WORKSHOP MANUAL

DIESEL ENGINE
V2003-T-B
F2503-T-B
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DIESEL ENGINE V2003-T-B/F2503-T-B

C O N T E N T S
TO THE READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-0
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CONTENTS

DIESEL ENGINE V2003-T-B/F2503-T-B

M

1. ENGINE BODY ...................................................................................................................M-1

[1] CYLINDER BLOCK..........................................................................................................M-1
[2] CYLINDER HEAD............................................................................................................M-1
[3] CRANKSHAFT.................................................................................................................M-2
[4] PISTON AND PISTON RINGS ........................................................................................M-2
[5] CONNECTING ROD........................................................................................................M-3
[6] ROCKER ARM.................................................................................................................M-3
[7] CAMSHAFT .....................................................................................................................M-3
[8] FUEL CAMSHAFT ...........................................................................................................M-4
[9] FLYWHEEL......................................................................................................................M-4
2. LUBRICATING SYSTEM....................................................................................................M-5
[1] GENERAL........................................................................................................................M-5
[2] OIL PUMP........................................................................................................................M-6
[3] RELIEF VALVE................................................................................................................M-6
[4] OIL FILTER CARTRIDGE................................................................................................M-7
[5] OIL PRESSURE SWITCH ...............................................................................................M-7
3. COOLING SYSTEM............................................................................................................M-8
[1] GENERAL........................................................................................................................M-8
[2] WATER PUMP.................................................................................................................M-8
[3] THERMOSTAT ................................................................................................................M-9
[4] RADIATOR (not included in the basic engine).................................................................M-9
[5] RADIATOR CAP ............................................................................................................M-10
4. INTAKE / EXHAUST SYSTEM........................................................................................ M-11
[1] AIR CLEANER (not included in the basic engine) .........................................................M-11
[2] MUFFLER (not included in the basic engine) ................................................................M-11
5. FUEL SYSTEM .................................................................................................................M-12
[1] GENERAL......................................................................................................................M-12
[2] INJECTION PUMP.........................................................................................................M-12
(1) Pump Element ..........................................................................................................M-13
(2) Delivery Valve...........................................................................................................M-13
(3) Dumping Valve .........................................................................................................M-14
(4) Injection Control........................................................................................................M-14
[3] INJECTION NOZZLE.....................................................................................................M-15
[4] FUEL FILTER (not included in the basic engine)...........................................................M-15
[5] GOVERNOR ..................................................................................................................M-16
6. ELECTRICAL SYSTEM....................................................................................................M-18
[1] CHARGING SYSTEM....................................................................................................M-18
(1) Alternator ..................................................................................................................M-18
(2) IC Regulator..............................................................................................................M-18
7. TURBO CHARGER SYSTEM...........................................................................................M-19
(1) Mechanism ...............................................................................................................M-20
(2) Turbine......................................................................................................................M-21
(3) Compressor ..............................................................................................................M-21
(4) Bearing .....................................................................................................................M-22
(5) Seals (Piston Rings) .................................................................................................M-23

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M-4

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M-5

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M-8

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M-9

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M-11

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M-12

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M-13

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M-14

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M-15

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M-16

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M-18

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M-20

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M-22

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M-23

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DIESEL ENGINE V2003-T-B/F2503-T-B

S

V
N

G. GENERAL.....................................................S-1

[3] PISTON AND CONNECTING ROD............S-52

[1] ENGINE IDENTIFICATION...........................S-1

[4] CRANKSHAFT............................................S-56

(1) Model Name and Engine Serial Number .......S-1

[5] CYLINDER..................................................S-61

(2) Cylinder Number......................................S-1

2. LUBRICATING SYSTEM.............................S-62

[2] GENERAL PRECAUTION............................S-2

CHECKING.......................................................S-62

[3] TIGHTENING TORQUES.............................S-3

SERVICING ......................................................S-63

(1) Tightening torques for special use

[1] OIL PUMP...................................................S-63

screws,bolts and nuts .......S-3

3. COOLING SYSTEM.....................................S-64

(2) Tightening torques for general use

CHECKING.......................................................S-64

screws,bolts and nuts .......S-3

[1] FAN BELT...................................................S-64

[4] TROUBLESHOOTING..................................S-4

[2] RADIATOR .................................................S-64

[5] SERVICING SPECIFICATIONS ...................S-7

DISASSEMBLING AND ASSEMBLING............S-65

(1) Engine Body............................................S-7

4. FUEL SYSTEM............................................S-67

(2) Lubricating System................................S-12

CHECKING AND ADJUSTING.........................S-67

(3) Cooling System .....................................S-12

[1] INJECTION PUMP......................................S-67

(4) Fuel System...........................................S-13

[2] INJECTION NOZZLE..................................S-69

(5) Electrical System...................................S-14

DISASSEMBLING AND ASSEMBLING............S-70

[6] MAINTENANCE CHECK LIST....................S-15

[1] INJECTION PUMP......................................S-70

[7] CHECK AND MAINTENANCE....................S-16

[2] INJECTION NOZZLE..................................S-70

(1) Daily Check Points ................................S-16

5. ELECTRICAL SYSTEM...............................S-71

(2) Check Point of Every 50 hours..............S-17

CHECKING.......................................................S-71

(3) Check Point of Every 100 hours............S-18

[1] STARTER...................................................S-71

(4) Check Point of Every 150 / 200 hours...S-19

[2] GLOW PLUG..............................................S-72

(5) Check Point of Every 400 hours............S-19

DISASSEMBLING AND ASSEMBLING............S-72

(6) Check Point of Every 800 hours............S-20

[1] STARTER...................................................S-72

(7) Check Point of Every 2 years................S-21

[2] ALTERNATOR............................................S-73

[8] SPECIAL TOOLS........................................S-22

SERVICING ......................................................S-76

1. ENGINE BODY............................................S-28

[1] STARTER...................................................S-76

CHECKING AND ADJUSTING.........................S-28

[2] ALTERNATOR............................................S-78

DISASSEMBLING AND ASSEMBLING............S-31

[1] DRAINING WATER AND OIL.....................S-32
[2] EXTERNAL COMPONENTS......................S-33
[3] CYLINDER HEAD AND VALVES ...............S-34
[4] GEAR CASE...............................................S-36
[5] PISTON AND CONNECTING ROD............S-39
[6] FLYWHEEL AND CRANKSHAFT...............S-42
SERVICING ......................................................S-44
[1] CYLINDER HEAD.......................................S-44
[2] TIMING AND CAMSHAFT..........................S-50

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S-17

S-17

S-67
S-69

S-28

S-38
S-54, 61
S-20
S-71

S-18

S-69
S-69
S-30
S-30
S-30

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S-16
S-54, 61
S-67
S-29

S-21
S-18
S-69
S-67
S-69
S-28
S-29
S-29
S-18
S-30

S-54
S-54
S-54
S-46
S-56, 57
58, 59

S-69

S-5

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S-45

S-58, 59
S-57
S-49

S-62, 63

S-19
S-18
S-16
S-65
S-67

S-64
S-80

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