Poly-V-Belts February Description and Operation of the Poly-V- Belts. Removal of the Poly-V- Belts. Inspection of the Poly-V- Belts

Transcription

1 SUBJECT DATE Poly-V-Belts February 2018 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change Description and Operation of the Poly-V- Belts DDC-SVC-MAN-0190 Removal of the Poly-V- Belts Inspection of the Poly-V- Belts DD HD Installation of the Poly-V- Belts Description and Operation of the Poly-V- Belts Updated HD procedures. DDC-SVC-MAN-0081 Removal of the Poly-V- Belts Inspection of the Poly-V- Belts Installation of the Poly-V- Belts All information subject to change without notice. 3

2 2 Description and Operation of the Poly-V Belts 2 Description and Operation of the Poly-V Belts The Poly-V belts are used to transmit power or torque from the crankshaft to each of the belt-driven accessory components. The DD Heavy Duty engine belts are currently constructed of a compound known as Ethylene Propylene Diene Monomer (EPDM). EPDM compound is elastic by design, making it more resistant to cracking than conventional neoprene. For maintenance intervals, Refer to section "EPA07/EPA10/GHG14/GHG17 Preventive Maintenance Tables - 93K222(CK-4) and 93K223(FA-4)". The belt tensioner provides the belt with constant, adequate tension Vibration Damper Poly-V-Belt for the Fan Alternator Pulley Fan Drive Idler Pulley Poly-V-Belt for Alternator, Refrigerant Compressor and Coolant Pump 6. Tensioner Pulley 7. Refrigerant Compressor Pulley Refrigerant Compressor Belt Tensioner Fan Clutch Assembly Accessory Drive Idler Pulley and Spacer Coolant Pump Accessory Drive Idler Pulley Bracket Accessory Drive Idler Pulley All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

3 3 Removal of the Poly-V-Belts Remove as follows: NOTICE: Do not use more than a six-inch extension when applying pressure to the belt tensioner to reduce the danger of cracking the tensioner. Apply smooth pressure to the tensioner. Jerking or sudden pressure could cause damage to tensioner. NOTICE: Never turn the belt tensioner arms clockwise. NOTICE: Do not use any type of cleaning solvent on the rubber parts of the tensioner or on the belt. 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. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Open the hood. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 3. Disconnect the batteries. 4. If necessary, remove the bumper. Refer to the Original Equipment Manufacturer (OEM) procedures. 5. Install a half-inch drive socket wrench into the square hole (1) on the tensioner grooved pulley idler arm. All information subject to change without notice. 5

4 3 Removal of the Poly-V-Belts 6. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft) Insert an M10 x 80 mm bolt (or equivalent pin) (2), into the bracket hole in the idler arm. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position. Remove the fan drive poly-v belt. Install a half-inch drive socket wrench and extension into the square hole on the tensioner's non-grooved pulley idler arm. 11. Turn the non-grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft). 6 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

5 12. Insert an M10 x 80 mm bolt (or equivalent pin), into the bracket hole (3) in the non-grooved pulley idler arm. 13. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position. 14. Remove the accessory drive poly-v belt. All information subject to change without notice. 7

6 4 Inspection of the Poly-V-Belts 4 Inspection of the Poly-V-Belts Inspect as follows: NOTE: Belts will track slightly forward on the non-grooved pulleys when the engine is running. Once the engine is turned off, the belt will re-center itself. NOTICE: Do not use any type of cleaning solvent on the rubber parts of the tensioner or on the belt. Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. 1. 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)". Replace if needed. NOTE: Where the belt contacts the pulleys there will be a polished shine to the pulley created by the belt contact. If misalignment is occurring, the belt may be riding off-centered on the pulley. 2. Inspect the belt contact surfaces for chips, flaking, cracks, and discoloration using the guidelines listed below. Table 1. ABRASION Poly-V-Belt Inspection Concerns CHUNK-OUT IMPROPER INSTALL CRACKING 8 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

7 Table 2. PILLING Poly-V-Belt Inspection Concerns UNEVEN RIB WEAR MISALIGNMENT GRAVEL PENETRATION a. If any of the above conditions are present, Refer to section "Belt Drive Noise". b. If the belt shows no abnormal wear, Go to step Using the appropriate belt wear gauge, measure the amount of wear on the belt. 4. Inspect the belt (2) for wear using the gauge (1). Place the long end of the tool between the ribs of the belt. All information subject to change without notice. 9

8 4 Inspection of the Poly-V-Belts a. If the wear gauge (2) is visible above the ribs (1) of the belt, the belt may be reused. See figure below. b. If the wear gauge (2) does not protrude above the ribs (4) of the belt, replace the belt. 5. Inspect the belt drive pulleys for abnormal wear or damage; rotate the belt drive pulleys by hand while checking for grinding, sticking, and excessive lateral or radial play. 10 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

9 5 Installation of the Poly-V-Belts Install as follows: NOTICE: Do not use any type of cleaning solvent on the rubber parts of the belt tensioner or on the belt. Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. 1. Install a half-inch drive socket wrench into the square hole (1) on the tensioner grooved pulley idler arm. 2. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft). 3. Insert an M10 x 80 mm bolt (or equivalent pin), into the bracket hole (4) in the grooved pulley idler arm. 4. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position. 5. Install a half-inch drive socket wrench and extension into the square hole (2) in the tensioner's non-grooved pulley idler arm bracket. 6. Turn the non-grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft). 7. Insert an M10 x 80 mm bolt (or equivalent pin), into the bracket hole (3) on the non-grooved pulley idler arm. 8. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position. NOTE: Be sure the belt being installed on the engine is the proper width to match the pulleys. Different engine types and different water pump configurations will use different belt part numbers. 9. Install the poly-v-belts onto the pulleys. 10. Ensure the belts are properly installed on the pulleys, making sure that the belt grooves are properly aligned within the grooves of each pulley. All information subject to change without notice. 11

10 5 Installation of the Poly-V-Belts 11. Install a half-inch drive socket wrench and extension into the square hole (2) on the tensioner non-grooved idler arm. 12. Turn the non-grooved pulley idler arm counterclockwise until the pin holding the idler arm can be removed. Remove the pin. 13. Install a half-inch drive socket wrench into the square hole (1) in the tensioner grooved pulley idler arm. 14. Turn the grooved pulley idler arm counterclockwise until the pin holding the grooved pulley idler arm can be removed. Remove the pin. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 15. Reconnect the batteries. WARNING: PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. WARNING: PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 12 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

11 WARNING: ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 16. Start the engine and inspect for proper belt alignment and belt drive operation. 17. If removed, install the bumper. Refer to the Original Equipment Manufacturer (OEM) procedures. 18. Close the hood. All information subject to change without notice. 13

12 6 Description and Operation of the Poly-V Belts 6 Description and Operation of the Poly-V Belts The Poly-V belts are used to transmit power or torque from the crankshaft to each of the belt-driven accessory components. The DD Heavy Duty engine belts are currently constructed of a compound known as Ethylene Propylene Diene Monomer (EPDM). EPDM compound is elastic by design, making it more resistant to cracking than conventional neoprene. For maintenance intervals, Refer to section "EPA07/EPA10/GHG14/GHG17 Preventive Maintenance Tables - 93K222(CK-4) and 93K223(FA-4)". The belt tensioner provides the belt with constant, adequate tension Vibration Damper Poly-V-Belt for the Fan Alternator Pulley Fan Drive Idler Pulley Poly-V-Belt for Alternator, Refrigerant Compressor and Coolant Pump 6. Tensioner Pulley 7. Refrigerant Compressor Pulley Refrigerant Compressor Belt Tensioner Fan Clutch Assembly Accessory Drive Idler Pulley and Spacer Coolant Pump Accessory Drive Idler Pulley Bracket Accessory Drive Idler Pulley All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

13 7 Removal of the Poly-V-Belts Remove as follows: NOTICE: Do not use more than a six-inch extension when applying pressure to the belt tensioner to reduce the danger of cracking the tensioner. Apply smooth pressure to the tensioner. Jerking or sudden pressure could cause damage to tensioner. NOTICE: Never turn the belt tensioner arms clockwise. NOTICE: Do not use any type of cleaning solvent on the rubber parts of the tensioner or on the belt. 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. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Open the hood. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 3. Disconnect the batteries. 4. If necessary, remove the bumper. Refer to the Original Equipment Manufacturer (OEM) procedures. 5. Install a half-inch drive socket wrench into the square hole (1) on the tensioner grooved pulley idler arm. All information subject to change without notice. 15

14 7 Removal of the Poly-V-Belts 6. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft) Insert an M10 x 80 mm bolt (or equivalent pin) (2), into the bracket hole in the idler arm. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position. Remove the fan drive poly-v belt. Install a half-inch drive socket wrench and extension into the square hole on the tensioner's non-grooved pulley idler arm. 11. Turn the non-grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft). 16 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

15 12. Insert an M10 x 80 mm bolt (or equivalent pin), into the bracket hole (3) in the non-grooved pulley idler arm. 13. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position. 14. Remove the accessory drive poly-v belt. All information subject to change without notice. 17

16 8 Inspection of the Poly-V-Belts 8 Inspection of the Poly-V-Belts Inspect as follows: NOTE: Belts will track slightly forward on the non-grooved pulleys when the engine is running. Once the engine is turned off, the belt will re-center itself. NOTICE: Do not use any type of cleaning solvent on the rubber parts of the tensioner or on the belt. Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. 1. 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)". Replace if needed. NOTE: Where the belt contacts the pulleys there will be a polished shine to the pulley created by the belt contact. If misalignment is occurring, the belt may be riding off-centered on the pulley. 2. Inspect the belt contact surfaces for chips, flaking, cracks, and discoloration using the guidelines listed below. Table 3. ABRASION Poly-V-Belt Inspection Concerns CHUNK-OUT IMPROPER INSTALL CRACKING 18 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

17 Table 4. PILLING Poly-V-Belt Inspection Concerns UNEVEN RIB WEAR MISALIGNMENT GRAVEL PENETRATION a. If any of the above conditions are present, Refer to section "Belt Drive Noise". b. If the belt shows no abnormal wear, Go to step Using the appropriate belt wear gauge, measure the amount of wear on the belt. 4. Inspect the belt (2) for wear using the gauge (1). Place the long end of the tool between the ribs of the belt. All information subject to change without notice. 19

18 8 Inspection of the Poly-V-Belts a. If the wear gauge (2) is visible above the ribs (1) of the belt, the belt may be reused. See figure below. b. If the wear gauge (2) does not protrude above the ribs (4) of the belt, replace the belt. 5. Inspect the belt drive pulleys for abnormal wear or damage; rotate the belt drive pulleys by hand while checking for grinding, sticking, and excessive lateral or radial play. 20 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

19 9 Installation of the Poly-V-Belts Install as follows: NOTICE: Do not use any type of cleaning solvent on the rubber parts of the belt tensioner or on the belt. Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear. 1. Install a half-inch drive socket wrench into the square hole (1) on the tensioner grooved pulley idler arm. 2. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft). 3. Insert an M10 x 80 mm bolt (or equivalent pin), into the bracket hole (4) in the grooved pulley idler arm. 4. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position. 5. Install a half-inch drive socket wrench and extension into the square hole (2) in the tensioner's non-grooved pulley idler arm bracket. 6. Turn the non-grooved pulley idler arm counterclockwise. Maximum allowable torque is 90 to 100 N m (66 to 73 lb ft). 7. Insert an M10 x 80 mm bolt (or equivalent pin), into the bracket hole (3) on the non-grooved pulley idler arm. 8. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position. NOTE: Be sure the belt being installed on the engine is the proper width to match the pulleys. Different engine types and different water pump configurations will use different belt part numbers. 9. Install the poly-v-belts onto the pulleys. 10. Ensure the belts are properly installed on the pulleys, making sure that the belt grooves are properly aligned within the grooves of each pulley. All information subject to change without notice. 21

20 9 Installation of the Poly-V-Belts 11. Install a half-inch drive socket wrench and extension into the square hole (2) on the tensioner non-grooved idler arm. 12. Turn the non-grooved pulley idler arm counterclockwise until the pin holding the idler arm can be removed. Remove the pin. 13. Install a half-inch drive socket wrench into the square hole (1) in the tensioner grooved pulley idler arm. 14. Turn the grooved pulley idler arm counterclockwise until the pin holding the grooved pulley idler arm can be removed. Remove the pin. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 15. Reconnect the batteries. WARNING: PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. WARNING: PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 22 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

21 WARNING: ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 16. Start the engine and inspect for proper belt alignment and belt drive operation. 17. If removed, install the bumper. Refer to the Original Equipment Manufacturer (OEM) procedures. 18. Close the hood. All information subject to change without notice. 23