Carrier V2203-DI (26--00128)- Manuals

Page 2 - Tier 4i

WORKSHOP MANUAL DIESEL ENGINE V2203-DI (26-00118) Tier 4i

Page 3 - TABLE OF CONTENTS; PARAGRAPH NUMBER

i 62-- 11362 TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFIC WARNING AND CAUTION STATEMENTS iv . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 6 - iv; SAFETY; SAFETY PRECAUTIONS; Engine Coolant; SPECIFIC WARNING AND CAUTION; DANGER; NOTE

iv 62-11362 SAFETY SAFETY PRECAUTIONS Your Carrier Transicold unit has been designed with thesafety of the operator in mind. During normal operation,all moving parts are fully enclosed to help prevent injury.During all pre-trip inspections, daily inspections, andproblem troubleshooting, you may be e...

Page 8 - ENGINE IDENTIFICATION; It indicates month and year of manufacture as follows:; Serial Number

1-- 1 62-- 11362 SECTION 1 General 1.1 ENGINE IDENTIFICATION S/N When contacting Carrier Transicold, always specifyyour engine model number and serial number. The engine model and its serial number need to beidentified before the engine can be serviced or partsreplaced. Engine Serial Number The engi...

Page 9 - ENGINE SPECIFICATIONS

1-- 2 62-- 11632 1.2 ENGINE SPECIFICATIONS Table 1-2. Specification Chart MODEL NUMBER 26-- 00128-- 00 26-- 00128-- 01 26-- 00128-- 02 26-- 00128-- 04 26-- 00128-- 05 TYPE Vertical, Water-- cooled, 4 cycle diesel engine NUMBER OF CYLINDERS 4 BORE X STROKE mm X mm (in. X in.) 83 X 102.4 (3.27 X 4.03)...

Page 20 - CHECK AND MAINTENANCE; CAUTION

1-- 13 62-- 11362 1.8 CHECK AND MAINTENANCE 1.8.1 Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to seethat the oil level lies between the two notches. 3. If the level is too low, add new o...

Page 22 - If the clearance is not within the factory specifica-

1-- 15 62-- 11362 1.8.7 Valve Clearance 1.8.8 Fuel Injection Refer to Section 5.2 NOTE Valve clearance must be checked and adjustedwhen the engine is cold. 1. Remove the valve cover. 2. Align the “1TC” mark line (3) on the flywheel and pro- jection (2) on the housing so that the Number 1 pistoncomes...

Page 23 - SPECIAL TOOLS; Injector nozzle tester kit used for

1-- 16 62-- 11632 1.9 SPECIAL TOOLS Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number62-- 03213. 1.9.1 Diesel Engine Compression Tester (Glow Plug) Part No. 07-- 00179-- 01 (Assembly) Application: Use to measure diesel enginecompression and diagnos...

Page 24 - Used to test belt tension.

1-- 17 62-- 11362 1.9 SPECIAL TOOLS (Continued) 1.9.6 Oil Pressure Tester Code No. 07916-- 32032 Application: Use to measure lubricating oilpressure. 1. Guage 2. Adapter 2 3. Cable 4. Adapter 3 5. Threaded Joint 6. Adapter 4 7. Adaptor 1 8. Adaptor 3 1.9.7 Auxiliary Socket For Fixing Crankshaft Slee...

Page 26 - 6 Crankshaft Bearing 1 Replacing Tool; Application: Use to press out and press fit the crankshaft

1-- 19 62-- 11362 1.9 SPECIAL TOOLS (Continued) 1.9.16 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 1 0 mm (0.39 in.) E 20 mm (0.79 in.) F 20 mm dia. (0.79...

Page 27 - CHECKING AND ADJUSTING

2-- 1 62-- 11362 SECTION 2 ENGINE BODY 2.1 CHECKING AND ADJUSTING 2.1.1 Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine and disconnect the 2P connector from the stop solenoid to prevent fuel delivery to theengine. 3. Remove the the air cleaner, the muffler and all th...

Page 28 - DISASSEMBLE AND REASSEMBLY; Open the coolant drain cock or remove the coolant; Air Cleaner, Muffler and Others

2-- 2 62-- 11362 2.2 DISASSEMBLE AND REASSEMBLY 2.2.1 Draining Coolant And Engine Oil CAUTION Never remove the radiator cap until coolanttemperature is below its boiling point.Loosen the cap slightly to the first stop torelieve any excess pressure before remov-ing the cap completely. 1. Open the coo...

Page 29 - Blow out any debris that may be in the pipes.

2-- 3 62-- 11362 2.2.3 Cylinder Head And Valves 2.2.3.a Valve Cover 1. Remove the breather hose (2). 2. Remove the valve cover bolts (1). 3. Remove the valve cover (3). When Reassembling Check to see that the valve cover gasket (4) is in goodcondition and in place. Tightening Torque Valve Cover Bolt...

Page 30 - Replace the copper gasket with a new one.; When Reassembling

2-- 4 62-- 11362 2.2.3 Cylinder Head And Valves (Continued) 3 4 1. Rocker Arm Bracket Mounting Bolt 2. Rocker Arm Assembly 3. Push Rod 4. Tappet 2.2.3.c Nozzle Holder Assembly 1. Remove the overflow pipe assembly. 2. Remove the nozzle holder assemblies (1). When Reassembling Replace the copper gaske...

Page 34 - two bolts and two nuts to the gear case.; Finally, install the injection pump cover to the gear

2-- 8 62-- 11362 2.2.4 Injection Pump and Gear Case (Continued) 2.2.4.b Governor Springs and Speed Control Plate (Continued) When Reassembling NOTE A length of string passed thru the governorspring can be used to retrieve the spring if it un-hooks from both the specific tool and the speedcontrol pla...

Page 35 - Lock the flywheel using the flywheel stopper; Apply grease to the splines of the coupling.

2-- 9 62-- 11362 2.2.4 Injection Pump and Gear Case (Continued) 1. Nut 2. Fan Drive Pulley 3. 46 mm Deep Socket wrench 4. Gear Puller 1. Gear Case 2. Gear Case Gasket 3. O-- ring 4. O-- ring 5. Oil seal 2.2.4.c Fan Drive Pulley 1. Lock the flywheel using the flywheel stopper 2. Remove the fan drive ...

Page 36 - Check to see each gear is aligned with its aligning mark.

2-- 10 62-- 11362 2.2.4 Injection Pump and Gear Case (Continued) 1. Crankshaft Collar 2. O-- ring 3. Crankshaft Oil Slinger 1. Injection Pump Gear 2. Idle Gear 3. Cam Gear 4. Crank Gear 5. Oil Pump Drive Gear 1. Camshaft Set Screw 2. Camshaft 1. Oil Pipe 2. Fuel Feed Pump 3. O-- ring 4. Fuel Feed Pu...

Page 37 - Remove the three fork lever holder mounting screws; Remove the four oil pump mounting bolts. Detach the

2-- 11 62-- 11362 2.2.4 Injection Pump and Gear Case (Continued) 1. Fuel Camshaft Stopper 2. Fork Lever Holder Mounting Screws 3. Fork Lever 1 4. Fork Lever 2 5. Injection Pump Gear 6. Fuel Camshaft 7. Fork Lever Holder 1. Oil Pump2. Oil Pump Drive Gear 3 Gear Puller 2.2.4.i Fuel Camshaft And Fork L...

Page 38 - pan with a wooden hammer.

2-- 12 62-- 11362 2.2.5 Oil Pan and Oil Strainer (7) 1. Oil Pan Mounting Screw 2. Oil Pan 3. Oil Pan Cover Gasket 4. Oil Pan Cover 5. O-- ring 6. Oil Strainer 7. Oil Pan Gasket 2.2.5.a Oil Pan and Oil Strainer 1. Remove the oil pan cover (4). 2. Remove the oil pan mounting bolts (1). 3. Remove the o...

Page 39 - Push the piston out by lightly tapping the connecting; ) from the piston pin’s direction as

2-- 13 62-- 11362 2.2.6 Piston and Connecting Rod 6 2.2.6.a Pistons1. Completely remove the carbon ridge (1) at the top of the cylinder walls. 2. Remove 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 r...

Page 41 - Screw two of the removed bolts into the bolt hole of

2-- 15 62-- 11362 2.2.7 Crankshaft 1. Flywheel 2. Flywheel Bolt 3. Flywheel Guide Bolts 1. Bearing Case Cover Mounting Bolt 2. Bearing Case Cover Mounting bolt 3. Bearing Case Cover 4. Oil Seal 5. Bearing Case Gasket 6. Bearing Case Cover Gasket (a). Top 2.2.7.a Flywheel1. Prevent the flywheel (1) f...

Page 43 - Remove the remaining main bearing cases as above.; Clean the oil passages in the main bearing case.

2-- 17 62-- 11362 2.2.7 Crankshaft (Continued) 7 8 8 2.2.7.d Main Bearing Case Assembly 1. Remove the two main bearing case bolts (7), and re- move the main bearing case assembly being carefulwith the thrust bearing and crankshaft bearing. 2. Remove the remaining main bearing cases as above. When Re...

Page 44 - SERVICING

2-- 18 62-- 11362 2.3 SERVICING 2.3.1 Cylinder Head And Valves 1. Red Dye 2. Detergent 3. White Developer 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 clear...

Page 45 - Guide

2-- 19 62-- 11362 2.3.1 Cylinder Head And Valves (Continued) 1. Cylinder Head Surface (A) Recess (B) Protrusion 2.3.1.c Valve Recessing 1. Clean the cylinder head surface (1), valve face and valve seat. 2. Insert the valve into the head, making certain that the valve is fully seated. 3. Measure the ...

Page 48 - Rocker Arm Shaft

2-- 22 62-- 11362 2.3.1 Cylinder Head And Valves (Continued) 2.3.1.i Free Length and Tilt of Valve Spring1. 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, pla...

Page 49 - Guide Bore

2-- 23 62-- 11362 2.3.1 Cylinder Head And Valves (Continued) 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 gauge and calculate the clearance. 3. If the measurement exceeds the all...

Page 52 - shing

2-- 26 62-- 11362 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 gauge. 2. If the measurement exceeds the allowable limit, re- place the piston. Piston Pin Bore I.D. Factory Specification...

Page 55 - ance

2-- 29 62-- 11362 2.3.4 Crankshaft (Continued) 2.3.4.c Crankpin to Connecting Rod Bearing Clear- ance 1. Clean the crankpin and the connecting rod bearing.2. Put a strip of plastigage on the center of the crankpin in each direction as shown in the figure. 3. Install the connecting rod cap and tighte...

Page 56 - side micrometer and calculate clearance.; (Reference) Undersize dimensions of crankshaft; journal bore, and apply engine oil to both.

2-- 30 62-- 11362 2.3.4 Crankshaft (Continued) 1. Seam 2. Crankshaft Bearing #1 3. Cylinder Block A Dimension 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 i...

Page 57 - Undersize dimensions of crankshaft journal.

2-- 31 62-- 11362 2.3.4 Crankshaft (Continued) 2.3.4.f Crankshaft Journal to Crankshaft Bearing #2 Clearance 1. Put a strip of plastigage on the center of the crank- shaft journal. 2. Install the bearing case and tighten the bolts to spe- cification. 3. Remove the bearing case again.4. Measure the a...

Page 58 - Heat the new sleeve to a temperature between 150 to

2-- 32 62-- 11362 2.3.4 Crankshaft (Continued) 1. Stopper 2. Sleeve Guide 3. Crankshaft Sleeve 4. Auxiliary Socket For Pushing 5. Crankshaft 2.3.4.g 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....

Page 60 - sure at idling and at rated speeds.

3-- 1 62-- 11362 SECTION 3 LUBRICATING SYSTEM 3.1 CHECKING AND ADJUSTING 3.1.1 Engine Oil Pressure1. Remove the engine oil pressure switch, and install an oil pressure gauge. 2. Start the engine. After warming up, read the oil pres- sure at idling and at rated speeds. 3. If the oil pressure is less ...

Page 62 - WARNING

4-- 1 62-- 11362 SECTION 4 COOLING SYSTEM 4.1 CHECKING AND ADJUSTING WARNING Beware of moving V -- belt and belt drivencomponents 4.1.1 Notched V -- Belt Service NOTE A frayed, cracked or worn V-- belt must be re-placed. After installing a new belt, it is advisableto check the adjustment after runni...

Page 64 - Remove the water pump from the gear case assem-

4-- 3 62-- 11362 4.2 SERVICING 4.2.1 Thermostat Assembly 1. Thermostat Cover Bolt 2. Thermostat Cover 3. Thermostat Cover Gasket 4. Thermostat Assembly 5. Thermostat Housing 1. Remove the thermostat cover mounting bolts (1), and remove the thermostat cover (2). 2. Remove the thermostat assembly (4)....

Page 67 - INJECTION NOZZLE

62-- 11362 5-- 3 5.2 INJECTION NOZZLE WARNING Check the injection nozzle only after confirming that nobody is near the spray. If the spray from thenozzle contacts the human body, cells may be destroyed and blood poisoning may result. (a) GOOD (b) BAD 5.2.1 Nozzle Injection Pressure 1. Set the inject...

Page 68 - STARTER TEST

6-- 1 62-- 11362 SECTION 6 ELECTRICAL SYSTEM 6.1 STARTER TEST 1. C Terminal 2. Positive Terminal 3. Negative Terminal 1. S Terminal 2. Positive Terminal 3. Negative Terminal 6.1.1 Motor Test WARNING Secure the starter to prevent it from movingwhen power is applied to it. 1. Disconnect the cable from...

Page 69 - FUEL SPEED SOLENOID

6-- 2 62-- 11362 6.2 FUEL SPEED SOLENOID 6.2.1 Solenoid Test WARNING The solenoid can become very warm to thetouch when energized for any length intime. 1. Disconnect the plug from the solenoid connector (2). 2. Remove the solenoid (1) from the engine. 3. Supply power (12VDC) to the solenoid thru te...

Page 70 - INTAKE AIR HEATER; Measure the resistance between the heater positive

6-- 3 62-- 11362 6.3 INTAKE AIR HEATER 6.3.1 Intake Air Heater Test 1. Disconnect the lead from the heater terminal (1). 2. Measure the resistance between the heater positive terminal (1) and the heater body (2). 3. If the resistance is infinity or significantly different than the specification, rep...

Page 71 - INDEX

INDEX Index-- 1 62-- 11362 B Battery, iv bearing case, 2-- 15, 2-- 17 C camshaft, 2-- 10, 2-- 24, 2-- 25 compression pressure, 2-- 1 connecting rod, 2-- 14, 2-- 27 coolant, iv, 2-- 2 coolant level, 1-- 13, 4-- 1 cooling system, 4-- 1 crankshaft, 2-- 28 crankshaft oil slinger, 2-- 10 cylinder, 2-- 33...

Page 72 - Safety Precautions, iv

INDEX Index-- 2 62-- 11362 S Safety Precautions, iv specifications, 1-- 2 speed control plate, 2-- 7, 2-- 8 starter motor, 6-- 1 T tappets, 2-- 5, 2-- 23 thermostat, 4-- 2 timing gear, 2-- 23 Torque Specification, 1-- 4 V V-- belt, 1-- 14 valve clearance, 1-- 15 valve guide, 2-- 20 valve seat, 2-- 2...