Chapter10 Cabin system

CHAPTER 10
CABIN SYSTEM
CABIN SYSTEM
1. STRUCTURE
1.1 HEATER
C45WA01A
(1) Radiator union
(7) Heater Switch
(2) Heater Hose (In-line)
(8) Warm Air Outlet
(3) Heater Hose (Out-line)
(9) Battery
(4) Heater system
(10) Slow Blow Fuse
(5) Duct Hose
(11) Main Switch
(6) Grill
(12) Fuse
•
The heater components are as shown in the
illustration.
•
Use the engine coolant and release hot air outside
the cabin through the heater unit.
•
When using the air conditioner, close the heater
valve.
DC45-W00
Nov. 2004
10-3
CHAPTER 10
DK45S(DK451)
1.2 AIR-CONDITIONER
C45WA02A
(10) Compressor Relay
(1) Compressor
(6) Air-con Control Switch
(2) Receiver Driver
(7) Warm Air Outlet
(11) Compressor Relay
(3) Condensor
(8) Fuse
(12) Main Switch
(4) Air-con Unit
(9) Pressure
(13) Thermostat
(5) Air-con Duct
10-4
DC45-W00
Nov. 2004
CABIN SYSTEM
An air-conditioner inside the cabin is operated in a ventilation method.
In cold weather, the air that is warmed by the pipe getting the heat from the engine is supplied through the
heater unit to the cabin.
If the temperature outside air is excessively high (for
example in summer), driving in the cabin is uncomfortable and so the air-conditioning system of the compressor begins to operate, lowering the temperature
inside the cabin.
Refrigerant in the air-conditioner unit circulates around
the closed circuit with the pressure loaded.
R134a (HFC) is used as refrigerant here.
This refrigerant undergoes the change of pressure and
temperature at the specified point in the circuit.
The compressor is driven through the engine by means
of the belt, keeping the upper side of the vaporizer that
draw in vapor in low pressure, compressing the refrigerant in gas state obtained thereby, and leading it via
the condenser finally to the air-conditioner unit.
As the air passage crosses the condenser located in
the front of engine’s radiator, the refrigerant is cooled
and condensed between them.
The refrigerant in liquid state will be then filtered in the
receiver drier.
Thereby humidity and impurities are removed from the
receiver drier.
The receiver drier is also used as a temporary repository of refrigerant.
R134, liquid refrigerant under high pressure is led to the
expansion valve controlling the flow rate, and its pressure will fall down here radically to vaporizable state.
This low-pressure fluid starts to vaporize and condense
in the heat exchanger, that is, the vaporizer. The air of
high temperature and humidity in the cabin will be sent
to the vaporizer by the fan, and be forced to return into
the cabin after being cooled by contacting the vaporizer.
Humidity in the air is compressed outside the vaporizer,
and discharged in the state of water through the drainage hose attached to the vaporizer’s discharge fan,
resulting in the reduction of humidity in the cabin.
Gaseous refrigerant returns to the compressor, which
now completes the cycle.
Main components of an air-conditioning system are as
follows:
•
Refrigerant
•
Vaporizer
•
Compressor
•
Condenser
•
Receiver Drier
•
Expansion Valve
DC45-W00
Nov. 2004
10-5
CHAPTER 10
DK45S(DK451)
2. TROUBLE SHOOTING
You can simply find the troubles by visual and sound check during daily inspection and season-in inspection. The
early finding of troubles and proper repair enable to extend the lifetime of equipment.
A. VISUAL AND AUDIO CHECK
1. Noise caused by loosened V-belt
When the friction noise is generated by loosened or worn out V-belt, adjust the velt tension.
2. Abnormal noise around compressor
Check the compressor bolts and mounting bracket bolts for loosened and retighten them if needed.
3. The abnormal noise inside the compressor results from the broken suction valve. Disassemble, Repair, or
replace it.
4. Mud or dust adhered to the condenser
As the mud or dust reduce the radiation performance remarkably which affects the cooling capacity, it is
required to wash out the mud or dust with water. Make sure not to damage the condenser fins.
5. Contamination on the connecting area of piping and condenser
The contaminated area by oil indicates the refrigerant leaks with oil. If the contaminated area is found, check
with leak tester and retighten or replace as necessary. Carefully check the gasket, O-ring, and shaft seal in
condenser.
6. Noise from blower fan motor
If the fan blower motor generates the noise or do not rotate properly, replace it with new one. The foreign
material inside the blower or insufficient tightening may cause this noise; so carefully check before starting
repair work.
10-6
DC45-W00
Nov. 2004
CABIN SYSTEM
B. TROUBLE DIAGNOSIS
Insufficient Cooling
Check discharging air flow
Air flow is insufficient or no air flow
Discharging air flow normal
Check the fan motor's operation
Inspect discharging air temperature
Motor does not operate
Only air flow is insufficient
FUSE wiring short
Check motor control circuit
Air temperature normal
Air temperature high abnormally
Check insulation state
Check H/T
COMP rotation abnormal
Check belt
Tension normal
Check the magnetic
clutch
EVAP Frozen
There is a foreign material
in the suction grille
Unfreeze EVAP
(Turn A/C S/W OFF into FAN 3) Remove the foreign material
Inspect the refrigerant in the
sight glass
Check THERMO AMP
Check COMP rotation
COMP rotation abnormal
Check SIGHT, GLASS
There is no air bubble
Measure pressure
Tension Loosen
Adjust tension
There is no air bubble
Measure pressure
Faulty clutch
Abnormal rotation of COMP
Inspect the clutch
engagement
There is a air bubble
Charge refrigerant
There is a air bubble
Check refrigerant
capacity and air mix
state
Inspect wiring
connection
Faulty electric
system in
MAGNET
Inspect battery
voltage drop,
control switch and
earth
Both high &
low pressure normal
A/C SYSTEM malfunction
Faulty A.C mix door
Faulty VENT, intake door
Both high &
low pressure is high
Excessive refrigerant
Foreign material in COND. FAN
Excessive oil in the pipe
Inlet temperature of
COMP. is low
Airtightness and close
adhereness is bad in
EVAP. thermostatic unit
Noise
High pressure is low &
low pressure is high
Inspect temperature of
EVAP. outlet &
COMP. inletCOMP. inlet
No temperature difference &
Fast pressure balance
COMP. discharging defference
malfunction
Inspect the point where occurred
COMP
Excessive oil
Faulty bearing
Faulty clutch
DC45-W00
Belt
Other
Faulty Belt
Faulty belt line
alignment
Check belt tension
Nov. 2004
10-7
CHAPTER 10
DK45S(DK451)
C. ADVANCED TROUBLESHOOTING
a . Poor Cooling
(A) Fan motor doesn’t rotate
Causes
Checking Methods
Action
Blown Fuse
Check the A/C fuse
Replace
Open wiring or poor contact
Check the ground and missing of
key boss
Repair the failure or connect
properly
Fan Motor Failure
Check two leads from motor with
circuit tester. Failure if no current
Replace
Open in Resistor
Check the continuity of resistor
with circuit tester. Failure if no
continuity
Replace
Fan Switch Failure
Check the fan revolution in each
stage.
Replace
(B) Fan motor is normal but airflow is not sufficient
Causes
Checking Methods
Action
Obstacles in the inlet of suction of
vaporizer
Contamination of vaporizer
Removal of obstacles and cleaning
Air leakage
Check the assembly status of
cooling unit case
Modification or adjustment
Poor thermo-switch
Check whether the vaporizer is
frozen with a circuit tester
Replac
(C) Airflow is sufficient and compressor runs normally but cooling is poor
Causes
1. Excessive/insufficient
refrigerant
Checking Methods
Action
Touch the high and low pressure pipes
by hand after 5~10 minutes from turning
on A/C. Check the refrigerant flows and
level by monitoring sight glass.
2. Insufficient refrigerant
The difference of temperature is too
Repair the leakage area and
small. Bubbles or foggy flows can be
charge to specified level.
seen through sight glass.
3. Excessive refrigerant
The high pressure is too high and
Discharge the refrigerant
cannot be seen any bubbles through
gradually till you can see bubble
sight glass even when cooling the
through sight glass.
condenser with water.
4. Normal pressure
High pressure: 14~15 kg/cm 2G
Low pressure: 1.5~2.0 kg/cm 2G
Ambient temperature: 30~35 ¡ÆC
Engine speed: approx. 2000 rpm
10-8
DC45-W00
Nov. 2004
CABIN SYSTEM
Causes
Checking Methods
Action
4-1. Low pressure is too high
1) Faulty thermo switch
Magnetic clutch is off before the extracted
Adjust or replace
air temperature fully falls down.
2) Faulty compressure gasket
or valve
When magnetic clutch is off, the high
Repair or replace
and low gauge pressure is balanced
immediately.
3) Poor contact of thermal
case in expansion valve
Frost is generated on connecting area
Adhere the thermal case to low
of compressor and its temperature is
pressure pipe
lower than that of outlet pipe.
4) Too widely open expansion
Same as above. No changes in pres-
Replace
sure regardless of thermal case’s
valve
existence.
5) Clogged compressure
suction filter
The low pressure hose is not cold and
Clean filter
only connecting area of compressor is
cold.
4-2. Low pressure is too low
1) Insufficient refrigerant
Refer to “Insufficient refrigerant”.
Add refrigerant
2) Clogged receiver drier
The difference of temperature between
Replace receiver drier
outlet ports is significant. Frost is
generated on the tank.
3) Clogged expansion valve
The inlet port of expansion valve is cold
Replace expansion valve
and frost is generated on the tank.
4) Gas leaks from thermal
The outlet port of expansion valve is not
case in expansion valve
cold and low pressure gauge indicates
Replace expansion valve
negative pressure.
5) Clogged and damaged
pipings
When the pipings are clogged, low
Clean or replace pipings
pressure may be low or the gauge may
indicate negative pressure.
6) Faulty thermo switch
Frozen vaporizer
Adjust or replace
Contaminated condenser or clogged,
Wash, repare or replace the fan
4-3. The high pressure is too
high
1) Poor cooling of condenser
faulty cooling fan, blown fuse, open
wiring and poor contact
2) Excessive refrigerant
Refer to “excessive refrigerant”.
Adjust refrigerant level
Vacuuming, recharge refrigerant
3) Air intrusion into cycle
4-4. The high pressure is too
low
1) Insufficient refrigerant
DC45-W00
Nov. 2004
Refer to “Insufficient refrigerant”.
Add refrigerant
10-9
CHAPTER 10
DK45S(DK451)
(D) The compressor does not rotate or hard to rotate
Causes
Checking Methods
Action
1. Loosened belt
Too large belt vibration
Adjust belt tension
2. Internal failure of compressor
Slippery belt
Repair or replace
3-1. Nattery boltage drop
Slipping when rotating
Charge the battery
3-2. Layer short of coil
Slipping when rotating
Replace magnetic clutch
3-3. Oil intrusion into clutch
Slipping due to contaminated magnetic
Replace or clean the clutch
clutch area
surface
Contact each other when pushing the
Adjust the clearance or replace
3. Magnetic clutch problem
surface
3-4. Too large clearance
between clutch plate and
clutch plate
clutch wheel
3-5. Open coil
Cannot contact when pushing the clutch
Replace compressor
and circuit tester doesn’t move when
checking the lead of ports.
3-6. Open wiring or poor
contact to ground
3-7. Check the wiring parts
Cannot contact regardless operation,
Repair
check the ground and connecting area
Check the continuity of pressure switch,
Replace
thermo switch and relay
b. Poor Heating
(A) Fan motor doesn’t rotate: refer to step 1 in section 2-(1)
(B) Fan motor doesn’t rotate: refer to step 1 in section 2-(1)
Causes
1. Too large ventilation resis-
Checking Methods
Action
Check the duct for clogged or damaged
Repair
Check the duct connecting area, Check
Repair
tance
2. Air leaks at duct connecting
the duct seal and assembled conditions
area
(C)Airflow is sufficient but hot air cannot be generated
Causes
1. Too low coolant temperature
Checking Methods
Check the coolant temperature after
Action
Replace thermostat
heating operation
2. Too low coolant level
Check the coolant level in radiator
Add coolant
3. Too low coolant circulating
Check the pipings for clogged
Air bleeding, repair
Check the operation of air mix door and
Adjust or replace control cable,
seal condition
check the seal
volume
4. Clogged heater core
(D)Airflow is sufficient but hot air cannot be generated
Causes
Checking Methods
Action
1. Faulty seal
Check the leaks from heater core, core,
Replace or repair
2. Too large play in connecting
connecting area, hose, and pipings
Replace or repair
area
Same as above
3. Porous heater core
Check heater core
10-10
Replace
DC45-W00
Nov. 2004
CABIN SYSTEM
D. TROUBLESHOOTING BY MANIFOLD GAUGE
The manifold gauge is used to check the high and low
pressure in cooling cycle, and troubles in certain cycle
can be found by reading the measured value.
a. Normal Condition
1. Connect the manifold gauge to high and low pressure connectors.
2. Exhaust the air from charging hose at manifold
gauge connecting area.
*
CONDITION
Ambient temperature: 30°C ~ 35°C (86°F ~ 95°F)
Engine speed: 2000 rpm
Blower fan: HI (Maximum speed)
Thermo switch (Coldest)
*
REFERENCE
Low pressure side: 1.5 ~ 2.0 kgf/cm 2 (0.15 ~ 0.19
Mpa, 21.3 ~ 28.4 psi)
High pressure side: 14.5 ~ 15 kgf/cm2 (1.42 ~ 1.47
Mpa, 206.2 ~ 213.3 psi)
C45WA03A
b. Insufficient Refrigerant
1. Status: Not cool
2. Symptoms:
- The pressure of high/low pressure side is low.
- The bubble in sight glass is seen.
- Discharging temperature doesn’t fall down.
3. Cause: Refrigerant leakage
4. Action: Check with gas leak tester and repair the
leaking part and add to specified level.
*
REFERENCE
Low pressure side: 0.8 kgf/cm 2 (0.08 Mpa, 11.37psi)
High pressure side: 8 ~ 9 kgf/cm2 (0.78 ~ 0.88 Mpa,
113.8 ~ 128.0 psi)
C45WA04A
c. Excessive Refrigerant, Poor Condenser
Cooling
1. Status: Not cool
2. Symptoms:
- The pressure of high/low pressure side is high.
3. Cause:
- Increased pressure due to excessive charging the
refrigerant
- Poor cooling performance of condenser
- Loosened A/C belt
4. Action:
- Clean the condenser
- Check and adjust the fan belt and condenser motor
- Check the refrigerant level
CAUTION
•
Discharge the refrigerant slowly from the low
pressure side of manifold gauge while checking
the refrigerant level by monitoring the pressure
gauge and sight glass. This may caused by contamination of radiator.
DC45-W00
Nov. 2004
C45WA05A
*
REFERENCE
Low pressure side: 2.5 kgf/cm2 (0.24 Mpa, 35.5 psi)
High pressure side: 20 kgf/cm2 (1.96 Mpa, 284.5 psi)
10-11
CHAPTER 10
DK45S(DK451)
d. Air Intrusion into Cycle
1. Status: Not cool
2. Symptoms:
- The pressure of high/low pressure side is high.
- The low pressure pipe is not cold.
3. Cause:
- Air intrusion into cooling cycle
- The measured value is shown in left figure.
4. Action:
- Read the measured value in charginf process while
vacuuming
- Replace the receiver drier after long operation with
air intruded.
- Check the contamination of refrigerant and oil.
C45WA06A
*
REFERENCE
Low pressure side: 2.5 kgf/cm2 (0.24 Mpa, 35.5 psi)
High pressure side: 23 kgf/cm2 (2.25 Mpa, 327.1 psi)
e. Faulty expansion valve
1. Status: Not cool
2. Symptoms:
- The pressure of high/low pressure side is high.
3, Cause:
- Poor expansion valve, poor refrigerant flow control
due to improper assembly of thermal case
4. Action:
- Check the assembled conditions, position and
adiabatic in thermal case. if normal, replace the
expansion valve.
*
REFERENCE
C45WA07A
Low pressure side: 2.5 kgf/cm2 (0.24 Mpa, 35.5 psi)
High pressure side: 19 ~ 20 kgf/cm 2 (1.86 ~ 1.96
Mpa, 270.2 ~ 284.5 psi)
f. Poor Compression
1. Status: Not cool
2. Symptoms:
- The pressure of low pressure side is high while
the pressure of high pressure side is very low.
- When stopping the operation, the pressure of high/
low pressure shall be the same immediately.
3. Cause:
- Poor compressor gasket, poor compressor caused
by the broken suction valve.
4. Action:
- Disassemble and repair the compressor.
C45WA08A
- Replace the compressor assembly.
*
REFERENCE
Low pressure side: 4~6 kgf/cm2 (0.39 ~ 0.59 Mpa,
56.9 ~ 85.3 psi)
High pressure side: 7~10 kgf/cm2 (0.69 ~ 0.98 Mpa,
99.6 ~ 142.2 psi)
10-12
DC45-W00
Nov. 2004
CABIN SYSTEM
g. Moisture Intrusion Into Cooling Cycle
1. Status: Sometimes cool, sometimes not cool
2. Symptoms:
- The pressure of low pressure side is sometimes
negative or sometimes returning normal.
3. Cause:
- The moisture inside cooling cycle is frozen which
makes the cycle closed in the expansion valve
and return to the normal by melting of ice.
4. Action:
- Replace the receiver drier.
- Repeat the vacuum working 2 ~ 3 times. Charge
the proper amount of refrigerant.
*
C45WA09A
REFERENCE
Low pressure side: Vacuum
High pressure side: 7 ~ 15 kgf/cm 2 (0.69 ~ 1.47
Mpa, 99.6 ~ 213.3 psi)
h. Poor Recirculation of refrigerant
1. Status: Nots cool (sometimes cool)
2. Symptoms:
- The pressure of low pressure side is negative
and the pressure of high pressure sidde shows
the pressure 5 ~ 6 kgf/cm 2 (0.49 ~ 0.59 Mpa, 71.1
~ 85.3 psi)
- Frost or dew forming in the receiver drier or the
front/rear pipe connecting section of expansion
valve.
3. Cause:
- The cycle is closed by moisture freezing or dust
in cooling cycle.
C45WA10A
- The cycle is blocked due to the poor thermal case
of expansion valve.
4. Action:
- Stop the operation once to check the clogging by
moisture or dust.
- If moisture has been found, perform the
vacuuming.
- Detach the expansion valve and remove the dust
by compressed air.
- Replace the receiver drier.
*
REFERENCE
Low pressure side: Vacuum
High pressure side: 6 kgf/cm 2 (0.59 Mpa, 85.3 psi)
DC45-W00
Nov. 2004
10-13
CHAPTER 10
DK45S(DK451)
3. INSPECTION AND ADJUSTMENTS
WARNING
1. Do not release refrigerants to the outside.
2. The refilling of air conditioner gas deals with high
pressure gas, and because of the dangers, it should
only be performed by specialists.
3. To prevent accidents like the loss of sight during
work, you must wear protective glasses, gloves etc.
4. Store the service container in a cool dry place, and
do not drop or knock it.
5. The air conditioner gas and equipment must exclusively use HFC-134a, and never use R12.
6. Use the UCON 488 compressor oil (265cc)
7. Do not work where there is poor ventilation.
8. Air conditioner gas in non-hazardous and non-toxic,
but if it comes into contact with high temperatures it
breaks down and forms harmful substances.
10.Over refilling of gas is a cause for bad cold air, overheating etc.
11. Do not turn the service container up side down.
12.Each refill hose connections must be firmly attached
by hand. (Do not attach with pliers and the like)
13.When you connect the refill hose to the service
container, check for damages in the packing.
IMPORTANT
•
After disassembling the pipe and it is left out for
more than a week, change the receiver.
•
When disassembling the pipe or hose of the cooler,
gas leakages and dust penetration must be prevented by plug or cap mounting attachments.
When connecting the pipe, compressor oil must
be applied to the O ring.
•
When replacing condensers, evaporators,
receivers, dryers etc. the compressor oil must
be replenished with the following amount.
10-14
DC45-W00
Nov. 2004
CABIN SYSTEM
A. LEAKAGE TEST
1. Using an extraction detector, check for leakages in
each section.
2. If a gas leakage is detected, refer to the next gas
emission stage (reference page…) and repair the
leakage section as outlined.
IMPORTANT
•
When disassembling parts, they must be thoroughly cleaned and sealed.
(When assembling)
•
Apply refrigerant lubrication oil to the O ring of the
connection area.
•
For gas vacuuming and refilling (reference page ),
refer to the relevant section and perform as outlined,
and after checking for leakages complete the
refilling.
C45WA11A
(1) Leak Tester
B. DISCHARGING SYSTEM
IMPORTANT
•
Do not discharge refrigerants to the outside.
•
HFC-134a equipments must be used exclusively.
•
Check if the service hose is properly connected.
WARNING
You must wear protective glasses and gloves.
1. Attach the manifold gavage and the recycling machine to the refrigerant lines as shown.
CAUTION
•
Be careful not to switch the connections for
the low and high pressure valves.
C45WA12A
(1) Low Pressure
(2) Low Pressure
(3) Recycling Machine
2. Open the high pressure valve slowly to release the
refrigerant to the recycling machine.
CAUTION
•
Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/
cm 2 (50 psi), slowly open the low pressure valve.
4. Open both the high and low pressure valves slowly
until the manifold gauge dials indicates 0 kg/cm 2 (0
psi).
DC45-W00
Nov. 2004
10-15
CHAPTER 10
DK45S(DK451)
C. EVACUATING
1. Connect the manifold low pressure service hose
(red) and the high pressure service hose (blue) to
the compressor low pressure end and high pressure end of the service valve.
2. Connect the manifold center hose (green) to the
vacuum pump.
3. Open the low pressure & high pressure valves, and
operate the vacuum pump in accordance with the
instructions to perform vacuuming.
4. Perform for about 15 minutes and when the low
pressure gauge reaches the lowest safe vacuum
level (750mmHg) stop the vacuum pump, close the
manifold low pressure, high pressure valves and
leave it for at least 5 minutes and check that the
gauge does not reach 0.
5. If the gauge reaches close to 0, there is a leak
somewhere, so after checking and repairing the pipe
connections, re-perform the vacuuming and check
that there are no gas leakages.
10-16
C45WA13A
(1) Low pressure
(3) Vacuum pump
(2) High pressure
(4) Air
(A) Open
DC45-W00
Nov. 2004
CABIN SYSTEM
D. CHARGING.
IMPORTANT
•
Refill the gas after gas has been released and
vacuuming has been performed.
•
When refilling gas, do not start the engine and
perform from the high pressure end first, and then
start the engine and put in the prescribed amount.
WARNING
•
When refilling gas on the high pressure end, do
not start the engine. This could cause rupture
from the back flow and as there are no refrigerants it could cause damage to the compressor.
C45WA14A
(1) High Pressure Gauge
(2) Low Pressure Gauge
1. Open the high pressure valve and put in about…….
of refrigerant.
2. Close the high pressure valve and check for any
gas leakages.
(3) Refrigerant
(A) High pressure (open)
(B) Low pressure (close)
WARNING
•
Because the engine is turned on when refrigerant
is put into the low pressure end, do not open the
high pressure valve.
•
When replacing the service can, release the air
from the charging hose (green).
3. After checking that the high pressure valve is closed,
start the engine and take it to about 2000rpm.
4. Open the interior door and adjust the temperature
control lever to cool, and the fan switch to high.
5. Open the low pressure valve and put in refrigerant
until the bubbles disappear from the receiver
window.
6. When the refrigerant has been filled, close the low
pressure valve and stop the engine.
7. Perform refrigerant leakage tests.
- Refrigerant insertion quantity : 700g (1.54 lbs)
- Manifold gauge pressure {when the exterior temperature in 30 degrees (86°F)}
- High pressure : 14.5 ~ 15 kgf/cm2 (1.42 ~ 1.47
Mpa, 206.2 ~ 213.3 psi)
- Low pressure : 1.5 ~ 2.0 kgf/cm2 (0.15 ~ 0.19 Mpa,
21.3 ~ 28.4 psi)
DC45-W00
Nov. 2004
10-17
CHAPTER 10
DK45S(DK451)
E. DISASSEMBLING AND CHECK
a . Draining Coolant
CAUTION
•
Never open radiator cap when the coolant’s temperature reaches boiling point.
•
When opening the cap, turn the cap slightly to let
off pressure and then open it.
1. Stop the engine and cool the water fully.
2. Open the drain cock and radiator cap to drain the
water completely.
3. Lock the drain cock, after the coolant drained
completely.
(1) Drain Cock
(Filling)
•
C45WA15A
(2) Radiator Cap
Fill water up the point between “Full” and ”low” mark
on the recovery water tank.
Coolant capacity
8.6
(2.3 U.S.gal)
C45WA16A
(1) Recovery Tank
(A) FULL
(B) LOW
b. Disassembling Hood, Side Cover and
Battery
1. Open the hood and disconnect battery (-)cable.
2. Disconnect the headlamp wiring (3).
3. Remove the hood (1).
1
3
4. Remove the side cover (4).
4
REFERENCE:
•
2
When disconnecting battery cable, (-) cable at first,
but link (+) cable at first when assembling.
C45WA17A
10-18
(1) Hood
(3) Head Lamp Wiring
(2) Battery (-) Cable
(4) Side Cover
DC45-W00
Nov. 2004
CABIN SYSTEM
c. Disassembling Air Conditioner Hose,
Heater Hose, Steering Hose, Wire, And
Hood Wiring Assembly
1. Remove the steering hose T, P, L, R.
2. Remove the PTO hydraulic pipe1 and 4 from
connector.
3. Remove the pipe bracket 2.
4. Remove the air conditioner hose valve A and B under cabin, and then detach hose.
5. Remove the heater hose.
6. Remove the governor wire.
7. Remove the pipe band and separate suction hose
and suction pipe 3.
C45WA18A
(1) Steering Hose (L)
(8) Air Conditioner Vlave
(Assembling)
(2) Steering Hose (R)
(9) Heater Hose 1
•
(3) Steering Hose (P)
(10) Heater Hose 2
(4) Steering Hose (T)
(11) Accelator Cable
(5) Hydraulic Pipe (3)
(12) Suction Hose
(6) Hydraulic Pipe (4)
(13) Suction Pipe 3
When assembling PTO hydraulic pipe 1 and 4, apply pipe sedent (LOCTITE #577 or equivalent).
Assembling torque of
steering hose T, P, L, R
24.5 N·m
2.5 kgf·m
18.1 lbf·ft
Assembling torque of
PTO hydraulic pipe 1
and 4
1/6~1/3 revolution after
the point of rapid
increasing torque of nut.
Assembling torque of
air conditioner coupler
Pipe band tightening
torque
9.8 N·m
DC45-W00
Nov. 2004
(7) Pipe Bracket
1 kgf·m
7.2 lbf·ft
10-19
CHAPTER 10
DK45S(DK451)
d. Disassembling cabin
1. Remove the mat.
2
2. Loosen the bolt and separate seat assy and bottom plate.
3. Pull of joystick lever from support and push it out of
cabin.
4. Remove the main shift lever.
5. Remove the range shift lever.
C45WA20A
(1) Mat
(4) Main Shift Lever
(2) Seat Assy
(5) Range Shift Lever
(3) Joystick Lever
6. Remove the PTO shift lever rod.
7. Remove the differential pedal rod.
8. Remove the MLS valve rod.
9. Remove the hydraulic control lever rod (position,
draft control lever).
10.Remove the double action valve lever rods.
C45WA21A
(1) PTO Shift Lever Rod
(2) Differential Pedal Rod
(3) MLS Valve Rod
(4) Double Action Valve Lever Rods
11. Remove the brake rod(LH / RH).
12.Remove the clutch rod.
13.Remove the rubber cover 2 and disconnect the suttle
lever and cabin wiring.
C45WA22A
(1) Brake Rod
(3) Rubber Cover 2
(2) Clutch Rod
10-20
DC45-W00
Nov. 2004
CABIN SYSTEM
15.Support the cabin hanging on hoist with nylon rope.
16.Unlock the bolt assembling cabin.
17.Remove the cabin from tractor.
REFERENCE:
•
Disassemble cabin slowly checking if there is any
obstacle.
(Assembling)
•
Assemble washer, cabin rubber, etc. at the original
place.
Torque of bolt and nut
assembling cabin
123.6 ~ 147.1 N·m
12.6 ~ 15.0 kgf·m
91.1 ~ 108.5 lbf·ft
C45WA23A
F. DISASSEMBLING THE COMPRESSOR
1. Open the hood.
2. Release the air conditioner gas.(refer to page 1015)
3. Remove the air conditioner hose.
Seal with a stopper when detaching.
4. Disassemble the wiring.
5. Remove the compressor belt.
4. Loosen the bolt and remove the compressor.
(When assembling)
•
Set the compressor belt tension (refer to page 129) & refill the air conditioner gas (refer to page
10-17).
C45WA24A
- Compressor oil quantity : 150 cc
- Tightening torque of air conditioner hose : 4.9 ~
5.7 kgf·m (48.1 ~ 55.9 N·m, 35.4 ~ 41.2 lb·ft)
- Tightening torque of compressor :
M8 : 2.4 ~ 2.8 kgf·m (23.6 ~ 27.4 N·m, 17.4 ~ 20.2 lb·ft)
M10 : 4.9 ~ 5.7 kgf·m (48.1 ~ 55.9 N·m, 35.4 ~ 41.2 lb·ft)
DC45-W00
Nov. 2004
10-21