C4.4 Marine Generator Set Engines Caterpillar

Installation Procedure

Show/hide table

Illustration 1	g00943872

1. Position idler gear hub (9) and install bolts (7) in order to locate idler gear hub (9). Tighten bolts (7) in order to seat idler gear hub (9).

   Note: The Lubrication Hole (X) of idler gear hub (9) must be positioned at the top of idler gear hub (9).

2. Use a suitable press and Tooling (D) to install bushings (8) on each side of idler gear (5).

3. Remove bolts (7) from idler gear hub (9). Install idler gear (5) on idler gear hub (9).

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

4. Install retainer plate (6) and bolts (7). Tighten bolts (7) to a torque of 44 N·m (32 lb ft).
   Show/hide table

   Illustration 2	g00944081

5. 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).
   Show/hide table

   Illustration 3	g00944084

6. 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).

7. 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).
   Show/hide table

   Illustration 4	g01166832

   Note: Ensure that the mating surfaces of the fuel injection pump gear and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut must turn freely until contact is made with the fuel injection pump gear.

8. Position fuel injection pump gear (4) on the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Install the washer and nut (3). Tighten nut (3) to a torque of 25 N·m (18 lb ft).
   Show/hide table

   Illustration 5	g01166697

9. Loosen bolt (1). Move spacer (2) in order to prevent bolt (1) from tightening against the shaft of the fuel injection pump. Tighten bolt (1) to a torque of 12 N·m (106 lb in).

   Note: Spacer (2) must be correctly positioned and bolt (1) must be tightened in order to prevent the bolt from contacting the shaft of the fuel injection pump.

   Show/hide table

   Illustration 6	g01166836

10. Tighten nut (3) to a torque of 88 N·m (65 lb ft).
    Show/hide table

    Illustration 7	g01166695

11. Remove Tooling (A) and Tooling (B).

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".