Universal M-25 - Starter and Injection System Issues

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TROUBLESHOOTING

Crankshaft does

not

turn.

Crankshaft turns.

170

No or small fuel injection

sounds.

Fuel injection sounds.

Main Page

Contents5
Specifications7
Engine Specifications24
Bolt Torques40
Tightening Bolts of Important Parts40
Preventive Maintenance45
General Warnings46
Applying Grease to Oil Seal46
Direction of Installing Circlips46
Maintenance Check List47
Points of Inspection and Changing48
Engine Lubricating Oil48
Checking Engine Oil Level48
Changing Engine Oil48
Changing Engine Oil Filter Cartridge49
Inspection of Fuel Filter49
Oil Filter Cartridge49
Venting the Fuel System50
Construction and Function51
Cylinder Block52
Cylinder Head52
Crankshaft53
Piston and Piston Rings54
Connecting Rods54
Camshaft and Fuel Camshaft55
Rocker Arm Assembly55
Inlet and Exhaust Valves56
Flywheel56
Lubrication, Cooling and Fuel Systems57
Lubrication System58
Engine Oil Flow59
Relief Valve60
By-Pass Valve60
Oil Switch61
Oil Pump61
Water Pump62
Thermostat62
Fuel System67
Fuel Filter67
Fuel Pump68
Fuel Injection Pump68
Fuel Pressure-Feed69
Injection Control70
Injection Zero70
Injection Medium70
Injection Maximum70
Delivery Valve71
Pump Element71
Control Rack71
Tappet71
Injection Nozzle72
Governor73
At Start73
At Idling73
At Middle/High Speed Running74
At High Speed Running with Overload75
To Stop Engine75
Electrical System77
Wiring Diagram78
General Information79
Alternator80
Alternator Sense81
Battery Sense81
Alternator Schematic Diagrams81
Integral Voltage Regulator82
Internal Regulator82
Typical Performance Curves82
Alternator Excitation83
Alternator Installation83
Alternator Rear Housing Rotation83
Belt Installation, Alignment & Tensioning84
Ammeter84
Ammeter Charge & Discharge Circuit84
Alternator/Regulator Test Procedure85
Preliminary Checks & Tests85
Test Equipment Requirement85
Storage Battery85
Troubleshooting Guide86
Test Procedure86
Integral Regulator Systems86
Problem Area Determination Section87
Battery Undecharged87
Battery Overcharged87
Alternator/Regulator Tests88
Open Diode-Trio Test88
Open Regulator Test88
Harness Voltage Test89
Alternator Output Test89
Cable Harness Voltage Test89
Alternator Terminal Identification90
Alternator Repair Procedure93
Alternator Troubleshooting93
Removing Back Cover93
Remove Brush Holder94
Inspect and Test Brush Assembly94
Remove Integral Voltage Regulator95
Test Diode Trio Assembly96
Test Diode Rectifier Bridge Assembly96
Separate Stator/Rear Housing Assy. from Front Housing97
Inspect Rear Housing97
Test Stator97
Remove Pulley, Fan and Spacer98
Separate Rotor from the Front Housing98
Remove Front Bearing from Housing99
Inspect Front Housing99
Rotor Inspection and Electrical Testing99
Current Draw or Resistance of the Winding99
Grounded Slip Ring or Winding100
Condition of Slip Rings100
Rotor Shaft and Pole Pieces100
Remove Slip Rings from Rotor Assembly101
Remove Rear Bearing from Rotor101
Alternator Reassembly102
Install Rear Bearing102
Install Slip Ring Assembly103
Install Front Bearing103
Assemble Rotor and Front Housing104
Assembly Spacer, Fan and Pulley104
Assembly Front & Rear Housing104
Install Diode Rectifier Bridge and Diode Trio104
Install Brush Assembly105
Install Rear Cover105
Alternator Performance105
Cranking System106
Minimum Acceptable Output Values106
Starter106
When Start Button Is Pushed107
When Contact Plate Is Closed107
Glow Plugs108
When Push Button Is Released108
Disassembly and Reassembly109
Removing Head Cover112
Removing Injection Pipes 1,2 and 3112
Removing Nozzle Holder Assemblies113
Removing AC Dynamo113
Removing Rocker Arm114
Removing Push-Rod114
Removing Cylinder Heads115
Removing Cylinder Head Gasket115
Removing O-Ring116
Removing Tappets116
Nozzle Holder117
Removing Valves117
Disassembling Nozzle Holder117
Injection Pump118
Removing Injection Pump Cover118
Removing Injection Pump118
Gear Case, Timing Gear, Camshaft, Oil Pump119
Detaching Governor Spring119
Removing Speed Control Plate119
Detaching Start Spring120
Removing Fan Drive Pulley120
Removing Gear Case121
Removing Crankshaft Oil Slinger121
Removing Idle Gear122
Removing Camsahft Stopper122
Removing Gear and Camshaft123
Removing Fork Lever Assembly123
Camshaft Assembly123
Fork Lever Assembly123
Removing Fuel Camshaft124
Removing Oil Pump Drive Gear124
Removing Oil Pump125
Removing Crank Gear125
Oil Pump Assembly125
13T Gear125
Piston, Crankshaft126
Removing Oil Pan126
Removing Oil Filter 1126
Removing Connecting Rod Cap127
Removing Pistons127
Removing Flywheel128
Removing Bearing Case Cover128
Removing Bearing Case Bolt 2129
Removing Crankshaft129
Removing Main Bearing Case130
Removing Cylinder Bearing130
Thermostat, Water Pump131
Removing Thermostat131
Removing Water Pump132
Checking Flatness of Cylinder Head Surface132
Checking Flaw of Cylinder Head Surface133
Repairing the Valve Seat134
Checking Valve Recessing134
Checking Guide Clearance135
Checking Valve Spring Free Length135
Checking Valve Spring Squareness136
Checking Valve Spring Tension136
Checking Oil Clearance between Rocker Arm Shaft and Bushing137
Checking Top Clearance137
Adjusting Valve Clearance138
Adjusting Compression Release138
Testing Opening Pressure of Nozzle139
Checking Fuel Tightness of Nozzle Valve Seat139
Checking Shape of Fumes Across Nozzle Tip140
Checking Fuel Tightness of Fuel Injection Pump Plunger140
Adjustment of Injection140
Checking Fuel Tightness of Delivery Valve of Fuel Injection Pump141
Choking and Adjusting Injection Timing142
Timing Gears, Camshaft143
Checking Oil Clearance of Camshaft143
Checking Camshaft Alignment143
Checking Cam Heights of Intake and Exhaust144
Checking Gear Backlash144
Testing Oil Pressure145
Checking Radial Clearance between Outer Rotor and Pump Body146
Checking End Clearance between Rotor and Cover146
Piston, Connecting Rod147
Checking Inside Diameter of Piston Bosses147
Checking Clearance between Piston Pin and Small End Bushings147
Checking Piston Ring Clearance148
Checking Side Clearance of Ring in Groove148
Checking Connecting Rod Alignment149
Checking Crankshaft Alignment149
Cylinder Liner152
Checking Wear of Cylinder Liner152
Reference153
Undersize and Oversize153
Replacing Valves Guides154
Replacing Rocker Arm Bushings154
Replacing Idle Gear Bushings155
Replacing Small End Bushings155
Replacing Crankshaft Bearing 1156
Dynamo and Regulator157
Battery158
Checking Battery Charging Current158
Checking AC Dynamo's no Load Voltage158
Starter and Glow Plug159
No Load Testing of Starter159
Motor Test160
Checking Magnet Switch Function160
Checking Magnet Switch - Holding Coil161
Checking Magnet Switch - Plunger Return161
Checking for Breakage and Short-Circuit of Glow Plug162
Disassembly of Starter162
Removing Magnet Switch162
Removing Armature Brake163
Removing End Frame163
Removing Brush Holder164
Removing Yoke164
Removing Armature164
Servicing Starter165
Checking and Adjusting Pinion Gap165
Checking Gap between Shaft and Brush166
Grounding Armature Coil166
Diameters of Shaft and Bushing166
Checking Commutator Wear167
Staining or Burning of Commutator168
Checking Mica168
Checking for Field Coil Breakage169
Checking Insulation between Field Coil and Yoke169
Checking for Brush Wear170
Checking Brush Spring170
Grounding of Brush Holder171
Troubleshooting172

Universal M-25 - Starter and Injection System Issues

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