Carrier V2203-DI (26--00128) manual

Diesel Engine 62 - - 1 1362 Rev - - WORKSHOP MA NUAL for V2203 - DI (26 - - 00128) T ier 4i R[...]

WORKSHOP MANUAL DIESEL ENGINE V2203 - DI (26 - 001 18) T ier 4i[...]

i 62- - 1 1362 T ABLE OF CONTENTS P ARAG RAPH NUMBER Page SAF ETY PRECA UTIO NS iv ................................................................... SPECIFIC WAR NING AND CAUTION ST A TEMENTS iv .......................................... Gene ra l 1- - 1 ...................................................................................... 1.1 EN[...]

ii 62-1 1362 P ARAG RAPH NUMBER Page ENGIN E BOD Y 2- -1 ............................................................................... 2.1 CHECKI NG AND ADJUS TING 2- - 1 ......................................................... 2.1. 1 Compres sion Pressur e 2- - 1 ............................................................. 2.1. 2 T op Clearanc[...]

iii 62- - 1 1362 P ARAG RAPH NUMBER Page FUEL SYSTEM 5- -1 ............................................................................... 5.1 CHECKI NG AND ADJUS TING 5- - 1 ......................................................... 5.1. 1 Injec tion T iming 5- - 1 ................................................................... 5.1. 2 Shim Iden[...]

iv 62-1 1362 SA FETY SAFE TY PRECAUT IONS Y our Carrier T ransic old unit has been designed wit h the safet y of t he operator in m ind. During norm al operation, all moving parts ar e fully enclos ed to help prevent injur y . During all pre-t rip inspect ions, daily inspec tions, and problem troubles hooting, you may be exposed to moving part s. P[...]

v 62-1 1362 The st atement s listed below ar e specifically applicable t o this unit and appear els ewhere in this m anual. These recom mended prec autions must be unders tood and applied dur ing operat ion and maint enance of the equipm ent cover ed herein. W ARNI NG Be war e of mov ing V - - be lt and belt dr ive n compone nts W ARNI NG Wh en rem[...]

1- - 1 62- - 1 1362 SECTI ON 1 General 1.1 ENGIN E IDE NTIFICA TION S/N When c ontacting Car rier T ransic old, always spec ify your engine m odel number and serial number. The engine m odel and it s s erial number need to be identif ied before t he engine can be serviced or parts replaced. Engine Se ria l Numbe r The engine ser ial number is an id[...]

1- - 2 62- - 1 1632 1.2 ENGINE SPECIFICA TIO N S T ab le 1 - 2. S pecifi catio n Chart MODEL NUM BER 26- - 00128 - - 00 26 - - 00128 - - 01 26- - 00128 - - 02 26 - - 00128 - - 04 26- - 00128 - - 05 TYPE V ert ica l, W ate r- - coo le d, 4 cycl e di ese l engine NUMBE R OF CYLINDERS 4 B O R EXS T R O K E m mXm m( i n .Xi n . ) 83 X 102.4 (3. 27 X 4.[...]

1- - 3 62- - 1 1362 1.3 CYL INDER NUMBER The c ylinder num bers of V2203 - - DI s eries engine ar e designated as s hown above. T he sequence of c ylinder numbers is given as No.1, No. 2, No. 3, and No. 4 st arting fr om the gear cas e end of the engine. 1.4 GE NERAL PRECAUTI ONS 1 2 3 2 3 1. Gr ease 2. Forc e 3. Place t he Sharp Edge against t he [...]

1- - 4 62- - 1 1632 1.5 TORQUE SPECIFI C A TIO N S Scr ews, bolts and nuts mus t be t ightened t o the s pecified tor que using a torque wrenc h. S everal screws , bolt s and nuts such as t hose used on the c ylinder head must be tight ened in the proper s equence and at t he proper torque. 1.5. 1 T o rque S pecifi catio ns Fo r Speci al Use Screws[...]

1- - 5 62- - 1 1362 1.6 T ROUBLES HOOT ING Symptom Pr obable Ca use Soluti on Reference Engine Doe s Not Start (Starte r Does Not Run) No fuel Air in the fuel system W ater in the fuel system Fuel pipe c logged Fuel f ilter clogged Exces sively high vis cosity f o fuel or engine oil at low t emperatur e Fuel wit h low cetane number Incor rect injec[...]

1- - 6 62- - 1 1632 1.6 TROU BLES HOOTING ( Continue d) Symptom Pr obable Ca use Soluti on Reference Excessive L ubricant Oi l Con sumpt i on Pist on ring’ s gap f acing the sam e direction O i lr i n gw o r no r s t u c k Pist on ring groove worn V alve s tem and valve guide wor n Cranks haft bearing, and crank pin bearing worn Oil leak ing due [...]

1- - 7 62- - 1 1362 1.7 SERVICING SPECIFICA TIONS 1.7 .1 Engine Body Item Factory S pecifi catio n A llowable Limit Cylinder Head S urface Flat ness -- 0.05 mm /500mm 0.0020 in. / 19.69 in. Comp ression Pressu re Differenc e Among Cylinders 2.95 t o 3.23 MPa/ 290 rpm 30 to 3 3 kgf/c m 2 290 rpm 427 to 469 psi/ 290 rpm -- 2.35 M Pa/ 290 rpm 24kgf /c[...]

1- - 8 62- - 1 1632 1.7 .1 Engine Body ( Continue d) Item Factory S pecifi catio n A llowable Limit V alve S pring Fr ee Length Sett ing Load/ Sett ing Length T ilt 41.7 t o 42.2 mm 1.65 t o 1.66 in. 1 1 8N/ 3 5 . 0m m 12.0 k gf / 35. 0 mm 26.5 lbs . / 1. 38 in. -- 41.2 m m 1.62 in. 100.0N / 35.0 m m 10.2k gf / 35.0 mm 22.5lbs / 1.38 in 1.0 m m 0.0[...]

1- - 9 62- - 1 1362 1.7 .1 Engine Body ( Continue d) Item Factory S pecifi catio n A llowable Limit Camshaf t Side Clearance 0.07 to 0. 22 mm 0.0028 t o 0.0086 in. 0.3 m m 0.012 I n. Camshaf t Alignment -- 0.01 m m 0.0004 in. Cam (Lobe) Height (I ntake) Height (Ex haust) 33.27 m m 1.310 in. 33.47 m m 1.318 in. 33.22 m m 1.308 in. 33.42 1.316 in. Ca[...]

1- - 1 0 62- - 1 1632 1.7 .1 Engine Body ( Continue d) Item Factory S pecifi catio n A llowable Limit Cranks haft Journal to Crankshaf t Bearing2 Cranks haft Journal Cranks haft Bearing2 Oil Clear ance O.D. I.D. 0.040 t o 0.104 mm 0.00158 t o 0.00409 in. 59.921 t o 59.940 mm 2.3591 t o 2.3598 in. 59.980 t o 60.025 mm 2.3615 t o 2.3631 in. 0.2 m m 0[...]

1- - 1 1 62- - 1 1362 1.7 .2 Lubric ating Sy st em Item Factory S pecifi catio n A llowable Limit Engine Oi l Pressure At I dle Speed At Rat ed Speed More T han 98 kPa 1.0 k gf/cm 2 14 psi 300 to 440 k Pa 3.0 to 4 .5kg f/cm 2 43 to 64 ps i 50 kPa 0.5 k gf/cm 2 7p s i 250 kPa 2.5 k gf/cm 2 36 psi Engine Oil Press ure Switch Work ing Pressure 5 0 kPa[...]

1- - 1 2 62- - 1 1632 1.7. 5 El ectrical System Item Factory S pecifi catio n A llowable Limit Starter Co mmu tator Mica Brush Brus h Holder and Holder Support O.D. Undercut Length Resista nce 32.0 m m 1.26 in. 0.50 m m 0.020 in. 0.18 m m 0.709 in. Infi ni ty 31.4 m m 1.24 in. 0.20 m m 0.0079 in. 11 . 0 m m 0.433 in. -- Int ake Air Heat er Resista [...]

1- - 13 62- - 1 1362 1.8 CHECK AND MAI NTENANCE 1.8. 1 Checki ng E ngi ne Oi l Level 1. Level t he engine. 2. T o check the oil level, draw out the dipstic k (1) , wipe it clean, reins ert it, and draw it out again. Check to see that the oil lev el lies between the t wo notches. 3. I f the level is too low , add new oil to t he specified level. NOT[...]

1- - 1 4 62- - 1 1632 1.8. 4 Bleed ing F uel System 1. Open t he air vent coc k (1) on top of the fuel injection pump. 2. Loosen t he priming pump handle ( 2), and pump the handle until bleeding is complet ed. 3. Depres s and twist the pr iming pump handle clock- w i s et ol o c ki n t op l a c e . 4. Clo se the air vent cock (1). NOTE Always k eep[...]

1- - 15 62- - 1 1362 1.8. 7 V alve Cl earance 1.8. 8 Fu el Inj ectio n Refer to Sec tion 5.2 NOTE V alve c learance m ust be checked and adjusted when the engine is c old. 1. Remo ve the valve cove r . 2. Align t he “ 1TC ” mar k line (3) on t he flywheel and pro- jection (2) on the housing so that the Number 1 pis ton comes to compress ion or [...]

1- - 1 6 62- - 1 1632 1.9 SPECI A L TOOLS Additi onal tools may be f ound in t he Carrier T ransic old Per formance P arts Serv ice T ool Cat alog Number 62- - 03213. 1.9. 1 Diesel Eng ine Compressi on T est er (Glo w Plug) Part No. 07- - 00179- - 01 ( Assembly ) Applicat ion: Use to meas ure diesel engine compr ession and diagnosis f or major over[...]

1- - 17 62- - 1 1362 1.9 SPECI A L TOOL S (C on tinued) 1.9. 6 Oi l Pressu re T ester Code No. 07916- - 32032 Applicat ion: Use to meas ure lubricat ing oil pressu re. 1. Guage 2. Adapter 2 3. Cable 4. Adapte r 3 5. Threaded J oint 6. Adapter 4 7. Adaptor 1 8 . Adapto r 3 1.9 .7 Aux iliary So cket Fo r Fi xing Cran kshaft Sleeve Code No. 07916- - 3[...]

1- - 1 8 62- - 1 1632 1.9 SPECI A L TOOL S (C on tinued) The f ollowing are drawings f or special tools that may need t o be fabricat ed. 1.9 .13 V alv e Guide Re plac ing T ool Applicat ion: Use t o press out and pr ess fit the valv e guide. A 20 mm dia. (0.79 in. dia. ) B 1 1.7 to 1 1.9 mm dia. (0.460 to 0.468 in. dia. ) C 6.5 to 6.6 mm dia. (0. [...]

1- - 19 62- - 1 1362 1.9 SPECI A L TOOL S (C on tinued) 1.9. 16 Cranksh aft Bearing 1 Repl acing T oo l Applicat ion: Use to pr ess out and press fit the cranks haft bearing No. 1 1. Ext racting tool A 130 mm (5.31 in.) B 72 mm (2.83 in.) C R40 m m (R1.5 7 in.) D 1 0 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 d[...]

2- - 1 62- - 1 1362 SECTI ON 2 ENGINE BODY 2.1 CHECKI NG AND ADJUSTI NG 2.1. 1 Comp ression P ressure 1. Run t he engine until it is war med up. 2. St op the engine and disconnec t the 2P c onnector fr om the st op solenoid to pr event f uel delivery t o t he engine. 3. Remov e the the air c leaner , the m uf fler and all t he in- jectio n nozzles.[...]

2- - 2 62- - 1 1362 2.2 DISASSEMBLE AN D REASSEMBL Y 2.2 .1 Dr aining Coola nt And E ngine Oil CAUTI ON Never remove t he rad iato r cap u nti l coo lant tem per atur e is below its boiling point. Lo osen t he cap sl igh tly to th e first stop t o reli eve any excess pressu re befo re remov- ing the c ap c omple tely . 1. O pen the coolant drain c [...]

2- - 3 62- - 1 1362 2.2. 3 Cyli nder Head And Valves 2.2.3. a V al ve Cover 1. Remov e the breather hose (2) . 2. Remo ve the valve cove r bolts (1). 3. Remo ve the valve cove r (3). Wh en Reassembli ng Check t o see that the valv e cover gas ket ( 4) is in good conditi on and in place. Tightening T orque Valve Cov er Bolts 6.87 to 1 1.2 N . m 0 . [...]

2- - 4 62- - 1 1362 2.2. 3 Cyli nder Head And Valves (Cont inu ed) 3 4 1. Rocke r Arm Br acke t Mounting Bolt 2. R ocke r A rm A ss embl y 3. Push R od 4. T appet 2.2. 3.c Noz zle Hol der Assemb ly 1. Remov e the overf low pipe assembly . 2. Remov e the nozzle holder as semblies (1) . Wh en Reassembli ng Replace the c opper gasket with a new one. T[...]

2- - 5 62- - 1 1362 2.2. 3 Cyli nder Head And Valves (Cont inu ed) 1 2 3 4 5 13 12 16 8 9 17 11 15 7 6 10 14 18 1. Hose Clam p 2. Filter - - D rier Inlet A: Gear Cas e Side B: Fly wheel Side 2.2. 3.e Cyli nder Head 1. Loosen t he hose clamp (1) , and remove the water re- turn pip e (2). 2. Remov e the cylinder head bolt s in the or der of ( 18 )t o[...]

2- - 6 62- - 1 1362 2.2. 4 In jecti on Pump an d Gear Case 2.2. 4.a In jecti on Pu mp 1. Remov e the fuel speed solenoid (2) and hi- - idling body (3). 2. Remov e the engine stop lev er (5) and st op solenoid guide (6). 3. Remov e the fuel inject ion pump assembly (7). NOTE Remove t he injection pump assembly ( 7) afte r remov ing the f uel speed s[...]

2- - 7 62- - 1 1362 2.2 .4 Injec tion Pump a nd Gea r C ase (Cont inued) 2.2.4. b Govern or Spri ngs and Sp eed Con trol Pl ate NOTE Speci fic T ool (1 ): A 1.2mm (.050 inch ) d iameter wire with a t otal lengt h of 200m m (8 inc h) with the t ip bent into a hook as depicted in the illustr ation is requir ed to hang the gover nor springs . 1. Remov[...]

2- - 8 62- - 1 1362 2.2 .4 Injec tion Pump a nd Gea r C ase (Cont inued) 2.2.4. b Govern or Spri ngs and Sp eed Con trol Pl ate (Cont inued) Wh en Reassembli ng NOTE A lengt h of string pas sed t hru the governor spring c an be used to ret rieve t he spring if it un- hooks f rom both t he specific tool and the speed contr ol plate. Begin reas sembl[...]

2- - 9 62- - 1 1362 2.2 .4 Injec tion Pump a nd Gea r C ase (Cont inued) 1. Nut 2. Fan Driv e Pulle y 3. 46 mm Deep Soc ket wr ench 4. Gear Puller 1. Gear Cas e 2. Gear C ase Gas ket 3. O - - r ing 4. O - - r ing 5. Oil s eal 2.2. 4.c Fan Drive P ull ey 1. Lock the f lywheel using the f lywheel stopper 2. Remov e the fan drive pulley mount ing nut [...]

2- - 1 0 62- - 1 1362 2.2 .4 Injec tion Pump a nd Gea r C ase (Cont inued) 1. Crank shaft Collar 2. O - - r in g 3. Crank shaft O il Slinger 1. Injection P ump Gear 2. Idle Gear 3. Cam Gear 4. Crank G ear 5. Oil Pump D rive G ear 1. Cams haft Set Scr ew 2. Cams haft 1. Oil Pipe 2. Fuel Feed Pump 3. O - - ring 4. Fuel Feed Pump H older 2.2. 4.e Cran[...]

2- - 1 1 62- - 1 1362 2.2 .4 Injec tion Pump a nd Gea r C ase (Cont inued) 1. Fuel Cams haft Stopper 2. Fork Lev er Holder Mounting Screws 3. Fork Lev er 1 4. Fork Lev er 2 5. Injection P ump Gear 6. Fuel Cams haft 7. Fork Lev er Holder 1. Oil Pump 2. Oil Pump D rive G ear 3 Gear Puller 2.2. 4.i Fu el Camshaft And F ork Lever Assembl y 1. Det ach t[...]

2- - 1 2 62- - 1 1362 2.2 .5 Oil Pan a nd Oil Str ainer (7) 1. Oil Pan Mounting S crew 2. Oil Pan 3. Oil Pan C over G asket 4. Oil Pan C over 5. O - - r ing 6. Oil Str ainer 7. Oil Pan G ask et 2.2 .5.a Oil Pan a nd Oil Stra iner 1. Remov e the oil pan cover ( 4). 2. Remov e the oil pan mounting bolt s (1). 3. Remove the oil pan ( 2) by light ly t [...]

2- - 1 3 62- - 1 1362 2.2. 6 Pi ston and Co nnect ing Ro d 6 2.2. 6.a Pi stons 1. Com pletely remov e the c arbon ridge ( 1) at the top of the cy linder walls. 2. Remov e the connect ing rod cap (3). 3. Turn the f lywheel and bring t he pist on to t op dead cent er . 4. Push t he piston out by light ly tapping t he connecting rod from t he bottom o[...]

2- - 1 4 62- - 1 1362 2.2 .6 Pist on and Conne ct ing Rod (C ontinued) 7 8 7 2.2. 6.b Pi ston Rin g and Con necti ng Rod 1. Remo ve the piston rin gs (1), (2), (3). 2. Remov e the piston pin ( 8) and t hen seperat e the con- necti ng rod (6) fr om the pist on (5). NOTE Mark bot h the connec ting r od and pis ton s o that if t hey are to be re - - u[...]

2- - 1 5 62- - 1 1362 2.2. 7 Crankshaf t 1. Fly wheel 2. Fl y wheel Bolt 3. Flyw heel Guide Bolts 1. Bearing Cas e Cov er Mounting Bolt 2. Bearing Cas e Cov er Mounting bolt 3. Bearing Cas e Cov er 4. Oil Seal 5. Bearing Cas e Gas ket 6. Bearing Cas e Cov er Gaske t ( a ). T op 2.2. 7.a Fl ywheel 1. Pr event the fly wheel (1) fr om rotating. 2. Rem[...]

2- - 1 6 62- - 1 1362 2.2. 7 Cranksh aft (Con tin ued) 2.2. 7.c Cranksh aft Assembl y Removal NOTE Befor e disassembling, check the s ide clearanc e of the cr ankshaft . Check it during reas sembly . 1. Remov e the three m ain bearing case bolt s (1). 2. Pull out t he crankshaf t assem bly (2), being caref ul not to dam age the crankc ase bearings [...]

2- - 1 7 62- - 1 1362 2.2. 7 Cranksh aft (Con tin ued) 7 8 8 2.2. 7.d Mai n Bearing Case Assembl y 1. Rem ove the two m ain bearing case bolts ( 7), and re- move t he main bearing case as sembly being caref ul with t he thrust bearing and cr ankshaft bearing. 2. Remove the rem aining main bearing cases as above. Wh en Reassembli ng Clean the oil pa[...]

2- - 1 8 62- - 1 1362 2.3 SER VICING 2.3. 1 Cyli nder Head And Valves 1. Red Dy e 2. Deter g ent 3. White Dev eloper 2.3. 1.a Cyli nder Head Su rface Fl atness 1. Clean t he cylinder head surf ace. 2. Pl ace a straight edge on the cylinder head surf ace, in six loc ations as depict ed in the drawing. 3. Meas ure any c learance between the s traight[...]

2- - 1 9 62- - 1 1362 2.3. 1 Cyli nder Head And Valves (Cont inu ed) 1. Cylinder H ead Surface (A) Re cess ( B ) Protr usion 2.3. 1.c V alve Recessi ng 1. Clean t he cylinder head surface ( 1), valve fac e and valve seat . 2. I nsert t he valve into t he head, making cert ain that the valve is fully s eated. 3. Meas ure the valve r ecessing wit h a[...]

2- - 2 0 62- - 1 1362 2.3. 1 Cyli nder Head And Valves (Cont inu ed) (A) When Remov ing (B) When Installing 1. Corre ct 2. I nco rre ct 3. I nco rre ct 2.3. 1.e Repl acing V alve G uid e (A) (W hen remo ving ) 1. Pres s out the used v alve guide using a valve guide re- placing tool. (B) (W hen i nstall ing ) 1. Clean a new valv e guide and valve gu[...]

2- - 2 1 62- - 1 1362 2.3. 1 Cyli nder Head And Valves (Cont inu ed) ab (1) (2) a. 0.26 rad.( 15 ° )o r 0.52 rad.( 30 ° ) b. 0.79 rad.( 45 ° )o r 1.0 rad.( 60 ° ) c. 0.52 rad.( 30 ° )o r 0.26 rad.( 15 ° ) A . C heck Contac t B . C orrect S eat Width C Chec k Contact 1 . V alve S eat Width 2. Identic al Dimensions 2.3. 1.g Correct ing V al ve [...]

2- - 2 2 62- - 1 1362 2.3. 1 Cyli nder Head And Valves (Cont inu ed) 2.3 .1.i Fre e Length and Tilt of V alve S pring 1. Measur e the free lengt h A of the valv e spring wit h ver- nier caliper s. If the m easurement is less than t he al- lowable limit, replac e the spring. 2. Put t he valv e spring on a surf ace plate, place a square on t he side [...]

2- - 2 3 62- - 1 1362 2.3. 1 Cyli nder Head And Valves (Cont inu ed) 2.3. 1.m Oil Cl earance Between T app et and T app et Guide Bor e 1. Meas ure the tappet O .D. wit h a micromet er . 2. Meas ure t he I. D. of t he t appet guide bor e with a cylin- der gauge and calc ulate the clear ance. 3. I f the meas urement exc eeds the allowable limit, or t[...]

2- - 2 4 62- - 1 1362 2.3. 2 Timi ng Gears, Camshaf t and F uel Camshaf t (Cont inu ed) 2.3. 2.c Camshaf t Sid e Clearance 1. Set a dial indicat or with it s tip on the c amshaft . 2. Move the c amshaft gear f ront to r ear to meas ure t he side clear ance. 3. I f the meas urement exc eeds the allowable limit, re- place t he camshaft st opper . Cam[...]

2- - 2 5 62- - 1 1362 2.3. 2 Timi ng Gears, Camshaf t and F uel Camshaf t (Cont inu ed) 2.3. 2.f Camshaf t Alig nment 1. Support the cam shaft wit h V blocks on a surf ace plate at bot h end journals. 2. Set a dial indic ator with it s tip on the interm ediate jour- nal. 3. Rot ate the cam shaft and measure f or run - - out . 4. I f the meas uremen[...]

2- - 2 6 62- - 1 1362 2.3. 3 Pi ston and Co nnect ing Ro d 2 .3.3.a P iston Pin Bore I.D . 1. Measur e the pist on pin bore I. D. in bot h t he horizontal and vert ical direct ions with a cylinder gauge. 2. I f the meas urement exc eeds the allowable limit, re- place the pis ton. Piston Pin Bore I.D. Factory Spec ification 25.000 to 25.013 mm 0.984[...]

2- - 2 7 62- - 1 1362 2.3 .3 Pist on and Conne ct ing Rod (C ontinued) 2.3. 3.d Pi ston Rin g Gap 1. Inser t t he pist on ring int o the lower part of t he cy linder (t he least worn sec tion). Us e the pis ton to squar e the ring in t he cylinder . 2. Meas ure the ring gap wit h a feeler gauge. 3. I f the gap exceeds t he allowable limit , replace[...]

2- - 2 8 62- - 1 1362 2.3. 4 Crankshaf t A B 2.3. 4.a Cranksh aft En d Clearan ce 1. Push on the end of t he crank shaft t o seat it towar d the fly wheel end of the engine block . 2. Att ach, t hen zero a dial indicator on the for ward end of the cr an ksha ft. 3. Meas ure the end play by pulling t he cr ankshaft for - ward. 4. I f the measur emen[...]

2- - 2 9 62- - 1 1362 2.3. 4 Cranksh aft (Con tin ued) 2.3. 4.c Crankpi n to Co nnect ing Ro d Beari ng Clear - ance 1. Clean t he crankpin and the c onnecting rod bear ing. 2. Put a st rip of plastigage on the cent er of t he crankpin in each direc tion as shown in t he figure. 3. I nstall the connect ing rod cap and tight en the bolt s to the spe[...]

2- - 3 0 62- - 1 1362 2.3. 4 Cranksh aft (Con tin ued) 1. Seam 2. Crank shaft Bear in g #1 3. Cylinder B lock A Dimens ion 2.3. 4.d Cran kshaft Jou rnal to Cran kshaft Bearin g #1 Clearan ce 1. Meas ure the O. D. of t he crankshaf t journal with an outs ide micromet er . 2. M easure the I .D. of cranks haft bearing #1 wit h an in- side mic rometer [...]

2- - 3 1 62- - 1 1362 2.3. 4 Cranksh aft (Con tin ued) 2.3. 4.f Cranksh aft Jou rnal to Cran kshaft Beari ng #2 Clearan ce 1. Put a st rip of plast igage on t he center of t he c rank- shaft j ournal. 2. I nstall the bear ing case and tight en the bolts to spe- cificatio n. 3. Remov e the bearing case again. 4. Measur e the amount of t he f latteni[...]

2- - 3 2 62- - 1 1362 2.3. 4 Cranksh aft (Con tin ued) 1. Stopper 2. Sleeve G uide 3. Crank shaft Sleev e 4. Auxiliar y Sock et For Pushing 5. Crank shaft 2.3. 4.g Repl acin g Crankshaf t Sleeve 1. Remov e the cranks haft s leeve (3) using a special - - use puller s et. 2. Set the s leeve guide (2) t o the cranks haft (5) . 3. Set t he stopper ( 1)[...]

2- - 3 3 62- - 1 1362 2.3. 5 Cylin der a. To p b. Middle c. Bottom (skirt) a. Right - - angled t o Piston Pin b. Pis ton Pin Direc tion 1. Cylinder I .D. (before c orrec tion) 2. Ov ersiz e Cylinder I .D. 2.3. 5.a Cylin der Wear 1. Meas ure the I. D. of t he cylinder at t he six positions (see figure with a cy linder gauge to find t he maxim um and[...]

3- - 1 62- - 1 1362 SECTI ON 3 LUBRICA TI NG SYSTEM 3.1 CHECKI NG AND ADJUSTI NG 3.1. 1 En gin e Oil Pressure 1. Remov e the engine oil pressur e switch, and inst all an oil press ure gauge. 2. Star t the engine. Aft er war ming up, read t he oil pres- sure at idling and at r ated speeds. 3. I f t he oil pr essure is less t han the allowable limit [...]

3- - 2 62- - 1 1362 3.2 SER VICING 3.2 .1 Rotor Lobe C lea ra nce 1. Measur e the clearanc e between lobes of t he inner ro- tor and the out er rotor wit h a feeler gauge. 2. Meas ure the clear ance between the out er rotor and the pum p body with a feeler gauge. 3. I f the clearance exceeds t he fac tory spec ifications , replace t he oil pump rot[...]

4- - 1 62- - 1 1362 SECTI ON 4 COOL ING SYSTEM 4.1 CHECKI NG AND ADJUSTI NG W ARNI NG Be war e of mov ing V - - belt and belt driv en com ponents 4.1. 1 Not ched V - - Bel t Service NOT E A fray ed, cracked or worn V - - belt must be re- placed. Af ter inst alling a new belt , it is advis able to chec k the adjust ment af ter running t he unit for [...]

4- - 2 62- - 1 1362 FULL LOW 2. I f t he coolant level is too low , check the reason f or t he lost coolant . a. I f coolant loss is due to evaporation, add only clean soft w ate r . b. I f coolant los s is due to a leak, repair the leak , t hen add a coolant m ixture of the same t ype and spec ifi- cation t h at is in the system. If the coo lant b[...]

4- - 3 62- - 1 1362 4.2 SER VICING 4.2. 1 Th ermostat Assemb ly 1. Thermos tat Cover B olt 2. Thermos tat Cover 3. Thermos tat Cover G ask et 4. Thermos tat Ass embly 5. Thermos tat Housing 1. Remove t he thermost at cover m ounting bolts (1) , and remove the the rmostat cover (2). 2. Remo ve the thermostat assembl y (4). (W hen Reassembl ing ) App[...]

62- - 1 1362 5- - 1 SECTI ON 5 FU EL SYSTEM 5.1 CHECKI NG AND ADJUSTI NG 5.1. 1 In jecti on Timin g 1. Remov e the fuel speed s olenoid. 2. Remov e the injection pipes and nozzle. 3. M ove the speed cont rol lever t o the maxim um speed position. NOT E T urn t he flywheel with a s crewdriver. 4. Turn the fly wheel countercl ockwise (f acing the fly[...]

62- - 1 1362 5- - 2 5.1 CHECKI NG AND ADJUSTI NG 1. Inj ect io n Pu mp P ressu re Te s t e r 2. Inj e ctio n No zzle 3. Protec tive Cov er 5.1. 3 Pu mp Pressure T est 1. Remov e the engine fuel speed s olenoid. 2. Remov e the injection pipes and nozzle. 3. Connect a press ure test er to the f uel inject ion pump. 4. Connect t he inject ion nozzle ([...]

62- - 1 1362 5- - 3 5.2 INJ ECTION N OZZLE W ARNI NG Che ck the inje ction nozzle only a fte r confir ming that nobody is ne ar the s pra y . If the s pray from t he nozzle c ontac ts the hum an body , cells m ay be de str oye d and blood poisoning ma y re sult. (a) GOOD (b) BAD 5.2. 1 Noz zle In jecti on P ressure 1. Set the injec tion nozzle in a[...]

6- - 1 62- - 1 1362 SECTI ON 6 ELECT RICAL SYSTEM 6.1 ST ARTER TEST 1. C T erminal 2. Posit ive T erminal 3. Negativ e T erminal 1. S T erminal 2. Posit ive T erminal 3. Negativ e T erminal 6.1. 1 Mo tor T est W ARNI NG Secure th e start er to preven t it f rom movi ng when powe r is applied t o it. 1. Disc onnect the c able from t he negative ter [...]

6- - 2 62- - 1 1362 6.2 F UEL SPEED SOLENOID 6.2. 1 So leno id T est W ARNI NG Th e sol enoi d can beco me very warm to th e touch whe n ene rgize d for any length in time. 1. Disc onnect t he plug from t he solenoid connec tor (2) . 2. Remov e the solenoid (1) f rom t he engine. 3. Supply power ( 12VDC) to t he solenoid thr u term inals (3) and (4[...]

6- - 3 62- - 1 1362 6.3 INT AKE AI R HEA T ER 6.3. 1 In take Air Heater T est 1. Disc onnect the lead f rom t he heater ter minal (1). 2. Meas ure the resis tance bet ween the heater positiv e ter minal (1) and the heat er body (2) . 3. I f the resist ance is infinity or s ignificantly diff erent than t he specific ation, replac e the heater . Inta[...]

INDEX Index - - 1 62- - 1 1362 B Batte ry , iv bearing case, 2 - - 15, 2 - - 17 C cams haft, 2 - - 10, 2 - - 24, 2- - 25 compre ssion pressu re, 2 - - 1 connect ing rod, 2 - - 14, 2 - - 27 coolant, i v , 2 - - 2 coolant level, 1 - - 13, 4 - - 1 cool ing system, 4 - - 1 cranksh aft, 2 - - 28 crank shaft oil slinger , 2- - 10 cylinder, 2- - 33 cylind[...]

INDEX Index - - 2 62- - 1 1362 S Safet y Precaut ions, iv specif ications, 1 - - 2 speed contr ol plat e, 2- - 7, 2 - - 8 st arter mot or , 6 - - 1 T tappet s, 2- - 5, 2 - - 23 ther mostat , 4- - 2 tim ing gear , 2- - 23 T orque Spec ification, 1 - - 4 V V - - belt , 1- - 14 valve clear ance, 1 - - 15 valve guide, 2 - - 20 valve seat , 2 - - 20 val[...]

© 2008 Carrier Corporatio n D Printed in U. S. A. 0508 Carrier Transic old Div ision, Carrier Corporat ion Truck/ T railer P roducts Group P . O. Box 4805 Sy racuse, N. Y . 13221 U.S .A. www . carrier . transic old.c om North America Carrier Transic old 700 Oly mpic Driv e At hens, GA 30601 USA T el: 1 - - 706 - - 357 - -7223 Fax : 1 - - 706 - - 3[...]