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Manuals
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Universal Manuals
Engine
M3-20
Service manual
Universal M3-20 Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
Specifications
Engine Specifications
Bolt Torques
Tightening Bolts of Important Parts
Preventive Maintenance
General Warnings
Applying Grease to Oil Seal
Direction of Installing Circlips
Maintenance Check List
Points of Inspection and Changing
Engine Lubricating Oil
Checking Engine Oil Level
Changing Engine Oil
Changing Engine Oil Filter Cartridge
Inspection of Fuel Filter
Oil Filter Cartridge
Venting the Fuel System
Construction and Function
Cylinder Block
Cylinder Head
Crankshaft
Piston and Piston Rings
Connecting Rods
Camshaft and Fuel Camshaft
Rocker Arm Assembly
Inlet and Exhaust Valves
Flywheel
Lubrication, Cooling and Fuel Systems
Lubrication System
Engine Oil Flow
Relief Valve
By-Pass Valve
Oil Switch
Oil Pump
Water Pump
Thermostat
Fuel System
Fuel Filter
Fuel Pump
Fuel Injection Pump
Fuel Pressure-Feed
Injection Control
Injection Zero
Injection Medium
Injection Maximum
Delivery Valve
Pump Element
Control Rack
Tappet
Injection Nozzle
Governor
At Start
At Idling
At Middle/High Speed Running
At High Speed Running with Overload
To Stop Engine
Electrical System
Wiring Diagram
General Information
Alternator
Alternator Sense
Battery Sense
Alternator Schematic Diagrams
Integral Voltage Regulator
Internal Regulator
Typical Performance Curves
Alternator Excitation
Alternator Installation
Alternator Rear Housing Rotation
Belt Installation, Alignment & Tensioning
Ammeter
Ammeter Charge & Discharge Circuit
Alternator/Regulator Test Procedure
Preliminary Checks & Tests
Test Equipment Requirement
Storage Battery
Troubleshooting Guide
Test Procedure
Integral Regulator Systems
Problem Area Determination Section
Battery Undecharged
Battery Overcharged
Alternator/Regulator Tests
Open Diode-Trio Test
Open Regulator Test
Harness Voltage Test
Alternator Output Test
Cable Harness Voltage Test
Alternator Terminal Identification
Alternator Repair Procedure
Alternator Troubleshooting
Removing Back Cover
Remove Brush Holder
Inspect and Test Brush Assembly
Remove Integral Voltage Regulator
Test Diode Trio Assembly
Test Diode Rectifier Bridge Assembly
Separate Stator/Rear Housing Assy. from Front Housing
Inspect Rear Housing
Test Stator
Remove Pulley, Fan and Spacer
Separate Rotor from the Front Housing
Remove Front Bearing from Housing
Inspect Front Housing
Rotor Inspection and Electrical Testing
Current Draw or Resistance of the Winding
Grounded Slip Ring or Winding
Condition of Slip Rings
Rotor Shaft and Pole Pieces
Remove Slip Rings from Rotor Assembly
Remove Rear Bearing from Rotor
Alternator Reassembly
Install Rear Bearing
Install Slip Ring Assembly
Install Front Bearing
Assemble Rotor and Front Housing
Assembly Spacer, Fan and Pulley
Assembly Front & Rear Housing
Install Diode Rectifier Bridge and Diode Trio
Install Brush Assembly
Install Rear Cover
Alternator Performance
Cranking System
Minimum Acceptable Output Values
Starter
When Start Button Is Pushed
When Contact Plate Is Closed
Glow Plugs
When Push Button Is Released
Disassembly and Reassembly
Removing Head Cover
Removing Injection Pipes 1,2 and 3
Removing Nozzle Holder Assemblies
Removing AC Dynamo
Removing Rocker Arm
Removing Push-Rod
Removing Cylinder Heads
Removing Cylinder Head Gasket
Removing O-Ring
Removing Tappets
Nozzle Holder
Removing Valves
Disassembling Nozzle Holder
Injection Pump
Removing Injection Pump Cover
Removing Injection Pump
Gear Case, Timing Gear, Camshaft, Oil Pump
Detaching Governor Spring
Removing Speed Control Plate
Detaching Start Spring
Removing Fan Drive Pulley
Removing Gear Case
Removing Crankshaft Oil Slinger
Removing Idle Gear
Removing Camsahft Stopper
Removing Gear and Camshaft
Removing Fork Lever Assembly
Camshaft Assembly
Fork Lever Assembly
Removing Fuel Camshaft
Removing Oil Pump Drive Gear
Removing Oil Pump
Removing Crank Gear
Oil Pump Assembly
13T Gear
Piston, Crankshaft
Removing Oil Pan
Removing Oil Filter 1
Removing Connecting Rod Cap
Removing Pistons
Removing Flywheel
Removing Bearing Case Cover
Removing Bearing Case Bolt 2
Removing Crankshaft
Removing Main Bearing Case
Removing Cylinder Bearing
Thermostat, Water Pump
Removing Thermostat
Removing Water Pump
Checking Flatness of Cylinder Head Surface
Checking Flaw of Cylinder Head Surface
Repairing the Valve Seat
Checking Valve Recessing
Checking Guide Clearance
Checking Valve Spring Free Length
Checking Valve Spring Squareness
Checking Valve Spring Tension
Checking Oil Clearance between Rocker Arm Shaft and Bushing
Checking Top Clearance
Adjusting Valve Clearance
Adjusting Compression Release
Testing Opening Pressure of Nozzle
Checking Fuel Tightness of Nozzle Valve Seat
Checking Shape of Fumes Across Nozzle Tip
Checking Fuel Tightness of Fuel Injection Pump Plunger
Adjustment of Injection
Checking Fuel Tightness of Delivery Valve of Fuel Injection Pump
Choking and Adjusting Injection Timing
Timing Gears, Camshaft
Checking Oil Clearance of Camshaft
Checking Camshaft Alignment
Checking Cam Heights of Intake and Exhaust
Checking Gear Backlash
Testing Oil Pressure
Checking Radial Clearance between Outer Rotor and Pump Body
Checking End Clearance between Rotor and Cover
Piston, Connecting Rod
Checking Inside Diameter of Piston Bosses
Checking Clearance between Piston Pin and Small End Bushings
Checking Piston Ring Clearance
Checking Side Clearance of Ring in Groove
Checking Connecting Rod Alignment
Checking Crankshaft Alignment
Cylinder Liner
Checking Wear of Cylinder Liner
Reference
Undersize and Oversize
Replacing Valves Guides
Replacing Rocker Arm Bushings
Replacing Idle Gear Bushings
Replacing Small End Bushings
Replacing Crankshaft Bearing 1
Dynamo and Regulator
Battery
Checking Battery Charging Current
Checking AC Dynamo's no Load Voltage
Starter and Glow Plug
No Load Testing of Starter
Motor Test
Checking Magnet Switch Function
Checking Magnet Switch - Holding Coil
Checking Magnet Switch - Plunger Return
Checking for Breakage and Short-Circuit of Glow Plug
Disassembly of Starter
Removing Magnet Switch
Removing Armature Brake
Removing End Frame
Removing Brush Holder
Removing Yoke
Removing Armature
Servicing Starter
Checking and Adjusting Pinion Gap
Checking Gap between Shaft and Brush
Grounding Armature Coil
Diameters of Shaft and Bushing
Checking Commutator Wear
Staining or Burning of Commutator
Checking Mica
Checking for Field Coil Breakage
Checking Insulation between Field Coil and Yoke
Checking for Brush Wear
Checking Brush Spring
Grounding of Brush Holder
Troubleshooting
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Troubleshooting
Troubleshooting guide
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Alternator repair procedure
93
Troubleshooting
172
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