PREVOST H3-41 Maintenance Manual
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COA CH M A N UFA CTURER
MAINTENANCE MANUAL
H3-41, H3-45, VIP
PA1217
th
(5
edition)

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Summary of Contents for PREVOST H3-41

  • Page 1 COA CH M A N UFA CTURER MAINTENANCE MANUAL H3-41, H3-45, VIP PA1217 edition)
  • Page 2: Table Of Contents

    SECTION 26: VIP SLIDE-OUT CONTENTS 1 SLIDE-OUT .............................. 5 1.1 INNER STOPPER ..........................5 1.1.1 Maintenance ........................... 5 1.1.2 Adjustment ..........................5 1.2 "IN LIMIT" STOPPER .......................... 5 1.2.1 Maintenance ........................... 6 1.2.2 Adjustment ..........................6 1.3 EXTERIOR EXTRUSION ........................6 1.3.1 Maintenance ...........................
  • Page 3 14.3.3 Seal assembly installation ....................21 14.3.4 Slide-out 2" inside retraction ....................22 15 SLIDE-OUT ELECTRICAL SYSTEM ....................22 15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE ..........23 15.2 SLIDE-OUT BREAKERS ......................23 15.3 PROBING VOLTAGE ON THE MULTIPLEX CIRCUITS .............. 23 15.4 MODULE REPLACEMENT ......................
  • Page 4 Section 26: VIP SLIDE-OUT LIST OF ILLUSTRATIONS ........................... 5 IGURE FRONT SLIDE ..........................5 IGURE REAR SLIDE ....................5 IGURE SIDE INNER STOPPER ADJUSTMENT ....................5 IGURE UPPER INNER STOPPERS ADJUSTMENT " " ....................... 6 IGURE LOWER IN LIMIT STOPPER "...
  • Page 5 Section 26: VIP SLIDE-OUT 55 : – ¼ ½ ..........30 IGURE SIDE WINDOW DOUBLE FACE ADHESIVE TAPE INSTALLATION 56 : – ....................30 IGURE HALF WINDOW SIKA AKTIVATOR 57 : – ....................30 IGURE SIDE WINDOW SIKA AKTIVATOR 58 : –...
  • Page 6: Slide-Out

    Section 26: VIP SLIDE-OUT 1 SLIDE-OUT stopper comes into contact with the structure key. 1.1 INNER STOPPER The front slide-out is equipped with six inner stoppers laid out in the following way: two stoppers on the top horizontal member of the slide-out, and two stoppers on each vertical upright, while the rear slide-out is equipped with only three stoppers (FIGURE 1 and figure 2).
  • Page 7: Maintenance

    Section 26: VIP SLIDE-OUT face of the slide-out flush with the vehicle body when retracted. 1.2.1 Maintenance Check that the "in limit" stoppers are clean and that there is no foreign matter accumulated between the stopper and its bearing surface. Check that the screws and set screws (where applicable) locking the stoppers in proper position are tight.
  • Page 8: Security Pin

    2.2 AIR CYLINDER REPLACEMENT done under supervision of a Prevost service representative. 1. Assure the parking brake is applied. 2. Disconnect the cylinder air tubing from the baggage compartment (front slide-out) or under the bed structure (rear slide-out).
  • Page 9: Rack

    Slide-Out Removal Procedure. Ask to one foot. your Prevost service representative). 9. Tighten the two remaining crews to a 2. From under the slide-out, unscrew all the maximum torque of 2 ft-lbs. Use Loctite™...
  • Page 10: Pinion

    Section 26: VIP SLIDE-OUT 5 PINION 5.2 FRONT SLIDE-OUT SHAFT PINION REPLACEMENT CAUTION CAUTION Make sure all keyless bushings tightened to 125 lb-ft before moving the Before reinstalling the pinion, clean the slide-out. Refer to paragraph 5.4 for torque following surfaces with alcohol to prevent wrench settings.
  • Page 11: Rear Slide-Out Shaft Pinion Replacement

    Section 26: VIP SLIDE-OUT keyless bushing as described in paragraph 5.4. To tighten the keyless bushing, use a special open-end wrench to retain the yellow part and 5. Reinstall the drive motor/gearbox assembly. another wrench to tighten the black part. Figure 20 shows how to tighten the keyless bushing.
  • Page 12 Section 26: VIP SLIDE-OUT PA1217...
  • Page 13: Figure 16 : Keyless Bushing Installation Instruction

    Section 26: VIP SLIDE-OUT FIGURE 16 : KEYLESS BUSHING INSTALLATION INSTRUCTION PA1217...
  • Page 14: Electric Motor

    Section 26: VIP SLIDE-OUT 6 ELECTRIC MOTOR 7 SPEED REDUCTION GEARBOX The power is supplied by a 24V 1/3 HP electric motor coupled with a speed reduction gearbox. The speed reduction gearbox used is a helical Opposite to the gearbox, the motor is equipped worm gear type.
  • Page 15: Jaw Coupling

    Section 26: VIP SLIDE-OUT 8 JAW COUPLING 6. Install a clamping hub on one of the gearbox shaft (opposite side of gearbox mounting bolts) flush with the shaft extremity (see 8.1 MAINTENANCE FIGURE 19 ). Tighten the clamping screw to Inspect the jaw couplings for backlash between a torque of 18 lbf-ft.
  • Page 16: Installation

    (removal must be performed according to WARNING Slide-Out Removal/Installation The slide-out must be retracted when the Procedure. Ask to your Prevost service level and tilt adjustment is performed. representative). 2. Disconnect the jaw coupling on the side of the linear bearing being replaced (refer to paragraph 8).
  • Page 17: Rail

    Section 26: VIP SLIDE-OUT 11. Verify that the tilt is still properly adjusted • The 2 upper “in limit” stoppers are removed (between 7/32" and 3/8"). from the slide-out (see paragraph1.2). 1. Loosen the blue flange bearings mounting screws (FIGURE 13). 2.
  • Page 18: Maintenance

    Slide-Out Removal/Installation foreign matter from entering inside the vehicle. Procedure. Ask to your Prevost service They also serve as bearing surface for: representative). 1. The inflatable seal each side of the rail.
  • Page 19: Slide-Out Pneumatic System

    Section 26: VIP SLIDE-OUT 2. From under the support plate, remove the The slide-out air pressure comes from the air acetal plastic block mounting screws (see pressure delivery valve on the pneumatic panel the oblong holes on figure 22). in the front service compartment (figure 28). 3.
  • Page 20: Maintenance

    Section 26: VIP SLIDE-OUT FIGURE 28 : FRONT SERVICE COMPARTMENT 12220 14.2 MAINTENANCE COMPRESSED AIR LINE Inspect all compressed air line tubing for cut, swelling, kink other damage deterioration. Inspect the pneumatic fittings and components for any leak. The slide-out air supply is connected to the accessory air tank and the required maintenance is described in Section 12 of this manual.
  • Page 21: Seal

    14.3 SEAL inflating solenoid to inflate the seal. NOTE Refer to the Prevost parts manual for description of sealant and adhesives used. The slide-out sealing device is used to prevent any type of infiltration that may occur between the body structure and the slide-out itself.
  • Page 22: Seal Assembly Removal

    Section 26: VIP SLIDE-OUT and the exterior panels and glasses. Add sealant 4. Clean the area with anti-silicone once again. if necessary. 5. Apply Sika 206 G+P on the area (see PR000001paragraphe D). 14.3.2 Seal assembly removal 6. Insert inflatable seal air inlet tube through WARNING the hole on the frame vertical member.
  • Page 23: Slide-Out 2" Inside Retraction

    5. Using the handheld control, retract the slide- WARNING out up to its normal “IN” position. Never modify the slide-out electrical wiring without the Prevost Car approval. Any 6. Manually deflate the seal completely by modifications may cause an unexpected turning the relieving shut-off valve clockwise...
  • Page 24: Electrical Interconnection With Prevost Vehicle

    “OFF” position. 15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE FIGURE 36 : SLIDE-OUT CONTROL PANEL The slide-out power supply comes from the 24- volts and 12-volts circuit breakers (FIGURE 35) 15.3 PROBING VOLTAGE ON THE in the main power compartment.
  • Page 25: Maintenance And Adjustment

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

    1. Remove the slide-out (according to the Slide-Out Removal Procedure. Ask to your • Keep the slide-out retracted; Prevost service representative). • Check where adhesive, sealant and double 2. Drill through the rivets located at the bottom face adhesive tape are on the structure and of the panel.
  • Page 27: Side Panel Installation

    Section 26: VIP SLIDE-OUT 6. Check the tape width and thickness. Use Do not remove the tape blue protective layer. tape with same width and thickness when The purpose of the tape is to maintain a installing new panels. certain gap and not to hold the panel in place. 3.
  • Page 28: Top And Bottom Panel Removal

    10. Smooth down the joint and remove glue in excess; 11. Install rivets as per instruction sheet IS- 06028 (ask your Prevost service FIGURE 47 : SIDE PANEL INSTALLATION – SIKA TACK+BOOSTER APPLICATION representative); 12. After drying, apply Sika 252 as a finishing joint.
  • Page 29: Top And Bottom Panel Installation

    5. Apply Sika Tack+Booster (triangular bead: Removal/Installation Procedure. Ask to your 9mm width X 6mm high) has shown in Prevost service representative). FIGURE 51 and glue panel in place as shown in figure 52 & figure 53 ; 2. Insert a flat screwdriver between the panel and the slide-out structure and unstick the 6.
  • Page 30: Side Window & Half-Window Removal

    Section 26: VIP SLIDE-OUT Top panel Bottom panel FIGURE 52 : TOP PANEL INSTALLATION FIGURE 50 TOP AND BOTTOM PANEL INSTALLATION - SIKA 206 G+P APPLICATION Top structure FIGURE 53 : BOTTOM PANEL INSTALLATION NOTE The removal and installation procedures are based on standard service methods described section BODY.
  • Page 31: Half-Window & Side Window Installation

    Section 26: VIP SLIDE-OUT 16.8 HALF-WINDOW & SIDE 13. Press the jigs on the windows and wait for the adhesive to dry (90 minutes minimum). WINDOW INSTALLATION 14. Smooth down the joint and remove glue in Refer to procedures described in section 18: excess.
  • Page 32: Face Window Installation

    Section 26: VIP SLIDE-OUT FIGURE 58 : HALF-WINDOW INSTALLATION – SIKA AKTIVATOR FIGURE 61 : HALF-WINDOW INSTALLATION – SIKA TACK+BOOSTER FIGURE 59 : HALF-WINDOW INSTALLATION FIGURE 62 : SIDE WINDOW 16.9 FACE WINDOW INSTALLATION Refer to procedures described in section 18: BODY of the maintenance manual for details.
  • Page 33: Awning Window Installation

    Section 26: VIP SLIDE-OUT FIGURE 63 : FACE WINDOW INSTALLATION - ANCHORING BLOCKS FIGURE 66: SIKA 255 APPLICATION 4. Place masking tape on the inside of the window pane as per FIGURE 67 to protect it from smudge; FIGURE 64 : FACE WINDOW INSTALLATION FIGURE 67: MASKING TAPE APPLICATION 16.10 AWNING WINDOW INSTALLATION...
  • Page 34: Figure 69: Awning Window - Rubber Bumper Installation

    Section 26: VIP SLIDE-OUT 10. Open the awning window manually and smooth down the joint (FIGURE 72) and remove glue in excess with Sika 208; FIGURE 69: AWNING WINDOW - RUBBER BUMPER INSTALLATION 7. Apply Sika FIGURE (triangular bead: 10mm width X 10mm high) [10mm≈3/8”];...
  • Page 35: Sliding Window Installation

    Section 26: VIP SLIDE-OUT FIGURE 74 : AWNING WINDOW – SEAL THE CHINK 16.11 SLIDING WINDOW INSTALLATION FIGURE 75 : SLIDING WINDOW - SIKA AKTIVATOR 1. Clean and prepare window and slide-out structure surface with appropriate cleaner, abrasives and primers. Clean surfaces with anti-silicone;...
  • Page 36: Finishing Joint

    Section 26: VIP SLIDE-OUT Apply Sika Aktivator and then apply Sika 252 (black) between: 1- face panel & vertical structural member at the corner; 2- side panel & vertical structural member at the corner; Note: as seen on the picture, protect the adjacent surface with masking tape.
  • Page 37 Section 26: VIP SLIDE-OUT Apply Sika Aktivator and then apply Sika 252 Apply Sika Aktivator and then apply Sika 252 between side window and structural member between R.H. side edge of top panel and structural member Bead must overlap both surfaces about 2mm Apply Sika Aktivator and then apply Sika 252 between L.H.
  • Page 38: Welding Precaution

    Section 26: VIP SLIDE-OUT • Make sure the barking brake is applied and Apply Sika Aktivator and then apply Sika252 that transmission is in the “NEUTRAL" between the bottom panel and the magnets position. Bead must overlap both surfaces about 2mm •...
  • Page 39: Figure 82 : Inflatable Seal Relieving Shut - Off Valve

    Section 26: VIP SLIDE-OUT CAUTION The pressure in the inflatable seal must be completely relieved to prevent any damage to the seal. Also, check that the security pin is retracted so it does not stop slide-out movement. NOTE When air pressure is relieved using the shut-off valve, the normal extending and retracting operation cycle is disabled, for that reason the slide-out cannot be...
  • Page 40: Manual Extending Procedure - Front And Rear Slide-Out

    Section 26: VIP SLIDE-OUT 18.1.2 Manual extending procedure – 6. Once the slide-out is lined up to its opened position, remove the tool from the motor. Front and rear slide-out 1. Apply barking brake to disengage the security pin from the receptacle. 2.
  • Page 41: Slide-Out Maximum Load

    Section 26: VIP SLIDE-OUT slide-out control system inhibits transmission range selection to prevent the vehicle from moving if the slide-out is not in its full "IN" position. 19 SLIDE-OUT MAXIMUM LOAD Front slide-out: Maximum load with vehicle at stand still (retracted or extended) …...1500 lb Maximum load with vehicle moving or slide-out...
  • Page 42: Conversion Checklist

    If not, an adjustment of the roof reinforcing rod may be required. This may be affected by the loading on the roof. See section 3 and contact your Prevost service representative. Make sure the front slide-out lower member deflection is within 1/4".
  • Page 43: Troubleshooting

    Section 26: VIP SLIDE-OUT 21 TROUBLESHOOTING 21.1 ERROR CONDITION OR MISSING OPERATION CONDITION When an error condition or a missing operation condition is present on a slide-out, the green indicator light on its respective handheld control starts blinking upon releasing of the IN/OUT rocker switch. Turning the ignition OFF and ON again, will stop the blinking and reset the fault.
  • Page 44 Section 26: VIP SLIDE-OUT CORRECTIVE PROBLEM CAUSE ACTION inflated water penetrate in the vehicle); E. Security pin valve solenoid open circuit (the security pin is not extended while vehicle is riding). The slide-out The parking brake is not seen Make sure the parking brake is does by the controller as being applied.
  • Page 45 Section 26: VIP SLIDE-OUT CORRECTIVE PROBLEM CAUSE ACTION (the slide- retracted. transmission inhibit. CAUTION, this is out telltale a temporary measure, the vehicle must light be serviced as soon as possible. illuminatin PA1217...
  • Page 46: Troubleshooting - Mechanical Components

    Section 26: VIP SLIDE-OUT 21.3 TROUBLESHOOTING - MECHANICAL COMPONENTS PROBLEM CAUSE CORRECTIVE ACTION Slide-out does not retract Electrical motor failure; A. Replace motor. or extend when depressing the control Speed reduction gearbox failure; B. Inspect gearbox components, switch. particularly: bronze wheel or first C.
  • Page 47 Section 26: VIP SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION moving Slide-out does not retract Interference between the exterior Check for straightness of up to its full "in" position extrusion and the vehicle upper horizontal member and adjust the horizontal member above the slide-out; roof reinforcing rod.
  • Page 48 Section 26: VIP SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION removed, or wiper seal with the manual procedure with the manually retracting or extending unstuck from the inflatable seal not deflated; the slide-out. structure. Pressure transducer malfunction; Check the pressure transducer condition, replace if necessary. C.
  • Page 49: Slide-Out Fault Message On Message Center Display (Mcd)

    Section 26: VIP SLIDE-OUT 21.4 SLIDE-OUT FAULT MESSAGE ON MESSAGE CENTER DISPLAY (MCD) FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION Voltage Module A56 Value Too Low Module A56 sees a Voltage less Check/ reset circuit breaker than 18 V on its power supply CBSo and CBSo1.
  • Page 50 Section 26: VIP SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION switch and CECM is shorted to 12v or 24v. SldO Mot SpeedA Ctr Shorted High Wiring harness shorted to 12v or Fix wiring harness Current Above Security pin or object stop the Check / fix security pin normal movement of a slide-out...
  • Page 51 Section 26: VIP SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION Bad connection on relay. connection Wiring harness is cut. Check / fix wiring harness Current Above Relay coil or wiring harness Fix relay coil or wiring normal shorted to 12v or 24v harness SldO Mot Pos Rly Shorted High...
  • Page 52 SECTION 00: GENERAL INFORMATION TABLE OF CONTENTS FOREWORD ............................2 SCHEMATICS ............................2 PRECAUTIONS TO BE OBSERVED BEFORE WELDING ..............2 SAFETY NOTICE ........................... 4 DATA PLATES AND CERTIFICATIONS ..................4 4.1.1 Engine............................4 4.1.2 Transmission ..........................4 4.1.3 Drive Axle ..........................5 4.1.4 Front Axle ..........................
  • Page 53: Section 00: General Information

    Section 00 : GENERAL INFORMATION 2. SCHEMATICS 1. FOREWORD Vehicle AIR SCHEMATICS are provided at the This manual includes procedures for diagnosis, end of Section 12, "Brake". SUSPENSION AIR service, maintenance and repair for components of the H3 series coaches or VIP model listed on SCHEMATICS are provided at the end of Section the front cover page.
  • Page 54 Section 00 : GENERAL INFORMATION Warning: Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that would render welding impossible. Warning: Only a qualified and experienced person must do welding. FCAW (Flux Cored Arc Welding) process ; Electrode wire conforms to A5.20 AWS (American Welding Society) specifications ;...
  • Page 55: Safety Notice

    Section 00 : GENERAL INFORMATION 4. SAFETY NOTICE This maintenance manual has been prepared in order to assist skilled mechanics in the efficient repair and maintenance of PRÉVOST vehicles. This manual covers only the procedures as of manufacturing date. Safety features may be impaired if other than genuine PRÉVOST parts are installed.
  • Page 56: Drive Axle

    4.1.8 DOT Certification Label This certifies that coaches manufactured by FIGURE 6: ISS TYPICAL SERIAL & MODEL NUMBERS Prevost Car Inc., comply with all Federal Motor 00025C Vehicle Safety Standards at the time of manufacture. The DOT Certification label is 4.1.5 Power Steering Pump...
  • Page 57: Epa Engine Label

    Section 00 : GENERAL INFORMATION 4.1.9 EPA Engine Label 4.1.11 Vehicle Identification Number (VIN) The exhaust emission certification label affixed The seventeen digit vehicle identification number above the oil reserve tank certifies that the (VIN) is located on a plate (Fig. 10 & 11) located engine conforms to federal and any state on the windshield frame pillar (driver's side).
  • Page 58 Section 00 : GENERAL INFORMATION FIGURE 11 : VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE 2000 2006 2001 2007 2002 2008 2003 2009 2004 2010 2005 2011 PA1217...
  • Page 59: Fastener Strength Identification

    Section 00 : GENERAL INFORMATION fasteners, be careful to use fasteners of the 5. FASTENER STRENGTH IDENTIFICATION same or greater strength than the original Most commonly used metric fastener strength fasteners (the same number marking or higher). property classes are 9.8 and 10.9 with the class It is also important to select replacement identification embossed on the head of each bolt.
  • Page 60: Six

    Section 00 : GENERAL INFORMATION the top thread of an all-metal nut or bolt or by 5.2 RECOMMENDATIONS FOR REUSE using a nylon patch on the threads. A nylon insert Clean, unrusted self-locking fasteners may be or the use of adhesives may also be used as a reused as follows: method of interference between nut and bolt threads (Fig.
  • Page 61 Section 00 : GENERAL INFORMATION FIGURE 15: METRIC - US STANDARD CONVERSION TABLE 00005 PA1217...
  • Page 62 Section 00 : GENERAL INFORMATION FIGURE 16: CONVERSION CHART 00006 PA1217...
  • Page 63 SECTION 01: ENGINE CONTENTS ENGINE ..............................3 ENGINE-MOUNTED COMPONENTS ....................3 ......................4 LECTRONIC ONTROL ODULE N3 E ......................4 LECTRONIC NJECTOR ..............................4 VPOD 2.3.1 VPOD Removal ........................5 2.3.2 VPOD Installation ........................5 ........................5 EGR HYDRAULIC VALVE ....................
  • Page 64 Section 01: ENGINE ILLUSTRATIONS ) ................... 3 IGURE DETROIT DIESEL SERIES ENGINE TYPICAL ) ....................4 IGURE ELECTRONIC CONTROL MODULE ....................... 4 IGURE UNIT INJECTOR CROSS SECTION ..........................4 IGURE VPOD LOCATION .......................... 5 IGURE VPOD INSTALLATION & ....................5 IGURE EGR VALVE ACTUATOR ASSEMBLY...
  • Page 65: Engine

    Section 01: ENGINE 1. ENGINE Refer to DDEC Troubleshooting Guide published by Detroit Diesel for more complete information This vehicle is powered by a 6-cylinder, four- on diagnosis components and system cycle, Detroit Diesel series 60 engine, equipped problems. with an electronic control system (DDEC V). DDEC V (Detroit Diesel Electronic Control) Two engine displacements are used in the controls the timing and amount of fuel injected...
  • Page 66: Electronic Control Module

    Section 01: ENGINE 2.1 ELECTRONIC CONTROL MODULE Permits continuous fuel flow for component cooling. The Electronic Control Module is mounted, on starter side engine (Fig. 2). Considered the "Brain" of the DDEC V system, it provides overall monitoring and control of the engine.
  • Page 67: Vpod

    Section 01: ENGINE 2.3.1 VPOD Removal 1. Remove airline from VPOD. 2. Unplug harness connection. 3. Remove two bolts and one stud holding VPOD assembly and bracket to engine block. 2.3.2 VPOD Installation 1. Align VPOD assembly and bracket to threaded holes in engine block;...
  • Page 68: Coolant Temperature Sensor

    Section 01: ENGINE sensor that sends an electrical signal to the helps to improve cold starts and reduces white ECM. The ECM uses this information to exhaust smoke. compute the volume of air entering the engine. 2.11 TURBO COMPRESSOR IN Turbo boost sensor information regulates fuel TEMPERATURE SENSOR supply to control engine exhaust.
  • Page 69: Engine-Related Components

    Section 01: ENGINE indicating engine oil temperature. The ECM uses manufacturer's specifications. this information to modify engine speed for better recommended that the idle count be at 50 or cold weather starts and faster warm-ups. Oil higher with a full throttle count of up to 200. temperatures exceeding engine specifications The TPS is self-calibrating and therefore has no for two seconds or more will illuminate the Check...
  • Page 70: Diagnostic System Accessories (Dsa)

    Section 01: ENGINE km/h). This switch allows the driver return to 3.4.3 Stop Engine Override Switch the last regulated speed following a brake or This switch, mounted on the dashboard, may be "DECEL" switch application. used to extend the 30-second delay period before engine shutdown when the Stop engine Note: On-off switch must be in the "ON"...
  • Page 71 Section 01: ENGINE In most instances, only the DDR can provide the a short pause, then three flashes in quick information necessary for a quick diagnosis of succession. the problem. If you just need to read out codes, Refer to DDEC Troubleshooting Manual 6SE497 however, and do not have a DDR available, the for more information and SAE codes.
  • Page 72 Section 01: ENGINE DDEC V Code DESCRIPTION Oxygen Content Circuit Input Voltage Low Reserved for ‘‘No Codes" Aux. Shutdown #1 Active Aux. Shutdown #2 Active Intake Manifold Temperature Sensor Input Voltage High Ambient Air Temperature Sensor Input Voltage High Air Temperature Sensor Input Voltage High Intake Manifold Temperature Sensor Input Voltage Ambient Air Temperature Sensor Input Voltage Low Air Temperature Sensor Input Voltage Low...
  • Page 73 Section 01: ENGINE DDEC V Code DESCRIPTION RSL Short to Battery (+) RSL Open Circuit AWL Short to Battery (+) AWL Open Circuit Turbo Boost Pressure Sensor Input Voltage High Turbo Boost Pressure Sensor Input Voltage Low High Range Oil Pressure Sensor Input Voltage High Oil Pressure Sensor Input Voltage High High Range Oil Pressure Sensor Input Voltage Low Oil Pressure Sensor Input Voltage Low...
  • Page 74 Section 01: ENGINE DDEC V Code DESCRIPTION Sensor Supply Pins V-11/V-12 Low Injector V (slope) Voltage Failed Low RTC Backup Battery Voltage Low, Pin E-59 Injector I (pull-in) Voltage Failed Low Sensor Supply Voltage Low, Pin E-12/E-26 High Range Fuel Pressure High Fuel Pressure High Turbo Boost Pressure High Engine Power Derate Due to Turbo Boost Pressure...
  • Page 75 Section 01: ENGINE DDEC V Code DESCRIPTION Injector xxx Response Time Long Aux. Output #1 Short to Battery (+) – Pin V-4 Aux. Output #1 Open Circuit - Pin V-4 Aux. Output #1 Mechanical System Not Responding — Properly - Pin V-4 Aux.
  • Page 76 Section 01: ENGINE DDEC V Code DESCRIPTION PWM #2 Short to Battery (+), Pin V-46 PWM #2 Open Circuit, Pin V-46 PWM #3 Above Normal Range, Pin E-3 PWM #3 Below Normal Range, Pin E-3 PWM #3 Short to Battery (+), Pin E-3 PWM #3 Open Circuit, Pin E-3 PWM #4 Above Normal Range, Pin E-4 PWM #4 Below Normal Range, Pin E-4...
  • Page 77 Section 01: ENGINE DDEC V Code DESCRIPTION Coolant Pressure Sensor Input Voltage High Coolant Pressure Sensor Input Voltage Low TPS Idle Validation Circuit Fault (open circuit) TPS Idle Validation Circuit Fault (short to ground) Injector xxx Response Time Short Vehicle Overspeed Vehicle Overspeed (Absolute) Oxygen Content Too High Oxygen Content Too Low...
  • Page 78 Section 01: ENGINE DDEC V Code DESCRIPTION — Exhaust Back Pressure at Rampdown Threshold — Fuel Filter Differential Pressure Low — Oil Filter Differential Pressure Low — Engine Oil Pressure High — Turbo Boost Pressure Low — Inlet Manifold Temperature Low —...
  • Page 79 Section 01: ENGINE DDEC V Code DESCRIPTION Exhaust Port Temperature #1 Sensor Voltage High Exhaust Port Temperature #2 Sensor Voltage High Exhaust Port Temperature #3 Sensor Voltage High Exhaust Port Temperature #4 Sensor Voltage High Exhaust Port Temperature #5 Sensor Voltage High Exhaust Port Temperature #6 Sensor Voltage High Exhaust Port Temperature #7 Sensor Voltage High Exhaust Port Temperature #8 Sensor Voltage High...
  • Page 80 Section 01: ENGINE DDEC V Code DESCRIPTION Exhaust Port Temperature #13 Sensor Voltage Low Exhaust Port Temperature #14 Sensor Voltage Low Exhaust Port Temperature #15 Sensor Voltage Low Exhaust Port Temperature #16 Sensor Voltage Low — EGR Rate Sensor Failed —...
  • Page 81: Engine Oil Level

    Section 01: ENGINE DDEC V Code DESCRIPTION Barometric Pressure Sensor Input Voltage Low High Range Coolant Pressure Low Coolant Pressure Low Fuel Restriction High Maintenance Alert Coolant Level Fault 5. ENGINE OIL LEVEL Check the oil level daily with the engine stopped. If the engine has just been stopped and is warm, wait at least 10 minutes to allow the oil to drain back to the oil pan before checking.
  • Page 82: Recommended Engine Oil Type

    Section 01: ENGINE 3. Remove the spin-on filter cartridge using a Note: Monograde oils should not be used in 1/2" drive socket wrench and extension. these engines regardless Service Classification. 4. Dispose of the used oil and filter in an environmentally responsible manner...
  • Page 83 Section 01: ENGINE "REAR BUMPER REMOVAL INSTALLATION". 3. Drain the engine cooling system. Refer to Section 05, COOLING under "DRAINING COOLING SYSTEM". FIGURE 16: ENGINE COMPARTMENT FIGURE 15: ENGINE COMPARTMENT 01069 01044 13. Disconnect and remove the air intake duct 4.
  • Page 84 Section 01: ENGINE 23. Close engine fuel supply shutoff valve on 36. Inspect the power plant assembly to ensure primary fuel filter. Disconnect the fuel line that nothing will interfere when sliding out the connected to inlet port. On vehicles equipped cradle.
  • Page 85 Section 01: ENGINE FIGURE 17: ENGINE COMPARTMENT H3 COACHES (TYPICAL) 01109 FIGURE 18: ENGINE COMPARTMENT VIP (TYPICAL) PA1217...
  • Page 86: Power Plant Assy. Installation

    Section 01: ENGINE 9. POWER PLANT ASSY. INSTALLATION Detroit Diesel service manual for series 60 engines. To install a power plant assembly, follow the same procedure as in "Power Plant Assembly 6. Verify engine cover gasket and replace if necessary. Removal"...
  • Page 87 Section 01: ENGINE FIGURE 19: POWER PLANT CRADLE INSTALLATION 01107 PA1217...
  • Page 88: Engine Troubleshooting Guide

    Section 01: ENGINE 13. ENGINE TROUBLESHOOTING GUIDE START does the is the go to engine engine step 2 rotate ? starting ? note 1 plug the Diagnostics Data Reader DDR into the receptacle does the red or momentarily depress the go to "Stop Engine"...
  • Page 89: Specifications

    Detroit Diesel Series 60 engine ratings Series 60 engine ratings used in Prevost Car Models are listed in the following tables. The standard engine ratings are written in bold, customer may easily switch from one rating to another within the same table by having the DDEC V system reprogrammed.
  • Page 90 Section 01: ENGINE Coach Base Engine (12.7L) VIP 45’ MTH Engine (14.0L) 470 HP @1800 rpm; 1650 lb-ft @1200 rpm 380 HP @1800 rpm; 1350 lb-ft @1200 rpm 490 HP @1800 rpm; 1650 lb-ft @1200 rpm Coach Standard Engine (12.7L) 515 HP @1800 rpm;...
  • Page 91 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM DESCRIPTION ......................3 FUEL LINES AND FLEXIBLE HOSES ....................4 FUEL VALVES ............................4 FILTERS AND WATER SEPARATOR ....................4 ..................4 ILTER ATER EPARATOR ERVICING ) ................ 5 ILTER ERVICING RIMARY AND ECONDARY 382 ........................
  • Page 92 Section 03: FUEL SYSTEM ILLUTRATIONS ........................ 3 IGURE FUEL SYSTEM SCHEMATIC ......................4 IGURE MANUAL SHUT OFF VALVES ...................... 5 IGURE FUEL FILTER WATER SEPARATOR ....................6 IGURE DAVCO FUEL PRO INSTALLATION ..................... 7 IGURE DAVCO FUEL PRO EXPLODED VIEW .......................
  • Page 93: Fuel System Description

    Section 03: FUEL SYSTEM FUEL SYSTEM DESCRIPTION Figure 1 shows a schematic of the fuel system. Fuel is drawn from the fuel tank through a manual shut-off valve, a primary fuel filter or a fuel filter/water separator (optional) before it enters the fuel pump. If the vehicle is equipped with the optional “Davco Fuel Pro 382”, it is designed to be the only fuel filter in the system, no secondary fuel filter is necessary.
  • Page 94: Fuel Lines And Flexible Hoses

    Section 03: FUEL SYSTEM FUEL LINES AND FLEXIBLE HOSES Make a visual check for fuel leaks at all engine- mounted fuel lines and connections and at the fuel tank suction and return lines. Since fuel tanks are susceptible to road hazards, leaks in this area may best be detected by checking for accumulation of fuel under the tank.
  • Page 95: Fuel Filter Servicing (Primary And Secondary )

    Section 03: FUEL SYSTEM Handtighten an additional 1/3 to 1/2 turn after making full seal contact. 8. Open valves of the engine fuel supply line. 9. Run the engine and check for leaks. Caution: If the water separator continuously requires draining, it is possible that water or sediment has accumulated in the fuel tank.
  • Page 96: Davco Fuel Pro 382

    Section 03: FUEL SYSTEM 3. Install new filters. Tighten until filter is snug against the gasket, with no side movement. Rotate an additional 1/2 turn by hand. 4. Open engine fuel supply line valves. Caution: Mechanical tightening of the fuel filters is not recommended and may result in seal and/or cartridge damage.
  • Page 97: Fuel Tank

    Section 03: FUEL SYSTEM is located just forward of the last baggage compartment, between the A/C condenser and evaporator. Fuel filling access doors on both sides of vehicle provide direct access to filler necks; offering the added advantage of refueling from either side of vehicle.
  • Page 98: Tank Installation

    Section 03: FUEL SYSTEM FIGURE 6: FUEL TANK ARRANGEMENT 03048 Warning: Before removing the bolts securing the tank support to the frame, make sure the tank is supported adequately. Failure to do so could result in injury as well as damage to the FIGURE 7: FUEL TANK INSTALLATION 03049 tank.
  • Page 99: Uel Tank Verification

    3. Drill perforation with a 23/64" bit. Make sure drill hole is perfectly round. 4. Insert a screw (Prevost #500196) and a washer (Prévost #5001244) into anchor nut (Prévost #500331). 5. Place assembly in drill hole. tighten screw by 10 complete turns.
  • Page 100: Fuel Pump Installation

    Section 03: FUEL SYSTEM If the vehicle is not equipped with a priming 5. Connect the fuel inlet and outlet lines to the pump: fuel pump and tighten. 1. Unscrew the cap on the priming valve located 6. Prime engine fuel system before starting on the secondary filter;...
  • Page 101: General Recommendations

    Section 03: FUEL SYSTEM 3. Make sure that the element seals securely; 4. Inspect element cover gasket and replace if necessary. Whenever it becomes necessary to remove the air cleaner assembly (dry type) for maintenance or other repair in this area, great care should be taken when installing air cleaner assembly.
  • Page 102: Potentiometer Replacement

    Section 03: FUEL SYSTEM potentiometer calibration is necessary (see With the ignition "ON" and the proper diagnostic this tool (DDR) (for information regarding the DDR, "FUEL PEDAL ADJUSTMENT" section). see "01 ENGINE" in this manual), check the throttle counts at idle and full throttle positions. Caution: Make sure the cable harness is Proper pedal output should be 20/30 counts at...
  • Page 103 Fuel tank Capacity ..........................235 US gal (890 liters) Air Cleaner Make ................................Nelson Prevost Number ............................530206 Service Part No ............................7182 8N Supplier number (element cartridge) ......................70337N Prévost number (element cartridge) ......................530197 Air Cleaner Restriction Indicator Make ..............................
  • Page 104: Make

    Section 03: FUEL SYSTEM Preheater Fuel Filter Make ................................ Webasto Supplier number ............................603.359 Prévost number ............................871037 Fuel Cooler Make ..............................Berendsen Supplier number ............................DB-1240 Prévost number ............................950109 PA1217...
  • Page 105 SECTION 04: EXHAUST SYSTEM CONTENTS DESCRIPTION ............................2 MAINTENANCE ............................. 2 MUFFLER REMOVAL / INSTALLATION ..................... 2 FLEXIBLE TUBE INSTALLATION......................2 ILLUSTRATIONS ......................2 IGURE FLEXIBLE TUBE INSTALLATION ..........................3 IGURE EXHAUST SYSTEM PA1217...
  • Page 106 Section 04: EXHAUST SYSTEM 1. DESCRIPTION 3. Remove U-clamp retaining the tail pipe to the frame bracket; The muffler is rubber mounted to the vehicle 4. Remove tail pipe; frame. This feature reduces the transmission of vibrations to the muffler thus resulting in 5.
  • Page 107 Section 04: EXHAUST SYSTEM FIGURE 2: EXHAUST SYSTEM 04008 PA1217...
  • Page 108 SECTION 05: COOLING SYSTEM CONTENTS DESCRIPTION ............................3 MAINTENANCE ............................. 4 ....................4 EHICLES WITHOUT COOLANT FILTERS ..................... 4 EHICLES WITH COOLANT FILTERS HOSES ..............................5 CONSTANT-TORQUE HOSE CLAMPS ..................5 3.1.1 Type ............................ 5 3.1.2 Type ........................... 5 CONSTANT-TORQUE HOSE CLAMPS (CAC) ......
  • Page 109 Section 05: COOLING SYSTEM 13.1 ......................15 ELT TENSION ADJUSTMENT FAN DRIVE ALIGNMENT ........................ 15 SPECIFICATIONS ........................... 16 ILLUSTRATIONS ..........................3 IGURE COOLING SYSTEM ...................... 4 IGURE SURGE TANK ENGINE COMPART ......................5 IGURE CONSTANT TORQUE CLAMP 4: 4- ....................
  • Page 110: Section 05: Cooling System

    Section 05: COOLING SYSTEM 1. DESCRIPTION A radiator and thermo-modulated fan are used to effectively dissipate the heat generated by the engine. A centrifugal-type water pump is used to circulate the engine coolant (Fig. 1). Two full blocking-type thermostats are used in the water outlet passage to control the flow of coolant, providing fast engine warm-up and regulating coolant temperature.
  • Page 111: Maintenance

    Section 05: COOLING SYSTEM o Drain, flush, thoroughly clean and refill the system every two years or every 200,000 miles (320 000 km), whichever comes first. For vehicle equipped with coolant filters, change the precharge element filter or the existing maintenance element filter for a new maintenance element filter.
  • Page 112: Type

    Section 05: COOLING SYSTEM normal expansion/contraction of a hose and Note: In order to ensure the integrity of the metal connection that occurs during vehicle system, it is recommended that a periodic operation and shutdown. The constant-torque cooling system pressure check be made. clamp virtually eliminates coolant losses due to Pressurize the cooling system to 103-138 kPa "Cold flow"...
  • Page 113: Constant-Torque Hose Clamps On Charge Air Cooler (Cac) Ssystem

    Section 05: COOLING SYSTEM regular basis. During vehicle operation and shutdown, the screw tip will adjust according to temperature pressure changes. Checking for proper torque should be done at room temperature. 3.2 CONSTANT-TORQUE HOSE CLAMPS ON CHARGE AIR COOLER (CAC) SSYSTEM FIGURE 4: 4-INCH CONSTANT-TORQUE CLAMP 05097 If for any reason such as an accident, hose...
  • Page 114: Coolant

    Recommended phosphate free coolants: Detroit frozen coolant fluid. Diesel “DDC Power Cool” (P/N 23512138) or Prestone AF977 (bulk) Prevost #685125, 72702 4.4 COOLANT REQUIREMENTS (3.78 L), 70119 (205L), 70102 (4L). The coolant provides a medium for heat transfer...
  • Page 115: Inhibitors

    Section 05: COOLING SYSTEM DDC Fully Formulated Glycol Coolant Limits 8.0 -– 11.0 40 ppm MAX Chlorides (ppm) 100 ppm MAX Sulfates (ppm) 4.6 INHIBITORS A coolant solution, which has insufficient Note: Above SCA values with Detroit Diesel inhibitors or no inhibitors at all, invites the #7se298 or TMC RP-329 “Type A”.
  • Page 116: Coolant Not Recommended

    Section 05: COOLING SYSTEM 4.7.1 Coolant Not Recommended radiator fan gearbox (Fig. 7). Another valve is located behind rear fender, above the L.H. o All antifreeze coolant containing rear wheelhousing near the optional coolant phosphorous; heater. o Automotive type coolants; Note: Refer to section 22 under "Preheating o Methoxy propanol-base antifreeze;...
  • Page 117: Filling Cooling System

    Section 05: COOLING SYSTEM Note: Make sure the purge line at top of thermostat housing is properly connected and not obstructed. The purge line (thermostat housing dome to radiator top tank) is required to ensure complete engine fill and proper purging of air in the system.
  • Page 118: Filter No

    Section 05: COOLING SYSTEM 5. Turn on the water and when the radiator is 7. Fully drain system. full, turn on the air in short blasts, allowing the Vehicles without coolant filters: radiator to fill between blasts. Fill with a 50/50-antifreeze/water solution Note: Apply air gradually.
  • Page 119: Radiator

    Section 05: COOLING SYSTEM 1. Close the two filter shutoff cocks on the filter flushing and reverse flushing in this section for mounting head and unscrew the old filter maintenance of radiator interior. from mounting. 10. CHARGE AIR COOLER (CAC) LEAKAGE Warning: Failure to relieve cooling system pressure may result in personal injury.
  • Page 120: Multiplexed Vehicles

    Section 05: COOLING SYSTEM 11.1.2 Multiplexed Vehicles 11.2 MAINTENANCE 5. Clean the fan and related parts with clean If the radiator fan clutch does not function and fuel oil and dry them with compressed air. Do the engine is overheating, execute the following not clean with steam or high-pressure jet.
  • Page 121: Fan Gearbox

    Section 05: COOLING SYSTEM engine to the radiator. During this period, all of 12.1 MAINTENANCE the coolant in the system is recirculated through Change the gearbox oil at 3,000 miles (4,800 the engine and directed back to the suction side km) and subsequently every 50,000 miles of the water pump via a bypass tube.
  • Page 122 Section 05: COOLING SYSTEM Remove existing belts (3″V″belts & 1 Poly) from fan assembly and replace with new ones. Turn the pressure-releasing valve counter- clockwise to its initial position to apply tension on the new belts. Note: For proper operation of the belts, adjust the air bellows tensioner pressure regulating valve (located next to control valve) to 45 psi (310 kPa).
  • Page 123 Section 05: COOLING SYSTEM FIGURE 20: PULLEY'S VERTICAL ANGLE 05063 5. Check alignments again (steps 3, 4 & 5) then replace temporary anchoring nuts (P/N 500709) (74, Fig. 18) with four nuts (P/N 500714) (47, Fig. 18) wrench tighten. 6. Align multi "V" pulley with fan pulley. Adjust the depth of the pulley on the gearbox shaft.
  • Page 124: Prévost Number

    Lubricating Oil ..........................MOBIL SHC 630 Prevost number (Oil) ..........................683666 Fan Belt (gearbox-fan) Make ................................Dayco Type ................................Poly-V Qty ..................................1 H3-45, H3-41 Coach & H3-45 VIP: Supplier number ........................... 12PK-2100 Prevost number ............................507627 Fan Belt (gearbox-motor) Make ................................Dayco Type ................................V-belt Qty ..................................
  • Page 125 Make ................................Nalco Type ................................Spin-on MAINTENANCE ELEMENT FILTER Supplier number..Detroit Diesel ......................23507545 Supplier number..Nalco ........................DDF3000 Prevost number ............................550630 PRECHARGE ELEMENT FILTER Supplier number..Detroit Diesel ......................23507189 Supplier number..Nalco .......................... DDF60 Prevost number ............................550629 PA1217...
  • Page 126 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION ........................5 WIRING DIAGRAMS ........................5 1.1.1 Using Wiring Diagrams ......................5 1.1.2 Testing Circuits ........................6 WIRE SIZES AND COLORS ......................6 SPARE WIRES ..........................6 CLEANING CONNECTORS ......................7 CIRCUIT BREAKERS ........................7 MULTIPLEX FUSES ........................
  • Page 127 Section 06: ELECTRICAL ESSENTIAL FUNCTIONS TO OPERATE THE VEHICLE ............38 4.8.1 Available Functions ....................... 38 LOWER PRIORITY MODULES FOR BREAKDOWN SERVICE ..........38 4.10 MULTIPLEX MODULES ....................... 38 4.10.1 CECM ............................ 38 4.10.2 MASTER ID ........................... 38 4.10.3 IO-A ............................38 4.10.4 IO-B ............................
  • Page 128 Section 06: ELECTRICAL 12.1 HEADLIGHTS ..........................55 12.1.1 Headlight Beam Toggle Switch....................55 12.1.2 Maintenance .......................... 55 12.1.3 Headlight Adjustment......................55 12.1.4 Sealed-Beam Unit........................59 12.1.5 Front Turn Signal ........................59 12.1.6 Optional Xenon Headlamp..................... 60 12.2 STOP, TAIL, DIRECTIONAL, BACK-UP, AND HAZARD WARNING LIGHTS ......61 12.2.1 Lamp Removal And Replacement ..................
  • Page 129 Section 06: ELECTRICAL ......................12 FIGURE MAIN POWER COMPARTMENT ) .................. 12 FIGURE MAIN POWER COMPARTMENT PARTIAL VIEW . & ..................14 FIGURE FRONT ELECT SERVICE COMPARTMENT ....................14 FIGURE ENGINE STARTING CONTROL PANEL .................. 14 FIGURE HVAC PANEL IN EVAPORATOR COMPARTMENT 10 : ....................
  • Page 130: General Description

    12, you will find the location, the b) At item CB possible output supply of 100 amps on the 12- Prevost number, the breaker function, the volt system. Both the 12 and 24-volt systems are breaker ampere rating and the page on controlled through individual main battery relays.
  • Page 131: Testing Circuits

    Section 06: ELECTRICAL c) At device SW61,SW62, find the fault Orange Connected to multiplex outputs message, the minimum condition to activate, White Connected to multiplex inputs other inputs involved in logic, the multiplex 24-volt system module related to switch 61 and switch 62, Yellow 12-volt system the connector and pin number on the module...
  • Page 132: Cleaning Connectors

    Section 06: ELECTRICAL CLEANING CONNECTORS When the pins and sockets of connectors become dirty, clean them with a good quality solvent containing HFC 134A refrigerant as its active ingredient. HFC 134A has two qualities that recommend it. First, it does not conduct electricity and therefore, will not cause shorting between connector pins and sockets.
  • Page 133: Relays

    Section 06: ELECTRICAL There is also hardware fuses used to protect the When the ignition switch is set to the OFF incoming power to the multiplex modules. These position, the electrical components are not fuses are located inside the VECF (Vehicle energized except for the CECM (Chassis Electrical Center Front) and VECR (Vehicle Electronic Control Module), engine ECM,...
  • Page 134: H3 Series Vehicles Electrical Compartments

    S ECONDARY LOCK grey YAZAKI IO-A See above green EXTRACTOR/TOOL: Prevost #682256 (Packard 12094429) INS ERT EXT RACT OR Remove the terminal by disengaging the flexible lock tab on the HERE terminal. Gently remove the terminal from the connector by pulling on the wire.
  • Page 135: Maintenance

    Section 06: ELECTRICAL FIGURE 4: ELECTRICAL COMPARTMENTS MAINTENANCE o Main circuit breakers for 12-volt and 24-volt A Cortec VCI-238 corrosion inhibitor has been electrical system; sprayed in all electrical compartments to protect components from corrosion. The life expectancy o Voltage regulator (if applicable); this product five...
  • Page 136 Section 06: ELECTRICAL 12V IGN & A/C Option I/O-B I/O-B Fluorescent (direct wake-up I/O-B lighting) mode Relays Service brakes Emergency cut-out 24V Master relay 24V Door lock LH Fluorescent (indirect Option 12V IGN & A/C 24V Door lock RH lighting) wake-up 24V Door unlock LH Fuses...
  • Page 137: Battery Charger Or In-Station Lighting Connector

    Section 06: ELECTRICAL FIGURE 5: MAIN POWER COMPARTMENT (PARTIAL VIEW) 06594 the front junction panel with the following components (Figure 7). o Resistors; o ABS module; o Fuses; o Relays; o Kneeling audible alarm; o Front multiplex modules; o Front fuse box known as VECF (Vehicle Electrical Center Front);...
  • Page 138 Section 06: ELECTRICAL CECM Multiplex chassis I/O-B electronic control ABS-ECU ABS system I/O-B module 12 volts I/O-A I/O-B CECM Multiplex chassis I/O-B I/O-A electronic control module Relays I/O-A I/O-B 24V Wake-up mode Engine brake I/O-A 12V Wake-up mode Upper windshield Relays wipers Wake-up mode...
  • Page 139: Engine Rear Start Panel

    Section 06: ELECTRICAL Pre-heating & Upper driver liquid windshield solenoid valve defroster Auxiliary unit fan HVAC & telltale panel Defroster unit Driver unit liquid solenoid valve (VIP) The following components are located in the Evaporator Compartment (HVAC). They are mounted on a panel located on the R.H. side wall when facing the compartment (Figure 9).
  • Page 140: Pneumatic Accessory Panel

    Section 06: ELECTRICAL 12). The top-mounted negative and positive heating system to keep the condenser terminals are tightly sealed to prevent leaks. compartment door closed in order to avoid Water never needs to be added to this type of faulty readings. battery.
  • Page 141: Battery Discharge Protection

    Section 06: ELECTRICAL 2. Stabilizing the voltage in the electrical gas, which is highly flammable. If ignited system. by a spark or flame, the gas may explode 3. Supplying current for a limited time, when violently, causing spraying acid, electrical demands of the equipment exceed fragmentation of the battery, which may the power output of the alternator.
  • Page 142: Battery Removal And Installation

    We recommend the use NOTE of Cortec VCI-238 (Prevost #682460) on all electrical connections. Main battery relays should be in the “Off” position before disconnecting cables from the BATTERY RATING batteries.
  • Page 143: Battery Testing

    Section 06: ELECTRICAL be used as a basis for comparing starting Dark - Green Dot Not Visible performance. If there is difficulty cranking the engine, the battery should be tested as described in this BATTERY TESTING section. On rare occasions, the test indicator may The maintenance-free battery has a strong ability turn light yellow.
  • Page 144: Testing Battery Cables

    Section 06: ELECTRICAL temperatures of 70ºF (21ºC) and above. For remove fuses F78 & F79 located in the temperatures below 70ºF (21ºC), refer to the VECR. Once these tests are completed, following "Voltage and Temperature Chart". reinstall F78 & F79. 1.
  • Page 145 Section 06: ELECTRICAL is obviously discharged. Should this occur, a Part of this gas escapes through the vent boost charge amperes-hour holes form explosive recommended. Under normal operating atmosphere around the battery itself if conditions, do not charge the battery if the green ventilation is poor.
  • Page 146: Battery Charging Guide

    Section 06: ELECTRICAL Battery charging consists of a charge current in 3.6.2 Emergency Jump Starting With Auxiliary amperes for a period of time in hours. Thus, a 25 (Booster) Battery ampere charging rate for 2 hours would be a 50 ampere-hour charge battery.
  • Page 147: Cleaning And Inspection

    Section 06: ELECTRICAL source and the other end to the positive (+) To insure good contact, the battery cable ring terminals should be tight on the battery posts. If post of the booster power block, located in the posts or cable ring terminals are corroded, the engine R.H.
  • Page 148: Bat" Battery Voltage Incorrect Telltale Light

    Section 06: ELECTRICAL 2. Defects in the charging system, such as high NOTE wiring resistance, faulty alternator, regulator Allow at least 15 minutes to balance batteries or battery equalizer. after any corrective measure has been taken. 3. A vehicle electrical load exceeding the 1.
  • Page 149: Probing Voltage On The Multiplex Circuits

    Section 06: ELECTRICAL module zone at a time while verifying if this module is powered by probing on its gray makes inactive the errors in the modules still connector. If it is, then you can conclude that connected. Connector C1 (front electrical & there is a CAN link problem.
  • Page 150: Information Available And Impact On The Functions In Switch/Sensor Test Mode

    Section 06: ELECTRICAL reactivate the test switch 1 time or turn OFF the Driver’s area lighting switch ignition. Reading lights switch 4.4.1 Information Available And Impact On The Multi-function lever LH turn signal Functions In Switch/Sensor Test Mode Multi-function lever RH turn signal Telltale panel audible alarm emits a beep each time an OFF/ON transition is detected on a Fog lights switch...
  • Page 151: Test Mode For Electric Motors

    Section 06: ELECTRICAL In test mode, with the parking brake applied and 4.5.1 Test Sequence – Coaches only the passenger set point set to a value higher than 1. Go to the condenser compartment. The 64°F (18°C), the circulator pump is not set to condenser fans start at speed 1, then after a OFF as it would normally do when the outside short pause, speed 2 activates.
  • Page 152: Test Sequence - Vip With Central Hvac System

    Section 06: ELECTRICAL 4.5.2 Test Sequence – VIP With Central HVAC This ends the test. Activate the dashboard System Telltale Light Test switch one time to leave the motor test mode. 1. Driver’s & passenger’s unit fresh air damper opening. [20 seconds delay] 4.5.3 Test Sequence –...
  • Page 153: Can Network Layout And Troubleshooting

    Section 06: ELECTRICAL CAN NETWORK LAYOUT AND TROUBLESHOOTING Main power comp. panel Pneumatic accessory panel (right console) Termination resistor CAN network Termination resistor Front electrical comp. panel Evaporator comp. panel Plug Connector 563589 Socket Connector 563590 Pneumatic accessory panel Plug with integrated Termination Resistor 563593 Main power comp.
  • Page 154 Section 06: ELECTRICAL A short circuit somewhere on the CAN network. • The network is completely open circuit. That means none of the two termination resistors are • connected. Several simple tests can be done to locate the problem. Use the spare "Front to Rear" CAN Front electrical comp.
  • Page 155 Section 06: ELECTRICAL Pneumatic Use the spare "Front to Pneumatic Accessory Panel" CAN accessory panel Pneumatic accessory panel: disconnect C13 Socket and connect C13S socket into C13 Plug. Front electrical comp. panel: Disconnect C5 Plug and connect C5S Plug into C5 Socket.
  • Page 156 Section 06: ELECTRICAL Pneumatic Isolate the evaporator module from the network accessory panel Disconnect C100. No need to connect a termination resistor there since C100 is a stub connection. If the short circuit problem is in the evaporator panel, all modules except A54 will respond normally.
  • Page 157: Roadside Troubleshooting

    Section 06: ELECTRICAL Isolate the main power comp. panel from the network Disconnect C3 Plug and connect the termination resistor into C3 Socket. If the short circuit problem is in the main power comp. panel, all front modules + the evaporator module will respond normally. baggage comp.
  • Page 158 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Vehicle does not Start Rear Start selector switch is 1. Check that the rear start selector not at the NORMAL position switch is flipped up to NORMAL start position and battery master switch is flipped up to ON and retry cranking Battery master switch in the 2.
  • Page 159 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions flashers, etc ) are functioning Many secondary functions The CECM module does not 1. Check / reset circuit breaker CB6 (4 (not essential for driving) receive 24 V power from the top on the right side column) functioning (interior Check / replace fuse F1...
  • Page 160 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Lower upper Module A46 is not powered 1. Check the SYSTEM DIAGNOSTIC windshield washer or is faulty menu of the message center display functioning (MCD). Select FAULT DIAGNOSTIC and ELECTRICAL SYSTEM. The message “No Response ModA46, Active”...
  • Page 161 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions 2. Check / reset circuit breaker CB2 3. Check / replace fuse F80 4. Probe gray connector on module to see if it is powered. Engine is overheating and Module A52 is not powered 1.
  • Page 162 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Fire alarm telltale light and Short-circuited fire sensor or 1. Prior to start the vehicle, cycle the audible alarm always ON defective sensor ignition key to the ON position, OFF and there is no fire or high position and then ON position again temperature in the engine and then start the vehicle.
  • Page 163: Essential Functions To Operate The Vehicle

    Section 06: ELECTRICAL o Ability to turn on the parking lights only, ESSENTIAL FUNCTIONS TO OPERATE THE VEHICLE o « Watch your step » sign, Even with a defective CECM (Chassis Electronic o Driver's area lighting, Control Module) or a CAN network problem, o Tag axle activation, essential base functions are maintained to rear start the vehicle from the engine compartment...
  • Page 164: Replacing Io-A Or Io-B Modules

    Section 06: ELECTRICAL program to it). The telltale panel LCD display indicates "CAN" during minutes approximately. "CAN" disappears and "---" is displayed alternately with "CAN" (during that sequence, "---" will be displayed up to 6 times and the audible alarm will ring). Wait until "CAN"...
  • Page 165 Section 06: ELECTRICAL 1. Install alternator mounting bracket (1,Figure 4. Install the snubber bracket (5, Figure 17) 17) to the gear case. Use the four flanged using three flanged bolts. Do not tighten the phosphor alloy bolts on the pulley end of the adjustment bolts on the snubber until after bracket flanged...
  • Page 166 Section 06: ELECTRICAL FIGURE 18: ALTERNATORS AND ACCESSORIES MOUNTING TORQUES FIGURE 19: 50DN DELCO ALTERNATOR SECTIONAL VIEW 06493 PA1217...
  • Page 167: Delco Alternator

    Section 06: ELECTRICAL operated with the oil supply line disconnected. A 6. DELCO ALTERNATOR continuous flow of engine oil through the The 24-volt charging system consists of a belt alternator lubricates the bearings and cools the driven, oil-cooled, brushless alternator, a 24-volt assembly.
  • Page 168: Alternator Or Voltage Regulator

    Section 06: ELECTRICAL “Battery Hi/Lo” telltale lights mounted in the terminal for more than 10 seconds. High dashboard (for location refer to the “Operator’s voltage could burn out the wires and Manual”). The definition of each warning light is components charging system explained under the “ELECTRICAL SYSTEM...
  • Page 169 Section 06: ELECTRICAL Each diode may be checked for short or open NOTE circuits with an ohmmeter. Use an ohmmeter with a single 1.5-volt cell. NOTE Most accurate reading will be determined when the 300 ohms value is calibrated to the The ohmmeter polarity may be determined by center one-third of the scale.
  • Page 170: Field Winding Check

    Section 06: ELECTRICAL The field winding may be checked for shorts and opens with an ohmmeter. To check the field winding, connect the ohmmeter to field terminal and to ground. A resistance reading above normal indicates an open, and a reading less than normal indicates a short field.
  • Page 171: Diode Replacement

    Section 06: ELECTRICAL 3. Remove the diode and support assembly. Then remove insert from small hole in support or from small stud in the end frame. 4. Remove nut and flat washer from diode mounting stud, then remove diode from the support.
  • Page 172: Field Installation

    Section 06: ELECTRICAL 7. Remove the four bolts and lock washers STATOR REPLACEMENT attaching the field to the end frame. tests performed under “Stator Winding Checks” earlier in this section indicated an open 8. To separate the field from the end frame, circuit or short in the stator, the stator and frame install four 3/8-24 x 3 inch bolts in place of assembly must be replaced.
  • Page 173: Alternator Removal (Delco)

    Section 06: ELECTRICAL 1. Make sure all diodes are properly installed After reconnecting electrical wires, it is and securely tightened. Leads from diodes important to cover terminals with protective threaded into the end frame must be sealer (Prévost #680745). securely attached to the diode supports. The relay terminal lead must also be attached to the left diode support.
  • Page 174: Alternator Cleaning And Inspection

    Section 06: ELECTRICAL frame, the three screws connecting the bearing must be replaced with a new one due to diode leads to the diode supports, and the the probability of damage during disassembly. three nuts which attach the stator studs to Removal and Disassembly the diode supports.
  • Page 175: Alternator Reassembly

    Section 06: ELECTRICAL 3. Position the rotor in an arbor press with the circulation periods exceeding shaft end up. Install the drive end frame and seconds, will cause the alternator to single-row bearing assembly over the rotor overheat, resulting in damage to the shaft.
  • Page 176: Adjustment

    Section 06: ELECTRICAL 7.9.1 Adjustment Voltage regulator maintenance Correct belt tension is required to maximize belt The voltage regulator is a service-free electronic life. The tensioning arm maintains proper belt unit. When it fails, it should be replaced. The tension, no adjustment is required. following procedure must be used: Check for wear and proper tension every 6,250 o Open the main power compartment door in...
  • Page 177: Undercharged Battery

    Section 06: ELECTRICAL voltage setting is satisfactory. Check Adjusment Screw following conditions: Checking Voltage Regulator Setting 1. To check the voltage setting, connect a voltmeter across the “POS” and “NEG” terminals on the regulator, and an ammeter to the “C” terminal on the alternator. Refer to Figure 31.
  • Page 178: Overcharged Battery

    Section 06: ELECTRICAL output as given in Delco-Remy Service digital ohmmeters cannot be used to check Bulletin 1G-187 or 1G-188. semiconductors. However, some digital ohmmeters are specially designed to test 10. Check the alternator field winding as follows: semiconductors and can be used to test Disconnect the lead from the field terminal components in the regulator.
  • Page 179: Adjusting Voltage

    Section 06: ELECTRICAL maintenance instruction on MELCO 105P70 starter. CAUTION Prior to the installation of the Mitsubishi starter, the Flywheel Ring Gear must be examined for excess wear or damage. Service Bulletin A1- M1N-1729EN included at the end of Section 06 shows acceptable levels of wear, and illustrates the proper measuring procedure.
  • Page 180: Headlights

    Section 06: ELECTRICAL diagrams are located in the technical publication aiming devices, follow manufacturer’s instructions. box. 12.1 HEADLIGHTS Each headlight assembly consists of two 90 mm (3½ inch) headlight module equipped with a 12- volt halogen bulb and one 100 mm (4 inch) 12- volt LED turn signal light.
  • Page 181 Section 06: ELECTRICAL 1. Park vehicle on a level floor. 2. Set the support rail (Prévost #29261) down (Figure 40). Using shims, adjust its level to stabilize it. FIGURE 40: SUPPORT RAIL INSTALLATION 06501 3. Install jigs #29263 and #29262 onto the support rail.
  • Page 182 Calibration must be performed annually. High beam adjustment 1. Set the support rail (Prevost #29261) down 1. Turn ON high beam lights. (Figure 40). Using shims, adjust its level to 2. Press ALIGN TO LAMP and move aligner in stabilize it.
  • Page 183 Section 06: ELECTRICAL 3. Adjust aligner height (move aligner sideways Headlight (centerline) Nominal Aim Inspection if needed) so that XX appears in the aligner Mounting Height Vertical Limits for Vertical sight. Lock aligner side handle. 4. Open Hoopy 100 aligner door. 56 to 90 cm (22 to 36 inch) 0 Vertical 10 cm (4 inch) up to...
  • Page 184: Sealed-Beam Unit

    Section 06: ELECTRICAL Bulb Removal and Replacement 1. Remove the headlight screw fixing the headlight assembly, then pivot headlight assembly out (Figure 37 and Figure 38). 2. Remove connector from headlight bulb. 3. Remove the bulb by pushing and rotating it out of the socket.
  • Page 185: Optional Xenon Headlamp

    Section 06: ELECTRICAL 1. Remove screw fixing headlight assembly to 5. Fasten back plate fixing screws then pivot its housing (Figure 37) and pivot assembly headlight assembly back into its housing out. then secure using fixing screw. NOTE 2. Partially unfasten back plate fixing screws, then remove signal lamp.
  • Page 186: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    Section 06: ELECTRICAL very high probability that the ballast is OK if the measure bulb voltage as instrument will be ballast can ignite the bulb. destroyed. One simple test to check the ballast would be to NOTE measure the Nominal current of 1.58 A after one minute for the 24V ballast.
  • Page 187: Clearance, Identification And Marker Lights

    Section 06: ELECTRICAL 1. Pry out the rubber seal with a small Two additional halogen sealed-beam units are screwdriver. Pull on the LED unit and installed on rear electrical compartment door disconnect it. (R.H.) and radiator door. These lights are used as docking lights and both will illuminate 2.
  • Page 188: Interior Lighting Equipement

    Section 06: ELECTRICAL 5. Reinstall the outer ring, pivot the assembly 4. To replace the telltale module, reverse the downwards. procedure. 6. Fasten the wing nut and securely close the 13.1.3 Gauge Light Bulb Replacement bumper. 1. For any gauge light bulb replacement, the dashboard panel must be removed in order 13.
  • Page 189: Vip Entrance And Bus Entrance Door

    Section 06: ELECTRICAL 1. Unsnap the lamp outer ring with a flat head The lavatory night-light is illuminated as soon as screwdriver and remove it. the ignition switch is set to the “ON” position. 2. Unfasten the three fixing screws, remove 13.3.1 Bulb Removal And Replacement and disconnect LED light assembly.
  • Page 190: Fluorescent Tube Replacement

    Section 06: ELECTRICAL batteries as soon as the 110-volt circuit is 4. Lift the hinged cover and replace the two connected. retaining screws (Figure 56). Moreover, adjustable reading lamps are installed Parcel Rack Interior Lighting under parcel racks passenger 1. Open the parcel rack access door, if so accommodation.
  • Page 191: Lavatory Light

    Section 06: ELECTRICAL Each light is sealed and can be replaced as mechanism upon locking to energize the circuit. follows: This switch is readily serviced by removing the two Phillips-head screws securing the mounting 1. Disconnect the light unit connection. plate to the door exterior frame.
  • Page 192 Section 06: ELECTRICAL Application Prévost Trade or SAE Watts or Volts part no. number Candle Power Rear directional 930365 0.55 A Stop 930366 0.3 A Back-up 930367 Sealed Unit 2.1 A Center stop (high-mounted) 930330 Tail 930366 0.03 A Exterior compartment (except 562278 6429 (78207) 10 W...
  • Page 193: Specifications

    Section 06: ELECTRICAL 15. SPECIFICATIONS Battery Make ............................... Volvo Model ............................... 20359831 Type ............................ Maintenance-free Terminal type .............................Top Stud Group size ..............................31 Volts ................................12 Load test amperage ..........................290 Reserve capacity (minutes) ........................195 Cold cranking (in amps) -At 0 F (-18 C) ........................
  • Page 194 Series ................................T1 Hot output -Amperes ........................140 at 25°C (AMBIENT) -Volts ................................28 -Approximate rpm ............................ 6000 Ground ............................... negative Prevost Number ..........................562752 Regulator Make ............................Delco-Remy Model Number ..............................Type ..............................Transistor Voltage adjustment........................External screw Prevost number ........................... 562775 Battery equalizer Make ..............................
  • Page 195 Operating voltage ..........................9-32 V Over voltage ............................. 35 V Number of inputs ............................15 Number of outputs ............................6 Prevost number ........................... 563272 IO-B Volvo multiplex module Rated voltage ..........................24 or 12 VDC Operating voltage ..........................9-32 V Over voltage .............................
  • Page 196 SECTION 07: TRANSMISSION CONTENTS DESCRIPTION ............................3 ALLISON AUTOMATIC TRANSMISSION ..................3 1.1.1 Retarder (if applicable) ......................3 ZF-ASTRONIC TRANSMISSION ....................3 WELDING PROCEDURES ........................4 MAINTENANCE ............................. 4 ALLISON TRANSMISSION ......................4 3.1.1 Manual Fluid Level Check ....................... 4 3.1.2 Cold Check ..........................
  • Page 197 Section 07: TRANSMISSION ILLUSTRATIONS ........................3 FIGURE ALLISON TRANSMISSION .................... 3 FIGURE ALLISON PUSHBUTTON SHIFT SELECTOR ......................4 FIGURE ASTRONIC TRANSMISSION ) ......................4 FIGURE OIL LEVEL DIPSTICK ALLISON ............................ 5 FIGURE COLD CHECK ............................6 FIGURE HOT CHECK ......................... 9 FIGURE DRAIN PLUG AND FILTERS ....................
  • Page 198: Description

    Section 07: TRANSMISSION memory. It then looks at these adjustments and DESCRIPTION resets parameters, which allow H3 Series vehicles may be provided with either an transmission quickly compensate Allison automatic transmission or a ZF-Astronic variations in load, terrain or environment and to transmission.
  • Page 199: Welding Procedures

    Section 07: TRANSMISSION FIGURE 3: ZF-ASTRONIC TRANSMISSION 07078 The actual shift procedure is performed by the electronic transmission control unit. The driver has the option of driving the vehicle in both semi- automatic mode as well as fully automatically. When in semi-automatic mode, manual shifting with the range selector is made easier.
  • Page 200: Hot Check

    Section 07: TRANSMISSION leading to transmission damage. Obtain an accurate fluid level by imposing the following conditions: • Engine is idling (500-800 rpm) in «N» 2. Run the engine at idle in «N» (Neutral) for (Neutral). about one minute. • Transmission fluid is at normal operating 3.
  • Page 201: Fluid Level Check Using The Pushbutton Shift Selector

    Section 07: TRANSMISSION FIGURE 6: HOT CHECK 07049 will stop the two minute countdown. One of the codes shown hereafter will indicate the cause NOTE of the countdown interruption. Once all parameters are met, the countdown will The Cold Check is more appropriate for continue from where it left off.
  • Page 202: Oil Contamination

    Section 07: TRANSMISSION performance, reliability and durability. Castrol signs of leakage. This, however, may also indicate TranSynd™ Synthetic Fluid and DEXRON-III® leakage from the engine oil system. fluids recommended on-highway applications. 3.1.9 Metal Particles • TranSynd™ is a full synthetic transmission Metal particles in the oil (except for minute fluid developed by Allison Transmission and particles normally trapped in the oil filter) indicate...
  • Page 203 Section 07: TRANSMISSION TABLE 1: Recommended Fluid and Filter Change Intervals (Non-TranSynd /Non-TES 295/Mixture) Coaches or MTH equipped with retarder Coaches or MTH without retarder Filters Filters Main Main Fluid Fluid Internal Lube/ Internal Lube/ Initial Break-in Initial Break-in Auxiliary Auxiliary 5,000 miles 5,000 miles...
  • Page 204: Oil And Filter Change

    Section 07: TRANSMISSION 3.1.11 Oil and Filter Change 5. Install twelve bolts and both covers, and then tighten to 38-45 Ft-lbs (51-61 Nm). Allison transmissions are factory fill with Castrol TranSynd™ fluid. Oil change must be performed 6. Inspect the drain plug and O-ring. Replace if with the vehicle on a flat and level surface and necessary.
  • Page 205: Zf Astronic Transmission

    Section 07: TRANSMISSION ZF AS-TRONIC TRANSMISSION studs and in their place install the remaining 2 bolts. information needed removal /installation maintenance When the bolts are hand tight, be sure that transmission is included in the documents the clutch cover fits into the flywheel annexed at the end of this section.
  • Page 206 Section 07: TRANSMISSION From underneath, push the clutch release bearing forward (in the direction of flywheel) using the release fork. Use force to snap the bearing into the retaining clip located on the “fingers” of the pressure plate. The installer should be able to both hear and feel the bearing seat into place.
  • Page 207: Installation Of Zf Or Allison Transmission Brackets

    Section 07: TRANSMISSION INSTALLATION OF ZF OR ALLISON TRANSMISSION BRACKETS FIGURE 9: ZF OR ALLISON TRANSMISSION BRACKETS 07114 ALLISON TRANSMISSION REMOVAL NOTE The following procedure deals with the removal of For more clearance between the tag axle and the Allison transmission without removing the transmission, the tag axle may be unloaded and power plant cradle from vehicle.
  • Page 208: Transmission Oil Cooler Removal

    Section 07: TRANSMISSION 6. Remove transmission dipstick and filler tube. 7. Disconnect propeller shaft from transmission and remove its safety guard. Refer to Section 09, "PROPELLER SHAFT". 8. Disconnect the two oil cooler hoses from transmission. Cover hose ends and fittings to prevent fluid contamination.
  • Page 209: Transmission With Retarder

    Section 07: TRANSMISSION CAUTION CAUTION To avoid damage to turbocharger, cover the To avoid damage to turbocharger, cover the turbocharger inlet opening to prevent foreign turbocharger inlet opening to prevent foreign material from entering. material from entering. 2. Disconnect the two transmission hoses from oil cooler.
  • Page 210: Breather

    Section 07: TRANSMISSION 5. Worn or frayed electrical harnesses, improper Severe damages and/or personal injury can routing; occur transmission adequately supported. 6. Worn or out of phase drive line U-joint and slip fittings. 6. Seat the transmission against the engine flywheel housing.
  • Page 211: Troubleshooting

    Section 07: TRANSMISSION between the rubber support and the frame with a bolt, nut and washer. Tighten the nut until the tolerance of 58 ± 2 mm is met (Fig. 13). 11. Remove jack from under transmission. 12. Connect all sensors. 13.
  • Page 212: Diagnostic Troubleshooting Codes (Dtc) - Allison 4Th Generation Controls

    Section 07: TRANSMISSION Unscrew the TCM unit; Displayed as: d1…P…07…22 Replace by reversing the procedure. The code list position is the first item displayed, followed by the DTC. Each item is displayed for about second. display cycles CAUTION continuously until the next code list position is accessed by pressing the MODE button.
  • Page 213: Diagnostic Code Response

    Section 07: TRANSMISSION when the condition causing the code is no longer detected by the TCM. To display stored codes: 1. Simultaneously press the (Up) and The Diagnostic Display Mode can be exited by (Down) arrow buttons twice to access the any of the following methods: Diagnostic Display Mode.
  • Page 214: Diagnostic Troubleshooting Codes (Dtc) List - Allison 4

    Section 07: TRANSMISSION All solenoids are commanded OFF (turning solenoids “A” and “B” off electrically cause them to be on hydraulically). RPR - Return to Previous Range Response When the speed sensor ratio or C3 pressure switch test associated with a shift not successful, the TCM commands the same range as commanded before the shift.
  • Page 215 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P070C Transmission Fluid Level Sensor Circuit – Low Input None P070D Transmission Fluid Level Sensor Circuit – High Input None Transmission Fluid Temperature Sensor Circuit P0711 Use default sump temp Performance P0712 Transmission Fluid Temperature Sensor Circuit Low Input...
  • Page 216 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P0973 Shift Solenoid 1 (SS1) Control Circuit Low DNS, SOL OFF (hydraulic default) P0974 Shift Solenoid 1 (SS1) Control Circuit High DNS, SOL OFF (hydraulic default) P0975 Shift Solenoid 2 (SS2) Control Circuit Open 7-speed: Allow 2 through 6, N, R 7-speed: Allow 2 through 6, N, R P0976...
  • Page 217: Zf-Astronic Transmission System Faults And Error Messages

    Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P2812 Pressure Control Solenoid 6 (PCS6) Control Circuit Open DNS, SOL OFF (hydraulic default) P2814 Pressure Control Solenoid 6 (PCS6) Control Circuit Low DNS, SOL OFF (hydraulic default) P2815 Pressure Control Solenoid 6 (PCS6) Control Circuit High DNS, SOL OFF (hydraulic default) U0001 Hi Speed CAN Bus Reset Counter Overrun (IESCAN) Use default values, inhibit SEM...
  • Page 218 Section 07: TRANSMISSION  Switch on ignition Depress “N” key  Hold down “ ” key  One or more error numbers appear on the display. These correspond errors presently active in the system. 07107 Calling up error numbers from the error memory: ...
  • Page 219 Section 07: TRANSMISSION DESCRIPTION 8, 7 Easy Start, Brake doesn't open completely 8, 14 Easy Start, Not Available 20,6 Short circuit to ground at output ACC (wakeup control signal for ZMTEC, keep alive signal for voltage doubler, and power signal for speed sensor #2) 20,5 Interruption at output ACC (wakeup control signal for ZMTEC, keep alive signal for voltage doubler, and power signal for speed sensor #2)
  • Page 220 Section 07: TRANSMISSION DESCRIPTION 34,3 Short circuit to positive at output stage to small disengagement clutch valve 34,3 Short circuit to positive at output stage to small engagement clutch valve 34,3 Short circuit to positive at output stage to large disengagement clutch valve 34,3 Short circuit to positive at output stage to large engagement clutch valve 35,5...
  • Page 221 Section 07: TRANSMISSION DESCRIPTION 51,3 Short circuit to positive at output stage to Y7 (Valve Shift) 54,6 Short circuit to ground at output stage to Y1 (inertia brake valve) 54,5 Interruption at output stage to Y1 (inertia brake valve) 54,3 Short circuit to positive at output stage to Y1 (inertia brake valve) 55,7 Clutch engaged unintentionally at standstill, gear engaged...
  • Page 222 Section 07: TRANSMISSION DESCRIPTION 151,14 Plausibility error between transmission input speed and output speed 152,6 Short circuit to ground at output stage to Y10 (Main valve) 152,5 Interruption at output stage to Y10 (Main valve) 152,3 Short circuit to positive at output stage to Y10 (Main valve) 153,14 Error on ISO 14320 communications line 154,14...
  • Page 223 Section 07: TRANSMISSION DESCRIPTION 231,14 CAN ”Engine retarder configuration” timeout 231,14 CAN EBC1 timeout 231,14 Error on ”ABS active” signal (EBC1) 231,14 Error on ”ASR engine control active” signal (EBC1) 231,14 Error on ”ASR brake control active” signal (EBC1) 231,14 Error on ”Cruise control active”...
  • Page 224 Capacity (excluding external circuits) ............... Initial fill 47 US qts (45 liters) Oil change ..........................24 US qts (23 liters) Oil change (with retarder) ....................27.6 US qts (26.5 liters) Oil Filters: Make ............................. Allison Transmission Type ............................Disposable cartridge Prevost part number (2-filters replacement kit) ..................571709 PA1217...
  • Page 225 SECTION 09: PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..........................2 ............................ 2 ESCRIPTION REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION ..........2 CLEANING, INSPECTION AND LUBRICATION .................. 3 ....................... 3 LEANING AND NSPECTION ............................ 3 UBRICATION EXPLANATION OF COMMON DAMAGES ..................3 TROUBLESHOOTING .......................... 3 SPECIFICATIONS ..........................
  • Page 226: Propeller Shaft

    Section 09: PROPELLER SHAFT PROPELLER SHAFT DESCRIPTION The rise and fall of the drive axle bring about The propeller shaft transmits power from the these variations as the vehicle passes over transmission to the differential (Fig. 1). Refer to uneven surfaces. The slip joint also eases paragraph "6.
  • Page 227: Cleaning, Inspection And Lubrication

    Section 09: PROPELLER SHAFT CLEANING, INSPECTION AND EXPLANATION OF COMMON DAMAGES LUBRICATION 1. Cracks: Stress lines due to metal fatigue. CLEANING AND INSPECTION Severe and numerous cracks will weaken the metal until it breaks. Thoroughly clean grease from bearings, journal, lubricating grease fittings and other parts.
  • Page 228 Cap and bolt kit, bolt torque 115-135 lbf•ft (156-183 N•m), Supplier number ........6.5-70-18X Cap and bolt kit, bolt torque 115-135 lbf•ft (156-183 N•m), Prevost number ..........580063 Bolts kit, bolt torque 38-48 lbf•ft (52-65 N•m), Supplier number ............. 6-73-209 Bolts kit, bolt torque 38-48 lbf•ft (52-65 N•m), Prevost number..............
  • Page 229 SECTION 10: FRONT AXLE CONTENTS FRONT AXLE ............................2 ............................ 2 DESCRIPTION LUBRICATION ............................2 MAINTENANCE ............................. 2 ......................3 IE ROD END PLAY ADJUSTMENT REMOVAL AND REPLACEMENT ......................3 ............................3 REMOVAL ..........................3 REPLACEMENT SERVICE INSTRUCTIONS FOR STEER AXLE ................... 3 FRONT WHEEL ALIGNMENT ......................
  • Page 230: Front Axle

    Section 10: FRONT AXLE FRONT AXLE lubrication. These grease fittings should be serviced every 6,250 miles (10 000 km) or twice DESCRIPTION a year whichever comes first. Good quality lithium-base roller bearing grease NLGI No.1 This front axle is of the ‘’Reverse Elliot’’ type and 2 are recommended.
  • Page 231: Tie Rod End Play Adjustment

    Section 10: FRONT AXLE TIE ROD END PLAY ADJUSTMENT equipped with U-adapters, or similar precautions must be taken. If end play exceeds 0.047” (1.2 mm), readjust- ment is necessary. 4. Disconnect the steering drag link from the steering arm. Remove protective cap, using a suitable tool ie: a 1”...
  • Page 232: Minor Front Wheel Alignment

    Section 10: FRONT AXLE and strains on the front-end system can, under INSPECTION BEFORE ALIGNMENT normal operating conditions, result in loss of front Check the following before doing a front wheel wheel alignment. alignment: Check the front wheel alignment when the Ensure that the vehicle is at normal riding following occurs: height.
  • Page 233: Turn Adjustment

    Section 10: FRONT AXLE 6.4.1 R.H. Turn Adjustment 7. If readjustment is required: Remove the swivel stop screw. Caution : To prevent the steering damper from interfering with the adjustment of turning angles, Add to the stop screw the required make sure its fixing bracket is at the correct number of washers to obtain the proper location on the axle center (refer to section 14...
  • Page 234: Camber Check

    Section 10: FRONT AXLE shoulder and excessive negative camber causes FIGURE 5: CASTER 10007 wear at the inner shoulder. Excessive caster results in hard steering around corners. A shimmy may also develop when 6.6.1 Camber Check returning to the straight ahead position (pulling out of curves).
  • Page 235: Inspection And Adjustment

    Section 10: FRONT AXLE When setting toe-in adjustment, the front suspension must be neutralized; that is, all component parts must be in the same relative position when marking the adjustment as they will be when in operation. To neutralize the suspension, the vehicle must be rolled forward, approximately ten feet.
  • Page 236: Troubleshooting

    Section 10: FRONT AXLE TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear out 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly or have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.
  • Page 237: Specifications

    Section 10: FRONT AXLE SPECIFICATIONS Front Axle Make ..........................DANA SPICER EUROPE Model ................................NDS Front Track ........................84.4 inches (2 145 mm) Rated load capacity ......................16,500 lbs (7 500 kg) Torque specifications FIGURE 7: AIR BELLOWS MOUNTING SUPPORT AND AXLE 10009 For more torque specifications, see ‘Dana Spicer Maintenance Manual NDS Axles and Maintenance Manual Model NDS’’...
  • Page 238: 4: Camber

    Section 10: FRONT AXLE FRONT WHEEL ALIGNMENT SPECIFICATIONS Front Wheel Alignment Minimal Nominal Maximal Camber, (degrees) -0.250 0.125 0.375 R.H. and L.H. * Caster, (degrees) 2.75 R.H. and L.H. Toe-in (A minus B), 0.06 0.08 0.10 (degrees) Note : Camber angle changes with loading. The given numbers are for an empty vehicle. PA1217...
  • Page 239 SECTION 11: REAR AXLES CONTENTS DRIVE AXLE ............................2 ............................ 2 DESCRIPTION ) ................ 2 DCDL DRIVER CONTROLLED MAIN DIFFERENTIAL LOCK ........................2 DRIVE AXLE LUBRICATION ........................... 3 MAINTENANCE 1.4.1 Checking and Adjusting the Oil Level ..................3 1.4.2 Draining and Replacing the Oil ....................3 1.4.3 Speed Sensors (Anti-Lock Brake system, ABS) ..............
  • Page 240: Drive Axle

    Section 11: REAR AXLES DRIVE AXLE DESCRIPTION The Meritor drive axle is equipped with a single reduction standard carrier mounted in front of the axle housing. The carrier consists of a hypoid drive pinion, a ring gear set and gears in the differential assembly.
  • Page 241: Maintenance

    Section 11: REAR AXLES 4. The oil level must be even with the bottom of the hole of the fill plug. a. If oil flows from the hole when the plug is loosened, the oil level is high. Drain the oil to the correct level.
  • Page 242: Disassembly And Reassembly

    Section 11: REAR AXLES 9. Remove the four shock absorbers as during removal and disassembly depends upon outlined in Section 16, "Suspension" under local conditions and available equipment. heading "Shock Absorber Removal". 1. Raise vehicle by its jacking points on the body 10.
  • Page 243: Drive Axle Alignment

    Section 11: REAR AXLES 1.11 DRIVE AXLE ALIGNMENT Note: When drive axle alignment is modified, tag axle alignment must be re-verified. For drive axle alignment specifications, Note: 1.11.1 Procedure refer to paragraph 3: ‘’Specifications’’ in this section. Park vehicle on a level surface, then chock front vehicle wheels.
  • Page 244: Axle Shaft Sealing Method

    Section 11: REAR AXLES TAG AXLE ALIGNMENT Remove and reinstall all wheel mount sensors on the drive and tag axles (fig. 8); Note: For an accurate alignment, the tag axle must be aligned with the drive axle. Note: Reinstall wheel mount sensors as shown in figure 8. For example, the sensor from the right side of the front axle is mounted on the left side of the tag axle.
  • Page 245: Grease Lubricated Wheel Bearings

    Section 11: REAR AXLES 3 ..............Gasket 2. Transferring extra weight and additional 4 ............. Wheel hub traction to the drive wheels on slippery surfaces. 1. Clean the mounting surfaces of both the axle shaft flange and wheel hub where silicone Caution: Never exceed 30 mph (50 km/h) with sealant will be applied.
  • Page 246: Tag Axle Alignment

    Section 11: REAR AXLES FIGURE 10: JACKING POINTS ON TAG AXLE 11023 Note: Refer to Section 16, "Suspension", for 4. Applies only to vehicles equipped with proper torque tightening suspension retractable tag axles: Disconnect tag axle components. lifting chain collars from lower longitudinal Refer to section 13 "Wheels, Hubs And Note: radius rods.
  • Page 247 Section 11: REAR AXLES 4.56:1 Optional Note: The drive axle alignment consists in aligning the axle with reference to the frame. The axle must be perpendicular to the frame. Tag Axle Make ................................Prévost Rear track ........................83.6 inches (2 124 mm) Axle type ......................
  • Page 248 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM............................4 BRAKES ............................4 AIR RESERVOIRS ..........................4 ..........................4 AINTENANCE 3.1.1 Wet (Main) Air Tank ......................... 4 3.1.2 Primary Air Tank ........................5 3.1.3 Accessory Air Tank........................5 3.1.4 Emergency/Parking Brake Overrule Air Tank ................. 5 3.1.5 Secondary Air Tank .........................
  • Page 249 Section 12: BRAKE AND AIR SYSTEM BRAKE RELAY VALVE (R-12 & R-14) ................... 11 QUICK RELEASE VALVES (QR-1) ....................12 SPRING BRAKE VALVE (SR-7)...................... 12 PRESSURE PROTECTION VALVE (PR-2) ..................12 LOW PRESSURE INDICATORS (LP-3) ..................13 SHUTTLE-TYPE DOUBLE CHECK VALVE (DC-4) ............... 13 EMERGENCY DOOR OPENING VALVES ..................
  • Page 250 Section 12: BRAKE AND AIR SYSTEM SPECIFICATIONS ........................... 29 ILLUSTRATIONS ......................4 IGURE AIR RESERVOIRS LOCATION ........................5 IGURE REAR VALVE LOCATION ....................... 5 IGURE FRONT SERVICE COMPARTMENT ........................6 IGURE ACCESSORY AIR FILTER ....................... 7 IGURE HALDEX AIR FILTER DRYER ....................
  • Page 251: Air System

    Section 12: BRAKE AND AIR SYSTEM AIR SYSTEM Furthermore, the brake application or release, which is speed up by pneumatic relay valves (R- The basic air system consists of an air 12 & R-12DC), will start with the rear axles and compressor, reservoirs, valves,...
  • Page 252: Primary Air Tank

    Section 12: BRAKE AND AIR SYSTEM This reservoir, located in front and above the drive axle in the rear wheelhousing, is provided with a bottom drain valve. A recommended purge using the bottom drain valve should be done every 12,000 miles (20 000 km), or once a year, whichever comes first.
  • Page 253: Air System Emergency Fill Valves

    140 psi (965 kPa). Air filled through these two (Fig. 4). points will pass through the standard air filtering system provided by Prevost. Do not fill system CLEANING by any other point on the system. Clean filter body and bowl with a warm water and The front valve is located in the front electrical soap solution.
  • Page 254: Air Filter/Dryer

    Section 12: BRAKE AND AIR SYSTEM AIR FILTER/DRYER tion code. Service instructions for each type of air line are also provided under the applicable headings. Color Circuit Secondary Green Primary and Delivery Yellow Parking Brake Blue Suspension Black Accessory Brown Trailer Brake COPPER PIPING A heat dissipation copper piping assembly is...
  • Page 255: Air Line Operating Test

    Section 12: BRAKE AND AIR SYSTEM engine R.H. side door. It is used for transmission AIR LINE OPERATING TEST retarder and should be adjusted to 80 ± 3 psi If any trouble symptom such as slow brake (550 ± 20 kPa). application or slow brake release indicates a restricted or clogged air line, disconnect the Air Pressure...
  • Page 256: Air Compressor (Ba-921)

    Section 12: BRAKE AND AIR SYSTEM FIGURE 8: AIR COMPRESSOR INSTALLATION 03061 10.1 COMPRESSOR REMOVAL INSTALLATION 1. Exhaust compressed air from air system by FIGURE 7: AIR PRESSURE REGULATOR 12143 opening the drain valve of each air tank. 2. Drain the engine cooling system. See AIR COMPRESSOR (BA-921) Section 5: "Cooling System".
  • Page 257: Emergency / Parking Brake Overrule Control Valve (Rd-3)

    Section 12: BRAKE AND AIR SYSTEM FIGURE 10: RD-3 12136 FIGURE 9: PP-1 12142 FLIP-FLOP CONTROL VALVE (TW-1) Maintenance and repair information on this valve A flip-flop control valve mounted on the L.H. is supplied in the applicable booklet annexed to lateral console is provided to unload tag axle air this section...
  • Page 258: Maintenance

    Section 12: BRAKE AND AIR SYSTEM 2. Tighten threaded rod lock nuts. 14.1.1 Maintenance Maintenance and repair information on the E-10P dual brake application valve is supplied in the applicable booklet annexed to this section under reference number SD-03-830. FIGURE 14: BENDIX SWITCH 12140 PARKING BRAKE ALARM SWITCH Refer to the appropriate annexed booklet...
  • Page 259: Quick Release Valves (Qr-1)

    Section 12: BRAKE AND AIR SYSTEM Maintenance and repair information on the spring brake valve is supplied in the applicable booklet annexed to this section under reference number SD-03-9043. FIGURE 16: R-14 12207 18. QUICK RELEASE VALVES (QR-1) One quick release valve is installed on this vehicle and is located on the front axle service brakes air line.
  • Page 260: Low Pressure Indicators (Lp-3)

    Section 12: BRAKE AND AIR SYSTEM 21. LOW PRESSURE INDICATORS (LP-3) other one is on the R.H. side lateral console, close to the entrance door. When used, the Maintenance and repair information on the low valve releases pressure in the door locking pressure indicators is supplied in the applicable cylinder, thus allowing the door to be manually booklet annexed to this section under reference...
  • Page 261: Brake Operation

    R.H. side of the driver’s seat (see non-approved friction materials or replacement "Operator's Manual" for more details). components are used, neither Prevost Car nor Furthermore, brake application or release, which Bendix Spicer Foundation Brake LLC will is sped up by a pneumatic relay valve (R-12 & R-...
  • Page 262: Caliper Maintenance

    Section 12: BRAKE AND AIR SYSTEM the end of Section 12 of Maintenance Manual. FIGURE 23: BRAKE PAD CHECK 12117 27.2 CALIPER MAINTENANCE FIGURE 24: CLEARANCE INSPECTION 12119 3. Measure pad to rotor clearance: Use the following procedure for brake calipers servicing.
  • Page 263: Roadside Inspection For Knorr -Bremse Air Disc Brakes

    Section 12: BRAKE AND AIR SYSTEM The Knorr-Bremse air disc brake is designed to Note: With increasing number of applications, move freely, with minimal force, in the axial the incremental adjustment will decrease. direction on the two sliding pins as identified in c) In case of malfunction, i.
  • Page 264: Pad Removal

    Section 12: BRAKE AND AIR SYSTEM 27.6 IMPORTANT PAD AND ROTOR MEASUREMENTS FIGURE 30: BRAKE PAD CHECK 12117 27.4 PAD REMOVAL Turn adjuster pinion (23) counterclockwise to increase pad to rotor clearance (a clicking noise will be heard). Push caliper toward actuator and remove pads (12).
  • Page 265: Checking The Tappet Boots

    Section 12: BRAKE AND AIR SYSTEM c) Depending on caliper manufacturing date, black paint may be present on the unsealed pin (short pin). Paint on the slide pin can prevent the caliper from sliding properly especially when the pad starts to wear. If paint is present on the pin, separate the pin from the bushing, clean and reinstall the pin according to procedure.
  • Page 266: Brake Tools

    Section 12: BRAKE AND AIR SYSTEM turning device turn the threaded tubes by the amount necessary to compensate the wear. Total running clearance should be between 0.020 and 0.035 inch (0.5 and 0.9 mm). Smaller clearances may lead to overheating problems. FIGURE 39: TORQUE SPECIFICATION 12149 SAFE SERVICE PROCEDURES...
  • Page 267: Air Brake Troubleshooting

    Section 12: BRAKE AND AIR SYSTEM AIR BRAKE TROUBLESHOOTING NEVER use compressed air or dry brushing to clean brake parts assemblies. OSHA The following tests and check lists have been recommends that you use cylinders that enclose designed to identify the cause(s) of a sluggish the brake.
  • Page 268 Section 12: BRAKE AND AIR SYSTEM FIGURE 40: AIR-OPERATED BRAKING SYSTEM H3 12197 PA1217...
  • Page 269 Section 12: BRAKE AND AIR SYSTEM If drive is slipping, replace gear. Pressure Build-Up / Low Pressure Warning / Cutoff Point Filter/Dryer Built-in If inlet valves are stuck, open or leaking Governor Cutout severely, replace unloader kit, inlet valves and/or seats as necessary. CONDITION: Vehicle leveled, parking brake applied.
  • Page 270: Brake Air Chamber

    Section 12: BRAKE AND AIR SYSTEM line connections and brake pneumatic FIGURE I-BEAM FRONT AXLE BRAKE CHAMBER components with a water and soap solution. 12158 Bubbles will indicate an air leak, and none should be permissible. Repair or replace defective parts. Listen for leaks and correct as required.
  • Page 271: Brake Chamber Removal

    Section 12: BRAKE AND AIR SYSTEM 2. Remove the release stud tool from its 7. Remove the cotter pin connecting brake storage place on drive axle brake air cham- chamber and slack adjuster (drive axle). ber. 8. Unbolt and remove the brake chamber from 3.
  • Page 272: Anti-Lock Braking System (Abs)

    Section 12: BRAKE AND AIR SYSTEM 4. For the drive and tag axles brake chambers, With this device, the vehicle is brought to a halt in the shortest possible time, while remaining manually release spring brakes (refer to stable and under the driver's control. “Emergency/Parking Brake Manual Release"...
  • Page 273 Section 12: BRAKE AND AIR SYSTEM FIGURE 43: ABS 4S/4M CONFIGURATION 12190 PA1217...
  • Page 274: Abs Components

    Section 12: BRAKE AND AIR SYSTEM 31.2 ABS COMPONENTS 31.2.2 ABS Modulator Valve The main components of the ABS system are This system equipped with four listed hereafter. Refer to each component for its modulator valves, located between the brake specific function in the system and for proper chamber and the relay valve or quick release maintenance.
  • Page 275: Spring Clip

    Section 12: BRAKE AND AIR SYSTEM portant criterion for adequate sensor opera- tion. Note: This installation should be of the "press fit" type. 31.2.4 Spring clip FIGURE 46: ABS SENSOR LOCATION 12153 FIGURE 47: SPRING CLIP 12161 Maintenance The spring clip retains the sensor in its mounting No specific maintenance is required for sensors, bracket close to the toothed pulse wheel.
  • Page 276 Section 12: BRAKE AND AIR SYSTEM FIGURE 49: HOSE FITTING 12054 Fitting Pipe Number of additional size diameter turns required (inches) following manual tightening FIGURE 50: HOSE FITTING 12055 1 ¼ Tubing Number of additional diameter turns required following 3/16 1 ¼...
  • Page 277 Section 12: BRAKE AND AIR SYSTEM Prévost number ..........................70303498 Desiccant cartridge Prévost number ....................3097369 Flip-Flop Control Valve Make ..........................Bendix Westinghouse Model ..............................TW-1 Type ..............................On-Off Supplier number ..........................229635 Prévost number ........................... 640136 Emergency/Parking Brake Control Valve Make ..........................
  • Page 278 Section 12: BRAKE AND AIR SYSTEM Prévost number ........................... 640439 Shuttle-Type Double Check Valve Make ..........................Bendix Westinghouse Model ............................... DC-4 Supplier number ..........................277988 Prévost number ........................... 641015 Low Pressure Indicators Make ..........................Bendix Westinghouse Model ................................ LP-3 Contact close ......................... 66 psi (455 kPa) Supplier number ..........................
  • Page 279 Section 12: BRAKE AND AIR SYSTEM Supplier number ..........................II 33976 Prévost number ........................... 611049 ABS ANTILOCK BRAKING SYSTEM (if applicable) ABS Modulator Valve Make ............................Meritor Wabco Voltage ..............................24 V Supplier number ........................472 195 006 0 Prévost number ........................... 641097 Sensor, Front Axle Supplier number ........................
  • Page 280 SECTION 13: WHEELS, HUBS & TIRES CONTENTS WHEELS ..............................3 WHEEL MAINTENANCE ........................3 ............................3 NSPECTION ......................... 3 INGLE HEEL EMOVAL ......................4 INGLE HEEL NSTALLATION DUAL WHEELS ............................. 4 ........................4 UTER HEEL REMOVAL ........................... 4 NNER HEEL ......................
  • Page 281 Section 13: WHEELS, HUBS & TIRES ILLUSTRATIONS ....................3 IGURE ALUM STEEL WHEEL ARRANGEMENT ........................3 IGURE TIGHTENING SEQUENCE ....................... 5 IGURE DIAL GAUGE INSTALLATION ......................... 6 IGURE STUD MOUNTED WHEELS ........................6 IGURE MOUNTED WHEELS ......................8 IGURE SPARE WHEEL COMPARTMENT ....................
  • Page 282: Wheels

    Section 13: WHEELS, HUBS & TIRES 1. WHEELS make sure that wheel nuts are tightened to the proper torque. In the case of a new vehicle, or When the vehicle is provided with stud-mounted after a wheel installation, stud nuts should be wheels, wheel studs and nuts on the left side of tightened every 100 miles (160-km) for the first the vehicle have left-hand threads whereas...
  • Page 283: Single Wheel Installation

    Section 13: WHEELS, HUBS & TIRES 2. Screw in the inner cap nuts (Fig. 4), so that Note: For stud-mounted wheels, turn nuts wheel will position itself concentrically with counterclockwise for R.H. side and clockwise for hub. Refer to Figure 2 for sequence; the L.H.
  • Page 284: Aluminum Wheel Anti-Corrosion Protection

    1. Remove any tar from wheel surface with a good quality tar remover. 2. Spray Alcoa Cleaner (Prevost #683529) evenly on cool outer surface of wheel. Let work 15-20 minutes (keep wet by spraying more Cleaner if necessary).
  • Page 285: Wheel Studs

    Section 13: WHEELS, HUBS & TIRES 6. WHEEL STUDS 7. HUB MOUNTED WHEELS Stripped threads may be the result of excessive Wheel surfaces in contact with hubs, nuts or torquing or may have been damaged during other wheels should be kept free of all rust, wheel installation when placing the wheel over grease and paint (except for initial “E”...
  • Page 286: Front And Tag Axle Wheel Hubs

    Section 13: WHEELS, HUBS & TIRES Find out why they are loose and whether any Note: For vehicles equipped with Independent damage has been caused. Front Suspension, refer Section "Suspension". Use trained personnel and keep records of all attention to wheels and fixings, including which parts were renewed and when.
  • Page 287: Spare Wheel (If Applicable)

    Section 13: WHEELS, HUBS & TIRES The spare wheel is stored in a dedicated Caution: Always mark position of the wheel on compartment behind the front bumper. To the axle before removal, to replace wheel at the access, pull the release handle located in the same location, thus avoiding a new wheel front electrical...
  • Page 288: Changing A Flat

    Section 13: WHEELS, HUBS & TIRES 2. Wheel nut wrench and lever; “Specifications” this section recommended tire inflation pressure). Inspect 3. Triangular reflectors kit. rim to ensure that there is no important corrosion. In addition, check if spare wheel covering is in good condition and check that spare tire is securely fastened in compartment.
  • Page 289 Weigh vehicle fully loaded and pressurize according to tire manufacturer's recommenda- tions. For other tire and wheel specifications, see Prevost tire pressure tabulation in "Coach Final Record". Warning: Incorrect...
  • Page 290: Tire Matching

    Section 13: WHEELS, HUBS & TIRES 11.2 TIRE MATCHING Unmatched tires on drive axle will cause tire wear and scuffing, as well as possible damage to the drive unit. Consequently, we recommend that tires be matched within 1/8" (3 mm) of the same rolling radius.
  • Page 291: Specifications

    (105 km/hr). Do not drive vehicle at a higher speed than 65 mph (105 km/h) or above the posted speed limit. ALUMINUM WHEEL CLEANING AND MAINTENANCE PRODUCTS Aluminum Wheel Cleaner (22 Oz bottle)................Prevost #683529 Aluminum Wheel Polish (16 Oz bottle) ................Prevost #683528 Aluminum Wheel Sealer (13 Oz bottle) ................Prevost #683527 PA1217...
  • Page 292 SECTION 14: STEERING CONTENTS STEERING SYSTEM ........................14-3 ..........................14-3 ESCRIPTION POWER STEERING GEAR ......................14-4 ..........................14-4 ESCRIPTION ....................14-4 OWER TEERING EMOVAL ..................14-5 OWER TEERING NSTALLATION BLEEDING POWER STEERING HYDRAULIC SYSTEM ............... 14-5 HYDRAULIC PRESSURE TEST ...................... 14-5 TROUBLESHOOTING ........................
  • Page 293 Section 14: STEERING ......................14-4 IGURE POWER STEERING GEAR ....................14-4 IGURE FRONT SERVICE COMPARTMENT ........................14-6 IGURE STEERING COLUMN ......................14-7 IGURE PITMAN ARM ADJUSTMENT ......................14-8 IGURE FIXING NUT PUNCH MARK ..................14-9 IGURE HYDRAULIC FLUID RESERVOIR LOCATION ...................
  • Page 294: Steering System

    Section 14: STEERING STEERING SYSTEM These elements are: 1. Steering stabilizer (damper); 2. A vane type hydraulic pump; and DESCRIPTION 3. Hydraulic reservoir and hoses. The steering system consists of the steering The steering stabilizer reduces road shocks and wheel and column assembly, a vane-type vibrations in the system.
  • Page 295: Power Steering Gear

    Section 14: STEERING POWER STEERING GEAR FIGURE 3: FRONT SERVICE COMPARTMENT 14050 A torsion bar, which is pinned with the valve slide and the worm, keeps the control valve in the neutral position as long as no opposing force is applied to the steering wheel.
  • Page 296: Power Steering Gear Installation

    Section 14: STEERING TROUBLESHOOTING Warning: steering gearbox weighs approximately 100 lbs (45 kg) dry. Exercise Perform troubleshooting of the steering gear as caution when maneuvering. outlined "ZF-SERVOCOM REPAIR 1. Put a container into place, then disconnect MANUAL", "ZF-SERVOCOM Operating, both the inlet and outlet hoses from the power Servicing/Maintenance and Inspection Instructions steering gear.
  • Page 297: Maintenance

    Section 14: STEERING 2. Bleed air from the system as per step 3, "Bleeding Power Steering Hydraulic System". MAINTENANCE Refer to the "ZF-SERVOCOM REPAIR MANUAL" and the "TRW - POWER STEERING PUMP SERVICE MANUAL" annexed to this section. STEERING WHEEL REMOVAL 1.
  • Page 298: Steering Linkage Adjustment

    Section 14: STEERING Caution: Do not drive (hammer in) pitman arm Hydraulic Stop on or off pitman shaft as this can damage the steering gear. Caution: Reduce or shut off the power steering hydraulic pressure before the boss on the axle Caution: Heating of components to aid in touches the stop screw.
  • Page 299: Installation

    Section 14: STEERING 11.2 INSTALLATION 12. MAINTENANCE 1. Position pitman arm on sector gear shaft with power steering system requires little reference marks aligned. maintenance. However, the system should be kept clean to ensure maximum operating per- 2. Install fixing nut (Prévost #661050). Tighten formance and troublefree service.
  • Page 300: Power Steering Reservoir And Filter

    Section 14: STEERING this manual. The intervals given in the schedule 5. Reinsert and tighten the dipstick. are recommended for normal service. More frequent intervals may be required under severe 12.1.2 Filter Replacement operating conditions. 1. Unscrew and remove the cover nut located on 12.1 POWER STEERING RESERVOIR AND top of the power steering reservoir.
  • Page 301: Drag Link

    Section 14: STEERING 13. DRIVING TIPS In order to maximize power steering pump service life, do not attempt to turn the steering wheel when the vehicle is stationary, and especially when service brakes are applied (wheel locking will oppose the effect of steering geometry which tends to make the front wheels rotate in opposite directions).
  • Page 302: Torque Specifications

    Section 14: STEERING 14. TORQUE SPECIFICATIONS FIGURE 10: DRAG LINK COMPONENTS 14054 FIGURE 12: FRONT AXLE COMPONENTS 14055 FIGURE 11: TIE ROD END 14036 PA1217...
  • Page 303 Power Steering Gear Make ..........................ZF-SERVOCOMTRONIC Model ................................8098 Supplier number ..........................8098-988-571 Prevost number ............................661044 F.E.W............................ 16,600 lbs (7 545 kg) Pressure rating ........................2,175 psi (150 Bar) Gear ratio (center) ............................22.2 : 1 Gear ratio (extremities) ..........................26.2 : 1 Minimum pump flow for 1.5 hwt/sec ..................
  • Page 304 Supplier number ............................91410A Prevost number ............................660982 Make ............................... Nelson Muffler Element filter - Supplier number ....................... 83804 E Element filter - Prevost number ........................660987 Steering Stabilizer Cylinder (Damper) Make ................................Arvin Extended length ..........................32.73±0.12" Collapsed length ..........................20.26±0.12"...
  • Page 305 SECTION 16: SUSPENSION CONTENTS DESCRIPTION ............................3 AIR SPRINGS ............................4 ............................4 NSPECTION ............................5 EMOVAL ........................... 5 NSTALLATION SHOCK ABSORBERS .......................... 5 ............................6 NSPECTION ............................6 EMOVAL ........................... 6 NSTALLATION RADIUS RODS ............................7 ............................7 NSPECTION ............................
  • Page 306 Section 16: SUSPENSION TROUBLESHOOTING ........................15 TORQUE SPECIFICATIONS ......................16 PARTS SPECIFICATIONS ......................19 ILLUSTRATIONS ....................3 FIGURE FRONT SUSPENSION COMPONENTS ....................... 3 FIGURE DETAILS OF FRONT SUSPENSION ....................4 FIGURE REAR SUSPENSION COMPONENTS ......................4 FIGURE DETAILS OF REAR SUSPENSION ........................
  • Page 307: Description

    Section 16: SUSPENSION DESCRIPTION The vehicle is provided with an air suspension system. The system consists of air springs, height control valves, radius rods, sway bars, tripod and shock absorbers (Fig. 1, 2, 3, 4 and 5). The system operation is fully automatic and maintains a constant vehicle height regardless of load, or load distribution.
  • Page 308: Air Springs

    Section 16: SUSPENSION FIGURE 3: REAR SUSPENSION COMPONENTS 16003 FIGURE 4: DETAILS OF REAR SUSPENSION 16106 FIGURE 5: TAG AXLE SUSPENSION 16107 AIR SPRINGS The air springs are made from a special compound rubber molded to the proper contour and dimensions. The entire vertical load of the vehicle is supported by these springs.
  • Page 309: Removal

    Section 16: SUSPENSION Visually inspect bellows for evidence of end and fitting to prevent the entry of foreign cracks, punctures, deterioration, or chafing. matter. Replace the bellows if any damage is 5. Remove the air spring upper nut, and then evident.
  • Page 310: Inspection

    Section 16: SUSPENSION each provided with two shock absorbers while 4. Visually check shock for dents that could the drive axle is provided with four of them (Fig. cause the shock to bind. Also, check for a 1, 2, 3, 4 and 5). bent rod.
  • Page 311: Radius Rods

    Section 16: SUSPENSION 2. Install new rubber mounting bushings on shock absorbers (upper and lower). 3. Place the inner washers (with washer convex side facing the shock absorber rubber bushing) on each shock absorber pin (Fig. 8). FIGURE 9: TYPICAL RADIUS ROD SETUP 16010 INSPECTION FIGURE 8: TYPICAL SHOCK ABSORBER SETUP...
  • Page 312: Bushing Installation

    (Fig. 12). rod and discard the bushing. 2. Put 3 drops of Loctite243 (Prevost #680038) in each radius rod support tapped blind BUSHING INSTALLATION holes and a line of Loctite on bolts.
  • Page 313: Sway Bar

    Section 16: SUSPENSION Caution: It is extremely important upon reconnection of the rods that the proper clearance height between the axle and body be maintained. Otherwise, the rubber bushings in radius rod ends will become preloaded, thus reducing their life span. SWAY BAR A sway bar is provided on the front and drive axles to increase vehicle stability.
  • Page 314: Air Line Test

    Section 16: SUSPENSION 1. Visually inspect the suspension air lines for air pressure is at normal operating pressure and evidence of chafing on metal parts or other raise the vehicle to the specified height. damage. Caution: Because of the ‘’deadband’’, always 2.
  • Page 315: Height Control Valves

    Section 16: SUSPENSION 8.1.1 Removal and installation HEIGHT CONTROL VALVES Before disconnecting any height control valve air lines, securely support the vehicle by its jacking points on the body, and place safety support underneath body. Refer to "VEHICLE JACKING POINTS" in Section 18, "Body". 1.
  • Page 316: Front Kneeling System

    Section 16: SUSPENSION overtravel lever to remove any excess water Only the bellows control solenoid valve is which may have entered exhaust valve energized, so the air coming from the kneeling chamber. Remove air line, connect it to the air tank is routed through air control valves, and air inlet port, and repeat operation to remove up to front air springs.
  • Page 317: Principles Of Operation

    Section 16: SUSPENSION 10.1 PRINCIPLES OF OPERATION The rear high-buoy system is added over the front kneeling (with front high-buoy). The front end uses the same valves as the front kneeling (with front high-buoy). A solenoid valve is added to send air to the double shuttle valves for the rear end.
  • Page 318: Disassembly

    This system can be put into service during normal vehicle operation. 11.1 PRINCIPLES OF OPERATION On H3-41 and H3-45 coaches, the rear low-buoy is added over the front kneeling system. The PA1217...
  • Page 319 Section 16: SUSPENSION TROUBLESHOOTING Condition Cause Correction Bellows deflate over time Defective check valve assembly. Replace check valve assembly. Defective exhaust valve assembly. Replace exhaust valve assembly. Leak in air line and/or bellows. Replace air line or bellows. Defective valve cover, rubber O-rings Replace valve cover, O-rings or or gasket.
  • Page 320 Section 16: SUSPENSION TORQUE SPECIFICATIONS TORQUE TABLE REFERENCE 9 TORQUE TABLE TORQUE TABLE REFERENCE 11 REFERENCE 3 TORQUE TABLE TORQUE TABLE REFERENCE 6 REFERENCE 7 TORQUE TABLE REFERENCE 1 TORQUE TABLE REFERENCE 1 TORQUE TABLE REFERENCE 4 TORQUE TABLE REFERENCE 5 FRONT TORQUE TABLE REFERENCE 7...
  • Page 321 Section 16: SUSPENSION TORQUE TABLE TORQUE TABLE REFERENCE 6 REFERENCE 6 TORQUE TABLE TORQUE TABLE REFERENCE 5 REFERENCE 5 FRONT TORQUE TABLE TORQUE TABLE REFERENCE 7 REFERENCE 7 FIGURE 19: TORQUE SPECIFICATIONS – TAG AXLE 16160 TORQUE TABLE REFERENCE 10 TORQUE TABLE REFERENCE 2 FRONT...
  • Page 322 Section 16: SUSPENSION TORQUE TABLE REFERENCE 6 TORQUE TABLE REFERENCE 8 TORQUE TABLE REFERENCE 6 FRONT TORQUE TABLE TORQUE TABLE REFERENCE 8 REFERENCE 6 FIGURE 21: TORQUE SPECIFICATIONS – REAR SUBFRAME 16162 TORQUE TABLE REFERENCE 3 TORQUE TABLE TORQUE TABLE REFERENCE 1 REFERENCE 11 TORQUE TABLE...
  • Page 323 (2 front axle air springs) 20-25 27-34 Note: During assembly, use “Loctite 242” (Prevost No 680038) with item 5 and 19. After assembly, apply “anti-seize compound” (Prevost No 680064) on all threads nuts. PARTS SPECIFICATIONS Front and tag axle air springs Make ......
  • Page 324 Color ............Black Type ..........N45X225HA Ext. Diam..........75 mm Collapsed length ....... 15.51” (394 mm) Extended length ....... 24.37” (619 mm) Prevost number ........630252 Drive and tag axle shock absorbers Make ............Sachs Color ............Black Type ..........N45X225HA Ext.
  • Page 325 Section 16: SUSPENSION Type ............. N/O Prevost number ........641356 Radius rod bushing Make ............Prevost Prevost number ........630021 Loctite Make ............Loctite Prevost number ........680039 Sway bar bushing (Front Axle) Make ............Prevost Prevost number ........131355 Sway bar bushing (Drive Axle) Make ............
  • Page 326 SECTION 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) CONTENTS INTRODUCTION ............................ 4 STEERING LINKAGE ..........................4 ....................7 OWER TEERING YDRAULIC ....................... 7 TEERING INKAGE DJUSTMENT ........................7 ITMAN EMOVAL ........................ 7 ITMAN NSTALLATION ............................8 DRAG LINK 2.5.1 Adjustment ..........................
  • Page 327 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) ............................19 EMOVAL ..........................19 NSTALLATION SHOCK ABSORBERS ......................... 20 ......................20 HOCK BSORBER EMOVAL ..................... 21 HOCK BSORBER NSTALLATION SWAY BAR ............................21 10.1 ............................21 EMOVAL INDEPENDENT FRONT SUSPENSION ADJUSTMENT ..............23 SUSPENSION HEIGHT ADJUSTMENT ...................
  • Page 328 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) ILLUSTRATIONS ....................4 IGURE SUSPENSION AND STEERING LINKAGE ........................5 IGURE LOCATION OF CLAMPS ........................6 IGURE TORQUE SPECIFICATIONS ........................6 IGURE TORQUE SPECIFICATIONS ........................6 IGURE TORQUE SPECIFICATIONS ........................6 IGURE TORQUE SPECIFICATIONS .........................
  • Page 329: Independent Front Suspension (Ifs)

    This supplement contains service procedures mounted to the steering gear, transfers the and specifications that apply to the PREVOST turning motion of the steering wheel to the VIP coach shell vehicles equipped with an steering arms.
  • Page 330 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) Turning Angle To check steering maximum turning angle, proceed with the following method: The maximum turning angle is set mechanically through the two steering stop screws installed on 1. Check if front tires rub against the frame or if the swivel assembly.
  • Page 331 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 5: TORQUE SPECIFICATIONS FIGURE 6: TORQUE SPECIFICATIONS 16149 FIGURE 3: TORQUE SPECIFICATIONS FIGURE 7: CLAMP POSITIONING 16150 FIGURE 4: TORQUE SPECIFICATIONS 16152 FIGURE 8: TORQUE SPECIFICATIONS 16151 PA1217...
  • Page 332: Power Steering Hydraulic Pump

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) Warning: POWER STEERING HYDRAULIC PUMP Always wear approved eye protection when operating pullers. Refer to the "TRW Power Steering Pump Service Manual" annexed at the end of Section Caution: Do not drive pitman arm on or off pitman shaft as this can damage the steering gear.
  • Page 333: Drag Link

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) rod aligned with centerline of vehicle, loosen clamp bolt at socket end (bell crank end) of drag link and adjust length of socket end assembly to fit in boss of bell crank. Note: Do not change position of pitman arm.
  • Page 334: Bell Crank Or Idler Arm Ball Joint Disassembly

    Note: installation. For bearing installation use tool Prevost # 110684. 4. Unscrew nut until bell crank or idler arm starts to turn by the application of 1 to 3 1. Install backup ring on bell crank or idler arm pounds load (Fig.
  • Page 335: Relay Rod

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) paragraph "2.10 Lubrication Fittings" in this supplement. Note: The relay rod is crimped in place and it is not possible to remove the ball joints. 2.7.1 Replacement 1. Remove cotter pins from bell crank and idler arm end of relay rod.
  • Page 336: Installation

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) 2. Torque steering arm to steering knuckle left steering arm (or idler arm) and right fixing bolts. Torque short bolt (M20 X 65) to steering arm. 520-575 lbf-ft (705-780 Nm). Torque long 2.
  • Page 337 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) the crank bell, every 6,250 miles (10 000 relief valve nearby, every 6,250 miles (10 km) with good quality lithium-base grease 000 km) with good quality lithium-base NLGI No. 2 (Shell Retinax LX or equivalent). grease NLGI No.
  • Page 338: Ball Joints

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) BALL JOINTS FIGURE 17: BALL JOINTS LOCATION -Free play; LOWER AND UPPER A-ARM BALL JOINT -Radial cracking of the external sheet-metal The assembly work may be done only by a race. recognized specialized workshop.
  • Page 339: Lower A- Arm Central Ball Joint

    Note: Apply grease, only in the case of repair kit (Prevost # 611114)). 2. Insert ball pin/bushing assembly. In case of the two-bolt type, ensure that the bolt bores are in the correct position in relation to the axis of the tube.
  • Page 340: Upper A-Arm Central Ball Joint

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) side of the housing shaft axis (retaining ring two dimensions is greater than 0.060" eyelet lug points to tube), and that retaining (1.5mm), then the ball joint should be re- ring is properly engaged in the groove of the placed.
  • Page 341: Terminology

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 23: STEERING LINKAGE MEASURE 16050 FRONT END INSPECTION ALIGNMENT TERMINOLOGY Before checking front end alignment, make the Wheel Camber following inspection: The amount the wheels are inclined from the 1. Check that the vehicle is at normal ride vertical plane (A, Fig.
  • Page 342: Front Wheel Camber

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) 3. Place the wheels in the straight ahead FRONT WHEEL CAMBER position and lower the vehicle to rest on the Positive camber is the outward inclination of the floor. wheels at the top, negative or reverse camber is the inward inclination of the wheels at the top.
  • Page 343 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 24: FRONT END ALIGNMENT DIAGRAM 16051 ALIGNMENT SPECS (See Figure 23) Minimal Nominal Maximal Load Non- Converted Non- Converted Non- Converted converted converted converted WHEEL CAMBER -0.150 0.35 0.55 0.200 KING PIN INCLINATION 8°...
  • Page 344: Front Air Springs

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) Warning: To prevent personal injury, do not FRONT AIR SPRINGS apply more than 10 psi (69 kPa) air pressure to Two "rolling lobe" type air springs are used with the unmounted air spring. the independent front suspension, one at each REMOVAL wheel.
  • Page 345: Shock Absorbers

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 26: AIR SPRING AND SHOCK ABSORBER 16145 on lower side. Shock absorbers are non- 1. Compress air spring as necessary, then adjustable and non-repairable. aligning studs with their holes, position air spring between both the lower and upper supports.
  • Page 346: Shock Absorber Installation

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) the hole in the mounting bracket and the shock absorber eyes over the mounting pins. Install the outer washer. 6. Place a rubber joint and washer on the shock absorber mounting stud. Place the lower shock absorber mounting stud nut and torque to 60-75 lbf-ft dry (81–102 Nm).
  • Page 347 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 28: SWAY BAR (FRONT SUSPENSION) 16138 PA1217...
  • Page 348: Independent Front Suspension Adjustment

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) 11. INDEPENDENT FRONT SUSPENSION Immediate response height control valves increase or decrease the air pressure in the ADJUSTMENT suspension system as required. One height VIP coach shells are equipped with "LEVEL- control valve is located at center of front sway LOW"...
  • Page 349: Height Control Valve

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) 2. Loosen the clamp on the height control valve rubber coupling and bring it up or down (Fig. 32). Note: Allow suspension to stabilize before taking reading. When the desired height is obtained, tighten clamp.
  • Page 350: Level-Low" Leveling System

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) 1. Exhaust air from air system by opening all DRIVE: air tank drain cocks. Remove height control When the ignition key is turned to the "ON" posi- valves. tion with selector knob in the "DRIVE" position, 2.
  • Page 351: Air Tank Maintenance

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 32: LOCATION OF AIR TANKS 12195 15.1 AIR TANK MAINTENANCE Ensure that the accessory air tank is purged during pre-starting inspection. A good practice is to purge this tank at the end of every driving day by the remote air tank drain valve located in the steering compartment (Fig.
  • Page 352: Accessory Air Tank

    Caution: Air filled through these two points will pass through the standard air filtering system provided by Prevost. Do not fill air through any other points. 16. HUB UNIT AND SWIVEL ASSEMBLY Refer to “DANA SPICER Service Manual General Information, Maintenance Manual Model NDS and Maintenance Manual NDS Axles”...
  • Page 353: Torque Table

    Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) 17. TORQUE TABLE TORQUE (DRY) DESCRIPTION REFERENCE lbf-ft / Nm Upper A-Arm Central Ball Joint (Castellated Hex Nut)* 310-340 420-461 Upper A-Arm Ball Joint 230-255 312- 346 Lower A-Arm Central Ball Joint (Castellated Nut)* 490-540 664- 732 Lower A-Arm Ball Joint...
  • Page 354 Section 16: VIP EQUIPPED WITH INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 35: TORQUE SPECIFICATIONS PA1217...
  • Page 355: Specifications

    Supplier number ........................481700000208 Prevost number ............................. 630251 Height Control Valve Make ..............................Barksdale Supplier number ................52321POAQ3-Q26 and 52321POAQ3-Q62 Prevost number ......................... 630156 and 630157 Steering Gear Box Make ............................ZF-Servocom Supplier number ......................... 8098-988-570 Prevost number ............................. 661045 Steering Gear Box (Optional) Make ...........................
  • Page 356 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR ..........................6 STRUCTURE ............................9 ............................9 ELDING EXTERIOR MAINTENANCE ......................... 9 ......................... 9 ORROSION REVENTION ....................9 PREVENTIVE MAINTENANCE SCHEDULE ......................10 RUST INHIBITOR APPLICATION FIBERGLASS REPAIR ........................15 ....................15 EPAIR SING IBERGLASS LOTH ....................
  • Page 357 Section 18: BODY ....................26 INDOW OR EGULATOR REMOVAL ................... 27 INDOW OR REGULATOR INSTALLATION ROOF ESCAPE HATCH ........................27 10.1 ............................27 EPAIR 10.2 ............................28 EALING 10.3 ....................28 SCAPE ATCH ANEL SSEMBLY 10.4 ........................28 SCAPE HATCH FRAME REPAIR OR REPLACEMENT OF “TARABUS”...
  • Page 358 Section 18: BODY 20.1 ......................54 NGINE DJUSTMENT 20.2 ................... 54 INOR EPTH DJUSTMENT 20.3 : ..................54 INOR OWER EPTH DJUSTMENT ENGINE AIR INTAKE GRILL ......................55 RADIATOR DOOR ADJUSTMENT ....................55 22.1 ......................55 EIGHT DJUSTMENT 22.2 ......................55 ATERAL DJUSTMENT 22.3...
  • Page 359 Section 18: BODY ILLUSTRATIONS 3-45 ........................6 IGURE EXTERIOR VIEW 3-41 ........................7 IGURE EXTERIOR VIEW ) .................. 8 IGURE VIP CONVERTED VEHICLE EXTERIOR TYPICAL ........................16 IGURE FIBERGLASS REPAIR ........................16 IGURE FIBERGLASS REPAIR ........................16 IGURE FIBERGLASS REPAIR ........................
  • Page 360 Section 18: BODY ....................52 IGURE BAGGAGE COMPARTMENT DOOR ....................53 IGURE BAGGAGE COMPARTMENT DOOR ....................53 IGURE BAGGAGE COMPARTMENT DOOR ....................53 IGURE BAGGAGE COMPARTMENT DOOR ....................53 IGURE BAGGAGE COMPARTMENT DOOR ....................53 IGURE BAGGAGE COMPARTMENT DOOR ..................... 54 IGURE ENGINE COMPARTMENT DOOR ..........................
  • Page 361 Section 18: BODY 1. VEHICLE EXTERIOR FIGURE 1: H3-45 EXTERIOR VIEW 18590 1. Engine air intake 12. Engine compartment rear door 2. Engine compartment R.H. side door 13. Rear-view mirrors 3. Main power compartment 14. Reclining bumper compartment 4. Wheelchair lift door (option Ricon) 15.
  • Page 362 Section 18: BODY FIGURE 2: H3-41 EXTERIOR VIEW 18591 1. Engine air intake 11. Engine compartment rear door 2. Engine compartment R.H. side door 12. Rear-view mirrors 3. Main power compartment 13. Reclining bumper compartment 4. Baggage compartment 14. Front electrical & service compartment 5.
  • Page 363 Section 18: BODY FIGURE 3: VIP CONVERTED VEHICLE EXTERIOR (TYPICAL) 18650 1. Engine air intake 10. Rear-view mirrors 2. Engine R.H. side access door 11. Reclining bumper compartment 3. Main power compartment 12. Front electrical and service compartment 4. Baggage compartment 13.
  • Page 364 CORROSION PREVENTION 2. STRUCTURE Preventive maintenance is a key factor in The body of the H3-41, H3-45 and VIP vehicles avoiding corrosion and must be considered as is an integral structure made of 14, 16 and 18 part of the regular service intervals. The entire...
  • Page 365 Section 18: BODY INTERVALS DESCRIPTION MAINTENANCE CORRECTIVE REFERENCE MONTH ACTION MILES BODY, EXTERNAL 40 000 VISUALLY INSPECT SEALING REPAIR OR REPLACE WINDOW FRAME 25 000 BEADS CONDITION SEALING BEADS IF NECESSARY VEHICLE 100 000 PRESSURE APPLY UNDERBODY 60 000 SPRAY TO CLEAN UNDER- UNDERCOATING STRUCTURE AND VISUALLY LOCALLY AS...
  • Page 366 Section 18: BODY 3.0 Front wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking. 3.1 Front wheelhousing Front view 3.2 Front wheelhousing PA1561...
  • Page 367 Section 18: BODY 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) 4.1 Rear wheelhousing (Entire braking system) PA1561...
  • Page 368 Section 18: BODY 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used. 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts.
  • Page 369 Section 18: BODY DEW POINT Relative Humidity (%) Temp (c) PA1561...
  • Page 370 Section 18: BODY Caution: Temperature should not exceed 4. FIBERGLASS REPAIR F (60 C) during 30 minutes in order to All repairs to fiberglass parts consist of filling the avoid distortion. damaged area with fiberglass cloth and resin or Cut fiberglass cloth with scissors or tin snips, 1 strand fiberglass and resin.
  • Page 371 Section 18: BODY A hacksaw blade, held flat to adjacent contour Apply another mat, followed by a cloth patch, and then moved in a sawing action across the and another mat. All layers must be thoroughly repair when the resin is in a gel state, will impregnated with polyester resin, brushed well remove excess resin from repair.
  • Page 372 5. PAINTING for color codes and paint brand. NEW PAINT CARE Prevost recommends using the original paint brand to ease color matching. Our paint supplier recommends that you follow these simple precautions the first months of your In the event you sand through to the gelcoat new vehicle’s life.
  • Page 373 Section 18: BODY 5.3.2 Surface Preparation and Paint Application Aluminum and / or Fiberglass Comments Stainless Steel Sand using P-150 grit sandpaper. Sand using P-180 or Do not use paint remover It is recommended to sandblast Surface Preparation P-240 sandpaper. over aluminum or fiberglass.
  • Page 374 Repeat procedure for the other spring. Note: A special tool kit is available from Prevost Car Inc: Kit # 410671 including tool #410708. 2. Remove 4 cap screws holding bumper to vehicle and remove bumper (Fig. 10).
  • Page 375 Section 18: BODY when the door control system does not function properly. Refer to the air system schematic diagram annexed at the end of section 12, “Brakes” and to page 22 of the wiring diagram. OPERATION The air-operated door is controlled from inside the coach by two push-button switches located on the R.H.
  • Page 376 Section 18: BODY To adjust opening and closing cycle speed on damper (Fig. 15): 1. Remove the damper from the vehicle and hold it vertically with the lower eye or pin attachment in a vice. Use clamp plates to prevent damage. 2.
  • Page 377 Section 18: BODY 5. Pull the damper out vertically without turning 3. Support the door with a wooden block and a for at least 3/8” (1cm) to disengage the hydraulic jack. adjusting mechanism. The dust cap or 4. Loosen the horizontal bolts retaining the piston rod may now be turned freely.
  • Page 378 Section 18: BODY 3. Remove the Allen button head screw and 6. Pull and fasten the rod end to the hinge with the washer retaining the rod end with the washer and the button screw. bearing to upper hinge. See figure 18. 7.
  • Page 379 Section 18: BODY SYMPTOM PROBABLE CAUSE REMEDY Module relay does not receive electric Reset breaker "ON" or check batteries current. power supply. Check voltage at door opening solenoid. Door opening solenoid does If the voltage is 24 volts then replace it. receive current.
  • Page 380 Section 18: BODY To adjust door depth on lock side: 8.2.1 Horizontal and Vertical Adjustments 1. Remove the screws and the plastic molding Depth adjustment is done by moving the two covering each of the hinges. door strikers. 1. Slightly loosen the door strikers. Note: Ask an assistant to help you to perform the following adjustments.
  • Page 381 Lubricant Frequency on it to get a good adhesion on the fiber- glass. Latches 10. Apply Sika #252 (Prevost #682462) temperature Every six months Upper door grease compound where it was previously applied. catch 11. Remove protective paper from the adhesive...
  • Page 382 Section 18: BODY 2. Set the battery master switch to the OFF 4. Fasten window support to actuator using the position. recovered bolts (item 1). Use Loctite on threads. 3. The window must be held in upper position. To do so, use duct tape to hold it in place. 5.
  • Page 383 Seal joint should be toward rear of 6. Clean both vehicle top and new hatch frame vehicle. with SIKA 205. 3. Apply rubber adhesive CA-40 (Prevost # 7. Apply rubber adhesive SIKA 221 under the 681285) in the gap between the seal ends. hatch frame surface.
  • Page 384 Section 18: BODY 11. REPAIR OR REPLACEMENT OF “TARABUS” FLOOR COVERING “Tarabus” covering installed in H3 coaches may be replaced or repaired. The purpose of this paragraph is to explain the steps to be followed to ensure the best results and adherence. MATERIAL Part No Description...
  • Page 385 Section 18: BODY FIGURE 25: TARABUS FLOOR COVERING ADHESIVE APPLICATION FIGURE 26: APPLICATION OF SIKA 221 GRAY PA1561...
  • Page 386 Section 18: BODY 11.1 FRONT STEPS REPLACEMENT PROCEDURE MATERIAL Part No Description 682989 Anti-silicone 683097 Sika 205 (1 liter) 685101 Sika Remover 208 683916 Sika 215 (1 liter) 684654 Adhesive, Contact (3M) 3.8L 684655 Adhesive, Contact (3M) 18.9L 684517 Sealant, gray 1.
  • Page 387 Section 18: BODY Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) Before applying any other If surface seems dusty, dust using damp cloth.
  • Page 388 Section 18: BODY GLUING OF WHITE SAFETY STRIP BETWEEN STEP AND “TARABUS” FLOOR COVERING 1. Sand fiberglass using “Scotchbrite”. 2. Clean using tack cloth. 3. Clean twice using anti-silicone (refer to Section A). 4. Protect surfaces around the step with masking tape. 5.
  • Page 389 Section 18: BODY Note: Keep a gap of 1 to 1.5 mm between “Tarabus” covering and white safety strip. 7. Remove masking tape. 11.2 WELDING OF JOINT BETWEEN WHITE SAFETY STRIP AND “TARABUS” FLOOR COVERING 1. Pre-heat welding torch; Set welding torch to position #4.5 (temperature of 500 °C), Heating time: 5 minutes.
  • Page 390 Section 18: BODY 5. Add (about 6 inches) some length to the required length of filler bead to make the joint then cut. 6. Take position with welding torch. The proper position is with a slight slope to the rear. 7.
  • Page 391 Section 18: BODY 10. Shave filler bead to make it level to the floor. Use supplied knife designed for that purpose. Note: To facilitate the cut, you can spray some soapy water onto the joint. Caution: The procedure for turning the torch off must absolutely be followed. If this step is not taken, the element may burn.
  • Page 392 12. PASSENGER SEATS manually, while the window armrest is fixed. H3-41 and H3-45 coaches can be equipped with any of 2 basic seat models and installed in a 12.1 ROTATING SEATS variety of seating arrangements: 1.
  • Page 393 Section 18: BODY 2. Lift front part of cushions and remove 12.3 UPHOLSTERY MAINTENANCE cushions. Coach seats are lightweight, with foam-padded 3. Remove 4 finishing screws holding plastic backs and cushions. For both appearance and cover between side wall and seat frame. wearability, best results...
  • Page 394 Seven passenger side windows are provided on pushing out the window frame (Fig. 31). each side on H3-41, while the H3-45 has eight. Emergency operating instruction decals are They are made of fixed, single or double-glazed, affixed under each emergency exit window.
  • Page 395 Section 18: BODY FIGURE 31: EMERGENCY EXIT WINDOW 18391 13.2.1 Emergency Exit Window Adjustment Emergency exit windows should be checked periodically for easy opening and closing. Pulling the lower part of the release bar with both hands placed near the safety latches should disengage both locks on the window simultaneously.
  • Page 396 Note where adhesives are used and apply • Masking tape; gluing techniques at these areas to complete • Tremshield tape (Prevost #681089); replacement of these windows. • Chix cloths (Prevost #682384); • Isopropyl alcohol or enamel reducer or NAPA 13.6...
  • Page 397 Section 18: BODY 7. Install Tremshield tape around the sealing Note: Use small shims to raise the glass in surface of the window opening. proper position. Shims can be cut from the tremshield tape (Fig. 35). FIGURE 35: ADHESIVE-MOUNTED WINDOW 18079 3.
  • Page 398 Section 18: BODY the state open or close of the master switch. 14.2 WINDOW REMOVAL However, the circuit is protected with fuse F41 Replacement awning window does not include a (10A) located in the front service compartment. new motor. If in working order, transfer the motor of the replaced window to the replacement 14.1 OPERATION...
  • Page 399 Section 18: BODY Actuators Horizontal latch handle Latch guide Proximity sensor Relay Guide Roller Swivelling arm Window pane Window ajar sensor Motor support Releasing bar Releasing bar Guide roller FIGURE 39: ELECTRIC AWNING WINDOW EXPLODED VIEW (SASH) 18583 4. Loosen the set screws #5 (rotate the arm to 14.3 ACTUATOR REPLACEMENT get to the second set screw) and disengage...
  • Page 400 The windshield is single-glazed AS-1 laminated installing a replacement windshield obtained safety glass. Each windshield side is laced to a from Prevost Parts to ensure proper fit. flange around an opening in the front structure Windshields obtained from other sources should by means of a one-piece black rubber extrusion be checked for proper size and curvature.
  • Page 401 For more information on windshield lifts the rubber lip from the vehicle exterior removal or installation, a video is available from using a plastic spatula from top to bottom. Prevost Parts Inc. 5. Remove the entire damaged windshield and 15.1 REMOVAL broken glass if applicable.
  • Page 402 Section 18: BODY 10. Using the special filler insertion tool, insert Note: Make sure windshield bottom edge is well the filler into the bottom rubber extrusion inserted into the rubber extrusion groove before groove. Gradually insert filler ensuring to proceeding with the sides. leave a 2 inch excess length at the filler 5.
  • Page 403 Section 18: BODY FIGURE 45: BODY PANEL SPACING 18496 17. WHEELCHAIR LIFT ACCESS DOOR 17.1 INSTALLATION Caution: Install the sliding door onto a suitable lifting device that will allow proper lifting and positioning. 1. Lift and move the sliding door near the opening. 2.
  • Page 404 Section 18: BODY FIGURE 47: WCL UPPER ARM AND RAIL 3. Pull the door in or push from the outside to adjust the door with reference to the vehicle outside surface. 4. - Unfasten the upper arm bolt located on the door side. - Position the top rail at 3mm from the ceiling bracket.
  • Page 405 Section 18: BODY 9. Adjust the distance between the bottom of the guide and the roller when the door is completely open. Required distance: 2 – 3mm. Make sure the roller stay in contact with the guide. 10. Install and adjust strikers. Torque to 60 Lb-ft (Refer to figure 46). Note: Make sure that a 2mm gap exists between the door structure and the striker.
  • Page 406 FIGURE 50: BAGGAGE COMPARTMENT DOOR 18061 There are 6 pantograph doors serving as baggage compartment doors on the H3-41, while there are 8 on the H3-45 and the V.I.P (depending on options, VIP model may have even more pantograph doors). Each of these doors is of identical design.
  • Page 407 Section 18: BODY 4. Pull down on the opposite side of the door to bend the door around the pantograph arm pivot (prevented from moving by the 2x4). 5. When the door is straight, remove the 2x4’s and check door operation and fit. A differ- ence of 3/32”...
  • Page 408 Section 18: BODY FIGURE 58: BAGGAGE COMPARTMENT DOOR 18069 7. With door shut, it should have a gap of 3/8” ± 5/64” (10mm ± 2mm) between door panel lip (at level of upper edge of lower section) and structural post. If not, move pins hori- FIGURE 56: BAGGAGE COMPARTMENT DOOR 18067 zontally until correct gap is obtained.
  • Page 409 20.2 MINOR TOP EDGE DEPTH gas-charged cylinders (Prevost # 980024). The ADJUSTMENT engine compartment opens by lifting a handle accessed from the R.H. side of the engine Two rubber spring loaded stops may be compartment.
  • Page 410 Section 18: BODY 7. Firmly tighten the striker pins (2) to lock them in position. 21. ENGINE AIR INTAKE GRILL When needed, the engine air intake grill can be changed: 1. Cut the seal around the grill with a sharp edged knife.
  • Page 411 Section 18: BODY FIGURE 66: PROPER DOOR POSITIONING 22.3 DOOR DEPTH ADJUSTMENT 1. Close radiator door. 2. Check parallelism between radiator door and rear fender (max. 0 ± 2 mm). FIGURE 69: DOOR LATCHES ADJUSTMENT 23. CONDENSER DOOR ADJUSTMENT 1. Open the condenser door. 2.
  • Page 412 Section 18: BODY FIGURE 70: CONDENSER DOOR D280201 2. Loosen nut (2, Fig. 72). 24. FUEL FILLER DOOR 3. Move part (1, Fig. 72), as close as possible 1. Open the fuel filler door (1, Fig. 71). to exterior of coach, so as to have enough 2.
  • Page 413 Section 18: BODY SECTION 8 ± 2 mm SECTION FIGURE 73: FRONT SERVICE DOOR 18195 REF .: 9,5 ± 2 mm 25.1 LATCH MECHANISM ADJUSTMENT FIGURE 72: DOOR HINGE 18194 To adjust the latch mechanism and the striker 7. Loosen screws (5, Fig. 73) to allow the door pin, open the door to access the striker pin.
  • Page 414 Section 18: BODY 7. Adjust the door in accordance with the Slightly loosen the striker pin. Using a hammer, required distance between exterior finishing adjust the striker pin to center it in the door latch parts (Fig. 45). mechanism. Tighten the striker pin. Check door fit and operation.
  • Page 415 Section 18: BODY 41,2 ± 41 ± 2 mm 8 ± 2 mm FIGURE 76: EVAPORATOR DOOR 18198 6. Adjust door panel to have the same gap 28. MAIN POWER COMPARTMENT space as neighboring panels or refer to To adjust the main power compartment door: figure 45 for specified gap space 1.
  • Page 416 31. FRONT CAP The front cap windshield frame does not need any maintenance. It is held in place with bolts and nuts. If it ever it has to be replaced, make an appointment at a Prevost service center near you. PA1561...
  • Page 417 Section 18: BODY 32. SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP Material: Scotchbrite gray (680226) Sika 206 G+P 1 liter (683446) √ √ Anti-silicone (682989) √ Tack cloth √ CHIX cloth (682384) √ Blue cloth (682383) Sika 252 black √...
  • Page 418 Section 18: BODY Clean using tack cloth. Repeat if surface seems dusty. Clean using anti-silicone See PR000001 section A. Apply primer 206 G+P. See PR000001 section D. PR000001 Section D Sika Primer 206 G+P Shake bottle to mix product Apply a thin layer CHIX cloth Allow to dry Minimum time : 10 minutes...
  • Page 419 Section 18: BODY 1.15 Seal entrance door perimeter using Sika 252 black, Smooth down the excess. Install lateral panel supports onto bottom 1.20 structural tubing. Install lateral panel onto supports to verify proper positioning. 1.25 Glue application Set (timer) or record time. ...
  • Page 420 Section 18: BODY Gap between lateral panel and rear cap must be 6mm +4/-3 and panels must be aligned within 1.5mm. Using a ruler, adjust front of lateral panel.  Verify if panel upper corner is in the middle of window post. 1.55 Remove excess of glue using a spatula.
  • Page 421 Section 18: BODY SECTION #2 DRIP MOLDING INSTALLATION 2.00 * A) Clean using Anti-silicone See PR000001 section A. Apply Sika 206 G+P See PR000001 section D. 2.05 Remove blue paper from drip molding. Remove protective tape from double- face self adhesive tape 2.10 Glue drip molding.
  • Page 422 Section 18: BODY Insert the ball stem into the mirror arm and 33. REAR VIEW MIRRORS (RAMCO) tighten the socket setscrews. Your vehicle is equipped with two exterior Note: Position the ball cup halves so the joint mirrors. between them lies on the centerline of the arm. The mirrors may be equipped with an optional Ensure that the setscrews are not on the joint electric heating system which serves to minimize...
  • Page 423 Section 18: BODY Warning: 33.5.2 Disassembly When it is necessary to raise the vehicle, care should be taken to ensure that At end of mirror arm, loosen the setscrews to pressure is applied only at the points indicated in relieve tension on the ball stud. Remove the ball figures 79, 80, 81 and 82.
  • Page 424 Section 18: BODY • Make sure the parking brake is released before towing. • Do not allow passengers to ride onboard the towed vehicle. • Tow the vehicle at a safe speed as dictated by road and weather conditions. • Accelerate decelerate slowly cautiously.
  • Page 425 Section 18: BODY sure must be a minimum of 75 psi (520 3. Position the tow truck so that the tow bar kPa), and the line should be attached to the contacts the front bumper of the vehicle. air line with a clip-on chuck. 4.
  • Page 426 36. SPECIFICATIONS Door cylinder Manufacturer ................................Bimba Type ................................Pneumatic I.D................................... 1½" ( mm) Stroke ................................. 8" ( mm) Prevost number ..............................780595 Damper Manufacturer ................................Koni Prevost number ..............................780565 Lock cylinder (upper) Manufacturer ................................Bimba Type ....................... Air, single action, 1/8 NPT, hexagonal rod I.D.
  • Page 427 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING ....................5 AIR CIRCULATION WITH CENTRAL HVAC SYSTEM ................ 5 DRIVER’S AREA ..........................5 2.1.1 Coaches only ........................... 5 2.1.2 VIP only ........................... 5 PASSENGER’S (CABIN) AREA...................... 5 AIR CIRCULATION WITH SMALL HVAC SYSTEM................7 AUXILIARY UNIT ..........................
  • Page 428 Section 22: HEATING AND AIR CONDITIONING 9.1.4 Longitudinal Compressor Alignment ..................23 9.1.5 Horizontal Compressor Alignment ..................23 9.1.6 Vertical Compressor Alignment ..................... 23 9.1.7 Compressor Maintenance ..................... 23 9.1.8 Troubleshooting Guide ......................24 MAGNETIC CLUTCH ........................25 9.2.1 HVAC Control Unit and Clutch Operation ................25 EVAPORATOR MOTOR.......................
  • Page 429 Section 22: HEATING AND AIR CONDITIONING 10.11 LEAK TEST PROCEDURE WITH COMPRESSOR REMOVED ..........43 10.12 TIGHTENING TORQUES ......................44 HEATING SYSTEM ......................... 47 11.1 SMALL HVAC SYSTEM ........................ 48 11.2 CENTRAL HVAC SYSTEM ......................48 11.3 DRAINING HEATING SYSTEM ....................48 11.3.1 Draining Driver’s Unit Heater Core ..................
  • Page 430 Section 22: HEATING AND AIR CONDITIONING ’ ) ......... 10 IGURE PASSENGER S UNIT EVAPORATOR COIL VIP WITH CENTRAL HVAC SYSTEM ONLY ’ ....................10 IGURE PASSENGER S UNIT CONDENSER COIL ) ................11 IGURE H CONSOLE AIR FILTER ACCESS GRILL COACHES ) ..................
  • Page 431: Heating And Air Conditioning

    Section 22: HEATING AND AIR CONDITIONING defogger/defroster system in the windshield HEATING AND AIR CONDITIONING upper-section, refer to paragraph: “Central The coach’s interior is pressurized by its Heating System” for more information. Heating, Ventilation, Air Conditioning (HVAC) system. Air flow and controls divide the vehicle in 2.1.2 VIP only two areas: driver’s area and passenger’s (cabin)
  • Page 432 Section 22: HEATING AND AIR CONDITIONING FIGURE 2: CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION (COACH) 22264 PA1217...
  • Page 433: Air Circulation With Small Hvac System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 4: CONTROL UNIT - SMALL HVAC SYST. 22286 AUXILIARY UNIT OPERATION The temperature control is provided by the small system HVAC control unit. The R.H. portion of the HVAC control unit enables to actuate the FIGURE 3: OVERHEAD COMPARTMENT VENTILATION Auxiliary Unit and to regulate the fan speed.
  • Page 434: Passenger's Unit

    Section 22: HEATING AND AIR CONDITIONING 1. The outside temperature is above 32°F 21371 (0°C). 16120 12261 The passenger's area temperature has 9399 reached 7°F (4°C) under the set point. 7263 5658 NOTE 4441 3511 Upon starting, if the outside temperature is 2795 above 32 °F (0°C) and then drops below...
  • Page 435: Overhead Compartment Unit

    Section 22: HEATING AND AIR CONDITIONING main power compartment (refer to Section 06, “Electrical System” in this manual for details). The condenser coil mounted on the opposite side of the evaporator is ventilated by two axial fans. The fan motors are protected by a manually-resettable 40 amp circuit breaker (CB 12) and a 70 amp circuit breaker (CB 7) mounted in the main power compartment on rear...
  • Page 436: Coil Cleaning

    Section 22: HEATING AND AIR CONDITIONING exception of cleaning their respective coil air filters. NOTE Squeeze rubber hose located under the concerned compartment, to eliminate water and dirt when you make routine maintenance. COIL CLEANING Check the external surface of the coil at regular intervals for dirt or any foreign matter.
  • Page 437: Passenger's Unit Air Filter

    Section 22: HEATING AND AIR CONDITIONING damaging filter. CAUTION sure reverse filter upon installation. FIGURE 12: R.H CONSOLE AIR FILTER ACCESS GRILL (COACHES) 18505 FIGURE 15: PASSENGER’S UNIT AIR FILTER 22100 OVERHEAD COMPARTMENTS FAN AIR FILTER FIGURE 13: R.H. CONSOLE AIR FILTER ACCESS GRILL Air conditioning evaporator coils may be installed (VIP) 22232...
  • Page 438: Hvac System And Test Mode For Switches And Sensors

    Section 22: HEATING AND AIR CONDITIONING diagrams to get a complete understanding of the This feature allows verification of the pump when HVAC components circuitry, read inside a garage. This is also useful when understand section 06:ELECTRICAL of this working on the heating system to remove air manual under "Troubleshooting And Testing The pockets trapped in the system.
  • Page 439: Hvac System Troubleshooting

    Section 22: HEATING AND AIR CONDITIONING 2 right compressor cylinders: Stop if: Passenger's area temperature is at less than 0.2°C above the set point or if the compressor input falls below 23 psi. Restart if: Passenger's area temperature is 0.7°C or more above the set point and the compressor input pressure is above 32 psi.
  • Page 440: Central Hvac System - Air Conditioning

    Section 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions Seized bearing Brush problem Bad wiring Defroster fan is functioning Module A46 is not powered or is Check the SYSTEM DIAGNOSTIC menu but no heat or cooling faulty of the message center display (MCD). available in the driver area Select FAULT...
  • Page 441: Refrigerant

    Section 22: HEATING AND AIR CONDITIONING tubes of the condenser causing the hot, high 8.2.1 Procurement pressure gas to be condensed into a liquid Refrigerant is shipped and stored in metal form. cylinders. It is serviced in 30 and 100 pound The liquid refrigerant flows to the receiver (13,6 and 45 kg) cylinders.
  • Page 442: Precautions In Handling Refrigerant

    Section 22: HEATING AND AIR CONDITIONING The use of the proper wrenches when which accidentally escape making connections on O-ring fittings is approximately -40 F (-40 C). If refrigerant important. The use of improper wrenches comes in contact with the eyes, serious may damage the connection.
  • Page 443: Clean-Out After Minor Compressor Failure

    Section 22: HEATING AND AIR CONDITIONING limited to the compressor with little or no system Valve), solenoid valves, check valves, and any other mechanical component that may contamination. A major failure, or burnout, have collected contaminants. results in extensive system contamination as well as compressor damage.
  • Page 444 Section 22: HEATING AND AIR CONDITIONING and female housings of connector C24 are kept unplugged. They are connected only for refrigerant refilling pumping down procedure. Procedure 1. Open the solenoid valves by connecting both male and female connector housing of C24 together.
  • Page 445: Adding Refrigerant (Vapor State)

    Section 22: HEATING AND AIR CONDITIONING FIGURE 17: CENTRAL HVAC SYSTEM – AIR CONDITIONING 22220 system. Backseat the valve and connect a ADDING REFRIGERANT (VAPOR charging line from the refrigerant cylinder to the STATE) valve. Tighten connection at level of refrigerant cylinder and open tank end slightly to purge air Use the suction service valve on the compressor from the charging line.
  • Page 446: Evacuating System

    Section 22: HEATING AND AIR CONDITIONING at the compressor. Screw in the stem of suction 2. Connect the evacuation manifold, vacuum valve approximately two turns. Start the engine pump, hoses and micron gauge to the unit. and run at fast idle. Add sufficient refrigerant to 3.
  • Page 447: Charging System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 18: DOUBLE SWEEP EVACUATION SET-UP 1. Backseat the two compressor shutoff valves CHARGING SYSTEM ("out"). When a system has been opened or if there are 2. Install the test gauges at the shutoff valves any questions about the air or moisture in the noting that the 400 psi (2758 kPa) gauge is system, evacuate the system.
  • Page 448: Central Hvac System - Air Conditioning Components

    Section 22: HEATING AND AIR CONDITIONING 6. Remove the cover cap from the service counterclockwise order release fitting in the top receiver valve. pressure and tension on belts. 7. Attach a charging hose to the R-134a tank. 2. Slip the old belts off and the new ones on. Open the tank valve slightly permitting R- 3.
  • Page 449: Belt Play

    Section 22: HEATING AND AIR CONDITIONING compressor clutch pulley (Figure 22 & Figure 23). 2. Check the distance between each extremity of straight edge (1, Figure 22) and the first drive belt. If they are different, loosen the compressor support bolts and with a hammer, knock support to slide it in order to obtain the same distance;...
  • Page 450: Troubleshooting Guide

    Section 22: HEATING AND AIR CONDITIONING compressed refrigerant vapor will be circulated between the suction and discharge sides of the head. The affected cylinder head will then have a relatively even temperature across its surface and be neither as hot as the normal discharge temperature nor as cool as the normal suction temperature.
  • Page 451: Magnetic Clutch

    Section 22: HEATING AND AIR CONDITIONING o Discharge valves not seated properly (liquid EVAPORATOR MOTOR drainback during shutdown). The evaporator motor is installed in the evaporator compartment (L.H. side of vehicle) o Expansion valve not controlling properly. (Figure 24). It is a 27.5 volt, 2HP (1,5 kW) motor Unloader Valve Stuck Open which activates a double blower fan unit.
  • Page 452: Installation

    Section 22: HEATING AND AIR CONDITIONING 9.3.5 Seating Brushes Grinding consists in giving to the seating face of a new brush the exact curve of the commutator or ring so that good mechanical and electric contact of the brush is ensured upon startup. For best results, remove oil and grease from commutator before applying brush seater.
  • Page 453: Brush Holder Adjustment

    Section 22: HEATING AND AIR CONDITIONING FIGURE 29: SEATING SURFACE OF THE BRUSH CAUTION FIGURE 27: IMPROPER GRINDING TECHNIQUE After grinding with the sandpaper or the seater stone, it is necessary to remove the CAUTION brushes from the brush holders and If grinding with a brush seater, you must vigorously clean with an air gun the disconnect the time delay in order to keep...
  • Page 454: Checking Commutator

    Section 22: HEATING AND AIR CONDITIONING condenser’s purpose is to dissipate heat from move all the brush holders at the same time. the hot refrigerant, it is important to keep the 1. Remove the screws securing the grid and cooling coils and fins clean. A clogged coil will remove the grid.
  • Page 455: Brush Wear Inspection / Replacement

    Section 22: HEATING AND AIR CONDITIONING RECEIVER TANK The receiver tank is located in the condenser compartment (Figure 33). The function of the receiver tank is to store the liquid refrigerant. During normal operation, the level of the refrigerant should be approximately at the mid- point of the lower sight glass.
  • Page 456: Replacement

    Section 22: HEATING AND AIR CONDITIONING 9.6.1 Replacement A moisture level of less than 15 p.p.m. for R- 134a indicated in the blue color range of the The filter is of the disposable type. When above table is generally considered dry and safe. replacement is required, remove and discard the A color indication of light blue to light violet complete unit and replace with a new unit of the...
  • Page 457: Valve Disassembly

    Section 22: HEATING AND AIR CONDITIONING 2. Take out the retaining screw at the top of the faces while the valve is apart. coil housing. The entire coil assembly can then be lifted off the enclosing tube. 9.7.4 Valve Reassembly 3.
  • Page 458 Section 22: HEATING AND AIR CONDITIONING sensitive control of the refrigerant liquid flowing to the evaporator is necessary to provide maximum evaporator capacity under load conditions. The spring is adjusted to give 12 to F (-11.1 to -8.8 C) of superheat at the evaporator outlet.
  • Page 459 Section 22: HEATING AND AIR CONDITIONING FIGURE 37: HIGH & LOW SWING TEMPERATURE AT REMOTE BULB 22047 Example of readings taken at Figure 37: A/C pressure gauge Temperature on converted to remote bulb temperature at FIGURE 36: SUPERHEAT ADJUST. INSTALLATION expansion valve fitting 22046 Install pressure gauge at the evaporator...
  • Page 460: Driver's System

    Section 22: HEATING AND AIR CONDITIONING reading is 40 F (4,4 C), subtract 32 F (0 C) and electrode can be used on low side pressure the result will be 8 F (4,4 C) of superheat. and liquid high side. CAUTION CAUTION When using heat near a valve, wrap with a...
  • Page 461: Troubleshooting

    Section 22: HEATING AND AIR CONDITIONING 9.10 TROUBLESHOOTING 9.10.1 Expansion Valve PROBABLE CAUSE PROBABLE REMEDY LOW SUCTION PRESSURE-HIGH SUPERHEAT XPANSION ALVE IMITING Gas in liquid line due to pressure drop in the line Locate cause of line flash and correct by use of or insufficient refrigerant charge.
  • Page 462 Section 22: HEATING AND AIR CONDITIONING PROBABLE CAUSE PROBABLE REMEDY Overcharge or refrigerant. Bleed to proper charge. Condenser dirty. Clean condenser. 9.10.2 A/C TROUBLE CAUSE Low suction pressure and frosting at dryer outlet. Clogged filter. Low Oil Level. Check for oil leaks and for leaking oil seal. Do not attempt to check oil level unless system has been stabilized at least 20 minutes.
  • Page 463 Section 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE 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.) An evaporator just does a proper cooling job without sufficient air.
  • Page 464: Temperatures & Pressures

    Section 22: HEATING AND AIR CONDITIONING 9.11 TEMPERATURES & PRESSURES VAPOR-PRESSURE TEMPERATURE PRESSURE °F °C -100 -73.3 27.8 191.7 -67.8 26.9 185.5 -62.2 25.6 176.5 -56.7 23.8 164.1 -51.1 21.5 148.2 -45.6 18.5 127.6 -40.0 14.7 101.4 -34.4 67.6 26.2 12.4 43.4 11.6...
  • Page 465: Small Hvac System - Air Conditioning Components

    Section 22: HEATING AND AIR CONDITIONING 180 cm³ WARNING Mass 4.9 kg (10.9 lbs) Do not inhale fumes from leak detector. 10.2 MAGNETIC CLUTCH The flow of acetylene to the burner causes a depression in the test line. Any gas refrigerant TYPE Electromagnetic single-plate present will be drawn through the hose and into...
  • Page 466: Refrigerant Handling

    Section 22: HEATING AND AIR CONDITIONING 10.3.2 Refrigerant Handling conditioning system, a refrigerant recovery unit must be used to recover the refrigerant. This Never directly heat refrigerant cylinder or put in refrigerant can then be recycled and reused, hot water heated above 40°C (104°F) since it which both environmentally...
  • Page 467: Installation Precautions

    Section 22: HEATING AND AIR CONDITIONING 10.5 INSTALLATION PRECAUTIONS The new compressor is filled with the specified quantity of compressor oil and nitrogen gas (N²). When mounting the compressor on the vehicle, take the following steps: Loosen the discharge side connector’s cap and gently release N²...
  • Page 468: Evacuating System Before Adding Refrigerant (Driver's Or Auxiliary System)

    Section 22: HEATING AND AIR CONDITIONING 10.6.1 Evacuating System Before Adding Refrigerant (Driver’s or Auxiliary System) When a system has been opened for repairs, change the filter dryer and evacuate the system. VIPs equipped with a driver’s system must use high-pressure service port located on the other side of check valve and low-pressure port located alongside rear truss.
  • Page 469: Leak Test Procedure With Compressor Removed

    Section 22: HEATING AND AIR CONDITIONING is necessary to check and replenish or replace the compressor oil in the following cases: o Whenever compressor, evaporator, condenser or filter-dryer is replaced. o Whenever refrigerant has leaked from the system, evaluate the amount of oily spot. o Whenever refrigerant is suddenly released from cooling...
  • Page 470: Tightening Torques

    Section 22: HEATING AND AIR CONDITIONING 10.12 TIGHTENING TORQUES FIGURE 47: TIGHTENING TORQUES PART THREAD SIZE TIGHTENING TORQUE 1. Bolt Armature M6 x 1.0 12 - 14 Nm (8.7 - 10.1 Lbf-ft) 2. Field Coil Screw M5 x 0.8 4 - 6 Nm (2.9 - 4.3 Lbf-ft) 3.
  • Page 471 Section 22: HEATING AND AIR CONDITIONING FIGURE 48: SMALL HVAC SYSTEM - AIR CONDITIONING 22293 FIGURE 49: SMALL HVAC SYSTEM - DRIVER'S AND AUXILIARY UNIT 22290 PA1217...
  • Page 472 Section 22: HEATING AND AIR CONDITIONING FIGURE 50: SMALL HVAC SYSTEM 22290 PA1217...
  • Page 473: Heating System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 51: CENTRAL HVAC SYSTEM – HEATING 22262 In addition to the normal heating provided by the 11. HEATING SYSTEM engine, a preheating system (104,000 Btu/hr) The schematics of Figure 50 and FIGURE 51 (optional on coaches only) may have been show respectively, the small HVAC system installed in the vehicle.
  • Page 474: Small Hvac System

    Section 22: HEATING AND AIR CONDITIONING 11.1 SMALL HVAC SYSTEM The small HVAC system driver’s unit is similar to the driver’s unit of the central HVAC system, except that the recirculating pump is located on the ceiling of the spare wheel compartment (Figure 60).
  • Page 475: Filling Heating System

    Section 22: HEATING AND AIR CONDITIONING If vehicle is equipped with a windshield upper section defroster, open front baggage compartment R.H. side door. Locate recirculating pump front wheelhousing, momentarily pinch the hose located between the recirculating pump suction and the defroster outlet connector to ensure windshield upper section defroster complete filling.
  • Page 476: Soldering

    Section 22: HEATING AND AIR CONDITIONING In test mode (see paragraph 7.1 HVAC SYSTEM AND TEST MODE FOR SWITCHES AND SENSORS), with the parking brake applied and the passenger set point set to a value higher than 64°F (18°C), the hot water circulating pump is not set to OFF as it would normally do when the outside temperature gets above 50°F (10°C).
  • Page 477: Hot Water Pneumatic Valve Reassembly

    Section 22: HEATING AND AIR CONDITIONING supply with voltmeter. It should agree with nameplate rating. 2. Check pressure at pilot solenoid valve inlet. It must be at least equal to the minimum pressure stamped nameplate. It should below minimum while valve is operating.
  • Page 478: Removal

    Section 22: HEATING AND AIR CONDITIONING 11.9.2 Disassembly Refer to Figure 61. Separate the housing from the adapter by first removing the 4 capscrews. Remove housing carefully to prevent damaging the O-ring. Remove rotor assembly, washers and shaft from the adapter. CAUTION Do not scratch or mark the sealing surface of this seat, as its sealing feature will be...
  • Page 479: Assembly

    Section 22: HEATING AND AIR CONDITIONING O-RING WAS HER IMPELLOR WAS HER 4. Fill cooling system previously ADAPT OR S HAFT instructed in this section under "Filling Heating System" and then bleed the system as previously instructed in this section under CAP S CREW “Bleeding Heating System".
  • Page 480: Bypass Solenoid Water Valve (Optional)

    Section 22: HEATING AND AIR CONDITIONING Make sure that the parts are placed on the enclosing tube in the following order: Be sure to change electrical data plate according to coil specifications change. Place coil and yoke assembly on the enclosing tube.
  • Page 481: Preheating System (Optional On Coaches Only)

    Section 22: HEATING AND AIR CONDITIONING FIGURE 64: WEBASTO PREHEATER (104,000 BTU) 22224 The pilot lamp turns on when the heater is switched on. Combustion air flows in to flush out combustion chamber water circulation pump is put into operation. The fuel metering pump conveys fuel in precise doses to combustion chamber...
  • Page 482: Operation

    Section 22: HEATING AND AIR CONDITIONING preventing local overheats. Once the delayed Preheating system must not operate when cutout time is over, both the combustion air vehicle is parked inside or during fuel fill blower and the water circulation pump switch off stops.
  • Page 483 Section 22: HEATING AND AIR CONDITIONING 1. Press button (5) for more than 2 seconds 4. Press button (8) or (9) to select the correct (time display flashes). startup day of week. 2. Press (8) or (9) button to set the time of day. 5.
  • Page 484: Troubleshooting And Maintenance

    Section 22: HEATING AND AIR CONDITIONING 12.3 TROUBLESHOOTING AND WARNING MAINTENANCE The preheating system uses the same fuel Refer to the Webasto manual for more as the engine. Do not operate in a building information. or while refueling. Operate only in a well- ventilated area.
  • Page 485 Horsepower ..............................2 Revolution ........................... 1400 & 1800 rpm Insulation ............................. Class F Motor Life ........................... 20 000 hours Brush life ............................ 10 000 hours Motor Prevost number ......................... 563008 Brush Prevost number ........................562951 Passenger’s unit condenser fan motors PA1217...
  • Page 486 Motor ............................20 000 hours Brush life ............................ 10 000 hours Qty ................................. 2 Prevost number ........................... 563051 Brush Prevost number ........................561914 Passenger’s unit evaporator air filter Make ............................. Permatron Corp. Type ................Washable 1” X 23 3/8” X 43 ½” Polypropylene filter Prevost number ...........................
  • Page 487 Make ........................... Carrier Transicold Type ............................Electric (AMC) Voltage ............................. 24 V DC) Watts ................................15 Prevost number (without coil) ......................950095 Coil Prevost numbert ........................... 950096 Magnetic clutch Make ........................... Carrier Transicold Type ....................Housing mounted 9” dia., 2-B grooves Voltage ..............................
  • Page 488 Section 22: HEATING AND AIR CONDITIONING Compressor V belts Make ..............................Dayco Model (matching set of 2) ........................BX97 Prevost number (with Delco 270/300 Amp Alternator) ................ 506664 Compressor V belt Make ..............................Dayco Model ..............................BX100 Prevost number (with two BOSH Alternators) ..................506681 Condenser coil Make ...........................
  • Page 489 Section 22: HEATING AND AIR CONDITIONING Coil Prevost number ..........................950055 Repair kit Prevost number ........................950056 Driver’s & passenger’s hot water pneumatic valve Make ............................... BURKERT Type ............................Normally open Voltage .............................. 24 V DC Pressure range ..........................0 to 230 psi Max.
  • Page 490 Section 22: HEATING AND AIR CONDITIONING Operating voltage ......................... 20-28 V DC Electric power consumption (without coolant recirc. pump) ............. 110 watts Fuel consumption ................... 1,2 US gallons/hr (4,5 liters/hr) Prevost number ........................... 871202 PA1217...
  • Page 491 Section 23: ACCESSORIES CONTENTS AUDIO AND VIDEO SYSTEM DESCRIPTION ..................4 AM/FM RADIO ..........................6 1.1.1 Vr300 Am/Fm Radio / Cd Player ..................... 6 1.1.2 Security Code .......................... 6 1.1.3 Removal ..........................6 1.1.4 Delphi Premium Satellite Radio Am/Fm/Mp3 Cd Stereo (Optional) ........7 VSS-04 SOUND SELECTOR ......................
  • Page 492 Section 23: ACCESSORIES 7.3.1 Description ..........................15 7.3.2 Maintenance .......................... 15 7.3.3 Removal And Installation ....................... 15 DOOR LOCK ..........................16 LAVATORY LIGHT ........................16 LAVATORY NIGHT-LIGHT ......................16 EMERGENCY BUZZER........................ 16 FRESH WATER TANK ......................... 16 7.8.1 Fresh Water Tank Heater (Optional) ..................16 7.8.2 Fresh Water Tank Draining ....................
  • Page 493 Section 23: ACCESSORIES ILLUSTRATIONS FIGURE 1: AUDIO-VIDEO PANEL ..........................4 FIGURE 2: AUDIO & VIDEO CONNECTIONS ......................5 FIGURE 3: RACKS ON AUDIO-VIDEO PANEL ......................6 FIGURE 4: AUDIO-VIDEO PANEL ..........................6 FIGURE 5: VR300 CD/AM/FM STEREO RECEIVER ....................6 FIGURE 6: DELPHI PREMIUM SATELLITE RADIO ......................
  • Page 494: Audio And Video System Description

    Each service module mounted to the underside of the parcel racks contains a 40-watt speaker. The speakers in the passenger section (twelve in H3-41 or sixteen in H3-45) are wired in stereo and are powered by the amplifier. A microphone outlet mounted in the driver’s area is provided as standard equipment.
  • Page 495 Section 23: ACCESSORIES FIGURE 2: AUDIO & VIDEO CONNECTIONS PA1217...
  • Page 496: Am/Fm Radio

    Section 23: ACCESSORIES • CD changer control • Quartz clock • Anti-theft • Mute function • Auto preset memory • Search & repeat • LED illumination • Track scan • Liquid crystal display • AUX input • Amber illumination • 4x20W power •...
  • Page 497: Delphi Premium Satellite Radio Am/Fm/Mp3 Cd Stereo (Optional)

    Section 23: ACCESSORIES route information on the monitor while the Remember that because power has been passengers may be watching a movie from the interrupted during removal, the radio must be DVD player. unlocked by entering the four-digit security With this unit, you can adjust each audio source code after reinstallation.
  • Page 498: Multichannel Power Amplifier Va400.8

    20- watt Coaxial 10cm speaker. The speakers (24 in H3-41 or 28 in H3-45) in the passenger’s section, wired in stereo and arranged in a delta configuration are powered by the amplifier.
  • Page 499: Video Cassette Player (Vcp)

    Section 23: ACCESSORIES 1.6.2 Installation 1. Install VCP/VCR unit into parcel compartment aligning rubber mount studs with mounting holes. Insert mount studs through mounting holes. 2. Install locknuts on mount studs. 3. Reconnect wiring. 5. Place the battery master switch in the ‘’ON’’ position.
  • Page 500: Wireless Microphone

    Section 23: ACCESSORIES FIGURE 14: HANDHELD PRIORITY MICROPHONE 23216 WIRELESS MICROPHONE The system 2000 16 channel wireless micro- phone, Receiver and Charging Cradle are custom designed units that allow for wireless PA communication from anywhere on the coach. The unit consists of a receiver mounted in the parcel area directly behind the driver, and a FIGURE 16: TUNER CONTROLS DESCRIPTION rechargeable...
  • Page 501: Scenic Viewing System

    Section 23: ACCESSORIES 3. Slide the monitor to the right to release it 5. Apply new seal SIKA 221 on both, vehicle from the mounting bracket. hole edge and antenna base. 6. Fix the antenna in place. 7. Remove excess seal and complete a finishing joint all around the antenna base.
  • Page 502: Back-Up Camera And Monitor

    Section 23: ACCESSORIES Torque stud nuts to 110-165 Lbf-ft (150-225 The thermal cutout valve is mounted on the Nm). engine (radiator side). Its function is to prevent discharge of ether when engine is warm (over ° ° F (32 C)). An atomizer is installed on top of BACK-UP CAMERA AND MONITOR the air intake duct (Fig.
  • Page 503: Thermal Cutout Valve Quick Test

    Section 23: ACCESSORIES 3. Actuate solenoid valve (Ask an assistant to Avoid breathing vapors and contacting fuel with actuate solenoid valve by means of the skin. Never smoke during test. rocker switch on the dashboard). Fuel 1. Check cylinder for hand tightness and fuel should be discharged through the thermal supply (Fig.
  • Page 504: Electric Motor Removal And Installation

    Section 23: ACCESSORIES 2. Check loose items sign To change the destination, depress the selecting mechanism, such as wire, loose clips, switches until the desired destination appears in hanging tape, etc. the LCD display. 3. Check tension and condition of the two drive belts and replace as required.
  • Page 505: Lavatory

    Section 23: ACCESSORIES 3. Now move the sunshade into the requested the lavatory with the vehicle ambient air. Air lower limit position by using the electric flows in the lavatory compartment through a vent motor (do not operate by hand). Press the grill located in the upper section of the lavatory button shaped like an arrow showing door and exhausts through a grill located next to...
  • Page 506: Door Lock

    Section 23: ACCESSORIES DOOR LOCK 2. Remove steel plate located on L.H. side of pushbutton switch. Lavatory door lock has inside and outside handles, as well as an inside latch to lock door 3. Remove switch through this opening, taking from inside the compartment.
  • Page 507: Liquid Soap Dispenser

    Section 23: ACCESSORIES Warning: Never put antifreeze in fresh water tank; antifreeze is toxic. Warning: If tank has not been drained for an extended period of time, draining and filling operations must be repeated three (3) times in order to clean tank and eliminate contaminated water.
  • Page 508: Pneumatic Timer Removal And Installation

    Section 23: ACCESSORIES allows an electric current flow during a preset time check the liquid projection while you manually to a pump into the sump tank. adjust the control valve 7.10.1 Pneumatic Timer Removal and 7.12 SUMP TANK Installation 1. Unscrew and remove the flush push-button 7.12.1 Sump Tank Draining locking ring.
  • Page 509: Air Horn Valve

    Section 23: ACCESSORIES the "Hansen" quick-release coupling, identified as "Cleaning Kit", located besides the engine oil The headlights cleaning system is independent reserve tank (Fig. 24). To prevent freezing during from the windshield washer system and has its cold weather, drain the hose after every use. To own washer fluid reservoir located in the front drain the hose, uncoil and open the nozzle near electrical and service compartment.
  • Page 510: Windshield Wipers And Washers

    Section 23: ACCESSORIES washer nozzles are aimed so that spray is within Because they are made of plastic, firmly the proper wiper pattern. tighten nozzle and bulkhead fittings by hand only. The windshield wipers are controlled by two electric wiper motors that are accessible for maintenance after raising the appropriate access panel at the front of the coach (refer to figure 33).
  • Page 511: Wiper Arm

    Section 23: ACCESSORIES adjustments as damage to the wiper linkage or motor may occur. If it is necessary to adjust the sweep of blades, remove the arms and make adjustment by positioning the arms using serration on the wiper arm pivot shafts. 10.2.1 Sweep Adjustment On a dry windshield, to avoid possible damage to the arm assembly or wiper motors, hold the...
  • Page 512: Removal

    Section 23: ACCESSORIES 4. Remove the drive and idler arms (Fig. 36) or 4. Lower windshield wiper (Fig. 36): loosen the clamping set screw on the base of the drive arm assembly (Fig. 37); arm; 5. Relocate the drive arm (Fig. 36) or arm 5.
  • Page 513: Upper Linkage Adjustment

    Section 23: ACCESSORIES 9. Check the adjustment on a wet windshield. 10.4 UPPER LINKAGE ADJUSTMENT 1. Make sure the wiper motor is in the stop position prior to working on the linkage. 2. Adjust rods length (Fig. 42). 3. Install the left wiper arm in its normal position (in the middle of the windshield (Fig.
  • Page 514: Upper Windshield Wiper Motor Replacement

    (Fig. 38). to the ‘’OFF’’ position prior to working on the 4. Remove the three bolts holding the motor to vehicle. the steel plate. 5. Remove the windshield wiper motor (Prevost #800304), reverse removal procedure to reinstall. 10.5.2 Upper Windshield...
  • Page 515 3. Remove the two Phillips-head screws on 9. Remove the windshield wiper motor (Prevost each roller side, pull out the sun visor. #800304), reverse removal procedure to 4. Remove the Phillips-head screws retaining reinstall.
  • Page 516: Automatic Fire Suppression System (Afss) (Optional On Coaches Only)

    Refer to Prevost Operator’s Manual for system operation and operational sequence (fire). If more information is needed on the system, please refer to Kidde Dual Spectrum “Operation &...
  • Page 517 Section 23: ACCESSORIES o Perform a comprehensive fire system test using a Kidde Dual Spectrum System Test Set (Optical Test Kit P/N 420871-2). o Service the extinguisher in accordance with KDS Document 160296, “KDS Pre-Engineered Fire Suppression System: Installation, Operation and Maintenance Manual”. EVERY SIX YEARS o Have the fire extinguisher rebuilt by a qualified fire protection equipment company familiar with Kidde Dual Spectrum equipment and in accordance with KDS Document 160296, “KDS Pre-Engineered Fire...
  • Page 518 Section 23: ACCESSORIES FIGURE 46: NOZZLE BRACKETS IDENTIFICATION AND INSTALLATION PA1217...
  • Page 519 Section 23: ACCESSORIES FIGURE 47: HOSES IDENTIFICATION AND ROUTING PA1217...
  • Page 520 Section 23: ACCESSORIES FIGURE 48: AFSS SYSTEM OVERVIEW PA1217...
  • Page 521: Tire Monitoring System (Tms)

    Section 23: ACCESSORIES 12. TIRE MONITORING SYSTEM (TMS) The optional SMARTIRE active tire pressure and temperature monitoring system is a sensing device designed to identify and display tire operating data and activate an alert or warning when pressure or temperature irregularities are detected.
  • Page 522 Section 23: ACCESSORIES 13. SPECIFICATIONS AMPLIFIER Model ..............................VA400-8 Output ................400 watts, 6 channel RMS at 4 ohm @ 0.5 T.H.D. Prevost number ........................... 901191 SOUND SELECTOR Model ..............................VSS-04 Power source ............................12 volts Prevost number ........................... 901192 AM/FM/CD PLAYER RADIO (standard) Model ..............................
  • Page 523 Section 23: ACCESSORIES BOOM-TYPE MICROPHONE Prevost number ........................... 900763 HANDHELD PRIORITY MICROPHONE Prevost number ........................... 900808 RUBBER COATED MICROPHONE Prevost number ........................... 900745 16 CHANNEL WIRELESS MICROPHONE Make ............................... R.E.I. Prevost number ........................... 900954 16 CHANNEL WIRELESS MICROPHONE CHARGING STATION Make ...............................
  • Page 524 Section 23: ACCESSORIES ELECTRONIC DESTINATION SIGN Make ..............................Pocatec Prevost number ........................... 940050 LAVATORY VENTILATION FAN MOTOR Make ..............................Aurora Type ..............................RG500EF Voltage ............................24 volts DC Rotation ..............................R.H. Prevost number ........................... 870844 EMERGENCY BUZZER SWITCH (PUSH BUTTON) Make .............................
  • Page 525 Section 23: ACCESSORIES Make ..........................Sprague device inc. Prevost number ........................... 800234 PA1217...
  • Page 526 SECTION 24: LUBRICATION CONTENTS LUBRICATION ............................2 ..................... 2 IRST ERVICE EHICLE 1.1.1 Differential..........................2 1.1.2 Coolant Strainer ........................2 1.1.3 Allison World Automatic Transmission ..................2 1.1.4 ZF-ASTRONICTransmission ....................2 1.1.5 Engine............................2 LUBRICATION AND SERVICE SCHEDULE ..................2 .......................
  • Page 527: First Service On New Vehicle

    Section 24: LUBRICATION 1.1.1 Differential LUBRICATION No initial oil or filter change necessary. Refer to The efficiency and life expectancy of mechanical regular lubrication and servicing schedule. equipment is largely dependant upon proper 1.1.2 Coolant Strainer lubrication servicing. mechanical components rely on a lubricating film between The coolant strainer is designed to recover the moving parts to reduce friction, prevent wear and soldering residues trapped inside the coolant...
  • Page 528: Engine Oil Reserve Tank

    Section 24: LUBRICATION however, that the oil change be performed after COLD WEATHER OPERATION every 10,000 miles (16 000 km). The proper selection of the engine oil grade will The drain intervals may then be gradually ease cold weather starting (refer to the increased or decreased with experience on a lubrication and servicing schedule for the engine specific...
  • Page 529 Section 24: LUBRICATION 2.3.3 Service life The limited service life of a hose is determined by the temperature and pressure of the gas or fluid within it, the time in service, its installation, the ambient temperatures, amount of flexing, and the vibration it is subjected to. With this in mind, it is recommended that all hoses be thoroughly inspected...
  • Page 530 Section 24: LUBRICATION FIGURE 2: LUBRICATION AND SERVICING POINTS ON I-BEAM FRONT SUSPENSION VEHICLES (TYPICAL) 24019 PA1217...
  • Page 531 Section 24: LUBRICATION FIGURE 3: LUBRICATION AND SERVICING POINTS ON INDEPENDENT FRONT SUSPENSION VEHICLES (TYPICAL) 24005 PA1217...
  • Page 532: Lubricant And Coolant

    Section 24: LUBRICATION ENGINE COMPARTMENT ITEM* DESCRIPTION Check engine crankcase oil level; Add if necessary. Check Allison World transmission oil level (can be checked from push-button shift selector); Add if necessary. Check power steering reservoir fluid level; Add if necessary. Check coolant surge tank fluid level;...
  • Page 533 NLGI No.2 Grade is suitable for most temperatures NLGI No.1 Grade is suitable for extremely low temperatures Item numbers refer to figures 2 and 3. PART NUMBER SPECIFICATIONS ITEM* DESCRIPTION PREVOST NO Engine Oil Filters #510458 Power Steering Reservoir Oil Filter #660987 Engine Air Cleaner Filter...
  • Page 534: Lubrication And Servicing Schedule

    DISTANCE TRAVELED (miles/km) LUBRICANT &/OR LUBRICATION AND SERVICING SCHEDULE PART GENERAL Flexible hoses, thoroughly inspect all hoses - 12 ● ● ● ● ------- Front discharge tube, qty:2, check to see if clogged ------- 01 ENGINE Air cleaner, inspect, clean, replace element if required 23 6 ●...
  • Page 535 DISTANCE TRAVELED (miles/km) LUBRICANT &/OR LUBRICATION AND SERVICING SCHEDULE PART 07 TRANSMISSION Allison World transmission equipped with retarder, Dexron-III/VI ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 13 6 change oil and filters (if filled with standard oil) Allison World transmission equipped with retarder, change oil (if TranSynd Synthetic Fluid 13 24...
  • Page 536 DISTANCE TRAVELED (miles/km) LUBRICANT &/OR LUBRICATION AND SERVICING SCHEDULE PART 14 STEERING Drag link ends, grease one fitting at each end ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Multi purpose grease ●...

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