Additions, Revisions, or Updates

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1 SUBJECT DATE Symptom Diagnostics - Belt Coming Off October 2017 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change DDC-SVC-MAN-0191 DDC-SVC-MAN-0084 DDC-SVC-MAN-0193 DD Platform Belt Coming Off, Shredding or Misalignment Updated diagnostic procedures DDC-SVC-MAN-0200 DiagnosticLink users: Please update the troubleshooting guides in DiagnosticLink with this newest version. To update the tool troubleshooting guide, open DiagnosticLink and from the Help Troubleshooting Guides menu, select the appropriate troubleshooting manual, then click Update. All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION

2 2 Belt Coming Off, Shredding or Misalignment 2 Belt Coming Off, Shredding or Misalignment Check as follows: NOTE: The belt will naturally track slightly forward on the pulley. 1. Verify the complaint. NOTICE: Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. WARNING: PERSONAL INJURY To avoid injury to hands and fingers from the spring-loaded auto belt tensioner violently snapping back, do not cut the belt to remove it. 4 All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

3 NOTE: Different engine types and different water pump configurations will use different belt part numbers. 2. Check the maintenance records to be sure the belts are not overdue for a maintenance interval. Refer to section "EPA07/EPA10/GHG14/GHG17 Preventive Maintenance Tables - 93K222(CK-4) and 93K223(FA-4)". Do the belts require replacement? a. Yes; replace both belts. Refer to section "Removal of the Poly-V-Belts". Verify repair. b. No; Go to step 3. All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION

4 2 Belt Coming Off, Shredding or Misalignment Table 1. Correct Pulley Installation Incorrect Pulley Installation Correct installation. The stud protrudes past the nut. Incorrect insulation. Pulley has been installed backwards, note the stud does not protrude past the nut. 3. Visually inspect the alternator pulley for correct installation. The pulley stud should stick out of nut that secures the pulley in place. Is the pulley installed backwards? a. Yes; correct the alternator pulley orientation and replace both belts. Verify repair. b. No; Go to step 4. NOTE: Misalignment will not be caused by a faulty belt tensioner. 6 All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

5 Visually inspect the belts and pulleys for signs of misalignment or damage. The wear pattern should never reach the edge of the idler pulley surface (A). Rotate each pulley by hand checking each pulley for misalignment or damage. Do the belts or pulleys show signs of misalignment or damage? a. Yes; replace both belts and the damaged pulley. Verify repair. b. No; Go to step Remove the belts. Refer to section "Removal of the Poly-V-Belts". 6. Check the belt for fluid contamination. Check for leaks from engine or chassis components. Are there any fluids leaking onto the belt? a. Yes; repair the leaks and replace both belts. Verify repair. b. No; Go to step Rotate the idler and accessory pulleys by hand while checking for grinding, sticking, and excessive lateral or radial play. Is damage present? a. Yes; replace damaged pulley and both belts. Verify repair. b. No; Go to step Visually inspect the belt tensioner for damage. Make sure the belt tensioner is applying constant adequate tension on the belt, and make sure that it does not stick or bind. Is damage present? a. Yes; replace the belt tensioner and both belts. Refer to section "Removal of the Belt Tensioner". Verify repair. b. No; Go to step Is the engine equipped with a strut type belt tensioner? a. Yes; Go to step 10. b. No; replace both belts. Refer to section "Removal of the Poly-V-Belts". Verify repair. NOTE: Oil leaks from the belt tensioner strut can normally be seen near the bottom of the strut. 10. Inspect the belt tensioner strut. Check for a broken strut mount or oil leaking at the strut (1). Is the strut mount broken or oil leaking at the strut? All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION

6 2 Belt Coming Off, Shredding or Misalignment a. Yes; replace the belt tensioner and both belts. Refer to section "Removal of the Belt Tensioner". Verify repair. b. No; replace both belts. Refer to section "Removal of the Poly-V-Belts". Verify repair. 8 All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

7 Belt Coming Off, Shredding or Misalignment Check as follows: NOTE: The belt will naturally track slightly forward on the pulley. 1. Verify the complaint. NOTICE: Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. WARNING: PERSONAL INJURY To avoid injury to hands and fingers from the spring-loaded auto belt tensioner violently snapping back, do not cut the belt to remove it. All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION 9

8 3 Belt Coming Off, Shredding or Misalignment NOTE: Different engine types and different water pump configurations will use different belt part numbers. 2. Check the maintenance records to be sure the belts are not overdue for a maintenance interval. Refer to section "EPA07/EPA10/GHG14/GHG17 Preventive Maintenance Tables - 93K222(CK-4) and 93K223(FA-4)". Do the belts require replacement? a. Yes; replace both belts. Refer to section "Removal of the Poly-V-Belts". Verify repair. b. No; Go to step All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

9 Table 2. Correct Pulley Installation Correct installation. The stud protrudes past the nut. Incorrect Pulley Installation Incorrect insulation. Pulley has been installed backwards, note the stud does not protrude past the nut. 3. Visually inspect the alternator pulley for correct installation. The pulley stud should stick out of nut that secures the pulley in place. Is the pulley installed backwards? a. Yes; correct the alternator pulley orientation and replace both belts. Verify repair. b. No; Go to step 4. NOTE: Misalignment will not be caused by a faulty belt tensioner. All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION 11

10 3 Belt Coming Off, Shredding or Misalignment 4. Visually inspect the belts and pulleys for signs of misalignment or damage. The wear pattern should never reach the edge of the idler pulley surface (A). Rotate each pulley by hand checking each pulley for misalignment or damage. Do the belts or pulleys show signs of misalignment or damage? a. Yes; replace both belts and the damaged pulley. Verify repair. b. No; Go to step Remove the belts. Refer to section "Removal of the Poly-V-Belts". 6. Check the belt for fluid contamination. Check for leaks from engine or chassis components. Are there any fluids leaking onto the belt? a. Yes; repair the leaks and replace both belts. Verify repair. b. No; Go to step Rotate the idler and accessory pulleys by hand while checking for grinding, sticking, and excessive lateral or radial play. Is damage present? a. Yes; replace damaged pulley and both belts. Verify repair. b. No; Go to step Visually inspect the belt tensioner for damage. Make sure the belt tensioner is applying constant adequate tension on the belt, and make sure that it does not stick or bind. Is damage present? a. Yes; replace the belt tensioner and both belts. Refer to section "Removal of the Belt Tensioner". Verify repair. b. No; Go to step Is the engine equipped with a strut type belt tensioner? a. Yes; Go to step 10. b. No; replace both belts. Refer to section "Removal of the Poly-V-Belts". Verify repair. NOTE: Oil leaks from the belt tensioner strut can normally be seen near the bottom of the strut. 10. Inspect the belt tensioner strut. Check for a broken strut mount or oil leaking at the strut (1). Is the strut mount broken or oil leaking at the strut? 12 All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

11 a. Yes; replace the belt tensioner and both belts. Refer to section "Removal of the Belt Tensioner". Verify repair. b. No; replace both belts. Refer to section "Removal of the Poly-V-Belts". Verify repair. All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION

12 4 Belt Coming Off, Shredding or Misalignment 4 Belt Coming Off, Shredding or Misalignment Check as follows: NOTE: The belt will naturally track slightly forward on the pulley. 1. Verify the complaint. NOTICE: Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. WARNING: PERSONAL INJURY To avoid injury to hands and fingers from the spring-loaded auto belt tensioner violently snapping back, do not cut the belt to remove it. NOTE: Different engine types and different water pump configurations will use different belt part numbers. 2. Check the maintenance records to be sure the belts are not overdue for a maintenance interval. Refer to section "DD Series Preventative Maintenance Tables". Do the belts require replacement? For Short Haul: Refer to section "DD5 Short Haul". For Long Haul: Refer to section "DD5 Long Haul". For Severe Service: Refer to section "DD5 Severe Service". a. Yes; replace both belts. Verify repair. Refer to section "Removal of the Accessory Drive Belt" b. No; Go to step All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

13 Visually inspect the alternator pulley for improper installation. The pulley stud should protrude from the pulley nut securing the pulley in place. Is the pulley installed backwards? a. Yes; correct the alternator pulley orientation and replace both belts. Verify repair. b. No; Go to step 4. NOTE: Misalignment will not be caused by a faulty belt tensioner. 4. Visually inspect the belts and pulleys for signs of misalignment or damage. The wear pattern should never reach the edge of the idler pulley surface. Rotate each pulley by hand checking each pulley for misalignment or damage. Do the belts or pulleys show signs of misalignment or damage? a. Yes; replace both belts and the damaged pulley. Verify repair. b. No; Go to step Remove the belts. Refer to section "Removal of the Accessory Drive Belt" 6. Check the belt for fluid contamination. Check for leaks from engine or chassis components. Are there any fluids leaking onto the belt? a. Yes; repair the leaks and replace both belts. Verify repair. b. No; Go to step Rotate the idler and accessory pulleys by hand while checking for grinding, sticking, and excessive lateral or radial play. Is damage present? a. Yes; replace damaged pulley and both belts. Verify repair. b. No; Go to step Visually inspect the belt tensioner for damage. Make sure the belt tensioner is applying constant adequate tension on the belts, and make sure that it does not stick or bind. Is damage present? a. Yes; replace the belt tensioner and both belts. Verify repair. Refer to section "Removal of the Belt Tensioner (Accessory Drive)" Refer to section "Removal of the Accessory Drive Belt" b. No; replace both belts. Verify repair. Refer to section "Removal of the Accessory Drive Belt" All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION

14 5 Belt Coming Off, Shredding or Misalignment 5 Belt Coming Off, Shredding or Misalignment Check as follows: NOTE: The belt will naturally track slightly forward on the pulley. 1. Verify the complaint. NOTICE: Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. WARNING: PERSONAL INJURY To avoid injury to hands and fingers from the spring-loaded auto belt tensioner violently snapping back, do not cut the belt to remove it. NOTE: Different engine types and different water pump configurations will use different belt part numbers. 2. Check the maintenance records to be sure the belts are not overdue for a maintenance interval. Refer to section "DD Series Preventative Maintenance Tables". Do the belts require replacement? For Short Haul: Refer to section "DD8 Short Haul". For Long Haul: Refer to section "DD8 Long Haul". For Severe Service: Refer to section "DD8 Severe Service". a. Yes; replace both belts. Verify repair. Refer to section "Removal of the Accessory Drive Belt " b. No; Go to step All information subject to change without notice. Copyright 2017 DETROIT DIESEL CORPORATION

15 Visually inspect the alternator pulley for improper installation. The pulley stud should protrude from the pulley nut securing the pulley in place. Is the pulley installed backwards? a. Yes; correct the alternator pulley orientation and replace both belts. Verify repair. b. No; Go to step 4. NOTE: Misalignment will not be caused by a faulty belt tensioner. 4. Visually inspect the belts and pulleys for signs of misalignment or damage. The wear pattern should never reach the edge of the idler pulley surface. Rotate each pulley by hand checking each pulley for misalignment or damage. Do the belts or pulleys show signs of misalignment or damage? a. Yes; replace both belts and the damaged pulley. Verify repair. b. No; Go to step Remove the belts. Refer to section "Removal of the Accessory Drive Belt " 6. Check the belt for fluid contamination. Check for leaks from engine or chassis components. Are there any fluids leaking onto the belt? a. Yes; repair the leaks and replace both belts. Verify repair. b. No; Go to step Rotate the idler and accessory pulleys by hand while checking for grinding, sticking, and excessive lateral or radial play. Is damage present? a. Yes; replace damaged pulley and both belts. Verify repair. b. No; Go to step Visually inspect the belt tensioner for damage. Make sure the belt tensioner is applying constant adequate tension on the belts, and make sure that it does not stick or bind. Is damage present? a. Yes; replace the belt tensioner and both belts. Verify repair. Refer to section "Removal of the Belt Tensioner (Accessory Drive)" Refer to section "Removal of the Accessory Drive Belt " b. No; replace both belts. Verify repair. Refer to section "Removal of the Accessory Drive Belt " All information subject to change without notice Copyright 2017 DETROIT DIESEL CORPORATION