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Carrier CT2-29-TV Specifications

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1. esel Engine WORKSHOP MANUAL for CT2 29 TV Z482 E 2B Truck ComfortP ro CT3 44 TV D722 E2B Truck Beginning With Serial Number 5A0001 6062 11161 Rev A TRANSICOLD WORKSHOP MANUAL DIESEL ENGINE CT2 29 TV Z482 E 2B Truck ComfortP ro CT3 44 TV D722 E2B Truck Beginning With Serial Number 5A0001 TABLE OF CONTENTS PARAGRAPH NUMBER Page TABLE OF CONTENTS cir A ee he ee a ea ee ee eee i SAFET PRECAUTIONS dossier ad iS ina SPECIFIC WARNING AND CAUTION STATEMENTS 0 0ccccccccc n teen teens Vc cd ee ee eR Te Tee ee re a ere 1 1 LL ENGINE IDENTIFICATION ita ra aaa E A EE gael acne ews 1 1 L2 ENGINE SPECIPICATIONS erat aru atte seeded aera athe aaah aio ae Oe aoe 1 2 EZ ie a ERIN sra a ee ee ee eee ee ee ee ee ae 1 3 LAA CVMMOSMINMUMDER sis dc fechas dave were athe sedate dan hie ade death al eke da 1 3 1 GENERAGCGPRECAUTION S secas atrapados dido niga 1 3 LA TORQUE SPECIFICATION A akan Aiea Aveo ache Geena Baa 1 4 1 4 1 Torque Specifications For Special Use Screws Bolts and Nuts cece eee eens 1 4 1 4 2 Torque Specifications For General Use Screws Bolts and NutS ccc eee eens 1 4 LS TROUBLESHOOTING suso te eras west ou das weld at ay he hating Beet aa hee oes 1 5 16 SERVICING SPECIFICATIONS i234 tctuniatacsiveie dian datas ira 1 8 LOE ENGINE BOY serk Wot cthat debive a 4 edt aed e ane as Ga ae Sele Re aca S 1 8 LOZ Lubica System ss aid di a ed ean
2. 2 23 62 11161 2 3 1 Cylinder Head And Valves Continued STAAAADIPOS1A SEEACAAIPO45 A 62 11161 2 24 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 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 0 016 to 0 052 mm Tappet Specification 0 00063 to 0 00205 in Tappet Guide Allowable 0 10 mm Bore Limit 0 0039 in Tappet O D Factory 17 966 to 17 984 mm PP o Specification 0 70732 to 0 70803 in Factory 18 000 to 18 018 mm Gi 0 70866 to 0 70937 in 2 3 2 Timinc Gears Camshaft and Fuel Camshaft SEEACAAIROA6AN 2 25 2 3 2 a Timing Gear Backlash 1 a dial indicator lever type with its tip on the gear tootn 2 Move the gear to measure the backlash holding its mating gear 3 Ifthe backlash exceeds the allowable limit check the bearing clearance of the shafts and the gear 4 If the bearing clearance is proper replace the gear Factory 0 043 to 0 124 mm Backlash Specification 0 00169 to 0 00488 in Idle Gear Allowable
3. 2 8 3TMABABOPO53A 1 Guage 5 Threaded J oint 2 Adapter 2 6 Adapter 4 3 Cable 7 Adaptor 1 4 Adapter 3 8 Adaptor 3 1 8 7 Auxiliary Socket For Fixing Crankshaft Sleeve Code No 07916 32091 Application Use to fix the crankshaft sleeve of the diesel engine 3TMABABOPO62A 1 8 8 Guage Belt Tension Part No 07 00203 00 Application Used to adjust belt tension of all cogged V belts 1 8 9 Tester Belt Tension Part No 07 00253 00 Application Used to test belt tension 1 8 10 Rubber Band Part No 07 00253 01 Application Replacement part for belt tension tester Part No 07 00253 00 1 15 62 11161 18 SPECIAL TOOLS Continued The following are drawings for special tools that may need to be fabricated 3TMABABOPO63A K TH 3TMABABOPOG64A C1 Joda p El JEEACAA1 POGIA 3 TMABABOPO67B 62 11161 1 8 11 Valve Guide Replacing Tool Application ae 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 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 mm 0 039in C2 Chamfer 2 0 mm 0 079in C0 3 Chamfer 0 3 mm 0 012in 1 8 12 Bush
4. 3 Bracket 11 Speed Control Plate 4 Injection Pump 12 Screw and Copper Washer 5 Injection Pump Control 13 Governor Lever Rack Pin 14 Governor Spring 6 Injection Pump Control Rod 15 Engine Stop Solenoid Rod 7 Start Spring 16 Engine Stop Solenoid 8 Specific Tool 2 9 62 11161 2 2 6 Timing Gear Camshaft and Fuel Camshaft Continued DA 2 2 6 c Fan Drive Pulley 1 Secure the flywheel to keep it from turning 2 Remove the fan drive pulley bolt 3 Remove the fan drive pulley with a puller When Reassembling Install the pulley to the crankshaft aligning the mark 1 on them Apply engine oil to the fan drive pulley retaining bolts and tighten them l 117 7 to 127 5 N m ceil Fan puna 12 0 to 13 0 kgfm i 86 8 to 94 0 ft lbs 2 2 6 d Gear Case 1 ls the start spring 2 from the fork lever 1 3 2 Remove the bolt 1 inside the gear case 3 Remove the remaining bolts securing the gear case to the engine block 4 Remove the gear case When Reassembling Apply a gasket sealer to both sides of the gear case gasket Be sure the three O rings in the gear case are in place h 1 Bolt Inside 3 Fork Lever 1 geL e 2 Start Spring 4 GearCase SEEACABIPOIBA 62 11161 2 10 2 2 6 Timing Gear Camshaft and Fuel Camshaft Cont inued 2 2 6 e Idle Gear 1 Remove the external snap ring 3 the collar 2 and the idle gear 1 2 Remove the idle gear shaft mounting bo
5. Top Ring Specification 0 0059 to 0 0118 in ENEE Second Ring Specification 0 0118 to 0 0177 in Oil Control Ring Specification 0 0059 to 0 0118 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 3 If the clearance exceeds the allowable limit replace the ring 4 If the clearance still exceeds the allowable limit after replacing the ring replace the piston Factory 0 090 to 0 120 mm nse Second Ring Specification 0 00354 to 0 00472 in Allowable Limit 0 15 mm 0 0059 in 3ITMABAB1PO72A pon Allowable Limit Factory 0 040 to 0 080 mm Oil Control Ring Specification 0 0016 to 0 0031 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 Installthe connecting rod onthe connecting rod align ment tool 3 Put a gauge over the piston pin and move it against the face 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 ai 1 iN O j 3TMABABOPO56A o ting R A cl oo Alignment 2
6. and adjust the linkage so as a leve r15 5 rests against the stopper 4 when the engine stop Ee IS not a There should be no tension on the z plunger arm 7 when the engine stop solenoid is not JEEACAA1POBGA energized Adjustment is accomplished by loosening the engine stop mounting screws and moving the engine stop solenoid 1 62 11161 2 2 2 2 4 Cylinder Head And Valves 1 Overflow Pipe 4 Glow Plug 2 Nozzle Holder Assembly 5 Copper Gasket 3 Glow Plug Bus Bar 6 Heat Seal JTAAAADIPOZGA 2 3 2 2 4 a Valve Cover 1 Remove the breather tube 1 2 Remove the valve cover bolts 2 3 Remove the valve cover 3 When Reassembling Check to see that the valve cover gasket is in good condition and in place 6 86 to 11 3 Nm 0 7 to 1 15 kgfm 5 1 to 8 32 ft lbs Tightening Valve Cover Torque Bolts 2 2 4 b Injection Pipes 1 Loosen the screws on the pipe clamps 1 2 Detach the injection pipes 2 When Reassembling Blow out any debris that may be in the pipes with compressed air then reassemble pipes Injection Pipe 24 5 to 34 3 Nem Retaining 2 5 to 3 5 kgf m Nut 18 1 to 25 3 ft lbs Tightening Torque 2 2 4 c Nozzle Holder Assembly and Glow Plug 1 Remove the overflow pipe assembly 1 2 Remove the nozzle holder assemblies 2 3 Remove the copper gasket 5 and heat seal 6 4 Remove the glow plug buss bar 3 from the glow plugs 4 5 Remove the glow plugs 4 When
7. 1 57417 to 1 57583 in 67 000 to 67 019mm 67 150 mm I D Standard 2 63779 to 2 63854 in 2 64370 in e yinacrLmer D Oversize 67 250 to 67 269mm 67 400mm eri 2 64764 to 2 64839 in 2 65354 in 62 11161 1 10 1 6 2 Lubricating System A lea Factory Specification Allowable Limit At Idle Speed A fa ale yt i x Engine Oil Pressure TET 196 to 441 kPa 147kPa p 2 0 to 4 5kgf cm2 28 to 64 psi 1 5kgf cm 21 psi 0 03 to 0 14 mm Inner Rotor to Outer Rotor os o 0 075 to 0 135 mm Inner Rotor to Cover 0 00295 to 0 00531 in E ngines installed in Genesis Solara and Supra units use an oil pressure safety switch which opens at 105 kPa 1 06 kgf cm 15 psi 1 6 3 Cooling System A Hem Factory Specification Allowable Limit 7 0 to 9 0 mm at 98N V Belt Tension 0 28 to 0 35 in at 98N 10kgf 22 lbs Valve Opening Temperature orca At Beginning Thermostat Valve Opening 350 Temperature 185 F Opened Completely 10 seconds or more l 88 to 59kP a Radiator Cap Pressure Falling Time 0 9 to 0 6 kgf cm 13 to 9 psi No leaks at specified Leakage Test pressure Radiator Pressure 157 kPa 1 6 kgf cm 23 psi 1 6 4 Fuel System AT Factory Specification Allowable Limit Injection Timing 0 33 to 0 37 rad 19 to 3600 min rpm 21 before T D C 13 73 MPa Pump Element Fuel Tightness 140 kgf cm 1991 psi 5 seconds ey econ 13 73 to12 75 13 73 to12 75 MPa Delivery Valve Fuel Tightne
8. 25 mm 0 0098 in 0 25 mm 0 25 mm 0 0098 in Piston Ring Assembly 16851 21090 SECTION 3 LUBRICATING SYSTEM 3 1 CHECKING AND ADJ USTING y 1G Lf oe a a MSI E in X b a i aA W E q a a a ie id PESTEN vil ele fe ae fit i db he li h f ae J bros Phen A A e a JEEACAA1P0928 Gg Al cee SEEACABORI02C 3 1 1 Checking Engine Oil Level 1 Level the engine 2 To check the oil level draw out the dipstick 2 wipe it clean reinsert it and draw it out again Check to see that the oil level lies between the two notches 3 Al 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 3 1 2 Changing Engine Oil 44 CAUTION Stop the engine when preparing to change the engine oil 1 Start and warm up the engine for approximately for 5 minutes 2 Turn the engine off 3 Place a proper receptacle bucket under the engine drain plug 3 1 Remove the oil drain plug 1 and drain the engine oil into a proper receptacle bucket 5 Remove the used oil filter and replace with a new one Refer to Section 3 1 3 6 After draining all of the oil in the engine replace the drain plug 1 7 Remove the oil fill cap 3 and add the corre
9. 8 14 Crankshaft Bearing 1 Replacing Tool oooooooocoorncnna ene e eee n tenes 1 17 62 11161 PARAGRAPH NUMBER Page ENGINE BODY siii diria ria rada an 2 1 2A CHECKING AND ADJUSTING coria 2 1 2 1 1 Compression Pressure naaa ada 2 1 22 A A A ey neue Aaah eo gem Hay Ge asa aaa a Oe eae ae 2 1 2 2 DISASSEMBLING AND ASSEMBLING coimas 2 2 22k Br ata SOM sra eee eee eee eR ee eee oe 2 2 22 2 Draining and ReEMMNG ENGING Ol dc ic4hisS bag ais 2 2 Zo EMS COMPONEN tast erar ear oer aru rias 2 2 2 2 4 Cylinder Head And Valves cc cece cece terete tent e teeta teeta tentenentanennas 2 3 2220 01 Pan ana Oil Pick up S CLOG ii AA Pha AAA ARA takes 2 6 2 2 6 Timing Gear Camshaft and Fuel Camshaft ooooocooccoccnccn eee eens 2 1 2 21 PASTOR ana Connecting RO sra a A AS 2 13 TES NE E ONS WWE PANOR 2 16 3 SERVICIO dra orina caos 2 19 23 1 Cylinder Head ANG ValWeS a44 toi atte Maine A TA AA dd AA 2 19 2 3 2 Timing Gears Camshaft and Fuel Camshaft 0 0 cc ccc cee eee eens 2 25 23 5 PIStOn and Connecting ROG ezo wots ta He sina is Sete ad Sa Pathe aoe Beat ata ha sen ee Pale ee 2 28 234 ChanKSNa ramita iii 2 30 25 A ROO 2 36 LUBRICATING SYSTEM savaesitnis trident cae a ee ee Oe nn 3 1 Sl CHECKING AND ADI WS TUNG ages tiled ee cea Ba aec ate tna Ate den a ud ae hares rn OE 3 1 3 1 1 Checking Engine Oil Level cee eee n tent eee e nent ene ene 3 1 2 CNN NO ENG INC O lie cal ae A eee de
10. Gasket When Reassembling 2 Water Pump Shaft 5 Mechanical Seal Replace the mechanical seal with a new one 3 Water Pump Body 6 Impeller Apply a liquid gasket to both sides of the gasket 4 4 3 62 11161 SECTION 5 FUEL SYSTEM 5 1 CHECKING AND ADJ USTING a A n j 95 3E 4A JTAAAABITPOGZA 3 1 5 1 1 Injection Timing 1 Remove the injection lines 2 Remove the engine stop solenoid when applicable 3 Turn the flywheel counterclockwise facing the fly wheel until fuel flows from the delivery valve holder 4 Turn the flywheel further and stop turning when the fuel level at the tip of the delivery valve holder begins to increase 5 Check to see which of the timing angle lines 1 on the flywheel is aligned with the alignment mark 2 NOTE Injection timing adjustment is accomplished by adding or removing shims under the injection pump The timing advances by removing one shim and retards by adding the same shim The addition or removal of 0 05 mm 0 002 in of shim changes the injection timing by approx imately 0 087 rad 0 5 Sealant should be applied to both sides of the soft metal gasket shim Rated Speed Ralado pect Specification 0 30 to 0 33 rad 3000 to 2501 o a Injection Timing EEN E Map 0 26 to 0 30 rad 2500 to 2001 15 to 17 B TD C 0 23 to 0 26 rad Under 2000 13 to 15 B T D C 5 1 2 Shim Identification NOTE Shims are available in thicknesses of 0 20 m
11. Ring Gap Second Ring 0 0118 to 0 0177 in 0 0472 in f 0 15 to 0 30 mm 1 20 mm Oil Rng 0 0059 to 0 0118 in 0 0472 in 1 9 62 11161 1 6 1 Engine Body Continued Ma Factory Specification Allowable Limit Second Ring 0 090 to 0 120 mm 0 15 mm Piston Ring to Piston Ring Groove Clearance 0 00354 to 0 00472 in 0 0059 in Oil Ring 0 040 to 0 080 mm 0 15 mm Clearance 0 0016 to 0 0031 in 0 0059 in Connecting Rod Alignment ee 0 15 to 0 31 mm 0 50 mm Side Clearance 0 0059 to 0 0122 in 0 0197 in Crankshaft O mm Aignment ooon 0 020 to 0 051 mm 0 15 mm cane 0 00079 to 0 00201 in 0 0059 in Crankpin to Crankpin Bearing Crankpin O D e Hy Crankpin Bearing 33 995 to 34 010 mm 1 D 1 33893 to 1 33898 in 0 034 to 0 106 mm 0 20 mm areal 0 00134 to 0 00417 in 0 0079 in Crankshaft J ournal to Crankshaft Bearing OO eee reg ea ME Crankshaft 39 984 to 40 040 mm Bearingl1 1 D 1 57148 to 1 57638 in 0 028 to 0 051 mm 0 20 mm ene aes 0 00110 to 0 00201 in 0 0079 in Crankshaft J ournal to Crankshaft Bearing2 Crankshaft 43 934 to 43 950 mm Flywheel Side J ournal O D 1 72968 to 1 73031 in Crankshaft 43 984 to 44 026 mm Bearing2 1 D 1 73165 to 1 73331 In 0 028 to 0 051 mm 0 20 mm canes 0 00110 to 0 00201 in 0 0079 in Crankshaft J ournal to Crankshaft Bearing3 Crankshaft 39 934 to 39 950 mm Intermediate Journal O D 1 57221 to 1 57284 in Crankshaft 39 984 to 40 026 mm Bearing3 I D
12. model month year and sequence of manufacture as follows A Last 3 Digits in Numerals 1 to 999 Units in Sequence 7th Digit Sequential Numeral or Letter Units Manufactured Alphabetical NumeralorLetter 0t9 A J 58 lt Unit Number Sequence to 19 998 19 999 20997 20 998 21 996 21 997 22 995 6th Digit Alpabetical Letter Month of Manufacture 1st Letter 1 9999 Units 2nd Letter 10 000 19 998 Units Alphabeticalletter AB ICDL EF IGHIJK LMINPIQRIST uv wx vz 5th Digit Alpabetical Letter or Numerals Year of Manufacture Alphabetical letter ornumerals W x Y 1 2 3 4 5 6 71 8 9 Year 98 99 00 01 02 03 04 05 06 07 08 09 Basic model number Table 1 1 Model Chart KUBOTA CARRIER NEW ENGINE MODEL NO MODEL NO PART NO PRIMARY USE REPLACES Z482 E2B CT2 29 TV 26 60001 03 SOLARA Units 26 60001 01 Z482 E2B CT2 29 TV 26 60001 04 SUPRA Units 26 60001 02 7482 E2B ATC 1 CT2 29 TV 96 101 05K ii Z482 E2B TFX 1 CT2 29 TV 96 101 20K ComfortP ro PC 6000 Units D722 E2B CT3 44 TV 26 60000 05 GENESIS Units 26 60000 00 Beginning with Serial Number 5A0001 1 1 62 11161 1 2 ENGINE SPECIFICATIONS Table 1 2 Specification Chart MODEL NUMBER Carrier Kubota CT2 29 TV Z482 E2B CT3 44 TV D722 E2B TYPE Vertical Water cooled 4 cycle IDI diesel BORE X STROKE mm X mm in X in 7 RRA 2 64 X 2 68 TOTAL DISPLACEMENT cm3 cu in 7929 23
13. 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 plasti gage 7 Ifthe measurement is not within the factory specifica tions check the clearances between the crank pin and bearing and between the piston pin and bushing Too CI Factory 0 50 to 0 70 mm Peeler Specification 0 0197 to 0 0276 in 37 3 to 42 2 N m 3 8 to 4 3 kgf m 27 5 to 31 1 ft lbs Tightening Cylinder Head Torque Bolts 62 11161 2 2 DISASSEMBLING AND ASSEMBLING 2 2 1 Draining Coolant Refer to Section 4 2 2 2 Draining and Refilling Engine Oil Refer to Section 3 2 2 3 External Components Alternator Starter and Others 1 Remove the air cleaner and muffler 2 Remove the engine stop solenoid 1 if so equipped 3 Remove the fan 2 fan belt 3 alternator and start er 4 Remove the alternator 5 Remove the starter SEEACABOPOOIE When Reassembling Replace the starter Replace the alternator Replace the fan fan belt alternator and starter NOTE When reinstalling the fan make sure that it Is Seated correctly Check to see that there are no cracks in the fan belt After reinstaling the fan belt be sure to adjust the fan belt tension Refer to Section 4 1 1 Replace the engine stop solenoid 1 if so equipped
14. piston is at TDC feet Sa et ee et j T JEEACAA1POGIA When No 1 piston is past TDC 7 If the clearance is not within the factory specifica tions adjust with the adjusting screw NOTE The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gearcase end After adjusting the valve clearance secure the adjusting screw with the lock nut JEEACA41P0684 1 Cylinder Head Cover A Gear Case End 2 ITC Mark a CT2 29 TV 3 Alignment Mark b CT3 44 TV 1 13 62 11161 1 8 SPECIAL TOOLS Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number 62 03213 1 8 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 8 2 Adapter Kubota 10 mm Part No 07 00179 05 Application Accessory for 07 00179 01 1 8 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 8 4 Replacement Bowl Tester Injector Nozzle Part No 07 00140 10 Application Accessory for 07 00140 00 1 8 5 Adapter Injector Line Part No 07 00036 00 Application Accessory for 07 00140 00 62 11161 1 14 18 SPECIAL TOOLS Continued 1 8 6 Oil Pressure Tester Code No 07916 32032 Application Use to measure lubricating oil pressure
15. terioration or damage is detected 4 After the fuel hose and clamps have been changed bleed air out of the fuel system 2 Energize the electric fuel pump for a period of 10 to 15 seconds orjustlong enough to expel fuel through the air vent cock 3 Close the air vent cock 1 44 CAUTION Stop the engine when attempting to check NOTE and change the fuel line 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 62 11161 1 12 1 7 6 Valve Clearance NOTE Valve clearance must be checked and adjusted when the engine is cold 1 Remove the valve cover 1 2 Align the ITC mark line 2 on the flywheel and pro jection 3 on the housing so thatthe Number 1 piston comes to compression top dead center TDC 3 Check the following valve clearance marked with at TDC using a feeler guage 4 If the clearance is not within the factory specifica tions adjust with the adjusting screw 5 Then turn the flywheel 6 28 rad 360 and align the 1TC mark 2 on the flywheel and alignment mark 3 on the rear end plate so that the No 1 piston come to the overlap position 6 Check the following valve clearance marked with past TDC using a feeler guage Valve Piston tocatonin Cynder IN ex When No 1 piston is at TDC Pez When No 1 piston is past TDC Hee Piston Location in Cylinder When No 1
16. the grip ofa ammer 5 Repeat the procedure for the other cylinder s 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 LJ N NOTE If re installing the original piston assemblies into the engine be sure that they are returned to their original cylinder When installing the piston into the cylinder place the gaps of allthe piston rings as shown in the figure Carefully insert the pistons into the cylinders using the piston ring compressor 1 When inserting the piston into the cylinder avoid 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 d is on top of the piston 1 Piston Ring Compressor a 0 785 rad 45 a A Top Ring Gap b 0 785 rad 45 B Second Ring Gap c 1 57 rad 90 C Oil Ring Gap d Mark D Piston Pin Hole 3TMABAB1 POAGF 62 11161 2 14 2 2 7 Piston and Connecting Rod Continued 2 2 7 C Piston Ring and Connecting Rod 1 Remove the piston rings 1 2 3 2 Remove the piston pin 7 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 o
17. the spring up Remove the brush holder Draw out the armature 10 and yoke 11 from the housing Draw out the shaft assembly 5 with the drive lever 6 and overrunning clutch 7 from the housing When Reassembling Tiahtenin 5 9 to 11 8 Nm oie ie C Terminal Nut 0 6 to 1 2 kgf m 4 3 to 8 7 ft lbs 6 5 62 11161 6 4 STARTER SERVICING SEEABABIP188A SEJABAA1PO52A SEEABABIP185A JEEABAB1P189A 62 11161 6 6 6 4 1 Overrunning Clutch 1 Inspect the pinion for wear or damage 2 If there is any defect replace the assembly 3 Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the crank ing direction 4 If the pinion slips or does not rotate in both directions replace the overrunning clutch assembly 6 4 2 Armature Bearing 1 Check the bearing for smooth rotation 2 If it does not rotate smoothly replace it 6 4 3 Brush Wear 1 Ifthe contactface of the brush is dirty or dusty clean it with emery cloth 2 Measure the brush length A with a vernier caliper 3 If the length is less than the the allowable limit re place the yoke assembly and the brush holder Factory 16 0 mm Specification 0 630 in CT2 29 TV Allowable 10 5 mm Brush Limit 0 413 in Length A Factory 14 0 mm Specification 0 551 in CT3 44 TV Allowable 9 0 mm Limit 0 354 in 6 4 4 Solenoid 1 Check the continuity across the C terminal and the B termi
18. 0 15 mm Crank Gear i l Limit 0 0059 in Factory 0 047 to 0 123 mm Backlash Specification 0 00185 to 0 00484 in Idle Gear Allowable 0 15 mm Cam Gear D Limit 0 0059 in Backlash Factory 0 046 to 0 124 mm Idle Gear S pecification 0 00181 to 0 00488 in Injection Pump Allowable 0 15 mm Gear Limit 0 0059 in Factory 0 041 to 0 123 mm Backlash Specification 0 00161 to 0 00484 in Crank Gear l Allowable 0 15 mm Oil Pump Gear Limit 0 0059 in 2 3 2 6 Idle Gear Side Clearance 1 Seta dial indicator with its tip on the idle gear 2 Move the gear frontto rear to measure the side clear ance 3 If the measurement exceeds the allowable limit re place the idle gear collar Factory 0 20 to 0 51 mm Idle Gear Specification 0 0079 to 0 0201 in S ide Allowable 0 80 mm Clearance att Limit 0 0315 in 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 15 to 0 31 mm Camshaft Specification 0 0059 to 0 0122 in S ide Allowable 0 50 mm Clearance a Limit 0 0197 in 62 11161 2 3 2 Timinc 62 11161 Gears Camshaft and Fuel Camshaft Continued 2 26 2 3 2 d Camshaft Run Out 1 Supportthe camshaft with V blocks ona surface plate at both end journals 2 Seta dial indicator with its tip o
19. 1 and the brush with an ohmmeter 2 If there is no continuity replace the yoke assembly 3 Check the continuity across the brush 2 and the yoke 3 with an ohmmeter 4 If there is continuity replace the yoke assembly JEEABAB1P190A JEEABAB1P191A 1 Lead 3 Yoke 2 Brush 62 11161 6 8 Battery bearing case 2 16 2 18 C camshaft 2 11 2 25 2 26 camshaft fuel 2 12 compression pressure 2 1 connecting rod 2 13 2 15 2 29 coolant i 2 2 4 1 coolant level 1 12 cooling system 4 1 crankshaft 2 30 crankshaft assembly 2 17 crankshaft gear 2 12 crankshaft sleeve 2 35 cylinder 2 36 cylinder head 2 3 2 4 2 19 D delivery valve 5 2 dye penetrant 2 19 electrical system 6 1 engine oil 1 12 2 2 3 1 F Fan Drive Pulley 2 10 flywheel 2 16 fuel injection 2 3 fuel system 5 1 fuel system bleeding 1 12 G Gear Case 2 10 glow plug 6 1 INDEX Identification 1 1 idle gear 2 11 injection nozzle 5 3 5 4 injection timing 5 1 L lubricating system 3 1 O oil filter 3 2 oil level 1 12 3 1 oil pressure 3 2 oil pump gear 2 12 oil pump service 3 3 p piston 2 14 2 28 2 29 piston ring 2 15 Pump element 5 2 push rod 2 24 R radiator 4 2 radiator cap 4 2 relief valve 3 3 rocker arm 2 23 S Safety Precautions Specific Warning and Cautions Statements ii Specifications 1 2 Starter service 6 6 6 7 6 8
20. 29 23 719 43 88 BRAKE SAE Intermittent H P HORSEPOWER kW HP RPM 3 12 5 3600 14 0 18 0 3600 FRING ORDER a y S INJECTION PRESSURE Valve Opening Pressure RECOMMENDED BATTERY CAPACITY 12V 28AH equivalent 12V 36AH equivalent 5 Hour a CHARGING GENERATOR sid GENERATOR 12V POW 12V E AV BOW FUEL Diesel Fuel No 2 D ASTM D975 LUBRICATING OIL Q uality Better Than CF Class API SAE 10W 30 or 15W 40 2 5 L 2 64 U S Quarts LUBRICATING OIL CAPACITY 3 8 L 4 02 U S Quarts 3 3 L 3 5 U S Quarts TFX 1 Only Weight DRY kg lbs DRY g Ibs 53 1 117 1 P8392 1 139 1 13 73 MPa 140 kgf cm 1991 psi S ee paragraph 1 7 2 62 11161 1 2 1 2 1 E2B ENGINE Carrier Kubota supply diesel engines conforming to federalemission regulations The emission controls that have been put into effect have been stepped up to the second stage Carrier Kubota has executed the improvement in the engines to conform to this regulation In order to discriminate between engines conforming to Tier 1 Phase 1 requirements and those conforming to Tier 2 Phase 2 requirements we have adapted E 2B as a new model name for the engines conforming to Tier2 Phase 2 regulations In the after sale services for Tier 2 Phase 2 engines only use the dedicated parts for E2B models and carry out the maintenance services accordingly 1 2 2 CYLINDER NUMBER SEEACAA1P067A The cylinder numbers of die
21. 29 62 11161 2 3 4 Crankshaft 3TMABAB1P074A Mil STAAAADIPOTSA 62 11161 2 30 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 ea the end play by pulling the crankshaft for ward 4 If the measurement exceeds the allowable limit re place the thrust bearings 5 If the new thrust bearings do not correct the exces sive end clearance condition over size thrust bea rings may be necessary Factory 0 15 to 0 31 mm Crankshaft Side Specification 0 0059 to 0 0122 in Clearance Allowable 0 50 mm Limit 0 0197 in Reference Oversize dimensions of thrust bearing 0 2mm Thrust Bearing 1 02 0200S 25 36430 01 0 008 in Thrust Bearing 2 02 020 0S Reference Oversize dimensions of crankshaft journal 0 2mm 0 0008 in 0 4mm 0 0016 in Di A 23 40 to 23 45 mm 23 80 to 23 85 mm S 0 9134 to 0 9154 in 0 9213 to 0 9232 in Di E 46 1 to 46 3 mm 46 3 to 46 5 mm Menci n 1 815 to 1 823 in 1 823 to 1 831 in 1 8 to 2 2 mm radius 1 8 to 2 2 mm radius Dimension C 0 071 to 0 087 in 0 071 to 0 087 in radius radius The crankshaft journal must be fine finished to higher than 0 8 S 2 3 4 6 Crankshaft Alignment 1 Support the crankshaft with V blocks on a surface plate at both end journals Seta dial indicator with Its tip on the intermedi
22. 3 950 mm 39 734 to 39 750 mm 39 534 to 39 550 mm A Specification 1 72968 to 1 73031 in Dimension dia dia Flywheel Side C 1 56433 to 1 56496 in 1 55646 to 1 55709 in dia dia 1 72181 to 1 72244 in 1 71394 to 1 71470 in dia dia Crankshaft Factory 39 984 to 40 026 mm The crankpin must be fine finished to higher than 0 8 S Bearing 3 1 D Specification 1 57417 to 1 57583 in Holes to be de burred and edges rounded with relief Crankshaft Journal O D Intermediate Factory 39 934 to 39 950 mm Specification 1 57221 to 1 57284 in Crankshaft Factory 43 984 to 44 026 mm dia dia Bearing 2 1 D Specification 1 73165 to 1 73331 in 43 734 to 43 750 mm 43 534 to 43 550 mm Dimension D 62 11161 2 34 2 3 4 Crankshaft Continued JEEACABIPOZOA 2 35 2 3 4 9 Crankshaft Sleeve Wear 1 Check the wear on the crankshaft sleeve 1 2 Ifthe wear exceeds the allowable limit or if the engine oil leaks replace the crankshaft sleeve 1 S W Allowable 0 1 mm SERS REAS Limit 0 004 in 2 3 4 h Replacing Crankshaft Sleeve 1 Remove the crankshaft sleeve using a special use puller set 2 Set the sleeve guide 4 to the crankshaft 2 3 Heat the new sleeve to a temperature between 150 to 200 C 302 to 392 F and fix the sleeve on the crank Shaft 2 as shown in the figure 4 Press fit the sleeve using the auxiliary socket for pushing 3 NOTE Install the sleeve with the largest chamfered
23. 62 11161 2 16 JEEACAA1PO7BA 2 2 8 Crankshaft Assembly NOTE Before disassembling check the side clear ance of the crankshaft Check it during reas sembly 1 Remove the two main bearing case bolts 1 2 Pull out the crankshaft being careful not to damage the crankshaft bearing When Reassembling Clean the oil passages of the crankshaft with compressed air Install the crankshaft assembly aligning the bolt hole of the main bearing case screw 2 with the bolt hole of the crankcase When tightening the main bearing case 2 apply oil to the main bearing case bolt 2 1 and tighten by hand before tightening to the specific torque If any resistance Is encountered while tightening re align the bolt holes Tightening Main Bearing aedeagal Torque Case Bolt 2 eo Hn 19 5 to 22 4 ft lbs 1 Main Bearing Case a 2482 E2B Bolt 2r b D722 E2B 62 11161 2 2 8 Crankshaft Continued 2 2 8 d Main Bearing Case Assembly 1 Remove the two main bearing case screws 1 7 and remove the main bearing case assembly 1 1 being careful with crankshaft bearing 3 4 2 Remove the main bearing case assembly 2 2 and the main bearing case assembly 3 as above Keep in mind that the thrust bearing 6 is installed in the main bearing case assembly 3 When Reassembling 7 JEEACAA1PO818B Clean the oil passages in the main bearing cases Apply clean engine oil on the bearings Reinstall the main bearing ca
24. A a eae oes 3 1 cel AA PU O A O 3 2 Sie Engine OIIP FessuUrS ii A A A A ad pace 3 2 Silo REE VIVO id ds A AAA IIA O 3 3 az DIEPUME SERVIC E smc sus ais nt raton 3 3 5 2 ROTO Lope CIGAlanCe oegi moeras ral dao ar dos e a 3 3 3 22 ROW OC Over Clear aNG rra rr a ET arena eek 3 3 COOLING SVS TE Mia AA aa 4 1 44 CHECKING AND ADIUS TING 000 A A ADA AAA ARA As 4 1 a el DE A ds e AN aa eae Rn had ae oa ta a AR 4 1 4 1 2 Fan Belt Damage and Wear oo ocoococccccnno eet e tent e tebe e nrnna 4 1 44 3 CNECKING COOLER A 4 1 Add J Tali OAM sean or da pato dre tt dois 4 1 Ale A E AAA 4 2 AO Raddio ii A AA NE AAA SAA AA ee 4 2 4 1 7 Thermostat Opening Temperature coooccocccconcnr ete n eet n ete nents 4 2 42 SERVICING sipat ace pias eS E ata Ae macht aoa Shar Ra ES aS eae awe ae oak 4 3 dz At WMemMOs tains SCINOIY sare KG ianen neuen eG bal om oia 4 3 4 2 2 Water Pump Assembly 00 ccc ccc cet eee eet e eet e ete nent enn nnes 4 3 62 11161 ii PARAGRAPH NUMBER Page FUEL SYSTEM scrieri riren inae erie eae euiaean tae ee aa bE eae anna aaa 5 1 SL GHECKING AND ADI LUSTING rr 5 1 Dene AMENA ia a ind ec ee 5 1 SLA MM dE NUNCA ii II A AA A A AAA ea eat 5 1 LS 2 mp lementruUe Seal Lira 5 2 5 1 4 Delivery Valve Fuel Seal oooomommoccccnar eee eee eee eens 5 2 2 INI ECTION NOZZLE 20d 5 3 5221 INOZZIE gt Pravin GONG NariG ow oe oe ree ce RG as errs y 5 3 5 2 2 Nozzle Injection Pressure ica
25. AAA ata A Rist 1 11 16 3 GOING SY Se Misa id res 1 11 LOA PUE Yesa id ee ee ee ee ae ee 1 11 LOS BIGCHICAlS St Maier sacha bane sths bite aks e a 1 12 L7 CHECK AND IMAINTENAN CEscurerposir arteria doen 1 12 1 7 1 Checking Engine Oil Level cc ete teen tent eee e A neenees 1 12 LAA Se MaNGINGie MOMS OU es 8s Siete S areca AAA AA A 1 12 Lro CHECKING CONE LEVE vs aros risa anode ANA EA aN Gd A MANES aa ear 1 12 1 44 CHeckind FUG HOSE airera tiroen a taa wei dt ake Pe ate a 1 12 EO SB ICC AIG UG Sy Se Ml eased eG en o rr areata eater eS balas 1 12 LLO Vave ClISarate arrasa ata ears baa aaa eae oe ea ee aA 1 13 Le DPE CIAL OOS 28 5 saa A eer tea ae bee ee ha eee be aa ae ee 1 14 1 8 1 Diesel Engine Compression Tester Glow Plug ccc ccc eee teen e eens 1 14 1 02 Adapter Kubota TOMIN i 5 4 eso oath iw alg ara A A ee A 1 14 1 6 3 Tester IMector Nozio TEE 1 14 1 8 4 Replacement Bowl Tester Injector Nozzle 10 cette tenet eens 1 14 1 8 5 Adapter Injector LING iii A AAA NA A BE Me ae 1 14 1000 DP POSS UNG Tester iia datada ea eee alee 1 15 1 8 7 Auxiliary Socket For Fixing Crankshaft Sleeve oo tenet nee ees 1 15 L8G Guage Bel TENSION coria 1 15 o OSC BIE AA eE E O O a oy ace eae at eis ee a ee eae Ce 1 15 Lo LO RUDDEE BANC siria daria eevee he beeen ae 1 15 1 011 Valve Guide Replacing TOO sita NA AAA 1 16 126 12 BUSHING WeEDIACING TOOLS sata a e a rra 1 16 10 03 Flywheel Sto De nasa a AS A ADS EAN AO 1 16 1
26. ADBABI1PO17D 44 WARNING 4 1 1 V Belt Tension When removing the radiator cap wait at 1 Measure the deflection A by depressing the belt least ten minutes after the engine has halfway between the fan drive pulley and alternator stopped and cooled down Otherwise hot pulley at the specified force Refer to1 6 3 water may discharge from the radiator 2 If the tension is not within the factory Jy ous G scalding anyone nearby o mor ams 2 Remove the radiator cap and check to see that the U f belt tensi Cai pais de coolant level is just below the port se of a belt tension gauge arrier Pa 07 00203 00 or a belt tension tester Carrier Part a leche eat att a erg that the coolant 07 00253 00 is advised 3EEABAB1P015D 3 Ifthe coolant level is too low check the reason for the lost coolant a If coolant loss is due to evaporation add only clean soft water b If coolantloss is due to a leak repair the leak and add a coolant mixture of the same type and specification that is in the system If the coolant brand cannot be identified drain out all of the remaining coolant and refill with a totally new mix NOTE When adding coolantto the system airmustbe vented from the engine coolant passages by jig gling the upper and lower radiator hoses When the engine is installed in an APU An air 4 1 2 Fan Belt Damage and Wear bleed screw is provided in the thermostat hous ing Be sure to close the radiator cap securely
27. And Bolt S43C S48C Refined 62 11161 1 4 1 5 TROUBLESHOOTING Symptom Probable Cause Solution Reference Replenish fu Air in the fuel system 1 7 5 Change fuel and Water in the fuel system repair or replace fuel 1 7 5 system Fuel pipe clogged 1 7 5 F uel filter clogged Clean or change Excessively high viscosity of fuel or engine oil Use specified fuel or at low temperature engine oll Fuel with low cetane number Use specified fuel i leak due to loose injection pipe retaining Tighten retaining nut sE Engine Does Not Incorrect Injection timing djus Stat Fuel camshaft wom Injection nozzle clogged 5 2 1 5 2 2 Injection pump malfunctioning Seizure of crankshaft camshaft piston cylinder or bearing Repair or Replace Replace head gasket tighten Compression leak from cylinder cylinder head screw glow plug and nozzle holder 7 Correct or replace Improper valve timing timing gear Piston ring and cylinder worn Excessive valve clearance Adiust Battery discharged Charge Starter Does Not Starter malfunctioning Repair or replace 6 2 6 3 Run Wiring disconnected connect Fuel filter clogged or dirty Clean or change Air cleaner clogged or dirty Clean or change ae a leak due to loose injection pipe retaining Tighten retaining nut Engine Revolution 3 Is Not Smooth Injection pump malfunctioning Replace 226a Incorrect nozzle injection pressure Replace Injection nozzle stuck or clogged G
28. D maa Toa 4 Slightly extended the start spring 7 and install the in 7 jection pump 4 NOTE Make sure the control rod 6 makes contact with the idling adjusting spring 2 Make sure the injection pump control rack pin 5 engages the fork lever 1 A length of string passed thru the governor spring 14 can be used to retrieve the spring if it unhooks from both the specific tool and the speed control plate 5 Hook the start spring 7 to the bracket 3 using the specific tool 8 6 Hook the governor springs small and large 14 to the governor lever 13 using the specific tool and in Stall the speed control plate 11 Use copper washers with the two screws 12 when securing the speed control plate 7 Install the engine stop solenoid rod 15 into the guide of the cylinder block 10 and secure the engine stop solenoid 16 with hex head bolts NOTE Be careful not to stretch the start spring 7 too far or you risk permanently deforming it Be sure the start spring 7 is attached to the bracket 3 Sealant is applied to both sides of the shims gasket cement is not required for assembly When replacing the old gasket shims with new always replace with the same thickness and number of gasket shims Addition or reduction of shim 0 05 mm 0 0020 in delays or advances the injection timing by approximately 0 5 1 Fork Lever 9 Fork Lever Hole 2 Idling Adjusting Spring 10 Guide Hole
29. If the cap is loose or improperly closed coolant may JEEABABIPOIGA 1 Check the fan belt for damage 2 If the belt is damage in any way replace it 3 Check if the beltis worn and sunk in the pulley groove leak out and the engine could overheat 4 If the fan belt is worn and deeply sunk in the pulley Do not use an antifreeze and scale inhibitor at groove replace it the same time A Good B Bad Never mix differenttypes or brands of coolants 4 1 62 11161 4 1 4 Draining Coolant 1 Turn the engine off 2 Remove the radiator cap 4 1 CHECKING AND ADJ USTING Continued JITAABABI1POGOA 31AAMAB1POG1A 62 11161 4 2 3 Open the coolant drain cock or remove the coolant drain plug and drain the coolant into a proper recep tacle bucket 4 1 5 Radiator Cap 1 Attach the radiator cap to a pressure tester 2 Apply pressure and observe the time for the pressure to fall 3 If the measurement is less than the factory specifica tion replace the cap More than 10 seconds for pressure fall from 88 to to 59kP a 0 9 to 0 6 kgf cm 13 to 9 psi Pressure Falling Factory Time Specification 4 1 6 Radiator 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 thatthe speci fied pressure will hold 157 kPa 1 6 kgf cm 23 psi Radiator Leakage Factory Test Specification 4 1 7 Thermos
30. Reassembling Replace the copper gasket s and heat seal s with a new one s 49 0 to 68 6 N m 5 0 to 7 0 kgfm 36 2 to 50 6 ft lbs Overflow Pipe 19 6 to 24 5 Nm Assembly 2 0 to 2 5 kgf m Retaining Nut 14 5 to 18 1 ft lbs Nozzle Holder Assembly Tightening Torque 7 85 to 14 7 Nm Glow Plug 0 8 to 1 5 kgfm 5 8 to 10 8 ft lbs 62 11161 2 2 4 Cylinder Head And Valves Continued 1 Rocker Arm Bracket Bolts 2 Rocker Arm Assembly A SEEABAB1P062B 1 C o 60 007 Ch DA po JEEACAM1PO73A4 1 Hose Clamp b CT3 44 TV 2 Water Return Hose A Gear Case Side 3 O ring B Flywheel Side a CT2 29 TV 62 11161 2 4 2 2 4 d Rocker Arm and Push Rod 1 Remove the rocker arm bracket mounting bolts 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 end are properly engaged with the dimples NOTE After instaling the rocker arm be sure to adjust the valve clearance Refer to Section 1 7 6 Tiahtenin Rocker Arm 9 8 to11 3 Nem ca El Bracket Mounting 1 00 to 1 15 kgfm 9 Bolt 7 2 to 8 3 ft lbs 2 2 4 e Cylinder Head 1 Loosen the hose clamps 1 and remove the water return hose 2 2 Remove the cylinder head bolts in the order of a 10 to 1 or b 14 to 1 3 Lift up the cylinder head and remove 4 Remove the cylinder head gasket and O ring 3 When Reassembling Replace th
31. Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping until the seated width becomes more than 70 of the total contact area a 5 Fact 7 l SEEACAAIPOSSA Valve Seat Angle actory 0 785 uae Specification 45 1 Valve Seat Cutter a Identical Dimensions A Check Contact b Valve Seat Width B Correct Seat Width c 0 262 rad 15 C Correct Seat Surface d 0 785 rad 45 D Check Contact 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 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 70 repeat valve lapping again SEEACAAIPO44A NOTE When valve lapping is performed be sure to check the valve recession and adjust the valve clearance after assembling the valve 62 11161 2 22 2 3 1 Cylinder Head And Valves Continued 2 3 1 1 Free Length and Tilt of Valve Spring 1 Measure the free length A of the valve spring with vernier calipers If the measurement is less than the allowable limit replace 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 th
32. Starter 2 cylinder 6 2 6 3 Starter 3 cylinder 6 4 6 5 Index 1 62 11161 INDEX T valve clearance 1 13 valve guide 2 21 tappets 2 5 2 24 thermostat 4 2 timing gear 2 25 valve seat 2 21 valve spring 2 23 timing gear camshafts 2 7 2 8 2 9 2 10 valves 2 5 2 6 2 20 2 22 2 11 2 12 Torque Specification 1 4 V water pump 4 3 v belt 4 1 water pump assembly 2 7 2 8 2 9 62 11161 Index 2 Y Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer amp Container Product Groups P O Box 4805 Syracuse N Y 13221 USA www carrier transicold com A member of the United Technologies Corporation family Stock symbol UTX TRANSICOLD 2007 Carrier Corporation DPrinted in U S A 0707
33. Surface facing outward 1 Crankshaft Sleeve 3 Auxiliary Socket For 2 Crankshaft Pushing 4 Sleeve Guide 62 11161 2 3 5 CYLINDER SEEACAAIPO it s SEEABAB1P155A 0 Top a Right angled to A Middle Piston Pin B Bottom skirt b Piston Pin Direction 8 e 2 e a k e JEEABAB1P1564 1 Cylinder I D 2 Oversize Cylinder I D before correction 62 11161 2 36 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 maxi mum and minimum l D s 2 Determine the difference maximum wear between the maximum and minimum D s 3 Ifthe wearexceeds the allowable limit bore and hone to the oversize dimension Refer to Section 2 3 5 b 4 Visually check the cylinder wall for scratches If deep scratches are found the cylinder walls should be bored Refer to Section 2 3 5 b Factory 67 000 to 67 019 mm Specification 2 63779 to 2 63854 in Cylinder Wear Allowable 67 169 mm Limit 2 64445 in 2 3 5 6 Correcting Cylinder Oversize 0 25 mm 1 When the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension o 67 250 to 67 269 mm Cylinder 1 D de 2 647644 to 2 64839 Specification n Maxi W Allowable 67 400 mm On Limit 2 65354 in Hone to 2 2 to 3 0 mm uR max Finishin 0 000087 to 0 00012 in uR max 2 Replace the piston and piston rings with oversize ones 0
34. aring clearance between crankshaft Massin and crankshaft bearing 1 er cade 25 343890 02 020US 0 008 in 0 4 mm Crankshaft Bearing 1 Reference Undersize dimensions of crankshaft journal 0 2mm 0 008 in 0 4mm 0 016 in 1 8 to 2 2 mm radius 1 8 to 2 2 mm radius Dimension A 0 071 to 0 087 in 0 071 to 0 087 in radius radius 1 0 to 1 5 mm dia 1 0 to 1 5 mm dia Dimension B 0 0394 to 0 0591 in 0 0394 to 0 0591 in dia dia 39 734 to 39 750 39 534 to 39 550 mm dia mm 1 56433 to 1 56496 1 55646 to 1 55709 in dia in dia The crankshaft journal must be fine finished to higher than 0 8 S 3TMABAB1PO79A Dimension C 62 11161 2 32 2 3 4 Crankshaft Continued N uyy 3TMABAB1 P0808 1 Seam 2 Crankshaft Bearing 1 3 Cylinder Block A Dimension 2 3 4 e Replacing Crankshaft Bearing 1 A When Removing 1 Press outthe crankshaft bearing 1 2 using a crank Shaft bearing replacing tool Refer to Special Tools 1 8 14 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 replacing tool press in the new bearing 1 2 so that its seam 1 is toward the exhaust manifold side NOTE Be sure to align the bushing so that the oil hole in the bushing aligns with the oil port Dimensi Factory 0 0 to 0 3 mm S pecification 0 0 to 0 118 in 62 11161 2 3 4 Crankshaft Continu
35. ate journal perpendicular 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 Section 2 2 7 b RN 4 Remove the cap again VIO 5 Measure the amount of the flattening with the scale to Hal A get the clearance A 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 0 020 to 0 051 mm Crankpin Specification 0 00079 to 0 00201 in Connecting Rod Allowable 0 15 mm Clearance ee Limit 0 0059 in Factory 33 959 to 33 975 mm EEN 1 33697 to 1 33760 in Connecting Rod Factory 33 995 to 34 010 mm Bearing I D Specification 1 33893 to 1 33898 in Reference Undersize dimensions of connecting rod bearing 0 2mm Connecting Rod 0 4mm Connecting Rod 0 016 in Bearing 25 34386 04 040US Reference Undersize dimensions of cra
36. ble limit resurface or replace the head NOTE Do not measure the combustion chamber Check the valve recessing after after resurfac ing the head Cylinder Head Allowable 0 05mm Surface Flatness Limit 0 0020 in 2 3 1 6 Cylinder Head Cracks 1 Cylinder head crack s can be found with using a oo test procedure using a dye pene trant kit 2 Clean the cylinder head surface using a good quality degreaser and detergent 2 3 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 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 62 11161 JEEACAA1POS44 1 Cylinder Head Surface A Recess B Protrusion SEEABAB1P115A SEEABAB1P116A 62 11161 2 3 1 Cylinder Head And Valves Continued u 2 20 2 3 1 c Valve Recessing 1 Clean the cylinder head surface 1 valve face and valve seat 2 Insert the valve into the head making certain that the valve Is fully seated 3 Measure the valve recession A with a depth gauge 4 If the measurement exceeds the allowable limit re place the valve 5 If the measurement still exceeds the allowable limit replace the cylinder head 0 10 protrusion mm to 0 10 recessing mm 0 0039 protrusion in to 0 0039 recess
37. ct oil to the engine 8 Add oil until the engine oil level is up to the upper line on the dipstick 2 NOTE Replace the engine oil filter with every oil change 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 MIL L 46152 MIL L 2104C or API classification CG 4 or CH 4 Cl oils Use the proper SAE Engine oil according to the ambient temperatures Above 25 C 77 F Ja SAE 30 or 15W 40 0 to 25 C 32 to 77 F SAE 20 or 10W 30 NOTE With emission controls now in effect the CG 4 or CH 4 Cl 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 or 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 ee POC KT O Recommended X Not Recommended 62 11161 3 1 CHECKING AND ADj USTING Continued JEEACAM1POOSA 62 11161 3 2 3 1 3 Changing Oil Filter 44 CAUTION Stop the engine when preparing to change the engine oil filter 1 Remove the oil filter cartridge 1 with a filter wrench 2 Apply a slightcoatof oil onto the new oll filter cartridge gaske
38. d ball for damage 3 If damaged replace 4 Check the free length of the spring 5 If itis less than the allowable limit replace Spring Free Specification 1 26 in Limit 1 10 in Oil Filter Base iio ll Tightening Torque e pee cdo Fee 29 0 to 36 3 ft lbs 3 2 1 Rotor Lobe Clearance 1 Measure the clearance between lobes of the inner ro tor and the outer rotor with a feeler guage 2 Measure the clearance between the outer rotor and the pump body with a feeler guage 3 If the clearance exceeds the factory specifications replace the oil pump rotor assembly Inner O uter Factory 0 03 to 0 14 mm Rotor Clearance Specification 0 0012 to 0 0055 in rae oa Factory 0 07 to 0 15 mm bd Specification 0 0028 to 0 0059 in Clearance 3 2 2 Rotor to Cover Clearance 1 Put a strip of plastigage onto the rotor face use a small dab of grease to hold the plastigage in place 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 R otor Cover Factory 0 075 to 0 135 mm Clearance Specification 0 00295 to 0 00531 in 62 11161 SECTION 4 COOLING SYSTEM 4 1 CHECKING AND ADJ USTING 4 1 3 Checking Coolant Level NOTE When the engine is installed in an APU follow OEM vehicle instructions as to checking adjust ing engine coolant levels 1 Turn the engine off JEE
39. daria ade diia aria a e i 9 3 D2 Vale Seat LIGMMICSS 1 ASA AA eee E E ea ARCOS 5 4 32A NOZZE TA ONG SU oras A E a A ig ah Pe SAR eae 5 4 ELECTRICAL SYSTEM ciori EREU Ea seers 198 ii aa 6 1 E GLOWPLUG iria taa tati ici 6 1 OL Lead Terminal Voltage criador did ra 6 1 6 2 GIOW PUG CONUNUILY seirer iea AAA bee eS See eda 6 1 2 pe eames 2 cad 2 a Oc ne ERA AA 6 2 02 MOU TES sora ora ado 2 oe a dico oa te tae Pe Seca de ones 6 2 6 2 2 MaqgneucSWiCh Testi detache Ghee bie bobeede the borate a a a 6 2 OZ A be two ayes bea oad eee bP esas amie a eRe eee pees A 6 3 63 STARTER AGT 3244 1 da ari A ATA A AAA a AA AAA 6 4 Ovo MOLOr TOS aa rr ei il 6 4 6 3 2 Magnetic Switch Test o oooooocooncrrrnr eee eet e eet e ete ee eteneennnnes 6 4 04 STARTER SERVICING 54 9 8 vee di ota coke a a ede Oe idee ew id 6 6 Dee OVER UNM GUC inc scons Conon o OR 6 6 6 4 2 Armature Bearing A eae eee nia ede dare an 6 6 64 3 ADUCE td aie beak AAA NS AA ARA ATA AAA Be 6 6 Dn SOIENO dare no ria iaa 6 6 Oo BRUSWHOIGCl sarao ds rs we at ala ela doo 6 6 OO AMAU taria a A A A A A AT ADO 6 7 A O AA 6 8 iii 62 11161 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 pretrip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Please stay clear of a
40. ds the allowable limit re place the bushing Factory 0 020 to 0 084 mm Idle Gear Journal Specification 0 00079 to 0 00331 in Clearance Allowable 0 10 mm Limit 0 0039 in Idle Gear J ournal Factory 19 967 to 19 980 mm O D Specification 0 78610 to 0 78661 in Idle Gear Bore Factory 20 000 to 20 051 mm I D Specification 0 78740 to 0 78941 in 2 3 2 h Replacing Idle Gear Bushing A When Removing 1 Press outthe bushing using an Idle Gear Bushing Re placing Tool B When Installing 1 Clean a new idle gear bushing and the idle gear bore and apply engine oil to both 2 Using the idle gear replacing tool press in the new bushing to the specified dimension see B 62 11161 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 20 000 to 20 013 mm Piston Pin Bore Specification 0 78740 to 0 78791 in I D Allowable 20 05 mm Limit 0 7894 in 2 3 3 b 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 Ifthe 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 S ma
41. e cylinder head gasket with a new one Install the cylinder head taking care notto damage the O ring 3 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 a 1to 10 orb 1to 14 R etighten the head bolts after running the engine for 30 minutes 37 3 to 42 2 N m a ea a 3 8 to 4 3 kgfm a 27 5 to 31 1 ft lbs 2 2 4 Cylinder Head And Valves Continued 2 5 2 2 4 f Tappets 1 Remove the tappets 1 from the crankcase 2 Visually check the tappets for any abnormal camshaft contact wear pattern If unusual wear damage has occurred replace the tappet 3 Coat the tappets with engine oil before reinstalling them back into the crankcase NOTE The tappets must always be reinstalled in their Original bores 2 2 4 9 Valves 1 Remove the valve caps 2 2 Remove the valve spring collet 3 pushing the valve Spring retainer 4 by the valve spring compressor 1 3 Remove the valve spring retainer 4 valve spring 5 and valve stem seal 6 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 3 lightly tap the stem with a plastic hammer to assure the collets have Seated on the valve stem NOTE When re installing valves into the cylinder head make sure that they are re i
42. e entire surface of the valve spring for defects If any are found replace it Factory 31 3 to 31 8 mm Specification 1 232 to 1 252 in Free Length A Allowable Limit ne owable Limi 1 118 in l P 1 2 mm Tilt B Allowable Limit 0 047 in 2 3 1 Valve Spring Setting Load 1 Place the valve spring on a tester and compress It to the same length it s 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 SEEABABIP 1216 Factor 64 7 N 27 0 mm S on 6 6 kgf 27 0 mm Setting Load i 14 6 lbs 1 063 in Setting Length 54 9 N 27 0 mm Allowable Limit 5 6 kgf 27 0 mm 12 3 lbs 1 063 in JEEABAB1P122A 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 rockerarm 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 3TAAAAD1POGDA Factory 0 016 to 0 045 mm Oil Clearance Specification 0 00063 to 0 00177 in Rocker Arm Allowable 0 15 mm Shaft NN Limit 0 0059 in Rocker Arm Factory 10 473 to 10 484 mm Shaft O D Specification 0 41232 to 0 41276 in Factory 10 500 to 10 518 mm ASEOS 0 41339 to 0 41410 in
43. e oil pump gear 6 2 Remove the oil pump mounting bolts then the oil pump 5 3 Remove the collar 4 O ring 3 and crankshaft oil Slinger 2 4 Remove the crankshaft gear 1 with a puller When Reassembling Begin reassembly by installing the crankshaft gear first Install the collar 4 after aligning the marks on the gear See 2 2 6 e Replace the oil pump Tightening Oil Pump a va Torque Mounting Bolt l ay 13 0 to 15 9 ft lbs 1 Crankshaft Gear 4 Crankshaft Collar 2 Crankshaft Oil Slinger 5 Oil Pump 3 O ring 6 Oil Pump Gear 2 2 7 Piston and Connecting Rod 2 2 7 a Connecting Rod 1 Remove the connecting rod caps 1 using a bihexa gonal 8 mm socket When Reassembling Align the marks a with each other Face the marks toward the injection pump z Apply engine oil to the ero rod bolts and lightly SEEACAAIPO75A S i e screw them in by hand then tighten to the specified torque If the connecting rod bolt does not screw in smoothly clean the connecting rod and bolt threads 26 5 to 30 4 N m es a i Rod 2 7 to 3 1 kgfm a 19 5 to 22 4 ft lbs 1 Connecting Rod Cap a Mark 2 13 62 11161 2 2 7 b Pistons 1 Completely remove the carbon ridge at the top of the cylinder walls Remove the the connecting rod cap Turn the flywheel and bring the piston to top dead center 4 Push the piston out by lightly tapping the connecting fi from the bottom of the crankcase with
44. ed 3TMABAB1P081A 3EEABAB1P152B 2 3 4 f Crankshaft J ournal to Crankshaft Bearing Clearance 1 Puta strip of plastigage on the center of the crank Reference Shaft journal 2 Install th tighten the bolts t j Oversize dimensions of crankshaft bearing 2 and 3 0 2 a e bearing case and tighten the bolts to speci mm 0 008 in and 0 4 mm 0 016 in 3 Remove the bearing case again 4 Measure the amount of flattening with the scale to get Oversize _ the clearance Crankshaft Bearing 2 25 36428 01 020US 5 If the measurement exceeds the allowable limit re 0 008 in Crankshaft Bearing 3 25 34390 02 020US place crankshaft bearing 0 4mm Crankshaft Bearing 2 25 34391 04 040US 6 If the allowable limit is not attainable with a standard 0 016 in Crankshaft Bearing 3 25 34390 04 040US size bearing install an undersize bearing by referring to the table below Reference NOTE Undersize dimensions of crankshaft journal Be sure not to move the crankshaft while the bearing bolts are tightened 0 2mm 0 008 in 0 4mm 0 016 in Dimension 1 8 to 2 2 mm radius 1 8 to 2 2 mm radius Factory 0 028 to 0 051 mm A 0 071 to 0 087 in radius 0 071 to 0 087 radius Clearance Specification 0 00110 to 0 00201 in Crankshaft sas 1 0 to 1 5 mm dia 1 0 to 1 5 mm dia J ournal to Bearing poner 0 20 mm 0 0394 to 0 0591 in 0 0394 to 0 0591 in Limit 0 0079 in B dia dia Crankshaft Factory 43 934 to 4
45. ed control plate 2 taking care not to damage the governor spring 4 3 Disconnect the governor spring 4 and remove the speed control plate 2 4 Remove the fuel feed pump 3 When Reassembling Hook the governor spring 4 to the governor lever 5 first and install the speed control plate 2 Be sure to replace the copper gaskets underneath two screws 6 in the speed control plate 2 Position the slot 7 on the fork lever just under the slot 8 on the crankcase Insert the injection pump 1 so that the control rod 10 Should be pushed by the idling adjusting spring 9 at its end and the pin 11 on the rod engages with the slot 7 on the fork lever NOTE Sealant is applied to both sides of the shims gasket cement is not required for assembly When replacing the old gasket shims with new 1 Injection Pump 7 Slot Fork Lever Side always replace with the same thickness and 2 Speed Control Plate 8 Slot Crankcase Side number of gasket shims 3 Fuel Feed Pump 9 Idling Adjusting Spring 4 Governor Spring ds Addition or reduction of shim 0 05 mm 0 0020 5 Governor Lever 11 Pin in delays or advances the injection timing by 6 Screw and Copper Washer approximately 0 5 2 1 62 11161 2 2 6 Timing Gear Camshaft and Fuel Camshaft Continued 2 2 6 6 Injection Pump Fuel Feed Pump and Speed Control Plate Z482 E 2b TFX 1 Only NOTE Specific Tool 1 A 1 2mm 050 inch diameter wire wi
46. ghtening Torque Terminal Nut 6 3 2 Magnetic Switch Test 1 Disconnect the cable from the negative terminal on the battery 2 Disconnect the positive cable and leads from the starter B terminal 3 Remove the starter from the engine 4 Disconnectthe the connecting lead 1 from the start er solenoid C terminal 2 5 Connecta jumper lead from the starter S terminal 3 to the positive battery post 6 Momentarily connect a jumper lead between the starter C terminal 2 and negative battery terminal 7 If the pinion gear nose does not pop out check the SEJABAA1P045B i magnetic switch 1 Connecting Lead 3 S terminal NOTE 2s C Termina 4 B terminal This test should only be carried out for a 3 to 5 second time period and not longer 62 11161 6 4 6 3 STARTER CT3 44 TV Continued 6 3 3 Assembly Magnetic Switch Mounting Nut Housing Magnetic Switch C Terminal Nut Shaft Assembly Drive Lever Overrunning Clutch Connecting Lead Mounting Screw Armature Yoke Brush Holder Rear End Frame 14 Through Bolt m ae Ra 12 m m oe ITAAAADOPOZ2A Unscrew the C terminal nut 4 and disconnect the connecting lead 8 Unscrew the magnetic switch mounting nuts 1 and remove the magnetic switch 3 from the housing 2 Unscrew the through bolts 14 and mounting screw 9 and remove the rear end frame 13 Remove the brush from the brush holder while holding
47. gine 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 glow plugs Install a compression tester with the adapter in one of the glow plug holes 5 While cranking the engine with the starter measure the compression pressure 6 Repeat steps 1 thru 5 for each cylinder 7 Ifthe measurementis below the allowable limit add a small amount of oil to the cylinder thru the glow plug 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 10 Echo 2 84 to 3 24 MPa S ion 29 to 33 kgt cm p 412 to 469 psi 2 26 MPa 23 kgt cm 327 psi Compression Pressure Allowable Limit 2 1 2 1 2 Top Clearance 3TMABAB1P023A SEEABAB1P05 7B 1 Piston 2 Plastigage 1 Remove the valve cover Refer to 2 2 4 a 2 Remove the cylinder head 3 Move the piston 1 up and stick a Strip of plastigage 2 on the piston head atthree positions shown on the illustration 4 Lower the
48. i Fan belt slips Adjust belt tension or p change belt Low Battery Charge wring disconnected Come Rectifier defecive Replace Altemator defective Replace Battery defective chme l 7 62 11161 1 6 SERVICING SPECIFICATIONS 1 6 1 Engine Body Mea Factory Specification Allowable Limit 0 145 to 0 185 mm Valve Clearance Cold Clearance Cold 0 00571 to 0 00728 in 2 84 to 3 24 MPa 2 26 MPa Compression Pressure 29 0 to 33 kgf cm 23 0kgf cm 412 to 469 psi 327 psi Difference Between Cylinders o 10 orless 0 50 to 0 70 mm HO scence 0 0197 to 0 0276 in Le 0 05 mm 0 10 to 0 10 mm 0 30 mm Valve Recessing Intake and Exhaust 0 0039 to 0 0039 in 0 0118 in 0 030 to 0 057 mm 0 10 mm Valve Stem 5 968 to 5 980 mm Valve Guide 6 010 to 6 025 mm I D 0 23661 to 0 23720 in Valve Seat aes TIm 0 0835 in 31 3 to 31 8 mm 28 4 mm Free Length 1 232 to 1 252 in 1 118 in Tilt 1 2 mm Valve Spring 0 047 in 64 7 N 27 0 mm 54 9N 27 0 mm a ee 6 6 kgf 27 0 mm 5 6kgf 27 0 mm O 14 6 lbs 1 063 in 12 3lbs 1 063 in 0 016 to 0 045 mm 0 15 mm Rocker Arm 10 473 to 0 484 mm Rocker Arm Shaft to Rocker Arm Shaft O D 0 41232 to 0 41276 in Lo 10 500 to 10 518 mm 0 25mm 0 016 to 0 052 mm 0 10 mm 0 00063 to 0 00205 in 0 0039 in Tappet to Tappet Guide Tappet O D a nae a Tappet Guide 18 000 to 18 018 mm 1 D 0 70866 to 0 70937 in 62 11161 1 8 1 6 1 Engine Body Continued
49. i fiter carriage cogged Repe Relef valve stuck with dit Cean ais Relief valve spring weak or broken Replace 315s gt Excessive clearance of crankshaft bearing Replace 234d gt Low Oil Pressure Excessive clearance of crankpin bearing Replace 234e gt Excessive clearance of rocker arm Replace 231k gt A Oil passage clogged Clean Use specified type of oll Piston ring s gap Piston rings gap facing the same direction Piston rings gap facing the same direction Same direction Incorrect oil type Oil pump defective Repair or replace 2 2 6 h 3 2 ae Incorrect oil type a specified type of pS High Oil Pressure oi Relief valve defective Replace 315 62 11161 1 6 15 TROUBLESHOOTING Continued Symptom ProbableCause Solution Reference Engneoilevelow Replemish Fan belt broken or improperly tensioned Replace or adjust Coolant insufficient Replenish Radiator net and radiator fin clogged with dust Cean inside of radiator corroded Cleamorreplace Coolant flow route corroded Cleanorreplace Engine Overheated l Radiator cap defective Relee J Radiator hose defective Relee Running overioaded Reduebad Head gasket defective Replace 224e incorrect injection timing Ajast J o oo Unsuitable fuelused Use speciedfuel Replenish distilled Battery electrolyte level low water and charge
50. ing in _ 0 30 recessing mm dl 0 0118 recessing in Factory Valve Specification Recessing 2 3 1 d 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 lace the valves If the clearance still exceeds the al owable limit replace the valve guide Factory 0 030 to 0 057 mm Specification 0 00118 to 0 00224 in a 0 10 mm Allowable Limit 0 0039 in Clearance Between Valve Stem and Guide Valve Stem Factory 5 968 to 5 980 mm O D Specification 0 23496 to 0 23543 in Valve Guide Factory 6 010 to 6 025 mm I D S pecification 0 23661 to 0 23720 in 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 I D of the valve guide to the specified di mension precisely Valve Guide I D Factory 6 010 to 6 025 mm Intake Exhaust Specification 0 2366 to 0 2372 in NOTE Do not hitthe valve guide with a hammer during replacement 2 3 1 f Valve Seating 1 Coatthe valve face lightly with
51. ing Replacing Tools Application Use to press out and press fit the bushing 1 For small end bushing 145 mm 5 71 in NN 20 mm 0 79 in 100 mm 3 94 in Bl 19 90 to 19 95 mm 0 7835 to 0 7854 in dia 21 90 to 21 95 mm 0 8622 to 0 8642 in dia 25 00 mm 098 in dia a 6 3 um 250 uin b 6 3 um 250 pin 2 For idle gear bushing 150 mm 5 91 in a 20 mm 0 79 in 100 mm 3 94 in MN 19 90 to 19 95 95 mm 0 7835 to 0 7854 in 21 90 to 21 95 mm 0 8622 to 0 8642 in dia 25 mm 0 98 in a 6 3 um 250 uin b 6 3 um 250 pin 1 8 13 Flywheel Stopper Application Use to loosen and tighten the flywheel screw 200 mm 7 87 in B 20 mm 0 79 in 30 mm 1 18 in D 8mm 0 31in 10 mm 0 39 in 1 88 SPECIAL TOOLS Continued 1 8 14 Crankshaft Bearing 1 Replacing Tool Application Use to press outand press fitthe crankshaft bearing No 1 1 Extracting tool e mesm o fomos A JOFABABOPOS 1 A 40 mm radius 1 57 in radius 20 mm dia 0 79 in dia 47 90 to 47 95 mm dia 1 8858 to 1 8878 in dia 43 90 to 43 95 mm dia 1 7283 to 1 7303 in dia H 2 Installing tool A EN 130 mm 5 12 in e mesm OS o femosm 20 mm dia 0 79 in dia ia 68 mm dia 2 68 in dia 39 90 to 39 95 mm dia 1 5709 to 1 5728 in dia l 17 62 11161 SECTION 2 ENGINE BODY 2 1 CHECKING AND ADJ USTING 2 1 1 Compression Pressure 1 Run the en
52. ll End Bush Allowable 0 10 mm ing Clearance ie Limit 0 0039 in Piston Pin O D Factory 20 002 to 20 011 mm A Specification 0 78748 to 0 78783 in Small End Factory 20 025 to 20 040 mm Bushing I D Specification 0 78839 to 0 78897 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 ARAS C A 1 Clean a new small end bushing and bore and apply eats Meare RE engine oil to both 2 Using the small end bushing replacing tool press in the new bushing to the specified dimension see B SEEABABIP 139A JEEABAB1P139A A A 5 A When Removing B Correct Seat Width 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 Small End Bush Specification 0 00059 to 0 00295 in ing Clearance Parts Limit 0 0059 in 3IGFABAB1PO53A Small End 1 Seam a 0 785 rad 45 Bushing I D Re 2 Oil Hole placement P arts Factory 20 026 to 20 77 mm Specification 0 78845 to 0 79043 in 62 11161 2 28 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 pis ton ring
53. ll moving parts when the unit is in operation and when the unit main power switch Is in the START RUN position Engine Coolant The 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 Ne 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 leadacid 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 4h DANGER DANGER warns againstan immediate hazard which WILL result in severe personal injury or death 44 WARNING WARNING wams 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 The statements listed on the next page are specifically a
54. lts 4 3 Remove the idle gear shaft 5 When Reassembling Apply engine oil to the idle gear shaft mounting bolt 4 and tighten them Install the idle gear aligning the marks 6 on the gears Refer to the illustration Tightening ideGearshat 22422 Nm Torque Mounting Bolt Enoc il 4 3 7 2 to 8 3 ft lbs 1 Idle Gear 4 Idle Gear Shaft Mounting 2 Idle Gear Collar Bolt 3 External Snap Ring 5 Idle Gear Shaft 6 Alignment Mark 2 2 6 Camshaft 1 Remove the camshaft mounting screws 1 and draw out the camshaft with the gear 2 on it When Reassembling Apply engine oil to the camshaft journals before installing it Apply engine oil to the camshaft mounting screws and tighten them 1 Camshaft Mounting Screw 2 Camshaft Gear 62 11161 2 2 6 Timing Gear Camshaft and Fuel Camshaft Cont 31AAMAB1P0S51B 62 11161 inued 2 2 6 9 Fuel Camshaft 1 Remove the retaining plate 1 2 Remove the fork lever holder mounting bolts 8 then draw out the injection pump gear 3 and fuel cam Shaft 2 with the governor fork assembly When Reassembling Hook the governor spring 7 to the fork lever 2 6 as Shown in the figure before installing the fork lever assembly to the crankcase 1 Retaining Plate 6 Fork Lever 2 2 Fuel Camshaft 7 Governor Spring 3 Injection Pump Gear 8 Fork Lever Holder Mounting 4 Governor Sleeve Bolt 5 Fork Lever 1 2 2 6 4 Oil Pump and Crankshaft Gears 1 Remove th
55. m 0 25 mm 0 30 mm and 0 35mm Combine shims for adjustments Refer to the figure below to check the thickness of shims 1 Shim soft metal 3 1 Hole 0 25 mm shim 2 2 Holes 0 20 mm shim 4 0 Holes 0 30 mm shim 62 11161 5 1 CHECKING AND ADJ USTING Continued 62 11161 5 2 5 1 3 Pump Element Fuel Seal 1 Remove the engine stop solenoid when applicable 2 Remove the injection lines and glow plugs 3 Install the injection pump pressure tester to the injec tion pump 4 Install the injection nozzle 1 jetted with the proper in ii pressure to the injection pump pressure tester 5 Set the speed control lever to the maximum speed position 6 Engage the starter 7 If the pressure does not build up replace the pump element with a new one and test again 13 73 MPa o Aae sab kate 1991 psi 5 1 4 Delivery Valve Fuel Seal 1 Remove the engine stop solenoid when applicable 2 Remove the injection lines and glow plugs 3 Install the injection pump pressure tester to the injec tion pump 4 Install the injection nozzle 1 jetted with the proper in jection pressure to the injection pump pressure tester 2 5 Engage the starter 6 Stop the starter when fuel jets from the injection nozzle Continue turning the flywheel by hand and raise the pressure to approximately 13 73 MPa 140 kgf cm 1991 psi 7 Now turn the flywheel about half a turn backward by hand to keep the plunger free Lea
56. n the intermediate jour nal 3 Rotate the camshaft and measure for run out 4 If the measurement exceeds the allowable limit re place the camshaft Camshaft Allowable 0 1 mm Run out Limit 0 0004 in 2 3 2 e Cam Height 1 Measure the cam lobe at its largest O D with an out side micrometer 2 Ifthe measurementis less than the allowable limit re place the camshaft Factory 26 88 mm Cam Height Specification 1 0583 in Intake E xhaust Allowable 26 83 mm Limit 1 0563 in 2 3 2 f Camshaft Bearing Clearance 1 Measure the camshaft journal O D with an outside micrometer 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 ournal Specification 0 00197 to 0 00358 in Clearance Allowable 0 15 mm Limit 0 0059 in Camshaft J ournal Factory 32 934 to 32 950 mm O D Specification 1 29661 to 1 29724 in Camshaft Bore Factory 33 000 to 33 025 mm I D S pecification 1 29921 to 1 30020 in 2 3 2 Timine 7 JEEABAB1P134A P 2 21 Gears Camshaft and Fuel Camshaft Continued 2 3 2 g Idle Gear Shaft and Idle Gear Bushing Clearance 1 Measure the idle gear shaft O D with an outside mi crometer 2 Measure the idle gear shaft bore I D with a cylinder gauge and calculate the oil clearance 3 If the oil clearance excee
57. nal by pushing the plunger then measuring resistance with an ohmmeter 2 If there is no continuity check the contacts 6 4 5 Brush Holder 1 Check the continuity across the brush holder and holder support with an ohmmeter 2 If there is any continuity replace the brush holder 6 4 STARTER SERVICING Continued 6 4 6 Armature 6 4 6 a Continuity Check 1 Check the continuity across the commutator and the armature with an ohmmeter 2 If there is continuity replace the armature 3 Check the continuity across the segments of the com mutator with an ohmmeter 4 If there is no continuity replace the armature JEEABAB1P186A 6 4 6 b Commutator and Mica 1 Check the contact pattern of the commutator for wear and grind the commutator with emery cloth if it is Slightly worn 2 Measure the commutator O D with an outside mi crometer at several points 3 If the minimum O D is less than the allowable limit replace the armature 4 If the difference of the O D s exceeds the allowable 3EEABAB1P182A limit correctthe commutator on a lathe to the factory specifications 5 Measure the mica undercut 6 If the undercut is less than the allowable limit correct it with a saw blade and chamfer the segment edges 1 Segment a Correct 2 Depth of Mica b Incorrect 3 Mica SEEABABIP184A 6 7 62 11161 6 4 STARTER SERVICING Continued 6 4 7 Field Coil 1 Check the continuity across the lead
58. nkpin journal Oversize 0 2mm 0 008 in 0 4mm 0 016 in Di GEA 2 3 to 2 7 mm 2 3 to 2 7 mm ds 0 091 to 0 106 in 0 091 to 0 106 in 1 0 to 1 5 mm dia 1 0 to 1 5 mm dia Dimension B 0 0394 to 0 0591 in 0 0394 to 0 0591 in dia dia 33 759 to 33 775 33 559 to 33 575 mm dia mm dia 1 32910 to 1 32973 1 32112 to 1 32185 in dia in dia I 11 3 ry k i j il i Le fi 3TMABAB1P075A 1 a ly S3TMABAB1P074B Dimension C The crankshaft journal must be fine finished to higher than 2 31 62 11161 2 3 4 Crankshaft Continued 2 3 4 d 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 e size bearing install an undersize bearing by referring STAAAADIPOT4A to the table below Crankshaft Factory 0 034 to 0 106 mm J ournal to 1 Specification 0 00134 to 0 00417 in Bearing Allowable 0 20 mm Clearance Limit 0 0079 in Crankshaft Factory 39 934 to 39 950 mm Journal O D Specification 1 57221 to 1 57284 in Crankshaft Factory 39 984 to 40 040 mm cie Specification 1 57148 to 1 57638 in SEEACAAIPOIZAY Reference Be
59. nstalled in their original location 62 11161 2 2 5 Oil Pan and Oil Pick up Screen CT2 29 TV 7 AAAABTPOS6C ITAAAAB1POS7TA 62 11161 Sealer Location 2 6 N Fe UJ UI o gt N 00 lo Remove the oil pan mounting bolts Remove the oil pan by lightly tapping the side of the pan with a soft hammer Scrape off the old adhesive from the mating surfaces of the oil pan and the engine block completely Remove the oil pick up screen 1 Clean and Inspect the oil pick up screen 1 for dam age Visually inspect the oil pick up screen O ring 4 for damage oil it and reinstall CT2 29 TV engine use hole labeled 2 CT3 44 TV engine use hole labeled 3 to install the pick up screen mounting bolt Apply gasket cement sealer so that the sealer is about 3 to 5 mm 0 12 to 0 20 in thick around the flange of the oil pan Apply the sealer on the center of a flange as well as on the inner wall of each bolt ole Within 20 minutes after the application of the sealer replace the oil pan and mounting bolts NOTE Refer to Section 1 4 for proper torque values on all fasteners 2 2 6 Timing Gear Camshaft and Fuel Camshaft gt 2 2 6 a Injection Pump Fuel Feed Pump and Speed Control Plate Solara Supra Genesis and PC5000 Units Only E Remove the socket head screws and nuts and re move the injection pump 1 2 Remove the screws and separate the spe
60. overnor malfunctioning Reduce to specified Excessive engine oll level l Piston ring and liner worn or ring stuck Repair or replace E ither White or Blue i en Adjust Exhaust Gas Is Observed Check the cylinder compression Deficient compression pressure and top clearance pa pl 1 5 62 11161 1 5 TROUBLESHOOTING Continued Symptom Probable Cause Solution Reference IT ECT A Either Black or Dark LOW gradefuelused Use specified ed ExhaustGas Is Fuel fiter cogged Clean orchange dS Observed Air cleaner clogged Clean or change Deficient nozzle injection Replace nozze 524 Incorrect injection ming Jadus si Engine s moving paris seem to be seizing Repairorreplace lt o Replace injection Deficient Output Repair or replace Deficient nozzle injection nozzle Deficient nozzle injection nozzle Check the Compression leak compression pressure and repair Shift ring gap direction aa OO 227b E ee ee Oil Consumption Piston ring groove wo Replacewompiston 233e Valve stem and valve guide wom Replace 231a Oi leaking due to defective seals or packing Replace Injection pump s plunger worn Replace Injection sa Fuel Mixed into pump Lubricant oil Defcientnozzle injection Replacemozzle B24 Injection pump broken Replace s Water Mixed into Head gasket defective Replace 224e Lubricant il Cyinderblock or cyinder head flawed Replace Engine ollevellow PRepenisn O
61. per lead from the connecting lead 2 to the positive post on the battery Connect a jumper lead momentarily between the Starter motor housing and the negative post on the battery If the starter does not run check the motor 2 2 Magnetic Switch Test 2 2 a Pull in Coil Test Connecta jumper lead from the negative battery post to the starter C terminal The plunger should be attracted strongly when a jumperleadis connected from the battery positive ter minal to the S terminal 2 2 6 Holding Coil Test Connecta jumper lead from the negative battery post to the starter case and and another jumper from the positive battery post to the starter S terminal Push the plunger in by hand and release it The plung er Should stay in 6 2 STARTER CT2 29 TV Continued 6 2 3 Assembly Solenoid Switch Mounting Nut Starter Drive Housing Drive Lever Gasket Solenoid Switch C Terminal Nut Snap Ring Overrunning Clutch Armature Brush Spring Connecting Lead Rear End Frame Gasket Break Spring Break Shoe End Frame Cap Screw Yoke Brush Brush Holder Through Bolt Rh ee ee WU NBE O 14 NN PP Pe 5 59 09 1700 En JEBAAABIPOASA Unscrew the C terminal nut 6 and disconnect the connecting lead 11 Unscrew the solenoid switch mounting nuts 1 and remove the solenoid switch 5 Remove the end frame cap 16 Remove the break shoe 15 break spring 14 and gasket 13 Unscrew
62. pplicable to this unit and appear elsewhere in this manual These recommended precautions must be understood and applied during operation and maintenance of the equip ment covered herein 62 11161 SPECIFIC WARNING AND CAUTION STATEMENTS Continued 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 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 Stop the engine when preparing to change the engine oil filter 44 CAUTION Secure the starter to prevent it from moving when power is applied to it 62 11161 ji SECTION 1 General 1 1 ENGINE IDENTIFICATION serial Number Z482 7 K A 176 When contacting Carrier Transicold always specify your engine model number and serial number The engine model and its serial number need to be identified before the engine can be serviced or parts replaced Engine Serial Number S N The engine serial number is an identified number for the engine It is marked after the engine model number It indicates basic
63. prussian blue and put the valve on its seat to check the contact pattern 2 Ifthe valve does notseatallthe way around the valve seat orthe contactis less than 70 correctthe valve Seating as outlined in 2 3 1 9 3 If the valve contact does not comply with the refer ence value replace the valve or correct the contact of valve seating Valve Seat Factory 2 12 mm Width Specification 0 0835 in 3TMABAB1P060A 1 Correct 3 Incorrect 2 Incorrect 2 21 62 11161 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 recession A Correcting the Valve 1 Correct the valve with a valve grinder Factory 0 785 rad vave face Ande specification B Correcting the Valve Seat 1 Slightly correct the valve seat surface with a 0 785 rad 45 valve seat cutter 2 Reinsert the valve check the contact pattern with prussian blue A valve seat width should be approxi mately 70 of the total valve contact area See A in the illustration 3 Resurface the seat surface with a 0 262 rad 15 valve seat cutter to the valve seat so that a equals b in the illustration 4 Grind the seat with a 0 785 rad 45 valve seat cutter again and visually recheck the contact between the valve and the seat 5
64. pte Factory Specification Allowable Limit eee 0 043 to 0 124 mm 0 15 mm Backlash 0 00169 to 0 00488 in 0 0059 in Idle Gear to Cam 0 047 to 0 123 mm 0 15 mm Gear Backlash 0 00185 to 0 00484 in 0 0059 in poda Idle Gear to Injec 0 046 to 0 124 mm 0 15 mm tion Pump Gear Backlash 0 00181 to 0 00488 in 0 0059 in h o ll 0 041 to 0 123 mm 0 15 mm Backlash 0 00161 to 0 00484 in 0 0059 in l 0 20 to 0 51 mm 0 80 mm Idle Gear Side Clearance 0 0079 to 0 0201 in 0 0315 in 0 15 to 0 31 mm 0 50 mm Side Clearance 0 0059 to 0 0122 in 0 0197 In 0 01 mm Height 26 88 mm 26 83 mm Intake Exhaust 1 0583 in 1 0563 In Clearance 0 050 to 0 091 mm 0 15 mm 0 00197 to 0 00358 in 0 00059 in Camshaft J ournal to Cylinder Block Bore i os ee ee Cylinder Block 33 000 to 33 025 mm Bore 1 D 1 29921 to 1 30020 Clearance 0 020 to 0 084 mm 0 1mm 0 00079 to 0 00331 in 0 0039 in Idle Gear Shaft to Idle Gear Bushing co ace ee ae ae i oy ON orero worst I D 0 78740 to 0 78791 in psonpinsore omwwomsan oman Piston Pin to Small End Bushing Piston Pin 0 ranoo s Small End 20 025 to 20 040 mm Bushing 1 D 0 78839 to 0 78897 in 0 015 to 0 075 mm 0 15 mm Clearance Piston Pin to Small End Bushing Clearance 0 00059 to 0 00295 in 0 0059 in Spare Parts Small End 20 026 to 20 077 mm mit E Top Rin 0 15 to 0 30 mm 1 20 mm Peg 0 0059 to 0 0118 in 0 0472 in l 0 30 to 0 45 mm 1 20 mm Piston
65. rews 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 4 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 tem i Size x Pitch Nm _ kgfm ft lbs oz Holder E EE BSED 2530289 POvertow Pipe oras 202s se Nozzle Holler Assenby at BE 50070 3620506 Starter B Terminal Nut CT3 44 TV 1 4 2 Torque Specifications For General Use Screws Bolts and Nuts Standard Screw and Bolt Grade 4 Special Screw and Bolt Grade 7 O Nm kgm fbs Nm kgm fes 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 Screw And Bolt Material Grade Standard Screw And Bolt SS41 S20C Special Screw
66. riginal com bination of parts will go back together Do notin terchange used parts When Reassembling When installing the ring assemble the rings so that the manufacturer s mark 12 near the gap faces the top of the piston 5 SEEACAA1PO8SA 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 7 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 When installing the connecting rod to the piston align the mark 8 on the connecting rod to the fan shaped concave 9 3EEABABIP100A 1 Top Ring 8 Mark 2 Second Ring 9 FanShaped Concave 3 Oil Control Ring 10 Expander J oint 4 Piston Snap Ring 11 OilRing Gap 5 Piston 12 Manufacturer s Mark 6 Connecting Rod 7 Piston Pin 2 15 62 11161 2 2 8 Crankshaft 2 2 8 4 Flywheel 1 Position the flywheel 2 so thatthe 1TC mark a on the outer surface of the flywheel aligns horizontally with the alignment mark b on the rear end plate 2 Prevent the flywheel 2 from rotating 3 Remove all of the flywheel screws 1 4 Remove the flywheel 2 When Reassembling Check to see thatthe mating surfaces of the crankshaft and flywheel are clean Align the 1TC mark a on the outer s
67. se assemblies into their original positions Since diameters of main bearing cases vary install them in order by marking b in the ada 1for Z482 and 1 2 for D722 from the gear case side The diameters of the main bearing cases vary Install them in order from the gear case end according to their markings Match the alignment numbers a on the main bearing 7 case assembly 1 JEEACAA1POS28 Do the same for the main bearing case assembly 2 2 and face the mark FLYWHEEL to the flywheel Install the thrust bearing 6 with its oil groove facing outward Confirm that the main bearing case moves smoothly after tightening the main case bolt 1 to the specified torque Tightening Main Bearing ee ad Torque Case Screw 1 E LO KONM 9 4 to 11 6 ft lbs 1 Main Bearing Case 5 Crankshaft Bearing 2 Assembly 1 6 Thrust Bearing 2 2 Main Bearing Case 7 Main Bearing Case Assembly 2 Screw 1 3 Main Bearing Case a Alignment Number Assembly b Marking 1 or 2 4 Crankshaft Bearing 3 62 11161 2 18 2 3 SERVICING 2 3 1 Cylinder Head And Valves 3TMABABOPO59B 1 Red Dye 2 Detergent 3 White Developer 2 3 1 4 Cylinder Head Surface Flatness 1 Clean the cylinder head 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 If the measurement exceeds the allowa
68. sel engines are designated as shown above The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the gear case end of the engine 1 3 GENERAL PRECAUTIONS During disassembly carefully arrange removed parts in a clean area to prevent confusion latter Screws bolts and nuts should be replaced in their original position to prevent reassembly errors When special tools are required use Carrier Transicold genuine special tools Special tools which are not frequently used should be made according to the drawings provided Before disassembling or servicing electrical 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 SEEABAB1P012A 1 Grease 2 Force 3 Place the Sharp Edge against the Direction of Force A External Snap Ring B Internal Snap Ring When reassembling external or internal snap rings position them so that the sharp edge faces against the direction from which force is 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 62 11161 14 TORQUE SPECIFICATION Sc
69. ss gt MPa 140 to130 kgf cm 2 1991 to 1849 psi 140 to130 kgf cm E 1991 to 1849 psi Injection Pump 13 73 to 14 71 MPa Injection Pressure 140 to 150 kgf cm 1991 to 2134 psi Fuel Injection Nozzle When the pressure is Valve Seat 12 75 MPa Tightness 130 kgf cm2 1843 psi the valve must not pass fuel 1 11 62 11161 1 6 5 Electrical System AT Factory Specification Allowable Limi Glow Plug Approximately 090M 28 0 mm 27 0mm CT2 29 1V 1 1 102 in 1 063 in Commutator O D 30 0 mm 29 0 mm CT3 44 1V 1 181 in 1 142 in Less than 0 05 mm 0 4 mm e con CT2 29 TV 0 0002 in 0 016 in Start naan CT3 44 TV Less than 0 02 mm 0 05 mm ante 0 0008 in 0 0020 in 0 50 to 0 80 mm 0 20 mm 0 16 mm 10 5 mm sass ath CT2 29 TV 0 630 in 0 413 in enh CT3 44 TV 0 14 mm 9 0 mm 0 551 in 0 354 in 1 7 CHECK AND MAINTENANCE 1 7 1 Checking Engine Oil Level 1 7 5 Bleeding Fuel System 1 Refer to Section 3 1 1 7 2 Changing Engine Oil 1 Refer to Section 3 1 1 7 3 Checking Coolant Level 1 Refer to Section 4 1 3 1 7 4 Checking Fuel Hose 1 If the clamp Is loose apply oil to the threads and securely retighten it A 2 The fuel hose is made of rubber and ages regardless sEEACABOPOOIE of the service period Change the hose and clamps 7 o together every two years 1 Open the air vent cock 1 on top of the fuel injection 3 Change the fuel hose and clamps whenever any de ai Available on Solara Supra and Genesis units
70. t 3 Install the new oil filter cartridge screwing it on by hand Overtightening it may cause deformation of the rubber gasket 4 After the new oil filter cartridge has been installed Start the engine and check for a leak around the oil fil ter cartridge gasket Recheck the crankcase oll level Refer to section 3 1 1 and adjust the engine oil level as necessary 3 1 4 Engine Oil Pressure 1 Remove the engine oil pressure switch and install an oil pressure guage 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 Engine oil sufficient Oil pump defective Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Relief valve stuck Allowable 103 kPa 2 At Idle Speed Limit 1 0 kgf cm 15 psi Factor 196 to 441 kPa S seston 2 0 to 4 5 kgf cm i 28 to 64 psi At Rated Speed 147 kPa Allowable aa 1 5 kgf cm Limit 21 psi When Reassembling After checking the engine oil pressure tighten the engine oil pressure switch to the specified torque Oil Pressure A A Tightening Torque Switch 1 5 to 2 0 kgfm 10 8 to 14 5 ft lbs 3 1 CHECKING AND ADj USTING Continued 3 2 OIL PUMP SERVICE gt 3TABAADIPOS1A 3 3 3 1 5 Relief Valve 1 o the oil filter cartridge and the oil filter base 2 Check the relief valve 1 for dirt and the seat an
71. tat 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 If the measurement is not within the factory specifica tions replace the thermostat Thermostat Opening Temperature Factory 69 5 to 72 5 C Specification 157 1 to 162 5 F Thermostat Full Open Temperature Factory Specification 4 2 SERVICING 4 2 1 Thermostat Assembly 1 Remove the thermostatcover mounting bolts and re move the thermostat cover 1 2 Remove the thermostat assembly 3 When Reassembling Apply a liquid gasketonly atthe thermostat cover side of the thermostat cover gasket 2 S3GFABAB1IPO041A 1 Thermostat Cover 3 Thermostat Assembly 2 Thermostat Cover Gasket 4 2 2 Water Pump Assembly 1 Remove the fan belt 2 Remove the water pump pulley 3 OS the water pump from the gear case assem y 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 JGFABAB1PF042B 1 Water Pump Flange 4 Water Pump
72. th 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 3EEADAA1P014A springs A length of string passed thru the governor spring 6 can be used to retrieve the spring if it unhooks from both the specific tool 1 and the speed control plate 1 Remove the socket head screws 2 and remove the engine stop solenoid 4 Remove the screws and separate the speed control plate 5 taking care not to damage the governor Spring 6 Disconnect the governor spring 6 and remove the Speed control plate 5 using the specific tool 1 4 Remove the fuel feed pump 3 Disconnect the start spring 8 from the bracket 9 using the specific tool 1 N UJ Ul 6 Remove the socket head screws and nuts then re move the injection pump 7 1 Specific Tool 6 Governor Spring 2 Socket Head Screw 7 Injection Pump 3 Fuel Feed Pump 8 StartSpring 4 Engine Stop Solenoid 9 Bracket 5 Speed Control P late 62 11161 2 8 2 2 6 Timing Gear Camshaft and Fuel Camshaft Continued 2 2 6 6 Injection Pump Fuel Feed Pump and Speed m Control Plate 2482 E2b TFX 1 Only E Continued When Reassembling 1 Move the fork lever 1 to the gear case side 2 Hook the start spring 7 to the injection pump control rack pin 5 3 Put the specific tool 8 through the fork lever hole of de the cylinder block 9 and hook the start spring 7
73. the through bolts 21 and remove the rear end frame 12 Unscrew the brush from the brush holder while holding the spring up Remove the brush holder 20 Draw out the yoke 18 from the starter drive housing 2 Draw out the armature 9 with the drive lever 3 NOTE Do not damage the brush and commutator When Reassembling Apply grease Carrier Part No 07 00245 00 to the parts indicated in the figure Joint of solenoid switch a Bushing b Drive lever c Collar d Teeth of pinion gear e Armature shaft f WO oO N OD UI BW N PH Tightenin POON a le C Terminal Nut 0 8 to 1 0 kgfm q 5 8 to 7 2 ft lbs 6 3 62 11161 6 3 STARTER CT3 44 TV 6 3 1 Motor Test 44 CAUTION Secure the starter to preventit from moving when power is applied to it 1 Disconnect the cable from the negative terminal on the battery 2 Disconnect the the positive cable and leads from the Starter B terminal 1 C Terminal 2 Connecting Lead 3 Remove the starter from the engine Se B emina 4 Disconnectthe the connecting lead 2 from the start er solenoid C terminal 1 5 Connecta jumper lead from the connecting lead 2 to the positive post on the battery 6 Connect a jumper lead momentarily between the Starter motor housing and the negative post on the battery 7 If the starter does not run check the motor 8 8 to 11 8 Nm 0 9 to 1 2 kgfm 6 5 to 8 7 ft lbs JEJABAA1P044B Ti
74. tion pressure by approximately 235 kPa 2 4kgf cm2 34 psi 62 11161 5 2 INJECTION NOZZLE Continued JEEABABIP 171A 62 11161 5 4 5 2 3 Valve Seat Tightness 1 Set the injection nozzle in a nozzle tester 2 Raise the fuel pressure and maintain 12 7MPa 130 kgf cm 1850 psi for 10 seconds 3 If any fuel leak is found or if there is any loss of pres Sure through the injection nozzle replace the injec tion nozzle assembly No fuel leak at Valve Seat Factory 12 7MPa Tightness Specification 130 kgf cm 1850 psi 5 2 4 Nozzle Holder 1 Secure the nozzle retaining nut 7 with a vise 2 Remove the nozzle holder 1 and remove the parts 3 If any fuel leak is found replace the injection nozzle assembly When Reassembling Assemble the nozzle in clean fuel oil Install the push rod 4 noting its direction After assembling the nozzle be sure to adjust the fuel injection pressure 34 3 to 39 2 N m Tightening Torque Nozzle Holder 3 5 to 4 0 kgf m 25 3 to 28 9 ft lbs 19 6 to 24 5 N m 2 0 to 2 5 kgf m 14 5 to 18 1 ft lbs 49 0 to 68 6 N m Overflow Pipe Nut Tightening Torque Nozzle Holder Tightening Torque 5 0 to 7 0 kgf m Aa Tay 36 2 to 50 6 ft Ibs 1 Nozzle Holder 5 Distance Piece 2 Adjusting Washer 6 Nozzle Piece 3 Nozzle Spring 7 Nozzle Retaining Nut 4 Push Rod SECTION 6 ELECTRICAL SYSTEM 6 1 GLOW PLUG 6 1 1 Lead Terminal Voltage Disconnectthe glow pl
75. ug wiring lead 1 from the glow plug 2 Connect a voltmeter between the glow plug wiring lead 1 and a suitable ground on the engine a N Pe Energize the glow plug lead and read the voltage D Energize the glow plug lead engage the starter atthe same time and read the voltage U1 If the voltage differs from the battery voltage in either sae the wiring harness or the switch or switches are aulty 3TMABAB9P011A 1 Wiring Lead Positive 2 Glow Plug 6 1 2 Glow Plug Continuity 1 Disconnectthe glow plug wiring lead 1 from the glow plug 2 2 Measure the resistance between the glow plug termi nal and the engine body with an ohmmeter 3 If 0 ohm is indicated the glow plug may be short cir cuited 4 If the factory specification is not met the plug is also faulty eS cle Approximately 0 9 ohm 3TMABAB9P012A Resistance Specification E oo 6 1 62 11161 JEEABABIPIT2A 1 C Terminal 62 11161 2 Connecting Lead 3 S Terminal 6 2 6 U NO Y or U ip 6 6 ip 2 6 1 N 2 1 Motor Test 44 CAUTION Secure the starter to prevent itfrom moving when power is applied to it Disconnect the cable from the negative terminal on the battery Disconnect the the positive cable and leads from the starter Remove the starter from the engine Disconnectthe the connecting lead 2 from the start er solenoid C terminal 1 Connecta jum
76. urface of the flywheel horizontally with the alignment mark b on the rear end plate and install the flywheel Apply engine oil to the flywheel bolts and install fis 53 9 to 58 8 N m ap De Flywheel Bolts 5 5 to 6 0 kgfm i 39 8 to 43 4 ft lbs 1 Flywheel Bolt a 1TC Mark 2 Flywheel b Alignment Mark 2 2 8 5 Bearing Case Cover 1 Remove the bearing case cover mounting bolts F irst remove the inside bolts 1 and then the outside screws 2 2 Screw two of the removed bolts into the bolt hole of the bearing case cover 6 to remove it NOTE The length of the inside and the outside bolts are different When reassembling reinstall the appropriate bolt in the correct location When Reassembling Fit the bearing case gasket 3 and the bearing case cover gasket 4 to the bearing case cover 6 Orient them correctly Install the bearing case cover 6 again orienting it correctly using the UP mark a EN Apply oil to the oil seal and take care that itis not rolled LEN while being installed SGFABABIPOA7C Tighten the bearing case cover bolts diagonally and evenly Tiahtenin Bearing Case 9 8 to 11 3N m ae le Cover Mounting 1 00 to 1 15 kgfm a Screw 7 2 to 8 3 ft lbs 1 Bearing Case Cover 5 OilSeal Mounting Bolt Inside 6 Bearing Case Cover 2 Bearing Case Cover a Top Mark UP Mounting Bolt Outside b Upside 3 Bearing Case Gasket 4 Bearing Case Cover Gasket 37144 44D1PO50A
77. ve the flywheel in this position while recording the time taken for the pressure to drop from 13 73 MPa 140 kgf cm2 1991 psi to 12 75 MPa 130 kgf cm2 1849 psi 8 Ifthe measurementis less than the allowable limit re place the pump with a new one 10 seconds Delivery valve Factory S pecifi 13 73 to 12 75 MPa fuel seal cation 140 to 130 kgf cm 1991 to 1849 psi 5 seconds Delivery valve Allowable 13 73 to 12 75 MPa fuel seal Limit 140 to 130 kgf cm 1991 to 1849 psi 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 result 3TLABAB1P0414 5 3 5 2 1 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 5 2 2 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 RT replace the adjusting washer 1 in the nozzle older Fuel Injection Factory 13 73 to 14 71 MPa Pressure os 140 to 150 kgt cm Ist Stage Specification 1991 to 2133 psi Reference A washer thickness of 0 01 mm 0 0004 in will vary the the nozzle injec

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