Cummins ISX11.9 CM2250 – Service Manual 016-005   Flywheel

CAUTION  There is a timing dowel pin on the rear face of the crankshaft that aligns the flywheel. If the dowel pin is damaged, broken, or missing, this can cause improper engine performance. The face runout can also be out of specification.

Check to see if the dowel pin is installed in the crankshaft.

Inspect the dowel pin for damage.

If the dowel pin is damaged or broken, replace the dowel pin.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Install two M6 x 1.5 guide studs.

Align the flywheel with the dowel pin in the crankshaft.

Install and seat the flywheel onto the crankshaft.

CAUTION  The flywheel mounting capscrews must be a minimum of SAE Grade 8 with rolled threads. Use identical capscrews as replacements to avoid possible flywheel malfunction, resulting in personal injury or property damage.

Lubricate the threads and underneath the heads of the capscrews with clean 15W-40 oil.

Allow the excess oil to drip off the parts.

Do not lubricate the threads of the crankshaft.

Install the ten capscrews.

Remove the “T-handles” and the guide pin.

Install the remaining two capscrews.

Tighten the capscrews in a star pattern.

Use flywheel capscrew socket, Part Number 2892191, to tighten the flywheel mounting capscrews in the sequence (star pattern) shown.

Use dial indicator gauge (1), Part Number 3376050, or equivalent, and dial gauge attachment (2), Part Number ST-1325, to inspect the flywheel bore (3) and face (4) runout.

Install the attachment to the flywheel housing.

Install the gauge on the attachment.

Install the contact tip of the indicator against the inside diameter of the flywheel bore, and set the dial indicator at zero.

Rotate the crankshaft one complete revolution (360 degrees). Refer to Procedure 009-035 in Section 9.

Flywheel Total Indicator Reading

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.

If the total indicator reading is greater than the specification:

Remove the flywheel.

Inspect the flywheel mounting surface for dirt or damage.

CAUTION  There is a timing dowel pin on the rear face of the crankshaft that aligns the flywheel. If the dowel pin is damaged, broken, or omitted, improper engine performance and/or face runout will be out of specfication.

Check to see if the dowel pin in the crankshaft is installed.

Inspect the dowel pin for damage. If the dowel pin is damaged or broken, replace the dowel pin.

Inspect the crankshaft for dirt or damage.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Install the flywheel, and inspect the bore runout again.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Replace the flywheel if the runout does not meet specifications.

Install the contact tip of the indicator against the flywheel face as close to the outside diameter as possible to inspect the face runout.

When locating the contact tip, see the Flywheel Face Runout Total Indicator Reading Table later in this procedure. Locate the contact tip so that it corresponds with a radius listed in the table, but is still as close to the outside diameter of the flywheel as possible, to inspect the flywheel face (1) runout.

Push the flywheel forward to remove the crankshaft end clearance.

Adjust the dial on the indicator until the needle points to zero.

Rotate the crankshaft one complete revolution. Measure and record the flywheel runout at four equal points on the flywheel. Refer to Procedure 009-035 in Section 9.

The flywheel must be pushed toward the front of the engine to remove the crankshaft end clearance each time a point is measured.

Determine the total indicator reading (TIR).

TIR is determined by calculating the difference between the highest and lowest measurement from the four locations measured.

If the flywheel face runout is not within specifications, remove the flywheel.

First check for nicks, burrs, or foreign material between the flywheel mounting surface and the crankshaft flange.

Replace the flywheel if the runout is not within specification.