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IMPORTANT SERVICE ACTIVITIES CHECK ITEMS Engine oil D1146 D1146Ti DE12 DE12T DE12Ti CHECK AND SERVICE INTERVALS PAGE Change : At end of first 1,000km, High-speed, long distance : every 15,000km In city, short distance : every 10,000km 163 Page DE08TiS Change : At end of first 1,000km, long distance : every 30,000km DE12TiS short distance : every 20,000km Engine oil filter D1146 Fuel filter D1146Ti DE08TiS DE12/T/Ti/TiS Change with engine oil Primary filter:clean filter : clean at every 5,000km, Primary at every 5,000km,change at every 15,000km there change at every 15,000km there after. secondary filter : change at every 5,000km. 164Page 166Page Change at every 20,000km. Valve clearance Adjust at end of first 1,000km and every 20,000km there after. 171 Page Air cleaner Clean at every 4,000km, change at every 12,000km there after. 176 Page Transmission oil Change at end of first 5,000km and every 20,000km there after. 178 Page Rear axle oil Change at end of first 5,000km and every 20,000km there after. 179 Page Power steering oil Change at end of first 1,000km and every 24,000km there after. 180 Page Power steering filter Change at end of first 1,000km and every 24,000km there after. 182 Page ҧAny failure resulting from a lack of normal maintenance as the maintenance service chart in this manual is not covered by warranty. FOREWORD This manual has been prepared to acquaint you with the operation and maintenance of your DAEWOO BUSES and the provide important safety information. We urge you to read it carefully and follow the recommendations to help assure the most enjoyable, safe and troublefree operation of your vehicle. When it comes to service, remember that your DAEWOO dealer knows your vehicle best and is interested in your complete satisfaction. We would like to take this opportunity to thank you for choosing a DAEWOO product and assure you of our continuing interest in your motoring pleasure and satisfaction. This manual should be considered as a permanent part of your vehicle, and must remain with the vehicle at the time of resale. All information, illustrations and specifications contained in this manual are based on the latest product information available at time of publication. The right is reserved to make changes at any time without notice. TABLE OF CONTENTS 1. IMPORTANT INFORMATION ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 2 2. OPERATION AND CARE OF NEW VEHICLE ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 4 3. GETTING ON AND OFF, DRIVER’S SEAT AND BELT ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 6 4. INSTRUMENT, SWITCHES AND CONTROLS ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 14 5. DRIVING ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 135 6. INSPECTION AND MAINTENANCE ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 162 7. LUBRICATION ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 213 8. SCHEDULED MAINTENANCE SERVICE ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 221 9. TROUBLESHOOTINGŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 225 10. MAIN DATA AND SPECIFICATION ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 234 11. BODY DIMENSION ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ 253 1 IMPORTANT INFORMATION LOCATION OF ENGINE NUMBER AND CHASSIS NUMBER It is advisable to keep note of the engine number and chassis number as they are required when contacting your dealer for repair services and parts order. V.I.N plate V.I.N plate Chassis number V.I.N(Vehicle identification Number) plate is attached to the inner panel above the front door. V.I.N(Vehicle identification Number) plate is attached to the inner panel above the front door. The chassis number is stamped on the upper face of the chassis frame within the engine compartment. Type A : Applicable for vehicles in all countries except GCC members. Type B : Applicable for vehicles in GCC members. 2 Engine number Key There are three types of key for the bus ; • Engine starting • Mechanical locking for entrance door (OPTION) • Doors – Entrance door operating – Luggage doors (OPTION) – Rear engine door (OPTION) – Side engine doors (OPTION) – Battery inspection door (OPTION) – Fuel tank inspection door (OPTION) – Fuel inlet flap door (OPTION) Engine No. 1378 3 The keys are not interchangeable, but door lock keys are interchangeable. The code number of each key is stamped on the key. Record the key number and keep it in a safe place. In the event that the original key is lost, duplicating can be done using the key code information. OPERATION AND CARE OF NEW VEHICLE It is important to observe the following precautions as operation and care of the vehicle, particularly during the break–in period have a strong influence over the performance and service life of the vehicle. 1. Start and let the engine idle until it becomes thoroughly warmed up and coolant temperature increases beyond 50°C (or 125°F) before starting off. 2. Avoid racing the engine, abrupt starts and hard stops. 3. Avoid over loading the vehicle during and after the break–in period. Over loading Maintenance Over loading not only shortens the service life of your vehicle but also create serious potential safety hazards. In order to maintain safe and dependable vehicle operation, inspection and adjustment should be performed as outlined in “INSPECTION AND MAINTENANCE”. The weight of payload must be limited within the GVW rating and distributed over the front and rear axles so as not to exceed the axle capacities. Refer to “MAIN DATA AND SPECIFICATION” for GVW and Axle capacity. 4 Your DAEWOO dealer is willing to perform regular maintenance operation on your vehicle. Engine oil change Maximum engine speed Change engine oil filter catridge to new one at the same time with engine oil. During the initial milage(Break–in period : 2,000km), confine engine speed to 70% of the maximum and scan the tachometer as you drive to prevent engine over–running. After the break–in period, increase the engine speed gradually to complete running–in of the vital parts. Engine Model Change Interval D1146 At end of first 1,000km D1146Ti High–speed, long distance : DE12Ti DE12Ti DE12Ti every 15,000km In city, short distance : every 10,000km At end of first 1,000Km DE08TiS Long distance : every 30,000km DE12TiS short distance : every 20,000km 5 GETTING ON AND OFF, DRIVER’S SEAT AND BELT DOOR OPENING AND CLOSING (Applicable for vehicles in all entrance door with mechanical key) When opening the front door to get in, first unlock the mechanical key on the entrance door and operate the entrance key on the right side of the front middle panel. When closing the front door to get off, open the front door by operating the door control switch and get off. (Applicable for vehicles in all entrance door except mechanical key) In the outside of bus, close the door with the key and look the mechanical key on the entrance door not to be opened in case of air leaking. NOTICE Before operating entrance key, unlock mechanical key on door frame. When opening the front door to get in, operate the entrance key on the right side of the froot middle panel. When closing the front door to get off, open the front door by operating the door control switch and get off. In the outside of bus, close the door with the key. CAUTION When opening front entrance door for a long time, setting emergency valve at manual position and put control switch in close position. When returning to automatic condition, putting control switch and door in same condition and set emergency valve at automatic position. (Type A : Toggle switch) N IDLI G H .. L 6 (Type B : One touch switch) MANUAL OPENING AND CLOSING Type A : Select type Type B : Push/Pull or rotary type (OPTION) As setting the “Auto–Manual” change lever installed right, lower inner side of front panel(beside of driver’s right leg), the door can be opened and closed by hands. As setting the "Auto-Manual" change knobs are installed two types. One of the types installed inner upper panel the entrance door operated by air. Other installed outer mid panel on left side of door operated by electric push button. the door can be opened and closed by hands. (Push/Pull type) N IDLI G H .. L 7 (Rotary type) DRIVER’S SEAT AND BELT Adjustment of Fixed type (S-104H) (BM090, BS090) 1. Back angle adjustment To adjust the seat back, turn No. 1 handle, and lean backwards and foreward until desired angle is achieved. 2. Slide adjustment To move the seat forward and backward. Pull No. 2 lever, forward and slide the seat. 3. Height (Tilting) adjustment Desired the seal height can be achieved by puling No. 3 lever upward and downward. 1 1 2 3 8 2 How to use non suspension seat Semi suspension seat can be infinitly adjusted to suit the weight of the driver. Height Adjustment Slide Adjustment 9 Back Angle Adjustment ofof AirAirsuspension suspension typetype driver’s driver’s seat (S-110A) seat (S-110A) (BH090, BS106, (BS106, BH115E, BH113/115/120E, BH120E) (BM090/BS090 BV120) : OPTION) 1. Slide adjustment To move the seat forward or rearward, pull No. 1 lever upwards and the slide the seat. 2. Back angle adjustment To adjust the seat back, pull No. 2 lever and lean backwards or forewards until the desired angle is achieved. 3. Height and slope adjustment Desired seat height can be achieved by pulling No. 3 lever. 4. Upper lumbar support air cushion adjustment. 4. Lower button is for inflation, upper button is for defl4. ation 5. Lower lumbar support air cushion adjustment. Push the lumbar support air cushion adjustment button to suit seating position. 4. Lower button is for inflation, upper button is for defl4. ation 6. Air suspension stroke support air undercushion adjustment řDo not adjust the driver’s seat while driving.Ś 2 1 4 5 6 3 3 4 5 1 10 2 How to use air suspension seat Air suspension seat can be infinitly adjusted to suit the weight of the driver. Height Adjustment Tilt Adjustment(RR) Slide Adjustment Tilt Adjustment(FRT) Lumbar Support(Upper) 11 Back Angle Lumbar Support(Lower) Seat Belts 2) Insert the metal latch plate ڹinto the buckle ں. 3) To remove the belt, depress the red push button on the buckle. And the belt wil roll up automatically. 4) When the driver’s seat belt is not in use, adjust the latch plate ڹwithin 10cm from the seat loop. The vehicle is equipped with three point type(driver’s) and reel type(passenger’s) Every person who drives or rides in this vehicle should wear a seat belt at all time. The buzzer will sound, if the driver’s seat belt is not fastened when the ignition switch is turned to the “ON” position. 1) Pull the belt evenly out of the retractor and guide it across the body making certain that it is not twisted. The seatback should not be in a reclining position anymore than needed for comfort. The belt must not be twisted when fitted. Do not wear the shoulder belt across the neck or under your outer arm. 1 2 12 Seat belt warning lamp The seat belt warning lamp comes on when the ignition switch is placed in the “ON” position unless the driver’s seat belt is securely fastened. NOTICE CAUTION 1. Never use the belt for more than one person at a time. 2. Never wear the belts twisted. 3. Make sure seat belts or their attachments not to be thrusted in metal parts of the seat or the door. 4. Seat belts should be adjusted as firmly as possible. 5. Do not wear seat belts low under your shoulder. 6. If you replace your seat belts incorrectly, you may by injured by hardware of the belts at sudden stops. 7. Do not wear your seat belts with hard or breakable objects such as glasses, pens, etc. put into the pocket of your upper garment. 1. Periodically inspect all parts of the belts and replace any damaged parts. 2. Make sure that the belts are not to be damaged by sharp edged objects. 3. The belts should be changed if webbing has become frayed or damaged. 4. Check if fixing bolts have been firmly installed to the floor. 5. Always keep the seat belts clean and dry. 6. Clean only with tepid soapy water. 7. Do not bleach or dye seat belts. Pilot indicator lamps 13 INSTRUMENTS, SWITCHES AND CONTROLS 25 14 1 5 2 3 4 6 7 8 9 21 12 13 17 10 15 29 11 32 18 31 28 19 30 27 26 23 24 14 22 20 LEGEND OF INSTRUMENT PANEL AND OTHER DEVICES No. Description No. Description No. Description 1 Voltage meter 11 Door opening switch(MID) (OPT) 22 Brake pedal 2 Engine coolant temperature gauge 12 Microphone stand 23 Horn switch 3 Fuel gauge–Engine 13 Radio & Cassette player 24 Bulb check 4 Engine oil pressure 14 Switches 25 Steering wheel 15 Door opening switch(RR) (OPT) 26 Head & Direction lamp lever 17 Defroster controller 27 Clutch pedal 18 Engine idling knob 19 Shift lever 28 Valve–cab control 29 Clutch oil reservoir 30 Control panel (OPTION) 31 Door controller 32 Cup holder (BM090, BS106) 5 6 Air pressure gauge Upper pilot lamps 7 Engine RPM gauge 8 Lower pilot lamps 9 Tachograph (OPTION) 20 Accelerator pedal Speedometer (OPTION) 21 Wiper 10 Door opening switch (FRT) (Except auto transmission) control brake lever and exhaust ҧThe quantities or locations of switches could be different from the figure, because the switches could be added or omitted, or locations could be changed by the requirements of customers. 15 ATTACHMENTS OF STEERING COLUMN Steering wheel and horn button Steering wheel adjustment Starter switch The steering wheel should not be turned while the vehicle is stationary as it adversely affects the tires and steering system. Horn button is equipped on the middle of steering wheel. Type A : Tilt & Telescopic (BH115E,BH120E) (BM090/BS090/BS106 : OPTION) Adjust the steering wheel to the desired position after pulling lock lever. Starter switch operates in the 4 stages as follows : ҮLOCK : The key can be inserted or removed only when the switch is in this position. ҮACC : This position turns on the radio, digital clock, cigarette lighter and consent. Adjusting angle : 8° Travel : 40mm 20mm 20mm 3° 5° unlock lock Type B : Fixed (BM090, BS106) 16 ҮON : This position turns on the electrical equipment. During the vehicle operation, hold the key in this position. ҧWhen the key is in “ON” position, the engine is automatically preheated according to outdoor temperature. Pre–heater warning lamp blinks for 0.3 second at a higher temperature(coolant temp. : above 25°C) and for 18 seconds at a lower temperature(coolant temp. : below 25°C), during which the engine is preheated for 20 seconds. ACC ON ҮSTART : Once the engine is started, it is preheated automatically according to outdoor temperature (until coolant temperature becomes 25°C or up to 6 minutes). This improves the engine condition. CAUTION ҮOnce the engine started, release the key immediately. ҮDo not exceed 10 seconds for the operation of starter. ҮGearshift lever should be in neutral position when attempting to start the engine. START LOCK Pilot indicator lamps 17 Turn signal switch Move this combination switch lever in the desired direction so that the corresponding turn signal lamp operates and causes the turn signal indicator lamp on the instrument panel to flash. The switch lever returns automatically to the neutral position when the steering wheel is returned to the reverse direction. When head lamp switch is in 2nd stage simultaneously with turn signal lamp “ON”, cornering lamp also comes on. High beam switch Lamp switch(turn type) Windshield wiper switch When the head lamps are on, pulling the lever down lights up not only the head lamps with high beam but also the high beam indicator lamp. When pulling it up, head lamps with low beam are on. Lamp switch operates in two stages as follows : 1st stage : tail lamp, license plate lamp, instrument panel lamp, clearance lamp 2nd stage : tail lamp, license plate lamp, instrument panel lamp, clearance lamp, head lamp, cornering lamp(simultaneously with turn signal lamp “ON”) The windshield wiper switch has 3 positions to control the windshield wiper. 1. OFF ˞ Off 2. INT ˞ Intermittent wipe 3. LO ˞ Continuous wipe, slow speed 4. HI ˞ Continuous wipe, fast speed Passing lamp switch To light up passing lamps at any time, pull up the lever towards the steering wheel. The lever will return to the OFF position when released. NOTICE Do not operate the wipers when the windshield remains dry. They may scratch the windshield glass. Do not operate the wipers if they are covered with snow or ice as this may damage the wiper system. high beam (passing) 2nd stage low beam OFF 3 4 1st stage 2 1 high beam 18 Wiper speed control switch Exhaust brake switch Hazard warning flasher switch The desired intermittent operation time can be controlled by turning the knob when the wiper switch is in “INT” position. The exhaust brake system is designed to shut off exhaust pipe when the engine brake is applied, resulting in assisting brake action. When the switch lever is pushed downward, and clutch and accelerator pedals are released, the indicator lamp comes on showing that the exhaust brake is in operation. When the clutch and accelerator pedals are depressed, the exhaust brake stops working. When the right–hand lever is pushed upward, all the turn signal lamps are made to flash regardless of the turn signal switch position. The hazard warning flasher switch is to be used when your vehicle gets in a traffic hazard or is parked in the darkness. Windshield washer switch To let washer fluid spray on the windshield, press and hold the center button of switch. And the windshield wipers are simultaneously operated for 2–3 cycles. 19 PERIPHERAL DEVICES OF STEERING COLUMN Idle control knob (Except MT643 auto T/M) Idle control valve (For MT643 auto T/M) Battery switch Turning the knob clockwise after cold starting of the engine will increase idling speed and thus facilitate quick normalization of the engine coolant temperature. Always drive with the knob turned back home. Valve position • FAST IDLE (UP) : 900~1000rpm. • IDLE (DOWN) : 550~650rpm. It controls the entire electrical circuits with the exception of parking lamps, hazard warning flashers. The electrical circuits are energized when the battery main switch is pressed. NOTICE Do not use this knob to stop the engine. FAST IDLE N IDLI G H .. L ascending position IDLE 20 Door opening switch The entrance door is operated by the air cylinders as the door opening switches on. Manual door opening switch Air parking brake switch When the manual door opening switch is placed at “auto” position, the doors are operated by the door opening switches, or when the switch is placed at “manual” position, the doors are not operated by the door opening switch and can be opened or closed by the hands. When the switch is pushed, the parking brake is actuated and the indicator lamp comes on. pushed one more the switch, releases the brake. Make sure that the indicator lamp is off before driving off. Type A : Cab control valve (Toggle switch type) Type B : Gradual control N IDLI G H .. L N IDLI G H .. L 21 ABS/ASR check switch(OPTION) The switch used for self Diagnosis of ABS/ASR system. It needs for a car mechanics, but not used for a driver usually, push the button about 3 seconds, self diagnosis started and the ABS/ASR warning lamp blinker on instrument panel. ASR POWER AUTOVE NTILATO R POWER AIRCONDI TIONER ABS ARS IONER ABS 1 2 3 4 AIRCONDIT ABS 22 ARS Engine check / clear switch (For DE12TiS ENG.) When engine malfunction pilot lamp comes on, follow the below procedure to solve the problem. 1. To check error type pressing engine check switch. With pressing this switch, engine malfunction lamp blinkers according to the error types. (Example) Malfunction Pilot lamp ҮError code No. 01 12 13 14 15 16 21 22 23 Defects Normal Prestroke control error Prestroke sensor error Prestroke offset error Prestroke actuater power error Engine rpm sensor error Coolant temp. sensor error Fuel rack sensor error Air heater relay error ON OFF Error code 12 : prestroke control error NE GI EN 1 CHECK 2 K R C HE A LE C Pilot indicator lamps NE GI EN C 1. Engine check switch (Blue color) 2. Engine clear switch (Black color) 23 2. After repairing defects according to the engine maintenance manual, press the engine clear switch for 5seconds to remove the errors on ECU. INSTRUMENTS AND INDICATOR LAMPS 2 1 11 10 7 1. 2. 3. 4. 5. 6. 80 100 60 120 40 32 24 16 0 Km/h 140 20 160 0 H 6 7 2 1 9 0 C 0 0 0 0 0 7. 15 AIR kg/cm2 0 x1000rpm Tachograph 3 E 80 60 4 0 8 100 120 40 000000 140 20 160 0 3 0 12 3 F 0 4 5 8 12 9 6 km/h Speedometer 24 8. 9. 10. 11. 12. Voltmeter Engine coolant temperature gauge Fuel gauge Engine oil pressure gauge Air pressure gauge Engine tachometer (If the engine RPM indicating function is included in tachograph, this gauge is substituted to blank cover.) Tachograph (BH115E, BH120E) (BM090/BS106 : OPT) Speedometer (BM090, BS106) Bulb check switch Cover Turn signal/hazard warning indicator Upper pilot indicator lamps Lower pilot indicator lamps Voltmeter Temperature gauge Fuel gauge The voltmeter indicates the battery condition. Check the voltmeter reading with the engine running. The gauge needle should stand between the reading of 24 and 28. The gauge indicates the engine coolant temperature. If the gauge needle stands below the red colored zone, it means that engine coolant temperature is normal. This gauge indicates fuel level of the fuel tank all the time regardless of the starter switch position. If the needle stands in “H”(overheating), stop the vehicle and run the engine at a moderately fast idle speed or put the gear in lower position to reduce engine load. If the vehicle is operated in abnormal condition, engine performance will be reduced and fuel consumption will be increased. The capital letter “E” represents almost “empty”. Top–up the fuel tank before the gauge indicates “E”. F H 32 24 16 0 E C 25 Oil pressure gauge Air pressure gauge Engine tachometer This gauge indicates oil pressure in the engine lubricating system. The indication of the gauge should be 1–3 kg/cm2 when the engine is at idle ; it should be 3–6.5kg/cm2 when the engine is running at medium speed. When the gauge needle does not move upward at all or hydraulic pressure changes abruptly, check the oil level in the engine crankcase. If the oil level is found normal, have the hydraulic system checked by your nearest Daewoo dealer. Air pressure gauge indicates air pressure in the air tanks. While driving, the gauge needle must be within the range of 5.3–8.2kg/cm2. The tachometer indicates the engine speed in revolutions per minute(rpm) and red colored zone represents critical engine speed. Be habitual of watching the gauge, while driving, to make sure the gauge needle indicates the normal conditions. NOTICE Excessively high engine rpm(red colored zone) may cause damage to the engine. To drive economically, keep the engine within 1,000Ŕ2,000rpm. If the gauge needle stands in the red zone, warning lamp comes on and alarm buzzer sounds. Immediately stop the vehicle, check for unusual conditions, run the engine at a moderately fast idle speed to increase air pressure, then drive off. Maximum allowable engine speed : D1146 ENG : 2,500rpm. D1146Ti/DE12/DE12T ENG. : 2,200rpm. DE08TiS ENG : 2,300rpm. DE12Ti/DE12TiS ENG.:2,100rpm 4 1 9 6 8 1 2 12 3 0 15 AIR kg/cm2 26 AO FUL H AIR L AI R Do not run the engine with low oil pressure indication. 0 x1000rpm 3 Tachograph (BH115E, BH120E) (BM090/BS090/BS106 : OPT) Speedometer (BM090, BS106) Bulb check switch The tachograph is consisted of odometer and clock. The vehicle speed and running distances are registered in a single chart. The speedmeter indicates the vehicle speed in kilometer per hour(km/h). The odometer indicates individual trip distances. The odometer records the total distance in km. The unit of registered distance is loom. For further information refer to “TACHOGRAPH” on page. The speedometer is consisted of odometer and clock. The vehicle speed and running distances are registered in a single chart. The speedmeter indicates the vehicle speed in kilometer per hour(km/h). The odometer indicates individual trip distances. The odometer records the total distance in km. The unit of registered distance is loom. When bulb check switch is pressed, warning lamp on instrument panel comes on. And also the warning buzzer sounds. For further information refer “SPEEDOMETER” on page. 80 60 80 Before driving, use this switch to check that all warning lamps including speed indicator lamps and their circuits are operating normally. to 32 24 16 0 100 100 60 120 40 120 40 000000 Km/h 140 20 7 0 0 0 0 0 0 0 6 20 F 160 0 81-100 27 0 15 AIR kg/cm2 0 x1000rpm 3 E T/M SAFETY SPEED 101-160 2 12 E km/h 0-80 1 9 3 140 160 0 H C 4 0 8 ABS ASR Turn signal indicator lamp When the turn signal switch or hazard warning flasher switch is turned on, the turn signal indicator lamp flashes to indicate the operation of the external turn signal lamps or hazard warning flashers. 28 UPPER PILOT INDICATOR LAMPS Type A 1. 2. 3. 4. 5. 6. 7. 8. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 9. 10. 11. 12. 13. 14. 15. 16. Engine coolant temperature (high) Air tank pressure (low) Brake oil level (low) (OPT : AOH Brake) Seat belt (Unfastened) Parking lamp (on) Engine oil pressure (low) Battery charging Engine door (open) 29 Emergency door (open) (OPTION) Mirror defroster (on) (OPTION) Air dryer operation (on) (OPTION) Engine preheat (on) High beam (on) Transmission neutral position Entrance door (open) Passenger’s stop order (OPTION) Type B 1 9 1. 2. 3. 4. 5. 6. 7. 8. 2 3 4 1 2 3 10 11 12 5 6 7 8 13 14 15 16 9. 10. 11. 12. 13. 14. 15. 16. Engine coolant temperature (high) Air tank pressure (low, Front) Air tank pressure (low, MID.) Air tank pressure (low, Rear EMER.) Brake oil level (low) (OPT : AOH Brake) Engine oil pressure (low) Battery charging Engine preheat (on) 30 Seat belt (Unfastened) Engine door (open) Air dryer operation (on) (OPTION) Engine room fire warning (OPTION) High beam (on) Transmission neutral position Entrance door (open) Passenger’s stop order (OPTION) Type C 1 9 1. 2. 3. 4. 5. 6. 7. 8. 2 3 4 1 2 3 10 11 12 5 6 7 8 13 14 15 16 9. 10. 11. 12. 13. 14. 15. 16. Engine coolant temperature (high) Air tank pressure (low, Front) Air tank pressure (low, MID.) Air tank pressure (low, Rear EMER) Brake oil level (low) (OPT : AOH Brake) Engine oil pressure (low) Battery charging Engine room fire warning (OPT) 31 Seat belt (Unfastened) Engine door (open) Air dryer operation (on) (OPTION) Engine preheat (on) High beam (on) Transmission neutral position Entrance door (open) Passenger’s stop order (OPTION) Type D 1. 2. 3. 4. 5. 6. 7. 8. 1 2 9 10 11 4 5 6 7 8 12 13 14 15 16 9. 10. 11. 12. 13. 14. 15. 16. Engine coolant temperature (high) Air tank pressure (low) Brake oil level (low) (OPT : AOH Brake) Seat belt (Unfastened) Parking lamp (on) Engine oil pressure (low) Battery charging Engine door (open) 32 Emergency door warning (open) (OPTION) Mirror defroster (on) (OPTION) Air dryer operation (on) (OPTION) Engine preheat (on) High beam (on) Transmission neutral position Entrance door (open) Passenger’s stop order (OPTION) Type E 1 9 1. 2. 3. 4. 5. 6. 7. 8. 2 3 4 1 2 3 10 11 12 5 6 7 8 13 14 15 16 9. 10. 11. 12. 13. 14. 15. 16. Engine coolant temperature (high) Air tank pressure (low, Front) Air tank pressure (low, MID.) Air tank pressure (low, Rear EMER) Brake oil level (low) (OPT : AOH Brake) Engine oil pressure (low) Battery charging Engine room fire warning (OPT) 33 Seat belt (Unfastened) Engine door (open) Air dryer operation (on) (OPTION) Engine preheat (on) High beam (on) Transmission neutral position Retarder warning (OPTION) Passenger’s stop order (OPTION) Engine coolant temperature (high) Seat belt (Unfastened) When the temperatue of engine coolant becomes near 100°C (210°F) the warning lamp turns on. The seat belt warning lamp comes on when the ignition switch is placed in the “ON” position unless the driver's seat belt is securely fastened. Air tank pressure (low) (Type A) Parking lamp (on) (Type B, C, E) (Type D) (Type A) AIR 1 2 3 PARKING The indicator lamp comes on and the warning buzzer is operated simultaneously, when air pressure within the air tank is lowered to 5.3kg/cm2. (Type D) If the air pressure indicator lamp comes on while driving, stop the vehicle and check to locate the cause of trouble and avioc driving with the indicator lamp turned on. Repeated application of service brakes could cause temporary lowering of air pressure. In such an instance, keep the engine running as fast idle until the indicator lamp goes out. The parking brake indicator lamp comes on when the parking brake lever is pulled with the starter switch “ON”. The parking brake indicator lamp does not indicate the action of the parking brake. Make sure to pull the parking brake lever fully when parking the vehicle. Before moving the vehicle, be sure to check that the parking brake indicator lamp is off. 34 Engine oil pressure (low) The lamp switch is engine is engine is Engine door (open) (Type A, B, C, E) (Type D) comes on when the battery main operated and goes out as the started and pressure of oil in the increased. ENG. DOOR If the lamp comes on while driving, stop the engine immediately and check the level of oil in the engine crank-case. If the oil level is normal, restrictions in the oil filter or a trouble in the lubricating system may be indicated and the system should be checked at your nearest service station. Do not run the engine with the lamp illuminated. The indicator lamp comes on when the engine room door is opened. If the lamp turns on even after closing the door, check the door lock and lock the door firmly Emergency door (open) (Type A) Battery charging (Type D) EMER. DOOR The indicator lamp comes on when the battery main switch is operated and goes out as the engine is started and alternator circuit is brought into normal function. The indicator lamp comes on when the emergency door is opened. If the lamp comes on even after closing the door, check the door lock and lock the door firmly.. The indicator lamp comes on while the engine is running, it indicates that the alternator circuit is malfunctioning, then immediately stop the vehicle and have the alternator ciruit checked by your nearest service shop. 35 Mirror defroster (on) (OPTION) Transmission neutral position Pressing the side mirror defroster switch, the indicator lamp “ON” and the defrosting coil in the mirror starts actuating. The indicator lamp comes on when the gear shift lever locates in neutral position. Air dryer operation (on) (OPTION) Entrance door (open) (Type A,B,C,E) (Type A,B,C,E) (Type D) (Type D) ENT. DOOR AIR DRYER The lamp comes on while the entrance door is opened. The indicator lamp comes on when the air dryer is operating. (Air dryer heating system on) Passenger's stop order (OPTION) Engine preheat (on) This lamp is designed to indicate preheating of the engine. It comes on when starter switch is positioned “ON”, while it goes out when the preheating is completed. (Type A,B,C,E) (Type D) STOP High beam (on) When the passenger push the button between windows, the buzzer sounds and this lamp comes on. The high beam indicator lamp comes on when head lamps with high beam are in use. 36 Engine room fire warning (OPTION) ENG. ROOM The indicator lamp comes on when the engien room is fired. Retarder system warning (OPTION) At the case that additional retarding system is applied, while the retarder is operating, the indicator lamp comes on. 37 LOWER PILOT INDICATOR LAMPS Type A 1 2 3 4 5 6 7 E 9 ABS ASR 10 11 12 8 CHECK 13 14 8. 9. 10. 11. 12. 13. 14. 15. 1. 2. 3. 4. 5. 6. Safety equipment operation Retarder system operation (OPTION) Retarder system warning (OPTION) Exhaust brake operation Speed 3 indication (OPTION) Electronically controlled air Suspension operation (OPTION) 7. Air condition warning (OPTION) 38 15 MIL Brake pad wear warning ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Speed limiter operation (OPTION) Speed 1 indication (OPTION) Speed 2 indication (OPTION) Type B 1 2 3 4 RTD RTD E ABS ASR 10 11 12 5 6 7 13 14 15 8. 10. 11. 12. 13. 14. 15. 1. 2. 3. 4. 5. 6. Safety equipment operation Retarder system operation (OPTION) Retarder system warning (OPTION) Exhaust brake operation Speed 3 indication (OPTION) Electronically controlled air Suspension operation (OPTION) 7. Transmission temperature 39 8 Do not shift ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Speed limiter operation (OPTION) Speed 1 indication (OPTION) Speed 2 indication (OPTION) Type C 1 2 3 4 5 6 7 13 14 15 8 E 9 1. 2. 3. 4. 5. 6. 7. 8. ABS ASR 10 11 12 9. 10. 11. 12. 13. 14. 15. Safety equipment operation Defroster operation Fuel empty warning Exhaust brake operation Battery main S/W operation Retarder operation (OPTION) T/M temperature warning Air condition warning (OPTION) 40 Over speed warning (OPTION) ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Light 1 step operation Head lamp low beam (on) Front fog lamp operation Type D 1 2 E 1. 2. 3. 4. 5. 6. 7. 3 4 FRONT MID. DOOR DOOR ABS ASR 10 11 5 6 REAR DOOR 7 8 EMER. V/ V-F EMER. V/ V-M EMER. V/ V-R 14 15 ENG. ROOM 12 13 8. 10. 11. 12. 13. 14. 15. Safety equipment operation Exhaust brake operation Front door opened Middle door opened (OPTION) Rear door opened (OPTION) Front emergency valve operation (OPT) Middle emergency valve operation (OPT) 41 Rear emergency valve operation (OPT) ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Engine room fire warning (OPTION) Front fog lamp operation Rear fog lamp operation (OPTION) Type E 1 2 E CHECK 9 1. 2. 3. 4. 5. 6. 7. 8. 3 4 FRONT MID. DOOR DOOR ABS ASR 10 11 5 6 REAR DOOR 7 8 EMER. V/ V-F EMER. V/ V-M EMER. V/ V-R 14 15 P 12 13 9. 10. 11. 12. 13. 14. 15. Safety equipment operation Exhaust brake operation Front door opened Middle door opened (OPTION) Rear door opened (OPTION) Front emergency valve operation (OPT) Middle emergency valve operation (OPT) Rear emergency valve operation (OPT) 42 MIL ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Parking lamp (ON) Front fog lamp operation Rear fog lamp operation (OPTION) Type F 1 2 E 1. 2. 3. 4. 5. 6. 7. 3 4 FRONT MID. DOOR DOOR ABS ASR 10 11 5 6 REAR DOOR 7 8 EMER. V/ V-F EMER. V/ V-M EMER. V/ V-R 14 15 P 12 13 8. 10. 11. 12. 13. 14. 15. Safety equipment operation Exhaust brake operation Front door opened Middle door opened (OPTION) Rear door opened (OPTION) Front emergency valve operation (OPT) Middle emergency valve operation (OPT) 43 Rear emergency valve operation (OPT) ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Parking lamp (ON) Front fog lamp operation Rear fog lamp operation (OPTION) Type G 1 2 3 4 5 6 1. 2. 3. 4. 5. 6. 7. 8. 8 P E 9 7 ABS ASR 10 11 12 13 14 9. 10. 11. 12. 13. 14. 15. Safety equipment operation Exhaust brake operation Speed 1 indication (OPTION) Speed 3 indication (OPTION) Speed 2 indication (OPTION) Parking lamp (ON) Mirror heater (OPTION) Air condition warning (OPTION) 44 15 Emergency door (OPEN) (OPTION) ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Speed limiter operation (OPTION) Front fog lamp operation Rear fog lamp operation (OPTION) Type H 1 2 3 4 5 6 E 1. 2. 3. 4. 5. 6. ABS ASR 7 8 9 10 11 7. 8. 9. 10. 11. 12. Safety equipment operation Retarder system operation (OPTION) Retarder system warning (OPTION) Exhaust brake operation Speed 3 indication (OPTION) T/M temperature warning 45 12 ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) MIL Speed 1 indication (OPTION) Speed 2 indication (OPTION) Type I 1 9 1. 2. 3. 4. 5. 6. 7. 8. 2 3 4 5 6 7 8 E FRONT DOOR MID. DOOR REAR DOOR EMER. V/ V-F EMER. V/ V-M EMER. V/ V-R ABS ASR 10 11 14 15 P 12 13 9. 10. 11. 12. 13. 14. 15. Safety equipment operation Exhaust brake operation Front door opened Middle door opened (OPTION) Rear door opened (OPTION) Front emergency valve operation (OPT) Middle emergency valve operation (OPT) Rear emergency valve operation (OPT) 46 Auto greaser operation (OPTION) ABS system warning (OPTION) ASR system warning (OPTION) Retarder system operation (OPTION) Parking lamp (ON) Front fog lamp operation Rear fog lamp operation (OPTION) Type J 1 2 3 4 5 6 7 13 14 15 8 E 9 1. 2. 3. 4. 5. 6. 7. 8. ABS ASR 10 11 12 9. 10. 11. 12. 13. 14. 15. Safety equipment operation Defroster operation Fuel empty warning Exhaust brake operation Battery main S/W operation Retarder operation (OPTION) T/M temperature warning Do not shift 47 Over speed warning (OPTION) ABS system warning (OPTION) ASR system warning (OPTION) Auto greaser operation (OPTION) Light 1 step operation Head lamp low beam (on) Front fog lamp (on) Safety equipment operation Retarder system warning (OPTION) (Type A-G, I, J) (Type A, H) (Type H) SAFETY RTD When the passenger stands at entrance step, the rear door is not closed, this lamp comes on. At the case that additional retarding system is applied, while the retarder is operating, the indicator lamp comes on. Retarder system operation (OPTION) (Type A, C, H-J) (Type B) Exhaust brake operation (Type B) E RTD For automatic transmission, while the retarder is operating, the indicator lamp comes on. The indicator lamp comes on while the exhaust brake is operating. Electronically controlled air suspension operation (OPTION) ECS 48 The height of the body is controlled automatically in accordance with the weight and speed of the vehicle, the lamps comes on when the system is operating. Speed 1 indication (OPTION) Speed 2 indication (OPTION) (Type A, B, G) (Type A, B, G) (Type H) SPEED 1 (Type H) SPEED 2 At the vehicle speed in 0~5km/H the lamp comes on, also the left Yellow-Green marker lamp on the roof at the front of the vehicle, lights on. At the vehicle speed in 80km/H the lamp comes on, also the middle red marker lamp on the roof at the front of the vehicle, lights on. Speed 3 indication (OPTION) Brake pad wear warning (Type A, B, G) (Type H) The indicator lamp comes on when the brake limning is too much worn out. SPEED 3 Over speed warning (OPTION) At the vehicle speed in 0~5km/H the lamp comes on, also the left Yellow-Green marker lamp on the roof at the front of the vehicle, lights on. SPEED 49 At the vehicle speed in 80km/H the lamp comes on, also the middle red marker lamp on the roof at the front of the vehicle, lights on. ABS system warning (OPTION) ABS Speed limiter operation (OPTION) As the battery relay and the starter switches are turned on, the indicator lamp comes on and goes put when the vehicle speed reach to 5~10km/H. If the lamp keeps lighting while driving, the ABS/ARS system is out of order and should be checked. SPEED LIMITER Air conditioner warning (OPTION) The lamp comes on when the high/low voltage is flowing or the compressor clutch is disconnected, etc. NOTICE When the ABS/ASR system is out of order, the brake system works as if ABS system is not applied. Head lamp low beam (ON) ASR system warning (OPTION) ASR The lamp comes on while the speed limiter system is operating. The high beam indicator lamp comes on when head lamps with high beam are in use. As the battery relay and the starter switches are turned on, the indicator lamp comes on and goes out in a short time. If the lamp keeps lighting while driving, the ASR system is out of order and should be checked. Engine malfunction lamp Check the state of engine operating when starter key on. This lamp flashes at engine cranking in normal of engine operating. Otherwise, on abnormal of Engine operating, lamp come on continuously and come on during of engine running. Auto greaser operation (OPTION) CHECK The indicator lamp comes on while the auto greasing system is operating or the main pressure of the system drops below 25kg/mm2. 50 Transmission temperature (Type B) (Type C, J) Fuel empty warning (Type H) When fuel indiator needle located around Empty state, (Red line) indicator lamp come on. T/M TEMP. Battery main S/W operating The lamp comes on when the oil temperature of automatic transmission is overheated beyond the specified value. The indicator lamp comes on when the battery relay switch is operated and goes out as the engine is started and alternator circuit is btought into normal function. Shift (Type B) (Type J) SHIFT T/M The indicator lamp comes on while the engine is running, it indicates that the alternator circuit is malfuncitioning, then immediately stop the vehicle and have the alternator circuit checked by your nearest service shop. The lamp comes on when the engine RPM rises beyond shifting point. Light 1 step operating Defroster operation At the vehicle speed in 0~5km/H the lamp comes on, also the Yellow-Green marker lamp on the roof at the front of the vehicle, lights on. For automatic transmission, while the retarder is operating, the indicator lamp comes on. At the tail lamps come on, indicator lamp come on. When the defroster in operating for refuse frost, the indicator lamp comes on. 51 Front fog lamp operation Front door operation The lamp comes on when the front fog lamp switch is turned “ON”. FRONT DOOR Rear fog lamp operation (OPTION) Middle door operation (OPTION) The lamp comes on when the tail lamp is “ON” and it light off while tail lamp come off. MID. DOOR Against rear fog lamp keep up “OFF” while tail lamp is comes on. The indicator lamp comes on when the middle door is opened. Rear door operation (OPTION) Parking lamp (On) P When the front door is opened, this indicator lamp comes on. REAR DOOR The parking brake indicator lamp comes on when the parking brake lever is pulled with the starter switch “ON”. The indicator lamp comes on when rear door is opened. Front emergency valve operation (OPTION) The parking brake indicator lamp does not indicate the action of the parking brake. Make sure to pull the parking brake lever fully when parking the vehicle. EMER V/V-F Before moving the vehicle, be sure to check that the parking brake indicator lamp is off. 52 The indicator lamp comes on while the middle emergency valve operation. Middle emergency valve operation (OPTION) EMER V/V-M Emergency door (open) (OPTION) The indicator lamp comes on while the Mid. emergency vlave operation. EMER. DOOR Rear emergency valve operation (OPTION) EMER V/V-R The indicator lamp comes on while the rear emergency valve operation. Engine room fire warning (OPTION) ENG. ROOM The indicator lamp comes on when the engien room is fired. Mirror defroster (ON) (OPTION) Pressing the side mirror defroster switch, the indicator lamp “ON” and the defrosting coil in the mirror starts actuating. 53 The indicator lamp comes on when the emergency door is opened. If the lamp coems on even after closing the door, check the door lock and lock the door firmly. SWITCHES Ɓ The quantities or locations of switches could be different from the figure, because the switches could be added or omitted, and locations could be changed by the requirement of customers. 54 Room lamp switch (Floor 1) Room lamp switch (Floor 2) (Apply for vehicles with lamp rack) Mood lamp switch 1 (OPTION) (Apply for vehicles with lamp rack) Push the switch to light on the first room lamp (incandescent) from the entrance door (Front). Push the switch, light come on the all room lamp (incandescent) but except first room lamp at the entrance door (Front). Pressing the switch to light on the mood lamp come on in order odd. F F F 55 Mood lamp switch 2 (OPTION) (Apply for vehicles with lamp rack) Pressing the switch to light on the mood lamp in order even. F Room lamp switch (Bulb) Driver lamp switch Push the switch to light on the fluorescent room lamps at the passenger’s compartment. Pressing the switch, the driver’s compartment lamp comes on. B 56 Luggage lamp switch (OPTION) Reading lamp switch (OPTION) Fog lamp switch (Front) Pressing the switch, the luggage compartment lamps come on. The switch operates when the light switch is on. Pressing the switch, reading lamps below the air–conditioner grill come on. Pressing the switch, the fog lamps come on to improve your Foreward/ backward vision in fog or snow. 57 Fog lamp switch(Rear) (OPTION) Battery main switch Parking lamp switch (OPTION) Pressing the switch, the fog lamps come on to improve your Backward vision in fog or snow. Pressing the switch to light on the battery lamp come on. Pressing the switch to light on the parking lamp lamp come on. P 58 Front ent. door switch (OPTION) Mid. ent. door switch (OPTION) Rear ent. door switch (OPTION) Pressing the switch, front ent. door lamps upper the front door come on. Pushing the switch, Mid. ent. door lamps come on. When Mid door opened. Pressubg the switch, rear ent. doorr lamps comes on when rear ent. door opened. 59 TV/VCR power switch (OPTION) Electric fan switch (OPTION) Step lamp switch (OPTION) Pressing the switch, electric power to TV/VCR is supplied. Pressing the switch, electric fan power supplied for driver's and passengeeer's fan. Push the switch to light on the search lamp from the front/middle/rear door. 60 Destination board switch (OPT) Door rack lamp switch (OPTION) Heater mirror switch (OPTION) Push the switch to light on the destination boards front and rear. Pressing the switch, door rack lamps come on.3 Pressing the switch, provide heater in mirror. 61 THE CAR VISION SYSTEM FOR VEHICLE (OPTION) òCAMERAó 1. LENS : It’s possible inputing the a picture and veiwing 130° degrees of an angle. 2. COVER : Profected the camera on water proof stuff. 3. DIN PLUG : Connect the monitor and camera. 2 1 3 12 ҮPower on by pressing the switch()ڹ, the indicator lamp( )ںlight comes on Automatically(power off by pressing the switch( )ڹagain). ҮTurn to right the contrast switch()ڻ, the scene state is kept distinctly, the turning to the bright control switch( ) ڼleft/right, the bright of scene is controlled darkly and brightly. ҮSelet( )ڽthe camera C1/C2 in case of two camera installed. C1 is inner 34 5 6 7 watching camera by pressing the upper button and other is outer watching. ҮSelect the Auto/Manual switch()ھ. –Auto : Rear situation is displayed the monitor with operation on camera in state of shifted reward gear of vehicle. –Manual : Camera operated by power on. ҮPress the light of scene controller button( )ڿthe scene is drak in night, othewise in daytime, it’s brighted. 62 HEATING AND DEFROSTING Heating and defrosting of driver’s compartment Heating and defrosting of driver’s compartment Move the upper control lever from the left end of right side, the blower fan starts to operate and the incoming air flow increases gradually. When the middle control lever to the right side end, in the blower is cycled in inner. Otherwise, the lever to the left side end, the blower is inhaled from outer for circulation. When the lower control lever is placed at the left and, the air comes by two directions, one is to the driver’s foot side and another is to the windshield glass side. OFF 1 2 3 By moving the control lever to the right side, the air coming into the foot side decreases and to the wind shield glass side increases gradually. When the lever reaches to the right end, the air comes in by the windshield glass side only. OFF 1 2 63 3 Heating of passenger's compartment (OPTION) HEATER Power switch Controller operator switch Power on by turning the end of left side (Light Red color part) to side of center (Red color) or Right (Dark color). Before press the units controller button, must be operated power switch () ڹ, and push the button for unit selector ()ں. Select the unit No. by pressing the buttons are ordinary order from unit No.1 to No.5. After, the selection fan by turning the Rotary selector ( )ڹto right side (Dark Red). It’s increase highly. (Heater–2EA) (Heater–3EA) HEATER HEATER 1 1 2 2 (Heater–4EA) HEATER 1 1 2 3 2 1 1 2 3 2 64 4 AIR–CONDITIONING COOLER (ROOF–ON TYPE) (OPTION) Cooling operator switch (3) Temperature controller (Type A : Rotary type control panel) Turning the end of left side(Dark blue), the temperature of indoor is decrease lowerly otherwise, turning the right side(Light blue) it’s increase highly. Power switch The cooler power switch is operated by pressing the button (2), then cooler blower fan is operated as each step of fan speed switch (4, 5, 6). While the cooling operator switch is not pressed, room air only cirrculates. Before press the button, must be operated power switch(1). Press the switch (3) and cooler starts operation. Warning indicator (7) When the refrigerant is flowing the high/low pressure or the disconnected of compressor clutch, etc., then the indicator lamp come on. Blower fan operator switch (4, 5, 6) Swithc (4) : 60% of max. capacity. Swithc (5) : 80% of max. capacity. Swithc (6) : 100% of max. capacity. Type ы Type ь AIRCONDITIONER AIRCONDITIONER 1 POWER 2 1 POWER 3 4 5 65 6 2 3 4 5 7 (Type B : Seesaw type control panel) Cooling ҮFirst start engine and set the room temperature with the control knob. ҮPush the cooling/vent switch to “cooling” side. ҮPush “ON” the power switch, the all systems like the compressor, condenser fan and evaporator blower start operation for cooling. (The “cooling” indicating lamp comes on). AIR-CONDITIONER VENT COOLING ON COOLING HIGH OFF VENT LOW TROUBLE 15 TEMP ҮWhen the room temperature drops below the set temperature, the system does air blowing operattion only, and the room temperature rises beyond the set temperature, the system returns to cooling operation automatically. Ventilation ҮPush the cooling/vent switch to “VENT” side. ҮPush “ON” the power switch, to maintain adequate room temperature by blowing in the fresh and cool outdoor air. ҮAt this time the compressor and condenser fan do not operate, but the blowers in the evaporator operate. 30 66 Stop ҮNormal stopping First push “cooling/vent” switch to “vent” side, then cooling stops and the system operates only for ventilation, Push power switch “OFF”, then all systems stop operation. ҮEmergency self stopping. - When refrigerant pressure rises abnormally high (over 22kg/cm2), the electric clutch of compressor is disengaged, so the compressor stops working. (The “Trouble” indicating lamp comes on). In the case that any troubles are checked in operation, the emergency self stop occurs, this means the stop of compressor, the condenser and evaporator fan do not stop and continue operating. - When refrigerant pressure goes down abnormally low(below 0.5kg/cm2), the electric clutch of compressor is disengaged, so the compressor stops working. (The “trouble” indicating lamp comes on). High/low switch operation By pushing the High/low switch, high or low ventilation in ventilation operation and high or low cooling in cooling operation could be selected. This switch enhances the performance of temperature control. NOTICE As the time goes by(about 10 minutes), the refrigerant pressure rises and the cooling can start again without any special actions. If emergency self stops by the abnormal low pressure occur frequently, stop the vehicle operation and have service for the ait–conditioner system. 67 Refrigerant amount No or few bubbles are seen on the sight glass under engine idling, when the refrigerant is sufficient. When the refrigerant is not sufficient, not a few bubbles are seen. If the refrigerant is overcharged, it shows high pressure than normal. In this case, purse the refrigerant a little to the specified amount. Sufficient amount is approx. 12ť0.5kg insufficiency Season check 1. Before season–off Do not separate the air conditioner in season–off. Keep the air conditioner under installation during season–off. Keeping refrigerant is helpful for protection of rust and oil consumption for long service life. 2. Season–off Operate once in a month and check for cooling performance.(Operate approx. 5 minutes) Not being operated by thermostat when inside–temperature is below 15°C. Do operate again after the temperature rises over 15°C by heating. 3. Season–in Closely check as the check lists. Naturally the refrigerant escapes as time passing. Refill refrigerant to the sufficient amount. sufficiency 68 Regular check & maintenance Maintenance schedule Maintenance items Refriger ant cycle Compressor Compressor oil Gas leak of connection & pipe Refrigerant amount Refrigerating hose Condenser Evaporator Air fillter Control device Drive cycle Fusible link Drier Control panel Pressure switch Lamp Clutch bearing Condenser fan Evaporator fan V–belt Pulley Method Standard Day Overhaul Check and refill Check with leak–tester Normal operating air–con. Sufficient No gas–leaks No damage Keep tighten clamp Check through sight glass No bubbles No leak Check No damage Wash, clean or replace Keep clean fin & tube Keep clean Check or replace Keep clean Clean with compressed air or water Operation Check Operation Replace desiccant Operation Check Operation Check Operation Check No damage Replace Noiseless Check and replace Noiseless Check and replace No damage Replace Keep reasonable belt tension Replace No damage 69 Periodic check Change Week Month Season period Standard 1,500HR 2Years ƃ Every ƃ season ƃ ƃ ƃ ƃ 3Years (high side) 5Years (low side) 5Years 5Years ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ 5Years 5Years 5Years 5Years 1,000HR 3Years 3Years ƃ 2 Years ƃ 5Years Check points (operation) Items Before operation During operation Stop Procedure & check point 1. 2. 3. 4. 5. 6. Check for V–belt tension and damage. Check for fixing position of crank pulley, tension pully and clutch pully. Check for clogged inlet of cooling–air and filter mat. Keep compressor clean without dust or oil. If not, clean it with compressed air. Check for fixing condition of bolts and nuts. If not, retighten them. Check for gas–leak of connected position with leak–tester and retighten. 1. 2. 3. 4. Check for operation when turning on the main switch after starting engine. Check for operation of vent, cooling and unloading by using the temperature volume. Check for capacity of cooling air from ducts. Check for operation of high–low pressure switch. Low pressure set : 0.5kg/cm2 (warning light turn “on” and compressor clutch is disconnected) High pressure set : 0.5kg/cm2 (warning light and buzzer turn “on” and compressor clutch is disconnected) 1. Check for stopping of cooler when pushing button switch to turn off. 2. Check for stopping when turning off the main switch. 70 Check points (cycle) Check point Items Refrigerant cycle Compressor 1. Check for operation. 2. Check for oil level and keep sufficient amount. Condenser 1. Clean fin and tube. 2. Check for gas leak and damages. Evaporator fan ҮCheck for operation. Hi, low pressure switch ҮCheck for operation. Drier ҮReplace desiccant and filters. Receiver tank ҮCheck for operation. Others 1. Check for clamping of connected parts. 2. Check for gas leak of connected parts. 3. Check for air filter mat, drain hose and keep clean. Engine Control devices V–belt ҮCheck for the tension of V–belt. Magnetic clutch ҮCheck for compressor pulley. Control panel 1. Check for switch 2. Check for lamps. 3. Check wirings for loosened condition and clamping condition. 4. Check for attaching condition. Cooling unit ҮCheck for the damages and looseness. Condenser fan ҮCheck wiring frame for looseness. Evaporator fan ҮCheck terminal for fixing condition. Magnetic clutch ҮCheck covered wire for damage. 71 Trouble shooting If show abnormal symptoms during operation, check the cause as followings. This chapter describes the details of troubleshooting. Cause Defect Measures 1. Air is mixed into the cycle. High pressure is operating at higher than standard 2. Overcharged refrigerant 3. 4. 5. 1. High pressure is operating at lower 2. than standard 3. 4. Low pressure is 1. operating at higher 2. than standard 3. 4. 5. 1. Discharge the refrigerant completely, charge refrigerant again to specified amount after check vacuum. 2. Discharge the refrigerant to specified amount.(12ť0.5kg) Choked and clogged condenser with dust and dirt. 3. Clean with water or compressed air. 4. Repair or exchange. Defective condenser fan. Too high ambient temperature when parking. 5. Reduce the temperature in the shade. Liquid back symptom : Refrigerant gas, which 1. Check the sensible bulb to the suction pipe. enter compressor, contain liqued refrigerant. 2. Replace The expansion valve worn–out 3. Replace Broken discharge valve of compressor. 4. Check and clean clogged part. Clogged inlet strainer of compressor. Liqued refrigerant enters compressor. 1. Check the sensible bulb sticked to the suction pipe. The expansion valve worn–out. 2. Replace Broken suction or discharge valve of compressor. 3. Replace 4. Discharge refrigerant to the standard level. Too much refrigerant in the cycle. 5. Charge refrigerant again to specified amount, Air is mixed into refrigerating cycle. after discharging the refrigerant 72 Measures Cause Defect 1. Disconnect them and check. 2. Check leaking part, then charge refrigerant up that the no–bubbles are seen on the sight glass. The evaporator is frosted or insufficient inlet 3. Stop operation temporarily. air for evaporator. 4. Check for clogged part and clean up. Air–inlet side clogged. 5. Keep the air filter clean with water or comAir filter clogged with dust and dirt. pressed. 6. Check for clogged part and clean. Evaporator clogged with dust and dirt. The sensible bulb or pipe of expansion valve. 7. Replace Frosted liquid refrigerant in refrigerating cycle. 8. Discharge the refrigerant completely, and charge the refrigerant again to the specified amount without liquid refrigerant. 9. Replace The expansion valve worn–out. 1. Clogged pipe, drier and expansion valve Low pressure is operating at lower 2. Lack of refrigerant. than standard 3. 4. 5. 6. 7. 8. 9. 73 Air–conditioning cycle 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. I. Comp. 10 10 9 8 3 7 6 3 5 4 2 1 12 13 11 74 Compressor Discharge shut–off valve Condenser Receiver tank Service shut–off valve Dryer Sight glass Expansion valve Distributor Evaporator Suction shut–off valve High pressure switch Low pressure switch Installation of components Condenser unit 12 13 2 1 7 5 6 15 9 14 4 3 11 10 8 75 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Condenser(LEFT) Condenser(RIGHT) Receiver tank Dryer Motor(DC24V) Fan Motor mount High pressurized gas line(hose) High pressurized liqued pipe(left) High pressurized liqued pipe(right) High pressurized liqued line(hose) Housing Sealing Locking Air intake duct Evaporator unit 18 9 8 12 16 2 14 1 15 4 19 5 13 7 6 22 21 20 17 23 3 11 10 76 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Evaporator(left) Evaporator(right) Expansion valve Sight glass Motor(DC24V) Fan Fan case High pressurized liqued pipe High pressurized gas pipe Low pressurized gas pipe Pressure equalizing pipe Air filter Drainage prevention filter Operating panel Temperature sensor Wiring Drain hose Panel support Pipe support Housing Sealing Locking Air intake COOLER (ROOF-ON TYPE W/POWER PACK) (OPTION) Part name & Treatment for each device 1. Control panel HEAT (10sec) MID H I GH 1) Operation & Pre-heater switch The organization of switch is dumbuler switch as 2 stage, heat ON is using for pre-heating to glow plug, start ON is using for engine operation of AIR -CON. (Do not use it for more than 10 sec. At pre-heater & for more than 3 sec. at operating) 4 AU TO OF F W LO 2. Function of each switch POWER 6 OIL START (3sec) 1 1. 2. 3. 4. 5. 6. 7. 8. 15 30 ROOM TEMP(¡C) 2 3 COMP 8 BAT WATER 2) Blower air control switch The switch is used at air control of AIR-CON blower & engine stop as 5 stages. 1 OFF : at AIR-CON stop. 2 LOW : The air of AIR-CON blower is operated at LOW.(60% of total air) 3 MID : The air of AIR-CON blower is operated at MID.(80% of total air) 4 HIGH : The air of AIR-CON blower is operated at HIGH.(100% of total air) 5 AUTO : Blower AIR-CON is controlled automatically depending on INDOOR & SETTING TEMP.(3 stage control of auto air) 5 7 Operation & Pre-heater switch Blower air control switch Indoor TEMP. setting switch Power operation lamp Oil buzzer lamp COMP. Buzzer lamp Battery charging lamp Cold water buzzer lamp 77 3. Operation turn of AIR-CON 3) Indoor TEMP. settimg switch It is designed that the INDOOR TEMP can be kept regularly by user’s setted temp(15~30°C) in order to keep fresh condition into the indoor cabine and indoor temp can be automaticalley controlled at auto driving. Therefore, unnecessary action would not be need and be contributed to safe driving. 4) Power operation lamp The lamp can be on and signed the control status at air con operation & blower air control switch on. 5) Oil buzzer lamp The buzzer lamp can be on if the E/G <less than 0.3Kg/cm2G> and simultaneously, E/G would be stopped with occurance of buzzer. 6) COMP. Buzzer lamp The lamp for pressure rejected buzzer would be on to compressor high <more than 24Kg/cm2G> & compressor low<less than 0.5Kg/cm2G> due to system failure at air con operation. At this time, E/G would be automatically stopped with buzzer. 7) Battery charging lamp The lamp would be on at the charging failure of battery due to over currency after E/G operation & alternator operation.(When BLOWER S/W is on at E/G operation, lamp on is not failure) 8) Cold water lamp The lamp would be on if temperature of cold water is high(100 ±2°C) after E/G operation. At this time, E/G would be automatically stopped with buzzer. 78 1) Fresh temperature shall be setted with setting temperature switch. 2) BLOWER AIR CONTROL SWITCH shall be conversed to LOW. : Power lamp, oil lamp, battery lamp would be on with buzzer in simultaneous. And AIR-CON BLOWER air is operated to LOW. 3) If you push E/G operation & preheating switch to E/G operation for 3 sec. E/G would be operated with aircon operation. <The lamp would be off after E/G operation, at this time, buzzer is not occured.> 4) Please control blower air depending on indoor cabine temperature. Check before operation 4. Operation stop of AIR-CON 1. Check point before operation 1) Normal stop : Blower swich shall be OFF <After E/G OFF, AIR-CON is off after condenser fan motor operation for 30 sec..> 1) 2) 3) 4) 5) 6) 2) Abnormal stop E/G would be stopped with buzzer in control at rejection of compressor high/low of air-con system. : E/G would be stopped with buzzer in control at E/G <OIL, COLD WATER> rejection. Fuel Check & fulfill of cooling water Amount of engine oil Leakage check for fuel system Leakage check of refrigerant Exhaustion status of engine 2. Check operation 1) Fuel The fuel of system is from fuel tank for main engine. ſ The fuel consumption of power pack system is about 4.7l/H at 1950rpm on operation. 2) Check & fulfill of cooling water It is an enough if the engine coolant is in full up to below of coolant inlet on radiator. If need supplementation, use it as distilled water or clean undergroud water.(Coolant : about 3.5l) 79 ſ In occasion of season(coolin season)-off, drain the coolant completely using drain cock, and then mix & refill the antifreezing solution in accordance with outdoor air condition. 3) Amout of engine oil Check the oil amout by oil level gauge at horizontal position. It is normal if the oil is between graduation line of gauge. If insufficient, refill up to high level. (High 5l, Low 4l) ſ Please replace the engine oil at first 50 hours after start of cooling operation, and then the day after at every 100 hour. Daily & regular check 1. Important check & repair 4) Leakange check for fuel system Please pay attention & keep an eye to the joint part of fuel pipes such like fuel filter and injection pump etc. When in leakage, re-tighten the clamp or plug more. 6) Exhaustion status of engine It is a normal when the exhaust gas is colorless, but in case of white or black, please contact to service station. 5) Leakage check of refrigerant Please check the joint part of refrigerant line in suction & discharge side. It is a system of gas leakage if you find some oil residues & dirts on joint parts. ſ It is impossible to find the gas leakage very small. In this case, check it with gas leak tester on the service center. 80 1) Engine part → refer to separate service manual of engine (1) Air cleaner With air cleaner of power pack ass’y is filter paper type whitch is avairable to filter minute dirt, please clean the element often. (2) Belt tension More tighter belt tension, more abrasion of each pulley bearing part and no good cooling effect. As it can cause an over heat, check & regulate it. Belt tension is that 12mm is reasonable when push the middle of each pulley. ſ Check period : Check belt tension, scratch or oil and sewage status every 100 hour, and adjust or replace them. If regulate, adjust it with guide B.K.T bolt for alternator fixation. 2) Cooler system Check of refrigerant amount : if insufficient, the cooling effect is decreased. In case that see the bubbles in sight glass, fill up the refrigerant properly. NOTICE No problem in case that can see the bubbles intermittently. Please decide it seeing sight glass during 3~5 minutes. Abnormal Normal Insufficient On the switch, bubbles be seen sometime, and then be clear later Nearly empty • Bubbles on operation and be seen with foggy status at the same time. • Causes - Sinsufficient refrigerant - Water contained 81 2. Regular check list 1) Engine(system) SYSTEM NO Check list Working 1 Cooling water Check Replace 2 Radiator Condensor fin 3 Rediator hose Cleaning Refrigerant 4 Fan belt cycle 5 Cooling system 6 Oil supply to water pump 7 Oil supply to main pulley 8 Engine oil Lubricant & fuel system 9 Others Check Replace Check Replace Cleaning Check Periodical check everyday every every every every Replace Standard Remarks or at any 100 200 1 2 period time hrs. hrs. season season Water After first 50hrs. 1 season drain the cooling amount ● water at season-off Be closed Prohibit a system ● with dust washing 1 season Wound ● ageing Tension check is Wound 1 season 12mm at pressing of Ageing ● Tension 5kg/f after first 50hrs. Dirty ● Designated goods ● Check Check Replace ● At designated maker ● ● 82 200hrs Designated goods Replace at first 100hrs 50hrs or the day after every 100hrs Refer to Engine service manual SYSTEM NO Air inspirator Others Check list 10 Air cleaner element 11 Air cleaner hose 12 Air cleaner hose clamp 13 Oil tube rubber hose 14 Joint part of exhaust gas pipe 15 Engine mounting bolt 16 Engine Working Cleaning Replace Check Jointing Check Periodical check everyday every every every every Replace Standard Remarks or at any 100 200 1 2 period time hrs. hrs. season season Dirty Replace after first 1 season ● 50hrs. Breakage ● Looseness ● Leakage Jointing Looseness Jointing Looseness ● ● ● Disassemble At designated & cleaning maker ſ Please refer to engine service manual about other non-discriced details. 83 1 season After first 50hrs 2) Cooler(system) SYSTEM NO Electrie equipments Control device Check list 1 Engine stop magnet 2 Engine control solenoid 3 Oil warning lamp (oil pressure) 4 Water temp lamp 5 Refrigerant high & low press lamp 6 An earth fixing bolt 7 Connection part of start cable 8 Jointing part of fuel pump 9 High press s/w 10 Low press s/w 11 Fusible plug Periodical check everyday every every every every Replace Working Standard Remarks or at any 100 200 1 2 period time hrs. hrs. season season Confirmation Operation Operate 5 season ● Confirmation Operation Confirmation Lightening Confirmation Lightening Confirmation Lightening Check Check ● Buzzer warning with operation ● ● ● Rust looseness Looseness ● ● ● ● ● Confirmation Operation Confirmation Operation Check Leakage ● 84 5 season OFF : 23.9Kg/cm2G 5 season ON : 18.9Kg/cm2G OFF : 0.28Kg/cm2G 5 season ON : 2.04Kg/cm2G SYSTEM NO Control device Check list Working 12 Refrigerant Check amount Replace 13 Change of desiccant in dryer 14 Refrigerant Check hose 15 Joint part of Check refrigerant pipe 16 Gas leakage Check Refrigerant cycle 17 Gas leakage 18 Expansion V/A 19 Oil amount Check Check Check Replace 20 Cylinder head bolt Jointing 21 Suction trainer Cleaning Periodical check everyday every every every every Replace Standard or at any 100 200 1 2 period time hrs. hrs. season season Sight glass ● no bubbles Replace at disjoint of refrigerant system Low press hose is 3 season for 3 seasons ● Leakage, wound, ageing Interval Remarks 1 season ● ● Sight check Every joint part (Low press side at stop, high press side just after operation stop) ● ● ● Operation Sight check Looseness Dirty 3 season ● 2 season ● Joint at first 50hrs ● 85 R-12, R-134a SYSTEM NO Compressor Check list 22 Suction & discharge V/A 23 Compressor 24 Compressor mounting 25 Evaporator fin Cooler 26 Fixing part of box evaporator fan 27 Operation of evaporator fan Connecting 28 Fan belt system Others 29 Unit fixing bolt 30 Viberation protector(rubber) 31 Cool air leakage 32 Duct insulator Working Check Periodical check everyday every every every every Replace Standard or at any 100 200 1 2 period time hrs. hrs. season season No cooling ● 1500hrs Jointing Looseness Cleaning Jointing Dirty Looseness Check Noise Check replace Wound aging, tension Looseness Jointing Check Check Check Remarks Disassemble & clean at every 4 seasons or 500hrs. ● ● Prohibit a steam seshing ● ● 1500hr 5mm is push down 2 seasons at 5Kg/force press ● ● ● ● ● Sight check Aging 86 2 seasons SYSTEM NO Check list Working 33 Air capacity 34 Cooling effect Check Check 35 Air filter Cleaning Compress or Periodical check everyday every every every every Replace Standard or at any 100 200 1 2 period time hrs. hrs. season season ● Difference between ● in/out door temp : 7~10C Dirty ● 87 Remarks Troubleshooting & Remedy 1. Check sheet for trouble & remedy CAUSES Refrigerant system Condenser Evaporator system system Expansion Refrigerant circulation Others valve system Others Compressor system 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Press Strange high of high-press system Strange low of high-press Strange high of low-press Strange low of low-press Comp No maintain the vaccum system No pumping down serious noise Badness of cooling air duct Lose belt for cooler High-pressure side is closed Low-pressure side is closed Half opened of discharge control V/A Closed receiver control V/A Closed dryer strainer Dusts & water are mixed So closed So opened Bad joint part of temp sensor box Multifuction Too little oil Too much oil Compress the liquid Damage of V/A plated Damaged or removed bearing Breakage of head packing Leakage of suction V/A Leakage of discharge V/A No rotating fan Dirty air filter Be frosted Closed all fin The temp of cooling wind is so low No rotating fan Closed all fin The temp of cooling wind is so high Water containded Air mixed No refrigerant Full refrigerant Over-charged refrigerant APPEARANCE ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Bubbles in sight glass very much Others Refrigerant circulation is stopped No flow of cooling air Poor cooling air flow ● ● ● ● ● ● ● ● ● ● ● ● ● ● 88 ● ● ● ● ● 2. Removal of troubleshooting Symptoms Causes & Check Remedy & Repair Refer to engine check point ڹNo engine start Refer to engine check point Badness of water temp. S/W S/W is on even though the water temp. is under Replace water temp. S/W 105°C When the valve sound is high due to refrigerant over charging and liquid hammering, it is ںHi-press. is defrosted on inlet pipe and comp. inlet side. high, Non-condensed gas is mixed. Low-press. is As air is not able to liquid or evaporized, press. high subject to strange. ڻHi-press. is low, Low-press. is low Drain the refrigerant to proper amout (8.5kg) Drain the gas completely, make it vaccum and then refill the gas. Dirty conderser fin Wash by water or air. (No steam washing) Outdoor temp. is high Sprinkle the water to condenser in the shade. Bad compression Check & repair the comp. dischange part. Breakage of comp. “0” ring Replace “0” ring Exp. V/A is so opened (Liquid hammering) Adjust a expansion V/A. (Counter-clockwise) Bad connection of temp. sensor box, broken Stick the temp. sensor body fast to inlet pipe insulator and stick the insulator closely. 89 Causes & Check Symptoms Remedy & Repair Poor refrigerant Repair thd gas leaking part. Bubbles on sight glass Fullfil the gas to proper amount. Suction pipe is not cool So closed exp. V/A ڼLow-press. is low, High-press. is high Open the V/A by adjust screw. Air filter is clogged. (Be frosted at frontal area of cooler) Outdoor air temp. is low. Check a Low-press. S/W, and replace if bad. No operation of Low-press S/W Weak air flow and noise due to the loosed belt. Gas leakage form temp. sensor body of expansion valve. unit Adjust belt tension or replace belt Replace a expansion valve. After disassemble dryer, replace the desicant Clogged dryer. ڽBad blower Clean the air filter and clean the strainer. No power supply. Check & repair fuse & related wiring diagram Injuried fan. Replace Serious vibration Replace Some gap between motor & fan. Jointing the fixing nut and clip again. 90 3. Check and remedy of poor cooling Symptoms Causes & Check Remedy & Repair Poor refrigerant Dischage the refrigerant properly. Be clogged in dryer. If clogged so often, chage it. Turn the adjust nut of exp. V/A one or twice ڹMany bubbles and see the low press. gauge. In case that through sight glass no chage in gauge due to traubled exp. V/A, Trouble of expansion valve change it. If change in, open to 50 of over heat degree. Air filter is clogged. ںBe frosted in evaporator Weak air EVA. fin is clogged. flow Much dusts on cooler fan Duct leakage Disassemble & clean pay attention to the change of balance weight. Check the setting temp. of temp. control S/W. ڻBe frosted from distributor of Clean the fin. Adjust the leaking part. Heat load in low inside of room. inlet of eva. to Cleaning. Same as symptom ڹ exp. V/A 91 Symptoms Causes & Check Remedy & Repair Over charged refrigerant Drain the refrigerant until 50 of over cooling ڼDew forms or frosts to the compressor. Check insulator and whether the temp. sensor box is closed to inlet pipe. Exp. V/A is so opened. Regulate the adjust nut of exp. V/A by 50 of over heat degree. ڽHi-press. is low, Lowpress. is high. Breakage of suction & discharge V/A of compressor. Check & repair of compressor valve. ھThe temp. of discharging gas Seal breakage of comp. Replace after disassemble. Be opened window or ventillation fan. Close the window and vent. fan. load inside of Poor connection of suction duct. Protect the heat from jointed duct. room Too many passengers. Keep the fixed seating capacity. is too high ڿHigh heat 92 COOLER (SUB ENGINE TYPE) (OPTION) 1. Operation 2. Control panel (1) Confirm the selector switch at “L” position. (2) Turn the key switch (counterclockwise) to “PREHEAT” position in order to heat the glow plugs with the engine for approximately 20 seconds. (3) Set the key switch to “ON” position, and make sure that the oil pressure lamp is lighted for a bulb check. (4) Then, turn the key switch (clockwise) to “START” position. The sub-engine will be driven by starter motor. Note : If not starting the sub-engine after. Running the starter motor for 20 seconds, try to restart the sub-engine by doing the above mentioned process “(1)” to “(4)” after one minutes. (5) Release your hand from the key switch after starting the sbu-engine. The sub-engine runs at low speed and the bus air conditioner is just operated. Note : The key switch should be remained with “ON” position while operating the bus air conditioner. 7 1. 2. 3. 4. 5. 93 1 2 3 4 5 8 Oil pressure lamp 6. Water temperature lamp 7. High/Low pressure lamp 8. Sediment lamp 9. Power lamp 10. 9 6 10 Fuse box Temp control switch Selector switch Glow pilot Key switch 3. Stopping (1) Normal stopping Turn the key switch “OFF” position, when you want to stop the engine. (2) Emergency stopping The GBŋ220SK air conditioning system provides the safety functions to stop automatically its operation under the following emergent conditions. a. When the refrigerant pressure of the bus air conditioner system may deviate abnormally from specified limit. b. When the coolant temperature of the engine may reach to the temperature of possible engine overheating. 94 4. Refrigerant system Use of refrigerant R-12 in this system cools the air in the bus with evaporation of the refrigerant. The evaporated refrigerant is fed into condenser after compressed at high pressure and high temperature by compressor for repeated use. Condenser fan converts the refrigerant into liquid at high pressure and high temperature by cooling. Use of expansion valve cause the liquid refrigerant to be decompressed, to enter the cooler again, and to evaporate to cool down the air in the bus. Liquid Cooling air, condenser receiver Evaporator Condenser Cooled air Evaporator Compressor Condenser Expansion valve Compressor Room air, returning Sight Dryer glass 95 Bypass Expansion Receiver tank solenoid valve High pressure line Low pressure line 5. Sub engine driving system 1. 2. 3. 4. 5. 6. 7. 4 2 7 3 6 1 Crank pulley Fan pulley Idler Coupling (Comp.) Bearing ass’y Drive shaft Blower 5 Condenser fan is driven by V-belt, and evaporator fan by driving shaft. 96 6. Cooling air circulating system 1. 2. 3. 4. 5. Cooler unit Underfloor duct Vertical duct Ceiling duct Grille Cooler blows off cooled air through the blow off grilles on the ceilling. 97 AUTOMATIC VENTILATOR (OPTION) Power switch ҮPressing the power button (1) for operator of Auto ventilator. Controller operator switch ҮPush the suction switch (2, 4) to open the shutter and intake the outdoor air to the compartment. ҮPush the exhaust switch (3, 5) to open the shutter and extract the air in the compartment to outdoor. (1EA) (OPTION) (2EA) (OPTION) AUTOVENTILATOR AUTOVENTILATOR POWER POWER 1 2 1 3 1. Power switch 2. Suction switch 3. Exhaust switch 98 1. 2. 3. 4. 5. 2 3 4 5 Power switch Suction switch (REAR) Exhaust switch (REAR) Suction switch (FRONT) Exhaust switch (FRONT) WATER COOLER (OPTION) Water cooler is operated by pressing the water pump on/off switch ()ڻ, and push the button ( )ںfor served the cold water through the nozzle ()ڹ. If water is not enough the cool. Operated the water cooler switch by pushing the button ( )ڼthen, the water is refrigerating. 1 2 3 99 4 1. Nozzle 2. Water on/off switch 3. Water pump on/off switch 4. Water cooler on/off switch PREHEATER (OPTION) Preheater operation 1. In the case that the ambient temperature is below 0°C, push the preheat switch ( )ںabout 20 seconds for preheating the fuel nozzle, then push the operate switch ()ڻ. (Preheat( )ںindicating lamp comes on when the preheating of fuel nozzle is finished) PREHEATER STOP 1 2 3 4 5 The time of indicating lamp coming on is different by ambient temperature. (The preheat temperature is about 30°C.) 2. By push the operate switch () ڻ, the indicating lamps “operate (”)ڻ and “pump ( ”) ڼcome on. Also “drive motor” and “Water pump motor” start operating. By the drive motor operating, the blowing fan and fuel pump work together. 3. Within 15Ŕ30 seconds after operating of “drive motor” and “water pump motor”, the solenoid valve is opened and fuel injection starts. At the same time electric discharge starts between the electrodes by high current. Then the injected fuel is ignited and combustion starts. (The indicating lamp “combustion ( ”)ڽcomes on). 1. Stop switch 2. Preheat switch 3. Operate switch 4. Pump switch 5. Combustion switch 100 4. After ignition, flame defector check the condition of combustion and stops the electric discharge between electrodes. 5. When the temperature of coolant reaches to 75°C, after normal combustion, the solenoid valve stops fuel injection by the thermo sensor and the “combustion (”) ڽ indicating lamp goes out. After stop of combustion, the drive motor operates 150Ŕ180 seconds more, and stops but the water pump motor continues operating. (The indicating lamps “operate (”)ڻ, “pump ( ”)ڼkeep lighting on). 6. At the condition of paragraph 5, when the coolant temperature drops below 65°C), the sequence from paragraph 2Ŕ4 repeats automatically and the heating of coolant is maintained. 7. To stop the operation of preheater, push the stop switch ()ڹ, then the combustion stops, but drive motor and water pump motor operate 150Ŕ 180 seconds more, then stop. 8. When push the pump switch ()ڼ, water pump motor operates only and the heating effect could by enhanced. (When operating heaters, heat loss in the heating line decreases and “pump ( ”)ڼindicating lamp comes on only). Check point before operation 1. Fuel level : Replenish if the fuel level is low. 2. Filter if it is clogged. 3. Fuel feeding pipe and/fittings. 4. Hot water circulation valve in the engine side is open. 5. Suction and exhaust pipe are clean. 6. Coolant level of the engine. 101 Maintenance 1. Periodically clean fuel filter element. 2. If required clean inside heat exchanger and remove dirts and carbon by brush and water. It will longer the service life. 3. For operating efficiently, remove dirts, carbon of flame detector with soft and dry cloth, and sure not no damage C.D.S surface. 4. Take off nozzle from nozzle holder, and clean or exhange. 5. When operating on rough and unpaved road, be sure to clean intake and exhaust tube periodically for efficient use of blow motor. Trouble shooting Indicating lights “on” even switches are operated Circulating pump doesnŮ t operate Maintenance Cause Problem 1. 2. 1. 2. 3. Fuel pump operates, but fuel 1. 2. is not injected 3. 4. Fuel injected, but doesnŮt 1. 2. ignite 3. Motor doesnŮt operate, even 1. the switches are turned “on” 2. 1. Change Cut of lamp 2. Change Fuse melted(F1 or F2) 1. Change Fuse melted(F1 or F2) 2. Heating or anti–freeze injection Water frozen Impeller restricted by contamination in 3. Clean water flow line 1. Refuel Lack of fuel 2. Clean or change Fuel filter blocked or frozen by water 3. Tightening Leakage of fuel piping 4. Change or overhaul repair Solenoid valve under quality 1. Change or correct the position Electrode under quality 2. Change Ignition unit under quality 3. Clean air intake and exhaust tube, adjust Lack or excess of combustion air damper. 1. Change Fuse melted(F1) 2. Inspection and repair Fault or uncorrect wiring of electricals 102 Problem Maintenance Cause Fuel cut, bad combustion 1. Not enough fuel supply by water and debris in fuel line 2. Leakage of fuel line 3. Lack of combustion air 4. Fuel pump under quality 5. Bad injection of burner nozzle Overheat of preheater body 1. Heat exchanger water valve shut off 2. Air in water line or body 3. Big resistance in water flow 4. Lack of water flow by old water pump 5. Bad adjustment of overheat sensor setting Abnormal shut off of com- 1. Overheat by blocking in water flow or lack of water bustion when operating 103 1Ŕ3. Pipe retightening, clean water, debris of intake, exhaust tube. 4. 5. 1. 2. 3. 4. 5. Change Change or clean nozzle Open the valve Bleed air Inspection and repair of line Change parts Change 1. Remove the cause of overheat, operate the push button of overheat sensor. Sectional view 2 1 3 4 22 5 21 6 10 11 12 8 7 20 19 13 18 17 14 16 9 15 104 23 1. 2. 3. 4. 5. 6. 7. 8. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Control unit Drive motor Ignition unit Coupling Combustion air fan Solenoid valve Electrode plug 9. Water pipes Ignition electrodes Fuel nozzle Control thermostat Preheat coil Overheat thermostat Heat exchanger Combustion chamber Air swirlier Exhaust pipe Flame detection photocell Fuel pump Fuel pipe Combustion air intake, socket Drain bolt TOILET (OPTION) Control panel Toilet operation control panel is fixed at driver left side on the switch board. Explanation of operation switch 1. Main power switch This switch is electric energy supplying to the toilet and toilet operation control panel. 2. Flushing switch (Commode) Do use this switch when clean up discharge waste from commode. • Openning cutoff valve : To push “OPEN” position. • Shutting cutoff valve : To push “CLOSE” position. 3. Feces tank warning lamp When full at the tank, the lamp turn on. 4. Feces tank cutoff valve switch Douse this switch when discharge waste from the toilet of feces tank. • Openning cutoff valve : Push button. • Shutting cutoff valve : Full button. CAUTION Do not use when lamp on (Feces tank warning lamp) and discharge waste from the tank at permitted location. TOILET OPEN ON CLOSE COMMODE OFF POWER OPEN CLOSE FULL FECES TANK FECES TANK 4 3 105 2 1 RADIO AND CASSETTE TAPE PLAYER ˝With echo type˟ (OPTION) 1 2 3 4 56 7 8 9 10 11 12 13 PROM EJ SW VOL OFF POWER Push LOC MAX TONE LO RADIO/MIC OFF RADIO ON MIC L 2 SEEK R TOME VOLUME MIC 3 4 BAND LOUD SPEED.ECHO FF 5 6 TUNE VOLUME MONITOR OFF ON LOW 14 1 BAL MI REW 15 18 HI MIN MAX 16 SLOW FAST 17 21 MIN MAX 20 19 106 1. Radio/cassette ON/OFF, and volume knob 2. Indicator displaying the operating situation of Radio cassette tape player. 3. Radio/cassette tone knob 4. LEFT/RIGHT speaker balance knob 5. Seek button 6. Eject button 7. Band button 8. Loud button 9. Tape slot 10. Fast rewind/progress button 11. Fast forward/progress button 12. Tune Button 13. Preset buttons 14. Power switch 15. Radio/Mic change switch 16. MIC volume knob 17. MIC jack 18. MIC tone knob 19. Monitor switch 20. Echo effect knob 21. Echo speed knob Radio operation ҮPress power switch 14 to power on the system. ҮPress Radio/MIC switch 15 to select the Radio/MIC operation. ҮTurn Radio/cassette ON/OFF and volume knob clockwise to operate and control the volume, then the indicator starts displaying and each lamps of knobs and buttons come on simultaneously. ҮPress band select button 7 to select AM/FM band. ҮPress seek button 5, then the frequency is automatically increases or decreases and stops when any receivable frequency is seeked. (֪: decrease, ֫ : increase) ҮKeep pressing the tune button 12, then the frequency increases or decreases, when the needed frequency is received, release the button ֪: decrease, ֫ : increase) ҮPress present button 13 to receive the memoried frequency. Also, to memory any frequencies on preset buttons, while the needed frequency is being received, keep pressing preset buttons more than 2 seconds. ҮTurn the tone knob 3 to control the strength of high sound. ҮTurn th balance knob 4 to balance the sounds of left and right speakers. ҮPress loud button 18 to enhance the low and high sound. ҮWhen the receiving condition is not good because of high impedance, magnetic interference of etc, push power switch 14, then receiving condition can be enhanced and “LOC” is displayed in indicator. Cassette operation ҮInsert tape into the slot 9, then the radio stops and tape play backe starts automatically. ҮKeep pressing fast rewind/progress or fast forward/progress button 10, 11 to rewind or forward the tape fastly. ҮPress fast rewind/progress and fast forward/progress buttons 10, 11 107 together, then the tape play back direction changes. ҮPress eject button 6, then the tape play back is stopped and the tape is ejected through the tape slot. ҮTone, balance and loudness controls are same as radio operation. MIC operation ҮInsert mail type jack of microphone into MIC jack 17. ҮPress RADIO/MIC switch 15 to select the Radio/MIC operation. ҮTurn mic volume knob 16 to control the volume of MIC sound. ҮTurn mic tone knob 18 to control the tone of MIC sound. Echo operation ҮTurn echo effect knob 20 to control the echo stength. ҮTurn echo speed knob 21 to control the echo speed. ҮThe volume and tone controls are same as MIC operation. RADIO AND CASSETTE TAPE PLAYER ˝Without echo type–A˟ (OPTION) 1 2 3 4 56 7 8 9 10 11 12 13 PROM EJ SW VOL OFF POWER Push LOC MAX TONE LO RADIO/MIC OFF RADIO ON MIC L R VOLUME 2 SEEK 3 4 BAND LOUD MIC FF 5 6 TUNE TONE MONITOR OFF ON MIN 14 1 BAL MI REW 15 MAX 16 LAW 17 HI 18 19 108 1. Radio/cassette ON/OFF, and volume knob 2. Indicator displaying the operating situation of Radio cassette tape player. 3. Radio/cassette tone knob 4. LEFT/RIGHT speaker balance knob 5. Seek button 6. Eject button 7. Band button 8. Loud button 9. Tape slot 10. Fast rewind/progress button 11. Fast forward/progress button 12. Tune Button 13. Preset buttons 14. Power switch 15. Radio/Mic change switch 16. MIC volume knob 17. MIC jack 18. MIC tone knob 19. Monitor switch Radio operation ҮPress power switch 14 to power on the system. ҮPress Radio/MIC switch 15 to select the Radio/MIC operation. ҮTurn Radio/cassette ON/OFF and volume knob clockwise to operate and control the volume, then the indicator starts displaying and each lamps of knobs and buttons come on simultaneously. ҮPress band select button 7 to select AM/FM band. ҮPress seek button 5, then the frequency is automatically increases or decreases and stops when any receivable frequency is seeked. (∇: decrease, ∆ : increase) ҮKeep pressing the tune button 12, then the frequency increases or decreases, when the needed frequency is received, release the button (∇: decrease, ∆ : increase) ҮPress present button 13 to receive the memoried frequency. Also, to memory any frequencies on preset buttons, while the needed frequency is being received, keep pressing preset buttons more than 2 seconds. ҮTurn the tone knob 3 to control the strength of high sound. ҮTurn th balance knob 4 to balance the sounds of left and right speakers. ҮPress loud button 18 to enhance the low and high sound. ҮWhen the receiving condition is not good because of high impedance, magnetic interference of etc, push power switch 14, then receiving condition can be enhanced and “LOC” is displayed in indicator. Cassette operation ҮInsert tape into the slot 9, then the radio stops and tape play backe starts automatically. ҮKeep pressing fast rewind/progress or fast forward/progress button 10, 11 to rewind or forward the tape fastly. ҮPress fast rewind/progress and fast forward/progress buttons 10, 11 109 together, then the tape play back direction changes. ҮPress eject button 6, then the tape play back is stopped and the tape is ejected through the tape slot. ҮTone, balance and loudness controls are same as radio operation. MIC operation ҮInsert mail type jack of microphone into MIC jack 17. ҮPress RADIO/MIC switch 15 to select the Radio/MIC operation. ҮTurn mic volume knob 16 to control the volume of MIC sound. ҮTurn mic tone knob 18 to control the tone of MIC sound. RADIO AND CASSETTE TAPE PLAYER ˝Without echo type–B˟ (OPTION) 1 3 ON VOL TONE 4 2 6 7 PROG EJ 8 9 TUNING AUTO REVERSE 1 4 2 5 3 6 BND FM AS PS PUSH BALANCE PUSH SEEK PL ON MIC MONI OFF MIX ROOF —10 POWER MIC/MIX FADER 11 12 13 0 MIN MAX TONE VOL 14 15 MIC 16 110 10 1. Power ON/OFF and balance (Tone/volumn) 2. LCD display 3. Eject button 4. Tape slot 5. Broadcasting remember button 6. Fast forward button 7. Fast rewind button 8. Seek knob 9. Band 10. AS/PS button 11. MIC Power switch 12. MIC/Radio fader 13. Monitor fader 14. MIC tone knob 15. MIC volume knob 16. MIC jack Radio operation Push the knob(1) control the balance fittingly and control the volume knob(1). Push the band button(9), select the FM/AM affirmed indicator. Select board casting turning the knob(8) manualy, or automatically boardcasting lony push the AS/PS button(10) more 2 seconds. ҮTUNING : Turning the knob(8) to enhance the low and high sound. ҮPUSH SEEK : Received the boardcasting automatically by pushing the button once or more. ҮAS/PS : Pushed the button(10) more 2 seconds longly, search the band automatically and remember the 1st ~ 6th boardcasting but, shortly push the button, searched the boardcasting in memory once more push the this button stop the searching. Each remembered the boardcasting in button(5), 18th boardcasting is remembered on AM1, FM1, FM2 each button. Controlled the high volume by turning the knob(1). Turn on the power, controlled volume and balance and the AMP volume like to RADIO operation insert tape in to the slot(4), then tape play starts automatically. Press the button(6, 7) to rewind or forward the tape fastly and inverted direction of playing the tape. Direction of play displayed the indicator(2) press the eject button(3), tape is ejected through tape slot. Don’t eject during tape playing Cassette tape player Turn on power(1) by turning to knob to right(In state of main power is on of AMP lifier) Controlled the volume, balance and 111 AMP volume replayed the sound by inserting the tape on tape slot(4) press the button(6, 7). Tape is Reward/Forward fastly press the button(7) tape direction is automatically reverse at time and indicator lamp(2) light comes on. Controlled the right/low tone by turing the knob(1) press the eject button(3) tape is ejected through tape slot. MIC operation ҮInsert mail type jack of microphone into MIC jack(16). ҮPress RADIO/MIC switch(12) to select the Radio/MIC operation. ҮTurn mic volume knob(15) to control the volume of MIC sound. ҮTurn mic tone knob(14) to control the tone of MIC sound. ҮPress the monitor fader button(13) in case of installation of monitor on side driver, controlled driver’s monitor or roof speaker. RADIO AND CASSETTE TAPE PLAYER ˝Stereo etr double deck w/program selector type˟ (OPTION) 1 11 10 (ETR RADIO & CASSETTE PLAYER) 9 (CASSETTE TAPE PLAYER) 12 1 2 3 4 5 6 10 13 12 14 17 15,16 18 14 1 9 19 3 (AMPLIFIER) 1 2 20 4 5 6 7 112 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Power ON/OFF and balance Selector(RADIO, TAPE, TV, MIC) Tone Bass controller Treble controller Echo interval controller MIC volume MIC jack Tone Eject Boardcasting remember button Tape slot LCD display Fast REWIND/FORWARD button Band AS/PS button Push seeking Monitor volume Tape direction Monitor/Loop Radio operation Turn on the power switch(1) by turning rightly the knob in the amplifier part. Select the button(2) and press any of RADIO, TV, TAPE, MIC, and control the tone fittingly, and push the knob(1) control the balance fittingly and control the volume knob(1). Push the band button(15), select the FM/AM affirmed indicator. Select board casting turning the knob(17) manualy, or automatically boardcasting lony push the AS/PS button(16) more 2 seconds. ҮTUNING : Turning the knob(17) to enhance the low and high sound. ҮPUSH SEEK : Received the boardcasting automatically by pushing the button once or more. ҮAS/PS : Pushed the button(16) more 2 seconds longly, search the band automatically and remember the 1st~6th boardcasting but, shortly push the button, searched the boardcasting in memory once more push the this button stop the searching. Each remembered the boardcasting in button(11), 18th boardcasting is remembered on AM1, FM1, FM2 each button. Controlled the high volume by turning the knob(9). Turn on the power, controlled volume and balance and the AMP volume like to RADIO operation insert tape in to the slot(12), then tape play starts automatically. Press the button(14) to rewind of forward the tape fastly and inverted direction of playing the tape. Direction of play displayed the indicator(13) press the eject button(10), tape is ejected. through tape slot. Don’t eject during tape playing 113 Cassette tape player Turn on power(1) by turning to knob to right(In state of main power is on of amplifier) Controlled the volume, balance and AMP. volume replayed the sound by inserting the tape on tape slot(12) press the button(14). Tape is Reward/ Forward fastly press the button(7) tape direction is automatically reverse at time and indicator lamp(19) light comes on. Controlled the right/low tone by turing the knob(9) press the eject button(10) tape is ejected through tape slot. Amplifier (AMP.) Power on by turning the knob(1) and select such of RADIO, TAPE, TV, MIC. Pressing the each button(2) controlled the tone turning the knob(3). Control the high/low volume by up/ down the lever(4,5) and select the speaker on driver by pressing the button(20) otherwise select of speaker in loop by poping it ҮPress the button(2), choose one of RADIO, TAPE, TV, MIC. ҮIn using MIC Press the echo knob(6) then echo controlled effectivity and must stick in the MIC jack(8) certainly controlled the tone by up/down the MIC lever(7). ҮPassenger could be listen to the any place boardcasting RADIO, TAPE, TV/VTR by controlling the tone fitting. So there are always connected with the individual program selector in the each seat through the this amplifier(Individual program selector of passanger estabilish on vehicle) It’s possible listen to CD player through amplifier on the estabished CD set. 114 PRECAUTION IN DRIVING Safety Driving and Parking 1. For safety driving, turn down volume, sufficiently.(To hear signal sound of horn.) 2. Over a period of time, direct sun light can cause the speaker or tape set to become malfunction, ventilate the air in the cab before operation. Cassette Handling Precaution 1. To clean the surface or body cassette with a cotton applicator. Don’t use benzene, thinner, solvent. 2. Be careful that the cassettes are not exposed to magnetic fields or not abrasive to other metal parts. 3. Keep speakers, tapes and radio not to be wet when cleaning the vehicle and be careful not to be exposed to moisture to protect electrical shock. 4. Cassettes are negative ground type and the power source is DC 24V. 5. Be careful not to repair by unskilled person because cassettes are precise parts. 115 Care and Maintenance 1. We recommend that the tape below T–90. A class of tape are T–60, T–90, T–120. 2. If a loop of tape has formed, it must be taken up by turning one of the spools with a suitable object such as a ballpen. 3. Keep tapes in their plastic cases when not in use. 4. Never leave cassette inserted in operating position with tape player inoperative. 5. Don’t apply oil to revolving parts of the tape player. 6. Store cassettes where they will not be exposed to high temperature, direct sunlight, magnetic fields, tape abrasion or dirt. 7. Clean the head of tape player carefully with a cotton applicator soaked in alcohol. If the tape player is used for more than one hour every day, the head should be cleaned once or twice a month. If it is not used frequently, you only need to clean the head every two or three months. Applicator Tape head Wooden pick 116 VTR SET (OPTION) 1 11 7 8 20 17 6 16 19 15 9 10 18 14 13 12 3 1 2 5 4 6 7 8 9 10 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Power ON/OFF STOP/EJECT button Record button Record speed button TV/VIDEO selector Repeat play Monitor–controller Fast rewind(Green) Play(Green) Fast forward(Green) Pause Record indicator(Red) Cassette indicator(Green) Repeat play indicator(Green) Normal speed indicator(Green) Remote–control receive Tape slot STOP button Slowly player Cover–control Notice : A letter of guarantee is separately bound, and brief enplanation refer to part manual. 117 VTR operation Pressing power switch(1) to power on the system. ҮPress cover(20) to opened the control panel cover and select TV/VTR operation by pressing TV/VIDEO switch. ҮInsert tape in the tape slot(19) with lightly over upside on the tape an arrow(®7) and comes on cassette indicator lamp(13). ҮPress the play button(9), scene appeared within one second. If tape wound of end, rewinding automatically. ҮPress the fast Forward(10)/Reward wind button(8), tape speed is fast wind or rewind without displaying the scene in state of stop. Otherwise with display the scene during playing. ҮPress the slowly play button(19) during tape playing. Scene displayed slowly and see to detail scene to move the striped during slowly playing with controller(+/-) button of scene by pressing to stripes moved up/down. ҮPress the pause button(11), scene once shift by pressing button a time over 5 minutes for the state of pause. Playing the tape protection. ˝Method of recording by TV˟ ҮConnect output of the field terminal and input of an image terminal on main system. ҮConnect output of the sound terminal on TV and input of the sound terminal on main system. ҮTurn on the power switch(1) of TV and select of scene channel. ҮPush the tape into tape slot(17) and push the record speed button(4) and select record speed (Normal or three multiple) ҮPushing record button(3), start record. ҮIf wanted stop, press the stop button(2). Don’t power off the TV until recording is end. 118 TV/VTR Controller (OPTION) (For NTSC type) 1 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 119 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. TV power switch TV/VTR selector Channel controllor Volumn controllor VTR power switch VTR tape eject button VTR playing stop button Fast rewind button VTR playing start button Fast forward button Guide broadcasting power switch Stop broadcasting button Pass by station button Rewind broadcasting button 1st campaign button 2nd campaign button EARPHONE (OPTION) 1. Volume controllor 2. Select the media (Tape 1, Tape 2, Radio, TV/VTR) 3. Earphone jack 1 2 3 120 Earphone controller ҮPower on of earphone controllor can used to same time the Radio or CASSETTE, TV/VTR's power on Automatically. ҮConnect the your earphone to jack (3), and put the earphone into your ear. ҮSelect the wanted Media by pushing the selector (2) that order Tape1, Tape 2, Radio, TV/VTR from top side to bottom and control the volumn suitability by moving the volumn controller (1). It is increased highly volumn from Downward to top ward. 121 DESTINATION KEYBOARD (L.E.D Sign Board) (OPTION) 1 2 3 4 5 6 7 8 9 Operating 1. Set a machine of vehicles. 2. Press the [RESET] button. (In order to being shown as follows[ooooo]) 3. After selecting the route with the operating panel, press the [#] button. (The route is appeared repeatedly without special operation on vehicle service) 4. If you want to change the route, press the [#] button after pressing [RESET] button on the operating panel and selecting the route. (The route is appeared repeatedly without special operation on vehicle service) 0 RESET 122 SPEEDOMETER (BM090, BS090, BS106) 80 60 100 120 40 000000 2 140 20 1 0 ҮSpeed Recording and indicating ranges of 160km/h are available. ҮDistance Calibrateable odometer, 7–digit creeping, without ZERO settings. 160 km/h 1. Speedometer needle 2. Odometer(distance) 123 TACHOGRAPH (BH115E, BH120E), (BM090/BS090/BS106 : OPT) Type A : Mechanical type–W/O RPM (SEPUNG), electric type–W/O RPM (SEPUNG, YAZAKI) 1 80 100 60 2 120 40 Km/h 3 140 20 4 160 0 7 5 0 0 0 0 0 0 0 7 6 124 1. 2. 3. 4. 5. 6. 7. Key hole Speed warning indicator light Speed graduations Speedometer needle Clock check window Odometer Screen paper mark Warning signal Lights up when the speed between 40% and 60% of the maximum speed is reached. – 100km/h (General) – 120km/h (GCC members) – 90km/h (SAUDI HAjj) Speed Recording and indicating ranges of 160km/h are available, depending on model type. 80 100 60 120 40 Km/h 140 20 160 0 7 0 0 0 0 0 0 0 Distance Calibrateable odometer without zero setting. 125 Time Time display with time correct rotation of the chart, controlled by a high-quality quartz clock. Illumination The tachograph scale has indirect illumination by means of 1.2W bulbs or 24V depending on vehicle voltage. Type B : electric type–W/RPM (VDO KIENZLE) 1 80 60 100 2 20 15 25 40 120 10 7 30 8 20 140 33 0 4 Km 0000000 3 6 160 Km/h ARCO 5 126 1. 2. 3. 4. 5. 6. 7. 8. Key hole Speed indicator light Minute hand Speedometer needle Odometer Clock graduations Hour hand RPM needle Warning signal Lights up when the speed between 40% and 60% of the maximum speed is reached. – 100km/h (General) – 120km/h (GCC members) – 90km/h (SAUDI HAjj) Speed Recording and indicating ranges of 160km/h are available, depending on model type. 80 60 100 20 15 25 40 120 10 30 20 140 33 0 Km 0000000 160 Km/h ARCO Engine speed Additional feature to certain tachograph models – measuring range depending on model type. 160km/h / 3300rpm Distance Calibrateable odometer without zero setting. 127 Time Time display with time correct rotation of the chart, controlled by a high-quality quartz clock. Illumination The tachograph scale has indirect illumination by means of 1.2W bulbs or 24V depending on vehicle voltage. Type C : electric type–W/O RPM (VDO KIENZLE) 1 2 3 6 4 5 128 1. 2. 3. 4. 5. 6. Key hole Speed graduations Speedometer needle Clock check window Odometer Speed warning lamp Speed Recording and indicating ranges of 160km/h are available, depending on model type. Time Time display with time correct rotation of the chart, controlled by a high-quality quartz clock. Illumination The tachograph scale has indirect illumination by means of 1.2W bulbs or 24V depending on vehicle voltage. Warning signal Lights up when the speed between 40% and 60% of the maximum speed is reached. – 100km/h (General) – 120km/h (GCC members) – 90km/h (SAUDI HAjj) Distance Calibrateable odometer without zero setting. 129 HOW TO HANDLE TACHOGRAPH RECORDS 1. Remove the recording chart paper set by depressing and turning the retaining ring counter-clockwise. If the paper is handled roughly at the time of removal, the cutting knife will be distorted and become useless for further operation. 4. Setting of recording chart paper set Position the recording chart paper set under the knife, then align the time on the paper with the red color mark near the knife. Install the retaining right by turning it clockwise while depressing it. 2. Filling out of recording chart paper Before setting the recording chart paper in position, fill out necessary items on the recording chart paper, exercise carefully not to scratch the paper. 3. Setting of clock Set the time by turning the time setting knob as necessary. 130 Further information by additional devices Basic information ڹStart of driving ںEnd of driving ڻRoad speed ڼDistance ڽTime scale ھENG Speed (OPTION) Tachograph for 7-day recordings A chart bundle is placed in to these special tachographs once a week. and for weekly, this is of particular advantage for vehicles which are being used regularly over extended periods. Automatically each day is recorded on a seperate chart ; these charts can be removed individually if required. 131 FLOOR CONTROLS Gearshift lever (Except auto transmission) Accelerator pedal Brake pedal When shifting the gear, fully depress the clutch pedal. Before shifting into reverse, be sure to stop the vehicle completely. If reverse warning buzzer is equipped, the buzzer sound when shifted into reverse position. The gearshift pattern is shown on the knob of shift lever. To avoid unnecessary increase in fuel consumption, the accelerator pedal should be operated smoothly and reasonably. Make sure that injection pump lever reaches maximum speed stopper when pressing accelerator pedal fully. If the lever won’t reach the stopper, use accelerator pedal cable adjusting nut to adjust the cable length. When stopping your vehicle, do not press the pedal forcibly but try to press it repeatedly. On a downhill, use this pedal together with exhaust brake as required. (5.O.D/D.D) 1 3 5 N R 2 4 (6.O.D) 1 3 5 N R 2 4 6 132 Clutch pedal (Except auto transmission) Fully depress the clutch pedal when changing gears. Do not rest your foot on the pedal when the clutch is not in use. Premature wear of the clutch will result. CAUTION Service life of the clutch could be reduced when keeping it in a partially engaged condition. 133 ENGINE STARTING IN ENGINE COMPARTMENT ҮEngine can be started by the engine start control panel installed at the upper side of engine in the engine compartment. ҮFirst switch “ON” the battery main switch in the driver’s compartment, then set the toggle type start switch to “ON” to operate the starter switch, to stop the engine, push the stop button. INTERRUPT INTERRUPT CLOSE CLOSE NOTICE When the engine starter switch in steering column is located in “OFF” position, by setting the toggle switch to “ON”, only the starter switch operates and the engine turns accordingly but the engine doesn’t combust because the engine fuel cut lever is pulled. To run the engine, the engine starter key should be located in “ON” position. BATTERY ENGINE STARTER INTERRUPT S/W INTERRUPT S/W STARTER SUB S/W 134 DRIVING INSPECTION BEFORE DRIVING Check items inside of engine room Belt tension Loose belt can adversely affect the alternator charging system and cause engine overheating or premature wear to the belt. On the other hand, a belt which is too tight can cause premature damage to the bearings of its peripheral devices. Frequently check and adjust belt tension. Engine oil level a. Pull out the oil level gauge(oil dipstick) to check if the oil tank has been filled up to the specified level. b. When the oil level is low, add the same brand oil according to “RECOMMENDED LUBRICANTS” and wait a while to check the level again. Also check for purity and viscosity of the oil before replenishing it. c. Always check the oil level with the vehicle parked on level ground and the engine stopped. 135 Power steering oil level a. Check the oil level and replenish as necessary. b. Check the pipe joints for fluid leakage. CAUTION We strongly urge you to use Daewoo recommended power steering fluid for replenishment. Engine coolant level Check the level by the mark on the reservoir installed at side of luggage door. After opening the cap, replenish the coolant within 40mm from the end of filling neck. Never open the cap when the engine is hot to avoid damages from the hot steam blowing out. Operate the service when the engine is cooled sufficiently and on the level ground. Start engine and keep idling for 10~30 minutes after replenishment, then recheck the level and replenish if necessary. 136 Air cleaner Check the element contamination indicator, when the signal of indicator is yellow, the condition of element is normal, but red signal means that the element is fouled, then clean or change the element after inspection. After service, push the botton at the top of indicator, then the signal returns to yellow. 137 Extract out the dust by pressing both ends of dust trap with hand installed at the bottom of air cleaner body. Never remove dust trap or substitute with different materials. Check items around driver’s compartment Clutch oil level Check the clutch oil reservoir for oil level and contamination. If the level of clutch oil in the reservoir is too low, replenish up to the MAX mark. Windshield washer fluid level Check fluid level in the reservoir and replenish as necessary. (For front folding door) (For front swing door) 138 Check items exterior and under chassis Battery(MF) (OPTION) a. This MF battery needs no periodic maintenance as long as it is used properly. b. Check the charge state through the indicator installed on the face of the battery. Test indicator Charge State C. If the external part of the battery is found foul, clean it with tepid water. Apply a thin coat of vaseline or grease to the battery terminals to prevent corrosion. Correction Green Normal Use Black Low charge level Recharge Transparent Low electrolyte level Replace Battery (PT/PTC) (OPTION) a. This PT/PTC battery for intense cold needs periodic maintenance every 5,000km on driving b. Must check the electiolyte in not enough properiety and slip of battery terminal c. If the external part of the battery is found foul, clean it with tepid water and apply a grease to the battery terminal to prevent corrosion. Properiety level 139 d. Level of battery electrolyte must kept up befween ‘upper level’ and ‘lower level’ When battery electrolyte in below the ‘lower’ position, Replenish the distieled water until state is ‘upper’ position (Only a position level on Battery is indicated ‘Lower’ position) e. If the level not indicated on battery, electrolyte must kept up within 10mm of a upper pole plate and when it below the properiety level, Replenish the distilled water 10mm (0.39in.) f. In water, the state of battery electrolyte must kept up replenish perfectly so to provnt dangerous of freezing NOTICE When exchange the battery, give special attention to connect cables correctly. If cables are misconnected, all the electric equipments will be damaged. Properiety level Pole plate 140 WARNING Unexpected and possible battery discharge may occur, if the following precautions are not taken. ҮWhile the engine is not running. Ү It may give rise to battery discharge, if leave the vehicle switched ‘ON’ of battery for long time or operate too many electric equipments at a same time. ҮFor long time parking, front entrance door must be closed by it’s key and for the long time suspension of operation, it would be better disconnect the battery cable. Ү While the engine is running. ҮWhile air conditioner is working, it is advisable to raise the engine RPM. Ɓ Specific gravity of electrolyte Zones Basic electrolyte temperature=20°C (68°F) Temperate Tropics Frigid Full-charge 1.26 or more 1.22 or more 1.28 or more Half-charge 1.25 – 1.14 1.21 – 1.10 1.27 – 1.16 Discharge 1.13 or less 1.09 or less 1.15 or less Condition Note : 1. When temperature of electrolyte deviates from 20°C(68°F) at hydrometer check, temperature correction should be made by the following formula. S20=St+0.0007Ŧ(t-20) ƒ1ƁS20 ŋŋŋŋŋŋŋŋŋŋ Corrected specific gravity (20°C) St ŋŋŋŋŋŋŋŋŋŋŋŋ Hydrometer reading at t°C t ŋŋŋŋŋŋŋŋŋŋŋŋŋŋŋ Temperature of electrolyte when checked 2. When lowering of electrolyte level is due to spillage, replenish with dilute sulfuric acid of the same specific gravity. 3. When replacing the battery, exercise extreme care so as not to make uncorrect connections, or damage to alternator silicon diodes will result. 141 Tire a. Check inflation pressure of the tires with a tire air gauge and add compressed air if necessary. b. Improper inflation pressure affects adversely tire service life, reduces motoring comfort, and, in the worst case, may cause tires to be overheated and consequently exploded. c. Check also the wheel pin nuts on the wheel for looseness. CAUTION Tighten to specified torque (60° 65kgҮm) as excessive tightening torque may cause damage to the wheel pin. Tire size 11.00R20–16PR (Tube, radial) 11R22.5–16PR (Tubeless) 12R22.5–16PR (Tubeless) 10.00–20–16PR (Tube) 10.00–20–14PR (Tube) 9.00–20–14PR (Tube) 9.00R–20–14PR (Tube, radial) Normal inflation pressure in kg/cm2 (PSI) Front : 8.4kg/cm2 (119PSI) Rear : 7.7kg/cm2 (109PSI) Front : 8.1kg/cm2 (115PSI) Rear : 7.4kg/cm2 (105PSI) Front : 7.0kg/cm2 (99PSI) Rear : 6.3kg/cm2 (89PSI) Front : 7.7kg/cm2 (109PSI) Rear : 7.0kg/cm2 (99PSI) Front : 8.0kg/cm2 (113PSI) Rear : 7.3kg/cm2 (103PSI) 142 Draining of air tank From time to time, pull forward the drain cock installed underneath the air tank to drain off condensates produced in it. ҮWhen opening the drain cock, pull it forward as shown. Chassis spring (Except air suspension) Check chassis springs for damage and tightening condition of 'U' blot. If any damaged or separatd spring leaf from normal position is found, stop the vehicle operation and have service. 143 STARTING AND STOPPING THE ENGINE Preparation for starting the engine 1. Apply the parking brake. 2. Manual transmission: Move the gearshift lever to Neutral position and depress the clutch pedal to the floor while cranking the engine. Automatic transmission: Press the push button to “P”(Park) or “N”(Neutral), although “P” is preferred. 3. Push on the battery main switch. 4. Turn the starter key to “ON”. Starting the engine 1. Turn the starter key to START position. Avoid excessive starter cranking(in excess of 10 seconds) to prevent any possible damage to starter motor or batteries. If the engine fails to start, wait about 30 seconds before attempting to start engine again. 144 2. Use the idle control knob to idle the engine at the normal speed (rpm) until the normal operating temperature is reached. 3. Do not overrun the engine under the normal operating temperature not obtained. This may shorten the engine life and increase fuel consumption. Starting weather 4. Take exceptional care to adjust idle speed when the engine temperature is low. 5. If you had attempted to start engine with no fuel in the fuel tank, you should bleed the fuel system. With no bleeding operation, you cannot start the engine even after refilling the fuel tank.(Refer to “Bleeding of fuel system” at page 168.) the engine in cold 1. With the switch in the “ON” position the indicator lamp will light up showing the engine is pre–heated automatically. After pre–heating is completed, the indicator lamp will go out. 2. After pre–heating is completed, press the clutch pedal and accelerator pedal to start the engine. 3. Use the idle control knob to idle the engine at a moderately fast speed. 3. Normal idle speed : 550~600 rpm. 4. Avoid unnecessary idling of the engine when coolant temperature reaches above 60°C. 5. After warming up the engine, bring the idle control knob back to its original position. CAUTION Abrupt start during warming–up operation may shorten the engine life. H C Pilot indicator lamps 145 Stopping the engine Turn the starter key switch off and turn and push the battery main switch off. Sudden stopping of the engine after severe operations like full load or ascending a slope causes overflow of coolant. In this case, idle the engine for 5 or 10 minutes before stopping it. Diesel engine is apt to keep running even after the battery main switch is off, while the engine is in running, do not push off the battery main switch, otherwise, alternator circuit may be failed. 146 BEFORE DRIVING OFF Steering wheel free play Air parking brake switch Check the amount of the steering wheel free play by gently turning the wheel in both directions. The free play should be within the range of 30 Ŕ50mm at the periphery of the wheel when checked with the front wheels positioned straight ahead. In air parking brake switch applied vehicle, be sure to release parking brake before driving, also check the park warning lamp goes out before driving. (Cab control valve type) CAUTION Check steering wheel for free play with the engine running. (Gradual control type) P PARKING Parking Pilot indicator lamps 147 Windshield wipers Check the operation of windshield wipers and washer fluid ejection, keep the front windshield glass clean all the time. Clutch pedal (Except auto TRANS.) heck the clutch pedal free play, if the free play deviates from 40~50mm, adjustment is necessary. Door Check the operation of door(open, close), be sure that the doors are closed before driving. Instrument panel, indicators and gages Check the instrument panel, indicators and gages operate in normal conditions when the related switches are actuated. Brake pedal Check the brake pedal free play, if the free play deviates from about 15mm, adjust the screw fitted at the bottom end of pedal. Mirror Adjust side mirrors to have wider visions, also check room mirror before driving. 32 24 16 0 H 6 80 2 0 100 60 120 40 12 3 F 1 9 C 15 AIR kg/cm2 0 x1000rpm 3 Km/h 140 20 160 0 E 7 E SAFETY SPEED 4 0 8 ABS ASR 0 0 0 0 0 0 0 148 WHEN DRIVING OFF ҮCheck if the needle of air pressure gauge indicates 5.3kg/cm2 or above. If the gauge indicates below this range of air pressure, keep the engine running at fast idle until the gauge needle points to the rated pressure. 6 ҮCheck again that any abnormal warning lamps or unnecessary lights are come on and recheck the “park” indicating lamp gone out surely. H 32 24 16 0 9 H 12 3 6 AIR kg/cm2 80 2 0 100 60 120 40 12 3 15 AIR kg/cm2 0 x1000rpm Km/h 140 3 20 160 0 E 7 AO FUL H AIR L AI R 15 1 9 C F 0 ҮLet the engine idle until it is fully warmed up and coolant temperature increases beyond 60°c (between “C” and the first “Ү”) before starting off, and start the vehicle with the shift lever in 1st position. E ABS 4 0 CHECK ASR 0 8 149 0 0 0 0 0 0 C WHILE TRAVELING ҮAvoid overrunning the engine during break-in period of new vehicle. ҮIf unusual sound or smell becomes noticeable while driving, stop the engine and check to locate the cause of trouble. ҮIf the air pressure falls below 5.3kg/ cm2, stop the engine and check to locate the cause of trouble. 2 6 0 x1000rpm 9 3 12 3 0 150 15 AIR kg/cm2 AO FUL H AIR L AI R 1 ҮIf indicator lamps or instruments give an indication of abnormal condition while driving, stop the vehicle and check to locate the cause of trouble. Ɓ If the cause of trouble was not located, check at your nearest Daewoo dealer. ҮThe engine coolant temperature gauge needle should indicate below the red point. If the gauge indicates above red point, stop the vehicle and keep the engine running at idle, and check the engine coolant level. Ɓ Severe burns to the skin can result from removing the pressure cap from a hot radiator. Wait until the engine temperature goes down and use rags to remove the cap for check-up and refilling operations. ҮAvoid engine racing, unnecessary sudden acceleration, or sudden stops. ҮDo not drive with your foot resting on the clutch pedal as it produces a partially disengaged condition, causing premature wear of clutch facing. H C 151 ҮStop your vehicl completely when attempting to shift gear lever into reverse. ҮWhen ascending a slope, shift to lower gear to relieve the engine from overload. ҮWhen descending a slope, shift to lower gear to gain retardation effect of the engine. It is advisable to use the exhaust brake and engine brake in combination when descending a slope. Frequent use of foot brakes while descending a long slope will cause brake drum overheating and consequential malfunction of the brake. 1 3 5 1 3 5 R 2 4 R 2 4 brake pedal exhaust brake ҮSpecial care should be taken when descending a slope, particularly when shifting down into lower gear, as the engine is liable to overrun. Excess engine rpm may result in trouble with each part of the engine, especially possible breakage of valve spring and push rod. 1 0 152 2 x1000rpm 3 Parking AFTER DRIVING Engine stop If there is an indication of engine overheating, never stop the engine immediately, keep running at idle for a while, after the temperature drops to the normal range, stop the engine. Also, push the battery main off before parking. Diesel engine is apt to keep running even after the battery switch off, while the engine continues running, never push the battery switch off, after check that engine stops running, push the battery switch off. Otherwise, the alternator circuit may be failed. H C 153 Place the gearshift lever in neutral position and pushed the parking brake knob securely. Service and repair after operation After operating the vehicle, always clean it thoroughly and check the following points : 1. Re–check the troubles found during the previous operation and take necessary corrective actions. For such troubles difficult to correct, contact your nearest Daewoo dealer. 2. Check for leakage and oil levels. 3. Add antifreeze to engine coolant to prevent freezing of the engine in cold weather. 154 DRIVING ON HIGHWAY The followings should be performed for safe and dependable vehicle operation. Before driving More special care should be taken to drive on highway than urban road. Make sufficient inspection according to “DAILY CHECK BEFORE DRIVING”. Rib pattern Lug pattern Tire Driving on highway Heat generation depends on vehicle speeds and load weights. For the vehicle which travels frequently on highway, rib pattern tires are preferable. Frequently watch speedometer readings in instrument panel. Driving on highway is more dangerous than the urban road, you should be more alert and have a stable preparations. CAUTION It is dangerous to drive your vehicle with tires whose treads have been worn out excessively, because the vehicle may lose traction. Limit of use : The depth of the tread grooves should be more than 3.2mm. Rib/Lug pattern 155 1. Speed perception On highway, driver’s speed perception is liable to become dull because its road surface is even and commands a wider prospect than urban road. Frequently watch speedometer readings in instrument panel. NOTE You must fully understand vehicle performance in dirving on highway. 1. Acceleration As running resistance increases greatly while driving on highway, the vehicle should be accelerated with allowance for its engine power. 2. Gradeability Maintain suitable engine rpm taking into account the relation of grade and maximum speed at each gearshift position. 3. Fuel consumption 2. Braking distance Braking efficiency is the most important thing when driving on highway. When recognizing the hazard ahead and preparing to apply the brake, your reaction time will take about one second. This means that your vehicle, if assumed to have run at speed of 80km/h, will travel additional 20 to 30m the moment you applied the brake. Therefore, you should maintain a safe following distance. 3. Distance between vehicles Normally, the following distance between your vehicle and the vehicle ahead depends on vehicle speeds. A safe following distance of about 80m should be maintained in 80km/h traffic. 4. Passing To pass, increase your vehicle’s speed by at least 10km/h more than the speed of the vehicle ahead. Before preparing to pass, 156 be sure to check the traffic behind you and then pull out into the left lane(in case of RHD, the right lane) promptly with turn signal “ON”. 5. Turning on a curve Generally curves of highway are given grade on their either side. With a light movement of the steering wheel the vehicle turns very easily. Therefore, be careful of tire slippage when applying the brake on a curve, especially in rainy weather or on an icy road. 6. Others ҮTo enhance braking efficiency, use the exhaust and engine brakes in combination. ҮReckless steering may cause danger not only to your own vehicle but also oncoming vehicles. ҮIn the event that a tire was punctured during driving, hold the steering wheel firmly and employ exhaust brake to slow down. Abrupt braking can cause damage to tires. 157 OPERATION AND CARE IN COLD WEATHER Protection of the engine against freezing Overcooled engine not only accelerates wear of its vital parts but also reduces fuel economy. Before driving off, warm up the engine beyond 60°C. Use of antifreeze To prevent freezing and corrosion of the engine when operating the vehicle in extremely cold places, be sure to add a specified amount of antifreeze to coolant. AREA RUSSIA(Frigid) Mixing Freezing ratio(%) point(°C) 55(%) –48(°C) 30(%) –12(°C) SOUTHEAST ASIA MIDDLE EAST AFRICA SOUTH AMERICA TAIWAN 50(%) –38(°C) OTHERS 30(%)~40(%) –16(°C)~–25(°C) 158 Precautions when using antifreeze 1. Wash off the inside of the cooling system including the radiator before using anti–freeze. 2. Replace any damaged rubber hoses. If there is just a hair crack on these hoses, antifreeze is liable to leak. 3. Antifreeze should be handled with extreme care as it can cause damage to coated surfaces of peripheral components. Engine oil Driving on ice or snow Engine oil tends to harden when the ambient temperature falls in cold weather. Use the specified engine oil having proper viscosity. It is advisable that chains or snow tires be used when traveling on an icy or snowcovered road. If you apply the brake hard on a slippy road, your vehicle is apt to lose its traction, resulting in losing the control of steering wheel. Batteries Battery condition tends to get worse with drop in ambient temperature. In extremely cold weather, maintain the battery in a full charge state. CAUTION Carefully fit chains on your tires so that the chain band may not scratch the other parts or interrupt their movements. 159 1. Be sure to use the chain of the same dimensions as the target tire. 2. Fit the chains on the rear tires and tighten them so that motions of the other parts may not be interrupted. IN CASE OF EMERGENCY Emergency stopping ҮIn case of vehicle trouble or emergency stopping, pull up the vehicle to the roadside as early as possible. Emergency starting ҮSet the parking brake and turn on the emergency warning lamp to prevent possible safety hazard. 160 ҮAvoid starting the engine while your vehicle is being toward as it may collide with the towing vehicle. Battery jumping In the case that the battery has been “dead”, refer to “BATTERY CARE” in this manual and make an emergency start as illustrated. 4 3 2 1 161 INSPECTION AND MAINTENANCE DAILY CHECK BEFORE DRIVING In order to maintain safety and dependable operation, following checks should be performed daily before driving : System Check item Check point Steering ҮSteering wheel and system 1. Vibrations or shimmy of steering wheel 2. Hard steering or sticky 3. Damage or looseness of component parts Brake ҮBrake pedal 1. Air mixed in brake circuit 2. Free play, stroke and force pedal ҮOil level ҮFunction ҮFunction ҮMoisture in tank and fluctuation of air pressure ҮBrake and clutch oil ҮExhaust brake ҮParking brake ҮAir tank and pressure Running ҮWheels and tires 1. Damage or looseness of bolts and nuts. 2. Damage or severe wear of wheels and tires, and tire inflation pressure. Suspension ҮChassis spring ҮDamage of spring, and tightening state of U–bolts and nuts. Engine ҮEngine 1. 2. 3. 4. 5. 6. 7. Power train ҮClutch ҮTransmission ҮPropeller shaft and rear axle Engine starting Abnormal sound and vibration Leakage of fuel, lubricants and coolants Cleanliness and damage of air cleaner element Exhaust gas Damage of fan belt Engine oil level ҮClutch pedal free play, stroke and function ҮFunction and oil leakage ҮVibration of propeller shaft, oil leakage in rear axle 162 PERIODIC INSPECTION AND MAINTENANCE Engine oil NOTE Oil level check Check oil level and replenish if required. Pull out the oil level gauge rod(dipstick) at the bottom side of the engine and wipe it clean, insert the gauge fully into guide tube and remove it carefully, then check the level of oil between the high and low level marks. Also check the oil sampled with the gauge rod for deterioration. After checking oil level, insert the level gauge into guide tube properly and tighten the oil filler cap firmly. MAX Engine oil level should be checked with the vehicle parked on a level ground and with the engine stationary. If the engine has been operated, allow 20 minutes for oil to settle down before checking the oil level. Changing engine oil Change engine oil at specified intervals or when found to be fouled considerably. To drain, remove the drain plug from oil pan, when changing oil warm up the engine sufficiently to remove moisture contained in oil. Thoroughly remove metal chips stuck to drain plug. Type oil 1. D1146/Ti, DE12/T/Ti ENGINE. • Frigid an area : API CF–4 or SAE 15W30 • Except Frigid an area : API CF–4 or SAE 15W40 2. DE08TiS, DE12TiS ENGINE. • API CH–4(SAE 15W40) or ACEA E2/E3 ſ Refer to “Lubrication list” at page 214. MIN Drain plug 163 Model D1146 D1146Ti DE12 DE12T DE12Ti Change intervals • Initial : 1,000km ENG.TOT 15.5ֹ • Inter–city or long Oil pan distance travel bus 13ֹ every : 15,000km ENG.TOT 20ֹ • City bus Oil pan every : 10,000km 17ֹ • Initial : 1,000km DE08TiS • Long distance : every 30,000km • Short distance DE12TiS Capacity : every 20,000km ENG.TOT 19ֹ Oil pan 15.5ֹ ENG.TOT 22ֹ Oil pan 19ֹ Engine oil filter Engine oil filter element should be changed together with engine oil at the same time.(DE engine is mounted with a cartridge type) 1. To drain oil, remove the drain plug installed on the lower part of oil filter body. Remove metal chips stuck to drain plug, Check gasket and replace as necessary. 2. Loosen the center bolt and remove the filter body together with the element. 3. Clean the inside of filter body and replace with new filter element. ſClean the element with diesel fuel and visually check gaskets installed on the upper and lower sides of element for damage and hardening, and replace as necessary. CAUTION It is strongly advisable to use genuine Daewoo oil filter element. 164 Engine coolant Coolant level Check the level of coolant by the reservoir installed at upper side of radiator. Use clean rain water or city water for the cooling system and avoid the use of hard water such as drawn out of a well. Never open the pressure cap while the engine is not or hot steam may blow out causing serious injuries. NOTE In order to avoid the accumulate of scale, corrosion for the entire cooling system and damage from cavitation, coolant mixed with 30% of antifreeze solution should be used all year around. Some regions where antifreeze solution is not easy to purchase, cavitation protection solution “Inhibitor” could be used, nevertheless antifreeze solution is the best way to have maximum service life. Change of coolants Drain the coolant by opening the drain cock of radiator. After completely draining off, close the drain cock and fill with new coolant. Run the engine for about 10 minutes and then recheck the coolant level. In the case that antifreeze is added to coolant, it is advisable to clean the inside of the radiator and engine water jacket 2 times a year(in spring and autumn). ҮRefer to ŗLubrication listŘat page 214. Model BM090 BS090 BH090 BS106 BH115E Engine Coolant volume(l) 44 (49) DE12 DE12T DE12Ti/TiS BV120/LA BH120E ∗( 165 ) : Preheater included 58 58 62 63 64 73 (62) (62) (66) (68) (68) (77) Fuel filter (D1146 ENG.) The fuel filter system is of the two stage type with a felt element as a primary filter and a paper element as a secondary filter. Fuel is transported from the outside of the filter to its inside. At this time, impurities contained in the fuel are caught outside the filter. Replacement Replace secondary element at the same time when the engine oil is changed. Clean primary filter at every 5,000km and replace with new one after the lapse of 3 cleaning intervals. Restricted fuel filter will hinder in smooth transportation of fuel, resulting in decrease in engine power. Cleaning (Primary element) Soak the felt element in diesel fuel and remove heavy dust particles by using a brush with soft bristles. If the element is found defective, replace it with a new one. Air bleeding screw Center bolt OUT Disassembly and cleaning 1. Unloosen center bolt, and remove filter body. 2. Take out felt element and paper element. 3. Clean filter body and feft element. 4. Change paper element. 5. When reassembling reverse the above sequence. CAUTION It is strongly advisable to use genuine Daewoo fuel filter element. IN Secondary filter(paper element) Primary filter (felt element) Filter body 166 NOTE Sometimes (at 10,000km) drain the filter pump of water until clear fuel is visible. Fuel filter (Except D1146 ENGINE) The fuel filter system is single catridge type with a paper element as a primary filter. Fuel is transported from the outside of the filter to its inside. At this time, impurities contained in the fuel are caught outside the filter. NOTE Sometimes (at water. 10.000km) CAUTION drain It is strongly advisable to use genuine Daewoo fuel filter catridge. Center Bolt OUT Replace the catridge At every 20,000km. Restricted fuel filter will hinder in smooth transportation of fuel, resulting in decrease in engine power. Filter (paper cafridge) IN Method of replacing 1. Unloosen drain plug 2. Remove old catridge. 3. Clean head sealing surface 4. Fill the fuel in new catridge. 5. Lubricate the rubber packing, surface 6. Spin catridge until packing contacts head. 7. Then tighten additional 3/4 to 1 turn. Filter body Drain plug 167 Bleeding of fuel system Bleeding of fuel system must be performed when fuel filter has been removed or the engine has been stopped due to lack of fuel. (D1146 ENG) 1. Turn the cap of fuel feed pump primer anti–clockwise. 2. Keep pumping the primer until meet strong resistance to pumping. By holding the primer pushed down, loosen the bleeder screw of primary fuel filter, bleed out the fuel with air bubbles, then retighten the bleeder screw quickly. (Except D1146 ENGINE) 168 3. Repeat (2) until pure fuel without air bubbles comes out. 4. Bleed secondary fuel and injection pump by doing the sequence (2), (3). 5. Bleed the air in injection pump, by the bleeder screw illustrated in the following figure. 6. After bleeding, push down the cap of primer and turn clockwise to be locked tightly. ңFuel system diagram D1146 ENGINE 1. 2. 3. 4. 5. 2 1 5 1 ы Ⅱь Ⅰ 4 3 7 6 13 9. 10. 11. 12. 13. 8 12 10 6. 7. 8. 11 9 169 Fuel filter ыь Air bleeder screw Injection nozzle Fuel return pipe Fuel feed pipe (filter ؠpump) Overflow valve Injection pipe Fuel feed pipe (pump ؠfilter) Fuel tank Fuel return pipe Fuel suction pipe Fuel feed pump Injection pump ңFuel system diagram (D1146Eng) D1146Ti, DE08TiS, DE12/T/Ti/TiS ENGINE 2 5 1 4 14 3 7 6. 7. 8. 6 13 8 12 10 1. 2. 3. 4. 5. 11 9 170 9. 10. 11. 12. 13. 14. Fuel filter Center bolt Injection nozzle Fuel return pipe Fuel feed pipe (filter ؠpump) Overflow valve Injection pipe Fuel feed pipe (pump ؠfilter) Fuel tank Fuel return pipe Fuel suction pipe Fuel feed pump Injection pump Drain plug Valve clearance adjustment Adjustment intervals Engine model Change intervals At end of first D1146 1,000km, D1146Ti Second : 2,500km Every 5,000km DE08TiS DE12 At end of first DE12T 1,000km and DE12Ti Every 20,000km Adjustment of valve clearance After removing the cylinder head covers, rotate the crank-shaft until the intake and exhaust valves of No. 6 cylinder are overlapped (water pump side). Loosen the lock nut of one rocker arm adjusting screw of the cylinder indicated in the following chart (֧). Insert a thickness gage of specified thickness into the clearance between the valve stem end and rocker arm, then adjust the clearance with the adjusting screw. DE12TiS When the correct adjustment is obtained, fully tighten the lock nut. As same manner, adjust the clearances of the other valves(֧). Turn the crank-shaft 360°(the intake and exhaust valves of No. 1 cylinder are over lapped) and adjust the clearances of the valves (Ƅ). Valve clearance adjustment chart (DE ENG.) 1 2 3 ֧ ֧ Ƅ Ƅ Engine model D1146 D1146Ti DE08TiS DE12 DE12T DE12Ti DE12TiS Change intervals Inake 0.30mm Exhaust 0.3mm 171 5 6 in ex in ex in ex in ex in ex in ex ֧ ֧ ֧ Rated valve clearance (cold) 4 ֧ Ƅ Ƅ Ƅ Ƅ Injection nozzle Turbo–charger (Except D1146 ENGINE) Check injection pressure and spray condition of injection nozzle at every 10,000km. To check injection nozzle, specific nozzle tester is required. Contact your nearest Daewoo dealer or repair workshop. Turbo–charger increases the density of intake air by the exhaust gas with high temperature and pressure. It make engine to reach to the state of complete combustion. Turbo–charger is very precise item and rotates by high rpm, periodical and frequent check should be held. Engine model Injection pressure D1146 214kg/cm22 214kg/cm D1146Ti DE08TiS 220kg/cm2 220kg/cm2 DE12/T/Ti/TiS Abnormal symptoms If any abnormal symptoms as followings are checked, have promt inspection and proper repair. Normal Abnormal Abnormal 172 ҮLack of engine power ҮBlack or blue smoke in exhaust gas ҮExcessive engine oil consumption ҮAnormal noise in turbo–charger ҮRepetition of high and low noise ҮOil leak of gasket of oil supply tube ҮOil leak of oil seals in turbo–charger ҮHigh and weeping sound ҮLeakage of intake and exhaust line Points of handling care Item Fuel tank Description Oil contamination Be sure to use genuine oil and filter, keep periodical oil change. Delay & lack of oil supplying Prevent abrupt accelerating when idling and starting. Every 8,000km drain water and remove sediments by removing the drain plug on the lower face of the fuel tank. Clean the inside of the tank every 24,000km. Foreign substances in intake air Check air cleaner and keep to be clean. Sudden engine stop after full Never stop the engine soon after full load load operation operation, maintain engine idle about 3Ŕ5 minutes before engine stop. Drain plug 173 Belt installation Check that the fan belt gives proper deflection when the intermediate part of the belt is depressed with finger. Also check the belt for cracks and damage. CAUTION : When belt replacement becomes necessary belts should be replaced by set. φ86 4 5 φ140 ALT 3 C/C F/D 1 CRS φ210 1. Idle pulley 2. Cooler compressor pulley (OPTION : Roof–on cooler) 3. Crank shaft pulley 4. Alternator pulley 5. Fan pulley 2 DE12/T/Ti/TiS TENSION : The suitable tension is less than 10mm when pressed with the thumb. 174 A/C 1 W/P 4 6 ALT 5 C/C 2 FAN 7 1 CRS 8 1. Idle pulley 2. Idle pulley (OPTION : Roof–on cooler) 3. Crank shaft pulley 4. Air compressor pulley 5. Water pump pulley 6. Alternator pulley 7. Fan pulley 8. Cooler compressor pulley (OPTION : Roof–on cooler) 3 D1146/Ti,DE08TiS ENGINE TENSION : The suitable tension is less than 10mm when pressed with the thumb. 175 Air cleaner Regular service of the air cleaner is one of the most important maintenance items. Neglecting of this service not only affects fuel comsumption but also the performance and service life of the engine. Inspection and service interval The filter element should be cleaned at every 4,000km or when the red color signal appears on the indicator. Under severe conditions and operations on the dusty or sandy roads, it should be cleaned more frequently than the recommended intervals. Replacement of element Replace the element annually or after 3 times cleaning, also replace when any damages are found. Gaskets and sealings should be replaced together with the element. Service of air cleaner 1. Disassembly Loosen the clamping screws and remove the dust pan, then the element is exposed. Loosen the wing nut fixing the element and pull out the element. 176 2. Cleaning of element Depending on the condition of contamination, clean the element by one of the following procedure. 2–1. Element is contaminated(dry). Blow dust off by compressed air(below 7kg/cm2), direction of compressed air should be from inside to outside of element. 2–2. Element is contaminated with carbon and oil. First prepare element cleaner dissolved tepid water, submerge the element for 20Ŕ30minutes and shake well in the water, then rinse the element with clean running water (below 2.8kg/cm2). After washing, dry the element in the shade or place of good ventilation. Drying of element takes 1 week, use spare element while drying. Never apply compressed air or heat for quick drying 3. Inspection of element After cleaning, inspect inside of element for tear, breakage and distortion, use lighting lamp for certain inspection. 4. Cleaning of air cleaner housing Discharge dust by opening the dust trap installed below the housing. Clean inside of housing, cover and gasket fitting flange, if any damages are found replace the element. Also the element should be replaced if the wall thickness is reduced to be broken easily. 5. Reassembly Reverse the disassembly sequence to reassemble, be sure to fit the element and gaskets, tighten the screws and nuts securely. Finally push the button of the air cleaner element indicator to restore the signal to yellow from red. NOTE Do not neglect to extract out the accumulated dust from the dust trap installed at the bottom of air cleaner housing. 177 Transmission oil Oil level check Check oil level at end of first 1,000km and thereafter at every 4,000km driving by the filler/level plug. If the oil level is below the level plug, replenish oil through the plug. drain plug filler plug Changing oil Replace transmission oil at end of first 5,000km and every 20,000km driving. Oil replacement should be done while the used transmission oil is hot. First drain the transmission oil by removing the drain plug at the bottem of the transmission housing. After draining of used oil is completed, retighten the drain plug, then fill new oil through the filler/lever plug. (Auto transmission) OIL CAPACITY (Manual transmission) Specification of oil ҮSpecification : API GL–4 or SAE 80W90 ҮRefer to “Lubrication list” at page 214. Transmission K1005C K1005P K1205C K1205P K805A K805P T–9 K806P K1006R K1206R T–10S5B Oil capacity 9.7ֹ 9.8ֹ 10.0ֹ 11.2ֹ 13.0ֹ 178 TRansmission MT643 B300R B400R D851.2 D863 D854.2 D864 HP 500 HP 590 HP 600 Oil capacity 25ֹ 28ֹ 30ֹ Rear axle oil Oil level check Check oil level at end of first 1,000km and thereafter at every 4,000km driving by the filler/level plug. If the oil level is below the level plug, replenish oil through the plug. Changing oil Replace rear axle oil at end of first 5,000km and every 20,000km driving. Oil replacement should be done while the rear axle oil is hot. First drain the rear axle oil by removing the drain plug at the bottom of the rear axle housing. After draining of used oil is completed, retighten the drain plug, then fill new oil through the filler/level plug. OIL CAPACITY Ү11.5 – 12.5ֹ Filler/level plug Drain plug 179 Specification of oil ҮSpecification : API GL–5 or SAE 80W90 ҮRefer to “Lubrication” at page 214 Power steering oil and filter Oil level check Check level by the mark on the oil reservoir at end of first 1,000km and thereafter at every 4,000km driving. Before checking power steering oil level, align the front wheels straight ahead. Changing oil Replace power steering oil at end of first 1,000km and every 24,000km driving by the following sequence. 1. With the engine stopped, raise front wheels until the tires have gap to the ground. Use hydraulic jack or proper equipment to raise front wheels, be careful of the vehicle not to fall or slip while servicing. 2. Loosen the two tube fittings coupled at the upper side of steering unit and turn the steering wheel slowly in both directions. 3. After discharging of used fluid, retighten the tube fittings securely. Then fill the reservoir with new oil to the specified level. 4. Retighten the cap of reservoir and wait 2Ŕ3 minutes, then lower the front wheels to the ground. 5. Start engine and keep idling for 2 Ŕ 3 minutes. Recheck the fluid level while the engine is idling and replenish as necessary. 6. After changing oil or if unusual sound is heard when the steering wheel is turned, perform air bleeding, refer following paragraph, “air bleeding of power steering unit”. OIL CAPACITY VEHICLE OIL CAPACITY BM090 BS090 6ֹ BH090 BS106 BH115E BH120E 180 7ֹ Air bleeding of power steering unit 1. With the engine stopped, raise front wheels until the tires have gap to the ground. Use hydraulic jack or proper equipment to raise front wheels, be careful of the vehicle not to fall or slip while servicing. 2. Remove the cap from the bleeder screw on the upper side of the steering unit. Prepare vinyl tube, connect one end of the vinyl tube to the bleeder screw and the other end to a transparent container. 3. After starting engine, turn the steering wheel right-hand direction to lock, then loosen the bleeder screw to discharge the fluid mixed with air bubbles. Soon after the fluid with air bubbles are forced out, retighten the bleeder screw. 4. Turn the steering wheel to lefthand direction and bleed air as the sequence(C). 5. Repeat air bleeding until the air is removed sufficiently. While bleeding, check fluid level and replenish if necessary. After bleeding, reinstall the cap on the bleeder screw and lower the wheels on the ground. Check the level again and leakage of fluid. 6. Test the vehicle on the road that steering is smooth and abnormal noise is not heard. Specification of oil ҮSpecification : AFT(DEXRON II) ҮRefer to “Lubrication list” at page 214. 181 Changing oil filter element Oil filter element(paper type) should be changed at the same time when the power steering oil is changed, except at the first 1,000km driving. Change the oil filter element at every 24,000km thereafter. To change, drain the oil in the reservoir and turn the cap of reservoir counter-clockwise. Pull out the oil filter element and change to new one. Cleaning fluid strainer Prior to changing steering oil or filter element, oil strainer installed in the filler of oil tank shall be cleaned. Remove dust or other foreign matters from the oil strainer before reinstalling it. 182 Brake system Adjustment of brake pedal free play Adjust the brake pedal free play by turning the adjust screw installed at the lower side of pedal. Free play is the stroke measured at the upper tip of pedal from released position to the contact point between the brake pedal and valve stem. NOTE Brake valve check Check the brake pedal move smoothly and return to the normal position without any sticking. Also check the brake valve that air discharging sound is heard when the brake pedal is released, this check should be performed when the pressure of air tank is about 7.0kg/cm2. Free play of brake pedal remains unchanged under normal condition, however, check the free play and adjust to the specified stroke, because insufficient free play could make brake dragging. pedal free play 6 9 adjust screw 0 15 AIR kg/cm2 183 AO FUL H AIR L AI R 12 3 Adjustment of brake lining clearance Check and adjust the clearance between the brake lining and drum at the first 500km operation and every month, or when the brake pilot lamp turns on. Adjustment procedure Full Air brake with auto slackadjuster(OPTION) Full air brake with mechanical slack–adjuster 1. With scale, measure the travel length of brake chamber push–rod from the released position to the fully depressed position, if the measured value exceeds the standard(front:33~35mm, rear:35~38mm.), adjust the clearance. 2. Jack up and check the wheels rotate smoothly without any resistance. 3. Remove the rubber plug fitted in the brake lining inspection hole. 4. By rotating the wheel with hand, turn the worm–shaft of the slack–adjuster to the direction in which the brake shoe expands until the brake drum drags by contacting with the brake lining, then turn the worm–shaft to reverse direction until the clearance becomes to the standard value. The standard clearance is 0.3mm, check the clearance by inserting the thickness gage between the brake lining and drum. 5. After ajustment, check again that the brake chamber push–rod travel length is front:33~35mm, rear:35~38mm. NOTE If the protruded point of the indicator comes into contact with the stopper by turning the worm–shaft for adjustment, it indicated that the lining has been worn to the limit and should be replaced. 184 For the vehicle on whick auto slackadjuster applied, ajustment of brake lining clearance is not necessary in normal, but periodical chekc and inspection should be done for the longer service life and safety. Inspection of brake lining 1. Remove the rubber plug fitted in the brake lining inspection hole. 2. Check the condition and amount of brake lining wear by the eyes. If the brake lining weared out to the stepped line, also any cracks, severely burnt sports or abnormal conditions are checked, replaced the brake lining to the new one. extrusion thickness shoe rivet 185 Clutch system (Except auto transmission) Adjustment of clutch pedal free play The clutch pedal free play decreases as wear develops in the clutch driven plate. The clutch pedal free play should be adjusted in the following manner when the amount of play becomes less than 25 mm using of the vehicle without making an adjustment result in clutch slip. 1. Free play : 25Ŕ30 mm 2. Height : 180Ŕ205 mm (BS106) 1 NOTE Inspection of free play To check the amount of clutch pedal free play, release air whithin the main air tank solely to interupt booster operation. Depress the clutch pedal carefully until a strong resistance is felt, then check the free stroke before the point of resistance is reached. Adjustment procedure 1. Disconnect the return spring on the mainpack, then remove the bellows at the minipack side. 2. Loosen the minipack push–rod lock nut and slowly turn the push–rod in direction of extension until a strong resistance is felt, then back off the push–rod 1Ŕ2/3 turns. When turning the push–road, avoid excess force, or adjust within the point at which resistance increases can not be felt. 3. Tighten the lock nut and install the return spring and bellows. The clutch pedal free play is adjusted from 25 to 30mm when the above adjustment procedure is followed. NOTE When the adjustment operation is completed, check that clutch pedal is provided with standard free play. 2 (BM090, BS090, BH115E, BH120E) 2 1 lock nut 186 push rod Clutch Oil Check to see if the level of oil in the reservoir is normal. When the level is too low, check the circuit for possible leakage and replenish with specified fluid. The clutch hydraulic circuit should be drained and refilled when oil is found to be contaminated. Oil change intervals : every 60,000km or 1 year. NOTE Any oil other than clutch oil should not be used for replenishment. Bleeding of clutch hydraulic circuits If air enters the clutch circuit, it cause clutch dragging. Therefore, bleeding operating should be performed if the clutch fluid reservoir has been emptied due to failure or if the hydraulic circuit has been disassembled. Bleeding operation calls for cooperative action of 2 men. 1. Set the parking brake. Bleeding of clutch hydraulic circuit should be perfomed with the air tank emptied. 2. Check the level of clutch fluid in the reservoir and replenish as necessary. 187 3. Remove the rubber cap from the bleeder screw on the clutch minipack and clean the screw. Connect a vinyl tube to the bleeder screw and insert the other end of the vinyl tube into a transparent container. 4. Pump the clutch pedal repeatedly and hold it depressed. 5. Loosen the bleeder screw to release clutch fluid with air bubbles into the container and tighten the bleeder screw immediately. 6. Release the clutch pedal carefully. Repeat the above operation until air bubbles disappear from the clutch fluid being pumped out into the container. During the bleeding operation, keep the clutch fluid reservoir filled to the specified level. Reinstall the rubber cap. PRESSURE REGULATOR (OPT) Application The pressure regulator is fitted in air brake systems to regulate the operating pressure and to clean the air delivered by the compressor. Some valve types are fitted with an intergral safety valve, in order to protect the compressed air systems against excessive pressures. The unloader valve/relief valve combination is required with air compressors having delivery ó700ֹ/min of free air, to provide for a relief of the unloader unit by means of division of the air flow. Charging position X 7 6 8 5 9 10 4 23 21 3 2 21 4 11 12 1 1 13 1 3 Legend : 1%Outlet 2%Cut–out piston 3%Outlet 4%Bore 5%Valve plunger 6%Control piston 7%Compression spring 188 14 15 3 8%Inlet 9%passage Ports : 10%Check valve 1%Energy inlet 11%Safety valve 21%Energy outlet 12%Screen (to reservoir) 13%Breather valve 23%Energy outlet 14%Compression spring (to relief valve) 15%Relief valve AE 13.. 3%Exhaust Method of operation Charging position Control piston(6) and cut–out piston(2) are held in their lower or upper end positions, respectively, by compression springs(7) and (14), so that outlet(1) and inlet(8) are closed while outlet(3) is open. One half of the air supplied by the compressor flows through port 1 and screen(12)–where coarse impurities such as oil carbon are retained–and on to check valve(10) ; it opens the latter valve and flows via port 21 into the pipeline to the supply air reservoirs ; at the same time, air is fed through passage(9) to act upon control piston(6). The other half of the air supplied also travels to the supply air reservoirs, though by way of the relief valve AE13..(15). Cut–out As the pressure in the supply air reservoirs rises, the same pressure builds up below control piston(6), via passage(9), causing this piston to move upwards. The spring–loaded valve plunger(5) follows this movement until outlet(3) is closed. When the pre–determined cut–out pressure has been reached, control piston(6) lifts off valve plunger(5), and inlet(8) opens ; compressed air passes down through the drilling in valve plunger(5) to act upon cut–out piston(2), and it is also communicated, via port 23, to the control device of relief valve(15). Cut–out piston(2) is moved downwards, thereby opening outlet(1) so that air continuously supplied by the compressor exhausts to atmosphere, through exhaust port 3, taking with it any oil carbon particles that may have accumulated. As a result of the control pulse fed in from port 23, the air supplied via relief valve(15) is also discharged to atmosphere. 189 Cut–in When, as a result of air being withdrawn, the pressure in the supply air reservoirs and thus the pressure in the chamber below control piston(6) drops to cut–in pressure, the spring loaded control piston(6) closes inlet(8) while outlet(3) opens ; the pressure prevailing above cut–out piston(2) and, via port 23, in the control pipeline to relief valve (15) is reduced through port(4). Compression spring(14) causes cut–out piston(2) to move upwards until outlet(1) is closed. The air supplied by the compressor is allowed to travel again through ports 21 of both the unloader valve and the relief valve(15) to the supply air reservoirs. Safety valve In the event of the unloader valve not cutting out, due to a malfunction, safety valve(11) will limit the supply air reservoir pressure by allowing the air supplied to exhaust to atmosphere when the opening pressure has been reached. Installation Unloader valve and relief valve are mounted in an uprght position, with exhaust port3 pointing downwards. The total volume of air supplied by the compressor must be allocated to two 18Ŧ1.5 pipelines, one line being connected to port 1 of the unloader valve and the other one to port 1 of the relief valve(see installation diagram). The pipelines should have a length of approx. 2m each(if necessary, to be coiled) and must be laid in such a manner that the temperature at ports 1 of both the unloader valve and the relief valve does not exceed 150°C. For the control line from port 23 of the unloader valve to port 4 of the relief valve use either a pressure/temperature–resistant hose with an inside diameter of 6mm, with fitting to suit dimensions as shown in drawing I, or a 6Ŧ1 pipe with connection to suit dimensional drawing II. In both cases a maximum length of 1 m should not be exceeded. The pressure relief noise generated in the cut–out phase is reduced by means of hoses attached to the exhaust connections 3 of both the unloader valve and the relief valve ; this can also serve to drain off any oil that may have been separated. Installation diagram 2 1 3 3 0 21 1 2 1 0 23 21 22 24 23 4 2 21 1 X 3 5 4 1 = Air compressor 2 = Unloader valve 3 = Four–circuit protection valve 4 = Relief valve AE 13.. 5= Tyre inflation valve ZB 31.. 190 Maintenance After a prolonged period of operation, the cut–out pressure may vary from the specified value. Turning the spring housing allows the precompression of spring(7) and thus the cut–out pressure to be adjusted. This operation should only be carried out by trained specialists. Technical features Type Dimen– Graphic Max. Min. Safety no. sional symbol cut–out cut–in valve drawing (see overleaf) pressure pressure opening pressure – – – bar bar bar DR 3218 I 1 7.35ť0.2 6.2 N/A DR 3226 I 1 10.00ť0.2 9.0 N/A DR 3227 I 1 8.10ť0.2 7.1 N/A DR 3242 II 2 9.50ť0.2 8.6 10.5 DR 3243 I 1 8.50ť0.2 7.3 N/A Accessory valve required : Relief valve AE 13.. according to catalogue sheet AE 1000–K 14 EN Temperature range : –40°C to ˌ150°C Weight : 0.9kg 191 Dimensional drawing I 108 Legend : ʨ = Not bored 63 70 60 30 35 Ports : 1 = Energy inlet 21 = Energy outlet (to reservior) 23 = Energy outlet (to relief valve) 3 = Exhaust 4 bar 23 21 3 18 min13 6 221–2 M22X1.5 M22X1.5 9 1 94 170 24 32 φ6 A/F min13 φ15 φ16.5 φ60 49 192 A Dimensional drawing II 108 Legend : ʨ = Not bored ʩ = Safety valve 63 70 60 30 35 4 bar M12X1.5 min13 6 21 3 min13 6 221–2 M22 X 1.5 M22X1.5 94 170 24 A/F 9 32 1 A 18 23 φ15 φ16.5 B φ60 37 193 Ports : 1 = Energy inlet 21 = Energy outlet (to reservior) 23 = Energy outlet (to relief valve) 3 = Exhaust ANTIFREEZE PUMP (OPTION) Application The antifreeze pump is used in brake systems in order to inject an anti– freeze based on glycol or alcohol during winter operation. This makes it unnecessary to unscrew the pipe connection. If the vehicle is operated without trailer, the pump must be actuated one or several times before sitting off, the number of strokes being dependent on the temperature and humidity of the air(see instruction plate on reservoir). In case the vehicle is operated with trailer with a consequently higher air consumption, the plunger rod must accordingly be depressed more often. 194 Mode of operation When the pump is inoperative, cylinder(6) communicates via the feed holes(5) with reservoir(2) containing the antifreeze. When plunger rod(1) is depressed, piston(4) moves downwards, closeing feed holes(5) and causing approx. 1cm3 of antifreeze to be injected into the air stream, via check valve(7). As long as plunger rod(1) is in the operating position, the further flow of fluid of from reservoir(2) is interrupted. When plunger rod(1) and piston(4) are released, they are moved back to their original positions, due to the action of return spring(3). Compression spring(8) closes check valve(7), and cylinder(6) is again filled with antifreeze through feed holes(5). At any further stroke, prior to setting off and with the compressor in operation, appr. 1 cm3 of antifreeze per stroke is fed into the air stream. Following any pump operation, several brake applications must be made. 1 2 3 4 5 6 7 8 195 1%Plunger rod 2%Reservoir 3%Return sprng 4%Pump 5%Feed hole 6%Cylinder 7%Check valve 8%Compression spring Installation Maintenance After winter operation the antifreeze pump must be cleaned and sprayed with acid–free oil. A B ≈166 80–2 φ 76 50±0.2 25 A = Rest position B = Stroke 16mm Ports M22Ŧ1.5–15deep φ 8.5 22±0.5 The antifreeze pump is installed in the delivery line between the unloader valve and the air reservoir, either close to the unlaoder valve or upstream of the air reservoir. The pump must be installed in a vertical position and sufficient clearance be allowed for operation and refilling. Only manual operation is permissible. The pipe line to the air reservoir should slightly slope downwards to ensure that the antifreeze flows immediately and at all events into the brake system. The antifreeze pump is fastened by means of two M8 bolts. φ 84 50±1 68 Technical features Type no. Antifreeze on an alcohol or glycol LA 1100 basis or pure alcohol. No methyl alcohol– LA 1101 toxic! Max. operating pressure : 10 bar(gauge pressuree) Temperature range : –40°C to ˌ80°C Reservoir capacity : 250 cm3 Reservoir : transparent 196 Paint Weight coating [ kg ] no 1.3 yes 1.3 AIR DRYER (OPTION) AIR DRYER Function of air dryer Since moisture contined in the atmosphere is compressed and warmed by the air compressor, the amount of moisture is in proportion to that of compressed air. This hot and humid air is cooled down in reserve tanks or pipings to form condensation. This condensation washes away lubricants from the moving parts of various devices or equipment, resulting in unsatisfactory actions of these devices or equipment. In addition, impurities contained in the condensation accelerates rusting action to shorten the lives of related devices or equipment. In cold weather, this condensation can be frozen and immobilize various devices and equipment. Therefore, it is essential to remove moisture from compressed air in order to extend the service lives of devices, to enhance reliablilty, and to prevent possible damage or breaks. Specifications Item Description Max. air pressure 9.8kg/cm Normal air pressure 5Ŕ9.8kg/cm2 2 Dew point 17°C Remaking time 50 sec Air compressor displacement 600L/min or less Heater capacity 24V/50W Temperature range ˎ30°CŔˌ70°C Thermostat temp. 4ť4°C Operation fluid Air Delivery 581L/min 197 Remarks Operation of air dryer Season Descriptions Before driving, always check the air Spring, pressure(8.2kg/cm2) in air tank. Summer, Autumn (warm or hot weather) When parking, check the amount of drained water and foreign substances in water. As thermostat is installed in air dryer, when the sensing temperature is above 4ť4°C, the electric Winter current to heater is cut off automatically. (cold weather) Before or after the operation, always follow the above instructions 1 and 2 to take care for the air tank. ңIn the case that temperature drop in air tank exceeds 16°C, a small amount of water may be drained. 198 Inspection of air dryer 1. At end of every 15,000km or 2months operation. Check for the drain amount and outflow of oil when draining condensation and dirts from air tank.(When oil is detected, check compressor.) 2. At end of every 45,000km or 6 monthes operation Disassemble air dryer and check if dessicant has been moistened by dirts. If the dessicant is found to be wet for about more than 1/5 of all, change it(In wet condition, the capacity drops). 3. At end of every 90,000km or 1 year operation. Disassemble air dryer and change dessicant, oil filter, cloth filter and whole rubber parts. Check air tubing and wiring connections. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Outlet Control piston Inlet Bore Bore Sliencer Outlet Blow–off valve Preliminary dewatering chamber Non–return valve Nozzle Ring filter Desiccant Regeneration air tank Bypass valve Adjusting screw Adjusting screw Vent bore Connections 1. Energy inlet 21. Energy outlet (to energy accumulator) 22. Energy outlet (to regeneration air tank) 3. Vent 199 Trouble shooting Daily inspection and periodic inspections will prevent the greater portion of air dryer troubles. In the event of troubles or complaints as listed, follow the correction procedures to correct the difficulty. Water comes Correction Cause Complaints Check and drain the main tank until the desiccant is dried Desiccant has been saturated. up. out from main tank. Cut–off pressure of governor is so low that Increase pressure for governor to 6kg/cm2 or higher. purge valve wonŮt open. Failure to change desiccant or oil filter within Change desiccant kit at end of every 12 months or scheduled period. 90,000km operation. As the purge time is less than the rated 1. If cut–off pressure of governor and closing pressure time (50 seconds), desiccant is not recovered sufficiently) of relief valve are low, purge time also is shortened, resulting in failure in recovery of the desiccant. 2. In the case of purge by relief valve, if cut–off pressure of governor and closing pressure of relief valve are low, purge time also is shortened, resulting in failure in recovery of the desiccant. Drain valve Freezing of air dryer due to heater trouble 1. Change faulty heater. 2. When the trouble is located in thermostat, change fails to drain. it. Change desiccant kit at end of every 12 months or Failure to regularly change desiccant 90,000km operation. No operation of purge valve due to the entry Disassemble and check the valve, and replace the valve, if necessary. of foreign substances into drain valve. 200 Inside of air Correction Cause Complaints Misattached dryer body or exposed to cold Correct the position of dryer body or install a wind screen. dryer has been weather at ˎ30°C while traveling frozen Heater has been short–circuited and no heat- 1. Use a tester to check the heater for short–circuit. 2. If heater has been short out, change it with a new ing one. Thermostat has been short, resulting in failure Leave thermostat at temperature of 0°C or below and use a tester to check it. Add heat to thermostat by hand of heater. to check for OFF state and change it if requied. The dryers temperature drops significantly due Remove ice or snow so carefully as not to cause damage to dryer body and electrical wiring connections for to ice or snow stuck to its body heater. No operation of heater due to disconnection of Check heater and thermostat for connection. the electrical wiring for heater or thermostat Air leaks from Poor contact of valve seat due to the entry of Disassemble and check the valve, and change the valve drain valve foreign substances into valve Excessively When the check valve of main tank fails to per- Disassemble and check the check valve located between low pressure form backward flow checking operation with main tank and purge tank, and change it if required. of main tank compressor in unload cycle, air can be leaked kit if required. When damage is found at the wet moving part of valve body, change the valve. through the main tank drain. 201 WATER TRAP (OPTION) Installation of water trap Water trap is always located between pressure regulater and main air tank. When the air dryer is installed, and if the pressure regulator is not used, at that case the water trap should be installed before air dryer. NOTICE Every driver should pull the drain cock to drain off the condensates in the water trap before and after you drive, especially below the temperature of freezing point. The function of water trap As shown at the above drawing, the water trap condensate the moisture and lubricant mixed at the compressed air from the air compressor. The vapor molecules are condensated while they pass out the 12–φ5 holes in the closed plate of water trap, and they can be drained through the drain cock at the bottom of water trap. The effect of condensation could be increased when the antifreeze pump is used before the water trap. Because, the alcohol molecule draw the water molecules and make water drops easily. 202 With pressure regulator (BM090, BS090) (BH090/BS106/BH115E/BH120E : OPT) With anti freeze pump (OPT) 1. 2. 3. 4. 1. Pressure Regulator 2. Hose 3. Water trap 1 With air dryer (BH090, BS106, BH115E, BH120E) (BM090/BS090 : OPTION) Pressure Regulator Anti freeze pump Hose Water trap 1. Air dryer 2. Hose 3. Regenerating tank 1 1 3 2 3 4 3 2 2 203 TIRES Tire rotation Tire wear depends on tire position, road conditions, or a habit of applying brakes. To avoid unbalanced wear of your tires and to prolong their lives, rotate tires periodically(every 5,000km normally). Tire pressure inspection Check tire pressure with air gauge and add compressed air if required. Improper inflation will adversely affect the life of tire, especially underinflation is a major contributor to overheating of tire, resulting in explosion. Tire air pressure Tire size 11.00R20–16PR (Tube, radial) 11R22.5–16PR (Tubeless) 12R22.5–16PR (Tubeless) 10.00–20–16PR (Tube) 10.00–20–14PR (Tube) 9.00–20–14PR (Tube) 9.00R–20–14PR (Tube, radial) Normal inflation pressure in kg/cm2 (PSI) Proper inflation Front : 8.4kg/cm2 (119PSI) Rear : 7.7kg/cm2 (109PSI) Front : 8.1kg/cm2 (115PSI) Rear : 7.4kg/cm2 (105PSI) Front : 7.0kg/cm2 (99PSI) Rear : 6.3kg/cm2 (89PSI) Front : 7.7kg/cm2 (109PSI) Rear : 7.0kg/cm2 (99PSI) Front : 8.0kg/cm2 (113PSI) Rear : 7.3kg/cm2 (103PSI) Underinflation Overinflation 204 Following these instructions withcare when rotating tires. 1. The wheel nuts on the right side wheels have right–hand threads and the wheel nuts on the left side wheels have left–hand threads. 2. Clean the wheel pins and nuts and apply oil to the threads. CAUTION After rotating tires, be sure to retighten the wheel nuts to specified torque at end of 50Ŕ 10km running.(Torque : 60Ŕ65kgŋm) 3. Place hydraulic jack shown. 3 L 1 5 R 8 7 6 2 L R 4 Wheel nuts tightening sequence Nut loosening directions 205 ELECTRICAL Aiming of headlamps The headlamps should be tested and properly aimed if found to be out of adjustment. The headlamps can be properly aimed using either the headlamp aimers or a headlamp tester. The headlamp testers include focus type and screen type. To aim headlamps, proceed as follows : Park the vehicle on a level floor and check tire inflation pressure and adjust as necessary. Remove the headlamp covers and wipe clean the lenses. BM090/BS090/BS106 Fog lamp Head lamp Turn signal/position BH090/BH115E/BH120E Fog lamp Head lamp Position Parking/ Turn signal Cornering 206 ҮAdjustment by the use of an aiming instrument One aiming instrument consists of two units : one is for right side and the other is for left side. Objective lens White line Eyepiece Level vial Dial Vacuum rubber cup Handle Type 2 Center of vehicle Type 2 1) Place the right and left units of the aiming instrument on the headlamps (type 1–inside, type 2–outside) in such a manner that the right and left units of the aiming instrument lightly contact the aiming bosses on the headlamp lenses. Support the aiming instrument so that the objective lens of the aiming instrument is faced to the center of the vehicle, and push the handle strongly to tightly contact the vacumn rubber cup of the instrument on the lens. 2) Look into the eyepiece of the aiming instrument, and adjust the left and right adjust screws so that the standard line seen in the instrument is correctly overlapped on the white line of the other side aiming unit. (This adjustment is the same for both type 1 and type 2.) 3) Next, set the dial of the level vial to the desired angle (0 deg for type 1 and 0.5 deg for type 2), and adjust the updown adjust screws of the headlamps so that air bubble in the level vial is in center of the level vial. 4) Thus, driving beam of the type 1 headlamp is tilted downward 0.5 deg, and passing beam of the type 2 is tilted downward 2 deg and turned 0.5 deg to the left side. 207 BULB DISTINCTION Head lamp High Low Fog Front combination lamp BM090/BS090 75/70W(H4) 70W(H3) – – 25W – – 10/25W Position – – 4W Parking (OPTION) – – – – – – – – – Fog Turning 10/25W – 25W Rear Stop/position 25/10W combination Stop/parking 25W lamp (OPT) 55W(H3) Parking/turning Turning Destination BH090/BH115E/BH120E Cornering Parking/turning lamp BS106 – Stop – – – Parking (OPTION) – – – Position – – – 12W 10W – – – – Front Middle Rear 12W Side turn signal (OPTION) 12W Back up lamp 21W 208 – 25W DISTINCTION BM090/BS090 BS106 NO. Plate lamp 12W ક 5W Engine Room lamp 12W ક ક Speed indicator lamp (OPTION) 12W ક ક Driver lamp 12W ક ક W/O lamp rack (OPT) 20W ક ક W/lamp rack (OPT) W/O lamp rack (OPT) 20W – 20W 12W ક ક W/lamp rack (OPT) 12W – 12W Mood lamp rack-5 COLOR 20W – 20W Mood lamp rack-GALAXY 20W – 20W Front marker lamp 12W ક ક Rear marker lamp 12W ક ક Step lamp (OPTION) 12W ક ક Search lamp (OPTION) 12W ક ક Luggage lamp (OPTION) 12W ક ક Reading lamp (OPTION) 12W ક ક Pilot lamp 1.2W ક ક 12W ક ક 70W(H3) – – Room lamp(FL) Room lamp(GLOW) Rack lamp(OPT) Side lamp (OPTION) Warning lamp (OPTION) 209 BH090/BH115E/BH120E Relay and fuse layout Ɓ The quantities or locations of fuses could be different from the figure, because the fuses or relay could be added or omitted, and locations could be changed by the requirement of custmers. WIPER MOTOR RH SPARE FUSE ROOM LAMP 2 ROOM LAMP 3 WIPER MOTOR LH 5A 10A HEAD LAMP(LOW) 10A HEAD LAMP(HIGH) 15A 20A FUSE 1 12 23 2 13 24 3 14 25 4 15 26 5 16 27 6 17 28 7 18 29 8 19 30 9 20 31 10 21 32 11 22 33 TV. VTR BLINKER UNIT TAIL LAMP ROOM LAMP 4 STOP LAMP FRONT DOOR MID DOOR LAMP READING LAMP FOG LAMP FRONT DOOR LAMP 210 No. Amp. Description No. Amp. Description No. Amp. Description Hot/cold cabinet (OPT), 1 15A Head lamp relay(HIGH) 12 5A Room lamp 1 23 10A 2 10A Head lamp relay(LOW) 13 10A Room lamp 2 24 15A 3 15A Tail lamp relay 14 10A Room lamp 3 (OPTION) 25 10A 15 10A Room lamp 4 (OPTION) 26 15A Starter key 27 10A Interrupt switch ENG. stop motor Preheater (OPTION) TV/VTR (OPT) Chandelier (OPTION), Auto grease power (OPT) 4 10A 5 10A Stop lamp, Horn, Radio 16 5A 6 20A A.B.S (OPTION) 17 15A Defroster 28 15A Fog, Tail, Meter lamp 7 15A Warning lamp (OPTION) 18 10A Reading lamp 29 15A Battery main power(1) 8 5A 19 5A 30 10A 9 5A 20 5A 31 5A Auto door, door lock key 10 15A 21 20A Heater (OPTION) 32 5A Clock, radio 11 10A 22 10A Auto ventilator 33 10A Battery main switch Destination lamp (OPT) Car vision (OPTION) Spot light (OPTION) Heater mirror (OPTION) Driver lamp Wiper control relay Button buzzer (OPTION) MID door (OPTION) Luggage, Public phone (OPTION) Exhaust brake Water level relay Meter panel, Warning buzzer 211 Blink unit, Park lamp (OPTION) Rear fuse box 1 1. 2. 3. 4. 4 3 2 212 CoverˎRR fuse box BracketˎRr fuse box Regulator Assembly 18P Fuse box LUBRICATION Lubrications should be carefully selected according to the lubrication chart it is important to select viscosity of Lubricants according to the ambient temperature by refering to the following table. VISCOSITY CHART Engine oil Gear oil SAE 20 20W SAE 10W Ambient -30 C Temperature (20 F) SAE 85W SAE 30 -15 C (10 F) -0 C (32 F) SAE 10W 15 C (60 F) SAE 140 SAE 80W SAE 40.50 SAE 90 25 C 33 C (80 F) (90 F) Ambient -30 C -25 C Temperature (20 F) (10 F) -30 -15 C (0 F) -0 C (32 F) 10 C (50 F) SAE 80W 90 SAE 10W -40 SAE 15W 40. 15W 50. 20W 40. 20W 50 SAE 5W 20 SAE 75W 80 213 SAE 80W 140 SAE 85W 140 20 C (70 F) 30 C (90 F) Lubrication list Lubricant Engine oil Lubrication List Engine Capacity Oil change period Specification CF Grade D1146/Ti : 15.5ֹ Initial : 1,000km Inter city or long distance (OIL PAN : 13ֹ) travel bus, every : 15,000km DE12/T/Ti : 20ֹ (Frigid an area : 15W30 Except Frigid an area : 15W40) City bus, every : 10,000km (OIL PAN : 17ֹ) DE08TiS : 19ֹ API CH–4 grade (SAE 15W40) Initial : 1,000km (OIL PAN : 15.5ֹ) Long distance : every DE12TiS : 22ֹ Short distance : every or ACEA E2/E3 grade 30,000km 20,000km (OIL PAN : 19ֹ) Engine coolant Radiator Every : 1 year BM090 BS090 44 (49)ֹ Anti–freeze LLC Grade AREA Mixing ratio(%) 55(%) Freezing point(°C) –48(°C) RUSSIA(Frigid) SOUTHEAST ASIA MIDDLE EAST 30(%) –12(°C) AFRICA SOUTH AMERICA TAIWAN 50(%) –38(°C) 30(%)~40(%) –16(°C)~–25(°C) OTHERS BH090 BS106 58 (62)ֹ DE12 : 58 (62)ֹ BH115E DE12T : 62 (68)ֹ DE12Ti/TiS : 63 (68)ֹ BH120E 73(77)ֹ (7T377)ֹ 214 Inhibitor DCA65L (1% of engine coolant in volume) Lubricant Gear oil Lubrication List Capacity Manual K1005C/P transmission K1205C/P Oil change period Initial : 5,000km 9.7ֹ K805A/P 9.8ֹ T–9 10.0ֹ Specification GL–4 Grade (80W/90) Every : 20,000km K806P K1006R 11.2ֹ K1206R T–10S5B 13.0ֹ Auto transmission MT643 B300R B400R D851.2 D863 D854.2 D864 25ֹ 25ֹ 28ֹ On high way : DEXRON–II every 1 year or 40,000km Off high way : every 1 year or 1,000h Initial : 1 year or 8,000km or 200h Every : 1.5 year or 40,000km or 1,000h DEXRON–IIE, III When use oil list of G607 : every 60,000km When use oil list of G1363 : every 100,000km DEXRON–IIE 215 ATF IIE, ATF E–S Lubricant Gear oil Lubrication List Capacity transmission HP500 30ֹ HP590 Specification Oil change period Initial : 1,000km Auto HP600 ATF TYPE A, Every : Suffix A, normal operation temp. : DEXRON–IID 1 year or 30,000km high operation temp. : 1 year or 20,000km Rear axle 11.5–12.5ֹ Initial : 5,000km GL–5 (80W/90) Every : 20,000km Power Power steering steering BM090 BS090 BH090 BS106 BH115E BH120E Initial : 1,000km 6ֹ DEXRON R–II Every : 24,000km 7ֹ 4ֹ Brake oil Brake and clutch Every : 1 year or 60,000km DOT3, DOT4 Multipurpose EP No.2 Grease Wheel bearings Needed quantity When hub repair Multipurpose type grease Grease fittings Maunal : Every 4,000km NLGI No.2 or 3 Auto grease KLGI No. 000.00 216 Moving parts(every 4,000km) Ɓ King pin (4 points) Ɓ Link arm (1 point) Ɓ Tie rod end (2 points) Steering shaft (1 point) Propeller shaft (3 points) Drag link-FRT (2 point) 217 Drag link-RR (2 points) (For leaf spring) Spring and shackle pin (12 points) 218 AUTO GREASING (OPTION) Auto control Operation Manual operation Grease pump operates periodically set by control unit, singnal lamp “ON” simultaneously with grease pump operation and keep lighting 42 second and “OFF”. If the pressure in main line is less than specified value, singnal lamp keeps lighting “ON” even at the rest time. When Battery main switch is turned “OFF”, the signal lamp also “OFF”. After troubleshooting, if normal pressure is available, the signal lamp operation returns to normal condition. In main switch “ON”, the operation and rest time repeat periodically. When main switch “OFF”, time recording stops and is memoried to the unit. Main switch “ON” again, time recording continues and the system operates again. Grease can be pumped manually by pushing manual switch(DK) equipped beside of unit. After manual operation, the rest time set returns to “O”. Pump operation time 154 second Signal lamp lighting time 42 second Rest time (adjustable) 0.5, 1.2Ŕ11hours Pilot indicator lamps 219 Grease replenishment Check the amount grease in the transparent jar of gear pump unit, frequently and replenish if necessary, use clean and same type grease. Trouble check Symptoms and diagnosis SYMPTOMS ҮManual operation switch is pushed on, but signal lamp doesn’t “ON”. ҮSignal switch keeps lighting about 3 minutes. ҮLack of grease delivery REMEDY CAUSE ҮLack of grease in transparent jar. ҮReplenish grease ҮLeakage of grease in main line. ҮInspect fitting and correct leakage part. ҮTrouble of pressure switch, control unit ҮChange damaged part and correct and signal lamp or incorrect wiring ҮForeign parts in main line wiring. ҮCheck the pressure in main line and clean. ҮIn normal condition, the operation pressure is over 30bar, after operation the pressure go down below 10bar quickly. ҮExcessive grease delivery ҮInadequate capacity of metering nipple ҮChange metering nipple ҮInadequate time set of control unit ҮReadjust time set ҮInadequate capacity of metering nipple. ҮChange metering nipple CAUTION Troubleshooting is not possible, turn “OFF” main switch and disconnect terminal connected to control unit ot stop the operation. (stop the rest time memoried in control unit.) 220 SCHEDULED MAINTENANCE SERVICE Maintenance of periodic inspection service and retention of records are owner’s responsbility. The owner should retain recods and carry out maintenance service in accordance with maintenance service chart. Those are very important checking items which have to be checked for general vehicles. As this maintenance service chart is based on the vehicle which travels about 4,000km per month under normal driving condition, it is requested to reduce interval of the periodic inspection for vehicle which travels over 4,000km per month or under severe driving condition than normal. It is requested to check another items, if necessary even not mentioned this chart. MAINTENANCE SERVICE CHART INSPECTION POINTS PERIOD : 1000 Km ENGINE Check easiness of engine starting and abnormal noise Check idling speed and acceleration Check and clean air cleaner Change air cleaner element Adjust valve clearances Check fuel injection time, and fuel injection nozzle pressure Check compression pressure in each cylinder Check for oil contamination Drain fuel filter and clean fuel strainer Washing fuel filter element (D1146 ENGINE) Change fuel filter element (D1146 ENGINE) Change fuel filter cartridge (Except D1146 ENGINE) Clean fuel tank inside Check exhaust gas and adjustment Check function of air compressor and turbo-charger Check exhaust pipes for looseness (every 100,000km) Check fan belt for damage 0.5 4 8 12 16 20 24 28 32 36 40 44 48 D ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Ӈ ƃ ƃ ƃ Ӈ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Ӈ (Primary ƃ ƃ ƃ ƃ ƃ * For engine oil and filter cartridge change Refer “periodic inspection and maintenance”. 221 ƃ ƃ ƃ ƃ ƃ ƃ Ӈ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ(10,000km) ƃ ƃ ƃ(30,000km) ƃ (Every 60,000 km) ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ֦ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ (Primary filter : every 5,000km) filter : every 15,000km, Secondary filter : every 5,000km) Ӈ Ӈ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ (1,000km) ƃ ƃ ƃ ƃ ƃ INSPECTION POINTS PERIOD : 1000 Km 4 8 12 16 20 24 28 32 36 40 44 48 D Check function of clutch system ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check clutch pedal free play and pedal stroke ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check minipack exhaust cover ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ 0.5 CLUTCH Change clutch oil (Every 1 year or 60,000km) TRANSMISSION Check for oil leakage and oil fill up ƃ ƃ (1,000km) Ӈ Change oil ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Ӈ Ӈ (5,000km) ƃ Check for looseness in linkage PROPELLER SHAFT Check loose connections (every 5,000km) ƃ ƃ ƃ ƃ Check splines for excessive wear ƃ Check for looseness in bearing and related parts Grease the universal joints and spline ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ FRONT AXLE & REAR AXLE Check for looseness clamp bolt on axle shaft Change front and rear hub bearing grease ƃ ƃ Check rear wheel bearing looseness Check for oil leakage in rear axle shaft and oil fill up ƃ ƃ ƃ ƃ Check front wheel bearing looseness ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ (1,000km) (When take off and attachment) Change rear axle oil (Initial 5,000km, every 20,000km) 222 INSPECTION POINTS PERIOD : 1000 Km 0.5 8 4 12 16 20 24 28 32 36 40 44 48 D SUSPENSION Retighten “U” bolt & nut ƃ Check spring for damage ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check mount for looseness and damage ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check shock absorber for leakage and damage ƃ Check shock absorber mount ƃ Grease spring pin and shackle pin ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ WHEELS Check for presence of foreign matters (nails, stones, etc.) Retighten wheel nuts as necessary ƃ Check wheel discs for damage STEERING ƃ Check for looseness in mount Check steering wheel free play ƃ Check steering linkage for damage, looseness and excessive play ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check for oil leakage in gear box ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check clearance between king pin & bearing ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Ӈ 223 (1,000km) Ӈ ƃ ƃ ƃ Check wheel alignment Change power steering oil ƃ ƃ Ӈ ƃ INSPECTION POINTS PERIOD : 1000 Km 0.5 4 8 12 16 20 24 28 32 36 40 44 48 D Check function of brake system and air dryer ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ Check brake pedal free play ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ SERVICE BARKE Check for air leakage ƃ ƃ ƃ Check linings for wear ƃ Check brake drums for wear and damage ƃ Check hoses and pipes for leakage, damage ƃ Change brake oil ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ (Every 1 year or 60,000km) PARKING BRAKE ƃ Check function of parking brake ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ELECTRICAL EQUIPMENT Check charge state of battery ƃ ƃ ƃ ƃ Check function of starter ƃ ƃ ƃ ƃ Check function of generator & regulator ƃ ƃ ƃ ƃ Check generator brushes for wear ƃ Check starter brushes for wear ƃ ƃ Check terminals of wiring for damage ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ƃ ҭRefer to above–mention chart field “D” means daily inspection point (ƃ˛Daily check ֦˛Check for needs) ҭƃ˛Inspection mark Ӈ˛Change mark 224 ƃ ƃ TROUBLE SHOOTING ENGINE Starter motor does not turn over or turning is slow. CAUSE REPAIR ҮMalfunction of contact point of battery relay. ҮRun down battery ҮLoosened, corroded or disconnected battery terminal ҮTurn “ON” battery main switch ҮBattery charging or change ҮRemove the corroded part of battery teminal with chiesel, retighten connector and apply grease. ҮBe sure to connect the wiring ҮChange oil with proper viscosity ҮGround cable cut ҮToo thick oil viscosity Start motor turns over but engine won’t start CAUSE REPAIR ҮRefill or replenish ҮPreheat exactly and sufficiently ҮBleed air in fuel ҮClean filter element or change ҮEmpty fuel tank ҮNone sufficient preheating ҮAir mixed in fuel ҮClogged fuel filter Engine stops at low speed REPAIR CAUSE ҮAdjust ҮClean ҮCover ҮClean ҮAdjust ҮToo low idle rpm ҮAir cleaner element contamination ҮOver cooled engine ҮClogged fuel filter ҮValve clearance deviated 225 idle rpm with knob. element or change radiator with curtain filter element or change valve clearance Engine lacks power REPAIR CAUSE ҮFully release parking brake ҮClean element or change ҮAdjust the clearance of brake lining ҮAdjust valve clearance ҮAdjust the clearances or change clutch disc. ҮClean or change ҮClean or change ҮCheck cylinder pressure and repair ҮParking brake not released ҮAir cleaner element contamination ҮBrake detention ҮIncorrect valve clearance ҮClutch slip ҮClogged fuel filter ҮClogged fuel strainer ҮWear out of position ring Engine overheat CAUSE REPAIR ҮRadiator curtain covered or Radiator contaimination ҮLack of coolant ҮUncover radiator curtain or clean radiator ҮReplenish coolant, check leakage and radiator cap tightly closed. ңDon’t open radiator cab when coolant is hot. ҮAdjust fan belt tension or change fan belt if damaged. ҮChange coolant or clean in side of the radiator ҮChange thermostat ҮFan belt loosened ҮRust or scale in coolant ҮMalfunction of thermostat Black smoke CAUSE REPAIR ҮAir cleaner contamination ҮIncorrect valve clearance ҮClean air cleaner element or change ҮAdjust valve clearance 226 Excessive fuel consumption REPAIR CAUSE ҮCheck ҮClean ҮCover ҮInflate ҮAdjust ҮAdjust ҮFuel leakage ҮAir cleaner contamination ҮEngine overcooling ҮLack of tire inflation ҮBrake detent ҮClutch slip fuel line and repair air cleaner element or change radiator with curtain tire to specified value. the clearance of brake lining the clearance or change clutch disc. Lack of engine oil pressure CAUSE REPAIR ҮLack of engine oil ҮOil leakage ҮImproper oil viscosity ҮReplenish to specified level ҮCheck lubrication line and retighten loosened fitting ҮChange oil with proper viscosity Excessive engine oil consumption REPAIR CAUSE ҮChange oil with proper specification ҮChange oil level to specified value. ҮCheck lubrication line and retighten loosened fitting ҮChange oil periodically ҮWarm up engine to specified temperature ҮCheck cylinder pressure and repair ҮImproper oil specification ҮExcessive oil amount ҮOil leakage ҮDelayed oil changing period ҮNeglected engine warming ҮPiston ring wear out 227 POWER TRAIN Abnormal noise in transmission or rear axle in operation CAUSE REPAIR ҮLack of gear oil ҮImproper oil viscosity ҮReplenish to specified level ҮChange oil with proper specification Abnormal vibration in operation CAUSE REPAIR ҮLoosened bolts and nuts of propeller shaft and peripheral parts. ҮUnbalanced propeller shaft ҮCheck and retighten ҮModify propeller shaft or change STEERING Hard steering CAUSE REPAIR ҮLack of front tire inflation ҮLack of oil of power steering ҮCharge air to specified pressure ҮReplenish or discharge Non return to straight position CAUSE REPAIR ҮLack of grease in parts of steering system ҮInterference between drag link joint and peripheral parts ҮInsert grease ҮCheck and correct 228 Steering wheel shimmy REPAIR CAUSE ҮReplenish to specified level ҮCharge air to be same ҮChange ҮAdjust steering wheel clearance ҮChange to new one ҮChange shim or adjust ҮLoosend hub nut ҮDifferent tire inflation of “RH” and “LH” ҮIrregular tire wear ҮExcessive handle clearance ҮWorn out drag link coil spring ҮWorn out knuckle shim BRAKE Poor brake action CAUSE REPAIR ҮExcessive tire inflation ҮLeakage of brake line ҮExcessive lining clearance ҮExcessive tire wear ҮCharge to ҮCheck the ҮAdjust the ҮChange to specified pressure connection and correct clearance and change lining new tire Side braking CAUSE REPAIR ҮDifferent tire inflation of “RH” and “LH” ҮSide wear of tire ҮDifferent lining clearances of “RH” and “LH” wheel ҮCharge to be same pressure ҮChange ҮAdjust clearances correctly 229 Detent braking CAUSE REPAIR ҮImproper lining clearance ҮAdjust clearance properly SUSPENSION Different vehicle height REPAIR CAUSE ҮCheck the spring and repair ҮCheck tire and correct ҮDamaged or mislocated spring ҮTire inflation or puncture Meandered advancing CAUSE REPAIR ҮRadius rod cut ҮImproper location axle ҮChange radius rod ҮAdjust the location 230 ELECTRICAL Excessive battery discharging REPAIR CAUSE ҮRemove corroded part of battery terminal with chiesel, retighten connector and apply grease. ҮChange ҮCheck belt tension, adjust or change ҮBe sure to turn “OFF” switch ҮCheck alternator charging condition and repair. ҮBattery terminal disconnected, loosened, corroded. ҮAged battery ҮV-belt slip or cut ҮKeeping lamp lights “ON” ҮImproper alternator charging LAMP DOESN’T LIGHT “ON” CAUSE REPAIR ҮLamp faulty ҮFuse cut ҮChange lamp ҮChange to specified fuse (Even after changing to new fuse, fuse cut again, precise inspection is necessary and be sure not to use deviated fuse. ҮBe sure to ground completely ҮNon–complete ground 231 SMOKE Cause and repair of smoke DESCRIPTION REPAIR CAUSE Excessive fuel ҮLow idle RPM Adjust idle RPM injection ҮMaximum speed increase Adjust maximum speed ҮPlunger worn out Change plunger ҮDelivery valve worn out, damaged Change delivery valve ҮDeviated flow rate Adjust flow rate ҮBlocked nozzle tip Change nozzle tip and holder ҮEnlarged nozzle tip injection hole Change nozzle tip ҮInjection pressure down Adjust injection pressure Compression pressure ҮPiston ring worn out, cut Change piston ring down ҮCylinder liner worn out, damage Change cylinder liner ҮPiston worn out, damaged Change piston ҮPoor contact of valve and valve seat Change valve ҮHead gasket damaged, poor sealing Change head gasket ҮPoor nozzle assembly Reassemble nozzle or change Incorrect timing of ҮIncorrect injection timing Adjust injection timing injection pump ҮIncorrect timer angle adjustment Adjust timer angle Poor nozzle injection 232 DESCRIPTION REPAIR CAUSE ҮAir cleaner element contamination Clean air cleaner or change ҮLack of capacity of air cleaner Change to genuine part ҮIncorrect intake valve clearance Adjust valve clearance ҮIntake ducts blcoked or deformed Change intake ducts ҮLeakage of turbo charged air Check and repair leaking parts ҮMalfunction of turbo charger Change turbo charger Excessive exhaust ҮExhaust gas manifold blocked Change exhaust manifold Pressure ҮIncorrect exhaust valve clearance Check or change Overload operation ҮOverloaded Unload to specified value ҮExcessive engine oil Extract oil to specified level ҮPiston stuck by overheat Change piston, piston ring and related Lack of intake air parts. Poor quality of fuel ҮMetal bearing burnt Change metal bearing ҮFuel quality poor Use specified fuel ҮWater mixed fuel Clean fuel tank and remove water ҮFuel filter contamination Clean fuel filter or change 233 MAIN DATA AND SPECIFICATION 1. ENGINE 1-1. D1146/Ti, DE12/T/Ti ENGINE Distinction D1146 Type DE12T DE12 D1146Ti DE12Ti(280PS) DE12Ti(310PS) DE12Ti(340PS) water cooled 4 cycle in–line, overhead valve type Cylinder liner type dry type No. of piston ring compression ring : 2ea, oil ring : 1ea No. of cylinder BoreŦstroke(mm) Piston displacement(cc) Compression ratio Engine dimensions(mm) 6 ← ← ← ← ← ← 111×139 ← 123×155 ← ← ← ← 8071 ← 11051 ← ← ← ← 18.0 : 1 16.7 : 1 17.1 : 1 ← 16.1 : 1 ← ← length 1253 ← 1317 ← ← ← ← width 811.5 812.5 744 847 ← ← ← height 934.5 1009 1015 1064 ← ← ← 730 745 872 900 910 ← ← 600±50 ← ← ← ← ← ← BTDC 15 BTDC 9 BTDC 10 ← ← open at BTDC 16 ← BTDC 18 ← ← ← ← close at ABDC 36 ← ABDC 34 ← ← ← ← open at BBDC 46 ← ← ← ← ← ← close at ATDC 14 ← ← ← ← ← ← Engine weight(dry) (kg) Idle speed Fuel injection timing Fuel injection order Intake vlaves Exhaust valves 234 BTDC 9 BTDC 12 1–5–3–6–2–4 Distinction D1146 D1146Ti DE12 Oil pump type water cooled, integral type Oil cooler type Oil capacity(liters) fresh water method forced circulation Cooling DE12T DE12Ti(280PS) DE12Ti(310PS) DE12Ti(340PS) gear type ENG.TOT : 15.5ֹ, OIL PAN : 13ֹ 11 ENG.TOT : 20ֹ, OIL PAN : 17ֹ 19 Water pump type ← centrifugal type Thermostat type wax-pellet type Cooling water capacity(liters) ← ← ← ← Max. output(kW(ps)/rpm) 130(182)/2500 150(205)/2200 169(230)/2200 220(300)/2200 205(280)/2100 227(310)/2100 250(340)/2100 Max. torque(N·m(kg.m)/rpm) 563(57)/1600 735(75)/1400 799(81)/1300 1078(110)/1300 1127(115)/1260 1225(125)/1260 1323(135)/1260 Starter motor output(V × kW) Engine location Battery capacity(V × AH) 24×4.5 ← 24×5.4 ← ← ← ← rear ← ← ← ← ← ← 24×150 ← ← ← ← ← ← 235 1-2. DE08TiS, DE12TiS ENGINE Distinction DE08TiS(225ps) Type DE08TiS(240ps) DE12TiS(290ps) DE12TiS(310ps) water cooled 4 cycle in–line, overhead valve type Cylinder liner type dry type No. of piston ring compression ring : 2ea, oil ring : 1ea No. of cylinder BoreŦstroke(mm) Piston displacement(cc) DE12TiS(340ps) 6 ← ← ← ← 111×139 ← 123×155 ← ← 8071 ← 11051 ← ← 18.5 : 1 ← 17.0 : 1 ← ← length 1169 ← 1317 ← ← width 812 ← 847 ← ← height 1003 ← 1064 ← ← 745 ← 910 ← ← Idle speed (rpm) 600~650 ← ← ← ← Fuel injection timing BTDC 3 ← BTDC 1 1–5–3–6–2–4 ← ← open at BTDC 16 ← BTDC 18 ← ← close at ABDC 36 ← ABDC 32 ← ← open at BBDC 46 ← BBDC 70 ← ← close at ATDC 14 ← ATDC 30 ← ← Compression ratio Engine dimensions(mm) Engine weight(dry) (kg) Fuel injection order Intake vlaves Exhaust valves 236 Distinction Oil pump type DE12TiS(290ps) gear type Oil cooler type water cooled, integral type Oil capacity(liters) DE08TiS(225ps) DE08TiS(240ps) ENG.TOT : 19l, OIL PAN : 15.5l DE12TiS(340ps) ENG.TOT : 22l, OIL PAN : 19l fresh water forced circulation Cooling method Cooling water capacity(liters) DE12TiS(310ps) 11 Water pump type 19 centrifugal type Thermostat type wax-pellet type ← ← ← Max. output(ps/rpm) 225/2300 240/2300 290/2100 310/2100 340/2100 Max. torque(kg.m/rpm) 82/1000 90/1000 112/1260 125/1260 145/1260 Starter motor output(V × kW) 24×4.5 ← 24×6.0 ← ← Rear ← ← ← ← 24×150 ← ← ← ← Engine location Battery capacity(V × AH) 237 2. CLUTCH Distinction Clutch clamping force(kg) BH090/BS106 BH115E BH120E dry single plate with coil spring dampers controlled by hydraulic with pressure assisted. Type Clutch facing dimensions(mm) BM090/BS090 outside dia inside dia thickness D1146 D1146Ti DE12 DE08TiS(210ps) DE08TiS(240ps) DE12T DE12Ti/TiS(280ps) DE12Ti/TiS(310ps) DE12Ti/TiS(340ps) ratio free play max. stroke 380 240 5 430 250 ← ← ← ← ← ← ← 1240 ± 10% 1470 ± 10% 1380 ± 10% 1360 ± 10% 1450 ± 10% 1950 ± 10% 2100 ± 10% 2320 ± 10% 6.75 46.4 170 6.67 46.6 150 6.75 47.2 170 ← 47.4 ← Clutch minipack start working pressure(kg/cm2) 5.5 6.1 5.5 ← Master cylinder bore dia.(mm) 20 ← ← ← Clutch pedal 238 3. TRANSMISSION 3–1. Manual transmission MODEL K–805A K–805P K–806P T–9 SPEED 5.D.D 5.O.D 6.O.D 5.D.D TORQUE(kgm) GEAR RATIO T–10S5B T–13S5B K–1005C K–1005P K–1006R K–1205C K–1205P K–1206R K–1405A 5.D.D 5.D.D 5.D.D 5.O.D 6.O.D 5.D.D 5.O.D 6.O.D 5.D.D 82 82 82 90 125 135 115 115 115 125 125 125 145 1ST 6.666 5.455 6.666 6.571 6.589 6.589 6.608 5.500 5.500 6.608 5.500 5.500 6.608 2ND 3.826 3.130 3.826 3.807 4.002 4.002 3.993 3.323 3.482 3.993 3.323 3.482 4.184 3RD 2.213 1.728 2.213 2.201 2.430 2.430 2.423 1.782 2.147 2.423 1.782 2.147 2.580 4TH 1.417 1.000 1.417 1.463 1.507 1.507 1.518 1.000 1.348 1.518 1.000 1.348 1.518 5TH 1.000 0.745 1.000 1.000 1.000 1.000 1.000 0.755 1.000 1.000 0.755 1.000 1.000 6TH – – 0.734 – – – – – 0.755 – – 0.755 – REV 6.851 5.606 6.851 6.239 6.888 6.888 6.937 5.774 5.774 6.937 5.774 5.774 7.003 DRY WEIGHT(kg) 192 192 200 240 250 250 250 250 260 250 250 260 290 OIL CAPACITY(ֹ) 9.8 9.8 11.2 10 13 13 9.7 9.7 11.2 9.7 9.7 11.2 14.5 239 3–2. Auto transmission MODEL SPEED TORQUE(kgm) 1ST 2ND GEAR RATIO 3RD MT643 B300R B400R B500R D851.2 4.D.D 4DD/5OD/6OD 4DD/5OD/6OD 4DD/5OD/6OD 3.D.D 97.8 125.4 179.6 102 88.4 3N 6.2 3S 5.9 3.49 3.49 3.51 3.58 4N 5.4 4S 5.1 3N/3S 1.43 1.86 1.86 1.91 2.09 4N/4S 1.36 3N/3S 1.00 1.41 1.41 1.43 1.39 4N/4S 1.00 4TH 1.00 1.00 1.00 1.00 – 5TH 6TH – – 0.75 0.65 0.75 0.65 0.74 0.64 REV 5.67 5.03 5.03 4.8 231 25 227 25 227 25 412 45 – – 3N 5.2 3S 4.7 4N 4.3 4S 3.8 295 28 DRY WEIGHT(kg) OIL CAPACITY(ֹ) 240 D863 3.D.D 132.7 – 3S 5.9 4N 5.4 4S 5.1 3N/3S 1.43 4N/4S 1.36 3N/3S 1.00 4N/4S 1.00 D854.2 4.O.D 102 3N 6.2 3S 5.9 4N 5.4 4S 5.1 3N/3S 1.43 4N/4S 1.36 3N/3S 1.00 4N/4S 1.00 3N/3S 0.70 – 4N/4S 0.73 – – – – 3N 5.2 – 3S 4.7 3S 4.7 4N 4.3 4N 4.3 4S 3.8 4S 3.8 330 300 28 28 D864 HP500 HP590 HP600 4.O.D 4DD/5OD/6OD 4DD/5OD/6OD 4DD/5OD/6OD 132.7 112.2 127.6 142.9 – 3S 5.9 3.43 3.43 3.43 4N 5.4 4S 5.1 3N/3S 1.43 2.01 2.01 2.01 4N/4S 1.36 3N/3S 1.00 1.42 1.42 1.42 4N/4S 1.00 3N/3S 0.70 1.00 1.00 1.00 4N/4S 0.73 – 0.83 0.83 0.83 – 0.59 0.59 0.59 – 3S 4.7 4.84 4.84 4.84 4N 4.3 4S 3.8 335 310 315 330 28 30 30 30 4. PROPELLER SHAFT 4–1. Manual transmission D1146 DE08TiS DE12 D1146Ti Distinction BM090 BM090 BH115E BS090 BS090 BH090 BS106 BS106 BH120E Length 320.0 340.0 320.0 K805A Outside dia. 88.9 88.9 ء K805P Inside dia. 80.9 80.9 ء Length 690.0 577.0 T-9 Outside dia. 88.9 88.9 Inside dia. 80.9 80.9 Length 557.0 ء K1005C Outside dia. 88.9 ء K1005P Inside dia. 80.9 ء Length 463.0 ء K1006R Outside dia. 88.9 ء Inside dia. 80.9 ء Length T-10 Outside dia. Inside dia. K1205C Length Outside dia. K1205P Inside dia. Length K1206R Outside dia. Inside dia. 241 DE12T BH115E BH120E 560.0 101.6 91.6 367.0 101.6 91.6 535.8 101.6 91.6 560.0 101.6 91.6 367.0 101.6 91.6 DE12Ti BS106 560.0 101.6 91.6 367.0 101.6 91.6 BH115E BH120E ء ء ء ء ء ء 535.8 101.6 91.6 560.0 101.6 91.6 367.6 101.6 91.6 DE12TiS BS106 560.0 101.6 91.6 367.0 101.6 91.6 BH115E BH120E ء ء ء ء ء ء 535.8 101.6 91.6 560.0 101.6 91.6 367.6 101.6 91.6 4–2. Auto transmission D1146 DE08TiS DE12 D1146Ti BM090 BM090 BH115E BS090 BS090 BH090 BS106 BS106 BH120E Length 577.0 470.0 ء ҫ 88.9 ء MT643 Outside dia. Inside dia. ҫ 80.9 ء Length 626.0 ء Outside dia. 88.9 88.9 ء B300 Inside dia. 80.9 80.9 ء Length Outside dia. B400 Inside dia. Length 660.0 557.0 ء 88.9 88.9 ء D851.2 Outside dia. Inside dia. 80.9 80.9 ء Length D854.2 Outside dia. Inside dia. Length Outside dia. D863 Inside dia. Length Outside dia. D864 Inside dia. 393.0 676.0 566.0 Length ء 88.9 ء HP500 Outside dia. 88.9 88.9 Inside dia. 80.9 ء 80.9 80.9 Length HP600 Outside dia. Inside dia. Distinction 242 DE12T BH115E BH120E 529.0 114.3 101.6 569.5 101.6 91.6 569.5 101.6 91.6 DE12Ti BS106 BH115E BH120E DE12TiS BS106 529.0 114.3 101.1 569.5 101.6 91.6 569.5 101.6 91.6 BH115E BH120E 5. FRT AXLE Tire. Tread(mm) Capacity(kg) King pin(mm) Wheel alignment outside dia. BH120E BH090 2050 ← ← ← ← 6500 ← ← ← ← 50 ← ← ← ← length 252 ← ← ← ← toeˎin(mm) 4~6 0~2 4~6 0~2 ← camber(°) 0.5°±30' ← ← ← ← caster(°) 0°12'±30' 1°30'±30' -0°36'±30' 0°12'±30' 1°30'±30' 7.5°±10' ← ← ← ← inside(°) 45° ← ← ← ← outside(°) 37° ← ← ← ← kingpin inclination(°) Steering angle BH115E BS106 Reverse Elliot I Beam BM090/BS090 Type 243 6. REAR AXLE BM090/BS090 BH090 Type Final Spiral drive gear type bevel OPTION gear ← ← – – 39/7 39/8 39/8 39/8 39/8 – – 39/10 – 39/10 39/10 – – – 39/11 39/11 – – – 39/12 9500 ← ← 10500 Oil capacity (Iiters) Axle load capacity (kg) Hypoid BH120E – 39/7 Final gear ratio ← BH115E BS106 Banjo full floating type 244 – 11.5–12.5 ← 7. STEERING Distinction Type Steering wheel diameter(mm) gear ratio sector gear Power steering operating angle gear oil capacity(ֹ) Length of drop arm(mm) Oil capacity(liters) BS106/BH115E/BH120E BM090/BS090/BH090 Recirculating ball with intergral power assisted 500 ← 22.4 : 1 ← 96° ← 1.5 ← 200 ← 6 7 245 8. BRAKES Distinction BM090/BS090/BH090/BS106/BH115E/BH120E 410 Drum inside front Diameter(mm) rear 410 Brake lining(mm) front 209Ŧ155Ŧ19ˎ8 LŦWŦTˎN rear 209Ŧ220Ŧ19ˎ8 Wheel cylinder front ˎ bore dia.(mm) rear ˎ Anchor pin(mm) front 30Ŧ106.5 dia.Ŧlengh rear 30Ŧ121.5 246 9. SUSPENSION 9-1. Left spring Distinction BM090/BS090 BS106 span(mm) 1500 ← ← ← width(mm) 90 ← ← ← 13-6 13–7 ← 13-8 spring constant(kg/mm) 25.33 33.5 ← 36.42 span(mm) 1660 ← ← ← width(mm) 100 ← ← ← thickess(mm) 14-4 15-1 ˎno.of leaff 15-4 14-9 ← 14-11 spring constant(kg/mm) 43.5 47.9 ← 50.31 thickess(mm) ˎno.of leaf Leaf Spring RR Hydraulic, double acting telescopic Type Shock absor- Damp ber force (kg) BH120E Semi elliptical alloy steel Type FRT BH115E Standard FRT rebound 595 ← ← ← FRT compression 260 ← ← ← RR rebound 650 ← ← ← RR compression 260 ← ← ← 247 9-2. Air spring Distinction FRONT REAR BH090 BH090 Variable throttle type with stabilizer type effective dia.(mm) Air Spring 250 design height(mm) 270 270 max.out. dia(mm) 310 310 no.of springs 2 4 stroke of ext. 100 100 spring(mm) comp. 100 86 86 76.3 76.3 2 2 extension(mm) 594 545 compression(mm) 384 338 1 2 out. dia.(mm) Shock base shell dia.(mm) Absor– no. of S/A L/V 100 Double acting telescopic type type ber 250 no of levering valve 248 10. WHEEL AND TIRES 9.00-20-14PR 9.00R20-14PR 10.00-20-14PR 10.00-20-16PR 10.00R20-16PR 11.00-20-16PR 11.00R20-16PR 11R22.5-16PR 12R22.5-16PR 295/80R22.5-16PR Distinction (Tube) OUT.Dia.(mm) MAX.width(mm) Tire Tire inflation pressure Disc wheel size (Tube, radial) (Tube) 1014~1034 1006~1032 1046~1076 229 ← 254 (Tube) (Tube, radial) (Tube) (Tube, radial) (Tubeless) (Tubeless) (Tubeless) ← ← ← ← 295 293 295 305 295 1078~1108 1068~1098 1037~1067 1068~1098 1030~1058 front 7.7kg/cm2(109psi) 8.0kg/cm2(113psi) 7.0kg/cm2(99psi) 8.1kg/cm2(115psi) ← 8.4kg/cm2(119psi) ← ← ← 8.3kg/cm2(118psi) rear 7.0kg/cm2(99psi) 7.3kg/cm2(103psi) 6.3kg/cm2(89psi) 7.4kg/cm2(105psi) ← 7.7kg/cm2(109psi) ← ← ← 8.3kg/cm2(118psi) ← 7.50V-20 ← 8.25Ŧ22.5 ← ← 7.00T–20 ← ← ← 249 11. COOLER 11–1. Roof on cooler Type Standard type Compressor Refrigerant type Condenser Condenser fan Heavy duty type ← R–12/R–134a (OPTION) 24000 ← 26000 ← 1 Cooling capacity(kcal/h) Compressor Tropical type ← 21000 4PFC/4PFCY(OPT) ← ← no. of cylinder 4 ← ← diameter(mm) 210 ← ← stroke(mm) 57 ← ← capacity(cc/rev) 560 ← ← AL FIN & CU TUBE ← ← 0.446 0.762 ← PROPELLER FANŦ3 PROPELLER FANŦ5 4700 7200 ← ← ← type total area(m2) type capacity(m3/h) required power(A) 5.5A/EA 250 ← Receiver tank Evaporator Evaporator fan Expansion valve Total weight(kg) type HORIZONTAL 3.4 ← ← ← ← AL FIN & CU TUBE ← ← 0.346 ← 0.505 SIROCCO FAN × 8 ← capacity(m3/h) 400/EA ← SIROCCO FAN × 12 ← required power(A) 5.5A/EA ← ← 8 EXTERNAL EQUALIZING PRESSURE ← ← 190 218 240 capacity(liters) type total area(m2) type type capacity (RT) 251 11–2. Sub cooler Type PBC–2400(D) Cooling capacity(kcal/h) 26000 Refrigerant R–12/R–134a (OPTION) Weight (kg) about 550 model Engine DWH–DC23 or KIA–S2 piston displacement(cc) 2238 or 2209 no. of cylinder rotating speed(rpm) 4 high 1850 MID 1450 low 1150 type Compressor ND 6C–500 piston displacement(cc/rev) 495 Condenser AL FIN & CU TUBE Blower capacity(m3/min)(AT 40mmAq) 66.7 Expansion valve thermostatic expansion valve Receiver capacity(liters) 2.6 252 BODY DIMENSION (APPROX.) BM090 (APPROX.) ROOF-ON COOLER NON COOLER 253 BS090 254 BH090 2490 2750 1975 4200 35 2050 8990 3225 30 1853 255 BS106 3225(APPROX.) 2490 3110 2100 5200 10550 2050 70 ROOF-ON COOLER 3110(APPROX.) 70 1853 SUB ENG.COOLER / NON COOLER 256 (APPROX.) BH115E (APPROX.) ROOF-ON COOLER SUB ENG COOLER / NON COOLER 257 (APPROX.) BH120E (APPROX.) ROOF-ON COOLER SUB ENG COOLER 258 BM090/BS090/BH090/BS106/BH115E/BH120E OWNER’S & DRIVER’S MANUAL TECHNICAL CENTER 75-11, GUMSA–DONG, GUMJUNG-KU, BUSAN, KOREA OM–BW–C1–11C–0306
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