Cummins ISX11.9 CM2250 – Service Manual 001-012   Camshaft Gear (Camshaft Installed)

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  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• If required, remove the radiator. Refer to the OEM service manual.
• Remove the cooling fan. Refer to Procedure 008-040 in Section 8.
• Remove the front gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the front camshaft idler gear. Refer to Procedure 001-036 in Section 1.
• Remove the camshaft position sensor. Refer to Procedure 019-363 in Section 19.

WARNING  The puller assembly is heavy. Use a lifting device when securing it to the cam gear.

WARNING  The cam gear and puller assembly may fall when released and cause serious personal injury.

Use the front camshaft gear removal tool kit, Part Number 4919610, to remove the gear from the camshaft.

Assemble the lifting eye (1) to the gear puller plate (2) using the included capscrew.

Attach a lift device to the lifting bracket on the gear puller.

Install the remover jaws (1) into the two round holes in the gear.

Place the puller assembly over the remover jaws.

Hand tighten the nuts to secure the assembly to the gear.

Thread the hydraulic cylinder into the assembly until the threads bottom out.

WARNING  Keep hands clear of the cam gear and puller during removal. Failure to keep clear may result in personal injury.

Connect the appropriate air/hydraulic pump hose to the gear puller hydraulic cylinder.

Connect the other end of the hydraulic pump hose to the output side of the air/hydraulic pump, Part Number 3823622.

Connect the air hose to the input side of the air/hydraulic pump.

Make sure that the lifting device is attached to the gear puller lifting bracket.

Step away from the engine to avoid personal injury when the camshaft gear and puller are released from the camshaft.

Slowly depress the air/hydraulic pump pedal on the side labeled “PRESS” and hold until the camshaft gear and puller are released from the camshaft.

After the camshaft gear and puller have been removed from the camshaft, depress the air/hydraulic pump pedal on the side labeled “RELEASE” and hold until the pressure is released.

Remove the camshaft gear from the puller.

Disconnect the air hose from the input side of the air/hydraulic pump.

Disconnect the air/hydraulic pump hose from the gear puller hydraulic cylinder.

Disconnect the other end of the hydraulic pump hose from the output side of the air/hydraulic pump.

Remove the lifting device from the puller lifting bracket.

Remove the four capscrews and camshaft position sensor plate from the rear of the camshaft gear.

Inspect the camshaft gear for cracks and chipped or broken teeth.

Inspect the bore of the gear for frets or burrs.

Remove any burrs with a fine grade abrasive pad, such as Scotch-Brite™ 7448, Part Number 3823258, a fine honing stone, or equivalent.

If the frets, burrs, or raised material can not be removed, replace the gear.

Inspect the camshaft gear keyway for burrs.

Remove burrs with a fine grade abrasive pad such as Scotch-Brite™ 7448, Part Number 3823258, a fine honing stone, or equivalent.

If the keyway is damaged or the burrs can not be removed, the camshaft gear must be replaced.

Inspect the camshaft nose for frets or burrs.

Remove any burrs with a fine grade abrasive pad such as Scotch-Brite™ 7448, Part Number 3823258, a fine honing stone, or equivalent.

If frets or burrs can not be removed, replace the camshaft.

Inspect the thrust surface of the camshaft for grooves or heavy wear.

Inspect the camshaft position sensor plate for cracks or other damage.

Replace the camshaft position sensor plate if it is cracked or otherwise damaged.

NOTE: The camshaft position sensor plate is not symmetric and can only be oriented in one position.

Align and assemble the camshaft position sensor plate to the rear face of the camshaft gear.

Tighten the four capscrews.

If removed, install the camshaft thrust bearing prior to installing the key.  Refer to Procedure 001-056 in Section 1.

Remove the camshaft rear cover plate. Refer to Procedure 001-011 in Section 1.

Install three ½ inch UNC capscrews into the 3-bolt pattern shown. This will secure the camshaft in position while installing the front camshaft gear.

NOTE: Gear housing clearance makes key installation more difficult. Use care in seating the key.

Be sure the gear mounting surface is clean and free of oil, dirt, or debris.

Use a leather hammer to install the camshaft gear key.

Heat the gear in an oven for a minimum of 2 hours, but not longer than 4 hours.

WARNING  Use insulated gloves, Part Number 3823730, and/or hot clamp pliers, Part Number 3823732, when handling heated parts. Hot parts can cause serious personal injury.

CAUTION  The timing marks and gear part number must be facing away from the camshaft when the gear is installed to prevent engine damage.

Use Lubriplate™ 105, or equivalent, to coat the camshaft nose before installing the camshaft gear.

Remove the gear from the oven. Install the gear on the camshaft within 30 seconds after removing it from the oven.

Align the gear keyway with the key in the camshaft and install the gear on the camshaft until the camshaft contacts the positive stop on the gear.

Install a C-clamp around the gear housing and the camshaft gear to hold the gear in position as it cools.

Remove the C-clamp after the gear has cooled for at least 10 minutes.

Measure the camshaft end clearance. Refer to Procedure 001-065 in Section 1.

Remove the three ½ inch UNC capscrews from the flywheel housing that were used to secure the camshaft in position while installing the front camshaft gear.

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  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

• Install the camshaft rear cover plate. Refer to Procedure 001-011 in Section 1.
• Install the front camshaft idler gear. Refer to Procedure 001-036 in Section 1.
• Check the engine timing. Refer to Procedure 001-088 in Section 1.
• Install the front gear cover. Refer to Procedure 001-031 in Section 1.
• Install the camshaft position sensor. Refer to Procedure 019-363 in Section 19.
• Install the cooling fan. Refer to Procedure 008-040 in Section 8.
• If removed, install the radiator. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks.