Carrier CT2-29-TV Workshop Manual Download Page 14

Page: 14 / 81

1--7

62--11161

1.5 TROUBLESHOOTING (Continued)

Symptom

Probable Cause

Solution

Reference

Engine Overheated

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

Low Battery Charge

Battery electrolyte level low

Replenish distilled

water and charge

Fan belt slips

Adjust belt tension or

change belt

Wiring disconnected

Connect

Rectifier defective

Replace

Alternator defective

Replace

Battery defective

Change

Summary of Contents for CT2-29-TV

Page 1: ...Diesel Engine 62 11161 Rev A WORKSHOP MANUAL for CT2 29 TV Z482 E2B Truck ComfortPro CT3 44 TV D722 E2B Truck Beginning With Serial Number 5A0001 R...

Page 2: ...WORKSHOP MANUAL DIESEL ENGINE CT2 29 TV Z482 E2B Truck ComfortPro CT3 44 TV D722 E2B Truck Beginning With Serial Number 5A0001...

Page 3: ...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...

Page 4: ...mshaft 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...

Page 5: ...alve 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...

Page 6: ...battery The battery normally vents small amounts of flammable hydrogen gas Do not smoke when checking the battery A battery explosion can cause serious physical harm and or blindness SPECIFIC WARNING...

Page 7: ...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 CAUTION Stop the engine...

Page 8: ...G H J K L M N P Q R S T U V W X Y Z Month 5th Digit Alpabetical Letter or Numerals Year of Manufacture Alphabetical letter or numerals W X Y Year 98 99 00 01 02 03 04 05 06 07 08 09 Jan Feb Mar May Ju...

Page 9: ...r 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 13 73 MPa 140 kgf cm2 1991 psi COMPRESSION RATIO 23 5 1 L...

Page 10: ...ved 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 Trans...

Page 11: ...Connecting Rod Bolt M7 x 0 75 26 5 to 30 4 2 7 to 3 1 19 5 to 22 4 Flywheel Bolt M10 x 1 25 53 9 to 58 8 5 5 to 6 0 39 8 to 43 4 Bearing Case Cover Mounting Bolt M6 x 1 9 8 to 11 3 1 00 to 1 15 7 2 t...

Page 12: ...gasket tighten 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 Adju...

Page 13: ...n 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 Fuel Mixed into Lubricant Oil Injection pump s plunger worn Replace...

Page 14: ...n 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...

Page 15: ...0 23543 in Valve Guide I D 6 010 to 6 025 mm 0 23661 to 0 23720 in Valve Face Angle 0 785 rad 45 Valve Seat Angle 0 785 rad 45 Width 2 12 mm 0 0835 in Valve Spring Free Length 31 3 to 31 8 mm 1 232 t...

Page 16: ...t Journal O D 32 934 to 32 950 mm 1 29661 to 1 29724 in Cylinder Block Bore I D 33 000 to 33 025 mm 1 29921 to 1 30020 Idle Gear Shaft to Idle Gear Bushing Clearance 0 020 to 0 084 mm 0 00079 to 0 003...

Page 17: ...arance 0 034 to 0 106 mm 0 00134 to 0 00417 in 0 20 mm 0 0079 in Crankshaft Journal O D 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft Bearing1 I D 39 984 to 40 040 mm 1 57148 to 1 57638 in Cran...

Page 18: ...98N 10kgf 22 lbs Thermostat Valve Opening Temperature At Beginning 69 5 to 72 5 C 157 to 162 5 F Valve Opening Temperature Opened Completely 85 C 185 F Radiator Cap Pressure Falling Time 10 seconds or...

Page 19: ...ion 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 hose is made of rubber and ages regardless of the service period Change the hos...

Page 20: ...60 and align the 1TC mark 2 on the flywheel and alignment mark 3 on the rear end plate so that the No 1 piston come to the overlap position 6 Check the following valve clearance marked with past TDC u...

Page 21: ...on 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 te...

Page 22: ...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 a...

Page 23: ...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 145 mm 5...

Page 24: ...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 Installi...

Page 25: ...with the spe cified valve clearance Always use a fully charged battery for perform ing this test Variances in cylinder compression values should be under 10 Compression Pressure Factory Specification...

Page 26: ...or Replace the fan fan belt alternator and starter NOTE When reinstalling the fan make sure that it is seated correctly Check to see that there are no cracks in the fan belt After reinstaling the fan...

Page 27: ...t any debris that may be in the pipes with compressed air then reassemble pipes Tightening Torque Injection Pipe Retaining Nut 24 5 to 34 3 N m 2 5 to 3 5 kgf m 18 1 to 25 3 ft lbs 2 2 4 c Nozzle Hold...

Page 28: ...to Section 1 7 6 Tightening Torque Rocker Arm Bracket Mounting Bolt 9 8 to11 3 N m 1 00 to 1 15 kgf m 7 2 to 8 3 ft lbs 2 2 4 e Cylinder Head 1 Loosen the hose clamps 1 and remove the water return ho...

Page 29: ...Valves 1 Remove the valve caps 2 2 Remove the valve spring collet 3 pushing the valve spring retainer 4 by the valve spring compressor 1 3 Remove the valve spring retainer 4 valve spring 5 and valve...

Page 30: ...1 for dam age 6 Visually inspect the oil pick up screen O ring 4 for damage oil it and reinstall 7 CT2 29 TV engine use hole labeled 2 CT3 44 TV engine use hole labeled 3 to install the pick up scree...

Page 31: ...plate 2 4 Remove the fuel feed pump 3 When Reassembling Hook the governor spring 4 to the governor lever 5 first and install the speed control plate 2 Be sure to replace the copper gaskets underneath...

Page 32: ...ecific tool 1 and the speed control plate 1 Remove the socket head screws 2 and remove the engine stop solenoid 4 2 Remove the screws and separate the speed control plate 5 taking care not to damage t...

Page 33: ...to the governor lever 13 using the specific tool and in stall the speed control plate 11 Use copper washers with the two screws 12 when securing the speed control plate 7 Install the engine stop solen...

Page 34: ...ulley retaining bolts and tighten them Tightening Torque Fan Drive Pulley Screw 117 7 to 127 5 N m 12 0 to 13 0 kgf m 86 8 to 94 0 ft lbs 2 2 6 d Gear Case 1 Disconnect the start spring 2 from the for...

Page 35: ...rks 6 on the gears Refer to the illustration Tightening Torque Idle Gear Shaft Mounting Bolt 9 8 to 11 3 N m 1 00 to 1 15 kgf m 7 2 to 8 3 ft lbs 1 Idle Gear 2 Idle Gear Collar 3 External Snap Ring 4...

Page 36: ...Sleeve 5 Fork Lever 1 6 Fork Lever 2 7 Governor Spring 8 Fork Lever Holder Mounting Bolt 2 2 6 h Oil Pump and Crankshaft Gears 1 Remove the oil pump gear 6 2 Remove the oil pump mounting bolts then t...

Page 37: ...h 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 If the connecting rod bolt does not...

Page 38: ...pump NOTE If re installing the original piston assemblies into the engine be sure that they are returned to their original cylinder When installing the piston into the cylinder place the gaps of all...

Page 39: ...ar the gap faces the top of the piston 5 When installing the oil control ring 3 onto the piston 5 place the expander joint 10 on the opposite side of the oil ring gap 11 Apply engine oil to the piston...

Page 40: ...aring case cover mounting bolts First remove the inside bolts 1 and then the outside screws 2 2 Screw two of the removed bolts into the bolt hole of the bearing case cover 6 to remove it NOTE The leng...

Page 41: ...of the crankshaft with compressed air Install the crankshaft assembly aligning the bolt hole of the main bearing case screw 2 with the bolt hole of the crankcase When tightening the main bearing case...

Page 42: ...in the illustration 1 for Z482 and 1 2 for D722 from the gear case side The diameters of the main bearing cases vary Install them in order from the gear case end according to their markings Match the...

Page 43: ...mbustion chamber Check the valve recessing after after resurfac ing the head Cylinder Head Surface Flatness Allowable Limit 0 05mm 0 0020 in 2 3 1 b Cylinder Head Cracks 1 Cylinder head crack s can be...

Page 44: ...protrusion in to 0 0039 recessing in Allowable Limit 0 30 recessing mm 0 0118 recessing in 2 3 1 d Clearance Between Valve Stem And Valve Guide 1 Remove carbon from the valve guide section 2 Measure t...

Page 45: ...ified di mension precisely Valve Guide I D Intake Exhaust Factory Specification 6 010 to 6 025 mm 0 2366 to 0 2372 in NOTE Do not hit the valve guide with a hammer during replacement 2 3 1 f Valve Sea...

Page 46: ...d the seat with a 0 785 rad 45 valve seat cutter again and visually recheck the contact between the valve and the seat 5 Repeat steps 3 and 4 until the correct contact is achieved 6 Continue lapping u...

Page 47: ...compressed in the en gine 2 Read the compression load on the gauge 3 If the measurement is less than the allowable limit re place it Setting Load Setting Length Factory Specification 64 7 N 27 0 mm 6...

Page 48: ...Bore 1 Measure the tappet O D with a micrometer 2 Measure the I D of the tappet guide bore with a cylin der gauge and calculate the clearance 3 If the measurement exceeds the allowable limit or the ta...

Page 49: ...to 0 124 mm 0 00181 to 0 00488 in Allowable Limit 0 15 mm 0 0059 in Backlash Crank Gear Oil Pump Gear Factory Specification 0 041 to 0 123 mm 0 00161 to 0 00484 in Allowable Limit 0 15 mm 0 0059 in 2...

Page 50: ...ss than the allowable limit re place the camshaft Cam Height Intake Exhaust Factory Specification 26 88 mm 1 0583 in Allowable Limit 26 83 mm 1 0563 in 2 3 2 f Camshaft Bearing Clearance 1 Measure the...

Page 51: ...Factory Specification 0 020 to 0 084 mm 0 00079 to 0 00331 in Allowable Limit 0 10 mm 0 0039 in Idle Gear Journal O D Factory Specification 19 967 to 19 980 mm 0 78610 to 0 78661 in Idle Gear Bore I D...

Page 52: ...ce Factory Specification 0 014 to 0 038 mm 0 00055 to 0 00150 in Allowable Limit 0 10 mm 0 0039 in Piston Pin O D Factory Specification 20 002 to 20 011 mm 0 78748 to 0 78783 in Small End Bushing I D...

Page 53: ...with a feeler gauge 3 If the clearance exceeds the allowable limit replace the ring 4 If the clearance still exceeds the allowable limit after replacing the ring replace the piston Second Ring Factor...

Page 54: ...rust Bearing 1 02 25 36430 01 020 OS Thrust Bearing 2 02 020 OS Reference Oversize dimensions of crankshaft journal Oversize 0 2mm 0 0008 in 0 4mm 0 0016 in Dimension A 23 40 to 23 45 mm 0 9134 to 0 9...

Page 55: ...pecification 0 020 to 0 051 mm 0 00079 to 0 00201 in Allowable Limit 0 15 mm 0 0059 in Crankpin O D Factory Specification 33 959 to 33 975 mm 1 33697 to 1 33760 in Connecting Rod Bearing I D Factory S...

Page 56: ...fication 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft Bearing Bearing I D Factory Specification 39 984 to 40 040 mm 1 57148 to 1 57638 in Reference Bearing clearance between crankshaft journal...

Page 57: ...ol Refer to Special Tools 1 8 14 B When Installing 1 Clean a new crankshaft bearing 1 2 and crankshaft journal bore and apply engine oil to both 2 Using the crankshaft bearing replacing tool press in...

Page 58: ...73331 in Crankshaft Journal O D Intermediate Factory Specification 39 934 to 39 950 mm 1 57221 to 1 57284 in Crankshaft Bearing 3 I D Factory Specification 39 984 to 40 026 mm 1 57417 to 1 57583 in Re...

Page 59: ...Crankshaft Sleeve 1 Remove the crankshaft sleeve using a special use puller set 2 Set the sleeve guide 4 to the crankshaft 2 3 Heat the new sleeve to a temperature between 150 to 200 C 302 to 392 F a...

Page 60: ...If deep scratches are found the cylinder walls should be bored Refer to Section 2 3 5 b Cylinder Wear Factory Specification 67 000 to 67 019 mm 2 63779 to 2 63854 in Allowable Limit 67 169 mm 2 64445...

Page 61: ...rain plug 1 7 Remove the oil fill cap 3 and add the correct oil to the engine 8 Add oil until the engine oil level is up to the upper line on the dipstick 2 NOTE Replace the engine oil filter with eve...

Page 62: ...ecessary 3 1 4 Engine Oil Pressure 1 Remove the engine oil pressure switch and install an oil pressure guage 2 Start the engine After warming up read the oil pres sure at idling and at rated speeds 3...

Page 63: ...the outer rotor with a feeler guage 2 Measure the clearance between the outer rotor and the pump body with a feeler guage 3 If the clearance exceeds the factory specifications replace the oil pump ro...

Page 64: ...ter the engine has stopped and cooled down Otherwise hot water may discharge from the radiator scalding anyone nearby 2 Remove the radiator cap and check to see that the coolant level is just below th...

Page 65: ...3 Apply pressure and look for leaks 4 Repair replace as necessary to assure that the speci fied pressure will hold Radiator Leakage Test Factory Specification 157 kPa 1 6 kgf cm2 23 psi 4 1 7 Thermost...

Page 66: ...bly 3 When Reassembling Apply a liquid gasket only at the thermostat cover side of the thermostat cover gasket 2 4 2 2 Water Pump Assembly 1 Remove the fan belt 2 Remove the water pump pulley 3 Remove...

Page 67: ...nt is accomplished by adding or removing shims under the injection pump The timing advances by removing one shimand retards by adding the same shim The addition or removal of 0 05 mm 0 002 in of shim...

Page 68: ...3 Install the injection pump pressure tester to the injec tion pump 4 Install the injection nozzle 1 jetted with the proper in jection pressure to the injection pump pressure tester 2 5 Engage the sta...

Page 69: ...defective replace the injection nozzle assembly 5 2 2 Nozzle Injection Pressure 1 Set the injection nozzle in a nozzle tester 2 Slowly move the tester handle to measure the pres sure at which fuel beg...

Page 70: ...vise 2 Remove the nozzle holder 1 and remove the parts 3 If any fuel leak is found replace the injection nozzle assembly When Reassembling Assemble the nozzle in clean fuel oil Install the push rod 4...

Page 71: ...d engage the starter at the same time and read the voltage 5 If the voltage differs from the battery voltage in either case the wiring harness or the switch or switches are faulty 6 1 2 Glow Plug Cont...

Page 72: ...ive post on the battery 6 Connect a jumper lead momentarily between the starter motor housing and the negative post on the battery 7 If the starter does not run check the motor 6 2 2 Magnetic Switch T...

Page 73: ...emove the solenoid switch 5 3 Remove the end frame cap 16 4 Remove the break shoe 15 break spring 14 and gasket 13 5 Unscrew the through bolts 21 and remove the rear end frame 12 6 Unscrew the brush f...

Page 74: ...between the starter motor housing and the negative post on the battery 7 If the starter does not run check the motor Tightening Torque B Terminal Nut 8 8 to 11 8 N m 0 9 to 1 2 kgf m 6 5 to 8 7 ft lbs...

Page 75: ...ecting lead 8 2 Unscrew the magnetic switch mounting nuts 1 and remove the magnetic switch 3 from the housing 2 3 Unscrew the through bolts 14 and mounting screw 9 and remove the rear end frame 13 4 R...

Page 76: ...sh is dirty or dusty clean it with emery cloth 2 Measure the brush length A with a vernier caliper 3 If the length is less than the the allowable limit re place the yoke assembly and the brush holder...

Page 77: ...contact pattern of the commutator for wear and grind the commutator with emery cloth if it is slightly worn 2 Measure the commutator O D with an outside mi crometer at several points 3 If the minimum...

Page 78: ...6 4 7 Field Coil 1 Check the continuity across the lead 1 and thebrush 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 w...

Page 79: ...n Drive Pulley 2 10 flywheel 2 16 fuel injection 2 3 fuel system 5 1 fuel system bleeding 1 12 G Gear Case 2 10 glow plug 6 1 I Identification 1 1 idle gear 2 11 injection nozzle 5 3 5 4 injection tim...

Page 80: ...4 2 timing gear 2 25 timing gear camshafts 2 7 2 8 2 9 2 10 2 11 2 12 Torque Specification 1 4 V v belt 4 1 valve clearance 1 13 valve guide 2 21 valve seat 2 21 valve spring 2 23 valves 2 5 2 6 2 20...

Page 81: ...n U S A 0707 Carrier Transicold Division Carrier Corporation Truck Trailer Container Product Groups P O Box 4805 Syracuse N Y 13221 U S A www carrier transicold com A member of the United Technologies...

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