100 SliRl4CE iu{ANLtAL

^,{BE

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

RetmevaE

Remove the crankshaft vibration damper as follo.uvs:

1.

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

2.

Install the engine ban'ing tool (.I-46392)r,vith the locking pin in place . Re{'er to section
1.16.2.

3.

'fo gain access to the vibration damper, remove the lower mounting bolts J}om tire bottorll
ol' the

4.

liont firing/burnper.

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

doul

41961

Damper
2. Mounting Bolt

3. Oil Deflector

1. Vibration

Figure

1-79

4.

End of Crankshaft

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 additional
drive belts. lt is not necessary to disassemble the vibration damper unless the crankshaft
pulley is damaged and needs to be replaced.

All nfarmatot1 subject to change witho!tt notice.

DDG-SVC-MAN-0023 Copyrigh

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

1.12.2

CrankshaftVibrationDamperlnstallation

Install 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.

All infarmalion subject to change wthout notce.

1-102

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h[]E
,I

.13

4OAO SERI/{CE T,IA|\JUAL

FLYWHEEL

Three special tools are required fbr this procedure. They are:

n
!
n

Engine Baruing lbol (J-46392)

19 mm Fll.wheel and Main Pulley Socket (.f-45390)
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

1. Crankshaft

3. Spacer

2. Crankshaft Gear

4.

Figure

1-80

1.13.1

Flywheel

Flywheel and Components

Flywheel Removal

Remove the flvr.r.heel as follows:

l.
2.

::'

Renlove the transnlission.

Remove the clutch from the flvr,.heel.

nformatol subject to change wthotlt lotice.

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5. Pilot Bearing

FLYT4/HEEL

3.

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

41962

1. Crankshaft Position (CKP) Sensor

l-81

Figure

2. Camshaft Position (CMP) Sensor

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 the
fl1.r,r4reel, one from each side of the bolt circle. See Figure 1-82.

41

2.

1. Flywheel Mounting Bolt (10 qty.)

Figure

1-82

963

Flywheel

Flywheel (exploded view)

All information subject to change wthaul notce

l-101

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MBE

6.

4OOO

SERVICE MAA"UAL

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

J-46389

41

2. Flywheel Mounting Bolt

1. Bolt used as a handle

Figure

1-83

S64

Flywheel Removal

[ cnuroN:
FALLING FLYWHEEL
To avoid injury from a falling flywheel when removing the
last bolt, hold the flywheel against the crankshaft by hand
to prevent it from slipping off the crankshaft. The flywheel
is not doweled to the crankshaft.
7.

Remove the remaining eight flywheel bolts.

8.

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 proper
lifting device is used.
9.

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.

Ail nfomaton subject to change without notce.

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1-105

13

FLYI,/HEEL

lb]

Using the two bolts as handles, dislodge the flyw'heel from the crankshaft flange
and 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

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.

11. Thoroughly

lZ.

Inspect the flywheel flange fbr signs of wear or traces of hollowing caused by the radial
seal.

13.

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

1.13.1.1

if

Flywheel lnsPection

Inspect the flywheel as follou's:

1.
Z.

Remove the flywheel. Refer to section 1'13'1'

rough
Tlioroughly clean the llywheel and check it for cracks, scoring, burned areas' or
spots.

AMnformation subject to change wthout notce

i-106

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,^,[BE 4OOO SERT'ICE

3.

TIANUAL

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

41S70

2.

1. Straightedge

Figure 1-85

1.

Friction Surface

Checking the Friction $urface for Evenness

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

1.13.1.2

Flywheel Machining

Machine the flywheel as follows:

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

WARNING:

PERSONAL INJURY
To avoid injury while performng the test or procedure, wear
adequate eye, face protection, and heat-resistant gloves.
1.

Machine the flyrvheel friction surfce, if required, to the specifications listed in Table 1-22.
See Figure 1-86. The surfirce finish (peak-to-valley height) after machining should be
0.016 mm (0.006 in.). A rougher surface finish will cause rapid clutch lining wear, while a

All informaton sLtbject to change withaut !1otice.

DDC-SVC-MAN-0023 Copyrighr O 2012 DETI{OIT DIESEL CORPOITAilON

]. ]

F:LYI4/HEEL

smoother finish cru1d cause difficultres in clutch disengagement. See Figure 1-87 for the
locations on the flywtreel to coordinate rvith the specifications in the table.

41q71

Figure 1-86

Machining the Flywheel Friction Surface

Specification: mm {in.}

Description

486.60-487.40

Flywheel Outside Diameter

F{ywheel Shoulder Diameter (for ring gear mounting)

Flywheel Diameter at Crankshaft Flange

s7-1 9. 1 89)

432.450-432.64s {17 .0256-17 .A332)

1 1

4.980-'1

47 5.O0A-47

Flywheel Diameter for Mounting Clutch

(1 9.

5.01

5 (4.5268-4.5281

5.063

(1

Flywheel Minimum Width Between Friction Surface

and 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)

Table 1-22

Flywheel Specifications

Alt nformaton

1-108

8.7008-1 8.7032)

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subject to change wthout notce

2012 DETROIT DIESEL CORPORATION

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

4tsl?
'1

2.

Flywheel

Ring Gear

Flywheel Cross $ection

Figure 1-87

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 lnstallation

Install tlre flywheel as follows:

All nformatot1 subject to change v{ithoul notce.

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l-r09