Nanni Marine Diesel Engine5.250 TDI Workshop Manual 60300077 - PDF DOWNLOAD

WORKSHOP MANUAL ENGINE BASE

5.250 TDI

NANNI INDUSTRIES S.A.S – Zone Industrielle 11 avenue MARIOTTE B.P.107 – 33260 LA TESTE - FRANCE 60 300 077

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

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1

CONTENTS

2

CONTENTS

3

CONTENTS

4

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45

CONTENTS

65

CONTENTS

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

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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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CONTENTS

M-1

INDEX

M-2

INDEX

M-3

INDEX

M-4

INDEX

M-5

INDEX

M-6

INDEX

M-7

INDEX

M-8

INDEX

M-9

INDEX

M-10

INDEX

M-11

INDEX

M-12

INDEX

M-13

INDEX

M-14

INDEX

M-15

INDEX

M-16

INDEX

M-17

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M-18

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M-19

INDEX

M-20

INDEX

M-21

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M-22

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M-23

INDEX

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

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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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CONTENTS

S-1

INDEX

S-2

INDEX

S-3

INDEX

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

S-4

INDEX

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

INDEX

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

S-6

INDEX

S-7

INDEX

S-8

INDEX

S-9

INDEX

S-10

INDEX

S-11

INDEX

S-12

INDEX

S-13

INDEX

S-14

INDEX

S-15

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S-16

INDEX

S-17

INDEX

S-18

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S-19

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INDEX

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INDEX

S-27

INDEX

S-28

INDEX

S-29

INDEX

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S-31

INDEX

S-32

INDEX

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INDEX

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INDEX

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INDEX

S-37

INDEX

S-38

INDEX

S-39

INDEX

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INDEX

S-41

INDEX

S-42

INDEX

S-43

INDEX

S-44

INDEX

S-45

INDEX

S-46

INDEX

S-47

INDEX

S-23

S-48

INDEX

S-49

INDEX

S-50

INDEX

S-51

INDEX

S-52

INDEX

S-53

INDEX

S-54

INDEX

S-55

INDEX

S-56

INDEX

S-57

INDEX

S-58

INDEX

S-59

INDEX

S-60

INDEX

S-61

INDEX

S-62

INDEX

S-63

INDEX

S-64

INDEX

S-65

INDEX

S-66

INDEX

S-67

INDEX

S-68

INDEX

S-69

INDEX

S-70

INDEX

S-71

INDEX

S-72

INDEX

S-73

INDEX

S-74

INDEX

S-75

INDEX

S-76

INDEX

S-77

INDEX

S-78

INDEX

S-79

INDEX

S-80

INDEX