Servic

e M

an

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,

AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

D339 Engine

S/N 34B1 & Up

CT-S-ENG D339

ISSUED 11-59

ENGINE

TABLE OF CONTENTS

Index

Specifications

General Instructions

Cutaway Views

Cooling System

Water Temperature Regulator

Fan Group

Water Pump

Raw Water Pump

Radiator

Lubricating System

Oil Pan

Oil Pump

Oil Cooler

Oil Filter and Manifolds

Fuel System

Fuel Supply Equipment

Fuel Injection Equipment

Fuel Injection Equipment (Later engines)

Accessory Drive and Governor

Accessory Drive and Governor

Manifolds

Cylinder Heads

Valve and Valve Mechanism

Front Support

Timing Gears

Pistons, Rings and Connecting Rods

Cylinder Liners

Main Bearings

Crankshaft

Gear-type Balancer

Flywheel and Flywheel Housing

2A-1O

Section Group

2A - 10

2A - 10

IA - 10

2A - 10

lA - 10

2A - 10

I A-I 0

2A - 10

lA - 10

2A - 10

2A - 10

2A - 10

2A - 10

2A - 10

2A - 10

1 A - 10

lA - 10

2A - 10

2A - 10

1 A-I 0

lA - 10

2A - 10

2A - 10

2A - 10

2A - 10

2A - 10

lA - 10

1 A-I 0

lA - 10

lA - 10

2A - 10

2A - 10

30.1

40.2

50

60.1

70

100.1

130

140

150

160.1

170.1

180.1

190.1

200

210

230.1

240.1

250

250.1

260.1

260.2

270

280.1

290

310.1

320

340

350

360

370

380

390

Group 20.1

Page I

ISSUED 12-62

Accessory Drive Housing

Accessory Shaft

Adjustments: Fuel Injection Pump Lifter Full Load Speed Governor Valve Clearance

Air Inlet Manifold

Balancer, Gear-type Bearings:

Connecting Rod Main,

Bell, Suction Bypass:

Fuel Oil Filter

Camshaft Gear Chambers, Precombustion Cleaning:

Engine Valves Fuel Injection Valve Pistons Temperature Regulators

Cutaway Views

A

B

C

Clearances and Tolerances Compression Release Mechanism Connecting Rod and Bearings Cooler, Oil Cooling System Core, Radiator Crankshaft Cylinder Head Cylinder Liners

Data, Engine Directors, Water Drive:

Accessory

Service Meter

Oil Pump

Engine Data Etching Cylinder Liners Exhaust Manifold

D

E

ENGINE

INDEX

260.1 260.2

260.1 6 260.2 - 3

250 4 260.1 - 4 260.1 4

40 2 270

380

340 360 190.1

240.1 210

3

2

320 2 280.1 2

290 3 250 340 - 2

100.1 2 60 1 40 I

290 5 340 200

70 160.1 -370 280 1

350 - I

Fan Group Filters:

Fuel Oil

Flow of Coolant Flow of Fuel Flow of Lubricating Oil Flywheel Front Support, Engine Fuel:

Bypass Filter Housing Injection:

Equipment Pumps Pump Housing

Pump Lifters Pump Lifter Settings Valves

System, Diesel Transfer Pump

Gauge: Fuel Oil

Gear: Accessory Drive

Camshaft Crankshaft Idler Ring, Flywheel Timing Timing Marks

Gear-type Balancer Governor:

Adjustments Control Shaft Operation and Lubrication

Head, Cylinder

Housing:

F

G

H

40 280.1

Accessory Drive and Governor

260.1 260.2 260.1 260.2 190.1

40 350 270

2

6 3

7

4

2

Flywheel Fuel Injection Pump Fuel Filter Timing Gear

Idler Gears Injection, Fuel Inlet:

Manifold Valve

2A-1O Group 30.1

Page 1

130

240.1 2 210

70 - 1 230.1 170.1 390 310.1

240.1 - 2 240.1 - 3

250 - 1 250 - 2 250 - 3 250 - 4 250 - 5 250 - I 230.1 - I 240.1 - 1

230.1 I 1';0.1 2

260.~ 6 320 - 2 370 - I 320 - I 39f - 1 320 - I 320 - 1 380 - 1

260.1 4 260.! - 5 260.1 2

280.1 - 1

260.1 - I 260.2 - I 390 250 - 2 240.1 - 3 320 - 1

320 I 250 - 1

270 - 1 250 - 1

Group 30.1

Page 2

Lifters:

2A-I0

Fuel Injection Pump Valve

Liners, Cylinder Lubricating System Lubrication:

Service Meter

Piston and Ring Timing Gear

Main Bearings Manifolds:

Exhaust Inlet Oil Filter Oil

Oil: Bypass Valvr r

Cooler Fil!L Mani Filters Manifold Pan Pump Pump Drive Pump Suction Bells

Operating ifficulties:

L

M

o

Engir.e voolant Overheating Engine Fuel System Engine Lubricating System

Overheating, Coolant

Pan, Oil Pistons Piston Pin Bushings Pis"on Rings Precombustion Chambers Pressure, Oil

Gauge Regulating Valve

Pump: Fuel:

Injection Transfer

Oil Water

p

R

Radiator Raising Ring Ridge in Cylinder Liners Regulators, Water Temperature Release, Compression Ring Gear, flywheel

ENGINE INDEX

250 - 4 290 - 4 350 170.1

260.1 260.2 340 170.1

360

270 270 210 210

210 200

7 4

2 2

210 2 210 1 210 2 180.1 1 190.1 190.1 -190.1

70 230.1 170.1

70 2 1

180.1 - 1 340 1 340 3 340 - 2 280.1 2 170.1 2 170.1 1 170.1 3

250 2 240.1 190.1 1 140 - 1

160.1 350 100.1 290 390

2

5

Rings, Piston Rocker Arms, Valve Rod, Connecting Running-in Schedule Run out:

Flywheel Flywheel Housing

Sealed Pressure Overflow Seals, Liner .. Service Meter Setting Fuel Pump Lifter Shaft, Accessory Drive

Sleeve, Liner Specifications Springs:

Governor Valve

Suction Bells Support, Engine Front

s

T

Testing Temperature Regulators Thrust Bearing:

Camshaft Crankshaft

Timing: Engine Gears Engine Valves Fuel Injection

Timing Gears Timing Marks Tolerances Transfer Pump, Fuel

Valve: Bypass, Fuel Bypass, Oil Inlet and Exhaust Fuel Injection

V

Inspecting and Reconditioning Lifters Operation Pressure Regulating, Oil Rocker Arm Rotators Seat Specifications Stem Bushings Timing

Valves and Valve Mechanisms

w Water:

Directors, Seals and Ferrules Pump Seal Replacement

Temperature Regulator

ISSUED 12-62

340 290 340 340

390 390

160.1 350 260.1 250

2 2 2

2

2

7 4

260.1 6 260.2 3 350 1

40

260.1 2 290 - 3 190.1 310.1

100.1

320 360

320 290 250 320 320

40 240.1

3

4 4

240.1·- 1 210 2 290 250 1 290 3 290 4 290 190.1 3 290 2 290 1 290 3 290 4 290 4 290 1

280.1 140 140 100.1

2

Group 40.2

Page 2

2A-IO

Cylinder Liner Inside Ji::lmeter

ENGINE SPECIFICATIONS

PerJT,'~slble liner wear (increase in diameter at top of ring travel)

Fan Belt Tension Slae ~.~ point midway between pulleys

F~~v.·l .(

l-:etm!1:ng bolt torque

Flywr a<'!;Housing Bol' and nut torque

Fuel Injection Equipment Fuel injection pump timing ~ 'el injection pump lifter setting

,with piston at top center) Injection pump lifter setting (off engine-see text) Fuel pump plunger length germissible wear (decrease in length of plunger) ,. jection nozzle orifice r'uel injection camshaft bearing bore Clearance between fuel inj ection camshaft and bearings Permissible clearance Nozzle retaining nut torque Precombustion chamber torque

Fuel Transfer Pump Clearance between gear and covers, total Bearing bore Bearing clearance Permissible bearing clearance

Governor Drive gear backlash Permissible upper retainer bearing clearance

Oil Pump Clearance between gears and end covers

Piston Pins Clearance in piston pin bearing Permissible clearance in piston pin bearing Clearance in piston Permissible clearance in piston

Piston Rings Piston ring side clearance

Top ring 2nd and 3rd ring Oil control ring Permissible clearance (top compression ring) Ring gap, top Ring gap, 2nd and 3rd Ring gap, oil

Rocker Arm Bearings Clearance between shaft and bearings T"":,!"missible clearance

Service Meter Permissible bearing clearance

5.750 - 5.751 in.

.020 in.

3/4 - 1 in.

230 lb. ft.

ISO lb. ft.

13° BTC

1. 733 -+- .004 in. 1.781 ± .001 in.

2.6575 - 2.6577 in. .005 in. .028 in.

1.436 - 1.437 in. .002 - .004 in.

.010 in. 105 lb. ft. 200 lb. ft.

.00 I - .002 in. .4950 - .4955 in.

.00 I - .002 in. .005 in.

.002 - .006 in. .005 in.

.002 - .004 in.

.00 I - .002 in. .006 in.

.0004 - .00 I in. .006 in.

.005 - .006 in. .003 - .0046 in.

.00 IS - .0035 in. .012 in.

.017 - .022 in.

.017 - .027 in.

.015 - .025 in.

.0020 - 0035 in. .010 in.

.012 in.

ISSUED 10-59

IA-5 Group 30

Page 4 SERVICE MANUAL GENERAL INSTRUCTIONS ISSUED 10-68

or washer against a shoulder on a shaft, be sure the chamfered side is toward the shoulder.

IHCO.RRE'CT

Correct and incorrect installation of spacer.

When pressing bearings into a retainer or bore, apply pressure to the outer race. If the bearing is pressed on the shaft, apply pressure on the inner race.

Preload

Preload is an initial load placed on the bearing at the time of assembly. Whether a taper roller bear­ing should have preload could depend on any of several conditions: rigidity of the housings and shaft, bearing spread, speed of operation, etc.

The only certain way to determine what a bear­ing requires, preload or end clearance, is to consult the disassembly and assembly topic pertaining to that bearing.

Care should be exercised in applying preload. Misapplication of preload to bearings requiring end clearance can result in bearing failure.

Sleeve Bearings

Do not install sleeve bearings with a hammer. Use a press if possible and be sure to apply the pressure directly in line with the bore. If it is necessary to drive on a bearing use a bearing driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part.

GASKETS

Be sure the holes in the gaskets correspond with the lubricant passages in the mating parts. If it is necessary to make gaskets, select stock of the proper type and thickness. Be sure to cut holes in the right places. Blank gaskets can cause serious damage.

When removed, always install new cylinder head and manifold gaskets using recommended gasket compound on head gaskets to allow uniform sealing.

BRAKE LININGS

Replace brake linings before they have worn enough to permit the rivet heads to contact and score the brake drums.

BATTERIES

Clean batteries by scrubbing with a solution of baking soda and water. Rinse with clear water. After cleaning, dry thoroughly and coat terminals and connections with an anti-corrosion compound or grease.

If a machine is to be stored or not used for a long period of time, the batteries should be removed. Store them in a warm, dry place, preferably on wooden shelves. Never store on concrete. A small charge should be introduced periodically to keep the specific gravity rating at recommended level..

SEALS

Duo-Cone Floating Seals

Floating ring seals have highly finished surfaces and are held together by toric sealing rings. The flexibility of the toric sealing rings makes the floating ring seals self aligning and compensates for wear on the metal faces.

During disassembly, tape the metal floating ring seals together so they will be kept in matched sets. Always install the metal floating ring seals in pairs; that is, two new seals together or two seals that have previously run together. Never reinstall a used toric sealing ring.

Handle all parts with care to avoid nicks. File smooth any parts, other than the sealing faces, that have nicks that may make assembly difficult or questionable. Wash off all dirt accumulation from used parts. Use a wire brush to clean dirt or rust from the bore of the seal retainers to assure they are clean and smooth. Remove all oil or the protec­tive coating from floating ring seals and retainers with a nonflammable cleaning solvent. Be sure the ramp on the retainers and on the floating ring seals are dry.

Check the ramps for tool marks and nicks. On used parts, remove dirt or rust deposits from the ramps. Smooth the surface with emery cloth.

1 2 3 4

~'~i -~ T87199

An example of a correct installation of a metal floating ring seal and toric sealing ring. The illustration shows the dimension (I) to be checked. the metal floating ring seal (2). the rubber toric sealing ring (3) and the toric sealing ring retainer (4). The dimension must be uniform around the entire circumference of the floating ring seal. Check the dimension at 90° intervals.