Sealey VS787 Auxiliary Stretch Belt Removal/Installation Tool User Manual

1. Introduction

The Sealey VS787 Auxiliary Stretch Belt Removal/Installation Tool is specifically designed for the safe and efficient removal and installation of elasticated or stretch drive belts. These belts are commonly found in modern auxiliary drive systems, such as those connected to alternators or power steering units. This tool set helps prevent damage to both the pulley and the belt during service, thereby extending the belt's operational life. It is suitable for use on most crankshaft pulleys.

This manual provides essential information for the correct and safe operation of your VS787 tool. Please read it thoroughly before use and retain it for future reference.

2. Safety Information

Always observe the following safety precautions to prevent personal injury and damage to the tool or vehicle.

• Read Instructions: Familiarize yourself with the tool's operation and applications, as well as the limitations and potential hazards.
• Personal Protective Equipment: Always wear appropriate eye protection (safety glasses) and gloves when working on vehicles.
• Work Area: Ensure your work area is clean, well-lit, and free from clutter. Keep children and unauthorized persons away from the work area.
• Vehicle Preparation: Before working on any vehicle, ensure it is securely supported on a level surface using appropriate jack stands. Disconnect the battery if necessary to prevent accidental starting or electrical shorts.
• Tool Condition: Inspect the tool before each use for any signs of damage or wear. Do not use damaged tools.
• Correct Application: Use the tool only for its intended purpose. Do not modify the tool or use it for tasks for which it was not designed.
• Avoid Over-Stretching: While designed for stretch belts, avoid excessive force that could damage the belt or pulley.
• Storage: Store the tool in its case in a dry, safe place, out of reach of children.

3. Product Overview

The Sealey VS787 kit includes two specialized tools: one for the removal of stretch belts and another for their installation. These tools are designed to engage with the crankshaft pulley and the belt, facilitating the process without causing damage.

The kit includes:

• Removal Tool: Designed to safely disengage the stretch belt from the pulley.
• Installation Tool: Designed to assist in smoothly stretching and seating the new belt onto the pulley.

4. Setup

Before beginning any work, ensure the vehicle is safely secured and the engine is cool. Identify the auxiliary stretch belt that needs to be serviced. The specific procedure for accessing the belt may vary depending on the vehicle model. Refer to the vehicle manufacturer's service manual for detailed instructions on accessing the auxiliary drive system.

No assembly of the VS787 tools is required. They are ready for use directly from the storage case.

5. Operating Instructions

5.1. Belt Removal

1. Position the Removal Tool: Carefully position the removal tool onto the crankshaft pulley, ensuring it engages securely with the belt and the edge of the pulley. The tool is designed to create a gap between the belt and the pulley as the crankshaft rotates.
2. Rotate Crankshaft: Slowly rotate the crankshaft by hand (or using an appropriate tool on the crankshaft bolt) in the direction of engine rotation. As the crankshaft turns, the removal tool will gradually lift the belt off the pulley.
3. Remove Belt: Continue rotating until the belt is fully disengaged from the pulley. Once loose, carefully remove the belt from all auxiliary components.

Note: Avoid forcing the belt off, as this can damage the belt or the pulley. The process should be smooth and controlled.

5.2. Belt Installation

1. Route New Belt: Route the new stretch belt around all auxiliary components (alternator, power steering pump, etc.) except for the crankshaft pulley. Ensure the belt is correctly aligned in all grooves.
2. Position the Installation Tool: Place the installation tool onto the crankshaft pulley. Position the new belt partially onto the crankshaft pulley, ensuring it is aligned with the grooves. The installation tool will help guide the belt onto the pulley as it rotates.
3. Rotate Crankshaft: Slowly rotate the crankshaft by hand in the direction of engine rotation. The installation tool will gradually stretch and guide the belt onto the pulley.
4. Verify Installation: Once the belt is fully seated on the crankshaft pulley and all other components, rotate the crankshaft a few full revolutions to ensure the belt is properly aligned and tensioned. Visually inspect the belt for any signs of damage or misalignment.

Caution: Ensure fingers and other body parts are clear of moving parts during crankshaft rotation. Improper installation can lead to premature belt failure.

6. Maintenance

The Sealey VS787 tool requires minimal maintenance to ensure its longevity and proper function.

• Cleaning: After each use, wipe the tools clean with a dry cloth to remove any grease, oil, or debris.
• Inspection: Periodically inspect the tools for any signs of wear, bending, or damage. Ensure the threaded components operate smoothly.
• Lubrication: A light application of general-purpose oil to the threaded parts can help maintain smooth operation.
• Storage: Always store the tools in their original protective case in a dry, secure environment, away from direct sunlight and extreme temperatures.

7. Troubleshooting

This tool is mechanical and has few points of failure. Most issues arise from improper application.

• Belt Not Coming Off/Going On:
  • Ensure the correct tool (removal or installation) is being used.
  • Verify the tool is correctly seated on the pulley and engaging the belt.
  • Confirm the crankshaft is being rotated in the correct direction.
  • Check for obstructions or incorrect belt routing.
• Tool Slipping:
  • Ensure the tool is firmly seated and properly aligned with the pulley and belt.
  • Clean any oil or grease from the tool's contact surfaces and the pulley.

If you encounter persistent difficulties, consult a professional mechanic or refer to the vehicle's specific service manual.

8. Specifications

9. Warranty and Support

For information regarding warranty coverage, technical support, or replacement parts for your Sealey VS787 tool, please refer to the official Sealey website or contact your authorized Sealey dealer. Keep your purchase receipt as proof of purchase.

Sealey Official Website: www.sealey.co.uk