Did you know that improper maintenance is the primary cause of drive belt problems?

According to Gates Corporation research, approximately 40% of belt drive failures are the result of poor maintenance or neglect. Factors might include inadequate tensioning, failure to replace worn parts, dirty assemblies, weak components or misalignment.

Gates, a global manufacturer of engineered power transmission solutions and BlackHawk partner, strongly recommends a regular and thorough maintenance program for all of your belt-driven machinery. The Gates Belt Drive Preventive Maintenance and Safety Guide lays it out, step by step. Here is a high-level look at the key points to consider.

Elements of a good maintenance program

• Keep it clean
• Maintain a safe working environment
• Regularly scheduled belt drive inspections
• Proper belt installation procedures
• Belt drive performance evaluations
• Belt product knowledge
• Belt storage and handling
• Troubleshooting

Keep it clean

Making sure that your belt drives are clean is the most important step in proper maintenance. Things like dust, dirt, and grease will cause components to wear out prematurely and unevenly and will force the motor to work harder to deliver the same power.

Your cleaning tools will vary depending on the specific machinery, but most likely, you will want to use a soft, damp cloth to clean the belt. Make sure that you aren't soaking any components or leaving excessive moisture when you are done, as this can further corrode or rot pieces. Don't use harsh chemicals that can destroy your belt.

Maintain a safe working environment

First and foremost: Power down the machinery and use lockout/tagout devices to keep it offline during maintenance. Maintain safe access to the belt drives. Make sure drive guards are in place. Wear protective clothing.

Proper training is essential for maintaining a safe work environment, and will help keep all of your power machinery, including your belt drive, in proper working shape. Make sure that everyone who uses the belt drive in your shop is trained in safety and knows how to perform maintenance tasks correctly. By following safety guidelines, the likelihood of accidents will diminish and your machinery will be treated better — both of which will lead to a longer life for your equipment as well as the safety of your workers.

Inspect regularly

The type of machinery and its use determine how frequently belt drives should be examined. For critical drives, inspect visually and measure noise levels weekly or every two weeks. Monthly checks may suffice for other belts. Schedule a complete shutdown and thorough inspection quarterly or semi-annually.

Remember that routine inspections are your first line of defense when it comes to maintenance. Getting into a rotation of scheduled inspections will identify problems before they escalate and will also familiarize workers with all of the intricacies of the machinery.

During inspections, look for things like signs of wear and tear, cracks, fraying, or glazing, as well as abnormal wear or signs of bending, torsion, or rubbing. During this inspection, check for proper tension on the belt, as well, because either an overly tight or loose belt can lead to damage. Overly tight belts will strain the system, and a loose belt can slip or wobble, ultimately delivering less power while forcing the motor to work harder.

You can use laser tools to verify that the belt is properly aligned, and it is very helpful to use either a tension meter or spring scale to adjust tension to the exact parameters. The more accurate you can be, the better your machinery will function.

What to look for

Examine belts for uneven wear, cracks, frays or cuts. Check tightness for slippage. Use laser tools to verify proper alignments. Use tension meters or spring scales to adjust tension. 

Install belts properly

Never service or change a belt until you confirm that the power is shut off and tagged out. Remove the guard. Loosen the motor mounting bolts or adjusting screws until you have enough slack to safely remove the belt. Inspect and clean the assembly. Check the alignment. Install the new belt and tighten the mounts. If there are multiple belts in the drive, replace all of them at the same time.

Make sure that you use the right tools to install, inspect, and repair your equipment. Alignment tools, tension gauges, and specific installation tools will all make the process faster and easier, and will also ensure an accurate installation so you can be confident in your work and keep your machine running smoothly.

Know your belts

Understanding the different types and sizes of belts and the advantages of each helps you to identify and choose the correct replacement belt. Options can be confusing. The Gates guide lists the most common types and sizes with illustrations.

If you need help while choosing replacement belts through BlackHawk Industrial, contact our team of experts right away. We are dedicated to making sure that our customers are getting the right tools and materials for the job, and can help you make sense of this purchase so you can hit "buy" with confidence.

Store belts properly

Prevent premature damage to belts by storing them in a cool, dry environment away from direct sunlight, moisture and chemicals.

Direct sunlight is as harmful to a belt as a caustic chemical, although it may take more time and might not be as obvious right away. Make sure that there are no major fluctuations in temperature or humidity in your storage area, and if possible, make sure there are no windows. If there is a window in your storage facility, it might be a good idea to cover it with a curtain or towel. UV light will cause rubber to harden and crack to the point that a brand-new belt might disintegrate when you take it out of the package.

Of course, chemicals will also damage your belts. Store your oils, solvents, and other chemicals far away from the rest of your inventory to keep everything in great condition.

V-belts can be hung on wall racks. Keep packaged belts in their boxes until ready to use. Do not leave them loose on the floor.

Replace Routinely

Regular maintenance will keep your belt drive running smoothly, but the reality is that components will need to be replaced over time. If you are noticing that your belt is showing signs of excessive wear, inability to stay tensioned properly, missing teeth, or reduced performance, it may be time to swap it out for a fresh one. Listening to your machinery and meeting its needs is the best way to avoid expensive breakdowns and repairs that will impact the efficiency of your operation and the quality of your output.

Troubleshooting

If anything feels off — even if you can't put your finger on it — turn off the belt drive and try to make sense of what is going on. The worst thing that could happen here is that you halt production for a bit, but you may also discover an issue that could lead to a serious problem.

Be systematic. Describe what went wrong, when it happened and how often it happens. (Excessive noise and vibration are two telltale signs that something is wrong.) Identify the belt used and any changes in machine operations or output. Document symptoms and observations. The Gates maintenance guide includes a comprehensive checklist for each type of belt. If necessary, contact BlackHawk or Gates for technical assistance.

Proper maintenance ensures that your belt drive systems deliver optimum performance and a long, trouble-free service life.

Why Work With BlackHawk Industrial For Your Belt Drive Needs?

BlackHawk Industrial is proud to be the #1 choice for industrial manufacturers who prioritize production savings and technical service. As your "across the production floor" partner, we can help you stay on time and on budget by optimizing your supply chain and keeping you equipped with high-performance products and equipment. With BlackHawk Industrial, you can lower your total cost of production with quality and reliability.

New from Gates

MegaSys™ MXG™ 4K Hydraulic Hose — lightweight, highly flexible and qualified to 1 million impulse cycles! Drop-in replacement for conventional spiral hoses. Exceeds many ISO and EN performance criteria.

G-Force Redline™ CVT Belts — designed for the wildest rides in dunes, deserts, mountains and racetracks.

Fun facts

The earliest recorded belt drive dates back to China in 15BC! Belt drives were used to power weaving machines to make silk fabric.

What Is a Belt Drive (aka drive belt)? A mechanical system that utilizes pulleys and belts to transfer motion from one shaft to another. It is utilized to transmit energy and motion within machinery and mechanical systems.