Cummins ISX11.9 CM2250 – Service Manual 016-004   Flexplate

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

• Disconnect the batteries. Refer to the OEM service manual.
• Remove the transmission and related components. Refer to the OEM service manual.

Inspect the flexplate ring gear teeth for damage.

If the flexplate ring gear is damaged, make sure to evaluate the possible causes, listed below, prior to replacing the flexplate.

Mechanical

A mechanical issue can typically be identified by damage to the ring gear of the flexplate in 3 distinct locations, commonly called 120 degree milling. The following can be causes for mechanical issues:

1. The possibility of improper starting motor spacing. Refer to Procedure 013-020 in Section 13.
2. The interference between the ring gear land area and the starting motor pinion. The wrong starting motor can be installed. Refer to the OEM service manual.
3. The possibility of a problem with the starting motor pinion. Inspect the pinion for nicks and burrs. Refer to Procedure 013-020 in Section 13.
4. The torque converter/transmission is damaged or incorrectly mounted. Refer to the OEM service manual.
5. Incorrect starting motor pinion to flexplate ring gear pitch and teeth match. Refer to the OEM service manual.

Electrical

An electrical issue can typically be identified by damage to the ring gear of the flywheel 360 degrees around the circumference of the ring gear (commonly called 360 degree milling). The following can be causes for electrical issues:

1. The operator is attempting to start the engine while the engine is already running. Check if a Starter Lockout feature is available through the OEM (activated with INSITE™ electronic service tool) or the starting motor manufacturer.
2. The keyswitch is causing intermittent starting motor engagement when the engine is running. Inspect the keyswitch. Refer to Procedure 013-030 in Section 13.
3. The orientation of the starter relay, so the direction of the pull contact is in the direction of the vehicle’s travel. This results in intermittent starting motor engagement when the engine is running. Relocate the starter relay. Refer to the OEM service manual.
4. Intermittent starting motor wiring issues. Refer to the OEM service manual.

Remove the flexplate capscrews and flexplate.

NOTE: Some flexplates require mounting plates and/or adapters. It will be necessary to remove any mounting plates and/or adapters prior to or with the flexplate. Make sure to note the location of any mounting plates and/or adapters for later installation.

Inspect the teeth of the ring gear for chips or uneven wear.

Check the flexplate for cracks or other damage.

Replace the flexplate if any damage is found.

NOTE: Some flexplates require mounting plates and/or clamp rings. It will be necessary to install any mounting plates and/or clamp rings prior to or with the flexplate as noted during removal.

Install the flexplate capscrews and flexplate.

Tighten the capscrews in the sequence illustrated.

Tighten the capscrews again in the sequence illustrated.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the transmission and related components. Refer to the OEM service manual.
• Connect the batteries. Refer to the OEM service manual.