V-BELTS

for

SG coaches
 V Belt: Governing specifications
• RDSO/PE/SPEC/AC/0059-2004 for V belts
• IS 2122 (Pt II) 1973 –For selection , storage, installation and
maintenance of belting for power transmission V belts
• IS: 2494-1991 –V belts for industrial purposes.
• IS:3142-1993- V groove pulleys for V belts sections A,B,C,D
and E
• RDSO/PE/SPEC/AC/006-2009 (Rev-1) for Nylon bushes
• ELPS/SPEC/TL/13-1998 for Axle and Alternator Pulley
Cross-section of V-belt
Type: C-122

TOP RUBBER

LOAD CARRYING CORDS

BASE
RUBBER
RUBBER IMPREGNATED
FABRIC JACKET
40º
INCLUDED ANGLE
 Technical data
• Belt consists of combination of elastomeric compounds
with polyester cord reinforcement and outside fabric of
cotton coated with polychloroprene.
• Power get transmitted through sides of belt and pulley.
• Belt to last 1 year.
• Max permissible tension during run (kg): 100
• Min Breaking strength: 1150 kgs.
• Alternator pulley transmitting capacity 5.01 kW at 800
rpm and 4.01 at 600 rpm.
 V-Belt dimensions
Dimensions of a C-Section Endless V-
Belts
 Nominal Top Width = 22 mm
 Thickness = 14 mm
 Angle = 40 degree
 Code Number: C-122
 C- Cross section
 122 - Length in inches
 Number of belts
 4.5 kW- 4 nos.
 25 kW - 2 x 6 = 12 nos.
400
V-belt grading
Type: C-122

Nominal pitch length 3155mm - Graded as ’50’

If the actual length is equal to nominal pitch

length ±1.0 mm, the belt coding is given as 50.

A deviation of 2.0 mm in length shall be

represented by one unit and the coding number
will increase or decrease as the length of belt
increases or decreases

5 grades are available: 48, 49, 50, 51, 52

ex: A belt with length between 3154 mm &

3152 mm will be coded as Grade ‘49’
 Definitions
• V-belt drive: Consists of V belt(s) and pulley.
• V-belt: A belt having cross section like trapezium.
• Angle of V-belt (A): Included angle obtained by
extending its sides.
• Pitch width (T): Width of V-belt at its pitch zone. It
remains unchanged when belt is bent perpendicular to its
base.
• Pitch length (Lp): Circumferential length at pitch
width
• Pulley groove pitch width (Wp): Pulley width
dimensionally same as pitch width of belt.
 Failure modes of V-belts

• Slippage
• Turn over and face twisted
• Rapid wear
• Excessive stretch
• Bottom cracks
• Top cracks
• Dropping
• Smoking
 Factors affecting life of V-belts

• Maintenance lapses

• House keeping

• Design inadequacies

• Miscellaneous
Factors affecting life of V-belts
Maintenance lapses
• Improper tension of V-belt.
• Loosening of tension gear.
• Loosening of axle pulley bolt & nut.
• Loosening of alternator pulley castle nut.
• Shifting of axle pulley.
• Alignment of alternator pulley and axle pulley.
• Lateral play of alternator.
 Factors affecting life of V-belts
Improper Alignment of Pulleys.

 Most of failures are due to misalignment of

alternator and axle pulley.
• Alignment of alternator and axle pulley to be
checked by metal bar with spirit level or by laser
beam or by cotton cord.
• Cord or laser beam or metal bar should touch four
edges of the two pulleys simultaneously.
Misalignment, if found to be corrected.
Alignment checking of alternator and axle
pulleys using metal bar
 Suspension bracket bushes
 Nylon-66 bushes provided in suspension
brackets.
 Wear of bogie bush may lead up to a maximum
alignment difference of 25 mm.
 It puts bending effect on V-belt and may lead to
it’s failure
 It may also cause widening (oval) of bracket holes
that may destroy the alignment of suspension
arrangement permanently.
 More wear due to suspension rotation if stopper
assembly not provided.
Worn out bogie bush in the
suspension bracket
 Suspension Bracket alignment
This can be checked by measurement tape and spirit level

Misalignment of suspension brackets due to bend in collar

Pin rotation stopper Arrangement
 Suspension Bracket alignment
 Distance between suspension brackets
 4.5 kW Alternator- 270 mm.
 25KW alternator- 400 mm.

 Length of alternator collar (Boss)

4.5 kW alternator- 268+-1 mm.
25KW alternator- 400 +0/-1 mm.

 More suspension bracket’s distance will provide lateral play to

alternator affecting the life of V-belts, due to the hammering effect.
 Use suitable washer between alternator collar and one of suspension
bracket duly checking the alignment to restrict alternator lateral play.
 Suspension Bracket alignment

Washer in the gap between suspension bracket collar

 Alternator bearing
 Due to bearing seizure, Alternator may stuck up and may
result in belt dropping.

 Bearing should be cleaned and greased properly during POH

 End shield of alternator should be properly tightened to avoid
entry of abrasive particles.
 Vibration testing and clearance checking for bearing must be
done during POH.
 Groove check of pulleys
 To be done during POH and at the time of replacement of V-belts
 Pulley to be replaced, if
groove width is increased by 0.5 mm or
angle of pulley is increased by 30” from standard value or
groove base of pulley is shining or mechanically damaged.
 Standard groove angle
 34o for alternator pulley and
 38o for axle pulley.

 Higher groove angle results into excessive wear at base section or

belt bottom crack and smaller groove angle may cause crushing and
wear of belt at top or belt top crack .
Checking of pulley groove angle
 Groove check of pulleys

Checking of Axle pulley Checking of Alternator pulley

 Checking of pulleys

Checking the verticality of Axle Checking the gap of Axle pulley

pulley halves by filler gauge
 Initial provision of V-belt
 Special care to be taken during installation since it’s damage
during installation is one of root causes of premature failures.

 Reinforcement cords get broken if belts are forced over pulleys/

wheel during installation.

 Change the belt set and install them in grooves only after loosening
tension spring.

 During replacement, do not ride wheels over belts that definitely

damage reinforcement cord of V-belt.

 In case of replacement, replace all the belts as set with same grade,
same make and of same batch.
 Proper Tension of V-belt
 If proper tension is not maintained ,V-belts may fail due to
slippage that increase the screeching noise and heat. Thus smoking
may result in subsequent V-belt dropping.

 Procedures to be followed to maintain proper

tension.

• Initial tension on new belts should be adjusted to a value about

15% higher than the final value ( at 5.0 kg).

• Adjustment of tension to final recommended value during first

three consecutive trips at base depots or after 500 Km
immediately after provision and thereafter every two months.
 Proper Tension of V-belt
 Use calibrated tension gauge to maintain proper belt tension.
 Normal length of spring is 345 mm. With the application of 105
Kg length of spring to be between 305 and 315 mm. For TL
coaches the spring may be kept at 310 mm. For AC coaches the
spring length is to be set at 295 mm.
 Tension should be felt by hand by striking it slightly. Belt in
correct tension respond ‘alive’ while low-tension belt respond
‘dead’ and over tension belt have ‘no give’ attitude.

Specification/ No. of turns of Dia of spring wire

Alternator Capacity
Drawing No. spring (mm)

RDSO/PE/SMI/AC/0042
25 KW 12½ 16
-2009 (Rev.0)

4.5 KW SKEL 3940 14 14

Spring tensioning device
In terms of RDSO/PE/SMI/AC/0042-2009 (Rev.0)
for 25 kW alternator, tension indicating plate
length is set at 295 mm.
 Spring tensioning device

COMPRESSED SPRING

GAP between Fixing Nut Sleeve

& Bogie Bracket Support
 Proper Tension of V-belt

Checking the tension of V-belt by fenner gauge

 Excessive stretch
• This is caused due to overloading and internal breaks.

• Overloading may be due to

 Bad design,

 Failed bearings of the alternator,

 Failure of output control of the regulator of the alternator, or

 Internal breaks during manufacture or due to forcing the belts

over top of the grooves.
Misalignment due to fixing of Axle pulley
Standard distance between wheel hub and axle pulley:

4.5 kW 141±0.5 mm
 25 kW 228±0.5 mm.

 More than 5% of the coaches show alignment difference, during

POH.
 Location of suspension bracket should be 810 mm and 1100
mm (4.5 kW) from inside face of bogie frame (bolster).
 Misalignment can be corrected at depot by shifting the axle pulley
duly considering the lateral clearance
Misalignment due to fixing of Axle pulley

Bolt nut missing of Axle pulley

 Missing of guide cups in bogie
suspension arrangement
 Longitudinal and lateral play between bogie transom and wheel
set is maintained to very close limits by Teflon guide cups located
in oil filled axle box guide cum shock absorber (4 per wheel set.)

 Cups can move vertically up and down by a few tens of mm in

either direction, with the vertical dynamic load augmentation due
to train motion on steel rails.

 These cups also support hydraulic damper circular rubber washer L

shaped at periphery to absorbs kinetic energy of vibration in the oil.
 Excess oscillation due to suspension
spring breakage
• Due to spring breakage of the suspension arrangement,
oscillations of bogie increases to a large extent which again
worsens the relative movement of alternator.

This will lead to belt creep and slip and finally results in
breaking of V-belt.
 House keeping
• It involves method of storage, grouping and tests to be conducted
on receipt of belts in the depots.
Storage
• To be kept in cool, dry & well ventilated place away from sun light.
• Not to be kept in a heavily bent or piled or twisted condition.
• To be used within two years from the date of manufacturing as age
and storage alters the length of the belt.
Grouping & Matching of belts
• Grouping can be done lengthwise, batch wise and make wise.
Practices to be followed before storing of belts.
• Grading should be done for all the belts on receipt by belt-
grading machine after applying a standard weight of 78.5Kg.
Do not believe in manufacture’s marking of
grade. It may differ from actual value. Insist manufacturer’s to
mark the batch number and year of manufacturing on belts.
 V-belt grading machine
IS 2494 stipulates that Age and storage conditions may
alter belt length, it shall therefore be measured as early as
possible after manufacture
Tests to be carried out
Before acceptance of V-belt the following tests are to be
carried out by RITES at manufacture’s premises.
• Visual Inspection
• Pitch length measurement
• Angle Checking
• Section checking
• Tensile strength test and elongation test
• Adhesion test
• Temperature ageing test for rubber
• Accelerated ageing test for V-belt
•Transmitting capacity of belt.
Tests to be carried out on belts Contd…

For better results it is recommended that consignee inspection

also must be done before acceptance immediately after receipt of the
material and before providing in the coach.

For that gauges for checking section of V-belt and Angle of V-

belt, V-belt grading machine, Fatigue test equipment for V-belt and
equipment for accelerated ageing test are required.
 V Belt: RDSO SMI’s
No Description
IRS/E-48-1991 Installation and maintenance of
belt & pulley
RDSO/PE/SMI/AC/0027/2006 For V belts
(Rev-0)
RDSO/PE/SMI/AC/0030/2005 For checking Axle and Alternator
pulley
RDSO/PE/SMI/TL/0042/2009 For checking belt tensioning
device
EL/7.1.38/1 dt 20.01.2011 Revised guidelines for belt
tightening
 RDSO’s revised instructions for
belt tensioning
(Issued vide letter No. EL/7.10.38/1 dt. 20.01.11.)
• Pitch length of all belts to be measured by pitch
length testing machine before provision on coaches
• All belts to be of same pitch length/grade (12 belts -
25 kW alternator and 4 belts- 4.5 kW

• Belt tension to be checked by hanging 4 kg weight at

the center of the belt span and top surface of this belt
not to go below bottom surface of remaining belts.
Self Generating- SMI for belt tensioning device
(No RDSO/PE/SMI/AC/0042-2009 (rev 0))
• Visually check assembly for :
– Tension rod thread damage
– Deformity in spring sheet
– Deformity in rotary spring sheet
– Damage of threads in special nut
– Cut/rubbing mark in spring coil

• Lengths of tensioning indicator plate to be as:

– 25 KW- 295 mm with modified spring (16 mm)
– 4.5 KW-310 mm
Self Generating- SMI for belt tensioning device
(No RDSO/PE/SMI/AC/0042-2009 (rev 0))
• Conduct compression test on springs before fitment
• Record spring compression in step of 10 mm and applied
weight and calculate deflection, kg/mm
• Compare the calculated avg deflection of old spring with
RDSO stipulated values given below:
– For 4.5/18/22.75 KW alternators: 2.8-3.2 kg/mm
– For 25 KW alternator: 4.8-5.5 kg/mm
• Get material conformity test conducted for each lot
 RDSO SMI for V belts
(RDSO/PE/SMI/TL/0027-2004 (Rev. O)
1. Check few sets from each lot of new V-belts for proper
fitment with the help of respective gadget :-
a) Pitch length of V belt
b) Angle of V belt
c) Section of V belt
2. For optimum performance exercise following precautions
a) Belts of same grading to be used as a set.
b) Two or more makes of belts not to be used in a set.
c) Check tension of V belt after fitment by tension gauge.
 RDSO SMI for V belts
(RDSO/PE/SMI/TL/0027-2004 (Rev. O)
d) Re-tension newly fitted belts after 1st trip or 500 km
run, whichever is convenient.
e) Check alignment or pulleys whenever alternator is
replaced.
f) Replace pulleys if grooves are worn out. Check by
GO/NO-GO gauges.
g) Measurement gadgets/gauges can be procured from
OEMs
 SECTION CHECKING
GUAGE FOR CHECKING THE SECTION
• Along a straight portion of belt in an un-tensioned
state, cross-section of belt shall be such that when
placed in a gauge , it shall not touch the bottom of
gauge, edges of the top width ‘s’ and ‘t’ shall not be
higher than the points ‘u’ and ‘v’ at top of template
and guiding mark ‘mn’ on the template shall cut whole
width of belt in its upper half.
Note: Pitch width of belt 19 mm, is the width of gauge
at the level of this guiding mark mn, drawn on gauge.
V-belt section checking gauge
 SMI for V groove pulleys
RDSO/PE/SMI/TL-0030-2005(REV 0)
• Replace Pulleys if
– Uniform shining of bottom of groove
– Groove walls worn out by more than 0.5 mm
– Surface matching between Alternator pulley bore and
shaft less than 80%
• Replace key of alternator shaft
• Gap between two halves of axle pulley 3+/-0.5 mm
 SMI for V groove pulleys
• No excess gap between bogie and alternator bracket
• Replacement of rubber pads
• Alignment of alternator and axle pulley
• No painting/greasing of pulley. It affects heat
dissipation
• Life of pulley 4 years. Date of fitment to be punched
on pulley face
 RDSO’s Code of practice for
installation and maintenance of V
belt & pulleys
No IRS: E-48-91
 Installation
• Adjustment of tension
– To be felt by hand
• Should respond ‘alive’ and ‘spring’
• Low tension belt will respond as ‘dead’
• Very tight belt will have ‘no give attitude’
• Warm pulleys after run indicate slippage
• Apply force P (as recommended by manufacturer) with
a spring balance at centre of span in perpendicular
direction. Deflection shall be:
– Fenner 16 mm/meter span for 4.1 to 6.1 kg weight
– Hilton 23 mm for 10 kg
• Gauges are also available
• Tension to be re-adjusted after initial 48 hrs of running
• Gap of 75/50 mm to be maintained between support
bracket and fixing nut of tension rod.
 Factors affecting life of V-Belts
Proper Tension of V-belts:
 If proper tension is not maintained for V-belts, they may get
failed due to belt slippage, increases the screeching noise and
heat.
 The smoking may starts from the belts that result in V-belts drop.
 The recommended tension is 4.0 kg.(To be checked by Fenner
gauge)

 Tension may be felt by hand by striking it slightly. Belt in correct

tension respond ‘Alive’ while low tension belt respond ‘Dead’
and over tension belt have ‘No give’ attitude.
 Examination at the time of POH
• Pulley to be replaced, if
– bottom of groove is shining uniformly,.
– ovality in power transmitting surfaces is > 0.8 mm
– Grooves are damaged
– Alternator pulley matching with shaft is < 80%
– Groove angle is increased
• Adjustment of tension
– Spring to be checked as RDSO SMI
– Appropriate tension to be ensured
 Check points
Item Std value Actual
value
Safety items
Gap between two halves of 3+-0.5 mm
axle pulley.
Condition and presence of No gap
rubber pads
Proper fixing of Axle pulley No bolt missing
Groove of the axle pulley To be checked
with gauge
Proper fixing of Alt pulley No bolt/pin
missing
 Check points
Item Std value Actual
value
Safety items
Tensioning device for proper Gap AC-75 mm
fitment. TL-50 mm
Fork eye clamp & cotter pin Not worn out
Bogie bracket No bend, crack
Sleeve condition Aligned and not
worn out
Condition of suspension To be intact &
hanger. with pin
 Check points
Item Std value Actual
value
Safety items
Presence and condition of
bogie bush.
Presence & condition of
safety chains, nut , bolt &
split pins
Failure investigation items
Alignment of Pulleys
Tension in remaining belts With 4 kg wt
 Check points
Item Std value Actual
value
Failure investigative items
Proper working of
RRU/ERRU
Pin anti rotation clamp
Condition of Pulley No bottom
grooves shining/blackening
 Failure analysis for V belt dropping
cases in AC/TL Coaches
General Information

Coach type & Train No. & Date Depot

No. Name

POH date Return Date POH Base

Workshop

Alternator: Alternator: ERRU/RRU ERRU/RRU

Capacity Make Capacity Make
Failure analysis for V belt dropping cases in AC Coaches
S.N Parameter to be Reference Permitted Actual Remarks
. checked Value Value
1 Condition of remaining belts
Make- Grade-
2 Belt tension of remaining belts ( force for 16 mm deflection at
the center as per fenner manual)-
Checking of V As per SMI No.
belts in Depot RDSO/PE/SMI/TL/00
27-2004(Rev. O)dated
3 Re-tensioning of
05.03.2004
newly fitted belt
after 1st trip or
500 km run.
4.3 (c) Groove Angle Drg. N0. Checked by
RDSO/PE/SK/ GO/NO GO
Groove No. 1 TL/0087-2005 gauge (32°-
Groove No. 2 (Rev.0) 36°)

Groove No. 3

Groove No. 4

Groove No. 5

Groove No. 6

4.4 Alternator Nylon Must change

bush condition item in POH
4.5 General Condition Replace after 4
of Alternator pulley years.
5.0 Axle pulley Grooves
5.1 (a) Ovality SMI No. Workshop /Depot
Groove No. 1 RDSO/PE/SMI/ <0.5mm/<0.8mm
TL/0030-2005
Groove No. 2 <0.5mm/<0.8mm
(Rev.0) dt.
Groove No. 3 <0.5mm/<0.8mm
12.08.2005
Groove No. 4 <0.5mm/<0.8mm
Groove No. 5 <0.5mm/<0.8mm
Groove No. 6 <0.5mm/<0.8mm
5.2 (b)Groove bottom Should be no
Groove No. 1 shining.

Groove No. 2
Groove No. 3
Groove No. 4
Groove No. 5
5.3 (c) Groove Drg N0. Checked by
Angle RDSO/PE/SK/TL/0087- GO/NO GO
Groove No. 1 2005 (Rev.0) gauge 32°-36° –
(AC) 36-400 - (TL)
Groove No. 2
Groove No. 3
Groove No. 4
Groove No. 5

Groove No. 6
5.4 Distance between - 227±2.5 mm (AC)
wheel hub & axle 140+-1 mm (TL)
pulley
5.5 Gap between two SMI No. 3.0±0.5mm
halves of axle RDSO/PE/SMI/TL/0030
pulley -2005 (Rev.0) dt.
12.08.2005
5.6 White band found
condition
5.7 Rubber pad of Axle Must change item in
pulley POH
6.0 Four-point SMI No. Should be
alignment RDSO/PE/SMI/TL/0030- correct
2005 (Rev.0) dt.
(a) On axle pulley
12.08.2005
Point ‘A’
Point’s’
(b) On alternator Should be
pulley correct
Point ‘C’
Point ’D’
7.0 Tensioning device condition
7.1 Sleeve
7.2 Bogie bracket for
tensioning device
7.3 Condition of Drg. No. SKEL3940
rotary spring seat
7.4 Free length of As per RDSO/ PE 345±3 mm
spring /AC/0068-2004 (Rev.0)
7.5 Working length of Drg. No. SKEL3940 295±3 (AC)
spring 310+-3 mm
7.6 Length of Indicator Drg. No. 250 mm
SKEL3940
7.7 Gap between plain Drg. No. 50 (AC)/35
washer & bogie bracket SKEL3940 mm (TL)
8.0 Other observations
8.1 Running of coach km.
8.2 Any abnormality
8.3 Coach marshaling Position from
engine
9.0 Condition of battery - Voltage off load:
Voltage on load Sp.
Gravity.
10.0 Discussion-How the
failure took place?
11. Conclusion:
1. Why did it fail?
2. Action taken
Cause wise analysis of V-belt failures

8 Age above 2 lakh Km

22 2
4 Alignment
5 Under cut
Top cut
Alternator stuckup
55
Excess Lateral play
22
Improper tension
Miscellaneous
Equipment wise analysis of ineffective of
TL&AC coaches

3 2 5
12 V-belt
AC equipment
Battery
Regulator
50
Alternator
28 Miscellaneous
Average life for all makes V-belts
ER 0.93 Lac km
NER 1.53 Lac km
NWR 0.79 Lac km
SR 2.05 Lac km
SER 1.61 Lac km
Average 1.09 Lac km
Minimum life required from IOH to IOH (700 km
per day) = 1.89 Lac km. Taking safety factor into
account it should be 2.5 Lac KM.

Source: Field data for 33509 coaches collected by RDSO in 2009

Thanks