E2/70264 AIR SYSTEMS FUEL SYSTEMS GO THE DISTANCE WITH GATES EXTRA SERVICE SYSTEMS SOLUTIONS Unexpected breakdowns cause a considerable loss of time and high costs. In order to avoid unwanted delays, spare parts have to assure reliable and trouble-free performance. Recognising the demands of trucks, buses and commercial vehicles, Gates provides a broad range of specific heavy-duty products. Gates commercial vehicle programme is specially designed for trouble-free and long-lasting service in the demanding working conditions of vans, trucks, buses and tractors. The products in this range are built to original equipment quality and offer excellent performance. The Gates Extra Service label is a guarantee for top quality and long service life. A complete and versatile range of belt drive system, cooling system, fuel system and air system products for vans, trucks, buses and tractors Trouble-free and reliable service to minimise operating costs per kilometre Replacement products in original equipment quality Up-to-date application data COOLING SYSTEMS BELT DRIVE SYSTEMS This brochure only shows a selection of Gates products. The automotive programme comprises also systems solutions for passenger cars. Ask your distributor for more information. Please consult Gates heavy duty catalogue E/70385 for more size and application information on the Extra Service product range. Gates Extra Service: premium quality products for commercial vehicle fleets and off-road equipment Your distributor: The manufacturers reserve the right to amend details where necessary. Gates Europe nv 2006 Printed in Belgium - 09/06.
1. BELT DRIVE SYSTEMS BELT DRIVE SYSTEMS A. EXTRA SERVICE MICRO-V XF MULTI-RIBBED BELT: DESIGNED TO LAST LONGER NEW! (Prod. type 8542) This high-performance OE equivalent belt is the perfect choice for your serpentine drives and other heavy-duty ribbed applications. It is also recommended for high-speed, small-diameter applications requiring increased power transmission. The new, improved construction ensures a longer belt life and excellent performance in all conditions. Aramid fibre reinforced EPDM belt ribs resist oil, heat, ozone, pilling and wear. Newly developed polyester tensile cords guarantee low stretch and optimum load-carrying capacity at even the highest tensions. Low belt profile increases flex life, thus ensuring higher mileage and trouble-free performance. Back fabric provides extremely high resistance to wear. Re-engineered heavy-duty construction resists cracking and wear to provide longer service life. Green colour makes it easier to identify this innovative belt construction. Size-based numbering system makes it easy to determine the right belt for the application. Largest product range offers complete market coverage. B. EXTRA SERVICE DRIVEALIGN TENSIONERS & PULLEYS (Prod. type 7808 & 7803) Long-lasting tensioners and pulleys built to endure the rigours of today s heavy-duty, fleet and off-road equipment. In laboratory tests, under extreme peak-to-peak vibration and contamination tests, DriveAlign Gates Extra Service tensioners lasted up to three times longer than competitive aftermarket tensioners did. For specific applications small design differences from the OEM tensioners allow Gates design to improve performance in the same space. Labyrinth seal prevents contamination of internal parts for maximum durability and service life. Optimised components, engineered for maximum strength and durability. Patented design provides superior belt alignment and tension for improved drive efficiency and life. Chrome-silicone torsion spring for improved flex fatigue characteristics. Patented damping mechanism provides maximum stability, reducing vibration and increasing tensioner life. 2
C. EXTRA SERVICE EXL BANDLESS MOULDED COG V-BELT (Prod. type 8701) This powerful and highly flexible V-belt is designed to live up to the demanding requirements of today s heavy-duty applications. The use of state-of-the-art materials and manufacturing processes results in improved belt performance. Belt stability is increased and tension decay is substantially reduced. Special, double layer of reinforcement not only protects the belt top, but also increases belt flexibility, thus ensuring long and trouble-free performance. Thermally active tensile cords for maintenance-free performance when the belt is properly installed and tensioned. Fibre-loaded rubber stock puts more flexibility along the belt length, yet gives the belt greater lateral stability and improved load-carrying capacity. Belt cogs are aramid fibre reinforced. Aramid fibre is self-lubricating, allows the belt to run smoothly and quietly in the pulleys and keeps it from turning over or coming off the drive. Fibre-reinforced rubber also improves wear resistance and therefore reduces maintenance. V-form is ground for precise top width, exact sidewall dimensions and proper belt fit. BELT DRIVE SYSTEMS D. EXTRA SERVICE BANDLESS LAMINATED V-BELT (Prod. type 8531-2) Long and strong belt, specially suited for long centre distance drives. Thanks to the flexible, yet very stable construction the belt easily resists shocks and vibrations common to long centre distance drives equipped with large pulleys. Extra strong, heat resistant polyester tensile cords. Cross-cord layers to support the load-carrying belt section and to increase lateral stability. Special fibre-reinforced rubber compound. Oil, heat and wear resistant. Flex-Weave layers in undercord for more flexibility along the length, increased lateral rigidity and crack resistance. E. EXTRA SERVICE BANDED BELT (Prod. types 8527 and 8569) Wrapped V-belt providing maximum protection in severe working conditions. Concave sidewalls straighten out to assure optimum contact with the pulley and uniform belt load. Strong flex-bonded tensile cords work as one solid and inseparable unit. Flexible Flex-Weave cover protects against dirt, grit and oil. With built-in static conductivity. Rubber compound withstands oil, heat and wear. Recommended for: older generations of heavily loaded V-belt drives (classical section 8527); drives subject to heavy vibration (high-capacity section 8569) where bandless laminated belts show stability problems. 3
BELT DRIVE SYSTEMS F. EXTRA SERVICE POWERBAND BANDED MULTIPLE V-BELT (Prod. type 8582) This belt replaces original equipment joined belts on heavy-duty problem or high-load drives. It consists of two or more banded V-belts joined together by a permanent reinforced rubber tie band. This strong band controls belt-to-belt distance and keeps the belts from bending sideways. Thanks to its construction PowerBand is specially suited for vibration and shock sensitive drives where single belts turn over or jump off the pulleys. Wrapped with Flex-Weave fabric for maximum protection in severe working conditions. Concave sidewalls for optimum contact with the pulley and uniform belt load. Strong flex-bonded tensile cords. Polychloroprene compound withstands oil, heat and wear. G. EXTRA SERVICE POWERBAND MOULDED COG MULTIPLE V-BELT (Prod. type 8541) Consists of two or more moulded cog belts joined together by a high-strength tie-band, thus being tougher than belts taken separately. Ensures excellent stability lacking in ordinary belt sets. The cogged PowerBand cannot turn over or slip off the drive. Evenly distributed strand-to-strand distance provides better shock load absorption. Moulded cogs reduce bending stress, especially on small diameter pulleys, and help dissipate heat. Unique tensile cord design gives extra strength, added flexibility and shock load resistance. Recommended for: heavy-duty automotive drives, subject to severe and problematic vibrations. H. GATES INDUSTRIAL V-BELTS Premium belts such as the raw edge, narrow section Quad-Power II and Super HC MN V-belts and the classical section Hi-Power MN V-belts ensure excellent performance on the heaviest industrial drives. They feature high modulus thermally active polyester cords that exhibit extremely low stretch. A leading-edge technology delivering the advantages every user is looking for: less maintenance and greater cost savings. 4
2. COOLING SYSTEMS A. GREEN STRIPE STRAIGHT COOLANT HOSE (Prod. type 4168) This resistant and flexible radiator hose is perfect for general use on straight or slightly bent connections in heavy-duty vehicles. 2-ply bias fabric construction to maximise flexibility and strength. Resists cold water leaks thanks to an advanced EPDM tube that stays soft and pliable, even under adverse operating conditions. Reduces water loss from water permeating the hose wall and cover, a distinct advantage over silicone. Engineered to resist electrochemical degradation the leading cause of hose failure. Ambient temperature range: -40 C to +135 C. Meets requirements of SAE 20R1 type EC, class D, standard wall. Available in 1 m lengths, cover is marked in 1 cm increments to facilitate customer-fit installation. Inside diameter range from 19 mm to 114 mm. COOLING SYSTEMS B. EXTRA SERVICE STRAIGHT SILICONE HOSE (Prod. type 4171) This straight silicone hose functions perfectly as radiator, heater or other coolant transfer hose in poorly ventilated conditions. Gates silicone hose resists extreme temperatures and is easy to cut to size. Multiple layers of first grade silicone material. Reinforced by high-temperature resistant knitted synthetic fibre. Extra thick and resilient tube prevents cold-water leaks and hardening under effect of heat. Resistant to weathering, ozone, coolants and lubricating oil. Temperature range from -40 C to +176 C. Meets requirements of SAE 20R1, class A, standard wall. Inside diameter range from 13 mm to 114 mm (1 m lengths). 5
COOLING SYSTEMS C. EXTRA SERVICE 90 CURVED SILICONE HOSE NEW! (Prod. type 4281) This silicone hose guarantees an outstanding performance in high-temperature environments, offers high durability and low maintenance and is made of a soft and flexible material, which exhibits excellent resistance to compression set. Its shape conforms to the cooling system configuration as often seen in today s heavy-duty vehicles. Multiple layers of first grade silicone material. Reinforcement : 3-ply polyester knit, unaffected by permeation of coolants and heat. Tube : extra thick and resilient, preventing cold water leaks and hardening under effect of heat. Cover : resistant to coolants, ozone, weathering, sunlight and extreme ambient temperatures. Temperature range from -55 C to +176 C. Meets requirements of SAE 20R3 HT, class A, and SAE 20R4 HT, class A. Inside diameter range from 10 mm to 75 mm. D. EXTRA SERVICE CURVED HOSE (Prod. type 4278) This versatile hose is used for many heavy-duty applications. It is easy to cut to size and to install. Symmetrical 90 curved hoses are frequently used in trucks, buses and tractors or other industrial type applications. Aramid knit reinforcement. Extra thick and resilient tube prevents cold-water leaks and hardening caused by heat. Resistant to heat, coolants, ozone and weathering. Temperature range from -40 C to +100 C, occasionally to +110 C. Meets requirements of SAE 20R4, class D2, and DIN 73411, class A. Inside diameter range from 10 mm to 80 mm. E. EXTRA SERVICE VULCO-FLEX RADIATOR HOSE (Prod. type 4284) Vulco-Flex is a flexible radiator hose with built-in spiral wire. It is a permanent replacement hose, equalling the performance of moulded hose. The Vulco- Flex hose can replace a multitude of curved hose sizes and shapes. Together with Gates straight and curved radiator hoses, this flexible quality hose allows optimum market coverage. The built-in steel spiral wire allows for medium sized curves without kinking or collapsing. Polyester fabric ply reinforcement. Easy to install. It vulcanises into shape without unnecessary strain on connections. Resistant to coolants, oil and ozone. Temperature range from -40 C up to 100 C. Available in different lengths. Inside diameter range from 45 mm to 76 mm. 6
F. EXTRA SERVICE WIRE-INSERTED GREEN STRIPE HOSE (Prod. type 4685) Practical, flexible and long radiator hose replacing many different shapes of curved hose. The built-in spiral wire enables it to bend to any required shape, with minimum strain on radiator and engine connections. Reinforcement: fabric around steel wire spiral. Resistant to heat, grease and oil. Temperature range from -40 C to +100 C. Meets requirements of SAE 20R5, class C. Available in 1.52 m lengths, individually cartoned. Inside diameter range from 25 mm to 102 mm. COOLING SYSTEMS G. EXTRA SERVICE STRAIGHT SILICONE HEATER HOSE (Prod. type 3231) Highly durable and flexible heater hose for commercial vehicles. Outstanding resistance to the extreme temperatures occurring in poorly ventilated conditions. Reinforcement: aramid knit unaffected by permeation of coolants and heat. Resistant to coolants, ozone and weathering. Temperature range from -55 C to +204 C. Meets requirements of SAE 20R3, class A. Packaging: 7.62 m length (25 ft) per carton. Inside diameter range from 10 mm to 25 mm. H. EXTRA SERVICE STRAIGHT HEATER HOSE (Prod. type 4230) Strong heater hose ensuring long, trouble-free service on straight or large bend radius connections. Rubber cover with textile imprint (wrapped appearance). Textile braid reinforcement. Resistant to cold water leaks, coolants, oil drops and ozone. Temperature range from -40 C to +110 C, occasionally +125 C. Meets requirements of SAE 20R3, class D2. Available in 15 m lengths in carton. Inside diameter range from 12 mm to 25 mm. 7
I. HOSE ID REDUCERS COOLING SYSTEMS (Prod. type 7736) ID reducers make it possible to adjust inside diameters of larger hoses for emergency replacements. They slip inside all current Gates coolant hose giving maximum coverage with minimum hose inventory. Recommended for coolant and air applications only. Quality rubber construction avoids leakage thus assuring maximum dependability. Packaging: 5 pcs in a plastic bag. J. HEATER HOSE CONNECTORS (Prod. type 7315) Gates heater hose connectors are recommended for small diameter heater and radiator hoses to provide a better seal between hoses with same or different inside diameters. Using straight, reducer, elbow and T connectors, almost any hose configuration can be constructed. The heater hose connectors are also available in a practical heater hose connector kit: a sturdy plastic case holding an assortment of 36 connectors. Made of 100% glass-reinforced nylon. Anti-rotation device prevents the hose from twisting off the fitting. Single-barb design ensures a leak-proof seal. Superior resistance to extreme temperatures from -65 C to +250 C and coolant additives, petrol, diesel, oil and LPG. Maximum working pressure up to 2 MPa (20 kg/cm 2 ). Outside diameter (= hose inside diameter) range from 6 mm to 25 mm. Packaging: 5 pcs in a plastic bag. 8
3. FUEL SYSTEMS A. FLEXIBLE FUEL FILL HOSE (Prod. type 4663) Flexible hose for connection between vehicle s filler neck and fuel tank. Also suited for auxiliary fuel tanks on recreational vehicles. High-quality nitrile tube makes hose suitable for use with most commercial fuel types. Especially resistant to leaded and unleaded petrol and diesel. Corrugated cover with helical wire reinforcement. Cuts easily with knife and wire cutters. Temperature range from -40 C to +100 C. Meets requirements of SAE 30R5. Packaging: 0.91 m (3 ft) length in a cardboard box. Inside diameter range from 38 mm to 63 mm. FUEL SYSTEMS B. FUEL LINE HOSE (Prod. type 3225) Small-diameter multi-purpose hose designed for different types of fuel circuit (leaded and unleaded petrol, diesel). Recommended for: clamped hose applications on all fuel systems, including fuel injection systems. Do not use for: in-tank applications, sour gas, LPG and bio diesel. Not designed to replace coupled hose assemblies on fuel injected engines. Cover resists heat, oil, ozone and weathering. Tube has been upgraded to meet changes in fuel characteristics and resists heat and oil. Spiral textile reinforcement. Working pressure up to 1 MPa (10 kg/cm 2 ). Ambient temperature range: -35 C to +125 C. Meets requirements of SAE J30R7, ISO 4639-2 and DIN 73379 (except for tolerances). Packaging: ID up to 8 mm: 15 m on a reel; ID of 10 mm: 10 m on a reel; ID of 10 and 12 mm: 15 m in a carton Inside diameter range from 3.2 mm to 12 mm. C. LOW PERMEATION FUEL HOSE (Prod. type 4219) A very high-quality hose that meets the latest environmental standards and requirements. Recommended for: clamped hose applications on fuel systems. Do not use for: in-tank applications and LPG. Not designed to replace coupled hose assemblies on fuel injected engines. Fluoroelastomer tube liner resists permeation of alcohol and sour gas. Tube resists heat, sour gas and fuel (leaded, unleaded and alcohol based petrol, diesel, bio diesel). Cover resists heat, ozone and abrasion. Polyester braid reinforcement. Working pressure up to 1.2 MPa (12 kg/cm 2 ). Ambient temperature range: -35 C to +150 C. Meets requirements of SAE 30R9. Available in 7.62 m or 3.048 m lengths. Inside diameter range from 6 mm to 10 mm. 9
D. FUEL CAPS FUEL SYSTEMS (Prod. type 7410) Gates fuel caps offer a durable construction of a wear-resistant thermoplastic compound to ensure tight closing and to avoid spills and leaks. Gates standard fuel cap range includes both locking and non-locking caps. The locking fuel caps lock securely and make tampering with your fuel tank impossible. All fuel caps are easy to install. On the inside, the caps can have two different breathing systems: vented or nonvented. A non-vented fuel cap is recommended when your fuel tank is ventilated through the filler neck, whereas the vented fuel cap is equipped with a special breathing valve so that it can be used on non-ventilated fuel tanks. In order to reduce air pollution as much as possible Gates supplies a special ecological cap. It is fitted with a venting valve system that prevents evaporation of harmful car fuel gasses and complies with the EEC directive no. 70/221. In case of an accident the safety valve prevents fuel leaking from the tank. More information on sizes and applications can be found in Gates fuel cap catalogue E/70328. E. CONNECTORS FOR FUEL LINE HOSE (Prod. type 7315) Gates connectors are recommended for small diameter hoses to provide a better seal between hoses with same or different inside diameters. Using straight, reducer, elbow, T and Y shapes almost any hose configuration can be constructed. Gates provides also a handy fuel line and vacuum tubing connector kit: a complete assortment of 36 connectors in a practical plastic case. Unique single-barb design ensures a leak-proof seal. For hoses with ID of 2 to 12 mm. Glass-reinforced nylon resists extreme temperatures from -65 C to +250 C and coolant additives, petrol, diesel, oil and LPG. Working pressure up to 2 MPa (20 kg/cm 2 ). F. FUEL INJECTION CLAMPS Fuel Injection clamps are zinc plated carbon steel clamps designed to provide the uniform sealing pressure required on fuel injection hose. They feature nonperforated rolled edge bands with a special nut and bolt tightening design. Screw: 6 mm (=1/4") hex-head. Zinc plated, clear chromate, carbon steel. Band: 10 mm (=3/8") wide. Zinc plated, clear chromate, carbon steel. 10
4. AIR SYSTEMS A. FLEXIBLE HEAVY-DUTY AIR VENT HOSE (Prod. type 4663) High strength, flexible hose for air cleaner-to-engine connections. Reinforcement: extra thick fabric layer around built-in, double steel wire. Cover resistant to heat, oil and abrasion. Heat and oil resistant tube. Easy to cut to size with knife and wire cutters. Temperature range from -40 C to +125 C. Packaging: 3.048 m length (10 ft) per carton. Inside diameter ranges from 102 mm to 140 mm. FUEL SYSTEMS B. FLEXIBLE AIR VENT HOSE (Prod. type 4663) Extremely flexible hose for air cleaner-to-engine connections, defroster ducts and air or heater ducting. Reinforcement: fabric ply and double steel wire. Heat and oil resistant tube. Easy to cut to size with knife and wire cutters. Temperature range from -40 C up to +100 C. Packaging: 3.048 m length (10 ft) per carton. Inside diameter ranges from 16 mm to 92 mm. C. SHAPED AIR VENT HOSE (Prod. types 3177, 4275, 4663, 7736) Straight, curved or humped short connections for air cleaner-to-engine or other ducting applications. Available on request in preformed hump, straight and curved configurations. Resistant to heat and oil. 11