R
Diesel Engine
CT2-29-TV (Z482-E2B)
CT3-44-TV (D722-E2B)
Beginning With Serial Number 5A0001
62--11161 Rev A
WORKSHOP MANUAL
for
Truck / ComfortPro
Truck
WORKSHOP MANUAL
DIESEL ENGINE
CT2-29-TV (Z482-E2B)
Truck / ComfortPro
CT3-44-TV (D722-E2B)
Truck
Beginning With Serial Number 5A0001
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
TABLE OF CONTENTS i........................................................................
SAFETY PRECAUTIONS i...................................................................
SPECIFIC WARNING AND CAUTION STATEMENTS i...........................................
General 1--1......................................................................................
1.1 ENGINE IDENTIFICATION 1--1............................................................
1.2 ENGINE SPECIFICATIONS 1--2............................................................
1.2.1 E2B Engine 1--3......................................................................
1.2.2 Cylinder Number 1--3..................................................................
1.3 GENERAL PRECAUTIONS 1--3............................................................
1.4 TORQUE SPECIFICATION 1--4............................................................
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts 1--4..........................
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts 1--4..........................
1.5 TROUBLESHOOTING 1--5................................................................
1.6 SERVICING SPECIFICATIONS 1--8........................................................
1.6.1 Engine Body 1--8......................................................................
1.6.2 Lubricating System 1--11................................................................
1.6.3 Cooling System 1--11...................................................................
1.6.4 Fuel System 1--11......................................................................
1.6.5 Electrical System 1--12..................................................................
1.7 CHECK AND MAINTENANCE 1--12..........................................................
1.7.1 Checking Engine Oil Level 1--12..........................................................
1.7.2 Changing Engine Oil 1--12...............................................................
1.7.3 Checking Coolant Level 1--12............................................................
1.7.4 Checking Fuel Hose 1--12...............................................................
1.7.5 Bleeding Fuel System 1--12..............................................................
1.7.6 Valve Clearance 1--13..................................................................
1.8 SPECIAL TOOLS 1--14.....................................................................
1.8.1 Diesel Engine Compression Tester (Glow Plug) 1--14.......................................
1.8.2 Adapter, Kubota 10 mm 1--14............................................................
1.8.3 Tester Injector Nozzle 1--14..............................................................
1.8.4 Replacement Bowl, Tester Injector Nozzle 1--14............................................
1.8.5 Adapter, Injector Line 1--14..............................................................
1.8.6 Oil Pressure Tester 1--15................................................................
1.8.7 Auxiliary Socket For Fixing Crankshaft Sleeve 1--15........................................
1.8.8 Guage, Belt Tension 1--15...............................................................
1.8.9 Tester, Belt Tension 1--15................................................................
1.8.10 Rubber Band 1--15.....................................................................
1.8.11 Valve Guide Replacing Tool 1--16.........................................................
1.8.12 Bushing Replacing Tools 1--16
1.8.13 Flywheel Stopper 1-- 16..................................................................
1.8.14 Crankshaft Bearing 1 Replacing Tool 1--17.................................................
...........................................................
i
62--11161
PARAGRAPH NUMBER
ENGINE BODY 2--1...............................................................................
2.1 CHECKING AND ADJUSTING 2--1.........................................................
2.1.1 Compression Pressure 2--1.............................................................
2.1.2 Top Clearance 2--1....................................................................
2.2 DISASSEMBLING AND ASSEMBLING 2--2..................................................
2.2.1 Draining Coolant 2--2..................................................................
2.2.2 Draining and Refilling Engine Oil 2--2....................................................
2.2.3 External Components 2--2..............................................................
2.2.4 Cylinder Head And Valves 2--3..........................................................
2.2.5 Oil Pan and Oil Pick--up Screen 2--6......................................................
2.2.6 Timing Gear, Camshaft and Fuel Camshaft 2--7...........................................
2.2.7 Piston and Connecting Rod 2--13.........................................................
2.2.8 Crankshaft 2--16.......................................................................
2.3 SERVICING 2--19.........................................................................
2.3.1 Cylinder Head And Valves 2--19..........................................................
2.3.2 Timing Gears, Camshaft and Fuel Camshaft 2--25..........................................
2.3.3 Piston and Connecting Rod 2--28.........................................................
2.3.4 Crankshaft 2--30.......................................................................
2.3.5 Cylinder 2--36..........................................................................
LUBRICATING SYSTEM 3--1.......................................................................
3.1 CHECKING AND ADJUSTING 3--1.........................................................
3.1.1 Checking Engine Oil Level 3--1..........................................................
3.1.2 Changing Engine Oil 3--1...............................................................
3.1.3 Changing Oil Filter 3--2................................................................
3.1.4 Engine Oil Pressure 3--2...............................................................
3.1.5 Relief Valve 3-- 3......................................................................
3.2 OIL PUMP SERVICE 3--3..................................................................
3.2.1 Rotor Lobe Clearance 3--3.............................................................
3.2.2 Rotor to Cover Clearance 3--3..........................................................
COOLING SYSTEM 4--1...........................................................................
4.1 CHECKING AND ADJUSTING 4--1.........................................................
4.1.1 V--Belt Tension 4--1....................................................................
4.1.2 Fan Belt Damage and Wear 4--1........................................................
4.1.3 Checking Coolant Level 4--1............................................................
4.1.4 Draining Coolant 4--1..................................................................
4.1.5 Radiator Cap 4--2.....................................................................
4.1.6 Radiator 4--2.........................................................................
4.1.7 Thermostat Opening Temperature 4--2...................................................
4.2 SERVICING 4--3.........................................................................
4.2.1 Thermostat Assembly 4-- 3..............................................................
4.2.2 Water Pump Assembly 4--3.............................................................
Page
62-11161
ii
PARAGRAPH NUMBER
FUEL SYSTEM 5--1...............................................................................
5.1 CHECKING AND ADJUSTING 5--1.........................................................
5.1.1 Injection Timing 5--1...................................................................
5.1.2 Shim Identification 5--1.................................................................
5.1.3 Pump Element Fuel Seal 5--2...........................................................
5.1.4 Delivery Valve Fuel Seal 5--2...........................................................
5.2 INJECTION NOZZLE 5--3.................................................................
5.2.1 Nozzle Spraying Condition 5--3..........................................................
5.2.2 Nozzle Injection Pressure 5--3..........................................................
5.2.3 Valve Seat Tightness 5--4..............................................................
5.2.4 Nozzle Holder 5--4....................................................................
ELECTRICAL SYSTEM 6--1........................................................................
6.1 GLOW PLUG 6--1........................................................................
6.1.1 Lead Terminal Voltage 6--1.............................................................
6.1.2 Glow Plug Continuity 6--1..............................................................
6.2 STARTER (CT2--29--TV) 6--2...............................................................
6.2.1 Motor Test 6--2........................................................................
6.2.2 Magnetic Switch Test 6--2..............................................................
6.2.3 Assembly 6--3.........................................................................
6.3 STARTER (CT3--44--TV) 6--4...............................................................
6.3.1 Motor Test 6--4........................................................................
6.3.2 Magnetic Switch Test 6--4..............................................................
6.4 STARTER SERVICING 6--6................................................................
6.4.1 Overrunning Clutch 6-- 6................................................................
6.4.2 Armature Bearing 6--6.................................................................
6.4.3 Brush Wear 6--6......................................................................
6.4.4 Solenoid 6--6.........................................................................
6.4.5 Brush Holder 6--6.....................................................................
6.4.6 Armature 6--7.........................................................................
6.4.7 Field Coil 6--8.........................................................................
Page
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 all 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
remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure
without spray.
Battery
This unit is equipped with a leadacid type battery.The battery normally vents small amounts of flammable hydrogen
gas. Do not smokewhen checking thebattery.Abattery explosioncan causeserious physical harmand/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:
DANGER
DANGER -- warns against an immediate hazard which WILL result in severe personal injury or death.
WARNING
WARNING -- warns against hazards or unsafe conditions which COULD result in severe personal injury or death.
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 applicable to this unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.
i
62-11161
SPECIFIC WARNING AND CAUTION STATEMENTS (Continued)
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.
WARNING
Checkthe injectionnozzle only after confirming that nobody is near the spray. If the spray fromthe
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.
CAUTION
Stop the engine when attempting to check and change the fuel line.
CAUTION
Stop the engine when preparing to change the engine oil.
CAUTION
Stop the engine when preparing to change the engine oil filter.
CAUTION
Secure the starter to prevent it from moving when power is applied to it.
62-11161
ii
SECTION 1
Serial
Numb
General
1.1 ENGINE IDENTIFICATION
S/N
er
Z482--
7 K A
176
Last 3 Digits in Numerals (1 to 999 Units in Sequence)
7th Digit Sequential Numeral or Letter (Units Manufactured)
Alphabetical Numeral or Letter
Unit Number Sequence
6th Digit Alpabetical Letter (Month of Manufacture -- 1st Letter 1--9999 Units, 2nd Letter 10,000--19,998 Units)
Alphabetical letter
Month
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)
Theengine serialnumber is an identified number forthe
engine. It is marked after the engine model number.
It indicates basic model, month, year and sequence of
manufacture as follows:
0to9
to 19,998
A,B C,DE,FG,HJ,K L,M N,P Q,R S,T U,V W,X Y,Z
Jan Feb Mar May Jun Jul Aug Sep OctApr Nov Dec
A
19,999--20997 20,998--21,996
BC
21,997--22,995
5th Digit Alpabetical Letter or Numerals (Year of Manufacture)
Alphabetical letter or numerals W XY
Year 98 99 00 01 02 03 04 05 06 07 08 09
Basic model number
1234 56789
Table 1-1. Model Chart
KUBOTA
MODEL NO.
Z482--E2B CT2--29--TV
Z482--E2B CT2--29--TV
Z4 82 -- E 2B -- AT C-- 1 CT2--29--TV 96-- 101--05K
CARRIER
MODEL NO.
NEW ENGINE
PART NO.
26--60001--03*
26--60001--04*
PRIMARY USE REPLACES
SOLARA Units 26--60001--01
SUPRA Units 26--60001--02
ProHeat / ComfortPro PC5000
Units
NEW
Z482--E2B--TFX--1 CT2--29--TV 96-- 101--20K ComfortPro PC6000 Units NEW
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 engine
NUMBER OF CYLINDERS 2 3
BOREXSTROKE mmXmm(in.Xin.) 67 X 68 (2.64 X 2.68)
TOTAL DISPLACEMENT cm3(cu.in.) 479 (29.23) 719 (43.88)
BRAKE
HORSEPOWER
MAXIMUM BARE SPEED RPM 3800
IDLING SPEED RPM 900 To 1000
COMBUSTION CHAMBER Spherical Type (E--TVCS)
FUEL INJECTION PUMP BoschMD TypeMini Pump
GOVERNOR Centrifugal Ball Mechanical Governor
INJECTION NOZZLE Bosch Throttle--Type
INJECTION TIMING (before T.D.C.) 19 to 21°
FIRING ORDER 1-- 2 1-- 2--3
INJECTION PRESSURE
(Valve Opening Pressure)
COMPRESSION RATIO 23.5 : 1
LUBRICATING SYSTEM Forced Lubrication by Pump
COOLING SYSTEM Pressurized Radiator, Forced Circulation With Water Pump
STARTING SYSTEM Cell Starter (With Glow Plug)
STARTING MOTOR 12V,0.8 kW
RECOMMENDED BATTERY CAPACITY
(5 Hour Capacity)
CHARGING GENERATOR 12V,150 W 12V, 150 W
FUEL Diesel Fuel No.2--D (ASTM D975)
LUBRICATING OIL *Quality Better Than CF Class (API), SAE 10W--30 or 15W--40
LUBRICATING OIL CAPACITY
Weight (DRY) kg (lbs.) 53.1 (117.1) 63.1 (139.1)
SAE Intermittent H.P.
kW (HP) / RPM
9.3 (12.5) / 3600 14.0 (18.0) / 3600
13.73 MPa (140 kgf/cm2, 1991 psi.)
12V,28AH, equivalent 12V,36AH, equivalent
2.5 L (2.64 U.S. Quarts)
3.3 L (3.5 U.S. Quarts) (TFX--1 Only)
3.8 L (4.02 U.S. Quarts)
*See paragraph 1.7.2.
62--11161
1--2
1.2.1 E2B ENGINE
Carrier/Kubota supply diesel engines conforming to
federalemission regulations.The emissioncontrols 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
Tier2/ Phase 2requirements, wehave adapted E2Bas
a new model namefor theengines 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
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.
The cylinder numbers of diesel 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
2
2
1. Grease
2. Force
3. Place the Sharp Edge
against the Direction of Force
3
A External Snap Ring
B Internal Snap Ring
3
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.
1--3
62--11161
1.4 TORQUE SPECIFICATION
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench. Several screws, bolts and
nuts such as those used on the cylinder head must be tightened in the proper sequence and at the proper torque.
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts
In removing andapplying the screws, bolts and nuts marked with “*”, apneumatic wrenchor similar tool, ifemployed,
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.
Item
SizexPitch N.m kgf.m ft--lbs
Cylinder Head Cover Bolt M6 x 1.0 6.9to11.3 0.7to1.15 5.1to8.3
Injection Pipe Retaining Nut M12 x 1.5 24.5 to 34.3 2.5to3.5 18.1 to 25.3
Overflow Pipe Retaining Bolt M12 x 1.5 19.6 to 24.5 2.0to2.5 14.5 to 18.1
Nozzle Holder Assembly M20 x 1.5 49.0 to 68.6 5.0to7.0 36.2 to 50.6
Glow Plug M8 x 1 7.85 to 14.7 0.8to1.5 5.8 to 10.8
*Rocker Arm Bracket Bolt M6 x 1 9.8to11.3 1.0to1.15 7.2to8.3
*Cylinder Head Bolt M8 x 1.25 37.3 to 42.2 3.8to4.3 27.5 to 31.1
*Fan Drive Pulley Bolt M12 x 1.5 1 17.7 to 127.5 12.0 to 13.0 86.8 to 94.0
*Idle Gear Shaft Mounting Bolt M6 x 1 9.8to11.3 1.0to1.15 7.2to8.3
Oil Pump Mounting Bolt M8 x 1.25 17.7 to 21.6 1.8to2.2 13.0 to 15.9
*Connecting Rod Bolt M7 x 0.75 26.5 to 30.4 2.7to3.1 19.5 to 22.4
*Flywheel Bolt M10 x 1.25 53.9 to 58.8 5.5to6.0 39.8 to 43.4
*Bearing Case Cover Mounting Bolt M6 x 1 9.8to11.3 1.00 to 1.15 7.2to8.3
*Main Bearing Case Bolt 2 M7 x 1 26.5 to 30.4 2.7to3.1 19.5 to 22.4
*Main Bearing Case Bolt 1 M6 x 1 12.7 to 15.7 1.3to1.6 9.4to11.6
Nozzle Holder -- 34.3 to 39.2 3.5to4.0 25.3 to 28.9
Overflow Pipe -- 19.6 to 24.5 2.0to2.5 14.5 to 18.1
Nozzle Holder Assembly -- 49.0 to 68.6 5.0to7.0 36.2 to 50.6
Oil Pressure Switch PT1/8 14.7 to 19.6 1.5to2.0 10.8 to 14.5
Starter (C Terminal Nut) (CT2--29--TV) M8 7.8to9.8 0.8to1.0 5.8to7.2
Starter (B Terminal Nut) (CT3--44--TV) M8 8.8to11.8 0.9to1.2 6.5to8.7
Starter (C Terminal Nut) (CT3--44--TV) M8 5.9to11.8 0.6to1.2 4.3to8.7
Drain Plug W/ Copper Gasket M12 x 1.25 32.4 to 37.3 3.3to3.8 23.9 to 27.5
Drain Plug W/ Copper Gasket M22 x 1.5 63.7 to 73.5 6.5to7.5 47.0 to 54.2
Drain Plug W/ Rubber Coated Gasket M12 x 1.25 44.1 to 53.9 4.5to5.5 32.5 to 39.8
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt Grade 4 Special Screw and Bolt Grade 7
N.m kgf.m ft--lbs N.m kgf.m ft--lbs
M6 7.9to9.3 0.80 to 0.95 5.8to6.9 9.8to11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8to2.1 13.0 to 15.2 23.5 to 27.5 2.4to2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0to4.6 28.9 to 33.3 48.1 to 55.9 4.9to5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4to7.4 46.3 to 53.5 77.5 to 90.2 7.9to9.2 57.1 to 66.5
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
None or 4 Standard Screw And Bolt SS41, S20C
7 Special Screw And Bolt S43C, S48C (Refined)
62--11161
1--4
1.5 TROUBLESHOOTING
Symptom
Engine Does Not
Start
(Starter Does Not
Run)
Engine Revolution
Is Not Smooth
Either White or Blue
Exhaust Gas Is
Observed
Probable Cause Solution Reference
No fuel Replenish fuel
Air in the fuel system Vent Air 1.7.5
Change fuel and
Water in the fuel system
repair or replace fuel
1.7.5
system
Fuel pipe clogged Clean 1.7.5
Fuel filter clogged Clean or change -Excessively high viscosity of fuel or engine oil
at low temperature
Use specified fuel or
engine oil
--
Fuel with low cetane number Use specified fuel -Fuel leak due to loose injection pipe retaining
nut
Tighten retaining nut 2.2.4.b
Incorrect injection timing Adjust 5.1.1
Fuel camshaft worn Replace 2.2.6.g
Injection nozzle clogged Replace 5.2.1/5.2.2
Injection pump malfunctioning Replace -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
Improper valve timing
Correct or replace
timing gear
2.2.6.e
Piston ring and cylinder worn Replace 2.3.3.d
Excessive valve clearance Adjust 1.7.6
Battery discharged Charge
Starter malfunctioning Repair or replace 6.2/6.3
Wiring disconnected Connect -Fuel filter clogged or dirty Clean or change 1.7.5
Air cleaner clogged or dirty Clean or change -Fuel leak due to loose injection pipe retaining
nut
Tighten retaining nut --
Injection pump malfunctioning Replace 2.2.6.a
Incorrect nozzle injection pressure Replace 5.2.2
Injection nozzle stuck or clogged Replace 5.2.2
Governor malfunctioning Repair 2.2.6.g
Excessive engine oil
Reduce to specified
level
1.7.1
Piston ring and liner worn or ring stuck Repair or replace 2.3.3.d
Incorrect Injection timing Adjust 5.1.1
Check the cylinder
Deficient compression
compression
pressure and top
2.1.1
clearance
1--5
62--11161
1.5 TROUBLESHOOTING (Continued)
Symptom
Either Black or Dark
Exhaust Gas Is
Observed
Deficient Output
Excessive Lubricant
Oil Consumption
Fuel Mixed into
Lubricant Oil
Water Mixed into
Lubricant Oil
Low Oil Pressure
High Oil Pressure
Probable Cause Solution Reference
Overload Lesson load -Low grade fuel used Use specified fuel -Fuel filter clogged Clean or change -Air cleaner clogged Clean or change -Deficient nozzle injection Replace nozzle 5.2.4
Incorrect injection timing Adjust 5.1.1
Engine’s moving parts seem to be seizing Repair or replace --
Uneven fuel injection
Deficient nozzle injection
Replace injection
pump
Repair or replace
nozzle
2.2.6.a
5.2.4
Check the
Compression leak
compression
2.1.1
pressure and repair
Piston ring’s gap facing the same direction
Shift ring gap
direction
2.2.7.b
Oilringwornorstuck Replace 2.3.3.d
Piston ring groove worn Replace worn piston 2.3.3.e
Valve stem and valve guide worn Replace 2.3.1.d
Oil leaking due to defective seals or packing Replace --
Injection pump’s plunger worn
Replace Injection
pump
5.1
Deficient nozzle injection Replace nozzle 5.2.4
Injection pump broken Replace 5.1
Head gasket defective Replace 2.2.4.e
Cylinder block or cylinder head flawed Replace -Engine oil level low Replenish -Oil filter cartridge clogged Replace -Relief valve stuck with dirt Clean 3.1.5
Relief valve spring weak or broken Replace 3.1.5
Excessive clearance of crankshaft bearing Replace 2.3.4.d
Excessive clearance of crankpin bearing Replace 2.3.4.c
Excessive clearance of rocker arm Replace 2.3.1.k
Oil passage clogged Clean --
Incorrect oil type
Use specified type of
oil
--
Oil pump defective Repair or replace 2.2.6.h/3.2
Incorrect oil type
Use specified type of
oil
--
Relief valve defective Replace 3.1.5
62--11161
1--6
1.5 TROUBLESHOOTING (Continued)
Symptom
Engine Overheated
Low Battery Charge
Probable Cause Solution Reference
Engine oil level low Replenish -Fan belt broken or improperly tensioned Replace or adjust -Coolant insufficient Replenish -Radiator net and radiator fin clogged with dust Clean -Inside of radiator corroded Clean or replace -Coolant flow route corroded Clean or replace -Radiator cap defective Replace -Radiator hose defective Replace -Running overloaded Reduce load -Head gasket defective Replace 2.2.4.e
Incorrect injection timing Adjust -Unsuitable fuel used Use specified fuel --
Battery electrolyte level low
Fan belt slips
Replenish distilled
water and charge
Adjust belt tension or
change belt
--
--
Wiring disconnected Connect -Rectifier defective Replace -Alternator defective Replace -Battery defective Change --
1--7
62--11161
1.6 SERVICING SPECIFICATIONS
1.6.1 Engine Body
Item
Valve Clearance (Cold)
Compression Pressure
Factory Specification Allowable Limit
0.145 to 0.185 mm
0.00571 to 0.00728 in.
2.84 to 3.24 MPa
29.0to33kgf/cm
2
412 to 469 psi
--
2.26 MPa
23.0kgf/cm
327 psi
Difference Between Cylinders -- 10% or less
Top Clearance
Cylinder Head Surface Flatness
Valve Recessing (Intake and Exhaust)
Clearance
ValveStemtoValveGuide
Valve Stem
O.D.
Valve Guide
I.D.
Valve Face Angle
Angle
Valve Seat
Width
Free Length
Valve Spring
Tilt --
Setting Load/
Setting Length
Clearance
Rocker Arm Shaft to Rocker Arm
Rocker Arm
Shaft (O.D.)
Rocker Arm (I.D.)
Push Rod Alignment
Clearance
Tappet to Tappet Guide
Tappet (O.D.)
Tappet Guide
(I.D.)
0.50 to 0.70 mm
0.0197 to 0.0276 in.
--0.10 to 0.10 mm
--0.0039 to 0.0039 in.
0.030 to 0.057 mm
0.00118 to 0.00224 in.
5.968 to 5.980 mm
0.23496 to 0.23543 in.
6.010 to 6.025 mm.
0.23661 to 0.23720 in.
0.785 rad.
45°
0.785 rad.
45°
2.12 mm
0.0835 in.
31.3 to 31.8 mm
1.232 to 1.252 in.
64.7 N / 27.0 mm
6.6 kgf / 27.0 mm
14.6 lbs. / 1.063 in.
0.016 to 0.045 mm
0.00063 to 0.00177 in.
10.473 to 10.484 mm
0.41232 to 0.41276 in.
10.500 to 10.518 mm
0.41339 to 0.41410 in.
-- 0.25mm
0.016 to 0.052 mm
0.00063 to 0.00205 in.
17.966 to 17.984 mm
0.70732 to 0.70803 in.
18.000 to 18.018 mm
0.70866 to 0.70937 in.
--
0.05 mm
0.0020 in.
0.30 mm
0.0118 in.
0.10 mm
0.0039 in.
--
--
--
--
--
28.4 mm
1.118 in.
1.2 mm
0.047 in.
54.9N / 27.0 mm
5.6kgf / 27.0 mm
12.3lbs /1.063 in.
0.15 mm
0.0059 in.
--
--
0.0098 in.
0.10 mm
0.0039 in.
--
--
2
62--11161
1--8
1.6.1 Engine Body (Continued)
Item
Crank Gear to
Idle Gear
(Backlash)
Idle Gear to Cam
Gear (Backlash)
Timing Gear
Idle Gear to Injection Pump Gear
(Backlash)
Crank Gear to Oil
Pump Gear
(Backlash)
Idle Gear Side Clearance
Side Clearance
Camshaft
Alignment -Height
(Intake / Exhaust)
Clearance 0.050 to 0.091 mm
Camshaft Journal to Cylinder Block Bore
Camshaft
Journal (O.D.)
Cylinder Block
Bore (I.D.)
Clearance 0.020 to 0.084 mm
Idle Gear Shaft to Idle Gear Bushing
Idle Gear Shaft
(O.D.)
Idle Gear Bushing
(I.D.)
Piston Pin Bore I.D.
Clearance
Piston Pin to Small End Bushing
Piston Pin (O.D.)
Small End
Bushing (I.D.)
Piston Pin to Small End Bushing
(Spare Parts)
Clearance
Small End
Bushing (I.D.)
Top Ring
Piston Ring Gap
Second Ring
Oil Rng
Factory Specification Allowable Limit
0.043 to 0.124 mm
0.00169 to 0.00488 in.
0.047 to 0.123 mm
0.00185 to 0.00484 in.
0.046 to 0.124 mm
0.00181 to 0.00488 in.
0.041 to 0.123 mm
0.00161 to 0.00484 in.
0.20 to 0.51 mm
0.0079 to 0.0201 in.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.80 mm
0.0315 in.
0.50 mm
0.0197 In.
0.01 mm
0.0004 In.
26.88 mm
1.0583 in.
26.83 mm
1.0563 In.
0.15 mm
0.00197 to 0.00358 in.
32.934 to 32.950 mm
1.29661 to 1.29724 in
33.000 to 33.025 mm
1.29921 to 1.30020
0.00059 in.
--
--
0.1 mm
0.00079 to 0.00331 in.
19.967 to 19.980 mm
0.78610 to 0.78661 in.
20.000 to 20.051 mm
0.78740 to 0.78791 in.
20.000 to 20.013 mm
0.78740 to 0.78941 in.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
20.002 to 20.011 mm
0.78748 to 0.78783 in.
20.025 to 20.040 mm
0.78839 to 0.78897 in.
0.015 to 0.075 mm
0.00059 to 0.00295 in.
20.026 to 20.077 mm
0.78845 to 0.79043 in.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
0.0039 in.
--
--
20.05 mm
0.7894 in.
0.10 mm
0.0039 in.
--
--
0.15 mm
0.0059 in.
--
1.20 mm
0.0472 in.
1.20 mm
0.0472 in.
1.20 mm
0.0472 in.
1--9
62--11161
1.6.1 Engine Body (Continued)
Item
Piston Ring to Piston Ring Groove
Second Ring
Clearance
Oil Ring
Clearance
Factory Specification Allowable Limit
0.090 to 0.120 mm
0.00354 to 0.00472 in.
0.040 to 0.080 mm
0.0016 to 0.0031 in.
Connecting Rod Alignment --
Side Clearance
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Crankshaft
Alignment --
0.020 to 0.051 mm
0.00079 to 0.00201 in.
33.959 to 33.975 mm
1.33697 to 1.33760 in.
33.995 to 34.010 mm
1.33893 to 1.33898 in.
0.034 to 0.106 mm
0.00134 to 0.00417 in.
39.934 to 39.950 mm
1.57221 to 1.57284 in.
39.984 to 40.040 mm
1.57148 to 1.57638 in.
0.028 to 0.051 mm
0.00110 to 0.00201 in.
43.934 to 43.950 mm
1.72968 to 1.73031 in.
43.984 to 44.026 mm
1.73165 to 1.73331 in.
0.028 to 0.051 mm
0.00110 to 0.00201 in.
39.934 to 39.950 mm
1.57221 to 1.57284 in.
39.984 to 40.026 mm
1.57417 to 1.57583 in.
67.000 to 67.019mm
2.63779 to 2.63854 in.
67.250 to 67.269mm
2.64764 to 2.64839 in.
Crankpin to Crankpin Bearing
Crankshaft Journal to Crankshaft Bearing1
Crankshaft Journal to Crankshaft Bearing2
(Flywheel Side)
Crankshaft Journal to Crankshaft Bearing3
(Intermediate)
Cylinder Liner
Oil Clearance
Crankpin (O.D.)
Crankpin Bearing
(I.D.)
Oil Clearance
Crankshaft
Journal (O.D.)
Crankshaft
Bearing1 (I.D.)
Oil Clearance
Crankshaft
Journal (O.D.)
Crankshaft
Bearing2 (I.D.)
Oil Clearance
Crankshaft
Journal (O.D.)
Crankshaft
Bearing3 (I.D.)
I.D. (Standard)
I.D. (Oversize) :
0.25mm
0.0098in.
0.15 mm
0.0059 in
0.15 mm
0.0059 in.
0.05 mm
0.0020 in.
0.50 mm
0.0197 in.
0.02 mm
0.0008 in.
0.15 mm
0.0059 in.
--
--
0.20 mm
0.0079 in.
--
--
0.20 mm
0.0079 in.
--
--
0.20 mm
0.0079 in.
--
--
67.150 mm
2.64370 in.
67.400mm
2.65354 in.
62--11161
1--10
1.6.2 Lubricating System
Item
At Idle Speed
Engine Oil Pressure*
At Rated Speed
Inner Rotor to Outer Rotor Clearance
Outer Rotor to Pump Body Clearance
Inner Rotor to Cover Clearance
*Engines installed in Genesis, Solara and Supra units use an oil pressure safety switch which opens at
105 kPa / 1.06 kgf/cm
2
/ 15 psi.
Factory Specification Allowable Limit
More than 49kPa
0.5 kgf/cm
196 to 441 kPa
2.0 to 4.5kgf/cm
2
/7psi
2
/28to64psi
147kPa
1.5kgf/cm
0.03 to 0.14 mm
0.0012 to 0.0055 in.
0.07 to 0.15 mm
0.0028 to 0.0059 in.
0.075 to 0.135 mm
0.00295 to 0.00531 in.
--
2
/21psi
--
--
--
1.6.3 Cooling System
Item
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.)
Thermostat
Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened Completely)
69.5 to 72.5°C
157 to 162.5°F
85°C
185°F
--
--
10 seconds or more
Radiator Cap Pressure Falling Time
88 to 59kPa
0.9 to 0.6 kgf/cm
2
--
13to9psi
No leaks at specified
Radiator
Leakage Test
Pressure
pressure
157 kPa / 1.6 kgf/cm
2
--
23 psi
1.6.4 Fuel System
Injection Pump
Item
Injection Timing
(3600 min
-- 1
rpm)
Factory Specification Allowable Limit
0.33 to 0.37 rad. (19° to
21°) before T.D.C
Pump Element Fuel Tightness --
10 seconds
Delivery Valve Fuel Tightness
13.73 to12.75 MPa
140 to130 kgf/cm
1991 to 1849 psi
13.73 to 14.71 MPa
Injection Pressure
140 to 150 kgf/cm
1991 to 2134 psi
Fuel Injection Nozzle
Valve Seat
Tightness
When the pressure is
12.75 MPa
(130 kgf/cm
valve must not pass fuel
1--11
2
2
2,1849 psi) the
--
13.73 MPa
140 kgf/cm
2
1991 psi
5 seconds
13.73 to12.75
MPa
140 to130 kgf/cm
1991 to 1849 psi
--
--
62--11161
2
1.6.5 Electrical System
Item
Glow Plug Resistance Approximately 0.9 OHM --
CT2--29--TV
Commutator O.D.
CT3--44--TV
CT2--29--TV
Difference of O.D.
Starter
Mica Undercut
Brush Length
1.7 CHECK AND MAINTENANCE
1.7.1 Checking Engine Oil Level
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.
2. The fuel hoseis made of rubber and ages regardless
of the service period. Change the hose and clamps
together every two years.
3. Change the fuel hose and clamps whenever any de-
terioration or damage is detected.
4. After the fuel hose and clamps have been changed,
bleed air out of the fuel system.
CT3--44--TV
CT2--29--TV
CT3--44--TV
1.7.5 Bleeding Fuel System
1. Open the air vent cock (1) on top of the fuel injection
2. Energizethe electricfuel pumpfor aperiodof 10to15
3. Close the air vent cock (1).
Factory Specification Allowable Limit
28.0 mm
1.1.102 in.
30.0 mm
1.181 in.
Less than 0.05 mm
0.0002 in.
Less than 0.02 mm
0.0008 in.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
0.16 mm
0.630 in.
0.14 mm
0.551 in.
1
pump. (Availableon Solara, Supraand Genesis units
only.)
seconds, orjust longenough toexpel fuelthroughthe
air vent cock.
27.0 mm
1.063 in.
29.0 mm
1.142 in.
0.4 mm
0.016 in.
0.05 mm
0.0020 in.
0.20 mm
0.0079 in.
10.5 mm
0.413 in.
9.0 mm
0.354 in.
CAUTION
Stop the engine when attempting to check
and change the fuel line.
62--11161
NOTE
Always keep the air vent cock on the fuel injectionpump closed except when bleedingthe fuel
system, or the engine may not run.
1--12
1.7.6 Valve Clearance
NOTE
Valveclearance must bechecked andadjusted
when the engine is cold.
1. Remove the valve cover (1).
2. Align the “1TC” mark line (2) on the flywheel and projection (3)on thehousing sothat the 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 specifications, 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 therear endplateso that theNo. 1pistoncome
to the overlap position.
6. Check the following valve clearance marked with “*”
(past TDC) using a feeler guage.
CT2--29--TV
Piston Location in Cylinder IN. EX.
When No. 1 piston is at TDC
When No. 1 piston is past TDC
No. 1 * *
No. 2 *
No. 1
No. 2 *
Valve
Arrangement
1. Cylinder Head Cover
2. “1TC” Mark
3. Alignment Mark
A. Gear Case End
a. CT2--29--TV
b. CT3--44--TV
CT3--44--TV
Piston Location in Cylinder IN. EX.
When No. 1 piston is at TDC
When No. 1 piston is past TDC
No. 1 * *
No. 2 *
No. 3 *
No. 1
No. 2 *
No. 3 *
Valve
Arrangement
7. If the clearance is not within the factory specifications, adjust with the adjusting screw.
NOTE
The sequence of cylinder numbers is given as
No.1,No.2 andNo.3startingfrom thegearcase
end.
After adjusting the valve clearance, secure the
adjusting screw with the lock nut.
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
1.8 SPECIAL TOOLS (Continued)
Adapte
3
8.Adapto
3
1.8.6 Oil Pressure Tester
Code No. 07916--32032
Application: Use to measure lubricating oil
pressure.
1. Guage
2. Adapter 2
3. Cable
4.
r
5. Threaded Joint
6. Adapter 4
7. Adaptor 1
r
1.8.7 Auxiliary Socket For Fixing Crankshaft
Sleeve
Code No. 07916--32091
Application: Use to fix the crankshaft sleeve of the
diesel engine.
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
1.8 SPECIAL TOOLS (Continued)
The following are drawings for special tools that may need to be fabricated.
1.8.11 Valve Guide Replacing Tool
Application: Use to press out and press fit the valve
A
B 11.7to 11.9mm dia. (0.460 to 0.468 in. dia.)
C 6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)
D 225 mm (8.86 in.)
E 70 mm (2.76 in.)
F 45 mm (1.77 in.)
G 25 mm (0.98 in.)
H 5 mm (0.197 in.)
I 6.7to 7.0 mm dia. (0.263 to 0.275 in. dia.)
J 20 mm dia. (0.787 in. dia.)
K 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.)
C1 Chamfer 1.0 mm (0.039in.)
C2 Chamfer 2.0 mm (0.079in.)
C0.3 Chamfer 0.3 mm (0.012in.)
1.8.12 Bushing Replacing Tools
Application: Use to press out and press fit the bushing.
1. For small end bushing.
A
B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95 mm (0.7835 to 0.7854 in.) dia.
E 21.90 to 21.95 mm (0.8622 to 0.8642 in.) dia.
F 25.00 mm (098 in.) dia.
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
2. For idle gear bushing.
A
B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95.95 mm (0.7835 to 0.7854 in.)
E 21.90 to 21.95 mm (0.8622 to 0.8642 in.) dia.
F 25 mm (0.98 in.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
1.8.13 Flywheel Stopper
Application: Use to loosen and tighten the flywheel
A
B 20 mm (0.79 in.)
C 30 mm (1.18 in.)
D 8 mm (0.31 in.)
E 10 mm (0.39 in.)
guide.
20 mm dia. (0.79 in. dia.)
145 mm (5.71 in.)
150 mm (5.91 in.)
screw.
200 mm (7.87 in.)
62--11161
1--16
1.8 SPECIAL TOOLS (Continued)
1.8.14 Crankshaft Bearing 1 Replacing Tool
Application: Usetopress outandpressfit thecrankshaft
bearing No. 1
1. Extracting tool
135 mm (5.31 in.)
A
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 10 mm (0.39 in.)
E 22 mm (0.87 in.)
F 20 mm dia. (0.79 in. dia.)
G 47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)
H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)
2. Installing tool
A
130 mm (5.12 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 9 mm (0.35 in.)
E 24 mm (0.95 in.)
F 20 mm dia. (0.79 in.dia.)
G 68 mm dia. (2.68 in. dia.)
H 39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)
1--17
62--11161
SECTION 2
ENGINE BODY
2.1 CHECKING AND ADJUSTING
2.1.1 Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine and disconnect the 2P connector
from the stop solenoid to prevent fuel delivery to the
engine.
3. Remove the the air cleaner, the muffler and all the
glow plugs.
4. Install acompressiontester withthe adapter inone 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.
2.1.2 Top Clearance
7. If themeasurementis belowthe allowablelimit,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. If thecompression pressureincreasesafterapplying
oil, check the cylinder wall and piston rings.
NOTE
Check the compression pressure with the specified valve clearance
Always use a fully charged battery for performing this test.
Variances in cylinder compression values
should be under 10%.
2.84 to 3.24 MPa
29 to 33 kgt/cm
412 to 469 psi
2.26 MPa
23 kgt/cm
2
327 psi
2
Compression
Pressure
Factory
Specification
Allowable Limit
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 thepistonhead atthreepositions shown on the
illustration.
4. Lower the piston andinstall 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 plastigage .
7. If the measurement is not within the factory specifications, check the clearances between the crank pin
and bearing and between the piston pinand bushing.
Top Clearance
Tightening
Torque
Factory
Specification
Cylinder Head
Bolts
0.50 to 0.70 mm
0.0197 to 0.0276 in.
37.3 to 42.2 N.m
3.8to4.3kgf
27.5 to 31.1 ft--lbs
.
m
2--1
62--11161
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