euro_iii_bh117l_service_manual_1st_january_2006.pdf

SM-1E-0505

SERVICE

MANUAL

SECTION INDEX

SECTION NAME

1 GENERAL INFORAMTION

2 CLUTCH

3 TRANSMISSION

4 PROPELLER

5 REAR AXLE

6 FRONT AXLE

7 STEERING

8 BRAKE

9 SUSPENSION

10 WHEEL AND TIRE

DAEWOO BUS

SERVICE MANUAL CHASSIS

FOREWORD This manual includes special notes, important

points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of the components of the vehicles.

The section index on the contents page enables the user to quickly locate any desired section.

At the beginning of each section containing more than one major subject is a Table of Contents, which gives the page number on which each major subject begins.

An index is placed at the beginning of each major subject within the section. Any reference to brand names in this manual is intended merely is an example o the types of lubricants, tools, materials ,etc. recommended for use in servicing Daewoobus vehicles.

In all cases, an equivalent may be used. This manual should be kept in handy place for

ready technician to better serve the owners of Daewoobus built vehicles.

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

1

SECTION 1

GENERAL INFORMATION

CONTENTS PAGE

1. GENERAL REPAIR INSTRUCTIONS 2

2. IDENTIFICATION

2.1. CHASSIS NUMBER 3

2.2. ENGINE NUMBER 3

2.3. V.I.N. PLATE 3

3. SPECIFICATION

3.1. BODY DIMENSION 4

3.2. MAIN DATA 9

4. LUBRICATION

4.1. OIL VISCOSITY CHART 36

4.2. RECOMMENDED LUBRICATION LIST 38

4.3. LUBRICATION CHART 39

1. General Information

2

1. General Repair Instructions To assure safety, park the vehicle on level ground and brace the front or rear wheels when lifting the vehicle. Raise the vehicle with a jack set against the axle or the frame and perform service operations after supporting the vehicle on chassis stands. Before performing service operation, disconnect the grounding cable from the battery to reduce the chance of cable damage of burning due to short-circuiting. Use a cover on the body, seats and floor to protect them against damage and contamination. Brake fluid and anti-freeze solution must be handled with reasonable care as they can cause paint damage. The use of proper tools and special tools where specified is important to efficient an reliable service operation. Use genuine Daewoobus parts. Use cotter pins, gaskets, O-rings, oil seal, lock washers and self lock nuts should be discarded and new ones should be prepared for installation as normal function of the parts can not be maintained if these parts are reused. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important as they vary in hardness and design depending on position of installation. Clean the parts before inspection or reassembly. Also clean oil ports, etc. with compressed air to make certain they are free from obstructions. Lubricate rotating and sliding faces of all parts with oil or grease before installation. When necessary, use a sealer on gaskets to prevent leakage. Carefully observe all specifications for bolt and nut torques.

When a service operation is completed, make a final check to be sure everything has been done properly. To assurance safety, always slowly release air pressure from the air tanks before disconnecting pipes, hoses or other parts from any unit under air pressure.


3

2. Identification 2.1. Chassis Number

The chassis number of the front engine bus is stamped on the left front side of the chassis frame.

The chassis number of the rear engine bus is stamped on the left rear side of the chassis frame within the engine compartment. 2.2. Engine Number

The engine number is stamped on the face of the cylinder body. 2.3. V.I.N. Plate The vehicle identification number plate is attached above the front door.

The type A is applicable for buses in all countries except GCC members.

The type B is applicable for buses in GCC members


4

3. Specification 3.1. Body dimension Model BF106

Model BM090


5

Model BS090

Model BH090


6

Model BS106

Model BH115E


7

Model BH116

Model BH117


8

Model BH120


9

3.2. MAIN DATA ENGINE ( Euro )

Model DE12 DE12T DE12Ti DV15T

Water cooled 4 cycle in-line, overhead valve type V type Type

Direct injection type

Cylinder liner type Dry type Wet type

No. of piston ring Compression ring : 2EA oil ring : 1 EA

No of cylinder 9 8

Bore x stroke () 123 x 155 128 x 42 Piston displacement () 11051 14618

Compression ratio 17.1 : 1 16.5 :1

Length 1317 1394

Width 746 847 874 1024 Engine

Dimension ()

Height 1028 1021 1090 963

Engine weight (dry) (kg) 945 960 990 1050

Idle speed 600 50 Fuel injection timing BTDC 10 BTDC 9 BTDC 12 BTDC 7

Fuel injection order 1-5-3-6-2-4 1-5-7-2-6-3-4-8

Open at BTDC 18 BTDC 12 Intake valves Close at ABDC 34 ABDC 48

Open at BBDC 46 BBDC 61 Exhaust valves Close at ATDC 14 ATDC 11

Oil pump type Gear type

Oil cooler type Water cooled

Oil capacity () Engine total : 20.0, (Oil fan : 17.0) Eng. total : 27.0 (Oil fan : 24.0) Cooling method Fresh water forced circulation

Cooling water capacity () 19

Water pump type Centrifugal type

Thermostat type Wax-pellet type Max. output (ps/rpm, SAE)

235/2200 300/2200 340/2100 365/2300

Max. torque (kg.m/rpm, SAE)

81.5/1400 110/1300 135/1200 138/1300

Starter motor output (V-KW)

24-6.0 24-6.6

Battery capacity (V-AH) 24-150


10

ENGINE ( Euro )

DE08Tis DE12Ti DE12Tis Model D1146 D1146Ti

225PS 240PS DE12

280PS 310PS 340PS 290PS 310PS 340PS DV15T DV15Tis

Water cooled 4 cycle in-line, overhead valve type Type


Cylinder liner type Dry type Wet type

No. of piston ring Compression ring : 2EA, Oil ring : 2EA

No of cylinder 6 8

Bore x stroke () 111x139 123x155 128x142 Piston displacement () 8,071 11,051 14,618

Compression ratio 18.0:1 16.7:1 18.5:1 17.1:1 16.1:1 17.0:1 16.5:1 17.4:1

Length 1,253 1,169 1,317 1,290 1,112

Width 811.5 812.5 812 744 847 1,024 1,024 Engine

Dimension ()

Height 934.5 1,009 1,003 1,015 1,064 1,023 1,015

Engine weight (dry) (kg) 730 745 872 910 920 950

Idle speed 60050 600~650 60050 600~650 60050 550~600 Fuel injection timing BTDC15 BTDC9 BTDC3 BTDC10 BTDC12 BTDC1 BTDC7 BTDC5.5

Fuel injection order 1-5-3-6-2-4 1-5-7-2-6-3-4-8

Open at BTDC16 BTDC18 BTDC18 BTDC12 BTDC15 Intake valves Close at ABDC36 ABDC34 ABDC32 ABDC48 ABDC35

Open at BBDC46 BBDC70 BBDC61 BBDC71.5 Exhaust valves Close at ATDC14 ATDC30 ATDC11 ATDC15.5


11

DE08Tis DE12Ti DE12Tis Model D1146 D1146Ti

225ps 240ps DE12

280PS 310PS 340PS 290PS 310PS 340PS DV15T DV15Tis

Oil pump type Gear type

Oil cooler type Water cooled, integral type

Oil capacity () Engine:15.5 Oil Pan:13.0

Engine:19.0 Oil Pan:15.5

Engine:20.0 Oil Pan:17.0 Engine:22.0 Oil Pan:19.0 Engine:27.0 Oil Pan:24.0

Engine:23.0

Oil Pan:20.0

Cooling method Fresh water forced circulation

Cooling water capacity () 11 19 21 Water pump type Centrifugal type

Thermostat type Wax-pellet type Max. output (ps/rpm, SAE)

182/2500 205/2200 225/2300 240/2300 230/2200 280/2100 310/2100 340/2100 290/2100 310/2100 340/2100 365/2300 390/2200

Max. torque (kg.m/rpm, SAE)

57/1600 75/1400 82/1000 90/1000 81/1300 115/1260 125/1260 135/1260 112/1260 125/1260 145/1260 138/1300 160/1300

Starter motor output (V-KW)

24x4.5 24x6.0 24x6.6

Battery capacity (V-AH) 24x150 24x200 24x150


12

CLUTCH

BF106 Distinction

D1146 DE08Tis DE12 DE08Tis

Type Dry single plate with coil spring dampers hydraulic circuit Incorporating clutch minipack

Outside dia. 380 430

Inside dia. 240 250 Clutch facing dimension()

Thickness 5

Clutch clamping force() 124010% 147010% 138010% Ratio 7.09

Free play 48.8 Clutch pedal

Max. stroke 170 Clutch minipack start working

pressure(/) 5.5

Master cylinder bore dia. () 20

Distinction BM090/BS090 BH090/BS106 BH115E BH120E


Outside dia. 380 430 Inside dia. 240 250 Clutch facing dimension() Thickness 5

D1146 124010% D1146Ti 147010% DE12 138010% DE08Tis(210ps) 136010% DE08Tis(240ps) 145010% DE12/T/Ti/Tis(280ps) 195010% DE12Ti/Tis(310ps) 210010%

Clutch clamping force()

DE12Ti/Tis(340ps) 232010% Ratio 6.75 6.67 6.75

Free play 46.4 46.6 47.2 47.4 Clutch pedal

Max. stroke 170 150 170 Clutch minipack start working

pressure(/) 5.5 6.1 5.5



13

Distinction BH116 BH117 BH120


Outside dia. 430 Inside dia. 250 Clutch facing dimension() Thickness 5 DE12T 195010% DE12Ti/Tis(310ps) 210010% DE12Ti/Tis(340ps)

Clutch clamping force()

DV15T/15Tis 232010%

Ratio 6.75 Free play 47.2 47.2 Clutch pedal Max. stroke 170

Clutch minipack start working pressure(/) 5.5



14

TRANSMISSION (MANUAL)

Model K805A K805P K806P T8HS5B T8HS5P T8HS6P T-9 T10S5B

Speed 5.D.D 5.O.D 6.O.D 5.D.D 5.O.D 6.O.D 5.D.D 5.D.D

Torque(.m) 82 90 125 1st 6.666 5.455 6.666 6.571 5.405 6.571 6.589 2nd 3.826 3.130 3.826 3.807 3.447 3.807 4.002 3rd 2.213 1.728 2.213 2.201 1.739 2.201 2.430 4th 1.417 1.000 1.417 1.463 1.000 1.463 1.507 5th 1.000 0.745 1.000 1.000 0.738 1.000 1.000 6th - - 0.734 - - 0.751 - -

Gear ratio

Rev. 6.851 5.606 6.851 6.240 5.650 6.240 6.239 6.888

Dry weight() 192 200 234 279 240 250 Oil capacity() 9.8 11.2 10.0 12.0 10 13

Model T13S5B K1005C K1005P K1006R K1205C K1205P K1206R K1405A K1406P

Speed 5.D.D 5.D.D 5.O.D 6.O.D 5.D.D 5.O.D 6.O.D 5.D.D 6.D.D

Torque(.m) 135 115 125 145 1st 6.589 6.608 5.500 6.608 5.500 6.608 6.608 2nd 4.002 3.993 3.323 3.482 3.993 3.323 3.482 4.184 4.184

3rd 2.430 2.423 1.782 2.147 2.423 1.782 2.147 2.580 2.580

4th 1.507 1.518 1.000 1.348 1.518 1.000 1.348 1.518 1.618

5th 1.000 0.755 1.000 0.755 1.000 6th - - - 0.755 - - 0.755 - 0.759

Gear ratio

Rev. 6.888 6.937 5.774 6.937 5.774 7.003 Dry weight() 250 260 250 260 290 340 Oil capacity() 13 9.7 11.2 9.7 11.2 14.5 16.0


15

TRANSMISSION (AUTO)

Model MT643 B300R B400R B500R D851.2 D863 D854.2 D864 HP500 HP590 HP600

Speed 4.D.D 4DD/5OD/6OD 4DD/5OD/6OD 4DD/5OD/6OD 3.D.D 3.D.D 4.O.D 4.O.D 4DD/5OD/6OD 4DD/5OD/6OD 4DD/5OD/6OD

Torque(.m) 88.4 97.8 125.4 179.6 102 132.7 102 132.7 112.2 127.6 142.9

1st 3.58 3.49 3.51 3N 6.2 3S 5.9 4N 5.4 4S 5.1

- 3S 5.9 4N 5.4 4S 5.1

3N 6.2 3S 5.9 4N 5.4 4S 5.1

3.43

2nd 2.09 1.86 1.91 3N/3S 1.43 4N/4S 1.36 2.01

3rd 1.39 1.41 1.43 3N/3S 1.00 4N/4S 1.00 1.42

4th 1.00 - - 3N/3S 0.70 4N/4S 0.73 1.00 5th - 0.75 0.74 - - - - 0.83 6th - 0.65 0.64 - - - - 0.59

Gear ratio

Rev. 5.67 5.03 4.80 3N 6.2 3S 5.9 4N 5.4 4S 5.1

3N 6.2 3S 5.9 4N 5.4 4S 5.1

3N 6.2 3S 5.9 4N 5.4 4S 5.1

3N 6.2 3S 5.9 4N 5.4 4S 5.1

4.84

Dry weight() 231 227 412 295 300 330 335 310 315 330 Oil capacity() 25 45 28 30


16

PROPELLER SHAFT (Manual Transmission)

BF106

D1146 D1146 DE12 Distinction K805A/P

T8HS5B/P K806P T8HS6P K806P T8HS6P

Length 1586 1494.2 1485.2 1535.8 1526.8

Outside dia. 88.9 1st piece()

(when equipped) Inside dia. 80.9

Length 1467.5 1334.1 Outside dia. 88.9 1

st piece() (when equipped)

Inside dia. 80.9 Length 1360 1350

Outside dia. 88.9 1st piece()

(when equipped) Inside dia. 80.9

D1146

D1146Ti DE08Tis DE12 DE12T DE12Ti DE12Tis

Distinction BM090 BS090

BM090 BS090

BH090 BS106 BS106 BH115E BH120E

BH115E BH120E

BS106 BH115E BH120E

BS106 BH115E BH120E

Length 320 340.0 320.0 Outside dia. 88.9 88.9 K805A K805P Inside dia. 80.9 80.9

Length 690.0 577.0 Outside dia. 88.9 88.9 T-9 Inside dia. 80.9 80.9

Length 557. 560.0 Outside dia. 88.9 101.6 K4005C K1005P Inside dia. 80.9 91.6

Length 463.0 367.0 Outside dia. 88.9 101.6 K1006R Inside dia. 80.9 91.6

Length 535.8 535.8 535.8 Outside dia. 101.6 101.6 101.6 T-10 Inside dia. 91.6 91.6 91.6

Length 560.0 560.0 560.0 Outside dia. 101.6 101.6 101.6 K1205C K1205P Inside dia. 91.6 91.6 91.6

Length 367.0 367.6 367.6 Outside dia. 101.6 101.6 101.6 K1206R Inside dia. 91.6 91.6 91.6


17

DE12T DE12Ti/Tis (310ps) DE12Ti/Tis

(340ps) DV15T DV15TiS Distinction BH116 BH116/BH117 BH117/BH120F

Length 600.2

Outside dia. 101.6 K1105C K1006R Inside dia. 91.6

Length 400.7

Outside dia. 101.6 K1006R

Inside dia. 91.6

Length 569.9 569.9

Outside dia. 101.6 101.6 T-10S5B

Inside dia. 91.6 91.6

Length 600.2

Outside dia. 101.3 K1205C K1205P Inside dia. 91.6

Length 400.7

Outside dia. 101.6 K1206R

Inside dia. 91.6

Length 541.4 730.3

Outside dia. 101.6 101.6 K1405A

Inside dia. 91.6 91.6

Length 620.3

Outside dia. 101.6 K1406P

Inside dia. 91.6

Length 709.8

Outside dia. 114.3 T16DS5A

Inside dia. 101.1

Length 678.0

Outside dia. 114.3 K1605A

Inside dia. 101.1


18

PROPELLER SHAFT (Auto Transmission)

D1146 D1146Ti

DE08Tis DE12 DE12T DE12Ti DE12Tis Distinction

BM090 BS090

BM090 BS090

BH090 BS106 BS106 BH115E BH120E

BH115E BH120E

BS106 BH115E BH120E

BS106 BH115E BH120E

Length 577.0 470.0 Outside dia. 88.9 MT643 Inside dia. 80.9

Length 626.0 Outside dia. 88.9 88.9 B300 Inside dia. 80.9 80.9

Length Outside dia. B400 Inside dia.

Length 660.0 557.0 Outside dia. 88.9 88.9 D851.2 Inside dia. 80.9 80.9

Length Outside dia. D854.2 Inside dia.

Length 529.0 529.0 Outside dia. 114.3 114.3 D863 Inside dia. 101.6 101.1

Length Outside dia. D864 Inside dia.

Length 393.0 676.0 566.0 569.5 569.5 Outside dia. 88.9 88.9 88.9 101.6 101.6 HP500 Inside dia. 80.9 80.9 80.9 91.6 91.6

Length 569.5 569.5 Outside dia. 101.6 101.6 HP600 Inside dia. 91.6 91.6


19

DE12T DE12Ti/Tis (310ps) DE12Ti/Tis

(340ps) DV15T/DV15Tis Distinction BH116 BH116 BH116/BH117 BH120F

Length

Outside dia. B400R

Inside dia.

Length

Outside dia. B500R

Inside dia.

Length

Outside dia. D851.2

Inside dia.

Length

Outside dia. D854.2

Inside dia.

Length 555.8 Outside dia. 114.3 D863 Inside dia. 101.1

Length 482.8 Outside dia. 101.6 D864 Inside dia. 91.6

Length 599.3

Outside dia. 101.6 HP500

Inside dia. 91.6

Length 599.3

Outside dia. 101.6 HP590

Inside dia. 91.6


20

FRONT AXLE

Distinction BF106 BM090 BS090 BH090 BS106 BH115E BH120E BH116 BH117 BH120

Type Reverse elliot I beam

Tire tread() 2050 Capacity() 6000

King pin() Outside dia. 50 Length 252

Toe-in() 4~6 0~2 4~6 0~2 Camber( ) 0.530 Caster( ) -1 0030 0 1230 1 3030 -0 3630 0 1230 1 3030

Wheel alignment

King pin Inclination( ) 7.510

Steering angle Inside( ) 42 45

Outside( ) 34 37


21

REAR AXLE

Distinction BF106 BM090 BS090 BH090 BS106 BH115E BH120E BH116 BH117 BH120

Type Banjo full floating type

Final drive gear type Spiral bevel Hypoid gear

39/6 39/7 - 39/7 -

39/7 39/8 39/8 39/8 39/8

39/8 - 39/10 - 39/10

39/11 39/10

39/11 39/11 39/11 39/11

Final gear Ratio

Option

39/12 39/12 39/12 39/12

Oil capacity () 11.5~12.5

Axle load capacity () 9500 10500


22

STEERING

Distinction BF106 BM090 BS090 BH090

BS106 BH115E BH120

BH116 BH117 BH120

Type Recirculating ball with integral power assisted

Steering wheel diameter () 500

Gear ratio 22.4:1

Sector gear Operating angle 96

Power steering

Gear oil capacity() 1 1.5

Length of drop arm () 200

Oil capacity () 5 6 7 7.5


23

BRAKES (Air Over Hydraulic circuit)

Distinction BF106

Front 410 Drum inside Diameter () Rear 410

Front 209 x 155 x 16 - 8 Brake lining () L x W x T-N Rear 209 x 180 x 16 - 8

Front 53.5 Wheel cylinder Bore dia. () Rear 55.56

Front 30 x 133.5 Anchor pin () Dia. x length Rear 35 x 132

Internal expansion drum type Type

K805A/P, K806P T8HS5B/P, T8HS6P

Brake drum inside dia. () 254 304.8 Brake lining ()

L x W x T 288 x 60 x 5.5 353 x 75 x 6.15

Parking Brake

Auxiliary brake Exhaust brake BRAKES ( Full Air circuit)

Distinction BF106 BM090/BS090/BH090 BS106/BH115E/BH120 BH116/BH117/BH120

Front 410 Drum inside Diameter () Rear 410

Front 209 x 155 x 19 - 8 Brake lining () L x W x T-N Rear 209 x 220 x 19 - 8

Front Wheel cylinder Bore dia. () Rear

Front 30 x 106.5 Anchor pin () Dia. x length Rear 35 x 121.5


24

SUSPENSION ( Leaf Spring )

Distinction BF106 BM090 BS090 BS106 BH115E BH120E

Type Semi elliptical alloy steel

Span() 1400 1500 Width() 80 90 Thickness -no. of leaf

11-2 12-7 11-1

13-6 13-7 13-8 Front

Spring constant (/) 32.83 25.33 33.5 36.42

Span() 1660 Width() 100 Thickness -no. of leaf

12-2 11-3 16-4

14-4 15-4

15-1 14-9 14-11

Leaf Spring

Rear

Spring constant (/) 32.86 43.5 47.9 50.31

Type Hydraulic, double acting telescopic

Front rebound 650 595

Front compression 275 260

Rear rebound 650 650

Shock absorber Damp

force()

Rear compression 260 260


25

SUSPENSION ( Air Spring )

FRONT REA R

BH116 Distinction BH090 BH116 BH1117 BH120 BH090

STD WIDE BH117 BH120

Type Variable throttle type with stabilizer

Effective dia. () 250 260 250 Design height() 270 270 260 Max. out dia. () 310 316 310

No. of springs 2 4

Stroke of ext. 100 100

Air Spring

Spring() comp. 100 100 Type Double acting telescopic type

Out. dia. () 86 86 74.5 Base shell dia. () 76.3 76.3 65

No. of S/A 2 2 4

Extension () 594 545 710

Shock Absorber

Compression () 384 338 465 L/V No of leveling valve 1 2


26

WHEEL AND TIRE

Distinction 9.00-20-14PR (Tube) 9.00R20-14PR (Tube,Radial)

10.00-20-14PR (Tube)

10.00-20-16PR (Tube)

10.00R20-16PR (Tube, Radial)

Out dia. () 1014~1034 1006~1032 1046~1076

Max width () 229 254

Front 7.7/(109psi) 8.0/(113psi) 7.0/(99psi) 8.1/(115psi) Tire

Tire Inflation Pressure Rear 7.0/(99psi) 7.3/(103psi) 6.3/(89psi) 7.4/(105psi)

Disc. Wheel size 7.00T-20

Distinction 11.00-20-16PR (Tube) 11.00R20-16PR (Tube, Radial)

11R22.5-16PR (Tubeless)

12R22.5-16PR (Tubeless)

295/80R22.5-16PR (Tubeless)

Out dia.() 1078~1108 1068~1098 1037~1067 1068~1098 1030~1058

Max width () 295 293 295 305 295

Front 8.4/(119psi) 8.3/(118psi) Tire

Tire Inflation Pressure Rear 7.7/(109psi) 8.3/(118psi)

Disc. Wheel size 7.50V-20 8.25x22.5


27

COOLER ( Sub Cooler )

Type PBC-2400(D)

Cooling capacity (/h) 26,000 Refrigerant R-12/R-134a (OPTION)

Weight ABOUT 550 Model KIA S-2

Piston displacement() 2209 No. of cylinder 4

High 1850

mid 1450

Engine

Rotating Speed (rpm)

Low 1150

Type ND 6C-500 Compressor

Piston displacement () 495 Condenser AL FIN & CU TUBE

Blower capacity (/min) (AT 40 Aq) 66.7 Expansion valve Thermostatic expansion valve

Receiver capacity () 2.6


28

COOLER ( Roof-On Cooler )

Type Standard Tropical Heavy duty

Compressor 1 Cooling capacity (/h) 21,000

Refrigerant R-12/R-134a (OPTION)

Type 4PFC/4PFCY(OPTION)

No. of cylinder 4 Diameter () 210

Stroke () 57 Compressor

Capacity (/rev) 560 Type AL FIN & CU TUBE

Condenser Total area () 0.466 0.762

Type PROPELLER FAN x 3 PROPELLER

FAN x 5

Capacity (/h) 4700 7200 Condenser

fan

Required power (A) 5.5A/EA Type Horizontal Receiver

Tank Capacity () 3.4 Type AL FIN & CU TUBE

Evaporator Total area () 0.346

Type SIROCCO FAN x 8 SIROCCO FAN x 12 Capacity (/h) 400/EA Evaporator Fan

Required power (A) 5.5A/EA Type External equalizing pressure Expansion

Valve Capacity (RT) 8 Total weight() 190 218 240


29

ENGINE ( Euro )

Model DL08 DV11 Water-cooled, 4 cycle, in-line Turbo charged & inter-cooled

Water-cooled, 4 cycle, V-type 90 Turbo charged & inter-cooled Type


Cylinder liner type Replaceable dry liner Wet type

Timing gear system Gear driven type

No. of piston ring 2 compression ring, 1 oil ring

No of cylinder 6

Bore x stroke () 108 x 139 128 x 142 Piston displacement () 7,640 10,964

Compression ratio 17:1 17.1 : 1 Engine Dimension ()

(Length x Width x Height) 1,356 x 919 x 1,153 1,203 x 1,031 x 1,070

Rotating direction (from flywheel) Counter clockwise

Engine weight (dry) (kg) 836 904

Firing order 1-5-3-6-2-4 1-4-2-5-3-6

Fuel high pressure Pump type Bosch CP3.3 fuel high pressure pump type Bosch CP3.4 fuel high pressure

pump type Engine control system Electric control type (ECU)

Injection type Multi-hole (9x0.147) Multi-hole (9x0.197 Bosch DLLA146) Fuel injection pressure (/) 250bar(operating pressure 1,600bar)

Intake valve 0.3 0.4

Exhaust valve 0.4 0.5 Valve clearance Jake brake 1.5 1.5

Open at 26.3 (BTDC) 24.0 (BTDC) Intake valves

Close at 34.3 (ABDC) 30.0 (ABDC)

Open at 53.0 (BBDC) 52.5 (BBDC) Exhaust valves Close at 13.0 (ATDC) 14.5 (ATDC)

Fuel filter type Full-flow (cartridge)

At idle speed 1.0~3.0 Fuel injection pressure (/) At rated speed 3.0~5.5


30

Model DL08 DV11

Using lubrication oil ACEA-E5 (API CI-4 class)

Lubrication method Full forced pressure feed type

Oil pump type Gear type driven by crank shaft

Oil filter type Cartridge type Full-flow, paper element type (double) Lubricating oil capacity

( max./min.) () Bus : 27 / 21 Bus : 34/26

Oil cooler type Water cooler

Oil pressure indicator Oil pressure unit

Water pump Belt driven centrifugal type

Cooling method Pressurized circulation

Cooling water capacity () 13.3 14.3 Type Wax pallet type

Open at () 83 Open wide at() 95

Thermostat

Valve lift () 8 Water temperature indicator Water temperature sensor mounted

Type Water cooled

Capacity(/rev) 440 550 Air compressor

Revolution ratio 1:1(engine speed ; air compressor speed) 1 : 1.265(engine speed ; air

compressor speed) Type Gear driven, vane type

Capacity 16 or 18 16 / 18 / 25 Adjusting

pressure(/) 125 125 / 150 Steering

pump

Revolution ratio 1 : 1.303 (engine speed : pump speed) 1 : 1.265

(engine speed : pump speed) Turbocharger Exhaust gas driven type ( waste gate)

Engine stop system Fuel feeding shut-off by ECU

Engine brake Control by ECU Alternator

( voltage-capacity) (V-A) 24-60 24-60 or 24-150

Starting motor (voltage-output)(V-kW) 24-4.5 24-6.0

Air heater capacity (V-A) 12V-1.3kW x 2EA 24V-2.64kW

Battery capacity (V-AH) 24-150


31

CLUTCH

Distinction BS090 BH090 BS106 BH115E BH116 BH117 BH119 BH120 BX212

Type Dry single plate with coil spring dampers hydraulic circuit incorporating clutch minipack

Outside dia. 430 430

Inside dia. 250 242

Clutch facing

dimensions ()

Thickness 5 4

Clutch clamping force() 158510%

200010%

DL08 : 200010% DV11 : 230010%

DV11(160.m) : 200010% DV11(170.m) : 230010%

Free play 46.4 47.4 47.5 47.1 47.4 Clutch pedal Max.

stroke 170

Clutch minipack start working pressure(/) 5.5

Master cylinder bore dia.() 20


32

TRANSMISSION

BS090 BH090 BS106

Type XDB HGF SCC XDB HGF SCC GBD FGC/FQD XAD/XMD/X01 GBE

Model T9DS5A T9DS5P K1005R K1005R K1005D T9DS5A T9DS5P T9DS5PN K1005R K1005RN K1005D T10DS5C T10DS5B K1005C

Speed 5 D.D 5 O.D 5 D.D 5 O.D 5 D.D 5 O.D 5 D.D

Speed Gear 14/6 15/6 14/6 15/6 14/6 14/6 12/6 11/6 12/6 11/6 12/6 11/6 12/6 11/6

Control MANUAL MANUAL MANUAL

Code MS6 MR5 MSS MN9 MS5 MS6 MR5 MS6 MR5 MT2 MN9 MN6 MK1 MT3 MP7 ML0

Engine DL08 GE08Ti DL08 DL08 GE12Ti

Power 250PS 240PS 250PS 270PS 250PS 270PS 300PS 290PS

BH115E BH116(BH115E) BH117/BH119/BH120

Type FBO FGC/FBO GBO FGC XAD GBO XHD IHD/HHD/ESD

Model T10DS5C K1205D T10DS6C 1206Q T10S5B K1205C T14DS5A K1405A T14DS6P K1405T K1205D T10DS5C K1206Q T10DS6Q K1205C T10S5B K1405A T14DS5A K1406T T14DS6P T16DS6F K1606T T17DS6F K1706T

Speed 5 D.D 6 O.D 5 D.D 5 D.D 6 O.D 5 D.D. 6 O.D 5 D.D 5 D.D 6 O.D 6 O.D

Speed Gear

12/6 14/6 11/6 11/7 12/7 12/6 14/6 11/6 12/7 12/7 12/7

Control MANUAL POWER SHIFT POWER SHIFT

Code MT3 MK1 MR6 MK2 MP7 MP9 MT5 MP5 MT4 MK3 MK1 MT3 MK2 MR6 MP9 MP7 MP5 MT5 MK3 MT4 MT6 MK4 MT7 MK5

Engine DL08 GE12Ti DV11 DV11

Power 310PS 310PS 340PS 360PS 380PS


33

PROPELLER SHAFT

Model BS090 BH090 BS106 BH115E BH116 BH117 BH119 BH120

GE08Ti DL08 DL08 GE12Ti DL08 DL08 GE12Ti DV11 DL08 GE12Ti DV11 DV11 Flange

(R/A-T/M) Engine 240PS 250PS 250PS 270PS 290PS 300PS 310PS 340PS 310PS 340PS 360PS/380PS

T9DS5A 347.6

K1005D 344.1

T9DS5A 370.0

K1005D 362.5

T9DS5P/PN 373.3

HR-CF

K1005R/RN 365.8

T10S5B 565.4 566.1 570.0

T10S5B 581.3 585.5

T10DS6Q 591.1 597.1

K1005C 596.1

K1205C 596.7 600.2

T10DS5C 670.6 671.2 675.5

K1205D 719.3 719.1 724.8

T14DS6P 836.2 841.7

K1406T 846.6 852.0

K1405A 897.6 903.0

C/F-C/F

T14DS5A 926.2 931.6

K1606 /1706T

741.8 741.8 X/S-X/S

T13 /T17DS6P

952.2 795.2


34

REAR AXLE

Distinction BS090 BH090 BS106 BH115E BH116 BH117 BH119 BH120

BX212

Type Banjo full floating type

Final drive gear type Spiral bevel Hypoid gear

Final gear ratio 39/8 39/8 39/9 39/10

39/8 39/9

39/12

39/8 39/9

39/12 39/11 39/11

Pinion cage length 425 ( 16 M12 x 1.25 ) 444.5

( 12 M16 x 1.5 ) Operation type 4 x 2

Oil capacity () 10.5 11.5 FRONT AXLE

Distinction BS090 BH090 BS106 BH115E BH116 BH117 BH119H BH120

Type Reverse elliot I beam

King pin out. dia. () 50x252 Front 2,050 Tire

Rear 1,853

Toe-in Bias : 4~6, Radial : 0~1 Camber 0.530 Caster 0 1230 1 3030 -0 3630 0 1230 1 3030 2 3630

Wheel Alignment

King pin Inclination 7 3030

Front 45 Steering angle Rear 37


35

STEERING

Distinction BS090 BH090 BS106 BH115E BH116 BH117 BH119H BH120

Type Recirculating ball with integral power assisted

Steering wheel Diameter() 500

Gear ratio 22.4 : 1 Sector gear

operating angle 96 Power

steering Gear oil

capacity() 1.5

Length of drop arm() 200

oil capacity() 7 BRAKE

Distinction BF106 BS090 BH090 BS106 BH115E

BH116 BH117 BH119 BH120 BX212

Service brake type Full air (dual circuit)

Drum inside diameter () 410 Front 209x155-19-8 Brake lining()

LxWxT-N Rear 209x220-19-8 Front 24-7.3 No. of

lining rivet -diameter Rear 32-7.3

Manual slack adjuster 0.30.1 Lining clearance Auto slack adjuster 0.5~0.8


36

SUSPENSION (Leaf Spring)

Leaf Spring Shock absorber Distinction

Length x Width x Thickness - no. of leaf

Damping force() Rebound/Compression

Front 1,500x9013-6 595/150 BS090

Rear 1,660x100x12-2 1,660x100x16-5 650/150

Front 1,500x90x13-6 595/150 BS106

Rear 1,500x100x14-5 1,500x100x15-4 650/150

Front 1,500x90x13-7 595/150 BH115E

Rear 1,660x100x15-1 1,660x100x14-9 650/150

SUSPENSION (Air Spring)

FRONT REAR Distinction

BH116 / BH117 / BH119 / BH120

Type Variable throttle type with stabilizer

Effective dia. () 250 250 Design height () 270 270(STD) 260(WIDE) Max out. dia. () 275 275

No. of springs 2 4

Extension 100

Air

Spring

Stroke Compression 100

Type Double acting telescopic type

Outside dia. () 86 Base shell dia. () 76.3

No. of S/A 2 2(STD) 4(WIDE)

Extension 570 595(SD) 300(WIDE)

Shock

Absorber

stroke Compression 100

L/V No. of leveling valve 1 2


37

4. LUBRICATION 4.1. OIL VISCOSITY CHART Engine oil

Gear oil


38

4.2. Recommended lubrication list

Lubricant Lubricant point Capacity Oil change period Specification Maker and brand name

Engine oil Engine 15.5

(BF,BS) 20 (BH)

First : 1,000 Every : 5,000

(D1146)

CC grade CD grade

CALTEX : 20RPM DELO 40 SHELL : RIMULA X

Gear oil Transmission

Rear axle

8 (BF,BS) 9.8 (BH) 8 (BF,BS) 10 (BH)

15,000 (DE12,DV15)

First : 3,000~5,000 GL-5 grade

CALTEX : Multi-Purpose THUBAN EP

SHELL : SPIRAX H.D MOBIL : MOBILUBE H.D

Power steering oil

Power steering

6 (BF,BS) 8.5 (BH) Every : 24,000 DEXRON R-11

CALTEX : DEXRON SHELL : DEXRON

Brake fluid Brake & clutch 4 First : 1,000 SAE J1703 CALTEX : BRAKE FLUID

Grease Wheel bearings Grease fittings

Needed quantity

Every : 24,000 Every 1 year

Every : 4,000

Multi-purpose Type grease

NLGI No. 2 or 3

CALTEX : MARFAK MOBIL : GREASE MP SHELL : ALVANIA EP R2

4.3. Lubrication chart The lubrication chart gives all information necessary for providing the vehicle chassis with correct lubricating attention. In the following chart, the kinds of lubricant and hydraulic oil to be used, intervals of lubricating services, type of service required, and lubrication points are indicants are for quick reference. The lubricants are recommended for use when adding lubricant or when disassembling parts. When using the lubricants, observe the following. When the vehicle was assembled in Daewoobus, the various parts were lubricated throughout. Therefore, before lubricating according to the following chart, drain and clean all parts thoroughly of all such lubricant. When lubricating, always use the same product consistently. Never mix lubricants of different manufactures. If the above precautions are observed conscientiously, bearing seizure or other troubles may be prevented and the vehicle service life will be appreciably lengthened.


39

LUBRICATION CHART FOR FRONT ENGINE BUS


40

LUBRICATION CHART FOR REAR ENGINE BUS

41

SECTION 2

CLUTCH

CONTENTS PAGE

1. GENERAL DESCRIPTION

1.1. CONSTRUCTION 42

1.2. SPECIFICATION 42

2. SERVICING OF CLUTCH ASSEMBLY

2.1. REMOVAL 44

2.2. DISASSEMBLY 45

2.3. INSPECTION OF DISASSEMBLED PARTS 46

2.4. REASSEMBLY AND INSTALLATION 49

3. SERVICING OF CLUTCH CONTROL ASSEMBLY

3.1. CLUTCH MASTER CYLINDER 51

3.2. MINI-PACK (AIR-BOOSTER) 53

3.3. CLUTCH PEDAL AND RELATIVE PARTS 62

3.4. ADJUSTMENT OF CLUTCH PEDAL FREE PLAY 68

3.5. BLEEDING OF CLUTCH HYDRAULIC CIRCUIT 69

4. TROUBLE SHOOTING 71

2. Clutch

42

1. General description 1.1. Construction This model is equipped with a dry single plate type clutch with coil spring dampers to permit coupling and uncoupling of the engine and transmission. The clutch assembly consists principally of the pressure plate, driven plate, clutch cover, springs, release levers, etc. The driven plate is positioned between the engine flywheel and pressure plate and is held in good contact with the flywheel and pressure plate by the action of the springs to carry the engine torque to the transmission through frictional resistance. The clutch control is hydraulically actuated and when the clutch pedal is depressed, foot pressure is relayed via the master cylinder and clutch mini-pack to the link rod which, in turn, move the clutch shift fork lever, shift block and release levers, thereby releasing the pressure plate. Thus, the driven plate is brought into free state to uncouple the engine and transmission. When the clutch pedal is released, the pressure plate forces the driven plate against the engine flywheel by the action of the clutch springs to couple the engine and transmission.

1.2. Specification

Distinction BM090 BF106 BS106 BH115E BH115 BH116 BH117 BH120

Type Dry single plate with coil spring dampers hydraulic circuit incorporating clutch minipack Outside dia. 380 430

Inside dia. 240 250 Clutch facing dimension()

Thickness 5

Clutch clamping force () 147010% (DE12Ti) 138010% (DE12) 195010%(DE12T) 210010%(DE12Ti)

2320+8%-6% (DE12Ti/DV15T)

Ratio 6.75 7.09 6.67 6.75 6.75 6.75

Free play 46.4 48.8 46.6 47.1 47.2 47.4 Clutch pedal

Max. stroke 170 180 150 170 170 170 Clutch minipack start working

pressure(/) 5.5


2. Clutch

43

CLUTCH ASSEMBLY IN DISASSEMBLED VIEW

1. Plate A-pressure 9. Bearing-clutch, REL.

2. Plate A-driven 10. Fork-shift, clutch

3. Bolt-hex M10 x 1.5 11. Screw-set, shift fork

4. Washer-spring 12. Washer-spring

5. Shaft-W/lever 13. Spring-return, shift block

6. Nipple-grease 14. Hose-flexible

7. Key-feather, clutch shaft 15. Nipple-grease

8. Block-shift 16. Clip

2. Clutch

44

2. Servicing of clutch assembly Service tools : A set of open-end wrenches, offset wrenches, socket wrenches, wire, pliers, hammer, hoist,

transmission jack, micrometer, vernier calipers, dial indicator, square, spring tester, feeler gauge, straighter edge.

Special tools : Clutch pilot bearing aligner, clutch release lever aligner, clutch pilot bearing remover, clutch release bearing ruler

2.1. Removal Removal the clutch assembly from vehicle together with the transmission assembly in the following procedure. Disconnect the propeller shaft at the flange yoke on the transmission side. Remove the bolts from the rubber holder fixing the center bearing cushion rubber. Remove the propeller shaft. Remove the floor board within the cab. Remove the gearshift lever assembly or connecting rod and disconnect the wiring of the back-up lamp switch on the quadrant box. Disconnect the parking lever assembly or connecting rod from the relay lever at the joint pin. Remove the parking brake lever assembly or connecting rod.

Remove the clutch mini-pack assembly together with the bracket and fasten the mini-pack assembly to the frame member with wire. It is not necessary to disconnect air and oil pipes unless when inspecting or replacing them.

Disconnect the speedometer cable at the joint on the transmission side. Raise the transmission assembly on a hoist or support the transmission assembly on a transmission jack and remove the bolts mounting the clutch housing. Remove the transmission assembly rearward.

Note. Handle the transmission assembly with care as it is heavy weighing approximately 280kg. Pull out the transmission assembly horizontally using care not to cause distortion of the driven plate.

Remove the bolts fixing the clutch pressure plate assembly. Remove the pressure plate assembly.

Note. The driven plate comes out of position when removing the pressure plate. For assurance of safety, hold the driven plate assembly in position by inserting special tool, clutch pilot bearing aligner into splined portion of the driven plate.

2. Clutch

45

2.2. Disassembly 2.2.1. Disassembly of Pressure Plate Assembly

Depress the clutch cover with a bench press to compress the clutch springs and remove the release lever lock nuts.

Note. Clutch springs can not be compressed by merely depressing the spring case without applying pressure onto the clutch cover.

Remove the release lever lock nuts and distance pieces.Turn loose bench press gradually and remove the clutch cover from the pressure plate.

Remove the clutch spring cases and clutch springs from the pressure plate.

Pull out the cotter pin from the release levers and remove the release lever pins. Remove the release

levers and holder springs.

Pull out cotter pin from the release levers and remove the release lever pins. Remove the release levers and holder springs.

2.2.2. Disassembly of Clutch Shift Fork and

Relative Parts

Remove the clutch shift fork set bolts. Remove the cover by tapping on the end of the shaft with a copper hammer from the shift lever side. ( clutch mini-pack side )

Drive the shaft part way out by tapping on its end from the cover side using a suitable bar and a hammer. When the keys on the shift form clear, remove the keys and pull out the shift fork shaft toward the mini-park side. Remove the shift fork from the front cover together with the shift block. Remove the return springs.

2. Clutch

46

Remove the bolts mounting the clutch housing. Remove the clutch housing from the transmission case. When replacing the release bearing, take out the bearing from the shift block using the special tool-bearing puller.

Wash clean disassembled parts. 2.3. Inspection of Disassembled Parts 2.3.1. Driven Plate

Check the friction face of the driven plate for cracks, hardening of material and a sign of slippage due to contact with oil or grease. Check the rivets for looseness and damper springs for checks and wear. Measure the depression (t) of the rivet heads from the surface of the clutch facing on both sides. Replace the driven plate if measured value is less than the limit.

Unit :

Nominal value Limit for

use BM/BF 3.6 0.2 Depression

of river heads (t) BS/BH 3.0 0.2

Check the clutch driven plate for warage using a dial indicator. Take measurement at the portion 170mm apart from the center of the driven plate. Replace the driven plate if the amount of warpage is beyond the limit.

Unit :

Allowance for assembly Limit for use

Driven plate warpage 1.0 or less 1.5 or more

Assemble the clutch driven plate to the splined portion of the transmission top gear shaft and check the amount of play in the springs in rotary direction at the outer edge of the driven plate. Note. To obtain correct measurement, apply a mark to the outer circumference of the driven plate and set the probe of surface rotary direction.

Unit :

Standard value for assembly

Limit for use

Play of clutch center splines in rotative direction (at the outer edge of driven plate)

0.09~0.24 0.42

2. Clutch

47

If the amount of play is beyond the limit, check condition of step wear on the top gear shaft splines to determine the parts to be replaced. Slight amount of step wear on the top gear shaft splined may be removed using a scrapper or other suitable tool. Check the clutch facing for cracking, scores and hardening of material due to heating. Replace the driven plate if found to be defective. Check the damper springs for weakening and rivets for looseness. Replace the driven plate assembly as necessary. 2.3.2. Pressure Plate and Clutch Cover

Check the pressure for scoring, warpage and reduction in thickness due to wear. If the amount of warpage or depth of scoring is within 1.5mm, correct with a surface grinder.

Unit :

Nominal thickness Limit for

use 15(380) 31 30.5 Thickness of

pressure plate (t) 17(430) 60 59.5

Note. If material in thickness of more than 1.0mm is to be removed from the pressure plate through correction, it is necessary to adjust set length of the clutch springs by installing a washer equivalent in thickness to the material removed under each spring. 2.3.3. Release Lever Pins

Measure the outside diameter of the release lever pins with an outside micrometer. Replace the release lever pin if the measured value is beyond the limit of heavy scores are noticeable.

Unit :

Nominal diameter Limit for

use 15(380) 31 30.5 Outside

diameter 17(430) 60 59.5 Check the dry bushing (made up of sintered alloy with teflon coating) for wear. Replace the parts if the amount of wear is considerable. 2.3.4. Release Levers Check the tip end of the release levers for wear. Release the release lever if the amount of wear is in excess of 1 mm.

2. Clutch

48

2.3.5. Clutch Springs.

With a spring tester measure the load required to compress the clutch springs to set length of 57.6 mm. Reject the spring if measured value is beyond the limit.

Measure the free length of the clutch springs with a spring tester. Replace the spring if measured value is beyond the limit.

Nominal spring tension

and free length

Limit of use

Set load : when compressed to set length of 67mm

115 105k

Free length (reference value) 62.6 61.3

Check ends of the clutch springs for distortion. Position the clutch springs on a surface plate as shown in the drawing and check the amount of inclination from vertical using a square. Replace upper end of the spring and square is beyond the limit.

Unit :

Nominal clearance Limit for

use Inclination from

vertical 1.0 or less 2.5 or more

2.3.6. Shift Fork and Relative Part

Check the contacting face of the shift fork and shift block for wear. Replace the parts if the amount of wear is in excess of 1 mm. If a slight amount of wear is noticeable, correct with an oil-stone. Inspection of thrust bearing Check the thrust bearing by turning it with hand. Replace the bearing if it produces abnormal noise. Check the clutch shift fork shaft for wear. If uneven wear or step wear is noticeable, replace the shift fork shaft together with the needle roller bearing. 2.3.7. Replacement of Needle Roller Bearing To replace needle roller bearing, proceed as follows Drive out the needle roller bearing from both sides of the housing using a soft metalbar and a hammer. The needle roller bearing on the shift lever side (clutch mini-pack side) is fitted with an oil seal. Remove the oil seal together with the bearing using a soft metal bar. Installation of new bearing Drive the bearing, with marked side out, into the housing, using a hammer carefully so as not to scratch the oil seal.

2. Clutch

49

Apply wheel bearing grease to the clearance between dust seal and needle roller bearing when installing the dust seal. Note. Refer to the drawing above for dust seal setting position Install the plug on the left side face of the housing when installing of the clutch shaft is completed. 2.3.8. Flywheel and Pilot Bearing Check the friction face of the flywheel for cracks, scores and damage. Replace or correct by grinding if cracks or scores could be removed within the limit of reduction in thickness. Measure the depth of the friction face of the flywheel from the clutch cover fitting face. If the amount of wear is excessive, replace

the flywheel.

Unit : Nominal

depth Limit for use Depth of friction face from clutch cover fitting face 48 49

If the friction face of the flywheel has been worn or ground, or if pressure plate has been ground, causing more than 1 mm of increase in the seat length of the clutch springs, resulting reduction in contacting pressure should be compensated for b installing washers equivalent in thickness to the amount of increase in the set length of the clutch springs in position between the pressure plate and clutch springs. The clutch pilot bearing is fitted to the engine flywheel. Remove the pilot bearing cover an remove the pilot bearing. Wash clean the bearing in detergent oil and abnormal noise. Replace the bearing if found to be defective. 2.4. Reassembly and Installation 2.4.1. Reassembly To reassemble the clutch assembly, follow the disassembly procedure in the reverse order and note the following points. If the set length of the clutch springs has been increased by more than 1 mm due to wear of the flywheel or through grinding of the pressure plate, clutch spring set load should be adjusted by installing under each clutch spring a washer which is equivalent in thickness to the amount of clutch spring set length increased.. Leave the release lever adjust nuts semi-tight as they are to be fully tightened when release lever height

2. Clutch

50

adjustment is completed after the installation of the clutch assembly on the vehicle. 2.4.2. Installation Before installation, wipe clean surface of the flywheel, driven plate and pressure plate and check that they are free from oil or grease.

2. Clutch

51

3. Servicing of clutch control assembly 3.1. Clutch master cylinder Clutch Master Cylinder in Disassembled View

A. Master cylinder A-clutch 10. Plate

1. Body 11. Ring-retaining

2. Piston 12. Rod

3. Primary cup 13. Boot

4. Secondary cup 14. Nut-hex M10 x 1.25

5. Spacer 15. Nut hex M10 x 1.25

6. Seat-spring 16. Joint-jaw

7. Spring 17. Packing

8. Valve A-check 18. Retainer

9. Connector 19. Nipple-hose

2. Clutch

52

3.1.1. Removal Disconnect the vinyl pipe connected between the master cylinder and fluid reservoir from master cylinder joint nipple. Take out the joint bolt and disconnect the flexible hose. Note. Prepare a suitable container to receive brake fluid that flows out when the pipe and hose are disconnected. Pull out the push rod joint pin and disconnect the pedal arm from the push rod.

Take out the master cylinder fixing bolts, then remove the master cylinder. 3.1.2. Disassembly and inspection Take out the boot and push rod.

Remove the clip, then take out the 1 stopper, 2 piston assembly, 3 spacer, 4 piston cup, 5 return spring and 6 check valve. Wash clean the disassembled parts and check them in the following manner. Note. : Never use the gasoline and diesel fuel. Check the primary and secondary cups for

wear, damage and elasticity and replace with new ones as necessary. Check the cylinder body and piston for wear and damage and replace with new ones if found to be excessive wear and damage.

Unit :


Limit for use

Clearance between the

body and piston 0.10 More than 0.15

Check the return spring for damage and weakening Reference

set load / set length 2.7

Free length Check the boot for damage and elasticity and replace with a new one as necessary. 3.1.3. Reassembly and Installation Reassembly and install the master cylinder on the vehicle in the reverse order of disassembly and removal and note the following points. Discard used piston cups and install new ones when reassembling. Submerge the parts in the clean brake fluid when reassembling. Note the director piston cups.

When installation of master cylinder is completed, adjust the clutch pedal free play and bleed the hydraulic circuit.

2. Clutch

53

3.2. Mini-Pack (Air-Booster) 3.2.1. General description The clutch mini-pack assembly is a compressed air assisted clutch booster and consists essentially of compressed air circuit and hydraulic circuit integrated into a compact unit. The mini-pack assembly is nearly equal to brake air-master in construction and operation. The clutch mini-pack serves as a clutch slave cylinder and controls the clutch lever, via the push rod.

2. Clutch

54

MINIPACK ASSEMBLY IN DISASSEMBLED VIEW

2. Clutch

55

A. Booster A-clutch 25. Gasket

1. Connector 26. Bush

2. Gasket 27. Bolt

3. Spring 28. Steel cylinder A

4. Valve-poppet 29. Washer

5. Body-valve 30. Nut

6. Spring 31. Guard A

7. Diaphragm 32. Cup-packing

8. Fitting 33. Cup-packing

9. Gasket 34. Piston

10. Ring-snap 35. Cylinder-hydraulic

11. Cup-packing 36. o-ring

12. Piston-relay 37. Ring-retainer

13. Cover-exh. 38. Washer

14. Cap-protector 39. Retainer

15. Screw-air bleeding 40. Cup-packing

16. End plate A 41. Washer

17. Seal-oil 42. Bolt-W/Washer

18. O-ring 43. Gasket

19. Rod-push 44. Gasket

20. Spring 45. Bolt-eye

21. O-ring 46. Connector-eye

22. Piston-power 47. clamp

23. Cup-packing

24. Nut

2. Clutch

56

3.2.2. Removal of Clutch Mini-pack Remove the clutch mini-pack return spring. Disconnect the air pipe and oil pipe at the

joint. Note. Plug or tape opening in the mini-pack and pipes to prevent entry of foreign matter. Remove the pin and disconnect the clutch lever from the yoke at the end of the clutch mini-pack push rod. Remove the stud bolts and nuts from the bottom the end plate flange bolts, then remove the clutch mini-pack from the remove the clutch mini-pack from the bracket. Drain the clutch mini-pack. Note. Oil can be drained by loosening bleeder screw on the way relay valve. 3.2.3. Disassembly of Clutch Mini-pack

Assembly Wipe clean exterior of the mini-pack assembly prior to disassembly. Apply setting mark to the joining portions before disassembling.

Clamp the end plate flange in a vise and remove the valve adapter from the upper valve body using a wrench, then remove he gasket, poppet valve spring and poppet valve.

Upper valve body removal Remove the bolts fixing the end plate and take out the upper valve body, valve spring and diaphragm assembly from the end plate. Note. Do not attempt to disassemble diaphragm assembly.

2. Clutch

57

Loosen the bushing connecting the end plate with the control tube. A seal is fitted into the end of the bushing. Remove the four bolts fixing the end plate to the cylinder shell and take out the end plate assembly, piston return spring and piston push rod assembly.

Removal of hydraulic cylinder assembly Remove the hydraulic cylinder assembly with the hydraulic piston using a wrench.

Remove the hydraulic piston and piston cups from the hydraulic cylinder. Note. Discard used hydraulic piston cups and O-rings and install new ones at the time of reassembly.

1. Hydraulic cylinder 2. Hydraulic piston 3. Hydraulic piston cup

Clamp the hexagonal portions of the push rod in a vise and removal the gasket retainer nut, piston gasket expander, felt gasket, gasket retainer plate, piston gasket and O-ring in the order described. Relay valve piston removal Clamp the end plate in a soft-jawed vise and remove the valve fitting using valve fitting wrench or a box wrench. The valve fitting includes retaining ring, relay valve piston, hydraulic piston cup, valve and fitting seal.

2. Clutch

58

Remove the hydraulic piston cup from the relay valve piston.

retaining ring valve fitting piston cup Relay valve piston

Remove the bleeder screw using a wrench. Removal of the exhaust pipe and screw assembly is unnecessary. Remove the O-ring and snap ring from inside of the hydraulic cylinder and take out the piston stop washer, seal retainer, hydraulic piston cup, push rod washer and oil seal in the order described. Note. Discard used hydraulic piston cups and O-rings and install new ones at the time of reassembly. These rubber parts are available as a repair kit.

snap ring push rod washer stop washer oil seal seal retainer end plate push cup

3.2.4 Inspection Wash metallic parts in essential metal cleaner ( Trichioroethylene, Metal clean, etc ) and keep them neatly on a clean bench. Check these parts for using, correction and damage. Metal parts with rust can be cleaned by lapping with chrome oxide power. Discard parts if condition of rust or corrosion is beyond correction. Note. Avoid hard with rust sanding or the use of coarse sand paper for removal of rust, or leakage of oil or air will result. Rubber parts are to be replaced with new ones each time the clutch mini-pack assembly is overhauled. However, they may be reused after cleaning with brake fluid if not too long a time has passed since previous overhauling. Check the hydraulic piston and hydraulic cylinder wall for wear of damage and replace them with new ones as necessary. Inspection of mini-pack return spring. Check free length of the return spring and replace with a new one if the measured value is beyond the limit.

Standard value Free length of return spring 100 mm

2. Clutch

59

3.2.5. Reassembly Reassembly of end plate assembly.

apply air master paste to the hydraulic piston cups, seals and O-ring before installation. Assemble the hydraulic piston cups, back to back, to the relay valve piston.

insert the relay valve piston with the cups into the valve fitting into wrench into which retaining ring has been assembled. ( check to make certain the lipped portions of the piston cups are correctly seated. ) Apply air master paste to the valve fitting seal and insert it into the adapter groove in the valve fitting. Clamp the flanged portion of the end plate in a vise and install the valve fitting using special tool : valve fitting wrench or I type box wrench.

Tightening torque 0.3m-

Insert the O-ring into the shell side groove of the end plate. Apply generous amount of air master paste to the inner face of the end plate, then assemble the push rod washer, hydraulic piston cups, retainer seal and piston stop washer to the end plate in the order described. Secure these parts in position with the snap ring, then install the O-ring and bleeder screw. Reassembly piston and push rod assembly.

Apply a thin coat of air master paste to the piston gasket fitting face of the piston plate before installation. Clamp the hexagonal portion of the push rod in a vise and install the O-ring, piston, cup packing and packing plate nut. Caulk opposed two portions of the nut. Note. 1. Apply generous amount of vacuum cylinder oil to the cup packing. 2. Apply air master paste to the push rod. Reassembly of hydraulic piston assembly

Apply air master paste to the hydraulic piston cups before fitting them to the hydraulic piston. The piston cups should be assembled, back to back, to the piston as illustrated. Installation of hydraulic piston Apply a thin coat of air master paste to the

2. Clutch

60

inner wall of the hydraulic cylinder and insert the hydraulic piston into the cylinder from the end plate fitting side.

Major reassembly Wipe clean the inner wall of the cylinder shell and apply a thin coat of air master paste to the entire wall. Insert the bushing and seal into the control tube. Insert the piston push rod assembly, piston spring, end plate and seal assembly, then fasten the clylinder shell with the end plate using bolts. Note. When installing the piston and push rod assembly use care not to cause distortion of the piston gasket.

Align setting marks applied at the time of disassembly and tighten the nuts evenly, then install the plug on the bottom face of the cylinder shell and tighten it to 1 m-kg torque. Then install the control tube bushing on the end plate. Apply air master paste to the hydraulic cylinder and screw it carefully into the end plate. Note. Screwing hydraulic cylinder quickly into end plate can cause damage to the O-ring. Clamp the flanged portion of the end plate in a vise and fully tighten the hydraulic cylinder with a wrench, then wipe clean the end plate and valve fitting. Install the diaphragm assembly and position the valve spring over the diaphragm. Align the upper valve body with the mark on the end plate, then install and tighten the bolts. Insert the poppet valve and spring to the upper valve body and tighten the valve adapter together with gasket to the upper valve body. Note. Before installing the upper valve body, check to mark certain the hydraulic piston returns quickly by applying compressed air into the cylinder shell from the end plate side. If the movement of the piston is unsmooth, loosen the nuts fastening the end plate with the cylinder shell and stroke the piston repeatedly before retightening the nuts. This test is important as slugguish movement of the piston will result in oil leakage. 3.2.6. Testing of Clutch Mini-Pack Assembly after Installation Air leak test When installation of the clutch mini-pack assembly is completed, start and let the engine run until compressed air reaches 6 kg/, then loosen the plug on the bottom face of the cylinder shell and exhaust cover and check for air leakage. Oil leak test Depress the clutch pedal and check the joints

2. Clutch

61

in the hydraulic circuit for leakage. Hold the clutch pedal depressed and check for variation in pedal feel and movement of the push rod. If the clutch pedal feel remains unchanged and push rod stays still, it indicates that the piston cups and oil seals are in good order. Operation test Depress and release the clutch pedal repeatedly and check movement of the mini-pack push rod and listen for hiss accompanied by discharge of compressed air to make certain clutch system operates without delay. Bench test Performance of the clutch mini-pack can be test accurately using a brake booster tester and a clutch test kit.

2. Clutch

62

3.3. Clutch Pedal and relative parts 3.3.1. Disassembled View

2. Clutch

63

1. Pedal arm A-clutch 18. Tank A-oil

2. Seal-plate 19. Hose

3. Seal-rubber 20. Grommet

4. Cover-seal, rubber 21. Clip-board

5. Pad-pedal 22. Clamp

6. Cover-pedal pad 23. Bracket-oil tank

7. Spring 24. Bolt hex M10 x 1.25

8. Shaft 25. Nut-hex M10 x 1.25

9. Screw-set 26. Washer-spring

10. Washer-spring 27. Bolt-hex M6 x 1.0

11. Nipple-grease 28. Nut-hex M6 x 1.0

12. Bracket-clutch master cylinder 29. Bolt-hex M10 x 1.25

13. Bracket-clutch pedal 30. Washer-spring

14. Master cylinder A-clutch 31. Bolt-hex M10 x 1.25

15. Pin-joint 32. Stopper-pedal

16. Washer-plain 33. Bolt-hex M6 x 1.0

17. Pin-split 34. Washer-spring

2. Clutch

64

3.3.2. DISASSEMBLED VIEW(BS106)

2. Clutch

65

1. Support A-clutch pedal 21. Washer-plain

2. Arm A-clutch pedal 22. Support-clutch pedal mounting

3. Bush 23. Bolt-hex, M12 x 1.25

4. Shaft 24. Washer-spring

5. Nut-hex, M10 x 1.25 25. Washer-plain

6. Washer-plain 26. Oil tank A-clutch master cylinder

7. Washer-spring 27. Bracket

8. Pad-clutch pedal 28. Bolt-hex M5 x 0.8

9. Bolt-hex, M10 29. Nut-hex, M5 x 0.8

10. Washer-spring 30. Washer-spring

11. Nut-hex, M10 31. Hose-rubber

12. Spring-return 32. Grommet

13. Master cylinder A-clutch 33. Clip

14. Pin-joint 34. Clamp

15. Washer-plain 35. Cover-clutch pedal pad

16. Pin-shaft

17. Stopper-upper

18. Stopper-lower

19. Bolt-hex

20. Washer-spring

2. Clutch

66

3.3.3. DISASSEMBLUED VIEW (BH Series)

2. Clutch

67

1. Pedal arm A-clutch 21. Clip

2. Rubber-seal 22. Clamp

3. Plate-seal 23. Bracket

4. Cover-seal rubber 24. Bolt-hex, M8 x 1.25

5. Pedal-pad 25. Nut-hex M8 x 1.25

6. Cover-pedal pad 26. Washer-spring

7. Spring 27. Bolt-hex M8 x 1.25

8. Shaft 28. Nut-hex M8 x 1.25

9. Stopper 29. Washer-spring

10. Bracket-clutch pedal 30. Bolt-hex M10 x 1.25

11. Bracket-clutch pedal 31. Washer-spring

12. Bracket-clutch control 32. Bolt-hex M10 x 1.25

13. Bracket 33. Nut-hex M10 x 1.25

14. Master cylinder A-clutch 34. Washer-spring

15. Pin-joint 35. Bolt-hex

16. Washer-plain 36. Nut-hex M5 x 0.8

17. Pin-split 37. Washer-spring

18. Oil tank A-clutch M/cyl. 38. Bolt-hex M8 x 1.25

19. Hose-vinyl 39. Nut-hex M8 x 1.25

20. Grommet 40. Washer-spring

2. Clutch

68

3.3.4. Inspection of clutch pedal bushing for wear

Check the clutch pedal bushing for play by shaking the clutch pedal vertically with the clutch pedal return spring and master cylinder push rod jaw joint pin removal. If a considerable amount of play is noticeable, disassemble the clutch pedal assembly and check the bushing for wear. Measure the clearance between the pedal bushing and shaft. If the amount of clearance is beyond the value indicating need for servicing, replace either the bushing or the shaft with higher rate of wear.


Value indicating need for servicing

Clearance between bushing and shaft

0.06 0.25 or more

Apply grease to the clutch pedal bushing and shaft after installation.

3.3.5. Inspection of pedal jaw joint pin for

wear Replace the jaw joint pin with a new one if a considerable amount of play is noticeable.

Standard value for assembly ( clearance between pin and pin hole ) 0.1

3.3.6. Inspection of pedal stopper rubber Check end stopper rubber for fatigue or damage and replace with a end new one as necessary. 3.4. Adjustment of clutch pedal free play It is necessary to adjust the clutch pedal free play when overhauling of the clutch pedal assembly, master cylinder assembly or clutch mini-pack assembly is completed. Clutch pedal free play adjustment is also necessary when the amount of free play is decreased ( less than 35mm ) due to driven plate wear. Note. Clutch pedal free play should be checked with the mini-pack in free state. ( air pressure 0kg/). Clutch pedal free play consists of the following two factors. Clutch pedal free stroke before mini-pack push rod begins to move. 25~30mm. Clutch pedal free stroke before relese bearing comes into contact with release lever ( clearance between release bearing and release lever 1.5~2.0mm) 20~25mm. Standard free play ( and ) 45~55mm. 3.4.1. Adjustment of clutch pedal stopper

Adjust the clutch pedal stroke to 165mm by means of the pedal stopper bolt. ( reference ) Height of pedal from floor : approx. 180mm

2. Clutch

69

3.4.2. Adjustment of master cylinder push rod

Remove the boot and loosen the push rod lock nut and turn the push rod until it is brought into contact with the piston, then back off 1/2 of a turn and tighten the lock nut. Remove the return spring and check that a clearance exists between the push rod and piston.

Pull out the lock pin and install the boot and return spring. 3.4.3. adjustment of mini-pack push rod Remove the push rod return spring and boot.

Loosen the push rod lock nut and turn the push rod until the piston is fully returned, then back off the push rod 1 2/3 turns and tighten the lock nut. Note. When adjusting the mini-pack push rod clearance without removing return spring, remove the check hole cover on the clutch housing and check the clearance between the release lever and release bearing (1.5~2.0mm) Install the boot and return spring.

3.5. Bleeding of clutch hydraulic circuit Bleeding operation should be performed when the clutch hydraulic circuit is drained and refilled or when overhauling of master cylinder assembly of mini-pack assembly is completed. To bleed the clutch hydraulic circuit, proceed as follows: Check the level of fluid in the clutch fluid reservoir and replenish as necessary to maintain the specified level during the bleeding operation.

Remove the bleeder rubber cap on the upper part of the mini-pack. Connect the vinyl tube to the bleeder and insert the other end o the tube into a transparent container filled with brake fluid. Depress and release the clutch pedal repeatedly and hold it down. Note. Bleeding operation should be performed with the engine stationary and with air drained from the air tank to hold the clutch mini-pack in free state. With the clutch pedal depressed, loosen the bleeder screw 1/2 of a turn to discharge brake fluid with air and tighten it immediately.

2. Clutch

70

Repeat the operation until air bubbles disappear completely from the fluid being forced out into the container. When bleeding operation is completed, check clutch pedal free play and operation of the clutch.

2. Clutch

71

4. Trouble shooting 4.1. Clutch slipping when accelerating, vehicle speed does not increase sharply in response to increase in engine speed. Engine overheating Engine lacks power.

CAUSE CORRECTION

Clutch pedal free play insufficient Oil or grease on driven plate Driven plate worn excessively Clutch spring broken or weakened Shift block binding

Adjust to specification (45~55mm) Clean or replace driven plate Replace Replace Correct shift block and front cover

4.2. Clutch dragging Hard-shifting gear grating occurs when gear shifting is attempted.

CAUSE CORRECTION

Clutch pedal free play excessive Clutch fluid leaking Height of release levers unequal Uneven wear of clutch parts. Clutch mini-pack push rod stroke

insufficient due to presence of air in clutch hydraulic circuit

Movement of driven plate unsmooth due to wear or sticking of driven plate and top gear shaft splines

Adjust to specification (45~55mm) Replace piston cups. Replace piston and cylinder if found to be worn. Adjust Correct or replace driven plate, pressue

plate, fly-wheel, thrust bearing, support pins.

Readjust Perform bleeding operation or correct

mini-pack assembly Clean splines and apply bell moly paste

( made by sumico lubracation co.) 4.3. Clutch juddering Juddering occurs when clutch is engaged for starting.

CAUSE CORRECTION

Driven plate warped or worn unevenly Pressure plate and flywheel

worn unevenly Cushion plate on driven plate cracked

or broken Rivet(s) on driven plate broken Damper spring(s) on driven plate

weakened or broken Height of release levers unequal Clutch springs weakened or broken

Replace Correct or replace Replace Replace Replace Adjust Replace

2. Clutch

72

4.4. Clutch noisy Rattling noise occurs when clutch pedal is depressed Clutch pedal arm squeaks.

CAUSE CORRECTION

Thrust bearing worn or seized Clutch pedal shaft poorly

Replace Apply grease

73

SECTION 3

TRANSMISSION

CONTENTS PAGE

1. GENERAL DESCRIPTIN

1.1. MODEL 74

1.2. MAIN DATA AND SPECIFICATION 74

1.3. TRANSMISSION CONTROL 87

2. SERVICING OF K SERIES TRANSMISSION

2.1. REMOVAL AND INSTALLATION 91

2.2. DISASSEMBLY 93

2.3. INSPECTION 103

2.4. REASSEMBLY 105

3. TROUBLE SHOOTING 110

3. Transmission

74

1. General description 1.1.Model The transmission is 5 speed overdrive type or 5 speed direct drive type and has constant mesh type gears with blocker ring type synchromesh on the 2nd, 3rd, 4th and 5th gears. The gears are supported on the main shaft via the needle roller bearings for improved durability. The countershaft is supported in the ball bearing at the front end and by the roller bearing at the rear to provide a long service life under severe operation condition. 1.2. Main data and specification

TRANSMISSION MODELS APPLICATION

Model K805A K805P K806P T-9 T-10S5B T-13S5B

Type 5.D.D 5O.D 6O.D 5D.D 5D.D 5D.D

1st 6.666 5.455 6.666 6.571 6.589 6.589

2nd 3.826 3.130 3.826 3.807 4.002 4.002

3rd 2.213 1.728 2.213 2.201 2.430 2.430

4t 1.417 1.000 1.417 1.463 1.507 1.507

5th 1.000 0.745 1.000 1.000 1.000 1.000

6th - - 0.734 - - -

Gear Ratio

Rev 6.851 5.606 6.851 6.239 6.888 6.888

Oil capacity() 9.8 9.8 11 11 13 13 Input torque(.m) 82 82 82 90 125 135

Weight() 192 192 200 240 250 250

Model K1005C K1005P K1006R K1205C K1205P K1206R K1405A

Type 5D.D 5O.D 6O.D 5D.D 5O.D 6O.D 5D.D

1st 6.608 5.500 5.500 6.608 5.500 5.500 6.608

2nd 3.993 3.323 3.482 3.993 3.323 3.482 4.184

3rd 2.423 1.782 2.147 2.423 1.782 2.147 2.580

4t 1.518 1.000 1.348 1.518 1.060 1.346 1.518

5th 1.000 0.755 1.000 1.000 0.755 1.000 1.000

6th - - 0.755 - - 0.755 -

Gear Ratio

Rev 6.937 5.774 5.774 6.937 5.774 5.774 7.003

Oil capacity() 9.7 9.7 11.2 9.7 9.7 11.2 14.5 Input torque(.m) 115 115 115 125 125 125 145

Weight() 250 250 260 250 250 260 290

3. Transmission

75

TRANSMISSION IN SECTIONAL VIEW

Model K805

3. Transmission

76

TRANSMISSION IN DISASSEMBLED VIEW

Model K805

3. Transmission

77

1 Shaft-Top gear, W/Dog clutch 26 Sleeve-1st/ Reverse

2 Bearing-Top gear shaft 27 Gear-1st main

3 Ring-Snap, Top gear shaft 28 Collar-1st gear

4 Shaft-Main, Transmission 29 Washer-Thrust, 1st gear

5 Bearing-Pilot main shaft 30 Bearing-Main shaft, Rear

6 Ring-Snap, Pilot bearing 31 Piece-Distance, Main shaft

7 Hub-Clutch, 4th/5th 32 Gear-Speedometer

8 Sleeve- 4th/5th 33 Shaft-Counter

9 Ring-Block, 4th/5th 34 Bearing-Counter shaft, front

10 Block-Detent, Synchronizer 35 Ring-Snap

11 Plunger-Detent, Synchronizer 36 Gear-Counter shaft drive

12 Spring-Detent, Synchronizer 37 Key-Feather counter

13 Ring-Snap, 4th/5th clutch hub 38 Collar-Distance

14 Gear-4th, W/Dog, clutch 39 Gear-O/Drive, counter shaft

15 Bearing-Needle, 4th Gear 40 Key-Feather counter

16 Gear-3rd, Main W/Ring 41 Bearing-Counter shaft, rear

17 Bearing-Needle, 2nd/3rd 42 Ring-Snap, counter shaft, rear

18 Collar-3rd, gear 43 Shaft-Reverse

19 Ring-Snap, 3rd gear 44 Gear-Reverse

20 Hub-Clutch, 2th/3th 45 Bearing-Needle, reverse

21 Synchronizer A-2nd/3rd 46 Piece-Distance, needle bearing

22 Gear-2nd main 47 Washer-Thrust, reverse

23 Bearing-1st/reverse gear 48 Screw- Set, reverse shaft

24 Gear-Reverse, main 49 O ring-Reverse shaft

25 Hub-Clutch, 1st/Reverse

3. Transmission

78


Model K1005/K1205

3. Transmission

79


Model K1005/K1205

3. Transmission

80

1. Shaft-Top gear 28. Hub-Clutch 1st/ Reverse

2. Clutch-Dog Top gear 29. Sleeve-1st/ Reverse

3. Circlip-Dog, clutch set 30. Gear-1st main shaft

4. Bearing-Top gear shaft 31. Collar-1st gear

5. Ring-Snap, Top gear shaft 32. Washer-Thrust, 1st gear

6. Shaft-Main 33. Bearing-Main shaft rear

7. Bearing-Pilot main shaft 34. Gear-Speedometer drive

8. Ring-Snap pilot bearing 35. Shaft-Counter

9. Hub-Clutch 4th/5th 36. Bearing-Counter shaft, front

10. Sleeve-4th/5th 37. Ring-Snap

11. Ring-Block 4th/5th 38. Gear-Counter shaft drive

12. Insert-Synchronizer 39. Key-Feather counter

13. Plunger-Synchronizer 40. Piece-Distance

14. Spring-Plunger 41. Gear-4th counter shaft

15. Spring-Block, ring set 42. Synchronizer A-4th/5th

16. Ring-Snap 4th/5th clutch 43. Gear-3rd counter shaft

17. Gear-4th, W/Dog clutch 44. Key-Feather counter

18. Bearing-Needle, 4th gear 45. Bearing-Top gear shaft

19. Gear-3rd main W/Ring 46. Ring-Snap bearing

20. Bearing-3rd gear 47. Shaft- Reverse

21. Collar-3rd gear 48. Gear- Reverse

22. Ring-Snap, 3rd gear 49. Bearing-Needle reverse

23. Hub-Clutch, 2nd/3rd 50. Piece-Distance needle bearing

24. Synchronizer A-2nd/3rd 51. Washer-Thrust reverse

25. Gear-2nd main shaft 52. Screw-Set reverse shaft

26. Bearing-3rd gear 53. Washer-Spring

27. Gear-Reverse main shaft

3. Transmission

81


Model K1405

3. Transmission

82


Model K1405

3. Transmission

83

1. Shaft-Top gear 28. Hub-Clutch 2nd/3rd

2. Clutch-Dog Top gear 29. Sleeve-1st/ Reverse

3. Circlip-Dog, clutch set 30. Gear-1st main

4. Bearing-Top gear shaft 31. Collar-1st gear

5. Ring-Snap, Top gear shaft 32. Washer-Thrust gear

6. Shaft-Main mission 33. Bearing-Main shaft rear

7. Bearing 34. Gear-Speedometer drive

8. Ring-Snap pilot bearing 35. Shaft-Counter

9. Hub-Clutch 4th/5th 36. Bearing-Counter shaft, front

10. Sleeve-4th/5th 37. Ring-Snap 3rd collar

11. Ring-Block 4th/5th 38. Gear-Counter shaft drive

12. Insert-Synchronizer 39. Key-Counter shaft/4th

13. Plunger-Synchronizer 40. Piece- Counter shaft

14. Spring-Plunger 41. Gear-4th counter shaft

15. Spring-Block, ring set 42. Bearing-2nd gear

16. Ring-Snap 4th/5th clutch 43. Gear-3rd counter shaft

17. Gear-4th, M/Shaft W/Dog(28T) 44. Key- counter shaft 3rd gear

18. Bearing-Needle, 4th gear 45. Bearing-Main shaft rear

19. Gear-3rd main W/Ring 46. Ring-Snap 3rd gear

20. Bearing-3rd 47. Shaft- Reverse, shaft

21. Collar-3rd 48. Gear- Reverse, shaft

22. Ring-Snap, 3rd collar 49. Bearing-Needle reverse

23. Hub-Clutch, 2nd/3rd 50. Piece-Distance needle bearing

24. Synchronizer A-2nd/3rd 51. Washer-Thrust reverse

25. Gear-2nd main 52. Screw-Set reverse shaft

26. Bearing-2nd gear 53. Washer-Spring

27. Gear-Reverse main 54. Synchronizer A-4th/5th

3. Transmission

84


Model T-9

3. Transmission

85


Model T-9

3. Transmission

86

1. Shaft-Main 25. Sleeve-1st/ Reverse

2. Ring-Snap 26. Hub-1st/ Reverse constant

3. Bearing-Pilot 27. Bearing- Ball

4. Nut-Lock 28. Gear-Main shaft 1st

5. Washer-Lock 29. Bearing-Needle roller

6. Ring-SYN, 4th/5th 30. Sleeve-1st gear bearing

7. Hub-4th O/D 31. Pinion A-Drive

8. Key-Shifting 32. Bearing -Ball

9. Spring-Detent 33. Ring-Snap

10. Sleeve-4th O/D Synchronizer 34. Shaft-Reverse gear

11. Gear A-M/S 4th 35. Gear-Reverse idle

12. Bearing-Needle roller 36. Bearing-Needle

13. Spacer-Bearing 37. Spacer-Bearing

14. Sleeve-Needle bearing 38. Washer-Reverse gear side

15. Washer-Thrust 39. O-ring

16. Gear A-M/S 3rd 40. Piece-Reverse shaft lock

17. Bearing-Needle roller 41. Bolt-Flange, M10 X 20

18. Sleeve-Needle bearing 42. Shaft-Counter

19. Hub-2nd/3rd synchronizer 43. Gear-C/S constant

20. Synchronizer A-2nd/3rd 44. Gear-C/S 4th

21. Gear A-M/S 2nd 45. Key-Sunk

22. Washer-1st gear 46. Bearing-Ball

23. Gear-Main shaft reverse 47. Ring-Snap

24. Bearing-Needle 48. Bearing-Ball

3. Transmission

87

1.3. Transmission control

TRANSMISSION CONTROL IN DISASSEMBLED VIEW

Model BF105 (LHD TYPE)

1. Lever A-Charge, T/M cont. 7. Nut-Hex M10 X 1.25 13. Pin-Split

2. Seal-Dust 8. Washer-Spring 14. Joint

3. Knob A-Change lever 9. Control rod A-Transmission 15. Collar

4. Bracket-Change lever 10. Pin-Joint, Rod end 16. Nut-Hex slotted

5. Bolt-Hex ,M10 X 1.5 11. Washer-Plain 17. Washer-Plain

6. Washer-Spring 12. Nut-Hex slot, M10 X 1.25 18. Nipple grease

3. Transmission

88


Model BH115/BH116/BH117

3. Transmission

89

1. Box A-Transmission control 17. Pin-Split

2. Knob A-Change lever 18. Nipple-Grease

3 Seal-Dust 19. Bolt-Reamer M10X 1.25

3-1. Adapter-Boots 20. Nut-Hex M10X 1.25

4. Seal-Dust 21. Washer-Spring

5. Bolt-Hex M8 X 1.25 22. Joint-Pipe

6. Washer-Spring 23. Bolt-Hex M6X 1.0 X 18

7. Cover-Transmission control box 24. Nut-Hex M6X 1.0

7-1. Boots 25. Washer-Spring

7-2. Retainer-Boots 26. Pin-Taper

8. Screw-Tap PH M5 X 1.0 27. Washer-Plain

9. Pipe-No.1 28. Pin-Split

10. Pipe-No.2 29. Bracket

11. Pipe-No.3 30. Support A-Transmission control

12. Universal joint A-Control rod 31. Seal-Dust

13. Yoke 32. Seal-Dust Support fix

14. Hub 33. Damper rod CPL A

15. Pin 34. Damper rod A

16. Nut-Hex slotted

3. Transmission

90


Model BH120

1. Control Box A- Transmission 10. Claim-Conduit

2. Knob-Change lever 11. Nut-Hex, M8 X 1.25

3. Retainer-Boots 12. Washer-Spring

4. Boots 13. Bracket-Transmission Upper

5. Adapter-Boots 14. Clip-Cable

6. Screw-Tapping 15. Bolt-Hex, M6 X 1.0

7. Bolt-Hex Flange, M8 X 1.25 16. Bolt-Hexagon, Flange

8. Cable A-Transmission control 17. Nut

9. Adapter 18. Washer

3. Transmission

91

2. SERVICING OF K SERIES TRANSMISSION 2.1. Removal and installation

Removal steps Installation steps

1. Gearshift control rod 1. Transmission assembly

2. Clutch minipack with bracket 2. Control rod

3. Yoke flange 3. Yoke flange

4. Control rod 4. Clutch minipack with bracket

5. Transmission assembly 5. Gearshift control rod

3. Transmission

92

2.1.1 Removal Remove the gearshift control rod. Remove the clutch minipack with bracket Remove the Yoke flange Remove the control rod

Remove the transmission assembly, using a

transmission jack. 2.1.2. Installation

Align the transmission inclination with the engine slope and shift the gear directly. Install the transmission to the engine

carefully. Install the control rod. Install the Yoke flange. Install the clutch minipack with bracket. Install the gear shift control rod.

3. Transmission

93

2.2. Disassembly 2.2.1. Major component

3. Transmission

94

A. Housing A-Clutch, W/Bearing

1. Housing-Clutch 18. Cover-Front, W/Oil seal

2. Bearing-Clutch release 19. Seal-Oil, Cover FRT

3. Seal-Dust, Clutch release 20. Bolt-Cover, FRT

4. Cover-Check hole, UPR 21. Washer-Spring

5. Cover-Check hole, Lower 22. Washer-Plain

6. Gasket-Liquid, T/M 23. O ring-Cover bolt FRT

7. Bolt-Hex HD cover fix 24. Cover-Rear

8. Bolt-Hex HD cover fix 25. Seal-Oil RR cover

9. Nut-Clutch, HSG fix 26. Cover-Dust

10. Bolt-Clutch, HSG T/M case 27. Bolt-cover RR

11. Washer-spring 28. Cover-Side, T/M case

12. Case-T/M 29. Bolt-Side cover fix

13. Plug-Oil drain 30. Cover-Seal C/Shaft

14. Packing-Filter 31. Gear-Speedometer driven

15. Plug-Oil drain magnetic 32. Bush-Speedometer, W/Seal & Ring

16. O ring-Drain plug 33. Seal-Oil speedometer gear

17. Bolt-Stud clutch HSG & T/M 34. O ring-Driven gear

35. Screw-Set, Bush

3. Transmission

95

Remove the quadrant box assembly

Engage two gear sets or wedge a piece of hard between the gears and case to prevent turning of main shaft, and remove the flange nut and O-ring Remove the flange and oil seal cover.

Remove the speedometer driven gear, oil

seal, bushing and O-ring with removers.

Remove the rear cover, oil seal and gasket. Remove the speedometer drive gear. Remove the clutch housing, front cover, oil

seal and gasket.

Remove the counter shaft front bearing

cover by gripping the knob with pliers.

Remove the counter shaft front bearing with

removers.

Remove the counter shaft rear bearing and snap

ring.

The dog gear is installed to the top gear

shaft with the circlip. The dog gear can be separated from the top

gear shaft by pulling strongly. Take out the top gear shaft assembly,

remaining the top gear shaft dog gear in the gear case

Remove the 5th blocker ring, main shaft rear

bearing and snap ring.

3. Transmission

96

Take out the blocker ring together with the

main shaft. Remove the main shaft assembly from the

case using a suitable hook or wire.

Note. When removing the main shaft assembly

from the case, it is convenient to install the duy collar.

Remove the counter shaft assembly.

Remove the reverse shaft assembly with a

remover.

3. Transmission

97

2.2.2. Upper Quadrant Box Assembly

A Control top A-Horizontal

1. Housing-Control 8. Screw-Set, Cover 15. Seat-Gear lever,Upper

2. Shaft-Control, Operating 9. Washer-Cover 16. Shim-Lever socket

3. Lever-Shift, Short gear 10. Lever-Shift, Gear stub 17. Washer-Spring, lever socket

4. Screw-Lock 11. Cover-Dust 18. Screw-Lever socket

5. Cap-Shift Rail 12. Clip-Hose 19. Breather

6. Gasket-Liquid 13. Socket-Lever 20. Bolt

7. Cover-Control housing 14. Seat-Gear lever, Lower 21. Washer-Spring

3. Transmission

98

2-2-3. Lower Quadrant Box Assembly

3. Transmission

99

1. Box-Quadrant, Lower 21. Arm-Shift, 1st/ Reverse

2. Bolt-Q/Box to T/M 22. Washer-Plain spindle

3. Washer 23. Spindle-1st / Reverse

4. Clip-harness 24. Washer

5. Bracket-Mounting 25. Nut-Hex M12 X 1.25

6. Gasket-Liquid, Transmission 26. Arm-Shift, 1st/ Reverse

7. Screw-Set, Q/Box reverse 27. Rod-Shift, 1st/ Reverse

8. Washer 28. Block-Shift, 2nd/3rd

9. Cover-Shift rod 29. Arm-Shift, 2nd/3rd

10. Switch-Back lamp 30. Rod-Shift, 2nd/3rd

11. Cover-Shift rod Quad 31. Pinion-4th/5th shift

12. Switch-Neutral 32. Bearing- Needle, Pinion

13. Block-Shift, 1st/Reverse, Front 33. Cover-Pinion

14. Spring-Coil sleeve 34. Bolt-Cover fix, pinion washer-Spring

15. Ball-Detent sleeve 35. Arm-Shift, 4th/5th

16. Spring-Coil 36. Block-Shift, 4th/5th

17. Sleeve-Shift, 1st/Reverse 37. Rod-4th/5th block

18. Cap-Shift, 1st/Reverse 38. Rod-4th/5th arm

19. Block-Shift, 1st/Reverse 39. Ball-Detent, Shift rod

20. Rod-Shift, 1st/Reverse,Block

3. Transmission

100

Remove the back-up lamp switch, neutral switch and inter lock ball.

Remove the 1st and reverse shifter rod, pin,

shift block and cover. Note. When removing parts, exercise care so as not to permit detent ball to snap out of position and be careful not to damage the shift rod hole. Remove the detent ball and detent spring.

Note. Be careful not to drop the ball into the hole from which the spring was removed.

Remove the inter lock ball. Remove the 2nd and 3rd shifter rod, shift

block, shift arm, pin, cover, detent ball, detent Spring, and inter lock ball.

Remove the 4th and 5th shifter rod, shift arm, cover, detent ball, and detent spring. Remove the 1st and reverse shifter rod, shift

arm and cover.

3. Transmission

101

2.2.4. Gears

1. Top gear shaft assembly 15. 2nd gear 2. Snap ring 16. Needle roller bearing 3. Pilot bearing 17. Thrust washer 4. 5th blocker ring 18. 1st gear, needle bearing and collar 5. Snap ring 19. Sleeve and clutch hub 6. 4th and 5th synchronizer assembly 20. Reverse gear and needle bearing 7. 4th blocker ring 21. Main shaft 8. 4th gear 22. Snap ring 9. Needl

euro_iii_bh117l_service_manual_1st_january_2006.pdf

Documents

service data

service operations

desired section

reliable service operation

use of proper tools

disassembled parts

genuine daewoobus parts

general inforamtion