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PREVOST X3-45 COMMUTER Maintenance Manual

PREVOST X3-45 COMMUTER Maintenance Manual

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Table of Contents

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COACH MANUFACTURER
MAINTENANCE MANUAL
X3-45 COMMUTER
DOB Bus Number Series 2490 - 2789
Final Version, Rev. 2

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Summary of Contents for PREVOST X3-45 COMMUTER

  • Page 1 COACH MANUFACTURER MAINTENANCE MANUAL X3-45 COMMUTER DOB Bus Number Series 2490 - 2789 Final Version, Rev. 2...
  • Page 2 PA1605 November 2014 (first release) Featuring:  GHG14 regulations engine  ZF A-132 Drive Axle REVISION DESCRIPTION DATE - Sec 22: Heating and Air Conditioning updated. Feb. 2015 - Sec 13: Wheels, Hubs and Tires: updated to reflect wheel dimensions on new build; Drive axle hub updated to “ZF”...
  • Page 3 CRITICAL EMISSION-RELATED MAINTENANCE Source of parts and repair: A repair shop or person of the owner’s choosing must maintain, replace, or repair emission control devices and systems per manufacturer's recommendations. Replacement of tires that are GHG certified: The original equipment tires installed on this vehicle at the factory were certified to the U.S. EPA Greenhouse Gas (GHG) and National Highway Traffic Safety Administration (NHTSA) Fuel Efficiency regulations.

  • Page 5: Table Of Contents

    FIGURE 10: BOLT STRENGTH MARKINGS ....................8   FIGURE 11: SELF-LOCKING FASTENERS .................... 11   FIGURE 12: METRIC - US STANDARD CONVERSION TABLE ............... 13   FIGURE 13: CONVERSION CHART ......................14 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 6: Foreword

    Do not use TIG welding process on the vehicle. reference. This high frequency current process can seriously damage the electronic components. DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 7 GMAW (Gas Metal-Arc Welding) process; Welding wire conforms to AWS (American Welding Standards) A5.9 specifications; 308LSi type welding wire with 0.035" diameter (0,9 mm); STEEL - STAINLESS STEEL WELDING DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 8: Safety Notice

    Also, the transmission, axles, power steering pump chassis and other major components are identified by serial numbers. DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 9: Engine

    4.1.7 Safety Certification Vehicle components meet specifications and standards as follows: FIGURE 3: TYPICAL SERIAL & MODEL NUMBERS 00007 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 10: Dot Certification Label

    The VIN is visible from the outside of the vehicle. Make sure correct vehicle identification number is given when ordering replacement parts. Using the VIN when ordering parts will facilitate processing. DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 11: Figure 8: Vehicle Identification Number

    FIGURE 8: VEHICLE IDENTIFICATION NUMBER 00056 YEAR CODE YEAR CODE YEAR CODE 2000 2006 2012 2001 2007 2013 2002 2008 2014 2003 2009 2015 2004 2010 2016 2005 2011 2017 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 12: Fastener Strength Identification

    M 12 X 1.75; suppliers. general, except special M 14 X 2; applications, the common sizes and pitches are: DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 13: Standard Torque Specifications

    (dry) 5/16-24 lbf-in (dry) 5/16-24 lbf-in (dry) 3/8-16 3/8-16 3/8-24 3/8-24 7/16-14 7/16-14 7/16-20 7/16-20 1/2-13 1/2-13 1/2-20 1/2-20 9/16-12 9/16-12 9/16-18 9/16-18 5/8-11 5/8-11 5/8-18 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 14 METRIC M22 X 2.5 nut 10 / screw 10.9 METRIC M24 X 3 nut 9 / screw 8.8 METRIC M24 X 3 nut 10 / screw 10.9 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 15: Self-Locking Fasteners

    5.4 SIX LOBED SOCKET HEAD Six lobed socket head (Torx) fasteners are used in some applications on vehicles covered in this manual. The tools designed for these fasteners DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 16 ALL-METAL BOLTS Lbf-in ADHESIVE OR NYLON COATED BOLTS Lbf-in ¼ 5/16 7/16 ½ 9/16 ¾ US STANDARD NUTS AND ALL-METAL BOLTS Lbf-in ADHESIVE OR NYLON COATED BOLTS Lbf-in DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 17: Figure 12: Metric - Us Standard Conversion Table

    SECTION 00: GENERAL INFORMATION FIGURE 12: METRIC - US STANDARD CONVERSION TABLE 00005 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 18: Figure 13: Conversion Chart

    SECTION 00: GENERAL INFORMATION FIGURE 13: CONVERSION CHART 00006 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 19: Section Change Log

    SECTION 00: GENERAL INFORMATION 6. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 21 Revision 00 : New procedure for cooling 2007 Revision 01 : Modified for EPA 2010 Revision 02 : Added: battery equalizer data connection (PRIME). DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 1 of 8...
  • Page 22 Location: Rear Junction Panel 2.05* Lift cover, trip circuit breakers CB2-CB6 located on junction panel. Push the red button to open the circuit DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 2 of 8...
  • Page 23 Disconnect all I/O A, I/O B modules. Disconnect C717 Disconnect 3 connectors from each I/O A module Disconnect 3 connectors from each I/O B module Disconnect C397 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 3 of 8...
  • Page 24 PROCEDURE NO: PR060041 REVISION 02 Location: battery compartment: 2.15.2 Disconnect data connector on equalizer DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 4 of 8...
  • Page 25 CECM, BERU, Volvo Link, Gsecu modules. Disconnect 3 connectors from I/O B and I/O A modules Disconnect 4 connectors from the ABS module Disconnect connector from master ID DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 5 of 8...
  • Page 26 PROCEDURE NO: PR060041 REVISION 02 Disconnect 3 connectors from VECU Disconnect 3 connectors from CECM DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 6 of 8...
  • Page 27 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 DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 7 of 8...
  • Page 28 CONNECTIONS, IF NOT, SOME SYSTEMS 2.70 OR COMPONENTS MAY NOT BE USABLE. Make sure that the connectors locking tab are well engaged! DOB 2490-2789 X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016) Page 8 of 8...
  • Page 29 FIGURE 11: NORMAL OIL COOLER POSITION  .......................  1 4   FIGURE 12: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION ................  1 5   FIGURE 13: ELECTRONIC FOOT PEDAL ASSEMBLY .......................  1 7   FIGURE 14: IDLER PULLEYS AND AUTOMATIC BELT TENSIONERS ON COOLING FAN DRIVE ........  1 8   FIGURE 15: IDLER AND AUTOMATIC BELT TENSIONER ON ALTERNATOR DRIVE ............  1 8   FIGURE 16: CHECKING BUSHING WEAR  ........................  1 9 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 30: Volvo D13 Engine

    The following is a list of engine sensors that signal proportional to the deflection. provide input to the EMS: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 31 The exhaust gas temperature sensor detects The modified signal returns to the control unit as exhaust gas temperature for DPF protection as DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 32 Mechanical pressure applied to the diaphragm causes the diaphragm to deflect and the amplifier to produce an electrical signal proportional to the deflection. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 33 Turbine Speed Crankcase pressure (CCP) EGR Temperature Aftertreatment Fuel Pressure EGR Differential Pressure Fuel Pressure Engine Coolant Temperature (ECT) Engine Oil Level / Temperature Crankshaft Position (CKP) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 34: Engine Overview

    5. Fuel pump 14. Alternator Belt 6. Engine Control module (ECM) 15. Water Pump Belt 7. Fuel filter 16. EGR mixing chamber 8. Fuel/Water Separator 9. Fuel Filter DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 35 19. Intake Air Heater (IAH) Opt. 26. Oil Pan 20. Thermostat 27. EGR Cooler 21. Belt tensioner 28. Turbocharger 22. Coolant Pump 29. Starter Motor 23. Coolant Filter .EGR Valve DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 36: Engine Oil

    If the vehicle is operating in heavy-duty operation, dusty or off-road conditions, etc., reduce the intervals for more frequent oil changes. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 37: Synthetic Lubrication

    Raise the elbow so the forearm is parallel to the ground to prevent oil running down the arm, causing burns. CAUTION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 38: Oil Filters Change

     Clean around the oil filter housing and remove the filters using the oil filter wrench or the oil filter socket. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 39: Checking The Oil Level

    (including  retarder if so equipped), air compressor, Check the oil level. Add approved engine alternator and transmission oil cooler. recommended level, necessary. Do not overfill. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 40 4. On vehicles equipped with an automatic starter, alternators and heater cables. transmission provided with a hydraulic Also disconnect AFSS cable output retarder, disconnect steel-braided applicable. airline from pressure regulator output. The DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 41  Disconnect and remove a section of coolant pipe assembly mounted between the thermostat housing and the radiator inlet. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 42: Power Plant Assy. Installation

    5. Start engine for a visual check. Check fuel, oil, cooling, pneumatic and hydraulic system connections for leakage. Test operation of engine controls and accessories. FIGURE 11: NORMAL OIL COOLER POSITION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 43: Engine Mounts

    It is recommended that new rubber mounts be installed at each major overhaul. NOTE Refer to the table on the following page for engine cradle tightening torques. FIGURE 12: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 44: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    14 counts, or when the full throttle position is more than 233 counts. Should these conditions occur, the CPC will signal diagnostic codes of 21-12 for idle error and 21-23 for wide-open throttle error. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 45 SECTION 01: ENGINE FIGURE 13: ELECTRONIC FOOT PEDAL ASSEMBLY 03035 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 46: Automatic Belt Tensioners And Idler Pulleys Inspection

    (see image below). AUTOMATIC BELT TENSIONERS System Torque lbs-ft cooling fan drive 32 (2x) water pump drive alternator drive DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 47: Belts And Idlers Visual Inspection

    In the event of a serious fault, the red STOP Pressure telltale light comes on and an audible alarm will sound if the engine is running. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 48: Specifications

    Engine oil filter ............. Tighten ¾ of a turn to 1 full turn after gasket contact Filters Engine Air Cleaner Filter Prevost number ..........................530197 Engine Coolant Filter/Conditioner Prevost number ..........................20458771 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 49: Section Change Log

    SECTION 01: ENGINE 6. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 51 JACK STANDS UNDER THE FUEL TANK CRADLE 15: L ........................10 IGURE OCATION OF OUNTING OINTS 16: T ........................10 IGURE RANSVERSE CREWS LOCATIONS 17: L ......................... 10 IGURE ONGITUDINAL CREWS LOCATIONS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)
  • Page 52 HIM INSTALLATION TRANSVERSE SCREW RRANGEMENT MAY VARY 01052_1 ......................12 IGURE RESTRICTION INDICATOR 21: RESTRICTION INDICATOR LIGHT ........................12 IGURE 03035 ......................13 IGURE ELECTRONIC FOOT PEDAL ASSEMBLY DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 53: Fuel System Description

    It is not necessary to bleed the fuel channel within the fuel filter housing (4). system after replacing the filter, since this is DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 54: Fuel Valves

    No manual valve is required on preheater fuel-supply line, since the positive-displacement fuel pump (located close to the fuel tank) prevents fuel flow when not activated. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 55: Primary Fuel Filter Replacement

    1.2.2 Secondary Fuel Filter Replacement 1. Stop engine, close the fuel supply line shut- off valve. Place an appropriate container under the fuel filter housing. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 56: Priming The Fuel System

    Position a container to catch any fuel that to follow these instructions could prematurely might drain from the pump or lines. damage the primer pump. • Remove the fuel pump. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 57: Fuel Lines And Flexible Hoses

    LCV will close when the fuel reaches the level in • Start the engine and let run for 5 minutes. the tank corresponding to 95% of the tank Make sure that there are no leaks. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 58: Fuel Tank Drain Plug

    Failure to do so could result in injury as well as damage to the tank. FIGURE 9: FUEL TANK DRAIN PLUG DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 59: Tank Installation

    1. Raise the vehicle with safe lifting equipment and procedures. 2. Place jack stands under the fuel tank cradle. FIGURE 11: FUEL TANK SUPPORT MOUNTING BOLTS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)
  • Page 60 Perform replacement one screw location FIGURE 19: SHIM INSTALLATION, TRANSVERSE at a time with appropriate support. Apply SCREW. ARRANGEMENT MAY VARY torque seal mark. Torque: 82 lbf-ft. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 61: Fuel Specifications

    ULSD fuel) in 2010 and later model year handle in the center of the air cleaner element. diesel engines is illegal and punishable with Install cleaner element as follows: civil penalties. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 62: General Recommendations

    With the ignition "ON" and the proper diagnostic Do not ignore the Warning given by the air tool (DDR) (for information regarding the DDR, restriction indicator. This could result in DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)

  • Page 63: Fuel Pedal Adjustment

    CAUTION Make sure the cable harness is routed correctly, and securely installed so that it does not become pinched, stretched, or otherwise damaged during vehicle operation. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)
  • Page 64 SECTION CHANGE LOG DESCRIPTION DATE Fuel tank strap torque was 60 lb-ft, changed to 20 lb-ft Oct 2016 Paragraph 3.4 Fuel Tank Yearly Inspection added May 2018 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 03 revised May 2018)
  • Page 65 FIGURE 13: TORQUE SPECIFICATIONS ....................15   FIGURE 14: TORQUE SPECIFICATIONS ....................15   FIGURE 15: TORQUE SPECIFICATIONS ....................16   FIGURE 16: TORQUE SPECIFICATIONS ....................16 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 66: Exhaust And Aftertreatment System Overview

    Particulate Filter (DPF) assembly to capture from hot gases could result as well. Replace and regenerate the soot on a regular or passive basis, then the exhaust gases flow through the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 67: Flexible Coupling Installation

    System surfaces, particularly during and after stationary regeneration. active or stationary regeneration. Hot surfaces can cause serious burns. Make sure Aftertreatment System components are cold before handling. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 68: Diesel Particulate Filter Assembly Removal

    External and internal temperatures remain hot long after engine has been shut down. Allow the Exhaust Aftertreatment System to cool before handling. Wear protective clothing and glove while servicing. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 69 5. Unfasten straps holding DOC and DPF facilitate gaskets positioning; assembly; 6. Carefully lower DOC and DPF assembly; DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 70: Catalytic Converter

    Procedure # 1 screws fixing radiator sealing frame. Radiator must be removed in order to lower the  Remove radiator and air cooler assembly. catalytic converter for replacement. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 71: Assembling Catalytic Converter

     Mark, with a vertical line the central position  Remove coolant surge tank. of the lower and upper clamps with regard to DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 72 Position the upper clamps above the upper emboss and the lower clamps below the Lower lower emboss of the catalytic converter. Lower CLAMP Upper Upper CLAMP CLAMP DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 73: Diffuser Assembly

     Make sure that the water drain tube is not not more than 3/32" (2mm). clogged. Pour a cup of water into the diffuser DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 74: Diesel Exhaust Fluid (Def) Tank And Injection System

    Rinse off these electrical connectors to be connected or well crystals with water. encapsulated, otherwise there is a risk that the DEF will cause oxidation that cannot be DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 75: Def Tank Cleaning

    DEF tank drain plug. MAINTENANCE Drain and clean DEF tank and filler neck insert filter with hot water every 50,000 miles, replace the filter every 100,000 miles. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 76: Aftertreatment Fuel Injector

    If there are cracks in the filter cover, the filter cover must be replaced. CAUTION Do not kink the line. Kinking the line may result in leakage. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 77 The fasteners already include pre-applied high-temperature anti-seize compound. 6. Connect the line to the aftertreatment hydrocarbon injector. Tighten the line fitting to135 lbf-in. FIGURE 10: FUEL LINE FITTING DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 78: Torque Specifications

    SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM TORQUE SPECIFICATIONS FIGURE 11: TORQUE SPECIFICATIONS FIGURE 12: TORQUE SPECIFICATIONS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 79 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM FIGURE 13: TORQUE SPECIFICATIONS FIGURE 14: TORQUE SPECIFICATIONS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 80 SECTION 04: EXHAUST AND AFTERTREATMENT SYSTEM FIGURE 15: TORQUE SPECIFICATIONS FIGURE 16: TORQUE SPECIFICATIONS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 81: Section Change Log

    Strap – DPF tank * Use Permatex 454G anti-seize lubricant or Loctite 76764 silver grade anti-seize SECTION CHANGE LOG DESCRIPTION DATE DPF removal, tool info added paragraph 2.1 2016/06/09 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 83 Mechanical Locking..........................  1 8     RIGHT ANGLE GEARBOX .........................  1 9     14.1 OIL CHANGE .............................  1 9     14.2 REMOVAL / INSTALLATION ........................  1 9     FAN REMOVAL AND INSTALLATION  ......................  2 0 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 84         FIGURE RIGHT ANGLE GEARBOX ..........................  2 0           FIGURE RADIATOR MOUNTING BOLTS ......................  2 0           DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 85: Description

    Refer section "”HEATING CONDITIONING" in this manual for information relating to heating system water circulation. FIGURE 1: COOLANT SURGE TANK 05132_3 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 86: Maintenance

    All hose clamps used on the heating and cooling connections may be caused by deformation of systems have a spring function (spring in the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 87 FIGURE 7: COOLANT LINE TO THE RADIATOR FIGURE 5: DOUBLED CLAMP POSITIONING CAUTION Do not over-tighten, especially during cold FIGURE 8: COOLANT LINE CONNECTED TO PUMP OUTLET weather when hose has contracted. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 88: Constant-Torque Hose Clamps On Charge Air Cooler (Cac)

    A function check must be carried out before installing a new thermostat. CAC HOSE CLAMPS TORQUE : 60 lbf-in FIGURE 11: CHARGE AIR COOLER HOSE CLAMPS - DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 89: Coolant

    (Figure 13). tank in the engine compartment will illuminate to indicate the need to add coolant to the system. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 90: Thawing Cooling System

    Provide adequate freeze protection during cold weather operation. When freeze protection is required, a mixture of suitable water antifreeze containing adequate inhibitors will provide a satisfactory coolant fluid. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 91: Coolant Sampling

    Also, ensure cleanliness throughout this procedure to make sure the coolant sample is not contaminated accidentally. Sampling should be performed on the surge tank, on a cold engine. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 92: Draining Cooling System

    “Draining Heating System” in Section 22. handling. Keep coolant out of reach of children and animals. Failure to follow these precautions can cause serious illness or death. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 93: Filling Cooling System

    Section 22, under After the engine and radiator have been “Bleeding Heating System”. thoroughly de-scaled, they should be reverse- flushed. The water pump should be removed DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 94: Spin-On Coolant Filter

    4. Coat surface of gasket with a light coat of Circulate the water through the radiator core clean antifreeze. from the bottom to the top during this operation. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 95: Radiator

    Do not use fuel oil, kerosene, gasoline, or any caustic material. It may be FIGURE 19: ACCESS PANEL (TYPICAL) necessary clean radiator more DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 96 FIGURE 23: RADIATOR ASSEMBLY LOWER MOUNTING FASTENERS 15. Cut cable tie and disconnect electrical connector from fan clutch. Remove fan drive shaft fasteners at the gear box. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 97 19. Lay radiator face down. Remove the fasteners that connect lower radiator mounts to radiator. FIGURE 28: REMOVING FAN SHROUD FROM RADIATOR 23. Reverse removal procedure to reinstall radiator assembly. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 98: Charge Air Cooler Leakage

    OFF position to prevent the 6 mounting bolts from behind the pulley, accidental starting of the engine. through the opening in the cast aluminum support (Figure 31). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 99: Idler Replacement

    FIGURE 32: IDLER MOUNTED ON THE CAST ALUMINUM SUPPORT 4. Bolt the new idler on the cast aluminum support. Tighten as prescribed. 5. Place a new protective cap. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 100: Locking Fan Clutch For Emergency Operation

    While in this mode, the rear start push-button can be used to manually engage the fan clutch. The multiplex system knows when the engine is DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 101: Right Angle Gearbox

    6. Unscrew and remove the oil level plug and the top filler plug/vent. 7. Add gear lubricant until oil level reaches the bottom of the side oil level check point. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 102: Fan Removal And Installation

    If the fan is still in the radiator fan shroud, accidental starting of the engine. place 2 of the mounting bolts on the opposite side of the flange, in reverse DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 103 Type ..................Fleet Charge 50/50 Fully Formulated Antifreeze Coolant Filter Cartridge – Volvo D13 Engine Number used ................................ 1 Type ..............Spin-on filter containing Supplemental Coolant Additives (SCA) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 104 SECTION 05: COOLING SYSTEM 17. SECTION CHANGE LOG DESCRIPTION DATE Added 5.6 coolant sampling. April 8, 2016 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 105 SYSTEM DIAGNOSTIC  ........................  2 4         PROBING VOLTAGE MULTIPLEX CIRCUITS  ..................  2 5           DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ) – Sec 06 revised June 2017...
  • Page 106 Switch lighting .............................  4 6     11.1.2 Telltale light replacement ........................  4 7     11.1.3 Gauge light bulb replacement ......................  4 7     11.2   ..............................  4 7 TEPWELL LIGHTS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 107 FIGURE 36: TWIN ALTERNATORS INSTALLATION  ......................  3 9  FIGURE 37: ALTERNATOR MOUNTING ‐ TIGHTENING SEQUENCE  ................  3 9  FIGURE 40: ½″ SOCKET DRIVE WRENCH ........................  4 0  FIGURE 41: CURBSIDE DOOR FAN CONTROL LOGIC ....................  4 1  FIGURE 42: HEADLIGHT ASSEMBLY ..........................  4 2  FIGURE 43: HEADLIGHT ASSEMBLY OPENED FOR BULB REPLACEMENT ..............  4 2  FIGURE 44: ALIGNMENT OF HEADLIGHT AIMING SCREEN ..................  4 3  DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 108 FIGURE 48: AIM INSPECTION LIMITS FOR LOWER‐BEAM HEADLIGHTS ..............  4 4  FIGURE 49: REAR TAIL LAMPS  ............................  4 5  FIGURE 50: TAILLAMP POD RETAINING SCREWS & NUTS ...................  4 6  FIGURE 51: DASHBOARD ROCKER SWITCH  ........................  4 7  FIGURE 52: ENGINE COMPARTMENT LIGHT  ........................  4 7  FIGURE 53: VARIOUS LIGHTS LOCATION ........................  4 8  DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 109: General Description

     Fuse code, a) Refer to wiring diagram index, and look for  Relay Code. "multiplexed device index", pages b1-b8. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 110: Testing Circuits

    24VA 12VA the wiring voltage and to assist in making 24VD 12VD connectors. The wires are color coded as follows: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 111: Spare Wires

    To specifically clean oxidized cables, a product connected to the battery. that offers the same qualities mentioned above DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 112: Multiplex Fuses

    5 minutes after the ignition switch has DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 113 OUT 06624 Setting the cluster clock is performed by the time/distance menu of the DID. Refer to the operator’s manual for additional details. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 114 Remove the terminal by disengaging the flexible lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 115 Remove the terminal by disengaging the flexible lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. VECF Bussman DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 116: X3 Series Commuter Coach Electrical Compartment Overview

    Use sprayed sealer in a well-ventilated area. Do not smoke. Avoid prolonged contact with skin and breathing of spray mist. FIGURE 5: REAR ELECTRICAL PANEL, JUNCTION PANEL & BATTERY COMPARTMENT DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 117: Rear Electrical Panel

    A/C Junction Box The a/c junction box is located in the evaporator compartment, on the evaporator fan motor housing. FIGURE 7: BATTERY COMPARTMENT 06773 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 118: Engine Rear Start Panel

    In the first road side overhead parcel rack, you equalizer and the cluster digital clock. will find the following systems (additional details are available in section 23, accessories): DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 119: Motorola Radio Power Mode

    Odyssey battery _owner's manual us- Always replace these batteries with identical ody-om-009_0611 make and model batteries as the system is balanced and optimized for this type of battery. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 120: Battery Discharge Protection

    AGM batteries should be replaced in pairs or position and battery master switch (master cut- four at a time. out) is turned on. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 121 3. Unscrew tie-down nuts (6x) and remove clamps (2x).(Figure 18) 7. Installation is the reverse of removal. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 122: Battery Rating

    3. Check for damaged or loose battery tie- Type: absorbed glass mat downs. Terminal type: top stud DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 123: Removing Surface Charge

    #16 (awg) or larger wire. 3. Check voltage drop between the starter housing and a good ground on the vehicle. The reading should be less than 0.2 volt. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 124: Booster Block

    DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 125: Agm Battery Charging Precautions

    Make sure your charger is multi-staged and period of time. minimally provides the following voltage values: Charge stage voltage: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 126: Troubleshooting

    DID (driver information display), check the voltmeter gauge to determine if the battery voltage is too high or too low. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 127: Prime Energy Management System

    80 series battery equalizer that monitors battery state of charge (soc). Battery temperature, voltage and current are also monitored to prevent overcharging and overheating. FIGURE 22: PRIME ELECTRICAL COMPONENTS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 128: Vanner 80 Series Battery Equalizer Fault Codes

    When more than one fault is recorded, an arrow pointing down appears on the right of DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 129: Probing Voltage On The Multiplex Circuits

    It has connectors installed at each end to facilitate swapping from the regular can network to the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 130: Multiplex Input Test Mode

    Note that while in Kneeling down switch test mode, the engine cannot be started. Electric horn button Prerequisite conditions for the motor test mode: Lh turn signal DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 131: Test Sequence

    “clicks” will be heard). speed 2 for 3 seconds.  Left and right overhead compartment fans run one after the other for 5 seconds. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 132: Forced Activation Of The Radiator Fan Clutch

    Mechanically lock the fan clutch as described in section 05: of the COOLING SYSTEM maintenance manual. CAN NETWORK OVERVIEW FIGURE 26: X3-45 COACH NETWORK LAYOUT DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 133: Multiplex Troubleshooting

    2. Flip the rear start selector switch to off position (down) “rear start” and start the vehicle from the rear DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 134 (start of vehicle from engine compartment, wipers speed flashers, etc ) are functioning DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 135 1 reset HVAC condenser fans not Circuit breaker Check / reset circuit breaker cb7 functioning in speed 2 manually tripped and not reset DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 136 3. Check / replace fuse f33 and f34 4. Check / replace relay r19 5. Probe gray connector on module to see if it is powered. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 137 3. Check / reset circuit breaker cb5 4. Check / replace fuse f67 , f68 5. Probe gray connector on module to see if it is powered. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 138 No backlighting in the Circuit breaker cb10 Check / reset circuit breaker cb10 instrument cluster tripped or fuse f20 blown Check / replace fuse f20 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 139: Multiplex Error Messages Troubleshooting List

    If the default mode does not activate, try to turn the ignition off while ensuring that no DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 140: Available Functions

    1. On rear electrical junction panel, trip circuit breaker cb6. 2. Replace the module and plug connectors (for IO-B modules, disconnect green DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 141: Replacing The Mcm

    (ex: a41, a42…etc). need (see Figure 30): 1x usb to serial db9 rs232 adapter (sold at staples); 1x prevost interface cable p/n 066009; DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 142 FIGURE 34: VALIDATING PROGRAM VERSION 9. On rear electrical junction panel, trip and reset circuit breaker cb6. FIGURE 32: PROPER PORT SETTINGS 10. Clear all diagnostics troubleshooting codes. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 143: Bosch Alternators

    If removed, install alternators help keep the pulley from turning when idler pulley (4, Figure 36) onto alternators tightening. arched support, torque tighten to 43 lb-ft. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 144: Alternator Periodic Inspection

    Back-probe pin 9 (A49 J1:9).  If multimeter reads 1-2 volts, the upper Installation alternator is defective; DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 145: Adjustment

    An access door is provided in the wall. For further details, consult Vanner battery charger model sp00155 owner’s manual included on your technical publications cd. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 146: Power Inverter

    Inner lamps are used for high Note beam or daytime running light. Make sure headlight assembly is properly positioned into its housing before securing using fixing screw. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 147: Headlight Adjustment

    4. The nominal vertical aim position on lower beam headlights shall be adjusted based on the headlight mounting height, from the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 148: Sealed Beam Unit

    The turn signal is a sealed unit (led) front service compartment to tilt down the located on each front corner and should be entire bumper assembly. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 149: Lamp Removal And Replacement

    The hazard warning flashing system uses the front, side rear directional lights simultaneously. This system is energized by a switch on the L.H. dashboard. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 150: Center Stoplights And Center High-Mounted Stop Light (Chsl) Removal And Replacement

    11.1.1 Switch lighting 1. Slightly pull the switch with a defective led away from the control panel. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...

  • Page 151: Telltale Light Replacement

    4. Replace the rear dashboard housing. 11.2 STEPWELL LIGHTS Two stepwell lights are illuminated when the FIGURE 50: ENGINE COMPARTMENT LIGHT door opening system is activated. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 152 4. Connect the light unit. 1. Disconnect the light unit connection. 2. Unfasten the two fixing screws then remove the lamp. FIGURE 51: VARIOUS LIGHTS LOCATION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 153 Low Battery Cut-Out ..........................20 Vdc High Battery Cut-Out ..........................32 Vdc Protection ......... Automatic Overload, Short Circuit, Over-Temp, Over-Volt, Under-Volt Transfert Relay Rating ........................15 Amps Starter DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 154 SECTION CHANGE LOG DESCRIPTION DATE Addition of “Alternator Periodic Inspection” & “Identifying a Single Defective Alternator” paragraphs. 06/12/2017 Removal of “Alternator Brush Replacement” procedure. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version) – Sec 06 revised June 2017...
  • Page 155 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 156 PROCEDURE NO: SAV00002E REVISION 02 Vehicle Zones Electrical Connectors Protection Procedure Table Product Note Model Zone Component X3-45 A- Front Elect. Compt Diode Block Nyogel Accepted to ease connection A- Front Elect. Compt Customer Terminal Block Nothing Terminal Block Electronic A Front Elect.
  • Page 157 PROCEDURE NO: SAV00002E REVISION 02 Product Note Model Zone Component X3-45 Color Guard C- Baggage Compt Structure Ground or Kent C- Baggage Compt Door Switch Nyogel Accepted to ease connection Door lock Actuator Module C- Baggage Compt (switch and solenoid) Nyogel Accepted to ease connection C- Baggage Compt...
  • Page 158 PROCEDURE NO: SAV00002E REVISION 02 Product Note Model Zone Component X3-45 H- Vehicle Exterior ABS Sensor Nothing H- Vehicle Exterior Docking & Cornering Lamps Nyogel Accepted to ease connection H- Vehicle Exterior Marker Light Nothing H- Vehicle Exterior Mirror Nothing H- Vehicle Exterior Light Module Nothing...
  • Page 159 • A52 module failure FMI 5 Open Circuit A52 module does not High side • Se23 failure detect Se23 pressure not • Circuit 77-20 open displayed on dash DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 160 Shorted Low Voltage below normal Left high beam • Sw2 failure on A45 J1:12 always ON • Connector C71 corroded • Circuit 61-20 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 161 FMI 3 Shorted High Voltage above Brake interlock • Se78 failure normal on A45 J1:13 not working • Connector C8 corroded • Circuit ANA-INTLK shorted to battery DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 162 Voltage present on L70 always ON • Connector C15 corroded output A50 J1:5 but • Connector C21 corroded output not active • Circuit 21A shorted to battery DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 163 • Connector C58 corroded active for overcurrent • Connector C15 Corroded • Circuit 46B shorted to ground • L67 or L69 low resistance value DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 164 • Connector C91 corroded active for overcurrent light L81 not working • Circuit 82A shorted to ground • Low resistance value DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 165 • A46 module failure FMI 4 Shorted Low Output A46 J1:6 Full heat in • Connector C4 corroded shorted to ground driver’s area • Circuit 50 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 166 • A46 module failure FMI 5 Open Circuit A46 module does not Driver’s A/C not • So7 open detect Driver Liquid working • Circuit 116A open Solenoid Valve So7 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 167 • Circuit ANA-86 open Temperature Sensor Se25 MID 188 SID # 64 Drv air Trap (A44 J1:2) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 168 Electrical horn • Connector C71 corroded on A45 J1:10 always ON • Circuit 69 shorted to ground MID 188 SID # 47 Emergency Lt R15 (A49 J1:13) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 169 • A46 module failure FMI 4 Shorted Low Output A46 J1:4 Aisle lights not • Connector C144 corroded shorted to ground working • Circuit 5 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 170 • Connector C91 corroded above normal internal software fuse clutch Mo2 not • Connector C426 corroded active for overcurrent working on speed 1 • Circuit 291 shorted to battery DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 171 Voltage below normal Entrance door • Se76 failure on A47 J1:10 cannot be • Connector CXC1 corroded closed with switch • Circuit 3 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 172 • Circuit 47 shorted to ground switch MID 188 PSID # 67 Ent Open Sol (A47 J1:7) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 173 • A54 module failure FMI 4 Shorted Low Output A54 J1:7 Evaporator fan • Evaporator Relay R12 failure shorted to ground not working • Circuit 67 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 174 Output A45 J1:2 Foot damper • Connector C72 corroded above normal internal software fuse Mo4 not • Circuit 65A shorted to ground active for overcurrent working DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 175 • Circuit 23AA shorted to ground above normal internal software fuse Front side L64 active for overcurrent not working MID 188 PSID # 58 Fr Start Sw (A36 JB:22) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 176 • Circuit 46A shorted to ground MID 188 PSID # 149 FrontMkr Lts RH (A48 J1:7) Type of Fault Condition: Possible Possible Causes: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 177 Hazard lights • Hazard switch Sw4 failure input A36 JB:4 but always ON • Connector C71 corroded switch Sw4 not active • Circuit 22 shorted to battery DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 178 • Foot switch Sw141 failure shorted to ground Beam • Connector Foot:A corroded headlights foot switch not • Connector C71 corroded working • Circuit 59 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 179 A45 J1:20 but L185 and L186 output not active always ON failure • Connector C4 corroded • Connector C101 corroded • Circuit 52A shorted to battery DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 180 Shorted Low Output A41 J1:14 Kneeling down • Kneeling down solenoid valve shorted to ground not working So16 failure • Connector C4 corroded • Connector C172 corroded DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 181 • A46 module failure FMI 4 Shorted Low Signal A46 Momentary switch • Kneeling level sensor Se79 J1:13 shorted function lost, holding to ground switch will lower coach failure DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 182 • A48 module failure FMI 6 Current Output A48 J1:4 RH Low beam • Connector C243 corroded above normal internal software fuse Headlamp active for overcurrent L59A not DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 183 Shorted Low Input A36 JB:16 Master • Master Interlock Bypass switch shorted to ground Interlock Bypass Sw140 failure • Circuit Master shorted to ground always ON DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 184 • A52 module failure FMI 5 Open Circuit A52 module does not Drain valve • Oil separator L350A open detect oil Separator discharge not L350A working circuit DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 185 • A54 module failure FMI 4 Shorted Low Output A54 J1:2 P Rack RH Fan • P Rack RH Fan Mo11 failure shorted to ground Mo11 not working DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 186 Parking Brake • Connector C4 or C172 corroded above normal internal software fuse solenoid valve • Circuit 8 shorted to ground active for overcurrent So17 not working DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 187 • Circuit 65P or 0EV3 open • A54 module failure FMI 6 Current Output A54 J1:20 Pass Gaz • Circuit 65P shorted to ground above normal internal software fuse Cylinder L205 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 188 • Water pump relay R20 shorted to ground MID 188 SID # 68 Read Light Tst (A42 J1:19) Type of Fault Condition: Possible Possible Causes: fault: Description: Symptoms: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 189 LH L71, upper rear J1:21 but output LH L286 and Rear corroded • Circuit 21AA shorted to battery not active Side markers LH L75 always ON DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 190 A50 J1:4 but L84, L85, L86, L87, output not active L88, L89, L90, L285 corroded • Circuit 63 shorted to and L286 always ON battery DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 191 Description: Symptoms: • A51 module failure FMI 3 Shorted High Voltage present Cruise control not • Connector C717 corroded on output A51 working J1:1 but output DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 192 Step Lights L18, • Connector C63 corroded above normal internal software fuse L19 or L20 not • Circuit 35 shorted to ground active for overcurrent working DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 193 Shifting not • Circuit 185 shorted to ground active for overcurrent working MID 188 PSID # 168 Trans Neutral Sens (A50 J1:11) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 194 Output A52 J1:21 Unloader RH • Unloader RH L199 failure shorted to ground L199 not • Connector C91 or C19 corroded working • Circuit 31 shorted to ground DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 195 Upper Defrost • Connector C45 or CMo5 corroded above normal internal software RH Heater • Circuit 5B shorted to ground fuse active for Res37 not overcurrent working DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 196 • Circuit 304 shorted to ground • A53 module failure FMI 6 Current Output A53 J1:5 WCL Pump • Connector C27, C31 or C29 above normal internal software Assy L207 not DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 197 • Connector C27, C31 or C29 above normal internal software open Relay fuse active for R47 not corroded • Circuit 306 shorted to ground overcurrent working DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 199  Address Jumper open circuit responding on CAN inputs and outputs  Fuse F12 or F13 defective network not responding ENTRANCE DOOR & WIPER CONTROL PANEL MODULES DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 200 A55 Module not A55 module all  Address Jumper open circuit responding on CAN inputs and outputs  Fuse F12 or F13 defective network not responding DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 201 Data Error A53 Module not A53 module all  Address Jumper open circuit responding on CAN inputs and outputs  Fuse F65 defective network not responding DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 203 Part 500449 added in the material list and in step 9. Torque added in figure 12. APPLICATION Model APPLICABLE TO: X3-45 Commuter DOB Bus Number Series 2400 - 2489 Model Year : From 2012 DOB Bus Number Series 2490 - 2789...
  • Page 204 MI14-40B / Page 2 / 10 REQUIRED TOOLS RATCHET AND SOCKET SET - METRIC TORQUE WRENCH BRASS WIRE CUP BRUSH SPECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT METRIC 10mm 12-POINTS SPLINE DRIVE LONG (CARLYLE SLTS3810M AVAILABLE FROM NAPA ) OFFSET 7/8 WRENCH (CYLINDER HEAD WRENCH), SNAP-ON PART NUMBER M4201 7/8 SOCKET (PART NUMBER WA28-...
  • Page 205 MI14-40B / Page 3 / 10 USING CYLINDER HEAD WRENCH WITH RATCHET AND A FLEX SOCKET WRENCH PROCEDURE DANGER Park vehicle safely, apply parking brake, stop engine. In the battery box, set the battery cut-off switch to the OFF position prior to working on the vehicle. 1.
  • Page 206 MI14-40B / Page 4 / 10 2. Remove the alternator belt (figure 2). 3. Unscrew the alternator pulley mounting nut (figure 2). 4. Remove the alternator pulley (2 pulleys) (figure FIGURE 2 5. Remove the existing alternators. To do so, unscrew identified mounting bolts on figure 3 and retain for use if in good condition.
  • Page 207 MI14-40B / Page 5 / 10 7. Install new alternators. Fix lower and upper alternators loosely to alternator supports using bolts C. Apply anti-seize compound inside the alternator mounting ears and inside the sleeves found on the support attached to the engine (see location C on figure 4).
  • Page 208 MI14-40B / Page 6 / 10 10. Install the alternator belt (figure 6) FIGURE 6 11. Cable connection overview. Upper and lower alternator (figure 7). FIGURE 7 <QF7720955 rev 2>...
  • Page 209 MI14-40B / Page 7 / 10 UPPER ALTERNATOR - (use new hardware for cable connection) 12. Power harness and jumper cable. a) Install jumper cable (a.k.a. positive cable) onto B1+ stud terminal on upper alternator (figure 8). b) Place one new flat washer #5001341 against the jumper cable ring terminal (figure 8). c) Screw and tighten the adapter stud #564590 (torque: 10 lbf-ft) (figure 8) prior installing main battery cable (power cable).
  • Page 210 MI14-40B / Page 8 / 10 LOWER ALTERNATOR - (use new hardware for cable connection) 15. Jumper cable (positive cable) installation. a) Fit jumper cable (a.k.a. positive cable) onto B1+ stud terminal on lower alternator (figures 7 & 10). b) Place one new flat washer #5001341 against the jumper cable ring terminal and screw new nut #5001787 (nut torque: 10 lbf-ft) (figure 10).
  • Page 211 MI14-40B / Page 9 / 10 18. Apply torque seal according to normal procedure. Apply anti-corrosion compound on alternator terminals and cable ring terminals or use color guard rubber coating #684013 if available. 19. Reinstall the A/C compressor idler pulley bracket assembly (figure 12). Apply Loctite 243 on threads.
  • Page 213   DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST ‐ ALLISON 5  GENERATION CONTROLS ....  1 5     SPECIFICATIONS  ............................  1 8     SECTION CHANGE LOG ..........................  1 9                   DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 214   FIGURE 4: COLD CHECK  ..............................  5   FIGURE 5: HOT CHECK ..............................  5   FIGURE 6: DRAIN PLUG AND FILTERS  ...........................  1 0   FIGURE 7: COOLER WITH RETARDER ...........................  1 1   FIGURE 8: AIR PRESSURE REGULATOR (TYPICAL) ......................  1 2   FIGURE 9: TRANSMISSION CONTROL MODULE ......................  1 2 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 215: Description

    When frame or other welding is required on the clutch pressures to meet immediate needs. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 216: Allison Transmission Maintenance

    Hot Check. If the fluid level is not within this DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 217: Hot Check

    «N» (Neutral). Apply the parking brake and 4. Oil level codes are displayed once the allow the engine to idle (500 - 800 rpm). following parameters are met : DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 218: Recommended Automatic Transmission Fluid

    Settling time too short the fluid will be based on the ambient temperatures reached in the geographical ENG RPM TOO Engine speed (rpm) too location for the vehicle. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 219: Importance Of Proper Fluid Level

    NEVER be used for handling transmission fluid. Antifreeze and coolant solutions contain ethylene glycol that, if introduced into the transmission, can cause the clutch plates to fail. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 220: Allison Recommended Oil And Filter Change Interval

    General vocation= intercity coach with duty cycle less than or equal to one (1) stop per mile and all other vocations not listed in severe vocation. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 221: Oil And Filter Change Interval

    1. The transmission should be at an operating temperature of 160ºF (71ºC) to 200ºF (93ºC) when the oil is drained. This will ensure quicker and more complete fluid drainage. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 222: Refill Transmission

    To drain the cooling system, proceed as per pushbutton shit selector fluid level check. Section 05 ‘’Cooling’’, paragraph 5: Draining. If the cooling system is contaminated, flush DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 223: Transmission With Retarder

    6. Start all torque converter housing screws, lines when they are disconnected. and then tighten four of them gradually and in a criss-cross sequence around the housing. Tighten remaining screws. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 224: Allison Transmission Troubleshooting

    Place the battery master switch to the ‘’OFF’’ pour approximately 24 US quarts (23 L) of position. automatic transmission fluid through the filler tube. Check and adjust oil level. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 225: Diagnostic Troubleshooting Codes (Dtc) - Allison 5Th Generation Controls

    TCM decision-making process. While in Diagnostic Mode, press and hold the MODE button for 10 seconds to clear both active DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 226: Exiting Diagnostic Mode

    When the Transmission Control Module (TCM) flags a Diagnostic Trouble Code (DTC) as active, the TCM may take a combination of diagnostic responses as listed in the following table. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 227: Diagnostic Troubleshooting Codes (Dtc) List - Allison

    Pressure Control Solenoid 3 Stuck Off DNS, RPR P0797 Pressure Control Solenoid 3 Stuck On DNS, RPR P0842 Transmission Fluid Pressure Switch 1 Circuit Low DNS, Lock in current range DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 228 Pressure Control Solenoid 4 (PCS4) Control Circuit High DNS, SOL OFF (hydraulic default) P2723 Pressure Control Solenoid 1 (PCS1) Stuck Off DNS, RPR P2724 Pressure Control Solenoid 1 (PCS1) Stuck On DNS, RPR DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 229 U0404 Selector) 1 gear shift direction circuit Invalid Data Received From Gear Shift Module (Shift Maintain range selected, observe U0592 Selector) 2 gear shift direction circuit DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 230: Specifications

    Oil change..........................24 US qts (23 liters) Oil change (with retarder) ....................27.6 US qts (26 liters) Oil Filters: Make ............................. Allison Transmission Type ............................Disposable cartridge DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 231: Section Change Log

    SECTION 07: TRANSMISSION 8. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 233 EXPLANATION OF COMMON DAMAGES ..................13     SPECIFICATIONS ..........................14     SECTION CHANGE LOG ........................14                 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016))
  • Page 234 SECTION 09: PROPELLER SHAFT ILLUSTRATIONS FIGURE 1: PROPELLER SHAFT ASSEMBLY DOB 2490-2789 ......................3  FIGURE 2: COLD FORMED BEARING RETAINER AND BOLTS AS USED ON PREVOST X3-45 COMMUTER ....... 4  FIGURE 3: BEARING LUBRICATION ZIRK ............................6  FIGURE 4: BEARING LUBRICATION ..............................6 ...

  • Page 235: Propeller Shaft Description

    SECTION 09: PROPELLER SHAFT PROPELLER SHAFT DESCRIPTION FIGURE 1: PROPELLER SHAFT ASSEMBLY DOB 2490-2789 09002_2 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 236: Nyct Propeller Shaft Maintenance Directive

    (phasing marks) (see paragraph 3.3 mark can result in separation of the driveline from propeller shaft (PHASING MARKS)) before the vehicle. removal to ensure reinstallation in the same position as removed. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 237: U-Joint Service - Quick Reference Guide

    It is the responsibility of the maintainer who  Only replace u-joints with genuine Dana begins the driveshaft installation to complete Spicer service parts. procedure entirety. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 238: Lubrication Procedure

    If all four bearing positions still do not purge, releasing seal tension may be necessary. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 239: Mark Propeller Shaft (Phasing Marks)

    Clean zerk nipples before greasing. OTHER INSPECTIONS Refer to Spicer Driveshaft’s Service Manual DSSM-0100 for detailed information on:  The slip member inspection,  Grease zerk inspection, DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 240: Inspect Companion Flange/Flange Yokes

    Once the bearing cup assemblies are free, collapse the propeller shaft until both bearing DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 241: Removal Procedure For Universal Joint Kits

    3. Using an arbor press, press down on the fine-toothed file and/or emery cloth. upper bearing cup assembly until the shoulder of the journal cross makes contact with the inside of the yoke ear. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 242: Removal Procedure For Slip Member Boot

    7. Inspect entire slip assembly marking device. contaminants. If the slip assembly shows evidence of rust or the lube is severely DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 243: Propeller Shaft Installation

    2. With safety straps in place, align the phasing marks between the yoke and propeller shaft. Failure to torque bearing retainer bolts in the proper sequence could result in premature failure. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 244: Universal Joint Installation

    2. Position the journal cross into the yoke cross height tool. holes with the grease zerk fitting inward toward tubing. The double-headed, grease Prevost production line torque value DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 245: Explanation Of Common Damages

    SPRING TAB BOLT TORQUE Bolts are specially heat-treated. DO NOT substitute inferior grade bolts. Series Head size Size Bolt torque SPL250 6 point 8-1mm 25-30 lbf-ft DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 246: Specifications

    SECTION 09: PROPELLER SHAFT SPECIFICATIONS PROPELLER SHAFT Make ................................Spicer Series ................................. SPL250 SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 247 FIGURE 2: FRONT AXLE GREASING POINTS ................... 5   FIGURE 3: CAMBER ............................. 9   FIGURE 4: CASTER ............................. 9   FIGURE 5: TOE-IN MEASUREMENTS ...................... 10 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 248: Description

    Dana Parts & Service Instructions S84U Steer Axle KING PIN REWORK_ Manual NO 1985 B iss A For hub bearing rework: Dana Parts & Service Instructions S84U Steer Axle HUB BEARING REWORK_ Manual NO 1963 a + B iss DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 249 SECTION 10: FRONT AXLE FIGURE 1: FRONT AXLE ASSEMBLY 10025 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 250 Shim .015" Washer Shim .008" Bearing Cone Shim .006" Bearing Cup Oil Seal Steering Lever - Stud Grease Fitting Steering Lever Nut - Self Lock Axle, I-Beam DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 251: Lubrication

    Steering knuckles, knuckle pins and bushings can be overhauled or replaced without removing the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 252: Replacement

    Check permissible slackness in the kingpins as Steer Axle KING PIN REWORK_ Manual NO follows: 1985 B iss A. Aspects to be considered are:  Lateral slackness  Vertical slackness DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 253: Front Wheel Alignment

    Correct if Check if front tires rub against the frame or if the necessary. Replace any worn or damaged steering gear has been serviced. fasteners. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 254: Turn Adjustment

    Measure the distance between those two points. 3. The distance between these two points should be approximately 1/8 inch (3 mm). If DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 255: Camber Check

    Take measurements at both front and rear of axle (see ’’A and ‘’B’’ in Figure 5). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 256: Inspection And Adjustment

    2.75 R.H. and L.H. Toe-in (A minus B), 0.04 0.06 0.08 (degrees) NOTE Camber angle changes with loading. The given numbers are for an empty vehicle. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 257: Troubleshooting

    2. Wheels and/or tires out-of balance. 2. Balance or replace wheels and/or tires. operation. 3. Worn steering stabilizer cylinder. 3. Replace steering stabilizer cylinder. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 258: Specifications

    Please refer to Section 16: SUSPENSION of this manual. For more torque specifications, refer to Dana Spicer manuals. SECTION CHANGE LOG DESCRIPTION DATE Vertical slackness corrected. Was 0.040” changed for 0.030” Jan. 2017 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 259   FIGURE 6: TAG AXLE ALIGNMENT ......................8   FIGURE 7: JACKING POINTS ON TAG AXLE ..................10   FIGURE 8: INSTALLING EXTRACTOR TOOL ..................10 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 260: Drive Axle

    ZF’s list of lubricants TE-ML 12. Check in immediately after the vehicle has been Lubricant class 12M. operated for an extended period of time.  Renew seals components (O-rings). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 261: Compact Bearing (Hub Unit) Axial Play Check

    (O-ring) and reinstall drain plug. Change The compact bearing grease must be change every 4 years or 300 000 miles, whichever comes first. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 262: Speed Sensors (Anti-Lock Brake System, Abs)

    (with impulse disc) compact bearing (hub unit) shaft seal cap screw Torx M16x1.5x60 slotted nut torque=221 lbf-ft (use E20 Torx socket) locking plate flange shaft DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 263: Removal And Reinstallation

     AXLE A132 REPAIR MANUAL #5871 figure 4. 207 002E FIGURE 4: SUPPORT THE DRIVE AXLE SUBFRAME AT THE FOUR LOCATIONS SHOWN DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 264 NOTE When drive axle alignment is modified, tag axle alignment must be re-verified. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 265: Drive Axle Alignment

    TAG AXLE Minimum Nominal Maximum value value value Thrust angle* -0.02 0.02 (degrees) 0.08° 0.02° Total toe 0° toe-in toe-out (*) Use the drive axle as reference DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 266: Unloading Tag Axle

    5 mph (8 km/h) and with more than 1½ turn from Do not use tag axle in raised position for an the steering. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 267: Retracting Tag Axle For Repair Purposes

    3. Install jacks under tag axle jacking points to NOTE support the axle weight (refer to figure 8). For more information on front and tag axle wheel hub, refer to “DANA SPICER Service DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 268: Removing Transversal Radius Rod

    NOTE CAUTION Refer to Section 16, "Suspension", for proper torque tightening of suspension components. If this setting is altered significantly, it will cause excessive tire wear. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 269: Specifications

    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. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 271 FLIP-FLOP CONTROL VALVE (TW-1) ................... 13     DUAL BRAKE APPLICATION VALVE (E-8P) ................13 15.1 BRAKE PEDAL ADJUSTMENT ....................13     15.2 STOPLIGHT SWITCHES ......................14     DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 272 SAS-70 STEERING ANGLE SENSOR ................ 31         30.4.1 Removal of the steering angle sensor ................... 31     FITTING TIGHTENING TORQUES ....................32     SPECIFICATIONS ........................... 33 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 273 FIGURE 42: ABS SENSOR LOCATION…....................28   FIGURE 43: SPRING CLIP…........................28   FIGURE 44: M-40QR PRESSURE MODULATOR VALVE ................ 30   FIGURE 45: HOSE FITTING…........................32   DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 274: Air System

    The wet tank automatic drain valve (Figure 2) is drain valve by applying the service brake. designed to remove liquids from the wet tank each time the brake is applied as the solenoid is DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 275: Maintenance

    Prevost. Do not fill system by any point on the system. The front valve is located in the front service compartment close to R.H. side of door frame (Figure 4). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 276: Accessory Air Filter

    Replace the gauge with a new unit if there is a difference of 4 psi METAL BOWL W/ MANUAL DRAIN (27 kPa) or more in the reading. PURGE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 277: Air Dryer

    For more information on Meritor Wabco Air dryer, refer to the following manuals included on your technical publications CD:  Meritor Wabco System Saver Series Single Cartridge Air Dryers Maintenance Manual 34 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 278: Air Dryer Replacement

    5. If the air dryer exhausts air for 10-20 12. Unscrew and remove three bolts mounting seconds after the compressor cuts out, it is the air dryer to the bulkhead. working correctly. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 279: Final Check

    The automatic drain valve activates when the 9. Thread replacement cartridge onto the base rear stop lights turn ON, with the prerequisite until the seal touches the base. Then, DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 280: Maintenance

    Hose chamber hoses. Hose connections should be spring guards should be in usable condition and DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 281: Pressure Regulating Valves

    Refer to Wabco 636 Twin Cylinder Service Documentation for Maintenance and repair information. FIGURE 12: AIR PRESSURE REGULATING VALVE 12141A DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 282: Compressor Removal And Installation

    60 psi (414 kPa). In the down this control valve. Maintenance and repair DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 283: Flip-Flop Control Valve (Tw-1)

    FIGURE 19: PINS 2. Loosen threaded rod lock nut and turn the threaded rod CW or CCW in order to obtain a 45 brake pedal inclination. Use Prevost DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 284: Stoplight Switches

    The spring brake valve is located in the rear released. underframe. The SR-7 Modulating Valve is used in conjunction with a dual air brake system and spring brake actuator and performs the following functions: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 285: Pressure Protection Valve (Pr-4)

    When used, the valve releases pressure in the the air filter. entrance door locking cylinders, thus allowing the door to be manually opened. FIGURE 25: THREE-WAY VALVE 12186 FIGURE 23: PR-4 12174 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 286: Air System Troubleshooting

    The primary circuit is connected to the drive and tag axle brakes, while the secondary circuit is connected to the front axle DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 287: Disc Brakes

    Check condition of the slack adjuster cap and sliding pin covers. (see Knorr-Bremse Y006471 Service Manual) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 288: Pad Replacement Procedure

    There is no inner or outer pad, since all pads are the same. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 289: Front And Tag Axle - Equipped With L-Bracket Wear Indicator

    FIGURE 29: PAD WEAR CHECK FRONT AND TAG AXLE Please refer to Knorr-Bremse Service Manual for additional details. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 290: Continuous Wear Sensor

    If the disc dimension E ≤ 1.535 in (39mm), FIGURE 31: MINOR BREAKOUTS AT THE EDGES ARE it is recommended that the disc should be PERMITTED renewed when brake pads changed. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 291: Caliper Running Clearance

    FIGURE 35: CALIPER CARRIER MOUNTING BOLTS suppliers recommend that workers use caution TORQUE SPECIFICATION - I-BEAM AXLE to avoid creating and breathing dust when working on brakes that contain non-asbestos fibers. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 292 Material safety data sheets on this product, as required OSHA, available from Rockwell and Knorr-Bremse. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 293: Air Brake Troubleshooting

    CONDITION: Vehicle leveled, parking brake applied.  Redo list to check all items repaired or replaced. 4. Completely drain wet, primary secondary air reservoirs only. Air Supply Reservoir Leakage DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 294: Brake Air Chamber

    To maintain your vehicle’s air disc brakes at their original performance standard, strongly recommend use of only genuine, FIGURE 39: DRIVE AXLE BRAKE AIR CHAMBER approved service replacement parts on Bendix 12126 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 295: Emergency/Parking Brake Manual Release

    52 lbf-ft (70 Nm). FIGURE 40: TYPICAL AIR CHAMBER MOUNTING NUTS TORQUE – ZF A132 DRIVE AXLE SHOWN DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 296: Brake Chamber Disassembly

    To gain access to a given brake air chamber, braking). The other diagonal half remains under the corresponding wheel can be removed full ABS control. (refer to Section 13: "Wheels, Hubs and Tires"). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 297: Troubleshooting And Testing

    Maintenance No specific maintenance is required. The ECU is not serviceable. When found to be defective, replace. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 298: Spring Clip

    ESC stability system consists of Yaw Control NOTE (YC) and Roll Stability Program (RSP) features. This installation should be of the "press fit" type. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 299: Components

     Front Axle Traction Control Valve integral ing the most wheel slip. to the service brake relay valve; DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 300: Advanced Abs With Electronic Stability Control (Esc)

    (RSP) and Yaw Control. During operation, the ECU of the Bendix Advanced ABS system constantly compares performance models to the vehicle’s actual movement, using the wheel DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 301: Removal Of The Steering Angle Sensor

    Adjustment of the wheel alignment or wheel 5. Unscrew all three of the mounting screws track; that hold the body of the sensor to the steering column body. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 302: Fitting Tightening Torques

    3/8 to 1/2 5/8 to 3/4 3 ½ FIGURE 45: HOSE FITTING 12055 NOTE Use Loctite pipe sealant to seal pipe thread (Prevost number 680098). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 303 Cut in pressure ............................ 122 psi Cut-out pressure ..........................140 psi SECTION CHANGE LOG DESCRIPTION DATE Added information to the brake pedal replacement & adjustment paragraph (15.1) 2016/06/17 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 305 TIRE MATCHING  ............................  1 6     10.3 WHEEL BALANCING .............................  1 6     10.4 TIRE ROTATION ............................  1 6     SPECIFICATIONS  .............................  1 7     SECTION CHANGE LOG ...........................  1 7 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)
  • Page 306 FIGURE 23: HUB FLANGE HEX CAP SCREW TIGHTENING SEQUENCE ..........13   FIGURE 24: COMPACT BEARING ......................13   FIGURE 25: TIRE INFLATION........................15   FIGURE 26: TIRE LIFE / INFLATION PRESSURE ................15     DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 307: Wheels

    2. Loosen wheel nuts about one turn (do not remove the nuts). This is not necessary if equipped with hydraulic powered gun. FIGURE 1:STEEL WHEEL ARRANGEMENT 13001 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 308: Single Wheel Installation

    1. Slightly raise axle to be checked and place a stud nuts progressively as shown in Figure 2. safety support underneath; The final tightening should be done with a torque DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 309: Wheel Studs

    The reason for this is retaining the wheel stud to wheel hub and to assure that all faces are clamped together replace if they are deformed, damaged or DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 310: Care Of Wheels

    The bearings are greased for life and there is no need or facility for re-lubrication. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)
  • Page 311 SECTION 13: WHEELS, HUBS & TIRES FIGURE 6: TAG AXLE HUB AND ROTOR ASSEMBLY FIGURE 7: TAG AXLE UNITIZED BEARING & WHEEL HUB 13040 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 312: Tag Axle Hub Bearing Inspection

    Again check endplay to make sure that the clamping process is done properly.  If the endplay is equal to or greater than 0.008 in (0.20mm), replace the unitized hub bearing as DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)
  • Page 313 The clip can be dislodged as per the two pictures below. FIGURE 12: CLEANING HUB BEARING, ROTOR AND HUB FLANGE CLAMPING SURFACES Install rotor onto hub bearing. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)
  • Page 314 Screw in the hex stud nuts (refer to Figure 2 for sequence) so that wheel will position itself concentrically with hub. This important, otherwise wheel may be eccentric DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 315: Front Axle Wheel Hubs

    Place magnetic base of a dial indicator on indicator. brake caliper and position dial indicator stem DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 316: Front Axle Hub Bearing Removal

    1. Clean spindle using EFX degreaser (Prevost #685313). 2. Screw insertion tool onto spindle (FIGURE 17). FIGURE 20: INSTALL THRUST WASHER FIGURE 17: INSERTION TOOL DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 317: Drive Axle Wheel Hubs

    Dana Parts & Service Instructions S84U Steer Axle HUB BEARING REWORK_ Manual NO 1963 A+B iss A FIGURE 22: HUB FLANGE HEX CAP SCREW FIGURE 24: COMPACT BEARING 1 = Hub DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 318: Compact Bearing Axial Play And Grease Change

    At regular intervals, verify the tire pressures. Use an accurate tire pressure gauge when checking inflation pressures. Never exceed the maximum inflation pressure specified on each tire. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)
  • Page 319 "Coach Final Record". WARNING Incorrect tire pressures cause increased tire wear and adversely affect road holding of the vehicle, which may lead to loss of vehicle control. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 320: Tire Matching

    CAUTION A maximum of 16-oz (450 g) of balancing weight is recommended. If more weight is necessary, check and correct the cause. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)

  • Page 321: Specifications

    (105 km/hr). Do not drive vehicle at a higher speed than 65 mph (105 km/h) or above the posted speed limit. 12. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version ‒ Rev.2 April 2016)
  • Page 323 Dismantling Drop Type Ball Joint ......................  1 6     12.6.4 Assembling Drop Type Ball Joint ......................  1 6     12.7  ..........................  1 7 STRAIGHT BODY TYPE BALL JOINT     12.7.1 Visual Inspection ..........................  1 7     12.7.2 Straight Body Type Ball Joint End Play And Looseness.................  1 7 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)
  • Page 324 FIGURE 25: BALL PIN HAS LOCAL WORN FLATS .................. 16   FIGURE 25: STRAIGHT BODY TYPE BALL JOINT .................. 17   FIGURE 26: ADEQUATE CLAMPING CONDITION .................. 17 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 325: Steering System Description

    These elements are: 1. Steering stabilizer (damper); 2. A vane type hydraulic pump; and 3. Hydraulic reservoir and hoses. FIGURE 1: I-BEAM AXLE STEERING SYSTEM SETUP 14041 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 326: Power Steering Gear

    The valve slide, designed with steering shaft connection, turns together with the worm as the steering wheel is turned. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 327: Power Steering Gear Removal

    Check that the adapter and fuel pump drive axle are not damaged. Perform a pressure test as outlined in the "ZF- SERVOCOM Repair Manual" under heading "Setting And Functional Test". DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 328: Steering Column Removal

    U-joint and the steering slip joint are accessible Install the fuel pump. Torque-tighten bolts to from the front driver's area. To access these specification. joints, proceed as follows: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 329: Steering Wheel

    2. Pull the horn pad straight up gently to detach it from the steering wheel (Figure 9). 3. Disconnect the horn wire (white) connected to the horn pad and the steering wheel harness 4-pin connector. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 330: Installation

    Refer to section 10 "Front Axle" under heading steering column covers (Figure 8). ‘’6.4 ‘’Turning Angle Adjustment". 3. Route the new clockspring harness through the opening in the clockspring support DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 331: Steering Linkage Adjustment

    6. "Front Wheel Alignment". 5. Check the radial position of the pitman arm in relation to the sector shaft prior to removal of pitman arm. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 332: Installation

    1. Disconnect the drag link from pitman arm. Center steering wheel by dividing the total number of steering wheel turns in two. Scribe a reference mark on steering gearbox at the center previously determined. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 333: Drag Link

    Refer to section 10 "Front Axle" under heading 6: "Front Wheel Alignment". DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 334: Steering System Play Inspection

    DESIGN, OPERATION, MAINTENANCE, INSPECTION (8090) manual. Take note that the maximum travel covered value specified in ZF’s manual doesn’t apply to the Prevost design which uses a DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 335: Filter Element Replacement

    Clean the large gasket and the mating surfaces on the cover and reservoir. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 336: Drag Link

    With the engine running and the vehicle on the ground (with a load on the axle) turn the steering wheel left and right. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 337: Tie Rod

    1. Remove protective cap, using a suitable tool damaging it) until ball pin surface is visible. i.e.: a 1” x 1/8” x 9” long flat bar, tighten DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 338: End Play Adjustment Limitation

    NOTE: Ball pin and ball pin tapers in bottom tie body. This operation will also remove cover rod arms must be clean, dry and free from oil plate from body. prior to assembly. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)

  • Page 339: Straight Body Type Ball Joint

    Any movement detected by hand requires replacement of the ball joint. FIGURE 27: ADEQUATE CLAMPING CONDITION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)
  • Page 340 (wheel locking will oppose the effect of steering and vehicle overloading are some of the geometry which tends to make the front wheels causes that may increase steering effort. rotate in opposite directions). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)
  • Page 341 2. Wheels and/or tires out-of balance. 2. Balance or replace wheels and/or tires. operation. 3. Worn steering stabilizer cylinder. 3. Replace steering stabilizer cylinder. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)
  • Page 342 Collapsed length ..........................20.26±0.12" Stroke..............................12.47±0.12" 17. SECTION CHANGE LOG DESCRIPTION DATE Addition of section 12.1 STEERING SYSTEM PLAY INSPECTION 08/16/2016 Addition of section 12.6.2 END PLAY ADJUSTMENT LIMITATION 04/30/2018 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 14 revised April 2018)
  • Page 343 Wet Air Tank ............................  2 1     8.1.2 Primary Air Tank ..........................  2 1     8.1.3 Secondary Air Tank ..........................  2 1     8.1.4 Accessory Air Tank ..........................  2 1     8.1.5 Kneeling Air Tank ..........................  2 1 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 344 FIGURE 22: I-BEAM FRONT SUSPENSION AIR TANKS LOCATION ............. 21   FIGURE 23: REAR VALVE LOCATION ..................... 22   FIGURE 24: FRONT SERVICE COMPARTMENT ..................22       DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 345: Description

    Bubbles will the air spring mounting plates is indicate leak, none greater than the normal clearance permissible. Repair or replace defective (normal ride height). parts. Remove wheel. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 346: Installation

    DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 347: Inspection

    Deep cracks bushing material extremity. (shallow surface cracks are normal); Loose shock absorber pins; Presence of convex washers, and their position relative to the rubber bushing. NOTE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 348: Radius Rods

    Take off the load from the ball joint by lifting the vehicle. Apply a load on the joint in all of the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 349: Stripping Down

    3. Place joint in receiving fixture and mount annular assembly tool on the housing. Then locate Circlip in the housing using axial load with the aid of assembly stamp. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 350: Radius Rod Installation

    1. Disconnect the two links from sway bar. 2. Safely support the sway bar. Unbolt the four bushing brackets from subframe. Remove sway bar. TORQUE SPECIFICATIONS - FRONT I-BEAM AXLE SUSPENSION AND STEERING DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 351 SECTION 16: SUSPENSION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 352 SECTION 16: SUSPENSION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 353 AIR SPRING NUT 31-38 42-52 STEERING DAMPER ARM NUTS 285-315 386-427 For more torque specifications, see ‘Dana Spicer Maintenance Manual NDS Axles and Maintenance Manual Model NDS’’. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 354: Rear Suspension

    For a description of all these systems, refer to the appropriate heading in this section. FIGURE 8: REAR SUSPENSION COMPONENTS 16184 16144 FIGURE 9: SWAY BAR (REAR SUSPENSION) Figure 10: TAG AXLE SUSPENSION 16107 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 355: Air Springs

    Remove air spring. 3.1.3 Installation 1. Compress air spring as necessary, then aligning studs with their holes, position air spring between both the lower and upper DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 356: Shock Absorbers

    500 - 550 lbf-ft (680 - 750 Nm) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 357: Removal

    These rods transmit both braking and driving forces from the axles to the vehicle body. Refer to section 2.3 for additional details. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 358 SECTION 16: SUSPENSION REAR SUSPENSION TORQUE SPECIFICATIONS FIGURE 13: TORQUE SPECIFICATIONS – DRIVE AXLE 16158_A FIGURE 14: TORQUE SPECIFICATIONS – DRIVE AXLE 16159 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 359 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. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 360: Suspension Air System

    SUSPENSION HEIGHT ADJUSTMENT The flow of pressurized air from the accessory air tank to the air springs is controlled by three DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 361 Front I-beam axle air spring clearance 1. With the vehicle at normal operating air pressure [100 - 125 psi (689 - 860 kPa)], measure spring clearance. This DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 362: Height Control Valve

    4. Remove the nuts retaining the height control valve to the mounting bracket, then remove FIGURE 21: REAR HEIGHT CONTROL VALVE 16093 valve assembly. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)

  • Page 363: Air System

    A remote valve located in engine compartment and accessible through engine R.H. side door is used to drain the air dryer (Figure 23). FIGURE 22: I-BEAM FRONT SUSPENSION AIR TANKS LOCATION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 364 For diagnosis and understanding of the system, front valve will supply air for accessories only. refer to wiring diagrams, and to the appropriate air system schematic. CAUTION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 365 2. Overhaul height control valve assembly Vehicle body fails to 1. Improper height control valve Adjust lever as directed. level to satisfactory ride overtravel lever adjustment height DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 366 11, reference 12 was 171-209 lbf-ft, changed for 207-253 lbf-ft Apr.04,2016 page 18, reference 7 was 228-252 lbf-ft, changed for 171-209 lbf-ft page 14, air spring nut wrong torque value 20-25 lbf-ft removed Apr.16,2019 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Section 16 revised April 2019)
  • Page 367 (figures 2 & 3). CLEANING PRODUCT COMPATIBLE WITH POLYCARBONATE Cleaning products designed for external washing of vehicles shall be used to clean your vehicle. Prevost suggests a high PH cleaner compatible with polycarbonate. See the description of the product in the...
  • Page 368 MI15-41 / Page 2 / 4 High PH cleaning product compatible with polycarbonate - product sheet FIGURE 1: PRODUCT SHEET QF7720956 rev3>...
  • Page 369 MI15-41 / Page 3 / 4 IMAGES SHOWING THE CRACKING ISSUE FIGURE 2: Cracks at the boss and ribs due to the use of engine degreaser FIGURE 3: Cracking of the outer surface of the taillight due to the use of engine degreaser Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone.
  • Page 371   15.5.1 Baggage Compartment Doors (Aluminum) ................43     15.5.2 Wheelchair Lift Cassette Compartment Door ................ 45     15.5.3 Evaporator Compartment Door ..................... 47 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 372 FIGURE 28: ZONE 2 ........................... 32   FIGURE 29: X3-45 COMMUTER ........................ 34   FIGURE 30: EMERGENCY EXIT WINDOW ....................34   FIGURE 31: ESCAPE HATCH ........................36 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 373 FIGURE 54: SEAT PEDESTAL ASSEMBLY ....................63   FIGURE 55: TARABUS FLOOR COVERING ADHESIVE APPLICATION ..........66   FIGURE 56: APPLICATION OF SIKA 221 GRAY ..................66 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 374: Vehicle Exterior

    9. Entrance door control switch 19. Evaporator compartment 10. Bi-fold entrance door 20. Coolant heater & air dryer compartment 11. Electronic destination sign or route number 21. Radiator door DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 375 SECTION 18: BODY 22. SCR converter access door DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 376: Vehicle Structure

    It should not be used for exterior vehicle. side paneling. Extreme care should be taken not to sandblast excessively. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 377 SECTION 18: BODY 3. Apply correct primer, paint and undercoating after removing all corrosion to prevent further damage. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 378: Preventive Maintenance Schedule

    PANELS FROM BOTTOM TO WINDOWS FLOOR CLEAN FLOOR COVERING AS CLEANING NECESSARY WARNING Failure to follow this preventive maintenance schedule will result in warranty void. 6. RUST INHIBITOR APPLICATION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 379 Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking. 3.1 Front wheelhousing Front view DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 380 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 381 A spray gun and pumping system are required to apply wheelhousing mechanical parts. the rust inhibitor. If the application is done inside a paint room, select high speed ventilation. Minimum required DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 382 12 16 19 21 23 25 27 13 16 20 22 24 26 28 10 14 17 20 23 25 27 29 11 15 19 21 24 26 28 30 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 383 12 17 20 23 26 28 30 32 13 17 21 24 27 29 31 33 14 19 22 25 27 30 32 34 15 20 23 26 29 31 33 35 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 384: Common Fiberglass Repair Procedure

    Sides of "V" should have a Fiberglass paste is used for repairing small shallow pitch for maximum bonding area. dents, scratches, and pits. Paste is made by DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 385: Typical Fiberglass Hole Repair Procedure

    FIGURE 4: FIBERGLASS HOLE REPAIR 18091 Allow area to harden and contour the area with FIGURE 2: FIBERGLASS HOLE REPAIR 18089 coarse sandpaper #100 (Figure 5). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 386: Common Painting Procedure

    CAUTION for color codes and paint brand. Prévost recommends using the original paint Apply these recommendations after repainting brand to ease color matching. vehicle. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 387: Painting

    3. Maintain adequate ventilation at all times. 4. Dispose of any leftover paint mix properly. 5. Wear rubber gloves, rubber apron, and face shield during all phases of paint and chemical handling DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 388: Surface Preparation And Paint Application Recommendation

    Product listing above is based on factory applied products. Local VOC (Volatile Organic Compound) regulations may vary, consult your paint supplier and use a VOC compliant product that matches the factory recommendations if required to do so. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 389: X3-45 Coaches Exterior Finishing And Body Repair

    Refer to the appropriate zone then component for complete procedure. FIGURE 7: X3 SERIES COACH ZONES 18623 15.1 ZONE 1 FIGURE 8: ZONE 1 18624 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 390: Front Bumper

    NOTE To facilitate spring tension adjustment during re-installation, take note of the spring hook length (taken from the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 391: Headlights

    18398B R/H side round mirror is non-adjustable.  Adjustment At the base of the mirror arm, loosen the mounting bolt to swing arm in or out. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 392: Windshield Wipers

    A metal rod or screwdriver to clean the seal under the over-hang tab covering the mirror groove, glass. A filler insertion tool, Goggles and protective gloves. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 393 ¼” of excess length to vehicle, gradually inserting the wind- thwart filler contraction over time then shield into the groove. insert filler into groove. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 394: Bi-Fold Entrance Door

    (Figure 20). valve is de-energized and loads the door lock cylinders. The cylinder moves the door lock in a DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 395 When the door reaches the fully opened position, the system will keep pressure in the cylinder locking the door in that position. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 396 Use clamp plates to prevent damage. FIGURE 24: EXTERIOR UNLATCH AIR VALVE 12209 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 397 3. Adjust the door horizontally and vertically with the jack. Tighten the bolts. Remove the jack and the wooden block. FIGURE 26: DAMPER 18643 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 398: Front Electrical & Service Compartment Door

     Remove interior finishing panels to access rub rail fixing bolts, then remove rub rail.  Remove windshield washer reservoir, door lock and power window connector. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 399 NOTE Anti-friction side must be on glass side.  Check body panel flatness using a 2-foot ruler (must be within 2mm). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 400  Dry fit the gutter on the vehicle. If required, straighten up gutter using a hammer and a wooden block.  Clean window using window cleaner. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 401: Front Cap

     Install gutter under driver’s window then compress in order to fix double face self- adhesive tape.  Install 3 clamps and allow curing for 4 hours. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 402: Zone 2

    SECTION 18: BODY 15.2 ZONE 2 FIGURE 28: ZONE 2 18625 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 403: Lateral Fixed Window

     Pull in turn from the inside and the outside extrusion one inch from each window of vehicle to gradually cut the Sika bead edge. on the window perimeter. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 404 NOTE  Tangs on the lock must be in a horizontal Emergency Exit Release Bar DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 405: Emergency Exit Windows

    Ensure that cleaning solutions are compatible with the materials used on the escape hatch. Graffiti removing cleaners often contain acetone, ether, lacquer thinner or other solvents known to DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 406 FIGURE 32: ESCAPE HATCH 18105 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 407: Zone 3

    SECTION 18: BODY 15.3 ZONE 3 FIGURE 33: ZONE 3 18626 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 408: Rear Cap

    5. Check that the door swings freely and center it in the door latch mechanism. closes properly. 4. Tighten the striker pin. 5. Check door fit and operation. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 409: Zone 4

    SECTION 18: BODY 15.4 ZONE 4 FIGURE 36: ZONE 4 18627 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 410: Rear Fender

    4. Tighten the striker pin latch bolts. 5. Check door fit and operation. 15.4.3 ENGINE RADIATOR DOOR Radiator door may be adjusted for proper fit by untightening hinge bolts: DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 411 8. Adjust the latch position to allow easy door closing. 9. Tighten the striker pin latch bolts. 10. Check door fit and operation. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 412: Zone 5

    SECTION 18: BODY FIGURE 42: HINGE DETAIL 15.5 ZONE 5 FIGURE 43: ZONE 5 18628 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 413: Baggage Compartment Doors (Aluminum)

     All adjustments are to be made with door closed, unless specified. NOTE Vertical adjustment is achieved by moving the door along the mounting plate slots. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 414  Check handle adjustment. Handle must remain tight against its plastic housing. NOTE Adjustment is made by moving UP or DOWN the lock plates. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 415: Wheelchair Lift Cassette Compartment Door

    Remove rub procedure. rail.  Unfasten bolts and disconnect cable if  WCL Cassette Door Adjustment necessary in order to remove door from vehicle. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 416  WCL Cassette Door latch adjustment To allow adjustment of the latch mechanism, lightly tighten retaining hardware receptacle and striker support (arrows). 1. Place centering tool G34148_500 in the receptacle cavity. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 417: Evaporator Compartment Door

    29mm +/- 2mm meas- ured from bus frame out. 9. Close door to center the latch assembly. 10. Tighten the Receptacle screws only. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 418 12. Make sure that backing plate is parallel to structure before tightening hardware 13. Make sure that skid bar only touches slightly bus structure at bottom. The door should not move up when closing. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 419: Condenser Compartment Door

    3. Adjust the fuel filler door position according distance required between exterior Use “Dupont IMRON” paint. Apply using a paint finishing panels. brush or roller depending on gravity. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 420 Spray pure water onto Sika. Use a floor sample to create some texture onto the adhesive. If possible spray some more water onto the adhesive to accelerate curing. Rear baggage compartment without WCL. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 421 Rear baggage compartment without WCL. Rear baggage compartment equipped with WCL Rear baggage compartment equipped with WCL Prepare baggage compartment Mantex floor. Clean panel underside and edges. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 422 Use plastic spatula #682838 to perform radius Rear baggage compartment equipped with WCL Clean with anti-silicone the area where the Simson glue will be applied. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 423: Fuel Filler Door

    8. Adjust the fuel filler door position according distance required between exterior finishing panels. 9. Tighten the nuts. 10. Check that the door swings freely and closes properly. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 424: Zone 6

    Front fender may be removed using the following procedure: Remove the nuts on the inside of the fender. Remove the fender from the vehicle. To reinstall, reverse the procedure. 15.7 ZONE 7 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 425: X3 Smooth Side Panel Replacement Procedure

    Check panel horizontal supports for straightness Tolerance : 1mm towards the outside and using a straight edge. Take measurements with a 1.5mm towards the inside. ruler. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 426 Minimum time : Wait for product to evaporate After 2 hours: Start cleaning operation again Before applying any other If surface seems dusty, greasy or with finger marks, start product cleaning operation again. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 427 3.00 tape position onto vehicle side. Apply 1/8 X ½”double-face tape as per marking. Compress tape Remove protective film from double-face self adhesive tape center section. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 428 6 mm ± 1 with reference to vertical tubing – Sand rear of side panel 2" wide Perform tig spot welding (1” apart) Quantity of "tig spot": 30 minimum. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 429 Use a caulking nozzle and grey Sikaflex 221 adhesive to fill the cavity between the panel and vehicle structure. Clean using Sika 205. Allow 5 minutes minimum for drying. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 430 Install panel onto structure Use a jig to make sure that panel is lined up with 4.30 engine door tubing. 4.40 Use a brush to compress Sika bead DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 431: Side Crest

    Clean vehicle surface using anti-silicone where the side crest and stickers will be applied.  Using hands apply and compress side crest.  Apply required stickers. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 432: Body Panel And Window Spacing

    SECTION 18: BODY 16. BODY PANEL AND WINDOW SPACING DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 433: Passenger Seats

    “J” clamp brackets. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 434 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 435: Tarabus Floor Covering Repair Or Replacement

    7. Compress floor covering using a roller so as to remove any trapped air bubble. 8. Apply Sikaflex 221 gray sealant (680532) alongside passenger seat fixing tracks (refer to figure 48). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 436 SECTION 18: BODY FIGURE 55: TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 56: APPLICATION OF SIKA 221 GRAY 18641 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 437: Front Steps Replacement Procedure

    Before applying any other If surface seems dusty, greasy or with finger marks, start cleaning product operation again. 3. Apply Sika Primer 215 (refer to Section D). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 438 Use a serrated spreader with 1/8-inch surface. Countersink if needed. serration to spread Sika. 4. Apply a bead of Sika 221 onto the perimeter of the step. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 439: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering

    10. Temporarily fix white safety strip with a piece of duct tape, leaving 1 to 2 inches free at each end. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 440 6. Take position with welding torch. The proper position is with a slight slope to the rear. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 441: Repair Of A Welded Joint

    If this is beginning and at the end of repair. the case, repair the joint. 5. Perform steps indicated in paragraphs 9, 10 and 11. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 442: Section Change Log

    SECTION 18: BODY 19. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 443 INFORMATION DATE : JANUARY 2014 SUBJECT : HOISTING AND TOWING PROCEDURE FOR NYCT X3-45 COMMUTER BUSES APPLICABLE TO: DOB Bus Number Series 2400 – 2489 DOB Bus Number Series 2490 - 2789 Addition of comments following front tow demonstration at Zerega CMF, Bus 2491, March 19, 2014...
  • Page 444 TABLE OF CONTENT     HOISTING AND TOWING POINTS  ........................ 3     GENERAL DESCRIPTION ..........................  3       CHASSIS HOISTING POINTS  ...........................  3         AXLES HOISTING POINTS ..........................  5         WHEELS HOISTING POINTS  ........................  8  ...

  • Page 445: Hoisting And Towing Points

    HOISTING AND TOWING POINTS GENERAL DESCRIPTION This procedure applies to NYCT X3-45 Commuter buses DOB bus number series 2400-2489 and 2490- 2789. There are several hoisting and towing points. Use only these points when performing hoisting and towing of the bus (fig.1).
  • Page 446 FIG.5 JACK STAND AT CHASSIS HOISTING RECEPTACLE FIG.6 JACK STAND AT CHASSIS HOISTING RECEPTACLE - AFT OF FRONT AXLE, ROAD SIDE - AFT OF FRONT AXLE, CURB SIDE FIG.7 JACK STAND AT CHASSIS HOISTING RECEPTACLE FIG.8 JACK STAND AT CHASSIS HOISTING RECEPTACLE –...

  • Page 447: Axles Hoisting Points

    WARNING Hydraulic jacks are intended for lifting only. Do not get under the bus for any reason unless it is properly supported with safety jack stands. AXLES HOISTING POINTS AXLES HOISTING POINTS 2 front axle hoisting points (fig.12-15) 2 drive axle underframe hoisting points (fig.16-17) 2 hoisting points under the tag axle (tag axle must be unloaded) (fig.18) To assure stability, always use the two hoisting points under a specific axle simultaneously.
  • Page 448 FRONT AXLE HOISTING POINTS – DOB Bus Number Series 2400 - 2489 FIG.13 FRONT AXLE HOISTING POINT – ROAD SIDE FIG.12 FRONT AXLE HOISTING POINT - CURBSIDE FRONT AXLE HOISTING POINTS – DOB Bus Number Series 2490 - 2789 FIG. 15 FRONT AXLE HOISTING POINT – ROAD SIDE FIG.14 FRONT AXLE HOISTING POINT - CURBSIDE Mi14-01A Page 6 / 31 Rev: June 26, 2014...
  • Page 449 DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB Bus Number Series 2400 - 2489 FIG.16 DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB BUS NUMBER SERIES 2400 - 2489 DRIVE AXLE UNDERFRAME HOISTING POINTS – DOB Bus Number Series 2490 - 2789 FIG.17 DRIVE AXLE UNDERFRAME HOISTING POINTS –...

  • Page 450: Wheels As Hoisting Points

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

  • Page 451: Towing

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

  • Page 452: Before Towing Preparation

    BEFORE TOWING PREPARATION 1. Set the transmission to neutral and apply parking brake. 2. Chock the wheels to prevent the bus from moving at time of releasing the parking brake during the towing preparation. 3. On the L.H. dashboard panel, turn on the hazard warning flashers.
  • Page 453 While the vehicle is being towed, connect an auxiliary air supply from the tow truck to the quick connect fitting identified AIR SUPPLY to supply air for all systems (brakes, suspension, accessories) through the air dryer (fig.21 & 22). FIG.22 FRONT TOWING AIR SUPPLY ACCESS PANEL QUICK CONNECT FITTINGS FIG.21 Engine compartment emergency air-fill valve...

  • Page 454: Drive Axle Flange Shafts Removal

    2.1.2 Drive Axle Flange Shafts Removal 1. Apply the bus parking brake. 2. Remove the stud nuts and the washers (with Meritor drive axle) or cap screws (with ZF drive axle) from the flange shaft. NOTE: there is oil behind the flange shaft which comes out during disassembly FIG.
  • Page 455 3. Meritor axle: Loosen the tapered dowels in the flange of the axle shaft using the following methods. a) Do not strike the round driving lugs on the flange of an axle shaft. Pieces can break off and cause serious personal injury. A 1.5-inch (38.1 mm) diameter brass hammer can be used as a drift.

  • Page 456: Towing From The Front

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

  • Page 457: First Lift

    2.2.1 First Lift To allow lifting equipment fitted with axle forks to reach under the front axle or tow eyes, it is necessary to perform a first lift of the front of the bus using the tow eye pads as lifting points. This first lift will allow tow cans or blocks to be placed underneath front tires.
  • Page 458 3. Deploy the tow truck stinger arm, placing the axle fork holders under the tow eye pads (fig. 30). FIG.30 4. Lift the front end of the bus high enough to allow installation of tow cans or blocks. Place the tow cans or blocks perfectly centered underneath each front wheel (fig.

  • Page 459: Second Lift- Front Tow Eye Pads As Lifting Point For Towing

    2.2.2 Second Lift- Front Tow Eye Pads as Lifting Point for Towing The tow eye pads fixed to the vehicle chassis, fore of the front axle will be used as front end lifting point for towing. 1. Perform the first lift as instructed in paragraph 2.2.1 if not already done.
  • Page 460 FIG.35 6. Raise the front of the bus. 7. Install a jack stand under the stinger arm for support and safety purposes and then lower the stinger arm so it rests on the jack stand (fig.36). The tow cans or blocks can be removed from under the front axle wheels.
  • Page 461 9. Attach the two tow truck safety chains from each of the two front lower radius rods (fig.38) of the bus to the truck’s tow eyes (fig.39). FIG.38 10. Connect the two truck air lines to the service and brake supply air quick connect fittings adjacent and right above the front bumper (for more details, refer to paragraph 2.1.1 Air...
  • Page 462 14. If required, use the appropriate jig to assure that the highest point on the bus does exceed maximum allowable height for towing (fig.41). 15. Make sure the parking brake is released before moving the vehicle. 16. Observe safety precautions when towing.

  • Page 463: Second Lift- Front Axle As Lifting Point For Towing

    2.2.3 Second Lift- Front Axle as Lifting Point for Towing This method uses the front axle as lifting point for towing (see fig.12-15). 1. Perform the first lift as instructed in paragraph 2.2.1 if not already done. 2. Install regular axle forks onto tow bar fork holders.
  • Page 464 6. Install a jack stand under the stinger arm for support and safety purposes and then lower the stinger arm so it rests on the jack stand (fig.46). The tow cans or blocks can be removed from under the front axle wheels. 7.
  • Page 465 FIG.48 12. Use bungee cords to support the safety chains (fig.49). FIG.49 13. Make sure that the parking brake is released before moving the vehicle. 14. Observe safety precautions when towing. FIG.50 Mi14-01A Page 23 / 31 Rev: June 26, 2014...
  • Page 466 Avoid sharp turns where possible as safety chains may rub and damage the front bumper (fig.51) FIG.51 CAUTION Make sure a safe distance is kept between the front of the bus and the tow truck. This space ensures that bus does not suffer damages when being towed. CAUTION Make sure axle shafts or driveshaft are installed correctly after towing.

  • Page 467: Towing With All Wheels On The Ground Using Rear Tow Eyes - Fitted On Dob Bus Number Series 2490-2789 Only

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

  • Page 468: Rear Tow Using Not Approved Lifting Points - For Emergency Situations Only

    3. REAR TOW USING NOT APPROVED LIFTING POINTS - FOR EMERGENCY SITUATIONS ONLY CAUTION The bus should NOT be lifted and towed from the rear unless an emergency situation occurs or when the bus has already been damaged and must be moved over a very short distance such as in a parking lot.

  • Page 469: First Lift

    DANGER Do not carry passengers while the bus is being towed. 3.2 FIRST LIFT A first lift of the bus is necessary. This first lift will allow tow cans or blocks to be placed underneath the drive axle tires. 1. Prepare the bus for towing as instructed in paragraphs 2.1 and 2.1.1 2.

  • Page 470: Second Lift

    6. Raise the tag axle to prevent it from hanging unsupported. To do so, open the front service compartment located on street side and move the tag axle air valve lever forward as shown on figure 57. FIG.57 7. Lift the rear end of the bus high enough to allow installation of tow cans or blocks underneath the drive axle wheels (fig.58).
  • Page 471 1. Perform the first lift as instructed in paragraph 3.2 if not already done. 2. Retract the tow truck stinger arm. 3. Pre-adjust spacing between the axle fork holders to 43 inches. FIG.59 4. Install either long or short axle forks into fork holders.
  • Page 472 6. DOB 2400 – 2489: Lift the tow bar until the axle forks grab the side-members (fig.61). DOB 2490 – 2789: Lift the tow bar until the axle forks fit snuggly into the side-members tow eyes. Avoid lifting at the side-members further toward the rear of the bus (close to the bumper) FIG.61 PROPER LOCATION WHEN LIFTING THE SIDE-...
  • Page 473 10. Install the choke chains. Tie the two choke chains together to secure the side members to the tow bar (fig.64 & 65). Take up any slack that may remain and maintain proper tension on chains. FIG.64 11. Shorten the stinger arm to the minimum safest distance between the bus and the tow truck to allow the towed bus to be as close as possible to the truck yet allowing enough...
  • Page 475 6.8.1  Determining Severity of Failure .................... 24  6.8.2  Clean‐out after Minor Compressor Failure ................ 25  6.8.3  Clean‐out After Major Compressor Failure ................ 25  7.  A/C SYSTEM COMPONENTS ...................... 25  7.1  COMPRESSOR .......................... 25  7.1.1  Belt Replacement ........................ 25  7.1.2  Belt Tension Adjustment –A/C drive belt ................ 25  7.1.3  Suction and Discharge Hose Connection  ................ 26  7.1.4  Compressor Maintenance ..................... 27  7.1.5  Oil Level Check and Oil Change ..................... 27  7.1.6  Troubleshooting Guide  ...................... 27  DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 476 Pilot Solenoid Valve  ....................... 46  8.6  CENTRAL HOT WATER PNEUMATIC VALVE ASSEMBLY .............. 46  8.6.1  Description .......................... 46  8.6.2  Pneumatic Water Valve Disassembly  .................. 46  8.6.3  Pneumatic Water Valve Reassembly .................. 46  8.6.4  Pilot Solenoid Valve  ....................... 47  8.7  HOT WATER CIRCULATING PUMP  .................... 47  9.  SPECIFICATIONS  ........................... 49  10.  SECTION CHANGE LOG ...................... 50  DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 477 FIGURE 47: HIGH & LOW SWING TEMPERATURE AT REMOTE BULB ..........36 FIGURE 48: CEILING OF THE SPARE WHEEL COMPARTMENT ............42 FIGURE 49: DRIVER'S HVAC/DEFROST UNIT ..................42 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 478 FIGURE 56: PNEUMATIC WATER VALVE ....................46 FIGURE 57: CENTRAL HOT WATER PNEUMATIC VALVE ASSEMBLY ..........46 FIGURE 58: PNEUMATIC WATER VALVE ....................47 FIGURE 59: PUMP LOCATION ........................47 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 479: Heating And Air Conditioning System Overview

    : 1) heating or cooling; 2) dehumidification; 3) ventilation; 4) Filtering; FIGURE 1: PASSENGERS’ UNIT AIR CIRCULATION 22308 FIGURE 2: HEATING CIRCUIT DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 480 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 3: REFRIGERANT CIRCUIT 22220C DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 481 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 4: EVAPORATOR COMPARTMENT ARRANGEMENT DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 482: Air Circulation

    L.H. side of vehicle (Figure 1). FIGURE 7: PASSENGERS’ PARCEL RACK VENTILATION SYSTEM 22211 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 483: Hvac System Operation

    To prevent battery run-down, the central HVAC sensors: unit will not operate if the battery voltage drops below 24 volts. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 484: Passengers' Section Operation

    9399 dehumidification. 7263 5658 4441 3511 2795 2240 1806 1465 1195 PASSENGERS’ SECTION OPERATION passengers’ section preset FIGURE 10: EVAPORATOR COMPARTMENT 22301 temperature of 68°F (20°C). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 485: Hvac Unit Basic Maintenance

    With the air filters removed, clean the Bagg.Cmpt Lights passengers’ unit evaporator and heater coils Bagg.Cmpt Lights with low-pressure air jet or a stream of low- DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 486 RECirculation button on the HVAC control unit is not engaged. FIGURE 14: EVAPORATOR COIL CLEANING 22373 FIGURE 16: DRIVER'S HVAC UNIT ACCESS GRILL DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 487: Passengers' Section Air Filter

    The air filters are accessible from the two discharge pressure vehicle parcel racks equipped with A/C units value (HiS=high side). (center of the vehicle, both side). Slide the filter DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 488: On Demand Activation Of Hot Water Circulating Pump

    Refer to Section 06: ELECTRICAL under "TEST MODE FOR ELECTRICAL MOTORS" for complete information. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 489: Modes Of Operation

    32°F automatically if (2 required conditions) return air temperature in passengers’ area is 61°F or above (∆T=7° with set point) passengers’ area temperature 68°F set point DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 490: Hvac System Multiplex Troubleshooting

    Defroster fan is functioning Module A46 is not powered or is Check the Diagnostics menu of Driver but no heat or cooling faulty Information Display (DID). Select Fault DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 491 Probe gray connector on module to see if it is powered. Check / replace condenser power relay R12 (probe R12 coil power circuit 67, should be 24 volts). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 492: Air Conditioning System

    The purpose of the cap is to is also serves as a restriction to the air flow. protect the valve and safety plug from damage. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 493: Treatment In Case Of Injury

    O-ring. If leaks are encountered at the couplings or connectors, DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 494: Pumping Down

    POSITION (NORMAL OPERATING POSITION) compressor and receiver tank, use a recovery unit to remove refrigerant from the system. WARNING To prevent any injury, when air conditioning DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 495: Liquid Refrigerant Recovery

    (FIGURE 22). drops and remains to 0 psig. 8. Stop the compressor. 9. Close (frontseat) the suction shut-off valve on the compressor (FIGURE 21). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 496: Evacuating System

    To do so, uncap and connect male and filter will make some flash gas and give a female connector housings of C24 together “milky” sight glass. for the passengers’ area (located on the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 497: Refrigerant Addition

    12. Before stopping the engine, check the off valve service port. Hoses should be compressor oil level and note it in the repair purged of air at installation (evacuated). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 498: Charging System

    R-134a tank. be used. A high acid content would indicate a DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 499: Clean-Out After Minor Compressor Failure

    Adjustment Screw (B). Tighten the Lock Bolt (A) Run the unit for 8 hours and monitor the to 43 lbf-ft. to preserve adjustment. pressure drop across the filter-dryer. Also DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 500: Suction And Discharge Hose Connection

    Belt tensions should be within the following values: BX71 Double Belt 90 - 100 lbs. – new 75 - 85 lbs. – used FIGURE 27: PRESSURE TRANSDUCERS DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 501: Compressor Maintenance

    This tube collects oil seeping temperature nor as cool as the normal suction through the shaft seal. temperature. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 502: Electro-Magnetic Clutch

    Even cylinder head temperature. 7.3.1 Removal Cause:  Set the battery master switch (Kissling Unloader body stem bent. switch) to the OFF position. Foreign material binding unloader plunger. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 503: Installation

    7.3.2 Installation To reinstall the evaporator motor, reverse "Evaporator Motor Removal" procedure. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 504: Condenser Fan Motor Removal

    The filter-dryer is of the disposable type. When point of the lower sight glass. replacement is required, remove and discard the DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 505: Moisture Indicator

    The liquid refrigerant is readily visible through the center opening of the moisture element where the presence of bubbles or flash gas DANGER indicates an insufficient system charge, low DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 506: Shut-Off Valve With Service Port

    The service port is equipped with a Schrader valve. FIGURE 41: DRIVER'S UNIT LIQUID SOLENOID VALVE FIGURE 39: REFRIGERANT CIRCUIT SHUT-OFF VALVE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 507: Typical Malfunctions

    C44 for the before brazing solder-type bodies into the line. driver's unit liquid solenoid valve (located on the ceiling of the spare wheel compartment). DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 508: Valve Reassembly

    11 lbf-ft. 7. Place the coil assembly. FIGURE 43: TYPICAL REFRIGERANT SOLENOID VALVE 22044 FIGURE 44: REFRIGERANT SOLENOID VALVE 22044 CAUTION DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 509: Thermostatic Expansion Valve

    Liquid would damage DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 510 2-minute intervals and record the low and high swing readings of the needle (refer to Figure 47). Example of readings taken: pressure gauge 40°F DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 511: Driver's Hvac Unit

    These conditions will give a high Before welding any part of refrigeration superheat. system, make sure the area is well ventilated. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 512: Troubleshooting

    Add R-134a to system. HIGH DISCHARGE PRESSURE Air or non-condensable gases in condenser. Purge and recharge system. Overcharge or refrigerant. Bleed to proper charge. Condenser dirty. Clean condenser. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 513: A/C

    Only non-condensable will cause this. (Example: Pressure of idle R-134a system in 80°F (26.6°C) room should be 86.4 psi (595.7 kPa). See temperature chart in this section.) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.1 Feb 2015)
  • Page 514 Incorrect rotation of fan; Fan speed too low; Fan motor going out on overload; or Prevailing winds. Too much refrigerant in system. Remove refrigerant if necessary. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 515: Temperatures & Pressures Chart

    1185.3 54.4 199.8 1377.6 230.5 1589.3 65.6 264.4 1823.0 301.5 2078.8 76.7 342.0 2358.1 82.2 385.9 2660.8 87.8 433.6 2989.7 93.3 485.0 3344.1 98.9 540.3 3725.4 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.1 Feb 2015)

  • Page 516: Leak Testing

    (Figure 49) to ensure an efficient draining. Close the hot water lines shut-off valves located next the engine on street side (see Figure 2 & Figure 52). FIGURE 49: DRIVER'S HVAC/DEFROST UNIT DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 517 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 50: DRIVER'S HVAC UNIT FIGURE 51: DRIVER'S HVAC UNIT DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.1 Feb 2015)

  • Page 518: Filling Heating System

    The main heater core drain cock is located flux sparingly and apply solder (95-5 round wire in the evaporator compartment. To access 1/8 inch). After completing repairs, test for leaks. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 519: Driver's Hot Water Pneumatic Valve Assembly

    3. Check for proper operation. FIGURE 54: TYPE 1 (UP TO VIN F-7014) DRIVER'S UNIT HOT WATER PNEUMATIC VALVE ASSEMBLY DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.1 Feb 2015)

  • Page 520: Central Hot Water Pneumatic Valve Assembly

    3. Check for proper operation. admitted to the actuator casing, the cylinder spring pushes up against the cylinder, thereby DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 521: Hot Water Circulating Pump

    2. Check that there while the pump is in operation. restriction to the air escaping DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.1 Feb 2015)
  • Page 522 4. Fill the cooling system as previously instructed in this section under "8.2 Filling Heating System", then bleed the system as previously instructed in this section under "8.3 Bleeding Heating System". DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 523: Specifications

    No. of cylinders ............................. 4 Cylinder volume ........................39 in (647 cm Operating speed ........................500 to 3500 rpm Oil capacity ........................ 0.66 U.S. gal (2,5 liters) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.1 Feb 2015)

  • Page 524: Section Change Log

    Passengers’ unit hot water pneumatic valve Make ............................... BURKERT Type ......................Normally open 3 ways/2 positions Voltage .............................. 24 V DC 10. SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 525 FIGURE 17: RADIO POWER MODE CHANGE ................... 9   FIGURE 18: CAMERAS AND MICROPHONE (UPPER FRONT OF VEHICLE) ........10   FIGURE 19: CAMERA LOCATIONS (TOP VIEW) ..................10 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 526: Hubodometer

    Operator’s Manual for operation. activate the windshield washer. Turn the button to activate the wipers. The first position activates the wipers intermittently. The second position is DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 527: Wiper Arm

    2. To find the final position of the wiper arms, Check operation of the wipers for proper blade lift then release the wiper arm so if falls back sweep and angle. on the windshield. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 528: Windshield Wiper Motor

    5. Remove windshield wiper motor 6. Check the adjustment on a wet windshield. (Prevost #800328), reverse removal procedure to reinstall. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 529: Troubleshooting

    A. Replace with proper type solution. SLOW OPERATION B. Jet stream improperly directed. B. Reposition nozzles. C. Check if valve is stuck in the C. Remove, clean or replace. open position. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 530: Automatic Fire Suppression System (Afss)

    If more information is needed on the system, please refer to Kidde Dual Spectrum “Operation & Maintenance Manual. FIGURE 12: FIRE SYSTEM OVERVIEW FIGURE 13: TLSE (ACTUAL ROUTING MAY DIFFER) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 531: Periodic Maintenance

    Extinguisher & Distribution System o Verify that that the extinguisher pressure gauge pointer is in the green arc at room temperature. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 532: Nyct Auxiliary Systems And Radio In Parcel Rack

    A volume control microphone (AVC) is located in SpeakEasy2 system. The foot switch is located the bus mid-section, in the overhead module along the left console. above the road side wheelchair provision area. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

  • Page 533: Motorola Communication Radio Power

    (7) cameras. One of the cameras is hidden in the “stop request” sign area. A motion sensor (final location still determined) and a microphone are also installed inside the vehicle. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 534 SECTION 23: ACCESSORIES FIGURE 18: CAMERAS AND MICROPHONE (UPPER FRONT OF VEHICLE) FIGURE 19: CAMERA LOCATIONS (TOP VIEW) SECTION CHANGE LOG DESCRIPTION DATE DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 535 LUBRICATION AND SERVICING SCHEDULE  .....................  5     SECTION CHANGE LOG  ..........................  7 ILLUSTRATIONS   ‐   FIGURE   LUBRICATION AND SERVICING POINTS  I BEAM AXLE FRONT SUSPENSION VEHICLES     FIGURE   COMPONENTS IDENTIFICATION  COMPONENTS REPRESENTATION MAY DIFFER SLIGHTLY FROM AN ACTUAL VEHICLE         DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 536 FLEXIBLE HOSE MAINTENANCE The performance of engine and equipment are greatly related to the ability of flexible hoses to supply lubricating oil, air, coolant, and fuel oil. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 537 Quality of replacement hose assemblies should always be equal to or superior to those supplied by the Original Equipment Manufacturer. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 538 SECTION 24: LUBRICATION FIGURE 1: LUBRICATION AND SERVICING POINTS, I-BEAM AXLE FRONT SUSPENSION VEHICLES 24030_1 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 539 SECTION 24: LUBRICATION LUBRICATION AND SERVICING SCHEDULE 24039_4 FIGURE 2: COMPONENTS IDENTIFICATION (COMPONENTS REPRESENTATION MAY DIFFER SLIGHTLY FROM AN ACTUAL VEHICLE) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 540 Other maintenance requirements and specific instructions on how to check and service different components are covered in their respective sections in this maintenance manual. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 541 SECTION 24: LUBRICATION SECTION CHANGE LOG DESCRIPTION DATE Item numbers added in figure 2 12 Oct. 2016 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)
  • Page 543 Based on 71347 mi on average before 4500 hrs at Yukon depot and 55782 mi on average before 4500 hrs at Ulmer depot. Median value=63565 mi, increased to 66000 mi to fit with 6000 mi interval based schedule. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)
  • Page 544 TranSynd or TES295 required to fill the transmission to the proper level), perform the fluid & filter change according to the TES389 intervals. Extended TranSynd or TES 295 fluid & filter change intervals are only allowed with Allison High-Capacity filters. DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)
  • Page 545 11 Passengers’ HVAC unit – clean condenser core with a stream of low-pressure  water or low pressure air jet 12 A/C compressor – change oil, clean oil filter   (approximately every 4 years, 10000-12000 operating hours) DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)
  • Page 546 Approved equivalent 1 Schedule 1 TES-389 fluids Transmission Oil Good quality lithium-base grease: NLGI No.2 Grade is suitable for most temperatures Multi Purpose Grease NLGI No.1 Grade is suitable for extremely low temperatures DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)
  • Page 547 14 mm hex socket driver (Allen) E20 Torx socket slotted nut wrench 5870 401 146 N67817-21 lifting bracket 5870 281 043 19400451 driver 5870 050 007 19400449 DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)
  • Page 548 18 BODY none 22 HEATING & AIR CONDITIONING A/C compressor – change oil, clean oil filter Refrigerant recovery unit *: Common tool. Contact your local tool supplier DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)
  • Page 549 3  Ref. F, updated to reflect differential oil used on NYCTA Prevost X3‐45 Commuter bus 06/27/2014 4  Ref. E, added for ZF A132 compact bearing (hub unit)   08/28/2014 5    6    7    8    9    10    11    12    13    14    15    DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Sec 24A revised April_2019)

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