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R
Diesel Engine
WORKSHOP MANUAL
for
V2203-DI (26--00128)
Tier 4i
62--11362 Rev --
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WORKSHOP MANUAL DIESEL ENGINE V2203-DI (26-00118) Tier 4i
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TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS ................................................................... iv SPECIFIC WARNING AND CAUTION STATEMENTS .......................................... iv General ...................................................................................... 1--1 1.1 ENGINE IDENTIFICATION ............................................................ 1--1 Engine Serial Number .......................................................................
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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 DISASSEMBLY AND REASSEMBLY .................................................... 2--2 2.2.1 Draining
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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 Pressure Test ............................................................... 5--2 5.1.
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SAFETY SAFETY PRECAUTIONS cap must be removed, do so very slowly in order to release the pressure without spray. Your Carrier Transicold unit has been designed with the safety of the operator in mind. During normal operation, Battery all moving parts are fully enclosed to help prevent injury. This unit is equipped with a lead-acid type battery. The During all pre-trip inspections, daily inspections, and battery normally vents small amounts of flammable problem troubleshooting, you may be exposed
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The statements listed below 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 equipment covered herein. WARNING Beware of moving V--belt and belt driven components 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
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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 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: Serial Number V2203-- Y A 4321 Lower 4 digits in numerals
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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 BOREXSTROKE mmXmm(in.Xin.) 83 X 102.4 (3.27 X 4.03) 3 TOTAL DISPLACEMENT cm (cu.in.) 2216 (135.2) BRAKE HORSEPOWER 23.65 (31.7) / 23.87 (32.0) / 26.85 (36.0) / 23.87 (32.0) / 23.65 (31.7) / SAE Intermittent HP kW (HP) / RPM 1700 1800 2200 1800 1700 MAXIMUM SPEED RPM Below 2470 IDLING S
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1.3 CYLINDER NUMBER 1.4 GENERAL PRECAUTIONS 1 The cylinder numbers of V2203--DI series engine are 2 designated as shown above. The sequence of cylinder numbers is given as No.1, No. 2, No. 3, and No. 4 starting from the gear case end of the engine. 2 3 3 1. Grease A External Snap Ring 2. Force B Internal Snap Ring 3. Place the Sharp Edge against the Direction of Force During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be
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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
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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 fo 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 no
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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.a Oil Consumption direction Oilringwornor 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 Injec
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1.7 SERVICING SPECIFICATIONS 1.7.1 Engine Body Item Factory Specification Allowable Limit Cylinder Head Surface Flatness -- 0.05 mm/500mm 0.0020 in./ 19.69 in. Compression Pressure 2.95 to 3.23 MPa/ 2.35 MPa/ 290 rpm 290 rpm 2 2 30 to 33 kgf/cm 24kgf/cm 290 rpm 290 rpm 427 to 469 psi/ 341 psi/ 290 rpm 290 rpm Difference Among Cylinders -- 10% or less Top Clearance 0.60 to 0.70 mm -- 0.0236 to 0.0276 in. Valve Clearance (When Cold) 0.18 to 0.22 mm -- 0.0071 to 0.0086 in. Valve Seat Width (Intake)
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1.7.1 Engine Body (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 41.7 to 42.2 mm 41.2 mm 1.65 to 1.66 in. 1.62 in. Setting Load/ 118N/ 35.0mm 100.0N / 35.0 mm Setting Length 12.0 kgf / 35.0 mm 10.2kgf / 35.0 mm 26.5 lbs. / 1.38 in. 22.5lbs /1.38 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 0.0017 in. 0.039 in. Rocker Shaft O.D. 13.973 to 13.984 mm -- 0.55012 to 0.55055 in. Rocker Arm I.D. 14.000 to 14.01
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1.7.1 Engine Body (Continued) Item Factory Specification Allowable Limit Camshaft Side Clearance 0.07 to 0.22 mm 0.3 mm 0.0028 to 0.0086 in. 0.012 In. Camshaft Alignment -- 0.01 mm 0.0004 in. Cam (Lobe) Height (Intake) 33.27 mm 33.22 mm 1.310 in. 1.308 in. Height (Exhaust) 33.47 mm 33.42 1.318 in. 1.316 in. Camshaft Journal to Cylinder Block Bore Clearance 0.050 to 0.091 mm 0.15 mm 0.0020 to 0.0035 in. 0.00059 in. Camshaft Journal O.D. 39.934 to 39.950 mm -- 1.5722 to 1.5728 in. Cylinder Block B
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1.7.1 Engine Body (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing2 Oil Clearance 0.040 to 0.104 mm 0.2 mm 0.00158 to 0.00409 in. 0.0079 in. Crankshaft Journal O.D. 59.921 to 59.940 mm -- 2.3591 to 2.3598 in. Crankshaft Bearing2 I.D. 59.980 to 60.025 mm -- 2.3615 to 2.3631 in. Crankpin to Crankpin Bearing Oil Clearance 0.025 to 0.087 mm 0.2 mm 0.00099 to 0.0034 in. 0.0079 in. Crankpin O.D. 46.959 to 46.975 mm -- 1.8488 to 1.8494 in. Crankpin Bearing
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1.7.2 Lubricating System Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More Than 98 kPa 50 kPa 2 2 1.0 kgf/cm 0.5 kgf/cm 14 psi 7psi At Rated Speed 300 to 440 kPa 250 kPa 2 2 3.0 to 4.5kgf/cm 2.5 kgf/cm 43 to 64 psi 36 psi Engine Oil Pressure Switch Working 50 kPa -- 2 Pressure 0.5kgf/cm 7psi Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm 0.2 mm 0.0012 to 0.0055 in. 0.008 in. Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm 0.25 mm 0.0044 to 0.0074 in. 0.00
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1.7.5 Electrical System Item Factory Specification Allowable Limit Starter Commutator O.D. 32.0 mm 31.4 mm 1.26 in. 1.24 in. Mica Undercut 0.50 mm 0.20 mm 0.020 in. 0.0079 in. Brush Length 0.18 mm 11.0 mm 0.709 in. 0.433 in. Brush Holder and Holder Support Resistance Infinity -- Intake Air Heater Resistance (cold) Approx. 0.3 ohm -- 62--11632 1--12
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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. Venting air can be accomplished by jiggling 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 thesametime. Never mix different types or brands of coolants. 1. Level the engine.
