important service activities - daewoo bus · this manual has been prepared to acquaint you with the...

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

D1146DE12

102 PageEngine oil

DE08TiS

Engine oil filter Change with engine oil 103 Page

D1146Fuel filter

105 Page

DE08TiS

DE12Chang at every 20,000km.

Valve clearance Adjust at end of first 1,000km and every 20,000km there after. 110 Page

Air cleaner Change at every 4,000km, change at every 12,000km there after. 115 Page

Transmission oil Change at end of first 5,000km and every 20,000km there after. 117 Page

Rear axle oil Change at end of first 5,000km and every 20,000km there after. 118 Page

Power steering oil Change at end of first 1,000km and every 24,000km there after. 119 Page

Power steering filter Change at end of first 1,000km and every 24,000km there after. 121 Page

Change : At end of first 1,000km,High–speed, long distance : every 15,000kmIn city, short distance : every 10,000km

Change : At end of first 1,000km,long distance : every 30,000kmShort distance : every 20,000km

Primary filter : clean at every 5,000km,change at every 15,000km there after.

Secondary filter : change at every 5,000km.

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.

DAEWOO MOTOR CO., LTD.BUSAN, KOREA

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 13

5. DRIVING 73

6. INSPECTION AND MAINTENANCE 101

7. LUBRICATION 154

8. SCHEDULED MAINTENANCE SERVICE 159

9. TROUBLESHOOTING 163

10. MAIN DATA AND SPECIFICATION 172

11. BODY DIMENSION 188

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

Type B : Applicable for vehicles inGCC members.

( I )

( II )

Chassis number

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

3

Engine number Key

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

door(OPTION)• Door

– Entrance door operating– Driver door(OPTION)– Fuel inspection door(OPTION)– Tool box door(OPTION)– Luggage doors(OPTION)– Battery inspection door(OPTION)

The keys are not 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

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) beforestarting 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 capacity.

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

D1146High–speed, long distance :

every 15,000kmDE12 In city, short distance :

every 10,000km

At end of first 1,000km

DE08TiS Long distance : every 30,000km

Short distance : every 20,000km

6

GETTING ON AND OFF, DRIVER’S SEAT AND BELT

DOOR OPENING AND CLOS-ING(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.

DOOR OPENNING AND(Applicable for vehicles in allentrance door except mechanicalkey)

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.

IDLING

H..L

68

10

12

4

2

0AIR

km/mm

SWVOL

PushLOC TONE BAL

SEEK BAND LOUD

MICVOLUMERADIO/MICPOWER

OFF

ON

RADIO

MIC

MIN MAX LAW

EJ

1 2 3 4

OFF MAX LO MI L R

Before operating entrance key, unlockmechanical key on door frame.

NOTICE

When opening front entrance door for a long time, setting emergency valve at manual posi-tion and put control switch in close position. When returning to automatic condition, puttingcontrol switch and door in same condition and set emergency valve at automatic position.

CAUTION

7

1. Back angle adjustmentTo adjust the seat back, turn No. 1 handle, and leanbackwards and foreward until the desired angle isachieved.

2. Slide adjustmentTo move the seat forward and backward.Pull No. 2 lever, forward and slide the seat.

3. Height(Tilting) adjustment.Desired the seal height can be achieved by pullingNo. 3 lever upward and downward.

2

1

2

3

1

DRIVER’S SEAT AND BELT

Adjustment of non suspension type driver's seat (S-104H Type)

8

How to use non suspension seat

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

Height Adjustment Back AngleSlide Adjustment

9

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

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

10

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

11

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

12

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

13

INSTRUMENTS, SWITCHES AND CONTROLS

31

14

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 (OPTION)

Speedometer (OPTION)

10 Door opening switch (FRT)

11 Air pressure gauge (OPT)

12 Microphone stand

13 Radio & Cassette player

14 Switches

15 Battery OPEN/CLOSE switch

16 Parking brake lever

(For AOH brake)

17 Rear wiper control switch(OPT)

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

(For full air brake)

29 Clutch oil tank

30 Warning lamp switch(OPTION)

31 Sub cooler controller(OPT)

15

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

Fixed type

Starter switch

Starter switch operates in the 4stages as follows :

LOCK : The key can be inserted orremoved only when the switch is inthis position.ACC : This position turns on theradio, digital clock, cigarette lighterand consent.

16

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

Pilot indicator lamps

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

17

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

18

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.

19

PERIPHERAL DEVICES OF STEERING COLUMN

Idle control knob

Turning the knob clockwise aftercold starting of the engine willincrease idling speed and thus facili-tate quick normalization of theengine coolant temperature.

Always drive with the knob turnedback home.

Battery switch

It controls the entire electrical cir-cuits with the exception of parkinglamps, hazard warning flashers. Theelectrical circuits are energized whenthe battery main switch is pressed.

Rear wiper switch (OPTION)

• Washer push button (1)push (ON) : To wash clean the rear

glass.• Rear wipers operation lever (2)

LOW (UP) : Wipers move at inter-vals of two point fourseconds(25cycle/min)

INT (DOWN) : Wipers move at inter-vals of four sec-onds(15cycle/min)

IDLING

H..L

ascendingposition

Do not use this knob to stop theengine.

NOTICE

20

Front door control switch

The front door are operated by theair cylinder as the door openingswitch on.OPEN (RIGHT) : door openCLOSE (LEFT) : door close

Air parking brake switch (OPT)(For full air brake)

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.

MID. or rear door control switch (OPT)

The middle or rear doors are operat-ed by the air cylinders as the dooropening switches on.OPEN (down) : door openCLOSE (up) : door close

∗ The quantities or locations ofswitches could be different from fig-ure.

CLOSE

OPEN

21

Stop arm control switch (OPT)

Raise the toggle switch position “ON”Stop arm is operating voluntary bydriver which have no relation withdoor opening then, warning lamps(Red) on roof comes on with blinker.

Warnning lamp switch (OPTION)

Raise the toggle switch position “ON”Warning lamps(Yellow) on roof comeson but, if stop arm switch is operat-ed, yellow lamps come off, and Redlamps comes on.

OFF

ONSTOP ARM

STOP

OFF

ONWARNING 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 blank cover.)

7. Tachograph (OPTION)Speedomter

8. 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

0

3

6 9

12

15

kg/cm

A I R2

7101112

3 4 5 8 12 9 6

7

0

20

40

6080

100

120

140

160

Km/h

0 0 0 0 0 0 0

Tachograph

Speedometer

0

80

0 0 0 0 0 0

km/h

60

40

20

160

140

120

100

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 representscritical 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 :D1146 ENG : 2,500rpm.DE12 ENG : 2,200rpm.DE08TiS ENG : 2,300rpm.

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

7

0

20

40

6080

100

120

140

160

Km/h

0 0 0 0 0 0 0

Tachograph(OPTION)

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.

Speedometer

The speedometer is consisted ofodometer and clock. The vehiclespeed and running distances are reg-istered in a single chart. The speed-meter indicates the vehicle speed inkilometer per hour(km/h). The odome-ter indicates individual trip distances.The odometer records the total dis-tance in km. The unit of registereddistance is loom.

For further information refer to“SPEEDOMETER” 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.

0

80

0 0 0 0 0 0

km/h0-80 101-16081-100

60

40

20

160

140

120

10032

24160

0

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

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.

27

UPPER PILOT INDICATOR LAMPS

9 10 11 12 13 14 15 16

1 2 4 5 6 7 83

1. Engine coolant temperature (high)2. Air tank pressure (low)3. Brake oil level (low) (For AOH Brake)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)

28

Engine coolant temperature (high)

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

Air tank pressure (low)

The indicator lamp comes on and the warn-ing buzzer is operated simultaneously, whenair pressure within the air tank is lowered to5.3kg/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.

Parking lamp (on)

The parking brake indicator lamp comes onwhen the parking brake lever is pulled withthe starter switch “ON”. The parking brakeindicator lamp does not indicate the actionof the parking brake. Make sure to pull theparking brake lever fully when parking thevehicle.

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

PARKINGAIR

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)

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

Emergency door (open)

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

29

ENG.�DOOR

EMER.�DOOR

30

Emergency door (open)

The indicator lamp comes on when theemergency door is opened. If the lampcomes on even after closing the door, checkthe 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)

The indicator lamp comes on when the airdryer is operating.(Air dryer heating system on)

Engine preheat (on) (OPTION)

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 dooris opened.

Passenger's stop order (OPTION)

When the passenger push the buttonbetween windows, the buzzer sounds andthis lamp comes on.

ENT.�DOOR

STOP

EMER.�DOOR

AIR�DRYER

31

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.

ENG.�ROOM

32

LOWER PILOT INDICATOR LAMPS

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 indication (OPTION)6. Electronically controlled air

Suspension operation (OPTION)7. Air condition warning (OPTION)

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 indication (OPTION)15. Speed 2 indication (OPTION)

33

Safety equipment operation (OPTION)

When the passenger stands at entrancestep, the rear door is not closed, this lampcomes on.

Retarder system operation (OPTION)

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

Retarder system warning (OPTION)

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

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.

Speed 1 indication (OPTION)

At the vehicle speed in 0~5km/H the lampcomes on, also the left Yellow-Green mark-er lamp on the roof at the front of the vehi-cle, lights on.


At the vehicle speed in 0~5km/H the lampcomes on, also the left Yellow-Green mark-er lamp on the roof at the front of the vehi-cle, lights on.


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.

SAFETY

E

ECS

SPEED 1

SPEED 3

SPEED 2

34

Brake pad wear warning (NOT USE)

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

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 (NOT USE)

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

Engine malfunction lamp (NOT USE)

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.

ASR

SPEED�LIMITERABS

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

NOTICE

CHECK

35

SWITCHES

★ 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.

36

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 lamprack)

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

Room lamp switch (Bulb)

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

F F B

37

Driver lamp switch

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

Fog lamp switch (Front)

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

Fog lamp switch(Rear) (OPTION)

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

38

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 lamp come on.

Reading lamp switch (OPTION)

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

P

39

Stop arm switch (OPTION)

Push the this button, the stop arm isoperated automatically when door isopenaing and warning lamps(Red) onroof comes on with blinker

Destination board switch (OPT)

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

40

Heating and defrosting of driver’s compartment

Power on by moving the control leverto upper or lower and control thespeed of blower fan, the indicatorlamp comes on when the levermoved upper or lower when the leverreaches to the upper, the blower fanstart to operate powerfully, otherwisereaches to the lower, fan’s speed isslowly the lever reaches to the cen-tor, the defroster’s power is off.

Heating of passenger’s com-partment (OPTION)

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.

HEATING AND DEFROSTING

FUSE FUSE

HIGH

OFF

LOW

Dhi Donghwan Ind.Corp.

HEATER

COOLER (SUB ENG. TYPE) (OPTION)

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

41

7 1 2 3 4 8 9 6 105

AIR CONDITIONING

42

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.

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.

43

Cooling air, condenserLiquidreceiver

CondenserCooled air

Evaporator

CompressorRoom air, returning

Expansionvalve

Sight �glass

Dryer

Evaporator

Expansion�valve

Receiver tankDypass�solenoid

High pressure line�Low pressure line

Condenser

Compressor

44

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

45

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

46

AUTOMATIC VENTILATOR (OPTION)

ExhaustSet the knob to “Exhaust” to open theshutter and extract the air in the com-partment to outdoor.

SuctionSet the knob to “suction” to open theshutter and intake the outdoor air tothe compartment.

CirculationSet the knob to circulation, then theblowing fan repeat Exhaust and suc-tion by changing the rotating direc-tions.

(1EA) (OPTION)

VentilationSet the knob to “Ventilation”, then theshutter opens only, the air is ventilat-ed by natural.

(2EA) (OPTION)

AUTO VENTILATOR

DONG JIN PRECISION

STOPCIRCULATION VENTILATION

SUCTIONEXHAUST

AUTO VENTILATOR

DONG JIN PRECISION


SUCTIONEXHAUST


SUCTIONEXHAUST

47

PREHEATER (OPTION)

Preheater operation

1. In the case that the ambient tem-perature is below 0°C, set the con-trol knob to the “PREHEAT” posi-tion about 20 seconds for pre-heating the fuel nozzle, then shiftthe knob to “ignite” position.(Preheat indicating lamp comes onwhen the preheating of fuel nozzleis finished, the time of indicatinglamp coming on is different byambient temperature.The preheat temperature is about30°C.)

2. By setting the control knob to the“ignite” position, the indicatinglamps “ignite” and “pump” comeon. Also “drive motor” and “Waterpump motor” start operating. Bythe drive motor operating, theblowing fan and fuel pump worktogether.

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 “operate”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 “ignite” indicatinglamp goes out.After stop of combustion, the drivemotor operates 150 180 secondsmore, and stops but the waterpump motor continues operating.(The indicating lamps “operate”,“pump” keep lighting on).

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.

PREHEATER

DO

NG

WH

AN

IGNITION OPERATE PUMP

OFF

FUSE FUSE

10A 15A

PREHEAT

48

7. To stop the operation of preheater,set the control knob at “stop” posi-tion, then the combustion stops,but drive motor and water pumpmotor operate 150 180 secondsmore, then stop.

8. When the control knob is set to“pump” position, water pump motoroperates only and the heatingeffect could by enhanced.(When operating heaters, heat lossin the heating line decreases and“pump” indicating lamp comes ononly).

49

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.

50

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

51

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.

52

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

53

RADIO AND CASSETTE TAPE PLAYER

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

54

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 fast

forward/progress buttons 10, 11together, 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.

55


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

56

Radio operation

Push the knob(1) control the balancefittingly and control the volumeknob(1).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 andAMP 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

57


MIC AMP. type (OPTION)

1. Power switch2. MIC. volume knob3. MIC. jack4. MIC. tone knob5. Speaker IN/OUT switch

OFF

ON

POWERVOLUME

MIN MAX

MIC TONE

LOW

IN

SPEAKER

HI

OUT

1� 2� 3� 4� 5�

58

MIC operation

• Press power switch 1 to power onthe system.

• Insert mail type jack of microphoneinto MIC jack 3.

• Turn mic volume knob 2 to controlthe volume of MIC sound.

• Turn mic tone knob 4 to control thetone of MIC sound.

• Press speaker switch 5 to convertthe sounds of IN/OUT speakers.

59

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.

60

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.

61

SPEEDOMETER

0

80

0 0 0 0 0 0

km/h

60

40

20

160

140

120

100

2

1

1. Speedometer needle2. Odometer(distance)

SpeedRecording and indicating ranges of 160km/hare available.DistanceCalibrateable odometer, 7–digit creeping,without ZERO settings.

62

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

TACHOGRAPH (OPTION)

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

63

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)

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.

64

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

65

100

120

140

160KmKm/h

ARCO

20

40

60

10

15 20

25

30

33

0

80

0 0 0 0 0 0 0


Warning signalLights up when the speed is reachedbetween 40% and 60% of the maximumspeed.-100km/h (General)-120km/h (GCC members)

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


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.

66

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

67


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

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.


68

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

69

Further information by additional devices

Basic informationStart of drivingEnd of drivingRoad speedDistanceTime scaleENG Speed (OPTION)

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.

70

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 3 5

R 2 4

N

1 3 5

R 2 4

N

6

(6.O.D)

(5.O.D/D.D)

71

Clutch pedal(Except auto transmission)

Fully push down the clutch pedalwhen changing gears. Do not restyour foot on the pedal when theclutch is not in use. Premature wear of the clutch willresult.

Parking brake lever(For AOH brake)

The parking brake is applied by push-ing the knob backward.To release, pull the knob slightlyupward.Be sure to set the parking brake leverfirmly when parking the vehicle atunattended place.

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

CAUTION

72

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.

NOTICEEngine 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.

INTERRUPTINTERRUPT

ENGINE STARTER �INTERRUPT S/W

BATTERY�INTERRUPT S/W

CLOSE CLOSE

STARTER�SUB S/W

73

DRIVING

Proper care and operation not onlyextend the service life of your vehiclebut also improve oil and fuel con-sumption.

Preparation for engine starting

1. Fix the vehicle with the parkingbrake lever.

2. Place transmission in neutral.3. Put the engine stop handle off.4. Press the battery main switch.

Check items inside of engine roominstallation of V–BELTLoose belt can adversely affect thealternator charging system and causeengine overheating or premature wearto the belt.On the other hand, a belt which is tootight can cause premature damage tothe bearings of its peripheral devices.Frequently check and adjust belt ten-sion. (Refer to page 113.)

74

(No.1)When installing a new belt, adjust the V-belt to beconsidered tension in the original position of tensiondevice.(No.2)Check for fixing position of main engine pulley andcompressor pulley.(No.3)Test operation for 2–3 minutes after adjusting the belttension.A sufficient tension is hung down 6mm from the beltcenter by vertically pulling-down of a spring balance.(No.4)It takes a few days to harmonize the belt to the pulley.

Adjust belt tension in accordance with No.3, when thebelt became loose.Keep the belt tension to moderate looseness so asnot to slip off the belt from the pulley.(No.5)Check the belt tension two or three times per day fornew belt, and check it once per day after a few days,after then, check it once in a month.The belt slip-off might be caused by water or oil onthe pulley.Check belt tension as folling :(Push down the belt center with 8–11 kg load).

Span

Load

Specified drooping amount :4mm Per 100mm in the span

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

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

b. When the oil level is low, add thesame brand oil according to“RECOMMENDED LUBRICANTS”and wait a while to check the levelagain. Also check for purity andviscosity of the oil before replen-ishing 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.

Engine coolant levelCheck the level by the mark on thereservoir installed at upper side ofradiator.If the Engine coolent temperaturelamp light comes on with sound inupper pilot lamp.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.

75

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

CAUTION

76

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.

77

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.

Check items around driver’s compartment

78

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)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

79

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

80

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

81

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 inflation

Tire size pressure in

kg/cm2(PSI)

10.00–20–16PR Front : 8.1kg/cm2

(Tube) (115PSI)

10.00R–20–16PR Rear : 7.4kg/cm2

(Tube, radial) (105PSI)

11.00–20–16PR Front : 8.4kg/cm2

(Tube) (119PSI)

11.00R–20–16PR Rear : 7.7kg/cm2


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

CAUTION

82

Chassis springCheck chassis springs for damageand tightening condition of 'U' blot.If any damaged or separatd springleaf from normal position is found,stop the vehicle operation and haveservice.

Preparation for starting the engine

1. Apply the parking brake firmly andshift the gear lever to NEUTRALposition.

2. Push on the battery main switch. 3. 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 idle theengine at the normal speed (rpm)until the normal operating tempera-ture is reached.

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

83

STARTING AND STOPPING THE ENGINE

84

Abrupt start during warming–upoperation may shorten the enginelife.

CAUTION

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

5. If you had attempted to start enginewith no fuel in the fuel tank, youshould bleed the fuel system. Withno bleeding operation, you cannotstart the engine even after refillingthe fuel tank.(Refer to “Bleeding offuel system” on page 107.)

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.

C

H


85

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.

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(For full air brake)

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

Parking brake lever(For AOH brake)

Before travel, manipulate the parkingbrake lever to check for its motion.Pull downward the lever to start run-ning.Check the park warning lamp goesout before driving.

86

Check steering wheel for free playwith the engine running.

CAUTION

PARKING


87

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 T/M)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.

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

88

WHEN DRIVING OFF

Check if the needle of air pressuregauge indicates 4.8kg/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 before start-ing off, and start the vehicle withthe shift 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

89

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

90

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

91

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.

0

12

3x1000rpm

92

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, turn and push the battery switchoff before parking.

Diesel engine is apt to keep runningeven after the battery relay switch off,while the engine continues running,never push the battery switch off,after check that engine stops running,turn and push the battery switch off.

Otherwise, the alternator circuit maybe failed.

Parking

Place the gear shift lever in neutralposition and set the parking brakelever securely.

C

H

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.

93

94

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

95

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

96

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.

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.

97

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)

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.

98

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

CAUTION

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.

99

100

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

101

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

102

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 oil• Frigid an area :

API CF–4 or SAE 15W/30Except Frigid an area :

API CF–4 or SAE 15W/40• Refer to “Lubrication list” at page

155.

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 with theengine stationary. If the enginehas been operated, allow 20 min-utes for oil to settle down beforechecking the oil level.

NOTE

103

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

CAUTION

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.

Model

D1146

DE12

DE08TiS

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

• Short distance

: every 20,000km

Capacity

ENG.TOT19

Oil pan15.5

ENG.TOT15.5Oil pan13

ENG.TOT20

Oil pan17

104

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 hotor 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 155.

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. Model Coolant volume

BF106 33(37)

( ) : Preheater included

NOTE

105

Fuel filter (D1146 ENG.)

The fuel filter system is of the twostage type with a felt element as aprimary filter and a paper element asa secondary filter.Fuel is transported from the outsideof the filter to its inside. At this time,impurities contained in the fuel arecaught outside the filter.

ReplacementReplace secondary element at thesame time when the engine oil ischanged. Clean primary filter at every5,000km and replace with new oneafter the lapse of 3 cleaning intervals.Restricted fuel filter will hinder insmooth transportation of fuel, resultingin decrease in engine power.

Cleaning (Primary element)Soak the felt element in diesel fueland remove heavy dust particles byusing a brush with soft bristles. If theelement is found defective, replace itwith a new one.

Disassembly and cleaning1. Unloosen center bolt, and remove

filter body.2. Take out felt element and paper

element.3. Clean filter body and feft element.4. Change paper element.5. When reassembling reverse the

above sequence.

OUT

IN

Centerbolt

Air bleeding screw

Secondaryfilter(paperelement)

Primary filter(felt element)

Filter body

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

CAUTION

Sometimes (at 10,000km) drainthe filter pump of water until clearfuel is visible.

NOTE

106

Fuel filter(DE12, DE08TiS ENGINE)

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

107

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.

(DE12, DE08TiS ENG.)

(D1146 ENG.)

108

Fuel system diagramD1146 ENGINE

1. Fuel filter 2. Air bleeder screw3. Injection nozzle4. Fuel return pipe5. Fuel feed pipe

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

(pump filter)9. Fuel tank10. Fuel return pipe11. Fuel suction pipe12. Fuel feed pump13. Injection pump

13

12

1110

9

8

6

34

7

5

2

11 1

109

Fuel system diagram (D1146Eng)DE12, DE08TiS ENGINE

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

110

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

Engine model Change intervals

At end of first

D1146 1,000km,

second : 2,500km

Every 5,000km

DE08TiSAt end of first

DE121,000km and

Every 20,000km

Engine model Change intervals

Intake 0.30mm,

Exhaust 0.30mm

D1146DE12DE08TiS

1 2 3 4 5 6

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

(DE ENG.)

111

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.

Points of handling care

Engine model Injection pressure

D1146 214kg/cm2

DE08TiS220kg/cm2

DE12

Normal

Abnormal Abnormal

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.

112

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

113

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

2

1

ALT

DE12 ENGINE

1. Crank shaft pulley2. Alternator pulley

114

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

CRS

W/PA/C

ALT

2

1 43

5

D1146, DE08TiS ENGINE

1. Idle pulley2. Crank shaft pulley3. Air compressor pulley4. Water pump pulley5. Alternator pulley

115

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).

116

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

117

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 page155.

drain plug filler plug

TRANSMISSION OIL CAPACITYK805A 9.8K805PT8HS5B

10.0T8HS5PK806P 11.2T8HS6P 12.0

TRANSMISSION OIL CAPACITY

MT643 25

118

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

OIL CAPACITY• 11.5 – 12.5

Specification of oilSpecification : API GL–5 or SAE80W90Refer to “Lubrication list” at page155.

Filler/level�plug

Drain plug

119

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

BF106 5

120

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.

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 page155.

121

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 oil 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.

122

Brake system

Adjustment of brake pedal free playAdjust 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 checkCheck 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 R2

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

123

Adjustment procedure

A.O.H brake1. Jack up and check the wheels rotate

smoothly without any resistance.2. Remove the rubber plug fitted in the

brake lining inspection hole.3. By ratating the wheel by hand, turn

the adjusting cam to the direction inwhich the brake shoe expands untilthe brake drum drags by contactingwith the brake lining, then turn thecam to reverse direction until theclearance becones th the standardvalue.The standard clearance is 0.3mm,check the clearance by inserting thethickness gage between the brakelining and drum through the inspec-tion hole.

Full air brake with mechanicalslack–adjuster (OPTION)1. 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 theclearance.

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.

If the protruded point of the indicatorcomes into contact with the stopper byturning the worm–shaft for adjustment, itindicated that the lining has been wornto the limit and should be replaced.

NOTE

124

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 spots or abnormalconditions are checked, replacedthe brake lining to the new one.

Brake oil for A.O.H brake1. Check the level of the brake oil

reservoir and replenish if neces-sary. If the level is too low or thelevel goes down fastly even afterreplenishment, inspect thehydraulic circuit of the brake oiland have service at your nearestDaewoo dealer.

2. When brake oil is found to be con-taminated, inspect and repair ifnecessary, before refilling, drainthe contaminated oil thoroughly.

3. Change brake oil at every60,000km operation or 1 year.

thickness

rivetshoe

extru-� sion

125

Parking brake adjustment (For AOH brake)The parking brake lever travel is nor-mal when it is within 5 7 notches asthe lever is pulled out fully. If the brakelever travel exceeds 10 notches, park-ing brake action is limited and adjust-ment should be made in the followingmanner.

1. Brace the front wheels and fullyrelease the parking brake lever.

2. Jack up the rear wheels clear of theground and hold the transmission inneutral. Bring the adjusting hole inthe brake drum into alignment withthe adjuster by turning the propellershaft as necessary with hand.

3. Insert a screw driver into the adjust-ing hole in the brake drum and turnthe adjuster upward to stop.

4. Then, back off the adjuster 8 notch-es. When the above steps of adjust-ment are completed, the clearancesbetween the brake linings and drumare adjusted to the standard value,normalizing the brake lever travel.

126

Clutch system(Except auto transmission)

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 25mm, using thevehicle without adjustment result inclutch slip.1. Free play : 25~30mm2. Height : 180~205mm

Inspection of free playTo 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

127

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 specifiedoil. The clutch hydraulic circuit shouldbe drained and refilled when fluid isfound to be contaminated. Oil changeintervals : every 60,000km or 1 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 fluid other than clutch fluidshould not be used for replenish-ment.

NOTE

128

PRESSURE REGULATOR

ApplicationThe pressure regulator is fitted in airbrake systems to regulate the operat-ing pressure and to clean the airdelivered 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 airflow.

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

129

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.

130

Tyre inflationThis unloader valve range is general-ly not provided with an intergal tyreinflation valve.A tyre inflation valve of the ZB 31..range can, however, be fitted in eitherof the delivery lines between the com-pressor and the unloader or reliefvalve.Breather valve(13) is only requiredwith unloader valves having an inte-gral tyre inflation port(see DR 3000–K11EN) ; it has only been fitted forparts commonality. It is of no signifi-cance to the operation of theunloader valve descried in the presentcatalogue sheet.

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..

131

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

132

ANTIFREEZE PUMP (OPTION)

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.

133

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

134

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

135

AIR DRYER (OPTION)

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

136

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.

137

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

138

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.

139

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.

140

WATER TRAP (OPTION)

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.

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

NOTICE

1

2

3

1. Pressure Regulator2. Hose3. Water trap

141

With anti freeze pump(OPT) With air dryer(OPTION)

1

3

4

2

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

2�

3

1

1. Air dryer2. Hose3. Regenerating tank

142

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 inflation

Tire size pressure in

kg/cm2(PSI)

10.00–20–16PR Front : 8.1kg/cm2

(Tube) (115PSI)

10.00R–20–16PR Rear : 7.4kg/cm2


11.00–20–16PR Front : 8.4kg/cm2

(Tube) (119PSI)

11.00R–20–16PR Rear : 7.7kg/cm2


Type A

Type B

143

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

ELECTRICAL

Aiming of headlampsThe 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.

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 the head-lamps (type 1–inside, type2–outside) in such a manner thatthe right and left units of the aim-ing instrument lightly contact theaiming bosses on the headlamplenses.

Support the aiming instrument sothat the objective lens of the aim-ing instrument is faced to the cen-ter of the vehicle, and push thehandle strongly to tightly contactthe vacumn rubber cup of theinstrument on the lens.

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.

144

White line

Type 2

Objective

Eyepiece

Levelvial

Dial

Handle

Type 2Center of vehicle

Vacuumrubbercup

Fog lampHead lamp

Turn signal/position

145

Adjustment by the use of a screenSupport a screen vertically in posi-tion 3 meters ahead of the head-lamps and adjust the beam to thevalues given in the table below.(Keep the headlamps on one sidecovered with a suitable cloth whenmaking adjustment.)Adjustment of beam relative to theline in the center of headlamps.

A Type1 26mm below horizontal line

B Type2 105mm below (low beam) horizontal line

B Type2 26mm swung tothe right

(low beam) (RHD, left)

A B

3m

146

Bulb

DISTINCTION

Head lampHigh

Low

Fog

Cornering

Front Parking/turning

combination Position

lamp Parking (OPTION)

Turning/Position

Turning

Fog

Turning

Rear Stop/position

combination Stop/parking

lamp Stop

Parking (OPTION)

Position

DestinationFront

lamp (OPT)Middle

Rear

BF106

75/70W(H4) × 2

70W(H3) × 2

–

–

–

3W × 2

25/10W × 2

–

–

25W × 2

25/10W × 2

25W × 2

–

3W × 2

–

12W × 2

–

–

147

DISTINCTION

Side turn signal

Back up lamp

NO. Plate lamp

Engine Room lamp

Speed indicator lamp (OPTION)

Driver lamp

Room lamp (FL)

Room lamp (GLOW)

Front marker lamp

Rear marker lamp

Side marker lamp

Step lamp (OPTION)

Search lamp (OPTION)

Luggage lamp (OPTION)

Reading lamp (OPTION)

Pilot lamp

Side lamp (OPTION)

Warning lamp (OPTION)

BF106

12W × 2 / 12W × 4

21W × 2

12W × 2

–

12W × 3

12W

20W × 6

12W × 6

12W × 2

12W × 2

–

12W

12W

12W

–

1.2W × 32

12W × 2

–

148

Relay and fuse layout

★ The quantities or locations of fuses could be different from the figure, because the fuses or relay could be addedor omitted, and locations could be changed by the requirement of custmers.

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) WIPER MOTOR(LH) WIPER MOTOR(RH)

SP

AR

E F

US

E

20A

15A

10A

5A

HEAD LAMP(LOW) PARKING, MARKER LAMP BATTERY WARNING

TAIL LAMP WARNING LAMP(LH) SEAT BELT

STOP LAMP BLINKER (WARN LAMP)

BLINKER (EMER DOOR)

BLINKER (HAZARD)

ENT DOOR LAMP

WARNING LAMP(RH) STOP SAFETY

FUSERELAY RELAY

Type A

149

No. Amp. Fuse name No. Amp. Fuse name No. Amp. Fuse name

1 15A Head lamp (HIGH)

2 10A Head lamp (LOW)

3 15A Tail lamp

4 10A Stop lamp, Back up lamp

5 5A Room lamp FL 1

6 5A Room lamp FL 2

7 5A Room lamp BULB

8 5A Driver lamp

9 5A Destination lamp

10 5A Meter power, Sensor power

11 30A Airconditioner

12 15A Starter sub relay

13 5A Exhaust brake

14 10A Regulator, Air dryer

15 10A Front LH wiper motor

16 10A Front RH wiper motor

17 5A Horn

18 20A Electric fan

19 10A Spare

20 10A Auto ventilator

21 15A Stop arm, Warning lamp

22 15A Rear wiper motor & switch

23 10A Head lamp high (LH)

24 10A Head lamp high (RH)

25 5A Head lamp low (LH)

26 5A Head lamp low (RH)

27 15A Tail lamp

28 5A Battery main switch

29 10A Blinker unit (HAZARD)

30 5A Blinker unit (EMER. DOOR)

31 5A Parking lamp

32 5A Warning buzzer

33 5A Radio

150

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) WIPER MOTOR(LH) WIPER MOTOR(RH)

SP

AR

E F

US

E 20A

15A

10A

30A

HEAD LAMP(LOW) PARKING, MARKER LAMP FOG LAMP

TAIL LAMP WARNING LAMP(LH) �

STOP LAMP BLINKER (WARN LAMP)

BLINKER (WARN LAMP)

BLINKER (HAZARD)

ENT DOOR LAMP

WARNING LAMP(RH) STOP SAFETY

FUSERELAY RELAY

Type B

151




3 15A Tail lamp

4 10A Stop lamp, Back up lamp

5 5A Room lamp FL 1

6 5A Room lamp FL 2

7 5A Room lamp BULB

8 5A Driver lamp

9 5A Destination lamp

10 5A Meter power, Sensor power


12 15A Starter sub relay

13 5A Exhaust brake

14 10A Regulator, Air dryer

15 10A Front LH wiper motor

16 10A Front RH wiper motor

17 5A Horn

18 20A Electric fan

19 5A Warning buzzer


21 15A Stop arm, Warning lamp

22 15A Rear wiper motor & switch

23 10A Head lamp high (LH)

24 10A Head lamp high (RH)

25 5A Head lamp low (LH)

26 5A Head lamp low (RH)

27 15A Tail lamp

28 5A Defroster

29 20A Battery master fuse

30 10A Blinker unit (HAZARD)

31 5A Parking lamp


33 5A Radio

152

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 20A

15A

10A

HEAD LAMP(LOW) ROOM LAMP 3 WIPER MOTOR(LH)

TAIL LAMP READING LAMP STOP LAMP

FRONT DOOR LAMP

BLINKER UNIT

TV, VTR

�

� FOG LAMP

FUSERELAY RELAY

30A

Type C

153




3 15A Tail lamp

4 10A Engine stop motor,

5 5A Stop lamp, Horn, Radio

6 20A A. B. S

7 15A Warning lamp(SPARE)


9 10A Spare

10 15A Wiper control relay

11 10A Meter power, Buzzer, Door

12 10A Room lamp 1

13 10A Room lamp 2

14 10A Room lamp 3

15 10A Air dryer

16 10A Luggage, Phone

17 15A Defroster, Preheater

18 10A Reading lamp

19 10A Exhaust brake,

20 10A Regulator

21 20A Heater


23 10A Back up lamp

24 15A TV/VTR

25 10A Auto grease power

26 15A Starter key

27 10A Interrupt switch

28 15A Fog, Tail, Meter lamp

29 15A Battery main power(1)

30 10A Blinker unit, Park lamp

31 10A Door, Clock, Radio

32 10A Spare


Destination lamp

Heater mirror

154

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

155

Lubrication list

Lubricant Lubrication List Capacity Oil change period Specification

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)

D1146 : 15.5(OIL PAN : 13 )

DE08TiS : 19

(OIL PAN : 15.5 )

33(37)

DE12 : 20(OIL PAN : 17 )

Initial : 1,000km

Inter city or long distance

travel bus, every : 15,000km

City bus, every : 10,000km

Initial : 1,000kmLong distance : every

30,000kmShort distance : every

20,000km

Every : 1 year

CF Grade(Frigid an area : 15W30(Except Frigid an

area : 15W40)

API CH-4 grade(SAE 15W40)

or ACEA E2/E3 grade

Engine oil

Enginecoolant

Engine

Radiator Anti–freeze LLC Grade

Inhibitor DCA65L(1% of engine coolant involume)

156

Lubricant Lubrication List Capacity Oil change period Specification

Gear oil K805A/P 9.8 GL-4 Grade(80W/90)

Manual T8HS5B/P 10.0Initial : 5,000km

transmission K806P 11.2Every : 20,000km

T8HS6P 12.0

On high way : DEXRON-

Auto every 1 year or 40,000km

transmissionMT643 25

Off high way :

every 1 year or 1,000h

Rear axle 11.5–12.5 Initial : 5,000km GL-5(80W/90)

Every : 20,000km

Power Power steering 5 Initial : 1,000km DEXRON R–

steering Every 24,000km

Brake oil Brake and clutch 4 Every : 1 year or 60,000km DOT 3, DOT 4 Multipurpose EP No.2

Grease Wheel bearings When hub repair Multipurpose type grease

Needed quantity Manual : Every 4,000km NLGI No.2 or 3

Auto grease KLGI No. 000.00Grease fittings

157

Moving parts(every 4,000km)

King pin (4 points) Link arm (1 point) Tie rod end (2 points)

Drag link-FRT (2 points)Propeller shaft (2 points)Steering shaft (1 point)

158

Spring and shackle pin(12 points)

Drag link-RR (2 points)

159

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 element

Adjust valve clearancesD1146 ENGINEDE08TiS/DE12 ENGINE

Check fuel injection time, and fuel injection nozzle pressureCheck compression pressure in each cylinderCheck for oil contaminationDrain fuel filter and clean fuel strainerWashing fuel filter element (D1146 ENGINE)Change fuel filter element (D1146 ENGINE)Change fuel filter cartridge (EXCEPT D1146 ENGINE)Clean 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

* For engine oil and filter cartridge change Refer “periodic inspection and maintenance”.

(Every 60,000 km)

(Primary filter : every 5,000km)(Primary filter : every 15,000km, Secondary filter : every 5,000km)

(1,000km)First 1,000km, second 2,500km, every 5,000km

(10,000km) (30,000km)

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

160

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)

40

(1,000km)

(1,000km)

(5,000km)

(5,000km)

161

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)

162

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)

163

TROUBLESHOOTING

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

164

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

165

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

166

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 and periph-eral 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

167

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

168

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

169

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

170

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

171

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

172

MAIN DATA AND SPECIFICATION

1. ENGINE1-1. D1146, DE12 ENGINE

Distinction

water cooled 4 cycle in–line, overhead valve type

dry type

compression ring ; 2ea, oil ring : 1ea

1–5–3–6–2–4

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

D1146

6

111×139

8071

18.0 : 1

1253

811.5

934.5

730

600±50

BTDC 15

BTDC 16

ABDC 36

BBDC 46

ATDC 14

DE12

←

123×155

11051

17.1 : 1

1317

744

1015

872

←

BTDC 10

BTDC 18

ABDC 34

←

←

173

Distinction

gear type

water cooled, integral type

fresh water forced circulation

centrifugal type

wax-pellet type

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)

D1146

ENG.TOT : 15.5 , OIL PAN : 13

11

130(182)/2500

563(57)/1600

24×4.5

rear

24×150

DE12

ENG.TOT : 20 , OIL PAN : 17

19

169(230)/2200

799(81)/1300

24×5.4

←

←

174

Distinction

water cooled 4 cycle in–line, overhead valve type

dry type

compression ring : 2ea, oil ring : 1ea

1–5–3–6–2–4

DE08TiS(225ps)

6

111×139

8071

18.5 : 1

1169

812

1003

745

600~650

BTDC 3

BTDC 16

ABDC 36

BBDC 46

ATDC 14

DE08TiS(240ps)

←

←

←

←

←

←

←

←

←

←

←

←

←

←

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 (rpm)

Fuel injection timing

Fuel injection order

Intake vlaves

Exhaust valves

length

width

height

open at

close at

open at

close at

1-2. DE08TiS ENGINE

175

DE08TiS(225ps)

11

225/2300

82/1000

24×4.5

Rear

24×150

DE08TiS(240ps)

←

240/2300

90/1000

←

←

←

Distinction

gear type

water cooled, integral type

ENG.TOT : 19l, OIL PAN : 15.5l

fresh water forced circulation

centrifugal type

wax-pellet type

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)

BF106

D1146 DE08TiS(225ps) DE12 DE08TiS(240ps)

176

2. CLUTCH

ratio

free play

max. stroke

Type

Clutch facing

dimensions(mm)

Clutch clamping force(kg)

Clutch pedal

Clutch minipack

start working pressure(kg/cm2)

Master cylinder bore dia.(mm)

dry single plate with coil spring dampers hydraulic circuit

incorporating clutch minipack

380 430

240 250

5

1240 10% 1470 10% 1380 10%

7.09

48.8

170

5.5

20

outside dia

inside dia

thickness

Distinction

K805A

5.D.D

82

6.666

3.826

2.213

1.417

1.000

–

6.851

192

9.8

K805P

5.O.D

82

5.455

3.130

1.728

1.000

0.745

–

5.606

192

9.8

K806P

6.O.D

82

6.666

3.826

2.213

1.417

1.000

0.734

6.851

200

11.2

T8HS5B

5.D.D

82

6.571

3.807

2.201

1.463

1.000

–

6.240

234

10.0

T8HS5P

5.O.D

82

5.405

3.447

1.739

1.000

0.738

–

5.650

234

10.0

T8HS6P

6.O.D

82

6.571

3.807

2.201

1.463

1.000

0.751

6.240

279

12.0

177

3. TRANSMISSION

3–1. Manual transmission

MODEL

SPEED

TORQUE(kgm)

1ST

2ND

GEAR3RD

RATIO4TH

5TH

6TH

REV

DRY WEIGHT(kg)

OIL CAPACITY( )

178

MT643

4.D.D

88.4

3.58

2.09

1.39

1.00

–

–

5.67

231

25

3–2. Auto transmission

MODEL

SPEED

TORQUE(kgm)

1ST

2ND

GEAR 3RD

RATIO 4TH

5TH

6TH

REV

DRY WEIGHT(kg)

OIL CAPACITY( )

179

Distinction

BF106

D1146

K805A/P. T8HS5B/P

1586

88.9

80.9

1467.5

88.9

80.9

1360

88.9

80.9

D1146

K806P T8HS6P

1494.2 1485.2

← ←

← ←

← ←

← ←

← ←

← ←

← ←

← ←

DE12

K806P T8HS6P

1535.8 1526.8

← ←

← ←

1334.1 ←

← ←

← ←

1350 ←

← ←

← ←

1st piece(mm)

(when equipped)

2nd piece(mm)

(when equipped)

3rd piece(mm)

(when equipped)

length

outside dia.

inside dia.

length

outside dia.

inside dia.

length

outside dia.

inside dia.

4. PROPELLER SHAFT

180

Type Reverse Elliot I Beam

Tire. Tread(mm)

Capacity(kg)

King pin(mm)

Wheel alignment

Steering angle

BF106

2050

6000

50

252

4 6

0.5° 30

–1°00 30

7.5° 10

42°

34°

5. FRT AXLE

outside dia.

length

toe in(mm)

camber(°)

caster(°)

kingpininclination(°)

inside(°)

outside(°)

181

Type

Final drive gear type

Final gear ratio

Oil capacity (liters)

Axle load capacity (kg)

BF106

Banjo full floating type

Spiral bevel

39/6

39/7

39/8

11.5~12.5

9500

6. REAR AXLE

OPTION

182

Distinction

Type Recirculating ball with intergral power assisted

Steering wheel diameter(mm)

Power steering

Length of drop arm(mm)


BF106

500

22.4 : 1

96°

1

200

5

7. STEERING

gear ratio

sector gearoperating angle

gear oil

capacity( )

183

Distinction

Drum insideDiameter(mm)

Brake lining(mm)

L W T N

Wheel cylinder

bore dia.(mm)

Anchor pin(mm)dia. lengh

Type

Brake drum inside dia.(mm)

Brake lining(mm) L W T

Auxiliary brake

BF106

410

410

209 155 16 8

209 180 16 8

53.5

55.56

30 133.5

35 132

Internal expansion drum type

K805A/P, K806P T8HS5B/P, T8HS6P

254 304.8

288 60 5.5 353

Exhaust brake

8. BRAKES

8–1. Air over hydraulic dual circuit brake

front

rear

front

rear

front

rear

front

rear

Parking brake

184

8–2. Full air dual circuit brake (OPTION)

Distinction

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

BF106

410

410

209 155 19 8

209 220 19 8

30 106.5

30 121.5

185

Distinction

type

span(mm)

width(mm)

FRT thickess(mm)

no.of leaf

spring constant(kg/mm)

span(mm)

width(mm)

RR thickess(mm)

no.of leaff

spring constant(kg/mm)

type

FRT rebound

damp force FRT compression

(kg) RR rebound

RR compression

1400

80

11–2

12–7

11–1

32.83

1660

100

12–2

11–3

16–4

32.86

650

275

650

260

9. SUSPENSION

Leaf spring

Leaf

Spring

Shock

Absor

ber

BF106

Semi elliptical alloy steel

Hydraulic, double acting telescopic

186

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)

10.00R-20-16PR

(Tube, radial)

11.00-20-16PR

(Tube)

11.00R20-16PR

(Tube, radial)

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

←

←

←

187

11 COOLER

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 550kg

KIA S-2

2209

4

1850

1450

1150

ND 6C 500

495

AL FIN & CU TUBE

66.7

thermostatic expansion valve

2.6

188

BODY DIMENSION

FRONT ENTRANCE DOOR(OPT : MID ENT DOOR, DRIVER DOOR, EMERGENCY DOOR)

BF106OWNER’S MANUAL

BUS TECHNICAL CENTERDAEWOO MOTOR CO., LTD

188–9 JEON PO–DONG, JIN–KU,BUSAN, KOREA

OM–BF–C2–03C–0205

important service activities - daewoo bus · this manual has been prepared to acquaint you with the...

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