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Universal M12 Workshop Manual

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This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanisms, service and maintenance of Universal Diesel
Engines Models 12, 18 & 25.The basic block is manufactured by Kubota to
Universal specs. It is divided into two parts, "Mechanisms" and "Disassembly
and Servicing."
B
Mechanisms
Information on construction and functions is included for each engine section.
This part should be understood before proceeding to troubleshooting, disas­
sembly or servicing.
B
Di sassemb ly a nd Servicing
Under the heading "General" come general precautions, troubleshooting, lists
of servicing specifications and periodic inspection items.
section, there are "Checking and Adjustment," "Disassembly and Assembly,"
and "Servicing" which cover procedures, precautions, factory specifications
and allowable limits.
All information, illustrations and specifications contained in this manual are
based on the latest production information available at the time of publication.
The right is reserved to make changes in all information at any time without
notice.
TO THE READER
1
For each engine

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  • Page 1: Lub R I C At I N G Syste

    This Workshop Manual has been prepared to provide servicing personnel with information on the mechanisms, service and maintenance of Universal Diesel Engines Models 12, 18 & 25.The basic block is manufactured by Kubota to Universal specs. It is divided into two parts, "Mechanisms" and "Disassembly and Servicing." Mechanisms Information on construction and functions is included for each engine section.

  • Page 2: Table Of Contents

    F E ATUR E E NG I N E BODY Cylinder Block ....7 Cylinder Head ..... 7 Crankshaft......8 [ 4] Piston and Piston Ring ....8 CONTENTS Connecting Rod ....8 Camshaft and Fuel Camshaft ..9 Rocker Arm Assembly ....
  • Page 4 4.00 to 4.05 ID.1575 to 0.1594) 16.000 HS to 16.027 HS dia. I0.6299 HS to 0.6310 HS dia.) 25.4 dia. 11.00 dia.) 106.000 HS to 106.054 HS dia. · 14.1732 HS to 4.1754 HS dia.) 1210.471 SI0.31) � 6.5 10.261 - 4.5 10.1 SI 1 1/11.'!Fi!ll.'J 4.00 to 4.05...
  • Page 5 FEATURE IJJIJ9FOJ I 12 , 18 & 25 Models are vertical, water-cooled, 4-cycle diesel engines. UNIVERSA L'S They incorporate foremost tech­ UN IVERSA L'S nologies. With spherical combustion chamber, well-known Bosch mini type injection pump and the well-balanced design, they give greater power, fuel consumption,...
  • Page 6 l)fl).'JFl!l:!

  • Page 7: Engine Body

    ENGINE BODY [ 1 ] CY L I N D E R B LOCK The e n g i n e has a h ig h l y d u r a b l e tu n n e l -type cy l i nder block i n which the bea r i ngs, pistons, cran kshaft a n d camshafts are insta l led .

  • Page 8: Crankshaft

    [ 3 ] C RA N K S H A F T T h e cra nk shaft with t h e connecti ng rod converts t h e rec ipro­ cat i n g m otion of the p i ston i nto rotating motion to d river the o i l pu m p a nd camshafts.

  • Page 9: Camshaft And Fuel Camshaft

    CAMS H A FT A N D FUE L CAM S H A FT The cams on the camshaft ( 1 ) cause the i n l et and exhaust valves to open as the camshaft rotates. The journals and the beari ngs are force-l u bricated .

  • Page 10: Inlet And Exhaust Valves

    [8 ] I N L ET A N D E X H AUST V A L V E S T h e valve a n d its gu ide for t h e i nl et a re d ifferent from those for the exhaust.

  • Page 13: Oil Pump

    ----- O I L PUM P The oil pump is a gear pump, whose rotors have trochoid lobes_ The inner rotor lobes and the outer rotor ( 3) lobes, and they are eccentrically engaged with each other. The inner rotor, which is driven by the crankshaft through the gears, rotates the outer rotor in the same di­...

  • Page 15: Cooling System

    COOLING SYSTEM The cooling system consists of a radiator (not included in ( 1 ) a basic model), a centrifugal water pump a suction fan ( 4), ( 2 ) and a thermostat ( 3 ) . The water i s cooled through the radiator core, and the tar: behind the radiator pulls the cooling air through the core to improve cooling.

  • Page 16: Thermostat

    T H E RMOSTAT The thermostat is of the wax pellet type. The thermostat controls the flow of the cooling water to the radiator to keep the proper temperature. The case, which serves as a valve seat has a spindle in­ ( 1 ) , serted in the pellet which is installed to the valve...

  • Page 17: Radiator

    [ 3] RA D I AT O R The radiator core consists of water carrying tubes ( 1 ) fins at a right angle to the tubes. The fin is a louverless, ( 2) corrugated type which is light in weight, high in heat ex­ change ratio and less apt to clog.

  • Page 18: Fuel System

    FUEL SYSTEM IJW9FIJ32 T he fuel is fed from the fuel t a n k ( 1 ) ( not incl uded in the F u e l Tan k basic model) t h rough the fuel fi lter ( 6 ) to the i njection pump (2) F u e l Overf low P ipe ( 5) by the fuel feed p u m p ( 7) (in the basic model) .

  • Page 19: Fuel Filter

    F U EL F ILT E R The fuel f i l te r is i nstal led i n the fuel l ne from the fuel tank to the i njection p u m p ( between the tank and the feed p u m p i n the basic m ode l ) .

  • Page 20: Fuel Feed Pump

    [2] F U EL F E E D PUMP The fi ltered fue l is fed to the i nject i o n p u m p b y t h e fuel fed p u m p . T h e chamber ( 1 ) i s encl osed with the i n let valve ( 2 ) , the out­ let va lve ( 5 ) and the d ia p h ragm ( 6) , wh ich is l i n ked to the rocker arm with the pu l l rod ( 7 ).

  • Page 21: Fuel Injection Pump

    [3] F U E L I NJ E CT I O N PUMP The i njection pu m p is a Bosch M D type m i n i -i njection p u m p , which gives high i nject ion q u a l ity even a t l o w engine speeds. The p l u nger is reciprocated by the cam on the camshaft with the tappet and forces the fuel i nto the injectio n nozzle.
  • Page 22 2 ) Del ivery V alve The d e l ivery valve consists of the va lve ( 1 ) and the V a lve seat ( 2 ) . The d e l ivery valve p revents the fuel from flowing back i nto the d e l ivery chamber through the i njectio n p ipe.

  • Page 23: Governor

    4 ) Plunger Position N o fuel del ivery At the engine stop position of the control rack ( 3) , the lengthw ise slot ( 1 ) on the p l u nger ( 2 ) a l igns w ith the feed A nd the del ivery c h am ber ( 4) is led to the feed hole ( 5 ) .
  • Page 24 At start The steel ba l l ( 4) h as no centrifugal force. F ork lever 1 ( 2 ) is p u l led by the start spring ( 1 ) and the control rack (3) moves to the m a x i m u m i njection position for easy sta rt i ng.
  • Page 25 At m ed ium or high speed ru nning When the speed control lever ( 1 ) is tu rned fu rther, the gover nor sp ring ( 2) i ncreases the tens ion a nd the control rac k i�...

  • Page 26: To Stop The Engine

    To stop the engi ne When the stop l ever ( 1) is m oved to the stop position , fork l ever 1 (2) i s p u shed and the contro l rack (3) i s m ov ed to stop the fuel injection .

  • Page 27: Electrical System

    ELECTRICAL SYSTEM , � , , ' � IJ/IJ.'IFl!C The e lectrical system of the eng ine consists of a starti ng ( 1) O i l Pressure Switch system ( i ncluding a starter, glow p l ugs and other s ) , a chargi ng (2) G low P l u g system ( includi ng an AC dynamo, a reg u l ator and other s ) , (3) AC D ynamo...

  • Page 28: 1] Starting System

    [1] STA R T I N G SYSTE M Start er The starter is of the electromag netic drive type. Type o f motor DC, Series, E lectro mag netic d r ive S up p l y Vo ltage 1 2V 0.7 kW Rated output...

  • Page 29: Magnetic Switch

    ------- - -- When the starting switch is tu rned on The co ntacts of sta rting switch ( 1 ) cl ose a nd the h o l d i n g c o i l ( 3 ) is connected t o the battery to pu l l t h e p l u nger ( 5) . T h e pu l l- i n co i l ( 4) a nd t h e sta rting m otor are a l so co nnected to the battery.
  • Page 30 • When the starting switch is released The current fro m the battery flows to th e h o l d i ng co i l (1) through the p u l l- i n c o i l (2) t o d im i n i sh the m ag net ism between them.
  • Page 31 W I R I NG D I A G R AM Glow Plugs (lper cyl.) Storter L:gnt "O "' "O � � &! "' ,"O � O> a... '1l1 20Am Fuse Panel Harness WIRE No. COLOR W I RE SIZE Block -#10 Grey...

  • Page 32: Charging System

    1) AL TERNA TOR AL TERNA TOR GROUP Unit Description Item Part No. Spacer Alternator Arm 300105 Alternator Adj u sting Arm 299809 5/16 Plain Washer 231875 Was h er· Spring Lock 5/16 231891 Sere"' . Hex Head 5 . ' 16· 18x3·114 301019 V·Belr 300805...
  • Page 33 II While the engine is stopped sma l l amou nt of current is appl ied to the base of tra nsistor T2, and tra nsistor T2 turns o n, t ur n i ng on transistor T3. Tra n sistor T3 pulls u p the gate voltage of the SC R 's SC R 1 and SC R 2 .
  • Page 34 G E N E R AL Engine Identification [ 1] ....36 Cylinder Number ....36 General Precautions .

  • Page 35: Disassembly And Assembly

    ELECT R I CAL SYSTE M [ 1] Starter C H ECKING D ISASSEMBLY AND ASSEMBLY S E RVICING AC Dynamo and Regulator CHECKING CONTENTS Glow Plug CHECKING...

  • Page 36: 1] Engine Identification

    GENERAL [1 ] E N G I N E I D E N T I F I CATI ON IJ / 11.'i/'IJIJ:.! W he n contact i n g your l ocal U NIVE R SA L d i stributor, a lways s pecify the engine serial n u m ber.

  • Page 37: General Precautions

    G E N E R AL P R ECAUT I ON S • D u r i n g di sasse m b l y , carefu l ly a rrange removed parts i n a c l e a n area t o preven t con fusion l ate r. Screws, bol ts a n d n u ts s h o u l d b e rep l aced i n thei r ori g i n al position to preven t reassembly errors .

  • Page 38: 4] Tightening Torques

    [4] T I GHT E N I N G TO RQU ES Screws, bolts and n u ts must b e tigh tened t o t h e specified torque u s i n g a torque wrench . Several screws, bolts and n u ts s u c h a s th ose used on t h e cy l in der head must b e ti ghtened i n proper sequence a n d a t the proper torque.

  • Page 39: 5 ] Troubleshooting

    [5] T RO U B L E SHOOT I N G S o l u tion S y m ptom Probable Cause Reple n i s h fuel " No fuel Engine does not start • Vent air A i r in the fuel system Replace fuel and repa i r or replace fuel system "...
  • Page 40 Symptom Solu tion Probable Cause E xcessive l u bricant • Piston ring's gap fac i n g the same d i recti on S h i ft r i n g gap d i rection oil consu m p t i on O i l r i n g worn or stuck Repl ace Repl ace the p i ston...

  • Page 41: Servicing Specifications

    [6] S E R V I C I N G S P EC I F I CAT I ONS E NG I N E BODY [ Cy l i nder Head ] A l l owable L i m i t Factory Specif icat i o n I t em 0 .05 mm per 1 00 m m...
  • Page 42 [ Rocker Arm ] Factory Specif i cat ion A l l owab l e Limit Item " C learance between rocker arm 0 .0 1 6 to 0 .068 mm 0 . 1 5 m m a nd b u s h i n g (0.00063 to 0 .00268 i n .
  • Page 43 [ Crankshaft ] A l l owab l e L i m i t Factory Specification I te m 0.08 m m 0.02 mm Crankshaft a l i g n m e n t (0.00 3 1 i n . ) (0.0008 i n .

  • Page 44: Elect R I Cal Syst E M

    COOL I N G SYST E M [ Fan Belt ] Factory Specificat ion A l l owable Limit Item Belt deflection u nder load of 9 8 N 7 to 9 m m ( 1 0 kgf, 2 1 l bs ) ( 0 .28 t o 0.35 i n .

  • Page 45: Maintenance Check List

    M A I NT E N A N C E C H E C K L I ST [ 7 ] To m a inta i n lo�1g-last i ng a nd safe engine performance, make it a rule to carry o u t regu lar inspections by fo l lowin9 the table be l ow.

  • Page 46: Checking And Maintenance

    C H E C K AN D M A I N T E N A N C E [ 8 ] Checki n g Engine O i l Level 1 . Leve l the engine. 2. To check the oil leve l , d raw out the d i pstick (1 ) , wi pe it clean, re insert it, and draw it out aga i n .

  • Page 47: Bleeding Fuel System

    Chan ging Engine O i l Fi l ter Cartridge 1 . Remove the o i l fi l ter cartridge with a f i l ter wrench. 2 . Apply engine oil to the rubber gasket on the new cart ridge.
  • Page 48 Antifreeze If the coo l i n g wate r freezes, the e n gi n e cy l i nder block, cy l i nder h ead a n d radiator may crack. In col d weath e r before the temperature d rops b e l ow 0 °...

  • Page 49: Belt Tension

    Belt Tension 1. M e asure the deflection, depressi ng the belt ha lfway between the fan d r ive pu l ley and the AC dynamo p u l ley at 9 8 N ( 10 kgf, 22 lbs) of force. 2.

  • Page 50: Checki N G Compressi On Pressure

    Checki n g Compressi on Pressure 1 . Warm up th e e n g i n e and stop it. 2. Re move the air cleaner a n d the muffler. 3. R e move the n oz z l e h o l de rs from all the cyl i n de rs. 4.

  • Page 51: Special Tools

    Checking Fuel I njection Pressure 1 . Set the i njecti on n ozzle to the n ozzle tester. 2. Measure the i njection pressure . 3 . I f the measurement i s n o t w i th i n the factory specifica­ ti ons adjust with the adjusting washer i ns i de the n ozzle holder.

  • Page 53: Radi Ator Tester

    Radi ator Tester Code N o . : 07909-3 1 55 1 Appl ication: Use to check radiator cap pressu re a nd leaks from coo l i ng systems. Cof.'IFIJl>S Connecting Rod A l i gnment Tool Code N o . : 07909-3 1 66 1 Appl icati on : Use t o check the connecti n g rod a l i gn ment.

  • Page 54: I Njection Pump Pressure Tester

    Red Check (Crack check l iquid) Code No. : 07909-3 1 37 1 Appli cati on : Use to check cracks on cy l i n der h e ads, crank­ cases, etc. RC-AB ...n. NOT E : T h e f o l l owing specia l tool s are n ot p rovided, s o m a k e CO:"...

  • Page 55: Valve G Uide Replacing Tool

    Valve G uide Replacing Tool Appl i cati on : Use to press out and to press fi t the valve guide. 1 90 ( 7 .4 8 ) 80 (3 . 1 5 ) ..� "'. ci o '""-: 0 lD - �...
  • Page 56 I d le Gear Bushi n g Replacing Tool 1 50 ( 5 .9 1 ) Appl icati on : Use to press out and to press fit the idle gear bush i n g. 3 0 ( 1 . 1 8 ) 20 ( 0.79 ) 01u1ri fr: * Chamfe r...

  • Page 57: Crankshaft Bearing

    Crankshaft Bearing Replacing Tool Appl icati on : Use to press out and to press fit the cra n kshaft 1 30 15. 1 2 1 beari n g 1 . � - - - - 10 391 10.87 1 �...

  • Page 58: Engine Body

    ENGINE BODY CHE C K I N G AND ADJUST M E NT Compression Pressure 1 . R u n the engine u nt i l it is warm ed u p . 2 . Stop the engine a n d remove t h e air clea ner, t h e m uffler and a l l n oz z l e h olders.

  • Page 59: Disassembly And Assembly

    Valve Clea rance -·-·�-- - 1 . Loose n the l ock n u t and the adj u st i n g screw on the rncke1· a r m . 2. T u r n t h e adj u st i ng screw t o adju st t h e valve clearance at the top dead cente1·...

  • Page 60: 1] External Components

    E xterna l Components [ 1 ] Cool ing Wat� 1 . Open the cock ( 1 ) and d r a i n coo l i ng water. 2 . R emove the p l ug (2) and d ra i n e n g i n e o i l . Capacity M-12 1 .9...
  • Page 61 R ocker Arm and Cyl i nder Head 1 . Re m ove the grow p l u g s ( 3 ) . 2. Remove t h e rocker a rm s and shaft assembly ( 1 ) . 3 .

  • Page 62: Adjusting Valve Clearance

    Adjusting Va lve Clearance · - · - - -,·-·�---- 1 . Loosen the l ock nut and the adj usting screw on the rocker arm. 2. T u r n the adj u st i n g screw to adj u st the va Ive c leara nce at the top dead center (T.

  • Page 63: Injection Pump And Levers

    I njection Pump and Levers I njection Pump and Speed Contro l Plate 1 . Re move the socket headed screws and n uts, and remove the i njection p u m p ( 3 ) . 2 . R emove t h e screws a nd separate t h e speed co n tro l p l ate ( 2 ) , taking care not to harm t h e spring ( 4 ) .

  • Page 64: Gear Case And Flywheel

    Gear Case and F lywheel Pu l ley and Gear Case 1 . Prepare the stopper (See figure) a nd i nsta l l it to the flywhe e l so that the crankshasft does not tu r n . 2 .

  • Page 65: 5 ] Timing Gears And Camshafts

    F l ywheel ------ 1 . I n sta l l the stopper to the fl ywhee l so that the f l ywheel does not turn. 2 . R emove the screws a n d the f l ywhe e l . (When reassembling) Place the f l ywhee l washer on the fl ywh eel and i.nsta l l them t o the cra n k s h aft, not i ng t h e l ocation of the holes.
  • Page 66 Gear and Camshaft 1 . R e m ove the screws (3) and draw out the camshaft ( 4 ) with the gear o n i t . 2. R e m ove the reta i n i ng p l ate ( 1 ) . 3 .

  • Page 67: Crankshaft And Piston

    O i l Seal Sl eeve and Gear 1. Pu l l o u t the o i l sea l sleeve (2) together with the gear ( 1 ) usi ng a gear p u l l er. (When reassembling) I nsta l l the i d l e gear before i nsta l l i ng t he s l eeve ( See figure at "...
  • Page 68 Crankshaft 1 . R emove the o i l p;in ; rnd the str<i i ner . 2 . R e move the screw<; 1 ) a nd t h e connecting rod caps, a n rl push o u t t h e p istons. 3.

  • Page 69: Piston And Connecting Rod

    Main Bearing Case anti 1 . R e m ove the screws separa tf' the bea r i n g case . (When reassembling) • App l y engine o i l to the bea r i ng surface and i n sta l l the -;...

  • Page 70: S Ervicing

    S E R V I C I NG Cyl inder H ead [ 1 ] Top C learance 1 . R emove the nozzle holder and lower the piston i n the cyl i nder. 2 . I n sert a h igh-qua l ity fuse from the n ozzle holder hole on the piston except where it faces the valve or the com­...

  • Page 71: Valve And Rocker Arm

    Valve and R ocker A rm [ 2 ] Valve C learance 1 . Loosen the l ock nut and the adjust i nq snew on the rock ier arm. 2 . Tu r n the adjust i n g screw to adj u st the valve c l eara nce at the top dead center (T.

  • Page 72: Valve Seat W Idth

    Valve Seat W idth 1 . Chec k the valve seat surface a nd the w idth . 2. I f the seat wi dth is not with in the specified val ues or ( b ) is n o t equ a l to (c) ( See F igure ) , correct the v a l v e seat referring to "Correcting Valve a nd Seat".

  • Page 73: Valve Spring Squareness

    V alve Spri ng F ree L ength and Tension 1 . Measure the free l ength of the spri ng w ith vernier cal ipers. 2. P lace the spr i n g o n a spring com pre5sion tester and compress to the specified l e ngth , and get the tension.

  • Page 74: Camshaft And Timing Gear

    R ep lac i ng R ocker Arm Bush ing (When removing) 1 . Press out the rocker arm bu shing u sing a rocker arm bu shing replacing too l . • (When installing) 1 . C l ea n the rocker a rm bush ing a n d the bore, and app l y engine o i l to them .

  • Page 75: Camshaft Al Ignment

    I d le Gear O i l Clearance 1 . M ea sure the l . D . of the idle gear bush i ng w ith an inside m icrometer. 2 . Measu re the O . D . of the i d l e gea r shaft with a n outs1t1e m icrometer.

  • Page 76: Cylinder Block

    Camshaft Lobes H e ight 1 . M easure the height of the camsh aft lobes at their l argest O . D . with an outside m icrometer. 2 . I f the measurement is less than the a l lowable l i mit, replace the camshaft.

  • Page 77: Crankshaft A L Ignment

    [ 5] C ranksahft C ranksh aft E n d P l ay 1 . Set a d i a l i nd icator with its i n d icator t i p touch i ng the end of the cra n kshaft. 2.
  • Page 78 O i l C learance between Crankshaft Jou rnal and Bearing 1 1 . Measure the I . D. of the cra n kshaft bearing 1 with a n i nside m icrometer. 2 . Measure the O . D . of the crankshaft front journal with an outside m icrom eter.
  • Page 79 O i l Clearance between Crankshaft Jou rna l and Bearings 2 and 1 . Put a str ip of Plastigage l e ngthwise i n the center of the jou rna l . 2 . I n sta l l the bea r i ng cap a n d tighten the screws t o the specified torque, and remove the bea ring cap.
  • Page 80 O i l C learance between Crankpin and Connecting Rod Bearing 1 . Put a stri p o-f Plastigage lengthwise i nto the beari ng cap. , ��I 2 . I nsta l l the beari ng cap noting that the gauge may not meet with the hole on the crank pin, t ighten the screws to t he specified torque, and remove the cap.

  • Page 81: Piston And Connecting Rod

    Crankshaft S leeve 1 . Check the wear on the c ra n kshaft sleeve. 2 . If the wear exceeds the a l lowable l i m it o r when the engine o i l l ea ks, repl ace the cran kshaft s l eeve. 0 .

  • Page 82: Piston R Ing Clearance

    Piston R ing G ap � � · 1 . I nsert the p iston r i ng i nto the cyl i nder and push down to the bottom, where the wear is least, using a piston head. 2. Measure the ring gap wit h a feeler gauge. 3 .

  • Page 83: Lubricating System

    LUBRICATING SYSTEM C H EC K I N G E ng ine O i l Pressure 1 . R em ove the o i l pressure switch a nd i nsta l l the oi l pressure adaptor and the oi I pressu re tester ( Code No. : 079 1 6- 3203 1 ) .

  • Page 84: S Ervicing

    S E R V I C I N G Pump R otor and Lobe Clearance 1 . R e m ove the o i l p u m p from the cran kcase. 2. R emove the screw a nd the port p l ate . 3.

  • Page 85: Thermostat Valve Open I Ng Temperature

    COOLl l\IG SYSTEM C H EC K I N G Belt Ten sion 1 . Measure the deflectio n , depressi ng the belt ha lfway between the fan d r ive pu l ley and t he AC dynamo p u l l ey at 98 N ( 1 0 kgf, 22 lbs) of force.

  • Page 86: D Isassembly And Assembly

    R ad iator Cap Openi ng Pressu re 1 . Set a radiator tester on the radi ator cap. 2 . Apply the pressure of 88 kPa (0.9 kgf/cm 2 , 1 3 psi ) and m easure the t i m e for the pressure to fal l to 59 kPa 0.6 kgf/cm 2 , 9 psi ) .

  • Page 87: Fuel System

    FUEL SYSTEM C H ECK I NG AND ADJ U ST M ENT [ 1 ] I njection Pump I njection T i m ing -- - · ·-· --�--- 1 . R e m ove the injection pipes. 2. Set the speed control lever to the m a x i m u m fuel d ischa rge position.
  • Page 88 Pump E lement F uel T ightness 1 . I n sta l l the p ressure tester ( See p age S- 5 1 ) to the fuel i n­ jection pump. 2. With the speed con tr o l lever a t t he max i m u m p osition of the fuel i njection, rotate the fl ywheel to raise the fuel pressure to 39.23 M Pa (400 kgf/cm 2 , 5689 p si ) .

  • Page 89: Injection Nozzle

    Del ivery Va lves F u el Tightness 1 . I nsta l l the p ressu re tester ( See page S-5 1 ) to the fuel in­ jection pump. 2. With t he speed con trol lever at t he m ax i m u m position of t he fuel i njection, rotate the f l ywheel to raise the fuel p ressure to 2 1 .57 MPz (220 kgf/cm 2 , 3 1 29 psi ) .

  • Page 90: Va Lve Seat T Ightness

    Va lve Seat T ightness 1 . Set the n ozzle to a n ozzle tester. 2. R a ise the fuel p ressure and keep at 1 2. 7 5 MPa ( 1 30 kgf/ cm 2 , 1 849 psi) for 1 0 seconds. 3 .

  • Page 91: Disassembly And Assembly

    D I SASS E M B L Y AND ASS E M B LY [ 1 ] I njection N ozzle N ozz le H o lder 1 . Secure t h e nozzle n u t ( 1 ) i n a vise. 2 .

  • Page 92: Air Bleeding

    [ 2 ] A ir B leed i n g B leed t he a ir from t he fuel system before atte mpting to start the engi ne whenev e r : • T h e f u e l filter has b e e n removed or t he f u e l syste m l ines h ave been d i sconnected.

  • Page 93: Electrical System

    ELECTRICAL SYSTEM [ 1 ] Starter C H E C K I NG No-l oad Test 1 . Co n nect a cab le fro m the negative term i na l of the ba ttery to the body of the starter. 2.
  • Page 94 D ISASS E M B LY AND ASS E M B LY Solenoid Sw itch 1 . R emove the screws ( 3 ) to separate the solenoid switch. 2. P u l l out the p l uger ( 2 ) a nd the spr i ng ( 1 ) . 1 ) Spring (2) P l u nger (3) Screw...

  • Page 95: Armatu Re Coil

    Overu n n ing Clutch 1 . Tap i n the stop r i ng ( 3 ) . 2. R em ove the ret a i ner r i ng ( 2 ) . 3. R em ove the stop r i ng ( 3 ) and the overru n i ng cl utch ( 1 ) . (When reassembling) •...

  • Page 96: F Ield Coil

    Commutator 1 . R otate the armature in V b locks to check out-of-round­ ness and run-out, sett ing a dial indicator with its tip on the com m utator. 2. I f the varia nce a m o ng the readings is more t h a n the a l l owab le l i m it, turn the a r m ature in the lathe.
  • Page 97 Bru sh Spring 1 . P u l l the brush i n t h e brush h o l d er w ith a spring sca l e . 2 . Meassu re the brush spri ng t e n s i o n requ i red t o raise t h e spr i ng f r o m contact posit ion w i t h the comm utator.
  • Page 98 Solenoid Switch 1 . Check the co nt i n u ity across " B " and " M " term i na l s with an o h m m eter, push ing in the p l u nger. 2 .

  • Page 99: N O- Load Dynamo Output

    [2] AC Dynamo and R egu l ator C H EC K I N G N o- Load Dynamo Output 1 . D isco n nect the lead w ires from the AC dynamo. 2 . Start the e n g i n e and o perate the AC dynamo at the specified speed.

This manual is also suitable for:

M18M25

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