PREVOST X3-45 2016 Maintenance Manual
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PREVOST X3-45 2016 Maintenance Manual

PREVOST X3-45 2016 Maintenance Manual

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COACH MANUFACTURER
MAINTENANCE MANUAL
X3-45 COACH
DOB Bus Number Series 2400 - 2489
Revision 03 - September 2016

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Summary of Contents for PREVOST X3-45 2016

  • Page 1 COACH MANUFACTURER MAINTENANCE MANUAL X3-45 COACH DOB Bus Number Series 2400 - 2489 Revision 03 - September 2016...
  • Page 2 PA1593 revision 02 First issue of this manual: May 31, 2011 REVISION DESCRIPTION DATE Sections modified: March 2012 06 Electrical 10 Front Axle 12 Brake And Air System 13 Wheels, Hubs And Tires 14 Steering 16 Suspension 18 Body 22 Heating And Air Conditioning 24A Lubrication And Servicing Schedule Sections modified: July 2012...
  • Page 3 CRITICAL EMISSION-RELATED MAINTENANCE Source of parts and repair: A repair shop or person of the owner’s choosing must maintain, replace, or repair emission control devices and systems per manufacturer's recommendations. Replacement of tires that are GHG certified: The original equipment tires installed on this vehicle at the factory were certified to the U.S. EPA Greenhouse Gas (GHG) and National Highway Traffic Safety Administration (NHTSA) Fuel Efficiency regulations.

  • Page 5: Table Of Contents

    SECTION 00: GENERAL INFORMATION CONTENTS FOREWORD ............................2 SCHEMATICS ............................2 PRECAUTIONS TO BE OBSERVED BEFORE WELDING ..............2 SAFETY NOTICE ..........................4 DATA PLATES AND CERTIFICATIONS ..................4 4.1.1 Engine ............................. 4 4.1.2 Transmission ........................... 5 4.1.3 Drive Axle ..........................5 4.1.4 Front Axle ..........................

  • Page 6: Section 00: General Information

    CAUTION minor illustration difference may exist when compared to actual parts or other publications. Position welding machine ground clamp as close as possible to the work. Ensure that the Prevost occasionally sends Maintenance welding machine ground return clamp is well...
  • Page 7 Section 00: GENERAL INFORMATION STEEL – STEEL WELDING CAUTION Before welding, perform multiplex modules disconnection procedure. NOTE Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that would render welding impossible. DANGER Only a qualified and experienced person must do welding. FCAW (Flux Cored Arc Welding) process ;...

  • Page 8: Safety Notice

    4. SAFETY NOTICE NOTE This maintenance manual has been prepared in order to assist skilled mechanics in the efficient Indicates supplementary information essential repair and maintenance of PREVOST vehicles. to the proper operation of the vehicle. Although, mere reading such...

  • Page 9: Transmission

    Section 00: GENERAL INFORMATION Also the engine data plate certifies that the 4.1.5 Power Steering Pump engine conforms to federal and any state Power steering pump is mounted on the engine exhaust emissions regulations. and located underneath the air compressor (Fig. 4.1.2 Transmission The transmission identification plate is located on the oil level dipstick side of the transmission...

  • Page 10: Dot Certification Label

    Section 00: GENERAL INFORMATION 4.1.8 DOT Certification Label This certifies that vehicles manufactured by Prevost Inc., comply with all Federal Motor Vehicle Safety Standards at the time of manufacture. Information such as date of manufacture, model year, gross vehicle weight rating, tire types and inflation pressure is also etched on this plate.

  • Page 11: Figure 8 : Vehicle Identification Number

    Section 00: GENERAL INFORMATION FIGURE 8 : VEHICLE IDENTIFICATION NUMBER 00056 YEAR CODE YEAR CODE YEAR CODE 2000 2006 2012 2001 2007 2013 2002 2008 2014 2003 2009 2015 2004 2010 2016 2005 2011 2017 PA1593...

  • Page 12: Fastener Strength Identification

    Section 00: GENERAL INFORMATION metric fasteners, be careful to use fasteners of 5. FASTENER STRENGTH IDENTIFICATION the same or greater strength than the original Most commonly used metric fastener strength fasteners (the same number marking or higher). property classes are 9.8 and 10.9 with the class It is also important to select replacement identification embossed on the head of each fasteners...

  • Page 13: Standard Torque Specifications

    Section 00: GENERAL INFORMATION 5.1 STANDARD TORQUE SPECIFICATIONS The following table lists the standard tightening torques for bolts and nuts, relating tightening torque to thread diameter. Use the following table as a general guide for tightening torques. Use this table only for the bolts and nuts which do not require a specific torque value.
  • Page 14 Section 00: GENERAL INFORMATION RECOMMENDED TORQUE TYPE DESCRIPTION THREAD GRADE lbf-ft (dry) otherwise specified Tolerance: ±10% 5/8-18 3/4-10 3/4-10 3/4-16 3/4-16 7/8-9 7/8-9 7/8-14 7/8-14 METRIC M6 X 1 nut 9 / screw 8.8 METRIC M6 X 1 nut 10 / screw 10.9 METRIC M8 X 1.25 nut 9 / screw 8.8...

  • Page 15: Self-Locking Fasteners

    Section 00: GENERAL INFORMATION 5.3 RECOMMENDATIONS FOR REUSE 5.2 SELF-LOCKING FASTENERS Clean, rust-free self-locking fasteners may be A self-locking fastener is designed with an reused as follows: interference fit between the nut and bolt threads. This is most often accomplished by distortion of a) Clean dirt and other foreign matter from the top thread of an all-metal nut or bolt or by the fastener;...

  • Page 16: Figure 12: Metric - Us Standard Conversion Table

    Section 00: GENERAL INFORMATION FIGURE 12: METRIC - US STANDARD CONVERSION TABLE 00005 PA1593...

  • Page 17: Figure 13: Conversion Chart

    Section 00: GENERAL INFORMATION FIGURE 13: CONVERSION CHART 00006 PA1593...
  • Page 19 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING PROCEDURE NO: PR060041 REVISION 01 2010-12-01 Material: Equipment(s): Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: Safety rules: - Wear safety goggles - Set the battery master switch to the OFF position first Recommendations: This procedure should be performed by qualified personnel only.
  • Page 20 PROCEDURE NO: PR060041 REVISION 01 X3-45 Coaches 2.00* Location: Rear Electrical Panel and Dashboard Set the battery master switch to the OFF position Place the ignition switch to the OFF position. 2.05* Location: Rear Junction Panel Lift cover, trip circuit breakers CB2-CB4-CB6 located on junction panel.
  • Page 21 PROCEDURE NO: PR060041 REVISION 01 2.10* Location: Rear Electrical Panel Disconnect the electronic ground terminals from this stud. Use electric tape; make sure that cables do not touch each others and the vehicle body. Note : With disconnection of the electronic ground terminals, disconnecting engine...
  • Page 22 PROCEDURE NO: PR060041 REVISION 01 2.20 * Location: Front Electrical Compartment Disconnect the I/O A, I/O B, ABS, master ID, VECU, CECM, BERU, Volvo Link, Gsecu modules. Disconnect 3 connectors from I/O B and I/O A modules Disconnect 4 connectors from the ABS module Disconnect connector from master ID Page 4 of 7...
  • Page 23 PROCEDURE NO: PR060041 REVISION 01 Disconnect 3 connectors from VECU Disconnect 3 connectors from CECM Disconnect connector A 83 under Volvo Link module Page 5 of 7...
  • Page 24 PROCEDURE NO: PR060041 REVISION 01 2.30 Location: Pneumatic accessory panel inside right console Remove the access panel on the right console (R.H. side of dashboard) Disconnect both I/O B modules 2.40 Location: Condenser Compartment Disconnect connector A 137 Page 6 of 7...
  • Page 25 PROCEDURE NO: PR060041 REVISION 01 2.50 Location: Evaporator Compartment Disconnect A 54 module located inside the evaporator compartment, on the door. 2.60 When all the previous steps are done, you can do ENSURE THAT THE WELDING GROUND welding on the vehicle. RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE...

  • Page 27: Volvo D

    SECTION 01: ENGINE CONTENTS VOLVO D13 ENGINE ..........................2 ........................... 2 YSTEM VERVIEW ........................... 6 NGINE VERVIEW ............................7 NGINE 1.3.1 General ............................ 7 1.3.2 Oil Quality ..........................7 1.3.3 Oil Change Intervals ........................ 8 1.3.4 Oil Filters ..........................8 1.3.5 Synthetic Lubrication .......................

  • Page 28: Volvo D13 Engine

    Section 01: ENGINE  1. VOLVO D13 ENGINE Ambient Air Temperature Sensor  Ambient Pressure sensor 1.1 SYSTEM OVERVIEW  Boost Air Pressure (BAP) Sensor NOTE  The “Premium Tech Tool” (PTT) is the Camshaft Position (Engine Position) Sensor preferred tool for performing diagnostic work. ...
  • Page 29 SECTION 01: ENGINE The Ambient (Atmospheric) Pressure Sensor is the exhaust temperature of the EGR system to built into the Engine Management System confirm EGR operation. The sensor uses a (EMS) Module. thermistor that is sensitive to the change in temperature.
  • Page 30 Section 01: ENGINE Exhaust Temperature Sensor (DPF Sensors) Intake Manifold Pressure Sensor The exhaust gas temperature sensor detects The Intake Manifold Pressure Sensor contains a exhaust gas temperature for DPF protection as pressure sensitive diaphragm and an electrical well as DPF regeneration control. The sensor amplifier.
  • Page 31 SECTION 01: ENGINE FIGURE 1: ENGINE SENSORS LOCATION Fuel Pressure Air Temperature Crankcase Pressure Humidity/Ambient Air Temperature Oil Level/Temperature Camshaft Speed EGR Differential Pressure Crankshaft Speed EGR Temperature Oil Pressure Coolant Temperature AFI Fuel Pressure Boost Pressure PA1593...

  • Page 32: Engine Overview

    Section 01: ENGINE 1.2 ENGINE OVERVIEW NOTE For maintenance on or repair of engine components or engine-related components, please refer to Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service, purchase engine literature, D13F engine. FIGURE 2: D13F ENGINE, TURBO SIDE (TYPICAL) 1.

  • Page 33: Engine Oil

    SECTION 01: ENGINE FIGURE 3: D13F ENGINE, ALTERNATOR SIDE (TYPICAL) 1. Venturi Pipe 8. Fuel Pump 2. EGR Mixing Chamber 9. Hand Primer 3. Intake Manifold 10. Fuel/Water Separator 4. Engine Electronic Control Unit (EECU) 11. Fuel Filter 5. Breather Tube 12.

  • Page 34: Oil Change Intervals

    Section 01: ENGINE EO-O Premium Plus (or VDS-4) diesel engine oil NOTE is mandatory for use in all 2010 emission Oil filters should always be changed when compliant Volvo engines. These engines, which changing the oil. can be identified by the presence of an exhaust aftertreatment system using Selective Catalytic Reduction (SCR), also require the use of Ultra 1.3.4 Oil Filters...

  • Page 35: Oil Additives

    SECTION 01: ENGINE Choose the viscosity grade for the typical 1.3.9 Oil Change ambient temperature application. Multigrade oils have a broad range that suit WARNING operation in changing temperature. A hot engine or engine oil can be dangerous. Volvo North America recommends Serious burns can result from contact with a...

  • Page 36: Oil Filters Change

    Section 01: ENGINE 1.3.10 Oil Filters Change WARNING Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves. CAUTION Volvo-branded oil filters are designed to provide the proper level of filtration and protection for Volvo engines.

  • Page 37: Checking The Oil Level

    SECTION 01: ENGINE 1.3.11 Checking the Oil Level NOTE Ensure that the vehicle is parked on level No parts within the EECU are serviceable. If ground before checking the oil level. Wait five found defective, replace the EECU as a unit. minutes after shutting off the engine and then proceed with checking the oil.
  • Page 38 Section 01: ENGINE  Close engine fuel supply shut-off valve on primary fuel filter. Disconnect the fuel line located above fuel filters and connected to inlet port. Disconnect fuel return line located  above fuel filters.  Disconnect alternators cooling duct and put aside.
  • Page 39 SECTION 01: ENGINE  Disconnect and remove the air intake  Unfasten aside engine duct mounted between the charge air compartment lighting fixture cooler outlet and the engine intake. turbocharger fire suppression nozzle if applicable.  Engine Compartment L.H. side ...

  • Page 40: Power Plant Assy. Installation

    Section 01: ENGINE FIGURE 11: ENGINE COMPARTMENT X3 COACHES (TYPICAL) 01184_A 1.5 POWER PLANT ASSY. INSTALLATION To install a power plant assembly, follow the same procedure as in "Power Plant Assembly Removal" except in reverse order, then proceed with the following: 1.

  • Page 41: Engine Mounts

    SECTION 01: ENGINE 1.6 ENGINE MOUNTS The power plant assembly is mounted to the cradle by means of rubber mounts and supports. Two engine support brackets are used at the front of the engine while two rubber mounts are mounted underneath the engine &...

  • Page 42: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    Section 01: ENGINE DRY TORQUES REFERENCE DESCRIPTION Lbf-Ft SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G8.8 SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G10.9 SCREW, CAP HEXAGONAL HEAD M10 – 1.5 G10.9 SCREW, CAP HEXAGONAL HEAD M12 – 1.75 G8.8 SCREW, CAP HEXAGONAL HEAD M14 –...

  • Page 43: Specifications

    SECTION 01: ENGINE FIGURE 14: ELECTRONIC FOOT PEDAL ASSEMBLY 03035 3. SPECIFICATIONS Volvo D13 Engine Make ..............................Volvo Type ..................Diesel four cycle/in-line direct injection engine Description ...................... Turbo/Air to air charge cooled No. of cylinders ............................. 6 Operating range ........................1400-1800 RPM X3-45 Coaches Peak Power Rating ...................
  • Page 44 Oil Pan Capacity, High Limit ..................... 34 quarts/32 liters Total Engine Oil Capacity with Filters ................41 quarts/39 liters Lubricating oil filter elements Type ..............................By-pass Prevost number ..........................510938 Type ..............................Full Flow Prevost number ..........................488736 Torque specification Engine oil filter ............
  • Page 45 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM WITH VOLVO D13 ENGINE ..................3 ............................ 3 ESCRIPTION ............................ 4 ALVES ........................... 4 ILTERS 1.3.1 Primary Fuel Filter Replacement ..................... 5 1.3.2 Secondary Fuel Filter Replacement ..................5 ......................6 RIMING YSTEM ..................
  • Page 46 Section 03: FUEL SYSTEM ILLUTRATIONS ) ................3 IGURE FUEL SYSTEM SCHEMATIC VOLVO D ENGINE ) ................. 4 IGURE MANUAL SHUT OFF VALVE VOLVO D ENGINE ....................4 IGURE FUEL LINE COMPRESSION FITTING ..................... 5 IGURE FUEL FILTERS WITH VOLVO D ENGINE ........................

  • Page 47: Fuel System With Volvo D13 Engine

    Section 03: FUEL SYSTEM FUEL SYSTEM WITH VOLVO D13 ENGINE 1.1 DESCRIPTION NOTE For additional information concerning Volvo D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On Volvo web site, you will find detailed service procedures for parts replacement, repair and maintenance.

  • Page 48: Fuel Valves

    Section 03: FUEL SYSTEM Other Shut-off valve is designed to prevent loss of fuel prime. No manual valve is required on preheater The fuel filter housing eliminates the need to fuel-supply line, since the positive-displacement drain the fuel when replacing the filter. The valve fuel pump (located close to the fuel tank) prevents pegs (17) and (21) close when the fuel filter is fuel flow when not activated.

  • Page 49: Primary Fuel Filter Replacement

    Section 03: FUEL SYSTEM 7. Check that the drainage hole in the water separator bowl is not blocked. Apply a thin coating of clean engine oil to the surface of the water separation bowl. 9. Install a new gasket to the water separation bowl and then reinstall the separation bowl FIGURE 4: FUEL FILTERS WITH VOLVO D13 ENGINE to the new primary fuel filter cartridge.

  • Page 50: Priming The Fuel System

    Section 03: FUEL SYSTEM 2. Clean around sealing area on fuel filter and NOTE housing. When the fuel system is empty, 200 or more 3. Unscrew and remove the secondary fuel pump strokes may be needed to properly filter from the fuel filter housing. prime system.

  • Page 51: Fuel Lines And Flexible Hoses

    Section 03: FUEL SYSTEM   Remove the fuel pump. Start the engine and let run for 5 minutes. Make sure that there are no leaks. NOTE Only unfasten the bolts marked with arrows. FUEL LINES AND FLEXIBLE HOSES Make a visual check for fuel leaks at all engine- mounted fuel lines and connections and at the fuel tank suction and return lines.

  • Page 52: Tank Removal

    Before removing the bolts securing the tank support to the frame, make sure the tank is 4. Insert a screw (Prevost #500196) and a supported adequately. Failure to do so could washer (Prevost #5001244) into anchor nut result in injury as well as damage to the tank.

  • Page 53: Fuel Specifications

    Section 03: FUEL SYSTEM FIGURE 8: 208 US GAL. FUEL TANK 03094 To meet EPA standards, the petroleum industry NYLON WASHER SCREW produces Ultra Low Sulfur Diesel (ULSD) fuel, also referred to as S15, containing a maximum 15ppm (parts-per-million) sulfur. On-highway diesel engines...

  • Page 54: Blending

    Volvo or Prevost product warranty. Also, any engine performance problem related to the use of biodiesel fuel would not be recognized nor NOTE considered as Volvo or Prevost’s responsibility.

  • Page 55: Air Cleaner Servicing

    Section 03: FUEL SYSTEM 5.2 AIR CLEANER SERVICING CAUTION Stop the engine, open the R.H. side engine compartment door, and loosen the wing nut Do not ignore the Warning given by the air retaining the air cleaner element to the air restriction indicator.

  • Page 56: Potentiometer Replacement

    Secondary Fuel Filter With Volvo D13 Engine Part number ............................20972293 Filter torque ......................¾- 1 turn after gasket contact Fuel tank Capacity Standard (All vehicles) ....................208 US gallons (787 liters) Air Cleaner Service Part No ............................7182 8N Prevost number (element cartridge) ......................530197 PA1593...
  • Page 57 Section 03: FUEL SYSTEM Air Cleaner Restriction Indicator Indicates ......................... at 20" (508 mm) of water Prevost number ............................530161 PA1593...
  • Page 59 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM CONTENTS EXHAUST AFTERTREATMENT SYSTEM OVERVIEW ..............2 MAINTENANCE..........................2 FLEXIBLE COUPLING INSTALLATION ..................3 DIESEL PARTICULATE FILTER (DPF) ....................3 DIESEL PARTICULATE FILTER ASSEMBLY REMOVAL ............. 4 CATALYTIC CONVERTER ........................5 REMOVAL ............................5 ASSEMBLING CATALYTIC CONVERTER ..................

  • Page 60: Exhaust Aftertreatment System Overview

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM EXHAUST AFTERTREATMENT SYSTEM OVERVIEW FIGURE 1: EXHAUST SYSTEM Particulate Filter (DPF) assembly to capture The technology behind clean emissions is and regenerate the soot on a regular or passive through the immediate aftertreatment of engine basis, then the exhaust gases flow through the exhaust.

  • Page 61: Flexible Coupling Installation

    Clean remanufactured DPF cartridge NOTE will be available through Prevost on an exchange basis. For most commuter vehicle The key to successful regeneration is high applications and duty cycle, this will occur after exhaust temperature for an extended period of approximately 4500 hours of operation.
  • Page 62 Section 04: EXHAUST AND AFTERTREATMENT SYSTEM FIGURE 3: DIESEL OXIDATION CATALYST (DOC) & DIESEL PARTICULATE FILTER (DPF) ASSEMBLY 04016 CAUTION WARNING External and internal temperatures remain hot long after engine has been shut down. Allow HOT EXHAUST the Exhaust Aftertreatment System to cool During stationary regeneration, exhaust gases before handling.

  • Page 63: Catalytic Converter

    SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM 7. To make sure components are reinstalled in For proper DPF assembly installation, inlet the same position, mark position of DOC, and outlet alignment is important. When DPF and V-band clamps in relation with one reassembling the DPF, a straight edge must another before taking apart;...
  • Page 64 Section 04: EXHAUST AND AFTERTREATMENT SYSTEM  Set the starter selector switch to the OFF WARNING position.  Shut off the heater line shut-off valves. Due to the heavy load of the radiator assembly, it must be adequately supported before ...

  • Page 65: Assembling Catalytic Converter

    SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM  the emboss located at the bottom and at the Release tension from drive belt (Refer to top of the catalytic converter. paragraph 12.1 and 15.1 in Section 05: Cooling System). Lower  Cut cable ties and disconnect electrical connector from fan clutch.

  • Page 66: Diffuser Assembly

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM  centered with the exhaust inlet of the Using the lines made earlier, line up the catalytic converter. lower and upper clamps with regard to the emboss of the converter and afterward, line up the lines made earlier on the clamps with regard to the clamp supports on the catalytic EXHAUST converter.

  • Page 67: Maintenance

    SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM  Make sure that the water drain tube is not CAUTION clogged. Pour a cup of water into the diffuser housing and assure that all the water is Tighten clamps properly in order to prevent drained at once at the other end of the drain any movement of the diffuser assembly.

  • Page 68: Diesel Exhaust Fluid

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM  If the DEF solution is spilled onto the vehicle, 5.1 DIESEL EXHAUST FLUID wipe off the excess and rinse with water. When handling DEF solution, it is important that Spilled DEF solution can form concentrated electrical connectors to be connected or well white crystals on the vehicle.

  • Page 69: Pump Assembly Filter Element Replacement

    SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM MAINTENANCE Drain and clean DEF tank and filler neck insert filter with hot water every 175,000 miles or once a year, whichever comes first. 5.3 PUMP ASSEMBLY FILTER ELEMENT REPLACEMENT  Remove filter cover. CAUTION CAUTION Protect filter area in the housing from...

  • Page 70: Aftertreatment Fuel Injector

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM 6.1 REPLACEMENT 1. Remove fastener and p-clamp securing the line to the mounting bracket on the diffuser pipe. WARNING Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire and result in component damage and serious personal injury.
  • Page 71 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM NOTE The fasteners already include pre-applied high-temperature anti-seize compound. 6. Connect the line to the aftertreatment hydrocarbon injector. Tighten the line fitting to135 lbf-in. FIGURE 10: FUEL LINE FITTING 7. Install the P-clamp and fastener to secure the line to the mounting bracket on the diffuser pipe.

  • Page 72: Torque Specifications

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM TORQUE SPECIFICATIONS PA1593...
  • Page 73 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM PA1593...
  • Page 74 Section 04: EXHAUST AND AFTERTREATMENT SYSTEM PA1593...
  • Page 75 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM The following table lists the tightening torques for the bolts, nuts, etc. on the DPF assembly which do require a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE DESCRIPTION QTY REFERENCE TORQUE DRY (±10 lbf-ft)
  • Page 77 SECTION 05: COOLING SYSTEM CONTENTS     DESCRIPTION  .............................. 3     MAINTENANCE ............................ 4     ..........................  4 GENERAL RECOMMENDATIONS      ....................  4  VEHICLES EQUIPPED WITH VOLVO D  ENGINE     HOSES ................................ 4     CONSTANT‐TORQUE HOSE CLAMPS – 13  ..............  5      ON COOLANT LINES  VOLVO D  ...
  • Page 78 Section 05: COOLING SYSTEM     FAN RIGHT ANGLE GEARBOX  ........................  1 7     14.1   ..............................  1 7 AINTENANCE     14.2  ..............................  1 8 IL CHANGE     14.3  ..........................  1 8 REMOVAL   INSTALLATION     COOLING FAN DRIVE BELT  ........................  1 8  ...

  • Page 79: Description

    Section 05: COOLING SYSTEM 1. DESCRIPTION Upon starting a cold engine or when the coolant is below normal operating temperature, the A radiator and thermo-modulated fan are used closed thermostat directs coolant flow from the to effectively dissipate the heat generated by the thermostat housing through the by-pass tube to engine.

  • Page 80: Maintenance

    Section 05: COOLING SYSTEM 2. MAINTENANCE cause of the internal leak has been corrected before flushing the contaminated system. 2.1 GENERAL RECOMMENDATIONS Leaks thermostat housing hose A systematic routine inspection of cooling connections may be caused by deformation of system components is essential to ensure connections or by rough surfaces on the castings maximum engine and heating system efficiency.

  • Page 81: Constant-Torque Hose Clamps On Coolant Lines -Volvo D13

    Section 05: COOLING SYSTEM When installing a new hose, clean pipe 100 lbf-in. (10 to 11 Nm). The Belleville spring connections and apply a thin layer of a washer stacks should be nearly collapsed flat non-hardening sealing compound. Replace worn and the screw tip should extend ¼"...

  • Page 82: Thermostat Operation

    Section 05: COOLING SYSTEM 4. Position the thermostat housing to the cylinder head, install the bolts and torque- tighten to 24 ± 4 Nm (18 ±3 ft-lb). 5. Install the rubber radiator hose to the thermostat housing. Position the clamp and tighten to secure.

  • Page 83: Coolant Level Sensor

    In an engine having Recommended coolants for MTA X3-45 proper coolant flow, some of the combustion coaches equipped with Volvo D13 engine: heat is conveyed through the cylinder walls and  Prevost the cylinder head into the coolant. Without #685352 (pre-diluted 50/50 adequate coolant, normal heat transfer cannot mixture);...

  • Page 84: Draining Cooling System

    Section 05: COOLING SYSTEM 4. Unscrew the surge tank pressure cap counterclockwise, ¼ turn to let air enter the system and permit the coolant to drain completely from system. 5. Connect coolant extractor (Fig. 8). Use coolant extractor to drain the coolant from the engine.

  • Page 85: Filling Cooling System

    Section 05: COOLING SYSTEM NOTE CAUTION If for any reason, the coolant level drops below the surge tank level probe, the Check Drain water pump completely before extended Engine warning light will illuminate. storage avoid possible water pump damage. 5. Stop engine and allow cooling. If freezing weather is anticipated and the 6.

  • Page 86: Cooling System Descalers

    Section 05: COOLING SYSTEM Dispose of spent fluids in an environmentally 5. Turn on the water and when the radiator is responsible manner according to regulations in full, turn on the air in short blasts, allowing effect in your area. the radiator to fill between blasts.

  • Page 87: Radiator

    Section 05: COOLING SYSTEM 2. Remove and discard the filter. Recover the 10.1 MAINTENANCE coolant remaining in the filter with a suitable container. MAINTENANCE 3. Clean the filter adapter with a clean, lint-free cloth. Inspect the exterior of the radiator core every 4.
  • Page 88 Section 05: COOLING SYSTEM 10. Remove clamps and then break hoses from the front coolant and charge air pipes (Fig. DANGER 13 & 14). Coolant is toxic; risk of poisoning. Do not drink coolant. Use proper hand protection when handling. Keep coolant out of reach of children and animals.
  • Page 89 Section 05: COOLING SYSTEM 12. Remove upper radiator assembly 15. Cut cable tie and disconnect electrical support bracket (Fig. 15). connector from fan clutch. Remove fan drive shaft fasteners at the gear box. FIGURE 17: DISCONNECTING FAN DRIVE SHAFT 16. Position forklift under radiator...

  • Page 90: Charge Air Cooler Leakage

    Section 05: COOLING SYSTEM 11. CHARGE AIR COOLER LEAKAGE Spec for CAC acceptable leakage: “The CAC is considered acceptable if it can hold 30 psi (206 kpa) gauge pressure with less than 5 psi (34.5 kpa) loss in 15 seconds after turning off the hand valve.”...

  • Page 91: Idler Replacement

    Section 05: COOLING SYSTEM 1. Unwrap the drive belt from around the pulley (see paragraph MOUNTING THE DRIVE BELT). 2. Dismount the drive pulley. Gain access to the 6 mounting bolts from behind the pulley, through the opening in the cast aluminum support (Fig.

  • Page 92: Locking Radiator Fan For Emergency Operation

    Section 05: COOLING SYSTEM NOTE temperature 203°F: 189°F: 225°F: fan HIGH dropping HIGH HIGH If the fan clutch does not engage using this SPEED SPEED SPEED procedure then the clutch is faulty or the disengages disengages disengage wiring between the multiplex module and the clutch is faulty.

  • Page 93: Maintenance

    7. When questions arise, obtain answers before proceeding. Assistance is available through the Prevost After-Sales Service Support serving your area. 13.3 INSPECTION FIGURE 27: RADIATOR FAN MOUNTING BOLTS 05125 14. FAN RIGHT ANGLE GEARBOX...
  • Page 94 Section 05: COOLING SYSTEM Use Shell transmission oil MA 75W90. 14.2 OIL CHANGE 1. Stop engine and make sure that all engine safety precautions have been observed. 2. Turn the ignition switch and set starter selector switch to the OFF position to prevent accidental starting of the engine.
  • Page 95 Fully closed ............................185°F (85°C) Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2526 Qty ..................................1 Prevost number ............................5060097 Coolant - Volvo D13 Engine Type ..................Fleet Charge 50/50 Fully Formulated Antifreeze Prevost Number ............................685352 Coolant Filter Cartridge –...
  • Page 97 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION ........................4 WIRING DIAGRAMS ........................4 1.1.1 Using Wiring Diagrams ....................... 4 1.1.2 Testing Circuits ........................... 5 WIRE SIZES AND COLORS ......................5 SPARE WIRES ..........................5 CLEANING CONNECTORS ......................6 CIRCUIT BREAKERS ........................6 1.5.1 X3-45 Coaches ...........................
  • Page 98 Section 06: ELECTRICAL 4.10.1 Available Functions ........................27 4.11 LOWER PRIORITY MODULES FOR BREAKDOWN SERVICE ..........27 4.12 MULTIPLEX MODULES ....................... 27 4.12.1 MCM ............................27 4.12.2 IO-A ............................27 4.12.3 IO-B ............................27 4.13 MULTIPLEX MODULES REPLACEMENT ................... 27 4.13.1 Replacing IO-A Or IO-B Modules ....................
  • Page 99 Section 06: ELECTRICAL ILLUSTRATIONS ........................5 FIGURE WIRE IDENTIFICATION ....................6 FIGURE REAR ELECTRICAL JUNCTION PANEL ..................7 FIGURE MULTIPLEX MODULE CONNECTORS PIN 3-45 ) ..................9 FIGURE ELECTRICAL COMPARTMENTS COACH & ..........9 FIGURE REAR ELECTRICAL PANEL JUNCTION PANEL BATTERY COMPARTMENT ........................

  • Page 100: General Description

    13, you will find the location, the reached through the engine compartment doors. b) At item CB Prevost number, the breaker function, the breaker ampere rating and the page on WIRING DIAGRAMS which to find the corresponding diagram.

  • Page 101: Testing Circuits

    Section 06: ELECTRICAL Problem: DID displays the fault "Elec. Horn distinctly colored in order to determine visually SW61 SW62; shorted to ground" as being the wiring voltage and to assist in making connectors. The wires are color coded as active. follows: a) Refer to wiring diagram index, and look for "Multiplexed Device Index", pages B1-B8.

  • Page 102: Cleaning Connectors

    Section 06: ELECTRICAL NOTE CIRCUIT BREAKERS Front distribution 24 VI 90 amps Spare wires identified wire Distribution 12 VD 90 amps identification number and by the letters “SP”, to HVAC - evaporator 24 VI 90 amps designate “spare”. Sound system 12 VD 30 amps Rear distribution...

  • Page 103: Relays

    Section 06: ELECTRICAL Electrical Center Front) and VECR (Vehicle NOTE Electrical Center Rear). When the ignition switch is set to the OFF position, the electrical components are not RELAYS energized except for the MCM (Master Relays are used to automatically energize or Chassis Module), ECM (Engine Control deenergize a circuit from a remote location.
  • Page 104 06630 Remove the terminal by disengaging the flexible lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. EXTRACTOR/TOOL: Prevost #682256 (Packard INS ERT 12094429) EXT RACT OR HERE Remove the terminal by disengaging the flexible lock tab on the terminal.

  • Page 105: X3 Series Coach

    Section 06: ELECTRICAL X3 SERIES COACH FIGURE 4: ELECTRICAL COMPARTMENTS (X3-45 COACH) 06672 MAINTENANCE A corrosion inhibitor has been sprayed on certain electrical components in order to protect them from corrosion. Refer to procedure SAV00002E at the end of this section for recommended products and where they are used.

  • Page 106: Rear Electrical Panel

    Section 06: ELECTRICAL REAR ELECTRICAL PANEL FIGURE 9: BATTERY COMPARTMENT FIGURE 7: REAR ELECTRICAL PANEL FRONT ELECTRICAL AND SERVICE The rear electrical panel provides access to the COMPARTMENT following: The front electrical and service compartment is  located on L.H. side of vehicle, under the Rear terminal block;...

  • Page 107: Engine Rear Start Panel

    Section 06: ELECTRICAL FIGURE 13: ENTRANCE DOOR & WIPER CONTROL PANEL 06619 BATTERIES vehicle provided with maintenance-free Group 8-D 12 volt heavy-duty batteries connected in series-parallel (Fig. 4 & 9). The top-mounted negative and positive terminals are tightly sealed to prevent leaks. FIGURE 11: A/C JUNCTION BOX Water never needs to be added to this type of battery.

  • Page 108: Battery Discharge Protection

    Section 06: ELECTRICAL  Battery equalizer check module; DANGER  MCM;  TCM (World transmission); All lead-acid batteries generate hydrogen gas,  ECM (Engine Control Module), which is highly flammable. If ignited by a spark  Water recirculating pump; or flame, the gas may explode violently, ...

  • Page 109: Battery Rating

    Section 06: ELECTRICAL CAUTION DANGER Ensure that connections are not reversed prevent possible electric shocks when reinstalling batteries, since damage to sparking, the battery master switches should electrical system components will result. be in the "Off" position before disconnecting cables from the batteries. NOTE 2.

  • Page 110: Battery Maintenance

    Section 06: ELECTRICAL starter will not be obtained. An abnormal voltage BATTERY MAINTENANCE drop can be detected with a low-reading Please consult “Deka Group 8D Commercial voltmeter as follows: Battery Care And Maintenance” document included with the OEM publications for specific information concerning battery...

  • Page 111: Battery Charging

    Section 06: ELECTRICAL BATTERY CHARGING The batteries used on this vehicle can be charged either on or off the vehicle; however, when they are removed from the vehicle, it is recommended that an adapter kit, which is available from any "A/C DELCO" dealer, be FIGURE 18: ALLIGATOR CLAMPS used in charging sealed-terminal batteries.

  • Page 112: Common Causes Of Battery Failure

    Section 06: ELECTRICAL by using energy from a booster battery or the DANGER battery from another vehicle. Any procedure other than the above could DANGER result in personal injury, property damage due to battery explosion, or damage to the Jump starting may be dangerous and should charging system of the booster vehicle or of be attempted only if the following conditions the boosted vehicle.

  • Page 113: Troubleshooting

    Section 06: ELECTRICAL 8. A constant drain caused by a shorted circuit Voltmeter exceeds 30 volts dc such as an exposed wire or water infiltration Check alternator output. in junction boxes causing ground fault. Check voltage regulator. 9. Failing to close disconnect switches during the night.

  • Page 114: Probing Voltage On The Multiplex Circuits

    Section 06: ELECTRICAL connected. Connector C1 (front electrical & NOTE service compartment) disconnects It is of the utmost importance to have a DID modules at the rear of the vehicle from the (Driver Information Display) working network. Connector C5 (front electrical & service condition because it is the most important tool compartment) disconnects all the modules from to achieve troubleshooting on a multiplex...
  • Page 115 Section 06: ELECTRICAL  Retarder active signal, Certain inputs are doubled (door operating buttons) and also other inputs activate at the  Radiator fan speed 1 & 2 signals. same time (ex. kneeling switch and Kneeling proximity sensor switch). For these inputs, 2 In test mode, with the parking brake applied and beeps are emitted.

  • Page 116: Test Sequence

    Section 06: ELECTRICAL SEQUENCE and press ENTER button to Inside the vehicle: initiate the test mode for electrical motors;  The driver's HVAC unit refrigerant solenoid 3. Ten (10) beeps can be heard indicating the valve cycles 3 times and the hot water motor test mode has started.

  • Page 117: Can Network Layout And Troubleshooting

    Section 06: ELECTRICAL CAN NETWORK LAYOUT AND TROUBLESHOOTING FIGURE 20: X3-45 COACHES CAN NETWORK LAYOUT 06637 TROUBLESHOOTING Problem/Symptom Probable Causes Actions Vehicle does not Start Rear Start selector switch is 1. Check that the rear start selector not in the NORMAL position switch is flipped up to NORMAL start position and master cut-out switch is Master cut-out switch on the...
  • Page 118 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions 2. Verify that engine Engine ECM is not powered powered and get the ignition signal a) Check / reset circuit breaker CB8 Check / replace fuse F74 b) Check / reset circuit breaker CB2 Check / replace fuse F78 None of the Multiplexed The program version in the...
  • Page 119 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions 2. Check / reset circuit breaker CB6 3. Check / replace fuse F5 4. Check / replace relay R18 5. Probe gray connector on module to see if it is powered. 6. Use the air release valves near the entrance door and in the front service compartment to lock / unlock the door Windshield...
  • Page 120 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Low beam headlights and Module A48 is not powered 1. Check the Diagnostics menu of flasher on right side not or is faulty Driver Information Display (DID). functioning Select Fault Diagnostics Electrical System. The message “No Response ModA48, Active”...
  • Page 121 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Response ModA54, Active” indicates a power problem on the module. (A CAN network problem would show same message doesn't produce this symptom). 3. Check / reset circuit breaker CB5 4. Check / replace fuse F67 , F68 5.
  • Page 122 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions The radiator fan clutch Set the ignition switch to the ON does not function and the position. engine is overheating Activate the dashboard Telltale Light Test switch 3 times within 4 seconds. In the engine compartment, set the starter selector switch to REAR START and then start the engine from the rear.

  • Page 123: Available Functions

    Section 06: ELECTRICAL 4.10.1 Available Functions function accordingly to the vehicle options. It keeps the specific back-up program of the o Startup: Turn on the ignition in the driver's vehicle. area and rear start the vehicle from the engine compartment, 4.12.2 IO-A o Opening the door: Functions normally, IO-A modules receive inputs and control...

  • Page 124: Replacing The Mcm Module

    (4, figure 23) onto alternators equipped with (Vehicle Program arched support, torque tighten to 43 Lb-Ft. Generator) software must be connected to the DB9 (9-pin) connector (identified C226) found in the electrical harness near the Please contact your Prevost MCM. Service Representative. PA1593...

  • Page 125: Alternator Brush Replacement

    Section 06: ELECTRICAL ALTERNATOR BRUSH REPLACEMENT 1. Disconnect the electrical harnesses and remove the alternator. 2. Remove the cover located on the rear side of the alternator. 3. Dismount the brush holder and voltage regulator assembly. To do so, remove the 3 screws indicated with arrows.

  • Page 126: Identifying The Defective Alternator

    Section 06: ELECTRICAL Nut A, 43 lb-ft. MID (188) ELECTRICAL SYSTEM Nut B, 43 lb-ft (2x). PSID 35 ALTERNATOR 2 FMI (5) OPEN CIRCUIT Nut C, 80 lb-ft (2x) 9. On the upper alternator, connect the power ALTERNATOR DRIVE BELT harness onto the adaptor.

  • Page 127: Power Inverter

    Section 06: ELECTRICAL POWER INVERTER 10.1.1 Headlight Beam Toggle Switch Xantrex Power Inverter is located in the battery Toggle between high and low beams by charger and power inverter compartment; which pressing the foot-operated switch. is located at the rear of the coach, behind the last row of passenger’s seats.

  • Page 128: Headlight Adjustment

    Section 06: ELECTRICAL Headlight aim should be checked after installing TABLE 1 – VERTICAL BEAM AIM GUIDELINES a new bulb. Aiming can be performed without Headlight Nominal Aim Inspection opening headlight assembly. Horizontal and (centerline) Vertical Limits for Vertical vertical aiming of each module is provided by Mounting Height two adjusting screws that pivot the module in the housing for proper alignment (fig.

  • Page 129: Sealed-Beam Unit

    Section 06: ELECTRICAL FIGURE 31: HIGH-INTENSITY ZONE (SHADED AREA) OF A PROPERLY AIMED UPPER BEAM ON THE AIMING FIGURE 34: AIM INSPECTION LIMITS FOR LOWER- SCREEN 7.6 M (25FT) IN FRONT OF VEHICLE BEAM HEADLIGHTS 06503 06506 10.1.4 Sealed-Beam Unit Bulb Removal and Replacement 1.

  • Page 130: Front Turn Signal

    Section 06: ELECTRICAL 7. Tilt headlight assembly up into its housing are also used as directional signal and marker then secure using fixing screw. lights. The stop, tail, directional signal and back-up NOTE lights consist of individual LED lights mounted Make sure headlight assembly is properly on the engine rear door, and each light is positioned into its housing before securing...

  • Page 131: Clearance And Identification Light Removal And Replacement

    Section 06: ELECTRICAL The rear clearance and identification lights are red and the front ones are amber. The amber marker lights are mounted along the sides of vehicle. The side marker light is a sealed unit (LED) and should replaced assembly accordance with the following procedure: 1.
  • Page 132 Section 06: ELECTRICAL 11.3 DRIVER’S AREA LIGHTS 11.4 ENGINE COMPARTMENT LIGHTING Two halogen ceiling lights are installed over the A switch located on R.H. side of rear junction stepwell and the driver’s area. These lights are box can be used to actuate the engine frequently used for night-time operation when compartment LED lights.
  • Page 133 Make ..............................BOSCH Series ..............................HD 10 Amperes ..............................120 Volts ................................. 28.4 Output Power ............................3 Kw Ground .............................. negative Prevost Number ..........................564119 Battery equalizer Make ..............................Vanner Model ........................... Vann-Guard 70-Series Amperes ............................100 amps Starter Make ....................Mitsubishi Electric Corporation (MELCO) Type ..............................
  • Page 135 ELECTRICAL CONNECTORS PROTECTION NOVEMBER 2009 PROCEDURE NO SAV00002E REVISION 02 Kent Sealer Sprayed sealer. It is used for structure ground connections. It prevents corrosion and ensures maximum contact Refer to table for proper use. Apply this product once installation is finished. Warning: It is very important to be in a well ventilated area when applying this product.
  • Page 136 PROCEDURE NO: SAV00002E REVISION 02 Vehicle Zoning Electrical Connectors Protection Procedure Table Product Note Model Zone Component X3-45 A- Front Elect. Compt Diode Block Nyogel Accepted to ease connection A- Front Elect. Compt Customer Terminal Block Nothing Terminal Block Electronic A Front Elect.
  • Page 137 PROCEDURE NO: SAV00002E REVISION 02 Product Note Model Zone Component X3-45 Color Guard C- Baggage Compt Structure Ground or Kent C- Baggage Compt Door Switch Nyogel Accepted to ease connection Door lock Actuator Module C- Baggage Compt (switch and solenoid) Nyogel Accepted to ease connection C- Baggage Compt...
  • Page 138 PROCEDURE NO: SAV00002E REVISION 02 Product Note Model Zone Component X3-45 H- Vehicle Exterior ABS Sensor Nothing Accepted to ease H- Vehicle Exterior Docking & Cornering Lamps Nyogel connection H- Vehicle Exterior Marker Light Nothing H- Vehicle Exterior Mirror Nothing H- Vehicle Exterior Light Module Nothing...
  • Page 139 SECTION 06B: ELECTRICAL MULTIPLEX ERROR MESSAGES TROUBLE SHOOTING LIST MID (Message Identification Description) : Identification of a control unit PID (Parameter Identification Description) : Identification of a parameter (value) PPID (Proprietary Parameter Identification : Unique Identification of a parameter (value) Description) SID (Subsystem Identification Description) : Identification of a component...
  • Page 140 SECTION 06B: ELECTRICAL MID 188 PSID # 13 A/C Pres LoSd (A52 J1:14) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A52 module failure FMI 3 Shorted High Voltage above Low side normal on A52 J1:14 pressure not ...
  • Page 141 SECTION 06B: ELECTRICAL  Circuit BrkAux shorted to battery FMI 4 Shorted Low Output A42 J1:11 Brake interlock  A42 module failure shorted to ground not working  Connector C172 corroded  Connector C8 corroded  Circuit BrkAux shorted to ground FMI 5 Open Circuit...
  • Page 142 SECTION 06B: ELECTRICAL MID 188 PSID # 119 Brk Lts Sens (A36 JB:13) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A36 module failure FMI 3 Shorted High Voltage above Stop lights normal on A36 JB:13 always ON ...
  • Page 143 SECTION 06B: ELECTRICAL  Circuit 21A shorted to ground  L70 low resistance value MID 188 PSID # 125 Center Flash RH (A50 J1:7) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A50 module failure FMI 3 Shorted High Voltage present on L68 always ON...
  • Page 144 SECTION 06B: ELECTRICAL FMI 4 Shorted Low Output A54 J1:5 Condenser  A54 module failure shorted to ground fans not  Cond Power Relay R10 failure working  Circuit 67A shorted to ground  A54 module failure FMI 5 Open Circuit A54 module does not Condenser detect power relay...
  • Page 145 SECTION 06B: ELECTRICAL  A49 module failure FMI 4 Shorted Low Output A49 J1:11 Direct lights not shorted to ground working  Direct Lights Relay R6 failure  Circuit 38 shorted to ground  A49 module failure FMI 5 Open Circuit A49 module does not Direct lights not detect direct lights...
  • Page 146 SECTION 06B: ELECTRICAL MID 188 PSID # 104 Driver Light Sw (A44 J1:3) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A44 module failure FMI 3 Shorted High Voltage present on Driver Light output A44 J1:3 but L16 always ON ...
  • Page 147 SECTION 06B: ELECTRICAL MID 188 PSID # 28 Driver Sensor (A55 J1:1) Type of Fault Condition: Possible Symptoms: Possible Causes: fault: Description:  A55 module failure FMI 3 Shorted High Voltage above Driver temperature not normal on A55 J1:1 displayed on HVCA ...
  • Page 148 SECTION 06B: ELECTRICAL  Mo3 low resistance value MID 188 PSID # 30 Drv Rec Cylind (A47 J1:4) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms: FMI 3 Shorted High Voltage present on Driver’s area  A47 module failure output A47 J1:4 but always in ...
  • Page 149 SECTION 06B: ELECTRICAL  Relay R15 open circuit detect relay R15 lights not working  Circuit 64 open  A49 module failure FMI 6 Current Output A49 J1:13 Emergency above normal internal software fuse lights not  Connector C35 corroded active for overcurrent working ...
  • Page 150 SECTION 06B: ELECTRICAL compressor  Se31 failure door switch  Connector C91 corroded Se31 always  Circuit 9A shorted to battery FMI 4 Shorted Low Voltage below normal Engine door  A49 module failure on A49 J1:2 switch Se30 & ...
  • Page 151 SECTION 06B: ELECTRICAL  Connector C426 corroded  Circuit 292 open  A52 module failure FMI 6 Current Output A52 J1:2 Radiator fan above normal internal software fuse clutch Mo2 not  Connector C91 corroded active for overcurrent working on ...
  • Page 152 SECTION 06B: ELECTRICAL MID 188 PSID # 64 Ent Door Close (A36 JB:10) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A36 module failure FMI 3 Shorted High Voltage above Entrance door normal on A36 J1:10 cannot be closed ...
  • Page 153 SECTION 06B: ELECTRICAL  Unlk solenoid valve So3 failure output A47 J1:8 but Valve So3 or output not active Unlk Solenoid  Unlk dolenoid valve So4 failure Valve So4 always  Circuit 12W shorted to battery ON - Entrance door cannot be locked FMI 4 Shorted Low...
  • Page 154 SECTION 06B: ELECTRICAL MID 188 PSID # 130 Flasher LH (A45 J1:9) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A45 module failure FMI 3 Shorted High Voltage present on LH flasher not input A45 J1:9 but working ...
  • Page 155 SECTION 06B: ELECTRICAL  A45 module failure FMI 4 Shorted Low Output A45 J1:3 Front LH shorted to ground flasher and  Connector C4 corroded marker lights  Connector C242 corroded not working  Circuit 21A shorted to ground FMI 6 Current Output A45 J1:3 Front LH...
  • Page 156 SECTION 06B: ELECTRICAL MID 188 PSID # 148 FrontMkr Lts LH (A45 J1:21) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A45 module failure FMI 3 Shorted High Voltage present on Front Flasher output A45 J1:21 but LH L62 always ...
  • Page 157 SECTION 06B: ELECTRICAL MID 188 PSID # 81 Fuel Filt Sens (A49 J1:20) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms: FMI 3 Shorted High Voltage present on No warning of  A49 module failure input A49 J1:20 water in fuel ...
  • Page 158 SECTION 06B: ELECTRICAL shorted to ground always ON low  Headlight switch Sw2 failure beam  Connector C71 corroded  Circuit 66 shorted to ground MID 188 SID # 62 Hi Low Beam (A43 J1:8) Type of Fault Condition: Possible Possible Causes: fault: Description:...
  • Page 159 SECTION 06B: ELECTRICAL Headlamp L59B L59B not L59B open circuit  Circuit 57R open working FMI 6 Current Output A48 J1:3 RH High beam  A48 module failure above normal internal software fuse Headlamp  Connector C243 corroded active for overcurrent L59B not ...
  • Page 160 SECTION 06B: ELECTRICAL MID 188 PSID # 89 Knee down Sol (A41 J1:14) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A41 module failure FMI 3 Shorted High Voltage present on Kneeling down output A41 J1:14 but always ON, ...
  • Page 161 SECTION 06B: ELECTRICAL MID 188 SID # 81 Kneeling Level Se (A46 J1:13) Type of Fault Possible Symptoms: Possible Causes: fault: Description: Condition: FMI 3 Shorted High Voltage Momentary switch  A46 module failure present on function lost, holding  Kneeling level sensor Se79 signal A46 switch will raise coach failure...
  • Page 162 SECTION 06B: ELECTRICAL output A48 J1:4 but Headlamp  Connector C243 corroded output not active L59A always  Circuit 58R shorted to battery FMI 4 Shorted Low Output A48 J1:4 RH Low beam  A48 module failure shorted to ground Headlamp ...
  • Page 163 SECTION 06B: ELECTRICAL Bypass Sw140 failure  Circuit Master shorted to ground always ON MID 188 SID # 80 Next Stop Sign (A41 J1:13) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A41 module failure FMI 3 Shorted High Voltage present on Next Stop Light...
  • Page 164 SECTION 06B: ELECTRICAL MID 188 SID # 78 Open Door Sw (A44 J1:4) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms: FMI 3 Shorted High Voltage present on Interlock is  A44 module failure output A44 J1:4 but disabled and ...
  • Page 165 SECTION 06B: ELECTRICAL  Circuit 43 open  A54 module failure FMI 6 Current Output A54 J1:2 P Rack RH Fan above normal internal software fuse Mo11 not working  Connector C15, C21, C35, active for overcurrent C57 or C75 corroded ...
  • Page 166 SECTION 06B: ELECTRICAL FMI 3 Shorted High Voltage present on Pass heat  A54 module failure output A54 J1:8 but Solenoid valve  Pass heat Solenoid valve output not active So13 always ON So13 failure if R26 is ON  Circuit 45 shorted to battery ...
  • Page 167 SECTION 06B: ELECTRICAL output not active Valve So11 failure  Connector C9, C15 or C58 always ON corroded  Circuit 77C or 77B shorted to battery FMI 4 Shorted Low Output A54 J1:3 Pass Liquid  A54 module failure shorted to ground Solenoid ...
  • Page 168 SECTION 06B: ELECTRICAL MID 188 PSID # 113 Read Lts Rly (A49 J1:15) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A49 module failure FMI 3 Shorted High Voltage present on Reading output A49 J1:15 but Lights always ...
  • Page 169 SECTION 06B: ELECTRICAL MID 188 PSID # 132 RearFlsh RH (A51 J1:3) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A51 module failure FMI 3 Shorted High Voltage present Rear Flasher Light on output A51 RH L73, upper rear ...
  • Page 170 SECTION 06B: ELECTRICAL MID 188 PSID # 59 Rear Start Sw (A53 J1:11) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  A53 module failure FMI 3 Shorted High Voltage present on Rear Start output A53 J1:11 Switch Sw59 ...
  • Page 171 SECTION 06B: ELECTRICAL  Connector C397 corroded above normal internal software fuse not working active for overcurrent  Circuit 231A shorted to ground MID 188 SID # 77 Step Led light (A43 J1:30) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:...
  • Page 172 SECTION 06B: ELECTRICAL output not active L79, L80, L82 or C120 corroded  Circuit 46 shorted to battery L83 always ON  A51 module failure FMI 4 Shorted Low Output A51 J1:8 Tail Lights L72, shorted to ground L74, L77, L78, ...
  • Page 173 SECTION 06B: ELECTRICAL  Connector C6, C2 or C59 above normal internal software compartment lights fuse active for L176, L177, L180, corroded overcurrent L181, L182 or L183  Circuit 10A shorted to ground not working MID 188 PSID # 31 Unloader LH (A52 J1:8) Type of Fault Condition: Possible...
  • Page 174 SECTION 06B: ELECTRICAL FMI 5 Open Circuit A46 module does Upper Defrost  A46 module failure not detect Upper LH Heater  Upper Defrost LH Heater Res37 Defrost LH Res37 not failure Heater Res37 working  Circuit 5A open  A46 module failure FMI 6 Current Output A46 J1:1...
  • Page 175 SECTION 06B: ELECTRICAL  Circuit 85B shorted to ground or position  A36 module failure FMI 5 Open Circuit A36 module does Various systems not detect 24v Fr not working  Various WUp Relays R17, WUp relay R18, depending on relay R18, R19, R34 open circuit 12v Fr WUp relay or position...
  • Page 176 SECTION 06B: ELECTRICAL overcurrent working  Circuit 306 shorted to ground...
  • Page 177 SECTION 06C: ELECTRICAL MULTIPLEX MODULE “NO RESPONSE” TROUBLESHOOTING LIST FRONT JUNCTION BOX MODULES MID 188 PSID # 216 A41 MODULE NO RESPONSE Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  CAN network open FMI 2 Data Error A41 Module not A41 module all responding on CAN...
  • Page 178 SECTION 06C: ELECTRICAL ENTRANCE DOOR & WIPER CONTROL PANEL MODULES MID 188 PSID # 222 A47 MODULE NO RESPONSE Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  CAN network open FMI 2 Data Error A47 Module not A47 module all responding on CAN inputs and outputs...
  • Page 179 SECTION 06C: ELECTRICAL REAR JUNCTION BOX MODULES MID 188 PSID # 224 A49 MODULE NO RESPONSE Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms:  CAN network open FMI 2 Data Error A49 Module not A49 module all responding on CAN inputs and outputs ...
  • Page 181 SECTION 07: TRANSMISSION CONTENTS DESCRIPTION ............................2 WELDING PROCEDURES ........................2 MAINTENANCE ............................ 3 ......................3 ANUAL LUID EVEL HECK 3.1.1 Cold Check ..........................3 3.1.2 Hot Check ..........................4 ............4 LUID EVEL HECK SING THE USHBUTTON HIFT ELECTOR ....................

  • Page 182: Description

    Section 07: TRANSMISSION DESCRIPTION match the shift to desired profile stored in its memory. It then looks at these adjustments and Series coaches featuring Metropolitan resets parameters, which allow Transportation Authority (MTA) specifications are transmission quickly compensate provided with an Allison automatic transmission variations in load, terrain or environment and to adjust for clutch wear and engine power changes.

  • Page 183: Maintenance

    Section 07: TRANSMISSION 00: GENERAL INFORMATION, paragraph 3: Always check the oil level reading at least twice “Precautions to be observed before welding” for when the engine is running. Consistency is complete procedure. important in maintaining the accuracy of the reading.

  • Page 184: Hot Check

    Section 07: TRANSMISSION fluid as necessary to bring the level within the Repeat the check procedure to verify the COLD CHECK band. reading. 8. Perform a Hot Check at the first opportunity 5. If the level is not within this band, add or drain after the normal operating temperature of fluid as necessary to bring the level within the 160ºF (71ºC) to 200ºF (93ºC) is attained.

  • Page 185: Importance Of

    Severe Duty and Extended malfunction improper condition Drain Intervals. TranSynd™ is fully qualified to conducting the check. the Allison TES295 specifications and is available through Prevost Parts. CODE CAUSE OF CODE NOTE OL…-…0X Waiting period is not complete OL…-…EL...

  • Page 186: Oil Contamination

    Section 07: TRANSMISSION  To be sure a fluid is qualified for use in Allison METAL PARTICLES transmission, check for the DEXRON-III® Metal particles in the oil (except for minute license number on the container or consult the particles normally trapped in the oil filter) indicate lubricant manufacturer.
  • Page 187 Section 07: TRANSMISSION When a specified threshold is detected for any selector movement, with the ignition on and the serviceable conditions, engine not running. TRANSMISSION SERVICE indicator CAUTION illuminated to alert the operator. Failure to attend service condition reset TRANSMISSION SERVICE indicator within a Required calendar-based oil &...
  • Page 188 Section 07: TRANSMISSION can be performed by depressing and holding the The TRANSMISSION SERVICE indicator will be MODE button for ten (10) seconds while the illuminated, indicating the need for clutch Filter Life Monitor function is displayed. It may maintenance, when the remaining clutch life also be reset by selecting N-R-N-R-N-D-N on reaches approximately 10%, or if the running the shift selector, pausing briefly (less than 3...
  • Page 189 Section 07: TRANSMISSION TABLE 1 Recommended Fluid and Filter Change Intervals Using Dexron-III / Non-TranSynd /Non-TES 295/Mixture Severe All vehicles equipped with a retarder and not using High-Capacity Filters Fluid Filters Main Internal Lube/ Auxiliary 12,000 Miles 12,000 Miles Overhaul 12,000 Miles (20 000 km) (20 000 km)

  • Page 190: Oil And Filter Change Interval

    Section 07: TRANSMISSION 3.10 OIL AND FILTER CHANGE INTERVAL filters. If any other fluids or filters are used, Prognostic mode must be disabled. Prognostic Filter Change interval With information will not be accurate with any other Prognostics Mode Disabled fluids or filters and could result in missed maintenance activities resulting in transmission Allison transmissions are factory fill with Castrol damage.

  • Page 191: Allison Transmission Removal

    Section 07: TRANSMISSION 4. To install filters, pre-lube and install the two O- Refilling Transmission rings, the two square cut seals followed by the The amount of refill fluid is less than the amount filters (lube the O-ring in filter cartridge only) used for the initial fill.

  • Page 192: Transmission Oil Cooler Removal

    Section 07: TRANSMISSION WARNING It is better to drain oil when it is still warm. Avoid contact with oil since it can be very hot and cause personal injury. 6. Remove transmission dipstick and filler tube. 7. Disconnect propeller shaft from transmission and remove its safety guard.

  • Page 193: Cleaning And Inspection Of Allison Automatic Transmission

    Section 07: TRANSMISSION ALLISON TRANSMISSION INSTALLATION WARNING NOTE A significant amount of oil may drain from oil For more clearance between the tag axle and lines when they are disconnected. transmission, the tag axle may be unloaded and jacked up, or retracted (if applicable). 4.

  • Page 194: Allison Automatic Transmission Troubleshooting

    Section 07: TRANSMISSION start the remaining screws; tighten to 17-21 lbf-ft (23-28 Nm). NOTE Remove the plug located below starter motor and install cranking tool (88800014). Crank the engine to gain access to the threaded holes by FIGURE 9: AIR PRESSURE REGULATOR (TYPICAL) 07130 turning the cranking tool using a suitable ALLISON AUTOMATIC TRANSMISSION...

  • Page 195: Diagnostic Troubleshooting Codes (Dtc) - Allison 4Th Generation Controls

    Section 07: TRANSMISSION The code list position is the first item displayed, CAUTION followed by the DTC. Each item is displayed for about second. display cycles Place the battery master switch to the ‘’OFF’’ continuously until the next code list position is position.
  • Page 196 Section 07: TRANSMISSION To begin the diagnostic process: NOTE 1. Bring the vehicle to a stop at a safe location. All active indicators are cleared at TCM power down. 2. Apply the parking brake. Some codes will clear their active indicator when the condition causing the code is no To display stored codes: longer detected by the TCM.
  • Page 197 Section 07: TRANSMISSION DNA - Do Not Adapt Response The TCM stops adaptive shift control while the code is active. SOL OFF - SOLenoid OFF Response All solenoids are commanded OFF (turning solenoids “A” and “B” off electrically cause them to be on hydraulically).

  • Page 198: Diagnostic Troubleshooting Codes (Dtc) List - Allison

    Section 07: TRANSMISSION DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST - ALLISON 4 GENERATION CONTROLS CHECK Inhibited Operation Description TRANS Description Light May inhibit retarder operation if not C1312 Retarder Request Sensor Failed Low using J1939 datalink May inhibit retarder operation if not C1313 Retarder Request Sensor Failed High using J1939 datalink...
  • Page 199 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P071A RELS Input Failed On Inhibit RELS operation P071D General Purpose Input Fault None P0720 Output Speed Sensor Circuit P0721 Output Speed Sensor Circuit Performance DNS, Lock in current range P0722 Output Speed Sensor Circuit No Signal DNS, Lock in current range...
  • Page 200 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P0971 Pressure Control Solenoid 3 (PCS3) Control Circuit High DNS, SOL OFF (hydraulic default) P0973 Shift Solenoid 1 (SS1) Control Circuit Low DNS, SOL OFF (hydraulic default) P0974 Shift Solenoid 1 (SS1) Control Circuit High DNS, SOL OFF (hydraulic default) P0975 Shift Solenoid 2 (SS2) Control Circuit Open...
  • Page 201 Capacity (excluding external circuits) ..............Initial fill 47 US qts (45 liters) Oil change ..........................24 US qts (23 liters) Oil change (with retarder) ....................27.6 US qts (26 liters) Oil Filters: Make ............................. Allison Transmission Type ............................Disposable cartridge Prevost Part Number (2-filter replacement kit) ..................571709 PA1593...
  • Page 203 SECTION 09: PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..........................2 ............................ 2 ESCRIPTION REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION ..........2 CLEANING, INSPECTION AND LUBRICATION ................. 2 ....................... 2 LEANING NSPECTION ............................ 2 UBRICATION EXPLANATION OF COMMON DAMAGES ..................4 TROUBLESHOOTING .......................... 4 SPECIFICATIONS ..........................

  • Page 204: Section 09: Propeller Shaft

    Section 09: PROPELLER SHAFT PROPELLER SHAFT It is extremely important that bearing assemblies absolutely clean blown with DESCRIPTION compressed air, since small particles of dirt or grit can cause rapid bearing wear. Do not attempt to The propeller shaft transmits power from the disassemble needle bearings.
  • Page 205 Section 09: PROPELLER SHAFT FIGURE 1: PROPELLER SHAFT ASSEMBLY 09002 PA1593...

  • Page 206: Explanation Of Common Damages

    If excessive, pitting can Manual". lead to surface wear and eventual failure. SPECIFICATIONS PROPELLER SHAFT ALL VEHICLES EQUIPPED WITH ALLISON WORLD TRANSMISSION Make ............................Hayes-Dana Inc. Series ................................. SPL250 Prevost number ............................580090 Length ................................ 485 mm PA1593...
  • Page 207 SECTION 10: FRONT AXLE CONTENTS FRONT AXLE ............................2 DESCRIPTION ..........................2 LUBRICATION ............................2 MAINTENANCE ............................ 4 REMOVAL AND REPLACEMENT......................4 REMOVAL ............................4 REPLACEMENT ..........................4 SERVICE INSTRUCTIONS FOR STEER AXLE ................... 5 STEERING KNUCKLE (KING) PIN INSPECTION ................. 5 5.1.1 Checking Lateral Slackness ....................

  • Page 208: Front Axle

    Section 10: FRONT AXLE FRONT AXLE Good quality lithium-base roller bearing grease NLGI No.1 and 2 are recommended. DESCRIPTION The Dana Spicer S84U front axle is of the ‘’Reverse Elliot’’ type manufactured by Dana Spicer Europe. The front axle consists of a girder section axle bed or beam with stub axles.
  • Page 209 Section 10: FRONT AXLE TYPICAL S84U AXLE ITEM DESCRIPTION ITEM DESCRIPTION Flanged Bolt 161-197 lbf-ft Draw key, Nut, Washer 51-62 lbf-ft Tie Rod End Brake Disc V-Ring Seal Stake Hub Nut 563-687 lbf-ft Kingpin Collet Washer Kingpin - Bushing Hub Bearing O-Ring Seal Nut –...

  • Page 210: Removal And Replacement

    Section 10: FRONT AXLE 2. Exhaust compressed air from the air supply MAINTENANCE system by opening the drain valve of each A periodic inspection of the front axle assembly reservoir. should be made to check that all bolts are tight, and that no damage and distortion have taken 3.

  • Page 211: Service Instructions For Steer Axle

    Section 10: FRONT AXLE NOTE Refer Section Suspension recommended tightening torques. SERVICE INSTRUCTIONS FOR STEER AXLE STEERING KNUCKLE (KING) PIN INSPECTION MAINTENANCE An inspection should be made at intervals of 30,000 miles (48 000 km) or twice a year whichever comes first. Aspects to be considered are: Lower Bushing Lateral Inspection ...

  • Page 212: Checking Vertical Slackness

    Section 10: FRONT AXLE Every 200,000 miles (320 000 km) or 24 months (normal maintenance); NOTE When the vehicle does not steer correctly; or To avoid inaccurate measurements, be careful not to let the knuckle turn while moving To correct a tire wear condition. assembly in and out.

  • Page 213: Major Front Wheel Alignment

    Section 10: FRONT AXLE Inspect all the systems that affect the wheel 6.4.1 R.H. Turn Adjustment alignment. See paragraph 6.1, ‘’Inspection Before Alignment’’ in this section. CAUTION Check the hub bearings. See section 13, To prevent the steering damper from interfering ‘’Wheels, hubs and Tires’’...

  • Page 214: Hydraulic Stop

    Section 10: FRONT AXLE Check the stroke of the steering stabilizer cylinder (damper). It should not exceed 12.59 inches (320 mm). 5. This must be done for a full left turn. 6. If readjustment is required: a. Remove the swivel stop screw. b.

  • Page 215: Front Wheel Toe-In

    ‘’Toe-in’’ measurements must be taken at the needs adjustment; it can be adjusted by means horizontal axis of the wheel centerline. of shims (Prevost #110663) on the left-hand side upper radius rod support in order to obtain minor adjustment. FRONT WHEEL TOE-IN...

  • Page 216: Inspection And Adjustment

    Section 10: FRONT AXLE 6.8.1 Inspection and Adjustment Before checking front wheel toe-in, first check the camber angles and make the necessary corrections. 1. Measure the toe-in. 2. If the toe-in measurement is not within the specified tolerance, carry out the following procedure : Loosen the pinch bolt nuts and bolts on each tie rod end.

  • Page 217: Troubleshooting

    Section 10: FRONT AXLE TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear out 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly or have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.

  • Page 218: Specifications

    Section 10: FRONT AXLE SPECIFICATIONS Front Axle Make ..........................DANA SPICER EUROPE Model ................................NDS Front Track ........................84.4 inches (2 145 mm) Rated load capacity ......................16,500 lbs (7 500 kg) TORQUE SPECIFICATIONS The torque specifications applicable to the front axle are grouped with information regarding the front suspension.
  • Page 219 SECTION 11: REAR AXLES CONTENTS DRIVE AXLE ............................2 DESCRIPTION ..........................2 DRIVE AXLE LUBRICATION ......................2 MAINTENANCE..........................2 1.3.1 Checking and Adjusting the Oil Level ..................3 1.3.2 Draining and Replacing the Oil ....................3 1.3.3 Speed Sensors (Anti-Lock Brake system, ABS) ..............3 REMOVAL AND REINSTALLATION ....................

  • Page 220: Drive Axle

    Section 11: REAR AXLES DRIVE AXLE In extreme conditions, or for better performance, fill with synthetic gear oil. DESCRIPTION The Meritor drive axle is equipped with a single MAINTENANCE reduction standard carrier mounted in front of the axle housing. The carrier consists of a Check oil level and add (if necessary) every hypoid drive pinion, a ring gear set and gears in 5,000 miles (8 000 km) or once a month,...

  • Page 221: Checking And Adjusting The Oil Level

    Section 11: REAR AXLES Maintenance of the axle mountings consists 2. Remove the drain plug from the bottom of the primarily in a regular and systematic inspection of axle. Drain and discard the oil in an the air suspension units and radius rods, as environment friendly manner.

  • Page 222: Disassembly And Reassembly

    Section 11: REAR AXLES 2. Exhaust compressed air from the air supply 13. Remove the two retaining nuts from each of system by opening the drain cock on each four bellows lower mounting air reservoir. supports. 3. Disconnect the propeller shaft as directed in 14.

  • Page 223: Drive Axle Alignment

    Section 11: REAR AXLES The drive axle alignment consists in aligning the Using two jacking points (which are at least axle according to the frame. The axle must be 30 inches [76 cm] apart) on drive axle, raise perpendicular to the frame. The alignment is the vehicle sufficiently so that wheels can achieved with the use of shims inserted between turn freely at about ½...

  • Page 224: Axle Shaft Sealing Method

    Section 11: REAR AXLES TAG AXLE ALL VEHICLES Alignment / value Minimum value Nominal value Maximum value Parallelism (deg.) -0.02 0.02 Total Toe (deg.) 0.18 Toe-in 0.18 Toe-out FIGURE 6: FRONT & DRIVE AXLE ALIGNMENT FIGURE 7: TAG AXLE ALIGNMENT 11025 11026 1.11 AXLE SHAFT SEALING METHOD...

  • Page 225: Tag Axle

    Dry both surfaces. FIGURE 9: TORQUE SPECIFICATION 2. Apply a continuous thin bead of silicone sealant* (Prevost P/N 680053) on the TAG AXLE mounting surfaces and around the edge of all The tag axle is located behind the drive axle. It fastener holes of both the axle shaft flange carries a single wheel and tire on each side.

  • Page 226: Retracting Tag Axle For Repair Purposes

    Section 11: REAR AXLES NOTE CAUTION For more information on front and tag axle wheel hub, refer to “DANA SPICER Service Do not use tag axle in raised position for an Manual NDS Axle Range” found in the OEM extended period. Raising tag axle increases manuals folder.

  • Page 227: Removing Transversal Radius Rod

    Section 11: REAR AXLES 2. Exhaust compressed air from the air supply 14. Reverse removal procedure to reinstall tag system by opening the drain cock on each air axle. reservoir and deplete air bags by moving NOTE leveling valve arm down. Refer to Section 16, "Suspension", for proper 3.

  • Page 228: Specifications

    NOTE The drive axle alignment consists in aligning the axle with reference to the frame. The axle must be perpendicular to the frame. Tag Axle Make ................................Prevost Rear track ........................83.6 inches (2 124 mm) Axle type ..............................Forged NOTE The tag axle alignment consists in aligning the tag axle parallel to the drive axle.
  • Page 229 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM ............................4 BRAKES ..............................4 AIR RESERVOIRS ..........................4 ..........................4 AINTENANCE 3.1.1 Wet (Main) Air Tank ......................... 4 3.1.2 Primary Air Tank ........................4 3.1.3 Accessory Air Tank........................4 3.1.4 Secondary Air Tank .........................
  • Page 230 Section 12: BRAKE AND AIR SYSTEM STOPLIGHT SWITCHES ......................... 11 PARKING BRAKE ALARM SWITCH ....................12 BRAKE RELAY VALVE (R-12 & R-14) ................... 12 QUICK RELEASE VALVES (QR-1) ....................12 SPRING BRAKE VALVE (SR-7)...................... 12 PRESSURE PROTECTION VALVE (PR-4) ..................13 LOW PRESSURE INDICATOR (LP-3) ....................
  • Page 231 Section 12: BRAKE AND AIR SYSTEM ILLUSTRATIONS FIGURE 1: 12213 ..............4 BEAM FRONT SUSPENSION AIR RESERVOIRS LOCATION FIGURE 2: 12211 .................... 5 REAR VALVE LOCATION TYPICAL FIGURE 3: FRONT SERVICE COMPARTMENT 12210 ..................5 FIGURE 4: ACCESSORY AIR FILTER 12088 ......................

  • Page 232: Air System

    Section 12: BRAKE AND AIR SYSTEM AIR SYSTEM Furthermore, the brake application or release, which is speed up by a pneumatic relay valve (R- The basic air system consists of an air 12), will start with the rear axles and will be compressor, reservoirs, valves,...

  • Page 233: Secondary Air Tank

    Maximum allowable air pressure is 125 psi (860 kPa). Air filled through these two points will pass through the standard air filtering system provided by Prevost. Do not fill system by any point on the system. The front valve is located in the front service compartment close to R.H.

  • Page 234: Accessory Air Filter

    Section 12: BRAKE AND AIR SYSTEM ACCESSORY AIR FILTER AIR GAUGES (PRIMARY, SECONDARY AND ACCESSORY) The air pressure gauges, located on the dashboard (see "Operator's Manual"), connected to the DC-4 double check valve, located on the pneumatic accessory panel in the front service compartment.

  • Page 235: Air Filter Dryer Purge Tank

    Section 12: BRAKE AND AIR SYSTEM Change cartridge every 100,000 miles (160 000 FIGURE HALDEX CONSEP CONDENSER/SEPARATOR km) or once every two years, whichever comes first. The air dryer may be purged for mainte- nance purposes using the remote drain valve MAINTENANCE located engine...

  • Page 236: Flexible Hoses

    Section 12: BRAKE AND AIR SYSTEM year, whichever comes first. Tighten or replace with a soapy solution to check for air leakage. when necessary. When replacing copper piping, leakage permitted. Leakage the parts must be free of burrs, copper cuttings, sometimes be corrected by tightening the and dirt.

  • Page 237: Pressure Setting Procedure

    Section 12: BRAKE AND AIR SYSTEM the regulating valve and wash all metal parts in a 3. Remove pressure gauge and replace dust cleaning solvent (Fig. 7). Examine cap on the air pressure check valve. diaphragm; if cracked, worn or damaged, replace with a new one.

  • Page 238: Compressor Removal And Installation

    Section 12: BRAKE AND AIR SYSTEM supplied in the applicable booklet annexed at the end of this section. Item Description Notes Air Compressor Wabco 636 O’Ring Stud (3) Flange Nut (3) Torque to 15lb-ft (20 Nm) Nipple (2) Hose Assembly 11.1 COMPRESSOR REMOVAL AND INSTALLATION...

  • Page 239: Flip-Flop Control Valve (Tw-1)

    Section 12: BRAKE AND AIR SYSTEM 2. Tighten threaded rod lock nuts. 15.1.1 Maintenance Maintenance and repair information on the E-10P dual brake application valve is supplied in the applicable booklet annexed to this section under reference number SD-03-830. FIGURE 11: RD-3 12136 14.

  • Page 240: Parking Brake Alarm Switch

    Section 12: BRAKE AND AIR SYSTEM FIGURE 17: R-14 12207 FIGURE 15: BENDIX SWITCH 12140 19. QUICK RELEASE VALVES (QR-1) 17. PARKING BRAKE ALARM SWITCH The quick release valve is located on the front Refer to the appropriate annexed booklet axle service brakes air line and permit rapid (Bendix, SL-5 Stop Light Switch;...

  • Page 241: Pressure Protection Valve (Pr-4)

    Section 12: BRAKE AND AIR SYSTEM 22. LOW PRESSURE INDICATOR (LP-3) Maintenance and repair information on the low pressure indicators is supplied in the applicable booklet annexed to this section under reference number SD-06-1600. The air system includes two low pressure switches (Fig.

  • Page 242: Emergency Bi-Fold Entrance Door Opening Valves

    Section 12: BRAKE AND AIR SYSTEM 24. EMERGENCY BI-FOLD ENTRANCE Air pressure rises above a normal setting: DOOR OPENING VALVES • Defective air gauge (registering incorrectly). Two emergency door opening three-way valves • Governor poorly adjusted or defective. are installed on the coach. One is in the front service compartment, readily accessible.

  • Page 243: Checking Disc Brake Pads

    Section 12: BRAKE AND AIR SYSTEM chambers have a 14 or 16 square inch effective removed. If any minimal tolerance limits have area for service. The Knorr-Bremse SN7000 been reached, the pads and/or disc must be brakes are supplied with automatic clearance changed.

  • Page 244: Brake Pads And Discs Minimal Tolerance Limits

    Section 12: BRAKE AND AIR SYSTEM BRAKE PAD ARE NOT PERMITTED If the thickness of the friction material at its thinnest point is less than 0.079 inch or 2 mm (measurement C), the pads must be replaced. Overall thickness of new brake pad: 1.18 in (30 mm) Back plate SN7 type: 0.354 in (9 mm) Minimal thickness of friction material:...

  • Page 245: Torque Specifications

    Section 12: BRAKE AND AIR SYSTEM If, even using a high level of hand pressure (no tools), the caliper is not moveable, the caliper guidance must be further examined. FIGURE 28: CALIPER CARRIER MOUNTING BOLTS - MERITOR DRIVE AXLE FIGURE 26: RUNNING CLEARANCE 12116 27.4 TORQUE SPECIFICATIONS...

  • Page 246: Air Brake Troubleshooting

    Section 12: BRAKE AND AIR SYSTEM the air. WARNING Material safety data sheets on this product, as required OSHA, available from Rockwell and Knorr-Bremse. Whenever possible, work on brakes in a separate area away from other operations. 29. AIR BRAKE TROUBLESHOOTING Always wear a respirator approved by NIOSH The following tests and check lists have been (National Institute of Occupational Safety and...
  • Page 247 Section 12: BRAKE AND AIR SYSTEM Pressure Build-Up / Low Pressure Warning / • If discharge valves leak, pull head and Cutoff Point Filter/Dryer Built-in correct or replace cylinder head. Governor Cutout • If drive is slipping, replace gear. CONDITION: Vehicle leveled, parking brake •...

  • Page 248: Maintenance

    Prevost Car nor Bendix Spicer Foundation Brake LLC will accept any air disc brake- related warranty returns or claims. For more information on this policy, refer to Bendix-Prevost product notification annexed at the end of Section 12 of Maintenance Manual.

  • Page 249: X3-45 Commuter Pa1593 Dob 2400-2489

    30.3 BRAKE CHAMBER REMOVAL dations must be applied: WARNING o Prevost recommends the installation of a new spring brake chamber if it is found to be defective. To prevent personal injuries, brakes should be o Spring brake chamber maintenance and/or inoperative prior to working on any of their components.

  • Page 250: Anti-Lock Braking System (Abs)

    Section 12: BRAKE AND AIR SYSTEM With this device, the vehicle is brought to a halt WARNING in the shortest possible time, while remaining stable and under the driver's control. To prevent personal injuries, brakes should be Since the braking system has dual circuits, the inoperative prior to working on any of their ABS is also provided with a secondary system components.

  • Page 251: Electronic Control Unit (Ecu)

    No specific maintenance is required for sensors, except if the sensors have to be removed for axle servicing. In such a case, sensors should 31.2.2 ABS Modulator Valve be lubricated with special grease (Prevost This ABS system is equipped with four or five #680460) before reinstallation.

  • Page 252: Spring Clip

    1. Apply recommended lubricant (Prevost #680460) to spring clip and sensor. CAUTION Use only this type of grease on the sensors. FIGURE 36: HOSE FITTINGS 12053 2.

  • Page 253: Specifications

    2 ½ additional turns. (Fig. 37). From that point, tighten using a wrench the number of turns indicated in the following NOTE chart. Use Locktite (Prevost number 680098) pipe sealant to seal pipe thread. Tubing Number of additional turns diameter...
  • Page 254 Prevost number 640136 Emergency/Parking Brake Control Valve Make ..........................Bendix Westinghouse Model ............................... PP-1 Automatic release pressure ..................60 psi (414 kPa) nominal Prevost number ........................... 641128 Dual Brake Application Valve Make ..........................Bendix Westinghouse Model ..............................E-10P Prevost number ........................... 642169 Stoplight Switches Make ..........................
  • Page 255 Type ........................... With manual drain Prevost number ........................... 641338 Front Wheel Brake Chambers Make ............................Knorr-Bremse Type ................................24 Prevost number (R.H.) ........................641414 Prevost number (L.H.) ......................... 641413 Drive Axle Brake Chambers Make ............................Knorr-Bremse Type ......................24 as service -24 as emergency Prevost number ...........................
  • Page 257 SECTION 13: WHEELS, HUBS & TIRES CONTENTS WHEELS ..............................2 WHEEL MAINTENANCE ........................2 INSPECTION ..........................2 SINGLE WHEEL REMOVAL ......................2 SINGLE WHEEL INSTALLATION ....................3 DUAL WHEELS ............................. 3 OUTER WHEEL REMOVAL ......................3 INNER WHEEL REMOVAL ......................3 INNER WHEEL INSTALLATION ....................

  • Page 258: Wheels

    Section 13: WHEELS, HUBS & TIRES 1. WHEELS 2. WHEEL MAINTENANCE The vehicle is equipped with hub-mounted Wheel maintenance consists periodic wheels as standard equipment, all studs and inspections. Check all parts for damage and nuts have right-hand threads Steel wheels are make sure that wheel nuts are tightened to the installed on the vehicle and are mounted with proper torque.

  • Page 259: Single Wheel Installation

    Section 13: WHEELS, HUBS & TIRES 2. Loosen wheel nuts about one turn (do not 3.3 INNER WHEEL INSTALLATION remove the nuts). This is not necessary if Mount the wheel over studs, being careful not to equipped with hydraulic powered gun. damage stud threads;...

  • Page 260: Wheel Straightness Test

    Section 13: WHEELS, HUBS & TIRES of the nuts in present use, a few unengaged the studs. A stud having damaged threads must be replaced. Broken studs are a direct result of threads at the outer end will cause no problem operating with loose stud nuts or improperly provided at least 5-7 full turns are required to disengage the nut depending on thread size.

  • Page 261: Hub Mounted Wheels

    Section 13: WHEELS, HUBS & TIRES NOTE NOTE Wheel studs and nuts must be kept free from Tightening should not be done immediately grease and oil. No lubricant whatsoever after prolonged braking or when wheel ends should be used. are hot. Check wheel nut torque at every 100 miles (160 6.

  • Page 262: Care Of Wheels

    Section 13: WHEELS, HUBS & TIRES  6.1 CARE OF WHEELS Apply parking brake, raise wheels off the ground and support axle on stands. Check for cracks in wheels, especially around  the fixing holes, studs, nuts and washers. If in When the wheels are raised, they should doubt, renew.

  • Page 263: Hub Bearing Removal

     Add some grease (25-50 ml) (Fuchs 931 Nm)], then the retaining clip within the unit Renolite LX PEP-2) (Prevost #685325) into is damaged and a new unit must be fitted. the bottom of the hub flange cap. Mount hub flange onto rotor.

  • Page 264: Disassembly And Repair

    Section 13: WHEELS, HUBS & TIRES Remove gaskets. Unscrew lock nut and and drive the seal into the retainer bore until remove adjusting nut lock ring. it bottoms. 3. To adjust, tighten adjusting nut until the 7. When installing wheel on spindle, center the wheel binds.

  • Page 265: Inflation Pressure

    In addition, cold tire inflation pressures are listed on the Department of Transport's certification plate, affixed on the panel behind the driver’s seat. For special tire selection, a “PREVOST COACH SPECIAL FIGURE 8: TIRE INFLATION 13009 SPECIFICATION” chart is supplied with the vehicle and is affixed on the left wall near the driver’s...

  • Page 266: Tire Matching

    Section 13: WHEELS, HUBS & TIRES 9.3 WHEEL BALANCING Before balancing, wheels must be clean and free from all foreign matter. The tires should be in good condition and properly mounted. An unbalanced wheel can be due to a bent wheel or improper mounting.
  • Page 267 Section 13: WHEELS, HUBS & TIRES 10. SPECIFICATIONS STEEL WHEELS (except inner drive axle) Wheel size ............................ 9.0" X 22.5" Wheel nut torque .................... 450 - 500 lbf-ft (610 - 680 Nm) Tire size ............................ 315/80 R 22.5 STEEL WHEELS (inner drive axle) Wheel size ..........................
  • Page 269 SECTION 14: STEERING CONTENTS STEERING SYSTEM DESCRIPTION ....................3 POWER STEERING GEAR ........................4 DESCRIPTION ..........................4 POWER STEERING GEAR REMOVAL ..................4 POWER STEERING GEAR INSTALLATION ................. 5 TROUBLESHOOTING........................5 BLEEDING POWER STEERING HYDRAULIC SYSTEM ..............5 HYDRAULIC PRESSURE TEST ......................5 POWER STEERING HYDRAULIC PUMP ....................
  • Page 270 Section 14: STEERING TORQUE SPECIFICATIONS ......................16 SPECIFICATIONS ........................... 16 ILLUSTRATIONS ..................... 3 FIGURE BEAM AXLE STEERING SYSTEM SETUP ........................4 FIGURE POWER STEERING GEAR ......................4 FIGURE FRONT SERVICE COMPARTMENT ........................5 FIGURE FUEL PUMP REMOVAL ........................6 FIGURE FUEL PUMP DRIVE AXLE ....................
  • Page 271 Section 14: STEERING STEERING SYSTEM DESCRIPTION These elements are: 1. Steering stabilizer (damper); The steering system consists of the steering 2. A vane type hydraulic pump; and wheel and column assembly, a vane-type 3. Hydraulic reservoir and hoses. hydraulic pump, reservoir, filter, interconnecting system lines and hoses, integral power steering The steering stabilizer reduces road shocks and gear, linkage and steering damper (Fig.
  • Page 272 Section 14: STEERING POWER STEERING GEAR FIGURE 3: FRONT SERVICE COMPARTMENT 18611 A torsion bar, which is pinned with the valve slide and the worm, keeps the control valve in the neutral position as long as no opposing force is FIGURE 2: POWER STEERING GEAR 14035 applied to the steering wheel.
  • Page 273 Section 14: STEERING The power steering pump is a gear driven The steering gearbox weighs approximately 100 hydraulic unit which supplies hydraulic pressure lbs (45 kg) dry. Exercise caution when handling. for the operation of the steering gear. The pump is mounted on the engine, at the flywheel end and is 1.
  • Page 274 Section 14: STEERING • Install the fuel pump. Torque-tighten bolts to specification. NOTE Use a new sealing ring. Check that the fuel pump drive axle sits correctly in the power steering pump. • Start the engine and let run for 5 minutes. Make sure that there are no leaks.
  • Page 275 Section 14: STEERING U-joint is easily accessible through the front 3. Disconnect the horn wire (white) connected to service compartment. The upper steering column the horn pad and the steering wheel harness U-joint and the steering slip joint are accessible 4-pin connector.
  • Page 276 Section 14: STEERING FIGURE 11: LOCKING THE CLOCKSPRING IN PLACE FIGURE 12: CLOCKSPRING INSTALLATION NOTE 4. Mount the clockspring in place with 2 screws. The clockspring mechanism permits a certain number of turns in each direction. At the 5. Break the paper seal and rotate the center moment of reinstalling the steering wheel, if part of the clockspring about 50°...
  • Page 277 Section 14: STEERING 2. Disconnect drag link from pitman arm, using with the adjustment of turning angles, make jaw style pullers (pressure screw type). sure its fixing bracket is at correct location on the axle (refer to "12.2 Steering Stabilizer Cylinder (Damper)).

  • Page 278: Specifications

    1. Position pitman arm on sector gear shaft with 4. When adjustment is achieved, replace fixing reference marks aligned. nut and torque to 470-570 lbf-ft (637-773Nm). 2. Install fixing nut (Prevost #661050). Tighten nut to 470-570 lbf-ft (637-773 Nm). 10.4 TAG AXLE...
  • Page 279 Section 14: STEERING use "Dexron-IIE or Dexron-III" automatic power steering fluid reservoir. transmission oil. If the steering linkage between the steering gear 5. Reinsert and tighten the dipstick. and the two front wheels is not properly adjusted, or if it is bent, twisted or worn, the steering of the 6.
  • Page 280 Section 14: STEERING FIGURE 19: STEERING STABILIZER (DAMPER) 14042 11.3 DRAG LINK Visually inspect drag link components for broken clamps, loose nuts and gauges on tube from rubbing parts. MAINTENANCE FIGURE 18: POWER STEERING FLUID RESERVOIR 14018 Drag link ends (ball joint) are provided with grease fittings for pressure lubrication.
  • Page 281 Section 14: STEERING 11.4 TIE ROD Degrease the ball pin surface and inspect carefully. 3. If there is corrosion of the ball pin or the sealing boot has deteriorated through ageing or is damaged, replace the ball joint. 4. If there is corrosion of the steering arm or tie rod arm area which is in contact with the sealing boot or dirt seal, clean and eliminate all surface irregularities.
  • Page 282 Section 14: STEERING 2. Thoroughly grease rubbing pad and ball pin with Shell Retinax LX or equivalent. 3. Insert ball pin into body. 4. Insert thrust cap, compression spring and adjuster piece into body. 5. Tighten adjuster piece fully home (SOLID) locating thrust cup onto ball pin.
  • Page 283 Section 14: STEERING 17. Re-charge ball socket with Shell “Retinax torque by applying a constant load on the LX” or equivalent grease through grease bearing and stud. fitting. As wear occurs on the components, the spring creates less resistive torque. With less torque, you no longer have the precise joint needed for 11.7 STRAIGHT BODY TYPE BALL JOINT optimum steering, but you do still have a safe...
  • Page 284 Section 14: STEERING hydraulic system work at the relief pressure, and consequently, cause the hydraulic fluid to become overheated. CAUTION Never maintain the hydraulic system at the relief pressure for longer than 5/10 seconds to avoid damaging the power steering pump. NOTE Unequal or low tire pressure, oversize tires, and vehicle overloading are some of the causes that...
  • Page 285 Section 14: STEERING 13. TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear out 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly or have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.
  • Page 286 Make ............................... Nelson Muffler Oil capacity ..........................4 US qts (3.7 liters) Prevost number ............................660982 Make ............................... Nelson Muffler Element filter - Prevost number ........................660987 Magnetic Drain Plug ........................... 667586 Steering Stabilizer Cylinder (Damper) Make ................................Arvin Extended length ..........................32.73±0.12"...
  • Page 287 SECTION 16: SUSPENSION CONTENTS Description ............................3 I-Beam Axle Front Suspension ......................3 ............................ 3 PRINGS 2.1.1 Inspection ..........................3 2.1.2 Removal ..........................4 2.1.3 Installation ..........................4 .......................... 4 HOCK BSORBERS 2.2.1 Inspection ..........................5 2.2.2 Removal ..........................5 2.2.3 Installation ..........................
  • Page 288 Section 16: SUSPENSION Front Kneeling System ........................25 ......................25 RINCIPLE PERATION ..........................26 AINTENANCE ................... 26 ELLOWS ONTROL OLENOID ALVES 7.3.1 Removal And Installation ....................... 26 Troubleshooting ..........................26 Parts Specifications .......................... 27 ILLUSTRATIONS ................. IGURE FRONT SUSPENSION COMPONENTS .......................

  • Page 289: Description

    Section 16: SUSPENSION DESCRIPTION The vehicle is provided with an air suspension system. The system consists of air springs, height control valves, radius rods, sway bars, tripod and shock absorbers. The system operation is fully automatic and maintains a constant vehicle height regardless of load, or load distribution. The vehicle is also equipped with this system: ...

  • Page 290: Removal

    Section 16: SUSPENSION supports. Thread the lower nuts and the WARNING small upper nut a few turns. NOTE To prevent personal injury, do not apply more than 10 psi (69 kPa) of air pressure to the To facilitate air spring installation, compress it uninstalled air spring.

  • Page 291: Inspection

    Section 16: SUSPENSION 5. Extend and collapse shock several times to absorber replacement occurs. If a shock determine that it has control (resistance) in absorber becomes inoperative, complete unit both rebound and compression. must be replaced. 6. Visually inspect the shock mountings and CAUTION vehicle mounting for: Broken mounts;...

  • Page 292: Installation

    Section 16: SUSPENSION 2.2.3 Installation 1. Ensure that the shock absorber mounting pins are tight and that the threads are not stripped. 2. Install new rubber mounting bushings on shock absorbers (upper and lower). 3. Place the inner washer (with washer convex side leaning on the shock absorber rubber bushing).

  • Page 293: Bushing Installation

    Section 16: SUSPENSION FIGURE 8: RADIUS ROD BUSHING INSTALLATION 16012 FIGURE 7: RADIUS ROD BUSHING REMOVAL 16011 2.3.5 Radius Rod Installation 2. Place a flat steel disc, slightly smaller than the outside diameter of the bushing (Fig. 7). 1. Lightly spray the radius rod support with water.

  • Page 294: Sway Bar

    Section 16: SUSPENSION CAUTION It is extremely important upon reconnection of the rods that the proper clearance height between the axle and body be maintained. Otherwise, the rubber bushings in radius rod ends will become preloaded, thus reducing their life span. SWAY BAR A sway bar is provided on the front axle to increase vehicle stability.

  • Page 295: Torque Specifications

    SECTION 16: SUSPENSION TORQUE SPECIFICATIONS PA1593...
  • Page 296 Section 16: SUSPENSION PA1593...
  • Page 297 Section 16: SUSPENSION PA1593...
  • Page 298 Section 16: SUSPENSION The following table lists the tightening torque for fasteners requiring a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE 1 – FRONT AXLE SUSPENSION & STEERING DESCRIPTION QTY REFERENCE TORQUE DRY ( lbf-ft / Nm...

  • Page 299: Rear Suspension

    Section 16: SUSPENSION REAR SUSPENSION For a description of all these systems, refer to the appropriate heading in this section. FIGURE 11: REAR SUSPENSION COMPONENTS 16167 FIGURE 12: SWAY BAR (REAR SUSPENSION) 16144 PA1593...

  • Page 300: Air Springs

    Section 16: SUSPENSION The air springs are made from a special compound rubber molded to the proper contour and dimensions. The entire vertical load of the vehicle is supported by these springs. Each of the two axles is provided with air springs that are attached to the subframe and to the axles (Fig.

  • Page 301: Installation

    Section 16: SUSPENSION a) Jack vehicle until the tire clears the Install elbow (if applicable), then connect air ground, place safety supports line. underneath body. Connect the height control valve link. Build up air pressure in system. CAUTION NOTE Only the recommended jacking points must be To accelerate this operation, air reservoirs can used as outlined in Section 18, “Body”.

  • Page 302: Inspection

    Section 16: SUSPENSION 3.2.1 Inspection 3.2.2 Removal Loosen lower mounting of both shocks, and then 1. Remove nuts and washers from shock carefully attempt to raise and lower the bottom absorbers on upper and lower mounting portion of each shock. Note the rate of effort for pins, taking care to identify the inner and distance of travel.

  • Page 303: Radius Rods

    Section 16: SUSPENSION damaged part should be replaced with a new one. NOTE New bushings should be used when rods are replaced. 3. The radius rod bushings should be checked periodically signs shearing, deterioration, or damage. Any defective part should be replaced with a new one. FIGURE 17: TYPICAL SHOCK ABSORBER SETUP 16009 5.

  • Page 304: Tag Axle Suspension

    Section 16: SUSPENSION Bushing installation 1. Lightly spray the inner and outer surfaces of radius rod bushing with water. CAUTION No lubricant whatsoever is to be used on the rubber bushing. 2. Safely support the radius rod, and place new bushing on top of the radius rod end (Fig.
  • Page 305 Execute assembly of the new joint parts in the following sequence: 1. Complete moistening of the contact surface between housing bore and ball pin through application of the grease. NOTE Apply grease, only in the case of repair kit (Prevost # 611114)). PA1593...

  • Page 306: Torque Specifications

    Section 16: SUSPENSION TORQUE SPECIFICATIONS The following table lists the tightening torque for fasteners requiring a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE 2 –...

  • Page 307: Suspension Height Adjustment

    Section 16: SUSPENSION normal operating pressure and raise the vehicle to the specified height. SUSPENSION HEIGHT ADJUSTMENT The flow of pressurized air from the accessory CAUTION air tank to the air springs is controlled by three height control valves. The two rear valves are Always adjust on "fill cycle".

  • Page 308: Height Control Valve

    Section 16: SUSPENSION When the desired height is obtained, tighten load distribution. Each valve adjusts clamp. independently according following conditions: Rear air spring clearance Loading Position 1. With the vehicle at normal operating air pressure [100 - 125 psi (689 - 860 kPa)], As the load increases and lowers the vehicle measure spring...

  • Page 309: Air System

    Section 16: SUSPENSION Reverse removal procedure to replace height 6.1.3 Secondary Air Tank control valve. After installation, check for This tank is located in front wheelhousing, leakage using a soap and water solution. between air springs. The tank is provided with a bottom drain valve (Fig.

  • Page 310: Accessory Air Tank

    Section 16: SUSPENSION 6.1.4 Accessory Air Tank The accessory air tank is installed next to the secondary air tank. The tank is provided with a bottom drain valve (Fig. 27). It is recommended to purge the tank by its bottom drain valve, every 12,500 miles (20 000 km) or once a year, whichever comes first.

  • Page 311: Emergency Fill Valves

    R.H. through the standard air filtering system side door (Fig. 28). provided by Prevost. Do not fill air through any other points. FRONT KNEELING SYSTEM The kneeling system is used to lower the front of vehicle.
  • Page 312 Section 16: SUSPENSION MAINTENANCE BELLOWS CONTROL SOLENOID Since the kneeling action is issued from both the VALVES air system and electrical system, refer to Section: 12, “Brake and Air System” and Section 7.3.1 Removal and installation 06, “Electrical System”. 1. On the rear side of steering compartment, For diagnosis and understanding of the system, locate both the bellows control and bellows refer to wiring diagrams, and to the appropriate...
  • Page 313 Section 16: SUSPENSION PARTS SPECIFICATIONS Type ............. N/O Prevost number ........641356 I-Beam Front Axle and tag axle air springs Radius rod bushing Type ........... Mae West Make ............Prevost Nominal diameter ......12” (304 mm) Prevost number ........630021 Prevost number ........630125...
  • Page 315 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR ..........................4 VEHICLE STRUCTURE ........................5 VEHICLE EXTERIOR MAINTENANCE ....................5 ......................... 5 ORROSION REVENTION ..................... 6 REVENTIVE AINTENANCE CHEDULE ......................6 NHIBITOR PPLICATION COMMON FIBERGLASS REPAIR PROCEDURE ................11 ....................11 EPAIR SING IBERGLASS LOTH ....................
  • Page 316 Section 18: BODY 7 ............................42 6.7.1 X3 Smooth Side Panel Replacement Procedure ..............43 6.7.2 Side Crest ..........................49 ....................50 ANEL INDOW PACING ........................51 ASSENGER EATS 6.9.1 Rotating Seats ........................51 6.9.2 Removing Fixed Seats ......................51 6.9.3 Upholstery Maintenance .......................
  • Page 317 Section 18: BODY 3 ............................32 IGURE ZONE ....................33 IGURE ENGINE COMPARTMENT DOORS ..........................33 IGURE REAR BUMPER 4 ............................33 IGURE ZONE ..................34 IGURE ENGINE COMPARTMENT R IDE DOOR .......................... 34 IGURE RADIATOR DOOR 5 ............................35 IGURE ZONE ........................

  • Page 318: Vehicle Exterior

    Section 18: BODY VEHICLE EXTERIOR FIGURE 1: X3 COACHES EXTERIOR VIEW 18606 Engine air intake 13. Engine compartment rear doors 2. Engine compartment curb-side door 14. Rear-view mirrors 3. Hinged rear fender 15. Transmission retarder OFF indicator light 4. Fuel filler door 16.

  • Page 319: Vehicle Structure

    Section 18: BODY VEHICLE STRUCTURE underside of the vehicle is sprayed with a heavy application of asphalt base undercoating. The body of the X3-45 coaches is an integral structure made of 14, 16 and 18 gauge welded The operating environment the vehicle is and braced high tensile steel and stainless steel subjected to will largely influence the amount of dirt and corrosion that will accumulate over a...

  • Page 320: Corrosion

    Section 18: BODY PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor has been applied on your vehicle underbody, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section. INTERVALS DESCRIPTION MAINTENANCE CORRECTIVE REFERENCE MONTHS ACTION MILES...
  • Page 321 Section 18: BODY 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be hot masking. to reduce washing time especially during winter. If parts are soiled with oil, clean using R1KG21. Avoid rubber parts. 2.0 Dry all water sprayed parts. Surface temperature and Air pressure system may be used, refer to annex 1 for dew point must be respected before applying rust surface temperature and dew point.
  • Page 322 Section 18: BODY 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) 4.1 Rear wheelhousing (Entire braking system) PA1593...

  • Page 323: Application

    Section 18: BODY 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used. 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts.
  • Page 324 Section 18: BODY DEW POINT Relative Humidity (%) 20 30 40 50 60 70 80 90 100 Temp (c) -16 -11 -8 -5 -3 -1 0 -15 -10 -7 -5 -3 -1 1 -14 -10 -6 -4 -1 0 -13 -9 -5 -3 -1 1 -13 -8 -5 -2 0 -11 -7 -4 -1 1 -11 -8 -3 0...

  • Page 325: Common Fiberglass Repair Procedure

    Section 18: BODY COMMON FIBERGLASS REPAIR NOTE PROCEDURE Roughening the surface improves adhesion of All repairs to fiberglass parts consist of filling the resin. damaged area with fiberglass cloth and resin or If part is warped from original shape, use strand fiberglass and resin.

  • Page 326: Procedure

    Section 18: BODY Preheat the area to be repaired using heat lamps. Mix desired quantities of resin and hardener according manufacturer's instructions. Add powdered fiberglass strand into mixture to thicken it into a putty state. NOTE If repair is made on a vertical surface, adding powdered filler material to mixture will reduce tendency of hot resin to flow or run.

  • Page 327: Common Painting Procedure

    Section 18: BODY During the first 30 days:  Do not use a commercial bus wash. Stiff brushes or sponges could mar the finish and damage the surface. Wash the vehicle by hand only and with cool water and a very mild bus wash solution.

  • Page 328: Painting

    Section 18: BODY If you sand through to metal surface, first prime 5.3.1 Safety with Standox “Etch Primer (ST-11858)” then with Care should be exercised in storing, handling, Standox “Non Stop Fill Primer (ST-11000)”. mixing, and applying paint and chemicals listed in this manual.

  • Page 329: X3-45 Coaches Exterior Finishing And Body Repair

    Section 18: BODY X3-45 COACHES EXTERIOR FINISHING AND BODY REPAIR The following procedures explain the steps to be followed for proper repair, installation and replacement for various doors, panels and windows. The paragraph divides the vehicle into zones to facilitate the search;...

  • Page 330: Headlights

    Section 18: BODY remove the two bolts on each bumper side to 6.1.2 Headlights separate the bumper from the compartment Refer to Paragraph Headlights, included in door. To install bumper, reverse the removal Section 06: Electrical of the Maintenance procedure. Manual for complete information on headlights.

  • Page 331: Rear View Mirrors (Rosco)

    Section 18: BODY NOTE Position the ball cup halves so the joint between them lies on the centerline of the arm. Ensure that the setscrews are not on the joint between the cup halves.  Replacement of Mirror Glass Remove the broken glass. Position new glass in mirror head and press to lock the Velcro in place.

  • Page 332: Windshield Wipers

    Section 18: BODY 6.1.4 Windshield Wipers  Spray rubber seal with soapy water to ease windshield insertion. Refer to Paragraph 3 WINDSHIELD WIPERS  Insert rope into rubber extrusion leaving AND WASHERS, included in Section 23: enough length at each corner to make a Accessories of the Maintenance Manual for loop.
  • Page 333 Section 18: BODY  Spray filler and rubber seal groove generously with soapy water.  Using the special filler insertion tool, insert the filler into the rubber seal groove.  Gradually insert filler into the rubber seal groove ensuring to leave a 2 inch excess length at the filler extremity.
  • Page 334 Section 18: BODY To open the door, initial action from multiplex Close by pressing and holding the door closing module output de-energizes the air lock solenoid switch (R.H. button) on the dashboard. If the valve, venting the door locking cylinders. The closing switch is released before the door is fully return locking spring pulls the door lock away closed, the door will stop in that position.
  • Page 335 Section 18: BODY FIGURE 22: INTERIOR UNLATCH AIR VALVE 18330 Without Air and/or Without Electricity If the air pressure drops while the coach has or hasn’t any electricity, the spring loaded cylinders will unlatch the door. In such a case, unlock the door by moving the lever on the door or by using the key, then open the door manually.
  • Page 336 Section 18: BODY 6. Reinstall panels and R.H. entrance door NOTE panel hinge cover. In figure 23, if there is an indentation (B) in the dust cap (C) and the cover shows two holes  Entrance Door Panel Adjustments (A), the damper is fitted with a bump rubber (D).
  • Page 337 Section 18: BODY o Depth adjustment 5. Pull and fasten the rod end to the hinge with the washer and the button screw. 1. Support the door panel with a wooden block and a hydraulic jack. 6. Screw the plastic moldings covering the hinges.
  • Page 338 Section 18: BODY 5. Peel of protective paper from the seal.  Apply some Sika 206 G+P onto door Position the seal flush with the top, sides frame. and lower edges of the door. 6. Progress slowly all around the door. 7.
  • Page 339 Section 18: BODY  From the inside of the door, apply some Sika 221 between door body panel and frame and on welding spots as per figure.  Position body panel onto door frame and compress with your hands. Use a ruler. ...
  • Page 340 Section 18: BODY  Insert window into frame.  Secure window pane raising mechanism.  Adjust window travel (6±3mm above window wiper).  Discard waste according to applicable environmental regulations, use dangerous waste containers. Electrical Power Window  Insert 2 seals in the window frame. ...

  • Page 341: Front Cap

    Section 18: BODY  Install 3 clamps and allow curing for 4 hours. 6.1.8 Front Cap The fiberglass front cap does not need any maintenance except painting as needed. It is held in place with adhesive. If ever it has to be replaced, make an appointment at a Prévost service center near you.
  • Page 342 Section 18: BODY ZONE 2 FIGURE 27: ZONE 2 18625 Hammer or; 6.2.1 Lateral Fixed Window Drill equipped with a sharp pointed rod into Nine passenger side windows are provided on which a small hole was drilled; each side on X3-45. They are made of fixed, single or double-glazed, heat absorbing AS-3 Braided windshield wire and a pair of handles;...
  • Page 343 Section 18: BODY Method B Installation of Window  Using a drill equipped with the special  Use window cleaner around window sharp pointed rod, drill through the window interior perimeter and edges to remove seal into one of the bottom corners, from a any oily film while inspecting for damages.
  • Page 344 Section 18: BODY  Emergency Exit Window Adjustment Emergency exit windows should be checked periodically for easy opening and closing. Pulling the lower part of the release bar with both hands placed near the safety latches should disengage both locks on the window simultaneously.
  • Page 345 Section 18: BODY CAUTION CAUTION Use of lubricants, paints, or other coatings Hinge assembly is critical and hinge should such as graffiti deterring sprays is not never be removed from cover assembly. recommended. Fasteners used in this assembly are special and have critical torque requirements and Suggested maintenance...

  • Page 346: Rear Cap

    Section 18: BODY  Escape Hatch Frame CAUTION When necessary, the escape hatch frame can be removed and replaced in the following way: When installing, roof escape hatch’s hinge must be toward the front of vehicle, to prevent 1. Support the frame from inside the vehicle. the hatch from being ripped out if accidentally 2.

  • Page 347: Rear Bumper

    Section 18: BODY 3. Adjust the doors position depending on the 6.3.3 Rear Bumper gap needed between exterior finishing Remove three bolts on each side holding panels. bumper to vehicle and remove bumper. 4. Tighten the bolts. To install bumper, reverse the procedure. 5.

  • Page 348: Rear Fender

    Section 18: BODY 6.4.1 Rear Fender adjust the door latch to get proper fit and operation. On the "X3" series vehicle, rear fenders are To adjust the latch mechanism (3, Fig. 35) and hinged maintenance brakes the striker pin: suspension. Each rear fender panel has two mechanical spring loaded holding devices fixing 1.
  • Page 349 Section 18: BODY 5. Check that the door swings freely and 1. Open the door to access the striker pin. closes properly. It may be necessary to 2. Slightly loosen the striker pin. adjust the door latch to get proper fit and operation.
  • Page 350 Section 18: BODY  Clean door frame again using anti-  Prepare door frame using a scratch pad silicone. “Scotch Brite”.  Apply some Sika 206 G+P onto door  Clean door frame again using anti- frame. silicone.  Clean door lower panel using anti-silicone. ...
  • Page 351 Section 18: BODY  Open baggage compartment door and  Center door in the opening using the side adjust height using the catch plates. plate shims.  Tighten cylinder blocks fixing screws. NOTE 6.5.2 Baggage Compartment Floor Adjustment is made using shims on the side plates.
  • Page 352 Section 18: BODY Remove masking tape and protection around damaged area. Spray pure water onto Sika. Use a floor sample to create some texture onto the adhesive. If possible spray some more water onto the Rear baggage compartment without WCL. adhesive to accelerate curing.
  • Page 353 Section 18: BODY Using a triangular nozzle, apply “Simson” glue (685126) onto support structure. Carefully install panel onto support structure. Evenly distribute and install conforming weights (6 to 8) (80 to 100 lbs total) onto panel for at least 4 hours. Make sure panel does not move. Finishing Joints In the case of lateral finishing joint, apply some masking tape ¼“...
  • Page 354 Section 18: BODY Apply some Simson glue to fill the gap. Rear baggage compartment without WCL. Front finishing joint Section 2 Flat joint in front of fuel tank access panel Remove masking tape. Smooth down joints using soapy water. 6.5.3 Evaporator Compartment Door Use plastic spatula #682838 to perform radius 1.
  • Page 355 Section 18: BODY 5. Respect the required gap between exterior finishing panels. 6. Check that the door swings freely and closes properly. It may be necessary to adjust the door latch to get proper fit and operation. FIGURE 40: CONDENSER DOOR 18638 FIGURE 39: EVAPORATOR DOOR 18637...

  • Page 356: Front Fender

    Section 18: BODY ZONE 6 FIGURE 42: ZONE 6 18629 6.6.1 Front Fender Front fender may be removed using the following procedure: Remove the nuts on the inside of the fender. Remove the fender from the vehicle. To reinstall, reverse the procedure.
  • Page 357 Section 18: BODY 6.7.1 X3 Smooth Side Panel Replacement Procedure Material: Anti-silicone (682989)  Scotchbrite gray (680226)  Sika 221 gray  CHIX cloth (682384)  Sika 205 1liter (683097)  Sika 252 black  Blue cloth (682383)  Equipment: Glue gun ...
  • Page 358 Section 18: BODY SECTION 2 PREPARATION OF SURFACES 2.00 VEHICLE SURFACE PREPARATION Clean using "anti-silicone" until all clothes come clean. See PR000001 section A. Use the belt sander (grit coarse) Use a new paper on each vehicle side. Clean using "anti-silicone" until all clothes come clean.
  • Page 359 Section 18: BODY Section B Sika 205 Apply CHIX cloth Allow drying Mandatory For a smooth surface (aluminum, stainless, 2 minutes Minimum steel, fiber glass (gelcoat side), etc.) time - Pour a porous surface (fiber glass (non 10 minutes gelcoat side), etc.) After 2 hours : Reactivate surface with Sika 205 If surface seems dusty, greasy or with finger marks, start Before applying any...
  • Page 360 Section 18: BODY 3.05 Install 1/8 X ½” foam tape onto middle reinforcement then compress. 3.10 Apply Sika 252 Section A-A Section B-B Section C-C – Onto vehicle surface – Cut nozzle as per template – Use the guide for the application Bead must be continuous for the whole perimeter.
  • Page 361 Section 18: BODY 3.20 Install pulling equipment at the other end of side panel Make a final adjustment in height Sand front of side panel 2" wide Make sure the equipment pulls along the Pull side panel so that panel moves 1/8” whole width of side panel Perform tig spot welding Quantity of "tig spot": 30 minimum.
  • Page 362 Section 18: BODY Wear surgical gloves and smooth down the joint with your finger. SECTION 4 ENGINE AIR INTAKE PANEL INSTALLATION 4.00 Make sure that sealing of structure has been performed properly 4.05 Prepare vehicle surface as for side panel. Refer to step # 2.00 Refer to step # 2.05 4.10...
  • Page 363 Section 18: BODY 5.00 * Finition Joint Install a protective tape onto the tubing above welding Apply Sika 205 Use a plastic spatula inside a Chix cloth to ensure that Sika 205 reaches as far as the corner. See PR000001 section B. Apply Sika 252 black at the junction of both tubing.
  • Page 364 Section 18: BODY BODY PANEL AND WINDOW SPACING FIGURE 45: BODY PANEL AND WINDOW SPACING (TYPICAL) 18631 PA1593...
  • Page 365 Section 18: BODY PASSENGER SEATS NOTE X3 coaches are equipped with Torino G 4ONE Bottom end of rod is coated with Locktite and seat models: threaded in a steel block which slides in the floor track. Removal of rod is possible if Each pair of seats is built on a welded steel loosened from block.
  • Page 366 Section 18: BODY fabric. Seat fabric is made of 50% wool, 33% CAUTION cotton, 9% nylon, and 8% acrylic. Oil in the air line will soil the fabric. Blow the  Routine Cleaning line clear and test air discharge against a plain white piece of paper.
  • Page 367 Section 18: BODY 6.10 TARABUS FLOOR COVERING REPAIR OR REPLACEMENT On X3-45 coaches equipped with “Gerflor Natura Cedar 8813” covering, it is possible to replace or repair this covering. The purpose of this paragraph is to explain the steps to be followed to ensure the best results and adherence.
  • Page 368 Section 18: BODY FIGURE 48: TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 49: APPLICATION OF SIKA 221 GRAY 18641 PA1593...
  • Page 369 Section 18: BODY 6.10.1 Front Steps Replacement Procedure MATERIAL Part No Description 682989 Anti-silicone 683097 Sika 205 (1 liter) 685101 Sika Remover 208 683916 Sika 215 (1 liter) 1. Cut and remove damaged step(s). 2. Remove dirt and adhesive residue. NOTE In wintertime, condensation and cold temperature may greatly influence bonding parameters.
  • Page 370 Section 18: BODY Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer 3. Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) Before applying any other If surface seems dusty, dust using damp cloth.
  • Page 371 Section 18: BODY 3. Apply some Sika 252 onto the step; make sure to cover the whole surface of the step. Use a serrated spreader with 1/8-inch serration to spread Sika. 4. Apply a bead of Sika 221 onto the perimeter of the step. 5.
  • Page 372 Section 18: BODY 6.10.2 Welding Of Joint Between White Safety Strip And “Tarabus” Floor Covering 1. Pre-heat welding torch; Set welding torch to position #4.5 (temperature of 500 °C), Heating time: 5 minutes. 2. Before welding, visually ensure that a 1 to 1.5 mm gap exists between white safety strip and “Tarabus”...
  • Page 373 Section 18: BODY 4. Use chamfer knife. Be careful not to overcut or to cut to the side to prevent damaging “Tarabus” covering. 5. Add (about 6 inches) some length to the required length of filler bead to make the joint then cut. 6.
  • Page 374 Section 18: BODY 9. Allow cooling down of filler bead (about 5 minutes). 10. Shave filler bead to make it level to the floor. Use supplied knife designed for that purpose. NOTE To facilitate the cut, you can spray some soapy water onto the joint. CAUTION The procedure for turning the torch off must absolutely be followed.
  • Page 375 Section 18: BODY 6.10.3 Repair Of A Welded Joint NOTE In wintertime, condensation and cold temperature may greatly influenced bonding parameters. Working area must be at a temperature sufficient to prevent reaching condensation point. Mechanically preheat working area (heat lamp or heat gun) or wait until vehicle reaches room temperature. 1.
  • Page 376 Section 18: BODY Ten jacking points are located on the vehicle: WARNING two are located on each side of the frame and two are located under each axle. Refer to the The jacking points on the tag axle must be following illustrations for the location of jacking used for raising the tag axle only.
  • Page 377 Section 18: BODY FIGURE 55: TOW EYES UNDER VEHICLE 18401  Disconnect driveshaft or remove both drive axle shafts to prevent damage to the trans-  Raise the front of the coach then install mission. Plug axle tube to prevent oil loss. wooden blocks underneath front tires.
  • Page 378 Section 18: BODY  Flip down the access door located in the front bumper, connect an auxiliary air supply to the two quick connectors so the emergency/ parking brakes don’t apply while towing. FIGURE 57: FRONT TOWING AIR SUPPLY CONNECTORS TOWING WITH A FRONT FLAT TIRE ...
  • Page 379 Section 18: BODY CAUTION To prevent damage to the vehicle structure, it is not recommended to tow the vehicle from the rear. In case of damage to the drive train components, use a low bed semi-trailer to support the rear end. DANGER Do not carry passengers while the coach is being towed.
  • Page 381 PR20103-05 For internal use only BI-FOLD DOOR HINGE ARM PIVOTS PRE-ADJUSTMENT Service issue: Feb. 20, 2012 Effective: REVISION 05 This revision: step 30 & 40, new stud part number 2012-06-18 L.H. SIDE DOOR PANEL HINGE ARM PIVOT Pivot p/n 281162 (qty 1) Stop p/n 281296 (qty 1) Machine screw...
  • Page 382 PROCEDURE NO: PR20103-05 REVISION 05 L.H. SIDE DOOR PANEL HINGE ARM PIVOT Stud p/n 281252 (qty 2) Jam nut p/n 5001806 (qty 2) ½ -20X5/16 left-hand threads Jam nut p/n 5001798 (qty 2) ½ -20X5/16 Pivot Rod end p/n 502196 (qty 2) Tighten jam nuts lock ends.
  • Page 383 PR20103-13 For internal use only BI-FOLD DOOR POSITION SENSOR Service issue: Feb. 10, 2012 Effective: REVISION 01 Revision 01 : step 10, part number changed for 068358 2011-06-23 AIR PRESSURE RELEASE Prior to perform the following procedure, release the air pressure from the bi-fold door air cylinders and latch cylinders.
  • Page 384 PROCEDURE NO: PR20103-13 REVISION 00 Procedure applicable to : COMMUTER COACH SENSOR GAP ADJUSTMENT To gain access to the sensor probe, remove the R.H. side hinge cover (item 4) Sensor 068358 (qty 1) Place sensor probe at Toothed washer & clamping nut 0.059"...
  • Page 385 PR20103-14 For internal use only BI-FOLD ENTRANCE DOOR HINGE ARM PIVOTS INSTALLATION Service issue: Feb. 10, 2012 Effective: C-5176 REVISION 02 Revision 02: torque was 27 lbf-ft, changed for 22 lbf-ft, step 16 and 26 2011-09-29 Procedure applicable to: COMMUTER COACH R.H.
  • Page 386 PROCEDURE NO: PR20103-14 REVISION 02 L.H. SIDE HINGE ARM PIVOT L.H. side hinge arm pivot Upper support Bolt p/n 5001780 cap screw hex M8-1.25X16 grade 8.8 Torque as per bolt type and grade: 16 lbf-ft (qty 3) Bearing Unscrew/tighten p/n 5001780 bearing bolts (green on (qty 2) the image)
  • Page 387 PR20103-18 For internal use only BI-FOLD DOOR BALANCE ARM AND LINK ARM LENGTH PRE-ADJUSTMENT Effective: REVISION 01 Service issue: Feb. 10, 2012 Revision 01: Step 11 & 21, part number 500860 changed for 5001757 2011-11-23 Procedure applicable to: COMMUTER COACH BALANCE ARM 2 balance arms per coach p/n 281155 (qty 1)
  • Page 389 PR20103-20 For internal use only BI-FOLD DOOR HINGE AIR CYLINDERS AND DAMPER REPLACEMENT Service issue: Feb. 10, 2012 Effective: REVISION 00 2011-06-22 AIR PRESSURE RELEASE Prior to perform the following procedure, release the air pressure from the bi-fold door air cylinders and latch cylinders.
  • Page 390 PROCEDURE NO: PR20103-20 REVISION 00 Remove the R.H. side dashboard access panels (items 2, 3) and hinge cover (item 4) R.H. SIDE DOOR HINGE CYLINDER REMOVAL / INSTALLATION Cylinder Detach bridge p/n 502180 (qty 1) (fixed eye end, left side of cylinder on the image) Unscrew bolt at the p/n 5001615 (qty 1 )
  • Page 391 PROCEDURE NO: PR20103-20 REVISION 00 DO NOT Damper Install damper as shown with label facing downwards Item B= washer p/n 500445 (qty 1) Item C= spring nut p/n 502601 (qty 2) TO PRESSURIZE A DAMPER THAT HAS LOST PRESSURIZATION Place damper vertically as shown and extend rod at maximum stroke.
  • Page 392 PROCEDURE NO: PR20103-20 REVISION 00 L.H. SIDE DOOR HINGE CYLINDER REMOVAL / INSTALLATION Cylinder Detach bridge pin p/n 502180 (qty 1) (fixed eye end, right side of cylinder on the image) Unscrew bolt at the p/n 5001615 (qty 1 ) piston rod end cap screw, button hex socket head M12-1.75X30...
  • Page 393 PR20103-22 For internal use only BI-FOLD ENTRANCE DOOR INSTALLATION AND ADJUSTMENT Service issue: Feb. 10, 2012 Effective : REVISION 04 Revision 04: Addition of step 81. 2012-01-09 AIR PRESSURE RELEASE Prior to perform the following procedure, release the air pressure from the bi-fold door air cylinders and latch cylinders.
  • Page 394 PROCEDURE NO: PR20103-22 REVISION 04 L.H. SIDE DOOR PANEL INSTALLATION L.H. Side Panel 1) Lean L.H. door panel against the 3 jigs (spacers). Top, bottom underneath 2) Adjust the door panel position in order to have approximately ⁄ " mm) between seal jamb and exterior surface (painted) of the door panel...
  • Page 395 PROCEDURE NO: PR20103-22 REVISION 04 FIXING LOWER END OF DOOR PANEL Pivot hinge arm until rod end ball joint bolt A lines up with the attachment bracket nut. Bolts B should be slightly untightened to allow bracket to move Tighten bolt A p/n 5001615 cap screw, button hex Torque: 74 lbf-ft...
  • Page 396 PROCEDURE NO: PR20103-22 REVISION 04 ADJUSTING BALANCE ARM AND LINK ARMS CAUTION: For the next steps, air pressure must be applied and bi-fold entrance door panels must have been closed using the dashboard door operating button for the latch cylinders to be extended (latched). Anti-seize lubricant p/n 680335 (Permatex or similar...
  • Page 397 PR20103-30 For internal use only BI-FOLD ENTRANCE DOOR PANEL REMOVAL AND REINSTALLATION Effective : REVISION 01 Service issue: Feb. 10, 2012 Revision 01: Changing of word "nuts" for "bolts". 2011-10-07 Addition of torque specification at step 21. AIR PRESSURE RELEASE Prior to perform the following procedure, release the air pressure from the bi-fold door air cylinders and latch cylinders.
  • Page 398 PROCEDURE NO: PR20103-30 REVISION 01 Procedure applicable to: COMMUTER COACH REMOVAL AND REINSTALLATION OF A BI-FOLD DOOR PANEL Removal Unscrewing the 3 bolts identified on the image will maintain proper door panel adjustment. No adjustment will be required at time of reinstallation.
  • Page 399 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING ....................4 AIR CIRCULATION WITH CENTRAL HVAC SYSTEM ............... 4 ’ ..........................4 RIVER ’ A .......................... 4 ASSENGERS CENTRAL HVAC SYSTEM OPERATION .................... 5 ’ ......................5 RIVER ECTION PERATION ’...
  • Page 400 Section 22: HEATING AND AIR CONDITIONING ........................... 24 ONDENSER 7.4.1 Condenser Fan Motors......................24 7.4.2 Condenser Fan Motor Removal .................... 24 ..........................24 ECEIVER TANK ..........................25 ILTER RYER 7.6.1 Replacement ......................... 25 7.6.2 Moisture Indicator ........................25 ................... 26 IQUID EFRIGERANT OLENOID...
  • Page 401 Section 22: HEATING AND AIR CONDITIONING FIGURE 18: REFRIGERANT CIRCUIT (CENTRAL SYSTEM) ..................15 FIGURE 19: DOUBLE-SWEEP EVACUATION SET-UP ..................... 18 FIGURE 20: AIR PRESSURE REGULATOR ....................... 20 FIGURE 21: BELT ARRANGEMENT ........................... 20 FIGURE 22: IDLER PULLEY INSTALLATION ON VOLVO D13 ENGINE ..............21 FIGURE 23: A/C COMPRESSOR BELT ADJUSTMENT .....................

  • Page 402: Passengers' Area

    Section 22: HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING PASSENGERS’ AREA The interior of the vehicle is pressurized by its Fresh air enters the vehicle on the L.H. side, Heating, Ventilation, Air Conditioning (HVAC) through the recirculation damper located inside system.

  • Page 403: S Section Operation

    Section 22: HEATING AND AIR CONDITIONING FIGURE 3: CENTRAL HVAC SYSTEM AIR CIRCULATION 22308 The overhead compartment air registers are controlled. It requires the passengers HVAC used to control air flow for the passenger seats. section to engage the A/C compressor magnetic One register per seat direct air flow by pointing clutch.
  • Page 404 Section 22: HEATING AND AIR CONDITIONING Temperature control is provided in conjunction NOTE with a thermistor sensor inside register duct, The driver’s area air temperature sensor is located on L.H. side of vehicle (Figs. 3 & 6). located behind the grill of the R.H. side console (Refer to fig.14).
  • Page 405 Section 22: HEATING AND AIR CONDITIONING The condenser coil mounted on the opposite Diodes side of the evaporator is ventilated by four axial HVAC fans. The fan motors are protected by a Pass. Liq. Sol. Lugg. 5 Compt manually-resettable 70 amp circuit breaker Lugg.
  • Page 406 Section 22: HEATING AND AIR CONDITIONING FIGURE 13: CONDENSER COMPARTMENT 22311 DRIVER'S SECTION AIR FILTERS The driver HVAC system is located behind the FIGURE 11: EVAPORATOR COIL ACCESS PANEL (TYPICAL) 22309 dashboard’s R.H. side lateral plastic panel. To gain access to the A/C filters, unscrew the R.H. lateral console’s grill located at the top step of entrance door...

  • Page 407: Filters

    Section 22: HEATING AND AIR CONDITIONING CAUTION Do not use high pressure water jet to avoid damaging filter. Be sure not to reverse filter upon installation. OVERHEAD COMPARTMENT FAN AIR FILTER The air filters are accessible from inside the overhead compartments. FIGURE 15: DRIVER'S SECTION AIR FILTERS 22171 MAINTENANCE...
  • Page 408 Section 22: HEATING AND AIR CONDITIONING display. This feature can be used when the This feature allows verification of the pump vehicle is traveling to check the A/C compressor when inside a garage. This is also useful when pressure values. working on the heating system to remove air pockets trapped in the system.
  • Page 409 Section 22: HEATING AND AIR CONDITIONING HVAC SYSTEM TROUBLESHOOTING Problem/Symptom Probable Causes Actions Check the Diagnostics menu of the Driver Defroster fan not functioning Module A47 is not powered or is Information Display (DID). Select Fault faulty Diagnostics and Electrical System. The message “No Response ModA47, Active”...
  • Page 410 Section 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions The A/C compressor clutch Module A52 is not powered or is Check the Diagnostics menu of Driver does not engage faulty Information Display (DID). Select Fault Diagnostics and Electrical System. The message “No Response ModA52, Active”...
  • Page 411 Section 22: HEATING AND AIR CONDITIONING Other causes of inadequate cooling are the cylinder is exposed to the sun’s radiant heat dirty coils or filter. Dirt acts as insulation and pressure increase resulting may cause release is also serves as a restriction to the air flow. of the safety plug or the cylinder may burst.
  • Page 412 Section 22: HEATING AND AIR CONDITIONING on the flow of refrigerant. A single kink can greatly reduced the refrigeration capacity of the entire system. The flexible hose lines should never be allowed to come within a distance of 2-½" (6,3 cm) from the exhaust manifold. Use only sealed lines from parts stock.
  • Page 413 Section 22: HEATING AND AIR CONDITIONING FIGURE 18: REFRIGERANT CIRCUIT (CENTRAL SYSTEM) PA1593...
  • Page 414 Section 22: HEATING AND AIR CONDITIONING WARNING WARNING To prevent any injury, when air conditioning system must be opened, refer to previous Always wear safety goggles when opening paragraph “PRECAUTIONS IN HANDLING refrigerant lines. REFRIGERANT”. In the event that any line is opened to the atmosphere, should immediately...

  • Page 415: Adding Refrigerant (V Apor State )

    Section 22: HEATING AND AIR CONDITIONING Close compressor suction valve by turning it 6.5.1 Double Sweep Evacuation Procedure clockwise until it is properly seated. Remove any remaining refrigerant from the Wait until pressure gauge reaches 1 to 2 psi system using refrigerant recovery...

  • Page 416: Charging System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 19: DOUBLE-SWEEP EVACUATION SET-UP 22298 CHARGING SYSTEM When charging an empty system, weigh the When a system has been opened or if there are amount of refrigerant put into the system. This any questions about the air or moisture in the will eliminate any possibility of overfilling.

  • Page 417: Refrigerant System Clean - Out After Compressor Failure

    Section 22: HEATING AND AIR CONDITIONING 3. Turn in the two shutoff valves 3 to 4 turns. cleaned out using one of the clean-out procedures mentioned. 4. Open the lower receiver valve by turning “out” all the way. 6.7.1 Determining Severity of Failure 5.

  • Page 418: Compressor

    Section 22: HEATING AND AIR CONDITIONING Remove the failed compressor and repair it if R.H. side door next to the air pressure possible. regulator, then turn handle clockwise in order to release pressure and tension on Install new or repaired compressor. belts.

  • Page 419: Pulley Alignment

    Section 22: HEATING AND AIR CONDITIONING 7.1.4 Longitudinal Compressor Alignment 1. Rest an extremity of a straight edge of approximately 46 inches (117 cm) against the upper part of the outer face of crankshaft pulley, positioning the other end close to the compressor clutch pulley (Figs.

  • Page 420: Compressor Maintenance

    Section 22: HEATING AND AIR CONDITIONING a relatively even temperature across its surface and be neither as hot as the normal discharge temperature nor as cool as the normal suction temperature. Blown Head Gaskets Symptom: Loss of unit capacity at low temperature. Even cylinder head temperature.

  • Page 421: Magnetic Clutch

    Section 22: HEATING AND AIR CONDITIONING Expansion valve not controlling properly. unlock open evaporator compartment door. Unloader Valve Stuck Open  Remove the evaporator motor and coil Symptom: access panel. Loss of unit capacity at all temperatures.  Identify the L.H. side discharge duct inside compartment and remove the Phillips head Higher than normal suction pressure.
  • Page 422 Section 22: HEATING AND AIR CONDITIONING FIGURE 29: CONDENSER FAN MOTOR 22322 7.4.2 Condenser Fan Motor Removal Set the battery master switch to the “Off” position. Disconnect wiring from terminals on motor. Tag each wire to aid in identification at time FIGURE 28: EVAPORATOR MOTOR ASSEMBLY of reconnection.
  • Page 423 Section 22: HEATING AND AIR CONDITIONING will break at 450 psi (3103 kPa) and relieve the Do not use carbon tetrachloride or similar receiver tank pressure. solvents to clean parts. Do not use steam guns. Use mineral spirits or naphtha. All parts should be thoroughly cleaned.
  • Page 424 Section 22: HEATING AND AIR CONDITIONING compressor and other components causing a 2. Take out the retaining screw at the top of malfunction and eventual failure of the system. the coil housing. The entire coil assembly Uncontrolled moisture in the system can result can then be lifted off the enclosing tube.
  • Page 425 Section 22: HEATING AND AIR CONDITIONING As the temperature of the refrigerant gas at the evaporator outlet increases above the saturation temperature corresponding to the evaporator pressure, becomes superheated. pressure thus generated in the remote bulb and power assembly surpasses combined pressures of the evaporator pressure and the superheat spring, causing the valve pin to move...
  • Page 426 Section 22: HEATING AND AIR CONDITIONING because it provides savings in both initial evaporator cost of operation. Accurate and sensitive control of the refrigerant liquid flowing to the evaporator is necessary to provide maximum evaporator capacity under load conditions. The spring is adjusted to give 12 to 16 F (-11.1 to -8.8 C) of superheat at the...
  • Page 427 Section 22: HEATING AND AIR CONDITIONING Example of readings taken at fig. 35: Disconnect the external equalizer line from the under side of the power head, and A/C pressure gauge Temperature on unclamp the remote control bulb from the converted to remote bulb evaporator coil outlet line.
  • Page 428 Section 22: HEATING AND AIR CONDITIONING 7.10 TROUBLESHOOTING 7.10.1 Expansion Valve PROBABLE CAUSE PROBABLE REMEDY LOW SUCTION PRESSURE-HIGH SUPERHEAT XPANSION ALVE IMITING Gas in liquid line due to pressure drop in the line Locate cause of line flash and correct by use of or insufficient refrigerant charge.
  • Page 429 Section 22: HEATING AND AIR CONDITIONING 7.10.2 A/C TROUBLE CAUSE Low suction pressure and frosting at dryer outlet. Clogged filter. Low Oil Level. Check for oil leaks and for leaking oil seal. Do not attempt to check oil level unless system has been stabilized at least 20 minutes.
  • Page 430 Section 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE An evaporator just does a proper cooling job without sufficient air. Shortage of air can be caused by the following: Dirty filters; or Dirty coils. Testing condenser pressure. NOTE : R-134A pressure is function of the temperature variation. Example, for an exterior temperature of 100°F.
  • Page 431 Section 22: HEATING AND AIR CONDITIONING 7.11 TEMPERATURES & PRESSURES VAPOR-PRESSURE TEMPERATURE PRESSURE °F °C -100 -73.3 27.8 191.7 -67.8 26.9 185.5 -62.2 25.6 176.5 -56.7 23.8 164.1 -51.1 21.5 148.2 -45.6 18.5 127.6 -40.0 14.7 101.4 -34.4 67.6 26.2 12.4 43.4 11.6...
  • Page 432 Section 22: HEATING AND AIR CONDITIONING VAPOR-PRESSURE TEMPERATURE PRESSURE °F °C 87.8 433.6 2989.7 93.3 485.0 3344.1 98.9 540.3 3725.4 7.12 LEAK TESTING Some methods such as nitrogen pressure, soap NOTE and electronic sniffer can be used for leak testing. However, the most common method This gas is put into the suction and discharge used is a "Halide"...
  • Page 433 Section 22: HEATING AND AIR CONDITIONING FIGURE 36: CENTRAL HEATING SYSTEM COMPONENTS PA1593...
  • Page 434 Section 22: HEATING AND AIR CONDITIONING CENTRAL HEATING SYSTEM Loosen hose clamp, install an appropriate container recover coolant, As seen earlier in this section, the vehicle disconnect silicone hose from water interior is pressurized by its Heating, Ventilation solenoid valve. and Air Conditioning (HVAC) system.
  • Page 435 Section 22: HEATING AND AIR CONDITIONING Open drain cock in bottom of heater core, you can unfasten a hose connection on top of heater core (Fig.40) in order to allow air to enter while draining. FILLING HEATING SYSTEM Ensure that the drain hose is reconnected and the manual vent and drain cock are closed.
  • Page 436 Section 22: HEATING AND AIR CONDITIONING DRIVER’S HOT WATER PNEUMATIC access seals VALVE ASSEMBLY replacement Pneumatic water valve replacement seal  Description kits: The flow of hot water to the driver’s heater core * Water Side: 871311 is controlled by a pneumatic NO water valve * Actuator Side: 871312 assembly.
  • Page 437 Section 22: HEATING AND AIR CONDITIONING   Valve Troubleshooting Pneumatic Water Valve Disassembly 1. Shut off air supply pressure and electrical current pilot solenoid valve. PROBLEM PROCEDURE Disconnect wires. 1. Check electrical supply with a 2. The water valve need not be removed from Valve fails voltmeter.
  • Page 438 Section 22: HEATING AND AIR CONDITIONING 2. A pilot solenoid valve replacement seal kit is WATER RECIRCULATING PUMP available: 871390. ® This vehicle is provided with a Rotron brushless DC sealess water circulation pump which is located in the engine coolant heater compartment (Fig.
  • Page 439 Section 22: HEATING AND AIR CONDITIONING Close shutoff valves. Refer "05 COOLING" under heading "Draining Cooling System" for location of valves. Disconnect the electrical wiring from the motor. WARNING Before proceeding with the following steps, check that coolant has cooled down. 4.
  • Page 440 Voltage ............................27.6 V DC Current draw ............................. 68 amps Horsepower ..............................2 Revolution ........................... 1400 & 1700 rpm Insulation ............................. Class F Motor Prevost number......................... 563586 Condenser fan motors Type ..........................AXIAL BRUSHLESS Voltage .............................. 24 V DC Qty ................................. 4 Prevost number ...........................
  • Page 441 F (20 C) ................... 5.15 – 5.69 ohms Prevost number ........................... 950204 Compressor V belt (Carrier) Model ..............................BX100 Prevost number (with two BOSH Alternators) ..................506864 Condenser coil (Central system) Make ........................... Carrier Transicold Copper Prevost number ........................... 870729 Evaporator coil (Central system) Prevost number ...........................
  • Page 442 Section 22: HEATING AND AIR CONDITIONING Voltage .............................. 24 V DC Amperage draw ..........................0.67 amps Watts ................................16 Prevost number (without coil) ......................95-0054 Coil Prevost number ..........................950055 Repair kit Prevost number ........................950056 Hot water pneumatic valve (Central system) Type ..............................
  • Page 443 SECTION 23: ACCESSORIES CONTENTS HUBODOMETER ..........................2 ............................ 2 ESCRIPTION ............................2 PERATION ............................2 EMOVAL ........................... 2 NSTALLATION HORN INSTALLATION ......................... 2 ......................2 LECTRIC AINTENANCE WINDSHIELD WIPERS AND WASHERS ..................... 2 ........................2 ENERAL ESCRIPTION ............................3 IPER 3.2.1 Wiper Arms Positioning ......................
  • Page 444 Section 23: ACCESSORIES HUBODOMETER DESCRIPTION A wheel hubodometer (Fig. 1) has been installed on the R.H. side of the drive axle. It indicates the total distance in miles covered by the coach since it has left the factory, including road testing.
  • Page 445 Section 23: ACCESSORIES the wipers intermittently. The second position is the slow speed and the third position is for high speed wiping. FIGURE 4: WINDSHIEL WASHER - WIPERS CONTROL 23133 FIGURE 3: R.H. DASHBOARD PANEL FIGURE 5: WINSHIELD WASHER RESERVOIR 23220 FIGURE 6: WINDSHIELD WIPER INSTALLATION 23287...
  • Page 446 4. Remove the three bolts holding the motor to 5. Connect the windshield washer tubing at the the steel plate. base of the wiper arm. 5. Remove the windshield wiper motor (Prevost 6. Check the adjustment on a wet windshield. #800328), reverse removal procedure to reinstall.
  • Page 447 Section 23: ACCESSORIES FIGURE 11: WIPER ARMS POSITIONING 23253 TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY A. Reservoir empty. A. Add proper fluid FAIL TO SPRAY WASHER FLUID B. Store coach or parts in heated area, B. If below 32°F (0°C), improper then purge system with low- washer fluid frozen.
  • Page 448 Refer to Prevost Operator’s Manual for system operation and operational sequence (fire). If more information is needed on the system, please refer to Kidde Dual Spectrum “Operation &...
  • Page 449 Section 23: ACCESSORIES EVERY 18000 MILES OR SEMI-ANNUALLY (whichever comes first) o Perform a comprehensive fire system test using a Kidde Dual Spectrum System Test Set (Optical Test Kit P/N 420871-2). o Service the extinguisher in accordance with KDS Document 160296, “KDS Pre-Engineered Fire Suppression System: Installation, Operation and Maintenance Manual”.
  • Page 450 Section 23: ACCESSORIES SPECIFICATIONS HUBODOMETER (US model: miles) Prevost number ........................... 650002 ELECTRIC HORN (HIGH) Prevost number ........................... 563023 ELECTRIC HORN (LOW) Prevost number ........................... 563015 WINDSHIELD WIPER MOTOR Prevost number ........................... 800328 WIPER (BLADE) Prevost number ........................... 800329 WIPER ARM Prevost number ...........................
  • Page 451 SECTION 24: LUBRICATION CONTENTS LUBRICATION ............................2 LUBRICATION AND SERVICE SCHEDULE ..................2 ......................2 LEXIBLE AINTENANCE 2.1.1 Hose Inspection ........................2 2.1.2 Leaks ............................2 2.1.3 Service life ..........................2 ..................5 UBRICANT OOLANT PECIFICATIONS ..................6 UBRICATION ERVICING CHEDULE ILLUSTRATIONS .....
  • Page 452 Section 24: LUBRICATION FLEXIBLE HOSE MAINTENANCE 1. LUBRICATION The efficiency and life expectancy of mechanical The performance of engine and equipment are equipment is largely dependent on proper greatly related to the ability of flexible hoses to lubrication servicing. mechanical supply lubricating oil, air, coolant, and fuel oil.
  • Page 453 Section 24: LUBRICATION It is also recommended that all hoses in this vehicle be replaced during major overhaul and/or after a maximum of five service years. Quality of replacement hose assemblies should always be equal to or superior to those supplied by the Original Equipment Manufacturer.
  • Page 454 Section 24: LUBRICATION FIGURE 1: LUBRICATION AND SERVICING POINTS ON I-BEAM AXLE FRONT SUSPENSION VEHICLES 24030_1 PA1593...
  • Page 455 Section 24: LUBRICATION LUBRICANT AND COOLANT SPECIFICATIONS DESCRIPTION SPECIFICATIONS VOLVO D13 Total Rubia TIR 10W-30 FE for best fuel economy. Engine Oil SAE Viscosity Grade 5W-30 & 15W-40 oils, meeting Volvo specification VDS-4 and CJ4, are also approved Power Steering Oil Automatic Transmission Oil, Dexron-III, VI or Exxon Mobil ATF SHC VOLVO D13 Engine Coolant...
  • Page 456 Section 24: LUBRICATION LUBRICATION AND SERVICING SCHEDULE For lubrication and servicing schedule, refer to table A. IMPORTANT NOTE Refer to the manufacturers documentation included in this maintenance manual for specific manufacturer’s maintenance requirements. PA1593...
  • Page 457 Proceed to maintenance operation every (miles) LUBRICATION AND SERVICING SCHEDULE NYCT X3-45 Commuter DOB 2400-2489 GENERAL 1 Flexible hoses - thoroughly inspect all hoses  01 ENGINE  1 Engine oil & filter - heavy operation condition, change 2 Drive belts and idlers – visually inspect for signs of deterioration, cracks or frayed ...
  • Page 458 Proceed to maintenance operation every (miles) LUBRICATION AND SERVICING SCHEDULE NYCT X3-45 Commuter DOB 2400-2489 & using High–Capacity filters. Transmission Main & Lube filters – change every 42 000 miles 09 PROPELLER SHAFT 1 Perform Spicer’s Driveshaft Assembly Inspection Procedures ...
  • Page 459 Proceed to maintenance operation every (miles) LUBRICATION AND SERVICING SCHEDULE NYCT X3-45 Commuter DOB 2400-2489  10 Passengers HVAC unit – clean condenser core with low pressure water hose CHANGE LOG - LUBRICATION AND SERVICING SCHEDULE DATE 1 In table heading, “ODOMETER READING IN MILE” removed 09/22/2014 2 UPDATED: 01 ENGINE –...

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