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Carrier 50ZH024-060 Air Conditioner User Manual

1. LD Allowable 25 05 mm Limit 0 9862 in 2 3 3 6 Piston Pin and Bushing Clearance 1 Measure the piston pin O D with an outside microme ter 2 Measure the connecting rod small end bushing I D with an inside micrometer 3 If the clearance exceeds the allowable limit replace the bushing If the clearance is still excessive replace the piston pin Factory 0 014 to 0 038 mm Piston Pin to Specification 0 00055 to 0 00150 in Small End Bush Allowable 0 15 mm ing Clearance e Limit 0 0059 in Factory 25 002 to 25 011 mm SOME 0 98433 to 0 98468 in Small End Factory 25 025 to 25 040 mm Bushing D Specification 0 98523 to 0 98582 in 2 3 3 c Replacing Connecting Rod Small End Bu shing A When Removing 1 Press out the small end bushing using a Small End Bushing Replacing Tool B When Installing 1 Clean a new small end bushing and bore and apply engine oil to both 2 Using the small end bushing replacing tool press in the new bushing to the specified dimension see B NOTE Be sure to align the bushing so that the oil hole in the bushing aligns with the oil port in the con necting rod 2 3 3 Piston and Connecting Rod Continued 2 3 3 d Piston Ring Gap 1 Insert the piston ring into the lower part of the cylinder the least worn section Use the piston to square the ring in the cylinder 2 Measure the ring gap with a feeler gauge 3 If the gap exceeds the allowable limit replace the
2. Diesel Engine Tomo NY WR rie Ret Ec S WORKSHOP MANUAL for V2203 DI 26 0012838 Tier 4i 602 113602 Rev TRANSICOLD WORKSHOP MANUAL DIESEL ENGINE V2203 DI 26 00118 Tier 41 TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS Guarita bios ta RC Pv d bt bor vt is IV SPECIFIC WARNING AND CAUTION STATEMENTS ssseee n HH mn IV Generalis eaves EP aaa ada 1 1 El GNOINEJSDENTIFICATION EEN 1 1 ECs Se er et sordes e POE dr eor Ecran ace anto Dr deoa duca chu tta auda AO 1 1 L2 ENGINE SPEGIFICATIONS bis ii delen SOR ea ada elio SO E De 1 2 La EXUNDER NUMBER cuire Eat e ra op ES etr o dec Co ear eta o bera bar dus 1 3 Ld GENERALPRECAUTIONS 25328 eid de etti pea bei ute hae b bp det ene E EIER 1 3 L5 qJOROUESPECIFICATIONS ociosa RU Up nta deren rr eee 1 4 1 5 1 Torque Specifications For Special Use Screws Bolts and Nuts cee eee eee 1 4 1 5 2 Torque Specifications For General Use Screws Bolts and Nuts cece eee eee 1 4 LO TROUBLESHOOTING 2 x E aatem i e dar om ar xx ddp rer Rasa 1 5 LT SERVICING SPECIFICATIONS 21 34 3 9 Gba ER VH aci dba obe ropes acd dep S ERU eoque Seu 1 7 LE GINS ee 1 7 142 L prncaufig Ste ass taa o Racer tar Pa tee ia ea optar opea Cac ra rei at a b dh 1 11 L gt C 091975 EH 1 11 Leica EuebsSySteltb aed tage hate Tre VE EY verre de SEE Ee OE eR PRG 1 11 L 7 5 a EE 1 12 Lo CHECK AND MAINTENANCE 5isttadtautted cd vix imd ta
3. Replace Replace Replace Injection pump Replace nozzle Replace Water Mixed into Head gasket defective Replace Lubricant Oil Cylinder block or cylinder head flawed Replace Low Oil Pressure Engine oil level low Oil strainer clogged Relief valve stuck with dirt Replenish Clean Clean Relief valve spring weak or broken Replace Excessive oil clearance of crankshaft bearing Replace Excessive oil clearance of crankpin bearing Replace Excessive oil clearance of rocker arm Replace Oil passage clogged Incorrect oil type Clean Use specified type of oll Oil pump defective High Oil Pressure Incorrect oil type Relief valve defective Engine Overheated Engine oil level low Fan belt broken or elongated Coolant insufficient Radiator net and radiator fin clogged with dust Inside of radiator corroded Coolant flow route corroded Radiator cap defective Overload running Head gasket defective Incorrect injection timing Unsuitable fuel used Low Battery Charge Battery electrolyte level low Fan belt slips Wiring disconnected Rectifier defective Alternator defective Battery defective 62 11632 Repair or replace 3 2 Use specified type of oil Replace Replenish Replace or adjust Replenish Clean Clean or replace Clean or replace Replace Loosen load Replace Adjust Use specified fuel Replenish distilled water and charge Adjust belt tension or change belt Connect Replace Rep
4. ring Factory 0 20 to 0 35 mm Top Ring Specification 0 0079 to 0 013 in Keystone Type Allowable Limit 1 25 mm 0 0492 in Factory 0 40 to 0 55 mm S econd Ring Specification 0 016 to 0 021 in Allowable Limit 1 25 mm 0 0492 in Factory 0 25 to 0 45 mm Oil Control Ring Specification 0 0099 to 0 017 in Allowable Limit 1 25 mm 0 0492 in 2 3 3 e Piston Ring to Groove Clearance 1 Clean the rings and the ring grooves and install each ring in its groove 2 Measure the clearance between the ring and its groove with a feeler gauge with the exception of the top ring Keystone Type which cannot be accurately measured with a feeler gauge 3 If the clearance exceeds the allowable limit replace the ring 4 f the clearance still exceeds the allowable limit after replacing the ring replace the piston Factory 0 093 to 128 mm Second Ring Specification 0 00367 to 0 00503 in Allowable Limit 0 20 mm 0 0079 in JEEABAB1P144A Factory 0 020 to 0 060 mm Oil Control Ring Specification 0 00079 to 0 0023 in Allowable Limit 0 15 mm 0 0059 in 2 3 3 f Connecting Rod Alignment NOTE Since the I D of the connecting rod small end bushing is the basis of this procedure check the bushing for wear before proceeding 1 Install the piston pin into the connecting rod 2 Install the connecting rod on the connecting rod align ment tool 3 Put a gauge over the piston pin and move it against the fa
5. 1 2 Detach the rocker arm assembly 2 3 Remove the push rods 3 When Reassembling When putting the push rods 3 onto the tappets 4 check to see if the push rod end is properly seated in the tappet dimples NOTE After instaling the rocker arm be sure to adjust the valve clearance Refer to Section 1 8 7 SEEABAB1P062B 1 Rocker Arm Bracket 3 Push Rod Mounting Bolt 4 Tappet Tightening Rocker Arm 24 to 27 N m 2 Rocker Arm Assemblv Torque Bracket Mounting 2 4 to 2 8 kgf m Bolt 18 to 20 ft lbs 62 11362 2 4 2 2 3 Cylinder Head And Valves Continued 2 2 3 e Cylinder Head 1 Loosen the hose clamp 1 and remove the water re turn pipe 2 2 oe the cylinder head bolts in the order of 18 to 1 3 Lift up the cylinder head and remove 4 Remove the cylinder head gasket 3 When Reassembling Replace the cylinder head gasket 3 with a new one Apply oil to then re install the cylinder head bolts Tighten the cylinder head bolts in sequence starting from the center in the order of 1 to 18 Tighten the head bolts uniformly or head warpage may occur 93 1 to 98 0 Nm od disci 9 5 to 10 0 kgfm i 68 7 to 72 3 ft lbs NOTE When replacing the cylinder head gasket 3 be sure you are using a new gasket that matches Hose Clamp the original gasket Filter Drier Inlet Gear Case Side Flywheel Side 3EEABAB1P065B DG H rz 2 2 3 f Tappets 1 Remove the tappets 1
6. 2 1 1 Compression Pressure 1 Run the engine until it is warmed up 2 Stop the engine and disconnect the 2P connector from the stop solenoid to prevent fuel delivery to the engine 3 Remove the the air cleaner the muffler and all the in jection nozzles Install a compression tester with the adapter in one of the nozzle hole 5 While cranking the engine with the starter measure the compression pressure 6 Repeat steps 4 and 5 for each cylinder 7 Ifthe measurementis below the allowable limit add a small amountof oilto the cylinder thru the nozzle hole and measure the compression again a If the compression pressure is still less than the al lowable limit check the top clearance valves and cylinder head b Ifthe compression pressure increases after applying oil check the cylinder wall and piston rings NOTE Check the compression pressure with the spe cified valve clearance Always use a fully charged battery for perform ing this test Variances in cylinder compression values should be under 1096 2 95 to 3 23 MPa S n 30 to 33 kgt cm P 427 to 469 psi 2 35 MPa 24 kgt cm 341 psi Compression Pres sure Allowable Limit 2 1 2 1 2 Top Clearance 3EEABAB 1P057B 1 Piston 2 Plastic gauge Remove the valve cover Refer to Section 2 2 3 a 2 Remove the cylinder head 3 Move the piston 1 up and stick a strip of plastic gauge 2 onthe piston head atthree positions s
7. 2 9 governor 2 7 2 8 INDEX Identification 1 1 idle gear 2 10 injection nozzle 5 3 injection timing 5 1 intake air heater 6 3 L lubricating system 3 1 Notched V Belt 4 1 O oil level 1 13 oil pan 2 12 oil pressure 3 1 oil pump 2 11 3 2 p piston 2 13 2 26 2 27 piston ring 2 14 Poly V belt 4 1 push rod 2 22 R radiator 4 2 radiator cap 4 2 rocker arm 2 22 Index 1 62 11362 S Safety Precautions iv Specifications 1 2 Speed control plate 2 7 2 8 Starter motor 6 1 T tappets 2 5 2 23 thermostat 4 2 timing gear 2 23 Torque Specification 1 4 62 11362 INDEX V V belt 1 14 valve clearance 1 15 valve guide 2 20 valve seat 2 20 valve spring 2 22 valves 2 5 2 19 2 21 W water pump 4 3 Index 2 Y Carrier North America Mexico and Carrier Transicold Central America A United Technologies Company 700 Olympic Drive Ejercito Nacional No 418 Carrier Transicold Division Athens GA 30601 USA Piso 9 Torre Yumal Carrier Corporation Tel 1 706 357 7223 Col Chapultepec Morales Truck Trailer Products Group Fax 1 706 355 5435 11570 Mexico D F P O Box 4805 Tel 5255 9126 0300 Syracuse N Y 13221 U S A Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX TRANSICOLD 2008 Carrier Corporation D Printed in U S A 0508 WWW Carrier transicold com
8. 3 Speed Control P late 7 Speed Control P late Mounting Nut 4 Speed Control P late Mounting Bolt 62 11362 2 8 2 2 4 Injection Pump and Gear Case Continued m 2 2 4 c Fan Drive Pulley 1 Lock the flywheel using the flywheel stopper 2 Remove the fan drive pulley mounting nut 1 using the 46 mm deep socket wrench 3 3 Remove the fan drive pulley 2 with a gear puller 4 4 Remove the feather key When Reassembling Apply grease to the splines of the coupling 138 to 156 Nim Ken i n Se H q 102 to 115 ft lbs JEEAFAB1P0344 1 Nut 3 46 mm Deep Socket wrench 2 2 4 r 2 Fan Drive Pulley 4 Gear Puller d Gear Case 1 Remove the gear case 1 2 Remove the O rings 3 4 When Reassembling Replace the gear case gasket and O rings 3 4 Apply gasket sealant to both sides of the gear case gasket 2 Check insure thatthe four O rings 3 4 are in place on the gear case 1 1 Gear Case 4 O ring g A ilb Apply a thin film of oil to the crankshaftoil seallip 5 and O ring take care notto roll the lip when installing the gear case 2 9 62 11362 1 Crankshaft Collar 2 O ring 1 Injection Pump Gear 2 Idle Gear 3 Cam Gear 1 Camshaft Set Screw 1 Oil Pipe 2 Fuel Feed Pump 62 11362 3 Crankshaft Oil Slinger 4 Crank Gear 5 Oil Pump Drive Gear 2 Camshaft 3 O ring 4 Fuel Feed Pump Holder 2 2 4 e Crankshaft Oil Slinger 1 Remove the cran
9. 3 using a special use puller set Set the sleeve guide 2 to the crankshaft 5 Set the stopper 1 to the crankshaft 5 as shown in the figure Heat the new sleeve to a temperature between 150 to 200 C 302 to 392 F and fix the sleeve on the crank Shaft 5 as shown in the figure Press fit the sleeve using the auxiliary socket for pushing 4 NOTE Install the sleeve with the largest chamfered Surface facing outward 2 3 5 Cylinder 2 3 5 a Cylinder Wear 1 Measure the I D of the cylinder at the six positions see figure with a cylinder gauge to find the maximum and minimum I D s 2 Determine the difference maximum wear between the maximum and minimum I D s 3 If the wear exceeds the allowable limit bore and hone to the oversize dimension refer to Correcting Cylinder 4 Visually check the cylinder wall for scratches If deep scratches are found the cylinder walls should be bored refer to Correcting Cylinder Cylinder 1 D Factory 83 000 to 83 022 mm d o Specification 3 2678 to 3 2685 in N Allowable 83 170 mm er UNE Limit 3 2744 in 3EEABAB1P155A a Top a Right angled to b Middle Piston P in c Bottom skirt b Piston Pin Direction 2 3 5 b Correcting Cylinder Oversize 0 25 mm c ee a m r 1 When the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension Cylinder LD Factory 83 250 to 83 272 mm B Specifica
10. 38 in 22 5lbs 1 38 in Tilt 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm Clearance 0 016 to 0 045 mm 1 0 mm 0 00063 to 0 0017 in 0 039 in Rocker S haft D 13 973 to 13 984 mm 0 55012 to 0 55055 in Rocker Arm D 14 000 to 14 018 mm 0 55119 to 0 55188 in Push Rod Alignment 0 25mm 0 0098 in Tappet to Tappet Guide Clearance 0 020 to 0 062 mm 0 07 mm 0 00079 to 0 0024 in 0 003 in 23 959 to 23 980 mm 0 94327 to 0 94409 in 24 000 to 24 021 mm 0 94489 to 0 94570 in Timing Gear Crank Gear to Idle Gear Backlash 0 0415 to 0 1122 mm 0 15 mm 0 001634 to 0 004417 in 0 0059 in Idle Gear to Cam Gear Backlash 0 0415 to 0 1154 mm 0 15 mm 0 00163 to 0 004543 in 0 0059 in Idle Gear to Injection Pump Gear Backlash 0 0415 to 0 1154 mm 0 15 mm 0 001634 to 0 004543 in 0 0059 in Crank Gear to Oil Pump Gear Backlash 0 0415 to 0 1090 mm 0 15 mm 0 001634 to 0 004291 in 0 0059 in Idle Gear Side Clearance 0 12 to 0 48 mm 0 9mm 0 0048 to 0 018 in 0 04 in Idle Gear Shaft to Idle Gear Bushing Clearance 0 025 to 0 066 mm 0 1mm 0 00099 to 0 0025 in 0 0039 in Idle Gear Shaft D 37 959 to 37 975 mm 1 4945 to 1 4950 in Idle Gear Bushing D 38 000 to 38 025 mm 1 4961 to 1 4970 in 62 11632 1 8 1 7 1 Engine Body Continued Wem Factory Specification Allowable Limit Camshaft Side Clearance 0 07 to 0 22 mm 0 3 mm 0 0028 to 0 0086 in 0 012 In Camshaft Alignment 0 01 mm 0 0004 in Cam Lobe
11. Thermostat Cover Gasket 4 Thermostat Assembly 5 Thermostat Housing 1 Remove the thermostat cover mounting bolts 1 and remove the thermostat cover 2 2 Remove the thermostat assembly 4 When Reassembling Apply a liquid gasketonly atthe thermostat cover side of the thermostat cover gasket 3 4 3 Water Pump Assembly 4 2 2 1 Water Pump Flange 4 Water Pump Gasket 2 Water Pump Shaft 5 Mechanical Seal 3 Water Pump Body 6 Impeller 1 Remove the fan belt Remove the water pump pulley Remove the water pump from the gear case assem bly 4 Remove the water pump flange 1 5 Press out the water pump shaft 2 with the impeller 6 on it 6 Remove the impeller from the water pump shaft 7 Remove the mechanical seal When Reassembling Replace the mechanical seal with a new one Apply a liquid gasket to both sides of the gasket 4 62 11362 SECTION 5 FUEL SYSTEM 5 1 CHECKING AND ADJ USTING 5 1 1 Injection Timing 1 Remove the fuel speed solenoid 2 Remove the injection pipes and nozzle 3 Move the speed control lever to the maximum speed position NOTE Turn the flywheel with a screwdriver 4 Turn the flywheel counterclockwise facing the fly wheel until the fuel fills up the hole of the delivery valve holder for 1 cylinder 5 Turn the flywheel further and stop turning when the fuel begins to flow over 6 Open the view port on the flywheel bell housing and r
12. applied A newly serviced or reassembled engine should be run in with no load for 15 minutes Serious damage to the engine may result otherwise 1 3 62 11362 15 TORQUE SPECIFICATIONS Screws bolts and nuts must be tightened to the specified torque using a torque wrench Several screws bolts and nuts such as those used on the cylinder head must be tightened in the proper sequence and at the proper torque 1 5 1 Torque Specifications For Special Use Screws Bolts and Nuts In removing and applying the screws bolts and nuts marked with a pneumatic wrench or similar tool if employed must be used with care Failure to do so may result in stripped or seized screws bolts and nuts When replacing marked screws bolt and nuts apply engine oil to their threads and seats before reassembly The letter M in size and pitch means that the screw bolt or nut dimension is metric The size is the nominal outside diameter in mm of the threads The pitch is the nominal distance in mm between two threads em SWexPih Nm ts EE 1 5 2 Torque Specifications For General Use Screws Bolts and Nuts Standard Screw and Bolt Special Screw and Bolt Grade 4 Grade 7 Nm kom fis Nm km fis Screw and bolt material grades are shown by numbers punched on the screw and bolt heads Prior to tightening be sure to check out the numbers as shown below Punched Number S crew And Bolt Material Grade Standard Screw And
13. b od veo ee hee hs eh a eii as 1 13 Lo GHECKING ENGINE Ol EeyVela sss dada 1 13 18 2 Gheckilg CoblalitiLe Vel arras 1 13 1 9 3 GhEEKING Fuel HOS at te aa acide cac a e e Cane Eee as es acie ab GC EP 1 13 1 94 Bleeding UGS VS Le TA ide xd cs acia av arin o eE Ue AO enc des ai p at acte not ado cobs x 1 14 1 9 5 sGNeCKING V SB6elt 135995 x 0 pe aad d pom o9 Ha dI Hel aom ond d d ala ba Se ag donar x 1 14 1 06 Enangiid ENGINE OT su iia aote Eta EP ida a Pet QA hc Seb acte Bey Ses 1 14 19 7 VaVe Clearance sudaud ub dico ba Eds Job w pw ase Ea udo AA AS 1 15 120 9 VEH HOP yd ae ee ee a ee pudet ee eee ed iol alin Au 1 15 L9 SPECIAL TOOLS aactor de IS Vased Oro dc IA AA een ee ae OS 1 16 1 9 1 Diesel Engine Compression Tester Glow Plug cece cece n I e 1 16 19 2 Adapter Injector To Tester HOS savia alba mirc ceo e e eeu evens a 1 16 1 9 3 Tester Inje amp ctor NOZZE oxi ioa e ir ROG T SCR eC e Re de e ER aaa eds 1 16 1 9 4 Replacement Bowl Tester lniechorhNozzle n nee o 1 16 19 5 Adapter Injector LING usa esca A A A Ge do oe e 1 16 1 9 6 Oil Pressure Tester odas aca aoe ates wal aad aah ate oo rta d a bel SER a pr lod p ratu ac bel ee 1 17 1 9 7 Auxiliary Socket For Fixing Crankshaft Sleeve oo cette II 1 17 1 9 9 Gatge Belt TENSION 3 suce ac pono Re ana ond aUe ia NAA EA aS dA NAO acide a 1 17 1 9 9 Tester Belt TEEN mirar 1 17 L9 TO RUDDeH BANG aac odo qc moe aa HER UP SO A erin Lane Ga etur een Ue o c
14. from the crankcase When Reassembling Visually check the contact between the tappets 1 and individual cam lobes Coat the tappets with engine oil before installing them NOTE When re installing tappets into the engine make sure that they are re installed in their ori ginal location 2 2 3 9 Valves 1 Remove the valve caps 3 2 Remove the valve spring collet 4 pushing the valve spring retainer 5 by the valve spring compressor 1 3 Remove the valve spring retainer 5 valve spring 6 and valve stem seal 2 4 Remove the valve 7 When Reassembling Clean the valve stem and the valve guide Apply engine oil to the valve stem when reassembling After installing the valve spring collets 4 lightly tap the stem with a plastic hammer to assure the collets have m pe o e Oe ted on the valve st 6 idee seated on me valve stem 4 5 JEEAFAB1P0194 NOTE When re installing valves into the engine make sure that they are re installed in their original location 2 5 62 11362 2 2 4 Injection Pump and Gear Case Eis 2 2 4 a Injection Pump 1 Remove the fuel speed solenoid 2 and hi idling body 3 2 Remove the engine stop lever 5 and stop solenoid guide 6 3 Remove the fuel injection pump assembly 7 NOTE Remove the injection pump assembly 7 after removing the fuel speed solenoid 2 and hi id ling body 3 engine stop lever 5 and stop solenoid guide 6
15. in radius radius 1 0 to 1 5 mm radius 1 0 to 1 5 mm radius Dimension B 0 040 to 0 059 in 0 040 to 0 059 in radius radius 59 72 to 59 740 59 52 to 59 540 Dimension C mm mm 2 3513 to 2 3519 in 2 3434 to 2 3440 in The crankshaft journal must be fine finished to higher than 0 4 S Holes to be de burred and edges rounded with 1 0 to 1 5 mm 0 040 0 059 in relief STMABAB1P079A 2 3 4 e Replacing Crankshaft Bearing 1 A When Removing 1 Press outthe crankshaft bearing 1 2 using a crank Shaft bearing 1 replacing tool B When Installing 1 Clean a new crankshaftbearing 1 2 and crankshaft journal bore and apply engine oil to both 2 Using the crankshaft bearing 1 replacing tool press 3TMABAB1P080A in the new bearing 1 2 so that Its seam 1 directs toward the exhaust manifold side 1 Seam 3 Cylinder Block 2 Crankshaft Bearing 1 A Dimension NOTE Be sure to align the bushing so that the oil hole in the bushing aligns with the oil port in the con necting rod 62 11362 2 30 2 3 4 Crankshaft Continued 2 3 4 f Crankshaft J ournal to Crankshaft Bearing 2 Clearance 1 Puta strip of plastigage on the center of the crank Shaft journal 2 Install the bearing case and tighten the bolts to spe cification Remove the bearing case again 4 Measure the amount of the flattening with the scale to get the clearance 5 If the measurement exceeds the allowable limit re
16. is different When reassembling reinstall the appropriate bolt in the correct location When Reassembling Fit the bearing case gasket 5 and the bearing case cover gasket 6 to the bearing case cover 3 Orient them correctly Install the bearing case cover 3 again orienting it correctly using the UP mark a Apply oil to the oil seal 4 and take care not to roll the seal when installed Tighten the bearing case cover bolts diagonally and evenly Tantei Bearing Case 24 to 27 Nem e SS Cover Mounting 2 4 to 2 8 kgf m bolt 18 to 20 ft lbs 62 11362 2 2 7 Cranks 62 11362 haft Continued 2 2 7 c Crankshaft Assembly Removal NOTE Before disassembling check the side clearance of the crankshaft Check it during reassembly 1 Remove the three main bearing case bolts 1 2 Pulloutthe crankshaftassembly 2 being careful not to damage the crankcase bearings 3 3 While pulling the crankshaft assembly 2 out use care to align each of the crank pins 5 leftor right to clear the crankcase relief a When Reassembling When installing the main bearing case assembly align the bolt holes of the crankshaft assembly 2 with the holes of the crankcase SE oil to the threads of the main bearing case bolts 1 before re insertion Tightening Main Bearing EM Torque Case Bolt pou KH i 51 to 54 ft lbs 1 Main Bearing Case Screw 2 5 Cylinder 4 Crank Pin 2 Main Bearing
17. oll pressure l Guage 5 Threaded J oint 2 Adapter 2 6 Adapter 4 3 Cable 7 Adaptor 1 4 Adapter 3 8 Adaptor 3 1 9 7 Auxiliary Socket For Fixing Crankshaft Sleeve Code No 07916 32091 Application Use to fix the crankshaft sleeve of the diesel engine 3TMABABOP062A 1 9 8 Gauge Belt Tension Part No 07 00203 00 Application Used to adjust belt tension of all cogged V belts 1 9 9 Tester Belt Tension Part No 07 00253 00 Application Used to test belt tension 1 9 10 Rubber Band Part No 07 00253 01 Application Replacement part for belt tension tester Part No 07 00253 00 1 9 11 Main Bearing Install Tool Part No 07 00472 00 Application Used on engines starting with S N 350001 1 9 12 Main Bearing Extract Tool Part No 07 00473 00 Application Used on A starting with S N 350001 l 17 62 11362 1 9 SPECIAL TOOLS Continued The following are drawings for special tools that may need to be fabricated 1 9 13 Valve Guide Replacing Tool Application K to press out and press fit the valve guide 20 mm dia 0 79 in dia MEN 11 7 to 11 9 mm dia 0 460 to 0 468 in dia 6 5 to 6 6 mm dia 0 256 to 0 259 in dia 225 mm 8 86 in 70 mm 2 76 in F 45 mm 1 77 in E 3TMABABOPO63A H 5 mm 0 197 in 6 7 to 7 0 mm dia 0 263 to 0 275 in dia 20 mm dia 0 787 in dia 12 5 to 12 8 mm dia 0 492 to 0 504 in dia L 8 9 to 9 1 mm 0 350 to 0 358 in Cl Chamfer 1 0
18. on top of the piston JEEADAB1P043B 1 Carbon 7 Piston Ring Compressor 2 Connecting Rod Bolt A Top Ring Gap 3 Connecting Rod Cap B Second Ring Gap 4 Connecting Rod C Oil Ring Gap 5 Molybdenum Disulfide D Piston Pin Hole Coating on Piston Skirt 6 Piston ID Mark a 2 09 rad 120 Tightening Connecting sagen Torque Rod Bolt EE 33 to 36 ft lbs 2 13 62 11362 2 2 6 Piston and Connecting Rod Continued 2 2 6 b Piston Ring and Connecting Rod 1 Remove the piston rings 1 2 3 2 Remove the piston pin 8 and then seperate the con necting rod 6 from the piston 5 NOTE Mark both the connecting rod and piston so that if they are to be re used that the original com bination of parts will go back together Do notin terchange used parts When Reassembling When installing the rings assemble so that the manufacturer s mark 12 near the gap faces the top of the piston 5 When installing the oil control ring 3 onto the piston 5 place the expander joint 10 on the opposite side of the oil ring gap 11 Apply engine oil to the piston pin 8 When assembling the connecting rod 6 to the piston 5 immerse the piston 5 in hotoil 80 C 176 F for 10 to 15 minutes then assemble the piston piston pin and connecting rod JEEADAB1POGOA NOTE Assemble the piston 5 on to the connecting rod 6 with the FW mark 9 facing the flywheel end and the connecting rod mark
19. the fan belt tension When reinstalling the fan make sure that it is put on correctly 2 2 3 Cylinder Head And Valves 2 2 3 a Valve Cover 1 Remove the breather hose 2 2 Remove the valve cover bolts 1 3 Remove the valve cover 3 When Reassembling Check to see that the valve cover gasket 4 is in good condition and in place 6 87 to 11 2 N m 0 7 to 1 15 kgfm 5 07 to 8 31 ft lbs Tightening Valve Cover Torque Bolts 1 Valve Cover Bolt 4 Valve Cover Gasket 2 Breather Hose 5 Breather Valve 3 Valve Cover 6 Plate STMABAB1PO25E 2 2 3 b Injection Pipes 1 Loosen the bolts on the pipe clamps 1 2 Detach the injection pipes 2 When Reassembling Blow out any debris that may be in the pipes Injection Pipe 15 to 24 N m Retaining 1 5 to 2 5 kgfm Nut 11 to 18 ft lbs Tightening Torque 2 3 62 11362 2 2 3 Cylinder Head And Valves Continued 2 2 3 c Nozzle Holder Assembly 1 Remove the overflow pipe assembly o ES E Y 2 Remove the nozzle holder assemblies 1 Ay DI X A i SE Zu Ac Um Y As TOU Replace the copper gasket with a new one Nozzle Holder POS 2 6 to 3 0 kgf m Assembly Tightening 19 to 21 ft lbs When Reassembling Si d A Oi e m 3EEAFAB1P01 A e o Torque Overflow Pipe 9 81 to 11 2 Nm Assembly 1 00 to 1 15 kgfm Retaining Bolt 7 24 to 8 31 ft lbs 2 2 3 d Rocker Arm and Push Rod 1 Remove the rocker arm bracket mounting bolts
20. 0 do pq A ida Soc apo dae Vel Ra pcd 5 1 91 3 E un e Pressure LOST oue rrt toba Ee xx iEn AA 5 2 5 1 4 Delivery Valve Fuel Seal sss mmm 5 2 32 INIEGHONINNOZZLE EE 5 3 2 21 NOZZE eS SUG uuo ar atur newer xo aol aie dada 5 3 5 2 2 NOZZ18S praying CONGION 4 e s wie E Rope ainda eC p 8 He nd ee etd ten opea ien a 5 3 dida Vave S egt TONES S veas icesdorddu dvor o AAA AAA Rb red bx 5 3 ELECTRICAL SYSTEM 5 oco ee aa 6 1 MEE SE d Rz E cel PIC EE leede 6 1 OIL MOWO IOS ss cently cee fare doen P PEERS Re dams edt d addon eau qeu cdot dahin 6 1 6 1 2 iMagneucSWICI TES said acia aut aac bett p puc od rd a scu purus rand auc odia d 6 1 62 FUEL SPEED SOLENOID yd toO detenta CIPUE de DTE ache CDU dd v cnp Eas 6 2 OZ ih SOMO MOS obser bro b eto beret iure ea dread abt tug at Reti ane ue 6 2 563 JINTAKE AIR HEATER es iex starts SE iu hd Sener dnt Je Od d aa UR ac a Ear e Sine ou n 6 3 6 3 1 Intake AIL Heater TOS cad amid adhi eb ERR 6 3 i 62 11362 SAFETY SAFETY PRECAUTIONS Your Carrier Transicold unit has been designed with the Safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Please stay clear of all moving parts when the unit is in operation and when the unit main power Switch is inthe START RUN position Engine Coolant Th
21. 15 to 8 030 mm Intake amp Exhaust Specification 0 3156 to 0 3161 in SEEABAB1P117A A When Removing B When Installing 2 3 1 f Valve Seating 1 Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact pattern 2 Ifthe valve does notseat all the way around the valve seat orthe contactis less than 70 correct the valve seating as outlined in paragraph 2 3 1 g 3 If the valve contact does not comply with the refer ence value replace the valve or correctthe contact of valve seating 3TMABAB1P060A l Correct 3 Incorrect 2 Incorrect 62 11362 2 20 2 3 1 Cylinder Head And Valves Continued 2 3 1 g Correcting Valve and Valve Seat NOTE Before correcting the valve seat make certain that the valve and valve guide are within factory Specifications After correcting the valve seat be sure to check the valve recessing A Correcting the Valve 1 Correct the valve with a valve grinder Factory PIN 0 79 rad 45 Valve Face Angle ant Specification 0 79 rad 45 B Correcting the Valve Seat 1 Slightly correct the valve seat surface with a 1 0 rad 60 intake valve or 0 79 rad 45 exhaust valve seat cutter 2 Resurface the seat surface with a 0 52 rad 30 valve seat cutter to the Intake valve seat and with a 0 26 rad 15 valve seat cutter to the exhaust valve seat so that the width is close to the specified valve seat width 2 12 mm 0 08
22. 2 Oil Clearance 0 040 to 0 104 mm 0 2mm 0 00158 to 0 00409 in 0 0079 in Crankshaft J ournal D 59 921 to 59 940 mm 2 3591 to 2 3598 in Crankshaft Bearing2 D 59 980 to 60 025 mm 2 3615 to 2 3631 in Crankpin to Crankpin Bearing Oil Clearance 0 025 to 0 087 mm 0 2 mm 0 00099 to 0 0034 in 0 0079 in Crankpin D 46 959 to 46 975 mm 1 8488 to 1 8494 in Crankpin Bearing D 47 000 to 47 046 mm 1 8504 to 1 8522 in Crankshaft Side Clearance 0 15 to 0 31 mm 0 5mm 0 0059 to 0 012 in 0 02 in Crankshaft Sleeve Wear 0 1mm 0 0059 in Cylinder Bore Standard 83 00 to 83 022mm 83 170 mm 3 2678 to 3 2685 in 3 2744 in Oversize 83 250 to 83 272 mm 83 420 mm 3 2776 to 3 2784 in 3 2843 in 62 11632 1 7 2 Lubricating System Mem Factory Specification Allowable Limit Engine Oil Pressure At Idle S peed More Than 98 kPa 50 kPa 1 0 kgf cm 0 5 kgf cm 14 psi 7 psi At Rated S peed 300 to 440 kPa 250 kPa 3 0 to 4 5kgf cm 2 5 kgf cm 43 to 64 psi 36 psi Engine Oil Pressure S witch Working 50 kPa Pressure 0 5kgf cm 7 psi Inner Rotor to AAA Rotor Clearance 0 03 to 0 14 mm 0 2 mm 0 0012 to 0 0055 in 0 008 in Outer Rotor to Pump ma Clearance 0 11 to 0 19 mm 0 25 mm 0 0044 to 0 0074 in 0 0098 in Inner Rotor to Cover Clearance 0 105 to 0 150 mm 0 2 mm 0 00414 to 0 00590 in 0 008 in 1 7 3 Cooling System Factory Specification Allowable Limit ea V Belt Tension 7 0 to 9 0 mm 0 28 to 0 35 in d
23. 35 in 3 After resurfacing the seat apply a thin film of valve lapping compound between the valve and the seat then use a valve lapping tool to seat the valve to the valve seat 4 Checkthe valve seating with prussian blue The valve seating should show good contactallthe way around a 0 26 rad 15 o A Check Contact Scion IN 0 79rad 45 0 52 rad 30 B Correct Seat Width Valve Face Angle Geesen b 0 79 rad 45 o C Check Contact 1 0 rad 60 1 Valve Seat Width c 0 52 rad 30 o 2 Identical Dimensions 0 26 rad 15 2 3 1 h Valve Lapping 1 Apply compound evenly to the valve lapping surface 2 Insert the valve into the valve guide Lap the valve onto its seat with a valve lapper or bolt driver 3 After lapping the valve wash the compound away and apply oil then repeat valve lapping with oil 4 Apply prussian blue to the contact surface to check the contact pattern if itis less than 7096 repeat valve lapping again NOTE When valve lapping is performed be sure to check the valve recessing and adjust the valve clearance after assembling the valve OL 3TMABAB1PO061A 2 21 62 11362 2 3 1 Cylinder Head And Valves Continued 3EEABAB1P121A 3EEABAB 1P123A STMABAB1P062A 62 11362 2 22 2 3 1 1 Free Length and Tilt of Valve Spring 1 Measure the free length A of the valve spring with ver nier calipers If the measurement is less than the al lowable limit repla
24. 5 mm radius 1 0 to 1 5 mm radius Dimension B 0 040 to 0 059 in 0 040 to 0 059 in radius radius 46 759 to 46 775 46 559 to 46 575 mm mm 1 8409 to 1 8415 in 1 8331 to 1 8336 in radius radius IN l 3TMABAB1 PO75A 3TMABAB1PO074B Dimension C The crankshaft journal must be fine finished to higher than 0 8 S Holes to be de burred and edges rounded with 1 0 to 1 5 mm 0 040 to 0 059 in relief 2 29 62 11362 2 3 4 Crankshaft Continued 2 3 4 0 Crankshaft J ournal to Crankshaft Bearing 1 Clearance 1 Measure the O D of the crankshaft journal with an outside micrometer 2 Measure the I D of crankshaft bearing 1 with an in side micrometer and calculate clearance 3 If the clearance exceeds the allowable limit replace crankshaft bearing 1 4 If the allowable limit is not attainable with a standard size bearing install an undersize bearing by referring to the table below Crankshaft Factory 0 040 to 0 118 mm J ournal to 1 Specification 0 00158 to 0 00464 in Bearing Allowable 0 2 mm Clearance Limit 0 0079 in Crankshaft Factory 59 921 to 59 940 mm Journal O D Specification 2 3591 to 2 3598 in EICH Factory 59 980 to 60 039 mm di UNE Specification 2 3615 to 2 3637 in Reference Undersize dimensions of crankshaft 3TMABAB1P078A journal 0 2mm 0 0008 in 0 4mm 0 0016 in 2 8 to 3 2 mm radius 2 8 to 3 2 mm radius Dimension A 0 11 to 0 12 in 0 11 to 0 12
25. 7 facing the injection pump side 1 Top Ring 7 Mark 2 Second Ring 8 Piston Pin 3 Oil Control Ring 9 FW Mark 4 Piston Pin Snap Ring 10 Expander J oint 5 Piston 1l Oil Ring Gap 6 Connecting Rod 12 Manufacturer s Mark 62 11362 2 14 2 2 7 Crankshaft 3EEAFAB1PO052A 1 Flywheel 2 Flywheel Bolt l Bearing Case Cover Mounting B olt 2 Bearing Case Cover Mounting bolt 3 Bearing Case Cover 4 OilSeal 5 Bearing Case Gasket 6 Bearing Case Cover Gasket a Top 2 2 7 a Flywheel 1 Prevent the flywheel 1 from rotating 2 Remove two flywheel bolts 2 NOTE The use of air tools to remove the flywheel bolts may damage the threads in the crankshaft 3 Install two flywheel guide bolts 3 4 Remove all of the flywheel bolts 2 5 Remove the flywheel 1 slowly along the flywheel guide bolts 3 When Reassembling Install two flywheel guide bolts 3 Check to see that the mating surfaces of the crankshaft and flywheel are clean Apply engine oil to the flywheel bolts and install mum 98 0 to 107 8 Nm n Flywheel Bolts 10 0 to 11 0 kgfm 4 72 3 to 79 5 ft lbs 2 2 7 6 Bearing Case Cover 1 Remove the bearing case cover mounting bolts F irst remove the inside bolts 2 and then the outside bolts 1 2 Screw two of the removed bolts into the bolt hole of the bearing case cover 3 to remove it NOTE The length of the inside 2 and the outside 1 bolts
26. Apply pressure and observe the time forthe pressure to fall 3 If the measurementis less than the factory specifica tion replace the cap More than 10 seconds for pressure fall from 88 to to 59kPa 0 9 to 0 6 kgf cm 13 to 9 psi Pressure Falling Factory Time Specification 62 11362 4 1 5 Radiator JIAAAABTPOGTA 1 Fill the radiator with water 2 Attach the pressure tester to the radiator 3 Apply pressure and look for leaks 4 Repair replace as necessary to assure that the speci fied pressure will hold 157 kPa 1 6 kgf cm 23 psi Radiator Leakage Factory Test Specification 4 1 6 Thermostat Opening Temperature 1 Suspend the thermostat in water by a string with one end of the string inserted between the valve and its seat 2 Immerse the thermostat in water and raise the tem perature of the water gradually 3 With a thermometer read the temperature of the water when the valve opens and leaves the string 4 Continue heating the water read the temperature of the water when the valve has opened approximately 6mm 0 236 in 5 Ifthe measurementis not within the factory specifica tions replace the thermostat Thermostat Opening Temperature 80 5 to 83 5 5 C 176 9 to 182 3 F Factory Specification Thermostat Full Open Temperature Factory Specification 4 2 SERVICING 4 2 1 Thermostat Assembly n 3EFAFABIBO20A 1 Thermostat Cover Bolt 2 Thermostat Cover 3
27. Bolt S41 S20C Special Screw And Bolt S43C S48C Refined 62 11632 1 4 16 TROUBLESHOOTING Symptom Probable Cause Solution Reference Engine Does Not Start Starter Does Not Run Engine Revolution Is Not Smooth Either White or Blue Exhaust Gas Is Observed Either Black or Dark Exhaust Gas Is Observed Deficient Output No fuel Air in the fuel system Water in the fuel system Fuel pipe clogged Fuel filter clogged Excessively high viscosity fo fuel or engine oll at low temperature Fuel with low cetane number Incorrect injection timing Injection nozzle clogged Injection pump malfunctioning Seizure of crankshaft camshaft piston cylinder or bearing Compression leak from cylinder Improper valve timing Piston ring and cylinder worn Excessive valve clearance Battery discharged Starter malfunctioning Key switch malfunctioning Wiring disconnected F uel filter clogged or dirty Air cleaner clogged or dirty Fuel leak due to loose injection pipe retaining nut Injection pump malfunctioning Incorrect nozzle injection pressure Injection nozzle stuck or clogged Excessive engine oll Piston ring and liner worn or ring stuck Incorrect Injection timing Deficient compression Overload Low grade fuel used Fuel filter clogged Air cleaner clogged Deficient nozzle injection Incorrect injection timing Engine s moving parts seem to be seizing Injection pump malfunctioning Deficient nozzl
28. Case 2 a Main Bearing Case Relief 3 Crankshaft Bearing 1 4 Crankshaft Assembly 2 2 7 Crankshaft Continued pa 2 2 7 d Main Bearing Case Assembly 1 Remove the two main bearing case bolts 7 and re move the main bearing case assembly being careful with the thrust bearing and crankshaft bearing 2 Remove the remaining main bearing cases as above When Reassembling Clean the oil passages in the main bearing case Apply clean engine oil to the bearings Install the main bearing case assemblies in their original locations The diameters of the main bearing cases vary Install them in order from the gear case end according to their markings A B C Match the alignment numbers 1 and mark 2 on the main bearing case When installing the main bearing case face the mark FLY WHEEL to the flywheel Install the thrust bearing with its oil groove facing 8 outward Confirm that main bearing case moves smoothly after torquing the main bearing case bolt to specification Tightening Main Bearing Ee Torque Case bolt He STU E 34 to 37 ft lbs l Alignment Number 5 B 2 Alignment Mark 6 A 3 No Mark 7 Main bearing Case Bolt 4 C 8 Oil Groove STLABAB1P035 2 17 62 11362 2 3 SERVICING 2 3 1 Cylinder Head And Valves 3TMABAB1P056A JEEABAB1P112B 3IMABABOPOSSB 1 Red Dye 2 Detergent 62 11362 3 White Developer 2 3 1 a Cylinder Head Surface Flatness 1 Clean the cylinder h
29. Height Intake 33 27 mm 33 22 mm 1 310 in 1 308 in Height Exhaust 33 47 mm 33 42 1 318 in 1 316 in Camshaft ournal to Cylinder Block Bore Clearance 0 050 to 0 091 mm 0 15 mm 0 0020 to 0 0035 in 0 00059 in Camshaft J ournal D 39 934 to 39 950 mm 1 5722 to 1 5728 in Cylinder Block Bore D 40 000 to 40 025 mm 1 5748 to 1 5757 Piston Pin Bore 25 000 to 25 013 mm 25 05 mm 0 98425 to 0 98476 in 0 9862 in Second Ring to Ring Groove Clearance 0 093 to 0 128 mm 0 2mm 0 00367 to 0 00503 in 0 0079 in Oil Ring to Ring Groove Clearance 0 020 to 0 060 mm 0 15 mm 0 00079 to 0 0023 in 0 0059 in Top Ring Ring Gap 0 20 to 0 35 mm 1 25 mm 0 0079 to 0 013 in 0 0492 in Second Ring Ring Gap 0 40 to 0 55 mm 1 25 mm 0 016 to 0 021 in 0 0492 in Oil Rng Ring Gap 0 25 to 0 45 mm 1 25 mm 0 0099 to 0 017 in 0 0492 in Connecting Rod Alignment 0 05 mm 0 002 in Piston Pin to Small End Bushing Clearance 0 014 to 0 036 mm 0 15 mm 0 00056 to 0 0014 in 0 0059 in Piston Pin D 25 004 to 25 011 mm 0 98441 to 0 98468 in Small End Bushing D 25 025 to 25 040 mm 0 98524 to 0 98582 in Crankshaft 0 040 to 0 118 mm 0 2mm 0 00158 to 0 00464 in 0 0079 in Crankshaft J ournal D 59 921 to 59 940 mm 2 3591 to 2 3598 in Crankshaft Bearing D 59 980 to 60 039 mm 2 3615 to 2 3637 in 1 9 62 11362 1 7 1 Engine Body Continued Factory Specification Allowable Limit Crankshaft J ournal to Crankshaft Bearing
30. NG ROG ud teu Dea on A ea EE 2 26 ACE MM A E ES ASI A A t ILU 2 28 2 3 5 CVINGC ee ee taa a 2 33 EUBRICATING SYSTEM curar Ada 3 1 S1 CHEGKINGAND ADUSTING 5 0413 is A AS 3 1 Seck che AA A PA oid n ee eee i ae a eee ee 3 1 22 OERANG russe cette ae tv ey acts tna aoc evi Bids qu ves BS ards shee sie dada 3 2 32 1 ROWMLODe Cledral eG ere bes ined lt A 3 2 3 2 2 Rotor tO Cover Clearance serrat trate dae ara 3 2 COOLING SYSTEM 5353 5 debis acil ER rain Scri ee ae C RC RR E 4 1 2d CHECKING AND AD US TING crm suet Eb Ee ve cte CL e T vb ae Ob deas 4 1 4 1 1 Notched V Belt Service ccc ccc n mmm mmm mmm mr 4 1 4 lla Pol VBE SOVICE esse aa isa tn e pace t ale du See bach 4 1 4 12 Fa BetDamage and Weal Ee EE A aea tip apa Qo ox aea a Ep at ROC ous aea hd 4 1 4 1 3 Checking Coolant Level s rro pvo p a dodi Miele Pax TE Y e a vais 4 1 4 L4 Radiator Cap aa ssde aM dated da ete eres rv e p he ve Pe Tas 4 2 e Eo Mame tee 4 2 4 1 06 Thermostat Opening Temperature 4 2 Ale SERVICING ivan tia Ra 4 3 424b ThernnostatAssembly uisa sona dis eto wed Ra Ore ex f cta t vr CR Powe ters pas 4 3 4 2 2 WaterPump Assembly ccc ccc eee eee ee eee E A nan arr raa 4 3 62 11362 ji PARAGRAPH NUMBER Page FUELSYSIEM sieges enced ee cee rs EE 5 1 oli CHECKING ANDAADIUSTING 35 rac itii wp P Re ad 5 1 Dol LMSC EON dll ira ds red dac ttem peut edis me Framed acea idera ud ana ene ec d 5 1 5 2 ST ele t leg elen 533
31. When Reassembling Install the fuel speed solenoid 2 the hi idling body 3 and the stop solenoid guide 6 after Installing the injection pump 7 Replace the hi idling body gasket 4 with a new one Install the fuel speed solenoid guide 6 and then the stop lever 5 into the gear case Cycle the stop lever to insure that it functions NOTE When installing the fuel speed solenoid 2 use care to keep the O ring 1 in place Be sure to insert the push rod of the stop solenoid into the hole at the center of the solenoid guide 6 mm 45 0 to 49 0 N m Ed Ke Hi idling Body 4 5 to 5 0 kgfm 33 to 36 ft lbs l O ring 5 Stop Lever 2 Fuel Speed Solenoid 6 Stop Solenoid Guide 3 Hi Idling Body 7 Injection Pump Assembly 4 Hi Idling Body Gasket 62 11362 2 6 2 2 4 Injection Pump and Gear Case Continued 2 1 2 2 4 b Governor Springs and Speed Control Plate NOTE Specific Tool 1 A 1 2mm 050 inch diameter wire with a total length of 200mm 8 inch with the tip bent into a hook as depicted in the illustration is required to hang the governor springs 1 Remove the injection pump cover 2 Remove the speed control plate 7 mounting nuts 3 and bolts 4 3 Using the Specific Tool 1 undo the the large governor spring 5 from the fork lever 2 4 Setthe speed control lever 6 as shown in the figure 5 Remove the speed control plate 7 using care notto
32. an a n 1 17 1 9 11 Main Bearing Install TOO isses HH Hm Hm Hmmm mm 1 17 1 9 12 Main Bearing EXtract TOOL iud esa Sit eC tb E ele RES ctr e CR p ES 1 17 1 9 15 Valve GUIDE REDIGCING IO Ll nao d aur ar ee denen n XE RE aan 1 18 1 9 14 Bushing Replacing Tools sssseeee RR HH HH Hm 1 18 159515 PIVWHEEIS LOD DES used ai Set wie aod E es Ova phar tas Cx nn tei 1 18 1 9 16 Crankshaft Bearing 1 Replacing 100 m ER dC hw added 1 19 62 11362 PARAGRAPH NUMBER Page ENGINE BODY stssppessexue a EVER PE ici ia o Gre 2 1 2l CHECKING AND ADJUSTING coria 2 1 2 1 1 Compression Pressure s ri deac esta wd race ew aaa leds dada 2 1 2 1 2 A AAMC e aig bad ade qud ao Oba Q8 Ve nau SOR RO I RUES Ge qoa acd el Ed a Oe eae ea 2 1 22 DISASSEMBLY ANDIJREASSEMBLY etaed dx et er on bio Cet e ren Ces 2 2 2 2 1 Draining Coolant And Engine Ou 2 2 252 2 extemal C Ompollenits soa det wes ddp ic PIRE eder exea eee ees 2 2 2 23 Cynder Aedd ANd V AV OS ao en azica ae e aet aet on acie o e am ara ee par aci o o ocd ae de ah 2 3 2 2 4 Injection Pump and Gear Case ccc ehh rrr rs 2 6 2 2 9 Ol Panend OIEStUralliel esrb ere ARA Ad a ee eh ee aa 2 12 2 2 6 Piston and Connecting Rod ccc ccc ete hrs 2 13 PAY CNK MATES os as e DOCTR TILES 2 15 2 9 COBRA VICIO torito 2 18 2 3 1 Cylinder Head And Valves cc ccc IHR HH hu 2 18 2 3 2 Timing Gears Camshaft and Fuel Camshaft 0 ccc ccc RR 2 23 Za SP ISTORII C One CHI
33. an belt is worn and deeply sunk in the pulley groove replace it JEEABAB1PU18A A Good B Bad 4 1 3 Checking Coolant Level 44 WARNING When removing the radiator cap wait at least ten minutes after the engine has stopped and cooled down Otherwise hot water may discharge from the radiator scalding anyone nearby I Remove the radiator cap and check to see that the coolant level is just below the port With the recovery tank Check to see thatthe coolant level lies between FULL and LOW 62 11362 LOW 3EEABAB1P015D 2 Ifthe coolant level is too low check the reason forthe lost coolant a If coolant loss is due to evaporation add only clean soft water b If coolant loss is due to a leak repair the leak then add a coolant mixture of the same type and specifi cation that Is in the system If the coolant brand can not be identified drain out all of the remaining cool ant and refill with a totally new mix NOTE When adding coolant to the system air mustbe vented from the engine coolant passages by jig gling the upper and lower radiator hoses Be sure to close the radiator cap securely If the cap is loose or improperly closed coolant may leak out and the engine could overheat Do not use an antifreeze and scale inhibitor at the same time Never mix differenttypes or brands of coolants 4 1 4 Radiator Cap JIAAAABTPOGDA 1 Attach the radiator cap to a pressure tester 2
34. ance between lobes of the inner ro tor and the outer rotor with a feeler gauge 2 Measure the clearance between the outer rotor and the pump body with a feeler gauge 3 If the clearance exceeds the factory specifications replace the oil pump rotor assembly Factory 0 03 to 0 14 mm Inner O uter Specification 0 0012 to 0 0055 in Rotor Clearance Allowable 0 2mm Limit 0 008 in Factory 0 11 to 0 19 mm Outer R otor Specification 0 0044 to 0 0074 in Pump Body Allowable 0 25 mm Clearance M Limit 0 0098 in 3 2 2 Rotor to Cover Clearance 1 Put a strip of plastigage onto the rotor face with grease 2 Install the cover and tighten the bolts 3 Remove the cover carefully and read the plastigage 4 If the clearance exceeds the factory specifications replace the oil pump rotor assembly Factory 0 105 to 0 150 mm Rotor Cover Specification 0 00414 to 0 00590 in Clearance Allowable 0 20 mm Limit 0 008 in SECTION 4 COOLING SYSTEM 4 1 CHECKING AND ADJ USTING 44 WARNING Beware of moving V belt and belt driven components 4 1 1 Notched V Belt Service NOTE A frayed cracked or worn V belt must be re placed After installing a new belt itis advisable to check the adjustment after running the unit for three or four hours This will allow for the ini tial stretch which is common on new belts Once this initial stretch has taken place the belt Should be checked at regular intervals To replace or a
35. applied during operation and maintenance of the equipment covered herein 44 WARNING Beware of moving V belt and belt driven components 44 WARNING When removing the radiator cap wait at least ten minutes after the engine has stopped and cooled down Otherwise hot water may discharge from the radiator scalding anyone nearby 44 WARNING Check the injection nozzle only after confirming that nobody is near the spray If the spray from the nozzle contacts the human body cells may be destroyed and blood poisoning may result 44 WARNING Secure the starter to prevent it from moving when power is applied to it 44 CAUTION Do not remove the radiator cap until the coolant temperature is below its boiling point Loosen the cap slightly to relieve excess pressure before removing the cap completely 44 CAUTION Stop the engine when attempting to check and change the fuel line 44 CAUTION Stop the engine when preparing to change the engine oil 44 CAUTION Never remove the radiator cap until coolant temperature is below its boiling point Loosen the cap slightly to the first stop to relieve any excess pressure before removing the cap completely V 62 11362 SECTION 1 General 1 1 ENGINE IDENTIFICATION Serial Number V2203 Y A 4321 Lower 4 digits in numerals Digit Alpabetical Letter Month of SC When contacting Carrier Transicold always specify your engine model number and serial numbe
36. ar bushing I D with an inside mi crometer and calculate the the clearance 3 If the measurement exceeds the allowable limit re 3TMABAB1P069A place the bushing F actory 0 025 to 0 066 mm Idle Gear Shaft Specification 0 00099 to 0 00260 in Bushing Al b Clearance yia S a ea Limit 0 0039 in Idle Gear Shaft Factory 23 959 to 23 980 mm O D Specification 0 94327 to 0 94410 in Idle Gear Shaft Factory 24 000 to 24 021 mm I D S pecification 0 94488 to 0 94571 in 2 3 2 e Idle Gear Shaft and Idle Gear Bushing Clearance A When Removing 1 Press outthe bushing using an Idle Gear Bushing Re placing Tool B When Installing mn gt E 1 Clean a new idle gear bushing and the idle gear bore A ZA EZ ZZ A and apply engine oil to both Tam T nma E D G EE 2 Using the idle gear replacing tool press in the new 3EEABAB1P134A bushing to the specified dimension see B 62 11362 2 24 2 3 2 Timing Gears Camshaft and Fuel Camshaft Continued 2 3 2 f Camshaft Alignment 1 Supportthe camshaft with V blocks ona surface plate at both end journals 2 d dial indicator with its tip on the intermediate jour nal 3 Rotate the camshaft and measure for run out 4 f the measurement exceeds the allowable limit re place the camshaft Camshaft Allowable 0 1 mm Run out Limit 0 0004 in 2 3 2 9 Cam Height 1 Measure the cam lobe at its largest O D with an out side micrometer 2 Ifthe measu
37. bitor at the same time Never mix differenttypes or brands of coolants 1 8 3 Checking Fuel Hose 1 If the clamp is loose apply oil to the threads and securely retighten it 2 he fuel hose is made of rubber and ages regardless of the service period Change the hose and clamps together every two years 3 Change the fuel hose and clamps whenever any de terioration or damage is detected 4 After the fuel hose and clamps have been changed bleed air out of the fuel system 44 CAUTION Stop the engine when attempting to check and change the fuel line 62 11362 1 8 4 Bleeding Fuel System 1 Open the air vent cock 1 on top of the fuel injection pump 2 Loosen the priming pump handle 2 and pump the handle until bleeding is completed 3 Depress and twist the priming pump handle clock wise to lock into place 4 Close the air vent cock 1 NOTE Always keep the air vent cock on the fuel injec tion pump closed except when bleeding the fuel system or the engine may not run 1 8 5 Checking V Belt Refer to Section 4 1 1 8 6 Changing Engine Oil 44 CAUTION Stop the engine when preparing to change the engine oil E After warming up the engine shut it off Place a pan underneath the engine Remove the drain plug drain the engine oil completely Inspect the drain plug gasket Replace if necessary Reinstall the drain plug Replace the oil filter with a new oil filte
38. ce plate 4 If the gauge does not fit squarely against the face plate measure the space between the pin of the gauge and the face plate 5 If the measurement exceeds the allowable limit re place the connecting rod Wei ET 3TMABABOPOS6A EE ting R O aa Alignment 2 21 62 11362 2 3 4 Crankshaft JEEAFAB1PO64A 3TMABAB1P074 JEEABAB1P147A 62 11362 2 28 2 3 4 a Crankshaft End Clearance 1 Push on the end of the crankshaftto seat it toward the flywheel end of the engine block 2 Attach then zero a dial indicator on the forward end of the crankshaft 3 EN the end play by pulling the crankshaft for ward 4 f the measurement exceeds the allowable limit re place the thrustwashers Factory 0 15 to 0 31 mm Crankshaft Side Specification 0 0059 to 0 012 in Clearance Allowable 0 5mm Limit 0 02 in Reference Oversize dimensions of crankshaft journal 0 2mm 0 008 in 0 4mm 0 02 in A 54 5 to 54 7 mm 54 6 to 54 8 mm stint 2 146 to 2 153 in 2 150 to 2 157 in Bee 26 20 to 26 25 mm 26 40 to 26 45 mm 1 032 to 1 033 in 1 040 to 1 041 in 2 8 to 3 2 mm radius 2 8 to 3 2 mm radius Dimension C 0 11 to 0 12 in 0 11 to 0 12 in radius radius The crankshaft journal must be fine finished to higher than 2 3 4 b Crankshaft Alignment 1 Support the crankshaft with V blocks on a surface plate at both end journals Seta dial indicator with its tip on ps intermediate journal perpendicu
39. ce the spring 2 Put the valve spring on a surface plate place a Square on the side of the valve spring 3 Check to see if the entire side is in contact with the Square Rotate the spring and measure for maximum tilt B Check the entire surface of the valve spring for defects If any are found replace it Factory 41 7 to 42 2 mm Specification 1 65 to 1 66 in Free Length A Allowable Limit es owable Limi 1 62 in i 1 0 mm Tilt B Allowable Limit 0 039 in 2 3 1 j Valve Spring Setting Load 1 Place the valve spring on a tester and compress it to the same length it is actually compressed in the en gine 2 Read the compression load on the gauge 3 Ifthe measurementis less than the allowable limit re place it Factor 118N 35 mm Bm 12 0 kgf 35 mm Setting Load 26 5 Ibs 1 38 in Setting Length ae 100 N 35 mm Limit 10 2 kgf 35 mm 22 5 Ibs 1 38 in 2 3 1 k Oil Clearance Between Rocker Arm and Rocker Arm Shaft 1 Measure the rocker arm shaft O D with an outside micrometer 2 Measure the rocker arm I D with a inside micrometer then calculate the oil clearance 3 If the oil clearance exceeds the allowable limit re place the rocker arm then measure the oil clearance again If the clearance is still out of specification re place the rocker arm shaft Factory 0 016 to 0 045 mm Oil Clearance S pecification 0 0063 to 0 0017 in Rocker Arm Al b 010 S haft pua Pu Limit 0 0039 in Rock
40. cover gasket 3 and fit the gasket to the oil pan cover 4 Install the oil pan cover 4 to the oil pan 2 Install and tighten the oil pan cover bolts diagonally Avoid uneven tightening of the oil pan cover mounting bolts Refer to Section 1 5 2 Torque Specifications 2 2 6 a Pistons 1 Completely remove the carbon ridge 1 at the top of the cylinder walls 2 Remove the connecting rod cap 3 3 Turn the flywheel and bring the piston to top dead center 4 Push the piston out by lightly tapping the connecting D from the bottom ofthe crankcase with the grip of a ammer 5 Repeat the procedure for the other three cylinders When Reassembling Liberally coat the piston and piston rings with engine oll When inserting the piston into the cylinder face the mark on the connecting rod to the injection pump NOTE If re installing the original piston assemblies into the engine be sure that they are returned to their original cylinder Place the piston rings with their gaps at 2 09 rad 120 from the piston pin s direction as shown Carefully insert the pistons into the cylinders using the piston ring compressor 7 When inserting the piston into the cylinderavoid damaging the molybdenum disulfide coating on the piston skirt This coating is useful in mini mizing the clearance between the piston and cylinder When replacing a piston use a replacement piston with the same code number The piston ID mark 6 is
41. djust the notched V belt do the following a Replacing the V Belt 1 Loosen the idler pivot bolt 2 GE the belt and adjust tension in accordance with the following steps b Adjusting Tension 1 Measure the deflection A by depressing the belt halfway between the fan drive pulley and alternator pulley at the specified force Refer to1 7 3 JEEABABT1PU017B 2 Use hand force only on the idler pulley to tighten belt Do not use a pry bar or excessive force as it may cause damage to the engine Use of a belt tension gauge Carrier Part 07 00203 00 or a belt tension tester Carrier Part 07 00253 00 is advised 3 When belt is at correct tension tighten pivot bolt 4 1 1a Poly V Belt Service a Replacing the Poly V Belt 1 Apply the proper size socket to the crank pulley nut then slowly rotate the crank Atthe same time usea flat blunt object to guide the belt off the crank pulley towards radiator Be careful not to damage grooves on the pulley 2 Replace the Poly V Belt by positioning the belt on the water pump pulley and while rotating the engine as in step 1 use a flat bluntobjectto guide the belt onto the crank pulley Be careful not to damage grooves on the pulley or belt 4 1 2 Fan Belt Damage and Wear 1 Check the fan belt for damage 2 If the belt is damage in any way replace it JEEABAB1PU018A A Good B Bad 3 Check ifthe beltis worn and sunk in the pulley groove 4 If the f
42. e engine is equipped with a pressurized cooling system Under normal operating conditions the coolant in the engine and radiator is under high pressure and is very hot Contact with hot coolant can cause severe burns Do not remove the cap from a hot radiator If the cap must be removed do so very slowly in order to release the pressure without spray Battery This unit is equipped with a lead acid type battery The battery normally vents small amounts of flammable hydrogen gas Do notsmoke when checking the battery A battery explosion can cause serious physical harm and or blindness SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the unit and explain the level of awareness each one carries an explanation Is given with the appropriate consequences A DANGER DANGER warns againstan immediate hazard which WILL result in severe personal injury or death 44 WARNING WARNING warns against hazards or unsafe conditions which COULD result in severe personal in jury or death 44 CAUTION CAUTION warns against potential hazard or unsafe practice which could result in minor personal injury or product or property damage NOTE NOTE gives helpful information that may help and avoid equipment and property damage 62 11362 The statements listed below are specifically applicable to this unit and appear elsewhere in this manual These recommended precautions must be understood and
43. e injection Compression leak Gas leak from exhaust system Air cleaner dirty or clogged 1 5 Replenish fuel Vent Air Change fuel and repair or replace fuel system Clean Clean or change Use specified fuel or engine oil Use specified fuel Adjust Replace Replace Repair or Replace Replace head gasket tighten cylinder head screw glow plug and nozzle holder Correct or replace timing gear Replace Adjust Charge Repair or replace Repair or replace Connect Clean or change Clean or change Tighten retaining nut Replace Replace Replace Reduce to specified level Repair or replace Adjust Check the cylinder compression pressure and top clearance Lesson load Use specified fuel Clean or change Clean or change Replace nozzle Adjust Repair or replace Replace Replace nozzle Check the compression pressure and repair Repair or replace Clean or replace 62 11362 16 TROUBLESHOOTING Continued Symptom Probable Cause Solution Reference Oil Consumption Oil ring worn or stuck Piston ring groove worn Valve stem and valve guide worn Crankshaft bearing and crank pin bearing worn Oil leaking due to defective seals or packing Fuel Mixed into Injection pump s plunger worn Lubricant Oil Deficient nozzle injection Injection pump broken Excessive Lubricant Piston ring s gap facing the same direction Shift ring gap direction Replace Replace worn piston Replace
44. e two notches 3 is level is too low add new oil to the specified evel NOTE When adding oil to the crankcase be sure that the fresh oil is the same type and viscosity as the oil that is already in the crankcase Never mix two different types of oil Never over fill a crankcase 1 8 2 Checking Coolant Level 1 Remove the radiator cap and check to see that the coolant level is just below the port With the recovery tank Check to see thatthe coolant level lies between FULL and LOW 2 If the coolantlevel is too low check the reason for the lost coolant a If coolantloss is due to evaporation add only clean soft water b If coolant loss is due to a leak repair the leak then add a coolant mixture of the same type and specifi cation thatis in the system If the coolant brand can not be identified drain out all of the remaining cool ant and refill with a totally new mix 44 CAUTION Do not remove the radiator cap until the coolant temperature is below its boiling point Loosen the cap slightly to relieve ex cess pressure before removing the cap completely NOTE When adding coolant to the system air mustbe vented from the engine coolant passages Venting air can be accomplished by jiggling the upper and lower radiator hoses Be sure to close the radiator cap securely If the cap is loose or improperly closed coolant may leak out and the engine could overheat Do not use an antifreeze and scale inhi
45. ead surface 2 Place a straightedge on the cylinder head surface in Six locations as depicted in the drawing 3 Measure any clearance between the straightedge and cylinder head with a feeler gauge 4 f the measurement exceeds the allowable limit resurface or replace the head NOTE Check the valve recessing after after resurfac ing the head 0 05mm over a span of Cylinder Head Factory 500mm Surface Flatness Specification 0 002 in over a span of 20 in 2 3 1 b Cylinder Head Cracks 1 Cylinder head crack s can be found with using a ER test procedure using a dye pene trant kit N Clean the cylinder head surface using a good quality degreaser and detergent 2 Spray the cylinder head surface with the red liquid or dye 1 Let it sit on the surface for ten minutes 4 Wash the dye off the head using the detergent 2 and dry the head UJ 5 Spray the white developer 3 on to the head 6 Red marks will bleed through the developer identify ing cracks in the head if they are present 2 3 1 Cylinder Head And Valves Continued 2 3 1 c Valve Recessing 1 Clean the cylinder head surface 1 valve face and valve seat 2 Insertthe valve into the head making certain thatthe valve is fully seated 3 Measure the valve recessing with a depth gauge 4 f the measurement exceeds the allowable limit re 3TMABAB1P058A place the valve 1 Cylinder Head A Recess bag Gen B Protrus
46. ead the number on the flywheel The number indi cated is the timing value for the engine The flywheel has a mark 1TC and marks every 5 of engine timing to 25 total NOTE Injection timing adjustment is accomplished by adding or removing shims under the injection pump Thetiming advances by removing one shim and 3EEADAA1PO24C retards timing by adding the same shim The addition or removal of 0 05 mm 0 0020 in of shim changes the injection timing by approx imately 0 009 rad 0 5 Sealant should be applied to both sides of soft metal gasket shims except for the 0175mm shim A 0175mm shim should have sealantap plied to one side only When replacing the injection pump be sure to use the same number and size of new gasket shims 5 1 2 Shim Identification Shims are available in thicknesses of 0 20 mm 0 25 mm 0 30 mm and 0 35mm Combine shims for adjustments 1 Delivery Valve Holder 5 0 Holes 0 30 mm shim 2 Timing Mark 6 3 Holes 0 35 mm shim 3 2 Holes 0 20 mm shim 7 2 Holes 0 175 mm shim 4 1 Hole 0 25 mm shim 3EEADAHTPOO01C 5 1 62 11362 5 1 CHECKING AND ADJ USTING 1 Injection Pump Pressure 2 Injection Nozzle Tester 3 Protective Cover 5 1 3 Pump Pressure Test 1 Remove the engine fuel speed solenoid 2 Remove the injection pipes and nozzle 3 4 Connectthe injection nozzle 2 jetted with the proper Connecta pressure tester to the fuel injection pump injection
47. eflection at 98N 10kof 22 Ibs of force Thermostat Valve Opening 80 5 to 83 5 C Temperature 176 9 to 182 3 F At Beginning Valve Opening 95 C Temperature 203 F O pened Completely 1 7 4 Fuel A AU Factory Specification Allowable Limit Pump Injection Timing 0 0568 to 0 0829 rad 3 25 to a s before Pump Element Fuel Tightness 18 63 Mpa 190 0 kgf cm 2702 psi Delivery Valve Fuel Tightness 10 seconds 5 seconds 18 62 to 17 76 Mpa 18 63 to 17 65 Mpa 190 0 to 180 0 kgf cm 190 0 to 180 0kgf cm 2702 to 2560 psi 2702 psi to 2560 psi Injection Nozzle Injection Pressure 18 64 to 20 10 Mpa 1st stage 190 0 to 205 0 kgf cm 2703 to 2915 psi Injection Nozzle Valve Seat Valve Seat When the pressure is Tightness 16 67 Mpa 170 0 kgf cm 2418 psi the valve seat must not leak 1 11 62 11362 1 7 5 Electrical System Mem Factory Specification Allowable Limit Starter Commutator O D 32 0 mm 31 4 mm 1 26 in 1 24 in Mica Undercut 0 50 mm 0 20 mm 0 020 in 0 0079 in Brush Length 0 18 mm 11 0 mm 0 709 in 0 433 in Brush Holder and Holder Support Resistance Infinity Intake Air Heater Resistance cold Approx 0 3 ohm 62 11632 1 12 1 8 CHECK AND MAINTENANCE 1 8 1 Checking Engine Oil Level 1 Level the engine 2 To check the oil level draw out the dipstick 1 wipe it clean reinsert it and draw it out again Check to see that the oil level lies between th
48. ening Pressure 19 35 MPa 197 5 kgf cm 2809 psi Weght ORY ep S ee paragraph 1 8 6 62 11632 1 2 13 CYLINDER NUMBER 14 GENERAL PRECAUTIONS J m Y SEEABAB1P011A The cylinder numbers of V2203 DI series engine are Ge as shown above The sequence of cylinder numbers is given as No 1 No 2 No 3 and No 4 Starting from the gear case end of the engine JEEABAB1P012A 1 Grease A External Snap Ring 2 Force B Internal Snap Ring 3 Place the Sharp Edge against the Direction of Force During disassembly carefully arrange removed parts in a Clean area to prevent confusion later Screws bolts and nuts should be replaced in their original position to prevent reassembly errors When special tools are required use KUBOTA genuine special tools Special tools which are not frequently used should be made according to the drawings provided Before disassembling or servicing live wires make sure to always disconnect the grounding cable from the battery first Remove oil and dirt from parts before taking any measurements Use only Carrier Transicold genuine parts for parts replacements to maintain engine performance and to ensure safety Gaskets and O rings must be replaced during reassembly Apply grease to new O rings or oil seals before assembling When reassembling external or internal snap rings position them so that the sharp edge faces against the direction from which force is
49. enoid C ter minal 1 to the positive battery terminal 6 Connect a jumper lead momentarily between the starter motor housing and the negative post on the battery 7 Ifthe starter does notrun repairorreplace the starter 1 C Terminal 3 Negative Terminal 2 Positive Terminal 6 1 2 Magnetic Switch Test NOTE This test should only be carried out for a 3 to 5 second time period and not longer 1 Disconnect the cable from the negative terminal on the battery 2 Disconnectthe cable from the positive terminal on the battery 3 Disconnect the the positive cable and leads from the starter B terminal 4 Remove the starter from the engine 5 Connecta jumper lead from the starter S terminal 1 to the positive battery post 2 6 Momentarily connect a jumper lead between the starter housing and negative battery terminal 3 7 If the pinion gear nose does not pop out replace the starter f 3EEABAD1P004A NOTE The B terminal is the terminal that connects the cable from the battery to the starter 1 S Terminal 3 Negative Terminal e b The S terminal is the terminal that connects the 2 Positive Terminal cable from the starter switch to the magnetic switch 6 1 62 11362 6 2 FUEL SPEED SOLENOID 6 2 1 Solenoid Test 44 WARNING The solenoid can become very warm to the touch when energized for any length in time 1 Disconnect the plug from the solenoid connector 2 2 Remove the
50. er Arm Factory 13 973 to 13 984 mm Shaft O D Specification 0 55012 to 0 55055 in Factory 14 000 to 14 018 mm SE 0 55119 to 0 55188 in 2 3 1 1 Push Rod Alignment 1 Place the push rod on V blocks 2 Measure the push rod alignment 3 If the measurement exceeds the allowable limit re place the push rod Push Rod Allowable 0 25 mm Alignment Limit 0 0098 in 2 3 1 Cylinder Head And Valves Continued 2 3 1 m Oil Clearance Between Tappet and Tappet Guide Bore 1 Measure the tappet O D with a micrometer 2 Measure the I D of the tappet guide bore with a cylin der gauge and calculate the clearance 3 If the measurement exceeds the allowable limit or the tappet is damaged replace the tappet Oil Clearance Factory 0 020 to 0 062 mm Tappet Specification 0 00079 to 0 00244 in Tappet Guide Allowable 0 07 mm Bore Limit 0 003 in TEBEO D Factory 23 959 to 23 980 mm di Specification 0 94327 to 0 94409 in Factory 24 000 to 24 021 mm TRDE 0 94489 to 0 94570 in 2 3 2 a Timing Gear Backlash 2 3 2 Timinc Gears Camshaft and Fuel Camshaft l ds dial indicator lever type with its tip on the gear tooth 2 Move the gear to measure the backlash holding its mating gear 3 If the backlash exceeds the allowable limit check the oil clearance of the shafts and the gear 4 If the oil clearance is proper replace the gear Factory 0 0415 to 0 1122 mm Backlash Specification 0 00163 to 0 00442 in Id
51. ft Stopper 5 Injection Pump Gear 2 Fork Lever Holder Mounting 6 Fuel Camshaft Screws 7 Fork Lever Holder 3 Fork Lever 1 4 Fork Lever 2 2 2 4 Oil Pump 1 Remove the nut 2 e out the oil pump drive gear 2 with a gear puller 3 Remove the four oil pump mounting bolts Detach the oil pump 1 JEEAFAB1P0434 1 OilPump 3 Gear Puller 2 Oil Pump Drive Gear 2 11 62 11362 2 25 Oil Pan and Oil Strainer SEEAFABIPO45A 1 2 3 4 62 11362 Oil Pan Mounting Screw Oil Pan Oil Pan Cover Gasket Oil Pan Cover 5 O ring 6 Oil Strainer 7 Oil Pan Gasket 2 2 5 a Oil Pan and Oil Strainer 1 Remove the oil pan cover 4 2 Remove the oil pan mounting bolts 1 3 Remove the oil pan 2 by lightly tapping the rim ofthe pan with a wooden hammer 4 Remove the old gaskets 3 and 7 5 Remove the oil strainer 6 and O ring 5 When Reassembling Check to see that the oil filter strainer 6 is clean Visually checkthe O ring 5 apply engine oil and install it to the pick up tube Install the strainer 6 and O ring 5 Apply gasket sealant to the oil pan side of the oil pan gasket 7 and fit the gasket to the oil pan 2 Install the oil pan 2 to the engine and tighten the oil pan mounting bolts 1 diagonally Avoid uneven tightening of the oil pan mounting bolts Refer to Section 1 5 2 Torque Specifications Apply gasket sealant to the oil pan cover side of the oil pan
52. hatthe Number 1 piston la to compression or overlap top dead center TDC 3 Check the following valve clearance 1 marked with using a feeler guage Valve Cl Factory 0 18 to 0 22 mm Sear oats cee Specification 0 0071 to 0 0086 in 4 f the clearance is not within the factory specifica tions adjust with the adjusting screw Valve Arrangement Piston Location in Cylinder When No 1 piston is at TD i oa When No 1 piston is at past TDC Noa ON EX Es NE WS se WE SE o AO A MIN e 62 11362 1 9 SPECIAL TOOLS Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number 62 03213 1 9 1 Diesel Engine Compression Tester Glow Plug Part No 07 00179 01 Assembly Application Use to measure diesel engine compression and diagnosis for major overhaul 1 9 2 Adapter Injector To Tester Hose Part No 07 00484 00 Application Accessory for 07 00179 01 1 9 3 Tester Injector Nozzle Part No 07 00140 00 Application Injector nozzle tester kit used for checking and adjusting of the fuel injectors in diesel engines 1 9 4 Replacement Bowl Tester Injector Nozzle Part No 07 00140 10 Application Accessory for 07 00140 00 1 9 5 Adapter Injector Line Part No 07 00036 00 Application Accessory for 07 00140 00 62 11632 1 16 19 SPECIAL TOOLS Continued 1 9 6 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating
53. hown on the illustration 4 Lowerthe piston and install the cylinder head Use a new cylinder head gasket and tighten the cylinder head bolts to the proper torque 5 Turn the flywheel until the piston 1 passes through top dead center 6 Remove the cylinder head and measure the plastic gauge 7 Ifthe measurementis not within the factory specifica tions check the clearances between the crank pin and bearing and between the piston pin and bushing Top CI Factory 0 60 to 0 70 mm xc Specification 0 024 to 0 027 in 93 2 to 98 0 N m 9 5 to 10 0 kotm 68 8 to 72 3 ft lbs Tightening Cylinder Head Torque Bolts 62 11362 2 2 DISASSEMBLE AND REASSEMBLY 2 2 1 Draining Coolant And Engine Oil 44 CAUTION Never remove the radiator cap until coolant temperature is below its boiling point Loosen the cap slightly to the first stop to relieve any excess pressure before remov ing the cap completely 1 Open the coolant drain cock or remove the coolant drain plug and drain the coolant into a proper recep tacle bucket 2 Remove the oil drain plug and drain the engine oil into a proper receptacle bucket 62 11362 2 2 2 2 2 External Components Air Cleaner Muffler and Others 1 Remove the air cleaner and muffler 2 Remove the fan fan belt alternator and starter When Reassembling NOTE Check to see that there are no cracks on the belt Surface After reinstaling the fan belt be sure to adjust
54. ion 5 If the measurement still exceeds the allowable limit replace the cylinder head 0 065 protrusion mm to Factory 0 085 recessing mm Valve Specification 0 026 protrusion in to Recessing 0 033 recessing in Allowable Limit 2 3 1 4 Clearance Between Valve Stem And Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with a micrometer 3 Measure the valve guide with a small hole gauge and calculate the clearance 4 If the clearance exceeds the the allowable limit re 3EEABAB1P115A place the valves If the clearance still exceeds the al lowable limit replace the valve guide Clearance Factory 0 040 to 0 070 mm Between Specification 0 0016 to 0 0027 in Valve Stem NN 0 1 mm and Guide Allowable Limit 0 0039 in Valve Stem Factory 7 960 to 7 975 mm O D Specification 0 3134 to 0 3139 in LE Valve Guide Factory 8 015 to 8 030 mm 3EEABAB1P116A LD Specification 0 3156 to 0 3161 in 2 19 62 11362 2 3 1 Cylinder Head And Valves Continued 2 3 1 e Replacing Valve Guide A When removing 1 Press outthe used valve guide using a valve guide re placing tool B When installing 1 Clean a new valve guide and valve guide bore then apply oil to them 2 Press ina new valve guide using a valve guide replac ing tool 3 Ream the D of the valve guide to the specified di mension precisely Valve Guide I D Factory 8 0
55. kshaft collar 1 2 Remove the O ring 2 3 Remove the crankshaft oil slinger 3 When Reassembling Insert the crankshaft collar 1 after installing the gear case to the crankcase 2 2 4 f Idle Gear 1 Detach the external snap ring 2 Remove the idle gear collar 3 Remove the idle gear 2 When Reassembling Check to see each gear is aligned with its aligning mark Idle gear 2 and crank gear 4 Idle gear 2 and cam gear 3 Idle gear 2 and injection pump gear 1 2 2 4 9 Camshaft 1 Remove the camshaft retaining bolt 1 and pull the camshaft 2 out When Reassembling Refer to installation of Idle Gear Refer to Section 2 2 4 f Tightening Camshaft pe dd Torque retaining bolt ee eat q S 18 to 20 ft lbs 2 2 4 h Fuel Feed Pump Holder 1 Disconnect the oil pipe 1 2 Remove the fuel feed pump 2 3 Remove the fuel feed pump holder 4 When Reassembling Replace the O rings 3 with new O rings 2 2 4 Injection Pump and Gear Case Continued A 2 2 4 1 Fuel Camshaft And Fork Lever Assembly 1 Detach the fuel camshaft stopper 1 2 GZ the three fork lever holder mounting screws 3 Remove the fuel camshaft assembly 5 6 and fork lever assembly 3 4 and 7 at the same time When Reassembling After installation check to see that the fork levers 1 3 and 2 4 are fixed to the fork lever shaft and that they can turn smoothly in the holder 7 1 Fuel Camsha
56. lace Change 17 SERVICING SPECIFICATIONS 1 7 1 T qa Body Factory Specification Allowable Limit Me Oe Ter Head Surface Flatness 0 05 mm 500mm 0 0020 in 19 69 in Compression Pressure 2 95 to 3 23 MPa 2 35 MP a 290 rpm 290 rpm 30 to 33 kgf cm 24kgf cm2 290 rpm 290 rpm 427 to 469 pel 341 psi 290 rpm 290 rpm Difference Among Cylinders 10 or less Top Clearance 0 60 to 0 70 mm 0 0236 to 0 0276 in Valve Clearance When Cold 0 18 to 0 22 mm 0 0071 to 0 0086 in Valve Seat Width Intake 2 12 mm 0 0835 in Width Exhaust 2 12 mm 0 0835 in Valve Seat Angle 0 79 rad Intake Exhaust 45 Valve Face Angle 0 79 rad Intake Exhaust 45 Valve Stem to Valve Guide Clearance 0 040 to 0 070 mm 0 1 mm 0 0016 to 0 0027 in 0 0039 in Valve Stem D 7 960 to 7 975 mm 0 3134 to 0 3139 in Valve Guide D 8 015 to 8 030 mm 0 3156 to 0 3161 in Valve Recessing P rotrusion 0 65 mm 0 026 in to Recessing 0 85 mm 0 033 in Valve Timing Intake Valve 0 1 rad 8 before T D C 0 35 rad 20 before T D C Valve Timing Exhaust Valve 0 87 rad 50 before B D C 0 21 rad 12 before B D C 1 7 62 11362 1 7 1 Engine Body Continued Factory Specification Allowable Limit Valve Spring Free Length 41 7 to 42 2 mm 41 2 mm 1 65 to 1 66 in 1 62 In Setting Load 118 N 35 0 mm 100 0N 35 0 mm Setting Length 12 0 kgf 35 0 mm 10 2kgf 35 0 mm 26 5 lbs 1
57. lar to the journal 2 Rotate the crankshaft on the V blocks and get the misalignment half of the measurement 3 If the misalignment exceeds the allowable limit re place the crankshaft Crankshaft Allowable 0 02 mm Alignment Limit 0 0008 in 2 3 4 Crankshaft Continued 2 3 4 c Crankpin to Connecting Rod Bearing Clear ance 1 Clean the crankpin and the connecting rod bearing 2 Puta strip of plastigage on the center of the crankpin in each direction as shown in the figure 3 Install the connecting rod cap and tighten the bolts to the specification Refer to 2 2 6 a 4 Remove the cap again 5 Measure the amount of the flattening with the scale to get the clearance 6 If the measurement exceeds the allowable limit re place the connecting rod bearing 7 If the allowable limit is not attainable with a standard size bearing install an undersize bearing by referring to the table below Factory 0 025 to 0 087 mm Crankpin Specification 0 00099 to 0 0034 in Connecting R od Allowable 0 2 mm Clearance E Limit 0 0079 in Factory 46 959 to 46 975 mm Connecting R od Factory 47 000 to 47 046 mm Bearing I D Specification 1 8504 to 1 8522 in Reference Undersize dimensions of crankpin journal Undersize 0 2mm 0 008 in 2mm 0 2mm 0 008 in 0 008 in 0 4mm 0 02 in 4mm 0 4mm 0 02 in 0 02 in Dim A 3 3 to 3 7 mm 3 3 to 3 7 mm mene en 0 13 to 0 14 in 0 13 to 0 14 in 1 0 to 1
58. le Gear Allowable 0 15 mm Crank Gear m Limit 0 0059 in Factory 0 0415 to 0 1154 mm Backlash Specification 0 00163 to 0 00454 in Idle Gear Allowable 0 15 mm Cam Gear Ge Limit 0 0059 in Backlash Factory 0 0415 to 0 1154 mm Idle Gear Specification 0 00163 to 0 00454 in Injection Pump Allowable 0 15 mm Gear Limit 0 0059 in Factory 0 0415 to 0 1090 mm Backlash Specification 0 00163 to 0 00429 in Crank Gear Allowable 0 15 mm Oil Pump Gear ee Limit 0 0059 in 2 3 2 b Idle Gear Side Clearance 1 Set a dial indicator with its tip on the idle gear 2 Move the gear front to rear to measure the side clear ance 3 If the measurement exceeds the allowable limit re place the idle gear collar Factory 0 12 to 0 48 mm Idle Gear S pecification 0 0047 to 0 018 in STMABAB1P064A Side Allowable 0 9mm Clearance o Limit 0 04 in 2 23 62 11362 2 3 2 Timing Gears Camshaft and Fuel Camshaft Continued 2 3 2 c Camshaft Side Clearance 1 Seta dial indicator with its tip on the camshaft 2 Move the camshaft gear front to rear to measure the Side clearance 3 If the measurement exceeds the allowable limit re place the camshaft stopper Factory 0 07 to 0 22 mm Camshaft S pecification 0 0028 to 0 0087 in Se Allowabl 0 30 Clearance awa 5 AN Limit 0 0118 in 2 3 2 d Idle Gear Shaft and Idle Gear Bushing Clearance 1 Measure the idle gear shaft O D with a micrometer 2 Measure the idle ge
59. let the governor spring 5 disengage from the plate and fall into the gear case 3 EC a eh OH 031A Y 3EEAFABIP 5 Large Governor Spring 6 Speed Control Lever 7 Speed Control Plate 1 Specific Tool 2 Fork Lever 3 Speed Control Plate Mounting Nut 4 Speed Control Plate Mounting Bolt 62 11362 2 2 4 Injection Pump and Gear Case Continued PS VW 2 2 4 6 Governor Springs and Speed Control Plate Continued When Reassembling NOTE A length of string passed thru the governor spring can be used to retrieve the spring if itun hooks from both the specific tool and the speed control plate Begin reassembly by inserting the specific tool 1 thru the injection pump cover opening thru to the speed control plate opening 1 Using the specific tool 1 capture the governor spring 5 and speed control plate 7 assembly 2 Pull the governor spring 5 speed control plate 7 assembly thru and secure it to the fork lever 2 3 Seat and assemble the speed control 5 plate with two bolts and two nuts to the gear case 4 Check the movement of the speed control lever 4 NOTE The speed control lever 6 must be free to move from low idle position to maximum speed position and should always return to the high idle position 5 Finally install the injection pump cover to the gear Case 1 Specific Tool 5 Large Governor S pring 2 Fork Lever 6 Speed Control Lever
60. mm 0 039in C2 Chamfer 2 0 mm 0 079in os CENE a VEM K L H C0 3 Chamfer 0 3 mm 0 012in STMABABOPOG4A 1 9 14 Bushing Replacing Tools Application Use to press out and press fit the bushing 1 For small end bushing 162 mm 6 38 in B 35 mm 1 38 in 27 mm 1 06 in oa 35 mm dia 1 38 in dia 27 90 to 27 95 mm dia 1 098 to 1 100 in dia 25 00 to 25 01 mm dia 0984 to 0 985 in dia 2 For idle gear bushing 175 mm 6 89 in B 40 mm 1 57 in 38 mm 1 49 in D 45mm 1 77 in 41 90 to 41 95 mm dia 1 650 to 1 652 in dia 37 95 to 37 97 mm dia 1 494 to 1 495 in dia 1 9 15 Flywheel Stopper Application Use to loosen and tighten the flywheel Screw 200 mm 7 87 in B 20 mm 0 79 in 3 TMABABOPO66A 30 mm 1 18 in D 8mm 0 32 in 10 mm 0 39 in 3 TMABABOP06 7B 62 11632 1 18 19 SPECIAL TOOLS Continued 1 9 16 Crankshaft Bearing 1 Replacing Tool Application Use to press outand press fitthe crankshaft bearing No 1 1 Extracting tool 20 mm dia 0 79 in dia 64 8 to 64 9 mm dia 2 551 to 2 555 in dia 59 8 to 59 9 mm dia 2 354 to 2 358 in dia 2 Extracting tool 130 mm 5 31 in Led Le 8 umen D fomos SS 3TMABABOPOG68A 59 8 to 59 9 mm dia 2 354 to 2 358 in dia 64 8 to 64 9 mm dia 2 551 to 2 555 in dia 1 19 62 11362 SECTION 2 ENGINE BODY 2 1 CHECKING AND ADJ USTING
61. place crankshaft bearing 2 6 If the allowable limit is not attainable with a standard size bearing install an undersize bearing by referring to the table below UI 3TMABAB1P081A NOTE Be sure not to move the crankshaft while the bearing bolts are tightened Crankshaft Factory 0 040 to 0 104 mm J ournal to 2 Specification 0 00158 to 0 00409 in Bearing Allowable 0 2 mm 3EEABAB1P152B p l Clearance Limit 0 0079 in Crankshaft Factory 59 921 to 59 940 mm Journal O D S pecification 2 3591 to 2 3598 in Crankshaft Factory 59 980 to 60 025 mm MC Specification 2 3615 to 2 3631 in Reference Undersize dimensions of crankshaft journal 0 2mm 0 008 in 0 4mm 0 016 in 2 8 to 3 2 mm radius 2 8 to 3 2 mm radius Dimension A 0 11 to 0 12 in 0 11 to 0 12 in radius radius 1 0 to 1 5 mm radius 1 0 to 1 5 mm radius Dimension B 0 040 to 0 059 in 0 040 to 0 059 in radius radius 59 72 to 59 740 59 52 to 59 540 Dimension C mm mm 2 3513 to 2 3519 in 2 3433 to 2 3440 in The crankshaft journal must be fine finished to higher than 0 4 S Holes to be de burred and edges rounded with 1 0 to 1 5 mm 0 040 0 059 in relief 2 31 62 11362 2 3 4 Crankshaft Continued 3TMABAB1P084A 1 Stopper 2 Sleeve Guide 3 Crankshaft Sleeve 62 11362 4 Auxiliary Socket For Pushing 5 Crankshaft 2 3 4 9 Replacing Crankshaft Sleeve 1 UJ N LP Remove the crankshaft sleeve
62. pressure to the injection pump pressure test er 1 Using the starter rotate the crankshaft until the fuel pressure is built up If the pressure does not build up replace the pump element with a new one and test again 62 11362 5 2 Fuel Pump Factory Pressure Test Specification 5 1 4 Delivery Valve Fuel Seal 1 2 Remove the injection pipes and nozzle 3 4 Connectthe injection nozzle 2 jetted with the proper 18 63 MPa 190 kgf cm 2702 psi Remove the engine fuel speed solenoid Connecta pressure tester to the fuel injection pump injection pressure to the injection pump pressure test er 1 Using the starter rotate the crankshaft until the fuel pressure is built up Release the pressure in the delivery chamber by ro tating the crankshaft to bottom dead center turn the crankshaft 1 57 rad 90 clockwise from fuel timing set point Ifthe pressure drop for 5 seconds exceeds the allow SCH limit replace the delivery valve or pump assem y 10 seconds 18 63 to 17 65 MPa 190 to 180 kgf cm 2702 to 2560 psi Factory Specification Delivery Valve Fuel Seal Bseconds 18 63 to 17 65 MPa 190 to 180 kgf cm 2702 to 2560 psi Allowable Limit 5 2 INJECTION NOZZLE 44 WARNING Check the injection nozzle only after confirming that nobody is near the spray If the spray from the nozzle contacts the human body cells may be destroyed and blood poisoning may res
63. r Fill the crankcase with new oil Checkforthe correctoillevel Referto Section 1 8 1 U N CON O Ul A 62 11632 NOTE When changing to a different oil manufacturer or viscosity be sure to remove all of the old oil completely Never mix different types of oil Use only API classification CG 4 or better oils Use the proper SAE engine oil according to the ambient temperatures Above 25 C 77 F SAE 30 or 10W 30 10W 40 0 to 25 C 32 to 77 F SAE 20 or 10W 30 10W 40 Below 0 C 32 F SAE 10W or 10W 30 NOTE With emission controls now in effect the CG 4 or CH 4 CI lubricating oils have been devel oped for use of a low sulfur fuel on road ve hicles engines When an off road vehicle en gine runs on a high sulfur fuel itis advisable to employ the CH 4 Cl lubricating oil with a high total base number If the CG 4 lubricating oil is used with a high sulfur fuel change the lubricat ing oil at shorter intervals Lubricating oil recommended when a low sulfur or high sulfur fuel is employed a 9 90 O Recommended X NotRecommended 1 8 7 Valve Clearance 3TMABABOP046C 3EEADAA1POO7A 1 8 8 Fuel Injection Refer to Section 5 2 1 15 NOTE Valve clearance must be checked and adjusted when the engine is cold 1 Remove the valve cover 2 Align the ITC mark line 3 on the flywheel and pro jection 2 on the housing so t
64. r The engine model and its serial number need to be identified before the engine can be serviced or parts replaced Engine Serial Number The engine serial number is an identified number for the engine It is marked after the engine model number It indicates month and year of manufacture as follows Table 1 1 Model Chart SERVICE ENGINE MODEL NUMBER ENGINE TYPE PART NUMBER PRIMARY USE REPLACES CT4 134 DI Ultra XT Ultra XTC X2 1800 2 2 A eae 1700 RPM A ies X2 2100 X2 2100A X2 2100R NA CT4 134 DI CT4 134 DI Ultima XTC Extra XT 2 2 V2203L DI E3B CTD 1 2200 RPM 26 00128 02 X2 2500 A X2 2500 R ESCH CT4 134 DIl V2203L DI E3B CTD 6 1800 RPM 26 00128 04 UG Genset BE EM CT4 134 DI V2203L DI E3B CTD 4 1700 RPM 26 00128 05 TM Ultra XL 1 1 62 11362 1 2 ENGINE SPECIFICATIONS Table 1 2 Specification Chart MODEL NUMBER 26 00128 00 26 00128 01 26 00128 02 26 00128 04 26 00128 05 TYPE Vertical Water cooled 4 cycle diesel engine BORE XSTROKE mm A mm in X in 83 X 102 4 3 27 X 4 03 TOTAL DISPLACEMENT cm cu in 2216 135 2 BRAKE HORSEPOWER 23 65 31 7 23 87 32 0 26 85 36 0 23 87 32 0 23 65 31 7 SAE Intermittent HP kW HP RPM 1700 1800 2200 1800 1700 CTE A AN Bosch K Type Mini Pump Bosch P Type Hole Nozzle 4 0 Bef INJ ECTION TIMING UNPRESSURIZED 2 5 Before T D C 2 5 Before T D C FIRING ORDER 1 3 4 2 INJ ECTION PRESSURE Valve Op
65. rementis less than the allowable limit re place the camshaft Factory 33 27 mm Cam Height Specification 1 310 in Intake Allowable 33 22 mm Limit 1 308 in JEEABAB1P129A Factory 33 47 mm Cam Height Specification 1 318 in Exhaust Allowable 33 42 mm Limit 1 316 in 2 3 2 h Camshaft Oil Clearance l AP mj EVA a e E if aia p D Lol EN d a e 1 gt 9 1 Measure the camshaft journal O D with an outside micrometer Anf F UA 2 Measure the cylinder block camshaft bore I D with a cylinder gauge and calculate the oil clearance 3 If the oil clearance exceeds the allowable limit re place the camshaft Factory 0 050 to 0 091 mm Camshaft J ournal Specification 0 0020 to 0 0035 in Clearance Allowable 0 15 mm Limit 0 0059 in s rr a za K d 0 Jw e Wie D SP 7 T v f a JEEADAB1PO61A Camshaft J ournal Factory 39 934 to 39 950 mm O D Specification 1 5722 to 1 5728 in Camshaft Bore Factory 40 000 to 40 025 mm LD Specification 1 5748 to 1 5757 in 3TMABABIPO71A 2 25 62 11362 2 3 3 Piston and Connecting Rod JEEABAB1P138A JEEABAB1P139A JEEABAB1P140A 62 11362 2 26 2 3 3 a Piston Pin Bore I D 1 Measure the piston pin bore I D in both the horizontal and vertical directions with a cylinder gauge 2 If the measurement exceeds the allowable limit re place the piston Factory 25 000 to 25 013 mm Piston Pin Bore Specification 0 98426 to 0 98476 in
66. solenoid 1 from the engine 3 Supply power 12VDC to the solenoid thru terminals 3 and 4 4 If the rod in the solenoid 1 moves smoothly approx imately 0 6 the solenoid is normal if the rod does not move or moves only a fraction of that distance replace it 1 Fuel Speed Solenoid A Actuator Rod Power Off 2 Solenoid Connector B Actuator Rod 12VDC 3 Terminal 2 applied 4 Terminal 1 4 3EEAAAB1P022B JEEAFABTPOOBA 62 11362 6 2 6 3 INTAKE AIR HEATER SEEABAC1P047A 6 3 6 3 1 Intake Air Heater Test 1 Disconnect the lead from the heater terminal 1 2 Measure the resistance between the heater positive terminal 1 and the heater body 2 3 If the resistance is infinity or significantly different than the specification replace the heater Intake Air Heater Factory 0 3 oh Resistance Specification RS l Positive Terminal 2 Heater Body 62 11362 Battery iv bearing case 2 15 2 17 C camshaft 2 10 2 24 2 25 compression pressure 2 1 connecting rod 2 14 2 27 coolant iv 2 2 coolant level 1 13 4 1 cooling system 4 1 crankshaft 2 28 crankshaft oil slinger 2 10 cylinder 2 33 cylinder head 2 3 2 5 2 18 D dye penetrant 2 18 electrical system 6 1 engine oil 1 14 2 2 F fan drive pulley 2 9 flywheel 2 15 fuel injection 1 15 2 3 2 6 fuel speed solenoid 6 2 fuel system 5 1 fuel system bleeding 1 14 G gear case
67. tion 3 2776 to 3 2784 in Maio West Allowable 83 420 mm Limit 3 2843 in Hone to 2 2 to 3 0 mm uR max Finishin 0 00087 to 0 00118 in uR max JEEABAB1P156A 1 Cylinder I D 2 Oversize Cylinder I D bef t EEN 2 Replace the piston and piston rings with oversize 0 25 mm ones 2 33 62 11362 SECTION 3 LUBRICATING SYSTEM 3 1 CHECKING AND ADJ USTING 3 1 1 Engine Oil Pressure 1 Remove the engine oil pressure switch and install an oil pressure gauge 2 Start the engine After warming up read the oil pres Sure at idling and at rated speeds 3 If the oil pressure is less than the allowable limit check the following E ngine oil sufficient Oil pump defective Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged E xcessive oil clearance Relief valve stuck Esci More than 98 kPa Sech 1 0 kgf cm Specification 14 psi At Idle Speed 50 kPa Allowable 0 5 kaficm Limit EE 7 psi Factor 300 to 440 kPa S sane 3 0 to 4 5 kgf cm i 43 to 64 psi At Rated S peed 250 kPa Allowable Limit 2 5 kgf cm 36 psi When Reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque 3 1 62 11362 3 2 SERVICING 3TMABAB1P086A STMABAB1P087A LIT UU E PORE PERG TE LS Tut PERFECT CIRCLE PLASTIGAG PB CLEARANCE 3TMABAB1P088A 62 11362 3 2 3 2 1 Rotor Lobe Clearance 1 Measure the clear
68. ult 5 2 1 Nozzle Injection Pressure 1 Set the injection nozzle in a nozzle tester 2 Slowly move the tester handle to measure the pres sure at which fuel begins jetting out from the nozzle 3 If the measurement is not within factory specifica tions replace the nozzle assembly Fuel Injection 18 64 to 20 1 MPa Factory 190 to 205 kgt cm 2703 to 2915 psi Pressure 1st Stage Specification 5 2 2 Nozzle Spraying Condition 1 Set the injection nozzle in a nozzle tester and check the nozzle spraying condition 2 If the spraying condition is defective replace the injection nozzle assembly 3EEADAB1PO04B a GOOD b BAD 5 2 3 Valve Seat Tightness 1 Set the injection nozzle in a nozzle tester 2 Raise the fuel pressure and maintain 16 67 MPa 170 kgf cm2 2418 psi for 10 seconds 3 If any fuel leak is found replace the injection nozzle assembly No fuel leak at Valve Seat Tight Factory 16 67MPa ness Specification 170 kgf cm 2418 psi 5 3 62 11362 SECTION 6 ELECTRICAL SYSTEM 6 1 STARTER TEST 6 1 1 Motor Test 44 WARNING Secure the starter to prevent itfrom moving when power is applied to it 1 Disconnect the cable from the negative terminal on the battery SEEABAD P003A 2 GER cable from the positive terminal on the attery 3 Disconnect the leads from the starter B terminal 4 Remove the starter from the engine 5 Connecta jumper lead from the starter sol

Carrier 50ZH024-060 Air Conditioner User Manual

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