Body chasis Hệ thống khung gầm xe hyundai bus

Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus Body chasis Hệ thống khung gầm xe hyundai bus

COMPONENTS BD-60REMOVAL BD-61INSPECTION BD-61OUTSIDE REAR VIEW MIRROR

COMPONENTS BD-62REPLACEMENT BD-64MUD GUARD

COMPONENTS BD-66REMOVAL BD-67INSTALLATION BD-67SPARE TIRE CARRIER

COMPONENTS BD-68REMOVAL BD-69

INTERIOR

SIDE SWITCH BOXCOMPONENTS BD-70REMOVAL BD-70SUNVISOR

COMPONENTS BD-72REMOVAL BD-72HEADLINING

COMPONENTS BD-73REMOVAL BD-74INSTRUMENT PANEL

COMPONENT LOCATION BD-75COMPONENTS BD-76REMOVAL BD-77FRONT WINDOW

COMPONENTS BD-79REMOVAL BD-80INSTALLATION BD-80DRIVER'S WINDOW

COMPONENTS BD-82REMOVAL BD-83INSTALLATION BD-84SIDE WINDOW

DESCRIPTION BD-85COMPONENTS BD-86REMOVAL BD-88INSTALLATION BD-89

REMOVAL BD-95INSTALLATION BD-95SIDE SLIDING WINDOW

REMOVAL BD-96INSTALLATION BD-97DRIVER'S SEAT

OPERATION BD-100DESCRIPTION BD-100COMPONENT LOCATION BD-101COMPONENTS BD-102REMOVAL BD-105PASSENGER SEAT

DESCRIPTION BD-106COMPONENT LOCATION BD-107COMPONENTS BD-109REMOVAL BD-110INSTALLATION BD-110

SPECIFICATION E64DC276

FRONT WINDOW GLASS

Bronze2fold glass

Bronze2fold glass

Adhesiveheatabsorptionglass

CLEAR

Green

REAR WINDOW GLASS

1 fold glass

DRIVER SIDE WINDOW GLASS

SIDE WINDOW GLASS

Hardening heat

STAY DAMPER

FOLDING DOOR GLASS

SWING DOOR GLASS

Upper fixing glass

DOOR ENGINE

Operation type Differential motion

Open-close: Back-and-forth motion of the air cylinder isconverted to door rotation by the ball thread

Rise: Ending the rotation, the ball thread is fixed and risewith the air cylinder back-and-forth motion

Weight of the engine Approx 7.7kg(mounting

Standard operation

time

Open 3.0±0.5seconds

DOOR ENGINE PIPING

3 WAY VALVE

FRONT BUMPER

REAR BUMPER

OUTSIDE REAR VIEW MIRROR

UNDER VIEW MIRROR

Adjust with hinge

Contact between the door upperstopper assembly and the lockassembly:

Contact between the door lowerstopper and the stopper plate

boltsFolding door

Clearance between be the bearingand the tightening nut at doorassembly mounting area

tightening nut

Clearance between the door upperpart and the body at door lock

stopper nut at doorengine upper partSwing door

Contact between the body sideretainer and door side retainer

To the back ofthe vehicle 3mm

or more 3mm

or more

Door engine for folding

door

Door engine for swing

door

Plug the "OUT" side at IN-OUT openposition and apply 0.88Mpa(9kg/cm²)

of air to "IN" side Check the air leak

3 way valve

At IN-OUT close position, apply0.88Mpa(9kg/cm²) of air to "IN"

side Check the air leak

TIGHTENING TORQUE

Folding door

Swing door

Low air pressure

Speed control

Door engine

replace Main tank

Rise preventing stopper position is deviated

Correct the ing of the cam part

match-Air leak when

the door is open.

Door engine cylinder leak

Solenoid valve leak

Speed control valve

Charge Faulty solenoid-operation

by discharged battery

Charge Low air pressure

Replace Faulty operation of

solenoid

Repair Circuit break

Check Driver side conversion

switch is mismatched

Exhaustion side speed control valve is leaned significantly to one side.

The operation switch cannot open or close the door.

Unable to open or close manually(emergency cock operation)

Door does not

open and close

Full air pressure

Full air pressure

lubricate Door mounting ball joint

Door lock material is

Door engine upper guide

is absent (resin color) (high resistance)

Disassemble or lubricate

lubricate

The door is

rattling during

driving

Lock is not good

Door lock retainer is

Earlier contact of door

Poor compression of the

Door engine piston is bottoming

Adjust the clamp position

Loose mounting

Rattling when

the door is open

Stopper is not good

Loose mounting parts

Door engine piston’s

Re-tighten

DESCRIPTION ED93F21C

The frame consists of the front sub frame, center frame

and rear sub frame

INSPECTION EA207B3F

1 Cleaning the frame

Remove dirts, grease, and rust from the frame inside

and outside

2 Checking the frame deformation

Make visual check of the frame deformation and

cor-rect it, if required

3 Frame crack

Make visual check for crack Remove the painting, if

required, for precise inspection If a visual inspection

is not enough to determine the crack, use color-check

or magnetic detection for correct inspection

If a crack is found, repair it in the following procedure

SPYBD7005L

4 Correcting the frame crack

NOTE

• Gas welding works generate high temperature

that may degrade and weaken welding parts.

Use are welding only.

• The welder’s current may reverse back from

the grounding circuit to damage electric parts.

Therefore do not fail to perform the below

proce-dures prior to welding.

1) Disconnect the battery(-) terminal

2) Ground the welder circuit at near to the welding

part

3) Do not fail to cover, piping, wiring, rubber parts,

and fuel tank with protective asbestos around the

welding part prior to welding

CAUTION

- Use low hydrogen series covering arc trodes and make no harmful defects as un- der-cut and blow hole.

elec In low temperature environment below 0 C, pre-heat welding area to approx 50~350 C prior to welding When a body side part may affected by heat, perform heat insulation mea- sures using heat shield.

5 With the vehicle unloaded, hold the frame horizontal,and make holes of diameter 6-9mm

CAUTION

• Make a hole at 10mm forward the end of the crack When the crack end is hard to find, use color check to detect the repairing area.

• When the crack is located inside the frame, make holes at both ends of the crack.

SPYBD7006L

6 When the crack crosses over unevenly matched nection of plates, correct the connection evenly

con-7 Welding

1) Grind V-grooves with 3mm width and weld the

groove

SPYBD7008L

2) Grind V-grooves at the other surface at the same

time Then weld the groove and the both end

holes of the crack

Grinding finish direction

Grinding finish direction

3) Temporarily install remove the bolt and weld theremaining part of the crack within 20mm and fill

up the hole at the same time

4) Make a bolt hole and install the bolt

CAUTION Welding procedure shall be same as the said pro- cedure.

Step 1 Step 2

5) When using a reinforcement plate, take a plate of

which both ends shall be widened in 30 C or less

in order to avoid concentrated stress at the ends

The reinforcement plate shall be marginally large

over the crack

SPYBD7012L

6) Upon welding after-heat the repaired area and

the area 50mm around the repaired area to

ap-prox 600-700 C

CAUTION

When a body side part may affected by heat,

per-form heat insulation measures using heat shield.

BODY REPAIR PROCEDURE

Putty finishWelding finishReinforced welding finishDamaged condition

SPYBD7014L

DAMAGED CONDITION

Holes or significant

Hit trace or light damage Putty finish

Hit trace or light damage Tapping finish

One fold out plate may be repaired as the above table

ac-cording to damage level If the repair requires to remove

the plate consult with the manufacturer

For repairing twist, or welding and correction, remove

seats and interior objects around the repairing area

1 Reinforced welding finish1) Cut off deformed area around the hole, matchingwith the reinforcement plate

2) Match the plate and weld it

3) Correct twist, tapping with a hammer4) Finish with a file

Reinforcement plate

Protrusion matching welding

Diagonal member

Protrusion matching welding

Protrusion matching welding Reinforce- ment plate Two side

adhesive tape

2 Welding finish

1) Finish with grinding

2) Finish with putty and sand paper

3 Putty finish

After grinder finish, perform putter coating and finish

with sand paper

Protrusion matching welding

Protrusion matching welding Reinforce- ment plate Two side

adhesive tape

SPYBD7016L

4 Tapping finish

Repair procedure with the trim installed

1) Weld a copper ring at the damaged area with

a sponter and pull it out outside with a sliding

hammer

a Repeat to tap it out with a hammer

b Finish with a grinder

Sliding hammer

c Correct twist and finish with a file

d Perform putty coating and sand paper

SPYBD7018L

5 Repair requiring to cut the frame(diagonal member)

15 15 22 45 70

40 40 1.6

Arc welding holes

Do not weld the section

Apply sealer

SPYBD7019L

When deformation of the outer plate is required to

re-pair and to cut the frame(diagonal member), the least

area of the frame(diagonal member) should be cut off

Tap out the outer plate, repair the twist and repair the

frame(diagonal member)

6 Painting

Apply lacker partly and leave it to-dry

FOLDING DOOR

DESCRIPTION E2DFC3D3

The folding door consists of the door body, the shaft hinge

assembly, the guide roller, the door lock assembly, and

weather strip

The door body is shaped to match with the body line

When closed, it matches with the body outer plate

sur-face The door has large glasses and match with the body

shape The shaft hinge is configured to adopt bearing type

mechanism at the upper and lower part of the shaft

facili-tating easy opening and closing

REMOVAL E08F2ABE

45

2

28

88

3

11

4~5mm

15~20 15~20

A

A

+2 0

DISASSEMBLY E184685B

0.5~1.0

45

11 Bearing assembly (Lower)

12 Front door weatherstrip

13 Weatherstrip

14 Weatherstrip

15 Weatherstrip

16 Weatherstrip

17 Door opening weatherstrip

18 Door opening weatherstrip

19 Door opening weatherstrip

20 Weatherstrip(wedge rubber)

21 Door glass

22 Door glass weatherstrip (H rubber)

23 Door assembly

For removal and installation of the door glass,

sealant and material for the Window Glass, and

get ready required materials.

1 Remove the front head lining

2 Loosen the roller bracket(A) mounting bolt and

re-move the roller bracket

7 Fix the door assembly(B) and remove the bearing

Be careful not to damage bearing outer boot when

remove the bearing.

A

B

9 Door glass1) Remove the weatherstrip (wedge rubber).2) Remove the door glass by cutting adhesive be-tween weatherstrip and door glass (H rubber)

Door assembly

Adhesive Door glass weather strip(H rubber)

Sealant

Weather strip(wedge rubber)

Door glass

SPYBD7030L

REASSEMBLY EEABD19B

Installation is the reverse of removal

1 Remove the adhesive of door glass, weatherstrip,

door assembly

If paintwork is damaged, repair the damaged area

with touch-up paint or antirust solvent

2 Clean the door glass, the door assembly, and the

weather strip with unleaded gasoline

3 Door glass

1) Apply the adhesive (CEMEDINE 560) to the door

assembly H rubber mounting part

2) Apply the sealant (CEMEDINE 366) to the door

glass mounting part and be careful the water

leak

Door assembly

Adhesive (CEMEDINE 560) Door glass weather strip(H rubber)

Sealant (CEMEDINE 3662H)

Weather strip(wedge rubber)

Door glass

SPYBD7031L

3) Install the wedge rubber

4) Clean the adhesive or pollutants with gasoline on

the glass and door assembly

4 Installation of weather strip

Adhesive (CEMEDINE 560)

Insert the clip to door

Door opening weatherstripDoor opening weatherstrip

Door opening weatherstrip

Door opening weatherstrip

Apply the adhesive(cemedine 560) not to overflow out of the weather

strip, and wipe out the surplus adhesive

5 Bearing assembly

Apply thread locking agent on the bearing

assem-bly(lower), and insert the assembly deep into the door

frame assembly The bearing assembly(upper) shall

be installed in accordance with the dimension on the

illustration

CAUTION

• Replace new one if bearing boot is damaged.

• Apply the grease as necessary

6.2~8.7kgf.m

Bearing assembly (Upper)

Grease apply

Grease apply Hinge assembly

Adjust below 10mm

Apply thread locking agent and insert

• Check the hinge assembly for play and

re-place it, if damaged, with a new one.

• Lubricate properly the hinge assembly shaft

area.

SPYBD7034L

7 StopperInstall the stopper and the stopper plate using themounting bolt overlapping 4~5mm

Stopper assembly

Shaft Roller (Nylon)

10 Door lock assembly

CAUTION

• If play is found at the lock lever, release the

screw and rotate the lock nut to adjust the rod

length.

• If over lapping between the door lock

assem-bly and the stopper assemassem-bly is 8mm below,

adjust with the spacer at the stopper

assem-bly mounting.

SWING DOOR

DESCRIPTION EC7CDAD0

The swing door consists of the door engine, the rotating

shaft, the swing arm, the electronic valve, and the air

pip-ing For opening and closing the door, the ball thread

con-vert the back-and-forth motion of the air cylinder of the

door engine to the door rotation

For closing the door, the ball thread will be fixed upon

fin-ishing the swing door rotation, and the door will rise with

the back-and-forth motion of the air cylinder

OPERATION EB133B62

The door can not be opened and closed as power comes in

even though door switch is operated under locking

condi-tion by recognizing condicondi-tion through micro switch of

man-ual locking mechanism The door can be opened and

closed under release condition as power is supplied if door

switch is operated The door is opened and closed as air

line of valve is changed if power is supplied to magnetic

valve(momentary power-on type) momentarily by instant

signal Door operating switch is installed in driver’s seat

and external two places and it is possible to open and close

them individually as they are installed in parallel

respec-tively External switch is operated by a key but it can be

op-erated with ease by installing button switch Manual

lock-ing mechanism will be locked if manual locklock-ing mechanism

is under locking condition with a key to prevent theft and

damage of manual locking Also manual locking

mecha-nism can be operated by operating lever from inside

vehi-cle

Driver's door operating switch

External door operating switch: which is installed

in door out side handle

- Not operated by a key but installed by a switch

Manual locking mechanism: Operated by a key Micro switch installation

Under locking: Power shortUnder release: Power on

SPYBD7088L

ADVANTAGE

1 The door is possible to maintain current condition

even though problem of electrical circuit occurs

2 The door can be opened or closed respectively by

using driver’s seat or external switch

3 It is easy to open and close the door from outside

4 It is possible to prevent damage of manual lockingmechanism

CIRCUIT DIAGRAM E90CDC73

Micro switch operated by manual locking mechanism: Power short under manual locking condition, Power continuity under manual locking release

External switch

Driver's seat switch

Magnetic valve(Momentary power-on type)

COMPONENT LOCATION E25721D5

2 Swing door engine

3 Door arm assembly

4 Magnetic valve

REMOVAL E5EEEBD0

1 Remove the swing door and guide arm

SPYBD7090L

2 Remove the door engine connector

3 Remove the lower door arm attaching bolt

SPYBD7091L

4 Remove the upper door arm attaching bolt

INSTALLATION E2A9DDAA

Installation is the reverse of removal

1 Adhesive stuck on the body side weather strip ing area shall be removed carefully Damage and rustshall be repaired as well

attach-2 The body side weather strip shall be cleaned with leaded gasoline

un-3 Swing door assembly1) Position the swing door to face with the body sur-face, and connect with the swing door arm mak-ing both of right and left(Ce) clearance same.2) Install swing door and guide arm assembly

DISASSEMBLY EB6B25EE

4

5

76

For the door glass works, refer to the item

"Window glass adhesive sealant and materials"

and get ready required and materials

SWING DOOR GLASS

1 Remove the weatherstrip(A)

2 Remove the screw (17EA)

3 Remove the glass assembly

A

SPYBD7096L

4 Clean the adhesive of swing door and glass

< Door glass rear surface >

REASSEMBLY EAF4C600

Reassembly is the reverse of disassembly

CAUTION When installing the window, carry out taking care of use instruction and handling of adhesive (seeker flex 250PC)

1 Clean the adhesive of swing door and door glass

2 Weather stripInstall the weatherstrip in the top of swing door asillustrated

3 Swing door glass

1) Clean the glass with gasoline about width 30 mmand leave 3 minutes over to dry

Window molding

4) Apply SEEKER CLEANER No 1 around door

glass and swing door contact surface and least

5-10 minutes

CAUTION

• Carefully apply on spot traces and adhesion

area.

• After applying cleaner, do not touch with

hands or attach oily parts.

Glass No.1 Molding

Glass No.2 Molding Rubber sealing

• At beginning and finishing and corner areas,

adhesive may be discontinued or applied

ex-cessively Be careful.

• It is a quick-hardening adhesive Finish the

work within 8 minutes from starting to apply

the adhesive to fitting and fixing the glass.

• It is made of urethane and non-compatible

with silicon sealer Silicon sealer, if required,

must be applied at least 1mm apart from the

adhesive and ensure good ventilation.

• The adhesive shall be beaded in triangle of

8mm base and 12mm height.

Adhesive (seeker flex)

8mm

12mm

SPYBD7102L

6) In order not to contaminate cleaner applied area

on the door glass, use suction cups to lift up thedoor glass

7) Put the door glass(lower) on the spacer

8) Install the door glass heed to clearance betweenleft and right

9) Immediately remove surplus adhesive beforehardening

10) Clean the adhesive or pollutants with gasoline onthe door glass or window molding

FOLDING DOOR ENGINE

ASSEMBLY

COMPONENT E6FDFB45

SPYBD7104L

Door operation system consists of the door engine body,

the air piping, the electronic valve, and the door operation

switch It operate the door using a compressed air

OPERATION E82CBA33

The door engine and the accessory devices are configured

as illustrated The door engine is connected with the clevis

door side bracket at the piston end, and open and close the

door by operating the door engine moving the electronic

valve

4

2

33

1 1 Folding door cylinder

2 Magnetic valve

3 Thermo plastic tube

4 Folding door

Check valveball (C)

Check valve ball (C)

Openingcushion board (E)

4D4 magnetic valve (H)

Flexible hose

To air tank

1 Operation Principle

The door engine is configured that the adjusting screw

installed in the front cover adjust the closing cushion

The operation is of differential type and operate by

the area difference between the opening cylinder (B)

and the closing cylinder(A) Now the cylinder diameter

is "F" and the piston diameter is "G" Then closing

cylinder (A) section will be applied of force Ds and the

opening cylinder(B) section of force(Ds-Gs)X(P) (P is

compressed air pressure.)

2 Door open operation

Opening the door, the 4D4 magnetic valve is

magne-tized and the compressed air in the close cylinder(A)

is exhausted by 4D4 magnetic valve

The open cylinder(B) is pressed by the check valve

ball (C) and compressed air comes in with the

ex-haust adjustment screw (E) side to open the door By

the 4D4 magnetic valve (H), the cushion exhaust the

close cylinder (A) and the piston starts to move

Un-til the piston reach the cushion pipe end, the

com-pressed air in the cylinder exhausts at the cushion

pipe center board After piston pass the cushion pipe

end, open cushion board (E) only exhausts to

gener-ate back pressure into the open cylinder(A) and the

cushion adheres

(The cushion board fixed route will become narrow to

generate back pressure in the close cylinder(A))

The board will stop by the check valve ball (C) and

stop exhaustion

3 Door close operation

Closing the door, the 4D4 magnetic valve is

magne-tized and the close cylinder is aspirated

In-taken compressed air will press cushion and the

C ball through the electronic valve to take in air at

both sides of Then the cushion opens and air comes

directly and rapidly into (A)

Therefore open cylinder(B) and close cylinder(A) take

air in together, but the differential system as

afore-mentioned closes the door by the force adjustment

screw (D) corresponding to by piston section area

dif-ference in case of closing

As for exhaust check ball side, the check valve ball

closes the route, and only the adjusting screw (D) is

open Then the adjusting screw (D) is enough to

ad-just the closing cushion

INSTALLATION E4F9F84A

1 Check the door engine mounting bottom surface for

unevenness, and repair the unevenness, if required

Installing the door engine with the uneven bottom

sur-face, the door operation will not be smooth

CAUTION

Extreme case unevenness may result to axial

twist between the set bolts and the mounting die.

2 Manually operate the door to check smooth operation

and then start the installation If the manual operation

is not smooth, check each part of the door for defect,

and repair it, if required

(Rubber part)

(Hinge part)

(End mounting part)

(Lower bearing part)

SPYBD7109L

3 Temporarily decide the door engine mounting positionand the door side bracket(door engine connection de-vice) position in reference with the door engine mount-ing standard Then operate the door with hands tocheck the door for enough travel

Door side bracket Door engine

Check the travel

SPYBD7110L

4 If the door operation completely, tighten the door gine mounting die securely to the bottom surface.Turn and set the back cover set bolt of the door en-gine

en-5 Shift the door to ’open’ position and pull the door gine clevis(through to ’close’ position) and combine

en-it wen-ith the door side bracket Decide the door sidebracket position at the up/down play center of the cle-vis part, and install it

6 Upon installation, take air into the door engine, insertthe clevis pin into the door side bracket, and fix it withthe cotter pin

Door side bracket Door engine

Clevis

7 Upon installation, take air into the door engine, insert

the clevis pin into the other side bracket, and fix it with

the cotter pin

8 Once again operate the door with hands for smooth

operation and proper travel

9 If the stroke is not enough, adjust the door engine

speed with adjusting screw

Adjusting screw for closing.

Do not over tighten or uneven tighten of U-bolt.

2 Replace the new check valve cover, check ball, toggle,O-ring if they were corroded or defected

NOTE

• Do not excessively apply grease on the valve seat

surface, check valve ball, etc prior to assembly.

• Replace gaskets and packing with new ones.

SWING DOOR CONTROL

ASSEMBLY

COMPONENT EA9B042C

62

31

1 Thermo plastic tube

2 swing door arm

Door operation system consists of the door engine body,

the air piping, the electronic valve, and the door operation

switch It operate the door using a compressed air