Page 3 MAINTENANCE MANUAL H3-41, H3-45, H3-45 VIP X3-45, X3-45 VIP PA1621 Revision 06...
Page 4 PA1621 Featuring: H series new electrical architecture   H Series electric cooling fans. This manual is applicable from the following vehicles: K-0185 (H Series)   H-6180 (X Series CAN) H-7417 (X-Series US)  Including the following individual vehicles: ...
Page 5 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 7 CONTENTS CONTENTS SECTION 00 GENERAL INFORMATION MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING SECTION 01 ENGINE MI16-16 STARTER REMOVAL AND INSTALLATION SECTION 03 FUEL SYSTEM SECTION 04 EXHAUST AND AFTERTREATMENT SECTION 05 COOLING SYSTEM SECTION 06 ELECTRICAL ELECTRICAL CONNECTORS PROTECTION MI15-24 POWER CABLES INSPECTION GUIDELINES MI16-17 TWIN BOSCH HD10 ALTERNATOR REMOVAL AND INSTALLATION SECTION 07...
Page 9: Table Of Contents
SECTION 00: GENERAL INFORMATION CONTENTS SECTION CHANGE LOG ............................2 FOREWORD ..............................3 SCHEMATICS ..............................3 SAFETY NOTICE ............................... 3 DATA PLATES AND CERTIFICATIONS ....................... 4 3.1.1 Engine ..............................4 3.1.2 Transmission ............................4 3.1.3 Drive Axle ............................... 4 3.1.4 Front Axles .............................
Page 10: Section Change Log
SECTION 00 : GENERAL INFORMATION SECTION CHANGE LOG DESCRIPTION DATE UPDATED FIGURE 6: I-Beam axle Oct 2018 UPDATED FIGURE 9: X3-OPP2 Sept 2019 PA1621 Maintenance Manual All Series | Section 00 revised Sept 2019...
Page 11: Foreword
This manual includes procedures for diagnosis, 2. SCHEMATICS service, maintenance and repair for components of all series of Prevost coaches and motorhomes Vehicle pneumatic and electrical schematics can listed on the front cover. This manual should be be found in your technical publications box.
Page 12: Data Plates And Certifications
SECTION 00 : GENERAL INFORMATION (assembly number), and model number. Use all NOTE three numbers when ordering parts. Indicates supplementary information essential to the proper operation of the vehicle. Although, mere reading such information does not eliminate the hazard, understanding of the information will promote its correct use.
Page 13: Coach Final Record
(driver's side). The This certifies that vehicles manufactured by VIN is visible from the outside of the vehicle. Prevost Car Inc., comply with all Federal Motor Make sure the correct vehicle identification Vehicle Safety Standards at the time of number is given when ordering replacement manufacture.
Page 14 SECTION 00 : GENERAL INFORMATION FIGURE 9: VEHICLE I.D. 00048/00045-2 NOTE Record the VIN in the vehicle documentation and keep with company records. The VIN will normally be used for vehicle registration and for obtaining vehicle insurance coverage. PA1621 Maintenance Manual All Series | Section 00 revised Sept 2019...
Page 15 SECTION 00 : GENERAL INFORMATION FIGURE 10: VEHICLE IDENTIFICATION NUMBER 00057_5 YEAR CODE YEAR CODE YEAR CODE 1997 2005 2013 1998 2006 2014 1999 2007 2015 2000 2008 2016 2001 2009 2017 2002 2010 2018 2003 2011 2019 2004 2012 2020 PA1621 Maintenance Manual All Series | Section 00 revised Sept 2019...
Page 16: Fastener
SECTION 00 : GENERAL INFORMATION 4. FASTENER When replacing metric fasteners, be careful to use fasteners of the same or greater strength than the original fasteners (the same number marking or higher). It is also important to select 4.1 FASTENER STRENGTH IDENTIFICATION replacement fasteners of the correct size.
Page 17: Standard Torque Specifications
SECTION 00 : GENERAL INFORMATION The metric fasteners used on the coach are designed to new standards and may not yet be manufactured by some non-domestic fastener suppliers. In general, except for special applications, the common sizes and pitches are: M 8 X 1.25;...
Page 18 SECTION 00 : GENERAL INFORMATION RECOMMENDED TORQUE TYPE DESCRIPTION THREAD GRADE Tolerance: ±10% 9/16-12 94 lb-ft (127 Nm) 9/16-12 132 lb-ft (179 Nm) 9/16-18 101 lb-ft (137 Nm) 9/16-18 143 lb-ft (194 Nm) 5/8-11 130 lb-ft (176 Nm) 5/8-11 184 lb-ft (249 Nm) 5/8-18 142 lb-ft (193 Nm) 5/8-18...
Page 19: Metric
SECTION 00 : GENERAL INFORMATION 4.2.2 Metric RECOMMENDED TORQUE, ±10% TYPE DESCRIPTION THREAD GRADE lb-ft (dry) otherwise specified Tolerance: ±10% METRIC M6 X 1 nut 8 / screw 8.8 7 lb-ft (10 Nm) METRIC M6 X 1 nut 10 / screw 10.9 10 lb-ft (13 Nm) METRIC M6 X 1...
Page 20 SECTION 00 : GENERAL INFORMATION RECOMMENDED TORQUE, ±10% TYPE DESCRIPTION THREAD GRADE lb-ft (dry) otherwise specified Tolerance: ±10% METRIC M24 X 3 nut 12 / screw 12.9 777 lb-ft (1054 Nm) METRIC: STAINLESS NUT A2-70 AND STAINLESS SCREW A2-70 (NSS-SS) RECOMMENDED RECOMMENDED TIGHTENING Tolerance:...
Page 21: Self-Locking Fasteners
SECTION 00 : GENERAL INFORMATION a) Clean dirt and other foreign matter from the fastener; 4.3 SELF-LOCKING FASTENERS b) Inspect the fastener to ensure there is no crack, elongation, or other sign of fatigue A self-locking fastener is designed with an or over tightening.
Page 22: Six Lobed Socket Head
SECTION 00 : GENERAL INFORMATION 4.5 SIX LOBED SOCKET HEAD Six lobed socket head (Torx) fasteners are used in some applications on vehicles covered in this manual. The tools designed for these fasteners are available commercially. However, in some cases, if the correct tool is not available, a hex socket head wrench may be used.
Page 23 SECTION 00 : GENERAL INFORMATION FIGURE 14: METRIC - US STANDARD CONVERSION TABLE 00005 PA1621 Maintenance Manual All Series | Section 00 revised Sept 2019...
Page 24 SECTION 00 : GENERAL INFORMATION FIGURE 15: CONVERSION CHART 00006 PA1621 Maintenance Manual All Series | Section 00 revised Sept 2019...
Page 25: Hose Clamp Torque
SECTION 00 : GENERAL INFORMATION 4.6 HOSE CLAMP TORQUE HOSE CLAMP NGLISH RECOMMENDED TIGHTENING ESCRIPTION ONSTANT TORQUE 3/8 Hex 90-110 CAUTION HOSE CLAMP (WAVE Cover electronic control components and wiring NGLISH SEAL BREEZE) to protect from hot sparks, etc. RECOMMENDED ESCRIPTION CAUTION TIGHTENING...
Page 26: Welding Process
SECTION 00 : GENERAL INFORMATION 5. WELDING PROCESS 5.1 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.
Page 27: Steel - Stainless Steel Welding
SECTION 00 : GENERAL INFORMATION 5.3 STEEL - STAINLESS STEEL WELDING Steel Thickness SS Thickness Voltage Current Wire Feed Rate Shielding Gas 90% He, 7.5% Less than 1/8” Any type 20±1.5 volts 130±15 Amps 290 ipm approx. Ar, 2.5% CO2 90% He, 7.5% 1/8”...
Page 29 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING JANUARY 2018 Table of contents COMMUTERS ..................................... 2 H3 SERIES - WITH NEW ELECTRICAL ARCHITECTURE ........................5 X3 SERIES - WITH NEW ELECTRICAL ARCHITECTURE ........................7 Material: Equipment(s): Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: N/A...
Page 30 PROCEDURE REFERENCE NO: PR10177-232 (COMMUTER) REVISION 00 COMMUTERS Disconnection prior to welding Switch ignition OFF Open the 2 circuit breakers (each end) Switch Master cut-out OFF Press here Disconnect both electronic grounds Disconnect C397 and C355 Use insulating tape to make sure that cables don’t touch each other or the vehicle body Page 2 of 8...
Page 31 PROCEDURE REFERENCE NO: PR10177-232 (COMMUTER) REVISION 00 Disconnection prior to welding Disconnect all the connectors from the I/O-A and Disconnect the control connector from the battery I/O-B modules in rear junction box equalizer In the front junction box Disconnect all the connectors from : I/O-A modules I/O-B modules Vancso Gateway...
Page 32 PROCEDURE REFERENCE NO: PR10177-232 (COMMUTER) REVISION 00 Disconnection prior to welding Behind the right console panel In the condensor compartment Disconnect all the connectors from the I/O-B Disconnect the ACM connector (A137A) modules In the evaporator compartment The vehicle is now ready for welding Disconnect all the connectors from I/O-B module Make sure that the welding ground is as close as possible of the...
Page 33 H3 SERIES ‒ PROCEDURE REVISION 00 H3 SERIES - with New Electrical Architecture Cover electronic control components and wiring to protect from hot sparks, etc. Do not use TIG welding process on the vehicle. This high frequency current process can seriously damage the electronic components.
Page 34 H3 SERIES ‒ PROCEDURE REVISION 00 3. Trip circuit breakers CB2 & CB6. 4. Disconnect the chassis ground cable “00” (GND) from the appropriate battery post (figure on your right). CAUTION Position welding machine ground clamp as close as possible to the work. Ensure that the welding machine ground return clamp is well secured and makes a good electrical contact with a large metallic area of the chassis located as close as possible to the welding point.
Page 35 X3 SERIES ‒ PROCEDURE REF NO: PR10177-487 REVISION 00 X3 SERIES - with New Electrical Architecture Cover electronic control components and wiring to protect from hot sparks, etc. Do not use TIG welding process on the vehicle. This high frequency current process can seriously damage the electronic components.
Page 36 X3 SERIES ‒ PROCEDURE REF NO: PR10177-487 REVISION 00 3. Trip circuit breakers CB2 & CB6. 4. Disconnect the chassis ground cable “00” (GND) from the appropriate battery post (figure on your right). CAUTION Position welding machine ground clamp as close as possible to the work. Ensure that the welding machine ground return clamp is well secured and makes a good electrical contact with a large metallic area of the chassis located as close as possible to the welding point.
Page 37 SECTION 01: ENGINE CONTENT SECTION CHANGE LOG ............................2 TORQUE TABLES ............................. 3 POWER PLANT CRADLE INSTALLATION ......................3 BELT TENSIONERS AND IDLERS ........................4 VOLVO D13 ENGINE ............................6 SYSTEM OVERVIEW ............................6 ENGINE HARNESS ............................7 ENGINE OVERVIEW ............................11 ENGINE &...
Page 38: Section Change Log
SECTION 01 : ENGINE SECTION CHANGE LOG DESCRIPTION DATE Commuter coach info added & EFD update (cradle, straps & idlers) May 2018 Updated engine mount torque values was 90 lb-ft; is 94 lb-ft Sept 2018 OBD19, new engine harness, new engine sensor CAC out Feb 2019 PA1621 Maintenance Manual All Series | Section 01 revised Feb 2019...
Page 39: Torque Tables
SECTION 01 : ENGINE 1. TORQUE TABLES 1.1 POWER PLANT CRADLE INSTALLATION VOLVO ENGINE CRADLE INSTALLATION DESCRIPTION TORQUE Screw, cap hexagonal head M8 – 1.25 g8.8 14 lb-ft (19 Nm) Screw, cap hexagonal head M12 – 1.75 g8.8 60 lb-ft (81 Nm) Screw, cap hexagonal head M14 –...
Page 40: Belt Tensioners And Idlers
SECTION 01 : ENGINE 1.2 BELT TENSIONERS AND IDLERS PA1621 Maintenance Manual All Series | Section 01 revised Feb 2019...
Page 41 SECTION 01 : ENGINE 01226_ VOLVO ENGINE – DRIVE BELT IDLERS & TENSIONERS DESCRIPTION TORQUE Idler, water pump drive 43 lb-ft (58 Nm) pulley 16 lb-ft (22 Nm) Idler, water pump drive shaft 32 lb-ft (43 Nm) Idler, A/C compressor drive 31.5-38.5 lb-ft (43-52 Nm) Idler, A/C compressor drive 82 lb-ft (111 Nm)
Page 42: Volvo D13 Engine
SECTION 01 : ENGINE 2. VOLVO D13 ENGINE 2.1 SYSTEM OVERVIEW NOTE The “Premium Tech Tool” (PTT) is the preferred tool for performing diagnostic work. Contact your local dealer for more information. The Engine Management System (EMS) controls many engine functions such as: fuel timing and delivery, engine protection functions, engine brake operation, EGR valve function and the turbocharger nozzle function.
Page 43: Engine Harness
SECTION 01 : ENGINE 2.2 ENGINE HARNESS FIGURE 1: D13 ENGINE HARNESS Throttle, Engine Air Mass Regulation Variable geometry Turbo Actuator Charge Air Cooler Temperature Sensor Turbocharger Speed Sensor EGR Solenoid Valve Oil Pressure Sensor Engine Speed Sensor Camshaft Crankcase Pressure Sensor EGR Temperature sensor Engine Speed Sensor Crankshaft EGR Delta-P (differential pressure)
Page 44 SECTION 01 : ENGINE PA1621 Maintenance Manual All Series | Section 01 revised Feb 2019...
Page 45 SECTION 01 : ENGINE PA1621 Maintenance Manual All Series | Section 01 revised Feb 2019...
Page 46 SECTION 01 : ENGINE FIGURE 2: ENGINE HARNESS CONNECTION POINTS IMPORTANT NOTE Disconnection of Auxiliary Emission Control Device - 25% engine derate Auxiliary Emission Control Device (EACD) defines as any element of design which senses temperature, vehicle speed, engine RPM, transmission gear, manifold vacuum, or any other parameter for the purpose of activating, modulating, delaying, or deactivating the operation of any part of the emission control system.
Page 47: Engine Overview
SECTION 01 : ENGINE 2.3 ENGINE OVERVIEW FIGURE 3: D13 ENGINE OVERVIEW, CURB SIDE 1. Mixing Chamber 8. Fuel filter (Primary) 2. Intake Manifold 9. Fuel/Water separator 3. CCV Breather Pipe 10. Fuel Filter (Secondary) 4. Air Compressor 11. Crankcase Ventilator 5.
Page 48 SECTION 01 : ENGINE FIGURE 4: D13 ENGINE OVERVIEW, ROAD SIDE 15. Exhaust Manifold 21. Coolant Inlet Pipe 16. Valve Cover 22. Oil Filters 17. Thermostat Cover 23. EGR Cooler 18. Belt Tensioner 24. Turbocharger Actuator 19. Venturi 25. Starter 20.
Page 49: Engine & Exhaust Aftertreatment System Diagram
SECTION 01 : ENGINE 2.4 ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM FIGURE 5: : 2010 AND LATER ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (1 OF 2) 01222 PA1621 Maintenance Manual All Series | Section 01 revised Feb 2019...
Page 50 SECTION 01 : ENGINE FIGURE 6: 2010 AND LATER ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (2 OF 2) 01222 NOTE For maintenance or repair information of engine components or engine-related components, please refer to Volvo Trucks USA Web Site under: Parts & Services, Online Manuals. http://www.volvotrucks.us/parts-and-services/service/online-manuals/ PA1621 Maintenance Manual All Series | Section 01 revised Feb 2019...
Page 51: Engine Oil
SECTION 01 : ENGINE 2.5 ENGINE OIL MAINTENANCE Keep the engine oil at the proper level and change it at the recommended intervals. Always Engine oil and filters change replace the oil filters at the same time as when Change engine oil and filters at the intervals the oil is changed.
Page 52: Synthetic Lubrication
SECTION 01 : ENGINE FIGURE 7: D13 OIL FILTERS 2.5.4 Synthetic Lubrication Synthetic oils are offered by some oil suppliers as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality levels of the traditional, petroleum based oils for engines and provided they meet the quality level VDS-4 or VDS-4.5.
Page 53: Oil Additives
SECTION 01 : ENGINE 2.5.6 Oil Additives CAUTION CAUTION Always dispose of all lubricants (motor oil, coolant, gear box oils, etc) and filters according to Federal or local regulations. Extra oil additives must never be added to any Used oil disposed of in nature or waterways engine oil used.
Page 54: Checking The Oil Level
SECTION 01 : ENGINE • Clean around the oil filter housing and • Start the engine and check for leaks remove the filters using the oil filter wrench around the oil filter housing and filters. or the oil filter socket. Check the oil level.
Page 55: Power Plant Assembly Removal
SECTION 01 : ENGINE With Vehicle Raised • 2.6 POWER PLANT ASSEMBLY REMOVAL 1. Using a vehicle lift or jack, raise vehicle to access engine engine-related access transmission fasteners and wire components, the vehicle power plant assembly harness. must be removed as a whole unit by means of a slide-out cradle.
Page 56 SECTION 01 : ENGINE 7. Remove the retaining bolts, washers and nuts securing the power plant cradle to the vehicle rear subframe. 8. Disconnect the engine coolant hose near the starter. 9. Disconnect air compressor suction and discharge hoses. FIGURE 13: BELT TENSIONER VALVE ON REAR CONTROL PANEL (OPTION) 9.
Page 57 SECTION 01 : ENGINE Unfasten aside engine compartment lighting fixture and turbocharger fire suppression nozzle if applicable. Disconnect Exhaust Aftertreatment System control cable. • Last 1. Inspect the power plant assembly to ensure that nothing will interfere when sliding cradle. Check connections or hoses not mentioned in this list as some vehicles are equipped with...
Page 58: Power Plant Assy. Installation
SECTION 01 : ENGINE FIGURE 14: TYPICAL X SERIES ENGINE COMPARTMENT 2.7 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 59: Engine Mounts
SECTION 01 : ENGINE 3. Refill cooling system with saved fluid (refer to Section 05 COOLANT SYSTEM 4. Once engine fuel system has been drained, it will aid restarting if fuel filters are filled with fuel oil (refer to Section 03 FUEL SYSTEM 5.
Page 60: Bearing Inspection
SECTION 01 : ENGINE A=alternator C=crank pulley I=dler WP=water pump T=tensioner AC=air conditioning compressor FIGURE 17: COACH BELT ROUTING I= IDLER FIGURE 18: VIP BELT ROUTING – SMALL A/C SYSTEM, T= TENSIONER 01233 FIGURE IDLER PULLEYS, AUTOMATIC BELT TENSIONERS ON ENGINE ACCESSORIES 4.1 BEARING INSPECTION 1.
Page 61: Automatic Belt Tensioner Bushing Wear
SECTION 01 : ENGINE FIGURE 23: CHECKING BUSHING WEAR 3. If bushing wear is suspected, remove the tensioner. Inspect the tensioner for any signs of wear. Check for bearing noise as well as metal to metal contact between the arm and spring case which is a sign of bushing wear.
Page 62 SECTION 01 : ENGINE Prior to an actual automatic shutdown, the High VGT actuator temperature Derate only engine will automatically derate, go to idle, and High pre-Diesel Oxidation Derate only then stop in 30 seconds. Catalyst (DOC) temperature High Compressor Discharge Derate only Temperature (CDT –...
Page 63 Oil Pan Capacity, High Limit ....................34 quarts/32 liters Refill volume including filter change .................. 40 quarts/38 liters Lubricating oil filter elements Type ..............................By-pass Prevost number ..........................510938 Type ..............................Full Flow Prevost number ..........................488736 Torque specification Engine oil filter ............. Tighten ¾ of a turn to 1 full turn after gasket contact...
Page 65 MAINTENANCE MI16-16 INFORMATION DATE : FEBRUARY 2016 SECTION : 01 - Engine VOLVO D13 ENGINE – SUBJECT : STARTER REMOVAL AND INSTALLATION DESCRIPTION This procedure applies to current Melco 105P70 starter part number #21212425. REQUIRED TOOLS RATCHET EXTENSION BAR RATCHET AND SOCKET SET – METRIC CORDLESS DRILL BRASS WIRE CUP BRUSH TORQUE WRENCH...
Page 66 MI16-16 / Page 2 / 6 PROCEDURE – STARTER REMOVAL AND INSTALLATION DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition the battery master switch to the OFF position switch to the OFF position, and trip the main circuit breakers equipped with a trip button.
Page 67 MI16-16 / Page 3 / 6 5. Using a 18mm socket, unscrew three bolts fastening the starter to the flywheel housing ( FIGURE 3 6. Detach the starter from the flywheel housing. FIGURE 3 STARTER INSTALLATION 1. If the starter is replaced with a brand new starter, prepare the new starter as follows (refer to FIGURE 5...
Page 68 MI16-16 / Page 4 / 6 FIGURE 6 FIGURE 5 FIGURE 7 2. Install the replacement starter with the solenoid located on the underside of the starter motor as shown on FIGURE 8 3. Hand tighten the three mounting nut. Flange nut M12 p/n 990942 qty: 3 4.
Page 69 504637 as shown on FIGURE 12 FIGURE 12 14. Apply anti-corrosion compound or Color Guard Rubber Coating (Prevost p/n 684013) on starter terminals, cable lugs and nuts (see FIGURE 13 FIGURE 15 FIGURE 13 <QF7720955 rev 2>...
Page 70 MI16-16 / Page 6 / 6 FIGURE 14 FIGURE 15 FUNCTIONAL TEST 1. Reset main circuit breakers if applicable. Set the battery master switch (master cut-out) to the ON position and start the engine. PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone.
Page 71 SECTION 03 : FUEL SYSTEM CONTENTS SECTION CHANGE LOG ............................3 TORQUE TABLES ............................. 4 FUEL SYSTEM ..............................4 MISCELLANEOUS TORQUES ........................... 4 FUEL SYSTEM ..............................5 FUEL VALVES ..............................5 FUEL FILTERS ..............................5 2.2.1 Primary Fuel Filter Replacement ......................6 2.2.2 Secondary Fuel Filter Replacement ......................
Page 72: Specifications
SECTION 03 : FUEL SYSTEM POTENTIOMETER REPLACEMENT ........................ 22 SPECIFICATIONS ............................23 PA1621 Maintenance Manual All Series | Revised May 2018...
Page 73: Section Change Log
SECTION 03 : FUEL SYSTEM SECTION CHANGE LOG DESCRIPTION DATE Added: information about specific fuel filters for GHG17 engines Sept. 7, 2017 Commuter Coach info added (steel fuel tank & air filter restriction indicator) May 29 2018 PA1621 Maintenance Manual All Series | Revised May 2018...
Page 74: Torque Tables
SECTION 03 : FUEL SYSTEM 1. TORQUE TABLES 1.1 FUEL SYSTEM 03100 03101 FUEL FILTER HOUSING – VOLVO D13 ENGINE DESCRIPTION TORQUE Fuel filter housing assembly screws 15-21 lb-ft (20-28 Nm) Dosing module mounting screws 7.5 lb-ft (10 Nm) 1.2 MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION TORQUE...
Page 75: Fuel System
SECTION 03 : FUEL SYSTEM 2. FUEL SYSTEM Fuel pressure sensor (low pressure system) NOTE Aftertreatment hydrocarbon injector module For additional information concerning Volvo D13 engine components or engine-related Hand pump (fuel primer pump) components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: 2.1 FUEL VALVES Parts &...
Page 76: Primary Fuel Filter Replacement
SECTION 03 : FUEL SYSTEM MAINTENANCE The primary and secondary (aka pre-filter and main filter) fuel filters are of a spin-on type and must be replaced at the intervals specified by the Lubrication And Servicing Schedule in 4. Unscrew and remove Section 24: LUBRICATION &...
Page 77 SECTION 03 : FUEL SYSTEM 10. Clean contact surface apply CAUTION engine oil to the filter seals (inner & outer). Primary & secondary fuel filters on GHG17 engines CAUTION Do not install pre-GHG17 fuel filters on GHG17 Fuel in the old filter must absolutely not be engines.
Page 78: Secondary Fuel Filter Replacement
SECTION 03 : FUEL SYSTEM Difference between secondary fuel filter end CAUTION caps Fuel in the old filter must absolutely not be poured into the new filter. This kind of contaminated fuel can damage the unit injectors. Prime the fuel system by pumping the hand priming pump on the fuel filter housing until resistance is felt indicating that the system is full of fuel.
Page 79: Filter Replacement
SECTION 03 : FUEL SYSTEM If a Fuel Pro 382 fuel processor is installed on the vehicle, refer to paragraph 2.4 Davco Fuel Pro 382 otherwise, perform the steps below: 1. Prime filter operating hand primer pump until resistance is felt indicating that the system is full of fuel.
Page 80: Fuel Pump Removal And Installation
SECTION 03 : FUEL SYSTEM 9. Ensure the filter spring is installed at the top of the clear cover. If missing, the spring must be replaced to insure proper filter operation. 10. After ensuring the seal is properly positioned at the base of the clear cover, install it with the collar onto the fuel processor.
Page 81: Fuel Lines And Flexible Hoses
SECTION 03 : FUEL SYSTEM Start the engine and let run for 5 minutes.  NOTE Make sure that there are no leaks. Only unfasten the bolts marked with arrows. 3. 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 82: Fuel Tank
SECTION 03 : FUEL SYSTEM NOTE MAINTENANCE Before removal, the fuel tank should be completely drained by unscrewing the drain Replace preheater fuel filter at the intervals plug. Ensure that the container used has a specified by the Lubrication And Servicing capacity equal to the amount of fuel remaining Schedule in Section 24: LUBRICATION &...
Page 83 SECTION 03 : FUEL SYSTEM WARNING For proper assembly, check connections and fasteners for tightness. FIGURE 12: 208 US GALLONS FUEL TANK 03094 WARNING FIGURE 13: FUEL TANK RETENTION 03019_2 Before removing the bolts securing the tank For each fuel tank retainer (Figure 13): support to the frame, make sure the tank is 1.
Page 84: Polyethylene Fuel Tank Repair
3. Drill perforation with a 23/64" bit. Make sure drill hole is perfectly round. 4. Insert a screw (Prevost #500196) and a washer (Prevost #5001244) into anchor nut FIGURE 15: STEEL FUEL TANK ASSEMBLY (Prevost #500331).
Page 85: Steel Tank Removal
SECTION 03 : FUEL SYSTEM 4. Disconnect the fuel level sender electrical wires (3wires). Prior disconnecting, identify the wires and proper terminal on the fuel level sender as reference for reinstallation (Figure 17). 5. Using mobile column lifts, raise the vehicle to gain access to the fuel tank support from underneath.
Page 86: Steel Tank Installation
SECTION 03 : FUEL SYSTEM 5.9 STEEL TANK INSTALLATION To install tank, simply reverse the "Tank Removal" procedure. Apply Valvoline anti- corrosion compound on retainer strap studs, nuts and fuel tank cradle mounting bolts. Fasten tank to cradle (tank straps). TORQUE: 20 lb-ft (27 Nm) Fasten tank support to vehicle.
Page 87: Fuel Specifications
SECTION 03 : FUEL SYSTEM FIGURE 22: LOCATION OF MOUNTING POINTS FIGURE 25: VISIBLE GAP ON TRANSVERSAL SCREW JOINT 6. If shims are not present, the visible gap should be shimmed using U-shims #030082 and/or #030083 as required. FIGURE 23: TRANSVERSE SCREWS, 2 LOCATIONS 7.
Page 88: Fuel Type
NOTE biodiesel fuel would not be recognized nor considered as Volvo or Prevost’s responsibility. Burning Low Sulfur Diesel fuel (instead of ULSD fuel) in 2010 and later model year diesel However, Volvo engines are certified to comply...
Page 89: Biodiesel Fuels And Preheater
Consisting of a black tube, it is fixed on the main Workshop Manual for Thermo 230, 300, 350, intake hose. available on the Technical Publications USB flash drive and on Prevost technical publications website. ESTRICTION INDICATOR 6.3.2 Biodiesel Fuels and the Engine Use an oil sampling method to establish the appropriate oil drain interval for your application.
Page 90 SECTION 03 : FUEL SYSTEM LEAN BOTH SIDES OF THE FLANGE FIGURE 29  Look for traces of dirt and particles on the outer surface of the old filter, indicating possible leakage. If so, the leakage cause FIGURE 30 should be investigated and solved. ...
Page 91: General Recommendations
SECTION 03 : FUEL SYSTEM 7.4 AIR CLEANER RESTRICTION INDICATOR A resettable restriction indicator may be installed on the engine air-intake duct, clearly visible from the rear engine compartment. The indicator monitors the vacuum level between the air cleaner and the engine. A red marker is displayed when the air cleaner is clogged and must be replaced.
Page 92: Fuel Pedal
SECTION 03 : FUEL SYSTEM 3. Discard potentiometer (Figure 34). MAINTENANCE CAUTION Air cleaner Note the routing and clamping locations of the Change the filter element when indicated by the cable before disassembly. Proper cable restriction indicator or at the intervals specified routing and fastening is critical to the by the Lubrication And Servicing Schedule in operation of this system.
Page 93 SECTION 03 : FUEL SYSTEM 9. SPECIFICATIONS Davco Fuel Pro 382 Fuel Filter / Water Separator Element Max Fuel Flow ........................180 US gal/h (681 l/h) Water removal @ 25 microns ........................99.6% Dirt holding capacity @ 25 microns ....................... 110 g Primary Fuel Filter (Fuel/Water Separator) Filter type ............................
Page 95 SECTION 04 : EXHAUST AND AFTERTREATMENT CONTENTS SECTION CHANGE LOG ............................2 TORQUE TABLES ............................. 3 1.1. X3 SERIES ................................ 3 1.2. H3 SERIES ............................... 5 1.3. MISCELLANEOUS TORQUES ........................... 9 EXHAUST AFTERTREATMENT SYSTEM (EATS) OVERVIEW................10 1.4..............................11 MAINTENANCE 1.5.
Page 96: Section Change Log
SECTION 04 : EXHAUST AND AFTERTREATMENT SECTION CHANGE LOG DESCRIPTION DATE Torque table: Added torque #16 [9.4.20.17] Nov 2017 Torque table: Added, temp sensor T4 on SCR converter Feb 2019 PA1621 Maintenance Manual All Series | Section 04 revised Feb 2019...
Page 97: Torque Tables
SECTION 04 : EXHAUST AND AFTERTREATMENT 1. TORQUE TABLES The following tables show specific torque values for the DPF assembly. In the absence of a torque specification for a given item, standard torque applies. See table in Section 00: General Information. 1.1.
Page 98 SECTION 04 : EXHAUST AND AFTERTREATMENT * Use Permatex 454G anti-seize lubricant or Loctite 76764 silver grade anti-seize 04038 04037 X3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE DPF inlet temperature sensor (T1) 30-37 lb-ft (41-50 Nm)* DPF tank strap 17-23 lb-ft (23-31 Nm) DPF tank V-band clamp 17-23 lb-ft (23-31 Nm) * Use Permatex 454G anti-seize lubricant or Loctite 76764 silver grade anti-seize...
Page 99: H3 Series
SECTION 04 : EXHAUST AND AFTERTREATMENT X3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE SCR tank strap bolts 30-37 lb-ft (41-50 Nm) NOx sensor 2 (outlet) 30-44 lb-ft (41-60 Nm) Module mounting bolts 5.9-8.8 lb-ft (8-11.93 Nm) SCR tank particulate matter sensor 33-40.5 lb-ft (45-55 Nm) SCR tank temperature sensor (T4) 30-37 lb-ft (41-50 Nm)*...
Page 100 SECTION 04 : EXHAUST AND AFTERTREATMENT * Use Permatex 454G anti-seize lubricant or Loctite 76764 silver grade anti-seize H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE V-band clamp 4-inch & 5-inch 6.5-9.5 lb-ft (9-13 Nm) DPF filter outlet pressure sensor 3.7-4.6 lb-ft (5.02-6.24 Nm) * DPF filter inlet pressure sensor 3.7-4.6 lb-ft (5.02-6.24 Nm) * Diesel Oxydation Catalyst (DOC) temperature sensor (T2)
Page 101 SECTION 04 : EXHAUST AND AFTERTREATMENT H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE V-band clamp 4-inch & 5-inch 6.5-9.5 lb-ft (9-13 Nm) DPF inlet temperature sensor (T1) 30-37 lb-ft (41-50 Nm) * DPF tank V-band clamp 17-23 lb-ft (23-31 Nm) Vibration damper screw downstream from turbo 15.5-18.5 lb-ft (21-25 Nm) PA1621 Maintenance Manual All Series | Section 04 revised Feb 2019...
Page 102 SECTION 04 : EXHAUST AND AFTERTREATMENT H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE SCR tank strap 30-37 lb-ft (41-50 Nm) Module mounting bolt 6.3-8.5 lb-ft (9-12 Nm) SCR tank NOx sensor 2 (outlet) 30-44 lb-ft (41-60 Nm) SCR tank particulate matter sensor 33-40.5 lb-ft (45-55 Nm) SCR tank temperature sensor (T4) 30-37 lb-ft (41-50 Nm)*...
Page 103: Miscellaneous Torques
SECTION 04 : EXHAUST AND AFTERTREATMENT 1.3. MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION TORQUE Aftertreatment hydrocarbon doser fuel line fitting 177-213 lb-in (20-24 Nm) Aftertreatment hydrocarbon doser mounting bolts 120-130 lb-in (14-15 Nm) DEF pump filter cover 22 lb-ft (30 Nm) PA1621 Maintenance Manual All Series | Section 04 revised Feb 2019...
Page 104: Exhaust Aftertreatment System (Eats) Overview
SECTION 04 : EXHAUST AND AFTERTREATMENT 2. EXHAUST AFTERTREATMENT SYSTEM The EATS is rubber mounted to the vehicle structure. This feature reduces the transmission (EATS) OVERVIEW of vibrations to the EATS thus resulting in extended life of the system, brackets and also noise reduction.
Page 105: Maintenance
SECTION 04 : EXHAUST AND AFTERTREATMENT • Engine timing sensor; NOTE • Engine coolant temperature; INSULATING BLANKETS • EGR temperature sensor. The key to successful regeneration is high exhaust temperature for an extended period of 1.4. MAINTENANCE time. For this reason, insulating blankets must remain permanently on the exhaust system.
Page 106: Diesel Particulate Filter (Dpf)
Clean remanufactured DPF cartridge will be available through Prevost on an exchange basis. For most vehicle applications and duty cycle, this will occur after approximately 200,000 to 400,000 miles (320,000 to 640,000 km) of operation.
Page 107 SECTION 04 : EXHAUST AND AFTERTREATMENT FIGURE 3: DIESEL OXIDATION CATALYST (DOC) & DIESEL PARTICULATE FILTER (DPF) ASSEMBLY FIGURE 4: EATS SENSORS LOCATION - OBD19 VERSION PA1621 Maintenance Manual All Series | Section 04 revised Feb 2019...
Page 108: Diesel Particulate Filter Assembly Removal
SECTION 04 : EXHAUST AND AFTERTREATMENT CAUTION WARNING HEAVY DEVICE HOT EXHAUST A suitable lifting or holding device is required. During stationary regeneration, exhaust gases Properly support and attach lifting equipment temperature may get very hot at the diffuser to prevent the DOC and DPF assembly from outlet.
Page 109 SECTION 04 : EXHAUST AND AFTERTREATMENT FIGURE 5: TAKING DOC AND DPF APART 9. Always put DOC and DPF filtration cartridge back together again in a vertical position to facilitate gaskets positioning; 10. Tighten V-band clamps. TORQUE: 20 lb-ft (27 Nm) CAUTION Always torque clamps by hand.
Page 110: Catalytic Converter
SECTION 04 : EXHAUST AND AFTERTREATMENT 4. CATALYTIC CONVERTER In the first instance, the catalytic converter of the Selective Catalytic Reduction (SCR) does not need any maintenance. Unless an accident or damage occurs in the vicinity of the engine compartment; the catalytic converter will not have to be replaced.
Page 111: Assembling Catalytic Converter
SECTION 04 : EXHAUST AND AFTERTREATMENT way or that might prevent removing the Remove clamps holding catalytic converter • catalytic converter. then lower. With all setups: Procedure # 2 • Remove disconnect piece • Set the starter selector switch to the OFF equipment or component that might be in the position.
Page 112 SECTION 04 : EXHAUST AND AFTERTREATMENT regard to the clamp supports on the catalytic converter. Lower Upper Upper Assembling Position the upper clamps above the upper • emboss and the lower clamps below the lower emboss of the catalytic converter. Lower Lower CLAMP...
Page 113: Diffuser Assembly
SECTION 04 : EXHAUST AND AFTERTREATMENT centered with the exhaust inlet of the roof surface or may not exceed the roof catalytic converter. surface more than 3/32 inch (2 mm). EXHAUST CAUTION INLET Tighten clamps properly in order to prevent any movement of the diffuser assembly.
Page 114: Maintenance
SECTION 04 : EXHAUST AND AFTERTREATMENT • Check for proper functioning of the rain cap inside the diffuser housing, make sure that it moves freely; • Make sure that the water drain tube is not clogged. Pour a cup of water into the diffuser housing and assure that all the water is drained at once at the other end of the drain tube.
Page 115 SECTION 04 : EXHAUST AND AFTERTREATMENT CAUTION Diesel Exhaust Fluid (DEF) is a nontoxic aqueous solution of urea (32.5%) and ultra- pure water (67.5%). Urea is a compound of nitrogen that turns to ammonia when heated. The fluid is non-flammable, and is not dangerous when handled as recommended.
Page 116 SECTION 04 : EXHAUST AND AFTERTREATMENT FIGURE 11: H SERIES DEF TANK AND PUMP FIGURE 12 X SERIES DEF TANK AND PUMP PA1621 Maintenance Manual All Series | Section 04 revised Feb 2019...
Page 117: Def Tank Cleaning
SECTION 04 : EXHAUST AND AFTERTREATMENT 1.14. PUMP ASSEMBLY FILTER ELEMENT REPLACEMENT 1.13. DEF TANK CLEANING 1. Clean the area around filter cover. Removing the DEF tank for cleaning is not 2. Before you loosen the filter cover, place a necessary.
Page 118: Filler Nec Kstrainer
SECTION 04 : EXHAUST AND AFTERTREATMENT 5. Install new filter element and equalizer. In addition to the activation of the CHECK Checks filter element cover and housing for telltale, emission of diagnostic troubleshooting damage. If either the filter or housing is codes (DTC) by the engine ECM (MID128) will damaged, the damaged part must be indicate malfunction of the aftertreatment system...
Page 119 SECTION 04 : EXHAUST AND AFTERTREATMENT Clean the sealing surface on the diffuser pipe before mounting the aftertreatment hydrocarbon injector. FIGURE 14: AFTERTREATMENT HYDROCARBON DOSER Install the new aftertreatment hydrocarbon injector and new gasket onto the diffuser pipe (which attaches to the turbocharger outlet) and tighten the fasteners.
Page 121 SECTION 05: COOLING SYSTEM CONTENTS SECTION CHANGE LOG ............................2 TORQUE TABLES ............................. 3 HOSE CLAMPS ..............................3 PULLEYS, IDLERS & TENSIONERS ........................4 COOLING ASSEMBLY ............................5 MISCELLANEOUS ............................6 DESCRIPTION ..............................7 MAINTENANCE ............................... 9 GENERAL RECOMMENDATIONS ........................9 COOLANT FILTER HOUSING SHUT-OFF VALVE –...
Page 122 SECTION 05: COOLING SYSTEM SECTION CHANGE LOG DESCRIPTION DATE Section 05A & 05B merged - intro H3 Series NEA & Electric Fans Jan 2018 Addition of paragraph 3.2: coolant filter housing shut-off valve – spindle servicing Apr 2018 New X3 Series recovery tank and CAC clamps torque values June 2018 New component torque value added –...
Page 123: Torque Tables
SECTION 05: COOLING SYSTEM TORQUE TABLES HOSE CLAMPS Note : X3 shown 05179_1 X3 shown. Torque values applicable to X3 & H3 HOSE CLAMPS DESCRIPTION TORQUE Hose clamps - coolant lines (2.5 in O.D) 30 lb-in (3.39 Nm) Constant-torque hose clamps - charge air cooler (CAC) 4.5-5.5 lb-ft (6.1-7.46 Nm) PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 124: Pulleys, Idlers & Tensioners
SECTION 05: COOLING SYSTEM Intake elbow - V-clamps (both) 4.5-6 lb-ft (6.1-8.13 Nm) 5.3-6.5 lb-ft (7-9 Nm) Screw, CAC air temperature sensor PULLEYS, IDLERS & TENSIONERS 01225_3 PULLEYS, IDLERS & TENSIONERS DESCRIPTION TORQUE Water pump idler pulley bolts 16 lb-ft (22 Nm) Crank pulley bolts 22 lb-ft (30 Nm) Idler bolt –...
Page 125: Cooling Assembly
SECTION 05: COOLING SYSTEM COOLING ASSEMBLY COOLING ASSEMBLY DESCRIPTION TORQUE CAC upper & lower mounting bolts (with plastic bushings) 9 lb-ft (12 Nm) Radiator to cooling pack frame mounting bolts (pass through) 9 lb-ft (12 Nm) Cooling pack frame bolts (all 8mm bolts – both sides) 9 lb-ft (12 Nm) Brackets, fan shroud hinge, shroud support &...
Page 126: Miscellaneous
SECTION 05: COOLING SYSTEM MISCELLANEOUS MISCELLANEOUS DESCRIPTION TORQUE Water pump - Back cover to engine 29-41 lb-ft (39-56 Nm) Water pump - body to back cover 15-21 lb-ft (20-28 Nm) Thermostat housing bolts 15-21 lb-ft (20-28 Nm) Electric cooling fan mounting bolts 30 lb-in (3 Nm) Coolant level sensor (arrow on side must point up) 2 Threads out MAX*...
Page 127: Description
SECTION 05: COOLING SYSTEM Upon starting a cold engine or when the coolant is below normal operating temperature, the DESCRIPTION closed thermostat directs coolant flow from the thermostat housing through the by-pass tube to A radiator and variable speed electric cooling the water pump.
Page 128 SECTION 05: COOLING SYSTEM FIGURE 1: COOLING ASSEMBLY & RELATED COMPONENTS (X3 SERIES SHOWN) FIGURE 2: COOLANT SURGE TANK AND RECOVERY TANK ON X3 SERIES VEHICLES PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 129: Maintenance
SECTION 05: COOLING SYSTEM FIGURE 3: COOLANT SURGE TANK ON H3 SERIES VEHICLES radiator mounts periodically. Test replace thermostat regularly. MAINTENANCE NOTE In order to ensure the integrity of the system, it is recommended that a periodic cooling system GENERAL RECOMMENDATIONS pressure check be made.
Page 130: Coolant Filter Housing Shut-Off Valve - Spindle Servicing
SECTION 05: COOLING SYSTEM NOTE 4. Drain the coolant from the engine. Refer to DRAINING COOLING SYSTEM this For additional information concerning Volvo section. D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web site under: Shut-off valve corrosion repair procedure Parts &...
Page 131: Hoses
SECTION 05: COOLING SYSTEM 8. Gently scrape by hand and remove any loose 11. Reinsert the spindle (2) into the coolant filter debris or corrosion from the spindle and housing (3) and tighten the M5 hex socket coolant filter housing using an abrasive screw (1).
Page 132: Constant-Torque Hose Clamps On Charge Air Cooler (Cac)
SECTION 05: COOLING SYSTEM connection that occurs during vehicle operation and shutdown. These clamps are worm-driven and made of stainless steel. All connections equal or greater than 2 inches OD have doubled clamps (two clamps, side by side) with screw housing separated from at least 90°.
Page 133: Maintenance
SECTION 05: COOLING SYSTEM FIGURE 15: VOLVO D13 THERMOSTAT HOUSING 19. Install the new thermostat. Make sure that the rubber seal remains properly seated. 20. Position the thermostat housing to the cylinder head, install the bolts and tighten. TORQUE: 15-21 lb-ft (20-28 Nm) 21.
Page 134: Coolant
SECTION 05: COOLING SYSTEM COOLANT COOLANT RECOMMENDATIONS FOR VOLVO D13 ENGINE The coolant provides a medium for heat transfer COOLANT LEVEL VERIFICATION and controls the internal temperature of the engine during operation. In an engine having Cold engine coolant level is correct when coolant proper coolant flow, some of the combustion is visible halfway up through the surge tank heat is conveyed through the cylinder walls and...
Page 135 SECTION 05: COOLING SYSTEM Recommended coolants for Volvo D13 engine: • Texaco CPS#227998 (pre-diluted 50/50 mixture); • Chevron CPS#227811 (pre-diluted 50/50 mixture); • Volvo 20358716 (pre-diluted 50/50 mixture); coolant slow depleting additive chemistry does not require regular testing, but the coolant can be tested with a FleetFix® Maintenance Test Strip (to measure nitrite and carboxylate levels) and the FleetFix®...
Page 136 SECTION 05: COOLING SYSTEM FIGURE 16: LOCATION OF HEATER LINE SHUT-OFF VALVES IN ENGINE COMPARTMENT (X3 SERIES) PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 137: Coolant Sampling
SECTION 05: COOLING SYSTEM FIGURE 17: LOCATION OF HEATER LINE SHUT-OFF VALVES IN ENGINE COMPARTMENT (H3 SERIES) Providing a sample of coolant for lab analysis may be required at some point in the life of the COOLANT SAMPLING vehicle. Typical material required: NOTE •...
Page 138: Draining Cooling System
SECTION 05: COOLING SYSTEM On X3 Series vehicles, the valves are located in NOTE the engine compartment. One is located under Watch out for accidental contamination! the turbocharger inlet pipe in the lower L.H side of the engine compartment; another valve is Hand vacuum pump should be used for located behind the L.H.
Page 139: Filling Cooling System
SECTION 05: COOLING SYSTEM 4. Unscrew the surge tank pressure cap of the 6. Open the radiator drain cock. H3 Series vehicles counterclockwise, ¼ turn 7. Remove the transmission oil cooler. Drain, to let air enter the system and permit the flush and inspect.
Page 140: Flushing
SECTION 05: COOLING SYSTEM 4. Install the pressure cap, then start the engine Fill with a 50/50-antifreeze/water solution and run it at fast idle until reaching normal and add required inhibitors. operating temperature. Check for leaks. Vehicles with coolant filters: Fill with a 50/50-antifreeze/water solution.
Page 141: Reverse Flushing
SECTION 05: COOLING SYSTEM 2. Attach a hose to the top of the radiator to lead CAUTION water away from the engine. 3. Attach a hose at the bottom of the radiator Only use de-scaling products sold by a and insert a flushing gun in the hose. reputable manufacturer, product must be aluminum and copper compatible and must be 4.
Page 142 SECTION 05: COOLING SYSTEM 1. Close the filter shutoff cock on the filter COOLING ASSEMBLY mounting head and unscrew the old filter from mounting. The cooling assembly uses a total of 8 identical 12 inches (305mm) brushless (24V) electric WARNING cooling fans to dissipate the heat generated by the engine.
Page 143 SECTION 05: COOLING SYSTEM FIGURE 20: FAN ORDER AND CONNECTOR NUMBER AT CIRCUIT BREAKER BOX PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 144 SECTION 05: COOLING SYSTEM 11.1 MAINTENANCE FIGURE 21: COOLING ASSEMBLY MAIN COMPONENTS PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 145 SECTION 05: COOLING SYSTEM NOTE WARNING Electric cooling fan motors are sealed and certified IP6K9K and IP68.They can therefore Cooling fans may start when the engine is be safely power/pressure washed. shut down in the following conditions: • If a High Exhaust Temperature condition NOTE exists (e.g.
Page 146: Cooling Assembly
SECTION 05: COOLING SYSTEM 11.2 COOLING FAN REPLACEMENT Proceed as follow to remove one (or more) individual fan from the shroud. Remove the cooling fan shroud cover by unscrewing the 10 plastic fasteners holding it to the fan shroud. FIGURE CONNECTOR &...
Page 147 SECTION 05: COOLING SYSTEM 5. Unfasten the limiter strap at the bottom of • Remove wires from wire the shroud assembly. separator and move them out of the way. 6. Support the bottom of the shroud assembly with a lift table or other suitable equipment. 7.
Page 148: H3 Series Vehicles - Cooling Pack (Radiator & Cac) Removal & Installation
SECTION 05: COOLING SYSTEM 11.4 H3 SERIES VEHICLES - COOLING PACK (RADIATOR & CAC) REMOVAL & INSTALLATION NOTE For CAC only replacement, removal of the entire cooling pack is not necessary. Refer to paragraph 11.6 in this section for “in vehicle” CAC replacement instructions.
Page 149 SECTION 05: COOLING SYSTEM 1. Open rear engine compartment door. 2. Open rear engine door and set engine stop button to the OFF position (push). 3. Remove L.H. side hinged rear fender. FIGURE 27: REMOVE REAR FENDER 4. If the vehicle is equipped with a coolant preheater, loosen the preheater exhaust clamp and remove the exhaust pipe.
Page 150 SECTION 05: COOLING SYSTEM 8. Connect coolant extractor to the radiator drain cock and drain the coolant system as per Draining cooling system in paragraph 7 of this section. FIGURE 31: RADIATOR & CAC LOWER CONNECTION 13. Proceed to the cooling fan shroud removal following paragraph 11.3 of this section.
Page 151 SECTION 05: COOLING SYSTEM FIGURE 33: COOLING PACK SUPPORTS AND COMPONENTS 15. Remove the protective (splash) plate fixed to 16. Support the cooling assembly with a lift table the cooling pack lower support. positioned under the lower support. 17. Unscrew the lower support from the vehicle (two hex bolts at each end of the support).
Page 152 SECTION 05: COOLING SYSTEM cooling pack frame upper and lateral sections and slide the old radiator out. FIGURE 35: LOWER SUPPORT MOUNTING BOLTS FIGURE 37: COOLING PACK PARTS TO BE REMOVED 18. Unscrew the two upper supports from the FOR RADIATOR REPLACEMENT vehicle structure so they will be removed with the cooling assembly.
Page 153 SECTION 05: COOLING SYSTEM NOTE Reinstallation of the cooling components as a complete assembly is recommended. - Install fan shroud on the cooling pack frame then install complete assembly to vehicle structure. 24. Lay the cooling pack horizontally at working height (use large workbench or sawhorses) FIGURE 39: SHROUD HINGES INSTALLATION exterior face pointing up.
Page 154: X3 Series Vehicles - Cooling Pack (Radiator & Cac) Removal & Installation
SECTION 05: COOLING SYSTEM 32. Slide back the cooling assembly into position and reverse removal procedure to reinstall in vehicle. 33. Make sure that there is no conductivity between the CAC/radiator units and the cooling pack frame (see note at the beginning of paragraph 11.4).
Page 155 SECTION 05: COOLING SYSTEM 36. Open rear engine compartment door. 37. Open rear engine door and set engine stop button to the OFF position (push). 38. Raise L.H. side hinged rear fender. FIGURE 42: RAISING REAR FENDER 39. Remove access panel located behind L.H tag axle wheel.
Page 156 SECTION 05: COOLING SYSTEM FIGURE COOLANT DRAIN EXTRACTOR CONNECTION FIGURE 46: RADIATOR & CAC LOWER CONNECTION DANGER 47. Proceed to the cooling fan shroud removal following paragraph 11.3 of this section (radiator door must be removed). Risk of poisoning. Do not drink coolant. Use proper hand protection when handling.
Page 157 SECTION 05: COOLING SYSTEM FIGURE 48: COOLING PACK SUPPORTS AND COMPONENTS 49. Remove the radiator door lower hinge 50. Remove the protective (splash) plate fixed to bracket. the cooling pack lower support. FIGURE 49: RADIATOR DOOR LOWER HINGE BRACKET FIGURE 50: PROTECTIVE PLATE MOUNTING BOLTS PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 158 SECTION 05: COOLING SYSTEM 51. Support the cooling assembly with a lift table 55. To proceed to the radiator replacement, positioned under the lower support. remove radiator upper pipe section, bracket and hardware, unbolt the four support bolts passing through the radiator and holding it to 52.
Page 159 SECTION 05: COOLING SYSTEM NOTE Reinstallation of the cooling components as a complete assembly is recommended. - Install fan shroud on the cooling pack frame then install complete assembly to vehicle structure. 59. Lay the cooling pack horizontally at working height (use large workbench or sawhorses) FIGURE 55: SHROUD HINGES INSTALLATION exterior face pointing up.
Page 160: Charge Air Cooler (Cac) In Vehicle Removal
SECTION 05: COOLING SYSTEM 67. Slide back the cooling assembly into position 5. Disconnect the upper CAC pipe: On the X3 and reverse removal procedure to reinstall in Series, it is possible to disconnect the pipe vehicle. middle section junction and loosen the hose clamps at the CAC connection to pivot down the pipe (to clear radiator).
Page 161 SECTION 05: COOLING SYSTEM FIGURE 60: COOLING PACK EXPLODED VIEW 7. Remove CAC upper front frame structure by 8. Remove the CAC lower front frame structure unscrewing the 11 hex bolts holding it. by unscrewing the 8 hex bolts holding it. FIGURE 61: UPPER FRAME BOLTS FIGURE 62: LOWER FRAME BOLTS PA1621 Maintenance Manual All Series...
Page 162 SECTION 05: COOLING SYSTEM 9. Also remove the CAC lateral support (3 hex bolts). FIGURE 65: CAC UPPER BRACKETS & PIPE WARNING FIGURE 63: CAC LATERAL SUPPORT BOLTS 10. From under the vehicle, unscrew the CAC from the lower support (two hex bolts with To prevent galvanic corrosion, the CAC upper plastic insulating bushings).
Page 163 SECTION 05: COOLING SYSTEM 15. Reinstall both (upper and lower) front frame NOTE sections. To ease installation and ensure that the TORQUE: 9 lb-ft (12 Nm) bushings will not move during reinstallation, use masking tape to hold the inner bushings to the lower support.
Page 164 Coolant (ELC) - Volvo D13 Engine Volvo Number ............................20358716 Texaco CPS ...............................227998 Chevron CPS .............................227811 Coolant Filter Cartridge – Volvo D13 Engine Number used ................................ 1 Type ................................Spin-on Prevost number ............................. 20458771 PA1621 Maintenance Manual All Series Section 05 revised Feb 2019...
Page 165 SECTION 06 : ELECTRICAL CONTENTS SECTION CHANGE LOG ............................5 TORQUE TABLES ............................. 6 ALTERNATORS AND SURROUNDING COMPONENTS ..................6 ELECTRICAL CONNECTIONS – BATTERIES, MISCELLANEOUS ................. 9 GENERAL DESCRIPTION ..........................15 WIRING DIAGRAMS............................15 2.1.1 Using Wiring Diagrams ........................15 TESTING CIRCUITS ............................
Page 166 SECTION 06: ELECTRICAL SPARE DL0 (BBUS MUX) ..........................34 TROUBLESHOOTING ............................. 34 PROBING VOLTAGE ON THE MULTIPLEX CIRCUITS ..................34 DL0 (BBUS MUX) NETWORK LAYOUT AND TROUBLESHOOTING ..............35 MULTIPLEX TROUBLESHOOTING TABLE ...................... 40 ELECTRICAL SYSTEM DIAGNOSTIC THROUGH THE DID ................47 ELECTRICAL COMPARTMENTS ........................
Page 167 SECTION 06: ELECTRICAL 12.1 COMPONENTS ............................. 73 12.2 DID DISPLAY ..............................74 ALTERNATORS ............................74 13.1 IDENTIFYING A DEFECTIVE ALTERNATOR ....................74 13.1.1 Alternator identification ........................74 13.1.2 Identifying a defective alternator using the instrument cluster DID ............ 74 13.1.3 Identifying a Defective Alternator –...
Page 168 SECTION 06: ELECTRICAL 17.2 X3 SERIES - STEPWELL LIGHTS ........................93 17.2.1 Bulb Removal and Replacement ......................93 17.3 H3 SERIES - STEPWELL LIGHTS ........................93 17.3.1 Coach Entrance ............................ 93 17.3.2 VIP Entrance ............................93 Bulb Removal And Replacement .......................... 93 17.4 DRIVER’S AREA CEILING LIGHTS ........................
Page 169: Section Change Log
SECTION 06: ELECTRICAL SECTION CHANGE LOG DESCRIPTION DATE Added missing images in Torque Table, items 20 & 21 July 06, 2017 Section 06A & 06B merged together with introduction of H3 Series NEA Jan 15, 2018 Added: Optional KBI Starting Module May 10, 2018 Commuter info added (rear start panel&...
Page 170: Torque Tables
SECTION 06: ELECTRICAL TORQUE TABLES ALTERNATORS AND SURROUNDING COMPONENTS COLD SIDE ALTERNATORS COLD SIDE ALTERNATORS 06783 06784 COLD SIDE ALTERNATORS COLD SIDE ALTERNATORS 06785 06786 HOT SIDE ALTERNATORS (motorhomes) HOT SIDE ALTERNATOR, LOW LH (coaches) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 171 SECTION 06: ELECTRICAL BOSCH HD10 ALTERNATORS DESCRIPTION TORQUE A/C tensioner / idler bracket mounting bolts (2) 43 lb-ft (58 Nm) A/C tensioner / idler bracket mounting bolt (1) 22 lb-ft (30 Nm) Alternator pulley (2) LH threads 70-80 lb-ft (95-108 Nm) Alternator mounting bracket mounting bolts 48 lb-ft (65 Nm) Alternator belt tensioner mounting bolt...
Page 172 SECTION 06: ELECTRICAL DELCO REMY ALTERNATORS DESCRIPTION TORQUE A/C tensioner / idler bracket mounting screws (2) 43 lb-ft (58 Nm) Alternator pulley nut (2) 70-80 lb-ft (95-108 Nm) Alternator bracket mounting screws (8) 35 lb-ft (47 Nm) Alternator mounting screws (8) 48 lb-ft (65 Nm) Idler, hot side 59 lb-ft (80 Nm)
Page 173: Electrical Connections - Batteries, Miscellaneous
SECTION 06: ELECTRICAL ELECTRICAL CONNECTIONS – BATTERIES, MISCELLANEOUS X3 SERIES X3 SERIES H3 SERIES COLD SIDE ALTERNATORS HOT SIDE ALTERNATOR, LOW LH (single) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 174 SECTION 06: ELECTRICAL ELECTRICAL CONNECTIONS - BATTERIES, MISC. DESCRIPTION TORQUE AGM battery Ground, 12VD & 24VD terminal nut 170 lb-in (19 Nm) AGM battery connections, cap nut 170 lb-in (19 Nm) Alternator power connection – nut & adaptor 11 lb-ft (15 Nm) Alternator ground connection –...
Page 175 SECTION 06: ELECTRICAL ATC type fuse box – #8-32 screw terminal 15 lb-in (2 Nm) Battery equalizer – 5/16-18 stud 91-101 lb-in (10-11 Nm) VECR/F – M8-1.5 studs 164-181 lb-in (19-20 Nm) 24-V Inverter– M8-1.25 studs 104-115 lb-in (12-13 Nm) Evaporator fan motor –...
Page 176 SECTION 06: ELECTRICAL ELECTRICAL CONNECTIONS – MAIN POWER COMPARTMENT DESCRIPTION TORQUE Main circuit breaker 3/8-16 stud nut 135 lb-in (15 Nm) Main circuit breaker (switchable, manual reset) 3/8-16 stud nut 135 lb-in (15 Nm) Power relay stud nut 44 lb-in (5 Nm) Master relay R1- Port 30 –...
Page 177 SECTION 06: ELECTRICAL PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 178 SECTION 06: ELECTRICAL MISCELLANEOUS COMPONENTS DESCRIPTION TORQUE Battery cover vent mounting nut 40-48 lb-in (4.5-5.4 Nm) Cable pass-through assembly nut 90-110 lb-in (10-12 Nm) Strain relief mounting lock nut 90-110 lb-in (10-12 Nm) Screw - power cable support- electrical cooling fans 50-60 lb-in (5.6-6.8 Nm) Battery cover stud nut (X3 Series only) 86-106 lb-in (10-12 Nm)
Page 179: General Description
5, you will find the location, the b) At item CB doors. Prevost number, the breaker function, the breaker ampere rating and the page on This vehicle is equipped with PRIME energy which to find the corresponding diagram.
Page 180: Testing Circuits
SECTION 06: ELECTRICAL a) Refer to wiring diagram index, and look for connectors. The wires are color coded as "Multiplexed Device Index", pages B1-B8. follows: b) In first column DEVICE ID, look for device Yellow Data link High SW63. Green Data link Low c) At device SW63, find the fault message, the Orange...
Page 181 SECTION 06: ELECTRICAL VOLTAGE READING OR NETWORK J1939 J2284 0/12 BBUS 0/24 DATA DBUS J1587 …other CIRCUIT IDENTIFICATION Ground circuits Electronic: I/O module number followed by an R, followed by the connector number and pin number (cavity) (ex: A47RJ1.8, A54 RJ2.14). Electronic ground studs: Number 00 followed with the stud location and sequential number (ex: 00R1, 00F4).
Page 182: Spare Wires
SECTION 06: ELECTRICAL 2.6.1 Main Circuit Breakers On Coaches SPARE WIRES When the vehicle leaves the factory, and even in the case of a fully-equipped vehicle, an important number of unconnected spare wires routed between junction boxes. Consequently, connection FIGURE 2: MAIN CIRCUIT BREAKERS ON COACHES additional accessory, refer to page "Spare wires"...
Page 183: Vecr/Vecf Circuit Breakers
SECTION 06: ELECTRICAL 2.6.3 VECR/VECF Circuit Breakers MULTIPLEX FUSES Smaller circuit breakers are located in the VECF The multiplex outputs are protected in current by VECR front rear electrical internal “soft-fuse”. Each output compartment respectively. programmed specific maximum amperage. When an output is shorted, the current gets CIRCUIT BREAKERS above the limit and the soft-fuse intervenes to Wipers - VECF...
Page 184: Cooling Fan Connections
SECTION 06: ELECTRICAL CAUTION WARNING The Multiplex vehicle uses a VF4 relay WHEN THE ENGINE IS RUNNING… specially designed for Volvo that has different Cooling fans may start running at any internal characteristics than the current VF4 moment. relay. It is important to use only the new part marked Volvo as a replacement in Multiplex Keep hands away from cooling fans or keep vehicles.
Page 185: Precautions
SECTION 06: ELECTRICAL 2.11 PRECAUTIONS CAUTION Never put grease or other product on the DANGER multiplex modules connector terminals. Prior to working on a system inside vehicle, make sure to cut electrical power and air DANGER supply. A component could be supplied with electricity even if the ignition switch is set to Use sprayed sealer in a well-ventilated area.
Page 186: Uploading A Multiplex Program Update Into The Mcm
Please contact your Prevost not completed. For this reason, wait another Service Representative in order to get the 5 minutes before proceeding to the next step. vehicle specific multiplex program and upload procedure.
Page 187: Electronic Modules Connector Pin-Out
SECTION 06: ELECTRICAL ELECTRONIC MODULES CONNECTOR PIN-OUT FIGURE 8: ELECTRONIC MODULES CONNECTOR PIN-OUT - BACK PROBING VIEW PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 188 SECTION 06: ELECTRICAL VECR / VECF ORANGE, BLACK, RED, GREY, BROWN, GREEN, YELLOW FIGURE 9: ELECTRONIC MODULES CONNECTORS PIN-OUT - BACK PROBING VIEW PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 189 SECTION 06: ELECTRICAL FIGURE 10: I/O-EB MODULE FIGURE 11: I/O-EA MODULE I/O-EA & I/O-EB MUX modules Connector: AMP MCP 2.8 Contact loading of housings Loading the contacts is only possible if the secondary lock is in the unlock position. Proper orientation of the contact is important. If the orientation is incorrect, the contact stops too early in the region of the secondary lock and the whole crimp stands out from the housing.
Page 190 Keep the tool in that position and EXTRACTOR/TOOL: Prevost 568103 then take the contact out by pulling on the cable. Note: Do not pull the cable before unlocking the contact; on the other hand by pressing the cable gently against the cable outlet direction the unlocking procedure will be facilitated.
Page 191: Available Test Modes
SECTION 06: ELECTRICAL SWITCHES AND SENSORS SUPPORTED AVAILABLE TEST MODES BY THE SWITCH/SENSOR TEST MODE The available test modes are the followings: HVAC control unit driver’s section ON/OFF MUX (multiplex) Input test; HVAC control unit driver recirculate switch Electric motors test sequence; HVAC overhead compartment fan switch Alternator test.
Page 192: Electric Motor Test Sequence
SECTION 06: ELECTRICAL Upper windshield wipers switch, 2 positions DANGER The following inputs, either certain options or Before starting the test sequence, make sure sensors which are difficult to activate, are not that no one is doing maintenance in the supported by the switch/sensor test: evaporator compartment,...
Page 193: Test Sequence - Coaches Only
SECTION 06: ELECTRICAL 4.2.1 Test Sequence – Coaches only Test Sequence – Coaches only Go to the condenser compartment • The condenser fans start. Speed will gradually increase to maximum speed. The passenger's unit refrigerant solenoid valve • activates. The refrigerant solenoid valve of the overhead compartment A/C system activates.
Page 194: Test Sequence - Vip With Central Hvac System
SECTION 06: ELECTRICAL 4.2.2 Test Sequence – VIP With Central HVAC System Test Sequence – VIP With Central HVAC System Driver’s & passenger’s unit fresh air damper • open. [20 seconds delay] Go to the condenser compartment The condenser fans start. Speed will gradually •...
Page 195: Test Sequence - Vip With Small Hvac System
SECTION 06: ELECTRICAL 4.2.3 Test Sequence – VIP With Small HVAC System Test Sequence – VIP With Smal System Driver’s unit fresh air damper opening. [20 • seconds delay] Go to the condenser compartment The condenser fan start. Speed will gradually •...
Page 196: Alternator Test
SECTION 06: ELECTRICAL The limp-home mode will cancel if no switch is ALTERNATOR TEST pressed before a 1 minute delay after activation. Anytime an alternator is suspected of being Limp-home mode action defective, this test will help you when performing Activate RH flasher your own alternator power output test, without the need to disconnect the alternator power...
Page 197: Essential Functions To Operate The Vehicle
SECTION 06: ELECTRICAL • Disconnect the charger before starting the vehicle, if not the default functions will not activate, • If the default mode does not activate, try to turn the ignition OFF while ensuring that no charger is connected and then restart the vehicle.
Page 198: Dl0 (Bbus Mux) Connection On The Telltale Panel And The Hvac Control Unit
SECTION 06: ELECTRICAL isolated to help locate short-circuit on the DL0 network to the spare DL0 (BBUS MUX) network. (BBUS MUX). Refer to the vehicle wiring diagram and section 4.6 for more information. In case of a short-circuit on the DL0 (BBUS MUX) network, this affects all the modules and they all act as “No response”...
Page 199: Dl0 (Bbus Mux) Network Layout And Troubleshooting
SECTION 06: ELECTRICAL 7.2 DL0 (BBUS MUX) NETWORK LAYOUT AND TROUBLESHOOTING MUX MODULE MODULE TYPE LOCATION IDENTIFICATION AE41 I/O-EA AE42 I/O-EA AE43 I/O-EB AE44 I/O-EB AE45 I/O-EB AE46 I/O-EB AE47 I/O-EB R.H. CONSOLE AE48 I/O-EB R.H. CONSOLE AE49 I/O-EB MAIN POWER COMPARTMENT AE50 I/O-EB MAIN POWER COMPARTMENT...
Page 200 SECTION 06: ELECTRICAL If all 17 modules (AE41 to AE57) are showed as Not Responding and Active Fault, the problem could be: A short circuit somewhere on the DL0H, DL0L (BBUS MUX) network. • The network is completely open circuit. That means none of the two termination resistors are •...
Page 201 SECTION 06: ELECTRICAL NOTE All modules including Wake-up modules and MCM have to be powered OFF prior to probe the DL0 (BBUS MUX) lines with an ohmmeter. Probing the resistance between the DL0H and DL0L wire is a useful method to localize short circuits or open circuit on the DL0 (BBUS MUX) network.
Page 202 SECTION 06: ELECTRICAL Isolate the front from the rear Take one of the termination resistors in the MAIN POWER COMPARTMENT. Disconnect C1 and connect the termination resistor to C1 pin housing. If all the front modules respond normally, the short circuit is in the rear portion. Isolate the evaporator module from the network Disconnect C100.
Page 203 SECTION 06: ELECTRICAL Isolate the pneumatic accessories panel modules from the network In the FRONT ELECTRICAL COMPARTMENT, disconnect C5. Take the spare termination resistor on C3S in the MAIN POWER COMPARTMENT and connect it to C5 pin housing. If the short circuit problem is in the pneumatic accessories panel all modules except AE47 and AE48 located into the pneumatic accessories panel will respond normally.
Page 204: Multiplex Troubleshooting Table
SECTION 06: ELECTRICAL DL0 (BBUS MUX) wires are not like other common electrical wires. Maintaining a proper wire twisting is important. The two yellow and green wires must be twisted • and in close contact all along the network to maintain the transmission line impedance. A slack handmade twisting is not acceptable.
Page 205 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions None of the Multiplexed The program version in the 1. Engage the auto-programming of the functions are operating, MCM is different than the I/O modules: Turn the ignition key to including the basic limp- program in the I/O modules the ON position, trip and reset circuit home functions (door...
Page 206 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Entrance door does not Module AE47 is not powered 1. Check the DIAGNOSTICS menu of open nor close using the or is faulty Driver Information Display (DID). control buttons Select VIEW ACTIVE FAULTS and ELECTRICAL.
Page 207 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Module AE47 is not powered 1. Check the DIAGNOSTICS menu of Defroster or is faulty Driver Information Display (DID). functioning but no heat or Select VIEW ACTIVE FAULTS and cooling available in the ELECTRICAL.
Page 208 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Rear flashers not Module AE51 is not powered 1. Check the DIAGNOSTICS menu of functioning or is faulty Driver Information Display (DID). Select VIEW ACTIVE FAULTS and Stoplights and center ELECTRICAL. The message “No stoplights not functioning Response ModA51, Active”...
Page 209 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Evaporator fan not Circuit breaker CB3 tripped 1. Check circuit breaker CB3 functioning 2. Check relay R12 Module AE54 is not powered or is faulty 3. Check the DIAGNOSTICS menu of Driver Information Display (DID).
Page 210 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions A single light, a group of The multiplex outputs are Turn the ignition key to the OFF position LED lights or another protected in current by an and turn to the ON position again. This function of the vehicle is internal “soft-fuse”.
Page 211: Electrical System Diagnostic Through The Did
SECTION 06: ELECTRICAL ELECTRICAL SYSTEM DIAGNOSTIC THROUGH THE DID Using the Driver’s Info Display (DID), check if there are active errors in the vehicle electrical system. With DIAGNOSTICS menu, highlight VIEW ACTIVE FAULTS and then highlight ELECTRICAL to request a diagnostic of the electrical system from the MCM.
Page 212: Electrical Compartments
SECTION 06: ELECTRICAL ELECTRICAL COMPARTMENTS FIGURE 13: ELECTRICAL COMPARTMENTS (X3-45 COACH) FIGURE 14: ELECTRICAL COMPARTMENTS (X3-45 VIP) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 213 SECTION 06: ELECTRICAL FIGURE 15: ELECTRICAL COMPARTMENTS (X3-45 VIP COMMERCIAL BUS SHELL) FIGURE 16: ELECTRICAL COMPARTMENTS (H3-45 COACH) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 214: X3 Series Main Power Compartment (Rjb)
SECTION 06: ELECTRICAL SERIES MAIN POWER COMPARTMENT (RJB) The main power compartment (a.k.a. rear junction box) and battery installation (Figure 17) are accessible from the engine compartment curb-side door. The batteries are housed and secured on the engine R.H side deck. The battery posts and connections are protected by a watertight cover.
Page 215 SECTION 06: ELECTRICAL FIGURE 21: X3 SERIES MAIN POWER COMPARTMENT COMPONENTS IDENTIFICATION PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 216: X3 Series Front Electrical And Service Compartment (Fjb)
SECTION 06: ELECTRICAL X3 SERIES FRONT ELECTRICAL AND SERVICE COMPARTMENT (FJB) The front electrical and service compartment is located on L.H. side of vehicle, under the driver's window. It contains the following components (Figure 22): Front terminal block; • Master Control Module (MCM); •...
Page 217 SECTION 06: ELECTRICAL FIGURE 23: X3 SERIES FRONT ELECTRICAL & SERVICE COMPARTMENT COMPONENTS IDENTIFICATION PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 218: H3 Series Main Power Compartment (Rjb)
SECTION 06: ELECTRICAL SERIES MAIN POWER COMPARTMENT (RJB) The main power compartment is located on rear R.H. side vehicle behind rear wheelhousing. This compartment contains the following components shown on Figure 24. • Four 12-volt batteries; • Main circuit breakers for 12-volt and 24-volt electrical system;...
Page 219: H3 Series Vehicle Electrical Center Rear (Vecr)
SECTION 06: ELECTRICAL 8.3.1 H3 Series Vehicle Electrical Center Rear (VECR) FIGURE 26: VECR – FUSE IDENTIFICATION FIGURE 25: H3 SERIES MAIN POWER COMPARTMENT H3 SERIES FRONT ELECTRICAL AND SERVICE COMPARTMENT (FJB) The front electrical and service compartment is located on L.H. side of vehicle, under the driver's window.
Page 220: H3 Series Vehicle Electrical Center Front (Vecf)
SECTION 06: ELECTRICAL • Emergency door opening unlock valve (coaches only); Windshield washer reservoir; • Reclining bumper opening handle; • Accessories air tank purge valve; • Accessories system fill valve; • Keyless entry system module (VIP only); • Electronic ground bus bar. •...
Page 221: Engine Rear Start Panel
SECTION 06: ELECTRICAL ENGINE REAR START PANEL This control panel is located close to the back- up alarm in the engine compartment. This control panel includes the engine rear start push button and the engine stop/ignition interlock button. some vehicles, tachometer is also integrated in the start panel.
Page 222: Overhead Compartment Module
SECTION 06: ELECTRICAL BATTERIES The battery has four (4) major functions: 1. Providing a source of current for starting the engine. 2. Stabilizing the voltage in the electrical system. 3. Supplying current for a limited time, when electrical demands of the equipment exceed the power output of the alternator.
Page 223 SECTION 06: ELECTRICAL FIGURE 36: BATTERY CONNECTIONS SCHEMATIC – X3 SERIES FIGURE 37: AGM BATTERY CONNECTIONS – X3 SERIES PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 224: Battery Installation H3 Series
SECTION 06: ELECTRICAL BATTERY INSTALLATION H3 SERIES The battery bank is composed of four AGM batteries. To prevent improper installation of the batteries, place the battery negative and positive poles according to the image below ( Figure 38). FIGURE 38: BATTERY CONNECTIONS SCHEMATIC – H3 SERIES FIGURE 39: AGM BATTERY CONNECTIONS –...
Page 225: Agm Batteries
SECTION 06: ELECTRICAL AGM BATTERIES BATTERY DISCHARGE PROTECTION This vehicle is equipped with PRIME energy To prevent discharge of the batteries when the management system, it is provided with four (4) engine in not running, some functions are Absorbed Glass Mat (AGM) 12-volt batteries automatically switched off if the batteries voltage connected in series-parallel.
Page 226: Battery Removal And Installation - X3 Series
SECTION 06: ELECTRICAL 1. Remove the battery bank cover and place behind the battery bank (FIGURE 42). 06798 FIGURE 40: X3 SERIES MAIN ELECTRICAL SHUT-OFF FIGURE 42: BATTERY BANK COVER REMOVED SWITCH 2. Disconnect the ground cable first (FIGURE 43). FIGURE 43: DISCONNECT GROUND CABLE FIRST 3.
Page 227 SECTION 06: ELECTRICAL FIGURE 48 FIGURE 45 Battery Installation 5. Unscrew three nuts (indicated with arrows) and then remove the front angle (FIGURE 46). Reinstalling the batteries is quite similar as the removal procedure but in reverse order. However, special care should be taken to the following points: 1.
Page 228 SECTION 06: ELECTRICAL 4. Tighten the rod nut to the following torque: TORQUE: 45-55 lb-in (5-6 Nm) FIGURE 53: INSTALL THE BATTERY CABLE LUGS 6. Connect the ground cable last (FIGURE 54). Tighten the ground cable nut to the following torque: TORQUE: 170 lb-in (19 Nm) FIGURE 51: SHAPE OF THE ROD...
Page 229: Agm Battery Rating
SECTION 06: ELECTRICAL equal to half the CCA across the terminal for 5 seconds to remove surface charge from the AGM BATTERY RATING battery. Each of the 12-volt batteries used on the vehicle 9.8.3 Load Test has the following rating: This test is one means of checking the battery to Reserve capacity: 200 minutes •...
Page 230: Battery Charging
SECTION 06: ELECTRICAL DANGER Voltage and Battery Temperature Chart During charging of the batteries, an explosive Battery Temperature Minimum Voltage gas mixture forms in each cell. Part of this gas escapes through the vent holes and may form 70ºF (21ºC) and above an explosive atmosphere around the battery 60ºF (16ºC) itself if ventilation is poor.
Page 231 SECTION 06: ELECTRICAL CHARGING TIME TABLE FOR A SINGLE BATTERY STATE OF CHARGER MAXIMUM RATE CHARGE (AGM) 30 A 20 A 10 A 12.8V 100% Ready to use 12.6V 12.2V 12.0V 11.8V 10.7 CAUTION FIGURE 56 ALLIGATOR CLAMP POSITION– TYPICAL AGM BATTERY AGM Battery Charging Considerations Many common battery chargers are not fully...
Page 232 SECTION 06: ELECTRICAL Charger Capacity Apply parking brake and place the transmission to Neutral (N) position in both vehicles. Turn off A charger supplying only 5 amperes will require lights, heater and other electrical loads. a much longer period of charging than a charger that can supply 30 amperes.
Page 233: Agm Battery Charging Precautions
SECTION 06: ELECTRICAL 4. Connect one end of the black jumper cable 9.11 BATTERY EQUALIZATION AND AGM to the negative (-) post on the booster power BATTERIES source; Equalization a controlled over charge. 5. Connect the other end of the same black Conventional batteries may benefit from this jumper cable to the negative (-) terminal on procedure, stirring the chemistry of the entire...
Page 234: Common Causes Of Battery Failure
SECTION 06: ELECTRICAL as prescribed. Refer to torque tables at the 9.14 TROUBLESHOOTING beginning of this section. If a battery is known to be good and then has Replace protective caps to prevent corrosion not performed satisfactorily in service for no and sparks.
Page 235: Battery Warning Pictogram May Appear As A Reminder
SECTION 06: ELECTRICAL NOTE Allow at least 15 minutes to balance batteries after any corrective measure has been taken. 1. Batteries out of balance (difference greater than 1.5 volts between the two battery banks). Check battery equalizer connections. Check equalizer cables for proper gauge. Check battery connections.
Page 236: Starting Module Status Led
SECTION 06: ELECTRICAL 11.3 TROUBLESHOOTING WARNING Refer to supplier manual KSM Starting Module Manual RevD.pdf from KBI on the technical The Starting Module is a product of high publications web site or on the technical electric power. Avoid shorting module publications USB drive for troubleshooting terminals! instructions.
Page 237: Prime Energy Management System
SECTION 06: ELECTRICAL Battery temperature, voltage and current are also monitored to prevent overcharging and 12. PRIME ENERGY MANAGEMENT SYSTEM overheating. Maximum fuel economy is obtained on a ride acronym “PRIME” stands Power when the mix of hilly and flat portions allows the Recovery by Intelligent Management of Energy.
Page 238: Did Display
SECTION 06: ELECTRICAL In this configuration, the multiplex system will identify the alternator on the right (cold side) as 12.2 DID DISPLAY Upper Right and the left (hot side) as Lower Left. In the DID you will find the percentage of trip 13.1 IDENTIFYING A DEFECTIVE made with regenerated electricity displayed along with the instantaneous fuel consumption.
Page 239: Identifying A Defective Alternator - Back-Probing Ae49 & Ae52 Multiplex Modules Method
SECTION 06: ELECTRICAL 13.1.3 Identifying a Defective Alternator – Back-probing AE49 & AE52 Multiplex Modules 13.2 ALTERNATOR DRIVE BELT Method Prerequisite conditions: MAINTENANCE a) Engine running; Drive belt b) Parking brake applied. Inspect for crack or frayed material at the intervals specified by the Lubrication And Alternator Up RH =pin J1:20, module AE49 Servicing...
Page 240: Starter
SECTION 06: ELECTRICAL 15.1 MAINTENANCE 14. STARTER This heater is non-serviceable except for the Refer Mitsubishi Electric Corporation cord, and if faulty, must be replaced as a unit. (MELCO) Service bulletin ME003-P found on your Technical Publications USB flash drive for information and maintenance instruction on MELCO 105P70 starter.
Page 241 SECTION 06: ELECTRICAL FIGURE 66: VARIOUS LIGHTS LOCATION, REAR DIRECTIONAL LIGHT MAY BE ON TOP POSITION ON SOME VEHICLES PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 242 SECTION 06: ELECTRICAL FIGURE 67: VARIOUS LIGHT LOCATIONS PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 243: X3 Series Headlamps
SECTION 06: ELECTRICAL SECTION 06: ELECTRICAL 16.1 X3 SERIES HEADLAMPS The Head light assembly is installed on a hinge and a cable stops the rotation Figure 69. Each headlamps assembly consists of two 90 mm (3½ inch) headlamp module (Figure 70) equipped with a halogen bulb and one 100 mm (4 inch) 12-volt LED turn/signal lamp.
Page 244: Halogen Bulb Replacement
SECTION 06: ELECTRICAL 16.1.2 Halogen Bulb Replacement NOTE 1. Remove the two screws (Figure 71) fixing Do not disrupt headlamp module adjustment the headlamps assembly, and then turn the screws. headlamps assembly down. 16.1.3 Headlamp Module Replacement 1. Remove the two screws (Figure 71) fixing the headlamps assembly, and then turn the headlamps assembly down.
Page 245: Directional Turn Signal Replacement
SECTION 06: ELECTRICAL FIGURE 75: UNLOCK THREADED ROD 6. Use pliers to lock threaded rods by rotating the tab until it “clicks” into place (Figure 75). 7. Snap new plastic mounts on threaded rods (3x) (item 2 in Figure 73). FIGURE 77: LOW BEAM ADJUSTMENT 8.
Page 246: Xenon Bulbs Replacement
SECTION 06: ELECTRICAL FIGURE 78: TURN SIGNAL LIGHT 2. Disconnect the electrical harness connector FIGURE 79: XENON HEADLAMP from the light module. 2. Remove connector from headlamp bulb by turning counterclockwise. 3. Unscrew the 4 mounting fasteners and 3. Unscrew the three Phillips head screws replace the light module.
Page 247: H3 Series Headlamps
SECTION 06: ELECTRICAL therefore switch off the lamp before working on CAUTION this part). After taking out the lamp, the contact pins are in During this step, avoid contacting the bulb a practically idle state (< 34 Volt) after < 0.5 with the fingers not to alter the bulb life.
Page 248: Front Turn Signal Replacement
SECTION 06: ELECTRICAL FIGURE 83: HEADLAMPS ASSEMBLY REAR VIEW CAUTION CAUTION • To prevent burning yourself, do not replace the light bulbs while they are hot. During this step, avoid contacting the bulb with the fingers not to alter the bulb life. •...
Page 249: Aiming Headlamps
SECTION 06: ELECTRICAL Current is detected in the lamp circuit before the entire module in the housing for proper ignition time and ignition prevented. Connection alignment ( ). There is no adjustment for FIGURE 85 of the "hot" lamp to the body mass also prevents focus since the module is set for proper focus ignition.
Page 250 SECTION 06: ELECTRICAL 2. The four movable vertical tapes should be located on the screen at the left and right limits called for in the specification with reference to centerlines ahead of each headlamps assembly. The headlamp centerlines shall be spaced either side of the fixed centerline on the screen by ½...
Page 251: X3 Series Stop, Tail, Directional, Back-Up, And Hazard Warning Lights
SECTION 06: ELECTRICAL 7. The inspection limits in the vertical direction for low-beam headlamps or the low beam of dual-beam headlamp, shall described in Table 1. In the horizontal direction, the left edge of the high-intensity zone shall be located from 10 cm (4 in) left to 10 cm (4 in) right of the vertical centerline of the beam.
Page 252: H3 Series Stop, Tail, Directional, Back-Up, And Hazard Warning Lights
SECTION 06: ELECTRICAL FIGURE 93: H3-SERIES REAR TAIL LAMPS 16.5.1 Lamp Removal And Replacement 1. Open engine compartment rear door. 2. Unscrew the lamp support retaining screws FIGURE 92: TAILLAMP POD RETAINING SCREWS & (2), and then from the outside, remove the NUTS lamp and its support.
Page 253: Clearance, Identification And Marker Lights
SECTION 06: ELECTRICAL 16.7 CLEARANCE, IDENTIFICATION MARKER LIGHTS vehicle equipped with marker, identification and clearance lights (LED). The clearance lights are mounted at each corner of the coach near the top and the identification lights are in the upper center of rear and front sections.
Page 254: Lamp Removal And Replacement
SECTION 06: ELECTRICAL V.I.P. model, a dashboard-mounted rocker switch may be actuated to cancel this system in special situations. Two additional halogen sealed-beam units are installed on rear electrical compartment door (R.H.) and radiator door. These lights are used as docking lights and both will illuminate automatically when reverse range is selected to facilitate back-up or docking procedure.
Page 255: X3 Models Fog Light Removal And Replacement
SECTION 06: ELECTRICAL Install the new fog light pod on the pod support with the existing screws and lockwashers. Tighten screws to a torque value of 26.5-35 lb-in (3-4 Nm) FIGURE 101: FOG LIGHT MOUNTING BOLT 3. Dismount the screws (2) fixing the pod from the fog light support, keep the screws and the lockwashers.
Page 256: Baggage Compartment, Main Power Compartment Lights
SECTION 06: ELECTRICAL 10. Test the fog light. 16.10 BAGGAGE COMPARTMENT, MAIN POWER COMPARTMENT LIGHTS This type of compartment light is a sealed unit (LED) and can be replaced as a complete unit. It is found in the following locations: Baggage compartments •...
Page 257: Switch Lighting
SECTION 06: ELECTRICAL 17.1.1 Switch Lighting 1. Slightly pull the switch with a defective LED away from the control panel. 2. Disconnect the electric cable from the switch. 3. To install a new switch, reverse the procedure (Figure 107) NOTE Switches are lighted by the use of LED.
Page 258: Bulb Removal And Replacement
SECTION 06: ELECTRICAL 1. Unscrew the two Phillips-head screws 17.4.1 Bulb Removal and Replacement retaining the lens to the wall, and remove it. 1. Pull the lamp assembly by the outer ring using your fingers. 2. With the light lens removed, pull bulb from the lamp while applying lateral pressure.
Page 259: Led Indirect Lighting / Overhead Compartment Interior Lighting
SECTION 06: ELECTRICAL 4. Replace the screen lens by first inserting one side in the seat, then push the other side in and snap it in place by running it in from one corner to the next. FIGURE 113: LED DIRECT LIGHTING AND LENS 17.5.3 Removal Replacement...
Page 260: Light Bulb Data
SECTION 06: ELECTRICAL 2. With the light lens removed, pull bulb from the lamp while applying lateral pressure. 3. Install the new bulb into the lamp. 4. Position the light lens and install it. 18. LIGHT BULB DATA Please, refer to your vehicle Parts Manual for selection of replacement light bulbs.
Page 261: Specifications
SECTION 06: ELECTRICAL 19. SPECIFICATIONS AGM Battery Make ............................... Volvo Type ..........................Absorbed Glass Mat Terminal type ........................... Top Stud Group size ............................... 8A31 Volts ................................12 Load test amperage ..........................400 Reserve capacity (minutes)........................200 Cold cranking (in amps) -At 0 F (-18 C) ........................
Page 263 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 264 PROCEDURE NO: SAV00002E REVISION 02 Vehicle Zoning REAR FRONT REAR FRONT Page 2 of 6...
Page 265 PROCEDURE NO: SAV00002E REVISION 02 Electrical Connectors Protection Procedure Table Model Zone Component Product Note Accepted to ease A- Front Elect. Compt Diode Block Nyogel connection Customer Terminal A- Front Elect. Compt Block Nothing Terminal Block A Front Elect. Compt Electronic Ground Kent A- Front Elect.
Page 266 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note Color Guard C- Baggage Compt Structure Ground or Kent Accepted to ease C- Baggage Compt Door Switch Nyogel connection Accepted to Door lock Actuator Module ease C- Baggage Compt (switch and solenoid) Nyogel connection C- Baggage Compt...
Page 267 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note G- Engine Compt Alternator Color Guard G- Engine Compt Booster Block (+) Color Guard G- Engine Compt Starter Terminal Color Guard G- Engine Compt Volvo Air Element Terminal Color Guard G- Engine Compt Customer Terminal Block Nothing...
Page 268 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note I- Vehicle Interior Dashboard Switch Nothing I- Vehicle Interior Electronic Module Nothing Accepted to ease I- Vehicle Interior Slide-out Motor Nyogel connection Accepted to ease I- Vehicle Interior Wiper Motor Nyogel connection I- Vehicle Interior...
Page 269 Please note that some images in this document may represent arrangements different from those found on vehicles of former generations. However, inspection criteria and points to check presented in this document remain applicable in essence for all models of Prevost vehicles. POWER CABLES MAINTENANCE SCHEDULE...
Page 270 MI15-24B / Page 2 / 14 POWER CABLES ‒ The power cables are those through which flow the highest currents. These cables are those with the largest electrical conductor diameters on the vehicle. ‒ The power cables are 1/0, 2/0, 3/0 wire gauges respectively Ø0.325in, Ø0.365in, Ø0.409in. Note: not to be confused with the 1, 2, 3 wire gauges that are actually smaller.
Page 271 MI15-24B / Page 3 / 14 Figure 4: Bussman Junction Block - X3 Series. Figure 5: Bussman Junction Block - H3 Series. • On the starter positive (+) stud terminals and from there, up to Bussman junction block in the electrical compartment (Figure 6, Figure 7).
Page 272 MI15-24B / Page 4 / 14 In the electrical compartment, connected to the junction block (Figure 8). • Figure 8 In the battery compartment between battery and master relay R1 (Figure 9). • Figure 9 QF7720956 rev3>...
Page 273 MI15-24B / Page 5 / 14 Between Bussman junction block and main circuit breaker bus bar (Figure 10 & Figure 11). • Figure 11: Power cable on main circuit breakers' bus bar. Figure 10 • From the electric fan drive breaker box up to fuse F199 in main power compartment (Figure 12) Figure 12: ELECTRIC FAN DRIVE BREAKER BOX QF7720956 rev3>...
Page 274 MI15-24B / Page 6 / 14 PROCEDURE DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
Page 275 MI15-24B / Page 7 / 14 For power cables passing through a corrugated protective sheath, it is recommended to apply two • layers of fabric tape every 3 to 6 inches minimum to prevent the cable from coming out of the corrugated protective sheath (Figure 14).
Page 276 MI15-24B / Page 8 / 14 RING CABLE LUGS Figure 16: Cable lugs must be closed type, crimped or welded. Ring cable lugs should not be distorted. • • Ring cable lugs should not suffer strains that can deform. Ring cable lugs must be installed with smooth washers and nuts to prevent damage to the cable lug •...
Page 277 MI15-24B / Page 9 / 14 Figure 19: No exposed or broken copper strands. A shrink tubing (or fabric tape) should cover the copper strands. • Ensure that the power cables and ground wire are not stretched tight. • Ensure that the cable lugs are still properly crimped on the copper conductor, that the conductor •...
Page 278 MI15-24B / Page 10 / 14 STEEL P-CLAMPS Figure 21: P-clamps are no longer used to secure power cables, but they can nevertheless be found on coaches of older generations. The piece of rubber that protects cable against the P-clamp steel loop must absolutely be in place.
Page 279 MI15-24B / Page 11 / 14 ALTERNATORS TERMINAL NUT PRESCRIBED TORQUE Delco Remy 55SI - Ground : 50-60 lb-in - Positive (+): 80-125 lb-in - Sense (S) 25-45 lb-in - Indicator (I) 25-45 lb-in Bosch HD10 - B1(+) terminal: 10 lbf-ft - ground: 6 lbf-ft Bosch T1 - D+: 21-28 lbf-in...
Page 280 CORROSION PROTECTION • Power cable connections on alternators, starter and ground connections exposed to water, dust, etc. should be protected against corrosion with Loctite Color Guard rubber coating (Figure 26) (Prevost p/n: 684013). Figure 26: Loctite Color Guard. QF7720956 rev3>...
Page 281 MI15-24B / Page 13 / 14 Figure 28: Lower R.H. side Bosch alternator power cable lug protected with Color Guard rubber coating. Figure 27: Upper R.H. side Bosch alternator power cable lug protected with Color Guard rubber Protect the cable lug similarly on the L.H. side coating.
Page 282 MI15-24B / Page 14 / 14 PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone. E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive our warranty bulletins by e-mail.
Page 283 MAINTENANCE MI16-17 INFORMATION DATE : FEBRUARY 2016 SECTION: 06 - Electrical SUBJECT : BOSCH HD10 ALTERNATOR REMOVAL AND INSTALLATION Please, get the latest revision of Maintenance Information MI16-17 on Prevost Technical Publications web site: https://techpub.prevostcar.com/en/ <QF7720955 rev 2>...
Page 285 SECTION 07: TRANSMISSION CONTENTS SECTION CHANGE LOG ............................3 TORQUE TABLES ............................. 4 ALLISON TRANSMISSION ..........................4 VOLVO I-SHIFT TRANSMISSION ........................5 DESCRIPTION ..............................6 AUTOMATIC TRANSMISSION ......................6 ALLISON 2.1.1 Retarder ..............................6 VOLVO I-SHIFT ........................... 6 TRANSMISSION ALLISON TRANSMISSION MAINTENANCE ....................... 7 ..........................
Page 286 SECTION 07: TRANSMISSION ALLISON TRANSMISSION REMOVAL ......................26 VOLVO I-SHIFT TRANSMISSION MAINTENANCE .................... 27 TYPE ........................... 27 RANSMISSION ............................28 HECKING EVEL DRAINS INTERVAL ........................... 28 ..............................28 HANGE VOLVO I-SHIFT TRANSMISSION TECU FAULT CODES ..................30 VOLVO I-SHIFT TRANSMISSION GSECU FAULT CODES ................69 SPECIFICATIONS ............................
Page 287: Section Change Log
SECTION 07: TRANSMISSION SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...
Page 288: Torque Tables
SECTION 07: TRANSMISSION TORQUE TABLES ALLISON TRANSMISSION ALLISON TRANSMISSION DESCRIPTION TORQUE Lube and main filter cover bolts 38-45 lb-ft (52-61 Nm) Drain Plug 18-24 lb-ft (24-33 Nm) Flex plate screws 24-30 lb-ft (33-41 Nm) Transmission housing screws to engine housing 46-50 lb-ft (62-68 Nm) PA1621 Maintenance Manual All Series | January 2017...
Page 289: Volvo I-Shift Transmission
SECTION 07: TRANSMISSION VOLVO I-SHIFT TRANSMISSION VOLVO I-SHIFT TRANSMISSION DESCRIPTION TORQUE Oil drain plug 18-24 lb-ft (24-33 Nm) Oil fill plug 22-30 lb-ft (30-41 Nm) Transmission mounting screws 66 lb-ft (89 Nm) Filter housing drain plug 11-13 lb-ft (15-18 Nm) PA1621 Maintenance Manual All Series | January 2017...
Page 290: Allison Automatic Transmission
SECTION 07: TRANSMISSION the shift, and makes minute adjustments to match the shift to desired profile stored in its DESCRIPTION memory. It then looks at these adjustments and resets parameters, which allow H3 and X3 Series vehicles may be provided with transmission quickly compensate...
Page 291: Allison Transmission Maintenance
SECTION 07: TRANSMISSION If the I-Shift transmission system is to be used, system since it will cause valves to stick, undue the vehicle must have an electronic engine wear transmission parts, clogged control unit as well as CAN communication. passages. Check level using...
Page 292: Hot Check
SECTION 07: TRANSMISSION  Engine is idling (500-800 rpm) in «N» The oil level rises as sump temperature (Neutral). increases. DO NOT fill above the Cold Run band if the transmission oil is below normal  Transmission fluid is at normal operating operating temperature.
Page 293: Fluid Level Check Using The Pushbutton Shift Selector
SECTION 07: TRANSMISSION The Cold Check is more appropriate for 7. High fluid level condition verifying the oil level after the first fill-up. In case with the number of quarts of conflict, the Hot Check has priority over the in excess is displayed as Cold Check;...
Page 294: Importance Of Proper Fluid Level
SECTION 07: TRANSMISSION Allison Transmission recommends you take the 3.3.1 Importance of Proper Fluid Level following into consideration when selecting the It is important that the proper fluid level be appropriate fluid type for your transmission: maintained at all times because the transmission fluid cools, lubricates, and transmits hydraulic ...
Page 295: Coolant Leakage
SECTION 07: TRANSMISSION 3.3.5 Coolant Leakage 3.4.1 Normal Prognostics Indication at Engine Start If engine coolant leaks into the transmission oil  A system bulb check illuminates the system, immediate action must be taken to TRANSMISSION SERVICE indicator prevent malfunction possible serious approximately 0.5 seconds.
Page 296 SECTION 07: TRANSMISSION may also be reset by selecting N-D-N-D-N-R-N the need for a fluid change before 60 months on the shift selector, pausing briefly (less than 3 have passed when using TES295 fluid type or seconds) between each selector movement, with before 24 months have passed when using the ignition on and the engine not running.
Page 297 SECTION 07: TRANSMISSION enter filter life monitor, press (Downshift) arrows four times. An acceptable clutch life status is displayed as “TRANS simultaneously (Upshift) HEALTH OK”. An unacceptable filter life status is (Downshift) arrows three times. An acceptable displayed as “TRANS HEALTH LO”. filter life status is displayed as "OIL FILTER OK".
Page 298 SECTION 07: TRANSMISSION The following table illustrates how to access Oil Level Check, Prognostics & Diagnostic Troubleshooting Codes functions on the Allison pushbutton shift selector. Description Message (Upshift) & (Downshift) arrow buttons pressed simultaneously * press Allison transmission oil level check press Oil Life Monitor "...
Page 299: Oil And Filter Change Interval
SECTION 07: TRANSMISSION OIL AND FILTER CHANGE INTERVAL TABLE 1 Allison Transmission Recommended Fluid And Filter Change Intervals With Prognostics Mode Disabled Using TES389 or Mixture Severe vocation General vocation Coaches or MTH equipped with retarder Coaches or MTH without retarder Filters Filters Fluid...
Page 300: Oil And Filter Change Interval With Prognostics Mode Disabled
SECTION 07: TRANSMISSION TABLE 3 Recommended Fluid And Filter Change Intervals With Prognostics Mode Enabled FLUID CHANGE INTERVALS HIGH CAPACITY MAIN & LUBE SUCTION FILTER FILTERS CHANGE INTERVALS ASSEMBLY CHANGE INTERVAL TES295 Whichever is the first of the following: Whichever is the first of the following: time transmission overhaul...
Page 301: Fluid And Filter Change Procedure
SECTION 07: TRANSMISSION must be disabled. Prognostic information will 6. Install twelve bolts and both covers. not be accurate with any other fluids or filters TORQUE: 38-45 lb-ft (52-61 Nm) and could result in missed maintenance activities resulting in transmission damage. See "TABLE 3 7.
Page 302: Cleaning And Inspection Of Allison Automatic Transmission
SECTION 07: TRANSMISSION Using the oil level dipstick filler tube, refill with 24 ALLISON TRANSMISSION OIL COOLER US qts (23 liters), 28 US qts (26.5 liters) if REMOVAL equipped with retarder, and check the oil level Fluid Level Check Using using TRANSMISSION WITHOUT RETARDER Pushbutton Shift Selector procedure in this...
Page 303: Allison Transmission Installation
FIGURE 10: VOLVO ENGINE TURNING TOOL #88800014 ALLISON TRANSMISSION INSTALLATION 4. Apply clear silicone (Prevost #680457 or equivalent) on the spacer and install it on the 1. Place the transmission on a transmission engine housing (Figure 11). jack.
Page 304 SECTION 07: TRANSMISSION 8. Apply clear silicone (Prevost #680457 or equivalent) around edge transmission housing (Figure 12: silicone application transmission housing). FIGURE 13: CRISS CROSS PATTERN FIGURE 12: SILICONE APPLICATION TRANSMISSION 12. Remove the headless guide bolt from the flex...
Page 305: Allison Transmission Troubleshooting
SECTION 07: TRANSMISSION 23. Install engine splash guards. 24. Adjust the retarder pressure to 80 ± 3 psi with pressure regulator. more information refer to Section 12, "BRAKE AND SYSTEM", under heading "AIR PRESSURE REGULATOR". The air pressure regulator is located at back of engine compartment, on R.H.
Page 306: Using Shift Selector For Accessing Diagnostics Information
SECTION 07: TRANSMISSION (historic) is dropped from the list. If all DTCs are DOC™ diagnostic tool, refer to the User active, the DTC with the lowest priority is Guide. dropped from the list. o Using the pushbutton shift selector. An active code is any code that is current in the To begin the diagnostic process: TCM decision-making process and has failed the test(s)
Page 307: Diagnostic Trouble Code Response
SECTION 07: TRANSMISSION NOTE Be sure to record all codes displayed before they cleared. This essential troubleshooting. NOTE If clearing a code while locked in a «D» (Drive) or «R» (Reverse) position (fail-to-range), the transmission will still be in «D» (Drive) or «R» (Reverse) when the clearing procedure is completed.
Page 308: Diagnostic Troubleshooting Codes (Dtc) List - Allison
SECTION 07: TRANSMISSION DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST - ALLISON 5 GENERATION CONTROLS CHECK Inhibited Operation Description Light Description 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 Use default throttle values.
Page 309 SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description P0842 Transmission Fluid Pressure Switch 1 Circuit Low DNS, Lock in current range P0843 Transmission Fluid Pressure Switch 1 Circuit High DNS, Lock in current range P0847 Transmission Fluid Pressure Switch 2 Circuit Low None P0848 Transmission Fluid Pressure Switch 2 Circuit High...
Page 310: Allison Transmission Removal
SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit Open DNS, SOL OFF (hydraulic default) P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit Low DNS, SOL OFF (hydraulic default) P2730 Pressure Control Solenoid 1 (PCS1) Control Circuit High DNS, SOL OFF (hydraulic default) P2736 Pressure Control Solenoid 5 (PCS5) Control Circuit Open...
Page 311: Volvo I-Shift Transmission Maintenance
SECTION 07: TRANSMISSION replace it if necessary. Reinstall the drain plug (see "3.5 Oil and Filter Change" in this section. TORQUE: 18-24 lb-ft (24-33 Nm) 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.
Page 312: Checking Oil Level
SECTION 07: TRANSMISSION CHECKING OIL LEVEL OIL DRAINS INTERVAL Check the transmission oil level at each service The length of time a transmission can operate interval. Park the vehicle on a level surface. before an oil change is required depends on the Check the oil level through the sight glass on the quality of the oil used and the vehicle application.
Page 313 SECTION 07: TRANSMISSION remove the filter. Torque tighten oil filter housing drain plug. TORQUE: 11-13 lb-ft (15-18 Nm) FIGURE 19: OIL FILTER HOUSING DRAIN PLUG FIGURE 20: OIL FILTER PA1621 Maintenance Manual All Series | January 2017...
Page 314: Volvo I-Shift Transmission Tecu Fault Codes
SECTION 07: TRANSMISSION VOLVO I-SHIFT TRANSMISSION TECU FAULT CODES FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 Conditions for activation: (and) The brake interlock function Activate: is activated (VTNA vehicles The gearlever is only) moved from White lamp is The vehicle speed is below neutral without sent together 5km/h...
Page 315 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 and, acc pedal released more than 6.0s or neutral, or driving without clutch slip Activate: If there is an attempt to start on a high range gear or White lamp is above gear 4 in Clutch load Special...
Page 316 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 temperature is valves are inactive above a specific - There is no active fault limit code on any of the clutch Deactivate: The cylinder position sensor (SEPoC) the clutch valves clutch response is OK - There is no active fault...
Page 317 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 4. There is no in the interval [set point active fault code +3mm; set point -1mm] after on any of the control of the clutch to near clutch cylinder the slip point position during valves and, 1.0s 5.
Page 318 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 speed < 300rpm, deactivate this fault code - Continue with the slip point calibration Yellow lamp is sent Cranking is Digital input inhibited Activate: The flash Engine can not Voltage voltage level for start NVRAM...
Page 319 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 any of the gearbox brake valve (VAGB) the sensor for the counter shaft speed (SECS) the sensor for the split cylinder position (SEPoS) low air pressure. The following conditions must be fulfilled for one activation of the gearbox brake in order to deactivate:...
Page 320 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 - There is no active fault on any of the sensor for the position of the 1/R cylinder (SEPo1R) the valve for shift to 1:st gear the valve for shift to reverse gear - There is no active fault code for low air pressure...
Page 321 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 The fault is deactivated if any of the following conditions are fulfilled: - The 1/R position sensor indicates that 1:st position is engaged - There is an active fault code on any of the 1/R position sensor (SEPo1R) the valve for shift to 1:st gear the valve for shift to...
Page 322 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 position sensor (SEPo1R) the valve for shift to 1:st gear the valve for shift to reverse gear - There is no active fault code for low air pressure The fault is deactivated if any of the following conditions are fulfilled: - The 1/R position sensor...
Page 323 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 shift to 3:rd gear - There is no active fault code for low air pressure Note: The fault will always have the state inactive. Check the fault count and last occurrence to get more information.
Page 324 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 code on any of the 2/3 position sensor (SEPo23) the valve for shift to 2:nd gear the valve for shift to 3:rd gear Detailed conditions to activate/deactivate The following conditions must be fulfilled three times (only once if the fault code- filter is switched OFF) in a...
Page 325 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 any of the following conditions are fulfilled: - The 2/3 position sensor indicates that neutral position is engaged - There is an active fault code on any of the 2/3 position sensor (SEPo23) the valve for shift to 2:nd gear the valve for shift to...
Page 326 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 received within when buttons are pressed on Deactivate: The the gear lever. FMI shall be cleared if message VP6 is received at normal rate Activate: The FMI shall be set if message ACC1 from ACC Missing data...
Page 327 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 ECU (ECS) received within 10s, and ECS is installed Deactivate: The FMI shall be cleared if message VW is received at normal rate Yellow lamp If pedal pos is undefined, automatic gear selection enters Activate: The...
Page 328 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 Deactivate: The performance FMI shall be cleared if message VP24/MID128 is received at normal rate Activate: Flash Yellow lamp is CS error or sent Data erratic, Program program code Cranking is SID240 FMI2 intermittent or...
Page 329 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 - There is no active fault code for low air pressure note: The fault will always have the state inactive. Check fault-count and last occurrence to get more information Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times...
Page 330 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 conditions are fulfilled: - The range cylinder position sensor indicates that high range is engaged - The gearbox oil temperature is below 10dgC - There is an active fault code on any of the range position sensor (SEPoR) low air pressure the range cylinder valves...
Page 331 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 calibrated Yellow lamp is Activate: 1. The sent sensor signal is The start gear above or below might be wrong Sensor for normal range Gear selection and 2. The Data erratic, performance vehicle has been inclination of...
Page 332 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 (SEPo23) Activate: The Checksum of the Sensor for NVRAM is not Yellow lamp is the position correct, or the sent Calibration sensor has not of the 2:nd Cranking is FMI13 value out of been calibrated and 3:rd...
Page 333 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 calibrated Detailed conditions to activate / deactivate: Activate: The position sensor is distributing a temperature-signal from the sensor ASIC, if the value from this sensor deviates Activate: The too much this fault code is position sensor triggered, the diagnostics is distributing a...
Page 334 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 Activate: 1. Yellow lamp is Sensor signal is sent in normal range Sensor for The symbol for Data valid but 2. Pressure is compressed air, the pressure below below 5.0 [bar] FMI1 gearbox is sent of the supply...
Page 335 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 of the split cylinder (SEPoS) -The sensor for the position of the shift cylinder1R (SEPo1R) -The sensor for the position of the shift cylinder 23 (SEPo23) -The sensor for the position of teh range cylinder (SEPoR) The fault is deactivated if...
Page 336 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 (SEPo23) -The sensor for the position of teh range cylinder (SEPoR) Yellow lamp is sent Reduced gear change performance Gearbox brake up shifts can not be used Activate: The Slip point cannot sensor signal is be updated Sensor for...
Page 337 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 speed sensor (SESC) is Sensor signal is more than 300rpm within normal The values of the input shaft range and, speed calculated from the 2. The main main shaft speed sensor shaft speed and (SESM) and the counter the counter shaft...
Page 338 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 of the shift cylinder1R (SEPo1R) The sensor for the position of the shift cylinder 23 (SEPo23) The sensor for the position of teh range cylinder (SEPoR) Detailed conditions to activate The following conditions must be fulfilled for a time of 2.0s in order to activate:...
Page 339 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 above 600 rpm, the clutch position is more engaged than the slip point and the engine speed is received from the engine ECU and above 600rpm A forward gear is engaged in the gearbox and the main shaft speed sensor (SESM) indicates forward movement...
Page 340 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 operational signal is in sent the vehicle has oil range normal range Symbol for high temperature sensor temperature 2. Temperature gearbox oil functionality installed of the is above 100dgC temperature is lit gearbox oil during 18000s Medium:...
Page 341 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 range sensor signal and the Deactivate: The sensor supply, they will difference follow the nominal relation between clutch (Usepoc + Usepoc_inv) / Usepoc5V = 100% positions indicated by the sensor signal (SEPoC) and the inverted sensor signal ( SEPoC...
Page 342 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 4. Short circuit between the two sensor signals Deactivate: Both sensor signals are not below normal level Activate: 1. The CS in NVRAM is not correct Sensor Yellow lamp is 2.
Page 343 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 note: The fault will always have the state inactive. Check fault-count and last occurrence to get more information Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times (only once if the fault code- filter is switched OFF) in a row, in order to set the fault...
Page 344 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times (only once if the fault code- filter is switched OFF) in a row, in order to set the fault code: - The split valve for reaching indirect split is activated for...
Page 345 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 code on any of the sensor for the position of the split cylinder (SEPoS) the valve for shift to direct split the valve for shift to indirect split Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times...
Page 346 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 deactivated Reduced gear change comfort Activate: The Yellow lamp is Valve for high side drive is sent Current below activating the open circuit The valve can FMI5 normal or PTO number Deactivate: The not be activated open circuit...
Page 347 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 Gear changes are slow Activate: 1. The Yellow lamp is high-side drive is sent short circuited to Fast Ubatt and, 2. Valve for fast Voltage engagement/dis there is no active engagement above normal engagement...
Page 348 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 selection enters faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve is Activate: The activated Valve for high side drive is Gears are Voltage short circuit to missing...
Page 349 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated high side drive is Gears are Valve for Current above short circuit to missing...
Page 350 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can not be activated Activate: The Valve for Gears are high side drive is Current below missing shifting to open circuit...
Page 351 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 changes only at certain vehicle speeds Yellow lamp is sent The valve is activated Activate: The Direct and Valve for high side drive is neutral split Voltage short circuit to gears are shifting to above normal...
Page 352 SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated high side drive is Range gears are Valve for Current above short circuit to...
Page 353: Volvo I-Shift Transmission Gsecu Fault Codes
SECTION 07: TRANSMISSION FUNCTION ERROR CONDITION SYMPTOM COMMENT PID/SID J1587 Yellow lamp is Activate: The sent Slow Valve for high-side drive is engagement Current above slow short circuit to disabled normal or engagement FMI6 Reduced clutch grounded Deactivate: The performance, of the clutch circuit high-side drive is...
Page 354 SECTION 07: TRANSMISSION PID/PPID LAMP CONTENT TEXT COMMENT CONSEQUENCES SID/PSID Fault displayed after ignition OFF. Risk of Check Gear Output actuator battery discharge if main PSID36 Selector System (REPS) circuit breaker is not at next stop opened when vehicle is not used Check Gear Output actuator...
Page 355: Specifications
SECTION 07: TRANSMISSION 11. SPECIFICATIONS ALLISON AUTOMATIC TRANSMISSION WITH OR WITHOUT RETARDER Coaches & Commercial use Allison B500 Gross input power (maximum) ....................500 HP (335 kW) Gross input torque (maximum) ..................1525 Lbf-ft (2068 Nm) Rated input speed (minimum-maximum) ..................1600-2300 rpm X3-45 VIP, H3-45 VIP motorhomes.
Page 356 SECTION 07: TRANSMISSION Oil Filters: Make ............................. Allison Transmission Type ............................Disposable cartridge VOLVO I-SHIFT TRANSMISSION Oil System: Oil change ..........................16 US qts (15 liters) Oil Filter: Make ................................Volvo Type ............................Disposable cartridge PA1621 Maintenance Manual All Series | January 2017...
Page 357 SECTION 09: PROPELLER SHAFT CONTENTS SECTION CHANGE LOG ............................2 STANDARD TORQUE SPECIFICATION TABLES ....................3 PROPELLER SHAFT ............................3 DESCRIPTION..............................3 PROPELLER SHAFT MAINTENANCE DIRECTIVE ....................4 U-JOINT SERVICE – QUICK REFERENCE GUIDE ....................5 ............................. 6 LUBRICATION PROCEDURE ...........................
Page 358: Section Change Log
SECTION 09: PROPELLER SHAFT SECTION CHANGE LOG DESCRIPTION DATE Maintenance information added May 30, 2018 PA1621 Maintenance Manual All Series Revised May 2018...
Page 359: Standard Torque Specification Tables
SECTION 09: PROPELLER SHAFT STANDARD TORQUE SPECIFICATION TABLES Refer to Section 00 general information for Standard Torque Specifications. FIGURE 1: PROPELLER SHAFT ASSEMBLY (typical) PROPELLER SHAFT The propeller shaft has a half round end yoke at each end. The slip yoke is connected to the DESCRIPTION differential by a half round end yoke with two needle bearings.
Page 360: Propeller Shaft Maintenance Directive
BOLTS AS USED ON PREVOST VEHICLES deterioration (rust or corrosion) or excessive play. If all components pass inspection, New cold formed bearing retainers CAN be grease universal joints until they are properly reused. Replace only if damaged.
Page 361: U-Joint Service - Quick Reference Guide
SECTION 09: PROPELLER SHAFT NOTE: If necessary, rotate driveshaft to allow • The driveshaft and yokes must be access to all grease fittings. marked (phasing marks) (see paragraph 4.3 mark propeller shaft (PHASING MARKS)) • It is the responsibility of the maintainer before removal to ensure reinstallation in the who begins the driveshaft installation to same position as removed.
Page 362: Lubrication Procedure
SECTION 09: PROPELLER SHAFT • Never heat components or use a sledgehammer or floor jack to remove the propeller shaft from the vehicle. Do NOT reuse spring tabs and bolts. • Do NOT reuse bearing retainer bolts. • Only replace u-joints with genuine Dana •...
Page 363: Mark Propeller Shaft
SECTION 09: PROPELLER SHAFT GREASE ZERKS • Visually inspect damaged bearing retainers, loose bearing retainer bolts, loose • Replace damaged zerks. companion flange, bolts and nuts, loose or missing spring tabs or spring tab bolts, damaged Torque zerks to 15 lbf-ft. •...
Page 364 SECTION 09: PROPELLER SHAFT FIGURE 9: PHASING MARKS FIGURE 12: COLD FORMED BEARING RETAINERS It may be necessary to unseat bearing cup assemblies by tapping on yoke or bearing cup with a soft-faced hammer. Once the bearing cup assemblies are free, collapse the propeller shaft until both bearing assemblies clear the open end yoke cross holes.
Page 365: Inspect Companion Flange/Flange Yokes
SECTION 09: PROPELLER SHAFT Inspect the end yoke cross holes for distortion and damage. 5.1.1 Inspect Companion Flange/Flange Yokes Inspect all flange bolt hole threads or through holes for damage. If the bolt hole FIGURE 17: INCORRECT POSITIONING threads or through holes are damaged, the flange must be replaced.
Page 366: Inspect Tube Yoke And Flange Yoke (If Applicable)
SECTION 09: PROPELLER SHAFT Completely collapse the boot toward the yoke shaft to expose weld ring and spline sleeve area. Wipe weld ring and spline sleeve areas clean. Remove the yoke shaft and boot from the spline sleeve. Discard boot. Inspect the yoke shaft spline surface for damage.
Page 367: Propeller Shaft Installation
SECTION 09: PROPELLER SHAFT After all traces of grease and cutting not stationary, recheck for proper clamp solvent have been removed from the yoke torque. If clamps still are not stationary, shaft and spline sleeve, apply half of the repeat disassembly assembly grease provided to the yoke shaft splines...
Page 368: Universal Joint Installation
FIGURE 27: GREASING BEARING CUP Align the yoke in an arbor press with the bearing assembly resting on the base of the press. Cover the yoke ear with a metal plate Prevost production line torque value PA1621 Maintenance Manual All Series Revised May 2018...
Page 369: Explanation Of Common Damages
SECTION 09: PROPELLER SHAFT that has 0.25 inch (6.4mm) minimum thickness. Push the yoke onto the bearing cup assembly until it is flush with the cross hole face. Do not remove the installation height tool. SPRING TAB BOLT TORQUE Bolts are specially heat-treated. DO NOT substitute inferior grade bolts.
Page 370: Specifications
SECTION 09: PROPELLER SHAFT SPECIFICATIONS PROPELLER SHAFT Make ............................Dana-Spicer Inc. Series ................................. SPL250 PA1621 Maintenance Manual All Series Revised May 2018...
Page 371 SECTION 10: FRONT I-BEAM AXLE CONTENTS SECTION CHANGE LOG ............................2 TORQUE TABLES ............................. 3 FRONT I-BEAM AXLE AND RELATED COMPONENTS ..................3 FRONT I-BEAM AXLE HUB, ROTOR AND BRAKES ................... 5 DESCRIPTION ..............................6 REFERENCE MANUALS ........................... 6 LUBRICATION ..............................8 MAINTENANCE ...............................
Page 372: Section Change Log
SECTION 10: FRONT I-BEAM AXLE SECTION CHANGE LOG DESCRIPTION DATE Front I-beam axle, new tie-rod 2018-10-16 PA1621 Maintenance Manual All Series Section revised October 2018...
Page 373: Torque Tables
SECTION 10: FRONT I-BEAM AXLE TORQUE TABLES The following tables list the tightening torques 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. For other torque specifications, refer to Dana manuals listed in paragraph 2.1 reference manuals in this section.
Page 374 SECTION 10: FRONT I-BEAM AXLE 16191 16194_1 FRONT I-BEAM AXLE DESCRIPTION TORQUE (dry) Sway bar link, upper and lower nuts 165-200 lb-ft (224-271 Nm) Sway bar bushing collars (front suspension) 80-100 lb-ft (108-136 Nm) Tie rod end clamp bolts 118-133 lb-ft (160-180 Nm) Tie rod end ball pin nuts 155-170 lb-ft (210-230 Nm) Steering arm stud nuts...
Page 375: Front I-Beam Axle Hub, Rotor And Brakes
SECTION 10: FRONT I-BEAM AXLE FRONT I-BEAM AXLE HUB, ROTOR AND BRAKES HUB, ROTOR AND BRAKE DESCRIPTION TORQUE (dry) Hub Flanged Bolt 174-192 lb-ft (236-260 Nm) Stake Hub Nut 575-626 lb-ft (780-849 Nm) Caliper Bracket Nut – Self Lock 85-103 lb-ft (115-140 Nm) Brake Caliper Mounting –...
Page 376: Description
SECTION 10: FRONT I-BEAM AXLE DESCRIPTION The Dana Spicer S84U front axle is of the ‘’Reverse Elliot’’ type. The front axle consists of a girder section beam with knuckles. Each knuckle is carried on a parallel king pin, with a steep angle taper roller bearing at its top and a plain phosphor bronze bush at bottom.
Page 377 SECTION 10: FRONT I-BEAM AXLE TYPICAL S84U AXLE ITEM DESCRIPTION ITEM DESCRIPTION Flanged Bolt Cap - Knuckle Top Top Steering Lever Brake Disc Top Steering Lever - Stud L.H. Nut – Self Lock Top Steering Lever - Stud R.H. Brake L.H. Nut - Self Lock Brake R.H.
Page 378: Lubrication
SECTION 10: FRONT I-BEAM AXLE Steering knuckles, knuckle pins and bushings can be overhauled or replaced without removing the LUBRICATION axle from the vehicle. However, if extensive overhaul work is necessary, the axle assembly should be removed. MAINTENANCE CAUTION Knuckle pins are provided with grease fittings for pressure lubrication.
Page 379: Replacement
SECTION 10: FRONT I-BEAM AXLE CAUTION Position the air lines and electric wires so they will not be damaged while removing the front axle assembly. 8. Proceed with steps a, b and c, while referring to Section 16: ‘’SUSPENSION’’. a) Disconnect sway bar links from axle brackets.
Page 380: Service Instructions For Steer Axle
SECTION 10: FRONT I-BEAM AXLE SERVICE INSTRUCTIONS FOR STEER NOTE AXLE To avoid inaccurate measurements, be careful not to let the knuckle turn while moving assembly in and out. Applying brakes will help lock wheel assembly. MAINTENANCE 6.1.2 Checking Vertical Slackness An inspection should be made at the intervals 1.
Page 381: Specifications
SECTION 10: FRONT I-BEAM AXLE SPECIFICATIONS Front Axle Make ..........................DANA SPICER EUROPE Model ................................S84U Front Track ........................84.4 inches (2 145 mm) Rated load capacity ......................16,500 lbs (7 500 kg) PA1621 Maintenance Manual All Series Section revised October 2018...
Page 383 SECTION 11: REAR AXLES CONTENTS TORQUE TABLES ............................. 3 ............................3 MERITOR DRIVE AXLE ............................4 ZF A DRIVE AXLE ................................5 TAG AXLE MERITOR DRIVE AXLE ............................. 6 ..............................6 ESCRIPTION DCDL ( ) ....................6 DRIVER CONTROLLED MAIN DIFFERENTIAL LOCK MAINTENANCE...............................
Page 384 SECTION 11: REAR AXLES SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...
Page 385: Torque Tables
SECTION 11: REAR AXLES TORQUE TABLES MERITOR DRIVE AXLE MERITOR DRIVE AXLE DESCRIPTION TORQUE Breather 12-18 lb-pi (16-24 Nm) Fill / Level check plug 35 lb-pi (47 Nm) minimum * Drain plug 35- lb-ft (47-0 Nm) Drive shaft flange nuts 5/8-18 150-230 lb-ft (203-312 Nm) Hub to disc cap screws 9/16-18 110-165 lb-ft (149-224 Nm)
Page 386: Zf A132 Drive Axle
SECTION 11: REAR AXLES ZF A132 DRIVE AXLE ZF A132 DRIVE AXLE DESCRIPTION TORQUE Filler plug 52 lb-ft (71 Nm) Drain plug 96 lb-ft (130 Nm) Level check plug 52 lb-ft (71 Nm) Breather 4 lb-ft (5 Nm) ZF A132 DRIVE AXLE DESCRIPTION TORQUE Caliper mounting bolts...
Page 387: Tag Axle
SECTION 11: REAR AXLES ZF A132 DRIVE AXLE DESCRIPTION TORQUE Drive shaft flange bolts cap screw M18x1.5x50mm G10.9 325 lb-ft (441 Nm) Hub cap screw Torx M16x1.5x60 221 lb-ft (300 Nm) TAG AXLE TAG AXLE DESCRIPTION TORQUE Tag axle transversal radius rod (stud) retaining bolt 198 lb-ft (268 Nm) Tag axle radius rods nut 228-252 lb-ft (309-342 Nm)
Page 388: Dcdl (Driver-Controlled Main Differential Lock)
SECTION 11: REAR AXLES MERITOR DRIVE AXLE Meritor Maintenance Manual 5A – single  reduction differential carriers DESCRIPTION The Meritor drive axle is equipped with a single reduction standard carrier mounted in front of the axle housing. The carrier consists of a hypoid drive pinion, a ring gear set and gears in the differential assembly.
Page 389: Maintenance
SECTION 11: REAR AXLES Fill Meritor axle with approved lubricants. Refer to Meritor technical bulletin TP-9539 Approved for oil selection. Rear Drive Axle Lubricants MAINTENANCE Differential oil level Check oil level (add if necessary) at the intervals specified by the Lubrication And Servicing Schedule Section...
Page 390: Checking And Adjusting The Oil Level
SECTION 11: REAR AXLES 2.3.2 Checking and Adjusting the Oil Level 2. Remove the drain plug from the bottom of the axle. Drain and discard the oil in an environment friendly manner. DANGER 3. Install and tighten the drain plug. Before servicing, park safely over a repair pit;...
Page 391: Disassembly And Reassembly
SECTION 11: REAR AXLES 11. Remove the lower and upper longitudinal radius rod supports from vehicle sub-frame as outlined in Section 16: Suspension, under heading "Radius Rod Removal". 12. Remove the transversal radius rod support from the vehicle sub-frame. FIGURE 5: JACKING POINTS ON FRAME 18524 13.
Page 392: Drive Axle Alignment
SECTION 11: REAR AXLES DRIVE AXLE ALIGNMENT to specifications chart below. Use static wheel alignment systems which work with angle NOTE measurements only, such as Josam or Hunter For drive axle alignment specifications, refer to systems. Static alignment specifications are paragraph 2.9.2 ‘’...
Page 393: Axle Shaft Sealing Method
Dry both surfaces. 2. Apply a continuous thin bead of silicone sealant* (Prevost P/N 680053) on the mounting surfaces and around the edge of all fastener holes of both the axle shaft flange and wheel hub.
Page 394: Zf A132 Drive Axle
SECTION 11: REAR AXLES ZF A132 DRIVE AXLE 3.1.2 Checking and Adjusting the Differential This vehicle may be equipped with a ZF model Oil Level A132 Hypoid Single Reduction drive axle, fitted with two Knorr Bremse brake chambers, Knorr Place the vehicle on a level surface. ...
Page 395: Compact Bearing (Hub Unit) Axial Play Check
SECTION 11: REAR AXLES Remove the drain plug from the bottom of the  MAINTENANCE differential case. Drain all the oil and discard in an environment friendly manner. Oil change interval – Lubricant class 12M Clean the magnetic insert of the drain plug, fit ...
Page 396: Compact Bearing (Hub Unit) Grease Change
SECTION 11: REAR AXLES MAINTENANCE Compact bearing (hub unit) axial play Check the bearing axial play once a year or every 100 000 miles (160 000 km) whichever occurs first. 3.1.5 Compact bearing (hub unit) Grease Change Perform compact bearing (hub unit) grease change as described in paragraph 7.3 GREASE CHANGE IN THE HUB of the following manual: OPERATING INSTRUCTIONS ZF AXLE A132...
Page 397 SECTION 11: REAR AXLES FIGURE 12: ZF A-132 DRIVE AXLE HUB ASSEMBLY Hub carrier Slotted nut Screen sheet Locking plate Shaft seal (with impulse disc) Flange shaft Cap screw M18x1.5x50mm G10.9 (14mm hex Compact bearing (hub unit) socket driver “Allen”) Cap screw Torx M16x1.5x60 (E20 Torx socket) Shaft seal PA1621 Maintenance Manual All Series | January 2017...
Page 398: Removal And Reinstallation
SECTION 11: REAR AXLES 16. Disconnect the lower ends of the four shock REMOVAL AND REINSTALLATION absorbers outlined Section under heading The following procedure deals with the removal "Suspension" "Shock of the drive axle assembly and its attachments Absorber Removal". as a unit.
Page 399: Tag Axle
SECTION 11: REAR AXLES If the axle has been removed for repairs or 4. With the system installed as in Figure 7, servicing and if all the parts are reinstalled adjust drive axle according to specifications' exactly in the same place, the axle alignment is chart below.
Page 400: Retracting Tag Axle
SECTION 11: REAR AXLES RETRACTING TAG AXLE MAINTENANCE The standard tag axle retraction system is controlled by a valve located on the right lateral Front and tag axle hub bearings need to be console and enables unloading and raising the checked at the intervals specified by the tag axle (refer to the "OPERATOR'S MANUAL"...
Page 401: Removing Transversal Radius Rod
SECTION 11: REAR AXLES 2. Remove drive axle wheels (if required, refer to CAUTION Section 13, "Wheels, Hubs And Tires"). 3. Exhaust compressed air from the air supply On vehicles equipped with an automatic system by opening the drain cock on each air transmission (with or without the output reservoir and deplete air bags by moving retarder), move tag assembly very carefully.
Page 402: Tag Axle Alignment
SECTION 11: REAR AXLES TAG AXLE ALIGNMENT TAG AXLE The tag axle alignment consists in aligning the Alignment / Minimum Nominal Maximum tag axle parallel to the drive axle position. Before value value value value Thrust angle -0.02 0.02 aligning the tag axle, proceed with the drive axle (deg.) alignment.
Page 403 Axle type .............................. Full floating Oil fill quantity ........................19.5 quarts (39 pints) Ratio ................................. 3.54 TAG AXLE Make ................................Prevost Rear track ........................83.6 inches (2 124 mm) Axle type ..............................Forged PA1621 Maintenance Manual All Series | January 2017...
Page 405 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS SECTION CHANGE LOG ............................4 TORQUE TABLES ............................. 5 BRAKE AND AIR SYSTEM ..........................5 MISCELLANEOUS TORQUES ........................... 6 AIR SYSTEM ..............................8 BRAKES ................................8 AIR RESERVOIRS ............................. 8 OPTIONAL WET TANK AUTOMATIC DRAIN VALVE ..................8 4.1.1 Installation .............................
Page 406 SECTION 12: BRAKE AND AIR SYSTEM 12.1.1 Compressor Removal and Installation ....................16 MISCELLANEOUS VALVES .......................... 17 13.1 EMERGENCY / PARKING BRAKE CONTROL VALVE (PP-1) ................20 13.2 OPTIONAL EMERGENCY / PARKING BRAKE OVERRULE CONTROL VALVE (RD-3) ......... 20 13.3 FLIP-FLOP CONTROL VALVE (TW-1)......................
Page 407 SECTION 12: BRAKE AND AIR SYSTEM 21.2 EMERGENCY/PARKING BRAKE MANUAL RELEASE ..................43 21.3 BRAKE CHAMBER REMOVAL ........................43 21.4 BRAKE CHAMBER INSTALLATION ......................... 44 21.5 BRAKE CHAMBER DISASSEMBLY ........................44 ANTI-LOCK BRAKING SYSTEM (ABS) ......................44 22.1 TROUBLESHOOTING AND TESTING ......................45 22.2 ABS COMPONENTS ............................
Page 408: Section Change Log
SECTION 12: BRAKE AND AIR SYSTEM SECTION CHANGE LOG DESCRIPTION DATE Updated valve info 06-2018 18 Disc Brake updated 06-2020 PA1621 Maintenance Manual All Series | Revised June 2020...
Page 409: Torque Tables
SECTION 12: BRAKE AND AIR SYSTEM 1. TORQUE TABLES BRAKE AND AIR SYSTEM BRAKE AND AIR SYSTEM DESCRIPTION TORQUE Compressor flange mounting nuts 63 lb-ft (85 Nm) Front IFS suspension caliper mounting bolts 405-495 lb-ft (549-671 Nm) Front I-beam caliper mounting bolts 350-393 lb-ft (475-533 Nm) Meritor drive axle &...
Page 410: Miscellaneous Torques
SECTION 12: BRAKE AND AIR SYSTEM BRAKE AND AIR SYSTEM DESCRIPTION TORQUE Meritor hub to disc cap screws 110-165 lb-ft (149-224 Nm) ZF drive axle caliper mounting bolts 200 lb-ft (271 Nm) ZF drive axle brake chamber mounting bolts 120-150 lb-ft (163-203 Nm) MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION...
Page 411 SECTION 12: BRAKE AND AIR SYSTEM Air filter/dryer connections - 1/2”-14 NPTF 37 lb-ft (50 Nm) 1/4" NTA-Type Plastic Tubing Connection 3 turns* 3/8” to 1/2" NTA-Type Plastic Tubing Connection 4 turns* 5/8” to 3/4" NTA-Type Plastic Tubing Connection 3 ½ turns* * Hand tight first then tighten using wrench the number of turns specified in table.
Page 412: Air System
SECTION 12: BRAKE AND AIR SYSTEM 4. AIR RESERVOIRS 2. AIR SYSTEM The air coming from the air dryer is first forwarded to the wet air tank, then to the primary The basic air system consists of an air (for the primary brake system), secondary (for compressor, reservoirs, valves,...
Page 413: Maintenance
SECTION 12: BRAKE AND AIR SYSTEM MAINTENANCE Ensure that both the accessories and the wet air tanks are purged during pre-starting inspection. In addition, it is good practice to purge these MAINTENANCE following the information below. Air tanks A recommended purge using the bottom drain valve should be done at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION &...
Page 414: Wet Air Tank
Tank is provided with a bottom drain system provided by Prevost. Do not fill system valve. by any other point on the system. 4.2.5...
Page 415: Accessory Air Filter
SECTION 12: BRAKE AND AIR SYSTEM ACCESSORY AIR FILTER ELEMENT The rear air system emergency fill valve will supply air to wet air tank, primary air tank, MAINTENANCE secondary air tank and accessories air tank for brakes, suspension and accessories systems while the front fill valve will supply air to Accessory air filter element accessories only.
Page 416: Air Dryer
SECTION 12: BRAKE AND AIR SYSTEM 8. AIR DRYER system before the air enters the system reservoir. The air filter/dryer also filters the air to remove dirt, compressor oil, other TORQUE for connections: contaminants that can damage the system. 3/8”-18 NPTF= 12 lb-ft (16 Nm) Change cartridge every 100,000 miles (160 000 km) or once every two years, whichever comes 1/4”-18 NPTF= 12 lb-ft (16 Nm)
Page 417: Air Leak Check / Warning
SECTION 12: BRAKE AND AIR SYSTEM 11. Thread replacement cartridge onto the base until the seal touches the base. Then, tighten the cartridge ONE additional turn. DO NOT OVERTIGHTEN. FIGURE 9: HALDEX CONSEP CONDENSER MAINTENANCE SEPARATOR The automatic heated drain valve installed on the Consep ensures that liquids are removed Air dryer cartridge upon each brake application for optimum...
Page 418: Air Lines
SECTION 12: BRAKE AND AIR SYSTEM 10. AIR LINES CAUTION Nylon-reinforced tubing and flexible hoses are Nylon air lines should be used to replace used to connect the units in the pneumatic existing nylon lines only, and must comply with system, including air brake system, suspension the color identification code to ease pneumatic system and accessory systems such as the...
Page 419: Pressure Regulating Valves
SECTION 12: BRAKE AND AIR SYSTEM securely located in position and free from any binding condition, which would hinder air flow. 11. PRESSURE REGULATING VALVES There is one pressure regulator (Figure 10) for small compressor accessories alternator drive belt tensioner, and an optional one installed on vehicles equipped with the world transmission output retarder.
Page 420: Compressor Removal And Installation
SECTION 12: BRAKE AND AIR SYSTEM function is to provide and maintain air under Stud (3) pressure to operate devices in brake and air Flange Nut (3) systems. Nipple (2) The compressor is driven by the ring gear, and is water cooled.
Page 421: Miscellaneous Valves
SECTION 12: BRAKE AND AIR SYSTEM 13. MISCELLANEOUS VALVES FIGURE 13 : PARTIAL PNEUMATIC DIAGRAM PA1621 Maintenance Manual All Series | Revised June 2020...
Page 422 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 14 PA1621 Maintenance Manual All Series | Revised June 2020...
Page 423 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 15 PA1621 Maintenance Manual All Series | Revised June 2020...
Page 424: Emergency / Parking Brake Control Valve (Pp-1)
SECTION 12: BRAKE AND AIR SYSTEM 13.1 EMERGENCY / PARKING BRAKE CONTROL VALVE (PP-1) A push-pull control valve mounted on the L.H. lateral console is provided for parking brake application or release. The spring brakes are self-actuated whenever the control valve supply pressure drops below 60 psi (414 kPa). In the UP position, brakes are ON.
Page 425: Dual Brake Application Valve (E-8P)
SECTION 12: BRAKE AND AIR SYSTEM 13.4 DUAL BRAKE APPLICATION VALVE (E-8P) The E-8P dual brake valve is a floor mounted, foot-operated type brake valve with two separate supply and delivery circuits. This valve is located in the front service compartment. 13.4.1 Brake Pedal Adjustment After brake pedal replacement or repair, adjust the pedal to its proper...
Page 426: Brake Relay Valve (R-14)
SECTION 12: BRAKE AND AIR SYSTEM 13.7 BRAKE RELAY VALVE (R-14) The primary air system includes two brake relay valves being supplied by the dual brake valve, and which function is to speed up the application and release of the service brakes. One R-14 valve located above the drive axle supplies the drive axle service brake air line, while the other R-14 valve supply the tag axle service brake air line and act as interlock valves.
Page 427: Pressure Protection Valve (Pr-4)
SECTION 12: BRAKE AND AIR SYSTEM 13.10 PRESSURE PROTECTION VALVE (PR-4) Maintenance and repair information on the pressure protection valve is supplied in the applicable booklet, found on your Technical Publications USB flash drive, under reference number Bendix SD-03-2010. The air system includes two pressure protection valves. One valve is installed on the manifold block, and insures at all times a minimum pressure of 70 psi (482 kPa) in the suspension air system in the event that a pressure drop occurs in either the suspension air system or accessory air...
Page 428: Antilock Modulator (M-32Qr)
SECTION 12: BRAKE AND AIR SYSTEM 13.13 ANTILOCK MODULATOR (M-32QR) The M-32QR (quick release) antilock system modulator is high capacity, on/off air valve that incorporate a pair of electrical solenoids for control. The solenoids provide the electro-pneumatic interface between the antilock controller electronics and the air brake system.
Page 429: Air Horn Valve
SECTION 12: BRAKE AND AIR SYSTEM 1. Unscrew the front R.H. decorative panel in • Engine speed too low. order to access the valve. Air pressure rises above a normal setting: 2. Unscrew and remove the valve handle. • Defective air gauge (registering incorrectly). 3.
Page 430: Disc Brakes
Y006471 Service Manual included on the 6. Check the caliper running clearance Technical Publications USB flash drive and also (see 18.2.7). available on Prevost Technical Publications site. 7. Check fitting and condition of the cover (item 10) and cover (item 68). MAINTENANCE Moisture and dirt is the enemy.
Page 431 SECTION 12: BRAKE AND AIR SYSTEM required by the brake manufacturer before filing a warranty claim. FIGURE 17: INSPECTION POINTS IDENTIFICATION PA1621 Maintenance Manual All Series | Revised June 2020...
Page 432 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 18: DISC BRAKE COMPONENTS PA1621 Maintenance Manual All Series | Revised June 2020...
Page 433 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 19: IDENTIFICATION OF GUIDE & SEAL VARIANTS PA1621 Maintenance Manual All Series | Revised June 2020...
Page 434: Functional And Visual Check
SECTION 12: BRAKE AND AIR SYSTEM If the thickness of the friction material at its thinnest point is less than 0.079 inch or 2 mm 18.2 FUNCTIONAL AND VISUAL CHECK (measurement C), the pads must be replaced. Overall thickness of new brake pad: 1.181 in (30 mm) 18.2.1 Wear Check of Pads Backplate SN7 type: 0.354 in (9 mm)
Page 435 SECTION 12: BRAKE AND AIR SYSTEM Example 2) E=0.453 in (11.5 mm) F=0.512 in (13 mm) > OK FIGURE 24: EXAGGERATED TANGENTIAL OBLIQUE WEAR OF BRAKE PADS Exaggerated taper wear of brake pads FIGURE EXAGGERATED WEAR DIFFERENCE The total thickness of the friction material in the BETWEEN INNER AND OUTER BRAKE PADS radial direction should be equal.
Page 436: Wear Check Of Disc
SECTION 12: BRAKE AND AIR SYSTEM 18.2.2 Wear Check of Disc B1 = Cracks less than 0.059 in (1.5 mm) deep or wide, running in a radial direction are allowed. Measure the thickness of the brake disc at the thinnest point. Be aware of possible burring at Cracks to a max.
Page 437: Wear Check Of Pads/Disc - Drive Axle Equipped With A Rubber Bushing And Exposed Guide Pin
SECTION 12: BRAKE AND AIR SYSTEM MEASUREMENT “C” WITH WORN DISC/BRAKE PADS FIGURE 28: BRAKE PAD WEAR CHECK ON THE DRIVE AXLE If measurement “C” is less than 0.039" (1 mm), this condition requires a check of the brake pad thickness and the brake disc with the wheel removed.
Page 438: Continuous Wear Sensor Option
SECTION 12: BRAKE AND AIR SYSTEM 18.2.5 Continuous Wear Sensor option Some vehicles have a potentiometer installed directly on the brake caliper. Wear percentage can be consulted via the DID. Access the « Brake Lining Remaining » MENU Front axle wear sensors are connected to multiplex module A44.
Page 439 SECTION 12: BRAKE AND AIR SYSTEM Check the gap between each of the tappets (13) and inboard pad backplate (12). This must be measured over the whole tappet surface of both tappets using two feeler gages simultaneously (feeler gages must be at least 8 ½ in / 220 mm long) (see Figure 33).
Page 440 SECTION 12: BRAKE AND AIR SYSTEM This ensures access is maintained for subsequent removal (see Figure 36). Note: A new adjuster cap (37) should be fitted even if the brake pads are not being replaced. FIGURE TURN ADAPTER CLICKS ANTICLOCKWISE As a visual aid, position a ring spanner or socket onto the adjuster (including Adapt- er (61)) as shown.
Page 441: Caliper Check - Caliper Running Clearance
SECTION 12: BRAKE AND AIR SYSTEM Lightly apply grease to the protruding area of the guide pin (4b). Check the brake disc. Remove brake pads. Check caliper running clearance (see 18.2.7 & 18.2.8). Fully wind back the tappets (13) using a ring spanner and shear adapter (61) (see Fit the brake pads.
Page 442: Clearance Measurement Check Of Bearing Variants (6)
SECTION 12: BRAKE AND AIR SYSTEM If the clearance exceeds the given tolerance, the complete bearing will need replacing using the relative service kit. If the clearance measuring is not taking place during a brake pad replacement, the new pads should be removed and the previously marked brake pads fitted in their original positions, otherwise renew the brake pads as an axle set...
Page 443: Checking Sealing Elements - Tappets And Boot Assemblies
SECTION 12: BRAKE AND AIR SYSTEM The floating bearing side with guide pin (4c, 4d or 4e) is sealed with inner boot (9c, 9d or 9e) and with cover (68c 68d or 68e). All variants (9), (10) and (68) must be free of any signs of damage (see Figure 43).
Page 444: Safe Service Procedures
SECTION 12: BRAKE AND AIR SYSTEM Then turn back the adjuster counterclock- wise  three “clicks” and check the caliper WARNING running clearance. • During the turning of the adjuster, you will notice a changed clicking noise. It is not NEVER use compressed air or dry brushing to caused by a defect of the mechanism.
Page 445 SECTION 12: BRAKE AND AIR SYSTEM which will guide you to the most common causes 5. At 85 psi (586 kPa), run engine at full rpm, of problems. then check that build up time to 100 psi (690 kPa) is 13 seconds or less. Before performing any test, check all air lines for kinks or dents, and hoses for signs of wear, 6.
Page 446: Brake Air Chamber
SECTION 12: BRAKE AND AIR SYSTEM CONDITION: Full pressure, engine stopped, 21. BRAKE AIR CHAMBER parking brake applied 1. Allow at least 1 minute for pressure to This vehicle uses “Knorr-Bremse” brake stabilize. chambers on all axles. The drive axle chambers consist of two separate air chambers, each 2.
Page 447: Emergency/Parking Brake Manual Release
SECTION 12: BRAKE AND AIR SYSTEM Every 100,000 Miles (160 000 km) or once a 4. To manually reset the emergency/parking year, whichever comes first depending on type of brake, turn the nut counterclockwise. Rein- operation: stall access plugs on the spring chambers, and release stud tools in their storage 1.
Page 448: Brake Chamber Installation
This system has been designed to ensure stability and permit steering control of vehicle o Prevost recommends the installation of a during hard braking, and to minimize its stopping new spring brake chamber if it is found to distance whatever the road conditions are.
Page 449: Troubleshooting And Testing
SECTION 12: BRAKE AND AIR SYSTEM lock controlled operation during ABS system wheel with this reference speed to determine failure. which wheel is accelerating or decelerating. As soon as wheel deceleration or wheel slip The ABS system consists of two diagonally threshold values are exceeded, the electronic related circuits, only the half of the system which control unit signals a solenoid control valve to...
Page 450: Spring Clip
Maintenance (Figure 36). No specific maintenance is required for sensors, except if the sensors have to be removed for axle servicing. In such a case, sensors should be lubricated with special grease (Prevost #680460) before reinstallation. Refer paragraph “Sensor Installation” for details.
Page 451: Bendix Automatic Traction Control (Atc) - Electronic Stability Control (Esc)
SECTION 12: BRAKE AND AIR SYSTEM 23. BENDIX AUTOMATIC TRACTION • Six (6) Bendix WS-24 wheel speed ® CONTROL (ATC) – ELECTRONIC STABILITY sensors. Each sensor is installed with a Bendix Sensor Clamping Sleeve; CONTROL (ESC) Five (5) Bendix Pressure Modulator •...
Page 452 Mixing valve type on the left and right sides of 6s/5m Configuration the vehicle may result in slight pull to one side Prevost vehicles utilize a 6 sensors/5 pressure when braking. modulator valves configuration, with the tag axle having two sensors, but only one Pressure...
Page 453: Removal Of The Steering Angle Sensor
4. Reconnect the connector. Ensure that there inputs to the SAS-70 sensor. will be no force applied to the sensor The SAS-70 sensor installed on Prevost vehicles because the connector is pulling on the is the 90° connector. sensor body.
Page 454: Fitting Tightening Torques
Any maintenance or repair work on the • NOTE steering linkage, steering gear or other related mechanism; Use Loctite pipe sealant to seal pipe thread (Prevost number 680098). Adjustment of the wheel alignment or wheel • track; After an accident that may have led to •...
Page 455 Model ............................... SR-1 Pressure Protection Valve Make ..............................Bendix Model ............................... PR-4 Nominal closing pressure ...................... 70 psi (482 kPa) Prevost number ........................... 641137 Shuttle-Type Double Check Valve Make ..............................Bendix Model ............................... DC-4 Air Pressure Regulator Make ..............................Norgren Adjustable output range ..................
Page 456 SECTION 12: BRAKE AND AIR SYSTEM Drive Axle Brake Chambers Make ............................Knorr-Bremse Type ..................... 24-inch as service -24-inch as emergency Tag Axle Brake Chambers Make ............................Knorr-Bremse Type ..............................16-inch Brake Lining (All Axles) Make ............................Knorr-Bremse PA1621 Maintenance Manual All Series | Revised June 2020...
Page 457 SECTION 13: WHEELS, HUBS AND TIRES CONTENTS SECTION CHANGE LOG ............................3 TORQUE TABLES ............................. 4 WHEEL NUTS ..............................4 TAG AXLE ................................ 4 FRONT AXLE ..............................5 MERITOR DRIVE AXLE ............................ 5 ZF A132 DRIVE AXLE ............................6 WHEELS ................................7 H3-45 &...
Page 458 SECTION 13: WHEELS, HUBS AND TIRES 12.1 COMPACT BEARING (HUB UNIT) AXIAL PLAY CHECK ................... 20 12.2 COMPACT BEARING (HUB UNIT) GREASE CHANGE ..................21 SPARE WHEEL ............................21 13.1 SUPER SINGLE TIRE REPLACEMENT ......................22 13.2 PULLING OUT SPARE WHEEL ........................22 13.3 CHANGING A FLAT TIRE (COACHES ONLY) ....................
Page 459: Section Change Log
SECTION 13: WHEELS, HUBS AND TIRES SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...
Page 460: Torque Tables
SECTION 13: WHEELS, HUBS AND TIRES 1. TORQUE TABLES 1.1 WHEEL NUTS WHEEL NUTS (ALL TYPES) – STEEL/ALUMINUM WHEELS DESCRIPTION TORQUE Wheel nuts (M22x1.5 threads)* 450-500 lb-ft (610-678 Nm) *Torque following sequence shown 1.2 TAG AXLE TAG AXLE DESCRIPTION TORQUE Tag axle hub flange cap screws 161-197 lb-ft (218-267 Nm) Tag axle hub nut...
Page 461: Front Axle
SECTION 13: WHEELS, HUBS AND TIRES 1.3 FRONT AXLE 13041_4 FRONT AXLE DESCRIPTION TORQUE Front axle hub flange cap screws 174-192 lb-ft (236-260 Nm) Front axle hub nut 575-625 lb-ft (780-847 Nm) 1.4 MERITOR DRIVE AXLE MERITOR DRIVE AXLE DESCRIPTION TORQUE Drive shaft flange nuts 5/8-18 150-230 lb-ft (203-312 Nm)
Page 462: Zf A132 Drive Axle
SECTION 13: WHEELS, HUBS AND TIRES 1.5 ZF A132 DRIVE AXLE ZF DRIVE AXLE DESCRIPTION TORQUE Drive shaft flange bolts cap screw M18x1.5x50mm G10.9 325 lb-ft (441 Nm) Hub cap screw Torx M16x1.5x60 221 lb-ft (300 Nm) PA1621 Maintenance Manual All Series | January 2017...
Page 463: Wheels
SECTION 13: WHEELS, HUBS AND TIRES 2. WHEELS The vehicle is equipped with hub-mounted wheels as standard equipment, all studs and nuts have right-hand threads Either steel wheels or optional aluminum-polished wheels may be installed on the vehicle. Both are mounted with radial tubeless tires.
Page 464: Inspection
SECTION 13: WHEELS, HUBS AND TIRES CAUTION CAUTION Wheel studs and nuts must be kept free from Always mark position of the wheel on the axle grease and oil. No lubricant whatsoever should prior to removal in order to replace wheel at be used.
Page 465: Inspection
180º apart in order to have good quality tar remover. access to both the inner and outer valves. 2. Spray Alcoa Cleaner (Prevost #683529) evenly on cool outer surface of wheel. Let 4.5 INSPECTION work 15-20 minutes (keep wet by spraying 1.
Page 466: Wheel Straightness Test
SECTION 13: WHEELS, HUBS AND TIRES Clean aluminum wheels as required to maintain If, within specifications, the hub is correct but  original look. the suspected wheel must be replaced. WARNING WARNING NEVER STRAIGHTEN ALUMINUM WHEELS. Never heat aluminum wheels to repair damages incurred after hitting a curb or Wheel surfaces may have sharp or cutting resulting from other causes.
Page 467: Front And Tag Axle Wheel Studs
SECTION 13: WHEELS, HUBS AND TIRES NOTE Tightening should not be done immediately 7.2 FRONT AND TAG AXLE WHEEL STUDS after prolonged braking or when wheel ends are hot. Wheel is hub mounted on front and tag axle (M22x1.5 thread). Check wheel nut torque at every 100 miles (160 km) for 500 miles (800 km) after fitting wheels.
Page 468 SECTION 13: WHEELS, HUBS AND TIRES FIGURE 7: TAG AXLE HUB AND ROTOR ASSEMBLY FIGURE 8: TAG AXLE UNITIZED BEARING & WHEEL HUB PA1621 Maintenance Manual All Series | January 2017...
Page 469 9.3 TAG AXLE HUB BEARING INSTALLATION Without releasing the pressure, turn bearing so that indicator stem again contacts the Clean spindle using EFX degreaser (Prevost marked spot and note new reading on #685313) indicator.
Page 470 SECTION 13: WHEELS, HUBS AND TIRES Clean thrust washer both sides and hub nut using EFX degreaser. FIGURE 10: APPLY GLEITMO 805 GREASE Install thrust washer and hub nut then torque Slip unitized hub bearing over spindle. hub nut. TORQUE: 563-687 lb-ft (763-931 Nm) Rotate bearing, minimum 10 revolutions necessary (simultaneous rotation till final clamp torque is achieved).
Page 471 FIGURE 14: ROTOR TORQUE: 450-500 lb-ft (610-678 Nm) Add some grease (25-50 ml) (Fuchs Renolite LX PEP-2) (Prevost #685325) into the bottom of the hub flange cap. Mount hub flange onto rotor. Secure hub flange and rotor to unitized hub bearing using 14 new cap screws (single- use only).
Page 472: Front Axle Wheel Hubs
SECTION 13: WHEELS, HUBS AND TIRES 10. FRONT AXLE WHEEL HUBS The FAG unitized hub bearings used on the NDS range of axles, are non-serviceable items. Bearings are pre-adjusted, lubricated and have seals fitted as part of the manufacturing process. The bearings are greased for life and there is no need or facility for re-lubrication.
Page 473: Front Axle Hub Bearing Removal
Axle HUB BEARING REWORK_ Manual NO 1963 A+B iss A. See OVERHAUL PROCEDURES, HUB END REASSEMBLY, pages No. B23 up to B30. 1. Clean spindle using EFX degreaser (Prevost FIGURE 20: SLIDE UNITIZED HUB BEARING OVER #685313). SPINDLE 2. Screw insertion tool onto spindle (FIGURE 18).
Page 474 HUB FLANGE CLAMPING SURFACES Install rotor onto hub bearing. Add some grease (25-50 ml) (Fuchs Renolite LX PEP-2) (Prevost #685325) into the bottom of the hub flange cap. Mount hub flange onto rotor. Secure hub flange and rotor to unitized hub bearing using 14 hub flange cap screws.
Page 475: Bearing Check/Adjustment
SECTION 13: WHEELS, HUBS AND TIRES  Meritor Maintenance Manual 23A – Bus and Coach Rear Drive Axles  Meritor Maintenance Manual 5A – single reduction differential carriers 11.1 BEARING CHECK/ADJUSTMENT To adjust drive wheel bearings, refer to “Adjustment – Wheel bearings” heading in Meritor Maintenance Manual 23A –...
Page 476: Zf Drive Axle Wheel Hubs
SECTION 13: WHEELS, HUBS AND TIRES reinstallation. 3. Remove lock nut, lock ring and adjusting nut from axle housing to prevent the outer bearing from falling out. Remove outer bearing cone and roller assembly. 4. Remove screws attaching inner oil seal retainer to hub, and remove inner oil seal assembly.
Page 477: Compact Bearing (Hub Unit) Grease Change
SECTION 13: WHEELS, HUBS AND TIRES MAINTENANCE Compact bearing (hub unit) axial play Check the bearing axial play at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION & SERVICING. FIGURE 27: ZF A-132 DRIVE AXLE HUB ASSEMBLY 12.2 COMPACT BEARING (HUB UNIT) GREASE CHANGE hub carrier...
Page 478: Super Single Tire Replacement
SECTION 13: WHEELS, HUBS AND TIRES The spare wheel is stored in a dedicated On H3 series vehicles, Untighten the pressure compartment behind the front bumper. To screw holding the tire in place. Lift the pressure access, pull the release handle located in the screw arm and move to the side.
Page 479: Changing A Flat Tire (Coaches Only)
SECTION 13: WHEELS, HUBS AND TIRES NOTE NOTE On H3 series vehicles, the pressure screw Check the inflation pressure of the spare tire arm must return to its initial position otherwise, periodically to keep it ready for use. Inflate the bumper cannot be latched in upper spare tire to the pressure of the tire, which has position.
Page 480: Spare Wheel Maintenance
SECTION 13: WHEELS, HUBS AND TIRES the triangular reflectors in accordance with applicable highway regulations. It is strongly suggested that you do not attempt to change a wheel, the wheel and tire are very heavy and there is usually no space available to put the removed flat.
Page 481: Valve Installation
When replacing valve stems, lubricate the threads and O-ring with Permatex Dielectric Tune- Up grease (Prevost #685324) to avoid galvanic corrosion. Tip: When installing the valves, use as needed a 15mm wrench to hold the valve and block the rotation.
Page 482: Tpms Sensors Installation
Super Single tire Valve 650013 Install the valve in place. Torque 106-133 lb-in (12-15 Nm) #Prevost 650013 14.1 TPMS SENSORS INSTALLATION Check proper valve positioning before installing sensor onto valve (risk of damaging the sensor or air leaks). Pressure sensor #560032.
Page 483: Tire Maintenance
SECTION 13: WHEELS, HUBS AND TIRES Apply decal facing the valve. #651091 ENGLISH #651090 BILINGUAL 15. TIRE MAINTENANCE 15.1 INFLATION PRESSURE Vehicles equipped with BERU TPMS  The most critical factor in tire maintenance is proper inflation (Figure 33). No tire is impervious On vehicles equipped with the Beru Tire to loss of air pressure.
Page 484 Incorrect tire pressures cause increased tire manufacturer's recommendations. For other wear and adversely affect road holding of the tire and wheel specifications, see Prevost tire vehicle, which may lead to loss of vehicle pressure tabulation in "Coach Final Record". control.
Page 485: Tire Matching
SECTION 13: WHEELS, HUBS AND TIRES 15.3 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 486: Specifications
SECTION 13: WHEELS, HUBS AND TIRES 16. SPECIFICATIONS STEEL WHEELS Wheel size ............................ 9.0" X 22.5" Tire size ............................. 315/80 R 22.5 ALUMINUM WHEELS Wheel size ............................9" X 22.5" Tire size ............................. 315/80 R 22.5 OPTIONAL FRONT & TAG AXLE ALUMINUM WHEELS (Standard on VIP vehicles) Wheel size ..........................
Page 487 SECTION 14: STEERING CONTENTS SECTION CHANGE LOG ............................4 TORQUE TABLES ............................. 5 STEERING COLUMN............................5 MISCELLANEOUS TORQUES ........................... 6 STEERING SYSTEM ............................7 FRONT I-BEAM AXLE STEERING SYSTEM DESCRIPTION ................. 7 INDEPENDENT FRONT SUSPENSION STEERING SYSTEM DESCRIPTION ............8 POWER STEERING GEAR ..........................
Page 488 SECTION 14: STEERING MAINTENANCE ............................19 14.1 POWER STEERING FLUID CONDITION ......................20 14.1.1 Power Steering Fluid Visual Inspection ..................... 20 14.2 POWER STEERING FLUID CHANGE ....................... 20 14.3 POWER STEERING FLUID RESERVOIR ......................21 14.3.1 Fluid Level Check ............................21 14.3.2 Filter Element Replacement ........................
Page 489 SECTION 14: STEERING TORQUE SPECIFICATIONS ......................... 41 SPECIFICATIONS ............................41 PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 490 SECTION 14: STEERING SECTION CHANGE LOG DESCRIPTION DATE New paragraphs added: 13.1 Power Steering Fluid Condition; 13.1.1 Power Nov. 2017 Steering Fluid Visual Inspection Updated tie rod on I-beam axle October 2018 New Power steering reservoir April 2019 Nut on I-beam axle tie rod is single use. June 2019 PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 491: Torque Tables
SECTION 14: STEERING TORQUE TABLES STEERING COLUMN 14046_5 STEERING COLUMN DESCRIPTION TORQUE Steering Wheel Nut 35-45 lb-ft (47-61 Nm) U-Joint Clamp Nut 48 lb-ft (65 Nm) Column Support Fore Bolts 11-13 lb-ft (15-18 Nm) Column Support Aft Bolts 15-19 lb-ft (20-26 Nm) Steering Angle Sensor Mounting Screws 9-12 lb-in (1.02-1.36 Nm) PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 492: Miscellaneous Torques
SECTION 14: STEERING MISCELLANEOUS TORQUES 14088_2 14085 MISCELLANEOUS DESCRIPTION TORQUE Tie rod end ball pin self locking nuts - I-Beam Axle 155-170 lb-ft (210-230 Nm) Tie rod end clamp bolts - I-Beam Axle 118-133 lb-ft (160-180 Nm) Pitman Arm Fixing Nut 470-570 lb-ft (637-773 Nm) Steering Gear Mounting Bolts 365-405 lb-ft (495-549 Nm)
Page 493: Steering System
SECTION 14: STEERING These elements are: 1. Steering stabilizer (damper); STEERING SYSTEM 2. A vane type hydraulic pump; 3. Hydraulic reservoir and hoses. FRONT I-BEAM AXLE STEERING The steering stabilizer reduces road shocks and SYSTEM DESCRIPTION vibrations in the system. The steering gearbox is self-powered and provides movement with power The steering system consists of the steering assistance to the left wheel.
Page 494: Independent Front Suspension Steering System Description
SECTION 14: STEERING These elements are: INDEPENDENT FRONT 1. A vane type hydraulic pump; SUSPENSION STEERING SYSTEM DESCRIPTION 2. Hydraulic reservoir and hoses. 3. Hydraulic power cylinder (VIP & Bus Shells) The steering system consists of the steering wheel and column assembly, a vane-type hydraulic pump, reservoir, filter, interconnecting NOTE system lines and hoses, integral power steering...
Page 495 SECTION 14: STEERING POWER STEERING GEAR FIGURE 4: 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 applied to the steering wheel.
Page 496: Power Steering Gear
Alterations to or adjustments of the front axle were carried out. Find the end limiter adjustment procedure in Maintenance Information MI20-12 available on Prevost Technical Publications site. FIGURE 5: PITMAN ARM ADJUSTMENT PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 497: Bleeding Power Steering Hydraulic System
SECTION 14: STEERING BLEEDING POWER STEERING HYDRAULIC SYSTEM To bleed the power steering hydraulic system, refer to “RB Robert Bosch Servocom - Service Manual (8090)”, found your Technical Publications USB flash drive, under heading "Setting and Functional Test". HYDRAULIC PRESSURE TEST Perform a pressure test as outlined in the "ZF- SERVOCOM Repair Manual"...
Page 498 SECTION 14: STEERING FIGURE 8: POWER STEERING PUMP REMOVAL Install the new power steering pump. Torque-tighten bolts to specification. NOTE Use a new gasket. Connect the hydraulic lines to the power steering pump. 10. Install the fuel pump. Torque-tighten bolts to specification.
Page 499: Steering Column
SECTION 14: STEERING column lower cover. Remove the lower cover (Figure 10). STEERING COLUMN 2. Unscrew the four retaining screws on steering column middle cover. 3. Unscrew the four retaining screws fixing REMOVAL steering column upper cover to middle cover. Remove the steering column middle and To disassemble the steering column from system, upper covers.
Page 500: Installation
SECTION 14: STEERING NOTE The clockspring mechanism permits a certain number of turns in each direction. At the moment of reinstalling the steering wheel, if the clockspring is not at its neutral position, the number of available turns will be reduced. This may damage the clockspring if the steering wheel is turned to its maximum amplitude.
Page 501: Turning Angle Adjustment
SECTION 14: STEERING FIGURE 14: CLOCKSPRING INSTALLATION 4. Mount the clockspring in place with 2 screws. 5. Break the paper seal and rotate the center FIGURE 16: STEERING STOP SCREW ON IFS part of the clockspring about 50° clockwise (Figure 15). This step is necessary for the installation of the steering wheel.
Page 502: Steering Linkage Adjustment
SECTION 14: STEERING CAUTION CAUTION Reduce or shut off the power steering hydraulic Front wheel alignment should be checked and pressure before the boss on the knuckle adjusted if necessary, any time a component of touches the stop screw. If not, the components the steering system is repaired, disassembled of the front axle will be damaged (refer to "ZF- or adjusted.
Page 503: Installation
SECTION 14: STEERING FIGURE 18: I-BEAM FRONT AXLE PITMAN ARM ADJUSTMENT 6. Add reference marks to the arm and shaft if necessary to ensure correct alignment at reassembly. FIGURE 20: FIXING NUT PUNCH MARK 16098 2. Connect drag link to pitman arm while ensuring that rubber stabilizer is in place on the rod end.
Page 504: Tag Axle Unloading Switch Adjustment (Optional)
SECTION 14: STEERING 4. When adjustment is achieved, replace fixing nut and tighten TORQUE: 470-570 lb-ft (637-773 Nm) 12.4 TAG AXLE UNLOADING SWITCH ADJUSTMENT (OPTIONAL) 1. Make sure vehicle wheels are straight and facing forward. 2. Line up switch lever with reference to the bracket center (Refer to Figure 21).
Page 505: Adjustment System Thread Lengths
SECTION 14: STEERING • Dimension V: 5/16″ (8mm) • Dimension W: 5/16″ (8mm) WARNING To preserve the integrity of the adjusting system, length V and W should never exceed 5/8″(16mm) ± 1 thread pitch. Length V and W should be equal within ± 1mm 14.
Page 506: Power Steering Fluid Condition
SECTION 14: STEERING overhaul of the various steering units will be clean white rag. Check the fluid color, smell and required. General overhaul procedure normally consistency. Use the color chart below to requires removal of the entire assembly, cleaning determine if the power steering fluid needs to be and inspection of all parts and final assembly.
Page 507: Fluid Level Check
SECTION 14: STEERING 14.3 POWER STEERING FLUID RESERVOIR The power steering reservoir is located on the R.H. side of the engine compartment. On H series vehicles it is fixed on the main power compartment wall, accessible by the R.H. compressor door. FIGURE 27: POWER STEERING FLUID RESERVOIR Gasket Filter screw...
Page 508: Filter Element Replacement
FIGURE 29: FILTER REMOVAL Steering wheel travel covered: 1. Remove the cap Maximum 1.732 inch (44mm) with Prevost 2. Prepare an appropriate container. 18-inch steering wheel 3. Disconnect the larger suction hose first.
Page 509: Steering Stabilizer Cylinder (Damper)
Servocom manual Servicing Schedule Section doesn’t apply to the Prevost design which LUBRICATION & SERVICING. uses a 18-inch steering wheel. Check the ball joint for wear, and replace if If the maximum value is exceeded, the steering necessary.
Page 510: Front I-Beam Axle Drag Link
SECTION 14: STEERING responsible for product quality. Figure 31 shows (6) Upper A-Arm Ball Joint: Lubricate at approximate location of steering lubrication fitting until you see some grease on the fittings. relief valve nearby, with good quality lithium-base grease NLGI No. 2 (Shell Retinax LX or equivalent).
Page 511: Front I-Beam Axle Tie Rod
SECTION 14: STEERING Clean the adjustment system with a brush and 14.7 FRONT I-BEAM AXLE TIE ROD compressed air prior to inspection, if required. With the engine running and the vehicle on the ground (with a load on the axle) turn the steering wheel left and right.
Page 512: Tube Inspection
SECTION 14: STEERING MAINTENANCE Inspect tie rod once a year. 14.8.1 Tube inspection Check the tube for damage. If there are signs of deformation, replace the tie rod assembly. 14.8.2 Ball joint play inspection FIGURE 37: 14.8.4 Tie rod ball joint inspection for corrosion MAINTENANCE Inspect tie rod ball joints for corrosion once a FIGURE 35 TIE ROD BALL JOINT...
Page 513: Drag Link Ball Joint Inspection For Corrosion
SECTION 14: STEERING expelled from the opening. Make sure the When dismantling the drag link, ensure that no bellows is in good condition, without any damage is caused to the sealing boots, dirt seals holes, tears, scratches of chafing marks. or ball joint housings.
Page 514: Straight Body Type Ball Joint End Play And Looseness
SECTION 14: STEERING was used to compensate for another problem CAUTION (e.g. bent steering components). No heavy corrosion is accepted for the clamps or Do not use a wrench or other object to apply screws. leverage when inspecting ball joint. Applying leverage with tools can give distorted Nuts and screws must be firmly in place.
Page 515: Alignment Terminology
SECTION 14: STEERING Regular service inspections concern toe-in, 2. Check the tires for proper inflation. camber and caster. 3. Check wheel installation and run-out. Any variation from the specified alignment will 4. Check wheel bearing adjustment. indicate either a need for adjustment or a more thorough inspection to determine if parts 5.
Page 516: Front Wheel Toe-In
SECTION 14: STEERING 4. Check that the angular relationship of the NOTE pitman arm to the steering gear is as shown Shim only the lower suspension arm to adjust in Figure 42. the front wheel camber. NOTE Use only tie rods to adjust toe-in. CAUTION Once perfect...
Page 517: Hydraulic End Limiter Adjustment After Wheel Alignment
Alterations to or adjustments of the front axle were carried out. Find the end limiter adjustment procedure in Maintenance Information MI20-12 available on Prevost Technical Publications site. PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 518: Alignment Specifications
SECTION 14: STEERING 16.1.8 Alignment Specifications Use static wheel alignment systems which work with angle measurements only, such as Josam or Hunter systems. NOTE On Independent Front Suspension, caster on right wheel must be equal or greater than caster on left wheel, with a maximum difference of 0.3°.
Page 519 SECTION 14: STEERING H3-45 VIP INDEPENDENT FRONT SUSPENSION Minimum value Nominal value Maximum value Non- Converted Non- Converted Non- Converted Load converted converted converted Right camber 0.20° -0.20° 0.30° 0° 0.50° 0.20° Left camber 0.20° -0.20° 0.30° 0° 0.50° 0.20° Right caster 2.55°...
Page 520 SECTION 14: STEERING FIGURE 43: IFS NOMINAL DIMENSIONS FIGURE 44: NOTE 2 INDICATES WHERE ADJUSTMENT MAY BE PERFORMED AT IFS ALIGNMENT PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 521 SECTION 14: STEERING WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 45: FRONT END ALIGNMENT DIAGRAM 16051 PA1621 Maintenance Manual All Series | Section revised June 2019...
Page 522: I-Beam Axle - Front Wheel Alignment
SECTION 14: STEERING Make sure all fasteners are tightened to the specified torque. Use a torque wrench for 16.2 I-BEAM AXLE - FRONT WHEEL verification. As soon as the fastener starts ALIGNMENT to move, record the torque. Correct if necessary. Replace any worn or damaged fasteners.
Page 523: Hydraulic End Limiter Adjustment After Wheel Alignment
Maintenance Information MI20-12 available afterwards. Two washers of different on Prevost Technical Publications site. thickness are available: 1/16 inch and 3/16 inch. 16.2.5 Turning Angle Adjustment 16.2.7 L.H. Turn Adjustment The maximum turning angle is set through the 1.
Page 524: Front Wheel Camber
SECTION 14: STEERING 16.2.8 Front Wheel Camber 4. Check the wheel lateral distortion as instructed in Section 13, ‘’Wheels, Hubs and under heading, Wheel camber is the number of degrees the top Tires’’ ‘’Checking Distorted Wheel on Vehicle’’. If distortion is of the wheel tilts outward (positive) or inward (negative) from a vertical angle (Figure 46).
Page 525: Front Wheel Toe-In
NOTE needs adjustment; it can be adjusted by means ‘’Toe-in’’ measurements must be taken at the of shims (Prevost #110663) on the left-hand horizontal axis of the wheel centerline. side upper radius rod support in order to obtain minor adjustment.
Page 526: Front Wheel Alignment Specifications
SECTION 14: STEERING 16.5 FRONT WHEEL ALIGNMENT SPECIFICATIONS Use static wheel alignment systems which work with angle measurements only, such as Josam or Hunter systems. Static alignment specifications are listed in the following tables: FRONT WHEEL ALIGNMENT SPECIFICATIONS WITH I-BEAM AXLE Front Wheel Alignment Minimal Nominal...
Page 527 SECTION 14: STEERING Worn broken 1. Drag link fasteners tightened past 1. Replace damaged part(s), tighten drag steering ball pin. specified torque. link fasteners to specified torque. 2. Lack of lubrication or incorrect 2. Lubricate linkage with specified lubricant. lubricant. 3.
Page 528 SECTION 14: STEERING Pressure rating ........................2,320 psi (160 Bar) Power Steering Reservoir Oil capacity ..........................4 US qts (3.7 liters) Make ............................... Nelson Muffler Steering Stabilizer Cylinder (Damper) Extended length ..........................32.73±0.12" Collapsed length ..........................20.26±0.12" Stroke ..............................12.47±0.12" Front I-Beam Axle Make ..........................
Page 529 Revision: A Added X3-45 commuter & US built vehicles 2019-02-28 IMPORTANT NOTICE This modification is recommended by Prevost to increase your vehicle's performance. Note that no reimbursement will be awarded for carrying out this modification. APPLICATION Model H3-41, H3-45 coaches From 2PCH3349XEC712505 up to …...
Page 530 MATERIAL H series Part No. Description 660865 DRAG LINK ASSEMBLY, H SERIES 502104 COTTER PIN 5/32 X 2 X series Part No. Description 660699 DRAG LINK ASSEMBLY, X SERIES 502104 COTTER PIN 5/32 X 2 Other parts that may be required, depending on condition Part No.
Page 531 MI19-05A Page 3 / 8 DANGER Park vehicle safely, apply parking brake, stop engine and set battery master switch(es) to the OFF position prior to working on the vehicle. PINCH HAZARD Keep hands and fingers clear of pinch zones around pitman arm.
Page 532 MI19-05A Page 4 / 8 5. Adjust the length of the draglink. To do so, try to install it between the steering arm and the pitman arm. If the length is not adequate, it must be adjusted to the required length. Use dimension “A”...
Page 533 MI19-05A Page 5 / 8 8. Next, unscrew the drag link elbow ball joint back out. H Series: Five (5) full turn from the initial / reference position. X Series: One (1) full turn from the initial / reference position. The tapered shank must point down as shown on (FIGURE 4).
Page 534 MI19-05A Page 6 / 8 11. Fine adjustment of the drag link length if required should be performed exclusively by turning the adjustment sleeve while preventing the tube and joint from rotating. The only part rotating should be the sleeve To extend, turn the sleeve clockwise.
Page 535 MI19-05A Page 7 / 8 SLEEVE ADJUSTMENT 12. Adjust sleeve to the values of FIGURE 10. 10/32”=8mm 13. Once the proper length adjustment is done, tighten the sleeve end ball joint clamp. To prevent interference between the ball joint clamp bolts with other components of the steering system, the clamp bolt must be positioned horizontally as shown on FIGURE 11.
Page 536 MI19-05A Page 8 / 8 DRAG LINK INSTALLATION 14. Install the drag link. 15. Ball joint castellated nut on both ends should be tightened to 150-200 lbf-ft. 16. Install cotter pin p/n 502104 and bend to lock bolt in place (see an example of a correct installation of a cotter pin on the image below).
Page 537 SECTION 16 : SUSPENSION CONTENTS SECTION CHANGE LOG ............................4 TORQUE TABLES ............................. 5 FRONT I-BEAM AXLE AND RELATED COMPONENTS ..................5 INDEPENDENT FRONT SUSPENSION ......................7 REAR SUSPENSION ............................9 DESCRIPTION ..............................14 FRONT I-BEAM AXLE SUSPENSION ........................ 14 AIR SPRINGS ..............................
Page 538 SECTION 16 : SUSPENSION 4.11 FRONT-END ALIGNMENT ..........................32 4.12 LOWER AND UPPER A-ARM BALL PIN BUSHING REPAIR ................36 4.12.1 Inspection ............................. 36 4.12.2 Stripping Down ............................ 36 4.12.3 Assembly .............................. 36 4.13 LOWER A-ARM BALL JOINT REPAIR ......................37 4.13.1 Stripping Down ............................
Page 539 SECTION 16 : SUSPENSION HIGH-BUOY SYSTEM (COACHES ONLY) ...................... 50 10.1 PRINCIPLES OF OPERATION ......................... 51 10.2 MAINTENANCE............................. 51 10.3 HIGH-BUOY – PRESSURE REGULATOR......................51 10.3.1 Adjustment............................51 10.3.2 Disassembly ............................51 10.3.3 Cleaning ............................... 51 10.3.4 Reassembly ............................52 LOW-BUOY SYSTEM (COACHES ONLY) ......................
Page 540: Section Change Log
SECTION 16 : SUSPENSION SECTION CHANGE LOG DESCRIPTION DATE Updated front axle; new tie rod 2018-10-16 PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 541: Torque Tables
SECTION 16 : SUSPENSION TORQUE TABLES FRONT I-BEAM AXLE AND RELATED COMPONENTS 16187 PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 542 SECTION 16 : SUSPENSION 16191 16194_1 FRONT I-BEAM AXLE DESCRIPTION TORQUE (dry) Sway bar link, upper and lower nuts 165-200 lb-ft (224-271 Nm) Sway bar bushing collars (front suspension) 80-100 lb-ft (108-136 Nm) Tie rod end clamp nuts 118-133 lb-ft (160-180 Nm) Tie rod end ball pin nuts 155-170 lb-ft (210-230 Nm) Steering arm stud nuts...
Page 543: Independent Front Suspension
SECTION 16 : SUSPENSION INDEPENDENT FRONT SUSPENSION 16204 PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 544 SECTION 16 : SUSPENSION 16205 INDEPENDENT FRONT SUSPENSION DESCRIPTION TORQUE (dry) Drag link socket end clamp pinch bolt 50-60 lb-ft (68-81 Nm) Drag link ball stud nut to pitman arm 245-270 lb-ft (332-366 Nm) Drag link ball stud nut to bell crank 245-270 lb-ft (332-366 Nm) Pitman arm to steering gear fixing nut 470-570 lb-ft (637-773 Nm)
Page 545 SECTION 16 : SUSPENSION Torque rod, nut 158-193 lb-ft (214-262 Nm) Torque rod, stud 90-110 lb-ft (122-149 Nm) Sway bar bushing collar (front suspension) 80-100 lb-ft (108-136 Nm) Shock absorber mounting stud nut 99-121 lb-ft (134-164 Nm) Shock absorber mounting stud 350-400 lb-ft (475-542 Nm) Shock absorber lower mounting pin nut 60-75 lb-ft (81-102 Nm)
Page 546 SECTION 16 : SUSPENSION 16158_C: Meritor Drive Axle PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 547 SECTION 16 : SUSPENSION 16159_B 16162_B PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 548: Rear Suspension
SECTION 16 : SUSPENSION 16160_B 16161_B REAR SUSPENSION DESCRIPTION TORQUE (dry) Air Spring Upper & Lower Stud Nut 31-38 lb-ft (42-52 Nm) Drive & Tag Axle Radius Rod stud 90-110 lb-ft (122-149 Nm) Sway Bar Link Upper & Lower Nut 99-121 lb-ft (134-164 Nm) PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 549 SECTION 16 : SUSPENSION Shock Absorber Pin Nut 99-121 lb-ft (134-164 Nm) Shock Absorber Pin 350-400 lb-ft (475-542 Nm) Drive axle Radius Rod Nut/bolt 225-255 lb-ft (305-346 Nm) Drive Axle Longitudinal Radius Rod Retaining Bolt 185-227 lb-ft (251-308 Nm) Tag Axle Radius Rod Nut 228-252 lb-ft (309-342 Nm) Sway Bar Bushing Collar Bolt 80-100 lb-ft (108-136 Nm)
Page 550: Description
SECTION 16 : SUSPENSION DESCRIPTION Visually inspect bellows for evidence of cracks, punctures, deterioration, or chafing. The vehicle is provided with an air suspension Replace the bellows if any damage is system. The system consists of air springs, evident. height control valves, radius rods, sway bars, tripod and shock absorbers (Figure 1 to Figure With the primary air system at normal operating pressure (122 - 140 psi (841 - 965...
Page 551: Installation
SECTION 16 : SUSPENSION Jack vehicle until the tire clears the FIGURE 3: AIR SPRING UPPER MOUNTING PLATE ground, and place safety supports underneath body. 3.1.3 Installation 1. Compress air spring as necessary and position air spring between both the lower and upper mounting plates.
Page 552: Inspection
SECTION 16 : SUSPENSION stability on the road. All shock absorbers are cause for replacement (Refer to the SACHS eye-type mountings. The front and tag axles are document “Guideline to Evaluate Warranty each provided with two shock absorbers while Claims” annexed at the end of this section the drive axle is provided with four of them.
Page 553: Installation
SECTION 16 : SUSPENSION Five radius rods are provided on the front I-beam axle suspension (four longitudinal and one transversal). Refer to Figure 1 and Figure 5 for details. These rods transmit both braking and driving forces from the axles to the vehicle body. FIGURE 4: SHOCK ABSORBER FIGURE 5: TYPICAL RADIUS ROD SETUP 16008...
Page 554: Radius Rod Removal
SECTION 16 : SUSPENSION deterioration, or damage. Any defective part with a conical (taper) pin that will require the should be replaced. use of an air hammer and a pointed 13mm (1/2inch) diameter chisel to remove it from the Take off the load from the ball joint by lifting the chassis (after the retaining nut is removed vehicle.
Page 555: Stripping Down
SECTION 16 : SUSPENSION cracking and/or deformations of the cast 4. Opening of the Circlip is located at 45° to the parts. housing shaft axis. Make sure that the Circlip is perfectly engaged in the housing. 3.3.5 Radius Rod Installation 1.
Page 556: Installation
SECTION 16 : SUSPENSION FIGURE 8: SWAY BAR 16028 NOTE Sway bar bushings are slit to ease their removal. 3.4.2 Installation 1. Loosely install the sway bar. 2. Tighten the eight bushing brackets nuts according to Torque Table 1 under heading Torque Specifications.
Page 557: Independent Front Suspension (Ifs)
SECTION 16 : SUSPENSION INDEPENDENT FRONT SUSPENSION (IFS) This section contains information and specifications unique to the independent front suspension (IFS), including suspension geometry and steering. FIGURE 9: INDEPENDENT FRONT SUSPENSION 16124 arm at the left side of the coach, and to the idler arm and steering arm at the right side of the STEERING LINKAGE coach.
Page 558 SECTION 16 : SUSPENSION added source of assistance and ensures that the total steering forces are produced with minimal stress on mechanical linkages. CAUTION Lower and upper A-arms are widely spaced. Clamp bolts are either in a vertical or They are mounted on ball joints. Torque rods horizontal position.
Page 559 SECTION 16 : SUSPENSION FIGURE 10: IFS STEERING LINKAGE OVERVIEW PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 560: Steering Linkage Installation Sequence
SECTION 16 : SUSPENSION 6. Install tie rods then adjust toe-in as described in "Front End Alignment" in this STEERING LINKAGE INSTALLATION section (for proper tightening torque, refer to SEQUENCE Torque Table 2). NOTE PITMAN ARM Whenever a steering linkage component has been removed and replaced, check steering geometry and front end alignment as directed 4.3.1...
Page 561: Drag Link
SECTION 16 : SUSPENSION 4.4.1 Adjustment Use a new nut if the previously removed nut was punched. It should not be necessary to alter the length of the drag link except when a new link is installed CAUTION or when removable end assembly has been replaced.
Page 562: Bell Crank Or Idler Arm Hub Disassembly
4.5.3 Bell Crank or Idler Arm Hub Reassembly 9. Tighten nut. NOTE TORQUE:130 lb-ft (176 Nm) For bearing installation use tool Prevost # 110684. 10. Rotate assembly 3 turns in each direction. NOTE Install grease retainer according to Figure 14.
Page 563: Relay Rod
SECTION 16 : SUSPENSION RELAY ROD Relay rod ends are equipped with lubrication fittings and should be lubricated as directed in “Lubrication Fittings” in this section. NOTE The relay rod is crimped in place and it is not possible to remove and replace the ball joint socket end assemblies.
Page 564: Removal
SECTION 16 : SUSPENSION or threads are damaged, replace the assembly. 3. Lubricate tie rod end fittings as directed in "Lubrication Fittings" in this section. 4.7.1 Removal 1. Remove cotter pins and stud nuts which attach tie rod socket ends to bell crank and left steering arm (or idler arm) and right steering arm.
Page 565: Steering Arms
SECTION 16 : SUSPENSION FIGURE 18: STREET SIDE TIE ROD - CLAMPS POSITION 16200 NOTE If tie rod is not properly aligned with stud, binding will result. STEERING ARMS The left and right wheel steering arms are secured to a steering knuckle at one end and to a tie rod at the other end.
Page 566 SECTION 16 : SUSPENSION FIGURE 19: STEERING LINKAGE NOMINAL LENGTHS 16202 PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 567: Lubrication Fittings
SECTION 16 : SUSPENSION FIGURE 20: LUBRICATION FITTINGS LOCATION 16046 proper lubricants, supplier reputation must be considered. The supplier must be responsible for product quality. Figure 20 shows approximate LUBRICATION FITTINGS location of steering lubrication fittings. All lubrication fittings must be clean before MAINTENANCE applying lubricant.
Page 568: Ball Joints - General Recommendations
SECTION 16 : SUSPENSION lithium-base grease NLGI No. 2 (Shell adjustment was used to compensate for another problem (e.g. bent steering arm). Retinax LX or equivalent). (4) Steering Knuckle (swivel assembly): Damaged sealing boots, salt and climatic Refer to DANA SPICER MAINTENANCE conditions can cause loss of the corrosion MANUAL NDS AXLES Lubrication and protection...
Page 569 SECTION 16 : SUSPENSION FIGURE 22: IFS NOMINAL DIMENSIONS FIGURE 23: IFS ADJUSTMENT Note 2 indicates where adjustment may be performed if needed when proceeding to IFS ALIGNMENT PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 570 SECTION 16 : SUSPENSION WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 24: FRONT END ALIGNMENT DIAGRAM 16051 PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 571 SECTION 16 : SUSPENSION FIGURE 25: A-ARM JOINT IDENTIFICATION PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 572: Lower And Upper A-Arm Ball Pin Bushing Repair
For this reason, all the old parts are to be Apply grease, only in the case of repair kit scrapped immediately after a joint has been (Prevost # 611114)). stripped down. A complete repair set must be used for each joint repaired, i.e. use of only part 2.
Page 573: Lower A-Arm Ball Joint Repair
SECTION 16 : SUSPENSION the retaining ring. Pay attention during assembly to ensure that the retaining ring eyelets are located on both sides of the housing shaft axis (retaining ring eyelet lug points to tube), and that retaining ring is properly engaged in the groove of the housing.
Page 574: Front Air Springs
SECTION 16 : SUSPENSION 2. Using a caliper, measure dimension “A” on 2. Visually inspect bellows for evidence of Figure 30. cracks, punctures, deterioration, or chafing. Replace the air spring if damage is evident. 3. With a lever tool, exert sufficient force under the upper A-arm as to separate the upper A- 3.
Page 575: Installation
SECTION 16 : SUSPENSION 5. Disconnect the height control valve link and and none is permissible. Repair or replace pull down the control arm to ensure all air is defective parts. exhausted from air springs. 6. Lower the IFS slightly while maintaining the 4.16 SHOCK ABSORBERS vehicle body at the same level.
Page 576: Shock Absorber Installation
SECTION 16 : SUSPENSION FIGURE 33: LOWER SHOCK MOUNTING BUSHINGS 5. Install the shock absorber as shown in Figure 32 with the mounting stud protruding through the hole in the mounting bracket and the shock absorber eyes over the mounting pins.
Page 577: Installation
SECTION 16 : SUSPENSION FIGURE SWAY (INDEPENDENT FRONT SUSPENSION) 16138_C 4.17.2 Installation 1. Loosely install the sway bar. 2. Torque bushing collar nuts as prescribed per Torque Table 2. 3. Torque sway bar link nuts as prescribed per Torque Table 2. PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 578: Rear Suspension
SECTION 16 : SUSPENSION REAR SUSPENSION FIGURE 36: TAG AXLE SUSPENSION FIGURE 35: DRIVE AXLE, DETAILS OF REAR SUSPENSION 16106 FIGURE 37: REAR SUSPENSION COMPONENTS 16003 PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 579: Air Springs
SECTION 16 : SUSPENSION uninstalled air spring. AIR SPRINGS The air springs are made from a special 5.1.2 Removal compound rubber molded to the proper contour and dimensions. The entire vertical load of the NOTE vehicle is supported by these springs. Each of Suspension air springs (drive and tag axles) the two axles is provided with air springs that are can be removed without removing the entire...
Page 580: Shock Absorbers
SECTION 16 : SUSPENSION supports. Thread the lower nuts and the Shock absorbers are non-adjustable and non- small upper nut a few turns. repairable. Maintenance requirements involve replacement of the rubber mounting bushings, and tightening of all shock absorber mounting pins at the proper torque (refer to Torque Table 3) when shock absorber replacement occurs.
Page 581: Removal
SECTION 16 : SUSPENSION 4. Visually check shock for dents that could 5.2.3 Installation cause the shock to bind. Also, check for a bent rod. 1. Ensure that the shock absorber mounting 5. Extend and collapse shock several times to pin is tight and that the threads are not determine that it has control (resistance) in stripped.
Page 582: Suspension Air System
SECTION 16 : SUSPENSION Refer to section 2.3 for more information AIR LINE TEST regarding radius rods. With the main air system at normal operating SUSPENSION AIR SYSTEM pressure, coat suspension line connections and air spring mountings with a The suspension air system has its own air solution of soap and water.
Page 583: Height Control Valves
SECTION 16 : SUSPENSION REAR SUSPENSION 4 air springs FORE AIR SPRINGS X = 11 ½ ± 1/16 inch (292 ± 1.5 mm) AFT AIR SPRINGS Y = 11 ½ ± 1/4 inch (292 ± 6 mm) FIGURE 41: HEIGHT CONTROL VALVE 16093 MAINTENANCE HEIGHT CONTROL VALVES...
Page 584 SECTION 16 : SUSPENSION Reverse removal procedure to replace height control valve. After installation, check for leakage using a soap and water solution. PA1621 Maintenance Manual All Series | Section revised October 2018...
Page 585: Air Leakage Test
SECTION 16 : SUSPENSION PRINCIPLES OF OPERATION 7.3.2 Air leakage test Down NOTE The (front/rear right/rear left) control solenoid The following procedure applies when valve valve supplies air to the (front/rear right/rear left) assembly has been removed from vehicle. five-way three-position air control valve, which bypasses the (front/rear right/rear left) height 1.
Page 586: Front Kneeling System (Coaches Only)
SECTION 16 : SUSPENSION FRONT KNEELING SYSTEM The height control valve is bypassed until the kneeling proximity switch signals the kneeling (COACHES ONLY) module to cut off the air spring control solenoid The kneeling system is used to lower front of valve, about 1"...
Page 587: Principles Of Operation
SECTION 16 : SUSPENSION be put into service during normal vehicle 3. Turn regulator adjustment handle clockwise operation. until the desired outlet pressure is reached. 4. To avoid minor readjustment after making a change in pressure setting, always approach 10.1 PRINCIPLES OF OPERATION the desired pressure from a lower pressure.
Page 588: Reassembly
SECTION 16 : SUSPENSION LOW-BUOY SYSTEM (COACHES ONLY) The purpose of the low-buoy system is to lower the whole suspension by about 4” (100 mm) in order to reduce the overall height for low clearances. This system can be put into service during normal vehicle operation.
Page 589: Air Tank Maintenance
SECTION 16 : SUSPENSION In addition, an expansion air tank is installed in series with each air spring. FIGURE 43: LOCATION OF AIR TANKS 12195 12.1.2 Primary Air Tank 12.1 AIR TANK MAINTENANCE The primary air tank is located above tag axle. Ensure that the accessory air tank is purged during pre-starting inspection.
Page 590: Secondary Air Tank
SECTION 16 : SUSPENSION FIGURE 45: REAR VALVE LOCATION ON X3 SERIES 12.1.3 Secondary Air Tank This tank is located in front wheel housing. The tank is installed vertically and is provided with a FIGURE 46: FRONT VALVE LOCATION ON H3 SERIES bottom drain valve.
Page 591: Emergency Fill Valves
CAUTION Air filled through these two points will pass through the standard air filtering system provided by Prevost. Do not fill air through any other points. NOTE Apply corrosion-protective compound on exposed threads.
Page 592 SECTION 16 : SUSPENSION Air springs raise to full A clogged exhaust screen in height Remove and clean screen. height and fail to exhaust control valve assembly. air pressure A combination clogged exhaust Clean exhaust screen and replace screen and defective air inlet valve air inlet valve assembly.
Page 593 Extended length ........................24.37” (619 mm) Height control valve (IFS) Quantity used ..............................1 Prevost number ......................Refer to Parts Manual Height control valve (coach, all axles & VIP, rear only) Quantity ..............................2 or 3 Prevost number ......................Refer to Parts Manual...
Page 594 Type ................................N/C Type ................................N/O Radius rod bushing Make ..............................Prevost Prevost number ......................Refer to Parts Manual Sway bar bushing (Independent Front Suspension Make ..............................Prevost Prevost number ......................Refer to Parts Manual Sway bar bushing (Front Axle) Make ..............................
Page 595 MAINTENANCE MI16-14 INFORMATION DATE : JUNE 2016 SECTION : 16 - Suspension SUSPENSION HEIGHT ADJUSTMENT USING SUBJECT : HEIGHT CONTROL VALVES APPLICATION Model All models Model Year : From 2014 DESCRIPTION Use this procedure when a suspension height check or adjustment must be performed. HEIGHT CONTROL VALVES Three height control valves automatically control air volume in the suspension air springs at three separate locations to maintain a constant vehicle height regardless of load or load distribution.
Page 596 MI16-14 / Page 2 / 10 The two rear suspension height control valves are mounted to the chassis and connected to the fore air springs of the rear underframe through a control arm and link. One front suspension valve is mounted to the chassis and connected to the front axle through a control arm and link.
Page 597 MI16-14 / Page 3 / 10 NORMAL RIDE HEIGHT The normal ride height is obtained by measuring and adjusting air spring height of front and rear suspension. TABLE 1 – PRESCRIBED AIR SPRING HEIGHTS FRONT SUSPENSION (I-BEAM AXLE) 2 air springs INDEPENDENT X = 12 7/8 ±...
Page 598 MI16-14 / Page 4 / 10 PROCEDURE DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
Page 599 MI16-14 / Page 5 / 10 5. Loosen the lower mounting bolt shown. Take note that the bolt is equipped with a nylon insert. The bolt should be replaced after three (3) tightenings. INCREASING CLEARANCE 6. Rotate the valve body to increase or decrease the clearance as shown (the mounting bracket has a slotted hole).
Page 600 MI16-14 / Page 6 / 10 FRONT SUSPENSION AIR SPRINGS ADJUSTMENT (I-BEAM AXLE) Measurement 1. Make sure that the air system pressure is at least 90 psi. 2. Measure the front axle springs clearance (two air springs). To do measure clearance between the support above the air spring and the lower end...
Page 601 MI16-14 / Page 7 / 10 5. Loosen the lower mounting bolt shown. Take note that the bolt is equipped with a nylon insert. This bolt should be replaced after three (3) tightenings. INCREASING CLEARANCE DECREASING CLEARANCE 6. Rotate the valve body to increase or decrease the clearance as shown (the mounting...
Page 602 MI16-14 / Page 8 / 10 INDEPENDENT FRONT SUSPENSION ADJUSTMENT Measurement 1. Make sure that the air system pressure is at least 90 psi. 2. Measure that the air springs clearance (two air springs). To do so, measure the clearance between the support found above the air spring and the lower end of the air spring (if needed, use a metal ruler to reach the lower end of the...
Page 603 MI16-14 / Page 9 / 10 Air springs height adjustment Adjust the air springs clearance with the height control valve 5. It is necessary to adjust clearance on "fill cycle". a) Disconnect the link. It is equipped with a rubber bushing that allows easy disconnection.
Page 604 MI16-14 / Page 10 / 10 <QF7720955 rev 6>...
Page 605 SECTION 18A: H3 SERIES BODY CONTENTS SECTION CHANGE LOG ..........................5 TORQUE TABLES ..........................6 VEHICLE EXTERIOR ..........................8 VEHICLE JACKING POINTS ....................... 10 HYDRAULIC JACK ........................... 10 TOWING THE VEHICLE ........................10 STRUCTURE ............................ 10 WELDING ............................10 EXTERIOR MAINTENANCE....................... 11 CORROSION PREVENTION ......................
Page 606 SECTION 18A: H3 SERIES BODY 10.8 TROUBLESHOOTING ........................28 ENTRANCE DOOR (V.I.P) ......................29 11.1 KEYLESS ENTRY SYSTEM ........................ 29 11.2 DOOR ADJUSTMENT ........................29 11.2.1 Horizontal and Vertical Adjustments ..................29 11.3 DEPTH ADJUSTMENT ........................29 11.4 DOOR LOWER SECTION ......................... 30 11.5 REFLECTOR STRIPE INSTALLATION ....................
Page 607 SECTION 18A: H3 SERIES BODY WINDSHIELD ..........................54 19.1 HYDROPHOBIC TREATMENT ON SIDE WINDOWS ................. 54 19.2 REMOVAL ............................54 19.3 WINDSHIELD INSTALLATION ......................55 19.4 INSTALLATION OF RUBBER EXTRUSION AND WINDSHIELD ............56 BODY PANELS AND DOORS ......................56 WHEELCHAIR LIFT ACCESS DOOR ....................
Page 608 SECTION 18A: H3 SERIES BODY SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP ..........72 REAR VIEW MIRRORS (RAMCO) ....................77 37.1 ADJUSTMENT ..........................77 37.2 DISASSEMBLY ..........................77 37.3 ASSEMBLY ............................. 77 37.4 REPLACEMENT OF MIRROR GLASS....................77 37.5 HEATED / REMOTE CONTROLLED REAR VIEW MIRRORS ..............
Page 609 SECTION 18A: H3 SERIES BODY SECTION CHANGE LOG DESCRIPTION DATE Jacking and towing now refers to MI18-18 June 06, 2018 Updated window gasket Sept 23 2019 PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 610: Torque Tables
SECTION 18A: H3 SERIES BODY TORQUE TABLES BODY DESCRIPTION TORQUE Entrance door horizontal adjusting bolts 55-65 lb-ft (75-88 Nm) Passenger seat mounting nuts (to sidewall and pedestal) 27 lb-ft (37 Nm) PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 611 SECTION 18A: H3 SERIES BODY WHEELCHAIR LIFT DOOR DESCRIPTION TORQUE Wheelchair lift door – Center hinge bolts 31-38 lb-ft (42-52 Nm) Wheelchair lift door - striker pin adjustment bolts 54-66 lb-ft (73-89 Nm) Wheelchair lift door - opening mechanism nuts 2.5-3.5 lb-ft (3.39-4.75 Nm) PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 612: Vehicle Exterior
SECTION 18A: H3 SERIES BODY 2. VEHICLE EXTERIOR 18681 FIGURE 1: H3-45 (TYPICAL) 1. Engine air intake 11. Diesel Particulate Filter (DPF) access door 2. Engine compartment curb-side door 12. Engine compartment rear door 3. Main power compartment (battery 13. Rear-view mirror compartment) 14.
Page 613 SECTION 18a: H3 SERIES BODY 18677 FIGURE 2: H3-45 VIP EXTERIOR VIEW PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 614: Hydraulic Jack
15. Heating, ventilating and air conditioning 5. STRUCTURE compartment (HVAC) baggage The body of the H3-41, H3-45 and VIP vehicles compartment is an integral structure made of 14, 16 and 18 16. Rear Slide-out gauge welded and braced high tensile steel and stainless steel members.
Page 615: Exterior Maintenance
SECTION 18a: H3 SERIES BODY potentially damaging events associated with areas must be thoroughly cleaned to remove dirt welding. accumulations from flanges, channels and ledges. These places accumulate dirt and salt 3. Refer “PRECAUTIONS and hold it in direct contact with steel and OBSERVED BEFORE WELDING”...
Page 616: Preventive Maintenance Schedule
SECTION 18A: H3 SERIES BODY PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section.
Page 617 SECTION 18a: H3 SERIES BODY RUST INHIBITOR APPLICATION Material: Tectyl 185 GW R1KG21 Safety Rules: Use safety glasses Supplied air hood Solvent-resistant rubber gloves 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be masking. hot to reduce washing time especially during winter.
Page 618 SECTION 18A: H3 SERIES BODY 3.2 Front wheelhousing 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) PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 619 SECTION 18a: H3 SERIES BODY 4.1 Rear wheelhousing (Entire braking system) 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.
Page 620 SECTION 18A: H3 SERIES BODY 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts. the rust inhibitor. If the application is done inside a paint room, select high speed ventilation. Minimum required thickness is 10 mils wet or 5 mils dry.
Page 621: Fiberglass Repair
SECTION 18a: H3 SERIES BODY DEW POINT Relative Humidity (%) Temp (c) performed. Use of the various materials is 7. FIBERGLASS REPAIR determined by the type of repair to be made. Large holes, torn sections and separate joints All repairs to fiberglass parts consist of filling the require the adhesive qualities of the resin and damaged area with fiberglass cloth and resin or the reinforcing qualities of the fiberglass.
Page 622 SECTION 18A: H3 SERIES BODY Small dents, scratches or pits can be repaired CAUTION using resin and strand fiberglass and filler mixed into paste. Instructions for either mix are Temperature should not exceed 140 F (60 explained under their respective headings in this during 30 minutes in order to avoid distortion.
Page 623: Typical Fiberglass Repair Procedure
SECTION 18a: H3 SERIES BODY Apply the material with a putty knife or similar object, building material up to the desired contour. For deep filling and on vertical surfaces, several layers of material may be used. A hacksaw blade, held flat to adjacent contour and then moved in a sawing action across the repair when the resin is in a gel state, will remove excess resin from repair.
Page 624: Painting
Our paint supplier recommends that you follow these simple precautions the first months of your Prevost recommends using the original paint new vehicle’s life. brand to ease color matching. In the event you sand through to the gelcoat...
Page 625: Safety
SECTION 18a: H3 SERIES BODY 8.3.1 Safety 2. Wear respirators approved by the governing safety and health regulations. Care should be exercised in storing, handling, mixing, and applying paint and chemicals listed 3. Maintain adequate ventilation at all times. in this manual. The topcoat, primer, solvent, 4.
Page 626 SECTION 18a: H3 SERIES BODY FRONT AND REAR BUMPERS 8.4.1 Paint touchup and surface preparation for vehicles equipped with urethane bumpers COMMENTS COACHES Cleaning Clean using red wool and Standoflex 11100 (ST-11425) thinner Clean again twice using Standoflex 11100 (ST-11425) thinner Apply Non-Stop primer (ST-13320) with flexible agent dilution Priming 2:1 10% in 2 or 3 coats, 15 min.
Page 627 FIGURE 10: FRONT BUMPER ASSEMBLY bumper (Figure 12). NOTE 2. Let the bumper rest face down on the lifting A special tool kit is available from Prevost: Kit equipment platform. # 410671 including tool #410708. 3. To install bumper, reverse the procedure.
Page 628: Operation
SECTION 18a: H3 SERIES BODY when the door control system does not function properly. Refer to the air system schematic and page 22 of the wiring diagram available on the technical publications web site. 10.1 OPERATION The air-operated door is controlled from inside the coach by two push-button switches located on the R.H.
Page 629 SECTION 18a: H3 SERIES BODY CAUTION It is important to make sure that damper does not reach end of stroke when door is completely closed or opened. The door cylinder must stop the door on opening. Screw or unscrew rod end to adjust if necessary. To adjust opening and closing cycle speed on damper (Figure 17): 1.
Page 630 SECTION 18a: H3 SERIES BODY damper is adjusted or not by keeping it assembly, first perform the following mechanical closed and gently turning further CCW, checks and procedure. counting at the same time the half-turns until Check around the perimeter of the door for a stop is felt.
Page 631 SECTION 18a: H3 SERIES BODY 10.5 DEPTH ADJUSTMENT 10.6 ROD END ADJUSTMENT 1. Turn the emergency exit valve to the 1. Turn the emergency exit valve to the “UNLOCK” position. “UNLOCK” position. 2. Remove the screws and the plastic molding 2.
Page 632: Troubleshooting
SECTION 18a: H3 SERIES BODY 10.8 TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Manual door locks engaged. Release manual door locks. Check voltage at solenoid locks when Upper and lower solenoid locks do not door is open. If the voltage is 24 volts disengage.
Page 633: Entrance Door (V.i.p)
SECTION 18a: H3 SERIES BODY 11.2.1 Horizontal and Vertical Adjustments 11. ENTRANCE DOOR (V.I.P) 1. Remove the screws and the plastic molding There are three ways of unlocking the entrance covering each of the hinges. door from the inside of vehicle. The two first consist in actuating the rocker switch on the NOTE dashboard, but this last operation will also unlock...
Page 634: Depth Adjustment
When a plastic door lower section replacement is needed, proceed the following way: 10. Apply Sika #252 (Prevost #682462) compound where it was previously applied. 1. Remove the reflective stripe at the top edge of the door’s lower section. Unscrew the 11.
Page 635: Door Lubrication
SECTION 18a: H3 SERIES BODY WARNING Wear rubber gloves and do not smoke when cleaning. 5. Peel of protective paper from the seal. Position the seal in order to leave ¼" (6 mm) from the upper molded edge of the door and 3/16"...
Page 636: Power Window Installation
SECTION 18a: H3 SERIES BODY 9. Detach the motor and actuator guide from CAUTION the support and plastic shield. Replace parts as required. Use of lubricants, paints, or other coatings such as graffiti deterring sprays is not recommended. Suggested maintenance includes periodic inspection of fasteners for evidence of loosening...
Page 637: Sealing
5. Drill holes (if needed) in the new metal Seal joint should be toward rear of vehicle. frame. 3. Apply rubber adhesive CA-40 (Prevost # 6. Clean both vehicle top and new hatch frame 681285) in the gap between the seal ends.
Page 638: Repair Or Replacement Of "Tarabus" Floor Covering
SECTION 18a: H3 SERIES BODY 14. REPAIR OR REPLACEMENT OF “TARABUS” FLOOR COVERING “Tarabus” covering installed in H3 coaches may be replaced or repaired. The purpose of this paragraph is to explain the steps to be followed to ensure the best results and adherence. MATERIAL Part No Description...
Page 639 SECTION 18a: H3 SERIES BODY FIGURE 25: TARABUS FLOOR COVERING ADHESIVE APPLICATION FIGURE 26: APPLICATION OF SIKA 221 GRAY PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 640: Front Steps Replacement Procedure
SECTION 18a: H3 SERIES BODY 14.1 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) 684654 Adhesive, Contact (3M) 3.8L 684655 Adhesive, Contact (3M) 18.9L 684517 Sealant, gray 1.
Page 641 SECTION 18a: H3 SERIES 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 642 SECTION 18a: H3 SERIES BODY –– H3 VEHICLE FRONT STEPS GLUING 1. Remove adhesive tape from underneath step. 2. Apply a thin and even layer of contact adhesive (3M) (684655 or 684654) onto fiberglass and step surfaces. Allow drying for 3 to 5 minutes.
Page 643: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering
SECTION 18a: H3 SERIES BODY 14.2 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 644: Repair Of A Welded Joint
SECTION 18a: H3 SERIES BODY 12. Perform adhesion test using the tip of a flat screwdriver; apply a slight pressure on the joint. 13. If welding was not performed properly, there 9. Allow cooling down of filler bead (about 5 will be a loss of adhesion on one side.
Page 645: Passenger Seats
SECTION 18a: H3 SERIES BODY 15.1 ROTATING SEATS WARNING 1. Loosen completely the threaded-stud knob under the seat on the aisle side (Figure 27). Nozzle is hot. 4. Always add an extra inch of filler bead at the FIGURE 27: LOOSEN THE KNOB beginning and at the end of repair.
Page 646: Removing Fixed Seats
SECTION 18a: H3 SERIES BODY 5. Remove 2 nuts and washers holding seat frame to pedestal rods. FIGURE 29: FINAL POSITION 4. Fasten the threaded-stud knob under the seat on the aisle side. FIGURE 31: SEAT PEDESTAL ASSEMBLY 18107 15.2 REMOVING FIXED SEATS NOTE NOTE Bottom end of rod is coated with Loctite and...
Page 647: Dry Cleaning
If covers are to be removed for cleaning, dry Seven passenger side windows are provided on cleaning is recommended since washing might each side on H3-41, while the H3-45 has eight. cause some shrinkage, preventing the covers They are made of fixed, single or double-glazed, from being reapplied to the seats without heat absorbing AS-3 glass.
Page 648: Emergency Exit Release Bar
Correct situation immediately. NOTE Tangs on the lock must be in a horizontal position. FIGURE 33: H3-41 COACH 16.3 FIXED WINDOW REPLACEMENT 18520 When it becomes necessary to replace the glass 16.2 EMERGENCY EXIT RELEASE BAR...
Page 649: Emergency Exit Window Replacement
SECTION 18a: H3 SERIES BODY FIGURE 36: EMERGENCY WINDOW 18435 16.5 TRAPEZOIDAL WINDOW REPLACE- MENT Apply procedure for fixed window replacement described in this section but with these variations: FIGURE 35: FIXED WINDOW 18434 • The angle at which the window will detach is NOTE considerably smaller (about 45 For all window replacement, it is extremely...
Page 650: Adhesive-Mounted Windows
• Masking tape; Remove glass and place it on a table with • Tremshield tape (Prevost #681089); the pencil mark facing up. • Chix cloths (Prevost #682384); 4. Place masking tape on the inside surface of •...
Page 651: Electric Awning Window
SECTION 18a: H3 SERIES BODY (shake well before applying). Let dry 5-6 material around both sides of the window as minutes minimum but no more than 8 hours. soon as possible before adhesive dries. NOTE CAUTION Remove most of the adhesive from the scraper or trowel with a rag, and then dip tool There must be absolutely no silicone on glass in solvent after each use for cleaning.
Page 652: Window Removal
SECTION 18a: H3 SERIES BODY 4. Loosen the set screws #5 (Figure 42) (rotate 17.2 WINDOW REMOVAL the arm to get to the second set screw) and disengage the swiveling arm from the motor Replacement awning window does not include a shaft extension.
Page 653: Actuator Replacement
SECTION 18a: H3 SERIES BODY FIGURE 42: ELECTRIC AWNING WINDOW EXPLODED VIEW (SASH) 18583 3. Remove actuator access cover by taking out 17.3 ACTUATOR REPLACEMENT screws #1 (8x). 1. Push the vertical latch handle downwards to 4. Loosen the set screws #5 (rotate the arm to release the track and then unlatch the get to the second set screw) and disengage window using the horizontal latch handle.
Page 654 SECTION 18a: H3 SERIES BODY ELECTRIC AWNING WINDOW – CONVERTER CHECKLIST Check the electrical circuit A: The latching system will not operate without power. & proximity sensor Is there electrical power to the latching circuit? The horizontal latch handle, on the sill sash will be seen to move if there is power on this circuit, or it can be checked with an electrical tester.
Page 655: Electric Sliding Window
SECTION 18a: H3 SERIES BODY 18. ELECTRIC SLIDING WINDOW FIGURE 43: ELECTRIC SLIDING WINDOW EXPLODED VIEW Sash Removal 1. Remove the Screen Assembly 2. Pull down on both release latches simultaneously and rotate the sash inwards approximately 10 degrees.(Figure 44) FIGURE 44: REMOVING THE SASH PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 656 SECTION 18a: H3 SERIES BODY 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 45) FIGURE 45: DISENGAGING THE BOTTOM OF THE SASH Installation 1. Align the leading edge of the slot on the lower cam follower block with the sash stop. Use the power toggle switch to obtain the correct alignment.
Page 657 SECTION 18a: H3 SERIES BODY FIGURE 47: POSITIONING THE LOWER LEFT CORNER OF THE SASH 3. Engage the sash pin with the leading edge of the slot of the cam follower block. Do the same at the rear of the sash. 4.
Page 658: Windshield
"Windshield Installation" in this section for Hydrophobic compound specially instructions on how to reinstall windshield. formulated for Prevost and can only be applied by Prevost technicians in Prevost service NOTE centers. If the rubber extrusion is damaged, remove and discard it, then clean the windshield 19.2 REMOVAL...
Page 659: Windshield Installation
SECTION 18a: H3 SERIES BODY 19.3 WINDSHIELD INSTALLATION 6. Insert the top curved corner then finish with the top of windshield. This procedure is provided as a general 9. Spray locking strip and rubber extrusion guideline to install a new windshield with a new groove generously with soapy water.
Page 660: Installation Of Rubber Extrusion And Windshield
SECTION 18a: H3 SERIES BODY 19.4 INSTALLATION OF RUBBER EXTRUSION AND WINDSHIELD CAUTION The black rubber extrusion securing the windshield in the opening fits correctly in only one position. Find the correct position of the rubber extrusion now, and make reference marks with a china marker to avoid searching for the correct position later in the procedure.
Page 661 Section 18: BODY FIGURE 52: BODY PANEL SPACING 18496...
Page 662: Wheelchair Lift Access Door
SECTION 18a: H3 SERIES BODY 21. WHEELCHAIR LIFT ACCESS DOOR 21.1 INSTALLATION CAUTION Install the sliding door onto a suitable lifting device that will allow proper lifting and positioning. 1. Lift and move the sliding door near the opening. 2. Push the door into the opening making sure the positioning lugs are properly inserted into their housing then pivot the main hinge and secure the door using 4 bolts.
Page 663 SECTION 18a: H3 SERIES BODY FIGURE 54: WCL UPPER ARM AND RAIL 3. Pull the door in or push from the outside to adjust the door with reference to the vehicle outside surface. 4. - Unfasten the upper arm bolt located on the door side. - Position the top rail at 3mm from the ceiling bracket.
Page 664 SECTION 18a: H3 SERIES BODY - Push the lower rail towards the outside of the vehicle in order to remove the play between the roller and rail then bolt the rail at front and center. Make sure the rollers stay in contact with the support when starting to close the door.
Page 665 SECTION 18a: H3 SERIES BODY FIGURE 56: WCL SLIDING DOOR OPENING MECHANISM 18740 PA1621 Maintenance Manual All Series Revised Sept 2019...
Page 666: Baggage Compartment Doors
There are 6 pantograph doors serving as the pantograph arms are misadjusted. baggage compartment doors on the H3-41, while Measure distance between a pantograph arm there are 8 on the H3-45 and the V.I.P end and a straight edge resting on structure.
Page 667: Door Handles
FIGURE 59: PANTOGRAPH DOOR ADJUSTMENT 18062 gas-charged cylinders (Prevost # 980024). The engine compartment opens by lifting a handle accessed from the R.H. side of the engine compartment.
Page 668: Minor Top Edge Depth Adjustment
SECTION 18a: H3 SERIES BODY 2. With the help of an assistant, pull down one 1. Cut the seal around the grill with a sharp side of door while holding up the other side edged knife. to bend the pantograph arms in the desired 2.
Page 669: Door Lateral Adjustment
SECTION 18a: H3 SERIES BODY 26.3 DOOR DEPTH ADJUSTMENT 1. Close radiator door. 2. Check parallelism between radiator door and rear fender (max. 0 ± 2 mm). 3. If the door is too far inside, adjust using a rubber mallet (Refer to Figure 68). 4.
Page 670: Condenser Door Adjustment
SECTION 18a: H3 SERIES BODY 5. Loosen bracket nuts holding the panel to condenser. Panel (6, Figure 70) may be shifted "IN or OUT", "LEFT or RIGHT" and "UP or DOWN". 6. Adjust condenser panel at brackets (2, Figure 70) and (5, Figure 70). 7.
Page 671: Fuel Filler Door
SECTION 18a: H3 SERIES BODY 28. FUEL FILLER DOOR 1. Open the fuel filler door (1, Figure 71). 8 ± 2 mm FIGURE 71: FUEL FILLER DOOR 1875003D 2. Loosen the screws (3,Figure 71) holding the panel to hinge (2,Figure 71) assembly. 3.
Page 672: Latch Mechanism Adjustment
SECTION 18a: H3 SERIES BODY 7. Adjust the door in accordance with the required distance between exterior finishing parts (Figure 52). SECTION 8. Loosen screws (4, Figure 75). 9. Screws allow the door to be shifted "UP or DOWN". 10. Adjust the door position according to the distance required between exterior finishing parts (Figure 52).
Page 673: Evaporator Door Adjustment
SECTION 18a: H3 SERIES BODY 31. EVAPORATOR DOOR ADJUSTMENT 9. Tighten the screws. Check that the door swings freely and closes 1. Open the door. properly. It may be necessary to adjust the door latch to get proper fit and operation. 2.
Page 674: Latch Mechanism Adjustment
SECTION 18a: H3 SERIES BODY 3. Using a hammer, adjust the striker pin to center it in the door latch mechanism. 4. Tighten the striker pin. Check door fit and operation. SECTION 33. FENDERS SECTION On the "H" series vehicle, all fenders are easily removable for maintenance on brakes and suspension.
Page 675: Front Cap
The front cap windshield frame does not need any maintenance. It is held in place with bolts and nuts. If it ever it has to be replaced, make an appointment at a Prevost service center near you. PA1621 Maintenance Manual All Series...
Page 676 SECTION 18a: H3 SERIES BODY 36. SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP Material: Anti-silicone (682989) Blue cloth (682383) Sika 206 G+P 1 liter (683446) √ √ √ Tack cloth Pure water Sika 252 black √ √ √ CHIX cloth (682384) Scotchbrite gray (680226) Masking tape √...
Page 677 SECTION 18a: H3 SERIES BODY Clean using tack cloth. Repeat if surface seems dusty. Clean using anti-silicone See SAV000001 section A. Apply primer 206 G+P. See SAV000001 section D. SAV000001 Section D Sika Primer 206 G+P Shake bottle to mix product Apply a thin layer CHIX cloth 3.
Page 678 SECTION 18a: H3 SERIES BODY Apply 206 G+P onto structure. See SAV000001 section D. 1.15 Seal entrance door perimeter using Sika 252 black, Smooth down the excess. Install lateral panel supports onto bottom 1.20 structural tubing. Install lateral panel onto supports to verify proper positioning.
Page 679 SECTION 18a: H3 SERIES BODY At the rear, adjust panel height so that it is level with rear cap Gap between lateral panel and rear cap must be 6mm +4/-3 and panels must be aligned within 1.5mm. Using a ruler, adjust front of lateral panel. ...
Page 680 SECTION 18a: H3 SERIES BODY 1.70 Do not move the vehicle for 48 hours Make sure room temperature is superior to 20°C (68°F) before gluing Perform a visual inspection before installing side windows SECTION #2 DRIP MOLDING INSTALLATION 2.00 * A) Clean using Anti-silicone See SAV000001 section A.
Page 681 SECTION 18a: H3 SERIES BODY SECTION #3 REPAIR 4.00 Remove fiberglass from structure using a screwdriver. Use wedges if necessary to hold down panel during the work. 4.05 Remove as much glue as possible. If primer is removed, apply primer 206 G+P locally. If primer is OK, reactivate as per SAV000001 section D.
Page 682 SECTION 18a: H3 SERIES BODY 37.5 HEATED / REMOTE CONTROLLED button’s (4) sides to adjust the selected mirror REAR VIEW MIRRORS viewing angle. Heated/remote controlled external rear view 37.5.2 Disassembly mirrors may be provided to prevent the mirrors from frosting up in cold weather. At end of mirror arm, loosen the setscrews to relieve tension on the ball stud.
Page 683 SPECIFICATIONS Door cylinder Manufacturer ................................Bimba Type ................................Pneumatic I.D................................... 1½" ( mm) Stroke ................................. 8" ( mm) Prevost number ..............................780595 Damper Manufacturer ................................Koni Prevost number ..............................780565 Lock cylinder (upper) Manufacturer ................................Bimba Type ....................... Air, single action, 1/8 NPT, hexagonal rod I.D.
Page 685 SECTION 18B: X3 SERIES BODY CONTENTS TORQUE TABLES ............................. 5 VEHICLE EXTERIOR ............................7 VEHICLE JACKING POINTS ..........................11 HYDRAULIC JACK ............................11 TOWING THE VEHICLE ..........................11 VEHICLE STRUCTURE ............................ 11 VEHICLE EXTERIOR MAINTENANCE ....................... 11 CORROSION PREVENTION ..........................11 PREVENTIVE MAINTENANCE SCHEDULE ......................
Page 686 SECTION 18B: X3 SERIES BODY ZONE 4 ................................. 58 9.4.1 Rear Fender ............................58 9.4.2 Engine R. H. Side Access Door Adjustment ..................58 9.4.3 Engine Radiator Door ........................... 64 ZONE 5 ................................. 66 9.5.1 Baggage Compartment Doors (Aluminum) ..................66 9.5.2 Wheelchair Lift Cassette Compartment Door ..................
Page 687 SECTION 18B: X3 SERIES BODY 10.5.3 Condenser Compartment Door ......................137 10.5.4 Evaporator Compartment Door (Aluminum) ..................138 10.5.5 Fuel Filler Door ........................... 140 10.6 ZONE 6 ............................... 141 10.6.1 Front Fender ............................141 10.7 ZONE 7 ............................... 142 10.7.1 Side Panel for Vehicles Not Fitted With Slide-Out ................
Page 688 SECTION 18B: X3 SERIES BODY SECTION CHANGE LOG DESCRIPTION DATE Commuter info’s added (door, mirrors & bumper) May 31, 2018 Jacking and towing now refers to MI18-18 June 06, 2018 From L-6492. Updated front end. New windshield gasket. Updated side windows. RH engine door Sept 20 2019 adjustment update.
Page 689 SECTION 18b: X3 SERIES BODY TORQUE TABLES BODY DESCRIPTION TORQUE Entrance door horizontal adjusting bolts 55-65 lb-ft (75-88 Nm) 27 lb-ft (37 Nm) Passenger seat mounting nuts (to sidewall and pedestal) Radiator door hinges bolts 68 lb-in (8 Nm) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 690 SECTION 18B: X3 SERIES BODY WHEELCHAIR LIFT DOOR DESCRIPTION TORQUE Wheelchair lift door – Center hinge bolts 31-38 lb-ft (42-52 Nm) Wheelchair lift door - striker pin adjustment bolts 54-66 lb-ft (73-89 Nm) Wheelchair lift door - opening mechanism nuts 2.5-3.5 lb-ft (3.39-4.75 Nm) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 691 SECTION 18b: X3 SERIES BODY VEHICLE EXTERIOR FIGURE 1: X3 COACHES EXTERIOR VIEW Engine air intake Rear-view mirror Engine compartment R.H. side door Reclining bumper Hinged rear fender Front electrical and service compartment Baggage compartment Driver’s power window Fuel filler door Evaporator or baggage compartment Condenser or baggage compartment Radiator door...
Page 692 SECTION 18B: X3 SERIES BODY FIGURE 2: X3-45 VIP MOTORHOME EXTERIOR VIEW (TYPICAL) Engine air intake Rear-view mirror Engine compartment R.H. side door Reclining bumper Hinged rear fender Front electrical and service compartment Baggage compartment Driver’s power window Fuel filler door Evaporator or baggage compartment Condenser or baggage compartment Radiator door...
Page 693 SECTION 18b: X3 SERIES BODY FIGURE 3: X3-45 VIP COMMERCIAL USE VEHICLE EXTERIOR VIEW (FRONT SLIDE-OUT) Engine air intake Rear-view mirror Engine compartment R.H. side door Front reclining bumper Hinged rear fender Front electrical and service compartment Baggage compartment Driver’s power window Fuel filler door Evaporator compartment Condenser compartment...
Page 694 SECTION 18b: X3 SERIES BODY FIGURE 4: X3-45 COMMUTER EXTERIOR VIEW (TYPICAL) Engine air intake 12. Exhaust aftertreatment system access door 2. Engine compartment curbside door 13. Engine compartment rear door 3. Hinged rear fenders 14. Rear-view mirrors 4. Fuel filler neck & DEF filler neck door 15.
Page 695 MI18-18, available on the technical Welding publications USB flash drive and website. Since welding is a procedure that may be carried out either as specific instructions from Prevost or 3.1 HYDRAULIC JACK by an independent decision of the owner, the following...
Page 696 SECTION 18b: X3 SERIES BODY is, however, an item that can be controlled when it is conscientiously looked after and the proper steps are taken in a timely manner. Certain areas of the coach are more vulnerable to corrosion than others, and it is these areas that should be addressed.
Page 697 SECTION 18b: X3 SERIES BODY 6.2 PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section.
Page 698 SECTION 18b: X3 SERIES BODY 6.3 RUST INHIBITOR APPLICATION Material: Tectyl 185 GW R1KG21 Safety Rules: Use safety glasses Supplied air hood Solvent-resistant rubber gloves 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be masking.
Page 699 SECTION 18b: X3 SERIES BODY 3.2 Front wheelhousing 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) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 700 SECTION 18b: X3 SERIES BODY 4.1 Rear wheelhousing (Entire braking system) 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.
Page 701 SECTION 18b: X3 SERIES BODY thickness is 10 mils wet or 5 mils dry. 7.0 Remove all masking material 30 minutes after application. ANNEX 1 Check and confirm that dew point and surface temperature are in accordance with the following criteria, Use the following table to determine dew point.: Surface temperature >...
Page 702 SECTION 18b: X3 SERIES 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...
Page 703 SECTION 18b: X3 SERIES 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 strand fiberglass and resin. The repair is allowed If part is warped from original shape, use clamping equipment to straighten the surface.
Page 704 SECTION 18b: X3 SERIES BODY undercoating from damaged area, and wipe polyester resin can be applied at this time clean with solvent. (Figure 6). Preheat the area to be repaired using heat lamps. Mix desired quantities of resin and hardener according manufacturer's instructions.
Page 705 CAUTION necessary, refer to the vehicle’s paint scheme for color codes and paint brand. Apply these recommendations after repainting Prevost recommends using the original paint vehicle. brand to ease color matching. PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 706 SECTION 18b: X3 SERIES BODY In the event you sand through to the gelcoat surface you should prime the area with Standox 8.3.1 Safety “Non Stop Fill Primer (ST-11000)”. Care should be exercised in storing, handling, If you sand through to metal surface, first prime mixing, and applying paint and chemicals listed with Standox “Etch Primer (ST-11858)”...
Page 707 SECTION 18b: X3 SERIES BODY X3-45 COACHES EXTERIOR FINISHING AND BODY REPAIR The following procedures cover repair, installation and replacement for various doors, panels and windows. The paragraph divides the vehicle into zones to facilitate the search; each zone is then sub- divided into components.
Page 708 SECTION 18b: X3 SERIES BODY 9.1.1 Front Bumper The front bumper is hinged to give access to the spare wheel and tire compartment. Pull the handle located in the front service compartment to open the spare wheel and tire compartment. Bumper must first be tilted down before its removal.
Page 709 SECTION 18b: X3 SERIES BODY Heated/remote controlled external rear view mirrors may be provided to prevent the mirrors from frosting up in cold weather. The remote controlled external rear view mirrors attach to support arms using a pivot collar secured by setscrews. Loosening the setscrews allows the whole head assembly to turn on the support arm for initial adjustment.
Page 710 SECTION 18b: X3 SERIES BODY Attach a stiff wire (snake) to the end of the harness and insert the wire through the mirror arm base and arm, gently pull the harness through the arm and disconnect the "snake". Connect the mirror head harness. Insert the harness connector back into the mirror arm.
Page 711 SECTION 18b: X3 SERIES BODY • Remote Controlled Rear View Mirrors The remote controlled external rear view mirrors attach to support arms using a pivot collar secured by setscrews. Loosening the setscrews allows the whole head assembly to turn on the support arm for initial adjustment.
Page 712 SECTION 18b: X3 SERIES BODY carrier. These adhesive spots are soft and pressure sensitive. They will adhere again when the glass is reinserted. FIGURE 17: REAR VIEW MIRROR GLASS REMOVAL To re-insert the glass, slide one side under the over-hang tab and spread the opposite over- hang tab with the wedge until the mirror glass is permitted to snap or drop in place.
Page 713 Hydrophobic compound specially The windshield is single-glazed AS-1 laminated formulated for Prevost and can only be applied safety glass. Each windshield is secured to a by Prevost technicians in Prevost service flange around the front structure opening by a centers.
Page 714 SECTION 18b: X3 SERIES BODY gasket on a clean structure. The method may NOTE vary depending on material aging and condition. Locking strips retract with time. Install ends of 1. Spray rubber extrusion with soapy water to locking strips as tight as possible in the V- ease windshield insertion.
Page 715 SECTION 18b: X3 SERIES BODY 9.1.6.4 Installation of Rubber Extrusion and Windshield CAUTION The black rubber extrusion securing the windshield in the opening fits correctly in only one position. Find the correct position of the rubber extrusion now, and make reference marks with a china marker to avoid searching for the correct position later in the procedure.
Page 716 SECTION 18b: X3 SERIES BODY Emergency exit valve, which opens the air valve circuit should be used only in emergencies, or 9.1.7 Regular Entrance Door (Coaches) when the door control system does not function properly. An air operated “sedan type” entrance door, with an air door cylinder and damper assembly are Refer to the air system schematic diagram installed under the right hand dash.
Page 717 SECTION 18b: X3 SERIES BODY To open the door, the switch must be pushed towards the front of the coach and held in position. When the door reaches the fully opened position, the system will keep pressure in the cylinder locking the door in that position. The door can be stopped in any position by releasing the switch.
Page 718 SECTION 18b: X3 SERIES BODY It is important to make sure that damper does not reach end of stroke when door is completely closed or opened. The door cylinder must stop the door on opening. Screw or unscrew rod end to adjust if necessary. To adjust opening and closing cycle speed on damper (Figure 27): 1.
Page 719 SECTION 18b: X3 SERIES BODY NOTE 4. Loosen the horizontal bolts retaining the door to the hinges. Adjust the door front measurements most horizontally and vertically with the jack. important. If required, ask an assistant to help Tighten the bolts. you to perform the following adjustments.
Page 720 SECTION 18b: X3 SERIES BODY Troubleshooting • SYMPTOMS PROBABLE CAUSES REMEDY Manual door locks engaged. Release manual door locks. Check voltage at solenoid locks when door is Upper and lower solenoid locks open. If the voltage is 24 volts then replace do not disengage.
Page 721 SECTION 18b: X3 SERIES BODY SYMPTOMS PROBABLE CAUSES REMEDY Emergency valve is open. Close emergency valve. Check latch bolt ground on door frame. If Lock solenoid stays electrified. needed clean locks for better contact. Check DOOR LOCKS DO NOT LOCK ground circuit.
Page 722 SECTION 18b: X3 SERIES BODY Apply some Sika 206 G+P onto door frame. • Install and center window onto door frame. • Using your hands, compress window. Discard waste according to applicable • environmental regulations, use dangerous waste containers. Apply masking tape before applying Sika •...
Page 723 SECTION 18b: X3 SERIES BODY Line-up body panel with window. There must • be a gap of 4±2mm between window and body panel. Apply some masking tape 1mm from • window edge and body panel. Apply Sika 255 onto door frame structure. •...
Page 724 SECTION 18b: X3 SERIES BODY 9.1.8 Commuter Type Entrance Door An air operated entrance door, with an air door cylinder and damper assembly installed under the right hand dash for the R.H. door panel opening. Another air door cylinder is installed behind the wall to the right of the first curb-side passengers’...
Page 725 SECTION 18b: X3 SERIES BODY position which engages a latch on the entrance door, holding the door positively closed. Emergency exit valve, which opens the air valve circuit should be used only in emergencies, or when the door control system does not function properly.
Page 726 SECTION 18b: X3 SERIES BODY FIGURE 35: EXTERIOR UNLATCH AIR VALVE 12209 FIGURE 36: 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.
Page 727 SECTION 18b: X3 SERIES BODY 8. Fully close the damper while turning the dust NOTE cap or piston rod slowly CCW until it is felt that the cams of the adjusting nut engage in Where a bump rubber was installed, refit same the recesses of the foot valve assembly inside the dust cap and by fully closing the (Figure 37).
Page 728 SECTION 18b: X3 SERIES BODY 1. Support the door panel with a wooden block and a hydraulic jack. 2. Unfasten and then disconnect rod ends from door panel fixing plates. Screw or unscrew rod end in order to adjust door panel depth. 3.
Page 729 SECTION 18b: X3 SERIES BODY  Position body panel onto door frame and compress with your hands. Use a ruler.  Apply some #680066 glue inside fiber glass groove and fix power window wiper. NOTE Anti-friction side must be on glass side. ...
Page 730 SECTION 18b: X3 SERIES BODY  Discard waste according to applicable environmental regulations, use dangerous waste containers. Electrical Power Window  Insert 2 seals in the window frame.  Apply some #680066 glue intersection of the 2 seals and also sparingly in order to fix the seal to the window frame.
Page 731 SECTION 18b: X3 SERIES BODY  Peel the back from double face self- adhesive tape.  Apply Sika 252 inside right angle.  Apply anti-silicone inside right angle.  If applicable, remove plastic film at the bottom of driver’s window. ...
Page 732 SECTION 18b: X3 SERIES BODY Apply masking tape before applying Sika glue to protect paint and adjacent window during surface treatment. For gluing of upper lateral window, refer to procedure SAV00632. • Glued Molding Installation  Clean window gluing area using window cleaner.
Page 733 SECTION 18b: X3 SERIES BODY  Apply a double-face self adhesive tape 1/8 by ¼ inch inside the molding onto the whole length. SECTION VIEW A-A  Apply a double-face self adhesive tape 1/32 by ¼ inch onto the whole length of the gutter.
Page 734 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 Prevost service center near you. For minor damages, refer to paragraph 7 “COMMON FIBERGLASS REPAIR PROCEDURE”...
Page 735 SECTION 18b: X3 SERIES BODY 9.2 ZONE 2 FIGURE 39: ZONE 2 9.2.1 Side Windows 9.2.2 Emergency Exit Windows Nine passenger side windows are installed on All side windows of the X3-45 serve as each side on X3-45. They are made, single or emergency exits.
Page 736 SECTION 18b: X3 SERIES BODY An emergency exit window can be opened by If too much effort is required to disengage the pulling the lower part of the release bar to locks when pulling the release bar or if the disengage the safety latches, and then by window doesn’t close tightly or rattles, check for pushing out the window frame (Figure 40).
Page 737 SECTION 18b: X3 SERIES BODY 1. Lift the bar release system; 2. Partly lift the window and support it so it stays open. 3. Remove the two extrusion locks with a flat screwdriver. 4. With the help of teammates, slowly rotate the window outward ninety degrees (90°).
Page 738 Seal joint should be toward rear of vehicle. chemicals that can attack the high strength 3. Apply rubber adhesive CA-40 (Prevost # materials used in the production of the escape 681285) in the gap between the seal ends.
Page 739 SECTION 18b: X3 SERIES BODY To remove the panel assembly, remove the 4 bolts fastening the 2 hinges to the escape hatch frame and retain the 4 flat washers. Reinstall the panel assembly by fastening the 2 hinges with the 4 bolts and flat washers removed earlier. CAUTION When installing, roof escape hatch’s hinge must be toward the front of vehicle, to prevent...
Page 740 To adjust the latch mechanism and the striker held in place with adhesive. If ever it has to be pin: replaced, take an appointment at a Prevost service center near you. For minor damages, 1. Open the door to access the striker pin.
Page 741 SECTION 18b: X3 SERIES BODY 9.3.3 Rear Bumper Remove three bolts on each side holding bumper to vehicle and remove bumper. To install bumper, reverse the procedure. FIGURE 47: REAR BUMPER 18634 9.3.4 Exhaust Aftertreatment System Access Door 1. Open exhaust aftertreatment system access door.
Page 742: Rear Fender
SECTION 18b: X3 SERIES BODY 9.4 ZONE 4 FIGURE 48: ZONE 4 18627 9.4.1 Rear Fender Rear fenders are hinged for maintenance on brakes and suspension. Each rear fender panel has two mechanical spring loaded holding devices fixing it to the vehicle’s structure. Push the spring type rod sideways to disengage the lock.
Page 743 SECTION 18b: X3 SERIES BODY FIGURE 50: DOOR INSTALLATION – LATCH SYSTEM A - BOLT FIGURE 52: HINGES B - BELLEVILLE WASHER C - STRIKE PLATE A – ENGINE R.H. SIDE ACCESS DOOR D - SPACER B - BOLT E - PIN C - BELLEVILLE WASHER F –...
Page 744 SECTION 18b: X3 SERIES BODY FIGURE 56: LOCKING PLATE Longitudinal adjustment 5. Check the gap between the door and the adjacent panel at the level of the upper FIGURE 54 attachment point of the arm on the door. The 4. If the vertical position is out of tolerance, gap should be ¼"...
Page 745 SECTION 18b: X3 SERIES BODY 7. Check the gap between the door and the adjacent panel at the level of the lower attachment point of the arm on the door. The gap should be ¼" (6 mm) (FIGURE 59). Gap 1/4" (6 mm) Tolerance is ±...
Page 746 SECTION 18b: X3 SERIES BODY 12. Close the door gently. FIGURE 64 FIGURE 66: USE A RULER (SHOWN IN BLACK) TO CHECK THAT SURFACES ARE EVEN 13. Open the door and perform a final tightening to the items indicated with arrows (FIGURE 15.
Page 747 SECTION 18b: X3 SERIES BODY 17. Perform the transversal adjustment by moving the strike plate using the slotted holes (FIGURE 69). FIGURE 71 FIGURE 69 18. The latch bolt must engage not less than 13/32” (10mm) behind the strike plate. 13/32”...
Page 748: Engine Radiator Door
SECTION 18b: X3 SERIES BODY 9.4.3 Engine Radiator Door Radiator door may be adjusted for proper fit by untightening hinge bolts: 1. Loosen the bolts, (“A” & “C”, Figure 74) holding the hinge to the vehicle structure to shift the door "LEFT or RIGHT". 2.
Page 749 SECTION 18b: X3 SERIES BODY PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 750: Zone 5
SECTION 18b: X3 SERIES BODY 9.5 ZONE 5 FIGURE 75: ZONE 5 9.5.1 Baggage Compartment Doors (Aluminum) PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 751 SECTION 18b: X3 SERIES BODY For the removal and installation of a baggage compartment door body panel, you will need: A drill with drill bits; Pneumatic hammer tool (Zip Gun); Razor sharp window scraper or putty knife;  Open damaged compartment door and unfasten rub rail fixing bolts.
Page 752 SECTION 18b: X3 SERIES BODY NOTE Adjustment is made by moving UP or DOWN the lock plates. 9. Tighten cylinder block fixing screws. 10. Door bottom edge compression can be adjusted moving pantograph arms at this location. 6. Open baggage compartment door and adjust using the cylinder mounting block.
Page 753: Wheelchair Lift Cassette Compartment Door
SECTION 18b: X3 SERIES BODY 9.5.2 Wheelchair Lift Cassette Compartment Door For the removal and installation of a wheelchair lift (WCL) cassette compartment door body panel, you will need: A drill with drill bits; Pneumatic hammer tool (Zip Gun); Razor sharp window scraper or putty knife; ...
Page 754 SECTION 18b: X3 SERIES BODY Close the door to center the latch mechanism. Tighten screws Check that the door swings freely and closes properly without interference or excessive force PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 755: Wheelchair Lift Access Door Installation
SECTION 18b: X3 SERIES BODY 9.5.3 Wheelchair Lift access door installation CAUTION Install the sliding door onto a suitable lifting device that will allow proper lifting and positioning. 1. Lift and move the sliding door near the opening. 2. Push the door into the opening making sure the positioning lugs are properly inserted into their housing then pivot the main hinge and secure the door using 4 bolts.
Page 756 SECTION 18b: X3 SERIES BODY FIGURE 77: WCL UPPER ARM AND RAIL 3. Pull the door in or push from the outside to adjust the door with reference to the vehicle outside surface. 4. - Unfasten the upper arm bolt located on the door side. - Position the top rail at 3mm from the ceiling bracket.
Page 757 SECTION 18b: X3 SERIES BODY 8. - Pull the upper rail towards the inside in order to remove the play between the roller and rail then bolt the rail at front and center. Add some shims if necessary between the rail and the structure before tightening the bolts.
Page 758: Baggage Compartment Floor
SECTION 18b: X3 SERIES BODY 9.5.4 Baggage Compartment Floor Repair of Mantex Urethane Covering • Minor Repair Use “Dupont IMRON” paint. Apply using a paint brush or roller depending on gravity. Allow drying for at least 2 hours then repaint as Paint Code: #J4099U per paragraph: Minor Repair.
Page 759 SECTION 18b: X3 SERIES BODY Using a triangular nozzle, apply “Simson” glue (685126) onto support structure. Rear baggage compartment equipped with WCL Rear baggage compartment without WCL. Prepare baggage compartment Mantex floor. Rear baggage compartment equipped with WCL Clean panel underside and edges. PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 760 SECTION 18b: X3 SERIES BODY Apply some Simson glue to fill the gap. Carefully install panel onto support structure. Evenly distribute and install conforming weights Front finishing joint (6 to 8) (80 to 100 lbs total) onto panel for at least 4 hours.
Page 761 SECTION 18b: X3 SERIES BODY Rear baggage compartment without WCL. Remove masking tape. Smooth down joints using soapy water. PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 762: Evaporator Compartment Door
SECTION 18b: X3 SERIES BODY 9.5.5 Evaporator Compartment Door FIGURE 80: EVAPORATOR DOOR (ALUMINUM) For the adjustment of an evaporator door, you will need:  Centering tool G34148_500 • Door adjustment 1. Open the evaporator door. 2. Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly.
Page 763 SECTION 18b: X3 SERIES BODY 12. Make sure that backing plate is parallel to structure before tightening hardware 13. Make sure that skid bar only touches slightly bus structure at bottom. The door should not move up when closing. 9. Close door to center the latch assembly. 10.
Page 764: Condenser Compartment Door
SECTION 18b: X3 SERIES BODY 9.5.6 Condenser Compartment Door FIGURE 81: CONDENSER DOOR 1. Open the condenser door. PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 765: Fuel Filler Door
SECTION 18b: X3 SERIES BODY 2. Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly. Loosening the screws allows the condenser door assembly to be shifted "LEFT or RIGHT" and "UP or DOWN" or “IN and OUT”.
Page 766: Zone 6
SECTION 18b: X3 SERIES BODY 9.6 ZONE 6 FIGURE 83: ZONE 6 18629 9.6.1 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 767: Zone 7
SECTION 18b: X3 SERIES BODY 9.7 ZONE 7 FIGURE 84: ZONE 7 18630 9.7.1 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 √...
Page 768 SECTION 18b: X3 SERIES BODY Grind tig weld spots at each end of side panel. Safely support or temporary fix side panel. Warning: Panel weights over 200 pounds Insert a flat screwdriver between the side panel and Be careful not to damage the adjacent the vehicle chassis, in the top left and right corners.
Page 769 SECTION 18b: X3 SERIES BODY SAV00001 Section A Alcohol or Anti-silicone 1. Apply 2. Dry immediately CHIX cloth Blue cloth 3. Allow to dry Mandatory Minimum time : Wait for product to evaporate After 2 hours: Start cleaning operation again Before applying any other If surface seems dusty, greasy or with finger marks, start cleaning operation again.
Page 770 SECTION 18b: X3 SERIES BODY SECTION 3 SIDE PANEL INSTALLATION 3.00 Using a pencil, mark the double-face self-adhesive tape position onto vehicle side. Apply 1/8 X ½”double-face tape as per marking. Compress tape Remove protective film from double-face self-adhesive tape center section. 3.05 Install 1/8 X ½”...
Page 771 SECTION 18b: X3 SERIES BODY Section A-A Section B-B Position side panel in front of vehicle structure Perform final adjustment to make sure that side 30 mm. ± 2 with reference to bottom – panel is true and square tubing 6 mm ±...
Page 772 SECTION 18b: X3 SERIES BODY Compress top and bottom section of side panel 3.50 Cut excess of side panel. Make sure that cut is parallel with tubing. Grind side panel end to line up with door tubing. 3.60 To seal each panel end, apply masking tape on each side of side panel joint.
Page 773 SECTION 18b: X3 SERIES BODY 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 Prepare air intake panel as for side panel 4.15...
Page 774 SECTION 18b: X3 SERIES 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 SAV00001 section C.
Page 775: Side Crest
SECTION 18b: X3 SERIES BODY 9.7.2 Side Crest FIGURE 85: SIDE CREST POSITIONING 18639 Clean vehicle surface using anti-silicone where the side crest and stickers will be applied. • Using hands apply and compress side crest. • • Apply required stickers. PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 776: Body Panel And Window Spacing
SECTION 18b: X3 SERIES BODY 9.8 BODY PANEL AND WINDOW SPACING FIGURE 86: BODY PANEL AND WINDOW SPACING PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 777: Passenger Seats
SECTION 18b: X3 SERIES BODY 9.9 PASSENGER SEATS The vehicle can be equipped with different seat models and installed in a variety of seating arrangements: 1. For coaches, standard seating arrangement includes two card tables, which can be folded and removed, and pivoting seats ahead of each card table.
Page 778: Upholstery Maintenance
SECTION 18b: X3 SERIES BODY 3. Remove 4 finishing screws holding plastic in the floor track. Removal is possible only by cover between side wall and seat frame. the front or rear end of track. 4. Remove 2 cap screws, nuts, and washers holding seat frame to side wall and retain the 9.9.3 Upholstery Maintenance...
Page 779: Tarabus Floor Covering Repair Or Replacement
SECTION 18b: X3 SERIES BODY Pour a small quantity into a flat pan and work into a thick foam with a sponge or brush. Apply only the foam to the fabric with a sponge or brush. Clean a small area of the fabric at a time with the foam.
Page 780 SECTION 18b: X3 SERIES BODY It would be preferable to cut under two rows of seats so that repair is not as noticeable. 3. Clean plywood using a scraper. NOTE Make sure that no staples are sticking out beyond surface. Adjacent plywood sheets must be leveled. 4.
Page 781: Front Steps Replacement Procedure
SECTION 18b: X3 SERIES BODY FIGURE 93: APPLICATION OF SIKA 221 GRAY 18641 9.10.1 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.
Page 782 SECTION 18b: X3 SERIES BODY PREPARATION OF “TARABUS” FLOOR COVERING 1. Sand under step using “Scotchbrite”. 2. Clean using anti-silicone (refer to Section A). Section A Alcohol or Anti-silicone Apply Dry immediately CHIX cloth Blue cloth 3. Allow drying Mandatory Minimum time : Wait for product to evaporate After 2 hours: Start cleaning operation again If surface seems dusty, greasy or with finger marks, start cleaning...
Page 783 SECTION 18b: X3 SERIES BODY 1. Clean using anti-silicone (refer to Section A). 2. Apply Sika 205 (refer to Section B). Section B Sika 205 Apply CHIX cloth 2. Allow drying Minimum Mandatory - For a smooth surface (aluminum, stainless, steel, 2 minutes fiberglass (gelcoat side), etc.): time...
Page 784 SECTION 18b: X3 SERIES BODY FRONT STEPS GLUING 1. Use step nosing to measure and cut necessary length of white safety strip. 2. Use screw check depth countersinking in step nosing. Screw top 9. Position white safety strip then press using must not stick out beyond the aluminum hands.
Page 785: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering
SECTION 18b: X3 SERIES BODY 9.10.2 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 5.
Page 786: Repair Of A Welded Joint
SECTION 18b: X3 SERIES BODY Leave the torch in operation as it is for 3 8. The heel of the fast nozzle must not lean minutes. against “Tarabus” covering (always parallel to the surface). 12. Perform adhesion test using the tip of a flat screwdriver;...
Page 787 SECTION 18b: X3 SERIES BODY WARNING Nozzle is hot. 4. Always add an extra inch of filler bead at the beginning and at the end of repair. 5. Perform steps indicated in paragraphs 9, 10 and 11. PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 788: X3-45 Vip Exterior Finishing And Body Repair
SECTION 18b: X3 SERIES BODY 10 X3-45 VIP EXTERIOR FINISHING AND BODY REPAIR The following procedures cover repair, installation and replacement of various doors, panels and windows pertaining to X3-45 VIP. The paragraph divides the vehicle into zones to facilitate the search; each zone is then sub-divided into components.
Page 789 SECTION 18b: X3 SERIES BODY ZONE 1 FIGURE 96: ZONE 1 PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 790: Front Bumper
SECTION 18b: X3 SERIES BODY 10.1.1 Front Bumper The front bumper can be tilted downward to give access to the bumper compartment. Pull the release handle located inside front service compartment to unlock. Tilt down the entire bumper assembly to access the compartment. Push the bumper back up firmly in place to lock in position.
Page 791 SECTION 18b: X3 SERIES BODY The remote controlled external rear view mirrors attach to support arms using a pivot collar secured by setscrews. Loosening the setscrews allows the whole head assembly to turn on the support arm for initial adjustment. A mounting bolt and washer hold the arm support to the mounting bracket.
Page 792: Windshield Wipers
Hydrophobic compound specially The windshield is single-glazed AS-1 laminated formulated for Prevost and can only be applied safety glass. Each windshield is secured to a by Prevost technicians in Prevost service flange around the front structure opening by a centers.
Page 793 SECTION 18b: X3 SERIES BODY would have to push against the top R.H. side 8. Then, working from both sides of windshield corner. bottom to top, gradually move the rubber extrusion lip aside to insert the windshield NOTE into the groove. Use also soapy water on the inside of vehicle to insert the windshield We are referring to the L.H.
Page 794 SECTION 18b: X3 SERIES BODY 16. IMPORTANT: Every 6 inches or so, slide backwards to compress the strip due to its tendency to contract during drying process. 17. When strip insertion is almost complete, cut end at a 45° angle leaving ¼” of excess length to prevent contraction over time then insert strip into groove.
Page 795 SECTION 18b: X3 SERIES BODY 10.1.5.4 Installation of Rubber Extrusion and Windshield CAUTION The black rubber extrusion securing the windshield in the opening fits correctly in only one position. Find the correct position of the rubber extrusion now, and make reference marks with a china marker to avoid searching for the correct position later in the procedure.
Page 796: Entrance Door
SECTION 18b: X3 SERIES BODY This molding is glued and will have to be replaced because it will be damaged at 10.1.6 Entrance Door removal. For the removal of entrance door body panel, Remove interior finishing panel to access you will need: rub rail fixing bolts, then remove rub rail.
Page 797: 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 Prevost service center near you. For minor damages, refer to paragraph 4 "Common Fiberglass Repair procedure"...
Page 798: Zone 2
SECTION 18b: X3 SERIES BODY 10.2 ZONE 2 FIGURE 103: ZONE 2 This procedure requires accuracy and it is possible not to succeed on the first 10.2.1 Upper Side Panel attempt. From the inside of vehicle, a For structure preparation, refer to procedure second person ensures the rod passes SAV00035.
Page 799: Electric Awning Windows
SECTION 18b: X3 SERIES BODY 1. Push the vertical latch handle downwards to NOTE release the track and then open the window Do not stretch plastic film and leave enough using the horizontal latch handle. play to be able to push window out without 2.
Page 800 SECTION 18b: X3 SERIES BODY FIGURE 104: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 FIGURE 105: ELECTRIC AWNING WINDOW EXPLODED VIEW (SASH) 18583 PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 801 SECTION 18b: X3 SERIES BODY Motor Replacement Actuator Replacement 1. Push the vertical latch handle downwards to 1. Push the vertical latch handle downwards to release the track and then unlatch the release the track and then unlatch the window using the horizontal latch handle window using the horizontal latch handle.
Page 802: Electric Sliding Windows
SECTION 18b: X3 SERIES BODY Were the shipping blocks in place during installation? C: Failure to remove the shipping blocks after installation can create interference between sash and frame. Have the shipping blocks been removed after installation? D: The window is misaligned or not installed squarely. Is there interference with any coach parts? Is there proper clearance between the bottom of the outer glass and the belt-line trim / seal?
Page 803 SECTION 18b: X3 SERIES BODY Sash Removal 1. Remove the Screen Assembly 2. Pull down on both release latches simultaneously and rotate the sash inwards approximately 10 degrees.(Figure 107) FIGURE 107: REMOVING THE SASH 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 108) FIGURE 108: DISENGAGING THE BOTTOM OF THE SASH PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 804 SECTION 18b: X3 SERIES BODY Installation 1. Align the leading edge of the slot on the lower cam follower block with the sash stop. Use the power toggle switch to obtain the correct alignment. (Figure 109) Lower Cam Sash Stop Follower FIGURE 109: PROPER ALIGNMENT 2.
Page 805: Rear Cap
10.3 ZONE 3 FIGURE 112: ZONE 3 held in place with adhesive. If ever it has to be replaced, make an appointment at a Prevost 10.3.1 Rear Cap service center near you. The fiberglass rear cap does not need any maintenance except painting as needed.
Page 806: Engine Compartment Doors
SECTION 18b: X3 SERIES BODY For minor damages, refer to Paragraph 4 "Common Fiberglass Repair Procedure" and Paragraph 5 "Common Painting Procedure". 10.3.2 Engine Compartment Doors  Engine Compartment Doors Adjustment The engine compartment door may be adjusted for proper fit by untightening support bolts: NOTE Consult the “BODY PANEL AND WINDOW SPACING DIAGRAM”...
Page 807: Rear Bumper
SECTION 18b: X3 SERIES BODY 10.3.3 Rear Bumper  Engine Compartment Door Body Panel Removal Remove three bolts on each side holding bumper to vehicle and remove bumper. For the removal of engine compartment door To install bumper, reverse the procedure. body panel, you will need: Pneumatic hammer tool (Zip Gun);...
Page 808: Rear Fender
SECTION 18b: X3 SERIES BODY 10.4 ZONE 4 FIGURE 115: ZONE 4 10.4.1 Rear Fender On X3-45 VIP vehicles, rear fenders are hinged for maintenance on brakes and suspension. Each rear fender panel has two mechanical spring loaded holding devices fixing it to the vehicle’s structure.
Page 809 SECTION 18b: X3 SERIES BODY FIGURE 117: USE A CABLE TIE TO KEEP SECONDARY LOCK DEPRESSED DURING ADJUSTMENT FIGURE 119 23. Compare the lower edge of the door level with the lower edge of the rear fender. The door should be flush with the fender (FIGURE 54).
Page 810 SECTION 18b: X3 SERIES BODY FIGURE 123 26. If the longitudinal position is out of tolerance, adjust using the adjustment provided on the inner side of the door, at the upper attachment point of the arm on the door FIGURE 121 (FIGURE 58).
Page 811 SECTION 18b: X3 SERIES BODY FIGURE 128 3. Before adjusting the pin, make sure that it doesn’t exceed more than 2" (50mm) at the FIGURE 126 first closing of the door (FIGURE 129). Damage to the door can result if this Latch installation condition is not respected.
Page 812 SECTION 18b: X3 SERIES BODY FIGURE 132: USE A RULER (SHOWN IN BLACK) TO CHECK THAT SURFACES ARE EVEN FIGURE 130 7. Use the pin to adjust the door so it is even with the adjacent steel sheet. Screw or 5.
Page 813 SECTION 18b: X3 SERIES BODY 14. Perform the transversal adjustment by moving the strike plate using the slotted holes (FIGURE 135). FIGURE 137 FIGURE 135 9. The latch bolt must engage not less than 13/32” (10mm) behind the strike plate. 13/32”...
Page 814: Engine Radiator Door
SECTION 18b: X3 SERIES BODY 10.4.3 Engine Radiator Door Radiator door may be adjusted for proper fit by untightening hinge bolts: 6. Loosen the bolts, (details “A” & “C”, Figure 139) holding the hinge to the vehicle structure to shift the door "LEFT or RIGHT". 7.
Page 815 SECTION 18b: X3 SERIES BODY PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 816 SECTION 18b: X3 SERIES BODY 10.5 ZONE 5 FIGURE 141: ZONE 5 10.5.1 Pantograph Baggage Compartment Doors (Aluminum) For the removal and installation of a baggage • A drill with drill bits; compartment door body panel, you will need: PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 817 SECTION 18b: X3 SERIES BODY Pneumatic hammer tool (Zip Gun); • Razor sharp window scraper or putty • knife;  Open damaged compartment door and unfasten rub rail fixing bolts. Remove rub rail.  Unfasten bolts and disconnect cable if necessary in order to remove door from vehicle.
Page 818 SECTION 18b: X3 SERIES BODY NOTE Adjustment is made by moving UP or DOWN the lock plates. 19. Tighten cylinder block fixing screws. 20. Door bottom edge compression can be adjusted moving pantograph arms at this location. 16. Open baggage compartment door and adjust using the cylinder mounting block.
Page 819 SECTION 18b: X3 SERIES BODY 10.5.2 Hinged Baggage Compartment Doors (Aluminum) Door Adjustment • 1. Open the door. 2. Loosen the screws fixing the hinge to door assembly. Loosening the screws allows the door assembly to be shifted "LEFT or RIGHT"...
Page 820 SECTION 18b: X3 SERIES BODY 5. To adjust door depth, loosen the screws fixing the hinge to frame assembly and slide the hinge horizontally to move the door in or out. Depth should be calculated at 29mm +/- 2mm measured from bus frame out or 5mm +1mm if measurement is taken from small square tube on frame.
Page 821: Condenser Compartment Door
SECTION 18b: X3 SERIES BODY 10.5.3 Condenser Compartment Door FIGURE 142: CONDENSER DOOR Door Adjustment • 1. Open the condenser door. 2. Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly. Loosening the screws allows the condenser door assembly to be shifted "LEFT or RIGHT"...
Page 822: Evaporator Compartment Door (Aluminum)
SECTION 18b: X3 SERIES BODY 10.5.4 Evaporator Compartment Door (Aluminum) FIGURE 143: EVAPORATOR DOOR (ALUMINUM) 5. Respect the required gap between exterior For the adjustment of an evaporator door, you finishing panels. will need: 6. Tighten the hinge screws.  Centering tool G34148_500 7.
Page 823 SECTION 18b: X3 SERIES BODY 12. Make sure that backing plate is parallel to structure before tightening the retainer 9. Close door to center the latch assembly. support hardware 10. Tighten the receptacle screws only. 13. Make sure that skid bar only touches slightly 11.
Page 824: Fuel Filler Door
SECTION 18b: X3 SERIES BODY 10.5.5 Fuel Filler Door Door release in the event of a latch • failure. Open the fuel filler door. If the door release mechanism is damaged or Loosen the screws holding the panel to ceases to function for any reason, the door can hinge assembly.
Page 825: Front Fender
SECTION 18b: X3 SERIES BODY 10.6 ZONE 6 FIGURE 145: ZONE 6 10.6.1 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 826: Side Panel For Vehicles Not Fitted With Slide-Out
SECTION 18b: X3 SERIES BODY 10.7 ZONE 7 FIGURE 146: ZONE 7 10.7.1 Side Panel for Vehicles Not Fitted With Slide-Out  Removal Remove top and bottom finishing moldings. Insert Be careful not to damage the adjacent surfaces a screwdriver into snap-on finishing molding joint. You need to remove the finishing molding support Bend finishing molding enough to be able to fix a and rivets in the case of engine air intake panel.
Page 827: Side Panel For Vehicles Fitted With Slide-Out
SECTION 18b: X3 SERIES BODY using a straight edge. Take measurements with a towards the inside. ruler. structure preparation before CAUTION installation of a ridged side panel, refer to procedure SAV00027. Because most junction panels are only riveted For gluing of ridged side panels, refer to and not spot welded, be careful when procedure SAV00028.
Page 828: Slide-Out Exterior Finishing Panels & Windows
SECTION 18b: X3 SERIES BODY 10.8 ZONE 8 FIGURE 147: ZONE 8 10.8.1 Slide-Out Exterior Finishing Panels & Windows For maintenance and procedures, refer to paragraphs on the vehicle’s finishing panels and windows. Methods, procedures, tools, cleaning products, adhesives and other products are the same as those used for the vehicle body.
Page 829: Slide-Out Exterior Finishing Panels & Windows
SECTION 18b: X3 SERIES BODY 10.9 ZONE 9 FIGURE 148: ZONE 9 10.9.1 Slide-Out Exterior Finishing Panels & Windows For maintenance and procedures, refer to paragraphs on the vehicle’s finishing panels and windows. Methods, procedures, tools, cleaning products, adhesives and other products are the same as those used for the vehicle body.
Page 830: Body Panel And Window Spacing For X3-45 Vip Not Fitted With Slide-Out
SECTION 18b: X3 SERIES BODY 10.10 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP NOT FITTED WITH SLIDE-OUT FIGURE 149: BODY PANEL & WINDOW SPACING FOR X3-45 VIP NOT FITTED WITH SLIDE-OUT PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 831: Body Panel And Window Spacing For X3-45 Vip With Front And Rear Slide-Out
SECTION 18b: X3 SERIES BODY 10.11 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP WITH FRONT AND REAR SLIDE-OUT FIGURE 150: BODY PANEL & WINDOW SPACING FOR X3-45 VIP WITH SLIDE-OUT, FRONT AND REAR PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 832: Body Panel And Window Spacing For X3-45 Vip Fitted With Front Slide-Out
SECTION 18b: X3 SERIES BODY 10.12 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP FITTED WITH FRONT SLIDE-OUT FIGURE 151: BODY PANEL & WINDOW SPACING FOR X3-45 VIP WITH SLIDE-OUT, FRONT PA1621 Maintenance Manual All Series | Revised Sept 2019...
Page 833 11 SPECIFICATIONS Door cylinder Manufacturer ............................Bimba Type ..............................Pneumatic I.D..............................1½" ( mm) Stroke ..............................8" ( mm) Prevost number ........................... 780595 Damper Manufacturer .............................Koni Prevost number ........................... 780565 Lock cylinder (upper) Manufacturer ............................Bimba Type ....................Air, single action, 1/8 NPT, hexagonal rod I.D.
Page 835 All Prevost models DESCRIPTION This procedure was made in order to support Prevost customers who are worried about their vehicle structure behavior due to corrosion. Five year old vehicles and older should be subjected to a thorough structural inspection; especially if clear signs of moderate or deep corrosion are visible.
Page 836 ) on Prevost structures are made of FIGURE 1 high strength steel. Although the structure on a Prevost vehicle receives a beneficial corrosion preventive compound application at the end of the manufacturing process, after many years of service with exposure to harsh environments (winter, frequent rains, road salt, stone projection, sand accumulation, etc.), the...
Page 837 MI15-18 / Page 3 / 6 WHEN SHOULD A STRUCTURE INSPECTION BE CARRIED OUT? Vehicles operating in harsh environments without an appropriate corrosion protection compound applied to the front and rear sub-frames, drive axle cradle and tag axle could be subject to corrosion. If parts of the tag axle or front and rear sub-frames structures present metal flaking, separation of metal layers, loss of material, perforation, etc.
Page 838 MI15-18 / Page 4 / 6 STRUCTURE INSPECTION PROCEDURE The thickness of main carbon steel parts on rear & front sub-frames, drive axle cradle and tag axle beam must be at least 1/8 inch (0.125") (3mm). There are two options to properly monitor the wall thicknesses: 1- Using an ultrasonic wall thickness gauge.
Page 839 MI15-18 / Page 5 / 6 CORROSION PROTECTION ON OLD AND CORRODED FRAME To maximize corrosion resistance on older frame exposed to harsh environment: 1) Clean rust on frame. If available, use sand blasting. 2) Apply a zinc-rich primer on cleaned surfaces. 3) Cover carbon steel parts with corrosion preventive compound Tectyl 185GW.
Page 840 MI15-18 / Page 6 / 6 PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone. E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive our warranty bulletins by e-mail.
Page 841 (figures 2 & 3). CLEANING PRODUCT COMPATIBLE WITH POLYCARBONATE Cleaning products designed for external washing of vehicles shall be used to clean your vehicle. Prevost suggests a high PH cleaner compatible with polycarbonate. See the description of the product in the...
Page 842 MI15-41 / Page 2 / 4 High PH cleaning product compatible with polycarbonate - product sheet FIGURE 1: PRODUCT SHEET QF7720956 rev3>...
Page 843 MI15-41 / Page 3 / 4 IMAGES SHOWING THE CRACKING ISSUE FIGURE 2: Cracks at the boss and ribs due to the use of engine degreaser FIGURE 3: Cracking of the outer surface of the taillight due to the use of engine degreaser Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone.
Page 844 MI15-41 / Page 4 / 4 QF7720956 rev3>...
Page 845 All Prevost vehicles models Model Year : 2014 - Current DESCRIPTION This maintenance information is for towing and hoisting Prevost vehicles. Tower experience, local rules and regulations apply in conjunction with the procedures outlined in this document. Images are for representation purpose only, actual vehicles may differ.
Page 846: Hoisting And Towing Points
MI18-18 Page 2 / 30 HOISTING AND TOWING POINTS As much as possible, use the wheels as the preferred lifting points. If lifting by the wheels is not possible or appropriate, there are several hoisting and towing points under the vehicle. Lifting should be performed without passengers and no luggage remaining in the vehicle.
Page 847: Jack Stands
MI18-18 Page 3 / 30 When using the chassis hoisting points to support the vehicle, the tag axle must be unloaded at all times. To prevent damage to the suspension, always support the drive and front axles using jack stands when using chassis hoisting points. CHASSIS HOISTING POINTS 2 hoisting points located aft of the tag axle (Figure3) 2 hoisting points or optional hoisting pads with receptacles located aft of the front axle (Figure4)
Page 848: Axle Hoisting Points
MI18-18 Page 4 / 30 FIGURE 5 : 20 000 LB (10 US TON) FIGURE 6 : 16500 LBF FIGURE 7 : 40 000 LB (20 US TON) CAPACITY CAPACITY JACK STAND CAPACITY JACK STAND AXLE HOISTING POINTS AXLE HOISTING POINTS 2 front axle hoisting points (Figure8, Figure9, Figure10) 2 drive axle sub frame hoisting points (Figure11) 2 hoisting points under the tag axle (tag axle must be unloaded) (Figure12)
Page 849 MI18-18 Page 5 / 30 FRONT AXLE HOISTING POINTS FIGURE 8 : I-BEAM AXLE HOISTING POINT - CURBSIDE FIGURE 9 : I-BEAM AXLE HOISTING POINT – ROAD SIDE FIGURE 10 : INDEPENDENT FRONT SUSPENSION (IFS) HOISTING POINTS. Writer: <QF7720955 rev 7>...
Page 850: Using Wheels As Lifting Points
MI18-18 Page 6 / 30 DRIVE AXLE SUB FRAME HOISTING POINTS FIGURE 11 : DRIVE AXLE SUB FRAME HOISTING POINTS. TAG AXLE HOISTING POINTS FIGURE 12 : TAG AXLE HOISTING POINTS (USE ONLY TO SUPPORT THE TAG AXLE) USING WHEELS AS LIFTING POINTS Use the front and drive axle wheels to lift the vehicle when using mobile column lifts.
Page 851: Optional Chassis Hoisting Points
MI18-18 Page 7 / 30 X-SERIES COMMUTER OPTIONAL CHASSIS HOISTING POINTS On certain vehicles, lifting pads and rear emergency recovery toe eyes may be added on the chassis. When axles or wheels are serviced, use the chassis hoisting points. FIGURE 13 : OPTIONAL FRONT CHASSIS HOISTING POINTS FIGURE 14 : X-SERIES OPTIONAL REAR CHASSIS HOISTING POINTS When using the chassis hoisting points to support the vehicle, the tag axle must be unloaded at all times.
Page 852 MI18-18 Page 8 / 30 FIGURE 15 : OPTIONAL CHASSIS HOISTING FIGURE 16 : OPTIONAL CHASSIS HOISTING RECEPTACLES - AFT OF TAG AXLE RECEPTACLES - AFT OF FRONT AXLE FIGURE 17 : JACK STAND AT CHASSIS HOISTING FIGURE 18 : JACK STAND AT CHASSIS HOISTING RECEPTACLE - AFT OF FRONT AXLE, ROAD SIDE RECEPTACLE - AFT OF FRONT AXLE, CURB SIDE FIGURE 19 : JACK STAND AT CHASSIS HOISTING...
Page 853: Towing
Page 9 / 30 TOWING Towing from the front is the recommended method. Prevost does not recommend towing from the rear using unapproved hoisting points as the vehicle may sustain structural damage. Observe normal precautions including, but not limited to list below: •...
Page 854: Engine Compartment Emergency Air-Fill Valve
MI18-18 Page 10 / 30 Place the front wheels in a straight-ahead position and keep the steering wheel from turning. To do so, slide the driver’s seat close to the steering wheel. Wrap the safety belt around and through the steering wheel and then fasten safety belts. This will ensure the vehicle rolls in straight direction to be stopped by the tow truck in case of mechanical failure of the lifting equipment.
Page 855 MI18-18 Page 11 / 30 While the vehicle is being towed, connect an auxiliary air supply from the tow truck to the quick connect fitting identified AIR SUPPLY to supply air for all systems (brakes, suspension, accessories) through the air dryer (Figure24, Figure25). FIGURE 25 : FRONT TOWING AIR SUPPLY ACCESS PANEL QUICK CONNECT FITTINGS FIGURE 24...
Page 856 MI18-18 Page 12 / 30 FIGURE 27: MERITOR RC23-165 AXLE CAUTION Do not use a chisel or wedge to loosen the axle flange shaft and tapered dowels. Using a chisel or edge can result in damage to the axle shaft, the gasket and seal, and/or the axle hub. 3.
Page 857: Drive Axle Flange Shaft Removal
MI18-18 Page 13 / 30 6. Remove opposite flange shaft similarly. 7. Install a temporary cover over the open end of each hub where an axle shaft was removed. This will prevent dirt from entering the bearing cavity and loss of lubricant. 2.1.4 After Towing 1.
Page 858: First Lift
MI18-18 Page 14 / 30 CAUTION The axle shafts must be disconnected to avoid serious damage to the Allison transmission. Lubrication is inadequate when towing. To prevent damage to the drive train components, disconnect drive axle shafts before towing. Do not attempt to push or pull start a vehicle equipped with an automatic transmission.
Page 859: Second Lift- Front Tow Eye Pads As Lifting Point For Towing
MI18-18 Page 15 / 30 FIGURE 31: TOW EYE 3. Deploy the tow truck stinger arm, placing the axle fork holders under the tow eye pads (Figure 32). FIGURE 32 4. Lift the front end of the vehicle high enough to allow installation of tow cans or blocks.
Page 860 MI18-18 Page 16 / 30 1. Perform the first lift as instructed in paragraph 2.2.1 if not already done. 2. Place the axle forks on the tow bar fork holders (Figure 34). Use 3" to 4 ½" mouth axle forks preferably FIGURE 34 REGULAR...
Page 861 MI18-18 Page 17 / 30 8. Tie the two choke chains together to secure the tow eyes to the tow bar attachment (Figure 38). FIGURE 37 9. Attach the two tow truck safety chains from each of the two front lower radius rods (Figure 38) of the vehicle to the truck’s tow eyes (Figure 38).
Page 862: Second Lift- Using I-Beam Front Axle As Lifting Point For Towing
MI18-18 Page 18 / 30 11. Raise the stinger arm and remove the support jack stand. 12. Lower the vehicle. The front tires should be 7″ to 8″ above the ground before the tow can proceed. 13. Use bungee cords to support the safety chains (Figure 40).
Page 863 MI18-18 Page 19 / 30 1. Perform the first lift as instructed in paragraph 2.2.1 if not already done. 2. Install regular axle forks onto tow bar fork holders. FIGURE 43 TALL REGULAR Pre-adjust spacing between axle forks Minimum spacing: 25 inches Maximum spacing: 33 inches 3.
Page 864 MI18-18 Page 20 / 30 tow cans or blocks can be removed from under the front axle wheels. 7. Tie the two choke chains together to secure the front axle to the tow bar. Take up any slack that may remain and maintain proper tension on chains.
Page 865 MI18-18 Page 21 / 30 12. Use bungee cords to support the safety chains (Figure 49). FIGURE 49 13. Make sure that the parking brake is released before moving the vehicle. 14. Observe safety precautions when towing. FIGURE 50 Avoid sharp turns where possible as safety chains may rub and damage the front bumper (Figure 51) FIGURE 51...
Page 866: X-Series Recovery Using Optional Rear Tow Eyes
MI18-18 Page 22 / 30 CAUTION Make sure a safe distance is kept between the front of the vehicle and the tow truck. This space ensures that vehicle does not suffer damages when being towed. CAUTION Make sure axle shafts or driveshaft are installed correctly after towing. Tighten axle shaft and driveshaft nuts to the correct torque settings.
Page 867: Emergency Towing
MI18-18 Page 23 / 30 EMERGENCY TOWING If the vehicle must be moved and standard towing procedures cannot be used, follow the alternate towing procedures below. 3.1 REAR TOW USING NON-APPROVED LIFTING POINTS - EMERGENCY ONLY CAUTION The vehicle should NOT be lifted and towed from the rear in normal situations. In an emergency, however, it can be moved from the rear over a very short distance such as in a parking lot or to place the vehicle back on pavement.
Page 868: First Lift
MI18-18 Page 24 / 30 DANGER Do not carry passengers while the vehicle is being towed. 3.1.2 FIRST LIFT A first lift of the vehicle is required. This first lift will allow tow cans or blocks to be placed underneath the drive axle tires.
Page 869: Second Lift
MI18-18 Page 25 / 30 7. On X-Series commuter vehicles only, the tag axle air valve lever is located in the front service compartment. Move it forward as shown on Figure 57. FIGURE 57:LOCATION OF COMMUTER TAG AXLE AIR VALVE 8.
Page 870 MI18-18 Page 26 / 30 TALL REGULAR 5. Deploy the tow truck stinger arm. Place the axle forks under the rear tow eyes if equipped or under the side members (Figure 60). Place the forks in a transversal position i.e. perpendicularly to the side members (Figure 61).
Page 871 MI18-18 Page 27 / 30 7. Place the fork’s shorter finger outboard for better clearance (see Figure 62). FIGURE 62 : PROPER LOCATION WHEN LIFTING THE SIDE MEMBERS – VEHICLE EQUIPPED WITH REAR TOW EYES 8. Raise the rear of the vehicle. 9.
Page 872 MI18-18 Page 28 / 30 10. Install the choke chains. Tie the two choke chains together to secure the side members to the tow bar (Figure 64 and Figure 65). Take up any slack that may remain and maintain proper tension on chains. FIGURE 64 11.
Page 873: Volvo I-Shift Transmission Towing Mode
MI18-18 Page 29 / 30 3.2 VOLVO I-SHIFT TRANSMISSION TOWING MODE The procedure will activate “tow mode” on the transmission and will allow the vehicle to be towed flat on all wheels without having to remove the driveshaft. CAUTION Check vehicle VIN before starting. Earlier vehicles do not have the proper software. This special procedure applies to: Model All X Series Vehicles...
Page 874 MI18-18 Page 30 / 30 PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on http://techpub.prevostcar.com/en/ Or scan the QR-Code with your smart phone Are you a vehicle owner? E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive warranty bulletins applicable to your vehicle(s) by e-mail.
Page 875 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS TORQUE TABLES ............................. 5 HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) ................5 HIGH/LOW PRESSURE SERVICE AND RECEIVER TANK VALVES ..............6 IDLERS & TENSIONERS ........................... 6 SMALL A/C SYSTEM X3-45 VIP ........................7 PREHEATER ..............................
Page 876 SECTION 22: HEATING AND AIR CONDITIONING 4.7.1 Replacement Of The Filter-Dryer After Pumping Down ............... 35 MOISTURE INDICATOR ..........................35 SHUT-OFF VALVE WITH SERVICE PORT ......................37 4.10 LIQUID REFRIGERANT SOLENOID VALVE...................... 37 4.10.1 Typical Malfunctions ..........................37 4.10.2 Electrical Bypass/On Demand Opening Of Liquid Refrigerant Solenoid Valves ........38 4.10.3 Coil Replacement ..........................
Page 877 SECTION 22: HEATING AND AIR CONDITIONING 6.5.6 Charging System ..........................67 LIQUID REFRIGERANT RECOVERY ........................ 68 EVACUATING SYSTEM ..........................68 SMALL HVAC SYSTEM ........................... 69 SYSTEM CONFIGURATION H-SERIES ......................69 SYSTEM CONFIGURATION X3 SERIES ......................69 AIR CIRCULATION ............................70 7.3.1 Auxiliary Unit ............................
Page 878 SECTION 22: HEATING AND AIR CONDITIONING SECTION CHANGE LOG DESCRIPTION DATE Added low pressure switch on central A/C system compressor. From J-7446 (X3 series US), J-6245 (X3 Nov. 2017 series CAN), J-3997 (H3 series). Compressor mounting bolts torque was 74 lb-ft; is 82 lb-ft Nov 2018 Preheater was Valeo, changed for Eberspächer starting from K-0655;...
Page 879: Torque Tables
SECTION 22: HEATING AND AIR CONDITIONING TORQUE TABLES HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) 22379 22378_1 22406 22407 HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) DESCRIPTION TORQUE Compressor flange connection screws 31-35 lb-ft (42-47 Nm) Compressor discharge & suction port screws 38-42 lb-ft (52-57 Nm) Compressor mounting bolts 82 lb-ft (111 Nm)
Page 880: High/Low Pressure Service And Receiver Tank Valves
SECTION 22: HEATING AND AIR CONDITIONING HIGH/LOW PRESSURE SERVICE AND RECEIVER TANK VALVES 1-HIGH PRESSURE SERVICE VALVE 2-LOW PRESSURE SERVICE VALVE 3-RECEIVER TANK VALVE SERVICE AND RECEIVER TANK VALVE DESCRIPTION TORQUE High pressure service valve (both positions) 43 lb-ft (58 Nm) Low pressure service valve (both positions) 21 lb-ft (28 Nm) Receiver tank valve (both positions)
Page 881: Small A/C System X3-45 Vip
SECTION 22: HEATING AND AIR CONDITIONING SMALL A/C SYSTEM X3-45 VIP SMALL A/C SYSTEM X3-45 VIP DESCRIPTION TORQUE Upper mounting screws 48 lb-ft (65 Nm) Belt Tensioner 48 lb-ft (65 Nm) Lower mounting screws 82 lb-ft (111 Nm) Compressor mounting fore bracket screws 35 lb-ft (47 Nm) Compressor mounting screws 35 lb-ft (47 Nm)
Page 882: Preheater
SECTION 22: HEATING AND AIR CONDITIONING PREHEATER Preheater DESCRIPTION TORQUE Banjo bolts (2) 96-116 lb-in (11-13 Nm) PA1621 Maintenance Manual All Series | Revised February 2019...
Page 883: Hvac System Overview
SECTION 22: HEATING AND AIR CONDITIONING HVAC SYSTEM OVERVIEW The vehicle interior is pressurized by its Heating Ventilation and Air Conditioning (HVAC) system. Two HVAC systems are available: Small HVAC System and Central HVAC System. Small HVAC System Driver’s unit only •...
Page 884: Central Hvac System Evaporator Compartment Arrangement
SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM EVAPORATOR COMPARTMENT ARRANGEMENT FIGURE 1: EVAPORATOR COMPARTMENT AND DISCHARGE DUCTING ARRANGEMENT PA1621 Maintenance Manual All Series | Revised February 2019...
Page 885: Central Hvac System - H3 Series
SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM – H3 SERIES FIGURE 2: H3 COACHES CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION PA1621 Maintenance Manual All Series | Revised February 2019...
Page 886 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 3: H3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT 22262 PA1621 Maintenance Manual All Series | Revised February 2019...
Page 887 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 4: H3 SERIES CENTRAL SYSTEM – REFRIGERANT CIRCUIT WITH OVERHEAD COMPARTMENT EVAPORATOR PA1621 Maintenance Manual All Series | Revised February 2019...
Page 888: Central Hvac System - X3 Series
SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM – X3 SERIES FIGURE 5: X3 COACHES CENTRAL HVAC SYSTEM - PASSENGER’S UNIT AIR CIRCULATION FIGURE 6: X3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT PA1621 Maintenance Manual All Series | Revised February 2019...
Page 889 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 7: X3 SERIES CENTRAL HVAC SYSTEM –CIRCUIT W/ OVERHEAD COMPARTMENT EVAPORATORS PA1621 Maintenance Manual All Series | Revised February 2019...
Page 890: Small Hvac System - H3 Series
SECTION 22: HEATING AND AIR CONDITIONING SMALL HVAC SYSTEM – H3 SERIES FIGURE 8: H3 SERIES SMALL HVAC SYSTEM – HEATING AND AIR CONDITIONING PA1621 Maintenance Manual All Series | Revised February 2019...
Page 891 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 9: SMALL HVAC SYSTEM - DRIVER'S AND AUXILIARY UNIT (H3 VIP ONLY) FIGURE 10: H3 SERIES SMALL HVAC SYSTEM – AIR CONDITIONING 22377 PA1621 Maintenance Manual All Series | Revised February 2019...
Page 892: Small Hvac System - X3 Series
SECTION 22: HEATING AND AIR CONDITIONING SMALL HVAC SYSTEM – X3 SERIES FIGURE 11: X3 SERIES SMALL HVAC SYSTEM - REFRIGERANT CIRCUIT PA1621 Maintenance Manual All Series | Revised February 2019...
Page 893 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 12: X-SERIES CONDENSER ARRANGEMENT FIGURE 13: X-SERIES SMALL HVAC SYSTEM - HEATING CIRCUIT PA1621 Maintenance Manual All Series | Revised February 2019...
Page 894: Hvac System Basic Maintenance
SECTION 22: HEATING AND AIR CONDITIONING HVAC SYSTEM BASIC MAINTENANCE 3.1.2 Passenger’s Unit Basic maintenance required on the passenger’s and driver’s units consists in cleaning their MAINTENANCE respective coils and cleaning or replacing air filters. With the air filters previously removed, clean However, periodic inspection for broken drains, the passenger’s unit evaporator and heater hoses and charging of system should be done.
Page 895: Passenger's Unit
SECTION 22: HEATING AND AIR CONDITIONING On H3 series vehicles, a fresh air intake filter is located behind R.H. side headlights assembly. Clean the steel wire screen as required. FIGURE 17: R.H CONSOLE AIR FILTER ACCESS GRILL (COACHES) 18505 FIGURE 16: CLEANING PASSENGER’S UNIT CONDENSER COIL WITH LOW-PRESSURE AIR JET 22362 DRIVER’S UNIT AIR FILTER...
Page 896: Overhead Compartment Fan Air Filter
SECTION 22: HEATING AND AIR CONDITIONING PASSENGER’S UNIT AIR FILTER – X3 CAUTION SERIES Be sure not to reverse filter upon installation. The cabin or passengers’ section air filter is located in the evaporator compartment above the evaporator coil and fans (Figure 22). MAINTENANCE Passenger’s unit air filter Clean or replace filter at the intervals specified...
Page 897: Compressor Belts
SECTION 22: HEATING AND AIR CONDITIONING For air conditioning unit, ball valves are added NOTE on supply and return lines in the condenser Both belts must always replaced compartment. They have service port simultaneously to ensure an equal distribution evacuate the A/C overhead compartment circuit. of load on each of them.
Page 898: Belt Tension Adjustment - Central System
SECTION 22: HEATING AND AIR CONDITIONING 3.6.2 Belt Tension Adjustment – Central System On the mechanical tensioner (Figure 26), slightly slack lock bolt (A). Adjust tension by turning adjustment screw (B). Tighten the lock bolt (A) to preserve adjustment. TORQUE: 43 lb-ft (58 Nm) Should the idler bearing need to be serviced, tighten shoulder bolt (C) at reassembly.
Page 899: Torch Brazing
FIGURE BELT LAYOUT WITH SMALL manuals found on your Technical Publications COMPRESSOR X-SERIES USB flash drive and on the Prevost Technical Publications web site. TORCH BRAZING • Bitzer kw-540-1 Maintenance Instruction • Bitzer kb-540-3 Operating Instructions Use electrode containing 35% silver.
Page 900: Electro-Magnetic Clutch
A/C compressor oil color & level check to the following manuals found on your Check compressor oil color and level at the Technical Publications USB flash drive and on intervals specified by the Lubrication And the Prevost Technical Publications site. Servicing Schedule Section LUBRICATION & SERVICING.
Page 901 SECTION 22: HEATING AND AIR CONDITIONING The oil level is expected to remain the same over time except if there is a loss of refrigerant. Adding oil must be done by taking the same precautions as when changing oil in order not to introduce the moisture content of the ambient air in the air-conditioning system.
Page 902: Maintenance - Compressor Oil Change
SECTION 22: HEATING AND AIR CONDITIONING 4.1.5 Maintenance - Compressor Oil Change Impurities from the system components or operation outside the application ranges can lead to deposits in the lubrication oil and darken its color. Change the oil in this case. At the same time, clean the oil filter and magnetic plug as well.
Page 903: Compressor - Small Hvac System
SECTION 22: HEATING AND AIR CONDITIONING divided into suction and discharge areas. The • Repeated liquid refrigerant floodback. upper central section of the cylinder is the • Flooded starts. suction side and it should be relatively cool to the touch, as opposed to the hot discharge area •...
Page 904: Brushless Evaporator Motor
SECTION 22: HEATING AND AIR CONDITIONING • Reinstall following system clean-out recommendations (Paragraph 7.6) FIGURE 37: COMPRESSOR MOUNTING H-SERIES FIGURE 40: X3 SERIES EVAPORATOR COMPARTMENT 4.3.1 Removal • Set the battery master switch to the OFF position and trip circuit breaker CB3 (CB6 on X3 VIP).
Page 905: Installation
SECTION 22: HEATING AND AIR CONDITIONING FIGURE 41: EVAPORATOR MOTOR BOLTS 22315 • Install the complete unit on a work bench, unfasten the fan square head set screws, the Phillips head screws retaining cages to base and slide out the assemblies from the evaporator motor output shaft.
Page 906: Condenser (Central A/C)
SECTION 22: HEATING AND AIR CONDITIONING CONDENSER (CENTRAL A/C) The central A/C system condenser coil is hinge mounted on the R.H. side of the vehicle on the condenser compartment door. Since condenser’s purpose is to dissipate heat from the hot refrigerant, it is important to keep the cooling coils and fins clean.
Page 907: Condenser Fan Removal
SECTION 22: HEATING AND AIR CONDITIONING FIGURE 44: CONDENSER FAN SPEED AND COMPRESSOR EVENTS IN RELATION WITH HIGH SIDE PRESSURE 4.4.2 Condenser Fan Removal Set the battery master switch to the OFF position. Unplug the fan harness connector (Figure 45). Remove the four hexagonal head cap screws retaining the fan assembly to the shroud.
Page 908 SECTION 22: HEATING AND AIR CONDITIONING On X3-series vehicles the condenser is installed in the 4th baggage compartment and has its own MUX controlled electrical fan. FIGURE 47: RECEIVER TANK (H3 SERIES) FIGURE 46 X3 SERIES SMALL A/C CONDENSER ASSEMBLY. RECEIVER TANK The receiver tank is located in the condenser compartment (Figure 47).
Page 909: Replacement Of The Filter-Dryer After Pumping Down
SECTION 22: HEATING AND AIR CONDITIONING FILTER-DRYER Turn off the vacuum pump. Backseat the outlet shutoff valve and then A filter-dryer, also located in the condenser disconnect the vacuum pump hose. compartment, is installed on the liquid refrigerant line after the receiver tank. It is used to absorb CAUTION moisture and foreign matter from refrigerant before it reaches the expansion valves.
Page 910 SECTION 22: HEATING AND AIR CONDITIONING COLOR INDICATOR CLEAR Normal, system OK LIGHT BLUE PINK TEMPERATURE VIOLET (ppm) (ppm) (ppm) Temporary condition, normal when A/C 75°F (24°C) system is turned on. Wait a few minutes for the system to stabilize. 100°F (38°C) 125°F (52°C) BUBBLES, FOAMY...
Page 911: Shut-Off Valve With Service Port
SECTION 22: HEATING AND AIR CONDITIONING SHUT-OFF VALVE WITH SERVICE used to control flow to the driver’s and PORT passenger’s main evaporators. On H3 VIP, one identical refrigerant solenoid This shutoff valve (FIGURE 51) is located in the valve is used on the small HVAC system condenser compartment.
Page 912: Electrical Bypass/On Demand Opening Of Liquid Refrigerant Solenoid Valves
SECTION 22: HEATING AND AIR CONDITIONING Low voltage: Check voltage across the coil 4. Insert the coil retaining screw, rotate coil leads. Voltage must be at least 85% of housing to proper position and tighten screw nameplate rating. securely. Excessive leakage: Disassemble valve and 5.
Page 913: Thermostatic Expansion Valve
SECTION 22: HEATING AND AIR CONDITIONING TORQUE: 20-40 lb-ft (27-54 Nm) expansion and pressure on the power head and spring. Such action causes the assembly valve 6. Put back manual lift stem. Tighten lift stem to open, allowing a flow of refrigerant liquid into assembly and seal cap.
Page 914: Superheat Adjustment
SECTION 22: HEATING AND AIR CONDITIONING the superheat necessary to open the valve. It is obvious, then, that it is most important to adjust the operating superheat correctly and that a minimum change in superheat to move the valve pin to full open position, is of vital importance because it provides savings in both initial evaporator cost of operation.
Page 915: Maintenance
SECTION 22: HEATING AND AIR CONDITIONING Example of readings taken: CAUTION A/C pressure gauge at compressor suction Before proceeding with the expansion valve 40°F converted to temperature adjustment, check for restriction on suction with chart side for plugged filter-dryer and partially open Low swing 44°F valves.
Page 916: Hot Water Pneumatic Valve
SECTION 22: HEATING AND AIR CONDITIONING 4.12 HOT WATER PNEUMATIC VALVE No maintenance is needed unless a malfunction occurs. Refer to Prevost parts manual for available service kits. Valve is normally closed. FIGURE 59: PASSENGER’S UNIT PNEUMATIC HOT WATER VALVE – TYPICAL CUT-OUT VIEW...
Page 917: Valve Troubleshooting
SECTION 22: HEATING AND AIR CONDITIONING 4.12.1 Valve Troubleshooting PROBLEM PROCEDURE Valve fails to close 1. Check electrical supply with a voltmeter. It should agree with nameplate rating. 2. Check pressure at pilot solenoid valve inlet. It must be at least equal to the minimum pressure stamped on the nameplate.
Page 918: Small Hvac System
SECTION 22: HEATING AND AIR CONDITIONING disassembled for repair (impeller assembly only). NOTE For complete information on seal-less water circulating pump, refer to Ametek 18 GPM Seal-Less ECDC Water Circulating Pump manual. Take note that the motor described in this manual is different from the one installed on your circulating pump which is not repairable.
Page 919: Hvac System Testing And Troubleshooting
SECTION 22: HEATING AND AIR CONDITIONING clamps over the motor and secure with When starting the A/C compressor, allow mounting bolts. enough time before checking pressures in order to give the system a chance to build its 2. Connect electrical wiring to the pump motor. pressure.
Page 920: Test Mode For Switches And Sensors
SECTION 22: HEATING AND AIR CONDITIONING The table values are for unloaded, disconnected temperature sensor (thermistor) probed at the TEMPERATURE SENSOR temperature sensor connector pins. Resistance Ohms If the temperature sensor resistance value is Temp °C Temp °F (temperature sensor disconnected) measured at the multiplex module inputs, the measured value includes a parallel 33 kohms...
Page 921: Test Mode For Electric Motors
SECTION 22: HEATING AND AIR CONDITIONING display. This feature can be used when the TEST MODE FOR ELECTRIC vehicle is traveling to check the A/C compressor MOTORS pressure values. The test mode allows testing the motors and In test mode, with the parking brake applied and electric contactors without the need to have the the passenger set point set to a value higher engine running.
Page 922: Hvac Electrical System Troubleshooting
SECTION 22: HEATING AND AIR CONDITIONING HVAC ELECTRICAL SYSTEM TROUBLESHOOTING Always check DID for electrical faults before performing repairs. Address any modules not responding and take corrective action. This should be the first step in troubleshooting. Problem/Symptom Probable Causes Actions No temperature control in the Problem with the temperature Instruct the driver to manually control the...
Page 923 SECTION 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions HVAC condenser fans not Module A49 (A54 on H3 VIP & Check the Diagnostics menu of Driver functioning in speed 1 X3 VIP) is not powered or is Information Display (DID). Select Fault faulty Diagnostics and Electrical System.
Page 924: Air Conditioning
SECTION 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions Evaporator fan not Circuit breaker CB3 (CB6 on X3 Check / reset circuit breaker CB3 (CB6 on functioning VIP) tripped X3 VIP) Check the Diagnostics menu of Driver Module A54 is not powered or is Information Display (DID).
Page 925 SECTION 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE external equalizer line, or filter-dryer. Reduced air flow: Dirty or iced evaporator coil. Clean air filter a. Dirty or clogged air filter; screen. Check return ducts for obstructions. b. Evaporator motor inoperative; or Check blower motor.
Page 926: Expansion Valve
SECTION 22: HEATING AND AIR CONDITIONING 5.7.2 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 927: Temperatures & Pressures Chart
SECTION 22: HEATING AND AIR CONDITIONING LEAK TESTING TEMPERATURES & PRESSURES Some methods such as nitrogen pressure and CHART soap, and electronic sniffer can be used for leak testing. However, the most common method R134a VAPOR-PRESSURE used is a "Halide" torch consisting of an acetylene tank, a burner and a suction test hose.
Page 928: Air Circulation In Driver's Area
SECTION 22: HEATING AND AIR CONDITIONING in the main power compartment/junction panel Multiplex Module (evaporator compartment) (Figure 65 & Figure 66). I/O-B Relays (evaporator compartment) The passenger’s unit condenser coil mounted on the opposite side of the evaporator is ventilated 24V Condenser fans by four brushless axial fans.
Page 929 SECTION 22: HEATING AND AIR CONDITIONING some air flow to the console, from which he can To clean filter, back flush with water or soapy direct air to his knees and/or upper body with water, then dry with air. adjustable HVAC air registers and to his feet with the appropriate button (see FIGURE 67 and Owner’s or Operator’s manual).
Page 930: Hvac System Operation
SECTION 22: HEATING AND AIR CONDITIONING eliminates odors, and finally heats or cools the NOTE lavatory with the vehicle’s ambient air. To perform a test of the driver's section windshield defroster, it is possible to run the system without running the engine. 6.3.1 Control Unit The temperature control in the driver’s area is...
Page 931: Overhead Compartment Unit
SECTION 22: HEATING AND AIR CONDITIONING dehumidification. 6.3.2 Overhead Compartment Unit Optional A/C evaporator coils may be added to both overhead compartment air systems. This air conditioning unit permits a wider temperature range in the passenger’s area. HEATING The schematic of FIGURE 3 shows the central FIGURE 71: DRIVER'S UNIT HOT WATER PNEUMATIC HVAC system heating arrangement.
Page 932 SECTION 22: HEATING AND AIR CONDITIONING Draining Driver’s Unit Heater Core 1. Stop engine and allow engine coolant to cool. 2. Locate normally open water pneumatic valve on the ceiling of the spare wheel compartment (Figure 71), disconnect its wiring connector, and then connect a 24- volt external power source, using jumper cables, to close valve.
Page 933 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 76: DRIVER'S HVAC UNIT FIGURE 77 X3 SERIES HEATER LINE SHUT-OFF VALVES- (ALLISON TRANS. PIPING ARRANGEMENT SHOWN) PA1621 Maintenance Manual All Series | Revised February 2019...
Page 934: Filling Heating System
SECTION 22: HEATING AND AIR CONDITIONING Draining Passenger’s Unit Heater Core 1. Stop engine and allow engine coolant to cool. 2. Close both heater line shutoff valves (Figure 77 or Figure 78). One is located in the engine compartment, lower road side, near the radiator while the other one is located behind the L.H.
Page 935: Bleeding Heating System
SECTION 22: HEATING AND AIR CONDITIONING H3 Series only: The liquid refrigerant 6.4.5 Bleeding Heating System leaves the receiver tank and then flows Whenever the heating system has been drained back to the condenser for sub-cooling and and refilled, or the system has run low on return to the receiver tank.
Page 936 SECTION 22: HEATING AND AIR CONDITIONING Welding or steam cleaning on or near any decompose. refrigerant line or components of the A/C system could build up dangerous and damaging Procurement pressures in the system. Refrigerant is shipped and stored in metal If a small cylinder is ever filled from a large one, cylinders.
Page 937: Refrigerant System Clean-Out After Compressor Failure
SECTION 22: HEATING AND AIR CONDITIONING When disconnecting any fitting in the 6.5.3 Refrigerant System Clean-Out After refrigeration system, the system must first Compressor Failure be discharged of all refrigerant. However, Although the vast majority of reciprocating proceed very cautiously, regardless of refrigerant compressors manufactured today are gauge readings.
Page 938: Pumping Down
SECTION 22: HEATING AND AIR CONDITIONING important that the oil level be adjusted to the compressor and the receiver tank, as well as the proper level. in their connecting line, in order to carry out repairs on other sections of the air-conditioning Withdraw a sample of the compressor oil and system (lines and components).
Page 939 SECTION 22: HEATING AND AIR CONDITIONING 2. Run the system for 10 minutes and then Manual ". shut it off. Procedure 1. Energize driver’s unit and passengers’ unit (main HVAC system) section liquid solenoid valve. To do so, connect male and female connector housings of C24 together for the 3.
Page 940: Condenser (Small A/C)
SECTION 22: HEATING AND AIR CONDITIONING NOTE During this operation, care must be taken not to fill the receiver tank over the upper sight glass. If so, stop process immediately. Always allow refrigerant piping and units to warm up to the ambient air temperature before opening system or sweating will take place inside the lines.
Page 941: Charging System
SECTION 22: HEATING AND AIR CONDITIONING 6.5.6 Charging System WARNING When a system has been opened or if there are any questions about the air or moisture in the Secure manifold gage hoses so they will not system, evacuate the system. Charging of an be damaged by engine belts and pulley.
Page 942: Liquid Refrigerant Recovery
SECTION 22: HEATING AND AIR CONDITIONING 9. Open the R-134a tank valve. The refrigerant 4. Make sure the receiver outlet shutoff valve is supply tank should be kept warm to allow in backseated position (normal operating more refrigerant to be transferred into the position).
Page 943: Small Hvac System
SECTION 22: HEATING AND AIR CONDITIONING Mid seat the compressor suction and discharge shutoff valves. Using connector C24 and C44, energize and open the liquid solenoid valves (driver’s unit, passengers’ unit overhead compartment units). To do so, uncap and connect male female connector...
Page 944: Air Circulation
SECTION 22: HEATING AND AIR CONDITIONING 7.3.1 Auxiliary Unit H3 VIP vehicles equipped with the small HVAC system are equipped with an auxiliary system that provides five additional registers. Three are located behind the driver’s seat and the other two are located near the entrance door, at bottom of first lateral window.
Page 945: Filter-Dryer
SECTION 22: HEATING AND AIR CONDITIONING REFRIGERANT RECOVERY OIL ADDITION The release of refrigerant into the atmosphere The chart below shows the approximate amount must be avoided. Whenever refrigerant is to be of oil to be added to the system when replacing released from the air-conditioning system, a a component.
Page 946: Auxiliary Preheating System (Option)
The preheater fuel filter is located beside the preheater. 8.3.1 Preheater Timer Instructions Basic instructions are provided in the Prevost MAINTENANCE operator’s manual. For more details, refer to the 7 day timer operating instructions, found on your Replace preheater fuel filter every 50,000 miles...
Page 947: Preheater Troubleshooting
SECTION 22: HEATING AND AIR CONDITIONING PREHEATER TROUBLESHOOTING The display is as follows: the current fault, e.g. AF 015. Fault codes can be displayed through the • Press button and keep it depressed, then preheater timer which can display up to 5 fault press button within 2 seconds.
Page 948 SECTION 22: HEATING AND AIR CONDITIONING The preheating system uses the same fuel as CAUTION the engine. Do not operate in a building or while refueling. Operate only in a well- To avoid running down the batteries, do not ventilated area. turn on the preheating system for more than one hour before starting the engine.
Page 949: Specifications
SECTION 22: HEATING AND AIR CONDITIONING SPECIFICATIONS Passenger’s unit evaporator motor Make ..........................AMETEK ROTRON Type ................ BRUSHLESS DC MICROPROCESSOR CONTROLED Voltage ............................27.6 V DC Current draw ............................. 68 amps Horsepower ..............................2 Revolution ........................... 1400 & 1700 rpm Insulation .............................
Page 950 SECTION 22: HEATING AND AIR CONDITIONING Magnetic clutch Make ................................ Lang Type ..............................KK73.1 Voltage .............................. 24 V DC A/C Compressor (Small HVAC system) Make ..............................Sanden Model ................................ SD7 Approved oil ............................PAG Condenser Fan (Small HVAC system) Diameter ............................12 in (30.5 cm) Power ................................
Page 951 SECTION 22: HEATING AND AIR CONDITIONING Hot water circulating pump Make ..............................AMETEK Flow ..............................15 gpm Inlet/outlet OD ............................3/8” Main expansion valve Make ............................Emerson-Alco Preheating system Make ............................Eberspächer Type ............................Hydronic L-II Model ............................Hydronic L30 Capacity ..............................30 kW Heating medium ..........................
Page 953 COMPRESSOR APPLICATION Model Prevost coaches, from year model 2014, with the Bitzer air conditioning compressor DESCRIPTION In this Maintenance Information, you will find instructions and important details necessary to perform the removal or installation of the Lang KK73.1 electromagnetic clutch, which equips the Bitzer (model 4NFCY) air conditioning compressor.
Page 954 MI18-37 Page 2 / 14 CONTENT PROCEDURE LANG KK73 CLUTCH IDENTIFICATION CLUTCH SECTION VIEW REMOVING THE ROTOR REMOVING THE BELTS M12 MOUNTING SCREW REMOVAL EXTRACTOR TOOL PULLING OFF THE ROTOR REMOVING THE COIL MOUNTING THE CLUTCH ON THE COMPRESSOR PREPARATION INSTALLING THE COIL PROPER WOODRUFF KEY POSITION SLIPING THE ROTOR...
Page 955 MI18-37 Page 3 / 14 PROCEDURE DANGER Park vehicle safely, apply parking brake, stop the engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
Page 956 MI18-37 Page 4 / 14 CLUTCH SECTION VIEW coil rotor M12 mounting screw 3a - straining washer bearing M8 screw (4x) flange shaft end woodruff key COLOR CODE rotor assembly compressor body Working gap must be: 0.024 in to 0.035 in 0.60 mm to 0.90 mm Figure 2: CLUTCH SECTION VIEW Writer:...
Page 957 MI18-37 Page 5 / 14 REMOVING THE ROTOR REMOVING THE BELTS 1) Remove the two drive belts. M12 MOUNTING SCREW REMOVAL 2) While holding the hexagonal part of the rotor with a wrench, loosen and remove the M12 mounting screw (3, Figure 2). EXTRACTOR TOOL 3) Screw extractor tool #680888 in the straining washer (3a, Figure 2).
Page 958 MI18-37 Page 6 / 14 PULLING OFF THE ROTOR 4) Pull off the rotor with the extractor tool. Due to the back pressure, the rotor detaches from the shaft end (7, Figure 2) of the compressor. DO NOT USE AN IMPACT WRENCH PULL OFF THE ROTOR TAKE OFF THE ROTOR REMOVING THE COIL...
Page 959 MI18-37 Page 7 / 14 MOUNTING THE CLUTCH ON THE COMPRESSOR PREPARATION 1) The flange and the shaft end must be free from dirt. 2) Apply high temperature approved assembly grease on the shaft end for easy dismounting of the clutch. Use of Molykote G-rapid-plus or Molykote P 40 is recommended INSTALLING THE COIL...
Page 960 MI18-37 Page 8 / 14 PROPER WOODRUFF KEY POSITION 5) To avoid damaging the rotor bore, make sure that the woodruff key is positioned as shown on the image at right, otherwise, it could move when the rotor is inserted on the shaft end.
Page 961 MI18-37 Page 9 / 14 FASTENING THE ROTOR 7) Fasten the rotor to the shaft end by using the M12 screw and holding-up with a wrench on the hexagonal part of the rotor. Rotor mounting screw: 60 lbf-ft (81 Nm) Use blue Loctite 243.
Page 962 MI18-37 Page 10 / 14 REINSTALLING THE BELTS 1. Reinstall the drive belts. A belt strand tension gage is needed On vehicles not equipped with an auxiliary alternator (i.e. 2 identical belts), belt tension should be within this range: 90-100 lbs new belts (mean of 2 belt values) 75-85 lbs used belts (mean of 2 belt values)
Page 963 MI18-37 Page 11 / 14 TROUBLESHOOTING, POSSIBLE DEFECTS, ELIMINATION PROBLEM CAUSE SOLUTION Clutch does not close any more, Intermittent contact in the plug Check plug no current stream Contact corroded Clean contact Connection cable defect Repair cable, replace coil Clutch does not close in spite of Insufficient voltage supply Check supply voltage current stream...
Page 964 MI18-37 Page 12 / 14 Friction surface polluted Disassemble the clutch, replace greasy or oily substances bearing, necessary, clean friction surfaces with alcohol and assemble them again. Blockade of the compressor. Clutch destroyed, replace it. Clutch slips, both components blue due to friction heating. Untrue run of the pulley, loud Bearing damaged due to wear or Check whether feather key and...
Page 965 MI18-37 Page 13 / 14 SUPPLEMENT HOW TO INSTALL A NEW “CLIP-ON” UNLOADER COIL 1. Loosen the screw securing the connector to the coil and then unplug the connector (A). Keep the screw and the connector rubber gasket for later use. 2.
Page 966 MI18-37 Page 14 / 14 PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on http://techpub.prevostcar.com/en/ Or scan the QR-Code with your smart phone Are you a vehicle owner? E-mail us at technicalpublications_prev@volvo.com and type “ADD”...
Page 967 SECTION 23A: ACCESSORIES - H3 SERIES CONTENTS SECTION CHANGE LOG ............................... 3 TORQUE TABLES ............................. 4 AUDIO AND VIDEO SYSTEM DESCRIPTION ...................... 6 TROUBLESHOOTING ............................9 HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS ............ 9 DASHBOARD RADIO ............................. 10 2.3.1 Removal/Installation..........................
Page 968 SECTION 23A: ACCESSORIES - H3 SERIES EMERGENCY BUZZER ........................... 21 FRESH WATER TANK ............................ 21 8.7.1 Fresh Water Tank Heater (Optional) ....................21 8.7.2 Fresh Water Tank Draining ........................21 8.7.3 Fresh Water Tank Filling ........................21 LIQUID SOAP DISPENSER..........................22 FLUSH PUSH-BUTTON ..........................
Page 969 SECTION 23A: ACCESSORIES - H3 SERIES SECTION CHANGE LOG DESCRIPTION DATE Added Wireless microphone pairing. Updated sunshade end of course setting Sept 2019 instructions. Wheelchair lift cassette installation procedure added Jan 2020 PA1621 Maintenance Manual All Series | Jan 2020...
Page 970: Torque Tables
SECTION 23A: ACCESSORIES - H3 SERIES 1. TORQUE TABLES MISCELLANEOUS DESCRIPTION TORQUE Hub odometer mounting bolts 110-165 lb-ft (149-224 Nm) Upper wiper arm cap nut 20-24 lb-in (2.26-2.71 Nm) Lower wiper arm cap nut (drive arm) 20-24 lb-in (2.26-2.71 Nm) Lower wiper arm cap nut (idler arm) 90-110 lb-in (10-12 Nm) Lower wiper arm clamping screw...
Page 971 SECTION 23A: ACCESSORIES - H3 SERIES WHEEL CHAIR LIFT CASSETTE INSTALLATION DESCRIPTION TORQUE WCL CASSETTE ANCHOR BOLTS 55-65 lb-ft (75-88 Nm) PA1621 Maintenance Manual All Series | Jan 2020...
Page 972 Each passenger’s overhead console mounted to the underside of the overhead compartments contains a 20-watt coaxial 10cm speaker. Powered by the amplifier, the speakers (24 in H3-41 or 28 in H3-45) are wired in stereo and arranged in a delta configuration.
Page 973 SECTION 23A: ACCESSORIES - H3 SERIES FIGURE 2: AUDIO-VIDEO CONTROLS AND INDICATORS ON THE FRONT FACE OF THE E-HDMI SWITCH FIGURE 3: AUDIO-VIDEO CONNECTIONS AT THE BACK OF THE E-HDMI SWITCH PA1621 Maintenance Manual All Series | Jan 2020...
Page 974 SECTION 23A: ACCESSORIES - H3 SERIES FIGURE 4: TYPICAL AUDIO-VIDEO CONNECTIONS USING FOUR OUTPUT SPLITTER BOX FIGURE 5: AUDIO-VIDEO CONNECTIONS USING TWO SPLITTER BOXES TO ALLOW THE USE OF SIX LCD MONITORS PA1621 Maintenance Manual All Series | Jan 2020...
Page 975 SECTION 23A: ACCESSORIES - H3 SERIES TROUBLESHOOTING Symptom Possible Causes / Solutions No picture, no sound Check for proper voltage supply and correct cable connections. Ensure that the desired input is selected. No picture Check whether AV cable is properly connected. Check whether HDMI cables are properly connected.
Page 976: Dashboard Radio
SECTION 23A: ACCESSORIES - H3 SERIES REI products that may be installed in your coach: MONITOR, COLOR BACK-UP CAMERA DVD REMOTE CONTROL MONITOR, LCD 15.6” CAMERA, COLOR BACK-UP MONITOR, CENTRAL LCD 15.6” CAMERA, COLOR PANORAMIC MONITOR, FLIP 19” MICROPHONE, 10” CB TYPE MONITOR, 16:9 CENTRAL LCD 19”...
Page 977: Speakers
SECTION 23A: ACCESSORIES - H3 SERIES 400W DSP POWER AMPLIFIER speakers (24 in H3-41 or 28 in H3-45) in the passenger’s section, wired in stereo and arranged in a delta configuration are powered by This 400-watt, 8 channels digital amplifier brings the amplifier.
Page 978: Installation
SECTION 23A: ACCESSORIES - H3 SERIES 3. Disconnect wiring. 2.7.2 Installation 1. Reconnect wiring. 2. Align mounting flange with holes and install screws. 3. Remove spacer block mounting screws. 4. Insert spacer block and install mounting screws. 5. Place the battery master switch in the ‘’ON’’ position.
Page 979: Driver's Speakers
SECTION 23A: ACCESSORIES - H3 SERIES 2.10 DRIVER’S SPEAKERS The driver’s speakers are mounted one on each side. This arrangement provides the driver with clear stereo sound. Controls for the driver’s audio allow selection between the radio and the auxiliary audio (independent of the passenger’s speakers) or muting the speakers.
Page 980 SECTION 23A: ACCESSORIES - H3 SERIES 3. BACK-UP CAMERA AND 4) SELECT This key has 3 functions MONITOR  Selection of the video sources (CA1 CA2  AV  CA1). Press less than 1.5 seconds; An optional back-up camera is available which ...
Page 981 SECTION 23A: ACCESSORIES - H3 SERIES INSTALL POSSIBLE SETTINGS: Selection priority camera REAR CAM1 (CAM1 CAM2) which triggered by rear gear. Selection real picture CAM1 mirrored picture for camera 1. Selection real picture CAM2 Select the function (e.g. contrast) by pressing mirrored picture for camera 2.
Page 982: Hub Odometer
SECTION 23A: ACCESSORIES - H3 SERIES 4. HUB ODOMETER DESCRIPTION An optional wheel hub odometer (Figure 18) may have been installed on the R.H. side of the drive axle. It indicates the total distance in miles or kilometers covered by the coach since it has left the factory, including road testing.
Page 983: Installation
SECTION 23A: ACCESSORIES - H3 SERIES 4.1.2 INSTALLATION NOTE Place the hub odometer unit over the wheel hub LCD display may be located at the back of the studs. Replace the lock washers and nuts. destination sign (series 600) or on the vehicle Torque stud nuts.
Page 984: End Of Stroke Adjustment On Motorized Sunshades With Cantilever Arms
5. Insert a small screwdriver and depress the corresponding button. Release when you Refer to AutoMotionShade quick reference guide provided on Prevost Technical Publications web hear a click. site to adjust the motor limits. 6. Use the sunshade dash button to adjust to the desired position by small pulses.
Page 985: Preload Adjustment
The special tool can be ordered from your two outside signs to indicate occupation. One Prevost part center under part # 685594 sign is located on the outer wall of the lavatory and another sign is located over the windshield.
Page 986: Removal And Installation
SECTION 23A: ACCESSORIES - H3 SERIES DOOR LOCK NOTE Lavatory door lock has inside and outside This fan runs constantly when the ignition handles, as well as an inside latch to lock door switch located on the dashboard is in the from inside the compartment.
Page 987: Dip Switch Settings
SECTION 23A: ACCESSORIES - H3 SERIES 2. Loosen rotation locking screw two (2) turns access panel, located at rear of last R.H. side (do not remove). Then, remove PCB as- row of seats and secured in place using 6 sembly from the back plate of the sensor. Phillips-head screws, allow access to the cleaning cabinet and fresh water tank tubing, 3.
Page 988 SECTION 23A: ACCESSORIES - H3 SERIES FIGURE 27: FRESH WATER TANK SERVICE VALVES LIQUID SOAP DISPENSER FIGURE 28: LIQUID SOAP DISPENSER 23039 A liquid soap dispenser may have been installed as optional equipment. To refill dispenser, CAUTION proceed as follows: Never use abrasive cleaners.
Page 989 SECTION 23A: ACCESSORIES - H3 SERIES decrease time. To gain access to the time adjust- ment screw, repeat steps 1, 2 and 3 in the previous paragraph. 8.10 FLUSH PUMP The submersible-type flush pump is mounted inside an enclosure in the sump tank (Figure 30). The enclosure is provided with a screened side which, serves as a strainer to prevent solid matters from entering the pump.
Page 990 SECTION 23A: ACCESSORIES - H3 SERIES "Cleaning Kit", located besides the engine oil reserve tank (Figure 27). To prevent freezing during cold weather, drain the hose after every use. To drain the hose, uncoil and open the nozzle near the lavatory floor drain. Have an assistant push on the spring ball of the quick- release coupling to allow air into the system.
Page 991 SECTION 23A: ACCESSORIES - H3 SERIES NOTE CAUTION When inspecting the headlights cleaning Do not operate the headlights washer system, check the washer fluid hoses, fittings while the washer fluid reservoir is empty. and connectors to be sure they are properly This may damage the washer fluid pump.
Page 992 SECTION 23A: ACCESSORIES - H3 SERIES 11. WINDSHIELD WIPERS AND FIGURE 35: DASHBOARD Rotate the multifunction lever forward to activate WASHERS lower windshield wipers (arrow 2, Figure 36). The first position operates the wipers at low speed and the second position operates the NOTE wipers at high speed.
Page 993 SECTION 23A: ACCESSORIES - H3 SERIES 11.1 WIPER ARM Check operation of the wipers for proper blade sweep and angle. CAUTION Do not attempt to manually move the wiper arms to make wiper blade sweep adjustments as damage to the wiper linkage or motor may occur.
Page 994 SECTION 23A: ACCESSORIES - H3 SERIES 8. Connect the windshield washer tubing at the 2. If the original arm is reinstalled, align the base of the wiper arm; marks made during removal; 9. Check the adjustment on a wet windshield. 3.
Page 995 4. Remove the three bolts holding the motor to the steel plate. 5. Remove the windshield wiper motor (Prevost #800304), reverse removal procedure to reinstall. PA1621 Maintenance Manual All Series | Jan 2020...
Page 996 SECTION 23A: ACCESSORIES - H3 SERIES FIGURE 40: LOWER WINDSHIELD WIPER INSTALLATION 23088 PA1621 Maintenance Manual All Series | Jan 2020...
Page 997 SECTION 23A: ACCESSORIES - H3 SERIES 11.4.2 Upper Windshield Wiper Motor Replacement The upper windshield wiper motor is located above L.H. upper windshield panel. To remove the motor, it is necessary to remove left sun visor and upper windshield panel. WARNING Park vehicle safely, apply parking brake, stop engine and set battery master switch to the ‘’OFF’’...
Page 998 8. Remove the three bolts holding the motor to 2. Turn to OFF, return to ON and START the steel plate. vehicle within 2 seconds. 9. Remove the windshield wiper motor (Prevost #800304), reverse removal procedure to reinstall. 12. AUTOMATIC FIRE SUPPRESSION...
Page 999 SECTION 23A: ACCESSORIES - H3 SERIES Manual Activation Switch MAINTENANCE o Verify that the tamper seal is intact and access to the switch is unobstructed. EVERY SIX YEARS Fire Detectors o Optical Have the fire extinguisher rebuilt by a qualified fire protection equipment company familiar with ...
Page 1000 SECTION 23A: ACCESSORIES - H3 SERIES On the vehicles equipped with this feature, the VECR fuses F117 & F119 are replaced by CB117 (20 Amp) & CB119 (30 Amp). 14.1 A40 CONNECTOR A40 connector is located in the front electrical and service compartment (aka front junction box).
Page 1001 SECTION 23A: ACCESSORIES - H3 SERIES 15. WHEEL CHAIR LIFT CASSETTE INSTALLATION 14.3 VECT WARNING The VECT includes the following components: For better stability, keep the platform at Relays 51, 52, 53, 54 and 55 minimum height when moving. CB301, 20 Amp Fuses (20A) 302, 303 and 304 WARNING Spare fuses: SP1-SP4...
Page 1002 SECTION 23A: ACCESSORIES - H3 SERIES Slide the cassette into the compartment to get Keep sliding the cassette inside the compart- the rear rollers backward the rail front stopper. ment to get the front rollers backward of the stoppers. FIGURE 48: SLIDE CASSETTE OVER STOPPERS Drop down the rear side of the cassette until it FIGURE 50: SLIDE THE CASSETTE INSIDE THE gets contact with the rail and make sure the...
Page 1003 SECTION 23A: ACCESSORIES - H3 SERIES Install locks in four locations and tighten screws Attach the protective wire. to a torque value of: 55-65 lb-ft (75-88 Nm) FIGURE 52: ANCHOR BOLTS INSTALLATION FIGURE 54: PROTECTIVE WIRE INSTALLATION Plug the electrical connectors and lock it with the connector cover.
Page 1004 SECTION 23A: ACCESSORIES - H3 SERIES Detach the protective wire. Keep sliding out the cassette until the rear rollers get to stoppers. Install jacks on the rear side of the cassette. Lift up the rear side until the rear rollers clear the stoppers. FIGURE 56: PROTECTIVE WIRE INSTALLATION Remove locks in four locations and keep it with the removed cassette.
Page 1005 SECTION 23b: ACCESSORIES - X3 SERIES CONTENTS SECTION CHANGE LOG ............................... 3 TORQUE TABLES ............................. 4 DESCRIPTION OF AUDIO AND VIDEO SYSTEM INSTALLED ON X3-45 COACHES ..........5 HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS ............. 8 DASHBOARD AM/FM RADIO ..........................
Page 1006 SECTION 23b: ACCESSORIES - X3 SERIES 8.7.2 Sump Tank Draining ..........................23 HORN INSTALLATION ........................... 23 ELECTRIC OR AIR HORN MAINTENANCE ....................... 23 HEADLIGHT CLEANING SYSTEM......................... 24 10.1 WASHER FLUID REFILLING ..........................24 10.2 WASHER NOZZLES ADJUSTMENT ......................... 24 WINDSHIELD WIPERS AND WASHERS ....................... 25 11.1 GENERAL DESCRIPTION ..........................
Page 1007: Section Change Log
SECTION 23b: ACCESSORIES - X3 SERIES SECTION CHANGE LOG DESCRIPTION DATE Additional information: sump tank tubing and fill couplings Dec. 2017 Added wireless microphone pairing. Updated sunshade end of course setting instructions. Sept 2019 Wheelchair lift cassette installation procedure added Jan 2020 PA1621 Maintenance Manual All Series | Revised Jan 2020...
Page 1008: Torque Tables
SECTION 23b: ACCESSORIES - X3 SERIES TORQUE TABLES MISCELLANEOUS DESCRIPTION TORQUE Hubodometer mounting bolts 110-165 lb-ft (149-224 Nm) Wiper arm mounting bolts (first tightening) 9 lb-ft (12 Nm) Wiper arm mounting bolts (second tightening) 22 lb-ft (30 Nm) WHEELCHAIR LIFT CASSETTE INSTALLATION DESCRIPTION TORQUE WCL CASSETTE ANCHOR BOLTS...
Page 1009: Description Of Audio And Video System Installed On X3-45 Coaches
SECTION 23b: ACCESSORIES - X3 SERIES DESCRIPTION OF AUDIO AND VIDEO SYSTEM INSTALLED ON X3-45 COACHES The rack mounted components are gathered on the audio-video panel which is located in the first driver’s side overhead compartment (Figure 1). In addition to the power amplifier, options for AM/FM radio, satellite radio, karaoke, wireless microphone, DVD, scenic view and back-up camera system and GPS Navigation System module may be featured.
Page 1010 SECTION 23b: ACCESSORIES - X3 SERIES FIGURE 2: AUDIO & VIDEO CONNECTIONS PA1621 Maintenance Manual All Series | Revised Jan 2020...
Page 1011 SECTION 23b: ACCESSORIES - X3 SERIES FIGURE 3: AUDIO-VIDEO CONNECTIONS FIGURE 4: RACKS ON AUDIO-VIDEO PANEL 23059 PA1621 Maintenance Manual All Series | Revised Jan 2020...
Page 1012: How To Receive Service For Your Rei Audio And Video Products
SECTION 23b: ACCESSORIES - X3 SERIES HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS For assistance in obtaining service for REI products call toll free 877-726-4617 (Continental United States and Canada) between the hours of 7:00 A.M. - 5:00 P.M. CST Monday thru Friday (excluding Holidays). Prior to calling REI, please have the part number, serial number, VIN number and detailed description of the problem ready to provide to the REI service representative.
Page 1013: Dashboard Am/Fm Radio
SECTION 23b: ACCESSORIES - X3 SERIES Place the ignition switch in the ‘’OFF’’ position. DASHBOARD AM/FM RADIO Remove the dashboard cover. Disconnect the electrical connectors from unit and unfasten back plate securing nut/screw. To separate the Sound Selector from its support, insert removal...
Page 1014: Multichannel Power Amplifier Va400.8
SECTION 23b: ACCESSORIES - X3 SERIES 3 video outputs with one dedicated self- SPEAKERS switching rear view monitor Each passenger’s overhead console mounted to  ADDITIONAL VIDEO FEATURES the underside of the overhead compartments contains a 20-watt Dual cone or coaxial 10cm Multi-angle, multi-view, multi-audio function, speaker.
Page 1015: Removal
SECTION 23b: ACCESSORIES - X3 SERIES 2.7.1 Removal 1. Place the ignition switch in the ‘’OFF’’ position. 2. Remove the mounting screws at mounting flange. 3. Disconnect wiring. 2.7.2 Installation 1. Reconnect wiring. 2. Align mounting flange with holes and install screws.

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