2008/02/25 Caterpillar

Industrial Engine:

3408 (S/N: 67U1-UP)

3412C (S/N: 8AR1-UP)

3412 (S/N: 38S1-UP)

D342C IND PC T (S/N: 49B1-UP)

Generator Set Engine:

3408 (S/N: 78Z1-UP)

3412 (S/N: 81Z1-UP; 4BZ1-UP)

3412C (S/N: DJN1-UP)

Marine Engine:

3408C MARINE (S/N: 9ER1-UP)

3408 (S/N: 99U1-UP)

There may be an issue with clearance with the front gear housing if the gear group is reused on a remanufactured engine. Follow the procedure below in order to ensure enough clearance between the front housing and the gear.

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Illustration 1	g01456046
10R-4388 Front Housing

1. Remove the engine and the torque converter from the application.

2. Remove the existing damper, front housing, camshaft drive gear, and cluster idler gear from the engine.

3. Clean the engine and inspect the engine in order to make sure that the engine does not contain any damaged parts or debris from damaged parts.

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Illustration 2	g01456047
(1) Not enough clearance between the gear and the front housing

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Illustration 3	g01456049
(2) Gear is sticking out too far from the front housing.

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Illustration 4	g01456050
Measure in 3.5 mm (0.1378 inch) from the front housing inside surface

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Illustration 5	g01456048
Remove 3.5 mm (0.1378 inch) of material from the inside surface (3) of the front housing.

4. Conversion to the new wider cam gear and idler gear assembly requires some modifications to the front gear housing. The inside surface of the front housing must be machined. Illustration 5 shows the inside surface of the front housing.

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Illustration 6	g01456419
(1) Centerline of the Crankshaft (2) Area of material that needs to be removed from the support (A) 29° (B) 19° (C) 50 mm (2 inch)

5. Modify the front support bracket for the engine to the dimensions that are shown in Illustration 6. This will make sure that the damper will have enough clearance. Do not flame cut the front engine support. The front engine support must be machined.

   Note: If the front engine support meets the dimensions in Illustration 6 then proceed to Step 6.

   Note: The 105-9083 Engine Support Gp requires some modifications.

   Note: The 7E-6385 Engine Support Gp does not require any modifications.

6. Install new 195-0318 Camshaft Gear onto the camshaft. Refer to the engines Disassembly and Assembly Manual for the proper instructions.

Note: The preferred method of installing the cam gear is by pressing the cam gear onto the camshaft without the use of heat. Heat may be used if the process is performed properly.

Note: Do not heat the cam gear with a torch. Do not heat the cam gear to a temperature that is greater than 205 °C (400 °F) for more than one hour.

7. Install the new 195-0316 Gear As .

8. Install the camshaft assembly into the engine.

9. Install the front housing, modified engine support, 167-8130 Damper, 6N-6037 Damper Adapter, 6N-7654 Spacer, and the required pulley assembly.