Universal M-25XP Manuals

Manuals and User Guides for Universal M-25XP. We have 1 Universal M-25XP manual available for free PDF download: Service Manual

Universal M-25XP Service Manual (185 pages)

Brand: Universal | Category: Engine | Size: 19.85 MB

Contents
5
Specifications
7
Engine Specifications
24
Bolt Torques
40
Tightening Bolts of Important Parts
40
Preventive Maintenance
45
General Warnings
46
Applying Grease to Oil Seal
46
Direction of Installing Circlips
46
Maintenance Check List
47
Points of Inspection and Changing
48
Engine Lubricating Oil
48
Checking Engine Oil Level
48
Changing Engine Oil
48
Changing Engine Oil Filter Cartridge
49
Inspection of Fuel Filter
49
Oil Filter Cartridge
49
Venting the Fuel System
50
Construction and Function
51
Cylinder Block
52
Cylinder Head
52
Crankshaft
53
Piston and Piston Rings
54
Connecting Rods
54
Camshaft and Fuel Camshaft
55
Rocker Arm Assembly
55
Inlet and Exhaust Valves
56
Flywheel
56
Lubrication, Cooling and Fuel Systems
57
Lubrication System
58
Engine Oil Flow
59
Relief Valve
60
By-Pass Valve
60
Oil Switch
61
Oil Pump
61
Water Pump
62
Thermostat
62
Fuel System
67
Fuel Filter
67
Fuel Pump
68
Fuel Injection Pump
68
Fuel Pressure-Feed
69
Injection Control
70
Injection Zero
70
Injection Medium
70
Injection Maximum
70
Delivery Valve
71
Pump Element
71
Control Rack
71
Tappet
71
Injection Nozzle
72
Governor
73
At Start
73
At Idling
73
At Middle/High Speed Running
74
At High Speed Running with Overload
75
To Stop Engine
75
Electrical System
77
Wiring Diagram
78
General Information
79
Alternator
80
Alternator Sense
81
Battery Sense
81
Alternator Schematic Diagrams
81
Integral Voltage Regulator
82
Internal Regulator
82
Typical Performance Curves
82
Alternator Excitation
83
Alternator Installation
83
Alternator Rear Housing Rotation
83
Belt Installation, Alignment & Tensioning
84
Ammeter
84
Ammeter Charge & Discharge Circuit
84
Alternator/Regulator Test Procedure
85
Preliminary Checks & Tests
85
Test Equipment Requirement
85
Storage Battery
85
Troubleshooting Guide
86
Test Procedure
86
Integral Regulator Systems
86
Problem Area Determination Section
87
Battery Undecharged
87
Battery Overcharged
87
Alternator/Regulator Tests
88
Open Diode-Trio Test
88
Open Regulator Test
88
Harness Voltage Test
89
Alternator Output Test
89
Cable Harness Voltage Test
89
Alternator Terminal Identification
90
Alternator Repair Procedure
93
Alternator Troubleshooting
93
Removing Back Cover
93
Remove Brush Holder
94
Inspect and Test Brush Assembly
94
Remove Integral Voltage Regulator
95
Test Diode Trio Assembly
96
Test Diode Rectifier Bridge Assembly
96
Separate Stator/Rear Housing Assy. from Front Housing
97
Inspect Rear Housing
97
Test Stator
97
Remove Pulley, Fan and Spacer
98
Separate Rotor from the Front Housing
98
Remove Front Bearing from Housing
99
Inspect Front Housing
99
Rotor Inspection and Electrical Testing
99
Current Draw or Resistance of the Winding
99
Grounded Slip Ring or Winding
100
Condition of Slip Rings
100
Rotor Shaft and Pole Pieces
100
Remove Slip Rings from Rotor Assembly
101
Remove Rear Bearing from Rotor
101
Alternator Reassembly
102
Install Rear Bearing
102
Install Slip Ring Assembly
103
Install Front Bearing
103
Assemble Rotor and Front Housing
104
Assembly Spacer, Fan and Pulley
104
Assembly Front & Rear Housing
104
Install Diode Rectifier Bridge and Diode Trio
104
Install Brush Assembly
105
Install Rear Cover
105
Alternator Performance
105
Cranking System
106
Minimum Acceptable Output Values
106
Starter
106
When Start Button Is Pushed
107
When Contact Plate Is Closed
107
Glow Plugs
108
When Push Button Is Released
108
Disassembly and Reassembly
109
Removing Head Cover
112
Removing Injection Pipes 1,2 and 3
112
Removing Nozzle Holder Assemblies
113
Removing AC Dynamo
113
Removing Rocker Arm
114
Removing Push-Rod
114
Removing Cylinder Heads
115
Removing Cylinder Head Gasket
115
Removing O-Ring
116
Removing Tappets
116
Nozzle Holder
117
Removing Valves
117
Disassembling Nozzle Holder
117
Injection Pump
118
Removing Injection Pump Cover
118
Removing Injection Pump
118
Gear Case, Timing Gear, Camshaft, Oil Pump
119
Detaching Governor Spring
119
Removing Speed Control Plate
119
Detaching Start Spring
120
Removing Fan Drive Pulley
120
Removing Gear Case
121
Removing Crankshaft Oil Slinger
121
Removing Idle Gear
122
Removing Camsahft Stopper
122
Removing Gear and Camshaft
123
Removing Fork Lever Assembly
123
Camshaft Assembly
123
Fork Lever Assembly
123
Removing Fuel Camshaft
124
Removing Oil Pump Drive Gear
124
Removing Oil Pump
125
Removing Crank Gear
125
Oil Pump Assembly
125
13T Gear
125
Piston, Crankshaft
126
Removing Oil Pan
126
Removing Oil Filter 1
126
Removing Connecting Rod Cap
127
Removing Pistons
127
Removing Flywheel
128
Removing Bearing Case Cover
128
Removing Bearing Case Bolt 2
129
Removing Crankshaft
129
Removing Main Bearing Case
130
Removing Cylinder Bearing
130
Thermostat, Water Pump
131
Removing Thermostat
131
Removing Water Pump
132
Checking Flatness of Cylinder Head Surface
132
Checking Flaw of Cylinder Head Surface
133
Repairing the Valve Seat
134
Checking Valve Recessing
134
Checking Guide Clearance
135
Checking Valve Spring Free Length
135
Checking Valve Spring Squareness
136
Checking Valve Spring Tension
136
Checking Oil Clearance between Rocker Arm Shaft and Bushing
137
Checking Top Clearance
137
Adjusting Valve Clearance
138
Adjusting Compression Release
138
Testing Opening Pressure of Nozzle
139
Checking Fuel Tightness of Nozzle Valve Seat
139
Checking Shape of Fumes Across Nozzle Tip
140
Checking Fuel Tightness of Fuel Injection Pump Plunger
140
Adjustment of Injection
140
Checking Fuel Tightness of Delivery Valve of Fuel Injection Pump
141
Choking and Adjusting Injection Timing
142
Timing Gears, Camshaft
143
Checking Oil Clearance of Camshaft
143
Checking Camshaft Alignment
143
Checking Cam Heights of Intake and Exhaust
144
Checking Gear Backlash
144
Testing Oil Pressure
145
Checking Radial Clearance between Outer Rotor and Pump Body
146
Checking End Clearance between Rotor and Cover
146
Piston, Connecting Rod
147
Checking Inside Diameter of Piston Bosses
147
Checking Clearance between Piston Pin and Small End Bushings
147
Checking Piston Ring Clearance
148
Checking Side Clearance of Ring in Groove
148
Checking Connecting Rod Alignment
149
Checking Crankshaft Alignment
149
Cylinder Liner
152
Checking Wear of Cylinder Liner
152
Reference
153
Undersize and Oversize
153
Replacing Valves Guides
154
Replacing Rocker Arm Bushings
154
Replacing Idle Gear Bushings
155
Replacing Small End Bushings
155
Replacing Crankshaft Bearing 1
156
Dynamo and Regulator
157
Battery
158
Checking Battery Charging Current
158
Checking AC Dynamo's no Load Voltage
158
Starter and Glow Plug
159
No Load Testing of Starter
159
Motor Test
160
Checking Magnet Switch Function
160
Checking Magnet Switch - Holding Coil
161
Checking Magnet Switch - Plunger Return
161
Checking for Breakage and Short-Circuit of Glow Plug
162
Disassembly of Starter
162
Removing Magnet Switch
162
Removing Armature Brake
163
Removing End Frame
163
Removing Brush Holder
164
Removing Yoke
164
Removing Armature
164
Servicing Starter
165
Checking and Adjusting Pinion Gap
165
Checking Gap between Shaft and Brush
166
Grounding Armature Coil
166
Diameters of Shaft and Bushing
166
Checking Commutator Wear
167
Staining or Burning of Commutator
168
Checking Mica
168
Checking for Field Coil Breakage
169
Checking Insulation between Field Coil and Yoke
169
Checking for Brush Wear
170
Checking Brush Spring
170
Grounding of Brush Holder
171
Troubleshooting
172

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