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Summary of Contents for PREVOST Le Mirage XL II Ultimate
- Page 1 SLIDE-OUT SERVICE MANUAL RELEASE 3 THE "ULTIMATE" CLASS CONVERSION BUS SHELLS PREVOST SLIDE-OUT TECHNOLOGY...
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Page 2: Table Of Contents
XL2 SLIDE-OUT SERVICE MANUAL CONTENTS 1. SLIDE-OUT .............................. 7 1.1 INNER STOPPER ..........................7 1.1.1 Maintenance ........................... 7 1.1.2 Adjustment ..........................7 1.2 EXTERIOR EXTRUSION ........................7 1.2.1 Maintenance ........................... 8 1.3 FRONT SLIDE-OUT REMOVAL ......................8 1.4 FRONT SLIDE-OUT INSTALLATION ....................9 1.5 REAR SLIDE-OUT REMOVAL ...................... - Page 3 11.2 UNIVERSAL JOINT REPLACEMENT ................... 22 11.3 VERTICAL SHAFT REPLACEMENT .................... 22 12. SLIDE-OUT PNEUMATIC SYSTEM ..................... 22 12.1 DESCRIPTION ..........................22 12.2 PNEUMATIC INTERCONNECTION WITH PREVOST VEHICLE ..........23 12.3 MAINTENANCE ..........................23 12.4 SEAL ............................. 24 12.4.1 Maintenance ......................... 25 12.4.2 Seal assembly removal ......................
- Page 4 XL2 SLIDE-OUT SERVICE MANUAL 18. SPECIFICATIONS ..........................44 18.1 SLIDE-OUT MAXIMUM LOAD ...................... 44 18.2 TRANTORQUE KEYLESS BUSHING................... 44 18.3 SPEED REDUCTION GEARBOX ....................46 18.4 LINEAR POSITION TRANSDUCER ..................... 46 18.5 RIGHT ANGLE DRIVE ........................46 18.6 ELECTRIC MOTOR ........................46 18.7 LOGIC CONTROLLER ........................
- Page 5 XL2 SLIDE-OUT SERVICE MANUAL 40 : ..................30 FIGURE SLIDE OUT LOGIC CONTROLLER SET UP 41 : ..................31 FIGURE SLIDE OUT PIN STATE INDICATOR MODULE 42 : ....................31 FIGURE LINEAR POSITION TRANSDUCER 43 : ....................32 FIGURE SLIDE OUT PANELS AND WINDOWS 44 : –...
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Page 6: Figure 1 : Slide - Out Mechanical Components
XL2 SLIDE-OUT SERVICE MANUAL FIGURE SLIDE OUT MECHANICAL COMPONENTS May 3, 2002... -
Page 7: Slide-Out
XL2 SLIDE-OUT SERVICE MANUAL 1. SLIDE-OUT 1.1 INNER STOPPER The front slide-out is equipped with six inner stoppers laid out in the following way: two stoppers on the top horizontal member of the slide-out, and two stoppers on each vertical upright, while the rear slide-out is equipped with only three stoppers (figure 2 and figure 3). -
Page 8: Maintenance
XL2 SLIDE-OUT SERVICE MANUAL EXTERIOR EXTRUSION SEAL SCREW SEALANT FIGURE EXTERIOR PANEL EDGE FIGURE EXTERIOR EXTRUSION Warning: The inner stoppers are used to stop and straighten the slide-out. The motor drive is 1.2.1 Maintenance controlled in overcurrent for three seconds after Inspect exterior extrusion... -
Page 9: Front Slide-Out Installation
XL2 SLIDE-OUT SERVICE MANUAL Caution: Be careful when moving the slide-out (figure 1 item 3 and 13). Slide the free to prevent any damage to the slide-out itself pinions to center them on their racks. Also, and/or its seal. When moving the slide-out, make sure that the guide wheel is in its track check constantly its four corners from inside and (figure 9 and figure 1 item 12). -
Page 10: Rear Slide-Out Removal
XL2 SLIDE-OUT SERVICE MANUAL 9. Reinstall the slide-out side inner stoppers 1.6 REAR SLIDE-OUT (section 1.1). INSTALLATION The procedure for installing the rear slide-out is Caution: Make sure all keyless bushings are almost the same as the procedure for the front tightened to 125 lb-ft before unlocking the pins slide-out. -
Page 11: Adjustment
XL2 SLIDE-OUT SERVICE MANUAL structure deflection, therefore the locking pin 6. Align horizontally the locking pin in the slide- adjustment, especially for the front slide-out. out receptacle and tighten the four nuts. After conversion process and twice a year, Caution: The locking pin and the slide-out inspect the locking pins proper movement by receptacle must be aligned before locking the pin. -
Page 12: Sensor Switch Adjustment
XL2 SLIDE-OUT SERVICE MANUAL axle is unloaded, switch the ignition to the (adjustment direction) when it "OFF" position. activated again, continue to move it on 1/8" to 5/32". Tighten the sensor screw (figure 4. Note the pneumatic tubing position, then 13). -
Page 13: Roof Reinforcing Rod
XL2 SLIDE-OUT SERVICE MANUAL 14 : FIGURE PIN RECEPTACLE INSTALLATION 5. Remove the pin receptacle. 16 : FIGURE PIN RECEPTACLE ON STAINLESS STEEL PANELS 10. Clean excess sealant with alcohol. 11. Readjust the locking pins as described in section 2.2 (if needed). 3. -
Page 14: Rack
XL2 SLIDE-OUT SERVICE MANUAL This rod allows an adjustment between the slide- 4. From inside the slide-out, unscrew all the out horizontal member and the roof. When rack screws (figure 2 and figure 3). screwing the turnbuckle, the roof is moved upward, and vice versa. -
Page 15: Pinion
XL2 SLIDE-OUT SERVICE MANUAL Caution: Make sure all keyless bushings are 2. Using the slide-out control switch and/or the manual override procedure, extend the tightened to 125 lb-ft before unlocking the pins slide-out about one foot. or moving the slide-out. Refer to section 5.6 for torque wrench settings. -
Page 16: Front Slide-Out Driver Side Lower Shaft Pinion Replacement
XL2 SLIDE-OUT SERVICE MANUAL 5. Loosen the upper shaft keyless bushing of 5.3 FRONT SLIDE-OUT DRIVER SIDE the rack pinion to be changed. LOWER SHAFT PINION REPLACEMENT 6. For the motor side pinion, remove the upper 1. Remove the front slide-out as described in jaw coupling and the upper right angle drive section 1.3. -
Page 17: Rear Slide-Out Lower Shaft Pinion Replacement
XL2 SLIDE-OUT SERVICE MANUAL 3. Disengage the lower shaft jaw coupling. 5. Remove the pinion and the keyless bushing from the shaft. 4. From the baggage compartment, unscrew the pillow block supporting plate screw 6. Check the keyless bushing and the guide (figure 19). -
Page 18: Figure 21 : Torque Wrench Formula
XL2 SLIDE-OUT SERVICE MANUAL another wrench to tighten the black part. Figure 3. On the driver side, tighten the upper shaft 20 shows how to tighten the keyless bushing. keyless bushing to 125 lb-ft (refer to figure When tightening, make sure the pinion does not 21 for wrench size compensation). -
Page 19: Guide Wheel
XL2 SLIDE-OUT SERVICE MANUAL 5.7 GUIDE WHEEL 5. Replace and tighten the motor holding metal strap (figure 23). A plastic wheel is mounted on one of the lower shaft pinion on each slide-out. This wheel is 6. Re-connect the motor electric cable. used to guide the slide-out when extending or retracting. -
Page 20: Right Angle Drive
XL2 SLIDE-OUT SERVICE MANUAL 5. Remove the gearbox assembly (figure 24 11. Using shims and, for the front slide-out, the and figure 25). Note the shim position. vehicle mounting bracket adjustment screw, align the right angle drive shaft jaw coupling 6. -
Page 21: Upper Shaft Right Angle Drive Replacement
XL2 SLIDE-OUT SERVICE MANUAL 8.3 UPPER SHAFT RIGHT ANGLE 9.2 REPLACEMENT DRIVE REPLACEMENT The jaw coupling replacement procedure is the same as for the right angle drive, section 8.2 and Note: This procedure is the same for both slide- 8.3. out. -
Page 22: Vertical Shaft And Universal Joint Assembly
XL2 SLIDE-OUT SERVICE MANUAL on the driver side, add or remove shims 4. Lock the taper keys against the shaft and under the pillow block (figure 26). the universal joint keyseats to prevent them from moving. Use Loctite 242 or equivalent 4. -
Page 23: Pneumatic Interconnection With Prevost Vehicle
29 : FIGURE FRONT SERVICE COMPARTMENT 12.2 PNEUMATIC INTERCONNECTION WITH PREVOST VEHICLE The slide-out pneumatic system air supply comes from the converter air supply valve located on the pneumatic panel in the front service compartment (figure 29). A valve is also... -
Page 24: Seal
XL2 SLIDE-OUT SERVICE MANUAL system" section from the Prevost maintenance INFLATABLE SEAL manual. WIPER SEAL INFLATABLE SEAL CIRCUIT The efficiency of the seal could be affected by impurities, such as white powder in the pneumatic control valve. It is recommended to... -
Page 25: Maintenance
XL2 SLIDE-OUT SERVICE MANUAL Caution: Always apply product in the same The vacuum generator valve is activated simultaneously with seal valve until the 16" Hg direction to prevent dirt from being brought back. vacuum is reached at the vacuum switch. The vacuum switch will detect an inflatable seal Caution: Check before using any cleaning or failure if the 16"... -
Page 26: Slide-Out 2" Inside Retraction
Warning: Never modify the slide-out electrical 9. Replace the bushing and plug the pneumatic wiring without the Prevost Car approval. Any tubing on the inflatable seal air inlet (figure modifications may cause an unexpected slide- 31 and figure 32). -
Page 27: Slide-Out Breakers/Fuse
BREAKER IN MAIN POWER COMPARTMENT 13.3 ELECTRONIC CONTROLLERS Warning: Never modify the slide-out electrical wiring without the Prevost Car approval. Any modifications may cause an unexpected slide- out action and could result in personal injury. The slide-out electronic control system consists of three electronic control modules for each slide-out. -
Page 28: Motor Controller Replacement
Take note of the new serial number with revision remove remaining electric cables at the top. (RV:) and version (V:) identifications to inform Remove the used logic controller and Prevost service department controller replace it by a new one. -
Page 29: Eprom Memory Chip Replacement
6. Take note of the new serial number with 7. Write the new software version (written on revision (RV:) and version (V:) identifications the chip) on the controller sticker (if it had to inform Prevost service department for changed), inform Prevost service controller tracking. -
Page 30: Slide-Out Stroke Limits Set-Up
XL2 SLIDE-OUT SERVICE MANUAL procedure is the same as above except that the 5. Memorize the slide-out inner limit by pushing breaker must be used. once the logic controller black push-button (see figure 40). The green LED "OUT6" confirms that the stroke limit is set in the logic controller memory (see figure 52). -
Page 31: Pin State Indicator Module
Prevost breakers (figure 38). maintenance manual. Refer to Prevost manual for procedures, tools, cleaner, adhesives and 2. Disconnect the connector located on the other product needed. -
Page 32: Side Panel Installation
14.2 SIDE PANEL INSTALLATION For surface cleaning, and preparation, panel installation and products needed, use the same procedure as the MTH side panel installation described in Prevost service manual, and: Keep the slide-out retracted and all pins locked for panel alignment; 44 : –... -
Page 33: Corner Panels Installation
Warning: Because of the adhesive toxicity, MTH side panel installation procedure described never use a buffer or other sanding method to in Prevost service manual, and: remove it. Protect adjacent surfaces with appropriate material;... -
Page 34: Slide-Out Fixed, Awning And Sliding Windows
Note: The removal and installation procedures based standard service methods described in the body section of the Prevost maintenance manual. Refer to these procedures for tools and adhesives specifications. Warning: Always wear safety equipment when working with glass and chemical adhesives. -
Page 35: Welding Precaution
XL2 SLIDE-OUT SERVICE MANUAL SEALAN CORNE PANE 49 : FIGURE WINDOW LOCATED OVER THE CORNER PANEL 5. From inside the slide-out, apply appropriate sealant between the windows and the structure. 6. Install the exterior extrusion as described in section 12.4.4 step 5. 7. -
Page 36: Figure 50 : Pinion & Pillow Block Adjustment ( Dimensions Are In Millimetres )
XL2 SLIDE-OUT SERVICE MANUAL 50 : & FIGURE PINION PILLOW BLOCK ADJUSTMENT DIMENSIONS ARE IN MILLIMETRES 1- FRONT SLIDE-OUT VACUUM SWITCH 2- REAR SLIDE-OUT VACUUM SWITCH 3- FRONT SLIDE-OUT SEAL VALVE 4- REAR SLIDE-OUT SEAL VALVE 5- FRONT SLIDE-OUT VACUUM GENERATOR 6- REAR SLIDE-OUT VACUUM GENERATOR 7- FRONT SLIDE-OUT PIN VALVE 8- REAR SLIDE-OUT PIN VALVE... -
Page 37: Figure 52 : Slide - Out Logic Controller Led Panel
XL2 SLIDE-OUT SERVICE MANUAL 52 : FIGURE SLIDE OUT LOGIC CONTROLLER LED PANEL PNEUMATIC CYLINDER SPRING PIN SLEEVE INNER PIN SENSOR SWITCH BASE SEGMENT HEAD 53 : FIGURE LOCKING PIN ASSEMBLY May 3, 2002... -
Page 38: Troubleshooting
• The vehicle is moving. .1 sec OFF Check the condition of the input LED (IN3, IN6, IN7, IN9) on the logic controller (figure 52). Check wiring and Prevost electrical components. Regular flashing: Stroke limits set- A. Logic controller changed without A. - Page 39 XL2 SLIDE-OUT SERVICE MANUAL SIGNAL PROBLEM CAUSE CORRECTIVE ACTION Regular flashing: Motor controller A. Motor controller power supply cable A. Check the power supply cable and ten flashes every error damaged or breaker tripped; breaker. Reset the power and try again. second (10 Hz) and abnormal B.
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Page 40: Logic Controller
XL2 SLIDE-OUT SERVICE MANUAL SIGNAL PROBLEM CAUSE CORRECTIVE ACTION One long flash Motor controller A. Excessive weight; A. Reduce the weight in the slide-out. each second software or .9 sec ON hardware B. Obstruction to the slide-out B. Remove any obstacle that may obstruct .1 sec OFF protection movement;... -
Page 41: Motor Controller
XL2 SLIDE-OUT SERVICE MANUAL 17.3 MOTOR CONTROLLER The motor controller has 4 LED to show the controller activity and indicate errors (figure 36). The error LED flashes once every 2 seconds when the controller is in operation. When retracting the slide-out, the "Motor In"... -
Page 42: Slide-Out Operation
XL2 SLIDE-OUT SERVICE MANUAL 17.4 SLIDE-OUT OPERATION PROBLEM CAUSE CORRECTIVE ACTION Slide-out does not retract or A. Driving mechanism failure; A. Check driving mechanical components. extend when depressing the control switch. B. Electrical problem; B. Refer to section 17.1 to 17.3. Slide-out is not straight when A. - Page 43 XL2 SLIDE-OUT SERVICE MANUAL PROBLEM CAUSE CORRECTIVE ACTION Watertightness problem A. Inflatable seal and/or wiper seal damaged A. Check both seals condition. or unstuck; B. Insufficient air pressure in the seal; B. Check the pressure regulator, the relieving shut-off valve and the seal valve condition.
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Page 44: Specifications
XL2 SLIDE-OUT SERVICE MANUAL 18. SPECIFICATIONS 18.1 SLIDE-OUT MAXIMUM LOAD Front slide-out: Maximum load (retracted or extended)…...2000 lb Maximum load when moving……………...1200 lb* Rear slide-out: Maximum load (retracted or extended) …..2000 lb Maximum load when moving ….………….1200 lb* * When the load is distributed in the slide-out to prevent a deflection of the inside lower member over 1/4"... -
Page 45: Figure 56 : Keyless Bushing Installation Instruction
XL2 SLIDE-OUT SERVICE MANUAL 56 : FIGURE KEYLESS BUSHING INSTALLATION INSTRUCTION May 3, 2002... -
Page 46: Speed Reduction Gearbox
XL2 SLIDE-OUT SERVICE MANUAL TECHNICAL AND PHYSICAL DESCRIPTION 18.3 SPEED REDUCTION GEARBOX Make………………………………..David Brown • 12 "High Side" inputs with high impedance, Type……..Series C Radicon helical worm gear filtered and protected against peak voltage; Unit size…………………………………...C0320 • 6 outputs "High Side" of continuous 2A with Ratio……………………………………….140 : 1 protection against spike voltage peaks produced by inductive loads;... -
Page 47: Safety Controller
XL2 SLIDE-OUT SERVICE MANUAL 18.9 SAFETY CONTROLLER Check the whole slide-out mechanism good functioning. The slide-out should retract and This module is used to prevent unexpected extend smoothly without vibration. actions from the logic controllers. This controller uses relays to interlock specific functions of the Final check: slide-out. - Page 48 Ω Ω XL2 DOUBLE SLIDE-OUT ELECTRIC DIAGRAM (RETROFIT) EFFECTIVE FROM SERIAL NUMBER Y-7450 TO 1-7718 AND FROM 1-7724 TO 1-7773 2002/04/26 (ALL WIRES ARE 18 AWG EXCEPT WHEN SPECIFIED)
- Page 49 Ω XL2 SINGLE SLIDE-OUT ELECTRIC DIAGRAM (RETROFIT) EFFECTIVE FROM SERIAL NUMBER Y-7450 TO 1-7718 AND FROM 1-7724 TO 1-7773 (ALL WIRES ARE 18 AWG EXCEPT WHEN SPECIFIED) 2002/04/26...
- Page 50 Ω Ω XL2 DOUBLE SLIDE-OUT ELECTRIC DIAGRAM (RETROFIT) EFFECTIVE FROM SERIAL NUMBER Y-7003 TO Y-7446 (ALL WIRES ARE 18 AWG EXCEPT WHEN SPECIFIED) 2002/04/26...
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