3054E Engine for Caterpillar Built Machines Idler Gear - Remove and Install Caterpillar


Idler Gear - Remove and Install
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3054E Engine for Caterpillar Built Machines [RENR2411]
BASIC ENGINE
GEAR GP
3054E Engine for Caterpillar Built Machines Idler Gear - Remove and Install
1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Name  Qty 
A  9U-6198  Crankshaft Turning Tool 
B  230-6284  Timing Pin (Camshaft) 
C  230-6283  Timing Pin (Crankshaft) 
D  150-3992  Timing Pin (Fuel Injection Pump) 
E  1P-0510  Driver Group 

Start By:

  1. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".

  2. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.


  1. Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".

    Note: Install Tooling (B) through the camshaft gear. Install Tooling (C) into the crankshaft web.



    Illustration 1g00944616
    Fuel Injection Pump Gear

  2. Insert Tooling (D) in the hole of fuel injection pump gear (2), through the slot in the hub and into the timing hole of the Fuel Injection Pump (X). If Tooling (D) can be fully inserted, the fuel injection timing is correct. There should be no resistance when Tooling (D) is inserted.

    Note: Do not remove hub nut (1) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed in the correct position from the factory in order to ensure proper timing. If hub nut (1) is removed and the hub is removed, the hub will need to be accurately installed on the shaft of the fuel injection pump by the use of special equipment. Refer to your AVSpare Dealer for more information.



    Illustration 2g00995133

  3. Loosen bolt (4). Remove spacer (5) in order to allow bolt (4) to tighten against the shaft of fuel injection pump (6). Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten bolt (4) to a torque of 31 N·m (23 lb ft).

    Note: Bolt (4) must be tightened in order to prevent the shaft of the fuel injection pump from rotating.



    Illustration 3g00995931

  4. Remove Tooling (D) from the body of the fuel injection pump.

  5. Remove bolts (3) and the washers from the hub of the fuel injection pump. Remove fuel injection pump gear (2).

  6. Remove bolts (9) and retaining plate (8).


    Illustration 4g00995934

  7. Remove idler gear (7) and idler gear hub (11).

  8. Use Tooling (E) and remove bushings (10) from each side of the idler gear.

Installation Procedure

Table 2
Required Tools 
Tool  Part Number  Part Name  Qty 
A  9U-6198  Crankshaft Turning Tool 
B  230-6284  Timing Pin (Camshaft) 
C  230-6283  Timing Pin (Crankshaft) 
D  150-3992  Timing Pin (Fuel Injection Pump) 
E  1P-0510  Driver Group 


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


  1. Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".


    NOTICE

    The valve timing and the fuel injection pump timing will be lost if the crankshaft is rotated when the idler gear is removed.




    Illustration 5g00995936

  2. Position idler gear hub (11) and install bolts (9) in order to locate the idler gear hub. Tighten the bolts in order to seat the idler gear hub.

    Note: The Lubrication Hole (Y) of the idler gear hub must be positioned at the top of the idler gear hub.

  3. Use a suitable press and Tooling (E) to install bushings (10) on each side of idler gear (7).

  4. Remove bolts (9) from the idler gear hub. Install idler gear (7) on idler gear hub (11).

    Note: When you install the idler gear, ensure that the marked teeth are facing toward the front.

  5. Install retainer plate (8) and bolts (9). Tighten the bolts to a torque of 44 N·m (32 lb ft).


    Illustration 6g00944081

  6. Check the end play for the idler gear. The end play for the idler gear is 0.10 to 0.20 mm (0.004 to 0.008 inch).


    Illustration 7g00944084

  7. Check the backlash between the idler gear and the camshaft gear. The backlash for the gears is 0.052 to 0.107 mm (0.0020 to 0.0042 inch).

  8. Check the backlash between the idler gear and the crankshaft gear. The backlash for the gears is 0.064 to 0.124 mm (0.0025 to 0.0049 inch).

  9. Ensure that the mating surfaces of the fuel injection pump gear and the hub of the fuel injection pump are clean.


    Illustration 8g00995951

  10. Insert Tooling (D) through the slot in the hub and into the timing hole of the fuel injection pump. If Tooling (D) can be fully inserted, the fuel injection timing is correct. There should be no resistance when Tooling (D) is inserted.

    Note: Tooling (B), Tooling (C), and Tooling (D) must be installed before fuel injection pump gear (2) is installed on the hub of the fuel injection pump.

    Note: Do not remove hub nut (1) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed in the correct position from the factory in order to ensure proper timing. If hub nut (1) is removed and the hub is removed, the hub will need to be accurately installed on the shaft of the fuel injection pump by the use of special equipment. Refer to your AVSpare Dealer for more information.

  11. Position the slot in the fuel injection pump gear (2) over Tooling (D). Install bolts (3) and washers. Do not tighten the bolts at this time.

  12. Rotate the fuel injection pump gear counterclockwise in order to remove the backlash between the idler gear and the fuel injection pump gear. Tighten bolts (3) to a torque of 22 N·m (16 lb ft).

  13. Remove Tooling (D) from the fuel injection pump. Remove Tooling (B) from the camshaft gear. Remove Tooling (C) from the crankshaft web.


    Illustration 9g00995133

  14. Loosen bolt (4). Install spacer (5) in order to prevent bolt (4) from tightening against the shaft of fuel injection pump (6). Tighten bolt (4) to a torque of 12 N·m (9 lb ft).

End By:

  1. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".

  2. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".

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