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Carrier TRANSICOLD X4 7700 Workshop Manual
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Carrier TRANSICOLD X4 7700 Workshop Manual

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Workshop Manual
Diesel Engine - V2403-CR-E4B
(26-00159)
X4 7700, Vector 8700, 8800MT,
8811MT, Genset RG, Genset UG
62-12258 Rev. A

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Summary of Contents for Carrier TRANSICOLD X4 7700

  • Page 1 Workshop Manual Diesel Engine - V2403-CR-E4B (26-00159) X4 7700, Vector 8700, 8800MT, 8811MT, Genset RG, Genset UG 62-12258 Rev. A...
  • Page 3 Workshop Manual V2403-CR-E4B (26-00159) Tier 4 Engine © Carrier Corporation, 2024 Printed in U. S. A. January 2024...
  • Page 4 Manual Revision History - 62-12258 Manual Revision History - 62-12258 Date Reason for Release 10/19/2023 New product – new manual Added Appendix A (Engine P Codes); Section 2 – Added note to reference 1/5/2024 Appendix A and updated Table 2-1...
  • Page 5 SAFETY PRECAUTIONS ............1–1 ENGINE COOLANT .
  • Page 6 COMPONENT DISASSEMBLY ..........3–12 3.3.1 Draining Engine Oil .
  • Page 7 COMPONENT INSTALLATION ..........3–33 3.4.1 Main Bearing Case Installation...
  • Page 8 MAINTENANCE ............. . 4–3 4.1.1 Checking Engine Oil .
  • Page 9 SENSORS ..............7–9 7.7.1 Checking Rail Pressure Sensor .
  • Page 10 62-12258 1–6...
  • Page 11 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 12 • Beware of moving V-belt and belt driven components. When working with belts, beware of pinch points. • 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. •...
  • Page 13 For a complete listing of Power Train (P) codes, refer to Appendix A at the end of this manual. Engine Identification When contacting Carrier Transicold, always specify your engine model number and serial number. The engine’s model and serial number need to be identified before the engine can be serviced or parts replaced.
  • Page 14 Engine Specifications The specification described below is of the standard engine of each model. Conversion formula: HP = 0.746 kW, PS = 0.7355 kW. V2403-CR-E4B-CTD Model Number of cylinder Engine type Vertical, water-cooled, 4-cycle diesel Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.) Total displacement 2434 cm3 (148.5 cu.in.) 32.4 kW / 2700 min-1 (rpm)
  • Page 15 Dimensions V2403-CR-E4 23.46 inches (596.0 mm) 20.4 inches (517 mm) 26.49 inches (596.0 mm) 2–3 62-12258...
  • Page 16 Figure 2.2 System Wiring Diagram Injector Shield cable Main relay Injector 1 Rail pressure sensor Fuel feed pump Injector 2 Boost pressure sensor CAN1 connector (for service) Injector 3 Stop switch CAN2 connector (for vehicle) Injector 4 Parked regeneration switch Not Used Crankshaft position sensor Parking switch...
  • Page 17 Special Tools Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog (62-12253). 2.4.1 Diesel Engine Compression Tester Figure 2.3 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 18 2.4.5 Gauge, Belt Tension Figure 2.7 Gauge, Belt Tension Part No. 07-00203-00 Application: Used to adjust belt tension of all cogged V-belts. 2.4.6 Tester, Belt Tension Figure 2.8 Tester, Belt Tension Part No. 07-00253-00 Application: Used to test belt tension. 2.4.7 Rubber Band Figure 2.9 Rubber Band...
  • Page 19 2.4.10 Valve Guide Replacing Tool Figure 2.12 Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. 20 mm dia. (0.79 in. dia.) 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.
  • Page 20 2.4.11 Bushing Replacing Tools Figure 2.13 Brushing Replacing Tool Application: Use to press out and press fit the bushing 1. For small end bushing. 162 mm (6.38 in.) 35 mm (1.38 in.) 27 mm (1.06 in.) 35 mm dia. (1.38 in. dia.) 27.90 to 27.95 mm dia.
  • Page 21 2.4.13 Crankshaft Bearing 1 Replacing Tool Figure 2.15 Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing No. 1 1. Extracting Tool 130 mm (5.31 in.) 72 mm (2.83 in.) R40 mm (R1.57 in.) 10mm (0.39 in.) 20 mm (0.79 in.) 20 mm dia.
  • Page 22 2.4.14 Crankshaft Sleeve Auxiliary Socket Figure 2.16 Crankshaft Sleeve Auxiliary Socket Stopper / Sleeve Guide Application: Use to fix diesel engine crankshaft sleeve Stopper 80.0 mm (3.15 in.) 60.10 to 60.30 mm (2.367 to 2.374 in.) 80.0 mm dia. (3.15 in. dia.) 85.0 mm dia.
  • Page 23 Auxiliary Socket Figure 2.17 Auxiliary Socket 120 mm (4.72 in.) 110 mm (4.33 in.) 25.0 mm (0.984 in.) 90.0 mm dia. (3.54 in. dia.) 81.0 mm dia. (3.19 in. dia.) 80.10 to 80.15 mm dia. (3.154 to 3.155 in. dia.) 30.0 mm dia.
  • Page 24 2.4.16 Bearing Case Cover Oil Seal Replacing Tool Figure 2.19 Bearing Case Cover Oil Seal Replacing Tool 42 mm dia. (1.7 in. dia.) 0.70 rad (40°) 32.000 to 32.025 mm dia. (1.2599 to 1.2608 129 mm dia. (5.08 in. dia.) in.
  • Page 25 SECTION 3 Engine Body Engine Body 3.1.1 Engine Body Structure The engine body consists of cylinder related components, primary motion and valve train mechanisms. Figure 3.1 Engine Body Structure 1. Cylinder head cover 5. Flywheel housing 9. Main bearing case 13.
  • Page 26 Disassembling and Assembling 3.2.1 Draining Coolant Refer to Section 3. 3.2.2 Draining and Refilling Engine Oil Refer to Section 4.2.1 Section 4.2.2 3.2.3 External Components 3.2.3.1 Alternator, Starter and others 1. Remove the air cleaner and muffler. 2. Remove the engine stop solenoid. 3.
  • Page 27 NOTE • B Terminal: Terminal that connects the cable from the battery to the starter • C Terminal: Terminal that connects the cable from the motor to the magnet switch. Tools Required: Circuit tester and Jumper lead 1. Disconnect the negative cable from the battery. 2.
  • Page 28 3.2.4 Checking Suction Control Valve (SCV) Tools Required: Circuit tester 1. Place the START/RUN-OFF switch (SROS) in the OFF position. 2. Disconnect the SCV wiring harness connector. 3. Measure the resistance between SCV terminals (1) and (2) Service Specifications Resistance = 2.6 to 3.5 Ω at 20°C / 68F NOTE If measurement is out of the service specifi- cations, replace the SCV.
  • Page 29 3.2.7 Measuring Angular Deviation Between Crankshaft T.D.C. and Crankshaft Position Sensor Detected T.D.C. Gasket Model mark and V2403-CR-E4 code number 1G790-03600 1G790-03310 1G790-03610 1G790-03620 1G790-03630 If the crankshaft, flywheel housing and/or flywheel are replaced, it is necessary to calibrate the injection timing with the diagnosis tool.
  • Page 30 IMPORTANT Do not drop the valve (5) into the cylinder (3) Dial gauge (4) O-ring (5) Valve 6. Turn the flywheel counterclockwise and measure the position where the tip of the valve (5) is the highest. NOTE When measuring the highest position of the tip of the valve (5), do not rotate the flywheel clockwise. If you go past the highest point of the valve (5), back the flywheel up slightly and measure the highest point of the valve (5).
  • Page 31 3.2.8 Adjusting Air Gap Between Crankshaft Position Sensor and Flywheel Tools Required: • Vernier caliper • Depth gauge 1. Measure the crankshaft position sensor length between the sensor tip and sensor flange (1) face with vernier caliper. 2. Measure the depth from sensor attaching face of flywheel housing to flywheel side (2) surface with depth gauge.
  • Page 32 NOTE Reference pulsar hole (12) is the 17th hold for 3-cylinder models or 20th hole for 4-cylinder models by rotating counterclockwise from the area where there is no pulsar hole (9). (9) Area where there is no pulsar hole (10) Flywheel (11) Crankshaft position sensor mounting hole (12) Reference pulsar hold (17th 3-cylinder models/20th 4-cylinder models) 4.
  • Page 33 (14) Tri-square (15) Reference line (16) Mark of crankshaft position sensor top dead center detection position 6. Measure the difference (A0 between the top dead center mark (17) and the crankshaft position sensor top dead center detection position mark (18). (17) Mark for top dead center (18) Mark of crankshaft position sensor top dead center detection position (19) Difference (mm)
  • Page 34 3.2.10 Adjusting Valve Clearance You must check and adjust the valve clearance when the engine is cold Tools Required: Feeler gauge 1. Remove the air cleaner and muffler. 2. Remove the cylinder head cover. 3. Align the [1TC] mark (2) line on the flywheel and projection on the housing. 4.
  • Page 35 Table 3–1 Valve Clearance 6. Install the removed parts. Table 3–2 Tightening Torque - Cylinder Head Cove 6.86 to 11.3 N:m Tightening Cylinder head 0.700 to 1.15 kgf:m 5.06 to 8.33 lbf ⋅ ft torque cover screw 3–11 62-12258...
  • Page 36 Component Disassembly 3.3.1 Draining Engine Oil 1. Warm up the engine and then stop it by placing the START/RUN-OFF switch in the OFF position. 2. Ensure the unit will not start automatically by disabling the starter. 3. If available, install oil drain tool (CTD part number 68-15763-01) (Figure 8.10.)The oil drain tool not only directs the oil over the door latch pin bracket and bottom panel on units so equipped, but also holds a typical drain bucket in place while the oil is draining from the engine.
  • Page 37 1. Install hose or drain plug, and fill the system with clean, untreated water. (2) Drain Plug NOTE NEVER POUR COLD WATER INTO A HOT ENGINE. However, hot water can be added to a cold engine. 2. Start the engine and drain system while warm. Rinse system three times after it has cooled down. Refill sys- tem with water.
  • Page 38 3.3.3 Removing Common Rail CAUTION Do not loosen the injection pipe (1) when fuel is under high pressure (within five minutes of stopping the engine). NOTE • Replace the rail assembly if the exchange of the pressure limiter (3) or the rail pressure sensor (5) if nec- essary.
  • Page 39 (4) Pressure limiter (5) Common rail (6) Rail pressure sensor 3.3.4 Removing Sensors 1. Remove the coolant temperature sensor (1). (1) Coolant temperature sensor 2. Remove the crankshaft position sensor mounting screw. 3. Remove the camshaft position sensor (2). (2) Camshaft position sensor (3) Camshaft position sensor mounting screw 4.
  • Page 40 (4) Crankshaft Position Sensor (5) Crankshaft position sensor mounting screw IMPORTANT If you drop the sensor, do not use it. 6. Remove the boost pressure sensor mounting screw (7). (7) Boost pressure sensor mounting screw. 3.3.5 Removing Cylinder Head Cover 1.
  • Page 41 3.3.6 Removing Injector 1. Remove the injector clamp (2). 2. Remove the injector (1) and its gasket (4) IMPORTANT • Do not disassemble the injector (1). • Do not damage the injector ID code (6). • Do not get the injectors out of order. •...
  • Page 42 3.3.7 Removing Rocker Arm Assembly 1. Remove the rocker arm assembly (1). (1) Rocker arm assembly 2. Remove the push rods (2). (2) Push rods 3.3.8 Removing Cylinder Head 1. Remove the intake manifold (1). (1) Intake manifold 2. Remove the exhaust manifold (2). 62-12258 3–18...
  • Page 43 (2) Exhaust manifold 3. Remove the cylinder head mounting screw in the sequence of (n or r) to (a). (A) Gear case side (B) Flywheel side 4. Remove the cylinder head (3) and cylinder head gasket (4). 3–19 62-12258...
  • Page 44 3.3.9 Removing Tappet NOTE Mark the cylinder number to the tappets to prevent interchanging. 1. Remove the tappets (1) from the crankcase (2). (1) Tappet (2) Crankcase 3.3.10 Removing Valve NOTE Mark the cylinder number to the valves to prevent interchanging. Tools required: Valve spring compressor 1.
  • Page 45 3.3.11 Removing Thermostat Assembly 1. Remove thermostat cover mounting screws and thermostat cover. (1) Thermostat cover 2. Remove thermostat assembly (2). (2) Thermostat assembly 3.3.12 Removing Suction Control Valve (SCV) IMPORTANT • To determine whether or not it is necessary to replace the SCV, refer to related DTC decision flow (P0089, P0628 and P0629) of diagnosis manual (DM).
  • Page 46 • Confirm that no O-ring remains at the supply pump body side. Remove if necessary. (1) SCV (2) SCV mounting screw 3.3.13 Removing Supply Pump 1. Remove the fuel feed pump (1). (1) Fuel feed pump 2. Remove the supply pump (2). (2) Supply pump 62-12258 3–22...
  • Page 47 3.3.14 Removing Water Pump 1. Remove the water pump (1). (1) Water pump 3.3.15 Removing Fan Drive Pulley Tools Required: • Flywheel stopper • Gear puller • 46 mm(1.8 inch) deep socket wrench 1. Mount a flywheel stopper (1) on the flywheel. (1) Flywheel stopper 2.
  • Page 48 (2) Fan drive pulley mounting nut (3) 46 mm (1.8 in) deep socket wrench (4) Fan drive pulley 4. Remove feather key. 3.3.16 Removing Gear Case Cover 1. Remove the hour meter gear case cover (if attached). 2. Remove gear case cover (1). (1) Gear case cover 3.3.17 Removing Crankshaft Oil Slinger...
  • Page 49 (1) Crankshaft oil slinger (2) O-ring (3) Crankshaft collar 3.3.18 Removing Idle Gear Tools Required: • Gear puller • Flywheel stopper 1. Mount a flywheel stopper (1) on the flywheel. (1) Flywheel stopper 2. Loosen the oil pump drive gear 1 mounting nut (5). 3.
  • Page 50 (4) Oil pump drive gear 2 (5) Oil pump drive gear 1 mounting nut 3.3.19 Removing Fuel Camshaft Assembly 1. Remove the fuel camshaft stopper (1). 2. Pull out the fuel camshaft assembly (2). (1) Fuel camshaft stopper (2) Fuel camshaft assembly 3.3.20 Removing camshaft with Cam Gear Remove the camshaft set screws and draw out the camshaft (1) with cam gear (2).
  • Page 51 2. Pull out the oil pump drive gear 1 (2) with gear puller (3). (2) Oil pump drive gear 1 (3) Gear puller 3. Remove the oil pump (4) (4) Oil pump 3.3.22 Removing Crank Gear Tools Required: Gear puller 1.
  • Page 52 3.3.23 Removing Oil Pan and Oil Strainer 1. Remove the oil pan (1). (1) Oil pan 2. Remove the oil strainer (2). NOTE Be careful not to damage the O-ring. 3.3.24 Removing Piston 1. Turn the flywheel and move piston to bottom dead center. 2.
  • Page 53 6. Pull the piston (3) out by lightly tapping the large end bore of the connecting rod from the bottom of the crankcase using the grip of a handle. IMPORTANT Do not change the combination of cylinder and piston. Align the position of each piston by its mark. For example, mark “1”...
  • Page 54 3.3.26 Disassembling Piston Assembly 1. Remove the pin snap ring (1) from piston (2). 2. Remove the piston pin (4) to disconnect the connecting rod (3) from the piston. IMPORTANT Put a mark on the connecting rod (3) and piston (2) with the same number to retain the same combination. NOTE If you cannot easily remove the piston pin (4), put the entire piston in 176°F (80°C) oil for 10 to 15 min- utes.
  • Page 55 4. Remove the flywheel (3). (3) Flywheel (4) Flywheel guide screw 3.3.28 Removing Flywheel Housing 1. Remove the flywheel housing (1). (1) Flywheel housing 3.3.29 Removing Bearing Case Cover NOTE Before disassembling, check the side clearance of the crankshaft. Be sure to check this during reassem- bly as well.
  • Page 56 (1) Inner mounting screw (2) External mounting screw 3. Remove bearing case cover (3). (3) Bearing case cover 3.3.30 Removing Crankshaft NOTE Before disassembling, check the side clearance of the crankshaft. Be sure to check this during reassem- bly as well. 1.
  • Page 57 CAUTION DO NOT change the combination of the main bearing case. (1) Main bearing case (2) Main bearing case screw 1 2. Remove other main bearing cases using above procedure. Component Installation 3.4.1 Main Bearing Case Installation 1. Install the main bearing case (7). IMPORTANT •...
  • Page 58 • Install the main bearing case assemblies in the initial positions. Since the diameters of the main bearing cases are different, install them in the sequence of their marks (A, B, C) from the gear case cover side. 62-12258 3–34...
  • Page 59 2. Tighten the main bearing case screw 1 to the specified torque. NOTE • Apply engine oil to the main bearing case screws 1. • After you tighten the main bearing case screw 1 to the specified torque, make sure that the main bearing case moves smoothly.
  • Page 60 2. Turn the crankshaft to set the crankpin of the fourth cylinder to the horizontal directions (right or left). 3. Align the screw hole of the main bearing case with the screw hole of the crankcase. 4. Install the main bearing case screw 2 (1) by hand. NOTE •...
  • Page 61 (a) Upside mark 2. Put the casting mark [UP} (A) of the bearing case cover (6) upward and then install the bearing case cover (6). IMPORTANT The length of inner mounting screws of the bearing case cover (4) and external mounting screws of bearing case cover (3) are different.
  • Page 62 3.4.4 Flywheel Housing Installation 1. Install the flywheel housing (1). (1) Flywheel housing NOTE Tighten the flywheel housing mounting screws with even force on the diagonal line. Refer to Section 3.2.7 3.4.5 Flywheel Installation IMPORTANT The flywheel is very heavy so be sure to hold it securely when installing. NOTE Do not use an impact wrench.
  • Page 63 (1) Flywheel (2) Flywheel guide screw Refer to Section 3.2.7 3.4.6 Assembly the Piston Assmbly CAUTION The end faces of the oil ring are plated with hard chrome. When you install the piston into the cylinder, do not give a damage to the cylinder by the oil ring. If the ring's planting is scratched, it may get stuck on the cylinder wall, causing serious damage.
  • Page 64 3. Install the piston pin snap ring (6) (6) Piston pin snap ring 3.4.7 Piston Ring Installation Tools Required: Piston ring pliers 4. Install the oil ring (3) to the piston with the piston ring pliers. (1) Expander joint (2) Oil ring gap (3) Oil ring 5.
  • Page 65 (4) Manufacturer mark (5) Top ring (6) Second ring 3.4.8 Piston Installation IMPORTANT • Do not change the combination of cylinder number and piston. • Align the position of each piston with its mark. For example, mark “1” on the No.1 piston. Tools Required: Piston ring compressor 1.
  • Page 66 IMPORTANT Carefully set the piston ring compressor. If care is not taken, the chrome-plated section of the piston rings may be scratched, causing trouble inside the liner. NOTE • Apply sufficient engine oil to the piston. • Align the mark [FW] (2) on the piston face to the flywheel side. •...
  • Page 67 NOTE • Apply engine oil to the connecting rod screws. • If the connecting rod screw does not screw in smoothly, clean the threads. If it is still difficult to insert, replace • When reusing the existing crankpin bearing, put tally marks on the crankpin bearing and connecting rod to retain their positioning.
  • Page 68 • Carefully and evenly apply the liquid gasket (2). (2) Liquid gasket 2. Install the oil pan (3) NOTE • Mount parts with a liquid gasket within ten minutes of application. • Tighten oil pan mounting screws (3) in diagonal sequence from the center to tighten equally. •...
  • Page 69 3.4.11 Oil Pump Installation 1. Install the oil pump (1). (1) Oil pump 2. Install the oil pump drive gear 1 (2). NOTE After the oil pump drive gear 1 (2) is installed, loosely tighten the oil pump drive gear 1 mounting nut (3). Tighten the oil pump drive gear 1 mounting nut (3) completely to the specified torque after installing oil pump drive gear 2.
  • Page 70 (1) Camshaft (2) Cam gear 62-12258 3–46...
  • Page 71 3.4.13 Fuel Camshaft with Supply Pump Gear Installation 1. Install the fuel camshaft with supply pump gear (2). 2. Install the fuel camshaft stopper (1). NOTE After installing the fuel camshaft, store oil in the pump room as shown in drawing Recommended oil amount: More than 50 ml (cc) (1) Fuel camshaft stopper (2) Fuel camshaft with supply pump gear...
  • Page 72 3.4.14 Idle Gear Installation 1. Install the idle gear (2) and idle gear collar. IMPORTANT • Apply the engine oil inside the idle gear (2) • When mounting the idle gear (2), bring the piston of cylinder 1 to T.D.C (refer to 3.2.7) and mount Section the gears with their marks aligned to the respective gears.
  • Page 73 4. Tighten the oil pump drive gear 1 (5) mounting nut completely to the specified torque after installing oil pump drive gear 2 (6). 3.4.15 Crankshaft Oil Slinger Installation 1. Install the crankshaft oil slinger (1). 2. Install the O-ring (2). NOTE Attach the crankshaft collar (3) after installing the gear case cover to the crankcase.
  • Page 74 3.4.17 Fan Drive Pulley Installation Tools Required: • Flywheel stopper • 46mm (1.8”) deep socket wrench 1. Mount the flywheel stopper (1) on the flywheel. (1) Flywheel stopper 2. Install the feather key. 3. Install the fan drive pulley (2). 4.
  • Page 75 (1) Water pump 3.4.19 Supply Pump Installation NOTE • Do not disassemble the supply pump. • When attaching the supply pump to crankcase, do not apply force on the SCV and overflow sections of the part. • Do not remove the dust protection cap until immediately before you attach the part. 1.
  • Page 76 3.4.20 Suction Control Valve (SCV) Installation NOTE Replace the SCV O-ring with a new one. Tools Required: • Silicone grease • Hexagon wrench (4mm square) 1. Install the SCV O-ring (1). NOTE Apply clean silicone grease to the tip of the SCV O-ring. 2.
  • Page 77 2. Install the thermostat cover (2). (2) Thermostat cover 3.4.22 Valve Installation NOTE Clean the valve stem and valve guide hole. Tools Required: Valve spring compressor 1. Install the valve stem seal (1). NOTE Install a sufficient amount of engine oil. 2.
  • Page 78 1. Install the tappets (1) to the crankcase (2). (1) Tappet (2) Crankcase 3.4.24 Cylinder Head Installation IMPORTANT • When replacing the piston, piston pin bushing, connecting rod or crankpin bearing, select the cylinder head gasket (2) thickness to meet the top clearance. Refer to (Selecting Cylinder Head Gasket).
  • Page 79 (1) Cylinder head (2) Cylinder head gasket (A) Gear case side (B) Flywheel side 3. Install the exhaust manifold (3) and tighten to the specified torque. NOTE Replace the exhaust manifold with new one. (3) Exhaust manifold 4. Install the intake manifold (4) and tighten to the specified torque. NOTE Replace the intake manifold gasket with a new one.
  • Page 80 (4) Intake manifold Refer to (Selecting Cylinder Head Gasket) Section 3.2.5 3.4.25 Rocker Arm Assembly Installation 1. Install the push rod (1). NOTE When installing the push rod (1), mount it securely in the groove of the tappet (2). (1) Push rod (2) Tappet 2.
  • Page 81 IMPORTANT After installing the rocker arm assembly, adjust the valve clearance. (3) Rocker arm assembly Refer to (Adjusting Valve Clearance). Section 3.2.10 3.4.26 Injector Installation IMPORTANT • Do not disassemble the injector • Do not damage the injector ID code (1) •...
  • Page 82 NOTE When installing injector clamps (3), set them correctly as show in the drawing. (2) Injector (3) Injector clamp (4) Gasket (5) Injector clamp screw Refer to Replacing Injector section. 62-12258 3–58...
  • Page 83 3.4.27 Glow Plug Installation 1. Install the glow plugs (1). NOTE • Adjust the direction of the ditch to the terminal side when the seal (2) is installed in the glow plug (1). • After installing the glow plug (1), make sure that the seal (2) was set to the specified position. (1) Glow plug (2) Seal (A) Good...
  • Page 84 1. Install the cylinder head cover (1) and tighten to the specified torque. (1) Cylinder head cover 3.4.29 Sensor Installation IMPORTANT Do not reuse the sensor if you drop it. NOTE • Replace the gasket with a new one. • Replace the O-ring with a new one.
  • Page 85 (2) Camshaft position sensor (3) Camshaft position sensor mounting screw 4. Install the crankshaft position sensor (4). 5. Tighten the crankshaft position sensor mounting screw (5) to the specified torque. NOTE If you are replacing the crankshaft position sensor, measure the air gap between the crankshaft posi- tion sensor and flywheel.
  • Page 86 3.4.30 Common Rail Installation IMPORTANT If the exchange of the pressure limiter (1) or the rail pressure sensor (3) is necessary, replace the rail assembly. NOTE • Do not remove the pressure limiter (1) and rail pressure sensor (3) from the common rail (2). •...
  • Page 87 3.4.31 CRS Intermediate Harness Installation 1. Connect the engine intermediate harness (engine side). 2. Connect the injector intermediate har- ness (engine side) (4) Name plate (22) Injector connector (10P) (23) Injector intermediate connector (12P) (k) Clamp 3. Connect the air flow sensor intermediate harness (engine side) (24) Air flow sensor intermediate con- nector (6P)
  • Page 88 4. Connect engine ECU intermediate har- ness (31) Injector intermediate harness (32) Engine intermediate harness (33) Not used 62-12258 3–64...
  • Page 89 3.4.32 External Component Installation NOTE Check for cranks on the fan belt surface. 1. Install the fan pulley (2) and loosely tighten the cooling fan mounting screw. IMPORTANT • Do not put the cooling fan (1) in the incorrect direction. •...
  • Page 90 IMPORTANT After installing the fan belt, adjust the fan belt tension 10.0 to 12.0 mm 0.394 to 0.472 in. Service specifi cation Deflection (A) (under load of 98 N (10 kg, 22.1 lbf)) 9.81 to 11.3 N ⋅ m 1.00 to 1.15 kgf ⋅ m Cooling fan mounting Tightening Torque 7.24 to 8.33 lbf ⋅...
  • Page 91 3.4.34 Filling Engine Oil IMPORTANT 6. Install the starter (8) • Do not mix different types of oil • Use the correct SAE engine oil by reference to the ambi- ent temperature. NOTE Make sure the drain plug is tightened. 1.
  • Page 92 Servicing Components 3.5.1 Checking Cylinder Head Top Clearance Tools Required: Plastigauge 1. Remove the cylinder head. 2. With the piston at T.D.C., use grease to affix three or four plastigauges (1) to the crown of the piston; keep the gauges away from the intake valve and combustion chamber fillings. (1) Plastigauge 3.
  • Page 93 (2) Crushed plastigauge (3) Scale 3.5.2 Checking Cylinder Head Flatness Tools Required: • Straight edge • Feeler gauge 1. Clean the cylinder head surface. 2. Place a straight edge on the four sides of the cylinder head (A, B, C, and D) and two diagonal (E and F) as shown in the following figure.
  • Page 94 3.5.3 Checking Cylinder Head Flaw Tools Required: • Red permeative liquid • Detergent • White developer 1. Clean the surface of the cylinder head with detergent (2). 2. Apply some red permeative liquid (1) on the cylinder head surface. 3. After you apply, do not touch it for 5 to 10 minutes. 4.
  • Page 95 3.5.4 Checking Valve Recessing Tools Required: Depth gauge 1. Clean the cylinder head surface (1), valve face and valve seat. 2. Set the valve into the valve guide. 3. Measure the valve recessing wht the depth gauge. NOTE • If the measurement exceeds the service limit, replace the valve. •...
  • Page 96 3.5.5 Adjusting Valve Lapping Tools Required: • Compound • Valve lapping tool • Prussian Blue 1. Apply the compound equally to the valve lapping surface. 2. Put the valve into the valve guide. Lap the valve on its seat with the valve lapping tool. 3.
  • Page 97 3.5.6 Checking Clearance Between Valve Stem and Valve Guide Tools Required: • Outside micrometer • Inside micrometer 1. Remove carbon from the valve guide section. 2. Measure the valve stem OD with an outside micrometer. 3. Measure the valve guide ID with an inside micrometer. 4.
  • Page 98 3.5.7 Replacing Valve Guide IMPORTANT Do not hit the valve guide with a hammer during replacement. Tools Required: • Press tool • Valve guide replacing tool 3.5.7.1 Removing Valve Guide 1. Press out the used valve guide with the valve guide replacing tool. Removing direction 3.5.7.2 Installing New Valve Guide 1.
  • Page 99 SECTION 4 Lubricating System Maintenance Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit. NOTES • As the engine owner, you are responsible for the performance of the required maintenance on the engine according to unit-specific maintenance schedule.
  • Page 100 Figure 4.1 Oil Dipstick 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches. 3.
  • Page 101 NOTE When changing to a different oil manufacturer or viscosity, be sure to remove all of the old oil com- pletely. Never mix different types of oil. NOTE With emission controls now in effect, the CG-4 or CH-4 / CI lubricating oils have been developed for use of a low-sulfur fuel on-road vehicles engines.
  • Page 102 4.2.3 Engine Oil Pressure 4.2.3.1 Checking Engine Oil Pressure Tools Required: Oil pressure tester 1. Remove the engine oil pressure switch. 2. Set the oil pressure tester. 3. Start the engine to warm up. 4. Measure the oil pressure at idle speed and rated speed.
  • Page 103 Replacing Oil Separator Element CAUTION Be sure to stop the engine before replacing the oil separator element. 1. Remove the cover (1) 2. Remove the oil separator element (3) and O-ring (2). 3. Replace the oil separator element (3) and O-ring (2) with a new one.
  • Page 104 Ensure that you stop the engine before replacing the oil filter cartridge To prevent serious damage to the engine, replacement element must be highly efficient. Use only a Carrier Transicold genuine filter or its equivalent, 1. Using a filter wrench, remove the oil filter car- NOTE tridge (1).
  • Page 105 SECTION 5 Cooling System Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit. NOTES • As the engine owner, you are responsible for the performance of the required maintenance on the engine according to unit-specific maintenance schedule.
  • Page 106 • As water is accumulated, the red float (6) goes up. • When the float (6) has reached the specified line (2), immediately drain the water separator. • When reattaching the water separator, be careful to keep off dust and dirt. Cleaning Air Cleaner Primary Element •...
  • Page 107 Checking Radiator Hose and Clamp Bands 1. Check that the radiator hoses (1 & 2) are con- nected correctly. 2. Check for radiator hose (1&2) or clamp damage. Replace damaged hoses or clamp if necessary. 3. If clamp is loose, apply oil to the threads and tighten again correctly.
  • Page 108 Cleaning Water Separator Filter (Type 2) Replace the water separator filter periodically to prevent wear of the supply pump or the injec- tor, due to dirt in the fuel. NOTE Replace the water separator filter with a new one every 500 hours or one year. 1.
  • Page 109 Anti-Freeze • There are two types of anti-freeze available. Use the permanent type (PT) for this engine. • When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft water several times. • The brand of the anti-freeze and the ambient temperature have an effect on the procedure to mix water and anti-freeze.
  • Page 110 Replacing Fan Belt 1. Remove the alternator (1). 2. Remove the fan belt (2). 3. Replace the fan belt (2) with the new one. 4. Reinstall the alternator (1). 5. Adjust the tension of belt halfway between the fan drive pulley and alternator pulley at a specified force to measure the deflection (3).
  • Page 111 Checking Valve Clearance Figure 5.1 Valve Clearance NOTE Valve clearance must be checked and adjusted when the engine is cold. 1. Remove the air cleaner and muffler. 2. Remove the cylinder head cover. 3. Align the [1TC] mark (2) line on the fly- wheel and projection (1) on the housing.
  • Page 112 5.10 Checking Positive Crankcase Ventilation (PCV) Valve 1. Remove cover (1) and element (3). 2. Look into the hole leading to the PCV valve of the oil separator body (4) inside, and then check if there is no crack, break or abnormal sediment in the PCV valve.
  • Page 113 5.11 Checking Intake Air Line To prevent serious damage to the engine, keep dust out of the intake air line. 1. Make sure that the intake air hose(s) (1) are connected correctly or not. 2. Visually check for cracks gas leak and anything else that is unusual.
  • Page 114 62-12258 5–12...
  • Page 115 SECTION 6 Fuel System Maintenance Schedule Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit. NOTES • As the engine owner, you are responsible for the performance of the required maintenance on the engine according to unit-specific maintenance schedule.
  • Page 116 Checking Fuel Hoses and Clamp Bands 1. Check fuel hose (1) and clamp (2) for damage. 2. If the fuel hose (1) or clamp (2) is damaged, replace it. 3. If the clamp (2) is loose, apply oil to the threads and tighten it again correctly NOTE Replace the fuel hose (1) and clamp (2) every two years.
  • Page 117 Checking Injector with Diagmaster 6.86 to 11.3 N ⋅ m Cylinder head cover screw Tightening torque 0.700 to 1.15 kgf ⋅ m 5.06 to 8.33 lbf ⋅ ft Tools Required: • Laptop computer with Diagmaster software installed • Interface (DST-i) 1.
  • Page 118 7. Click the [Send Specified Active Test Value] button (9). NOTE Confirm that each of the injectors are injecting normally. If so, the engine vibration and noise will increase and engine speed will fluctuate when the injector is stopped. 8. Click the [Finish Active Test] button (10). 62-12258 6–6...
  • Page 119 SECTION 7 Electrical System Maintenance Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit. NOTES • As the engine owner, you are responsible for the performance of the required maintenance on the engine according to unit-specific maintenance schedule.
  • Page 120 (1) Positive terminal (2) Negative terminal NOTE If the battery voltage is less than the service specification, check the battery specific gravity and charge the battery. Glow Plug 7.3.1 Checking Glow Plug Continuity CAUTION To prevent an accidental short circuit, attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal.
  • Page 121 Tools Required: Circuit tester 1. Remove glow plug (2). 2. Measure the resistance with circuit tester between glow plug terminal and glow plug hous- ing. NOTE If the measurement does not show the ser- vice specification, the glow plug is damaged. NOTE Adjust direction of the ditch to the terminal side when seal (1) is installed in the glow...
  • Page 122 7.3.2 Glow Plug Installation 1. Install the glow plugs (1). NOTE • Adjust the direction of the ditch to the terminal side when the seal (2) is installed in the glow plug (1). • After installing the glow plug (1), make sure that the seal (2) was set to the specified position. (1) Glow plug (2) Seal (A) Good...
  • Page 123 Starter 7.4.1 Checking Starter Motor CAUTION To prevent an accidental short circuit, attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. Do not remove the battery cap while the engine is in operation. Keep electrolyte away from eyes, hands and clothes.
  • Page 124 7.4.2 Checking Starter Magnetic Switch CAUTION To prevent an accidental short circuit, attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. Do not remove the battery cap while the engine is in operation. Keep electrolyte away from eyes, hands and clothes.
  • Page 125 7.4.3 Checking Magnetic Switch Continuity CAUTION To prevent an accidental short circuit, attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. Do not remove the battery cap while the engine is in operation. Keep electrolyte away from eyes, hands and clothes.
  • Page 126 Starter Assembly Starter Servicing Sensors 7.7.1 Checking Rail Pressure Sensor Tools Required: Diagnosis tool 1. Place the SROS in the ON position. 2. Check the “Actual Rail Pressure” and “Rail Pressure Sensor Output Voltage” on the diagnosis tool data monitor. 3.
  • Page 127 7.7.2 Checking Boost Pressure Sensor Tools Required: Circuit tester 1. Place the SROS in the ON position. 2. Measure the voltage between the boost pressure sensor terminal (1) and (4) connector from the wiring harness side. 3. Start the engine, change the depressed amount of the accelerator pedal and check the same items again. Service Specifications: SROS ON = Output voltage = Approx.
  • Page 128 7.7.3 Checking Crankshaft Position Sensor 7.7.4 Checking Camshaft Position Sensor 1. Disconnect the sensor and check the following 1. Disconnect the sensor and check the following items. items. • Check to determine whether or not there is a • Check to determine whether or not there is a large amount of magnetic foreign material large amount of magnetic foreign material adhering to the sensor surface.
  • Page 129 7.7.5 Checking Coolant Temperature Sensor Tools Required: Circuit Tester 1. Turn the SROS OFF. 2. Remove the connector from the sensor side. 3. Measure the resistance between the terminals on the sensor side. Table 7–1 Coolant Temperature Sensor Service Specifications Service specification Temperature Resistance...
  • Page 130 62-12258 7–14...
  • Page 131 Appendix A - Engine P Codes 03 series NA-DOC (for Carrier TRU) model DTC Code LIST Engine Time to action or Limp home action Behavior SPN name warnin Delay time for J1939-73 14229 Detection item DTC set preconditions DTC set parameter number by engine ECU Remark...
  • Page 132 - Insufficient - Engine is operating To minimize PM emission output Open circuit of Open circuit of harness Engine Injector - Battery voltage is normal Open circuit of harness or Output limitation: - Engine vibration P0201 harness or coil in 1st Open circuit of injector 3 times or more Key switch turn OFF...
  • Page 133 - Key switch is ON ECU CPU (Main IC) Engine Fuel Injection - Battery voltage is 10 V or more P0606 1077 Failure of CPU and/or IC CPU and/or IC fatal error one time or more Engine stop - Engine stops Key switch turn OFF ―...
  • Page 134 - Battery voltage is normal CAN-Kubota frame CAN-Kubota original - Key switch turn OFF to ON CAN2 Kubota Frame open circuit Forced idle - Insufficient error U0081 ##### 2 proprietary 5 sec or more Key switch turn OFF ― frame open circuit error - Starter switch signal is not error (Accelerator = 0%)
  • Page 135  Do not idle the engine except as necessary. For more information, go to www.P65warnings.ca.gov/diesel pecifications are subject to change without notice. Consult your Carrier Transicold representative for details on warranty coverage. North America Central America and Mexico Carrier Transicold Carrier Transicold...

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