2003-2009 Yamaha Wolverine 2wd 4wd Atv Service Repair Manual – PDF Download

Service Information Document Title: Cab, installation

Function Group: 810

Information Type: Service Information

Date: 2014/5/31

Profile:

Cab, installation   

Attach wire ropes to the lifting hooks of the cab, and lower the cab to the mounting position.

Tighten the 7 mounting screws (2, 5, 6).

Connect the main wiring connectors.

CAUTION Take care that the cab frame does not hit the control board when removing or installing the cab.

Figure 1 Cab 1 Cab

5 Screw

9 Screw

Tightening torque :

2 Screw

6 Screw

10 Plain washer

– 2, 5, 6 Screw: 20 ± 2 kgf·m (144 ± 14 lbf·ft)

3 Plain washer

7 Mirror support

11 Spring washer

– 9 Screw: 0.8 ± 0.1 kgf·m (5.8 ± 0.7 lbf·ft)

4 Spring washer

8 Rear view mirror

Service Information Document Title: Cab, removal

Function Group: 810

Information Type: Service Information

Date: 2014/5/31

Profile:

Cab, removal    

Attach wire ropes to the lifting hooks of the cab, and lift the cab until there is no slack in the wire ropes.

Remove the 7 mounting screws (2, 5, 6) located at the bottom plate of the cab.

Disconnect the main wiring connectors, air duct and storage box.

Lift the cab just a little, and after confirming safety all around, lift up and out.

NOTE! Cab weight : about 275 kg (605 lb)

Service Information Document Title: Cab, specifications

Function Group: 810

Information Type: Service Information

Date: 2014/5/31

Profile:

Cab, specifications Specifications Item

Unit

Specification

Length

mm (in)

1870 (73.6)

External

mm (in)

1670 (65,7)

Internal

mm (in)

1600 (63) - (With front window closed)

Height

1570 (61.8) - (With front window opened) Width

External

mm (in)

975 (38.4)

Internal

mm (in)

921 (36.3)

Height from Seat index position to mm (in) roof

1100 (43.3) - (With front window closed)

Side distance from Seat index position mm (in)

Left : 453 (17.8), Right : 445 (17.5)

Window

Seat

1070 (42.1) - (With front window opened)

Front Upper

-

Fully-open, laminated safety glass

Front Lower

-

Channel type detachable laminated safety glass

Side

-

Left : Sliding opened, tempered safety glass Right : FIxed, tempered safety glass

Rear

-

Fixed, tempered safety glass

Type

-

Adjustable suspension, reclinable with headrest and armrest (From vertical position)

Reclining

-

Front : 20°, Rear : 70° (with foldable mechanism)

Adjust

-

Horizontal : Forward 80 mm (3.2″), Rearward 70 mm (2.8″) Vertical : ± 30 mm (1.2″) Suspension load : 50 ~ 120 kg (110 ~ 265 lb)

Service Information Document Title: Function Group: Viscose mount, description 810

Information Type: Service Information

Date: 2014/5/31

Profile:

Viscose mount, description   

The bottom plate where cab is assembled is mounted on 5 viscose mounts, and then assembled to the upper deck.

Viscose mounts is designed to absorb vibration generated when operating the machine.

Silicon oil and gas inside the viscose mounts absorbs extreme shock impact.

CAUTION If the viscose mount is dropped or impacted, silicon oil may leaked and lower the performance.

CAUTION The exterior of viscose mount is natural rubber with low oil resistance. Avoid contact with grease and oil.

Installation position

Figure 1 Installation position 1 Bottom plate

6 Nut

2 Floor mat

7 Spring washer

3 Viscose mount

8 Screw

4 Plain washer

A Viscose mount

5 Spring washer

U Upper deck

Service Information Document Title: Function Group: Viscose mount, installation 810

Information Type: Service Information

Date: 2014/5/31

Profile:

Viscose mount, installation 1.

Install the viscose mount on upper deck by tightening screw (8).

Tightening torque : 6.5 ± 0.7 kgf·m (47 ± 5 lbf·ft)

2.

Check for deformation and debris on mounting surface.

CAUTION The difference of height for viscose mount installed (5 pieces) must be within 1mm.

3.

Tighten the lock nut (6) with specified torque.

Tightening torque : 26.7 ± 2.7 kgf·m (193 ± 19 lbf·ft)

4.

Cover the floor mat.

NOTE! If the ambient temperature is less than 0 °C, the viscosity of silicon oil inside the viscose mount is high, and the ride is some what rough. After operating a few minutes, the viscosity will be lowered by heating due to vibration and the ride will be much smoother.

Service Information Document Title: Viscose mount, removal

Function Group: 810

Information Type: Service Information

Date: 2014/5/31

Profile:

Viscose mount, removal 1.

2.

3.

Remove the cab.

Remove floor mat (2), and remove the bottom plate by loosening nut (6) tightened to bottom plate (1).

Remove the viscose mount by loosening screw tightened to upper deck.

Service Information Document Title: Air conditioning description

Function Group: unit, 870

Information Type: Service Information

Date: 2014/5/31

Profile:

Air conditioning unit, description The advanced integrated air conditioning system with the heating and the cooling system installed in a single unit is designed to provide a comfortable indoor environment in all seasons.

The integrated system is ergonomically designed for the most efficient air flow distribution. The easy to use control panel provides a selection of cooling/heating and indoor/outdoor air through 8 levels and 4 fan speeds.

Characteristics of an integrated air conditioning system    

This system provides a comfortable indoor environment with powerful cooling and heating capacity in all weather conditions.

The thermistor installed in the integrated air conditioner protects the evaporator and cooling system from freezing.

The cooling and heating system can be operated simultaneously to control humidity and indoor temperature.

According to the indoor and outdoor air condition, indoor or outdoor air circulation can be selected. All fresh air is drawn through the air filter installed between the duct and the cab vent.

Structure of integrated air conditioning system

Figure 1 Structure, air conditioning system 1 Engine

A Indoor air

2 Compressor

B Outdoor air

3 Condenser

C Face

4 Evaporator

D Foot

5 Heater core

E Defroster

System structure

Figure 2 Number of parts, air conditioning system Air conditioning system's parts No.

Item

Quantity A

C

1

Compressor

1

1

2

Receiver dryer & condenser

1

1

3

Air conditioner & heater

1

Air conditioner

1

Heater

1

4

Supply hose A

1

1

5

Supply pipe B

1

1

6

Supply hose C

1

1

7

Hose

1

1

8

Inlet hose A

1

1

9

Inlet pipe B

1

1

10

Inlet hose C

1

1

11

Belt tensioner

1

1

12

V-belt

1

1

13

Compressor bracket

1

1

14

O-ring

2

2

15

Drain hose

2

2

16

O-ring

4

4

17

O-ring

4

4

A : Air conditioner and heater mounted C : Only air conditioner mounted H : Only heater mounted Body structure

H

Figure 3 Structure, air conditioning unit body 1 Blower case

8 Intake upper case

15 Relay

2 Evaporator upper case

9 Intake lower case

16 Heater valve

3 Evaporator lower case

10 Heater valve motor

17 Power transistor

4 Blower motor and fan

11 Evaporator

18 Temperature sensor

5 Air flow control motor

12 Heater

19 Heater valve assembly

6 Air direction control motor

13 Indoor / Outdoor selection motor

7 Shutter

14 Indoor filter

Service Information Document Title: Air conditioning maintenance

Function Group: unit, 870

Information Type: Service Information

Date: 2014/5/31

Profile:

Air conditioning unit, maintenance Periodic inspection   

If the cooling or heating system are not used for a long time, see the periodic maintenance table and perform the required inspections.

During the off-season operate the air conditioner 2 ~ 3 times per month for 5 ~ 10 minutes to lubricate the compressor components.

In the summer season close the valve installed in the engine block to cut off the flow of coolant to the heater.

Check item Proper refrigerant handling Worldwide environmental protection regulations prohibit the discharge of any refrigerant into the atmosphere, and require that refrigerant be recovered using the approved recovery equipment.

CAUTION Use correct refrigerant recovery, recycling and charging stations, DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for use with other refrigerants.

Recovery, recycling and charging stations for R134a and other refrigerants MUST NOT be interchanged. Systems containing other refrigerants use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants.

R12 and R134a refrigerant precautions

WARNING Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

Repair and refilling of the refrigerant system must only be done by trained personnel. Contact your authorised Volvo Construction Equipment workshop. If liquid refrigerant contacts eyes or skin, do not rub the area. Splash large amounts of cool water on affected area, Go to a physician or hospital immediately for treatment. DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

DO NOT heat refrigerant over 52 °C (125 °F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. do not handle a damp refrigerant container with your bare hands. Skin may freeze to the container. Wear gloves. If skin freezes to the container, pour cool water over container to free the skin. Go to a physician or hospital immediately for treatment.

Periodic maintenance table Periodic maintenance items Component

Check item

Check period

Compressor

Operating condition

12 month

Condenser

Contamination

6 month

Motor

Operating condition

6 month

Condenser

Evaporator

Contamination

12 month

Refrigerant (R–134a)

Charging capacity

6 month

Idler pulley

Operating condition

12 month

V–belt

Looseness, damage, aging

6 month

Hose

Aging

12 month

Tube connection

Damage

6 month

Attached parts

Leakage, looseness, contacting damage

6 month

Heater core

Contamination

12 month

Blower motor

Operating condition

12 month

Heater valve

Leakage, operating condition

12 month

Outdoor filter

Contamination

6 month

Tube

Check method Check for gas leakage on refrigerant hose joint.  

When oil is found on the pipe joint, gas leakage could be occurring.

Check the union and tighten to the proper torque.

Check the tension of V-belt for driving compressor. 

Check the belt for looseness by pressing with your fingers. When a force of approximately 10 kg is applied to the belt center, allowable limit is 8 ~ 10 mm. After about 40 hours, recheck the belt tension.

Figure 1 Check, belt looseness A. B.

Compressor Crank pulley

Check the compressor. 

After operating air conditioner for 5 ~ 10 minutes, check the high-pressure pipe and low pressure pipe by hand. In normal condition the high pressure pipe is hot and low pressure is cold.

Check the condenser. 

When the condenser is contaminated, the radiating efficiency is lowered significantly. Clean the condenser to improve cooling.

CAUTION DO NOT use steam to clean the condenser core. The refrigerant can overheat! When cleaning with water, protect the electrical components.

Check the refrigerant capacity 

Check the sight glass of the receiver/dryer. (Measuring port is located on the compressor connecting hose union.)

CAUTION Note that bubble condition and discharging pressure are severely affected according to outdoor temperature, condenser ambient temperature, wind speed and weather condition.

Operating condition Checking method Preparation 1.

2.

3.

Checking method

Start and run the engine at 1500 rpm.

Set the control lever to indoor and blower to high.

Operate the air conditioner at least 5 minutes and keep the indoor temperature at 25 ~ 30 °C.

4. Turn off the air conditioner for 40 ~ 50 seconds.

5. Turn on the air conditioner for 40 ~ 50 seconds.

6. Turn off the air conditioner for 40 ~ 50 seconds.

7. Turn on the air conditioner for 40 ~ 50 seconds.

Judgement criteria Checking, amount of refrigerant Performance

Charge of Refrigerant

Condition

Normal

Temperature of the High pressure side is high / low pressure hot and low pressure hoses. side is cold.

Temperature difference is significant.

Low

Very low

High pressure side is warm and low-pressure side is slightly cool.

Temperature difference is slight.

There is almost no Abnormal temperature difference overheating at high between the high/low pressure hose. pressure hoses.

Too much

Refrigerant condition Almost transparent and Bubbles all the time Milky white fog by sight glass. a few bubbles. and flow in white is is visible.

New refrigerant visible.

HFC–134a: Immediately changed at reoperation.

No bubbles.

If air is mixed, very large bubbles are visible.

Pipe joint

Normal

Good

Air conditioner

Refrigerant charge is Leakage is found. sufficient and normal. Cooling efficiency is Normal operating lowered. system.

Pressure

High pressure : 11 ~ 18 kgf / cm2 Low pressure : 1.5 ~ 3 kgf/cm2

High / Low pressure are High / Low pressure are High/Low pressure low. low. are very high.

Repair

None

Fill with refrigerant.

ď‚&#x;

A little contaminated Excessively with oil. contaminated with oil.

Most refrigerant is used up.

Cooling efficiency is extremely low.

Check leakage.

Fill with refrigerant.

Refrigerant is excessive.

Cooling efficiency is lowered.

Stop the compressor.

Drain the refrigerant.

An overcharged system (Too much refrigerant) can result in the pressure switch circuit de-energizing the compressor magnetic clutch.

Service Information Document Title: Air conditioning refrigerant check recharging

Function Group: unit, 870 and

Information Type: Service Information

Date: 2014/5/31

Profile:

Air conditioning unit, refrigerant check and recharging WARNING DO NOT disassemble the compressor relief valve. The refrigerant in the circuit is rapidly ejected and may cause injury.

Special tools

Figure 1 Tools for refrigerant charging 1.

2.

3.

4.

5.

6.

Quick coupler Low pressure hose Gauge manifold High pressure hose Quick coupler Center filler hose

Quick coupler connecting method ď‚&#x; ď‚&#x;

Remove the filler valve cap.

Insert the quick coupler onto the filler valve, and press firmly sleeve (A) until a click sound is heard.

Figure 2 Quick coupling, connection

CAUTION When connecting, take care not to bend the pipes.

Quick coupler disconnecting method Hold body (A) of quick coupler and lift sleeve (B).

After removing the quick coupler, install the filler valve cap.

Figure 3 Quick coupling, disconnection Pressure check procedure         

Close both the low and high pressure valves on the gauge manifold.

Connect the appropriate quick coupler of the gauge set to the low (suction) pressure and high (discharge) pressure side of the compressor.

Connect the center filler hose to the refrigerant canister.

Open (1/2 turn) and close each pressure valve to release the air from the hoses and gauge set.

Start the engine and idle at approx. 1500 rpm for about 10 minutes to stabilize the system.

Turn on the air–con switch and select the temperature selection switch to maximum cooling at maximum fan speed.

Open all system vents for maximum air distribution.

After 5 minutes, read the gauge dial.

After checking, stop the engine, and then remove the gauge set.

Troubleshooting by gauge measured value Operating condition     

Vents : Open all duct vents.

Indoor, outdoor selection : Indoor circulating Fan speed : The highest speed Temperature : Maximum cooling Ambient temperature at air-con intake port : 30 ~ 35 °C

CAUTION The pressure value may change according to the ambient temperature.

Troubleshooting (for ambient temperature 30 ~ 35 °C at air con intake port) Troubleshooting Refrigerant

Pressure Mpa (kgf / cm2)

Phenomenon

Cause

Check, Repair

-

-

Low

High

Normal

0.15 ~ 0.25 (1.5 ~ 2.5)

1.37 ~ 1.57 (14 ~ 16)

-

Low

0.05 ~ 0.1 (0.5 ~ 1.0)

0.69 ~ 0.98 (7 ~ 10)

High/Low pressure are low.

Refrigerant is low Check and repair the Bubbles pass continuously in and has leaked. refrigerant leak. sight glass.

Fill with refrigerant.

Air conditioner outlet air is not cold.

Refrigerant is 0 ~ (-) not circulated.

0.5 ~ 0.6 (5 ~ 6)

If clogged completely, low Air conditioner Check and replace pressure is indicated refrigerant circuit is receiver/dryer and immediately to (-). clogged. expansion valve, etc.

If clogged a little, low pressure is indicated slowly to (-).

Moisture is 0 ~ (-) mixed into refrigerant circuit.

0.69 ~ 0.98 (7 ~ 10)

Start up operation is normal, Expansion valve is Check and after a while, low pressure frozen moisture valve. drops to (-). mixed.

Replace dryer.

Low compression of compressor.

0.4 ~ 0.6 (4 ~ 6)

0.69 ~ 0.98 (7 ~ 10)

Low pressure is higher than Faulty compressor normal.

If air conditioner is turned off, immediately High/Low pressure are the same.

Excessive refrigerant.

0.25 ~ 0.35 (2.5 ~ 3.5)

1.96 ~ 2.45 (20 ~ 25)

High / Low pressure are high, simultaneously.

Engine rpm is lowered, but bubbles on sight glass are not visible.

Air is mixed 0.25 ~ 0.3 into circuit.

(2.5 ~ 3.0)

1.96 ~ 2.45 (20 ~ 25)

High/Low pressure are high, Air is mixed. simultaneously.

High/Low pressure pipes are warm.

A lot of bubbles in sight glass are visible.

Excessive 0.3 ~ 0.4 opening of (3 ~ 4) expansion valve.

1.96 ~ 2.45 (20 ~ 25)

High/Low pressure are high, Faulty simultaneously. valve.

Frost on low pressure pipe is visible.

Excessive refrigerant.

Poor cooling condenser.

expansion receiver /

Check and replace compressor.

(When compression is poor, the outside is not hot to touch).

Check the amount of refrigerant. of Check and correct the cooling fin of condenser.

Refill refrigerant.

with

expansion Check expansion valve.

Check the mounting of heat sensing tube and bulb.

Replace expansion valve.

Refrigerant fill procedure

CAUTION Use only refrigerant (R134a). DO NOT use any other refrigerant. Use the correct refrigerant pressure measuring gauge set.

DO NOT use any other refrigerant pressure gauges.

Special tools Gauge set, vacuum pump, refrigerant.

Figure 4 Tools for refrigerant filling 1.

2.

3.

4.

Quick coupler Vacuum pump Filler hose Refrigerant service canisters

Refrigerant draining  



To drain the refrigerant, connect the gauge set with the valves closed to the compressor lines and the center filler hose to the service canisters.

Open the valve at the service canister, then open the manifold valve for the low pressure side, and if the high pressure side gauge reads below 3 kgf /cm2, open the high pressure side valve to drain both circuits simultaneously.

When the manifold gauges read 0 kgf /cm2 pressure, close both manifold valves and the service canister valve.

Evacuating   

Connect the center filler hose to the vacuum pump.

Open both high/low manifold valves and start the vacuum pump.

Evacuate the system until the low pressure side reads 710 mmHg vacuum, then close both manifold valves and stop the vacuum pump.

  

If the vacuum decreases more than 25 mmHg in 5 minutes, there is a leak in the system. Repair the leak and reevacuate the system.

If there is no change in the vacuum reading, restart the vacuum pump and continue evacuating until the gauge registers 760 mmHg. Close both the high/low manifold valves and stop the vacuum pump.

Refrigerant filling      

After removing the vacuum pump, connect the center filler hose to the service canister.

First open the high pressure side valve, and the refrigerant will automatically fill to the pipes.

If the filling rate is slow, close the high pressure side valve and leave for 5 ~ 10 minutes, and check for possible gas leakage. After repairs continue the recharging cycle.

Add refrigerant until the system is charged with the correct amount and close the manifold high pressure valve.

Start the engine, and idle at 1000 ~ 1500 rpm.

Turn ON the air conditioner and run at minimum temperature and maximum fan speed, and observe the refrigerant flow in the sight glass.

WARNING Do not open the high pressure side valve during the air conditioner running. At this time, reverse flow phenomenon of refrigerant may occur.     

Open the low pressure side valve to fully fill the refrigerant system.

If the refrigerant is fully filled, close the low pressure side valve.

Observe the refrigerant flow in the sight glass, check the pressure and inspect for leakage.

Stop the engine and remove the gauge set from the compressor.

Install with the filler valve cap.

Service Information Document Title: Air conditioning related components

Function Group: unit, 870

Information Type: Service Information

Date: 2014/5/31

Profile:

Air conditioning unit, related components Location of components

Figure 1 Location of components 1 Charging hose

6 Belt tensioner

11 Intake hose

2 Intake hose

7 Compressor

12 Drain hose

3 Heater valve

8 V-belt

13 Charging hose

4 Heater valve

9 Body

14 Condenser

5 Compressor bracket

10 Refrigerant hose

15 Receiver dryer

Tightening torque : Refrigerant hose 1.5 ~ 1.8 kgf路m Charging hose 2.0 ~ 2.5 kgf路m Intake hose 3.0 ~ 3.5 kgf路m Heater hose clamp 2.5 ~ 3.0 kgf路m Refrigerant circuit

Figure 2 Circuit, refrigerant 1 Receiver dryer

A Outside air

2 Compressor

B High temperature and high pressure gas

3 Condenser

C Low temperature and low pressure gas

4 Evaporator

D Cool air

5 Blower

E Low pressure liquid

6 Expansion

F Inside air G High pressure liquid

Switch and controller, description

Figure 3 Switch, air conditioning system

1.

2.

3.

4.

5.

Air flow control switch Air conditioner switch Fan speed control switch Indoor/outdoor selection switch Cool and heat temperature control switch

NOTE! The controller is integrated with switch.

Air flow control switch and air conditioner switch

Figure 4 Switch, air flow control 1.

2.

3.

4.

5.

Upper Lower Lower/defrost Defrost Air conditioner switch

 

Pressing the air flow control switch, the upper LED lights and the air direction is selected.

When the air con switch is pressed, the upper LED lights. But the cooling system operates only when the fan speed control switch is operated.

Upper direction switch does not operate under heating condition to prevent the operator from becoming sleepy.



Fan speed control switch

Figure 5 Switch, fan speed control     

Pressing the fan speed control switch, the upper LED lights.

Heating and cooling system operate only when the fan speed control switch is operated.

The air conditioning system stops when the OFF switch is pressed.

If heating is operated and air con switch is turned ON cooling and heating system work simultaneously. At this time, the temperature control switch operation conforms to step 3.

Any switch from step 1 - 4 can be selected. When any switch but step 1 is selected, a 2 second interval is required between steps.

Temperature control switch

Figure 6 Switch, temperature control A. B.

Cool Hot

 

Cooling and heating operations are composed of 4 steps respectively.

By pressing the right or left switch, temperature control moves by 1 step. Two LEDs light to indicate the current position.

Cooling operation : Composed of 4 steps, air temperature is controlled by the intermittent operation of the compressor.

Heating operation : Composed of 4 steps, air temperature is controlled by heater valve coolant flow.

Room temperature operation : Air is circulated without air conditioner or heater.

  

Indoor or outdoor air selection switch

Figure 7 Switch, air selection   

Indoor or outdoor air can be selected.

Indoor air : 100% of indoor air Outdoor air : 40% of outdoor air + 60% of indoor air

Method of operation Operation, air conditioning system Function

Air direction

Temperature control

Indoor or outdoor air

Fan

Compressor

Quick cooling

Cool 4 step

High speed

ON

Cooling

Cool 4 step

medium speed

ON

Defrost in the summer

Cool 4 step

High or medium

ON

Defrost in the spring & fall

Heat 2 ~ 3 step

medium speed

ON

Quick heating

Heat 4 step

High speed

OFF

Heating

Heat 2 ~ 3 step

medium speed

OFF

Ventilation

Neutral

Low or medium

OFF

NOTE! The above chart represents the normal method of operation. Choose the air selection mode according to the ambient condition.

Service Information Document Title: Air conditioning specifications

Function Group: unit, 870

Information Type: Service Information

Date: 2014/5/31

Profile:

Air conditioning unit, specifications Specifications Item Air conditioner

Specification Evaporator

Type

Laminate

Cooling capacity

4000 Kcal / h

Type

Parallel flow

Heat rejection

8,500 Kcal / h

Type

Wobble plate

Model

V-5

Displacement

148 cc / rev

Receiver dryer

Capacity

420 cc

Safety device (Dual pressure switch)

Dual Pressure

Condenser Compressor

Heating system

High pressure

OFF 32 ± 2 kgf / cm2 (455 ± 28 psi)

Low pressure

OFF 2.0 ± 0.2 kgf / cm2 (28 ± 3 psi)

ON 26 ± 3 kgf / cm2 (370 ± 43 psi) ON 2.1 ± 0.3 kgf / cm2 (30 ± 4 psi)

Refrigerant

R 134 a, 750 ± 50 g (1.65 ± 0.1 lbs)

Heating capacity

4,000 Kcal / h

Core

Cu-corrugated

Regular voltage

DC 24 V

Consumption electric power

360 W

Air flow

420 m3/ h (549 yd3/ h)

Service Information Document Title: Heating control description

Function Group: valve, 8735

Information Type: Service Information

Date: 2014/5/12

Profile:

Heating control valve, description Location of components See [Invalid linktarget] .

Heating control valve 

 

The valve regulates the flow of engine coolant in accordance with the set position of the heating temperature regulating switch. If setting the heating temperature high, the valve is opened to maximum coolant flow to the heater. If set to the cooling position, the flow of coolant is cut off.

In case hot air is blowing when the heater is set to off position, a faulty heater valve will allow coolant to flow through the heater core. In this case, cooling efficiency will be significantly deteriorated.

In summer, close the valve installed in the engine block to cut off the flow of coolant to the heater.

Service Information Document Title: Evaporator, description

Function Group: 8745

Information Type: Service Information

Date: 2014/5/12

Profile:

Evaporator, description Location of components See [Invalid linktarget] .

Expansion valve   

The expansion valve regulates refrigerant flow from the receiver/dryer to the evaporator.

As the high temperature / high pressure liquid passes through the valve it is restricted and sprayed into the evaporator side where it changes state and becomes a gas.

The rapid expansion of the refrigerant can cause moisture to freeze in the valve outlet port.

Figure 1 Structure, expansion valve 1 Spring

6 Evaporator

2 Ball

7 Outside uniform pressure tube

3 Valve rod

8 Heat reducing canister

4 Diaphragm

A Refrigerant inlet (liquid)

5 Capillary tube

B To compressor

Figure 2 Structure, expansion valve (side view) 1 Needle valve (Throttle valve)

6 Uniform pressure tube

2 Diaphragm

7 Pressure spring

3 Diaphragm compartment

8 Adjustment screw

4 Capillary tube

A Refrigerant inlet (liquid)

5 Heat reducing canister

B Refrigerant outlet

Evaporator ď‚&#x; ď‚&#x;

The refrigerant passing through the expansion valve is converted to a low pressure liquid as it is sprayed into the evaporator.

The mist flowing through the core tubing evaporates as it absorbs heat from the indoor / outdoor air passing over the evaporator fins. This process cools and dehumidifies the air, any moisture contained in the air is converted to water which collects on the fins and is then drained from the evaporator housing.

Figure 3 Evaporator 1.

2.

3.

4.

Lower tank Cooling fin Upper tank Plate

Service Information Document Title: Condenser, description

Function Group: 8746

Information Type: Service Information

Date: 2014/5/12

Profile:

Condenser, description Location of components See [Invalid linktarget] .

Condenser   

The condenser mounted in front of the oil cooler and consists of tubes, refrigerant passing through, and cooling fins, radiating heat rapidly.

The condenser will condense the refrigerant gas which is under high pressure, high temperature condition into a high pressure liquid, by cooling it with the air flow from the oil cooler fan.

Insufficient cooling of the condenser retards the conversion of the high pressure gas into a high pressure liquid, this causes the circuit pressure to rise which increases the system load and reduces the cooling capacity.

Figure 1 Structure, condenser

A. B.

Receiver Dryer Condenser

No.

Wire specification

1

AVX 0.85BG

2

AVX 0.85BW

Service Information Document Title: Compressor, description

Function Group: 8743

Information Type: Service Information

Date: 2014/5/31

Profile:

Compressor, description Location of components See [Invalid linktarget] .

Compressor 





The compressor is driven by the engine via a belt and the power is connected / disconnected by the magnetic clutch. The basic principle of the V–5 compressor is to control proper flow in accordance with the cooling load by changing the piston stroke (changing the angle of wobble plate).

With the engine running and the compressor magnetic clutch engaged, the compressor draws low pressure refrigerant in a gaseous state from the evaporator and compresses it into a high pressure, high temperature gas.

Increasing the pressure of refrigerant causes its boiling point to rise to a temperature higher than the outside air temperature. As the high pressure gas flows through the condenser, the condenser fans draw air through the condenser core which cools the refrigerant.

The oil flowing with the refrigerant activates cooling and lubricating of the compressor.

Figure 1 Structure, compressor A. B. C.

Discharge Suction “A” Groove

Service Information Document Title: Function Group: Compressor, specifications 8743 (V-5, R134a)

Information Type: Service Information

Date: 2014/5/31

Profile:

Compressor, specifications (V-5, R134a) Specifications Type

Wobble plate

Displacement

148 cc (8.3 cu·in) / rev.

Capacity (2000 rpm)

7,415 (20,300 BT/hr)

Number of cylinder

5

Speed

Max. Continuous

6500 rpm

Transient

8000 rpm

Refrigerant

R 134a

Lubricant

265 ml (ND–oil 8)

Direction of rotation

Clockwise

Clutch coil voltage

DC 24V

Service Information Document Title: Drying filter, description

Function Group: 8747

Information Type: Service Information

Date: 2014/5/31

Profile:

Drying filter, description Location of components See [Invalid linktarget] .

Receiver dryer  

 

 

The dryer installed between the condenser outlet and evaporator inlet, consists of the body, desiccant, strainer, filter, sight glass, safety plug and pressure switch.

The receiver/dryer is a reservoir to store excess liquid refrigerant in the system. Excess refrigerant is required for two reasons : Outside air temperature and humidity have an effect on the minimum quantity of refrigerant required in the system for the air conditioner to operate at maximum efficiency. The higher the temperature and humidity, the more refrigerant required in the system. More refrigerant is required due to the expansion valve opening farther allowing more refrigerant into the low pressure side of the system.

The strainer and filter remove particles caused by component failure, or corrosion due to acids and moisture in the system.

The desiccant is used to absorb moisture from the refrigerant. Moisture combined with refrigerant oil forms a sludge which prevents adequate lubrication. Moisture combined with refrigerant creates hydrofluoric and hydrochloric acids which are very corrosive to metal surfaces.

NOTE! Evacuating the system will not remove the moisture from the desiccant. The receiver/dryer must be replaced.

The safety plug is designed to protect the system from excessive pressure and temperature. It will release above 105 °C (221°F) or 35 kgf /cm2 (498 psi).

A sight glass is installed so the condition of the flow of refrigerant can be checked.

Figure 1 Drying filter 1 Desiccant

5 Pressure switch

2 Strainer

6 Sight glass

3 Filter

7 Refrigerant inlet

4 Refrigerant outlet

8 Plug

Many thanks for your purchase.

Happy every day.

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