Replace ring gear on flywheel

AR03.30-W-8312J

Replace ring gear on flywheel

29.7.11



Remove

1

Remove flywheel (2)

AR03.30-W-8002J

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

2

Use a welding torch to rapidly heat up ring gear (1) and press it off flywheel (2) using a suitable drift

 Underlay flywheel (2).

3

Measure flywheel diameter for mounting the ring gear (B) on the flywheel (2)

 Replace flywheel (2) if the value is outside the tolerance.

*BE03.30-N-1002-03B



Install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

4

Heat new ring gear (1)

 The correct pulling on temperature is reached once ring gear (1) has a bright yellow annealing color.

Starter ring gear - installation temperature

*BE03.30-N-1005-04B

5

Lay ring gear (1) onto flywheel (2) up to the contact surface

 Allow ring gear (1) to cool for at least
2 minutes and then set back using a brass drift. The ring gear (1) must lie all around the shoulder of the flywheel (2).

6

Bore out core bore holes for thread (M8) (arrow) in the ring gear (1)

 Only for version 403 mm dia. with a
362 mm dia. (2.2).

Use a 6.8 mm dia. drill bit.

7

Bring centerings onto the ring gear (1) through the threaded holes (M101.5) (A)

 Only for version with a 443 mm dia. with a 395 mm dia. clutch or version with a 487 mm dia. with a 430 mm dia. clutch (2.3).

Use a 9.0 mm dia. drill bit. The centering pins are needed for the core drillings.

8

Drill out core hole bores for thread (M10) in the ring gear (1)

 Only for version with a 443 mm dia. with a 395 mm dia. clutch or version with a 487 mm dia. with a 430 mm dia. clutch (2.3).

Use a 4.5 mm dia. drill bit.

9

Bore out core bores for thread (M10) in ring gear (1) on gauge block

 Only for version with a 443 mm dia. with a 395 mm dia. clutch or version with a 487 mm dia. with a 430 mm dia. clutch (2.3).

Use a 8.5 mm dia. drill bit.

10

Turn flywheel (2) and chamfer core hole bores in the ring gear (1)

 Only for version with a 443 mm dia. with a 395 mm dia. clutch or version with a 487 mm dia. with a 430 mm dia. clutch (2.3).

11

Cut a thread (M10) in all core hole bores in the ring gear (1)

 Only for version with a 443 mm dia. with a 395 mm dia. clutch or version with a 487 mm dia. with a 430 mm dia. clutch (2.3).

12

Install flywheel (2)

AR03.30-W-8002J

Number

Designation

Engine
900.9, 904.9
with a 403 dia. flywheel and a 362 dia. clutch

Engine
900.9, 904.9
with a 443 dia. flywheel and a 362 dia. clutch

BE03.30-N-1002-03B

Flywheel dia. for mounting starter ring gear (B)

mm

360.435 to 360.575

392.435 to 392.575

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9, 924.9
with a 443 mm dia. flywheel and a 395 mm dia. clutch

Engine
902.9, 906.9, 925.9, 926.9
with a 487 mm dia. flywheel and a 430 mm dia. clutch

BE03.30-N-1002-03B

Flywheel dia. for mounting starter ring gear (B)

mm

392.435 to 392.575

432.490 to 432.645

Number

Designation

Engine
925.9, 926.9
with a 443 mm dia. flywheel and a 395 mm dia. clutch

BE03.30-N-1002-03B

Flywheel dia. for mounting starter ring gear (B)

mm

392.435 to 392.575

Number

Designation

Engine
900.9, 904.9
with a 403 mm dia. flywheel and a 362 mm dia. clutch

Engine
900.9, 904.9
with a 443 mm dia. flywheel and a 362 mm dia. clutch

BE03.30-N-1005-04B

Starter ring gear - installation temperature

°C

250 to 280

250 to 280

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9, 924.9, 925.9, 926.9
with a 443 mm dia. flywheel and a 395 mm dia. clutch

Engine
902.9, 906.9, 925.9, 926.9
with a 487 mm dia. flywheel and a 430 mm dia. clutch

BE03.30-N-1005-04B

Starter ring gear - installation temperature

°C

250 to 280

250 to 280