Gates DriveAlign Automatic Accessory Drive Belt Tensioners & Idler

190 Pages·2004·4.14 MB·English

427-0725
5/04
DriveAlign
TM
DriveAlign
TM
Automatic Accessory Drive Belt Tensioners & Idler Pulleys
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DriveAlignTM Automatic Accessory Drive Belt Tensioners & Idler Pulleys
Table of Contents
Product Information
Passenger Cars & Light Trucks Tensioner & Pulleys . . . . . . . . . . . . A1-A21
Passenger Cars Decoupler Pulleys . . . . . . . . . . . . . . . . . . . . . . A22-A23
Heavy Duty Vehicles Tensioner & Pulleys . . . . . . . . . . . . . . . . . . . .A24-29
Idler Pulley Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A30-A32
Alphabetical Listings
Passenger Cars Alternator Decoupler Pulleys . . . . . . . . . . . . . . . . . . . .1-2
Passenger Cars Tensioner & Pulleys . . . . . . . . . . . . . . . . . . . . . . . . .3-45
Light Trucks Tensioner & Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . .46-81
Heavy Duty Fleet Tensioner & Pulleys . . . . . . . . . . . . . . . . . . . . . .82-103
Buses, Farm & Construction Equipment . . . . . . . . . . . . . . . . . . . .104-108
Changeover Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109-114
Manufacturers’ Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115-118
Numerical Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119-155
WARNING
Do not use Gates Corporation belts, pulleys or sprockets on any aircraft propeller or rotor drive systems or in-flight
accessory drives. Those Gates products are not designed or intended for aircraft use.
CAUTION
Use Gates products only on applications specified in Gates literature. Install and maintain products according to the
vehicle manufacturer’s recommended procedures and with recommended tools. Failure to follow these instructions
could result in injury or property damage. Gates disclaims all liability due to failure to follow these instructions.
Limited Warranty for the Life of the Merchandise
Merchandise is warranted to be free from defects in material or workmanship for the life of the merchandise.
Damages from misuse, abuse or gradual wear from normal use are excluded from this warranty. Gates Corporation
will, at its option, replace or repair any merchandise proved defective in material or workmanship, or both, during
the warranty period. This is the exclusive remedy. For warranty service please contact the Automotive Labor Claims
Department (Mail Code BN-A1), Gates Corporation, 1551 Wewatta Street, Denver, Colorado 80202. ALL OTHER
EXPRESS WARRANTY AND IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, HEREBY IS DISCLAIMED TO THE EXTENT SUCH EXCLUSION IS PERMITTED BY LAW.
LIABILITY FOR CONSEQUENTIAL, INDIRECT, SPECIAL, OR INCIDENTAL DAM-AGES HEREBY IS DISCLAIMED TO THE
EXTENT SUCH EXCLUSION IS PERMITTED BY LAW. Some states do not allow the exclusion or limitation of incidental
or consequential damages, and some states do not allow limitations on how long an implied warranty lasts, so the
above limitation and exclusion may not apply to you. This warranty gives you specific legal rights and you may also
have other rights, which vary from state to state.
We hereby certify that the goods will be produced in compliance with requirements of Sections 6 and 7 of the Fair
Labor Standards Act of 1938, as amended, and of regulations and orders of the U.S. Department of Labor issued
under Section 14 thereof.
Gates Corporation
P.O. Box 5887
Denver, Colorado 80217
Copyright ©2004 Printed in U.S.of America
DriveAlignTM Automatic Belt Tensioners
AAuuttoommaattiicc BBeelltt TTeennssiioonneerrss::
Why cars have them and where to get them
Over 100 million vehicles use automatic belt Tensioners are designed into the belt drive system for
tensioners. Tensioners, like any other part, several reasons:
don’t last forever, and automotive technicians •Proper tension is maintained throughout belt life.
will be replacing more and more of them. •Reduce maintenance by eliminating need to retension
belts on a periodic basis.
The vast majority of vehicles with serpentine belts often •Provides consistent and correct belt tension, thereby
have an automatic tensioner. Tension is provided by a increasing bearing life of accessories.
powerful spring located within a small canister-like •Increase belt life because belt is not over or
housing and tensioning arm to which a pulley is under tensioned.
attached. The arm pivots around the spring housing and •Prevent belt slip. A belt that slips is not only noisy but
generates a constant belt tension. can also cause accessories to not function properly.
How does a tensioner work?
The tensioner is a spring-loaded device consisting of A belt length variation gauge is built into most
eight basic parts. tensioners. The gauge indicates belt length. It consists
1. Base:stationary part of the tensioner that is bolted to of a pointer and either two or three marks indicating
engine block or other accessories. Base designs vary. the range of tensioner movement. Minimum belt length,
Some base components are very complicated and may ideal length and full take-up
include bracketry or conduits that carry engine coolant. length are usually indicated on
2. Tension Spring:preloaded at the factory. It provides the gauge. The gauge window is
force to tension the belt. located on or along the break
3. Damping Mechanism:a composite mechanism that between the base and tensioner
smooths system vibration. Tensioners with worn out arm. As a belt wears with age,
damping mechanisms need to be replaced. the tensioner automatically moves to keep belt tension
4. Arm:connects spring to tensioner pulley. Usually an constant. As this happens, the length gauge pointer will
aluminum casing. move toward maximum length. When the pointer is
5. Sealing Disk: attaches base to arm and prevents within 5% of the maximum belt length mark, the
internal contamination. tensioner is out of its useful
6. Pulleys/Bearings:are thermoplastic or steel and range and the belt should
4
may be grooved, flat or flat with flanges. Pulley be replaced. Belt wear
surfaces should be inspected regularly for damage often results in squeals and
or wear. The key component of a pulley is the 3 loose appearance.
bearing. For a pulley to function 5
2
properly, the bearing must be Careless belt
1
properly lubricated. The replacement can also
most frequent cause of result in tensioner failure.
pulley failure is loss of A tensioner that is
lubrication in the bearings. allowed to snap back to
Do not attempt to put new its original position can
bearings in an old pulley. crack and break. In
6
7. Dust Shield:protects bearing addition, a belt that is
from elements. too short can cause the
8. Bolt:connects pulley to arm. 7 tensioning arm to break.
8
Note: A tensioner cannot be rebuilt since internal parts are not available. Never try to disassemble a tensioner unit. Injury may result.
A1
DriveAlignTM Automatic Belt Tensioners
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DriveAlignTM tensioners fit and
perform like the original.
Only DriveAlign automatic tensioners look and install exactly What are the advantages of a DriveAlign
like the original equipment part. No more hunting for OE automatic tensioner?
replacement parts. No more worries about inferior “universal •Assures constant and correct belt tension,
fit” brands costing you money and valuable customers. No eliminating the need to re-tension
more time-consuming grinding or gluing during installation. •Dampens system vibrations within the belt accessory
Our tensioners bolt on just like the original tensioner. drive system
With DriveAlign tensioners, you’ll get performance that’s •Maintains correct belt alignment
equal to or better than the original. In fact, our engineers
• Prolongs life of other accessory drive components
analyze the early failure modes of OE designs and make
• Reduces belt noise and wear by preventing belt slip
any necessary adjustments to improve quality.
• Indicator of correct belt length
• Provides belt replacement gauge
Chrysler DriveAlignTM Competitor
Ford DriveAlignTM Competitor
General Motors DriveAlignTM Competitor
A2
DriveAlignTM Automatic Belt Tensioners
TThhee TTeecchhnniiccaall TTrruutthh AAbboouutt BBeelltt TTeennssiioonneerrss
Round Torsional Spring vs. Flat Spring Technology
DriveAlign’s Round Torsional Spring Competitor’s Flat Spring
• Even rotational load. Offers resistance to • Uneven resistance through distributed concentric coil.
compressive force.
• Tighter dimensional tolerances for better • Less dimensional tolerance control. As a result, flat spring
output control. dimensions may vary significantly.
• Coil diameter tension remains constant across a • Tension varies because flat design operates within a
wider range of motion. narrower range rather than operating across all areas
of the spring.
• Creates no heat build up. Less heat means • Builds up heat from friction caused by greater surface
longer tensioner life. contact of spring coils. Heat increases tensioner
component wear and failure.
• Fewer stress points to weaken tensioner. • More stress points along spring edges that can weaken
tensioner, resulting in spring fatigue.
• Vibration and noise free. Space between coils • Close-wrapped coils vibrate and become noisy as a
keeps them from rubbing together. tensioner wears.
• Damping mechanism absorbs shock loads for • Damping mechanisms are not included on most
stable operation. Damping remains constant aftermarket flat spring tensioners. This means shorter
throughout life of tensioners. belt life, more vibration noise, belt slip, and ultimately,
more returns.
• Not affected by contaminants because of the • Subject to failure due to contamination because dirt and
spacing between the spring coils. grime lodge between coils. Particles become trapped,
causing tensioner spring to seize.
• Damping mechanism is internal and protected • Damping disks are external and subject to wear by
from contaminants. contamination.
A3
DriveAlignTM Automatic Belt Tensioners
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TTeennssiioonneerr RReeppllaacceemmeenntt TTiippss::
Always disconnect battery and wear appropriate safety equipment before
performing any work under the hood.
1 Always refer to vehicle manufacture’s guidelines for installing tensioner and pulleys.
2 Refer to OE belt routing diagram located under hood or sketch routing before belt removal to provide
easy belt installation.
3 Observe the method for lifting the tensioner away from the belt.
General techniques for withdrawing the tension from belt:
• 3/8" or 1/2" square cavity on tensioner for breaker bar.
• Pulley bolt is designed to be used as a lifting feature if cavity is not present. Use breaker bar
and socket of proper fit. Bolt thread will be right or left in order to not loosen during lifting.
Double check socket size to ensure proper fit to bolt.
• Cast lug is utilized on some models. Lifting is performed by using an open-end wrench.
Proper seating of wrench or breaker bar is essential, otherwise slippage can
occur and cause injury. Use our professionally-designed tools on the following
page to assist in the removal and installation of belts and tensioners.
4 Lift tensioner arm away from the belt.
5 Remove belt from smallest pulley.
6 Slowly lower tensioner arm into original position.
Rapid release can cause injury and/or damage to tensioner and engine.
7 Remove the tensioner mounting bolt and washer (if supplied) for reinstallation.
8 Install new tensioner in the reverse order of removal.
• Additional instructions are supplied with each tensioner. Please review these instructions before
attempting to install the new tensioner.
9 Install belt in the reverse order of removal.
Ensure the belt is properly seated in all pulley grooves and routed correctly.
Start engine for 30 seconds, shut off, and recheck that the belt is seated
and tracking properly.
Torque Specifications:
When OE mounting bolt torques are Thread Size/Type Recommended Torque (ft. lbs)
unavailable, the following torques 8mm 16 – 24
are recommended for the bolt * 3/8 inch 24 – 35
sizes commonly used.
10mm 40 – 48
* 12mm 60 – 70
*usually found on pre-1990 vehicles
A4
DriveAlignTM Automatic Belt Tensioners
TToooollss
DriveAlign Laser Alignment Device
™
Quickly identifies two most common types of pulley misalignment—parallel offset
and angular—that reduce belt and pulley service life and produce unwanted
noise. Simply position tool within grooves of pulley and aim laser beam at
opposite pulley. Exclusive, patented tool is compatible with all automotive
serpentine belt drives. Lightweight, easy-to-use tool includes special laser
enhancement glasses for easy viewing in all light conditions. Comes with
high-impact resistant carrying case.
Serpentine Ratcheting Wrench Set
Provides fast way of releasing tension on serpentine belt drives. Reversible,
21-tooth ratcheting heads on each end allow for better tool positioning and
more swing than standard serpentine belt wrenches. No adapters to get lost
or fall out. Wrenches are 21-1/2" long, 6" longer than competitive designs
for increased leverage. Includes eight sizes for maximum application
coverage:13mm, 14mm, 15mm, 16mm, 17mm, 3/8", 1/2" and 3/4".
Heavy-Duty Ratcheting Serpentine Wrench
Only 13" long, wrench is designed for restricted areas where radiator
hoses,charged air cooler pipes, hydraulic lines and frame rails often interfere
with maintenance. Has 27-tooth ratchet for better tool positioning and more
swing than standard serpentine belt wrenches. Reversible ratchet head is only
1" thick to fit between tensioner face and fan blades like on series 60 Detroit
Diesel and Caterpillar engines. Great for buses and delivery vans where
doghouse or engine shrouding gets in the way of work area.Works on any
serpentine belt tensioner with a 1/2" square drive opening, including engines
made by Caterpillar, Cummins, Detroit Diesel, International, Navistar, Mack
and Volvo.
Serpentine Belt Tension Relief Tool
Provides necessary leverage and clearance to release spring pressure and
move tensioner pulley arm when removing and installing serpentine belts.
New 3-bar design includes seven sockets (13mm, 14mm, 15mm, 16mm,
18mm, 3/8" and 1/2").
Serpentine Belt Installation Tool
Reduces time and frustration of installing serpentine belts on hard-to-reach
drives. Two-pin hook end holds belt for precise placement while grooved
handle provides necessary grip to maneuver tool around pulleys. The 25" tool
is also handy for installing difficult-to-reach timing and V-belts.
A5
DriveAlignTM Automatic Belt Tensioners
AAcccceessssoorryy DDrriivvee BBeelltt TTeennssiioonneerrss
For Passenger Cars & Light Trucks
38101 38102 38103
38104 38105 38106
38107 38108 38109
38110 38111 38112
A6
DriveAlignTM Automatic Belt Tensioners
AAcccceessssoorryy DDrriivvee BBeelltt TTeennssiioonneerrss
For Passenger Cars & Light Trucks
38113 38114 38115
38116 38117 38118
38119 38120 38121
38122 38123 38124
A7
DriveAlignTM Automatic Belt Tensioners
AAcccceessssoorryy DDrriivvee BBeelltt TTeennssiioonneerrss
For Passenger Cars & Light Trucks
38125 38126 38127
38128 38129 38130
38131 38132 38133
38134 38135 38136
A8