Cummins ISX11.9 CM2250 – Service Manual 001-013   Camshaft Gear (Camshaft Removed)

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.

• Disconnect the batteries. Refer to the OEM service manual.
• Remove the gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the camshaft idler gear. Refer to Procedure 001-036 in Section 1.
• Remove the camshaft. Refer to Procedure 001-008 in Section 1.

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

CAUTION  Support the camshaft gear on the center hub when pressing it off the camshaft. Failure to do so can result in damage to the gear.

Install the camshaft and gear assembly in a hydraulic press.

Press the camshaft from the gear.

Remove the camshaft key.

Remove the thrust plate.

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 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.

Install the thrust plate on the camshaft. Make sure that the part number faces outward, toward the gear.

Be sure the key mounting groove is clean and free of oil, dirt, or debris.

Use a leather hammer to install the camshaft gear key.

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.

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

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

Properly support the camshaft in a vertical position, so that it doesn’t move during installation of the gear. Be sure not to damage the camshaft.

The side of the gear with the four threaded holes for the timing plate goes on facing inward, toward the camshaft (rear of the engine).

The gear must be installed within 30 seconds after being removed from the oven.

Remove the gear from the oven. Align the keyway in the gear with the key in the camshaft, and install the gear on the camshaft.

Keep the camshaft in a vertical position with the gear up until the gear has cooled.

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

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 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.

• Install the camshaft. Refer to Procedure 001-008 in Section 1.
• Install the camshaft idler gear. Refer to Procedure 001-036 in Section 1.
• Check the engine timing. Refer to Procedure 001-088 in Section 8.
• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for proper operation and leaks.