Diesel Engine v1903 v2203
Diesel Engine v1903 v2203
Diesel Engine v1903 v2203
WORKSHOP MANUAL
for
V1903-TV (26-00123)
V2203-TV (26-00124)
Beginning With Serial Number 4A0001
62--10866 Rev --
WORKSHOP MANUAL
DIESEL ENGINE
V1903-TV (26-00123)
V2203-TV (26-00124)
Beginning With Serial Number 4A0001
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 CYLINDER NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.1 Torque Specifications For Special Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7 SERVICING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.7.1 Engine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.7.2 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.7.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.7.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.8 CHECK AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8.1 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8.2 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8.3 Checking Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8.4 Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.8.5 Checking V--Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.6 Checking V--Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.7 Checking V--Belt Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.8 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.8.9 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.8.10 Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.9 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9.1 Diesel Engine Compression Tester (Glow Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9.2 Adapter, Kubota 10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9.3 Tester Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9.4 Replacement Bowl, Tester Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9.5 Adapter, Injector Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.9.6 Oil Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.9.7 Auxiliary Socket For Fixing Crankshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.9.8 Valve Guide Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.9.9 Bushing Replacing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.9.10 Flywheel Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.9.11 Crankshaft Bearing 1 Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
i 62--10866
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 And Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.2 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.3 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.5 Injection Pump and Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.6 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.2.7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.3 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.3.1 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.3.2 Timing Gears, Camshaft and Fuel Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.3.3 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.3.4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.3.5 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.2 Rotor to Cover Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
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 Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
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 Delivery Valves Fuel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.2 Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.3 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
62-10866 ii
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 TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 STARTER DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Disassembling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.2 Disassembling The Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.3 Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 STARTER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.1 Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.2 Armature Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.4 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.5 Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.6 Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.7 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.8 Commutator and Mica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.9 Starter Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
iii 62--10866
SAFETY
SAFETY PRECAUTIONS
Your Carrier Transicold unit has been designed with the very hot. Contact with hot coolant can cause severe
safety of the operator in mind. During normal operation, burns. Do not remove the cap from a hot radiator. If the
all moving parts are fully enclosed to help prevent injury. cap must be removed, do so very slowly in order to
During all pre-trip inspections, daily inspections, and release the pressure without spray.
problem troubleshooting, you may be exposed to
moving parts. Please stay clear of all moving parts when Battery
the unit is in operation and when the unit main power This unit is equipped with a lead-acid type battery. The
switch is in the START/RUN position. battery normally vents small amounts of flammable
Engine Coolant hydrogen gas. Do not smoke when checking the battery.
A battery explosion can cause serious physical harm
The engine is equipped with a pressurized cooling and/or blindness.
system. Under normal operating conditions, the coolant
in the engine and radiator is under high pressure and is
WARNING
WARNING When removing the radiator cap, wait at
WARNING -- warns against hazards or un- least ten minutes after the engine has
stopped and cooled down. Otherwise, hot
safe conditions which COULD result in se-
water may discharge from the radiator,
vere personal injury or death.
scalding anyone nearby.
CAUTION CAUTION
CAUTION -- warns against potential hazard
Do not remove the radiator cap until the
or unsafe practice which could result in mi-
coolant temperature is below its boiling
nor personal injury, or product or property
point. Loosen the cap slightly to relieve ex-
damage.
cess pressure before removing the cap
completely.
NOTE
NOTE -- gives helpful information that may help
and avoid equipment and property damage.
i 62-10866
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
Secure the starter to prevent it from moving
when power is applied to it.
62-10866 ii
SECTION 1
General
1.1 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.
S/N
Engine Serial Number (S/N)
The engine serial number is an identified number for the
engine. It is marked after the engine model number.
It indicates month and year of manufacture as follows:
Figure 1-1.
Year of Manufacture Month of Manufacture
1-1 62--10866
1.2 ENGINE SPECIFICATIONS
Table 1-2. Specification Chart
MODEL NUMBER 26-00123-00 26-00124-01
TYPE Vertical, Water-cooled, 4 cycle diesel engine
NUMBER OF CYLINDERS 4
BORE X STROKE mm X mm (in. X in.) 80 X 92.4 (3.15 X 3.64) 87 X 92.4 (3.43 X 3.64)
TOTAL DISPLACEMENT cm3 (cu.in.) 1857 (113.3) 2197 (134.1)
BRAKE HORSE- SAE Intermittent H.P.
18.2 (24.4) / 1700 27.0 (36.2) / 1950
POWER kW (HP) / RPM
MAXIMUM SPEED RPM Below 1920 Below 2170
IDLING SPEED RPM 900 To 1000
COMBUSTION CHAMBER E-T.V.C.S.
INJECTION PUMP PFR 4M Type Mini Pump
GOVERNOR Centrifugal Ball Mechanical Governor
INJECTION NOZZLE Throttle-Type DNOPD95
INJECTION TIMING (UNPRESSURIZED) 16 Before T.D.C. 14.5 Before T.D.C.
FIRING ORDER 1-3-4-2
INJECTION PRESSURE
13.73 MPa (140 kgf/cm2, 1991 psi.)
(Valve Opening Pressure)
COMPRESSION RATIO 23 : 1
LUBRICATION SYSTEM Forced Lubrication by Pump
OIL PRESSURE INDICATION Electrical Type Switch
LUBRICATION FILTER Full Flow Filter (Cartridge Type)
COOLING SYSTEM Pressurized Radiation, Forced Circulation With Water Pump
Electric Starting With Starting Motor
STARTING SYSTEM
12V, 2.0 kW
STARTING SUPPORT DEVICE By Glow Plug In Combustion Chamber
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 16.3 L (17.2 U.S. Quarts
Weight (DRY) kg (lbs.) 191.4 (422.0)
62--10866 1-2
1.3 CYLINDER NUMBER 1.4 GENERAL PRECAUTIONS
1-3 62--10866
1.5 TORQUE SPECIFICATIONS
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.
1.5.1 Torque Specifications For Special Use Screws, Bolts and Nuts
In removing and applying the screws, bolts and nuts marked with “*”, a pneumatic wrench or similar tool, if employed,
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.
1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt Special Screw and Bolt
Grade 4 Grade 7
N.m kgf.m ft--lbs N.m kgf.m ft--lbs
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 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 SS400, S20C
7 Special Screw And Bolt S43C, S48C (Refined)
62--10866 1-4
1.6 TROUBLESHOOTING
Symptom Probable Cause Solution Reference
Engine Does Not --
No fuel Replenish fuel
Start --
Air in the fuel system Vent Air
1.8.4
Water in the fuel system Change fuel and
1.8.4
repair or replace fuel
system
Fuel pipe clogged Clean
1.8.4
Fuel filter clogged Clean or change
--
Excessively high viscosity of fuel or engine oil Use specified fuel or
--
at low temperature engine oil
Fuel with low cetane number Use specified fuel
--
Incorrect injection timing Adjust
5.1.1
Injection nozzle clogged Replace
1.8.10
Injection pump malfunctioning Replace
--
Seizure of crankshaft, camshaft, piston, Repair or Replace
--
cylinder or bearing
Compression leak from cylinder Replace head
--
gasket, tighten
--
cylinder head screw,
--
glow plug and nozzle
--
holder
Improper valve timing Correct or replace
2.2.5.f
timing gear
Piston ring and cylinder worn Replace
2.3.3.d
Excessive valve clearance Adjust
1.8.9
(Starter Does Not
Battery discharged Charge
Run)
Starter malfunctioning Repair or replace
6.2
Key switch malfunctioning Repair or replace
--
Wiring disconnected Connect
--
Engine Revolution Fuel filter clogged or dirty Clean or change 1.8.4
Is Not Smooth Air cleaner clogged or dirty Clean or change --
Fuel leak due to loose injection pipe retaining Tighten retaining nut --
nut
Injection pump malfunctioning Replace 5.1
Incorrect nozzle injection pressure Replace 1.8.10.a
Injection nozzle stuck or clogged Replace 1.8.10.c
Either White or Blue Excessive engine oil Reduce to specified 1.8.1
Exhaust Gas Is level
Observed Piston ring and liner worn or ring stuck Repair or replace 2.3.3.d
Incorrect Injection timing Adjust 5.1.1
Deficient compression Check the cylinder 2.1.1
compression
pressure and top
clearance
Either Black or Dark Overload Lesson load --
Exhaust Gas Is Low grade fuel used Use specified fuel --
Observed Fuel filter clogged Clean or change --
Air cleaner clogged Clean or change --
Deficient nozzle injection Replace nozzle 1.8.10
Deficient Output Incorrect injection timing Adjust 5.1.1
Engine’s moving parts seem to be seizing Repair or replace --
Injection pump malfunctioning Replace 5.1
Deficient nozzle injection Replace nozzle 1.8.10.b
Compression leak Check the 2.1.1
compression
pressure and repair
Gas leak from exhaust system Repair or replace --
Air cleaner dirty or clogged Clean or replace --
1-5 62--10866
1.6 TROUBLESHOOTING (Continued)
Symptom Probable Cause Solution Reference
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap 2.2.6.b
Oil Consumption direction
Oil ring worn or stuck 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
Crankshaft bearing, and crank pin bearing Replace 2.3.4
worn
Oil leaking due to defective seals or packing Replace --
Fuel Mixed into Injection pump’s plunger worn Replace Injection 5.1
Lubricant Oil pump
Deficient nozzle injection Replace nozzle 1.8.10.c
Injection pump broken Replace 5.1
Water Mixed into Head gasket defective Replace 2.2.4.d
Lubricant Oil Cylinder block or cylinder head flawed Replace --
Low Oil Pressure Engine oil level low Replenish --
Oil strainer clogged Clean --
Relief valve stuck with dirt Clean 3.1.2
Relief valve spring weak or broken Replace 3.1.2
Excessive oil clearance of crankshaft bearing Replace 2.3.4.d
62--10866 1-6
1.7 SERVICING SPECIFICATIONS
1.7.1 Engine Body
Item Factory Specification Allowable Limit
Cylinder Head Surface Flatness D
Compression Pressure 2.94 to 3.24 MPa/ 2.35 MPa/
290 rpm 290 rpm
30 to 33 kgf/cm2 24kgf/cm2
290 rpm 290 rpm
427 to 469 psi/ 341 psi/
290 rpm 290 rpm
1-7 62--10866
1.7.1 Engine Body (Continued)
Item Factory Specification Allowable Limit
Valve Timing 26-00123-00 Intake Open 0.21 rad. (12) --
before T.D.C.
Intake Close 0.63 rad. (36) --
after B.D.C
Exhaust Open 1.03 rad. (60) --
before B.D.C.
Exhaust Close 0.21 rad. (12) --
after T.D.C
26-00124-01 Intake Open 0.14 rad. (8) --
before T.D.C.
Intake Close 0.35 rad. (20) --
after B.D.C
Exhaust Open 1.03 rad. (60) --
before B.D.C.
Exhaust Close 0.21 rad. (12) --
after T.D.C
Valve Spring Free Length 41.7 to 42.2 mm 41.2 mm
1.6417 to 1.6614 in. 1.6220 in.
Tilt -- 1.0 mm
0.039 in.
Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 1.0 mm
0.00063 to 0.00177 in. 0.039 in.
62--10866 1-8
1.7.1 Engine Body (Continued)
Item Factory Specification Allowable Limit
Idle Gear Side Clearance 0.12 to 0.48 mm 0.9 mm
0.0047 to 0.0189 in. 0.0039 in.
Idle Gear Shaft to Idle Gear Bushing Clearance 0.025 to 0.066 mm 0.1 mm
0.00098 to 0.00260 in. 0.0039 in.
1-9 62--10866
1.7.1 Engine Body (Continued)
Item Factory Specification Allowable Limit
Piston Pin to Small End Bushing Clearance 0.014 to 0.038 mm 0.15 mm
0.00055 to 0.00150 in. 0.0059 in.
62--10866 1-10
1.7.2 Lubricating System
Item Factory Specification Allowable Limit
Engine Oil Pressure At Idle Speed -- 49kPa
0.5 kgf/cm2
7 psi
1-11 62--10866
1.7.5 Electrical System
Item Factory Specification Allowable Limit
Starter Commutator O.D. 35.0 mm 34.0 mm
1.378 in. 1.339 in.
Mica Undercut 0.50 to 0.90 mm 0.20 mm
0.0197 to 0.0354 in. 0.0079 in.
Brush Length 0.15 mm 11.0 mm
0.591 in. 0.433 in.
Brush Holder and Resistance Infinity --
Holder Support
Glow Plug Resistance Approximately 1 OHM --
62--10866 1-12
1.8 CHECK AND MAINTENANCE
NOTE
1.8.1 Checking Engine Oil Level
When adding coolant to the system, air must be
vented from the engine coolant passages by jig-
gling the upper and lower radiator hoses.
Be sure to close the radiator cap securely. If the
cap is loose or improperly closed, coolant may
leak out and the engine could overheat.
Do not use an antifreeze and scale inhibitor at
the same time.
Never mix different types or brands of coolants.
1-13 62--10866
1.8.5 Checking V--Belt Tension 1.8.8 Changing Engine Oil
CAUTION
Stop the engine when preparing to change
the engine oil.
NOTE
1. Check the V--belt for damage.
Replace the engine oil filter with every oil
2. If the belt shows signs of chaffing or damage (see change.
above), replace the belt.
Lubricating oil recommended when a low--sulfur or
high--sulfur fuel is employed.
Lubricating Oil Class Fuel
Low--sulfur High--sulfur
CG--4 O X
CH--4 or CI O X
O : Recommended X : Not Recommended
62--10866 1-14
1.8.9 Valve Clearance
NOTE
Valve clearance must be checked and adjusted
when the engine is cold.
1-15 62--10866
1.8.10 Fuel Injection
WARNING
Check the injection nozzle only after con-
firming 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.
62--10866 1-16
1.9 SPECIAL TOOLS
Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number
62--03213.
1.9.1 Diesel Engine Compression Tester (Glow
Plug)
Part No. 07-00179-01 (Assembly)
Application: Use to measure diesel engine
compression and diagnosis for
major overhaul.
1-17 62--10866
1.9 SPECIAL TOOLS (Continued)
1.9.6 Oil Pressure Tester
Code No. 07916--32032
Application: Use to measure lubricating oil
pressure.
62--10866 1-18
1.9 SPECIAL TOOLS (Continued)
The following are drawings for special tools that may need to be fabricated.
1.9.8 Valve Guide Replacing Tool
Application: Use to press out and press fit the valve
guide.
A 20 mm dia. (0.79 in. dia.)
B 11.7 to 11.9 mm 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 6.7 to 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.)
1.9.9 Bushing Replacing Tools
Application: Use to press out and press fit the bushing.
1. For small end bushing.
A 162 mm (6.38 in.)
B 35 mm (1.38 in.)
C 27 mm (1.06 in.)
D 35 mm dia. (1.38 in. dia.)
E 27.90 to 27.95 mm dia. (1.098 to 1.100 in. dia.)
F 25.00 to 25.01 mm dia. (0984 to 0.985 in. dia.)
1-19 62--10866
1.9 SPECIAL TOOLS (Continued)
1.9.11 Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft
bearing No. 1
1. Extracting tool
A 130 mm (5.31 in.)
B 72 mm (2.83 in.)
C R40 mm (R1.57 in.)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
H 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
2. Extracting tool
A 130 mm (5.31 in.)
B 72 mm (2.83 in.)
C R40 mm (R1.57 in.)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm (0.79 in.)
G 20 mm dia. (0.79 in. dia.)
H 68 mm dia. (2.68 in. dia.)
I 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
J 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
62--10866 1-20
SECTION 2
ENGINE BODY
7 If the measurement is below the allowable limit, add a 1. Piston 2 Plastic gauge
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 allow- 1 Remove the valve cover. Refer to 2.2.3.a.
able limit, check the top clearance, valves and cylin-
der head. 2 Remove the cylinder head.
b If the compression pressure increases after applying 3 Move the piston (1) up and stick a strip of plastic
oil, check the cylinder wall and piston rings. gauge (2) on the piston head at three positions shown
on the illustration.
NOTE 4 Lower the piston and install the cylinder head. (Use a
new cylinder head gasket and tighten the cylinder
Check the compression pressure with the spe- head bolts to the proper torque.
cified valve clearance 5 Turn the flywheel until the piston (1) passes through
top dead center.
Always use a fully charged battery for perform-
ing this test. 6 Remove the cylinder head and measure the plastic
guage.
Variances in cylinder compression values
should be under 10%. 7 If the measurement is not within the factory specifica-
tions, check the clearances between the crank pin
and bearing and between the piston pin and bushing.
2.94 to 3.24 MPa
Factory
30 to 33 kgt/cm2 Factory 0.55 to 0.70 mm
Specification Top Clearance
Compression Pres- 427 to 469 psi Specification 0.0217 to 0.0276 in.
sure 2.35 MPa 93.1 to 98.0 N.m
Tightening Cylinder Head
Allowable Limit 24 kgt/cm2 9.5 to 10.0 kgf.m
Torque Bolts
341 psi 68.7 to 72.3 ft--lbs
2-1 62--10866
2.2 DISASSEMBLING AND ASSEMBLING
2.2.1 Draining Coolant And Engine Oil 2.2.2 External Components
Air Cleaner, Muffler and Others
1 Remove the air cleaner and muffler.
CAUTION
2 Remove the fan, fan belt, alternator and starter.
Never remove the radiator cap until coolant When Reassembling
temperature is below its boiling point.
Loosen the cap slightly to the first stop to
relieve any excess pressure before remov- NOTE
ing the cap completely.
Check to see that there are no cracks on the belt
surface.
1 Open the coolant drain cock or remove the coolant After reinstaling the fan belt, be sure to adjust
drain plug and drain the coolant into a proper recep-
tacle/bucket. the fan belt tension. Refer to 4.1.1.
2 Remove the oil drain plug and drain the engine oil into When reinstalling the fan, make sure that it is
a proper receptacle/bucket. put on correctly.
62--10866 2-2
2.2.3 Cylinder Head And Valves
2.2.3.a Valve Cover
1 Remove the Glow Plug Buss Bar (1).
2 Remove the breather hose (2).
3 Remove the valve cover bolts (3).
4 Remove the valve cover (4).
When Reassembling
Check to see that the valve cover gasket (5) is in good
condition and in place.
6.9 to 11.3 N.m
Tightening Valve Cover
0.7 to 1.15 kgf.m
Torque Bolts
5.1 to 8.32 ft--lbs
2-3 62--10866
2.2.4 Cylinder Head And Valves (Continued)
2.2.4.a Nozzle Holder Assembly and Glow Plug
1 Remove the overflow pipe assembly (5).
2 Remove the nozzle holder assemblies (2) using a
deep socket wrench.
3 Remove the copper gasket (3) and heat seal (4).
4 Remove the glow plugs (1).
When Reassembling
Replace the copper gasket and heat seal with a new
one.
49.0 to 68.6 N.m
Nozzle Holder
5.0 to 7.0 kgf.m
Clamp Screw
36.2 to 50.6 ft--lbs
Overflow Pipe 19.6 to 24.5 N.m
Tightening
Assembly 2.0 to 2.5 kgf.m
Torque
Retaining Nut 14.5 to 18.1 ft--lbs
1. Glow Plug 4. Heat Seal 19.6 to 24.5 N.m
2. Nozzle Holder Assembly 5. Overflow Pipe Assembly Glow Plug 2.0 to 2.5 kgf.m
3 Copper Gasket 14.5 to 18.1 ft--lbs
NOTE
Use a phillips head screw driver (1) that is
slightly larger than the heat seal hole
1 Drive the screw driver (1) lightly into the heat seal
hole.
2 Turn the screw driver (1) three or four times each way.
3 While turning the screw driver (1), slowly pull the heat
seal (4) out together with the copper gasket (3).
4 If the heat seal (4) does not come out, repeat the
procedure.
When Reassembling
The heat seal (4) and the copper gasket (3) must be
changed when the injection nozzle is removed for
cleaning or service.
NOTE
After instaling the rocker arm, be sure to adjust
the valve clearance.
62--10866 2-4
2.2.4.d Cylinder Head
1 Loosen the hose clamp (1), and remove the water re-
turn hose (2).
2 Remove the cylinder head bolts in the order of (r) to
(a).
3 Lift up the cylinder head and remove.
4 Remove the cylinder head gasket and O-ring.
When Reassembling
Replace the cylinder head gasket (3) with a new one.
Install the cylinder head, taking care not to damage the
O-ring.
Apply oil to, then re--install the cylinder head bolts.
Tighten the cylinder head bolts in sequence starting
from the center in the order of (a) to (r).
Retighten the head bolts after running the engine for 30
minutes.
93.1 to 98.0 N.m
Tightening Cylinder Head
9.5 to 10.0 kgf.m
Torque Bolt
68.7 to 72.3 ft--lbs
2.2.4.e Valves
1 Remove the valve caps (2).
2 Remove the valve spring collet (3), pushing the valve
1. Hose Clamp 5. Measuring Points spring retainer (4) by the valve spring compressor (1).
2. Filter-Drier Inlet A: Gear Case Side
3 Remove the valve spring retainer (4), valve spring (5)
3 Cylinder Head Gasket B: Flywheel Side
and valve stem seal (6).
4. Marking
4 Remove the valve.
When Reassembling
Clean the valve stem and the valve guide. Apply engine
oil to the valve stem when reassembling.
After installing the valve spring collets (3), lightly tap the
stem with a plastic hammer to assure the collets have
seated on the valve stem.
NOTE
When re--installing valves into the cylinder
head, make sure that they are re--installed in
their original location.
2.2.4.f Tappets
1 Remove the tappets (1) from the crankcase.
When Reassembling
Visually check the contact between the tappets (1) and
individual cam lobes.
Coat the tappets with engine oil before installing them.
NOTE
When re--installing tappets into the engine,
make sure that they are re--installed in their
original location.
2-5 62--10866
2.2.5 Injection Pump and Gear Case
2.2.5.a Speed Control Plate
1 Remove the mounting bolt/nut and lift up the speed
control plate (1).
2 Disconnect the governor spring (2).
3 Remove the control plate.
When Reassembling
Apply gasket sealer to both sides of the speed control
plate gasket.
Check that the speed control lever (3) positions low idle,
1. Speed Control Plate 3 Speed Control Lever after assembling the governor spring.
2. Governor Spring
Check that the speed control lever (3) returns to the high
idle position rather than the low idle position, after
moving the lever to the maximum speed position.
After assembling the engine, check the idling speed.
62--10866 2-6
2.2.5.b Injection Pump
NOTE
When Reassembling
Install the stop solenoid (1), guide (9) and the hi--idling
body (2) after attaching the injection pump.
2-7 62--10866
2.2.5.c Fan Drive Pulley
1 Lock the flywheel.
2 Remove the fan drive pulley mounting nut.
3 Remove the fan drive pulley with a gear puller.
4 Remove the feather key.
When Reassembling
Apply grease to the splines of the coupling.
62--10866 2-8
2.2.5.g Camshaft
1 Remove the camshaft retaining bolt (2) and pull the
camshaft (1) out.
When Reassembling
Refer to installation of Idle Gear (refer to 2.2.5.f).
23.5 to 27.5 N.m
Tightening Camshaft
2.4 to 2.8 kgf.m
Torque retaining bolt
17.4 to 20.3 ft--lbs
2-9 62--10866
2.2.5.j Oil Pump
1 Remove the nut.
2 Draw out the oil pump drive gear (1) with a gear puller
(2).
3 Remove the four oil pump mounting screws. Detach
the oil pump (3).
62--10866 2-10
2.2.6 Piston and Connecting Rod
2.2.6.a Oil Pan and Oil Strainer
1 Remove the oil pan mounting bolts.
2 Remove the oil pan by lightly tapping the rim of the
pan with a soft hammer.
3 Remove the oil pan gasket.
4 Remove the oil strainer (1) and O--ring (2).
When Reassembling
Check to see that the oil filter strainer (1) is clean.
Visually check the O--ring (2), apply engine oil and install
1. Oil Strainer
it to the pick--up tube.
2. O--ring Install the strainer (1) and O--ring (2).
Apply gasket sealant to the oil pan side of the oil pan
gasket and fit the gasket to the oil pan.
Install the oil pan to the engine, and tighten the oil pan
bolts diagonally. Avoid uneven tightening of the oil pan
mounting bolts. (Refer to 1.5.2 for torque specifications)
2-11 62--10866
2.2.6.b Pistons
1 Completely remove the carbon ridge (1) at the top of
the cylinder walls.
2 Remove the the connecting rod cap (3).
3 Turn the flywheel and bring the piston to top dead
center.
4 Push the piston out by lightly tapping the connecting
rod from the bottom of the crankcase with the grip of a
hammer.
5 Repeat the procedure for the other three cylinders.
When Reassembling
Liberally coat the piston and piston rings with engine oil.
When inserting the piston into the cylinder, face the
mark on the connecting rod to the injection pump.
NOTE
If re--installing the original piston assemblies
into the engine be sure that they are returned to
their original cylinder.
Place the piston rings with their gaps at 2.09
rad. (120) from the piston pin’s direction as
shown.
Carefully insert the pistons into the cylinders
using the piston ring compressor (6).
When inserting the piston into the cylinder avoid
damaging the molybdenum disulfide coating on
the piston skirt. This coating is useful in mini-
mizing the clearance between the piston and
cylinder.
When replacing a piston, use a replacement
piston with the same code number. The piston
ID mark (7) is on top of the piston.
62--10866 2-12
2.2.6.c Piston Ring and Connecting Rod
1 Remove the piston rings (1), (2), (3).
2 Remove the piston pin (7) and then seperate the con-
necting rod (6) from the piston (5).
NOTE
When Reassembling
When installing the ring, assemble the rings so that the
manufacturer’s mark (12) near 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 pin (7).
When assembling the connecting rod (6) to the piston
(5), immerse the piston (5) in hot oil (80C / 176F) for 10
to 15 minutes, then assemble the piston, piston pin, and
connecting rod.
NOTE
2-13 62--10866
2.2.7 Crankshaft
2.2.7.a Flywheel
1 Prevent the flywheel (1) from rotating.
2 Remove two flywheel bolts (2).
3 Install two flywheel guide screws (3).
4 Remove all of the flywheel screws (2).
5 Remove the flywheel (1) slowly along the flywheel
guide screws (3).
When Reassembling
Install two flywheel guide screws (3).
1. Flywheel 3 Flywheel Guide Screws Check to see that the mating surfaces of the crankshaft
2. Flywheel Bolt
and flywheel are clean.
Apply engine oil to the flywheel bolts and install.
98.0 to 107.8 N.m
Tightening
Flywheel Bolts 10.0 to 11.0 kgf.m
Torque
72.3 to 79.5 ft--lbs
NOTE
The length of the inside and the outside screws
is different. When reassembling reinstall the ap-
propriate screw in the correct location.
When Reassembling
Fit the bearing case gasket (1) and the bearing case
cover gasket (2) to the bearing case cover (5). Orient
them correctly.
Install the bearing case cover (5), again orienting it
correctly, using the “UP” mark (a).
1. Bearing Case Gasket 5. Bearing Case Cover Apply oil to the oil seal, and take care that it is not rolled
2. Bearing Case Cover 6. Bearing Case Cover
when installed.
Gasket Mounting Screw Tighten the bearing case cover screws diagonally and
3. Bearing Case Cover (a). Top evenly.
Mounting Screw
Bearing Case 23.5 to 27.5 N.m
4. Oil Seal Tightening
Cover Mounting 2.4 to 2.8 kgf.m
Torque
Screw 17.4 to 20.3 ft--lbs
62--10866 2-14
2.2.7.c Crankshaft
NOTE
Before disassembling, check the side clear-
ance of the crankshaft. Check it during reas-
sembly.
1. Alignment Number 5. C
2. Alignment Mark 6. No Mark
3. A 7. Oil Groove
4. B 8. Main bearing Case Screw
2-15 62--10866
2.3 SERVICING
2.3.1 Cylinder Head And Valves
2.3.1.a Cylinder Head Surface Flatness
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 guage.
4 If the measurement exceeds the allowable limit,
resurface or replace the head.
NOTE
Check the valve recessing after after resurfac-
ing the head.
62--10866 2-16
2.3.1.c Valve Recessing
2 Insert the valve into the head, making certain that the
valve is fully seated.
0.05 (protrusion) mm to
Factory 0.15 (recessing) mm
Valve Specification 0.0020 (protrusion) in. to
Recessing 0.0059 (recessing) in.
0.4 (recessing) mm
Allowable Limit
0.0157 (recessing) in.
2-17 62--10866
2.3.1.e Replacing Valve Guide
(A) (When removing)
1 Press out the used valve guide using a valve guide re-
placing tool.
(B) (When installing)
1 Clean a new valve guide and valve guide bore. then
apply oil to them.
2 Press in a new valve guide using a valve guide replac-
ing tool.
3 Ream the I.D. of the valve guide to the specified di-
mension (precisely).
Valve Guide I.D. Factory 8.015 to 8.030 mm
Intake & Exhaust Specification 0.31555 to 0.31614 in.
1. Correct 3 Incorrect
2. Incorrect
62--10866 2-18
2.3.1.g Correcting Valve and Valve Seat
NOTE
Before correcting the valve seat, make certain
that the valve and valve guide are within factory
specifications.
NOTE
When valve lapping is performed, be sure to
check the valve recessing and adjust the valve
clearance after assembling the valve.
2-19 62--10866
2.3.1.i Free Length and Tilt of Valve Spring
1 Measure the free length A of the valve spring with ver-
nier calipers. If the measurement is less than the al-
lowable limit, replace the spring.
2 Put the valve spring on a surface plate, place a
square on the side of the valve spring.
3 Check to see if the entire side is in contact with the
square. Rotate the spring and measure for maximum
tilt B. Check the entire surface of the valve spring for
defects. If any are found, replace it.
Factory 41.7 to 42.2 mm
Specification 1.6417 to 1.6614 in.
Free Length A
41.2 mm
Allowable Limit
1.6220 in.
1.0 mm
Tilt B Allowable Limit
0.039 in.
62--10866 2-20
2.3.1.m Oil Clearance Between Tappet and Tappet
Guide Bore
1 Measure the tappet O.D. with a micrometer.
2 Measure the I.D. of the tappet guide bore with a cylin-
der guage and calculate the clearance.
3 If the measurement exceeds the allowable limit, or
the tappet is damaged, replace the tappet.
Oil Clearance Factory 0.020 to 0.062 mm
Tappet/ Specification 0.00079 to 0.00244 in.
Tappet Guide Allowable 0.07 mm
Bore Limit 0.0028 in.
Factory 23.959 to 23.980 mm
Tappet O.D.
Specification 0.94327 to 0.94410 in.
Factory 24.000 to 24.021 mm
Tappet Guide I.D.
Specification 0.94488 to 0.94571 in.
2-21 62--10866
2.3.2.c Camshaft Side Clearance
1 Set a dial indicator with its tip on the camshaft.
2 Move the camshaft gear front to rear to measure the
side clearance.
3 If the measurement exceeds the allowable limit, re-
place the camshaft stopper.
62--10866 2-22
2.3.2.f Camshaft Alignment
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 jour-
nal.
3 Rotate the camshaft and measure for run-out.
4 If the measurement exceeds the allowable limit, re-
place the camshaft.
26-00123-00
Factory 33.47 mm
Cam Height Specification 1.3177 in.
Intake/Exhaust Allowable 33.22 mm
Limit 1.3079 in.
26-00124-01
Factory 33.27 mm
Cam Height Specification 1.3098 in.
Intake Allowable 33.22 mm
Limit 1.3079 in.
Factory 33.47 mm
Cam Height Specification 1.3177 in.
Exhaust Allowable 33.42 mm
Limit 1.3158 in.
2-23 62--10866
2.3.3 Piston and Connecting Rod
2.3.3.a Piston Pin Bore I.D.
1 Measure the piston pin bore I.D. in both the horizontal
and vertical directions with a cylinder guage.
2 If the measurement exceeds the allowable limit, re-
place the piston.
Factory 25.000 to 25.013 mm
Piston Pin Bore Specification 0.98425 to 0.98476 in.
I.D. Allowable 25.05 mm
Limit 0.9862 in.
NOTE
Be sure to align the bushing so that the oil hole
in the bushing aligns with the oil port in the con-
necting rod.
62--10866 2-24
2.3.3.d Piston Ring Gap
1 Insert the piston ring into the lower part of the cylinder
(the least worn section). Use the piston to square the
ring in the cylinder.
2 Measure the ring gap with a feeler guage.
3 If the gap exceeds the allowable limit, replace the
ring.
26-00123-00
Factory 0.20 to 0.35 mm
Specification 0.0079 to 0.0138 in.
Top Ring
Allowable 1.25 mm
Limit 0.0492 in.
Factory 0.30 to 0.45 mm
Specification 0.0118 to 0.0177 in.
Second Ring
Allowable 1.25 mm
Limit 0.0492 in.
Factory 0.25 to 0.45 mm
Specification 0.0098 to 0.0177 in.
Oil Control Ring
Allowable 1.25 mm
Limit 0.0492 in.
26-00124-01
Factory 0.30 to 0.45 mm
Specification 0.0079 to 0.0138 in.
Top Ring
Allowable 1.25 mm
Limit 0.0492 in.
Factory 0.30 to 0.45 mm
Specification 0.0118 to 0.0177 in.
Second Ring
Allowable 1.25 mm
Limit 0.0492 in.
Factory 0.25 to 0.45 mm
Specification 0.0098 to 0.0177 in.
Oil Control Ring
Allowable 1.25 mm
Limit 0.0492 in.
2-25 62--10866
2.3.3.e Piston Ring to Groove Clearance
1 Clean the rings and the ring grooves, and install each
ring in its groove.
2 Measure the clearance between the ring and its
groove with a feeler guage.
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.
26-00123-00
Factory 0.093 to 0.128 mm
Specification 0.0037 to 0.0050 in.
Second Ring
Allowable 0.2 mm
Limit 0.0079 in.
Factory 0.020 to 0.060 mm
Specification 0.0008 to 0.0024 in.
Oil Control Ring
Allowable 0.15 mm
Limit 0.0059 in.
26-00124-01
Factory 0.093 to 0.123 mm
Specification 0.0037 to 0.0048 in.
Second Ring
Allowable 0.2 mm
Limit 0.0079 in.
Factory 0.020 to 0.052 mm
Specification 0.0008 to 0.0021 in.
Oil Control Ring
Allowable 0.15 mm
Limit 0.0059 in.
NOTE
Since the I.D. of the connecting rod small end
bushing is the basis of this procedure, check the
bushing for wear before proceeding.
1 Install the piston pin into the connecting rod.
2 Install the connecting rod on the connecting rod align-
ment tool.
3 Put a guage over the piston pin and move it against
the face plate.
4 If the guage does not fit squarely against the face
plate, measure the space between the pin of the
guage and the face plate.
5 If the measurement exceeds the allowable limit, re-
place the connecting rod.
Connecting Rod Allowable 0.05 mm
Alignment Limit 0.0020 in.
62--10866 2-26
2.3.4 Crankshaft
2.3.4.a 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.
3 Measure the end play by pulling the crankshaft for-
ward.
4 If the measurement exceeds the allowable limit re-
place the thrust washers.
Factory 0.15 to 0.31 mm
Crankshaft Side Specification 0.0059 to 0.0122 in.
Clearance Allowable 0.5 mm
Limit 0.0197 in.
(Reference)
Oversize dimensions of crankshaft journal.
Oversize 0.2mm / 0.0008 in. 0.4mm / 0.0016 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension A
1.0315 to 1.0335 in. 1.0394 to 1.0413 in.
54.5 to 54.7 mm 54.6 to 54.8 mm
Dimension B
2.1456 to 2.1535 in. 2.1496 to 2.1574 in.
2.8 to 3.2 mm ra- 2.8 to 3.2 mm ra-
dius dius
Dimension C
0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
The crankshaft journal must be fine-finished to higher than
0.8-S.
2-27 62--10866
2.3.4.c Crankpin to Connecting Rod Bearing
Clearance
1 Clean the crankpin and the connecting rod bearing.
2 Put a strip of plastiguage on the center of the crankpin
in each direction as shown in the figure.
3 Install the connecting rod cap and tighten the bolts to
the specification (refer to 2.2.6.b) .
4 Remove the cap again
5 Measure the amount of the flattening with the scale to
get the clearance.
6 If the measurement exceeds the allowable limit re-
place the connecting rod bearing.
7 If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
Factory 0.25 to 0.87 mm
Crankpin/ Specification 0.00098 to 0.00343 in.
C
Connecting
ti Rod
R d
Allowable 0.2 mm
Clearance
Limit 0.0079 in.
(Reference)
Undersize dimensions of crankpin journal.
Oversize 0.2mm / 0.0008 in. 0.4mm / 0.0016 in.
3.3 to 3.7 mm 3.3 to 3.7 mm
Dimension A
0.1299 to 0.1457 in. 0.1299 to 0.1457 in.
1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
radius radius
46.759 to 46.775 46.559 to 46.575
mm mm
Dimension C
1.84091 to 1.84154 1.83303 to 1.83366
in. radius in. radius
The crankshaft journal must be fine-finished to higher than
0.8-S.
62--10866 2-28
2.3.4.d 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 in-
side micrometer and calculate clearance.
3 If the clearance exceeds the allowable limit, replace
crankshaft bearing #1.
4 If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
2-29 62--10866
2.3.4.f Crankshaft Journal to Crankshaft Bearing
#2 Clearance
1 Put a strip of plastiguage on the center of the crank-
shaft journal.
2 Install the bearing case and tighten the bolts to speci-
fication.
3 Remove the bearing case again.
4 Measure the amount of the flattening with the scale to
get the clearance.
5 If the measurement exceeds the allowable limit re-
place crankshaft bearing #2.
6 If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
NOTE
Be sure not to move the crankshaft while the
bearing screws are tightened.
(Reference)
Undersize dimensions of crankshaft journal.
Oversize 0.2mm / 0.008 in. 0.4mm / 0.016 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension A 0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
radius radius
59.721 to 59.740 59.521 to 59.540
mm mm
Dimension C
2.35122 to 2.35197 2.34335 to 2.34409
in. in.
The crankshaft journal must be fine-finished to higher than
0.8-S.
62--10866 2-30
2.3.4.h Replacing Crankshaft Sleeve
1 Remove the crankshaft sleeve (3) using a special--
use puller set.
2 Set the sleeve guide (2) to the crankshaft (5).
3 Set the stopper (1) to the crankshaft (5) as shown in
the figure.
4 Heat the new sleeve to a temperature between 150 to
200C (302 to 392F), and fix the sleeve on the crank-
shaft (5) as shown in the figure.
5 Press fit the sleeve using the auxiliary socket for
pushing (4).
NOTE
Install the sleeve with the largest chamfered
surface facing outward.
2-31 62--10866
2.3.5 CYLINDER
2.3.5.a Cylinder Wear
1 Measure the I.D. of the cylinder at the six positions
(see figure with a cylinder guage to find the maximum
and minimum I.D.’s.
2 Determine the difference (maximum wear) between
the maximum and minimum I.D.’s.
3 If the wear exceeds the allowable limit, bore and hone
to the oversize dimension. (refer to Correcting
Cylinder)
4 Visually check the cylinder wall for scratches. If deep
scratches are found, the cylinder walls should be
bored. (refer to Correcting Cylinder)
26-00123-00
Factory 80.000 to 80.022 mm
Cylinder I.D.
Specification 3.1500 to 3.1505 in.
Allowable 0.15 mm
Maximum Wear
Limit 0.0059 in.
26-00124-01
Factory 87.000 to 87.022 mm
Cylinder I.D.
Specification 3.42519 to 3.42606 in.
Allowable 0.15 mm
Maximum Wear
Limit 0.0059 in.
0. Top a. Right--angled to
a. Middle Piston Pin
b. Bottom (skirt) b. Piston Pin Direction
26-00124-01
Factory 87.250 to 87.272 mm
Cylinder I.D.
Specification 3.43503 to 3.43590 in.
Allowable 0.15 mm
Maximum Wear
Limit 0.0059 in.
Hone to 2.2 to 3.0 mm ←R max.
Finishing
1. Cylinder I.D. 2 Oversize Cylinder I.D. (0.00087 to 0.00118 in. ←R max.)
(before correction)
2 Replace the piston and piston rings with oversize
(+0.25 mm) ones.
62--10866 2-32
SECTION 3
LUBRICATING SYSTEM
(When Reassembling)
After checking the engine oil pressure, tighten the
engine oil pressure switch to the specified torque.
3--1 62--10866
3.2 SERVICING
3.2.1 Rotor Lobe Clearance
1 Measure the clearance between lobes of the inner ro-
tor and 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 rotor assembly.
62--10866 3--2
SECTION 4
COOLING SYSTEM
4-1 62--10866
4.2 SERVICING
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.
4.2.1 Thermostat Assembly
1 Remove the thermostat cover mounting bolts, and re-
move 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.
62--10866 4-2
SECTION 5
FUEL SYSTEM
5--1 62--10866
5.2 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.
5.2.1 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 begins jetting out from the nozzle.
3. If the measurement is not within factory specifica-
tions, replace the nozzle assembly.
62--10866 5--2
SECTION 6
ELECTRICAL SYSTEM
6-1 62--10866
6.2 STARTER TEST
6.2.1 Motor Test
CAUTION
Secure the starter to prevent it from moving
when power is applied to it.
62--10866 6-2
6.3 STARTER DISASSEMBLY AND ASSEMBLY
6.3.1 Disassembling Motor
1. Disconnect the connecting lead (9) from the solenoid
(8).
2. Remove the screws (6), and then separate the end
frame (4), yoke (2) and armature (1).
3. Remove the two screws (5), and then take out the
brush holder (3) from the end frame (4).
When Reassembling
Apply grease to the spline teeth A of the armature (1).
5.9 to 11.8 N.m
Tightening Torque Nut (7) 0.6 to 1.2 kgf.m
1. Armature 6. Screw
4.3 to 8.7 ft-lbs.
2. Yoke 7. Nut
3 Brush Holder 8. Magnetic Switch
4. End Frame 9. Connecting Lead
5. Screw A Spline Teeth
6.3.3 Plunger
1. Remove the end cover (1).
2. Take out the plunger (2).
6-3 62--10866
6.4 STARTER SERVICING
6.4.1 Overrunning Clutch
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 crank-
ing direction.
4. If the pinion slips or does not rotate in both directions,
replace the overrunning clutch assembly.
Factory 15.0 mm
Specification 0.591 in.
Brush Length A
Allowable 11.0 mm
Limit 0.433 in.
6.4.4 Solenoid
1. Check the continuity across the “C” terminal and the
“B” terminal by pushing the plunger, then measuring
resistance with an ohmmeter.
2. If there is no continuity, check the contacts.
62--10866 6-4
6.4.6 Field Coil 6.4.7 Armature
1. Lead 3 Yoke
2 Brush
6-5 62--10866
6.4.8 Commutator and Mica
1. Check the 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 O.D. is less than the allowable limit,
replace the armature.
4. If the difference of the O.D.’s exceeds the allowable
limit, correct the commutator on a lathe to the factory
specifications.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct
it with a saw blade and chamfer the segment edges.
6.4.9 Starter Specification
Factory 35.0 mm
Specification 1.378 in.
Commutator O.D.
OD
Allowable 34.0 mm
Limit 1.339 in.
Factory Less Than 0.02 mm
Specification 0.0008 in.
Difference of O.D.
OD
Allowable 0.05 mm
Limit 0.0020 in.
Factory 0.50 to 0.90 mm
Specification 0.0197 to 0.0354 in.
Mica Under Cut
Allowable 0.20 mm
Limit 0.0079 in.
62--10866 6-6
INDEX
B I
bearing case, 2-14, 2-15
Identification, 1-1
idle gear, 2-8
C injection nozzle, 5-2
camshaft, 2-9, 2-22, 2-23 injection timing, 5-1
camshaft -- fuel, 2-9
compression pressure, 2-1
connecting rod, 2-13, 2-26
L
coolant, 2-2
coolant level, 1-13 lubricating system, 3-1
cooling system, 4-1
crankshaft, 2-27
crankshaft oil slinger, 2-8 O
crankshaft sleeve, 2-30
cylinder, 2-32 oil level, 1-13
cylinder head, 2-3, 2-5, 2-16 oil pan, 2-11
oil pressure, 3-1
D oil pump, 2-10, 3-2
dye/penetrant, 2-16
E P
electrical system, 6-1 piston, 2-12, 2-24, 2-25
engine oil, 1-14, 2-2 piston ring, 2-13
push rod, 2-20
F
fan belt, 4-1
fan drive pulley, 2-8 R
flywheel, 2-14
relief valve, 3-1
fuel injection, 1-16, 2-3, 2-7
rocker arm, 2-20
fuel system, 5-1
fuel system -- bleeding , 1-13
G S
gear case, 2-8 specifications, 1-2
glow plug, 6-1 starter motor, 6-2
Index-1 62--10866
INDEX
T V
V--belt, 1-14
tappets, 2-5, 2-21 valve clearance, 1-15
thermostat, 4-1 valve guide, 2-18
valve seat, 2-18
timing gear, 2-21
valve spring, 2-20
Torque Specification, 1-4 valves, 2-5, 2-17, 2-19
62--10866 Index-2
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