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Table Of Contents - Universal M-25XPB Service Manual

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Operator's manual (52 pages)

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Operator's manual (52 pages)

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Operator's manual (54 pages)

Table Of Contents

Table of Contents

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Table of Contents

Safety Instructions3

Accidental Starting4

Toxic Exhaust Gases4

Battery Explosion4

Hazardous Noise5

Safe Engine Installations5

Table Of Contents7

Engine Overhaul8

Product Software8

Serial Number Location8

Parts Identification9

Specifications10

Testing For Overhaul12

How To Determine When To Overhaul The Engine12

Cause Of Low Compression12

Measuring Compression Pressure12

Engine Troubleshooting13

Service Standards21

Engine Components Data21

Engine Description24

Cylinder Block24

Cylinder Head24

Connecting Rod25

Fuel Camshaft25

Engine Disassembly And Reassembly27

External Components Disassembly/Reassembly28

Cylinder Head And Valves29

Nozzle Holder Assembly29

Cylinder Head Cover30

Rocker Arm And Push Rod30

Engine Stop Solenoid And Speed Control Plate31

Injection Pump32

Governor Shaft33

Piston And Connecting Rod34

Camshaft Gear And Idler Gear #134

Oil Pan And Oil Pan Filter34

Connecting Rod Cap34

Piston Ring And Connecting Rod35

Flywheel And Crankshaft36

Bearing Case Cover And Crankshaft36

Main Bearing Case Assembly37

Cylinder Head Distortion38

Cylinder Head Flaw38

Valve Recession38

Valve Stem To Valve Guide Clearance38

Engine Service39

Valve Seating39

Correcting Valve And Valve Seat39

Valve Lapping39

Replacing Valve Guide40

Measuring Valve Spring40

Oil Clearance Between Rocker Arm Shaft And Bearing40

Push Rod Alignment40

Timing Gears And Camshaft41

Oil Clearance Between Tappet And Tappet Guide Bore41

Camshaft Side Clearance41

Camshaft Alignment41

Piston Pin Bore Id42

Camshaft Journal Oil Clearance42

Replacing The Idler Gear Bushing42

Replacing Connecting Rod Small End Bushing42

Piston Ring Gap43

Piston Ring Clearances43

Connecting Rod Alignment43

Crankshaft Side Clearance44

Crankshaft Alignment44

Oil Clearance Between Crankpin And Crankpin Bearing44

Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 145

Oil Clearance Between Crankshaft Journal And Crankshaft Bearings 2, 346

Replacing Crankshaft Bearing No. 146

Cylinder Wear47

Correcting Cylinder48

Engine Adjustments49

Valve Clearance Adjustment49

Top Clearance49

Tightening The Cylinder Head Bolts49

Testing Engine Compression50

Drive Belt Adjustment51

Checking Belt Tension51

Adjustng Belt Tension51

Idle Speed Adjustment And Tachometer Check52

Exhaust Manifold Service53

Lubrication System Description54

Oil Pressure Switch55

Low Oil Pressure56

Checking The Oil Pressure56

Oil Pump - Rotor Lobe Clearance56

Clearance Between Outer Rotor And Pump Body57

Clearance Between Rotor And Cover57

Cooling System Description58

Raw Water Pump58

Coolant Recovery Tank59

Heat Exchanger59

Thermostat View60

Changing The Raw Water Impeller60

Checking The Thermostat Valve Opening Temperature60

Cooling System Service61

Coolant Pump Service61

Fuel System Description62

Injection Nozzle63

Delivery Valve63

Injection Control63

Fuel Lift Pump64

Fuel System Disassembly And Reassembly66

Fuel System Service67

Injection Timing67

Fuel Tightness Of Pump Element67

Fuel Tightness Of Delivery Valve67

Fuel Injectors Service68

Nozzle Injection Pressure68

Nozzle Spraying Condition68

Valve Seat Tightness68

Admiral Control Panel69

Captain Control Panel70

Control Panel Troubleshooting71

Hourmeter Inoperative71

Tachometer Inoperative71

Tachometer Sticking/Inaccurate71

Manual Starter Disconnect (Toggle Switches)72

Troubleshooting Water Temperature And Oil Pressure Gauges72

Glow Plugs Service73

Starter Service74

Starter Testing74

Magnet Switch Test (Pull-In, Holding Coils)74

Starter Disassembly And Assembly75

Commutator And Mica75

Armature Coil76

Armature Bearing77

Overrunning Clutch77

Magnet Switch77

Mando Alternator Service78

Precautions For Testing Alternator78

Preparing To Check Alternator78

Test Output Circuit79

Test Excitation Circuit79

Test Alternator Current Output80

Test Voltage Regulator80

Remove Alternator81

Disassemble Alternator82

Clean And Test Alternator Components83

Assemble Alternator85

Install Alternator87

Mando Alternator Specifications87

Prestolite Alternator Service88

Storage Battery88

Battery Inspection88

Prestolite Alternator Description89

Prestolite Alternator Troubleshooting90

Alternator/Regulator Tests91

Alternator Output Test92

Prestolite Alternator Repair Procedure92

Prestolite Alternator Disassembly And Testing92

Prestolite Alternator Reassembly97

Prestolite Alternator Performance Tests98

Dc Electrical System100

Wiring Diagram100

Hurth Hbw Transmissions104

Shaft Coupling104

Transmission Fluid Change105

Locking The Propeller105

When Under Sail Or Being Towed105

Hbw Transmission Specifications105

Operating Temperature (Transmission)106

Transmission Cooler106

Transmission Maintenance106

Transmission Troubleshooting107

Special Tools108

Standard Hardware111

Sealants And Lubricants111

Metric Conversions112

Standard And Metric Conversion Data113

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Table of Contents

Troubleshooting