Power Service Literature Page 1 of 6

Section 1.15
Crankshaft Pulley

Two crankshaft pulley arrangements exist. Some early engines were built with a pulley, a crankshaft pulley hub and woodruff keys. Later engines are built with the
crankshaft pulley bolted directly to the crankshaft.

For the crankshaft pulley bolted directly to the crankshaft, see Figure "Crankshaft Pulley Mounted Directly to the Crankshaft" . In this case the pulley is attached to the
crankshaft with six special bolts and washers. The vibration damper is clamped between the crankshaft pulley and the crankshaft.

Note: Do not substitute any other bolts or washers. The crankshaft pulley bolts and washers are special parts. These bolts are not reusable.

Figure 1. Crankshaft Pulley Mounted Directly to the Crankshaft

The crankshaft pulley is of the rigid design. Six bolt holes through the pulley are equally spaced. A relief area is machined around each bolt hole and acts as a seating
surface for the hardened washers. See Figure "Crankshaft Pulley Cross-Section" .

Figure 2. Crankshaft Pulley Cross-Section

Four 12.7 mm (0.50 in.) vee-type grooves in the crankshaft pulley provide drive belt seating surfaces.

A 3/4 in. square drive hole in the center of the crankshaft pulley allows the use of a 3/4 in. drive breaker bar or ratchet for barring the engine over. See Figure "Barring
Engine Over" .

Figure 3. Barring Engine Over

For the crankshaft pulley and hub assembly with spindle, see Figure "Crankshaft Pulley and Hub Assembly Installation with Spindle" . The spindle is attached to the
crankshaft with six special bolts and washers, which also secure the vibration damper to the crankshaft. Two woodruff keys and the crankshaft pulley bolt secure the
crankshaft pulley and hub assembly to the spindle.

Note: Do not substitute any other bolts or washers. The spindle bolts and washers are special parts. These bolts are not reusable.

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Figure 4. Crankshaft Pulley and Hub Assembly Installation with Spindle

The spindle has six equally spaced mounting holes. A relief area is machined around each bolt hole and acts as a seating surface for the hardened washers. See Figure
"Crankshaft Pulley Spindle" .

Figure 5. Crankshaft Pulley Spindle

The crankshaft pulley assembly is secured to the spindle with two woodruff keys, a crankshaft pulley bolt and hardened washer. The crankshaft pulley bolt is also used
to bar the engine over. See Figure "Crankshaft Pulley and Hub Assembly Installation with Spindle" .

Section 1.15.1
Repair or Replacement of Crankshaft Pulley

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure "Flowchart for Repair or Replacement of Crankshaft
Pulley" .

Figure 6. Flowchart for Repair or Replacement of Crankshaft Pulley

Section 1.15.2
Removal and Cleaning Crankshaft Pulley

Precleaning is not necessary.

Remove the crankshaft pulley as follows:

1. Remove the drive belts from the crankshaft pulley.

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2. Remove the inspection plug in the bottom of the flywheel housing.

3. Install the flywheel lock (J–36375–A) . See Figure "Flywheel Lock" .
4. Thread the center screw of the tool in until the top of the tool rests between two teeth of the flywheel ring gear.

Note: It may be necessary to bar the engine over (using the square hole in the middle of the crankshaft pulley) so that the tool center screw is exactly between two
teeth.

5. Finger-tighten the knurled knob.

6. Remove two of the six crankshaft pulley-to-crankshaft attaching bolts and hardened washers that are 180 degrees apart. Discard the bolts. These bolts are not
reusable. See Figure "Crankshaft Pulley Mounted Directly to the Crankshaft" .

Figure 7. Crankshaft Pulley Mounted Directly to the Crankshaft

7. Install two guide studs (J–36235) to the holes where the bolts were removed.

NOTICE:

Use care when removing the crankshaft pulley as the vibration damper, which is slip fitted over a pilot diameter of the crank, may come off. If the damper is allowed to fall,
internal damage to the damper will result.

8. Remove the remaining four crankshaft pulley bolts and hardened washers. Discard the bolts. These bolts are not reusable.
9. Remove the crankshaft pulley by sliding it off the guide studs.

Note: Leave the guide studs in place to prevent the vibration damper from falling off.

Remove the spindle-mounted pulley and hub assembly as follows:

1. Remove the drive belts from the crankshaft pulley.

2. Remove the inspection plug in the bottom of the flywheel housing.
3. Install the flywheel lock (J–36375–A) . See Figure "Flywheel Lock" .

Figure 8. Flywheel Lock

4. Thread the center screw of the tool in until the top of the tool rests between two teeth of the flywheel ring gear.

Note: It may be necessary to bar the engine over using the crankshaft pulley bolt so that the tool center screw is exactly between two teeth.

5. Finger-tighten the knurled knob.

6. Loosen the center bolt holding the pulley and hub assembly to the spindle. See Figure "Crankshaft Pulley and Hub Assembly Installation with Spindle" .

Figure 9. Crankshaft Pulley and Hub Assembly Installation with Spindle

7. With the pulley properly supported, remove the bolt and washer and pull the pulley and hub assembly off of the spindle.
8. Remove two of the six spindle-to-crankshaft attaching bolts and hardened washers that are 180 degrees apart. Discard the bolts. These bolts are not reusable.

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9. Install two guide studs (J–36325) to the holes from which the bolts were removed.

NOTICE:

Use care when removing the spindle as the vibration damper, which is slip fitted over a pilot diameter of the crank, may come off. If the damper is allowed to fall, internal
damage to the damper will result.

10. Remove the remaining four spindle attaching bolts and hardened washers. Discard all six bolts. These bolts are not reusable.
11. Remove the spindle by sliding it off the guide studs.

Note: Leave the guide studs in place to prevent the vibration damper from falling off.

Section 1.15.2.1
Inspection of Crankshaft Pulley or Spindle and Crankshaft Pulley and Hub Assembly

Inspect the crankshaft pulley, spindle or hub assembly components as follows:

1. Inspect the crankshaft pulley or spindle and crankshaft pulley and hub assembly.

NOTICE:

A loose or bent crankshaft pulley or spindle, after extended operation, may result in a cracked crankshaft.

a. Determine if the crankshaft pulley or spindle is bent, broken or has cracked edges.
b. If damage is detected, replace with a new part.
c. If damage to the crankshaft pulley, pulley and hub assembly or spindle is extensive, refer to "1.14.2.1 Inspection of the Vibration Damper" , and inspect the
vibration damper. Inspect the crankshaft, refer to "1.7 Crankshaft" .
2. Inspect the drive belt seat grooves.
a. Check drive belt seat grooves for bent flanges or a rough belt seating surface.
b. Smooth rough seating surfaces with an emery cloth or a stone.
c. If flanges are bent, replace the pulley.
3. Inspect the retaining bolt seat relief areas.
a. Check relief area for stress cracks.
b. If stress cracks are discovered, replace the pulley or spindle.

NOTICE:

A loose or bent crankshaft pulley, after extended operation, may result in a cracked crankshaft.

4. Inspect the direct-mounted pulley (or spindle) and vibration damper inner contact surfaces. See Figure "Crankshaft Pulley and Vibration Damper Inspection" .
a. Check for galling or burrs. See Figure "Crankshaft Pulley and Vibration Damper Inspection" .
b. Minor galls or burrs may be smoothed with an emery cloth.
c. If galls or burrs are major, the pulley or spindle will need to be replaced.

Figure 10. Crankshaft Pulley and Vibration Damper Inspection

Section 1.15.3
Installation of Crankshaft Pulley

Install the crankshaft-mounted pulley as follows:

1. If removed, install the flywheel lock (J–36375–A) to the inspection plug hole in the bottom of the flywheel housing. See Figure "Flywheel Lock" .
2. Thread the center screw of the tool until the tip of the tool rests between two teeth of the flywheel ring gear.

Note: It may be necessary to bar the engine slightly using engine barring tool (J–36237) so that the tool center screw is exactly between two teeth.

3. Finger-tighten the knurled knob.

NOTICE:

Use care when installing the crankshaft pulley as the vibration damper, which is slip fitted over a pilot diameter of the crank, may come off. If the damper is allowed to fall,
internal damage to the damper will result.

4. Install two guide studs to two of the holes in the crankshaft that are 180 degrees apart.
5. Install the vibration damper over the guide studs and onto the crankshaft. Refer to "1.14.3 Installation of Crankshaft Vibration Damper" .
6. Install the crankshaft pulley over the guide studs and onto the crankshaft. The crankshaft pulley may be installed in any position.

NOTICE:

Crankshaft pulley and spindle mounting blots are considered single-use items and must not be reused. Always use new bolts when mounting the crankshaft pulley or spindle.
Reusing bolts may result in excessive bolt stretch during installation, leading to breakage or loss of bolt torque and loosening during engine operation, which may cause severe
damage.

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7. Install four new special crankshaft pulley-to-crankshaft attaching bolts with hardened washers installed, through the pulley and damper and into the crankshaft.
Finger tighten the bolts. See Figure "Crankshaft Pulley Mounted Directly to the Crankshaft" .

Figure 11. Crankshaft Pulley Mounted Directly to the Crankshaft

8. Remove the two guide studs.

9. Install the remaining two new special crankshaft pulley-to-crankshaft attaching bolts with hardened washers installed.
10. Torque the six new special bolts to 182-210 N·m (134-155 lb·ft). Proceed in a clockwise direction until all bolts are torqued.
11. Remove the flywheel lock tool.
12. Install the pipe plug to the inspection hole in the flywheel housing.
13. Install the drive belts to the crankshaft pulley. Adjust the belt tensions to the specifications. Refer to "14.6.9 Drive Belts" .
14. Install any other components that were removed for this operation.

Install the spindle mounted pulley and hub assembly as follows:

1. Install the flywheel lock (J–36375–A) . See Figure "Flywheel Lock" .

Figure 12. Flywheel Lock

2. Thread the center screw of the tool in until the top of the tool rests between two teeth of the flywheel ring gear.
3. Finger tighten the knurled knob.

Note: It may be necessary to bar the engine over using the crankshaft pulley bolt so that the tool center screw is exactly between two teeth.

4. Install two guide studs to two of the holes in the crankshaft that are 180 degrees apart.
5. Install the vibration damper over the guide studs and onto the crankshaft. Refer to "1.14.3 Installation of Crankshaft Vibration Damper" .

NOTICE:

Use care when installing the crankshaft pulley spindle as the vibration damper, which is slip fitted over a pilot diameter of the crank, may come off. If the damper is allowed to
fall, internal damage to the damper will result.

6. Install the crankshaft pulley spindle over the guide studs, onto the crankshaft and against the vibration damper. The crankshaft pulley spindle may be installed in
any position. See Figure "Crankshaft Pulley and Hub Assembly Installation with Spindle" .

Figure 13. Crankshaft Pulley and Hub Assembly Installation with Spindle

7. Install four new special crankshaft pulley spindle-to-crankshaft attaching bolts with hardened washers installed.
8. Remove the two guide studs.
9. Install the remaining two new special crankshaft pulley spindle-to-crankshaft attaching bolts with hardened washers installed.
10. Torque the six new special bolts to 182-210 N·m (134-155 lb·ft). Proceed in a clockwise direction until all bolts are torqued.
11. With the pulley properly supported, install the bolt and washer and pull the pulley to the spindle.
12. Torque the center bolt holding the pulley to the spindle to 610 N·m (450 lb·ft).
13. Remove the flywheel lock tool.

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14. Install the pipe plug to the inspection hole in the flywheel housing.
15. Install the drive belts to the crankshaft pulley. Adjust the belt tensions to the specifications. Refer to "14.6.9 Drive Belts" .
16. Install any other components that were removed for this operation.
17. Refer to "12.3 Running" for verification of proper crankshaft pulley installation.

Series 60 Service Manual - DDC-SVC-MAN-0004 Printed Thu Dec 24 11:01:15 2009

Copyright © 2009 by Detroit Diesel Corporation. All rights reserved.

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