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DAEWOO BUS Motor DE12 9 Cil 11L DV15T V8 14.6L 2005 PDF
DAEWOO BUS Motor DE12 9 Cil 11L DV15T V8 14.6L 2005 PDF
MANUAL
SM-1E-0505
SECTION INDEX
DAEWOO BUS
SECTION NAME
CHASSIS
2 CLUTCH
3 TRANSMISSION
FOREWORD
4 PROPELLER
GENERAL INFORMATION
CONTENTS PAGE
2. IDENTIFICATION
3. SPECIFICATION
4. LUBRICATION
1
1. General Information
2
1. General Information
2. Identification
3
1. General Information
3. Specification
▣ Model BF106
▣ Model BM090
4
1. General Information
▣ Model BS090
▣ Model BH090
5
1. General Information
▣ Model BS106
▣ Model BH115E
6
1. General Information
▣ Model BH116
▣ Model BH117
7
1. General Information
▣ Model BH120
8
1. General Information
9
1. General Information
ENGINE ( Euro Ⅱ )
11
1. General Information
▣ CLUTCH
BF106
Distinction
D1146 DE08Tis DE12 DE08Tis
Dry single plate with coil spring dampers hydraulic circuit
Type
Incorporating clutch minipack
Outside dia. 380 430
Clutch facing
Inside dia. 240 250
dimension(㎜)
Thickness 5
Clutch clamping force(㎏) 1240±10% 1470±10% 1380±10% ←
Ratio 7.09
Clutch pedal Free play 48.8
Max. stroke 170
Clutch minipack start working
5.5
pressure(㎏/㎠)
Master cylinder bore dia. (㎜) 20
12
1. General Information
13
1. General Information
▣ TRANSMISSION (MANUAL)
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
rd
3 2.430 2.423 1.782 2.147 2.423 1.782 2.147 2.580 2.580
Gear th
4 1.507 1.518 1.000 1.348 1.518 1.000 1.348 1.518 1.618
ratio
5th 1.000 ← 0.755 1.000 ← 0.755 1.000 ← ←
6th - - - 0.755 - - 0.755 - 0.759
Rev. 6.888 6.937 5.774 ← 6.937 5.774 ← 7.003 ←
Dry weight(㎏) 250 ← ← 260 250 ← 260 290 340
Oil capacity(ℓ) 13 9.7 ← 11.2 9.7 ← 11.2 14.5 16.0
14
1. General Information
▣ 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
3N 6.2 - 3N 6.2
st 3S 5.9 3S 5.9 3S 5.9
1 3.58 3.49 ← 3.51 3.43 ← ←
4N 5.4 4N 5.4 4N 5.4
4S 5.1 4S 5.1 4S 5.1
3N/3S 1.43
2nd 2.09 1.86 ← 1.91 ← ← ← 2.01 ← ←
4N/4S 1.36
3N/3S 1.00
3rd 1.39 1.41 ← 1.43 ← ← ← 1.42 ← ←
4N/4S 1.00
Gear 3N/3S 0.70
ratio 4th 1.00 ← ← ← - - ← 1.00 ← ←
4N/4S 0.73
5th - 0.75 ← 0.74 - - - - 0.83 ← ←
6th - 0.65 ← 0.64 - - - - 0.59 ← ←
3N 6.2 3N 6.2 3N 6.2 3N 6.2
3S 5.9 3S 5.9 3S 5.9 3S 5.9
Rev. 5.67 5.03 ← 4.80 4.84 ← ←
4N 5.4 4N 5.4 4N 5.4 4N 5.4
4S 5.1 4S 5.1 4S 5.1 4S 5.1
Dry weight(㎏) 231 227 ← 412 295 300 330 335 310 315 330
Oil capacity(ℓ) 25 ← ← 45 28 ← ← ← 30 ← ←
15
1. General Information
BF106
D1146
DE08Tis DE12 DE12T DE12Ti DE12Tis
D1146Ti
Distinction
BM090 BM090 BH115E BH115E BH115E BH115E
BH090 BS106 BS106 BS106 BS106
BS090 BS090 BH120E BH120E BH120E BH120E
Length 320 340.0 320.0
K805A
Outside dia. 88.9 88.9 ←
K805P
Inside dia. 80.9 80.9 ←
Length 690.0 577.0
T-9 Outside dia. 88.9 88.9
Inside dia. 80.9 80.9
Length 557. ← 560.0 ← ← ← ←
K4005C
Outside dia. 88.9 ← 101.6 ← ← ← ←
K1005P
Inside dia. 80.9 ← 91.6 ← ← ← ←
Length 463.0 ← 367.0 ← ← ← ←
K1006R Outside dia. 88.9 ← 101.6 ← ← ← ←
Inside dia. 80.9 ← 91.6 ← ← ← ←
Length 535.8 535.8 535.8
T-10 Outside dia. 101.6 101.6 101.6
Inside dia. 91.6 91.6 91.6
Length 560.0 560.0 560.0
K1205C
Outside dia. 101.6 101.6 101.6
K1205P
Inside dia. 91.6 91.6 91.6
Length 367.0 367.6 367.6
K1206R Outside dia. 101.6 101.6 101.6
Inside dia. 91.6 91.6 91.6
16
1. General Information
DE12Ti/Tis DE12Ti/Tis
DE12T DV15T DV15TiS
Distinction (310ps) (340ps)
BH116 BH116/BH117 BH117/BH120F
Length 600.2
K1105C
Outside dia. 101.6
K1006R
Inside dia. 91.6
Length 400.7
K1006R Outside dia. 101.6
Inside dia. 91.6
Length 569.9 569.9
T-10S5B Outside dia. 101.6 101.6
Inside dia. 91.6 91.6
Length 600.2
K1205C
Outside dia. 101.3
K1205P
Inside dia. 91.6
Length 400.7
K1206R Outside dia. 101.6
Inside dia. 91.6
Length 541.4 730.3
K1405A Outside dia. 101.6 101.6
Inside dia. 91.6 91.6
Length 620.3
K1406P Outside dia. 101.6
Inside dia. 91.6
Length 709.8
T16DS5A Outside dia. 114.3
Inside dia. 101.1
Length 678.0
K1605A Outside dia. 114.3
Inside dia. 101.1
17
1. General Information
D1146
DE08Tis DE12 DE12T DE12Ti DE12Tis
D1146Ti
Distinction
BM090 BM090 BH115E BH115E BH115E BH115E
BH090 BS106 BS106 BS106 BS106
BS090 BS090 BH120E BH120E BH120E BH120E
Length 577.0 470.0 ←
MT643 Outside dia. 88.9 ←
Inside dia. 80.9 ←
Length 626.0 ←
B300 Outside dia. 88.9 88.9 ←
Inside dia. 80.9 80.9 ←
Length
B400 Outside dia.
Inside dia.
Length 660.0 557.0 ←
D851.2 Outside dia. 88.9 88.9 ←
Inside dia. 80.9 80.9 ←
Length
D854.2 Outside dia.
Inside dia.
Length 529.0 529.0
D863 Outside dia. 114.3 114.3
Inside dia. 101.6 101.1
Length
D864 Outside dia.
Inside dia.
Length 393.0 676.0 566.0 ← 569.5 569.5
HP500 Outside dia. 88.9 88.9 88.9 ← 101.6 101.6
Inside dia. 80.9 80.9 80.9 ← 91.6 91.6
Length 569.5 569.5
HP600 Outside dia. 101.6 101.6
Inside dia. 91.6 91.6
18
1. General Information
DE12Ti/Tis DE12Ti/Tis
DE12T DV15T/DV15Tis
Distinction (310ps) (340ps)
BH116 BH116 BH116/BH117 BH120F
Length
Inside dia.
Length
Inside dia.
Length
Inside dia.
Length
Inside dia.
Length 555.8 ←
D863 Outside dia. 114.3 ←
Inside dia. 101.1 ←
Length 482.8 ←
D864 Outside dia. 101.6 ←
Inside dia. 91.6 ←
Length 599.3
HP500 Outside dia. 101.6
Inside dia. 91.6
Length 599.3
HP590 Outside dia. 101.6
Inside dia. 91.6
19
1. General Information
▣ FRONT AXLE
BM090
Distinction BF106 BH090 BS106 BH115E BH120E BH116 BH117 BH120
BS090
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
Wheel Camber(˚) 0.5˚±30'
alignment
Caster(˚) -1˚00'±30' 0˚12'±30 1˚30'±30 -0˚36'±30 0˚12'±30 1˚30'±30
King pin
7.5˚±10'
Inclination(˚)
Steering angle Inside(˚) 42˚ 45˚
Outside(˚) 34˚ 37˚
20
1. General Information
▣ REAR AXLE
BM090
Distinction BF106 BH090 BS106 BH115E BH120E BH116 BH117 BH120
BS090
21
1. General Information
▣ STEERING
BM090 BS106
Distinction BF106 BS090 BH115E BH116 BH117 BH120
BH090 BH120
22
1. General Information
Distinction BF106
BM090/BS090/BH090
Distinction BF106 BH116/BH117/BH120
BS106/BH115E/BH120
23
1. General Information
BM090
Distinction BF106 BS106 BH115E BH120E
BS090
Type Semi elliptical alloy steel
Span(㎜) 1400 1500
Width(㎜) 80 90
11-2
Front Thickness
12-7 13-6 13-7 13-8
-no. of leaf
11-1
Spring constant
32.83 25.33 33.5 36.42
Leaf (㎏/㎜)
Spring Span(㎜) 1660
Width(㎜) 100
12-2
Rear Thickness 14-4 15-1
11-3 14-11
-no. of leaf 15-4 14-9
16-4
Spring constant
32.86 43.5 47.9 50.31
(㎏/㎜)
Type Hydraulic, double acting telescopic
Front rebound 650 595
Shock
Damp Front compression 275 260
absorber
force(㎏) Rear rebound 650 650
Rear compression 260 260
24
1. General Information
FRONT REA R
Distinction BH116
BH090 BH116 BH1117 BH120 BH090 BH117 BH120
STD WIDE
Type Variable throttle type with stabilizer
Effective dia. (㎜) 250 260 250
Design height(㎜) 270 270 260
Air
Max. out dia. (㎜) 310 316 310
Spring
No. of springs 2 4
Stroke of ext. 100 100
Spring(㎜) comp. 100 100
Type Double acting telescopic type
Out. dia. (㎜) 86 86 74.5
25
1. General Information
26
1. General Information
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
Engine
High 1850
Rotating
mid 1450
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 (ℓ) 2.6
27
1. General Information
PROPELLER PROPELLER
Type ←
FAN x 3 FAN x 5
Condenser
fan Capacity (㎥/h) 4700 7200 ←
Required power (A) 5.5A/EA ← ←
28
1. General Information
ENGINE ( Euro Ⅲ )
29
1. General Information
30
1. General Information
▣ CLUTCH
Distinction BS090 BH090 BS106 BH115E BH116 BH117 BH119 BH120 BX212
Master cylinder
20
bore dia.(㎜)
31
1. General Information
▣ TRANSMISSION
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
Code MS6 MR5 MSS MN9 MS5 MS6 MR5 MS6 MR5 MT2 MN9 MN6 MK1 MT3 MP7 ML0
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
12/6 14/6 11/6 11/7 12/7 12/6 14/6 11/6 12/7 12/7 12/7
Gear
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
32
1. General Information
▣ PROPELLER SHAFT
33
1. General Information
▣ REAR AXLE
BH117
Distinction BS090 BH090 BS106 BH115E BH116 BH119 BX212
BH120
Type Banjo full floating type
Final drive gear type Spiral bevel Hypoid gear
39/8 39/8
39/9
Final gear ratio 39/8 39/8 39/9 39/9 39/11 39/11
39/10
39/12 39/12
425 444.5
Pinion cage length
( 16 – M12 x 1.25 ) ( 12 –M16 x 1.5 )
Operation type 4x2
Oil capacity (ℓ) 10.5 11.5
▣ FRONT AXLE
Rear 1,853 ← ← ← ← ← ← ←
King pin
7˚30'±30'
Inclination
Steering Front 45˚
angle Rear 37˚
34
1. General Information
▣ STEERING
oil capacity(ℓ) 7 ← ← ← ← ← ← ←
▣ BRAKE
BH116
BH117
BS106
Distinction BF106 BS090 BH090 BH119
BH115E
BH120
BX212
Service brake type Full air (dual circuit)
Drum inside diameter (㎜) 410 ← ← ← ←
35
1. General Information
FRONT REAR
Distinction
BH116 / BH117 / BH119 / BH120
Type Variable throttle type with stabilizer
Effective dia. (㎜) 250 250
270(STD)
Design height (㎜) 270
Air 260(WIDE)
Max out. dia. (㎜) 275 275
Spring
No. of springs 2 4
Extension 100 ←
Stroke
Compression 100 ←
Type Double acting telescopic type
Outside dia. (㎜) 86 ←
36
1. General Information
4. LUBRICATION
▣ Engine oil
▣ Gear oil
37
1. General Information
Lubricant Lubricant point Capacity Oil change period Specification Maker and brand name
Brake fluid Brake & clutch 4ℓ First : 1,000㎞ SAE J1703 CALTEX : BRAKE FLUID
38
1. General Information
39
1. General Information
40
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
41
2. Clutch
1. General description
1.1. Construction
1.2. Specification
Clutch pedal Free play 46.4 48.8 46.6 47.1 47.2 47.4
42
2. Clutch
43
2. Clutch
44
2. Clutch
▣ Pull out the cotter pin from the release levers and ▣ Remove the shift fork from the front cover together
remove the release lever pins. Remove the release with the shift block. Remove the return springs.
45
2. Clutch
2.3. Inspection of Disassembled Parts ▣ Check the clutch driven plate for warage using a
dial indicator. Take measurement at the portion
2.3.1. Driven Plate 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
Limit for use
assembly
Driven plate
1.0 or less 1.5 or more
warpage
46
2. Clutch
▣ If the amount of play is beyond the limit, check Note. If material in thickness of more than 1.0mm is to
condition of step wear on the top gear shaft splines to be removed from the pressure plate through correction,
determine the parts to be replaced. Slight amount of it is necessary to adjust set length of the clutch springs
step wear on the top gear shaft splined may be by installing a washer equivalent in thickness to the
removed using a scrapper or other suitable tool. material removed under each spring.
▣ Check the clutch facing for cracking, scores and 2.3.3. Release Lever Pins
hardening of material due to heating. Replace the
driven plate if found to be defective.
Unit : ㎜
Nominal Limit for
▣ Check the pressure for scoring, warpage and diameter use
reduction in thickness due to wear. If the amount of 15”(Φ380) 31 30.5
Outside
warpage or depth of scoring is within 1.5mm, correct
diameter 17”(Φ430) 60 59.5
with a surface grinder.
Unit : ㎜
▣ Check the dry bushing (made up of sintered alloy
Nominal Limit for with teflon coating) for wear. Replace the parts if the
thickness use amount of wear is considerable.
Thickness of 15”(Φ380) 31 30.5 2.3.4. Release Levers
pressure plate
(t) 17”(Φ430) 60 59.5
▣ 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.
47
2. Clutch
48
2. Clutch
the flywheel.
Unit : ㎜
2.4.2. Installation
50
2. Clutch
51
2. Clutch
※ Reference
set load / set length 2.7
Free length
Note. : Never use the gasoline and diesel fuel. ▣ When installation of master cylinder is
completed, adjust the clutch pedal free play
① Check the primary and secondary cups for and bleed the hydraulic circuit.
52
2. Clutch
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.
53
2. Clutch
54
2. Clutch
55
2. Clutch
56
2. Clutch
1. Hydraulic cylinder
2. Hydraulic piston
3. Hydraulic piston cup
57
2. Clutch
3.2.4 Inspection
Note. Discard used hydraulic piston cups and Standard value Free
100 mm
O-rings and install new ones at the time of length of return spring
reassembly.
These rubber parts are available as a repair kit.
58
2. Clutch
② Insert the bushing and seal into the control ⑥ Install the diaphragm assembly and
tube. position the valve spring over the diaphragm.
Align the upper valve body with the mark on
③ Insert the piston push rod assembly, piston the end plate, then install and tighten the bolts.
spring, end plate and seal assembly, then fasten
the clylinder shell with the end plate using ⑦ Insert the poppet valve and spring to the
bolts. upper valve body and tighten the valve adapter
together with gasket to the upper valve body.
Note. When installing the piston and push rod
assembly use care not to cause distortion of the
piston gasket. 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.
60
2. Clutch
▣ 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.
61
2. Clutch
62
2. Clutch
63
2. Clutch
64
2. Clutch
65
2. Clutch
66
2. Clutch
67
2. Clutch
3.3.4. Inspection of clutch pedal bushing for Standard value for assembly
wear 0.1㎜
( clearance between pin and pin hole )
▣ Check the clutch pedal bushing for play by
shaking the clutch pedal vertically with the 3.3.6. Inspection of pedal stopper rubber
clutch pedal return spring and master cylinder
push rod jaw joint pin removal. Check end stopper rubber for fatigue or
If a considerable amount of play is noticeable, damage and replace with a end new one as
disassemble the clutch pedal assembly and necessary.
check the bushing for wear. Measure the
clearance between the pedal bushing and shaft. 3.4. Adjustment of clutch pedal free play
If the amount of clearance is beyond the value
indicating need for servicing, replace either the ▣ It is necessary to adjust the clutch pedal free
bushing or the shaft with higher rate of wear. play when overhauling of the clutch pedal
assembly, master cylinder assembly or clutch
Value mini-pack assembly is completed.
Standard value indicating Clutch pedal free play adjustment is also
for assembly need for necessary when the amount of free play is
servicing decreased ( less than 35mm ) due to driven
Clearance plate wear.
between 0.25㎜ or
0.06㎜ Note. Clutch pedal free play should be checked
bushing more
and shaft with the mini-pack in free state. ( air pressure
0kg/㎠).
Apply grease to the clutch pedal bushing and
shaft after installation. ① Clutch pedal free play consists of the
following two factors.
68
2. Clutch
3.4.2. Adjustment of master cylinder push 3.5. Bleeding of clutch hydraulic circuit
rod
Bleeding operation should be performed when
▣ Remove the boot and loosen the push rod the clutch hydraulic circuit is drained and
lock nut and turn the push rod until it is refilled or when overhauling of master cylinder
brought into contact with the piston, then back assembly of mini-pack assembly is completed.
off 1/2 of a turn and tighten the lock nut. To bleed the clutch hydraulic circuit, proceed
as follows:
▣ Remove the return spring and check that a
clearance exists between the push rod and ▣ Check the level of fluid in the clutch fluid
piston. reservoir and replenish as necessary to
maintain the specified level during the
bleeding operation.
▣ Pull out the lock pin and install the boot and
return spring.
69
2. Clutch
70
2. Clutch
4. Trouble shooting
▣ when accelerating, vehicle speed does not increase sharply in response to increase in engine speed.
▣ Engine overheating
▣ Engine lacks power.
CAUSE CORRECTION
① Clutch pedal free play insufficient ① Adjust to specification (45~55mm)
② Oil or grease on driven plate ② Clean or replace driven plate
③ Driven plate worn excessively ③ Replace
④ Clutch spring broken or weakened ④ Replace
⑤ Shift block binding ⑤ Correct shift block and front cover
71
2. Clutch
CAUSE CORRECTION
① Thrust bearing worn or seized ① Replace
② Clutch pedal shaft poorly ② Apply grease
72
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
73
3. Transmission
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.
74
3. Transmission
Model K805
75
3. Transmission
Model K805
76
3. Transmission
77
3. Transmission
Model K1005/K1205
78
3. Transmission
Model K1005/K1205
79
3. Transmission
80
3. Transmission
Model K1405
81
3. Transmission
Model K1405
82
3. Transmission
83
3. Transmission
Model T-9
84
3. Transmission
Model T-9
85
3. Transmission
86
3. Transmission
87
3. Transmission
Model BH115/BH116/BH117
88
3. Transmission
89
3. Transmission
Model BH120
90
3. Transmission
91
3. Transmission
2.1.1 Removal
2.1.2. Installation
92
3. Transmission
2.2. Disassembly
93
3. Transmission
94
3. Transmission
▣ Remove the counter shaft front bearing ▣ Remove the 5th blocker ring, main shaft rear
cover by gripping the knob with pliers. bearing and snap ring.
95
3. Transmission
96
3. Transmission
97
3. Transmission
98
3. Transmission
99
3. Transmission
▣ Remove the back-up lamp switch, neutral Note. Be careful not to drop the ball into the hole
switch and inter lock ball. from which the spring was removed.
▣ Remove the 1st and reverse shifter rod, pin, ▣ Remove the inter lock ball.
shift block and cover.
▣ Remove the 2nd and 3rd shifter rod, shift
Note. When removing parts, exercise care so as block, shift arm, pin, cover, detent ball,
not to permit detent ball to snap out of position detent Spring, and inter lock ball.
and be careful not to damage the shift rod hole.
▣ Remove the 4th and 5th shifter rod, shift arm,
▣ Remove the detent ball and detent spring. cover, detent ball, and detent spring.
100
3. Transmission
2.2.4. Gears
101
3. Transmission
Unit : ㎜
Standard Limit
Thickness
Unit : ㎜
Standard Limit
Thickness
103
3. Transmission
Unit : ㎜
Standard Limit
▣ Inspect the clearance between gear and blocker
Thickness
ring.
Unit : ㎜
Standard Limit
Thickness
104
3. Transmission
2.4. Reassembly
2.4.1. Gears
105
3. Transmission
▣ Assemble the counter shaft and collar. ▣ Assemble the 4th and 5th synchronizer
assembly, and assemble the block
▣ Assemble the 3rd gear, 4th gear, counter shaft in alignment with the circumferential
drive gear, keys and snap ring. direction of the clutch hub.
▣ Assemble the main shaft needle roller
bearing and 2nd gear. ▣ Assemble the snap ring.
2.4.2. Lower Quadrant Box Assembly ▣ Assemble the shift shaft and coat gear oil to
shaft and needle bearing.
▣ Assemble the 1st and reverse shifter rod,
shift arm, detent spring and detent ball. Note. Assemble so as to not to roll up the lip of
the oil seal.
107
3. Transmission
▣ Assemble the thrust washer. ▣ Assemble the main shaft assembly and
thrust washer.
▣ Assemble the reverse gear, distance piece
and needle roller bearing.
108
3. Transmission
109
3. Transmission
3. Trouble shooting
NOISE
If a noise arises from around the transmission when the engine is running at idle, disengage the clutch to
see if the noise stops, If so, it indicates that the trouble is within the transmission
Cause Correction
(1) Insufficient gear oil (1) Replenish
(2) Wrong oil in use (2) Replace with reco㎜ended oil
(3) Gears defective (3) Correct or replace
(4) Bearing or splines worn (4) Replace
Cause Correction
(1) Clutch dragging (1) Adjust
(2) Insufficient gear oil (2) Replenish
(3) Wrong oil in use (3) Replace with recommended oil
(4) Wrong synchronizer assembly (4) Replace
(5) Remote control rod joints worn (4) Replace worn parts
Cause Correction
(1) Worn shift rod of lock ball,or sagged spring (1) Adjust with shim or replace
(2) Worn shift rod ball groove (2) Replace
(3) Excess play in rotational direction of spline (3) Replace
(4) Parts off-centered due to loosening (4) Rectify or retighten
(5) Worn of bent shift arm (5) Rectify or replace
(6) Gear with considerable partial wear (6) Replace gear
(7) Bearing with considerable partial wear (7) Replace bearing
110
SECTION 4
PROPELLER SHAFT
CONTENTS PAGE
1. GENERAL DESCRIPTION
1.1. CONSTRUCTION 112
1.2. SPECIFICATION 112
2. SERVICING OF PROPELLER SHAFT
2.1. REMOVAL 117
2.2. DISASSEMBLY 117
2.3. INSPECTION 118
2.4. REASSEMBLY AND INSTALLATION 119
3. SERVICING OF PROPELLER SHAFT
3.1. REMOVAL 121
3.2. DISASSEMBLY 121
3.3. INSPECTION 122
3.4. REASSEMBLY 122
4. TROUBLE SHOOTING 124
111
4. Propeller shaft
1. General description
1.1. Construction
Each propeller shaft is made up of a hollow steel tube to provide sufficient bending strength and torsional
rigidity. Each propeller shaft assembly is carefully balanced for smooth rotation.
1.2. Specification
Length * 1,468 * * * * * *
nd
2 piece(㎜)
Outside dia. * 88.9 * * * * * *
(when equipped)
Inside dia. * 80.9 * * * * * *
Length * 1,360 * * * * * *
rd
3 piece(㎜)
Outside dia. * 88.9 * * * * * *
(when equipped)
Inside dia. * 80.9 * * * * * *
112
4. Propeller shaft
The propeller shaft assembly serves to deliver the engine torque to the rear axles.
The transmission is supported on the chassis frame with the engine while the rear axles are floatingly
suspended on the chassis frame via the springs. The relative position between the transmission and rear
axles varies because of flexibility of the chassis frame and springing action of the suspension system.
And, to allow for variation in the working length and relative angle of the propeller, shaft, the propeller
shaft assembly incorporates the spline shaft, sleeve and universal joints.
The propeller shaft assembly consists basically of the tube, spline shaft and flange of integral construction,
yoke flanges, sliding sleeve, universal joints (spiders, needle roller bearings, seals), etc.
113
4. Propeller shaft
FRONT ENGINE
114
4. Propeller shaft
115
4. Propeller shaft
REAR ENGINE
116
4. Propeller shaft
2.1. Removal
2.2. Disassembly
2.2.1. Universal joint assembly ▣ Remove the bolts fixing the lock washer and
remove the lock washer. Remove the flange nut
(hexagonal 56㎜) using a box wrench.
117
4. Propeller shaft
2.3. Inspection
2.3.3. Splines
Unit : ㎜
Nominal Limit for
▣ Check the amount of play between the sleeve
diameter use
Spider pin yoke and 2nd and 3rd propeller shaft splines in
outside 27.7 27.5 rotative direction using a pointed feeler gauge.
diameter If the amount of play is in excess of 0.5㎜, replace
Note. : S-1510 either of the parts with higher rate of wear.
Check the universal joint needle roller bearings 2.3.4. Center Bearing and Yokes
for wear, corrosion and seizure.
Replace the bearings if any abnormal condition is
noticeable.
118
4. Propeller shaft
2.4.1. Installation
119
4. Propeller shaft
Install the propeller shaft assembly in the reverse order of removal and note the following points;
The propeller shaft assembly is carefully balanced for smooth rotation.
Check to be certain the setting marks and flange yokes are lined up properly.
Tightening torque
Unit : ㎏.㎜
120
4. Propeller shaft
3.1. Removal
Prior to disassembly, apply setting mark to the 2. Dust cover 5. Needle roller bearing
joining portions of the propeller shaft assembly as 3. Rubber ring
it is carefully balanced.
121
4. Propeller shaft
3.3. Inspection Note. Note the direction of the dust cover and seat.
Unit : ㎜
Note. Note the direction of the needle roller
bearing stopper grooves.
Standard
Inspection item value for Limit for use
assembly
Play in splines 0.15 0.5
Note. S-1610
3.4. Reassembly
123
4. Propeller shaft
4. Trouble shooting
▣ Propeller shaft and vehicle vibrate.
CAUSE CORRECTION
① Yokes nut properly installed ① Correct setting of yokes
② Propeller shaft bent or distorted ② Replace or correct
③ Propeller shaft parts loosened in ② Replace or correct
mount or nut of balance
CAUSE CORRECTION
① Splines worn excessively ① Check amount of play in rotary
direction.
Replace worn parts
② Spider pins or needle roller bearing ② Replace
worn, seized or damaged
③ Propeller shaft parts loosened in mount ③ Correct
④ Propeller shaft parts poorly lubricated ④ Lubricate with chassis grease
⑤ Center bearing(s) worn or damaged ⑤ Replace
124
SECTION 5
REAR AXLE
CONTENTS PAGE
1. GENERAL DESCRIPTION 126
2. SERVICING OF DIFFERENTIAL CARRIER ASSEMBLY
2.1. REMOVAL 133
2.2. DISASSEMBLY 133
2.3. INSPECTION 135
2.4. REASSEMBLY 135
2.5. INSTALLATION 141
3. SERVICING OF REAR HUB ASSEMBLY
3.1. DISASSEMBLY 142
3.2. INSPECTION 143
3.3. REASSEMBLY 144
4. TROUBLE SHOOTING 146
125
5. Rear Axle
1. General description
These models adopt a full-floating type rear axle. The axle case is a banjo type of differential carrier
assembly consisting of the final drive gearing and differential assembly to which rear axle shafts are
connected. The outer end of each axle shaft is connected to the rear hub.
The final drive assembly uses a spiral or hypoid gearing to effect a signal reduction and final drive pinion
is fitted, via a pair of taper roller bearings and spacers, to the pinion cage which, in turn, is assembled to
the differential carrier.
The final driven gear is installed on the differential cage into which a pair of side gears and four pinion
gears are assembled via the spider. The differential assembly is mounted, via the taper roller bearings, to
the differential carrier and driven gear is engaged with the drive pinion.
Specification
126
5. Rear Axle
127
5. Rear Axle
128
5. Rear Axle
129
5. Rear Axle
130
5. Rear Axle
131
5. Rear Axle
132
5. Rear Axle
133
5. Rear Axle
2.3. Inspection
135
5. Rear Axle
spacers on the pinion. Install all of the shims and seal), or sliding resistance of the felt ring and oil seal
spacers removed at the time of disassembly. If the will give a false indication o bearing preload.)
shims are found to be defective, discard them and
install new ones in the order of thickness, so that ② If the measured value deviates greatly from the
thinner one is on the inner bearing side. Install the specified range, disassemble the final pinion
spacers. assembly and adjust the bearing preload by installing
shims of different thickness ( or by varying thickness
of shims of combines spacer ).
▣ Mount the flange yoke to the yoke bracket and ④ Install the gasket in position between and tighten
clamp these parts in a vise. Tighten the flange nut the flange nut to specification (50~60kg.m). bent
to 50~60kg.m using a box wrench. down the lock washer.
136
5. Rear Axle
▣ If the driven gear has been removed from the differential cage, install and fix in position with the bolts
in the following manner.
Procedure
Steps Cautions
No. Process
① Do not gasoline, kerosene or other
Wash clean bolts and driven petroleum product for washing.
gear in alkaline solution,
1 Washing ② Never use sparks or open flames when
tichloroethylene, aceton
or either. detergent is in use
③Use detergent in a well ventilated place.
2 Drying
Application of Apply loctite to top end of Apply Loctite i㎜ediately before
3
Loctite bolts cover 3-4 threads tightening.
Avoid applying shock load to the driven
Tightening of gear after tightening bolts.
4 Tighten the bolts to 33.2㎏.m
bolts At least 1(one) hour should be allowed for
Loctite to dry before testing driving
137
5. Rear Axle
Unit : ㎜
Standard Thrust
value for washer`s
assembly available
Clearance
2.8, 2.9, 3.0
between
0.20~0.28 3.1, 3.2, 3.3,
differential cage
3.4
and side gear
▣ Tighten the differential cage fixing bolts to When new bearings are installed
12.5~15.5kg-m.
At driven gear set bolt position : 4.5~5kg
Caulk 2-3 portions of each nut.
138
5. Rear Axle
139
5. Rear Axle
140
5. Rear Axle
2.5. Installation
141
5. Rear Axle
▣ Removal of wheels
Remove the wheel pin nuts with the wheel pin nut
wrench. Remove the wheels. Wheel pin nuts on
the right side wheels have right-handed threads
and those on the left side wheels have left-handed
threads.
142
5. Rear Axle
▣ Inspection of hubs
Check the wheel pin stopper grooves in the hubs
for expansion also check the portions into which
the oil seal and bearing are to be installed and
replace the parts if fitting interference is no longer
provided.
▣ Remove the snap ring and oil. Insert soft metal
bar into cut-away portions o the hub grease
reservoir and remove the outer bearing outer race
and inner bearing by tapping on the rear face of
the bearing sleeve.
Note. The left hub uses left-handed-thread and the Nominal size Unit : ㎜
right hub uses right-handed thread.
A Φ174
3.2. Inspection
B Φ170
▣ Inspection of rear axle shafts C Φ160
Support the rear axle shaft on V block at its end
and check for run-out using a dial indicator. If the D Φ163
amount of bending is in excess of 0.5㎜ (amount
of run-out is in excess of 1.0㎜), replace the shaft ▣ Inspection of rear axle case
with a new one. Also check the shaft with a new Check the entire rear axle case for bending and
one. cracking. Check oil seal fitting faces of the rear
axle case for wear and damage. Replace the rear
axle case if found to be defective. Also check
flanges and spring fitting faces for cracking and
distortion. The use of red check is recommended
143
5. Rear Axle
Nominal Size Unit : ㎜ ▣ Install the rear brake assembly in the reverse
order of removal. Fully contact the brake shoes by
A Φ118 turning the brake shoe adjust cam.
B Φ95 Assembly the rear hub assembly to the rear axle.
Install the outer bearing and hub bearing nut.
C Φ90
▣ Hub bearing preload adjustment
3.3. Reassembly With hub nut wrench turn in the hub bearing nut
until brake drum becomes dragged. Loosen the
▣ Mount the brake drum to the rear hub with the hub bearing nut just enough so that the brake
wheel pins and nuts. Tighten the nuts on the brake drum can be turned easily with hand. Retighten
drum side wheel pins to 45-50kg-m. Caulk three the bearing nut to obtain specified bearing preload.
portions of each nut with a chisel and a ha㎜er. To check bearing preload ( starting torque), hook
one of the wheel pins in tangential direction of
Note. When replacing brake drums, check o be rotation with a spring scale and read the scale
certain new drums are installed on the correct when the hub begins to rotate.
sides as they are unequal in direction o threads
and have different part numbers. * Starting torque = pull required to rotate hub x
distance between wheel pin and center of axle.
Amount of grease
required
Grease reservoir in
1,150g
rear hub
▣ Install the lock plate and fix it in position with
three lock bolts.
144
5. Rear Axle
145
5. Rear Axle
4. Trouble shooting
Rear axle noises
Complaint Cause Correction
Gear worn
Noise on pull
Gears backlash insufficient Replace gears or
adjust backlash
When driving at high Gear worn
speed
Gear backlash excessive
Continuous
noise Gear oil level too low Replenish
Drive pinion bearing or
differential bearings worn or Replace or adjust preload
When driving at a
loosen in mount
constant speed
Driven gear worn Replace
Replace bolts. Apply Loctite
Driven gear loosened
and tighten securely.
Gears defective Replace
Intermittent When driving at a Foreign matter in axle case Check
noise constant speed
Play in axle shaft splines
replace
excessive
Oil leak
Complaint Cause Correction
Oil leaks from the flange yoke(s) Oil seal(s) defective Replace
Oil leaks into brake drum(s) Hub oil seals defective replace
146
SECTION 6
FRONT AXLE
CONTENTS PAGE
1. GENERAL DESCRIPTION 148
2. SERVICING OF FRONT AXLE ASSEMBLY
2.1. DISASSEMBLY 154
2.2. INSPECTION 156
2.3. REASSEMBLY 158
2.4. ADJUSTMENT OF FRONT WHEEL ALIGNMENT 161
2.5. ADJUSTMENT OF MAXIMUM STEERING ANGLES 163
3. TROUBLE SHOOTING 165
147
6. Front Axle
1. General description
Two kind of front axle be equipped depending on the vehicle type. A steering knuckle is pivotally
assembled to each end of the axle via the kingpin. Each front wheel is mounted to the steering
knuckle via the front hub bearings and hub.
The knuckle arm and tie-rod to form a part of the steering linkage through which turning motion of
the steering wheel is relayed to the steering knuckles and causes them to pivot about the kingpin.
To maintain running stability of the vehicle, the front axle has various built-in angles such as “toe-in”,
“camber”, “caster”, “kingpin inclination” etc. that generally referred to as “front end alignment”.
Specifications
148
6. Front Axle
149
6. Front Axle
MODEL BF105
150
6. Front Axle
151
6. Front Axle
152
6. Front Axle
153
6. Front Axle
▣ Remove the front the hub cap. Note. The left side hub nuts have left-handed
threads and those on the right side have right
handed threads.
▣ Kingpin
1) Loosen the joint not fastening the tie-rod arm
with the tie-rod end until its outer face is flush
with the end of joint ball.
Disconnect the joint ball from the tie-rod arm by
tapping on the joint nut with a hammer.
2.2. Inspection
▣ Measure the outside diameter at several Note. Do not install the needle roller bearing with
portions of the kingpins using an outside portions their faces reversed, or damage to the bearing case
of the kingpins an outside micrometer. will result.
Take measurement at the upper and lower ends
(bearing fitting faces) in two directions at a right a. Install the upper side needle roller bearing by
angle to each other. aligning the grease hole in the knuckle and press it
in just enough, so that its outer face is depressed
▣ Assemble the needle roller bearings to the 2.5mm from the upper edge of the knuckle.
knuckle and install the kingpin, then check that b. Install the two lower side needle roller bearings
the needle roller bearings rotate smoothly without from the lower side of the knuckle. Press it in just
binding. enough, so that there is provided a clearance of
5.5mm between the inner edge of the knuckle and
▣ Measure the clearance between the kingpin and inner face of the bearing. Install another bearing
kingpin needle roller bearings. If the clearance is and press it in just enough so that its outer face is
beyond the value indicating need for servicing, flush with the plug fitting face.
replace the needle roller bearings with new ones.
3) Installation of oil seal
Standard
Value indicating Limit for
Inspection item value for
need for servicing use
assembly
Kingpin outside
50Φ - 49.9Φ
diameter
Clearance between 0.001~
kingpin and needle 0.12 -
roller bearing 0.007
156
6. Front Axle
Unit : ㎜
157
6. Front Axle
Unit : ㎜
Unit : ㎜
2) Install kingpins or test bars of the same
diameter into the kingpin fitting holes in the front
Nominal diameter axle.
Stretch a thin cord across the kingpin centers.
A Φ136.5
B Φ114.3
2.2.6. Bearings
2.3. Reassembly
▣ Assemble the front axle to the leaf springs 3)Look down on the front axle and check for
using U bolts. alignment between the cord and center bolt holes
in the spring seats.
U bolt nut torque(Kg-m) : 32~48
158
6. Front Axle
▣ Check the ends of the front axle carefully for ▣ Apply grease to the needle roller bearing and
cracks using red check. Replace the front axle thrust bearings. install the kingpin into position
with a new one if found to be cracked. using kingpin sleeper by aligning the groove with
the key bolt hole in the front axle.
Unit : mm
Standard value for Value indicating
When installing he kingpin, exercise care not to
assembly need for servicing cause distortion of kingpin head.
Clearance
Clearance more
between knuckles Interference 0.05
than 0.5
and front axle
159
6. Front Axle
▣ Install the kingpin cover with gasket and fix 4) Assemble the ball seat upper, joint ball, ball
these parts in position with the bolts. seat lower and spring to the tie-rod end in the
order described, then install the adjust plug. Turn
▣ Install the plug on the lower face of the steering in the adjust plug. Turn in the adjust plug fully
knuckle and fix it with the snap ring. and back out 1/3 of a turn and drill a hole sizing
2.2mm in diameter and 9-12mm in depth, then
▣ Assemble the knuckle arm to the steering install the snap ring.
knuckle. Apply Bell moly paste with engine oil
(paste 1 : oil 4) to the bolts and tighten the nuts, ▣ Assemble the tie-rod end assembly to the tie
and caulk 2 portion o each nut. rod.
Nut torque : 50~55kg-m Note. Apply generous amount o Bell moly paste
to the threaded portions of the tie-rod end. Turn in
▣ Front brake assembly the tie-rod end until a setting mark applied at the
time of disassembly is covered and leave it in that
position so that the bolt is torqued to specification
when toe-in
adjustment is completed.
160
6. Front Axle
3) Install the outer bearing outer race and apply ▣ Install the wheels and wheel pin nuts. Semi-
grease to the grease port. tighten the wheel pin nuts with a wheel pin nut
wrench. Remove the rigid racks from under the
Total amount of grease front axle and lower the wheels to ground. Tighten
400g
required (each wheel) the wheel pin nuts to 45-50kg-m. Do not over-
tighten wheel pin nuts.
▣ Fully contract the brake shoes by turning the
brake shoe adjust cam and install the brake drum 2.4. Adjustment of front wheel alignment
and front hub.
Various front end angles such as toe-in, camber,
▣ Install the outer bearing, bearing washer and caster, kingpin inclination, etc. are referred to as
hub nut. Fully tighten the hub nut and loosen it. “front wheel alignment”.
Standard
▣ Adjust the bearing preload by turning in the Tire size inflation
hub, so that a pull required to rotate the hub pressure
becomes 3-5kg when checked with a spring scale 10.00-20-16PR
hooked to one of the wheel pins. Front 6.75㎏/㎠
11.00-20-19PR
and rear (6.6x100kpa)
11R-22.5-16PR
Starting torque (or bearing
preload) when measured with ▣ Unload and park the vehicle on a level ground.
a spring scale hooked to
wheel pin
2.4.2. Adjustment of Tie-in
Hub bearing preload after
1.0㎏
break-in
▣ Apply chalk to front and rear part of the tire
Hub bearing preload on new
3.0~5.0㎏ tread. Mark a tire center line on the tread by
bearings
turning the wheel carefully with a scriber held in
contact with the center of the tire.
▣ Install lock washer and lock bolts
▣ Set the end o the positer on the toe-in gauge to
When the adjustment is completed, install the lock
the height of steering knuckle spindle.
plate.
161
6. Front Axle
Various types of instruments for measuring ▣ Measurement of caster angle and kingpin
camber angle, caster angle and kingpin inclination inclination
are in use but in this section front end angles are
measured using a level vial type camber, caster Take measurement on each front
and kingpin inclination gauge. Wheel in the following manner;(Right wheel)
162
6. Front Axle
2) Steer the front wheels to an angle of 20 degrees ▣ Position each front wheel on the center of the
(inner wheel) and hold then in position. Calibrate turning radius gauge in a straightened position.
the scale on the kingpin inclination and caster
gauge to zero by means of the adjust screw on the Set the parking brake securely.
rear face of the gauge.
2.4.4. Measurement of side slippage ▣ Adjust setting of the drop arm stopper bolt, so
that the drop arm comes into contact with the
When adjustment of the toe-in, camber, caster and stopper bolt when the knuckle is steered to stop.
kingpin inclination is completed, measure the
163
6. Front Axle
164
6. Front Axle
3. Trouble shooting
Cause Correction
Cause Correction
Moving parts poorly lubricated Lubricate
Joints worn Adjust or replace
Wheel alignment incorrect Adjust
(3) Hard-steering
Cause Correction
Moving parts poorly lubricated Lubricate
Kingpins fitted too tight Adjust clearance between kingpins and needle
roller bearings
Thrust bearings defective Replace
Joint balls fitted too tight Adjust
Tires under-inflated Adjust to recommended pressures
Front wheel alignment incorrect Adjust
Thrust bearing incorrectly installed Correct
Cause Correction
Tires not uniformly inflated Adjust
Tread height of tires unequal Adjust by replacing tires as necessary
Front springs on one side weakened or broken Replace
Front wheel alignment incorrect Correct
165
6. Front Axle
Cause Correction
Cause Correction
Tires not properly inflated
Adjust
Wear on center part of tread indicates over-
inflation
Wear on shoulders part of tread indicates under-
Correct
inflation
Balance
Front wheel alignment incorrect
Rotating parts out of balance
166
SECTION 7
STEERING
CONTENTS PAGE
1. GENERAL DESCRIPTION 167
2. SERVICING OF STEERING ASSEMBLY
2.1. REMOVAL 175
2.2. DISASSEMBLY, INSPECTION AND REASSEMBLY 176
3. POWER STEERING-ROTARY VALVE TYPE
3.1. CONSTRUCTION 180
3.2. OPERATION 181
3.3. MAIN SPECIFICATIONS 184
3.4. DISASSEMBLY AND REASSEMBLY 184
4. TROUBLE SHOOTING 198
167
7. Steering
1. General description
The steering system consists basically of the An increase force for steering operation gives a
steering wheel, steering shaft, yoke, universal rise to fatigue of the operator particulary in a
joint, spline shaft, steering column, steering long distance haulage, and therefore ,a means
unit, drop arm, drag link assembly, etc. should be provide that relieves the operator of
The steering unit is of an integral power- undue fatigue, for assurance of driving safety.
assisted type and worm shaft is connected, via The power steering system provides automatic
the yoke, universal joint and steering shaft, to hydraulic assistance to the turning effort
the steering wheel. When the steering wheel is applied to the mechanical steering system. The
turned, the turning motion of the worm shaft is power steering system consists of a control
changed into sliding motion of the ball-nut valve, power cylinder, and a hydraulic pump
rack is engaged with the taper gear on the used with the steering gear. The power cylinder
sector shaft to which the drop arm is connected, is moved by operation of the control valve
so that turning motion of the steering wheel is which supplies steering fluid to either side of
relayed to the steering linkage via the drop arm. the power cylinder piston as required,
Due to increase in the size of vehicles and depending on the position of the valve. The
resulting increase in the front axle load and to control valve is either a rotary-type or spool-
use of low inflation tires for improved riding type valve which is mounted directly to the
quality, ground contact resistance of the front steering gear assembly. The pressure used to
wheels has increased remarkably, causing a operate this system is supplied by a vane-type
substantial increase in the force for steering oil pump.
operation.
Specifications
168
7. Steering
MODEL BF106
169
7. Steering
170
7. Steering
171
7. Steering
172
7. Steering
MODEL BH116/BH117/BH120
173
7. Steering
174
7. Steering
2. Servicing of steering assembly Note. Before disconnecting the oil pipe, clean
the steering unit paying particular attention to
2.1. Removal the area around the joint, and plug or tape the
oil port after disconnecting the pipe, to prevent
2.1.1. Steering wheel assembly entry of dust or other foreign matter.
175
7. Steering
2.2.1. Disassembly
▣ Remove the mud guard. Remove the ▣ Tighten the adjust screw and back off
knuckle arm side ball joint assembly in the 2/12~3/12 of a turn(60~90˚) to align the cotter
order of the adjust screw, spacer, spring and pin holes then install the cotter pin.
ball seats.
2.2.2. Inspection
Set load
200kg/63.3mm 163kg/63.3mm
Set length
2.2.3. Reassembly
176
7. Steering
177
7. Steering
A. Steering unit-power
1. Gear box 19. O ring
2. Bearing-needle 20. Ring-piston
3. Plug-taper 21. Shaft-sector
4. Packing-Y 22. Screw-Adjust
5. Ring-back up 23. Retainer
6. Seal-oil 24. Cover-side
7. Housing-valve 25. Bearing-needle
8. O ring 26. Ring-back up
9. Ring-seal 27. Packing-Y
10. O ring 28. O ring
11. O ring 29. Nut-Hex
12. O ring 30. Bolt-W/washer
13. Shaft A-worm 31. Plug-breather
14. Pin-dowel 32. Nut-Hex
15. Plug-adjust 33. Bolt-W/washer
16. Bearing-ball 34. Washer-plain
17. Packing-Y 35. Washer-spring
18. Pistion-rack 36. Bolt-W/washer
37 Universal joint A
178
7. Steering
179
7. Steering
180
7. Steering
3.2. Operation
In the straight ahead or neutral position, oil rack position is located. Since all passages are
flows from the power steering pump through open, flow resistance is low in neutral position
the open position of the rotary valve and back at all times except when steering in turns, the
to the power steering pump reservoir without power required to operates the pump is at the
circulating in the power cylinder in which the minimum.
181
7. Steering
When the steering wheel is turned to the right, As a result the fluid flows, past the groove, into
resistance to turning is encountered between the chamber “A” within the cylinder and
the front wheels and the roadbed, tending to causes and increase in the pressure of fluid
twist the stub shaft. Since the stub shaft is pin- trapped within the chamber. As the pressure of
locked to the torsion at one end and the fluid increases, the piston receives a thrust
opposite end connects the rotor by a pin on the force in direction of the arrow and relays the
stub shaft, the twisting action moves the rotor force to the pitman shaft to turn and reduces
to right in relation to the valve body. As the driver turning effort in executing the right turn.
rotor turns, the clearance communicating the As the piston strokes, the fluid in the chamber
oil pump with the chamber “B” decreases and “B” is simultaneously forced out through the
prevents flow of fluid into the outlet port. rotary valve and back to the pump reservoir.
182
7. Steering
The higher the resistance to turning between amount of smooth hydraulic assistance at all
the roadbed and the front wheel, the more the times. As the driver stops applying steering
rotor is displaced, and the higher the oil effort to the steering wheel and then relaxes the
pressure in the chamber “A”. since the amount wheel, the rotor is forced back into is bar.
of valve displacement and, consequently, the When this happens, the fluid pressure is again
amount of hydraulic pressure built in the equal on both side of the rack piston nut and
cylinder is dependent upon the resistance to the steering geometry of the vehicle causes the
turning, the driver is assured of the proper wheels to return to the straight ahead position.
When the steering wheel is turned to the left, As shown on the figure, the fluid from the
similar action takes place but with the direction steering gear pump flows through rotary valve
of motion of the valve, torsion bar and piston into chamber “B’ to force the rack piston in
are reversed. direction of the arrow and this forces the
Executing a left turn causes the fluid to flow pitman shaft to turn and reduces driver turning
from the power steering ump through the effort in executing the left turn. The oil in the
rotary valve and to the area between the rotary chamber “A” is simultaneous by forced out
valve and the rack piston via drilled passage. through the rotary valve form a drilled passage
This is to assist in forcing the rack piston to in the housing and back to the pump reservoir.
turn the pitman shaft and linkage.
183
7. Steering
▣ Handling precautions
3.2.4. Manual Operation Keep the disassembled parts clean and in good
order to prevent the parts from loss or damage.
Even when no hydraulic pressure I applied to Such as pitman shaft, piston rotor and worm
the power steering as the engine has stopped or shaft should be treated with meticulous care as
due to a trouble of the oil pump or damaged they are precision finished and carefully
gydraulic circuit, a stopper is formed shaft and matched to maintain exact dimension.
groove on the stub shaft as illustrated, and
manual steering can be performed by pushing ▣ Special service tools
the piston directly. For efficient and correct service operations the
use of the special service tools is recommended.
Item Specification
▣ Preparation
Prior to disassembling the power steering unit
clean the work bench and wash the exterior
surface of the power steering unit with the
solvent.
Then drain the oil from the power steering unit
by stroking the piston.
184
7. Steering
3.4.2. Disassembly
185
7. Steering
186
7. Steering
187
7. Steering
▣ Wash all parts in clean solvent and blow out ▣ Inspect ball tubes, making sure that the ends
all oil holes with compressed air. where the balls enter and leave the guides are
not damaged.
▣ If the drive pin in the lower shaft or valve
body is cracked, excessively worn or broken, ▣ Inspect lower thrust bearing and washers for
replace the complete valve and shaft assembly. scores or excessive wear. If any of the
conditions are found, replace the thrust bearing
▣ If there is evidence of leakage between the and washer.
torsion bar and the stub shaft or scores, nicks,
or burrs on the ground surface of the sub shaft ▣ Inspect rack piston teeth for scoring or
that cannot be cleaned up with crocus cloth, the excessive wear. Inspect the external ground
entire valve and shaft assembly must be surfaces for wear, scoring or burrs. If any of
replaced. these conditions exist and are excessive, both
the rack piston and worm must be replaced.
▣ Check the outside diameter of the rotor and
the inside diameter of the valve body for nicks, 3.4.4. Reassembly
burrs, or bad weat spots. If the irregularities
cannot be cleaned up by the use of crocus cloth, ▣ Assemble the sector shaft assembly as
the complete valve and shaft assembly will follows.
have to be replaced.
▣ Check sector shaft bearing surface in the ① After protecting the sector shaft with cloth,
side cover for scoring. If badly worn or scored, clamp the sector shaft in a vise.
replace the side cover.
② Apply generous amount of grease into the
▣ Check the sealing and bearing surfaces of
adjusting screw hole on the sector shaft, then
the sector shaft for roughness, nicks, etc. if
install the adjusting screw and retainer and
minor irregularities in surface cannot be
tighten the retainer using special bar(910-
cleaned by use of crocus cloth, replace the
22811)
sector shaft.
Note. When installing the retainer tighten the
▣ Replace sector shaft assembly if teeth are
retainer fully, then loosen it to 180 degrees.
damaged or if the bearing surfaces are pitted or
And then tighten it again to 4kg.m o torque and
scored.
loosen it to 20 degrees. Check that adjusting
screw turns freely.
▣ Check sector shaft lash adjusting screw. It
must be free to turn with no perceptible end
play. If adjusting screw is loose replace the
sector shaft assembly.
189
7. Steering
④ Apply generous amount of grease to the lip steel balls are seated properly in position.
of Y-packing, then install the ball bearing.
⑭ Insert the O-rings into the grooves in the ⑤ Turn the worm shaft until the ball race of
outer circumference of valve housing and the piston is aligned with the ball race of worm
inner circumference of oil part respectively. shaft.
▣ Assemble the piston assembly as follows ⑥ Feed the remaining balls into the piston,
while slowly rotating the stub shaft clockwise.
191
7. Steering
193
7. Steering
3.4.5. Installation
194
7. Steering
Seal
1 Assembly Thrust bearing
(910-10611)
Guide
Thrust bearing
2 Seal
Steel ball guide
(910-23033)
Attachment
3 Assembly Valve housing
(910-10671)
Wrench
4 Assembly Lock ring
(910-10742)
Wrench
5 Assembly
(910-10743)
195
7. Steering
Inside
(910-21704 : Φ58
Output shaft
7 910-21715 : Φ48
Y-packing
910-51716 : Φ45
910-21717 : Φ40)
O-ring
Needle
9 Seal ring
(910-21200)
Y-packing
Inside
Piston
10 (910-21701 : 100Φ
Seal ring
910-21718 : 85Φ,90Φ)
196
7. Steering
197
7. Steering
4. Trouble shooting
Steering wheel fails to 1. Piston will not correspond to the 1.Replace with assembly
return to its position movement of steering wheel
(when front alignment us 2. Power steering control valve seized or 2. Clean or replace
correctly made) damaged
198
SECTION 8
CONTENTS PAGE
1. CONSTRUCTION
2. SPECIFICATON 204
7. TROUBLE SHOOTING 24
199
8. EXHAUST BRAKE
200
8. Brake (Full Air)
1. Construction
The full air brake system consists of the leading and trailing type front and rear brakes to ensure
positive brake action.
The front brakes are of the cam-actuated internal-expanding type with the brake drum and linings sizing
410㎜ in diameter and 155㎜ in width, respectively. The brake anchor bracket is of an integral
construction and is mounted to the knuckle with dowels and four bolts. The bolts on the lower part the
anchor bracket are also used to connect the tie-rod arm.
A pair of bushing are fitted to cam side of the anchor bracket to support the camshaft and are lubricated
with grease via the grease fitting. To balance the force applied to the leading and trailing shoes when
the shoes are expanded outward by the pivoting motion of the cam, the brake assembly adopts and
asymmetrical cam.
When assembling the front brake assembly, install the camshaft on the anchor bracket by turning
outward the arrow pointer on the splined end of the camshaft, then install the adjuster, stopper plate and
snap ring. The stopper plated should be installed by aligning the arrow mark on the plate with that n the
end of the camshaft.
The brake shoes have on their ends in contact with the cam, a roller and pin which are secured in
position with the snap ring. Two pieces of linings are riveted to each brake shoe.
With an aim to even out wear of the linings on the leading and trailing sides and to improve brake
action, concaved linings are installed on the trailing side broke shoes. These should not be interchanged
with those on the leading side at the time of relining.
201
8. Brake (Full Air)
1.2. Adjuster
The adjuster assembly consists of the worm gear and worm shaft assembled to the lever.
When the worm shaft is rotated, its motion is carried via the worm gear to the camshaft thereby
adjusting the power piston stroke and brake lining clearances. The adjuster is fitted with a stopper plate
to prevent adjustment beyond the limit as the linings are worn excessively.
202
8. Brake (Full Air)
The rear brakes are of the cam-actuated internal-expanding type with the brake drum and linings sizing
410㎜ in diameter and 220㎜ in width, respectively.
The brake anchor of the rear axle case with eight bolts.
The rear brake assembly is identical with the front brake assembly in construction except that two brake
show return springs are used in the rear brake system. The return springs are hooked to the pins on each
brake shoe.
Two pieces of brake linings are riveted to each brake shoe.
The brake linings on the leading and trailing side brake shoes are unequal in shape to help even out
lining wear.
203
8. Brake (Full Air)
The brake circuit consists of independent front and rear brake circuits which are operated
simultaneously by the action of the dual brake valve to ensure positive brake action.
When the brake pedal is depressed, air from the tank is fed, via the dual brake valve, to the relay valve
in the front and rear. The relay valve, in turn, feeds compressed air into the power chamber to provide
brake action.
2. Specification
204
8. Brake (Full Air)
205
8. Brake (Full Air)
A. Brake A-FRT
1. Cover-drum 21. Washer-lock
2. Cover-check hole 22. Bolt-Hex M10x1.25
3. Bolt-Hex M10x1.25 23. Bracket-anchor
4. Washer-spring 24. Seal-oil
5. Chamber A-power 25. Bush-cam shaft
6. Slack adjust A 26. Nipple-grease
7. Washer-spring 27. Ring-spacer
8. Bolt 28. Cam shaft
9. Shoe A-brake, FRT 29. Felt ring-cam shaft
10. Bush-brake shoe 30. Collar-cam shaft
11. Pin-roller 31. Spacer-cam shaft
12. Roller 32. Nut-Hex M16x1.5
13. Clip-roller pin 33. Plate-stopper
14. Pin-shoe return spring 34. Ring-snap
15. Shoe 35. Bracket-UPR
16. Rivet 36. Bracket-LWR
17. Lining-front 37. Washer-plain
18. Spring A-W/cover 38. Bolt-Hex M8x1.25
19. Pin-anchor 39. Nut-Hex
20. Lock plate 40. Washer-spring
206
8. Brake (Full Air)
207
8. Brake (Full Air)
A. Brake A-RR
1. Cover-drum 24. Roller
2. Cover-check hole 25. Clip-roller pin
3. Bolt-Hex M10x1.25 26. Pin-shoe return spring
4. Washer-spring 27. Bush
5. Bracket-anchor 28. Pin-spring
6. Bush-cam shaft 29. Spring A
7. Seal-oil 30. Spring A-return
8. Pin-anchor 31. Nut-Hex M14x1.5
9. Lock plate 32. Washer-spring
10. Washer-lock 33. O ring
11. Bolt-Hex M10x1.25 34. Bush-cam shaft
12. Bolt 35. Bracket-bush
13. Cam shaft 36. Nipple-grease
14. Ring 37. Bolt-Hex M10x1.25
15. Collar 38. Nut-Hex M10x1.25
16. Clip 39. Washer-spring
17. Felt ring-cam shaft 40. Spacer-cam shaft
18. Chamber A-spring 41. Plate-stopper
19. Shoe A-brake, RR 42. Ring-snap
20. Shoe 43. Washer-plain
21 Lining-rear 44. Washer-spring
22 Rivet 45. Bolt-Hex M12x1.25
23 Pin-roller 46. Bracket-auto slack adjust A
47. Slack adjust A
208
8. Brake (Full Air)
209
8. Brake (Full Air)
alignment.
211
8. Brake (Full Air)
212
8. Brake (Full Air)
5.2.3. Removal of camshaft and brake Compare the measured values to determine the
adjuster amount of clearance.
If the amount of clearance is beyond the valve
▣ Remove the snap ring retaining the camshaft indicating the need for servicing, replace the
and remove the stopper plate. Remove the bushing.
adjuster from the camshaft and pull out the
camshaft from the anchor bracket.
Unit : ㎜
Value
Standard
Nominal indicating
5.3. Inspection of disassembled parts value for Limit for use
diameter need for
servicing
servicing
5.3. Inspection of brake shoe assembly
Clearance
between
▣ Check the brake shoe for deformation or 0.25 or
anchor pin and
crack and replace with a new one as necessary. more00.1
brake shoe
Remove the end roller pin from the brake shoes bushing
and check the roller for wear or damage. Then Outside
check the amount of clearance between the diameter of Φ30 29.85
roller and pin. Replace the parts with new ones anchor pins
if the amount of clearance is excessive.
5.3.2. Inspection o brake shoe return springs
▣ Assemble the adjuster to the splined portion ▣ Check the retainer spring and o-ring for
of the camshaft and check for play in rotative wear and replace with new ones as necessary.
direction. Replace both of the parts if the Check the fit of the joint pin into the pin hole
amount of play is excessive. at the end of the adjuster for looseness.
Replace the parts if a considerable amount of
play is noticeable.
Unit : ㎜
Nominal diameter of joint pin 16Φ
Standard clearance between
0.09~0.17
bushing and pin
215
8. Brake (Full Air)
▣ Brace the front and rear wheels and release ▣ Remove the joint pin connecting the brake
the parking brake. adjuster with the power chamber.
▣ Insert a 0.3㎜ feeler gauge into the brake ▣ Disconnect the air hose.
216
8. Brake (Full Air)
5.6.2. Disassembly of power chamber ▣ Check the diaphragm and spring for damage
assembly and replace with new ones if found to be
defective.
▣ Clamp the power chamber assembly in a
vise and take out the two bolts fixing the clamp 5.6.4. Reassembly of power chamber
ring, then remove the clamp ring. assembly
Release the vise gradually and remove the
power chamber and individual parts. ▣ To reassembly the power chamber assembly,
follow the disassembly procedure in the
reverse order and adjust the length of the push-
rod to the standard value specified under
paragraph.
217
8. Brake (Full Air)
218
8. Brake (Full Air)
DANGER
Do not attempt to mechanically release (cage)
the spring when spring brake shows structural
damage and/or when safety ears* have been
removed. Caging the spring or disassembly of
the chamber may result in the forceful release
of the spring chamber and its contents which
could cause death, severe personal injury
and/or property damage. Remove spring brake DANGER
and replace with new unit. The above instructions only apply when spring
brake is not pressurized. If air pressure is used
▣ Insert release stud through key hole in
to compress the spring, do not tighten release
chamber into the pressure plate. stud nut more than finger tight. Torquing the
nut can cause pressure plate damage resulting
▣ Turn release stud 1/4 turn clockwise. is sudden release of the spring causing death or
sever personal injury.
▣ Pull on release stud to ensure stud cross pin
is properly seated in the pressure plate. WARNIGN : If the reco㎜ended “X”
dimension is not correct for chamber size and
▣ Assemble release stud washer and nut on torque value, the spring brake should be
release stud finger tight. considered structurally damaged. See removal
of instruction on preceding page.
X dimension
30 “chamber-2.875” Minimum
▣ To prevent sudden release spring of the ▣ Be certain the diaphragm is properly seated
piggy back or service push rod assembly and to between the adapter and housing lip and
facilitate the installation of the new diaphragm, reassemble the service clamp assembly. Torque
the service push rod should be prevented from carriage bolts and clap assembly for proper
retracting by clamping he service push rod in seating around the adapter and housing lip and
place with vise grip pliers as shown. remove vise grip pliers from service push rod.
DANGER
DO NOT attempt to remove the compression
spring.
Disassembly of the release fool from the
chamber assembly will result in the forceful
release of the compression spring and pressure
plate and may result in sever personal injury or
death.
▣ Inspect adapter push rod seal, adapter push ▣ Uncage compression spring and reassemble
rod plate and return spring. If any structural
221
8. Brake (Full Air)
DANGER
Failure to comply with all instructions of
▣ Remove service clamps an rotate housing to mechanical release may result may result in the
desired position forcefully release of the spring and cause death,
severe personal injury and/or property damage.
▣ For reassembly of the service housing
follow instructions. 5.7.3. ▣ Remove service clamp assembly. (follow
instructions 5.7.5.)
222
8. Brake (Full Air)
223
8. Brake (Full Air)
224
8. Brake (Full Air)
225
8. Brake (Full Air)
The dual brake valve assembly is adapted to control the dual circuits simultaneously to provide an extra
margin of safety.
226
8. Brake (Full Air)
227
8. Brake (Full Air)
6.1.1. Outline of Dual Brake The secondary valve senses the primary valve
pressure, and supplies a pressure nearly equal
The dual brake valve simultaneously controls to it to the air master relay valve for the
two brake systems, one for front axle an rear secondary system.
axle and the other for the rear axle. If the primary valve fails to generate a pressure
The dual brake valve is a control valve which due to damage to the primary system piping,
operates as the pedal is depressed by the foot, for example, the secondary valve is so
and supplies an air pressure corresponding to designed as to operate in direct response to t he
the depressed angle of the pedal th the relay depressing force applied to the pedal.
valve on the air master. The dual valve consists As explained above, the dual brake valve
of two controls valve, primary and secondary independently controls the two separate brake
each of w3hich has an air supply port for system (primary and secondary ) so that even if
supplying the air from the air tank, and a one of the brake systems should fail, the other
discharge port for sending the air to the relay system can apply the brake, and thus ensure the
valve for the air master. safety of the vehicle.
228
8. Brake (Full Air)
6.1.2. Construction
contact with a spring seat ③, to which a as the primary valve, and is pushed to the body
rubber spring ④, primary piston ⑤, stem seat by a spring ⑩. Each valve and reach relay
spring ⑥, relay piston ⑦, and relay piston piston ⑦ are hollow, an the discharged air
runs through their hollow centers to push up
spring ⑧ are fitted together.
the exhaust passage ○ D located at the bottom
The primary piston ⑤ is kept pushed upward
end to the exhaust port, and out into the
by a return spring ⑨. atmosphere.
The primary valve assembly ⑬ is mounted
229
8. Brake (Full Air)
6.1.3. Operation
▣ When the pedal ① is stepped on, the foot`s ▣ When the primary valve ⑬ operates, port
depressing force is conveyed via the plunger ⑮ of air pressure is routed through part of the
②, spring seat ③ and rubber spring ④ to body to chamber ○ B in the top part of the
the piston ⑤ so that the piston compresses the second valve relay piston ⑦ to push the relay
return spring ⑨ and moves downward. As the piston down.
piston ⑤ gone down, the primary exhaust
valve ⑫ at the bottom end of the piston ⑤
contacts the primary inlet valve ⑬ to close
the center exhaust passage
The piston further compresses the primary
valve return spring ④ so that the primary
valve opens to let air out of the supply port. ⑭
to chamber ○ A and the primary valve
discharge port, from which the air is supplied
to the primary system air master as a command
pressure.
230
8. Brake (Full Air)
3) The secondary exhaust valve seat ○ 16 to the 1) When a depressed angle is kept constant the
bottom end of the relay piston contact the air pressure generated by depressing the pedal
secondary inlet valve ○ 17 to close the center is stabilized at a level compressing to the
exhaust passage. depressed angle.
The secondary inlet valve ○17 is further pushed
When the pedal is stepped on, the exhaust
downward to make a clearance between it and passage ○ D closes and the inlet valve ○ 13 ○
17
the body inlet valve seat so that the air from opens to start air supply as mentioned above.
the supply port runs through chamber ○ C to The air pressure simultaneously works on the
the secondary discharge port, from which the bottom of the piston ⑤⑦to push it up.
air is supplied to the secondary system air
master as a command pressure.
231
8. Brake (Full Air)
2) If the pedal depressing angle is kept 3) The secondary relay piston ⑦ falls
constant, the air pressure on the bottom of the according to the air pressure supplied from the
pistons ⑤,⑦ raises the piston to compress the primary inlet valve ⑪, thus generating an air
rubber spring ④ on top of the piston ⑤,⑦. pressure in the secondary inlet valve ○ 17 . This
The piston ⑤ rises in contact with the inlet air pressure simultaneously acts on the bottom
valve ⑬, and the inlet valve contacts with the of the relay piston ○ 7 . When the secondary
body inlet valve seat ○ 18 to stop the air supply. pressure acts on the bottom of the relay piston
The piston ⑤ and inlet valve ⑬ are in ⑦ becomes equal to the primary pressure
contact with each other, and the air pressure applied to the top of the piston ⑦, the force
stabilizes at this point of time. pushing the relay piston ⑦ down is offset so
that the relay piston ⑦ moves upward in
contact with the secondary inlet valve ○17 .
232
8. Brake (Full Air)
4) When the inlet valve ③, ○ 17 contacts 1) When the pedal is released, the plunger ②
cover`s inlet valve seat ○18 ○
19 , air supply from and piston ⑤ are pushed up by the spring
the supply port to the discharge port is stopped. ⑨ and the primary valve air pressure so that
Because the exhaust port is closed at this time, the exhaust valve seat ○
19 at the bottom end
the air pressure stabilizes without rising. At of the piston ⑤ moves away from the
this point of time, the secondary air pressure
primary inlet valve ⑬, thus opening the
stabilizes at the same level as the primary air
pressure. center exhaust passage ○D.
The relay piston spring ⑨,⑩ plays the role of The primary valve ⑬ air pressure is released
reducing pressure difference between the through the exhaust passage ○
D and exhaust
primary inlet valve ⑬ and secondary inlet port ⑪ into the atmosphere.
valve ○17 .
233
8. Brake (Full Air)
234
8. Brake (Full Air)
6.1.4. Disassembly of Dual Brake Valve 2. Take out the bolts fixing the dual brake
Assembly valve assembly in position on the frame and
remove the valve assembly.
▣ Removal of dual brake valve assembly from
vehicle, discharge compressed air completely ▣ Disassembly
by opening the drain cock on the air tank
before removing the dual brake valve assembly. 1. Prior to disassembly, wash clean the exterior
of the dual brake valve assembly to prevent
entry of dust, grit, water or other foreign matter.
235
8. Brake (Full Air)
4. Take out the three mounting plate bolts and ▣ Take out the four bolts fastening the body
remove the mounting plate together with the with cover and remove the cover, return spring
brake pedal. and O-ring.
236
8. Brake (Full Air)
237
8. Brake (Full Air)
▣ Wash the clean metal parts to prevent entry 1. Depress the brake pedal gradually and check
of dust or other foreign matter. the angle of the brake pedal when the pressure
indicated on the air pressure gauge begins to
6.1.7. Brake Pedal Free Play Adjustment increase.
Adjust the length of the link rod with the turn Standard value 3.5~8㎜
buckle, so that free play of the brake pedal
(stroke of pedal before a resistance is felt) is Note. This adjustment is equal to brake pedal
held within 12~23㎜. free play adjustment.
▣ Operate the brake valve and check the air 6.1.9. Operating Test On Vehicle
pressure against the air pressure gauges to see
if the performance of the brake valve is within Start and let the engine at idle until pressure of
the specifications diagrammtically represented. air within the air tank reaches the specified
The upper and lower sections of the valve are level, connect air pressure gauge to the
equal in performance, however , the pressure discharge port in the upper and lower sides
of air at the discharge port of the lower section after making a leak test. Air pressure gauges
is slightly lower than that of the upper side may be connected to the pipes on the relay
(difference of pressure should be0.3kg/㎠ or valve side.
less).
238
8. Brake (Full Air)
5~11.5kg
Standard (a point 150㎜ away
value from the fulcrum point
of the pedal)
239
8. Brake (Full Air)
240
8. Brake (Full Air)
▣Take out the bolts fixing the body upper and ▣ Check around the discharge port for leakage
remove the body, diaphragm and spring. using soap water.
6.2.3. Inspection
6.2.4. Reassembly
241
8. Brake (Full Air)
6.3. Quick release valve (QRV) the spring brake actuator resulting from
repeated braking there by to prevent brake
6.3.1. General description dragging.
The quick release valve is to be installed in the When the pressure of air within the air tank
parking brake circuit utilizing a spring brake lowers beyond the valve opening pressure or
actuator for holding the pressure of air within when the parking is applied, the quick release
the spring chamber constant. valve functions to discharge air acting on the
The quick release valve is positioned between spring brake actuator spring, thereby
the spring brake actuator and parking brake facilitating smooth removal of compressed air.
valve to prevent lowering of air pressure within
6.3.2. Construction
▣ The function of the Quick Release Valve is ▣ When the parking brake valve is actuated
to speed up the exhaust of air from the air and pressure of air at the outlet side(A) of the
chamber. It is mounted close to the chambers it pressure control valve lowers beyond the valve
serves. In its standard configuration the valve opening pressure of 20.4kg/㎠(2.4x100Kpa),
is designed to deliver within one (1) psi of the diaphragm moves up, discharging air
control pressure to the controlled device; through the exhaust port.
however, for special applications the valve is
available with greater differential pressure 6.3.4. Servicing
designed into the valve. (1) Disassembly
(4) Reassembly
▣ Install diaphragm
▣ Install diaphragm.
▣ Install O-ring in cover groove;
▣ Install cover and tighten screws evenly and
securely. (torque to 30-60 inch pounds.)
243
8. Brake (Full Air)
7. Trouble shooting
7.1. Poor brake action
Cause Correction
1. Brake linings in poor contact with brake 1. Correct or reline.
drums.
2. Face of brake linings hardened, or oil or 2. Correct or reline.
grease on linings.
3. Brake linings clearances or power chamber 3. Adjust
stroke excessive.
4. Dual brake valve defective(air leaking) 4. Overhaul
5. Air pressure insufficient. 5. Check air pressure gauge and and air line and
correct as necessary.
6. Camshaft sticking or binding. 6. Lubricate or correct cam shaft bushing
7. Relay valve defective. 7. Overhaul
Cause Correction
1. Rivet heads exposed due to excessive wear to 1. Reline
brake linings, or a clearance exists between
brake linings and brake shoes.
2. Face of brake linings hardened, or material of 2. Correct or reline
linings poor.
3.Anchored face of brake shoes poorly 3. Lubricate
lubricated.
4.Brake lining clearances incorrect. 4. Adjust
brake shoe return springs or spring covers
defective.
5. Foreign matter between brake lining and 5. Replace
brake drum brake drum distorted, worn
excessively or loosened in mount
244
8. Brake (Full Air)
Cause Correction
1. Brake linings clearance uneven, linings is 1. Correct, adjust or reline.
poor contact with brake drums, linings
material poor, or oil or grease on
linings.(one side)
2. Brake drum run-out or loosened in mount. 2. Overhaul.
3. Brake drum run-out or loosened in mount. 3. Correct
4. Wheel bearings defective. 4. Overhaul
5. Tires not uniformly inflated. 5. Adjust
6. Pressure of air fed into power-chambers 6. Check air circuit for air leakage
unequal.
Cause Correction
245
8. Brake (Full Air)
8. Exhaust brake
General description
The exhaust brake consists basically of a butterfly valve installed within the engine exhaust manifold
and is connected with the air control cylinder via link rod.
The exhaust brake is remotely controlled by means of a switch mounted to the steering column.
8.1. Inspection
Common terminal, ② Normally open, Make a continuity test on the coil using a tester.
③ Normally closed. Check contacting face of the plunger and valve
Normally closed terminal is not in use. When seat.
installing the accelerator switch, note the Correct as necessary.
terminals carefully to avoid wrong connections. If the plunger is sticking, correct with a fine
sand paper and apply a thin coat of engine oil.
246
8. Brake (Full Air)
26.2㎜ A 23kg
48.6㎜(maximum) B 32.5kg
8.1.7. Testing of Exhaust Brake ▣ Depress the accelerator pedal and listen for
(With Engine Sationary) the same hissing sound. Operation of the
accelerator switch is under the influence of the
▣ Pull out the exhaust brake switch and check accelerator pedal stroke.
that exhaust brake indicator light operates.
( Operation of exhaust switch will be
accompanied by a hissing sound which
indicates that air is drawn into the power
chamber.)
Complaint Correction
Exhaust brake does not operate when switch is Fuse burned out. Circuit open
turned on (indicator light inoperative) Exhaust brake switch defective
Accelerator switch defective circuit open
Clutch switch defective, circuit open
Magnetic valve coil open or poorly grounded
Exhaust brake does not operate when switch is
Magnetic valve sticking
turned on ( indicator light operates)
Air pressure too low
Exhaust brake valve sticking
Exhaust brake cannot be released by depressing Clutch switch defective(when hydraulic circuit is
clutch pedal. operating normally)
Exhaust brake cannot be released by repressing
Accelerator switch defective or out of adjustment
accelerator pedal.
Discharge port in magnetic valve clogged valve
Valve returning action poor
piston sticking
248
8. Brake (Full Air)
9. Auto slack adjustment in the cover. Between the cover and the control
arm is a sealing ring. The control disc has a
9.1. Construction milled recess for the toe of the rack. The flanks
of the recess are hardened.
This system automatically adjusts linings Gasket 27 fits between control unit 12 and
clearance according to brake lining wear. housing 1.
Torx-slotted screw 24 (6 off.) hold the control
Caution : As lining wear amount is not unit in place.
indicated, check remained lining through check
hole on brake anchor plate.
Housing 1 is cast in nodular iron and tenifer O-rings 5 and 28 (2 off.), which are made o
treated to give a low coefficient of friction and nitrile rubber, protect the mechanical parts
high wear resistance. from salt, water and dirt.
The housing is available in different variations
with a choice of lever length, offset and
direction.
249
8. Brake (Full Air)
250
8. Brake (Full Air)
Starting position
252
8. Brake (Full Air)
253
8. Brake (Full Air)
254
8. Brake (Full Air)
256
8. Brake (Full Air)
ASR Operation
Vf Vehicle speed
Vr1,Vr2 Speed of powered wheels; Me injected fuel quantity
Pz1,Pz2 Brake pressure in the brake cylinders of the powered driving wheels
HV1,HV2 Pressure holding valves of the pressure control valves for the powered wheels
AV1,AV2 Outlet valves of the pressure control valve for the powered wheel.
257
8. Brake (Full Air)
The ABS/ASR control unit is of digital design The intergrated protection unit renders
with redundant microprocessors. If features electrical disturbances acting on the vehicle
four functional areas: electrical circuit ineffective.
4. Solenoid valve
5. Atmosphere
▣ Speed sensor
The bosch 4-channel ABS uses four wheel
speed sensors. The sensor consists of a
permanent magnet connected to a metal
rod, around which a coil has been wound.
PCV not working PCV workng A pulse wheel mounted to the hub induces
an alternating voltage in the sensor coil.
▣ Solenoid Valve and Shuttle Valve The frequency of the alternating voltage is
The solenoid valve is a combination of two proportional to the wheel speed.
pilot controlled 3/2 solenoid valves that
energize the brake cylinder of the powered axle
with compressed air when the corresponding
wheel tends to spin. Two control plungers are
controlled by these solenoid valves.
When no current is flowing, supply 1 is closed
and the cylinder connections are opened up to
the outside.
259
8. Brake (Full Air)
▣ Braking comparison
ABS/ASR component
5. Shuttle valve (connection to ASR)
6. Impulse ring
7. Wheel speed sensor
8. ABS/ASR controller
(electric control unit)
9. Pressure controller
10. Solenoid valve
260
8. Brake (Full Air)
10.5 ECU Self-test feature should illuminate for a moment after ignition is
switched on and, if the abs warning lamp does
When the ignition is switched on, the ECU not illuminate immediately after the ignition
microprocessors run a self-test. The self-test has been switched on, then the bulb or lamp
consists of checking the computer memory, the circuit is defective and must be repaired.
timer and a number of arithmetic and logic
functions. During operation, the ECR ▣ Abs failure modes
continuously runs a test of the permanent If a failure in the ABS/ASR system is detected
memory. Within 0.4 seconds after the ignition during vehicle operation, the failure is recorded
has been switched on, the valve relay (VR1 in the ECR memory and the defective portion
and VR2) are checked for proper operation and of the system is witched off. The abs warning
an active solenoid test is conducted. When the lamp will illuminate (and remain illuminated),
ABS or ASR functions are required in a indicating to the driver that there is as failure.
particular instance, the solenoid valves are The intact portion of the ABS/ASR system will
constantly checked for correct electrical continue to be operational.
function. During the initial self-test and when
abs or ASR is acutated, the solenoid valve ▣ On-Board Diagnostics
circuits are checked for failures. The self-test A blink code diagnostic readout can be called
will detect open circuits and shorts to ground up by pressing the abs diagnostic button. The
or 12 volts. If the ABS/ASR is not active, only blink code constants of three blocks of blink
open circuits and shorts to ground can be pulses. The number of blink pulses in the first
detected. The wheel speed sensor circuits are block identifies the configuration of the ECR
constantly monitored by the ECR whenever the (abs only, abs with ASR brake controller, etc.).
vehicle is in operation. The monitoring will The number of blink pulses in the second block
detect open circuits and shorts to ground and identifies a failure found in diagonal 1(left
12 volts in the sensor cables. In addition, front/right rear) and the number of blink pulses
changes in the air gap between the speed in the third block identifies a failure in
sensor and the pulse wheel are detected. diagonal 2 (right front/left rear).
The abs warning lamp illuminates after the To store the diagnostic codes, the ignition must
ignition has been turned on and remains lit be switched off and back on at least once. In
until the first successful speed sensor test. order to read the code, the abs diagnostic
When the sensors have been tested successfully, button must be pressed for at least one second.
four good sensor signals are received and all The diagnostic blink codes are covered in
other tests are good, the warning lamp goes out detail in the troubleshooting section of this
indicating that the abs is ready for operation. manual.
The warning lamp should go out no later than a If the ECR detects a failure, the corresponding
maximum speed of 9 mph has been reached. failure code is stored. The failure code remains
The lamp will remain out unless a fault is stored until it is detected from the ECR
detected in the system. memory by pressing the diagnostic button
ASR is ready even if the warning lamp is still while simultaneously turning the ignition on,
on, as would be the case when first driving the button should remain depressed for a brief
away in a low traction situation. moment after the ignition has been turned on.
This procedure will also cause the cu to
▣ ABS warning lamp and ASR/Diagnostic reconfigure itself to the vehicle system and to
lamp the ABS/ASR components which may be
The driver is responsible for monitoring the installed. If no response is received after the
abs warning lamp and (if equipped) the ASR button has been depressed, test the diagnostic
lamp (wheel slip indicator). The ASR light button.
261
8. Brake (Full Air)
262
8. Brake (Full Air)
1 Normal operation
Recheck on resetting
2 ECU trouble ECR replacement
Replace ECR in trouble
Exceed clearance between front wheel Sensor clearance adjusting Clearance between sensor and
3
speed sensor and impulse ring, harness short Harness check and replacement impulse ring : 0.1㎜
Exceed clearance between front wheel speed Sensor clearance adjusting Clearance between sensor and
4
sensor and impulse ring, harness short Harness check and replacement impulse ring : 0.1㎜
9 Voltage drop(below 19V)and short in PCV. Source voltage(24V) checking PCV voltage : 19V
RR PCV checking
10 Valve defect of rear pressure adjusting PCV resistance : 14~21Ω
and replacement
RR PCV checking
11 Valve defect of rear pressure adjusting PCV resistance : 14~21Ω
and replacement
13 Operation defective of valve relay Relay checking and replacement Relay resistance : 145~175Ω
263
8. Brake (Full Air)
POSSIBLE
SYMPTOM ACTION
CAUSE / RPOBLEM
ABS warning lamp stays on after ABS system has detected a failure Store Diagnostic Code
vehicle has exceeded 9 mph or Turn ignition to off position and then on.
illuminates during vehicle operation.
Read Diagnostic Code
A. Press diagnostic button of at least one
second and release.
B. Count blink pulses of diagnostic lamp
and write sequence down (Figure 4)
C. Compare configuration display by
blink code(Code block 1) with the
system installed in the vehicle. If
configuration numbers match, then
proceed to code block 2 and 3
troubleshooting procedures.
Diagnostic button was not held Press diagnostic button and hold for
Diagnostic lamp does not illuminate
long enough. more than a second.
after diagnostic button has been pressed.
264
8. Brake (Full Air)
POSSIBLE
SYMPTOM ACTION
CAUSE / RPOBLEM
CODE BLOCK 2
Diagnostic code (Cont.)
X-4-X Problem drive axle speed sensor(Right): Push in sensor
Large air gap or (toward pulse wheel)
Shorted wires
If sensor moves when pushed, Perform service step #7
Possible excessive wheel bearing play wheel bearing adjustment
X-6-X Problem steer axle speed sensor (Left): Perform service step #4
Faulty sensor resistance check of sensor
265
8. Brake (Full Air)
POSSIBLE
SYMPTOM ACTION
CAUSE / RPOBLEM
CODE BLOCK 2
Diagnostic code (Cont.)
X-7-X Problem drive axle speed sensor (Right) Perform service step #4
Faulty sensor resistance check of sensor
Broken wire in sensor circuit
Perform service step #4
Short to 12V or ground in sensor circuit.
with sensor connected
Measure resistance across pins 16 & 33
on ECU connector (Figure 10). If reading
is out of range and sensor is good, then
harness wires to sensor are faulty.
Replace section(s) of harness as required.
X-9-X Low electrical system voltage, VR1 relay Check batteries. Clean Battery terminals
not actuating. and charge or replace faulty batteries.
Truck batteries in poor condition Check charging system.
Replace blown fuse/reset of replace
Fuses/circuit breakers blown or faulty circuit breaker.
Check of cause of blown fuse of tripped
circuit breaker.
266
8. Brake (Full Air)
POSSIBLE
SYMPTOM ACTION
CAUSE / RPOBLEM
CODE BLOCK 2
Diagnostic code (Cont.)
Code block 3
troubleshoooting
(Diagonal 2 )
Diagnostic code
X-X-1 Diagonal is OK No action required on Diagonal 2
X-X-2 ECU defective
Perform service step #1
Be sure to perform service step #1 to
reconfigure
confirm that ECU is bad. If problem
ECR and erase failure memory
clears, ECU is NOT defective.
X-X-3 Problem steer axle speed sensor (Right): Push in sensor(toward pulse wheel)
Large air gap or Shorted wires
If sensor moves when pushed Perform service step #7
Check wheel bearing play wheel bearing adjustment
Code block 3
Troubleshooting
(Diagonal 2)
Diagnostic code (Cont.)
X-X-4 Problem drive axle speed sensor (Left): Push in sensor (toward pulse wheel)
Large air gap or shorted wires
267
8. Brake (Full Air)
POSSIBLE
SYMPTOM ACTION
CAUSE / RPOBLEM
Damaged pulse wheel Check pulse wheel/hub
Damaged hub If damaged, replace hub
Perform service step #8
Damaged speed sensor
replace sensor
X-X-6 Problem steer axle speed sensor (right): Perform service step #4
Faulty sensor resistance check of sensor
X-X-9 Low electrical system voltage, Check batteries. Clean battery terminals
VR1 relay not actuating and charge or replace faulty batteries.
Truck batteries in poor condition Check charging system.
Replace blown fuse/reset or replace
Fuses/circuit breakers blown or faulty circuit breaker. Check for cause of blown
fuse or tripped circuit breaker.
Faulty VR1 relay or Replace faulty relay. Use Bosch P/N
Faulty starter lock-out relay 0 332 204 101 or 0 332 204 151.
Code block 3
Troubleshooting
(Diagonal 2)
Diagnostic code (Cont.)
X-X-10 Problem pressure modulation
Perform service step #5
Valve(PMV) at steer axle(Right)
measure PMV coil resistance
Faulty PMV
Clean terminals or replace
Faulty PMV connector
harness section
Check for pinched or cut cable.
Faulty PMV cable
Replace harness section(s) as required
Bad vehicle ground to PMV Check and repair as required
268
8. Brake (Full Air)
POSSIBLE
SYMPTOM ACTION
CAUSE / RPOBLEM
X-X-11 Problem pressure modulation
Perform service step #5 measure
valve(PMV) at drive axle (Left):
PMV coil resistance
Faulty PMV
Clean terminals or replace
Faulty PMV connector
harness section
Check for pinched or cut cable.
Faulty PMV cable
Replace section(s) as required
Bad vehicle ground to PMV Check and repair as required
X-X-13 Replace VR2 relay with;
Problem VR2 relay (Diagonal 2) Bosch P/N 0 332 204 101 or
Sticking relay contacts 0 332 204 151
Other relay internal failure Perform service step #1
reconfigure and erase memory
269
SECTION 9A
SUSPENSION
(Leaf Spring)
CONTENTS PAGE
1. GENERAL DESCRIPTION
1.1. FRONT AND REAR LEAF SPRINGS 271
1.2. SPECIFICATIONS 273
2. SERVICING OF LEAF SPRING DISASSEMBLY
2.1. INSPECITION PRIOR TO DISASSEMBLY 278
2.2. REMOVAL 278
2.3. DISASSEMBLY 279
2.4. INSPECITION 279
2.5. REASSEMBLY 279
2.6. INSTALLATION 280
270
9A. Suspension (Leaf Spring)
Model BF105
271
9A. Suspension (Leaf Spring)
Model BH115E
272
9A. Suspension (Leaf Spring)
1.2. Specifications
273
9A. Suspension (Leaf Spring)
Model BF105
274
9A. Suspension (Leaf Spring)
275
9A. Suspension (Leaf Spring)
Model BF105
276
9A. Suspension (Leaf Spring)
277
9A. Suspension (Leaf Spring)
2.1. Inspection prior to disassembly ▣ Take out the U bolt nuts using a box wrench
and remove the U bolts.
The operation of the suspension assembly is under
a direct influence of the leaf springs, shock Note. When removing U bolt nuts, clean threads
absorbers, buffer rubbers, tire inflation pressure, and loosen them a few turns with a hand tool
etc. before using an impact wrench to prevent seizing.
When a suspension trouble is suspected, check the
following points and adjust or correct as necessary
before removing the suspension assembly.
2.2. Removal
Note. Brace the rear (front )wheels before jacking Note. When removing the leaf spring assembly,
up the front(rear) axle. use care not to damage brake flexible hoses and
drag link in contact with leaf springs.
278
9A. Suspension (Leaf Spring)
▣ Compress the leaf springs with a bench press or 1. Check the shock absorbers for oil leakage.
a leaf spring remover and installer shock absorber with a slight amount of oil seepage
is normal and may be used without any service
▣ Remove the spring clips and center bolt.
attention as it indicates that the piston rod and
Loosen the bench press gradually ( or loosen the seals are being lubricated:
nut on the leaf spring remover and installer) and
remove the leaf springs. 2. After driving over rough surface, check for rise
in temperature by touching the shock absorber
2.4 Inspection inner tube with hand. Normal operation of the
shock absorbers is accompanied by an increase in
▣ Check the leaf springs for cracking or damage temperature of the shock absorber body.
and center bolts and spring clips for distortion or If the shock absorber remains cold after driving
damage. over rough surface, it is out of normal function
Replace the parts with new ones if found to be and should be replaced with a new one.
defective.
Note. If the shock absorber (double-acting
▣ Check the spring pins visually and shackle pins type)does not give a resistance as pulled with
for abnormal wear or damage. Measure the hand, should be replaced with a new one.
outside diameter of the pins with and outside
micrometer and replace the pins with new ones if 3. check the shock absorber mounting rubbers for
the measured values are beyond the limit. fatigue or distortion and replace with new ones as
necessary.
▣ Measure the inside diameter of the bushings
and compare the measured values with the outside 2.5 Reassembly
diameter of the pins to determine the clearance.
Replace the bushings with new ones if the amount Reassembly the leaf spring assembly by following
of clearance is beyond the value indicating need the disassembly procedure in the reverse order
for servicing. after applying a thin coat of graphite grease to
both faces of each spring.
Unit : ㎜ Compress the leaf spring assembly with a bench
Standard value press or a leaf spring remover and installer, then
Limit for use
for assembly install and fully tighten the center bolt.
Pin diameter 32 31.7
Clearance
between pin and 0.1 0.5
bushing
279
9A. Suspension (Leaf Spring)
2.6 Installation
U-bolt Torque
(㎜) (kg.m)
BF105
Front M22 x 1.5 45~55
BS106
BF105 M24 x 2.0 70~85
Rear BS106
M27 x 2.0 85~95
BH115E
280
SECTION 9B
SUSPENSION
(Air Spring)
CONTENTS PAGE
1. GENERAL DESCRIPTION
1.1. FRONT AND REAR AIR SPRING 282
1.2. SPECIFICATIONS 283
2. SERVICING OF AIR SUSPENSION
2.1. DISASSEMBLY 292
2.2. INSPECTION 295
2.3. AIR SPRING 297
2.4 REASSEMBLY 298
2.5 CAUTION IN INSPECTING AND SERVICING 300
3. SERVICING OF LEVELING VALVE
3.1. GENERAL DESCRIPTION 301
3.2. OPERATING PRINCIPLE 301
3.3. LEVELING VALVE MAIN DATA 302
3.4. INSTALLTION REQUIREMENTS 302
3.5. MAINTENANCE 303
3.6. INSPECTION AND SERVICE STANDARDS 305
4. SERVICING OF AIR VALVE
4.1. GENERAL DESCRIPTION 307
4.2. DISASSEMBLY 308
4.3. ADJUSTMENT 308
4.4. INSPECTION 508
281
9B. Suspension (Air Spring)
1.1.3. Stabilizer
1.2. Specification
Front Rear
Distinction BH BH BH BH BH BH116 BH BH
115 116 117 120 115 STD WIDE 117 120
283
9B. Suspension (Air Spring)
MODEL BH115/116/117/120
284
9B. Suspension (Air Spring)
285
9B. Suspension (Air Spring)
286
9B. Suspension (Air Spring)
287
9B. Suspension (Air Spring)
288
9B. Suspension (Air Spring)
289
9B. Suspension (Air Spring)
MODEL BH115/116/117
290
9B. Suspension (Air Spring)
MODEL BH115/116/117/120
291
9B. Suspension (Air Spring)
1) Check that front axle is supported on jack Note. The rubber bushing is press-fitted to
securely. each end of the torque rod and nylon is fitted to
the inner tube into which pin is assembled via
2) Remove the three bolts on the axle side of the collar. Tap out the pins carefully.
the torque rod and radius rod, then remove the
lock plate together with the end plate. ▣ The front axle assembly is separated from
the body when the above steps are followed.
3) Loosen the three bolts attaching the end The arrangement of front side knuckles and
plate to the body side of the torque rod and front hubs is in common to the model with leaf
remove the rod. spring type suspension system.
4) Remove the throttle valve assembly from 2.2.2 Inspection of Torque Rods, Radius
the flange. (for the model and optional Rods, Stabilizer Rods and Stabilizer Bars.
equipment)
▣ Check these parts carefully for bending,
▣ Torque rod removal cracks and damage and replace with new ones
if found to be defective. The stabilizer bar is
1) Remove the three bolts fixing the torque rod, integrated with the stabilizer arm by welding
then remove the torque rod together with the and should be checked without disintegrating.
lock plate and the end plate.
▣ Inspection of torque rod and radius rod
2) Tap out the lower torque rod on each side bushings. Check the rubber bushings for
horizontally. deterioration, deformation, cracks and wear.
Replace the parts with new ones as necessary.
▣ Radius rod removal
2.2.3. Inspection of Rear axle case and Beam
1) remove the double nuts fixing the radius
rods, then remove the radius rod with the end Check the rear axle case and beams for
plate distortion, cracks and wear at rod fitting faces
and correct or replace the part as necessary.
2) tap out the upper radius rod on each side
horizontally. 2.2.4. Inspection of shock absorber
Note. Keep torque rods on each side separate The shock absorbers cannot be adjusted
to prevent interchanging. without the aid of an essential tester. Replace
the entire shock absorber assembly when found
▣ Beam removal to be faulty.
1) Loosen the U bolt nuts fixing the rear axle ▣ Inspection for oil leaks
to the beams. A slight amount of oil seepage is a result of rod
and seal lubrication and it does not indicate
2) Set a jock against the beam carefully to hold leaky condition.
the rear axle, then remove the U bolts and
beam. ▣ Testing
Touch the inner tube of the shock absorbers
▣ Remove the rear axle assembly with bare hand immediately after driving over
rough surface and check for increase in
2.2. Inspection temperature. Normal operation of the shock
absorber is accompanied by an increase in
2.2.1. Inspection of Air Spring Assembly temperature of the tube. If the shock absorber
remains cold, it is defective and should be
▣ Diaphragm replace.
Check the diaphragm visually for deterioration,
cuts, cracks, tears, wear, deformation and ▣ Check the rubber bushings and support
295
9B. Suspension (Air Spring)
296
9B. Suspension (Air Spring)
2.3.1. Construction
▣ Front
▣ Rear
297
9B. Suspension (Air Spring)
1) Assembly the end plate and rubber bushing Install the leveling on the bracket and check
to the pin on the radius rod and torque rod, that the air spring is adjusted to the standard
then mount the radius rod to the axle side length, then connect the joint ball on the
bracket. Install the bolts and nuts and leave the leveling valve connecting rod to the axle side
nuts semi-tight. bracket (when properly installed, the leveling
valve lever is held nearly horizontal).
Note. Never use oil or water as lubricant when
▣ Drag link installation
installing the rubber and bushing inner tube on
the axle side bracket. Connect the drag link to the knuckle arm.
Install and tighten the adjust plug to
Bring the front axle into alignment with the specification.
body side brackets and install the bolts and
nuts. Leave the nuts semi-tight. ▣ Air pipe installation
Connect the air pipe to the leveling valve, then
2) Install the remaining upper and lower torque connect the pipe immediately above the
rods in the similar manner and leave the nuts diaphragm using an eye joint.
semi-tight. Install the bolts with the double nut Discard used gaskets and install new ones.
side turned inward.
▣ Shock absorber installation
▣ Diaphragm installation Install the shock absorber in position using
rubber bushing(install the nut to compress the
1) Assemble the diaphragm ring, clip rings, rubber bushing).
stoppers and end plates and piston in the
reverse order of disassembly. ▣ Brake flexible hose installation
298
9B. Suspension (Air Spring)
▣ Wheel installation
Install the wheels, lower the jack supporting
the axle. Brace the wheels and lower the jack
supporting the body.
Close the drain cock on the air tank and start ▣ Torque (radius) rod installation
the engine to fill the air suspension system
with air.
When the pressure of air reaches 6.4~7.3kg/㎠
and air suspension system becomes stabilized,
check that the vehicle height is within the
specified range. When the vehicle height
deviates from the specified range, adjust the
height of the air springs with the turnbuckle on
the leveling valve connecting rods. It is
allowable to adjust the height of the front and
rear air springs to a range within 300 plus or
minus 5mm depending on the operating
condition of the vehicle.
2.4.2. Rear suspension Install the rubber bushing on the pin at the end
of the upper and lower torque rods.
▣ Wash clean the parts, paying particular Install the end plate on each end of the rod,
attention to faces in contact with the rubber then install and semi-tighten the bolts or studs.
bushings, to remove all traces of oil, then allow
▣ Stabilizer bar installation
to dry.
Install the tubular rubber bushing on each end
299
9B. Suspension (Air Spring)
of the stabilizer bar and connect the bar to the within the main tank to reach the specified
beam support. Install the cap and bolts and level, then check the joints of leaks by
leave the bolts semi-tight. Connect the rod applying soap water. When air leakage is found,
assembly to the stabilizer bracket on the lower re-tight the joint. If the leakage cannot be
face of the frame, then connect the arm with stopped, disconnect the joint and reconnect it
the rod. using a new gasket.
▣ Shock absorber installation ▣ With the pressure of air in the tank at normal
Compress the shock absorber and connect it to level, check that the height o the air springs is
the axle side bracket using the support rubbers within the standard value plus or minus 5mm
and washer. Then, connect the frame side and and variance in height between the springs is
fully tighten the nut by expanding the shock within the limit of plus or minus 5mm. If the
absorber. height deviates from the specified range, adjust
with the turnbuckle on the leveling valve
▣ Diaphragm installation connecting rod. Fully tighten the nut when a
correct adjustment is obtained.
1) Reassemble stoppers, end plates and piston
in the reverse order of disassembly. 2.5. Caution in inspection and servicing
2) Install the throttle valve and rubber seat on ▣ When inspecting and servicing the vehicle,
the air spring, the connect the air spring to the pay attention to keep oil from air spring. When
upper side flange. Connect the lower side of welding near air spring, always consider to
piston to the diaphragm seat on the beam and protect the air spring.
securely tighten the nut
▣ When jacking up the vehicle rapidly leaving
▣ Leveling valve installation and retightening axle beneath, the pressure in the air spring
of torque rod bolts. decrease, and guard ring might get out of place.
Adjust the vehicle height and axle center to After lowering the vehicle, make sure that the
specification and install the leveling valve by guard ring is in the right position. ( Inspection
connecting the connecting rod to the bracket on can be done by uncovering the protector)
the beam. Loosen the bolts fixing the upper
and lower side torque rods just enough to ▣ When parking vehicle for a long time, avoid
remove force acting on the rubber bushing air spring being compressed by air discharging,
tighten the bolts. Install the leveling valve and and keep it approximately normal height with
pipes on the intake and outlet sides properly to jack stands.
prevent air leaks.
▣ Wheel installation
Install the wheels after checking to make
certain the axle is tightly supported.
3.4. Installation requirements The rubber cap beneath the 3/2 –way valve is
to be removed for adjustment purposes and the
The valve is mounted either vertically with the setting screw turned with a screwdriver Trox
exhaust port facing downwards, or horizontally. T30: Turn it anticlockwise to reduce the
It is fastened to the chassis by means of two closing angle and clockwise to increase. One
bolts M8. full rotation is the equivalent of an angle of
To simplify the installation and the adjustment approx. 13.
of the lever and the connecting linkage, the
unit can be locked into its neutral position by FRU : Please pay attention to the service data
means of a spike Φ3h8 or a straight pin Φ3h8 of vehicle manufacturer.
x 24 DIN 7 (see dimensional installation
drawing). With the aide of the table it is possible to
The connecting linkage can be mounted with determine the increase in the vehicle`s height
the vehicle at its normal level. The air up to the point when the supply air to the
suspension valve is to be fitted with maximum raise/lower valve is cut off, as a function of the
lever length wherever possible. closing angle and the lever length.
302
9B. Suspension (Air Spring)
Once the body has been lowered onto the bump Important :
stops using the raise/lower valve the height of
the chassis should be measured. The chassis is The transmission rods and air suspension
then raised using the raise/lower valve. If the spring lever should not from a straight line
permissible overall travel of the spring is slince the linkage could invert and damage the
reached before the air suspension height air suspension valve.
limiting comes into effect the raising process is
to be stopped and the vehicle lowered. 3.5. Maintenance:
By turning the setting screw on the stop valve No special maintenance is necessary beyond
anticlockwise it is possible to reduce the the tests required by law.
closing angel and thus the travel of the spring.
If the height limitation comes into effect before
the vehicle has reached the desired height the
vehicle should again be lowered. The setting
screw should be turned clockwise to increase
the closing angle and thus travel of the spring.
This procedure is to be repeated until the
desired travel of the spring ( equal to or smaller
than the maximum travel of the spring
specified by the axle manufacturer) is reached.
The setting screw is self-locking.
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9B. Suspension (Air Spring)
304
9B. Suspension (Air Spring)
The table includes the inspection and service standards necessary to maintain proper operation the
leveling valves and air suspension assembly.
It is suggested that the leveling valve assembly be inspected and serviced by referring to the inspection
and service standard table.
Inspection interval
Remark
Inspection Items Daily 1 4 24 48
305
9B. Suspension (Air Spring)
306
9B. Suspension (Air Spring)
307
9B. Suspension (Air Spring)
4.2. Disassembly
308
SECTION 10
CONTENTS PAGE
1. GENERAL DESCRIPTION
309
10. Wheel and Tire
The road wheel assembly consists of tire and disc The term “ply” refers to number of carcass cord of
wheel assembly which plays an important role of the tire structure and in the past, number of layers
supporting the weight of vehicle and road as it of cotton cord is used to represent the tire strength.
rolls. However, with the development of advanced tire
cord, the term “ply rating” is used to represent the
Major Function of Tire tire strength. Higher number of ply rating
indicates that higher inflation pressure can be used
▣ Load characteristics to support load in the tire.
▣ Traction and braking force to carry engine In other words, tire higher inflation pressure can
torque and brake force to road. be made to greater load with safety.
▣ Riding comfort to absorb shocks from road.
▣ Steering characteristics and directional stability
to permit changing direction.
Tire Designation
▣ Numeric
10.00 - 20 - 16PR
Ply rating
310
10. Wheel and Tire
BM BF BS BH BH BH BH BH BH
Distinction
090 105 106 115E 115 115 116 117 120
11R-22.5-16PR
Size (FRT/RR) 10.00-20-16PR
10.00-20-16PR
Outer Dia.(mm) 1046 ~ 1076
1.2. Construction
311
10. Wheel and Tire
The tire consists principally of sections which 4) To provide a positive traction or steering ability
include tread, carcass, breaker or belt and beads. depending on vehicle models and types of service
The tread section can be split into tread shoulder intended.
section and side walls both of which have
different functions. ▣ The tread patterns can be classified broadly into
rib type, lug type and block type but for practical
applications, these basic patterns are combined in
▣ Tread section various forms to provide special characteristics
The term “tread” represents the outer layer of tire desired.
used to protect the carcass cord against wear
damage.
The tread section has on its face a tread pattern
carefully designed to drain water on wet surface
as well as to present tire slippage when a hard
traction or braking force is applied.
▣ Carcass section
The carcass section is made rugged to withstand
load on the tire, stocks from the road and inflation
pressure.
On bias tires, the carcass cord is belted diagonally
across the beads and on radial tires, the carcass
cord is belted radically across the beads.
312
10. Wheel and Tire
1) Rib design
2) Lug design
Features:
Tire tread with transverse grooves cut across the 1. Ribs at center of tread insure running
tread face is called lug design. stability and prevent side slippage.
2. Lugs at shoulders of tread provide excellent
Features : traction and brake force.
3) Block design
313
10. Wheel and Tire
1.2.3. Classification
▣ Radial tires
▣ Bias design
air.
1.4. Snow tire and snow spike tire Limit of performance of snow and snow spike
tires
▣ Principles of snow tires The snow and snow that of the conventional tires,
to provide a sufficient traction on ice.
However, traction provided tends to decline as
wear in the tread advances and to indicate the tire
service life or limit, platforms wear indicator ) are
provided in the tread grooves that appears as the
tread wear becomes 50 percent.
315
10. Wheel and Tire
▣ Speed
Tangential force acting the tires through traction,
braking while the vehicle is in motion increases in
proportion to speed squared.
In addition, tire temperature increases with an
increase in the speed, causing wear resistance of
tread rubber to deteriorate.
▣ Cornering
When cornering, the vehicle is subjected to
centrifugal force in proportion to the speed
squared and to reciprocal of the radius of the
curvature.
To combat the centrifugal force, tires slip and It is advantageous to use synthetic rubber tires in
tread deforms to produce a centripetal force which areas where variations in temperatures are high in
permits cornering when balanced with the rate because the affect of temperature over (SBR)
centrifugal force. is less than that of the natural rubber tires (NR).
The affect of cornering over the rate of tire wear is Advantages of higher wear resistance of synthetic
great and the rate of tire tread wear I great and the rubber tires over natural rubber tires become more
rate o tire tread wear is known to increase in pronounced when the
proportion to the tire slippage angle squared. temperature exceeds 16℃.
▣ Speed
Rotating speed of tires increase with the vehicle
316
10. Wheel and Tire
▣ Tread depth
Reduction in the tread depth will cause tire
temperature to lower due to reduced rate of
hysteresis loss and increased rate of heat
dissipation. This means that most heat is
generated when tire is new.
▣ Tire construction
When compared with bias tires, radial tier is lower
in rate of heat generation. The radial tire is lower
in rate of flexing of tread section and is therefore
lower in rate of hysteresis loss.
317
10. Wheel and Tire
2.1. Disassembly
▣ Insert pry bars alternately into position between
▣ Deflate tire by removing core from the air the rim and flap. Disengage tire bead from the
valve. disc wheel.
Mark setting position of the air valve on the tire.
▣ Remove the inner tube from the tire using care
not to scratch the inner tube.
2.2. Inspection
318
10. Wheel and Tire
▣ Check inner tube for swelling, deformation and ▣ Check the rim for distortion and disc wheel for
deterioration in material. run-out in the following manner: Mount the disc
Check air valve and valve seat for damage. wheel to the hub and turn the wheel slowly with
the probe of a dial indicator or surface gauge
resting on the wheel.
Unit : ㎜
Standard value
Limit for use
for assembly
Disc wheel run out
( vertical and from side 3.0 or less 5.0 or less
to side )
2.3. Reassembly
▣ Check tires for run-out using a surface gauge. If 2.3.1. Tube Tire
a considerable amount of run-out is noticeable,
check disc wheel for distortion an correct as ▣ Insert the inner tube into the tire.
necessary. To facilitate smooth installation of inner tube into
the tire, inflate the inner tube slightly and apply
2.2.2. Disc Wheel small amount of glycerine, silicone powder or talc
power to the inner tube and inner face of the tire.
▣ Check the rim, flange and base for corrosion
and deposit of rubber and other foreign matter. If ▣ Install the flap paying attention to the position
corrosion is noticeable , clean with a wire brush or of air valve.
sand paper.
▣ Fit tire to the disc wheel by aligning air valve
▣ Check condition of welding on rim and disc. on the inner tube with the air valve fitting hole in
Check wheel pin holes for wear and cracking. the disc wheel. Set the air valve into the hole in
Replace the disc wheel if any abnormal condition the rim using a pry bar.
is noticeable.
▣ Install the side ring into position using a pry bar
and hammer.]
319
10. Wheel and Tire
320
10. Wheel and Tire
322
10. Wheel and Tire
▣ Side force
▣ Tires are designed and constructed to provide ▣ Run-out, out-if-balance or looseness of parts
satisfactory performance when inflated to causes spotty wear.
recommend pressure and use of tires under
improperly inflated conditions will result in
abnormal wear.
spotty wear on the tire tread. piece of broken glass and nail on roads is called
If such a condition exists, jack up the front end of cut damaging.
the vehicle and check the wheels for run-out and The cut damaging occurs on tread, side wall and
looseness. Spotty wear could also result from portion where a tire chain used on a snowy comes
dragging brake or out-of-round brake drum which into contact, sometimes, this damaging is not
causes abnormal contact between the drum and limited on the rubber portion if a tire but also it is
linings. resulted in a burst.
▣ Separation
The breaker or carcass is separated from the tread
rubber, the breaker is separated from other
breakers, or the carcass is separated from other
breaking-up.
▣ Carcass breaking-up
A carcass cord is broken due to a fatigue. In a
serious case, the cord is broken toward the entire
circumference of the tire or a burst occurs. This
damaging occurs mainly in the range from the
shoulder and bead.
▣ Cut
A damaging of the due to foreign matters such as
324
10. Wheel and Tire
Spotty wear
1. Check tires and wheels for run-out
2. Check hubs and spindles for run-out and
Excessive flat spots
bending.
Change tire into
3. Check bearing and kingpins for play.
polygonal shape
4. Check rotating parts for out of balance.
gradually
Shoulder wear
1. This condition is caused by overloading
(Excessive wear
or underinflation.
at shoulders)
325
10. Wheel and Tire
326
Head Office : 188-9, JEONPO-DONG, BUSANJIN-GU
BUSAN, 614-739 KOREA
http://www.daewoobus.com
e-mail : warranty@daewoobus.co.kr