Body chasis Hệ thống khung gầm xe hyundai bus

BODY
GENERAL
SPECIFICATION .............................................. BD-3
TROUBLESHOOTING ..................................... BD-8

FRAME
DESCRIPTION ................................................. BD-11
INSPECTION ................................................... BD-12

EXTERIOR
FOLDING DOOR
DESCRIPTION ........................................... BD-18
REMOVAL .................................................. BD-19
DISASSEMBLY ........................................... BD-20
REASSEMBLY ............................................ BD-23
SWING DOOR
DESCRIPTION ........................................... BD-27
OPERATION ............................................... BD-28
CIRCUIT DIAGRAM ................................... BD-29
COMPONENT LOCATION ......................... BD-30
REMOVAL .................................................. BD-31
INSTALLATION ........................................... BD-31
DISASSEMBLY ........................................... BD-32
REASSEMBLY ............................................ BD-33
FOLDING DOOR ENGINE ASSEMBLY
COMPONENTS .......................................... BD-35
OPERATION ............................................... BD-36
REMOVAL .................................................. BD-37
INSTALLATION ........................................... BD-38
INSPECTION .............................................. BD-39
SWING DOOR CONTROL ASSEMBLY

COMPONENTS .......................................... BD-40
OPERATION ............................................... BD-41
REMOVAL .................................................. BD-42
INSTALLATION ........................................... BD-42
SIDE LID
COMPONENTS .......................................... BD-43
ADJUSTMENT ........................................... BD-49
ENGINE ROOM LID
COMPONENTS .......................................... BD-52
REMOVAL .................................................. BD-52
ADJUSTMENT ........................................... BD-53
DOOR CONTROL SWITCH
REMOVAL .................................................. BD-57
INSPECTION .............................................. BD-57

FRONT BUMPER
COMPONENTS .......................................... BD-58
REMOVAL .................................................. BD-59
REAR BUMPER
COMPONENTS .......................................... BD-60
REMOVAL .................................................. BD-61
INSPECTION .............................................. BD-61
OUTSIDE REAR VIEW MIRROR
COMPONENTS .......................................... BD-62
REPLACEMENT ........................................ BD-64
MUD GUARD
COMPONENTS .......................................... BD-66
REMOVAL .................................................. BD-67
INSTALLATION ........................................... BD-67
SPARE TIRE CARRIER

COMPONENTS .......................................... BD-68
REMOVAL .................................................. BD-69

INTERIOR
SIDE SWITCH BOX
COMPONENTS .......................................... BD-70
REMOVAL .................................................. BD-70
SUNVISOR
COMPONENTS .......................................... BD-72
REMOVAL .................................................. BD-72
HEADLINING
COMPONENTS .......................................... BD-73
REMOVAL .................................................. BD-74
INSTRUMENT PANEL
COMPONENT LOCATION ......................... BD-75
COMPONENTS .......................................... BD-76
REMOVAL .................................................. BD-77
FRONT WINDOW
COMPONENTS .......................................... BD-79
REMOVAL .................................................. BD-80
INSTALLATION ........................................... BD-80
DRIVER'S WINDOW
COMPONENTS .......................................... BD-82
REMOVAL .................................................. BD-83
INSTALLATION ........................................... BD-84
SIDE WINDOW
DESCRIPTION ........................................... BD-85
COMPONENTS .......................................... BD-86
REMOVAL .................................................. BD-88
INSTALLATION ........................................... BD-89

SIDE FIXING WINDOW
REMOVAL .................................................. BD-95
INSTALLATION ........................................... BD-95
SIDE SLIDING WINDOW
REMOVAL .................................................. BD-96
INSTALLATION ........................................... BD-97
DRIVER'S SEAT
OPERATION ............................................... BD-100
DESCRIPTION ........................................... BD-100
COMPONENT LOCATION ......................... BD-101
COMPONENTS .......................................... BD-102
REMOVAL .................................................. BD-105
PASSENGER SEAT
DESCRIPTION ........................................... BD-106
COMPONENT LOCATION ......................... BD-107
COMPONENTS .......................................... BD-109
REMOVAL .................................................. BD-110
INSTALLATION ........................................... BD-110


GENERAL

BD -3

GENERAL
SPECIFICATION

E64DC276

FRONT WINDOW GLASS
Shape
2fold glass
(Height-1454mm)
2fold glass
(Height-1263mm)

Thickness

Material

8.7mm

Adhesive
heat
absorption
glass

8.7mm

Color

Shade band color
Bronze

CLEAR

Green
Bronze

Green

REAR WINDOW GLASS
Thickness

Material

Color

5.0mm

Adhesive heat absorption glass

CLEAR

Installation area

Thickness

Material

Color

Upper fixing glass

5.0mm

Hardening heat absorption glass

CLEAR

Shape
1 fold glass
(Height-408mm)
DRIVER SIDE WINDOW GLASS

SIDE WINDOW GLASS
Installation area

Thickness

Front fixing glass

6.0mm

Upper fixing glass

5.0mm

Lower sliding glass

5.0mm

Material

Color

Shade band color

Hardening heat

absorption glass

CLEAR

Green


BD -4

BODY

STAY DAMPER
Range

L max, mm

L min, mm

Travel

Dimension

Swing type lid

715±3.0

415

300

"L"

SPYBD7001D

584±3.0

Engine room lid

344

240

"L"

SPYBD7002D

ENGINE ROOM LID BODY
Item

Specification

Engine room lid

Stay damper

Item

Specification

Floor cover

Soft resin seat (design long lithium t2.5)

Floor board

Water-proof veneer board(t2.5)

FLOOR

FOLDING DOOR GLASS
Thickness(mm)

Material

Color

6.3

Adhesive heat absorption glass

CLEAR

SWING DOOR GLASS
Installation
Upper fixing glass
Lower fixing glass

Thickness(mm)

Material

Color

6.0

Hardening heat absorption glass

CLEAR


GENERAL

BD -5

DOOR ENGINE
Item

Folding door

Swing door

Type

Folding door type operator

Swing-out type door engine
Open-close: Back-and-forth motion of the air cylinder is
converted to door rotation by the ball thread
Rise: Ending the rotation, the ball thread is fixed and rise
with the air cylinder back-and-forth motion

Operation type

Differential motion

Air pressure(P)

6~9kg/cm²

4~8kg/cm²

Travel

175mm

99mm

Weight of the engine

Approx. 7.7kg(mounting
die inclusive)

22kg (Swing arm inclusive)

Weight of the door

50kg

50kg

Standard operation
time

Open 3.0±0.5seconds
Close 3.5±0.5 seconds

4~7seconds(adjustable)

DOOR ENGINE PIPING
3 WAY VALVE
Item

Specification

Operational pressure range

0~9kg/cm²

Operational temperature range

-30℃~80℃(shall not freeze)

Warranted pressure range

15kg/cm²

FRONT BUMPER
Model

Shape

Material

All models

3-piece (center+corner(RH+LH))

SMC

REAR BUMPER
Model

Shape

Material

All models

3-piece (center+corner(RH+LH))

SMC(center)+TPO(LH,RH)

OUTSIDE REAR VIEW MIRROR
Item

Manual chromium mirror

Power chromium mirror

Curvature radius

Ball 1,000±100mm

Ball 1,000±100mm

Reflecting ratio

40% or more

Distortion ratio

7% or less

Adjusting torque

5±1.5kgf.cm or more

-

Adjusting range

All round 20

Right/left 14 or more, up/down 7 or more


BD -6

BODY

UNDER VIEW MIRROR
Item

Manual aluminum mirror

Curvature radius

Ball 102±15mm

Ball 120±15mm

Reflecting ratio

40% or more

40% or more

Distortion ratio

7% or less

7% or less

Adjusting torque

10~27kgf.cm

Adjusting range

All round 20 or more

SERVICE STANDARDS
Maintenance items
Side lid

Folding door

Swing door

Standard value

Limit

Remedy and
remarks

Clearance between lids

10

Clearance between lid and body

10

Contact between the door upper
stopper assembly and the lock
assembly:

8~10

-

Adjust with spacer

Contact between the door lower
stopper and the stopper plate

4~5

-

Adjust with mounting
bolts

Clearance between be the bearing
and the tightening nut at door
assembly mounting area

10 or less

-

Adjust with the
tightening nut

Clearance between the door upper
part and the body at door lock

5

-

Adjust with the
stopper nut at door
engine upper part

-

Adjust with shim

175~178

-

Adjust

Contact between the body side
retainer and door side retainer

To the back of
the vehicle 3mm
or more 3mm
or more

Adjust with hinge

Door engine for folding
door

Door engine travel

Door engine for swing
door

Door rise with swing door closed

Approx. 17

-

Adjust

3 way valve

Plug the "OUT" side at IN-OUT open
position and apply 0.88Mpa(9kg/cm²)
of air to "IN" side. Check the air leak.

Approx. 12

-

Correct or replace

At IN-OUT close position, apply
0.88Mpa(9kg/cm²) of air to "IN"
side. Check the air leak.

Approx. 17

-

Correct or replace


GENERAL

BD -7

TIGHTENING TORQUE
Item
Folding door

Swing door

Tightening torque kgf.m

Door engine connection part mounting bolt

0.6~0.9

Shaft hinge upper mounting bolt

1.5~2.0

Shaft hinge lower mounting bolt

15~20

Stopper assembly mounting bolt

0.5~1.0

Stopper mounting bolt

0.5~1.0

Bearing assembly tightening nut

6.2~8.7

Door engine bracket mounting bolt

1.5~2.0

Guide arm assembly mounting nut

16.~2.4

Door engine, arm assembly mounting bolt

3~4.5

Cylinder cover and guide mounting bolt

0.6~0.9

Door engine shaft tightening nut

3.5~5.5

Front hook mounting bolt

26~35

Rear hook mounting bolt

26~35


BD -8

BODY

TROUBLESHOOTING

EF319FD8

Door engine
cylinder leak

Damaged cup

Replace

Dirt in the cup

Check or replace

Dirt in the O-ring

Replace

Speed control
valve leak

Replace

Air leak
Solenoid valve leak
Impossible
to hold the
door lifting
up.
The door
descend during
stop

Exhaustion port leak

Check or replace

Outside leak

Replace

Piping leak

Re-tighten or
replace

Main tank
pressure is low

Raise the pressure

Filter is clogged

Check or replace

Low air pressure

Correct the matching of the cam part

Rise preventing stopper
position is deviated

Damaged cup(cylinder)

Outside leak

Dirts in the cup

Replace

Faulty O-ring(piston)

Check or replace

Damaged cup

Replace

Faulty O-ring (cylinder)

Replace

Door engine cylinder
leak

Air leak when
the door is
open.
Speed control valve
leak

Replace

Exhaust port leak

Replace

Outside leak

Check or replace

Solenoid valve leak

Piping leak

Replace

SPYBD7001L


GENERAL

BD -9

The operation switch
cannot open or close
the door.

Door does not
open and close

Unable to open or close
manually(emergency cock
operation)

Full air pressure

Faulty solenoid-operation
by discharged battery

Charge

Low air pressure

Charge

Faulty operation of
solenoid

Replace

Circuit break

Repair

Driver side conversion
switch is mismatched

Check

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

Adjust

Door engine grease is low

Disassemble or
lubricate

Door mounting ball joint
grease is low

Lubricate

Sub link ball joint grease

Lubricate

Door operation is faulty

Adjust

Malfunction
in operation

Door
operation
is not
smooth

Low air pressure

Charge air

Door engine grease is low

Disassemble or
lubricate

Door engine upper guide
is absent (resin color)
(high resistance)

Disassemble or
lubricate

Door lock material is
mismatched

Adjust

Door operation is faulty

Adjust

Full air pressure

Malfunction
in lifting
(lowering)

Low air pressure

Charge air

SPYBD7002L


BD -10

BODY

Door lock retainer is

mismatched

Adjust

Door engine piston is
bottoming

Adjust the
clamp position

Earlier contact of door
engine stopper nut

Adjust

Poor compression of the
door seal rubber

Adjust

Door operation is faulty

Adjust

Lock is not good

The door is
rattling during
driving

Loose mounting
parts

Re-tighten

Low air pressure

Check

Stopper is not good

Door engine piston’s
bottoming

Clamp position adjustment

Rattling when
the door is open
Loose mounting parts

Re-tighten

SPYBD7003L


FRAME

BD -11

FRAME

DESCRIPTION

ED93F21C

The frame consists of the front sub frame, center frame
and rear sub frame.

SPYBD7004L


BD -12

BODY

INSPECTION

EA207B3F

CAUTION

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 correct 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

-

-

5.

Use low hydrogen series covering arc electrodes and make no harmful defects as under-cut and blow hole.
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 measures using heat shield.

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.

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 procedures 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.

SPYBD7006L

6.

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

SPYBD7007L


FRAME
7.

BD -13

Welding
1)

8.

Grind even the welding bead at vertical direction to
the bid removing the creased area.

Grind V-grooves with 3mm width and weld the
groove.

CAUTION
Finished area shall be of same thickness as the
base plate.
Grinding finish direction

Grinding finish
direction

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.

SPYBD7010L

9.
CAUTION
After-heat the welding part after welding

When a crack is generated from a bolt hole, perform
the following procedure.
1)

Temporarily install the bolt at the cracked hole.

2)

Weld the cracked area at 20mm (radius) or farther from the bolt hole.

3)

Temporarily install remove the bolt and weld the
remaining 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

SPYBD7009L

Welding procedure shall be same as the said procedure.

Step 1
Step 2

SPYBD7011L


BD -14
5)

BODY
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.
CAUTION

Reinforcement plate thickness : 4.5~6.0mm
Reinforcement plate
material

SAPH 440(hot drawn steel plate) or
SS400 (general structural drawn
steel plate)

Do not weld.

Do not weld.

SPYBD7012L

6)

Upon welding after-heat the repaired area and
the area 50mm around the repaired area to approx. 600-700 C.
CAUTION

When a body side part may affected by heat, perform heat insulation measures using heat shield.

SPYBD7013L


FRAME

BD -15

BODY REPAIR PROCEDURE

Damaged condition

Reinforced welding finish

Welding finish

Putty finish

SPYBD7014L

1.

DAMAGED CONDITION
Damage level

Repair

Holes or significant
damage

Reinforced welding finish

Scratch

Welding finish

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 according 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.

Reinforced welding finish
1)

Cut off deformed area around the hole, matching
with the reinforcement plate.

2)

Match the plate and weld it.

3)

Correct twist, tapping with a hammer

4)

Finish with a file

Reinforcement
plate
Two side
adhesive tape

Protrusion
matching welding

Diagonal
member

Protrusion
matching
welding
Reinforcement plate

Protrusion
matching
welding

SPYBD7015L


BD -16
2.

3.

BODY

Welding finish

c.
d.

1)

Finish with grinding

2)

Finish with putty and sand paper.

Correct twist and finish with a file.
Perform putty coating and sand paper.

Putty finish
After grinder finish, perform putter coating and finish
with sand paper.

Protrusion
matching
welding
Reinforcement plate

Protrusion
matching welding

Two side
adhesive tape

Reinforcement plate

Diagonal
member

Protrusion
matching
welding

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

SPYBD7017L

SPYBD7018L


FRAME
5.

BD -17

Repair requiring to cut the frame(diagonal member)

15
15

Arc welding holes

22

70
45
40 40 1.6

Do not weld the section.

Apply sealer

SPYBD7019L

When deformation of the outer plate is required to repair 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.

SPYBD7020L

BD -18

BODY

EXTERIOR
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 surface. 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 facilitating easy opening and closing.


EXTERIOR
REMOVAL

BD -19
E08F2ABE

7
8
+2

8 0

5
7
6
A

1

2

A

8
1.0~1.5
0.6~0.9

5
Door engine
15~20

15~20

2
5

1

4

5
4~5mm

3
Section A-A

1.
2.
3.
4.

Cover
Bracket
Stopper plate
Spacer

5.
6.
7.
8.

Folding door assembly
Spring
Spacer
Stopper assembly

Tightening Torque : kgf.m

SPYBD7021L

BD -20

BODY

DISASSEMBLY

E184685B

16 15 18

3
6
13

5

4

3
1

23

9

10
7

8

14

0.5~1.0
7
6.28~8.7

8

12
11
12

21

22

20
21

22

20
1.
2.
3.
4.
5.
6.
7.

8.

Handle
Door lock assembly
Spacer
Spring assembly
Roller bracket
Bearing
Stopper
Hinge assembly

9.
10.
11.
12.
13.
14.
15.
16.

Bearing assembly (Upper)
Spacer
Bearing assembly (Lower)
Front door weatherstrip
Weatherstrip
Weatherstrip
Weatherstrip
Weatherstrip

17.

18.
19.
20.
21.
22.
23.

Door opening weatherstrip
Door opening weatherstrip
Door opening weatherstrip
Weatherstrip(wedge rubber)
Door glass
Door glass weatherstrip (H rubber)
Door assembly

Tightening Torque : kgf.m

SPYBD7022L


EXTERIOR

BD -21
4.

CAUTION

Remove the stopper(A) by loosening stopper mounting bolt.

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 remove the roller bracket.

A

Pull

SPYBD7025L

5.
A

Remove hinge assembly(B) by loosening door assembly(A) mounting bolt (16EA).
A
B

SPYBD7023L

3.

Remove the snap ring(A) and bearing(B) with plier.

A

B

SPYBD7026L

6.

Fix the bearing assembly(A)(upper) and release the
bearing assembly lock nut.
A

SPYBD7024L

SPYBD7027L


BD -22
7.

BODY

Fix the door assembly(B) and remove the bearing assembly(A).
A

9.

Door glass
1)

Remove the weatherstrip (wedge rubber).

2)

Remove the door glass by cutting adhesive between weatherstrip and door glass (H rubber).

Door assembly
Adhesive
Door glass weather
strip(H rubber)
Sealant
Door glass

B

SPYBD7028L

8.

Fix the door assembly(A) and remove the bearing assembly(B).

Weather strip(wedge
rubber)
SPYBD7030L

CAUTION
Be careful not to damage bearing outer boot when
remove the bearing.

A

B

SPYBD7029L


EXTERIOR
REASSEMBLY

BD -23
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)
Door glass

Weather strip(wedge
rubber)
SPYBD7031L

3)

Install the wedge rubber.

4)

Clean the adhesive or pollutants with gasoline on
the glass and door assembly.

BD -24
4.

BODY

Installation of weather strip

Weatherstrip

Adhesive (CEMEDINE 560)

Section A-A
Stiffner assembly
Weasherstrip
(Up to the top of stiffener)

Front door
weatherstrip

Weatherstrip

Door opening weatherstrip
Section A-A

Weatherstrip

Adhesive (CEMEDINE 560)
Install the clip on pillar

Insert the clip to door

Weatherstrip
Adhesive
Door opening weatherstrip
(CEMEDINE
Door opening weatherstrip
560)
Weatherstrip
Section C-C

Door opening weatherstrip

NOTE
Apply the adhesive(cemedine 560) not to overflow out of the weather
strip, and wipe out the surplus adhesive.

SPYBD7032L


EXTERIOR
5.

BD -25

Bearing assembly
Apply thread locking agent on the bearing assembly(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.

7.

Stopper
Install the stopper and the stopper plate using the
mounting bolt overlapping 4~5mm.

Stopper

CAUTION

0.5~1.0kgf.m

• Replace new one if bearing boot is damaged.
• Apply the grease as necessary
Stopper plate
Bearing assembly (Upper)
4~5m
Grease
apply

Adjust below 10mm
6.2~8.7kgf.m

Door
assembly

SPYBD7035L

8.

Apply thread
locking agent
and insert

Hinge assembly

CAUTION

Grease apply

• Install the bearing with the shield surface facing downward.
• If play is found by wear, replace it with a new
one

SPYBD7033L

6.

Guide roller
Install the bearing on the roller bracket and install the
snap ring with a plier.

Hinge assembly
CAUTION

9.

• Check the hinge assembly for play and replace it, if damaged, with a new one.
• Lubricate properly the hinge assembly shaft

area.

Stopper assembly
CAUTION
The stopper assembly shall rotate smoothly. If
worn out, replace with a new one or correct it.
Stopper assembly

Hinge assembly

Check for play

SPYBD7034L

Shaft
Roller (Nylon)
SPYBD7036L