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PREVOST X3-45 COMMUTER Maintenance Manual

PREVOST X3-45 COMMUTER Maintenance Manual

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MAINTENANCE
MANUAL
X3-45 COMMUTER COACH
PA-1648

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Summary of Contents for PREVOST X3-45 COMMUTER

  • Page 1 MAINTENANCE MANUAL X3-45 COMMUTER COACH PA-1648...
  • Page 3 MAINTENANCE MANUAL X3-45 COMMUTER DOB 1300-1556 B40668 PA-1648...
  • Page 4 PA-1648 Featuring: • New front and rear aerodynamic design • New flush mount windshield aerodynamic extrusion • New Electrical Architecture • New Electrical Fan Cooling This manual is applicable from the following vehicles: • Short VIN M-7751 FROM V.I.N. DESCRIPTION ISSUED Initial release Oct 2020...
  • 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 MI14-01 HOISTING AND TOWING PROCEDURE FOR X3-45 COMMUTER BUSES SECTION 22 HEATING AND AIR CONDITIONING MI18-37 LANG KK73.1 ELECTROMAGNETIC CLUTCH REMOVAL & INSTALLATION SECTION 23 ACCESSORIES SECTION 24 LUBRICATION & SERVICING SCHEDULE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 9: Table Of Contents

    HOSE CLAMP TORQUE WELDING PROCESS ............................18 STEEL – STEEL WELDING ..........................18 STEEL STAINLESS STAINLESS STAINLESS WELDING ..............18 WITH WITH STEEL - STAINLESS STEEL WELDING ......................19 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 10: Section Change Log

    SECTION 00 : GENERAL INFORMATION SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 11: Foreword

    Although, mere reading such information does not eliminate the hazard, understanding of the information will promote its correct use. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 12: Data Plates And Certifications

    (assembly number), and model number. Use all three numbers when ordering parts. FIGURE 5: POWER STEERING PUMP DATA PLATE FIGURE 2: ALLISON TRANSMISSION DATA PLATE 07076 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 13: Coach Final Record

    FIGURE 6: DOT CERTIFICATION PLATE 00016 3.1.9 Fuel Tank Label The fuel tank label is molded in front of the fuel tank (Figure 7). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 14 FIGURE 9: VEHICLE VIN NOTE Record the VIN and keep with company records. The VIN will normally be used for vehicle registration and for obtaining vehicle insurance coverage. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 15 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 16: Fastener

    Figure 12 shows the different strength markings. FIGURE 11: THREAD NOTATION 00002 FIGURE 12: BOLT STRENGTH MARKINGS 00003 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 17: Standard Torque Specifications

    65 lb-ft (88 Nm) 1/2-13 65 lb-ft (88 Nm) 1/2-13 92 lb-ft (125 Nm) 1/2-20 71 lb-ft (96 Nm) 1/2-20 100 lb-ft (136 Nm) 9/16-12 94 lb-ft (127 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 18 554 lb-ft (751 Nm) A2-70 (NSS-SS) RECOMMENDED TIGHTENING (LB-FT) Tolerance: ±10% DESCRIPTION COARSE THREAD 8-32 10-32 1/4-20 5/16-18 RECOMMENDED TIGHTENING (LB-FT) Tolerance: DESCRIPTION ±10% COARSE THREAD 3/8-16 7/16-14 1/2-13 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 19: Metric

    481 lb-ft (652 Nm) METRIC M24 X 3 nut 10 / screw 10.9 665 lb-ft (902 Nm) METRIC M24 X 3 nut 12 / screw 12.9 777 lb-ft (1054 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 20 RECOMMENDED RECOMMENDED TIGHTENING Tolerance: TIGHTENING Tolerance: DESCRIPTION ±10% ±10% (N-M) DRY (LB-FT) DRY M8 X 1.25 18.6 13.7 M10 X 1.5 37.3 27.5 M12 X 1.75 63.8 47.0 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 21: Self-Locking Fasteners

    ALL-METAL BOLTS lb-in ADHESIVE OR NYLON COATED BOLTS lb-in US STANDARD ¼ 5/16 7/16 ½ 9/16 ¾ NUTS AND ALL-METAL BOLTS lb-in ADHESIVE OR NYLON COATED BOLTS lb-in DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 22: Six Lobbed Socket Head

    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. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 23 SECTION 00 : GENERAL INFORMATION FIGURE 14: METRIC - US STANDARD CONVERSION TABLE 00005 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 24 SECTION 00 : GENERAL INFORMATION FIGURE 15: CONVERSION CHART 00006 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 25: Hose Clamp Torque

    ETRIC seriously damage the electronic components. (CAILLAU) ECOMMENDED Refer Multiplex Modules Disconnection IGHTENING Procedure Prior to Welding annexed at the end of this section. 7 mm Hex 30±2.2 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 26: Welding Process

    Only a qualified and experienced person must do welding. GMAW (Gas Metal-Arc Welding) process; Welding wire conforms to AWS (American Welding Standards) A5.9 specifications; 308LSi type welding wire with 0.035" diameter (0,9 mm); DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 27: Steel - Stainless Steel Welding

    Current: - 50 amperes to 90 amperes, optimum at 60 amperes. It is important to grind weld bead starts and stops and also to grind arc strikes from surfaces. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 29 DISCONNECTION PROCEDURE PRIOR TO WELDING Equipment(s): Ratchet handle 3/8" socket Safety rules: - Wear safety goggles - Set the battery master switch to the OFF position first Recommendations: This procedure should be performed by qualified personnel only. Cover electronic control components and wiring to protect from hot sparks, etc.
  • Page 30 2. Set the main electrical shut-off switch to the OFF position. 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 31 AUTOMATIC BELT TENSIONERS AND IDLER PULLEY INSPECTION ..............24 BEARING INSPECTION ..........................24 AUTOMATIC BELT TENSIONER BUSHING WEAR ..................25 BELTS AND IDLERS VISUAL INSPECTION ...................... 25 ENGINE PROTECTION STRATEGY ........................26 SPECIFICATIONS ..............................27 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 32: Section Change Log

    SECTION 01 : ENGINE SECTION CHANGE LOG DESCRIPTION DATE Mention about 5w-30 oil added Jan 15 2021 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 33: Torque Tables

    Screw, cap hexagonal head M20 – 2.5 g10.9 450 lb-ft (610 Nm) Ground stud M14 – 2.0 85-103 lb-ft (115-140 Nm) Nut on ground stud M22 – 2.5 165-201 lb-ft (224-273 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 34: Belt Tensioners And Idlers

    Idler, A/C compressor drive 31.5-38.5 lb-ft (43-52 Nm) Idler, A/C compressor drive 82 lb-ft (111 Nm) Tensioner, alternator drive 48 lb-ft (65 Nm) Idler, alternator drive 82 lb-ft (111 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 35: Volvo D13 Engine

    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/ DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 36: Engine Harness

    9. Solenoid Valve Oil Thermostat 20. Safety Valve, AHI Fuel System 10. Solenoid Valve Oil Piston Cooling Jet 21. Oil Level & Temperature Sensor 11. Engine Coolant Temperature Sensor DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 37 SECTION 01 : ENGINE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 38 Disconnection of the following EACD produces immediate activation of the Malfunction Indicator Lamp MIL and 25% engine derate after three (3) hours of a continuous open circuit. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 39: Engine Overview

    10. Fuel Filter (Secondary) 4. Air Compressor 11. Crankcase Ventilator 5. Power steering pump 12. Alternator 6. Fuel pump 13. Alternator 7. Hand-priming Pump 14. Alternator Belt DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 40 22. Oil Filters (full flow) 17. Thermostat Cover 23. EGR Cooler 18. Belt Tensioner 24. Turbocharger Actuator 19. Venturi 25. Starter 20. Coolant Filter 26. EGR Valve DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 41: Engine & Exhaust Aftertreatment System Diagram

    SECTION 01 : ENGINE 2.4 ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM FIGURE 5: 2017 AND LATER ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (1 OF 2) 01222 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 42 SECTION 01 : ENGINE FIGURE 6: 2017 AND LATER ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (2 OF 2) 01222 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 43: Engine Oil

    SAE Viscosity Grade 15W-40 oil meeting Volvo extra oil additives unnecessary, as these oils specification VDS-4.5 or API CK-4. already contain balanced treatment additives. Other possible oils: DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 44: Synthetic Lubrication

    DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 45: Oil Filters

    (2). Manually tighten the oil filters stringent requirements may void engine warranty. an additional ¾ to 1 full turn (3). FIGURE 8: D13 OBD20 OIL FILTERS FIGURE 9: OIL FILTER REPLACEMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 46: Checking The Oil Level

    Add oil through the oil filler pipe as required in order to maintain level within the safe range. FIGURE 10: ENGINE OIL FILLING COMPONENTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 47: Power Plant Assembly Removal

    9. Disconnect air compressor suction and Begin With Vehicle Raised • discharge hoses. 1. Using a vehicle lift or jack, raise vehicle to access transmission fasteners and wire harness. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 48 At the back of the air 9. Remove the A/C compressor clutch assembly cleaner, disconnect the engine-air intake duct (item A in Figure 14), refer to MI18-37 at the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 49 Disconnect Exhaust Aftertreatment System control cable. Last • 1. Inspect the power plant assembly to ensure that nothing will interfere when sliding cradle. Check DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 50 22. Coolant surge tank sight glass; 11. Battery bank; 23. Coolant surge tank filler cap; 12. A/C compressor; 24. Diesel Particulate Filter (DPF) assembly (behind heat shield). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 51: Power Plant Assy. Installation

    TORQUE: 190 lb-ft (258 Nm) 2. Reposition the oil filter as shown in Figure FIGURE 18: COMPRESSOR MOUNTING BOLTS FIGURE 17: NORMAL OIL COOLER POSITION 3. Reinstall compressor mounting bolts (4). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 52: Engine Mounts

    It is recommended that new rubber mounts be installed at each major overhaul. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 53: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    Monitor the (TPS) at the controls as you move it through its full stroke. Be sure there is no misalignment or obstruction preventing the smooth movement of the TPS through the full DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 54: Automatic Belt Tensioners And Idler Pulley Inspection

    T-1 thru T-3. I= IDLER 4. Listen if some idlers are noisy and check for T= TENSIONER play in the bearings by hand. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 55: Automatic Belt Tensioner Bushing Wear

    Replace belts if damaged. 2. Visually inspect all idlers for signs of deterioration, loose fasteners, etc. 3. Record the results of the inspection. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 56: Engine Protection Strategy

    EGR valve and position error Derate only Variable Geometry Turbo (VGT) Derate only valve and position error High VGT actuator temperature Derate only High pre-Diesel Oxidation Derate only Catalyst (DOC) temperature DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...

  • Page 57: Specifications

    Recommended engine oil ....................5W-30 VDS-5 Minimum requirement engine oil ..................10W-30 VDS-4.5 Torque specification Engine oil filter ............Tighten ¾ of a turn to 1 full turn after gasket contact. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 01 revised Jan 2021...
  • Page 59 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 60 MI16-16 / Page 2 / 6 PROCEDURE – STARTER REMOVAL AND INSTALLATION DANGER Park vehicle safely, apply parking brake, stop the engine. Prior to working on the vehicle, set the the battery master switch to the OFF position ignition switch to the OFF position, and trip the main circuit breakers equipped with a trip button.
  • Page 61 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 62 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 63 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 64 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 65 Checking restriction indicator ......................15 5.1.2 Replacing the Filter ..........................15 GENERAL RECOMMENDATIONS ........................17 ACCELERATOR PEDAL ........................... 17 PEDAL ADJUSTMENT ............................ 17 POTENTIOMETER REPLACEMENT ........................ 17 SPECIFICATIONS ............................19 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 66 SECTION 03 : FUEL SYSTEM DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 67: Section Change Log

    SECTION 03 : FUEL SYSTEM SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 68: Torque Tables

    Fuel tank support to frame 55 lb-ft (75 Nm) Air filter cover plastic screws (4) 10-15 lb-ft (14-20 Nm) Steel fuel tank retaining straps 20 lb-ft (27 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 69: Fuel System

    Overpressure relief valve Fuel pump Fuel tank Check valve Bowl (fuel / water separator) Primary Filter or Fuel Pro 382 FIGURE 2: FUEL SYSTEM – HIGH PRESSURE SYSTEM DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 70: Fuel Valve

    Close the shut-off valve on the “fuel in” side of the Fuel Pro unit and then pump fuel into the engine through the quick coupling. When DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 71: Filter Replacement

    The fuel level in the cover will start falling. When the fuel level falls to about one inch above the top of the collar, tighten the vent cap quickly by hand. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 72: Secondary Fuel Filter

    Then rotate clockwise another 1/2 - 3/4 turn. ALUMINUM PARTICLES FOUND ON A PRE-GHG17 FILTER CAUSED BY GRINDING OF THE TOP OF THE FILTER INTO THE FILTER RESTRICTOR DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 73: Fuel Pump Removal And Installation

    • housing, prime the fuel system. Start the engine and let run for 5 minutes. • Make sure that there are no leaks. FIGURE 9: FUEL PUMP REMOVAL DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 74: Fuel Lines And Flexible Hoses

    The tank is also equipped with a Emco-Wheaton posi-lock fuel filler neck and a Level Control Valve (LCV) on the fuel tank connection panel to DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 75: Removal

    7. Once properly supported, unscrew the bolts and remove it. (6) holding the fuel tank support to the vehicle 3. Unscrew engine fuel supply and return lines chassis. from fuel tank connection panel. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 76: Installation

    Inspect fuel tank cradle specific attachment points as described below. 1. Raise the vehicle with safe lifting equipment and procedures. FIGURE 15: FUEL TANK SUPPORT MOUNTING BOLTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 77: Fuel Tank Cradle Corrective Measures

    Perform replacement one screw location at a time with appropriate support. Apply torque FIGURE 19: VISIBLE GAP ON TRANSVERSAL SCREW seal mark. JOINT Torque: 82 lb-ft (111 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 78: Fuel Specifications

    Biodiesel Fuels and the Engine Use an oil sampling method to establish the NOTE appropriate oil drain interval for your application. Like Low Sulfur Diesel fuel, ULSD fuel requires DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 79: Air Cleaner (Dry Type)

    Reset by pressing on the FIGURE 23 RUBBER DRAIN VALVE UNDER FILTER indicator's extremity. Using a clean damp cloth, wipe the sealing • flange and the inside of the outlet tube. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 80 If so, the filter needs to be pushed further in the housing. Reset the restriction gage by pushing on the • right-hand side button. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 81: General Recommendations

    8. Store new elements in a closed area free from dust and possible damage. 4. Position potentiometer. Press potentiometer onto the potentiometer shaft, matching cutouts in shaft to drive tangs of potentiometer. Apply hand pressure until DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 82 Make sure the cable harness is routed correctly, and securely installed so that it does not become pinched, stretched, or otherwise damaged during vehicle operation. FIGURE 28: ELECTRONIC FOOT PEDAL ASSEMBLY 03035 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 83: Specifications

    Tank capacity (95% of total volume) ................180 US gallons (681 liters) Air Cleaner Filter type ........................ Dry-type replaceable element Filter change interval ..................Red marker on restriction indicator DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 85 FILLER NECK STRAINER ..........................20 7.3. DEF TANK CLEANING ............................ 20 7.4. PUMP ASSEMBLY FILTER ELEMENT REPLACEMENT ..................21 AFTERTREATMENT HYDROCARBON DOSER ....................22 8.1. REPLACEMENT ............................. 22 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 86: Section Change Log

    SECTION 04 : EXHAUST AND AFTERTREATMENT SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 87: Torque Tables

    30-37 lb-ft (41-50 Nm) * Cap screw 3.8-5.1 lb-ft (5.15-6.91 Nm) Module mounting bolt 5.9-8.8 lb-ft (8-11.93 Nm) Vibration damper screw downstream from turbo 4.5-5.5 lb-ft (6-7 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 88 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 89 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)* * Use Permatex 454G anti-seize lubricant or Loctite 76764 silver grade anti-seize DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 90: Miscellaneous Torques

    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 16.5 lb-ft (22 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 91: Exhaust Aftertreatment System (Eats) Overview

    NOx to minimum • Engine coolant temperature; level. Through constant monitoring of the • EGR temperature sensor. exhaust gas temperature and the system back DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 92: Maintenance

    WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 93: Diesel Particulate Filter (Dpf)

    MAINTENANCE DPF (Diesel Particulate Filter) Either clean or replace filter cartridge at the intervals specified by the Lubrication And Servicing Schedule Section 24A: LUBRICATION & SERVICING SCHEDULE. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 94 SECTION 04 : EXHAUST AND AFTERTREATMENT FIGURE 3: DIESEL OXIDATION CATALYST (DOC) & DIESEL PARTICULATE FILTER (DPF) ASSEMBLY FIGURE 4: EATS SENSORS LOCATION – OBD20 VERSION DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 95: Diesel Particulate Filter Assembly Removal

    1. First, Access the engine compartment 2. Put insulating blanket aside; 3. Remove the heat shield; • Position crane and support tool under DPF assembly. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 96 When replacing the DPF cartridge, refer to the specifications on the DPF attached tag for proper replacement DPF selection. • Lower and pull back to remove DPF from bus. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 97: Selective Catalytic Reduction Converter

    14. Fasten straps holding DOC and DPF assembly; 15. Reconnect pressure, NOx and temperature sensors; 16. Reinstall the heat shield; 17. Put insulating blanket back. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 98 Alternate Procedure DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 99: Assembling Catalytic Converter

    Lower converter. Lower DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 100 Lower Upper 5. Before tightening the parts, make sure that the catalytic converter lower support is well centered with the exhaust inlet of the catalytic converter. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 101: Diffuser Assembly

    If tube is clogged, remove tube and blow compressed air inside, in reverse flow; DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 102: Maintenance

    The fluid is non-flammable, and is not dangerous when handled as recommended. However, it is highly corrosive to certain metals, especially copper and brass. When detaching hoses and components, do DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 103 Rinse off these crystals with water. WARNING DEF spilt onto hot components will quickly vaporize. Turn your face away! FIGURE 12 04052 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 104: Filler Neck Strainer

    3. Let all of the DEF drain from the tank. water drain from the tank. Discard the used DEF according to local regulations. 6. Clean the filler neck insert screen with hot water. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 105: Pump Assembly Filter Element Replacement

    6. Install new filter element and equalizer. Checks filter element cover and housing for damage. If either the filter or housing is damaged, the damaged part must be changed. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...

  • Page 106: Aftertreatment Hydrocarbon Doser

    2. Disconnect the line from the aftertreatment hydrocarbon injector fitting. Collect any DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 107 If fault tracing was performed using Guided (which attaches to the turbocharger outlet) and Diagnostics, return to Guided Diagnostics for tighten the fasteners. repair verification. TORQUE: 120-130 lb-in (14-15 Nm) FIGURE 22 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 04 revised March 2021...
  • Page 109 COOLING FAN SHROUD REMOVAL & INSTALLATION ................... 23 11.4 COOLING PACK (RADIATOR & CAC) REMOVAL & INSTALLATION ..............24 11.5 CHARGE AIR COOLER (CAC) IN VEHICLE REMOVAL ..................30 SPECIFICATIONS ............................34 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 110: Section Change Log

    SECTION 05: COOLING SYSTEM SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 111: Torque Tables

    Constant-torque hose clamps - charge air cooler (CAC) 4.5-5.5 lb-ft (6.1-7.46 Nm) Intake elbow - V-clamps (both) 4.5-6 lb-ft (6.1-8.13 Nm) Screw, CAC air temperature sensor 5.3-6.5 lb-ft (7-9 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 112: Pulleys, Idlers & Tensioners

    22 lb-ft (30 Nm) Idler bolt – water pump 43 lb-ft (58 Nm) Automatic belt tensioner bolt – water pump 48 lb-ft (65 Nm) Water pump pulley 18 lb-ft (24 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 113: Cooling Assembly

    9 lb-ft (12 Nm) Brackets, fan shroud hinge, shroud support & upper support 9 lb-ft (12 Nm) Fan shroud hinge bolts (upper & lower) 68 lb-in (8 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 114: Miscellaneous

    Recovery tank threaded fitting (top of tank) 1 Threads out MAX** * Add Teflon – PTFE sealant to threads ** Add Loctite MR 5438 Plastic Pipe sealant to threads (DO NOT use PTFE sealant) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 115: Description

    The coolant then passes through a series of tubes where its heat is dissipated by airstreams created by the revolving fans and the motion of the vehicle. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 116 SECTION 05: COOLING SYSTEM FIGURE 1: COOLING SYSTEM & RELATED COMPONENTS FIGURE 2: COOLANT SURGE TANK AND RECOVERY TANK DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 117: Maintenance

    Quick Coupling. Do not exceed 15 psi. interlock button to prevent the engine from Any measurable drop in pressure may indicate being started. a leak. Whenever the oil pan is removed, the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 118 9. If the area containing corrosion cannot be reliably cleaned or there is damage to the sealing surface for the O-ring, the coolant filter housing must be replaced. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 119: Hoses

    14. Set the engine stop/ignition interlock back to the normal position. 15. Start the engine, check for leaks and proper operation. 16. After shutdown, replenish coolant FIGURE 12: DUAL CLAMP MINIMUM SPREAD ANGLE necessary. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 120: Constant-Torque Hose Clamps On Charge Air Cooler (Cac)

    Carefully clean the specified torque (dry) (Figure 15). thermostat seat and all cylinder head-to- thermostat housing mating surfaces (Figure TORQUE: 4.5-5.5 lb-ft (6.1-7.46 Nm) 16). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 121: Checking New Thermostat

    Dot on the sensor body is pointing down. • Loctite MR 5438 Plastic Pipe sealant is • applied to the threads. A maximum of one thread is visible once • tightened. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 122: Thawing Cooling System

    LUBRICATION & SERVICING. COOLANT RECOMMENDATIONS FOR Do not exceed recommended service intervals. VOLVO D13 ENGINE The coolant provides a medium for heat transfer and controls the internal temperature of the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 123: Coolant Sampling

    • Nitrile gloves and possible personal injury (scalding) from • Safety glasses the hot liquid. Shop Towels • Sampling should be performed on a cold engine. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 124: Draining Cooling System

    To drain engine and related components: the coolant into a suitable container using the drain hose. 1. Stop engine and allow engine to cool. Close both heater line shutoff valves. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 125: Filling Cooling System

    To drain the entire system, do the previous steps while maintaining the shutoff valves in the open DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 126: Flushing

    27.5 US gal (104 liters). water pump (refer to paragraph 9.2 Reverse Flushing below). 7. Flush the system. 8. Refill system with appropriate coolant. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 127: Reverse Flushing

    Allow jackets to fill with water between air blasts. 5. Continue flushing until the water from the engine runs clean. FIGURE 21: COOLANT FILTER DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 128: Cooling Assembly

    To prevent overheating, inspect rubber seal regularly to ensure proper sealing. FIGURE 22: FAN ORDER AND CONNECTOR NUMBER AT CIRCUIT BREAKER BOX DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 129 SECTION 05: COOLING SYSTEM 11.1 MAINTENANCE FIGURE 23: COOLING ASSEMBLY MAIN COMPONENTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 130: Maintenance

    Unplug the fan from the main fan harness certified IP6K9K and IP68.They can therefore be (blue connector). safely power/pressure washed. Remove the 4 hex screws holding the fan body to the shroud. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 131: Cooling Fan Shroud Removal & Installation

    3. Disconnect the cooling fans circuit breaker box (Figure 25). 7. Unscrew the shroud upper hinge at the vehicle structure and remove the hinge. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 132: Cooling Pack (Radiator & Cac) Removal & Installation

    100 000 (100K) ohms must be observed to be • Main connectors are fully engaged (paint considered acceptable for installation. mark are aligned Figure 27). FIGURE 27: INSTALLED HINGE & MAIN CONNECTOR DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 133 4. Remove access panel located behind L.H tag axle wheel. 5. Access the heater shut-off valve located behind the access panel and set it to the closed position (Figure 29). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 134 8. Disconnect the upper radiator pipe at the pipe junction between the radiator and the engine (Figure 31). FIGURE 33: COOLING ASSEMBLY GROUND 9. Also disconnect the upper CAC pipe at the mid-pipe junction. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 135 15. Remove the protective (splash) plate fixed to bracket (Figure 35). the cooling pack lower support (Figure 36). FIGURE 35: RADIATOR DOOR LOWER HINGE BRACKET FIGURE 36: PROTECTIVE PLATE MOUNTING BOLTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 136 19. Slightly lift the assembly and slide it out of the vehicles. Lower support & rubber mounts • Shroud support bracket • Lower hinge & hinge bracket • DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 137 There should be no gaps between the hinge • pivot point and the plastic bushing (upper & lower hinges Figure 41). FIGURE 43: RADIATOR & CAC UPPER PIPES DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 138: Charge Air Cooler (Cac) In Vehicle Removal

    11.3 of this section. FIGURE 45: UPPER SUPPORT (CAC SIDE) 4. Disconnect the lower CAC pipe (directly at the CAC connection or at the turbo connection). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 139 11 hex bolts holding it by unscrewing the 8 hex bolts holding it (Figure 47). (Figure 48). FIGURE 48: LOWER FRAME BOLTS FIGURE 47: UPPER FRAME BOLTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 140 CAC unit. TORQUE: 9 lb-ft (12 Nm) 13. In preparation for reinstallation of the CAC, install the inner insulating bushings in their location (lower support). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 141 (depressed) and start the vehicle. (lack of conductivity) between support and CAC body with a suitable ohmmeter or 22. Check for CAC leakage at the pipe continuity tester (buzzer). connections. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 142 Type ....................Final Charge Global Extended Life Coolant Ratio ..........................pre-diluted 50/50 mixture Coolant Filter Cartridge Number used ................................ 1 Type ................................Spin-on Long-Life without Coolant Additives (SCA) ....................Yes DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 143 DL0 (BBUS MUX) NETWORK ........................29 DL0 (BBUS MUX) CONNECTION ON THE TELLTALE PANEL AND THE HVAC CONTROL UNIT ....... 29 SPARE DL0 (BBUS MUX) ..........................29 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 144 PRIME ENERGY MANAGEMENT SYSTEM....................66 12.1 COMPONENTS ............................. 66 1.1.1 Vanner 80 Series Battery Equalizer Fault Codes .................. 67 12.2 DID DISPLAY ..............................67 ALTERNATORS ............................68 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 145 LED Indirect Lighting / Overhead compartment Interior Lighting ............80 16.4.2 LED Direct Lighting ..........................80 16.4.3 Removal and Replacement of Reading Lamp Bulb ................80 LIGHT BULB DATA ............................. 81 SPECIFICATIONS ............................82 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 146: Section Change Log

    SECTION 06: ELECTRICAL SECTION CHANGE LOG DESCRIPTION DATE Headlamps disassembly procedure updated March 2021 Limp-homes, available functions modified Oct 2021 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 147: Torque Tables

    Alternator mounting bolts, short 48 lb-ft (65 Nm) Alternator mounting bolts, long 82 lb-ft (111 Nm) Alternator belt idler mounting bolt (hot side) 59 lb-ft (80 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 148: Electrical Connections - Batteries, Miscellaneous

    SECTION 06: ELECTRICAL ELECTRICAL CONNECTIONS – BATTERIES, MISCELLANEOUS COLD SIDE ALTERNATORS HOT SIDE ALTERNATOR, LOW LH (single) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 149 84-108 lb-in (9-12 Nm) Engine ground studs – M10-1. 5 stud 240 lb-in (27 Nm) Alternator ground cable stud (hot side – M10-1. 5 stud 240 lb-in (27 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 150 180 lb-in (20 Nm) Ultracapacitor starting module 3/8-16 12V power stud 212 lb-in (24 Nm) Bus bar, chassis ground stud, M10-1.5, ultracap starting module 240 lb-in (27 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 151 100 lb-in (11 Nm) lb-in Fuse holder M8-1.25 stud nut 96 lb-in (11 Nm) Battery master relay mounting nut M5 15-35 lb-in 15-35 lb-in (2-4 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 152 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 86-106 lb-in (10-12 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 153: General Description

    • Circuit breaker code, Problem: DID displays the fault "Elec. Horn Connector code, • SW63; shorted to ground" as being active. Diode number code, • DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 154: Testing Circuits

    The vehicle electrical system is provided with different voltages. The insulation on each wire is distinctly colored in order to determine visually the wiring voltage and to assist in making DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 155 - DL7 (engine subnet) - DL9 (engine transmission/I-Shift subnet) J2284 - DL2 J1587 - DL4 (powertrain subnet 900/901) For stud location, refer to page 2.1 of wiring diagram DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 156: Spare Wires

    Simply pull the circuit breaker off the blade type mount to replace. FIGURE 1: BREAKER WITH MANUAL TRIP BUTTON AND RESET LEVER SUCH AS CB2 & CB6 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 157: Multiplex Fuses

    Once the coil is energized, it develops a magnetic field that pulls a switch arm closed or open, to either energize or de-energize a given DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 158: Cooling Fan Connections

    Cooling fans may start running at any powered different modules moment. redundancy need. Keep hands away from cooling fans or keep the radiator door closed. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 159: Precautions

    5. Replace the MCM. used. 6. Reset circuit breaker CB6. 7. The indicates "MUX AUTOPROGRAMMING MODULE PLEASE WAIT" until the reprogramming of DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 160: Uploading A Multiplex Program Update Into The Mcm

    “Axx Keep hands away from cooling fans or keep Responding” appears where Axx is the the radiator door closed. module number (Ex: A41, A42…etc). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 161: Electronic Modules Connector Pin-Out

    SECTION 06: ELECTRICAL ELECTRONIC MODULES CONNECTOR PIN-OUT FIGURE 7: ELECTRONIC MODULES CONNECTOR PIN-OUT - BACK PROBING VIEW DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 162 SECTION 06: ELECTRICAL VECR / VECF ORANGE, BLACK, RED, GREY, BROWN, GREEN, YELLOW FIGURE 8: ELECTRONIC MODULES CONNECTORS PIN-OUT - BACK PROBING VIEW DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 163 At a sufficient large surface a perpendicular force is initiated by (preferably) the thumb of one hand. Proper final position is reached a click noise can be heard. Make sure that both sides are locked. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 164 Remove the terminal by disengaging the flexible lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. VECR / VECF 06627 06632 BUSSMAN DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 165: Available Test Modes

    2 beeps are emitted. If only one beep is sensors which are difficult to activate, are not heard, one of the inputs is defective. supported by the switch/sensor test: DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 166: Electric Motor Test Sequence

    24.4 volts, remind that the motor test mode is underway. B. Engine not running, C. Parking brake applied, DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 167: Test Sequence - Coaches

    The upper windshield defroster (optional) starts • running. To exit the electric motors test sequence, press ESCAPE button, select TERMINATE TESTS & FORCED STATES submenu and then press ENTER button twice. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 168: Alternator Test

    CAC & radiator fans. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 169: Limp-Home Modes

    To activate the DID limp-home mode, press and engine compartment and drive in a secure hold the courtesy blinkers button for 3 seconds. manner. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 170: Available Functions

    • Headlamps: Low beams only, • Stoplights: 2 upper stoplights + high-mounted stoplight are functional, • HVAC: Defroster fixed at medium speed. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 171: Networks

    If the front modules (A41 to A46) now give inactive errors, which means short-circuit is elsewhere than in the front electrical & service compartment. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 172: Troubleshooting

    Inactive Multiplex output = Residual voltage of 18% to 33% of supply voltage. Inactive Multiplex input = Residual voltage of 50% of supply voltage. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 173: Dl0 (Bbus Mux) Network Layout And Troubleshooting

    MAIN POWER COMPARTMENT AE53 I/O-EB LAST OVERHEAD COMPARTMENT, L.H. SIDE AE54 I/O-EB EVAPORATOR CMPT AE55 I/O-EA DASHBOARD AE56 I/O-EA DASHBOARD AE57 I/O-EA WCL CMPT, ABOVE WHEELCHAIR LIFT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 174 FRONT ELECTRICAL COMPARTMENT: disconnect C1 and connect C1 pin housing to C1S socket housing. RJB: disconnect C3 and connect C3 socket housing to C3S pin housing. baggage compartment: disconnect C100 and connect C100 pin housing to C100S socket housing. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 175 Pneumatic accessories panel: disconnect C13 and connect C13S pin housing to C13 socket. FRONT ELECTRICAL COMPARTMENT: Disconnect C5 and connect C5S socket housing to C5 pin housing. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 176 No need to connect a termination resistor there since C100 is a stub connection. If the short circuit problem is in the evaporator panel, all modules except AE54 will respond normally. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 177 If the short circuit problem is in the MAIN POWER COMPARTMENT or downstream, all front modules + the evaporator module will respond normally. The same process can be for the overhead compartment module. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 178: Multiplex Troubleshooting Table

    Check / reset circuit breaker CB8 Check / reset CB91V b) Check / reset circuit breaker CB2 Check / reset CB99V DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 179 Set above 22°C Passenger temperature compartment air intake or the (72°F) to heat and below 22° C (72°F) to display indicates two sensor wiring cool dashes "--" DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 180 2. Check / reset circuit breaker CB1 3. Check / reset CB44V 4. Probe gray connector on module to see if it is powered. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 181 2. Check / reset circuit breaker CB10 3. Check / reset CB21V 4. Probe gray connector on module to see if it is powered. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 182 6. Check / reset circuit breaker CB5 7. Check / reset CB135V 8. Probe gray connector on module to see if it is powered. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 183 This will deactivate the fire alarm function. the engine compartment This has to be repeated each time the but there is no fire vehicle is parked DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 184 OFF position or press ESCAPE button, select TERMINATE TESTS & FORCED STATES submenu and then press ENTER button twice. TEST will disappear from the DID status line. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 185: Electrical System Diagnostic Through The Did

    If it is, then you can conclude that there is a DL0 (BBUS MUX) link problem. Refer to DL0 (BBUS MUX) NETWORK LAYOUT AND TROUBLESHOOTING in this section. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 186: Electrical Compartments

    SECTION 06: ELECTRICAL ELECTRICAL COMPARTMENTS FIGURE 13: ELECTRICAL COMPARTMENTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 187: Main Power Compartment (Rjb)

    Master relay R1; • 12V ignition relay R3; • Starter relay; • Relays and fuses; • FIGURE 17: MAIN CIRCUIT BREAKERS IN MPC Battery equalizer; • DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 188 SECTION 06: ELECTRICAL FIGURE 18: MAIN POWER COMPARTMENT COMPONENTS IDENTIFICATION DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 189: Front Electrical And Service Compartment (Fjb)

    • Relays and fuses; • ABS Electronic Control Unit (ECU); VECU with Volvo D13 engine; • Gateway module • FIGURE 19: FRONT ELECTRICAL & SERVICE COMPARTMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 190 SECTION 06: ELECTRICAL FIGURE 20: FRONT ELECTRICAL & SERVICE COMPARTMENT COMPONENTS IDENTIFICATION DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 191: A/C Module

    Door unlock Door opening solenoid valve solenoid valve Door unlock Door closing solenoid valve solenoid valve Diodes Windshield wipers Entrance door speed 2 Windshield wipers speed 1 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 192: Overhead Compartment Module

    OVERHEAD COMPARTMENT MODULE A single I/O B module, AE53 is found at the rear end of the left overhead compartment. FIGURE 24: OVERHEAD COMPARTMENT I/O-EB MODULE AE53 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 193: Nyct Auxiliary Systems In Parcel Rack

    Refer to pertaining supplier of the system and vehicle electrical schematics for information. FIGURE 25 NYCT AUXILIARY SYSTEMS, PLATES 1 & 2 FIGURE 26: NYCT AUXILIARY SYSTEMS, PLATES 3 & 4 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 194: Batteries

    FIGURE 27: BATTERY INSTALLATION Batteries also contain other chemicals known to the State of California to cause cancer. Wash hands after handling. FIGURE 28: BATTERY CONNECTIONS SCHEMATIC DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 195: Agm Batteries

    Float voltage: 13.4-13.6 Volt @77°F (25°C) Charging AGM battery on a typical constant current or taper current charger – even one time – may greatly shorten its life. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 196: Battery Discharge Protection

    Fire suppression system (momentarily); FIGURE 31: BATTERY BANK COVER REMOVED Horn, Hazard: • 2. Disconnect the ground cable first (Figure 32). Wheelchair lift system; • • Cluster memory. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 197 When installing the batteries, place the battery negative and positive poles according to the signs on the battery deck (Figure 38). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 198 5. Align the dowels on the angles with the holes Tighten the ground cable nut to the following on the cable guides (Figure 41). torque: TORQUE: 170 lb-in (19 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 199 Refer to Procedure SAV00002E included at the end of this section to know the recommended products and where they are used. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 200: Agm Battery Rating

    Figure 46. Connect a load DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 201: Seat Usb Power Supply

    Both the booster and must be placed between the terminal nuts and discharged batteries must be treated carefully the lead pads of the terminal studs after the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 202 1/3 of the battery’s content to increase, the charging current will reserve capacity minute rating. likewise increase. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 203: Emergency Jump Starting

    FIGURE 47: QUICK CONNECT JUMP START battery it counters stratification (layers of CONNECTOR different concentration of electrolyte), and also DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 204: Cleaning And Inspection

    Replace protective caps to prevent corrosion apparent reason, the following factors may and sparks. reveal the cause of trouble: 1. Vehicle accessories disconnect switches inadvertently left on overnight. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 205: Battery Voltage Warning" Pictogram

    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. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 206: Starting The Vehicle With Depleted Batteries

    Polarity should be strictly observed publications USB drive for troubleshooting when connecting the KAPower module into instructions. any circuit MODULE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 207: Maintenance

    It simply supplies the same voltage that it was charged up to. Handle it with the same respect you would give to a fully charged battery. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 208: Prime Energy Management System

    State of Charge (SOC). by an electric air dryer. This is covered in section 12 of this manual. CURRENT SENSORS EQUALIZER FIGURE 50: PRIME ELECTRICAL COMPONENTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 209: Vanner 80 Series Battery Equalizer Fault Codes

    12V and 24V battery banks in percentage. restarted. FIGURE 51: PRIME DID DISPLAY In addition to the standard voltage gage, the DID also includes a state of charge gage for the batteries: DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 210: Alternators

    R.H. alternator operates as Lower Left. normally. Back-probe pin 8 (AE52 J2:8) and a good Cold Side (R.H.): ground (use ground stud in the compartment): DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 211: Alternator Drive Belt

    Coach Final Record. 13.2.2 Adjustment Correct belt tension is required to maximize belt life. The tensioning arm maintains proper belt tension, no adjustment is required. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 212: Starter

    MELCO 105P70 starter. NOTE complete removal/installation instructions, refer to Maintenance Information MI16-16 Starter removal and installation included at the end of section 01ENGINE. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 213: Exterior Lighting

    The circuit for exterior lights, as well as their control switches, relays and circuit breakers are shown on the applicable wiring diagrams. FIGURE 55: EXTERIOR LIGHTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 214: Headlamps

    FIGURE 60: HEADLAMP ASSEMBLY BEZEL MODULE REPLACEMENT 4. Remove 4 screws holding the headlight module. 1. Unscrew the 2 bumper retaining bolts shown on the image (47 lbs-ft). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release March 2021...

  • Page 215: Directional Turn Signal Replacement

    This is done on a screen located at a distance of 25 feet (7,6 m) of the headlamps. It should be of DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 216 Table 1 and the left edge of the high-intensity zone is at the vertical centerline of the headlamp (Figure 68). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 217: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    6 LED lights, mounted together as a the following procedure: module. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 218: Lamp Removal And Replacement

    FIGURE 73: LED SEALED UNIT WIRE CONNECTION 2. Plug the new unit connectors. Engage the mating parts; push until the connector is fully seated. Turn slightly until you feel a click. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 219: Marker Lights Removal And Replacement

    R.H. side. The main function of these lights is to increase lateral visibility when turning DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 220: Engine Compartment Lighting

    FIGURE 81: PERIMETER LIGHT DISASSEMBLY 1. The engine compartment rear door or curbside door is open. 2. Disconnect light. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 221: Interior Lighting Equipment

    Two stepwell lights are illuminated when the compartments. The aisle or indirect lights are door opening system is activated. located on front of overhead compartments, and DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 222: Led Indirect Lighting / Overhead Compartment Interior Lighting

    4. Install new bulb in the socket, then push and turn clockwise to lock bulb in position. 5. Push the bulb socket in the reading lamp unit. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...

  • Page 223: Light Bulb Data

    17. LIGHT BULB DATA Please, refer to your vehicle Parts Manual for selection of replacement light bulbs. NOTE Exterior and interior lights can be 12 volts or 24 volts. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 224 -Max. current draw ........................125 amperes -Min. rpm ............................3000 rpm Starter solenoid Make ....................Mitsubishi Electric Corporation (MELCO) Pull In Voltage ..........................16 volts max. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 06 revised release October 2021...
  • Page 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234 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 235 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 236 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 237 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 238 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 239 MAINTENANCE MI16-17 INFORMATION SECTION: 06 - Electrical DATE : FEBRUARY 2016 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 241 7.1.4 Exiting Diagnostic Mode ........................16 7.1.5 Diagnostic Trouble Code Response ...................... 16 DIAGNOSTIC TROUBLESHOOTING CODES (DTC) L - ALLISON 5 CONTROLS ......17 RATION SPECIFICATIONS ............................22 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 242 SECTION 07: TRANSMISSION SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 243: Torque Tables

    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) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 244: Description

    Dirt or foreign transmission quickly compensate matter must not be permitted to enter the fluid variations in load, terrain or environment and to DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 245: Cold Check

    3.1.1 Cold Check The purpose of the Cold Check is to determine if the transmission has enough fluid to be operated safely until a Hot Check can be made. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 246: Hot Check

    • Fluid level sensor present and working. transmission breather is clean and not 5. Correct fluid level clogged. If readings are still not consistent, contact your nearest Allison dealer displayed as shown. distributor. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 247: Recommended Automatic Transmission Fluid

    Disregarding minimum fluid temperature limits TOO HIGH too high can result in transmission malfunction or reduced transmission life. VEH SPD TOO Output shaft speed SENSOR FAILED Sensor failure DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 248: Importance Of Proper Fluid Level

    Metal contamination will require complete disassembly of the transmission and cleaning of all internal and external circuits, coolers, and all other areas where the particles could lodge. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 249: Fluid And Filter Change Interval

    TES295 fluid have occurred, at which time the transmissions utilizing TES295 approved fluid or TES295 schedule may be used. TranSynd. High Capacity filters eliminate the requirement of the initial 5000 miles (8000km) main filter change. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 250: Fluid And Filter Change Procedure

    Fluid remains in the external circuits and transmission cavities after draining the transmission. NOTE Quantities listed below are approximations and do not include external fluid cooler lines. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 251: Cleaning And Inspection Of Allison Automatic Transmission

    1. Select transmission's "NEUTRAL" positions, apply parking brake, and then set battery master switch to the "OFF" position. 2. Jack up vehicle, then place safety supports underneath body. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 252 15. Slowly pull transmission straight out to clear 10. Disconnect main wiring harness. the engine. 11. Disconnect the air supply line (steel-braided 16. Remove the transmission. hose) from retarder control valve. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 253: Allison Transmission Installation

    (with the spacer in place). NO FORCE SHOULD REQUIRED. interference encountered, move transmission away from engine, then FIGURE 10: VOLVO ENGINE TURNING TOOL #88800014 investigate the cause. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 254 Reinstall access plug below starter motor. 14. Remove jack from under transmission. 15. Connect all sensors. FIGURE 14: AIR PRESSURE REGULATOR (TYPICAL) 16. Connect the main wiring harness. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 255: Allison Transmission Troubleshooting

    CHECK light, selector operating mode after approximately 10 minutes display change, lock in range, or inhibit shifts of operator inactivity. condition. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 256: Diagnostic Code Display And Clearing Procedure

    (Upshift) and (Downshift) arrow buttons at the same time on the pushbutton shift selector. 2. Press any range button «D», «N» or «R» on the pushbutton shift selector. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 257: Diagnostic Troubleshooting Codes (Dtc) List - Allison

    SOL OFF, DNA, Inhibit TCC P0657 Actuator Supply Circuit Voltage 1 Open (HSD 1) operation, Inhibit main modulation P0658 Actuator Supply Voltage 1 (HSD1) Low DNS, SOL OFF (hydraulic default) DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)
  • Page 258 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 259 Engine Coolant Temperature Sensor 2 Circuit Low Input Use default engine coolant values P2185 Engine Coolant Temperature Sensor 2 Circuit High Input Use default engine coolant values P2637 Torque Management Feedback Signal (A) Inhibit SEM DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 260 P2812 Pressure Control Solenoid 6 (PCS6) Control Circuit Open DNS, SOL OFF (hydraulic default) P2814 Pressure Control Solenoid 6 (PCS6) Control Circuit Low DNS, SOL OFF (hydraulic default) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 261 Maintain range selected, observe U0404 Selector) 1 gear shift direction circuit Invalid Data Received From Gear Shift Module (Shift Maintain range selected, observe U0592 Selector) 2 gear shift direction circuit DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 262: Specifications

    Total coverage is determined by dividing the highest gear ratio by the lowest gear ratio. Total coverage expresses the transmission gear ratio versatility. Transmissions with a larger total coverage number have a wider variety of available ratios DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 263 INSTALLATION .............................. 12 SLIP MEMBER AND BOOT INSTALLATION ..................... 12 PROPELLER SHAFT INSTALLATION ........................ 13 UNIVERSAL JOINT INSTALLATION ......................... 14 EXPLANATION OF COMMON DAMAGES ....................... 15 SPECIFICATIONS ............................16 DO DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 264 SECTION 09: PROPELLER SHAFT SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 265: 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) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 266: Propeller Shaft Description

    Lubrication And Servicing Schedule in Section 24: LUBRICATION & SERVICING. NOTE Repair kits are available for overhaul of the propeller shaft assembly. Refer to Parts Manual, Section 9. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 267: Nyct Propeller Shaft Maintenance Directive

    DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 268: U-Joint Service - Quick Reference Guide

    WARNING Maximum grease gun pressure should not exceed psi. Excessive grease pressures may cause seal damage. 2. Make sure fresh grease is evident at all u-joint bearing seals. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 269: Inspection Recommendations

    Take hold of the end d) Apply a c-clamp around the inboard fitting with both hands. Try to move it bearings. vertically and horizontally to feel any looseness. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 270: Mark Propeller Shaft (Phasing Marks)

    2. Reassembly of a propeller shaft that is out of phase can cause vibration and failure to propeller shaft components. FIGURE 7: PHASING MARKS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 271: Removal

    3. Remove the bearing retainers and bolts at rear end. Discard bolts, and bearing retainers. FIGURE 8: PHASING MARKS FIGURE 12: COLD FORMED BEARING RETAINERS FIGURE 9: PHASING MARKS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 272: Inspect Companion Flange/Flange Yokes

    FIGURE 14: RAISED METAL OR FRETTING ON OPEN YOKE CROSS HOLES 8. Inspect the end yoke cross holes for FIGURE 16: CORRECT POSITIONING distortion and damage. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 273: Inspect Tube Yoke And Flange Yoke (If Applicable)

    DO NOT reuse of the journal cross makes contact with the clamps. inside of the yoke ear. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 274: Installation

    FIGURE 23: APPLY GREASE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 275: Propeller Shaft Installation

    Mating surfaces should be clear of rust, failure. contamination and grease. 2. With safety straps in place, align the phasing marks between the yoke and propeller shaft. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 276: Universal Joint Installation

    4. 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 277: Explanation Of Common Damages

    A structural overload may cause propeller shaft tubing to twist under strain or it may cause cracks or breaks in U-joints and spline plugs. FIGURE 31 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual (Draft Version – April 2020)

  • Page 278: Specifications

    SECTION 09: PROPELLER SHAFT SPECIFICATIONS PROPELLER SHAFT Make ............................Dana-Spicer Inc. Series ................................. SPL250 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 279 Camber Check ............................14 FRONT AXLE CASTER ............................ 14 FRONT WHEEL TOE-IN ..........................14 7.8.1 Inspection and Adjustment ........................15 ALIGNMENT SPECIFICATIONS ........................16 TROUBLESHOOTING ............................. 17 SPECIFICATIONS ............................18 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 280 SECTION 10: FRONT I-BEAM AXLE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 281: Section Change Log

    SECTION 10: FRONT I-BEAM AXLE SECTION CHANGE LOG DESCRIPTION DATE D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 282: Torque Tables

    Information of the Maintenance Manual. For other torque specifications, refer to Dana manuals listed in paragraph 2.1 reference manuals in this section. FRONT I-BEAM AXLE AND RELATED COMPONENTS 16187 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 283 30-36 lb-ft (41-49 Nm) Air spring nut 25 lb-ft (34 Nm) Steering damper arm nuts 285-315 lb-ft (386-427 Nm) Drag link ball joint stud nut, aft 140-200 lb-ft (190-271 Nm) D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 284: Front I-Beam Axle Hub, Rotor And Brakes

    500-700 lb-ft (678-949 Nm) Draw key, Nut 51-62 lb-ft (69-84 Nm) Kingpin lower cover Screw 26-32 lb-ft (35-43 Nm) Back & Front Lock - Stop Bolt 85-103 lb-ft (115-140 Nm)a DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 285: Description

    For hub bearing rework: Dana Parts & Service Instructions S84U Steer Axle HUB BEARING REWORK_ Manual NO 1963 B iss A FIGURE 1: FRONT AXLE ASSEMBLY (I-BEAM) D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 286 Socket Assy L.H. Shim Kingpin - Bushing Bearing Cup O Ring Seal Bearing Cone Kingpin Washer (Collet) Washer Nut – Self Lock Cap - Knuckle Bottom Lub Nipple (Straight) Screw DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 287: Lubrication

    CAUTION Should removal of a locking device be required when undergoing repairs, disassembly or adjustments, always replace with a new one. FIGURE 2: FRONT AXLE GREASING POINTS D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 288: Removal And Replacement

    8. Proceed with steps a, b and c, while referring to Section 16: ‘’SUSPENSION’’. a) Disconnect sway bar links from axle brackets. b) Remove shock absorbers. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 289: Service Instructions For Steer Axle

    / bearing attention and possible renewal, is in evidence. NOTE To avoid inaccurate measurements, be careful not to let the knuckle turn while moving D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 290: Front Wheel Alignment

    Make sure all fasteners are tightened to the However, it should be checked and adjusted any specified torque. Use a torque wrench for DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 291: Turn Adjustment

    2. Verify the nearest point of contact of the ball socket body with the air bellows support assembly. Measure the distance between those two points. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 292: Camber Check

    For caster specifications, refer to paragraph vehicle front wheels are closer together than the 8: ‘’ALIGNMENT SPECIFICATIONS’’ in this rear part, measured at wheel centerline height section. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 293: Inspection And Adjustment

    7.8.1 Inspection and Adjustment Before adjusting front wheel toe-in, first check the camber angles and make the necessary corrections. 1. Measure the toe-in. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 294: Alignment Specifications

    Front Wheel Alignment Minimal Nominal Maximal Camber, (degrees) -0.250 0.125 0.375 R.H. and L.H. * Caster, (degrees) 2.75 R.H. and L.H. Total toe (A minus B), 0.04 0.06 0.08 (degrees) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 295: Troubleshooting

    2. Wheels and/or tires out-of balance. 2. Balance or replace wheels and/or tires. operation. 3. Worn steering stabilizer cylinder. 3. Replace steering stabilizer cylinder. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 296: Specifications

    SECTION 10: FRONT I-BEAM AXLE 10. SPECIFICATIONS Front Axle Make .............................. DANA SPICER Model ................................S84U Front Track ........................84.5 inches (2147 mm) Rated load capacity ......................16,500 lbs (7 500 kg) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 297 Removing Tag Axle Only ........................12 3.3.2 Removing Tag Axle Along With Suspension Components ..............12 3.3.3 Removing Transversal radius Rod ......................13 TAG AXLE ALIGNMENT..........................14 SPECIFICATIONS ..............................16 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...
  • Page 298 SECTION 11: REAR AXLES DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 299: Section Change Log

    SECTION 11: REAR AXLES SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 300: Torque Tables

    DESCRIPTION TORQUE Caliper mounting bolts 200 lb-ft (271 Nm) Brake air chamber mounting bolts 120-150 lb-ft (163-203 Nm) Axle to frame mounting bolts 405-495 lb-ft (549-671 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 301: Tag Axle

    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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 302: Zf A132 Drive Axle

    Section 16, "Suspension". 9. Reinstall the level check plug using a new seal (O-ring). Tighten to 52 lb-ft (71 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 303: Differential Oil Change

    Clean the magnetic insert of the drain plug, fit a new seal (O-ring) and reinstall drain plug. Compact bearing (hub unit) axial play Check the bearing axial play at the intervals DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 304: Compact Bearing (Hub Unit) Grease Change

    Replacement of Axle Insert in the following manuals, included on your vehicle USB flash drive: • OPERATING INSTRUCTIONS ZF AXLE A132 (version with US hub) #5871 207 982 EN. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...
  • Page 305 (hub unit) External Torx driver shaft seal cap screw external Torx M16x1.5x60 torque=221 lbf-ft slotted nut (use E20 External Torx driver) locking plate flange shaft DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 306: Removal And Reinstallation

    FIGURE 4 NOTE Refer to section 13 "Wheels, Hubs And Tires" correct wheel bearing adjustment procedure. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 307: Disassembly, Reassembly, Adjustment And Torque Chart

    DRIVE AXLE ZF A-132 Minimum Nominal Maximum value value value Thrust angle ±0.11° Total toe 0.15° 0.15° 0° toe-in toe-out DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 308: Tag Axle

    2. Remove drive axle wheels (if required, refer to Section 13, "Wheels, Hubs And Tires"). 3. Exhaust compressed air from the air supply system by opening the drain cock on each DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 309: Removing Transversal Radius Rod

    It is strongly suggested to use the extractor retarder), move tag assembly very carefully. tool in order to remove transversal radius rod. Pay special attention to the U-shaped section, DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 310: Tag Axle Alignment

    Josam or Hunter systems. TAG AXLE Alignment / value Minimum Nominal Maximum value value value Thrust angle -0.02 0.02 (deg.) Total toe (deg.) 0.08° toe-in 0° 0.02° toe-out DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...
  • Page 311 SECTION 11: REAR AXLES FIGURE 8: FRONT & DRIVE AXLE ALIGNMENT 11025 FIGURE 7: TAG AXLE ALIGNMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...

  • Page 312: Specifications

    Axle type ..........................Full floating Oil fill quantity ......................19.5 quarts (39 pints) Ratio..............................3.82 TAG AXLE Make ............................. Prevost Rear track ......................82.1 inches (2 084 mm) Axle type ............................Forged DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 11 revised Jan 2021...
  • Page 313 COMPRESSOR REMOVAL AND INSTALLATION .................... 22 MISCELLANEOUS VALVES ..........................23 12.1 EMERGENCY / PARKING BRAKE CONTROL VALVE (PP-1) ................26 12.2 EMERGENCY / PARKING BRAKE OVERRULE CONTROL VALVE (RD-3) ............26 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 314 EMERGENCY/PARKING BRAKE MANUAL RELEASE ..................50 19.3 BRAKE CHAMBER REMOVAL........................51 19.4 BRAKE CHAMBER INSTALLATION ........................ 51 19.5 BRAKE CHAMBER DISASSEMBLY........................51 ANTI-LOCK BRAKING SYSTEM (ABS) ....................... 52 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 315 BENDIX M-40QR PRESSURE MODULATOR VALVE ..................55 21.4 BENDIX ® SAS-70 STEERING ANGLE SENSOR ....................57 21.4.1 Removal of the steering angle sensor ....................57 FITTING TIGHTENING TORQUES ........................58 SPECIFICATIONS .............................. 59 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 316: Section 12: Brake And Air System

    SECTION 12: BRAKE AND AIR SYSTEM SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 317: Torque Tables

    ZF drive axle - hub to disc cap screws 221 lb-ft (300 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) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 318: Miscellaneous Torques

    Automatic drain valve mounting nuts to Consep 80-98 lb-in Dryer inlet and outlet manifold M22 banjo bolts 45-55 lb-ft Dryer control and purge manifold M12 banjo bolts 130-150 lb-in DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 319 Turbo protection valve 45-55 lb-ft Heater retaining screw 45-55 lb-in Valve unit bolts 62-80 lb-in * Hand tight first then tighten using wrench the number of turns specified in table. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 320: Air System

    FIGURE 1: WET TANK AUTOMATIC DRAIN VALVE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 321: Maintenance

    R.H. side door. This tank is used to dissipate heat and to reduce noise produced by the air compressor cycling on and off. The ping tank is not provided with a drain valve. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 322 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 2: AIR TANKS LOCATION – REAR END FIGURE 3: AIR TANKS LOCATION – FRONT END DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 323: Accessory Air Tank

    Lubrication And Servicing Schedule in Section 24A: LUBRICATION & SERVICING SCHEDULE. It is important to empty the tanks completely to ensure that water and moisture is totally evacuated from the tank. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 324: Emergency Air System Fill Valves

    FIGURE 5: AIR FILL VALVE IN FRONT SERVICE COMPARTMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 325: Accessory Air Filter

    The bowl is fitted with a manual/semi auto drain. Turn the drain valve to the ON position and then allow draining. Once purged, return to the OFF position. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 326: Air Gauges (Primary, Secondary And Accessory)

    Replace the gauge with a new unit if there is a difference of 4 psi (27 kPa) or more in the reading. FIGURE 12: ACCESSORY AIR FILTER ARRANGEMENT 8. AIR DRYER DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 327 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 13: AIR DRYER PLUMBING FIGURE 14: AIR DRYER CONNECTIONS SCHEMATIC DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 328 LOCTITE 567 thread sealant: Apply on all NPT threads Dual Consep Dual DRYest Air Dryers Cast Aluminum Purge Manifolds Cast Aluminum Outlet Manifolds Cast Aluminum Concep Manifolds Sealing Washers Banjo Bolts DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 329 By using the information from the vehicle included on your Technical Publications USB electronic system, the air dryer and compressor flash drive: control is optimized, so that drying of the air is DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 330: Replacing The Desiccant Cartridge

    3. Remove four retaining bolts from retaining collar. 8. Install desiccant cartridge into canister and rotate 45° to secure the cartridge to the canister. 4. Lift cartridge canister away from dryer base. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 331 Replace the air dryer desiccant cartridge at the intervals specified by the Lubrication & Servicing Schedule in Section 24A. 12. Using a cross pattern, tighten the four mounting bolts to 32-35 ft-lbs (43-47 Nm). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 332: Haldex Condenser - Separator

    Air compressor unload with activation of the rear stop lights to heat up Yellow air output to prevent it from freezing. However, Multiplex programming will ensure that the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 333: Nylon Tubing

    AIR LINE LEAKAGE TEST With air system fully charged and the brakes applied, coat all tubing and hose connections with a soapy solution to check for air leakage. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 334: Air Compressor

    6. Remove and retain the oil supply tube that runs between the compressor and the engine. 7. Reverse removal procedure for installation. FIGURE 18: AIR COMPRESSOR LOCATION DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 335: Miscellaneous Valves

    SECTION 12: BRAKE AND AIR SYSTEM 12. MISCELLANEOUS VALVES FIGURE 19 : PARTIAL PNEUMATIC DIAGRAM DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 336 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 20 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 337 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 21 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 338: Emergency / Parking Brake Control Valve (Pp-1)

    Maintenance and repair information on this valve is supplied in the applicable booklet, found on your Technical Publications USB flash drive, under reference number Bendix Service Data SD-03-3602. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 339: Dual Brake Application Valve (E-8P)

    NC relay to sound a warning alarm by completing the electrical circuit when the ignition key is turned OFF with parking brake released. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 340: Brake Relay Valve (R-14)

    Maintenance and repair information on the spring brake valve is supplied in the applicable booklet, found on your Technical Publications USB flash drive, under reference number Bendix Service Data SD-03-9043. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 341: Pressure Protection Valve (Pr-4)

    Maintenance and repair information on the pressure reducing valve is supplied in the applicable booklet, found on your Technical Publications USB flash drive, under reference number Bendix Service Data SD-03-3515. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 342: Antilock Modulator (M-32Qr)

    Maintenance and repair information on the inline quick release valve is supplied in the applicable booklet, found on your Technical Publications USB flash drive, under reference number Bendix Service Data SD-03-906. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 343: Emergency Door Opening Valves

    Additionally, a “push to exhaust” control valve is located in the front service compartment. Push two seconds to release air. The PP1 valve on the lateral console will pop up.(Figure 24) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 344: Air System Troubleshooting

    • Air system governor defective. Air pressure drops quickly when engine is stopped: • Leaks in compressor discharge valve. • Leaks in air lines. • Leaks in air system valves. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 345: Disc Brakes

    Section 24: LUBRICATION & SERVICING. impossible (due to corrosion or dirt) • A missing guide pin cap If an individual wheel has heated abnormally, please refer to Bendix BW7514_Single wheel DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 346 This checklist will help you through standard verifications required by the brake manufacturer before filing a warranty claim. FIGURE 25: INSPECTION POINTS IDENTIFICATION DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 347 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 26: DISC BRAKE COMPONENTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 348 SECTION 12: BRAKE AND AIR SYSTEM FIGURE 27: IDENTIFICATION OF GUIDE & SEAL VARIANTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 349: Visual And Functional Check

    Piping of the compressed air line • Example 1) E=0.748 in (19 mm) FIGURE 29:MAJOR BREAKOUTS ON THE SURFACE OF F=0.590 in (15 mm) > NOT OK THE BRAKE PAD ARE NOT PERMITTED DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 350 Example 1) G=21 mm H=18 mm > NOT OK Example 2) G=18 mm H=19 mm > OK FIGURE 33: BRAKE PAD WITH EXAGGERATED TAPER WEAR DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 351: Wear Check Of Disc

    FIGURE 34: BRAKE DISC THICKNESSES AND OPTICAL WEAR INDICATOR Check the discs per axle at each change of pads for grooves and cracks. If necessary, replace the disc. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 352: Wear Check Of Pad/Disc -Drive Axle - Equipped With L-Bracket Wear Indicator

    (FIGURE 38). If any minimal tolerance limits have been reached, the pads and/or disc must be changed. Refer to Knorr-Bremse Pneumatic Disc Brake Y006471 Service. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 353: Continuous Wear Sensor Option

    Jack up the axle and remove the wheel. Check the brake disc temperature, it should be between 14°F and 122°F (- 10°C and 50°C). FIGURE 38: PAD WEAR CHECK FRONT AND TAG AXLE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 354 0.051 in (1.3 mm) air gap has been achieved (measure between the brake pad and tappets (13). Apply the brakes 20x with medium pressure. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 355 (37) should be positioned as shown by the arrow in the adjacent figure. - Check for abnormal wear of the contact areas of the carrier. If necessary, replace the carrier. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 356: Caliper Check - Caliper Running Clearance

    (see 16.2.10 & 16.2.11). Guide Pins With the open bearing variant (6b), clean the protruding area of the guide pin (4b) from outside of the caliper and if neces- DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 357: Clearance Measurement Check Of Bearing Variants (6)

    Place a suitable tool (e.g. screwdriver with at least 200 mm in length) in a central position between carrier (2) and caliper (1) and lever them in opposite directions (us- ing normal hand-force). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 358: Checking Sealing Elements - Caliper Guide Pin Seals

    (see Figure 53). Knorr-Bremse Pneumatic Disc Refer to Brake Y006471 Service Manual. The tappets must not be extended more than 1.181 in / 30 mm, otherwise DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 359: Safe Service Procedures

    These tests require very little time to perform, and give you a general idea of the system condition. Each DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 360 • Listen for air leaks and repair. pressure warning lights should be "On". • Redo list to check all items repaired or 3. Start checking pressure at 50 psi (344 kPa). replaced. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 361 Bubbles will indicate an air leak, and none should be permissible. Repair or replace defective parts. • Listen for leaks and correct as required. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 362: Brake Chamber

    1/4 turn (clockwise) to anchor it into the spring plate. Install the flat washer and nut, Check all hoses and lines. They should be secure and in good condition. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 363: Brake Chamber Removal

    7. Remove the cotter pin connecting brake 1. Block the wheels to prevent the vehicle from chamber and adjuster (drive axle). moving. 8. Unbolt and remove the brake chamber from vehicle. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 364: Anti-Lock Braking System (Abs)

    SD-13-4986. Since the braking system has dual circuits, the ABS is also provided with a secondary system Maintenance should a fault develop in the ABS. Anti-lock DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 365: Sensors

    2. Insert spring clip in the holder on hub. Make sure the spring clip tabs are on the inboard side of the vehicle. Push in until the clip stops. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 366: Spring Clip

    Bendix ACom Even with ESC-equipped vehicles, the driver Diagnostics software. remains responsible for ensuring vehicle Bendix ACom Diagnostics software stability during operation. available for download at www.bendix.com. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 367: Components

    • An additional Modulator Valve (Bendix ® 40QR Pressure Modulator Valve) that controls pressure applied to the trailer brakes during system intervention. FIGURE 60: M-40QR PRESSURE MODULATOR VALVE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 368 ABS system, as well as lateral, yaw, and steering angle sensors. If the vehicle shows a tendency to leave an appropriate travel path, critical threshold values DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...

  • Page 369: Removal Of The Steering Angle Sensor

    6. Slide the sensor over the column to remove. Take note if the sensor label is facing Adjustment of the wheel alignment or wheel • upward or downward. track; Installation: DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 370: Fitting Tightening Torques

    (inch) manual tightening 3/8 to 1/2 5/8 to 3/4 3 ½ NOTE Use Loctite pipe sealant to seal pipe thread (Prevost number 680098). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 371 Spring Brake Valve Make .............................. Bendix Model ..............................SR-7 Brake Relay Valve Make .............................. Bendix Model ..............................R-14 Antilock Traction Relay Valve Make .............................. Bendix Model .............................. ATR-6 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 372 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 revised Jan 2021...
  • Page 373 COMPACT BEARING (HUB UNIT) GREASE CHANGE ..................21 TIRE MAINTENANCE ..........................22 11.1 INFLATION PRESSURE ..........................22 11.2 TIRE MATCHING ............................23 11.3 WHEEL BALANCING ............................. 24 11.4 TIRE ROTATION ............................24 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 374: Specifications

    SECTION 13: WHEELS, HUBS AND TIRES SPECIFICATIONS ............................25 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 375: Section Change Log

    SECTION 13: WHEELS, HUBS AND TIRES SECTION CHANGE LOG DESCRIPTION DATE Front and tag axle wheel hub insertion tool part numbers added Jan 2022 D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 376: Torque Tables

    *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 563-687 lb-ft (763-931 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 377: Front 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) D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 378: Wheels

    TORQUE : 450-500 lb-ft (610-678 Nm) FIGURE 2: TIGHTENING SEQUENCE 13018 3.2 SINGLE WHEEL REMOVAL FIGURE 1:STEEL WHEEL ARRANGEMENT 13001 1. Stop engine and apply parking brake. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 379: Single Wheel Installation

    2. Retighten the hex stud nut. TORQUE: 450-500 lb-ft (610-678 Nm) Repeat for each of the 10 "hex stud nuts" according to the tightening sequence in figure 3. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 380: Wheel Straightness Test

    • Check wheel lateral run-out as outlined in step 2; If, within specifications, the hub is correct • but the suspected wheel must be replaced. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 381: Wheel Studs

    M22 flange nut. FIGURE 4: DRIVE AXLE WHEELS 6.2 FRONT AND TAG AXLE WHEEL STUDS Wheel is hub mounted on front and tag axle (M22x1.5 thread). D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 382: Hub Mounted Wheels

    Torque relaxation occurs when wheel ends are hot but should revert to original setting when cool. Retightening when hot will produce a higher torque reading than recommended. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 383: Tag Axle Wheel Hubs

    FIGURE 6: TAG AXLE HUB AND ROTOR ASSEMBLY FIGURE 7: TAG AXLE UNITIZED BEARING & WHEEL HUB D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 384: Tag Axle Hub Unitized Bearing Inspection

    6. Loosen but do not remove the hub flange bolts. 7. Remove 2 diametrically opposed hub flange bolts. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 385 16. Using a small ended chisel, pry off the staking on the hub nut. 14. Tighten to free brake disc from hub bearing. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 386: Tag Axle Hub Bearing Installation

    (use Gleitmo 805 grease, Prevost #685274). FIGURE 15 19. Screw insertion tool onto spindle (Figure 16). insertion tool tag axle G32950 insertion tool front axle 491115 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 387 Always use an insertion tool FIGURE 20: INSTALL THRUST WASHER AND HUB NUT 9. Make sur there is no play between the bearing and the spindle shoulder. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 388 11. Stake the hub nut by deforming with a round nosed chisel. FIGURE 24: CORRECT – 2 to 3 mm / 0.078 to 0.118 in FIGURE 22 FIGURE 25: BROCKEN OR TORN LIP – REJECTED DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 389 Refer to Figure 32 for tightening sequence. TORQUE: 161-197 lb-ft (218-267 Nm) FIGURE 28 14. Install rotor onto hub bearing. FIGURE 31: HUB FLANGE HEX CAP SCREW D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 390 19. Position the stylus of dial test indicator onto brake disc as shown. FIGURE 34 20. Rotate the hub through 360° and note any movement of the dial test indicator. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 391: Front Axle Wheel Hubs

    0.20 mm (0.008”) for a bearing which has • been in service. Unitized bearing inspection should be made at the intervals specified by the Lubrication And Servicing Schedule Section LUBRICATION & SERVICING.. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 392: Front Axle Hub Bearing Removal

    Dana Parts & Service Instructions S84U Steer Axle HUB BEARING REWORK_ Manual NO 1963 A+B iss A. See OVERHAUL PROCEDURES, HUB END REASSEMBLY, pages No. B23 up to B30. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 393: Zf Drive Axle Wheel Hubs

    14mm hex socket driver “Allen” CHANGE IN THE HUB of the following manual: OPERATING INSTRUCTIONS ZF AXLE A132 (version with US hub) #5871 207 982 EN. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 394: Tire Maintenance

    At regular intervals, verify the tire pressures. Use an accurate tire pressure gauge when checking inflation pressures. Never exceed the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 395: Tire Matching

    1/8" (3 mm) of the same rolling radius. NOTE It is recommended that all tires on coach be of the same type. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...

  • Page 396: Wheel Balancing

    (from axle to axle), then tires should be rotated in such a manner as to alleviate the condition. NOTE There is no restriction on criss-cross rotation. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 397 Recommended tire inflation pressures and maximum allowable loads apply to speeds up to 65 mph (105 km/hr). Do not drive vehicle at a higher speed than 65 mph (105 km/h) or above the posted speed limit. D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual | Section 13 revised Jan 2022...
  • Page 399 Power Steering Fluid Visual Inspection....................19 13.2 POWER STEERING FLUID CHANGE ......................20 13.3 POWER STEERING FLUID TANK & FILTER ....................20 13.3.1 Fluid Level Check ..........................20 D DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 400 15.2 CAMBER CHECK ............................31 15.2.1 Front Axle Caster ..........................32 15.3 FRONT WHEEL TOE-IN ..........................32 15.3.1 Inspection and Adjustment ......................... 33 TROUBLESHOOTING............................35 SPECIFICATIONS .............................. 36 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 401: Section Change Log

    SECTION 14: STEERING SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020)

  • Page 402: Torque Tables

    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) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 403: Miscellaneous Torques

    Tie rod end clamp bolts - I-Beam Axle 118-133 lb-ft (160-180 Pitman Arm Fixing Nut 470-570 lb-ft (637-773 Steering Gear Mounting Bolts 365-405 lb-ft (495-549 Drag Link Clamp Bolts - I-Beam Axle 118-133 lb-ft (160-180 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020)
  • Page 404 Drag Link Ball Joint Stud Nut (Fore) - I-Beam 165-236 lb-ft (224-320 Drag Link Ball Joint Stud Nut (Aft) - I-Beam 140-200 lb-ft (190-271 Power Steering Pump Housing 15-21 lb-ft (20-28 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 405: Steering System Description

    FIGURE 1: I-BEAM AXLE STEERING SYSTEM SETUP 14041 14076 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020)

  • Page 406: Power Steering Gear

    The valve slide, designed with steering procedure of the steering gear. shaft connection, turns together with the worm as the steering wheel is turned. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 407: Power Steering Gear Removal

    1. Tighten fasteners as recommended. TORQUE: 365-405 lb-ft (495-549 Nm) 2. Bleed air from the system as per paragraph (Bleeding power steering hydraulic system). FIGURE 4: PITMAN ARM ADJUSTMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 408: Bleeding Power Steering Hydraulic System

    Only unfasten the bolts marked with arrows. from the pump or lines. 7. Unfasten the 3 power steering pump bolts. NOTE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 409 Use a new sealing ring. Check that the fuel pump drive axle sits correctly in the power steering pump. 11. Start the engine and let run for 5 minutes. Make sure that there are no leaks. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 410: Steering Column Removal

    2. Unscrew the four retaining screws on steering column middle cover. 3. Unscrew the four retaining screws fixing steering column upper cover to middle cover. Remove the steering column middle and upper covers. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 411: Steering Wheel

    4. Unscrew the steering wheel nut. To simplify 3. Tighten steering wheel retaining nut. installation ensure steering wheel TORQUE : 35-45 lb-ft (47-61 Nm) alignment, mark the relationship of the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 412: Clockspring Replacement

    50° clockwise (Figure 14). This step is necessary for the installation of the steering wheel. FIGURE 15: STEERING STOP SCREW ON I-BEAM AXLE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 413: Steering Linkage Adjustment

    Refer to section 10 "Front Axle" under heading 6. "Front Wheel Alignment". DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 414: Installation

    Tighten nut and install a new cotter pin. Depending on axle type, select the appropriate torque, FIGURE AXLE UNLOADING SWITCH TORQUE: 165-236 lb-ft (224-320 Nm) ADJUSTMENT 14061 CAUTION Input shaft marks must be aligned before DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 415: Drag Link

    Lengths V and W should be measured prior to removal to restore the steering system to its original state. FIGURE 19: DRAG LINK DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 416 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 ± DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 417: Steering System Maintenance

    Lubrication fittings must all be cleaned before applying lubricant. Moreover, always be sure the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 418: Power Steering Fluid Change

    3. Thoroughly clean the tank and its immediate right side of the engine compartment, accessible vicinity to protect the fluid from being soiled by the engine compartment door. by impurities. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 419: Filter Element Replacement

    10. Transfer the screw to the new filter and insert it into the oil tank. 11. Check that the filter is positioned correctly and is locked in place securely. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 420 Tighten the clamps to 30 lb-ft (41 Nm) 13. Top up with fresh oil to the MAX marking. 14. Double check cleanliness of cap and install. 15. Discard the oil collected during the filter change. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 421: Steering System Play Inspection

    If the steering linkage is in FIGURE 27: STEERING STABILIZER (DAMPER) good condition, then the steering column and steering gear should inspected. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 422: Drag Link Maintenance

    When play is discovered in the adjusting system, replace complete drag link. FIGURE 30:TIE ROD COMPONENTS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 423 SECTION 14: STEERING CAUTION Do not re-use tie rod joint nut. Joint nuts should be replaced every time they are unscrewed. additional details, refer supplier information: TRW_Front_Axle_Steering_Bar_Service_Inf ormation_XSZ143 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 424: Tie Rod Inspection Procedure

    0.020" (0.5 mm) into the housing. Replace the joint if the movement of the ball stud exceeds 0.020" (0.5 mm) axially in the housing. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 425: Tie Rod Ball Joint Inspection For Corrosion

    Clean corrosion on the axle steering lever sealing boot or dirt seal, clean and eliminate contact faces also. all surface irregularities. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 426: Straight Body Type Ball Joint

    Any movement detected by hand will require the replacement of the ball FIGURE 37: ADEQUATE CLAMPING CONDITION joint. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 427: Driving Tips

    Every 200,000 miles (320 000 km) or 24 months (normal maintenance); Perform the minor front wheel alignment in the following sequence: When the vehicle does not steer correctly; DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 428: Major Front Wheel Alignment

    Check if front tires rub against the frame or if the socket body with the air bellows support steering gear has been serviced. assembly. Measure the distance between those two points. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 429: Hydraulic Stop

    4. Check the wheel lateral distortion instructed in Section 13, ‘’Wheels, Hubs and Tires’’ under heading, ‘’Checking for Distorted Wheel on Vehicle’’. If distortion is excessive, straighten or replace wheel(s). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 430: Front Axle Caster

    (Prevost #110663) on the DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 431: Inspection And Adjustment

    Turn the adjuster sleeve (Figure 41) until the specified toe-in measurement is obtained. Tighten the pinch bolt nuts TORQUE: 118-133 lb-ft (160-180 Nm) FIGURE 41: FINE ADJUSTER SLEEVE ON TIE ROD DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 432 Front Wheel Minimum Nominal Maximum Alignment Camber -0.250 0.125 0.375 R.H. and L.H. (degrees) Caster 2.75 R.H. L.H. (degrees) Total toe 0.04 0.06 0.08 (A minus B) (degrees) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 433: Troubleshooting

    2. Wheels and/or tires out-of balance. 2. Balance or replace wheels and/or tires. operation. 3. Worn steering stabilizer cylinder. 3. Replace steering stabilizer cylinder. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 434: Specifications

    Stroke............................. 12.47±0.12" Front I-Beam Axle Make ......................... DANA SPICER EUROPE Model ............................... S84U Front Track ......................84.4 inches (2 145 mm) Rated load capacity ....................16,500 lbs (7 500 kg) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 435 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 436 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 437 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 438 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 439 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 440 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 •...
  • Page 441 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 442 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 443 IS-20913A Instruction Sheet POWER STEERING 20 ft STAINLESS STEEL PIPE REPAIR PROCEDURE This instruction sheet is applicable to the following: DOB Bus Number Series 1300 – 1606: power steering pipe #160089 Revision A Addition of ORS plug in Other Material Apr-24-2020 MATERIAL Abutment repair:...
  • Page 444 IS-20913A Page 2 / 13 OTHER MATERIAL EATON AEROQUIP ORS PLUG FF9767-10S Qty: 2 TORQUE SEAL OIL DRAIN PAN MOBIL DEXRON-VI ATF (AUTOMATIC TRANSMISSION FLUID) As required TOOLS TO BE USED HACKSAW or CUTTING WHEEL & POWER TOOL ADJUSTABLE HEAVY-DUTY WRENCH RATCHET AND SOCKET SET –...
  • Page 445 PERSONAL PROTECTIVE EQUIPMENT Wear your personal protective equipment, including but not limited to the followings: Safety shoes Safety goggles General purpose gloves DANGER Wear eye protection and remove rings, metal jewelry and watches with metal bands. DANGER Wear protective glasses when striking objects to avoid injury to your eyes.
  • Page 446 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. Lock out &...
  • Page 447 IS-20913A Page 5 / 13 3. Disconnect the blue power steering hoses at each end of the defective pipe. Have a container, as power steering fluid will drip from the pipe and hose. 4. Plug each blue hose with an ORS plug FF9767-10S. 5.
  • Page 448 ALONG THE PIPE REPAIR 1. The power steering pressure and return pipes (green pipes on ) measure 20 ft long Figure 1 and are made of stainless steel. They are 5/8 OD. 2. To prevent skin burns, make sure that steering fluid has sufficiently cooled before starting the next steps.
  • Page 449 IS-20913A Page 7 / 13 FIGURE 6: PIPE CLAMPS LOCATION & TYPE 9. Using two ORS-TF REPAIR KIT #501157 and one ORS-ORS ADAPTER FF2000T-1010S #501156, install the repair fittings as described in section ASSEMBLY INSTRUCTION ORS- TF TUBE FITTING. 10. At the front of the vehicle, pull on the blue power steering hose to take up the slack as the ORS-ORS adapter adds 43 mm to the total length of the line.
  • Page 450 ASSEMBLY INSTRUCTION ORS-TF TUBE FITTING FIGURE 10 FIGURE 11: ABUTMENT REPAIR FIGURE 12: ALONG THE PIPE REPAIR 1. Inspect the tubing to insure that no scratches, gouges, burrs or other surface defects like welding bead are present. 2. Cut the tubing squarely (±1°). Use a hacksaw or abrasive cutting wheel. 3.
  • Page 451 IS-20913A Page 9 / 13 FIGURE 13: DEBURR THE TUBE END - INNER FIGURE 14: DEBURR THE TUBE END - OUTER 4. Inspect ORS-ORS adapter and ORS-TF components for damage. Assure sealing surfaces are free from all surface gouges, scratches, dirt and contaminants. Inspect O-ring to make sure that it is properly seated in the groove and is free from damage.
  • Page 452 IS-20913A Page 10 / 13 FIGURE 16 FIGURE 15: PLACE A NUT, FERRULE AND SLEEVE ONTO TUBING FIGURE 18: MARK THE NUT IN RELATION WITH THE ORS-ORS ADAPTER AND TIGHTEN 1 ½ TURNS WITH A WRENCH (IMAGE FIGURE 17: ASSEMBLE THE NUT TO THE ORS-ORS NOT SHOWING REAL BUS CONDITION) ADAPTER UNTIL HANDTIGHT (IMAGE NOT SHOW- ING REAL BUS CONDITION)
  • Page 453 APPENDIX A FILLING AND BLEEDING THE SYSTEM FLUID FILLING 1. In the engine compartment, on engine curbside, remove the tank cover and place the nut on the spring to maintain normal pressure on the filter in the tank. FIGURE 19: POWER STEERING FLUID TANK, ITEM 8 ON PICTURE ABOVE 2.
  • Page 454 Use a pair of low profile jack stands to support the front axle beam. Always place safety stands when working under the vehicle. Refer to Maintenance Instruction MI14-01B Hoisting and Towing Procedure for NYCT X3-45 Commuter Buses for further details on lifting procedures and safe lifting practices.
  • Page 455 IS-20913A Page 13 / 13 STEERING GEAR WITH BLEEDER/BLEEDER SCREW Refer to paragraph 5.4.3 Bleeding of RB Robert Bosch Servocom Service Manual (8090) available on the Technical Publications site. https://techpub.prevostcar.com/en/down- load?id=352&type=publications FIGURE 21 : BLEEDER (item 57) & BLEED SCREWS 1.
  • Page 457 NORMAL RIDE HEIGHT ..........................19 HEIGHT CONTROL VALVES ........................... 20 MAINTENANCE............................. 20 6.3.1 Removal and installation ........................20 6.3.2 Air leakage test ............................ 20 FRONT KNEELING SYSTEM ..........................21 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 458 PRINCIPLE OF OPERATION ........................... 21 MAINTENANCE............................. 21 AIR SPRING CONTROL SOLENOID VALVES (REMOVAL & INSTALLATION) ............ 21 ACCESSORY AIR TANK MAINTENANCE ......................21 TROUBLESHOOTING ............................. 22 SPECIFICATIONS ............................23 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 459: Section Change Log

    SECTION 16 : SUSPENSION SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 460: Torque Tables

    SECTION 16 : SUSPENSION TORQUE TABLES FRONT I-BEAM AXLE AND RELATED COMPONENTS 16187 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 461: Description

    Steering damper arm nuts 285-315 lb-ft (386-427 Nm) Drag link ball joint stud nut, aft 140-200 lb-ft (190-271 Nm) * Use medium strenght thread locker on threads (Loctite 243 or equivalent) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 462 SECTION 16 : SUSPENSION REAR SUSPENSION 16206: ZF drive axle 16159_B DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 463 SECTION 16 : SUSPENSION 16159 16160_B DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 464 Tag Axle Radius Rod Stud 90-110 lb-ft (122-149 Nm) * Use medium strength thread locker on threads (Loctite 243 or equivalent) NOTE Apply corrosion-protective compound on exposed threads. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 465: Front I-Beam Axle Suspension

    Bubbles will (normal ride height). indicate an air leak, and none is permissible. Remove wheel. Repair or replace defective parts. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 466: Installation

    DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 467: Inspection

    (with Deep cracks bushing material washer convex side facing the shock (shallow surface cracks are normal); absorber rubber bushing) on each shock extremity. Loose shock absorber pins; DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 468: Radius Rods

    If damage to the inner housing contour or the Circlip groove is found during replacement of the molecular bearing, the entire radius rod must be replaced. FIGURE 6: BALL PIN JOINT CONSTRUCTION 16186 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 469: Radius Rod Removal

    A complete repair set must be used for each joint repaired, i.e. use of only part of a repair set is not permissible. Execute assembly of the new joint parts in the following sequence: DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 470: Radius Rod Installation

    Otherwise, the rubber bushings in radius rod ends will become preloaded, thus reducing their life span. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 471: Rear Suspension

    SECTION 16 : SUSPENSION REAR SUSPENSION FIGURE 9: DRIVE AXLE, REAR SUSPENSION FIGURE 10: TAG AXLE SUSPENSION 16106 FIGURE 11: REAR SUSPENSION COMPONENTS 16184.2.1 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 472: Air Springs

    Thread the lower nuts and the To prevent personal injury, do not apply more small upper nut a few turns. than 10 psi (69 kPa) of air pressure to the uninstalled air spring. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 473: Shock Absorbers

    If a both rebound and compression. shock absorber becomes inoperative, complete 6. Visually inspect the shock mountings and unit must be replaced. vehicle mounting for: DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 474: Removal

    2. Install new upper rubber mounting bushings axles to the vehicle body. on shock absorber. Refer to section 2.3 for more information regarding radius rods. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 475: Suspension Air System

    Y = 11 ½ ± 1/4 inch (292 ± 6 mm) connections and air spring mountings with a solution of soap and water. Air leakage will DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 476: Maintenance

    DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 477 “Brake and Air System” for more information height control valve is bypassed to ensure no air regarding air tanks location and function. is forwarded to air springs while lowering the front suspension. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 478 Install cover using new gasket. Defectives valves. Overhaul height control valve assembly Vehicle body fails to level to Improper height control valve control Adjust lever as directed. satisfactory ride height arm adjustment DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 479 Collapsed length ........................15.51” (394 mm) Extended length ........................24.37” (619 mm) Bellows control and exhaust solenoid valve assembly Make ..............................Norgren Coil Voltage .............................. 24 V DC Current draw ..........................29 amperes DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 481 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 482 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 483 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 484 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 485 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 486 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 air springs clearance (two air springs). To do so, measure the clearance between the support above the air spring and the lower...
  • Page 487 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 bracket has a...
  • Page 488 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...
  • Page 489 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 490 MI16-14 / Page 10 / 10 <QF7720955 rev 6>...
  • Page 491 10.2.2 Emergency Exit Windows ........................45 10.2.3 Roof Escape Hatch ..........................47 10.3 ZONE 3 ................................. 49 10.3.1 Rear Cap ............................... 49 10.3.2 Engine Compartment Door ........................49 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 492 Front Steps Replacement Procedure ....................94 12.3.2 Welding Of Joint Between White Safety Strip And “Tarabus” Floor Covering ........97 12.3.3 Repair Of A Welded Joint ........................99 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 493: Section Change Log

    SECTION 18: BODY SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 494: Torque Tables

    SECTION 18: BODY TORQUE TABLES BODY INTERIOR DESCRIPTION TORQUE 27 lb-ft (37 Nm) Passenger fixed seat mounting nuts (sidewall/pedestal) 15-20 lb-ft (20-27 Nm) Passenger sliding seat mounting nuts to pedestal DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 495 SECTION 18: BODY BODY EXTERIOR DESCRIPTION TORQUE Compressor door arm adjustment bolts 14 lb-ft (19 Nm) Radiator door hinges bolts 68 lb-in (8 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 496: Vehicle Exterior

    19. Evaporator compartment 9. Entrance door control switch 20. Air dryer compartment 10. Entrance door 21. Radiator door 11. Electric destination sigh or route number 22. SCR converter access door DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 497: Vehicle Jacking Points

    These places accumulate dirt and salt DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 498 It should not be used for exterior side paneling. Extreme care should be taken not to sandblast excessively. 3. Apply correct primer, paint and undercoating after removing all corrosion to prevent further damage. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 499: Preventive Maintenance Schedule

    TRACKS. INSPECT WALL PANELS FROM BOTTOM TO WINDOWS FLOOR CLEAN FLOOR COVERING AS CLEANING NECESSARY WARNING Failure to follow this preventive maintenance schedule will result in warranty void. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 500: Rust Inhibitor Application

    3.0 Front wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking. 3.1 Front wheelhousing Front view DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 501 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) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 502 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 503 Use the following table to determine dew point.: Surface temperature > 10°C Surface temperature > or = to dew point + 3°C Check and confirm that TECTYL temperature is between 10°C and 35°C. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 504 12 17 20 23 26 28 30 32 13 17 21 24 27 29 31 33 14 19 22 25 27 30 32 34 15 20 23 26 29 31 33 35 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 505: Common Fiberglass Repair Procedure

    Where necessary, sand paint away around damaged area and scrape away undercoating, if any, and wipe clean with solvent. Grind or file the damaged area to form a "V" at the broken or DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 506: Repair Using Fiberglass Paste

    Apply more layers of mat and cloth as required until the desired strength and thickness is obtained, minimum two 1-½ oz (43 g) mats and one 9 oz (255 g) cloth (Figure DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 507: Common Painting Procedure

    • transmission fluid or windshield solvent on new finish. IMMEDIATELY rinse off any such spill with clean water, DO NOT WIPE; FIGURE 6: FIBERGLASS REPAIR 18093 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 508: Paint Touchup

    9.3.2 Surface Preparation and Paint Application Aluminum and / or Fiberglass Comments Stainless Steel DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 509 Product listing above is based on factory applied products. Local VOC (Volatile Organic Compound) regulations may vary, consult your paint supplier and use a VOC compliant product that matches the factory recommendations if required to do so. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 510: Coach Exterior Finishing And Body Repair

    The paragraph divides the vehicle into zones to facilitate the search; each zone is then sub- divided into components. Refer to the appropriate zone and component for complete procedure. FIGURE 7: COACH ZONING DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 511: Zone 1

    SECTION 18: BODY 10.1 ZONE 1 FIGURE 8: ZONE 1 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 512: Front Bumper

    WARNING Bumper spring is under heavy tension; do not pry out the spring hook without completely removing the spring tension. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 513: Headlights

    Assembly • Mount the mirror arm base to the coach. Insert the ball stem into the mirror arm and tighten the socket set screws. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 514 Remove the ball stud. Remove the ball stud from dampen vibration. It is soft and can be cut fairly the arm and gently pull the harness out until the easily. connector is exposed. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 515: Windshield Wipers

    Prevost Service Center. Hydrophobic compound specially formulated for Prevost and can only be applied DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 516 Spray soapy water onto rope and hinged door and push the windshield on the rubber extrusion (Figure 20). R.H. side. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 517 Make sure windshield bottom edge is well inserted into the rubber extrusion groove FIGURE 23: STEPS 9 TO 11 before proceeding with the sides. Check the insertion inside and outside of the vehicle. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 518 12. 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. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 519 FIGURE 28: SECTION B-B FIGURE 26: SEAL TYPICAL SECTION PLANS FIGURE 29: SECTION C-C FIGURE 27: SECTION A-A FIGURE 30: SECTION D-D SEALANT APPLICATION DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 520 7. Install black seal on the fiber in the center of the frame (step 1). NOTE Do not use soapy water for this step. FIGURE 32: ADHESIVE LOCATION IN SEAL DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 521 16. Complete installation of the upper section of the seal (steps 13 and 14). 11. Insert the black seal in lower center (step 7). 12. Fit the seal toward the sides (step 8). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 522: Entrance Door

    R.H. door panel cylinder on the door hinge. Door activation is controlled by a panel (Figure 41), located near the defroster and wiper motors. The accessory air reservoir supplies air to this system. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 523 When the sensor lateral control panel. signals the door as closed, the air lock solenoid DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 524 To open the door in an emergency, pull the knob to release the air pressure. Push the lateral FIGURE 47: TO OPEN THE DOOR control panel relief valve down to reapply air pressure for normal operations. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 525 To adjust opening and closing cycle speed on damper (Figure 54): 1. Remove the damper from the vehicle and hold it vertically with the lower eye or pin DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 526 Horizontal and vertical adjustment 1. Support the door panel with a wooden block and a hydraulic jack. 2. Unfasten the bolts fixing the door panel plates. See Figure 55 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 527 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. Tighten the bolts. Remove the jack and the wooden block DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 528 Check ground circuit. WHEN DOOR IS CLOSED. Lock solenoid works in reverse. Reverse air hoses at solenoid locks. Relay does not function. Replace relay. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 529: Front Service Compartment Door

    Sika bead from each door frame edge. 6. Using a razor sharp window scraper, remove from door frame the Sika bead and double- face self-adhesive tape residue. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 530 18. Check body panel flatness using a 2-foot ruler (must be within 2mm). FIGURE 59: GLUE APPLICATION LAYOUT 16. Position skin panel onto door frame and compress with your hands. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 531 Figure 63. FIGURE 64: ANTI-FRICTION SIDE 23. From inside the door, apply some Sika 252 at the corners of window wiper. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 532 FIGURE 66: ANTI-FRICTION SIDE the side panel. 25. Install rub rail with fixing bolts. 26. Install windshield washer reservoir, new reflector amber #930212, door lock, handle and power window connector. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 533 9. Clean bottom of driver’s window using FIGURE 70: SEAL INTERSECTION window cleaner. 3. Clean window using window cleaner. 10. Apply Sika Aktivator at the bottom of driver’s window. 4. Insert window into frame. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 534: Front Cap

    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” paragraph “COMMON PAINTING PROCEDURE”. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 535: Zone 2

    In addition, when it becomes necessary to lay down the unprotected edges of the glass window, never use a steel or concrete floor as DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 536 Emergency Exit Window Adjustment • ergency exit windows should be checked periodically for easy opening and closing. Pulling the lower part of the release bar with both hands DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 537: Roof Escape Hatch

    See Figure 79. heading "Sealing" this paragraph procedures on how to seal this area. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 538 4 flat washers. Reinstall the 9. Remove excess adhesive and clean all panel assembly by fastening the 2 hinges with around. the 4 bolts and flat washers removed earlier. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 539: Zone 3

    Consult the “BODY PANEL AND WINDOW SPACING DIAGRAM” for proper door gaps 1. Open the door to access the striker pin. adjustment. (Figure 152) 2. Slightly loosen the striker pin. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 540 3. Adjust the door position according to distance required between exterior finishing parts. 4. Tighten the nuts. 5. Check that the door swings freely and closes properly. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 541: Rear Fender

    FIGURE 84: LEFT REAR FENDER LATCHES To lift a rear fender: FIGURE 85: SECONDARY LATCH 1. Push rod sideways on latch A and B (image above); DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 542: Engine Compartment R. H. Side Door Adjustment

    26 mm (1”) from the mounting face. FIGURE 87: BALANCING ARM MOUNTING SCREWS A) SCREWS B) BELLEVILLE WASHERS 3. Loosen adjustment bolts of the latches (4). FIGURE 90: STOPPERS INITIAL ADJUSTMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 543 95 flush with the door surface within a tolerance of ±1mm. C) FLAT WASHERS D) NUTS 8. Close the door gently. 9. Adjust the vertical angle of the door. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 544 17. Adjust roller support and tighten bolts (4) with the roller in place (door closed). FIGURE 97: LOWER ARM ADJUSTMENT SCREW 13. If previous step does not allow enough adjustment, move to next step. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 545 13/32” (10mm) behind the strike plate. 13/32” (10mm) min FIGURE 104: FRONT LATCH STRIKE PLATE FIGURE 102: REAR LATCH ADJUSTMENT 23. The front latch bolt has to be flush with the striker. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 546: Engine Radiator Door

    "LEFT or RIGHT". 2. Loosening the bolts (“B” and “D”, Figure 108) allows the door to be shifted "UP or DOWN". DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 547 (10mm). Add spacers between the latch and the vehicle body to adjust the engagement. NOTE There should be no gap between the washer and the hinge upper and lower halves. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 548: Zone 5

    FIGURE 111: BAGGAGE COMPARTMENT DOOR For the removal and installation of a baggage compartment door body panel, you will need: A drill with drill bits; DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 549 FIGURE 113: DOOR MOUNTING SCREWS 8. Center door in the opening using the retaining rings. Adjust the lateral position by adding or removing retaining rings in the location shown in Figure 114. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 550 16. Tighten cylinder block fixing screws. 17. Door bottom edge compression can be adjusted by moving in or out the pantograph arms at this location. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 551: Wcl Cassette Compartment Door

    5. Refer to SAV10054-67. Compartment Door Adjustment 6. Refer baggage compartment door procedure. WCL Cassette Door Adjustment FIGURE 121: WCL CASSETTE COMPARTMENT DOOR DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 552: Baggage Compartment Floors

    To allow adjustment of the latch mechanism, lightly tighten retaining hardware receptacle and striker support (arrows in Figure 124). 11. Place centering tool G34148_500 in the receptacle cavity. Cover and protect damaged area surroundings. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 553 Allow drying for at least 2 hours then repaint as per paragraph: Minor Repair. Baggage Compartment Floor Installation • Preparation and Installation Clean baggage compartment support structure using anti-silicone. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 554 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. Clean panel underside and edges. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 555 Front finishing joint In the case of front finishing joint, apply some masking tape on each side of joint. Section 2 Flat joint in front of fuel tank access panel DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 556 SECTION 18: BODY Use plastic spatula #682838 to perform radius Remove masking tape. Smooth down joints using soapy water. Rear baggage compartment equipped with WCL Rear baggage compartment without WCL. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 557: Evaporator Compartment Door

    17. For the ‘’Z’’ direction, adjust the top of the door panel between 5.5 and 6 mm from the horizontal trim as shown in Figure 128. FIGURE 126: VEHICLE XYZ DIRECTIONS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 558 21. On the striker side, the locking device is used to adjust the ‘’Y’’ direction. 22. To allow adjustment of the latch mechanism, lightly tighten the retaining hardware on receptacle and receptacle support to frame. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 559: Condenser Compartment Door

    FIGURE 135: CONDENSER DOOR DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 560: Fuel Filler Door

    6. Check that the door swings freely and closes properly. It may be necessary to adjust the door latch to get proper fit and operation. 10.5.6 Fuel Filler Door 1. Open the fuel filler door. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 561: Zone 6

    4. Front fenders are kept in place with glue, screws and rivets. Remove fender fasteners (screws and rivets) and move slightly out the fender. FIGURE 140: VERTICAL TRIM DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 562 8. Install rub rails, entrance door switch and (#683083). lights on the new fender. 9. Apply glue Simsons 70-03 (685126) on the fender mounting faces as shown in Figure 144. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 563 FIGURE 148: TRIM COMPRESSING 19. Compress a 2 time the trim, while slightly tilting the roller head towards the visible side 20. Reinstall the vertical trim. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 564: Zone 7

    Sika 221 gray √ √ √ CHIX cloth (682384) Sika 205 1liter (683097) Sika 252 black √ √ √ Blue cloth (682383) √ Equipment: Glue gun √ Pencil √ DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 565 206 G+P primer. Check panel horizontal supports for straightness Tolerance : 1mm towards the outside and 1.5mm using a straight edge. Take measurements with a towards the inside. ruler. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 566 Minimum time : Wait for product to evaporate After 2 hours: Start cleaning operation again If surface seems dusty, greasy or with finger marks, start Before applying any other cleaning operation again. product DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 567 After 2 hours : Reactivate surface with Sika 205 If surface seems dusty, greasy or with finger marks, start Before applying any operation again. other product DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 568 Section A-A Section B-B Section C-C – Onto vehicle surface – Cut nozzle as per template – Use the guide for the application Bead must be continuous for the whole perimeter. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 569 Make sure the equipment pulls along the whole width of Pull side panel so that panel moves 1/8” side panel Perform tig spot welding Quantity of "tig spot": 30 minimum. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 570 221 adhesive to fill the cavity between the panel and vehicle structure. Clean using Sika 205. Allow 5 minutes minimum for drying. Wear surgical gloves and smooth down the joint with your finger. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 571 Triangular bead: 10mm x 8mm Install panel onto structure Use a jig to make sure that panel is lined up with engine door tubing. Use a brush to compress Sika bead DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 572 Sika 205 reaches as far as the corner. See SAV00001 section C. Apply Sika 252 black at the junction of both tubing. Smooth down the joint Remove protective tape DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 573: Body Panel And Window Spacing

    SECTION 18: BODY 11 BODY PANEL AND WINDOW SPACING FIGURE 152: BODY PANEL AND WINDOW SPACING (CURB SIDE) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 574 SECTION 18: BODY DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 575 SECTION 18: BODY FIGURE 153: BODY PANEL AND WINDOW SPACING (CURB SIDE) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 576 SECTION 18: BODY FIGURE 154: BODY PANEL AND WINDOW SPACING (FRONT) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 577 SECTION 18: BODY FIGURE 155: BODY PANEL AND WINDOW SPACING (REAR) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 578 SECTION 18: BODY FIGURE 156: BODY PANEL AND WINDOW SPACING (WCL DOOR) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 579: Passenger Seats

    NOTE Cleaning With Covers in Place • Seats on one row are not interchangeable with seats of the other row. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 580: Amseco Sliding Seats

    12.2.2 Amseco Sliding Seats Torque: 15 to 20 lb-ft (20-27 Nm) Pedestal spacing adjustment DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 581 10. If too easy or too hard, make plunger 17. Repeat previous steps other adjustments as required. pedestal. 11. If the pedestal is too loose or too tight, you can adjust as the following steps. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 582: Tarabus Floor Covering Repair Or Replacement

    7. Compress floor covering using a roller so as to remove any trapped air bubble. 8. Apply Sikaflex 221 gray sealant (680532) alongside passenger seat fixing tracks (refer to Figure 167). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 583 SECTION 18: BODY FIGURE 166: TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 167: APPLICATION OF SIKA 221 GRAY 18641 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 584: Front Steps Replacement Procedure

    After 2 hours: Start cleaning operation again Before applying any other If surface seems dusty, greasy or with finger marks, start cleaning operation again. product 3. Apply Sika Primer 215 (refer to Section D). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 585 10 minutes etc.) After 2 hours : Reactivate surface with Sika 205 Before applying any other If surface seems dusty, greasy or with finger marks, start operation again. product DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 586 7. Clean top of step nosing using Sika 205 (refer to Section B). 8. Apply some Sika 221 onto white safety strip, spread with a spatula to cover the whole surface. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 587: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering

    There should be no excess of adhesive on top of surfaces, clean if required using “All-Sol”. 7. Once the welding torch is ready, insert the 3. Chamfer the joint. filler bead into the nozzle and immediately DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 588 10. Shave filler bead to make it level to the floor. supplied knife designed that purpose. NOTE To facilitate the cut, you can spray some soapy water onto the joint. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 589: Repair Of A Welded Joint

    3. Always add an extra inch of filler bead at the beginning and at the end of repair. 4. Perform steps 9, 10 and 11 in section 11.3.2. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 591 (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 592 MI15-41 / Page 2 / 4 High PH cleaning product compatible with polycarbonate - product sheet FIGURE 1: PRODUCT SHEET QF7720956 rev3>...
  • Page 593 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 594 MI15-41 / Page 4 / 4 QF7720956 rev3>...
  • Page 595 MAINTENANCE Mi14-01E INFORMATION DATE: JANUARY 2014 SUBJECT: HOISTING AND TOWING PROCEDURE FOR 45 COMMUTER BUSES APPLICABLE TO: DOB Bus Number Series 2400–2489 DOB Bus Number Series 2490–2789 DOB Bus Number Series 1300–1606 Addition of comments following front tow demonstration at Zerega CMF, Bus 2491, March 2014 Revision A: Addition of comments following rear tow demonstration at Zerega CMF, Bus 2425, December 2013 MI14-01A merged with MI12-03.
  • Page 596 Table of contents HOISTING AND TOWING POINTS ........................3 GENERAL DESCRIPTION ..........................3 CHASSIS HOISTING POINTS .......................... 3 AXLES HOISTING POINTS ..........................5 WHEELS AS HOISTING POINTS ........................9 TOWING ..............................10 BEFORE TOWING PREPARATION ........................ 11 2.1.1 Electrical Power and Air Supply......................12 2.1.2 Mechanical release of the emergency/parking brake ................

  • Page 597: Hoisting And Towing Points

    1 HOISTING AND TOWING POINTS 1.1 GENERAL DESCRIPTION This procedure applies to NYCT X3-45 Commuter buses DOB bus number series 2400–2489; 2490–2789 and 1300–1606. There are several hoisting and towing points. Use only these points when performing hoisting and towing of the bus (Figure 1).
  • Page 598 FIGURE 2: CHASSIS HOISTING POINTS FIGURE 3: CHASSIS HOISTING FIGURE 4: CHASSIS HOISTING - AFT OF TAG AXLE RECEPTACLES - AFT OF TAG AXLE RECEPTACLES - AFT OF FRONT AXLE FIGURE 5: JACK STAND AT CHASSIS HOISTING FIGURE 6: JACK STAND AT CHASSIS HOISTING RECEPTACLE - AFT OF FRONT AXLE, ROAD SIDE RECEPTACLE - AFT OF FRONT AXLE, CURB SIDE FIGURE 7: JACK STAND AT CHASSIS HOISTING...

  • Page 599: Axles Hoisting Points

    FIGURE 9: 10-TON CAPACITY JACK STAND FIGURE 10: 16500 LBF FIGURE 11: 20-TON CAPACITY JACK CAPACITY STAND WARNING Prior hoisting, park the bus on a level surface and apply parking brake. The bus can be supported at the chassis hoisting pads (refer to HOISTING AND LIFTING POINTS diagram).
  • Page 600 WARNING The suspension must be in the normal ride position before hoisting. WARNING To prevent damage to suspension components, always unload the tag axle before hoisting the bus. WARNING The hoisting points on the tag axle must be used for raising the tag axle only. Mi14-01E Page 6 / 38 Rev: Oct 2021...
  • Page 601 FRONT AXLE HOISTING POINTS – DOB Bus Number Series 2400–2489 Figure 12: FRONT AXLE HOISTING POINT - CURBSIDE Figure 13: FRONT AXLE HOISTING POINT – ROAD SIDE FRONT AXLE HOISTING POINTS – DOB Bus Number Series 2490–2789 and 1300–1606. FIGURE 15: FRONT AXLE HOISTING POINT – ROAD SIDE FIGURE 14: FRONT AXLE HOISTING POINT - CURBSIDE Mi14-01E Page 7 / 38 Rev: Oct 2021...
  • Page 602 DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB Bus Number Series 2400–2489 Figure 16: DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB BUS NUMBER SERIES 2400–2489 DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB Bus Number Series 2490–2789 and 1300– 1606 Figure 17: DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB BUS NUMBER SERIES 2490 TO 2789 and 1300 TO 1606 Mi14-01E Page 8 / 38 Rev: Oct 2021...

  • Page 603: Wheels As Hoisting Points

    TAG AXLE HOISTING POINTS Figure 18: TAG AXLE HOISTING POINTS (use only to support the tag axle) 1.4 WHEELS AS HOISTING POINTS Use the front and drive axle wheels to lift the bus when using mobile column lifts. When doing so, the tag axle must be unloaded at all time.

  • Page 604: Towing

    2 TOWING Towing from the front is recommended in order to move an immobilized bus. Prevost does not recommend towing from the rear using hoisting points that are not approved as the bus may sustain structural damage. The bus should be towed by truck operators authorized and experienced in towing highway buses.

  • Page 605: Before Towing Preparation

    2.1 BEFORE TOWING PREPARATION 1. Set the transmission to neutral and apply parking brake. 2. Chock the front and rear wheels to prevent the bus from moving at time of releasing the parking brake during the towing preparation. 3. On the L.H. dashboard panel, turn on the hazard warning flashers.

  • Page 606: Electrical Power And Air Supply

    2.1.1 Electrical Power and Air Supply Operate the engine when towing to maintain brake system air pressure. If the engine cannot be operated, connect external air pressure lines from the tow truck. CAUTION Do not tow the bus without external air pressure applied to the emergency fill valve if the engine does not operate.

  • Page 607: Mechanical Release Of The Emergency/Parking Brake

    Engine compartment emergency air-fill valve An additional emergency fill valves is available to supplement the air system when air pressure is low and Figure 23 the engine cannot be operated. This valve is located in the engine compartment ( ) and supplies air for all systems (brakes, suspension and accessories).
  • Page 608 Figure 25: TURN THE RELEASE BOLT (26) IN AN ANTI-CLOCKWISE DIRECTION UNTIL THE BRAKE IS RELEASED CAUTION! When the towing has been carried out, screw the release bolt (26) fully into the actuator, ensuring that the seal in the inner face of the release bolt head seals against its adjacent sealing face and tighten to a torque of min.

  • Page 609: Drive Axle Flange Shafts Removal

    2.1.3 Drive Axle Flange Shafts Removal 1. Apply the bus parking brake. 2. Remove the stud nuts and the washers (with Meritor drive axle) or cap screws (with ZF drive axle) from the flange shaft. DOB Bus Number Series 2490–2789 cap screw M18x1.5x50mm G10.9 (use 14mm hex socket driver “Allen”...
  • Page 610 3. Meritor axle: Loosen the tapered dowels in the flange of the axle shaft using the following methods. a) Do not strike the round driving lugs on the flange of an axle shaft. Pieces can break off and cause serious personal injury. A 1.5 inch (38.1 mm) diameter brass hammer can be used as a drift.
  • Page 611 CAUTION Make sure axle shafts or driveshaft are installed correctly after towing. Tighten axle shaft and driveshaft nuts to the correct torque settings. Do not invert shafts. Mi14-01E Page 17 / 38 Rev: Oct 2021...

  • Page 612: Towing From The Front

    2.2 TOWING FROM THE FRONT The towed bus must be lifted from the front with front wheels off the ground. The tow truck must be equipped with the proper lifting equipment i.e. tow bar, axle forks and holders to reach under the front axle or the front tow eye pads since no other lifting points are recommended for towing.

  • Page 613: First Lift

    2.2.1 First Lift To allow lifting equipment fitted with axle forks to reach under the front axle or tow eyes, it is necessary to perform a first lift of the front of the bus using the tow eye pads as lifting points. This first lift will allow tow cans or blocks to be placed underneath front tires.
  • Page 614 3. Deploy the tow truck stinger arm, placing the axle fork holders under the tow eye pads (Figure 33). Figure 33 4. Lift the front end of the bus high enough to allow installation of tow cans or blocks. Place the tow cans or blocks perfectly centered underneath each front wheel (Figure 34).

  • Page 615: Second Lift - Front Tow Eye Pads As Lifting Point For Towing

    2.2.2 Second Lift - Front Tow Eye Pads as Lifting Point for Towing The tow eye pads fixed to the vehicle chassis, fore of the front axle will be used as front end lifting point for towing. 1. Perform the first lift as instructed in paragraph 2.2.1 if not already done.
  • Page 616 Figure 38 6. Raise the front of the bus. 7. Install a jack stand under the stinger arm for support and safety purposes and then lower the stinger arm so it rests on the jack stand (Figure 39). The tow cans or blocks can be removed from under the front axle wheels.
  • Page 617 Figure 41: DOB BUS NUMBER SERIES 1300–1606 CHOKE CHAINS ROUTING Figure 42: DOB BUS NUMBER SERIES 1300–1606 CHOKE CHAINS ROUTING Mi14-01E Page 23 / 38 Rev: Oct 2021...
  • Page 618 Figure 43: : DOB BUS NUMBER SERIES 1300–1606 CHOKE CHAINS ROUTING Figure 44 Mi14-01E Page 24 / 38 Rev: Oct 2021...
  • Page 619 9. Attach the two tow truck safety chains from each of the two front lower radius rods (Figure 45) of the bus to the truck’s tow eyes Figure 46). Figure 45 10. Connect the two truck air lines to the service and brake supply air quick connect fittings adjacent and right above the front bumper (for more...
  • Page 620 14. If required, use the appropriate jig to assure that the highest point on the bus does exceed maximum allowable height for towing (Figure 48). 15. Make sure the parking brake is released before moving the vehicle. 16. Observe safety precautions when towing.

  • Page 621: Second Lift - Front Axle As Lifting Point For Towing

    2.2.3 Second Lift - Front Axle as Lifting Point for Towing This method uses the front axle as lifting point for towing (see Figure 12 to FIGURE 15). 1. Perform the first lift as instructed in paragraph 2.2.1 if not already done. 2.
  • Page 622 6. Install a jack stand under the stinger arm for support and safety purposes and then lower the stinger arm so it rests on the jack stand (Figure 53). The tow cans or blocks can be removed from under the front axle wheels. 7.
  • Page 623 Figure 55 12. Use bungee cords to support the safety chains (Figure 56). Figure 56 13. Make sure that the parking brake is released before moving the vehicle. 14. Observe safety precautions when towing. Figure 57 Mi14-01E Page 29 / 38 Rev: Oct 2021...
  • Page 624 Avoid sharp turns where possible as safety chains may rub and damage the front bumper ( Figure 58 Figure 58 CAUTION Make sure a safe distance is kept between the front of the bus and the tow truck. This space ensures that bus does not suffer damages when being towed.

  • Page 625: Towing With All Wheels On The Ground Using Rear Tow Eyes - Fitted On Dob Bus Number Series 2490-2789 And 1300-1606 Only

    2.3 TOWING WITH ALL WHEELS ON THE GROUND USING REAR TOW EYES – FITTED ON DOB BUS NUMBER SERIES 2490–2789 AND 1300–1606 ONLY To recover a bus which is no longer on a drivable surface, chains can be looped around or hooked to the rear tow eyes.

  • Page 626: Rear Tow Using Not Approved Lifting Points - For Emergency Situations Only

    3 REAR TOW USING NOT APPROVED LIFTING POINTS - FOR EMERGENCY SITUATIONS ONLY FOR EMERGENCY SITUATION ONLY CAUTION The bus should NOT be lifted and towed from the rear unless an emergency situation occurs or when the bus has already been damaged and must be moved over a very short distance such as in a parking lot. Lifting the rear end from the engine cradle or from the side-members located under the engine cradle support rails should be avoided.
  • Page 627 Lift with precautions as the vehicle may sustain structural damage at the vertical structure shown on the image at right (Figure 61). Figure 61: THE VEHICLE MAY SUSTAIN STRUCTURAL DAMAGE WHERE INDICATED WITH ARROWS DURING TOWING FROM THE REAR DANGER Do not carry passengers while the bus is being towed.

  • Page 628: First Lift

    3.2 FIRST LIFT A first lift of the bus is necessary. This first lift will allow tow cans or blocks to be placed underneath the drive axle tires. 1. Prepare the bus for towing as instructed in paragraphs 2.1 and 2.1.1 2.
  • Page 629 6. Unload or raise the tag axle to prevent it from hanging unsupported. To do so, open the front service compartment located on street side and move the tag axle air valve lever forward as shown on figure 57. Figure 64 7.

  • Page 630: Second Lift

    3.2.1 SECOND LIFT 1. Perform the first lift as instructed in paragraph 3.2 if not already done. 2. Retract the tow truck stinger arm. 3. Pre-adjust spacing between the axle fork holders to 43 inches. Figure 66 4. Install either long or short axle forks into fork holders.
  • Page 631 6. DOB 2400 – 2489: Lift the tow bar until the axle forks grab the side-members (Figure 68). DOB 2490 – 2789 and 1300 – 1606: Lift the tow bar until the axle forks fit snuggly into the side-members tow eyes. Avoid lifting at the side-members further toward the rear of the bus (close to the bumper)
  • Page 632 10. Install the choke chains. Tie the two choke chains together to secure the side members to the tow bar (Figure 71 & Figure 72). Take up any slack that may remain and maintain proper tension on chains. Figure 71 11.
  • Page 633 Electrical Bypass/On Demand Opening of liquid refrigerant solenoid valves ........25 4.8.3 Coil Replacement ..........................25 4.8.4 Valve Disassembly ..........................25 4.8.5 Valve Reassembly ..........................25 THERMOSTATIC EXPANSION VALVE ......................26 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 634 Pumping Down ............................. 51 6.7.5 Adding Vapor State Refrigerant ......................52 6.7.6 Charging System ..........................54 LIQUID REFRIGERANT RECOVERY ........................ 54 EVACUATING SYSTEM ..........................55 SPECIFICATIONS ............................56 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 635: Section Change Log

    SECTION 22: HEATING AND AIR CONDITIONING SECTION CHANGE LOG DESCRIPTION DATE DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 636: Torque Tables

    21 lb-ft (28 Nm) max Magnetic drain plug 37-52 lb-ft (50-71 Nm) Oil fill hole plug 15-17 lb-ft (20-23 Nm) Service port 7/16-20 UNF 7.5 lb-ft (10 Nm) Max DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 637: High/Low Pressure Service And Receiver Tank Valves

    Central A/C tensioner idler shaft bolt (M12 shoulder bolt) 31.5-38.5 lb-ft (43-52 Nm) Central A/C tensioner idler shaft bolt (M12 x 1.75 std bolt) 59 lb-ft (80 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 638: Hvac System Overview

    : Heating or cooling; Dehumidification; Ventilation; Filtering; CENTRAL HVAC SYSTEM EVAPORATOR COMPARTMENT ARRANGEMENT FIGURE 1: EVAPORATOR COMPARTMENT AND DISCHARGE DUCTING ARRANGEMENT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 639: Central Hvac System

    SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM FIGURE 2: X3 COACHES CENTRAL HVAC SYSTEM - PASSENGER’S UNIT AIR CIRCULATION FIGURE 3: X3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 640 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 4: X3 SERIES CENTRAL HVAC SYSTEM – REFRIGERANT CIRCUIT W/ OVERHEAD COMPARTMENT EVAPORATORS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 641: Hvac System Basic Maintenance

    PRESSURE AIR JET panel, remove the six bolts fixing the blower 22373 motor assembly. Use low air pressure to clean the coil. FIGURE 5: DRIVER'S UNIT AIR FILTERS 22171 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 642: Driver's Unit Air Filter

    The driver’s unit fresh air filter is not clogged; The fresh air damper (flapper door) is open, i.e. the recirculation button on the HVAC FIGURE 10: PASSENGERS' SECTION AIR FILTERS control unit is not engaged. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 643: Evaporator Door Fresh Air Intake Filter

    MAINTENANCE At the intervals specified in the Lubrication & Servicing Schedule in Section 24A, slide out the filters, then back flush with water, dry with air and reinstall. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 644: Compressor Belts

    Belt tension Tool:7770002 FIGURE 13: STANDARD BELT LAYOUT WITH CENTRAL HVAC SYSTEM NOTE Belts specifications may vary. For proper belt selection, always consult your vehicle Coach Final Record. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 645: Torch Brazing

    1/8 inch [3,1 mm]). After completing repairs, test for leaks. When using heat at or near a valve, wrap with a rag saturated of water to prevent overheating of vital parts. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 646: Hvac System Components

    Remove the tube plug and drain the oil into a container for disposal. Replace the cap on the tube and replace the tube into the clip bracket. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 647: Maintenance - Oil Color & Level Check

    R.H. sight glass: between ½ and ¾ of • sight glass height (Figure 18). L.H. sight glass: the full sight glass height • (Figure 19). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 648: Maintenance - Compressor Oil Change

    Oil Type: Polyolester ISO68. • Bitzer BSE55 (POE) Castrol Icematic SW 68 • • Mobil EAL Arctic 68 Shell S4 FR-F 68, Clavus R68 • DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 649: Troubleshooting Guide

    VIEW SHOWING • Higher than normal suction pressure. FILTER/STRAINER AND MAGNETIC DRAIN PLUG Cause: • Clean the magnetic drain plug and reinstall. • Improperly torqued cylinder head bolts. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 650: Brushless Evaporator Motor

    Never support evaporator motor assembly by 27.5 volt, 2 HP (1,5 kW) motor which activates a its output shafts while moving it. Always use double blower fan unit. double blower fan unit base. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 651: Installation

    • Remove motor from double blower fan unit base. FIGURE 24: EVAPORATOR MOTOR ASSEMBLY 4.2.2 Installation To reinstall the evaporator motor, reverse "Evaporator Motor Removal" procedure. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 652: Condenser (Central A/C)

    100 psi. Below 100 psi, the fans are not running. Refer to Figure 26 below. NOTE During normal conditions, fan function according to the following specifications: Full speed: 6200 cfm, 37A at 28 VDC Fan motor speed: 2950 rpm at full speed DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 653: Condenser Fan Removal

    Remove the motor. MAINTENANCE Check refrigerant level and add if necessary, at the intervals specified by the Lubrication & Servicing Schedule in Section 24A. FIGURE 27: CONDENSER FANS DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 654: Filter Dryer

    Perform the pumping down procedure to isolate refrigerant in the receiver tank. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 655: Moisture Indicator

    DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 656: Liquid Refrigerant Solenoid Valve

    Voltage must be at least 85% of the nameplate rating. Excessive leakage: Disassemble valve and clean all parts. Replace worn or damaged parts with a complete repair kit for best results. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 657: Electrical Bypass/On Demand Opening Of Liquid Refrigerant Solenoid Valves

    TORQUE: 20-40 lb-ft (27-54 Nm) 5. Plug coil connector. 6. Put back manual lift stem. Tighten lift stem assembly and seal cap. TORQUE: 11 lb-ft (15 Nm) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 658: Thermostatic Expansion 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 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 659: Superheat Adjustment

    82 (27,7 C), then set temperature to minimum to keep the compressor on 4 cylinders. FIGURE 38: HIGH & LOW SWING TEMPERATURE AT REMOTE BULB 22047 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 660: Maintenance

    40 F (4,4 C), subtract F (0 C) and the result will be 8 F (4,4 C) of FIGURE 33 superheat. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 661: Hot Water Pneumatic Valve

    2. Check that there is no restriction to the air escaping from the actuator casing. 3. Make sure that pilot solenoid valve operates properly. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 662: Hot Water Circulating Pump

    If there is evidence that the circulating pump is not operating as per specifications, the unit must be disassembled for repair. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 663: Hvac System Testing And Troubleshooting

    During the first 3 seconds after startup, the compressor is active on 4 cylinders and the A/C valve is open regardless of the pressure readings. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 664: Test Mode For Switches And Sensors

    06: ELECTRICAL for complete information), the A/C compressor HI and LO pressure values are displayed one after the other instead of the outside temperature in the telltale panel LCD. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 665: Test Mode For Electric Motors

    Compressor turns outside temperature is above 32°F automatically if (2 required conditions) return air temperature in passengers’ area is 61°F or above (∆T=7° with set point) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 666: Hvac Electrical System Troubleshooting

    Check / reset circuit breaker CB1, CB5, Check CB67 Probe gray connector on module to see if it is powered. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 667 Probe gray connector on module to see if it is powered. Check / replace condenser power relay R12 (probe R12 coil power circuit 67, should be 24 volts). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 668: Air Conditioning

    See temperature chart in this section.) An evaporator just does a proper cooling job without sufficient air. Shortage of air can be caused by the following: o Dirty filters; or DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 669 Plugged / kinked / chaffed lines. Clean, repair or replace lines. LOW SUCTION PRESSURE-LOW SUPERHEAT Uneven or inadequate evaporator loading due to Balance evaporator load distribution by providing DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 670 Add R-134a to system. HIGH DISCHARGE PRESSURE Air or non-condensable gases in condenser. Purge and recharge system. Overcharge or refrigerant. Recover to proper charge. Condenser dirty. Clean condenser. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 671: Temperatures & Pressure Chart

    1012.2 171.9 1185.3 54.4 199.8 1377.6 230.5 1589.3 65.6 264.4 1823.0 301.5 2078.8 76.7 342.0 2358.1 82.2 385.9 2660.8 87.8 433.6 2989.7 93.3 485.0 3344.1 98.9 540.3 3725.4 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 672: Central Hvac System

    CB144 15A Condenser fan up-aft or highly polluted areas. The recirculation REC CB143 15A Condenser fan down-aft button is located on the HVAC control unit. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 673 (Figure 45). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 674: Hvac System Operation

    61°F, at this moment, return air and discharge air duct. enough heat is available from the engine to warm up the area while the air DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 675: Passengers' Section Operation

    Temperature control is provided in conjunction with a thermistor sensor inside the return air box, located on the mid L.H. side of the vehicle under the seats (Figure 47). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 676: Overhead Compartment Unit

    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. FIGURE 49: DRIVER'S UNIT HOT WATER PNEUMATIC VALVE ASSEMBLY DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 677: Passenger's Unit Hot Water Pneumatic Valve

    Close the hot water lines shutoff valves located next the engine on the street side (see Figure 54). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 678 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 53: DRIVER'S HVAC UNIT FIGURE 54 X SERIES HEATER LINE SHUTOFF VALVES- (ALLISON TRANS. PIPING ARRANGEMENT SHOWN) DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 679: Filling Heating System

    The central system is equipped with 4-cylinder After initial filling, the hot water shutoff 4NFCY Bitzer compressor with valves should be open and the water DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 680: Refrigeration Cycle

    It is a good practice to replace the cap after stops, etc. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 681 O-ring. If leaks are Precautions in Handling Refrigerant Lines encountered at the couplings or connectors, no attempt should be made to correct the leaks by tightening the connections beyond DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 682: Refrigerant System Clean-Out After Compressor Failure

    Change liquid line filter dryer. contaminated, replace the oil and repeat step 7. If the oil is not contaminated, change the Run the unit for 2 hours on high speed cool only. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 683: Pumping Down

    “Precautions In Handling Refrigerant” to prevent any injury. NOTE For this procedure to be done properly, it is assumed the proper amount of refrigerant is in DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 684: Adding Vapor State Refrigerant

    0 psig. “milky” sight glass. 9. Stop the compressor. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 685 Connect the red valve of 15. Perform a road test for final verification. the gage set to the discharge shutoff valve service port. Hoses should be purged of air at installation (evacuated). DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 686: Charging System

    (normal operating position). Connect the recovery unit hose to 9. Open the R-134a tank valve. The refrigerant supply tank should be kept warm to allow DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...

  • Page 687: Evacuating System

    The evacuation of the system must be made suction and discharge shutoff valves service by authorized and qualified personnel only. ports. Refer to local laws for R-134a recuperation. 13. Disconnect C24 & C44. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 688 Cylinder volume ........................39 in (647 cm Operating speed ........................500 to 3500 rpm Oil capacity ........................2.8 quarts (2,6 liters) Weight ............................74 lbs (33 kg) Oil type ..........................Polyolester ISO68 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 689 Type ............................Normally open Voltage .............................. 24 V DC Hot water circulating pump Make ..............................AMETEK Flow ..............................15 gpm Inlet/outlet OD ............................3/8” Main expansion valve Make ............................Emerson-Alco DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 691 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 692 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 693 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 694 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 695 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 696 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 697 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 698 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 699 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 700 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 701 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 702 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 703 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 704 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 705 CLEVER DEVICE IVN5 ............................ 22 9.1.1 Pedestrian Turn Warning Speakers Location ..................22 MOTOROLA COMMUNICATION RADIO POWER ................... 22 AUTOMATIC PASSENGER COUNTER ......................23 MOBILEVIEW BUS CAMERA SECURITY SYSTEM (BCSS) ................. 24 DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 706: Section Change Log

    SECTION 23: ACCESSORIES SECTION CHANGE LOG DESCRIPTION DATE REMOVED: Every 2 years replace L-bracket and related components (both shims & hardware) Nov 2021 DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 707: Torque Tables

    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 55-65 lb-ft (75-88 Nm) DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 708 118 lb-ft (160 Nm) Pneumatic actuator to L-bracket 135 lb-ft (183 Nm) L-bracket to support plate 198 lb-ft (268 Nm) Support plate to frame bracket (all) 198 lb-ft (268 Nm) DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 709: Hub Odometer

    INSTALLATION Place the hub odometer unit over the wheel hub studs. Replace the lock washers and nuts. Torque stud nuts. TORQUE: 110-165 lb-ft (149-224 Nm) DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 710: Windshield Wipers And Washers

    FIGURE 3: WIPERS-WASHER MULTIFUNCTION BUTTON FIGURE 5: WIPER ELECTRICAL MOTOR LOCATION DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 711: Windshield Wiper Motor

    If it is necessary to adjust the sweep of blades, remove arms make adjustment by positioning the arms using serration on the wiper arm pivot shafts. DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 712: Wiper Arms Installation

    3. Lift the blades then release the wiper arm so it falls back on the windshield. If necessary, loosen the arm mounting nuts and adjust the position as shown in Figure 10. 23253 DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 713: Troubleshooting

    To start the vehicle, perform this ignition switch sequence. Reset the AFSS from the AFSS panel. • Reset manual switch in rear junction box • (curb side of engine compartment) DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 714: Checkout Procedure

    • Visually inspect the extinguisher for damage Verify that the windows on the face of such as pits, gouges, dents, or corrosion. detector free excess Have the extinguisher evaluated by a DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 715: System Testing

    The proper side is indicated manufacture past the 12 year mark will need to onto the telescopic leg. be hydrostatically tested by a qualified fire protection equipment company familiar with Kidde equipment. DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 716 FIGURE 15: JACKS REMOVAL ON REAR SIDE Install the fasteners on the dismounted jacks. Slide the cassette inside the compartment to get the front rollers backward of the stoppers. DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 717 FIGURE 17: JACKS REMOVAL Install the fasteners on the dismounted jacks. Install locks in four locations and tighten screws: FIGURE 20: ELECTRICAL CONNECTION TORQUE:.55-65 lb-ft (75-88 Nm) DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 718: Wheelchair Lift Cassette Dismounting

    Install jacks on the front side of the cassette. Lift up the front side of the cassette until the front rollers clear the front stoppers. FIGURE 23: PROTECTIVE WIRE INSTALLATION DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 719 Lift up the rear side until the rear rollers clear the stoppers. FIGURE 29: MOVE OUT THE CASSETTE FIGURE 27: DROP THE REAR SIDE ON RAILS Reinstall the control box with the screws (4). DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 720: Snow Chain System

    50% wear FIGURE 31) FIGURE 32). 5. Inspect inside sidewall of the tires. Tire wear indicates misalignment or damage to the system. DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 721 FIGURE 35: L-BRACKET AND RELATED COMPONENTS FIGURE 33: ACTIVATING THE CHAIN SYSTEM USING DASHBOARD SWITCHES 8. Clean the mechanical cam stop of the arms and lubricate with a lite oil (FIGURE 34). DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 722 (as shown in left picture). DO NOT MIX OR INVERT LEFT & RIGHT AIR REGULATORS. • Clean the inside of the regulator if erratic movements of the arm(s) are noticed. DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 723: Positioning Requirements

    (FIGURE 38). NOTE chain unit marked “SNOWCHAIN/RIGHT” for the curb side unit and the “SNOWCHAIN/LEFT” for the street side one. DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 724 SECTION 23: ACCESSORIES FIGURE 39: SNOW CHAIN WHEEL POSITIONING REQUIREMENTS VS TIRE DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 725: Nyct Auxiliary Systems

    A provision for Bus Customer Information System (BCIS) equipment is also provided. Refer to the equipment manufacturer’s documentation for these particular items. FIGURE 40: NYCT AUXILIARY SYSTEMS, PLATES 1 & 2 DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 726: Pedestrian Turn Warning Speakers Location

    The system is using speakers located on both sides of the vehicle and turns on automatically when the vehicle speed is less than 10 mph (16 FIGURE 44: RADIO POWER MODE CHANGE DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 727 COUNTER An automatic passenger counter is installed above the entrance door. It is connected to the ethernet switch. Refer to wiring diagram for details. FIGURE 45: APC LOCATION DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...

  • Page 728: Mobileview Bus Camera Security System (Bcss)

    Center looking backward Interior Rear looking forward Interior Front looking backward Interior Bus operator's area Exterior Curbside rear looking forward Exterior Driver side rear looking forward Exterior Backup view DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 729 SECTION 23: ACCESSORIES Note that an encoder for the hidden camera (7) is located above the driver’s area, fixed to the front cap. FIGURE 48: ENCODER DOB 1300-1556 X3-45 Commuter PA-1648 Maintenance Manual Section 23 revised Nov 2021...
  • Page 731 FLEXIBLE HOSE MAINTENANCE ....................3 2.1.1 Hose Inspection ........................3 2.1.2 Leaks ............................3 2.1.3 Service life ..........................3 LUBRICATION AND SERVICING SCHEDULE REFERENCE NUMBERS ........4 DOB 1300 -1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 732 Section 24: LUBRICATION SECTION CHANGE LOG DESCRIPTION DATE DOB 1300 -1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 733 Original Equipment Manufacturer. supply lubricating oil, air, coolant, and fuel oil. DOB 1300 -1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 734 SECTION 24: LUBRICATION LUBRICATION AND SERVICING SCHEDULE REFERENCE NUMBERS FIGURE 1: COMPONENTS IDENTIFICATION (COMPONENTS REPRESENTATION MAY DIFFER SLIGHTLY FROM AN ACTUAL VEHICLE) DOB 1300 -1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 735 Other maintenance requirements and specific instructions on how to check and service different components are covered in their respective sections in this maintenance manual. DOB 1300 -1556 | X3-45 Commuter PA-1648 Maintenance Manual First release Oct 2020...
  • Page 737  = Specialty tool required. You will find the SPECIALTY TOOLS REQUIRED FOR REGULAR MAINTENANCE table and the LUBRICANTS SPECIFICATIONS table following this Lubrication and Servicing Schedule. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 738 TES389 intervals. Refer to the Maintenance Manual for TES389 intervals. Extended TranSynd or TES 295 fluid & filter change intervals are only allowed with Allison High-Capacity filters. DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 739 9 Rotogrip snow chains – Check for proper chain wheel angle and position in  relation to the vertical centerline of the tire DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 740 Approved equivalent 1 Schedule 1 TES-389 fluids Transmission Oil Good quality lithium-base grease: NLGI No.2 Grade is suitable for most temperatures Multi Purpose Grease NLGI No.1 Grade is suitable for extremely low temperatures DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 741 14 mm hex socket driver (Allen) E20 Torx socket slotted nut wrench 5870 401 146 N67817-21 lifting bracket 5870 281 043 19400451 driver 5870 050 007 19400449 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 742 18 BODY none 22 HEATING & AIR CONDITIONING A/C compressor – change oil, clean oil filter Refrigerant recovery unit *: Common tool. Contact your local tool supplier DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 743 32 SEC 04 EXHAUST & AFTERTREATMENT SYSTEM – Diffuser assembly, rain cap & drain tube – check proper functioning & clean. Interval was 12/05/2021 24 000 miles, changed to 36 000 miles DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...
  • Page 744 3 ADDED: Ref A Engine oil – “New vehicle delivered with…” 05/29/2020 4 ADDED: Ref F Differential oil – “New vehicle delivered with…” 05/29/2020 5 REMOVED: Ref I. Was transmission fluid TES-389 06/12/2020 DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual section 24A revised Dec 2021...

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