PREVOST H3-41 Maintenance Manual
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PREVOST H3-41 Maintenance Manual

PREVOST H3-41 Maintenance Manual

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Table of Contents

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COACH MANUFACTURER
MAINTENANCE MANUAL
H3-41, H3-45, VIP
PA1602
Revision 1

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Summary of Contents for PREVOST H3-41

  • Page 1 COACH MANUFACTURER MAINTENANCE MANUAL H3-41, H3-45, VIP PA1602 Revision 1...
  • Page 2 PA1602 First issue: June 2013 Production begins with vehicle: D-2364 Featuring:  PRIME (Power Recovery by Intelligent Management of Energy) and Bitzer A/C compressor REVISION DESCRIPTION FROM DATE On coaches: new front suspension, new rear suspension, new drag link E-2505 September 3, 2013...

  • Page 3: Table Of Contents

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

  • Page 4: Section 00: General Information

    This high frequency current publications. process seriously damage Prevost Car occasionally sends Maintenance electronic components. Information, Warranty Bulletins, Safety Recalls or other literature to update users with the latest service procedures. They are issued, when required, supplement supersede information in this manual. Update sheet should...
  • Page 5 SECTION 00 : GENERAL INFORMATION STEEL – STEEL WELDING Caution: Before welding, disconnect electronic modules and battery terminals. Warning: Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that would render welding impossible. Warning: Only a qualified and experienced person must do welding.

  • Page 6: Safety Notice

    4. SAFETY NOTICE This maintenance manual has been prepared in order to assist skilled mechanics in the efficient repair and maintenance of PREVOST vehicles. This manual covers only the procedures as of manufacturing date. Safety features may be impaired if other than genuine PREVOST parts are installed.

  • Page 7: Drive Axle

     Volvo D13 Engine This certifies that coaches manufactured by Power steering pump is mounted on the engine Prevost Car Inc., comply with all Federal Motor and located underneath the air compressor Vehicle Safety Standards at the time of (Fig.7).

  • Page 8: Fuel Tank Label

    Section 00 : GENERAL INFORMATION 4.1.9 Fuel Tank Label The fuel tank label is molded on the side of the fuel tank. To read this label, unscrew the fuel tank access panel nuts located at the left in the condenser compartment. 4.1.10 EPA Engine Label The exhaust emission certification label affixed above the oil reserve tank certifies that the...

  • Page 9: Figure 11 : Vehicle Identification Number

    Section 00 : GENERAL INFORMATION FIGURE 11 : VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE YEAR CODE 2000 2006 2012 2001 2007 2013 2002 2008 2014 2003 2009 2015 2004 2010 2016 2005 2011 2017 PA1602 SECTION 00...

  • Page 10: Fasteners

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

  • Page 11: Standard Torque Specifications

    SECTION 00 : GENERAL INFORMATION 5.1 STANDARD TORQUE SPECIFICATIONS The following table lists the standard tightening torques for bolts and nuts, relating tightening torque to thread diameter. Use the following table as a general guide for tightening torques. Use this table only for the bolts and nuts which do not require a specific torque value.
  • Page 12 Section 00 : GENERAL INFORMATION RECOMMENDED TORQUE TYPE DESCRIPTION THREAD GRADE lbf-ft (dry) otherwise specified Tolerance: ±10% 3/4-10 3/4-10 3/4-16 3/4-16 7/8-9 7/8-9 7/8-14 7/8-14 METRIC M6 X 1 nut 9 / screw 8.8 METRIC M6 X 1 nut 10 / screw 10.9 METRIC M8 X 1.25 nut 9 / screw 8.8...

  • Page 13: Self-Locking Fasteners

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

  • Page 14: Figure 15: Metric - Us Standard Conversion Table

    Section 00 : GENERAL INFORMATION FIGURE 15: METRIC - US STANDARD CONVERSION TABLE 00005 PA1602 SECTION 00...

  • Page 15: Figure 16: Conversion Chart

    Section 00 : GENERAL INFORMATION FIGURE 16: CONVERSION CHART 00006 PA1602 SECTION 00...
  • Page 17 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING PROCEDURE NO: PR060041 REVISION 02 2013-04-08 Material: Equipment(s): Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: Safety rules: - Wear safety goggles - Set the battery master switch to the OFF position first Recommendations: This procedure should be performed by qualified personnel only.
  • Page 18 PROCEDURE NO: PR060041 REVISION 02 SECTION 1 H3 Coaches & VIP 1.00 Location: Main power compartment and dashboard. Set the battery master switch to the OFF position. Place the ignition switch to the OFF position. 1.05 Location: Main power compartment Trip rear junction box circuit breakers CB2, CB4, Push the red button to open the circuit Page 2 of 16...
  • Page 19 PROCEDURE NO: PR060041 REVISION 02 1.10 Location: Main power compartment Remove the protective cover WARNING LIVE WIRE This 12-volt terminal remains energized Disconnect the electronic ground terminals from the stud. Using electric tape, insulate the 2 largest gage wires. Make sure the ring terminals do not touch each others and the vehicle body.
  • Page 20 PROCEDURE NO: PR060041 REVISION 02 1.15 Location: Main power compartment Disconnect the electronic modules : Disconnect I/O A, I/O B modules Disconnect C397 Disconnect connector C717 Disconnect 3 connectors from I/O B and I/O A modules. Disconnect data connector on equalizer 1.20 * Location: Front electrical compartment VIP + COACH: Disconnect the I/O A, I/O B, ABS,...
  • Page 21 PROCEDURE NO: PR060041 REVISION 02 VIP: Disconnect all keyless module connectors. Disconnect 3 connectors from I/O B and I/O A modules Disconnect 4 connectors from the ABS module Disconnect connector from master ID Page 5 of 16...
  • Page 22 PROCEDURE NO: PR060041 REVISION 02 Disconnect 3 connectors from VECU Disconnect 3 connectors from CECM Page 6 of 16...
  • Page 23 PROCEDURE NO: PR060041 REVISION 02 Disconnect connector A 96 from BERU (OPTION) Disconnect connector A 83 under Volvo Link module I shift Disconnect connector A 108 from Gsecu module (OPTION) Page 7 of 16...
  • Page 24 PROCEDURE NO: PR060041 REVISION 02 1.25 Location: Pneumatic accessory panel inside right console Remove the access panel on the right console (R.H. side of dashboard) Disconnect both I/O B modules 1.30 * Location: Condenser Compartment Disconnect connector A 137 1.35 Location: Evaporator compartment Remove the protective cover and disconnect I/O B module...
  • Page 25 PROCEDURE NO: PR060041 REVISION 02 1.40 Kidde Automatic Fire Detection and Suppression System (optional) Disconnect C466 Kidde AFSS module is located on the lateral control panel. When all the previous steps are done, you can do ENSURE THAT THE WELDING GROUND 1.45 welding on the vehicle.
  • Page 26 PROCEDURE NO: PR060041 REVISION 02 SECTION 2 X3 Coaches, X3-45 VIP & XLII Bus Shells 2.00* Location: Rear Electrical Panel and Dashboard Set the battery master switch to the OFF position (X3 Coaches only) Place the ignition switch to the OFF position. 2.05* Location: Rear Junction Panel Lift cover, trip circuit breakers CB2-CB4-CB6 located...
  • Page 27 PROCEDURE NO: PR060041 REVISION 02 2.10* Location: Rear Electrical Panel Disconnect the electronic ground terminals from this stud. Use electric tape; make sure that cables do not touch each others and the vehicle body. Note : With disconnection of the electronic ground terminals, disconnecting engine...
  • Page 28 PROCEDURE NO: PR060041 REVISION 02 Location: battery compartment: 2.15.2 Disconnect data connector on equalizer Page 12 of 16...
  • Page 29 PROCEDURE NO: PR060041 REVISION 02 2.20 * Location: Front Electrical Compartment VIP + BUS: Disconnect the I/O A, I/O B, ABS, master ID, VECU, CECM, BERU, Volvo Link, Gsecu modules. VIP : Disconnect all keyless module connectors Disconnect 3 connectors from I/O B and I/O A modules Disconnect 4 connectors from the ABS module...
  • Page 30 PROCEDURE NO: PR060041 REVISION 02 Disconnect 3 connectors from VECU Disconnect 3 connectors from CECM Disconnect connector A 96 from BERU (option) Disconnect connector A 83 under Volvo Link module Page 14 of 16...
  • Page 31 PROCEDURE NO: PR060041 REVISION 02 Location: Front Electrical Compartment I shift Disconnect connector A 108 from Gsecu module (OPTION) 2.30 Location: Pneumatic accessory panel inside right console Remove the access panel on the right console (R.H. side of dashboard) Disconnect both I/O B modules 2.40 Location: Condenser Compartment Disconnect connector A 137...
  • Page 32 PROCEDURE NO: PR060041 REVISION 02 2.50 Location: Evaporator Compartment Disconnect A 54 module located inside the evaporator compartment, on the door. 2.60 When all the previous steps are done, you can do ENSURE THAT THE WELDING GROUND welding on the vehicle. RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE...
  • Page 33 SECTION 01: ENGINE CONTENTS VOLVO D13 ENGINE ..........................2 ........................... 2 YSTEM VERVIEW ........................... 6 NGINE VERVIEW ............................7 NGINE 1.3.1 General ............................ 7 1.3.2 Oil Quality ..........................8 1.3.3 Oil Change Intervals ........................ 8 1.3.4 Oil Filters ..........................9 1.3.5 Synthetic Lubrication .......................

  • Page 34: Volvo D13 Engine

    Section 01: ENGINE  1. VOLVO D13 ENGINE Ambient Air Temperature Sensor  Ambient Pressure sensor 1.1 SYSTEM OVERVIEW  Boost Air Pressure (BAP) Sensor NOTE  Camshaft Position (Engine Position) Sensor The “Premium Tech Tool” (PTT) is the preferred tool for performing diagnostic work. ...
  • Page 35 Section 01: ENGINE The Ambient (Atmospheric) Pressure Sensor is modifies a voltage signal from the control unit. built into the Engine Management System The modified signal returns to the control unit as (EMS) Module. the exhaust temperature of the EGR system to confirm EGR operation.
  • Page 36 Section 01: ENGINE Exhaust Temperature Sensor (DPF Sensors) Intake Manifold Pressure Sensor The exhaust gas temperature sensor detects The Intake Manifold Pressure Sensor contains a exhaust gas temperature for DPF protection as pressure sensitive diaphragm and an electrical well as DPF regeneration control. The sensor amplifier.
  • Page 37 Section 01: ENGINE FIGURE 1: ENGINE SENSORS LOCATION Fuel Pressure Air Temperature Crankcase Pressure Humidity/Ambient Air Temperature Oil Level/Temperature Camshaft Speed EGR Differential Pressure Crankshaft Speed EGR Temperature Oil Pressure Coolant Temperature AFI Fuel Pressure Boost Pressure PA1602 SECTION 01...

  • Page 38: Engine Overview

    Section 01: ENGINE 1.2 ENGINE OVERVIEW NOTE For additional information concerning Volvo D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On Volvo web site, you will find detailed service procedures for parts replacement, repair and maintenance.

  • Page 39: Engine Oil

    Section 01: ENGINE FIGURE 3: D13F ENGINE, TURBO SIDE (TYPICAL) 1. EGR Valve 8. Coolant Pump 2. Aftertreatment Fuel Injector 9. Oil Filters 3. Exhaust Manifold 10. EGR Cooler 4. Valve Cover 11. Oil Pan 5. Engine Preheater Element 12. Starter Motor 6.

  • Page 40: Oil Quality

    Section 01: ENGINE 1.3.2 Oil Quality Volvo North America recognizes engine oils that meet or exceed the standards given by American Petroleum Institute (API) for the oil classifications listed in this manual. Only oils licensed to carry the API symbol should be used. Lubricants meeting API standards have provided maximum engine life when used together with the recommended oil and oil filter change intervals.

  • Page 41: Oil Filters

    Section 01: ENGINE NOTE Choose the viscosity grade for the typical ambient temperature application. Oil filters should always be changed when Multigrade oils have a broad range that suit changing the oil. operation in changing temperature. Volvo North America recommends 1.3.4 Oil Filters viscosities shown in the viscosity/temperature There are three filters on the engine, one of...

  • Page 42: Oil Change

    Section 01: ENGINE 1.3.9 Oil Change 1.3.10 Oil Filters Change WARNING WARNING A hot engine or engine oil can be dangerous. Hot oil can cause severe burns. DO NOT Serious burns can result from contact with a allow hot oil to contact the skin. When hot engine or oil.

  • Page 43: Checking The Oil Level

    Section 01: ENGINE FIGURE 6: OIL FITER REPLACEMENT  Start the engine and check for leaks around the oil filter housing and filters.  Check the oil level. Add approved engine recommended level, FIGURE 7: ENGINE OIL FILLING TUBE necessary. Do not overfill. 1.3.11 Checking the Oil Level Ensure that the vehicle is parked on level ground before checking the oil level.
  • Page 44 Section 01: ENGINE  Preparation CAUTION 1. Close the heater lines shut-off valves. To avoid damage to turbocharger, cover the 2. Disconnect the battery or batteries from the turbocharger inlet opening to prevent foreign starting system by removing one or both of material from entering.
  • Page 45 Section 01: ENGINE 17. Close engine fuel supply shutoff valve on 26. Inside main power compartment, disconnect primary fuel filter or Fuel Pro. Disconnect the starter, alternators and heater cables. Also fuel line located above fuel filters and disconnect AFSS cable if applicable. connected to inlet port.

  • Page 46: Power Plant Assy. Installation

    Section 01: ENGINE FIGURE 10: ENGINE COMPARTMENT H3 COACHES (TYPICAL) 01193 1.5 POWER PLANT ASSY. INSTALLATION It is recommended that new rubber mounts be installed at each major overhaul. To install a power plant assembly, follow the NOTE same procedure as in "Power Plant Assembly Removal"...
  • Page 47 Section 01: ENGINE FIGURE 11: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION DRY TORQUES REFERENCE DESCRIPTION Lbf-ft SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G8.8 SCREW, CAP HEXAGONAL HEAD M12 – 1.75 G8.8 SCREW, CAP HEXAGONAL HEAD M14 – 2.0 G8.8 SCREW, CAP HEXAGONAL HEAD M16 –...

  • Page 48: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    Section 01: ENGINE 2. ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) & THROTTLE POSITION SENSOR The Electronic Foot Pedal Assembly (EFPA) connects the accelerator pedal to a Throttle Position Sensor (TPS). The (TPS) is a device, which sends an electrical signal to the Motor Control Module (MCM). The TPS varies in voltage depending on how far the pedal is depressed.

  • Page 49: Specifications

    Oil Pan Capacity; High Limit ..................... 34 quarts/32 liters Total Engine Oil Capacity with Filters ................41 quarts/39 liters Lubricating oil filter elements Prevost number ....................... 478736 (Full Flow) Prevost number ......................... 510938 (By-pass) Torque specification Engine oil filter ................Tighten 3/4 to 1 turn after gasket contact...
  • Page 51 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM WITH VOLVO D13 ENGINE ..................3 DESCRIPTION ..........................3 FUEL VALVES ..........................4 FUEL FILTERS ..........................5 1.3.1 Primary Fuel Filter Replacement ..................... 5 1.3.2 Secondary Fuel Filter Replacement ..................6 PRIMING THE FUEL SYSTEM ....................... 6 FUEL PUMP REMOVAL AND INSTALLATION ................
  • Page 52 Section 03: FUEL SYSTEM ILLUTRATIONS ) ................3 IGURE FUEL SYSTEM SCHEMATIC VOLVO D ENGINE ) ................. 4 IGURE MANUAL SHUT OFF VALVE VOLVO D ENGINE 382 ( ) ......4 IGURE MANUAL SHUT OFF VALVE LOCATION WITH DAVCO FUEL PRO VOLVO D ENGINE ....................

  • Page 53: Fuel System With Volvo D13 Engine

    Section 03: FUEL SYSTEM 1. FUEL SYSTEM WITH VOLVO D13 ENGINE 1.1 DESCRIPTION NOTE For additional information concerning Volvo D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On Volvo web site, you will find detailed service procedures for parts replacement, repair and maintenance.

  • Page 54: Fuel Valves

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

  • Page 55: Fuel Filters

    Section 03: FUEL SYSTEM 1.3 FUEL FILTERS A primary fuel filter (aka pre-filter) is installed on the engine. This filter consists of a filter cartridge, a water separation bowl with a drain valve. It is used to prevent water from entering the fuel system.

  • Page 56: Secondary Fuel Filter Replacement

    Section 03: FUEL SYSTEM  Service work has been done on the fuel 13. Purge air from the filter by operating the priming pump to draw fuel and fill the filter. system, (tank, fuel lines, filters, valves, etc.) When using the hand priming pump, for example cleaning or replacing fuel filter approximately 100 strokes will be required.

  • Page 57: Fuel Pump Removal And Installation

    Section 03: FUEL SYSTEM 5. Start the engine and run it at an increased idle speed for approximately 5 minutes to remove any remaining air in the system. Check the fuel system for leaks. 1.5 FUEL PUMP REMOVAL INSTALLATION The pump is located underneath the air compressor and is accessible through the engine compartment R.H.
  • Page 58 Section 03: FUEL SYSTEM 13. After the air is purged and with the engine still running, slowly loosen the vent cap on the filter cover. The fuel level in the cover will start falling. When the fuel level falls to the top of the collar, tighten the vent cap quickly by hand.

  • Page 59: Fuel Lines And Flexible Hoses

    Section 03: FUEL SYSTEM 3. FUEL LINES AND FLEXIBLE HOSES capacity of 235 US gallons (890 liters). The tank is located just forward of the last baggage Make a visual check for fuel leaks at all engine- compartment, between the A/C condenser and mounted fuel lines and connections and at the evaporator.

  • Page 60: Tank Installation

    Section 03: FUEL SYSTEM 5. Unscrew engine supply and return lines from fuel tank connection-panel, identify them for reinstallation. 6. Disconnect electrical wiring from tank on connection plate. FIGURE 12: FUEL TANK INSTALLATION 03049 FIGURE 11: FUEL TANK ARRANGEMENT 03048 NOTE Insert check valve assembly in right-side filler WARNING...

  • Page 61: Fuel Tank Verification

    3. Drill perforation with a 23/64" bit. Make sure CAUTION drill hole is perfectly round. ULSD fuel is necessary to avoid fouling the 4. Insert a screw (Prevost #500196) and a engine’s Exhaust Aftertreatment System. washer (Prevost #5001244) into anchor nut Improper fuel use will reduce the efficiency of (Prevost #500331).

  • Page 62: Blending

    Volvo. Failures attributed to the use of biodiesel fuel will not be covered by Burning Low Sulfur Diesel fuel (instead of Volvo or Prevost product warranty. Also, any ULSD fuel) in 2010 and later model year engine performance problem related to the use...

  • Page 63: Air Cleaner Servicing

    Section 03: FUEL SYSTEM 7.2 AIR CLEANER SERVICING CAUTION Stop the engine, open the R.H. side engine compartment door, and loosen the wing nut Do not ignore the Warning given by the air retaining the air cleaner element to the air restriction indicator.

  • Page 64: Fuel Pedal Adjustment

    Section 03: FUEL SYSTEM Proper pedal output should be 20/30 counts at idle and 200/235 at full throttle. If adjustment is necessary, remove the potentiometer retaining screws and rotate the potentiometer clockwise to increase counts or counterclockwise to decrease. When correct output is confirmed, tighten retaining screws.

  • Page 65: Specifications

    Fuel tank Capacity ..........................235 US gal (890 liters) Air Cleaner Prevost Number ......................Refer to the Parts Manual Prevost number (element cartridge) ................Refer to the Parts Manual Air Cleaner Restriction Indicator Prevost number ............................530161 Preheater Fuel Filter Prevost number ............................
  • Page 67 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM CONTENTS EXHAUST AFTERTREATMENT SYSTEM OVERVIEW ..............2 MAINTENANCE ..........................2 FLEXIBLE COUPLING INSTALLATION ..................3 DIESEL PARTICULATE FILTER (DPF)....................3 DIESEL PARTICULATE FILTER ASSEMBLY REMOVAL .............. 4 CATALYTIC CONVERTER ........................5 REMOVAL ............................5 ASSEMBLING CATALYTIC CONVERTER ..................

  • Page 68: Exhaust Aftertreatment System Overview

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM EXHAUST AFTERTREATMENT SYSTEM OVERVIEW FIGURE 1: EXHAUST SYSTEM and regenerate the soot on a regular or passive The technology behind clean emissions is basis, then the exhaust gases flow through the through the immediate aftertreatment of engine catalytic converter to reduce NOx to minimum exhaust.

  • Page 69: Flexible Coupling Installation

    State of required. Clean remanufactured DPF cartridge California to cause cancer, birth defects and will be available through Prevost on an exchange other reproductive harm. basis. For most vehicle applications and duty cycle,...

  • Page 70: Diesel Particulate Filter Assembly Removal

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM FIGURE 3: DIESEL OXIDATION CATALYST (DOC) & DIESEL PARTICULATE FILTER (DPF) ASSEMBLY 04016 2.1 DIESEL PARTICULATE FILTER WARNING ASSEMBLY REMOVAL To remove the DPF, proceed as follows: HOT EXHAUST During stationary regeneration, exhaust gases CAUTION temperature may get very hot at the diffuser outlet.

  • Page 71: Catalytic Converter

    SECTION 04: EXHAUST AND AFTERTREATMENTSYSTEM 6. Carefully lower DOC and DPF assembly; 7. To make sure components are reinstalled in the same position, mark position of DOC, DPF and clamps in relation with one another before taking apart; CAUTION FRAGILE - HANDLE WITH CARE Use extreme care when handling DPF cartridge as it could be damaged or destroyed by dropping or sudden impact.
  • Page 72 Section 04: EXHAUST AND AFTERTREATMENT SYSTEM • Shut off the heater line shut-off valves. WARNING • Using the quick-connect drain hose, drain the engine cooling system. Refer to Section Due to the heavy load of the radiator assembly, 05, COOLING under "DRAINING COOLING it must be adequately supported before SYSTEM".

  • Page 73: Assembling Catalytic Converter

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

  • Page 74: Diffuser Assembly

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM • • Using the lines made earlier, line up the Before tightening the parts, make sure that lower and upper clamps with regard to the the catalytic converter lower support is well emboss of the converter and afterward, line centered with the exhaust inlet of the up the lines made earlier on the clamps with catalytic converter.

  • Page 75: Maintenance

    SECTION 04: EXHAUST AND AFTERTREATMENTSYSTEM • Check for proper functioning of the rain cap surface more than 3/32 inch (2 mm). inside the diffuser housing, make sure that it moves freely; • Make sure that the water drain tube is not CAUTION clogged.

  • Page 76: Diesel Exhaust Fluid (Def) Tank And Injection System

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM DIESEL EXHAUST FLUID (DEF) TANK disconnected or unsealed connector, the connector must be removed immediately and AND INJECTION SYSTEM replaced. The DEF tank and injection system control unit continuously vary the amount of DEF injected in Things to know about spilt diesel exhaust fluid response to the engine’s current load conditions.

  • Page 77: Def Tank Cleaning

    SECTION 04: EXHAUST AND AFTERTREATMENTSYSTEM FIGURE 10: DEF TANK AND PUMP LOCATION (INSIDE CONDENSER COMPARTMENT) 5.2 DEF TANK CLEANING Removing the DEF tank for cleaning is not necessary. 1. Put a suitable container under the DEF tank. 2. Remove the DEF tank drain plug through the DEF tank support pan access hole.

  • Page 78: Pump Assembly Filter Element Replacement

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM 5.3 PUMP ASSEMBLY FILTER ELEMENT 5. Install new filter element and equalizer. REPLACEMENT Checks filter element cover and housing for damage. If either the filter or housing is 1. Clean the area around filter cover. damaged, the damaged part must be changed.

  • Page 79: Replacement

    SECTION 04: EXHAUST AND AFTERTREATMENTSYSTEM In addition to the activation of the CHECK 3. Remove aftertreatment hydrocarbon telltale, emission of diagnostic troubleshooting injector mounting fasteners. Remove the codes (DTC) by the engine ECM (MID128) will aftertreatment hydrocarbon injector from the indicate malfunction of the aftertreatment system diffuser pipe...

  • Page 80: Torque Specifications

    Section 04: EXHAUST AND AFTERTREATMENT SYSTEM TORQUE SPECIFICATIONS PA1602 SECTION 04...
  • Page 81 SECTION 04: EXHAUST AND AFTERTREATMENTSYSTEM PA1602 SECTION 04...
  • Page 82 Section 04: EXHAUST AND AFTERTREATMENT SYSTEM PA1602 SECTION 04...
  • Page 83 SECTION 04: EXHAUST AND AFTERTREATMENTSYSTEM The following table lists the tightening torques for the bolts, nuts, etc. on the DPF assembly which do require a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE REFERENCE TORQUE DRY (lbf-ft)
  • Page 85 SECTION 05: COOLING SYSTEM CONTENTS DESCRIPTION ............................3 MAINTENANCE ............................ 4 GENERAL RECOMMENDATIONS ....................4 VEHICLES EQUIPPED WITH VOLVO D13 ENGINE ..............4 HOSES ..............................4 CONSTANT-TORQUE HOSE CLAMPS ON COOLANT LINES - VOLVO D13 ......4 CONSTANT-TORQUE HOSE CLAMPS ON CHARGE AIR COOLER (CAC) SYSTEM ....5 THERMOSTAT OPERATION .......................
  • Page 86 Section 05: COOLING SYSTEM COOLING FAN DRIVE BELT ......................19 15.1 MOUNTING THE DRIVE BELT ....................19 SPECIFICATIONS ........................... 21 ILLUSTRATIONS FIGURE 1: COOLANT SURGE TANK ......................3 FIGURE 2: COOLANT FLOW TO RADIATOR ....................5 FIGURE 3: CONSTANT-TORQUE CLAMP 05037 ..................5 FIGURE 4: CHARGE AIR COOLER HOSE CLAMPS ...................

  • Page 87: Description

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

  • Page 88: Maintenance

    Section 05: COOLING SYSTEM 2. MAINTENANCE 2.2 VEHICLES EQUIPPED WITH VOLVO D13 ENGINE 2.1 GENERAL RECOMMENDATIONS NOTE A systematic routine inspection of cooling For additional information concerning Volvo system components is essential to ensure D13 engine components or engine-related maximum engine and heating system efficiency. components, consult Volvo Trucks Canada or ...

  • Page 89: Constant-Torque Hose Clamps On Charge Air Cooler (Cac) System

    Section 05: COOLING SYSTEM This type of clamp is designed to automatically clamp is properly installed and maintains a adjust its diameter to compensate for the normal leak-proof connection. Since the constant-torque expansion/contraction of a hose and metal clamp automatically adjusts to keep a consistent connection that occurs during vehicle operation sealing pressure, there is no need to re-torque and shutdown.

  • Page 90: Thermostat Operation

    Section 05: COOLING SYSTEM 4. THERMOSTAT OPERATION 2. After at least 30 seconds, check that the thermostat is still closed. 4.1 THERMOSTAT REPLACEMENT 1. Drain the cooling system. 2. Remove the bolts, the thermostat housing and the thermostat. Carefully clean the thermostat seat and all cylinder head-to- thermostat housing mating surfaces.

  • Page 91: Cooling System Recommendations

     Provide for adequate heat transfer. Recommended coolants for Volvo D13  Provide protection from cavitation damage. engine:  Provide a corrosion and erosion resistant  Prevost #685241 (pre-diluted 50/50 environment within the cooling system. mixture);  Texaco CPS#227998 (pre-diluted 50/50 ...

  • Page 92: Draining Cooling System

    Section 05: COOLING SYSTEM 6. DRAINING COOLING SYSTEM 4. Unscrew the surge tank pressure cap counterclockwise, ¼ turn to let air enter the Use the following procedures to drain the system and permit the coolant to drain cooling system partially or completely. completely from system.

  • Page 93: Filling Cooling System

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

  • Page 94: Cooling System Descalers

    Section 05: COOLING SYSTEM Fill with a 50/50-antifreeze/water solution 3. Attach a hose at the bottom of the radiator and add required inhibitors. and insert a flushing gun in the hose. Vehicles with coolant filters: 4. Connect the water hose of the gun to the water outlet and the air hose to the Fill with a 50/50-antifreeze/water solution.

  • Page 95: Radiator

    Section 05: COOLING SYSTEM 10. RADIATOR WARNING The radiator is mounted at the L.H. side of engine compartment. It is designed to reduce Failure to relieve cooling system pressure the temperature of the coolant under all may result in personal injury. operating conditions.
  • Page 96 Section 05: COOLING SYSTEM FIGURE 10: ENGINE COMPARTMENT DOOR FIGURE 12: L.H. SIDE REAR FENDER 2. Open engine compartment door (Fig. 10). 6. Remove tag axle L.H. side wheel. 3. Set starter selector switch to the OFF 7. Unfasten cap screws and remove access position (Fig.
  • Page 97 Section 05: COOLING SYSTEM 9. Remove radiator sealing frame (Fig. 15). 12. Remove upper radiator assembly support bracket (Fig. 18). FIGURE 15: RADIATOR SEALING FRAME FIGURE UPPER RADIATOR ASSY SUPPORT 10. Remove clamps and then break hoses from BRACKET the front coolant and charge air pipes (Fig. 13.
  • Page 98 Section 05: COOLING SYSTEM FIGURE 22: POSITIONING FORKLIFT 17. With assistance, slide radiator assembly out and onto the forklift. Transfer radiator FIGURE 20: RADIATOR ASSEMBLY LOWER MOUNTING assembly to a secure location. FASTENERS 18. Separate charge air cooler from radiator 15.

  • Page 99: Charge Air Cooler (Cac) Leakage

    Section 05: COOLING SYSTEM 11. CHARGE AIR COOLER (CAC) LEAKAGE Spec for CAC acceptable leakage: The CAC is considered acceptable if it can hold 30 psi (206 kPa) gauge pressure with not more than 5 psi (34 kPa) loss in 15 seconds after turning off the hand valve.

  • Page 100: Idler Replacement

    Section 05: COOLING SYSTEM FIGURE 29: TIGHTENING SPECIFICATIONS 05146 1. Remove the protective cap (replace with a new one). 2. Unscrew the idler mounting bolt. 3. Replace idler with a new one. CAUTION FIGURE 27: COOLING FAN DRIVE MECHANISM 05149 When installing the idler, make sure it rests perfectly against the bearing surface on the cast aluminum support.

  • Page 101: Locking Radiator Fan Clutch For Emergency Operation

    Section 05: COOLING SYSTEM The settings are: WARNING Engine Air intake Allison coolant temp. trans. oil Potential Accident Risk. Always use extreme temp. temp. caution when working in the vicinity of hot, rotating or moving parts. temperature 208°F: 194°F: 230°F: fan engages in engages in engages in...

  • Page 102: Maintenance

    7. When questions arise, obtain answers before FIGURE 32: RADIATOR FAN MOUNTING BOLTS 05125 proceeding. Assistance is available through the Prevost After-Sales Service support 14. FAN RIGHT ANGLE GEARBOX serving your area. The radiator fan is belt driven from the engine crankshaft pulley through a drive belt, a 13.3 INSPECTION...

  • Page 103: Maintenance

    Section 05: COOLING SYSTEM 14.1 MAINTENANCE 3. Dismount the fan and lean it against the radiator (refer to previous paragraph). 4. Disconnect the universal joint shaft. MAINTENANCE 5. Dismount the angle. Change the right angle gearbox oil only at 6. Loosen the gearbox upper support bracket operating temperature every 110,000 miles top bolts.
  • Page 104 Section 05: COOLING SYSTEM WARNING Potential Accident Risk. Always use extreme caution when working in the vicinity of hot, rotating or moving parts. FIGURE 36: DRIVE BELT ROUTING (VOLVO D13 ENGINE) 05127 1. Wrap the new drive belt around the fan drive mechanism pulley, idlers...
  • Page 105 Fully closed ............................185°F (85°C) Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2213 Qty ..................................1 Prevost number ............................5060096 Coolant - Volvo D13 Engine Prevost Number ............................685241 Texaco CPS .............................. 227998 Chevron CPS ............................2227805 Coolant Filter Cartridge –...
  • Page 112 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION ........................5 WIRING DIAGRAMS ........................5 1.1.1 Using Wiring Diagrams ......................5 1.1.2 Testing Circuits ........................6 WIRE SIZES AND COLORS ......................6 SPARE WIRES ..........................6 CLEANING CONNECTORS ......................6 CIRCUIT BREAKERS ........................7 MULTIPLEX FUSES ........................
  • Page 113 Section 06: ELECTRICAL MULTIPLEX INPUT TEST MODE ....................24 MOTOR TEST SEQUENCE ......................25 5.5.1 Test Sequence – Coaches only ..................... 26 5.5.2 Test Sequence – VIP With Central HVAC System ..............26 5.5.3 Test Sequence – VIP With Small HVAC System ..............27 FORCED ACTIVATION OF THE RADIATOR FAN CLUTCH ............
  • Page 114 Section 06: ELECTRICAL 11.2 STEPWELL LIGHTS ......................... 48 11.2.1 Coach Entrance ........................48 11.2.2 VIP Entrance ......................... 49 11.2.3 Bulb Removal And Replacement ................... 49 11.3 LAVATORY NIGHT-LIGHT ....................... 49 11.3.1 Bulb Removal And Replacement ................... 49 11.4 DRIVER’S AREA LIGHTS ......................49 11.4.1 Bulb Removal And Replacement ...................
  • Page 115 Section 06: ELECTRICAL ......................49 FIGURE VIP ENTRANCE STEPWELL ..........................50 FIGURE PARCEL RACK .................... 50 FIGURE ENGINE COMPARTMENT LED MODULE PA1602 SECTION 06...

  • Page 116: General Description

    12, you will find the location, the b) At item CB through the engine compartment door. Prevost number, the breaker function, the Vehicles equipped with optional PRIME energy breaker ampere rating and the page on management system are equipped slightly which to find the corresponding diagram.

  • Page 117: Testing Circuits

    Section 06: ELECTRICAL b) In first column DEVICE ID, look for device Orange Connected to multiplex outputs SW61, SW62. White Connected to multiplex inputs 24-volt system c) At device SW61,SW62, find the fault Yellow 12-volt system message, the minimum condition to activate, Black grounded wire other inputs involved in logic, the multiplex...

  • Page 118: Circuit Breakers

    Section 06: ELECTRICAL ingredient. HFC 134A has two qualities that recommend it. First, it does not conduct electricity and therefore, will not cause shorting between connector pins and sockets. Second, it evaporates quickly, eliminating the possibility of condensation within the connectors. Always shake out or gently blow out any excess HFC 134A before assembling a connector to its mating connector or hardware.

  • Page 119: Relays

    Section 06: ELECTRICAL Turn the ignition key to the OFF position and turn When the ignition switch is set to the OFF to the ON position again. This resets all "soft- position, the electrical components are not fuses". energized except for the MCM, ECM (engine Control Module), transmission...
  • Page 120 Remove the terminal by disengaging the flexible lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. EXTRACTOR/TOOL: Prevost #682256 (Packard 12094429) INS ERT EXT RACT OR...

  • Page 121: H3 Series Vehicles Electrical Compartments

    Section 06: ELECTRICAL H3 SERIES VEHICLES ELECTRICAL COMPARTMENTS FIGURE 4: ELECTRICAL COMPARTMENTS • Main circuit breakers for 12-volt and 24-volt MAINTENANCE electrical system; A corrosion inhibitor has been sprayed on certain • Voltage regulator (if applicable); electrical components in order to protect them from corrosion.
  • Page 122 Section 06: ELECTRICAL FIGURE 5: MAIN POWER COMPARTMENT (PARTIAL VIEW) 06594 FIGURE 6 : MAIN POWER COMPARTMENT PA1602 SECTION 06...

  • Page 123: Battery Charger Or In-Station Lighting Connector

    Section 06: ELECTRICAL FIGURE 7: FRONT ELECTRICAL AND SERVICE COMPARTMENT FRONT ELECTRICAL AND SERVICE 2.2.1 Battery Charger In-Station COMPARTMENT Lighting Connector The front electrical and service compartment is The vehicle may be equipped with a battery located on front L.H. side of vehicle. It contains charger or in-station lighting connector.

  • Page 124: Engine Rear Start Panel

    Section 06: ELECTRICAL • Front multiplex modules; • Front fuse box known as VECF (Vehicle Electrical Center Front); • Emergency door opening unlock valve (coaches only); • Windshield washer reservoir; • Reclining bumper opening handle; • Accessories air tank purge valve; •...

  • Page 125: Group 31 Acid-Lead Battery

    Section 06: ELECTRICAL The battery has four (4) major functions: 1. Providing a source of current for starting the engine. 2. Stabilizing the voltage in the electrical system. 3. Supplying current for a limited time, when electrical demands of the equipment exceed the power output of the alternator.

  • Page 126: Battery Discharge Protection

    Section 06: ELECTRICAL Absorbed Glass Mat (AGM) 12-volt batteries BATTERY DISCHARGE connected in series-parallel. PROTECTION To prevent discharge of the batteries when the These batteries require no maintenance for their lifetime. They can withstand deeper discharge engine in not running, some functions are cycles and several times the charging cycles of a automatically switched off if the battery voltage drops below 24 volts for more than 30 seconds.

  • Page 127: Battery Rating

    Section 06: ELECTRICAL To prevent possible electric shock or sparking, the main battery relays should be in the “Off” position before disconnecting cables from the batteries. 3. Remove battery cables from the batteries. NOTE When the battery cables have been removed from the batteries, wrap the battery terminals and cable ends with electric tape to prevent accidental grounding.

  • Page 128: Battery Testing

    Section 06: ELECTRICAL • Cold cranking (amps): 800 @ 0 F (-18 CAUTION • Weight (filled): 69 lb. (26,7 kg) Observe polarity of the meters and the battery The reserve capacity is defined as the number of when making connections, and select the minutes a new, fully charged battery at 80°F correct meter range.

  • Page 129: Testing Battery Cables

    Section 06: ELECTRICAL Any procedure other than the following could 60ºF (16ºC) cause personal injury or damages to the 50ºF (10ºC) charging system resulting from battery explosion or electrical burns. 40ºF (4ºC) Wear adequate eye protection when working 30ºF (-1ºC) on or near the batteries.

  • Page 130: Battery Charging Guide

    Section 06: ELECTRICAL are left on vehicle and make sure that the main batteries are charged by the booster block, battery disconnect switch is set to the “On” because of the series-parallel circuit. position. Battery charging consists of a charge current in The alligator clamps of the tester or charger must amperes for a period of time in hours.

  • Page 131: Emergency Jump Starting With Auxiliary (Booster) Battery

    Section 06: ELECTRICAL State of Charge For example, a completely discharged battery requires more than twice as much charge than a half-charged battery. Since the electrolyte is nearly pure water and a poor conductor in a completely discharged battery, current accepted is very low at first.

  • Page 132: Agm Battery Charging Precautions

    Section 06: ELECTRICAL for a few minutes, then start the engine in the The external condition of the battery and the vehicle that has the discharged batteries. battery cables should be checked periodically. The top of the battery should be kept clean and 5.

  • Page 133: Troubleshooting

    Section 06: ELECTRICAL • 7. Driving conditions or requirements under Check voltage regulator. which the vehicle is driven for short periods • Check battery connections. of time. • Check battery cells. 8. A constant drain caused by a shorted circuit •...

  • Page 134: Components

    Section 06: ELECTRICAL batteries to be charged when the vehicle is in free wheel. It basically means that batteries are charged with free energy and that no fuel consumption is dedicated to charge the batteries. COMPONENTS New components includes AGM batteries, a Vanner Battery equalizer, a temperature sensor located on the battery post and two voltage and current sensors monitoring 12V and 24 V circuits.

  • Page 135: Spare Can

    Section 06: ELECTRICAL In case of a short-circuit on the CAN link, this When performing electrical system affects all the modules and they all show “No diagnostic with the DID, the message « No Response” in the error messages of the Response ModA41»...

  • Page 136: Motor Test Sequence

    Section 06: ELECTRICAL Kneeling proximity sensor switch). For these Multi-function lever windshield wipers intermit. inputs, 2 beeps are emitted. If only one beep is heard, one of the inputs is defective. Lower windshield wipers backup switch Lower windshield washer switch SWITCHES AND SENSORS SUPPORTED BY THE SWITCH/SENSOR TEST MODE Upper windshield washer switch...

  • Page 137: Test Sequence - Coaches Only

    Section 06: ELECTRICAL A. The battery charger must be connected to a In the engine compartment, the sequence is 110-120 volt power supply. If not, the test will as follows: be interrupted when the voltage drops below • Toilet fan motor starts. 24 volts, •...

  • Page 138: Test Sequence - Vip With Small Hvac System

    Section 06: ELECTRICAL • To exit the electric motors test sequence, Check the fans. The condenser motors start at speed 1 for 3 seconds, then after a short press ESCAPE button, select STOP TEST pause, speed 2 activates. [3 seconds delay] submenu and then press ENTER button twice.

  • Page 139: Can Network Layout And Troubleshooting

    Section 06: ELECTRICAL To prevent the engine from overheating in case of malfunction of the clutch activation system, it is possible to force activation of the clutch. On the Driver Information Display, select DIAGNOSTICS menu. Select VEHICLE TESTS submenu and then ACTIVATE RADIATOR FAN SPEED 1 or ACTIVATE RADIATOR FAN SPEED 2 as required.
  • Page 140 Section 06: ELECTRICAL Main power comp. panel Pneumatic accessory panel (right console) Termination resistor CAN network Termination resistor Front electrical comp. panel Evaporator comp. panel Plug Connector 563589 Socket Connector 563590 Pneumatic accessory panel Plug with integrated Termination Resistor 563593 Main power comp.
  • Page 141 Section 06: ELECTRICAL Use the spare "Front to Rear" CAN Front electrical comp. panel: Disconnect C1 Plug and connect C1S Plug into C1 Socket. Main power comp panel: Disconnect C3 Socket and connect C3S socket into Pneumatic C3 Plug. accessory 5th baggage comp.: Disconnect C100 Socket and reconnect it to C100S Plug.
  • Page 142 Section 06: ELECTRICAL Pneumatic Use the spare "Front to Pneumatic Accessory Panel" CAN accessory panel Pneumatic accessory panel: disconnect C13 Socket and connect C13S socket into C13 Plug. Front electrical comp. panel: Disconnect C5 Plug and connect C5S Plug into C5 Socket.
  • Page 143 Section 06: ELECTRICAL Pneumatic Isolate the evaporator module from the network accessory panel Disconnect C100. 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 A54 will respond normally.

  • Page 144: Roadside Troubleshooting

    Section 06: ELECTRICAL Isolate the main power comp. panel from the network Disconnect C3 Plug and connect the termination resistor into C3 Socket. If the short circuit problem is in the main power comp. panel, all front modules + the evaporator module will respond normally. baggage comp.
  • Page 145 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Engine does b) Check / reset circuit breaker CB5 receive the ignition signal c) Check / replace fuse F65 d) Probe gray connector on module to see if it is powered. Engine ECM is not powered 2.
  • Page 146 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Entrance door does not Module A47 is not powered 1. Check DIAGNOSTICS menu of DID. open nor close using the or is faulty Select FAULT DIAGNOSTIC control buttons ELECTRICAL SYSTEM. message “No Response ModA47, Active”...
  • Page 147 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions see if it is powered. Low beam headlights and Module A48 is not powered 1. Check DIAGNOSTICS menu of the flasher on right side not or is faulty DID. Select FAULT DIAGNOSTIC and functioning ELECTRICAL SYSTEM.
  • Page 148 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions 3. Check / reset circuit breaker CB5 4. Check / replace fuse F67 , F68 5. Probe gray connector on module to see if it is powered. HVAC condenser fans not Module A54 is not powered 1.

  • Page 149: Essential Functions To Operate The Vehicle

    Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions SPEED 2. The DID status line will show TEST to confirm the forced activation of the radiator fan clutch. To cancel, turn the ignition switch to the OFF position or press ESCAPE button, select STOP TEST submenu and then press ENTER button twice.

  • Page 150: Multiplex Modules

    Section 06: ELECTRICAL • Front clearance lights. To disconnect the black connector, slide the red latch downwards. Remove the lower 5.11 MULTIPLEX MODULES screw that holds the cable attachment rod onto the floor portion of the panel and flip the 5.11.1 MCM rod up, this will relieve the I/O-B module, see Fig.

  • Page 151: Alternators

    DB9 (9-pins) connector (identified C226) found in the electrical harness near the MCM. FIGURE ALTERNATORS ACCESSORIES Please, contact your Prevost Service MOUNTING TORQUES (H3 COACH SHOWN) Representative if a reprogramming is required. 4. If applicable, mount the A/C compressor...

  • Page 152: Alternator Brush Replacement

    Section 06: ELECTRICAL 8. On the upper alternator, connect the power harness onto the adaptor. Tighten nut to 10 lbf-ft. WITH SMALL A/C SYSTEM Tighten in the following order: st Bolt /Nut A 43 lbf-ft. Bolt/Nut B, 43 lbf-ft (2x). Bolt/Nut C, 74 lbf-ft (2x).

  • Page 153: Alternator Drive Belt

    Section 06: ELECTRICAL 2. Select VIEW ACTIVE FAULTS and then BATTERY EQUALIZER ELECTRICAL SYSTEM. Vanner “Vann-Guard 70-Series” Battery 3. The active electrical system faults will equalizer is located beside the batteries in appear. Scroll through the active faults. You battery compartment. Battery Equalizer Owner’s will find one of the following messages: Manual (100 amps) is annexed at the end of this section.

  • Page 154: Exterior Lighting

    Section 06: ELECTRICAL NOTE Pulling the lever rearward while the lights are off will flash the headlights. 10.1.2 Maintenance Clean headlights with soap and water and a good glass cleaner whenever dirty. maximum illumination, headlight connections must be coated with a dielectric grease to prevent oxidation and proper voltage must be maintained.

  • Page 155: Replacing Front Turn Signal Led Module

    Section 06: ELECTRICAL 4. Unscrew the cap to gain access to the bulb 4. Install wiring connector on back of new turn connector. signal module. 10.1.5 Optional Xenon Headlamp (Low 5. HALOGEN: turn bulb base Beam) counterclockwise. XENON: Unscrew Phillips head screws indicated by arrows, pull The outer lamps of each headlight assembly the retainer and bulb out (fig.30).

  • Page 156: Aiming Headlights

    Section 06: ELECTRICAL result in immediate invisible re-ignition do not cause lamp cutoff. A warning notice on the lamp plug makes you aware of the fact that the lamp is operated in this system on a higher voltage (you should therefore switch off the lamp before working on this part).

  • Page 157: Licence Plate Light

    Section 06: ELECTRICAL FIGURE 33: VARIOUS LIGHTS LOCATION 18588_4 lights are in the upper center of rear and front 10.3 LICENCE PLATE LIGHT sections. The rear clearance and identification lights are red and the front ones are amber. Two LED units are mounted above the rear license plate(s) of vehicle.

  • Page 158: Clearance And Identification Light Removal And Replacement

    Section 06: ELECTRICAL 6. Finally, install the retaining ring and screw. 10.4.2 Clearance And Identification Light Removal And Replacement 10.6 FOG LIGHTS The clearance and identification lights are sealed Optional halogen fog lights can be mounted on units (LED) and should be replaced as an this vehicle to give the driver better visibility in assembly in accordance with the following foggy weather, or to improve the range of vision...

  • Page 159: Interior Lighting Equipement

    Section 06: ELECTRICAL 6. Fasten the fog light mounting nut and 1. For any gauge light bulb replacement, the securely close the bumper. dashboard panel must be removed in order to have access to the rear of gauges. 11 INTERIOR LIGHTING EQUIPEMENT 2.
  • Page 160 Section 06: ELECTRICAL 3. Connect and install the new LED assembly 2. With the light lens removed, pull bulb from in position. the lamp while applying lateral pressure. 4. Fasten the three fixing screws and replace 3. Install the new bulb into the lamp. the lamp outer ring by snapping it back in 4.
  • Page 161 Section 06: ELECTRICAL 2. Remove fluorescent tube from light socket 3. Push and turn bulb counterclockwise, then and install a new fluorescent tube. pull it out of the socket. 3. Lift the hinged cover and replace the two 4. Install new bulb in the socket, then push and retaining screws (fig.
  • Page 162 Section 06: ELECTRICAL CAUTION Do not touch halogen bulbs with bare hands as natural oils on skin will shorten bulb life span. 12 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.
  • Page 163 Section 06: ELECTRICAL 13 SPECIFICATIONS Battery Make ............................... Volvo Model ............................... 20359831 Type ............................ Maintenance-free Terminal type .............................Top Stud Group size ..............................31 Volts ................................12 Load test amperage ..........................290 Reserve capacity (minutes) ........................195 Cold cranking (in amps) -At 0 F (-18 C) ........................
  • Page 164 Series ..............................HD 10 Amperes ..............................120 Volts ................................. 28.4 Output Power ............................3 Kw Ground ............................... negative Prevost Number ..........................564119 Battery equalizer Make ..............................Vanner Model ........................... Vann-Guard 70-Series Amperes ............................100 amps Battery equalizer (with PRIME option) Make ..............................
  • Page 165 ELECTRICAL CONNECTORS PROTECTION NOVEMBER 2009 PROCEDURE NO SAV00002E REVISION 02 Kent Sealer Sprayed sealer. It is used for structure ground connections. It prevents corrosion and ensures maximum contact Refer to table for proper use. Apply this product once installation is finished. Warning: It is very important to be in a well ventilated area when applying this product.
  • Page 166 PROCEDURE NO: SAV00002E REVISION 02 Vehicle Zoning REAR FRONT REAR FRONT Page 2 of 6...
  • Page 167 PROCEDURE NO: SAV00002E REVISION 02 Electrical Connectors Protection Procedure Table Model Zone Component Product Note Accepted to ease A- Front Elect. Compt Diode Block Nyogel connection Customer Terminal A- Front Elect. Compt Block Nothing Terminal Block A Front Elect. Compt Electronic Ground Kent A- Front Elect.
  • Page 168 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note Color Guard C- Baggage Compt Structure Ground or Kent Accepted to ease C- Baggage Compt Door Switch Nyogel connection Accepted to Door lock Actuator Module ease C- Baggage Compt (switch and solenoid) Nyogel connection C- Baggage Compt...
  • Page 169 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note G- Engine Compt 120A Alternator Color Guard G- Engine Compt Booster Block (+) Color Guard G- Engine Compt Starter Terminal Color Guard G- Engine Compt Volvo Air Element Terminal Color Guard G- Engine Compt Customer Terminal Block Nothing...
  • Page 170 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note I- Vehicle Interior Dashboard Switch Nothing I- Vehicle Interior Electronic Module Nothing Accepted to ease I- Vehicle Interior Slide-out Motor Nyogel connection Accepted to ease I- Vehicle Interior Wiper Motor Nyogel connection I- Vehicle Interior...
  • Page 171 Mitsubishi Electric Corporation (MELCO) Service Bulletin ME003-P STARTER MOTORS (105P70) Figure 1 - 105P70 STARTER A starter is one of the parts installed to the flywheel housing. MELCO’s 105P70 starter Figure 2 shows the circuit diagram for the uses the planetary gear reduction system, 105P70 Ground-float type...
  • Page 172 Figure 3 - CROSS-SECTIONAL VIEW (GROUND-FLOAT TYPE) When the engine starts, the clutch prevents not be closed for more than 3 seconds. If excessive overrun of the armature. Because this time is exceeded, the starter solenoid the clutch is for a short-time rating, the start may be damaged.
  • Page 173 Figure 6 - TESTING HOLD-IN WINDINGS (GROUND- FLOAT TYPE) Figure 4 - TESTING PINION MOVEMENT AND PULL- Below are the resistance values for the P- IN WINDINGS (GROUND-FLOAT TYPE) and H-coils for reference. For the starter switch coils, refer to the switch circuit diagrams for the ground-wire Coil Resistance (reference)
  • Page 174 * If the output shaft does not move, stop brush pig tails, or poor contact between voltage application. If voltage continues to commutator and brushes be applied, excessive heat will occur in 6. High revolution speed and high current the starter solenoid and give thermal draw indicate: damage to the coil, thereby making it unserviceable.
  • Page 175 Valve-Regulated Lead-Acid (VRLA): Gelled Electrolyte (Gel) and Absorbed Glass Mat (AGM) Batteries EAST PENN Expertise and American Workmanship absorbed by the negative plate. This suppresses the production of hydrogen at the negative plate. Water (H O) is produced INTRODUCTION TO VRLA instead, retaining the moisture within the battery.
  • Page 176 II. AGM & GEL BATTERIES Advantages of GEL and AGM battery designs VRLA technology encompasses both gelled electrolyte or gel KEY BATTERY BENEFITS batteries and absorbed glass mat or AGM batteries. Both types are regulated by special one-way, pressure-relief valves and Premium maintenance-free design have significant advantages over flooded lead-acid products.
  • Page 177 assures a homogenous gel. Our equipment was designed High absorption and retention rate holds acid securely in by our engineers specifically for gel mixing – even down to glass fibers to prevent uneven saturation and acid strati- the contour of the tank bottoms and feed pipe locations. fication (see explanation of acid stratification under Acid Stratification Prevention section).
  • Page 178 East Penn’s Quality Assurance Checks IV. GENERAL QUESTIONS ABOUT VRLA BATTERIES Below are a few examples of the hundreds of quality checks that are performed on Gel or AGM battery types to assure total What do I need to know about confidence in the performance and life of our batteries: VRLA battery charging? Extended Shelf Stand Test.
  • Page 179 What are the safety precautions 5. Provide adequate ventilation as regulated by Federal, State and Local codes and follow recommended for VRLA batteries? charging voltages. Although all valve-regulated batteries have the electrolyte 6. Extinguishing media: Class ABC extinguisher. Note: CO immobilized within the cell, the electrical hazard associated may be used but not directly on the cells due to thermal with batteries still exists.
  • Page 180 What is a thermal runaway? V. GLOSSARY TERMS The appropriate charge voltage depends on the battery tem- ACTIVE MATERIAL — The porous structure of lead compounds peratures. A warmer battery requires a reduced voltage. If the that produce and store electrical energy within a lead-acid battery. voltage is not reduced, current accepted by the battery The active material in the positive plates is lead dioxide and that in increases.
  • Page 181 CIRCUIT (Parallel) — A circuit that provides more than one path GEL — Electrolyte that has been immobilized by the addition of a for the flow of current. A parallel arrangement of batteries (usu- chemical agent, normally fine silica, to prevent spillage. Batteries ally of like voltages and capacities) has all positive terminals made with gelled electrolyte are often referred to as Gel batteries.
  • Page 182 RESERVE CAPACITY RATING — The time in minutes that a new, SULFATION — The generation or conversion of the lead sulfate fully charged battery will deliver 25 amperes at 27°C (80°F) and discharge in the plates to a state that resists normal recharge. maintain a terminal voltage equal to, or higher than, 1.75 volts per Sulfation often develops when a battery is stored or cycled in a cell.
  • Page 183 ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § ¢ ¡ ¤ £ ¥ £ ¥ ¦ ¨ § Owners Manual Incorporated 11* 11* Battery Equalizer Table of Contents Introduction………………………………………………….………………… 2 Specifications…………………………………………………….………….… 3 Theory of Operation……………...…………………………………………… 4 Typical Applications…………………………...…………….…………..…… 5 Installation Instructions………………………….………...………………….

  • Page 184: Introduction

    © ¢  ¤  ¥  ¥  ¨  © ¢  ¤  ¥  ¥  ¨  Introduction Incorporated Introduction Thank you for purchasing a Vanner VANN-Guard Battery Equalizer. We are confident that you will be very pleased with its performance because our 70-Series are designed and manufactured by skilled professionals using the highest standards in workmanship.

  • Page 185: Specifications

     ¢  ¤  ¥  ¥  ¨   ¢  ¤  ¥  ¥  ¨  Specifications Incorporated Specifications 70-Series Equalizers Model Number 70-60 70-80 70-100 Input Voltage 24v 18 to 32 v Efficiency (Peak) >97% >97% >97%...

  • Page 186: Theory Of Operation

    Y ¢ ` ¤ a ¥ a ¥ b ¨ c Y ¢ ` ¤ a ¥ a ¥ b ¨ c Theory of Operation Incorporated Theory of Operation +24V 12 V +24V Battery B VANN-Guard +12V +12V +24 Volt +12 Volt 12 V Battery A...

  • Page 187: Typical Applications

    d ¢ e ¤ f ¥ f ¥ g ¨ h d ¢ e ¤ f ¥ f ¥ g ¨ h Typical Applications Incorporated Typical Applications Vanner VANN-Guard Battery Equalizers are used in many types of applications including transit and tour buses, private coaches, heavy trucks and off highway equipment, yachts, and alternative energy systems such as solar powered homes.
  • Page 188 i ¢ p ¤ q ¥ q ¥ r ¨ s i ¢ p ¤ q ¥ q ¥ r ¨ s Typical Applications Incorporated Typical Applications continued: TOUR/CHARTER COACH +24V 12 V +24V Battery B VANN-Guard Vanner +12V DC to AC Inverter +12V +24 Volt...

  • Page 189: Installation Instructions

    t ¢ u ¤ v ¥ v ¥ w ¨ x t ¢ u ¤ v ¥ v ¥ w ¨ x Installation Instructions Incorporated Installation Instructions Do not exceed the specified torque of 120 in-lbs. when connecting cables to the terminal posts (+24, GND, +12) during installation of all the VANN-Guard Models.
  • Page 190 y ¢ € ¤  ¥  ¥ ‚ ¨ ƒ y ¢ € ¤  ¥  ¥ ‚ ¨ ƒ Installation Instructions Incorporated Caution adding 12volt batteries Acceptable Unacceptable +24V +24V Battery A and Battery B Are Battery A and Battery B Are The Same Size NOT The Same Size 12 V...
  • Page 191 „ ¢ … ¤ † ¥ † ¥ ‡ ¨ ˆ „ ¢ … ¤ † ¥ † ¥ ‡ ¨ ˆ Installation Instructions Incorporated Wire Size and temperature rating Cables connecting the VANN-Guard to the batteries must be sufficiently sized to prevent unwanted voltage drops.

  • Page 192: Testing And Troubleshooting

    ‰ ¢  ¤ ‘ ¥ ‘ ¥ ’ ¨ “ ‰ ¢  ¤ ‘ ¥ ‘ ¥ ’ ¨ “ Testing and Troubleshooting Incorporated Testing and Troubleshooting Before testing the equalizer, be sure all battery connections are good and that fuses F1 and F2 are good. CAUTION Servicing of electrical systems should only be performed by trained and qualified technical personnel.
  • Page 193 ” ¢ • ¤ – ¥ – ¥ — ¨ ˜ ” ¢ • ¤ – ¥ – ¥ — ¨ ˜ Testing and Troubleshooting Incorporated Voltage Comparison VANN-Guard Status Stand-by Mode. Battery A is lower than Battery B but The VANN-Guard will not turn ON until Battery A is lower within 0.05 volt.
  • Page 194 ™ ¢ d ¤ e ¥ e ¥ f ¨ g ™ ¢ d ¤ e ¥ e ¥ f ¨ g OWNER’S MANUAL Incorporated Vanner Incorporated 4282 Reynolds Drive Hilliard, Ohio 43026 1-800-AC POWER (1-800-227-6937) Tel: 614-771-2718 Fax: 614-771-4904 www.vanner.com e-mail: pwrsales@vanner.com Part Number...
  • Page 195 FAULT CODE MANUAL Created on 00-04-25 15:30 FAULT CODE MANUAL B7L, B7TL, B12 - 1 -...
  • Page 196 FAULT CODE MANUAL Created on 00-04-25 15:30 Preface The content of this manual has been based upon information from design department at Volvo Bus, Volvo Trucks and external suppliers. Due to problems with retrieving updated documents, new signal specifications etc. we cannot guarantee that the information is 100% correct.
  • Page 197 FAULT CODE MANUAL Created on 00-04-25 15:30 Table of contents Bus Instrument Cluster (BIC)...................... 4 The instrument display........................ 4 The windscreen wiper handle ...................... 4 Display menus..........................5 Setting the display language......................5 Read fault codes from ECU......................6 Comparing chassis number with the VIC..................

  • Page 198: Bus Instrument Cluster (Bic)

    FAULT CODE MANUAL Created on 00-04-25 15:30 1. Bus Instrument Cluster (BIC) The bus instrument cluster contains a number of indicators and lamps that shows the status of different parts of the bus. It can also be used to display faultcodes from the different control units by using the windscreen wiper handle.

  • Page 199: Display Menus

    FAULT CODE MANUAL Created on 00-04-25 15:30 4. Display menus The image below displays the main menus in the display window. The window can only display three items at once, therefore the up/down button on the windscreen wiper handle must be used to browse through the menus. Simply press the “Return” button on the windscreen wiper handle to enter a desired menu.

  • Page 200: Read Fault Codes From Ecu

    FAULT CODE MANUAL Created on 00-04-25 15:30 6. Read fault codes from ECU From the main menu, use the up/down button on the windscreen wiper handle to move down to the “System diagnostic” menu and press the “Return” key. The line “Fault diagnostic” should now be highlighted, if it’s not you can simply use the up/down button on the windscreen wiper handle to move to that line.
  • Page 201 FAULT CODE MANUAL Created on 00-04-25 15:30 As in the example above, you can see that the fault code is set in MID 130, the SID number is 191 and the FMI number is 2. By looking at the fault code table for MID 130 (which represents the TECU) you can see that SID number 191 means “Output speed level error”...

  • Page 202: Comparing Chassis Number With The Vic

    FAULT CODE MANUAL Created on 00-04-25 15:30 7. Comparing chassis number with the VIC The VIC (Vehicle Identification Card) is a card that comes with every new bus that identifies the chassis number for the bus and the HW/SW id for each control unit. To check chassis number, select “Data log mode”...
  • Page 203 FAULT CODE MANUAL Created on 00-04-25 15:30 The image below shows the HW/SW id for the CECM, the display cannot display both SW id and HW id at the same time, therefore you have to use the up/down buttons on the windscreen wiper handle to show SW id instead of HW id.

  • Page 204: Fault Codes, Abs (Mid 136)

    FAULT CODE MANUAL Created on 00-04-25 15:30 9. Fault codes, ABS (MID 136) (P)PID/SID Seriousness Component/Function Display text SID 1 Air gap Sensor wheel sp LF SID 1 Incorrect tyre Sensor wheel sp LF SID 1 Shorted to UBATT Sensor wheel sp LF SID 1 Shorted to ground Sensor wheel sp LF...
  • Page 205 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID Seriousness Component/Function Display text SID 5 Air gap SID 5 Incorrect tyre SID 5 Shorted to UBATT SID 5 Shorted to ground SID 5 Open circuit SID 5 Short circuit SID 5 Incorrect pole wheel SID 5 Slip...
  • Page 206 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID Seriousness Component/Function Display text SID 14 Diag. 1 Voltage, low voltage/open Valve relay circuit SID 14 Ground diagonal, open circuit Valve relay SID 14 ECU-Ground or WL-Ground Valve relay SID 14 Ground diagonal 1, shorted to low Valve relay SID 14 Voltage feeding solenoid valve Valve relay...

  • Page 207: Fault Codes, Bic (Mid 140 & 234)

    FAULT CODE MANUAL Created on 00-04-25 15:30 10. Fault codes, BIC (MID 140 & 234) (P)PID/SID Seriousness Component/function Display text PID 84 Speed Road speed PID 190 Number of revolutions Engine speed 140&234 SID 240 Program memory Program memory 140&234 SID 253 EEPROM Calibration memory 140&234 SID 253...

  • Page 208: Fault Codes, Cecm (Mid 164)

    FAULT CODE MANUAL Created on 00-04-25 15:30 11. Fault codes, CECM (MID 164) (P)PID/SID Seriousness Component/Function Display text PID 43 Starting sw. status PID 43 Starting sw. status PID 70 Park brake switch PID 117 Brake pressure #1 PID 117 Brake pressure #1 PID 118 Brake pressure #2...

  • Page 209: Fault Codes, Cim (Mid 164)

    FAULT CODE MANUAL Created on 00-04-25 15:30 12. Fault codes, CIM (MID 164) (P)PID/SID FMI Seriousness Component/function Display text PSID 31 Short-circuit to battery PSID 31 Short-circuit to ground PSID 3 Alternator not charging PSID 4 Alternator not charging PSID 45 Alternator not charging PSID 46 Alternator not charging...

  • Page 210: Fault Codes, Eecu (Mid 128)

    FAULT CODE MANUAL Created on 00-04-25 15:30 13. Fault codes, EECU (MID 128) (P)PID/SID FMI Seriousness Component/function Display text PID 45 Yellow lamp Starting heater status relay Inlet air heat stat PID 45 Yellow lamp Starting heater status relay Inlet air heat stat PID 45 Yellow lamp Starting heater status relay...
  • Page 211 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID FMI Seriousness Component/function Display text PPID 100 Yellow lamp Outer actuator Ext. timing act. PPID 100 Yellow lamp Outer actuator Ext. timing act. PPID 100 Yellow lamp Outer actuator Ext. timing act. PPID 109 Yellow lamp Exhaust pressure governor EPG3...
  • Page 212 FAULT CODE MANUAL Created on 00-04-25 15:30 (P)PID/SID FMI Seriousness Component/Function Display text SID 24 Red lamp Control rod position Rack positoin sens. SID 24 Red lamp Control rod position Rack positoin sens. SID 64 Yellow lamp Engine speed pump Tim.

  • Page 213: Fault Codes, Tecu Voith 863,3 Retarders And Transmission (Mid 130)

    FAULT CODE MANUAL Created on 00-04-25 15:30 14. Fault codes, TECU Voith 863,3 retarders and transmission (MID 130) (P)PID/SID FMI Seriousness Component/function Display text PID 40 Hand brake sensor Retarder switches PID 65 Foot brake sensor Brake pedal switch PID 92 Software Engine load, % PID 93...
  • Page 214 FAULT CODE MANUAL Created on 00-04-25 15:30 15. Fault codes, ZF HP 502 retarder (MID 222) and transmission (MID 130) (P)PID/SID FMI Seriousness Component/function Display text PID 1 Transmission slip Invalid data PID 155 Not used dig. Out shorted high Aux.
  • Page 215 FAULT CODE MANUAL Created on 00-04-25 15:30 SID 10 Ret_On Valve shorted ground (P)PID/SID FMI Seriousness Component/function Display text SID 10 Ret_On Valve current circuit break SID 11 Retarder current resistor SID 11 Retarder current shorted high SID 11 Retarder current shorted ground SID 11 Retarder current circuit break SID 12...

  • Page 216: Fault Codes, Voith 115V Retarder (Mid 222)

    FAULT CODE MANUAL Created on 00-04-25 15:30 16. Fault codes, Voith 115v retarder (MID 222) (P)PID/SID FMI Seriousness Component/function Display text PID 110 Eng. coolant temp. Eng. coolant temp. PID 110 Eng. coolant temp. Eng. coolant temp. PID 110 Eng. coolant temp. Eng.

  • Page 217: Fault Codes, Retarder 133

    FAULT CODE MANUAL Created on 00-04-25 15:30 17. Fault codes, retarder 133 To the right of the bus instrument cluster there is a green checklamp (5022) for the retarder function and fault indications. At every voltage inflow the lamp will normally be lit for five seconds, if the lamp doesn’t go out after five seconds have passed, a fault code is set in the retarder.
  • Page 218 FAULT CODE MANUAL Created on 00-04-25 15:30 Code Description Internal fault concerning: ROM (CRC check). EEPROM (data record) 2/2-way valve fault Non-plausibility of brake pedal operation Pressure sensor fault Time-out > 500ms press signal (VECU) Time-out > 500ms ABS-signal (J1939) J 1939 link "bus off".

  • Page 219: Fault Codes, Vecu (Mid 144)

    FAULT CODE MANUAL Created on 00-04-25 15:30 18. Fault codes, VECU (MID 144) (P)PID/SID FMI Seriousness Component/Function Display text PID 29 Yellow lamp Extra throttle, percentage mode Second throttle PID 29 Yellow lamp Extra throttle, percentage mode Second throttle PID 46 Wet tank air pressure Wet tank air press PID 46...
  • Page 221 SECTION 07: TRANSMISSION CONTENTS DESCRIPTION ............................3 ALLISON AUTOMATIC TRANSMISSION ................... 3 1.1.1 Retarder (if applicable) ......................3 VOLVO I-SHIFT TRANSMISSION ....................... 3 WELDING PROCEDURES ........................4 MAINTENANCE ............................ 4 ALLISON TRANSMISSION ........................4 3.1.1 Manual Fluid level Check ......................4 3.1.2 Cold Check ..........................
  • Page 222 Section 07: TRANSMISSION ILLUSTRATIONS ........................3 IGURE ALLISON TRANSMISSION .................... 3 IGURE ALLISON PUSHBUTTON SHIFT SELECTOR ......................4 IGURE VOLVO I SHIFT TRANSMISSION ) ......................4 IGURE OIL LEVEL DIPSTICK ALLISON ........................... 5 IGURE COLD CHECK ............................. 6 IGURE HOT CHECK .......................

  • Page 223: Description

    Section 07: TRANSMISSION match the shift to desired profile stored in its DESCRIPTION memory. It then looks at these adjustments and H3 Series vehicles may be provided with either resets parameters, which allow an Allison automatic transmission or a Volvo I- transmission quickly compensate...

  • Page 224: Welding Procedures

    Section 07: TRANSMISSION If the I-Shift transmission system is to be used, 3.1.1 Manual Fluid level Check the vehicle must have an electronic engine Clean all dirt from around the end of the oil filler control unit as well as CAN communication. tube before removing the dipstick.

  • Page 225: Hot Check

    Section 07: TRANSMISSION 1. If the engine has been shut down for an extended period of time, park the vehicle on a CAUTION level surface and apply the parking brake. Obtain an accurate fluid level by imposing the CAUTION following conditions: ...

  • Page 226: Fluid Level Check Using The Pushbutton Shift Selector

    Section 07: TRANSMISSION DISPLAY INTERPRETATION Oil Level is invalid. Source of invalid reading is defined O L… – (fc) by a two-character fault FIGURE 6: HOT CHECK 07049 code (fc) NOTE NOTE The Cold Check is more appropriate for Note that the quantities LO 4 and HI 3 are the verifying the oil level after the first fill-up.

  • Page 227: Keeping Fluid Clean

    Drain Intervals. TranSynd™ is fully qualified to will restrict full operation until the sump the Allison TES295 specifications and is temperature is increased. available through Prevost Parts. 3.1.8 Oil Contamination NOTE At each oil change, examine the drained oil for The prognostics package requires the use of evidence of dirt or water.

  • Page 228: Coolant Leakage

    Section 07: TRANSMISSION To access the Prognostic Mode functions, CAUTION simultaneously press the (Up) and (Down) arrow buttons repeatedly. See the reference If excessive metal contamination has occurred, table at the end of this section. replacement of the oil cooler and replacement of all bearings within the transmission is ...
  • Page 229 Section 07: TRANSMISSION  Display: An acceptable clutch life status is Filter Life Monitor displayed as "OK". An unacceptable clutch life The display message denotes operating status status is displayed as "LO". The specific of the transmission main fluid filter, based on the clutch(es) for which the function indicates "LO"...
  • Page 230 Section 07: TRANSMISSION The following table illustrates how to access Oil Level Check, Prognostics & Diagnostic Troubleshooting Codes functions on the Allison pushbutton shift selector. Description SELECT MONITOR (up) & (down) arrow buttons pressed simultaneously press Allison transmission oil level check "...
  • Page 231 Section 07: TRANSMISSION TABLE 1 Recommended Fluid and Filter Change Intervals Using Dexron-III/Non-TranSynd / Non-TES 295 / Mixture Severe General Coaches or MTH equipped with retarder Coaches or MTH without retarder Filters Filters Fluid Fluid Main Internal Lube/ Main Internal Lube/ Auxiliary Auxiliary...

  • Page 232: Oil And Filter Change Interval

    Section 07: TRANSMISSION 3.1.12 Oil And Filter Change Interval IMPORTANT NOTE The following schedule is to be used with  Oil And Filter Change Interval With Prognostics enabled. Prognostics Mode Disabled 100% concentration TES-295 Allison Allison transmissions are factory fill with Castrol approved fluids and Allison High Capacity TranSynd™...

  • Page 233: Volvo I-Shift Transmission

    VOLVO I-SHIFT TRANSMISSION 3.2.1 Transmission Oil CAUTION Only use Castrol Syntrans SAE 75W85 (Prevost #684516) gearbox oil in the I-Shift transmission. Using non-approved oil can result in damage to transmission components. CAUTION Never reuse drained I-Shift oil. The oil must be replaced along with the oil filter.

  • Page 234: Oil Change Interval

    Section 07: TRANSMISSION MAINTENANCE For on-highway applications, change the transmission oil every 800 000 km (500,000 miles) or every 5 years whichever occurs first. This extended oil change interval only applies when using Castrol Syntrans SAE 75W85. Always replace the oil filter when the oil is changed.

  • Page 235: Allison Transmission Removal

    Section 07: TRANSMISSION 4. Remove cross member from under NOTE transmission. Torque tighten oil filter housing drain plug to 5. Remove the transmission drain plug and allow 16±2 Nm (12±1 lb-ft). oil to drain. Inspect the drain plug washer and replace it if necessary.

  • Page 236: Transmission Oil Cooler Removal

    Section 07: TRANSMISSION 3. Unfasten the constant-torque hose clamps and remove the two hoses. 4. Unscrew the four holding nuts and remove the U-bolts, remove the oil cooler from engine compartment. 5. Reinstall transmission oil cooler by using reverse procedure. TRANSMISSION WITH RETARDER Stop engine and allow engine to cool.

  • Page 237: Breather

    Section 07: TRANSMISSION 2. Oil leaks (correct immediately); the guide bolt previously installed in the flywheel with the flexible plate hole facing the 3. Loose, dirty, or improperly adjusted throttle access opening in the flywheel housing. sensor linkage; 4. Damaged or loose oil lines; WARNING 5.

  • Page 238: Allison Automatic Transmission Troubleshooting

    Section 07: TRANSMISSION 12. Connect the two transmission oil cooler GENERATION TRANSMISSION hoses as they were previously. CONTROL MODULE 13. Reinstall clamps and brackets, and replace locking ties previously removed during removal procedure. 14. Install propeller shaft and its safety guard. Refer to Section 09, "PROPELLER SHAFT".

  • Page 239: Diagnostic Codes - Allison

    Section 07: TRANSMISSION Diagnostic codes (DTC) and code information may be accessed through the pushbutton shift selector or using an Allison DOC™ diagnostic tool. The TCM separately stores the active and inactive codes. An active code is any code that is current in the TCM decision-making process.

  • Page 240: Diagnostic Code Response

    Section 07: TRANSMISSION NOTE NOTE Be sure to record all codes displayed before If clearing a code while locked in a «D» (Drive) they are cleared. This is essential for or «R» (Reverse) position (fail-to-range), the troubleshooting. transmission will still be in «D» (Drive) or «R» (Reverse) when the clearing procedure is NOTE completed.

  • Page 241: Diagnostic Troubleshooting Codes (Dtc) List - Allison

    Section 07: TRANSMISSION DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST - ALLISON 4 GENERATION CONTROLS CHECK Inhibited Operation Description TRANS Description Light May inhibit retarder operation if not C1312 Retarder Request Sensor Failed Low using J1939 datalink May inhibit retarder operation if not C1313 Retarder Request Sensor Failed High using J1939 datalink...
  • Page 242 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P071D General Purpose Input Fault None P0720 Output Speed Sensor Circuit P0721 Output Speed Sensor Circuit Performance DNS, Lock in current range P0722 Output Speed Sensor Circuit No Signal DNS, Lock in current range P0726 Engine Speed Sensor Circuit Performance Default to turbine speed...
  • Page 243 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P0975 Shift Solenoid 2 (SS2) Control Circuit Open 7-speed: Allow 2 through 6, N, R 7-speed: Allow 2 through 6, N, R P0976 Shift Solenoid 2 (SS2) Control Circuit Low Inhibit TCC operation P0977 Shift Solenoid 2 (SS2) Control Circuit High...

  • Page 244: Volvo I-Shift Transmission Tecu Fault Codes

    Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light Ignores PWM input from shift P2793 Gear Shift Direction Circuit selector P2808 Pressure Control Solenoid 6 (PCS6) Stuck Off DNS, RPR P2809 Pressure Control Solenoid 6 (PCS6) Stuck On DNS, RPR P2812 Pressure Control Solenoid 6 (PCS6) Control Circuit Open DNS, SOL OFF (hydraulic default)
  • Page 245 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 calibrated Deactivate: Slip point has been successfully calibrated Activate: The calculated stored energy is above 200kJ. The Yellow lamp is energy sent calculation is Start gear time-based for Data valid but changed to gear VTNA and Clutch load...
  • Page 246 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Gear changes are slow Yellow lamp is sent Clutch Activate: Reduced clutch Data valid but Voltage is below performance position below normal range Reduced sensor FMI1 operational Deactivate: gearbox comfort supply range Voltage is within...
  • Page 247 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 valves and, 0.1s 5. The PCB - If the position has moved temperature is more than 1mm in the above a specific engagement direction, the limit FMI is set, else if the clutch Deactivate: The has moved less than 0.2mm clutch response...
  • Page 248 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 any of: the sensor for the countershaft speed (SECS) the sensor for the clutch position (SEPoC) and the engine torque & engine speed is received from the engine ECU Deactivation: The clutch can transfer the maximum engine torque without slipping...
  • Page 249 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 for short circuit Reduced clutch to Gnd on VAFE performance or VAFD Gear changes are slow Deactivate: The low-side drive is Detailed conditions The following conditions must be fulfilled for five activations (only one with the fault code-filter switched OFF) of the gearbox brake...
  • Page 250 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 to 1:st gear the valve for shift to reverse gear - There is no active fault code for low air pressure Note: The fault will always have the state inactive. Check the fault count and last occurrence to get more information.
  • Page 251 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 engagement set the fault sent activate/deactivate engagement of 1:st gear Loss of torque code: The following conditions system -The 1:st gear The 1:st gears must be fulfilled three times will not be can not engage (only one time if the fault -There is no...
  • Page 252 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 the valve for shift to 1:st gear the valve for shift to reverse gear Detailed conditions to activate/deactivate The following conditions must be fulfilled three times (only one time if the fault code-filter is switched OFF) in a row in order to set the fault code:...
  • Page 253 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Detailed conditions to activate/deactivate The following conditions must be fulfilled three times (only once if the fault code- filter is switched OFF) in a row in order to set the fault code: (engagement of another gear will reset the count)
  • Page 254 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 2:nd gear may gear is activated for at least be made 0.8s - The 2/3 cylinder position sensor indicates that 2:nd position is not engaged - There is no active fault on any of the 2/3 position sensor (SEPo23) the valve for shift to 2:nd gear the...
  • Page 255 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 gear will reset the count) - The valve for reaching gear (2:nd and 3:rd gear cylinder) is activated for at least 0.8s - The 2/3 cylinder position sensor indicates that neutral position is not engaged - There is no active fault code on any of the 2/3...
  • Page 256 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 from BECU backup mode (MID136) is not with gear received within changes only at certain vehicle Deactivate: The speeds FMI shall be cleared if message WSI is received at normal rate Activate: The FMI shall be set if message VP6...
  • Page 257 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 message VP37 Automatic gear is received at selection normal rate performance might be reduced a certain time after a trailer has been connected/disco nnected Activate: The FMI shall be set if message VW from ECS Missing data...
  • Page 258 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 signals selection and engine. "busOFF" gear change Deactivate: The performance FMI shall be cleared if the CAN-transceiver does not signal "busOFF" Activate: The FMI shall be set if message VP24/MID128 is Yellow lamp is not received sent...
  • Page 259 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 gear will reset the count) - The range cylinder position indicates that the range gear leaves the high range position - The range cylinder valves are inactive - There is no active fault on any of the sensor for the position of the range cylinder (SEPoR) the valve...
  • Page 260 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 not engage within 3.8s - The gearbox oil temperature is above 10dgC - There is no active fault on any of the range position sensor (SEPoR) low air pressure the range cylinder valves - There is no active fault code for low air pressure...
  • Page 261 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Activate: The Checksum of the NVRAM is not Sensor for Yellow lamp is correct, or the sent the 1:st and Calibration sensor has not Cranking is reverse gear FMI13 value out of been calibrated inhibited range...
  • Page 262 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 gear cylinder (SEPo23) Sensor for Activate: Status the position Current above from the ASIC is Yellow lamp is of the 2:nd normal or short circuit to sent FMI6 grounded Slow gear and 3:rd circuit Deactivate:...
  • Page 263 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 sensor has not Engine can not (SEPoR) been calibrated start Deactivate: Sensor signal has been successfully calibrated Detailed conditions to activate / deactivate: Activate: The position sensor is distributing a temperature-signal from the sensor ASIC, if the value Activate: The...
  • Page 264 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 in normal range 2. Pressure is below 10.0 [bar] Activate: 1. Yellow lamp is Sensor signal is sent in normal range The symbol for Sensor for Data valid but 2. Pressure is compressed air, the pressure below...
  • Page 265 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 -The sensor for the position of the split cylinder (SEPoS) -The sensor for the position of the shift cylinder1R (SEPo1R) -The sensor for the position of the shift cylinder 23 (SEPo23) -The sensor for the position of teh range cylinder...
  • Page 266 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 of teh range cylinder (SEPoR) Yellow lamp is sent Reduced gear change performance Gearbox brake up shifts can not be used Activate: The Slip point cannot sensor signal is be updated Sensor for below normal which will give...
  • Page 267 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 2. The main speed calculated from the shaft speed and main shaft speed sensor the counter shaft (SESM) and the counter speed are equal shaft speed sensor (SESC) when the main differ more than 50rpm shaft is rotating The values of the input shaft...
  • Page 268 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 The sensor for the position of teh range cylinder (SEPoR) Detailed conditions to activate The following conditions must be fulfilled for a time of 2.0s in order to activate: The input shaft speed calculated from the countershaft speed sensor (SESC) is above 300 rpm...
  • Page 269 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 shaft speed sensor (SESM) indicates forward movement or A reverse gear is engaged and the main shaft speed sensor (SESM) indicates reverse movement. The fault is also deactivated if the main shaft speed sensor (SESM) signal is not within normal range, or if there is an active fault on...
  • Page 270 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 2. Temperature temperature is lit is below 100dgC High: Red lamp is sent Activate Symbol for high medium: 1. The gearbox oil temperature is lit sensor signal is in normal range 2.
  • Page 271 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 INV) is normal Activate: Sensor signal is short Yellow lamp is circuit to Ubatt or sent sensor supply, Sensor Reduced clutch when at least The PID 33 fault code Voltage performance position of one of the...
  • Page 272 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 has not been Engine can not supply (PPID 54) (SEPoC and calibrated start SEPoCINV) Deactivate: Sensor signal has been successfully calibrated Yellow lamp is sent Activate: The Slow low-side drive is engagement/dis Voltage Slow clutch...
  • Page 273 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 cylinder valves code: are inactive (engagement of another gear will reset the count) - The split cylinder position indicates that split gear leaves the direct position - The split cylinder valves are inactive - There is no active fault on any of the sensor for the...
  • Page 274 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 position of the split cylinder (SEPoS) the valve for shift to direct split the valve for shift to indirect split - There is no active fault code for low air pressure The fault is deactivated if any of the following conditions are fulfilled:...
  • Page 275 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 position is not engaged - There is no active fault on any of the sensor for the position of the split cylinder (SEPoS) the valve for shift to direct split the valve for shift to indirect split - There is no active fault code for low air pressure...
  • Page 276 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 high side drive is be deactivated Reduced gear change comfort Activate: The Yellow lamp is Valve for high side drive is sent Current below activating the open circuit The valve can FMI5 normal or Deactivate: The...
  • Page 277 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 grounded short circuit to Fast engagement circuit engagement of the clutch Deactivate: The disabled (VAFE) Reduced clutch high-side drive is performance Gear changes are slow Yellow lamp is sent The valve is activated Activate: The Indirect and...
  • Page 278 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Automatic gear selection enters faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated Valve for high side drive is Gears are Current above short circuit to...
  • Page 279 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can not be activated Activate: The Valve for Gears are high side drive is Current below missing shifting to...
  • Page 280 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 changes only at certain vehicle speeds Yellow lamp is sent The valve is Activate: The activated Valve for high side drive is Low range gears Voltage short circuit to are missing shifting to above normal SID35...
  • Page 281 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated Valve for high side drive is Split gears are Current above short circuit to missing shifting to normal or...
  • Page 282 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Valve for Yellow lamp is Activate: The sent slow high-side drive is Current below Slow disengage- open circuit FMI5 normal or disengagement Deactivate: The ment of the open circuit disabled high-side drive is clutch Reduced clutch...
  • Page 283 Section 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Deactivate: The Shifting to the (VAGB) start gear takes high side drive is long time 10. VOLVO I-SHIFT TRANSMISSION GSECU FAULT CODES PID/PPID LAMP CONTENT TEXT COMMENT CONSEQUENCES SID/PSID SAE J1939 SID231 None Redundancy on J1587...
  • Page 284 Section 07: TRANSMISSION PID/PPID LAMP CONTENT TEXT COMMENT CONSEQUENCES SID/PSID Only when second gear Not possible to switch Data Link, PSID214 None selector is to/from secondary gear MID249 installed, lever Boot 11. SPECIFICATIONS ALLISON AUTOMATIC TRANSMISSION WITH OR WITHOUT RETARDER H3 Buses Gross input power (maximum) ....................
  • Page 285 Section 07: TRANSMISSION Prevost part number (2-filters replacement kit) ..................571709 VOLVO I-SHIFT TRANSMISSION Oil System: Oil type ........................ CASTROL SYNTRANS 75W85 Oil change ..........................16 US qts (15 liters) Oil Filter: Make ................................Volvo Type ............................Disposable cartridge Prevost Part Number ..........................20779040...
  • Page 287 Service Bulletin Prevost Buses DRAFT Saint-Nicolas, Quebec, Canada Date Group Release Page 1( 9 ) 6.2010 Gear Selector Control Module (GSCM) MID 223, Diagnostic Trouble Code (DTC), Guide Gear Selector Control Module (GSCM) MID 223, Diagnostic Trouble Code (DTC), Guide Contents •...
  • Page 288 Prevost Group Page Date Release DRAFT Service Bulletin 2( 9 ) 6.2010 MID 223 Gear Selector Control Module The manufacturer scan tool is the preferred tool for performing diagnostic work. Contact your local dealer for more information or visit “www.premiumtechtool.com”.
  • Page 289 Prevost Group Page Date Release DRAFT Service Bulletin 3( 9 ) 6.2010 Gear Selector Control Module (MID 223), Diagnostic Fault Codes (DTC) The manufacturer scan tool is the preferred tool for performing diagnostic work. Contact your local dealer for more information or visit “www.premiumtechtool.com”.
  • Page 290 Prevost Group Page Date Release DRAFT Service Bulletin 4( 9 ) 6.2010 Diagnostic Trouble Code (DTC) List PSID “MID 223 PSID 9, Gear Selector, Position”, page 5 “MID 223 PSID 36, Relay Power Supply”, page 5 “MID 223 PSID 42, Signals Key”, page 6 “MID 223 PSID 200, Communication Interference, Data Link, Engine Control Module (ECM)”, page 6...
  • Page 291 Prevost Group Page Date Release DRAFT Service Bulletin 5( 9 ) 6.2010 MID 223 PSID 9, Gear Selector, Position Type of FMI Description: Fault Condition: Possible Possible Cause: Symptoms: fault: FMI 12 • • • • Faulty device or The sensor...
  • Page 292 Prevost Group Page Date Release DRAFT Service Bulletin 6( 9 ) 6.2010 MID 223 PSID 42, Signals Key Type of FMI Description: Fault Condition: Possible Possible Cause: Symptoms: fault: FMI 2 • • • • Data erratic, Inconsistency Transmission Wiring harness or connectors...
  • Page 293 Prevost Group Page Date Release DRAFT Service Bulletin 7( 9 ) 6.2010 MID 223 PSID 201, Communication Interference, Data Link, Vehicle Electronic Control Unit (VECU) Type of FMI Description: Fault Condition: Possible Possible Cause: fault: Symptoms: FMI 9 • •...
  • Page 294 Prevost Group Page Date Release DRAFT Service Bulletin 8( 9 ) 6.2010 MID 223 PSID 214, No Data From Bodybuilders Module (BBM) Type of FMI Description: Fault Condition: Possible Possible Cause: Symptoms: fault: FMI 9 • • • • Abnormal update...
  • Page 295 Prevost Group Page Date Release DRAFT Service Bulletin 9( 9 ) 6.2010 MID 223 SID 240, Program Memory Type of FMI Description: Fault Condition: Possible Possible Cause: Symptoms: fault: FMI 2 • • • • Data erratic, Fault data in...
  • Page 297 SECTION 09: PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..........................2 DESCRIPTION ..........................2 REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION ..........2 CLEANING, INSPECTION AND LUBRICATION ................. 2 CLEANING AND INSPECTION ...................... 2 LUBRICATION..........................2 EXPLANATION OF COMMON DAMAGES ..................4 TROUBLESHOOTING .......................... 4 SPECIFICATIONS ..........................

  • Page 298: Propeller Shaft

    Repair kits are available for overhaul of the needle bearings. propeller shaft assembly. Refer to H3-41, H3- The other extremity (tube yoke assembly) is 45, VIP Parts Manual, Section 9. connected to the transmission by a half round end...
  • Page 299 Section 09: PROPELLER SHAFT FIGURE 1: PROPELLER SHAFT ASSEMBLY 09003 PA1602 SECTION 09...

  • Page 300: Explanation Of Common Damages

    SPECIFICATIONS PROPELLER SHAFT H3 VEHICLES EQUIPPED WITH AN AUTOMATIC WORLD TRANSMISSION Make ............................Hayes-Dana Inc. Series ................................. SPL250 Prevost number ............................580087 Length ................................ 835 mm H3 COACHES EQUIPPED WITH I-SHIFT TRANSMISSION Make ............................Hayes-Dana Inc. Series ................................. SPL250 Prevost number ............................580085 Length ................................
  • Page 301 SECTION 10: FRONT I-BEAM AXLE CONTENTS DESCRIPTION ............................2 LUBRICATION ............................4 MAINTENANCE ............................ 4 REMOVAL AND REPLACEMENT......................4 REMOVAL ............................4 REPLACEMENT ..........................5 SERVICE INSTRUCTIONS FOR STEER AXLE ................... 5 STEERING KNUCKLE (KING) PIN INSPECTION ................. 5 5.1.1 Checking Lateral Slackness ....................

  • Page 302: Description

    Section 10: FRONT I-BEAM AXLE DESCRIPTION The Dana Spicer S84U front axle is of the ‘’Reverse Elliot’’ type manufactured by Dana Spicer Europe. The front axle consists of a girder section axle bed or beam with stub axles. Each stub axle is carried on a taper king pin, with a plain phosphor bronze bushing at the top and at the bottom.
  • Page 303 Section 10: FRONT I-BEAM AXLE TYPICAL S84U AXLE ITEM DESCRIPTION ITEM DESCRIPTION Flanged Bolt 161-197 lbf-ft Draw key, Nut, Washer 51-62 lbf-ft Tie Rod End Brake Disc V" Ring Seal Stake Hub Nut 563-687 lbf-ft Kingpin Collet Washer Kingpin - Bushing Hub Bearing O-Ring Seal Nut –...

  • Page 304: Lubrication

    Section 10: FRONT I-BEAM AXLE LUBRICATION axle from the vehicle. However, if extensive overhaul work is necessary, the axle assembly should be removed. MAINTENANCE CAUTION Knuckle pins are provided with grease fittings Should removal of a locking device be required for pressure lubrication.

  • Page 305: Replacement

    Section 10: FRONT I-BEAM AXLE NOTE CAUTION Before commencing checks, apply parking brake, raise wheels off ground and support axle Position the air lines and electric wires so they on stands. will not be damaged while removing the front axle assembly. 5.1.1 Checking Lateral Slackness 8.

  • Page 306: Checking Vertical Slackness

    Section 10: FRONT I-BEAM AXLE 4. If displacement exceeds stated allowance then need for bush / bearing attention and possible renewal, is in evidence. FRONT WHEEL ALIGNMENT NOTE Correct front wheel alignment must be maintained To avoid inaccurate measurements, be careful for steering comfort and satisfactory tire life.

  • Page 307: Minor Front Wheel Alignment

    Section 10: FRONT I-BEAM AXLE Make sure the front tires are the same NOTE size and type. If steering angle stoppers are changed, a Make sure the wheels are balanced. special procedure is required for readjusting gearbox steering limiter. See paragraph 6.5 Check wheel installation...

  • Page 308: Turn Adjustment

    Section 10: FRONT I-BEAM AXLE 6. This must be done for a full right turn. HYDRAULIC STOP 7. If readjustment is required: NOTE Remove the swivel stop screw. Before steering limiter readjustment, verify vehicle wheel alignment and ensure that oil Add to the stop screw the required level is checked and that air bleeding is done.

  • Page 309: Front Axle Caster

    (Prevost #110663) on the left-hand 4. Check the wheel lateral distortion as side upper radius rod support in order to obtain instructed in Section 13, ‘’Wheels, Hubs and...

  • Page 310: Inspection And Adjustment

    Section 10: FRONT I-BEAM AXLE NOTE ‘’Toe-in’’ measurements must be taken at the horizontal axis of the wheel centerline. 6.8.1 Inspection and Adjustment Before checking front wheel toe-in, first check the camber angles and make the necessary corrections. 1. Measure the toe-in. 2.

  • Page 311: Troubleshooting

    Section 10: FRONT I-BEAM AXLE Use static wheel alignment systems which work with angle measurements only, such as Josam or Hunter systems. Static alignment specifications are listed in the following tables: FRONT WHEEL ALIGNMENT SPECIFICATIONS WITH I-BEAM AXLE Front Wheel Alignment Minimal Nominal Maximal...

  • Page 312: Specifications

    Section 10: FRONT I-BEAM AXLE Worn or damaged 1. Drag link fasteners tightened past 1. Replace damaged part(s), tighten drag steering ball stud. specified torque. link fasteners to specified torque. 2. Lack of lubrication or incorrect 2. Lubricate linkage with specified lubricant.

  • Page 313: Torque Specifications

    Section 10: FRONT I-BEAM AXLE TORQUE SPECIFICATIONS PA1602 SECTION 10 REVISED SEPT 2013...
  • Page 314 Section 10: FRONT I-BEAM AXLE PA1602 SECTION 10 REVISED SEPT 2013...
  • Page 315 Section 10: FRONT I-BEAM AXLE The following table lists the tightening torques which do require a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE 1 –...
  • Page 316 Section 10: FRONT I-BEAM AXLE SPECIFIC TORQUE TABLE 1 – FRONT I-BEAM AXLE SUSPENSION & STEERING REFERENCE DESCRIPTION TORQUE DRY ( lbf-ft / Nm threads must be free of oil or other lubricant STEERING DAMPER ARM NUTS 285-315 386-427 For more torque specifications, see ‘Dana Spicer Maintenance Manual NDS Axles and Maintenance Manual Model NDS’’...
  • Page 317 SECTION 11: REAR AXLES CONTENTS DRIVE AXLE ............................2 DESCRIPTION ..........................2 DCDL (DRIVER-CONTROLLED MAIN DIFFERENTIAL LOCK) ............2 DRIVE AXLE LUBRICATION ......................2 MAINTENANCE..........................3 1.4.1 Checking and Adjusting the Oil Level ..................3 1.4.2 Draining and Replacing the Oil ....................3 1.4.3 Speed Sensors (Anti-Lock Brake system, ABS) ..............

  • Page 318: Drive Axle

    Section 11: REAR AXLES DRIVE AXLE DESCRIPTION The Meritor drive axle is equipped with a single reduction standard carrier mounted in front of the axle housing. The carrier consists of a hypoid drive pinion, a ring gear set and gears in the differential assembly.

  • Page 319: Checking And Adjusting The Oil Level

    Section 11: REAR AXLES 2. Make sure the axle is "cold" or at room temperature. 3. Clean the area around the fill plug. Remove the fill plug from the differential axle housing bowl (Fig. 4). 4. The oil level must be even with the bottom of the hole of the fill plug.

  • Page 320: Speed Sensors (Anti-Lock Brake System, Abs)

    Section 11: REAR AXLES 1.4.3 Speed Sensors (Anti-Lock Brake NOTE system, ABS) Position the hoses so they will not be damaged For removing and installing the drive axle speed when removing the axle. sensors (for anti-lock brake systems, ABS), refer 8.

  • Page 321: Gear Set Identification

    Section 11: REAR AXLES GEAR SET IDENTIFICATION been damaged by an accident or if there are requirements for replacement. Gear identification covered under If the axle has been removed for repairs or applicable heading in Meritor's "MAINTENANCE servicing and if all the parts are reinstalled MANUAL NO.

  • Page 322: Tag Axle

    Section 11: REAR AXLES TAG AXLE ALIGNMENT  Remove and reinstall all wheel mount sensors on the drive and tag axles (fig. 8); NOTE For an accurate alignment, the tag axle must be aligned with the drive axle. NOTE Reinstall wheel mount sensors as shown in figure 8. For example, the sensor from the right side of the front axle is mounted on the left side of the tag axle.

  • Page 323: Unloading Or Retracting Tag Axle

    FIGURE 10: TORQUE SPECIFICATION 2. Apply a continuous thin bead of silicone TAG AXLE sealant* (Prevost P/N 680053) on the mounting surfaces and around the edge of all The tag axle is located behind the drive axle. It fastener holes of both the axle shaft flange carries a single wheel and tire on each side.

  • Page 324: Retracting Tag Axle For Repair Purposes

    Section 11: REAR AXLES 1. Shortening of wheelbase, thus allowing tighter Bearings are pre-adjusted, lubricated and have turning in tight maneuvering areas such as seals fitted as part of the manufacturing process. parking lots or when making a sharp turn. The bearings are greased for life and there is no need or facility for re-lubrication.

  • Page 325: Removing Transversal Radius Rod

    Section 11: REAR AXLES during removal and disassembly depends upon CAUTION local conditions and available equipment. 1. Raise vehicle by its jacking points on the On vehicles equipped with an automatic body (fig. 5 or see Section 18, "Body" under transmission (with or without the output heading: "Vehicle Jacking Points").

  • Page 326: Tag Axle Alignment

    NOTE The drive axle alignment consists in aligning the axle with reference to the frame. The axle must be perpendicular to the frame. Tag Axle Make ................................Prevost Rear track ........................83.6 inches (2 124 mm) Axle type ..............................Forged NOTE The tag axle alignment consists in aligning the tag axle parallel to the drive axle.
  • Page 327 TP-9539 Revised 06-07 Approved Rear Drive Axle Lubricants Technical Bulletin CAUTION You must fill Meritor axles with Meritor-specified lubricants only. Do not fill an axle with non-approved lubricants, which will void Meritor’s warranty. Damage to axle components also can result. To avoid axle component damage, fill Meritor axles with approved lubricants only.
  • Page 328 Table B: Axle Oil Specifications A.P .I. Viscosity ArvinMeritor Outside Gear Oil Type Specification Grade Specification Specification Temperature 85W/140 O76-A Above +10°F (–12°C) 80W/140 O76-B Above –15°F (–26°C) 80W/90 O76-D Above –15°F (–26°C) 75W/90 O76-E Above –40°F (–40°C) Petroleum with SAE J2360 Tested GL-5 From –40°F (–40°C)
  • Page 329 Table C: Extended-Drain-Approved Synthetic Axle Oil Suppliers — United States Distributors Name of Lubricant Viscosity Manufacturer Gibraltar Syn-Gear 75W/90, 80W/140 David Weber Oil Company Gulf Syngear 75W/90, 80W/140 Gulf Oil Hi-Tek Synthetic 75W/90, 80W/140 Industrial Oils Limited Imperial SGO 75W/90, 80W/140 IPAC Lubemaster Syn EP 75W/90, 80W/140...
  • Page 330 Table D: Additional Extended-Drain-Approved Axle Oil Suppliers CANADA: Name of Lubricant Viscosity Manufacturer HDH Synthetic 75W/90, 80W/140 Irving Oil Limited NEMCO Syngear 75W/90, 80W/140 NemCo Resources Limited Sonic MP Gear Oil 75W/90, 80W/140 Federated Cooperatives Limited Titan Syndrive 75W/90, 80W/140 Fuchs Lubricants Canada Limited MEXICO: Name of Lubricant...
  • Page 331 For Meritor R-170 Axles Equipped Lubrication Analysis ® With Traction Equalizer Recommendations Meritor’s R-170 axles with Traction Equalizer Meritor recommends using a lubricant analysis normally operate with either standard petroleum, program. Perform lubricant analysis at semi-synthetic or full-synthetic oils. regularly-scheduled preventive maintenance intervals.
  • Page 332 Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is 2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the Troy, MI 48084 USA information presented or to discontinue the production of parts described at any time.
  • Page 333 TP-96105 Revised 07-03 ® Applying Loctite Ultra Grey Flange Sealant 5699/Meritor Maintenance Part Number 2297-Z-7098 Manual Update TP-96105 Revised 1 Maintenance Manual Update 07-03 Hazard Alert Messages Clean the surfaces where you will apply the silicone gasket material. Remove all oil, grease, dirt and moisture. Figure 1. Read and observe all Warning and Caution hazard alert messages in Dry both surfaces.
  • Page 334 Maintenance Manuals The information in this Technical Bulletin updates the following Maintenance Manuals. Title Date Tandem Axle Forward Rear Drive 09-88 Units Single-Reduction Hypoid Drive 08-79 Unit Tandem Axle Forward Rear Drive 03-91 Units Double-Reduction Differential 08-84 Carriers Hypoid Planetary Two-Speed 08-90 Differential Carriers Heavy-Duty Front Drive Steer...
  • Page 335 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM ............................4 BRAKES ..............................4 AIR RESERVOIRS ..........................4 ..........................4 AINTENANCE 3.1.1 Wet Air Tank ..........................5 3.1.2 Primary Air Tank ........................5 3.1.3 Accessory Air Tank........................5 3.1.4 Emergency/Parking Brake Overrule Air Tank ................. 5 3.1.5 Secondary Air Tank .........................
  • Page 336 Section 12: BRAKE AND AIR SYSTEM BRAKE RELAY VALVE (R-14) ......................12 ANTILOCK TRACTION RELAY VALVE (ATR-6) ................12 SPRING BRAKE VALVE (SR-7)...................... 12 PRESSURE PROTECTION VALVE (PR-4) ..................13 SHUTTLE-TYPE DOUBLE CHECK VALVE (DC-4) ............... 13 EMERGENCY DOOR OPENING VALVES ..................13 22.1 ....................
  • Page 337 Section 12: BRAKE AND AIR SYSTEM 31.3 (ESC) ............27 ADVANCED ABS WITH ELECTRONIC STABILITY CONTROL ® 31.4 .................. 27 ENDIX STEERING ANGLE SENSOR 31.4.1 Removal of the steering angle sensor ................... 27 FITTING TIGHTENING TORQUES ....................28 SPECIFICATIONS ........................... 29 ILLUSTRATIONS FIGURE 1: AIR TANKS LOCATION 12196 ......................

  • Page 338: Air System

    Section 12: BRAKE AND AIR SYSTEM AIR SYSTEM drive provided with spring-loaded emergency/parking brakes, which are applied The basic air system consists of an air automatically whenever the control valve supply compressor, reservoirs, valves, filters pressure drops below 60 psi (413 kPa). The interconnecting lines and hoses.

  • Page 339: Wet Air Tank

    Section 12: BRAKE AND AIR SYSTEM 3.1.1 Wet Air Tank This reservoir, located in front and above the drive axle in the rear wheelhousing, is provided with a bottom drain valve. A recommended purge using the bottom drain valve should be done every 12,000 miles (20 000 km), or once a year, whichever comes first.

  • Page 340: Air System Emergency Fill Valves

    15 psi (105 kPa) between filter system provided by Prevost. Do not fill system inlet and outlet ports. Check condition of all three by any other point on the system.

  • Page 341: Air Filter/Dryer

    Section 12: BRAKE AND AIR SYSTEM AIR FILTER/DRYER remove moisture that could damage the air system before the air enters the system reservoir. The air filter/dryer also filters the air to Meritor Wabco air dryer port identification remove dirt, compressor oil, other contaminants that can damage the system.

  • Page 342: Air Leak Check / Warning

    Section 12: BRAKE AND AIR SYSTEM 6. Lubricate cartridge seal. FLEXIBLE HOSES 7. Thread replacement cartridge onto the base A flexible hose is used normally where it is until the seal touches the base. Then, tighten impractical to use copper or nylon tubing due to the cartridge ONE additional turn.

  • Page 343: Maintenance

    Section 12: BRAKE AND AIR SYSTEM MAINTENANCE specified pressure setting and check for air leakage. Inspect all lines for cuts, swelling, kinks or other damage or deterioration. Check for lines being pinched by other components. Retaining clips and ties must be in place. Any support or bracket should be in good condition and mounted firmly in position.

  • Page 344: Compressor Removal And Installation

    Section 12: BRAKE AND AIR SYSTEM The compressor is driven by the ring gear, and is 10.1.1 Compressor Removal and Installation water cooled. Engine coolant is fed to the 1. Exhaust compressed air from air system by compressor through a flexible hose tapped into opening the drain valve of each air tank.

  • Page 345: Emergency / Parking Brake Overrule Control Valve (Rd-3)

    Section 12: BRAKE AND AIR SYSTEM 3. Disconnect the air tubes. DUAL BRAKE APPLICATION VALVE (E-10P) 4. Remove the retaining screws. The E-10P dual brake valve is a floor mounted, 5. Service or replace the valve. foot-operated type brake valve with two separate 6.

  • Page 346: Parking Brake Alarm Switch

    Section 12: BRAKE AND AIR SYSTEM 18. ANTILOCK TRACTION RELAY VALVE (ATR-6) The ATR-6 Antilock Traction Relay valve is a service relay valve fitted with a modified cover containing a control solenoid. It contains both air and electric components to provide the service braking and traction control (differential braking) as well as ESC advanced stability system ABS functions.

  • Page 347: Pressure Protection Valve (Pr-4)

    Section 12: BRAKE AND AIR SYSTEM 21. SHUTTLE-TYPE DOUBLE CHECK VALVE (DC-4) Maintenance and repair information on the shuttle-type double check valve is supplied in the applicable booklet annexed to this section under reference number SD-03-2202. The double check valve is located on the pneumatic accessories panel in the front service compartment.

  • Page 348: Air Horn Valve

    Section 12: BRAKE AND AIR SYSTEM 6. Reverse the procedure to install a new BRAKE OPERATION valve. The vehicle braking system uses both service and parking air-operated brakes. The air system AIR HORN VALVE is divided into two independent circuits to isolate the front axle brakes and the rear axle brakes The air horn solenoid valve is located in the front (drive and tag), thus providing safe brake...

  • Page 349: Inspection Points

    Manual included on the • excessive or abnormal play technical manuals CD and • movement along guide pins is hard or available Prevost impossible (due to corrosion or dirt) Technical Publications site. • A missing guide pin cap 26.1 INSPECTION POINTS...

  • Page 350: Pad Replacement Procedure

    Section 12: BRAKE AND AIR SYSTEM FIGURE 22: BRAKE COMPONENTS removed, worn pads should be replaced in their original position. 26.2 PAD REPLACEMENT PROCEDURE Brake pad replacement procedure has slightly 26.3.1 Drive Axle – Equipped With a Solid changed with the introduction of the new N2G Rubber Bushing and Exposed Guide Pin slack adjuster on our vehicles.

  • Page 351: Front And Tag Axle - Equipped With Visual Wear Indicator

    Section 12: BRAKE AND AIR SYSTEM (Fig 24). If any minimal tolerance limits have been reached, the pads and/or disc must be changed. MEASUREMENT “C” WITH NEW BRAKE PADS AND DISC MEASUREMENT “C” WITH WORN DISC/BRAKE PADS FIGURE 23: BRAKE PAD WEAR CHECK ON DRIVE AXLE FIGURE 24: BRAKE PAD WEAR CHECK ON FRONT AND If measurement “C”...

  • Page 352: Brake Pads And Discs Minimal Tolerance Limits

    Section 12: BRAKE AND AIR SYSTEM material: 0.433 in (11 mm) 26.4 BRAKE PADS AND DISCS MINIMAL TOLERANCE LIMITS 26.4.1 Brake Pads The thickness of the pads must be checked regularly dependent on the usage of the vehicle. The pads should be checked corresponding to any legal requirements that may apply.

  • Page 353: Torque Specifications

    Section 12: BRAKE AND AIR SYSTEM FIGURE 27: RUNNING CLEARANCE working on brakes that contain non-asbestos fibers. 26.6 TORQUE SPECIFICATIONS For proper caliper maintenance, refer to the following figures. WARNING Whenever possible, work on brakes in a separate area away from other operations. Always wear a respirator approved by NIOSH (National Institute of Occupational Safety and Health) or MSHA (Mine Safety and Health...

  • Page 354: Air Brake Troubleshooting

    Section 12: BRAKE AND AIR SYSTEM home. Vacuum your work clothes after use CONDITION: Vehicle leveled, parking brake applied. and then launder them separately, without shaking, to prevent fiber dust from getting into 1. Completely drain wet, primary the air. secondary air reservoirs only.

  • Page 355: Brake Air Chamber

    Section 12: BRAKE AND AIR SYSTEM nents with a water and soap solution. Bub- • If inlet valves are stuck, open or leaking bles will indicate an air leak, and none should severely, replace unloader kit, inlet valves be permissible. Repair or replace defective and/or seats as necessary.

  • Page 356: Maintenance

    Section 12: BRAKE AND AIR SYSTEM 29.1 MAINTENANCE DANGER Every 6,250 Miles (10 000 km) or twice a year, whichever comes first depending on type of Make sure the release stud is properly operation: anchored in spring plate receptacle prior to caging the spring.

  • Page 357: Brake Chamber Installation

    On o Prevost recommends the installation of a slippery roads and generally in emergency new spring brake chamber if it is found to situations, over-braking frequently induces wheel be defective.

  • Page 358: Troubleshooting And Testing

    Section 12: BRAKE AND AIR SYSTEM ABS is active on service brake, transmission retarder, engine brake, but is inactive on emergency/parking brake. NOTE The ABS system is inoperative at speeds under 4 mph (6 km/h). Illumination of ABS telltale indicator at these speeds is normal. CAUTION Disconnect the ECU or pull the ABS fuse before towing vehicle.

  • Page 359: Spring Clip

    Maintenance 30.4.1 Spring clip No specific maintenance is required for sensors, except if the sensors have to be removed for axle servicing. In such a case, sensors should be lubricated with special grease (Prevost #680460) before reinstallation. Refer paragraph “Sensor Installation” for details.

  • Page 360: The Ec-60 Tm Controller's Abs Function Utilizes The Following Components

    • Dash-mounted ESC/TCS status/indicator lamp (also serves as the ESC sta- 6s/5m Configuration tus/indicator lamp); Prevost vehicles utilize a 6 sensors/5 pressure • Dash-mounted TCS Mud/Snow switch; modulator valves configuration, with the tag axle • J1939 serial communication to engine having two sensors, but only one Pressure control module.
  • Page 361 SAS-70 sensor. tion. The level of braking application during an The SAS-70 sensor installed on Prevost vehicles RSP event will be proportional to roll risk. is the 90° connector.
  • Page 362 Section 12: BRAKE AND AIR SYSTEM Diagnostics: The steering angle sensor calibration can only be achieved when the sensor is powered by the The steering angle sensor is only operational in Advanced ABS ECU. No stand-alone sensor conjunction with Advanced ECU.
  • Page 363 Section 12: BRAKE AND AIR SYSTEM NOTE Use Loctite pipe sealant to seal pipe thread (Prevost number 680098). SPECIFICATIONS Air Compressor Make ............................Meritor Wabco Model ..............................SS636 Capacity (at 1250 rpm) .....................37.4 cfm (1,059 m /min.) Air Dryer Make ............................Meritor Wabco Model ............................
  • Page 364 Section 12: BRAKE AND AIR SYSTEM Pressure Protection Valve Make ..........................Bendix Westinghouse Model ............................... PR-4 Nominal closing pressure ...................... 70 psi (482 kPa) Prevost number ........................... 641137 Shuttle-Type Double Check Valve Make ..........................Bendix Westinghouse Model ............................... DC-4 Air Pressure Regulator Make ..............................
  • Page 365 Effective Date: 12/02/05 Bendix Air Disc Brake Pad Replacement on Prevost Car Vehicles Subject: Prevost Car and Bendix Spicer Foundation Brake • Shear testing of the friction material adhesion LLC are issuing this product notification about resulted in the friction material completely...
  • Page 366 work clothes home. Work clothes should be • Brake workers must take steps to minimize their exposure to airborne brake lining particles. vacuumed using a high efficiency particulate Procedures to reduce exposure include: filter (HEPA) vacuum and laundered separately working in a well-ventilated area, segregating without shaking.
  • Page 367 Start Here Bendix Air Disc Brake ® All foundation brakes are designed to convert kinetic energy (energy of motion) into heat and work (to stop the vehicle). Checklist for Air disc brakes work the same way and in everyday operation — compared to drum brakes Identifying Single Wheel —...
  • Page 368 SECTION TWO: Investigate Other Potential External Causes Inspect the brake pads. (New pads have 21 mm of brake pad, plus a 9 mm backing plate.) there Replace the pads (axle set recommended) 2 mm, or less, of after performing all Section Two inspections. brake pad friction (Not a Thermal Overload warranty condition.) material?*...
  • Page 369 SECTION TWO Continued Inspect On level ground, with the wheels chocked, cage the spring brake actuator (if equipped) per the manufacturer’s guidelines, remove and inspect the actuator. actuator. any of Service the actuator. these conditions (Not a Thermal Overload warranty condition.) found? With the actuator removed, inspect the internal caliper surfaces through...
  • Page 370 SAFE MAINTENANCE PRACTICES WARNING! PLEASE READ AND FOLLOW WARNING: Not all wheels and valve stems are THESE INSTRUCTIONS TO AVOID PERSONAL compatible with Bendix Air Disc Brakes. Use only wheels and valve stems approved by the vehicle manufacturer to avoid INJURY OR DEATH: the risk of valve stem shear and other compatibility issues.
  • Page 371 SECTION 13: WHEELS, HUBS & TIRES CONTENTS WHEELS ..............................3 WHEEL MAINTENANCE ........................3 INSPECTION ..........................3 SINGLE WHEEL REMOVAL ......................3 SINGLE WHEEL INSTALLATION ....................4 DUAL WHEELS ............................. 4 OUTER WHEEL REMOVAL ......................4 INNER WHEEL REMOVAL ......................4 INNER WHEEL INSTALLATION ....................
  • Page 372 Section 13: WHEELS, HUBS & TIRES ILLUSTRATIONS ....................3 FIGURE ALUM STEEL WHEEL ARRANGEMENT ........................3 FIGURE TIGHTENING SEQUENCE ........................ 5 FIGURE DIAL GAUGE INSTALLATION ......................... 6 FIGURE DRIVE AXLE WHEELS ..........................6 FIGURE SINGLE WHEEL & ......................7 FIGURE FRONT TAG AXLE WHEEL HUB &...

  • Page 373: Wheels

    Section 13: WHEELS, HUBS & TIRES 1. WHEELS CAUTION The vehicle is equipped with hub-mounted wheels as standard equipment, all studs and Wheel studs and nuts must be kept free from nuts have right-hand threads Either steel grease and oil. No lubricant whatsoever wheels or optional aluminum-polished wheels should be used.

  • Page 374: Single Wheel Installation

    Section 13: WHEELS, HUBS & TIRES 2.3 SINGLE WHEEL INSTALLATION NOTE 1. Mount the wheel over studs, being careful On dual wheel assemblies, position the not to damage stud threads; wheels with the tire valves 180º apart in order to have access to both the inner and outer 2.

  • Page 375: Wheel Straightness Test

    Section 13: WHEELS, HUBS & TIRES 1. Remove any tar from wheel surface with a 3. If the variation in lateral run-out exceeds good quality tar remover. 0.0625 inch (1,6 mm), the wheel must be replaced. 2. Spray Alcoa Cleaner (Prévost #683529) evenly on cool outer surface of wheel.

  • Page 376: Drive Axle Studs

    Section 13: WHEELS, HUBS & TIRES When installing wheel studs to hubs, check nuts protection, applied to stop rusting and to retaining the wheel stud to wheel hub and facilitate wheel removal). The reason for this is replace if they are deformed, damaged or to assure that all faces are clamped together severely corroded.

  • Page 377: Care Of Wheels

    Section 13: WHEELS, HUBS & TIRES FIGURE 6: FRONT & TAG AXLE WHEEL HUB  Apply parking brake, raise wheels off the 7.1 CARE OF WHEELS ground and support axle on stands. When the wheels are raised, they should revolve Check for cracks in wheels, especially around quite freely without roughness.

  • Page 378: Hub Bearing Removal

    Model  Maintenance Manual NDS Axles” annexed at Lubricate part of spindle where bearing will the end of Section 11. be located, use Gleitmo 805 grease (Prevost #685274). 8.2 HUB BEARING REMOVAL  Slide unitized hub bearing over spindle and position using insertion tool #32950.

  • Page 379: Drive Axle Wheel Hubs

    0.001/0.007" Add some grease (25-50 ml) (Fuchs (0.0254/0.1778 mm) endplay and to ensure Renolite LX PEP-2) (Prevost #685325) into that wheel turns freely. Replace the lock ring, the bottom of the hub flange cap. Mount hub and adjust nut dowel pin in one of the holes.

  • Page 380: Spare Wheel (If Applicable)

    Section 13: WHEELS, HUBS & TIRES selection). Lubricate, then install outer NOTE bearing cone. Adjust bearing and lock. Converted vehicles contain no spare wheel. Access to compartment is also obtained by 8. Assemble axle flange to axle using a new pulling the release handle located in the front gasket.

  • Page 381: Changing A Flat Tire

    Section 13: WHEELS, HUBS & TIRES WARNING To prevent personal injury and/or equipment damage, use only the recommended jacking points. Passengers must not remain inside vehicle while wheel is being replaced. CAUTION Adjust tire pressure according appropriate cold tire inflation-pressure. NOTE FIGURE 9: SPARE WHEEL AND TIRE 18415...

  • Page 382: Inflation Pressure

    Section 13: WHEELS, HUBS & TIRES 11.1 INFLATION PRESSURE NOTE  Vehicles equipped with BERU TPMS Inflation pressure should be checked when tires are cold. Cold tire inflation pressure can On vehicles equipped with the Beru Tire be measured when a vehicle has not been Pressure Monitoring System (TPMS), it is better driven for at least 3 hours or less than 1 mile to use the TPMS display as the primary...

  • Page 383: Tire Matching

    Unmatched tires on drive axle will cause tire recommendations. For other tire and wheel wear and scuffing, as well as possible damage specifications, see Prevost tire pressure to the drive unit. Consequently, we recommend tabulation in "Coach Final Record". that tires be matched within 1/8" (3 mm) of the same rolling radius.

  • Page 384: Wheel Balancing

    Section 13: WHEELS, HUBS & TIRES NOTE It is recommended that all tires on coach be of the same type. 11.3 WHEEL BALANCING Before balancing, wheels must be clean and free from all foreign matter. The tires should be in good condition and properly mounted. An unbalanced wheel can be due to a bent wheel or improper mounting.

  • Page 385: Specifications

    (105 km/hr). Do not drive vehicle at a higher speed than 65 mph (105 km/h) or above the posted speed limit. ALUMINUM WHEEL CLEANING AND MAINTENANCE PRODUCTS Aluminum Wheel Cleaner (22 Oz bottle) ................Prevost #683529 Aluminum Wheel Polish (16 Oz bottle) ................Prevost #683528 Aluminum Wheel Sealer (13 Oz bottle) ................Prevost #683527...
  • Page 387 SECTION 14: STEERING CONTENTS STEERING SYSTEM ..........................3 I-BEAM FRONT AXLE STEERING SYSTEM DESCRIPTION ............3 INDEPENDENT FRONT SUSPENSION STEERING SYSTEM DESCRIPTION ......4 POWER STEERING GEAR ........................5 DESCRIPTION ..........................5 POWER STEERING GEAR REMOVAL ..................6 POWER STEERING GEAR INSTALLATION ................. 6 TROUBLESHOOTING........................
  • Page 388 Section 14: STEERING 12.7.1 Visual Inspection ........................17 12.7.2 Straight Body Type Ball joint End Play and Looseness ............17 DRIVING TIPS ..........................18 TROUBLESHOOTING ........................19 TORQUE SPECIFICATIONS ......................20 SPECIFICATIONS ........................... 20 ILLUSTRATIONS ......................3 FIGURE STEERING SYSTEM AXLE SETUP ......................

  • Page 389: Steering System

    Section 14: STEERING STEERING SYSTEM These elements are: 1. Steering stabilizer (damper); I-BEAM FRONT AXLE STEERING 2. A vane type hydraulic pump; and SYSTEM DESCRIPTION 3. Hydraulic reservoir and hoses. The steering system consists of the steering The steering stabilizer reduces road shocks and wheel and column assembly, a vane-type vibrations in the system.

  • Page 390: Independent Front Suspension Steering System Description

    Section 14: STEERING INDEPENDENT FRONT SUSPENSION STEERING SYSTEM DESCRIPTION The steering system consists of the steering wheel and column assembly, a vane-type hydraulic pump, reservoir, filter, interconnecting system lines and hoses, integral power steering gear and linkage (Figure 2). The steering linkage consists of tie rods connected to the bell crank and the steering arm at the left side of the coach, and to the idler arm and steering arm at the right side of the coach.

  • Page 391: Power Steering Gear

    Section 14: STEERING POWER STEERING GEAR FIGURE 4: FRONT SERVICE COMPARTMENT 14050 A torsion bar, which is pinned with the valve slide and the worm, keeps the control valve in the neutral position as long as no opposing force is applied to the steering wheel.

  • Page 392: Power Steering Gear Removal

    Section 14: STEERING POWER STEERING GEAR REMOVAL BLEEDING POWER STEERING HYDRAULIC SYSTEM 1. Put a container into place, and then disconnect both the inlet and outlet hoses To bleed the power steering hydraulic system, from the power steering gear. Cover fittings refer to the "ZF-SERVOCOM REPAIR MANUAL"...
  • Page 393 Section 14: STEERING FIGURE 8: POWER STEERING PUMP REMOVAL 8. Install the new power steering pump. FIGURE 6: FUEL PUMP REMOVAL Torque-tighten bolts to specification. CAUTION NOTE Use a new gasket. Ensure to clean around the head of the bolts. Debris will prevent the tool from fitting properly 9.

  • Page 394: Steering Column

    Section 14: STEERING STEERING COLUMN REMOVAL FIGURE 10: STEERING COLUMN COVERS 14040 1. From the front driver's compartment area, remove the three plastic fasteners on steering column lower cover. Remove the lower cover (Figure 10). 2. Unscrew the four retaining screws on steering column middle cover.

  • Page 395: Installation

    Section 14: STEERING NOTE The clockspring mechanism permits a certain number of turns in each direction. At the moment of reinstalling the steering wheel, if the clockspring is not at its neutral position, the number of available turns will be reduced. This may damage the clockspring if the steering wheel is turned to its maximum amplitude.

  • Page 396: Turning Angle Adjustment

    Section 14: STEERING Break the paper seal and rotate the center part of the clockspring about 50° CAUTION clockwise (Figure 15). This step necessary for the installation of the steering Never maintain the relief pressure for more than wheel. 5 seconds, since damage to the power steering pump may occur.

  • Page 397: Installation

    Front Suspension) in relation with the vertical reference marks aligned. axis (towards rear of vehicle). If not, unscrew and remove fixing nut. Remove the pitman 2. Install fixing nut (Prevost #661050). Tighten arm according to the procedure outlined as per “Torque Specifications” in this section. under...

  • Page 398: Fine Adjustment

    Section 14: STEERING PINCH HAZARD CAUTION Too little pressure on the clamp can destroy the Keep hands and fingers clear of pinch zones around pitman arm. threaded adjustment system sleeve. Apply the recommended torque of 118-133 lbf-ft Pinch zones are between pitman arm and for clamp nut! clamp, and between front of pitman arm and vehicle structure.

  • Page 399: Power Steering Reservoir And Filter

    Section 14: STEERING Air in the hydraulic system will cause spongy action and noisy operation. When a hose has MAINTENANCE been disconnected or when fluid has been lost for any reason, the system must be bled. Bleed At regular intervals, fluid level should be system as outlined under heading 3: "BLEEDING checked in the reservoir and filter assembly.

  • Page 400: Steering Stabilizer Cylinder (Damper)

    Section 14: STEERING 3. Remove the retaining spring and finally the filter cartridge element. FIGURE 23: STEERING STABILIZER (DAMPER) 14053 12.3 DRAG LINK Visually inspect drag link components for broken, corroded or deformed clamps, loose, bent or corroded nuts and gauges on tube from rubbing parts.

  • Page 401: Tie Rod

    Section 14: STEERING Clean the adjustment system with a brush and 12.4 TIE ROD compressed air prior to inspection, if required. With the engine running and the vehicle on the ground (with a load on the axle) turn the steering wheel left and right.

  • Page 402: Drop Type Ball Joint

    Section 14: STEERING 3. If there is corrosion of the ball pin or the 12.6.2 Dismantling Drop Type Ball Joint sealing boot has deteriorated through ageing 1. Remove dirt seal and dirt seal pressing from or is damaged, replace the ball joint. ball pin.

  • Page 403: Straight Body Type Ball Joint

    Section 14: STEERING • 7. Fit cover plate into top of ball joint body, re- Check ball joint connection for missing cotter peen using a cold chisel to secure. pins. • 8. Screw assembled ball joint onto tie rod. Check for looseness in the ball/socket Lining up marks on both body and tie rod assembly.
  • Page 404 Section 14: STEERING 2. With the engine off and wheels straight ahead and no force is being exerted on the linkage by the steering gear, push and pull the ball joint in and hand (approximately 100 lbs. force) in the direction of ball pin.
  • Page 405 Section 14: STEERING 14. TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear out 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly or have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.
  • Page 406 F.E.W............................ 19,000 lbs (8 618 kg) Pressure rating ........................2,320 psi (160 Bar) Power Steering Reservoir Oil capacity ..........................4 US qts (3.7 liters) Prevost number ............................660982 Make ............................... Nelson Muffler Steering Stabilizer Cylinder (Damper) Extended length ..........................32.73±0.12"...
  • Page 407 SECTION 16: SUSPENSION CONTENTS DESCRIPTION ............................5 FRONT I-BEAM AXLE SUSPENSION ....................5 AIR SPRINGS ..........................5 2.1.1 Inspection ..........................5 2.1.2 Removal ..........................5 2.1.3 Installation ..........................6 SHOCK ABSORBERS ........................6 2.2.1 Inspection ..........................7 2.2.2 Removal ..........................7 2.2.3 Installation ..........................
  • Page 408 Section 16: SUSPENSION 3.12.1 Inspection ..........................32 3.12.2 Stripping Down ........................32 3.12.3 Assembly ..........................32 3.13 LOWER A-ARM BALL JOINT REPAIR ..................33 3.13.1 Stripping Down ........................33 3.13.2 Assembly ..........................33 3.14 UPPER A-ARM BALL JOINT ......................33 3.14.1 Visual Inspection ........................
  • Page 409 Section 16: SUSPENSION 10.3 HIGH-BUOY – PRESSURE REGULATOR .................. 46 10.3.1 Adjustment ..........................46 10.3.2 Disassembly .......................... 46 10.3.3 Cleaning ..........................46 10.3.4 Reassembly ........................... 47 LOW-BUOY SYSTEM ........................47 11.1 PRINCIPLES OF OPERATION ....................47 11.2 MAINTENANCE..........................47 AIR SYSTEM ........................... 47 12.1 AIR TANK MAINTENANCE ......................
  • Page 410 Section 16: SUSPENSION ....................33 FIGURE UPPER A ARM BALL PIN BUSHING ......................33 FIGURE LOWER A ARM BALL JOINT ......................34 FIGURE UPPER A ARM BALL JOINT ........................35 FIGURE SHOCK ABSORBER ..35 FIGURE SWAY BAR INDEPENDENT FRONT SUSPENSION ....................

  • Page 411: Description

    Section 16: SUSPENSION DESCRIPTION With the primary air system at normal operating pressure (95 - 125 psi (655 - 860 The vehicle is provided with an air suspension kPa)), coat suspension line system. The system consists of air springs, connections and bellows mounting areas height control valves, radius rods, sway bars, with a water and soap solution.

  • Page 412: Installation

    Section 16: SUSPENSION recommended jacking points. Make getting back into the air spring and keeps it sure that the measurement between compressed, thus enabling to place the air the air spring mounting plates is spring in between the mounting plates and greater than the normal clearance greatly easing installation.

  • Page 413: Inspection

    Section 16: SUSPENSION Deep cracks bushing material will help in determining if both shock (shallow surface cracks are normal); absorbers on the same axle have to be replaced. Loose shock absorber pins; Presence of convex washers, and their 2.2.1 Inspection position relative to the rubber bushing.

  • Page 414: Radius Rod Removal

    Section 16: SUSPENSION absorber rubber bushing) on each shock sense with a suitable lever tool. After the load is extremity. taken off, the joint has to spring back into its starting position. Free play is not acceptable. NOTE Separation of rubber from ball pin or sheet metal If shock absorber pins are removed, they must race is permissible up to a third of the be reinstalled using “Loctite”...

  • Page 415: Radius Rod Installation

    Section 16: SUSPENSION A complete repair set must be used for each 2. Safely support the sway bar. Unbolt the four joint repaired, i.e. use of only part of a repair set bushing brackets from subframe. is not permissible. 3. Remove sway bar. Execute assembly of the new joint parts in the following sequence: 1.
  • Page 416 Section 16: SUSPENSION TORQUE SPECIFICATIONS - FRONT I-BEAM AXLE SUSPENSION AND STEERING PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 417 Section 16: SUSPENSION PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 418 Section 16: SUSPENSION The following table lists the tightening torques which do require a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE 1 – FRONT I-BEAM AXLE SUSPENSION & STEERING TORQUE DRY ( REFERENCE DESCRIPTION...

  • Page 419: Independent Front Suspension (Ifs)

    Section 16: SUSPENSION INDEPENDENT FRONT SUSPENSION (IFS) This section contains information specifications unique to the independent front suspension (IFS), including suspension and steering. FIGURE 8: INDEPENDENT FRONT SUSPENSION 16124 STEERING LINKAGE the coach. The bell crank and idler arm are connected by a relay rod.
  • Page 420 Section 16: SUSPENSION such that the total steering forces are produced clamp bolts and nuts. Reposition if with minimal stress on mechanical linkages (Fig. required. 10). Lower and upper A-arms are widely spaced. CAUTION They are mounted on ball joints. Torque rods prevent rotation of the uprights around the lower Clamp bolts are either in a vertical or and upper ball joints.
  • Page 421 Section 16: SUSPENSION FIGURE 9: IFS STEERING LINKAGE OVERVIEW FIGURE 10: IFS - SUSPENSION COMPONENTS PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 422 Section 16: SUSPENSION FIGURE 11: IFS STEERING LINKAGE PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 423 Section 16: SUSPENSION The following table lists the tightening torques which do require a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE 2 – INDEPENDENT FRONT SUSPENSION DESCRIPTION QTY REFERENCE TORQUE DRY...

  • Page 424: Steering Linkage Installation Sequence

    Section 16: SUSPENSION STEERING LINKAGE INSTALLATION PITMAN ARM SEQUENCE 3.3.1 Removal NOTE 1. Remove cotter pin, nut and washer from Whenever a steering linkage component has drag link ball stud at pitman arm. been removed and replaced, check steering 2. Disconnect drag link from pitman arm, using geometry and front end alignment as directed jaw style pullers (pressure screw type).

  • Page 425: Drag Link

    Section 16: SUSPENSION 2. Center steering gear previously explained in "Steering Linkage Installation Sequence". 3. Remove cotter pin, nut and stud from drag link at bell crank. Locate centerline of vehicle and center of relay rod. With center of relay rod aligned with centerline of vehicle, loosen clamp bolt at socket end (bell crank end) of drag link and adjust length of socket end assembly to fit in boss...

  • Page 426: Bell Crank Or Idler Arm Hub Disassembly

    3.5.3 Bell Crank Idler Reassembly NOTE For bearing installation use tool Prevost # 110684. NOTE Install grease retainer according to figure 17. Grease must be able to exit the bell crank or idler arm mechanism. For grease retainer installation use tool Prevost # 110683.

  • Page 427: Relay Rod

    Section 16: SUSPENSION 4. Position new relay rod studs into bell crank and idler arm then tap stud ends with a brass hammer to seat tapered surfaces. Ball stud and taper bore must be clean and free of grease. 5. Install stud nuts. Tighten nuts to prescribed torque (refer to Torque Table 2).

  • Page 428: Steering Arms

    Section 16: SUSPENSION 2. Make sure threads on stud and in stud nut 2. Torque steering arm to steering knuckle are clean and not damaged. fixing bolts. Torque bolt to prescribed torque (refer to Torque Table 2). 3. Position ball studs (socket ends of tie rod) in holes in steering arm and bell crank or idler 3.
  • Page 429 Section 16: SUSPENSION FIGURE 18: STEERING LINKAGE NOMINAL LENGTHS PA1602 SECTION 16 REVISED SEPT 2013...

  • Page 430: Lubrication Fittings

    Section 16: SUSPENSION FIGURE 19: LUBRICATION FITTINGS LOCATION approximate location of steering lubrication 16046 LUBRICATION FITTINGS fittings. All lubrication fittings must be clean before applying lubricant. Also, always sure MAINTENANCE equipment used in applying lubricant is clean. Every precaution should be taken to prevent entry of dirt, grit, lint or other foreign matter into (1) Drag Link Ends: Lubricate at four fittings, lubricant...

  • Page 431: Ball Joints - General Recommendations

    Section 16: SUSPENSION Damaged sealing boots, salt and climatic Retinax LX or equivalent). conditions can cause loss of the corrosion (4) Steering Knuckle (swivel assembly): protection coating applied time Refer to DANA SPICER MAINTENANCE manufacturing. prevent corrosion from MANUAL NDS AXLES Lubrication and forming around the ball pin, remove the old Maintenance"...

  • Page 432: Front End Inspection

    Section 16: SUSPENSION Wheel Toe-In: a slight forward convergence Check kingpin inclination. If kingpin inclination is given to the wheels of motor vehicles to improve incorrect, readjust the camber and check kingpin steering and equalize tire wear (D minus E, fig. inclination again.

  • Page 433: Front Wheel Caster

    Section 16: SUSPENSION 5. Check the distance between the tire Variations from the specified caster will affect centerlines at the front and rear of the front steering stability, cause wandering, wheel tires. These two measurements must be shimmy, and reduce steer re-centering when made at the same height above the floor.
  • Page 434 Section 16: SUSPENSION 0.02° 0.04° 0.04° 0.06° 0.06° 0.08° H3-45 Coaches WITH INDEPENDENT FRONT SUSPENSION Minimum Nominal Maximum value value value Right camber 0.0° 0.150° 0.30° Left camber 0.0° 0.150° 0.30° 2.35° 2.6° 2.85° Right caster Left caster 2.35° 2.6° 2.85°...
  • Page 435 Section 16: SUSPENSION FIGURE 23: IFS NOMINAL DIMENSIONS FIGURE 24: NOTE 2 INDICATES WHERE ADJUSTMENT MAY BE PERFORMED IF NEEDED WHEN PROCEEDING TO IFS ALIGNMENT PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 436 Section 16: SUSPENSION WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 25: FRONT END ALIGNMENT DIAGRAM 16051 PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 437 Section 16: SUSPENSION FIGURE 26: A-ARM JOINT IDENTIFICATION PA1602 SECTION 16 REVISED SEPT 2013...

  • Page 438: Lower And Upper A-Arm Ball Pin Bushing Repair

    3.12 LOWER AND UPPER A-ARM BALL PIN Apply grease, only in the case of repair kit BUSHING REPAIR (Prevost # 611114)). The assembly work may be done only by a 2. Insert ball pin bushing assembly. In case of recognized specialized workshop. Ensure that...

  • Page 439: Lower A-Arm Ball Joint Repair

    Section 16: SUSPENSION FIGURE 29: UPPER A-ARM BALL PIN BUSHING apply pressure to press mount with ball- inner cone. 3.13 LOWER A-ARM BALL JOINT REPAIR Take off the load from the ball joint by lifting the front of the vehicle. Apply a load on the joint in all of the degrees of freedom in an axial, radial, etc.

  • Page 440: Front Air Springs

    Section 16: SUSPENSION 3.15.2 Removal NOTE Front air springs can be removed without removing the entire suspension assembly. 1. Jack up the vehicle using the axles jacking points. 2. Safely support the front of the vehicle at the recommended body jacking points. 3.

  • Page 441: Shock Absorbers

    Section 16: SUSPENSION easing installation. 1. Compress air spring as necessary, then aligning studs with their holes, position air spring between both the lower and upper supports. Thread the lower nuts a few turns. 2. Tighten and torque the lower stud nuts as prescribed in Torque Table 2.

  • Page 442: Sway Bar

    Section 16: SUSPENSION and the shock absorber eyes over the 3. Torque sway bar link nuts as prescribed per mounting pins. Install the outer washer. Torque Table 2. 6. Place a rubber joint and washer on the 3.18 INDEPENDENT FRONT SUSPENSION shock absorber mounting stud.
  • Page 443 Section 16: SUSPENSION FIGURE 36: FRONT HEIGHT CONTROL VALVE 16100 The normal ride height is obtained by adjusting FIGURE 34: HEIGHT CONTROL VALVE LOCATION 16057 air spring clearance of both front and rear The appropriate vehicle body height is obtained suspension as follows: by measuring the clearance of all the air springs installed on the vehicle.

  • Page 444: Rear Suspension

    Section 16: SUSPENSION REAR SUSPENSION FIGURE 38: TAG AXLE SUSPENSION FIGURE 37: DRIVE AXLEETAILS OF REAR SUSPENSION 16106 FIGURE 39: REAR SUSPENSION COMPONENTS 16003 PA1602 SECTION 16 REVISED SEPT 2013...

  • Page 445: Air Springs

    Section 16: SUSPENSION AIR SPRINGS 4.1.2 Removal The air springs are made from a special compound rubber molded to the proper contour NOTE and dimensions. The entire vertical load of the Suspension air springs (drive and tag axles) vehicle is supported by these springs. Each of can be removed without removing the entire the two axles is provided with air springs that axle assembly.

  • Page 446: Shock Absorbers

    Section 16: SUSPENSION line threaded fitting. This prevents air from always replace with a new set on affected getting back into the bag and keeps it axle, except if there has been a recent compressed, thus enabling to place the bag in replacement of one unit.

  • Page 447: Inspection

    Section 16: SUSPENSION d) Deep cracks in bushing material (shallow NOTE surface cracks are normal); If shock absorber pins are removed, they must e) Loose shock absorber pins; be reinstalled using “Loctite” (see “Parts Specifications” in this section). Presence of convex washers, and their position relative to the rubber bushing.

  • Page 448: Air Line Test

    Section 16: SUSPENSION Performing these procedures will allow down to lower it. Check that main air pressure substandard performance to be discovered is at normal operating pressure and raise the before the condition becomes bad enough to vehicle to the specified height. cause operator complaints and failure on a run.

  • Page 449: Height Control Valves

    Section 16: SUSPENSION 2. Loosen the adjusting nuts on the connecting rod of height control valve to raise or lower overtravel lever until desired clearance is reached. 3. If there is not enough play on adjusting nuts, it is possible to make further adjustments by loosening the clamp on the rubber coupling and bringing it up or down.

  • Page 450: "Level-Low" Leveling System - Vip Series Option Only

    Section 16: SUSPENSION 1. Clean the exterior of valve assembly. control valve, and opens a passage to allow the air control and exhaust valve to release air from 2. Connect air pressure line to air inlet port, (front/rear right/rear left) air springs. then allow air pressure build-up (70- 100 psi (480 - 690 kPa)).

  • Page 451: Principle Of Operation

    Section 16: SUSPENSION achieved by the kneeling air tank installed Section: 12, “Brake and Air System” and Section beside the secondary air reservoir (for exact 06, “Electrical System”. position, refer to Section 12, “Brake and Air For diagnosis and understanding of the system, System”).
  • Page 452 Section 16: SUSPENSION height control valves from releasing air from air springs. DOWN: The control valve, on the dashboard, cuts off air supply, so the double shuttle valves allow height control valves to accomplish their function. Height control valves release air from air springs until suspension returns to its normal position.
  • Page 453 This system can be put into service during normal vehicle operation. 11.1 PRINCIPLES OF OPERATION On H3-41 and H3-45 coaches, the rear low- buoy is added over the front kneeling system. The control valve on the left console panel sends an electric signal from its pressure switch to control the front suspension as if kneeling.
  • Page 454 Section 16: SUSPENSION The air coming from the air dryer is first directed to the wet air tank, then to the primary (for the primary brake system), secondary (for the secondary brake system), and accessory (for the pneumatic accessories) air tanks (Fig. 47). In addition, an expansion air tank is installed in series with each air spring.
  • Page 455 Section 16: SUSPENSION FIGURE 48: REAR VALVE LOCATION 12162 12.1.3 Secondary Air Tank This tank is located in front wheelhousing. The tank is installed vertically and is provided with a FIGURE 49: FRONT VALVE LOCATION 12144 bottom drain valve. 12.1.5 Expansion Air Tank MAINTENANCE Two expansion tanks are located in front wheelhousing.
  • Page 456 CAUTION Air filled through these two points will pass through the standard air filtering system provided by Prevost. Do not fill air through any other points. 13 REAR SUSPENSION TORQUE SPECIFICATIONS FIGURE 50: TORQUE SPECIFICATIONS – DRIVE AXLE...
  • Page 457 Section 16: SUSPENSION FIGURE 51: TORQUE SPECIFICATIONS – DRIVE AXLE 16159 FIGURE 52: TORQUE SPECIFICATIONS – TAG AXLE 16160 PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 458 Section 16: SUSPENSION FIGURE 53: TORQUE SPECIFICATIONS – TAG AXLE 16161 FIGURE 54: TORQUE SPECIFICATIONS – DRIVE AXLE, TOP 16162 PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 459 Section 16: SUSPENSION The following table lists the tightening torques of bolts and nuts requiring a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. SPECIFIC TORQUE TABLE 3 –...
  • Page 460 Make ........................Goodyear Tire and Rubber Diameter ............................14 inches Air Inlet ........................1/2’’-14 NPTF AIR INLET Prevost number ......................Refer to Parts Manual Front I-Beam axle air springs and tag axle air springs Make ........................Goodyear Tire and Rubber Type ..............................
  • Page 461 Section 16: SUSPENSION Height control valve (coach, all axles & VIP, rear only) Quantity ..............................2 or 3 Prevost number ......................Refer to Parts Manual Bellows control and exhaust solenoid valve assembly Make ..............................Norgren Solenoid valve manifold Prevost number ......................Refer to Parts Manual Coil Voltage ..............................
  • Page 462 Section 16: SUSPENSION High-Buoy Pressure regulator Recommended pressure setting ..................90 psi (621 kPa) Prevost number ......................Refer to Parts Manual PA1602 SECTION 16 REVISED SEPT 2013...
  • Page 463 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers Index: 1) Inspection 2) Misting 3) Leakage 4) Noise – Rubber Bushings 5) Noise – Scratching Metal Dust Cover 6) Damping Performance 1) Inspection It is recommended to inspect Sachs shocks visually during regular maintenance schedules, however at least: linehaul applications: every 100,000 miles vocational applications: every 50,000 miles...
  • Page 464 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 2) “Misting“ Appearance might be deceptive. A certain degree of vapor is normal and actually necessary for lubrication of the rod seal. The inspection must not be conducted after drive in wet weather or a vehicle wash. Shock needs to be free from water.
  • Page 465 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 3) „Leaker“ OBSERVATION A shock is considered a „leaker“, if • the reservoir tube (smaller diameter) is largely covered with oil • finger gets wet, when touching shock (see „Misting“) • after above finger test, shock exhibits a glossy film of oil and/or dirt, or an oil droplet forms on reservoir tube...
  • Page 466 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 4) Noise - Rubber Bushings Noise emitted during operation is not necessarily caused by defective shocks. Therefore in case of noise issues: Check all relevant suspension and axle components, e.g. rubber mounts, springs, jounce stops, bushings, steering.
  • Page 467 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 5) Noise - Scratching Metal Dust Cover Noise emitted during operation is not necessarily caused by defective shocks. Therefore in case of noise issues: Check all relevant suspension and axle components, e.g. rubber mounts, springs, jounce stops, bushings, steering.
  • Page 468 Guideline to Evaluate Warranty Claims Heavy-duty Shock Absorbers 6) Degradation of Damping Performance It is impossible to verify the correct damping characteristic of a shock absorber without a dynamometer. In the field, the following, more practical test can help to identify a shock, which is suspected to have failed: 1) Conduct test few minutes after operating the vehicle 2) Touch a metal element of the chassis to determine a reference temperature...
  • Page 469 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR ..........................6 STRUCTURE ............................8 ............................8 ELDING EXTERIOR MAINTENANCE ......................... 8 ......................... 8 ORROSION REVENTION ....................9 REVENTIVE AINTENANCE CHEDULE ......................9 NHIBITOR PPLICATION FIBERGLASS REPAIR ........................14 ....................14 EPAIR SING IBERGLASS LOTH ....................
  • Page 470 Section 18: BODY ....................... 26 ATCH ECHANISM DRIVER’S POWER WINDOW ......................26 ......................26 OWER INDOW EMOVAL ....................... 26 OWER INDOW NSTALLATION ROOF ESCAPE HATCH ......................... 27 10.1 R ............................27 EPAIR 10.2 S ............................27 EALING 10.3 E ....................28 SCAPE ATCH ANEL...

  • Page 471: Door Latch Mechanism

    Section 18: BODY DOOR HANDLES ..........................56 ENGINE COMPARTMENT DOOR ....................56 21.1 E ......................56 NGINE DJUSTMENT 21.2 M ................... 57 INOR EPTH DJUSTMENT 21.3 M : ..................57 INOR OWER EPTH DJUSTMENT ENGINE AIR INTAKE GRILL ......................57 RADIATOR DOOR ADJUSTMENT ....................
  • Page 472 Section 18: BODY SPECIFICATIONS ........................... 73 ILLUSTRATIONS 3-45 ( ) ..........................6 IGURE TYPICAL 3-45 ........................ 7 IGURE VIP EXTERIOR VIEW ........................15 IGURE FIBERGLASS REPAIR ........................15 IGURE FIBERGLASS REPAIR ........................15 IGURE FIBERGLASS REPAIR ........................15 IGURE FIBERGLASS REPAIR ........................
  • Page 473 Section 18: BODY ......................52 IGURE WCL UPPER ARM AND RAIL ....................53 IGURE WCL LOWER RAIL INSTALLATION ..................54 IGURE WCL SLIDING DOOR OPENING MECHANISM ....................55 IGURE BAGGAGE COMPARTMENT DOOR ......................55 IGURE PANTOGRAPH ADJUSTMENT ....................56 IGURE PANTOGRAPH DOOR ADJUSTMENT ....................

  • Page 474: Vehicle Exterior

    Section 18: BODY 1. VEHICLE EXTERIOR FIGURE 1: H3-45 (TYPICAL) 18681 1. Engine air intake 11. Diesel Particulate Filter (DPF) access door 2. Engine compartment curb-side door 12. Engine compartment rear door 3. Main power compartment (battery 13. Rear-view mirror compartment) 14.
  • Page 475 Section 18: BODY FIGURE 2: H3-45 VIP EXTERIOR VIEW 18677 1. Engine air intake 13. Driver’s power window 2. Engine R.H. side access door 14. Front Slide-out 3. Main power compartment 15. Heating, ventilating and air conditioning compartment (HVAC) baggage 4.

  • Page 476: Structure

    The entire underbody of the vehicle is sprayed with a heavy The body of the H3-41, H3-45 and VIP vehicles application of asphalt base undercoating. is an integral structure made of 14, 16 and 18...

  • Page 477: Preventive Maintenance Schedule

    Section 18: BODY PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section.
  • Page 478 Section 18: BODY 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be hot masking. to reduce washing time especially during winter. If parts are soiled with oil, clean using R1KG21. Avoid rubber parts. 2.0 Dry all water sprayed parts. Surface temperature Air pressure system may be used, refer to annex 1 for and dew point must be respected before applying rust surface temperature and dew point.
  • Page 479 Section 18: BODY 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) 4.1 Rear wheelhousing (Entire braking system) PA1602 SECTION 18...
  • Page 480 Section 18: BODY 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used. 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts.
  • Page 481 Section 18: BODY DEW POINT Relative Humidity (%) Temp (c) PA1602 SECTION 18...

  • Page 482: Fiberglass Repair

    Section 18: BODY 4. FIBERGLASS REPAIR If part is warped from original shape, use clamping equipment to straighten the surface. All repairs to fiberglass parts consist of filling the Preheat area to be repaired with one or two heat damaged area with fiberglass cloth and resin or lamps placed 18 to 24 inches (450-610 mm) strand fiberglass and resin.

  • Page 483: Typical Fiberglass Repair Procedure

    Section 18: BODY NOTE If repair is made on a vertical surface, adding powdered filler material to mixture will reduce tendency of hot resin to flow or run. Apply the material with a putty knife or similar object, building material up to the desired contour.

  • Page 484: New Paint Care

    5. PAINTING for color codes and paint brand. NEW PAINT CARE Prevost recommends using the original paint brand to ease color matching. Our paint supplier recommends that you follow these simple precautions the first months of your In the event you sand through to the gelcoat new vehicle’s life.

  • Page 485: Surface Preparation And Paint Application

    Section 18: BODY 1. Do not smoke in the paint room or in 5. Wear rubber gloves, rubber apron, and face adjacent area exposed to residue fumes. shield during all phases of paint and chemical handling. 2. Wear respirators approved by the governing safety and health regulations.

  • Page 486: Front And Rear Bumpers

    FIGURE 10: FRONT BUMPER ASSEMBLY FIGURE 8: BUMPER ATTACHING BOLTS NOTE 18498 To reinstall the front bumper, reverse the A special tool kit is available from Prevost: Kit procedure. # 410671 including tool #410708. 2. Remove 4 cap screws holding bumper to 6.1.2 Front Bumper Skin Removal vehicle and remove bumper (Fig.

  • Page 487: Rear Bumper Removal And Installation

    Section 18: BODY cylinder on the door hinge (Fig. 16). Door activation is controlled by a relay panel, located near the defroster and wiper motors. accessory air reservoir supplies air to this system. The door is held in the closed position during coach operation by two air cylinder locking mechanisms (Fig.

  • Page 488: Emergency Exit Valves

    Section 18: BODY 7.2.2 With Air but Without Electricity To open the door, the switch must be pushed towards the front of the coach and held in From inside the vehicle, turn the emergency exit position. When the door reaches the fully valve to the "UNLOCK”...

  • Page 489: Horizontal And Vertical Adjustment

    Section 18: BODY FIGURE 17: DAMPER FIGURE 16: COACH ENTRANCE DOOR 18439 3. The damper may have already been HORIZONTAL AND VERTICAL adjusted. Therefore check whether the ADJUSTMENT damper is adjusted or not by keeping it Before attempting to correct any door operating closed and gently turning further CCW, problem by adjusting any part of the air cylinder counting at the same time the half-turns until...

  • Page 490: Depth Adjustment

    Section 18: BODY FIGURE 18: UPPER DOOR HINGE (COACH) 18058 5. Pull and fasten the rod end to the hinge with the washer and the button screw. 6. Screw the plastic moldings covering the FIGURE 19: DOOR LATCH (COACH) 18059 hinges.

  • Page 491: Troubleshooting

    Section 18: BODY TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Manual door locks engaged. Release manual door locks. Check voltage at solenoid locks when Upper and lower solenoid locks do not door is open. If the voltage is 24 volts disengage. then replace solenoid #641217. Else, check circuit power.

  • Page 492: Entrance Door (V.i.p)

    Section 18: BODY 8.2.1 Horizontal and Vertical Adjustments 8. ENTRANCE DOOR (V.I.P) There are three ways of unlocking the entrance 1. Remove the screws and the plastic molding covering each of the hinges. door from the inside of vehicle. The two first consist in actuating the rocker switch on the NOTE dashboard, but this last operation will also...

  • Page 493: Door Lower Section

    DOOR LOWER SECTION 10. Apply Sika #252 (Prevost #682462) compound where it was previously applied. When a plastic door lower section replacement 11. Remove protective paper from the adhesive is needed, proceed the following way: tape and install the door lower section.

  • Page 494: Driver's Power Window

    Section 18: BODY 3/16" (4,5 mm) from the sides and lower 9. DRIVER’S POWER WINDOW molded edges of the door. To replace window or motor, the whole 6. Progress slowly all around the door. assembly must be removed. The following instructions refer to figure 23.

  • Page 495: Roof Escape Hatch

    Section 18: BODY 2. Using alcohol, a sharp knife or 240-grit Graffiti-resisting coatings often leave a sticky sandpaper, clean off the butyl strip from the residue that interferes with smooth up/down shield and frame. Install new butyl strip on movement of the hatch mechanism. Some of plastic shield.

  • Page 496: Escape Hatch Panel Assembly

    Section 18: BODY 3. Apply rubber adhesive CA-40 (Prevost # 10.4 ESCAPE HATCH FRAME 681285) in the gap between the seal ends. When necessary, the escape hatch frame can 4. Apply Sikaflex 221 sealant (Prevost # be removed and replaced in the following way: 680532) along the outline of the escape 1.

  • Page 497: Repair Or Replacement Of "Tarabus" Floor Covering

    Section 18: BODY 11. REPAIR OR REPLACEMENT OF “TARABUS” FLOOR COVERING “Tarabus” covering installed in H3 coaches may be replaced or repaired. The purpose of this paragraph is to explain the steps to be followed to ensure the best results and adherence. MATERIAL Part No Description...
  • Page 498 Section 18: BODY FIGURE 25: TARABUS FLOOR COVERING ADHESIVE APPLICATION FIGURE 26: APPLICATION OF SIKA 221 GRAY PA1602 SECTION 18...

  • Page 499: Front Steps Replacement Procedure

    Section 18: BODY 11.1 FRONT STEPS REPLACEMENT PROCEDURE MATERIAL Part No Description 682989 Anti-silicone 683097 Sika 205 (1 liter) 685101 Sika Remover 208 683916 Sika 215 (1 liter) 684654 Adhesive, Contact (3M) 3.8L 684655 Adhesive, Contact (3M) 18.9L 684517 Sealant, gray 1.
  • Page 500 Section 18: BODY Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer 3. Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) Before applying any other If surface seems dusty, dust using damp cloth.
  • Page 501 Section 18: BODY GLUING OF WHITE SAFETY STRIP BETWEEN STEP AND “TARABUS” FLOOR COVERING 1. Sand fiberglass using “Scotchbrite”. 2. Clean using tack cloth. 3. Clean twice using anti-silicone (refer to Section A). 4. Protect surfaces around the step with masking tape. 5.

  • Page 502: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering

    Section 18: BODY NOTE Keep a gap of 1 to 1.5 mm between “Tarabus” covering and white safety strip. 7. Remove masking tape. 11.2 WELDING OF JOINT BETWEEN WHITE SAFETY STRIP AND “TARABUS” FLOOR COVERING 1. Pre-heat welding torch; Set welding torch to position #4.5 (temperature of 500 °C), Heating time: 5 minutes.
  • Page 503 Section 18: BODY 5. Add (about 6 inches) some length to the required length of filler bead to make the joint then cut. 6. Take position with welding torch. The proper position is with a slight slope to the rear. 7.
  • Page 504 Section 18: BODY 10. Shave filler bead to make it level to the floor. Use supplied knife designed for that purpose. NOTE To facilitate the cut, you can spray some soapy water onto the joint. CAUTION The procedure for turning the torch off must absolutely be followed. If this step is not taken, the element may burn.

  • Page 505: Repair Of A Welded Joint

    Each seat has a easily removable bottom 12. PASSENGER SEATS cushion. Upholstery is clipped on the cusion H3-41 and H3-45 coaches can be equipped with frame for cleaning or replacement. To remove any of 2 basic seat models and installed in a the fabric, simply unclip from the frame.

  • Page 506: Removing Fixed Seats

    Section 18: BODY 12.2 REMOVING FIXED SEATS NOTE NOTE Bottom end of rod is coated with Locktite and threaded in a steel block which slides in the Seats on one row are not interchangeable with floor track. Removal of rod is possible if seats of the other row.

  • Page 507: Coach Side Windows

    (Fig. 32). Seven passenger side windows are provided on Emergency operating instruction decals are each side on H3-41, while the H3-45 has eight. affixed under each emergency exit window. To They are made of fixed, single or double-glazed, close the window, pull back the window and heat absorbing AS-3 glass.

  • Page 508: Emergency Exit Release Bar

    Section 18: BODY 13.3 FIXED WINDOW REPLACEMENT 13.2 EMERGENCY EXIT RELEASE BAR When it becomes necessary to replace the glass The emergency exit release bar system is of a fixed-type window, follow this procedure: generally maintenance free. 1. Unscrew the decorative plate and the It has been designed to answer the twenty bottom window bar in order to get access to pound resistance criteria for opening the...

  • Page 509: Trapezoidal Window Replace Ment

     The angle at which the window will detach is  Masking tape; considerably smaller (about 45  Tremshield tape (Prevost #681089);  These windows are also glued to the  Chix cloths (Prevost #682384); structure at certain areas on their perimeter.
  • Page 510 Section 18: BODY 2. Place the new window glass in the opening 6. Put masking tape on the inner and outer and center it to leave an even gap top and contour of the window opening on the bottom, and from side to side. structure, approximately 1/16"...

  • Page 511: Electric Awning Window

    Section 18: BODY CAUTION 14.2 WINDOW REMOVAL Replacement awning window does not include a Never use solvents to clean excess adhesive. new motor. If in working order, transfer the 11. Remove masking tape at once, clamp motor replaced window window glass suitably and let dry overnight replacement window.

  • Page 512: Actuator Replacement

    Section 18: BODY Actuators Horizontal latch handle Latch guide Proximity sensor Relay Guide Roller Swivelling arm Window pane Window ajar sensor Motor support Releasing bar Releasing bar Guide roller FIGURE 39: ELECTRIC AWNING WINDOW EXPLODED VIEW (SASH) 18583 3. Remove actuator access cover by taking out 14.3 ACTUATOR REPLACEMENT screws #1 (8x).
  • Page 513 Section 18: BODY ELECTRIC AWNING WINDOW – CONVERTER CHECKLIST Check the electrical circuit & A: The latching system will not operate without power. proximity sensor Is there electrical power to the latching circuit? The horizontal latch handle, on the sill sash will be seen to move if there is power on this circuit, or it can be checked with an electrical tester.

  • Page 514: Electric Sliding Window

    Section 18: BODY 15. ELECTRIC SLIDING WINDOW FIGURE 40: ELECTRIC SLIDING WINDOW EXPLODED VIEW Sash Removal 1. Remove the Screen Assembly 2. Pull down on both release latches simultaneously and rotate the sash inwards approximately 10 degrees.(Figure 43) FIGURE 41: REMOVING THE SASH PA1602 SECTION 18...
  • Page 515 Section 18: BODY 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 42) FIGURE 42: DISENGAGING THE BOTTOM OF THE SASH Installation 1. Align the leading edge of the slot on the lower cam follower block with the sash stop. Use the power toggle switch to obtain the correct alignment.
  • Page 516 Section 18: BODY FIGURE 44: POSITIONING THE LOWER LEFT CORNER OF THE SASH 3. Engage the sash pin with the leading edge of the slot of the cam follower block. Do the same at the rear of the sash. 4. Pull down on the release latches and rotate the sash inwards until it is parallel with the window frame. 5.

  • Page 517: Removal

    FIGURE 47: WINDSHIELD INSTALLATION TOP VIEW from Prevost Parts to ensure proper fit. 18098 Windshields obtained from other sources should 3. From inside of vehicle, push against the top be checked for proper size and curvature.
  • Page 518 Section 18: BODY NOTE 6. Insert the top curved corner then finish with the top of windshield. Spray lubricant on a regular basis to ease 7. At the top of windshield, clean surface windshield insertion. between fiberglass and rubber extrusion using Sika 205 (Fig.

  • Page 519: Installation Of Rubber Extrusion And Windshield

    Section 18: BODY 16.3 INSTALLATION OF RUBBER 3. Find the reference marks made earlier and EXTRUSION AND WINDSHIELD install the rubber extrusion in the windshield opening. CAUTION 4. Install windshield as per paragraph 10.2: “Windshield Installation Only”. The black rubber extrusion securing the windshield in the opening fits correctly in only 17.

  • Page 520: Adjustment

    Section 18: BODY FIGURE 52: WCL SLIDING DOOR INSTALLATION 18.2 ADJUSTMENT 1. Adjust sliding door height with reference to the side panels and windows. 2. Slide the top rail into the upper arm then bolt the rail to the structure. Do not fully tighten (Refer to fig. 54).
  • Page 521 Section 18: BODY FIGURE 54: WCL LOWER RAIL INSTALLATION 5. Adjust the gap between the positioning lugs and their housing, required gap: 0.5 – 1.5mm. Add shims underneath the lugs to get the proper adjustment. 6. Take away the plays from the upper arm assembly by lifting the main hinge using a crowbar. Tighten the main hinge bolts to 43 Lb-ft.
  • Page 522 Section 18: BODY FIGURE 55: WCL SLIDING DOOR OPENING MECHANISM PA1602 SECTION 18...

  • Page 523: Baggage Compartment Doors

    Refer, if needed, to figure 57 for identification There are 6 pantograph doors serving as of door components. baggage compartment doors on the H3-41, while there are 8 on the H3-45 and the V.I.P If the door bends when opening or if pantograph...

  • Page 524: Door Handles

    FIGURE 58: PANTOGRAPH DOOR ADJUSTMENT 18062 gas-charged cylinders (Prevost # 980024). The engine compartment opens by lifting a handle accessed from the R.H. side of the engine compartment.

  • Page 525: Minor Top Edge Depth Adjustment

    Section 18: BODY to bend the pantograph arms in the desired 3. On the vehicle grill opening, using the knife, position; remove as much adhesive as possible. 3. Close the door and check the top edge 4. Sand the new grill backing edge to remove parallelism between the door and the the glossy surface.

  • Page 526: Door Lateral Adjustment

    Section 18: BODY 3. Tighten the bolt. 23.2 DOOR LATERAL ADJUSTMENT FIGURE 64: DOOR LATERAL ADJUSTMENT FIGURE 66: DOOR DEPTH ADJUSTMENT 1. Using a rubber mallet, adjust radiator door 6. Make sure that latch striker pin engages positioning with reference to pantograph behind the strike plate at least 10 mm.

  • Page 527: Condenser Door Adjustment

    Section 18: BODY 24. CONDENSER DOOR ADJUSTMENT 5. Loosen bracket nuts holding the panel to condenser. Panel (6, Fig. 70) may be shifted 1. Open the condenser door. "IN or OUT", "LEFT or RIGHT" and "UP or DOWN". 2. Loosen the nuts (1, Fig. 70) holding the hinge (3, Fig.

  • Page 528: Door

    Section 18: BODY 3. Move part (1, Fig. 72), as close as possible to exterior of coach, so as to have enough clearance for proper door opening. SECTION 4. Tighten nut (2, Fig. 72). 5. Loosen nut (3, Fig. 72). Hinge allows the door to be shifted "IN or OUT".

  • Page 529: Latch Mechanism Adjustment

    Section 18: BODY 7. Adjust the door in accordance with the 28. EVAPORATOR DOOR ADJUSTMENT required distance between exterior finishing 1. Open the door. parts (Fig. 52). 2. Loosen nut (1, Fig. 76). 8. Loosen screws (4, Fig. 75). 3. Move part as shown in figure for "LEFT or 9.

  • Page 530: Main Power Compartment

    Section 18: BODY 41,2 ± 8 ± 2 mm 41 ± 2 mm FIGURE 75: EVAPORATOR DOOR 18198 6. Adjust door panel to have the same gap 29. MAIN POWER COMPARTMENT space as neighboring panels or refer to figure 45 for specified gap space To adjust the main power compartment door: 7.

  • Page 531: Front Fender Removal

    It is held in place with bolts holding devices. and nuts. If it ever it has to be replaced, make an appointment at a Prevost service center near 4. Holding the fender firmly, pull it down until you.

  • Page 532: Side Panel Installation Procedure For Coaches And Vip

    Section 18: BODY 33. SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP Material:    Anti-silicone (682989) Blue cloth (682383) Sika 206 G+P 1 liter (683446)    Tack cloth Pure water Sika 252 black    CHIX cloth (682384) Scotchbrite gray (680226) Masking tape...
  • Page 533 Section 18: BODY Clean using anti-silicone See SAV000001 section A. Apply primer 206 G+P. See SAV000001 section D. PR000001 Section D Sika Primer 206 G+P Shake bottle to mix product Apply a thin layer CHIX cloth 3. Allow to dry Minimum time : 10 minutes Mandatory 206 G+P...
  • Page 534 Section 18: BODY 1.15 Seal entrance door perimeter using Sika 252 black, Smooth down the excess. Install lateral panel supports onto bottom 1.20 structural tubing. Install lateral panel onto supports to verify proper positioning. 1.25 Glue application Set (timer) or record time. ...
  • Page 535 Section 18: BODY Gap between lateral panel and rear cap must be 6mm +4/-3 and panels must be aligned within 1.5mm. Using a ruler, adjust front of lateral panel.  Verify if panel upper corner is in the middle of window post. 1.55 Remove excess of glue using a spatula.
  • Page 536 Section 18: BODY SECTION #2 DRIP MOLDING INSTALLATION 2.00 * A) Clean using Anti-silicone See SAV000001 section A. Apply Sika 206 G+P See SAV000001 section D. 2.05 Remove blue paper from drip molding. Remove protective tape from double- face self adhesive tape 2.10 Glue drip molding.

  • Page 537: Rear View Mirrors (Ramco)

    Section 18: BODY 34. REAR VIEW MIRRORS (RAMCO) Insert the ball stem into the mirror arm and tighten the socket setscrews. Your vehicle is equipped with two exterior NOTE mirrors. Position the ball cup halves so the joint The mirrors may be equipped with an optional between them lies on the centerline of the electric heating...

  • Page 538: Assembly

    Section 18: BODY button’s (4) sides to adjust the selected mirror WARNING viewing angle. 34.5.2 Disassembly DO NOT tow or jack vehicle with people on board. At end of mirror arm, loosen the setscrews to relieve tension on the ball stud. Remove the ball WARNING stud.

  • Page 539: Towing The Vehicle

    Section 18: BODY CAUTION Always unload or retract the tag axle before jacking the vehicle from the front and drive axle jacking points to prevent damage to suspension components. FIGURE 85: JACKING POINTS ON TAG AXLE FIGURE 80: JACKING POINTS ON FRONT UNDERFRAME –...

  • Page 540: Lifting And Towing

    Section 18: BODY  Do not allow passengers to ride onboard the 3. Lift the vehicle from under the front axle, and adequately secure the underside to the towed vehicle. tow vehicle lifting attachment with chains.  Tow the vehicle at a safe speed as dictated 4.
  • Page 541 SPECIFICATIONS Door cylinder Manufacturer ................................Bimba Type ................................Pneumatic I.D................................... 1½" ( mm) Stroke ................................. 8" ( mm) Prevost number ..............................780595 Damper Manufacturer ................................Koni Prevost number ..............................780565 Lock cylinder (upper) Manufacturer ................................Bimba Type ....................... Air, single action, 1/8 NPT, hexagonal rod I.D.
  • Page 543 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING ....................5 AIR CIRCULATION WITH CENTRAL HVAC SYSTEM ............... 5 DRIVER’S AREA ..........................5 2.1.1 Coaches only ........................... 5 2.1.2 VIP only ........................... 5 PASSENGER’S (CABIN) AREA ..................... 5 AIR CIRCULATION WITH SMALL HVAC SYSTEM ................
  • Page 544 Section 22: HEATING AND AIR CONDITIONING 9.1.2 Belt Tension Adjustment ....................... 25 9.1.3 Compressor Maintenance ..................... 25 9.1.4 Troubleshooting Guide ......................25 MAGNETIC CLUTCH ........................26 9.2.1 HVAC Control Unit and Clutch Operation ................26 BRUSHLESS EVAPORATOR MOTOR ..................27 9.3.1 Removal ..........................
  • Page 545 Section 22: HEATING AND AIR CONDITIONING 11.9 HOT WATER RECIRCULATING PUMP ..................46 11.9.1 Removal ..........................47 11.9.2 Disassembly .......................... 47 11.9.3 Brushes ..........................47 11.9.4 Assembly ..........................48 11.9.5 Installation ..........................48 11.10 BYPASS SOLENOID WATER VALVE (OPTIONAL) ..............48 11.10.1 Improper Operation ......................
  • Page 546 Section 22: HEATING AND AIR CONDITIONING ILLUSTRATIONS   FIGURE 1: DRIVER’S UNIT AIR CIRCULATION ........................5   FIGURE 2: CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION (COACH) .......... 6   FIGURE 3: OVERHEAD COMPARTMENT VENTILATION SYSTEM..................7   FIGURE 4: CONTROL UNIT - SMALL HVAC SYST........................ 7  ...

  • Page 547: Heating And Air Conditioning

    Section 22: HEATING AND AIR CONDITIONING Optionally, the coach may be equipped with a 1. HEATING AND AIR CONDITIONING defogger/defroster system in the windshield The coach’s interior is pressurized by its upper-section, refer to paragraph: “Central Heating, Ventilation, Conditioning Heating System” for more information. (HVAC) system.
  • Page 548 Section 22: HEATING AND AIR CONDITIONING FIGURE 2: CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION (COACH) 22264 PA1602 SECTION 22...

  • Page 549: Air Circulation With Small Hvac System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 4: CONTROL UNIT - SMALL HVAC SYST. 22286 4.2 AUXILIARY UNIT OPERATION The temperature control is provided by the small system HVAC control unit. The R.H. portion of FIGURE 3: OVERHEAD COMPARTMENT VENTILATION the HVAC control unit enables to actuate the SYSTEM 22211...

  • Page 550: Passenger's Unit

    Section 22: HEATING AND AIR CONDITIONING 1. The outside temperature is above 32°F TEMPERATURE SENSOR (0°C). Temp °C Temp °F Resistance Ohms The passenger's area temperature has (temperature sensor disconnected) reached 7°F (4°C) under the set point. 100865 NOTE 72437 52594 Upon starting, if the outside temperature is 38583...

  • Page 551: Overhead Compartment Unit (H3 Coaches)

    Section 22: HEATING AND AIR CONDITIONING when the heating mode is one. A green LED indicator illuminates when compressor clutch is in operation. evaporator motor located evaporator compartment on the L.H. side of vehicle is protected by a 90 amp, with manual- reset (CB3) circuit breaker mounted in the main power compartment (refer to Section 06, “Electrical System”...

  • Page 552: Hvac Unit Maintenance

    Section 22: HEATING AND AIR CONDITIONING MAINTENANCE For the passenger’s unit evaporator coil, back flush the coil (figure 9) every 12,500 miles (20 000 km) or once a year whichever comes first and for the condenser, back flush the coil (figure 11) every 6,250 miles (10 000 km) or twice a year, whichever comes first.

  • Page 553: Driver's Unit Air Filters

    Section 22: HEATING AND AIR CONDITIONING FIGURE 13: R.H. CONSOLE AIR FILTER ACCESS GRILL (VIP) 22232 FIGURE 11: PASSENGER’S UNIT CONDENSER COIL 22362 CAUTION Direct the pressure straight through the coil to prevent bending of fins and do not use extremely high pressure.

  • Page 554: Overhead Compartments Fan Air Filter

    Section 22: HEATING AND AIR CONDITIONING CAUTION Be sure not to reverse filter upon installation. FIGURE 17: PARCEL RACK FAN AIR FILTER 22201 7. HVAC SYSTEM PARTICULARITIES, TESTING AND TROUBLESHOOTING FIGURE 15: PASSENGER'S UNIT 2-PART AIR FILTER Before undertaking any troubleshooting on the HVAC system, study the appropriate wiring diagrams to get a complete understanding of the HVAC...

  • Page 555: Hvac System And Test Mode For Switches And Sensors

    Section 22: HEATING AND AIR CONDITIONING When performing an A/C cooling test and having pump, hot water solenoid valve and overhead the water pump shut off in switch/sensor test compartment air register fans. mode is required, just set the passenger set point temperature to the minimum 64°F (18°C) to shut off the pump.

  • Page 556: Hvac System Troubleshooting

    Section 22: HEATING AND AIR CONDITIONING 7.4 HVAC SYSTEM TROUBLESHOOTING Problem/Symptom Probable Causes Actions No temperature control in the Problem with the temperature Instruct the driver to manually control the passenger area sensor located in the temperature by playing with the passenger passenger’s area return air duct set point.

  • Page 557: Central Hvac System - Air Conditioning

    Section 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions The A/C compressor clutch Module A52 is not powered or is Check the SYSTEM DIAGNOSTIC menu does not engage faulty of the message center display (MCD). Select FAULT DIAGNOSTIC ELECTRICAL SYSTEM. The message “Voltage Module A52, Value too Low, Active”...

  • Page 558: Precautions In Handling Refrigerant

    Section 22: HEATING AND AIR CONDITIONING The refrigeration load is not constant and For the same reason, the refrigerant cylinder varies. It is also affected by outside should never subjected excessive temperature, relative humidity, passenger temperature when charging a system. The load, compressor speed, the number of refrigerant cylinder...

  • Page 559: Refrigerant System Clean-Out After Compressor Failure

    Section 22: HEATING AND AIR CONDITIONING The flexible hose lines should never be defective lines, etc.) corrected. Use new allowed to come within a distance of 2-½" O-ring. (6,3 cm) from the exhaust manifold. Use only sealed lines from parts stock. 8.3 REFRIGERANT SYSTEM CLEAN-OUT AFTER COMPRESSOR FAILURE When disconnecting any fitting in the...

  • Page 560: Clean-Out After Major Compressor Failure

    Section 22: HEATING AND AIR CONDITIONING fails. This oil will return to the replacement 8.4 PUMPING DOWN compressor when it is started, causing an This procedure is intended to reduce refrigerant overcharge of oil in the sump of the loss by isolating it in the compressor and the replacement compressor.
  • Page 561 Section 22: HEATING AND AIR CONDITIONING 5. Run the compressor until pressure reaches 1-2 psi (7-14 kPa). NOTE During this operation, care must be taken not to fill the receiver tank over the upper sight glass. If so, stop process immediately. Always allow refrigerant piping and units to warm up to the ambient air temperature before opening system or sweating will take place inside the...
  • Page 562 Section 22: HEATING AND AIR CONDITIONING FIGURE 18: CENTRAL HVAC SYSTEM – AIR CONDITIONING 22220 PA1602 SECTION 22...

  • Page 563: Adding Refrigerant (Vapor State)

    Section 22: HEATING AND AIR CONDITIONING 8.5 ADDING REFRIGERANT (VAPOR STATE) NOTE Addition of vapor state refrigerant is carried-out Use a bottle that is more than half full. to compensate for hose permeation and shaft Always charge the system with the cylinder seal losses over a long period.

  • Page 564: Evacuating System

    Section 22: HEATING AND AIR CONDITIONING 13. Before stopping the engine, check the 2. Connect the evacuation manifold, vacuum compressor oil level and note it in the repair pump, hoses and micron gauge to the unit. book as well as the amount of refrigerant 3.

  • Page 565: Charging System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 19: DOUBLE SWEEP EVACUATION SET-UP 8.7 CHARGING SYSTEM 1. Backseat the two compressor shutoff valves When a system has been opened or if there are ("out"). any questions about the air or moisture in the 2.

  • Page 566: Central Hvac System - Air Conditioning Components

    Section 22: HEATING AND AIR CONDITIONING 6. Remove the cover cap from the service 4. Slip the old compressor belts off and the fitting in the top receiver valve. new ones on. 7. Attach a charging hose to the R-134a tank. Open the tank valve slightly permitting R- 134a to escape thus purging the hose of air.

  • Page 567: Belt Tension Adjustment

    Section 22: HEATING AND AIR CONDITIONING 9.1.2 Belt Tension Adjustment On the mechanical tensioner, slightly slack lock bolt (A). Adjust tension by turning adjustment screw (B). Tighten the lock bolt (A) to 43 lbf-ft. to preserve adjustment. Should the idler bearing need to be serviced, tighten shoulder bolt (C) to 74 lbf-ft.

  • Page 568: Magnetic Clutch

    Section 22: HEATING AND AIR CONDITIONING  Flooded starts. as opposed to the hot upper discharge side. If a valve plate or head gasket is blown, or a  Overcharge of oil. compressor unloader is stuck open, partially compressed refrigerant vapor will be circulated ...

  • Page 569: Brushless Evaporator Motor

    Section 22: HEATING AND AIR CONDITIONING 9.3 BRUSHLESS EVAPORATOR MOTOR 7. Install the complete unit on a work bench, unfasten the fan square head set screws, the The brushless evaporator motor is installed in Phillips head screws retaining cages to base the evaporator compartment (L.H.

  • Page 570: Condenser Fan Motor Removal

    Section 22: HEATING AND AIR CONDITIONING tank, fan motors operate at half speed and, with Remove the four hexagonal head cap a high pressure in receiver tank, fan motors screws retaining the fan motor assembly to operate at full speed. Removing 24-volt applied the shroud.

  • Page 571: Replacement

    Section 22: HEATING AND AIR CONDITIONING 9.6.1 Replacement A moisture level of less than 15 p.p.m. for R- 134a indicated in the blue color range of the The filter is of the disposable type. When above table is generally considered dry and replacement is required, remove and discard the safe.

  • Page 572: Manual Bypass

    Section 22: HEATING AND AIR CONDITIONING through the reclining bumper while the central HVAC system solenoid valve is located in the condenser compartment. 9.7.1 Manual Bypass To ease purging, pumping down and refilling of refrigerant, it is possible to open the driver's, passengers and overhead compartment system liquid solenoid valves.
  • Page 573 Section 22: HEATING AND AIR CONDITIONING door. The valve regulates the flow of refrigerant As the operating superheat is raised, the liquid into the evaporator coils and is controlled evaporator capacity decreases, since more of by the suction gas temperature leaving the the evaporator surface is required to produce evaporator.
  • Page 574 Section 22: HEATING AND AIR CONDITIONING A/C pressure gauge Temperature on converted to remote bulb temperature at expansion valve fitting Low- High swing swing 40°F(4,4°C) 44°F 54°F (6,6°C) (12,2°C) Formula for superheat Average of low and 49°F-40°F=9°F high swing is 49°F (9,4°C-4,4°C = 5°C) (9,4°C) NOTE...

  • Page 575: Driver's System

    Section 22: HEATING AND AIR CONDITIONING Remove the two cap screws holding the power assembly to the valve body flange. Lift off the power assembly and remove the cage assembly. When reassembling, replace with the new gaskets in proper location. Make sure the two lugs on the cage assembly fit into grooves provided in the power assembly.

  • Page 576: Troubleshooting

    Section 22: HEATING AND AIR CONDITIONING 9.10 TROUBLESHOOTING 9.10.1 Expansion Valve PROBABLE CAUSE PROBABLE REMEDY LOW SUCTION PRESSURE-HIGH SUPERHEAT XPANSION ALVE IMITING Gas in liquid line due to pressure drop in the line Locate cause of line flash and correct by use of or insufficient refrigerant charge.

  • Page 577: Expansion Valve

    Section 22: HEATING AND AIR CONDITIONING 9.10.2 A/C Compressor TROUBLE CAUSE Low suction pressure and frosting at dryer outlet. Clogged filter. Low Oil Level. Check for oil leaks and for leaking oil seal. Do not attempt to check oil level unless system has been stabilized at least 20 minutes.
  • Page 578 Section 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE An evaporator just does a proper cooling job without sufficient air. Shortage of air can be caused by the following: o Dirty filters; or o Dirty coils. Testing condenser pressure. Note: R-134A pressure is function of the temperature variation. Example, for an exterior temperature of 100°F.

  • Page 579: Temperatures & Pressures

    Section 22: HEATING AND AIR CONDITIONING 9.11 TEMPERATURES & PRESSURES VAPOR-PRESSURE TEMPERATURE PRESSURE F C -100 -73.3 27.8 191.7 -67.8 26.9 185.5 -62.2 25.6 176.5 -56.7 23.8 164.1 -51.1 21.5 148.2 -45.6 18.5 127.6 -40.0 14.7 101.4 -34.4 67.6 26.2 12.4 43.4 11.6...

  • Page 580: Leak Testing

    Section 22: HEATING AND AIR CONDITIONING 9.12 LEAK TESTING WARNING Some methods such as nitrogen pressure and soap, and electronic sniffer can be used for leak Read the cautionary information in the small testing. However, the most common method Compressor Service Manual included at the used is a "Halide"...

  • Page 581: Oil Addition

    Section 22: HEATING AND AIR CONDITIONING side of check valve and low-pressure port 10.3 OIL ADDITION located alongside rear truss (figure 38). It would The chart below shows the approximate amount be good practice to open the solenoid valve. of oil to be added to the system when replacing a component.
  • Page 582 Section 22: HEATING AND AIR CONDITIONING FIGURE 38: SMALL HVAC SYSTEM - AIR CONDITIONING 22344 FIGURE 39: SMALL HVAC SYSTEM - DRIVER'S AND AUXILIARY UNIT 22290 PA1602 SECTION 22...
  • Page 583 Section 22: HEATING AND AIR CONDITIONING FIGURE 40: SMALL HVAC SYSTEM 22345 PA1602 SECTION 22...
  • Page 584 Section 22: HEATING AND AIR CONDITIONING FIGURE 41: CENTRAL HVAC SYSTEM – HEATING 22262 PA1602 SECTION 22...

  • Page 585: Heating System

    Section 22: HEATING AND AIR CONDITIONING 11. HEATING SYSTEM 3. Loosen hose clamp, install an appropriate container to recover coolant, and disconnect The schematics of figure 39 & 40 show silicone hose from hot water pneumatic respectively, the small HVAC system heating valve.

  • Page 586: Filling Heating System

    Section 22: HEATING AND AIR CONDITIONING If vehicle is equipped with a windshield upper section defroster, open front baggage compartment R.H. side door. Locate recirculating pump front wheelhousing, momentarily pinch the hose located between the recirculating pump suction and the defroster outlet connector to ensure windshield upper section defroster complete filling.

  • Page 587: Bleeding Heating System

    Section 22: HEATING AND AIR CONDITIONING 11.7 DRIVER’S UNIT WATER PNEUMATIC VALVE The flow of hot water to the driver's unit heater core is controlled by a pneumatic valve like the passenger’s unit hot water pneumatic valve. It is mounted on the coolant inlet line of the driver’s heater core, and is accessible through the spare wheel compartment (see figure 40, 41 &...

  • Page 588: Hot Water Pneumatic Valve Disassembly

    Section 22: HEATING AND AIR CONDITIONING 11.8.2 Hot Water Pneumatic Valve 2. Tighten the nipple in place in the body cavity Disassembly as per Figure 49. Fasten pilot solenoid vale to the pneumatic water valve. Reconnect air Assemble Shut off air supply pressure and supply pressure and electrical current to the electrical current to the pilot solenoid valve.
  • Page 589 Section 22: HEATING AND AIR CONDITIONING centrifugal pump and an electric motor which WARNING are mounted in a compact assembly. The motor is equipped with pre-lubricated Before proceeding with the following steps, sealed ball bearings which require check that coolant has cooled down. maintenance.
  • Page 590 Section 22: HEATING AND AIR CONDITIONING between the terminal and the brush tube. the mounting bracket. Position the mounting Replace brushes showing evidence clamps over the motor and secure with annealed springs. mounting bolts. Frayed or broken pigtail 2. Connect electrical wiring to the pump motor. An improperly installed brush may have the 3.
  • Page 591 Section 22: HEATING AND AIR CONDITIONING To reassemble: NOTE Make sure that the parts are placed on the The above procedure must be followed before enclosing tube in the following order: brazing solder type bodies into the line. Be sure to change electrical data plate Reassembly: according to coil specifications change.
  • Page 592 Section 22: HEATING AND AIR CONDITIONING the combustion chamber where fuel and 12.2 OPERATION combustion air form a combustible mixture Switch on the heater. The operation indicator which is ignited by the glow plug. lamp comes on and the heater motor and Once the flame sensor has signaled to the circulating pump begin to run.
  • Page 593 Section 22: HEATING AND AIR CONDITIONING NOTE 5. Wait 5 seconds. The day of week is stored. Preheating system uses the same fuel as the Viewing the Time (Ignition ON) engine. Continuous display of current time and day of the week. In case of failure: 1.
  • Page 594 Section 22: HEATING AND AIR CONDITIONING NOTE NOTE We recommend that memory locations 1 and Switch on the preheating system briefly about 2 be used for presetting times within 24 hours once a month, even during the warm season. of setting the timer. Memory location 3 can be used for a starting time within the next 7 days of setting the timer.
  • Page 595 Section 22: HEATING AND AIR CONDITIONING Failure Symptom Probable Cause Check and Correct - Fuel system - Fuel level 1X Flash (F 01) No combustion after completion - Type of fuel being used - Fuel filter of startup sequence. - Fuel line connections (air bubbles in fuel lines) - Fuel nozzle plugged - Combustion air - Air intake or exhaust, restricted or plugged...
  • Page 596 Current draw ............................. 68 amps Horsepower ..............................2 Revolution ........................... 1400 & 1700 rpm Insulation ............................. Class F Motor Prevost number......................... 563586 Passenger’s unit condenser fan motors Make ............................EBMPAPST Type ......................... 12” AXIAL BRUSHLESS Voltage .............................. 24 V DC Qty .................................
  • Page 597 Operating speed ........................500 to 3500 rpm Oil capacity ........................ 0.66 U.S. gal (2,5 liters) Weight ............................74 lbs (33 kg) Approved oil Bitzer ............................BSE55 (POE) Prevost number ........................... 950001 Magnetic clutch Make ..............................Linnig Type ................................ LA16 Voltage .............................. 24 V DC A/C Compressor (Small HVAC system) Make ..................
  • Page 598 Type ..................... Normally closed with manual bypass Voltage .............................. 24 V DC Amperage draw ..........................0.67 amps Watts ................................16 Prevost number (without coil) ......................95-0054 Coil Prevost number ..........................950055 Repair kit Prevost number ........................950056 Driver’s & passenger’s hot water pneumatic valve Make ...............................
  • Page 599 Bypass solenoid water valve Make ............................Parker Hannifin Bypass Prevost number ........................870886 Coil Prevost number ..........................870886 Repair kit Prevost number ........................870980 Preheating system Make .............................. SPHEROS Model ............................THERMO 300 Capacity ........................104 000 Btu/h (30 kW) Heating medium ..........................
  • Page 601 SECTION 23: ACCESSORIES CONTENTS AUDIO AND VIDEO SYSTEM DESCRIPTION ..................4 HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS ....... 7 DASHBOARD RADIO ........................8 1.2.1 Removal/Installation ........................ 8 VSS-05 SOUND SELECTOR ......................8 1.3.1 Removal/Installation ........................ 8 MULTICHANNEL POWER AMPLIFIER VA400.8 ................
  • Page 602 Section 23: ACCESSORIES 6.9.1 Pneumatic Timer Removal and Installation ................18 6.9.2 Timer Adjustment ........................18 6.10 FLUSH PUMP ..........................18 6.10.1 Flush Pump Pressure Adjustment ..................18 6.11 SUMP TANK ..........................18 6.11.1 Sump Tank Draining ......................18 6.11.2 Sump Tank Filling ........................
  • Page 603 Section 23: ACCESSORIES ILLUSTRATIONS FIGURE 1: AUDIO-VIDEO PANEL ....................... 4  FIGURE 2: AUDIO-VIDEO CONNECTIONS ....................5  FIGURE 3: AUDIO-VIDEO CONNECTIONS ....................6  FIGURE 4: RACKS ON AUDIO-VIDEO PANEL ................... 6  FIGURE 5: DASHBOARD RADIO ........................ 8  FIGURE 6: VSS-05 SOUND SELECTOR ....................8  FIGURE 7:MULTICHANNEL POWER AMPLIFIER VA400.8 ...............
  • Page 604 Each service module mounted to the underside of the parcel racks contains a 40-watt speaker. The speakers in the passenger section (twelve in H3-41 or sixteen in H3-45) are wired in stereo and are powered by the amplifier. A microphone outlet mounted in the driver’s area is provided as standard equipment.
  • Page 605 Section 23: ACCESSORIES FIGURE 2: AUDIO-VIDEO CONNECTIONS PA1602 SECTION 23...
  • Page 606 Section 23: ACCESSORIES FIGURE 3: AUDIO-VIDEO CONNECTIONS FIGURE 4: RACKS ON AUDIO-VIDEO PANEL PA1602 SECTION 23...
  • Page 607 Section 23: ACCESSORIES HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS For assistance in obtaining service for REI products call toll free 877-726-4617 (Continental United States and Canada) between the hours of 7:00 A.M. - 5:00 P.M. CST Monday thru Friday (excluding Holidays). For assistance in obtaining service for REI products call toll free 877-726-4617 (Continental United States and Canada only) between the hours of 7:00 A.M.
  • Page 608 Section 23: ACCESSORIES DASHBOARD RADIO each side in order to separate the unit from the support. 5. From behind, push the unit through the front dashboard panel. 6. Installation of a new unit is the same as removal but in reverse order. The operating instructions are included in the FIGURE 5: DASHBOARD RADIO Operator’s Manual.
  • Page 609 20- watt coaxial 10cm speaker. The speakers (24 in 1. Reconnect wiring. H3-41 or 28 in H3-45) in the passenger’s 2. Align mounting flange with holes and install section, wired in stereo and arranged in a delta screws.
  • Page 610 Section 23: ACCESSORIES TV TUNER 1.12 MONITOR 1. Place the ignition switch in the ‘’OFF’’ For TV tuner control descriptions, refer to fig. 13. position. 2. Unfasten the retaining screw located on the monitor R.H. side. 3. Slide the monitor to the right to release it from the mounting bracket.
  • Page 611 Section 23: ACCESSORIES  Selection of the video sources (CA1 CA2  AV  CA1). 4. With SIKA 205, wash the vehicle hole edge Press less than 1.5 seconds; and the antenna base surface, wait at least  Selection of the functions e.g. picture setting (after calling up the two (2) minutes for chemical evaporation.
  • Page 612 Section 23: ACCESSORIES - Hour-Month adjustable by UP BUTTON TIME - Minute/Date adjustable by DOWN BUTTON TIME 08:25 - Year adjustable by UP/DOWN BUTTON DATE MAY01 YEAR 2005 For calling up the menu INSTALL press the key MENU once again. The menu TIME appears.
  • Page 613 Section 23: ACCESSORIES HUB ODOMETER ELECTRONIC DESTINATION SIGN (Optional) DESCRIPTION To change the destination, depress the selecting switches until the desired destination appears in An optional wheel hub odometer (Fig. 17) may the LCD display. have been installed on the R.H. side of the drive axle.
  • Page 614 Section 23: ACCESSORIES FIGURE 19: DRIVER'S SUNSHADE FIGURE 21: FACTORY ADJUSTMENT OF UPPER AND LOWER END POSITION LAVATORY DESCRIPTION The lavatory is located in the rear R.H. corner of the coach. It is equipped with a chemical flush toilet, bathroom tissue dispenser, washbasin, towel dispenser, waste...
  • Page 615 Section 23: ACCESSORIES MAINTENANCE The servicing procedure for the lavatory is described in the '‘Operator’s Manual'’ included in the technical publications box delivered with the vehicle. VENTILATION FAN 6.3.1 Description The lavatory ventilation fan, mounted in engine compartment over the oil reserve tank (Fig. 23), serves two purposes.
  • Page 616 Section 23: ACCESSORIES wall (over cleaning cabinet), supplies water to the washbasin by gravity. Two tubes are connected in the upper section of tank (Fig. 27). One serves as overflow as well as vent tube and runs along the wall to the underside of the lavatory close to the engine air filter housing, while the other tube is connected to the fresh water fill valve which is mounted besides the...
  • Page 617 Section 23: ACCESSORIES Warning: Never put antifreeze in fresh water tank; antifreeze is toxic. Warning: If tank has not been drained for an extended period of time, draining and filling operations must be repeated three (3) times in order to clean tank and eliminate contaminated water.
  • Page 618 Section 23: ACCESSORIES This timer allows an electric current flow during a assistant to activate the flush pushbutton and preset time to a pump into the sump tank. check the liquid projection while you manually adjust the control valve 6.9.1 Pneumatic Timer Removal and Installation 6.11 SUMP TANK...
  • Page 619 Section 23: ACCESSORIES 6.12 CLEANING CABINET The headlights cleaning system is independent A coiled hose located in the cleaning cabinet from the windshield washer system and has its above the toilet can be used during lavatory own washer fluid reservoir located in the front cleaning.
  • Page 620 Section 23: ACCESSORIES The windshield wipers are controlled by two CAUTION electric wiper motors that are accessible for Because they are made of plastic, firmly maintenance after raising the appropriate access tighten nozzle and bulkhead fittings by panel at the front of the coach (refer to figure 32). hand only.
  • Page 621 Section 23: ACCESSORIES Each windshield washer pump is independently Sweep adjustment is a rough adjustment. It operated: must be followed by lower and upper linkage adjustment. See paragraph 10.3 and 10.4. To activate the upper windshield washer pump, depress and hold the top of the rocker switch on In order to obtain the sweep adjustment, it may dashboard L.H.
  • Page 622 Section 23: ACCESSORIES 9. Check the adjustment on a wet windshield. 4. Lower windshield wiper: Tighten clamping nut onto the drive arm. Install cap nuts onto the arm shafts; 5. Connect the windshield washer tubing at the base of the wiper arm; 6.
  • Page 623 3. Loosen clamping screw retaining the lever at the end of the motor driving shaft. 4. Remove the three bolts holding the motor to the steel plate. 5. Remove the windshield wiper motor (Prevost #800304), reverse removal procedure to reinstall. PA1602 SECTION 23...
  • Page 624 Section 23: ACCESSORIES FIGURE 38: LOWER WINDSHIELD WIPER INSTALLATION 23088 PA1602 SECTION 23...
  • Page 625 Section 23: ACCESSORIES 9.5.2 Upper Windshield Wiper Motor Replacement The upper windshield wiper motor is located above L.H. upper windshield panel. To remove the motor, it is necessary to remove left sun visor and upper windshield panel. Warning: Park vehicle safely, apply parking brake, stop engine and set battery master switch to the ‘’OFF’’...
  • Page 626 Verify that no obvious physical damage or activated by the operator at any time. condition exists that might prevent system operation. Refer to Prevost Operator’s Manual or Owner’s Manual for system operation and operational Protection Panel sequence (fire). o Verify that all warning lamps and the audible...
  • Page 627 Section 23: ACCESSORIES Engineered Fire Suppression System: Instal- nation (dirt, oil, grease, etc.) – if neces- lation, Operation and Maintenance Manual”. sary, clean using a water soaked non- abrasive towel. o Linear Thermal  Verify that there is no obvious physical damage and that the unit is free of ex- cess contamination (dirt, oil, grease, etc.) –...
  • Page 628 All wheels a) Install Beru valve Torque valve to 44.5lb- in +/- 9.5 b) no extension piece #Prevost 681083 Front axle and tag axle wheels with 365 tires– a) Remove Alcoa valve b) Install Beru valve Torque valve to 102lb-...
  • Page 629 Drive axle inner and outer wheels with 315 tires– a) Remove Alco valve b) Install Beru valve Torque valve to 102lb- #Prevost 651081 in +/- 22 c) no extension piece “Super Single” Tires a) Remove Alcoa valve b) Install Beru valve...
  • Page 630 Section 23: ACCESSORIES 11.2 BERU SENSORS INSTALLATION IMPORTANT NOTE Beru sensors have a limited lifespan (5 years on average) Check proper valve positioning before WASHER installing sensor onto valve (risk of damaging the sensor or air leaks). Beru pressure sensor 564078 Remove bar code with supplied removable tie-rap.
  • Page 631 Section 23: ACCESSORIES #651091 ENGLISH #651090 BILINGUAL Decal Glue decal facing the valve. DRIVE AXLE OUTER WHEEL PA1602 SECTION 23...
  • Page 633 SECTION 24: LUBRICATION & SERVICING CONTENTS     LUBRICATION .............................. 2     LUBRICATION AND SERVICE SCHEDULE ......................2 FLEXIBLE HOSE MAINTENANCE ........................2 2.1.1 HOSE INSPECTION ..........................2 2.1.2 LEAKS ..............................2 2.1.3 SERVICE LIFE ............................2 FLUIDS AND LUBRICANTS SPECIFICATIONS ....................8 LUBRICATION AND SERVICING SCHEDULES ....................
  • Page 634 Section 24: LUBRICATION & SERVICING LUBRICATION FLEXIBLE HOSE MAINTENANCE The efficiency and life expectancy of mechanical The performance of engine and equipment are equipment is largely dependent on proper greatly related to the ability of flexible hoses to lubrication servicing. mechanical supply lubricating oil, air, coolant, and fuel oil.
  • Page 635 Section 24: LUBRICATION & SERVICING outer surface or hoses with a damaged metal reinforcement should be considered unfit for further service. It is also recommended that all hoses in this vehicle be replaced during major overhaul and/or after a maximum of five service years. Quality of replacement hose assemblies should always be equal to or superior to those supplied by the Original Equipment Manufacturer.
  • Page 636 Section 24: LUBRICATION & SERVICING FIGURE 1: LUBRICATION AND SERVICING POINTS (I-BEAM FRONT AXLE SHOWN) TYPICAL SECTION 24 REVISED AUGUST 2015...
  • Page 637 Section 24: LUBRICATION & SERVICING Accessories air tank drain cock Primary fuel filter Accessories air filter Secondary fuel filter Steering drag link Power steering fluid tank Height control valve (front) Engine oil filter Steering tie rod Cooling fan gearbox Accessories air tank Allison transmission oil dipstick Steering column U-joints Engine coolant surge tank...
  • Page 638 Section 24: LUBRICATION & SERVICING FIGURE 2: LUBRICATION AND SERVICING POINTS – HVAC UNIT HVAC air filter – driver’s unit Coolant preheater A/C receiver tank A/C system – passenger’s overhead console Refrigerant moisture indicator Upper windshield defrost unit A/C compressor Condenser coil HVAC air filter –...
  • Page 639 Section 24: LUBRICATION & SERVICING FIGURE 3: LUBRICATION AND SERVICING POINTS - INDEPENDENT FRONT SUSPENSION VEHICLES (TYPICAL) SECTION 24 REVISED AUGUST 2015...
  • Page 640 Section 24: LUBRICATION & SERVICING FLUIDS AND LUBRICANTS SPECIFICATIONS FLUIDS & LUBRICANTS DESCRIPTION SPECIFICATIONS VOLVO D13 SAE Viscosity Grade: 10W-30 Engine Oil API Classification CJ-4 meeting Volvo specification VDS-4 and EO-O Premium Plus Power Steering Oil Automatic Transmission Oil, Dexron-III VOLVO D13 Engine Coolant Texaco or Chevron Extended Life Coolant (ELC)
  • Page 641 Section 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use GENERAL 1 Flexible hoses – thoroughly inspect all hoses  01 ENGINE 1 Engine oil &...
  • Page 642 Section 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use 8 Cooling system – drain, flush & refill (fully formulated coolant) 27 24 ...
  • Page 643 Section 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use 3 Drive axle – change differential oil, clean breather 17 12  4 Drive axle –...
  • Page 644 Section 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use 7 Parcel rack fans air filter – clean or replace 47 6 ...
  • Page 645 Section 24: LUBRICATION & SERVICING INTENTIONALLY LEFT BLANK SECTION 24 REVISED AUGUST 2015...
  • Page 646 Section 24: LUBRICATION & SERVICING LUBRICATION AND SERVICING SCHEDULE H3-45 VIP & X3-45 VIP MOTORHOMES (Private Use) GENERAL All flexible hoses – inspect H3 VIP Series only: Main power compartment fan air filter – inspect 01 ENGINE Engine oil and filters – replace Air cleaner –...
  • Page 647 Section 24: LUBRICATION & SERVICING LUBRICATION AND SERVICING SCHEDULE H3-45 VIP & X3-45 VIP MOTORHOMES (Private Use) Filled with TES389 approved fluid only, no mixture with Prognostics mode enabled – Change fluid & filters when indicated by TRANSMISSION SERVICE indicator or 24 month whichever occurs first. In addition, change filters with every fluid change.
  • Page 648 Section 24: LUBRICATION & SERVICING LUBRICATION AND SERVICING SCHEDULE H3-45 VIP & X3-45 VIP MOTORHOMES (Private Use) A/C compressor drive belt – check tension, inspect for cracks or frayed material, replace if required CHANGE LOG - LUBRICATION AND SERVICING SCHEDULE DATE A red stripe in the left margin of the schedule highlights the latest changes 1 ADDED: 04 EXHAUST &...
  • Page 649 SECTION 26: SLIDE-OUT CONTENTS 1 SLIDE-OUT .............................. 5 1.1 INNER STOPPER ..........................5 1.1.1 Maintenance ........................... 5 1.1.2 Adjustment ..........................5 1.2 "IN LIMIT" STOPPER .......................... 5 1.2.1 Maintenance ........................... 6 1.2.2 Adjustment ..........................6 1.3 EXTERIOR EXTRUSION ........................6 1.3.1 Maintenance ...........................
  • Page 650 14.3.3 Seal assembly installation ....................21 14.3.4 Slide-out 2" inside retraction ....................22 15 SLIDE-OUT ELECTRICAL SYSTEM ....................22 15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE ..........23 15.2 SLIDE-OUT BREAKERS ......................23 15.3 PROBING VOLTAGE ON THE MULTIPLEX CIRCUITS .............. 23 15.4 MODULE REPLACEMENT ......................
  • Page 651 Section 26: SLIDE-OUT LIST OF ILLUSTRATIONS ..........................5 FIGURE FRONT SLIDE ..........................5 FIGURE REAR SLIDE ....................5 FIGURE SIDE INNER STOPPER ADJUSTMENT ....................5 FIGURE UPPER INNER STOPPERS ADJUSTMENT " " ....................... 6 FIGURE LOWER IN LIMIT STOPPER " "...
  • Page 652 Section 26: SLIDE-OUT 55 : ................31 FIGURE FACE WINDOW RUBBER SEAL INSTALLATION 56 : – ¼ ½ ..........31 FIGURE SIDE WINDOW DOUBLE FACE ADHESIVE TAPE INSTALLATION 57 : – ....................31 FIGURE HALF WINDOW SIKA AKTIVATOR 58 : –...

  • Page 653: Slide-Out

    Section 26: SLIDE-OUT stopper comes into contact with the structure 1 SLIDE-OUT key. 1.1 INNER STOPPER The front slide-out is equipped with six inner stoppers laid out in the following way: two stoppers on the top horizontal member of the slide-out, and two stoppers on each vertical upright, while the rear slide-out is equipped with only three stoppers (FIGURE 1 and figure 2).

  • Page 654: Exterior Extrusion

    Section 26: SLIDE-OUT 1.2.1 Maintenance Check that the "in limit" stoppers are clean and that there is no foreign matter accumulated between the stopper and its bearing surface. Check that the screws and set screws (where applicable) locking the stoppers in proper position are tight.

  • Page 655: Security Pin

    2.2 AIR CYLINDER REPLACEMENT done under supervision of a Prevost 1. Assure the parking brake is applied. service representative. 2. Disconnect the cylinder air tubing from the baggage compartment (front slide-out) or under the bed structure (rear slide-out).

  • Page 656: Front Slide-Out Rack Replacement

    Slide-Out Removal Procedure. Ask to one foot. your Prevost service representative). 9. Tighten the two remaining crews to a 2. From under the slide-out, unscrew all the maximum torque of 2 ft-lbs. Use Loctite™...

  • Page 657: Pinion And Keyless Bushing Positioning

    Section 26: SLIDE-OUT 5.2 FRONT SLIDE-OUT SHAFT 5 PINION PINION REPLACEMENT CAUTION CAUTION Make sure all keyless bushings are tightened to 125 lb-ft before moving the Before reinstalling the pinion, clean the slide-out. Refer to paragraph 5.4 for torque following surfaces with alcohol to prevent wrench settings.

  • Page 658: Rear Slide-Out Shaft Pinion Replacement

    Section 26: SLIDE-OUT 5. Reinstall the drive motor/gearbox assembly. To tighten the keyless bushing, use a special open-end wrench to retain the yellow part and another wrench to tighten the black part. Figure CAUTION 20 shows how to tighten the keyless bushing. Make sure keyless...
  • Page 659 Section 26: SLIDE-OUT PA1602 SECTION 26...
  • Page 660 Section 26: SLIDE-OUT FIGURE 16 : KEYLESS BUSHING INSTALLATION INSTRUCTION PA1602 SECTION 26...

  • Page 661: Electric Motor

    Section 26: SLIDE-OUT 6 ELECTRIC MOTOR 7 SPEED REDUCTION GEARBOX The power is supplied by a 24V 1/3 HP electric motor coupled with a speed reduction gearbox. The speed reduction gearbox used is a helical Opposite to the gearbox, the motor is equipped worm gear type.

  • Page 662: Jaw Coupling

    Section 26: SLIDE-OUT bolts) flush with the shaft extremity (see 8 JAW COUPLING FIGURE 19 ). Tighten the clamping screw to a torque of 18 lbf-ft. 8.1 MAINTENANCE 7. Install the second clamping hub on the Inspect the jaw couplings for backlash between gearbox shaft.

  • Page 663: Linear Bearing

    The slide-out must be retracted when the (removal must be performed according to level and tilt adjustment is performed. Slide-Out Removal/Installation Procedure. Ask to your Prevost service representative). 2. Disconnect the jaw coupling on the side of the linear bearing being replaced (refer to paragraph 8).
  • Page 664 Section 26: SLIDE-OUT Before proceeding with the level and tilt adjustment, check the following conditions: 9. Using crisscross pattern, tighten progressively (3 rounds) the retaining screw  The slide-out is retracted; A, B, C & D to a torque of 50±5 ft-lb dry. ...

  • Page 665: Acetal Plastic Blocks

    Slide-Out Removal/Installation They also serve as bearing surface for: Procedure. Ask to your Prevost service 1. The inflatable seal each side of the rail. representative). 2. The “in limit” stoppers. 2. Remove the bolt hole cap covers. To do so, pierce a hole in the center and hook them out.

  • Page 666: Removal / Installation

    Section 26: SLIDE-OUT 13.1 REMOVAL / INSTALLATION 14.1 DESCRIPTION 1. Gain access to the linear bearing support AIR PRESSURE DELIVERY VALVE plate. The slide-out air pressure comes from the air pressure delivery valve on the pneumatic panel 2. From under the support plate, remove the in the front service compartment (figure 29).
  • Page 667 Section 26: SLIDE-OUT FIGURE 29 : FRONT SERVICE COMPARTMENT 12220 14.2 MAINTENANCE COMPRESSED AIR LINE Inspect all compressed air line tubing for cut, swelling, kink other damage deterioration. Inspect the pneumatic fittings and components for any leak. The slide-out air supply is connected to the accessory air tank and the required maintenance is described in Section 12 of this manual.

  • Page 668: Seal

    14.3 SEAL NOTE Refer to the Prevost parts manual for description of sealant and adhesives used. The slide-out sealing device is used to prevent any type of infiltration that may occur between the body structure and the slide-out itself.

  • Page 669: Seal Assembly Removal

    Section 26: SLIDE-OUT and the exterior panels and glasses. Add sealant 4. Clean the area with anti-silicone once again. if necessary. 5. Apply Sika 206 G+P on the area (see PR000001paragraphe D). 14.3.2 Seal assembly removal 6. Insert inflatable seal air inlet tube through WARNING the hole on the frame vertical member.

  • Page 670: Slide-Out 2" Inside Retraction

    “IN” position. Never modify the slide-out electrical wiring 6. Manually deflate the seal completely by without the Prevost Car approval. Any turning the relieving shut-off valve clockwise modifications may cause an unexpected (FIGURE 30). Make sure the pressure...

  • Page 671: Electrical Interconnection With Prevost Vehicle

    “OFF” position. 15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE FIGURE 37 : SLIDE-OUT CONTROL PANEL The slide-out power supply comes from the 24- volts and 12-volts circuit breakers (FIGURE 36) in the main power compartment. The other 15.3 PROBING VOLTAGE ON THE...

  • Page 672: Maintenance And Adjustment

    Section 26: SLIDE-OUT limit" and "out limit" sensor detect two pairs of permanent magnets fixed on the slide-out underbody. 15.5.1 Maintenance and adjustment The rear slide-out sensors are accessible from inside of the vehicle, under the bed structure while the front slide-out sensors can be reached from the 3 baggage compartment access panel.

  • Page 673: Slide-Out Exterior Finishing Panels & Windows

    1. Remove the slide-out (according to the Slide-Out Removal Procedure. Ask to your  Keep the slide-out retracted; Prevost service representative).  Check where adhesive, sealant and double 2. Drill through the rivets located at the bottom face adhesive tape are on the structure and of the panel.

  • Page 674: Side Panel Installation

    Section 26: SLIDE-OUT 6. Check the tape width and thickness. Use NOTE tape with same width and thickness when Do not remove the tape blue protective layer. installing new panels. The purpose of the tape is to maintain a certain gap and not to hold the panel in place. Caution: Make sure the heat gun nozzle tip is at least 4"...
  • Page 675 9. Exert pressure and let dry for at least 90 minutes; 10. Smooth down the joint and remove glue in excess; 11. Install rivets as per instruction sheet IS- FIGURE 48 : SIDE PANEL INSTALLATION – SIKA 06028 (ask your Prevost service TACK+BOOSTER APPLICATION representative); PA1602 SECTION 26...

  • Page 676: Top And Bottom Panel Removal

    4. Apply Sika 206 G+P on panel as shown in Removal/Installation Procedure. Ask to your FIGURE 51; Prevost service representative). 5. Apply Sika Tack+Booster (triangular bead: 2. Insert a flat screwdriver between the panel 9mm width X 6mm high) has shown in...
  • Page 677 Section 26: SLIDE-OUT Top panel Top structure, front S-O & rear super S-O Top structure, rear S-O Bottom panel Bottom structure, front S-O FIGURE 51 TOP AND BOTTOM PANEL INSTALLATION - SIKA 206 G+P APPLICATION Top structure Bottom structure, rear S-O Bottom structure, front S-O Bottom structure, rear super S-O Bottom structure, rear super S-O...

  • Page 678: Side Window & Half-Window Removal

    Section 26: SLIDE-OUT 16.8 HALF-WINDOW & SIDE WINDOW INSTALLATION Refer to procedures described in section 18: BODY of the maintenance manual for details. 1. Clean and prepare window and slide-out structure surface with appropriate cleaner, abrasives and primers [48mm≈1 7/8” ]; 2.
  • Page 679 Section 26: SLIDE-OUT 13. Press the jigs on the windows and wait for the adhesive to dry (90 minutes minimum). 14. Smooth down the joint and remove glue in excess. Clean excess adhesive with Sika 208. 15. Refer to paragraph 16.12 for the finishing joint application procedure.

  • Page 680: Face Window Installation

    Section 26: SLIDE-OUT FIGURE 64 : FACE WINDOW INSTALLATION - ANCHORING BLOCKS FIGURE 62 : HALF-WINDOW INSTALLATION – SIKA TACK+BOOSTER FIGURE 65 : FACE WINDOW INSTALLATION 16.10 AWNING WINDOW INSTALLATION FIGURE 63 : SIDE WINDOW 1. Clean and prepare window and slide-out structure surface with appropriate cleaner, abrasives and primers;...
  • Page 681 Section 26: SLIDE-OUT FIGURE 67: SIKA 255 APPLICATION 4. Place masking tape on the inside of the window pane as per FIGURE 68 to protect it from smudge; FIGURE 70: AWNING WINDOW - RUBBER BUMPER INSTALLATION 7. Apply Sika 252 as per FIGURE (triangular bead: 10mm width X 10mm high) [10mm≈3/8”];...

  • Page 682: Sliding Window Installation

    Section 26: SLIDE-OUT 10. Open the awning window manually and smooth down the joint (FIGURE 73) and remove glue in excess with Sika 208; FIGURE 75 : AWNING WINDOW – SEAL THE CHINK 16.11 SLIDING WINDOW INSTALLATION FIGURE 73 : SMOOTH DOWN THE JOINT 1.

  • Page 683: Finishing Joint

    Section 26: SLIDE-OUT FIGURE 79 : CORRECT TIGHTENING SEQUENCE FIGURE 76 : SLIDING WINDOW - SIKA AKTIVATOR FIGURE 80 : SLIDING WINDOW – SEAL THE UPPER CORNERS 16.12 FINISHING JOINT For surface cleaning and preparation, tools, cleaner, adhesives and other product needed, refer to the “side panel installation”...
  • Page 684 Section 26: SLIDE-OUT Apply Sika Aktivator and then apply Sika 252 Apply Sika Aktivator and then apply Sika 252 (black) between: between side window and structural member 1- face panel & vertical structural member at the corner; Bead must overlap both surfaces about 2mm 2- side panel &...

  • Page 685: Welding Precaution

    Section 26: SLIDE-OUT Apply Sika Aktivator and then apply Sika 252 Apply Sika Aktivator and then apply Sika252 between R.H. side edge of top panel and between the bottom panel and the magnets structural member Bead must overlap both surfaces about 2mm Apply Sika Aktivator and then apply Sika 252 between L.H.

  • Page 686: Manual Retracting Procedure - Front And Rear Slide-Out

    Section 26: SLIDE-OUT  Make sure the barking brake is applied and CAUTION that transmission is in the “NEUTRAL" position. The pressure in the inflatable seal must be completely relieved to prevent any damage to  Make sure the voltage is high enough by the seal.

  • Page 687: Manual Extending Procedure - Front And Rear Slide-Out

    Section 26: SLIDE-OUT 18.1.2 Manual extending procedure – Front and rear slide-out 1. Apply barking brake to disengage the security pin from the receptacle. 2. Turn the ignition switch to the "OFF" position, and remove the ignition key for more safety. 3.

  • Page 688: Slide-Out Maximum Load

    Section 26: SLIDE-OUT 6. Once the slide-out is lined up to its opened slide-out control system inhibits position, remove the tool from the motor. transmission range selection to prevent the vehicle from moving if the slide-out is not in its full "IN"...

  • Page 689: Conversion Checklist

    If not, an adjustment of the roof reinforcing rod may be required. This may be affected by the loading on the roof. See section 3 and contact your Prevost service representative. Make sure the front slide-out lower member deflection is within 1/4".

  • Page 690: Error Condition Or Missing Operation Condition

    Section 26: SLIDE-OUT 21 TROUBLESHOOTING 21.1 ERROR CONDITION OR MISSING OPERATION CONDITION When an error condition or a missing operation condition is present on a slide-out, the green indicator light on its respective handheld control starts blinking upon releasing of the IN/OUT rocker switch. Turning the ignition OFF and ON again, will stop the blinking and reset the fault.
  • Page 691 Section 26: SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION slide-out The parking brake is not seen by the Make sure the parking brake is applied. does controller as being applied; Confirm parking brake application with the extend parking brake light on the telltale panel. Not enough air pressure in the Run the engine at fast idle a few minutes to accessory air tank to permit proper...

  • Page 692: Troubleshooting - Mechanical Components

    Section 26: SLIDE-OUT 21.3 TROUBLESHOOTING - MECHANICAL COMPONENTS PROBLEM CAUSE CORRECTIVE ACTION Slide-out does not retract Electrical motor failure; A. Replace motor. or extend when depressing the control Speed reduction gearbox failure; B. Inspect gearbox components, switch. particularly: bronze wheel or first C.
  • Page 693 Section 26: SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION moving Slide-out does not retract Interference between the exterior Check for straightness of up to its full "in" position extrusion and the vehicle upper horizontal member and adjust the horizontal member above the slide-out; roof reinforcing rod.
  • Page 694 Section 26: SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION removed, or wiper seal with the manual procedure with the manually retracting or extending unstuck from the inflatable seal not deflated; the slide-out. structure. Pressure transducer malfunction; Check the pressure transducer condition, replace if necessary. C.

  • Page 695: Slide-Out Fault Message On Message Center Display (Mcd)

    Section 26: SLIDE-OUT 21.4 SLIDE-OUT FAULT MESSAGE ON MESSAGE CENTER DISPLAY (MCD) FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION Voltage Module A56 Value Too Low Module A56 sees a Voltage less Check/ reset circuit breaker than 18 V on its power supply CBSo and CBSo1.
  • Page 696 Section 26: SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION switch and CECM is shorted to 12v or 24v. SldO Mot SpeedA Ctr Shorted High Wiring harness shorted to 12v or Fix wiring harness Current Above Security pin or object stop the Check / fix security pin normal movement of a slide-out...
  • Page 697 Section 26: SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION Bad connection on relay. connection Wiring harness is cut. Check / fix wiring harness Current Above Relay coil or wiring harness Fix relay coil or wiring normal shorted to 12v or 24v harness SldO Mot Pos Rly Shorted High...

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