40 RPP® / HTD®
8M torque
RPP® Silver2 extra high
mm 14 6.00 9.70 RPP® / HTD®
14M torque
RPP® Gold super high
mm 8 3.20 5.40 RPP® / HTD®
8M torque
RPP® Gold super high
mm 14 6.00 9.70 RPP® / HTD®
14M torque
ultra high RPP® / HTD® /
RPC Platinum 8M mm 8 3.46 5.40
torque Poly Chain®
ultra high RPP® / HTD® /
RPC Platinum 14M mm 14 6.10 9.70
torque Poly Chain®

10
 BEST PRACTICES
Synchronous Belt Identification
Tooth Belt
in or Pitch Sprocket
Belt Type / Pitch Code Service Duty Height Height
mm (P) Compatibility
(ht) (H)
Curvilinear

HTD /HTB 3M
® ®
high torque mm 3 1.22 2.41 HTD®

HTD®/HTB® 5M high torque mm 5 2.08 3.81 HTD®

HTD®/HTB® 8M high torque mm 8 3.4 6.0 HTD®

HTD®/HTB® 14M high torque mm 14 6.0 10.0 HTD®

Dual Sided Synchronous Belt Identification

Tooth Belt
in or Pitch Sprocket
Belt Type / Pitch Code Service Duty Height Height
mm (P) Compatibility
(ht) (H)
Trapezoidal
standard
DXL extra light in 0.200 1/5 0.050 0.120
timing
standard
DL light in 0.375 3/8 0.075 0.180
timing
standard
DH heavy in 0.500 1/2 0.090 0.232
timing
Parabolic

DRPP5 high torque mm 5 2.00 5.20 RPP® / HTD®

DRPP8 high torque mm 8 3.20 7.80 RPP® / HTD®

DRPP14 high torque mm 14 6.0 14.00 RPP® / HTD®

Curvilinear

HTD /HTB 5M
® ®
high torque mm 5 2.08 5.30 HTD®

HTD®/HTB® 8M high torque mm 8 3.4 8.10 HTD®

HTD®/HTB® 14M high torque mm 14 6.0 14.8 HTD®

Once the correct belts are identified, it is good practice for

maintenance personnel to label each drive with the correct
belt part number. When replacement belts are required it’s
as simple as obtaining the part number from the drive label.
Additionally, the installation date and installation tension for
each drive can be recorded on the label to further enhance
your preventive maintenance program.

11
BEST PRACTICES

MATCHING V-BELTS
When using multiple grooved sheaves, be sure that all of the
belts are the same brand. Always replace complete sets of
v-belts even if only one is worn or damaged.

INSTALLING BELTS
After you correctly install and align the pulleys you can
install the belts. Always move the drive unit to create slack
so you can easily slip the belts onto the pulleys without
force. Never force belts onto a drive with a tool such as a
screwdriver or a wedge. Doing so may rupture the fabric
cover or break the load-carrying cords inside the belt.

12
 USING THE TENSION TESTER GUAGE

TENSION
Proper tension is essential to higher maintenance
for maximum belt life and costs and inefficient power
efficiency. Improper belt transmission.
tension is the leading
cause of premature belt Also, over-tensioning belts
failure and increased leads to premature wear of
costs. Under-tensioned bearings, shafts and pulleys.
belts lead to slippage, The result is more frequent
overheating, excessive replacement of drive
pulley wear, rollover and components and costly
noise, all of which lead downtime.

USING THE TENSION TESTER GUAGE

1. With the drive stopped and locked out, measure the
belt span length of the drive. Set the large rubber
O-ring on the body of the tension gauge at the
dimension equal to 1/64” for every inch of span length.

2. Set the O-Ring on the plunger at 0 against the body of

the tension gauge.

3. With the tension gauge perpendicular to the span,

apply a force to the belt in the middle of the span.
Deflect the belt until the bottom of the Large O-Ring
is even with the top of the next belt or the bottom of a
straight edge laid across the span length.

4. For v-belts, run the belts in until they seat and re-
tension. Check again after 5-10 minutes. Re-check
after 24 hours, then every 100 hours and periodically
thereafter is recommended for maximum belt life.

NOTE: Proper tension is the lowest tension at which the belt

won’t slip or jump teeth under peak conditions.

13
 Large O-Ring on Plunger Zero setting on Plunger
USING THE TENSION TESTER GUAGE

Small O-Ring on Plunger

Deflection Distance Scale
De ection Distance Scale
TESTER Bottom of straight edge
Small O-Ring
or top of adjacent belt
Span

14
Large O-Ring
DEFLECTION TO BE 1/64” PER INCH OF SPAN
BELT INSTALLATION CHECKLIST
Belt Installation Checklist

1 Cut off and lock out power source

2 Observe all other safety procedures

3 Follow recommendations of the manufacturer

4 Remove the belt guard

5 Loosen the motor mounts

6 Shorten center distance

7 Remove old belts

8 Inspect wear patterns for possible troubleshooting

9 Inspect pulleys, shafts, bearings and other components

10 Inspect pulleys for wear and clean them

11 Check pulleys for initial alignment

12 Select proper replacement belt

13 Install new belt

14 Apply tension

15 Re-check pulley alignment

16 Replace belt guard

17 Start drive and observe for noise, vibration, etc.

18 Check drive after 24 hours - re-tension if necessary

15
TENSIONING & INSTALLATION: V-BELTS

V-belt tensioning and deflect 1/64-inch for

adjustment can be made every inch of belt span (see
using a tension tester sketch below).
gauge or other type spring
scale, using the following For example, a deflection
procedure. for a 50-inch belt span is
50/64ths, or 25/32-inch. The
After seating the belts in amount of force required
the sheave groove and to deflect the belt should
adjusting center distance compare with the deflection
so as to take up slack in the forces noted in the following
belts, further increase the tables. Also notice for
tension until only a slight V-belts the deflection forces
bow on the slack side is vary from the initial “run-in”
apparent while the drive is values, which are greater
operating under load. Stop (reflecting higher run-in
the drive and use the gauge tensioning) to the “normal”
to measure the necessary values for after the run-in
force to depress the belt period.
or on multiple belt drives
use one of the center belts,

16
TENSIONING & INSTALLATION: V-BELTS
Simplified Tensioning Procedure
Multi-Rib Deflection Force Table

Small Sheave
Belt Pitch Force “F” Weight
Diameter Range
Cross Section Lbs./Rib Kg/m/rib
(inch)

1.32 – 1.67 0.4

J 1.77 – 2.20 0.5 0.008
2.36 – 2.95 0.6
2.95 – 3.74 1.7
L 3.94 – 4.92 2.1 0.032
5.20 – 6.69 2.5
7.09 – 8.82 6.4
M 9.29 – 11.81 7.7 0.110
12.40 – 15.75 8.8
For drives with shock loading or other unusual conditions,
the tension may have to be increased for proper operation
of the drive. If the belt slips, tighten the belt. Utilization of
this simplified tension procedure may not result in optimum
belt life, due to the static tensions being less accurate than
the static tension based on the Horsepower. For exact
calculation consult Megadyne Application Engineering or
refer to Megadyne Technical Manuals.

17
TENSIONING & INSTALLATION: V-BELTS
Simplified Tensioning Procedure
V-Belt Deflection Force Table

Small Pulley Deflection Force

Belt Weight
Diameter Range
Cross Section Run-In Normal Kg/m
(inch)
(lbs.) (lbs.)
3.0 – 3.6 3.375 2.25
A 3.8 – 4.8 4.25 2.875 0.13
5.0 – 7.0 5.125 3.375
3.0 – 3.6 4.125 2.75
AX 3.8 – 4.8 5.0 3.25 0.12
5.0 – 7.0 6.0 4.0
3.4 – 4.2 4.0 2.625
B = 0.19
B 4.4 – 5.2 6.0 4.0
*RB = 0.27/rib
5.4 – 9.4 7.125 5.25
3.4 – 4.2 5.250 3.5
BX 4.4 – 5.2 7.125 4.75 0.19
5.4 – 9.4 9.0 6.0
7.0 – 9.0 11.25 7.50 C = 0.33
C
9.5 – 16.0 15.75 10.50 *RC = 0.42/rib

7.0 – 9.0 13.5 9.0

CX 0.31
9.5 – 16.0 17.5 11.75
12.0 – 16.0 24.5 16.50
D 0.64
18.0 – 22.0 33.0 22.0
E 21.6 – 27.0 48.0 32.0 0.98
3.4 – 4.2 6.0 4.0 3V = 0.08
3V
4.2 – 10.6 7.0 5.0 *R3V = 0.12/rib

2.2 – 3.65 7.0 5.0 3VX = 0.07

3VX
4.12 – 10.6 8.0 6.0 *R3VX = 0.09/rib

7.1 – 10.9 16.0 10.0 5V = 0.20

5V
11.8 – 16.0 20.0 12.5 *R5V = 0.30/rib

4.4 – 10.9 18.0 12.0 5VX = 0.18

5VX
11.8 – 16.0 22.0 15.0 *R5VX = 0.23/rib

12.5 – 17.0 36.0 22.5 8V = 0.59

8V
18.0 – 22.4 40.0 25.0 *R8V = 0.70/rib

* RB, RC, R3V, R3VX, R5V, R5VX, R8V = Banded V-Belts

For drives with shock loading or other unusual conditions, the tension may have
to be increased for proper operation of the drive. If the belt slips, tighten the belt.
Utilization of this simplified tension procedure may not result in optimum belt life,
due to the static tension being less accurate than the static tension based on the
Horsepower. For exact calculation consult Megadyne Application Engineering or
Megadyne Technical Manuals.

18
TROUBLESHOOTING V-BELT DRIVES

19
TENSIONING & INSTALLATION
ISORAN® SYNCHRONOUS BELTS

SIMPLIFIED TENSIONING FOR

ISORAN SYNCHRONOUS BELTS
Use the Belt Deflection Static tension and deflection
Force Calculator graph force value tolerances
that follows for calculation calculated by this method
of the approximate static are approximately ± 25%.
tension and deflection force
for Megadyne RPP, RPP To make calculations
Silver 2, RPP Gold and RPC electronically, visit
Platinum belts. http://megadyne.
productselectionpro.
This simplified method is for com and register to gain
determining recommended access to the Megadyne
deflection force. As with Product Selection Pro online
all simplified methods, it software. This software
may not result in optimum will automatically calculate
belt life. Our application deflection force and
engineers are available to distance values in addition
perform the calculation to being a useful tool for
for you if your drive life is drive design calculation.
critical.
If in doubt, refer to the
This method is based on appropriate Megadyne
prime movers having an technical drive design
overload torque from 150% manual or contact
to 250% of rated torque. For Megadyne Application
normal torque motors, the Engineering.
tensions can be decreased
by 10% (f x 0.9) and for high NOTE: Synchronous belts
torque motors the tensions are extremely sensitive to
should be increased by correct tension. Follow the
17% (f x1.17). Use rated tensioning procedure fully
motor power to determine or request that Megadyne
static tension and deflection perform the calculation.
force.

20
 BELT DEFLECTION
FORCE CALCULATOR

21
TROUBLESHOOTING
SYNCHRONOUS DRIVES

22
 FLANGE REQUIREMENTS
SYNCHRONOUS TIMING BELT
SPROCKETS
1. On all two point drives, the minimum flanging
requirement is two flanges on one sprocket or one
flange on each sprocket on opposite sides.

2. On drives where the center distance is more than

eight times the diameter of the small sprocket, both
sprockets should be flanged on both sides.

3. On Vertical shaft drives, one sprocket should be

flanged on both sides. All other sprockets in the
system should be flanged on the bottom only.

4. On drives with more than two sprockets, the minimum

flanging requirement is two flanges on every other
sprocket or one flange on every sprocket, alternating
sides around the system.

23
IDLER USAGE WITH
SYNCHRONOUS DRIVES
Idlers in synchronous belt drives are only recommended
when necessary to take up belt slack, apply installation
tension, clear obstructions within a system or increase wrap
on the smaller pulley. Idlers induce an additional bending
force (especially outside idlers) and this accelerates wear.
Every pulley in a drive wears on the belt and shortens
service life.

IDLER GUIDELINES:

• The idler diameter should not be smaller than the

smallest driven pulley

• Idlers may be placed inside or outside the belt

• Inside placement is recommended as it does not

backbend the belt

• Outside idlers must be flat faced (not crowned)

• Inside idlers must be toothed

• Idlers should be capable of being locked down after

adjustment

• Backside idlers should be at least 40% larger than the

smallest pulley in the drive and located as close to the
driver as possible on the slack side of the drive.

INSIDE/OUTSIDE
Inside idlers are generally preferred over backside idlers
from a belt fatigue standpoint. Both are commonly used
with good success. Inside idlers should be toothed pulleys,
but can be flat if the O.D. is equivalent to the pitch diameter
of a 40-groove pulley. Backside idlers should be flat and
uncrowned.

24
 IDLER USAGE WITH
SYNCHRONOUS DRIVES

TIGHT SIDE/SLACK SIDE

Idlers should be placed on the slack (non-load carrying)
side, if possible. Their effect on belt fatigue is less on the
slack side than on the tight (load-carrying) side. If spring-
loaded idlers must be used, they should never be placed on
the tight side. Also, note that drive direction reversals cause
the tight and slack spans to reverse, potentially placing the
idler on the tight side.

IDLER PLACEMENT
Synchronous drives are much less sensitive to idler
placement and belt wrap angles than V-belt drives. The
designer should make sure that at least 6 belt teeth are
in mesh on load-carrying sprockets. For every tooth in
mesh less than this (minimum of 2), 20% of the belt torque
rating must be subtracted. To minimize potential for belt
ratcheting, each loaded pulley in the system should also
have a wrap angle of at least 60°. If a loaded sprocket has
less than 6 teeth in mesh and 60° of wrap, idlers can be
used to improve this condition. Non-loaded idlers have no
tooth meshing or wrap angle restrictions.

SPRING-LOADED IDLERS
Using a spring to apply a predetermined force against a
tensioning idler to obtain proper belt installation tension is
acceptable as long as the idler can be locked down after
belt installation.

25
ALIGNMENT

CHECK ALIGNMENT:
Proper alignment is essential for long belt life. Check
belt alignment whenever you maintain or replace belts or
whenever you remove or install pulleys.

SYNCHRONOUS BELT V-BELT

Synchronous belt should V-belts are much less
not be used where severe sensitive to perfect
misalignment is inherent in alignment than synchronous
the drive. Total misalignment drives. Perfect alignment of
of synchronous belt drives sheaves is not critical to the
should be less than 1/16” operation of the drive. V-belt
per 12” of center distance. misalignment should be less
than 1/10” per 12 inches of
center distance.

ALIGNMENT PROCEDURE:
Place a straight edge (or shafts will show up as a gap
string) along the outside between the outside face of
face of both pulleys. When the pulley and the straight
properly aligned, the straight edge. The straight edge
edge will contact each should touch the pulleys at
pulley evenly. The straight the four points indicated.
edge should touch the two Ideally, one should always
outer edges of each pulley. have four points of contact.
Misalignment of pulleys and

26
 ALIGNMENT

PROPER ALIGNMENT:
• Driver and Driven pulleys are parallel, both
horizontally and vertically

• Driver and Driven pulleys are in a straight line

• Both pulleys should be mounted as near to the

bearings as possible to reduce overhung weight

MISALIGNED PULLEYS:
• Misalignment leads to rapid belt and pulley wear,
generates excessive noise and will shorten the life of
both belt and pulley.

• Proper alignment in conjunction with adequate

tension results in a belt drive that operates at its
quietest level.

27
ALIGNMENT
TYPES OF MISALIGNMENT
HORIZONTAL ANGULAR
shafts in same horizontal plane but not parallel

SOLUTION:
Loosen motor mounting bolts and rotate motor until all 4
points touch straightedge as shown in illustration below.

VERTICAL ANGULAR
shafts in same vertical plane but not parallel

SOLUTION:
Place straightedge about 1-1/4” radius from the outside
diameter of both sheaves, a straightedge should make
contact at the 4 points indicated. Motor base can be
shimmed to correct alignment.

28
 ALIGNMENT
TYPES OF MISALIGNMENT
PARALLEL
shafts are parallel but the pulleys are not in the same plane

SOLUTION:
Reposition the pulley so the straightedge makes contact at
the 4 points indicated.

MISALIGNED PULLEYS:

V-BELT
A misaligned V-belt drive will be noisier than a properly
aligned v-belt drive due to the interference misalignment
creates at the point where the belt enters the sheave.

SYNCHRONOUS BELT
It is normal for a synchronous drive to be somewhat louder
than a v-belt drive but a misaligned synchronous belt drive
will be much noisier than a properly aligned synchronous belt
drive due to the even greater amount of interference that is
created between the belt teeth and the sprocket grooves.

Do not attempt to align a synchronous drive to try to make

the synchronous belt ride in the center of the sprocket.
Synchronous belts normally operate in light contact with a
flange on one side of the sprockets. Attempting to adjust
alignment to force the belt to ride in the center of the sprocket
may result in misalignment, additional wear and noise.

29
BELT GUARDS

It is important to use a belt guard to ensure safe and

efficient operation of the drive. Periodically check the guard
for wear and damage. Look for areas where the belt may
make contact with the guard. Clean off any dirt, grease
or oil to prevent it from becoming blocked and closed to
ventilation.

CHARACTERISTICS OF A PROPERLY
DESIGNED GUARD
• Should completely enclose the drive

• Has grills or vents for good ventilation, synchronous

belt drives do not require ventilation

• Grills and vents must be small enough to prevent

debris entry

• Has accessible inspection doors or panels

• Can easily be removed and replaced if damaged

• Protects the drive from weather, debris and damage

30
 FAILED BELT ANALYSIS - V-BELTS

Exposure to Oil & Grease Weathering or “Crazing”

Cause: Belt swelling, exterior Cause: Belt drive elements, as well
softness and bottom envelope seam as aggravation by small sheaves.
to open/split.
Remedy: Splash guards, don’t over Remedy: Check tension, provide
lubricate, clean belts/sheaves. drive protection and replace belt(s)

Cut Bottom & Sidewall Severe Localized Wear

Cause: Belt being pried over sheave Cause: Spin burn caused by a frozen
during installation, as cut above or locked drive sheave not able to
indicates. turn freely.
Remedy: Use proper length belts and Remedy: Determine that drive
tension properly when installing. components turn freely and, if
necessary, tighten belt.

Rough Sheave Sidewalls Broken Belt

Cause: Constant slippage due to belt Cause: Rough sheaves and dust
being misaligned on worn sheaves. build-up can both cause belt failure
and severe envelope wear.
Remedy: Use correct belt size, Align Remedy: Shield the drive
or replace sheaves.

Snub Break Abrasion

Cause: Cover wear indicates slippage Cause: Sidewall wear a result of foreign
and clean break reveals sudden snap material and rust in sheaves. Belt
due to non-proper drive tensioning dropped to bottom of sheave groove.
Remedy: Maintain proper drive Remedy: Dust guards to prevent
tension abrasion.

31
FAILED BELT ANALYSIS - V-BELTS

Worn Side Pattern Oil Deterioration

Cause: Worn or misaligned sheaves. Cause: Rubber softened by
Remedy: Retension drive to stop excessive oil exposure, causing
slipping, realign sheaves (replace if deterioration.
needed) replace belt if incorrect size. Remedy: Splash guards to protect
drive against oil.

Cover Fabric Rupture Base Cracking

Cause: Fabric cover ruptured during Cause: Loose tensioning. Belt
installation due to belt being pried slippage causes heat build-up and
over belt sheave. gradual undercord hardening.
Remedy: Proper installation of belts. Remedy: New belt. Proper tensioning.

Distorted Belt Ply Separation

Cause: Distortion caused by broken Cause: Split along pitch line
cords or adhesion breakdown. indicating belt ran on too small
Remedy: Avoid prying on belts. diameter of sheave.
Check sheaves for recommended Remedy: Install a (x) cogged type
diameters. belt.

Ruptured Belt Slip Burn

Cause: Ruptured cords in the plies, Cause: Belt slipping under starting or
caused by high shock load or foreign stalling load.
object between belt and sheave groove. Remedy: Replace belt and tighten
Remedy: Check tension, shield drive drives until slipping stops.

32
 FAILED BELT ANALYSIS
SYNCHRONOUS BELTS

Clean Straight Break

Cause: Remedy:

Mishandling Avoid improper storage of the belts

Inadequate belt installation tension Increase tension of the belts

Small pulley diameter Increase diameter of the pulleys

Debris or foreign object in the drive Remove debris and check the guard

TIMING BELTS IN RUBBER

Tooth Separation Belt Edge Wear

Cause: Remedy: Cause: Remedy:

Excessive Reduce the Pulley Check and

tensioning tension misalignment set the pulleys
alignment

Cracking from High Temp Tooth Root Cracks

Cause: Remedy: Cause: Remedy:

Excessive Reduce the Shock load Redesign the

temperature temperature drive
or change the
compound of the belt

33
FAILED BELT ANALYSIS
SYNCHRONOUS BELTS
TIMING BELTS IN RUBBER

Abnormal Abrasion
Laceration of the Teeth
of the Truth
Cause: Remedy: Cause: Remedy:

Shock load Redesign the Belt excessively Reduce the

drive taut center distance

Excessive Use a wider belt

overloading

Incorrect Replace pulley

contour or after checking
diameter of contour or
pulley diameter

Abnormal Wear of the Belt Abnormal Wear of the Belt

at the Tooth Root on the Side of the Tooth
Cause: Remedy: Cause: Remedy:

High Reduce the Low belt Increase the

belt land pretension of the belt installation tension
pressure tension

34
 ULTIMATE SOLUTION
If all else fails and the information provided here does not
resolve your drive issue, Megadyne is ready to assist you
with a drive design calculation. The form below will help us
create a drive design that can resolve your drive problems.
Please fill in the blanks and email a copy to
[email protected]
BELT DRIVE DATA SHEET
Company:

Address:

City: State: Zip:

Contact Name:

Telephone: E-Mail:

GENERAL INFORMATION
*Drive Layout:

*What does the new drive do:

Model/Project Name: New Design Existing

Design

If Existing. Current Supplier? *# of Units

per Year?

MOTOR DATA
Electric Torque: STD To 250% To 400%

Internal Combustion: =>8 =6 =<4 cylinders

*Power (hp) *Speed (rpm)

Existing Pulley: Outside Diameter: # of Teeth: Pitch:

*Shaft Diameter (in.):

DRIVEN DATA
*Speed (rpm)

Existing Pulley: Outside Diameter: # of Teeth: Pitch:

*Shaft Diameter (in.):

*Indicates minimum information required to perform drive calculation. CONTINUED ON BACK

35
ULTIMATE SOLUTION
BELT DRIVE DATA SHEET (CONTINUED)
CENTER DISTANCE
*Desired Center Distance (in.):

Minimum CD: Maximum CD:

OPERATING CONDITIONS
*Daily Duty Cycle (Select One):

Intermittent (8 hrs.) Normal (8-16 hrs.) Continuous (16+ hrs.)

Operating Temperature (°F):

Oil Water Abrasives

Start-Up:

Soft Start Clutch No Load Full Load

ADDITIONAL INFORMATION

*Indicates minimum information required to perform drive calculation.

36
 ADDITIONAL PRODUCTS

MXV False Tooth

PPJ Accu-Link

Platinum Cleats

Our full product offering

is available online at:

www.MegdayneGroup.com
www.JasonByMegadyne.com

General Urethane
37
NOTES

38
 NOTES

39
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*Manufacturing Location

www.megadynegroup.com/usa
www.jasonindustrial.com
MD-MM-R OCT 2020

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