Carrier CT2-29-TV Instruction manual

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

WORKSHOP MANUAL
DIESEL ENGINE
CT2-29-TV (Z482-E2B)
Truck / ComfortPro
CT3-44-TV (D722-E2B)
Truck
Beginning With Serial Number 5A0001

i62--11161
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
TABLE OF CONTENTS i........................................................................
SAFETY PRECAUTIONS i...................................................................
SPECIFIC WARNING AND CAUTION STATEMENTS i...........................................
General 1--1......................................................................................
1.1 ENGINE IDENTIFICATION 1--1............................................................
1.2 ENGINE SPECIFICATIONS 1--2............................................................
1.2.1 E2B Engine 1--3......................................................................
1.2.2 Cylinder Number 1--3..................................................................
1.3 GENERAL PRECAUTIONS 1--3............................................................
1.4 TORQUE SPECIFICATION 1--4............................................................
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts 1--4..........................
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts 1--4..........................
1.5 TROUBLESHOOTING 1--5................................................................
1.6 SERVICING SPECIFICATIONS 1--8........................................................
1.6.1 Engine Body 1--8......................................................................
1.6.2 Lubricating System 1--11................................................................
1.6.3 Cooling System 1--11...................................................................
1.6.4 Fuel System 1--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 Bleeding Fuel System 1--12..............................................................
1.7.6 Valve Clearance 1--13..................................................................
1.8 SPECIAL TOOLS 1--14.....................................................................
1.8.1 Diesel Engine Compression Tester (Glow Plug) 1--14.......................................
1.8.2 Adapter, Kubota 10 mm 1--14............................................................
1.8.3 Tester Injector Nozzle 1--14..............................................................
1.8.4 Replacement Bowl, Tester Injector Nozzle 1--14............................................
1.8.5 Adapter, Injector Line 1--14..............................................................
1.8.6 Oil Pressure Tester 1--15................................................................
1.8.7 Auxiliary Socket For Fixing Crankshaft Sleeve 1--15........................................
1.8.8 Guage, Belt Tension 1--15...............................................................
1.8.9 Tester, Belt Tension 1--15................................................................
1.8.10 Rubber Band 1--15.....................................................................
1.8.11 Valve Guide Replacing Tool 1--16.........................................................
1.8.12 Bushing Replacing Tools 1--16
...........................................................
1.8.13 Flywheel Stopper 1--16..................................................................
1.8.14 Crankshaft Bearing 1 Replacing Tool 1--17.................................................

ii
62-11161
PARAGRAPH NUMBER Page
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 2--2..................................................................
2.2.2 Draining and Refilling Engine Oil 2--2....................................................
2.2.3 External Components 2--2..............................................................
2.2.4 Cylinder Head And Valves 2--3..........................................................
2.2.5 Oil Pan and Oil Pick--up Screen 2--6......................................................
2.2.6 Timing Gear, Camshaft and Fuel Camshaft 2--7...........................................
2.2.7 Piston and Connecting Rod 2--13.........................................................
2.2.8 Crankshaft 2--16.......................................................................
2.3 SERVICING 2--19.........................................................................
2.3.1 Cylinder Head And Valves 2--19..........................................................
2.3.2 Timing Gears, Camshaft 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..........................................................
3.1.2 Changing Engine Oil 3--1...............................................................
3.1.3 Changing Oil Filter 3--2................................................................
3.1.4 Engine Oil Pressure 3--2...............................................................
3.1.5 Relief Valve 3--3......................................................................
3.2 OIL PUMP SERVICE 3--3..................................................................
3.2.1 Rotor Lobe Clearance 3--3.............................................................
3.2.2 Rotor to Cover Clearance 3--3..........................................................
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 Checking Coolant Level 4--1............................................................
4.1.4 Draining Coolant 4--1..................................................................
4.1.5 Radiator Cap 4--2.....................................................................
4.1.6 Radiator 4--2.........................................................................
4.1.7 Thermostat Opening Temperature 4--2...................................................
4.2 SERVICING 4--3.........................................................................
4.2.1 Thermostat Assembly 4--3..............................................................
4.2.2 Water Pump Assembly 4--3.............................................................

iii 62--11161
PARAGRAPH NUMBER Page
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 Pump Element Fuel Seal 5--2...........................................................
5.1.4 Delivery Valve Fuel Seal 5--2...........................................................
5.2 INJECTION NOZZLE 5--3.................................................................
5.2.1 Nozzle Spraying Condition 5--3..........................................................
5.2.2 Nozzle Injection Pressure 5--3..........................................................
5.2.3 Valve 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........................................................................
6.2.2 Magnetic Switch Test 6--2..............................................................
6.2.3 Assembly 6--3.........................................................................
6.3 STARTER (CT3--44--TV) 6--4...............................................................
6.3.1 Motor Test 6--4........................................................................
6.3.2 Magnetic Switch Test 6--4..............................................................
6.4 STARTER SERVICING 6--6................................................................
6.4.1 Overrunning Clutch 6--6................................................................
6.4.2 Armature Bearing 6--6.................................................................
6.4.3 Brush Wear 6--6......................................................................
6.4.4 Solenoid 6--6.........................................................................
6.4.5 Brush Holder 6--6.....................................................................
6.4.6 Armature 6--7.........................................................................
6.4.7 Field Coil 6--8.........................................................................

i62-11161
SAFETY
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 pretrip inspections, daily inspections, and problem
troubleshooting, you may be exposed to moving parts. Please stay clear of all moving parts when the unit is in
operation and when the unit main power switch is in the START/RUN position.
Engine Coolant
The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the
engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not
remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure
without spray.
Battery
This unit is equipped with a leadacid type battery. The battery normally vents small amounts of flammable hydrogen
gas. Donotsmokewhencheckingthebattery.Abatteryexplosioncancauseserious physicalharm and/orblindness.
SPECIFIC WARNING AND CAUTION STATEMENTS
To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is
given with the appropriate consequences:
DANGER
DANGER -- warnsagainst an immediate hazard which WILL result in severe personal injury or death.
WARNING
WARNING -- warns against hazards or unsafe conditions which COULD result in severe personal in-
jury or death.
CAUTION
CAUTION -- warns against potential hazard or unsafe practice which could result in minor personal
injury, or product or property damage.
NOTE
NOTE -- gives helpful information that may help and avoid equipment and property damage.
The statements listed on the next page are specifically applicable to this unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the equip-
ment covered herein.

ii
62-11161
SPECIFIC WARNING AND CAUTION STATEMENTS (Continued)
WARNING
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may discharge from the radiator, scalding anyone nearby.
WARNING
Check the injection nozzle only after confirming that nobody is near the spray. If the spray from the
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.
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
Stop the engine when preparing to change the engine oil filter.
CAUTION
Secure the starter to prevent it from moving when power is applied to it.

1--1 62--11161
SECTION 1
General
1.1 ENGINE IDENTIFICATION
S/N
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.
Engine Serial Number (S/N)
The engineserialnumber is an identified number forthe
engine. It is marked after the engine model number.
It indicates basic model, month, year and sequence of
manufacture as follows:
S
er
i
a
l
N
um
b
er
7 K A
Last 3 Digits in Numerals (1 to 999 Units in Sequence)
6th Digit Alpabetical Letter (Month of Manufacture -- 1st Letter 1--9999 Units, 2nd Letter 10,000--19,998 Units)
Alphabetical letter A,B C,DE,FG,HJ,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 XY
Year 98 99 00 01 02 03 04 05 06 07 08 09
Jan Feb Mar May Jun Jul Aug Sep OctApr Nov Dec
1234 56789
Z482--
Basic model number
176
7th Digit Sequential Numeral or Letter (Units Manufactured)
Alphabetical Numeral or Letter
Unit Number Sequence A
to 19,998 19,999--20997 20,998--21,996
BC
21,997--22,995
0to9
Table 1-1. Model Chart
KUBOTA
MODEL NO. CARRIER
MODEL NO. NEW ENGINE PART NO. PRIMARY USE REPLACES
Z482--E2B CT2--29--TV 26--60001--03*SOLARA Units 26--60001--01
Z482--E2B CT2--29--TV 26--60001--04*SUPRA Units 26--60001--02
Z482 -- E2B-- AT C-- 1 CT2--29--TV 96-- 101--05K ProHeat / ComfortPro PC5000
Units NEW
Z482--E2B--TFX--1 CT2--29--TV 96-- 101--20K ComfortPro PC6000 Units NEW
D722--E2B CT3--44--TV 26--60000--05*GENESIS Units 26--60000--00
*Beginning with Serial Number 5A0001

1--2
62--11161
1.2 ENGINE SPECIFICATIONS
Table 1-2. Specification Chart
MODEL NUMBER (Carrier / Kubota) CT2--29--TV / Z482--E2B CT3--44--TV / D722--E2B
TYPE Vertical, Water--cooled, 4 cycle IDI diesel engine
NUMBER OF CYLINDERS 2 3
BOREXSTROKE mmXmm(in.Xin.) 67 X 68 (2.64 X 2.68)
TOTAL DISPLACEMENT cm3(cu.in.) 479 (29.23) 719 (43.88)
BRAKE
HORSEPOWER SAE Intermittent H.P. kW (HP) / RPM 9.3 (12.5) / 3600 14.0 (18.0) / 3600
MAXIMUM BARE SPEED RPM 3800
IDLING SPEED RPM 900 To 1000
COMBUSTION CHAMBER Spherical Type (E--TVCS)
FUEL INJECTION PUMP Bosch MD Type Mini Pump
GOVERNOR Centrifugal Ball Mechanical Governor
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
LUBRICATING SYSTEM Forced Lubrication by Pump
COOLING SYSTEM Pressurized Radiator, Forced Circulation With Water Pump
STARTING SYSTEM Cell Starter (With Glow Plug)
STARTING MOTOR 12V, 0.8 kW
RECOMMENDED BATTERY CAPACITY
(5 Hour Capacity) 12V, 28AH, equivalent 12V, 36AH, equivalent
CHARGING GENERATOR 12V, 150 W 12V, 150 W
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 2.5 L (2.64 U.S. Quarts) 3.8 L (4.02 U.S. Quarts)
3.3 L (3.5 U.S. Quarts) (TFX--1 Only)
Weight (DRY) kg (lbs.) 53.1 (117.1) 63.1 (139.1)
*See paragraph 1.7.2.

1--3 62--11161
1.2.1 E2B ENGINE
Carrier/Kubota supply diesel engines conforming to
federalemissionregulations.Theemissioncontrolsthat
have been put into effect have been stepped up to the
second stage. Carrier/Kubota has executed the
improvement in the engines to conform to this
regulation.
In order to discriminate between engines conforming to
Tier 1 / Phase 1 requirements and those conforming to
Tier 2/ Phase 2 requirements, we have adapted E2B as
a new model name for theengines conforming to Tier2/
Phase 2 regulations.
In the after--sale services for Tier 2 / Phase 2 engines,
only use the dedicated parts for E2B models and carry
out the maintenance services accordingly.
1.2.2 CYLINDER NUMBER
The cylinder numbers of diesel engines are designated
as shown above. The sequence of cylinder numbers is
given as No.1, No. 2, and No. 3 starting from the gear
case end of the engine.
1.3 GENERAL PRECAUTIONS
During disassembly, carefully arrange removed parts in
a clean area to prevent confusion latter. Screws, bolts
and nuts should be replaced in their original position to
prevent reassembly errors.
When special toolsare required, use Carrier Transicold
genuine special tools. Special tools which are not
frequently used should be made according to the
drawings provided.
Before disassembling or servicing electrical wires,
make sure to always disconnect the grounding cable
from the battery first.
Remove oil and dirt from parts before taking any
measurements.
Use only Carrier Transicold genuine parts for parts
replacements to maintain engine performance and to
ensure safety.
Gaskets and o--rings must be replaced during
reassembly. Apply grease to new o--rings or oil seals
before assembling.
1
2
3
23
1. Grease
2. Force
3. Place the Sharp Edge
against the Direction of Force
A External Snap Ring
B Internal Snap Ring
When reassembling external or internal snap rings,
position them so that the sharp edge faces against the
direction from which force is applied.
A newly serviced or reassembled engine should be
run--in with no load for 15 minutes. Serious damage to
the engine may result otherwise.