Euro IV - BH117L - Daewoo Bus Australia

Euro IV - BH117L - Daewoo Bus Australia
IMPORTANT SERVICE ACTIVITIES
Maintenance Schedule
Items
Remarks
DE08TIS Change : At end of first 1,000km,
long distance : every 30,000km
DE12TIS
shot distance : every 20,000km
DV15TIS
Engine oil & Filter
DL06
DL08
DV11
GE08TI
GE12TI
ISM
The initial change is at 5,000 km.
※ It is recommended to
Replace it every 40,000 km (Driving in downtown/short-haul)
replace this part at least twice
Replace it every 60,000 km (Driving at high speed/long-haul)
a year even if the vehicle is
The initial change is at 1,000 km.
not regularly operated.
Replace it every 20,000 km (Driving in downtown/short-haul)
Replace it every 30,000 km (Driving at high speed/long-haul)
The initial change is at 1,000 km.
Replace it every 24,000km.
DE08TIS
DE12TIS Replace it every 20,000 km.
DV15TIS
Fuel Filter
DL06
DL08
DV11
ISM
Replace it every 40,000 km (Driving in downtown/short-haul)
Replace it every 60,000 km (Driving at high speed/long-haul)
Replace it every 24,000 km.
’(6-3 page) for more details.
※ Please refer to‘Regular Check-up List and Periodic Table’
Items
Maintenance Schedule
Gas Filter
GE08TI
GE12TI
Inspect it every 5,000 km and replace every 20,000 km.
Spark Plug
GE08TI
GE12TI
Replace it every 80,000 km.
Air Cleaner Filter
Clean it every 12,000 km or 300 hour.
Replace : After 3 cleaning
Manual Transmission Oil
Replacement : Eevery 24,000km after the initial change at 5,000km.
Inspection & Refill : Every 4,000km after the initial one at 1,000km.
Rear Axle Oil
Replacement : Every 24,000km after the initial change at 5,000km.
Inspection & refill : Every 4,000km after the initial one at 1,000km.
Power Steering Oil & Filter
APU (Air dryer) Cartridge
APU Oil Separator
Fan Clutch Oil
BX212
Clutch Oil
Hub Grease
Antifreezing Solution
Replace it every 40,000km after the initial change at 5,000km.
Replace it every 100,000km or one year.
Clean every 30,000km (O-Ring replacement)
Replace it every 80,000 ~ 100,000km or one year.
Replace it every 60,000km or one year.
Replace this part when attaching and detaching it.
Concentration check & refill : Every month.
Replacement : Every year.
’(6-3 page) for more details.
※ Please refer to‘Regular Check-up List and Periodic Table’
Remarks
Periodic check
FOREWORD
Thank you very much for choosing a DAEWOO BUS.
This manual contains explanations in easy way about correct driving method and general inspection operation for your
vehicle that could have maximum performance in optimal condition.
Contents of this manual describe all the possible options which are fixable for a vehicle, therefore it can be different
from you vehicle depending on your chosen options and design change.
All written contents in this book can be changed without any notice for improvement of the product and we will be
grateful if you understand that our company has no obligation to apply it for delivered vehicles about changed contents.
Please read and familiarize this manual before driving a vehicle. You can gain maximum efficiency and optimal
economic result if you follow the constructions.
DAEWOO BUS has expert service manpower and modern facilities in order to be ready to take care of you vehicle.
We promise to provide continuous support that you can be satisfied and enjoy driving a DAEWOO BUS. Thank you
very much for using our vehicles.
It is recommended to use always DAEWOO BUS standard parts with
indicated label shown right side to keep your vehicle in optimal
condition.
OM-B520E
WARRANTY INFORMATION
We are pleased that you have purchased
a Daewoo Bus.
This is the warranty and maintenance
record of your Daewoo Bus.
This booklet should always be kept as a
permanent part of the vehicle, and remain
with your Daewoo Bus at time of resale.
When service is due according to the time
period or mileage indicated in the Owner s
Manual, present this Warranty to any
authorized Daewoo Bus dealer and
request that the appropriate service be
performed.
We sincerely hope that you will be
delighted with your Daewoo Bus and that
it brings you much enjoyment over the
years to come.
OWNER S IDENTIFICATION
Owner Service No. (O.S. NO.) :
Model :
Vehicle Ident. No.(VIN) :
Engine No. :
Body Color :
Date of Delivery :
Mileage at Delivery
Issued by
Dealer s Name :
Dealer s Address :
Dealer representative s
Signature :
1. Owner s Name :
Address :
Phone :
License No :
2. Owner s Name :
Address :
Phone :
License No :
Dealer s
Stamp
NEW VEHICLE WARRANTY
Daewoo Bus Corp., hereinafter called the manufacturer, warrants to the owner of each Daewoo Bus that the
Daewoo Bus shall be free, under normal use and maintenance, from any defects in material and workmanship,
subject to the following terms and conditions.
1. Warranty period
This warranty shall exist for a period 12 months from the date of either delivery to the first retail purchaser or
first use to the vehicle as a company vehicle by distributor or dealer, or until the vehicle has been driven for a
distance of 100,000 km ( -- miles), whichever comes first.
2. What is covered
Except as provided in paragraphs 3 hereof, an authorized Daewoo dealer or distributor shall either repair or
replace, at its option, any Daewoo genuine part that is defective in material or workmanship within the warranty
period set forth in paragraph 1 hereof, without charge to the owner of the Daewoo Bus.
3. What is not covered
This warranty shall not apply to or include any of the following.
(a) Repair or replacement required not as a result in material or workmanship of manufacturer but as a result of
(i) accident, (ii) misuse, (iii) lack of proper maintenance, (iv) repairs improperly performed or replacements
improperty installed by any person other than an authorized Daewoo dealer, (v) a replacement part or
accessory not conforming to the Manufacturer’s specifications, (vi) usage of any fuel other than that
specified for the Daewoo Bus, (vii) alterations by changing or adding to the vehicle, or (viii) damage grom
environmental conditions such as airborne fallout, salt, hail, windstorm, lightning, flood and the like, (ix)
transportation damage, (x) storage damage, (xi) diagnosis time.
(b) Any Daewoo Bus equipment subject to normal wear and tear, including, without limitation, filters, drive
belt(s), fuses, clutch facing, brake linings, wiper blades, and the like.
(c) Normal maintenance service, including, without limitation, cleaning and polishing, lubrication, adding
coolant, replacement of consumable parts, adjustment of necessary parts and engine tune-up.
(d) Any Daewoo Bus on which the odometer mileage has been altered or on which the actual mileage of the
Daewoo Bus cannot be readily determined.
(e) Extra expenses including, without limitation, payment for loss of the use of the vehicle, lodging bills, towing,
vehicle rentals, other travel costs and loss of pay.
(f) The further details are subject to the Daewoo Bus warranty policy and procedure manual.
Tire Warranty
Tires installed as original equipment on Daewoo Bus are warranted by their respective manufacturers and not
warranted by Manufacturer.
’
Owner’
s Responsibility
1. Maintenance service are the owner’s responsibility
You should retain evidence that proper maintenance has been performed on your Daewoo Bus. Claims made
during the warranty period will not quality under the warranty if resulting from lack of mainrenance rather than
from defective material or workmanship. We recommend that such services be performed by an authorized
Daewoo dealer using genuine parts. Please note that the maintenance services described in the Owner s Manual
should be performed even more frequently if your Daewoo Bus is subject to severe conditions such as
operation in extremely dusty or extreme (high or low) temperature areas. Under such severe conditions, we
recommend that your engine oil level should be checked each time your purchase fuel for your Daewoo Bus
and that your engine coolant and cooling fan belt should be inspected frequently. Refer to the Owner’s
Manual for applicable specifications.
2. You must deliver your Daewoo Bus to an authorized Daewoo dealer or distributor to obtain warranty service.
SUGGESTIONS DAEWOO PRODUCTS
Please write down any suggestions concerning Daewoo products that help Manufacturee to develop Daewoo products.
DAEWOO BUS
OWNERSHIP REGISTRATION CARD/The copy for Manufacturer, Dealer and Owner
This card should be sent to Manufacturer by Dealer.
Owner Service No.
(O.S No.)
Model
Vehicle Ident. No.
(VIN)
cut here
Engine No.
Date of Delivery
Mileage at Delivery
Shipping Date
Owner s Name
Owner s Phone No.
Street
Owner s Address
City
Dealer s Signature
Country
Dealer s Name
Dealer s Signature
DAEWOO BUS
OWNER INFORMATION
Please read this owner information carefully to familiarize yourself with the type of service which you are entitled
under each of the warranties applicable to your new Daewoo Bus.
1. Pre-Delivery Inspection
To insure your satisfaction and long term enjoyment of your new Daewoo Bus, your Daewoo dealer inspects whether
the vehicle is complete or not in accordance with the standard factory instruction before delivery to you. If, after
delivery, an unexpected defect is found, please come to see selling dealer s service manager or authorized service
man immediately. On this defect, your selling dealer will be willing to perform the service as requested.
2. Parts Repair and Replacement by Warranty
Should any defects in material or workmanship occur within the period, said part will be repaired or replaced without
cost to you after certification of the Daewoo dealer.
3. Change of Residence Privileges
Although you have changed your residence within the warranty period, you are entitled, on presentation of this Service
Guide/Warranty Information booklet which will be signed and stamped by the selling dealer, to erceive the services at
any Daewoo dealer s service shop, regardless of where the vehicle may have been purchased.
4. Periodic Inspection and Service
Regular inspection and maintenance by skilled technicians is the key to more efficient operation of the vehicle. Should
the safety inspection and lubrication service be performed as described in owner s manual, your vehicle will always
maintain trouble-free operation and optimum performance.
Pre-Delivery
Inspection
O.S. NO.
PRE-DELIVERY INSPECTION
We hereby certify to have delivered
the vehicle in proper operating
condition.
Owner s Name :
Address :
Performed at
City :
km
Telephone Number :
License Plate No. :
cut here
Dealer s
Stamp
Model :
Engine Number :
Vehicle Ident. Number :
Dealer s Name :
Signature of Dealer Representative :
I hereby certifty that the vehicle has been delivered in an
orderly and proper operating condition, including a tool-kit,
keys, an owner s manual and service guide booklet. I also took
notice of the warranty terms as presented in this booklet. The
warranty commencess as of the date of delivery.
Date :
Date
Owner s Signature
※ Where applicable, adjust if necessary
ENGINE COMPARTMENT
CHASSIS, UNDERBODY
□ 1. Idling speed-check
□ 1. Front suspension-check
□ 2. Fuel system-check
□ 2. Manual transmission leakage-check
□ 3. Drive belt-check
□ 3. Rear axle oil-check
□ 4. Engine oil levels-check
□ 4. Brake line connection-check
□ 5. Power steering fluid levels-check
□ 5. Tire condition, inflation pressure and
□ 6. Brake fluid level & leakage-check
□ 7. Clutch fluid level & leakage-check
wheel nut-check
□ 6. Brake system-check
□ 8. Coolant level & leakage-check
□ 9. Battery electrolyte level-leakage,
terminal-check
BODY, INTERIOR
□ 10. Hose connections-check
□ 1. Lights and signaling device-check
□ 11. Air cleaner-check. Clean
□ 2. Windshield wipe system-check
□ 12. Fuel filter check and water drain
□ 3. Seat mechanism-check
□ 4. Parking brake-check
□ 5. Door looks and hinges-check
□ 6. Power window system-check
Record oil brand used
DEALER IMPRINT
INTRODUCTION
◆ This manual contains the signs like
WARNING ,
CAUTION
and REFERENCE when it is related in safety.
Please read and follow these instructions all the time.
WARNING
This sign describes potentially dangerous situations and if you are not following this instruction, you
can get serious injury and could cause a death.
CAUTION
This sign shows potentially dangerous situations and if you are not following this instruction, it can
cause considerable damages for your vehicle and other properties.
REFERENCE This is an information sign to help for instruction contents or maintenance that is related with
customer’s vehicle.
• We will appreciate for your understanding about the fact that all the information in this manual could be changed
without notice and we would not offer a note or apply this changed situation for delivered vehicle.
• The parts and accessories which are not originated from our company, cannot receive a repair and inspection
services. Safety and suitability are not attested to the none-original parts and accessories, therefore we are not
responsible for damages and injuries from those causes.
• It is recommended that all the customer′
s should read and be aware of this manual before using the vehicle.
• This manual is prepared based on LHD(Left Hand Drive) Vehicles. The description pictures may differ with
RHD(Right Hand Drive) Vehicles since their installation Iocations of certain accessories are the opposite of
LHD vehicles, but operation techniques are equal.
CONTENTS
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
SAFETY CAUTIONS
DEVICE CONTROL TIPS
START-UP & DRIVING
EMERGENCY AID
VEHICLE INSPECTION AND MAINTENANCE
FAULTY DIAGNOSIS
1
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
1. VEHICLE SPECIFICATIONS AND SERVICE DATA
Vehicle Specifications (VIN) …………………… 1-2
Engine Number …………………………………… 1-2
Chassis Number …………………………………… 1-2
2. INTERIOR & EXTERIOR VIEW OF VEHICLE
Exterior View of Vehilce ………………………… 1-3
Interior View of Vehicle …………………………… 1-5
3. SPECIFICATIONS
Vehicle …………………………………………… 1-7
Engine……………………………………………… 1-9
Tire and Wheel …………………………………… 1-11
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
1. VEHICLE SPECIFICATIONS AND SERVICE DATA
Vehicle Specifications (VIN)
Engine Number
The vehicle specifications plate located
at the front of a front door shows the
name and type of the DAEWOO BUS.
As for the vehicle of non step, The
vehicle specifications plate is placed
on the control panel to the left side of a
driver.
Chassis Number
The engine number is stamped on the
right side of an engine block.
The chassis number is stamped on the
upper right rear of the chassis frame.
TYPE A
OM-F002
OM-B521
TYPE B
OM-B522
OM-F001E
1-2
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
2. INTERIOR & EXTERIOR VIEW OF VEHICLE
Exterior View of Vehicle
※ Specs may vary depeding on the type and options.
OM-H206
1. Air Conditioner
2. Manual Ventilator
3. Engine Air Intake
4. Side Lamps
5. Luggage Door
6. Entrance Door
7. Outside rearview Mirrors
8. Wiper
9. Side Turn Signal
10. Fog Lamps
11. Headlamps
12. Side Window
13. Engine Room Air Rotation Hole
14. Back Lamp
15. Towing Hook
16. Fuel Inlet
17. Entrance Door lock
18. Door Opening and Shutting Switch
1-3
19. Marker Lamps
20. Auto Ventilator
21. Antenna
22. Rear combination Lamps
23. Back Eye Camera
24. Spare Tire Carrier Hole
25. Coolant Injection Door
26. Exhaust Pipe
27. Rear Engine Door
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
OM-S108
1. Air Conditioner
2. Manual Ventilator
3. Engine Air Intake
4. Side Lamps
5. Side Door
6. Entrance Door
7. Outside rearview Mirrors
8. Wiper
9. Side Turn Signal
10. Fog Lamps
11. Front Combination Lamps
12. Side Window
13. Engine Room Air Rotation Hole
14. Back Lamp
15. Towing Hook
16. Entrance Door lock
17. Door Opening and Shutting Switch
18. Marker Lamps
1-4
19. TV Antenna
20. Radio Antenna
21. Rear combination Lamps
22. Middle Entrance Door
23. Destination Plate
24. Spare Tire Carrier Hole
25. Coolant Injection Door
26. Exhaust Pipe
27. Rear Engine Door
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
Interior View of Vehicle
※Specs and locations may vary depeding on the type and options.
OM-H250E
1-5
1. Instrument Panel
2. Speedometer
3. Back Eye Camera Monitor / Navigation
4. Mike Holder
5. Audio
6. Switches
7. Tachograph
8. Defroster Control Panel
9. Idle Speed Actuator and Cruise Switch
10. Gearshift
11. Wiper & Exhaust Brake Controls
12. Horn
13. Steering Wheel
14. Turn Signal & Headlamp Controls
15. Parking Brake
16. Clutch Oil Reserve
17. Engine Self-Diagnosis Swicth (Diesel Vehicle)
18. Outside Rearview Mirrors Adjustment
19. Control Panels
20. Power Window /
Luggage Door Lock Switch (BX212)
21. Voltmeter
22. Retarder Brake Lever
23. Power Supply (12V)
24. Engine Diagnostic Switch (Self-Diagnosis)
25. Idle Speed Actuator (CNG Vehicle)
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
※ Specs and locations may vary depeding on the type and options.
1. Instrument Panel
2. Speedometer
3. Audio
4. Switches
5. Tachograph
6. Idle Speed Actuator Switch (Diesel Vehicle)
7. Gearshift
8. Accelerator Pedal
9. Brake Pedal
10. Clutch Pedal
11. Horn
12. Steering Wheel
13. Parking Brake
14. Clutch Oil Reserve
15. Turn Signal & Headlamp Controls
16. Wiper & Exhaust Brake Controls
17. Engine Self-Diagnosis Swicth (Diesel Vehicle)
18. Control Panels
19. Door Opening and Shutting Switch
20. Defroster Control Panel
21. Engine Diagnostic Switch (Self-Diagnosis)
(CNG Vehicle)
22. Idle Speed Actuator (CNG Vehicle)
OM-S112
1-6
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
3. SPECIFICATIONS
Vehicle
Units : mm
Items
Body
Tread
Overhang
BS090
BH090
BS106
BS110CN
BS120CN
BC211M
BC212M
BV120MA
Length
8,990
8,990
10,590
11,010
11,990
11,000
11,940
11,940
Width
2,490
2,490
2,490
2,490
2,490
2,490
2,500
2,490
Height
3,240
3,220
3,200
3,005
3,060
3,235
3,179
3,190
Front
2,050
2,050
2,050
2,096
2,096
2,050
2,050
2,050
Rear
1,853
1,853
1,853
1,836
1,836
1,853
1,853
1,853
Front
1,960
1,975
2,100
2,410
2,600
2,400
2,680
2,640
Rear
2,710
2,750
3,110
3,110
3,110
3,110
3,160
3,110
4,200
4,200
5,200
5,400
6,100
5,400
6,100
6,100
Wheelbase
※Example : BS106
OM-B503E
1-7
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
Units : mm
Items
Body
Tread
Overhang
BH115E
BH120E
BH116
BH117
BH119
BH120
BX212
Length
11,550
11,950
11,550
11,750
12,000
12,000
12,000
BH125
Width
2,490
2,490
2,490
2,490
2,490
2,490
2,490
Height
3,225
3,225
3,225
3,395
3,395
3,415
3,545
Front
2,050
2,050
2,050
2,050
2,050
2,050
2,050
2,050
Rear
1,853
1,853
1,853
1,853
1,853
1,853
1,853
1,853
Front
2,225
2,225
2,225
2,425
2,425
2,280
2,750
Rear
3,110
3,110
3,110
3,110
3,110
3,080
3,150
6,100
6,500
6,100
6,100
6,350
6,500
6,100
Wheelbase
6,650
※ Example : BX212
OM-H207E
1-8
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
Engine
DIESEL (EURO II)
Model
DE08TIS
(240 ps)
DE12TIS
(310 ps)
(340 ps)
(290 ps)
Type
DV15TIS
(390 ps)
(360 ps)
Water cooled 4 cycle in-line, Overhead valve type
Piston displacement
8,071
Power ouput (ps/rpm)
240/2,300
290/2,100
Torque (kg.m/rpm)
90/1,000
112/1,260
14,618
11,051
Combustion sequence
310/2,100
340/2,100
390/2,100
125/1,260
145/1,260
145/1,260
390/2,200
160/1,300
1-5-3-6-2-4
1-5-7-2-6-3-4-8
DIESEL (EURO III)
Model
Type
DL08
(250 ps)
(270 ps)
DV11
(300 ps)
(310 ps)
In-line 4-stroke, water-cooled supercharging,
air-cooled type
Piston displacement
(340 ps)
(420 ps)
90°-V type 4-stroke, water-cooled
supercharging, air-cooled type
7,640
10,964
Power ouput (ps/rpm)
250/2,200
270/2,200
300/2,200
310/2,200
340/1,800
Torque (kg.m/rpm)
90/1,200
100/1,200
115/1,200
145/1,200
145/1,200
Combustion sequence
(400 ps)
1-5-3-6-2-4
1-9
400/1,800
420/1,800
173/1,200
187/1,200
1-4-2-5-3-6
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
DIESEL (EURO IV)
Model
Type
Piston displacement
DL06
(250 ps)
DL08
(270 ps)
(300 ps)
ISM
(340 ps)
(410 ps)
DV11
(430 ps)
In-line 4-stroke, water-cooled supercharging, air-cooled type
5,900
7,640
(400 ps)
(430 ps)
90°-V type 4-stroke,
water-cooled supercharging,
air-cooled type
10,824
10,964
Power ouput (ps/rpm)
250/2,500
270/2,200
300/2,200
340/2,200
410/2,100
430/2,100 400/1,900
430/1,900
Torque (kg.m/rpm)
90/1,400
100/1,400
115/1,200
145/1,200
187/1,200
192/1,200 173/1,200
192/1,200
Combustion sequence
1-5-3-6-2-4
1-4-2-5-3-6
CNG
Model
Type
GE08TI
GE12TI
(240 ps)
(290 ps)
(310 ps)
In-line 4-stroke, water-cooled supercharging, air-cooled type
Piston displacement
8,071
Power ouput (ps/rpm)
240/2,300
Torque (kg.m/rpm)
90/1,300
11,051
Combustion sequence
290/2,100
310/2,100
115/1,260
125/1,260
1-5-3-6-2-4
1-10
INTERIOR & EXTERIOR VIEW AND SPECIFICATIONS
Tires and Wheel
Tire size
9.00-20-14PR
9.00R20-14PR
Wheel size
Air pressure Front wheel
(kgf/cm2) Rear wheel
Wheel Torque (kg.m)
Tire size
Wheel Torque (kg.m)
10.00-20-16PR
10.00R20-16PR
7.00T-20
7.7
8.0
7.0
8.1
8.1
7.0
7.3
6.3
7.4
7.4
Steel Wheel : 70~80(10 hole), 70~85(8 hole) / AL Wheel : 60~70(10 hole), 62~70(8 hole)
11.00-20-16PR
Wheel size
Air pressure Front wheel
(kgf/cm2) Rear wheel
10.00-20-14PR
11.00R20-16PR
11R22.5-16PR
7.50V-20
12R22.5-16PR
295/80R22.5-16PR
8.25×22.5
8.4
8.4
8.4
8.4
8.3
7.7
7.7
7.7
7.7
8.3
Steel Wheel : 70~80(10 hole), 70~85(8 hole) / AL Wheel : 60~70(10 hole), 62~70(8 hole)
1-11
2
SAFETY CAUTIONS
1. GENERAL INSTRUCTIONS
Regular Inspections & Maintenance ………… 2-2
Inspections Prior to Driving …………………… 2-2
Tips on Driving a New Vehicle …………… 2-3
2. SAFETY INSTRUCTIONS BEFORE & AFTER DRIVING
Seat Belt ……………………………………… 2-3
Correct Driving Posture ……………………… 2-3
Check for Any Disturbance …………………… 2-3
Check the Tire Condition and Pressure …… 2-4
Check Gauges and Warning Indications …… 2-4
Parking Safety Cautions …………………… 2-4
3. SAFETY CAUTIONS WHEN DRIVING
Do Not Talk on Mobile Phone ………………… 2-5
Do Not Drive with the Doors Open …………… 2-5
Do Not Turn the Engine Off While Driving … 2-5
4. DIRECTIONS FOR THE VEHICLE MAINTENANCE
Use Standard Parts …………………………… 2-6
Directions for Engine Room Maintenance …… 2-6
How to Wash the Car ……………………… 2-6
5. DIRECTIONS FOR TURBOCHARGER INSTALLED VEHICLES
Turbocharger ………………………………… 2-7
6. RISKS AND OTHER CAUTIONS
Do Not Place Flamable or Explosive Articles
in the Car ……………………………………… 2-8
Fire Extinguisher …………………………… 2-8
7. CAUTIONS FOR CNG VEHICLES
Compressed Natural Gas(CNG) ……………… 2-9
CNG Recharge ……………………………… 2-9
Cautions When Driving ……………………… 2-9
Maintenance Directions…………………… 2-10
How to Handle Accidents ………………… 2-10
SAFETY CAUTIONS
1. GENERAL INSTRUCTIONS
Regular Inspections & Maintenance
Regular inspections are vital for
passenger safety and vehicle
maintenance.
CAUTION
Inappropriate maintenance and
installation
of
inappropriate
components could result in reduced
performance or fatal damages.
Inspections Prior to Driving
The inspections are to be done by the
driver prior to driving.
・Check for people or obstructions
around the vehicle
・Fuel, break pressure
・Fulid leakage at the bottom of the
vehicle
・Exterior check-up
・Various lamp conditions
・Horn and wiper condition
Tips on Driving a New Vehicle
First 1,000km is where the vehicle is
acclimated. New vehicle care will bring
out vehicle’
s optimal efficiency and
also lengthen the vehicle life.
・Warm up engine after the ignition
・Avoid sudden star or sudden
acceleration
・Do not exceed the maximum speed.
Reduce speed about 30%.
・Do not bring the vehicle to a sudden
stop.
OM-B020
2-2
SAFETY CAUTIONS
2. SAFETY INSTRUCTIONS BEFORE & AFTER DRIVING
Seat Belt
Ensure that belt is not twisted and the
back of chair is not leaning backward
too much.
Fasten it near to pelvis for lower part of
the belt.
Correct Driving Posture
Check for Any Disturbance
A correct driving posture is when the
center of the body is facing the center
of the handle.
The arms on the handle should be
slightly bent.
The back should be closely laid on the
seat and the feet should be able to fully
step on padals.
The center of the headrest should be
adjusted to eye level.
The seat should be adjusted with the
lever according to the driver’s body
size.
OM-B023
2-3
Remove any disturbance around the
driving seat. It could be extremely
dangerous if objects like cans get stuck
under the pedals.
Mats under the seat must be fixed on
the floor.
Use the ones that are not thick.
SAFETY CAUTIONS
Check the Tire Condition and
Pressure
Check whether the pressure of the tire
and check if there are any ware and
abrasion in the tire.
Upon checking the tire pressure with the
air pressure gauge, if the air pressure
isn’
t enough, make sure the air pressure
is stable.
Check Gauges and Warning Indications
Parking Safety Cautions
Check battery voltage, oil pressure, air
pressure and fuel before driving.
Check if gauges and indications are
fully functioning.
If any faults are found, immediately
take an appropriate action and get
proper maintenance.
Please park at safe locations and
activate parking break, gearshift should
be set on‘1’for uphill and“R”for
downhill and place a stopage at the
back.
OM-B180
OM-B027
REFERENCE
Please refer to“Vehicle Inspection
and Maintenance”(6-35 Page) for
tire inspection details.
OM-B024
2-4
CAUTION
Please avoid parking on steep hill.
Unexpected movement of the vehicle
could result in disastrous accidents.
SAFETY CAUTIONS
3. SAFETY CAUTIONS WHEN DRIVING
Do Not Talk on Mobile Phone
Using mobile phone while driving is a
distraction and is very dangerous.
Please use mobile phones after
properly parking the vehicle.
Do Not Drive with the Doors Open
The vehicle should never move while
the doors are open.
Open the door only when the vehicle is
properly stopped by stepping on the
break or activating the parking break.
WARNING
Do not drive while the doors are
open.
Passangers may fall off the vehicle
and could end up with heavy injuries
or death.
OM-B028
OM-B029
2-5
Do Not Turn the Engine Off
While Driving
Do not turn of start-up switch while
driving.
It could result in reduced break
performance and handling malfunction.
REFERENCE
If the engine stops while driving, do
not panic and reduce the speed
accordingly with break pedal.
The steering becomes heavy when
the engine stops because power
steering pump stops. Strongly grip
the steering handle and park the
vehicle for due inspections.
OM-B032
SAFETY CAUTIONS
4. DIRECTIONS FOR THE VEHICLE MAINTENANCE
Use Standard Parts
Directions for Engine Room Maintenance
Standard components are guaranteed
by us. They will maintain the vehicle
condition for a long time.
We do not compensate any damages
occurred by non-standard components
installed on the vehicle.
※ Standard Daewoo Bus components
are marked with below stickers.
The vehicle will not start-up when the
start-up isolation switch is set on
“OFF”.
Start-up isolation switch should be set
on“STARTER”in order to start the
engine.
Do not use the switch other than
inspection and maintenance purposes.
WARNING
Starter switch lever at “ OFF”
position, when you repair.
OM-B520E
OM-F107
2-6
How to Wash the Car
Close the door or the window.
The bus should be washed from top to
bottom. High pressure water should
used to clean the bottom and inner
fender.
Sponges or such should be used to
clean the surface.
CAUTION
・Engine room should be cleaned
with air.
・Please pay extra care so that water
does not enter the air cleaner
intake.
・Any remaining water on the vehicle
should be removed after washing.
SAFETY CAUTIONS
5. DIRECTIONS FOR TURBO CHARGER INSTALLED VEHICLES
Turbocharger
and maintenance matters before and
after operating the vehicle.
Before operating the vehicle
Do not start driving right after ignition.
You may start driving once you allow
the engine to run for 3 minutes so that
enough oil is supplied to each
lubrication conpartment of the turbo
charger.
●
OM-B399E
As the exhaust gas high pressure and
heat energy spins the turbine fins
which is installed at the exhaust has
exit at a high speed, the compressor
fins which is directly connected to the
turbine axe spins at the same speed to
provide excess fresh air into the engine
cylinder.
Vehicle operating mrthod
Since the turbo charger spins at a high
speed, when engine oil is supplied too
late or too insufficiently, it might bring
harm to the bearing.
It is therefore essential that you follow
the instructions for starting the vehicle
Maintenance method
Since the turbo charger spins at a very
fast speed (50,000~200,000rpm), it is
very sensitive to the dust particles and
other substances from the air, and
pollution and insufficient supply of
engine oil. It is therefore very important
that you pay close attention to its
maintenance.
Maintaining the air cleaner
To prevent the turbo charger’
s compressor’
s
fin and driving section from early
deterioration and breakdown due to
inhalation of dust particles and other
substances, you must regularly clean
and replace the air cleaner element and
also inspect it there is any defect in the
connection hose between the air
cleaner and the turbo charger.
●
After operating the vehicle
Do not turn the car off right after wideopen throttle operation.
When suddenly suspending the engine
at a wide open throttle condition, the
high temperature from the exhaust gas
and oil might cause the turbo charger’
s
lubrication compartment to leak.
You should therefore turn the car off
after 5 minutes of running(idling)
●
Maintaining the engine oil
Always use standard oil and standard
oil filter and adhere to replacement
period intervals.
●
2-7
SAFETY CAUTIONS
6. RISKS AND OTHER CAUTIONS
Do Not Place Flamable or
Explosive Articles in the Car
Explosive, Flamable materials in the
vehicle are potential disasters(Gas
lighter, spray, butane gas can and etc)
when the interior temperature rises.
Remove them immediately from the
vehicle.
They are potentially very dangerous.
Fire Extinguisher
Fire extinguishers should always be
equipped in the vehicle.
If fire occurs within the bus, do not
panic and safely guide the passengers
out. Extinguish the fire afterwards.
How to use the fire extinguisher
a. Face against the wind and remove
the safety pin.
b. Direct the nozle towards the origin of
fire.
c. Grab the handle and spray.
●
2-8
SAFETY CAUTIONS
7. CAUTIONS FOR CNG VEHICLES
Compressed Natural Gas(CNG)
Definition of CNG
Fuel in gaseous state that is stored in
high pressure container by compressing
the natural gas.
●
CNG constituent and character
CNG evaporates quickly in the
atmosphere it is constituted mostly with
methane gas.
CNG liquefaction degree is below -162
degrees. Above this temperature, it will
stay as liquid. CNG is compressed with
high pressure and is used as bus fuel.
●
CNG Recharge
Cautions When Driving
Ignition should be turned off and the
vehicle must be on parking mode when
refueling.
Refueling cannot be performed with
the ignition on.(Pressure : 210kgf/cm2)
WARNING
No
flammable materials should be
・
near the bus since the bus uses high
pressure gas fuel.
・Be careful of any injuries when
handling the fuel since the pressure
difference inside the compressor
container and the atmosphere are
grave and when the gas leaks out
the temperature around it will sharply
drop and cause injury.
・If gas leakage is detected, remove
any flammable materials and stop all
the electrical components.Ventilate
the area.
・In fixing or checking for gas
leakages, follow the stops described
in this manual. If not followed,
serious injuries might occur.
2-9
This vehicle uses compressed natural
gas as fuel, so smoking is not allowed
inside the vehicle.
Refueling can be done up to 210kgf/cm2.
Under the gas pressure of 30kgf/cm2,
the“CNG”lamp light on. This is when
the refueling in needed.
CAUTION
Under 30kgf/cm2 of gas pressure, the
vehicle would not function properly.
SAFETY CAUTIONS
How to Handle Accidents
Maintenance Directions
Lock the manual isolation valve when
changing gas filter or repairung engine.
Repair must be performed after all the
gas are used and the engine come to
natural stop.
Also when checking fuel pipe section
before the manual isolation valve,
close all the gas container valve and
use up the remaining gas. Perform
repair when the pressure gauge points
to“0”.
WARNING
This vehicle’
s fuel line uses maximum
of 210kgf/cm 2, so it might cause
injuries and damages when the parts
are disassembled voluntarily.
Eliminate the remaining gas pressure
before any work.
When vehicular accident occur
When the vehicle is damaged, turn the
engine off, and turn off the main switch
and the emergency isolation switch.
Have the passenger evacuated off the
vehicle.
●
Close the fuel line’
s manual isolation
valve.
Transport the injured to a safe place
and check whether there is a gas
leakage.
CAUTION
Do
・ not touch oil drain plug, oil filter,
and coolant radiator cap with bare
hands when the engine is running.
There is a danger of burn.
・When installing other electrical
components on the vehicle, do not
use the wiring of the compressed
natural gas related parts.
REFERENCE
Frost might be formed around the
gas leakage, because the sudden
pressure expansion causes the
temperature to drop.
2-10
SAFETY CAUTIONS
When fire accident occur
Turn off the engine, and also turn off
the main switch and the emergency
isolation switch. Have the passengers
evacuated off the vehicle.
●
Close the fuel line’s manual isolation
valve.
Notify the authorities immediately.
REFERENCE
Prsssure relief valve is installed in
this vehicle. If the temperature
around this valve rises, the valve will
melt and release gas outside
preventing gas explosion.
2-11
3
DEVICE CONTROL TIPS
1. HOW TO USE THE KEY
Key ………………………………………………… 3-3
Remote Control Key (OPTION) ………………… 3-3
2. HOW TO OPEN&CLOSE THE DOOR
Opening&Closing the Entrance Door …………
Manually Opening&Closing the Entrance Door ……
Driver’s Seat Window(BX212) …………………
Engine Room Door ………………………………
3-4
3-5
3-6
3-6
Luggage Room Door (OPTION) ………………
Side Door …………………………………………
Fuel Inlet …………………………………………
Side Windows ……………………………………
3-7
3-7
3-8
3-9
’
3. DRIVER’
S SEAT
Steering Handle Control and Horn Button …… 3-10
Adjusting Driver’s Seat………………………… 3-11
Seat Belt ………………………………………… 3-17
4. INSTRUMENT PANEL
Speedometer ……………………………………
Engine RPM Meter………………………………
Fuel Gauge ………………………………………
Coolant Temperature Gauge …………………
Air Pressure Gauge ……………………………
Voltmeter …………………………………………
3-20
3-20
3-20
3-21
3-22
3-23
Engine Oil Pressure Gauge ……………………
( EURO II/III, ISM, CNG Engine )
Urea Gauge(EURO IV(DL06,DL08,DV11)) ……
Bulb Check Switch(ABS Self-Diagnosis)…………
Indication Lamps & Warning Lamps …………
3-23
3-24
3-24
3-25
5. SWITCHES
Turn Signal Activation Lever
Light Switch
Subsidiary Brake Switch
Emergency Warning Lamp Switch
Wiper Switch
Intermittence Interval Control Switch
3-36
3-36
3-37
3-38
3-38
3-38
Washer Fluid Switch
Parking Brake
Engine Diagnosis(Self-Diagnosis)
Idle Speed Actuator
Auto Cruise Control (OPTION)
Interior Eletrical Device Switches
3-39
3-39
3-40
3-40
3-43
3-44
6. HEATING, VENTILATION, AND A/C RELATED SWITCH
Automatic Air Conditioner(OPTION)
Air Conditioner (OPTION)
Defroster Controls
Heater
3-55
3-58
3-59
3-60
Preheater (OPTION)
Automatic Ventilation (OPTION)
Side Ventilation (OPTION)
3-60
3-61
3-62
3-63
3-63
Kneeling System (OPTION)
Wheelchair Ramp (OPTION)
Wheelchair Lift (OPTION)
Wheelchair Fixture Belt and Lock-ups
3-65
3-70
3-71
3-72
7. OTHER DEVICES
Audio (OPTION)
Tachograph (OPTION)
Refrigerator/Heating Cabinet,
Water Cooler/Water-Heater(OPTION)
Toilet (OPTION)
3-63
3-64
DEVICE CONTROL TIPS
1. HOW TO USE THE KEY
Key
Remote Control Key (OPTION)
WARNING
Do not use duplicated key.
The starter motor may get damaged
or wiring may catch fire due to
incorrect start up (START → ON).
OM-B341
OM-H239
Please be careful not to lose the key.
Spare keys should be stored in a safe
place.
Door open
The door opens when remote control
button is double pressed within 1.5
seconds. The direction indication blinks
twice.
●
If the key is stolen or lost, entire key
set must be replaced with new ones to
avoid vehicle theft.
Door close
The door opens when remote control
button is double pressed within 1.5
seconds. The direction indication blinks
once
●
CAUTION
The bus key should be with you at all
times even when you are briefly
leaving the bus.
3-3
DEVICE CONTROL TIPS
2. HOW TO OPEN&CLOSE THE DOOR
Opening&Closing the Entrance Door
Front Door Opening and Closing
Getting On
Door Lock
TYPE A
●
●
Getting Off
TYPE A
OM-S095
OM-S007
TYPE B
TYPE B
OM-S083
OM-H209
The door lock can be activated/deactivated with the key.
If the lock is de-activated, you can use
the key(the switch) to open/close the
door automatically.
CAUTION
The lock may get damaged if you
attempt to open/close the door while
the lock is on.
3-4
OM-H008
You can open/close the door
automatically with interior switch.
DEVICE CONTROL TIPS
Manually Opening&Closing the Entrance Door
CAUTION
The air-tank pressure will be
dramatically reduced if you
consecutively open/close the door
while the engine is turned off.
WARNING
・Do never operate the door
open/close switch while driving.
・Pay close attention to approaching
cars, bicycle, motorcycle and people
from behind when opening the door.
CAUTION
Battery may run out if you leave the
・door open automatically for a long
time.
Leave the emergency open/close
lever on manual mode if you are
going to leave the door open.
The automatic door open/close may
・malfunction due to low air pressure
caused by air leakage, if you leave
the bus parked for a long time.
Manually Opening/Closing the Door From Inside the Bus
TYPE A
REFERENCE
Check the position of the open/close
switch and the door status before
setting the lever back on automatic
from manual operation.
If they do not match, set them to
correct positions.
OM-B286
WARNING
Always set the lever on automatic
while driving and set it on manual
only on emergency.
TYPE B
OM-F010
If you set“Manual⇔Automatic”lever
on manual, you can open/close the
door manually.
If the lever is set on automatic, the
door will be controlled by the driver.
3-5
DEVICE CONTROL TIPS
’s Seat Window (BX212)
Driver’
Engine Room Door
Manually Opening the Door From
Outside the Vehicle (BX212)
OM-H210
Set“Manual⇔Automatic”lever, located
inside the door below the driver’
s seat,
on manual mode the door can then be
opened manually.
The door is operated by the driver if the
lever is set on automatic.
OM-H240
OM-H212
Press the lower part of the switch to
lower the window to the left of the
driver’s seat.
Press the upper part of the switch to
raise the window.
If there is a lock, unlock it with a key
and pull the grip to open the door.
Securely close the door and lock it if
there is a locking device.
REFERENCE
・The window will only be operated
with the switch.
・The switch is only functional while
the power is“ON”.
3-6
DEVICE CONTROL TIPS
Luggage Door (OPTION)
Side Door
Driver Lower Door (BX212)
Side Engine Door
OM-H211
Operate the door after unlocking any
existing locking devices.
The Lock/Unlock Switch is located
around the driver’s seat for BX212
type.
The door opens when you pull and
raise the lower part of the door handle.
Securely close the door and lock it with
a key if applicable.
OM-H213
OM-H214
Unlcok any locking device on the door
with a key before operating.
The door opens if you pull and raise
the lower part of the door.
Securely close the door when closing.
Lock it with a key or switch if there is
any locking device.
The door opens if you pull the lower
rear part of the door after unlocking the
locking device.
3-7
CAUTION
At inner part of Driver Lower Door,
you can see a valve for manual door
open/close. Always lock the door to
prevent theft.
DEVICE CONTROL TIPS
Fuel Inlet
Fender Door (BX212)
OM-B042
OM-F017E
The door can be opened if the bolts
holding the Fender Door are taken out.
CAUTION
If the door is not properly opened
and fixed, the door may close and
result in injury.
Unlock the locking device if there is
any.
Pull it to open and open the cap to
refuel.
Close the door and the cap securely
after refuelling.
3-8
CAUTION
・Using unapproved fuels could result
in serious damage to the engine.
Only use approved standard fuels.
・We are not held responsible for any
damages occurred from using
unapproved huels.
・Close the cap securely after
refueling to prevent fire or excess
fuel consumption.
・Do not leave any fuel on the vehicle
surface, the fuel may damage the
painting.
WARNING
・Fuels and fuel vapors are highly
flamable. Keep away any flamable
objects when refueling.
・Park the vehicle on a level ground
and settle the vehicle with parking
break before stopping the engine.
DEVICE CONTROL TIPS
Side Window
Quarter Glass
Side Open Glass
OM-B415
OM-H242
Pull the lock to open.
Close the door securely until you hear
a clicking sound.
Hold the rear part of the lock and pull it
to open.
Close the door and press the rear part
of the fixing device.
CAUTION
Rain water could leak into the
vehicle if the shed is not closed
properly.
3-9
DEVICE CONTROL TIPS
’
3. DRIVER’
S SEAT
Controlling the Wheel and Horn Button
Wheel Operating Point
Turning the wheel by force while a
vehicle is stopped, it cause not only tire
abrasion but also irrational force is
added to each steering system and this
is a factor of defect.
Therefore, do not turn the wheel by
force while a vehicle is stopped.
●
CAUTION
If the wheel is turned and stays with
knocking like this more than 10
seconds while a vehicle is parked, a
problem can be caused include
wheel oil pump sticking.
Controlling method for angle of
the wheel
a. Turn locked wheel to
counterclockwise.
b. Control the position as you want
while you are sitting on the chair in
proper way and move the steering
wheel to the front-back and up-down.
c. Turn locked wheel to clockwise and
fix it completely.
●
Horn Button
Horn button is placed in the middle of
the wheel.
Use it in unexpected or dangerous
situation while you are driving.
●
WARNING
If you control angle of the wheel
while you are driving and lost control
of its operation, it can be cause
unexpected accident.
OM-B043
OM-B431
3-10
OM-H012
DEVICE CONTROL TIPS
Controlling Driver s Seat
CAUTION
Do not place a sharp or heavy items
on the seat.
Do not use organic solvents(thinner,
benzene, alcohol, gasoline) to clean
the seats.
WARNING
Adjusting the seat while driving is
dangerous. Adjust the seat before
you begin to drive.
Protection effect will be decreased if
the back of a seat leaned too much
to backward.
Always set up the back of the seat
straight and seat in right posture
because one can have serious injury
or lose life from body slipping under
the safety belt in a clash accident.
Check the comfort level after you
adjust the seat.
Do not place anything that can be
disturbance to driving around the
driver’s seat.
Adjust the seat so that seat belt does
not get in the way.
3-11
REFERENCE
If makes easy to enter and leave
because the height gets down when
you leave the seat. And when driver
is seated the height is a adjusted
depends on the weight.
DEVICE CONTROL TIPS
■ Air Suspension Driver s Seat (Standard Type)
Seat Pan Angle Adjustment
Backrest Adjustment
Fore/Aft Adjustment
OM-F121
OM-F122
OM-F123
The fore/aft adjustment can be
adjusted by pulling the locking handle
and by simultaneously sliding the seat
foreards or backwards. The seat must
lock into place with an audible click
when the lever is released.
Pull up the locking lever to release the
backrest catch. The backrest is
brought into the desired position by
simultaneously exerting or relieving
pressure. Release the locking lever to
lock the backrest.
To adjust the angle of the seat pan,
pull the left handle upwards. The seat
pan can be moved to the desired
position by simultaneously pressing or
relieving the seat to the front or to the
rear
REFERENCE
Adjustment travel : 200 mm in steps
of 10 mm each.
REFERENCE
It should not be possible to move the
backrest into another position after it
has been locked.
REFERENCE
The adjustment angle can be
adjusted within a range between -6°
and +10°
.
3-12
DEVICE CONTROL TIPS
Lumbar Support
Height Adjustment
OM-F124
OM-F162
Pull or press the handle for height
adjustment to move the seat upwards
or downwards.
With the front(1) and back(2) switch
the curvature in the upper and lower
area of the backrest upholstery can be
adjusted individually.
The air compartments will be filled by
setting the respective switch to“+”and
emptied by setting it to“-”.
REFERENCE
・The seat height can be adjusted
continuously within a range of 100
mm.
・Always release the handle after
reaching the upper or lower stop.
3-13
DEVICE CONTROL TIPS
■ Air Suspension Driver s Seat (Multi-Function Type)
Seat Pan Angle Adjustment
Backrest Adjustment
Fore/Aft Adjustment
OM-F021
OM-F022
OM-F023
The fore/aft adjustment can be
adjusted by pulling the locking handle
and by simultaneously sliding the seat
foreards or backwards. The seat must
lock into place with an audible click
when the lever is released.
Pull up the locking lever to release the
backrest catch. The backrest is
brought into the desired position by
simultaneously exerting or relieving
pressure. Release the locking lever to
lock the backrest.
To adjust the angle of the seat pan,
pull the left handle upwards. The seat
pan can be moved to the desired
position by simultaneously pressing or
relieving the seat to the front or to the
rear.
REFERENCE
Adjustment travel : 200 mm in steps
of 10 mm each.
REFERENCE
It should not be possible to move the
backrest into another position after it
has been locked.
REFERENCE
The adjustment angle can be
adjusted within a range between -6°
and +10°
.
3-14
DEVICE CONTROL TIPS
Vertical Shock Absorber Adjustment
Height Adjustment
Seat Depth Adjustment
OM-F024
OM-F025
OM-F163
To adjust the depth of the seat cushion,
pull the right handle upwards. By
moving the seat cushion, backwards or
forwards the desired seating position
can be reached.
Pull or press the handle for height
adjustment to move the seat upwards
or downwards.
The vertical vibration behavior of the
seat can be adjusted continuously from
soft to hard by using the turning knob.
REFERENCE
Adjustable within a range of 60 mm
in 6 steps.
REFERENCE
・The seat height can be adjusted
continuously within a range of 100
mm.
・Always release the handle after
reaching the upper or lower stop.
3-15
1 = Soft shock absorption
2 = Medium shock absorption
3 = Hard shock absorption
DEVICE CONTROL TIPS
Lumbar Support
Lateral Support Adjustment
Quick Lowering
OM-F027
OM-F030
OM-F164
By pressing the key and locking it, the
seat can be lowered to the lowest
position.
By actuating the switch, the curvature
of the lateral guide right and left of the
backrest can be adjusted individually
by means of compressed air.
By setting the switch to“+”, the air
compartments will be filled. By setting
it to“-”, they will be emptied.
With the front(1) and back(2) switch
the curvature in the upper and lower
area of the backrest upholstery can be
adjusted individually.
The air compartments will be filled by
setting the respective switch to“+”and
emptied by setting it to“-”.
CAUTION
By pressing the key again and
releasing it, the seat will be lifted
back to the driving position.
3-16
DEVICE CONTROL TIPS
Seat Belt
Seat Heater (OPTION)
’
Seat belt for driver’
s seat
The warning buzzer and warning light
on dashboard will turn on when you
are not fasten driver’
s seat belt while
main switch is“ON”.
OM-F033
By operating the seat heater switch,
the heating mats in backrest and seat
cushion can be heated in two heating
steps.
・Catch a latch plate(1), pull it over the
shoulder and fix to buckle(2).
・Ensure that belt is not twisted and
the back of chair is not leaning
backward too much. Fasten it neer to
pelvis for lower part of the belt.
・The belt will placed to original position
when you press red button on the
buckle to release the seat belt.
OM-B049
OM-F127E
OM-B050
3-17
DEVICE CONTROL TIPS
’
Safety belt for passenger’
s seat
Just fasten pelvis and ensure that belt
is not twisted. Insert latch plate buckle
until you hear a click sound.
Press red button on the buckle to
release the belt.
OM-B051
WARNING
・Do not add on any additional
devices on the seat belt. It could
reduce the safety of the seat belt.
・Do not wear the seatbelt loosely.
・Check the seatbelt and related
parts for safety reasons. If any
faults are found, immediately get a
repair before driving.
・The waist part of the seat belt must
be worn below stomach level.
・Children, pregnant ladies, injured
and disabled must wear seat belts
as well.
・Injured people or pregnant people
should consult doctors before
wearing seat belts.
OM-B052
3-18
DEVICE CONTROL TIPS
4. INSTRUMENT PANEL
OM-H215
1. Air Pressure Gauge (Front)
2. Engine Coolant Temperature Gauge
3. Fuel Gauge
4. Engine Oil Pressure Gauge
(EURO II/III, ISM, CNG Engine)
5. Urea Gauge
(EURO IV Engine (DL06,DL08,DV11))
6. Air Pressure Gauge (Rear)
7. Speedometer
8. Turn Signal
3-19
9. Bulb Check Switch
(ABS Self-Diagnosis Switch)
10. Engine RPM Meter
11. Pilot Indicator Lamp
12. Illumination Controller
DEVICE CONTROL TIPS
Speedometer
Fuel Gauge
Engine RPM Meter
OM-H216
OM-S011
Vehicles with different options come
with different models of tachometers.
This meter indicates the engine’s
rotation speed. Shift gears within
appropriate RPM range in order to
prevent the engine from overloading.
The speedometer uses km/h to
indicate the distance the vehicle travels
in an hour period.
CAUTION
The
engine can be damaged if it is
・
operated at excessive speed.
・The RPM meter should not reach
the red zone.
REFERENCE
This engine RPM meter does not
apply to the vehicles with tachograph
that include internal engine RPM
meter.
3-20
OM-B056
Diesel Vehicles
This gauge indicates the remaining fuel
amount in the fuel tank, and should be
refilled when the indicator indicates
near the“E”line.
Always operate the vehicle with
sufficient fuel.
●
DEVICE CONTROL TIPS
Coolant Temperature Gauge
CNG Vehicles
The gauge indicates the remaining
amount of compressed natural gas
(CNG) in the gas tank
(Unit : kgf/cm2)
Fuel
Remaining
Status
Indicator
Pressure
●
F
210
Full Tank
Mid-point
103
Based on
when the
gas tank’s
temperature
is 13℃.
E
21
Short on gas
REFERENCE
・Since the vehicle consumes
gaseous fuel, the pressure varies
according to the storage tank’
s
temperature. Therefore, the value
indicated in the instrument panel is a
converted amount of fuel based
on the gas tank’s pressure and
temperature by the engine’
s
ECM(Electronic Control Module),
and is displayed in the gas fuel
gauge.
・The gas pressure gauge installed
next to the gas cap indicates only
the pressure of recharged gas in
the gas tank, with no relation to its
temperature.
•Conversion of Unit of Pressure
1 kgf/cm2 = 14.22 psi = 0.98 bar
210 kgf/cm2 ≒ 3,000 psi ≒ 207 bar
3-21
The thermometer indicates the
temperature of the engine’s coolant,
and should indicate below the red zone
during operation of the vehicle.
The engine may be over heated when
the indication is pointing at red area.
Park the car and leave the engine on
and then leave the engine to cool off
itself. If there is not enough coolant,
open the surge tank cap and refill the
coolant.
Wrap the surge cap with a cloth and
slowly turn it to open so that inner
pressure is gradually released
CAUTION
The interior of the engine may crack
if you pour cold coolant into the
system too quickly.
WARNING
Do not open the radiator cap when
the engine is overheated. Hot
coolant may overflow and may result
in injury.
DEVICE CONTROL TIPS
Air Pressure Gauge
Air Pressure Gauge (Rear)
Air Pressure Gauge (Front)
CAUTION
Make sure the indicator of the gauge
is within the normal range before
operating the vehicle.
OM-B053
OM-B054
This gauge indicates the air pressure
in the front brake air tank, and should
indicate 8~9 kg/cm 2 during normal
operation of the vehicle.
This gauge indicates the air pressure
in the rear brake air tank, and should
indicate 8~9 kg/cm 2 during normal
operation of the vehicle.
3-22
WARNING
Frequent breaking will reduce the air
pressure drastically. Always maintain
safe distance.
When the indicator indicates below
5.3 kg/cm2 during vehicle’
s operation,
the warning lamp turns on and alarm
sounds. As continuous operation with
the air pressure warning lamp lit may
result invehicle’
s lower braking
capability, it may lead to an accident.
You should park the vehicle on a
close road, inspect the vehicle for
any possible cause of the drop in air
pressure, and operate the vehicle
when the air pressure recovers.
DEVICE CONTROL TIPS
Voltmeter
Engine Oil Pressure Gauge ( EURO II/III, ISM, CNG Engine )
OM-B283
OM-B057
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 oil
pressure, and is considered normal if it
indicates 0.7~1.0 kgf/cm 2 during
engine’
s idling, and 2.1~3.5 kgf/cm 2
during mid-speed rotation.
Inspect the amount and the oil
pressure systems of the engine oil if
the pressure level falls below the
normal range.
A warning lamp turns on and an alarm
sound when the vehicle has insufficient
amount of engine oil or when the oil
pressure falls.
3-23
WARNING
Engine oil pressure warning lamp
turns on when the vehicle has
insufficient amount of engine oil. If
the vehicle is continuously operated
with the warning lamp lit, the engine
can be burnt as a result. Therefore,
the vehicle must be parked,
inspected on its oil levels, and sent to
a close repair shop immediately for
further inspection.
DEVICE CONTROL TIPS
Urea Gauge
( EURO IV (DL06,DL08,DV11) )
Bulb Check Switch
(ABS Self-Diagnosis Button)
OM-B426
OM-H218
If the urea capacity decrease down to
lower than 10%, indication will warn
you. Please refull the fluid when the
indication is on.
This switch turns on some of the lamps
in the instrument panel and an alarm.
WARNING
・If you continue driving when the
urea level is lower than 5%, it may
result in output power engine parts
may be affected negatively.
・please use ureas that our company
recommend.
REFERENCE
If you want to check if the guage
lamps are functional, check it with
bulb check switch.
Please refer to page 7-61 for ABS
self diagnosis.
REFERENCE
Recommended urea : DIN V 70070-05
3-24
DEVICE CONTROL TIPS
Indicator & Warning Lamps
OM-B523
※ The indicator and warning lamps for options that are not applicable to your vehicle or that are not selected by the owner do
not operate.
3-25
DEVICE CONTROL TIPS
Upper Pilot Indicator Lamps
Position
Name
Lower Pilot Indicator Lamps
Color
Position
Name
Color
A1
Seat Belt Warning Lamp
Red
A3
Windshield Fan Operation Indicator Lamp
Amber
B1
Engine Coolant Warning Lamp
Red
B3
Subsidiary Brake Operation Indicator Lamp
Amber
C1
Engine Oil Pressure Warning Lamp
Red
C3
Retarder System Warning Lamp
D1
Air Pressure Warning Lamp
Red
D3
Retarder System Operation Lamp
E1
Front Wheel Brake Air Pressure Warning Lamp Red
E3
Aftertreatment Filter Warning Lamp (ISM Engine)
F1
Rear Wheel Brake Air Pressure Warning Lamp
Red
F3
Neutral Gear Position Indicator Lamp
Green
G1
Parking Brake Air Pressure Warning Lamp
Red
G3
A/C Warning Lamp
Amber
H1
Parking Brake Operation Indicator Lamp
Red
H3
Engine Warning Lamp
Amber
A2
Battery Recharge Warning Lamp
Red
A4
Engine Door Open Warning Lamp
B2
Insufficient Fuel Warning Lamp
Amber
B4
ABS Warning Lamp
Amber
C2
Air Dryer Operation Indicator Lamp
Red
C4
ASR Warning Lamp
Amber
D2
Auto Greaser Operation Indicator Lamp
Green
D4
Rear Wheel Brake Pad Warning Lamp
Red
E2
High Beam Operation Indicator Lamp
Blue
E4
Engine Aftertreatment Warning Lamp
Red
F2
Engine Pre-heating Operation Indicator Lamp
Amber
F4
Front Fog Lamp Operation Indicator Lamp
Green
G2
Entrance Door Open Indicator Lamp
Red
G4
Rear Fog Lamp Operation Indicator Lamp
Amber
H2
Passenger Stop Indicator Lamp
Amber
H4
Emergency Door Open Warning Lamp
3-26
Red
Amber
Red
Red
Red
DEVICE CONTROL TIPS
Seat Belt Warning Lamp
The lamp turns on when the driver is not
wearing the seat belt.
If the driver is not wearing the seat belt
OM-B377 after the main switch has been moved to
the“ON”position, the alarm sounds and the warning lamp
light up in the instrument panel.
Although the alarm stops when the driver starts the engine
without wearing the seat belt, the warning lamp in the
instrument panel remains continuously turned on.
Engine Coolant Warning Lamp
The warning lamp turns on and the
alarm sounds when the vehicle has
insufficient coolant or when the coolant’
s
temperature is over 98℃.
CAUTION
If the vehicle’
s engine coolant thermometer indicates high
temperature, always wait until the coolant cools down
while continuously having the engine operate.
Engine Oil Pressure Warning Lamp
The lamp turns on when the battery
main switch is in the“ON”position, and
turns off when the engine starts and the
engine oil pressure reaches over the
2
OM-B365 suggested level (0.6 kg/cm ).
The lamp turns on and the alarm sounds when the vehicle
has insufficient engine oil or when there’
s a drop in the oil
pressure.
Upon such incident, park the vehicle on a flat road, turn of
the engine, wait for about 10 minutes, and check the amount
of engine oil by observing the engine oil level gauge. If it
indicates insufficiency, supplement your engine oil.
OM-B421
Check the temperature indicator in the instrument panel and
if the temperature has risen over the red zone, park your
vehicle on the lane and maintain the engine station speed at
the idle speed while continuously having the engine operate.
3-27
WARNING
If you continue to drive while the oil pressure warning
indication is on, it will result in critical damages in engine
system.
You must park the vehicle and check the oil level before
visiting a nearest service center.
DEVICE CONTROL TIPS
Air Pressure (Subsidiary, Suspension) Warning Lamp
Air Tank (Parking Brake) Air Pressure Warning Lamp
TYPE A
TYPE A
TYPE B
OM-B372
OM-B524E
TYPE B
OM-B371
The lamp turns on when the air pressure drops below about
5.3 kgf/cm2, indicating that the subsidiary and suspension
system air tanks have insufficient air.
OM-B525
The lamp turns on when the air pressure falls below 6.2
kgf/cm2 due to insufficient air in the parking brake tank, while
the lamp flickers when the air pressure falls below 4.2 kgf/cm2.
Air Tank (Front Wheel) Air Pressure Warning Lamp
The lamp turns on when the air pressure
falls below 5.3 kgf/cm2 due to insufficient
air in the front wheel brake tank.
OM-B369
Air Tank (Rear Wheel) Air Pressure Warning Lamp
The lamp turns on when the air pressure
falls below 5.3 kgf/cm2 due to insufficient
air in the rear wheel brake tank.
OM-B370
3-28
REFERENCE
Parking brake is applied using the spring power of the
spring power of the spring brake chamber, and only
applies to the rear wheels.
WARNING
Operate the vehicle with recommended safe distance to
other vehicles, since frequent application of the brake
results in a sudden drop in the air pressure.
DEVICE CONTROL TIPS
Parking Brake Operation Indicator Lamp
The lamp turns on in the instrument
panel when the parking brake applicator
is operated during parking after vehicle’
s
operation.
OM-B373 Operate the vehicle after making sure
that the lamp has been turned off by releasing the parking
brake.
Battery Recharge Warning Lamp
The lamp turns on when the battery
main switch is in the“ON”position, and
turns off when the engine starts.
When the lamp continuously turns on
OM-B368 during operation of the vehicle, park on
a close lane, turn off the battery main switch, turn the switch
to the“ON”position, and start the engine again. If this
happens continuously, inspect you vehicle’s recharging
system.
Auto Greaser Operation Indicator Lamp
The lamp turns on when the auto
greaser device is operate.
Auto greaser operation time depends on
the control operation time of each auto
OM-B212 greaser model.
Insufficient Fuel Warning Lamp
The lamp turns on when there
insufficient fuel in the vehicle. When the
lamp turns on, immediately refill fuel.
The lamp turns on in CNG vehicles
OM-B416 when the remaining gas pressure of the
gas tank drops below 30kgf/cm 2. Upon such incident,
recharge the tank with CNG fuel.
CAUTION
If the remaining gas pressure falls below 10 kgf/cm2 in
CNG vehicles, the vehicle may have insufficient output
power of the engine due to the lack. Restarting the engine
may be difficult when the engine has turned off.
Air Dryer operation Indicator Lamp
TYPE A
TYPE B
OM-B083
OM-B527E
The lamp turns on upon the activation of the heater of the air
dryer.
3-29
DEVICE CONTROL TIPS
High Beam Operation Indicator Lamp
The lamp turns on upon operation of
high beam lamps.
Entrance Door Open Indicator Lamp
TYPE A
OM-B354
TYPE B
TYPE C
OM-B528
OM-B079
OM-B529E
The lamp turns on when the entrance door is open.
WARNING
Immerdiately convert to low beam lamps when a vehicle is
approaching from the other direction. High beams can
distract the approaching vehicle driver’s view instantly,
which may cause unexpected accident.
Passenger Stop Indicator Lamp
TYPE A
Engine Pre-heating Operation Indicator Lamp
The lamp is indicates the pre-heating
state of the diesel engine.
Diesel engine powered vehicles must
wait with key in the“ON”position when
OM-B347 this lamp turns on, and start the engine
when the lamp turns off.
Windshield Fan Operation Indicator Lamp
The lamp turns on when the windshield
fan switch is turned on.
TYPE B
OM-B378
OM-B530E
The lamp turns on with a buzzer when a passenger presses
the stop button inside the vehicle.
REFERENCE
The lamp turns off after the entrance doors have been
opened and closed.
Subsidiary Brake Operation Indicator Lamp
The lamp turns on when subsidiary
(Exhaust, Jake) brake is operate.
OM-B418
OM-B361
3-30
DEVICE CONTROL TIPS
Aftertreatment Filter Warning Lamp (ISM Engine)
The indication is on when there is
excess amount of foreign substances in
the aftertreatment filter.
You must imeediately refresh the
OM-B425 aftertreatment filter when the indication
is on.
Retarder System Operation Indicator Lamp (Amber)
TYPE A
TYPE B
OM-B420
OM-B531
Applicable to vehicles equipped with a retarder. The lamp
turns on when the brake are applied.
Aftertreatment Filter Regeneration Working Lamp
The indication is on when the
aftertreatment filter is refreshing.
CAUTION
Since retarder brakes function as subsidiary brakes, they
must be used to reduce speed, while brake pedal must be
used for full stoppage.
OM-B346
Neutral Gear Position Indicator Lamp
The lamp turns on when the gear is in
the neutral position “N”
(
).
REFERENCE
Refer to page 4-23 for more information of the aftertreatment
filter.
Retarder System Warning Lamp (Red)
TYPE A
TYPE B
OM-B420
OM-B417
OM-B531
Applicable to vehicles equipped with a retarders. The lamp
turns on when a problem occurs in the retarder brake
system.
3-31
WARNING
Start the engine after making sure that the gear is shifted
to the neutral position “N”
(
). Manual transmission vehicles
may abruptly move forward and lead to an unexpected
accident.
DEVICE CONTROL TIPS
Engine Warning Lamp (Amber)
A/C Warning Lamp
During the operation of A/C, if the
refrigerant pressure drops or rises
excessively, the A/C compressor clutch
is cut off with failure in operation.
TYPE A
OM-B422
OM-B343
Upon such incident, the lamp turns on.
While the A/C automatically restarts itself from the
emergency stoppage when it recovers the refrigerant
pressure from low level to normal level, it must be restarted
after turning it“OFF”and waiting for about 10 minutes if it
was stopped from high refrigerant pressure.
It is selectively applicable depending on the A/C activation
switch type.
TYPE B
OM-B359
WARNING
Continuous operation of the vehicle with this lamp turned
on may result in damage in the electronic control system,
therefore you should get inspection and maintenance
within a close time.
TYPE C
OM-B532
OM-B533E
OM-B097
The lamp Turns on in the instrument panel when the main
switch is pressed and the key is in the“ON”position, and
turns off when the engine is started.
The lamp remains turned off while the engine is in normal
condition.
If the problem in the engine is temporary, the lamp turns off
as soon as the problem is solved.
Engine Door Open Indicator Lamp
TYPE A
TYPE B
Master Switch
The lamp turns on when the master
switch is turned on.
The lamp turns on when the engine room door is open.
WARNING
Do not start the engine or operate the vehicle while this
warning lamp is turned on. An individual can be working in
the engine room.
OM-B106
3-32
DEVICE CONTROL TIPS
ABS Warning Lamp
The lamp turns on when the key is in the
“ON”position.
If the lamp turns on during operation of
the vehicle, it means that there’s some
OM-B374 problem in the ABS system.
REFERENCE
Regular brakes function perfectly even when the warning
lamp is turned on during the operation of the vehicle.
Engine Aftertreatment Warning Lamp (Red)
● EURO IV Engine (DL06,DL08,DV11)
The indication is on when SCR
(Aftertreatment) malfunctions. The
indication is on when urea tank capacity
OM-B344 falls down to 10%.
Refill urea and if the indication is still on, visit the nearest
service center.
● ISM Engine
The indication is on when there is a problem with the
engine system.
You must visit the nearest service center if the indication is
on.
ASR System Warning Lamp
The lamp turns on when the key is in the
“ON”position.
Applicable only to the vehicle equipped
with ASR system. The lamp turns on
OM-B419 upon activation of ASR.
The lamp turns on during the initial start of the engine, and
turns off upon application of the brake pedal.
REFERENCE
ASR makes it possible for the vehicle to escape from a
situation in which one wheel of the driving wheels has
slipped (on ice or sand) and the driver is having difficulties
in moving the vehicle due to the wheels skidding, by fixing
only one side of the wheels.
WARNING
If you continue to drive with lower than 5% urea capacity, it
may result in reduced power and damaged aftertreatment
parts.
Tail Lamp Activation Indicator Lamp
The lamp turns on when the tail lamp is
activated.
OM-B352
3-33
DEVICE CONTROL TIPS
Front Fog Lamp Operation Indicator Lamp
The lamp turns on together with the front
fog lamp upon operation of the front fog
lamp switch.
Low Beam Operation Indicator Lamp
The lamp turns on when the leadlight is
activated.
OM-B433
OM-B353
Rear Fog Lamp Operation Indicator Lamp
The lamp turns on together with the rear
fog lamp upon operation of the rear fog
lamp switch.
Speed Control Device Warning Lamp
The lamp turns on when the vehicle is
operated over the speed limit while the
speed control device is in activation.
OM-B356
OM-B091
Emergency Door Open Warning Lamp
Speed 1 Indication
TYPE A
TYPE A
TYPE B
OM-B291
TYPE B
OM-B535
OM-B534E
The indicator lamp Turns on when the emergency door is
opened. If the lamp turns on even after closing the door,
check the door lock and lock the door firmly.
OM-B536E
At the vehicle speed in 0~5 km/h the lamp turns on, also the
left Yellow-Green marker lamp on the roof at the front of the
vehicle, lights on.
3-34
DEVICE CONTROL TIPS
Rear Door Operation
The indicator lamp turns on when the
rear door is opened.
Speed 2 Indication
TYPE A
TYPE B
OM-B537
OM-B542
OM-B539E
At the vehicle speed in 80 km/h the lamp turns on, also the
middle Red marker lamp on the roof at the front of the
vehicle, lights on.
Front Emergency Valve Operation
The indicator lamp turns on while the
front emergency valve operation.
Speed 3 Indication
TYPE A
TYPE B
OM-B543
OM-B538
OM-B540E
At the vehicle speed in 0~5 km/h the lamp turns on, also the
left Yellow-Green marker lamp on the roof at the front of the
vehicle, lights on.
Middle Emergency Valve Operation
The indicator lamp turns on while the
middle emergency valve operation.
OM-B544
Middle Door Operation
The indicator lamp turns on when the
middle door is opened.
Rear Emergency Valve Operation
The indicator lamp turns on while the
rear emergency valve operation.
OM-B541
OM-B545
3-35
DEVICE CONTROL TIPS
5. SWITCHES
Turn Signal Activation Lever
OM-B109
Pushing the lever flickers the right turn
signal lamps and pulling it flickers the
left turn signal lamps.
It activates both turn signal lamps on
vehicle’s exterior and those on the
instrument panel, and indicates turn or
lane change signals to other vehicles.
CAUTION
Leaving the turn signal lamps
activated while the engine is turned
off may discharge the battery.
Light Switch
REFERENCE
・Turning the steering wheel to make
the turn and returning it to its
original position to complete the
turn while the lever is activated,
automatically lead the lever to its
original position and the indicator
lamps to turn off also.
・Replace the signal lamp bulb when
it fickers faster than normal speed,
since it indicates that the bulb is
out.
・If you operate the turn signal lamp
while the light switch is in the 1st or
the 2nd mode, the cornering lamps
are also activated on vehicles
equipped with cornering lamps.
3-36
OM-B110E
The light switch operates by turning the
switch to 1st and 2nd modes, and the
lights work as follows.
•OFF : Turned off
•1st mode : Sidelights, Tail Lights,
Instrument Panel Lights,
License Plate Lights.
•2nd mode : Headlights, Sidelights,
Tail Lights,
Instrument Panel Lights,
License Plate Lights.
DEVICE CONTROL TIPS
Subsidiary Brake Switch
REFERENCE
・Operating the light switch to the
2nd mode turns on the low beam
activation inducator lamp in the
instrument panel.
・Fog lamps and destination lamps
can be operated separately in 1st
or higher modes.
・Parking lamps can be activation
separately from the light switch
using another switch.
OM-B409E
OM-B112
High Beam Headlamps :
Pulling down the lever while
headlamps are activated (light switch
in 2nd mode) turns on the high beam
headlamps and also the high beam
activation indicator lamp in the
instrument panel.
● Passing :
Independent of the light switch,
pulling up the lever turns on the high
beam headlamps, and releasing it
returns the lever to its original
position and turns of the headlamps.
Pulling the lever spplies the subsidiary
brake and turns on the indicator lamp
in the instrument panel.
●
3-37
Refer to page 4-19 for Subsidiary
break.
DEVICE CONTROL TIPS
Emergency Warning Lamp Switch
Wiper Switch
Intermittence Interval Control Switch
OM-B113
OM-B114E
OM-B115
Pushing this lever up flickers all front /
rear and right / left turn signal lamps,
informing other vehicles for caution.
Operate the windshield wipers in 3
steps by turning the tip of the right
lever.
CAUTION
Turn signal lamps do not operate
while emergency warning lamp is in
activation. Therefore, make turns
and lane changes with caution and
attention to the vehicles and the
situation around you while the
emergency warning lamp is in
activation, to prevent unexpected
accidents from occurring.
Turn the middle section of the lever to
control the intermittence interval of the
wipers while the wiper switch is in the
“INT”position.
•OFF : Wipers are not activated.
•Step 1 : Intermittent activation of
wipers (INT)
•Step 2 : Low speed activation of
wipers (LOW)
•Step 3 : High speed activation of
wipers (HIGH)
3-38
DEVICE CONTROL TIPS
Washer Fluid Switch
Parking Brake
TYPE A
TYPE B
OM-B116
Press the button on the tip of the lever
to spray washer fluid onto the
windshield. Single operation of the
switch automatically activates the
wipers 2~3 times.
OM-B546
When the switch is pushed, the parking
brake is actuated and the indicator
lamp comes on. Pushed one more the
switch, release the brake. Make sure
that the indicator lamp is off before
driving off.
OM-B117E
Pull the parking brake application
valve’s lever and fix the lever using
the LOCK button to have the vehicle in
a parked state. The parking indicator
lamp turns on in the instrument panel
when the key switch in the “ON”
position.
Pull the parking brake application
valve’s LOCK button up and push it
together with the lever to release the
parking brake.
3-39
DEVICE CONTROL TIPS
Engine Diagnostic (Self-Diagnosis)
Idle Speed Actuator
TYPE A
CAUTION
The warning alarm sounds when the
engine is turned off without applying
the parking brake upon parking of
the vehicle. Always apply the parking
brake when parking the vehicle to
prevent the vehicle from moving.
OM- S111E
The button is used during engine
inspection, repair, and maintenance.
The installed location may defer
depending on the vehicle type.
The engine warning lamp flickers while
the button is pressed with the engine
turned off, the battery main switch
positioned in the“ON”position, and
the key turned to the“ON”position.
The number of indcation blinks inform
you the faults of the vehicle.
Refer to“Engine Diagnostic”of Simple
Faulty Diagnosis for more details.
3-40
OM-B547
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.
CAUTION
Always operate the engine speed
actuator while the engine is running
and adjust it in the idle state.
DEVICE CONTROL TIPS
Put the switch to“FAST ILDE”only
when operating the A/C while the while
the vehicle is parking for a long period,
or when trying to raise the indoor
temperature during the winter seasons.
TYPE B
•IDLE (Down) : 550~650 rpm.
•FAST IDLE (Up) : 700 rpm.
OM-S015E
CAUTION
CNG buses run on electronically
controlled engines which enables
rthe engine ECM to automatically
control its engine idle rotation speed.
As a result, the switch should be in
the“IDLE”position during regular
use of the vehicle.
TYPE C
OM-H222E
This switch selects the engine idle
rotation speed (RPM).
3-41
REFERENCE
During the operation of the vehicle,
having the idle selection switch in the
“FAST IDLE”position results in
lower fuel efficiency, wearing of
clutch disk, wearing of each parts
due to the high rotation of the engine.
Consequently, always operate the
vehicle with the switch in the“IDLE”
position.
DEVICE CONTROL TIPS
Setting the new idle rotation value
TYPE D
Press the Save/Return switch changing
the rotation value.
OM-S018E
When the value is set by pressing the
Save/Return switch, the lastly set value
is maintained even after the following
srating of the engine.
Adjusting the idle rotation value
DL06, DL08, DV11 Engine
While holding the brake pedal, press
the save/return switch for 1 second,
and then push the idle control switch
upwards to increase engine rotation
value and downwards to decrease
engine rotation value.
●
ISM Engine
Push the idle control switch upwards to
increase engine rotation value and
downwards to decrease engine
rotation value.
●
When the engine si turned off without
pressing the Save / Return switch, it
returns to the initial value.
You must repeat the idle rotation value
changing procedures by pressing the
Save / R eturn switch to change the
engine rotation value when wanting to
return to the initial value after having
set a new idle rotation value.
3-42
●
Releasing the adjustment of idle
rotation value.
Release the brake pedal or press the
Save / Return switch.
CAUTION
Always operate the engine speed
actuator while the engine is running
and adjust it in the idle state.
WARNING
Do not operate the speed actuator
while driving as it change the speed
which is dangerous.
DEVICE CONTROL TIPS
Auto Cruise Control (OPTION)
・Pressing the Cruise Switch once
results in increase or decrease of 1
step in speed, and holding them
results in continuous increase or
decrease of speed.
Releasing Cruise Control
Press the Cruise Switch“OFF”.
OM-H223E
Auto Cruise Function
This function allows the vehicle to
maintain a driver set speed.
Operating Process
・Speed range for cruise control :
40~100 km/h.
・Step on acceleration while the
Cruiser Switch is“ON”. If you reach
desired speed.
Press Idle Control Switch upward or
donward.
・While on Cruiser mode, pressing Idle
Control Switch upward will increase
the speed and downward will
decrease the speed.
Automatic Releasing Cruise Control
・Upon a fault in cruise control related
switches.
・Upon application of a fault in the
brake pedal.
・Upon application of the clutch pedal.
・Upon activation of the Jake/Exhaust
brake.
・Upon opening of a door.
・When the vehicle’s speed is below
40 km/h.
・Upon a fault in the vehicle speed
sensor.
・When the number of engine rotation
is greater than that of high idle
rotation.
3-43
・When the gear is too low.
・upon sudden acceleration/deceleration.
・When gear shifting is necessary to
go up a hill.
REFERENCE
Upon application of the accelerator
pedal during cruise operation, the
cruise function is temporarily released.
The cruise operation function is
resumed when the vehicle’s speed
decreases from the acceleration to
the previously set cruise speed.
After the cruise control has been
released, pressing the Resume
Switch at a speed over 40 km/h
results in a cruise control at the
finally set speed.
After pressing the Cruise switch
“OFF”, if the cruise speed is not
reset, the Save / Return Switch does
not activate the system.
DEVICE CONTROL TIPS
Interior Electronic Sub Assemblies Related Switch
Battery Main Switch
Front Entrance Switch
CAUTION
Be aware of the fact that turnring the
switch off while the engine is
operating not only fails to recharge
the battery but also brings damage
to the vehicle’s electronic sub
assemblies.
OM-B342
OM-S124
This switch controls power to every
electronic device excluding the parking
lamps, the emergency warning lamps,
the entrance door, and the lock.
Turn on the switch before starting the
engine so that the main power is
provided.
Turn off the battery main switch by
pressing it again after turning off the
engine when parking the vehicle after
operation.
OM-B393
Can open and close using switch.
3-44
DEVICE CONTROL TIPS
Middle Entrance Switch
Emergency Fuel Cut-off Switch
OM-S125
OM-B435
※Only applicable to CNG vehicles.
The switch manually cuts off the fuel
supply to the engine.
Operate the vehicle with the switch in
the“ON”position for regular use, and
activate it only in dangerous situations
(accident) or during repair and
maintenance.
OM-B434
Can open and close using switch.
CAUTION
The engine turns off automatically it
the switch is accidentally activated to
the “ OFF” position during the
vehicle’s operation, since it cuts the
fuel supply to the engine. Restart the
engine after returning the switch to
the“ON”position.
3-45
Entrance Door Lock Switch
OM-B436
This switch will lock/unlock the door.
DEVICE CONTROL TIPS
Front Fog Lamps Switch
Rear Fog Lamps Switch
Room Lamps
lights) Switch
OM-B433
OM-B356
Activation of the switch turns on the
front fog lamps when the light switch is
in 1st or higher mode (when lamps are
“ON”).
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
Activation of the switch turns on the
rear fog lamps when the light switch is
in 1st or higher mode (when lamps are
“ON”).
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
3-46
(Fluorescent
OM-B437
Activation of the switch turns on the
fluorescent lights within the vehicle.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
DEVICE CONTROL TIPS
Room Lamps (Incandescent
Lights) Switch
OM-B121
Activation of the switch turns on the
incandescent lights within the vehicle.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
Destination Lamp Switch
’
Driver’
s Seat Lamp Switch
OM-B438
OM-B439
Activation of the switch turns on the
destination lamp when the light switch
is in 1st or higher mode (when tail
lamps are“ON”).
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
Activation of the switch turns on the
driver’s seat lamp.
The lamp are turned off when the
switch is deactivated to return to the
“OFF”position.
3-47
DEVICE CONTROL TIPS
Passengeway Lamps Switch
Reading Lamps Switch
Luggage Room Lamps Switch
OM-B440
OM-B441
OM-B442
Activation of the switch turns on the
passengeway lamps.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
Activation of the switch turns on the
reading lamps in the passenger seats.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
Activation of the switch turns on the
luggage room lamps when the door for
the compartment is opened.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
3-48
DEVICE CONTROL TIPS
Side Lamps Switch
Rack Lamps Switch
Driver s Seat Heater Switch
OM-B443
OM-B444
OM-B445
Activation of the switch turns on the
side lamps.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
Activation of the switch turns on the
rack lamps.
The lamps are turned off when the
switch is deactivated to return to the
“OFF”position.
The heater in the driver’s seat is
activated when the switch is pressed.
The heater in the driver’s seat is
deactivated when the switch is pressed
again.
3-49
DEVICE CONTROL TIPS
Rearview Mirror Heating Switch
TV & VCR Switch
OM-B446
Activation of the switch turns on
heating indicator lamp in
instrument panel and defogs
outside rearview mirrors.
The heating is turned off when
switch is deactivated to return to
“OFF”position.
the
the
the
the
the
Luggage Door Switch
OM-B397
OM-H241
Activation of the switch supplies power
to the TV & VCR.
Turn on the switches on the TV & VCR
after activating this switch.
The power supply is cut off to the TV &
VCR when the switch is deactivated to
return to the“OFF”position.
It can be operated at the driver’s seat,
pressing the switch down closes the
luggage door to“LOCK”, and pressing
up will cancel the lock to open the
luggage door with hands.
3-50
DEVICE CONTROL TIPS
Children Flashing Lamp Switch
Car Vision (Back Eye Camera)
Switch (OPTION)
OM-B134
Activation of the switch supplies power
to the flashing lamps on children
protection vehicles.
With the switch in the“ON”position,
red flashing lamps attached to the
vehicle’s exterior flicker when the
vehicle is parked, and yellow flashing
lamps ficker when the vehicle is
moving at under 20 km/h.
All flashing lamps are turned off when
the cehicle travels above 21 km/h.
Wheel Chair Lift Switch
OM-S065
OM-B135
The device displays the rear of the
vehicle through a monitor screen.
The screen appears when the gear is
shifted to reverse position, and it
disappears when the gear id shifted to
any other position.
The screen is displayed independent of
the gear’s position when the car vision
switch is activated.
3-51
The power will be supplied to the
control installed in the center door
when you press this switch.
If you press this switch once more, the
power to the remote control will be shut
and the wheelchair lift will not be
operated.
CAUTION
Turn the switch off if you are not
going to use the lift to avoid any
unwanted operations.
DEVICE CONTROL TIPS
Rearview Mirror Adjustment
Switch
● Left/Right Selection
Turn the switch to the left when
adjusting the driver side’s side mirror,
and turn the switch to the right when
adjusting the entrance side’s side
mirror.
OM-H205
3-52
● Angle Adjustment
Adjust the mirror to the desired angle
by moving the switch up(▲), down(▼),
left(◀), and right(▶).
CAUTION
Do not operate the adjustment
switch when the mirrors are
adhered.
DEVICE CONTROL TIPS
Handsfree Switch
How to use the handsfree
The handsfree switch operation power
is operated when the vehicle key is at
“ON”.
Connect the mobile phone jack (③)
and ear mike jack of mobile phone with
the mobile phone connection code.
OM-S100
The vehicle audio system and the
mobile phone can be used connected
with the inner handsfree within car.
The switch constitution and main
functions of the handsfree are :
① Communication Switch
(Receiving / Ending / Making a call)
② Ear Mike Jack (For personal calls)
③ Mobile phone Jack
(For connecting the handsfree unit
and the mobile phone)
④ Mike
For receiving the call
Press the communication switch(①) for
longer than 0.5 seconds until you hear
the beep. Then the handsfree
operation indicating lamp turns off.
For regular communication
The calls are connected and you can
talk with the other person.
CAUTION
Control the communication sound to
an appropriate level considering the
surrounding noise so you can listen
to the sound.
3-53
WARNING
・Using cell phone during driving is
strictly prohibiter by the law.
・Stop or park the car before using
cell phone.
DEVICE CONTROL TIPS
6. HEATING, VENTILATION, AND A/C RELATED SWITCH
WARNING
・Allow ventilation by leaving the
windows slightly open while the
vehicle is parked, when leaving a
child alone or when having a nap in
the vehicle. Operating the A/C or
the heater for a long period may
result in loss of life due to failure of
ventilation.
・The AC coolant is charged with high
pressure and is potentially very
dangerous when disassembling
parts. Therefore, the system must be
serviced at service center.
CAUTION
・If the AC is operated for too long
while the car is stopped, he engine
could be over heated. Be reminded
of the matter.
・If the AC or fanning function is
operated while the engine is off, The
battery may run out prematurely.
・If you turn off the engine while the
AC/heater is on, fanning motor is
shut down, trapping the hot or cool
air in the system. The trapped air
could result in fungi or unpleasant
odors.
・If you start up the engine while the
AC and other electrical devices are
on, unstable RPM may cause the
vehicle to shake and could also be
hard to start up the engine.
3-54
REFERENCE
・Shut hot water valve inside
engine room when operating
AC.
・Open hot water valve inside
engine room when operating
heater.
the
the
the
the
DEVICE CONTROL TIPS
Automatic Controlling Air Conditioner (OPTION)
TYPE A
TYPE B
OM-H224
1. Automatic Air Conditioning
2. System Off
3. Fan Speed Control
4. Manual Air Conditioning
5. Temperature Setup (Ascending)
6. Temperature Setup (Descending)
7. Temperature confirming
8. AQS
3-55
OM-H225
9. Interior/Exterior Unit Selection
10. Dehumidify
11. A Negative Ion
12. Emergency Air Conditioning
DEVICE CONTROL TIPS
①)
Automatic Air Conditioning (①
This switch is used to control cooling
automatically.
The wind direction is automatically
controlled.
The
temperature
adjustment switches(⑤,⑥) are used to
adjust the temperature by 0.5℃.
The system halts when system
suspension switch(②) is pressed.
②)
System Off (②
The system is suspended if the switch
is pressed during the operation and
standby status is displayed.
③)
Fan Speed Control (③
•DOOWON, POONGSUNG
1~4 levels can be adjusted by pressing
the switch.
④)
Manual Air Conditioning (④
The air cooling can be manually
controlled with wind direction
switch(③) and temperature adjustment
switch (⑤ ,⑥ ) while pressing the
switch.
⑤, ⑥)
Temperature Setup (⑤
The temperature can be adjusted from
17℃ to 30℃ by 0.5℃ units.
⑦)
Temperature confirming (⑦
Interior/exterior temperatures are
displayed evertime the switch is
pressed.
⑧)
AQS (⑧
AQS automatically detect pollutions in
the open air and prevent toxin inflow.
The function is suspended by pressing
the switch once more.
•DONGHWAN
The temperature adjustment switch
(⑤,⑥) is used to adjust 1~4 levels.
3-56
⑨)
Interior/Exterior Unit Selection (⑨
The function will ventilate interior
atmosphere with the aspiraotr.
・1st stage : forced aspiration,
forced exhaustion
・2nd stage : natural inflow,
forced exhaustion
・3rd stage : natural inflow,
natural exhaustion
・4th stage : inner circulation
REFERENCE
Extended ventilation will reduce the
cooling effect during the summer.
WARNING
If you use the inner atmospheric
circulation for too long, it could result
in fogged windows and oxygen
shortage, which causes headaches
and drowsiness.
DEVICE CONTROL TIPS
⑩)
Dehumidify (⑩
This is used to dehumidify rearview
mirror and interior.
Pressing the switch one more time will
suspend the function.
TYPE C
⑪)
A Negative Ion (⑪
Indoor anion devices are controlled
with this switch.
⑫)
Emergency Air Conditioning (⑫
Emergency cooling operation is
controlled with this switch when the
control is malfunctioning.
REFERENCE
Error indication is displayed when
there are problems with the controller
or the AC system.
Visit a service center or the factory to
get serviced when the indication is
displayed.
OM-H227
This is only applicable to vehicles
equipped with the automatic
temperature control A/C system.
・Upon activation of the number ①
“ON” switch, power is supplied to the
A/C and the fan power starts in level 1.
Upon activation of the number ②
“OFF”switch, the system is turned
off with only the temperature display
showing, and all setting, except for
the set temperature and fan power,
are returned to their initial settings.
3-57
・Upon activation of the numbers ③
and ④ set temperature switches (▲,
▼), the current temperature display
changes to the set temperature
display, which can be controlled
within the range of 15℃ ~ 30℃.
During the temperature setting, the
last digit of the temperature display
continues to ficker. The temperature
changes in multiples of 0.5℃, but it
does not change when it is changed
from room temperature to initial set
temperature. When 5 seconds have
elapsed after set temperature has
been changed or when other buttons
are pressed, the room temperature is
displayed. Upon initial battery power
supply the set temperature is set to
25℃, and the set temperature is
stored until the battery main switch is
turn“OFF”.
DEVICE CONTROL TIPS
Air Conditioner (OPTION)
・Upon activation of the number ⑤
automatic switch, the A/C operates
until it reaches the set temperature,
and the A/C compressor switch lamp
turns on. The unloading valve
operates until the set temperature -2℃
is reached, and the compressor is
only 50% operated.
・Upon activation of the number ⑥ A/C
compressor activation switch, the
compressor clutch turns“ON”and
the A/C activates.
・The numbers ⑦,⑧, and ⑨ fan power
control switches are used to
manually select low, mid, and high
speed operations of the A/C.
Activation of theses switches during
automatic operation shifts the system
to manual operation.
・The number ⑩ warning indicator lamp
turns on when a fault is detected in the
pressure of the A/C compressor, and
the warning buzzer activates twice in
intervals of 5 seconds.
OM-B448
The control is used to activate the A/C.
・Press the power switch (②) after
starting the engine, and control the
temperature by turning the rotary
switch (①).
・Press the air cooler activation button
(③) for air cooling, and control the
power levels using the power level
activation buttons (④,⑤,⑥).
・The air cooler activation button (③)
can only be activated when the
power switch(②) is in the“ON”
position.
3-58
Without the activation of the air
cooler activation button(③), only the
internal air is circulated.
・The clutch of the A/C compressor is
blocked and the air cooler stops
operation when the refrigerant
pressure drops or rises excessively.
Upon such incident, the A/C
emergency warning lamp in the
instrument panel turns on.
・The A/C reactivates upon recovery of
the refrigerant pressure after an
emergency stop caused by an
excessive drop in the refrigerant
pressure. However, when emergency
stop is caused by excessive rise in the
refrigerant pressure, the A/C must be
reactivated after turning“OFF”the
power for about 10 minutes.
REFERENCE
Upon repetitive emergency stops,
receive inspection from our
company’s service providers of from
the A/C manufacturer.
DEVICE CONTROL TIPS
Defroster Controls
TYPE A
The number ③ rotary switch is used to
shift the source of the fan. Turning the
switch counterclockwise allows air from
outside, and turning it clockwise
circulates the air within.
TYPE B
OM-S019
OM-H226
The controls are used to activate the
heater for the driver’s seat.
The number ① rotary switch is used
for the activation/desctivation of the
driver seat heater and the control of
fan speed. Turning the switch
clockwise activates the system and
increases the fan power.
・The upper lever controls the
activation and the power of the
heater. Pushing the lever to the right
results in increase of power.
・The lower lever controls the direction
of the heater. Positioning the lever to
the further left controls the heater to
activate in the lower parts of the
driver’s seat and the windshield,
while positioning it to the further right
controls the heater to activate only in
the windshield.
The number ② rotary switch is used to
shift fan directions. Turning the switch
counterclockwise directs the fan
toward the front and lower section of
the driver, and turning it clockwise
dorects the fan towards the windshield.
3-59
REFERENCE
For more effective elimination of frost
and moisture from the windshield, turn
the number ② rotary switch clockwise
and the number ③ rotary switch
counterclockwise.
WARNING
Operating the vehicle with the inflow
of outside air blocked may disturb
safe operation of the vehicle due to
the moisture in the windshield and the
impure internal air.
DEVICE CONTROL TIPS
Heater
Preheater (OPTION)
REFERENCE
The heater switch type depends on
the number of heaters within the
vehicle.
WARNING
The hot water valve must be opened
before heater is turned on.
OM-H228
OM-B449
The controls are used to activate the
interior heater.
The preheater in only installed as on
option.
① Rotary Switch
It is used to adjust wind power by
steps.
・Upon pressing in activate button(③),
the activate button(③) lamp and the
pump button(④) lamp turns on, the
drive motor and the circulation pump
motor activates, and also the fan and
the fuel pump activates.
② Button Switchs
It is used for activating the passenger
area heater and to turn ON/OFF the
main power.
3-60
DEVICE CONTROL TIPS
Automatic Ventilation (OPTION)
・Ignition occurs 15~30 seconds after
the activation of the drive motor and
the circulation pump motor, and as a
result, combustion begins. At the
same time, ignition indicator lamp(⑤)
turns on.
・The combustion stops and the
ignition indicator(⑤) lmap turns off
when the coolant’s temperature
reaches over 75℃ as a result of
successful combustion process.
The drive motor activates only for
about 3 minutes while the circulation
pump continuously remains activated.
・Re-ignition occurs automatically
when the coolant’s temperature
drops below 65℃.
・Press the“STOP”button(①) to
deactivate the preheater. Upon such
action, combustion stops, and the
drive motor and the circulation pump
motor stops after about 3 minutes of
activation.
・Position the battery main switch to the
“OFF”position after the circulation
pump motor has completely stopped,
when parking the vehicle.
・Pressing the pump button(④) turns
on the lamp, activates the circulation
pump motor only, and increases the
heating efficiency.
・Warning lamp(②) is turned on when
there is a problem with the preheater.
OM-B500
The power button(①) activates the
ventilator’
s shutter, which opens/closes
the ventilator.
Activating only the power button(①)
enables ventilation using the air
circulation caused by the natural wind,
since it only opens the ventilator’s
shutter and does not activate the fan.
3-61
DEVICE CONTROL TIPS
Side Ventilation (OPTION)
Pressing the button ② opens the
induction shutter, activates the fan, and
lets the external air inside.
Pressing button ④ will open the
ventilation but the fan will not spin. The
air is ventilated naturally.
Pressing button ③
opens the
exhaustion shutter, activates the fan,
and lets the internal air outside.
Pressing button ⑤ will open the
ventilation and the fan will spin to feed
exernal air into the interior.
The induction button and exhaustion
button
cannot
be
activated
simultaneously
OM-H229
Power can be supplied to side
ventilation by pressing the power
button(①).
Pressing button ② will open the side
ventialtion and the fan will spin to
exhaust interior air.
Pressing button ③ will open the rear
ventialtion and the fan will spin to
exhaust interior air
3-62
CAUTION
Turn off the battery main switch once
the ventilator’s shutter is completely
closed after turning off the ventilator’
s
power switch and waiting for 3 ~ 5
seconds. Turning off the battery
main switch before the ventilator’s
shutter closed, leaves the shutter in
an open state which may let rain into
the vehicle.
DEVICE CONTROL TIPS
7. OTHER DEVICES
Audio (OPTION)
Refrigerator/Heating Cabinet
Water Cooler/Water-Heater
Tachograph (OPTION)
OM-F054
OM-F053
Refer to separately supplied manual
for more detailed instructions.
Refer to separately supplied manual
for more detailed instructions.
3-63
OM-F105
Refer to separately supplied manual
for more detailed instructions.
DEVICE CONTROL TIPS
Toilet (OPTION)
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
OM-B548
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.
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
WARNING
Do not use when lamp on (feces
tank warning lamp) and discharge
waste from the tank at permitted
location.
3-64
DEVICE CONTROL TIPS
Kneeling System (OPTION)
ECAS (Electronically Controlled Air Suspension)
The system controls the pressure of the air spring and the height of the vehicle from the ground through the ECAS ECU
control of the ECAS solenoid valve after detecting the change in height of the vehicle from the ground by the height sensor.
OM-F133E
1. ECAS ECU
2. ECAS Solenoid Valve
3. Height Sensor
4. Air Spring
5. Air Tank
6. Pressure Switch
Main Functions of ECAS
・Improves the fuel efficiency by significantly reducing the air consumption during the vehicle’s operation.
・The height adjustment is automatically and quickly executed according to the change in vehicle load.
・The driver is able to adjust the height by operating the switch to accommodate to the road conditions and other operating
conditions.
・Height adjustment and kneeling can be executed while safety is assured.
・Provides convenient and safe maintenance capability with its self-diagnosis capability.
3-65
DEVICE CONTROL TIPS
■ TYPE A (BC211M / BS110CN / BS120CN)
Operation of ECAS Switches
OM-B509E
※ Leave the switch ① and ② on the center after the operation of ① and ② when retrning to the garage.
Pressing ⑤ while ①~④ are operational will activate emergency suspension.
3-66
DEVICE CONTROL TIPS
Activation of Lamps (BC211M / BS110CN / BS120CN)
The lamp turns on when the key is turned on and turns off after about 2 seconds under the condition that there is no defect in
the ECAS. On the contray, the lamp turns on ir flickers when the key is turned on if there are any defects. Upon such incident,
operate the vehicle after receiving inspection.
Type
Lighting
Flickering
Green indication
Yellow indication
When arriving at garages When the sensors in the
equipped with ECU while height are beyond relative
① ,② ,④ switches are standards of ECU.
activated.
N/A
Red indication
White indication
It indicates low voltages When switch ① is
and signal errors or such. activated.
Servicing is required.
・When Safety Strip is ・When Safety Strip is
activated.
activated.
When
air
tank
pressure
is
・
・When there is a critical
N/A
problem must be serviced.
low. (6 bar or lower)
・When detection sencor is ・When ECU is on selfdiagnosis mode.
malfuctioning.
ETC
•The entrance door must be closed before switch ①, ②, ③ are activated.
•Switch ① and ② can be activated even while driving and are not related to restoration after kneeling ④.
3-67
DEVICE CONTROL TIPS
■ TYPE B (BH120 / BX212)
Operation of ECAS Switches
1. Regular Height Level UP Selection Switch
(Regular Operation Height 30mm UPWARD (Only Front))
2. Regular Height Level DOWN Selection Switch
(Regular Operation Height 30mm DROP)
3. Regular Height Recovery Switch
4. Kneeling Activation Switch
5. Emergency Stop Switch
(Ongoing kneeling is deactivated when this switch is operated)
6. Regular Height Level UP Indicator Lamp
7. ECAS Yellow Indicator Lamp (Warning)
OM-H251
8. ECAS Red Indicator Lamp (Prohibition)
3-68
DEVICE CONTROL TIPS
Activation of Lamps
The lamp turns on when the key is turned on and turns off after about 2 seconds under the condition that there is no defect in
the ECAS. On the contray, the lamp turns on ir flickers when the key is turned on if there are any defects. Upon such incident,
operate the vehicle after receiving inspection.
Section
ECAS Yellow Indicator Lamp
Regular Height Level UP
Indicator Lamp
ECAS Red Warning Lamp
・When the sensor in the height are It indicates low voltages and
signal errors or such.
beyond relative standard of ECU.
Servicing is required.
Lighting ・Activating Kneeling.
・When Safety Strip is activated.
・When Safety Strip is activated.
When
the
air
tank
pressure
is
low.
・
・When there is a critical problem
(under
6
bar)
must be serviced.
Flickering
When
detection
sencor
is
malfuctioning.
・
・When ECU is on self-diagnosis
mode.
When the height level UP (①)
selection switch is turned on, which
increases the height of the vehicle
by 60mm in comparison to that at
level DOWN(②).
N/A
ETC
・Press the button ③ (regular height recovery switch) to turn off the warning lamp(⑦).
・Regular height level selection switches(①,②) and regular height recovery switch(③) can only be activated when the
entrance door is closed.
・Height selection switches(①,②) can be activates while the vehicle is in operation.
・If you reach 40km/h after activating switch ①, the height will return to normal height.
3-69
DEVICE CONTROL TIPS
Wheelchair Ramp (OPTION)
Wheelchair ramp standby
Check if the elevation shaft of the mid
door of the vehicle is properly shut.
Check if there are any obstructions
around before the ramp is activated.
Park the vehicle near the pavement so
that the ramp can be activated on the
borderline of the road.
Pull the parking brake to securely park
the vehicle.
Riding and getting off the wheelchair.
OM-S079E
OM-S080
3-70
・Open the mid-door entrance.
・Set the ramp switch on“OUT”. The
ramp will extend to outside and
setting the switch on“IN”will retract
the ramp.
・The alarm buzzes until the operation
is over while the ramp is operational.
・Safely guide the passenger when the
ramp operation is completed.
・Park the wheelchair on a safe spot
and and secure it with safety belt.
・You must use safety belt for
passenger safety.
WARNING
While
the ramp is operating, it
・
should never be riden by
wheelchairs or be stood on.
・Please get on the ramp when it is
fully extended.
DEVICE CONTROL TIPS
Wheelchair Lift (OPTION)
Manually operating the ramp
OM-S081
・You must pull the parking brake.
・Take out the cover located below the
mid door of the vehicle.
・Insert the supplied tool (②) on the
pivot(⊥).
・Push it and spin it to operate the
ramp.
・If you do not have the tool, use other
tools to press the pivot from inside
and open the frontal cover of the
ramp and pull the ramp by the center
until it is fully extended.
・Insert the ramp back into the slot.
Maintain the parallel position.
・Check if the protective cover is
securely shut after putting the ramp
back in.
CAUTION
Be careful for sharp parts of the
ramp.
3-71
Refer to seprately provided manual for
more details.
DEVICE CONTROL TIPS
Wheelchair Fixture Belt and Lock-ups
b. Confirm the flickering of the green
lamp(1) and press red switch(2).
c. The green light will change from
flickering to lighting if the fixation is
complete.
d. If you want to unlock the fixation,
press the red switch.
OM-S049
Operation manual
a. The wheel of the wheechair should
be placed on the center of the
support and reverse until the tire
touches the support.
OM-S050
How to unfix manually
a. Loosen the bolts with flat tools and
take off the cover.
b. Put your finger into the ring of the
pin and pull it.
CAUTION
・Fix the wheelchair on the support
device and pull the wheelchair
brake.
・Do never put your handsor feet on
the supporting device.
・Do not use the device for any other
purposes.
・Secure the wheelchair with a safety
belt.
3-72
Belt fixture and loosening
OM-S051
Use the hook on the belt to hook the belt
on the front(1 hook) and rear (2 hooks).
Turn the lever (2) to secure the
wheelchair.
When you loose the belt, press the
lever(1) at the back to release the hook.
The belt will automatically retract.
CAUTION
・Securely tighten the hook when
securing the wheelchair.
・You must pull the wheelchair break
after seuring it.
・Fully retract the belt after the hook
is released.
4
START-UP & DRIVING
1. DRIVING METHOD
Setting Of ………………………………………… 4-2
Safe Driving ……………………………………… 4-2
Driving in the Summer …………………………… 4-4
Driving in the Winter……………………………… 4-4
Driving at Night …………………………………… 4-6
Driving on Highway ……………………………… 4-6
2. DRIVING
Engine Check Ups Before Start-up …………… 4-8
Engine Start-up…………………………………… 4-8
Pre-heating Diesel Engine …………………… 4-10
Standby After Starting the Engine …………… 4-10
Accelerator ……………………………………… 4-11
Brake Pedal……………………………………… 4-12
Clutch Pedal …………………………………… 4-13
Gearshift (Manual) ……………………………… 4-13
Gear Shift (Automatic) ………………………… 4-14
ABS / ASR ………………………………………
Exhaust Brake …………………………………
Jake Engine Brake ………………………………
Retarder Brake …………………………………
Parking Brake ……………………………………
Reminders for driving vehicles that’s been
rested for a while ………………………………
Engine Aftertreatment …………………………
4-1
4-18
4-19
4-20
4-21
4-21
4-22
4-23
START-UP & DRIVING
1. DRIVING METHOD
Setting Off
Safe Driving
Driver is responsible for the safety of
the vehicle outside and the people in
and outside of the vehicle. Therefore,
driver must drive carefully. Most of the
accidents occur from driver s
carelessness.
OM-B054
a. Check if the air pressure is higher
than 8.0kgf/cm2. Check for any airpressure related warning indications.
b. Increase the rpm to increase the air
pressure if needed.
c. Release Parking Brake.
d. Check surrounding area and driving
direction. Especially watch out for
children and pedestrians.
e. Star the vehicle with the gearshift on
1st gear after warming up the
engine.
・Check for the turned on lamps
among the pilot lamp during driving.
All the not operative lamps must be
off during driving.
・Keep engine revolution around the
maximum torque.
・Accelerate the vehicle smoothly, and
in outrunning the vehicle in front,
check the environment and keep the
speed of the vehicle steady.
・In shift the gear, optimal revolution of
the engine must be kept.
・Do not set foot on the clutch pedal
except when shifting the gear.
4-2
・In braking, keep distance between
the vehicles in front, Especially if the
vision is blur or the road conditions
are bad, slow down the vehicle and
keep distance.
REFERENCE
・When braking during driving, driver
must hold on to the stirring wheel
the gear on. If the speed reduces,
shift the gear to the lower gear and
step on the clutch pedal when the
vehicle comes to a full stop.
・When braking in safe distance, use
both the engine brake and assistant
brake, and step on the main brake
several times before bring the
vehicle into a full stop.
・Step on the brakes several times is
effect since the actual brake
distance gets longer because of the
riction of the tire causes the stirring
wheel to be useless. ABS brake
system does this itself to minimize
this process acting to help avoid
such dangers.
START-UP & DRIVING
・In climbing steep hill, change the
gear before hand to avoid straining
the engine.
・When climbing down the hill, use
engine brake effectively to avoid high
revolution of the engine, and also use
assistant brake to decrease speed.
CAUTION
When using engine brake during
high speed driving, lower the gear
one step down. Lower suddenly to
the lowest gear might cause
problems in engine.
WARNING
・The gear should be in place even
when driving down hill. Do not drive
down the hill with the gear in
neutral.
・If the brake is used continuously
during down hill drive, decrease in
air pressure of the brake tank and
the lining/drum overheating might
cause accidents. So in decreasing
speed, use both the main brake and
the assistant brake.
・Braking on a ice road might cause
the vehicle to skid and cause
accidents.
4-3
WARNING
Driver’
s carefulness and general
knowledge is needed in safe driving.
When driving, following obstacles
must be minimized or avoided.
・Using cell phone.
・Adjusting sitting, stirring wheel, and
rearview mirror.
・Using other electrical equipments.
・Looking at the maps or other
reading materials.
・Putting on and off seatbelts.
・Taking drinks or food.
Above actions would increase the
danger of accidents and also might
cause serious damages and even
death. Therefore, these actions must
be taken after the vehicle has come
to a full stop.
START-UP & DRIVING
Driving in the Summer
Driving in the Winter
Inspections Prior to Driving
Inspect the lower body of the vehicle
and remove ices from the vehicle
carefully.
Check the performance of pedals when
starting up the engine.
OM-B151
Pay special attention to AC and
coolant during the summer season.
Pay attention to coolant capacity and
clean the radiator for the cooling
efficiency is reduced if the radiator is
polluted.
OM-B152
Pay extra attention for coolant,
lubricant and air line so that they don’t
freeze during the winter season.
Briefly warm up before driving. If the
engine is operation while it is frozen,
the lubrication may get damaged.
The tire will loss grip on icy or snowy
roads. Abrupt turnsm acceleration, or
braking are likely to result in accidents.
4-4
Remove any frosts on the mirrors and
windows before driving.
Check if the wiper is stuck(frozen) on
the windows.
Check if the coolant is frozen.
START-UP & DRIVING
Tire and Chain
Use snow tire when driving in winter,
change the snow tire when the
abrasion level reaches above 50%.
On an ice road, snow chain looses its
effect. Use the snow chain and follow
the steps below.
c. Move the vehicle so that the wheel is
positioned about 40~50cm from the
hook.
f. Left over chain must be connected to
the spring band’s latch.
a. Place the vehicle on a flat level
ground.
OM-B156
b. Place the chain in front or in the rear
of the wheels. Make sure the chain
hook faces downwards.
OM-B155
d. Hook the chain by wrapping the
chain to the tire. Do hook up the
inner side.
e. Place the chain spring band’s each
katch and pull on the chain link.
OM-B154
4-5
CAUTION
・If you are equipping the vehicle with
snow tires or chains, you should
drive with half the normal speed.
・If you are driving with snow tires,
use same tires on the same axle
line.
・You are advised not to equip the
front tires with chains. If you must,
check if steering is not interfered.
START-UP & DRIVING
Driving at Night
Driving on Highway
Driving on high way requires more care
than driving in normal road.
・Check tire condition and the air
pressure. High temperature of the
road might cause the tire to explode.
OM-B157
Night driving requires more attention
than day light driving.
・Avoid using high beam if possible.
Turn it off when you see an
approaching vehicle in front.
The approaching driver could be
distracted by the strong light.
・Increase safety distance while driving
at night.
・Inspect head light and always keep it
clean.
REFERENCE
Maximum Speed of the Tire
Maximum speed of the tire is located
on the side of the tire. Tire must be
adhusted to the vehicle operation
condition.
Alphabetical
Code
Maximum Speed
( km/h )
F
80
G
90
J
100
K
110
L
120
M
130
OM-B159E
4-6
START-UP & DRIVING
・On high way, as the speed of the
vehicle increases, the driving
resistance increase. Accelerate by
giving space to the vehicle output.
・On high way, even the slight turning
of the stirring wheel nakes the
vehicle turn. However, when the road
condition is bad, slow down and drive
safe.
・Fill enough gas before driving on a
high way, because as the driving
resistance increases, the fuel
consumption also increases.
・Keep safe speed. The driver might be
aware of the speed on the high way.
・In braking, always keep safe
distance. Especially if the vision is
blur or the road conditions are bad,
slow down the vehicle and keep
distance.
・When outrunning a vehicle, the
outrunning vehicle must run 10km/h
faster than the vehicle in front. Give
the driver in front signal before
outrunning and safely outrun the
vehicle safely.
4-7
START-UP & DRIVING
2. DRIVING
Engine Check Ups Before Start-up
a. Make sure the parking brakes are
applied.
If it’s not, activate the brakes.
Engine Start-up
c. If your vehicle is a CNG vehicle,
check if the emergency fuel cut
switch is applied. If it’s not, activate
the switch.
OM-B167
OM-B373
OM-B435
b. Put the gearshift box to neutral
position “
( N”). For automatic
transmission, make sure the
geafshift button is in the neutral
position “N”
(
). The engine won’t
start if any other button is selected.
d. Press the battery main switch.
OM-B342
4-8
Turning the key to the starting position
(START) activates the starting motor,
which starts the engine, and the key
automatically returns to the“ON”
position. Therefore, let go of the key
when the engine starts. Holding the
key continuously may cause damages
to the starting motor.
START-UP & DRIVING
CAUTION
・ Holding the key in the starting
position (START) for longer than 10
seconds due to a delay in starting
of the engine, may result in a
excess current which causes
damages to the motor. Therefore,
when a delay in starting of the
engine occurs, turn the key to its
original position and restart the
engine after waiting for about a
minute. If the engine fails to start
within 2~3 times, inspect your
vehicle.
・ Leaving the battery main switch on
for a long period without starting
the engine, may cause a
discharged battery. Do not leave
the battery main switch on for a
long period when the engine is not
running.
WARNING
・ Turning the key to the“LOCK”
position or pulling out the key
during vehicle operation may result
in an unexpected accident. Never
turn the key to the“LOCK”position
or pull out the key while the vehicle
is in operation.
・ Start the engine after checking if
inspection indications for Engine,
ABS/ASR, intarder brake and
eletrical devices are turned off. The
devices may malfunction if you start
the engine while devices are being
inspected.
REFERENCE
Check list when start-up malfunctions
- Battery Condition
- Battery Relay
- Battery Main Fuse
- Starter Fuse
- Fuel Quantity
- Starter Motor
4-9
Operation of Key Switch
OM-B168
•LOCK : Insert or pull out the key in
this position.
•ACC : Power is supplied to the audio
system, digital clock, and other
devices when the key is in this
position.
•ON : Power is supplied to all
electronic devices in the vehicle
when the key is in this position.
•START : Turn the key to this position
when starting the engine, and let it
go when the engine srarts so that it
automatically returns to the“ON”
position.
START-UP & DRIVING
Pre-heating Diesel Engine
Standby After Starting the Engine
How to disengage fixed steering wheel
OM-H024
Steer the wheel lightly and turn the key
from “LOCK”to“ACC”.
REFERENCE
Battery will run out if you leave the
key position on“ACC”or“ON”for
too long.
OM-B347
OM-B171
The preheating lamp remains on for about
0.3 seconds when the coolant s temperature
is above 10℃, and for about 20 seconds
when the coolants temperature is lower
than 10℃. Start the engine by turning the
key to the“START”position after the
preheating lamp has turned off in the
“ON”position.
The engine s rotation speed is unstable
during the first 10 seconds following
the start of the engine.
Standby until the engine ECM controls
the vehicle s engine rotation speed to
stabilize.
During winter period, never start the
engine before preheating it.
Vehicles ewuipped with preheater must
start the engine after the coolant s
temperature has risen after activation
of preheater.
4-10
Since the vehicle is equipped with a
turbocharger, give the vehicle enough
warming-up time so that the engine oil
can reach up to the turbocharger.
START-UP & DRIVING
Accelerator
CAUTION
・A sudden operation of the
accelerator after starting the engine
has negative effect on the vehicle s
state and causes critical damage to
the turbocharger by burning it.
・Never restart the engine when the
engine is running, since it may
cause damages to the starting
motor.
OM-B172
The Vehicle is equipped with electronic
accelerator.
Apply the pedal smoothly and
appropriately to prevent unnecessary
fuel consumption and to reduce
exhaust fumes.
Occasionally inspect whether the
engine ratation is reacting appropriately
upon full application of the accelerator.
4-11
CAUTION
・The vehicle s maximum speed
means the possible speed powered
by the maximum output of the
engine, and it consumes excessive
fuel and may lead to unsafe
operation of the vehicle.
Always operate the vehicle safely
by applying the accelerator
appropriately to maintain the safe
distance from the vehicle in front.
・For the vehicles with the turbo
charger, sudden acceleration right
after engine ignition is the cause for
the damages of the engine and
turbo charger, so avoid from
sudden acceleration.
START-UP & DRIVING
Brake Pedal
OM-B173
The pedal is applied to reduce speed
or to bring the vehicle to a stop during
operation.
The rear brake lamp turns on when the
brake pedal is applied.
Applying the brake pedal during rain or
on an icy road activates the anti-lock
brake system, which prevents the lockup of the steering wheel and allows
proper steering of the vehicle.
Therefore, it makes it possible for the
driver to avoid accidents by steering
the vehicle even when the vehicle falls
into danger.
REFERENCE
Anti-lock brake system allows the
steering of the vehicle while the
brake pedal is applied. The braking
capability depends on the effort
applied in the brake pedal.
The braking capability depends on the
effort applied on the brake pedal.
Since sudden braking causes wearing
out of tires and consumption of fuel,
reduce the vehicle’s speed before the
expected stopping point, and bring the
vehicle to a complete stoppage by
applying the brake pedal.
4-12
WARNING
・Operating the vehicle with the
brake pedal applied does not only
result in a failure in activation of the
brake and ABS, but also in quick
wearing out of the brake parts and
distraction on the vehicle behind as
the brake lamp remains turned on
continuously.
・Continuous application of only the
brake pedal while operating the
vehicle down a extensive declined
road may drop the braking capability
due to overheating of the pad and
the drum. Since this may lead to an
unexpected accident, apply the
brake pedal along with the engine
brake or the subsidiary brake to
reduce the vehicle’s speed.
START-UP & DRIVING
Clutch Pedal
CAUTION
・The braking capability may drop
when the brake lining is wet after
operating the vehicle on a wet road
or a car wash. Operate the vehicle
after inspecting the braking
capability by lightly applying the
brake several times while operating
in a low speed.
・An allophonic sound may be heard
during operation or braking of the
vehicle when the brake lining
reaches its abrasion limit. Upon
such incident, receive vehicle
inspection and replace the lining if
necessary.
Gearshift (Manual)
OM-B174
Apply enough pressure on the clutch
pedal while shifting gears, and operate
the vehicle without your feet on the
clutch pedal.
CAUTION
Shift
gears by fully applying the
・
clutch pedal. Failure to do so may
result in damage caused by clutch
disk slip or damage in the pressure
plate and the transmission.
・Vehicles with turbocharger have low
torque due to the characteristic of
turbo chargers.
You must begin to drive at the first
gear.
4-13
OM-B175
Always shift gears by fully applying the
clutch pedal.
After the vehicle starts to move, shift
gears gradually in accordance with the
vehicle’s speed.
CAUTION
・Shifting the transmission to the
reverse gear while the vehicle’s in
operation, may damage the
transmission.
・Especially, bring the vehicle to a
complete stoppage and wait for 2~3
seconds before shifting to the
reverse gear.
START-UP & DRIVING
Gear Shift (Automatic) (OPTION)
■ TYPE A - ALLISON
CAUTION
Warm the engine up at“N”(neutral)
gear position if the outside temperature
is lower than -15℃ before setting off.
WARNING
Never position the gear on neutral
while driving.
OM-S107E
Start-up and setting off
・Step on the brake pedal while the
gear is set on neutral (N). Start the
engine and release the brake gear.
・Shift the gearshift to driving(D) and
accelerate to begin driving.
•D(driving) : The button is used when
driving. The gear is automatically
shifted from 1st to 5th gear as the
speed rises. Also, if the vehicle
speed is reduced, the gear will shift
to lower gears automatically.
▲(UP) / ▼(DOWN)
If you press ▲/▼ buttons while driving,
you can set speed change range from
1st to 5th gear.
Pressing ▼ button while driving will
lower the gear by one level.
CAUTION
・Pressing ▼ button at high speed
will increase the RPM abrubtly and
will result in abrupt speed
reduction.
It could be very dangerous if this
happens.
・Avoid shifting the gear while driving
at high speed.
・If you select too high or low gear
while driving, it could result in
damaged engine or damaged
clutch.
Warm the engine up at“N”(neutral)
gear position if the outside temperature
is lower than -15℃ before setting off.
4-14
START-UP & DRIVING
Reverse
Shifting from“N”to“R”will let you
reverse.
CAUTION
・The gear box could be damaged if
you shift to reverse while driving
ahead.
・Stop the car completely if you are
shifting from forward to reverse, or
shifting from reverse to forward
Tips on stopping and parking
If you are stopping the vehicle briefly,
leave the gear shift button as it is and
step on the brake constantly. If you are
stopping the car for a while, leave the
gear on“N”and step on brake pedal
constantly.
If you are leaving the vehicle, you must
activate parking brake.
4-15
MODE Button
If you use mode button, programed
special functions can be used.
The mode indication will be turned on
when you press the mode button.
REFERENCE
・The first number displayed is the
highest possible gear that can be
shifted and the second number is
selected gear position.
・Flickering display means that the
gear will not shift.
START-UP & DRIVING
■ TYPE B - ZF
•2nd & 3rd Gear :
Operate the vehicle with the gear
shifted to this position when the
vehicle needs to be operated in a low
gear depending on the road
conditions, the number of passengers
onboard, and the traffic situations.
OM-S070
The gears are shifted automatically in
accordance with the vehicle’s speed.
CAUTION
Do not operate the gear shift buttons
while the accelerator is being applied.
Using the Buttons
•1st Gear :
Operate the vehicle with the gear
shifted to this position when operating
on mud, snow, or a greatly inclined
road. The transmission continuously
maintains the 1st gear un this
position. Therefore, shift the gear shift
button to the “ D”position upon
improvenments in road conditions.
•D (Drive) :
The button is used during operation of
the vehicle. The vehicle starts with the
gear positioned in the 1st gear, and
the gears are shifted automatically to
2nd, 3rd, and 4th gear as the vehicle’
s
speed increases. The gears are
automatically down shifted when the
vehicle’
s speed is reduced.
•R (Reverse) :
Press the button when reversing the
vehicle.
4-16
•N (Neutral) :
Start or turn off the engine and
activate the parking brake activation
lever with this button pressed.
CAUTION
Stop the car completely if you are
shifting from forward to reverse, or
shifting from reverse to forward.
REFERENCE
Each button is installed with an
independent lamp, which turns on
when the button is pressed.
CAUTION
A malfunction in the transmission is
indicated by the button lamp’s
blinking. Upon such incident,
carefully and slowly drive the vehicle
to a close service plant and receive
inspection and service
START-UP & DRIVING
Starting the Vehicle
Start the engine with the“N”selected,
press the desired shift button, wait for
about 1 ~ 2 seconds, release the brake
pedal, and apply the accelerator to
start the vehicle.
CAUTION
Warm the engine up at“N”(neutral)
gear position if the outside
temperature is lower than -15℃
before setting off.
Driving the Vehicle
Operate the vehicle using the“3”
,“2”
,
and“1”buttons appropriately to reduce
the vehicle’s speed and checking the
engine rotation speed(engine RPM
meter), when driving down a greatly
declined road. Reduce the engine
rotation speed by applying the brake
pedal if the engine rotation speed is too
fast.
Prevent the vehicle from skidding by
applying the accelerator right after
releasing the brake pedal when
starting the vehicle from a stoppage on
a greatly inclined road.
To change the direction of the vehicle,
shift the gears from“D”to“R”or from
“R”to“D”after the vehicle has come
to a complete stoppage and the gear
has been shifted to the“N”position.
REFERENCE
Operating the gear shift selection
button when changing direction.
•Drive to Recerse “D”⇒“N”⇒“R”
:
•Recerse to Drive “R”⇒“N”⇒“D”
:
WARNING
Never position the gear on neutral
while driving.
4-17
CAUTION
・Avoid shifting the gear while driving
at high speed.
・If you select too high or low gear
while driving, it could result in
damaged engine or damaged
clutch.
Tips on stopping and parking
If you are stopping the vehicle briefly,
leave the gear shift button as it is and
step on the brake constantly. If you are
stopping the car for a while, leave the
gear on“N”and step on brake pedal
constantly.
If you are leaving the vehicle, you must
activate parking brake.
START-UP & DRIVING
ABS / ASR
This control system does not activate
but just holds and detects during a
regular operation and while the brake
pedal is applied in a normal manner.
However it is activated in the following
situations, in which are expressed as
“the ABS is in activation”.
・Applying the brakes on a very
slippery surface.
・Applying the brakes in an abrupt and
forceful manner.
However, it only activates when the
vehicle s speed and the road coefficient
of friction are satisfied.
When the brake is suddenly applied on
a slippery surface, the wheels do not
turn even though the vehicle is moving
at a fast speed. This state is called the
“wheel lock”state.
The vehicle cannot be controlled in this
state and will eventually move off the
road. To prevent the wheels from
locking, the ABS accurately controls
the pressure in each wheel for better
control of the vehicle, and ultimately
allows a safe operation of the vehicle.
Equipped with ABS
Braking Manner
ABS (Anti-lock Brake System)
A sensor that exactly detects the
wheels speed is installed near the
wheels. The sensor sends the detected
to the ECU, which is installed inside
the vehicle, and the speed is used in a
calculation to supply and contril the
appropriately compressed air.
OM-H232E
Unequipped with ABS
OM-H233E
4-18
START-UP & DRIVING
Exhaust Brake
ASR (Anti Slip Regulation)
The ASR operates in addition of the
ABS. If is very useful during the start of
the vehicle on an icy surface or when
accelerating suddenly. If the ASR
warning lamp turns on during operation
of the vehicle, it indicates that the
driving wheels are slipping during the
start of the vehicle.
CAUTION
・ABS is a device that enhances
safety and is not equipped to assist
high speed or dangerous driving
habits.
・ABS warning indication will be
turned off after 3 secs while the
battery switch and the key is ON.
If it does not turn off, it means that
ABS is malfunctioning, and you
must get it serviced.
・The brake will function normally like
a vehicle wihtout an ABS system
even if there is a problem with the
ABS.
CAUTION
・If ABS is operating, you will feel
vibration at the brake pedal and will
hear air exhaustion.
・Generally speaking, ABS equipped
vehicles have shorter braking
distance but it depends largely on
the road surface. Always maintain
safe distance from the vehicle
ahead.
・When washing the vehicle, if the
water enters ABS system, it could
damage the system and could be a
cause for malfunctioning.
・Sudden brake will require large
amount air and could result in air
pressure warning. In this case, park
the car on a safe location and wait
until the pressure is recovered.
4-19
OM-B112
Exhaust brake will be activated when
you pull the lever.
If you release the accelerator when the
lever is pulled, the magnetic valve will
be activated and the pressurized air
will be applied to the air room. The
valve will then be closed and create
pressure.
Also, if you accelerate, the magnetic
valve will release the inner air and will
open the valve releasing the pressure.
START-UP & DRIVING
Jake Engine Brake (OPTION)
OM-B112
Jake Brake Activation Conditions
More than 900 engine rpm, Faster than
10km/h vehicle speed.
It won’t function while the car is
stopped.
When Jake Brake is not working
Check the engine room fuse box for
blown fuses. Subsidiary brake relay
check up.
Check ECU“74”at the tacograph for
disconnections.
WARNING
・Driving while the spare brake is
activated could over load the
engine. Only use the spare brake
when necessary.
・Put it back on the original position
after the usage before continuing to
drive.
CAUTION
・Apply exhaust and jake engine
brakes when reducing the speed of
your vehicle as they function as
subsidiary brakes. On the other
hand, apply brake pedal to bring the
vehicle to a stoppage.
・Be aware of the fact that excessive
application of subsidiary brake and
its application during the engine’s
high rotation state may cause
surging (change in valve timing) in
the engine valve, bringing critical
damage to the engine.
4-20
REFERENCE
・Stepping on the brake pedal or the
clutch pedal while the subsidiary
brake is activated will deactivate the
subsidiary brake.
・Subsidiary brakes will not work on
vehicles with retarder brake.
START-UP & DRIVING
Retarder Brake (OPTION)
■ Manual Transmission
■ Automatic Transmission
“B”
”(Constant speed) mode
If you place the lever on“B”position
while driving down a hill, ECU will
remember the speed and the intarder
brake will control the speed so that the
speed is maintained at the recorded
speed.
OM-B178
・The activation lever for the retarder
brake operates in 5 steps, in which
the steps with greater numbers have
greater braking capabilities.
・Release the accelerator when
applying the retarder brake.
・Return the activation lever to the“0”
position when restarting the vehicle
after an application of the retarder
brake.
・As a subsidiary brake, the retarder
brake reduces the vehicle’s speed.
Therefore, the brake pedal must be
applied to bring the vehicle to a
complete stoppage.
OM-B410
・The activation lever for the retarder
brake operates in 5 steps, in which
the steps with greater numbers have
greater braking capabilities.
・Release the accelerator when
applying the retarder brake.
・Return the activation lever to the
“OFF”position when restarting the
vehicle after an application of the
retarder brake.
・As a subsidiary brake, the retarder
brake reduces the vehicle’s speed.
Therefore, the brake pedal must be
applied to bring the vehicle to a
complete stoppage.
4-21
If you want to change the driving
speed, position the lever at“OFF”and
put it back on“B”when you reach
desired speed.
If you want to increase the speed while
driving, step on acceleration pedal and
brake. The speed will be memorized by
ECU and the speed will be maintained.
START-UP & DRIVING
Parking Brake
Reminders for driving vehicles
’s been rested for a while
that’
WARNING
Do not reduce the vehicle’s speed
with the retarder brake only when the
road conditions are bad. Reduce the
speed by applying the engine brake
and the brake pedal appropriately.
CAUTION
・Do not shift the gear up while the
retarder brake is operational.
・If you use retarder brake down the
gill, coolant temperature will rise
and the retarder brake may not
work. Use it on“B”mode.
Vehicles that has been rested for a
long time will have issues of dried up
lubricating oil and the engine bearings
may suffer from abrasion. Crank in
before the star-up as follows.
OM-B117E
Pull the parking brake application
valve’s lever and fix the lever using
the LOCK button to have the vehicle in
a parked state. The parking indicator
lamp turns on in the instrument panel
when the key switch in the “ON”
position.
Pull the parking brake application
valve’s LOCK button up and push it
together with the lever to release the
parking brake.
4-22
a. Activate Parking Brake
b. Check the engine oil
c. Turn the battery switch on
d. Place the start up switch on“ACC”
e. Crank it for apx. 15 seconds while
pressing on start up switch button
located inside the engine room.
START-UP & DRIVING
Engine Aftertreatment
REFERENCE
・Urea gauge can bee seen at Multi
Display (LCD).
・Recommended urea : DIN V 70070-05
OM-F081
■ SCR (EURO IV - DL06,DL08,DV11)
It is a post-processing device that
helps toxic exhaust to pass through
urea so that toxic materials are
removed.
Engine after treatment warning lamp
will be turned on when there is less
than 10% urea capacity.
Refill urea when this lamp is turned on.
WARNING
Use standard urea we recommend.
■ EGR (EURO IV - ISM Engine)
High exhaust pressure and exhaust
filter will reduce PM(particles) and
exhausts passed through cooling
process will be re-circulated through
the combustion chamber so that the
chamber temp will decrease resulting
in reduced Nox (Nitrogen Oxide) it is a
after treatment reducing toxins within
exhausts
Engine Aftertreatment Filter Warning
Lamp will be turned on when there is
excess amount of substances blocking
the filter.
The filter needs to be refreshed when
the light is on
4-23
When you press the engine check
switch (self diagnosis switch) after the
engine start-up, the exhaust filter is
combusted so that the filter is
refreshed.
OM-H252
WARNING
・During the refreshment of the filter,
the exhaust is very hot. Pay extra
care not to get injured.
・If there is a flamable substances
around the exhaust, the substance
may catch fire. Pay extra care.
5
How to Handle Malfunctions ……………………
When lamps on the gauges panel turns
on while driving ……………………………………
When the Engine Does Not Start-up ……………
Engine Overheating ………………………………
How to Handle Fan Clutch is Malfunction………
When Engine Stops While Driving ………………
EMERGENCY AID
5-2
5-2
5-2
5-3
5-3
5-3
Electrical Device Malfunctions …………………
Flat Battery ………………………………………
Tire Punctures ……………………………………
How to Change Tires ……………………………
Tools ………………………………………………
Brake Malfunction ………………………………
Vehicle Tow ………………………………………
5-4
5-5
5-5
5-6
5-8
5-9
5-9
EMERGENCY AID
How to Handle Malfunctions
If abnormality is found during driving,
bring the vehicle into a full stop and
make sure that the other vehicles on the
road know the problems. Also make
sure that the passengers are safe.
a. Turn the emergency light on.
b. Activate the parking brake.
c. Place a support behind the wheel.
d. Place a warning sign 100 meters
away the vehicle if it is on a highway
or vehicle-only road.
CAUTION
・An accident is likely to happen by
an approaching vehicle if the
warning sign is not placed.
・Be aware of the vehicles approaching if
you are fixing the vehicle yourself.
・It is very dangerous to repair the
vehicle on a highway ot inside a
tunnel.
・Parking on a curve is very dangerous.
When the Engine Does Not Start-up
When lamps on the gauges
panel turns on while driving
・Check if the main battery switch is
“ON”.
・Check starter fuse and starter motor.
・Check the battery status.
・Check the battery relay and the main
fuse.
・Check the fuel level.
OM-B180
When the lamp lights on, immediately
bring the vehicle into a full stop, and
check for the problems.
REFERENCE
Lamps such as direction lamp,
speed lamp, and gear neutral light
on during driving.
5-2
CAUTION
Attempting to start engine for more
than 10 seconds continuously by
turning the key on START position
could damage the motor with
overcurrent.
Reconvey the key when the engine
start-up is delayed. Wait for a minute
and try again.
If the car won’t start even after 2~3
attempts, examine the vehicle.
EMERGENCY AID
Engine Overheating
a. Park the car on a safe spot if the
thermometer on the gauge board is
pointing at red area.
b. If the AC is on, turn it off and idle the
engine.
c. If the coolant or steam is leaking
from the tank or if the fan is not
spinning, turn the engine off and
contact the service center.
d. Cool the engine off sufficiently and
check the cooling system and
coolant level.
WARNING
Opening the radiator cap abruptly
could result in serious burn injury. Be
aware when you are refilling the
coolant.
How to Handle Fan Clutch is
Malfunction (BX212)
OM-F119
Release 4 bolts(①) located in the
support under the fan clutch and
connect it to the side of the clutch(②)
and the disc. The clutch will then be
forced to spin.
The fan will spin constantly the engine
could be over cooled. Therefore, this
method should only be used in
emergency and should immediately
serviced.
5-3
When Engine Stops While Driving
If the engine stops while driving, the
steering wheel will become heavier
than usual. Grip the wheel strongly and
park the vehicle on a safe spot for
inspection.
The air pressure will drastically reduce
if the engien stops. Carefully control
the brake.
EMERGENCY AID
Electrical Device Malfunctions
Fuse
Fuses are installed in electrical devices
in the vehicle to prevent overload.
Check the fuse box first if the devices
are malfunctioning.
Rear fuse box locations differ by
vehicle types but they are generally
located within the engine room or the
luggage room.
WARNING
If you use fuses of different capacities,
the electrical devices could get
damaged and cause fire.
You must use appropriate fuses.
Main fuse box is located near the battery.
Fuse Box
CAUTION
・Never use metallic tools such as
drivers to replace the fuse.
・If replaced fuses are damaged
again, it is likely that there is a
problem in the wiring.
You have to get serviced in this
case.
Replacing the fuse
OM-H237E
Front fuse box is located on the right
hand side of the lift inside the dash
panel. The name of the fuse and relay
and their capacities are written on the
board.
OM-B186E
If the fuse is blown, use the fuse picker
in the fuse box to replace them.
REFERENCE
The name, location and the capacity
differ by the vehicle type and
specification. Refer to the fuse box
cover for details.
5-4
EMERGENCY AID
Flat Battery
Tire Punctures
OM-B187E
Use the other battery to start up the
vehicle by following the next steps.
a. Use the parking brake so that the
vehicle would not move.
b. Place the gear shift to“N”.
c. Use the jumper cable to connect the
assistant battery and the discharged
battery.
d. Connect the assistant battery’s“-”
terminal to the unpainted side.
e. Turn the ignition key.
f. When disconnecting jumper cable,
remove the “-”terminal before
removing“+”terminal.
g. Let the engine run to recharge the
discharged battery.
CAUTION
・Do not tow the vehicle to start up
the vehicle.
・Remove the cable after the flat
battery is paritially charged.
Removing the cable right after the
start-up could damage electrical
devices.
・After the battery is discharged,
readjust electrical parts such as
radio and clock.
WARNING
・Do connect the“+”terminal first,
and do not directly connect the“-”
terminal. If this would not be
followed, seriously damages and
injuries might occur.
・Do not place the battery near the
flammable materials because the
battery gives off glammable gas.
5-5
If tires are puctured while driving, the
vehicle will tilt to one side. Grip the
steering wheel and turn the emergency
light on before moving the vehicle to
the side of the road.
Slowly brake the vehicle in several
steps to stop the vehicle.
Slowly brake the vehicle in several
steps to stop the vehicle.
If the tire cannot be replaced, contact
neareast service center for help.
EMERGENCY AID
How to Change Tires
Removing tires
a. Activated the parking brake and turn
the emergency warning lamp on.
b. Place a warning sign behind the
vehicle.
c. Fix the tire which is diagonally
located from the punctured tire with
a support.
d. Remove the wheel cover.
e. Loosen wheel nuts with a socket
ranch.
f. Use a jack to raise the vehicle until
the tire is slightly off the ground.
g. Remove wheel nuts completely with
a wheel nut ranch. Remove the tire.
Tire Installation
When installing the tire, if the bolting
area is dirty, it could affect proper
installation. Clean the area first and oil
the area, bolts and nuts before
assembling them.
a. Put in the tire. Match the disc wheel
holes and bolts.
b. Tighten until the tire is firmly placed.
c. All nuts are to be tightened as the
diagram using a wheel nut ranch.
Refer to the standard torque.
Do not tighten them as the standard
torque at once. Tighten them in 2~3
stages.
REFERENCE
・In case of 8 hole wheel, wheel nuts
of wheels on each side are
tightened in different directions.
The left tire nut is marked with“L”
and the right hand side tire nut is
marked with“R”.
・In case of 10 hole wheel, wheel
nuts spin on the same direction.
CAUTION
The
torque of the wheel nuts must
・
be tightened as the standard.
(refer to 1-11p)
・If you experience steering wheel
vibration, steering problem or such,
stop driving and contact a service
center.
OM-B549
5-6
EMERGENCY AID
If the problem tire is on the front, place
the jack under the front axle.
Insert the ranch handle in the jack and
slowly move it up and down to lift the
vehicle.
CAUTION
Never place the jack anywhere else
than the lower part of the vehicle.
Only place them on dedicated
locations.
OM-B413E
Place the jack under the rear axle in
case of the rear wheels.
OM-B550
How to use the jack
Use the jack only when you are
replacing the tire
OM-B412E
Place the jack on a firm ground when
you are lifting the vehicle.
5-7
WARNING
Use
the jack only in safe places.
・
It
is
very dangerous to start the
・
engine while using the jack.
・It is very dangerous to get under the
vehicle while the vehicle is lifted by
the jack.
・Lifting both wheels off the ground is
very dangerous.
EMERGENCY AID
Tools
Spare Tire
① Toolbox
② Jack
③ Toolbag
④ Handle-Spare Tire
⑤ Plier
⑥ Monkey Wrench
⑦ Wrench-Wheel Nut
⑧ Spanner
⑨ Screwdriver (75mm)
⑩ Screwdriver (150mm)
⑪ Handle-Wrench
OM-B193
Insert the spare tire handle into the tire
carrier hole and turn it clockwise to lower
the tire and turning it anti-clockwise will
raise the tire.
Direct ∩ part of the disc wheel upward
so that the chain does not get tangled.
OM-B194
Tools that are needed for inspections
and repair are stored in the toolbox
located in the luggage room.
5-8
REFERENCE
Toolbox location may differ
depending on the vehicle type and it
may not be there.
EMERGENCY AID
Brake Malfunction
If the brake does not work while
driving, gear down step by step from
5th to 1st gear to reduce the speed.
And use the parking brake to stop the
vehicle completely. It is ok to use the
parking brake directly In emergency
cases.
Vehicle Tow
Towing
Raise the rear wheels when towing.
Release the parking brake and place
the gear on neutral (N).
Lifting the front wheels may cause the
vehicle to activate the brake due to
reduced pressure. Release the parking
brake before towing.
Refer to the next page for how to
release the brake.
CAUTION
・Take the bumper out when towing.
・Be careful not to damage the
bottom part of the vehicle when
towing.
・In case of Air Suspension type
vehicles, pay attention to the air
spering so that it does not come off.
・Use towing vehicles when towing.
5-9
Emergency moving
The start-up key must be turned to
“ON”position.
Gear shift lever is to be set on neutral.
Towing rope should be shorter than 5M
tie a white cloth in the middle of the
rope to make a clear indication.
If the engine does not start, use towing
vehicles.
CAUTION
・Towing speed should be maintained
under 30km/h.
・You must release the parking
brake.
If you cannot release it due to low
air pressure, refer to how to
manually release parking brake.
・Avoid towing for the purpose of
engine start-up.
・Towing hook is for short distance
towing and emergencies. It should
not be used for general purpose of
towing.
EMERGENCY AID
How to manually release parking brake
If you cannot release the brake due to
low air pressure, use the chamber
bolts in the rear wheel spring to
manually release the brake before
towing.
Taking off axle shaft
b. Trun it clockwise and if it gets stuck,
connect the washer and tighten the
nut with a 19mm spanner.
The spring in the chamber will be
compressed and the brake will be
released.
a. Open the cap on the rear part of the
spring brake chamber and insert the
“T”part into the bolt groove in the
chamber.
OM-B200
OM-B199E
c. You have to put bolts, nuts and
washers back into their original
positions.
OM-B198E
5-10
CAUTION
・Rear axle shaft on each side and
propeller shafts should be taken out
before towing.
The automatic gear box may get
damaged if not taken out.
・Be reminded that parking brake and
engine brake will not function if
propeller shaft is taken out.
6
VEHICLE INSPECTION AND MAINTENANCE
1. REGULAR INSPECTIONS
Regular Check-up List and Periodic Table …… 6-2
Oil Standards …………………………………… 6-7
Grease Lubrication …………………………… 6-10
2. GENERAL INSPECTIONS
Accelerator ………………………………………
Brake Pedal ……………………………………
Clutch Pedal ……………………………………
Steering Wheel & Horn …………………………
Heater and Air Conditioner ……………………
6-15
6-15
6-15
6-16
6-16
Ventilation and Fire Extinguisher………………
Wiper and Washer Liquid ………………………
Seatbelt …………………………………………
Pilot Lamp and Instruments ……………………
CNG Vehicles ……………………………………
6-16
6-17
6-17
6-17
6-18
6-19
6-21
6-22
6-22
6-23
6-23
6-24
6-26
6-27
6-28
6-29
6-30
Clutch Oil …………………………………………
Power Steering Oil ………………………………
Air Related Parts ………………………………
Air Cleaner ………………………………………
Tire ………………………………………………
Suspension ………………………………………
Battery ……………………………………………
Starting Motor ……………………………………
V-belt ……………………………………………
Windshield Washer Liquid ……………………
Windshield Wiper Blade ………………………
Bulb Standard / Replacing Various Lamps………
6-30
6-30
6-31
6-33
6-35
6-36
6-38
6-39
6-39
6-41
6-42
6-43
3. VEHICLE MAINTENANCE
Engine Oil ………………………………………
Supplementary Filter for Engine Oil …………
Fuel Filter (Diesel) ………………………………
Gas Filter …………………………………………
Releasing Air from the Fuel System …………
Fuel Injection System …………………………
Coolant……………………………………………
Manual Transmission Oil ………………………
Automatic Transmission Oil ……………………
Rear Axle Oil ……………………………………
Rear Axle and Hub Oil …………………………
Fan Clutch Oil (BX212) …………………………
VEHICLE INSPECTION AND MAINTENANCE
1. REGULAR INSPECTIONS
Regular Check-up List and Periodic Table
Inspection for the listed check items are mandatory, and inspection for unlisted items should be conducted when necessary.
The inspection cycle was established based on the assumption that the vehicles are operated about 5,000km per month on
average under normal conditions. The inspection cycle should be shortened if the vehicle was operated more than the average
distance or under bad conditions.
Inspection
Cycle
Engine
I
B
A
C
D
Initial 1,000km Inspection Every 5,000km Inspection Every 10,000km Inspection Every 20,000km Inspection Every 40,000km
Item
Oil Contamination & Regular Amount of Oil Leakage Part
Air Cleaner Cleaning
Air Cleaner Change
Starting Condition & Noise
Belt Tension & Damage
Oil Change
Oil Filter Change
Idling Speed & Accelerating Condition
Compression Pressure Inspection
Breather Pipe Cleaning
Supercharger Inspection
Exhaust Pipe Damage & Loosening
Valve Clearance Adjustment
Nozzle Spray Pressure Inspection & Adjustment
Nozzle Change
Injection Pump Disassembling, Inspection & Repair
Injection Pump Strainer Cleaning
6-2
Initial
Inspection Cycle
Daily inspection
Every 12,000 km or 300 hour
After 3 cleaning
Daily inspection
Daily inspection
Refer to the Oil Standards
Change with engine oil
Daily inspection
Every 60,000km
C
D
Every 100,000km
C
B
Every 60,000km
Every 20,000km
B
VEHICLE INSPECTION AND MAINTENANCE
Item
Fuel Filter Change (DE08TIS / DE12TIS / DV15TIS Engine)
Fuel Filter Change (DL06 / DL08 / DV11 Engine)
Fuel Filter Change (ISM Engine)
Engine
Gas Filter Change (GE08TI / GE12TI Engine)
Spray Timing Inspection
Fuel Line Leakage Inspection
Exhaust Fume Condition Inspection
Radiator Leakage & Contamination
Water Pump Leakage & Noise
Radiator Core Interior Cleaning
Belt Tension & Damage
Cooling
System
Coolant Change
Antifreezing Solution Density Inspection & Adjustment
Cooling System Inspection
Cooling Hose Change
Oil Leakage
Transmission Oil Change
Control Link Loosening & Damage
Function Inspection & Oil Amount
Pedal Free Play & Height
Clutch
Mini Pack Inspection & Cleaning
Clutch Oil Change
Connection Part Loosening & Damage
Thrust Shaft Spline Abrasion
Bearing
6-3
Initial
Inspection Cycle
C
D
Every 24,000km
C
C
A
Daily inspection
Daily inspection
Daily inspection
Every 100,000km
Daily inspection
Every year
Every new season
Daily inspection
Every 80,000km
A
I
C
D
Daily inspection
Daily inspection
C
Every year
I
A
D
C
VEHICLE INSPECTION AND MAINTENANCE
Rear Axle
Front Axle
Suspension
Steering
Initial
I
Item
Oil Change
Breather Cleaning
Oil Leakage Inspection
Axle Connection Bolt Tightening
Hub Bearing Cleaning & Free Play
Axle Shaft & Housing
Axle Connection Bolt Tightening
Hub Bearing Cleaning & Free Play
Axle Transformation
Tie Rod Bolt & Damage
Air Spring Diaphragm Damage
Leveling Valve & Rod
Shock Absorber Oil Leakage & Function
Shock Absorber Condition
Torque Rod Bushing
Torque Rod Damage
Radius Rod Bushing
Radius Rod Damage
Leaf Spring Damage
Leaf Spring Circle Pin Washer
Leaf Spring“U”Bolt Tightening
Steering Wheel Free Play
Steering Wheel Attached State
Steering Unit Oil Leakage
Steering Unit Attached State
Drag Link Ball Joint
I
Inspection Cycle
C
C
B
Every 100,000km
I
Upon Impact
Every 100,000km
D
D
I
Upon Impact
Every 60,000km
B
B
B
D
B
D
B
D
D
B
D
Daily inspection
B
B
D
I
6-4
Every 60,000km
VEHICLE INSPECTION AND MAINTENANCE
Steering
Brake
Item
Wheel Alignment State
Rotation Degree Inspection
King Pin & Bearing Free Play
Power Steering Oil Inspection
Power Steering Oil & Filter Change
Function Inspection
Brake Pedal Free Play
Compressed Air Leakage State
Subsidiary Brake & Parking Brake Activation Inspection
Lining & Drum Abrasion Inspection
Relay Valve Inspection
Auto Drain Valve
Pressure Control Valve Inspection
Brake, Relay, Pressure Control Valve Exhaust Pipe Cleaning
ABS Wheel Speed Sensor Clearance Inspection & Adjustment
Air Compressor Pipe Inspection & Head Carbon Elimmination
APU Drying Agent Change
APU Oil Separator Cleaning (O Ring Change)
Governor Activation Inspection
Brake Valve Disassembling & Inspection
Brake Chamber Disassembling & Inspection
Relay Valve Disassembling & Inspection
Pressure Control Valve Disassembling, Inspection & Change
Governor Pressure Disassembling & Inspection
Slack Adjuster Disassembling & Inspection
Stop light Switch Inspection
6-5
Initial
Inspection Cycle
C
C
D
A
D
Daily inspection
Daily inspection
Daily inspection
Daily inspection
When Necessary
C
D
C
A
D
D
Every year or 100,000km
Every 300,000km
C
Every 80,000km
Every 80,000km
Every 100,000km
Every 100,000km
D
Every 100,000km
C
VEHICLE INSPECTION AND MAINTENANCE
Brake
Wheel
&
Tire
Retarder
Brake
Item
Air Tank Inspection & Compressed Water Elimination
Brake Cam Oiling Inspection
On Hill Parking Capability Inspection
Elasticity & Braking Capability Inspection
Tire Damage & Air Pressure
Wheel Nut Tightening
Wheel Disk Rust Elimination & Cleaning
Wheel Balance
Tire Position Change & Tire Change
Function Inspection
Oil Inspection
Initial
I
Inspection Cycle
Daily inspection
Upon Attachment/Detachment of Hub
C
D
Daily inspection
D
Upon Attachment/Detachment of Wheel
When Necessary
When Necessary
A
C
CAUTION
1. Conduct inspection and maintenance on a flat location.
2. Prevent accidents by preparing for them during inspection and maintenance.
3. Always use the lift when working under the vehicle during inspection and maintenance.
4. Allow ventilation when working in a closed space with the engine running to prevent exhaust fume inhalation during
inspection and maintenance.
6-6
VEHICLE INSPECTION AND MAINTENANCE
Oil Standards
Subject
Oil Type
Diesel
Engine Oil
Engine
CNG
Engine Oil
Engine Oil
Cleaner
CNG
Engine Oil
Manual
Transmission
Gear Oil
Model
DE08TIS
DE12TIS
DV15TIS
Change Cycle
Capacity
・Initial : 1,000km
19ℓ
・Long distance : every 30,000 km
22ℓ
・Shot distance : every 20,000 km
23ℓ
・Initial : 5,000 km
DL06
・Driving in downtown/short-haul :
17ℓ
DL08
Every 40,000 km
27ℓ
DV11
・Driving at high speed/long-haul :
34ℓ
Every 60,000 km
・Initial : 1,000 km
32ℓ
ISM
・Every 24,000km
・Initial : 1,000 km
・Driving in downtown/short-haul :
15.5ℓ
GE08TI
Every 20,000 km
17ℓ
GE12TI
・Driving at high speed/long-haul :
Every 30,000 km
Change
along
with engine oil
FILTECK
2.5ℓ
(Inapplicable for diesel engine vehicles)
RRR
2.5ℓ
T9DS5A
11ℓ
T9DS5P
11ℓ
・Initial : 5,000 km
T10S5B
13ℓ
T10DS5C
13ℓ
・Every 24,000 km
T14DS5A
13ℓ
T16DS6Q
17ℓ
※ Inspection & Refill :
T17DS6Q
17ℓ
Every 4,000km after the initial one at
T17DS5A
17ℓ
1,000km
T18DS6Q
17ℓ
T18DS5A
17ℓ
6-7
Standard (Grade)
API CH-4 Grade
(SAE 15W40)
or ACEA E2/E3 Grade
SAW 10W40
(API CI-4 Grade)
SAE 15W40
(Above API CH-4 Grade)
CD Grade or Above CE Grade
15W40
CD Grade or Above CE Grade
15W40
SAE 80W90
(GL-4 Grade)
VEHICLE INSPECTION AND MAINTENANCE
Subject
Oil Type
Gear Oil
Manual
Transmission
Engine Oil
Auto
Transmission
ATF-AUTO
T/M
FLUID
Model
K1005D
K1005R
K1005C
K1205D
K1405A
K1606R
K1706R
6S1901
T270
T350
T270R
T350R
D851
D854
D863
D864
Capacity
Change Cycle
9.7ℓ ・Initial : 5,000 km
9.7ℓ ・Every 24,000 km
9.7ℓ
9.7ℓ ※ Inspection & Refill :
14.5ℓ
Every 4,000km after the initial one at
16ℓ
1,000km
16ℓ
Driving in downtown/short-haul :
・
Every 120,000km or year
16ℓ
Driving at high speed/long-haul :
・
Every 160,000km or year
※Filter Change : Change along with engine oil.
Driving in downtown :
25~28ℓ ・Every 120,000km or 3 year or 3,000 hours
Driving at high speed :
28~30ℓ ・Every 240,000km or 4 year or 4,000 hours
25~28ℓ
Every 60,000km or 2 year
Driving in downtown :
・
Every 90,000km or 2 year or 3,000 hours
23~25ℓ
Driving at high speed :
・
Every 120,000km or 2 year or 3,000 hours
Driving in downtown :
・
Every 360,000km or 3 year
12AS2001 15.5ℓ
Driving at high speed :
・
Every 540,000km or 3 year
HP502C
HP592C
HP602C
Gear Oil
6-8
Standard (Grade)
SAE 80W90
(GL-4 Grade)
SAE30
TES 295
DEXRONⓇ-III
TE-ML14
SAE 75W80
TE-ML02E (ZF)
VEHICLE INSPECTION AND MAINTENANCE
Subject
Oil Type
Model
Capacity
Propeller
Shaft
Chassis
Grease
ALL
0.01ℓ
Rear Axle
Gear Oil
ALL
11.5~12.5ℓ
・Initial : 5,000 km
・Every 24,000 km
SAE 80W90
(GL-4 Grade , GM 4744M)
Power
Steering
Steering
Oil
ALL
8.5ℓ
・Initial : 5,000 km
・Every 40,000 km
DEXRON-III
Clutch
Brake Oil
ALL
2~2.5ℓ
Retarder
Engine Oil
Hub
Bearing
Grease
ALL
Necessary
Amount
When attaching/detaching hub or
every 40,000km
NLG, 1/2/3
(KSM2130, GM 4750M)
Auto
Greaser
Chassis
Grease
Equipped
Vehicles
Set
Amount
Automatic oiling activated by timer
NLGI 0 (VOGEL, GUMHO)
NLGI 2 (LINCOLN)
Manual
Greaser
Chassis
Grease
ALL
Necessary
Amount
Fan Clutch
Gear Oil
Application
Vehicles
400㎖
Antifreezing
Liquid
ALL
Rust
Inhibitor
ALL
Cooling
System
6ℓ
40% off
coolant
amount
3~5% off
coolant
amount
Change Cycle
When Necessary
Every year or 60,000km
Every 4,000km
Every 4,000km
Every 80,000 km ~ 100,000km
・Concentration Inspection & Supplement :
Every month
・Change : Every year
Change along with antifreezing liquid
REFERENCE Use oils fit for above standards.
6-9
Standard (Grade)
NLGI 2~3
FMVSS 116 , DOT3 , KSM2141
SAE 15W40 (CG-4)
GM 6013M
Symth SAE 75W90
Antifreeze LLC Grade
DCA65L
VEHICLE INSPECTION AND MAINTENANCE
Grease Lubrication
■ Grease Lubrication Points
※ Grease feeding locations differ by vehicles types and installed options.
TYPE A
OM-S092E
6-10
VEHICLE INSPECTION AND MAINTENANCE
TYPE B
OM-F115E
6-11
VEHICLE INSPECTION AND MAINTENANCE
■ Manual Grease Lubrication
Apply appropriate amount of oil to the
check points using a grease pump
after every 4,000km.
CAUTION
・Feed recommended grease after
thoroughly cleaning the grease
nipple.
・Be careful not to spill the grease on
the floor.
・Clean smeared grease off the
wiring and vehicle body after
refilling.
WARNING
Turn the start-up isolation switch
located engine room power off when
greasing propeller shaft, engine idle
pulley and other spinning parts.
(Refer to 2-6p)
■ Automatic Lubrication Device(OPTION)
Grease is applied automatically and
periodically at set times on to the
check points by the automatic control
system in vehicles equipped with the
automatic lubrication device.
REFERENCE
・Even though a vehicle may be
equipped with the automatic
lubrication device, grease is not
applied to some parts depending on
the device’s model. Therefore,
grease must be manually applied
every 40,000km.
・Manual Lubrication Points : Rotating
points such as the propeller shaft and
the engine idle pulley.
The automatic greaser warning lamp
turns on for 3 seconds when the
battery main switch is in the“ON”
position, and it turns off when the
engine starts.
The indication is on when automatic
grease feeding device is operational. It
will be constantly on if the device
malfunctions.
6-12
OM-B212
Lubrication is automatically applied to
each point through the activation of the
pump at set times of the controller. The
interval time cycle is continuously
repeated upon every operation of the
battery main switch, and the interval
time is not accumulated when the main
switch turned“OFF”.
REFERENCE
The factory set automatic lubrication
time.
・Interval Time : 7 hours
・Contact Time : 2 minutes 30
seconds
※ Maintaining the factory set time is
highly recommended.
VEHICLE INSPECTION AND MAINTENANCE
Using the Automatic Lubrication Device Controller (KUMHO, VOGEL)
•SET : The switch is used to apply
the changed setting such as the
interval time, the contact time, and
the count.
•MODE : This switch is used to move
between options. It moves in the
order of INTERVAL TIME →
CONTACT TIME → COUNT →
VOLTAGE → ERROR CODE →
INTERVAL TIME.
OM-B213
•MANUAL : The switch is used when
operating the motor manually. Initial
activation of the switch activates the
device for a set contact time.
Therefore, it allows manually
application of the lubrication to each
point, and is especially effective
during a rain or after a car wash.
•TEST : The switch is used to test the
lubrication by repeating on/off after
reducing the interval time and the
time to a specific cycle. Activating the
TEST switch activates the device for
15 seconds, deactivates it for 15
seconds, activates it again for 15
seconds, and repeats this cycle
continuously. Therefore, return the
switch to its original position after the
testing is completed.
•▲ : The switch increases a value.
Holding the switch down results in a
faster increase in the value due to
the automatic repeat function.
•▼ : The switch decreases a value.
Holding the switch down ewsults in a
faster decrease in the value due to
the automatic repeat function.
REFERENCE
The controller is installed in the fuse
box in the luggage room.
6-13
VEHICLE INSPECTION AND MAINTENANCE
●
Refilliong Grease in & Evacuating Air from the Automatic Lubrication Device
Always maintain the amount of grease
in the automatic lubrication device over
the“MIN”line, which indicates the
minimum required amount. Fill the tank
up to the“MAX”line, which indicates
the maximum capacity using the
grease supplementing device.
Make sure to evacuate air after filling
the device with grease. With the
battery main switch in the “ ON”
position, open the plug at the end of
the separator, press the “ TEST”
switch on the automatic lubrication
device controller, wait until grease
flows over, connect the plug at the end,
and press the“TEST”switch again.
CAUTION
・If there is no grease in the grease
storage tank of the automatic
lubrication device, pressure cannot
be generated upon activation of the
pump, and as a result, it may cause a
break down. Therefore, occasionally
check the tank for sufficient amount
of grease, and refill it if there is
insufficient amount remaining.
・Make sure that no other substance
flows into the tank while refilling,
and also that the grease is being
properly to the lubrication points.
6-14
REFERENCE
・The automatic Greaser warning
lamp turns on even when the
storage tank does not have sufficient
amount of grease.
・Check the storage tank and receive
inspection from a close maintenance
plant if the warning lamp repeatedly
turns on during operation of the
vehicle.
VEHICLE INSPECTION AND MAINTENANCE
2. GENERAL INSPECTIONS
Accelerator
Brake Pedal
Clutch Pedal
Check the accelerator condition.
Check for the brake pedal condition.
For the diesel vehicles, check whether
the engine reaches its maximum rpm
when the accelerator was pressed to
the limit.
Check whether the brake chamber’s
lot functions properly and the return
motion is smooth.
In case of CNG vehicles, check if the
RPM reaches the max speed and
maintains the speed when acceleration
pedal is fully pushed in.
CAUTION
For the vehicles with the turbo
charger, sudden acceleration right
after engine ignition is the cause for
the damages of the engine and turbo
charger, so avoid from sudden
acceleration.
Check whether the braking functions
well by driving short distance.
OM-B174
CAUTION
Brake test must be performed at the
designated location, and must be
performed where there are no
people and other vehicles.
If the brake pedal feels deeper and
heavier, you have to get the vehicle
serviced immediately.
Driving with the condition could result
in severe accident.
6-15
Check for pedal condition, and the
smoothness in changing gears.
VEHICLE INSPECTION AND MAINTENANCE
Steering Wheel & Horn
Heater and Air Conditioner
Check the wheel by turning it to the
right and the left with the engine
started.
Check whether the heater works by
opening the heater valve of the engine
room.
Check whether the wheels rotation is
normal.
Check whether the air conditioner
functions normally, even in the winter.
Use air conditioner at least once a
week.
Check the condition of the wheel by
driving through a short section of the
road.
Check the horn my pressing the horn
button.
REFERENCE
Steering wheel condition and
revolution
・ Condition : Straight course
approximately 20~50mm.
・ Revolution : 2 and 1/3 times to the
right and the left respectively.
6-16
Ventilation and Fire Extinguisher
Check ventilation system is functioning
properly.
Check whether the fire extinguishers
are on board and check whether they
are ready to use.
Check whether the
hammer is present.
emergency
VEHICLE INSPECTION AND MAINTENANCE
Wiper and Washer Liquid
Seatbelt
Pilot Lamp and Instruments
Check whether the seatbelts at the
driver’s and passenger’s seats are
working properly.
Check whether the seatbelt
confirmation lamp is working properly.
OM-H067
OM-H234
Check whether the wiper works
properly, and also check for the
damages on the wiper. Check for the
washer liquid spary and the amount of
liquid.
Check whether the pilot lamp and
instruments are working properly.
Check upon ignition whether the pilot
lamp and other lamps are working
properly and if the warning lamp is
turned on, check and fix that part.
6-17
VEHICLE INSPECTION AND MAINTENANCE
CNG Vehicles
Examination of CNG Leakage
CNG bus uses gas as its fuel and
therefore gas leakage in the gas pipe
line must be frequently checked.
Main gas leakage inspection parts
must be checked with soap solution,
concentrating on the connection parts.
If gas leakage occurs, retighten the
connection parts and run the gas
leakage inspection again.
Electronic Device Examination
Due to the application of electronic
control engine in the CNG bus, many
electronic devices are installed in the
vehicle.
Run the inspection of the electronic
devices with the concentrating on the
wiring connection parts and check the
connection state. Also, examine the
fixed parts of electronic wiring so that
wiring due to intervention is not
damaged.
6-18
VEHICLE INSPECTION AND MAINTENANCE
3. VEHICLE MAINTENANCE
Engine Oil
Engine Oil Pressure
Engine Oil Care
Oil checkup must be performed on the
flat level ground and perform checkup
on a vehicle after 20~30 minutes of
driving.
OM-B216
Check the engine oil gauge for
standard capacity.
In case of shortage of engine oil, fill
engine oil and check again after
running the engine for 5 minutes.
In using engine oil, diesel engine oil
and CNG engine oil must be
separated. And for oil filter use the
product of our company.
Oil level must be between the
maximum level and the minimum level,
if it reaches minimum level refill.
Oil can be used up during driving.
Frequently refill engine oil.
※DV11 Engine
If the oil’
s viscosity or color is consideres
abnormal, request mechanics to check
and fix.
OM-H026
6-19
(kgf/cm2)
Engine
DL06
DL08
DV11
GE08TI
GE12TI
ISM
Idling
Driving
1.0 ~ 3.0
3.0 ~ 5.5
1.5 ~ 3.0
3.5 ~ 5.5
0.8 ~ 1.4
3.0 ~ 4.8
0.7 ~ 1.0
2.1 ~ 3.5
Engine Oil Change Cycle & Capacity
Refer to “ Oil Standards”(6-7page).
REFERENCE
While a vehicle may not be operated
frequently, it must change engine oil
at minimum of twice a year.
VEHICLE INSPECTION AND MAINTENANCE
Changing the Engine Oil
a. Place a container under the oil fan
drain plug to hold the engine oil.
b. Pull out the drain plug form the oil fan
while the engine is warm, and open
the oil inlet cap for easier draining.
※DV11 Engine
c. After the oil gas been completely
drained, assemble the drain plug
with a new sealing.
CAUTION
A new sealing must be used, and
follow the suggested tightening
torque. ( Approximately 8kg.m )
d. Dissemble the oil filter.
e. Assemble the new oil filter.
f. Fill the new engine oil through the oil
inlet, idle the engine for about 5~10
minutes, and check the amount of oil
using the oil dipstick gauge.
Supplement more oil when necessary.
OM-H027E
WARNING
Since the oil and the engine
component parts are hot when
conducting the inspection right after
operation of the vehicle, be careful
not to get burned.
6-20
CAUTION
・Always use genuine parts for the oil
filter, and make sure not leave out
the sealing and the o-ring during
assembling.
・Always follow the regulated torque
for the oil filter housing fixing bolts.
(Approximately 5kg.m)
VEHICLE INSPECTION AND MAINTENANCE
Supplementary Filter for Engine Oil
Applies only to compressed CNG
vehicles.
OM-B217
Carbon, moisture, sludge, sulfur
powder, metallic powder that results in
the oil due to engine operation is
filtered the main filter and than
continuously eliminated through the
supplementary filter to maintain a high
degree of purity of the oil.
■ FILTEC
・Type : FTK-50
・Standard : Ø160 x h195
・Replacement period
Type
Replacement
period
Engine oil cleaner
supplementary filter
20,000km
■ TRIPLE R
・Type : TR-5C100
・Standard : Ø210 x h160
・Replacement period
Type
Replacement
period
Engine oil cleaner
supplementary filter
8,000km
6-21
CAUTION
・Since the oil temperature is very
hot, you might suffer a burn when
inspecting or replacing the filter.
Always inspect and replace the filter
after the oil has sufficiently been
cooled down.
・Since the oil and filter replacement
period differs according to the
vehicle’s engine condition and
operating condition, inspect and
replace regularly.
・When replacing the filter, if you find
any other substances or twisted
filter, call and have an after service.
VEHICLE INSPECTION AND MAINTENANCE
Fuel Filter (Diesel)
Gas Filter (CNG)
Replacement of Fuel Filter
Filter out the moisture and other
substances in the fuel filter every
20,000km (at most)
(Inspect as regularly as possible)
a. Stop the engine.
b. Turn the drain valve which is under
the cartridge counter clockwise
about 3 times to filter out the dirty
fuel and moisture.
c. If pure fuel drains continuously, turn
the drain valve clockwise to close.
CAUTION
・Fuel leakage can be the cause of
fire, so please make sure whether
fuel is leaking around the filter after
replacing the fuel filter by initializing
a test drive.
・Always use the original product
when replacing the fuel filter.
Inspecting & Change Cycle
Refer to“Regular Check-up List and
Periodic Table”(6-2 page).
OM-S024E
The filter filters the contamination of
the CNG tank is supplied to the engine
from the gas tank.
Periodically inspect the gas filter and
clean the gas filter housing. If the gas
filter is contaminated, replace it.
REFERENCE
Recommended gas filter inspection
and replacement cycle
・Inspection : Every 5,000km
・Replacement : Every 20,000km
OM-B218E
6-22
VEHICLE INSPECTION AND MAINTENANCE
Releasing Air from the Fuel System
If the engine turns off due to fuel
shortage, the engine may not startup
again just by refueling. This could be
because of air inside the system and
the air should be released as following.
Fuel Injection System
CAUTION
・ Check if the fuel is leaking after the
process.
・ The fuel may catch fire if it is
smeared on the vehicle.
high pressured fuel created from the
high pressure pump is stored in the
common rail, and the timing of the
initial injection period and fuel amount
is calculated according to the data
programmed in the ECU (Electrical
Control Unit). The ECU then operates
the injector’s solenoid valve, which is
installed in each engine cylinder to
inject the fuel.
※DV11 Engine
OM-B219
a. Loosen the plug(2) on the fuel filter.
b. Press priming pump(1) several times
untill fuels come out without
bubbles.
c. Securely tighten the plug(2) if fuels
come out of the plug with out bubbles.
OM-H028E
6-23
VEHICLE INSPECTION AND MAINTENANCE
Coolant
Common rail
Common rail denotes the direct
injection engine.
Unlike the basic engine that injects the
mixer, this method uses technology
which significantly improved combustion
efficiency by supplying fuel to the
cylinder directly. For the directly injected
fuel to sustain a constant explosion
within the cylinder, it must maintain a
pressure so high close to that of gas. An
injection, which maintains high pressure
of compressed fuel, makes it possible to
maintain a proper level of fuel pressure
for all kinds of engine operation state
through common rail injection.
Characteristics of common rail
High pressurized injection (1,600 bar)
Inspection and Replenishment
If the coolant, open the surge tank cap
and refill.
Realize optimization of mixed fuel air.
Achieving high output, low air pollution
of exhaust gas, optimal fuel efficiency.
Maintain the middle level between min
and max line of the surge tank for
coolant.
Control of speed and output’s injection
pressure, and injection timing in all
areas.
Realize injection digression.
Optimal noise, combustion, and output
capabilities.
Supplementary function for after
processing exhaust gas.
6-24
OM-F136E
WARNING
If the coolant cap is opened while the
engine is hot, hot vapor and water
might cause burns.
VEHICLE INSPECTION AND MAINTENANCE
CAUTION
・When the temperature gauge of the
dashboard goes up abnormally
during operation of the vehicle,
inspect the amount of coolant.
・If the antifreezing solution is stained
on the surface of the coating, the
coated surface might be damaged
so be careful not stain, and
immendiately wipe it off with water.
・If the coolant is stained on your
skin, it might irritate your causing
skin disease. Wash it off with soap
and water or hand cleaner.
Replacement of coolant
Open up the drainage cork, which is
located under the radiator and the rear
side of the engine to drain the coolant.
After completely draining the coolant,
close the cork and supplement the
coolant. Open up the drainage cork
again to drain some amount of the
newly supplied coolant and then
completely close the cork and supply
the coolant again. After 10 to 30
minutes, run the engine so that the air
is discharged. Make your final
inspection of the coolant amount and
supply some more coolant if necessary.
Close the cap.
※DL08 Engine
OM-S027E
6-25
OM-S105
CAUTION
Inspect
to see if there is any leakage
・
after replacing the coolant.
・ If you do use any antifreezing
solution and just use water, the
engine and the coolant department of
your vehicle wil corrode and
decrease significantly the life span of
the engine. Always use our original
product when using antifreezing
solution.
REFERENCE
Internal cleaning of the radiator once
every year will increase the cooling
circuits durability, and increase the
cooling effect.
VEHICLE INSPECTION AND MAINTENANCE
Manual Transmission Oil
Replacement of Oil
a. Loosen the drain plug and tighten it
back after releasing the oil.
b. Open the oil fill and checkup plug
and refill oil until overflowing.
c. Close and secure the oil fill and
checkup plug.
Coolant Care in Summer
Use the antifreezer (more than 15%)
even in summer.
Coolant Care in Winter
Antifreezing liquid
Atmospheric
Temperature
Coolant
Antifreezer
Above 0℃
85%
15%
-10℃ ~ 0℃
80%
20%
-15℃ ~ -10℃
73%
27%
-20℃ ~ -15℃
67%
33%
-25℃ ~ -20℃
60%
40%
-30℃ ~ -20℃
56%
44%
-40℃ ~ -30℃
50%
50%
Oil Change and Checkup Period
・Replacement : Refer to“Oil Standards”
(6-7 page).
・Checkup and Refill : At the first
1,000km and every 4,000km.
●
OM-B223E
Oil checkup must be performed on a flat
level ground, and must be performed
after driving when the oil is hot.
Oil level checkup must be performed
by disengaging oil fill and checkup
plug, and oil level must adjusted so
that the oil flows down to the oil fill and
checkup plug.
6-26
VEHICLE INSPECTION AND MAINTENANCE
Automatic Transmission Oil
Long term parked vehicle automatic oil
level checkup how to
℃)
(Approximately 30℃
Following three steps must be followed
in checking oil level for the vehicle that
was parked for a long time.
OM-S075E
Oil level checkup how to in the operative
℃)
temperature range (80~90℃
Check must be performed with the
vehicle not in motion and with the shift
button adjusted to“N”and with engine
running (Approximately 500~700rpm)
for about 2 minutes.
・First step : Checkup before engine
ignition.
Check if the oil level is over the
“Engine Stop Condition”zone.
Do not drain oil even if the oil level is
slightly higher.
・Second step : Checkup after the
engine ignition.
Checkup must be performed with the
vehicle not in motion and with the
shift button adjusted to“N”and with
engine running (Approximately
500~700rpm) for about 3~5 minutes.
Check if oil level is slightly above the
“Cooling Condition”zone.
Do not drain oil, even if the oil level is
slightly higher.
・Third step : Oil level checkup in the
operative temperature
range.
Oil level checkup is performed in the
1’s operative temperature range.
Checkup whether oil exists in the
automatic oil level gauge’s operative
temperature range.
6-27
VEHICLE INSPECTION AND MAINTENANCE
Rear Axle Oil
Replacement of Oil
a. Loosen the drain plug and tighten it
back after releasing the oil.
b. Open the oil fill and checkup plug
and refill oil until overflowing.
c. Close and secure the oil fill and
checkup plug.
Replacement of Oil
Oil Change and Checkup Period
・Replacement : Refer to“Oil Standards”
(6-7 page).
・Checkup and Refill : At the first
1,000km and every 4,000km.
●
OM-S073E
a. Unscrew oil drain plug when the oil
is hot and then stop the engine,
disengage oil filter cover and change
filter, oiling, and washer.
b. After oil drain plug is installed,
disengage oil level gauge and fill oil.
c. Check oil level.
CAUTION
When changing automatic oil, also
change the filter.
OM-B224E
Oil checkup must be performed on a flat
level ground, and must be performed
after driving when the oil is hot.
Oil level checkup must be performed
by disengaging oil fill and checkup
plug, and oil level must adjusted so
that the oil flows down to the oil fill and
checkup plug.
6-28
REFERENCE
Oil capacity is directed oil capacity,
and must be kept in checking oil level.
VEHICLE INSPECTION AND MAINTENANCE
Rear Axle and Hub Oil ( BS110CN / BS120CN )
Replacement of Oil
Unscrew drain plug at the axle case and
axle shaft wide beam and drain oil. Put
the plug back on after draining.
●
OM-S076E
OM-S074E
Rear Axle Case
Oil check must be performed on a flat
level ground and performed after
driving when the oil is hot.
Rear / Front Axle Hub
Oil level check must be performed by
leveling oil drain plug and vehicle.
Disengage drain plug and check the oil
level.
Disengage oil level check plug before
oil level check, and adjust oil with oil
level check plug so that oil would flow
down.
6-29
Replacement of Oil
a. Drain oil by turning the tire so that the
drain plug’
s axle hub faces down.
b. Fill oil with drain plug by turning the
tire so that the drain plug’s axle hub
and vehicle gets leveled.
●
REFERENCE
● Oil Change and Checkup Period
・Replacement : Initial 5,000 ~ 10,000km.
Every 90,000km
※Change at least once a year, even
if the vwhicle isn’
t used often.
・Checkup period : At least once a
month.
● Oil Capacity
・Recommended Model : Gear Oil
API GL-5, MIL L-2105D
・Rear Axle Case Oil Capacity :
Approximately 18~21ℓ
・Axle Hub Oil Capacity : Approximately
0.7ℓ(For each hub)
※ Above oil capacity is directed oil
capacity, and must be kept in
checking oil level.
VEHICLE INSPECTION AND MAINTENANCE
Fan Clutch Oil (BX212)
Clutch Oil
Power Steering Oil
OM-F120
OM-B225
OM-B226
Replacing oil should be performed on a
level ground after driving when the oil
is warm.
Check for cluctch oil level and
contamination level, and if the oil is
short, do refill up to the marked level.
Performed the checkup on flat level
ground and refill short.
Replacement of Oil
a. Release the oil by opening drain
plug(1) and close it back again.
b. Feed new oil after opening pressure
release valve(2). Replace the sealing.
c. Close the pressure release valve(2).
●
REFERENCE
・Replacement :
Every 80,000 ~ 100,000km
・Capacity : 400㎖
・Standard : Synth SAE 75W90
Oil Change Period and Recommended
Spec.
Refer to“Oil Standards”(6-7 page).
WARNING
・ Accident might occur, if the clutch
oil is low.
・ If clutch oil cap is not completely
closed, oil could overflow and
damage the surface or cause fire.
6-30
Oil must be leveled between the“MIN”
and“MAX”.
When changing oil, also change the oil
filter.
Oil and Filter Change Period
Refer to“Oil Standards”(6-7 page).
●
VEHICLE INSPECTION AND MAINTENANCE
Air Related Parts
APU (Air Processing Unit)
Air Tank
Safety Valve
Inspect damages in the exterior and
in each part, and replace with new
parts, if defects are found.
If the air pressure is below the valve
opening pressure, there must not be
any air leakage to the safety valve.
●
CAUTION
Condensed dews in the air line may
freeze during the winter season.
Replace APU cartridge and check if
the condensation is properly released
from the air tank.
OM-F118
It is a device that dehumidifies the air
inside the compressor and distributes
the air.
Automatic Drain Valve
Check if humidity and air are
automatically and smoothly released.
Release the humidity manually by
pressing the rubber cap below the
valve.
●
The cartridge should be replaced every
year or every 100,000km trip distance.
Oil seperator should be cleaned every
30,000km and the O-ring should be
replaced.
Replace the oil separator if necessary.
OM-B429E
6-31
VEHICLE INSPECTION AND MAINTENANCE
Automatic Drain Valve
OM-B230
Activation principles
The solenoid coil(4) loses its electric
power and core(1) which is under the
pressure of the storage tank,
approaches the sheet(2), while the bus
is in operation.
●
A mixture of water and oil is collected
in the empty space(5) through the
open sheet(6).
The solenoid oil earns its electric
power and starts its movement, and
the core(1) approaches the upper
sheet(2) after opening the lower sheet
(6), upon application of the brake
pedal. The contaminated mixture flows
to the empty space(5), which is now
below the core, through the core’s
route.
● Inspection point
Check the air evacuation of the auto
drain valve and the magnetic activation
noise by applying and releasing the
brake pedal about 5 times.
The circulation stops, the solenoid coil
(4) loses its electric power and stops
the movement, and the core eliminates
the contaminated mixture from being
under the pressure of the storage tank
and become in contact with the sheet
(2), upon releasing of the brake.
Check the operating condition again
after reinstallation, and check for air
leakage using soap water.
Drain function can be tested manually
by pressing the red button(3) of the
automatic drain valve.
Inspection & Maintenance cycle
Every 10,000km or every 3 months.
●
6-32
If any defect is found, repair or replace
the automatic drain valve using the
repair kit.
REFERENCE
・Contaminants such as air and oil
are drained automatically from the
auto drain valve upon releasing of
the brake pedal. Approximately 2cc
of air is evacuated such action.
・Adjust the tightening torque of the
tank connecting nut to 30 ± 5Nm,
when reinstalling the automatic
drain valve.
VEHICLE INSPECTION AND MAINTENANCE
Air Cleaner
Air cleaner must be periodically
checked and changed.
Check if the indicator located at the air
cleaner pipe is red, clean or change.
Then make sure that the indicator turns
to brown.
CAUTION
If the air cleaner condition is unfit, it
will have a negative effect on the
vehicle.
REFERENCE
Air cleaner element cleaner and
change period
・Clean : Every 12,000km or 300
hours
・Change : After cleaning about 3
times
Inspection of the air cleaner indicator
A yellow indicator signal indicates that
the element is in normal condition,
while a red indicator signal indicates
that the element has been polluted.
Polluted element should be removed
and cleaned or replaced to maintain
normal condition of the device.
Returning the indicator
After cleaning or replacing the element,
press the push button on the upper
section of the indicator to return the
signal to its original position(Yellow).
OM-B233E
6-33
Replacing the element
OM-B285
a. Remove the dust cover fixing wing
nut and washer from the element
housing.
b. Remove the air cleaner element by
removing the element fixing nut.
c. Balance the element well during
mounting, and after it’s mounted
tighten the nut.
d. Assemble the dust cover plate of the
element housing.
CAUTION
Always use genuine parts for the
element, and replace with new
element after cleaning about 3 times.
VEHICLE INSPECTION AND MAINTENANCE
Cleaning the element
If the element is polluted in a dried
condition, use the compressed air to
blow the element from inside out.
CAUTION
Use the compressed air with the
pressure below about 7kgf/cm2, and
always blow the dust and contamination
from inside out.
When the Element is Covered with
Soot
Put the element into lukewarm water
for about 30 minutes, in which some
element cleaning detergent is
dissolved in. Take out the element and
wash it under running water.
(Pressure below 2.8kgf/cm2)
●
● Element Inspection
Check for any damages by shining a
light inside the element after it is
completely dried.
OM-B235
6-34
OM-B236
VEHICLE INSPECTION AND MAINTENANCE
Tire
Check whether the pressure of the tire
and check if there are any ware and
abrasion in the tire.
Tire Care in Summer
Check for tire air pressure, since in
summer, tire temperature rises as the
surrornding temperature rises.
Prevent the damages on tire due to the
sudden temperature increase when
braking.
OM-B237
OM-B159E
Radial tire, due to its characteristics,
shows significant ware of the tire. So it
must be changed often.
Upon checking the tire pressure with
the air pressure gauge, if the air
pressure isn’t enough, make sure the
air pressure is stable. Abnormal air
pressure of the tire might cause
shortage of the tire life span, and
especially if the tire air pressure is low,
it will cause tire damage.
OM-B238E
Also, if the tire gets worn down about
1.6mm, change the tire.
6-35
VEHICLE INSPECTION AND MAINTENANCE
Suspension
Air Spring Control
● Caution for Maintenance & Inspection
Make sure that oils are not applied to the air spring during
maintenance and repair. Upon welding, always cover the air
spring area with the air spring protection device.
・Adjustment height of the vehicle’s attachment state
Front
Rear
Check whether the guide ring is in the standard position after
the jack has be lowered since sudden lifting of the vehicle’
s
body may lead to detachment of the guide ring due to the
negative pressure within the air spring.
Regular Height ※ Can be adjusted depending
on conditions such as the
270
vehicle’
s operating condition.
260
CAUTION
Adjust the spring height on a surface after starting the
engine.
(At normal air pressure)
Support the vehicle with standard height supporters when
the vehicle is not being operated for a long period. This
prevents compression even when air evacuates from the air
spring.
Air Spring Inspection
Check the height of the air spring.
●
・Air Spring
Standard
Height
Maximum
Compression/Tension Amount
Front
270
±100
Rear
260
±100
OM-H001E
6-36
VEHICLE INSPECTION AND MAINTENANCE
•Suspension Rod Control
・Stabilizer Bar & Connecting Rod
Inspect the bending and cracking of the stabilizer bar, the
loosening of the rod pin’
s nut, and the abrasion and cracking
of the rubber bushing.
•Leveling Valve
Connected to the frame and axle, the rod of the leveling
valve controls the height of the air spring.
Front : 1 leveling valve
Rear : 2 leveling valves (Left, Right)
・Torque Rod, Radius Rod
Inspect the cracking of each rod and the wearing off and the
cracking of the rubber bushing of each rod pin.
REFERENCE
・Inspect the torque rod if the vehicle was operated with
repetitive sudden accelerations & stops. Inspect the
radius rod if the vehicle was operated on sharp corners
and frequent turns.
・Periodically replace the rubber bushings of each rod at
appropriate times. If excessive noise is heard, dissemble,
inspect, and repair it.
OM-H002E
6-37
VEHICLE INSPECTION AND MAINTENANCE
Battery
Battery Inspection
Remove the battery cable terminal.
Check whether the battery terminal is
loosened, clean the terminal, and apply
grease onto it.
OM-B239
CAUTION
Firmly fix the terminal do that it does
not fall off by the vibration of the
vehicle.
CAUTION
・Do not misconnect the terminal(+)
and terminal(-) upon connection of
the battery terminals. Make sure that
removed batteries terminals are not
in contact.
・The battery could be discharged if the
vehicle is not operated for a long
period. Separate the terminal(-) to
prevent the battery from discharging,
and recharge the battery by turning
on the engine about once a month.
・Separating the terminal while the
engine is still running results in a
sever damage in the electronic
devices of the vehicle.
Always separate the battery terminal
after turning off the engine.
・Make sure the wires are connected
properly upon battery replacement.
REFERENCE
Regular Voltage (20 ~ 24)
・24~26V (Engine Stopped)
・27±0.4V (Engine Running)
6-38
WARNING
・Since gas and sulphuric acid is
included, be careful and protect
your eyes and face.
・Deal with care, since it is explosive.
・Do not use inflammables such as
cigarettes and electric sparks as it
produces flammable hydrogen gas.
・Make sure sulphuric acid does not
spill on you body or clothes. If it is on
your body, wash it off immediately
with clean soap water. If it was spilt
on a wounded part of your body or
your eyes, wash it off immediately
with clean water and receive care
from a hospital.
VEHICLE INSPECTION AND MAINTENANCE
Starting Motor
a. Separate the“+”line of the starting
motor.
b. Loosen the fixing bolt of the starting
motor, and remove the starting
motor.
c. Apply molybdenum grease on to the
starting motor’s pinion gear sliding
section and the motor’s sliding
section.
d. Clean the spline section of the
pinion gear.
e. Clean the terminal section of the
starting motor.
CAUTION
Since the wires of the starting motor
are easy to be contaminated, inspect
the wire connections everyday and
maintain cleanliness.
V-belt
V-belt inspection and replacement
OM-B241
Check belt’s tightness by pressing on
the middle of the belt.
Too tight or loose belt might cause
engine overheating and belt damage.
WARNING
Make sure the engine is stopped
before checking any engine belt in
order to avoid any injuries.
OM-B242
If the belt tension is not adequate, it
may be the cause of over heating or
damage of belt, so inspect the center of
the belt by pressing your fingers (about
10kgf) and see whether it is proper.
Always replace the two belts with 1 set
simultaneously.
WARNING
When inspecting the belt, always shut
off the starter switch in the engine
room so to prevent the starting of the
engine due to a malfunction of the
vehicle.
6-39
VEHICLE INSPECTION AND MAINTENANCE
Fan Belt Adjustment
(Electrical Fan Clutch (BX212))
Adjusting the Fan Belt
OM-B243
The pulley can be adjusted up and own
with the nut(1) or to the sides with the
nut(2).
Alternator Belt
TYPE A
OM-H031
OM-F138
The tension can be controlled with the
bolt and the belt can be replaced.
The nut should be tightened after the
adjustment and replacement.
Pulling the autotensioner with a tool
inserted in the groove will fix the
autotensioner.
Lightly push the autotensioner to
release the spring and the device will
be put back on original position.
REFERENCE
Autotensioner will adjust the tension
automatically.
6-40
VEHICLE INSPECTION AND MAINTENANCE
Windshield Washer Liquid
Cooler compressor belt adjustment
TYPE B
TYPE A
OM-B246
OM-S031
The belt tension can be adjusted with 3
nuts and the belt can be replaced.
OM-B244
TYPE B
Washer liquid tank is located on the
right hand side of the dash panel.
Open the washer liquid tank cap to
refill washer fluid.
You must tighten the nut after the
adjustment and replacement is
complete.
Always maintain sufficient amount of
washer liquid.
OM-B245
The tension can be controlled with the
bolt or the belt can be replaced.
6-41
Use washer fluid made for winter
season during the cold season.
REFERENCE
Washer liquid tank locations and
shapes may differ by vehicle types.
VEHICLE INSPECTION AND MAINTENANCE
Windshield Wiper Blade
CAUTION
・The motor may get damaged if you
force washer spray when there is
no washer liquid left in the tank.
・Do not use coolant or soap water
as washer liquid. It could block
driver’s view and could block the
washer spray nozzle.
Wahser liquid refilling ratio
Season
Washer Liquid : City Water
Summer
1:2
Winte
1:1
※ Reduce water when colder and use
washer liquid made for winter season.
CAUTION
Use tap water for mixin with washer
liquid.
Using rainwater or groundwater
could block the nozzle with
sediments and other parts of the
system could be damaged with
abrasion.
OM-B247
Change the wiper blade if the wiper
does not function well.
How to replace the wiper blade
a. Raise the wiper arm.
b. Loosen the bolt and opposite but to
tak out the blade.
c. Assembling is done in reverse order
of dismantling.
6-42
VEHICLE INSPECTION AND MAINTENANCE
Bulb Standard / Replacing Various Lamps
Bulb Standard
●
Front Combination Lamp
Type A
Type C
Type E
OM-B551
Type B
OM-H253
Type D
OM-H255
Type F
OM-S122
OM-H254
6-43
OM-H256
VEHICLE INSPECTION AND MAINTENANCE
●
Rear Combination Lamp
Type A
Type C
Type E
OM-B552
Type B
OM-H257
Type D
OM-H259
Type F
OM-S123
OM-H258
6-44
OM-H260
VEHICLE INSPECTION AND MAINTENANCE
Name
BS090
Front
Destination
Lamp
Rear
Side Lamp
Side Turn Signal
NO. Plate Lamp
Engine Room Lamp
Speed indicator Lamp
Driver Lamp
Room Lamp (Fluorescent)
Room Lamp (Glow)
Rack Lamp
Front Marker Lamp
Rear Marker Lamp
Step Lamp
Search Lamp
Luggage Room Lamp
Reading Lamp
Pilot Lamp
Warning Lamp
12W
12W
BS105/106
BS110/112/120
BH090
BH115E
BH120E
BV120
BC211M / MA
BC212M / MA
-
12W
12W
10W
-
BH116/117
BH119
BH120
BX212
-
10W
10W
12W
12W
5W
10W
12W
10W
21W
-
20W
12W
20W
10W
10W
12W
12W
-
12W
12W
-
12W
10W
10W
5W
1.2W
70W (H3)
※ There are lamps that are not applicable depending on vehicle types and specifications.
The bulb standard may differ by specifications.
6-45
10W
10W
12W
VEHICLE INSPECTION AND MAINTENANCE
Replacing Front Combination Lamp
Warnings on Handling Bulbs
Halogen lamps and flourescent have
inner pressure that can cause injuries
when broken.
Please wear protective glasses.
Type A
OM-B254
OM-S057
Touching lighted bulbs with naked
hand could result in injury. Wait until
the bulb is cooled after the light is
turned off before changing the bulb.
Loosen the bolts that is holding the
lamp. Pull the lamp and replace the
bulb.
Using non-standard bulbs could result
in damaged componenets or fire.
You must use standard bulbs.
Do not touch the glass part of Halogen
bulbs with naked hands.
Grease on the bulb could reduce the
brightness and the bulb could blow.
6-46
VEHICLE INSPECTION AND MAINTENANCE
Type B
Type C
Type D
OM-S034
OM-H055
OM-H033
Head light and fog light bulbs are
replaced by taking out the rear cover of
the light and spring at the back.
a. unscrew the screws on the head
light housing and take the bezel.
And then take the bolts out of the
lamp housing.
b. Pull the housing to reveal the
behind.
c. Turn the housing to take out and
assemble again in reverse order.
Head light and fog light bulbs are
replaced by taking out the rear cover of
the light and spring at the back.
Position Lamp bulb is replaced by
taking the rubber off and taking the
socket out.
Turn Signal bulb is replaced by
removing the rear socket.
Position Lamp bulb is replaced by taking
the rubber off and taking the socket out.
Turn Signal bulb is replaced by
removing the rear socket.
CAUTION
Do not adjust the irradiation degrees
as it is closely related to safety
issues. Upon need of adjustment,
visit service center, where
adjustment tools are equipped.
6-47
VEHICLE INSPECTION AND MAINTENANCE
Rear combination lamp bulb
replacement
Exchanging Bulb of the Reading
Light on the Passenger Seat
Mood Lamp (Panorama)
Open the engine room door to replace
the bulbs.
OM-H043
OM-H042
a. Using the tools supplied when the
car was bought, fix into the crack on
the lamp edge, and turn one round
anti-clockwise.
b. Take off the lens by pulling the
rotated lamp using the tool,
exchange the bulb, and reassembly
is the opposite order of disassembly.
CAUTION
Do not overdo power on the lens
while working, and be careful not to
scratch with the tool and the lens.
6-48
If you are willing to replace the
flourescent bulb on the rack, turn over
or take out the moulding(1) next to the
rack and replace the bulbs after
disassebling the lens(2) and the
cap(3).
7
FAULTY DIAGNOSIS
1. SIMPLE FAULTY DIAGNOSIS
Engine Related ……………………………………
Power Train related………………………………
Steering Related …………………………………
Brake related ……………………………………
7-2
7-5
7-5
7-6
Suspension Related …………………………… 7-7
Electrical Devices Related……………………… 7-8
Door Related……………………………………… 7-9
Air Dryer Related ……………………………… 7-11
2. Engine Diagnostic(Self-Diagnosis) -- CNG(OH1.2) (GE08TI, GE12TI)
Engine Diagnostic ……………………………… 7-13
Fault Code Table ……………………………… 7-14
3. Engine Diagnostic(Self-Diagnosis) -- CNG(OH2.0) (GE08TI, GE12TI)
ECM Diagnostication ………………………… 7-17
Engine Diagnostic ……………………………… 7-18
Fault Code Table ……………………………… 7-19
4. Engine Diagnostic(Self-Diagnosis) -- DE12TIS
Engine Diagnostic ……………………………… 7-32
Fault Code Table ……………………………… 7-33
5. Engine Diagnostic(Self-Diagnosis) -- DL06, DL08, DV11
Engine Diagnostic ……………………………… 7-34
Fault Code Table ……………………………… 7-36
6. Engine Diagnostic(Self-Diagnosis) -- ISM Engine
Engine Diagnostic ……………………………… 7-44
Fault Code Table ……………………………… 7-46
7. ABS Diagnostic(Self-Diagnosis) (OPTION)
ABS Diagnostic …………………………………
System Composition Code ……………………
Fault Code ………………………………………
ABS 6 Fault Code Table ………………………
7-61
7-62
7-63
7-64
Fault Code Delete ……………………………… 7-69
Roller Bench Test Mode ……………………… 7-69
(ASR“OFF”Function)
FAULTY DIAGNOSIS
1. SIMPLE FAULTY DIAGNOSIS
Engine Related
When the start-up motor does not work or when it spins slowly
Cause
Battery relay movement is not smooth
Flat battery
Abraision, loose or fallen out battery terminal
Slack ground cable
The oil is too thick
How to handle
Check the battery relay condition by activating battery main switch.
Check and replace the wiring if relay is not functioning.
Charge the battery or replace it.
Clean the rusty part of the battery terminal and secure the
connection and then apply grease on it.
Secure the cable.
Replace the oil with appropriate thickness oil.
Start-up motor is operational but it does not start-up
Cause
Fuel shortage
Not enough warming-up
When air leaked into the fuel system
The fuel filter is blocked
How to handle
Charge the fuel and release the air.
Check the pre-heat system.
Release the air.
Replace the filter element.
Low speed spinning will result in engine shut down
Cause
Low idle RPM
Air cleaner element is contaminated
Engine is over cooled
Fuel filter is blocked
The valve gap is abnormal
How to handle
Adjust idle speed.
Clean or replace the element.
Cover with the radiator curtain.
Replace the filter element.
Adjust the valve gap.
7-2
FAULTY DIAGNOSIS
Engine power shortage
Cause
Parking brake is not released
Air cleaner element is contaminated
The brake is applied constantly
The valve gap is abnormal
The clutch slips
How to handle
Repeat activating/deactivating parking brake.
Clean or replace the element.
Maintain the brake lining gap to normal level.
Adjust the valve gap.
Adjust the gap or replace the clutch disc.
Black exhaust
Cause
Air cleaner element is contaminated
The valve gap is abnormal
How to handle
Clean or replace the element.
Adjust the valve gap.
The engine is over heated
Cause
How to handle
Radiator cutton is covering the component or is contaminated Remove the radiator curtain or clean/replace the radiator.
Coolant refill and check if there is a leakage.
Coolant shortage
Confirm if radiator cap is properly shut.
Adjust fan belt tension or replace the belt if it is too old.
Fan belt is loose
Coolant refreshing or chealn the radiator interior.
Rust particles or slimes are found in the coolant
Replace the thermostat.
Thermostats are malfunctioning
7-3
FAULTY DIAGNOSIS
Fuel consumption rate is too high
Cause
The fuel is leaking
Air cleaner element is contaminated
The engine is over-coolled
Tire pressure is too low
The brake is applied constantly
The clutch slips
How to handle
Check the fuel system and check for leakages.
Clean or replace the element.
Cover with the radiator curtain.
Adjust it to standard pressure.
Maintain the brake lining gap to normal level.
Adjust the gap or replace the clutch disc.
The engine oil pressure is too low
Cause
The engine oil shortage
The engine oil is leaking
The oil thickness is not applicable
How to handle
Refill as appropriate.
Check the lubrication system and tighten loose parts.
Replace the oil with appropriate thickness oil.
The engine oil consumption rate is too high
Cause
Incorrect oil type
Over supplied oil
The engine oil is leaking
The oil replacement period is delayed
The engine warming-up was ignored
How to handle
Replace it with standard oil.
Adjust as regulated.
Check the lubrication system and tighten loose parts.
Change the oil according to the refreshing period.
Perform standard warming up.
7-4
FAULTY DIAGNOSIS
Power Train related
Strange sounds from the gear box and rear axle
Cause
Oil shortage
Oil thickness is not appropriate
How to handle
Refill as required.
Replace it with standard oil.
The vehicle is badly vibrating while driving
Cause
Propeller shaft’s connection bolts and nuts are loose
The propeller shaft is shaking too much
How to handle
Examine it and secure the bolts.
Repair or replace the propeller shaft.
Steering Related
The steering feels heavy
Cause
Front tire pressure shortage
Power steering oil shortage
How to handle
Adjust it to standard pressure.
Release the air according to the regulation.
Steering wheel recovery is faulty
Cause
The steering wheel components are not greased enough
Joint parts of drag links are interfered
How to handle
Apply grease.
Examine and repair, or replace.
7-5
FAULTY DIAGNOSIS
The steering wheel is shaking
Cause
Hub nuts are loose
Tire pressures are different on each side
Tires are worn out ununiformly
The steering wheel’s control gap is too much
Severe knuckle brake abrasion
How to handle
tighten as the standard.
Adjust the pressure evenly as the standard.
Replace the tire.
Adjust the steering wheel gap.
Replace and adjust the shim.
Brake related
Insufficient braking ability
Cause
Too high tire pressure
Air leakage at the braking system
Too high lining gap or too much abrasion
The tire is too worn out
How to handle
Adjust to regulation pressure.
Check and adjust the connection.
Adjust the lining gap or replace the lining.
Replace it with a new tire.
Tilted braking
Cause
Tire pressures are different on each side
Worn out tires
lining gaps are different from each side
How to handle
Adjust the pressure evenly as the standard.
Rearrange tire locations or replace the tire.
Adjust it to standard gaps.
7-6
FAULTY DIAGNOSIS
Brakes are dragged
Cause
Lining gaps are too small
Shoe return spring is faulty
How to handle
Adjust the lining gap.
Replace shoe return spring.
Suspension Related
Unstable rolling and pitching
Cause
Inclined or damaged radius road bush
Faulty shock absorber
Faulty leveling valve (air spring equipped vehicles)
How to handle
Replace the rubber bush or replace the rod.
Shock absorber should be replaced.
Repair the laveling valve.
Strange sounds from the spring while driving
Cause
Abrasion in spring pin busing or shackle pin bushing
Too much gap in spring pin bracket or shackle bracket
How to handle
Rpelace the bushing.
Replace or adjust the washer.
Too much vibrations in steering wheel and vehicle
Cause
Inclined radius rubber bush
Loose radius bracket bolts
How to handle
Replace the rubber bush.
Tighten with standard torque.
7-7
FAULTY DIAGNOSIS
Electrical Devices Related
Too much battery consumption
Cause
Isolated, loose and rusty battery terminals
Battery fluid shortage
Old battery
Slippery V belt or cut off
The light was turned on constantly
The alternator is poorly charged
How to handle
Clean the rusty part of the battery terminal and secure the
connection and then apply grease on it.
Refill or replace.
Replace the battery.
Check the tension level on the building.
Check and recharge the batre.
Check the charged condition of the alternator.
The lightings are not turning on
Cause
The bulbs are having problems
Fuses are blown
wiring and connections are poor
How to handle
Replace the bulb.
Replace the fuse.
Repair the wiring and connections.
7-8
FAULTY DIAGNOSIS
Door Related
The front door is not opening with the key or the switch
Cause
Mechanical lock is not operational
Air pressure is abnormal
Flat battery
How to handle
Un-lock the mechanical lock and activate the door switch.
Refill air.
Repair and replace after checking the battery.
Use magnetic air hose located in the front bumper to insert
and release the air. Lower the door 15mm and force it to turn
122˚ and take the door off the vehicle. (swing door)
The inner switch was set on close when getting ot the vehicle
Connect the magnetic valve inside the bumperf with“+”side
(How to open door an emergency)
of the battery.
The door will open if the power is connected. And the door
will close when there is no voltage.
The door opens and closes too fast or too slow
Cause
Faulty air pressure in the door cylinder speed control valve
How to handle
Adjust it with opening speed adjustment valve.
(located under the cylinder)
Adjust it with closing speed adjustment valve.
(located on the cylinder)
Turning clock-wise will slow it down and anti-clockwise will
make it faster.
7-9
FAULTY DIAGNOSIS
The door opens right after the door is closed, or the door will not open after overladed closing.
Cause
Rotation cam setting is faulty
How to handle
Set them in a way that the center of the roller and rotation
cam edges Are on the same line.
Door operation feels weak
Cause
Faulty air pressure
Basic reaction setting is faulty
How to handle
Check if air pressure is higher than 6kgf/cm2 and adjust it to
6~9kgf/cm2 if different.
Arrange them so that they are lined with the marking line by
turning universal shafts. (Basic reaction value : 75kgf)
’
The upper part of the door (locking) is stuck on the body and the swing door won’
t open
Cause
How to handle
The door will drop 15mm and turn when opening. Press the
front part of the door so that the rear part is opened first.
Guide arm balance is faulty
Adjust the guide arm while the door is open to balance the
door. (Extend the lever)
Strange noises from the door while driving
Cause
The door and body locking is faulty, making it shake
How to handle
Adjust the air pressure.
Adjust the reaction setting.
7-10
FAULTY DIAGNOSIS
Air Dryer Related
Too much humidity released from the air tank
Cause
Contaminated cartridges and delayed replacement period
Air dryer’s temperature is too high
Water leaks after the replacement
How to handle
Replace the cartridge.
Examine connected piping and remove any contamination.
Left over residue could come out after the replacement.
Re-examine after 3 weeks.
℃ atmosphere
The body is hot in when the vehicle is parked in 13℃
Cause
How to handle
The heater is operational due to faulty power connection
Check the power connection and replace bad parts.
The dryer is frozen
Cause
Heater wire disconnection
Faulty heater
How to handle
Replace.
Replace
’
The gauge at the driver’
s seat and the standard governor pressure are different from each other
Cause
How to handle
Faulty governor setting / Mis controlled
Reset the governor. (Bear in mind the gauge error of ±0.3bar)
It is purged at the cut-out pressure and the pressure is maintained lower
Cause
System line leakage
How to handle
Check the line.
7-11
FAULTY DIAGNOSIS
Compressed air flows out only through outside the governor
Cause
Faulty control of the setting bolt or the connection screw is loose Reset the governor.
How to handle
The pressure will gradually reach 0 bar after the car stops
Cause
Minimal leakage of the system
How to handle
It is normal if it takes 13 hours for the pressure to decline
completely.
7-12
FAULTY DIAGNOSIS
2. Engine Diagnostic(Self-Diagnosis) --- CNG (OH1.2) (GE08TI, GE12TI)
Engine Diagnostic
OM-S042E
※ The installed location may defer
depending on the vehicle type.
Diagnostic Procedures
・With the engine turned off, when the key is turned to the“ON”position, the
engine warning lamp lights on.
・At this time, if you press and hold the Engine Check button, engine warning lamp
flickers.
・Whether the vehicle has a problem or not could be detected with the number of
flickers of the engine warning lamp.
・The first flicker which is long indicates the ones digit. These flickering digits are
repeated three times and if there are multiple-check codes, it continues to flicker
the next code after the complete cycle of the previous code.
Fault Code Indication
<Example> Fault code #12 (System normal)
OM-S043E
7-13
FAULTY DIAGNOSIS
Fault Code Table
Fault
Code
12
13
14
15
16
21
22
23
24
25
26
27
28
33
34
35
36
37
38
39
41
Inspection Tesult
Related Part
System Normal
Exhaust Pipe Oxygen Sensor
Gas Temperature Sensor
Engine ECM
Accelerator
Supercharged Temperature
Intake Air Temperature
Supercharged Temperature
Coolant Temperature
Intake Pressure
Barometric Pressure
Booster Pressure
Gas Pressure
Normal
Malfunction in the Detection Module of the Exhaust Pipe Oxygen Sensor
Gas Temperature Sensor Voltage High
Gas Temperature Sensor Voltage Low
Standard 5V Voltage Malfunction
Accelerator Voltage High
Accelerator Voltage Low
Intake Air temperature Sensor Voltage High
Access Intake Air Temperature
Intake Air temperature Sensor Voltage Low
Engine Coolant Temperature Sensor Voltage High
Engine Coolant Temperature Sensor Voltage Low
Extreme Engine Coolant Temperature
Intake Pressure Sensor Voltage High
Intake Pressure Sensor Voltage Low
Barometric Pressure High
Barometric Pressure Low
Access Intake Temperature
Gas Pressure Sensor Voltage High
Gas Pressure Sensor Voltage Low
Access Gas Pressure
7-14
FAULTY DIAGNOSIS
Fault
Code
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
59
62
63
64
65
Inspection Tesult
Related Part
Ignition Timing Sensor
Gas Pressure
Combustion State
Booster Pressure
Engine ECM
Engine ECM Power
Throttle Valve
Engine ECM
Throttle Valve
Exhaust Pipe Oxygen Sensor
Exhaust Pipe Oxygen Sensor
Gas Tnak Temperature
Sensor Signal at the Ignition Time Malfunction
Insufficient Gas Pressure
Access Oxygen Concentration in the Exhaust Gas
Insufficient Oxygen Concentration in the Exhaust Gas
Cumulated Control Variable Upper Limit Exceeded
Cumulated Control Variable Lower Limit Exceeded
Intake Pressure Sensor Voltage Low
Intake Pressure Sensor Disabled
Memory Error
System Voltage Low
System Voltage High
Throttle Valve Opening Sensor Voltage High
ECM Error
Throttle Valve Opening Sensor Voltage Low
Access Throttle Valve Opening
Exhaust Pipe Oxygen Sensor Heater Voltage High
Exhaust Pipe Oxygen Sensor Heater Voltage Low
Exhaust Pipe Oxygen Sensor Pump Cell Voltage Low
Exhaust Pipe Oxygen Sensor Pump Cell Voltage High
Gas Tank Temperature High
Gas Tank Temperature Low
7-15
FAULTY DIAGNOSIS
Fault
Code
66
67
68
69
71
72
73
74
75
77
78
79
81
83
84
85
91
92
93
94
96
Inspection Tesult
Related Part
Gas Tank Pressure
Exhaust Pipe Oxygen Sensor
Supercharged Pressure
Booster Pressure
Engine Oil
Injector
Gas Temperature
Accelerator
Throttle Valve
Gas Tank Pressure
Engine ECM
Ignition Coil
Exhaust Pipe Oxygen Sensor
Engine ECM
Gas Pressure Controller
Gas Tank Pressure High
Gas Tank Pressure Low
Exhaust Pipe Oxygen Sensor Resistance Voltage High
Exhaust Pipe Oxygen Sensor Resistance Voltage Low
access Supercharged Pressure
Insufficient Supercharged Pressure
Over boost
Engine Oil Pressure Low
Injector Duty-Ratio Malfunction
Gas Temperature Low
Confirm Idle Switch Voltage High
Confirm Idle Switch Voltage Low
Insufficient Throttle Valve Opening
Gas Tank Pressure High
Vehicle Communication Connection Malfunction
Vehicle Reception Connection Malfunction
First Ignition Coil Disconnection Malfunction
First Ignition Coil Short Circuit Malfunction
Exhaust Pipe Oxygen Sensor Feature Malfunction
Internal ECM Standard 5V Voltage Malfunction
System Over-Pressure
7-16
FAULTY DIAGNOSIS
3. Engine Diagnostic(Self-Diagnosis) --- CNG (OH2.0) (GE08TI, GE12TI)
ECM (Engine Control Modulde) Diagnostication
ECM has diagnosis details to solve general problems.
The malfunctions are indicated via engine warning lamp on
the gauge board.
Function of Engine Warning Lamp
・It informs the driver of the problems of the ECM and related
components so that the problems can be solved as quickly
as possible.
・It shows system faults stored.
・The lamp is indicated with the light when the key is at“ON”
position. The engine does not spin at this mement.
・Precise repair methods will be instructed here.
ECM Fault Code
・Fault code is displayed after self diagnosis and when there
is a fault.
Engine warning lamp will flicker when fault code occurs and
the info will be stored at ECM.
・Oxygen sensor and engine control related malfunctions are
constantly indicated until the problem is solved through self
diagnosis.
・If the lamp is flickering and if the problem is persisted, the
system will continue to appear.
・General problems will automatically dissapear in about 30
seconds of driving mode, but engine related problems will
not be removed automatically.
・If the sensor is experiencing difficulty, ECM will operate
according to stored values.
・Every self diagnosis of ECM will be obtained while the
vehicle is driven fault-less.
・If more than one fault code is detected, less fault codes will
be displayed first and will continue to examine until the
malfunction is no longer detected.
・fault codes can be confirmed with engine warning lamp and
Faulty Diagnosis device(SCAN-200).
7-17
FAULTY DIAGNOSIS
Engine Diagnostic
Diagnostic Procedures
・If you turn the key to“ON”position and step on acceleration
3 times within 20 seconds without starting the engine, all fault
codes stored in ECM will flicker.
・If the acceleration pedal is having a problem, you may not
obtain the fault code through this method.
Fault code Engine Warning Lamp operation order
・Fault codes consists of 3 digits. The beginning and the ending
code digits consists of 2 digits and the number is always 12.
Number 0 is not used.
・The number represents the number of flickering while the
indication lamp stops in between operations.
For example, if the lamp flickers 3 times, it will be indicated
with number 3.
・The numbers are differentiated by the time of the light flicker.
・If two fault codes(3digits) are there, the flickering will be long.
The order of fault code appearing will be from low number to
high number. The priority or the order of fault detected will not
be related to the order of appearance.
・Fault codes will flicker twice before the next code is indicated.
・For example, if there are fault code 231 and 711, the order of
flicker display on the emergency warning lamp will be as
following.
12
12
231
231
711
711
12
12
Indication of the initiation.
The examination process is indicated again.
The first fault code.
Repeated indication of the fault code.
The second fault code number.
Repeated indication of the second fault code.
Indication of the examination completion.
Repeated indication of the completion.
・The indication will be repeated again when the key is
turned to“OFF”position or on the engine start up.
Fault code history display and delete
Turn the key on“ON”position without starting the engine up.
Fully stepping on the acceleration pedal more than 8 times
within 20 seconds will delete all fault codes stored in ECM.
7-18
FAULTY DIAGNOSIS
Fault Code Table
Fault Code
Fault Subject
133
UEGO(Universal Exhaust Gas Oxygen
Sensor) Heater Voltage Low
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Fuel Adaptive Learn Function is not working
- Fuel Closed Loop Function is not working
- Boost pressure is reduced
134
UEGO Heater Voltage High
The key is on“ON”position
- The engine warning lamp is on
- Fuel Adaptive Learn Function is not working
- Fuel Closed Loop Function is not working
- Boost pressure is reduced
139
UEGO Air Cal Learned Outside Limits
The engine warning lamp is constantly on until the fault is resolved
141
NGT(Natural Gas Temperature Sensor)
Voltage High
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
151
NGT Voltage Low
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
Supply Voltage High
(XDRP_A (+5 V) Voltage High)
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
- Accelerator Restrictions
161
7-19
FAULTY DIAGNOSIS
Fault Code
162
163
164
165
166
Fault Subject
Supply Voltage Low
( XDRP_A (+5 V) Voltage Low )
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
- Accelerator Restrictions
Supply Voltage High
( XDRP_B (+5 V) Voltage High )
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
- Accelerator Restrictions
Supply Voltage Low
( XDRP_B (+5 V) Voltage Low )
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
- Accelerator Restrictions
+ 14V Power Supply High
The key is on“ON”position
- Adaptive Learn Function is not working
- Closed Loop Function is not working
- Boost pressure is reduced
- Accelerator Restrictions
+ 14V Power Supply Low
The key is on“ON”position
- Adaptive Learn Function is not working
- Closed Loop Function is not working
- Boost pressure is reduced
- Accelerator Restrictions
7-20
FAULTY DIAGNOSIS
Fault Code
Fault Subject
181
Barometer Voltage Low
Conditions of Fault
The engine warning lamp is constantly on until the fault is resolved
182
Barometer Voltage High
The engine warning lamp is constantly on until the fault is resolved
191
Oil Pressure Sensor Voltage Low
The engine warning lamp is constantly on until the fault is resolved
192
Oil Pressure Sensor Voltage High
The engine warning lamp is constantly on until the fault is resolved
211
FPP(Foot Pedal Position Sensor)
Voltage High
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
221
FPP Voltage Low
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
231
MAT(Manifold Air Temperature Sensor)
Voltage High
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
- Cooling Fan max operation(if equipped)
241
MAT Higher Than Expected
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
MAT Voltage Low
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
- Cooling Fan max operation(if equipped)
251
7-21
FAULTY DIAGNOSIS
Fault Code
Fault Subject
261
ECT(Engine Coolant Temperature
Sensor) Voltage High
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Cooling Fan max operation(if equipped)
ECT Voltage Low
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Cooling Fan max operation(if equipped)
281
ECT Higher Than Expected
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
311
UEGO(Universal Exhaust Gas Oxygen
Sensor) UN Fault
The key is on“ON”position
- The engine warning lamp is on
- Closed Loop Function is not working
- Boost Pressure Fault Limp Home Mode
UEGO VM Fault
The key is on“ON”position
- The engine warning lamp is on
- Closed Loop Function is not working
- Boost Pressure Fault Limp Home Mode
UEGO IP Fault
The key is on“ON”position
- The engine warning lamp is on
- Closed Loop Function is not working
- Boost Pressure Fault Limp Home Mode
271
312
313
7-22
FAULTY DIAGNOSIS
Fault Code
Fault Subject
314
UEGO(Universal Exhaust Gas Oxygen
Sensor) IA Fault
315
UEGO Heater Fault
331
341
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Closed Loop Function is not working
- Boost Pressure Fault Limp Home Mode
The key is on“ON”position
- The engine warning lamp is on
- Closed Loop Function is not working
- Boost Pressure Fault Limp Home Mode
MAP(Manifold Air Pressure Sensor)
Higher Than Expected
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Closed Loop Function is not working
- Boost Pressure Control Valve is off
- Standard Fuel / Air mixture ratio (Phi) = diagnosed level
- Max throttle value = examination is limited at“ON”position
MAP Voltage Low
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Closed Loop Function is not working
- Boost Pressure Control Valve is off
- Standard Fuel / Air mixture ratio (Phi) = diagnosed level
- Max throttle value = examination is limited at“ON”position
7-23
FAULTY DIAGNOSIS
Fault Code
Fault Subject
342
MAP(Manifold Air Temperature Sensor)
Voltage High
351
Barometer Lower Than Expected
361
Barometer Higher Than Expected
371
PTP(Pre-throttle Pressure Sensor)
Higher Than Expected
372
PTP Voltage Low
373
PTP Voltage High
381
NGP(Nature Gas Pressure Sensor)
Voltage High
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Closed Loop Function is not working
- Boost Pressure Control Valve is off
- Standard Fuel / Air mixture ratio (Phi) = diagnosed level
- Max throttle value = examination is limited at“ON”position
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
7-24
FAULTY DIAGNOSIS
Fault Code
Fault Subject
391
NGP(Nature Gas Pressure Sensor)
Voltage Low
411
NGP Higher Than Expected
412
System Overpressure Fault
421
CAM(Cam Shaft rpm) Sensor Fault
422
CRANK(Crank Shaft rpm) Sensor Fault
423
Engine Timing Config Fault
424
Engine Overspeed
425
ECM(Engine Control Module) Chassis
Error
426
ECM Temperature Alarm
427
Vehicle Speed Sensor Fault
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Main Power Interception and Gas Low Pressure Interception
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Main Power Interception and Gas Low Pressure Interception
The engine warning lamp is constantly on until the fault is resolved
The key is on“ON”position
- The engine warning lamp is on
- Main Power Interception and Gas Low Pressure Interception
The engine warning lamp is constantly on until the fault is resolved
The key is on“ON”position
- The engine warning lamp is on
- Boost Pressure Control Valve is off
- Max throttle = examination is limited
7-25
FAULTY DIAGNOSIS
Fault Code
Fault Subject
428
Clutch Switch Stuck On
429
Neutral Switch Stuck On
431
NGP(Nature Gas Pressure Sensor)
Lower Than Expected
432
Brake Switch Stuck
Closed Loop Correction on High Limit
441
451
Closed Loop Correction on Low Limit
461
Adaptive Learn Correction on High Limit
471
Adaptive Learn Correction on Low Limit
491
PTP(Pre-throttle Pressure Sensor)
Lower Than Expected
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost pressure is reduced
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
7-26
FAULTY DIAGNOSIS
Fault Code
Fault Subject
521
Battery Voltage Low
531
Battery Voltage High
541
TPS(Throttle Position Sensor) Voltage
High
551
Low RAM Available
552
Ignition Failure of Ignition Control
Device (Rate Group 5 Slip)
553
CPU Load Higher Than Expected
554
Low Flash Memory Available
555
Low EEPROM Available
556
Low Calibrate Memory Available
557
Primary EEPROM Fault
558
Secondary EEPROM Fault
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Main Power Interception and Gas Low Pressure Interception
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
7-27
FAULTY DIAGNOSIS
Fault Code
Fault Subject
561
TPS(Trottle Position Sensor) Voltage Low
571
TPS Higher Than Expected
611
Relative Humidity Sensor High Fault
612
Relative Humidity Sensor Low Fault
Relative Humidity Temperature Sensor
High Fault
Relative Humidity Temperature Sensor
Low Fault
NGTT(Natural Gas Tank Temperature
Sensor) Voltage High
613
614
641
651
661
671
NGTT Voltage Low
NGTP(Natural Gas Tank Pressure
Sensor) Voltage High
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Limited fuel supply
The engine warning lamp is constantly on until the fault is resolved
The engine warning lamp is constantly on until the fault is resolved
NGTP Voltage Low
711
Boost Pressure Higher Than Expected
721
Boost Pressure Lower Than Expected
The key is on“ON”position
- The engine warning lamp is on
- Boost pressure is reduced
- Boost Pressure Fault Limp Home Mode
The engine warning lamp is constantly on until the fault is resolved
7-28
FAULTY DIAGNOSIS
Fault Subject
Fault Code
731
Overboost
732
Boost Air Regulator Set Point Fault
733
Wastegate Control Valve Pressure Fault
734
735
Boost Air Pressure Voltage High Fault
Boost Air Pressure Voltage Low Fault
741
Oil Pressure Low
751
Injector Duty Cycle Too High
771
781
791
811
NGT(Nature Gas Temperature Sensor)
Lower Than Expected
IVS(Idle Validation System) Higher
Than Expected
IVS(Idle Validation System) Lower Than
Expected
TPS(Throttle Position Sensor) Voltage
Lower Than Expected
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Boost pressure is reduced
- Boost Pressure Fault Limp Home Mode
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Boost Pressure Control Valve is off
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
The key is on“ON”position
- The engine warning lamp is on
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Accelerator Restrictions
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Limited fuel supply
7-29
FAULTY DIAGNOSIS
Fault Code
Fault Subject
841
SCI Port Fault
911
SmartCoil #1 Open Faults
912
SmartCoil #2 Open Faults
913
SmartCoil #3 Open Faults
914
SmartCoil #4 Open Faults
915
SmartCoil #5 Open Faults
916
SmartCoil #6 Open Faults
921
SmartCoil #1 Shorted Faults
922
SmartCoil #2 Shorted Faults
923
SmartCoil #3 Shorted Faults
924
SmartCoil #4 Shorted Faults
925
SmartCoil #5 Shorted Faults
926
SmartCoil #6 Shorted Faults
951
Injector #1 Open or Shorted to Ground Faults
952
Injector #2 Open or Shorted to Ground Faults
953
Injector #3 Open or Shorted to Ground Faults
954
Injector #4 Open or Shorted to Ground Faults
955
Injector #5 Open or Shorted to Ground Faults
956
Injector #6 Open or Shorted to Ground Faults
957
Injector #7 Open or Shorted to Ground Faults
958
Injector #8 Open or Shorted to Ground Faults
Conditions of Fault
The engine warning lamp is constantly on until the fault is resolved
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost Pressure Control Valve is off
- Max throttle = examination is limited
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
- Boost Pressure Control Valve is off
- Max throttle = examination is limited
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
7-30
FAULTY DIAGNOSIS
Fault Code
Fault Subject
961
Injector #1 Shorted to Voltage Faults
962
Injector #2 Shorted to Voltage Faults
963
Injector #3 Shorted to Voltage Faults
964
Injector #4 Shorted to Voltage Faults
965
Injector #5 Shorted to Voltage Faults
966
Injector #6 Shorted to Voltage Faults
967
Injector #7 Shorted to Voltage Faults
968
Injector #8 Shorted to Voltage Faults
Conditions of Fault
The key is on“ON”position
- The engine warning lamp is on
- Adaptive Learn Function is not working
7-31
FAULTY DIAGNOSIS
4. Engine Diagnostic (Self-Diagnosis) --- DE12TIS
Engine Diagnostic
Diagnostic Procedures
Fault Code Indication
The engine warning lamp located on the instrument panel the operator of a
program.
System fault codes can be detected and displayed by using the check engine light.
a. Turn the engine check switch ON, then check light the engine warning lamp.
b. The Engine Warning Lamp displays two digit codes by flashing the first digit,
pausing, then flashing the second digit. There will be a long pause between
codes.
OM-B553
a. Turn the battery main switch“ON”.
b. The starting key is in the ON
position.
c. The engine is not running.
d. Push the engine check switch.(Hold)
e. The Engine Warning Lamp will begin
to flash.
f. Check the Fault Code, then starting
key off.
< Example is one fault code 21 >
OM-B554
7-32
FAULTY DIAGNOSIS
Fault Code Table
< Example is two fault code 13 and 22 >
Code
01
12
13
14
15
16
21
22
23
24
OM-B555
Fault Code Clear
a. Engine suspension
b. Delete fault codes stored in ECM by pressing Engine Clear Switch while the key
is on“ON”position.
7-33
Defects
Normal
Pre stroke control servo error
Pre stroke sensor error
Pre stroke offset learning error
Pre stroke actuator power error
Engine speed sensor error
Water temper sensor error
Fuel rack sensor error
Intake air heater relay error
Engine starting abnormal
FAULTY DIAGNOSIS
5. Engine Diagnostic (Self-Diagnosis) --- DL06 , DL08 , DV11
Engine Diagnostic
Engine diagnostic check can be
conducted by using the diagnostic
system (SCAN-200) or by checking the
fault code with number of flickers of the
engine warning lamp. We recommend
using the diagnostic system, since it is
provides quick and accurate process.
Diagnostic Procedures
a. Turn the battery main switch“ON”.
b. The starting key is in the ON
position.
c. The engine is not running.
d. Push the engine check switch.(Hold)
e. The Engine Warning Lamp will begin
to flash.
f. Check the Fault Code, then starting
key off.
Fault Code Indication
The following explains how fault codes are informed by the engine warning lamp.
< Example is one fault code 21 >
OM-B554
< Example is two fault code 13 and 22 >
OM-B555
7-34
FAULTY DIAGNOSIS
- The lamp flickers twice with an interval of 1 second,
flickers twice after 1 second, and repeats this sequence 3
times : Indication of Fault Code 22 Completed.
a. Check the engine warning lamp while the engine check
switch is turned on.
b. The engine warning lamp pauses after flickering as much
as the first digit of the fault code, and then flicker as much
as the second digit of the fault code. For example, if the
fault code is“21”, the engine warning lamp flickers twice
(First digit“2”), pauses for 1 second, and flickers once
(Second digit“1”). The cycle is repeated for a fault code
for clearer indication.
c. If there are 2 or more fault codes, the first fault code is
indicated 3 times, and the next fault code is indicated after
a 3 second pause. As mentioned above, every fault code
is repeatedly indicated 3 times.
- After flickering one sequence, there is a 3 second pause.
- The fault code continues to flicker repeatedly until the
inspection process completes.
Fault Code Clear
The fault codes stored in ECM can only be deleted with
Faulty Diagnosis Device.
d. The following is an example of indicating the fault codes
when the fault codes #13 and #22 have occurred
simultaneously.
- Engine stop & starting key-on.
- The lamp flickers once with an interval of 1 second,
flickers 3 times after 1 second, and repeats this sequence
3 times : Indication of Fault Code 13 Completed.
7-35
FAULTY DIAGNOSIS
Fault Code Table
● EURO
III (DL08, DV11) Engine
Fault
Code
Contents of trouble
Lamp
1.1
Relation to coolant temperature sensor is abnormal
C
1.2
Relation to fuel temperature sensor is abnormal
C
1.3
Relation to boost temperature sensor is abnormal
C
1.4
Relation to boost pressure sensor is abnormal
C
1.6
Atmosphere pressure sensor is abnormal
C
1.7
Relation to oil temperature sensor is abnormal
N
1.8
Relation to oil pressure sensor is abnormal
C
2.1
2.2
2.3
Battery voltage is abnormal
Relation to fuel pressure sensor is abnormal
Relation to accelerator pedal is abnormal
C
B
B
2.4
Relation to accelerator pedal is abnormal
B
2.5
Vehicle speed sensor or vehicle meter is abnormal
C
Conditions of occurring
Sensor / harness is abnormal
Coolant temperature is too high
Sensor / harness is abnormal
Fuel temperature is too high
Sensor / harness is abnormal
Intake temperature is excessive after intercooler
Engine / turbocharger / intercooler is abnormal
Sensor / harness is abnormal
Intake pressure is excessive after intercooler
Engine / turbocharger / intercooler is abnormal
Atmosphere pressure sensor attached to ECU is abnormal ECU
Sensor / harness is abnormal
Oil temperature is too high
Sensor / harness is abnormal
Oil pressure is abnormal (Leakage etc.)
Battery / alternator / ECU is abnormal
Sensor / harness is abnormal
Accelerator pedal sensor / switch / harness is abnormal
Foot brake and accelerator pedal is operated simultaneously
on driving
Foot brake switch / harness is abnormal
Sensor / vehicle tachometer / harness is abnormal
7-36
FAULTY DIAGNOSIS
Fault
Code
2.7
2.8
2.9
3.2
3.6
3.7
3.8
Contents of trouble
Lamp
Conditions of occurring
Relation to clutch pedal is abnormal
Relation to pedal brake switch is abnormal
Relation to cruise control switch is abnormal
Common rail pressure is excessive fluctuation
Input signal is abnormal at operating ASR
CAN signal of ASR and auto transmission is abnormal
Warning which engine speed is excessive
C
C
C
B
N
N
C
3.9
ECU inner relay is abnormal
B
4.1
Abnormality bt abnormal stopping of engine
B
4.2
Relation to crank shaft speed sensor is abnormal
C
4.3
Relation to cam shaft speed sensor is abnormal
C
4.4
Engine speed sensor is abnormal
C
4.5
Dater storage of EEPROM in ECU is abnormal
C
4.6
Initialization is not good after power supply to ECU
C
4.7
Pressure limit valve of common rail is opened by
excessive rail pressure
B
4.8
Power supplying source is abnormal
N
Clutch pedal switch / harness is abnormal
Pedal brake switch / harness is abnormal
Switch or harness is abnormal
Common rail pressure is abnormal
ASR connector / harness is abnormal
Connector of ASR and auto transmission / harness is abnormal
Engine overspeed
ECU inner main relay is abnormal
Power supplying is abnormal
Abnormal engine stopping
Sensor / harness is abnormal
Sensor gap is abnormal
Sensor / harness is abnormal
Sensor gap is abnormal
Motivation of cam shaft / crank shaft speed sensor signal is
abnormal
Error is occurred during storing improtant data of operating
in ECU to EEPROM when engine stop
ECU initialization is abnormal
Pressure limit value is opened compulsory when rail
pressure is occurred at excessive pressure more than rail
pressure or high pressure pump
Battery voltage is abnormal : ECU, battery and alternator is
abnormal
7-37
FAULTY DIAGNOSIS
Fault
Contents of trouble
Lamp
Conditions of occurring
Code
B
4.9 Supplying voltage of injector (#1,5,3) is abnormal
Injector cable / connector is abnormal or ECU is trouble
B
5.1 Supplying voltage of injector (#6,2,4) is abnormal
Relation to connecting of injector #1 harness is
5.8
B
abnormal
Relation to connecting of injector #5 harness is
5.9
B
abnormal
Relation to connecting of injector #3 harness is
B
6.1
abnormal
Injector cable / connector is abnormal
Relation to connecting of injector #6 harness is
6.2
B
abnormal
Relation to connecting of injector #2 harness is
6.3
B
abnormal
Relation to connecting of injector #4 harness is
6.4
B
abnormal
Lamp / harness is abnormal
N
6.6 Relation to air heater lamp is abnormal
Lamp / harness is abnormal
7.1 Relation to diagnostic lamp is abnormal
N
Air heater relay / harness is abnormal
7.2 Air heater operation relay is abnormal
C
Engine
brake
#2
relay
is
abnormal
#2 engine brake solenoid / connector / harness is abnormal
7.3
N
#1 engine brake solenoid / connector / harness is abnormal
7.5 Engine brake #1 relay is abnormal
C
8.3
Relation to high pressure pump control is abnormal
C
Fuel metering unit of high pressure pump / harness is abnormal
8.6
Engine speed meter of vehicle is abnormal
N
9.1
Abnormal starting
B
Engine tachometer of vehicle / harness is abnormal
Starting procedure is abnormal, ECU is abnormal, power
supplying is abnormal
7-38
FAULTY DIAGNOSIS
Fault
Code
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
Contents of trouble
Lamp
Ignition of #1 cylinder is not good
Ignition of #5 cylinder is not good
Ignition of #3 cylinder is not good
Ignition of #6 cylinder is not good
Ignition of #2 cylinder is not good
Ignition of #4 cylinder is not good
Ignition of several cylinder is not good
Injector is opened too long
Engine speed is abnormal
10.1
(Additional function)
C
C
C
C
C
C
C
C
10.2 Relation to accelerator pedal is abnormal
B
Cooling fan is abnormal
Fuel pressure is abnormal
Smooth running control is abnormal
Smooth running control is abnormal
Smooth running control is abnormal
Smooth running control is abnormal
Smooth running control is abnormal
Smooth running control is abnormal
C
B
N
N
N
N
N
N
10.3
10.4
11.1
11.2
11.3
11.4
11.5
11.6
C
Conditions of occurring
Injector is abnormal, compression pressure is a drop,
camshaft / crankshaft speed sensor signal is abnormal
Operating time of injector is excessive from standard values
Error is occurred when calculate engine speed using
crankshaft / camshaft speed sensor
Foot brake and accelerator pedal is operated simultaneously
when vehicle is started
Sensor or connector harness is abnormal
Fluctuation of fuel pressure in common rail is excessive
Cylinder’s deflection of injector solenoid is excessive
Cylinder’s deflection of injector solenoid is excessive
Cylinder’s deflection of injector solenoid is excessive
Cylinder’s deflection of injector solenoid is excessive
Cylinder’s deflection of injector solenoid is excessive
Cylinder’s deflection of injector solenoid is excessive
※ Check of the lamp’s operation
N : Case of no damage to the performance and the engine.
C : Case of requirement for the check after running (no emergency check).
B : Case of requirement for the check and measure after running at the low speed at the time of occurring.
7-39
FAULTY DIAGNOSIS
● EURO IV (DL06, DL08, DV11) Engine
Fault
Code
Contents of trouble
Lamp
1.1
Relation to coolant temperature sensor is abnormal
C
1.2
Relation to fuel temperature sensor is abnormal
C
1.3
Relation to boost temperature sensor is abnormal
C
1.4
Relation to boost pressure sensor is abnormal
C
1.6
Atmosphere pressure sensor is abnormal
C
1.7
Relation to oil temperature sensor is abnormal
N
1.8
Relation to oil pressure sensor is abnormal
C
2.1
2.2
2.3
Battery voltage is abnormal
Relation to fuel pressure sensor is abnormal
Relation to accelerator pedal is abnormal
C
B
B
2.4
Relation to accelerator pedal is abnormal
B
2.5
2.7
2.8
Vehicle speed sensor or vehicle meter is abnormal
Relation to clutch pedal is abnormal
Relation to pedal brake switch is abnormal
C
C
C
Conditions of occurring
Sensor / harness is abnormal
Coolant temperature is too high
Sensor / harness is abnormal
Fuel temperature is too high
Sensor / harness is abnormal
Intake temperature is excessive after intercooler
Engine / turbocharger / intercooler is abnormal
Sensor / harness is abnormal
Intake pressure is excessive after intercooler
Engine / turbocharger / intercooler is abnormal
Atmosphere pressure sensor attached to ECU is abnormal ECU
Sensor / harness is abnormal
Oil temperature is too high
Sensor / harness is abnormal
Oil pressure is abnormal (Leakage etc.)
Battery / alternator / ECU is abnormal
Sensor / harness is abnormal
Accelerator pedal sensor / switch / harness is abnormal
Foot brake and accelerator pedal is operated simultaneously
on driving
Foot brake switch / harness is abnormal
Sensor / vehicle tachometer / harness is abnormal
Clutch pedal switch / harness is abnormal
Pedal brake switch / harness is abnormal
7-40
FAULTY DIAGNOSIS
Fault
Contents of trouble
Code
2.9 Relation to cruise control switch is abnormal
3.2 Common rail pressure is excessive fluctuation
3.6 Input signal is abnormal at operating ASR
CAN signal of ASR and auto transmission is
3.7
abnormal
3.8 Warning which engine speed is excessive
Lamp
Conditions of occurring
C
B
N
Switch or harness is abnormal
Common rail pressure is abnormal
ASR connector / harness is abnormal
N
Connector of ASR and auto transmission / harness is abnormal
C
Engine overspeed
ECU inner main relay is abnormal
Power supplying is abnormal
Abnormal engine stopping
Sensor / harness is abnormal
Sensor gap is abnormal
Sensor / harness is abnormal
Sensor gap is abnormal
Motivation of cam shaft / crank shaft speed sensor signal is
abnormal
Error is occurred during storing improtant data of operating
in ECU to EEPROM when engine stop
ECU initialization is abnormal
Pressure limit value is opened compulsory when rail
pressure is occurred at excessive pressure more than rail
pressure or high pressure pump
Battery voltage is abnormal : ECU, battery and alternator is
abnormal
SCB Main Relay is Abnormal
ECU Main Relay is Abnormal
3.9
ECU inner relay is abnormal
B
4.1
Abnormality bt abnormal stopping of engine
B
4.2
Relation to crank shaft speed sensor is abnormal
C
4.3
Relation to cam shaft speed sensor is abnormal
C
4.4
Engine speed sensor is abnormal
C
4.5
Dater storage of EEPROM in ECU is abnormal
C
4.6
Initialization is not good after power supply to ECU
C
4.7
Pressure limit valve of common rail is opened by
excessive rail pressure
B
4.8
Power supplying source is abnormal
N
4.9
5.1
SCB main relay is abnormal
ECU main relay is abnormal
B
B
7-41
FAULTY DIAGNOSIS
Fault
Code
Contents of trouble
Lamp
Conditions of occurring
5.8
Solenoid Power Supplying 1 is Abnormal
B
Engine Cylinder Number 1
5.9
Solenoid Power Supplying 2 is Abnormal
B
Engine Cylinder Number 2
6.1
Solenoid Power Supplying 3 is Abnormal
B
Engine Cylinder Number 3
6.2
Solenoid Power Supplying 4 is Abnormal
B
Engine Cylinder Number 4
6.3
Solenoid Power Supplying 5 is Abnormal
B
Engine Cylinder Number 5
6.4
Solenoid Power Supplying 6 is Abnormal
B
Engine Cylinder Number 6
6.5
Low Power Supplying 1 is Abnormal
N
Fuel High Pressure Pump
6.7
Low Power Supplying 3 is Abnormal
N
Low Temperature Starting Lamp
6.8
Low Power Supplying 4 is Abnormal
C
Engine Brake 1 Rl 25 is Abnormal
7.5
Low Power Supplying 10 is Abnormal
N
Engine Warning Lamp is Abnormal
7.7
Low Power Supplying 12 is Abnormal
N
Fuel Preheating Relay RL04
8.3
Low Power Supplying 17 is Abnormal
N
Low Temperature Starting Preheating Relay RL04
9.1
CAN-A Line is Abnormal
N
CAN-A Line is Abnormal
9.3
Low Power Supplying 25 is Abnormal
N
Dial RL31 is Abnormal
9.4
Low Power Supplying 26 is Abnormal
N
Engine rpm Output DA41 is Abnormal
9.5
Fuel Pressure Checking(MPROPH/GH) is abnormal
B
Fuel Pressure Checking(MPROPH/GH) is Abnormal
7-42
FAULTY DIAGNOSIS
Fault
Code
Contents of trouble
Lamp
Conditions of occurring
9.7
Ignition of #1 cylinder is not good
C
9.8
Ignition of #5 cylinder is not good
C
9.9
Ignition of #3 cylinder is not good
C
10.1 Ignition of #6 cylinder is not good
C
10.2 Ignition of #2 cylinder is not good
C
10.3 Ignition of #4 cylinder is not good
C
10.4 Ignition of several cylinder is not good
C
10.5 Injector is opened too long
C
Operating time of injector is excessive from standard values
C
Error is occurred when calculate engine speed using
crankshaft / camshaft speed sensor
12.3 Low Speed Torque Limit is abnormal
N
Low Speed Torque Limit Protecting Device is abnormal
12.4 High Speed Torque Limit is abnormal
N
High Speed Torque Limit Protecting Device is abnormal
12.5 Working Lamp of Restoration Catalyzer is abnormal
C
Working Lamp of Restoration Catalyzer is abnormal
10.6
Engine speed is abnormal
(Additional function)
Injector is abnormal, compression pressure is a drop,
camshaft / crankshaft speed sensor signal is abnormal
※ Check of the lamp’s operation
N : Case of no damage to the performance and the engine.
C : Case of requirement for the check after running (no emergency check).
B : Case of requirement for the check and measure after running at the low speed at the time of occurring.
7-43
FAULTY DIAGNOSIS
6. Engine Diagnostic (Self-Diagnosis) --- ISM Engine
Engine Diagnostic
Turning on the Engine Diagnostic Switch
located within interior fuse box will make
the warning lamp flicker and will inform
you which part is having a problem.
You can connect the Faulty Diagnosis
Device to a laptop to find fault codes.
Flickering faults are currently experienced
faults.
Past faults can be confirmed with Faulty
Diagnosis Device.
Diagnostic Procedures
・Turn the key on“ON”position.
(While the engine is suspended)
2 seconds after Engine Warning Lamp
and Engine Aftertreatment Warning
Lamp on the gauge board are lighted,
Engine Warning Lamp will be turned off
and Engine Aftertreatment Warning
Lamp will be turned off 0.5 seconds later
this means that the vehicle is in normal
status.
.
・Turn the Faulty Diagnosis switch“ON”
・Check the faulty code according to the
flicker.
Diagnostic Lamps
Engine Warning Lamp and Engine Aftertreatment Warning Lamp are on the gauge
board to provide various information to drivers and mechanics.
It is normal for two lamps to be turned off after turning on when the key is on ON
position.
●Engine Warning Lamp (Amber) : faults related to electrical devices
- It is remained turned on if the system is faulty.
- It remains turned on even after the engine start-up.
●Engine Aftertreatment Warning Lamp (Red) : faults related to engine protection
functions
- If the engine warning indication is turned on while driving, it means the problem
is severe (lubrication problems or overheated devices) you must get the vehicle
serviced immediately.
- If you leave it to the faulty condition, it will severely damage the engine.
Engine Aftertreatment Engine Warning
Indication Lamp (Red)
Lamp (Amber)
Self-diagnosis/normal
Turned on and turned off
It is turned on once
Fault code
Fault code indicated
and turned off / red / it
flicker
is turned on and turned off
Engine protection activated
1sec/1 flicker
Idle shutdown activated
1sec/1 flicker
Idle shutdown extended
0.5sec /1 flicker
Light fault stored
Turned on
Severe fault stored
Turned on
Substance
7-44
Remarks
The engine
stops after
30seconds
FAULTY DIAGNOSIS
Fault Code Clear
The fault codes stored in ECM can only be deleted with Faulty Diagnosis Device.
Fault Code Indication
OM-H078E
7-45
FAULTY DIAGNOSIS
Fault Code Table
Fault
LAMP
Code
REASON
EFFECT
Error internal to the ECM(electronic control module) related to
memory hardware fiilures or internal ECM voltage
Engine Magnetic Speed/Position Lost Both of Two Signals - Data
115 Red
Erratic, Intermittent, or Incorrect
122 Amber High signal voltage detected at the intake manifold pressure circuit
Low signal voltage or open circuit detected at the intake manifold
123 Amber
pressure circuit
High Voltage detected at accelerator pedal position number 1
131 Red
circuit
Low Voltage detected at accelerator pedal position number 1 signal
132 Red
circuit
133 Red High signal voltage detected at remote accelerator position signal
circuit
111
134
Red
Red
Low Voltage decteced at remote accelerator position signal circuit
135 Amber High signal voltage detected at the engine oil pressure circuit
141 Amber Low signal voltage detected at the engine oil pressure circuit
143 Amber
Engine oil pressure signal indicates engine oil pressure is below
the engine protection warning limit
144 Amber High signal voltage or open circuit detected at engine coolant
temperature circuit
145 Amber Low signal voltage detected at engine coolant temperature circuit
7-46
Engine may not start.
None on performance.
Derate in power ouput of the engine.
Derate in power ouput of the engine.
Severe derate in power output of the engine.
Limp home power only.
Severe derate in power output of the engine.
Limp home power only.
Remote accelerator will not operate.
Remote accelerator position will be set to 0 percent.
Remote accelerator will not operate.
Remote accelerator position will be set to 0 percent.
None on performance.
No engine protection for oil pressure.
None on performance.
No engine protection for oil pressure.
Progressive power derate increasing in severity
from time of alert.
Possible white smoke.
Fan will stay ON if controlled by ECM.
No engine protection for engine coolant temperature.
Possible white smoke.
Fan will stay ON if controlled by ECM.
No engine protection for engine coolant temperature.
FAULTY DIAGNOSIS
Fault
LAMP
Code
146 Amber
151
Red
153 Amber
154 Amber
155
Red
187
195
196
197
Amber
Amber
Amber
Amber
212 Amber
213 Amber
REASON
EFFECT
Engine coolant temperature is above engine protection Power derate and possible engine shutdown if
Engine Protection Shutdown feature is enabled.
warning limit
Progressive power and derate increasing in
severity from time of alert.
Engine coolant temperature signal indicates engine coolant If the Engine Protection Shutdown feature is
temperature above engine protection critical limit
enabled, engine will shut down 30 seconds after
the red lamp starts flashing.
Possible white smoke.
High signal voltage detected at intake manifold air Fan will stay ON if controlled by ECM.
No engine protection for engine coolant
temperature circuit
temperature.
Possible white smoke.
Low signal voltage detected at intake manifold air Fan will stay ON if controlled by ECM.
No engine protection for engine coolant
temperature circuit
temperature.
Progressive power and derate increasing in
severity from time of alert.
Intake manifold air temperature signal indicates intake
If the Engine Protection Shutdown feature is
manifold air temperature above engine protection critical limit
enabled, engine will shut down 30 seconds after
the red lamp starts flashing.
Low voltage detected at the sensor supply number 2 circuit Derate in power ouput of the engine
None on performance
High signal voltage detected at the engine coolant level circuit
Low signal voltage detected at the engine coolant level circuit None on performance
None on performance
Low engine coolant level detected
High signal voltage or an open circuit detected at the
No engine protection for engine oil temperature.
engine oil temperature circuit
Low signal voltage detected at the engine oil temperature circuit No engine protection for engine oil temperature.
7-47
FAULTY DIAGNOSIS
Fault
LAMP
Code
214
Red
221 Amber
222 Amber
227 Amber
234
Red
238 Amber
241 Amber
242 Amber
245 Amber
249 Amber
254
Red
REASON
EFFECT
Progressive speed deratre increasing in
severity from time of alert.
Engine oil temperature signal indicates engine oil If the Engine Protection Shutdown feature is
temperature above engine protection critical limit
enabled, engine will shut down 30 seconds after
the red lamp starts flashing.
Engine power derate.
High signal voltage detected at barometric pressure circuit
Engine power derate.
Low signal voltage detected at barometric pressure circuit
Engine will run derated.
No engine protection for intake manifold air
High voltage detected at sensor supply number 2 circuit
temperature.
Engine speed signal indicates engine speed above engine Fuel injection disabled until engine speed falls
below the overspeed limit.
protection limit
Low voltage detected on the +5 volt sensor supply circuit to
Possible hard starting and rough running.
the engine speed sensor
Engine speed limited to Maximum Engine
Speed without VSS parameter value.
The ECM lost the vehicle speed signal
Cruise control, Gear-Down Protection, and
Road speed Governor will not work.
Engine speed limited to Maximum Engine
Signal indicates an intermittent connection or VSS Speed without VSS parameter value.
Cruise control, Gear-Down Protection, and
tampering
Road speed Governor will not work.
Low signal voltage detected at the fan control circuit when The fan can possibly stay on continuously or
not run at all.
commanded ON
High signal voltage detected at ambient air temperature circuit None on performance.
Fuel shutoff valve will close.
Low voltage detected at fuel shutoff valve circuit
Engine will shutdown.
7-48
FAULTY DIAGNOSIS
Fault
LAMP
Code
REASON
EFFECT
Fuel shutoff valve may not open when starting
235 Amber Open circuit or short to voltage source detected at fuel key is in ON position, or may not close when
shutoff valve circuit
starting key is in OFF position.
None on performance
256 Amber Low voltage detected at ambient air temperature circuit
One or more multiplexed devices will not
The ECM expected information from a multiplexed device
operate properly.
285 Amber
but did not receive it soon enough or did not receive it at all
One or more symptoms will occur.
The ECM expected information from a multiplexed device At least one multiplexed device will not operate
286 Amber
properly.
but only receive a portion of the necessary information
The OEM vehicle electronic control unit(VECU) detected a Engine may only idle or engine will not
287 Red
accelerate to full speed.
fault with its accelerator pedal
The engine will not respond to the remote
The OEM vehicle electronic control unit(VECU) detected a throttle.
288 Red
Engine may only idle.
fault with the remote accelerator
The primary or cab accelerator may be able to be used.
The ambient air pressure sensor is reading an erratic value
295 Amber
Engine power derate.
at initial key-on
Current detected at injector number 1 when voltage is Current to injector is shut off.
311 Amber turned off
Engine can possibly misfire or run rough.
Current detected at injector number 5 when the voltage is Current to injector is shut off.
312 Amber
Engine can possibly misfire or run rough.
turned off
Current detected at injector number 3 when voltage is Current to injector is shut off.
313 Amber
Engine can possibly misfire or run rough.
turned off
Current to injector is shut off.
Current
detected
at
injector
number
6
when
voltage
is
314 Amber
Engine can possibly misfire or run rough.
turned off
Current detected at injector number 2 when voltage is Current to injector is shut off.
315 Amber
Engine can possibly misfire or run rough.
turned off
7-49
FAULTY DIAGNOSIS
Fault
LAMP
Code
REASON
EFFECT
319 Amber Real-time clock lost power
321 Amber
322 Amber
323 Amber
324 Amber
325 Amber
331 Amber
332 Amber
338 Amber
339 Amber
Current detected at injector number 4 circuit when voltage
is turned off
Current detected at injector number 1 when the voltage is
turned off
Current detected at injector number 5 when the voltage is
turned off
Current detected at injector number 3 when the voltage is
turned off
Current detected at injector number 6 when the voltage is
turned off
Current detected at injector number 2 when the voltage is
turned off
Current detected at injector number 4 when the voltage is
turned off
Open circuit or short to voltage source detected at the idle
shutdown vehicle accessory / ignition bus relay circuit
Low voltage detected at the adle shutdown vehicle
accessory / ignition bus relay circuit when commanded. on
343 Amber ECM power supply errors have been detected
351 Amber The ECM measured injector boost voltage is low
7-50
None on performance.
Data in the ECM will not have accurate time and
date information.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Current to injector is shut off.
Engine can possibly misfire or run rough.
Vehicle accessories or ignition bus loads controlled
by the idle shutdown relay will not power up.
Vehicle accessories or ignition bus loads controlled
by the idle shutdown relay will not power up.
Possible no noticeable performance effects or
engine dying or hard starting.
Fault information, trip information, and maintenance
monitor data can be inaccurate.
Possible low power, engine misfire, and.or engine
will not start.
FAULTY DIAGNOSIS
Fault
LAMP
REASON
Code
352 Amber Low voltage detected at sensor supply number 1 circuit
386 Amber High voltage detected at sensor supply number 1 circuit
415
Red
418
Maintenance
427
None
428 Amber
429 Amber
435 Amber
441 Amber
442 Amber
555 Amber
556 Red
584 Amber
585 Amber
596 Amber
EFFECT
Engine power detare.
Engine power detare.
Progressive power derate increasing in severity
from time after alert.
Oil pressure signal indicates oil pressure is below the
If the Engine Protection Shutdown feature is
engine protection critical limit
enabled, engine will shut down 30 seconds after
the red lamp starts flashing.
Possible white smoke, loss of power, or hard
Water has been detected in the fuel filter
starting.
Communication between the ECM(Electronic Control Module)
Engine speed will ramp down and remain at idle.
and another device on the SAE J1939 data link has been lost
None on performance.
High voltage detected at the water-in-fuel circuit
No water-in-fuel warning available.
None on performance.
Low voltage detected at the water-in-fuel circuit
No water-in-fuel warning available.
None on performance.
The engine oil pressure sensor is reading an erratic value at key-on
No engine protection for oil pressure.
Engine may stop running or be difficult to start.
ECM supply voltage is below the minimum system voltage level
ECM supply voltage is above the maximum system voltage level Possible electrical damage to all electrical components.
None on performance.
The crankcase breather filter requires maintenance
Engine power derate.
The crankcase breather filter requires maintenance
Either the engine will not start or the engine will
Open circuit or high voltage detected at starter lockout circuit
not have starter lockout protection.
The engine will not have starter lockout protection.
Low voltage detected at starter lockout circuit
High battery voltage detected by the battery voltage Amber warning lamp illuminated until high battery
monitor feature
voltage condition is corrected.
7-51
FAULTY DIAGNOSIS
Fault
LAMP
Code
REASON
EFFECT
Amber lamp will light until low battery voltage
condition is corrected.
Very low battery voltage detected by the battery voltage Red lamp illuminated until very low battery
voltage condition is corrected.
monitor feature
597 Amber Low battery voltage detected by the battery voltage monitor feature
598
Red
MainteMaintenamce reminder only.
nance Change engine oil and filter
An invalid turbocharger speed signal has been detected by None on performance.
686 Amber
the ECM
The ECM uses an estimated turbocharger speed.
Engine power derate.
687 Amber Low turbocharger speed detected by the ECM
The ECM uses an estimated turbocharger speed.
Engine can run rough. Possibly poor starting capability.
689 Amber Loss of signal from primary camshaft engine position sensor
Engine runs using backup speed sensor.
Engine power is reduced.
High signal voltage detected at the turbochanger compressor
691 Amber
Engine power derate.
inlet air temperature circuit
Low signal voltage detected at the turbochanger compressor
692 Amber
Engine power derate.
inlet air temperature circuit
High signal voltage or open circuit detected at the internal
None on performance.
697 Amber
ECM temperature sensor
Low signal voltage detected at the internal ECM temperature
698 Amber
None on performance.
sensor
Engine can run rough.
The ECM has detected an error in the camshaft position
Possibly poor starting capability.
778 Amber
sensor signal
Engine runs using primary engine position sensor.
Adaptive cruise control will not operate.
784 None Loss of communication with adaptive cruise control
Standard cruise control may not operate.
649
7-52
FAULTY DIAGNOSIS
Fault
LAMP
Code
1117
1239
1241
1242
1663
1664
1665
1666
1667
1674
1675
1676
REASON
EFFECT
Possible no noticeable performance effects or
Supply voltage to the ECM fell below 3.2 volts momentarily, or
engine dying or hard starting.
None the ECM was not allowed to power down correctly (retain
Fault information, trip onformation, and
battery voltage for 30 seconds after key OFF)
amintenance monitor data can be inaccurate.
High voltage detected at accelerator pedal position number 2 Severe derate in power output of the engine.
Amber signal circuit
Limp home power only.
Low voltage detected at accelerator pedal position number 2 Severe derate in power output of the engine.
Amber
Limp home power only.
signal circuit
Accelerator position sensor number 1 and number 2 are
The engine will only idle.
Red
reading different values
The inlet and outlet catalyst temperature sensor connections Active aftertreatment diesel particulate filter
Amber are swapped
regeneration will be disabled.
Active aftertreatment diesel particulate filter
Amber The aftertreatment catalyst in the exhaust system is not present
regeneration will be disabled.
Active aftertreatment diesel particulate filter
Amber Low signal voltage detected at the catalyst inlet sensor circuit regeneration will be disabled.
High signal voltage detected at the catalyst inlet temperature Active aftertreatment diesel particulate filter
Amber
regeneration will be disabled.
sensor circuit
The aftertreatment diesel oxidation catalyst inlet temperature Active aftertreatment diesel particulate filter
Amber sensor is not changing with engine operating conditions
regeneration will be disabled.
Low signal voltage detected at the aftertreatment diesel Active aftertreatment diesel particulate filter
Amber particulate filter inlet temperature sensor circuit
regeneration will be disabled.
High signal voltage detected at the aftertreatment diesel Active aftertreatment diesel particulate filter
Amber particulate filter inlet temperature sensor circuit
regeneration will be disabled.
The aftertreatment dieselparticulate filter inlet temperature Active aftertreatment diesel particulate filter
Amber
regeneration will be disabled.
sensor is not changing with engine operating conditions
7-53
FAULTY DIAGNOSIS
Fault
LAMP
Code
1691 Amber
1695 Amber
1696 Amber
1843 Amber
1844 Amber
1866 Amber
1876 Amber
1877 Amber
1878 Amber
1879 Amber
1881 Amber
1883 Amber
1893 Amber
1895 Amber
REASON
EFFECT
The temperature increase across the aftertreatment diesel
oxidation catalyst is lower than expected
High voltage detected at sensor supply number 5 circuit in the
OEM harness
Low voltage detected at sensor supply number 5 circuit in the
OEM harness
High signal voltage detected at the crankcase pressure circuit
Low signal voltage detected at the crankcase pressure circuit
An error in the EGR delta pressure signal was detected at initial
key-on or the sensor failed the auto-zero test
High signal voltage detected at the catalyst inlet temperature
sensor circuit
Low signal voltage detected at the aftertreatment diesel
particulate filter outlet temperature sensor circuit
The temperature diesel oxidation catalyst inlet temperature
sensor is not changing with engine operating conditions
High signal voltage detected at the aftertreatment differential
pressure sensor circuit
Low signal voltage or open circuit detected at the aftertreatment
differential pressure sensor circuit
The aftertreatment diesel particulate filter differential pressure
sensor is reading an erratic value at initial key-on or during
engine operation
No communications or invalid data transfer rate detected on the
J1939 datalink between the ECM and the smart EGR valve
A calibration mismatch between the EGR valve and the ECM
has been detected
7-54
None on performance.
Severe derate in power output of the engine.
Limp home power only.
Severe derate in power output of the engine.
Limp home power only.
No engine protection for high crankshaft pressure.
No engine protection for high crankshaft pressure.
EGR valve actuation will be disabled.
None on performance.
None on performance.
None on performance.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
FAULTY DIAGNOSIS
Fault
LAMP
Code
1896 Amber
1899 Amber
1921 Amber
1922
Red
1923 Amber
1924 Amber
1926 Amber
1927 Amber
1928 Amber
1932 Amber
1933 Amber
1934 Amber
1935 Amber
1938 Amber
REASON
EFFECT
The EGR valve has failed the automatic calibration procedure
at initial key-on
The EGR differential pressure sensor has detected low EGR
gas flow or the EGR differential pressure reading is not valid
for engine operating conditions
The soot load of the aftertreatment diesel particulate filter has
exceeded the recommended limits
The soot load of the aftertreatment diesel particulate filter has
exceeded the recommended limits
High signal voltage detected at the aftertreatment differential
fuel shutoff valve circuit
Low signal voltage detected at the aftertreatment differential
fuel shutoff valve circuit
The ECM has detected that the aftertreatment fuel pressure
signal is not changing with engine operating conditions
High signal voltage detected at the aftertreatment fuel
pressure sensor circuit
Low signal voltage detected at the aftertreatment fuel
pressure sensor circuit
An error has been detected in rither the aftertreatment fuel
injector or the aftertreatment fuel shutoff valve system
High battery voltage detected by the EGR valve
Low battery voltage detected by the EGR valve
Intermittent communication between the smart EGR valve
controller and the ECM has been detected
Low battery voltage detected by the VGT actuator
7-55
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
The aftertreatment dash lamp will flash.
Engine protection derate.
Severe engine derate.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
None on performance.
None on performance.
None on performance.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
EGR valve actuation will be disabled.
Low voltage information fault code only.
The EGR valve will hold the position of the last
valid J1939 message.
None on performance.
FAULTY DIAGNOSIS
Fault
LAMP
Code
1942 Amber
1943 None
1962 Amber
1968 Amber
1969
Red
1972 Amber
1973
Red
REASON
EFFECT
The ECM has detected that the crankcase pressure signal
is not changing with engine operating conditions
Engine torque has been reduced because the vehicle was
operating at a high altitude condition
High internal VGT actuator temperature has been detected
The aftertreatment diesel particulate filter inlet temperature
sensor reading has exceeded the maximum temperature limit
The aftertreatment diesel particulate filter inlet temperature
sensor reading has exceeded the maximum engine
protection temperature limit
The aftertreatment diesel particulate filter outlet temperature
sensor reading has exceeded the maximum temperature limit
The aftertreatment diesel particulate filter outlet
temperature sensor reading has exceeded the maximum
engine protection temperature limit
1974 Mainte- The crankcase breather filter requires maintenance
nance
High resistance, short circuit, or open circuit detected on
1977 Amber
the aftertreatment fuel injector circuit
The aftertreatment differential pressure has exceeded the
1981 Amber
maximum operating limits or the diesel particulate filter is plugged
The aftertreatment diesel particulate filter in the exhaust
1993 Amber
system is not present
High voltage or an open circuit detected at the engine brake
2182 Amber
solenoid number 1 signal circuit
Low voltage detected at the engine brake solenoid number
2183 Amber
1 signal circuit
7-56
None on performance.
Possible engine derate.
None on performance.
Active aftertreatment diesel
regeneration will be disabled.
Engine power derate.
Active aftertreatment diesel
regeneration will be disabled.
Active aftertreatment diesel
regeneration will be disabled.
Engine power derate.
Active aftertreatment diesel
regeneration will be disabled.
particulate filter
particulate filter
particulate filter
particulate filter
None on performance.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
Engine brake on cylinder numbers 1, 2, and 3
can be on all the time or can not be activated.
Engine brake on cylinder numbers 1, 2, and 3
can not be activated.
FAULTY DIAGNOSIS
Fault
LAMP
Code
2185 Amber
2186 Amber
2198 Amber
2272 Amber
2273 Amber
2274 Amber
REASON
EFFECT
High voltage detected at the +5 volt sensor supply circuit to
the accelerator pedal position sensor
Low voltage detected at the +5 volt sensor supply circuit to
the accelerator pedal position sensor
Intermittenet communication between the smart VGT controller
and the ECM has been detected. The VGT controller is not
interpreting the J1939 message from the ECM correctly
Low signal voltage has been detected at the EGR position
sensor circuit
High signal voltage detected at the EGR differential
pressure sensor circuit
Low signal voltage detected at the EGR differential
pressure sensor circuit
Engine will only idle.
Engine will only idle.
VGT actuation will be disabled.
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
2288 Amber High turbocharger speed has been detected by the ECM
Engine power derate to lower the turbocharger speed.
The turbocharger speed sensor has detected an erroneous
2345 Amber speed value
Turbocharger turbine inlet temperature has exceeded the
2346 None engine protection limit
High turbocharger compressor outlet air temperature has
2347 None been calculated by the ECM
Motor terminal or motor coil open circuit has been detected
2349 Amber by the smart EGR controller
Motor terminal or motor coil short circuit to ground, or power
2351 Amber supply has been detected by the smart EGR controller
The EGR motor has exceeded the duty cycle limit,
2357 Amber
indicating a stuck open EGR valve
None on performance.
The ECM uses an estimated turbocharger speed.
Fuel is limited in an attempt to decrease the
exhaust gas temperature entering the turbocharger.
Fuel is limited in an attempt to decrease the calculated
turbocharger compressor outlet air temperature.
7-57
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
FAULTY DIAGNOSIS
Fault
LAMP
Code
REASON
EFFECT
The EGR differential pressure sensor has detected high EGR
2359 Amber gas flow or the EGR differential pressure reading is not valid
for engine operating conditions
Low voltage detected at the engine brake solenoid number 2
2363 Amber signal circuit
Low voltage detected at the engine brake solenoid number 2
2367 Amber
signal circuit
High signal voltage detected at the exhaust gas pressure
2373 Amber
circuit
2374 Amber Low signal voltage detected at the exhaust gas pressure circuit
2375 Amber High signal voltage detected at EGR temperature circuit
2376 Amber Low signal voltage detected at EGR temperature circuit
2377 Amber Open circuit or high voltage detected at the fan control circuit
The smart VGT controller has detected incorrect stop limits,
2387 Amber
or the VGT is unable to move to the closed position
2412 Amber The fan speed signal has been lost
2448 Mainte- Low engine coolant level detected
nance
The VGT has failed the automatic calibration procedure at
2449 Red
initial key-on. VGT will be in the open position
Turbocharger turbine inlet temperature has exceeded the
2451 None engine protection limit
The exhaust gas pressure sensor is reading an erratic value
2554 None
at initial key-on
2634 Red An internal error has been detected by the smart VGT controller
A calibration mismatch between the VGT actuator and the
2635 Red
ECM has been detected
7-58
EGR valve actuation will be disabled.
Engine brake on cylinders number 4, 5, and 6
can not be ctivated.
Engine brake on cylinders number 4, 5, and 6
can not be deactivated, or can be activated.
None on performance.
None on performance.
EGR valve actuation will be disabled.
EGR valve actuation will be disabled.
The fan may stay on continuously or not run at all.
VGT travel may be limited.
The fan will only be in the ON or OFF position.
None on performance.
Low intake manifold pressure.
Fuel is limited in an attempt to decrease the calculated
exhaust gas temperature entering the turbocharger.
The ECM will estimate the exhaust gas pressure.
VGT actuation will be disabled.
VGT actuation will be disabled.
FAULTY DIAGNOSIS
Fault
LAMP
Code
REASON
EFFECT
No communications on the J1939 datalink between the
engine ECM and the smart VGT controller
The front face of the aftertreatment diesel oxidation catalyst
2637 None has been detected to be plugged with soot
The temperature increase across the a aftertreatment
2638 None diesel oxidation catalyst is lower than expected
2636
Red
VGT actuation will be disabled.
Active aftertreatment diesel particulate filter
regeneration will be disabled.
None on performance.
The aftertreatment dash lamp will be illuminated
The soot load of the aftertreatment diesel particulate filter and will begin to flash as the severity of the soot
2639 None
has exceeded the recommended limits
load increases.
Possible engine protection derate based on severity.
EGR valve actuation will be disabled.
2646 Amber The EGR valve was closed to reduce engine coolant temperature
EGR valve actuation will be disabled.
2659 None The EGR valve was closed to reduce engine coolant temperature
Excessive fuel injection into the aftertreatment system has
2728 None
None on performance.
been detected
High signal voltage detected at the aftertreatment fuel drain Active aftertreatment diesel particulate filter
2732 Amber
valve circuit
regeneration will be disabled.
Low signal voltage detected at the aftertreatment fuel drain Active aftertreatment diesel particulate filter
2733 Amber
valve circuit
regeneration will be disabled.
High signal voltage or open circuit detected at the ether
2738 Amber
Ether start functionality will be disabled.
start solenoid circuit
2739 Amber Low signal voltage detected at the ether start solenoid circuit Ether start functionality will be disabled.
Aftertreatment fuel shutoff valve 1 and aftertreatment fuel Active aftertreatment diesel particulate filter
2741 Amber
regeneration will be disabled.
drain valve wiring harness connections are reversed
The temperature in the aftertreatment system can not
2742 None
None on performance.
reach the required temperature for stationary regeneration
7-59
FAULTY DIAGNOSIS
Fault
LAMP
Code
REASON
EFFECT
Aftertreatment Exhaust Gas Temperature 2 - Data Valid but
2743 None Below Normal Operating Range - Moderately Severe Level
Excessive black smoke has been detected exiting the engine
2754 Amber
and entering the aftertreatment diesel particulate filter
High exhaust gas pressure has been detected by the
2765 Amber
exhaust gas pressure sensor
Plugged EGR differential pressure sensor tubes have been
2774 Amber
detected
2963 None
2964 None
2973 Amber
None on performance.
Fueling derate to bring exhaust gas pressure
below the maximum operating limits.
EGR valve actuation will be disabled.
Slight fueling derate to bring EGR temperature
under the maximum limit.
Severe fueling derate to bring EGR temperature
EGR temperature has exceeded the engine protection limit under the maximum limit.
Engine coolant temperature is above the engine coolant Power derate and possible engine shutdown if
engine protection shutdown feature is enabled.
temperature engine protection warning limit
Intake manifold air temperature signal indicates intake manifold Progressive power derate increasing in severity
from time of alert.
air temperature is above engine protection warning limit
The ECM has detected an intake manifold pressure signal
Engine power derate.
that is too high or low for current engine operating conditions
2961 None EGR temperature has exceeded the engine protection limit
2962 Amber
None on performance.
7-60
FAULTY DIAGNOSIS
7. ABS Diagnostic (Self-Diagnosis) (OPTION)
ABS Diagnostic
General operation
ABS system operates normally on engine start-up.
If no problems are found when the key is on ON, ABS and ASR
warning indications will be turned off shortly after turning on.
If no system faults are found while the engine is operational,
the warning indication will not flicker.
Faults found
If any faults or problems are found while suspended
examination is performed by ECU, ABS warning indication
will flicker and ABS system will be partially or fully shut down.
If any problems are found on wheel speed sensor by ECU
while driving, the ABS indications will flicker until ECU
receives all-clear result from all wheel sensors.
ABS warning indication will be turned off when normal
condition is confirmed.
If flicker codes are operated with Faulty Diagnosis button,
Flicker code will be indicated within the short period of ABS
warning indication.
Flickering number can be interpreted with flicker code table.
Faulty Diagnosis button oepration
Flicker codes indicated by ABS warning indications are
expressed in two methods.
・Off and On lamp are indicated with a couple of symbols
・It is expressed in steps in the graph according to basic time
ABS warning indications are turned on to indicated that
Faulty Diagnosis button has been pressed.
Flicker code
ABS warning indications inform you of faults and indicate
them by flickering.
Flicker code within ECU are used for indicating two types of
flicker code.
・Composition code : It shows system composition of ECU
programming.
・Fault code : It provides information on faults detected by ECU.
7-61
OM-B293E
FAULTY DIAGNOSIS
System Composition Code
・Concerning ECU with power supply(the switch is on), press
the Faulty Diagnosis button twice after waiting for at least a
second and release the button.
・Composition code is indicated by flickering of ABS warning
indication.
・Composition code is divided into two sections. Each section
consists of 2 numbers. Two numbers are will stop for 0.5
seconds or wll operate for 0.5 seconds.
・Suspend for 1.5 seconds after confirming a flickering
number in the first section. After that, 2 flickering of the first
section should be confirmed.
・Suspend for apx. 4 seconds after confirming the first
section. Confirm one flickering of the seconds section and
suspend for 1.5 seconds. Confirm 2 flickering in the
seconds section.
・It will shut down when Faulty Diagnosis button is pressed
while the composition code is flickering.
System composition code table
SEC. NO.
1
Flickering
number
1st
2
24 volts
2nd
2
4S/4M (4 WSS & 4 PCV)
Retarder and J1939 CAN not applied.
Exhaust brake/Retarder relay (DBR)
not applied.
Retarder and J1939 CAN not applied.
Exhaust brake/Retarder relay (DBR)
not applied.
Retarder and J1939 CAN not applied.
Exhaust brake/Retarder relay (DBR)
not applied.
Retarder and J1939 CAN not applied.
Exhaust brake/Retarder relay (DBR)
not applied.
Engine and J1939 CAN not applied.
ASR valve not applied.
Engine and J1939 CAN not applied.
ASR valve not applied.
Engine and J1939 CAN not applied.
ASR valve not applied.
Engine and J1939 CAN not applied.
ASR valve not applied.
1
2
1st
3
2
4
2
3
2nd
4
5
OM-B294E
7-62
Composition
FAULTY DIAGNOSIS
Fault Code
・If ECU power is on (ignition on), wait for at least a second
and press Faulty Diagnosis button once (0.5~5secs)and
release it.
Fault code transfer will happen.
・Faulty code is indicated with brief flicker of ABS warning
indication lamp.
・Fault codes indicating details of faults are divided into two
flickering.
・The first flicker(apx 0.5 secs each) indicate“the first
number”, and the second flicker (apx 0.5 secs each) after
1.5 seconds suspension indicate“the second number”.
You can confirm the composition and faults with Faulty
Diagnosis code table.
・If more than two faults are found, the next fault code will
activated about 4 seconds later.
・ABS ECU memory can store upto 16 faults.
・Most recent fault will be displayed the first and the oldest
will be displayed at last.
・The indication will not flicker anymore if found faults flicker
is completed.
Pressing Faulty Diagnosis button again will repeat the
flicker process again.
Pressing Faulty Diagnosis button while the ABS warning
lamp is flickering, will suspend Faulty Diagnosis process.
・It is not possible activate general ECU performances while
Fault Codes are operational.
(ABS function is not operational)
Fault code explanation
7-63
OM-B295E
FAULTY DIAGNOSIS
ABS 6 Fault Code Table
Malfunction Part
Normal Code
Wheel Speed Sensor,
Front Axle (Left)
Wheel Speed Sensor,
Front Axle (Right)
Wheel Speed Sensor,
Rear Axle (Left)
1st 2nd
NO. NO.
Fault Details
1
1
System is in normal state
2
1
The air gap is too large. ( >0.6mm)
2
2
Speed sensor indication is missed out.
2
3
Impulse Ring damaged or contaminated. Faulty sensor signal. Ring check and adjustment, and wheel bearing adjustment.
2
4
Unstable sensor signal. Impulse Ring check and adjustment. Wheel bearing adjustment. Wiring check.
2
5
Speed sensor signal failed.
2
6
Speed sensor wiring disconnected or damaged.
3
1
The air gap is too large. ( >0.6mm)
3
2
Speed sensor indication is missed out.
3
3
Impulse Ring damaged or contaminated. Faulty sensor signal. Ring check and adjustment, and wheel bearing adjustment.
3
4
Unstable sensor signal. Impulse Ring check and adjustment. Wheel bearing adjustment. Wiring check.
3
5
Speed sensor signal failed.
3
6
Speed sensor wiring disconnected or damaged.
4
1
The air gap is too large. ( >0.6mm)
4
2
Speed sensor indication is missed out.
4
3
Impulse Ring damaged or contaminated. Faulty sensor signal. Ring check and adjustment, and wheel bearing adjustment.
4
4
Unstable sensor signal. Impulse Ring check and adjustment. Wheel bearing adjustment. Wiring check.
4
5
Speed sensor signal failed.
4
6
Speed sensor wiring disconnected or damaged.
7-64
FAULTY DIAGNOSIS
Malfunction Part
Wheel Speed Sensor,
Rear Axle (Right)
Pressure Control
Valve(PCV),
Front Axle (Left)
Pressure Control
Valve(PCV),
Front Axle (Right)
1st 2nd
NO. NO.
Fault Details
The air gap is too large. ( >0.6mm)
5
1
5
2
Speed sensor indication is missed out.
5
3
Impulse Ring damaged or contaminated. Faulty sensor signal. Ring check and adjustment, and wheel bearing adjustment.
5
4
Unstable sensor signal. Impulse Ring check and adjustment. Wheel bearing adjustment. Wiring check.
5
5
Speed sensor signal failed.
5
6
Speed sensor wiring disconnected or damaged.
8
1
Release Solenoid Short.
8
2
Release Solenoid Short.
8
3
Release Solenoid Wiring Short Circuit.
8
4
Valve Earthing Wiring Short Circuit.
8
5
Hold Solenoid Short.
8
6
Hold Solenoid Short.
8
7
Hold Solenoid Wiring Short Circuit.
8
8
Valve Composition Error. Valve / System Wiring / ECU Composition Check.
9
1
Release Solenoid Short.
9
2
Release Solenoid Short.
9
3
Release Solenoid Wiring Short Circuit.
9
4
Valve Earthing Wiring Short Circuit.
9
5
Hold Solenoid Short.
9
6
Hold Solenoid Short.
9
7
Hold Solenoid Wiring Short Circuit.
9
8
Valve Composition Error. Valve / System Wiring / ECU Composition Check.
7-65
FAULTY DIAGNOSIS
Malfunction Part
Pressure Control
Valve(PCV),
Rear Axle (Left)
Pressure Control
Valve Earthing
Pressure Control
Valve(PCV),
Rear Axle (Right)
ASR Valve Fault
1st 2nd
NO. NO.
Fault Details
10
1
Release Solenoid Short.
10
2
Release Solenoid Short.
10
3
Release Solenoid Wiring Short Circuit.
10
4
Valve Earthing Wiring Short Circuit.
10
5
Hold Solenoid Short.
10
6
Hold Solenoid Short.
10
7
Hold Solenoid Wiring Short Circuit.
10
8
Valve Composition Error.
Valve / System Wiring / ECU Composition Check.
10 10
Short. Remove the ECU X2 Plug. Valve Earthing Wire Electric power Check. Wiring Replace (When necessary).
10 11
Short/Valve Internal Damage. Remove the X2 Plug. Valve/Chassis Earthing Check.
11
1
Release Solenoid Short.
11
2
Release Solenoid Short.
11
3
Release Solenoid Wiring Short Circuit.
11
4
Valve Earthing Wiring Short Circuit.
11
5
Hold Solenoid Short.
11
6
Hold Solenoid Short.
11
7
Hold Solenoid Wiring Short Circuit.
11
8
Valve Composition Error.
14
5
ASR Valve Short - High.
14
6
ASR Valve Short - Low.
14
7
ASR Valve Wiring Short Circuit.
14
8
ASR Valve Composition Fault.
Valve / System Wiring / ECU Composition Check.
7-66
FAULTY DIAGNOSIS
Malfunction Part
ECU Internal Fault
Power Supply
1st 2nd
NO. NO.
15
1
15
2
15
3
15
4
15
5
15
6
15
7
15
8
15
9
15
10
15
11
15
15
16
16
16
16
16
16
1
2
3
4
9
10
Fault Details
Faulty internal microprocessor. Faulty memory erased.
Change ECU if this fault code constantly appears.
Faulty ECU data. Faulty memory erased.
Change ECU if this fault code constantly appears.
Faulty internal microprocessor.
Faulty memory erased.
Change ECU if this fault code constantly appears.
Faulty ECU system compostion. Faulty memory erased.
Change ECU if this fault code constantly appears.
Interior of ECU is not converted to Relay. Faulty memory erased.
Change ECU if this fault code constantly appears.
ECU’s inner Relay permanent switch is activated. Faulty memory is erased.
Change ECU if this fault code constantly appears.
ABS Software does not match with the hardware.
Check the system installation and ECU composition.
Battery supply - temporary high voltage. Generator/Voltage check.
Battery supply - temporary low voltage. Check the low voltage battery condition and shutdown of ABS control.
Battery supply - Faulty wiring.
Supplied voltage - power line noise. Temporary power line noise.
Ignition supply - temporary high voltage. Check the condition of Generator/voltage.
Ignition supply - temporary low voltage. Check the battery condition and shutdown.
7-67
FAULTY DIAGNOSIS
Malfunction Part
Exhaust Brake,
Retarder
Tire Size
Braking Lamp
ABS / ASR
ETC.
Warning Lamp
Wheel Speed
Sensor
J1969 CAN Data
Connection
1st 2nd
NO. NO.
Fault Details
17
1
Retarder(Exhaust) Control Relay Short.
17
2
Retarder(Exhaust) Control Relay Short or Wiring Dhort Circuit. Wiring Check.
17
5
Non-standard tire. Check the size and pressure.
17
6
C-3 Signal Inspection.
17
7
Braking light switch is not functioning.
17
14
Faulty braking light.
17
8
ASR or ESP are not working. Roller test-run mode.
17
9
Off road ABS function not available.
17
11
ASR control time limit exceeded.
17
10
Warning lamp wiring short circuit or disconnected. Check the warning lamp wiring.
17
12
Faulty wheel speed sensor which was in previous“Power ON”cycle.
(The condition where the warning indication is on after ECU memory erase)
If the sensor fault is taken care of, the indication will turn off when the vehicle speed reaches
20km/h.
Stop the vehicle if the warning remains lighted and check the fault code again.
17
13
18
3
4
5
6
18
18
18
Wiring Check.
Check if the wiring for wheel speed sensor in front axle or rear axle are proper.
Check the wiring for the plug.
CAN-bus off. Check CAN-Bus related connector and connected resistance.
Faulty indication of exceeded communication time limit for Retarder and CAN. Check CAN connector.
Faulty indication of exceeded communication time limit for engine ECU and CAN
Faulty indication of exceeded communication time limit for Engine ECU and ASR CAN.
7-68
FAULTY DIAGNOSIS
Fault Code Delete
Delete every faulty code from the ECU memory.
・Press Faulty Diagnosis button.
・Turn the key to ON position.
・Release Faulty Diagnosis button.
REFERENCE
・ABS warning indication will turn on if you press Faulty
Diagnosis button while the key is turned to ON.
ECU memory will not be deleted in this case.
・ECU fault memory related to wheel speed sensor could
cause the ABS warning indication to flicker constantly in
certain situations.
In this case, if you reach 20km/hr, the ABS warning
indication will no longer flicker if the problem is solved.
”Function)
Fault Code Delete (ASR“OFF”
You can force the ASR function to turn off in order to avoid
brake control and engine torque increase/decrease when
you need to deactivate ASR to measure the speed of the
roller bench test (when driving for a long time)or on other
occasions.
a. Press ABS examination switch for 5 seconds when you
turn key to“ON”position or on start-up.
b. ASR indication will be lighted after more than 5 seconds.
c. Lighted lamp means that ASR is“OFF”.
d. Fault code 17/80 will flicker if you perform ABS self
diagnosis at this time.
e. ASR lamp will be turned off when you delete the fault code
after completing required process.
The ASR function will then be activated normally.
7-69
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement