^,{BE 100 SliRl4CE iu{ANLtAL

1.12 e RANKSFIAFT VIBRATIO\ DAMPFR

A special tooi, Lngine Rarring Tool (J-46392) is requited for this proceelure

1,12.1 erankshaft Vibration Damper RetmevaERemove the crankshaft vibration damper as follo.uvs:

1. Remove the drive belts fiom the altenrator, coolant-pump, idler, and air-conditionercompressol pullevs, as installed.

2. Install the engine ban'ing tool (.I-46392)r,vith the locking pin in place . Re{'er to section1.16.2.

3. 'fo gain access to the vibration damper, remove the lower mounting bolts J}om tire bottorllol' the liont firing/burnper.

4. Remove the mounting bolts fiom the vibration damper. Drop the vibration clarnper doulbelorv the radiator and remove it froln the engine. See Figure l-79.

41961

1. Vibration Damper 3. Oil Deflector2. Mounting Bolt 4. End of Crankshaft

Figure 1-79 Vibration Damper Rernoval

5. Remove the oil deflector from the crankshaft.6. Inspect the vibration damper for signs of wear, dents, cleformation, or other signs of

damage. Replace the damper if the belt contact surface is wom or damaged.

NOTE:The vibration damper has a crankshaft pulley bolted to it to accommCIdate two additionaldrive belts. lt is not necessary to disassemble the vibration damper unless the crankshaftpulley is damaged and needs to be replaced.

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C k4 ! KS IIAFT V t ]) RATI Ol\t DA MP E R

1.12.2 CrankshaftVibrationDamperlnstallationInstall the crankshaft vibration damper as 1b1lows:

NOTE:Check the crankshaft front seal for oil leaks. lf leakage is found, replace the front seal.Refer to section 1.7.

1. Install the oil deffector. Make sure the rim is facing the engine.2. install the vibration clarnper on the crankshatt, as removed. Tighten the bolts 200 N'm

(148 lb'ft). Use an alternating sequence until all six bolts are tight.3. Install the lower mounting bolts on tlie bottorn of the front fairingiburnper, as retnoved.4. Remove the engine barring tool from the flyweel housing. Refet to section 1.16.2.5. Install the drive belts on their pulleys, as retnoved.

1-102All infarmalion subject to change wthout notce.

DDC-SVC-MAN-0023 Copyri-qht O 2012 DETROIT DIESEL COR-PORATION

h[]E 4OAO SERI/{CE T,IA|\JUAL

,I .13 FLYWHEEL

Three special tools are required fbr this procedure. They are:n Engine Baruing lbol (J-46392)! 19 mm Fll.wheel and Main Pulley Socket (.f-45390)n Flyw'heel Guide Pins (set aI'2) (J*46172)

The fl,'wheel has a pilot bearing and spacer pressed into the fi.vw'heel hub bore. See Figure 1-80.

47579

4

1. Crankshaft

2. Crankshaft Gear3. Spacer4. Flywheel

5. Pilot Bearing

Figure 1-80 Flywheel and Components1.13.1 Flywheel RemovalRemove the flvr.r.heel as follows:

l. Renlove the transnlission.2. Remove the clutch from the flvr,.heel.

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FLYT4/HEEL

3. Remove the crankshaft position sensor from the flywheel housing. See Figure 1-81.

(

41962

1. Crankshaft Position (CKP) Sensor 2. Camshaft Position (CMP) Sensor

Figure l-81 Crank Angle Position Sensor Removal

4. Remove the inspection cover from the flyw;heel housing and install the engine barring tool(J-463g2).Insert the pin and make sure the tool is locked. Refer to section 1.16.2.

5. Using the i9 mm socket (J-45390), remove two flywheel socket-head bolts from thefl1.r,r4reel, one from each side of the bolt circle. See Figure 1-82.

41 963

1. Flywheel Mounting Bolt (10 qty.) 2. Flywheel

Figure 1-82 Flywheel (exploded view)

l-101All information subject to change wthaul notce

Copyright O 2012 DETROIT DIESEL CORPORATIONDDC-SVC-MAN-0023

6.

MBE 4OOO SERVICE MAA"UAL

Screw the two flywheel guide pins (J-46172) tnto the empty bolt holes in the center ofthe flywheel. See Figure 1-83.

J-46389

41 S64

2. Flywheel Mounting Bolt1. Bolt used as a handle

Figure 1-83 Flywheel Removal

Ail nfomaton subject to change without notce.DDC-SVC-MAN-0023 Copyright (g 2012 DETROIT DIESEL CORPORATION

7.

8.

Remove the remaining eight flywheel bolts.Remove the engine baning tool (J-46392). Refer to section I.16.2.

[, onlrGER:FALLING COMPONENT

To avoid injury from a falling component, ensure a properlifting device is used.

Remove the t1yr,r,heel, leaving the guide pins (J-,16172) in place. See Figure 1-83.[a] On opposite sides of the bolt circle, screw a bolt into each of two threaded clutch

bolt holes.

9.

[ cnuroN:FALLING FLYWHEEL

To avoid injury from a falling flywheel when removing thelast bolt, hold the flywheel against the crankshaft by handto prevent it from slipping off the crankshaft. The flywheelis not doweled to the crankshaft.

1-105

I 13 FLYI,/HEEL

lb] Using the two bolts as handles, dislodge the flyw'heel from the crankshaft flangeand remove it fiom the flywheel housing'

[c] After removing the flyw'heel, remove the bolts fi'onr the clutch bolt holes.10. Inspect the flywheel bolts. Replace the bolts if any of the shanks are stretched bevond the

maximum length ot- 77 .0 mm (3.03 in.)' See Figure 1-84'

4i95

1. Shank

Figure 1-84 Measuring the Flywheel Bolts

11. Thoroughly clean the flrwheel and check the clutch surface for cracks, burned spots,or scoring. If the damage exceeds the maximum depth of stock, replace the flur'r'heel.Refer to section 1.13.1.2.

lZ. Inspect the flywheel flange fbr signs of wear or traces of hollowing caused by the radialseal.

13. Inspect the flywheel ring gear for damaged teeth or signs of-wear. Replace the ring gear ifnecessarv. Ref'er to section 1 .14.1 .

1.13.1.1 Flywheel lnsPectionInspect the flywheel as follou's:

1. Remove the flywheel. Refer to section 1'13'1'Z. Tlioroughly clean the llywheel and check it for cracks, scoring, burned areas' or rough

spots.

AMnformation subject to change wthout notceCopyright O 2012 DETROIT DIESEL CORPORATIONi-106 DDC-SVC-MAN-0023

,^,[BE 4OOO SERT'ICE TIANUAL

3. Using an accurate straighteclge and a feeler gauge, check the fi'iction (clutch) surface lorevenness. See Figure 1-85. If the surface has areas that are too high or too low; repl;roethe flylvheel.

1. Straightedge

Figure 1-85

41S70

2. Friction Surface

Checking the Friction $urface for Evennesst

*

1. Check the bearing surf'ace and the threaded holes fol wear and damage.

1.13.1.2 Flywheel MachiningMachine the flywheel as follows:

NOTE:Before beginning any machining work on the flywheel, check it to see if machining ispossible. lf the scores or cracks are deeper than 1 mm (0.04 in.), replace the flywheel. lfthe width of the flywheel between the friction surface and the mountng flange is lessthan 60 mm (2.4 in.), replace the flywheel.

WARNING:

PERSONAL INJURYTo avoid injury while performng the test or procedure, wearadequate eye, face protection, and heat-resistant gloves.

1. Machine the flyrvheelSee Figure 1-86. The0.016 mm (0.006 in.).

friction surfce, if required, to the specifications listed in Table 1-22.surfirce finish (peak-to-valley height) after machining should beA rougher surface finish will cause rapid clutch lining wear, while a

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]. ] 3 F:LYI4/HEEL

smoother finishlocations on the

cru1d cause difficultresflywtreel to coordinate

in clutch disengagement. See Figure 1-87 for thervith the specifications in the table.

41q71

Machining the Flywheel Friction Surface

Table 1-22 Flywheel Specifications

Figure 1-86

Alt nformaton subject to change wthout notcecopyright o 2012 DETROIT DIESEL CORPORATION

Description Specification: mm {in.}Flywheel Outside Diameter 486.60-487.40 (1 9. 1 s7-1 9. 1 89)

F{ywheel Shoulder Diameter (for ring gear mounting) 432.450-432.64s {17 .0256-17 .A332)

Flywheel Diameter at Crankshaft Flange 1 1 4.980-'1 1 5.01 5 (4.5268-4.5281 )Flywheel Diameter for Mounting Clutch 47 5.O0A-47 5.063 (1 8.7008-1 8.7032)

Flywheel Minimum Width Between Friction Surfaceand Mounting Flange After Machining

60 (2.4)

Flywheel Maximum Overall Width 70 (2.8)

Peak-to-Valley Height (R .) of Clutch Friction Surface 0.016 (0.006)

Flywheel Permissible Deviation From True(radial and lateral)

0.2 (0.008)

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I,{BE 1000 SERVCE L{.4*"LiLL

4tsl?

'1 . Flywheel

Figure 1-87

2. Ring Gear

Flywheel Cross $ection

After machining, the friction surface must not have any cavities or chatter marks.2. Check the radial and lateral deviation from true of the flyrvheel. The deviation flonr

true must not exceed 0.2 mm (0.008 in.).3. Install the {lyu'heel. Refer to section 1.13.2.

1.13.2 Flywheel lnstallationInstall tlre flywheel as follows:

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