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By Counterman
You might not be able to see it, but an accessory-drive belt is always both speeding up and slowing down. When a piston accelerates downward after the ignition of the fuel and air, the crankshaft speeds up and then slows down as it reaches the bottom of the stroke. These changes in speed are minimal, but big enough to cause problems over time.
If the pulses aren’t minimized, they can hammer the belt and the attached rotating components. On a four-cylinder engine, the degrees of rotation between power pulses are greater than on a V-8 – so the amount of change in speed on the four-cylinder pulley is greater than on a V-6 or V-8. This has a direct effect on how the belt system is designed.
The belt-drive system is working hardest when the engine is at idle. When the engine is below 1,000 rpm, the alternator, A/C compressor and power-steering pump are putting the greatest strain on the belt.
Some of the forces can be taken up by the belt slipping on the pulleys. But, slipping causes friction and wear on the belt, as well as flutter. Over time, the slipping can get worse as removal of material from the ribs causes the belt to bottom out.
There are three components that help to keep the belt on the pulleys without slipping. The tensioner, harmonic balancer and decoupler pulley work together to keep the accessory-belt system quiet and the belt lasting until the replacement interval.
Tensioner
The tensioner applies force on the belt. Some tensioners have devices that dampen the movement of the spring and arm, helping to keep constant force on the belt even under a wide variety of conditions.
Harmonic Balancer
The harmonic dampener puts a layer of soft material between the crankshaft and outer ring of the pulley. The material helps to dissipate the power pulses and resonant frequencies. While the dampener may only flex one or two degrees of movement, this takes a lot of strain off attached components.
Decoupler Pulley
Some alternators have a decoupler pulley. This device serves two purposes. First, it helps to decouple the pulley from the alternator with a one-way clutch. The decoupler reduces parasitic losses by not having to fight against the momentum of the armature in the alternator while the engine is decelerating and accelerating.
Some decoupler pulleys have a spring and friction dampener to reduce vibration. When an alternator decoupler pulley is compromised, it can no longer absorb the same level of abuse, which has a trickle-down effect throughout the system.
Alternator decouplers and pulleys should be inspected every 10,000 miles for wear. Early design versions have a service life of 40,000 to 60,000 miles, with more recent versions lasting more than 100,000 miles.
When inspecting a decoupler or pulley, there are two signs that replacement is needed. First, after shutting down the engine, if there’s an audible buzzing, the bearings in the pulley have likely failed. The second sign depends on whether the vehicle has a one-way clutch (OWC), overrunning alternator pulley (OAP) or decoupler (OAD).
With the inspection cap/cover removed and the center locked, turn the pulley or decoupler with the appropriate tool. If it’s an OAP or OWC, the pulley can only be turned in the clockwise direction. If it’s an OAD, a counterclockwise turn will reveal a noticeable increase in spring force; a clockwise turn will only have slight resistance. The tensioner, harmonic balancer and decoupler pulley work together to keep the belt in contact with grooves in the pulleys. The three components are engineered together to match the engine. If one part is compromised, all are compromised, including the belt.
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By Counterman
Litens Aftermarket introduced its new “System Reset” campaign, aiming to bring awareness to the importance of proper drive-belt system maintenance.
In an effort to educate professional vehicle service technicians, Litens details what a system reset entails, its significance and the potential repercussions of neglecting this essential maintenance step when replacing a drive belt.
For a belt-drive system to perform optimally, the system’s components must be properly maintained and in tune with each other throughout the lifespan of the vehicle. When it’s time to replace the drive belt, it’s also time to replace the drive-belt system’s tensioners and pulleys. The system is properly reset when all components of the belt-drive system, including the tensioner, idler pulley(s) and the belt, are all replaced at the same time.
“As vehicle belt-drive systems become more complex, we’re aiming to equip technicians with both education and solutions,” said Scott Howat, national sales manager, Litens Aftermarket. “Properly resetting the belt-drive system enables the technician to reset the vehicle to its optimal OE level of performance.”
Benefits of a system reset – replacing the tensioner and idler pulley(s) along with the belt – include enhancing the system’s reliability and longevity, as well as reducing the risk of component failure and subsequent breakdowns. Resetting all of the belt-drive system components together promotes optimal power transmission, minimizing slippage and improving overall efficiency, which can contribute to enhanced fuel economy and performance.
Failing to fully reset the system can lead to imbalanced stress distribution, reduced overall system efficiency and premature wear of both the newly replaced parts and the remaining older components. This could result in increased friction, potential belt slippage and an elevated risk of component failure, ultimately compromising the entire belt-drive system’s reliability and performance.
Litens designs OE belt-drive systems and components to last for a designated period of time. While that number also depends on miles driven and the number of vehicle starts/stops, the belt-drive system typically runs for 100,000 miles before needing maintenance. As all of the system’s components are designed to work together, when the belt is due for replacement, it’s highly likely that the rest of the components in the system are also due.
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By Counterman
Litens Aftermarket recently introduced its latest OE improvement, the 999420A belt tensioner.
This new tensioner boasts improvements to the OE design, enabling an efficient belt-tensioner replacement process by a single technician, according to Litens.
“This tensioner was engineered to improve upon the OE design by addressing the challenges technicians encounter during the installation of belt tensioners, particularly in the confined spaces of engine compartments,” Litens explained in a news release. “Focusing on ease of installation, Litens integrated a design advancement to simplify the installation process significantly.”
The design upgrade is the lift feature, strategically placed in an offset position between the mounting bolts that secure the tensioner – adding an extra inch under the lip for a technician, providing greater ease of access.
Typically, a tensioner is located at the side of the engine compartment where there’s very little room for working hands to get a wrench on the tensioner to loosen the belt during installation. The configuration in the Litens tensioner facilitates easy access for technicians to position their wrench when loosening the belt, streamlining the installation process even in the tightest engine compartments, according to the company.
Additionally, the lift feature is designed for a 14-millimeter hex wrench consistent with OE design, rather than using a 15-millimeter hex wrench traditionally used on aftermarket tensioners. Consequently, Litens says, the technician has one less tool to keep track of throughout the replacement process.
“As an engineering company that manufactures parts, we recognize the struggles that come with installing these parts in tight space,” said Randy Wolters, product manager, belt-tensioning products, Litens Aftermarket. “With these design improvements we’re able to give the tech an extra set of hands and save them from the bloody knuckles you get when working in such a tight space.”
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By Counterman
Litens Aftermarket recently introduced 18 new SKUs to its product lineup, consisting of pulleys, belt tensioners and overrunning alternator decoupler (OAD) pulleys.
The new SKUs represent an increase in coverage for more than 9.2 million additional vehicles in operation (VIO), including more than 310,000 2023-model vehicles.
The portfolio additions are for late-model Ford, Hyundai, Porsche, Mercedes Benz, Jeep, Chevrolet and Toyota vehicles.
Litens now offers more than 900 pulleys, belt tensioners and overrunning alternator decoupler pulleys, with SKUs covering more than 275 million VIO, according to the company.
“Our continuous expansion of belt-drive products demonstrates our ongoing commitment to maintaining our position as the global leader in this product category,” said John Lussier, president of Litens Aftermarket. “Litens is the world’s largest OE supplier of belt-tensioning products, and we pride ourselves on being first-to-market in the aftermarket.”
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By Counterman
Dayco announced that Craig Frohock accepted the opportunity to join Dayco Aftermarket and Belts as its new chief executive officer, effective Jan. 16.
Reporting directly to the board of Dayco, Frohock is responsible for the business unit’s global operational performance and strategic direction.
For the past six years, Frohock has held several senior leadership roles with Tenneco. Most recently he was the group vice president and general manager of the company’s OE ride-control business, and prior to that he served as the group vice president and general manager of its integrated supply chain operations within the global aftermarket business. He also served as group vice president and general manager of the company’s aftermarket chassis business and the sealing, engine and underhood services business.
Prior to joining Tenneco, his career included 19 years at Meritor Inc., where he held positions of increasing responsibilities, including leading the aftermarket business.
Frohock earned a bachelor of science degree in mechanical engineering and a master of business administration degree from Oakland University.
“I am incredibly excited to join Dayco, a company with a rich history, a great brand and a strong market presence,” Frohock said. “I’m truly humbled by the opportunity to lead such a capable team as the company enters its next chapter.”
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