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

PREVOST H3-41 Maintenance Manual

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Summary of Contents for PREVOST H3-41

  • Page 3 MAINTENANCE MANUAL H3-41, H3-45, H3-45 VIP X3-45, X3-45 VIP PA1615 Revision 2B PA1615...
  • Page 4 G-3030 (H3 VIP) G-5878 (X3 Coaches) G-5927 (X3-45 VIP) H-3645 (H3 VIP) Section 26a: New Prevost Slide-out with Flush Floor. November 2016 Units included : H-3567, H-3579, H-3609 H-6139 (X Series) Section 12: Air Dryer "Cartridge Change" Parameter (CUA) deactivated from October 30th.
  • Page 5 CRITICAL EMISSION-RELATED MAINTENANCE Source of parts and repair: A repair shop or person of the owner’s choosing must maintain, replace, or repair emission control devices and systems per manufacturer's recommendations. Replacement of tires that are GHG certified: The original equipment tires installed on this vehicle at the factory were certified to the U.S. EPA Greenhouse Gas (GHG) and National Highway Traffic Safety Administration (NHTSA) Fuel Efficiency regulations.
  • Page 7 CONTENTS CONTENTS • SECTION 00: GENERAL INFORMATION • MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING • SECTION 01: ENGINE • MI16-16 STARTER REMOVAL AND INSTALLATION • SECTION 03: FUEL SYSTEM • SECTION 04: EXHAUST AND AFTERTREATMENT • SECTION 05A: H3 SERIES COOLING SYSTEM •...

  • Page 9: Table Of Contents

    SECTION 00: GENERAL INFORMATION CONTENTS ILLUSTRATIONS ..............................1 FOREWORD ..............................2 SCHEMATICS ............................... 2 PRECAUTIONS TO BE OBSERVED BEFORE WELDING ..................2 SAFETY NOTICE ............................6 DATA PLATES AND CERTIFICATIONS ......................6 4.1.1 Engine ..............................6 4.1.2 Transmission ............................6 4.1.3 Drive Axle ...............................

  • Page 10: Illustrations

    This manual includes procedures for diagnosis, service, maintenance and repair for components Vehicle pneumatic and electrical schematics can series Prevost coaches be found in your the technical publications box. motorhomes listed on the front cover. This Refer to those schematics for detailed circuit information and diagnosis.
  • Page 11 SECTION 00 : GENERAL INFORMATION STEEL – STEEL WELDING CAUTION Before welding, perform multiplex modules disconnection procedure. NOTE Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that would render welding impossible. DANGER Only a qualified and experienced person must do welding.
  • Page 12 SECTION 00 : GENERAL INFORMATION STEEL - STAINLESS STEEL OR STAINLESS STEEL - STAINLESS STEEL WELDING CAUTION Before welding, perform multiplex modules disconnection procedure. NOTE Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that would render welding impossible.
  • Page 13 SECTION 00 : GENERAL INFORMATION STEEL - STAINLESS STEEL WELDING Steel Thickness SS Thickness Voltage Current Wire Feed Rate Shielding Gas 90% He, 7.5% Less than 1/8” Any type 20±1.5 volts 130±15 Amps 290 ipm approx. Ar, 2.5% CO2 90% He, 7.5% 1/8”...

  • Page 14: Safety Notice

    This maintenance manual has been prepared in identified by serial numbers. order to assist skilled mechanics in the efficient repair and maintenance of PREVOST vehicles. 4.1.1 Engine This manual covers only the procedures as of manufacturing date.

  • Page 15: Drive Axle

    FIGURE 6: I-BEAM AXLE TYPICAL SERIAL & MODEL NUMBERS 00008 This certifies that vehicles manufactured by Prevost Car Inc., comply with all Federal Motor Vehicle Safety Standards at the time of PA1615 Maintenance Manual All Series | Section 00 revised September 2016...

  • Page 16: Fuel Tank Label

    SECTION 00 : GENERAL INFORMATION manufacture. Information such as date of FIGURE 9: EMISSION CONTROL LABEL 23229 manufacture, model year, gross vehicle weight rating, tire types and inflation pressure is also 4.1.11 Vehicle Identification Number (VIN) etched on this plate. The DOT Certification plate seventeen digit vehicle...

  • Page 17: Figure 11: Vehicle Identification Number

    SECTION 00 : GENERAL INFORMATION FIGURE 11: VEHICLE IDENTIFICATION NUMBER 00057_5 YEAR CODE YEAR CODE YEAR CODE 1997 2005 2013 1998 2006 2014 1999 2007 2015 2000 2008 2016 2001 2009 2017 2002 2010 2018 2003 2011 2019 2004 2012 2020 PA1615 Maintenance Manual All Series | Section 00 revised September 2016...

  • Page 18: Fastener

    SECTION 00 : GENERAL INFORMATION 5. FASTENER 5.1 FASTENER STRENGTH IDENTIFICATION Most commonly used metric fastener strength property classes are 9.8 and 10.9 with the class identification embossed on the head of each bolt. Customary (inch) strength classes range from grade 2 to 8 with radial line identification embossed on each bolt head actual grade (i.e., a grade 7 bolt will have 5 embossed radial lines on the bolt head).

  • Page 19: Figure 12: Thread Notation

    SECTION 00 : GENERAL INFORMATION FIGURE 12: THREAD NOTATION 00002 FIGURE 13: BOLT STRENGTH MARKINGS 00003 The metric fasteners used on the coach are designed to new standards and may not yet be manufactured by some non-domestic fastener suppliers. general, except special applications, the common sizes and pitches are:...

  • Page 20: Standard Torque Specifications

    SECTION 00 : GENERAL INFORMATION 5.2 STANDARD TORQUE SPECIFICATIONS The following table lists the standard tightening torques for bolts and nuts, relating tightening torque to thread diameter. Use the following table as a general guide for tightening torques. Use this table only for the bolts and nuts which do not require a specific torque value.
  • Page 21 SECTION 00 : GENERAL INFORMATION RECOMMENDED TORQUE TYPE DESCRIPTION THREAD GRADE Tolerance: ±10% 5/8-18 200 lb-ft (271 Nm) 3/4-10 228 lb-ft (309 Nm) 3/4-10 321 lb-ft (435 Nm) 3/4-16 245 lb-ft (332 Nm) 3/4-16 346 lb-ft (469 Nm) 7/8-9 368 lb-ft (499 Nm) 7/8-9 519 lb-ft (704 Nm) 7/8-14...

  • Page 22: Metric

    SECTION 00 : GENERAL INFORMATION 5.2.2 Metric RECOMMENDED TORQUE, ±10% TYPE DESCRIPTION THREAD GRADE lb-ft (dry) otherwise specified Tolerance: ±10% METRIC M6 X 1 nut 8 / screw 8.8 7 lb-ft (10 Nm) METRIC M6 X 1 nut 10 / screw 10.9 10 lb-ft (13 Nm) METRIC M6 X 1...
  • Page 23 SECTION 00 : GENERAL INFORMATION RECOMMENDED TORQUE, ±10% TYPE DESCRIPTION THREAD GRADE lb-ft (dry) otherwise specified Tolerance: ±10% METRIC M24 X 3 nut 12 / screw 12.9 777 lb-ft (1054 Nm) METRIC: STAINLESS NUT A2-70 AND STAINLESS SCREW A2-70 (NSS-SS) RECOMMENDED RECOMMENDED TIGHTENING Tolerance:...

  • Page 24: Self-Locking Fasteners

    SECTION 00 : GENERAL INFORMATION 5.3 SELF-LOCKING FASTENERS A self-locking fastener is designed with an interference fit between the nut and bolt threads. This is most often accomplished by distortion of the top thread of an all-metal nut or bolt or by using a nylon patch on the threads.

  • Page 25: Six Lobed Socket Head

    SECTION 00 : GENERAL INFORMATION SELF-LOCKING FASTENER TORQUE CHART METRIC 6 & 6.3 NUTS AND ALL-METAL BOLTS lb-in ADHESIVE OR NYLON COATED BOLTS lb-in ¼ 5/16 7/16 ½ 9/16 ¾ US STANDARD NUTS AND ALL-METAL BOLTS lb-in ADHESIVE OR NYLON COATED BOLTS lb-in 5.5 SIX LOBED SOCKET HEAD...

  • Page 26: Figure 15: Metric - Us Standard Conversion Table

    SECTION 00 : GENERAL INFORMATION FIGURE 15: METRIC - US STANDARD CONVERSION TABLE 00005 PA1615 Maintenance Manual All Series Section 00 revised September 2016...

  • Page 27: Figure 16: Conversion Chart

    SECTION 00 : GENERAL INFORMATION FIGURE 16: CONVERSION CHART 00006 PA1615 Maintenance Manual All Series | Section 00 revised September 2016...

  • Page 28: Hose Clamp Torque

    SECTION 00 : GENERAL INFORMATION 5.6 HOSE CLAMP TORQUE HOSE CLAMP NGLISH RECOMMENDED TIGHTENING ESCRIPTION ONSTANT TORQUE 3/8 Hex 90-110 HOSE CLAMP (WAVE SEAL NGLISH BREEZE) RECOMMENDED TIGHTENING ESCRIPTION ONSTANT TORQUE 5/16 Hex 55-65 HOSE CLAMP (CAILLAU) ECOMMENDED IGHTENING ETRIC 7 mm Hex 30±2.2 PA1615 Maintenance Manual All Series...
  • Page 29 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING PROCEDURE NO: PR10177-232 (COM) / 233 (H) / 234 (X) 2015-04-23 Material: Equipment(s): Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: Safety rules: - Wear safety goggles - Set the battery master switch to the OFF position first Recommendations: This procedure should be performed by qualified personnel only.
  • Page 30 PROCEDURE NO: PR10177-232 (COMMUTER) REVISION 00 Disconnection prior to welding Switch ignition OFF Open the 2 circuit breakers (each end) Switch Master cut-out OFF Press here Disconnect both electronic grounds Disconnect C397 and C355 Use insulating tape to make sure that cables don’t touch each other or the vehicle body Page 2 of 10...
  • Page 31 PROCEDURE NO: PR10177-232 (COMMUTER) REVISION 00 Disconnection prior to welding Disconnect all the connectors from the I/O-A and Disconnect the control connector from the battery I/O-B modules in rear junction box equalizer In the front junction box Disconnect all the connectors from : I/O-A modules I/O-B modules Vancso Gateway...
  • Page 32 PROCEDURE NO: PR10177-232 (COMMUTER) REVISION 00 Disconnection prior to welding Behind the right console panel In the condensor compartment Disconnect all the connectors from the I/O-B Disconnect the ACM connector (A137A) modules In the evaporator compartment The vehicle is now ready for welding Disconnect all the connectors from I/O-B module Make sure that the welding ground is as close as...
  • Page 33 PROCEDURE NO: PR10177-232 (H SERIES) REVISION 00 Disconnection prior to welding Switch ignition OFF Open the 3 circuit breakers Switch Master cut-out OFF Press here Disconnect both electronic grounds Disconnect C397 Use insulating tape to make sure that cables don’t touch each other or the vehicle body Page 5 of 10...
  • Page 34 PROCEDURE NO: PR10177-232 (H SERIES) REVISION 00 Disconnection prior to welding Disconnect all the connectors from the I/O-A et Disconnect the control connector from the battery I/O-B modules in rear junction box equalizer (Optional) In the engine compartment Disconnect C355 In the front junction box Disconnect all the connectors from : I/O-A modules...
  • Page 35 PROCEDURE NO: PR10177-232 (H SERIES) REVISION 00 Disconnection prior to welding Behind the right console panel In the condensor compartment Disconnect all the connectors from the I/O-B Disconnect the ACM connector (A137A) modules In the evaporator compartment The vehicle is now ready for welding Disconnect all the connectors from I/O-B module Make sure that the welding ground is as close as...
  • Page 36 PROCÉDURE NO: PR10177-234 (X SERIES) RÉVISION 00 Disconnection prior to welding Switch ignition OFF Open the 3 circuit breakers Switch Master cut-out OFF Press here Disconnect both electronic grounds Disconnect C397 and C355 Use insulating tape to make sure that cables don’t touch each other or the vehicle body Page 8 of 10...
  • Page 37 PROCÉDURE NO: PR10177-234 (X SERIES) RÉVISION 00 Disconnection prior to welding Disconnect all the connectors from the I/O-A et Disconnect the control connector from the battery I/O-B modules in rear junction box equalizer (Optional) In the front junction box Disconnect all the connectors from : I/O-A modules I/O-B modules Vancso Gateway (Optional)
  • Page 38 PROCÉDURE NO: PR10177-234 (X SERIES) RÉVISION 00 Disconnection prior to welding Behind the right console panel In the condensor compartment Disconnect all the connectors from the I/O-B Disconnect the ACM connector (A137A) modules In the evaporator compartment The vehicle is now ready for welding Disconnect all the connectors from I/O-B module Make sure that the welding ground is as close as...

  • Page 39: Volvo D

    SECTION 01 : ENGINE CONTENT TORQUE TABLES ............................. 3 POWER PLANT CRADLE INSTALLATION ......................3 ..........................4 BELT TENSIONERS AND IDLERS VOLVO D13 ENGINE ............................5 SYSTEM OVERVIEW ............................5 ................................. 8 OVERVIEW ..............................13 ENGINE OIL 2.3.1 Oil Quality ............................13 Oil Change Intervals .........................
  • Page 40 SECTION 01 : ENGINE ILLUSTRATIONS ............................9 FIGURE H ENGINE HARNESS ) ....................10 FIGURE H ENGINE OVERVIEW ALTERNATOR SIDE TYPICAL ) ...................... 10 FIGURE H ENGINE OVERVIEW TURBO SIDE TYPICAL 4: 2010-2015 & ............11 FIGURE ENGINE EXHAUST AFTERTREATMENT SYSTEM DIAGRAM 5: 2010-2015 &...

  • Page 41: Torque Tables

    SECTION 01 : ENGINE 1. TORQUE TABLES 1.1 POWER PLANT CRADLE INSTALLATION VOLVO ENGINE POWER PLANT CRADLE INSTALLATION DESCRIPTION TORQUE Screw, cap hexagonal head m8 – 1.25 g8.8 14 lb-ft (19 Nm) Screw, cap hexagonal head m12 – 1.75 g8.8 60 lb-ft (81 Nm) Screw, cap hexagonal head m14 –...

  • Page 42: Belt Tensioners And Idlers

    SECTION 01 : ENGINE 1.2 BELT TENSIONERS AND IDLERS 01226_1 01225_1 VOLVO ENGINE – DRIVE BELT IDLERS & TENSIONERS DESCRIPTION TORQUE Idler, cooling fan drive 50 lb-ft (68 Nm) Idler, cooling fan drive 35 lb-ft (47 Nm) Idler, cooling fan drive 45-55 lb-ft (61-75 Nm) Idler, water pump drive 43 lb-ft (58 Nm)

  • Page 43: Volvo D13 Engine

    SECTION 01 : ENGINE The following is a list of engine sensors that provide input to the EMS: 2. VOLVO D13 ENGINE 2.1 SYSTEM OVERVIEW • Ambient Air Temperature Sensor NOTE • Ambient Pressure sensor The “Premium Tech Tool” (PTT) is the •...
  • Page 44 SECTION 01 : ENGINE Ambient (Atmospheric) Pressure Sensor pressure between the two ports. Measurement of the pressure before and after the EGR valve The Ambient (Atmospheric) Pressure Sensor is used to calculate EGR flow. contains a pressure sensitive diaphragm and an electrical amplifier.
  • Page 45 SECTION 01 : ENGINE Engine Oil Level (EOL) Sensor The Intake Air Temperature and Humidity (IATH) Sensor is located in the air intake tube just The Engine Oil Level Sensor is located in the oil downstream from the air filter canister. pan.

  • Page 46: Overview

    SECTION 01 : ENGINE Variable Geometry Turbocharger Smart Remote Actuator (VGT SRA) The Variable Geometry Turbocharger Smart Remote Actuator (VGT SRA) takes the position commands from the EMS, moves the nozzle of the turbocharger to the desired position, and performs all of the diagnostics and self-checks on the actuator.
  • Page 47 SECTION 01 : ENGINE FIGURE 1: D13H ENGINE HARNESS 1 Vehicle harness connector 11 Preheater, engine 21 Oil thermostat 2 Engine control module (ECM) 12 Unit injectors 22 Oil piston cooling jet connector 3 Engine control module (ECM) 13 Solenoid valve, VEB 23 Sensor, boost temp connector 4 Sensor, oil level &...
  • Page 48 SECTION 01 : ENGINE FIGURE 3: D13H ENGINE OVERVIEW, TURBO SIDE (TYPICAL) FIGURE 2: D13H ENGINE OVERVIEW, ALTERNATOR SIDE (TYPICAL) 1. Breather tube 16. EGR mixing chamber 2. Intake Manifold 17. Exhaust Manifold 3. Air compressor 18. Valve Cover 4. Power steering pump 19.
  • Page 49 SECTION 01 : ENGINE FIGURE 4: 2010-2015 ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (1 OF 2) 01222 PA1615 Maintenance Manual All Series | Section 01 revised April 2017...
  • Page 50 SECTION 01 : ENGINE FIGURE 5: 2010-2015 ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (2 OF 2) 01222 PA1615 Maintenance Manual All Series | Section 01 revised April 2017...

  • Page 51: Engine Oil

    SECTION 01 : ENGINE NOTE For maintenance or repair of engine components or engine-related components, please refer to Volvo Trucks North America Web Site under: Parts & Service, purchase engine literature, D13H engine. 2.3 ENGINE OIL MAINTENANCE Keep the engine oil at the proper level and change it at the recommended intervals.

  • Page 52: Synthetic Lubrication

    SECTION 01 : ENGINE FIGURE 6: D13F OIL FILTERS 2.3.6 Oil Additives 2.3.4 Synthetic Lubrication CAUTION Synthetic oils are offered by some oil suppliers as an alternative to the traditional, petroleum Extra oil additives must never be added to any based oils for engines.

  • Page 53: Oil Change

    SECTION 01 : ENGINE 2.3.8 Oil Change NOTE WARNING Since about 1 liter of oil remains in the engine after draining, approximately 38 liters will be needed for a complete oil change. A hot engine or engine oil can be dangerous. Serious burns can result from contact with a hot engine or oil.

  • Page 54: Checking The Oil Level

    SECTION 01 : ENGINE FIGURE 9: ENGINE OIL FILLING TUBE 01192_2 FIGURE 10: ENGINE OIL LEVEL DIPSTICK 2.4 POWER PLANT ASSEMBLY REMOVAL access engine engine-related components, the vehicle power plant assembly must be removed as a whole unit by means of a slide-out cradle.
  • Page 55 SECTION 01 : ENGINE before attempting to remove it. 1. If applicable, remove auxiliary sump tank to ease access. 3. Remove rear bumper assembly 2. Purge the A/C system and disconnect complete with hitch if applicable from the the A/C compressor hoses. Refer to vehicle.
  • Page 56 SECTION 01 : ENGINE 9. At the back of the air cleaner, disconnect 5. Disconnect and remove a section of the engine-air intake duct mounted coolant pipe assembly mounted between cleaner housing between the thermostat housing and turbocharger inlet. the radiator inlet. 6.

  • Page 57: Power Plant Assy. Installation

    SECTION 01 : ENGINE FIGURE 12: TYPICAL ENGINE COMPARTMENT(X3 COACHES SHOWN) 01184_B 2.5 POWER PLANT ASSY. INSTALLATION 2.6 ENGINE MOUNTS The power plant assembly is mounted to the To install a power plant assembly, follow the cradle by means of rubber mounts and supports. same procedure as in "Power Plant Assembly Removal"...

  • Page 58: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    SECTION 01 : ENGINE 3. ELECTRONIC FOOT PEDAL ASSEMBLY occur when the idle position is less than 14 counts, or when the full throttle position is more (EFPA) & THROTTLE POSITION SENSOR than 233 counts. Should these conditions occur, The Electronic Foot Pedal Assembly (EFPA) the CPC will signal diagnostic codes of 21-12 for connects the accelerator pedal to a Throttle idle error and 21-23 for wide-open throttle error.

  • Page 59: Automatic Belt Tensioner Bushing Wear

    SECTION 01 : ENGINE 3. If bushing wear is suspected, remove the tensioner. Inspect the tensioner for any signs of wear. Check for bearing noise as well as metal to metal contact between the arm and spring case which is a sign of bushing wear. Check for cracks in the tensioner body.
  • Page 60 SECTION 01 : ENGINE High intake manifold Derate only temperature High transmission oil temperature Derate only High temperature cooled Derate only exhaust gas (EGR) - after EGR cooler EGR valve and position error Derate only Variable Geometry Turbo (VGT) Derate only valve and position error High VGT actuator temperature Derate only...

  • Page 61: Specifications

    Oil Pan Capacity, High Limit ....................34 quarts/32 liters Refill volume including filter change .................. 40 quarts/38 liters Lubricating oil filter elements Type ..............................By-pass Prevost number ..........................510938 Type ..............................Full Flow Prevost number ..........................488736 Torque specification Engine oil filter ............. Tighten ¾ of a turn to 1 full turn after gasket contact...
  • Page 62 MAINTENANCE MI16-16 INFORMATION DATE : FEBRUARY 2016 SECTION : 01 - Engine SUBJECT : VOLVO D13 ENGINE – STARTER REMOVAL AND INSTALLATION DESCRIPTION This procedure applies to current Melco 105P70 starter part number #21212425. REQUIRED TOOLS RATCHET EXTENSION BAR RATCHET AND SOCKET SET – METRIC CORDLESS DRILL BRASS WIRE CUP BRUSH TORQUE WRENCH...
  • Page 63 MI16-16 / Page 2 / 6 PROCEDURE – STARTER REMOVAL AND INSTALLATION DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition the battery master switch to the OFF position switch to the OFF position, and trip the main circuit breakers equipped with a trip button.
  • Page 64 MI16-16 / Page 3 / 6 5. Using a 18mm socket, unscrew three bolts fastening the starter to the flywheel housing ( FIGURE 3 6. Detach the starter from the flywheel housing. FIGURE 3 STARTER INSTALLATION 1. If the starter is replaced with a brand new starter, prepare the new starter as follows (refer to FIGURE 5...
  • Page 65 MI16-16 / Page 4 / 6 FIGURE 6 FIGURE 5 FIGURE 7 2. Install the replacement starter with the solenoid located on the underside of the starter motor as shown on FIGURE 8 3. Hand tighten the three mounting nut. Flange nut M12 p/n 990942 qty: 3 4.
  • Page 66 504637 as shown on FIGURE 12 FIGURE 12 14. Apply anti-corrosion compound or Color Guard Rubber Coating (Prevost p/n 684013) on starter terminals, cable lugs and nuts (see FIGURE 13 FIGURE 15 FIGURE 13 <QF7720955 rev 2>...
  • Page 67 MI16-16 / Page 6 / 6 FIGURE 14 FIGURE 15 FUNCTIONAL TEST 1. Reset main circuit breakers if applicable. Set the battery master switch (master cut-out) to the ON position and start the engine. PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone.
  • Page 69 SECTION 03 : FUEL SYSTEM CONTENTS     TORQUE TABLES ............................ 3     FUEL LINE FITTINGS  ............................  3         MISCELLANEOUS TORQUES ...........................  4       FUEL SYSTEM  .............................. 5      ..............................  5 FUEL VALVES      ..............................  6 FUEL FILTERS  ...
  • Page 70 SECTION 03 : FUEL SYSTEM ILLUSTRATIONS   )  ......................  5 FIGURE   FUEL SYSTEM SCHEMATIC  VOLVO D  ENGINE   ‐ ) ......................  6 FIGURE   MANUAL SHUT OFF VALVE  VOLVO D  ENGINE   ‐   ............  6 FIGURE   MANUAL SHUT OFF VALVE LOCATION WITH DAVCO FUEL PRO    VOLVO D  ENGINE   –  ..........................  6 FIGURE ...

  • Page 71: Torque Tables

    SECTION 03 : FUEL SYSTEM 1. TORQUE TABLES 1.1 FUEL LINE FITTINGS   FUEL LINE FITTINGS – VOLVO D13 ENGINE DESCRIPTION TORQUE Fuel line fitting 11-15 lb-ft (15-20 Nm) Fuel line fitting 17.5-23.5 lb-ft (24-32 Nm) Fuel line fitting 19-25 lb-ft (26-34 Nm) Fuel line fitting 22-30 lb-ft (30-41 Nm) Fuel line compression fitting...

  • Page 72: Miscellaneous Torques

    SECTION 03 : FUEL SYSTEM 1.2 MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION TORQUE Brake pedal potentiometer holding screws 10-20 lb-in (1-2 Nm) Fuel tank support to frame 55 lb-ft (75 Nm) PA1615 Maintenance Manual All Series Section 03 revised September 2016...

  • Page 73: Fuel Valves

    SECTION 03 : FUEL SYSTEM Supply Pump Valves 2. FUEL SYSTEM Two valves are located in the supply pump (1). NOTE The safety valve (11) allows fuel to flow back to For additional information concerning Volvo the suction side when the pressure becomes too D13 engine components or engine-related high, e.g., if the fuel filter is blocked or is too components, consult Volvo Trucks Canada or...

  • Page 74: Fuel Filters

    SECTION 03 : FUEL SYSTEM FIGURE 4: FUEL LINE COMPRESSION FITTING CAUTION ALWAYS replace the fuel line compression sealing washers when troubleshooting for fuel aeration or performing any service procedure that requires the removal of engine fuel lines. 2.2 FUEL FILTERS FIGURE 2: MANUAL SHUT-OFF VALVE (VOLVO D13 ENGINE) 03088_2...

  • Page 75: Primary Fuel Filter Replacement

    SECTION 03 : FUEL SYSTEM 7. Check that the drainage hole in the water separator bowl is not blocked. Apply a thin coating of clean engine oil to the surface of the water separation bowl. 9. Install a new gasket to the water separation bowl and then reinstall the separation bowl FIGURE 5: FUEL FILTERS WITH VOLVO D13 ENGINE 03085...

  • Page 76: Secondary Fuel Filter Replacement

    SECTION 03 : FUEL SYSTEM 2.2.2 Secondary Fuel Filter Replacement CAUTION 1. Stop engine, close the fuel supply line shut- off valve. Place an appropriate container When priming the system, movement of the under the fuel filter housing. primer pump should be as up and down as 2.

  • Page 77: Fuel Pump Removal And Install Tion

    SECTION 03 : FUEL SYSTEM 2.4 FUEL PUMP REMOVAL INSTALLATION The pump is located underneath the air compressor and is accessible through the engine compartment R.H. access door. To remove the pump, proceed as follows:  Clean around the fuel pump and fuel lines. Position a container to catch any fuel that might drain from the pump or lines.
  • Page 78 SECTION 03 : FUEL SYSTEM onto the fuel processor. Tighten the collar by hand until secure; MAINTENANCE 10. Fill the cover full of clean fuel through spin off Replace Fuel Pro 382 filter element when the cap located on top of cover. Install vent cap fuel level in the see-thru filter cover reaches the seal and then reinstall the cap and tighten by top of the filter element or after one year of...

  • Page 79: Fuel Lines And Flexible Hoses

    SECTION 03 : FUEL SYSTEM MAINTENANCE Check hoses daily as part of the pre-start-up inspection. Examine hoses for leaks and check all fittings, clamps and ties carefully. Make sure that the hoses are not resting on or touching shafts, couplings, heated surfaces, including exhaust manifolds, any sharp edges...

  • Page 80: Tank Removal

    SECTION 03 : FUEL SYSTEM necks; offering the added advantage of refueling 5. Unscrew engine supply and return lines from either side of vehicle. from fuel tank connection-panel, identify them for reinstallation. X3 series are equipped with a high-density cross-link polyethylene fuel tank with a legal 6.

  • Page 81: Tank Installation

    2. If necessary, remove fuel tank as per instructions in this section. 3. Drill perforation with a 23/64" bit. Make sure drill hole is perfectly round. 4. Insert a screw (Prevost #500196) and a washer (Prevost #5001244) into anchor nut (Prevost #500331). FIGURE 13: FUEL TANK RETENTION 03019 5.

  • Page 82: Fuel Specifications

    SECTION 03 : FUEL SYSTEM NYLON WASHER SCREW CAUTION Owners of 2010 and later model year on- highway diesel engine must refuel only with ULSD fuel. FUEL TANK INTERIOR ANCHOR NUT NOTE FIGURE 14: FUEL TANK REPAIR 03014 Burning Low Sulfur Diesel fuel (instead of ULSD fuel) in 2010 and later model year diesel engines is illegal and punishable with 7.

  • Page 83: Biodiesel Fuels And Auxiliary Heaters

    9003656D), available Technical Publications USB flash drive and on Prevost The pre-filter should be installed snugly in the air technical publications website. duct and clamped tightly to the air cleaner inlet to prevent any dust infiltration into the air 7.3.2...

  • Page 84: Air Cleaner Restriction Indicator

    SECTION 03 : FUEL SYSTEM surface of the housing must be cleaned with 9. FUEL PEDAL a soft clean cloth; The EFPA (Electronic Foot Pedal Assembly) 6. Periodically inspect the entire system. Dust- connects accelerator pedal laden air can pass through an almost potentiometer (a device that sends an electrical invisible crack...
  • Page 85 SECTION 03 : FUEL SYSTEM 4. Position potentiometer. Press potentiometer onto the potentiometer shaft, matching cutouts in shaft to drive tangs of potentiometer. Apply hand pressure until potentiometer has bottomed out in housing. Reinstall screws (Figure 16) and tighten just enough to secure potentiometer lightly.

  • Page 86: Specifications

    SECTION 03 : FUEL SYSTEM 10. SPECIFICATIONS Davco Fuel Pro 382 Fuel Filter / Water Separator Element Max Fuel Flow ........................180 US gal/h (681 l/h) Water removal @ 25 microns ........................99.6% Dirt holding capacity @ 25 microns ......................110 g Primary Fuel Filter (Fuel/Water Separator) Filter type ............................
  • Page 87 SECTION 04 : EXHAUST AND AFTERTREATMENT CONTENTS TORQUE TABLES ............................. 2 X3 SERIES ................................ 2 H3 SERIES ............................... 4 MISCELLANEOUS TORQUES ........................... 7 EXHAUST AFTERTREATMENT SYSTEM OVERVIEW ..................8 MAINTENANCE............................... 8 FLEXIBLE COUPLING INSTALLATION ....................... 9 DIESEL PARTICULATE FILTER (DPF) ........................9 DIESEL PARTICULATE FILTER ASSEMBLY REMOVAL ..................

  • Page 88: Torque Tables

    SECTION 04 : EXHAUST AND AFTERTREATMENT TORQUE TABLES The following tables list the tightening torques for the bolts, nuts, etc. on the DPF assembly which do require a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual.
  • Page 89 SECTION 04 : EXHAUST AND AFTERTREATMENT 04038 04037 X3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE DPF inlet temperature sensor 30-37 lb-ft (41-50 Nm)* DPF tank strap 17-23 lb-ft (23-31 Nm) DPF tank V-band clamp 17-23 lb-ft (23-31 Nm) * Use Permatex 454G anti-seize lubricant or Loctite 76764 silver grade anti-seize 04039_2 X3 SERIES TORQUE SPECIFICATIONS DESCRIPTION...

  • Page 90: H3 Series

    SECTION 04 : EXHAUST AND AFTERTREATMENT 1.2 H3 SERIES H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE DEF injection nozzle mounting bolt 6.3-8.5 lb-ft (9-12 Nm) DPF outlet temperature sensor 30-37 lb-ft (41-50 Nm) * V-band clamp 4-inch & 5-inch 6.5-9.5 lb-ft (9-13 Nm) NOx sensor 1 30-44 lb-ft (41-60 Nm) * DPF tank strap...
  • Page 91 SECTION 04 : EXHAUST AND AFTERTREATMENT H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE V-band clamp 4-inch & 5-inch 6.5-9.5 lb-ft (9-13 Nm) DPF filter outlet pressure sensor 3.7-4.6 lb-ft (5.02-6.24 Nm) * DPF filter inlet pressure sensor 3.7-4.6 lb-ft (5.02-6.24 Nm) * Diesel Oxidation Catalyst (DOC) temperature sensor (T2) 30-37 lb-ft (41-50 Nm) * Cap screw...
  • Page 92 SECTION 04 : EXHAUST AND AFTERTREATMENT H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE V-band clamp 4-inch & 5-inch 6.5-9.5 lb-ft (9-13 Nm) DPF inlet temperature sensor 30-37 lb-ft (41-50 Nm) * DPF tank V-band clamp 17-23 lb-ft (23-31 Nm) H3 SERIES TORQUE SPECIFICATIONS DESCRIPTION TORQUE SCR tank strap...

  • Page 93: Miscellaneous Torques

    SECTION 04 : EXHAUST AND AFTERTREATMENT 1.3 MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION TORQUE Aftertreatment hydrocarbon doser fuel line fitting 177-213 lb-in (20-24 Nm) Aftertreatment hydrocarbon doser mounting bolts 120-130 lb-in (14-15 Nm) DEF pump filter cover 22 lb-ft (30 Nm) PA1615 Maintenance Manual All Series | Section 04 revised September 2016...

  • Page 94: Exhaust Aftertreatment System Overview

    SECTION 04 : EXHAUST AND AFTERTREATMENT The exhaust aftertreatment system is rubber EXHAUST AFTERTREATMENT mounted to the vehicle structure. This feature SYSTEM OVERVIEW reduces the transmission of vibrations to the exhaust aftertreatment system thus resulting in extended life of the system, brackets and also noise reduction.

  • Page 95: Maintenance

    NOTE required. Clean remanufactured DPF cartridge The key to successful regeneration is high will be available through Prevost on an exchange exhaust temperature for an extended period of basis. For most vehicle applications and duty time. For this reason, insulating blankets must...

  • Page 96: Diesel Particulate Filter Assembly Removal

    SECTION 04 : EXHAUST AND AFTERTREATMENT 04016 FIGURE 3: DIESEL OXIDATION CATALYST (DOC) & DIESEL PARTICULATE FILTER (DPF) ASSEMBLY 3.1 DIESEL PARTICULATE FILTER WARNING ASSEMBLY REMOVAL To remove the DPF, proceed as follows: HOT EXHAUST During stationary regeneration, exhaust gases CAUTION temperature may get very hot at the diffuser outlet.

  • Page 97: Catalytic Converter

    SECTION 04 : EXHAUST AND AFTERTREATMENT 5. Unfasten clamps holding DOC and DPF 9. Always put DOC and DPF filtration cartridge assembly; back together again in a vertical position to facilitate gaskets positioning; 6. Carefully lower DOC and DPF assembly; 7.

  • Page 98: Removal

    SECTION 04 : EXHAUST AND AFTERTREATMENT • 4.1 REMOVAL Disconnect and remove the air intake duct mounted between the turbocharger outlet Procedure # 1 and the air cooler inlet. Radiator must be removed in order to lower the • Open radiator door. Unfasten bolts and catalytic converter for replacement.

  • Page 99: Assembling Catalytic Converter

    SECTION 04 : EXHAUST AND AFTERTREATMENT • Upper Disconnect and remove a section of coolant pipe assembly mounted between thermostat housing and the radiator inlet. • Disconnect and remove the air intake duct mounted between the turbocharger outlet and the air cooler inlet. •...

  • Page 100: Diffuser Assembly

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

  • Page 101: Diffuser Adjustment

    SECTION 04 : EXHAUST AND AFTERTREATMENT 3. Using a straightedge, adjust the diffuser assembly level. The top surface of the warning plate fixed on the diffuser louvered cover must be flush with the roof surface or may exceed about 3/32in (2mm). 4.

  • Page 102: Diesel Exhaust Fluid (Def) Tank And Injection System

    SECTION 04 : EXHAUST AND AFTERTREATMENT 4. Place the diffuser louvered cover over the The system notifies the driver when it is time to assembly and secure with a second set of 10 top up with DEF. identical cap nuts. 6.1 DIESEL EXHAUST FLUID When handling DEF solution, it is important that electrical connectors to be connected or well...
  • Page 103 SECTION 04 : EXHAUST AND AFTERTREATMENT • The DEF solution is highly corrosive to certain metals, including copper aluminum. • If the DEF solution is spilled onto the vehicle, wipe off the excess and rinse with water. Spilled DEF solution can form concentrated white crystals on the vehicle.

  • Page 104: Def Tank Cleaning

    SECTION 04 : EXHAUST AND AFTERTREATMENT FIGURE 10: H SERIES DEF TANK AND PUMP FIGURE 11 X SERIES DEF TANK AND PUMP 2. Remove the DEF tank drain plug through the 6.2 DEF TANK CLEANING DEF tank support pan access hole. Removing the DEF tank for cleaning is not 3.

  • Page 105: Pump Assembly Filter Element Replacement

    SECTION 04 : EXHAUST AND AFTERTREATMENT 4. Remove the DEF tank filler neck insert. To do 4. Use needle nose pliers to carefully remove so, release the retaining tab and remove filler the equalizer and filter element. Do not neck insert. Replace old seal if damaged. damage the sealing surface on the housing.

  • Page 106: Filler Neck Strainer

    SECTION 04 : EXHAUST AND AFTERTREATMENT MAINTENANCE MAINTENANCE Replace pump filter element Aftertreatment hydrocarbon doser equalizer at the intervals specified by the Replace the aftertreatment hydrocarbon doser Lubrication And Servicing Schedule in Section at the intervals specified by the Lubrication And 24: LUBRICATION &...
  • Page 107 SECTION 04 : EXHAUST AND AFTERTREATMENT Remove the aftertreatment hydrocarbon injector mounting fasteners. Remove the aftertreatment hydrocarbon injector from the diffuser pipe (which attaches turbocharger outlet). Clean the sealing surface on the diffuser pipe before mounting the aftertreatment hydrocarbon injector. Install aftertreatment hydrocarbon injector and new gasket onto the...
  • Page 109 SECTION 05a: H3 SERIES COOLING SYSTEM CONTENTS TORQUE TABLES ............................. 4 HOSE CLAMPS ..............................4 PULLEY, IDLERS & TENSIONERS ........................5 COOLING FAN DRIVE MECHANISM ........................ 6 RIGHT ANGLE GEARBOX ..........................7 MISCELLANEOUS TORQUES ........................... 8 DESCRIPTION ................................. 9 MAINTENANCE ............................. 10 GENERAL RECOMMENDATIONS ........................
  • Page 110 SECTION 05a: H3 SERIES COOLING SYSTEM 13.1.1 ELECTRICAL LOCKING ........................... 25 13.1.2 MECHANICAL LOCKING IN CASE OF POWER FAILURE ................25 13.2 MAINTENANCE............................. 26 13.3 INSPECTION..............................26 13.4 FAN REMOVAL / INSTALLATION ........................26 FAN RIGHT ANGLE GEARBOX ........................26 14.1 MAINTENANCE.............................
  • Page 111 SECTION 05a: H3 SERIES COOLING SYSTEM ILLUSTRATIONS ......................... 9 FIGURE COOLANT SURGE TANK & ................10 FIGURE CLAMP TYPE USED ON HEATING COOLING SYSTEMS ..................... 11 FIGURE PROPER HOSE CLAMP INSTALLATION ......................11 FIGURE DOUBLED CLAMP POSITIONING 13) ..................11 FIGURE COOLANT FLOW TO RADIATOR VOLVO D...

  • Page 112: Torque Tables

    SECTION 05a: H3 SERIES COOLING SYSTEM TORQUE TABLES HOSE CLAMPS HOSE CLAMPS DESCRIPTION TORQUE Constant-Torque hose clamps - coolant lines 90-100 lb-in (10-11 Nm) Oetiker hose clamps – Green spring - coolant lines 12-18 lb-in (1.36-2.03 Nm) Oetiker hose clamps – unpainted spring - coolant lines 8-9 lb-in (0.9-1.02 Nm) Caillau hose clamps - coolant lines 30 lb-in (3.39 Nm)

  • Page 113: Pulley, Idlers & Tensioners

    SECTION 05a: H3 SERIES COOLING SYSTEM PULLEY, IDLERS & TENSIONERS PULLEY, IDLERS & TENSIONERS DESCRIPTION TORQUE Automatic belt tensioner bolt – cooling fan drive 32 lb-ft (43 Nm) Fan drive support (casting) 60 lb-ft (81 Nm) Automatic belt tensioner 2 bolt 32 lb-ft (43 Nm) Idler, cooling fan drive...

  • Page 114: Cooling Fan Drive Mechanism

    SECTION 05a: H3 SERIES COOLING SYSTEM COOLING FAN DRIVE MECHANISM COOLING FAN DRIVE MECHANISM DESCRIPTION TORQUE Shaft – universal joint bolts 16-18 lb-ft (22-24 Nm) Fan bolts 32 lb-ft (43 Nm) Fan pulley hub to casting 16 lb-ft (22 Nm) PA1615 Maintenance Manual All Series | Section 05a revised September 2016...

  • Page 115: Right Angle Gearbox

    SECTION 05a: H3 SERIES COOLING SYSTEM RIGHT ANGLE GEARBOX RIGHT ANGLE GEARBOX DESCRIPTION TORQUE Spare bolts (when used to lock fan clutch) 7.5 lb-ft (10 Nm) Right angle gearbox - Oil fill plug 5.4-6.6 lb-ft (7.32-8.95 Nm) Right angle gearbox - Oil level plug 24-28 lb-ft (33-38 Nm) Right angle gearbox - Oil drain plug 24-28 lb-ft (33-38 Nm)

  • Page 116: Miscellaneous Torques

    SECTION 05a: H3 SERIES COOLING SYSTEM MISCELLANEOUS TORQUES MISCELLANEOUS DESCRIPTION TORQUE Water pump - Back cover to engine 29-41 lb-ft (39-56 Nm) Water pump - Body to back cover 15-21 lb-ft (20-28 Nm) Thermostat housing bolts 15-21 lb-ft (20-28 Nm) PA1615 Maintenance Manual All Series | Section 05a revised September 2016...

  • Page 117: Description

    SECTION 05a: H3 SERIES COOLING SYSTEM Upon starting a cold engine or when the coolant DESCRIPTION is below normal operating temperature, the A radiator and thermo-modulated fan are used to closed thermostats direct coolant flow from the effectively dissipate the heat generated by the thermostat housing through the by-pass tube to engine.

  • Page 118: Maintenance

    SECTION 05a: H3 SERIES COOLING SYSTEM MAINTENANCE CAUTION GENERAL RECOMMENDATIONS Castings should be clean and free of oil and A systematic routine inspection of cooling grease before applying compound. No other system components is essential to ensure sealer should used with RTV-102 maximum engine and heating system efficiency.
  • Page 119 SECTION 05a: H3 SERIES COOLING SYSTEM FIGURE 3: PROPER HOSE CLAMP INSTALLATION All connections equal or greater than of 2-in OD have doubled clamps (two clamps side by side) with screw housing separated from at least 90°. FIGURE 6: COOLANT LINE TO THE RADIATOR A torque wrench should be used for proper installation.

  • Page 120: Oetiker Screw Clamps

    SECTION 05a: H3 SERIES COOLING SYSTEM 6. Turn the screw anti-clockwise to loosen the Self-Tensioning Screw Clamp. 7. Relocate the interlock in the next smaller diameter position. 8. Tighten the screw to the required torque. CONSTANT-TORQUE HOSE CLAMPS ON CHARGE AIR COOLER (CAC) SYSTEM If for any reason hose clamps need to be FIGURE 10: COOLANT LINE AT PUMP INLET...

  • Page 121: Thermostat Operation

    SECTION 05a: H3 SERIES COOLING SYSTEM 2. After at least 30 seconds, check that the THERMOSTAT OPERATION thermostat is still closed. THERMOSTAT REPLACEMENT 1. Drain the cooling system. 2. Remove the bolts, the thermostat housing and the thermostat. Carefully clean the thermostat seat and all cylinder head-to- thermostat housing mating surfaces.

  • Page 122: Thawing Cooling System

    Recommended coolants for Volvo D13 Select and maintain coolant in order to meet the engine: following basic requirements: • Prevost #685241 (pre-diluted 50/50 • Provide for adequate heat transfer. mixture); • Texaco CPS#227998 (pre-diluted 50/50 •...

  • Page 123: Coolant Sampling

    SECTION 05a: H3 SERIES COOLING SYSTEM NOTE CAUTION Watch out for accidental contamination! On Volvo D13 engine, use only Extended Life Hand vacuum pump should be used for Coolant (ELC). Do not add supplemental coolant sampling only to prevent cross- coolant additives (SCA) to extended life contamination.
  • Page 124 SECTION 05a: H3 SERIES COOLING SYSTEM rear wheelhousing near the optional coolant 3. Open the shut-off valve on the coolant filter heater. mounting head and drain the coolant into a suitable container. Close the shut-off valve. NOTE Refer to section 22 under "Preheating System" for information about preheater access and 4.

  • Page 125: Filling Cooling System

    SECTION 05a: H3 SERIES COOLING SYSTEM NOTE CAUTION If for any reason, the coolant level drops below the surge tank level probe, the Check Engine Drain water pump completely before extended warning light will illuminate. storage avoid possible water pump damage.

  • Page 126: Cooling System Descalers

    SECTION 05a: H3 SERIES COOLING SYSTEM Fill with a 50/50-antifreeze/water solution 3. Attach a hose at the bottom of the radiator and add required inhibitors. and insert a flushing gun in the hose. Vehicles with coolant filters: 4. Connect the water hose of the gun to the water outlet and the air hose to the Fill with a 50/50-antifreeze/water solution.

  • Page 127: Radiator

    SECTION 05a: H3 SERIES COOLING SYSTEM RADIATOR WARNING The radiator is mounted at the L.H. side of engine compartment. It is designed to reduce Failure to relieve cooling system pressure may the temperature of the coolant under all result in personal injury. operating conditions.
  • Page 128 SECTION 05a: H3 SERIES COOLING SYSTEM FIGURE 19: ENGINE COMPARTMENT DOOR FIGURE 21: L.H. SIDE REAR FENDER 6. Remove tag axle L.H. side wheel. 2. Open engine compartment door (Figure 19). 7. Unfasten cap screws and remove access 3. Set starter selector switch to the OFF panel located behind tag axle L.H.
  • Page 129 SECTION 05a: H3 SERIES COOLING SYSTEM 9. Remove radiator sealing frame (Figure 24). 12. Remove upper radiator assembly support bracket (Figure 27). FIGURE 24: RADIATOR SEALING FRAME FIGURE UPPER RADIATOR ASSY SUPPORT 10. Remove clamps and then break hoses from BRACKET the front coolant and charge air pipes 13.
  • Page 130 SECTION 05a: H3 SERIES COOLING SYSTEM 14. Remove lower radiator assembly mounting fasteners. FIGURE 31: POSITIONING FORKLIFT 17. With assistance, slide radiator assembly out and onto the forklift. Transfer radiator assembly to a secure location. 18. Separate charge air cooler from radiator FIGURE 29: RADIATOR ASSEMBLY LOWER MOUNTING (Figure 32).

  • Page 131: Charge Air Cooler (Cac) Leakage

    SECTION 05a: H3 SERIES COOLING SYSTEM CHARGE AIR COOLER (CAC) LEAKAGE Spec for CAC acceptable leakage: The CAC is considered acceptable if it can hold 30 psi (206 kPa) gauge pressure with not more than 5 psi (34 kPa) loss in 15 seconds after turning off the hand valve.

  • Page 132: Idler Replacement

    SECTION 05a: H3 SERIES COOLING SYSTEM FIGURE 38: PULLEYS ARRANGEMENT 05146 1. Remove the protective cap (replace with a new one). 2. Unscrew the idler mounting bolt. 3. Replace idler with a new one. FIGURE 36: COOLING FAN DRIVE MECHANISM 05149 CAUTION When installing the idler, make sure it rests...

  • Page 133: Variable Speed Cooling Fan

    SECTION 05a: H3 SERIES COOLING SYSTEM 13.1 LOCKING RADIATOR FAN CLUTCH VARIABLE SPEED COOLING FAN FOR EMERGENCY OPERATION The cooling fan clutch has two thermostatically controlled speeds, plus neutral (clutch 13.1.1 Electrical Locking disengaged). The engine control module controls the speed by comparing data from engine If the radiator fan clutch does not function due to coolant temperature, charge air temperature, an electrical control system malfunction and the...

  • Page 134: Maintenance

    7. When questions arise, obtain answers before proceeding. Assistance is available through the Prevost After-Sales Service support FIGURE 41: RADIATOR FAN MOUNTING BOLTS 05125 serving your area. FAN RIGHT ANGLE GEARBOX 13.3...

  • Page 135: Maintenance

    SECTION 05a: H3 SERIES COOLING SYSTEM 14.1 MAINTENANCE WARNING Note that warranty may be voided if oil change MAINTENANCE interval is not respected or an inappropriate type of oil is used. Refer to refer to Linnig Change the right angle gearbox oil only at bulletin 142.377 for the list of approved oils.

  • Page 136: Cooling Fan Drive Belt

    SECTION 05a: H3 SERIES COOLING SYSTEM FIGURE 44: RIGHT ANGLE GEARBOX 05126 FIGURE 46: DRIVE BELT ROUTING (VOLVO D13 ENGINE) 05127 1. Wrap the new drive belt around the fan drive mechanism pulley, idlers automatic tensioner idler as shown on Figure 2.
  • Page 137 Start to close ............................203°F (95°C) Fully closed ............................185°F (85°C) Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2213 Qty ..................................1 Prevost number ............................5060096 Coolant - Volvo D13 Engine Prevost Number ............................685241 Texaco CPS ...............................227998 Chevron CPS ............................2227805 Coolant Filter Cartridge –...
  • Page 139 SECTION 05b: X3 SERIES COOLING SYSTEM CONTENTS TORQUE TABLES ............................. 4 Constant-Torque hose clamps - charge air cooler (CAC) ................... 4 Fan bolts ..................................6 Right angle gearbox - Oil level plug ........................... 7 Water pump - Body to back cover ..........................8 DESCRIPTION ..............................
  • Page 140 SECTION 05b: X3 SERIES COOLING SYSTEM 14.1 LOCKING RADIATOR FAN CLUTCH FOR EMERGENCY OPERATION ............... 23 14.1.1 Electrical Locking ..........................23 14.1.2 Mechanical Locking In Case Of Power Failure ..................23 14.2 MAINTENANCE............................. 24 14.3 INSPECTION..............................24 14.4 FAN REMOVAL / INSTALLATION ........................24 FAN RIGHT ANGLE GEARBOX ........................
  • Page 141 SECTION 05b: X3 SERIES COOLING SYSTEM ILLUSTRATIONS ............................. 9 FIGURE COOLANT SURGE TANK 13) ......................11 FIGURE COOLANT FLOW TO RADIATOR VOLVO D ........................11 FIGURE CONSTANT TORQUE CLAMP ........................11 FIGURE CHARGE AIR COOLER HOSE CLAMPS ........................12 FIGURE VOLVO D THERMOSTAT HOUSING ..........

  • Page 142: Torque Tables

    SECTION 05b: X3 SERIES COOLING SYSTEM 1. TORQUE TABLES HOSE CLAMPS DESCRIPTION TORQUE Constant-Torque hose clamps - coolant lines (2.5in O.D) 90-100 lb-in (10-11 Nm) Constant-Torque hose clamps - charge air cooler (CAC) 4.5-5.5 lb-ft (6.1-7.46 Nm) PA1615 Maintenance Manual All Series Section 05b revised September 2016...
  • Page 143 SECTION 05b: X3 SERIES COOLING SYSTEM 01225_2 PULLEY, IDLERS & TENTIONERS DESCRIPTION TORQUE Automatic belt tensioner bolt – cooling fan 32 lb-ft (43 Nm) Fan drive support (casting) 60 lb-ft (81 Nm) Automatic belt tensioner 2 bolt 32 lb-ft (43 Nm) Lower idler bolt –...

  • Page 144: Fan Bolts

    SECTION 05b: X3 SERIES COOLING SYSTEM COOLING FAN DRIVE MECHANISM DESCRIPTION TORQUE Shaft – universal joint bolts 16-18 lb-ft (22-24 Nm) Fan bolts 32 lb-ft (43 Nm) Fan pulley hub to bracket 16 lb-ft (22 Nm) PA1615 Maintenance Manual All Series Section 05b revised September 2016...

  • Page 145: Right Angle Gearbox - Oil Level Plug

    SECTION 05b: X3 SERIES COOLING SYSTEM 05124_2 05118_5 05126_3 RIGHT ANGLE GEARBOX DESCRIPTION TORQUE Spare bolts (when used to lock fan clutch) 7.5 lb-ft (10 Nm) Right angle gearbox - Oil fill plug 5.4-6.6 lb-ft (7.32-8.95 Nm) Right angle gearbox - Oil level plug 24-28 lb-ft (33-38 Nm) Right angle gearbox - Oil drain plug 24-28 lb-ft (33-38 Nm)

  • Page 146: Water Pump - Body To

    SECTION 05b: X3 SERIES COOLING SYSTEM MISCELLANEOUS DESCRIPTION TORQUE Water pump - Back cover to engine 29-41 lb-ft (39-56 Nm) Water pump - Body to back cover 15-21 lb-ft (20-28 Nm) Thermostat housing bolts 15-21 lb-ft (20-28 Nm) PA1615 Maintenance Manual All Series Section 05b revised September 2016...
  • Page 147 SECTION 05b: X3 SERIES COOLING SYSTEM Upon starting a cold engine or when the coolant 2. DESCRIPTION is below normal operating temperature, the closed thermostat directs coolant flow from the A radiator and thermo-modulated fan are used to thermostat housing through the by-pass tube to effectively dissipate the heat generated by the the water pump.

  • Page 148: Maintenance

    SECTION 05b: X3 SERIES COOLING SYSTEM 3. MAINTENANCE NOTE 3.1 GENERAL RECOMMENDATIONS For additional information concerning Volvo A systematic routine inspection of cooling D13 engine components or engine-related system components is essential to ensure components, consult Volvo Trucks Canada or maximum engine and heating system efficiency.

  • Page 149: Installation

    SECTION 05b: X3 SERIES COOLING SYSTEM is extending ¼" (6 mm) out of the housing, the clamp is properly installed and maintains a leak-proof connection. Since the constant-torque clamp automatically adjusts to keep a consistent sealing pressure, there is no need to re-torque hose clamps on a regular basis.

  • Page 150: Thermostat Operation

    SECTION 05b: X3 SERIES COOLING SYSTEM 5. THERMOSTAT OPERATION 5.1 THERMOSTAT REPLACEMENT 1. Drain the cooling system. 2. Remove the bolts, the thermostat housing and the thermostat. Carefully clean the thermostat seat and all cylinder head-to- 2. After at least 30 seconds, check that the thermostat housing mating surfaces.

  • Page 151: Cooling System Recommendations

    Select and maintain coolant in order to meet the following basic requirements: Recommended coolants for Volvo D13 engine: • Provide for adequate heat transfer. • Prevost #685241 (pre-diluted 50/50 • Provide protection from cavitation damage. mixture); •...

  • Page 152: Coolant Sampling

    SECTION 05b: X3 SERIES COOLING SYSTEM FIGURE 6: LOCATION OF HEATER LINE SHUT-OFF VALVES IN ENGINE COMPARTMENT 05105 6.6 COOLANT SAMPLING WARNING Providing a sample of coolant for lab analysis Before proceeding with the following steps, may be required at some point in the life of the make sure the coolant has cooled down.

  • Page 153: Draining Cooling System

    SECTION 05b: X3 SERIES COOLING SYSTEM Typical material required: 8. Throw plastic tube away. (Not to be re-used) • Hand Vacuum Pump w/ bottle provision 9. Complete forms required laboratory. 7. DRAINING COOLING SYSTEM Use the following procedures to drain the cooling system partially or completely.

  • Page 154: Filling Cooling System

    SECTION 05b: X3 SERIES COOLING SYSTEM 4. Unscrew the surge tank pressure cap CAUTION counterclockwise, ¼ turn to let air enter the system and permit the coolant to drain Drain water pump completely before extended completely from system. storage avoid possible water pump...

  • Page 155: Flushing

    SECTION 05b: X3 SERIES COOLING SYSTEM NOTE Fill with a 50/50-antifreeze/water solution. Replace coolant filter as per the Lubrication If for any reason, the coolant level drops below and Servicing Schedule in section 24 if the surge tank level probe, the Check Engine required.

  • Page 156: Spin-On Coolant Filter

    SECTION 05b: X3 SERIES COOLING SYSTEM 4. Connect the water hose of the gun to the WARNING water outlet and the air hose to the compressed air outlet. Failure to relieve cooling system pressure may 5. Turn on the water and when the radiator is result in personal injury.

  • Page 157: Radiator Removal & Installation

    SECTION 05b: X3 SERIES COOLING SYSTEM 11.1 MAINTENANCE DANGER MAINTENANCE Coolant is toxic; risk of poisoning. Do not drink coolant. Use proper hand protection when Inspect the exterior of the radiator core at the handling. Keep coolant out of reach of children intervals specified by the Lubrication And animals.
  • Page 158 SECTION 05b: X3 SERIES COOLING SYSTEM 10. Remove clamps and then break hoses from 12. Remove upper radiator assembly the front coolant and charge air pipes support bracket (Figure 14). (Figure 12 & Figure 13). FIGURE 14: UPPER SUPPORT BRACKET & TUBE FIGURE 12: RADIATOR HOSE CLAMPS PROTECTOR 11.

  • Page 159: Charge Air Cooler Leakage

    SECTION 05b: X3 SERIES COOLING SYSTEM 15. Cut cable tie and disconnect electrical connector from fan clutch. Remove fan drive shaft fasteners at the gear box. FIGURE 18: REMOVING FASTENERS 20. Remove upper fan drive support bracket from the upper section of the radiator. FIGURE 16: DISCONNECTING FAN DRIVE SHAFT 16.

  • Page 160: Cooling Fan Drive Mechanism

    SECTION 05b: X3 SERIES COOLING SYSTEM Installation of the universal joint shaft is the 13. COOLING FAN DRIVE MECHANISM same as removal, but in reverse order. TORQUE: 16 lb-ft (22 Nm) FIGURE 22: PULLEY AND SHAFT 05123B 13.2 IDLER REPLACEMENT If an idler is defective, replace as follow: WARNING FIGURE 21: COOLING FAN DRIVE MECHANISM...

  • Page 161: Variable Speed Cooling Fan

    SECTION 05b: X3 SERIES COOLING SYSTEM 4. Bolt the new idler on the cast aluminum WARNING support. TORQUE: 32 lb-ft (43 Nm) DO NOT work near the fan with the engine running or the ignition in the ON position. The 5.

  • Page 162: Maintenance

    7. When questions arise, obtain answers before proceeding. Assistance is available through the Prevost After-Sales Service support FIGURE 25: RADIATOR FAN MOUNTING BOLTS 05125_2 serving your area. 14.3 INSPECTION 15. FAN RIGHT ANGLE GEARBOX...

  • Page 163: Maintenance

    SECTION 05b: X3 SERIES COOLING SYSTEM 9. Start the engine and allow running a few minutes. Stop the engine and check for leaks. 15.3 REMOVAL / INSTALLATION To remove the right angle gearbox, proceed as follow: 1. Set the ignition to the OFF position and remove the key from the contact switch to prevent accidental starting of the engine.

  • Page 164: Cooling Fan Drive Belt

    With Volvo D13 engine prevent accidental starting of the engine. Type: 14PK2526 Prevost number: 5060097 WARNING Potential Accident Risk. Always use extreme caution when working in the vicinity of hot, rotating or moving parts.
  • Page 165 Start to close ............................203°F (95°C) Fully closed ............................185°F (85°C) Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2526 Qty ..................................1 Prevost number ............................5060097 Coolant - Volvo D13 Engine Prevost Number ............................685241 Texaco CPS ...............................227998 Chevron CPS ............................2227805 Coolant Filter Cartridge –...
  • Page 167 CIRCUIT BREAKERS ............................11 2.4.1 X3-45 Coaches ............................12 2.4.2 X3-45 VIP .............................. 12 2.4.3 H3-41, H3-45 Coaches ......................... 12 2.4.4 H3-45 VIP ............................. 12 MULTIPLEX FUSES ............................12 RELAYS ................................. 13 PRECAUTIONS .............................. 13 X3 SERIES ELECTRICAL COMPARTMENTS ....................15 MAINTENANCE ............................
  • Page 168 SECTION 06: ELECTRICAL 5.7.3 Load Test .............................. 27 5.7.4 Testing Battery Cables ......................... 28 BATTERY CHARGING ............................ 28 5.8.1 Battery Charging Guide ........................29 5.8.2 Emergency Jump Starting With Auxiliary (Booster) Battery..............30 AGM BATTERY CHARGING PRECAUTIONS ....................31 5.10 BATTERY EQUALIZATION AND AGM BATTERIES ..................
  • Page 169 SECTION 06: ELECTRICAL STARTER ..............................60 ENGINE BLOCK HEATER .......................... 60 11.1 MAINTENANCE ............................60 X3 SERIES EXTERIOR LIGHTING ....................... 60 12.1 HEADLIGHTS ..............................60 12.1.1 Headlight Beam Toggle Switch ......................61 12.1.2 Maintenance ............................61 12.1.3 Headlight Adjustment .......................... 61 12.1.4 Sealed-Beam Unit ..........................
  • Page 170 SECTION 06: ELECTRICAL 14.4 CLEARANCE, IDENTIFICATION AND MARKER LIGHTS .................. 75 14.4.1 Marker Light Removal And Replacement .................... 75 14.4.2 Clearance And Identification Light Removal And Replacement ............75 14.5 DOCKING AND CORNERING LIGHTS ......................75 14.6 LAMP REMOVAL AND REPLACEMENT ......................75 14.7 FOG LIGHTS ..............................
  • Page 171 SECTION 06: ELECTRICAL ILLUSTRATIONS FIGURE 1: WIRE IDENTIFICATION ......................10 FIGURE 2: TYPICAL REAR ELECTRICAL JUNCTION PANEL – X3 SERIES ......... 11 FIGURE 3: MAIN BREAKER PANELS – H3 SERIES ................11 FIGURE 4: MULTIPLEX MODULE CONNECTOR PIN-OUT ..............13 FIGURE 5: ELECTRICAL COMPARTMENTS (X3-45 COACH) ..............
  • Page 172 SECTION 06: ELECTRICAL FIGURE 54: REAR TAIL LAMPS ........................ 65 FIGURE 55: TAILLAMP POD RETAINING SCREWS & NUTS ..............65 FIGURE 56: SWITCH ..........................67 FIGURE 57: VARIOUS LIGHTS LOCATION ....................68 FIGURE 58: PARCEL RACK LIGHTING ....................69 FIGURE 59: ENGINE COMPARTMENT LIGHT ..................70 FIGURE 60: HEADLIGHT ASSEMBLY ......................

  • Page 173: Torque Tables

    SECTION 06: ELECTRICAL TORQUE TABLES ALTERNATORS AND SURROUNDING COMPONENTS 06783 06784 BOSCH HD10 ALTERNATORS DESCRIPTION TORQUE A/C tensioner / idler bracket mounting bolts (2) 43 lb-ft (58 Nm) A/C tensioner / idler bracket mounting bolt (1) 22 lb-ft (30 Nm) Alternator pulley (2) LH threads 70-80 lb-ft (95-108 Nm) Alternator mounting bracket mounting bolts...

  • Page 174: Electrical Connections And Batteries

    SECTION 06: ELECTRICAL Alternator mounting bolts (2) (small A/C system) 48 lb-ft (65 Nm) Alternator mounting bolts (2) (small A/C system) 82 lb-ft (111 Nm) Alternator belt idler mounting bolt (small A/C system) 48 lb-ft (65 Nm) ELECTRICAL CONNECTIONS AND BATTERIES 06787 06788 ELECTRICAL CONNECTIONS AND BATTERIES...

  • Page 175: General Description

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

  • Page 176: Testing Circuits

    SECTION 06: ELECTRICAL a) Refer to wiring diagram index, and look for connectors. The wires are color coded as "Multiplexed Device Index", pages B1-B8. follows: b) In first column DEVICE ID, look for device Yellow Multiplex modules communication SW61, SW62. CAN-H (twisted with green) Green Multiplex modules communication...

  • Page 177: Spare Wires

    SECTION 06: ELECTRICAL SPARE WIRES When the vehicle leaves the factory, and even in the case of a fully-equipped vehicle, an important number of unconnected spare wires routed between junction boxes. Consequently , for any connection of an additional accessory, refer to page D "Spare wires" in master wiring diagram to determine the number, the gauge and location of these wires.

  • Page 178: X3-45 Coaches

    SECTION 06: ELECTRICAL 2.4.3 H3-41, H3-45 Coaches 2.4.1 X3-45 Coaches Smaller circuit breakers may be located in the VECF of the front service compartment. Smaller circuit breakers may be located in the CIRCUIT BREAKERS (H3 series coaches) VECF of the front service compartment.

  • Page 179: Relays

    SECTION 06: ELECTRICAL above the limit and the soft-fuse intervenes to Always refer to the appropriate wiring and turn the output OFF. The output stays OFF until pneumatic diagrams prior to working on the "soft-fuse" is reset. electrical and/or pneumatic systems. Turn the ignition key to the OFF position and NOTE turn to the ON position again.
  • Page 180 Remove the terminal by disengaging the flexible 06630 lock tab on the terminal. Gently remove the terminal from the connector by pulling on the wire. EXTRACTOR/TOOL: Prevost #682256 (Packard INS ERT 12094429) EXT RACT OR HERE Remove the terminal by disengaging the flexible lock tab on the terminal.

  • Page 181: X3 Series Electrical Compartments

    SECTION 06: ELECTRICAL X3 SERIES ELECTRICAL COMPARTMENTS 06672 FIGURE 5: ELECTRICAL COMPARTMENTS (X3-45 COACH) 06765 FIGURE 6: ELECTRICAL COMPARTMENTS (X3-45 VIP) PA1615 Maintenance Manual All Series | Section 06 revised July 2017...

  • Page 182: Maintenance

    SECTION 06: ELECTRICAL FIGURE 7: ELECTRICAL COMPARTMENTS (X3-45 VIP COMMERCIAL BUS SHELL) are accessible from the engine compartment MAINTENANCE curb-side door. A corrosion inhibitor has been sprayed on certain electrical components in order to protect them from corrosion. Refer to procedure SAV00002E at the end of this section for recommended products and where they are used.

  • Page 183: Rear Electrical Panel

    SECTION 06: ELECTRICAL FIGURE 9: REAR ELECTRICAL PANEL FIGURE 11: BATTERY COMPARTMENT FRONT ELECTRICAL AND SERVICE COMPARTMENT REAR ELECTRICAL PANEL The front electrical and service compartment is The rear electrical panel provides access to the located on L.H. side of vehicle, under the following: driver's window.

  • Page 184: Engine Rear Start Panel

    SECTION 06: ELECTRICAL under the larger utility compartment at the base of the windshield. FIGURE 13: A/C JUNCTION BOX 06619 FIGURE 15: ENTRANCE DOOR & WIPER CONTROL ENGINE REAR START PANEL PANEL This control panel is located in the R.H. side of Entrance Door &...

  • Page 185: H3 Series Electrical Compartments

    SECTION 06: ELECTRICAL H3 SERIES ELECTRICAL COMPARTMENTS FIGURE 17: ELECTRICAL COMPARTMENTS PA1615 Maintenance Manual All Series | Section 06 revised July 2017...

  • Page 186: Maintenance

    SECTION 06: ELECTRICAL MAINTENANCE A corrosion inhibitor has been sprayed on certain electrical components in order to protect them from corrosion. Refer to procedure SAV00002E at the end of this section for recommended products and where they are used. DANGER Use sprayed sealer in a well ventilated area.

  • Page 187: Front Electrical And Service Compartment

    SECTION 06: ELECTRICAL is connected to an external 110-120 VAC power A/C AND HEATING CONTROLS source, in-station lighting circuit The following components are located in the beenergized without depleting the batteries. The main power compartment (Figure 18). receptacle is usually located on the main power compartment door or engine compartment R.H.

  • Page 188: Pneumatic Accessory Panel

    SECTION 06: ELECTRICAL PNEUMATIC ACCESSORY PANEL WARNING Battery posts, terminals and other related accessories contain lead lead compounds, chemical known to the State of California cause cancer other reproductive harm. Batteries also contain other chemicals known to the State of California to cause cancer. Wash hands after handling.

  • Page 189: Group 31 Agm Batteries

    SECTION 06: ELECTRICAL top-mounted negative positive These batteries require no maintenance for their terminals are tightly sealed to prevent leaks. lifetime. They can withstand deeper discharge Water never needs to be added to this type of cycles and several times the charging cycles of battery.
  • Page 190 SECTION 06: ELECTRICAL FIGURE 26: H3 SERIES AGM BATTERY CONNECTIONS (PRIME SYSTEM) PA1615 Maintenance Manual All Series | Section 06 revised July 2017...

  • Page 191: Battery Discharge Protection

    SECTION 06: ELECTRICAL FIGURE 27: X3 SERIES AGM BATTERY CONNECTIONS MAIN BATTERY RELAYS BATTERY DISCHARGE PROTECTION Main battery (master) relays (12V and 24V) are To prevent discharge of the batteries when the provided for this vehicle. The relays are located engine in not running, some functions are in the battery compartment and on the rear automatically switched off if the batteries voltage...

  • Page 192: Battery Removal And Installation

    SECTION 06: ELECTRICAL • Cluster memory. BATTERY REMOVAL AND INSTALLATION The batteries are located in the battery DANGER compartment on the R.H. side of the engine compartment and are accessible from the To prevent possible electric shock or sparking, engine compartment curb-side door. the battery master switch must be set to the 1.

  • Page 193: Battery Testing

    SECTION 06: ELECTRICAL BATTERY TESTING Several factors influence battery performance. methods inspection procedures proposed here will ensure your batteries are in good shape. 5.7.1 Visual Inspection 1. Check the outside of the battery for a broken or cracked cover or case that could permit loss of electrolyte.

  • Page 194: Testing Battery Cables

    SECTION 06: ELECTRICAL 5.7.4 Testing Battery Cables contact with it) as a short circuit will result. Do not attempt to jump start a vehicle suspected Check all cable ring terminals and connections of having a frozen battery because the battery to determine if they are in good condition.

  • Page 195: Battery Charging Guide

    SECTION 06: ELECTRICAL The alligator clamps of the tester or charger Battery temperature can be estimated by must be placed between the terminal nuts and touching or feeling the battery case. No further the lead pads of the terminal studs (Figure 30) charging is required.

  • Page 196: Emergency Jump Starting With Auxiliary (Booster) Battery

    SECTION 06: ELECTRICAL Temperature A longer time will be needed to charge any battery at 0 F (-18 C) than at 80 F (27 C). When a fast charger is connected to a cold battery, the current accepted by the battery will be very low at first, and then in time, the battery will accept a higher rate as it warms.

  • Page 197: Agm Battery Charging Precautions

    SECTION 06: ELECTRICAL 2. Connect one end of the remaining negative 5.10 BATTERY EQUALIZATION AND AGM jumper cable (black) to the negative (-) BATTERIES terminal of the booster power source, and Equalization is a controlled over charge. the other end of the black jumper cable to Conventional batteries may benefit from this the negative (-) post of the booster power procedure, stirring the chemistry of the entire...

  • Page 198: Common Causes Of Battery Failure

    SECTION 06: ELECTRICAL soda solution and a wire brush. Install cable ring 5.13 TROUBLESHOOTING terminals on battery posts and tighten. If a battery is known to be good and then has not performed satisfactorily in service for no TORQUE: 13-15 lb-ft (18-20 Nm) apparent reason, the following factors may reveal the cause of trouble: Replace protective caps to prevent corrosion...

  • Page 199: Battery Warning Pictogram May Appear As A Reminder

    SECTION 06: ELECTRICAL Checking Battery Balance Vanner 80 series battery equalizer that monitors battery State of Charge (SOC). NOTE Battery temperature, voltage and current are Allow at least 15 minutes to balance batteries also monitored to prevent overcharging and after any corrective measure has been taken. overheating.
  • Page 200 SECTION 06: ELECTRICAL FIGURE 33: PRIME ELECTRICAL COMPONENT PA1615 Maintenance Manual All Series | Section 06 revised July 2017...

  • Page 201: Vanner 80 Series Battery Equalizer Fault Codes

    SECTION 06: ELECTRICAL 6.2.1 Vanner 80 Series Battery Equalizer Fault Codes The 80 Equalizer Can Bus Interface supports SAE J1939 Diagnostic Message 1 (DM1) for active Diagnostic Trouble Codes. See list below. Refer to OEM publication Vanner Vann-Guard 80 Series Owner's Manual PDF for additional details.
  • Page 202 SECTION 06: ELECTRICAL PA1615 Maintenance Manual All Series | Section 06 revised July 2017...

  • Page 203: Did Display

    SECTION 06: ELECTRICAL NOTE DID DISPLAY o Verify on the wiring diagram whether the In the DID you will find the percentage of trip voltage is 12V or 24V, made with regenerated electricity displayed o For a 12V module: an active voltage would along with the instantaneous fuel consumption.

  • Page 204: Spare Can

    SECTION 06: ELECTRICAL Moreover, specific error messages from these 2 NOTE modules can be read in the ELECTRICAL Because it is easier to do, check first if the SYSTEM menu. module is powered by probing on its gray NOTE connector. If it is, then you can conclude that there is a CAN link problem.

  • Page 205: Motor Test Sequence

    SECTION 06: ELECTRICAL The following inputs, either certain options or HVAC control unit passenger’s section sensors which are difficult to activate, are not ON/OFF supported by the switch/sensor test: Radiator fan clutch switch • Service chime enable switch, Engine rear start selector switch “rear start” •...

  • Page 206: Test Sequence - Coaches Only

    SECTION 06: ELECTRICAL • A/C compressor clutch activates 3 times. DANGER • Left compressor unloader activates 3 times. Before starting the test sequence, make sure • Right compressor unloader activates 3 nobody is working in the evaporator or times. condenser compartment. •...

  • Page 207: Test Sequence - Vip With Small Hvac System

    SECTION 06: ELECTRICAL pause, speed 2 activates. [3 seconds Inside the spare wheel compartment: delay] • Driver's unit refrigerant solenoid valve • The passenger's unit refrigerant solenoid activates 3 times. valve activates 3 times. [10 seconds • Driver's unit hot water pneumatic valve delay] cycles 3 times.

  • Page 208: Forced Activation Of The Radiator Fan Clutch

    SECTION 06: ELECTRICAL • Hot water pump starts running for 5 seconds. • Driver’s unit refrigerant solenoid valve activates 3 times. • Driver’s unit hot water pneumatic valve cycles 3 times. • Closing of the fresh air dampers. To exit the electric motors test sequence, press ESCAPE button, select STOP TEST submenu and then press ENTER button twice.

  • Page 209: 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 210 SECTION 06: ELECTRICAL Use the spare "Front to Rear" CAN Pneumatic Front electrical comp. panel: Disconnect C1 Plug and connect C1S Plug into accessory C1 Socket. panel Main power comp panel: Disconnect C3 Socket and connect C3S socket into C3 Plug. 5th baggage comp.: Disconnect C100 Socket and reconnect it to C100S Plug.
  • Page 211 SECTION 06: ELECTRICAL Use the spare "Front to Pneumatic Accessory Panel" CAN Pneumatic Pneumatic accessory panel: disconnect C13 Socket and connect C13S socket into accessory panel C13 Plug. Front electrical comp. panel: Disconnect C5 Plug and connect C5S Plug into C5 Socket.
  • Page 212 SECTION 06: ELECTRICAL Isolate the evaporator module from the network Pneumatic Disconnect C100. accessory panel 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 213: 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.
  • Page 214 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions If the vehicle does not start from the rear: network problem 1. Verify that module A53 is powered: (Multiplex) a) Check the SYSTEM DIAGNOSTIC menu of Driver Information Display Module A53 not powered or (DID).
  • Page 215 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Many secondary functions The MCM module does not 1. Check / reset circuit breaker CB6. (not essential for driving) receive 24 V power. Check / replace fuse F1 not functioning (interior 2. Operate limp-home mode lighting,...
  • Page 216 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Windshield washer Module A46 is not powered 1. Check the SYSTEM DIAGNOSTIC functioning or is faulty menu of Driver Information Display (DID). Select FAULT DIAGNOSTIC Windshield upper section and ELECTRICAL SYSTEM. The de-icing system message “No Response ModA46, functioning...
  • Page 217 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions Rear flashers not Module A51 is not powered 1. Check the SYSTEM DIAGNOSTIC functioning or is faulty menu of Driver Information Display (DID). Select FAULT DIAGNOSTIC Stoplights and center and ELECTRICAL SYSTEM. The stoplights not functioning message “No Response ModA51, Active”...
  • Page 218 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions HVAC condenser fans not Module A54 is not powered 1. Check the SYSTEM DIAGNOSTIC functioning in speed 1 or is faulty menu of Driver Information Display (DID). Select FAULT DIAGNOSTIC and ELECTRICAL SYSTEM. The message “No Response ModA54, Active”...
  • Page 219 SECTION 06: ELECTRICAL Problem/Symptom Probable Causes Actions You can manually engage the radiator fan The radiator fan clutch clutch speed 1 or speed 2. does not function and the engine is overheating On the Driver Information Display, select DIAGNOSTICS menu. Select VEHICLE TESTS submenu and then ACTIVATE RADIATOR FAN SPEED 1 or ACTIVATE RADIATOR FAN...

  • Page 220: Essential Functions To Operate The Vehicle

    SECTION 06: ELECTRICAL • High beams, ESSENTIAL FUNCTIONS TO OPERATE • THE VEHICLE Ability to turn on the parking lights only, Even with a defective MCM (Chassis Electronic • “Watch your step” sign, Control Module) or a CAN network problem, •...

  • Page 221: Replacing Io-A Or Io-B Modules

    DB9 connector (identified C226) reprogrammed. module found front service compartment electrical panel. Please contact your Prevost reprogrammed, message “Axx Service Representative in order to get the Responding” appears where Axx is the vehicle specific multiplex program and upload module number (Ex: A41, A42…etc).
  • Page 222 SECTION 06: ELECTRICAL support (item 3). Use some Loctite 243 blue (680038) onto the threads. If the alternators needed to be removed, reinstall as follows. 5. Fix lower and upper alternators loosely to alternators support assembly (bolts 5). Also, 1. If necessary, tighten screws...

  • Page 223: Identifying The Defective Alternator

    SECTION 06: ELECTRICAL FIGURE 40: ALTERNATOR MOUNTING, TIGHTENING SEQUENCE – SMALL A/C SYSTEM IDENTIFYING THE DEFECTIVE ALTERNATOR When an alternator is not charging, the instrument cluster ALTERNATOR telltale will illuminate. To identify which alternator is defective (1=lower alternator, 2=upper alternator), proceed ALTERNATOR FIGURE 41: ½″...
  • Page 224 SECTION 06: ELECTRICAL FIGURE 42: TWIN BOSCH ALTERNATORS INSTALLATION (X3-45 COACH) EPA 2010 ALTERNATORS AND COMPRESSORS LAYOUT X3-45 COACH 2 X : HD-10 BOSCH ALTERNATOR 28V – 150 A – PART # 564593 LOCATION A 1 X : CENTRAL A/C SYSTEM BITZER COMPRESSOR LOCATION B X3-45 VIP BUS SHELL WITH CENTRAL A/C SYSTEM 2 X : HD-10 BOSCH ALTERNATOR 28V –...
  • Page 225 SECTION 06: ELECTRICAL X3-45 VIP BUS SHELL WITH SMALL AUXILIARY A/C SYSTEM 1 X : HD-10 BOSCH ALTERNATOR 28V – 150 A – PART # 564593 LOCATION A OPTION 1 X : SMALL A/C SYSTEM ICE COMPRESSOR TM-16HD – PART # 950436 LOCATION B 2 X : HD-10 BOSCH ALTERNATOR 28V –...

  • Page 226: Battery Equalizer

    SECTION 06: ELECTRICAL BATTERY EQUALIZER Vanner “Vann-Guard 70-Series” Battery equalizer is located beside the batteries in battery compartment. Battery Equalizer Owner’s Manual (100 amps) is annexed at the end of this section. For vehicles with PRIME energy management system, a Vanner “Vann-Bus 80 Series” 100amp Battery equalizer with Smart Monitor is installed beside the batteries in the battery compartment.

  • Page 227: Headlight Beam Toggle Switch

    SECTION 06: ELECTRICAL 06547 FIGURE 46: OPENING HEADLIGHT ASSEMBLY NOTE 06546 FIGURE 45: HEADLIGHT ASSEMBLY Make sure headlight assembly is properly positioned into its housing before securing 12.1.1 Headlight Beam Toggle Switch using fixing screw. The multifunction lever located on the steering column is used to select proper lighting.
  • Page 228 SECTION 06: ELECTRICAL the floor on which the screen rests (Figure 47). TABLE 1 – VERTICAL BEAM AIM GUIDELINES Headlight Nominal Aim Inspection (centerline) Vertical Limits for Vertical Mounting Height 56 to 90 cm (22 to 0 Vertical 10 cm (4 inch) up to 36 inch) 10 cm ( 4 inch) down 90 to 120 cm (36 to...

  • Page 229: Sealed-Beam Unit

    SECTION 06: ELECTRICAL 6. Install wiring connector on back of new sealed beam unit. 7. Tilt headlight assembly up into its housing then secure using fixing screw. NOTE Make sure headlight assembly is properly positioned into its housing before securing using fixing screw.
  • Page 230 SECTION 06: ELECTRICAL These lamps improve visibility and provide better lifespan. CAUTION Never connect a voltmeter or V.O.M. to measure bulb voltage as instrument will be destroyed. Troubleshooting and Safety When switching on the Xenon headlamp using the rocker switch, a lamp short-circuit test is performed.

  • Page 231: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    SECTION 06: ELECTRICAL With this safety concept there is no danger to 12.2.1 Lamp Removal and Replacement check the ballast with a new bulb. There is a 1. Open engine compartment rear door. very high probability that the ballast is OK if the ballast can ignite the bulb.

  • Page 232: Clearance, Identification And Marker Lights

    SECTION 06: ELECTRICAL the LED unit must be changed according to the 3. Unscrew the outer ring. Disconnect the light following procedure. unit connection and remove the bulb. 1. Pry out the rubber seal with a small 4. Install the new bulb, reconnect the light unit screwdriver.

  • Page 233: Telltale Light Replacement

    SECTION 06: ELECTRICAL 06321 FIGURE 55: SWITCH 13.1.2 Telltale Light Replacement Telltale module is non-serviceable and must be replaced as a unit. 1. Unscrew and remove the top dashboard panel. 2. Remove the telltale back wire electric connectors. 3. Unscrew and remove the telltale module. 4.

  • Page 234: Stepwell Lights

    SECTION 06: ELECTRICAL FIGURE 56: VARIOUS LIGHTS LOCATION 13.2 STEPWELL LIGHTS 13.3.1 Bulb Removal and Replacement Two Stepwell lights are illuminated when the 1. Unscrew the two Phillips-head screws door opening system is activated. retaining the lens to the wall, and remove it. 2.

  • Page 235: Passenger Section Lighting

    SECTION 06: ELECTRICAL 2. Pull the defective bulb out of the socket. 4. Lift the hinged cover and replace the two retaining screws. 3. Install the new bulb by pushing it in position. 4. Replace the lamp by snapping it back in 13.5.2 Removal and Replacement of In-Station place.

  • Page 236: Engine Compartment Lighting

    SECTION 06: ELECTRICAL 13.6 ENGINE COMPARTMENT LIGHTING CAUTION Two 24-volts LED module illuminate the engine compartment when the following conditions are Do not touch halogen bulbs with bare hands met: as natural oils on skin will shorten bulb life span. 1.

  • Page 237: Maintenance

    SECTION 06: ELECTRICAL 14.1.2 Maintenance Clean headlights with soap and water. 14.1.3 Replacing headlight bulbs The following illustrations show how to gain access to the bulbs. When replacing a bulb, make sure the ignition switch and light switch are off. CAUTION •...

  • Page 238: Aiming Headlights

    SECTION 06: ELECTRICAL These lamps improve visibility and provide therefore switch off the lamp before working on better lifespan. this part). After taking out the lamp, the contact pins are in CAUTION a practically idle stat (< 34 Volt) after < 0.5 seconds so that there is no immediate danger of To avoid breaking the bulb, make sure the electric...

  • Page 239: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    SECTION 06: ELECTRICAL 06717 FIGURE 63: VERTICAL AIMING 14.2 STOP, TAIL, DIRECTIONAL, BACK-UP, AND HAZARD WARNING LIGHTS A combination stoplight, taillight, directional signal light and back-up light assembly is mounted at the rear, on each side of the vehicle. Furthermore, when braking, a high-mounted stoplight will illuminate simultaneously with the stoplights on the sides for increased safety.
  • Page 240 SECTION 06: ELECTRICAL FIGURE 64: VARIOUS LIGHT LOCATIONS 18588_4 PA1615 Maintenance Manual All Series | Section 06 revised July 2017...

  • Page 241: Licence Plate Light

    SECTION 06: ELECTRICAL They are mounted on the vehicle as follows: one 14.3 LICENCE PLATE LIGHT is mounted on the front L.H. side service compartment door, while the other is located Two LED units are mounted above the rear between the front wheel and the entrance door license plate(s) of vehicle.

  • Page 242: H3 Series Interior Lighting

    SECTION 06: ELECTRICAL near the door lower hinge. The bumper will position. A control dimmer located on the lower gradually. dashboard is used to vary the brightness of the panel gauges, switches and indicator lights. The gauge lights, panel lights, switch lights and indicator lights have...

  • Page 243: Stepwell Lights

    SECTION 06: ELECTRICAL 3. Push a new bulb and socket ASM and turn 3. Connect and install the new LED assembly clockwise to lock in place. in position. 4. Replace the rear dashboard housing. 4. Fasten the three fixing screws and replace the lamp outer ring by snapping it back in place.

  • Page 244: Driver's Area Lights

    SECTION 06: ELECTRICAL 1. Unscrew the two Phillips-head screws Moreover, adjustable reading lamps retaining the lens to the lavatory wall, and installed under the parcel racks for passenger remove it. accommodation. 2. With the light lens removed, pull bulb from the lamp while applying lateral pressure.

  • Page 245: Removal And Replacement Of Reading Lamp Bulb

    SECTION 06: ELECTRICAL 3. Install a new fluorescent tube, rotating the exterior frame, is activated by the door lock tube to secure it in the sockets. mechanism upon locking to energize the circuit. This switch is readily serviced by removing the 4.
  • Page 246 Make ..............................BOSCH Series ..............................HD 10 Amperes ..............................150 Volts ................................. 28.4 Output Power ............................3 Kw Ground .............................. negative Prevost Number ..........................564593 Battery equalizer standard Make ..............................Vanner PA1615 Maintenance Manual All Series | Section 06 revised July 2017...
  • Page 247 Model ..........................Vann-bus 80-Series Amperes ............................100 amps Starter Make ....................Mitsubishi Electric Corporation (MELCO) Type ..............................105P70 Voltage ................................ 24 Prevost Number ..........................510752 No-load test -Volts ................................ 23.5 -Max. current draw ........................125 amperes -Min. rpm ............................3000 rpm Starter solenoid Make ....................
  • Page 248 SECTION 06: ELECTRICAL PA1615 Maintenance Manual All Series | Section 06 revised July 2017...
  • Page 249 ELECTRICAL CONNECTORS PROTECTION NOVEMBER 2009 PROCEDURE NO SAV00002E REVISION 02 Kent Sealer Sprayed sealer. It is used for structure ground connections. It prevents corrosion and ensures maximum contact Refer to table for proper use. Apply this product once installation is finished. Warning: It is very important to be in a well ventilated area when applying this product.
  • Page 250 PROCEDURE NO: SAV00002E REVISION 02 Vehicle Zoning REAR FRONT REAR FRONT Page 2 of 6...
  • Page 251 PROCEDURE NO: SAV00002E REVISION 02 Electrical Connectors Protection Procedure Table Model Zone Component Product Note Accepted to ease A- Front Elect. Compt Diode Block Nyogel connection Customer Terminal A- Front Elect. Compt Block Nothing Terminal Block A Front Elect. Compt Electronic Ground Kent A- Front Elect.
  • Page 252 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note Color Guard C- Baggage Compt Structure Ground or Kent Accepted to ease C- Baggage Compt Door Switch Nyogel connection Accepted to Door lock Actuator Module ease C- Baggage Compt (switch and solenoid) Nyogel connection C- Baggage Compt...
  • Page 253 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note G- Engine Compt 120A Alternator Color Guard G- Engine Compt Booster Block (+) Color Guard G- Engine Compt Starter Terminal Color Guard G- Engine Compt Volvo Air Element Terminal Color Guard G- Engine Compt Customer Terminal Block Nothing...
  • Page 254 PROCEDURE NO: SAV00002E REVISION 02 Model Zone Component Product Note I- Vehicle Interior Dashboard Switch Nothing I- Vehicle Interior Electronic Module Nothing Accepted to ease I- Vehicle Interior Slide-out Motor Nyogel connection Accepted to ease I- Vehicle Interior Wiper Motor Nyogel connection I- Vehicle Interior...
  • Page 255 Please note that some images in this document may represent arrangements different from those found on vehicles of former generations. However, inspection criteria and points to check presented in this document remain applicable in essence for all models of Prevost vehicles. POWER CABLES MAINTENANCE SCHEDULE...
  • Page 256 MI15-24 / Page 2 / 11 POWER CABLES ‒ The power cables are those through which flow the highest currents. These cables are those with the largest electrical conductor diameters on the vehicle. ‒ The power cables are 1/0, 2/0, 3/0 wire gauges respectively Ø0.325in, Ø0.365in, Ø0.409in. Note: not to be confused with the 1, 2, 3 wire gauges that are actually smaller.
  • Page 257 MI15-24 / Page 3 / 11 Figure 4 Figure 5: starter cables  In the electrical compartment, connected to Bussman junction block (Figure 6). Figure 6 QF7720956 rev3>...
  • Page 258 MI15-24 / Page 4 / 11  In the battery compartment between battery no2 and master relay R1 (Figure 7). Figure 7  Between Bussman junction block and main circuit breakers’ bus bar (Figure 8). Figure 9: Power cable on main circuit breakers' bus bar.
  • Page 259 MI15-24 / Page 5 / 11 PROCEDURE DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
  • Page 260 MI15-24 / Page 6 / 11 corrugated protective sheath (Figure 11). The ends of the corrugated protective sheath should be covered with fabric tape (Figure 12). Figure 11: Two layers of fabric tape applied every 3 Figure 12: The ends of the corrugated protective to 6 inches to prevent the cable from coming out of sheath should be covered with fabric tape.
  • Page 261 MI15-24 / Page 7 / 11  Ring cable lugs must be installed with smooth washers and nuts to prevent damage to the cable lug when tightening. Figure 14: Power cable shouldn’t be bent just next to the cable lug. Angled cable lugs are used to avoid mechanical stress.
  • Page 262 MI15-24 / Page 8 / 11 BATTERY CABLES  Battery interconnection cables must be checked too : ‒ Ensure the cables are properly fastened to battery posts and that the cables are in good condition (consult battery manufacturer documentation for appropriate tightening torque). ‒...
  • Page 263 MI15-24 / Page 9 / 11 Figure 19: P-clamp with appropriate diameter prevents the power cable or corrugated protective sheath from moving and rubbing inside the clamp. ALTERNATORS TERMINAL NUT PRESCRIBED TORQUE Bosch HD10 - B1(+) terminal: 10 lbf-ft - ground: 6 lbf-ft Bosch T1 - D+: 21-28 lbf-in - B+, B-: 88-115 lbf-in...
  • Page 264 CORROSION PROTECTION  Power cable connections on alternators, starter and ground connections exposed to water, dust, etc. should be protected against corrosion with Loctite Color Guard rubber coating (Figure 23) (Prevost p/n: 684013). Figure 23: Loctite Color Guard. Figure 25: Lower alternator power cable lug Figure 24: Upper alternator power cable lug protected with Color Guard rubber coating.
  • Page 265 MI15-24 / Page 11 / 11 PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone. E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive our warranty bulletins by e-mail.
  • Page 267 MAINTENANCE MI16-17 INFORMATION DATE : FEBRUARY 2016 SECTION: 06 - Electrical SUBJECT : BOSCH HD10 ALTERNATOR REMOVAL AND INSTALLATION Please, get the latest revision of Maintenance Information MI16-17 on Prevost Technical Publications web site: https://techpub.prevostcar.com/en/ <QF7720955 rev 2>...
  • Page 269 SECTION 07: TRANSMISSION CONTENT TORQUE TABLES ............................. 3 ALLISON TRANSMISSION ............................3 VOLVO I-SHIFT TRANSMISSION ..........................4 DESCRIPTION ..............................5 ALLISON AUTOMATIC TRANSMISSION ......................... 5 1.3.1 Retarder ..............................5 VOLVO I-SHIFT TRANSMISSION ..........................5 WELDING PROCEDURES ..........................6 ALLISON TRANSMISSION MAINTENANCE ....................... 6 MANUAL FLUID LEVEL CHECK ..........................
  • Page 270 SECTION 07: TRANSMISSION ALLISON TRANSMISSION REMOVAL ......................25 VOLVO I-SHIFT TRANSMISSION MAINTENANCE .................... 26 TRANSMISSION OIL TYPE ............................ 26 CHECKING OIL LEVEL ............................26 OIL DRAINS INTERVAL ............................27 OIL CHANGE ................................ 27 VOLVO I-SHIFT TRANSMISSION TECU FAULT CODES ..................28 VOLVO I-SHIFT TRANSMISSION GSECU FAULT CODES ................

  • Page 271: Torque Tables

    SECTION 07: TRANSMISSION TORQUE TABLES ALLISON TRANSMISSION ALLISON TRANSMISSION DESCRIPTION TORQUE Lube and main filter cover bolts 38-45 lb-ft (52-61 Nm) Drain Plug 18-24 lb-ft (24-33 Nm) Flex plate screws 24-30 lb-ft (33-41 Nm) Transmission housing screws to engine housing 46-50 lb-ft (62-68 Nm) PA1615 Maintenance Manual All Series | Section 07 revised March 2017...

  • Page 272: Volvo I-Shift Transmission

    SECTION 07: TRANSMISSION VOLVO I-SHIFT TRANSMISSION VOLVO I-SHIFT TRANSMISSION DESCRIPTION TORQUE Oil drain plug 18-24 lb-ft (24-33 Nm) Oil fill plug 22-30 lb-ft (30-41 Nm) Transmission mounting screws 66 lb-ft (89 Nm) Filter housing drain plug 11-13 lb-ft (15-18 Nm) PA1615 Maintenance Manual All Series | Section 07 revised March 2017...

  • Page 273: Allison Automatic Transmission

    SECTION 07: TRANSMISSION resets parameters, which allow DESCRIPTION transmission quickly compensate H3 and X3 Series vehicles may be provided with variations in load, terrain or environment and to either an Allison automatic transmission or a adjust for clutch wear and engine power changes. Volvo I-Shift transmission.

  • Page 274: Welding Procedures

    SECTION 07: TRANSMISSION longer fitted), the driver no longer has to activate To gain access to the dipstick, open the engine the clutch. compartment rear door; dipstick is located on the radiator side of the engine (Figure 4). Clean all dirt from around the end of the oil filler tube before removing the dipstick.

  • Page 275: Cold Check

    SECTION 07: TRANSMISSION 3.1.1 Cold Check CAUTION The purpose of the Cold Check is to determine if the transmission has enough fluid to be operated Obtain an accurate fluid level by imposing the safely until a Hot Check can be made. following conditions: ...

  • Page 276: Fluid Level Check Using The Pushbutton Shift Selector

    SECTION 07: TRANSMISSION 6. Low fluid level displayed as shown. The number indicates number of quarts of fluid FIGURE 6: HOT CHECK transmission requires. NOTE 7. High fluid level condition The Cold Check is more appropriate for with the number of quarts verifying the oil level after the first fill-up.

  • Page 277: Importance Of Proper Fluid Level

    SECTION 07: TRANSMISSION transmission. Refer to TES295 or TES389 3.3.1 Importance of Proper Fluid Level Approved Fluids list, found under It is important that the proper fluid level be Service/Parts heading on the home page of the maintained at all times because the transmission Allison Transmission site...

  • Page 278: Coolant Leakage

    SECTION 07: TRANSMISSION indicating the increased probability that the CAUTION service condition will develop into a more serious condition. If excessive metal contamination has occurred, To access the Prognostic Mode functions, replacement of the oil cooler and replacement simultaneously press the (Upshift) and of all bearings within the transmission is (Downshift) arrow buttons repeatedly.
  • Page 279 SECTION 07: TRANSMISSION Reset CAUTION The TRANSMISSION SERVICE indicator can be reset by a message over the SAE J1939 Required calendar-based oil & filter change communication interface, with the Allison DOC™ intervals (based on month) still apply because for PC diagnostic program, or by depressing and Oil Life Monitor function cannot measure time holding the MODE button for ten (10) seconds while ignition power is OFF.
  • Page 280 SECTION 07: TRANSMISSION displayed as “TRANS HEALTH OK”. Failure to perform maintenance and reset the monitor after a calibration-defined number of unacceptable clutch life status is displayed as “TRANS HEALTH LO”. warnings will result in the illumination of the CHECK light with associated message in the DID and diagnostic code P088B will be recorded Read and Reset Transmission Health Monitor to indicate a highly deteriorated filter.
  • Page 281 SECTION 07: TRANSMISSION The following table illustrates how to access Oil Level Check, Prognostics & Diagnostic Troubleshooting Codes functions on the Allison pushbutton shift selector. Description Message (Upshift) & (Downshift) arrow buttons pressed simultaneously * press Allison transmission oil level check press Oil Life Monitor "...

  • Page 282: Oil And Filter Change Interval

    SECTION 07: TRANSMISSION OIL AND FILTER CHANGE INTERVAL TABLE 1 Allison Transmission Recommended Fluid And Filter Change Intervals With Prognostics Mode Disabled Using TES389 or Mixture Severe vocation General vocation Coaches or MTH equipped with retarder Coaches or MTH without retarder Filters Filters Fluid...

  • Page 283: Oil And Filter Change Interval With Prognostics Mode Disabled

    SECTION 07: TRANSMISSION TABLE 3 Recommended Fluid And Filter Change Intervals With Prognostics Mode Enabled FLUID CHANGE INTERVALS HIGH CAPACITY MAIN & LUBE SUCTION FILTER FILTERS CHANGE INTERVALS ASSEMBLY CHANGE INTERVAL TES295 Whichever is the first of the following: Whichever is the first of the following: time transmission overhaul...

  • Page 284: Fluid And Filter Change Procedure

    SECTION 07: TRANSMISSION 6. Install twelve bolts and both covers. must be disabled. Prognostic information will not be accurate with any other fluids or filters TORQUE: 38-45 lb-ft (52-61 Nm) and could result in missed maintenance activities resulting in transmission damage. See "TABLE 3 7.

  • Page 285: Cleaning And Inspection Of Allison Automatic Transmission

    SECTION 07: TRANSMISSION Using the oil level dipstick filler tube, refill with 24 ALLISON TRANSMISSION OIL COOLER US qts (23 liters), 28 US qts (26.5 liters) if REMOVAL equipped with retarder, and check the oil level using Fluid Level Check Using TRANSMISSION WITHOUT RETARDER Pushbutton Shift Selector procedure in this...

  • Page 286: Allison Transmission Installation

    FIGURE 10: VOLVO ENGINE TURNING TOOL #88800014 ALLISON TRANSMISSION INSTALLATION 4. Apply clear silicone (Prevost #680457 or equivalent) on the spacer and install it on the 1. Place the transmission on a transmission engine housing (Figure 11). jack.
  • Page 287 SECTION 07: TRANSMISSION 8. Apply clear silicone (Prevost #680457 or 12. Remove the headless guide bolt from the flex equivalent) around edge plate adapter through the engine starter transmission housing (Figure 12: silicone access opening. Replace it with a self-locking application transmission housing).

  • Page 288: Allison Transmission Troubleshooting

    SECTION 07: TRANSMISSION CAUTION CAUTION Place the battery master switch to the ‘’OFF’’ Do not overfill the transmission. Overfilling can cause oil aeration (milky appearance) and position. overheating. If overfilling occurs, drain oil as required to bring it to the proper level. DIAGNOSTIC TROUBLESHOOTING CODES (DTC) —...

  • Page 289: Display Sequence

    SECTION 07: TRANSMISSION historic. An active DTC is a DTC that is current MODE message should remain in the TCM decision-making process. Historic illuminated if the active DTC shown in the display DTCs are retained in the TCM memory and do has cleared.

  • Page 290: Diagnostic Troubleshooting Codes (Dtc) List - Allison

    SECTION 07: TRANSMISSION CATEGORY OF RESPONSE ACTIONS TAKEN DNS - Do Not Shift Release lock up (LU) clutch and inhibit lock up operation. Inhibit shifts from the current attained range. Turn on the CHECK light. Display the current attained range in the MONITOR window of the shift selector.
  • Page 291 SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description Transmission Fluid Temperature Sensor Circuit High P0713 Use default sump temp Input P0715 Turbine Shaft Speed Sensor Circuit DNS, Lock in current range P0716 Turbine Shaft Speed Sensor Circuit Performance DNS, Lock in current range P0717 Turbine Shaft Speed Sensor Circuit No Signal DNS, Lock in current range...
  • Page 292 SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description Command 2 and allow shifts 2 P1739 Incorrect Low Gear Ratio through 6, N, R Shift selector language or units P1790 Gear Shift Module 1 Calibrated Invalid incorrect Shift selector language or units P1791 Gear Shift Module 2 Calibrated Invalid incorrect...

  • Page 293: Allison Transmission Removal

    SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description U0304 Incompatible Gear Shift Module 1 (Shift Selector) Ignore shift selector inputs U0333 Incompatible Gear Shift Module 2 (Shift Selector) Ignore shift selector inputs Invalid Data Received From Gear Shift Module (Shift Maintain range selected, observe U0404 Selector) 1...

  • Page 294: Volvo I-Shift Transmission Maintenance

    SECTION 07: TRANSMISSION CAUTION Never reuse drained I-Shift oil. The oil must be replaced along with the oil filter. Reusing drained oil can result in damage to transmission components. CHECKING OIL LEVEL Check the transmission oil level at each service interval.

  • Page 295: Oil Drains Interval

    SECTION 07: TRANSMISSION  Inspect the drain plug and O-ring. Replace if Add oil through the oil filling point if necessary. Reinstall the drain plug. necessary (3) ;  Torque tighten fill plug. TORQUE: 18-24 lb-ft (24-33 Nm) TORQUE: 22-30 lb-ft (30-41 Nm) CAUTION OIL DRAINS INTERVAL Always dispose of all lubricants (engine oil,...

  • Page 296: Volvo I-Shift Transmission Tecu Fault Codes

    SECTION 07: TRANSMISSION VOLVO I-SHIFT TRANSMISSION TECU FAULT CODES FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Conditions for activation: (and) The brake interlock function Activate: is activated (VTNA vehicles The gearlever is only) moved from White lamp is The vehicle speed is below neutral without sent together 5km/h...
  • Page 297 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Deactivate: 7.0s The clutch is after activation slowly engaged and, acc pedal released more than 6.0s or neutral, or driving without clutch slip Activate: If there is an attempt to start on a high range gear or White lamp is...
  • Page 298 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 valves and, engaged state 5. The PCB - The clutch disengagement temperature is valves are inactive above a specific - There is no active fault limit code on any of the clutch cylinder position sensor Deactivate: The clutch response...
  • Page 299 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 for low air 1.0 s pressure and, - The clutch position is not 4. There is no in the interval [set point active fault code +3mm; set point -1mm] after on any of the control of the clutch to near clutch cylinder...
  • Page 300 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 speed > 300rpm, activate this fault code if input shaft speed < 300rpm, deactivate this fault code - Continue with the slip point calibration Yellow lamp is sent Cranking is Digital input inhibited Activate: The...
  • Page 301 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 greater than -500 rpm/s - There is no active fault on any of the gearbox brake valve (VAGB) the sensor for the counter shaft speed (SECS) the sensor for the split cylinder position (SEPoS) low air pressure.
  • Page 302 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 - The 1/R cylinder valves are inactive - There is no active fault on any of the sensor for the position of the 1/R cylinder (SEPo1R) the valve for shift to 1:st gear the valve for shift to reverse gear - There is no active fault...
  • Page 303 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 - There is no active fault code for low air pressure The fault is deactivated if any of the following conditions are fulfilled: - The 1/R position sensor indicates that 1:st position is engaged - There is an active fault code on any of the 1/R...
  • Page 304 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 - There is no active fault code on any of the 1/R position sensor (SEPo1R) the valve for shift to 1:st gear the valve for shift to reverse gear - There is no active fault code for low air pressure The fault is deactivated if any of the following...
  • Page 305 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 (SEPo23) the valve for shift to 2:nd gear the valve for shift to 3:rd gear - There is no active fault code for low air pressure Note: The fault will always have the state inactive.
  • Page 306 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 position is engaged - There is an active fault code on any of the 2/3 position sensor (SEPo23) the valve for shift to 2:nd gear the valve for shift to 3:rd gear Detailed conditions to activate/deactivate...
  • Page 307 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 code for low air pressure The fault is deactivated if any of the following conditions are fulfilled: - The 2/3 position sensor indicates that neutral position is engaged - There is an active fault code on any of the 2/3 position sensor (SEPo23) the valve for shift to 2:nd...
  • Page 308 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 from GECU changes and form GECU (MID223) is not slow response received within when buttons are pressed on Deactivate: The the gear lever. FMI shall be cleared if message VP6 is received at normal rate Activate: The...
  • Page 309 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 from ECS after loading and from the (MID150) is not unloading suspension received within ECU (ECS) 10s, and ECS is installed Deactivate: The FMI shall be cleared if message VW is received at normal rate Yellow lamp...
  • Page 310 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 not received selection and within 100ms gear change performance Deactivate: The FMI shall be cleared if message VP24/MID128 is received at normal rate Activate: Flash Yellow lamp is CS error or sent Data erratic, Program...
  • Page 311 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 for shift to high range the valve for shift to low range - There is no active fault code for low air pressure note: The fault will always have the state inactive. Check fault-count and last occurrence to get more information...
  • Page 312 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 The fault is deactivated if any of the following conditions are fulfilled: - The range cylinder position sensor indicates that high range is engaged - The gearbox oil temperature is below 10dgC - There is an active fault code on any of the range position sensor (SEPoR)
  • Page 313 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 has been successfully calibrated Yellow lamp is Activate: 1. The sent sensor signal is The start gear above or below might be wrong Sensor for normal range Gear selection and 2. The Data erratic, performance vehicle has been...
  • Page 314 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Deactivate: and 3:rd Status is OK gear cylinder (SEPo23) Activate: The Checksum of the Sensor for NVRAM is not Yellow lamp is correct, or the the position sent Calibration sensor has not of the 2:nd Cranking is FMI13...
  • Page 315 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 has been successfully calibrated Detailed conditions to activate / deactivate: Activate: The position sensor is distributing a temperature-signal from the sensor ASIC, if the value from this sensor deviates Activate: The too much this fault code is position sensor triggered, the diagnostics...
  • Page 316 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 below 10.0 [bar] Activate: 1. Yellow lamp is Sensor signal is sent in normal range The symbol for Sensor for Data valid but 2. Pressure is compressed air, the pressure below below 5.0 [bar] FMI1...
  • Page 317 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 -The sensor for the position of the split cylinder (SEPoS) -The sensor for the position of the shift cylinder1R (SEPo1R) -The sensor for the position of the shift cylinder 23 (SEPo23) -The sensor for the position of teh range cylinder...
  • Page 318 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 of the shift cylinder 23 (SEPo23) -The sensor for the position of teh range cylinder (SEPoR) Yellow lamp is sent Reduced gear change performance Gearbox brake up shifts can not be used Activate: The Slip point cannot...
  • Page 319 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Deactivate: 1. from the counter shaft speed sensor (SESC) is Sensor signal is more than 300rpm within normal The values of the input shaft range and, speed calculated from the 2.
  • Page 320 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 The sensor for the position of the shift cylinder1R (SEPo1R) The sensor for the position of the shift cylinder 23 (SEPo23) The sensor for the position of teh range cylinder (SEPoR) Detailed conditions to activate...
  • Page 321 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 speed sensor (SECS) is above 600 rpm, the clutch position is more engaged than the slip point and the engine speed is received from the engine ECU and above 600rpm A forward gear is engaged in the gearbox and the main shaft speed sensor (SESM)
  • Page 322 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 above normal 1.The sensor Yellow lamp is fault codes are only set if operational signal is in sent the vehicle has oil temperature range normal range Symbol for high temperature sensor of the 2.
  • Page 323 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 is within normal sensor signal, the inverted range sensor signal and the sensor supply, they will Deactivate: The difference follow the nominal relation between clutch (Usepoc + Usepoc_inv) / Usepoc5V = 100% positions indicated by the sensor signal...
  • Page 324 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 on supply, or 4. Short circuit between the two sensor signals Deactivate: Both sensor signals are not below normal level Activate: 1. The CS in NVRAM is not correct Sensor Yellow lamp is 2.
  • Page 325 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 code for low air pressure note: The fault will always have the state inactive. Check fault-count and last occurrence to get more information Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times (only once if the fault code- filter is switched OFF) in a...
  • Page 326 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times (only once if the fault code- filter is switched OFF) in a row, in order to set the fault code: - The split valve for reaching indirect split is activated for...
  • Page 327 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 code on any of the sensor for the position of the split cylinder (SEPoS) the valve for shift to direct split the valve for shift to indirect split Detailed conditions to activate/deactivate: The following conditions must be fulfilled three times...
  • Page 328 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 deactivated Reduced gear change comfort Activate: The Yellow lamp is Valve for high side drive is sent Current below activating the open circuit The valve can FMI5 normal or not be activated PTO number Deactivate: The open circuit...
  • Page 329 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Gear changes are slow Activate: 1. The Yellow lamp is high-side drive is sent short circuited to Fast Ubatt and, 2. Valve for fast Voltage engagement/dis there is no active engagement above normal engagement...
  • Page 330 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 selection enters faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve is Activate: The activated high side drive is Gears are Valve for Voltage short circuit to missing...
  • Page 331 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated high side drive is Gears are Valve for Current above short circuit to missing...
  • Page 332 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can not be activated Activate: The Gears are Valve for high side drive is Current below missing shifting to open circuit...
  • Page 333 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 changes only at certain vehicle speeds Yellow lamp is sent The valve is activated Activate: The Direct and high side drive is neutral split Valve for Voltage short circuit to gears are shifting to above normal...
  • Page 334 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 faulty gearbox mode with gear changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated high side drive is Range gears are Valve for Current above short circuit to...

  • Page 335: Volvo I-Shift Transmission Gsecu Fault Codes

    SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Yellow lamp is Activate: The sent Slow Valve for high-side drive is engagement Current above slow short circuit to disabled normal or engagement FMI6 Reduced clutch grounded performance, Deactivate: The of the clutch circuit high-side drive is...
  • Page 336 SECTION 07: TRANSMISSION PID/PPID LAMP CONTENT TEXT COMMENT CONSEQUENCES SID/PSID sensors at next stop Fault displayed after ignition OFF. Risk of Check Gear Output actuator battery discharge if main PSID36 Selector System (REPS) circuit breaker is not at next stop opened when vehicle is not used Check Gear...

  • Page 337: Specifications

    SECTION 07: TRANSMISSION 11. SPECIFICATIONS ALLISON AUTOMATIC TRANSMISSION WITH OR WITHOUT RETARDER Over-the-road coaches. Commercial use Allison B500 Gross input power (maximum) ....................500 HP (335 kW) Gross input torque (maximum) ..................1525 Lbf-ft (2068 Nm) Rated input speed (minimum-maximum) ..................1600-2300 rpm X3-45 VIP, H3-45 VIP motorhomes.
  • Page 338 SECTION 07: TRANSMISSION Type ............................Disposable cartridge VOLVO I-SHIFT TRANSMISSION Oil System: Oil change ..........................16 US qts (15 liters) Oil Filter: Make ................................Volvo Type ............................Disposable cartridge PA1615 Maintenance Manual All Series | Section 07 revised March 2017...
  • Page 339     INSPECTION, LUBRICATION, REMOVAL AND INSTALLATION ................ 2     EXPLANATION OF COMMON DAMAGES  ...................... 4     SPECIFICATIONS ............................ 4 ILLUSTRATIONS    FIGURE 1: STRAPS (STAMPED)  ............................  2   FIGURE 2: BEARING RETAINER (COLD FORMED)  ......................  2   FIGURE 3: COLD FORMED BEARING RETAINER AND BOLTS AS USED ON PREVOST VEHICLES ........  2   FIGURE 4: PROPELLER SHAFT ASSEMBLY (TYPICAL)  ......................  3 PA1615 Maintenance Manual All Series Section 09 revised September 2016...

  • Page 340: Propeller Shaft

    FIGURE 3: COLD FORMED BEARING RETAINER AND BOLTS AS USED ON PREVOST VEHICLES The other extremity (tube yoke assembly) is connected to the transmission by a half round end...
  • Page 341 SECTION 09: PROPELLER SHAFT NOTE NOTE Repair kits are available for overhaul of the Do not assume that bearing cavities have been propeller shaft assembly. Refer to Parts filled with new grease unless it has expelled Manual, Section 9. around all seals. MAINTENANCE Lubricate propeller shaft universal joints at the intervals specified by the Lubrication And...

  • Page 342: Explanation Of Common Damages

    SECTION 09: PROPELLER SHAFT EXPLANATION OF COMMON DAMAGES 1. Cracks: Stress lines due to metal fatigue. Severe and numerous cracks will weaken the metal until it breaks. 2. Galling: Scraping off of metal or metal displacement due to friction between surfaces. This is commonly found on trunnion ends.
  • Page 343 SECTION 10: FRONT I-BEAM AXLE CONTENTS TORQUE TABLE ............................... 2 FRONT I-BEAM AXLE AND SOME RELATED COMPONENTS ................4 FRONT I-BEAM AXLE HUB, ROTOR AND BRAKES ..................23 DESCRIPTION ..............................28 REFERENCE MANUALS ..........................31 LUBRICATION ............................... 42 MAINTENANCE ............................. 45 REMOVAL AND REPLACEMENT ........................

  • Page 344: Torque Table

    SECTION 10: FRONT I-BEAM AXLE TORQUE TABLE The following tables list the tightening torques requiring a specific torque value. When no torque specifications are indicated, use the Standard Torque Specifications table found in Section 00: General Information of the Maintenance Manual. For other torque specifications, refer to Dana manuals listed in paragraph 2.1 reference manuals in this section.

  • Page 345: Description

    SECTION 10: FRONT I-BEAM AXLE 16191 16193 16194_1 FRONT I-BEAM AXLE DESCRIPTION TORQUE (dry) Sway bar link, upper and lower nuts 165-200 lb-ft (224-271 Nm) Sway bar bushing collars (front suspension) 80-100 lb-ft (108-136 Nm) Tie rod end clamp bolts 65-75 lb-ft (88-102 Nm) Tie rod end ball pin nuts 150-200 lb-ft (203-271 Nm)
  • Page 346 SECTION 10: FRONT I-BEAM AXLE Drag link ball joint stud nut, aft 140-200 lb-ft (190-271 Nm) PA1615 Maintenance Manual All Series Section 10 revised September 2016...
  • Page 347 SECTION 10: FRONT I-BEAM AXLE FRONT I-BEAM AXLE HUB, ROTOR AND BRAKES 10034 HUB, ROTOR AND BRAKE DESCRIPTION TORQUE (dry) Hub Flanged Bolt 174-192 lb-ft (236-260 Nm) Stake Hub Nut 575-626 lb-ft (780-849 Nm) Caliper Bracket Nut – Self Lock 85-103 lb-ft (115-140 Nm) Brake Caliper Mounting –...

  • Page 348: Reference Manuals

    SECTION 10: FRONT I-BEAM AXLE DESCRIPTION The Dana Spicer S84U front axle is of the ‘’Reverse Elliot’’ type manufactured by Dana Spicer Europe. The front axle consists of a girder section axle bed or beam with stub axles. Each stub axle is carried on a taper king pin, with a plain phosphor bronze bushing at the top and at the bottom.
  • Page 349 SECTION 10: FRONT I-BEAM AXLE TYPICAL S84U AXLE ITEM DESCRIPTION ITEM DESCRIPTION Flanged Bolt Draw key, Nut, Washer Tie Rod End Brake Disc V" Ring Seal Stake Hub Nut Kingpin Collet Washer Kingpin - Bushing Hub Bearing O-Ring Seal Nut – Self Lock Washer Brake Mounting Bracket Screw...

  • Page 350: Lubrication

    SECTION 10: FRONT I-BEAM AXLE Steering knuckles, knuckle pins and bushings can be overhauled or replaced without removing the LUBRICATION axle from the vehicle. However, if extensive overhaul work is necessary, the axle assembly should be removed. MAINTENANCE CAUTION Knuckle pins are provided with grease fittings for pressure lubrication.

  • Page 351: Replacement

    SECTION 10: FRONT I-BEAM AXLE 7. Disconnect lines from front brake Aspects to be considered are: chambers, and cover line ends and fittings to • Lateral slackness prevent the entry of foreign matter. • Vertical slackness CAUTION NOTE Position the air lines and electric wires so they Before commencing checks, apply parking will not be damaged while removing the front brake, raise wheels off ground and support axle...

  • Page 352: Front Wheel Alignment

    SECTION 10: FRONT I-BEAM AXLE Check radius rods for bending and rubber Dana Parts & Service Instructions S84U Steer Axle KING PIN REWORK_ Manual NO 1985 B bushings for evidence of excessive wear. iss A. Make sure all fasteners are tightened to the specified torque.

  • Page 353: Turn Adjustment

    SECTION 10: FRONT I-BEAM AXLE center. The turning angle is factory adjusted to 2. Verify the nearest point of contact of the ball accommodate the chassis design, and therefore, socket body with the air bellows support does not require adjustment on new vehicles. assembly.

  • Page 354: Camber Check

    (Prevost #110663) on the left-hand side upper radius rod support in order to obtain 3. Check the wheel lateral distortion as minor adjustment.

  • Page 355: Inspection And Adjustment

    SECTION 10: FRONT I-BEAM AXLE Incorrect toe-in results in excessive tire wear Loosen the pinch bolt nuts and bolts on caused by side slippage and also steering each tie rod end. instability with a tendency to wander. Toe-in may Turn the tie rod until the specified toe-in be measured from the center of tire tread or from measurement is obtained.

  • Page 356: Troubleshooting

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

  • Page 357: Specifications

    SECTION 10: FRONT I-BEAM AXLE Worn kingpins and 1. Worn or missing seals and gaskets. 1. Replace damaged part(s), replace seals knuckle bushings. and gaskets. 2. Incorrect lubricant. 2. Lubricate axle with specified lubricant. 3. Axle not lubricated at scheduled 3.
  • Page 359 SECTION 11: REAR AXLES CONTENTS       TORQUE TABLES ............................ 3     MERITOR DRIVE AXLE ............................  3     ZF A132 DRIVE AXLE ............................  4     TAG AXLE ...............................  5     MERITOR DRIVE AXLE .......................... 6     DESCRIPTION ..............................  6     DCDL (DRIVER‐CONTROLLED MAIN DIFFERENTIAL LOCK)  ................  6     MAINTENANCE ..............................  6     2.3.1 Drive Axle Lubrication .......................... ...
  • Page 360 SECTION 11: REAR AXLES ILLUSTRATIONS     ................................  6 FIGURE   DRIVE AXLE   ............................  6 FIGURE   DIFFERENTIAL ASSEMBLY   ‐   ........................  6 FIGURE   DRIVER CONTROLLED DIFFERENTIAL LOCK    ..........................  7 FIGURE   DIFFERENTIAL HOUSING BOWL     .............................  8 FIGURE   JACKING POINTS ON FRAME    ..........................  8 FIGURE   JACKING POINTS ON DRIVE AXLE  ...

  • Page 361: Torque Tables

    SECTION 11: REAR AXLES TORQUE TABLES MERITOR DRIVE AXLE MERITOR DRIVE AXLE DESCRIPTION TORQUE Breather 12-18 lb-ft (16-24 Nm) Fill / Level check plug 35 lb-ft (47 Nm) minimum * Drain plug 35-50 lb-ft (47-68 Nm) Drive shaft flange nuts 5/8-18 150-230 lb-ft (203-312 Nm) Hub to disc cap screws 9/16-18 110-165 lb-ft (149-224 Nm)

  • Page 362: Zf A132 Drive Axle

    SECTION 11: REAR AXLES ZF A132 DRIVE AXLE         ZF A132 DRIVE AXLE DESCRIPTION TORQUE Filler plug 52 lb-ft (71 Nm) Drain plug 96 lb-ft (130 Nm) Level check plug 52 lb-ft (71 Nm) Breather 4 lb-ft (5 Nm)  ...

  • Page 363: Tag Axle

    SECTION 11: REAR AXLES ZF A132 DRIVE AXLE DESCRIPTION TORQUE Drive shaft flange bolts cap screw M18x1.5x50mm G10.9 325 lb-ft (441 Nm) Hub cap screw Torx M16x1.5x60 221 lb-ft (300 Nm) TAG AXLE TAG AXLE DESCRIPTION TORQUE Tag axle transversal radius rod (stud) retaining bolt 198 lb-ft (268 Nm) Tag axle radius rods nut 228-252 lb-ft (309-342 Nm)

  • Page 364: Dcdl (Driver-Controlled Main Differential Lock)

    SECTION 11: REAR AXLES DCDL (DRIVER-CONTROLLED MAIN MERITOR DRIVE AXLE DIFFERENTIAL LOCK) DESCRIPTION Meritor Single-reduction carriers with driver- controlled main differential lock (DCDL) have the The Meritor drive axle is equipped with a single same type of gears and bearings as the reduction standard carrier mounted in front of standard-type carriers.

  • Page 365: Checking And Adjusting The Oil Level

    SECTION 11: REAR AXLES synthetic gear oil must be used for extended 2.3.2 Checking and Adjusting the Oil Level drains interval. In extreme conditions, or for better performance, fill with synthetic gear oil. DANGER Fill Meritor axle with approved lubricants.Refer Before servicing, park safely over a repair pit;...

  • Page 366: Removal And Reinstallation

    SECTION 11: REAR AXLES 2. Remove the drain plug from the bottom of the axle. Drain and discard the oil in an environment friendly manner. 3. Install and tighten the drain plug. TORQUE: 35-50 lb-ft (47-68 Nm) 4. Clean the area around the fill plug. Remove FIGURE 5: JACKING POINTS ON FRAME 18524 the fill plug from the differential housing bowl.

  • Page 367: Disassembly And Reassembly

    SECTION 11: REAR AXLES 11. Remove the lower and upper longitudinal TIRE MATCHING radius rod supports from vehicle sub-frame Drive axle tire matching is covered under the as outlined in Section 16: Suspension, applicable heading in Section 13, "Wheels, Hubs under heading "Radius Rod Removal".

  • Page 368: Drive Axle Alignment Specifications

    Dry both surfaces. 2. Apply a continuous thin bead of silicone sealant* (Prevost P/N 680053) on the mounting surfaces and around the edge of all fastener holes of both the axle shaft flange and wheel hub.

  • Page 369: Zf A132 Drive Axle

    SECTION 11: REAR AXLES 3. Assemble components immediately to permit Bremse SN7 disc brake and companion flange the silicone sealant to compress evenly for Dana Spicer SPL250 propeller shaft. Visual between parts. wear indicator or potentiometer wear indicator may be installed. The carrier gear ratio is 3.54. a.

  • Page 370: Differential Oil Change

    SECTION 11: REAR AXLES  comes first. Check oil level at room temperature only. Hot Region Operation. Change differential MAINTENANCE oil and breather, clean the drain plug’s magnetic inserts after 80 000 miles (120 000 Oil level check km) or 2 years, whichever comes first. Check differential oil level and add if necessary at every engine oil change.

  • Page 371: Compact Bearing (Hub Unit) Axial Play Check

    SECTION 11: REAR AXLES  3.1.5 Compact bearing (hub unit) Grease Clean the magnetic insert of the drain plug, fit Change a new seal (O-ring) and reinstall drain plug. Perform compact bearing (hub unit) grease WARNING change as described in paragraph 7.3 GREASE CHANGE IN THE HUB of the following manual: The oil temperature may be extremely high! OPERATING INSTRUCTIONS ZF AXLE A132...
  • Page 372 SECTION 11: REAR AXLES FIGURE 12: ZF A-132 DRIVE AXLE HUB ASSEMBLY Hub carrier Slotted nut Screen sheet Locking plate Shaft seal (with impulse disc) Flange shaft Cap screw M18x1.5x50mm G10.9 (14mm hex Compact bearing (hub unit) socket driver “Allen”) Cap screw Torx M16x1.5x60 (E20 Torx socket) Shaft seal PA1615 Maintenance Manual All Series...

  • Page 373: Removal And Reinstallation

    SECTION 11: REAR AXLES REMOVAL AND REINSTALLATION The following procedure deals with the removal of the drive axle assembly and its attachments as a unit. The method used to support the axle during removal and disassembly depends upon local conditions and available equipment. 2.

  • Page 374: Zf A132 Drive Axle Alignment

    SECTION 11: REAR AXLES  3.5.1 Procedure AXLE A132 REPAIR MANUAL #5871 207 002E Park vehicle on a level surface, then chock front vehicle wheels. ZF A132 DRIVE AXLE ALIGNMENT Using two jacking points (which are at least 30 inches [76 cm] apart) on drive axle, raise The drive axle alignment consists in aligning the the vehicle sufficiently so that wheels can axle according to the frame.

  • Page 375: Unloading Tag Axle (Optional)

    SECTION 11: REAR AXLES  Raise the vehicle using the lifts. CAUTION WARNING Do not use tag axle in raised position for an extended period. Raising tag axle increases Lift manufacturers recommended lowering the load on the drive axle, suspension and tires. vehicle to the ground or installing some safety Do not drive vehicle with tag axle raised when stands before activating the suspension to...

  • Page 376: Removing Tag Axle Along With Suspension Components

    SECTION 11: REAR AXLES 7. Disconnect the tag axle brake chamber WARNING hoses. Install a protective cover to prevent unfortunate CAUTION lever operation while work is being carried out under the vehicle. Position the hoses so they will not be damaged when removing axle.

  • Page 377: Tag Axle Alignment

    SECTION 11: REAR AXLES 2. Remove the air bellows retaining nuts from each of the two upper mounting plates. NOTE 3. Install extractor tool g32952 onto transversal It may be necessary to adjust the axle TOE as rod. well as its alignment. In this case, insert shims (7 min.
  • Page 378 SECTION 11: REAR AXLES FIGURE 16: TAG AXLE ALIGNMENT 11026 PA1615 Maintenance Manual All Series Section 11 revised September 2016...
  • Page 379 Axle type .............................. Full floating Oil fill quantity ........................19.5 quarts (39 pints) Ratio ................................. 3.54 TAG AXLE Make ................................Prevost Rear track ........................83.6 inches (2 124 mm) Axle type ..............................Forged PA1615 Maintenance Manual All Series | Section 11 revised September 2016...
  • Page 381 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS TORQUE TABLES ............................. 5 BRAKE AND AIR SYSTEM ..........................5 MISCELLANEOUS TORQUES ........................... 7 AIR SYSTEM ................................8 BRAKES ................................8 AIR RESERVOIRS ............................. 8 MAINTENANCE............................... 8 3.1.1 Wet Air Tank ............................9 3.1.2 Primary Air Tank ............................
  • Page 382 SECTION 12: BRAKE AND AIR SYSTEM DUAL BRAKE VALVE (E-8P) ........................16 14.1 BRAKE PEDAL ADJUSTMENT ........................16 14.1.1 Maintenance ............................16 STOPLIGHT SWITCHES ..........................16 PARKING BRAKE ALARM SWITCH......................17 BRAKE RELAY VALVE (R-14)........................17 ANTILOCK TRACTION RELAY VALVE (ATR-6) ....................17 SPRING BRAKE VALVE (SR-7) ........................
  • Page 383 SECTION 12: BRAKE AND AIR SYSTEM 30.4 SENSORS ..............................29 30.4.1 Spring clip............................. 30 BENDIX AUTOMATIC TRACTION CONTROL (ATC) – ELECTRONIC STABILITY CONTROL (ESC) ...... 31 31.1 COMPONENTS.............................. 31 31.1.1 The EC-60 controller’s ABS function utilizes the following components: .......... 31 31.1.2 The EC-60 controller’s ATC function utilizes the following components: ..........
  • Page 384 SECTION 12: BRAKE AND AIR SYSTEM ILLUSTRATIONS FIGURE 1: INDEPENDENT SUSPENSION AIR TANKS LOCATIONS (SHOWN WITH VIP EXPANSION TANKS) ....9 FIGURE 2: BEAM AXLE SUSPENSION AIR TANKS LOCATIONS (TYPICAL WITH VIP EXPANSION TANKS) ......9 FIGURE 3: FRONT SERVICE COMPARTMENT ........................9 FIGURE 4: ACCESSORY AIR FILTER ..........................

  • Page 385: Torque Tables

    SECTION 12: BRAKE AND AIR SYSTEM 1. TORQUE TABLES BRAKE AND AIR SYSTEM PA1615 Maintenance Manual All Series revised Octobber2016...
  • Page 386 SECTION 12: BRAKE AND AIR SYSTEM PA1615 Maintenance Manual All Series | Section 12 revised October 2016...

  • Page 387: Brake And Air System

    SECTION 12: BRAKE AND AIR SYSTEM BRAKE AND AIR SYSTEM DESCRIPTION TORQUE Compressor flange mounting nuts 63 lb-ft (85 Nm) Front IFS suspension caliper mounting bolts 405-495 lb-ft (549-671 Nm) Front I-beam caliper mounting bolts 350-393 lb-ft (475-533 Nm) Meritor drive axle & Tag axle caliper mounting bolts 405-495 lb-ft (549-671 Nm) Meritor hub to disc cap screws 110-165 lb-ft (149-224 Nm)

  • Page 388: Air System

    SECTION 12: BRAKE AND AIR SYSTEM AIR SYSTEM brakes, and to move the vehicle to a safe parking place, such as in the case of a self- The basic air system consists of an air application of these brakes due to a drop in air compressor, reservoirs, valves,...

  • Page 389: Wet Air Tank

    SECTION 12: BRAKE AND AIR SYSTEM FIGURE 1: INDEPENDENT SUSPENSION AIR TANKS LOCATIONS (SHOWN WITH VIP EXPANSION TANKS) FIGURE 2: BEAM AXLE SUSPENSION AIR TANKS LOCATIONS (TYPICAL WITH VIP EXPANSION TANKS) 3.1.1 Wet Air Tank This reservoir located in front and above the L.H. wheel of the drive axle in the rear wheel housing, is provided with a bottom drain valve.

  • Page 390: Kneeling Air Tank

    (20 000 km). will pass through the standard air filtering To purge, open drain valve (FIGURE 4) let the system provided by Prevost. Do not fill system moisture come out, then close the drain valve. by any other point on the system.

  • Page 391: Accessory Air Filter Element

    SECTION 12: BRAKE AND AIR SYSTEM accurate test gauge. Replace the gauge with a new unit if there is a difference of 4 psi (27 kPa) or more in the reading. ACCESSORY AIR FILTER ELEMENT 7. AIR FILTER/DRYER TORQUE for connections: MAINTENANCE 3/8”-18 NPTF= 12 lb-ft (16 Nm) 1/4”-18 NPTF= 12 lb-ft (16 Nm)

  • Page 392: Replacing The Desiccant Cartridge

    SECTION 12: BRAKE AND AIR SYSTEM The air filter/dryer is located in front of rear 7. Thread replacement cartridge onto the base wheel housing above drive axle. Its purpose is to until the seal touches the base. Then, tighten remove moisture that could damage the air the cartridge ONE additional turn.

  • Page 393: Flexible Hoses

    SECTION 12: BRAKE AND AIR SYSTEM AIR LINE LEAKAGE TEST Color Circuit With air system fully charged and the brakes Secondary applied, coat all tubing and hose connections Green Primary, Supply/Delivery with a soapy solution to check for air leakage. Yellow Parking Brake leakage...

  • Page 394: Maintenance

    SECTION 12: BRAKE AND AIR SYSTEM (psi) Pressure (kPa) 30 (Single belt) Belt Tensioner 45 (Dual belts) Retarder MAINTENANCE Every 100,000 miles (160 000 km) or once every two years, whichever comes first, disassemble the pressure regulating valve and wash all metal parts in a cleaning solvent (Figure 8).

  • Page 395: Compressor Removal And Installation

    SECTION 12: BRAKE AND AIR SYSTEM Remove and retain the oil supply tube that runs between the compressor and the engine Reverse removal procedure for installation. 11. EMERGENCY / PARKING BRAKE CONTROL VALVE (PP-1) A push-pull control valve mounted on the L.H. lateral console is provided for parking brake application or release.

  • Page 396: Flip-Flop Control Valve (Tw-1)

    SECTION 12: BRAKE AND AIR SYSTEM spring brakes due to a pressure drop, the brakes 14.1 BRAKE PEDAL ADJUSTMENT can be released by holding down this control After brake pedal replacement or repair, adjust valve. Maintenance and repair information on the pedal to its proper position according to the this valve is supplied in the applicable booklet following procedure:...

  • Page 397: Parking Brake Alarm Switch

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

  • Page 398: Pressure Protection Valve (Pr-4)

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

  • Page 399: Air Horn Valve

    SECTION 12: BRAKE AND AIR SYSTEM • Air 5. Disconnect the air tubes. filter/dryer built-in governor poorly adjusted or defective. 6. Reverse the procedure to install a new valve. Air pressure drops quickly when engine is stopped: 23. AIR HORN VALVE •...

  • Page 400: Inspection Points

    Inspect all sealing elements (boots and caps). Technical Publications USB flash drive and available on At each pad replacement, make sure the caliper Prevost Technical operates smoothly over its full range of Publications site. movement. If the caliper shows the following 26.1...

  • Page 401: Pad Replacement Procedure

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

  • Page 402: Front And Tag Axle - Equipped With Visual Wear Indicator

    SECTION 12: BRAKE AND AIR SYSTEM MEASUREMENT “C” WITH WORN DISC/BRAKE PADS FIGURE 23: BRAKE PAD WEAR CHECK ON DRIVE AXLE If measurement “C” is less than 0.039" (1 mm), this condition requires a check of the brake pad thickness and the brake disc with the wheel removed.

  • Page 403: Brake Pads And Discs Minimal Tolerance Limits

    SECTION 12: BRAKE AND AIR SYSTEM FIGURE 27:MAJOR BREAKOUTS ON THE SURFACE OF THE BRAKE PAD ARE NOT PERMITTED If the thickness of the friction material at its thinnest point is less than 0.079 inch or 2 mm (measurement C), the pads must be replaced. Overall thickness of new brake pad: 1.18 in (30 mm) Back plate SN7 type: 0.354 in (9 mm)

  • Page 404: Caliper Running Clearance

    SECTION 12: BRAKE AND AIR SYSTEM Worn condition = 1.457 in (37mm) (the disc must be replaced) WARNING If the disc dimension E ≤ 1.535 in (39mm), it is recommended that the disc should be renewed when brake pads Whenever possible, work on brakes in a changed.

  • Page 405: Air Brake Troubleshooting

    SECTION 12: BRAKE AND AIR SYSTEM CONDITION: Vehicle leveled, parking brake Material safety data sheets on this product, as applied. required OSHA, available from Rockwell and Knorr-Bremse. 1. Completely drain wet, primary secondary air reservoirs only. 28. AIR BRAKE TROUBLESHOOTING 2.

  • Page 406: Brake Air Chamber

    SECTION 12: BRAKE AND AIR SYSTEM • If inlet valves are stuck, open or leaking kPa) and foot brake applied, coat all air line connections and brake pneumatic compo- severely, replace unloader kit, inlet valves nents with a water and soap solution. Bub- and/or seats as necessary.

  • Page 407: Maintenance

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

  • Page 408: Brake Chamber Installation

    30. ANTI-LOCK BRAKING SYSTEM (ABS) dations must be applied: This device has been designed to ensure o Prevost recommends the installation of a stability and permit steering control of vehicle new spring brake chamber if it is found to during hard braking, and to minimize its stopping be defective.

  • Page 409: Troubleshooting And Testing

    SECTION 12: BRAKE AND AIR SYSTEM The ABS system consists of two diagonally Maintenance related circuits, only the half of the system which No specific maintenance is required. The ECU has sustained damage or other fault is switched is not serviceable. When found to be defective, off (i.e.

  • Page 410: Spring Clip

    Maintenance (Figure 34). No specific maintenance is required for sensors, except if the sensors have to be removed for axle servicing. In such a case, sensors should be lubricated with special grease (Prevost #680460) before reinstallation. Refer paragraph “Sensor Installation” for details.

  • Page 411: Components

    SECTION 12: BRAKE AND AIR SYSTEM 31.1.2 The EC-60 controller’s ATC function 31. BENDIX AUTOMATIC TRACTION utilizes the following components: CONTROL (ATC) – ELECTRONIC STABILITY CONTROL (ESC) • Drive axle traction control valve; In addition to the ABS function, vehicle is •...

  • Page 412: Advanced Abs With Electronic Stability Control (Esc)

    Bendix booklet annexed at the end of this section under 6s/5m Configuration reference number SD-13-4958. Prevost vehicles utilize a 6 sensors/5 pressure modulator valves configuration, with the tag axle 31.3 ADVANCED ABS WITH ELECTRONIC...

  • Page 413: Removal Of The Steering Angle Sensor

    TORQUE: 35-39 lb-ft (47-53 Nm) inputs to the SAS-70 sensor. 4. Reconnect the connector. Ensure that there The SAS-70 sensor installed on Prevost vehicles will be no force applied to the sensor is the 90° connector. because the connector is pulling on the sensor body.

  • Page 414: Fitting Tightening Torques

    After an accident that may have led to damage of the steering angle sensor or Use Loctite pipe sealant to seal pipe thread assembly. (Prevost number 680098). WARNING If the steering angle sensor is not properly recalibrated as needed, the yaw control...

  • Page 415: Specifications

    Model ............................... SR-1 Pressure Protection Valve Make ..........................Bendix Westinghouse Model ............................... PR-4 Nominal closing pressure ...................... 70 psi (482 kPa) Prevost number ........................... 641137 Shuttle-Type Double Check Valve Make ..........................Bendix Westinghouse Model ............................... DC-4 Air Pressure Regulator Make ..............................Norgren Adjustable output range ..................
  • Page 416 SECTION 12: BRAKE AND AIR SYSTEM Drive Axle Brake Chambers Make ............................Knorr-Bremse Type ..................... 24-inch as service -24-inch as emergency Tag Axle Brake Chambers Make ............................Knorr-Bremse Type ..............................16-inch Brake Lining (All Axles) Make ............................Knorr-Bremse PA1615 Maintenance Manual All Series | Section 12 revised October 2016...
  • Page 417 SECTION 13: WHEELS, HUBS AND TIRES CONTENTS       TORQUE TABLES ............................ 4     WHEEL NUTS  ..............................  4     TAG AXLE ...............................  4     FRONT AXLE ..............................  5     MERITOR DRIVE AXLE ............................  5     ZF A132 DRIVE AXLE ............................  6     WHEELS  .............................. 7     H345 & X3‐45 COACHES .......................... ...
  • Page 418 SECTION 13: WHEELS, HUBS AND TIRES     12.2 COMPACT BEARING (HUB UNIT) GREASE CHANGE ..................  2 0     SPARE WHEEL ............................  2 1     13.1 SUPER SINGLE TIRE REPLACEMENT ......................  2 1     13.2 PULLING OUT SPARE WHEEL ........................  2 1     13.3 CHANGING A FLAT TIRE (COACHES ONLY)  ....................  2 3     13.4 CHANGING A FLAT TIRE (VIP &  CONVERTED BUS SHELLS) ................. ...
  • Page 419 SECTION 13: WHEELS, HUBS AND TIRES    ..................  2 2 FIGURE   FRONT SERVICE COMPARTMENT OF A    X  SERIES VEHICLE   . ...........  2 2 FIGURE   FORWARD COMPARTMENT OF  H  SERIES VEHICLE WITH JACK  WRENCH AND REFLECTOR KIT     ..............................  2 7 FIGURE   TIRE INFLATION     ...........................  2 8 FIGURE   TIRE LIFE   INFLATION PRESSURE PA1615 Maintenance Manual All Series Section 13 revised September 2016...

  • Page 420: Torque Tables

    SECTION 13: WHEELS, HUBS AND TIRES 1. TORQUE TABLES 1.1 WHEEL NUTS WHEEL NUTS (ALL TYPES) – STEEL/ALUMINUM WHEELS DESCRIPTION TORQUE Wheel nuts (M22x1.5 threads)* 450-500 lb-ft (610-678 Nm) *Torque following sequence shown 1.2 TAG AXLE TAG AXLE DESCRIPTION TORQUE Tag axle hub flange cap screws 161-197 lb-ft (218-267 Nm) Tag axle hub nut...

  • Page 421: Front Axle

    SECTION 13: WHEELS, HUBS AND TIRES 1.3 FRONT AXLE FRONT AXLE DESCRIPTION TORQUE Front axle hub flange cap screws 174-192 lb-ft (236-260 Nm) Front axle hub nut 575-625 lb-ft (780-847 Nm) 1.4 MERITOR DRIVE AXLE MERITOR DRIVE AXLE DESCRIPTION TORQUE Drive shaft flange nuts 5/8-18 150-230 lb-ft (203-312 Nm) Hub to disc cap screws 9/16-18...

  • Page 422: Zf A132 Drive Axle

    SECTION 13: WHEELS, HUBS AND TIRES 1.5 ZF A132 DRIVE AXLE ZF DRIVE AXLE DESCRIPTION TORQUE Drive shaft flange bolts cap screw M18x1.5x50mm G10.9 325 lb-ft (441 Nm) Hub cap screw Torx M16x1.5x60 221 lb-ft (300 Nm) PA1615 Maintenance Manual All Series Section 13 revised September 2016...

  • Page 423: Wheels

    SECTION 13: WHEELS, HUBS AND TIRES 2. WHEELS The vehicle is equipped with hub-mounted wheels as standard equipment, all studs and nuts have right-hand threads Either steel wheels or optional aluminum-polished wheels may be installed on the vehicle. Both are mounted with radial tubeless tires.

  • Page 424: Inspection

    SECTION 13: WHEELS, HUBS AND TIRES CAUTION CAUTION Wheel studs and nuts must be kept free from Always mark position of the wheel on the axle grease and oil. No lubricant whatsoever prior to removal in order to replace wheel at should be used.

  • Page 425: Inspection

    180º apart in order good quality tar remover. to have access to both the inner and outer valves. 2. Spray Alcoa Cleaner (Prevost #683529) evenly on cool outer surface of wheel. Let work 15-20 minutes (keep wet by spraying 4.5 INSPECTION more Cleaner if necessary).

  • Page 426: Wheel Straightness Test

    SECTION 13: WHEELS, HUBS AND TIRES  Clean aluminum wheels as required to maintain If, within specifications, the hub is correct original look. but the suspected wheel must be replaced. WARNING NEVER STRAIGHTEN ALUMINUM WARNING WHEELS. Never heat aluminum wheels to repair damages incurred after hitting a curb or Wheel surfaces may have sharp or cutting resulting from other causes.

  • Page 427: Front And Tag Axle Wheel Studs

    SECTION 13: WHEELS, HUBS AND TIRES NOTE Tightening should not be done immediately 7.2 FRONT AND TAG AXLE WHEEL STUDS after prolonged braking or when wheel ends are hot. Wheel is hub mounted on front and tag axle (M22x1.5 thread). Check wheel nut torque at every 100 miles (160 km) for 500 miles (800 km) after fitting wheels.
  • Page 428 SECTION 13: WHEELS, HUBS AND TIRES FIGURE 7: TAG AXLE HUB AND ROTOR ASSEMBLY FIGURE 8: TAG AXLE UNITIZED BEARING & WHEEL HUB 13040 PA1615 Maintenance Manual All Series Section 13 revised September 2016...

  • Page 429: Tag Axle Hub Bearing Inspection

    9.3 TAG AXLE HUB BEARING INSTALLATION Without releasing the pressure, turn bearing so that indicator stem again contacts the Clean spindle using EFX degreaser (Prevost marked spot and note new reading on #685313) indicator.
  • Page 430 SECTION 13: WHEELS, HUBS AND TIRES Clean thrust washer both sides and hub nut using EFX degreaser. FIGURE 10: APPLY GLEITMO 805 GREASE Install thrust washer and hub nut then Slip unitized hub bearing over spindle. torque hub nut. TORQUE: 563-687 lb-ft (763-931 Nm) Rotate bearing, minimum 10 revolutions necessary (simultaneous rotation till final clamp torque is achieved.
  • Page 431 FIGURE 14: ROTOR nuts. Add some grease (25-50 ml) (Fuchs TORQUE: 450-500 lb-ft (610-678 Nm) Renolite LX PEP-2) (Prevost #685325) into the bottom of the hub flange cap. Mount hub flange onto rotor. Secure hub flange and rotor to unitized hub bearing using 14 new cap screws (single- use only).

  • Page 432: Front Axle Wheel Hubs

    SECTION 13: WHEELS, HUBS AND TIRES 10. FRONT AXLE WHEEL HUBS The FAG unitized hub bearings used on the NDS range of axles, are non-serviceable items. Bearings are pre-adjusted, lubricated and have seals fitted as part of the manufacturing process. The bearings are greased for life and there is no need or facility for re-lubrication.

  • Page 433: Front Axle Hub Bearing Removal

    Rotate REASSEMBLY, pages No. B23 up to B30. unitized hub bearing whilst tightening. Do not stake hub nut at this stage. 1. Clean spindle using EFX degreaser (Prevost #685313). TORQUE: 575-625 lb-ft (780-847 Nm) PA1615 Maintenance Manual All Series...

  • Page 434: Meritor Drive Axle Wheel Hubs

    This Renolite LX PEP-2) (Prevost #685325) into important, otherwise wheel may be eccentric the bottom of the hub flange cap. Mount hub with hub and will not run straight. In this flange onto rotor. initial step, slightly tighten the nuts to Secure hub flange and rotor to unitized hub correctly position the wheel.

  • Page 435: Bearing Check/Adjustment

    SECTION 13: WHEELS, HUBS AND TIRES lubricant (refer to Section 24 "Lubrication" for No. 23A" annexed to Section 11 of this proper oil grade selection) to ensure adequate manual. oil supply to wheel bearings at all times. 2. Remove wheels and tires. Additional information is found in the following NOTE manuals, included on your vehicle Technical...

  • Page 436: Zf Drive Axle Wheel Hubs

    SECTION 13: WHEELS, HUBS AND TIRES MAINTENANCE Compact bearing (hub unit) axial play Check the bearing axial play at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION & SERVICING. 12.2 COMPACT BEARING (HUB UNIT) GREASE CHANGE When grease is changed within the scope of the maintenance, it is necessary to completely remove the compact bearing.

  • Page 437: Spare Wheel

    SECTION 13: WHEELS, HUBS AND TIRES The spare wheel is stored in a dedicated compartment behind the front bumper. To access, pull the release handle located in the front service compartment. Although the bumper is heavy, sprung hinges permit one person operation.
  • Page 438 SECTION 13: WHEELS, HUBS AND TIRES On H3 series vehicles, Untighten the pressure screw holding the tire in place. Lift the pressure NOTE screw arm and move to the side. The jack and wheelnut wrench are stored in the front service compartment for X3 series Using the strap, pull the spare out of the vehicles and at the ceiling of the forward compartment (refer to the following illustrations).

  • Page 439: Changing A Flat Tire (Coaches Only)

    SECTION 13: WHEELS, HUBS AND TIRES 13.3 CHANGING A FLAT TIRE (COACHES There are truck tire service enterprises all over ONLY) the country that can bring a wheel and make the change safely. In case of flat tire, refer to appropriate procedure under “Wheel Maintenance"...

  • Page 440: Valve Installation

    When replacing valve stems, lubricate the threads and O-ring with Permatex Dielectric Tune- Up grease (Prevost #685324) to avoid galvanic corrosion. Tip: When installing the valves, use as needed a 15mm wrench to hold the valve and block the rotation.

  • Page 441: Tpms Sensors Installation

    Super Single tire Valve 650013 Install the valve in place. Torque 106-133 lb-in (12-15 Nm) #Prevost 650013 14.1 TPMS SENSORS INSTALLATION Check proper valve positioning before installing sensor onto valve (risk of damaging the sensor or air leaks). Pressure sensor #560032.

  • Page 442: Tire Maintenance

    SECTION 13: WHEELS, HUBS AND TIRES #651091 ENGLISH #651090 BILINGUAL Apply decal facing the valve. 15.1 INFLATION PRESSURE 15. TIRE MAINTENANCE  Vehicles equipped with BERU TPMS The most critical factor in tire maintenance is proper inflation (Figure 33). No tire is impervious On vehicles equipped with the Beru Tire to loss of air pressure.
  • Page 443 Weigh vehicle fully loaded and pressurize according to tire manufacturer's recommendations. For other tire and wheel specifications, see Prevost tire pressure tabulation in "Coach Final Record". PA1615 Maintenance Manual All Series Section 13 revised September 2016...

  • Page 444: Tire Matching

    SECTION 13: WHEELS, HUBS AND TIRES in good condition and properly mounted. An unbalanced wheel can be due to a bent wheel or improper mounting. Before removing the wheel from the vehicle, check for swaying movement and if necessary, check the wheel lateral run-out as outlined under heading "Wheel Straightness Check".

  • Page 445: Specifications

    SECTION 13: WHEELS, HUBS AND TIRES 16. SPECIFICATIONS STEEL WHEELS Wheel size ............................ 9.0" X 22.5" Tire size ............................ 315/80 R 22.5 ALUMINUM WHEELS Wheel size ............................9" X 22.5" Tire size ............................ 315/80 R 22.5 OPTIONAL FRONT & TAG AXLE ALUMINUM WHEELS (Standard on VIP vehicles) Wheel size ..........................
  • Page 447 SECTION 14: STEERING CONTENTS TORQUE TABLES ............................29 STEERING COLUMN............................29 MISCELLANEOUS TORQUES ......................... 37 STEERING SYSTEM ............................44 FRONT I-BEAM AXLE STEERING SYSTEM DESCRIPTION ................45 INDEPENDENT FRONT SUSPENSION STEERING SYSTEM DESCRIPTION ............52 POWER STEERING GEAR ..........................61 DESCRIPTION..............................
  • Page 448 SECTION 14: STEERING 13.2.1 Oil Level Check Procedure ......................... 186 13.2.2 Filter Replacement ........................... 188 13.3 STEERING STABILIZER CYLINDER (DAMPER) ....................191 13.4 DRAG LINK ..............................197 13.4.1 Independent Front Suspension ......................198 Lubrication Fittings ............................198 13.4.2 Front I-beam Axle ..........................211 13.5 TIE RODS ..............................
  • Page 449 SECTION 14: STEERING ILLUSTRATIONS FIGURE 1: I-BEAM AXLE STEERING SYSTEM SETUP ....................... 51 FIGURE 2: IFS STEERING SYSTEM SETUP ........................60 FIGURE 3: POWER STEERING GEAR ..........................62 FIGURE 4: FRONT SERVICE COMPARTMENT ......................... 68 FIGURE 5: PITMAN ARM ADJUSTMENT ........................80 FIGURE 6: FUEL PUMP REMOVAL ..........................

  • Page 450: Torque Tables

    SECTION 14: STEERING TORQUE TABLES STEERING COLUMN 14046_5 STEERING COLUMN DESCRIPTION TORQUE Steering Wheel Nut 35-45 lb-ft (47-61 Nm) U-Joint Clamp Nut 48 lb-ft (65 Nm) Column Support Fore Bolts 11-13 lb-ft (15-18 Nm) Column Support Aft Bolts 15-19 lb-ft (20-26 Nm) Steering Angle Sensor Mounting Screws 9-12 lb-in (1.02-1.36 Nm) PA1615 Maintenance Manual All Series...

  • Page 451: Miscellaneous Torques

    SECTION 14: STEERING MISCELLANEOUS TORQUES 10029_1 14088_2 14085 MISCELLANEOUS DESCRIPTION TORQUE Drop Type Ball Joint Castellated Nut - I-Beam Axle 175-200 lb-ft (237-271 Nm) Drop Type Ball Joint Clamp Bolts - I-Beam Axle 65-75 lb-ft (88-102 Nm) Pitman Arm Fixing Nut 470-570 lb-ft (637-773 Nm) Steering Gear Mounting Bolts 365-405 lb-ft (495-549 Nm)

  • Page 452: Steering System

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

  • Page 453: Independent Front Suspension Steering System Description

    SECTION 14: STEERING INDEPENDENT FRONT SUSPENSION NOTE STEERING SYSTEM DESCRIPTION VIP vehicles and Bus Shells are also equipped The steering system consists of the steering with a hydraulic power cylinder. The hydraulic wheel and column assembly, a vane-type power cylinder provides an added source of hydraulic pump, reservoir, filter, interconnecting assistance and being connected to the R.H.

  • Page 454: Power Steering Gear

    SECTION 14: STEERING POWER STEERING GEAR FIGURE 4: FRONT SERVICE COMPARTMENT 18611 A torsion bar, which is pinned with the valve slide and the worm, keeps the control valve in the neutral position as long as no opposing force is FIGURE 3: POWER STEERING GEAR 14035 applied to the steering wheel.

  • Page 455: Power Steering Gear Removal

    SECTION 14: STEERING TROUBLESHOOTING Also available is the ZF-Servocomtronic, which provides variable assistance in function of Perform troubleshooting of the steering gear as speed. outlined "ZF-SERVOCOM REPAIR MANUAL", "ZF-SERVOCOM Operating, Servicing/Maintenance Inspection POWER STEERING GEAR REMOVAL Instructions. WARNING BLEEDING POWER STEERING HYDRAULIC SYSTEM The steering gearbox weighs approximately 100 lbs (45 kg) dry.

  • Page 456: Steering Column

    SECTION 14: STEERING FIGURE 8: POWER STEERING PUMP REMOVAL Install the new power steering pump. FIGURE 6: FUEL PUMP REMOVAL Torque-tighten bolts to specification. CAUTION NOTE Use a new gasket. Ensure to clean around the head of the bolts. Debris will prevent the tool from fitting properly Connect the hydraulic lines to the power and cause damage to the fasteners.

  • Page 457: Steering Wheel

    SECTION 14: STEERING FIGURE 10: STEERING COLUMN COVERS STEERING WHEEL REMOVAL NOTE Before undertaking the steering wheel removal, assure that the front wheels are pointing straight ahead, aligned with the vehicle. 1. Set the battery master switch located in the rear electrical compartment to the "OFF"...

  • Page 458: Installation

    SECTION 14: STEERING INSTALLATION 1. Route the white horn wire and the 4-pin connector through the opening on the steering wheel. 2. Align the mark on the steering wheel hub with the mark on the spline shaft and slide the wheel onto the shaft. FIGURE 12: STEERING HARNESS &...

  • Page 459: Turning Angle Adjustment

    SECTION 14: STEERING FIGURE 15: PROPER CLOCKSPRING POSITION 6. Reinstall the steering wheel. TURNING ANGLE ADJUSTMENT The maximum turning angle is set through two (2) steering stop screws installed on the knuckles, above the ABS wheel sensors. Steering stop screws are factory adjusted to accommodate the FIGURE 17: STEERING STOP SCREW ON I-BEAM AXLE chassis design, and therefore, do not require adjustment on new vehicles.

  • Page 460: Steering Linkage Adjustment

    SECTION 14: STEERING 10. STEERING LINKAGE ADJUSTMENT CAUTION Steering linkage pivot points should be checked each time they are lubricated. Looseness can be Do not drive (hammer in) pitman arm on or off visually detected while rotating the steering wheel pitman shaft as this can damage the steering in both directions.

  • Page 461: Pitman Arm

    SECTION 14: STEERING 7. Use a suitable puller and remove pitman arm. a reference mark on steering gearbox at the center previously determined. 11.2 INSTALLATION 2. Using a protractor, check the angle of the pitman arm (refer to Figure 19 & Figure 19 for 1.

  • Page 462: Fine Adjustment

    SECTION 14: STEERING around pitman arm. Pinch zones are between pitman arm and clamp, and between front of pitman arm and vehicle structure. FIGURE 23: DRAG LINK ADJUSTMENT SYSTEM CAUTION Too little pressure on the clamp can destroy the threaded adjustment system sleeve. Apply the recommended torque for clamp nut.

  • Page 463: Maintenance

    ZF’s manual doesn’t apply adjusted, steering geometry and front wheel to the Prevost design which uses a 18-inch alignment must be checked and necessary steering wheel. corrections made. Refer to section 10 "FRONT AXLE"...

  • Page 464: Power Steering Reservoir And Filter

    SECTION 14: STEERING I-BEAM FRONT AXLE Perform the steering play inspection every 185000 miles (300 000 km) or once a year whichever comes first. MAINTENANCE INDEPENDENT FRONT SUSPENSION (Private use only) Perform the steering play inspection every 48 months. 13.2 POWER STEERING RESERVOIR AND FILTER The power steering reservoir is located on R.H.

  • Page 465: Steering Stabilizer Cylinder (Damper)

    SECTION 14: STEERING FIGURE 27: STEERING STABILIZER (DAMPER) 13.4 DRAG LINK Visually inspect drag link components for broken, corroded or deformed clamps, loose, bent or corroded nuts and gauges on tube from rubbing parts. 13.4.1 Independent Front Suspension Lubrication Fittings All lubrication fittings must be clean before applying lubricant.

  • Page 466: Front I-Beam Axle

    SECTION 14: STEERING MAINTENANCE Intervals below are recommended for normal service. More frequent intervals may be applied under severe operating conditions. The lubrication fittings (see FIGURE 28 ) should be serviced at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION &...

  • Page 467: Tie Rods

    SECTION 14: STEERING • Visual inspection • Place a finger on the separation line from the MAINTENANCE adjuster sleeve to the threaded ball joint shaft. Tie rod ends (ball joint) are provided with Keep fingers clear of pinch zones. grease fittings for pressure lubrication. These •...

  • Page 468: Drop Type Ball Joint

    SECTION 14: STEERING When dismantling tie rod or drag link, ensure remove adjuster piece. Waggle ball pin to that no damage is caused to the sealing boots, free thrust cap. dirt seals or ball joint housings. 5. Remove compression spring and thrust cap from ball joint body.

  • Page 469: Straight Body Type Ball Joint

    SECTION 14: STEERING 10. Fit dirt seal (pressing) and dirt seal (rubber) onto ball pin. 11. Locate ball joint and tie rod assembly with lever, carefully align and fit ball pin into hole in tie rod arm. NOTE: Ball pin and ball pin tapers in bottom tie rod arms must be clean, dry and free from oil prior to assembly.

  • Page 470: Driving Tips

    SECTION 14: STEERING 2. With the engine off and wheels straight ahead and no force is being exerted on the linkage by the steering gear, push and pull the ball joint in and out by hand (approximately 100 lbs. force) in the direction of the ball pin.

  • Page 471: Front Wheel Alignment

    SECTION 14: STEERING Front Axle Caster: The inclination of the kingpin FRONT WHEEL ALIGNMENT from vertical in the fore and aft direction (C, 15.1 INDEPENDENT FRONT SUSPENSION Figure 38). ALIGNMENT 15.1.2 Front End Inspection Proper front end alignment must be maintained insure ease steering...

  • Page 472: Front Wheel Toe-In

    SECTION 14: STEERING NOTE made at the same height above the floor. The front measurement must be 3/32 ±1/32 Camber is more important than kingpin of an inch less than the rear measurement. inclination, so adjust camber and verify kingpin inclination.

  • Page 473: Major Damage

    SECTION 14: STEERING NOTE X3-45 Coaches On Independent Front Suspension, caster on WITH INDEPENDENT FRONT SUSPENSION right wheel must be equal or greater than caster on left wheel, without exceeding 0.3°. Minimum Nominal Maximum value value value 15.1.6 Major Damage Right 0.0°...
  • Page 474 SECTION 14: STEERING FIGURE 36: IFS NOMINAL DIMENSIONS FIGURE 37: NOTE 2 INDICATES WHERE ADJUSTMENT MAY BE PERFORMED AT IFS ALIGNMENT PA1615 Maintenance Manual All Series Section 14 revised September 2016...
  • Page 475 SECTION 14: STEERING WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 38: FRONT END ALIGNMENT DIAGRAM 16051 PA1615 Maintenance Manual All Series Section 14 revised September 2016...

  • Page 476: I-Beam Axle - Front Wheel Alignment

    SECTION 14: STEERING 15.2 I-BEAM AXLE - FRONT WHEEL Make sure all fasteners are tightened to the ALIGNMENT specified torque. Use a torque wrench for verification. As soon as the fastener starts Correct front wheel alignment must be maintained to move, record the torque. Correct if for steering comfort and satisfactory tire life.

  • Page 477: Turning Angle Adjustment

    SECTION 14: STEERING 15.2.4 Turning Angle Adjustment 15.2.6 L.H. Turn Adjustment The maximum turning angle is set through the 1. Turn steering wheel to the left until the boss two steering stop screws installed on the axle on the axle center touches the left stop screw. center.

  • Page 478: Camber Check

    4. Check the wheel lateral distortion as needs adjustment; it can be adjusted by means instructed in Section 13, ‘’Wheels, Hubs and of shims (Prevost #110663) on the left-hand Tires’’ under heading, ‘’Checking side upper radius rod support in order to obtain Distorted Wheel on Vehicle’’.

  • Page 479: Front Wheel Toe-In

    SECTION 14: STEERING 15.2.11 Front Wheel Toe-In NOTE Wheel toe-in is the degree (usually expressed in ‘’Toe-in’’ measurements must be taken at the fractions of an inch) to which the forward part of horizontal axis of the wheel centerline. the vehicle front wheels are closer together than the rear part, measured at wheel centerline height 15.2.12 Inspection and Adjustment with the wheels in the normal ‘’straight-ahead’’...

  • Page 480: Troubleshooting

    SECTION 14: STEERING 16. 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 481: Torque Specifications

    SECTION 14: STEERING 17. TORQUE SPECIFICATIONS The torque specifications applicable to the front axle steering are grouped with information regarding the front suspension. Please refer to Section 16: SUSPENSION of this manual. 18. SPECIFICATIONS Power Steering Gear Make ..........................ZF-SERVOCOMTRONIC Type .............................
  • Page 483 SECTION 16 : SUSPENSION CONTENTS TORQUE TABLES ............................. 5 FRONT I-BEAM AXLE AND RELATED COMPONENTS ..................5 INDEPENDENT FRONT SUSPENSION ......................7 REAR SUSPENSION ............................9 DESCRIPTION ..............................14 FRONT I-BEAM AXLE SUSPENSION ........................ 14 AIR SPRINGS ..............................14 3.1.1 Inspection .............................
  • Page 484 SECTION 16 : SUSPENSION 3.15.3 Front Wheel Camber ..........................32 3.15.4 Front Wheel Toe-In ..........................32 3.15.5 Front Wheel Caster ..........................33 3.15.6 Major Damage ............................. 33 3.15.7 Alignment Specifications ........................33 3.16 LOWER AND UPPER A-ARM BALL PIN BUSHING REPAIR ................38 3.16.1 Inspection .............................
  • Page 485 SECTION 16 : SUSPENSION PRINCIPLE OF OPERATION ........................... 50 MAINTENANCE............................. 50 AIR SPRING CONTROL SOLENOID VALVES....................50 8.3.1 Removal and installation ........................50 HIGH-BUOY SYSTEM (COACHES ONLY) ......................50 PRINCIPLES OF OPERATION ......................... 50 MAINTENANCE............................. 51 HIGH-BUOY – PRESSURE REGULATOR......................51 9.3.1 Adjustment............................
  • Page 486 SECTION 16 : SUSPENSION FIGURE 22: SHIMS AT THE LOWER A-ARMS ......................... 32 FIGURE 23: IFS PITMAN ARM ALIGNMENT ........................33 FIGURE 24: IFS NOMINAL DIMENSIONS........................34 FIGURE 25: IFS ADJUSTMENT LOCATIONS ........................35 FIGURE 26: FRONT END ALIGNMENT DIAGRAM ......................36 FIGURE 27: A-ARM JOINT IDENTIFICATION ........................

  • Page 487: Torque Tables

    SECTION 16 : SUSPENSION TORQUE TABLES FRONT I-BEAM AXLE AND RELATED COMPONENTS 16188 16187 16192 PA1615 Maintenance Manual All Series Section 16 revised September 2016...
  • Page 488 SECTION 16 : SUSPENSION 16191 16193 16194_1 FRONT I-BEAM AXLE DESCRIPTION TORQUE (dry) Sway bar link, upper and lower nuts 165-200 lb-ft (224-271 Nm) Sway bar bushing collars (front suspension) 80-100 lb-ft (108-136 Nm) Tie rod end clamp bolts 65-75 lb-ft (88-102 Nm) Tie rod end ball pin nuts 150-200 lb-ft (203-271 Nm) 285-315 lb-ft (386-427 Nm)
  • Page 489 SECTION 16 : SUSPENSION INDEPENDENT FRONT SUSPENSION 16204 PA1615 Maintenance Manual All Series Section 16 revised September 2016...

  • Page 490: Independent Front Suspension

    SECTION 16 : SUSPENSION 16205 INDEPENDENT FRONT SUSPENSION DESCRIPTION TORQUE (dry) Drag link socket end clamp pinch bolt 50-60 lb-ft (68-81 Nm) Drag link ball stud nut to pitman arm 245-270 lb-ft (332-366 Nm) Drag link ball stud nut to bell crank 245-270 lb-ft (332-366 Nm) Pitman arm to steering gear fixing nut 470-570 lb-ft (637-773 Nm)
  • Page 491 SECTION 16 : SUSPENSION Torque rod, nut 158-193 lb-ft (214-262 Nm) Torque rod, stud 90-110 lb-ft (122-149 Nm) Sway bar bushing collar (front suspension) 80-100 lb-ft (108-136 Nm) Shock absorber mounting stud nut 99-121 lb-ft (134-164 Nm) Shock absorber mounting stud 350-400 lb-ft (475-542 Nm) Shock absorber lower mounting pin nut 60-75 lb-ft (81-102 Nm)
  • Page 492 SECTION 16 : SUSPENSION 16158_C: Meritor Drive Axle PA1615 Maintenance Manual All Series Section 16 revised September 2016...
  • Page 493 SECTION 16 : SUSPENSION 16159_B 16162_B PA1615 Maintenance Manual All Series Section 16 revised September 2016...

  • Page 494: Rear Suspension

    SECTION 16 : SUSPENSION 16160_B 16161_B REAR SUSPENSION DESCRIPTION TORQUE (dry) Air Spring Upper & Lower Stud Nut 31-38 lb-ft (42-52 Nm) Drive & Tag Axle Radius Rod stud 90-110 lb-ft (122-149 Nm) Sway Bar Link Upper & Lower Nut 99-121 lb-ft (134-164 Nm) PA1615 Maintenance Manual All Series Section 16 revised September 2016...
  • Page 495 SECTION 16 : SUSPENSION Shock Absorber Pin Nut 99-121 lb-ft (134-164 Nm) Shock Absorber Pin 350-400 lb-ft (475-542 Nm) Drive axle Radius Rod Nut/bolt 225-255 lb-ft (305-346 Nm) Drive Axle Longitudinal Radius Rod Retaining Bolt 185-227 lb-ft (251-308 Nm) Tag Axle Radius Rod Nut 228-252 lb-ft (309-342 Nm) Sway Bar Bushing Collar Bolt 80-100 lb-ft (108-136 Nm)

  • Page 496: Front I-Beam Axle Suspension

    SECTION 16 : SUSPENSION Replace the bellows if any damage is DESCRIPTION evident. The vehicle is provided with an air suspension With the primary air system at normal system. The system consists of air springs, operating pressure (122 - 140 psi (841 - 965 height control valves, radius rods, sway bars, kPa)), coat...

  • Page 497: Installation

    SECTION 16 : SUSPENSION 2. Align the upper attachments with holes in the CAUTION mounting plate. Rotate air spring clockwise. 3. Thread the lower nuts a few turns. Only the recommended jacking points must be used as outlined in Section 18, “Body”. NOTE Support the axle with a suitable To facilitate air spring installation, compress it...

  • Page 498: Inspection

    SECTION 16 : SUSPENSION replacement occurs. If a shock absorber 5. Extend and collapse shock several times to becomes inoperative, complete unit must be determine that it has control (resistance) in replaced. both rebound and compression. 6. Visually inspect the shock mountings and CAUTION vehicle mounting for: Broken mounts;...

  • Page 499: Installation

    SECTION 16 : SUSPENSION 3.2.3 Installation 1. Ensure that the shock absorber mounting pins are tight and that the threads are not stripped. 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.

  • Page 500: Radius Rod Removal

    SECTION 16 : SUSPENSION • Circlip (retaining ring) detached from groove • Broken Circlip • Loss of Circlip • Incipient crack If damage to the inner housing contour or the Circlip groove is found during replacement of the molecular bearing, the entire radius rod must be replaced.

  • Page 501: Stripping Down

    SECTION 16 : SUSPENSION 3.3.3 Stripping Down CAUTION Strip down the defective joint by removing the Circlip, and ball pin/bushing assembly. It is extremely important upon reconnection of Clean out housing bore and Circlip groove. the rods that the proper clearance height between the axle and body be maintained.
  • Page 502 SECTION 16 : SUSPENSION INDEPENDENT FRONT SUSPENSION (IFS) This section contains information and specifications unique to the independent front suspension (IFS), including suspension and steering. FIGURE 9: INDEPENDENT FRONT SUSPENSION 16124 STEERING LINKAGE connected by a relay rod. A drag link connected to the bell crank and the pitman arm, which is Turning motion of the steering wheel is mounted to the steering gear, transfers the...
  • Page 503 SECTION 16 : SUSPENSION Lower and upper A-arms are widely spaced. CAUTION They are mounted on ball joints. Torque rods prevent rotation of the uprights around the lower Clamp bolts are either in a vertical or and upper ball joints. horizontal position.
  • Page 504 SECTION 16 : SUSPENSION FIGURE 10: IFS STEERING LINKAGE OVERVIEW PA1615 Maintenance Manual All Series Section 16 modified September 2016...

  • Page 505: Steering Linkage

    SECTION 16 : SUSPENSION STEERING LINKAGE INSTALLATION section (for proper tightening torque, refer to SEQUENCE Torque Table 2). NOTE PITMAN ARM Whenever a steering linkage component has been removed and replaced, check steering 3.7.1 Removal geometry and front end alignment as directed 1.

  • Page 506: Drag Link

    SECTION 16 : SUSPENSION or when removable end assembly has been CAUTION replaced. If drag link adjustment is necessary, proceed as follows: Lock nut with sector shaft using a punch mark 1. Position front wheels in straight ahead into the groove, minimum depth 3/32 inch position.

  • Page 507: Bell Crank Or Idler Arm Hub Disassembly

    3.9.3 Bell Crank or Idler Arm Hub Reassembly using nut. NOTE 9. Tighten nut. For bearing installation use tool Prevost # TORQUE:130 lb-ft (176 Nm) 110684. 10. Rotate assembly 3 turns in each direction. NOTE Install grease retainer according to Figure 14.

  • Page 508: Relay Rod

    SECTION 16 : SUSPENSION FIGURE 15: BELL CRANK 3.10.1 Replacement 16044 1. Remove cotter pins from bell crank and idler 11. Unscrew nut until bell crank or idler arm arm end of relay rod. Loosen nuts flush with starts to turn with the application of 1 to 3 lbs end of studs.

  • Page 509: Installation

    SECTION 16 : SUSPENSION 2. Remove tie rod ball stud by tapping on steering arm and bell crank or idler arm with brass hammer, while using sledge hammer to absorb shocks. NOTE If tie rod end assemblies are damaged in any way, they must be replaced 3.11.2 Installation 1.

  • Page 510: Removal

    SECTION 16 : SUSPENSION 3.12.1 Removal 1. Remove wheel as directed in Section 13, "Wheel, Hubs and Tires" of the maintenance manual. 2. Remove cotter pin and nut from stud securing tie rod to steering arm. Remove ball stud from steering arm by tapping on arm with a hammer, placing a sledge hammer underneath steering arm to absorb shocks.
  • Page 511 SECTION 16 : SUSPENSION FIGURE 19: STEERING LINKAGE NOMINAL LENGTHS 16202 PA1615 Maintenance Manual All Series Section 16 modified September 2016...

  • Page 512: Lubrication Fittings

    SECTION 16 : SUSPENSION FIGURE 20: LUBRICATION FITTINGS LOCATION 16046 product quality. Figure 20 shows approximate 3.13 LUBRICATION FITTINGS location of steering lubrication fittings. All lubrication fittings must be clean before applying lubricant. Also, always sure MAINTENANCE equipment used in applying lubricant is clean. Every precaution should be taken to prevent (1) Drag Link Ends: Lubricate at four fittings, entry of dirt, grit, lint or other foreign matter into...

  • Page 513: Ball Joints - General Recommendations

    SECTION 16 : SUSPENSION Damaged sealing boots, salt and climatic (4) Steering Knuckle (swivel assembly): conditions can cause loss of the corrosion Refer to DANA SPICER MAINTENANCE protection coating applied time MANUAL NDS AXLES Lubrication and manufacturing. prevent corrosion from Maintenance"...

  • Page 514: Front End Inspection

    SECTION 16 : SUSPENSION Wheel Toe-In: a slight forward convergence Check kingpin inclination. If kingpin inclination is given to the wheels of motor vehicles to improve incorrect, readjust the camber and check kingpin steering and equalize tire wear inclination again. (D minus E, Figure 26).

  • Page 515: Front Wheel Caster

    SECTION 16 : SUSPENSION 5. Check distance between tire Variations from the specified caster will affect centerlines at the front and rear of the front steering stability, cause wandering, wheel tires. These two measurements must be shimmy, and reduce steer re-centering when made at the same height above the floor.
  • Page 516 SECTION 16 : SUSPENSION H3-45 Coaches WITH INDEPENDENT FRONT SUSPENSION Minimum Nominal Maximum value value value Right camber 0.0° 0.150° 0.30° Left camber 0.0° 0.150° 0.30° Right caster 2.35° 2.6° 2.85° Left caster 2.35° 2.6° 2.85° Total toe-in 0.04° 0.06° 0.08°...
  • Page 517 SECTION 16 : SUSPENSION FIGURE 25: IFS ADJUSTMENT Note 2 indicates where adjustment may be performed if needed when proceeding to IFS ALIGNMENT PA1615 Maintenance Manual All Series Section 16 modified September 2016...
  • Page 518 SECTION 16 : SUSPENSION WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 26: FRONT END ALIGNMENT DIAGRAM 16051 PA1615 Maintenance Manual All Series Section 16 modified September 2016...
  • Page 519 SECTION 16 : SUSPENSION FIGURE 27: A-ARM JOINT IDENTIFICATION PA1615 Maintenance Manual All Series Section 16 modified September 2016...

  • Page 520: Lower And Upper A-Arm Ball Pin Bushing Repair

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

  • Page 521: Lower A-Arm Ball Joint Repair

    SECTION 16 : SUSPENSION side of the housing shaft axis (retaining ring eyelet lug points to tube), and that retaining ring is properly engaged in the groove of the housing. 3. Faultlessly apply grease by mechanical means to bracket-outer core and ball-inner cone.

  • Page 522: Front Air Springs

    SECTION 16 : SUSPENSION dimension A again. If the difference between indicate an air leak, and none is permissible. the two dimensions is greater than 0.060" Repair or replace defective parts. (1.5mm), then the ball joint should be NOTE replaced. If air spring is removed from vehicle, bellows can be lightly inflated and submerged in water to detect any leakage.

  • Page 523: Installation

    SECTION 16 : SUSPENSION 7. Disconnect air line from air spring, remove elbow (if applicable), and cover both the line end and fitting to prevent the entry of foreign CAUTION matter. 8. Unscrew the two air spring lower nuts (2 When a shock absorber is found defective, nuts).

  • Page 524: Shock Absorber Installation

    SECTION 16 : SUSPENSION 3.20.2 Shock Absorber Installation 3. Remove sway bar. 1. Check that the shock absorber mounting NOTE stud is tightened as prescribed in Torque Table 2. Ensure that the stud is clean and Sway bar bushings are slit to ease their not stripped (upper end).

  • Page 525: Rear Suspension

    SECTION 16 : SUSPENSION REAR SUSPENSION FIGURE 38: TAG AXLE SUSPENSION FIGURE 37: DRIVE AXLE, DETAILS OF REAR SUSPENSION 16106 FIGURE 39: REAR SUSPENSION COMPONENTS 16003 PA1615 Maintenance Manual All Series Section 16 modified September 2016...

  • Page 526: Air Springs

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

  • Page 527: Shock Absorbers

    SECTION 16 : SUSPENSION NOTE CAUTION To facilitate air spring installation, compress it manually then put a piece of tape over the air When a shock absorber is found defective, line threaded fitting. This prevents air from always replace with a new set on affected axle, getting back into the bag and keeps it except if there has been a recent replacement compressed, thus enabling to place the bag in...

  • Page 528: Removal

    SECTION 16 : SUSPENSION b) Extreme bushing wear; 3. On the lower mounting, take care to install the rubber joints with the wide end of the c) Shifted bushing or sleeve; tapered hole as shown in Figure 42. d) Deep cracks in bushing material (shallow surface cracks are normal);...

  • Page 529: Inspection

    SECTION 16 : SUSPENSION The pressure protection valve (PR-4) is mounted pressure in the springs to the vehicle load, to the supply port of the tank. This valve controls maintaining normal ride height. the pressure at which compressed air is adjust suspension height,...

  • Page 530: Height Control Valves

    SECTION 16 : SUSPENSION HEIGHT CONTROL VALVES 6.3.1 Removal and installation The height control valves automatically add air Before disconnecting any height control valve air to, or release air from air springs to maintain lines, securely support the vehicle by its jacking constant suspension height regardless of load, points on the body, and place safety support load...

  • Page 531: Air Leakage Test

    SECTION 16 : SUSPENSION PRINCIPLES OF OPERATION 6.3.2 Air leakage test Down NOTE The (front/rear right/rear left) control solenoid valve supplies air to the (front/rear right/rear left) The following procedure applies when valve five-way three-position air control valve, which assembly has been removed from vehicle. bypasses the (front/rear right/rear left) height 1.

  • Page 532: Front Kneeling System (Coaches Only)

    SECTION 16 : SUSPENSION FRONT KNEELING SYSTEM (COACHES module to cut off the air spring control solenoid valve, about 1" (25 mm) below normal ride ONLY) height. The final height adjustment is achieved The kneeling system is used to lower front of by the height control valve.

  • Page 533: High-Buoy - Pressure Regulator

    SECTION 16 : SUSPENSION to send air to the double shuttle valves for the 9.3.2 Disassembly rear end. It uses the same dash switch as the 1. Shut off inlet pressure and reduce pressure kneeling. in inlet and outlet lines to zero. Turn regulator adjustment handle (1, Figure 44) counterclockwise until all load is removed The air coming from the control valve flows...

  • Page 534: Reassembly

    SECTION 16 : SUSPENSION LOW-BUOY SYSTEM (COACHES ONLY) The purpose of the low-buoy system is to lower the whole suspension by about 4” (100 mm) in order to reduce the overall height for low clearances. This system can be put into service during normal vehicle operation.

  • Page 535: Air Tank Maintenance

    SECTION 16 : SUSPENSION FIGURE 45: LOCATION OF AIR TANKS 12195 11.1 AIR TANK MAINTENANCE MAINTENANCE Ensure that the accessory air tank is purged during pre-starting inspection. A good practice is It is recommended to purge the primary air to purge this tank at the end of every driving day tank by its bottom drain valve every 12,500 by the remote air tank drain valve located in the miles (20 000 km), or once a year, whichever...

  • Page 536: Secondary Air Tank

    SECTION 16 : SUSPENSION 11.1.3 Secondary Air Tank This tank is located in front wheelhousing. The tank is installed vertically and is provided with a bottom drain valve. MAINTENANCE It is recommended to purge the secondary air tank by its bottom drain valve every 12,500 miles (20 000 km), or once a year, whichever comes first.

  • Page 537: Troubleshooting

    CAUTION Air filled through these two points will pass through the standard air filtering system provided by Prevost. Do not fill air through any other points. NOTE Apply corrosion-protective compound on exposed threads.

  • Page 538: Specifications

    Extended length ........................24.37” (619 mm) Height control valve (IFS) Quantity used ..............................1 Prevost number ......................Refer to Parts Manual Height control valve (coach, all axles & VIP, rear only) Quantity ..............................2 or 3 Prevost number ......................Refer to Parts Manual...
  • Page 539 Type ................................N/C Type ................................N/O Radius rod bushing Make ..............................Prevost Prevost number ......................Refer to Parts Manual Sway bar bushing (Independent Front Suspension Make ..............................Prevost Prevost number ......................Refer to Parts Manual Sway bar bushing (Front Axle) Make ..............................
  • Page 540 MAINTENANCE MI16-14 INFORMATION DATE : JUNE 2016 SECTION : 16 - Suspension SUBJECT : SUSPENSION HEIGHT ADJUSTMENT USING HEIGHT CONTROL VALVES APPLICATION Model All models Model Year : From 2014 DESCRIPTION Use this procedure when a suspension height check or adjustment must be performed. HEIGHT CONTROL VALVES Three height control valves automatically control air volume in the suspension air springs at three separate locations to maintain a constant vehicle height regardless of load or load distribution.
  • Page 541 MI16-14 / Page 2 / 9 The two rear suspension height control valves are mounted to the chassis and connected to the fore air springs of the rear underframe through a control arm and link. One front suspension valve is mounted to the chassis and connected to the front axle through a control arm and link.
  • Page 542 MI16-14 / Page 3 / 9 NORMAL RIDE HEIGHT The normal ride height is obtained by measuring and adjusting air spring height of front and rear suspension. TABLE 1 – PRESCRIBED AIR SPRING HEIGHTS FRONT SUSPENSION (I-BEAM AXLE) 2 air springs INDEPENDENT X = 12 7/8 ±...
  • Page 543 MI16-14 / Page 4 / 9 PROCEDURE DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
  • Page 544 MI16-14 / Page 5 / 9 5. Loosen the lower mounting bolt shown. Take note that the bolt is equipped with a nylon insert. The bolt should be replaced after three (3) tightenings. INCREASING CLEARANCE 6. Rotate the valve body to increase or decrease the clearance as shown (the mounting bracket has a slotted hole).
  • Page 545 MI16-14 / Page 6 / 9 FRONT SUSPENSION AIR SPRINGS ADJUSTMENT (I-BEAM AXLE) Measurement 1. Make sure that the air system pressure is at least 90 psi. 2. Measure the front axle springs clearance (two air springs). To do measure clearance between the support above the air spring and the lower end...
  • Page 546 MI16-14 / Page 7 / 9 5. Loosen the lower mounting bolt shown. Take note that the bolt is equipped with a nylon insert. This bolt should be replaced after three (3) tightenings. 6. Rotate the valve body to INCREASING CLEARANCE DECREASING CLEARANCE increase or decrease the clearance as shown (the...
  • Page 547 MI16-14 / Page 8 / 9 INDEPENDENT FRONT SUSPENSION ADJUSTMENT Measurement 1. Make sure that the air system pressure is at least 90 psi. 2. Measure that the air springs clearance (two air springs). To do so, measure the clearance between the support found above the air spring and the lower end of the air spring (if needed, use a metal ruler to reach the lower end of the...
  • Page 548 MI16-14 / Page 9 / 9 Air springs height adjustment Adjust the air springs clearance with the height control valve 5. It is necessary to adjust clearance on "fill cycle". a) Disconnect the link. It is equipped with a rubber bushing that allows easy disconnection.
  • Page 549 SECTION 18a: H3 SERIES BODY CONTENTS      TORQUE TABLES .......................... 6     VEHICLE EXTERIOR  ......................... 8     STRUCTURE .......................... 10     WELDING ............................ 10     EXTERIOR MAINTENANCE ...................... 10     CORROSION PREVENTION ...................... 10     PREVENTIVE MAINTENANCE SCHEDULE .................. 11     RUST INHIBITOR APPLICATION ..................... 12     FIBERGLASS REPAIR ........................ 17     REPAIR USING FIBERGLASS CLOTH .................... 17     REPAIR USING FIBERGLASS PASTE .................... 17  ...
  • Page 550 SECTION 18a: H3 SERIES BODY     DEPTH ADJUSTMENT ........................ 28     DOOR LOWER SECTION ........................ 28     REFLECTOR STRIPE INSTALLATION .................... 29     DOOR SEAL REPLACEMENT...................... 29     DOOR LUBRICATION ........................ 29     DOOR LATCH MECHANISM  ...................... 29     DRIVER’S POWER WINDOW ..................... 30     10.1 POWER WINDOW REMOVAL  ...................... 30     10.2 POWER WINDOW INSTALLATION  .................... 30  ...
  • Page 551 SECTION 18a: H3 SERIES BODY     BODY PANELS AND DOORS ...................... 57     WHEELCHAIR LIFT ACCESS DOOR  .................... 58     19.1 INSTALLATION  .......................... 58     19.2 ADJUSTMENT  .......................... 58     BAGGAGE COMPARTMENT DOORS .................. 61     20.1 PANTOGRAPH ADJUSTMENT ...................... 61     DOOR HANDLES ........................ 62     ENGINE COMPARTMENT DOOR  .................... 62  ...
  • Page 552 SECTION 18a: H3 SERIES BODY     35.3 ASSEMBLY ............................. 76     35.4 REPLACEMENT OF MIRROR GLASS .................... 76     35.5 HEATED / REMOTE CONTROLLED REAR VIEW MIRRORS ............. 76     35.5.1 Mirror Control ........................ 76     35.5.2 Disassembly .......................... 77     35.5.3 Assembly .......................... 77     35.5.4 Convex & Flat Mirror Removal  .................... 77     VEHICLE JACKING POINTS  ...................... 77  ...
  • Page 553 SECTION 18a: H3 SERIES BODY   ‐   ...................... 46 FIGURE   ADHESIVE MOUNTED WINDOW   ‐   ...................... 47 FIGURE   ADHESIVE MOUNTED WINDOW   ‐   ...................... 47 FIGURE   ADHESIVE MOUNTED WINDOW   ) ................ 49 FIGURE   ELECTRIC AWNING WINDOW EXPLODED VIEW  FRAME   )................. 49 FIGURE   ELECTRIC AWNING WINDOW EXPLODED VIEW  SASH   .................... 52 FIGURE ...
  • Page 554 SECTION 18a: H3 SERIES BODY TORQUE TABLES BODY DESCRIPTION TORQUE Entrance door horizontal adjusting bolts 55-65 lb-ft (75-88 Nm) Passenger seat mounting nuts (to sidewall and pedestal) 27 lb-ft (37 Nm) PA1615 Maintenance Manual All Series Section 18a revised September 2016...
  • Page 555 SECTION 18a: H3 SERIES BODY WHEEL CHAIR LIFT DOOR DESCRIPTION TORQUE Wheel chair lift door – Center hinge bolts 43 lb-ft (58 Nm) Wheel chair lift door - striker pin adjustment bolts 54-66 lb-ft (73-89 Nm) Wheel chair lift door - opening mechanism bolts 30-42 lb-ft (41-57 Nm) PA1615 Maintenance Manual All Series Section 18a revised September 2016...
  • Page 556 SECTION 18a: H3 SERIES BODY 2. VEHICLE EXTERIOR 18681 FIGURE 1: H3-45 (TYPICAL) 1. Engine air intake 11. Diesel Particulate Filter (DPF) access door 2. Engine compartment curb-side door 12. Engine compartment rear door 3. Main power compartment (battery 13. Rear-view mirror compartment) 14.
  • Page 557 SECTION 18a: H3 SERIES BODY 18677 FIGURE 2: H3-45 VIP EXTERIOR VIEW 1. Engine air intake 11. Reclining bumper compartment 2. Engine R.H. side access door 12. Front electrical and service compartment 3. Main power compartment 13. Driver’s power window 4.
  • Page 558 SECTION 18a: H3 SERIES BODY CORROSION PREVENTION 3. STRUCTURE The body of the H3-41, H3-45 and VIP vehicles Preventive maintenance is a key factor in is an integral structure made of 14, 16 and 18 avoiding corrosion and must be considered as gauge welded and braced high tensile steel and part of the regular service intervals.
  • Page 559 SECTION 18a: H3 SERIES BODY 3. Apply correct primer, paint and undercoating further damage. after removing all corrosion to prevent PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly.
  • Page 560 SECTION 18a: H3 SERIES BODY RUST INHIBITOR APPLICATION Material: Tectyl 185 GW R1KG21 Safety Rules: Use safety glasses Supplied air hood Solvent-resistant rubber gloves 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be hot masking.
  • Page 561 SECTION 18a: H3 SERIES BODY 3.2 Front wheelhousing 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) PA1615 Maintenance Manual All Series Section 18a revised September 2016...
  • Page 562 SECTION 18a: H3 SERIES BODY 4.1 Rear wheelhousing (Entire braking system) 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used.
  • Page 563 SECTION 18a: H3 SERIES BODY 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts. the rust inhibitor. If the application is done inside a paint room, select high speed ventilation. Minimum required thickness is 10 mils wet or 5 mils dry.
  • Page 564 SECTION 18a: H3 SERIES BODY DEW POINT Relative Humidity (%) Temp (c) PA1615 Maintenance Manual All Series Section 18a revised September 2016...
  • Page 565 SECTION 18a: H3 SERIES BODY NOTE 5. FIBERGLASS REPAIR All repairs to fiberglass parts consist of filling the Roughening the surface improves adhesion of damaged area with fiberglass cloth and resin or resin. strand fiberglass and resin. The repair is allowed If part is warped from original shape, use to harden, and then finishing operations may be clamping equipment to straighten the surface.
  • Page 566 SECTION 18a: H3 SERIES BODY Preheat the area to be repaired using heat NOTE lamps. Mix desired quantities of resin and Remove all air between surfaces being joined. hardener according manufacturer's Allow area to harden and sand surface to instructions. Add powdered fiberglass strand into remove any wax.
  • Page 567 Our paint supplier recommends that you follow these simple precautions the first months of your Prevost recommends using the original paint new vehicle’s life. brand to ease color matching. CAUTION...
  • Page 568 SECTION 18a: H3 SERIES BODY catalysts, accelerators, and cleaners are highly CAUTION volatile and/or toxic if not properly used. Observe all safety instructions marked on the Be sure to heed all paint manufacturer’s different packagings, as well as the following: recommendations, especially concerning paint 1.
  • Page 569 SECTION 18a: H3 SERIES BODY Sand Non-Stop primer using P-320 grit sandpaper Sanding Use a tack cloth Basecoat Apply basecoat. Wait 30 minutes. Dilution without flexible agent Varnish dilution Apply varnish Varnishing If assistance or technical information on STANDOX products is needed, please dial: 1 (800) 551-9296 7.
  • Page 570 2. Let the bumper rest face down on the lifting NOTE equipment platform. A special tool kit is available from Prevost: Kit 3. To install bumper, reverse the procedure. # 410671 including tool #410708. 2. Remove 4 cap screws holding bumper to vehicle and remove bumper (Figure 10).
  • Page 571 SECTION 18a: H3 SERIES BODY latch, unlocking the door. Door movement starts only when pressure in the central air door lock is below 10 psi. The “air cylinder open solenoid valve” opens and allows air to flow to the door cylinder, “the air cylinder close solenoid valve”...
  • Page 572 SECTION 18a: H3 SERIES BODY DOOR CYCLE SPEED ADJUSTMENT To do any adjustment, remove the two panels located next to the door hinge, as well as the door’s upper hinge control. GREASE FITTING DOOR CYLINDER DOOR HINGE DAMPER DAMPER SUPPORT PIVOT SNAP RING LUBRICATE PINS...

  • Page 573: Depth Adjustment

    SECTION 18a: H3 SERIES BODY CAUTION Make sure the entrance door does not interfere with the exterior panel. FIGURE 18: UPPER DOOR HINGE (COACH) 18058 6. Pull and fasten the rod end to the hinge with the washer and the button screw. 7.
  • Page 574 SECTION 18a: H3 SERIES BODY 6. Pull and fasten the rod end to the hinge with 3. Remove the Allen button head screw and the washer and the button screw. the washer retaining the rod end with bearing to upper hinge. See figure 19. 7.
  • Page 575 SECTION 18a: H3 SERIES 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 not If the voltage is 24 volts then replace it. receive current.

  • Page 576: Door Lower Section

    SECTION 18a: H3 SERIES BODY DOOR ADJUSTMENT 3. Ask your assistant to press the door from the exterior, until it will adjust with the Check around the perimeter of the door for vehicle structure. Then, tighten the vertical binding. If any binding is found, adjust as bolts.

  • Page 577: Reflector Stripe Installation

    DOOR LUBRICATION 10. Apply Sika #252 (Prevost #682462) Part Lubricant Frequency compound where it was previously applied. Latches 11. Remove protective paper from the adhesive...

  • Page 578: Driver's Power Window

    SECTION 18a: H3 SERIES BODY 9. Detach the motor and actuator guide from the support and plastic shield. Replace parts as required. FIGURE 22: DRIVER’S WINDOW 23358 10.2 POWER WINDOW INSTALLATION FIGURE 21: ENTRANCE DOOR (VIP, TYPICAL) 18440 1. Energize the motor and position the actuator to its full extended position.

  • Page 579: Sealing

    Seal joint should be toward rear of vehicle. reduce the strength of certain components. 3. Apply rubber adhesive CA-40 (Prevost # 681285) in the gap between the seal ends. CAUTION 4. Apply Sikaflex 221 sealant (Prevost #...

  • Page 580: Escape Hatch Panel Assembly

    SECTION 18a: H3 SERIES BODY 11.3 ESCAPE HATCH PANEL ASSEMBLY The frame of the escape hatch is riveted to the roof of the vehicle. The escape hatch panel assembly can be replaced as a unit and a new panel assembly installed in the existing frame. To remove the panel assembly, remove the 4 bolts fastening the 2 hinges to the escape hatch frame and retain the 4 flat washers.

  • Page 581: Repair Or Replacement Of "Tarabus" Floor Covering

    SECTION 18a: H3 SERIES BODY 12. 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 582 SECTION 18a: H3 SERIES BODY FIGURE 25: TARABUS FLOOR COVERING ADHESIVE APPLICATION FIGURE 26: APPLICATION OF SIKA 221 GRAY PA1615 Maintenance Manual All Series Section 18a revised September 2016...

  • Page 583: Front Steps Replacement Procedure

    SECTION 18a: H3 SERIES BODY 12.1 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 584 SECTION 18a: H3 SERIES BODY Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer 3. Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) If surface seems dusty, dust using damp cloth.
  • Page 585 SECTION 18a: H3 SERIES 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 586: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering

    SECTION 18a: H3 SERIES BODY NOTE Keep a gap of 1 to 1.5 mm between “Tarabus” covering and white safety strip. 7. Remove masking tape. 12.2 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 587 SECTION 18a: H3 SERIES 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 588 SECTION 18a: H3 SERIES 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 589: Repair Of A Welded Joint

    SECTION 18a: H3 SERIES BODY 12.3 REPAIR OF A WELDED JOINT NOTE In wintertime, condensation and cold temperature may greatly influenced bonding parameters. Working area must be at a temperature sufficient to prevent reaching condensation point. Mechanically preheat working area (heat lamp or heat gun) or wait until vehicle reaches room temperature. 1.

  • Page 590: Passenger Seats

    13. PASSENGER SEATS frame. H3-41 and H3-45 coaches can be equipped with 2. Lift front part of cushions and remove any of 2 basic seat models and installed in a cushions.

  • Page 591: Upholstery Maintenance

    If covers are to be removed for cleaning, dry Seven passenger side windows are provided on cleaning is recommended since washing might each side on H3-41, while the H3-45 has eight. cause some shrinkage, preventing the covers They are made of fixed, single or double-glazed, from being reapplied to the seats without heat absorbing AS-3 glass.

  • Page 592: Emergency Exit Windows

    Three of the windows on each side serve as pound resistance criteria for opening the emergency exits on the H3-41, while there are emergency window. If this handle should be three of them on curb side of the H3-45, and replaced: four on driver’s side.

  • Page 593: Fixed Window Replacement

    SECTION 18a: H3 SERIES BODY 14.4 EMERGENCY EXIT WINDOW position. REPLACEMENT 14.3 FIXED WINDOW REPLACEMENT 1. Lift the bar release system and follow the When it becomes necessary to replace the glass same procedure mentioned above for fixed of a fixed-type window, follow this procedure: windows.

  • Page 594: Adhesive-Mounted Windows

     Masking tape; opening on the glass with a china pencil. Remove glass and place it on a table with  Tremshield tape (Prevost #681089); the pencil mark facing up.  Chix cloths (Prevost #682384); 4. Place masking tape on the inside surface of ...

  • Page 595: Electric Awning Window

    SECTION 18a: H3 SERIES BODY NOTE Bead should touch the side surface of the window opening. 9. Place shims correctly, and position window glass in the opening. Press firmly and evenly. Excess adhesive should flow out from behind glass. NOTE Add adhesive in areas where overflow is minimal or if air bubbles are present.

  • Page 596: Window Removal

    SECTION 18a: H3 SERIES BODY window is closed, PROX1 is activated, turning 15.2 WINDOW REMOVAL on SOL1-A and SOL1-B in reverse polarity latching the window closed. Replacement awning window does not include a new motor. If in working order, transfer the motor replaced window...
  • Page 597 SECTION 18a: H3 SERIES BODY Fixing fra me Screen Ga s spring Fra me Relea sing bar keeper T rack Proximity sensor ma gnet Vertica l la tch ha ndle D-sea l Window ajar sensor Spring T ra ck release la tch FIGURE 38: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 Actuators...

  • Page 598: Actuator Replacement

    SECTION 18a: H3 SERIES BODY 15.3 ACTUATOR REPLACEMENT 1. Push the vertical latch handle downwards to release the track and then unlatch the window using the horizontal latch handle. 2. Remove actuator access cover by taking out screws #1 (8x). 3.
  • Page 599 SECTION 18a: H3 SERIES BODY ELECTRIC AWNING WINDOW – CONVERTER CHECKLIST Check the electrical circuit & A: The latching system will not operate without power. proximity sensor Is there electrical power to the latching circuit? The horizontal latch handle, on the sill sash will be seen to move if there is power on this circuit, or it can be checked with an electrical tester.

  • Page 600: Electric Sliding Window

    SECTION 18a: H3 SERIES BODY 16. ELECTRIC SLIDING WINDOW FIGURE 40: ELECTRIC SLIDING WINDOW EXPLODED VIEW Sash Removal 1. Remove the Screen Assembly 2. Pull down on both release latches simultaneously and rotate the sash inwards approximately 10 degrees.(Figure 43) FIGURE 41: REMOVING THE SASH PA1615 Maintenance Manual All Series Section 18a revised September 2016...
  • Page 601 SECTION 18a: H3 SERIES BODY 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 42) FIGURE 42: DISENGAGING THE BOTTOM OF THE SASH Installation 1. Align the leading edge of the slot on the lower cam follower block with the sash stop. Use the power toggle switch to obtain the correct alignment.
  • Page 602 SECTION 18a: H3 SERIES BODY FIGURE 44: POSITIONING THE LOWER LEFT CORNER OF THE SASH 3. Engage the sash pin with the leading edge of the slot of the cam follower block. Do the same at the rear of the sash. 4.

  • Page 603: Windshield Installation Only

    FIGURE 47: WINDSHIELD INSTALLATION TOP VIEW from Prevost Parts to ensure proper fit. 18098 Windshields obtained from other sources should 3. From inside of vehicle, push against the top be checked for proper size and curvature.
  • Page 604 SECTION 18a: H3 SERIES BODY NOTE Spray lubricant on a regular basis to ease windshield insertion. FIGURE 49: WINDSHIELD INSTALLATION SIDE VIEW 8099 6. Insert the top curved corner then finish with the top of windshield. FIGURE 48: WINDSHIELD INSTALLATION USING ROPE 7.

  • Page 605: Installation Of Rubber Extrusion And Windshield

    SECTION 18a: H3 SERIES BODY 11. Every 6 inches or so, it is important to 2. Clean the rubber extrusion with wiping compress the filler due to its tendency to towels soaked with Sika 205 and let dry 1 to contract during drying process.

  • Page 606: Wheelchair Lift Access Door

    SECTION 18a: H3 SERIES BODY 19. WHEELCHAIR LIFT ACCESS DOOR 19.1 INSTALLATION CAUTION Install the sliding door onto a suitable lifting device that will allow proper lifting and positioning. 1. Lift and move the sliding door near the opening. 2. Push the door into the opening making sure the positioning lugs are properly inserted into their housing then pivot the main hinge and secure the door using 4 bolts.
  • Page 607 SECTION 18a: H3 SERIES BODY FIGURE 53: 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 608 SECTION 18a: H3 SERIES BODY - Push the lower rail towards the outside of the vehicle in order to remove the play between the roller and rail then bolt the rail at front and center. Make sure the rollers stay in contact with the support when starting to close the door.

  • Page 609: Baggage Compartment Doors

    NOTE There are 6 pantograph doors serving as Refer, if needed, to Figure 56 for identification baggage compartment doors on the H3-41, of door components. while there are 8 on the H3-45 and the V.I.P (depending on options, VIP model may have If the door bends when opening or if pantograph even more pantograph doors).

  • Page 610: Door Handles

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

  • Page 611: Engine Door Adjustment

    SECTION 18a: H3 SERIES BODY 22.2 MINOR TOP EDGE DEPTH ADJUSTMENT Two rubber spring loaded stops may be adjusted. They are located near the top edge on each side of the rear door. FIGURE 61: DOOR STOP 18324 To adjust: 1.

  • Page 612: Radiator Door Adjustment

    SECTION 18a: H3 SERIES BODY 6. Apply SIKA 205 primer to the grill opening 24.2 DOOR LATERAL ADJUSTMENT and the grill edges. Allow to dry at least 2 minutes for chemical evaporation. 7. Apply SIKA 255 FC adhesive on the grill edge.

  • Page 613: Condenser Door Adjustment

    SECTION 18a: H3 SERIES BODY 25. CONDENSER DOOR ADJUSTMENT 1. Open the condenser door. 2. Loosen the nuts (1, Figure 69) holding the hinge (3, Figure 69) to hinge attachment (4, Figure 69). Loosening nuts (1, Figure 69) allows the condenser assembly to be shifted "LEFT or RIGHT"...

  • Page 614: Fuel Filler Door

    SECTION 18a: H3 SERIES BODY 8. Respect the required gap between exterior 5. Loosen bracket nuts holding the panel to finishing panels (Figure 51). condenser. Panel (6, Figure 69) may be shifted "IN or OUT", "LEFT or RIGHT" and 9. Check that the door swings freely and "UP or DOWN".

  • Page 615: Latch Mechanism Adjustment

    SECTION 18a: H3 SERIES BODY 6. Adjust door panel to have the same gap space as neighboring panels or refer to Figure 51for specified gap space. Only if necessary, use the adjustment allowed by SECTION moving part 1, Figure 71. 8 ±...

  • Page 616: Latch Mechanism Adjustment

    SECTION 18a: H3 SERIES BODY 7. Adjust the door in accordance with the required distance between exterior finishing parts (Figure 51). 29. EVAPORATOR DOOR ADJUSTMENT 8. Loosen screws (4, Figure 74). 1. Open the door. 9. Screws allow the door to be shifted "UP or 2.

  • Page 617: Main Power Compartment

    SECTION 18a: H3 SERIES BODY 41,2 ± 41 ± 2 mm 8 ± 2 mm FIGURE 75: EVAPORATOR DOOR 18198 6. Adjust door panel to have the same gap 30. MAIN POWER COMPARTMENT space as neighboring panels or refer to figure 45 for specified gap space To adjust the main power compartment door: 7.

  • Page 618: Rear Fender Removal

    It is held in place with bolts the top edge disengages from the holding and nuts. If it ever it has to be replaced, make plates. an appointment at a Prevost service center near you. To reinstall, reverse the procedure. 31.2 FRONT FENDER REMOVAL 1.

  • Page 619: Side Panel Installation Procedure For Coaches And Vip

    SECTION 18a: H3 SERIES BODY 34. SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP Material:    Anti-silicone (682989) Blue cloth (682383) Sika 206 G+P 1 liter (683446)    Tack cloth Pure water Sika 252 black  ...
  • Page 620 SECTION 18a: H3 SERIES BODY Clean using anti-silicone See SAV000001 section A. Apply primer 206 G+P. See SAV000001 section D. PR000001 Section D Sika Primer 206 G+P Shake bottle to mix product Apply a thin layer CHIX cloth 3. Allow to dry Minimum time : 10 minutes Mandatory 206 G+P...
  • Page 621 SECTION 18a: H3 SERIES 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 622 SECTION 18a: H3 SERIES 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 623 SECTION 18a: H3 SERIES BODY SECTION #2 DRIP MOLDING INSTALLATION 2.00 * A) Clean using Anti-silicone See SAV000001 section A. Apply Sika 206 G+P See SAV000001 section D. 2.05 Remove blue paper from drip molding. Remove protective tape from double- face self adhesive tape 2.10 Glue drip molding.

  • Page 624: Rear View Mirrors (Ramco)

    SECTION 18a: H3 SERIES BODY Insert the ball stem into the mirror arm and 35. REAR VIEW MIRRORS (RAMCO) tighten the socket setscrews. Your vehicle is equipped with two exterior NOTE mirrors. Position the ball cup halves so the joint The mirrors may be equipped with an optional between them lies on the centerline of the electric...
  • Page 625 SECTION 18a: H3 SERIES BODY Turn pointer knob to the left for mirror head for lifting the front of the vehicle must have a adjustments and to the right for convex mirror combined lifting capacity of at least 20,000 lb. (9 adjustment, then push down on either of the 100 kg).
  • Page 626 SECTION 18a: H3 SERIES BODY FIGURE 83: JACKING POINTS ON IND. SUSPENSION FIGURE 79: JACKING POINTS ON FRONT UNDERFRAME – I BEAM AXLE 16183 FIGURE 84: JACKING POINTS ON DRIVE AXLE 18085 CAUTION Always unload or retract the tag axle before jacking the vehicle from the front and drive axle jacking points to prevent damage to suspension components.
  • Page 627 SECTION 18a: H3 SERIES BODY vehicle should be towed by truck operators 2. Operate the engine when towing to maintain authorized and experienced in towing highway brake system air pressure. If the engine coaches. cannot be operated, connect an external air pressure line from the tow truck to the Tow eyes emergency...
  • Page 628 SECTION 18a: H3 SERIES BODY pressure line from the tow truck to the emergency fill valve engine Applying the procedure will allow tow mode to compartment. The emergency fill valve in be activated and vehicle to be towed without the the front service compartment does not removal of the driveshaft for whatever distance supply air pressure to the brake system.
  • Page 629 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 631 SECTION 18b: X3 SERIES BODY CONTENTS   1.  TORQUE TABLES  .......................... 6  2.  VEHICLE EXTERIOR ........................ 7  3.  VEHICLE STRUCTURE ........................ 10  4.  VEHICLE EXTERIOR MAINTENANCE  .................... 10  PREVENTION ...................... 10  4.1  CORROSION   4.2  PREVENTIVE MAINTENANCE SCHEDULE  .................. 11      4.3  RUST INHIBITOR APPLICATION ..................... 12      5.  COMMON FIBERGLASS REPAIR PROCEDURE  ................ 17  5.1 ...
  • Page 632 SECTION 18b: X3 SERIES BODY 7.4.3  Engine Radiator Door ...................... 49  7.5  ZONE 5 ............................ 51    7.5.1  Baggage Compartment Doors (Aluminum)  ................ 51  7.5.2  Wheelchair Lift Cassette Compartment Door  ................ 54  7.5.3  Baggage Compartment Floor .................... 55  7.5.4  Evaporator Compartment Door..................... 59  7.5.5  Condenser Compartment Door  .................... 61  7.5.6  Fuel Filler Door ........................ 61  7.6  ZONE 6 ............................ 62    7.6.1  Front Fender .......................... 62  7.7  ZONE 7 ............................ 62    7.7.1  X3 Smooth Side Panel Replacement Procedure ...
  • Page 633 SECTION 18b: X3 SERIES BODY 8.5  ZONE 5 ............................ 103    8.5.1  Pantograph Baggage Compartment Doors (Aluminum)  ............. 103  8.5.2  Hinged Baggage Compartment Doors (Aluminum)  ............. 106  8.5.3  Condenser Compartment Door  .................... 108  8.5.4  Evaporator Compartment Door (Aluminum)  ............... 109  8.5.5  Fuel Filler Door ........................ 111  8.6  ZONE 6 ............................ 111    8.6.1  Front Fender ........................ 112  8.7  ZONE 7 ............................ 112    8.7.1  Side Panel for Vehicles Not Fitted With Slide‐Out ............... 112  8.7.2  Side Panel for Vehicles Fitted With Slide‐Out .............. 113 ...
  • Page 634 SECTION 18b: X3 SERIES BODY    .........................  2 6 FIGURE   ENTRANCE DOOR OPERATING BUTTONS    ............................  2 6 FIGURE   COACH ENTRANCE DOOR    ........................  2 7 FIGURE   ENTRANCE DOOR CONTROL SWITCH    ..........................  2 7 FIGURE   INTERIOR UNLATCH AIR VALVE    ..........................  2 7 FIGURE   EXTERIOR UNLATCHES AIR VALVE    .................................  2 8 FIGURE   DAMPER  ...
  • Page 635 SECTION 18b: X3 SERIES BODY    ..........................  9 8 FIGURE   ENGINE COMPARTMENT DOOR    ..............................  9 9 FIGURE   REAR BUMPER   4 .................................  1 00 FIGURE   ZONE      ......................  1 00 FIGURE   ENGINE COMPARTMENT R  SIDE DOOR     .............................  1 01 FIGURE   RADIATOR DOOR  ...
  • Page 636 SECTION 18b: X3 SERIES BODY TORQUE TABLES BODY DESCRIPTION TORQUE Entrance door horizontal adjusting bolts 55-65 lb-ft (75-88 Nm) Passenger seat mounting nuts (to sidewall and pedestal) 27 lb-ft (37 Nm) PA1615 Maintenance Manual All Series | Section 18b revised September 2016...
  • Page 637 SECTION 18b: X3 SERIES BODY VEHICLE EXTERIOR FIGURE 1: X3 COACHES EXTERIOR VIEW 18606 Engine air intake Rear-view mirror Engine compartment R.H. side door Reclining bumper Hinged rear fender Front electrical and service compartment Baggage compartment Driver’s power window Fuel filler door Evaporator or baggage compartment Condenser or baggage compartment Radiator door...
  • Page 638 SECTION 18b: X3 SERIES BODY FIGURE 2: X3-45 VIP MOTORHOME EXTERIOR VIEW (TYPICAL) Engine air intake Rear-view mirror Engine compartment R.H. side door Reclining bumper Hinged rear fender Front electrical and service compartment Baggage compartment Driver’s power window Fuel filler door Evaporator or baggage compartment Condenser or baggage compartment Radiator door...
  • Page 639 SECTION 18b: X3 SERIES BODY FIGURE 3: X3-45 VIP COMERCIAL USE VEHICLE EXTERIOR VIEW (FRONT SLIDE-OUT) Engine air intake Rear-view mirror Engine compartment R.H. side door Front reclining bumper Hinged rear fender Front electrical and service compartment Baggage compartment Driver’s power window Fuel filler door Evaporator compartment Condenser compartment...
  • Page 640 Since welding is a procedure that may be for corrosion. Other areas include the front carried out either as specific instructions from wheelhousing area engine Prevost or by an independent decision of the compartment. owner, the following information pertaining to Road splash will...
  • Page 641 SECTION 18b: X3 SERIES BODY PREVENTIVE MAINTENANCE SCHEDULE NOTE TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section.
  • Page 642 SECTION 18b: X3 SERIES BODY RUST INHIBITOR APPLICATION Material: Tectyl 185 GW R1KG21 Safety Rules: Use safety glasses Supplied air hood Solvent-resistant rubber gloves 1.0 Wash both wheelhousing mechanical parts before A water-hose nozzle is recommended. Water may be hot masking.
  • Page 643 SECTION 18b: X3 SERIES BODY 3.2 Front wheelhousing 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) PA1615 Maintenance Manual All Series | Section 18b revised September 2016...
  • Page 644 SECTION 18b: X3 SERIES BODY 4.1 Rear wheelhousing (Entire braking system) 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used.
  • Page 645 SECTION 18b: X3 SERIES BODY thickness is 10 mils wet or 5 mils dry. 7.0 Remove all masking material 30 minutes after application. ANNEX 1 Check and confirm that dew point and surface temperature are in accordance with the following criteria: Surface temperature >...
  • Page 646 SECTION 18b: X3 SERIES BODY DEW POINT Relative Humidity (%) 20 30 40 50 60 70 80 90 100 Temp (c) -16 -11 -8 -5 -3 -1 0 -15 -10 -7 -5 -3 -1 1 -14 -10 -6 -4 -1 0 -13 -9 -5 -3 -1 1 -13 -8 -5 -2 0 -11 -7 -4 -1 1...
  • Page 647 SECTION 18b: X3 SERIES BODY COMMON FIBERGLASS REPAIR NOTE PROCEDURE All repairs to fiberglass parts consist of filling the Roughening the surface improves adhesion of resin. damaged area with fiberglass cloth and resin or strand fiberglass and resin. The repair is allowed If part is warped from original shape, use to harden, and then finishing operations may be clamping equipment to straighten the surface.
  • Page 648 SECTION 18b: X3 SERIES BODY undercoating from damaged area, and wipe purpose polyester resin can be applied at this clean with solvent. time (Figure 5). Preheat the area to be repaired using heat lamps. Mix desired quantities of resin and hardener according manufacturer's...
  • Page 649 Prevost recommends using the original paint brand to ease color matching. CAUTION In the event you sand through to the gelcoat...
  • Page 650 SECTION 18b: X3 SERIES BODY 7.3.1 Safety CAUTION Care should be exercised in storing, handling, mixing, and applying paint and chemicals listed Be sure to heed all paint manufacturer’s in this manual. The topcoat, primer, solvent, recommendations, especially concerning paint catalysts, accelerators, and cleaners are highly dilution and application.
  • Page 651 SECTION 18b: X3 SERIES BODY X3-45 COACHES EXTERIOR FINISHING AND BODY REPAIR The following procedures explain the steps to be followed for proper repair, installation and replacement for various doors, panels and windows. The paragraph divides the vehicle into zones to facilitate the search;...
  • Page 652 SECTION 18b: X3 SERIES BODY 8.1.1 Front Bumper The front bumper is hinged to give access to the spare wheel and tire compartment. Pull the handle located in the front service compartment to open the spare wheel and tire compartment. Bumper must first be tilted down before its removal.

  • Page 653: Rear View Mirrors (Ramco)

    SECTION 18b: X3 SERIES BODY At the base of the mirror arm, loosen the mounting bolt to swing arm in or out. To pivot the mirror head, loosen the setscrews on each side of the ball stub at the base of the mirror head to facilitate the adjustment.

  • Page 654: Windshield Wipers

    SECTION 18b: X3 SERIES BODY wiring diagram annexed technical strips. Remove the mirror glass by gently pulling publication box. the lens to release the Velcro. Disconnect the heater grid at the two connectors. Connect the connectors of the new mirror’s grid CAUTION to the harness.

  • Page 655: Entrance Door

    SECTION 18b: X3 SERIES BODY  NOTE At the top of windshield, clean surface between fiberglass and rubber extrusion Rubber seal may have to be replaced if it was using Sika 205. used on several windshield replacements.  Apply Sika 221 black (Figure 16) between ...
  • Page 656 SECTION 18b: X3 SERIES BODY The air-operated door is controlled from inside the coach by two push-button switches located on the R.H. dashboard. FIGURE 18: ENTRANCE DOOR OPERATING BUTTONS 06464 Opening and closing of the door from outside the coach is accomplished by a momentary FIGURE 17: ENTRANCE DOOR &...
  • Page 657 SECTION 18b: X3 SERIES BODY FIGURE 22: EXTERIOR UNLATCHES AIR VALVE 12209 Without Air and/or Without Electricity If the air pressure drops while the coach has or hasn’t any electricity, the spring loaded cylinders will unlatch the door. In such a case, unlock the door by moving the lever on the door or by using the key, then open the door manually.
  • Page 658 SECTION 18b: X3 SERIES BODY felt that the cams of the adjusting nut Where a bump rubber was installed, refit engage in the recesses of the foot valve same inside the dust cap and by fully closing assembly (Figure 23). the damper, the rubber will seat again at top of the dust cap.
  • Page 659 SECTION 18b: X3 SERIES BODY 2. Remove the old seal and with a sharp edge knife, scrape tape left on the fiberglass door surface. 3. Sand the surface of the door where a new seal will be applied with 240 grit sandpaper. FIGURE 24: UPPER DOOR HINGE 18058 Seal Compression Adjustment...
  • Page 660 SECTION 18b: X3 SERIES BODY 4. Clean the surface with alcohol or anti- silicone. WARNING Wear rubber gloves and do not smoke when cleaning. 5. Peel off protective paper from the seal. Position the seal flush with the top, sides and lower edges of the door.
  • Page 661 SECTION 18b: X3 SERIES BODY SYMPTOM PROBABLE CAUSE REMEDY FROM INTERIOR SWITCH. Check voltage at door closing solenoid. If Door closing solenoid does not receive the voltage is 24 volts then replace it. electric current. Else replace control relay. Release manual door locks...
  • Page 662 SECTION 18b: X3 SERIES BODY  Body Panel Using a scratch pad “Scotch Brite”, scratch the perimeter of the window frame where For the removal of entrance door body panel, the adhesive will be applied. you will need:  Clean door frame again using anti-silicone. Pneumatic hammer tool (Zip Gun);...
  • Page 663 SECTION 18b: X3 SERIES BODY  Clean body panel using anti-silicone.  Apply some Sika 206 G+P onto body panel. Note: Leave some space at the bottom (50mm) water dripping.  Apply 1/8 x1/4 double face self-adhesive tape onto door frame. ...

  • Page 664: Front Electrical & Service Compartment Door Body Panel And Window

    SECTION 18b: X3 SERIES BODY  Fill the gap between window and body panel Wear ear plugs during this operation. with Sika 255.  Separate body panel from door.  Smooth down the joint with a plastic scraper  Using a razor sharp window scraper, then remove masking tape.
  • Page 665 SECTION 18b: X3 SERIES BODY  Check proper power window sliding inside window frame.  Apply an even coat of Sika 255 onto the  If applicable, remove excess of Sika door frame. adhesive all around door frame using Sika 208.
  • Page 666 SECTION 18b: X3 SERIES BODY  Clean window using window cleaner.  Insert window into frame.  Secure window pane raising mechanism.  From inside the door, apply some Sika 252 at the corners of window wiper.  Apply some #680066 glue inside finishing panel groove and fix power window wiper.
  • Page 667 SECTION 18b: X3 SERIES BODY  Peel the back from double face self- adhesive tape.  Apply Sika 252 inside right angle.  Apply anti-silicone inside right angle.  If applicable, remove plastic film at the bottom of driver’s window. ...
  • Page 668 SECTION 18b: X3 SERIES BODY Apply masking tape before applying Sika glue to protect paint and adjacent window during surface treatment. For gluing of upper lateral window, refer to procedure SAV00632.  Glued Molding Installation  Clean window gluing area using window cleaner.
  • Page 669 SECTION 18b: X3 SERIES BODY  Apply a double-face self adhesive tape 1/8 by ¼ inch inside the molding onto the whole length. SECTION VIEW A-A  Apply a double-face self adhesive tape 1/32 by ¼ inch onto the whole length of the gutter.

  • Page 670: Front Cap

    The fiberglass front cap does not need any maintenance except painting as needed. It is held in place with adhesive. If ever it has to be replaced, make an appointment at a Prevost service center near you. For minor damages, refer to section 4 "Fiberglass Repair" and section 5 "Painting".

  • Page 671: Zone

    SECTION 18b: X3 SERIES BODY ZONE 2 FIGURE 26: ZONE 2 18625 8.2.1 Lateral Fixed Window Drill equipped with a sharp pointed rod into Nine passenger side windows are provided on which a small hole was drilled; each side on X3-45. They are made of fixed, Braided windshield wire and a pair of handles;...

  • Page 672: Emergency Exit Windows

    SECTION 18b: X3 SERIES BODY Method B Installation of Window  Using a drill equipped with the special  Use window cleaner around window sharp pointed rod, drill through the window interior perimeter and edges to remove seal into one of the bottom corners, from a any oily film while inspecting for damages.

  • Page 673: Roof Escape Hatch

    SECTION 18b: X3 SERIES BODY  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 674 CAUTION Seal joint should be toward rear of vehicle. Ensure that cleaning solutions are compatible 3. Apply rubber adhesive CA-40 (Prevost # with the materials used on the escape hatch. 681285) in the gap between the seal ends. Graffiti removing cleaners often contain acetone, 4.
  • Page 675 SECTION 18b: X3 SERIES BODY  panel assembly by fastening the 2 hinges with Escape Hatch Frame the 4 bolts and flat washers removed earlier. When necessary, the escape hatch frame can be removed and replaced in the following way: 1.

  • Page 676: Zone

    It is held in place with adhesive. If ever it has to be To adjust the latch mechanism and the striker replaced, make an appointment at a Prevost pin: service center near you. For minor damages, refer to Paragraph 4 "Common Fiberglass...

  • Page 677: Rear Bumper

    SECTION 18b: X3 SERIES BODY 8.3.3 Rear Bumper Remove three bolts on each side holding bumper to vehicle and remove bumper. To install bumper, reverse the procedure. FIGURE 33: REAR BUMPER 18634 8.3.4 Exhaust Aftertreatment System Access Door 1. Open exhaust aftertreatment system access door.

  • Page 678: Rear Fender

    SECTION 18b: X3 SERIES BODY ZONE 4 FIGURE 34: ZONE 4 18627 8.4.1 Rear Fender On the "X3" series vehicle, rear fenders are hinged maintenance brakes suspension. Each rear fender panel has two mechanical spring loaded holding devices fixing it to the vehicle’s structure. Push the spring type rod sideways to disengage the lock.

  • Page 679: Engine Radiator Door

    SECTION 18b: X3 SERIES BODY 5. Check that the door swings freely and 5. Check that the door swings freely and closes properly. It may be necessary to closes properly. It may be necessary to adjust the door latch to get proper fit and adjust the door latch to get proper fit and operation.
  • Page 680 SECTION 18b: X3 SERIES BODY FIGURE 38: STRIKER PIN ENGAGEMENT 18695 NOTE There should be no gap between the washer and the hinge upper and lower halves. PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 681: Baggage Compartment Doors (Aluminum)

    SECTION 18b: X3 SERIES BODY ZONE 5 FIGURE 39: ZONE 5 18628 8.5.1 Baggage Compartment Doors (Aluminum) Razor sharp window scraper or putty knife; For the removal and installation of a baggage compartment door body panel, you will need:  Open damaged compartment door and unfasten rub rail fixing bolts.
  • Page 682 SECTION 18b: X3 SERIES BODY  Unfasten bolts and disconnect cable if necessary in order to remove door from vehicle.  Preferably install the door onto a work surface where it can be solidly fixed.  Door Panel replacement  Refer to SAV10054-67. ...
  • Page 683 SECTION 18b: X3 SERIES BODY 10. Door bottom edge compression can be adjusted moving pantograph arms at this location. 6. Open baggage compartment door and adjust using the cylinder mounting block. 7. Door should be adjusted in reference to neighboring doors. 8.

  • Page 684: Wheelchair Lift Cassette Compartment Door

    SECTION 18b: X3 SERIES BODY 8.5.2 Wheelchair Lift Cassette Compartment Door For the removal and installation of a wheelchair lift (WCL) cassette compartment door body panel, you will need: A drill with drill bits; Pneumatic hammer tool (Zip Gun); Razor sharp window scraper or putty knife; ...

  • Page 685: Baggage Compartment Floor

    SECTION 18b: X3 SERIES BODY Using a plastic spatula, apply some Sika 221 grey onto the damaged area. Close the door to center the latch mechanism. Tighten screws Check that the door swings freely and closes properly without interference or excessive force Remove masking tape and protection around damaged area.
  • Page 686 SECTION 18b: X3 SERIES BODY Rear baggage compartment equipped with WCL Glue spacers (790392) about 16-inch apart. Prepare baggage compartment Mantex floor. Clean panel underside and edges. Rear baggage compartment without WCL. Using a triangular nozzle, apply “Simson” glue (685126) onto support structure. PA1615 Maintenance Manual All Series | revised September 2016...
  • Page 687 SECTION 18b: X3 SERIES BODY Rear baggage compartment without WCL. In the case of front finishing joint, apply some masking tape on each side of joint. Rear baggage compartment equipped with WCL Clean with anti-silicone the area where the Simson glue will be applied. Apply some Simson glue to fill the gap.
  • Page 688 SECTION 18b: X3 SERIES BODY Section 2 Flat joint in front of fuel tank access panel Remove masking tape. Use plastic spatula #682838 to perform radius Smooth down joints using soapy water. Rear baggage compartment equipped with WCL Rear baggage compartment without WCL. PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 689: Evaporator Compartment Door

    SECTION 18b: X3 SERIES BODY 8.5.4 Evaporator Compartment Door FIGURE 40: EVAPORATOR DOOR (ALUMINUM) 5. Respect the required gap between For the adjustment of an evaporator door, you exterior finishing panels. will need: 6. Tighten the hinge screws.  Centering tool G34148_500 ...
  • Page 690 SECTION 18b: X3 SERIES BODY 10. Tighten the Receptacle screws only. 11. .Door exterior panel on latch side should be positioned at 8mm +1mm from frame. Make the adjustments by moving the receptacle support. 14. Check that the door swings freely and closes properly.

  • Page 691: Condenser Compartment Door

    SECTION 18b: X3 SERIES BODY 8.5.5 Condenser Compartment Door FIGURE 41: CONDENSER DOOR 1. Open the condenser door. 3. Adjust the fuel filler door position according distance required between exterior 2. Loosen the screws fixing the hinge to hinge finishing panels. attachment or hinge to door assembly.

  • Page 692: Zone

    SECTION 18b: X3 SERIES BODY ZONE 6 FIGURE 43: ZONE 6 18629 8.6.1 Front Fender Front fender may be removed using the following procedure: Remove the nuts on the inside of the fender. Remove the fender from the vehicle. To reinstall, reverse the procedure.

  • Page 693: X3 Smooth Side Panel Replacement Procedure

    SECTION 18b: X3 SERIES BODY 8.7.1 X3 Smooth Side Panel Replacement Procedure Material:    Anti-silicone (682989) Scotchbrite gray (680226) Sika 221 gray    CHIX cloth (682384) Sika 205 1liter (683097) Sika 252 black  Blue cloth (682383) Equipment: ...
  • Page 694 SECTION 18b: X3 SERIES BODY SECTION 2 PREPARATION OF SURFACES 2.00 VEHICLE SURFACE PREPARATION Clean using "anti-silicone" until all clothes come clean. See SAV00001 section A. Use the belt sander (grit coarse) Use a new paper on each vehicle side. Clean using "anti-silicone"...
  • Page 695 SECTION 18b: X3 SERIES BODY Section B Sika 205 Apply CHIX cloth Allow drying Mandatory For a smooth surface (aluminum, stainless, 2 minutes Minimum steel, fiber glass (gelcoat side), etc.) time - Pour a porous surface (fiber glass (non 10 minutes gelcoat side), etc.) After 2 hours : Reactivate surface with Sika 205 If surface seems dusty, greasy or with finger marks, start...
  • Page 696 SECTION 18b: X3 SERIES BODY 3.05 Install 1/8 X ½” foam tape onto middle reinforcement then compress. Apply Sika 252 3.10 Section A-A Section B-B Section C-C – Onto vehicle surface Cut nozzle as per template – – Use the guide for the application Bead must be continuous for the whole perimeter.
  • Page 697 SECTION 18b: X3 SERIES BODY 3.20 Install pulling equipment at the other end of side panel Make a final adjustment in height Sand front of side panel 2" wide Make sure the equipment pulls along the Pull side panel so that panel moves 1/8” whole width of side panel Perform tig spot welding Quantity of "tig spot": 30 minimum.
  • Page 698 SECTION 18b: X3 SERIES BODY Wear surgical gloves and smooth down the joint with your finger. SECTION 4 ENGINE AIR INTAKE PANEL INSTALLATION 4.00 Make sure that sealing of structure has been performed properly Prepare vehicle surface as for side panel. Refer to step # 2.00 4.05 Refer to step # 2.05...

  • Page 699: Side Crest

    SECTION 18b: X3 SERIES BODY 5.00 * Finition Joint Install a protective tape onto the tubing above welding Apply Sika 205 Use a plastic spatula inside a Chix cloth to ensure that Sika 205 reaches as far as the corner. See SAV00001 section C.

  • Page 700: Body Panel And Window Spacing

    SECTION 18b: X3 SERIES BODY BODY PANEL AND WINDOW SPACING FIGURE 46: BODY PANEL AND WINDOW SPACING 18631 PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 701: Passenger Seats

    SECTION 18b: X3 SERIES BODY 8.9.2 Removing Fixed Seats PASSENGER SEATS NOTE X3 coaches can be equipped with any of 3 basic seat models and installed in a variety of seating Seats on one row are not interchangeable with arrangements: seats of the other row.

  • Page 702: Upholstery Maintenance

    SECTION 18b: X3 SERIES BODY while they are in place, dry cleaning is not recommended, since the resulting fumes could be hazardous in the confines of the coach and the solvent could be detrimental to the foam padding of the seats. ...

  • Page 703: Tarabus Floor Covering Repair Or Replacement

    SECTION 18b: X3 SERIES BODY 8.10 TARABUS FLOOR COVERING REPAIR OR REPLACEMENT On X3-45 coaches equipped with “Tarabus” covering, it is possible to replace or repair this covering. 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 704 SECTION 18b: X3 SERIES BODY FIGURE 49: TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 50: APPLICATION OF SIKA 221 GRAY 18641 PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 705: Front Steps Replacement Procedure

    SECTION 18b: X3 SERIES BODY 8.10.1 Front Steps Replacement Procedure MATERIAL Part No Description 682989 Anti-silicone 683097 Sika 205 (1 liter) 685101 Sika Remover 208 683916 Sika 215 (1 liter) 1. Cut and remove damaged step(s). 2. Remove dirt and adhesive residue. NOTE In wintertime, condensation and cold temperature may greatly influence bonding parameters.
  • Page 706 SECTION 18b: X3 SERIES BODY 3. Apply Sika Primer 215 (refer to Section D). Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer 3. Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) If surface seems dusty, dust using damp cloth.
  • Page 707 SECTION 18b: X3 SERIES BODY 3. Apply some Sika 252 onto the step; make sure to cover the whole surface of the step. Use a serrated spreader with 1/8-inch serration to spread Sika. 4. Apply a bead of Sika 221 onto the perimeter of the step. 5.

  • Page 708: Welding Of Joint Between White Safety Strip And "Tarabus" Floor Covering

    SECTION 18b: X3 SERIES BODY 11. Apply some masking tape onto the step perimeter, clean using Sika 205 (refer to Section B) then apply a bead of Sika 252 black. Smooth out the joints then remove masking tape. 12. Install weights onto the steps. Minimum waiting time: 2 hours. 8.10.2 Welding Of Joint Between White Safety Strip And “Tarabus”...
  • Page 709 SECTION 18b: X3 SERIES BODY NOTE The chamfer width must always be less than the filler bead diameter (between 2.5 and 3 mm). 4. Use chamfer knife. Be careful not to overcut or to cut to the side to prevent damaging “Tarabus”...
  • Page 710 SECTION 18b: X3 SERIES BODY 8. The heel of the fast nozzle must not lean against “Tarabus” covering (always parallel to the surface). 9. Allow cooling down of filler bead (about 5 minutes). 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.

  • Page 711: Repair Of A Welded Joint

    SECTION 18b: X3 SERIES BODY 12. Perform adhesion test using the tip of a flat screwdriver; apply a slight pressure on the joint. 13. If welding was not performed properly, there will a loss of adhesion on one side. If this is the case, repair the joint.

  • Page 712: X3-45 Vip Exterior Finishing And Body Repair

    SECTION 18b: X3 SERIES BODY 4. Always add an extra inch of filler bead at the beginning and at the end of repair. 5. Perform steps indicated in paragraphs 9, 10 and 11. X3-45 VIP EXTERIOR FINISHING AND BODY REPAIR The following procedures explain the steps to be followed for proper repair, installation and replacement for various doors, panels and windows pertaining to X3-45 VIP.
  • Page 713 SECTION 18b: X3 SERIES BODY FIGURE 52: X3-45 VIP FITTED WITH SLIDE-OUT ZONE 1 FIGURE 53: ZONE 1 PA1615 Maintenance Manual All Series | Section 18b revised September 2016...

  • Page 714: Front Bumper

    SECTION 18b: X3 SERIES BODY 9.1.1 Front Bumper The front bumper can be tilted downward to give access to the bumper compartment. Pull the release handle located inside front service compartment to unlock. Tilt down the entire bumper assembly to access the compartment. Push the bumper back up firmly in place to lock in position.

  • Page 715: Rear View Mirrors

    SECTION 18b: X3 SERIES BODY  Adjustment Compress the crest three pieces using your hands. At the base of the mirror arm, loosen the mounting bolt to swing arm in or out. To pivot the mirror head, loosen the setscrews on each side of the ball stub at the base of the mirror head to facilitate the adjustment.

  • Page 716: Windshield Wipers

    SECTION 18b: X3 SERIES BODY (between 60-80°F) by a thermostat. Refer to The mirror glass assembly is mounted to the wiring diagram annexed technical control mechanism or to mirror base with Velcro publication box. strips. Remove the mirror glass by gently pulling the lens to release the Velcro.

  • Page 717: Front Face Body Panel

    SECTION 18b: X3 SERIES BODY If applicable, using a screwdriver or metal the rubber seal lip aside to insert the rod, remove black butyl sealant residue windshield into the groove. Use also from rubber seal then clean with Sika 205. soapy water on the inside of vehicle to insert the windshield into the rubber seal groove.

  • Page 718: Entrance Door

    SECTION 18b: X3 SERIES BODY Olfa knife, For gluing of front face molding, refer to “C”-clamp, procedure SAV00212 . Razor sharp window scraper.  Front face Body Panel Installation For gluing of front face body panels, refer to procedure SAV470047 . 9.1.8 Entrance Door For the removal of entrance door body panel,...

  • Page 719: Upper Lateral Window

    If ever it has to be SAV280022. replaced, make an appointment at a Prevost service center near you. For minor damages, 9.1.10 Upper Lateral Window refer to paragraph 4 "Common Fiberglass For the removal of driver’s window or upper Repair procedure"...

  • Page 720: Upper Side Panel

    SECTION 18b: X3 SERIES BODY ZONE 2 FIGURE 60: ZONE 2 9.2.1 Upper Side Panel Remove the rod; thread the wire into the For structure preparation, refer to procedure small hole. Reinsert the rod and the wire SAV00035. into the hole far enough so that the person inside the vehicle can pull the rod using a For installation of upper side panel neoprene pair of pliers.

  • Page 721: Electric Awning Windows

    SECTION 18b: X3 SERIES BODY Carefully push window out and lift it up disengage the swiveling arm from the motor sufficiently separate from shaft extension. aluminum molding. 5. Push the glass window out ninety degrees Attach the windshield wire to a fish wire (90°).
  • Page 722 SECTION 18b: X3 SERIES BODY Fixing fra me Screen Ga s spring Fra me Relea sing bar keeper T rack Proximity sensor ma gnet Vertica l la tch ha ndle D-sea l Window ajar sensor Spring T ra ck release la tch FIGURE 61: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 Actua tors...
  • Page 723 SECTION 18b: X3 SERIES BODY Motor Replacement Actuator Replacement 1. Push the vertical latch handle downwards to 1. Push the vertical latch handle downwards to release the track and then unlatch the release the track and then unlatch the window using the horizontal latch handle window using the horizontal latch handle.

  • Page 724: Electric Sliding Windows

    SECTION 18b: X3 SERIES BODY Were the shipping blocks in place during installation? C: Failure to remove the shipping blocks after installation can create interference between sash and frame. Have the shipping blocks been removed after installation? D: The window is misaligned or not installed squarely. Is there interference with any coach parts? Is there proper clearance between the bottom of the outer glass and the belt-line trim / seal?
  • Page 725 SECTION 18b: X3 SERIES BODY Sash Removal 1. Remove the Screen Assembly 2. Pull down on both release latches simultaneously and rotate the sash inwards approximately 10 degrees.(Figure 64) FIGURE 64: REMOVING THE SASH 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 65) FIGURE 65: DISENGAGING THE BOTTOM OF THE SASH PA1615 Maintenance Manual All Series | Section 18b revised September 2016...
  • Page 726 SECTION 18b: X3 SERIES BODY Installation 1. Align the leading edge of the slot on the lower cam follower block with the sash stop. Use the power toggle switch to obtain the correct alignment. (Figure 66) Lower Cam Sash Stop Follower FIGURE 66: PROPER ALIGNMENT 2.

  • Page 727: Engine Compartment Doors

    It is held in place with adhesive. If ever it has to be 9.3.2 Engine Compartment Doors replaced, make an appointment at a Prevost  Engine Compartment Doors Adjustment service center near you. The engine compartment door may be adjusted...
  • Page 728 SECTION 18b: X3 SERIES BODY NOTE  Engine Compartment Door Body Panel Removal Consult the “BODY PANEL AND WINDOW SPACING DIAGRAM” for proper door gaps For the removal of engine compartment door adjustment. (Figure 46 Page 65 of this body panel, you will need: section) Pneumatic hammer tool (Zip Gun);...

  • Page 729: Rear Bumper

    SECTION 18b: X3 SERIES BODY 9.3.3 Rear Bumper Remove three bolts on each side holding bumper to vehicle and remove bumper. To install bumper, reverse the procedure. FIGURE 71: REAR BUMPER PA1615 Maintenance Manual All Series | Section 18b revised September 2016...

  • Page 730: Rear Fender

    SECTION 18b: X3 SERIES BODY ZONE 4 FIGURE 72: ZONE 4 9.4.1 Rear Fender On X3-45 VIP vehicles, rear fenders are hinged for maintenance on brakes and suspension. Each rear fender panel has two mechanical spring loaded holding devices fixing it to the vehicle’s structure.

  • Page 731: Pa1615 Maintenance Manual All Series | Section 18B Revised September

    SECTION 18b: X3 SERIES BODY 8. Using a hammer, adjust the striker pin to adjust the door latch to get proper fit and center it in the door latch mechanism. operation. 9. Tighten the striker pin. To adjust the latch mechanism (3, Figure 75) 10.
  • Page 732 SECTION 18b: X3 SERIES BODY FIGURE 76: STRIKER PIN ENGAGEMENT 18695 NOTE There should be no gap between the washer and the hinge upper and lower halves. PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 733: Pantograph Baggage Compartment Doors (Aluminum)

    SECTION 18b: X3 SERIES BODY ZONE 5 FIGURE 77: ZONE 5 9.5.1 Pantograph Baggage Compartment Doors (Aluminum)  Razor sharp window scraper or putty For the removal and installation of a baggage knife; compartment door body panel, you will need: ...
  • Page 734 SECTION 18b: X3 SERIES BODY  Open damaged compartment door and 14. Adjust door position and evenness with unfasten rub rail fixing bolts. Remove rub reference to adjacent panels and doors. rail. NOTE  Unfasten bolts and disconnect cable if Vertical adjustment is achieved by moving necessary in order to remove door from the door along the mounting plates slots.
  • Page 735 SECTION 18b: X3 SERIES BODY 18. Target is to have 5 ½” (140mm) from bus body panel to door panel and +/- 2mm vertically between doors. NOTE Adjustment is made by moving UP or DOWN the lock plates. 19. Tighten cylinder block fixing screws. 20.
  • Page 736 SECTION 18b: X3 SERIES BODY 9.5.2 Hinged Baggage Compartment Doors (Aluminum)  Door Adjustment 1. Open the door. 2. Loosen the screws fixing the hinge to door assembly. Loosening the screws allows the door assembly to be shifted "LEFT or RIGHT"...
  • Page 737 SECTION 18b: X3 SERIES BODY 5. To adjust door depth, loosen the screws fixing the hinge to frame assembly and slide the hinge horizontally to move the door in or out. Depth should be calculated at 29mm +/- 2mm measured from bus frame out or 5mm +1mm if measurement is taken from small square tube on frame.

  • Page 738: Condenser Compartment Door

    SECTION 18b: X3 SERIES BODY 9.5.3 Condenser Compartment Door FIGURE 78: CONDENSER DOOR  Door Adjustment 1. Open the condenser door. 2. Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly. Loosening the screws allows the condenser door assembly to be shifted "LEFT or RIGHT"...

  • Page 739: Evaporator Compartment Door (Aluminum)

    SECTION 18b: X3 SERIES BODY 9.5.4 Evaporator Compartment Door (Aluminum) FIGURE 79: EVAPORATOR DOOR (ALUMINUM) 5. Respect the required gap between exterior For the adjustment of an evaporator door, you finishing panels. will need: 6. Tighten the hinge screws.  Centering tool G34148_500 7.
  • Page 740 SECTION 18b: X3 SERIES BODY 9. Close door to center the latch assembly. 10. Tighten the receptacle screws only. 11. .Door exterior panel on latch side should be positioned at 8mm +1mm from frame. Make the adjustments by moving the receptacle support.

  • Page 741: Fuel Filler Door

    SECTION 18b: X3 SERIES BODY 9.5.5 Fuel Filler Door Open the fuel filler door. Loosen the screws holding the panel to hinge assembly. Adjust the fuel filler door position according distance required between exterior finishing panels. Tighten the nuts. Check that the door swings freely and closes properly.

  • Page 742: Front Fender

    SECTION 18b: X3 SERIES BODY 9.6.1 Front Fender Front fender may be removed using the following procedure: Remove the nuts on the inside of the fender. Remove the fender from the vehicle. To reinstall, reverse the procedure. For the installation of front fender body panel, refer to procedure SAV470024. ZONE 7 FIGURE 82: ZONE 7 9.7.1...

  • Page 743: Side Panel For Vehicles Fitted With Slide-Out

    SECTION 18b: X3 SERIES BODY Remove as much glue as possible from the Never heat SikaFlex adhesive to remove. structure using a putty knife or pneumatic knife without damaging 206 G+P primer. Check panel horizontal supports for straightness Tolerance: 1mm towards the outside and 1.5mm using a straight edge.

  • Page 744: Slide-Out Exterior Finishing Panels & Windows

    SECTION 18b: X3 SERIES BODY ZONE 8 FIGURE 83: ZONE 8 9.8.1 Slide-Out Exterior Finishing Panels & Windows Refer to Maintenance Manual, Section 26: Paragraph 16 for the procedure on slide-out exterior finishing panels & windows. PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 745: Slide-Out Exterior Finishing Panels & Windows

    SECTION 18b: X3 SERIES BODY ZONE 9 FIGURE 84: ZONE 9 9.9.1 Slide-Out Exterior Finishing Panels & Windows Refer to Maintenance Manual, Section 26: Paragraph 16 for the procedure on slide-out exterior finishing panels & windows. PA1615 Maintenance Manual All Series | Section 18b revised September 2016...

  • Page 746: Body Panel And Window Spacing For X3-45 Vip Not Fitted With Slide-Out

    SECTION 18b: X3 SERIES BODY 9.10 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP NOT FITTED WITH SLIDE-OUT FIGURE 85: BODY PANEL & WINDOW SPACING FOR X3-45 VIP NOT FITTED WITH SLIDE-OUT PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 747: Body Panel And Window Spacing For X3-45 Vip With Front And Rear Slide-Out

    SECTION 18b: X3 SERIES BODY 9.11 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP WITH FRONT AND REAR SLIDE- FIGURE 86: BODY PANEL & WINDOW SPACING FOR X3-45 VIP WITH SLIDE-OUT, FRONT AND REAR PA1615 Maintenance Manual All Series | Section 18b revised September 2016...

  • Page 748: Body Panel And Window Spacing For X3-45 Vip Fitted With Front Slide-Out

    SECTION 18b: X3 SERIES BODY 9.12 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP FITTED WITH FRONT SLIDE-OUT FIGURE 87: BODY PANEL & WINDOW SPACING FOR X3-45 VIP WITH SLIDE-OUT, FRONT PA1615 Maintenance Manual All Series | revised September 2016...

  • Page 749: Vehicle Jacking Points

    SECTION 18b: X3 SERIES BODY 10. VEHICLE JACKING POINTS The vehicle can be lifted by applying pressure under body jacking points or front and drive axle jacking points. When it is necessary to lift the vehicle, care should be taken to ensure that the pressure is applied only on the specified areas.

  • Page 750: Hydraulic Jack

    SECTION 18b: X3 SERIES BODY CAUTION DANGER Always unload or retract the tag axle before Do not overload jack above rated capacity. jacking the vehicle from the front and drive Prevent "side loading", make sure load is axle jacking points to prevent damage to centered on ram.

  • Page 751: Lifting And Towing

    SECTION 18b: X3 SERIES BODY 2. Operate the engine when towing to maintain brake system air pressure. If the engine CAUTION cannot be operated, connect an external air pressure line from the tow truck to the To prevent damage to the drive train emergency fill valve...

  • Page 752: Volvo I-Shift Alternate Towing Mode

    SECTION 18b: X3 SERIES BODY CAUTION Transmission lubrication is inadequate when towing. The drive axle shafts must be removed to avoid serious damage to the transmission. CAUTION Failure disconnect driveshaft, remove the drive axle shafts or lift the drive wheels off the ground before towing can FIGURE 95: TOW EYES cause serious transmission damage and 11.3 Volvo I-Shift Alternate Towing Mode...
  • Page 753 SECTION 18b: X3 SERIES BODY D. Shift pad must be in neutral E. Vehicle must be towed FORWARD only PA1615 Maintenance Manual All Series | Section 18b revised September 2016...

  • Page 754: Specificationsdoor Cylinder

    SECTION 18b: X3 SERIES BODY 12. SPECIFICATIONSDoor 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 ....................
  • Page 755 All Prevost models DESCRIPTION This procedure was made in order to support Prevost customers who are worried about their vehicle structure behavior due to corrosion. Five year old vehicles and older should be subjected to a thorough structural inspection; especially if clear signs of moderate or deep corrosion are visible.
  • Page 756 ) on Prevost structures are made of FIGURE 1 high strength steel. Although the structure on a Prevost vehicle receives a beneficial corrosion preventive compound application at the end of the manufacturing process, after many years of service with exposure to harsh environments (winter, frequent rains, road salt, stone projection, sand accumulation, etc.), the...
  • Page 757 MI15-18 / Page 3 / 6 WHEN SHOULD A STRUCTURE INSPECTION BE CARRIED OUT? Vehicles operating in harsh environments without an appropriate corrosion protection compound applied to the front and rear sub-frames, drive axle cradle and tag axle could be subject to corrosion. If parts of the tag axle or front and rear sub-frames structures present metal flaking, separation of metal layers, loss of material, perforation, etc.
  • Page 758 MI15-18 / Page 4 / 6 STRUCTURE INSPECTION PROCEDURE The thickness of main carbon steel parts on rear & front sub-frames, drive axle cradle and tag axle beam must be at least 1/8 inch (0.125") (3mm). There are two options to properly monitor the wall thicknesses: 1- Using an ultrasonic wall thickness gauge.
  • Page 759 MI15-18 / Page 5 / 6 CORROSION PROTECTION ON OLD AND CORRODED FRAME To maximize corrosion resistance on older frame exposed to harsh environment: 1) Clean rust on frame. If available, use sand blasting. 2) Apply a zinc-rich primer on cleaned surfaces. 3) Cover carbon steel parts with corrosion preventive compound Tectyl 185GW.
  • Page 760 MI15-18 / Page 6 / 6 PARTS / WASTE DISPOSAL Discard according to applicable environmental regulations (Municipal/State[Prov.]/ Federal) Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone. E-mail us at technicalpublications_prev@volvo.com and type “ADD” in the subject to receive our warranty bulletins by e-mail.
  • Page 761 (figures 2 & 3). CLEANING PRODUCT COMPATIBLE WITH POLYCARBONATE Cleaning products designed for external washing of vehicles shall be used to clean your vehicle. Prevost suggests a high PH cleaner compatible with polycarbonate. See the description of the product in the...
  • Page 762 MI15-41 / Page 2 / 3 High PH cleaning product compatible with polycarbonate - product sheet FIGURE 1: PRODUCT SHEET QF7720956 rev3>...
  • Page 763 MI15-41 / Page 3 / 3 IMAGES SHOWING THE CRACKING ISSUE FIGURE 2: Cracks at the boss and ribs due to the use of engine degreaser FIGURE 3: Cracking of the outer surface of the taillight due to the use of engine degreaser Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone.
  • Page 765 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS TORQUE TABLES ..........................5 HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) ............... 5 IDLERS & TENSIONERS ........................6 HVAC SYSTEM OVERVIEW ........................ 7 – ......................8 CENTRAL HVAC SYSTEM SERIES – ....................... 11 CENTRAL HVAC SYSTEM SERIES ..........................
  • Page 766 SECTION 22: HEATING AND AIR CONDITIONING 4.3.2 Maintenance ......................... 34 4.3.3 Driver’s Unit .......................... 34 ......................35 ATER NEUMATIC ALVE 4.4.1 Disassembly .......................... 35 4.4.2 Reassembly ........................... 35 4.4.3 Valve Troubleshooting ......................35 ......................36 ATER IRCULATING 4.5.1 Removal ..........................37 4.5.2 Installation ..........................
  • Page 767 SECTION 22: HEATING AND AIR CONDITIONING ............................ 64 IL ADDITION ...................... 64 OMPRESSOR ONTAMINATION ........................64 IL RETURN OPERATION PREHEATING SYSTEM (OPTION) ..................... 64 PREHEATER FUEL FILTER ....................... 65 ............................65 OPERATION ........................ 66 REHEATING YSTEM IMER 8.3.1 Preheater timer instructions ....................66 ................
  • Page 768 SECTION 22: HEATING AND AIR CONDITIONING 37: EVAPORATOR MOTOR ASSEMBLY....................26 IGURE ............. 26 IGURE CONDENSER FAN SPEED IN RELATION WITH HIGH SIDE PRESSURE 39: CONDENSER FAN ......................27 IGURE 40: RECEIVER TANK..........................27 IGURE ..................... 27 IGURE SERIES CONDENSER COMPARTMENT FIGURE 42: ISOLATED SECTION ........................
  • Page 769 SECTION 22: HEATING AND AIR CONDITIONING TORQUE TABLES HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) 22378_1 22379 HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) DESCRIPTION TORQUE Compressor flange connection screws 31-35 lb-ft (42-47 Nm) Compressor discharge & suction port screws 38-42 lb-ft (52-57 Nm) Compressor mounting bolts 74 lb-ft (100 Nm) Support arm to compressor screws...
  • Page 770 SECTION 22: HEATING AND AIR CONDITIONING IDLERS & TENSIONERS 22381 22382_1 IDLERS & TENSIONERS DESCRIPTION TORQUE Central A/C tensioner lock bolt 43 lb-ft (58 Nm) Central A/C tensioner idler shaft bolt (M12 shoulder bolt) 31.5-38.5 lb-ft (43-52 Nm) Central A/C tensioner idler shaft bolt (M12 x 1.75 std bolt) 59 lb-ft (80 Nm) Idler support bolt 22 lb-ft (30 Nm)
  • Page 771 SECTION 22: HEATING AND AIR CONDITIONING HVAC SYSTEM OVERVIEW The vehicle interior is pressurized by its Heating Ventilation and Air Conditioning (HVAC) system. Two HVAC systems are available: Small HVAC System and Central HVAC System.  Driver’s unit only Small HVAC System ...
  • Page 772 SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM – H3 SERIES FIGURE 1: H3 COACHES CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION 22264 PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 773 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 2: H3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT 22262 PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 774 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 3: H3 SERIES CENTRAL SYSTEM – REFRIGERANT CIRCUIT WITH PARCEL RACK EVAPORATOR 22220 PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 775 SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM – X3 SERIES FIGURE 4: X3 COACHES CENTRAL HVAC SYSTEM - PASSENGER’S UNIT AIR CIRCULATION 22308 FIGURE 5: X3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 776 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 6: X3 SERIES CENTRAL HVAC SYSTEM – REFRIGERANT CIRCUIT WITH OPTIONAL PARCEL RACK A/C SYSTEM PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 777 SECTION 22: HEATING AND AIR CONDITIONING SMALL HVAC SYSTEM FIGURE 7: SMALL HVAC SYSTEM – HEATING AND AIR CONDITIONING 22345 PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 778 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 8: SMALL HVAC SYSTEM - DRIVER'S AND AUXILIARY UNIT (H3 VIP ONLY) 22290 FIGURE 9: SMALL HVAC SYSTEM – AIR CONDITIONING 22377 PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 779 SECTION 22: HEATING AND AIR CONDITIONING SMALL HVAC SYSTEM – X3 SERIES FIGURE 10: X3 SERIES SMALL HVAC SYSTEM - REFRIGERANT CIRCUIT 22350 PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 780 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 11: X3 SERIES SMALL HVAC SYSTEM - HEATING CIRCUIT TYPICAL EVAPORATOR COMPARTMENT ARRANGEMENT FIGURE 12: EVAPORATOR COMPARTMENT ARRANGEMENT PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 781 SECTION 22: HEATING AND AIR CONDITIONING Passenger’s Unit 3.1.2 HVAC SYSTEM BASIC MAINTENANCE Basic maintenance required on the passenger’s and driver’s units consists in cleaning their MAINTENANCE respective coils and cleaning or replacing air filters. With the air filters previously removed, clean the passenger’s unit evaporator and heater However, periodic inspection for broken drains, coils with low air pressure or a stream low-...
  • Page 782 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 15: CLEANING PASSENGER’S UNIT CONDENSER COIL WITH LOW-PRESSURE AIR JET 22362 DRIVER’S UNIT AIR FILTER The driver’s unit is located behind the R.H. console panel. To gain access to the air filter, unscrew the R.H. console’s grill located in the entrance stepwell.
  • Page 783 SECTION 22: HEATING AND AIR CONDITIONING MAINTENANCE Passenger’s unit air filter Clean or replace filter at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION & SERVICING. To clean filter, back flush with water or soapy water, then dry with air FIGURE 18: PASSENGER’S UNIT EVAPORATOR COIL 22332...
  • Page 784 SECTION 22: HEATING AND AIR CONDITIONING Twin BX71 belt proper tension New: 90-100 lbs FIGURE 22: PARCEL RACK FAN AIR FILTER 22201 Used: 75-85 lbs FIGURE 23: STANDARD BELT LAYOUT WITH CENTRAL COMPRESSOR BELTS HVAC SYSTEM Belt Replacement – Central System 3.6.1 DANGER Set the main battery disconnect switch to the...
  • Page 785 SECTION 22: HEATING AND AIR CONDITIONING Belt Tension Adjustment – Central 3.6.2 System On the mechanical tensioner (Figure 25), slightly slack lock bolt (A). Adjust tension by turning adjustment screw (B). Tighten the lock bolt (A) to preserve adjustment. TORQUE: 43 lb-ft (58 Nm) Should the idler bearing need to be serviced, tighten shoulder bolt (C) at reassembly.
  • Page 786 SECTION 22: HEATING AND AIR CONDITIONING DANGER Before welding any part of refrigeration system, make sure the area is well ventilated. SOLDERING Before soldering any part of the system, make sure the area is well ventilated. Use (stay clean) flux sparingly and apply solder (95-5 round wire 1/8 inch [3,1 mm]).
  • Page 787 SECTION 22: HEATING AND AIR CONDITIONING 4.1.3 Oil Level Check and Oil Change MAINTENANCE Oil level should be at ¼ to ¾ of sight glass height. Empty the shaft seal oil collecting tube. This Oil Type: Polyoester ISO68. tube collects oil seeping through the felt shaft ...
  • Page 788 SECTION 22: HEATING AND AIR CONDITIONING  Even cylinder head temperature. Cause:  Improperly torqued cylinder head bolts. Cause:  Unloader body stem bent.  Improperly positioned gasket at assembly.  Foreign material binding unloader piston or  Warped cylinder head. plunger.
  • Page 789 SECTION 22: HEATING AND AIR CONDITIONING NOTE Belts specifications may vary. For proper belt selection, always consult your vehicle Coach Final Record. 4.2.2 Removal - When the Compressor Is Inoperable  Perform the “Refrigerant Recovery” operation (paragraph 6.3).  Slacken bolts fixing small...
  • Page 790 SECTION 22: HEATING AND AIR CONDITIONING cause high discharge pressure and insufficient cooling. 4.4.1 Condenser Fans Four brushless motors fan are installed in condenser compartment on R.H. side of vehicle in order to ventilate the condenser coil. The fans pull outside air through the condenser coil and discharge it through an opening at bottom of compartment.
  • Page 791 SECTION 22: HEATING AND AIR CONDITIONING 4.4.2 Condenser Fan Removal Set the battery master switch to the OFF position. Unplug the fan harness connector (Figure 39). Remove the four hexagonal head cap screws retaining the fan assembly to the shroud. Remove the motor.
  • Page 792 SECTION 22: HEATING AND AIR CONDITIONING moisture and foreign matter from refrigerant Backseat the outlet shut-off valve and then before it reaches the expansion valves. disconnect the vacuum pump hose. The filter-dryer should be replaced after a MAX TORQUE: 11 lb-ft (15 Nm) severe system failure, after a prolonged exposure and most important, when the moisture indicator sight glass turns to pink.
  • Page 793 SECTION 22: HEATING AND AIR CONDITIONING COLOR INDICATOR MILKY, CLOUDED Contaminated system LIGHT BLUE PINK TEMPERATURE VIOLET (ppm) (ppm) (ppm) OIL STREAKS Oil contamination 75°F (24°C) 100°F (38°C) FIGURE 43: CONDITIONS THAT MAY BE OBSERVED IN 125°F (52°C) THE MOISTURE INDICATOR SIGHT GLASS p.p.m.= parts per million (moisture content) SHUT-OFF VALVE WITH SERVICE PORT...
  • Page 794 SECTION 22: HEATING AND AIR CONDITIONING ) and is accessible through the reclining open breaker, open-circuited or grounded coil, bumper. broken lead wires. Two identical NC (normally closed) refrigerant Burned-out coil: Check for open-circuited coil. solenoid valves are found in the condenser Replace coil if necessary.
  • Page 795 SECTION 22: HEATING AND AIR CONDITIONING 3. Place the new coil on the enclosing tube. 5. Put back the enclosing tube locknut and Lay data identification plate in place. tighten. Do not over tighten. 4. Insert the coil retaining screw, rotate coil TORQUE: 20-40 lb-ft (27-54 Nm) housing to proper position and tighten screw 6.
  • Page 796 SECTION 22: HEATING AND AIR CONDITIONING The valve regulates the flow of refrigerant liquid into the evaporator coils and is controlled by the suction gas temperature leaving the evaporator. The bulb head senses the refrigerant gas temperature as it leaves the evaporator. High temperature will cause expansion and pressure on the power head and spring.
  • Page 797 SECTION 22: HEATING AND AIR CONDITIONING cause the valve pin to move in the closing (27,7 C), Then set temperature to minimum position. to keep the compressor on 6 cylinders. As the operating superheat is raised, the evaporator capacity decreases, since more of the evaporator surface is required to produce the superheat necessary to open the valve.
  • Page 798 SECTION 22: HEATING AND AIR CONDITIONING Regulate suction pressure to temperature reading according to temperature chart or to the R-134a temperature scale on the pressure gauge. Example: Suction pressure 30 psi (207 kPa) converted to 32 F (0 C) on chart. If temperature reading is 40 F (4,4 C), subtract 32...
  • Page 799 SECTION 22: HEATING AND AIR CONDITIONING central system, but no superheat adjustment is 2. Tighten the nipple in place in the body cavity required ( as per Figure 53. Fasten pilot solenoid vale FIGURE 46 to the pneumatic water valve. Reconnect air HOT WATER PNEUMATIC VALVE supply pressure and electrical current to the pilot solenoid valve.
  • Page 800 SECTION 22: HEATING AND AIR CONDITIONING HOT WATER CIRCULATING PUMP Central HVAC system The vehicle is provided with a seal-less/brushless water circulating pump which is located in:  H3 Series - evaporator compartment  X3 Series - coolant preheater compartment (Figure 55) ...
  • Page 801 SECTION 22: HEATING AND AIR CONDITIONING section to gain access to the heater line Small HVAC system shutoff valve. Water circulating pump which is located on the 3. Disconnect the electrical wiring from the ceiling spare wheel compartment motor. (Figure 57) The water circulating pump consists of a WARNING centrifugal pump and an electric motor which are...
  • Page 802 SECTION 22: HEATING AND AIR CONDITIONING NOTE The driver’s area air temperature sensor is A/C Compressor Pressure Displays located below the dashboard, just ahead of the compressor suction driver's right knee. pressure value (LoS=low side) and discharge pressure NOTE value (HiS=high side). VIP vehicles equipped with Small HVAC System have two air temperature sensors;...
  • Page 803 SECTION 22: HEATING AND AIR CONDITIONING A/C compressor HI and LO pressure values are displayed one after the other instead of the TEMPERATURE SENSOR outside temperature in the telltale panel LCD Temp °C Temp °F Resistance Ohms display. This feature can be used when the (temperature sensor vehicle is traveling to check the A/C compressor disconnected)
  • Page 804 SECTION 22: HEATING AND AIR CONDITIONING MODES OF OPERATION COOLING DEMAND - The 2 speed engages if the passengers' area temperature is 1 degree above the set point and it revert to speed 1 if the Conditions for engaging the temperature gets equal or below the set point.
  • Page 805 SECTION 22: HEATING AND AIR CONDITIONING HVAC SYSTEM TROUBLESHOOTING Problem/Symptom Probable Causes Actions No temperature control in Problem with the temperature Instruct the driver to manually control the the passenger area sensor located in the temperature playing with passenger’s area return air duct passenger set point.
  • Page 806 SECTION 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions it is powered. HVAC condenser fans not Circuit breaker CB7 (CB5 on X3 1. Check / reset circuit breaker CB7 functioning in speed 2 VIP) tripped 2. See HVAC condenser fans not Seized bearing functioning &...
  • Page 807 SECTION 22: HEATING AND AIR CONDITIONING 5.7.1 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 808 SECTION 22: HEATING AND AIR CONDITIONING 5.7.2 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 809 SECTION 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE An evaporator just does a proper cooling job without sufficient air. Shortage of air can be caused by the following: o Dirty filters; or o Dirty coils. Testing condenser pressure. NOTE : R-134A pressure is function of the temperature variation. Example, for an exterior temperature of 100°F.
  • Page 810 SECTION 22: HEATING AND AIR CONDITIONING TEMPERATURES & PRESSURES LEAK TESTING CHART Some methods such as nitrogen pressure and soap, and electronic sniffer can be used for leak R134a VAPOR-PRESSURE testing. However, the most common method TEMPERATURE PRESSURE used is a "Halide" torch consisting of an acetylene tank, a burner and a suction test hose.
  • Page 811 SECTION 22: HEATING AND AIR CONDITIONING in the main power compartment/junction panel Multiplex Module (evaporator compartment) (Figure 59 & Figure 60). I/O-B The passenger’s unit condenser coil mounted on Relays (evaporator compartment) the opposite side of the evaporator is ventilated 24V Condenser fans by four brushless axial fans.
  • Page 812 SECTION 22: HEATING AND AIR CONDITIONING adjustable HVAC air registers and to his feet with the appropriate button (see FIGURE 61 MAINTENANCE Owner’s or Operator’s manual). Passenger’s area fresh air intake filter (X3 Series only) Clean or replace filter at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION &...
  • Page 813 SECTION 22: HEATING AND AIR CONDITIONING console to control air flow. Return air is drawn NOTE just below the middle side windows through an air Upon starting, if the outside temperature is filter into overhead compartment fan; above 32 °F (0°C) and then drops below °F discharge air is fed to the rotating registers (0°C), the compressor will keep running up to...
  • Page 814 SECTION 22: HEATING AND AIR CONDITIONING a port which directs air pressure to the actuator casing, thereby opening or closing the valve. When the vehicle is operating without electrical supply to the pilot solenoid valve, no air pressure is admitted to the actuator casing, the cylinder spring pushes up against the cylinder, thereby keeping the water valve open.
  • Page 815 SECTION 22: HEATING AND AIR CONDITIONING Passenger’s Unit Hot Water Pneumatic 6.4.2 WARNING Valve The flow of hot water to the vehicle’s central Before proceeding with the following steps, heater core is controlled by a normally-open NO check that coolant has cooled down. 3-way pneumatic water valve assembly (Figure 68).
  • Page 816 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 71: DRIVER'S HVAC UNIT FIGURE 72: DRIVER'S HVAC UNIT PA1615 Maintenance Manual All Series Section 22 revised September 2016...
  • Page 817 SECTION 22: HEATING AND AIR CONDITIONING WARNING Draining Passenger’s Unit Heater Core 1. Stop engine and allow engine coolant to cool. Before proceeding with the following step, check that coolant has cooled down. 2. Close both heater line shutoff valves (Figure 73 or Figure 74).
  • Page 818 SECTION 22: HEATING AND AIR CONDITIONING 6.4.4 Filling Heating System NOTE Ensure that the driver’s unit heater core In test mode (see paragraph 5.4 TEST MODE purge valve and the passenger’s unit heater FOR SWITCHES AND SENSORS), with the parking brake applied and the passenger set core drain cock are closed.
  • Page 819 SECTION 22: HEATING AND AIR CONDITIONING refrigerant is drawn into the compressor to water or heating blanket when charging the repeat the air conditioning cycle. system will assure the extraction of a maximum amount of refrigerant from the cylinder. The success of the air conditioning system depends on retaining the conditioned air Precautions in Handling Refrigerant within the vehicle.
  • Page 820 SECTION 22: HEATING AND AIR CONDITIONING Treatment in Case of Injury flexible hose connections, it is important that the swaged fitting and the flare nut, as well If liquid refrigerant comes in contact with the as the coupling to which it is attached, be skin, treat the injury as if the skin was frost-bitten held at the same time using three different or frozen.
  • Page 821 SECTION 22: HEATING AND AIR CONDITIONING its color, odor and acidity. A Virginia Chemical Run the unit for 8 hours and monitor the "TKO" one step acid test kit is one of several pressure drop across the filter-dryer. Also compressor oil test kits that may be used. A high check the liquid line dryer for signs of acid content would indicate a major failure or restriction.
  • Page 822 SECTION 22: HEATING AND AIR CONDITIONING CAUTION The filter-dryer should be changed each time a line in the system is opened. NOTE Before attempting repair between compressor and receiver tank, use a recovery unit to remove refrigerant from the system. FIGURE COMPRESSOR SHUT-OFF...
  • Page 823 SECTION 22: HEATING AND AIR CONDITIONING 7. Run the A/C compressor until suction method is less accurate when ambient pressure is pulled down to 0 psig. temperature gets high. With the AC on for at least 10 minutes, the 8. Disconnect the compressor clutch to stop moisture indicator sight glass (FIGURE 79) the compressor from pulling the system into should be clear, not milky, without bubbles...
  • Page 824 SECTION 22: HEATING AND AIR CONDITIONING Temperatures & Pressure), find this compressor R.H. cylinder. The aluminum temperature corresponding cap on top of the coil may become loose; it saturation pressure and add 10 psi for the can result in failure of the unloader pressure drop between compressor and stem/valve (FIGURE 32).
  • Page 825 SECTION 22: HEATING AND AIR CONDITIONING forcing liquid R-134a directly into the receiver 11. The proper charge of R-134a is 24 lbs, to tank. This may be accomplished by placing the this, add 2 lbs for parcel racks A/C system. refrigerant cylinder upside down on a scale with When the scale indicates this amount of the valves at the bottom.
  • Page 826 SECTION 22: HEATING AND AIR CONDITIONING connector housings of C24 together for the passengers’ area (located on the HVAC module in evaporator compartment) or C44 for the driver's area (located on the ceiling of the spare wheel compartment). Start the vacuum pump. The pressure will drop to approximately 29 in-HG gauge vacuum.
  • Page 827 SECTION 22: HEATING AND AIR CONDITIONING 7.2.2 Auxiliary Unit - H3 VIP Vehicles Only 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 auxiliary unit and to regulate the fan speed. FIGURE 82: CONTROL UNIT - SMALL HVAC SYST.
  • Page 828 SECTION 22: HEATING AND AIR CONDITIONING Check to insure that vacuum holds. (If the the compressor must be run in advance to pressure continues to rise, it indicates a leak ensure return. This procedure is as follows: or moisture in the system). ...
  • Page 829 SECTION 22: HEATING AND AIR CONDITIONING and transmit their heat to the water passing PREHEATER FUEL FILTER through the heat exchanger. The preheater fuel filter is located beside the The heat is thermostatically controlled and preheater above the rear wheelhousing, behind the vehicle’s L.H.
  • Page 830 SECTION 22: HEATING AND AIR CONDITIONING PREHEATING SYSTEM TIMER CAUTION The timer, located on L.H. lateral console is used to program the starting and stopping time of the To avoid running down the batteries, do not preheating system. The system indicator light, turn on the preheating system for more than located on the timer, illuminates when the one hour before starting the engine.
  • Page 831 SECTION 22: HEATING AND AIR CONDITIONING Failure Symptom Probable Cause Check and Correct 1X Flash (F 01) - Fuel system - Fuel level - Type of fuel being used No combustion after completion of startup sequence. - Fuel filter - Fuel line connections (air bubbles in fuel lines) - Fuel nozzle plugged - Combustion air - Air intake or exhaust, restricted or plugged...
  • Page 832 SECTION 22: HEATING AND AIR CONDITIONING SPECIFICATIONS Passenger’s unit evaporator motor Make ..........................AMETEK ROTRON Type ................ BRUSHLESS DC MICROPROCESSOR CONTROLED Voltage ............................27.6 V DC Current draw ............................68 amps Horsepower ..............................2 Revolution ........................... 1400 & 1700 rpm Insulation ............................. Class F Passenger’s unit condenser fan motors Make ...............................
  • Page 833 Voltage .............................. 24 V DC A/C Compressor (Small HVAC system) Make ..................ICE (International Components Engineering) Model ............................... TM-16HD Prevost number ........................... 950436 Approved oil ..........................OIL-ICE (PAG) Receiver tank (with sight glasses) Make ............................Westermeyer Maximum pressure ..........................450 psig Filter-dryer assembly Make ............................
  • Page 834 Voltage .............................. 24 V DC Hot water circulating pump Make ..............................AMETEK Flow ..............................15 gpm Inlet/outlet OD ............................3/8” Driver’s expansion valve Prevost number ........................... 950221 Main expansion valve Make ............................Emerson-Alco Preheating system Make .............................. SPHEROS Model ............................THERMO 300 Capacity........................
  • Page 835 SECTION 23a: H3 SERIES ACCESSORIES CONTENTS      TORQUE TABLES ............................ 4     TROUBLESHOOTING ............................  8     HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS  ...........  8     DASHBOARD RADIO  .............................  1 0     1.3.1 Removal/Installation ...........................  1 0     VSS‐05 SOUND SELECTOR  ..........................  1 0    ...
  • Page 836 SECTION 23a: H3 SERIES ACCESSORIES     6.5.2 Dip Switch Settings ..........................  1 9     EMERGENCY BUZZER ...........................  1 9     FRESH WATER TANK ............................  1 9     6.7.1 Fresh Water Tank Heater (Optional) ....................  1 9     6.7.2 Fresh Water Tank Draining  ........................  1 9     6.7.3 Fresh Water Tank Filling ........................  1 9  ...
  • Page 837 SECTION 23a: H3 SERIES ACCESSORIES   ILLUSTRATIONS FIGURE AUDIO‐VIDEO PANEL PARCEL RACK ......................  5               FIGURE AUDIO‐VIDEO CONTROLS INDICATORS FRONT FACE E‐HDMI SWITCH ......  6                        ...

  • Page 838: Torque Tables

    SECTION 23a: H3 SERIES ACCESSORIES TORQUE TABLES MISCELLANEOUS DESCRIPTION TORQUE Hubodometer mounting bolts 110-165 lb-ft (149-224 Nm) Upper wiper arm cap nut 20-24 lb-in (2.26-2.71 Nm) Lower wiper arm cap nut (drive arm) 20-24 lb-in (2.26-2.71 Nm) Lower wiper arm cap nut (idler arm) 90-110 lb-in (10-12 Nm) Lower wiper arm clamping screw 120-130 lb-ft (163-176 Nm)
  • Page 839 Each passenger’s overhead console mounted to the underside of the parcel racks contains a 20-watt coaxial 10cm speaker. Powered by the amplifier, the speakers (24 in H3-41 or 28 in H3-45) are wired in stereo and arranged in a delta configuration.
  • Page 840 SECTION 23a: H3 SERIES ACCESSORIES FIGURE 2: AUDIO-VIDEO CONTROLS AND INDICATORS ON THE FRONT FACE OF THE E-HDMI SWITCH FIGURE 3: AUDIO-VIDEO CONNECTIONS AT THE BACK OF THE E-HDMI SWITCH PA1615 Maintenance Manual All Series Section 23a revised September 2016...
  • Page 841 SECTION 23a: H3 SERIES ACCESSORIES FIGURE 4: TYPICAL AUDIO-VIDEO CONNECTIONS USING FOUR OUTPUT SPLITTER BOX FIGURE 5: AUDIO-VIDEO CONNECTIONS USING TWO SPLITTER BOXES TO ALLOW THE USE OF SIX LCD MONITORS PA1615 Maintenance Manual All Series Section 23a revised September 2016...
  • Page 842 SECTION 23a: H3 SERIES ACCESSORIES TROUBLESHOOTING Symptom Possible Causes / Solutions No picture, no sound Check for proper voltage supply and correct cable connections. Ensure that the desired input is selected. No picture Check whether AV cable is properly connected. Check whether HDMI cables are properly connected.
  • Page 843 SECTION 23a: H3 SERIES ACCESSORIES REI products that may be installed in your coach: MONITOR, COLOR BACK-UP CAMERA DVD REMOTE CONTROL MONITOR, LCD 15.6” CAMERA, COLOR BACK-UP MONITOR, CENTRAL LCD 15.6” CAMERA, COLOR PANORAMIC MONITOR, FLIP19” MICROPHONE, 10” CB TYPE MONITOR, 16:9 CENTRAL LCD 19”...

  • Page 844: Dashboard Radio

    SECTION 23a: H3 SERIES ACCESSORIES DASHBOARD RADIO 4. On the front side of the unit, insert the removal tool #20584494 in the holes found each side in order to separate the unit from the support. 5. From behind, push the unit through the front dashboard panel.
  • Page 845 20- watt coaxial 10cm speaker. The speakers (24 in 3. Disconnect wiring. H3-41 or 28 in H3-45) in the passenger’s section, wired in stereo and arranged in a delta 1.7.2 Installation configuration are powered by the amplifier.

  • Page 846: Tv Tuner

    SECTION 23a: H3 SERIES ACCESSORIES The System 2000 16 channel wireless micro- FIGURE 14: TUNER CONTROLS DESCRIPTION phone, Receiver and Charging Cradle are custom designed units that allow for wireless PA 1.11 KARAOKE communication from anywhere on the coach. The modified Panasonic DVD Player powers up The unit consists of a receiver mounted in the automatically when...
  • Page 847 SECTION 23a: H3 SERIES ACCESSORIES BACK-UP CAMERA AND MONITOR An optional back-up camera is available which provides the driver with visual assistance when backing-up. camera automatically activated when the transmission is put in reverse gear and the ignition switch is "ON". FIGURE 16: MONITOR MOUNTING 23221 1.14 SCENIC VIEWING SYSTEM...
  • Page 848 SECTION 23a: H3 SERIES ACCESSORIES PICTURE= Functions for the image setting; CAM2: Selection of real picture or mirrored picture CAM2 USER= Selection of the system function; for camera 2 TIME= Setting time and date; NOTE The distance mark will appear on the picture of camera which set as MIR INSTALL= Setting the camera function (e.g.

  • Page 849: Hub Odometer

    SECTION 23a: H3 SERIES ACCESSORIES 3.1.2 INSTALLATION Place the hub odometer unit over the wheel hub studs. Replace the lock washers and nuts. Torque stud nuts. TORQUE: 110-165 lb-ft (149-224 Nm) FIGURE 18: HUBODOMETER 23027 OPERATION The hub odometer is calibrated for a specific wheel size (diameter).

  • Page 850: Sunshades

    SECTION 23a: H3 SERIES ACCESSORIES FIGURE 19: DESTINATION SIGN – ELECTRONIC 23123 Note: destination sign must programmed with a computer connected to the RS-232 connector prior to first use. Follow the FIGURE 20: DRIVER'S SUNSHADE instructions on the computer disk to install and run the software.

  • Page 851: Passenger Sunshades

    A night-light is permanently lit in the The special tool can be ordered from your lavatory when the ignition switch is in the ON Prevost part center under part # 685594 position. 5.2.1 Preload Adjustment Using the chart below, preload the sunshade...

  • Page 852: Ventilation Fan

    SECTION 23a: H3 SERIES ACCESSORIES VENTILATION FAN 6.3.1 Description The lavatory ventilation fan, mounted in engine compartment over the oil reserve tank (Figure 24), serves two purposes. It exhausts objection- able odors and provides a constant air circula- tion in the lavatory compartment by heating or cooling the lavatory with the vehicle ambient air.
  • Page 853 SECTION 23a: H3 SERIES ACCESSORIES The fresh water tank located at rear of lavatory wall (over cleaning cabinet), supplies water to the washbasin by gravity. Two tubes are connected in the upper section of tank (Figure 28). One serves as overflow as well as vent tube and runs along the wall to the underside of the lavatory close to the engine air filter housing, while the other tube is connected to the fresh...
  • Page 854 SECTION 23a: H3 SERIES 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 855 SECTION 23a: H3 SERIES ACCESSORIES This timer allows an electric current flow during a check the liquid projection while you manually preset time to a pump into the sump tank. adjust the control valve 6.9.1 Pneumatic Timer Removal and 6.11 SUMP TANK Installation 6.11.1 Sump Tank Draining 1.
  • Page 856 SECTION 23a: H3 SERIES ACCESSORIES 6.12 CLEANING CABINET flow of washer fluid. Check that the washer nozzles are properly aimed. A coiled hose located in the cleaning cabinet above the toilet can be used during lavatory The headlights cleaning system is independent cleaning.
  • Page 857 SECTION 23a: H3 SERIES ACCESSORIES The windshield wipers are controlled by two CAUTION electric wiper motors that are accessible for Because they are made of plastic, firmly maintenance after raising the appropriate access tighten nozzle and bulkhead fittings by panel at the front of the coach (refer to figure 32). hand only.
  • Page 858 SECTION 23a: H3 SERIES ACCESSORIES FIGURE 35: MULTIFUNCTION LEVER through the holes at the base of each wiper arm 23133 specially drilled for this purpose. Each windshield washer pump is independently Sweep adjustment is a rough adjustment. It operated: must be followed by lower and upper linkage adjustment.
  • Page 859 SECTION 23a: H3 SERIES ACCESSORIES 9.2.3 Installation TORQUE: 22-27 lb-in (2.49-3.05 Nm) 1. Make sure the wiper motor is in the stop position. Lower windshield wiper: position the 7. Install the pivot shafts cap nuts. wiper arm on the knurled drive shaft and idler arm on the pivot shaft.
  • Page 860 3. Loosen clamping screw retaining the lever at the end of the motor driving shaft. 4. Remove the three bolts holding the motor to the steel plate. 5. Remove the windshield wiper motor (Prevost #800304), reverse removal procedure to reinstall. PA1615 Maintenance Manual All Series...
  • Page 861 SECTION 23a: H3 SERIES ACCESSORIES FIGURE 39: LOWER WINDSHIELD WIPER INSTALLATION 23088 PA1615 Maintenance Manual All Series Section 23a revised September 2016...
  • Page 862 SECTION 23a: H3 SERIES ACCESSORIES 9.5.2 Upper Windshield Wiper Motor Replacement The upper windshield wiper motor is located above L.H. upper windshield panel. To remove the motor, it is necessary to remove left sun visor and upper windshield panel. Warning: Park vehicle safely, apply parking brake, stop engine and set battery master switch to the ‘’OFF’’...
  • Page 863 SECTION 23a: H3 SERIES ACCESSORIES FIGURE 40: UPPER WINDSHIELD WIPER INSTALLATION 23089 PA1615 Maintenance Manual All Series Section 23a revised September 2016...
  • Page 864 Verify that no obvious physical damage or condition exists that might prevent system Refer to Prevost Operator’s Manual or Owner’s operation. Manual for system operation and operational sequence (fire).
  • Page 865 SECTION 23a: H3 SERIES ACCESSORIES  Verify that the windows on the face of the detector are free of excess contami- MAINTENANCE nation (dirt, oil, grease, etc.) – if neces- sary, clean using a water soaked non- abrasive towel. EVERY TWELVE YEARS o Linear Thermal Have the Extinguisher cylinder hydrostatically tested by a qualified fire protection equipment...
  • Page 866 SECTION 23a: H3 SERIES ACCESSORIES 11. TIRE PRESSURE MONITORING SYSTEM (TPMS) The optional 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. For more information on the operation and troubleshooting of the system, refer to the Operator’s Manual, chapters “Controls and Instruments”...
  • Page 867 SECTION 23b: X3 SERIES ACCESSORIES CONTENTS      TORQUE TABLES ............................ 4     DESCRIPTION OF AUDIO AND VIDEO SYSTEM INSTALLED ON X3‐45 COACHES .......... 5     RECEIVE SERVICE YOUR AUDIO VIDEO PRODUCTS ............  8                AND        DASHBOARD AM/FM RADIO  ..........................  9      ...
  • Page 868 SECTION 23b: X3 SERIES ACCESSORIES     FRESH WATER TANK  .............................  2 0         7.8.1 Fresh Water Tank Draining  ........................  2 0     7.8.2 Fresh Water Tank Filling ........................  2 2     LIQUID SOAP DISPENSER  ..........................  2 2    ...
  • Page 869 SECTION 23b: X3 SERIESACCESSORIES ILLUSTRATIONS    ‐  .............................  5 FIGURE     AUDIO VIDEO PANEL   &  ..........................  6 FIGURE   AUDIO   VIDEO CONNECTIONS   ‐  ...........................  7 FIGURE   AUDIO VIDEO CONNECTIONS   ‐   ..........................  7 FIGURE   RACKS ON AUDIO VIDEO PANEL    ............................  9 FIGURE   DASHBOARD AM FM RADIO  ...

  • Page 870: Torque Tables

    SECTION 23b: X3 SERIES ACCESSORIES TORQUE TABLES MISCELLANEOUS DESCRIPTION TORQUE Hubodometer mounting bolts 110-165 lb-ft (149-224 Nm) Wiper arm mounting bolts (first tightening) 9 lb-ft (12 Nm) Wiper arm mounting bolts (second tightening) 22 lb-ft (30 Nm) PA1615 Maintenance Manual All Series Section 23b revised September 2016...

  • Page 871: Description Of Audio And Video System Installed On X3-45 Coaches

    SECTION 23b: X3 SERIES ACCESSORIES DESCRIPTION OF AUDIO AND VIDEO SYSTEM INSTALLED ON X3-45 COACHES The rack mounted components are gathered on the audio-video panel which is located in the first driver’s side overhead compartment (Figure 1). In addition to the power amplifier, options for AM/FM radio, satellite radio, karaoke, wireless microphone, DVD, scenic view and back-up camera system and GPS Navigation System module may be featured.
  • Page 872 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 2: AUDIO & VIDEO CONNECTIONS PA1615 Maintenance Manual All Series Section 23b revised September 2016...
  • Page 873 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 3: AUDIO-VIDEO CONNECTIONS FIGURE 4: RACKS ON AUDIO-VIDEO PANEL 23059 PA1615 Maintenance Manual All Series Section 23b revised September 2016...

  • Page 874: How To Receive Service For Your Rei Audio And Video Products

    SECTION 23b: X3 SERIES ACCESSORIES HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS For assistance in obtaining service for REI products call toll free 877-726-4617 (Continental United States and Canada) between the hours of 7:00 A.M. - 5:00 P.M. CST Monday thru Friday (excluding Holidays). For assistance in obtaining service for REI products call toll free 877-726-4617 (Continental United States and Canada only) between the hours of 7:00 A.M.

  • Page 875: Dashboard Am/Fm Radio

    SECTION 23b: X3 SERIES ACCESSORIES DASHBOARD AM/FM RADIO To remove the Sound Selector from its location, proceed as follows: Place the ignition switch in the ‘’OFF’’ position. Remove the dashboard cover. Disconnect the electrical connectors FIGURE 5: DASHBOARD AM/FM RADIO from unit and unfasten back plate securing nut/screw.

  • Page 876: Multichannel Power Amplifier Va400.8

    SECTION 23b: X3 SERIES ACCESSORIES 1 AUX video output 1 rear camera video input 3 video outputs with one dedicated self switching rear view monitor  ADDITIONAL VIDEO FEATURES FIGURE 9: CROSSOVER ADJUSTMENT Multi-angle, multi-view, multi-audio function, multi-level forward and backward motion, play SPEAKERS position memory, resume stop and repeat function.

  • Page 877: Wireless Microphone

    SECTION 23b: X3 SERIES ACCESSORIES 2.7.1 Removal 1. Place the ignition switch in the ‘’OFF’’ position. 2. Remove the mounting screws at mounting flange. 3. Disconnect wiring. 2.7.2 Installation 1. Reconnect wiring. 2. Align mounting flange with holes and install screws.

  • Page 878: Driver'sspeakers

    SECTION 23b: X3 SERIES ACCESSORIES If so equipped, instructions for proper use of the video switcher located on the audio-video panel Karaoke system are included in the ‘’Operating (Figs. 1 & 17). Manual’’ that is provided in the technical publica- tions box delivered with the vehicle.
  • Page 879 SECTION 23b: X3 SERIES ACCESSORIES 5) MENU: This key has 2 functions  Activation of the dimmer function (press less than 1.5 seconds) during normal operation;  Calling up the menu (press longer than 1.5 seconds, four menus can be called up). Press the key once again to call up the individual menus;...
  • Page 880 SECTION 23b: X3 SERIES ACCESSORIES necessary. The setting within the function can be modified with the keys UP and DOWN. Voltage supply 12-volt to 24-volt (max. 32-volt) POSSIBLE SETTINGS: USER BLACK/BROWN Earth cable LANGUAGE: ENGLISH/GERMAN LANGUE ENG WHITE Control wire for switching on the (ENG/DEUT) dimmer function (night operation) SCREEN...
  • Page 881 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 18: HUBODOMETER 23024 OPERATION The hubodometer is calibrated for a specific wheel size (diameter). Wheel rotation causes a mechanism inside the hubodometer to record distance after a predetermined number of rotations. The unit should be serviced at a competent speedometer repair facility.

  • Page 882: Windshield Sunshades

    SECTION 23b: X3 SERIES ACCESSORIES FIGURE 19: DESTINATION SIGN – ELECTRONIC 23123 NOTE The destination sign must be programmed with a computer connected to the RS-232 FIGURE 20: DRIVER'S SUNSHADE connector prior to first use. Follow the instructions on the computer disk to install and run the software.

  • Page 883: Passenger Sunshades

    SECTION 23b: X3 SERIES ACCESSORIES LAVATORY INSTALLED X3-45 COACHES DESCRIPTION The lavatory is located in the rear R.H. corner of the coach. It is equipped with a chemical flush toilet, bathroom tissue dispenser, washbasin, towel dispenser, waste container, mirror, ashtray, and a cleaning cabinet. A liquid soap dispenser and moist towel dispenser are optional.

  • Page 884: Ventilation Fan

    SECTION 23b: X3 SERIES ACCESSORIES MAINTENANCE The servicing procedure for the lavatory is described in the '‘Operator’s Manual'’ included in the technical publications box delivered with the vehicle. VENTILATION FAN 7.3.1 Description The lavatory ventilation fan (Figure 24), mounted in engine compartment behind the oil reserve tank, serves two purposes.

  • Page 885: Door Lock

    SECTION 23b: X3 SERIES ACCESSORIES FIGURE 24: VENTILATION FAN INSTALLATION 23222 DOOR LOCK Lavatory door lock has inside and outside handles, as well as an inside latch to lock door from inside the compartment. If the lock fails to release, the door can be opened from the outside using a special key which is supplied to the driver.

  • Page 886: Lavatory Night-Light

    SECTION 23b: X3 SERIES ACCESSORIES LAVATORY NIGHT-LIGHT The lavatory night-light is illuminated as soon as the ignition switch is set to the "ON" position. See Section 06, Electrical System, “Parcel Rack / Lavatory Night Light - "Bulb Removal and Replacement" for lights replacement. EMERGENCY BUZZER The lavatory emergency buzzer is mounted on the inner curb side wall of lavatory and sounds...
  • Page 887 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 26: FUNCTIONING OF LAVATORY 23051 PA1615 Maintenance Manual All Series Section 23b revised September 2016...
  • Page 888 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 28: LIQUID SOAP DISPENSER 23039 3. Fill dispenser with soap. This model can dispense vegetable oil soaps, synthetic FIGURE 27: SUMP TANK & F/W TANK SERVICE VALVES detergents, and lotion soaps. 7.8.2 Fresh Water Tank Filling CAUTION Connect the fresh water supply hose to the fresh water reservoir fill connection (Figure 26)
  • Page 889 However, (Prevost part #900329) in toilet before adding the for maximum seal life, the run dry periods should antifreeze and starting final filling of sump tank.
  • Page 890 SECTION 23b: X3 SERIES ACCESSORIES 5. Service or replace the defective horn; CAUTION 6. Reinstall by reversing procedure. When cold weather is expected and there is no HEADLIGHTS CLEANING SYSTEM antifreeze in the tank, sump tank must be drained. GENERAL DESCRIPTION NOTE NOTE If there is no antifreeze solution in the tank,...
  • Page 891 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 30: HEADLIGHTS CLEANING SYSTEM 23380 FIGURE 32: WASHER NOZZLES ADJUSTMENT 23382 CAUTION 10. WINDSHIELD WIPERS AND WASHERS Because they are made of plastic, firmly 10.1 GENERAL DESCRIPTION tighten nozzle and bulkhead fittings by hand only.
  • Page 892 SECTION 23b: X3 SERIES ACCESSORIES 10.2.1 Wiper Arms Positioning 1. Reinstall the wiper arms and position as shown in figure 40. Before positioning the wipers at their final position, tighten the nuts at first. TORQUE 9 lb-ft (12 Nm) 2. To find the final position of the wiper arms, lift then release the wiper arm so if falls back on the windshield.
  • Page 893 5. Connect the windshield washer tubing at the 5. Remove windshield wiper motor base of the wiper arm. (Prevost #800328), reverse removal 6. Check the adjustment on a wet windshield. procedure to reinstall. PA1615 Maintenance Manual All Series...
  • Page 894 SECTION 23b: X3 SERIES ACCESSORIES FIGURE 40: WIPER ARMS POSITIONING 23253 10.4 TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY A. Reservoir empty. A. Add proper fluid FAIL TO SPRAY WASHER FLUID B. Store coach or parts in heated B. If below 32F (0C), improper area, then purge system with low- washer fluid frozen.
  • Page 895 For more information on the operation and troubleshooting of the system, refer to Prevost X3-45 Coaches Operator’s Manual, chapters “Controls and Instruments” and “Safety Features and Equipment”...
  • Page 896 SECTION 23b: X3 SERIES ACCESSORIES Extinguisher & Distribution System 12.2 PERIODIC MAINTENANCE o Verify that that the extinguisher pressure gauge pointer is in the green arc at room PRE-TRIP temperature. o Verify that the Protection Panel ”SYSTEM o Verify that distribution piping and nozzles are OK”...
  • Page 897 SECTION 24: LUBRICATION & SERVICING CONTENTS      LUBRICATION .......................... 2     LUBRICATION AND SERVICING ....................... 2     FLEXIBLE HOSE MAINTENANCE  ....................... 2         2.1.1 Hose Inspection  ........................ 2     2.1.2 Leaks ............................ 2     2.1.3 Service life .......................... 2     FLUIDS LUBRICANTS SPECIFICATIONS  .................. 8  ...

  • Page 898: Flexible Hose Maintenance

    SECTION 24: LUBRICATION & SERVICING potential problems before they become major ones. LUBRICATION The efficiency and life expectancy of mechanical FLEXIBLE HOSE MAINTENANCE equipment is largely dependent on proper The performance of engine and equipment are lubrication servicing. mechanical greatly related to the ability of flexible hoses to components rely on a lubricating film between supply lubricating oil, air, coolant, and fuel oil.
  • Page 899 SECTION 24: LUBRICATION & SERVICING km). Look for surface damage or indications of damaged, twisted, worn, crimped, brittle, cracked, or leaking lines. Hoses having a worn outer surface or hoses with a damaged metal reinforcement should be considered unfit for further service.
  • Page 900 SECTION 24: LUBRICATION & SERVICING FIGURE 1: LUBRICATION AND SERVICING POINTS (I-BEAM FRONT AXLE SHOWN) TYPICAL PA1615 Maintenance Manual All Series Schedule revised Sept 2016...
  • Page 901 SECTION 24: LUBRICATION & SERVICING Accessories air tank drain cock Primary fuel filter Accessories air filter Secondary fuel filter Steering drag link Power steering fluid tank Height control valve (front) Engine oil filter Steering tie rod Cooling fan gearbox Accessories air tank Allison transmission oil dipstick Steering column U-joints Engine coolant surge tank...
  • Page 902 SECTION 24: LUBRICATION & SERVICING FIGURE 2: LUBRICATION AND SERVICING POINTS – HVAC UNIT HVAC air filter – driver’s unit Coolant preheater A/C receiver tank A/C system – passenger’s overhead console Refrigerant moisture indicator Upper windshield defrost unit A/C compressor Condenser coil HVAC air filter –...
  • Page 903 SECTION 24: LUBRICATION & SERVICING FIGURE 3: LUBRICATION AND SERVICING POINTS - INDEPENDENT FRONT SUSPENSION VEHICLES (TYPICAL) PA1615 Maintenance Manual All Series Schedule revised Sept 2016...

  • Page 904: Fluids And Lubricants Specifications

    SECTION 24: LUBRICATION & SERVICING FLUIDS AND LUBRICANTS SPECIFICATIONS FLUIDS & LUBRICANTS TABLE SYSTEMS DESCRIPTIONS / SPECIFICATIONS SAE Viscosity Grade: 10W-30 Engine Oil API Classification CJ-4 meeting Volvo specification VDS-4 and EO-O Premium Plus Power Steering Oil Automatic Transmission Oil, Dexron-III Texaco or Chevron Extended Life Coolant (ELC) Engine Coolant 50% antifreeze/water solution is normally used...
  • Page 905 SECTION 24: LUBRICATION & SERVICING FLUIDS & LUBRICANTS TABLE SYSTEMS DESCRIPTIONS / SPECIFICATIONS Cooling Fan Gearbox Oil Synthetic gear lubricant 75W-90 (refer to Linnig bulletin 142.377 for the list of approved oils) Extended drains Allison Transmission Oil Castrol TranSynd™ Synthetic Transmission Fluid for Allison or TES 295 approved equivalent Regular drains Allison Transmission Oil Schedule 1 TES-389 fluids or approved equivalent...

  • Page 906: Fluids And Lubricants Specifications Change Log

    SECTION 24: LUBRICATION & SERVICING 2.2.1 Fluids And Lubricants Specifications Change Log CHANGE LOG  DATE  1   Lubricant And Coolant Specifications Table – Dexron‐VI removed from Ref I. Dexron‐VI is no longer recommended for  Nov.11, 2015 use in commercial on‐highway transmission. Allison Service Tip #1099revS  2   I‐Shift  transmission:  Castrol  Syntrans  Grade  SAE  75W‐85  synthetic  oil  is  no  longer  approved  for  extended  drains  Nov.25, 2015   interval 3   Added: Lubricants “G” & “H” for ZF drive axle  Apr.26, 2016 4 ...
  • Page 907 SECTION 24: LUBRICATION & SERVICING OPERATING CONDITION Use the information that follows to determine the operating condition and usage applicable to your vehicle Severe Heavy Normal Less than 5 mpg Between 5 and 6 mpg Greater than 6 mpg More than 50 L/100km Between 39 and 50 L/100km Less than 39 L/100km PROCEED TO MAINTENANCE OPERATION EVERY...
  • Page 908 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use  4 Radiator – inspect exterior core & clean with low pressure water jet if necessary ...
  • Page 909 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use  7 Volvo I-Shift Transmission extended drains 20 60 – change fluid & filter 09 PROPELLER SHAFT ...
  • Page 910 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use  4 Steering knuckle (king) pins – grease two fittings per knuckle ...
  • Page 911 SECTION 24: LUBRICATION & SERVICING CHANGE LOG ‐ LUBRICATION AND SERVICING SCHEDULE  DATE  A red stripe in the left margin of the schedule highlights the latest changes  1   ADDED: 04 EXHAUST & AFTERTREATMENT SYSTEM ‐ Diffuser assembly, rain cap & drain tube – check proper functioning, clean  Sept.04, 2014 2  UPDATE: 01 ENGINE – Engine oil & filter change heavy operation, was 25 000mi, changed to 35 000mi   Jan.08, 2015 3  UPDATE: 01 ENGINE – Engine oil & filter change normal operation, was 35 000mi, changed to 45 000mi   Jan.08, 2015 4  UPDATE: 01 ENGINE – Initial valve adjustment, was 125 000mi, changed to 150 000mi  Jan.08, 2015 5  UPDATE: 01 ENGINE – Valve check & adjustment, was 250 000mi, changed to 300 000mi  Jan.08, 2015 6  ADDED: 01 ENGINE – Drive belt tensioners inspection  Jan.08, 2015 7  UPDATE: 04 EXHAUST & AFTERTREATMENT SYSTEM – DEF tank cleaning, was 185 000mi, changed to 150 000mi to match with DEF pump filter  Jan.08, 2015 change   8  UPDATE: 04 EXHAUST & AFTERTREATMENT SYSTEM – DPF filter cleaning or replacement, was 250 000mi, changed to 400 000mi  Jan.08, 2015 9  UPDATE: 05 COOLING – Cooling system with extended life coolant, drain flush & refill, was 650 000mi, changed to 750 000mi or 96 months  Jan.08, 2015 10  ADDED: 22 HEATING & AIR CONDITIONING – Recommended maintenance: A/C compressor –  change oil, clean oil filter  Jan.08, 2015   11 ...
  • Page 912 SECTION 24: LUBRICATION & SERVICING LUBRICATION AND SERVICING SCHEDULE H3-45 VIP & X3-45 VIP MOTORHOMES (Private Use) GENERAL All flexible hoses – inspect H3 VIP Series only: Main power compartment fan air filter – inspect 01 ENGINE Engine oil and filters – replace Air cleaner –...
  • Page 913 SECTION 24: LUBRICATION & SERVICING LUBRICATION AND SERVICING SCHEDULE H3-45 VIP & X3-45 VIP MOTORHOMES (Private Use) Filled with TranSynd or TES295 approved fluid only, no mixture with Prognostics mode enabled - Change fluid & filters when indicated by TRANSMISSION SERVICE indicator or 60 month whichever occurs first. In addition, change filters with every fluid change.
  • Page 914 SECTION 24: LUBRICATION & SERVICING LUBRICATION AND SERVICING SCHEDULE H3-45 VIP & X3-45 VIP MOTORHOMES (Private Use) A/C compressor – check oil and replenish if required A/C compressor – empty shaft seal oil collection tube (Bitzer A/C compressor) A/C receiver tank – check refrigerant level, add if required Refrigerant moisture indicator –...
  • Page 915 SECTION 26a: H3 SERIES SLIDE-OUT CONTENTS TORQUE TABLE ............................... 4 OVERVIEW ..............................8 INNER STOPPER ............................10 2.1.1 Maintenance ............................10 2.1.2 Adjustment............................10 "IN LIMIT" STOPPER ............................. 11 2.2.1 Maintenance ............................11 2.2.2 Adjustment............................11 EXTERIOR EXTRUSION ..........................11 SECURITY PIN ...............................
  • Page 916 Manual retracting procedure – Front and rear slide-out ..............31 18.1.2 Manual extending procedure – Front and rear slide-out ..............31 SLIDE-OUT MAXIMUM LOAD ........................32 PREVOST SLIDE-OUT WITH FLUSH FLOOR (H3-45 VIP) ................34 20.1 MECHANISM OVERVIEW (H3-45 VIP) ......................34 20.1.1 Control system overview ........................
  • Page 917 SECTION 26a: H3 SERIES SLIDE-OUT CONVERSION CHECKLIST .......................... 42 TROUBLESHOOTING ..........................42 22.1 ERROR CONDITION OR MISSING OPERATION CONDITION ................42 22.2 TROUBLESHOOTING – OPERATING CONDITIONS, CONTROL & MECHANICAL COMPONENTS ..... 43 22.3 SLIDE-OUT FAULT MESSAGE ON DID ......................48 ILLUSTRATIONS 1: H3-45 VIP TYPICAL CONFIGURATION ..................
  • Page 918 SECTION 26a: H3 SERIES SLIDE-OUT 48: EXTENSION MOTOR (FORE SHOWN) ................... 35 IGURE 49 EXTENSION MOTOR GEARS (FORE SHOWN) ............... 35 IGURE 50: FLOOR BEARING & PROXIMITY SWITCHES ................. 36 IGURE 51 LINEAR BEARINGS ........................36 IGURE 52: PHYSICAL STOPPERS ......................37 IGURE 53: UPPER INNER STOPPERS ADJUSTMENT ................
  • Page 919 SECTION 26a: H3 SERIES SLIDE-OUT STANDARD PREVOST SLIDE-OUT DESCRIPTION TORQUE Rack mounting bolt 1.9-2.1 lb-ft (3-3 Nm) maximum Keyless bushing 120-130 lb-ft (163-176 Nm) Drive motor/gearbox assembly mounting bolts 16-20 lb-ft (22-27 Nm) Jaw coupling clamping hubs screw 16-20 lb-ft (22-27 Nm)
  • Page 920 SECTION 26a: H3 SERIES SLIDE-OUT PA1615 Maintenance Manual All Series Section 26a revised December 2016...
  • Page 921 SECTION 26a: H3 SERIES SLIDE-OUT PREVOST SLIDE-OUT WITH FLUSH FLOOR DESCRIPTION TORQUE Stacked bearing assembly mounting bolts (8) 59 lb-ft (80 Nm) Floor lift shaft bearing clamp screws(16) 14 lb-ft (19 Nm) Floor to linear bearing bracket screws (8) 17 lb-ft (23 Nm)
  • Page 922 1: H3-45 VIP TYPICAL CONFIGURATION IGURE H3-45 VIP vehicles can accommodate up to 4 Prevost slide-outs units. Exclusive to the H3-45 VIP in the front right (curb side) position you will find a Prevost slide-out with flush floor system. Due to the high current demand and safety requirements of the slide-out system, room operation is on a "first in, first served"...
  • Page 923 SECTION 26a: H3 SERIES SLIDE-OUT by the motor shaft extension (H). Closely follow instructions provided further in this manual to perform this procedure. The system includes in and out limit proximity sensors (J) and physical inner and outer stoppers. Tilt and leveling adjustment is carried-out by the adjustment plate and screws (K). Structural integrity of the vehicle platform is ensured with stainless steel casting corner reinforcements (L) in the luggage bays and a roof reinforcement rod for the front slide-out.

  • Page 924: Inner Stopper

    SECTION 26a: H3 SERIES SLIDE-OUT 2.1 INNER STOPPER The front left 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 3 &...

  • Page 925: In Limit" Stopper

    SECTION 26a: H3 SERIES SLIDE-OUT LOWER “IN LIMIT” STOPPER 2.2 "IN LIMIT" STOPPER Each slide-out has four "in limit" stoppers. Two "in limit" stoppers are mounted on the exterior extrusion at the top of the slide-out (Figure 8) and two other "in limit" stoppers are mounted SCREW under the slide-out, next to the rail (Figure 7).

  • Page 926: Security Pin

    SECTION 26a: H3 SERIES SLIDE-OUT replace with Sika 221 sealant or equivalent 3.2 AIR CYLINDER REPLACEMENT product. 1. Ensure the parking brake is applied. 3 SECURITY PIN 2. Disconnect the cylinder air tubing from the baggage compartment (front slide-out) or During normal ride, the slide-out cannot extend under the bed structure (rear slide-out).

  • Page 927: Rack

    11: FRONT SLIDE-OUT ROOF REINFORCING IGURE (removal must be performed according to the Slide-Out Removal Procedure. Ask your Prevost service representative). This rod allows an adjustment between the slide- out horizontal member and the roof. When 2. From under the slide-out, unscrew all the screwing the turnbuckle, the roof is moved rack screws and remove the rack.

  • Page 928: Pinion

    SECTION 26a: H3 SERIES SLIDE-OUT 5. From under the slide-out, unscrew all the rack screws and remove the rack. 6. Install a new rack between the slide out structural rack seat and the pinion and tighten the screws. Use Loctite™ 242 or equivalent product.

  • Page 929: Rear Slide-Out Shaft Pinion Replacement

    SECTION 26a: H3 SERIES SLIDE-OUT mechanism from under the bed structure. Refer to paragraph 6.2. 6.4 KEYLESS BUSHING The keyless bushings need a specific tightening torque value to ensure proper pinion transmitting torque. They also need specific tools to be tightened.
  • Page 930 SECTION 26a: H3 SERIES SLIDE-OUT Take note that when the keyless bushing nut is tightened, the pinion moves about 1/16" to 3/32" toward the slide-out center. NOTE On the front slide-out, the driver side keyless bushing is not accessible for tightening or removal unless you remove the front left wheel.
  • Page 931 SECTION 26a: H3 SERIES SLIDE-OUT 18: KEYLESS BUSHING INSTALLATION INSTRUCTIONS IGURE PA1615 Maintenance Manual All Series Section 26a revised December 2016...

  • Page 932: Electric Motor

    SECTION 26a: H3 SERIES SLIDE-OUT 2. Unplug the electric cable connector. 7 ELECTRIC MOTOR 3. Remove the motor from the gearbox. The power is supplied by a 24V, 1/3 HP electric motor coupled with a speed reduction gearbox. 4. Fasten the new motor to the gearbox using screws.

  • Page 933: Jaw Coupling

    SECTION 26a: H3 SERIES SLIDE-OUT so that they are flush with the shafts extremity (Figure 21). DRIVE MOTOR/GEARBOX ASSEMBLY IGURE MOUNTING BOLTS 9 JAW COUPLING 9.1 MAINTENANCE 21: CLAMPING HUB POSITION ON GEARBOX IGURE SHAFT Inspect the jaw couplings to check if there is 8.

  • Page 934: Locking Collar

    The flange bearings are pre-lubricated and no the Slide-Out Removal Procedure. Ask your subsequent lubrication is required due to the Prevost service representative). very low extending and retracting speed of the slide-out system. 2. Disconnect the jaw coupling on the side of the linear bearing being replaced (refer to paragraph 9).

  • Page 935: Level & Tilt Adjustment

    SECTION 26a: H3 SERIES SLIDE-OUT • 7. Reinstall the support plate, retaining screws, The slide-out is retracted; blue flange bearing and reengage the jaw • The 2 lower “in limit” stoppers are perfectly coupling. Refer to the specific procedures. adjusted, that means that the lower edge of the slide-out outer panel is flush or 12.3 LEVEL &...
  • Page 936 1. Remove the slide-out from the vehicle (removal must be performed according to the Slide-Out Removal Procedure. Ask your Prevost service representative). 2. Remove the bolt hole cap covers. To do so, pierce a hole in the center and hook them out.
  • Page 937 SECTION 26a: H3 SERIES SLIDE-OUT 13.1 REMOVAL / INSTALLATION 1. Gain access to the linear bearing support plate. 2. From under the support plate, remove the acetal plastic block mounting screws (see the oblong holes on Figure 26 and arrows, Figure 29).
  • Page 938 SECTION 26a: H3 SERIES SLIDE-OUT 14 SLIDE-OUT PNEUMATIC SYSTEM The slide-out is controlled by a pneumatic and electrical system. The pneumatic system consists of electrically controlled valves that operate slide-out components and control safety operations. 32: PNEUMATIC COMPONENT PANEL IGURE for example), the valve will keep its state even if 14.1 DESCRIPTION the solenoid is deactivated.
  • Page 939 SECTION 26a: H3 SERIES SLIDE-OUT 14.3 SEAL The vacuum generator valve is activated The slide-out sealing device is used to prevent simultaneously with seal deflating valve solenoid any type of infiltration that may occur between for 10 seconds. A pressure transducer will detect the structure body and the slide-out itself.
  • Page 940 SECTION 26a: H3 SERIES SLIDE-OUT NOTE 14.3.1 Maintenance The inflatable seal pressure must be set Refer to the product specification for drying between 10 and 12 psi with the pressure time. regulator. It is recommended to check the inflatable seal pressure once a month to ensure 1.
  • Page 941 SECTION 26a: H3 SERIES SLIDE-OUT 35 ACETAL BLOCKS & LIMIT SENSORS IGURE CAUTION Do not use the slide-out control pad to move 36 TOP EXTRUSION REMOVAL IGURE the slide-out inwards. The limits are not 4. Using the manual override procedure, move recognized over the closed position.
  • Page 942 For standard Prevost slide-outs, each I/O-EB electrical diagrams of your vehicle. module has two power relays assigned. For Prevost slide-outs with flush floor, the I/O-EB A blinking green light on the control pad means module has six power relays assigned.
  • Page 943 SECTION 26a: H3 SERIES SLIDE-OUT 1. Retract the slide-out to its full “IN” position with the “in limit” stoppers in contact with their bearing surface. CAUTION 2. Loosen the “in limit” sensor mounting Never put grease, Cortec VCI-238 or other bracket screws and move back the sensor product on the multiplex modules connector completely (toward the inside of the vehicle).
  • Page 944 SECTION 26a: H3 SERIES SLIDE-OUT To adjust the "out limit" sensors: 18 SLIDE-OUT MANUAL Prior to adjusting the “out limit” sensors, ensure that the inner stoppers are perfectly adjusted OVERRIDE PROCEDURES (see paragraph 2.1). CAUTION 1. The slide-out is slightly tilted except when it is in its full “IN”...
  • Page 945 SECTION 26a: H3 SERIES SLIDE-OUT 18.1.1 Manual retracting procedure – Front CAUTION and rear slide-out 1. Turn the ignition switch to the "OFF" Slow down the closing speed as the slide-out position, and remove the ignition key for approaches its closed position. As soon as the more safety.
  • Page 946 SECTION 26a: H3 SERIES SLIDE-OUT on the inflatable seal regulator to see if the NOTE pressure is increasing to 11 psi (Figure 42). When air pressure is relieved using the shut- 19 SLIDE-OUT MAXIMUM LOAD off valve, the normal extending and retracting operation cycle is disabled, for that reason the Front slide-out: slide-out cannot be moved with the control...
  • Page 947 SECTION 26a: H3 SERIES SLIDE-OUT CAUTION Never remove the structural reinforcement angle brackets inside the baggage compartments. Doing so could lead to termination of the warranty coverage concerning the structural integrity. PA1615 Maintenance Manual All Series Section 26a revised December 2016...
  • Page 948 Integral, Derivative.) control to achieve precise and fail-safe operation of the slide-out. CAUTION Manual operation of the Prevost slide-out with flush floor differs significantly from standard Prevost slide-outs and should not be attempted unless you are familiar with the procedure.
  • Page 949 SECTION 26a: H3 SERIES SLIDE-OUT 46: FLUSH FLOOR LIFTING IGURE 47: EXTENSION MOTOR (FORE SHOWN) 48 EXTENSION MOTOR GEARS (FORE SHOWN) IGURE IGURE PA1615 Maintenance Manual All Series Section 26a revised December 2016...
  • Page 950 The electric motor and gearbox used are the same 24V, 1/3 HP motors with speed reduction gearbox as the standard Prevost slide-outs. As the room reaches its fully extended position, the mobile floor (F) is lifted in position on a pair of vertical linear bearings (G).
  • Page 951 SECTION 26a: H3 SERIES SLIDE-OUT Logic control and operation is achieved by using Volvo multiplex modules. Troubleshooting is performed through the DID. The flip-down control panel is typically located in the first road side luggage bay, attached to the ceiling. The position of the room is provided by two absolute position sensors (K), one on each side of the room.
  • Page 952 SECTION 26a: H3 SERIES SLIDE-OUT Adjustment screws on the fore rail assembly can 20.2.1 Maintenance be reached by an access hatch in the vehicle’s side wall (Figure 54). Remove the front curbside Check that the stopper screws are tight and that fender to access the hatch.
  • Page 953 SECTION 26a: H3 SERIES SLIDE-OUT Once the room is fully extended, remove the screw holding the flexible plastic rail cover in place. You will notice a notch in the plastic cover's inner end, indicating the screw position. (Figure 56) Perform this on both sides. 58 STOPPER MOUNTING NUTS IGURE The room can now be extended further.
  • Page 954 20.5 SLIDE-OUT REMOVAL behind the navigator's seat. Removal must be performed according to the 20.8.1 Manual extension on failure of Slide-Out Removal Procedure. Ask your Prevost only one motor service representative. Two persons are required for this procedure. 20.6 SLIDE-OUT INSTALLATION...
  • Page 955 SECTION 26a: H3 SERIES SLIDE-OUT 20.9 MOBILE FLOOR HAND CRANK WARNING PROCEDURE The floor lifting mechanism of the slide-out can Make sure there are no objects or persons be manually operated in the event of a power on the or around the floor while hand failure.
  • Page 956 SECTION 26a: H3 SERIES SLIDE-OUT 21 CONVERSION CHECKLIST The converter should check these points before closing the walls covering the roof reinforcing rod and the pinions: 1. Check that the front slide-out exterior panels are parallel with the vehicle panels when retracted. If not, readjust the tilt.
  • Page 957 SECTION 26a: H3 SERIES SLIDE-OUT 22.2 TROUBLESHOOTING – OPERATING CONDITIONS, CONTROL & MECHANICAL COMPONENTS PROBLEM CAUSE CORRECTIVE ACTION slide-out Something defective Request a diagnostic from the electrical system using the MCD SYSTEM DIAGNOSTIC menu. functions eventually create an issue if not repaired. normally The problem may be: handheld...
  • Page 958 SECTION 26a: H3 SERIES SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION FLUSH The slide out motors goes out of Make sure that load is distributed evenly across the FLOOR synchronization. slide out. Check for wear/obstructions in the slide ONLY out mechanism. Problem: Motor stopping temporarily during...
  • Page 959 C. Security pin still engaged in shaft. Replace damaged components. receptacle; (Standard Prevost Slide- out) C. Disengage pin and check if air cylinder is damaged. Slide-out is not A. Broken rack tooth;...
  • Page 960 SECTION 26a: H3 SERIES SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION Slide-out Acetal plastic block rubbing against Realign acetal plastic block. vibrating the slide-out structure; noisy when Replace wiper seal. extending Worn-out anti-friction coating on retracting wiper seal around slide-out; C. Remove lower acetal plastic block and machine down 1mm (0.039").
  • Page 961 SECTION 26a: H3 SERIES SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION Watertightness Inflatable seal and/or wiper seal A. Check both seals condition. problem damaged or unstuck; B. Check the pressure regulator, the relieving Insufficient air pressure in the seal; shut-off valve and the seal valve condition. C.
  • Page 962 Slide-out seal damaged or air leak Run engine at fast idle to in the seal deflating pneumatic recharge accessories tank. circuit. Accessories tank near empty. SldO Motor/Limit se Mechanical Standard Prevost slide-outs: Standard Prevost slide- outs: Or Electrical Slide-Out motor is activated for Fault...
  • Page 963 For SID items 9 & 10 (SldO Mot SpeedX Ctr) it should be noted that standard Prevost slide-outs are now only wired to ‘’SpeedA Ctr output’’. ‘’SpeedB Ctr output’’ can be used as a spare in the event output A fails. On Prevost slide-out with flush floor, the front motor is wired to ‘’SpeedA Ctr output’’;...
  • Page 964 Fix solenoid or wiring Above normal shorted to 12v or 24v harness Items 15 & 16 (SldO Mot XXX Rly) apply to standard slide outs. Applies to standard Prevost slide-outs only. PA1615 Maintenance Manual All Series Section 26a revised December 2016...
  • Page 965 Bad sensor adjustment Se_FF4_XXUp should Fault located above SeFF4_XXDn. Make sure the sensor head is adjusted 1.5mm (0.06’’) away from the sliding bracket that activates it. Applies to standard Prevost slide-outs only PA1615 Maintenance Manual All Series Section 26a revised December 2016...
  • Page 966 In the event that a sensor would require to be readjusted, contact your Prevost service representative.. 100 FFlr4 Mot Neg Rly Shorted High Relay coil or wiring harness Fix relay coil or wiring shorted to 12v or 24v...
  • Page 967 SECTION 26a: H3 SERIES SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION 102 SldO4 Mot Neg Rly Shorted High Relay coil or wiring harness Fix relay coil or wiring shorted to 12v or 24v harness Shorted Low Relay coil or wiring harness Fix relay coil or wiring shorted to ground harness...
  • Page 969 SECTION 26b: X3 SERIES SLIDE-OUT CONTENTS TORQUE TABLE ............................... 2 OVERVIEW ..............................2 INNER STOPPER .............................. 3 2.1.1 Maintenance ............................3 2.1.2 Adjustment............................. 3 "IN LIMIT" STOPPER ............................4 2.2.1 Maintenance ............................4 2.2.2 Adjustment............................. 4 EXTERIOR EXTRUSION ............................ 5 SECURITY PIN ..............................
  • Page 970 14.3.3 Seal assembly installation ........................20 14.3.4 Slide-out 2" inside retraction ....................... 21 SLIDE-OUT ELECTRICAL SYSTEM ........................ 22 15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE ................22 15.2 SLIDE-OUT BREAKERS / FUSES ........................22 15.2.1 Multiplex fuses ............................. 22 15.3 PROBING VOLTAGE ON THE MULTIPLEX CIRCUITS ..................23 15.4...
  • Page 971 SECTION 26b: X3 SERIES SLIDE-OUT ILLUSTRATIONS 1: X3-45 VIP TYPICAL CONFIGURATION ..................2 IGURE 2: TYPICAL MECHANISM OVERVIEW .................... 2 IGURE 3: FRONT SLIDE-OUT ........................3 IGURE 4: REAR SLIDE-OUT ........................4 IGURE 5: SIDE INNER STOPPER ADJUSTMENT ..................4 IGURE 6: UPPER INNER STOPPERS ADJUSTMENT ................
  • Page 972 SECTION 26b: X3 SERIES SLIDE-OUT 1 TORQUE TABLE PA1615b Maintenance Manual All Series Section 26b revised November 2016...
  • Page 973 SECTION 26b: X3 SERIES SLIDE-OUT MISCELLANEOUS DESCRIPTION TORQUE Rack mounting bolt 1.9-2.1 lb-ft (3-3 Nm) maximum Keyless bushing 120-130 lb-ft (163-176 Nm) Drive motor/gearbox assembly mounting bolts 16-20 lb-ft (22-27 Nm) Jaw coupling clamping hubs screw 16-20 lb-ft (22-27 Nm) Linear bearing mounting screws 59 lb-ft (80 Nm) Linear bearing support plate retaining screws...
  • Page 974 SECTION 26b: X3 SERIES SLIDE-OUT 2 OVERVIEW 1: X3-45 VIP TYPICAL CONFIGURATION IGURE X3-45 VIP can be fitted with up to two slide-outs. (Figure 1) 2: TYPICAL MECHANISM OVERVIEW IGURE Each slide-out is moved in and out on rails resting on linear bearings Figure 2, (B). Power comes from one electrical motor (C).

  • Page 975: Inner Stopper

    SECTION 26b: X3 SERIES SLIDE-OUT Tilt and leveling adjustment is carried-out by the adjustment plate and screws (K). Structural integrity of the vehicle platform is ensured with stainless steel casting corner reinforcements (L) in the luggage bays and a roof reinforcement rod for the front slide-out. A security pin locks the slide-out in the retracted or “in”...
  • Page 976 SECTION 26b: X3 SERIES SLIDE-OUT extrusion at the top of the slide-out (Figure 8) and two other "in limit" stoppers are mounted under the slide-out, next to the rail (Figure 7). These stoppers are used to position the outer face of the slide-out flush with the vehicle body when retracted.

  • Page 977: Exterior Extrusion

    SECTION 26b: X3 SERIES SLIDE-OUT LOWER “IN LIMIT” STOPPER replace with Sika 221 sealant or equivalent product. 3 SECURITY PIN SCREW During normal ride, the slide-out cannot extend by itself because the 740:1 ratio speed reduction worm gear type gearbox system reversible, the output shafts are self-locking.

  • Page 978: Front Slide-Out Rack Replacement

    (removal must be performed according to 11: FRONT SLIDE-OUT ROOF REINFORCING IGURE the Slide-Out Removal Procedure. Ask your Prevost service representative). This rod allows an adjustment between the slide- 2. From under the slide-out, unscrew all the out horizontal member and the roof. When rack screws and remove the rack.

  • Page 979: Rear Slide-Out Rack Replacement

    SECTION 26b: X3 SERIES SLIDE-OUT 9. Tighten the two remaining crews. Use 3. Install a new rack and tighten the screws. Loctite™ 242 or equivalent product. Use Loctite™ 242 or equivalent product on threads. TORQUE: 1.9-2.1 lb-ft (3-3 Nm) MAX TORQUE: 1.9-2.1 lb-ft (3-3 Nm) MAX 10.

  • Page 980: Front Slide-Out Shaft Pinion Replacement

    SECTION 26b: X3 SERIES SLIDE-OUT NOTE If necessary, loosen the blue and gray flange bearing to move the pinion away from the rack. 2. Assemble new pinion on the keyless bushing and then slide on the shaft. Do not tighten the bushing at this moment. 3.
  • Page 981 SECTION 26b: X3 SERIES SLIDE-OUT 6.4.1 Installation Take note that when the keyless bushing nut is tightened, the pinion moves about 1/16" to 3/32" toward the slide-out center. NOTE On the front slide-out, the driver side keyless bushing is not accessible for tightening or removal unless you remove the front left wheel.
  • Page 982 SECTION 26b: X3 SERIES SLIDE-OUT PA1615b Maintenance Manual All Series Section 26b revised November 2016...
  • Page 983 SECTION 26b: X3 SERIES SLIDE-OUT 18: KEYLESS BUSHING INSTALLATION INSTRUCTIONS IGURE PA1615 Maintenance Manual All-Series Section 26b revised November 2016...

  • Page 984: Electric Motor

    SECTION 26b: X3 SERIES SLIDE-OUT 7 ELECTRIC MOTOR The power is supplied by a 24V, 1/3 HP electric motor coupled with a speed reduction gearbox. Opposite to the gearbox, the motor is equipped with a 3/8 hexagonal socket shaft extension allowing slide-out movement without the control pad.

  • Page 985: Jaw Coupling

    SECTION 26b: X3 SERIES SLIDE-OUT 3. Remove the 4 cap screws securing the drive NOTE motor/gearbox assembly and dismount the assembly. It may be necessary to loosen the blue flange 4. Remove the gearbox from the motor and bearings to move the shaft out of the way. install the new one.

  • Page 986: Flange Bearing

    Slide-Out Removal Procedure. Ask your very low extending and retracting speed of the Prevost service representative). slide-out system. 2. Disconnect the jaw coupling on the side of the linear bearing being replaced (refer to 11 LOCKING COLLAR paragraph 9).
  • Page 987 SECTION 26b: X3 SERIES SLIDE-OUT Dismount the linear bearing and install the 12.3.1 Procedure new one. NOTE For the front slide-out, the front linear bearing leveling screws are accessible from the access panel located over the front wheel while the rear linear bearing leveling screws are accessible from the access panel in the evaporator compartment.
  • Page 988 Clean accumulated dirt from the rails with a soft cloth. 12.5 RAIL REPLACEMENT 1. Remove the slide-out from the vehicle (removal must be performed according to the Slide-Out Removal Procedure. Ask your Prevost service representative). PA1615b Maintenance Manual All Series Section 26b revised November 2016...
  • Page 989 SECTION 26b: X3 SERIES SLIDE-OUT 2. Remove the bolt hole cap covers. To do so, pierce a hole in the center and hook them out. They will not be reusable. 3. Remove the rail mounting bolts. 4. Wipe off the rust preventive oil applied to the new rail.
  • Page 990 SECTION 26b: X3 SERIES SLIDE-OUT 5. Reinstalling the upper acetal plastic blocks. Fold the wiper seal toward the outside with a flat tool to ease installation (Figure 31) and tighten the mounting screws. Leave no gap between the blocks and the rail. TORQUE: 6.5-7.5 lb-ft (9-10 Nm) LOWER ACETAL...
  • Page 991 SECTION 26b: X3 SERIES SLIDE-OUT pressure inlet valve on the pneumatic panel in the front service compartment. The slide-out air supply comes from the accessory air tank. For maintenance information, INFLATABLE SEAL VALVE refer to Section 12, “Brake and air system”. Seal inflation and deflation is done using a 5-port INFLATABLE SEAL CIRCUIT 2-position manifold valve with two solenoids.
  • Page 992 SECTION 26b: X3 SERIES SLIDE-OUT wiper seal and the exterior panels and glasses. 14.3.3 Seal assembly installation NOTE This procedure is to install the inflatable seal assembly on the structure. 34: TYPICAL INFLATABLE SEAL AIR INLET IGURE CAUTION CAUTION Make sure the inflatable seal is deflated when Always apply product in the same direction to manually moving the slide-out during service prevent dirt from being brought back.
  • Page 993 SECTION 26b: X3 SERIES SLIDE-OUT them in place for 90 to 120 seconds. Install 3. Using a knife, cut the sealant between the the lower corners next, then the straight extrusion roof. section. Press the straight inflatable seal (Figure 36) Unscrew and remove the central sections on the structure for at least 15 exterior extrusion screws and the two end seconds.
  • Page 994 “OFF” position. 15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE The slide-out power supply comes from the 24- volt circuit breaker in the rear electrical compartment. The other interconnections are located on the pneumatic panel and the...
  • Page 995 SECTION 26b: X3 SERIES SLIDE-OUT 1. Retract the slide-out to its full “IN” position CAUTION with the “in limit” stoppers in contact with their bearing surface. Never put grease, Cortec VCI-238 or other 2. Loosen the “in limit” sensor mounting product on the multiplex modules connector bracket screws and move back the sensor terminals.
  • Page 996 SECTION 26b: X3 SERIES SLIDE-OUT To adjust the "out limit" sensors: 18 SLIDE-OUT MANUAL Prior to adjusting the “out limit” sensors, ensure that the inner stoppers are perfectly adjusted OVERRIDE PROCEDURES (see paragraph 2.1). CAUTION 1. The slide-out is slightly tilted except when it is in its full “IN”...
  • Page 997 SECTION 26b: X3 SERIES SLIDE-OUT 18.1.1 Manual retracting procedure – Front CAUTION and rear slide-out 1. Turn the ignition switch to the "OFF" Slow down the closing speed as the slide-out position, and remove the ignition key for approaches its closed position. As soon as the more safety.
  • Page 998 SECTION 26b: X3 SERIES SLIDE-OUT on the inflatable seal regulator to see if the NOTE pressure is increasing to 11 psi (Figure 42). When air pressure is relieved using the shut- 19 SLIDE-OUT MAXIMUM LOAD off valve, the normal extending and retracting operation cycle is disabled, for that reason the Front slide-out: slide-out cannot be moved with the control...
  • Page 999 SECTION 26b: X3 SERIES SLIDE-OUT CAUTION Never remove the structural reinforcement angle brackets inside the baggage compartments. Doing so could lead to termination of the warranty coverage concerning the structural integrity. 20 CONVERSION CHECKLIST The converter should check these points before closing the walls covering the roof reinforcing rod and the pinions: 1.
  • Page 1000 SECTION 26b: X3 SERIES SLIDE-OUT TROUBLESHOOTING Fault diagnostic To get detailed information about the error 21.1 ERROR CONDITION OR condition or the missing operation condition, MISSING OPERATION request a diagnostic using the dashboard CONDITION Driver’s Info Display (DID). Check if there are When an error condition or a missing operation active errors in the slide-out electrical system.
  • Page 1001 SECTION 26b: X3 SERIES SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION slide-out The parking brake is not seen by the Make sure the parking brake is applied. does controller as being applied; Confirm parking brake application with the extend parking brake light on the telltale panel. Not enough air pressure in the Run the engine at fast idle a few minutes to accessory air tank to permit proper...
  • Page 1002 SECTION 26b: X3 SERIES 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 1003 SECTION 26b: X3 SERIES SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION Top of slide-out moves Roof reinforcing rod misadjusted; Readjust as per procedure. sideways when vehicle is 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;...
  • Page 1004 SECTION 26b: X3 SERIES SLIDE-OUT PROBLEM CAUSE CORRECTIVE ACTION Knocking sound when Security pin retracts too rapidly; Adjust security pin air flow parking brake is released regulator. Inflatable seal damaged or Slide-out has been retracted or extended Always deflate the seal when removed, or wiper seal with the manual procedure with the manually retracting or extending...
  • Page 1005 SECTION 26b: X3 SERIES SLIDE-OUT 21.4 SLIDE-OUT FAULT MESSAGE ON DID 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 1006 SECTION 26b: X3 SERIES SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION SldO Park Br Signal Mechanical Or Parking brake is not applied. Make sure the parking brake Electrical Fault Wire between parking brake is applied and the parking switch and MCM is open. brake telltale illuminates.
  • Page 1007 SECTION 26b: X3 SERIES SLIDE-OUT FAULT MESSAGE TEXT PROBABLE CAUSE CORRECTIVE ACTION Current Above Solenoid wiring harness Fix Solenoid or wiring normal shorted to 12v or 24v harness SldO Mot Neg Rly Shorted High Relay coil or wiring harness Fix relay coil or wiring shorted to 12v or 24v harness Shorted Low...

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H3-45H3-45 vipX3-45X3-45 vip

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