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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

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

2

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

5

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

6

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

S-0

1

CONTENTS

2 CONTENTS .

3 CONTENTS .

4 CONTENTS .

45 CONTENTS .

65 CONTENTS .

.............M-8 [3] THERMOSTAT .............................................................................................................................................M-8 [2] WATER PUMP..................................................................................................................................................................................................................M-3 [7] CAMSHAFT .......................................................................................M-23 M-0 CONTENTS .....................M-15 [4] FUEL FILTER (not included in the basic engine)...............................M-2 [5] CONNECTING ROD.......................M-22 (5) Seals (Piston Rings) ............................................................................................................... ENGINE BODY ..............................................M-21 (4) Bearing .................................................................................M-12 [1] GENERAL.......................................M-7 3....................................................M-11 [2] MUFFLER (not included in the basic engine) ........................................................................M-10 4................................................................................................................................... LUBRICATING SYSTEM..........................................................................................................................................M-9 [5] RADIATOR CAP ...................................................................................M-5 [1] GENERAL..................M-18 (2) IC Regulator.......................................................M-6 [4] OIL FILTER CARTRIDGE............................................................................................................................................................................................................................................................................................................................................................................................................................M-1 [2] CYLINDER HEAD........................................................................................................................... M-11 [1] AIR CLEANER (not included in the basic engine) .M-13 (2) Delivery Valve...................................................................................M-13 (3) Dumping Valve .............M-9 [4] RADIATOR (not included in the basic engine)..........................................................................................................................M-19 (1) Mechanism ...........................................................................................................................................................M-7 [5] OIL PRESSURE SWITCH ...............M-15 [5] GOVERNOR ...........................................M-20 (2) Turbine......................................M-14 (4) Injection Control..........................................M-14 [3] INJECTION NOZZLE..........................................................................M-5 [2] OIL PUMP..........................M-3 [8] FUEL CAMSHAFT ........................M-3 [6] ROCKER ARM.....................................................................................................................................................M-18 [1] CHARGING SYSTEM.................................................................................................................................................................. INTAKE / EXHAUST SYSTEM...............................................................................................................................................................................................................................................................................................................................................................................M-6 [3] RELIEF VALVE................ TURBO CHARGER SYSTEM.....................................................................................................M-18 (1) Alternator .............................................................................................................. FUEL SYSTEM ...M-12 [2] INJECTION PUMP........M-12 (1) Pump Element ............................................................................................................................................M-11 5..............................M-1 [1] CYLINDER BLOCK....................................................................................................................................................................................................................... ELECTRICAL SYSTEM......................M-4 [9] FLYWHEEL..............................................M-16 6.....................M-8 [1] GENERAL...............................................................................................M-2 [4] PISTON AND PISTON RINGS ................................................................................................................................................................................................................. COOLING SYSTEM.............................................................DIESEL ENGINE V2003-T-B/F2503-T-B M E C I H N A D E N X I S M 1...............................................................................................M-1 [3] CRANKSHAFT.............................................M-18 7............................M-21 (3) Compressor .........................................................................................................................................................................................M-4 2............................................

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M-23 INDEX .

.........................................S-70 (1) Daily Check Points ....................................S-7 4...S-76 1...........S-64 screws........................................................S-20 [1] STARTER................................................S-72 (7) Check Point of Every 2 years............................................S-3 [1] FAN BELT...........................S-28 [2] ALTERNATOR......S-12 CHECKING AND ADJUSTING....................S-7 DISASSEMBLING AND ASSEMBLING....................S-44 [1] CYLINDER HEAD...S-1 [4] CRANKSHAFT... COOLING SYSTEM........................................................S-17 CHECKING..........................................S-16 [2] INJECTION NOZZLE................................................................S-64 (2) Tightening torques for general use CHECKING............................ GENERAL.............................................S-67 (3) Cooling System ...S-62 [3] TIGHTENING TORQUES.........S-64 [5] SERVICING SPECIFICATIONS .........................................................................................S-71 (3) Check Point of Every 100 hours........S-1 [3] PISTON AND CONNECTING ROD..........................S-39 [6] FLYWHEEL AND CRANKSHAFT.....................................S-71 (2) Check Point of Every 50 hours..S-3 3...............S-22 SERVICING ..........S-70 [6] MAINTENANCE CHECK LIST................................S-16 5...............S-67 (4) Fuel System.....S-72 (6) Check Point of Every 800 hours...........................................S-42 SERVICING ................................S-61 (2) Cylinder Number......S-73 [8] SPECIAL TOOLS.................................................................................................bolts and nuts .........................S-3 SERVICING .........S-1 [5] CYLINDER................................................................................. ELECTRICAL SYSTEM.............DIESEL ENGINE V2003-T-B/F2503-T-B S E R I V N I D C E X I N G G....S-34 [4] GEAR CASE.................S-63 screws...........................S-78 DISASSEMBLING AND ASSEMBLING.......................................................S-56 (1) Model Name and Engine Serial Number .......S-19 DISASSEMBLING AND ASSEMBLING.................................................S-72 (5) Check Point of Every 400 hours......S-2 CHECKING..........................................................S-1 2............S-67 (2) Lubricating System...............S-15 [1] INJECTION PUMP......................S-14 DISASSEMBLING AND ASSEMBLING.......S-44 [2] TIMING AND CAMSHAFT................................................S-50 S-0 CONTENTS ..............................S-52 [1] ENGINE IDENTIFICATION..............................................................S-32 [2] EXTERNAL COMPONENTS............... ENGINE BODY...................S-70 [7] CHECK AND MAINTENANCE.....................................S-19 [2] GLOW PLUG............S-63 (1) Tightening torques for special use [1] OIL PUMP.................................................................S-31 [1] DRAINING WATER AND OIL..S-62 [2] GENERAL PRECAUTION.....S-76 CHECKING AND ADJUSTING..................................S-65 (1) Engine Body...............................................S-12 [1] INJECTION PUMP......................S-21 [2] ALTERNATOR..S-33 [3] CYLINDER HEAD AND VALVES ......................................................S-69 (5) Electrical System..........................................................S-36 [5] PISTON AND CONNECTING ROD..................bolts and nuts ...........................................................S-13 [2] INJECTION NOZZLE................S-28 [1] STARTER..............................S-18 [1] STARTER..........S-4 [2] RADIATOR .............. FUEL SYSTEM.....................................S-64 [4] TROUBLESHOOTING................... LUBRICATING SYSTEM..S-71 (4) Check Point of Every 150 / 200 hours...................

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S-2 INDEX .

S-3 INDEX .

61 S-20 S-71 S-18 S-69 S-69 S-30 S-30 S-30 S-4 INDEX .S-17 S-17 S-67 S-69 S-28 S-38 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 INDEX .S-16 S-54.

S-45 S-58. 63 S-19 S-18 S-16 S-65 S-67 S-64 S-80 S-6 INDEX . 59 S-57 S-49 S-62.

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