Cummins ISX11.9 CM2250 – Service Manual 001-033   Gear Housing, Front

The ISX11.9 has two front gear housing options; non-hydraulic drive and hydraulic drive. The hydraulic drive front gear housing is larger and provides accommodations for a second idler gear to drive a hydraulic pump mounted at the lower end of the gear housing.

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 engine coolant. Refer to Procedure 008-018 in Section 8.
• Remove the cooling fan. Refer to Procedure 008-040 in Section 8.
• Remove the camshaft position sensor. Refer to Procedure 019-363 in Section 19.
• Remove the lubricating oil fill tube. Refer to Procedure 007-065 in Section 7.
• Remove the hydraulic drive pump, if equipped. Refer to Procedure 009-016 in Section 9.
• Remove the air compressor, if equipped. Refer to Procedure 012-014 in Section 12.
• 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 hydraulic drive idler gear, if equipped. Refer to Procedure 001-039 in Section 1.
• Remove the front camshaft gear. Refer to Procedure 001-012 in Section 1.
• Remove the camshaft thrust bearing. Refer to Procedure 001-056 in Section 1.

NOTE: This section is for removing removing the non-hydraulic drive gear housing option.

Remove the capscrews that secure the gear housing to the cylinder block.

Remove the gear housing from the cylinder block.

If necessary, the air compressor mounting studs on the back of the gear housing can be removed by tightening two mounting nuts on the stud, then remove the stud.

WARNING  Lubricating oil is captured in the hydraulic drive adapter cavity. Use care not to spill oil on the person, equipment, or facilities.

NOTE: This section is for removing removing the hydraulic drive gear housing option.

Remove the capscrews that secure the gear housing to the cylinder block.

Remove the gear housing from the cylinder block. Drain the lubricating oil in the hydraulic adapter cavity.

If necessary, the air compressor mounting studs on the back of the gear housing can be removed by tightening two mounting nuts on the stud, then remove the stud.

Remove the seals from the grooves in the front and rear of the gear housing.

Clean with air and check for debris.

If additional cleaning is required, brush with a nylon bristle brush.

Remove and inspect the hydraulic drive adapter, if equipped. Refer to Procedure 009-016 in Section 9.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  When using a steam cleaner, wear protective clothing and safety glasses, or a face shield. Hot steam can cause serious personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use steam or solvent to clean the gear housing.

Dry with compressed air.

Inspect the gear housing for cracks and other damage.

Inspect the seal grooves on both sides of the housing for debris and damage.

Inspect the air compressor mounting studs.

Inspect the camshaft position sensor mounting bore for cracks and other damage.

If equipped with a hydraulic drive, inspect the needle bearings pressed in the gear housing for damage. Refer to Procedure 009-016 in Section 9.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Locate the air compressor oil supply port on the back side of the gear housing. Use compressed air to remove any debris.

Remove the STOR plug on the side of the gear housing and clean the drilling in the housing with a small brush and compressed air.

Inspect the camshaft bore locating ring dowel. If the ring dowel is damaged or loose, press out the locating dowel ring with an arbor and press.

Measure the gear housing camshaft bore inside diameter with the locating ring dowel removed.

Camshaft Bore Inside Diameter

If the camshaft bore is out of specification, replace the gear housing.

Press the camshaft bore locating dowel ring into the back of the gear housing with an arbor press. Press the dowel until the shoulder is flush with the gear housing.

NOTE: This section is for installing the non-hydraulic drive gear housing option.

If removed, install the air compressor mounting studs on the back of the gear housing.

Tighten by installing two mounting nuts on the stud.

Install the three seals into the appropriate grooves on the back of the gear housing.

Align the seals to the mating grooves and press into place.

Align the locating dowel ring on the back of the gear housing with the cylinder block camshaft bore.

Be sure the two seals on the back of the gear housing are installed properly and secured in the grooves.

Install the gear housing.

Install the four inner gear housing mounting capscrews and the tail support capscrew.

Tighten the four inner capscrews in a diagonal pattern, starting with the lowest capscrew, as shown.

Tighten the tail support capscrew.

Install and tighten the STOR plug(s) on the side of the gear housing.

NOTE: This section of the procedure is for installing the hydraulic drive gear housing option.

Install the hydraulic adapter drive. Refer to Procedure 009-016 in Section 9.

If removed, install the air compressor mounting studs on the back of the gear housing.

Tighten by installing two mounting nuts on the stud.

Install the three seals into the appropriate grooves on the back of the gear housing.

Align the seals to the mating grooves and press into place.

Align the locating dowel ring on the back of the gear housing with the cylinder block camshaft bore.

Be sure the three seals on the back of the gear housing are installed properly and secured in the grooves.

Install the gear housing.

Install the four inner gear housing mounting capscrews and the tail support capscrew.

Tighten the four inner capscrews in a diagonal pattern, starting with the lowest capscrew, as shown.

Tighten the tail support capscrew.

Install and tighten the STOR plug(s) on the side of the gear housing.

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 thrust bearing. Refer to Procedure 001-056 in Section 1.
• Install the front camshaft gear. Refer to Procedure 001-012 in Section 1.
• Install the front camshaft idler gear. Refer to Procedure 001-036 in Section 1.
• Install the air compressor. Refer to Procedure 012-014 in Section 12.
• Install the hydraulic drive pump, if equipped. Refer to Procedure 009-016 in Section 9.
• Install the hydraulic drive idler gear, if equipped. Refer to Procedure 001-039 in Section 1.
• Install the front gear cover. Refer to Procedure 001-031 in Section 1.
• Install the lubricating oil fill tube. Refer to Procedure 007-065 in Section 7.
• 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.
• Fill the engine cooling system. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine to operating temperature and check for leaks.