Agora Models LONDON TRANSPORT ROUTEMASTER RM 857 Build Instructions Download Page 1

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STAGE 21: FITTING THE SECOND PAIR OF REAR

WHEELS

STAGE 22: ASSEMBLING THE DRIVE UNIT

STAGE 23: HEADER TANK ASSEMBLY AND ROD

FOR BRAKE SYSTEM

STAGE 24: GEARBOX CASING AND CONNECTIONS

STAGE 25: EXHAUST MANIFOLD, CRANKCASE AND

OIL SUMP

STAGE 26: ASSEMBLING THE CRANKCASE

STAGE 27: FITTING THE FRONT SUBFRAME AND

FRONT AXLE

STAGE 28: ASSEMBLING THE RADIATOR

STAGE 29: FINISHING AND FITTING THE ENGINE

STAGE 30: FITTING THE EXHAUST PIPE

Pack 03

B U I L D I N S T R U C T I O N S

ONDON TRANSPOR

ROUTEMASTER BUS

RM 857

Summary of Contents for LONDON TRANSPORT ROUTEMASTER RM 857

Page 1: ... AND CONNECTIONS STAGE 25 EXHAUST MANIFOLD CRANKCASE AND OIL SUMP STAGE 26 ASSEMBLING THE CRANKCASE STAGE 27 FITTING THE FRONT SUBFRAME AND FRONT AXLE STAGE 28 ASSEMBLING THE RADIATOR STAGE 29 FINISHING AND FITTING THE ENGINE STAGE 30 FITTING THE EXHAUST PIPE Pack 03 B U I L D I N S T R U C T I O N S ONDON TRANSPOR ONDON TRANSPOR L L T T ROUTEMASTER BUS RM 857 ...

Page 2: ... STAGE 21 FITTING THE SECOND PAIR FITTING THE SECOND PAIR OF REAR WHEELS OF REAR WHEELS With this stage you receive the second rear tyre and wheel rim for the right hand pair of rear wheels The pair of rear wheels is assembled and fitted to the rear axle 21A 21B 21C 21D GM IM 2 2 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 3: ...e correctly aligned fix the wheel rims firmly together with three GM screws 2 1Soften the tyre 21A for a couple of minutes in warm water and dry it Alternatively you can heat it with a hair dryer Fit the tyre over the rear inner wheel rim 21B Ensure that it is properly fitted over the wheel rim on both sides inset 1 21B 20C GM x3 21B 21A 3 3 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 4: ...in place inset right Do not overtighten 4 3 3Noting the notch in the brake disc 21C fit the disc over the offside end of the rear axle 14A on the chassis assembly Fit the pair of wheels onto the axle Study the diagram carefullly to ensure that you have the pair of wheels the right way round See also step 4 4 20C 21B IM 14A 21C 21D 21B 4 4 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 5: ...5Fit the wheel rim cover 20B into the centre of the wheel NOTE This is a push fit connection 5 Assembly guide 21B 20B 5 5 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 6: ...e second pair of rear wheels is fitted to the offside of the axle chassis assembly The top illustration shows the view from below and the lower illustration is the view from above 6 6 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 7: ... DP 1 7 x 4mm x4 HP 1 7 x 6mm x2 Note that parts 22L and 22M are the same See Step 8 4 STAGE 22 ASSEMBLING THE ASSEMBLING THE DRIVE UNIT DRIVE UNIT The drive unit is part of the hydraulic system for the brakes and also includes an air compressor that is connected to the gearbox Tweezers have been supplied to help with the construction 22A 22H 22E 22L 22M 22B 22I 22F 22N 22C 22K 22G DP 22D 22J HP T...

Page 8: ... in the side of the drive unit housing 22I There are locating pegs and notches to ensure these parts are assembled correctly Fix in place with a DP screw inserted from the other side of part 22I 3 1 3Fit pulley part 22A over the stem of the screw socket in 22I circled and then fit pulley part 22B in place on top of it to form a pulley wheel Fix in place with a DP screw 22D 22E 22F 22I 22I DP DP DP...

Page 9: ... there is a channel in each of the pulley wheels and in the brake pump drive 22F Stretch the belt to fit over the parts and into the channels The inset above shows the belt in place 5Turn the drive unit housing 22I around so that you can see the opposite end Identify the socket for the cooling fins Fit the peg on the end of the cooling fins 22G into the socket Again this is a push fit connection 4...

Page 10: ...Assembly guide Finished views 10 10 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 11: ...ht way round to match the diagram Store the brake line assembly carefully until needed 9Fix the connectors 22M and 22L to the bracket 22K using an HP screw 8 10 9 Assembly guide Finished view Make sure that the arrangement of the connectors on either side of the eyelet in the bracket matches the illustration before fixing in place 4 Parts 22L and 22M are the same but we have labelled them separate...

Page 12: ... DP 1 7 x 4mm x4 FP 1 5 x 4mm x3 1 STAGE 23 HEADER TANK ASSEMBLY AND ROD HEADER TANK ASSEMBLY AND ROD FOR BRAKE SYSTEM FOR BRAKE SYSTEM The header tank for the hydraulic fluid in the brake system is assembled and fitted to the sub frame We also add other details to the underside of the sub frame 23B 23A 23D 23C 23G 23H 23I 23F 23E DP FP CM 12 12 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 13: ...o CM screws The inset right shows the bracket 23F in place 1Work from the upper side of the chassis frame and check the orientation of the accumulators 23E Slot part 23E over the two eyelets in the chassis frame 17A as indicated by the dotted lines When part 23E is in position with screw sockets aligned fix in place from the top using two CM screws The inset shows the accumulators 23E in place see...

Page 14: ...ce 4 5On the underside of the chassis frame identify the fixing point on the control lever 13I circled top inset for the connector 23A Slot the ends of the connector over the eyelet in part 13I NOTE The larger eyelet of part 23A is uppermost as you work Support part 13I which is quite delicate while you fix the connector in place with a DP screw The inset on the right shows part 23A in place 5 CM ...

Page 15: ...across the sub frame to ensure the correct orientation it fits between the control levers 12I and 13I as shown in the inset The ends of part 23G slot over the corresponding eyelets in the control levers Fix each end in place with an FP screw NOTE Part 23G goes under the brake line connection that has been made to part 12I 6At the other end of the suspension arm repeat the assembly process of Step ...

Page 16: ... the work for stage 23 The illustration at the top shows the upper side of the chassis and the illustration below shows the underside Label and store the two prop shafts 23H and 23L for use in future stages 16 16 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 17: ...Position the two screw eyelets on the flange of the valve base 24J over the screw sockets on the gearbox casing 24A Fix in place with two EM screws 1 2 STAGE 24 GEARBOX CASING GEARBOX CASING AND CONNECTIONS AND CONNECTIONS Terminals are fitted to the gearbox casing and lines are used to connect them The drive unit housing is fitted to the gearbox casing and the assembly is attached to the sub fram...

Page 18: ...ew Turn the casing over see below and fit the pegs on the valves 24D into the sockets in part 24A Fix in place with two AP screws 3Fit the stem of the screw socket on the valve 24C into the corresponding hole in the gearbox casing 24A as shown Fix in place from the inside of part 24A with an AP screw 3 4 5 6Take the drive unit housing assembled in stage 22 Fit the flange in part 22I into the reces...

Page 19: ...ank 24F This is a push fit connection Fit parts 24I and 24H into the corresponding holes in the tank cap 24G as shown in the inset right Again these are push fit connections The pins on parts 24I and 24H are spaced differently to ensure you fit them correctly 8Looking at the underside of the sub frame identify the fixing point for the tank circled Fix the tank 24F in place with an AM screw as show...

Page 20: ...in the inset below with the screws in place 11Check the fit of the prop shaft 23H The protrusion on one end fits into the socket in the differential 14B The other end has an eyelet that aligns with a screw socket in part 24A When you have the prop shaft in the correct position use an FM screw to fix it in place at the eyelet end The screw fixing is circled in the inset right 10 11 FM x3 24A 23H 24...

Page 21: ... underside Finished views 5 12Take the cover 24M and check the fixing point near the end of the prop shaft 23H Position part 24M over the opening in the sub frame and fix in place with a single AM screw The inset below shows the cover in place 12 AM 24M AM 24M 21 21 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 22: ...lange DP 1 7 x 4mm x9 FM 2 3 x 4mm x4 1 1Fit the flange 25Q to the end of the exhaust manifold 25P This is a push fit connection 1 Finished views STAGE 25 EXHAUST MANIFOLD CRANKCASE EXHAUST MANIFOLD CRANKCASE AND OIL SUMP AND OIL SUMP In this stage you will find the exhaust manifold There are also parts for the oil sump crankcase and a flywheel Follow the instructions to assemble them 25A 25B 25C ...

Page 23: ... fluid indicator 25K to the side of the reservoir 25H see inset Again this is a push fit connection 4 5 2Fit the fuel filter 25F to the left crankcase 25B The arm on the filter goes into the raised socket on the crankcase Fix in place with a DP screw 3In a similar way fit the steering fluid reservoir 25H to part 25B and fix in place with a DP screw 2 3 Study the diagrams and make sure you fit part...

Page 24: ...ter 25F see inset below 6 7Take the fuel pipe 25E and test fit it to the left crankshaft assembly NOTE The joint at one end of the fuel pipe circled is larger than the other the larger end is attached to the injection pump 25D The other end fits into the socket at the top of the fuel filter 25G When you have the pipe in the correct position push the ends into the sockets They are push fit connecti...

Page 25: ...ugh the corresponding holes in parts 25M and 25L Then take the shaft 25O and fit it through the centre hole as shown red dotted line Use a DP screw to fix the shaft 25O in place Finally fix the flywheel firmly together using two more DP screws inset right 9Check that the flywheel rotates on part 25O If it is stiff loosen the DP screw that was used to fit the flywheel parts to the shaft Align the s...

Page 26: ...Assembly guide 5 26 26 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 27: ...aised screw socket circled fits in the hole in part 26K Fix in place with a DP screw Fit the alternator cover 26L to the open end This is a push fit connection 2Take the two small pulley parts 26O and 26N and check that you have them the right way round Fit part 26O onto the raised screw socket on the alternator front 26M Fit part 26N over part 26O Fix in place with a DP screw STAGE 26 ASSEMBLING ...

Page 28: ...the screw hole on part 26I is aligned with the hole on part 25A Fix in place with a CM screw The inset shows the assembly so far 4Position the alternator 26K in the cradle 26P so that the screw sockets are aligned Turn the crankcase on its side as shown and fix the alternator in place with two DP screws 3 6 4 5Take the two parts of the starter motor 26I and 26J Check the fit When the two parts are...

Page 29: ...an FM screw When the fan is in place stretch the belt 26H over the small pulley formed by parts 26O and 26N on the end of the alternator as shown right 9Fit the screw socket tab on oil filler cover 26R between the eyelets on the oil filler neck 26Q checking that you have the correct orientation Fix in place with two BP screws Do not overtighten 10Take the left crankcase assembly from the previous ...

Page 30: ...t the top of the crankcase Fix in place with an FM screw Repeat the process to fit the second cylinder head 26B NOTE The cylinder heads are not the same In particular there is a different arrangement of screw holes around the rim outlined see also next step Make sure that you fit the right one in the right place Do not overtighten the screws for the cylinder heads until you have fitted part 26T in...

Page 31: ...tted tighten the FM screws holding the cylinder heads in place 17Peel the backing paper of the first AEC logo sticker 26C Stick it in place in the recess in the cylinder head 26A so that the screw head is covered Repeat the process to stick the second logo sticker in place on top of part 26B Finished views 26T 26B 26A 26C 26A 26B 31 31 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 32: ...w 2Fit the right mounting 27F to the right beam 27B and fix in place with two FM screws Repeat to fit the left mounting 27E to the left beam 27A inset above 1 2 STAGE 27 FITTING THE FRONT SUBFRAME AND FITTING THE FRONT SUBFRAME AND FRONT AXLE FRONT AXLE The beams of the front part of the subframe are fitted to the rear subframe The front axle is fitted between the beams of the front subframe 27A 2...

Page 33: ... FM screws The inset above shows the cross rod in place 3 5 Insert the FM screws one at a time and half tighten each one When all are fitted they can be fully tightened 4 5Take the front axle and steering mechanism completed in stage 11 Identify the shock absorber fixtures 6C fitted in stage 6 Remove the eight EM screws holding the fixtures in place and remove the shock absorber fixtures as indica...

Page 34: ... drive 27C into the hollow end of part 11E The inset below shows the axle in place with the fitting of the steering drive circled in red 6 7When you have the suspension arm 5A in the correct position fix it to the beams 27A and 27B with four FM screws The insets show the same fixing in close up from another angle with the FM screws circled in red 27B FM FM 27A 27C 11E 5A 27A 27D 27B 5A 34 34 AGORA...

Page 35: ...osition the screw eyelet in command arm 11C over the right mounting 27F Fix in place with an FM screw Repeat to fix the push rod link 11B to the left mounting 27E The inset shows a different view with the FM screws circled in red 8 9 10 10Take the connector and line assembly from stage 22 inset right Identify the fixing points on the subframe above The bracket 22K is fitted to the screw hole on pa...

Page 36: ...CM screw Pass the line 22N over the crosspiece on the subframe and through the opening circled in red in the subframe 16A 17A Fit the end of the line onto the connector 23A The inset shows the view from above CM 22K 23A 23A 22N 27B 17A 22K 16A 36 36 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 37: ... x15 1 The thermostat 28A and radiator lower pipe 28I are not fitted in this stage Label them and store them carefully until they are needed 4 STAGE 28 ASSEMBLING THE ASSEMBLING THE RADIATOR RADIATOR The main parts for the radiator and its casing are supplied with this stage Follow the step by step instructions to assemble the parts 28B 28A 28D 28C 28F 28G 28H 28I 28E AP 37 37 AGORAMODELS ROUTEMAS...

Page 38: ...E Fix in place with four AP screws 2 S T E P B Y S T E P 1Take the radiator 28B and check how it fits into the radiator back panel 28E When it is in position fix in place with four AP screws 1 28B 28E AP AP 28F 28E AP AP 38 38 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 39: ...th three AP screws 4Take the two mounting brackets 28H Fit the peg on each of the mounting brackets into the lower hole on the side of the radiator 28B as indicated by the dotted lines Fix in place with an AP screw on each side 3 4 AP AP 28F 28E 28G 28B 28H 28H AP AP 39 39 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 40: ...28D circled in red Fit the sockets in the radiator top panel 28C over the pegs on the top of the radiator 28B as indicated by the dotted lines This is a push fit connection Repeat to fit the radiator lower panel 28D to the bottom of the radiator 5 28B 28D 28C 40 40 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 41: ...am shows the parts that are assembled in this stage Two spare AP screws are supplied A photograph of RML2589 during restoration showing the radiator in position at the front of the bonnet 41 41 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 42: ...5mm x7 JM 1 2 x 3mm x3 DP 1 7 x 4mm x4 KEY TO PARTS SUPPLIED Many small parts are supplied with this stage Work carefully checking the instructions thoroughly as it is detailed and delicate work 4 STAGE 29 FINISHING AND FITTING FINISHING AND FITTING THE ENGINE THE ENGINE Fuel lines are fitted to the engine together with the thermostat and other details The engine is then fitted to the subframe 29A...

Page 43: ...stat 28A into the socket on the end of the cylinder head 26B This is a push fit connection 1Take the duct 29C Fit the four pegs on part 29C into the cylinder head two pegs are fitted to part 26A and two are fitted to 26B These are push fit connections 4 3 5 1 4Fit the peg on the thermostat 28A supplied with stage 28 into the hole on the side of the coolant tank 29F This is a push fit connection 29...

Page 44: ...ad one in part 26B and one in part 26A NOTE Ensure that the connections between the cylinder head and the feed pipe remain at right angles and do not swivel as you fix the feed pipe in place The correct position circled on the left is shown here 6Check that the two screw holes at the bottom of the coolant tank 29F are aligned with the sockets on the end of the front housing 26S of the crank case F...

Page 45: ...he sockets in the feed pipe 29P the lower ends fit into the sockets in the injection pump 25D When each of these is in place fit the other three fuel lines 29L 29K and 29J in a similar manner 8 9 Parts 29J 29O are delicate so handle them with care Note that the longest parts 29O and 29J are furthest away from part 25D while 29M and 29L towards the middle are the shortest 4 26A 26B 29D 29P 29O 29N ...

Page 46: ... upper end fits through the hole in the instruction plate 29T the lower end fits into the cap of the fuel filter 25G from the back circled in inset right NOTE Take care not to disturb the other lines whilst fitting this part 12Fit the fuel line 29R one end fits into the back of the tap cirled in inset above The other end fits into the injection pump 25D in the centre hole These are push fit connec...

Page 47: ...29F 13Take the line 29S Fit one end into the hole in the feed pipe 29P Fit the lower bent end into the socket in the top of the cap 25G as indicated by the red dotted line 16 15 13 16Take the exhaust manifold 25P It has three pegs that fit into the cylinder heads 26A and 26B Take care not to disturb the fuel lines These are push fit connections The inset shows the manifold in place 29S 29P 29G GP ...

Page 48: ... the pulley part 22D The other end goes under the cross rod 27D The shaft rests on the notch in the narrow cross bar on part 17A inset right 17 18Turn the assembly the right way up to fit the engine to the sub frame Fit the free end of the drive shaft 23I into the flywheel 25N Two sockets on the underside of the engine assembly fit over the eyelets on the subframe as shown by red dotted lines and ...

Page 49: ...ious step Support the assembly and engine while you fix it in place with two GM screws see inset below 20Mount the radiator assembly on the front of beams 27A and 27B using the mounting brackets 28H At the same time guide the peg on the end of the thermostat pipe 28A into the top socket on the radiator as indicated in red Ensure the fan 26D fits into the fan ring on the back of the radiator Fix in...

Page 50: ...et in back plate 26U behind the front housing 26S Fit the peg on the lower end of the pipe into the socket on the radiator lower panel 28D The inset above shows the pipe fixed in place viewed from behind 21 Finished views 28D 26S 26U 28L 28L 50 50 AGORAMODELS ROUTEMASTER BUS RM 857 ...

Page 51: ...tant that the assembly is properly supported when it is turned upside down to work on details This will prevent damage to the engine parts 4 STAGE 30 FITTING THE FITTING THE EXHAUST PIPE EXHAUST PIPE Three sections of exhaust pipe and the silencer are fitted to the subframe reaching from the exhaust manifold on the engine to the rear of the bus 30B 30D 30E 30A 30C CM DP 51 51 AGORAMODELS ROUTEMAST...

Page 52: ...he inset right NOTE Support part 30A from below while you fix it in place 2 S T E P B Y S T E P 1Take the silencer top 30A and the subframe assembly Work on the underside supporting the frame carefully and taking care not to rest the assembly on any engine parts Identify the two holes in the rear part of the frame 16A circled in red Position the two screw eyes on the side of part 30A over the scre...

Page 53: ...ts Check that the screw hole on part 30D is over the screw socket in part 30A Fix the end of the exhaust in place with a DP screw 5Fit the silencer bottom 30B to the silencer top 30A so that the ends of the exhaust pipes 30D and 30C are enclosed The end of part 30B has a recess which goes under the brake line as indicated by the red arrow NOTE The diagram on the left is a view from below Working w...

Page 54: ...order 6Take part 30E and identify the fixing points One end fits on a peg at the end of the exhaust manifold 25Q The shaped end of part 30E fits on top of the end of part 30D 7Fix the shaped end of exhaust pipe 30E to the end of pipe 30D using two DP screws Ensure that the other end of part 30E remains correctly fitted to the exhaust manifold 25Q 6 7 DP 30E 30D 25Q 30E 25Q 30D 54 54 AGORAMODELS RO...

Page 55: ...5 Finished views The assembly viewed from above top and from underneath below 55 55 AGORAMODELS ROUTEMASTER BUS RM 857 ...

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Agora Models LONDON TRANSPORT ROUTEMASTER RM 857, Build Instructions

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