Repair Manual For Case 85XT 90XT 95XT Skid Steer Loader. Illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-up.
Format: PDF
Language: English
Pages: 1436
Bookmarks: Yes
Number: 7-52254
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Case 85XT, 90XT, 95XT
Contents
- – General
–STANDARD TORQUE SPECIFICATIONS FLUIDS AND LUBRICANTS
TORQUE SPECIFICATIONS – DECIMAL HARDWARE
GradeBolts, Nuts, and Studs
GradeBolts, Nuts, and Studs
TORQUE SPECIFICATIONS-METRIC HARDWARE
GradeBolts, Nuts, and Studs
GradeBolts, Nuts, and Studs
GradeBolts, Nuts, and Studs
TORQUE SPECIFICATIONS-STEEL HYDRAULIC FITTINGS
Degree Flare Fitting
Straight Threads with O-ring
Split Flange Mounting Bolts
O-Ring Face Seal End
O-Ring Boss End
Fitting or Lock Nut
Pipe fittings
–METRIC CONVERSION CHART
CONVERSION FACTORS
Metric To U.S
U.S. To Metric
–FLUIDS AND LUBRICANTS
CAPACITIES AND LUBRICANTS
ENVIRONMENT
ENGINE LUBRICATION
Engine Oil Selection
Oil Viscosity/Temperature Ranges
DIESEL FUEL SYSTEM
Fuel Storage
Specifications for Acceptable No 2 Diesel Fuel - – Engines
–ENGINE AND RADIATOR REMOVAL AND INSTALLATION
Removal
Installation
–AFTERCOOLER
Removing The Aftercooler
Inspecting The Aftercooler
Installing The Aftercooler
Intake System Pressure Test
–CYLINDER HEAD AND VALVE TRAIN
IDENTIFICATION MARKS
SPECIFICATIONS
SPECIAL TORQUES
SPECIAL TOOLS
CYLINDER HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY
CHECKING AND RESURFACING THE CYLINDER HEAD
VALVE GUIDE REPLACEMENT
14 mm Replacement Valve Guides
11 mm Replacement Valve Guides
INSPECTION OF THE VALVES AND VALVE SEATS
VALVE SEAT INSTALLATION
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS
DIAGNOSIS OF DIFFERENT DYE PATTERNS
45 Degree Exhaust Valve
30 Degree Intake Valve Only
CYLINDER HEAD ASSEMBLY
ROCKER ARM DISASSEMBLY
ROCKER ARM ASSEMBLY
Head Gasket Application
LOCATING TOP CENTER
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE
Cold Setting
THERMOSTAT SERVICE
–CYLINDER BLOCK
SPECIFICATIONS
SPECIAL TORQUES
SPECIAL TOOLS
FRONT OIL SEAL REPLACEMENT
REAR OIL SEAL REPLACEMENT
FRONT OIL SEAL AND WEAR SLEEVE INSTALLATION
REAR OIL SEAL AND WEAR SLEEVE INSTALLATION
REMOVAL OF PISTONS AND RODS
CYLINDER WALL INSPECTION
RECONDITIONING THE ENGINE CYLINDER BLOCK
Checking And Resurfacing The Cylinder Block
Reconditioning The Cylinder Block For Oversize Pistons
Reconditioning The Cylinder Block For Sleeves
PISTON AND CONNECTING ROD DISASSEMBLY AND INSTALLATION
PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION
REPLACEMENT OF THE MAIN BEARING WITHOUT REMOVING THE CRANKSHAFT
CRANKSHAFT AND MAIN BEARINGS
CRANKSHAFT GEAR REMOVAL
CRANKSHAFT INSPECTION
CRANKSHAFT RECONDITIONING
Grinding A Crankshaft
Crankshaft Rehardening
CRANKSHAFT GEAR INSTALLATION
CRANKSHAFT INSTALLATION
CAMSHAFT
Removal
Camshaft Bore And Bushing Inspection
Camshaft Bushing Removal And Installation
Valve Lifter Inspection
Camshaft Gear Installation
Camshaft Gear Installation
Camshaft Installation
FLYWHEEL
Removal
Ring Gear Removal And Installation
TACHOMETER DRIVE, IF EQUIPPED
Removal And Disassembly
EXPANSION PLUG REMOVAL AND INSTALLATION
60 mm Expansion Plug, Camshaft
58 mm Expansion Plugs
26 mm Expansion Plugs
225 mm Expansion Plug
18 mm Expansion Plug
10 mm Expansion Plugs
CRANKCASE PRESSURE CHECK (BLOW BY)
Manometer Installation
Testing
Manometer Removal
–LUBRICATION SYSTEM
SPECIFICATIONS
SPECIAL TORQUES
LUBE FLOW CHART
OIL PUMP
Removal
Disassembly and Assembly
Installation
OIL PRESSURE RELIEF VALVE SERVICE
Bottom Mounted Relief Valve
Top Mounted Relief Valve
OIL FILTER HOUSING AND OIL COOLER
Removal
Installation
OIL PAN AND OIL INLET TUBE
Removal And Installation
–COOLING SYSTEM
SAFETY RULES
HOW TO CLEAN THE COOLING SYSTEM
SPECIAL TORQUES
SPECIFICATIONS
WATER PUMP
Removal
Installation
THERMOSTAT
Removal
Installation
COOLANT INLET MANIFOLD
Removal
Installation
FAN PULLEY BRACKET
Removal
Installation
BELT TENSIONER
Removal
Installation
THERMOSTAT SERVICE
–TURBOCHARGER
SPECIFICATIONS
SPECIAL TORQUES
SPECIAL TOOLS
TROUBLESHOOTING GUIDE
SERVICING THE TURBOCHARGER
Removal
Inspection
Disassembly
Inspection After Disassembly
Assembly
Installation
–TURBOCHARGER FAILURE ANALYSIS - – Fuel System
–FUEL SYSTEM AND FILTERS
Filter Replacement
Bleeding Air From The Fuel System
–FUEL INJECTORS
SAFETY RULES
SPECIFICATIONS
Bosch Injectors
CAV Injectors
SPECIAL TOOLS
SPECIAL TORQUES
GENERAL INFORMATION
OPERATING PROCEDURES
LOCATING FAULTY INJECTORS
Locating Faulty Injectors At The Fuel Pump
Locating Faulty Injectors At The Cylinder Head
INJECTOR
Removal
Installation
FUEL INJECTOR TESTER
Nozzle Tester Preparation
TESTING INJECTORS
Checking Opening Pressure
Checking Seat Leakage
Spray Pattern
INJECTOR
Disassembly
Cleaning and Inspection
Assembly
Adjustments
INJECTOR SLEEVE
Installation
–BOSCH MODEL VE FUEL INJECTION PUMP
SPECIAL TOOLS
SPECIAL TORQUES
TROUBLESHOOTING GUIDE
FUEL INJECTION PUMP
Removal
Installation
INJECTION PUMP GEAR
Removal
Installation
INJECTION PUMP TIMING
FUEL SHUT-OFF SOLENOID
Removal and Disassembly
Assembly and Installation
PRIMER PUMP
Removal
Installation
TIMING LOCKING PIN
Removal
Installation - – Electrical
–ELECTRICAL ‘HOW IT WORKS’
Interlock System
–REMOVAL AND INSTALLATION OF ELECTRICAL COMPONENTS
SPECIAL TORQUES
STARTER
Removal
Installation
ALTERNATOR
Removal
Installation
–ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING
Fuses
GENERAL INFORMATION
Circuit Diagram Legends
LEFT-HAND INSTRUMENT PANEL
RIGHT-HAND INSTRUMENT PANEL
CONTROL LEVERS
Left Hand Control Lever
CONTROL LEVERS
Right Hand Control Lever
TROUBLESHOOTING EXAMPLE
TROUBLESHOOTING
–BATTERY
SAFETY RULES
MAINTENANCE
Electrolyte Level
Inspecting And Cleaning A Battery
NONSPILL CAPS
BATTERY TEST
Visual Checks
Specific Gravity Check
Capacity (Load) Test
CHARGING A BATTERY
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
PREPARING A DRY CHARGED BATTERY FOR USE
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTERIES
–STARTER AND STARTER SOLENOID
SPECIFICATIONS
LUBRICATION
NO-LOAD TEST
General Information
Test Equipment
Test Procedure
DISASSEMBLY
INSPECTION
Brushes and Brush Springs
Brush Holder
Armature
Field Coil Test
ASSEMBLY
STARTER SOLENOID TEST
Starter Solenoid Test Procedure
–ALTERNATOR
ALTERNATOR
Disassembly
Inspection of Brushes
Inspection and Testing of Rotor
Inspection and Testing of Stator
Testing the Capacitor
Testing the Rectifier Bridge
Inspection and Replacement of Bearings
Assembly - – Power Train
–HYDROSTATIC HOW IT WORKS
HYDROSTATIC SYSTEM HOW IT WORKS
Hydrostatic System Overview
Hydrostatic System Overview Continued
Hydrostatic System Overview Continued
Hydraulic Pump I Constant Pressure Priority Valve
Constant Pressure Priority Valve
Constant Pressure Priority Valve Continued
Servo Control System
Hydrostatic Pump
Pump Rotation
85XT HYDROSTATIC DRIVE MOTOR
9OXT AND95XT HYDROSTATIC DRIVE MOTOR
90XT AND 95XT PLANETARY GEAR REDUCER
85XT PARKING BRAKE
9OXT AND 95XT PARKING BRAKE
Hydrostatic Control Levers
Hydrostatic System Cleanup
Hydrostatic Start-Up Procedure
Hydrostatic Start-Up Procedure Continued
Instructions
Chain Drive System
Axle Housing Assembly
–REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS
TORQUE SPECIFICATIONS
85XT/90XT/95XT – TANDEM (HYDROSTATIC) PUMP WITH GEAR PUMP
Removal
Installation
85XT – HYDRAULIC (DRIVE) MOTOR
Removal
Installation
90XT/95XT – (TWO SPEED) HYDRAULIC (DRIVE) MOTOR WITH GEARBOX AND BRAKE
Removal
Installation
–HYDROSTATIC TROUBLESHOOTING
SAFETY RULES
CHECKS TO DO BEFORE TROUBLESHOOTING
HYDROSTATIC SYSTEM TROUBLESHOOTING
One Transmission (Right Or Left) Works Correctly And The Other Does Not
Machine Does Not Have Enough Power
PUMP ADJUSTMENTS
Stopping Machine Creep
Servo Piston Centering Spring Adjustment
Hydraulic Neutral Adjustment
HYDROSTATIC SYSTEM TROUBLESHOOTING
Checking Charge Pressure/Flow
test analysis
Checking Charge Pressure/Flow
CHECKING CIRCUIT RELIEF VALVE PRESSURE
When To Check The High Pressure Circuit Relief
Circuit Relief Test
Test Analysis
Hydrostatic System Testing
HYDROSTATIC PRESSURE TEST
HYDRAULIC SYSTEM TROUBLESHOOTING
Checking Charge Pressure/Flow
Drive Chain Adjustment
Tilting the ROPS Canopy Forward
Testing The Seat Bar
Testing the Operator’s Presence Switch
–DRIVE COUPLING
TORQUE SPECIFICATIONS
DRIVE COUPLING
DISASSEMBLY
INSPECTION
ASSEMBLY
DRIVE COUPLING
(85XT Machines with PIN JAF0352525 AND AFTER)
(90XT Machines with PIN JAF0353008 AND AFTER)
(95XT Machines with PIN JAF0342625 AND AFTER)
Disassembly
Inspection
Assembly
Drive Alignment Procedure
–PISTON PUMPS TANDEM PUMP
SPECIFICATIONS
SPECIAL TORQUES
FRONT PISTON PUMP
Disassembly
Inspection
Exploded Views of Pumps
Assembly
REAR PISTON PUMP
Disassembly
Inspection
Exploded Views Of Pumps
Assembly
–DRIVE MOTORS
Special Torques
Disassembly
Inspection
Assembly
–GEAR BOX
Disassembly
Inspection
Assembly
–SPROCKETS, CHAINS, AND AXLE ASSEMBLIES
TORQUE SPECIFICATIONS
ADJUSTING DEFLECTION OF THE CHAINS
AXLE DISASSEMBLY (MACHINES PRIOR TO PIN JAF0298062 85XT, JAF0298848 90XT, JAF0299275 95XT)
Inspection
CROSS SECTION OF AXLE ASSEMBLY
AXLE ASSEMBLY (MACHINES PRIOR TO PIN JAF0298062 85XT, JAF0298848 90XT, JAF0299275 95XT) 10
AXLE DISASSEMBLY(MACHINES WITH PIN JAF0298062 85XT, JAF0298848 90XT, JAF0299275 95XT AND AFTER)
Axle Inspection
CROSS SECTION OF AXLE ASSEMBLY (MACHINES WITH PIN JAF0298062 85XT, JAF0298848 90XT,JAF0299275 95XT AND AFTER)
AXLE ASSEMBLY(MACHINES WITH PIN JAF0298062 85XT, JAF0298848 90XT, JAF0299275 95XT AND AFTER)
–SOLENOID VALVE FOR TWO SPEED DNVE MOTOR ACCUMULATOR FOR CHARGE CIRCUIT
SOLENOID VALVE
Disassembly
Exploded View of Solenoid Valve
Assembly
–ACCUMULATOR FOR CHAROE CIRCUIT
WHEELS AND TIRES
Tire Pressure
Inflating the Tire
Wheel Nut Torque - – Brakes
–BRAKE SYSTEM “HOW IT WORKS”
85XT – SKID STEER
Brake System Overview
Moving A Disabled Machine Not Equipped With A Brake Release System
Moving A Disabled Machine Equipped With A Brake Release System
90XT/95XT SKID STEER
Brake System Overview
Moving A Disabled Machine Not Equipped With A Brake Release System
Moving A Disabled Machine Equipped With A Brake Release System
–BRAKE – 85XT
Special Tools
Disassembly
Assembly
–BRAKE PUMP - – Hydraulics
–HYDRAULIC SYSTEM TROUBLESHOOTING
859095XT HYDRAULIC COMPONENTS
Components Oefiried
Reservoir
Hydraulic Pump/Priority Valve
Constant Pressure Priority Valve
LOADER CONTROL VALVE
Functional Overview of the Loader Control Valve
Component Overview ol the Loader Control Valve
Main Relief Valve
Operation: Closed Position
Operation: Open Position
Direct Acting Circuit Relief Valve
A2 Port Orifice
Control Valve
Loader Spool Actuated to
Raise Loader
Loader Spool Actuated to Lower Loader
Loader Spool Actuated to Raise
Spool Actuated to Dump Loader Spool Actuated to Lower
Bucket Spool Actuated to Curl
Loader Spool Actuated to Float
Auxiliary Spool Actuated
Spool Lock Red Assembly
Spool Lock Solenoid Valve
SELF-LEVELING VALVE
Bucket Self-Level ng
Loader Raise-Bucket Self-Leveling
Loader Raise-Bucket At Full Dump
Loader Lowering
Troubleshooting
NOTES
CYLINDERS
FILTRATION AND COOLING
HIGH FLOW HYDRAULIC SYSTEM
HIGH FLOW HIGH PRESSURE HYDRAULIC SYSTEM
–REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS
GEAR PUMP
Removal
Installation
HYDRAULIC LOADER CONTROL VALVE
Removal
Installation
HYDRAULIC FILTER BASE ASSEMBLY
Removal
Inspection
Installation
SELF LEVELING VALVE
Removal
Installation
HIGH FLOW GEAR PUMP
Removal
Installation
HIGH FLOW PISTON PUMP
Removal
Installation
HIGH FLOW CHARGE FILTER
Removal
Installation
–GEAR PUMP
EQUIPMENT PUMP
Disassembly
Inspection
Assembly
–LOADER CONTROL VALVE
DISASSEMBLY
INSPECTION
Exploded View of Loader Control Valve
ASSEMBLY
–CYLINDERS
SPECIAL TORQUES
SPECIAL TOOLS
GENERAL
Retaining Screw – Tube to Gland Procedure
LOADER LIFT CYLINDER-85XT AND 95XT SKID STEERS
Disassembly
Inspection
Assembly
LOADER LIFT CYLINDER-90XT SKID STEER
Disassembly
Inspection
Assembly
LOADER BUCKET CYLINDER-85XT AND 95XT SKID STEERS
Disassembly
Inspection
Assembly
LOADER BUCKET CYLINDER-90XT SKID STEER
Disassembly
Inspection
Assembly
BACKHOE SWING CYLINDER
Disassembly
Inspection
Assembly
BACKHOE BOOM, BUCKET, AND DIPPER CYLINDERS
Disassembly
Inspection
Assembly
BACKHOE FOLD DOWN STABILIZER CYLINDER
Disassembly
Inspection
Assembly
BACKHOE VERTICAL STABILIZER CYLINDER
Disassembly
Inspection
Assembly
TRENCHER BOOM LIFT CYLINDER – 90XT AND 95XT SKID STEERS
Disassembly
Inspection
Assembly
–OPTIONAL HIGH PRESSURE HIGH FLOW PUMP (PISTON PUMP)
Disassembly
Inspection
Assembly
–OPTIONAL LOW PRESSURE HIGH FLOW PUMP (GEAR PUMP)
LOW PRESSURE HIGH FLOW PUMP (GEAR PUMP)
Disassembly
Inspection
Assembly
–CONTROL VALVE FOR LOW PRESSURE HIGH FLOW SYSTEM
Disassembly
Inspection
Assembly
–SELF-LEVELING VALVE
Disassembly
Inspection
Assembly
–SOLENOID VALVE FOR HYDRAULIC COUPLER SYSTEM
SOLENOID VALVE FOR HYDRAULIC COUPLER SYSTEM
Disassembly
Exploded View of Solenoid Valve
Assembly
90XT / 95XT Solenoid Valve Installation
–D125 BACKHOE CONTROL VALVE – NORTH AMERICAN ONLY
SEPARATING THE PARTS OF THE BACKHOE CONTROL VALVE
Inspection
Assembly
CHECK VALVE ASSEMBLY
Disassembly
Assembly
MAIN RELIEF VALVE
CIRCUIT RELIEF VALVE
ASSEMBLING THE PARTS OF THE BACKHOE CONTROL VALVE
–ACCUMULATOR FOR RIDE CONTROL
Specifications
Special Tools
Discharging An Accumulator
Disassembly
Inspection
Assembly
Checking The Nitrogen Charge In The Accumulator
Charging The Accumulator With Dry Nitrogen
–FLAT FACED COUPLERS
–SOLENOID VALVE FOR HIGH PRESSURE HIGH FLOW SYSTEM
SOLENOID VALVE
Disassembly
Exploded View of Solenoid Valve
Assembly. - – Mounted Equipment
–PEDALS AND LEVERS
THROTTLE CONTROL LINKAGE ADJUSTMENT
LOADER AND GROUND DRIVE LINKAGE WITHOUT FOOT CONTROLS
Fore/Aft Adjustment.
Loader and Bucket Adjustment.
LOADER AND GROUND DRIVE LINKAGE WITH FOOT CONTROLS LH
LOADER AND GROUND DRIVE LINKAGE WITH FOOT CONTROLS RH
ATTACHMENT MECHANICAL COUPLER ADJUSTMENT
Adjustment Procedure
AUXILIARY HYDRAULIC PEDAL
HIGH FLOW HIGH-PRESSURE CONTROL LEVER
REAR LATCH AND PIVOT
SEAT BAR
Seat Bar Switch.
Magnetic Seat Bar Switch Adjustment.
Plunger Seat Bar Switch Adjustment.
–LOADER
REPLACING THE CUTTING EDGE 85XT 90XT AND 95XT BUCKETS
WELD SPECIFICATIONS FOR 85XT 90XT / 95XT
190079A1 / 192538A2 / 244554A2 / 248138A2 / 248140A2 BUCKETS
WELD SPECIFICATIONS FOR 85XT 90XT / 95XT
245077A2 / 245078A2 / 248139A2 / 248141A2 BUCKETS
REMOVAL OF THE 95XT LOADER FRAME
INSPECTION
INSTALLATION OF THE 95XT LOADER FRAME.
95XT LOADER FRAME.
95XT LOADER FRAME H BAR ASSEMBLY.
95XT LOADER FRAME SUPPORT.
85XT / 90XT / 95XT PALLET FORK.
REMOVAL OF THE 90XT LOADER FRAME
INSPECTION
INSTALLATION OF THE 90XT LOADER FRAME.
90XT LOADER FRAME.
85XT / 90XT / 95XT PALLET FORK.
–ATTACHMENT COUPLER
Attachment Coupler (Mechanical)
Attachment Coupler (Hydraulic)
–ROPS CANOPY, SEAT, SEAT BELTS, AND OPERATORS COMPARTMENT
Possible Damage To The Rops Canopy.
Maintenance And Inspection Of The Rops Canopy
Removal Of The 90Xt And 95Xt Rops Canopy
Installation Of The 90Xt And 95Xt Rops Canopy
Rops Canopy – Frame And Seat Bar.
Rops Canopy – Rear Latch And Pivot.
Rops Canopy – Top And Side Windows (If Equipped).
Rops Canopy – Headliner And Heat Shield.
Rops Canopy – Extension Panels.
Rops Canopy – Front Door Mounting And Frame (If Equipped).
Rops Canopy – Front Door Latch (If Equipped).
Non – Suspension Seat Mounting (If Equipped).
Suspension Seat Mounting (If Equipped).
Suspension Seat (If Equipped).
Suspension Seat (If Equipped)
–HEATER
HEATER
REMOVAL OF HEATER.
INSPECTION
INSTALLATION OF HEATER.
BASIC HEATER
Removal
Inspection
Installation.
DELUXE HEATER.
Removal Of Heater Core
Removal Of The Blower Fan.
Inspection
Installation Of Heater Core
Installation Of The Blower Fan
–BACKHOE (D125 BACKHOE)
REPLACING THE CUTTING EDGE 85XT 90XT AND 95XT BUCKETS
WELD SPECIFICATIONS FOR 85XT 90XT / 95XT
190079A1 / 192538A2 / 244554A2 / 248138A2 / 248140A2 BUCKETS
WELD SPECIFICATIONS FOR 85XT 90XT / 95XT
245077A2 / 245078A2 / 248139A2 / 248141A2 BUCKETS
REMOVAL OF THE 95XT LOADER FRAME
INSPECTION
INSTALLATION OF THE 95XT LOADER FRAME
95XT LOADER FRAME
95XT LOADER FRAME H BAR ASSEMBLY
95XT LOADER FRAME SUPPORT
85XT / 90XT / 95XT PALLET FORK
REMOVAL OF THE 90XT LOADER FRAME
INSPECTION
INSTALLATION OF THE 90XT LOADER FRAME
90XT LOADER FRAME
85XT / 90XT / 95XT PALLET FORK
–TRENCHER
Specifications
Special Tools
Removal And Installation Of Chain
Adjustment Of Chain For Standard Boom
Adjustment Of Chain For Rock Boom
Removal And Installation Of Boom
Removal Of Planetary
Disassembly And Assembly Of Primary And Secondary Carrier
Installation Of Planetary
Removal Of Boom Mount
Installation Of Boom Mount
Removal Of Flywheel And Shaft
Installation Of Flywheel And Shaft
Removal And Installation Of Drive Sprocket
Removal And Installation Of Auger
Removal And Installation Of Boom Sprocket For Standard Boom
Removal And Installation Of Idler Sprocket
Removal And Disassembly Of Idler For Rock Boom
Assembly And Installation Of Idler For Rock Boom
Removal And Disassembly Of Chain Adjuster For Rock Boom
Assembly And Installation Of Chain Adjuster For Rock Boom
–STEEL TRACK
STEEL TRACK
Track Pad Fit To Tire
Tire Clearance
Wheel Spacer
Installation
Adjustments
Steel Track Testing
Removal
–RUBBER TRACK
RUBBER TRACK
Installation
Removal
–AIR CONDITIONING TROUBLESHOOTING – FOR SYSTEMS WITH R134A REFRIGERANT
SAFETY PROCEDURES
SPECIAL TOOLS
TROUBLESHOOTING
Problem: No Cooling
Problem: No Cooling
TROUBLESHOOTING
Problem: Not Enough Cooling
Problem: Intermittent Cooling
Problem: System Makes Noise
EXTERNAL COMPRESSOR CHECK
Compressor And Fan Belts
Compressor Mounting Brackets
Compressor Clutch
EXTERNAL COMPRESSOR CHECK (CONTINUED)
Pulley And Belt Alignment
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK
Keyed Power Blower Fuse (25 Ampere)
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK (CONTINUED)
Blower Switch
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK (CONTINUED)
Blower Motor
Air Conditioner Control Switch
Cutoff Relay
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK (CONTINUED)
High and Low-Pressure Switches
Compressor Clutch
CAB TEMPERATURE CHECK
Air Louvers
Air Conditioner Hose Check
CAB TEMPERATURE CHECK (CONTINUED)
Louver Temperature
VISUAL REFRIGERANT CHECK
Compressor Hoses
Leak Finding Check
CAB HEATER CHECK
Heater Hoses
Heater Control Valve
EVAPORATOR AND PLENUM CHECK
Evaporator Core
Plenum Sealing
Filter
PRESSURE SWITCH CHECK
AIR CONDITIONING TEMPERATURE CONTROL CHECK
Temperature Control Check
Sensing Line Check
–AIR CONDITIONER SYSTEM GAUGES AND TESTING – FOR SYSTEMS WITH R134A REFRIGERANT
SAFETY PROCEDURES
SPECIAL TOOLS
PRESSURE-TEMPERATURE CHART
A/C RECOVERY AND CHARGING STATION CONNECTIONS
PROBLEM – NO COOLING
No Refrigerant – Indications:
PROBLEM – NO COOLING
Condenser Malfunctioning – Indications:
PROBLEM-NO COOLING (CONTINUED)
Expansion Valve Malfunctioning – Indications:
PROBLEM – NOT ENOUGH COOLING
Heater Control Valve Not Working – Indications:
Air or Moisture in the System – Indications:
Thermostat Sensing Tube Low on Charge or out of Calibration – Indications:
PROBLEM – NOT ENOUGH COOLING
Not Enough Refrigerant – Indications:
High Side Restrictions – Indications:
PROBLEM – NOT ENOUGH COOLING (CONTINUED)
Expansion Valve not Operating – Indications:
PROBLEM – NOT ENOUGH COOLING
Compressor Turning but not Pumping Properly – Indications:
PROBLEM – NOT ENOUGH COOLING
Condenser not Operating – Indications:
Air in System – Indications:
PROBLEM – NOT ENOUGH COOLING
Thermostat Sensing Tube not Functioning – Indications:
PROBLEM – INTERMITTENT COOLING
Moisture in the System – Indications:
PROBLEM – INTERMITTENT COOLING
Expansion Valve not Operating – Indications:
PROBLEM – NOISE IN SYSTEM
To Many refrigerants in System – Indications:
–AIR CONDITIONER SYSTEM SERVICE – FOR SYSTEMS WITH R134A REFRIGERANT REFRIGERANT RECOVERY, COMPRESSOR REMOVAL AND SYSTEM EVACUATION AND RECHARGING
Specifications
Safety Procedures
Special Tools
Air Conditioner System Refrigerant Recovery
Compressor Removal
Compressor Installation
Air Conditioning System Evacuation And Recharging
Pressure – Temperature Chart
–AIR CONDITIONER COMPONENT SERVICE – FOR SYSTEMS WITH R134A REFRIGERANT
SAFETY PROCEDURES
SPECIAL TOOLS
COMPRESSOR BELT CHECK AND ADJUSTMENT
COMPRESSOR OIL LEVEL CHECK
COMPRESSOR REPAIR
Clutch Disassembly
CLUTCH ASSEMBLY
EXPANSION VALVE TESTING
EVAPORATOR AND EXPANSION VALVE
CONDENSER, RECEIVER-DRIER, AND TUBES
EVAPORATOR CORE REMOVAL
EVAPORATOR CORE INSTALLATION - -Hydraulic and Electrical Schematic Foldout
What you get
You will receive PDF file with high-quality manual on your email immediately after the payment.
Anonymous (verified owner) –
Excellent detail
Anonymous (verified owner) –
your diagrams are very good however the detail of the work to be done was not complete. Paul