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Carrier TRANSICOLD CT2-29-TV Workshop Manual

Truck / comfortpro
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Diesel Engine
Workshop Manual
For
CT2-29-TV (Z482-E2B)
Truck / ComfortPro
CT3-44-TV (D722-E2B)
Truck
Beginning with Serial Number 5A0001
62-11161 Rev D

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Summary of Contents for Carrier TRANSICOLD CT2-29-TV

  • Page 1 Diesel Engine Workshop Manual CT2-29-TV (Z482-E2B) Truck / ComfortPro CT3-44-TV (D722-E2B) Truck Beginning with Serial Number 5A0001 62-11161 Rev D...

  • Page 3: Workshop Manual

    Workshop Manual CT2-29-TV (Z482-E2B) Truck / ComfortPro CT3-44-TV (D722-E2B) Truck Beginning with Serial Number 5A0001 © Carrier Corporation, 2018 Printed in U. S. A. September 2018...
  • Page 5 Manual Revision History FOR 62-11161 Rev. Date Reason for Release New product – new manual 10/12/2017 Converted to FrameMaker. No content changed. 10/01/2018 Removed reference to use of sealant on injection pump gaskets (page 6-1); added Revision History...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS PARAGRAPH NUMBER PAGE SAFETY SUMMARY ..............1–1 SAFETY PRECAUTIONS .
  • Page 8 ENGINE BODY ............... . 3–1 CHECKING AND ADJUSTING .
  • Page 9 7–1 STARTER (CT2-29-TV) ............
  • Page 11 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2.1 Serial Number Location ............2–1 Figure 2.2 Serial Number Reference Chart .
  • Page 12 Figure 3.22 Pistons ..............3–15 Figure 3.23 Piston Ring and Connecting Rod .
  • Page 13 Figure 7.3 Starter Test CT2-29-TV ........

  • Page 14: List Of Tables

    LIST OF TABLES TABLE NUMBER Page Table 2–1 Model Chart With Service Parts List ..........2–2 Table 2–2 Specification Chart .

  • Page 15: Safety Summary

    SAFETY SUMMARY Safety Precautions Your Carrier Transicold unit has been designed with the safety of the operator in mind. During normal operation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspections, and problem troubleshooting, you may be exposed to moving parts.
  • Page 16 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 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.

  • Page 17: Engine Identification

    SECTION 2 GENERAL Engine Identification 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. Application information and service parts lists for specific engines are listed in Table 2–1.

  • Page 18: Table 2-1 Model Chart With Service Parts List

    Table 2–1 Model Chart With Service Parts List CARRIER SERIAL ENGINE TIER PART NO. & NUMBER PRIMARY USE TYPE LEVEL PARTS LIST MODEL BREAK 26-60001-00/-02 SUPRA 422/522/550 Z482-B-CTD-2E Prior to S/N – 62-02782 5A0001 26-60001-01/-03 SOLARA Units Z482-B-CTD-1 26-60001-04 SUPRA 422/522/550 Z482-E2B-CTD-2 5A0001 CT2-29TV...

  • Page 19: Engine Specifications

    Engine Specifications Table 2–2 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 BORE X STROKEmm X mm (in. X in.) 67 X 68 (2.64 X 2.68) TOTAL DISPLACEMENT cm (cu.in.)

  • Page 20: Cylinder Number

    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.

  • Page 21: Figure 3.21 Connecting Rod

    36.2 to 50.6 Oil Pressure Switch PT1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5 Starter (C Terminal Nut) (CT2-29-TV) 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2 Starter (B Terminal Nut) (CT3-44-TV) 8.8 to 11.8 0.9 to 1.2 6.5 to 8.7...

  • Page 22: Troubleshooting

    2.4.2 Torque Specifications For General Use Screws, Bolts and Nuts Table 2–4 Torque Specifications For General Use Screws, Bolts and Nuts Standard Screw and Bolt Grade 4 Special Screw and Bolt Grade 7 kgf.m ft-lbs kgf.m ft-lbs 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3...
  • Page 23 Table 2–5 Troubleshooting Chart (Continued) Symptom Probable Cause Solution Reference Battery discharged Charge – Starter Does Starter malfunctioning Repair or replace 7.2/7.3 Not Run Wiring disconnected Connect – Fuel filter clogged or dirty Clean or change 2.7.5 Air cleaner clogged or dirty Clean or change –...

  • Page 24: Lubricant Oil

    Table 2–5 Troubleshooting Chart (Continued) Symptom Probable Cause Solution Reference Water Mixed Head gasket defective Replace 3.2.4 into Cylinder block or cylinder head flawed Replace – Lubricant Oil Engine oil level low Replenish – Oil strainer clogged Clean – Relief valve stuck with dirt Clean 4.1.5 Relief valve spring weak or broken...

  • Page 25: Servicing Specifications

    Servicing Specifications Table 2–6 Servicing Specifications Item Factory Specification Allowable Limit 2.6.1 Engine Body 0.145 to 0.185 mm Valve 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 412 to 23.0kgf/cm 469 psi 327 psi Difference Between Cylinders...
  • Page 26 Table 2–6 Servicing Specifications (Continued) Item Factory Specification Allowable Limit 0.016 to 0.052 mm 0.10 mm Clearance 0.00063 to 0.00205 in. 0.0039 in. 17.966 to 17.984 mm Tappet to Tappet Guide Tappet (O.D.) 0.70732 to 0.70803 in. 18.000 to 18.018 mm Tappet Guide (I.D.) 0.70866 to 0.70937 in.
  • Page 27 Table 2–6 Servicing Specifications (Continued) Item Factory Specification Allowable Limit 0.015 to 0.075 mm 0.15 mm Clearance 0.00059 to 0.00295 in. 0.0059 in. Piston Pin to Small End Bushing (Spare Parts) Small End 20.026 to 20.077 mm Bushing (I.D.) 0.78845 to 0.79043 in. 0.15 to 0.30 mm 1.20 mm Top Ring...

  • Page 28: Lubricating System

    Table 2–6 Servicing Specifications (Continued) Item Factory Specification Allowable Limit 67.000 to 67.019mm 67.150 mm I.D. (Standard) 2.63779 to 2.63854 in. 2.64370 in. Cylinder Liner I.D. (Oversize): 67.250 to 67.269mm 67.400mm 0.25mm 0.0098in. 2.64764 to 2.64839 in. 2.65354 in. 2.6.2 Lubricating System More than 49kPa At Idle Speed...

  • Page 29: Electrical System

    12.75 MPa Tightness ,1849 psi) the (130 kgf/cm valve must not pass fuel 2.6.5 Electrical System Starter 28.0 mm 27.0 mm CT2-29-TV 1.1.102 in. 1.063 in. Commutator O.D. 30.0 mm 29.0 mm CT3-44-TV 1.181 in. 1.142 in. Less than 0.05 mm 0.4 mm...

  • Page 30: Check And Maintenance

    Check and Maintenance 2.7.1 Checking Engine Oil Level Refer to Section 4.1.1 2.7.2 Changing Engine Oil Refer to Section 4.1.2 2.7.3 Checking Coolant Level Refer to Section 5.1.3 2.7.4 Checking Fuel Hose 1. If the clamp is loose, apply oil to the threads and securely re-tighten it. 2.

  • Page 31: Valve Clearance

    2.7.6 Valve Clearance Figure 2.6 Valve Clearance NOTE Valve clearance must be checked and adjusted when the engine is cold. 1. Remove the valve cover. 2. Align the “1TC” mark line (2) on the fly- wheel and projection (3) on the housing so that the Number 1 piston comes to com- pression or overlap top dead center (TDC).

  • Page 32: Special Tools

    Special Tools Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number 62-03213 2.8.1 Diesel Engine Compression Tester Figure 2.7 Diesel Engine Compression Tester (Glow Plug) Part No. 07-00179-01 (Assembly) Application: Use to measure diesel engine compression and diagnosis for major overhaul.

  • Page 33: Adapter, Injector Line

    2.8.5 Adapter, Injector Line Figure 2.11 Adapter, Injector Line Part No. 07-00036-00 Application: Accessory for 07-00140-00 2.8.6 Oil Pressure Tester Figure 2.12 Oil Pressure Tester Code No. 07916-32032 Application: Use to measure lubricating oil pressure. 1. Guage 5. Threaded Joint 2.

  • Page 34: Tester, Belt Tension

    2.8.9 Tester, Belt Tension Figure 2.15 Tester, Belt Tension Part No. 07-00253-00 Application: Used to test belt tension. 2.8.10 Rubber Band Figure 2.16 Rubber Band Part No. 07-00253-01 Application: Replacement part for belt tension tester (Part No. 07-00253-00) The following are drawings for special tools that may need to be fabricated. 2.8.11 Valve Guide Replacing Tool Figure 2.17 Valve Guide Replacing Tool...

  • Page 35: Flywheel Stopper

    2.8.12 Bushing Replacing Tools Figure 2.18 Brushing Replacing Tool Application: Use to press out and press fit the bushing 1. For small end bushing. 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm (0.7835 to 0.7854 in.) dia.
  • Page 36 2.8.14 Crankshaft Bearing 1 Replacing Tool Figure 2.20 Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing No. 1 1. Extracting Tool 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10mm (0.39 in.) 22 mm (0.87 in.) 20 mm dia.

  • Page 37: Engine Body

    SECTION 3 ENGINE BODY Checking and Adjusting 3.1.1 Compression Pressure Figure 3.1 Compression Test 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.

  • Page 38: Top Clearance

    3.1.2 Top Clearance Figure 3.2 Piston Top Clearance Figure 3.3 Piston Gauge 1. Piston 2. Plastic Gauge 1. Remove the valve cover. (Refer to Section 3.2.4) 2. Remove the cylinder head. 3. Move the piston (1) up and stick a strip of plastic gauge (2) on the piston head at three positions shown on the illustration.
  • Page 39 3.2.3 External Components Alternator, Figure 3.4 Starter and 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 starter. 4.

  • Page 40: Cylinder Head And Valves

    3.2.4 Cylinder Head And Valves Valve Cover Figure 3.5 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 condi- tion and in place.

  • Page 41: Figure 3.7 Nozzle Holder Assembly And Glow Plugs

    Nozzle Holder Assembly and Glow Plug Figure 3.7 Nozzle Holder Assembly and Glow Plugs 1. Remove the overflow pipe assembly. 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).

  • Page 42: Figure 3.9 Cylinder Head

    Cylinder Head Figure 3.9 Cylinder Head 1. Loosen the hose clamp (1), and remove the water return pipe (2). 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.
  • Page 43 Tappets Figure 3.10 Tappets 1. Remove the tappets (1) from the crankcase. 2. Visually check the tappets for any abnormal cam- shaft 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.

  • Page 44: Oil Pan And Oil Pick-Up Screen

    6. Visually inspect the oil pick-up screen O-ring (4) for damage, oil it and reinstall. CT3- -44- -TV 7. CT2-29-TV engine, use hole labeled 2, CT3-44-TV engine, use hole labeled 3 to install the pick-up screen mounting bolt. 8. Apply gasket cement (sealer) so that the sealer is about 3 to 5 mm (0.12 to 0.20 in.) thick around the...

  • Page 45: Timing Gear, Camshaft And Fuel Camshaft

    3.2.6 Timing Gear, Camshaft and Fuel Camshaft Injection Pump, Fuel Feed Pump and Speed Control Figure 3.13 Injection Pump, Fuel Feed Pump and Plate (Solara, Supra, Genesis and PC5000 Units Only.) Speed Control Plate (Solara, Supra, Genesis and PC5000 Units Only.) 1.
  • Page 46 Injection Pump, Fuel Feed Pump and Speed Control Figure 3.14 Injection Pump, Fuel Feed Pump and Plate (Z482-E2b-TFX-1 Only) Speed Control Plate (Z482-E2b-TFX-1 Only) NOTE Specific Tool (1): A 1.2mm (.050 inch) diameter wire with a total length of 200mm (8 inch) with the tip bent into a hook as depicted in the illus- tration is required to hang the governor springs.
  • Page 47 Injection Pump, Fuel Feed Pump and Speed Control Plate (Z482-E2b-TFX-1 Only) (Continued) When Reassembling 1. Move the fork lever (1) to the gear case side. 2. Hook the start spring (7) to the injection pump con- trol rack pin (5). 3.

  • Page 48: Figure 3.15 Fan Drive Pulley

    Fan Drive Pulley Figure 3.15 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.

  • Page 49: Figure 3.17 Idle Gear

    Idle Gear Figure 3.17 Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting bolts (4). 3. Remove the idle gear shaft (5). When Reassembling Apply engine oil to the idle gear shaft mounting bolt (4) and tighten them.

  • Page 50: Figure 3.19 Fuel Camshaft

    Fuel Camshaft Figure 3.19 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.

  • Page 51: Piston And Connecting Rod

    3.2.7 Piston and Connecting Rod Connecting Rod Figure 3.21 Connecting Rod 1. Remove the connecting rod caps (1) using a bi- hexagonal 8 mm socket. Connecting Rod Cap When Reassembling Align the marks (a) with each other. Face the marks toward the injection pump. Apply engine oil to the connecting rod bolts and lightly screw them in by hand, then tighten to the specified torque.

  • Page 52: Figure 3.23 Piston Ring And Connecting Rod

    Piston Ring and Connecting Rod Figure 3.23 Piston Ring and Connecting Rod 1. Remove the piston rings (1), (2), (3). 2. Remove the piston pin (7) and then separate the connecting rod (6) from the piston (5). NOTE Mark both the connecting rod and piston so that if they are to be re-used that the original combi- nation of parts will go back together.

  • Page 53: Crankshaft

    3.2.8 Crankshaft Flywheel Figure 3.24 Crankshaft 1. Position the flywheel (2) so that the “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.

  • Page 54: Crankshaft Assembly

    Crankshaft Assembly Figure 3.26 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 dam- age the crankshaft bearing.

  • Page 55: Figure 3.27 Main Bearing Case Assembly

    Main Bearing Case Assembly Figure 3.27 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.

  • Page 56: Servicing

    Servicing 3.3.1 Cylinder Head And Valves Cylinder Head Surface Flatness Figure 3.28 Cylinder Head Surface 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.

  • Page 57: Figure 3.29 Valve Recessing

    Valve Recessing Figure 3.29 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 recessing (A) with a depth gauge.

  • Page 58: When Installing

    Figure 3.31 Valve Replacing Replacing Valve Guide a. When removing 1. Press out the used valve guide using a valve guide replacing tool. b. When installing 1. Clean a new valve guide and valve guide bore, then apply oil to them. 2.

  • Page 59: Figure 3.34 Valve Lapping

    Correcting Valve and Valve Seat Figure 3.33 Correcting Valve and Valve Seat NOTE Before correcting the valve seat, make certain that the valve and valve guide are within factory specifications. After correcting the valve seat, be sure to check the valve recessing.

  • Page 60: Figure 3.35 Tilt Of Valve Spring

    Free Length and Tilt of Valve Spring Figure 3.35 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.

  • Page 61: Figure 3.38 Push Rod Alignment

    Push Rod Alignment Figure 3.38 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, replace the push rod Push Rod Allowable 0.25 mm Alignment Limit 0.0098 in.

  • Page 62: Timing Gears, Camshaft, And Fuel Camshaft

    3.3.2 Timing Gears, Camshaft, and Fuel Camshaft Timing Gear Backlash Figure 3.39 Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3.

  • Page 63: Figure 3.42 Camshaft Run-Out

    Camshaft Run-Out Figure 3.42 Camshaft Run-Out 1. Support the camshaft with V blocks on a surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Rotate the camshaft and measure for run-out. 4.

  • Page 64: Figure 3.45 Idle Gear Shaft

    Idle Gear Shaft and Idle Gear Bushing Clearance Figure 3.45 Idle Gear Shaft 1. Measure the idle gear shaft O.D. with a micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the clearance. 3. If the measurement exceeds the allowable limit, replace the bushing.

  • Page 65: Piston And Connecting Rod

    3.3.3 Piston and Connecting Rod Piston Pin Bore I.D. Figure 3.47 Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the hori- zontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.

  • Page 66: Figure 3.51 Piston Ring To Groove Clearance

    Piston Ring Gap Figure 3.50 Piston Ring Gap 1. Insert the piston ring into the lower part of the cylin- der (the least worn section). Use the piston to square the ring in the cylinder. 2. Measure the ring gap with a feeler gauge. 3.

  • Page 67: Crankshaft

    3.3.4 Crankshaft Crankshaft End Clearance Figure 3.53 Crankshaft End Clearance 1. Push on the end of the crankshaft to seat it toward the flywheel end of the engine block. 2. Attach, then zero a dial indicator on the forward end of the crankshaft.

  • Page 68: Figure 3.55 Crankpin To Connecting Rod Bearing Clearance

    Crankpin to Connecting Rod Bearing Clearance Figure 3.55 Crankpin to Connecting Rod Bear- ing Clearance 1. Clean the crankpin and the connecting rod bearing. 2. Put a strip of plastigage on the center of the crankpin in each direction as shown in the figure. 3.
  • Page 69 Crankshaft Journal to Crankshaft Bearing #1 Clearance Figure 3.56 Crankshaft Journal 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 inside micrometer and calculate clearance. 3.
  • Page 70 Crankshaft Journal to Crankshaft Bearing Clearance Figure 3.58 Crankshaft Journal to Crankshaft Bearing Clearance 1. Put a strip of plastigage on the center of the crank- shaft journal. 2. Install the bearing case and tighten the bolts to specifi- cation. 3.

  • Page 71: Figure 3.59 Crankshaft Sleeve Wear

    Crankshaft Sleeve Wear Figure 3.59 Crankshaft Sleeve Wear 1. 1. Check the wear on the crankshaft sleeve (1). 2. If the wear exceeds the allowable limit or if the engine oil leaks, replace the crankshaft sleeve (1). Allowable 0.1 mm Sleeve Wear Limit 0.004 in.

  • Page 72: Correcting Cylinder

    3.3.5 Cylinder Cylinder Wear Figure 3.61 Cylinder Wear 1. 1. Measure the I.D. of the cylinder at the six posi- tions (see figure with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Determine the difference (maximum wear) between the maximum and minimum I.D.’s.

  • Page 73: Lubricating System

    SECTION 4 LUBRICATING SYSTEM Checking and Adjusting 4.1.1 Checking Engine Oil Level Figure 4.1 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.

  • Page 74: Changing Oil Filter

    Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed. Lubricating Oil Class Fuel Low- sulfur High- sulfur CG- 4 CH- 4 or CI O: Recommended X: Not Recommended 4.1.3 Changing Oil Filter Figure 4.2 Engine Oil Filter CAUTION Stop the engine when preparing to change the engine oil filter.

  • Page 75: Engine Oil Pressure

    4.1.4 Engine Oil Pressure Figure 4.3 Engine Oil Pressure 1. Remove the engine oil pressure switch, and install an oil pressure gauge. 2. Start the engine. After warming up, read the oil pressure at idling and at rated speeds. 3. If the oil pressure is less than the allowable limit, check the following: Engine oil sufficient •...

  • Page 76: Servicing

    Servicing 4.2.1 Rotor Lobe Clearance Figure 4.5 Rotor Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge. 2. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 3.

  • Page 77: Cooling System

    SECTION 5 COOLING SYSTEM Checking and Adjusting WARNING Beware of moving V-belt and belt driven components 5.1.1 V-Belt Tension 1. Measure the deflection (A), by depressing the belt halfway between the fan drive pulley and alternator pulley at the specified force (Refer to Section 2.6.3).

  • Page 78: Checking Coolant Level

    5.1.3 Checking Coolant Level NOTE When the engine is installed in an APU, follow OEM vehicle instructions as to checking/adjusting engine coolant levels. 1. Turn the engine off. WARNING When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.

  • Page 79: Radiator Cap

    5.1.5 Radiator Cap Figure 5.5 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 Pressure Falling...

  • Page 80: Servicing

    Servicing 5.2.1 Thermostat Assembly Figure 5.8 Thermostat Assembly 1. Remove the thermostat cover mounting bolts, and remove the thermostat cover (1) 2. Remove the thermostat assembly (3). When Reassembling Apply a liquid gasket only at the thermostat cover side of the thermostat cover gasket (2). 1.

  • Page 81: Fuel System

    SECTION 6 FUEL SYSTEM Checking and Adjusting 6.1.1 Injection Timing Figure 6.1 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.

  • Page 82: Pump Element Fuel Seal

    6.1.3 Pump Element Fuel Seal Figure 6.3 Injection Pump Seal 1. Remove the engine stop solenoid (when applica- ble). 2. Remove the injection lines and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2).

  • Page 83: Injection Nozzle

    Injection Nozzle 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. 6.2.1 Nozzle Injection Pressure Figure 6.4 Nozzle Injection Testing 1.

  • Page 84: Valve Seat Tightness

    6.2.3 Valve Seat Tightness Figure 6.5 Nozzle Injection Testing 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 pressure through the injection nozzle, replace the injection nozzle assembly.

  • Page 85: Electrical System

    SECTION 7 ELECTRICAL SYSTEM Glow Plug 7.1.1 Lead Terminal Voltage Figure 7.1 Glow Plug 1. Disconnect the glow plug wiring lead (1) from the glow plug (2). 2. Connect a voltmeter between the glow plug wiring lead (1) and a suitable ground on the engine. 3.

  • Page 86: Starter (Ct2-29-Tv)

    Starter (CT2-29-TV) 7.2.1 Motor Test Figure 7.3 Starter Test CT2-29-TV CAUTION Secure the starter to prevent it from moving when power is applied to it. 1. Disconnect the cable from the negative terminal on the battery 2. Disconnect the positive cable and leads from the starter.

  • Page 87: Assembly

    7.2.3 Assembly Figure 7.4 Starter CT2-29-TV Assembly 1. Unscrew the C terminal nut (6), and disconnect the connecting lead (11). 2. Unscrew the solenoid switch mount- ing nuts (1), and remove the solenoid switch (5). 3. Remove the end frame cap (16).

  • Page 88: Starter (Ct3-44-Tv)

    Starter (CT3-44-TV) 7.3.1 Motor Test Figure 7.5 Motor Test CT3-44-TV CAUTION Secure the starter to prevent it from moving when power is applied to it. 1. Disconnect the cable from the negative terminal on the battery 2. Disconnect the positive cable and leads from the starter B terminal.

  • Page 89: Assembly

    7.3.3 Assembly Figure 7.7 Starter CT3-44-TV Assembly 1. Unscrew the C terminal nut (4), and disconnect the connecting lead (8). 2. Unscrew the magnetic switch mount- ing nuts (1), and remove the mag- netic switch (3) from the housing (2). 3.

  • Page 90: Starter Servicing

    Starter Servicing 7.4.1 Overrunning Clutch Figure 7.8 Starter Servicing 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 cranking direction.

  • Page 91: Armature

    7.4.6 Armature Figure 7.9 Armature 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 commutator with an ohmmeter. 4.

  • Page 92: Figure 7.10 Field Coil

    7.4.8 Field Coil Figure 7.10 Field Coil 1. Check the continuity across the lead (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.

  • Page 93: Index

    Adapter, Injector Line 2-17 Crankshaft Oil Slinger 3-12 Adapter, Kubota 10 mm 2-16 Crankshaft Sleeve Wear 3-36 Air Cleaner, Muffler and Others 3-4 CT2-29-TV Magnetic Switch Test 7-2 Armature 7-7 CT2-29-TV Starter Assembly 7-3 Armature Bearing 7-6 CT2-29-TV Starter Motor Test 7-2...
  • Page 94 Shim Identification 6-1 Main Bearing Case Assembly 3-19 Solenoid 7-6 Special Tools 2-16 Specific Warning and Caution Statements 1-1 Starter (CT2-29-TV) 7-2 Nozzle Holder 6-4 Starter (CT3- 44- TV) 7-4 Nozzle Holder Assembly and Glow Plug 3-5 Starter Does Not Run 2-7...
  • Page 95 Torque Specifications For General Use Screws, Bolts and Nuts 2-6 Torque Specifications For Special Use Screws, Bolts and Nuts 2-5 Troubleshooting 2-6 Valve Clearance 2-15 Valve Cover 3-4 Valve Guide Replacing Tool 2-18 Valve Lapping 3-23 Valve Recessing 3-21 Valve Seat Tightness 6-4 Valve Seating 3-22 Valve Spring Setting Load 3-25 Valves 3-7...
  • Page 97 North America Central America and Mexico Carrier Transicold Ejercito Nacional 253−A Piso 5 700 Olympic Drive Colonia Anahuac Athens, GA 30601 USA 11320 Mexico, D.F. Tel: 1-706-357-7223 Tel: 55315010 Fax: 1-706-355-5435 Fax: 55315010 ext. 1005 Carrier Transicold P.O. Box 4805 Syracuse, NY 13221 USA A part of UTC Building &...

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