V-belt replacement and tensioning procedure

What’s inside

1. 1

   Isolate the drive

   Isolate and lock out the motor following your lockout / tagout procedure and check that the drive cannot start. Wait until the pulleys have stopped completely.

   Action10 min

   Tools: Lockout devices

   Risks: Unexpected start-up of the drive.

2. 2

   Remove the belt guard

   Remove the guard and keep its fixings. Check the guard for damage that would stop it being refitted correctly.

   Action10 min

   Tools: Spanners

3. 3

   Slacken the drive and remove the old belts

   Loosen the motor base and move the motor towards the driven pulley until the belts come off freely. Never lever or roll belts over the pulley flanges.

   Action10 min

   Tools: Spanners

   Risks: Fingers caught between belt and pulley.

4. 4

   Inspect the pulleys

   Clean the grooves and check them with a groove gauge: worn sidewalls or a shiny groove bottom mean the pulley must be replaced. Also check for cracks, chipped flanges and loose hubs or keys.

   Inspection10 min

   Tools: Groove gauge, wire brush, cloth

5. 5

   Fit a matched set of new belts

   Replace every belt of a multi-belt drive at the same time with a matched set of the correct section and length. Never mix old and new belts or belts from different sets.

   Action10 min

   Tools: Matched belt set

6. 6

   Align the pulleys

   Check parallel and angular alignment of the pulley faces with a straight edge or a laser alignment tool, and correct the motor position until within the belt manufacturer’s tolerance.

   Measurement20 min

   Tools: Straight edge or laser pulley alignment tool

7. 7

   Tension the belts

   Tension to the manufacturer’s value with the deflection method: apply the specified force at mid-span and measure the deflection (often about 16 mm per metre of span), or use a belt tension meter. Tighten the motor base fixings and recheck alignment.

   Measurement15 min

   Tools: Belt tension tester or tension meter, ruler, torque wrench

8. 8

   Refit the guard

   Refit the guard with all its fixings and check that nothing rubs against the belts or pulleys.

   Action10 min
9. 9

   Restore and check the drive running

   Remove the locks following your lockout procedure, start the drive and check that the belts run without slipping, squealing, flapping or excessive vibration.

   Verification15 min

   Risks: Keep hands and loose clothing away from the drive while it runs.

10. 10

    Re-tension after the run-in period

    New belts stretch and seat in the grooves: after the run-in period given by the manufacturer (often 24 to 48 hours of running), isolate the drive again, recheck the tension and adjust.

    Measurement20 min

    Tools: Belt tension tester or tension meter, lockout devices

    Risks: Isolate the drive again before removing the guard.

11. 11

    Record the work

    Record the belt reference, the number of belts, the final tension and the alignment readings for the next replacement.

    Action5 min

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