200 BENCH PROCEDURES

Make sure there is enough clearance between the end of the camshaft and the floor while removing the gears. Do not let camshaft fall or strike the floor when pressed from the gears. The camshaft can be bent easily, and the bend may go unnoticed. Installing a bent camshaft in the engine could result in cam bushing failure.

4.Remove the thrust washer.

200 Bench Procedures

Inspection

Refer to Figure 5-19.

1.Thoroughly clean camshaft (3).

Use magnaflux (PT7190) inspection procedure to detect cracks.

2.Inspect camshaft lobes and journals for evidence of cracks, pitting, scoring or severe wear. If any of these conditions exist, replace camshaft.

3.Inspect camshaft gear (1), injection pump driving gear (5), and camshaft captured thrust washer (2) for cracks, pitting, scoring or adverse wear.

4.Visually inspect key (4) for signs of distortion or breakage.

Assembly

Two methods can be used to assemble camshaft gears on a camshaft. Use the heat method to install new gears on a new camshaft. Use the press method if reusing any service parts. Do not use heat method on used parts.

HEAT METHOD — CAMSHAFT/INJECTION PUMP DRIVING GEAR INSTALLATION

Refer to Figure 5-19.

1.Thoroughly clean camshaft (3) and gears (1 and 5) using a contact-type cleaner that dries rapidly and leaves no residue.

2.Insert key (4) into camshaft (3). It may be necessary to tap key with a rubber mallet to ensure proper seating of key.

3.Install a new camshaft captured thrust washer (2) on camshaft.

200 Bench Procedures

Wear protective gloves when handling heated gears.

Refer to Figure 5-20.

4.Using an oven (not a torch), heat new camshaft gear and new injection pump driving gear to 400°F (205°C). Do not exceed 400°F (205°C) and do not heat for more than one to two hours. Do not exceed two hours. Position camshaft gear with timing marks facing out, and align keyway with key.

7.Install injection pump driving gear (5) by applying a quick, even pressure until gear bottoms onto camshaft gear. Make sure camshaft thrust washer holes are accessible through injection pump driving gear.

PRESS METHOD — CAMSHAFT/INJECTION PUMP DRIVING GEAR INSTALLATION

Refer to Figure 5-19.

1.Thoroughly clean and degrease camshaft (3) and camshaft drive gear (1) with a suitable contact cleaner that dries rapidly and leaves no residue.

2.Install a new key (4) in camshaft key slot.

3.Place camshaft in a press, making sure camshaft is supported by plates between journal and first lobe.

Approximately 5 tons (4.54 MT) of force is required to press each gear onto the camshaft. When in the press, use suitable plates to support the camshaft between the journal and first lobe. Do not allow camshaft to rest on the floor.

4.Position a new thrust washer (2) on the camshaft.

5.Prepare the gear bore with Locquic™ Primer T, or equivalent.

5.Push downward with a quick, even pressure to install camshaft gear onto camshaft.

The heat-expanded gear bore will begin to transfer heat to the camshaft as soon as the gear bore and camshaft contact each other. This makes it absolutely necessary that the gear be installed in one very rapid motion to the fully seated position. If the gear is allowed to stop on the camshaft part way before fully seating, it will become immovable. If this occurs, do not pressinstall the gear. It should be press removed, allowed to cool, and re-installed using the press method.

6.There should be between 0.003–0.012 inch (0.076–0.305 mm) clearance between rear face of gear and thrust washer when measured with thickness gauge.

6.Apply a bead of Loctite 609, or equivalent, to the gear bore.

7.Using a clean brush, spread Loctite 609 evenly onto the entire surface of the gear bore.

Refer to Figure 5-21.

8.Position gear on camshaft with timing marks facing upward and key slot in gear aligned with key in shaft.

Do not attempt to increase clearance between camshaft and gears by sanding gear bores or camshaft.

Page 5-21