Thermo King KD-II SR, Manual

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Engine Maintenance (Rev. 04/03)
73
4. A dirty filter.
5. A stuck seat in the outlet fitting.
Injection Pump Adjustments
When the diesel engine fails to maintain the correct engine
speed, check the following before adjusting the speed:
1. Check the prefilter screen. Recheck the speed.
2. Bleed air out of the fuel system. Recheck the speed.
3. Bleed air out of the nozzles. Recheck the speed.
4. Operation of electric transfer pump.
Make the engine speed adjustments with the engine fully
warmed up.
The KD-II SR has one solenoid to control the high speed
function. The speed of the engine should be checked with a
hand tachometer, TK P/N 204-220, on the crankshaft pulley
bolt or by the use of a stroboscope tachometer, TK P/N
204-436.
Timing the Injection Pump to the Engine
There are two different types of timing procedures used on
the TK 3.74 engine. One procedure involves checking to
make sure the cylinders are timed correctly to each other,
and the second procedure times the injection pump correctly
to the engine. If the cylinders are not timed correctly to each
other, it is of no value to time the injection pump to the
engine because one or two of the three cylinders would be
out of time. The individual plungers in the injection pump
are timed to each other by the use of spacers in the pump
plunger base. It is rare that an injection pump would change
individual cylinder timing unless it had been through some
type of repair process, but if all other possible problems
with a rough running engine have been checked, and espe-
cially if the engine’s injection pump has been replaced or
repaired recently, it may be beneficial to check individual
cylinder timing. Because the possibility of incorrect individ-
ual cylinder timing is so minimal, the procedure for timing
the pump to the engine will be covered first. The procedure
for individual cylinder timing is very similar to timing the
injection pump so it will be covered last.
CAUTION: The cylinders on the engine are num-
bered from the flywheel end to the water pump end.
The number 1 cylinder is next to the flywheel. The number
2 cylinder is the center cylinder. The number 3 cylinder is
next to the water pump. The timing marks on the flywheel
are matched to this system.
1. Rotate the engine in the direction of rotation (clockwise
as viewed from the water pump end) until the number 1
cylinder (closest to flywheel) is at approximately top
dead center of the compression stroke. The valve cover
should be removed to identify the compression stroke.
Both rocker arms of the number 1 cylinder will be
loose. Check to see that the number 1 cylinder top dead
center mark on the flywheel is aligned with the timing
mark on the starter mounting plate.
NOTE: The timing marks for each of the three cylin-
ders are stamped 120° apart. Top dead center marks
are identified by the number of the cylinder stamped
next to them. Injection timing marks are unmarked.
The timing marks on the TK 3.74 engine can be diffi-
cult to align. This is because the timing mark on the
starter mounting plate is near the air cleaner, on the
side of the plates that faces the flywheel. It cannot be
seen when looking through the curbside door opening
unless you use a mirror.
The timing mark on the starter mounting plate is a
line stamped on the side of the plate facing the fly-
wheel. To locate the timing mark, feel the back side of
the plate 0.4 in. (10 mm) below the center of round
notch in the edge of the plate. To make it easier to
align the timing marks, file a V-notch in the edge of
the plate in line with the timing mark on the plate.
Units manufactured after 3-15-89 will have this
V-notch in the edge of the plate.