important service activities

IMPORTANT SERVICE ACTIVITIES

Any failure resulting from a lack of normal maintenance as the maintenance service chart in this manual is not coveredby warranty.

Check items Check and Service Intervals Page

DE12Ti

DE12Ti

DV15T

Engine oil 159 Page

DE12TiS

DV15TiS

Engine oil filter Change with engine oil 160 Page

Fuel filter Change at every 20,000km. 162 Page

Valve clearance Adjust at end of first 1,000km and every 20,000km there after. 165 Page

Air cleaner Clean at every 4,000km, change at every 12,000km there after. 170 Page

Transmission oil Change at end of first 5,000km and every 20,000km there after. 172 Page

Rear axle oil Change at end of first 5,000km and every 20,000km there after. 173 Page

Power steering oil Change at end of first 1,000km and every 24,000km there after. 174 Page

Power steering filter Change at end of first 1,000km and every 24,000km there after. 176 Page

Change : At end of first 1,000km,

High–speed, long distance : every 15,000km

In city, short distance : every 10,000km

Change : At end of first 1,000km,

long distance : every 30,000km

Shot distance : every 20,000km

This manual has been prepared to acquaint you with the operation and maintenance of your DAEWOOBUSES and the provide important safety information. We urge you to read it carefully and follow therecommendations to help assure the most enjoyable, safe and troublefree operation of your vehicle.

When it comes to service, remember that your DAEWOO dealer knows your vehicle best and isinterested in your complete satisfaction.

We would like to take this opportunity to thank you for choosing a DAEWOO product and assureyou of our continuing interest in your motoring pleasure and satisfaction.

This manual should be considered as a permanent part of your vehicle, and must remain with thevehicle at the time of resale.

All information, illustrations and specifications contained in this manual are based on the latest productinformation available at time of publication.The right is reserved to make changes at any time without notice.

FOREWORD

1

1. IMPORTANT INFORMATION 2

2. OPERATION AND CARE OF NEW VEHICLE 4

3. GETTING ON AND OFF, DRIVER’S SEAT AND BELT 6

4. INSTRUMENT, SWITCHES AND CONTROLS 12

5. DRIVING 132

6. INSPECTION AND MAINTENANCE 158

7. LUBRICATION 214

8. SCHEDULED MAINTENANCE SERVICE 222

9. TROUBLESHOOTING 226

10. MAIN DATA AND SPECIFICATION 235

11. BODY DIMENSION 253

TABLE OF CONTENTS

2

IMPORTANT INFORMATION

LOCATION OF ENGINE NUMBER AND CHASSIS NUMBER

It is advisable to keep note of the engine number and chassis number as they are required when contacting your deal-er for repair services and parts order.

V.I.N plate

V.I.N(Vehicle identification Number)plate is attached to the inner panelabove the front door.

Type A : Applicable for vehicles inall countries except GCCmembers.

V.I.N plate

V.I.N(Vehicle identification Number)plate is attached to the inner panelabove the front door.

Type B : Applicable for vehicles inGCC members.

Chassis number

The chassis number is stamped onthe upper face of the chassis framewithin the engine compartment.

(DE12Ti/TiS ENG.)

(DE12T, DV15T/TiS ENG.)

3

Engine number Key

There are three types of key for thebus ;• Engine starting• Mechanical locking for entrance

door (OPTION)• Doors– Entrance door operating– Luggage doors (OPTION)– Rear engine door (OPTION)– Side engine doors (OPTION)– Battery inspection door (OPTION)– Fuel tank inspection door (OPTION)– Fuel inlet flap door (OPTION)

The keys are not interchangeable, butdoor lock keys are interchangeable.The code number of each key isstamped on the key.Record the key number and keep itin a safe place.In the event that the original key islost, duplicating can be done usingthe key code information.

Engine No.

1378

(DE12T/Ti/TiS)

(DV15T/TiS)

4

OPERATION AND CARE OF NEW VEHICLE

It is important to observe the follow-ing precautions as operation and careof the vehicle, particularly during thebreak–in period have a strong influ-ence over the performance and ser-vice life of the vehicle.

1. Start and let the engine idle untilit becomes thoroughly warmed upand coolant temperature increasesbeyond 50°C (or 125°F) before st-arting off.

2. Avoid racing the engine, abruptstarts and hard stops.

3. Avoid over loading the vehicle dur-ing and after the break–in period.

Over loading

Over loading not only shortens theservice life of your vehicle but alsocreate serious potential safety haz-ards.

The weight of payload must be limit-ed within the GVW rating and distrib-uted over the front and rear axles soas not to exceed the axle capacities.

Refer to “MAIN DATA AND SPECIFI-CATION” for GVW and Axle capaci-ty.

Maintenance

In order to maintain safe and depend-able vehicle operation, inspection andadjustment should be performed asoutlined in “INSPECTION AND MAIN-TENANCE”.

Your DAEWOO dealer is willing toperform regular maintenance opera-tion on your vehicle.

5

Engine oil change

Change engine oil filter catridge to new one at thesame time with engine oil.

Maximum engine speed

During the initial milage(Break–in period : 2,000km),confine engine speed to 70% of the maximum andscan the tachometer as you drive to prevent engineover–running.After the break–in period, increase the engine speedgradually to complete running–in of the vital parts.

Engine Model Change Interval

At end of first 1,000km

DE12TiS High–speed, long distance :

DE12TiS every 15,000km

DV15TiS In city, short distance :

every 10,000km

DE12TiSAt end of first 1,000km

Long distance : every 30,000kmDV15TiS

Shot distance : every 20,000km

6

GETTING ON AND OFF, DRIVER’S SEAT AND BELT

DOOR OPENING AND CLOSING(Applicable for vehicles in allentrance door with mechanical key)

When opening the front door to getin, first unlock the mechanical key onthe entrance door and operate theentrance key on the right side of thefront middle panel.When closing the front door to getoff, open the front door by operatingthe door control switch and get off.

In the outside of bus, close the doorwith the key and look the mechanicalkey on the entrance door not to beopened in case of air leaking.

(Applicable for vehicles in allentrance door except mechanical key)

When opening the front door to getin, operate the entrance key on theright side of the froot middle panel.When closing the front door to getoff, open the front door by operatingthe door control switch and get off.In the outside of bus, close the doorwith the key.

x1000 rpm

0

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15AIR

kg/cm2

0

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0 0 0 0 0 0

POWER

AUTOVENTILATOR POWER

POWER

AIRCONDITIONER

Before operating entrance key, unlockmechanical key on door frame.

NOTICE

When opening front entrance door for a long time, setting emergency valve at man-ual position and put control switch in close position. When returning to automaticcondition, putting control switch and door in same condition and set emergency valveat automatic position.

CAUTION

7

MANUAL OPENING ANDCLOSING

Type A : Select type

As setting the “Auto–Manual” changelever installed right, lower inner sideof front panel(beside of driver’s rightleg), the door can be opened andclosed by hands.

Type B : Push/Pull or rotary type(OPTION)

As setting the "Auto-Manual" changeknobs are installed two types. One ofthe types installed inner upper panelthe entrance door operated by air.Other installed outer mid panel on leftside of door operated by electric pushbutton. the door can be opened andclosed by hands.

IDLING

H..L

(Push/Pull type) (Rotary type)

8

Adjustment of Air suspension type driver’sseat (S-110A)

1. Slide adjustmentTo move the seat forward or rearward, pull No. 1 leverupwards and the slide the seat.

2. Back angle adjustmentTo adjust the seat back, pull No. 2 lever and leanbackwards or forewards until the desired angle isachieved.

3. Height and slope adjustmentDesired seat height can be achieved by pulling No. 3lever.

4. Upper lumbar support air cushion adjustment.4. Lower button is for inflation, upper button is for defl-4. ation5. Lower lumbar support air cushion adjustment.

Push the lumbar support air cushion adjustment but-ton to suit seating position.

4. Lower button is for inflation, upper button is for defl-4. ation6. Air suspension stroke support air undercushion adjust-

mentDo not adjust the driver’s seat while driving.

2

2

445

33

6

1

5

4

1

DRIVER’S SEAT AND BELT

9

How to use air suspension seat

Air suspension seat can be infinitly adjusted to suit the weight of the driver.

Height Adjustment Tilt Adjustment(RR) Tilt Adjustment(FRT) Back Angle

Lumbar Support(Lower)Lumbar Support(Upper)Slide Adjustment

10

The vehicle is equipped with three point type(driver’s)and reel type(passenger’s)Every person who drives or rides in this vehicleshould wear a seat belt at all time.The buzzer will sound, if the driver’s seat belt is notfastened when the ignition switch is turned to the“ON” position.1) Pull the belt evenly out of the retractor and guide

it across the body making certain that it is nottwisted.The seatback should not be in a reclining positionanymore than needed for comfort.

2) Insert the metal latch plate into the buckle .3) To remove the belt, depress the red push button

on the buckle.And the belt wil roll up automatically.

4) When the driver’s seat belt is not in use, adjustthe latch plate within 10cm from the seat loop.

The belt must not be twisted when fitted.

Do not wear the shoulder belt across the neck orunder your outer arm.

Seat Belts

1

2

11

Seat belt warning lamp

The seat belt warning lamp comes onwhen the ignition switch is placed inthe “ON” position unless the driver’sseat belt is securely fastened.

Pilot indicator lamps

1. Never use the belt for morethan one person at a time.

2. Never wear the belts twisted.3. Make sure seat belts or their

attachments not to be thrustedin metal parts of the seat orthe door.

4. Seat belts should be adjustedas firmly as possible.

5. Do not wear seat belts lowunder your shoulder.

6. If you replace your seat beltsincorrectly, you may by injuredby hardware of the belts atsudden stops.

7. Do not wear your seat beltswith hard or breakable objectssuch as glasses, pens, etc. putinto the pocket of your uppergarment.

NOTICE

1. Periodically inspect all parts ofthe belts and replace any dam-aged parts.

2. Make sure that the belts arenot to be damaged by sharpedged objects.

3. The belts should be changed ifwebbing has become frayed ordamaged.

4. Check if fixing bolts have beenfirmly installed to the floor.

5. Always keep the seat beltsclean and dry.

6. Clean only with tepid soapywater.

7. Do not bleach or dye seatbelts.

CAUTION

12

INSTRUMENTS, SWITCHES AND CONTROLS

x1000 rpm

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kg/cm2

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1011

85 6 71�2�3�4

9 10

15

1213

18

192021222324

30

2627 25

28

17

16

29

14

13

The quantities or locations of switches could be different from the figure, because the switches could be added oromitted, or locations could be changed by the requirements of customers.

LEGEND OF INSTRUMENT PANEL AND OTHER DEVICES

No. Description No. Description No. Description

1 Voltage meter

2 Engine coolant temperature gauge

3 Fuel gauge–Engine

4 Engine oil pressure

5 Air pressure gauge

6 Upper pilot lamps

7 Engine RPM gauge

8 Lower pilot lamps

9 Tachograph

10 Defroster heater grille

11 Monitor–car vision (OPTION)

12 Microphone stand

13 Radio & Cassette player

14 Switches

15 Switches

16 VTR (OPTION)

17 Defroster controller

18 Engine idling knob

19 Shift lever (Except auto transmission)

20 Accelerator pedal

21 Wiper control and exhaust brake lever

22 Brake pedal

23 Horn switch

24 Bulb check

25 Steering wheel

26 Head & Direction lamp lever

27 Clutch pedal

28 Valve–cab control

29 Clutch oil reservoir

30 Control panel (OPTION)

14

ATTACHMENTS OF STEERING COLUMN

Steering wheel and horn button

The steering wheel should not beturned while the vehicle is stationaryas it adversely affects the tires andsteering system.Horn button is equipped on the mid-dle of steering wheel.

Steering wheel adjustment

Adjust the steering wheel to thedesired position after pulling locklever.

Adjusting angle : 8°Travel : 40mm

Starter switch

Starter switch operates in the 4stages as follows :

LOCK : The key can be inserted orremoved only when theswitch is in this position.

ACC : This position turns on theradio, digital clock, cigarettelighter and consent.

unlock

3°

5°

lock

20mm20mm

15

ON : This position turns on theelectrical equipment. During thevehicle operation, hold the key inthis position.

When the key is in “ON” position,the engine is automatically pre-heated according to outdoor tem-perature. Pre–heater warninglamp blinks for 0.3 second at ahigher temperature(coolant temp. :above 25°C) and for 18 secondsat a lower temperature(coolanttemp. : below 25°C), duringwhich the engine is preheated for20 seconds.

START : Once the engine is start-ed, it is preheated automaticallyaccording to outdoor temperature(until coolant temperature becomes25°C or up to 6 minutes). Thisimproves the engine condition.

Turn signal switch

Move this combination switch lever inthe desired direction so that the cor-responding turn signal lamp operatesand causes the turn signal indicatorlamp on the instrument panel to flash.The switch lever returns automatical-ly to the neutral position when thesteering wheel is returned to thereverse direction. When head lampswitch is in 2nd stage simultaneouslywith turn signal lamp “ON”, corneringlamp also comes on.

LOCK

ACC ONSTART


Once the engine started,release the key immediately.Do not exceed 10 seconds forthe operation of starter.Gearshift lever should be inneutral position when attemptingto start the engine.

CAUTION

16

High beam switch

When the head lamps are on, pullingthe lever down lights up not only thehead lamps with high beam but alsothe high beam indicator lamp. Whenpulling it up, head lamps with lowbeam are on.

Passing lamp switch

To light up passing lamps at anytime, pull up the lever towards thesteering wheel.The lever will return to the OFF posi-tion when released.

Lamp switch(turn type)

Lamp switch operates in two stagesas follows :1st stage : tail lamp, license plate

lamp, instrument panellamp, clearance lamp

2nd stage : tail lamp, license platelamp, instrument panellamp, clearance lamp,head lamp, corneringlamp(simultaneously withturn signal lamp “ON”)

Windshield wiper switch

The windshield wiper switch has 3positions to control the windshieldwiper.1. OFF Off2. INT Intermittent wipe3. LO Continuous wipe, slow speed4. HI Continuous wipe, fast speed

high beam(passing)

high beam

low beam

2nd stage

1st stageOFF

1

2

34

Do not operate the wipers when thewindshield remains dry. They mayscratch the windshield glass. Do notoperate the wipers if they are cov-ered with snow or ice as this maydamage the wiper system.

NOTICE

17

Wiper speed control switch

The desired intermittent operationtime can be controlled by turning theknob when the wiper switch is in“INT” position.

Windshield washer switch

To let washer fluid spray on the wind-shield, press and hold the center but-ton of switch.And the windshield wipers are simul-taneously operated for 2–3 cycles.

Exhaust brake switch

The exhaust brake system isdesigned to shut off exhaust pipewhen the engine brake is applied,resulting in assisting brake action.When the switch lever is pusheddownward, and clutch and acceleratorpedals are released, the indicatorlamp comes on showing that theexhaust brake is in operation. Whenthe clutch and accelerator pedals aredepressed, the exhaust brake stopsworking.

Hazard warning flasher switch

When the right–hand lever is pushedupward, all the turn signal lamps aremade to flash regardless of the turnsignal switch position.The hazard warning flasher switch isto be used when your vehicle gets ina traffic hazard or is parked in thedarkness.

18

PERIPHERAL DEVICES OF STEERING COLUMN

Idle control knob

Turning the knob clockwise after coldstarting of the engine will increaseidling speed and thus facilitate quicknormalization of the engine coolanttemperature.Always drive with the knob turnedback home.

Battery main switch

It controls the entire electrical circuitswith the exception of parking lamps,hazard warning flashers. The electri-cal circuits are energized when thebattery main switch is pressed.

Door opening switch

The entrance door is operated by theair cylinders as the door openingswitches on.

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POWER

AIRCONDITIONER

ER

23

4IDLING

H..L

x1000 rpm

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POWER


POWER

AIRCONDITIONER

ONER

23

4

x1000 rpm

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POWER


POWER

AIRCONDITIONER

R

23

4

Do not use this knob to stop theengine.

NOTICE

19

Manual door opening switch

When the manual door openingswitch is placed at “auto” position, thedoors are operated by the door open-ing switches, or when the switch isplaced at “manual” position, the doorsare not operated by the door openingswitch and can be opened or closedby the hands.

Air parking brake switch

When the switch is pushed, the park-ing brake is actuated and the indica-tor lamp comes on. pushed one morethe switch, releases the brake. Makesure that the indicator lamp is offbefore driving off.

x1000 rpm

0

12

3

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3

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15AIR

kg/cm2

0

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0 0 0 0 0 0

POWER


POWER

AIRCONDITIONER

NDITIONER

23

4

Type A : Cab control valve

Type B : Gradual control

20

ABS/ASR check switch(OPTION)

The switch used for self Diagnosis ofABS/ASR system.It needs for a car mechanics, but notused for a driver usually, push thebutton about 3 seconds, self diagno-sis started and the ABS/ASR warninglamp blinker on instrument panel.

ABS ARS

ABS

ABS ARS

ASRx1000 rpm

0

12

3

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kg/cm2

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POWER

AIRCONDITIONER

R

23

4

21

Engine check / clear switch(For DE12TiS ENGINE)

When engine malfunction pilot lampcomes on, follow the below procedureto solve the problem.

1. To check error type pressingengine check switch.With pressing this switch, enginemalfunction lamp blinkers accord-ing to the error types.

(Example)

Error code 12 : prestroke control error

Error code

1. Engine check switch (Blue color)2. Engine clear switch (Black color)

2. After repairing defects according tothe engine maintenance manual,press the engine clear switch for5seconds to remove the errors onECU.


CHECK

ENGINE

CHECK

ENGINE

CLEAR

1 2

No. Defects01 Normal12 Prestroke control error13 Prestroke sensor error14 Prestroke offset error15 Prestroke actuater power error16 Engine rpm sensor error21 Coolant temp. sensor error22 Fuel rack sensor error23 Air heater relay error

ON

OFF

MalfunctionPilot lamp

22

INSTRUMENTS AND INDICATOR LAMPS

1. Voltmeter2. Engine coolant temperature gauge3. Fuel gauge4. Engine oil pressure gauge5. Air pressure gauge6. Engine tachometer

(If the engine RPM indicating func-tion is included in tachograph, thisgauge is substituted to blankcover.)

7. Tachograph8. Bulb check switch9. Cover

10. Turn signal/hazard warning indicator11. Upper pilot indicator lamps12. Lower pilot indicator lamps

3224

160

0

48

C

H

E

F0

12

3x1000rpm

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3

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12

15

kg/cm

A I R2

7101112

3 4 5 8 12 9 6

7

0

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120

140

160

Km/h

0 0 0 0 0 0 0

E

ABSABS ASR

CHECK

23

Voltmeter

The voltmeter indicates the batterycondition. Check the voltmeter read-ing with the engine running. Thegauge needle should stand betweenthe reading of 24 and 28.

Temperature gauge

The gauge indicates the enginecoolant temperature. If the gaugeneedle stands below the red coloredzone, it means that engine coolanttemperature is normal.

If the needle stands in “H”(overheat-ing), stop the vehicle and run theengine at a moderately fast idlespeed or put the gear in lower posi-tion to reduce engine load. If thevehicle is operated in abnormal con-dition, engine performance will bereduced and fuel consumption will beincreased.

Fuel gauge

This gauge indicates fuel level of thefuel tank all the time regardless of thestarter switch position.

The capital letter “E” representsalmost “empty”. Top–up the fuel tankbefore the gauge indicates “E”.

3224

160 C

H

E

F

24

Oil pressure gauge

This gauge indicates oil pressure inthe engine lubricating system. Theindication of the gauge should be 1–3kg/cm2 when the engine is at idle ; itshould be 3–6.5kg/cm2 when theengine is running at medium speed.When the gauge needle does notmove upward at all or hydraulic pres-sure changes abruptly, check the oillevel in the engine crankcase. If theoil level is found normal, have thehydraulic system checked by yournearest Daewoo dealer.

Do not run the engine with low oilpressure indication.

Air pressure gauge

Air pressure gauge indicates air pres-sure in the air tanks. While driving,the gauge needle must be within therange of 5.3–8.2kg/cm2.

Be habitual of watching the gauge,while driving, to make sure the gaugeneedle indicates the normal condi-tions.

Engine tachometer

The tachometer indicates the enginespeed in revolutions per minute(rpm)and red colored zone represents crit-ical engine speed.

Excessively high engine rpm(red col-ored zone) may cause damage to theengine.To drive economically, keep theengine within 1,000 2,000rpm.

Maximum allowable engine speed :DE12Ti/TiS, DV15TiS ENG. : 2100rpm

DE12T ENG. : 2200rpm.

DV15T ENG. : 2300rpm

1

48

0

3

6 9

12

15

kg/cm

A I R AOH AIR

FULL

AIR

2 0

12

3x1000rpm

If the gauge needle stands in thered zone, warning lamp comes onand alarm buzzer sounds. Imme-diately stop the vehicle, check forunusual conditions, run the engineat a moderately fast idle speed toincrease air pressure, then drive off.

NOTICE

25

Tachograph

The tachograph is consisted of odo-meter and clock. The vehicle speedand running distances are registeredin a single chart. The speedmeterindicates the vehicle speed in kilome-ter per hour(km/h). The odometer indi-cates individual trip distances. Theodometer records the total distance inkm. The unit of registered distance isloom.For further information refer to“TACHOGRAPH” on page.

Bulb check switch

When bulb check switch is pressed,warning lamp on instrument panelcomes on.And also the warning buzzer sounds.

Before driving, use this switch tocheck that all warning lamps includ-ing speed indicator lamps and theircircuits are operating normally.

Turn signal indicator lamp

When the turn signal switch or haz-ard warning flasher switch is turnedon, the turn signal indicator lampflashes to indicate the operation ofthe external turn signal lamps or haz-ard warning flashers.

7

0

20

40

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140

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0 0 0 0 0 0 0

3224

160

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48

C

H

E

F0

12

3x1000rpm

0

3

6 9

12

15

kg/cm

A I R2

SPEED

T/MSAFETY

ABS ASR

E

26

UPPER PILOT INDICATOR LAMPS

Type A

9 10 11 12 13 14 15 16

1 2 4 5 6 7 8

1. Engine coolant temperature (high)2. Air tank pressure (low)4. Seat belt (Unfastened)5. Parking lamp (on)6. Engine oil pressure (low)7. Battery charging8. Engine door (open)9. Emergency door (open) (OPTION)

10. Mirror defroster (on) (OPTION)11. Air dryer operation (on) (OPTION)12. Engine preheat (on)13. High beam (on)14. Transmission neutral position15. Entrance door (open)16. Passenger’s stop order (OPTION)

27

Type B

9 10 11 12 13 14 15 16

1 2 4 6 7 83

321

1. Engine coolant temperature (high)2. Air tank pressure (low, Front)3. Air tank pressure (low, MID.)4. Air tank pressure (low, Rear EMER.)6. Engine oil pressure (low)7. Battery charging8. Engine preheat (on) 9. Seat belt (Unfastened)

10. Engine door (open)11. Air dryer operation (on) (OPTION)12. Engine room fire warning (OPTION)13. High beam (on)14. Transmission neutral position15. Entrance door (open)16. Passenger’s stop order (OPTION)

28

Type C

9 10 11 12 13 14 15 16

1 2 3 4 6 7 8

321

1. Engine coolant temperature (high)2. Air tank pressure (low, Front)3. Air tank pressure (low, MID.)4. Air tank pressure (low, Rear EMER)6. Engine oil pressure (low)7. Battery charging8. Engine room fire warning (OPT)9. Seat belt (Unfastened)

10. Engine door (open)11. Air dryer operation (on) (OPTION)12. Engine preheat (on)13. High beam (on)14. Transmission neutral position15. Entrance door (open)16. Passenger’s stop order (OPTION)

29

Type D

9 10 11 12 13 14 15 16

1 2 4 5 6 7 8

1. Engine coolant temperature (high)2. Air tank pressure (low)4. Seat belt (Unfastened)5. Parking lamp (on)6. Engine oil pressure (low)7. Battery charging8. Engine door (open)9. Emergency door warning (open) (OPTION)

10. Mirror defroster (on) (OPTION)11. Air dryer operation (on) (OPTION)12. Engine preheat (on)13. High beam (on)14. Transmission neutral position15. Entrance door (open)16. Passenger’s stop order (OPTION)

30

Type E

9 10 11 12 13 14 15 16

1 2 4 6 7 83

321

1. Engine coolant temperature (high)2. Air tank pressure (low, Front)3. Air tank pressure (low, MID.)4. Air tank pressure (low, Rear EMER)6. Engine oil pressure (low)7. Battery charging8. Engine room fire warning (OPT)9. Seat belt (Unfastened)

10. Engine door (open)11. Air dryer operation (on) (OPTION)12. Engine preheat (on)13. High beam (on)14. Transmission neutral position15. Retarder warning (OPTION)16. Passenger’s stop order (OPTION)

31

Engine coolant temperature (high)

When the temperatue of engine coolantbecomes near 100°C (210°F) the warninglamp turns on.

Air tank pressure (low)

(Type A) (Type B, C, E) (Type D)

The indicator lamp comes on and the warning buzzer isoperated simultaneously, when air pressure within the airtank is lowered to 5.3kg/cm2.

If the air pressure indicator lamp comes on while driving,stop the vehicle and check to locate the cause of troubleand avioc driving with the indicator lamp turned on.Repeated application of service brakes could cause tem-porary lowering of air pressure. In such an instance, keepthe engine running as fast idle until the indicator lampgoes out.

Seat belt (Unfastened)

The seat belt warning lamp comes on whenthe ignition switch is placed in the “ON”position unless the driver's seat belt issecurely fastened.

AIR 321

Parking lamp (on)

(Type A)

The parking brake indicator lamp comeson when the parking brake lever is pulledwith the starter switch “ON”. The parkingbrake indicator lamp does not indicate theaction of the parking brake. Make sure topull the parking brake lever fully when park-ing the vehicle.

Before moving the vehicle, be sure to check that the park-ing brake indicator lamp is off.

Engine oil pressure (low)

The lamp comes on when the battery mainswitch is operated and goes out as theengine is started and pressure of oil in theengine is increased.

If the lamp comes on while driving, stop the engine imme-diately and check the level of oil in the engine crank-case.If the oil level is normal, restrictions in the oil filter or atrouble in the lubricating system may be indicated and thesystem should be checked at your nearest service station.Do not run the engine with the lamp illuminated.

Battery charging

The indicator lamp comes on when the bat-tery main switch is operated and goes outas the engine is started and alternator cir-cuit is brought into normal function.

The indicator lamp comes on while the engine is running,it indicates that the alternator circuit is malfunctioning, thenimmediately stop the vehicle and have the alternator ciruitchecked by your nearest service shop.

Engine door (open)

(Type A, B, C, E) (Type D)

The indicator lamp comes on when the engine room dooris opened. If the lamp turns on even after closing the door,check the door lock and lock the door firmly.

32

PARKING

ENG.�DOOR

(Type D)

Emergency door (open)

(Type A) (Type D)

The indicator lamp comes on when the emergency dooris opened. If the lamp comes on even after closing thedoor, check the door lock and lock the door firmly.

Mirror defroster (on) (OPTION)

Pressing the side mirror defroster switch, theindicator lamp “ON” and the defrosting coilin the mirror starts actuating.

Air dryer operation (on) (OPTION)

(Type A,B,C,E) (Type D)

The indicator lamp comes on when the air dryer is oper-ating. (Air dryer heating system on)

Engine preheat (on)

This lamp is designed to indicate preheatingof the engine. It comes on when starterswitch is positioned “ON”, while it goes outwhen the preheating is completed.

High beam (on)

The high beam indicator lamp comes onwhen head lamps with high beam are inuse.

Transmission neutral position

The indicator lamp comes on when the gearshift lever locates in neutral position.

Entrance door (open)


The lamp comes on while the entrance door is opened.

33

EMER.�DOOR

AIR�DRYER ENT.�

DOOR

Passenger's stop order (OPTION)


When the passenger push the button between windows,the buzzer sounds and this lamp comes on.

Engine room fire warning (OPTION)

The indicator lamp comes on when theengien room is fired.

Retarder system warning (OPTION)

At the case that additional retarding systemis applied, while the retarder is operating,the indicator lamp comes on.

34

STOP

ENG.�ROOM

35

LOWER PILOT INDICATOR LAMPS

Type A

9 10 11 12 13 14 15

1 2 3 4 5 6 7 8

E

ABS ASR

CHECK

1. Safety equipment operation2. Retarder system operation (OPTION)3. Retarder system warning (OPTION)4. Exhaust brake operation5. Speed 3 indication6. Electronically controlled air

Suspension operation (OPTION)7. Air condition warning

8. MIL9. Brake pad wear warning

10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Speed limiter operation (OPTION)14. Speed 1 indication15. Speed 2 indication

36

Type B

10 11 12 13 14 15

1 2 3 4 5 6 7 8

RTD RTD E

ABS ASR

1. Safety equipment operation2. Retarder system operation (OPTION)3. Retarder system warning (OPTION)4. Exhaust brake operation5. Speed 3 indication6. Electronically controlled air

Suspension operation (OPTION)7. Transmission temperature

8. Do not shift10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Speed limiter operation (OPTION)14. Speed 1 indication15. Speed 2 indication

37

Type C

9 10 11 12 13 14 15

1 2 3 4 5 6 7 8

SPEED

SAFETY E

ABS ASR

1. Safety equipment operation2. Defroster operation3. Fuel empty warning4. Exhaust brake operation5. Battery main S/W operation6. Retarder operation (OPTION)7. T/M temperature warning8. Air condition warning

9. Over speed warning10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Light 1 step operation14. Head lamp low beam (on)15. Front fog lamp operation

38

Type D

10 11 12 13 14 15

1 2 3 4 5 6 7 8

E

ABS ASR

FRONT�DOOR

MID.�DOOR

REAR�DOOR

EMER.�V/ V-F

ENG.�ROOM

EMER.�V/ V-M

EMER.�V/ V-R

1. Safety equipment operation2. Exhaust brake operation3. Front door opened4. Middle door opened (OPTION)5. Rear door opened (OPTION)6. Front emergency valve operation (OPT)7. Middle emergency valve operation (OPT)

8. Rear emergency valve operation (OPT)10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Engine room fire warning (OPTION)14. Front fog lamp operation15. Rear fog lamp operation (OPTION)

39

Type E

109 11 12 13 14 15

1 2 3 4 5 6 7 8

E

PABS ASR

FRONT�DOOR

MID.�DOOR

REAR�DOOR

EMER.�V/ V-F

EMER.�V/ V-M

EMER.�V/ V-R

CHECK

1. Safety equipment operation2. Exhaust brake operation3. Front door opened4. Middle door opened (OPTION)5. Rear door opened (OPTION)6. Front emergency valve operation (OPT)7. Middle emergency valve operation (OPT)8. Rear emergency valve operation (OPT)

9. MIL10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Parking lamp (ON)14. Front fog lamp operation15. Rear fog lamp operation (OPTION)

40

Type F

10 11 12 13 14 15

1 2 3 4 5 6 7 8

E

PABS ASR

FRONT�DOOR

MID.�DOOR

REAR�DOOR

EMER.�V/ V-F

EMER.�V/ V-M

EMER.�V/ V-R

1. Safety equipment operation2. Exhaust brake operation3. Front door opened4. Middle door opened (OPTION)5. Rear door opened (OPTION)6. Front emergency valve operation (OPT)7. Middle emergency valve operation (OPT)

8. Rear emergency valve operation (OPT)10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Parking lamp (ON)14. Front fog lamp operation15. Rear fog lamp operation (OPTION)

41

Type G

109 11 12 13 14 15

1 2 3 4 5 6 7 8

E P

ABS ASR

1. Safety equipment operation2. Exhaust brake operation3. Speed 1 indication4. Speed 3 indication5. Speed 2 indication6. Parking lamp (ON)7. Mirror heater (OPTION)8. Air condition warning

9. Emergency door (OPEN) (OPTION)10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Speed limiter operation (OPTION)14. Front fog lamp operation15. Rear fog lamp operation (OPTION)

42

Type H

7 8 9 10 11 12

1 2 3 4 5 6

1. Safety equipment operation2. Retarder system operation (OPTION)3. Retarder system warning (OPTION)4. Exhaust brake operation5. Speed 3 indication6. T/M temperature warning

7. ABS system warning (OPTION)8. ASR system warning (OPTION)9. Auto greaser operation (OPTION)

10. MIL11. Speed 1 indication12. Speed 2 indication

43

Type I

109 11 12 13 14 15

1 2 3 4 5 6 7 8

1. Safety equipment operation2. Exhaust brake operation3. Front door opened4. Middle door opened (OPTION)5. Rear door opened (OPTION)6. Front emergency valve operation (OPT)7. Middle emergency valve operation (OPT)8. Rear emergency valve operation (OPT)

9. Auto greaser operation (OPTION)10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Retarder system operation (OPTION)13. Parking lamp (ON)14. Front fog lamp operation15. Rear fog lamp operation (OPTION)

44

Type J

9 10 11 12 13 14 15

1 2 3 4 5 6 7 8

SPEED

T/MSAFETY

ABS ASR

E

1. Safety equipment operation2. Defroster operation3. Fuel empty warning4. Exhaust brake operation5. Battery main S/W operation6. Retarder operation (OPTION)7. T/M temperature warning8. Do not shift

9. Over speed warning10. ABS system warning (OPTION)11. ASR system warning (OPTION)12. Auto greaser operation (OPTION)13. Light 1 step operation14. Head lamp low beam (on)15. Front fog lamp (on)

Safety equipment operation

(Type A-G, I, J) (Type H)

When the passenger stands at entrance step, the reardoor is not closed, this lamp comes on.

Retarder system operation (OPTION)

(Type A, C, H-J) (Type B)

For automatic transmission, while the retarder is operating,the indicator lamp comes on.

Retarder system warning (OPTION)

(Type A, H) (Type B)

At the case that additional retarding system is applied,while the retarder is operating, the indicator lamp comeson.

Exhaust brake operation

The indicator lamp comes on while theexhaust brake is operating.

Electronically controlled air suspension opera-tion (OPTION)

The height of the body is controlled auto-matically in accordance with the weight andspeed of the vehicle, the lamps comes onwhen the system is operating.

45

SAFETY

E

ECS

RTD

RTD

46

Speed 1 indication

(Type A, B, G) (Type H)

At the vehicle speed in 0~5km/H the lamp comes on, alsothe left Yellow-Green marker lamp on the roof at the frontof the vehicle, lights on.

Speed 3 indication


At the vehicle speed in 0~5km/H the lamp comes on, alsothe left Yellow-Green marker lamp on the roof at the frontof the vehicle, lights on.

Speed 2 indication


At the vehicle speed in 80km/H the lamp comes on, alsothe middle red marker lamp on the roof at the front of thevehicle, lights on.

Brake pad wear warning

The indicator lamp comes on when thebrake limning is too much worn out.

Over speed warning

At the vehicle speed in 80km/H the lampcomes on, also the middle red marker lampon the roof at the front of the vehicle, lightson.

SPEED 1 SPEED 2

SPEED 3

SPEED

ABS system warning (OPTION)

As the battery relay and the starter switch-es are turned on, the indicator lamp comeson and goes put when the vehicle speedreach to 5~10km/H. If the lamp keeps light-ing while driving, the ABS/ARS system is outof order and should be checked.

ASR system warning (OPTION)

As the battery relay and the starter switch-es are turned on, the indicator lamp comeson and goes out in a short time. If the lampkeeps lighting while driving, the ASR systemis out of order and should be checked.

Auto greaser operation (OPTION)

The indicator lamp comes on while the autogreasing system is operating or the mainpressure of the system drops below25kg/mm2.

Speed limiter operation (OPTION)

The lamp comes on while the speed limitersystem is operating.

Air conditioner warning

The lamp comes on when the high/low volt-age is flowing or the compressor clutch isdisconnected, etc.

Head lamp low beam (ON)

The high beam indicator lamp comes onwhen head lamps with high beam are inuse.

Engine malfunction lamp

Check the state of engine operating whenstarter key on.This lamp flashes at engine cranking innormal of engine operating.

Otherwise, on abnormal of Engine operating, lamp comeon continuously and come on during of engine running.

47

ASR

CHECK

SPEED�LIMITERABS

When the ABS/ASR system is out of order, the brakesystem works as if ABS system is not applied.

NOTICE

48

Transmission temperature

(Type B) (Type C, J) (Type H)

The lamp comes on when the oil temperature of automatictransmission is overheated beyond the specified value.

Shift

(Type B) (Type J)

The lamp comes on when the engine RPM rises beyondshifting point.

Defroster operation

For automatic transmission, while theretarder is operating, the indicator lampcomes on.

When the defroster in operating for refuse frost, the indi-cator lamp comes on.

Fuel empty warning

When fuel indiator needle located aroundEmpty state, (Red line) indicator lamp comeon.

Battery main S/W operating

The indicator lamp comes on when the bat-tery relay switch is operated and goes outas the engine is started and alternator cir-cuit is btought into normal function.

The indicator lamp comes on while the engine is running,it indicates that the alternator circuit is malfuncitioning, thenimmediately stop the vehicle and have the alternator cir-cuit checked by your nearest service shop.

Light 1 step operating

At the vehicle speed in 0~5km/H the lampcomes on, also the Yellow-Green markerlamp on the roof at the front of the vehicle,lights on.

At the tail lamps come on, indicator lamp come on.

T/M�TEMP.

SHIFT T/M

49

Front fog lamp operation

The lamp comes on when the front fog lampswitch is turned “ON”.

Rear fog lamp operation (OPTION)

The lamp comes on when the tail lamp is“ON” and it light off while tail lamp comeoff.

Against rear fog lamp keep up “OFF” while tail lamp iscomes on.

Parking lamp (On)

The parking brake indicator lamp comes onwhen the parking brake lever is pulled withthe starter switch “ON”.

The parking brake indicator lamp does not indicate theaction of the parking brake. Make sure to pull the park-ing brake lever fully when parking the vehicle.

Before moving the vehicle, be sure to check that the park-ing brake indicator lamp is off.

Front door operation

When the front door is opened, this indica-tor lamp comes on.

Middle door operation (OPTION)

The indicator lamp comes on when the mid-dle door is opened.

Rear door operation (OPTION)

The indicator lamp comes on when reardoor is opened.

Front emergency valve operation (OPTION)

The indicator lamp comes on while the mid-dle emergency valve operation.

FRONT�DOOR

MID.�DOOR

REAR�DOOR

EMER�V/V-F

P

50

Middle emergency valve operation (OPTION)

The indicator lamp comes on while theMid. emergency vlave operation.

Rear emergency valve operation (OPTION)

The indicator lamp comes on while therear emergency valve operation.

Engine room fire warning (OPTION)

The indicator lamp comes on when theengien room is fired.

Mirror defroster (ON) (OPTION)

Pressing the side mirror defroster switch, theindicator lamp “ON” and the defrosting coilin the mirror starts actuating.

Emergency door (open) (OPTION)

The indicator lamp comes on when theemergency door is opened. If the lampcoems on even after closing the door, checkthe door lock and lock the door firmly.

EMER�V/V-M

EMER.�DOOR

EMER�V/V-R

ENG.�ROOM

51

SWITCHES

x1000 rpm

0

12

3

0

3

6 9

12

15AIR

kg/cm2

0

0

20

40

6080

00

20

40

60

1

1

1

1

Km/h

0 0 0 0 0 0

★ The quantities or locations of switches could be different from the figure, because the switches could be added oromitted, and locations could be changed by the requirement of customers.

52

Room lamp switch (Floor 1)

Push the switch to light on the firstroom lamp (incandescent) from theentrance door (Front).

Room lamp switch (Floor 2)(Apply for vehicles with lamp

Push the switch, light come on the allroom lamp (incandescent) but exceptfirst room lamp at the entrance door(Front).

Mood lamp switch 1 (OPTION)(Apply for vehicles with lamp rack)

Pressing the switch to light on themood lamp come on in order odd.

F F F

53

Mood lamp switch 2 (OPTION)(Apply for vehicles with lamp rack)

Pressing the switch to light on themood lamp in order even.

Room lamp switch (Bulb)

Push the switch to light on the fluo-rescent room lamps at the passen-ger’s compartment.

Driver lamp switch

Pressing the switch, the driver’s com-partment lamp comes on.

F B

54

Luggage lamp switch

Pressing the switch, the luggage com-partment lamps come on. The switchoperates when the light switch is on.

Reading lamp switch (OPTION)

Pressing the switch, reading lampsbelow the air–conditioner grill comeon.

Fog lamp switch (Front)

Pressing the switch, the fog lampscome on to improve your Foreward/backward vision in fog or snow.

55

Fog lamp switch(Rear) (OPTION)

Pressing the switch, the fog lampscome on to improve your Backwardvision in fog or snow.

Battery main switch

Pressing the switch to light on thebattery lamp come on.

Parking lamp switch (OPTION)

Pressing the switch to light on theparking lamp come on.

P

56

Front ent. door switch

Pressing the switch, front ent. doorlamps upper the front door come on.

Mid. ent. door switch (OPTION)

Pushing the switch, Mid. ent. doorlamps come on.When Mid door opened.

Rear ent. door switch (OPTION)

Pressubg the switch, rear ent. doorrlamps comes on when rear ent. dooropened.

57

TV/VTR power switch (OPTION)

Pressing the switch, electric power toTV/VCR is supplied.

Electric fan switch (OPTION)

Pressing the switch, electric fanpower supplied for driver's and pas-sengeeer's fan.

Step lamp switch (OPTION)

Push the switch to light on the searchlamp from the front/middle/rear door.

58

Destination board switch (OPT)

Push the switch to light on the des-tination boards front and rear.

Door rack lamp switch (OPTION)

Pressing the switch, door rack lampscome on.

Heater mirror switch (BH120)(BH116/BH117 : OPTION)

Pressing the switch, provide heater inmirror.

59

Power on by pressing the switch( ),the indicator lamp( ) light comes onAutomatically(power off by pressingthe switch( ) again).Turn to right the contrast switch( ),the scene state is kept distinctly,the turning to the bright controlswitch( ) left/right, the bright ofscene is controlled darkly andbrightly.Selet( ) the camera C1/C2 in caseof two camera installed. C1 is inner

watching camera by pressing theupper button and other is outerwatching.Select the Auto/Manual switch( ).–Auto : Rear situation is displayed

the monitor with operationon camera in state of shift-ed reward gear of vehicle.

–Manual : Camera operated bypower on.

Press the light of scene controllerbutton( ) the scene is drak in night,

othewise in daytime, it’s brighted.

CAMERA1. LENS : It’s possible inputing the a

picture and veiwing 130°degrees of an angle.

2. COVER : Profected the camera onwater proof stuff.

3. DIN PLUG : Connect the monitorand camera.

THE CAR VISION SYSTEM FOR VEHICLE (OPTION)

1 2 3 4 5 6 7

2

1

3

60

HEATING AND DEFROSTING

Heating and defrosting of driver’s compartment

Turn the first control knob from theleft end of right side, the blower fanstarts to operate and the incommingair flow increases gradually.When the second control knob isplaced at the left end of right side theair comes by two direction, one is tothe driver’s foot side and another isto the windshield glass side.By turning the control knob to the right,the air coming into the foot sidedecreases and to the windshield glassside increases gradually the part ofthird control knob is circulation of air bymoving the control knob to the left end.Air changed by inner circulation andcontrol knob to the right end.Applied cleaner air by comes in outer.

OFF

OFF

OFF

61

Heating of passenger's com-partment (OPTION)(Type A : Rotary type controlpanel)

Power switch

Power on by turning the end of leftside (Light Red color part) to side ofcenter (Red color) or Right (Darkcolor).

HEATER

Controller operator switch

Before press the units controller but-ton, must be operated powerswitch ( ), and push the button forunit selector ( ).Select the unit No. by pressing thebuttons are ordinary order from unitNo.1 to No.5.After, the selection fan by turning theRotary selector ( ) to right side (DarkRed).It’s increase highly.

HEATER

(Type B : Toggle type controlpanel)

Shift the toggle switch “High” or “Low”position of the heater control panel tooperate the blower fan of each heaterplaced below the passenger’s seat,then the air in the compartment will bewarmed by circulation. By the require-ment of customer, the quantity of theheaters will be added or omitted.

321 4

HEATER

1

2

321 4 5

HEATER

1

2

FUSE FUSE FUSE FUSE

HIGH

OFF

LOW

Dhi Donghwan Ind.Corp.

HEATER

(Heater–4EA) (Heater–5EA) (Heater–4EA)

62

AIR–CONDITIONINGCOOLER (ROOF–ON TYPE)Temperature controller(Type A : Rotary type controlpanel)

Turning the end of left side(Darkblue), the temperature of indoor isdecrease lowerly otherwise, turningthe right side(Light blue) it’s increasehighly.

Power switch

The cooler power switch is operatedby pressing the button (2), then cool-er blower fan is operated as eachstep of fan speed switch (4, 5, 6).While the cooling operator switch isnot pressed, room air only cirrculates.

Cooling operator switch (3)

Before press the button, must beoperated power switch(1).Press the switch (3) and cooler startsoperation.

Blower fan operator switch(4, 5, 6)Swithc (4) : 60% of max. capacity.Swithc (5) : 80% of max. capacity.Swithc (6) : 100% of max. capacity.

Warning indicator (7)

When the refrigerant is flowing thehigh/low pressure or the disconnectedof compressor clutch, etc., then theindicator lamp come on.

POWER

AIRCONDITIONER

1

2 3 4 5 6

POWER

AIRCONDITIONER

1

2 3 4 5 7

Type Type

63

(Type B : Seesaw type controlpanel)

CoolingFirst start engine and set the roomtemperature with the control knob.Push the cooling/vent switch to“cooling” side.Push “ON” the power switch, the allsystems like the compressor, con-denser fan and evaporator blowerstart operation for cooling.(The “cooling” indicating lampcomes on).

When the room temperature dropsbelow the set temperature, the sys-tem does air blowing operattiononly, and the room temperature rises beyond the set temperature,the system returns to cooling oper-ation automatically.

VentilationPush the cooling/vent switch to“VENT” side.Push “ON” the power switch, tomaintain adequate room tempera-ture by blowing in the fresh andcool outdoor air.At this time the compressor andcondenser fan do not operate, butthe blowers in the evaporator oper-ate.

StopNormal stoppingFirst push “cooling/vent” switch to“vent” side, then cooling stops andthe system operates only for venti-lation, Push power switch “OFF”,then all systems stop operation.Emergency self stopping.- When refrigerant pressure rises

abnormally high (over 22kg/cm2),the electric clutch of compressor isdisengaged, so the compressorstops working.(The “Trouble” indicating lampcomes on).In the case that any troubles arechecked in operation, the emer-gency self stop occurs, this meansthe stop of compressor, the con-denser and evaporator fan do notstop and continue operating.

AIR-CONDITIONERVENT COOLING

COOLINGON

OFF VENT

HIGH

LOW TEMP

TROUBLE

15 30

64

- When refrigerant pressure goesdown abnormally low(below0.5kg/cm2), the electric clutch ofcompressor is disengaged, so thecompressor stops working.(The “trouble” indicating lampcomes on).

High/low switch operationBy pushing the High/low switch, highor low ventilation in ventilation opera-tion and high or low cooling in cool-ing operation could be selected. Thisswitch enhances the performance oftemperature control.

As the time goes by(about 10minutes), the refrigerant pressurerises and the cooling can startagain without any special actions.If emergency self stops by theabnormal low pressure occur fre-quently, stop the vehicle operationand have service for the ait–condi-tioner system.

NOTICE

65

Refrigerant amountNo or few bubbles are seen on thesight glass under engine idling, whenthe refrigerant is sufficient. When therefrigerant is not sufficient, not a fewbubbles are seen. If the refrigerant is overcharged, itshows high pressure than normal.In this case, purse the refrigerant a lit-tle to the specified amount.

Season check1. Before season–off

Do not separate the air conditionerin season–off.Keep the air conditioner underinstallation during season–off.Keeping refrigerant is helpful forprotection of rust and oil consump-tion for long service life.

2. Season–offOperate once in a month and checkfor cooling performance.(Operateapprox. 5 minutes)Not being operated by thermostatwhen inside–temperature is below15°C.Do operate again after the temper-ature rises over 15°C by heating.

3. Season–inClosely check as the check lists.Naturally the refrigerant escapes astime passing.Refill refrigerant to the sufficientamount.

insufficiency sufficiency

Sufficient amount is approx. 12 0.5kg

66

Regular check & maintenance

Maintenance schedule

Maintenance items Method StandardPeriodic check Change

Day Week Month Season period Standard

Refrigerantcycle

Controldevice

Drivecycle

CompressorCompressor oilGas leak ofconnection &pipeRefrigerant amountRefrigerating hose

CondenserEvaporatorAir fillter

Fusible linkDrierControl panelPressure switchLampClutch bearingCondenser fanEvaporator fanV–belt

Pulley

OverhaulCheck and refillCheck withleak–tester

Check through sight glassCheck

Wash, clean or replaceCheck or replaceClean with com-pressed air or waterCheckReplace desiccantCheckCheckCheckReplaceCheck and replaceCheck and replaceReplace

Replace

Normal operating air–con.SufficientNo gas–leaksNo damageKeep tighten clampNo bubblesNo leakNo damageKeep clean fin & tubeKeep clean Keep clean

OperationOperationOperationOperationOperationNo damageNoiselessNoiseless No damageKeep reasonable belt tensionNo damage

1,500HR2Years

5Years5Years

5Years5Years5Years5Years

1,000HR3Years3Years

5Year

Everyseason

2 Years

3Years (high side)5Years (low side)

67

Check points (operation)

Items Procedure & check pointBefore operation

During operation

Stop

1. Check for V–belt tension and damage.2. Check for fixing position of crank pulley, tension pully and clutch pully.3. Check for clogged inlet of cooling–air and filter mat.4. Keep compressor clean without dust or oil. If not, clean it with compressed air.5. Check for fixing condition of bolts and nuts. If not, retighten them.6. Check for gas–leak of connected position with leak–tester and retighten.

1. Check for operation when turning on the main switch after starting engine.2. Check for operation of vent, cooling and unloading by using the temperature volume.3. Check for capacity of cooling air from ducts.4. Check for operation of high–low pressure switch.

Low pressure set : 0.5kg/cm2 (warning light turn “on” and compressor clutch is disconnected)High pressure set : 0.5kg/cm2 (warning light and buzzer turn “on” and compressor clutch is disconnected)

1. Check for stopping of cooler when pushing button switch to turn off.2. Check for stopping when turning off the main switch.

6868

Check points (cycle)

Refrigerant cycle

Engine

Control devices

Items

Compressor

Condenser

Evaporator fan

Hi, low pressure switch

Drier

Receiver tank

Others

V–belt

Magnetic clutch

Control panel

Cooling unit

Condenser fan

Evaporator fan

Magnetic clutch

Check point

1. Check for operation.

2. Check for oil level and keep sufficient amount.

1. Clean fin and tube.

2. Check for gas leak and damages.

Check for operation.


Replace desiccant and filters.


1. Check for clamping of connected parts.

2. Check for gas leak of connected parts.

3. Check for air filter mat, drain hose and keep clean.

Check for the tension of V–belt.

Check for compressor pulley.

1. Check for switch

2. Check for lamps.

3. Check wirings for loosened condition and clamping condition.

4. Check for attaching condition.

Check for the damages and looseness.

Check wiring frame for looseness.

Check terminal for fixing condition.

Check covered wire for damage.

69

Trouble shootingIf show abnormal symptoms during operation, check the cause as followings.This chapter describes the details of troubleshooting.

Defect

High pressure isoperating at higherthan standard

High pressure isoperating at lowerthan standard

Low pressure isoperating at higherthan standard

Cause

1. Air is mixed into the cycle.

2. Overcharged refrigerant

3. Choked and clogged condenser with dust and dirt.4. Defective condenser fan.5. Too high ambient temperature when parking.1. Liquid back symptom : Refrigerant gas, which

enter compressor, contain liqued refrigerant.2. The expansion valve worn–out3. Broken discharge valve of compressor.4. Clogged inlet strainer of compressor.1. Liqued refrigerant enters compressor.2. The expansion valve worn–out.3. Broken suction or discharge valve of compressor.4. Too much refrigerant in the cycle.5. Air is mixed into refrigerating cycle.

Measures

1. Discharge the refrigerant completely, chargerefrigerant again to specified amount aftercheck vacuum.

2. Discharge the refrigerant to specifiedamount.(12 0.5kg)

3. Clean with water or compressed air.4. Repair or exchange.5. Reduce the temperature in the shade.1. Check the sensible bulb to the suction pipe.

2. Replace3. Replace4. Check and clean clogged part.1. Check the sensible bulb sticked to the suction pipe.2. Replace3. Replace4. Discharge refrigerant to the standard level.5. Charge refrigerant again to specified amount,

after discharging the refrigerant

70

Defect

Low pressure isoperating at lowerthan standard

Cause

1. Clogged pipe, drier and expansion valve2. Lack of refrigerant.

3. The evaporator is frosted or insufficient inletair for evaporator.

4. Air–inlet side clogged.5. Air filter clogged with dust and dirt.

6. Evaporator clogged with dust and dirt.7. The sensible bulb or pipe of expansion valve.8. Frosted liquid refrigerant in refrigerating cycle.

9. The expansion valve worn–out.

Measures

1. Disconnect them and check.2. Check leaking part, then charge refrigerant up

that the no–bubbles are seen on the sightglass.

3. Stop operation temporarily.

4. Check for clogged part and clean up.5. Keep the air filter clean with water or com-

pressed.6. Check for clogged part and clean.7. Replace8. Discharge the refrigerant completely, and

charge the refrigerant again to the specifiedamount without liquid refrigerant.

9. Replace

71

Air–conditioning cycle

10 10

9

876

5

4

1213

21

11

3 3

I. Comp.

� 1. Compressor2. Discharge shut–off valve3. Condenser4. Receiver tank5. Service shut–off valve6. Dryer7. Sight glass8. Expansion valve9. Distributor

10. Evaporator11. Suction shut–off valve12. High pressure switch13. Low pressure switch

72

Installation of components

Condenser unit1. Condenser(LEFT)2. Condenser(RIGHT)3. Receiver tank4. Dryer5. Motor(DC24V)6. Fan7. Motor mount8. High pressurized gas line(hose)9. High pressurized liqued pipe(left)

10. High pressurized liqued pipe(right)11. High pressurized liqued line(hose)12. Housing13. Sealing14. Locking15. Air intake duct

14

15

2

1312

1

9

657

4 3 11 10 8

73

1. Evaporator(left)2. Evaporator(right)3. Expansion valve4. Sight glass5. Motor(DC24V)6. Fan7. Fan case8. High pressurized liqued pipe9. High pressurized gas pipe

10. Low pressurized gas pipe11. Pressure equalizing pipe12. Air filter13. Drainage prevention filter14. Operating panel15. Temperature sensor16. Wiring17. Drain hose18. Panel support19. Pipe support20. Housing21. Sealing22. Locking23. Air intake

17

21

13

194

1

16

23 3 11 10

18 8 9

12

2

14

15

5

76

22

20

Evaporator unit

74

Part name & Treatment for each device

1. Control panel

1. Operation & Pre-heater switch2. Blower air control switch3. Indoor TEMP. setting switch4. Power operation lamp5. Oil buzzer lamp6. COMP. Buzzer lamp7. Battery charging lamp8. Cold water buzzer lamp

2. Function of each switch

1) Operation & Pre-heater switchThe organization of switch is dumbuler switch as2 stage, heat ON is using for pre-heating to glowplug, start ON is using for engine operation of AIR-CON.(Do not use it for more than 10 sec. At pre-heater& for more than 3 sec. at operating)

2) Blower air control switchThe switch is used at air control of AIR-CON blow-er & engine stop as 5 stages.

OFF : at AIR-CON stop.LOW : The air of AIR-CON blower is operated

at LOW.(60% of total air)MID : The air of AIR-CON blower is operated at

MID.(80% of total air)HIGH : The air of AIR-CON blower is operated

at HIGH.(100% of total air)AUTO : Blower AIR-CON is controlled automati-

cally depending on INDOOR & SET-TING TEMP.(3 stage control of auto air)

OIL COMP

15 30

HIGH

AUTO

MIDLOW

OFF

HEAT(10sec)

START(3sec) ROOM TEMP(¡C)

POWER

BAT WATER

1 2 3 75

4

6

8

COOLER (ROOF-ON TYPE W/POWER PACK) (OPTION)

75

3) Indoor TEMP. settimg switchIt is designed that the INDOORTEMP can be kept regularly byuser’s setted temp(15~30°C) inorder to keep fresh condition intothe indoor cabine and indoor tempcan be automaticalley controlled atauto driving.Therefore, unnecessary actionwould not be need and be con-tributed to safe driving.

4) Power operation lampThe lamp can be on and signedthe control status at air con oper-ation & blower air control switchon.

5) Oil buzzer lampThe buzzer lamp can be on if theE/G <less than 0.3Kg/ G> andsimultaneously, E/G would bestopped with occurance of buzzer.

6) COMP. Buzzer lampThe lamp for pressure rejectedbuzzer would be on to compressorhigh <more than 24Kg/cm2G> & com-pressor low<less than 0.5Kg/cm2G>due to system failure at air con oper-ation. At this time, E/G would beautomatically stopped with buzzer.

7) Battery charging lampThe lamp would be on at thecharging failure of battery due toover currency after E/G operation& alternator operation.(When BL-OWER S/W is on at E/G opera-tion, lamp on is not failure)

8) Cold water lampThe lamp would be on if temper-ature of cold water is high(100±2°C) after E/G operation. At thistime, E/G would be automaticallystopped with buzzer.

3. Operation turn of AIR-CON

1) Fresh temperature shall be settedwith setting temperature switch.

2) BLOWER AIR CONTROL SWITCHshall be conversed to LOW.: Power lamp, oil lamp, batterylamp would be on with buzzer insimultaneous. And AIR-CONBLOWER air is operated toLOW.

3) If you push E/G operation & pre-heating switch to E/G operation for3 sec.E/G would be operated with air-con operation. <The lamp wouldbe off after E/G operation, at thistime, buzzer is not occured.>

4) Please control blower air depend-ing on indoor cabine temperature.

76

4. Operation stop of AIR-CON

1) Normal stop: Blower swich shall be OFF<After E/G OFF, AIR-CON is offafter condenser fan motor opera-tion for 30 sec..>

2) Abnormal stopE/G would be stopped with buzzerin control at rejection of compres-sor high/low of air-con system.: E/G would be stopped withbuzzer in control at E/G <OIL,COLD WATER> rejection.

Check before operation

1. Check point before operation

1) Fuel2) Check & fulfill of cooling water3) Amount of engine oil4) Leakage check for fuel system5) Leakage check of refrigerant6) Exhaustion status of engine

2. Check operation

1) FuelThe fuel of system is from fueltank for main engine.

The fuel consumption of powerpack system is about 4.7l/H at1950rpm on operation.

2) Check & fulfill of cooling waterIt is an enough if the enginecoolant is in full up to below ofcoolant inlet on radiator.If need supplementation, use it asdistilled water or clean undergroudwater.(Coolant : about 3.5l)

In occasion of season(coolinseason)-off, drain the coolantcompletely using drain cock,and then mix & refill theantifreezing solution in accor-dance with outdoor air condi-tion.

3) Amout of engine oilCheck the oil amout by oil levelgauge at horizontal position. It isnormal if the oil is between grad-uation line of gauge.If insufficient, refill up to high level.(High 5l, Low 4l)

Please replace the engine oilat first 50 hours after start ofcooling operation, and then theday after at every 100 hour.

Please use the engine oil as hon-esty goods.

NOTICE

77

4) Leakange check for fuel systemPlease pay attention & keep aneye to the joint part of fuel pipessuch like fuel filter and injectionpump etc.When in leakage, re-tighten theclamp or plug more.

5) Leakage check of refrigerantPlease check the joint part ofrefrigerant line in suction & dis-charge side.It is a system of gas leakage ifyou find some oil residues & dirtson joint parts.

It is impossible to find the gasleakage very small. In thiscase, check it with gas leaktester on the service center.

6) Exhaustion status of engineIt is a normal when the exhaust gasis colorless, but in case of white orblack, please contact to service sta-tion.

Daily & regular check

1. Important check & repair

1) Engine part → refer to separateservice manual of engine

(1) Air cleanerWith air cleaner of power packass’y is filter paper type whitchis avairable to filter minute dirt,please clean the element often.

(2) Belt tensionMore tighter belt tension, moreabrasion of each pulley bearingpart and no good cooling effect.As it can cause an over heat,check & regulate it. Belt tensionis that 12mm is reasonable whenpush the middle of each pulley.

Check period : Check belttension, scratch or oil andsewage status every 100hour, and adjust or replacethem. If regulate, adjust itwith guide B.K.T bolt foralternator fixation.

78

2) Cooler systemCheck of refrigerant amount : ifinsufficient, the cooling effect isdecreased.In case that see the bubbles insight glass, fill up the refrigerantproperly.

No problem in case that can seethe bubbles intermittently. Please decide it seeing sight glassduring 3~5 minutes.

Normal

On the switch, bubbles be seensometime, and then be clear later

Insufficient Nearly empty

Abnormal

• Bubbles on operation and be seen with foggy status at the same time.• Causes

- Sinsufficient refrigerant- Water contained

NOTICE

79

2. Regular check list

1) Engine(system)

Periodical check

SYSTEM NO Check list Working Standardeveryday every every every every Replace

Remarksor at any 100 200 1 2 period

time hrs. hrs. season season1 Cooling water Check Water

Replace amount ● 1 season

2 Radiator Cleaning Be closed●

Condensor fin with dust3 Rediator hose Check Wound

●1 season

Replace ageing4 Fan belt Check Wound

Replace Ageing ● 1 seasonTension

5 Cooling system Cleaning Dirty ●

6 Oil supply to Check●

water pump7 Oil supply to Check

● 200hrsmain pulley

8 Engine oil Check At Replace designated ● 100hrs

maker9 Others

●

After first 50hrs.drain the coolingwater at season-offProhibit a systemwashing

Tension check is12mm at pressing of5kg/f after first 50hrs.

Designated goods

Designated goods

Replace at first50hrs or the dayafter every 100hrsRefer to Engineservice manual

Refrigerantcycle

Lubricant&

fuel system

80

Please refer to engine service manual about other non-discriced details.

Periodical check



time hrs. hrs. season season10 Air cleaner Cleaning Dirty

● 1 seasonelement Replace

11 Air cleaner Check Breakage●

hose12 Air cleaner Jointing Looseness

●hose clamp

13 Oil tube rubber Check Leakage● 1 season

hose14 Joint part of Jointing Looseness

●exhaust gas pipe

15 Engine Jointing Looseness●

mounting bolt16 Engine Disassemble At designated

& cleaning maker

Replace after first50hrs.

After first 50hrs

Airinspirator

Others

81

2) Cooler(system)

Periodical check



time hrs. hrs. season season1 Engine stop Confirmation Operation

● 5 seasonmagnet

2 Engine control Confirmation Operation●

solenoid3 Oil warning lamp Confirmation Lightening

●(oil pressure)

4 Water temp lamp Confirmation Lightening ●

5 Refrigerant high & Confirmation Lightening●

low press lamp6 An earth Check Rust

●fixing bolt looseness

7 Connection part Check Looseness●

of start cable8 Jointing part of

●fuel pump

9 High press s/w Confirmation Operation ● 5 season10 Low press s/w Confirmation Operation ● 5 season11 Fusible plug Check Leakage

● 5 season

Operate

Buzzer warningwith operation

OFF : 23.9Kg/cm2GON : 18.9Kg/cm2GOFF : 0.28Kg/cm2GON : 2.04Kg/cm2G

Electrieequip-ments

Controldevice

82

Periodical check



time hrs. hrs. season season12 Refrigerant Check Sight glass

●amount no bubbles

13 Change of Replace● 1 season

desiccant in dryer14 Refrigerant Check Leakage,

hose wound, ● 3 seasonageing

15 Joint part of Check Interval●

refrigerant pipe16 Gas leakage Check Sight

check●

17 Gas leakage Check ●

18 Expansion V/A Check Operation ● 3 season19 Oil amount Check Sight

● 2 seasonReplace check

20 Cylinder head bolt Jointing Looseness ●

21 Suction trainer Cleaning Dirty ●

Replace at disjoint ofrefrigerant systemLow press hose isfor 3 seasons

Every joint part (Lowpress side at stop,high press side justafter operation stop)

R-12, R-134a

Joint at first 50hrs

Controldevice

Refrigerantcycle

83

Periodical check



time hrs. hrs. season season22 Suction & Check No cooling

●discharge V/A

23 Compressor1500hrs

24 Compressor Jointing Looseness●

mounting25 Evaporator fin Cleaning Dirty ●

26 Fixing part of Jointing Looseness●

evaporator fan27 Operation of Check Noise

● 1500hrevaporator fan

28 Fan belt Check Woundreplace aging, ● 2 seasons

tension29 Unit fixing bolt Jointing Looseness ●

30 Viberation Check● 2 seasons

protector(rubber)31 Cool air leakage Check Sight check ●

32 Duct insulator Check Aging ●

Disassemble & clean atevery 4 seasons or 500hrs.

Prohibit a steam seshing

5mm is push downat 5Kg/force press

Compressor

Coolerbox

Connectingsystem

Others

84

Periodical check



time hrs. hrs. season season33 Air capacity Check ●

34 Cooling effect Check Differencebetween

●in/out doortemp : 7~10C

35 Air filter Cleaning Dirty ●

Compressor

85

Troubleshooting & Remedy

1. Check sheet for trouble & remedy

Refrigerant Condenser Evaporator Compressor Expansion Refrigerant circulationOthers

CAUSES system system system system valve system Others

APPEARANCE

Press system

Comp system

Others

Strange high of high-pressStrange low of high-pressStrange high of low-pressStrange low of low-pressNo maintain the vaccumNo pumping downserious noise

Bubbles in sightglass very muchRefrigerant circula-tion is stoppedNo flow of cooling airPoor cooling air flow

●

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●

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●

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●

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●

●

●

●

●

●

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●

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●

●

●

●

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●

●

●

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●

●

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33Badnessofcooling

airductLose

beltfor

coolerHigh-pressure

sideis

closedLow-pressure

sideis

closedHalfopenedofdischargecontrolV/AClosed

receivercontrolV/AC

loseddryer

strainerDusts

&water

aremixed

So

closedS

oopened

BadjointpartoftempsensorboxM

ultifuctionT

oolittle

oilT

oom

uchoil

Com

pressthe

liquidDam

ageof

V/Aplated

Damagedorremoved

bearingBreakage

ofheadpacking

Leakageof

suctionV/A

Leakageofdischarge

V/AN

orotating

fanD

irtyair

filterB

efrosted

Closed

allfin

ThetempofcoolingwindissolowN

orotating

fanC

losedall

finThetempofcoolingwindissohighW

atercontainded

Air

mixed

No

refrigerantF

ullrefrigerant

Over-chargedrefrigerant

●

●

● ●

86

2. Removal of troubleshooting

Symptoms

No engine

start

Hi-press. is

high,

Low-press. is

high

Hi-press. is

low,

Low-press. is

low

Causes & Check

Refer to engine check point

Badness of water temp. S/W

S/W is on even though the water temp. is under

105°C

When the valve sound is high due to refriger-

ant over charging and liquid hammering, it is

defrosted on inlet pipe and comp. inlet side.

Non-condensed gas is mixed.

As air is not able to liquid or evaporized, press.

subject to strange.

Dirty conderser fin

Outdoor temp. is high

Bad compression

Breakage of comp. “0” ring

Exp. V/A is so opened (Liquid hammering)

Bad connection of temp. sensor box, broken

insulator

Remedy & Repair

Refer to engine check point

Replace water temp. S/W

Drain the refrigerant to proper amout (8.5kg)

Drain the gas completely, make it vaccum and

then refill the gas.

Wash by water or air. (No steam washing)

Sprinkle the water to condenser in the shade.

Check & repair the comp. dischange part.

Replace “0” ring

Adjust a expansion V/A. (Counter-clockwise)

Stick the temp. sensor body fast to inlet pipe

and stick the insulator closely.

87

Symptoms

Low-press. is

low,

High-press. is

high

Bad blower

unit

Causes & Check

Poor refrigerant

Bubbles on sight glass

Suction pipe is not cool

So closed exp. V/A

Air filter is clogged. (Be frosted at frontal area

of cooler)

Outdoor air temp. is low.

No operation of Low-press S/W

Weak air flow and noise due to the loosed belt.

Gas leakage form temp. sensor body of expan-

sion valve.

Clogged dryer.

No power supply.

Injuried fan.

Serious vibration

Some gap between motor & fan.

Remedy & Repair

Repair thd gas leaking part.

Fullfil the gas to proper amount.

Open the V/A by adjust screw.

Clean the air filter

Check a Low-press. S/W, and replace if bad.

Adjust belt tension or replace belt

Replace a expansion valve.

After disassemble dryer, replace the desicant

and clean the strainer.

Check & repair fuse & related wiring diagram

Replace

Replace

Jointing the fixing nut and clip again.

88

3. Check and remedy of poor cooling

Symptoms

Many bubbles

through sight

glass

Be frosted

in evaporator

Be frosted from

inlet of eva. to

distributor of

exp. V/A

Causes & Check

Poor refrigerant

Be clogged in dryer.

Trouble of expansion valve

Air filter is clogged.

Weak air EVA. fin is clogged.

flow Much dusts on cooler fan

Duct leakage

Heat load in low inside of room.

Same as symptom

Remedy & Repair

Dischage the refrigerant properly.

If clogged so often, chage it.

Turn the adjust nut of exp. V/A one or twice

and see the low press. gauge. In case that

no chage in gauge due to traubled exp. V/A,

change it.

If change in, open to 50 of over heat degree.

Cleaning.

Clean the fin.

Disassemble & clean pay attention to the

change of balance weight.

Adjust the leaking part.

Check the setting temp. of temp. control S/W.

89

Symptoms

Dew forms or

frosts to the

compressor.

Hi-press. is

low, Low-

press. is high.

The temp. of

discharging gas

is too high

High heat

load inside of

room

Causes & Check

Over charged refrigerant

Exp. V/A is so opened.

Breakage of suction & discharge V/A of com-

pressor.

Seal breakage of comp.

Be opened window or ventillation fan.

Poor connection of suction duct.

Too many passengers.

Remedy & Repair

Drain the refrigerant until 50 of over cooling

Check insulator and whether the temp. sen-

sor box is closed to inlet pipe.

Regulate the adjust nut of exp. V/A by 50 of

over heat degree.

Check & repair of compressor valve.

Replace after disassemble.

Close the window and vent. fan.

Protect the heat from jointed duct.

Keep the fixed seating capacity.

90

1. Operation

(1) Confirm the selector switch at “L” position.(2) Turn the key switch (counterclockwise) to

“PREHEAT” position in order to heat the glowplugs with the engine for approximately 20seconds.

(3) Set the key switch to “ON” position, and makesure that the oil pressure lamp is lighted for abulb check.

(4) Then, turn the key switch (clockwise) to“START” position. The sub-engine will be dri-ven by starter motor.

Note : If not starting the sub-engine after. Runningthe starter motor for 20 seconds, try torestart the sub-engine by doing the abovementioned process “(1)” to “(4)” after oneminutes.

(5) Release your hand from the key switch afterstarting the sbu-engine. The sub-engine runsat low speed and the bus air conditioner isjust operated.

Note : The key switch should be remained with“ON” position while operating the bus airconditioner.

2. Control panel

1. Oil pressure lamp 6. Fuse box2. Water temperature lamp 7. Temp control switch3. High/Low pressure lamp 8. Selector switch4. Sediment lamp 9. Glow pilot5. Power lamp 10. Key switch

COOLER (SUB ENGINE TYPE) (OPTION)

7 1 2 3 4 8 9 6 105

91

3. Stopping

(1) Normal stoppingTurn the key switch “OFF” position, when youwant to stop the engine.

(2) Emergency stoppingThe GB 220SK air conditioning system pro-vides the safety functions to stop automatical-ly its operation under the following emergentconditions.a. When the refrigerant pressure of the bus air

conditioner system may deviate abnormallyfrom specified limit.

b. When the coolant temperature of the enginemay reach to the temperature of possibleengine overheating.

92

4. Refrigerant system

Use of refrigerant R-12 in this system cools theair in the bus with evaporation of the refrigerant.The evaporated refrigerant is fed into condenserafter compressed at high pressure and high tem-perature by compressor for repeated use.

Condenser fan converts the refrigerant into liquidat high pressure and high temperature by cooling.Use of expansion valve cause the liquid refriger-ant to be decompressed, to enter the cooler again,and to evaporate to cool down the air in the bus.

Cooling air, condenserLiquidreceiver

CondenserCooled air

Evaporator

CompressorRoom air, returning

Expansionvalve

Sight �glass

Dryer

Evaporator

Expansion�valve

Receiver tankBypass�solenoid

High pressure line�Low pressure line

Condenser

Compressor

93

5. Sub engine driving system

Condenser fan is driven by V-belt, and evaporator fan by driving shaft.

7

6

51

3

2

41. Crank pulley2. Fan pulley3. Idler4. Coupling (Comp.)5. Bearing ass’y6. Drive shaft7. Blower

94

6. Cooling air circulating system

Cooler blows off cooled air through the blow off grilles on the ceilling.

1. Cooler unit2. Underfloor duct3. Vertical duct4. Ceiling duct5. Grille

95

AUTOMATIC VENTILATOR

1. Power switch 2. Suction switch3. Exhaust switch

ROOF

Power switchPressing the power button (1) foroperator of Auto ventilator.

Controller operator switchPush the suction switch (2, 4) toopen the shutter and intake the out-door air to the compartment.

Push the exhaust switch (3, 5) toopen the shutter and extract the airin the compartment to outdoor.

SIDE (OPTION) (BH120)

Pressing the power button (1) foroperator of Auto ventilator.

Push the suction switch (2) to openthe shutter and intake the sidedoorair to the compartment.Push the exhaust switch (3) to openthe shutter and extract the air inthe compartment to sidedoor.

POWER

1 2 3

AUTOVENTILATOR

POWER

AUTOVENTILATOR

1 2 31 2 3 4 5

POWER

AUTOVENTILATOR

(1EA)

(2EA) (OPTION)

1. Power switch2. Suction switch3. Exhaust switch

1. Power switch2. Suction switch (REAR)3. Exhaust switch (REAR)4. Suction switch (FRONT)5. Exhaust switch (FRONT)

96

WATER COOLER (OPTION)

Water cooler is operated by pressingthe water pump on/off switch ( ), andpush the button ( ) for served thecold water through the nozzle ( ).If water is not enough the cool.Operated the water cooler switch bypushing the button ( ) then, the wateris refrigerating.

4

2�

3

1

1. Nozzle2. Water on/off switch3. Water pump on/off

switch4. Water cooler on/off

switch

97

PREHEATER (OPTION)

Preheater operation

1. In the case that the ambient tem-perature is below 0°C, push thepreheat switch ( ) about 20 sec-onds for preheating the fuel noz-zle, then push the operateswitch ( ).(Preheat( ) indicating lamp comeson when the preheating of fuelnozzle is finished)

The time of indicating lamp com-ing on is different by ambient tem-perature.(The preheat temperature is about30°C.)

2. By push the operate switch ( ),the indicating lamps “operate ( )”and “pump ( )” come on. Also“drive motor” and “Water pumpmotor” start operating. By the drivemotor operating, the blowing fanand fuel pump work together.

3. Within 15 30 seconds after oper-ating of “drive motor” and “waterpump motor”, the solenoid valve isopened and fuel injection starts. Atthe same time electric dischargestarts between the electrodes byhigh current. Then the injected fuelis ignited and combustion starts.(The indicating lamp “combustion( )” comes on).

4. After ignition, flame defector checkthe condition of combustion andstops the electric dischargebetween electrodes.

5. When the temperature of coolantreaches to 75°C, after normalcombustion, the solenoid valvestops fuel injection by the thermosensor and the “combustion ( )”indicating lamp goes out.After stop of combustion, the drivemotor operates 150 180 secondsmore, and stops but the waterpump motor continues operating.(The indicating lamps “oper-ate ( )”, “pump ( )” keep lightingon).

6. At the condition of paragraph 5,when the coolant temperaturedrops below 65°C), the sequencefrom paragraph 2 4 repeats auto-matically and the heating ofcoolant is maintained.

STOP��

PREHEATER

1 2 3 4 5

1. Stop switch 2. Preheat switch3. Operate switch 4. Pump switch5. Combustion switch

98

7. To stop the operation of preheater,push the stop switch ( ), then thecombustion stops, but drive motorand water pump motor operate150 180 seconds more, thenstop.

8. When push the pump switch ( ),water pump motor operates onlyand the heating effect could byenhanced.(When operating heaters, heat lossin the heating line decreases and“pump ( )” indicating lamp comeson only).

99

Check point before operation1. Fuel level : Replenish if the fuel

level is low.2. Filter if it is clogged.3. Fuel feeding pipe and/fittings.4. Hot water circulation valve in the

engine side is open.5. Suction and exhaust pipe are

clean.6. Coolant level of the engine.

Maintenance1. Periodically clean fuel filter ele-

ment.2. If required clean inside heat

exchanger and remove dirts andcarbon by brush and water. It willlonger the service life.

3. For operating efficiently, removedirts, carbon of flame detector withsoft and dry cloth, and sure not nodamage C.D.S surface.

4. Take off nozzle from nozzle hold-er, and clean or exhange.

5. When operating on rough andunpaved road, be sure to cleanintake and exhaust tube periodi-cally for efficient use of blowmotor.

100

Problem

Indicating lights “on” evenswitches are operatedCirculating pump doesn′toperate

Fuel pump operates, but fuelis not injected

Fuel injected, but doesn tignite

Motor doesn t operate, eventhe switches are turned “on”

Cause

1. Cut of lamp2. Fuse melted(F1 or F2)1. Fuse melted(F1 or F2)2. Water frozen3. Impeller restricted by contamination in

water flow line1. Lack of fuel2. Fuel filter blocked or frozen by water3. Leakage of fuel piping4. Solenoid valve under quality1. Electrode under quality2. Ignition unit under quality3. Lack or excess of combustion air

1. Fuse melted(F1)2. Fault or uncorrect wiring of electricals

Maintenance

1. Change2. Change1. Change2. Heating or anti–freeze injection3. Clean

1. Refuel2. Clean or change3. Tightening4. Change or overhaul repair1. Change or correct the position2. Change3. Clean air intake and exhaust tube, adjust

damper.1. Change2. Inspection and repair

Trouble shooting

101

Problem

Fuel cut, bad combustion

Overheat of preheater body

Abnormal shut off of com-bustion when operating

Cause

1. Not enough fuel supply by water anddebris in fuel line

2. Leakage of fuel line3. Lack of combustion air4. Fuel pump under quality5. Bad injection of burner nozzle1. Heat exchanger water valve shut off2. Air in water line or body3. Big resistance in water flow4. Lack of water flow by old water pump5. Bad adjustment of overheat sensor set-

ting1. Overheat by blocking in water flow or

lack of water

Maintenance

1 3. Pipe retightening, clean water, debrisof intake, exhaust tube.

4. Change5. Change or clean nozzle1. Open the valve2. Bleed air3. Inspection and repair of line4. Change parts5. Change

1. Remove the cause of overheat, operatethe push button of overheat sensor.

102

Sectional view

2 1 3 4 5 6 10 11 8 12 14 9

231516171813192072122

1. Control unit2. Drive motor3. Ignition unit4. Coupling5. Combustion air fan6. Solenoid valve7. Electrode plug8. 9. Water pipes

10. Ignition electrodes11. Fuel nozzle12. Control thermostat13. Preheat coil14. Overheat thermostat15. Heat exchanger16. Combustion chamber17. Air swirlier18. Exhaust pipe19. Flame detection photocell20. Fuel pump21. Fuel pipe22. Combustion air intake, socket23. Drain bolt

103

TOILET (OPTION)

Control panel

Toilet operation control panel is fixedat driver left side on the switch board.

Explanation of operation switch

1. Main power switchThis switch is electric energy sup-plying to the toilet and toilet oper-ation control panel.

2. Flushing switch (Commode)Do use this switch when clean updischarge waste from commode.• Openning cutoff valve :

To push “OPEN” position.• Shutting cutoff valve :

To push “CLOSE” position.

3. Feces tank warning lamp When full at the tank, the lampturn on.

4. Feces tank cutoff valve switchDouse this switch when dischargewaste from the toilet of feces tank.

• Openning cutoff valve :Push button.

• Shutting cutoff valve :Full button.

Do not use when lamp on (Fecestank warning lamp) and dischargewaste from the tank at permittedlocation.

CAUTION

TOILETOPENOPEN ON

CLOSECOMMODE

OFFPOWER

FULLFECES TANKFECES TANK

1234

CLOSE

104

RADIO AND CASSETTE TAPE PLAYER

<With echo type> (OPTION)

1. Radio/cassette ON/OFF, and vol-ume knob

2. Indicator displaying the operatingsituation of Radio cassette tapeplayer.

3. Radio/cassette tone knob4. LEFT/RIGHT speaker balance

knob5. Seek button6. Eject button7. Band button8. Loud button9. Tape slot

10. Fast rewind/progress button11. Fast forward/progress button12. Tune Button13. Preset buttons14. Power switch15. Radio/Mic change switch16. MIC volume knob17. MIC jack18. MIC tone knob19. Monitor switch20. Echo effect knob21. Echo speed knob

14 15 18 16 17 2021 19

13121110987654321

SWVOL

PushLOC TONE BAL

SEEK BAND LOUD TUNE

MONITORSPEED.ECHOMICTOME VOLUME VOLUMERADIO/MICPOWER

OFF

ON

RADIO

MIC

LOW HI MIN MAX MIN MAXSLOW FAST

ON

OFF

PROM

EJ REW FF

1 2 3 4 5 6

OFF MAX LO MI L R

105

Radio operation

Press power switch 14 to power onthe system.Press Radio/MIC switch 15 to selectthe Radio/MIC operation.Turn Radio/cassette ON/OFF andvolume knob clockwise to operateand control the volume, then theindicator starts displaying and eachlamps of knobs and buttons comeon simultaneously.Press band select button 7 to selectAM/FM band.Press seek button 5, then the fre-quency is automatically increases ordecreases and stops when anyreceivable frequency is seeked.( : decrease, : increase)Keep pressing the tune button 12,then the frequency increases ordecreases, when the needed fre-quency is received, release the but-ton ( : decrease, : increase)Press present button 13 to receivethe memoried frequency. Also, tomemory any frequencies on presetbuttons, while the needed frequency

is being received, keep pressingpreset buttons more than 2 seconds.Turn the tone knob 3 to control thestrength of high sound.Turn th balance knob 4 to balancethe sounds of left and right speak-ers.Press loud button 18 to enhance thelow and high sound.When the receiving condition is notgood because of high impedance,magnetic interference of etc, pushpower switch 14, then receiving con-dition can be enhanced and “LOC”is displayed in indicator.

Cassette operation

Insert tape into the slot 9, then theradio stops and tape play backestarts automatically.Keep pressing fast rewind/progressor fast forward/progress button 10,11 to rewind or forward the tapefastly.Press fast rewind/progress and fastforward/progress buttons 10, 11

together, then the tape play backdirection changes.Press eject button 6, then the tapeplay back is stopped and the tapeis ejected through the tape slot.Tone, balance and loudness controlsare same as radio operation.

MIC operation

Insert mail type jack of microphoneinto MIC jack 17.Press RADIO/MIC switch 15 toselect the Radio/MIC operation.Turn mic volume knob 16 to controlthe volume of MIC sound.Turn mic tone knob 18 to control thetone of MIC sound.

Echo operation

Turn echo effect knob 20 to controlthe echo stength.Turn echo speed knob 21 to controlthe echo speed.The volume and tone controls aresame as MIC operation.

106


Without echo type–A (OPTION)

1. Radio/cassette ON/OFF, and vol-ume knob

2. Indicator displaying the operatingsituation of Radio cassette tapeplayer.

3. Radio/cassette tone knob4. LEFT/RIGHT speaker balance

knob5. Seek button6. Eject button7. Band button8. Loud button9. Tape slot

10. Fast rewind/progress button11. Fast forward/progress button12. Tune Button13. Preset buttons14. Power switch15. Radio/Mic change switch16. MIC volume knob17. MIC jack18. MIC tone knob19. Monitor switch

14 15 16 17 18 19

13121110987654321

SWVOL

PushLOC TONE BAL

SEEK BAND LOUD TUNE

MONITORTONEMICVOLUMERADIO/MICPOWER

OFF

ON

RADIO

MIC

MIN MAX LAW HI

ON

OFF

PROM

EJ REW FF

1 2 3 4 5 6

OFF MAX LO MI L R

107

Radio operation

Press power switch 14 to power onthe system.Press Radio/MIC switch 15 to selectthe Radio/MIC operation.Turn Radio/cassette ON/OFF andvolume knob clockwise to operateand control the volume, then theindicator starts displaying and eachlamps of knobs and buttons comeon simultaneously.Press band select button 7 to selectAM/FM band.Press seek button 5, then the fre-quency is automatically increases ordecreases and stops when anyreceivable frequency is seeked.(∇: decrease, ∆ : increase)Keep pressing the tune button 12,then the frequency increases ordecreases, when the needed fre-quency is received, release the but-ton (∇: decrease, ∆ : increase)Press present button 13 to receivethe memoried frequency. Also, tomemory any frequencies on presetbuttons, while the needed frequency

is being received, keep pressingpreset buttons more than 2 seconds.Turn the tone knob 3 to control thestrength of high sound.Turn th balance knob 4 to balancethe sounds of left and right speak-ers.Press loud button 18 to enhance thelow and high sound.When the receiving condition is notgood because of high impedance,magnetic interference of etc, pushpower switch 14, then receiving con-dition can be enhanced and “LOC”is displayed in indicator.

Cassette operation

Insert tape into the slot 9, then theradio stops and tape play backestarts automatically.Keep pressing fast rewind/progressor fast forward/progress button 10,11 to rewind or forward the tapefastly.Press fast rewind/progress and fastforward/progress buttons 10, 11

together, then the tape play backdirection changes.Press eject button 6, then the tapeplay back is stopped and the tapeis ejected through the tape slot.Tone, balance and loudness controlsare same as radio operation.

MIC operation

Insert mail type jack of microphoneinto MIC jack 17.Press RADIO/MIC switch 15 toselect the Radio/MIC operation.Turn mic volume knob 16 to controlthe volume of MIC sound.Turn mic tone knob 18 to control thetone of MIC sound.

108


Without echo type–B (OPTION)

1. Power ON/OFF and balance(Tone/volumn)

2. LCD display3. Eject button4. Tape slot5. Broadcasting remember button6. Fast forward button7. Fast rewind button8. Seek knob9. Band

10. AS/PS button11. MIC Power switch12. MIC/Radio fader13. Monitor fader14. MIC tone knob15. MIC volume knob16. MIC jack

VOL

PUSH SEEK

PL

ON MIC MONI

OFF MIX

POWER MIC/MIX FADER TONEMIC—10 0 MIN MAX

ROOF

VOLON TONE TUNING

PUSH BALANCESP

SA

BND

654

321

FM

EJ

AUTO REVERSE

PROG

1 3 4 2 6

10

7 8

161514131211

9

109

Radio operation

Push the knob( ) control the balancefittingly and control the volumeknob( ).Push the band button(9), select theFM/AM affirmed indicator.Select board casting turning theknob(8) manualy, or automaticallyboardcasting lony push the AS/PSbutton(10) more 2 seconds.

TUNING : Turning the knob(8) toenhance the low and highsound.

PUSH SEEK : Received the board-casting automaticallyby pushing the but-ton once or more.

AS/PS : Pushed the button(10)more 2 seconds longly,search the band automati-cally and remember the 1st

6th boardcasting but,shortly push the button,searched the boardcastingin memory once more pushthe this button stop thesearching.

Each remembered the boardcasting inbutton(5), 18th boardcasting isremembered on AM1, FM1, FM2each button.Controlled the high volume by turningthe knob(1).Turn on the power, controlled volumeand balance and the AMP volume liketo RADIO operation insert tape in tothe slot(4), then tape play starts auto-matically.Press the button(6, 7) to rewind orforward the tape fastly and inverteddirection of playing the tape.Direction of play displayed the indica-tor(2) press the eject button(3), tapeis ejected through tape slot.

Cassette tape player

Turn on power(1) by turning to knobto right(In state of main power is onof AMP lifier)Controlled the volume, balance and

AMP volume replayed the sound byinserting the tape on tape slot(4)press the button(6, 7). Tape is Rewa-rd/Forward fastly press the button(7)tape direction is automatically reverseat time and indicator lamp(2) lightcomes on.Controlled the right/low tone by turingthe knob(1) press the eject button(3)tape is ejected through tape slot.

MIC operation

Insert mail type jack of microphoneinto MIC jack(16).Press RADIO/MIC switch(12) toselect the Radio/MIC operation.Turn mic volume knob(15) to controlthe volume of MIC sound.Turn mic tone knob(14) to controlthe tone of MIC sound.Press the monitor fader button(13) incase of installation of monitor onside driver, controlled driver’s moni-tor or roof speaker.

Don’t eject during tape playing

110


Stereo etr double deck w/program selector type (OPTION)

1. Power ON/OFF and balance2. Selector(RADIO, TAPE, TV, MIC)3. Tone4. Bass controller5. Treble controller6. Echo interval controller7. MIC volume8. MIC jack9. Tone

10. Eject11. Boardcasting remember button12. Tape slot13. LCD display14. Fast REWIND/FORWARD button15. Band16. AS/PS button17. Push seeking18. Monitor volume19. Tape direction20. Monitor/Loop

(ETR RADIO & CASSETTE PLAYER)

(CASSETTE TAPE PLAYER)

(AMPLIFIER)

1

6

3

5

2

4

110

11 12 13 14

18

19

10 12 149

19

1715,16

3

1

204 5 86 7

2

111

Don’t eject during tape playing

Radio operation

Turn on the power switch( ) by turn-ing rightly the knob in the amplifierpart.Select the button( ) and press anyof RADIO, TV, TAPE, MIC, and con-trol the tone fittingly, and push theknob( ) control the balance fittinglyand control the volume knob( ).Push the band button(15), select theFM/AM affirmed indicator.Select board casting turning theknob(17) manualy, or automaticallyboardcasting lony push the AS/PSbutton(16) more 2 seconds.

TUNING : Turning the knob(17) toenhance the low and highsound.

PUSH SEEK : Received the board-casting automaticallyby pushing the but-ton once or more.

AS/PS : Pushed the button(16)more 2 seconds longly,search the band automati-cally and remember the 1st

6th boardcasting but,

shortly push the button,searched the boardcastingin memory once more pushthe this button stop thesearching.

Each remembered the boardcasting inbutton(11), 18th boardcasting isremembered on AM1, FM1, FM2each button.Controlled the high volume by turningthe knob(9).Turn on the power, controlled volumeand balance and the AMP volume liketo RADIO operation insert tape in tothe slot(12), then tape play startsautomatically.Press the button(14) to rewind of for-ward the tape fastly and inverteddirection of playing the tape.Direction of play displayed the indica-tor(13) press the eject button(10),tape is ejected. through tape slot.

Cassette tape player

Turn on power(1) by turning to knobto right(In state of main power is onof amplifier)Controlled the volume, balance andAMP. volume replayed the sound byinserting the tape on tape slot(12)press the button(14). Tape is Reward/Forward fastly press the button(7)tape direction is automatically reverseat time and indicator lamp(19) lightcomes on.Controlled the right/low tone by turingthe knob(9) press the eject button(10)tape is ejected through tape slot.

112

Amplifier (AMP.)

Power on by turning the knob(1) andselect such of RADIO, TAPE, TV,MIC.Pressing the each button(2) controlledthe tone turning the knob(3).Control the high/low volume by up/down the lever(4,5) and select thespeaker on driver by pressing the but-ton(20) otherwise select of speaker inloop by poping it

Press the button(2), choose one ofRADIO, TAPE, TV, MIC.In using MICPress the echo knob(6) then echocontrolled effectivity and must stickin the MIC jack(8) certainly con-trolled the tone by up/down the MIClever(7).Passenger could be listen to the anyplace boardcasting RADIO, TAPE,TV/VTR by controlling the tone fit-ting. So there are always connectedwith the individual program selectorin the each seat through the thisamplifier(Individual program selectorof passanger estabilish on vehicle)

It’s possible listen to CD playerthrough amplifier on theestabished CD set.

113

PRECAUTION IN DRIVING

Safety Driving and Parking1. For safety driving, turn down vol-

ume, sufficiently.(To hear signalsound of horn.)

2. Over a period of time, direct sunlight can cause the speaker ortape set to become malfunction,ventilate the air in the cab beforeoperation.

Cassette Handling Precaution1. To clean the surface or body cas-

sette with a cotton applicator.Don’t use benzene, thinner, sol-vent.

2. Be careful that the cassettes arenot exposed to magnetic fields ornot abrasive to other metal parts.

3. Keep speakers, tapes and radio notto be wet when cleaning the vehicleand be careful not to be exposed tomoisture to protect electrical shock.

4. Cassettes are negative ground typeand the power source is DC 24V.

5. Be careful not to repair by unskilledperson because cassettes are pre-cise parts.

Care and Maintenance1. We recommend that the tape below

T–90. A class of tape are T–60,T–90, T–120.

2. If a loop of tape has formed, it mustbe taken up by turning one of thespools with a suitable object suchas a ballpen.

3. Keep tapes in their plastic caseswhen not in use.

4. Never leave cassette inserted inoperating position with tape playerinoperative.

5. Don’t apply oil to revolving parts ofthe tape player.

114

6. Store cassettes where they will notbe exposed to high temperature,direct sunlight, magnetic fields,tape abrasion or dirt.

7. Clean the head of tape playercarefully with a cotton applicatorsoaked in alcohol. If the tape play-er is used for more than one hourevery day, the head should becleaned once or twice a month.If it is not used frequently, youonly need to clean the head everytwo or three months.

Tape headApplicator

Wooden pick

115

VTR SET (OPTION)

1. Power ON/OFF2. STOP/EJECT button3. Record button4. Record speed button5. TV/VIDEO selector6. Repeat play7. Monitor–controller8. Fast rewind(Green)9. Play(Green)

10. Fast forward(Green)11. Pause12. Record indicator(Red)13. Cassette indicator(Green)14. Repeat play indicator(Green)15. Normal speed indicator(Green)16. Remote–control receive17. Tape slot18. STOP button19. Slowly player20. Cover–control

1

117

818109

19

1

6

2 4 6 8 9 10 11

15�

14�

13�

12

7

17

3 5

1620

Notice : A letter of guarantee is separately bound, and brief enplanation refer to part manual.

116

VTR operation

Pressing power switch(1) to power onthe system.

Press cover(20) to opened the controlpanel cover and select TV/VTR oper-ation by pressing TV/VIDEO switch.Insert tape in the tape slot(19) withlightly over upside on the tape anarrow( ) and comes on cassetteindicator lamp(13).Press the play button(9), sceneappeared within one second.If tape wound of end, rewindingautomatically.Press the fast Forward(10)/Rewardwind button(8), tape speed is fastwind or rewind without displayingthe scene in state of stop.Otherwise with display the sceneduring playing.Press the slowly play button(19)during tape playing. Scene dis-played slowly and see to detailscene to move the striped duringslowly playing with controller( / )button of scene by pressing tostripes moved up/down.

Press the pause button(11), sceneonce shift by pressing button a timeover 5 minutes for the state ofpause.Playing the tape protection.

Method of recording by TVConnect output of the field terminaland input of an image terminal onmain system.Connect output of the sound termi-nal on TV and input of the soundterminal on main system.Turn on the power switch(1) of TVand select of scene channel.Push the tape into tape slot(17)and push the record speed but-ton(4) and select record speed(Normal or three multiple)Pushing record button(3), startrecord.If wanted stop, press the stop but-ton(2).

Don’t power off the TV untilrecording is end.

117

TV/VTR Controller (OPTION)

1. TV power switch2. TV/VTR selector3. Channel controllor4. Volumn controllor5. VTR power switch6. VTR tape eject button7. VTR playing stop button8. Fast rewind button9. VTR playing start button

10. Fast forward button11. Guide broadcasting power switch12. Stop broadcasting button13. Pass by station button14. Rewind broadcasting button15. 1st campaign button16. 2nd campaign button

1 2 3 3 4 4

5 6 7 8 9 10

11 12 13 14 15 16

(For NTSC type)

118

EARPHONE (OPTION)

1. Volume controllor2. Select the media

(Tape 1, Tape 2, Radio, TV/VTR)3. Earphone jack

3

2

1

119

Earphone controller

Power on of earphone controllorcan used to same time the Radioor CASSETTE, TV/VTR's power onAutomatically.Connect the your earphone tojack (3), and put the earphone intoyour ear.Select the wanted Media by push-ing the selector (2) that orderTape1, Tape 2, Radio, TV/VTRfrom top side to bottom and controlthe volumn suitability by moving thevolumn controller (1).It is increased highly volumn fromDownward to top ward.

120

DESTINATION KEYBOARD (L.E.D Sign Board) (OPTION)

1 2 3

4 5 6

7 8 9

0

RESET

Operating1. Set a machine of vehicles.2. Press the [RESET] button.

(In order to being shown as follows-[ooooo])

3. After selecting the route with the oper-ating panel, press the [#] button.(The route is appeared repeatedly with-out special operation on vehicle ser-vice)

4. If you want to change the route, pressthe [#] button after pressing [RESET]button on the operating panel andselecting the route.(The route is appeared repeatedly with-out special operation on vehicle ser-vice)

121

1. Key hole2. Speed warning indicator light3. Speed graduations4. Speedometer needle5. Clock check window6. Odometer7. Screen paper mark

TACHOGRAPH

Type A : Mechanical type–W/O RPM (SEPUNG), electric type–W/O RPM (SEPUNG, YAZAKI)

7

0

20

40

6080

100

120

140

160

Km/h

0 0 0 0 0 0 0

1

2

3

7

6

5

4

122

7

0

20

40

6080

100

120

140

160

Km/h

0 0 0 0 0 0 0

SpeedRecording and indicating ranges of 160km/hare available, depending on model type.

Warning signalLights up when the speed between 40%and 60% of the maximum speed isreached.– 100km/h (General)– 120km/h (GCC members)– 90km/h (SAUDI HAjj)

DistanceCalibrateable odometerwithout zero setting.

TimeTime display with time correct rotation ofthe chart, controlled by a high-quality quartzclock.

IlluminationThe tachograph scale has indirect illumina-tion by means of 1.2W bulbs or 24Vdepending on vehicle voltage.

123

1. Key hole2. Speed indicator light3. Minute hand4. Speedometer needle5. Odometer6. Clock graduations7. Hour hand8. RPM needle

Type B : electric type–W/RPM (VDO KIENZLE)

100

120

140

160KmKm/h

ARCO

20

40

60

10

15 20

25

30

33

0

80

0 0 0 0 0 0 0

1

2

7

36

8

4

5

124

100

120

140

160KmKm/h

ARCO

20

40

60

10

15 20

25

30

33

0

80

0 0 0 0 0 0 0

SpeedRecording and indicating ranges of 160km/hare available, depending on model type.

Warning signalLights up when the speed between 40%and 60% of the maximum speed isreached. – 100km/h (General)– 120km/h (GCC members)– 90km/h (SAUDI HAjj)

Engine speedAdditional feature to certain tachographmodels – measuring range depending onmodel type.160km/h / 3300rpm Distance

Calibrateable odometerwithout zero setting.

TimeTime display with time correct rotation ofthe chart, controlled by a high-quality quartzclock.IlluminationThe tachograph scale has indirect illumina-tion by means of 1.2W bulbs or 24Vdepending on vehicle voltage.

125

1. Key hole2. Speed graduations3. Speedometer needle4. Clock check window5. Odometer6. Speed warning lamp

Type C : electric type–W/O RPM (VDO KIENZLE)

2

1

6

3

4

5

126

SpeedRecording and indicating ranges of 160km/hare available, depending on model type. Warning signal

Lights up when the speedbetween 40% and 60% of themaximum speed is reached. – 100km/h (General)– 120km/h (GCC members)– 90km/h (SAUDI HAjj)

TimeTime display with time correct rotation ofthe chart, controlled by a high-qualityquartz clock.IlluminationThe tachograph scale has indirect illumi-nation by means of 1.2W bulbs or 24Vdepending on vehicle voltage.

DistanceCalibrateable odometerwithout zero setting.

127

1. Remove the recording chart paperset by depressing and turning theretaining ring counter-clockwise. Ifthe paper is handled roughly at thetime of removal, the cutting knifewill be distorted and become use-less for further operation.

2. Filling out of recording chart paperBefore setting the recording chartpaper in position, fill out necessaryitems on the recording chart paper,exercise carefully not to scratchthe paper.

3. Setting of clockSet the time by turning the timesetting knob as necessary.

4. Setting of recording chart papersetPosition the recording chart paperset under the knife, then align thetime on the paper with the redcolor mark near the knife.Install the retaining right by turningit clockwise while depressing it.

HOW TO HANDLE TACHOGRAPH RECORDS

128

Further information by additional devices

Basic informationStart of drivingEnd of drivingRoad speedDistanceTime scale

Tachograph for 7-day recordingsA chart bundle is placed in to these specialtachographs once a week. and for weekly, this is ofparticular advantage for vehicles which are beingused regularly over extended periods.Automatically each day is recorded on a seperatechart ; these charts can be removed individually ifrequired.

129

FLOOR CONTROLS

Gear shift lever(Except auto transmission)When shifting the gear, fully depressthe clutch pedal. Before shifting intoreverse, be sure to stop the vehiclecompletely.If reverse warning buzzer is equipped,the buzzer sound when shifted intoreverse position.The gear shift pattern is shown onthe knob of shift lever.

Accelerator pedal

To avoid unnecessary increase in fuelconsumption, the accelerator pedalshould be operated smoothly and rea-sonably.Make sure that injection pump leverreaches maximum speed stopperwhen pressing accelerator pedal fully.If the lever won’t reach the stopper,use accelerator pedal cable adjustingnut to adjust the cable length.

Brake pedal

When stopping your vehicle, do notpress the pedal forcibly but try topress it repeatedly. On a downhill,use this pedal together with exhaustbrake as required.

1

R

3

2

5

4

N

1

R

3

2

5

4

N

6

(6.O.D)

(5.O.D/D.D)

130

Clutch pedal(Except auto transmission)Fully depress the clutch pedal whenchanging gears. Do not rest your footon the pedal when the clutch is notin use.

Premature wear of the clutch willresult.

Service life of the clutch could bereduced when keeping it in a par-tially engaged condition.

CAUTION

131

Engine can be started by theengine start control panel installedat the upper side of engine in theengine compartment.First switch “ON” the battery mainswitch in the driver’s compartment,then set the toggle type start switchto “ON” to operate the starterswitch, to stop the engine, push thestop button.

ENGINE STARTING IN ENGINE COMPARTMENT

When the engine starter switch insteering column is located in“OFF” position, by setting the tog-gle switch to “ON”, only the starterswitch operates and the engineturns accordingly but the enginedoesn’t combust because theengine fuel cut lever is pulled.To run the engine, the enginestarter key should be located in“ON” position.

NOTICE

INTERRUPTINTERRUPT

ENGINE STARTER �INTERRUPT S/W

BATTERY�INTERRUPT S/W

CLOSE CLOSE

STARTER�SUB S/W

132

DRIVING

INSPECTION BEFORE DRIVING

Check items inside of engine room

Belt tensionLoose belt can adversely affect thealternator charging system and causeengine overheating or premature wearto the belt.On the other hand, a belt which istoo tight can cause premature dam-age to the bearings of its peripheraldevices.Frequently check and adjust belt ten-sion.

Engine oil levela. Pull out the oil level gauge(oil dip-

stick) to check if the oil tank hasbeen filled up to the specified level.

b. When the oil level is low, add thesame brand oil according to “RECOM-MENDED LUBRICANTS” and wait awhile to check the level again. Alsocheck for purity and viscosity of theoil before replenishing it.

c. Always check the oil level with thevehicle parked on level ground andthe engine stopped.

Power steering oil levela. Check the oil level and replenish

as necessary.b. Check the pipe joints for oil leak-

age.

We strongly urge you to useDaewoo recommended powersteering fluid for replenishment.

CAUTION

133

Engine coolant levelCheck the level by the mark on thereservoir installed at side of luggagedoor.After opening the cap, replenish thecoolant within 40mm from the end offilling neck.

Never open the cap when the engineis hot to avoid damages from the hotsteam blowing out.Operate the service when the engineis cooled sufficiently and on the levelground. Start engine and keep idlingfor 10 30 minutes after replenish-ment, then recheck the level andreplenish if necessary.

134

Air cleanerCheck the element contamination indi-cator, when the signal of indicator isyellow, the condition of element isnormal, but red signal means that theelement is fouled, then clean orchange the element after inspection.

After service, push the botton at thetop of indicator, then the signalreturns to yellow.

Extract out the dust by pressing bothends of dust trap with hand installedat the bottom of air cleaner body.Never remove dust trap or substitutewith different materials.

135

Clutch oil levelCheck the clutch oil reservoir for oillevel and contamination. If the level ofclutch oil in the reservoir is too low,replenish up to the MAX mark.

Windshield washer fluid levelCheck fluid level in the reservoir andreplenish as necessary.

POWER


POWER

AIRCONDITIONER

AIRCONDITIONER

Check items around driver’s compartment

(BH116 front folding door)

(Except BH116 front folding door)

136

Battery(MF) (OPTION)a. This MF battery needs no period-

ic maintenance as long as it isused properly.

b. Check the charge state throughthe indicator installed on the faceof the battery.

C. If the external part of the batteryis found foul, clean it with tepidwater.Apply a thin coat of vaseline orgrease to the battery terminals toprevent corrosion.

Battery (PT/PTC) (OPTION)a. This PT/PTC battery for intense

cold needs periodic maintenanceevery 5,000km on driving

b. Must check the electiolyte in notenough properiety and slip of bat-tery terminal

c. If the external part of the batteryis found foul, clean it with tepidwater and apply a grease to thebattery terminal to prevent corro-sion.

Check items exterior and under chassis

Test indicator Charge State Correction

Green Normal Use

Black Low charge level Recharge

Transparent Low electrolyte level Replace

Properietylevel

137

Unexpected and possible batterydischarge may occur, if the fol-lowing precautions are not taken.

While the engine is not running.It may give rise to battery dis-charge, if leave the vehicleswitched ‘ON’ of battery forlong time or operate toomany electric equipments at asame time.For long time parking, frontentrance door must be closedby it’s key and for the longtime suspension of operation,it would be better disconnectthe battery cable.

While the engine is running.While air conditioner is work-ing, it is advisable to raisethe engine RPM.

WARNINGd. Level of battery electrolyte mustkept up befween ‘upper level’ and‘lower level’When battery electrolyte in belowthe ‘lower’ position, Replenish thedistieled water until state is ‘upper’position(Only a position level on Battery isindicated ‘Lower’ position)

e. If the level not indicated on bat-tery, electrolyte must kept up with-in 10mm of a upper pole plate andwhen it below the properiety level,Replenish the distilled water

f. In water, the state of battery elec-trolyte must kept up replenish per-fectly so to provnt dangerous offreezing

Properiety level10mm

(0.39in.)

Pole plate

When exchange the battery, givespecial attention to connect cablescorrectly.If cables are misconnected, all theelectric equipments will be dam-aged.

NOTICE

138

Specific gravity of electrolyte Basic electrolyte temperature 20°C (68°F)

Note : 1. When temperature of electrolyte deviates from 20°C(68°F) at hydrometer check, temperature correction shouldbe made by the following formula.S20 St 0.0007 (t 20)

S20 Corrected specific gravity (20°C)St Hydrometer reading at t°Ct Temperature of electrolyte when checked

2. When lowering of electrolyte level is due to spillage, replenish with dilute sulfuric acid of the same specificgravity.

3. When replacing the battery, exercise extreme care so as not to make uncorrect connections, or damage toalternator silicon diodes will result.

Full-charge 1.26 or more 1.22 or more 1.28 or more

Half-charge 1.25 – 1.14 1.21 – 1.10 1.27 – 1.16

Discharge 1.13 or less 1.09 or less 1.15 or less

ZonesTemperate Tropics Frigid

Condition

139

Tirea. Check inflation pressure of the

tires with a tire air gauge and addcompressed air if necessary.

b. Improper inflation pressure affectsadversely tire service life, reducesmotoring comfort, and, in the worstcase, may cause tires to be over-heated and consequently exploded.

c. Check also the wheel pin nuts onthe wheel for looseness.

Draining of air tankFrom time to time, pull forward thedrain cock installed underneath the airtank to drain off condensates pro-duced in it.

When opening the drain cock, pullit forward as shown.

Normal inflationTire size pressure in

kg/cm2 (PSI)

11.00R20–16PR(Tube, radial) Front : 8.4kg/cm2

11R22.5–16PR (119PSI)(Tubeless) Rear : 7.7kg/cm2

12R22.5–16PR (109PSI)(Tubeless)

Front : 8.1kg/cm2

10.00–20–16PR (115PSI)(Tube) Rear : 7.4kg/cm2

(105PSI)

Front : 7.0kg/cm2


(89PSI)

Tighten to specified torque (6065kg m) as excessive tighteningtorque may cause damage to thewheel pin.

CAUTION

140

STARTING AND STOPPING THE ENGINE

Preparation for starting theengine

1. Apply the parking brake2. Manual transmission:

Move the gearshift lever to Neutralposition and depress the clutchpedal to the floor while crankingthe engine.Automatic transmissionPress the push button to “P”(Park)or “N”(Neutral), although “P” is pre-ferred

3. Push on the battery main switch.4. Turn the starter key to “ON”.

Starting the engine

1. Turn the starter key to STARTposition. Avoid excessive startercranking(in excess of 10 seconds)to prevent any possible damage tostarter motor or batteries. If theengine fails to start, wait about 30seconds before attempting to startengine again.

2. Use the idle control knob to idlethe engine at the normalspeed (rpm) until the normal oper-ating temperature is reached.

3. Do not overrun the engine underthe normal operating temperaturenot obtained. This may shorten theengine life and increase fuel con-sumption.

x1000 rpm

0

12

3

0

3

6 9

12

15AIR

kg/cm2

0

0

20

40

6080

00

20

40

60

1

1

1

1

Km/h

0 0 0 0 0 0

POWER


POWER

AIRCONDITIONER

34

141

4. Take exceptional care to adjustidle speed when the engine tem-perature is low.

5. If you had attempted to startengine with no fuel in the fueltank, you should bleed the fuelsystem. With no bleeding opera-tion, you cannot start the engineeven after refilling the fueltank.(Refer to “Bleeding of fuelsystem” at page 163.)

Starting the engine in coldweather

1. With the switch in the “ON” posi-tion the indicator lamp will light upshowing the engine is pre–heatedautomatically. After pre–heating iscompleted, the indicator lamp willgo out.

2. After pre–heating is completed,press the clutch pedal and accel-erator pedal to start the engine.

3. Use the idle control knob to idlethe engine at a moderately fastspeed. Normal idle speed : 550600 rpm.

4. Avoid unnecessary idling of theengine when coolant temperaturereaches above 60°C.

5. After warming up the engine, bringthe idle control knob back to itsoriginal position.


Abrupt start during warming–upoperation may shorten the enginelife.

CAUTION

C

H

142

Stopping the engine

Turn the starter key switch off andturn and push the battery main switchoff.

Sudden stopping of the engine aftersevere operations like full load orascending a slope causes overflow ofcoolant. In this case, idle the enginefor 5 or 10 minutes before stoppingit.

Diesel engine is apt to keep runningeven after the battery main switch isoff, while the engine is in running, donot push off the battery main switch,otherwise, alternator circuit may befailed.

x1000 rpm

0

12

3

0

3

6 9

12

15AIR

kg/cm2

0

0

20

40

6080

00

20

40

60

1

1

1

1

Km/h

0 0 0 0 0 0

POWER


AIRCONDITIONER

34

143

BEFORE DRIVING OFF

Steering wheel free play

Check the amount of the steeringwheel free play by gently turning thewheel in both directions. The freeplay should be within the range of 30

50mm at the periphery of the wheelwhen checked with the front wheelspositioned straight ahead.

Air parking brake switch

In air parking brake switch appliedvehicle, be sure to release parkingbrake before driving, also check thepark warning lamp goes out beforedriving.

Check steering wheel for free playwith the engine running.

CAUTION

PARKING


P

x1000 rpm

0

12

3

0

3

6 9

12

15AIR

kg/cm2

0

0

20

40

6080

00

20

40

60

1

1

1

1

Km/h

0 0 0 0 0 0

POWER


POWER

AIRCONDITIONER

(Cab control valve type)

(Gradual control type)

144

Windshield wipersCheck the operation of windshieldwipers and washer fluid ejection, keepthe front windshield glass clean allthe time.

Instrument panel, indicators andgagesCheck the instrument panel, indicatorsand gages operate in normal condi-tions when the related switches areactuated.

Clutch pedal(Except auto TRANS)Check the clutch pedal free play, ifthe free play deviates from 4050mm, adjustment is necessary.

Brake pedalCheck the brake pedal free play, ifthe free play deviates from about15mm, adjust the screw fitted at thebottom end of pedal.

DoorCheck the operation of door(open,close), be sure that the doors areclosed before driving.

MirrorAdjust side mirrors to have widervisions, also check room mirror beforedriving.

x1000 rpm

0

12

3

0

3

6 9

12

15AIR

kg/cm2

0

0

20

40

6080

00

20

40

60

1

1

1

1

Km/h

0 0 0 0 0 0

3224

160

0

48

C

H

E

F0

12

3x1000rpm

0

3

6 9

12

15

kg/cm

A I R2

7

0

20

40

6080

100

120

140

160

Km/h

0 0 0 0 0 0 0SPEED

SAFETY

ABS ASR

E

145

WHEN DRIVING OFF

Check if the needle of air pressuregauge indicates 5.3kg/cm2 or above.If the gauge indicates below thisrange of air pressure, keep theengine running at fast idle until thegauge needle points to the ratedpressure.

Check again that any abnormalwarning lamps or unnecessarylights are come on and recheck the“park” indicating lamp gone outsurely.

Let the engine idle until it is fullywarmed up and coolant temperatureincreases beyond 60°c (between “C”and the first “ ”) before startingoff, and start the vehicle with theshift lever in 1st position.

0

3

6 9

12

15

kg/cm

A I R2

AOH AIR

FULL

AIR

3224

160

0

48

C

H

E

F0

12

3x1000rpm

0

3

6 9

12

15

kg/cm

A I R2

7

0

20

40

6080

100

120

140

160

Km/h

0 0 0 0 0 0 0

E

ABS ASR

CHECK C

H

146

WHILE TRAVELING

Avoid overrunning the engine dur-ing break-in period of new vehicle.

If indicator lamps or instrumentsgive an indication of abnormal con-dition while driving, stop the vehicleand check to locate the cause oftrouble.

If the cause of trouble was notlocated, check at your nearestDaewoo dealer.

If unusual sound or smell becomesnoticeable while driving, stop theengine and check to locate thecause of trouble.If the air pressure falls below 5.3kg/cm2, stop the engine and check tolocate the cause of trouble.

0

12

3x1000rpm

0

3

6 9

12

15

kg/cm

A I R2

AOH AIR

FULL

AIR

147

The engine coolant temperaturegauge needle should indicate belowthe red point. If the gauge indicatesabove red point, stop the vehicleand keep the engine running atidle, and check the engine coolantlevel.

Severe burns to the skin canresult from removing the pres-sure cap from a hot radiator.Wait until the engine temperaturegoes down and use rags toremove the cap for check-up andrefilling operations.

Avoid engine racing, unnecessarysudden acceleration, or suddenstops.Do not drive with your foot restingon the clutch pedal as it producesa partially disengaged condition,causing premature wear of clutchfacing.

Stop your vehicl completely whenattempting to shift gear lever intoreverse.

C

H

148

When ascending a slope, shift tolower gear to relieve the enginefrom overload.

When descending a slope, shift tolower gear to gain retardation effectof the engine. It is advisable to usethe exhaust brake and enginebrake in combination whendescending a slope. Frequent useof foot brakes while descending along slope will cause brake drumoverheating and consequential mal-function of the brake.

Special care should be taken whendescending a slope, particularlywhen shifting down into lower gear,as the engine is liable to overrun.Excess engine rpm may result introuble with each part of theengine, especially possible break-age of valve spring and push rod.

brake�pedal

exhaust� brake1 3 5

6R 2 4

R 2 4 6

1 3 5

0

12

3x1000rpm

149

AFTER DRIVING

Engine stop

If there is an indication of engineoverheating, never stop the engineimmediately, keep running at idle fora while, after the temperature dropsto the normal range, stop the engine.Also, push the battery main off beforeparking.

Diesel engine is apt to keep runningeven after the battery switch off, whilethe engine continues running, neverpush the battery switch off, aftercheck that engine stops running, pushthe battery switch off.

Otherwise, the alternator circuit maybe failed.

Parking

Place the gear shift lever in neutralposition and pushed the parkingbrake knob securely.

C

Hx1000 rpm

0

12

3

0

3

6 9

12

15AIR

kg/cm2

0

0

20

40

6080

00

20

40

60

1

1

1

1

Km/h

0 0 0 0 0 0

POWER


POWER

AIRCONDITIONER

34

150

Service and repair after opera-tion

After operating the vehicle, alwaysclean it thoroughly and check the fol-lowing points :1. Re–check the troubles found dur-

ing the previous operation andtake necessary corrective actions.For such troubles difficult to cor-rect, contact your nearest Daewoodealer.

2. Check for leakage and oil levels.3. Add antifreeze to engine coolant to

prevent freezing of the engine incold weather.

151

DRIVING ON HIGHWAY

The followings should be performedfor safe and dependable vehicle oper-ation.

Before driving

More special care should be taken todrive on highway than urban road.Make sufficient inspection accordingto “DAILY CHECK BEFORE DRI-VING”.

Tire

Heat generation depends on vehiclespeeds and load weights. For thevehicle which travels frequently onhighway, rib pattern tires are prefer-able.Frequently watch speedometer read-ings in instrument panel.

Driving on highway

Driving on highway is more danger-ous than the urban road, you shouldbe more alert and have a stablepreparations.

1. Speed perceptionOn highway, driver’s speed per-ception is liable to become dullbecause its road surface is evenand commands a wider prospectthan urban road.Frequently watch speedometerreadings in instrument panel.

Rib�pattern

Lug�pattern

Rib/Lug� pattern

It is dangerous to drive your vehi-cle with tires whose treads havebeen worn out excessively,because the vehicle may losetraction.Limit of use : The depth of thetread grooves should be morethan 3.2mm.

CAUTION

152

2. Braking distanceBraking efficiency is the mostimportant thing when driving onhighway. When recognizing thehazard ahead and preparing toapply the brake, your reaction timewill take about one second. Thismeans that your vehicle, ifassumed to have run at speed of80km/h, will travel additional 20 to30m the moment you applied thebrake. Therefore, you should main-tain a safe following distance.

3. Distance between vehiclesNormally, the following distancebetween your vehicle and the vehi-cle ahead depends on vehiclespeeds. A safe following distanceof about 80m should be main-tained in 80km/h traffic.

4. PassingTo pass, increase your vehicle’sspeed by at least 10km/h morethan the speed of the vehicleahead. Before preparing to pass,

be sure to check the traffic behindyou and then pull out into the leftlane(in case of RHD, the rightlane) promptly with turn signal“ON”.

5. Turning on a curveGenerally curves of highway aregiven grade on their either side.With a light movement of thesteering wheel the vehicle turnsvery easily. Therefore, be carefulof tire slippage when applying thebrake on a curve, especially inrainy weather or on an icy road.

You must fully understand vehicleperformance in dirving on high-way.

1. AccelerationAs running resistance increas-es greatly while driving onhighway, the vehicle should beaccelerated with allowance forits engine power.

2. GradeabilityMaintain suitable engine rpmtaking into account the relationof grade and maximum speedat each gearshift position.

3. Fuel consumption

NOTE

153

6. OthersTo enhance braking efficiency,use the exhaust and enginebrakes in combination.Reckless steering may causedanger not only to your ownvehicle but also oncoming vehi-cles.In the event that a tire waspunctured during driving, holdthe steering wheel firmly andemploy exhaust brake to slowdown. Abrupt braking can causedamage to tires.

154

Protection of the engine againstfreezing

Overcooled engine not only acceler-ates wear of its vital parts but alsoreduces fuel economy. Before drivingoff, warm up the engine beyond 60°C.

Use of antifreeze

To prevent freezing and corrosion ofthe engine when operating the vehi-cle in extremely cold places, be sureto add a specified amount ofantifreeze to coolant.

Precautions when usingantifreeze

1. Wash off the inside of the coolingsystem including the radiatorbefore using anti–freeze.

2. Replace any damaged rubberhoses. If there is just a hair crackon these hoses, antifreeze is liableto leak.

3. Antifreeze should be handled withextreme care as it can cause dam-age to coated surfaces of periph-eral components.

OPERATION AND CARE IN COLD WEATHER

AREAMixing Freezing

ratio(%) point(°C)

RUSSIA(Frigid) 55(%) –48(°C)

SOUTHEAST ASIA

MIDDLE EAST30(%) –12(°C)

AFRICA

SOUTH AMERICA

TAIWAN 50(%) –38(°C)

OTHERS 30(%)~40(%) –16(°C)~–25(°C)

155

Engine oil

Engine oil tends to harden when theambient temperature falls in coldweather. Use the specified engine oilhaving proper viscosity.

Batteries

Battery condition tends to get worsewith drop in ambient temperature. Inextremely cold weather, maintain thebattery in a full charge state.

Driving on ice or snow

It is advisable that chains or snowtires be used when traveling on anicy or snowcovered road. If you applythe brake hard on a slippy road, yourvehicle is apt to lose its traction,resulting in losing the control of steer-ing wheel.

1. Be sure to use the chain of thesame dimensions as the targettire.

2. Fit the chains on the rear tires andtighten them so that motions of theother parts may not be interrupted.

Carefully fit chains on your tiresso that the chain band may notscratch the other parts or interrupttheir movements.

CAUTION

156

IN CASE OF EMERGENCY

Emergency stopping

In case of vehicle trouble or emer-gency stopping, pull up the vehicleto the roadside as early as possi-ble.

Set the parking brake and turn onthe emergency warning lamp toprevent possible safety hazard.

Emergency starting

Avoid starting the engine while yourvehicle is being toward as it maycollide with the towing vehicle.

157

Battery jumping

In the case that the battery has been“dead”, refer to “BATTERY CARE” inthis manual and make an emergencystart as illustrated.

2

4

3

1

158

INSPECTION AND MAINTENANCE

DAILY CHECK BEFORE DRIVING

In order to maintain safety and dependable operation, following checks should be performed daily before driving :

System Check item Check point

1. Vibrations or shimmy of steering wheel2. Hard steering or sticky3. Damage or looseness of component parts

1. Air mixed in brake circuit2. Free play, stroke and force pedal

Oil levelFunctionFunctionMoisture in tank and fluctuation of air pressure

1. Damage or looseness of bolts and nuts.2. Damage or severe wear of wheels and tires, and tire inflation pressure.

Damage of spring, and tightening state of U–bolts and nuts.

1. Engine starting2. Abnormal sound and vibration3. Leakage of fuel, lubricants and coolants4. Cleanliness and damage of air cleaner element5. Exhaust gas6. Damage of fan belt7. Engine oil level

Clutch pedal free play, stroke and functionFunction and oil leakageVibration of propeller shaft, oil leakage in rear axle

Steering

Brake

Running

Suspension

Engine

Power train

Steering wheel and system

Brake pedal

Brake and clutch oilExhaust brakeParking brakeAir tank and pressure

Wheels and tires

Chassis spring

Engine

ClutchTransmissionPropeller shaft and rear axle

159

Engine oil

Oil level checkCheck oil level and replenish ifrequired. Pull out the oil level gaugerod(dipstick) at the bottom side of theengine and wipe it clean, insert thegauge fully into guide tube andremove it carefully, then check thelevel of oil between the high and lowlevel marks. Also check the oil sam-pled with the gauge rod for deterio-ration.After checking oil level, insert thelevel gauge into guide tube properlyand tighten the oil filler cap firmly.

Type of oil1. DE12T/Ti, DV15T ENGINE

Frigid an area :API CF–4 or SAE 15W30

Except Frigid an area :API CF–4 or SAE 15W40

2. DE12TiS, DV15TiS ENG.API CH–4 (SAE 15W40) or ACEAE2/E3Refer to “Lubrication list” at page215.

Changing engine oilChange engine oil at specified inter-vals or when found to be fouled con-siderably. To drain, remove the drainplug from oil pan, when changing oilwarm up the engine sufficiently toremove moisture contained in oil.Thoroughly remove metal chips stuckto drain plug.

MINMAX

Drain plug

PERIODIC INSPECTION AND MAINTENANCE

Engine oil level should bechecked with the vehicle parkedon a level ground and withthe engine stationary. If theengine has been operated, allow20 minutes for oil to settle downbefore checking the oil level.

NOTE

160

Engine oil filterEngine oil filter element should bechanged together with engine oil atthe same time.(DE engine is mount-ed with a cartridge type)1. To drain oil, remove the drain plug

installed on the lower part of oil fil-ter body. Remove metal chipsstuck to drain plug, Check gasketand replace as necessary.

2. Loosen the center bolt and removethe filter body together with theelement.

3. Clean the inside of filter body andreplace with new filter element.

Clean the element with dieselfuel and visually check gasketsinstalled on the upper and lowersides of element for damageand hardening, and replace asnecessary.

It is strongly advisable to use gen-uine Daewoo oil filter element.

CAUTION

Model

DE12T

DE12Ti

DV15T

DE12TiS

DV15TiS

Change intervals

Initial : 1,000km

Inter–city or long

distance travel bus

Every : 15,000km

City bus

Every : 10,000km

Initial : 1,000km

Long distance

Every : 30,000km

Every : 20,000km

Capacity

ENG.TOT20

Oil pan17

ENG.TOT27

Oil pan24

ENG.TOT22

Oil pan19

ENG.TOT23

Oil pan20

161

Engine coolant

Coolant levelCheck the level of coolant by thereservoir installed at upper side ofradiator. Use clean rain water or citywater for the cooling system andavoid the use of hard water such asdrawn out of a well. Never open thepressure cap while the engine is notor hot steam may blow out causingserious injuries.

Change of coolantsDrain the coolant by opening thedrain cock of radiator. After com-pletely draining off, close the draincock and fill with new coolant. Runthe engine for about 10 minutes andthen recheck the coolant level.In the case that antifreeze is addedto coolant, it is advisable to clean theinside of the radiator and enginewater jacket 2 times a year(in springand autumn).

Refer to Lubrication list at page 215.

∗( ) : Preheater included

In order to avoid the accumulateof scale, corrosion for the entirecooling system and damage fromcavitation, coolant mixed with 30%of antifreeze solution should beused all year around. Some regions where antifreezesolution is not easy to purchase,cavitation protection solution“Inhibitor” could be used, never-theless antifreeze solution is thebest way to have maximum ser-vice life.

NOTE

Model Engine Coolant volume

BH116DE12T/Ti/TiS(310PS) 63(67)

DE12Ti/TiS(340PS) 65(69)

BH117DE12Ti/TiS 69(74)

DV15T/DV15TiS 70(75)

BH120 DV15T/DV15TiS 73(77)

162

Fuel filter

The fuel filter system is singlecatridge type with a paper element asa primary filter.Fuel is transported from the outsideof the filter to its inside. At this time,impurities contained in the fuel arecaught outside the filter.

Replace the catridgeAt every 20,000km.Restricted fuel filter will hinder insmooth transportation of fuel, resultingin decrease in engine power.

Method of replacing1. Unloosen drain plug2. Remove old catridge.3. Clean head sealing surface4. Fill the fuel in new catridge.5. Lubricate the rubber packing, sur-

face6. Spin catridge until packing contacts

head.7. Then tighten additional 3/4 to 1

turn.

It is strongly advisable to use gen-uine Daewoo fuel filter catridge.

CAUTION

Sometimes (at 10.000km) drainwater.

NOTE

OUT

IN

Filter�(paper�cafridge)

Filter�body

Center Bolt

Drain plug

163

Bleeding of fuel systemBleeding of fuel system must be per-formed when fuel filter has beenremoved or the engine has beenstopped due to lack of fuel.

1. Turn the cap of fuel feed pumpprimer anti–clockwise.

2. Keep pumping the primer untilmeet strong resistance to pumping.By holding the primer pusheddown, loosen the bleeder screw ofprimary fuel filter, bleed out thefuel with air bubbles, then retight-en the bleeder screw quickly.

3. Repeat (2) until pure fuel withoutair bubbles comes out.

4. Bleed secondary fuel and injectionpump by doing the sequence (2),(3).

5. Bleed the air in injection pump, bythe bleeder screw illustrated in thefollowing figure.

6. After bleeding, push down the capof primer and turn clockwise to belocked tightly.

164

Fuel system diagram

1. Fuel filter2. Center bolt3. Injection nozzle4. Fuel return pipe5. Fuel feed pipe

(filter pump)6. Overflow valve7. Injection pipe8. Fuel feed pipe

(pump filter)9. Fuel tank

10. Fuel return pipe11. Fuel suction pipe12. Fuel feed pump13. Injection pump14. Drain plug

13

12

1110

9

8

6

34

7

5

2

1

14

165

Valve clearance adjustment

Adjustment intervals

Rated valve clearance (cold)

Adjustment of valve clearanceAfter removing the cylinder head cov-ers, rotate the crank-shaft until theintake and exhaust valves of No. 6cylinder are overlapped (water pumpside).Loosen the lock nut of one rockerarm adjusting screw of the cylinderindicated in the following chart ( ).Insert a thickness gage of specifiedthickness into the clearance betweenthe valve stem end and rocker arm,then adjust the clearance with theadjusting screw.

When the correct adjustment isobtained, fully tighten the lock nut. Assame manner, adjust the clearancesof the other valves( ).Turn the crank-shaft 360°(the intakeand exhaust valves of No. 1 cylinderare over lapped) and adjust the clear-ances of the valves ( ).

Valve clearance adjustment chart(DE ENG)

(DV ENG)

Engine model Change intervals

DE12T/Ti/TiSAt end of first

1,000km andDV15T/TiS

Every 20,000km

Engine model Change intervals

Intake 0.30mm,

Exhaust 0.30mm

Intake 0.25mm,

Exhaust 0.35mm

1 2 3 4 5 6

in ex in ex in ex in ex in ex in exDE12T/Ti/TiS

DV15T

DV15TiS

1 2 3 4 5 6 7 8

in ex in ex in ex in ex in ex in ex in ex in ex

166

Injection nozzle

Check injection pressure and spraycondition of injection nozzle at every10,000km.To check injection nozzle, specificnozzle tester is required.Contact your nearest Daewoo dealeror repair workshop.

Turbo–charger

Turbo–charger increases the densityof intake air by the exhaust gas withhigh temperature and pressure.It make engine to reach to the stateof complete combustion.Turbo–charger is very precise itemand rotates by high rpm, periodicaland frequent check should be held.

Abnormal symptomsIf any abnormal symptoms as follow-ings are checked, have promt inspec-tion and proper repair.

Lack of engine powerBlack or blue smoke in exhaust gasExcessive engine oil consumptionAnormal noise in turbo–chargerRepetition of high and low noiseOil leak of gasket of oil supply tubeOil leak of oil seals in turbo–chargerHigh and weeping soundLeakage of intake and exhaust line

Engine model Injection pressure

DE12T/Ti/TiS 220kg/cm2

DV15T/TiS 204kg/cm2

Normal

Abnormal Abnormal

167

Points of handling care Fuel tank

Every 8,000km drain water andremove sediments by removing thedrain plug on the lower face of thefuel tank. Clean the inside of the tankevery 24,000km.

Drain plug

Item

Oil contamination

Delay & lack of oil supplying

Foreign substances in intake air

Sudden engine stop after fullload operation

Description

Be sure to use genuine oil and filter, keepperiodical oil change.

Prevent abrupt accelerating when idling andstarting.

Check air cleaner and keep to be clean.

Never stop the engine soon after full loadoperation, maintain engine idle about 3 5minutes before engine stop.

168

Belt installationCheck that the fan belt gives proper deflection when the intermediate part of the belt is depressed with finger. Also check the belt for cracks and damage.

CAUTION : When belt replacement becomes necessary belts should be replaced by set.

TENSION : The suitable tension is less than 10mm when pressed with the thumb.

CRS

F/D

3

1

4 ALT

5

2

C/C

DE12T/Ti/TiS ENGINE

1. Idle pulley2. Cooler compressor pulley

(OPTION : Roof–on cooler)3. Crank shaft pulley4. Alternator pulley5. Fan pulley

169

TENSION : The suitable tension is less than 10mm when pressed with the thumb.

FAN

2

1

5

6

3

CRS

W/P

ALT

1

1

4

C/C

1. Idle pulley2. Cooler compressor pulley

(OPTION : Roof–on cooler)3. Crank shaft pulley4. Water pump pulley5. Alternator pulley6. Fan pulley

DV15T/TiS ENGINE

170

Air cleaner

Regular service of the air cleaner isone of the most important mainte-nance items.Neglecting of this service not onlyaffects fuel comsumption but also theperformance and service life of theengine.

Inspection and service intervalThe filter element should be cleanedat every 4,000km or when the redcolor signal appears on the indicator.Under severe conditions and opera-tions on the dusty or sandy roads, itshould be cleaned more frequentlythan the recommended intervals.

Replacement of elementReplace the element annually or after3 times cleaning, also replace whenany damages are found. Gaskets andsealings should be replaced togetherwith the element.

Service of air cleaner1. Disassembly

Loosen the clamping screws andremove the dust pan, then the ele-ment is exposed. Loosen the wingnut fixing the element and pull outthe element.

2. Cleaning of elementDepending on the condition of con-tamination, clean the element byone of the following procedure.2–1. Element is contaminated(dry).

Blow dust off by compressedair(below 7kg/cm2), direction ofcompressed air should be frominside to outside of element.

2–2. Element is contaminated withcarbon and oil.First prepare element cleanerdissolved tepid water, submergethe element for 20 30minutesand shake well in the water, thenrinse the element with clean run-ning water (below 2.8kg/cm2).

171

After washing, dry the ele-ment in the shade or placeof good ventilation.Drying of element takes 1week, use spare elementwhile drying.Never apply compressed airor heat for quick drying

3. Inspection of elementAfter cleaning, inspect inside ofelement for tear, breakage anddistortion, use lighting lamp forcertain inspection.

4. Cleaning of air cleaner housingDischarge dust by opening thedust trap installed below the hous-ing.Clean inside of housing, cover andgasket fitting flange, if any dam-ages are found replace the ele-ment.Also the element should bereplaced if the wall thickness isreduced to be broken easily.

5. ReassemblyReverse the disassembly sequenceto reassemble, be sure to fit theelement and gaskets, tighten thescrews and nuts securely.Finally push the button of the aircleaner element indicator torestore the signal to yellow fromred.

Do not neglect to extract out theaccumulated dust from the dusttrap installed at the bottom of aircleaner housing.

NOTE

172

Transmission oil

Oil level checkCheck oil level at end of first 1,000kmand thereafter at every 4,000km dri-ving by the filler/level plug.If the oil level is below the level plug,replenish oil through the plug.

Changing oilReplace transmission oil at end offirst 5,000km and every 20,000km dri-ving.Oil replacement should be done whilethe used transmission oil is hot.First drain the transmission oil byremoving the drain plug at the bottemof the transmission housing.After draining of used oil is complet-ed, retighten the drain plug, then fillnew oil through the filler/lever plug.

OIL CAPACITY(Manual transmission)

(Auto transmission)

Specification of oilSpecification : API GL–4 or SAE80W90Refer to “Lubrication list” at page215.

drain plug filler plug

TRANSMISSION OIL CAPACITYK1005CK1005PK1205P

9.7

K1205CK1006RK1206R

11.2L

T 10S5B 13.0K1405A 14.5K1406P 16.0

TRANSMISSION OIL CAPACITY

B400R 25L

B500R 45L

D851.2

D863.128L

D854.2

D864.2

4HP500

5HP50030L

4HP590

5HP600

173

Rear axle oil

Oil level checkCheck oil level at end of first 1,000kmand thereafter at every 4,000km dri-ving by the filler/level plug.If the oil level is below the level plug,replenish oil through the plug.

Changing oilReplace rear axle oil at end of first5,000km and every 20,000km driving.Oil replacement should be done whilethe rear axle oil is hot.First drain the rear axle oil by remov-ing the drain plug at the bottom ofthe rear axle housing.After draining of used oil is complet-ed, retighten the drain plug, then fillnew oil through the filler/level plug.

OIL CAPACITY

Specification of oilSpecification : API GL–5 or SAE80W90Refer to “Lubrication” at page 215.

Filler/level�plug

Drain plug

VEHICLE OIL CAPACITY

BH116

BH117 11.5 12.5

BH120

174

Power steering oil and filter

Oil level checkCheck level by the mark on the oilreservoir at end of first 1,000km andthereafter at every 4,000km driving.Before checking power steering oillevel, align the front wheels straightahead.

Changing oilReplace power steering oil at end offirst 1,000km and every 24,000km dri-ving by the following sequence.1. With the engine stopped, raise

front wheels until the tires havegap to the ground.

Use hydraulic jack or proper equip-ment to raise front wheels, becareful of the vehicle not to fall orslip while servicing.

2. Loosen the two tube fittings cou-pled at the upper side of steeringunit and turn the steering wheelslowly in both directions.

3. After discharging of used fluid,retighten the tube fittings securely.Then fill the reservoir with new oilto the specified level.

4. Retighten the cap of reservoir andwait 2 3 minutes, then lower thefront wheels to the ground.

5. Start engine and keep idling for 23 minutes. Recheck the fluid

level while the engine is idling andreplenish as necessary.

6. After changing oil or if unusualsound is heard when the steeringwheel is turned, perform air bleed-ing, refer following paragraph, “airbleeding of power steering unit”.

OIL CAPACITY

VEHICLE OIL CAPACITY

BH1167

BH117

BH120 7.5

175

Air bleeding of power steering unit1. With the engine stopped, raise

front wheels until the tires havegap to the ground. Use hydraulicjack or proper equipment to raisefront wheels, be careful of thevehicle not to fall or slip while ser-vicing.

2. Remove the cap from the bleederscrew on the upper side of thesteering unit. Prepare vinyl tube,connect one end of the vinyl tubeto the bleeder screw and the otherend to a transparent container.

3. After starting engine, turn thesteering wheel right-hand directionto lock, then loosen the bleederscrew to discharge the fluid mixedwith air bubbles.Soon after the fluid with air bub-bles are forced out, retighten thebleeder screw.

4. Turn the steering wheel to left-hand direction and bleed air as thesequence(C).

5. Repeat air bleeding until the air isremoved sufficiently.While bleeding, check fluid leveland replenish if necessary.After bleeding, reinstall the cap onthe bleeder screw and lower thewheels on the ground.Check the level again and leakageof fluid.

6. Test the vehicle on the road thatsteering is smooth and abnormalnoise is not heard.

Specification of oilSpecification : AFT(DEXRON II)Refer to “Lubrication list” at page215.

176

Changing oil filter elementOil filter element(paper type) shouldbe changed at the same time whenthe power steering oil is changed,except at the first 1,000km driving.Change the oil filter element at every24,000km thereafter.To change, drain the oil in the reser-voir and turn the cap of reservoircounter-clockwise.Pull out the oil filter element andchange to new one.

Cleaning fluid strainerPrior to changing steering oil or filterelement, oil strainer installed in thefiller of oil tank shall be cleaned.Remove dust or other foreign mattersfrom the oil strainer before reinstallingit.

177

Brake system

Adjustment of brake pedal freeplayAdjust the brake pedal free play byturning the adjust screw installed atthe lower side of pedal. Free play isthe stroke measured at the upper tipof pedal from released position to thecontact point between the brake pedaland valve stem.

Brake valve check

Check the brake pedal move smooth-ly and return to the normal positionwithout any sticking.Also check the brake valve that airdischarging sound is heard when thebrake pedal is released, this checkshould be performed when the pres-sure of air tank is about 7.0kg/cm2.

Adjustment of brake lining clear-anceCheck and adjust the clearancebetween the brake lining and drum atthe first 500km operation and everymonth, or when the brake pilot lampturns on.

0

3

6 9

12

15

kg/cm

A I R AOH AIR

FULL

AIR

2

Free play of brake pedal remainsunchanged under normal condi-tion, however, check the free playand adjust to the specified stroke,because insufficient free playcould make brake dragging.

NOTE

pedal free play

adjust�screw

178

Adjustment procedure

Full air brake with mechanicalslack–adjuster1. With scale, measure the travel length

of brake chamber push–rod from thereleased position to the fully depressedposition, if the measured valueexceeds the standard(Front:33~35mm,Rear:35~38mm), adjust the clearance.

2. Jack up and check the wheels rotatesmoothly without any resistance.

3. Remove the rubber plug fitted in thebrake lining inspection hole.

4. By rotating the wheel with hand, turnthe worm–shaft of the slack–adjuster tothe direction in which the brake shoeexpands until the brake drum drags bycontacting with the brake lining,

then turn the worm–shaft to reversedirection until the clearance becomesto the standard value.The standard clearance is 0.3mm,check the clearance by inserting thethickness gage between the brake lin-ing and drum.

5. After ajustment, check again that thebrake chamber push–rod travel lengthis front:33~35mm, rear:35~38mm.

Full Air brake with auto slack-adjuster (OPTION)For the vehicle on whick auto slack-adjuster applied, ajustment of brakelining clearance is not necessary innormal, but periodical chekc andinspection should be done for thelonger service life and safety.

If the protruded point of the indi-cator comes into contact with thestopper by turning the worm–shaftfor adjustment, it indicated that thelining has been worn to the limitand should be replaced.

NOTE

179

Inspection of brake lining1. Remove the rubber plug fitted in

the brake lining inspection hole.2. Check the condition and amount of

brake lining wear by the eyes. Ifthe brake lining weared out to thestepped line, also any cracks,severely burnt sports or abnormalconditions are checked, replacedthe brake lining to the new one.

thickness

rivetshoe

extru-� sion

180

Clutch system

Adjustment of clutch pedal freeplayThe clutch pedal free play decreasesas wear develops in the clutch drivenplate. The clutch pedal free playshould be adjusted in the followingmanner when the amount of playbecomes less than 25 mm using ofthe vehicle without making an adjust-ment result in clutch slip.1. Free play : 25 30 mm2. Height : 180 205 mm

Inspection of free play

To check the amount of clutch pedalfree play, release air whithin the mainair tank solely to interupt boosteroperation. Depress the clutch pedalcarefully until a strong resistance isfelt, then check the free stroke beforethe point of resistance is reached.

Adjustment procedure1. Disconnect the return spring on

the mainpack, then remove thebellows at the minipack side.

2. Loosen the minipack push–rod locknut and slowly turn the push–rodin direction of extension until astrong resistance is felt, then backoff the push–rod 1 2/3 turns.

3. Tighten the lock nut and install thereturn spring and bellows.The clutch pedal free play is adjust-ed from 25 to 30mm when theabove adjustment procedure is fol-lowed.

When turning the push–road,avoid excess force, or adjust with-in the point at which resistanceincreases can not be felt.

NOTE

When the adjustment operation iscompleted, check that clutch pedalis provided with standard freeplay.

NOTE

lock nut push rod

12

181

Clutch Oil

Check to see if the level of oil in thereservoir is normal. When the level istoo low, check the circuit for possibleleakage and replenish with specifiedfluid. The clutch hydraulic circuitshould be drained and refilled whenoil is found to be contaminated. Oilchange intervals : every 60,000km or1 year.

Bleeding of clutch hydraulic cir-cuitsIf air enters the clutch circuit, it causeclutch dragging. Therefore, bleedingoperating should be performed if theclutch fluid reservoir has been emp-tied due to failure or if the hydrauliccircuit has been disassembled.Bleeding operation calls for coopera-tive action of 2 men.

1. Set the parking brake.Bleeding of clutch hydraulic circuitshould be perfomed with the airtank emptied.

2. Check the level of clutch fluid inthe reservoir and replenish as nec-essary.

3. Remove the rubber cap from thebleeder screw on the clutch mini-pack and clean the screw.Connect a vinyl tube to the bleed-er screw and insert the other endof the vinyl tube into a transparentcontainer.

4. Pump the clutch pedal repeatedlyand hold it depressed.

5. Loosen the bleeder screw torelease clutch fluid with air bubblesinto the container and tighten thebleeder screw immediately.

6. Release the clutch pedal carefully.Repeat the above operation untilair bubbles disappear from theclutch fluid being pumped out intothe container. During the bleedingoperation, keep the clutch fluidreservoir filled to the specifiedlevel. Reinstall the rubber cap.

Any oil other than clutch oilshould not be used for replenish-ment.

NOTE

182

PRESSURE REGULATOR (OPT)(BH116)

ApplicationThe pressure regulator is fitted in airbrake systems to regulate the operat-ing pressure and to clean the air deliv-ered by the compressor.Some valve types are fitted with anintergral safety valve, in order to pro-tect the compressed air systemsagainst excessive pressures.The unloader valve/relief valve combi-nation is required with air compressorshaving delivery 700 /min of free air,to provide for a relief of the unloaderunit by means of division of the air flow.

Charging position

Legend : 8 Inlet1 Outlet 9 passage Ports :2 Cut–out piston 10 Check valve 1 Energy inlet3 Outlet 11 Safety valve 21 Energy outlet4 Bore 12 Screen (to reservoir)5 Valve plunger 13 Breather valve 23 Energy outlet6 Control piston 14 Compression spring (to relief valve)7 Compression spring 15 Relief valve AE 13.. 3 Exhaust

7

8

910

6

5

4

32

1

1 1

3 3

2123

21 4

X

11

12

13

14 15

183

Method of operation

Charging positionControl piston(6) and cut–out piston(2)are held in their lower or upper endpositions, respectively, by compres-sion springs(7) and (14), so that out-let(1) and inlet(8) are closed whileoutlet(3) is open.One half of the air supplied by thecompressor flows through port 1 andscreen(12)–where coarse impuritiessuch as oil carbon are retained–andon to check valve(10) ; it opens thelatter valve and flows via port 21 intothe pipeline to the supply air reser-voirs ; at the same time, air is fedthrough passage(9) to act upon con-trol piston(6). The other half of the airsupplied also travels to the supply airreservoirs, though by way of the reliefvalve AE13..(15).

Cut–outAs the pressure in the supply airreservoirs rises, the same pressurebuilds up below control piston(6), viapassage(9), causing this piston tomove upwards. The spring–loadedvalve plunger(5) follows this movementuntil outlet(3) is closed. When thepre–determined cut–out pressure hasbeen reached, control piston(6) lifts offvalve plunger(5), and inlet(8) opens ;compressed air passes down throughthe drilling in valve plunger(5) to actupon cut–out piston(2), and it is alsocommunicated, via port 23, to the con-trol device of relief valve(15).Cut–out piston(2) is moved down-wards, thereby opening outlet(1) sothat air continuously supplied by thecompressor exhausts to atmosphere,through exhaust port 3, taking with itany oil carbon particles that may haveaccumulated. As a result of the con-trol pulse fed in from port 23, the airsupplied via relief valve(15) is also dis-charged to atmosphere.

Cut–inWhen, as a result of air being with-drawn, the pressure in the supply airreservoirs and thus the pressure in thechamber below control piston(6) dropsto cut–in pressure, the spring loadedcontrol piston(6) closes inlet(8) whileoutlet(3) opens ; the pressure prevailingabove cut–out piston(2) and, via port23, in the control pipeline to relief valve(15) is reduced through port(4). Com-pression spring(14) causes cut–out pis-ton(2) to move upwards until outlet(1)is closed. The air supplied by the com-pressor is allowed to travel againthrough ports 21 of both the unloadervalve and the relief valve(15) to thesupply air reservoirs.

Safety valveIn the event of the unloader valve notcutting out, due to a malfunction, safetyvalve(11) will limit the supply air reser-voir pressure by allowing the air suppliedto exhaust to atmosphere when theopening pressure has been reached.

184

Installation

Unloader valve and relief valve aremounted in an uprght position, withexhaust port3 pointing downwards.The total volume of air supplied bythe compressor must be allocated totwo 18 1.5 pipelines, one line beingconnected to port 1 of the unloadervalve and the other one to port 1 ofthe relief valve(see installation dia-gram). The pipelines should have alength of approx. 2m each(if neces-sary, to be coiled) and must be laidin such a manner that the tempera-ture at ports 1 of both the unloadervalve and the relief valve does notexceed 150°C.For the control line from port 23 ofthe unloader valve to port 4 of therelief valve use either a pressure/tem-perature–resistant hose with an insidediameter of 6mm, with fitting to suitdimensions as shown in drawing I, ora 6 1 pipe with connection to suitdimensional drawing II. In both casesa maximum length of 1 m should notbe exceeded.

The pressure relief noise generated inthe cut–out phase is reduced bymeans of hoses attached to theexhaust connections 3 of both theunloader valve and the reliefvalve ; this can also serve to drain offany oil that may have been separat-ed.

Installation diagram

1 2 3

45

X

2

2

1

1

3

4

21

21211

23

3

2224

230

0

1 = Air compressor2 = Unloader valve3 = Four–circuit protection valve4 = Relief valve AE 13..5= Tyre inflation valve ZB 31..

185

Maintenance

After a prolonged period of operation,the cut–out pressure may vary fromthe specified value. Turning the springhousing allows the precompression ofspring(7) and thus the cut–out pres-sure to be adjusted.This operation should only be carriedout by trained specialists.

Technical features

Type Dimen– Graphic Max. Min. Safety

no. sional symbol cut–out cut–in valve

drawing (see overleaf) pressure pressure opening

pressure

– – – bar bar bar

DR 3218 I 1 7.35 0.2 6.2 N/A

DR 3226 I 1 10.00 0.2 9.0 N/A

DR 3227 I 1 8.10 0.2 7.1 N/A

DR 3242 II 2 9.50 0.2 8.6 10.5

DR 3243 I 1 8.50 0.2 7.3 N/A

Accessory valve required : Relief valve AE 13.. according to catalogue

sheet AE 1000–K 14 EN

Temperature range : –40°C to 150°C

Weight : 0.9kg

186

Dimensional drawing I

φ15

φ 6

170

φ60

φ16.5

49

32A/

F

6 18

23

3060

bar

10863

70

35

4

A

3

21 �

M2

2X

1.5

M2

2X

1.5

min13

221–2

min13

1

9

24

94

Legend := Not bored

Ports :1 = Energy inlet

21 = Energy outlet(to reservior)

23 = Energy outlet(to relief valve)

3 = Exhaust

187

Dimensional drawing II

φ15

170

φ60

φ16.5

37

32A/F

6 18

3060

bar

M12

X1.

5

M22

X1.

5

23

10863

70

35

4

A

B

3

21 �

M2

2X1.

56

min13

221–2

min13

1

9

94

24

Legend := Not bored= Safety valve

Ports :1 = Energy inlet

21 = Energy outlet(to reservior)

23 = Energy outlet(to relief valve)

3 = Exhaust

188

Application

The antifreeze pump is used in brakesystems in order to inject an anti–freeze based on glycol or alcohol dur-ing winter operation. This makes itunnecessary to unscrew the pipe con-nection. If the vehicle is operatedwithout trailer, the pump must beactuated one or several times beforesitting off, the number of strokesbeing dependent on the temperatureand humidity of the air(see instructionplate on reservoir).

In case the vehicle is operated withtrailer with a consequently higher airconsumption, the plunger rod mustaccordingly be depressed more often.

ANTIFREEZE PUMP (OPTION) (BH116)

189

Mode of operation

When the pump is inoperative, cylin-der(6) communicates via the feed ho-les(5) with reservoir(2) containing theantifreeze. When plunger rod(1) isdepressed, piston(4) moves down-wards, closeing feed holes(5) andcausing approx. 1cm3 of antifreeze tobe injected into the air stream, viacheck valve(7). As long as plungerrod(1) is in the operating position, thefurther flow of fluid of from reser-voir(2) is interrupted. When plungerrod(1) and piston(4) are released,they are moved back to their originalpositions, due to the action of returnspring(3). Compression spring(8) clos-es check valve(7), and cylinder(6) isagain filled with antifreeze throughfeed holes(5). At any further stroke,prior to setting off and with the com-pressor in operation, appr. 1 cm3 ofantifreeze per stroke is fed into theair stream. Following any pump oper-ation, several brake applications mustbe made.

8

7

6

5

4

3

2

1

1 Plunger rod2 Reservoir3 Return sprng4 Pump5 Feed hole6 Cylinder7 Check valve8 Compression spring

190

Installation

The antifreeze pump is installed inthe delivery line between the unloadervalve and the air reservoir, eitherclose to the unlaoder valve orupstream of the air reservoir. Thepump must be installed in a verticalposition and sufficient clearance beallowed for operation and refilling.Only manual operation is permissible.The pipe line to the air reservoirshould slightly slope downwards toensure that the antifreeze flowsimmediately and at all events into thebrake system.The antifreeze pump is fastened bymeans of two M8 bolts.

MaintenanceAfter winter operation the antifreezepump must be cleaned and sprayedwith acid–free oil.

Technical features

Type no. AntifreezePaint Weight

coating [ kg ]

LA 1100on an alcohol or glycol

no 1.3basis or pure alcohol.

LA 1101No methyl alcohol–

yes 1.3toxic!

Max. operating pressure : 10 bar(gauge pressuree)

Temperature range : –40°C to 80°C

Reservoir capacity : 250 cm3

Reservoir : transparent

22±0

.5

50±0.2

80–2

25

AB

φ 84

φ 76

φ 8.

5

≈166

50±1

68

A = Rest positionB = Stroke 16mmPorts M22 1.5–15deep

191

AIR DRYER

Function of air dryerSince moisture contined in the atmos-phere is compressed and warmed bythe air compressor, the amount ofmoisture is in proportion to that ofcompressed air.This hot and humid air is cooleddown in reserve tanks or pipings toform condensation. This condensationwashes away lubricants from themoving parts of various devices orequipment, resulting in unsatisfactoryactions of these devices or equip-ment. In addition, impurities containedin the condensation accelerates rust-ing action to shorten the lives of relat-ed devices or equipment. In coldweather, this condensation can befrozen and immobilize various devicesand equipment. Therefore, it is essen-tial to remove moisture from com-pressed air in order to extend theservice lives of devices, to enhancereliablilty, and to prevent possibledamage or breaks.

AIR DRYER

Specifications

Item Description Remarks

Max. air pressure 9.8kg/cm2

Normal air pressure 5 9.8kg/cm2

Dew point 17°C

Remaking time 50 sec

Air compressor displacement 600L/min or less

Heater capacity 24V/50W

Temperature range 30°C 70°C

Thermostat temp. 4 4°C

Operation fluid Air

Delivery 581L/min

192

Operation of air dryer Inspection of air dryer1. At end of every 15,000km or

2months operation.Check for the drain amount andoutflow of oil when draining con-densation and dirts from airtank.(When oil is detected, checkcompressor.)

2. At end of every 45,000km or 6monthes operationDisassemble air dryer and check ifdessicant has been moistened bydirts. If the dessicant is found tobe wet for about more than 1/5 ofall, change it(In wet condition, thecapacity drops).

3. At end of every 90,000km or 1year operation.Disassemble air dryer and changedessicant, oil filter, cloth filter andwhole rubber parts.Check air tubing and wiring con-nections.

In the case that temperature drop in air tank exceeds 16°C, a small amountof water may be drained.

Season

Spring,

Summer,

Autumn

(warm or hot weather)

Winter

(cold weather)

Descriptions

Before driving, always check the air

pressure(8.2kg/cm2) in air tank.

When parking, check the amount of drained water

and foreign substances in water.

As thermostat is installed in air dryer, when the

sensing temperature is above 4 4°C, the electric

current to heater is cut off automatically.

Before or after the operation, always follow the above

instructions 1 and 2 to take care for the air tank.

193

1. Outlet2. Control piston3. Inlet4. Bore5. Bore6. Sliencer7. Outlet8. Blow–off valve9. Preliminary dewatering chamber

10. Non–return valve11. Nozzle12. Ring filter13. Desiccant14. Regeneration air tank15. Bypass valve16. Adjusting screw17. Adjusting screw18. Vent bore

Connections1. Energy inlet

21. Energy outlet(to energy accumulator)

22. Energy outlet(to regeneration air tank)

3. Vent

194

Trouble shootingDaily inspection and periodic inspections will prevent the greater portion of air dryer troubles.In the event of troubles or complaints as listed, follow the correction procedures to correct the difficulty.

Complaints

Water comes

out from main

tank.

Drain valve

fails to drain.

Cause

Desiccant has been saturated.

Cut–off pressure of governor is so low that

purge valve won t open.

Failure to change desiccant or oil filter within

scheduled period.

As the purge time is less than the rated

time (50 seconds), desiccant is not recovered

sufficiently)

Freezing of air dryer due to heater trouble

Failure to regularly change desiccant

No operation of purge valve due to the entry

of foreign substances into drain valve.

Correction

Check and drain the main tank until the desiccant is dried

up.

Increase pressure for governor to 6kg/cm2 or higher.

Change desiccant kit at end of every 12 months or

90,000km operation.

1. If cut–off pressure of governor and closing pressure

of relief valve are low, purge time also is shortened,

resulting in failure in recovery of the desiccant.

2. In the case of purge by relief valve, if cut–off pres-

sure of governor and closing pressure of relief valve

are low, purge time also is shortened, resulting in fail-

ure in recovery of the desiccant.

1. Change faulty heater.

2. When the trouble is located in thermostat, change

it.

Change desiccant kit at end of every 12 months or

90,000km operation.

Disassemble and check the valve, and replace the valve,

if necessary.

195

Complaints

Inside of air

dryer has been

frozen

Air leaks from

drain valve

Excessively

low pressure

of main tank

Cause

Misattached dryer body or exposed to cold

weather at 30°C while traveling

Heater has been short–circuited and no heat-

ing

Thermostat has been short, resulting in failure

of heater.

The dryers temperature drops significantly due

to ice or snow stuck to its body

No operation of heater due to disconnection of

the electrical wiring for heater or thermostat

Poor contact of valve seat due to the entry of

foreign substances into valve

When the check valve of main tank fails to per-

form backward flow checking operation with

compressor in unload cycle, air can be leaked

through the main tank drain.

Correction

Correct the position of dryer body or install a wind screen.

1. Use a tester to check the heater for short–circuit.

2. If heater has been short out, change it with a new

one.

Leave thermostat at temperature of 0°C or below and

use a tester to check it. Add heat to thermostat by hand

to check for OFF state and change it if requied.

Remove ice or snow so carefully as not to cause dam-

age to dryer body and electrical wiring connections for

heater.

Check heater and thermostat for connection.

Disassemble and check the valve, and change the valve

kit if required. When damage is found at the wet mov-

ing part of valve body, change the valve.

Disassemble and check the check valve located between

main tank and purge tank, and change it if required.

196

WATER TRAP (OPTION) (BH116)

Installation of water trap

Water trap is always located betweenpressure regulater and main air tank.When the air dryer is installed, and ifthe pressure regulator is not used, atthat case the water trap should beinstalled before air dryer.

The function of water trapAs shown at the above drawing, thewater trap condensate the moistureand lubricant mixed at the com-pressed air from the air compressor.The vapor molecules are condensat-ed while they pass out the 12–φ5holes in the closed plate of watertrap, and they can be drained throughthe drain cock at the bottom of watertrap.The effect of condensation could beincreased when the antifreeze pumpis used before the water trap. Because, the alcohol molecule drawthe water molecules and make waterdrops easily.

Every driver should pull the draincock to drain off the condensatesin the water trap before and afteryou drive, especially below thetemperature of freezing point.

NOTICE

197

With pressure regulator (OPT)(BH116)

With anti freeze pump (OPT)(BH116)

With air dryer

1

3

4

2

1. Pressure Regulator2. Anti freeze pump3. Hose4. Water trap

2�

3

1

1. Air dryer2. Hose3. Regenerating tank

1

2

3

1. Pressure Regulator2. Hose3. Water trap

198

TIRES

Tire pressure inspectionCheck tire pressure with air gaugeand add compressed air if required.Improper inflation will adversely affectthe life of tire, especially underinfla-tion is a major contributor to over-heating of tire, resulting in explosion.

Tire air pressure

Tire rotationTire wear depends on tire position,road conditions, or a habit of apply-ing brakes.To avoid unbalanced wear of yourtires and to prolong their lives, rotatetires periodically(every 5,000km nor-mally).

Proper inflation

Underinflation

Overinflation

Normal inflationTire size pressure in

kg/cm2 (PSI)

11.00R20–16PR(Tube, radial) Front : 8.4kg/cm2

11R22.5–16PR (119PSI)(Tubeless) Rear : 7.7kg/cm2

12R22.5–16PR (109PSI)(Tubeless)

Front : 8.1kg/cm2


(105PSI)

Front : 7.0kg/cm2


(89PSI)

199

Following these instructions with-care when rotating tires.1. The wheel nuts on the right side

wheels have right–hand threadsand the wheel nuts on the left sidewheels have left–hand threads.

2. Clean the wheel pins and nuts andapply oil to the threads.

3. Place hydraulic jack shown.

L

L R

R

Nut loosening directions

2

7

53 1

8

64

Wheel nuts�tightening�sequence

After rotating tires, be sure toretighten the wheel nuts to speci-fied torque at end of 50 10kmrunning.(Torque : 60 65kg m)

CAUTION

200

ELECTRICALAiming of headlamps

The headlamps should be tested andproperly aimed if found to be out ofadjustment. The headlamps can beproperly aimed using either the head-lamp aimers or a headlamp tester.The headlamp testers include focustype and screen type. To aim head-lamps, proceed as follows : Park thevehicle on a level floor and check tireinflation pressure and adjust as nec-essary. Remove the headlamp coversand wipe clean the lenses.

BH116/BH117

BH120 with dual headlamps

201

Adjustment by the use of an aim-ing instrumentOne aiming instrument consists oftwo units :one is for right side and the otheris for left side.

1) Place the right and left units of theaiming instrument on theheadlamps (type 1–inside, type2–outside) in such a manner that theright and left units of the aiminginstrument lightly contact the aimingbosses on the headlamp lenses.Support the aiming instrument so thatthe objective lens of the aiming

instrument is faced to the center ofthe vehicle, and push the handlestrongly to tightly contact the vacumnrubber cup of the instrument on thelens.

2) Look into the eyepiece of the aim-ing instrument, and adjust the leftand right adjust screws so that thestandard line seen in the instru-ment is correctly overlapped on thewhite line of the other side aimingunit. (This adjustment is the samefor both type 1 and type 2.)

3) Next, set the dial of the level vialto the desired angle (0 deg for type1 and 0.5 deg for type 2), andadjust the updown adjust screws ofthe headlamps so that air bubblein the level vial is in center of thelevel vial.

4) Thus, driving beam of the type 1headlamp is tilted downward 0.5deg, and passing beam of the type2 is tilted downward 2 deg andturned 0.5 deg to the left side.

White line

Type 2

Objective

Eyepiece

Levelvial

Dial

Handle

Type 2Center of vehicle

Vacuumrubbercup

202

Bulb

DISTINCTION BH116 BH117 BH120

Head High75/70W (H4)

lamp Low

Fog. 55W (H3) 35W

Cornering 25W –

Front Parking(OPT)/Turning 10/25W –

combi. Position 4W –

lamp Parking (OPTION) – – 3W

Position/Turning – – 10/25W

Turning 25W –

Turning 25W

Rear Stop/Position 25/10W

combi. Stop/Parking – – 25/10W

lamp Stop – – –

Parking (OPTION) 3W –

Back up lamp 25W

Side turn signal 12W

White color : 12WAmber color : 25/10W

203

DISTINCTION BH116 BH117 BH120

NO. Plate lamp 12W 5W

ENG. Room lamp 12W

Speed indicator lamp 12W

Driver lamp 12W

Room lamp (FL) 20W

Room lamp (GLOW) 12W

Room lamp (Line light) (OPTION) – – 20W

Rack lamp (OPT) 20W

FRT marker lamp 12W

RR marker lamp 12W

Step lamp 12W

Serach lamp (OPTION) 12W

Luggage lamp 12W

Reading lamp (OPTION) 5W

Pilot lamp 1.2W

Side lamp (OPTION) 12W

204

Relay and fuse layout★ The quantities or locations of fuses could be different from the figure, because the fuses or relay could be added

or omitted, and locations could be changed by the requirement of custmers.

BH116

1 12 23

24

25

26

27

28

29

30

31

32

33

13

14

15

16

17

18

19

20

21

22

2

3

4

5

6

7

8

9

10

11

HEAD LAMP(HIGH) ROOM LAMP 2 WIPER MOTOR RH

SP

AR

E F

US

E

5A20

A15

A10

A

HEAD LAMP(LOW) ROOM LAMP 3 WIPER MOTOR LH

TAIL LAMP ROOM LAMP 4 STOP LAMP

MID DOOR LAMP FRONT DOOR

FRONT DOOR LAMP

BLINKER UNIT

TV. VTR

READING LAMP FOG LAMP

FUSE

205

No. Amp. Description No. Amp. Description No. Amp. Description

1 15A Head lamp relay(HIGH)

2 10A Head lamp relay(LOW)

3 15A Tail lamp relay

4 10AENG. stop motor

Destination lamp (OPT)

5 10A Stop lamp, Horn, Radio

6 20A A.B.S (OPTION)

7 15A Warning lamp (OPTION)

8 5ACar vision (OPTION)

Spot light (OPTION)

9 5AHeater mirror (OPTION)

Driver lamp

10 15A Wiper control relay

11 10AButton buzzer (OPTION)

MID door (OPTION)

12 5A Room lamp 1

13 10A Room lamp 2

14 10A Room lamp 3 (OPTION)

15 10A Room lamp 4 (OPTION)

16 5ALuggage,

Public phone (OPTION)

17 15A Defroster

18 10A Reading lamp

19 5AExhaust brake

Water level relay

20 5AMeter panel,

Warning buzzer

21 20A Heater (OPTION)

22 10A Auto ventilator

23 10AHot/cold cabinet (OPT),

Preheater (OPTION)

24 15A TV/VTR (OPT)

25 10AChandelier (OPTION),

Auto grease power (OPT)

26 15A Starter key

27 10A Interrupt switch

28 15A Fog, Tail, Meter lamp

29 15A Battery main power(1)

30 10ABlink unit,

Park lamp (OPTION)

31 5A Auto door, door lock key

32 5A Clock, radio

33 10A Battery main switch

206

10 A

15 A

10 A

5 A

10 A

10 A

20 A

5 A

5 A

5 A

10 A

5 A

5 A

10 A

5 A

5 A

10 A

10 A

10 A

10 A

5 A

50494847464544434241403938373635343332313029282726

10 A

5 A

10 A

5 A

15 A

20 A

10 A

5 A

15 A

10 A

20 A

10 A

10 A

10 A

15 A

10 A

10 A

10 A

15 A

15 A

15 A

15 A

20 A

15 A

10 A

10 A

10 A

10 A

15 A

5

43

67

21

88

1 2

7 6

3 4

5A

5

43

67

21

8 8

1 2

7 6

3 4

5 5

43

67

21

8

5

4 3

6 7

2 1

88

12

76

34

55

4 3

6 7

2 1

8 8

12

76

34

5 5

4 3

6 7

2 1

8

B C D E

J I H G F

25242322212019181716151413121110987654321

BH117, BH120

<Type A>

207

FUSE NO FUSE NAME CONN. NO FUSE NO FUSE NAME CONN. NO1 15A HEAD LAMP (HIGH) A7, A8 26 15A READING LAMP (OPTION) J5, J62 10A HEAD LAMP (LOW) A1 27 5A STOP LAMP J43 10A ROOM LAMP FL 1 A2 28 10A ROOM MOOD LAMP (OPTION) J34 10A ROOM LAMP FL 2 A3 29 5A RADIO J25 10A ROOM LAMP FL 4 A4 30 10A DRIVER LAMP, LUGGAGE LAMP J16 10A PREHEATER POWER (OPTION) A5, A6 31 5A AUTO VENTILATOR J7, J87 15A DEFROSTER B1, B8 32 10A HEATER MIRROR, SEAT, DRIVER GLASS(OPT) 14, 158 20A A.B.S (OPTION) B2, B7 33 10A CHANDELIER ROOF, SIDE (OPT) 139 15A WIPER POWER B3, B6 34 10A SPOT LIGHT (OPTION) 12, 1710 15A TAIL LAMP B4, B5 35 10A SPEED IND. LAMP (OPTION) 1111 15A TV/VCR(OPT), CAR VISION(OPT) C7, C8 36 5A HORN 1812 15A WARNING LAMP C1 37 5A METER POWER, WARING BUZZER(OPT) H513 10A HOT/COLD CABINET (OPTION) C2 38 10A SPARE FUSE H3, H414 10A PUBLIC PHONE (OPTION) C3 39 5A SPARE FUSE H215 10A SPARE FUSE C4 40 5A SPARE FUSE H116 15A STARTER KEY POWER C5, C6 41 10A SPARE FUSE H817 10A TOILET POWER 1 (OPTION) D8 42 5A ENGINE STOP MOTOR H718 10A TOILET POWER 2 (OPTION) D1 43 5A EXHAUSR BRAKE G4, G519 10A NO SMOKING, SAFETY BELT LAMP D2, D7 44 5A AUTO GREASE POWER (OPTION) G320 20A HEATER POWER 1 (OPTION) D3, D4 45 20A HEATER POWER 2 (OPTION) G1, G221 10A TAIL LAMP 1 D5, D6 46 10A TAIL LAMP 2 F4, F522 15A BATTERY MAIN POWER (1) E1, 2, 7, 8 47 10A STAPTER CIRCUIT F3, 6, 7, 823 5A RADIO, CLOCK E3 48 5A AUTO DOOR, DOOR LOCK KEY F224 10A BATTERY SWITCH, PARKING LAMP E4 49 10A BLINKER UNIT F125 20A SPARE FUSE E5, E6 50 15A SPARE FUSE F7, F8

208

FUSE NO FUSE NAME FUSE NO FUSE NAME

1 FRONT STEP LAMP RELAY 10 STOP LAMP RELAY

2 HEAD LAMP HIGH RELAY 11 CHANDELIER LAMP RELAY

3 HEAD LAMP LOW RELAY 12 STARTER SAFETY RELAY

4 WIPER MOTOR LH RELAY 13 READING LAMP RELAY

5 WIPER MOTOR RH RELAY 14 ROOM LAMP RELAY 1

6 TV/VTR RELAY (OPTION) 15 ROOM LAMP RELAY 2

7 AUTO DOOR RELAY 16 MOOD LAMP RELAY (OPTION)

8 TAIL LAMP RELAY 17 WIPER CONTROL RELAY

9 FOG LAMP RELAY 18 ENG. PREHEATER UNIT

15 161413

7654321 12111098

1718

209

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

8

1 2

7 6

3 4

5B

8

1 2

7 6

3 4

5 8

1 2

7 6

3 4

5 8

1 2

7 6

3 4

5 8

1 2

7 6

3 4

5 8

1 2

7 6

3 4

5 8

1 2

7 6

3 4

5

8

12

76

34

5

8

1 2

7 6

3 4

5C D I

J

HGFE

10 A

10 A

20 A

10 A

15 A

10 A

10 A

10 A

10 A

30 A

15 A

10 A

10 A

10 A

15 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

20 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

10 A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

HEAD LAMP LOW HEAD LAMP HIGH WIPER INT TAIL LAMP ENG STOP MOTOR STOP LAMP HORN WIPER MOTOR RH WIPER MOTOR LH AUTO DOOR

A8

1 2

7 6

3 4

5

<Type B>

210

Fuse No. AMP. Fuse name

1 10A Room lamp 1

2 10A Room lamp 2

3 20A Heater (OPTION)

4 10A Head lamp LOW

5 15A Head lamp HIGH

6 10A Warning buzzer, Meter power

7 10A Exhaust brake

8 10A Auto grease power (OPTION)

9 10A Reading lamp

10 30A Heater (OPT), Defroster

11 15A Driver glass, Heater mirror (OPT)

12 10A Room lamp 3, Driver lamp

13 10A Step, Luggage, Phone lamp (OPT)

14 10A Cornering lamp

15 15A Tail lamp

16 10A A. B. S (OPTION)



19 10A Spare fuse

20 10A Engine stop motor

Fuse No. AMP. Fuse name

21 10A Engine stop motor

22 10A Ventilator

23 10A Hot/Cold cabinet (OPTION)

24 10A TV/VTR (OPTION)

25 10A Car vision (OPTION)

26 10A Spot light (OPT), Moodd lamp (OPT)

27 10A Chandelier roof (OPTION)

28 10A Horn, stop lamp

29 20A Wiper

30 10A Spare fuse

31 10A Battery relay

32 10A Parking (OPT), Blinker unit

33 10A Auto door, Door lock key

34 10A Clock, Radio

35 15A Spare fuse

36 10A Stater circuit

37 10A Tail lamp

38 10A Preheater (OPTION)

39 10A Spare fuse

40 10A Spare fuse

211

NO NAME NO NAME

1 Auto door relay 5 Blinker relay RH

2 Water level relay 6 Blinker unit

3 Heater mirror relay (OPTION) 7 Wiper motor control box

4 Blinker relay LH 8 Preheater control unit (OPTION)

1 2 3 4 5 6

78

212

1. Cover RR fuse box2. Bracket Rr fuse box3. Regulator Assembly4. 18P Fuse box

Rear fuse box (DE12T/Ti/TiS ENG)

1

3

4

2

213

1. Cover2. 18P Fuse box3. Regulator Assembly4. Starter Auxiliary relay

Rear fuse box (DV15T/TiS ENG)

1

2

34

214

LUBRICATION

Lubrications should be carefully selected according to the lubrication chart it is important to select viscosity of Lubricantsaccording to the ambient temperature by refering to the following table.

VISCOSITY CHART

Engine oil Gear oil

SAE 20 20W

SAE 30SAE 10W

SAE 10W �-30

SAE 10W -40

SAE 15W 40. 15W 50. 20W 40. 20W 50

SAE 5W 20

SAE 40.50

AmbientTemperature

-30 C(20 F)

-15 C(10 F)

-0 C(32 F)

15 C(60 F)

25 C(80 F)

33 C(90 F)

AmbientTemperature

-30 C(20 F)

-15 C(0 F)

-0 C(32 F)

20 C(70 F)

30 C(90 F)

10 C(50 F)

-25 C(10� F)

SAE 80W

SAE 85W

SAE 90

SAE 80W �90

SAE 140

SAE 80W �140

SAE 85W �140

SAE 75W 80

215215

Lubrication list

Capacity Oil change periodDE12T/Ti : 20 Initial : 1,000km(OIL PAN : 17 ) Inter city or long distance

DV15T : 27 travel bus, every : 15,000km(OIL PAN : 24 ) City bus, every : 10,000km

DE12TiS : 22 Initial : 1,000km

(OIL PAN : 19 ) Long distance : every30,000km

DV15TiS : 23 Short distance : every(OIL PAN : 20 ) 20,000km

Every : 1 year

LubricantEngine oil

Engine coolant

Lubrication ListEngine

Radiator

SpecificationCF Grade(Frigid an area : 15W30(Except Frigid an

area : 15W40)

API CH–4 grade(SAE 15W40)or ACEA E2/E3 grade

Anti–freeze LLC Grade

Inhibitor DCA65L(1% of engine coolant involume)

DE12T/Ti/TiS(310ps) : 63(67)

BH116DE12Ti/TiS(340ps) : 65(69)

BH117DE12Ti/TiS : 69(74)

DV15T/TiS : 70(75)

BH120 DV15T/TiS : 73(77)

AREAMixing Freezing

ratio(%) point(°C)RUSSIA(Frigid) 55(%) –48(°C)SOUTHEAST ASIAMIDDLE EAST 30(%) –12(°C)AFRICASOUTH AMERICA

TAIWAN 50(%) –38(°C)OTHERS 30(%)~40(%) –16(°C)~–25(°C)

216

Lubricant Lubrication List Capacity Oil change period SpecificationGear oil Initial : 5,000km GL–4 Grade(80W/90)

Every : 20,000km

Auto lnitial : 1 year or 8,000km DEXRON–IIE, IIItransmission or 200h

Every : 1.5 year or 40.000km or 1,000h

When use oil list of G607 : DEXRON–IIEevery 60,000km

When use oil list of G1363 : ATF IIE,every 100,000km ATF E-SInitial : 1,000km ATF TYPE A,Every : Suffix A,normal operation temp : DEXRON–IID

1 year or 30,000kmhigh operation temp. :

1 year or 20,000kmRear axle 11.5–12.5 Initial : 5,000km GL–5 (80W/90)

Every : 20,000km

B400R 25

B500R 45

D851.2D863.2 28D854.2D864.2

4HP5005HP500

304HP5905HP600

K1005CK1005P 9.7K1205PK1205CK1006R 11.2K1206RT–10S5B 13.0K1405A 14.5K1406P 16.0

Manual Transmission

217

Lubricant Lubrication List Capacity Oil change period Specification

Power steering Power steering BH116 Initial : 1,000km DEXRON R–

BH117 Every 24,000km

BH120

Brake oil Brake and clutch 4L Every : 1 year or 60,000km DOT 3, DOT 4 Multipurpose EP No.2

Grease Wheel bearings Needed quantity When hub repair Multipurpose type grease

Grease fittings Manual : Every 4,000km NLGI No.2 or 3

Auto grease KLGI No. 000.00

7L

7.5L

218

Moving parts(every 4,000km)

King pin (4 points) Link arm (1 point) Tie rod end (2 points)

Drag link-FRT (2 point)Propeller shaft (3 points)Steering shaft (1 point)

219

Drag link-RR (2 points)

220

AUTO GREASING (OPTION)

Auto control

Grease pump operates periodicallyset by control unit, singnal lamp “ON”simultaneously with grease pumpoperation and keep lighting 42 secondand “OFF”. If the pressure in mainline is less than specified value,singnal lamp keeps lighting “ON” evenat the rest time. When Battery mainswitch is turned “OFF”, the signal lamp also “OFF”. After troubleshooting,if normal pressure is available, thesignal lamp operation returns tonormal condition.

Operation

In main switch “ON”, the operationand rest time repeat periodically.When main switch “OFF”, timerecording stops and is memoried tothe unit. Main switch “ON” again, timerecording continues and the systemoperates again.

Manual operation

Grease can be pumped manually bypushing manual switch(DK) equippedbeside of unit. After manual operation,the rest time set returns to “O”.

Grease replenishment

Check the amount grease in thetransparent jar of gear pump unit,frequently and replenish if necessary,use clean and same type grease.

Pump operation time 154 second

Signal lamp lighting time 42 second

Rest time (adjustable) 0.5,

1.2 11hours


221

Trouble check

Symptoms and diagnosis

SYMPTOMS

Manual operation switch is pushed

on, but signal lamp doesn’t “ON”.

Signal switch keeps lighting about 3

minutes.

Lack of grease delivery

Excessive grease delivery

CAUSE

Lack of grease in transparent jar.

Leakage of grease in main line.

Trouble of pressure switch, control unit

and signal lamp or incorrect wiring

Foreign parts in main line

Inadequate capacity of metering nipple

Inadequate time set of control unit

Inadequate capacity of metering nipple.

REMEDY

Replenish grease

Inspect fitting and correct leakage part.

Change damaged part and correct

wiring.

Check the pressure in main line and

clean.

In normal condition, the operation

pressure is over 30bar, after operation

the pressure go down below 10bar

quickly.

Change metering nipple

Readjust time set

Change metering nipple

Troubleshooting is not possible, turn “OFF” main switch and disconnect terminal connected to control unit ot stopthe operation. (stop the rest time memoried in control unit.)

CAUTION

222

0.5 4 8 12 16 20 24 28 32 36 40 44 48 DINSPECTION POINTS PERIOD : 1000 KmENGINE

Check easiness of engine starting and abnormal noiseCheck idling speed and accelerationCheck and clean air cleanerChange air cleaner elementAdjust valve clearancesCheck fuel injection time, and fuel injection nozzle pressureCheck compression pressure in each cylinderCheck for oil contaminationDrain fuel filter and clean fuel strainerChange fuel filter cartridgeClean fuel tank insideCheck exhaust gas and adjustmentCheck function of air compressor and turbo-chargerCheck exhaust pipes for looseness (every 100,000km)Check fan belt for damage

SCHEDULED MAINTENANCE SERVICEMaintenance of periodic inspection service and retention of records are owner’s responsbility. The owner should retainrecods and carry out maintenance service in accordance with maintenance service chart.Those are very important checking items which have to be checked for general vehicles. As this maintenance servicechart is based on the vehicle which travels about 4,000km per month under normal driving condition, it is requested toreduce interval of the periodic inspection for vehicle which travels over 4,000km per month or under severe drivingcondition than normal. It is requested to check another items, if necessary even not mentioned this chart.

MAINTENANCE SERVICE CHART

* For engine oil and filter cartridge change Refer “periodic inspection and maintenance”.

(Every 60,000 km)

(1,000km)

(10,000km) (30,000km)

223

INSPECTION POINTS PERIOD : 1000 Km

CLUTCH

Check function of clutch system

Check clutch pedal free play and pedal stroke

Check minipack exhaust cover

Change clutch oil

TRANSMISSION

Check for oil leakage and oil fill up

Change oil

Check for looseness in linkage

PROPELLER SHAFT

Check loose connections (every 5,000km)

Check splines for excessive wear

Check for looseness in bearing and related parts

Grease the universal joints and spline

FRONT AXLE & REAR AXLE

Check front wheel bearing looseness

Check rear wheel bearing looseness

Check for looseness clamp bolt on axle shaft

Check for oil leakage in rear axle shaft and oil fill up

Change front and rear hub bearing grease

Change rear axle oil

0.5 4 8 12 16 20 24 28 32 36 44 48 D

(Every 1 year or 60,000km)

(When take off and attachment)

(Initial 5,000km, every 20,000km)

40

(1,000km)

(1,000km)

(5,000km)

224

48 D44403632282420161280.5INSPECTION POINTS PERIOD : 1000 Km

SUSPENSION

Retighten “U” bolt & nut

Check spring for damage

Check mount for looseness and damage

Check shock absorber for leakage and damage

Check shock absorber mount

Grease spring pin and shackle pin

WHEELS

Check for presence of foreign matters(nails, stones, etc.)

Retighten wheel nuts as necessary

Check wheel discs for damage

STEERING

Check for looseness in mount

Check steering wheel free play

Check steering linkage for damage, loosenessand excessive play

Check for oil leakage in gear box

Check clearance between king pin & bearing

Check wheel alignment

Change power steering oil

4

(1,000km)

225

48 D44403632282420161280.5INSPECTION POINTS PERIOD : 1000 Km

SERVICE BARKE

Check function of brake system and air dryer

Check brake pedal free play

Check for air leakage

Check linings for wear

Check brake drums for wear and damage

Check hoses and pipes for leakage, damage

Change brake oil

PARKING BRAKE

Check function of parking brake

ELECTRICAL EQUIPMENT

Check charge state of battery

Check function of starter

Check function of generator & regulator

Check generator brushes for wear

Check starter brushes for wear

Check terminals of wiring for damage

4

Refer to above–mention chart field “D” means daily inspection point ( Daily check Check for needs)Inspection markChange mark

(Every 1 year or 60,000km)

226

TROUBLE SHOOTING

ENGINE

Starter motor does not turn over or turning is slow.

Start motor turns over but engine won’t start

Engine stops at low speed

CAUSE

Malfunction of contact point of battery relay.Run down batteryLoosened, corroded or disconnected battery terminal

Ground cable cutToo thick oil viscosity

REPAIR

Turn “ON” battery main switchBattery charging or changeRemove the corroded part of battery teminal withchiesel, retighten connector and apply grease.Be sure to connect the wiringChange oil with proper viscosity

CAUSE

Empty fuel tankNone sufficient preheatingAir mixed in fuelClogged fuel filter

REPAIR

Refill or replenishPreheat exactly and sufficientlyBleed air in fuelClean filter element or change

CAUSE

Too low idle rpmAir cleaner element contaminationOver cooled engineClogged fuel filterValve clearance deviated

REPAIR

Adjust idle rpm with knob.Clean element or changeCover radiator with curtainClean filter element or changeAdjust valve clearance

227

Engine lacks power

Engine overheat

Black smoke

CAUSE

Parking brake not releasedAir cleaner element contaminationBrake detentionIncorrect valve clearanceClutch slipClogged fuel filterClogged fuel strainerWear out of position ring

REPAIR

Fully release parking brakeClean element or changeAdjust the clearance of brake liningAdjust valve clearanceAdjust the clearances or change clutch disc.Clean or changeClean or changeCheck cylinder pressure and repair

CAUSE

Radiator curtain covered or Radiator contaiminationLack of coolant

Fan belt loosenedRust or scale in coolantMalfunction of thermostat

REPAIR

Uncover radiator curtain or clean radiatorReplenish coolant, check leakage and radiator captightly closed.Don’t open radiator cab when coolant is hot.Adjust fan belt tension or change fan belt if damaged.Change coolant or clean in side of the radiatorChange thermostat

CAUSE

Air cleaner contaminationIncorrect valve clearance

REPAIR

Clean air cleaner element or changeAdjust valve clearance

228

Excessive fuel consumption

Lack of engine oil pressure

Excessive engine oil consumption

CAUSE

Fuel leakageAir cleaner contaminationEngine overcoolingLack of tire inflationBrake detentClutch slip

REPAIR

Check fuel line and repairClean air cleaner element or changeCover radiator with curtainInflate tire to specified value.Adjust the clearance of brake liningAdjust the clearance or change clutch disc.

CAUSE

Lack of engine oilOil leakageImproper oil viscosity

REPAIR

Replenish to specified levelCheck lubrication line and retighten loosened fittingChange oil with proper viscosity

CAUSE

Improper oil specificationExcessive oil amountOil leakageDelayed oil changing periodNeglected engine warmingPiston ring wear out

REPAIR

Change oil with proper specificationChange oil level to specified value.Check lubrication line and retighten loosened fittingChange oil periodicallyWarm up engine to specified temperatureCheck cylinder pressure and repair

229

POWER TRAIN

Abnormal noise in transmission or rear axle in operation

Abnormal vibration in operation

STEERING

Hard steering

Non return to straight position

CAUSE

Lack of gear oilImproper oil viscosity

REPAIR

Replenish to specified levelChange oil with proper specification

CAUSE

Loosened bolts and nuts of propeller shaft andperipheral parts.Unbalanced propeller shaft

REPAIR

Check and retighten

Modify propeller shaft or change

CAUSE

Lack of front tire inflationLack of oil of power steering

REPAIR

Charge air to specified pressureReplenish or discharge

CAUSE

Lack of grease in parts of steering systemInterference between drag link joint and peripheralparts

REPAIR

Insert greaseCheck and correct

230

Steering wheel shimmy

BRAKE

Poor brake action

Side braking

CAUSE

Loosend hub nutDifferent tire inflation of “RH” and “LH”Irregular tire wearExcessive handle clearanceWorn out drag link coil springWorn out knuckle shim

REPAIR

Replenish to specified levelCharge air to be sameChangeAdjust steering wheel clearanceChange to new oneChange shim or adjust

CAUSE

Excessive tire inflationLeakage of brake lineExcessive lining clearanceExcessive tire wear

REPAIR

Charge to specified pressureCheck the connection and correctAdjust the clearance and change liningChange to new tire

CAUSE

Different tire inflation of “RH” and “LH”Side wear of tireDifferent lining clearances of “RH” and “LH” wheel

REPAIR

Charge to be same pressureChangeAdjust clearances correctly

231

Detent braking

SUSPENSION

Different vehicle height

Meandered advancing

CAUSE

Damaged or mislocated springTire inflation or puncture

REPAIR

Check the spring and repairCheck tire and correct

CAUSE

Radius rod cutImproper location axle

REPAIR

Change radius rodAdjust the location

CAUSE

Improper lining clearance

REPAIR

Adjust clearance properly

232

ELECTRICAL

Excessive battery discharging

LAMP DOESN’T LIGHT “ON”

CAUSE

Battery terminal disconnected, loosened, corroded.

Aged batteryV-belt slip or cutKeeping lamp lights “ON”Improper alternator charging

REPAIR

Remove corroded part of battery terminal with chiesel,retighten connector and apply grease.ChangeCheck belt tension, adjust or changeBe sure to turn “OFF” switchCheck alternator charging condition and repair.

CAUSE

Lamp faultyFuse cut

Non–complete ground

REPAIR

Change lampChange to specified fuse (Even after changing to newfuse, fuse cut again, precise inspection is necessaryand be sure not to use deviated fuse.Be sure to ground completely

233

SMOKE

Cause and repair of smoke

CAUSE

Low idle RPM

Maximum speed increase

Plunger worn out

Delivery valve worn out, damaged

Deviated flow rate

Blocked nozzle tip

Enlarged nozzle tip injection hole

Injection pressure down

Piston ring worn out, cut

Cylinder liner worn out, damage

Piston worn out, damaged

Poor contact of valve and valve seat

Head gasket damaged, poor sealing

Poor nozzle assembly

Incorrect injection timing

Incorrect timer angle adjustment

DESCRIPTION

Excessive fuel

injection

Poor nozzle injection

Compression pressure

down

Incorrect timing of

injection pump

REPAIR

Adjust idle RPM

Adjust maximum speed

Change plunger

Change delivery valve

Adjust flow rate

Change nozzle tip and holder

Change nozzle tip

Adjust injection pressure

Change piston ring

Change cylinder liner

Change piston

Change valve

Change head gasket

Reassemble nozzle or change

Adjust injection timing

Adjust timer angle

234

CAUSE

Air cleaner element contamination

Lack of capacity of air cleaner

Incorrect intake valve clearance

Intake ducts blcoked or deformed

Leakage of turbo charged air

Malfunction of turbo charger

Exhaust gas manifold blocked

Incorrect exhaust valve clearance

Overloaded

Excessive engine oil

Piston stuck by overheat

Metal bearing burnt

Fuel quality poor

Water mixed fuel

Fuel filter contamination

DESCRIPTION

Lack of intake air

Excessive exhaust

Pressure

Overload operation

Poor quality of fuel

REPAIR

Clean air cleaner or change

Change to genuine part

Adjust valve clearance

Change intake ducts

Check and repair leaking parts

Change turbo charger

Change exhaust manifold

Check or change

Unload to specified value

Extract oil to specified level

Change piston, piston ring and related

parts.

Change metal bearing

Use specified fuel

Clean fuel tank and remove water

Clean fuel filter or change

235

MAIN DATA AND SPECIFICATION

1. ENGINE1-1. DE12T/Ti, DV15T ENGINE

Distinction DE12T DE12Ti(310ps) DE12Ti(340ps) DV15T

water cooled 4 cycle in – line, overhead valve type

dry type wet type

compression ring : 2ea oil ring : 1ea

6 ← ← 8

123 155 ← ← 128 142

11051 ← ← 14618

17.1 : 1 16.1 : 1 ← 16.5 : 1

1317 ← ← 1290

847 ← ← 1024

1064 ← ← 1023

900 910 ← 920

600 ± 50 ← ← ←

BTDC 9 BTDC 12 ← BTDC 7

1 5 3 6 2 4 ← ← 1–5–7–2–6–3–4–8

BTDC 18 ← ← BTDC 12

ABDC 34 ← ← ABDC 48

BBDC 46 ← ← BBDC 61

ATDC 14 ← ← ATDC 11

Type

Cylinder liner type

No. of piston ring

No. of cylinder

Bore stroke(mm)

Piston displacement(cc)

Compression ratio

Engine

dimensions(mm)

Engine weight(dry) (kg)

Idle speed

Fuel injection timing

Fuel injection order

Intake vlaves

Exhaust valves

length

width

height

open at

close at

open at

close at

236

Distinction DE12T DE12Ti(310ps) DE12Ti(340ps) DV15T

gear type

water cooled, integral type

ENG.TOT. : 20 , OIL PAN : 17 ENG.TOT. : 27 , OIL PAN : 24

fresh water forced circulation

19 ← ← ←

centrifugal type

wax pellet type

220(300)/2200 227(310)/2100 250(340)/2100 268(365)/2300

1078(110)/1300 1225(125)/1260 1323(135)/1260 1353(138)/1300

24 × 5.4 ← ← 24 × 6.6

rear ← ← ←

24 × 150 ← ← 24 × 200

Oil pump type

Oil cooler type

Oil capacity(liters)

Cooling method

Cooling water capacity(liters)

Water pump type

Thermostat type

Max. output(kW(ps)/rpm)

Max. torque(N·m(kg.m)/rpm)

Starter motor output(V × kW)

Engine location

Battery capacity(V × AH)

237

MAIN DATA AND SPECIFICATION

1. ENGINE1-2. DE12TiS, DV15TiS ENGINE

Distinction

Tpye

Cylinder liner type

No. of piston ring

No. of cylinder

Bore stroke(mm)

Piston displacement(cc)

Compression ratio

Engine

dimensions(mm)

Engine weight(dry) (kg)

Idle speed(rpm)

Fuel injection timing

Fuel injection order

Intake vlaves

Exhaust valves

length

width

height

open at

close at

open at

close at

DE12TiS(310ps)

6

123 155

11051

17.0 : 1

1317

847

1064

910

600~650

BTDC 1

BTDC 18

ABDC 32

BBDC 70

ATDC 30

DE12TiS(340ps)

←

←

←

←

←

←

←

←

←

←

←

←

←

←

DV15TiS

8

128 142

14618

17.4 : 1

1112

1024

1015

950

550~600

BTDC 5.5

1–5–7–2–6–3–4–8

BTDC 15

ABDC 35

BBDC 71.5

ATDC 15.5

1 5 3 6 2 4

water cooled 4 cycle in - line, overhead valve type

dry type wet type

compression ring : 2ea oil ring : 1ea

Distinction

238

Oil pump type

Oil cooler type


Cooling method

Cooling water capacity(liters)

Water pump type

Thermostat type

Max. output(ps/rpm)

Max. torque(kg.m/rpm)

Starter motor output(V × kW)

Engine location

Battery capacity(V × AH)

DE12TiS(310ps)

19

310/2100

125/1260

24 × 6.0

rear

24 × 150

DE12TiS(340ps)

←

340/2100

145/1260

←

←

←

DV15TiS

21

390/2200

160/1300

24 × 6.6

←

←

gear type

water cooled, integral type

ENG.TOT. : 20 OIL PAN : 17 ENG.TOT : 23 OIL PAN : 20

fresh water forced circulation

centrifugal type

wax-pellet type

239

2. CLUTCH

Distinction BH116 BH117 BH120

dry single plate with coil spring dampers hydraulic circuit

incorporating clutch minipack

430 ← ←

250 ← ←

5 ← ←

1950 ±10%

2100 ±10%

2320 ±10%

6.75 ← ←

47.2 47.4 ←

170 ← ←

5.5 ← ←

20 ← ←

Type

Clutch facing

dimensions(mm)

Clutch clamping

force(kg)

Clutch pedal

Clutch minipack

start working pressure(kg/cm2)

Master cylinder bore dia.(mm)

outside dia

inside dia

thickness

DE12T

DE12Ti/TiS(310ps)

DE12Ti/TiS(340ps)

DV15T/TiS

ratio

free play

max. stroke

240

3. TRANSMISSION

3–1. Manual transmission

MODEL

SPEED

TORQUE(kgm)

1ST

2ND

GEAR3RD

RATIO4TH

5TH

6TH

REV

DRY WEIGHT(kg)

OIL CAPACITY( )

T–10S5B

5.D.D

125

6.589

4.002

2.430

1.507

1.000

–

6.888

250

13

T–13S5B

5.D.D

135

6.589

4.002

2.430

1.507

1.000

–

6.888

250

13

K–1005C

5.D.D

115

6.608

3.993

2.423

1.518

1.000

–

6.937

250

9.7

K–1005P

5.O.D

115

5.500

3.323

1.782

1.000

0.755

–

5.774

250

9.7

K–1006R

6.O.D

115

5.500

3.482

2.147

1.348

1.000

0.755

5.774

260

11.2

K–1205C

5.D.D

125

6.608

3.993

2.423

1.518

1.000

–

6.937

250

9.7

K–1205P

5.O.D

125

5.500

3.323

1.782

1.000

0.755

–

5.774

250

9.7

K–1206R

6.O.D

125

5.500

3.482

2.147

1.348

1.000

0.755

5.774

260

11.2

K–1405A

5.D.D

145

6.608

4.184

2.580

1.518

1.000

–

7.003

290

14.5

K–1406P

6.D.D

145

6.608

4.184

2.580

1.618

1.000

0.759

7.003

340

16.0

241

3–2. Auto transmission

MODELSPEED

TORQUE(kgm)

1ST

2ND

GEAR3RD

RATIO

4TH

5TH6TH

REV

DRY WEIGHT(kg)OIL CAPACITY( )

B400R4DD/5OD/6OD

125.4

3.49

1.86

1.41

1.00

0.750.65

5.03

22725

B500R4DD/5OD/6OD

179.6

3.51

1.91

1.43

1.00

0.740.64

4.8

41245

D851.23.D.D102

3N 6.23S 5.94N 5.44S 5.1

3N/3S 1.434N/4S 1.363N/3S 1.004N/4S 1.00

–

––

3N 5.23S 4.74N 4.34S 3.8

29528

D8633.D.D132.7

–3S 5.94N 5.44S 5.1

3N/3S 1.434N/4S 1.363N/3S 1.004N/4S 1.00

–

–––

3S 4.74N 4.34S 3.8

30028

D854.24.O.D102

3N 6.23S 5.94N 5.44S 5.1

3N/3S 1.434N/4S 1.363N/3S 1.004N/4S 1.003N/3S 0.704N/4S 0.73

––

3N 5.23S 4.74N 4.34S 3.8

33028

D8644.O.D132.7

–3S 5.94N 5.44S 5.1

3N/3S 1.434N/4S 1.363N/3S 1.004N/4S 1.003N/3S 0.704N/4S 0.73

–––

3S 4.74N 4.34S 3.8

33528

HP5004DD/5OD/6OD

112.2

3.43

2.01

1.42

1.00

0.830.59

4.84

31030

HP5904DD/5OD/6OD

127.6

3.43

2.01

1.42

1.00

0.830.59

4.84

31530

HP6004DD/5OD/6OD

142.9

3.43

2.01

1.42

1.00

0.830.59

4.84

33030

242

DistinctionDE12T DE12Ti/TiS(310ps) DE12Ti/TiS(340ps) DV15T DV15TiSBH116 BH116 BH116/BH117 BH117/BH120F BH117/BH120F

K1005CK1005P

K1006R

T-10S5B

K1205CK1205P

K1206R

K1405A

K1406P

T16DS5A

K1605A

lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.

600.2101.691.6400.7101.691.6569.9101.691.6

569.9101.691.6600.2101.391.6400.7101.691.6

541.4101.691.6

730.3101.691.6620.3101.691.6

709.8114.3101.1678.0114.3101.1

4. PROPELLER SHAFT4–1. Manual transmission

243

DistinctionDE12T DE12Ti/TiS(310ps) DE12Ti/TiS(340ps) DV15T/TiSBH116 BH116 BH116/BH117 BH120F

B400R

B500R

D851.2

D854.2

D863

D864

HP500

HP590

lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.lengthoutside dia.inside dia.

555.8114.3101.1482.8101.691.6599.3101.691.6

555.8114.3101.1482.8101.691.6

599.3101.691.6

4. PROPELLER SHAFT4–2. Auto transmission

244

5. FRT AXLE

BH116 BH117 BH120

Reverse Elliot I Beam

2050

6500

50

252

0–2

0.5° ± 30'

1°30' ± 30'

7.5° ± 10'

45°

37°

Type

Tire. Tread(mm)

Capacity(kg)

King pin(mm)

Wheel alignment

Steering angle

outside dia.

length

toe in(mm)

camber(°)

caster(°)

kingpin

inclination(°)

inside(°)

outside(°)

245

6. REAR AXLE

BH116 BH117 BH120

Banjo full floating type

Hypoid gear

39/10 – –

39/11 39/11 39/11

39/12 39/12 39/12

11.5–12.5

10500 ← ←

Type

Final drive gear type

Final gear ratio OPTION

Oil capacity (Iiters)

Axle load capacity (kg)

246

7. STEERING


Recirculating ball with intergral power assisted

500 ← ←

22.4 : 1 ← ←

96° ← ←

1.5 ← ←

200 ← ←

7 ← 7.5

Type

Steering wheel diameter(mm)

Power steering

Length of drop arm(mm)


gear ratio

sector gearoperating angle

gear oilcapacity( )

247

8. BRAKES


Full air

410

410

209 155 19 8

209 220 19 8

30 106.5

30 121.5

Service brake type

Drum inside

Diameter(mm)

Brake lining(mm)

L W T N

Wheel cylinder

bore dia.(mm)

Anchor pin(mm)

dia. lengh

front

rear

front

rear

front

rear

front

rear

248

9. SUSPENSION

Air spring

FRT RR

DistinctionBH116 BH117 BH120

BH116BH117 BH120

STD WIDE

Air

Spring

Shock

Absor–

ber

L/V

type

effective dia.(mm)

design height(mm)

max.out. dia(mm)

no.of springs

stroke of ext.

spring(mm) comp.

type

out. dia.(mm)

base shell dia.(mm)

no. of S/A

extension(mm)

compression(mm)

no of levering valve

Variable throttle type with stabilizer

250 260 ← 250 ← ← ←

270 ← ← 270 260 ← ←

310 316 ← 310 ← ← ←

2 ← ← 4 ← ← ←

100 ← ← 100 ← ← ←

100 ← ← 100 ← ← ←

Double acting telescopic type

86 ← ← 86 74.5 ← ←

76.3 ← ← 76.3 65 ← ←

2 ← ← 2 4 ← ←

594 ← ← 545 710 ← ←

384 ← ← 338 465 ← ←

1 ← ← 2 ← ← ←

249

Disc wheel size

OUT.Dia.(mm)

MAX.width(mm)

10. WHEEL AND TIRES

front

rear

Tireinflationpressure

Tire

Distinction9.00-20-14PR

(Tube)

9.00R20-14PR

(Tube, radial)

10.00-20-14PR

(Tube)

10.00-20-16PR

(Tube)

10.00R20-16PR

(Tube, radial)

11.00-20-16PR

(Tube)

11.00R20-16PR

(Tube, radial)

11R22.5-16PR

(Tubeless)

12R22.5-16PR

(Tubeless)

295/80R22.5-16PR

(Tubeless)

1014~1034

229

7.7kg/cm2(109psi)

7.0kg/cm2(99psi)

7.00T–20

1006~1032

←

8.0kg/cm2(113psi)

7.3kg/cm2(103psi)

←

1046~1076

254

7.0kg/cm2(99psi)

6.3kg/cm2(89psi)

←

←

←

8.1kg/cm2(115psi)

7.4kg/cm2(105psi)

←

←

←

←

←

←

1078~1108

295

8.4kg/cm2(119psi)

7.7kg/cm2(109psi)

7.50V-20

1068~1098

293

←

←

←

1037~1067

295

←

←

8.25 22.5

1068~1098

305

←

←

←

1030~1058

295

8.3kg/cm2(118psi)

8.3kg/cm2(118psi)

←

250

11. COOLER

11–1. Roof on cooler

Type Tropical type Heavy duty type

Compressor 1 ←

Cooling capacity(kcal/h) 24000 26000

Refrigerant R–12/R–134a (OPTION) ←

4PFC/4PFCY(OPTION) ←

4 ←

Compressor 210 ←

57 ←

560 ←

CondenserAL FIN & CU TUBE ←

0.762 ←

CondenserPROPELLER FAN 5 ←

fan7200 ←

5.5A/EA ←

type

no. of cylinder

diameter(mm)

stroke(mm)

capacity(cc/rev)

type

total area(m2)

type

capacity(m3/h)

required power(A)

251

Receiver HORIZONTAL ←

tank 3.4 ←

EvaporatorAL FIN & CU TUBE ←

0.346 0.505

EvaporatorSIROCCO FAN × 8 SIROCCO FAN × 12

fan400/EA ←

5.5A/EA ←

Expansion EXTERNAL EQUALIZING PRESSURE

valve 8 ←

Total weight(kg) 218 240

type

capacity(liters)

type

total area(m2)

type

capacity(m3/h)

required power(A)

type

capacity (RT)

252

11–2. Sub cooler

Type

Cooling capacity(kcal/h)

Refrigerant

Weight

model

pistondisplacement(cc)

Engine no. of cylinder

rotating high

midspeed(rpm) low

type

Compressor pistondisplacement(cc/rev)

Condenser

Blower capacity(m3/min) (AT 40mm Aq)

Expansion valve

Receiver capacity(liters)

PBC 2400(D)

26000

R-12/R-134a (OPTION)

about 550

DWH–DC23 or KIA-S2

2238 or 2209

4

1850

1450

1150

ND 6C 500

495

AL FIN & CU TUBE

66.7

thermostatic expansion valve

2.6

253

BODY DIMENSION

BH116

(AP

PR

OX

)31

10

2050

1853

(AP

PR

OX

)32

25

452225610031107011550

2490

254

(AP

PR

OX

)32

50

2050

1853

(AP

PR

OX

)33

65

452425610031107011750

2490

BH117

255

70 3080 6500 2280 70

2490

2050

3415

(AP

PR

OX

.)33

00(A

PP

RO

X.)

1853

12000

BH120

BH116 / BH117 / BH120OWNER’S & DRIVER’S MANUAL

TECHNICAL CENTER

75-11, GUMSA-DONG, GUMJUNG–KU,BUSAN, KOREA

OM–BH–C1–09C–0306

important service activities

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