Service Manual

Flywheel ISB, ISBe and QSB (Common Rail [...]
Page 16-20 Section 16 - Mounting Adaptations - Group 16
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Mechanical
A mechanical issue can typically be identified by seeing
damage to the ring gear of the flywheel in 3 distinct
locations for 6 cylinder engines (commonly called 120
degree milling), and 2 locations for 4 cylinder engines
(commonly called 180 degree milling). The following could
be causes for mechanical issues:
1 Upon installation of the flywheel, make sure to check
for proper starter motor spacing. Refer to Procedure
Procedure 013-020
2 Interference between the ring gear land area and the
starting motor pinion. The wrong starting motor may be
installed. Refer to the original equipment
manufacturer's specifications
3 There may be a defect with the starter motor pinion.
Inspect the pinion for nicks and burrs. If replacement
of the starting motor is necessary, Refer to Procedure
Procedure 013-020
4 The ring gear may be improperly installed or damaged.
Refer to Procedure Procedure 016-008
5 The flywheel face runout may be out of specification.
See the Measure section of this procedure
6 Incorrect starting motor pinion to flywheel ring gear
pitch/teeth match. Refer to the original equipment
manufacturer's specifications.
Electrical
An electrical issue can typically be identified by seeing
damage to the ring gear of the flywheel 360 degrees
around the circumference of the ring gear (commonly
called 360 degree milling). The following could be causes
for electrical issues:
1 Operator is attempting to start engine while engine is
already running. Check if a starter lockout feature is
available through the OEM (activated with the
INSITE™ Electronic Service Tool) or the starting motor
manufacturer
2 Key switch causing intermittent starting motor
engagement when the engine is running. Inspect the
key switch. Refer to Procedure Procedure 013-030
3 Orientation of the starter relay so that the direction of
the pull contact is in the direction of the vehicle's
travel. This results in intermittent starter motor
engagement when the engine is running. Relocate the
starter relay. Refer to the original equipment
manufacturer's specifications
4 Intermittent starter motor wiring issues. Refer to the
original equipment manufacturer's specifications.