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Agora Models LONDON TRANSPORT ROUTEMASTER RM 857 Build Instructions
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Agora Models LONDON TRANSPORT ROUTEMASTER RM 857 Build Instructions

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L L
T T
ONDON TRANSPOR
ONDON TRANSPOR
ROUTEMASTER BUS
RM 857
Pack 03
B U I L D
I N S T R U C T I O N S
STAGE 21: FIT TING THE SECOND PAIR OF REAR
STAGE 26: ASSEMBLING THE CRANKCASE
WHEELS
STAGE 27: FIT TING THE FRONT SUBFRAME AND
STAGE 22: ASSEMBLING THE DRIVE UNIT
FRONT AXLE
STAGE 23: HEADER TANK ASSEMBLY AND ROD
STAGE 28: ASSEMBLING THE RADIATOR
FOR BRAKE SYSTEM
STAGE 29: FINISHING AND FIT TING THE ENGINE
STAGE 24: GEARBOX CASING AND CONNECTIONS
STAGE 30: FIT TING THE EXHAUST PIPE
STAGE 25: EXHAUST MANIFOLD, CRANKCASE AND
OIL SUMP

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Summary of Contents for Agora Models LONDON TRANSPORT ROUTEMASTER RM 857

  • Page 1 ONDON TRANSPOR ONDON TRANSPOR ROUTEMASTER BUS RM 857 Pack 03 B U I L D I N S T R U C T I O N S STAGE 21: FIT TING THE SECOND PAIR OF REAR STAGE 26: ASSEMBLING THE CRANKCASE WHEELS STAGE 27: FIT TING THE FRONT SUBFRAME AND STAGE 22: ASSEMBLING THE DRIVE UNIT...
  • Page 2 RM 857 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.
  • Page 3 RM 857 Soften the tyre ( ) 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 ( ). Ensure that it is properly fitted over the wheel rim on both sides (inset).
  • Page 4 RM 857 Noting the notch in the brake disc ( ), fit the disc over the offside end of the rear axle ( ) 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.
  • Page 5 RM 857 Fit the wheel rim cover ( into the centre of the wheel. NOTE: This is a push-fit connection. Assembly guide AGORAMODELS ROUTEMASTER BUS...
  • Page 6 RM 857 Finished views The 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. AGORAMODELS ROUTEMASTER BUS...

  • Page 7: Drive Unit

    RM 857 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. Tweezers Note that parts 22L...
  • Page 8 RM 857 Fit the stem of pulley part into the hole in the centre of pulley part to form a pulley wheel. Then fit the wheel into the socket in the side of the drive unit housing ( ). There are locating pegs and notches to ensure these parts are assembled correctly.
  • Page 9 RM 857 Turn the drive unit housing ( ) around, so that Fit the two pins at the end of part into you can see the opposite end. Identify the socket for the sockets in the hexagonal cap ( the cooling fins. Fit the peg on the end of the cooling fins NOTE: This is a push-fit connection.
  • Page 10 RM 857 Assembly guide Finished views AGORAMODELS ROUTEMASTER BUS...

  • Page 11: Assembly Guide

    RM 857 Parts 22L and 22M are the same, but we have labelled them separately for clarity when you come to connect the brake line. Take the two brake line connectors, . Take the bracket ( ) and check the orientation matches the Fix the connectors ( diagram.
  • Page 12 RM 857 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.
  • Page 13 RM 857 Work from the upper side of the chassis frame, and check the orientation of the accumulators, . Slot part over the two eyelets in the chassis frame , as indicated by the dotted lines. When part is in position, with screw sockets aligned, fix in place from the top, using screws.
  • Page 14 RM 857 Turn the frame over and identify on the side of the tank and into the the fixing points for the tank, sockets on the side of the frame circled in inset, top. Fix the tank in The inset (right) shows the tank in NOTE: place, using two screws.
  • Page 15 RM 857 Identify the control levers, , each with a brake line connection. Test-fit rod across the sub-frame to ensure the correct orientation; it fits between the control levers, ) as shown in the inset. The ends of part slot over the corresponding eyelets in the control levers.
  • Page 16 RM 857 Finished views This completes 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.
  • Page 17 RM 857 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-frame. KEY TO PARTS SUPPLIED Gearbox casing Lines...
  • Page 18 RM 857 Looking at the inside of the gearbox casing , position the tab on the cover through the slot in the casing, over the screw hole. Fix the cover in place with an screw. Turn the casing over (see below) and fit the pegs on the valves into the sockets in part .
  • Page 19 RM 857 Fit the tank end to the tank This is a push-fit connection. Fit parts into the corresponding holes in the tank cap , as shown in the inset, right. Again, these are push-fit connections. The pins on parts are spaced differently to ensure you fit them correctly.
  • Page 20 RM 857 When the screw eyelets in the tabs on part are correctly aligned with the fixing points, use three screws to fix part in place. NOTE: The lines that were fitted in steps 5 and 6 have to be arranged to one side, as shown in the inset below, with the screws in place.
  • Page 21 RM 857 Take the cover check the fixing point near the end of the prop shaft . Position part over the opening in the sub-frame and fix in place with a single screw. The inset below shows the cover in place.
  • Page 22 RM 857 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.
  • Page 23 RM 857 Study the diagrams and make sure you fit Fit the fuel filter to the left In a similar way, fit the parts 25F and 25H crankcase . The arm on the steering fluid reservoir in the correct filter goes into the raised socket on the sockets.
  • Page 24 RM 857 Take the injection pump and test-fit it to the left crankcase . Check that you have the correct orientation. There are two protruding screw sockets on part that fit into corresponding holes on part . When you have it in the correct position, fix in place with two screws.
  • Page 25 RM 857 25L, 25M Take the three flywheel pieces and check the orientation. When you have them aligned as shown in the diagram, push the three pieces together so that the screw sockets on part fit through the corresponding holes in parts .
  • Page 26 RM 857 Assembly guide AGORAMODELS ROUTEMASTER BUS...
  • Page 27 RM 857 STAGE 26 ASSEMBLING THE ASSEMBLING THE CRANKCASE CRANKCASE KEY TO PARTS Cylinder head Further parts are fitted to the sides of the crankcase. The two sides Cylinder head AEC logo stickers are joined and topped with cylinder heads. Pulley parts Fan mounting axle Belt...
  • Page 28 RM 857 Take oil sump ( ) and crankcase assembly from Position the alternator in the cradle the previous stage. Fit the alternator cradle so that the screw sockets are aligned. Turn the the base of the oil sump and fix in place with two crankcase on its side as shown and fix the alternator in screws.
  • Page 29 RM 857 Take the fan mounting axle and the two pulley parts . Fit part part and then fit part on top of part checking that you have the pulley parts oriented correctly. Fit the fan over the pulley, with the concave sides of the fins (indicated by red lines) facing the pulley.
  • Page 30 RM 857 Take the back plate and the Align the two eyelets on the front You may front housing and fit the parts housing with the screw find it helpful to first loosen the FM together as shown. Fix in place with two sockets near the fan on the crankcase screws fitted in step 10 of screws.
  • Page 31 RM 857 Fit the two pegs on the connector into the Peel the backing paper of the first AEC logo corresponding sockets on the inner corners of sticker . Stick it in place in the recess parts . These are push-fit connections. in the cylinder head , so that the screw head is When part...

  • Page 32: Front Axle

    RM 857 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.
  • Page 33 RM 857 Fit the cross rod between the left mounting and the right mounting . Fix in place with two screws. The inset above shows the cross rod in place. Insert the FM screws one at a time, and half- tighten each one.
  • Page 34 RM 857 Turn the subframe over to fit the front axle assembly. The suspension sits on top of the beams However, at the same time, pass the steering bar under the cross rod insert the end of the steering drive into the hollow end of part .
  • Page 35 RM 857 Replace the shock With the suspension arm fixed in place, the steering absorber fixtures mechanism can be anchored: position the screw in the springs . Fix eyelet in command arm over the right mounting both of the parts .
  • Page 36 RM 857 Fit the bracket to the beam and f ix in place using a screw. Pass the line over the crosspiece on the subf rame, and through the opening (circled in red) in the subf rame . Fit the end of the line onto the connector .
  • Page 37 RM 857 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. KEY TO PARTS SUPPLIED Thermostat Radiator Radiator top panel Radiator lower panel Radiator back panel Fan ring panel...
  • Page 38 RM 857 Take the radiator and check how it fits into the 28E. radiator back panel When it is in position, fix in place with four screws. Fit the fan ring panel to the radiator back panel . Fix in place with four screws.
  • Page 39 RM 857 Take the fan ring and check how it fits against the fan ring panel . Once aligned, fix in place with three screws. Take the two mounting 28H. brackets Fit the peg on each of the mounting brackets into the lower hole on the side of the radiator , as indicated by the...
  • Page 40 RM 857 Study the diagram, noting the sloping sides of parts (circled in red). Fit the sockets in the radiator top panel over the pegs on the top of the radiator , as indicated by the dotted lines. This is a push-fit connection. Repeat to fit the radiator lower panel to the bottom of the radiator.

  • Page 41: Assembly Guide

    RM 857 Assembly guide This diagram 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. AGORAMODELS ROUTEMASTER BUS...
  • Page 42 RM 857 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. Many small parts are supplied with this stage.
  • Page 43 RM 857 Take the duct . Fit the four pegs on part into Fit the peg on the cap into the recess in the the cylinder head – two pegs are fitted to part stub pipe . Fit the peg on part into the hole two are fitted to .
  • Page 44 RM 857 Finished view Check that the two screw holes at the bottom The engine with the of the coolant tank are aligned with the coolant header tank and sockets on the end of the front housing of the thermostat fitted in place. crank case.
  • Page 45 RM 857 Take the link and fit the two pegs into the sockets in the cylinder head, one in part and one in part . This is a push-fit connection. The inset (right) shows part in place. Fit the first three fuel lines: the upper ends of parts fit into the sockets in the feed pipe...
  • Page 46 RM 857 Fit the tap to the steering fluid reservoir : the peg on the flange on the tap fits into a socket. Fix in place with a screw through the hole in the flange. Fit the eyelet in the instruction plate over the peg on the bottom of the tap (above).
  • Page 47 RM 857 Take the line . Fit one end into the hole in the feed pipe . Fit the lower (bent) end into Take the instruction plate . Check the socket in the top of the cap , as indicated by the the fit over the top corner of the coolant red dotted line.
  • Page 48 RM 857 Take the drive shaft , supplied with stage 23, and the subframe assembly completed in stage 27. Check the difference between the ends of part , and ensure you have it the right way round. Working from below, fit one end under the notch in the cross bar on the rear sub-frame and into the socket on the pulley part .
  • Page 49 RM 857 Take the beam and fit it across the two front beams of the sub-frame, , in front of the engine assembly but behind the fan. Ensure the screw holes in are over the NOTE: holes in the beams. The screw holes fit over the second holes in the beams, not the end ones.
  • Page 50 RM 857 Take the radiator lower pipe and fit the peg lower end of the pipe into the socket on the radiator lower in the upper end into the socket in back plate panel . The inset above shows the pipe fixed in place, , behind the front housing .

  • Page 51: Exhaust Pipe

    RM 857 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. Now that the engine is fitted to the KEY TO PARTS SUPPLIED sub-frame assembly, it is...
  • Page 52 RM 857 Take the silencer top 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 (circled in red).
  • Page 53 RM 857 Take the next section of exhaust pipe, and fit the screw hole on the NOTE: end into the silencer in this diagram the view is from the top side of the subframe. There is a recess in the end of the silencer that the pipe fits into.
  • Page 54 RM 857 Take part identify the fixing points. One end fits on a peg at the end of the exhaust manifold . The shaped end of part fits on top of the end of part Fix the shaped end of exhaust pipe to the end of pipe...
  • Page 55 RM 857 Finished views The assembly viewed from above (top) and from underneath (below). AGORAMODELS ROUTEMASTER BUS...