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Accessory Belt Drive Training

Gates, Feb, 23rd, 2017

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Agenda

› You will learn:   Heavy Duty Accessory Belt Drive System (ABDS)

  Problem Solving Solutions

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Video

We Can’t Do It Like We Used To!

An Introduction to I60/R90 Be System Smart

•  Is the Glass Half Empty or Half Full

•  Is the Tire Half Empty or ….

Sitting on an Airplane

Warranty Survey Says:

•  40% of Radiator failure due to coolant contamination

•  40% of Batteries returned, just needed charging

•  70% of returned Rotating Electrical perform as intended

•  90% of Timing Belts fail after the tech installs just a belt

•  91% of OE Coolant Hose failures are spiking at 10-11 years

•  95% of replaced Water Pumps fail because of non-flushing

Research Says You’re Missing Something Important!

Warranty Survey Says:

•  40% of Radiator failure due to coolant contamination

•  40% of Batteries returned, just needed charging

•  70% of returned Rotating Electrical perform as intended

•  90% of Timing Belts fail after the tech installs just a belt

•  91% of OE Coolant Hose failures are spiking at 10-11 years

•  95% of replaced Water Pumps fail because of non-flushing

Research Says You’re Missing Something Important!

Tech is the First Responders to Failure

First Responders

The road is filled with pot holes and visual queues of failure along the way

Red Flag illuminators! Complaints! •  The belt is making noise / squealing

•  This is the second time I have replaced this belt …

•  The alternator is just not charging / This is the second time I have replaced it!

•  The battery is not holding a charge

•  The air conditioning is not cooling and the belt is squealing

•  There is a DTC on and we can’t get it to cycle off!

HDABDS Challenges!

Underlying Assumptions … Ask more questions to discover the root of the problem!

If you are replacing the same component a second time for the

same reason, then fully inspect the system for proper diagnosis before

reinstalling another component.

Second Time Ø Profits/Production

Worn components put the entire system at risk!

Think About The System As A Whole

Source: Continuing Consumer Automotive Maintenance Survey

Chart: – 100,000 households representing 175 – 200 K vehicles are surveyed annually

•  Replacement Rate by Mileage Ranges for the Serpentine Belt and Related Belt Driven Component

Source: Continuing Consumer Automotive Maintenance Survey

Accessory Belt Drive System (ABDS)

› HD Tensioners

Heavy Duty Accessory Belt Drive System (HDABDS)

1998 – 40% of engines had a tensioner

2015 – Over 95% of engines have one or more tensioners

AC Belt Tensioner

Fan / Alternator Belt Tensioner

Freightliner FLD W/ Cat C12 Motor

Parts in the System:

•  Serpentine Belt

•  Tensioner

•  Alternator Decoupler Pulley

•  System Pulleys

•  Related Accessories

Source: Continuing Consumer Automotive Maintenance Survey

HDABDS

An Example of Change

Belt Wear Message •  OEMs shifted from Neoprene to EPDM

material starting in 1996

•  EPDM extends belt-life beyond 100K miles

•  Rib wear now becomes a significant factor

in belt performance, not cracks!

•  Traditional belt wear signs no longer apply!

100,000 miles +

Just 5% of belt wear will facilitate belt slip.

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ABDS System: “PAT”

Pulleys

Alignment

Tension

Off Tracking

Spray Bottle Test for Noise

My Belt is Squealing

Spray the bottom of the belt. •  If the noise increases, it’s tension-related •  If the noise goes away and then comes back, it’s an

alignment problem

Belt Troubleshooting Examples

COMPRESSOR INSTALLATION INSTRUCTIONS Follow all Federal, State and Local Regulations. Proper A/C performance is dependent on all systems performing properly. Make certain that the engine cooling system is at peak operation, and that the cooling fan / fan clutch is operating properly. Worn belts, idlers and tensioners can cause poor cooling system performance due to belt slippage. Low voltage at the A/C clutch assembly can cause premature compressor failure.

Heavy Duty OE Support

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A Slipping Belt Creates False Codes

PO308 CYLINDER 8 MISFIRE

Correct Tension is Critical to the Application!

The tensioner performs two job functions

–  Maintains the correct belt tension throughout the tensioners duty cycle

–  Dampens the impulses from the engine as each cylinder fires (Torsional Vibration)

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Cycles a billion times in 100,000 miles

The Accessories’ Operation Revolves Around the Tensioner!

Have You Seen One of These?

ü  Perform the “Spin Cycle” Test

• Remove the belt, check and “Spin” the pulleys for wear

• Cycle the tensioner at least three times to check for wear

“Spin Cycle” Test

›  Belts and Tensioners

Focus On Two Growth Opportunities Gates Problem Solving Products

Problem Solving Solution DriveAlign HD Tensioner

DESIGN OBJECTIVES: ü 500,000 Mile Durability

• Built to exceed OEM specifications

• Last longer

• Superior round torsion spring

• Double row bearings

• Increased damper size

• Labyrinth seal

• Increased system life

Gates Drive Align HD Tensioner Exceeds OE Specifications

Problem Solving Solution for the DD

A Drop-in Replacement with Superior Performance •  LargerPivotBushing•  LabyrinthSealTechnology•  BeltTensionDampingSystem•  UniqueDesignforDrop-InReplacement•  DoubleRowPulleyBearing

Part # 38667

OE on the DD platforms January 2017

Root cause failure analysis: •  Is there belt system noise (PAT)?

•  Observe the HDABDS in operation before removing belt

•  Perform Spray Bottle test for tension/alignment challenges •  Are you replacing the same component a second time?

•  Review troubleshooting guide for latest information •  Perform simple belt analysis •  Inspect all accessories/clean all the pulleys

•  Spin cycle the tensioner to test for failure

Belt Noise Indicates System Failure

A Simple Analogy

RP320 – Inspection, Maintenance and Tension of Accessory Belt Drive Systems

Comprehensive Training Begins at the HUB

•  Performance Center: Interactive 24/7 eLearning

•  Tools for Schools Educator’s Resource Website

•  YouTube Video Training

•  Hydraulic Training Program

•  Webinars

•  NaviGates

Training begins at www.gates.com/hub

We Can’t Do It Like We Used To!

Worn components put the entire system at risk.

Questions?