Kubota RTV-X1100C Utility Vehicle Workshop Manual- PDF DOWNLOAD
DESCRIPTION:
Kubota RTV-X1100C Utility Vehicle Workshop Manual- PDF DOWNLOAD
TO THE READER :
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the RTV-X1100C. It contains 4 parts: “Information”, “General”, “Mechanism” and
“Servicing”.
Information
This section primarily contains information below.
• Safety First
• Safety Decal
• Specifications
• Dimensions
General
This section primarily contains information below.
• Engine Identification
• Model Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to the latest version of Workshop Manual (Code No. 9Y021-01870) for the diesel engine that
this workshop manual does not include.
Servicing
This section primarily contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
- All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication. - KUBOTA reserves the right to change all information at any time without notice.
TABLE OF CONTENTS:
Kubota RTV-X1100C Utility Vehicle Workshop Manual- PDF DOWNLOAD
RTV-X1100C…………………………………………………………………………………………………………………………………………….. 1
TO THE READER………………………………………………………………………………………………………………………………………. 2
I INFORMATION………………………………………………………………………………………………………………………………………. 3
INFORMATION…………………………………………………………………………………………………………………………………….. 4
1. SAFETY FIRST……………………………………………………………………………………………………………………………… 5
2. SAFETY DECALS…………………………………………………………………………………………………………………………….. 8
3. SPECIFICATIONS……………………………………………………………………………………………………………………………. 12
4. TRAVELLING SPEEDS…………………………………………………………………………………………………………………………. 13
5. DIMENSIONS……………………………………………………………………………………………………………………………….. 14
G GENERAL………………………………………………………………………………………………………………………………………….. 15
GENERAL………………………………………………………………………………………………………………………………………… 16
1. PRODUCT IDENTIFICATION…………………………………………………………………………………………………………………….. 17
2. GENERAL PRECAUTIONS……………………………………………………………………………………………………………………….. 18
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING………………………………………………………………………………………….. 19
[1] WIRING………………………………………………………………………………………………………………………………. 19
[2] BATTERY……………………………………………………………………………………………………………………………… 21
[3] FUSE………………………………………………………………………………………………………………………………… 21
[4] CONNECTOR……………………………………………………………………………………………………………………………. 21
[5] HANDLING OF CIRCUIT TESTER…………………………………………………………………………………………………………….. 22
[6] COLOR OF WIRING………………………………………………………………………………………………………………………. 23
4. LUBRICANTS, FUEL AND COOLANT……………………………………………………………………………………………………………….. 24
5. TIGHTENING TORQUES………………………………………………………………………………………………………………………… 28
[1] GENERAL USE SCREWS, BOLTS AND NUTS……………………………………………………………………………………………………… 28
[2] STUD BOLTS…………………………………………………………………………………………………………………………… 28
[3] HYDRAULIC FITTINGS……………………………………………………………………………………………………………………. 29
(1) Hydraulic Hose Fittings……………………………………………………………………………………………………………. 29
(2) Hydraulic Pipe Cap Nuts……………………………………………………………………………………………………………. 29
(3) Adaptors, Elbows and Others………………………………………………………………………………………………………… 29
[4] METRIC SCREWS, BOLTS AND NUTS………………………………………………………………………………………………………….. 30
[5] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS…………………………………………………………………………… 30
[6] PLUGS……………………………………………………………………………………………………………………………….. 30
6. MAINTENANCE CHECK LIST…………………………………………………………………………………………………………………….. 31
7. CHECK AND MAINTENANCE……………………………………………………………………………………………………………………… 34
[1] DAILY CHECK………………………………………………………………………………………………………………………….. 34
[2] CHECK POINTS OF INITIAL 50 HOURS……………………………………………………………………………………………………….. 40
[3] CHECK POINTS OF EVERY 50 HOURS…………………………………………………………………………………………………………. 46
[4] CHECK POINTS OF EVERY 100 HOURS………………………………………………………………………………………………………… 49
[5] CHECK POINTS OF EVERY 200 HOURS………………………………………………………………………………………………………… 55
[6] CHECK POINT OF EVERY 300 HOURS…………………………………………………………………………………………………………. 65
[7] CHECK POINTS OF EVERY 400 HOURS………………………………………………………………………………………………………… 65
[8] CHECK POINT OF EVERY 500 HOURS…………………………………………………………………………………………………………. 67
[9] CHECK POINT OF EVERY 800 HOURS…………………………………………………………………………………………………………. 67
[10] CHECK POINT OF EVERY 1500 HOURS……………………………………………………………………………………………………….. 67
[11] CHECK POINT OF EVERY 3000 HOURS……………………………………………………………………………………………………….. 67
[12] CHECK POINTS OF EVERY 1 YEAR………………………………………………………………………………………………………….. 67
[13] CHECK POINTS OF EVERY 2 YEARS…………………………………………………………………………………………………………. 68
[14] CHECK POINT OF EVERY 4 YEARS………………………………………………………………………………………………………….. 71
[15] SERVICE AS REQUIRED………………………………………………………………………………………………………………….. 72
8. SPECIAL TOOLS…………………………………………………………………………………………………………………………….. 76
[1] SPECIAL TOOLS FOR ENGINE………………………………………………………………………………………………………………. 76
[2] SPECIAL TOOLS FOR MACHINE……………………………………………………………………………………………………………… 83
9. TIRES……………………………………………………………………………………………………………………………………. 89
[1] TYPE OF TIRES………………………………………………………………………………………………………………………… 89
[2] TYPE PRESSURE………………………………………………………………………………………………………………………… 90
[3] VEHICLE LIMITATIONS…………………………………………………………………………………………………………………… 91
[4] CARGO BED……………………………………………………………………………………………………………………………. 92
[5] SHOCK ABSORBERS………………………………………………………………………………………………………………………. 93
1 ENGINE…………………………………………………………………………………………………………………………………………… 94
MECHANISM………………………………………………………………………………………………………………………………………. 95
1. ENGINE BODY………………………………………………………………………………………………………………………………. 96
[1] CLOSED BREATHER………………………………………………………………………………………………………………………. 96
[2] GOVERNOR…………………………………………………………………………………………………………………………….. 97
2. LUBRICATING SYSTEM………………………………………………………………………………………………………………………… 99
3. COOLING SYSTEM…………………………………………………………………………………………………………………………….100
4. FUEL SYSTEM……………………………………………………………………………………………………………………………….101
SERVICING……………………………………………………………………………………………………………………………………….102
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………103
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………106
[1] Engine Body…………………………………………………………………………………………………………………………..106
[2] Lubricating System…………………………………………………………………………………………………………………….109
[3] Cooling System………………………………………………………………………………………………………………………..110
[4] Fuel System…………………………………………………………………………………………………………………………..110
3. TIGHTNING TORQUES………………………………………………………………………………………………………………………….111
[1] GENERAL………………………………………………………………………………………………………………………………111
[2] ENGINE BODY…………………………………………………………………………………………………………………………..111
4. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..112
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………112
(1) Engine Body……………………………………………………………………………………………………………………….112
(2) Lubricating System…………………………………………………………………………………………………………………115
(3) Cooling System…………………………………………………………………………………………………………………….118
(4) Fuel System……………………………………………………………………………………………………………………….120
[2] PREPARATION…………………………………………………………………………………………………………………………..122
(1) Dismounting Transmission and Engine………………………………………………………………………………………………….122
(2) Separating Transmission Engine………………………………………………………………………………………………………134
[3] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………136
(1) Cylinder Head and Valve…………………………………………………………………………………………………………….136
(2) Gear Case and Timing Gears………………………………………………………………………………………………………….139
(3) Piston and Connecting Rod…………………………………………………………………………………………………………..143
(4) Flywheel and Crankshaft…………………………………………………………………………………………………………….145
5. SERVICING…………………………………………………………………………………………………………………………………147
[1] Cylinder Head and Valves……………………………………………………………………………………………………………….147
[2] Timing Gears, Camshaft and Governor Gear…………………………………………………………………………………………………153
[3] Piston and Connecting Rod………………………………………………………………………………………………………………156
[4] Crankshaft……………………………………………………………………………………………………………………………158
[5] Cylinder……………………………………………………………………………………………………………………………..163
[6] Oil Pump……………………………………………………………………………………………………………………………..164
2 TRANSMISSION………………………………………………………………………………………………………………………………………165
MECHANISM……………………………………………………………………………………………………………………………………….166
1. STRUCTURE…………………………………………………………………………………………………………………………………167
2. POWER TRAIN……………………………………………………………………………………………………………………………….168
[1] HYDROSTATIC TRANSMISSION (HST)………………………………………………………………………………………………………….168
(1) Structure…………………………………………………………………………………………………………………………168
(2) Oil Flow………………………………………………………………………………………………………………………….170
(3) Function of Components……………………………………………………………………………………………………………..171
(4) HST Oil Flow………………………………………………………………………………………………………………………179
(5) HST Control Linkage………………………………………………………………………………………………………………..185
(6) Cables……………………………………………………………………………………………………………………………187
[2] RANGE GEAR SHIFT SECTION AND FRONT WHEEL DRIVE SECTION…………………………………………………………………………………….188
SERVICING……………………………………………………………………………………………………………………………………….189
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………190
[1] HYDROSTATIC TRANSMISSION……………………………………………………………………………………………………………….190
[2] TRAVELLING GEAR SHIFT SECTION…………………………………………………………………………………………………………..192
[3] DIFFERENTIAL GEAR SECTION………………………………………………………………………………………………………………192
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………193
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………194
4. CHECKING AND ADJUSTING……………………………………………………………………………………………………………………..195
5. PREPARATION……………………………………………………………………………………………………………………………….206
[1] SEPARATING HYDRAULIC TRANSMISSION……………………………………………………………………………………………………….206
[2] DISMOUNTING TRANSMISSION AND ENGINE……………………………………………………………………………………………………..212
[3] SEPARATING TRANSMISSION AND ENGINE………………………………………………………………………………………………………221
6. DISASSEMBLING AND ASSEMBLING………………………………………………………………………………………………………………..223
[1] TRANSMISSION………………………………………………………………………………………………………………………….223
(1) Removing HST Assembly………………………………………………………………………………………………………………223
(2) Disassembling Transmission………………………………………………………………………………………………………….224
(3) Disassembling HST………………………………………………………………………………………………………………….230
7. SERVICING…………………………………………………………………………………………………………………………………234
[1] TRANSMISSION………………………………………………………………………………………………………………………….234
[2] HST………………………………………………………………………………………………………………………………….238
3 REAR AXLE…………………………………………………………………………………………………………………………………………243
MECHANISM……………………………………………………………………………………………………………………………………….244
1. STRUCTURE…………………………………………………………………………………………………………………………………245
SERVICING……………………………………………………………………………………………………………………………………….246
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………247
2. TIGHTENING TORQUES…………………………………………………………………………………………………………………………248
3. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..249
[1] ADJSUTING…………………………………………………………………………………………………………………………….249
[2] PREPARATION…………………………………………………………………………………………………………………………..250
(1) Rear Knuckle Case………………………………………………………………………………………………………………….250
(2) Rear Shock Absorber………………………………………………………………………………………………………………..251
[3] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………252
(1) Rear Knuckle Case………………………………………………………………………………………………………………….252
[4] SERVICING…………………………………………………………………………………………………………………………….252
4 BRAKES……………………………………………………………………………………………………………………………………………253
MECHANISM……………………………………………………………………………………………………………………………………….254
1. GENERAL OUTLINE……………………………………………………………………………………………………………………………255
2. KNUCKLE (FRONT BRAKE)………………………………………………………………………………………………………………………256
3. REAR BRAKE………………………………………………………………………………………………………………………………..257
4. MASTER CYLINDER……………………………………………………………………………………………………………………………258
5. BRAKE OIL…………………………………………………………………………………………………………………………………259
6. PARKING BRAKE……………………………………………………………………………………………………………………………..260
SERVICING……………………………………………………………………………………………………………………………………….261
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………262
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………263
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………264
4. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..265
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………265
[2] PREPARATION…………………………………………………………………………………………………………………………..269
(1) Front Brake……………………………………………………………………………………………………………………….269
(2) Master Cylinder……………………………………………………………………………………………………………………273
[3] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………274
(1) Front Brake……………………………………………………………………………………………………………………….274
(2) Master Cylinder……………………………………………………………………………………………………………………276
(3) Rear Brake………………………………………………………………………………………………………………………..276
[4] SERVICING…………………………………………………………………………………………………………………………….277
(1) Front Brake……………………………………………………………………………………………………………………….277
(2) Rear Brake………………………………………………………………………………………………………………………..277
(3) Brake Piston………………………………………………………………………………………………………………………278
5 FRONT AXLE………………………………………………………………………………………………………………………………………..279
MECHANISM……………………………………………………………………………………………………………………………………….280
1. STRUCTURE…………………………………………………………………………………………………………………………………281
[1] FRONT AXLE……………………………………………………………………………………………………………………………281
[2] FRONT SUSPENSION………………………………………………………………………………………………………………………282
[3] LIMITED SLIP DIFFERENTIAL (LSD)…………………………………………………………………………………………………………283
(1) Structure…………………………………………………………………………………………………………………………283
(2) Operation…………………………………………………………………………………………………………………………284
SERVICING……………………………………………………………………………………………………………………………………….285
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………286
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………287
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………288
4. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..289
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………289
[2] PREPARATION…………………………………………………………………………………………………………………………..291
(1) Knuckle Case………………………………………………………………………………………………………………………291
(2) Front Differential Case…………………………………………………………………………………………………………….295
(3) Front Shock Absorber……………………………………………………………………………………………………………….300
[3] DISASSEMBRING AND ASSEMBRING……………………………………………………………………………………………………………301
(1) Knuckle Case………………………………………………………………………………………………………………………301
(2) Front Differential Case…………………………………………………………………………………………………………….302
(3) Front Shock Absorber……………………………………………………………………………………………………………….305
[4] SERVICING…………………………………………………………………………………………………………………………….306
6 STEERING………………………………………………………………………………………………………………………………………….310
MECHANISM……………………………………………………………………………………………………………………………………….311
1. STRUCTURE…………………………………………………………………………………………………………………………………312
2. HYDRAULIC CIRCUIT………………………………………………………………………………………………………………………….313
3. STEERING CONTROLLER………………………………………………………………………………………………………………………..314
4. STEERING CYLINDER………………………………………………………………………………………………………………………….316
SERVICING……………………………………………………………………………………………………………………………………….317
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………318
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………319
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………320
4. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..321
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………321
[2] PREPARATION…………………………………………………………………………………………………………………………..322
(1) Separating Power Steering Controller…………………………………………………………………………………………………322
(2) Separating Power Steering Cylinder…………………………………………………………………………………………………..324
(3) Separating Hydraulic Pump…………………………………………………………………………………………………………..325
(4) Removing Power Steer Hoses………………………………………………………………………………………………………….326
[3] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………328
(1) Power Steering Cylinder…………………………………………………………………………………………………………….328
(2) Hydraulic Pump…………………………………………………………………………………………………………………….329
7 HYDRAULIC SYSTEM…………………………………………………………………………………………………………………………………..330
MECHANISM……………………………………………………………………………………………………………………………………….331
1. STRUCTURE…………………………………………………………………………………………………………………………………332
2. HYDRAULIC CIRCUIT………………………………………………………………………………………………………………………….333
3. HYDRAULIC PUMP…………………………………………………………………………………………………………………………….334
4. HYDRAULIC CYLINDER…………………………………………………………………………………………………………………………335
5. CONTROL VALVE……………………………………………………………………………………………………………………………..336
[1] DOUBLE ACTING TYPE 1…………………………………………………………………………………………………………………..336
(1) Floating with Detent Valve………………………………………………………………………………………………………….336
SERVICING……………………………………………………………………………………………………………………………………….338
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………339
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………340
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………341
4. CHECKING AND DISASSEMBLING………………………………………………………………………………………………………………….342
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………342
(1) Hydraulic Control Valve, Pump and Cylinder……………………………………………………………………………………………342
[2] PREPARATION…………………………………………………………………………………………………………………………..344
(1) Removing Hydraulic Pump…………………………………………………………………………………………………………….344
(2) Removing Hydraulic Cylinder LIft Cylinder…………………………………………………………………………………………….345
[3] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………346
(1) Hydraulic Pump…………………………………………………………………………………………………………………….346
(2) Hydraulic Lift Cylinder…………………………………………………………………………………………………………….347
(3) Control Valve……………………………………………………………………………………………………………………..348
8 ELECTRICAL SYSTEM………………………………………………………………………………………………………………………………….349
MECHANISM……………………………………………………………………………………………………………………………………….350
1. WIRING DIAGRAM…………………………………………………………………………………………………………………………….351
2. ELECTRICAL CIRCUIT…………………………………………………………………………………………………………………………352
3. STARTING SYSTEM……………………………………………………………………………………………………………………………353
[1] STARTER………………………………………………………………………………………………………………………………353
(1) Structure…………………………………………………………………………………………………………………………353
(2) Operation of Starter……………………………………………………………………………………………………………….354
(3) Overrunning Clutch…………………………………………………………………………………………………………………355
(4) Magnetic Switch……………………………………………………………………………………………………………………355
[2] GLOW PLUG…………………………………………………………………………………………………………………………….356
[3] SAFETY SWITCH (NEUTRAL SWITCH)………………………………………………………………………………………………………….357
[4] ENGINE STOP SOLENOID…………………………………………………………………………………………………………………..358
4. CHARGING SYSTEM……………………………………………………………………………………………………………………………359
[1] ALTERNATOR……………………………………………………………………………………………………………………………360
[2] IC REGULATOR………………………………………………………………………………………………………………………….360
5. LIGHTING SYSTEM……………………………………………………………………………………………………………………………361
6. COOLING SYSTEM…………………………………………………………………………………………………………………………….362
[1] FAN MOTOR…………………………………………………………………………………………………………………………….363
[2] RADIATOR FAN MOTOR SWITCH………………………………………………………………………………………………………………363
7. GAUGES……………………………………………………………………………………………………………………………………364
[1] FUEL QUANTITY…………………………………………………………………………………………………………………………365
[2] ENGINE WATER TEMPERATURE SENSOR…………………………………………………………………………………………………………365
[3] TRAVELING SPEED SENSOR…………………………………………………………………………………………………………………366
8. METER PANEL……………………………………………………………………………………………………………………………….367
[1] EASY CHECKER™…………………………………………………………………………………………………………………………367
[2] ERROR CODE DISPLAY…………………………………………………………………………………………………………………….369
SERVICING……………………………………………………………………………………………………………………………………….370
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………371
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………375
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………376
4. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..377
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………377
(1) Battery…………………………………………………………………………………………………………………………..377
(2) Key Switch………………………………………………………………………………………………………………………..379
(3) Starter…………………………………………………………………………………………………………………………..381
(4) Glow Plug…………………………………………………………………………………………………………………………382
(5) Safety Switch……………………………………………………………………………………………………………………..382
(6) Engine Stop Solenoid……………………………………………………………………………………………………………….383
(7) Charging System……………………………………………………………………………………………………………………384
(8) Lighting System……………………………………………………………………………………………………………………386
(9) Cooling System…………………………………………………………………………………………………………………….390
(10) Gauges…………………………………………………………………………………………………………………………..393
(11) Relays…………………………………………………………………………………………………………………………..395
(12) Others…………………………………………………………………………………………………………………………..395
[2] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………396
(1) Starter…………………………………………………………………………………………………………………………..396
(2) Alternator………………………………………………………………………………………………………………………..398
[3] SERVICING…………………………………………………………………………………………………………………………….400
(1) Starter…………………………………………………………………………………………………………………………..400
(2) Alternator………………………………………………………………………………………………………………………..402
9 CABIN…………………………………………………………………………………………………………………………………………….404
MECHANISM……………………………………………………………………………………………………………………………………….405
1. AIR CONDITIONING SYSTEM…………………………………………………………………………………………………………………….406
[1] OUTLINE OF AIR CONDITIONING SYSTEM………………………………………………………………………………………………………406
[2] SYSTEM LAYOUT AND COMPONENT PART………………………………………………………………………………………………………..408
(1) Compressor………………………………………………………………………………………………………………………..409
(2) Condenser…………………………………………………………………………………………………………………………411
(3) Receiver………………………………………………………………………………………………………………………….412
(4) Air Conditioner Unit……………………………………………………………………………………………………………….413
[3] SYSTEM CONTROL………………………………………………………………………………………………………………………..418
[4] AIR FLOW……………………………………………………………………………………………………………………………..419
[5] AIR CONTROL VENT………………………………………………………………………………………………………………………420
[6] ELECTRICAL SYSTEM……………………………………………………………………………………………………………………..421
(1) Electrical Circuit…………………………………………………………………………………………………………………421
SERVICING……………………………………………………………………………………………………………………………………….422
1. TROUBLESHOOTING……………………………………………………………………………………………………………………………423
2. SERVICING SPECIFICATIONS……………………………………………………………………………………………………………………426
3. TIGHTENING TORQUES…………………………………………………………………………………………………………………………427
4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE……………………………………………………………………………………………………428
[1] HANDLING OF SERVICE TOOLS………………………………………………………………………………………………………………429
(1) Manifold Gauge Set…………………………………………………………………………………………………………………429
(2) Refrigerant Charging Hose…………………………………………………………………………………………………………..430
(3) Vacuum Pump Adaptor………………………………………………………………………………………………………………..431
(4) Electric Gas Leak Tester……………………………………………………………………………………………………………431
(5) Can Tap Valve……………………………………………………………………………………………………………………..431
(6) T-joint…………………………………………………………………………………………………………………………..432
(7) R134a Refrigerant Recovery and Recycling Machine………………………………………………………………………………………432
5. CHECKING AND CHARGING REFRIGERANT CYCLE………………………………………………………………………………………………………433
[1] CHECKING WITH MANIFOLD GAUGE……………………………………………………………………………………………………………433
[2] DISCHARGING, EVACUATING AND CHARGING…………………………………………………………………………………………………….438
(1) Discharging Evacuating and Charging the Refrigerant……………………………………………………………………………………438
6. CHECKING, DISASSEMBLING AND SERVICING………………………………………………………………………………………………………..439
[1] CHECKING AND ADJUSTING…………………………………………………………………………………………………………………439
(1) Compressor………………………………………………………………………………………………………………………..439
(2) Control Panel (Blower Switch, Air Conditioner Switch, Mode Control Dial, Temperature Control Dial and Recirculation/Fresh Air Selection Switch)….440
(3) Blower Motor………………………………………………………………………………………………………………………441
(4) Blower Resistor……………………………………………………………………………………………………………………442
(5) Pressure Switch……………………………………………………………………………………………………………………443
(6) Relays……………………………………………………………………………………………………………………………444
[2] DISASSEMBLING AND ASSEMBLING……………………………………………………………………………………………………………445
(1) Removing Compressor Assembly………………………………………………………………………………………………………..445
(2) Removing Air Conditioner Unit……………………………………………………………………………………………………….449
(3) Removing Condenser…………………………………………………………………………………………………………………454
(4) Removing Air Conditioner Hoses………………………………………………………………………………………………………455
(5) Removing Heater Hoses………………………………………………………………………………………………………………458
(6) Removing Front Glass……………………………………………………………………………………………………………….461
(7) Removing Rear Glass………………………………………………………………………………………………………………..462
(8) Removing Door……………………………………………………………………………………………………………………..463
(9) Removing Door Glass………………………………………………………………………………………………………………..463
[3] SERVICING…………………………………………………………………………………………………………………………….464
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PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V