Kubota U35-4 Excavator Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kubota U35-4 Excavator Workshop Manual – PDF DOWNLOAD
Precautions Before Working on the Equipment :
TABLE OF CONTENTS:
Kubota U35-4 Excavator Workshop Manual – PDF DOWNLOAD
U35-4……………………………………………………………………………………………………. 1
CONTENTS……………………………………………………………………………………………… 2
TO THE READER…………………………………………………………………………………………. 3
I INFORMATION…………………………………………………………………………………………. 4
INFORMATION……………………………………………………………………………………….. 5
1. SAFETY FIRST………………………………………………………………………………… 6
2. IN THE INTEREST OF WORK SAFETY………………………………………………………………… 7
[1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS:…………………… 7
(1) Precautions Before Working on the Mini-Excavator………………………………………… 7
(2) Precautions Before Working on the Equipment…………………………………………….. 8
3. LABELS DISPLAYED TO PROMOTE WORK SAFETY………………………………………………………… 10
[1] LOCATIONS………………………………………………………………………………. 10
[2] LABEL MAINTENANCE……………………………………………………………………….. 16
4. MAIN SPECIFICATIONS………………………………………………………………………….. 17
5. DIMENSIONS………………………………………………………………………………….. 18
G GENERAL…………………………………………………………………………………………….. 19
GENERAL…………………………………………………………………………………………… 20
1. CHECKING EXCAVATOR IDENTIFICATION……………………………………………………………… 21
2. ENGINE IDENTIFICATION………………………………………………………………………… 22
[1] MODEL NAME AND SERIAL NUMBER……………………………………………………………… 22
[2] E4B ENGINE……………………………………………………………………………… 24
[3] CYLINDER NUMBER…………………………………………………………………………. 24
3. GENERAL PRECAUTIONS………………………………………………………………………….. 25
4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING…………………………………………….. 29
[1] WIRING…………………………………………………………………………………. 29
[2] FUSES………………………………………………………………………………….. 31
[3] CONNECTOR………………………………………………………………………………. 31
[4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER…………………………………………….. 32
5. TYPES OF OIL………………………………………………………………………………… 33
[1] TABLE OF OIL AND FLUID CAPACITIES…………………………………………………………. 33
[2] CHECKING AND FILLING HYDRAULIC OIL………………………………………………………… 33
6. TIGHTENING TORQUES…………………………………………………………………………… 34
[1] GENERAL USE SCREWS, BOLTS AND NUTS………………………………………………………… 34
[2] STUD BOLTS……………………………………………………………………………… 34
[3] TORQUE FOR HYDRAULIC HOSE FITTINGS………………………………………………………… 35
(1) Torque for Hydraulic Hose Fittings…………………………………………………….. 35
(2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings (Straight Threads)…. 36
(3) Torque for Tapering Adaptors………………………………………………………….. 36
[4] HOSE CLAMP SCREW TORQUE………………………………………………………………….. 37
7. MAINTENANCE…………………………………………………………………………………. 39
1 MACHINE BODY………………………………………………………………………………………… 41
SERVICING…………………………………………………………………………………………. 42
1. FRONT EQUIPMENT……………………………………………………………………………… 44
[1] MACHINE STRUCTURE……………………………………………………………………….. 44
[2] ARM ASSEMBLY/DISASSEMBLY…………………………………………………………………. 45
[3] RELATIVE DIMENSIONS OF BUCKET INSTALLATION JOINTS…………………………………………… 46
[4] BOOM ASSEMBLY/DISASSEMBLY………………………………………………………………… 47
[5] FRONT PIN DIMENSIONS…………………………………………………………………….. 48
[6] FRONT BUSHING DIMENSIONS…………………………………………………………………. 49
[7] BLADE DISASSEMBLY/ASSEMBLY……………………………………………………………….. 51
[8] BLADE DEMENSIONS………………………………………………………………………… 54
2. UPPER SWIVEL………………………………………………………………………………… 55
[1] WEIGHT…………………………………………………………………………………. 55
(1) Weight Disassembly/Assembly…………………………………………………………… 55
[2] CANOPY…………………………………………………………………………………. 56
(1) Canopy Assembly/Disassembly…………………………………………………………… 56
[3] FUEL TANK………………………………………………………………………………. 57
(1) Fuel Tank components…………………………………………………………………. 57
(2) Fuel Tank Assembly/Disassembly………………………………………………………… 58
(3) Fuel Hose Routing……………………………………………………………………. 60
[4] HYDRAULIC OIL TANK………………………………………………………………………. 61
(1) Hydraulic oil tank components…………………………………………………………. 61
(2) Hydraulic Oil Tank Assembly/Disassembly………………………………………………… 62
[5] ENGINE…………………………………………………………………………………. 63
(1) Engine Assembly/Disassembly…………………………………………………………… 63
(2) Engine Mounts……………………………………………………………………….. 66
(3) Muffler…………………………………………………………………………….. 67
(4) Arch, Air Cleaner……………………………………………………………………. 68
(5) Radiator……………………………………………………………………………. 69
(6) Accelerator Cable……………………………………………………………………. 70
[6] OPERATING LEVER, PEDAL…………………………………………………………………… 71
(1) Steering pilot lever…………………………………………………………………. 71
(2) Travel Lever………………………………………………………………………… 72
(3) Blade Lever…………………………………………………………………………. 73
(4) Swing pedal…………………………………………………………………………. 74
3. TRACK FRAME…………………………………………………………………………………. 76
[1] SWIVEL BEARING………………………………………………………………………….. 76
[2] CRAWLER………………………………………………………………………………… 78
(1) Rubber Track Assembly/Disassembly……………………………………………………… 78
(2) Iron Track Assembly/Disassembly……………………………………………………….. 79
(3) Track Dimensions…………………………………………………………………….. 81
[3] FRONT IDLER…………………………………………………………………………….. 82
(1) Front Idler Assembly/Disassembly………………………………………………………. 82
(2) Front Idler Components……………………………………………………………….. 82
(3) Assembly/Disassembly of the Front Idler………………………………………………… 83
[4] SPRING ASSY…………………………………………………………………………….. 86
(1) Spring Assy Assembly/Disassembly………………………………………………………. 86
[5] CYLINDER ASSY…………………………………………………………………………… 87
(1) Cylinder assy Assembly/Disassembly…………………………………………………….. 87
[6] TRACK ROLLER……………………………………………………………………………. 88
(1) Assembly/Disassembly of Track Roller…………………………………………………… 88
(2) Mounting the track roller…………………………………………………………….. 89
(3) Track roller structural components…………………………………………………….. 89
(4) Assembly/Disassembly of the Track Roller……………………………………………….. 90
[7] CARRIER ROLLER………………………………………………………………………….. 92
(1) Assembly/Disassembly of Carrier Roller…………………………………………………. 92
(2) Mounting the carrier roller…………………………………………………………… 93
(3) Carrier roller structural components…………………………………………………… 93
2 ENGINE……………………………………………………………………………………………… 95
GENERAL…………………………………………………………………………………………… 96
1. SPECIFICATIONS………………………………………………………………………………. 97
2. EXTERNAL DIMENSIONS………………………………………………………………………….. 98
3. PERFORMANCE CURVE……………………………………………………………………………. 99
3 HYDRAULIC SYSTEM……………………………………………………………………………………..100
MECHANISM………………………………………………………………………………………….101
1. DAIGRAM OF HYDRAULIC CIRCUIT…………………………………………………………………..103
[1] DAIGRAM OF HYDRAULIC CIRCUIT [U35-4 CANOPY VERSION (ANGLE BLADE OPTION)]……………………….103
[2] DAIGRAM OF HYDRAULIC CIRCUIT [U35-4 CAB VERSION (ANGLE BLADE OPTION)]………………………….104
2. HYDRAULIC DEVICE LAYOUT……………………………………………………………………….105
3. PUMP………………………………………………………………………………………..107
[1] SPECIFICATIONS…………………………………………………………………………..107
[2] COMPONENTS (STANDARD VERSION)……………………………………………………………..110
[3] FUNCTION AND STRUCTURE……………………………………………………………………111
(1) Pump Operating Principles……………………………………………………………..111
(2) Pump Hosepower Control Mechanism……………………………………………………….112
(3) A/C mode…………………………………………………………………………….113
4. CONTROL VALVE………………………………………………………………………………..114
[1] STANDARD VERSION…………………………………………………………………………114
[2] ANGLE VERSION……………………………………………………………………………115
[3] DIAGRAM OF HYDRAULIC CIRCUIT………………………………………………………………116
[4] FUNCTION AND STRUCTURE……………………………………………………………………117
(1) Auto-Idle Signal Circuit………………………………………………………………117
(2) Travel Straight Forward Circuit………………………………………………………..118
(3) Boom-up Operation…………………………………………………………………….119
(4) Boom-down Operation…………………………………………………………………..120
5. SWIVEL MOTOR…………………………………………………………………………………121
[1] SPECIFICATIONS…………………………………………………………………………..121
[2] COMPONENTS………………………………………………………………………………122
[3] FUNCTION AND STRUCTURE……………………………………………………………………124
(1) Operating Principles………………………………………………………………….124
(2) Make Up Circuit………………………………………………………………………124
(3) Shockless Valves……………………………………………………………………..125
(4) Parking Brake………………………………………………………………………..125
6. TRAVEL MOTOR…………………………………………………………………………………126
[1] SPECIFICATIONS…………………………………………………………………………..126
[2] COMPONENTS………………………………………………………………………………127
[3] FUNCTION AND STRUCTURE……………………………………………………………………129
(1) Operating Principles………………………………………………………………….129
(2) Counter-balance valve…………………………………………………………………129
(3) Auto-decelerator Function……………………………………………………………..131
(4) Parking Brake………………………………………………………………………..133
(5) Decelerator………………………………………………………………………….133
7. HYDRAULIC CYLINDER……………………………………………………………………………134
[1] BOOM CYLINDER……………………………………………………………………………134
(1) Specifications……………………………………………………………………….134
(2) Components…………………………………………………………………………..134
(3) Function and Structure………………………………………………………………..135
[2] ARM CYLINDER…………………………………………………………………………….136
(1) Specifications……………………………………………………………………….136
(2) Components…………………………………………………………………………..136
[3] BUCKET CYLINDER………………………………………………………………………….137
(1) Specifications……………………………………………………………………….137
(2) Components…………………………………………………………………………..137
[4] SWING CYLINDER…………………………………………………………………………..138
(1) Specifications……………………………………………………………………….138
(2) Components…………………………………………………………………………..138
[5] BLADE CYLINDER…………………………………………………………………………..139
(1) Specifications……………………………………………………………………….139
(2) Components…………………………………………………………………………..139
[6] ANGLE CYLINDER…………………………………………………………………………..140
(1) Specifications……………………………………………………………………….140
(2) Components…………………………………………………………………………..140
8. PILOT VALVE………………………………………………………………………………….141
[1] PILOT VALVE (BOOM, ARM, BUCKET, SWIVEL)…………………………………………………….141
(1) Specifications……………………………………………………………………….141
(2) Components…………………………………………………………………………..143
(3) Function and Structure………………………………………………………………..144
[2] PILOT VALVE (TRAVEL)……………………………………………………………………..145
(1) Specifications……………………………………………………………………….145
(2) Components…………………………………………………………………………..146
(3) Function and Structure………………………………………………………………..147
9. UNLOAD VALVE…………………………………………………………………………………149
[1] SPECIFICATIONS…………………………………………………………………………..149
[2] COMPONENTS………………………………………………………………………………150
[3] FUNCTION AND STRUCTURE……………………………………………………………………151
(1) Function…………………………………………………………………………….151
(2) Operation……………………………………………………………………………151
10. AUX SOLENOID VALVE…………………………………………………………………………..153
[1] SPECIFICATIONS…………………………………………………………………………..153
[2] COMPONENTS………………………………………………………………………………154
[3] FUNCTION AND STRUCTURE……………………………………………………………………155
11. PROPORTIONAL VALVE FOR ANGLE BLADE CONTROL……………………………………………………..156
[1] SPECIFICATIONS…………………………………………………………………………..156
[2] COMPONENTS………………………………………………………………………………156
[3] FUNCTION AND STRUCTURE……………………………………………………………………157
12. PROPORTIONAL VALVE FOR AC MODE CONTROL…………………………………………………………158
[1] SPECIFICATIONS…………………………………………………………………………..158
[2] COMPONENTS………………………………………………………………………………158
[3] FUNCTION AND STRUCTURE……………………………………………………………………159
(1) Function…………………………………………………………………………….159
(2) Operation……………………………………………………………………………159
SERVICING………………………………………………………………………………………….160
1. PUMP………………………………………………………………………………………..162
[1] PUMP REMOVAL AND INSTALLATION……………………………………………………………..162
[2] PUMP DISASSEMBLY PROCEDURES (STANDARD SPEC)…………………………………………………165
(1) Disassembly Procedures………………………………………………………………..166
(2) Assembly Procedures…………………………………………………………………..169
[3] SERVICE STANDARDS FOR PUMP PARTS…………………………………………………………..173
2. CONTROL VALVE………………………………………………………………………………..174
[1] CONTROL VALVE REMOVAL AND INSTALLATION……………………………………………………..174
[2] CONTROL VALVE DISASSEMBLY / ASSEMBLY PROCEDURES……………………………………………..177
3. SWIVEL MOTOR…………………………………………………………………………………191
[1] SWIVEL MOTOR REMOVAL AND INSTALLATION………………………………………………………191
[2] SWIVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES………………………………………………193
(1) Disassembly Procedures………………………………………………………………..195
(2) Assembly Procedures…………………………………………………………………..197
4. SWIVEL JOINT…………………………………………………………………………………202
[1] SWIVEL JOINT REMOVAL AND INSTALLATION………………………………………………………202
5. TRAVEL MOTOR…………………………………………………………………………………206
[1] TRAVEL MOTOR REMOVAL AND INSTALLATION………………………………………………………206
[2] TRAVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES………………………………………………..208
(1) Gear Case Disassembly…………………………………………………………………211
(2) Motor Disassembly…………………………………………………………………….214
(3) Gear Case Assembly……………………………………………………………………217
(4) Motor Assembly……………………………………………………………………….223
[3] SPECIAL TOOLS……………………………………………………………………………228
6. HYDRAULIC CYLINDER……………………………………………………………………………231
[1] HYDRAULIC CYLINDER DISASSEMBLY / ASSEMBLY PROCEDURES…………………………………………231
(1) Hydraulic Cylinder Components………………………………………………………….231
(2) Disassembly Procedures………………………………………………………………..232
(3) Assembly Procedures…………………………………………………………………..235
7. PILOT VALVE (CONTROL)…………………………………………………………………………242
[1] USED PARTS OF PILOT VALVE HYDRAULIC HOSE……………………………………………………242
[2] PILOT VALVE (CONTROL) DISASSEMBLY/ASSEMBLY PROCEDURES………………………………………..243
(1) Pilot Valve Components………………………………………………………………..243
(2) Disassembly………………………………………………………………………….243
(3) Assembly…………………………………………………………………………….247
(4) U-joint Tightening Tool……………………………………………………………….250
8. PILOT VALVE (TRAVEL)………………………………………………………………………….251
[1] PILOT VALVE (TRAVEL) DISASSEMBLY/ASSEMBLY PROCEDURES…………………………………………252
(1) Disassembly Procedures………………………………………………………………..253
(2) Assembly Procedures…………………………………………………………………..256
9. UNLOAD VALVE…………………………………………………………………………………261
[1] UNLOAD VALVE ASSEMBLY PROCEDURES…………………………………………………………..261
[2] UNLOAD VALVE DISASSEMBLY/ASSEMBLY PROCEDURES………………………………………………..262
(1) Unload Valve Components……………………………………………………………….262
(2) Disassembly / Assembly Procedures………………………………………………………263
10. TPSS VALVE………………………………………………………………………………….266
[1] TPSS VALVE………………………………………………………………………………266
(1) Specifications……………………………………………………………………….266
(2) Components…………………………………………………………………………..267
11. AUX SOLENOID VALVE…………………………………………………………………………..268
[1] AUX SOLENOID VALVE REMOVAL AND INSTALLATION…………………………………………………268
[2] AUX SOLENOID VALVE HOSE ROUTING……………………………………………………………269
[3] AUX SOLENOID VALVE DISASSEMBLY PROCEDURES…………………………………………………..269
12. ANGLE SOLENOID VALVE…………………………………………………………………………270
[1] ANGLE SOLENOID VALVE ASSEMBLY PROCEDURES……………………………………………………270
13. THIRD LINE VALVE ASSEMBLY…………………………………………………………………….271
[1] THIRD LINE VALVE ASSEMBLY COMPONENTS……………………………………………………….271
14. ROUTING OF HYDRAULIC HOSES……………………………………………………………………272
[1] HYDRAULIC HOSE SPECIFICATIONS……………………………………………………………..272
(1) Hydraulic Hose Total Length……………………………………………………………272
(2) Types of Connector Fittings (Screw)…………………………………………………….272
[2] DELIVERY HOSE ROUTING…………………………………………………………………….273
[3] FRONT HOSE ROUTING……………………………………………………………………….274
[4] ROUTING OF TRAVEL, SWIVEL AND BLADE HOSES (ANGLE BLADE)………………………………………275
[5] DRAIN HOSE ROUTING……………………………………………………………………….277
[6] PILOT HOSE ROUTING (P)……………………………………………………………………278
[7] PILOT HOSE ROUTING (DELIVERY)……………………………………………………………..279
[8] PILOT HOSE ROUTING (FRONT)………………………………………………………………..280
[9] PILOT HOSE ROUTING (TRAVEL, AUX1 ANGLE BLADE)……………………………………………….282
[10] PILOT HOSE ROUTING (DRAIN)……………………………………………………………….283
15. MEASURING THE PERFORMANCE OF HYDRAULIC DEVICES………………………………………………….284
16. TROUBLESHOOTING……………………………………………………………………………..297
4 ELECTRICAL SYSTEM…………………………………………………………………………………….300
SERVICING………………………………………………………………………………………….301
1. READING THE ELECTRICAL CIRCUIT DIAGRAMS…………………………………………………………303
[1] LAYOUT OF ELECTRICAL CIRCUIT DIAGRAMS………………………………………………………303
(1) Main Layout………………………………………………………………………….303
[2] LAYOUT OF CONNECTOR DIAGRAMS………………………………………………………………307
(1) Main Layout………………………………………………………………………….307
[3] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS……………………………………………….309
2. ELECTRONIC DEVICE LAYOUT………………………………………………………………………310
3. WIRING CIRCUIT……………………………………………………………………………….314
[1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING……………………………………………314
[2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS……………………………………………….314
[3] UNPLUGGING ELECTRICAL CONNECTORS AND WIRING LAYOUT…………………………………………..315
4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION)…………………………………………………….317
5. CHECKS………………………………………………………………………………………318
[1] POWER AND GROUND…………………………………………………………………………318
[2] STARTING AND STOPPING DEVICES……………………………………………………………..321
6. METER PANEL OPERATING PROCEDURE………………………………………………………………..325
[1] METER OPERATING UNIT……………………………………………………………………..325
(1) Names and Functions of Each Meter and Switch…………………………………………….325
[2] OPERATING METHOD REFERENCE LIST……………………………………………………………325
[3] DETAILS OF THE OPERATIONAL PROCEDURES………………………………………………………326
(1) Refer to the Hour Meter, Clock, Engine rpm, Water Temperature, and Fuel…………………….326
(2) View Operating Information…………………………………………………………….326
(3) Checking Periodic Inspection Items……………………………………………………..328
(4) How to set the Clock………………………………………………………………….329
(5) Switching-over of the items of “AM/PM · 24 hours”………………………………………..329
(6) Anti-Theft Settings…………………………………………………………………..330
(7) Auxiliary Port Operation………………………………………………………………331
[4] SERVICE DEALER SETTINGS…………………………………………………………………..339
(1) Diagnosis……………………………………………………………………………340
(2) Setting……………………………………………………………………………..349
[5] LIST OF WARNING ALARM DISPLAYS…………………………………………………………….366
(1) Warning Display List………………………………………………………………….366
(2) Warning Display List………………………………………………………………….368
7. TROUBLESHOOTING (METER PANEL EDITION)…………………………………………………………..370
[1] MACHINE RELATED SYSTEM……………………………………………………………………370
(1) Engine Oil Pressure Errors…………………………………………………………….370
(2) Charging System Errors………………………………………………………………..374
(3) Fuel Sensor Errors……………………………………………………………………377
(4) Water Temperature Sensor Errors………………………………………………………..381
[2] FRONT-END SYSTEMS………………………………………………………………………..385
(1) Lever Lock System Errors………………………………………………………………385
(2) Travel 2-Speed System Error……………………………………………………………390
[3] AUTO IDLING (AI) SYSTEM…………………………………………………………………..395
(1) Governor Sensor Errors………………………………………………………………..395
(2) Accelerator Sensor Errors……………………………………………………………..399
(3) AI Motor Errors………………………………………………………………………403
(4) Testing the AI Pressure Switch…………………………………………………………408
(5) Testing the AI Switch…………………………………………………………………412
[4] POWER SUPPLY SYSTEM………………………………………………………………………416
(1) Over Voltage…………………………………………………………………………416
(2) 5V Short System Error…………………………………………………………………417
[5] COMMUNICATION SYSTEM……………………………………………………………………..418
(1) CAN Communication Errors………………………………………………………………418
[6] AUX SYSTEM………………………………………………………………………………421
(1) AUX1/Thumb System Errors………………………………………………………………421
[7] ANGLE BLADE SYSTEM……………………………………………………………………….426
(1) Angle Blade System Error………………………………………………………………426
[8] TRAVEL ALARM (OPTION)…………………………………………………………………….431
5 CABIN……………………………………………………………………………………………….433
MECHANISM………………………………………………………………………………………….434
1. AIR CONDITIONING SYSTEM……………………………………………………………………….435
[1] STRUCTURE……………………………………………………………………………….435
[2] HOW THE MECHANISMS OF THE SYSTEM WORK………………………………………………………436
[3] COMPRESSOR………………………………………………………………………………437
[4] AIR CONDITIONING UNIT…………………………………………………………………….440
[5] CONDENSER……………………………………………………………………………….445
[6] RECEIVER………………………………………………………………………………..446
[7] PRESSURE SWITCH………………………………………………………………………….447
[8] SYSTEM CONTROLS………………………………………………………………………….448
[9] ADJUSTING THE AIR FLOW AND DIRECTION……………………………………………………….449
[10] ELECTRICAL SYSTEM……………………………………………………………………….450
(1) Electrical Circuits…………………………………………………………………..450
(2) Relays………………………………………………………………………………451
(3) Blower Switch………………………………………………………………………..452
2. WIPER……………………………………………………………………………………….453
[1] WIPER SWITCH…………………………………………………………………………….453
[2] WIPER…………………………………………………………………………………..453
[3] WIPER MOTOR……………………………………………………………………………..454
SERVICING………………………………………………………………………………………….455
1. TROUBLESHOOTING………………………………………………………………………………457
2. MAINTENANCE AND SERVICE RELATED SPECIFICATIONS…………………………………………………..460
3. TORQUE………………………………………………………………………………………461
4. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM………………………………………………..462
[1] USE OF SERVICE TOOLS……………………………………………………………………..462
(1) Manifold Gauge Set……………………………………………………………………462
(2) Refrigerant Charging Hoses…………………………………………………………….465
(3) Vacuum Pump Adapter…………………………………………………………………..466
(4) Electric Gas Leak Tester………………………………………………………………466
(5) Canister Tap Valve……………………………………………………………………466
(6) T-Joint……………………………………………………………………………..467
(7) R134a Refrigerant Collection/Recycling Device……………………………………………467
5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM…………………………………………………..468
[1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE…………………………………………………..468
[2] COLLECTION, VACUUMING AND CHARGING…………………………………………………………472
(1) Collecting Refrigerant………………………………………………………………..472
(2) Vacuuming Out the System………………………………………………………………472
(3) Charging from the High-Pressure Side……………………………………………………474
(4) Charging from the Low-Pressure Side…………………………………………………….474
(5) Inspections and Troubleshooting………………………………………………………..475
6. INSPECTION AND DISASSEMBLY…………………………………………………………………….477
[1] CHECKS AND ADJUSTMENTS……………………………………………………………………477
(1) Compressor…………………………………………………………………………..477
(2) Relays………………………………………………………………………………477
(3) Blower Motor…………………………………………………………………………479
(4) Blower Resistor………………………………………………………………………480
(5) Blower Switch………………………………………………………………………..481
(6) Servo Motor (for Temp Control)…………………………………………………………482
(7) Pressure Switch………………………………………………………………………483
[2] DISASSEMBLY AND ASSEMBLY………………………………………………………………….484
(1) Connecting / Disconnecting AC Hoses…………………………………………………….485
(2) Mounting and Removing the Compressor……………………………………………………487
(3) Connecting / Disconnecting Hoses……………………………………………………….490
(4) Removing and Mounting the Receiver……………………………………………………..492
(5) Removing and Mounting AC Ducts…………………………………………………………493
(6) Removal and Installation of AC Cabin Outside Sir…………………………………………495
7. CABIN REMOVAL AND MOUNTING…………………………………………………………………….497
[1] REMOVING THE CABIN……………………………………………………………………….497
8. WINDOW WASHER………………………………………………………………………………..499
[1] WIPER SWITCH…………………………………………………………………………….499
[2] COMPONENT SCHEMATIC………………………………………………………………………500
[3] WIPER MOTOR……………………………………………………………………………..501
[4] WASHER MOTOR…………………………………………………………………………….501
9. LIGHTING DEVICES (CAB WORK LIGHT, INTERIOR LIGHT)………………………………………………..502
10. REMOVAL AND INSTALLATION OF GLASS……………………………………………………………..505
[1] PREPARATION……………………………………………………………………………..505
[2] REMOVING GLASS…………………………………………………………………………..505
[3] INSTALLING GLASS…………………………………………………………………………506
[4] GLASS TRIM TYPE………………………………………………………………………….507
[5] HOW TO REPLACE THE GLASS OF THE RIGHT-SIDE WINDOW……………………………………………507
11. FRONT WINDOW………………………………………………………………………………..510
[1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP)…………………………………………510
[2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP)……………………………………………511
ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………………512
CONNECTOR CHART………………………………………………………………………………………..513
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V