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Diesel Engine

62--11362 Rev A

WORKSHOP MANUAL

for

V2203-DI (26--00128)

Tier 4i

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Содержание 26-00128

Страница 1: ...Diesel Engine 62 11362 Rev A WORKSHOP MANUAL for V2203 DI 26 00128 Tier 4i R Downloaded from ManualsNet com search engine...

Страница 2: ...WORKSHOP MANUAL DIESEL ENGINE V2203 DI 26 00118 Tier 4i Downloaded from ManualsNet com search engine...

Страница 3: ...g Coolant Level 1 13 1 8 3 Checking Fuel Hose 1 13 1 8 4 Bleeding Fuel System 1 14 1 8 5 Checking V Belt 1 14 1 8 6 Changing Engine Oil 1 14 1 8 7 Valve Clearance 1 15 1 8 8 Fuel Injection 1 15 1 9 SP...

Страница 4: ...ing Gears Camshaft and Fuel Camshaft 2 23 2 3 3 Piston and Connecting Rod 2 26 2 3 4 Crankshaft 2 28 2 3 5 Cylinder 2 33 LUBRICATING SYSTEM 3 1 3 1 CHECKING AND ADJUSTING 3 1 3 1 1 Engine Oil Pressure...

Страница 5: ...el Seal 5 2 5 2 INJECTION NOZZLE 5 3 5 2 1 Nozzle Injection Pressure 5 3 5 2 2 Nozzle Spraying Condition 5 3 5 2 3 Valve Seat Tightness 5 3 ELECTRICAL SYSTEM 6 1 6 1 STARTER TEST 6 1 6 1 1 Motor Test...

Страница 6: ...y in order to release the pressure without spray Battery This unit is equipped with a lead acid type battery The battery normally vents small amounts of flammable hydrogen gas Do not smoke when checki...

Страница 7: ...the spray If the spray from the nozzle contacts the human body cells may be destroyed and blood poisoning may result WARNING Secure the starter to prevent it from moving when power is applied to it C...

Страница 8: ...or Numerals Year of Manufacture Alphabetical letter or numerals W X Y Year 98 99 00 01 02 03 04 05 06 07 08 09 Jan Feb Mar May Jun Jul Aug Sep Oct Apr Nov Dec 1 2 3 4 5 6 7 8 9 Z482 Basic model numbe...

Страница 9: ...sch P Type Hole Nozzle INJECTION TIMING UNPRESSURIZED 2 5 Before T D C 4 0 Before T D C 2 5 Before T D C FIRING ORDER 1 3 4 2 INJECTION PRESSURE Valve Opening Pressure 19 35 MPa 197 5 kgf cm2 2809 psi...

Страница 10: ...Special tools which are not frequently used should be made according to the drawings provided Before disassembling or servicing live wires make sure to always disconnect the grounding cable from the b...

Страница 11: ...to 49 4 5 to 5 0 33 to 36 Rocker Arm Bracket Bolt M8 x 1 25 24 to 27 2 4 to 2 8 18 to 20 Idle Gear Shaft Bolt M8 x 1 25 24 to 27 2 4 to 2 8 18 to 20 Crank Pulley Mounting Nut M30 x 1 5 138 to 156 14 0...

Страница 12: ...ne Revolution Is Not Smooth Fuel filter clogged or dirty Air cleaner clogged or dirty Fuel leak due to loose injection pipe retaining nut Injection pump malfunctioning Incorrect nozzle injection press...

Страница 13: ...ive oil clearance of crankpin bearing Excessive oil clearance of rocker arm Oil passage clogged Incorrect oil type Oil pump defective Replenish Clean Clean Replace Replace Replace Replace Clean Use sp...

Страница 14: ...6 in Valve Seat Width Intake Width Exhaust 2 12 mm 0 0835 in 2 12 mm 0 0835 in Valve Seat Angle Intake Exhaust 0 79 rad 45 Valve Face Angle Intake Exhaust 0 79 rad 45 Valve Stem to Valve Guide Valve S...

Страница 15: ...23 980 mm 0 94327 to 0 94409 in 24 000 to 24 021 mm 0 94489 to 0 94570 in 0 07 mm 0 003 in _ Timing Gear Crank Gear to Idle Gear Idle Gear to Cam Gear Idle Gear to Injection Pump Gear Crank Gear to Oi...

Страница 16: ...0079 in Oil Ring to Ring Groove Clearance 0 020 to 0 060 mm 0 00079 to 0 0023 in 0 15 mm 0 0059 in Top Ring Ring Gap 0 20 to 0 35 mm 0 0079 to 0 013 in 1 25 mm 0 0492 in Second Ring Ring Gap 0 40 to...

Страница 17: ...nkpin to Crankpin Bearing Crankpin Crankpin Bearing Oil Clearance O D I D 0 025 to 0 087 mm 0 00099 to 0 0034 in 46 959 to 46 975 mm 1 8488 to 1 8494 in 47 000 to 47 046 mm 1 8504 to 1 8522 in 0 2 mm...

Страница 18: ...Tension 7 0 to 9 0 mm 0 28 to 0 35 in deflection at 98N 10kgf 22 lbs of force Thermostat Valve Opening Temperature At Beginning Valve Opening Temperature Opened Completely 80 5 to 83 5 C 176 9 to 182...

Страница 19: ...Commutator Mica Brush Brush Holder and Holder Support O D Undercut Length Resistance 32 0 mm 1 26 in 0 50 mm 0 020 in 0 18 mm 0 709 in Infinity 31 4 mm 1 24 in 0 20 mm 0 0079 in 11 0 mm 0 433 in Intak...

Страница 20: ...d can not be identified drain out all of the remaining cool ant and refill with a totally new mix CAUTION Do not remove the radiator cap until the coolant temperature is below its boiling point Loosen...

Страница 21: ...the correct oil level Refer to Section 1 8 1 NOTE When changing to a different oil manufacturer or viscosity be sure to remove all of the old oil completely Never mix different types of oil Use only A...

Страница 22: ...es to compression or overlap top dead center TDC 3 Check the following valve clearance 1 marked with using a feeler guage Valve Clearance Factory Specification 0 18 to 0 22 mm 0 0071 to 0 0086 in 4 If...

Страница 23: ...verhaul 1 9 2 Adapter Injector To Tester Hose Part No 07 00484 00 Application Accessory for 07 00179 01 1 9 3 Tester Injector Nozzle Part No 07 00140 00 Application Injector nozzle tester kit used for...

Страница 24: ...ngine 1 9 8 Gauge Belt Tension Part No 07 00203 00 Application Used to adjust belt tension of all cogged V belts 1 9 9 Tester Belt Tension Part No 07 00253 00 Application Used to test belt tension 1 9...

Страница 25: ...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 14 Bushing Replacing Tools Application Use to press out and press fit the bushing 1 For small end bushing A 162 m...

Страница 26: ...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...

Страница 27: ...ance Always use a fully charged battery for perform ing this test Variances in cylinder compression values should be under 10 Compression Pres sure Factory Specification 2 95 to 3 23 MPa 30 to 33 kgt...

Страница 28: ...and drain the coolant into a proper recep tacle bucket 2 Remove the oil drain plug and drain the engine oil into a proper receptacle bucket 2 2 2 External Components Air Cleaner Muffler and Others 1...

Страница 29: ...Valve Cover Bolts 6 87 to 11 2 N m 0 7 to 1 15 kgf m 5 07 to 8 31 ft lbs 1 Valve Cover Bolt 2 Breather Hose 3 Valve Cover 4 Valve Cover Gasket 5 Breather Valve 6 Plate 2 2 3 b Injection Pipes 1 Loose...

Страница 30: ...Assembly Retaining Bolt 9 81 to 11 2 N m 1 00 to 1 15 kgf m 7 24 to 8 31 ft lbs 2 2 3 d Rocker Arm and Push Rod 1 Remove the rocker arm bracket mounting bolts 1 2 Detach the rocker arm assembly 2 3 R...

Страница 31: ...g a new gasket that matches the original gasket 2 2 3 f Tappets 1 Remove the tappets 1 from the crankcase When Reassembling Visually check the contact between the tappets 1 and individual cam lobes Co...

Страница 32: ...de 6 after Installing the injection pump 7 Replace the hi idling body gasket 4 with a new one Install the fuel speed solenoid guide 6 and then the stop lever 5 into the gear case Cycle the stop lever...

Страница 33: ...the speed control plate 7 mounting nuts 3 and bolts 4 3 Using the Specific Tool 1 undo the the large governor spring 5 from the fork lever 2 4 Set the speed control lever 6 as shown in the figure 5 Re...

Страница 34: ...d control plate 7 assembly 2 Pull the governor spring 5 speed control plate 7 assembly thru and secure it to the fork lever 2 3 Seat and assemble the speed control 5 plate with two bolts and two nuts...

Страница 35: ...e feather key When Reassembling Apply grease to the splines of the coupling Tightening Torque Drive Pulley Mounting Nut 138 to 156 N m 14 0 to 16 0 kgf m 102 to 115 ft lbs 2 2 4 d Gear Case 1 Remove t...

Страница 36: ...tach the external snap ring 2 Remove the idle gear collar 3 Remove the idle gear 2 When Reassembling Check to see each gear is aligned with its aligning mark Idle gear 2 and crank gear 4 Idle gear 2 a...

Страница 37: ...ft stopper 1 2 Remove the three fork lever holder mounting screws 2 3 Remove the fuel camshaft assembly 5 6 and fork lever assembly 3 4 and 7 at the same time When Reassembling After installation chec...

Страница 38: ...oil and install it to the pick up tube Install the strainer 6 and O ring 5 Apply gasket sealant to the oil pan side of the oil pan gasket 7 and fit the gasket to the oil pan 2 Install the oil pan 2 to...

Страница 39: ...heir 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...

Страница 40: ...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 8 When assembling the connecting rod...

Страница 41: ...ning Torque Flywheel Bolts 98 0 to 107 8 N m 10 0 to 11 0 kgf m 72 3 to 79 5 ft lbs 2 2 7 b Bearing Case Cover 1 Remove the bearing case cover mounting bolts First remove the inside bolts 2 and then t...

Страница 42: ...each of the crank pins 5 left or right to clear the crankcase relief a When Reassembling When installing the main bearing case assembly align the bolt holes of the crankshaft assembly 2 with the holes...

Страница 43: ...iameters of the main bearing cases vary Install them in order from the gear case end according to their markings A B C Match the alignment numbers 1 and mark 2 on the main bearing case When installing...

Страница 44: ...head Cylinder Head Surface Flatness Factory Specification 0 05mm over a span of 500mm 0 002 in over a span of 20 in 2 3 1 b Cylinder Head Cracks 1 Cylinder head crack s can be found with using a non...

Страница 45: ...protrusion in to 0 033 recessing in Allowable Limit 2 3 1 d Clearance Between Valve Stem And Valve Guide 1 Remove carbon from the valve guide section 2 Measure the valve stem O D with a micrometer 3 M...

Страница 46: ...I D of the valve guide to the specified di mension precisely Valve Guide I D Intake Exhaust Factory Specification 8 015 to 8 030 mm 0 3156 to 0 3161 in 2 3 1 f Valve Seating 1 Coat the valve face ligh...

Страница 47: ...rad 15 valve seat cutter to the exhaust valve seat so that the width is close to the specified valve seat width 2 12 mm 0 0835 in 3 After resurfacing the seat apply a thin film of valve lapping compou...

Страница 48: ...place it Setting Load Setting Length Factory Specification 118 N 35 mm 12 0 kgf 35 mm 26 5 lbs 1 38 in Allowable Limit 100 N 35 mm 10 2 kgf 35 mm 22 5 lbs 1 38 in 2 3 1 k Oil Clearance Between Rocker...

Страница 49: ...backlash exceeds the allowable limit check the oil clearance of the shafts and the gear 4 If the oil clearance is proper replace the gear Backlash Idle Gear Crank Gear Factory Specification 0 0415 to...

Страница 50: ...eter and calculate the the clearance 3 If the measurement exceeds the allowable limit re place the bushing Idle Gear Shaft Bushing Clearance Factory Specification 0 025 to 0 066 mm 0 00099 to 0 00260...

Страница 51: ...eight Intake Factory Specification 33 27 mm 1 310 in Allowable Limit 33 22 mm 1 308 in Cam Height Exhaust Factory Specification 33 47 mm 1 318 in Allowable Limit 33 42 mm 1 316 in 2 3 2 h Camshaft Oil...

Страница 52: ...xcessive replace the piston pin Piston Pin to Small End Bush ing Clearance Factory Specification 0 014 to 0 038 mm 0 00055 to 0 00150 in Allowable Limit 0 15 mm 0 0059 in Piston Pin O D Factory Specif...

Страница 53: ...cannot be accurately measured with a feeler gauge 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...

Страница 54: ...54 5 to 54 7 mm 2 146 to 2 153 in 54 6 to 54 8 mm 2 150 to 2 157 in Dimension B 26 20 to 26 25 mm 1 032 to 1 033 in 26 40 to 26 45 mm 1 040 to 1 041 in Dimension C 2 8 to 3 2 mm radius 0 11 to 0 12 i...

Страница 55: ...ankpin Connecting Rod Clearance Factory Specification 0 025 to 0 087 mm 0 00099 to 0 0034 in Allowable Limit 0 2 mm 0 0079 in Crankpin O D Factory Specification 46 959 to 46 975 mm 1 8488 to 1 8494 in...

Страница 56: ...Oversize 0 2mm 0 0008 in 0 4mm 0 0016 in Dimension A 2 8 to 3 2 mm radius 0 11 to 0 12 in radius 2 8 to 3 2 mm radius 0 11 to 0 12 in radius Dimension B 1 0 to 1 5 mm radius 0 040 to 0 059 in radius...

Страница 57: ...g Clearance Factory Specification 0 040 to 0 104 mm 0 00158 to 0 00409 in Allowable Limit 0 2 mm 0 0079 in Crankshaft Journal O D Factory Specification 59 921 to 59 940 mm 2 3591 to 2 3598 in Cranksha...

Страница 58: ...t 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 200 C 302 to 392 F and fix the sleev...

Страница 59: ...Visually check the cylinder wall for scratches If deep scratches are found the cylinder walls should be bored refer to Correcting Cylinder Cylinder I D Factory Specification 83 000 to 83 022 mm 3 2678...

Страница 60: ...fficient Oil pump defective Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Relief valve stuck At Idle Speed Factory Specification More than 98 kPa 1 0 kg...

Страница 61: ...0 0055 in Allowable Limit 0 2 mm 0 008 in Outer Rotor Pump Body Clearance Factory Specification 0 11 to 0 19 mm 0 0044 to 0 0074 in Allowable Limit 0 25 mm 0 0098 in 3 2 2 Rotor to Cover Clearance 1 P...

Страница 62: ...sed 3 When belt is at correct tension tighten pivot bolt 4 1 1a Poly V Belt Service a Replacing the Poly V Belt 1 Apply the proper size socket to the crank pulley nut then slowly rotate the crank At t...

Страница 63: ...pecifica tion replace the cap Pressure Falling Time Factory Specification More than 10 seconds for pressure fall from 88 to to 59kPa 0 9 to 0 6 kgf cm2 13 to 9 psi 4 1 5 Radiator 1 Fill the radiator w...

Страница 64: ...r gasket 3 4 2 2 Water Pump Assembly 1 Water Pump Flange 2 Water Pump Shaft 3 Water Pump Body 4 Water Pump Gasket 5 Mechanical Seal 6 Impeller 1 Remove the fan belt 2 Remove the water pump pulley 3 Re...

Страница 65: ...ication 0 0568 to 0 0829 rad 3 25 to 4 75 B T D C NOTE Injection timing adjustment is accomplished by adding or removing shims under the injection pump The timing advances by removing one shimand reta...

Страница 66: ...Fuel Seal 1 Remove the engine fuel speed solenoid 2 Remove the injection pipes and nozzle 3 Connect a pressure tester to the fuel injection pump 4 Connect the injection nozzle 2 jetted with the proper...

Страница 67: ...ce the nozzle assembly Fuel Injection Pressure 1st Stage Factory Specification 18 64 to 20 1 MPa 190 to 205 kgt cm2 2703 to 2915 psi 5 2 2 Nozzle Spraying Condition 1 Set the injection nozzle in a noz...

Страница 68: ...estarter Tightening Torque B Terminal Nut 8 8 to 11 8 N m 0 9 to 1 2 kgf m 6 5 to 8 7 ft lbs 6 1 2 Magnetic Switch Test NOTE This test should only be carried out for a 3 to 5 second time period and no...

Страница 69: ...enoid 1 from the engine 3 Supply power 12VDC to the solenoid thru terminals 3 and 4 4 If the rod in the solenoid 1 moves smoothly approx imately 0 6 the solenoid is normal if the rod does not move or...

Страница 70: ...ure 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 replace the heater Intake Air Heater R...

Страница 71: ...2 F fan drive pulley 2 9 flywheel 2 15 fuel injection 1 15 2 3 2 6 fuel speed solenoid 6 2 fuel system 5 1 fuel system bleeding 1 14 G gear case 2 9 governor 2 7 2 8 I Identification 1 1 idle gear 2 1...

Страница 72: ...l 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 20 valve spring 2 22 valv...

Страница 73: ...old com North America Carrier Transicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Mexico and Central America Ejercito Nacional No 418 Piso 9 Torre Yumal Col Chapulte...

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