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

PREVOST H3-41 Maintenance Manual

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Table of Contents

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MAINTENANCE MANUAL
H3-41, H3-45, H3-45 VIP
X3-45, X3-45 VIP
PA1621

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Do you have a question about the H3-41 and is the answer not in the manual?

Questions and answers

Matt Kouri
May 15, 2025

cannot find adjustment or removal of 2008 H3 Prevost rear bumper

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1 comments:
Mr. Anderson
May 22, 2025

To remove the rear bumper on a 2008 Prevost H3, follow the removal procedure in reverse for installation. Use proper lifting equipment to support the bumper during removal and installation to avoid injury, as the bumper is heavy. The document does not provide specific adjustment instructions for the rear bumper.

This answer is automatically generated

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Related Manuals for PREVOST H3-41

Summary of Contents for PREVOST H3-41

  • Page 1 MAINTENANCE MANUAL H3-41, H3-45, H3-45 VIP X3-45, X3-45 VIP PA1621...
  • Page 2 PA1621 First issue: January 2017 Featuring: GHG17 engine, X series new electrical architecture and electric cooling fans. This manual is applicable to the following model year 2017 vehicles, From: H-3735 (H Series); H-6180 (X Series CAN); H-7417 (X-Series US) Including the following individual vehicles: H-3670, H-6175, H-7386, H-7395 FROM V.I.N.
  • Page 3 CRITICAL EMISSION-RELATED MAINTENANCE Source of parts and repair: A repair shop or person of the owner’s choosing must maintain, replace, or repair emission control devices and systems per manufacturer's recommendations. Replacement of tires that are GHG certified: The original equipment tires installed on this vehicle at the factory were certified to the U.S. EPA Greenhouse Gas (GHG) and National Highway Traffic Safety Administration (NHTSA) Fuel Efficiency regulations.
  • Page 5 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 7: Table Of Contents

    SECTION 00: GENERAL INFORMATION CONTENTS   SECTION CHANGE LOG ............................ 2     FOREWORD .............................. 3     SCHEMATICS  ............................... 3     PRECAUTIONS TO BE OBSERVED BEFORE WELDING .................. 3     SAFETY NOTICE  ............................ 7     DATA PLATES CERTIFICATIONS ......................  7           4.1.1 Engine ..............................  7     4.1.2 Transmission ............................ ...

  • Page 8: Section Change Log

    SECTION 00 : GENERAL INFORMATION SECTION CHANGE LOG  DESCRIPTION DATE   PA1621 Maintenance Manual All Series | January 2017...

  • Page 9: Foreword

    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 technical publications box. motorhomes listed on the front cover. This Refer to those schematics for detailed circuit information and diagnosis.
  • Page 10 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 11 SECTION 00 : GENERAL INFORMATION STEEL with STAINLESS STEEL ou STAINLESS STEEL with 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 12 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 13: 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 14: Drive Axle

    4.1.7 DOT Certification Label This certifies that vehicles manufactured by 4.1.4 Front Axles Prevost Car Inc., comply with all Federal Motor Vehicle Safety Standards at the time of manufacture. Information such as date of manufacture, model year, gross vehicle weight rating, tire types and inflation pressure is also etched on this plate.

  • Page 15: Epa Engine Label

    SECTION 00 : GENERAL INFORMATION tank access panel nuts located at the left in the replacement parts. Using the VIN when ordering condenser compartment. parts will facilitate processing. 4.1.9 EPA Engine Label The exhaust emission certification label affixed in the engine compartment certifies that the engine conforms to federal and any state exhaust emission regulations (Figure 8).
  • Page 16 SECTION 00 : GENERAL INFORMATION FIGURE 10: 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 PA1621 Maintenance Manual All Series | January 2017...

  • Page 17: Fastener

    SECTION 00 : GENERAL INFORMATION the same or greater strength than the original 5. FASTENER fasteners (the same number marking or higher). 5.1 FASTENER STRENGTH IDENTIFICATION It is also important to select replacement fasteners correct size. Correct Most commonly used metric fastener strength replacement fasteners are available through the property classes are 9.8 and 10.9 with the class parts division.

  • Page 18: 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 19 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 20: 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 21 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 22: Self-Locking Fasteners

    SECTION 00 : GENERAL INFORMATION a) Clean dirt and other foreign matter from 5.3 SELF-LOCKING FASTENERS the fastener; A self-locking fastener is designed with an b) Inspect the fastener to ensure there is no interference fit between the nut and bolt threads. crack, elongation, or other sign of fatigue This is most often accomplished by distortion of or over tightening.

  • Page 23: Six Lobed Socket Head

    SECTION 00 : GENERAL INFORMATION 5.5 SIX LOBED SOCKET HEAD Six lobed socket head (Torx) fasteners are used in some applications on vehicles covered in this manual. The tools designed for these fasteners are available commercially. However, in some cases, if the correct tool is not available, a hex socket head wrench may be used.
  • Page 24 SECTION 00 : GENERAL INFORMATION FIGURE 15: CONVERSION CHART 00006 PA1621 Maintenance Manual All Series | January 2017...

  • Page 25: 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 PA1621 Maintenance Manual All Series | January 2017...
  • Page 26 SECTION 00 : GENERAL INFORMATION PA1621 Maintenance Manual All Series | January 2017...
  • Page 27 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING Table of contents     COMMUTERS ..................................  2     H3 SERIES....................................  5     X3 SERIES  ....................................  8 Material: Equipment(s): Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: N/A Safety rules: - Wear safety goggles - Set the battery master switch to the OFF position first...
  • Page 28 PROCEDURE REFERENCE NO: PR10177-232 (COMMUTER) REVISION 00 COMMUTERS 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 8...
  • Page 29 PROCEDURE REFERENCE 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 30 PROCEDURE REFERENCE 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 possible of the...
  • Page 31 PROCEDURE REFERENCE NO: PR10177-233 (H3 SERIES) REVISION 00 H3 SERIES 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 8...
  • Page 32 PROCEDURE REFERENCE NO: PR10177-233 (H3 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 33 PROCEDURE REFERENCE NO: PR10177-233 (H3 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 possible of the...
  • Page 34 X3 SERIES For vehicles equipped with a WCL system, Cover electronic control components and disconnect electronic controller connector. wiring to protect from hot sparks, etc. Position welding machine ground clamp as Do not use TIG welding process on the close as possible to the work. Ensure that the vehicle.
  • Page 35 SECTION 01: ENGINE CONTENT    SECTION CHANGE LOG ............................ 2     TORQUE TABLES ............................ 3     X‐SERIES POWER PLANT CRADLE INSTALLATION ..................  3     BELT TENSIONERS AND IDLERS  ........................  4     H‐SERIES POWER PLANT CRADLE INSTALLATION ..................  6     VOLVO D13 ENGINE  ............................ 7     SYSTEM OVERVIEW ............................  7     OVERVIEW ..............................  8     ENGINE OIL ..............................  1 4  ...

  • Page 36: Section Change Log

    SECTION 01 : ENGINE SECTION CHANGE LOG  DESCRIPTION DATE   PA1621 Maintenance Manual All Series | January 2017...

  • Page 37: Torque Tables

    SECTION 01 : ENGINE 1. TORQUE TABLES 1.1 X-SERIES POWER PLANT CRADLE INSTALLATION X-SERIES VOLVO ENGINE 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 38: Belt Tensioners And Idlers

    SECTION 01 : ENGINE 1.2 BELT TENSIONERS AND IDLERS PA1621 Maintenance Manual All Series | January 2017...
  • Page 39 SECTION 01 : ENGINE 01226_ VOLVO ENGINE – DRIVE BELT IDLERS & TENSIONERS DESCRIPTION TORQUE Idler, water pump drive 43 lb-ft (58 Nm) pulley 16 lb-ft (22 Nm) Idler, water pump drive shaft 32 lb-ft (43 Nm) Idler, A/C compressor drive 31.5-38.5 lb-ft (43-52 Nm) Idler, A/C compressor drive 82 lb-ft (111 Nm)

  • Page 40: H-Series Power Plant Cradle Installation

    SECTION 01 : ENGINE 1.3 H-SERIES POWER PLANT CRADLE INSTALLATION H-SERIES VOLVO ENGINE 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 41: Volvo D13 Engine

    SECTION 01 : ENGINE 2. VOLVO D13 ENGINE 2.1 SYSTEM OVERVIEW NOTE The “Premium Tech Tool” (PTT) is the preferred tool for performing diagnostic work. Contact your local dealer for more information. The Engine Management System (EMS) controls many engine functions such as: fuel timing and delivery, engine protection functions, engine brake operation, EGR valve function and the turbocharger nozzle function.

  • Page 42: Overview

    SECTION 01 : ENGINE 2.2 OVERVIEW FIGURE 1: ENGINE SENSORS 1. Engine coolant temperature sensor 7. Crankshaft position sensor 2. EGR temperature sensor 8. OBD Oil pressure sensor 3. EGR differential pressure sensor 9. Crankcase pressure sensor 4. Camshaft position sensor 10.
  • Page 43 SECTION 01 : ENGINE FIGURE 2: D13H ENGINE HARNESS 1. HDE throttle connector 14. Turbocharger Speed 2. Injectors 15. Oil Pressure Sensor 3. Aftertreatment Fuel Injector Pigtail 16. Crankcase Pressure Sensor 4. Camshaft Speed 17. Crankshaft Speed 5. Venturi – DP Switch 18.
  • Page 44 SECTION 01 : ENGINE FIGURE 3: D13 ENGINE OVERVIEW, CURB SIDE SIDE 1. Mixing Chamber 8. Fuel filter (Primary) 2. Intake Manifold 9. Fuel/Water separator 3. CCV Breather Pipe 10. Fuel Filter (Secondary) 4. Air Compressor 11. Crankcase Ventilator 5. Power steering pump 12.
  • Page 45 SECTION 01 : ENGINE FIGURE 4: D13 ENGINE OVERVIEW, ROAD SIDE 15. Exhaust Manifold 21. Coolant Inlet Pipe 16. Valve Cover 22. Oil Filters 17. Thermostat Cover 23. EGR Cooler 18. Belt Tensioner 24. Turbocharger Actuator 19. Venturi 25. Starter 20.
  • Page 46 SECTION 01 : ENGINE 01222 FIGURE 5: 2010-2017 ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (1 OF 2) PA1621 Maintenance Manual All Series | January 2017...
  • Page 47 SECTION 01 : ENGINE 01222 FIGURE 6: 2010-2017 ENGINE & EXHAUST AFTERTREATMENT SYSTEM DIAGRAM (2 OF 2) NOTE For maintenance or repair information of engine components or engine-related components, please refer to Volvo Trucks USA Web Site under: Parts & Services, Online Manuals. http://www.volvotrucks.us/parts-and-services/service/online-manuals/ PA1621 Maintenance Manual All Series | January 2017...

  • Page 48: Engine Oil

    SECTION 01 : ENGINE 2.3 ENGINE OIL Keep the engine oil at the proper level and change it at the recommended intervals. Always replace the oil filters at the same time as when the oil is changed. MAINTENANCE 2.3.1 Oil Quality Engine oil and filters change Volvo North America recognizes engine oils that Change engine oil and filters at the intervals...

  • Page 49: Synthetic Lubrication

    SECTION 01 : ENGINE FIGURE 7: D13 OIL FILTERS 2.3.4 Synthetic Lubrication Synthetic oils are offered by some oil suppliers as an alternative to the traditional, petroleum based oils for engines. These oils may be used in Volvo engines, provided they meet the quality levels of the traditional, petroleum based oils for engines and provided they meet the quality level VDS-4 or VDS-5.

  • Page 50: Oil Additives

    SECTION 01 : ENGINE 2.3.6 Oil Additives CAUTION CAUTION Always dispose of all lubricants (motor oil, coolant, gear box oils, etc) and filters according to Federal or local regulations. Extra oil additives must never be added to Used oil disposed of in nature or waterways any engine oil used.

  • Page 51: Oil Filters Change

    SECTION 01 : ENGINE 2.3.9 Oil Filters Change WARNING Hot oil can cause severe burns. DO NOT allow hot oil to contact the skin. When changing oil, wear protective gloves. CAUTION Volvo-branded oil filters are designed to provide the proper level of filtration and protection for Volvo engines.
  • Page 52 SECTION 01 : ENGINE FIGURE 10: ENGINE OIL FILLING TUBE FIGURE 11: ENGINE OIL LEVEL DIPSTICK PA1621 Maintenance Manual All Series | January 2017...

  • Page 53: Power Plant Assembly Removal

    SECTION 01 : ENGINE 1. Using a vehicle lift or jack, raise vehicle to 2.4 POWER PLANT ASSEMBLY REMOVAL access transmission fasteners and wire harness. access engine engine-related components, the vehicle power plant assembly 2. From under the vehicle, disconnect the must be removed as a whole unit by means of a propeller shaft as detailed in Section 09, slide-out cradle.
  • Page 54 SECTION 01 : ENGINE 6. Close engine fuel supply shut-off valve on mounted between air cleaner housing and primary fuel filter or Fuel Pro. Disconnect turbocharger inlet. the fuel line located above fuel filters and Disconnect and remove section of connected to inlet port.

  • Page 55: Power Plant Assy. Installation

    SECTION 01 : ENGINE FIGURE 13: TYPICAL X SERIES ENGINE COMPARTMENT 4. Start engine for a visual check. Check fuel, 2.5 POWER PLANT ASSY. INSTALLATION oil, cooling, pneumatic and hydraulic system connections for leakage. Test operation of To install a power plant assembly, follow the engine controls and accessories.

  • Page 56: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    SECTION 01 : ENGINE occur when the idle position is less than 14 3. ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) & THROTTLE POSITION SENSOR counts, or when the full throttle position is more 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 57 SECTION 01 : ENGINE A=alternator C=crank pulley I=dler WP=water pump T=tensioner AC=air conditioning compressor FIGURE 15: X3 COACH BELT ROUTING I= IDLER T= TENSIONER 01233 FIGURE 16: X3 VIP BELT ROUTING – SMALL A/C FIGURE 19: X-SERIES IDLER PULLEYS, AUTOMATIC SYSTEM, BELT TENSIONERS ON ENGINE ACCESSORIES FIGURE 17: X3 VIP BELT ROUTING –...

  • Page 58: Bearing Inspection

    SECTION 01 : ENGINE 4.1 BEARING INSPECTION 1. First, set parking brake, turn the ignition OFF and set the rear start selector switch to the OFF position. 2. Remove all belts on left hand alternator, water pump drive, A/C compressor drive and alternator drive.
  • Page 59 SECTION 01 : ENGINE Prior to an actual automatic shutdown, the High VGT actuator temperature Derate only engine will automatically derate, go to idle, and High pre-Diesel Oxidation Derate only then stop in 30 seconds. Catalyst (DOC) temperature High Compressor Discharge Derate only Temperature (CDT –...

  • Page 60: 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 61 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 62 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 63 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 64 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 65 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 66 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 67 SECTION 03 : FUEL SYSTEM CONTENTS   SECTION CHANGE LOG ............................ 2     TORQUE TABLES ............................ 3     FUEL SYSTEM ..............................  3     MISCELLANEOUS TORQUES ...........................  3     FUEL SYSTEM  .............................. 4     FUEL VALVES  ..............................  4     FUEL FILTERS  ..............................  4     2.2.1 Primary Fuel Filter Replacement  ......................  5  ...

  • Page 68: Section Change Log

    SECTION 03 : FUEL SYSTEM SECTION CHANGE LOG DESCRIPTION DATE Added: information about specific fuel filters for GHG17 engines Sept. 7, 2017   PA1621 Maintenance Manual All Series | Section Revised September 2017...

  • Page 69: Torque Tables

    SECTION 03 : FUEL SYSTEM 1. TORQUE TABLES 1.1 FUEL SYSTEM     03100 03101 FUEL FILTER HOUSING – VOLVO D13 ENGINE DESCRIPTION TORQUE Fuel filter housing assembly screws 15-21 lb-ft (20-28 Nm) Dosing module mounting screws 7.5 lb-ft (10 Nm) 1.2 MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION...

  • Page 70: Fuel System

    SECTION 03 : FUEL SYSTEM Fuel pressure sensor (low pressure 2. FUEL SYSTEM system) NOTE Aftertreatment hydrocarbon injector module For additional information concerning Volvo D13 engine components or engine-related Hand pump (fuel primer pump) components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: 2.1 FUEL VALVES Parts &...

  • Page 71: Primary Fuel Filter Replacement

    SECTION 03 : FUEL SYSTEM MAINTENANCE The primary and secondary (aka pre-filter and main filter) fuel filters are of a spin-on type and must be replaced at the intervals specified by the Lubrication And Servicing Schedule in 4. Unscrew and remove Section 24: LUBRICATION &...
  • Page 72 SECTION 03 : FUEL SYSTEM 10. Clean contact surface apply CAUTION engine oil to the filter seals (inner & outer). Primary & secondary fuel filters on GHG17 engines CAUTION Do not install pre-GHG17 fuel filters on GHG17 Fuel in the old filter must absolutely not be engines.

  • Page 73: Secondary Fuel Filter Replacement

    SECTION 03 : FUEL SYSTEM Difference between secondary fuel filter end CAUTION caps Fuel in the old filter must absolutely not be poured into the new filter. This kind of contaminated fuel can damage the unit injectors. Prime the fuel system by pumping the hand priming pump on the fuel filter housing until resistance is felt indicating that the system is full of fuel.

  • Page 74: Davco Fuel Pro 382

    SECTION 03 : FUEL SYSTEM If a Fuel Pro 382 fuel processor is installed on the vehicle, refer to paragraph 2.4 Davco Fuel Pro 382 otherwise, perform the steps below: 1. Prime filter operating hand primer pump until resistance is felt indicating that the system is full of fuel.

  • Page 75: Fuel Pump Removal And Installation

    SECTION 03 : FUEL SYSTEM 9. Ensure the filter spring is installed at the top of the clear cover. If missing, the spring must be replaced to insure proper filter operation. 10. After ensuring the seal is properly positioned at the base of the clear cover, install it with the collar onto the fuel processor.

  • Page 76: Fuel Lines And Flexible Hoses

    SECTION 03 : FUEL SYSTEM   Remove the fuel pump. Start the engine and let run for 5 minutes. Make sure that there are no leaks. NOTE Only unfasten the bolts marked with arrows. 3. FUEL LINES AND FLEXIBLE HOSES Make a visual check for fuel leaks at all engine- mounted fuel lines and connections and at the fuel tank suction and return lines.

  • Page 77: Fuel Tank

    SECTION 03 : FUEL SYSTEM NOTE MAINTENANCE Before removal, the fuel tank should be completely drained by unscrewing the drain Replace preheater fuel filter at the intervals plug. Ensure that the container used has a specified by the Lubrication And Servicing capacity equal to the amount of fuel remaining Schedule in Section 24: LUBRICATION &...

  • Page 78: Tank Installation

    SECTION 03 : FUEL SYSTEM WARNING For proper assembly, check connections and fasteners for tightness. FIGURE 12: 208 US GALLONS FUEL TANK 03094 WARNING FIGURE 13: FUEL TANK RETENTION 03019_2 Before removing the bolts securing the tank For each fuel tank retainers (Figure 13): support to the frame, make sure the tank is 1.

  • Page 79: Polyethylene Fuel Tank Repair

    Fuel used must meet engine manufacturer’s drill hole is perfectly round. specification. Refer Volvo engine 4. Insert a screw (Prevost #500196) and a specifications. washer (Prevost #5001244) into anchor nut (Prevost #500331). CAUTION 5. Place assembly in drilled hole. Tighten screw ULSD fuel is necessary to avoid fouling the by 10 complete turns.

  • Page 80: Blending

    Workshop Manual for Thermo 230, 300, 350, to inhibit corrosion will be added to ULSD fuel available on the Technical Publications USB prior to its retail sale. flash drive and on Prevost technical publications website. 6.2 BLENDING 6.3.2 Biodiesel Fuels and the Engine Only ultra low sulfur kerosene –...

  • Page 81: Pre-Cleaner Servicing

    SECTION 03 : FUEL SYSTEM  7.1 PRE-CLEANER SERVICING Empty the drain rubber valve located under the filter housing; if damaged this part can be ordered and changed. MAINTENANCE UBBER DRAIN VALVE pre-cleaner designed self-cleaning; however, it should be inspected and any accumulated foreign material removed during periodic...

  • Page 82: General Recommendations

    SECTION 03 : FUEL SYSTEM ESET BUTTON FIGURE 20 7.3 GENERAL RECOMMENDATIONS The following maintenance procedures will ensure efficient air cleaner operation: FIGURE 18 1. Keep the air cleaner housing tight on the air  Replace the filter cover and tighten the 4 intake pipe;...

  • Page 83: Air Cleaner Restriction Indicator

    SECTION 03 : FUEL SYSTEM 7.4 AIR CLEANER RESTRICTION INDICATOR EFPA is serviced. In addition, the sensor should be adjusted any time codes 21 and 22 are flashed. A resettable restriction indicator may be installed With the ignition "ON" and the proper diagnostic on the engine air-intake duct, clearly visible from tool (DDR) (for information regarding the DDR, the rear engine compartment.
  • Page 84 SECTION 03 : FUEL SYSTEM FIGURE 22: ELECTRONIC FOOT PEDAL ASSEMBLY 03035 PA1621 Maintenance Manual All Series | Section Revised September 2017...

  • Page 85: Specifications

    SECTION 03 : FUEL SYSTEM 9. 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 86 SECTION 03 : FUEL SYSTEM PA1621 Maintenance Manual All Series | Section Revised September 2017...
  • Page 87 SECTION 04 : EXHAUST AND AFTERTREATMENT CONTENTS   SECTION CHANGE LOG ............................ 2     TORQUE TABLES ............................ 3     SERIES................................  3       SERIES ...............................  5       MISCELLANEOUS TORQUES ...........................  8       EXHAUST AFTERTREATMENT SYSTEM OVERVIEW .................. 9      ..............................  9 MAINTENANCE      ........................  1 0 FLEXIBLE COUPLING INSTALLATION  ...

  • Page 88: Section Change Log

    SECTION 04 : EXHAUST AND AFTERTREATMENT SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...

  • Page 89: Torque Tables

    SECTION 04 : EXHAUST AND AFTERTREATMENT 1. 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 90 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 91: H3 Series

    SECTION 04 : EXHAUST AND AFTERTREATMENT 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 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 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 Oxydation Catalyst (DOC) temperature sensor (T2) 30-37 lb-ft (41-50 Nm) * Cap screw...
  • Page 93 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 94: Miscellaneous Torques

    SECTION 04 : EXHAUST AND AFTERTREATMENT 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) PA1621 Maintenance Manual All Series | January 2017...

  • Page 95: Exhaust Aftertreatment System Overview

    SECTION 04 : EXHAUST AND AFTERTREATMENT The exhaust aftertreatment system is rubber 2. EXHAUST AFTERTREATMENT SYSTEM OVERVIEW mounted to the vehicle structure. This feature reduces the transmission of vibrations to the exhaust aftertreatment system thus resulting in extended life of the system, brackets and also noise reduction.

  • Page 96: Maintenance

    2.2 FLEXIBLE COUPLING INSTALLATION notifying the operator that an ash cleaning is required. Clean remanufactured DPF cartridge The flexible coupling contains a rigid interior will be available through Prevost on an pipe ( exchange basis. For most vehicle applications duty...

  • Page 97: Diesel Particulate Filter Assembly Removal

    SECTION 04 : EXHAUST AND AFTERTREATMENT 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 98: Catalytic Converter

    SECTION 04 : EXHAUST AND AFTERTREATMENT CAUTION HEAVY DEVICE A suitable lifting or holding device is required. Properly support and attach lifting equipment to prevent the DOC and DPF assembly from falling when servicing. 5. Unfasten clamps holding DOC and DPF FIGURE 4: TAKING DOC AND DPF APART assembly;...

  • Page 99: Removal

    SECTION 04 : EXHAUST AND AFTERTREATMENT need any maintenance. Unless an accident or damage occurs in the vicinity of the engine compartment; the catalytic converter will not have to be replaced. However if the catalytic converter must be replaced, following procedures: 4.1 REMOVAL Procedure # 1...

  • Page 100: Assembling Catalytic Converter

    SECTION 04 : EXHAUST AND AFTERTREATMENT   Remove disconnect piece Disconnect catalytic converter outlet NOx equipment or component that might be in sensor. the way or that might prevent removing the  Remove clamps holding catalytic converter catalytic converter. then lower.
  • Page 101 SECTION 04 : EXHAUST AND AFTERTREATMENT regard to the clamp supports on the catalytic converter. Upper Lower Assembling  Position the upper clamps above the upper Upper emboss and the lower clamps below the lower emboss of the catalytic converter. Lower CLAMP Lower...

  • Page 102: Diffuser Assembly

    SECTION 04 : EXHAUST AND AFTERTREATMENT 5.1 DIFFUSER ADJUSTMENT Should an adjustment of the diffuser position be necessary, first remove exhaust aftertreatment roof ventilation grill. CAUTION To prevent paint damage and fiberglass overheating caused by hot exhaust gases, the diffuser louvered cover must be flush with the ...

  • Page 103: Maintenance

    SECTION 04 : EXHAUST AND AFTERTREATMENT 5.2 MAINTENANCE At vehicle inspection intervals, inspect the diffuser assembly as follows:  Inspect diffuser grille for stress cracking;  Check for presence of foreign matter and debris inside the diffuser housing, remove and clean if applicable; ...

  • Page 104: Diesel Exhaust Fluid

    SECTION 04 : EXHAUST AND AFTERTREATMENT  The DEF solution is highly corrosive to 6.1 DIESEL EXHAUST FLUID certain metals, including copper When handling DEF solution, it is important that aluminum. electrical connectors to be connected or well  If the DEF solution is spilled onto the vehicle, encapsulated, otherwise there is a risk that the wipe off the excess and rinse with water.

  • Page 105: Def Tank Cleaning

    SECTION 04 : EXHAUST AND AFTERTREATMENT FIGURE 10: H SERIES DEF TANK AND PUMP FIGURE 11 X SERIES DEF TANK AND PUMP 1. Put a suitable container under the DEF tank. 6.2 DEF TANK CLEANING 2. Remove the DEF tank drain plug through the Removing the DEF tank for cleaning is not DEF tank support pan access hole.

  • Page 106: Pump Assembly Filter Element Replacement

    SECTION 04 : EXHAUST AND AFTERTREATMENT 3. Let all of the DEF drain from the tank. 3. Remove filter cover. Discard the used DEF according to local regulations. CAUTION 4. Remove the DEF tank filler neck insert. To Contamination or damage of the sealing do so, release the retaining tab and remove surface on the housing is not acceptable.

  • Page 107: Filler Nec Kstrainer

    SECTION 04 : EXHAUST AND AFTERTREATMENT Then check the DPF soot level with SOOT CAUTION LEVEL GAUGE. Check if there are cracks around the area of the filter cover. No cracks in the material are MAINTENANCE allowed. Aftertreatment hydrocarbon doser MAINTENANCE Replace the aftertreatment hydrocarbon doser at the intervals specified by the Lubrication And...
  • Page 108 SECTION 04 : EXHAUST AND AFTERTREATMENT Remove the aftertreatment hydrocarbon injector mounting fasteners. Remove the aftertreatment hydrocarbon injector from the diffuser pipe (which attaches to the turbocharger outlet). Clean the sealing surface on the diffuser pipe before mounting the aftertreatment hydrocarbon injector.
  • Page 109 SECTION 05A: H3 SERIES COOLING SYSTEM CONTENTS    SECTION CHANGE LOG ............................ 3     TORQUE TABLES ............................ 4     HOSE CLAMPS  ..............................  4     PULLEY, IDLERS & TENSIONERS ........................  5     COOLING FAN DRIVE MECHANISM  ........................  6     RIGHT ANGLE GEARBOX ..........................  7     MISCELLANEOUS TORQUES ...........................  8     DESCRIPTION  .............................. 9  ...
  • Page 110 SECTION 05A: H3 SERIES COOLING SYSTEM     14.1 LOCKING RADIATOR FAN CLUTCH FOR EMERGENCY OPERATION ..............  2 6     14.1.1 Electrical Locking ..........................  2 6     14.1.2 Mechanical Locking In Case Of Power Failure ..................  2 6     14.2 MAINTENANCE ............................  2 6     14.3 INSPECTION ..............................  2 6     14.4 FAN REMOVAL / INSTALLATION ........................  2 7  ...

  • Page 111: Section Change Log

    SECTION 05A: H3 SERIES COOLING SYSTEM SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...

  • 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) PA1621 Maintenance Manual All Series | January 2017...

  • 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) Coolant level sensor (arrow on side must point up) 2 Threads out MAX* * Use Teflon –...
  • Page 117 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 closed thermostats direct coolant flow from the to effectively dissipate the heat generated by the thermostat housing through the by-pass tube to engine.

  • Page 118: Maintenance

    SECTION 05A: H3 SERIES COOLING SYSTEM MAINTENANCE NOTE GENERAL RECOMMENDATIONS For additional information concerning Volvo D13 engine components or engine-related A systematic routine inspection of cooling components, consult Volvo Trucks Canada or system components is essential to ensure Volvo Trucks North America Web Site under: 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 5: COOLANT FLOW TO RADIATOR (VOLVO D13) A torque wrench should be used for proper installation.

  • Page 120: Oetiker Screw Clamps

    SECTION 05A: H3 SERIES COOLING SYSTEM 3. Position the open clamp around the hose. Locate the tongue in the groove and position the apertures of the mechanical interlock over the mating features. Engage the interlock at the smallest possible diameter. 4.

  • Page 121: Thermostat Operation

    SECTION 05A: H3 SERIES COOLING SYSTEM FIGURE 13: VOLVO D13 THERMOSTAT HOUSING 3. Install the new thermostat. Make sure that the rubber seal remains properly seated. FIGURE 12: CHARGE AIR COOLER HOSE CLAMPS 4. Position the thermostat housing to the cylinder head, install and tighten the bolts.

  • Page 122: Coolant

    SECTION 05A: H3 SERIES COOLING SYSTEM CAUTION Do not run engine with the “Check Engine” light flashing. The level probe is mounted on the front of the 3. Now warm the water to 100°C (212°F). After surge tank. at least 30 seconds at the boiling point, check that the thermostat has opened at THAWING COOLING SYSTEM least 7mm (9/32in).

  • Page 123: Coolant Sampling

    SECTION 05A: H3 SERIES COOLING SYSTEM A decal located on the surge tank provides WARNING information on recommended coolants. Before proceeding with the following steps, CAUTION make sure the coolant has cooled down. The sudden release of pressure from a heated On Volvo D13 engine, use only Extended Life cooling system can result in loss of coolant Coolant (ELC).

  • Page 124: Draining Cooling System

    SECTION 05A: H3 SERIES COOLING SYSTEM 2. Thread the sample bottle to the pump. Hand tightens. MAINTENANCE 3. Slide the plastic tubing in the fitting on the Cooling system pump until it exceeds about 1/2 inch into pump cavity. Drain, flush, thoroughly clean and refill the system at the intervals specified by the 4.

  • Page 125: Filling Cooling System

    SECTION 05A: H3 SERIES COOLING SYSTEM 5. Connect coolant extractor (Figure 16). Use CAUTION coolant extractor to drain the coolant from the engine. An alternate method is to drain the Drain water pump completely before extended coolant into a suitable container using the storage avoid possible...

  • Page 126: Flushing

    SECTION 05A: H3 SERIES COOLING SYSTEM Fill with a 50/50-antifreeze/water solution NOTE and add required inhibitors. If for any reason, the coolant level drops Vehicles with coolant filters: below the surge tank level probe, the Check Engine warning light will illuminate. Fill with a 50/50-antifreeze/water solution.

  • Page 127: Reverse Flushing

    SECTION 05A: H3 SERIES COOLING SYSTEM 4. Drain descaling solution from the cooling 1. Remove the thermostats and the water system. pump. 2. Attach a hose to the water inlet of oil cooler 5. Refill with clean water and carefully rinse the housing to drain water away from engine.

  • Page 128: Radiator

    SECTION 05A: H3 SERIES COOLING SYSTEM oil, kerosene, gasoline, or any caustic material. CAUTION It may be necessary to clean the radiator more frequently if the vehicle is operated in exceed recommended service extremely dusty or dirty areas. Refer to coolant intervals.
  • Page 129 SECTION 05A: H3 SERIES COOLING SYSTEM FIGURE 22: ACCESS PANEL BEHIND TAG AXLE WHEEL 8. Open radiator door to access radiator assembly. Unfasten upper arm assembly FIGURE 20: REAR START PANEL (Figure 23). 4. Connect coolant extractor (Figure 16). Use coolant extractor to drain the coolant from the engine.
  • Page 130 SECTION 05A: H3 SERIES COOLING SYSTEM 13. Remove the lower radiator assembly tube protector from the lower section (Figure 28). FIGURE 25: FRONT COOLANT & CHARGE AIR PIPES 11. Remove rear coolant and charge air hose clamps then break hoses loose (Figure 26). FIGURE LOWER RADIATOR...
  • Page 131 SECTION 05A: H3 SERIES COOLING SYSTEM FIGURE 30: DISCONNECTING FAN DRIVE SHAFT 16. Position forklift under radiator assembly that is capable of safely lifting the radiator. FIGURE 32: SEPARATING CHARGE AIR COOLER 19. Lay radiator face down. Remove the fasteners that connect lower radiator mounts to radiator.

  • Page 132: Charge Air Cooler (Cac) Leakage

    SECTION 05A: H3 SERIES COOLING SYSTEM FIGURE 34: REMOVING UPPER FAN DRIVE SUPPORT 1. Unwrap the drive belt from around the pulley BRACKET (see paragraph MOUNTING THE DRIVE BELT). 21. With assistance, remove fan drive and drive frame from radiator. 2.

  • Page 133: Variable Speed Cooling Fan

    SECTION 05A: H3 SERIES COOLING SYSTEM VARIABLE SPEED COOLING FAN WARNING The cooling fan clutch has two thermostatically controlled speeds, plus neutral (clutch Set the ignition to the OFF position and disengaged). engine control module remove the key from the contact switch to controls the speed by comparing data from prevent accidental starting of the engine.

  • Page 134: Locking Radiator Fan Clutch For Emergency Operation

    3. Unscrew and remove the 4 spare M6x12 hex proceeding. Assistance is available through bolts screwed to the angle on the fan the Prevost After-Sales Service support gearbox mounting support (FIGURE 40). serving your area. 4. Screw in 4 hex bolts through the clutch 14.3...

  • Page 135: Fan Removal / Installation

    SECTION 05A: H3 SERIES COOLING SYSTEM  Check drive belt for fraying, cracking, and 15.1 MAINTENANCE proper tension.  Turn fan through at least 360° of rotation. It MAINTENANCE should turn smoothly with no resistance. 14.4 FAN REMOVAL / INSTALLATION Change the right angle gearbox oil only at operating temperature at the intervals specified The fan is bolted to the right angle gearbox shaft...

  • Page 136: Removal / Installation

    SECTION 05A: H3 SERIES COOLING SYSTEM bolts as specified in the torque table at the WARNING beginning of this section. Note that warranty may be voided if oil change interval is not respected or an inappropriate type of oil is used. Refer to refer to Linnig bulletin 142.377 for the list of approved oils.
  • Page 137 SECTION 05A: H3 SERIES COOLING SYSTEM belt and hold the tensioner in that position rotating or moving parts. (Figure 46). 3. Finally, place the drive belt around the engine crankshaft pulley. 4. Release the tensioner slowly and let it return to its natural position.
  • Page 138 Fully closed ............................185°F (85°C) Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2213 Qty ..................................1 Prevost number ............................5060096 Coolant (ELC) - Volvo D13 Engine Volvo Number ............................20358716 Texaco CPS .............................. 227998 Chevron CPS ............................227811 Coolant Filter Cartridge –...
  • Page 139 SECTION 05B: X3 SERIES COOLING SYSTEM CONTENTS   SECTION CHANGE LOG ............................ 2     TORQUE TABLES ............................ 3     HOSE CLAMPS  ..............................  3     PULLEYS, IDLERS & TENSIONNERS  .........................  4     COOLING ASSEMBLY ............................  5     MISCELLANEOUS  ............................  6     DESCRIPTION  .............................. 7    ...

  • Page 140: Section Change Log

    SECTION 05B: X3 SERIES COOLING SYSTEM SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series January 2017...

  • Page 141: Torque Tables

    SECTION 05B: X3 SERIES COOLING SYSTEM TORQUE TABLES HOSE CLAMPS 05179 HOSE CLAMPS DESCRIPTION TORQUE Hose clamps - coolant lines (2.5in O.D) 30 lb-in (3.39 Nm) Constant-torque hose clamps - charge air cooler (CAC) 4.5-5.5 lb-ft (6.1-7.46 Nm) PA1621 Maintenance Manual All Series January 2017...

  • Page 142: Pulleys, Idlers & Tensionners

    SECTION 05B: X3 SERIES COOLING SYSTEM PULLEYS, IDLERS & TENSIONNERS 01225_3 PULLEYS, IDLERS & TENTIONERS DESCRIPTION TORQUE Water pump idler pulley bolts 16 lb-ft (22 Nm) Crank pulley bolts 22 lb-ft (30 Nm) Idler bolt – water pump 43 lb-ft (58 Nm) Automatic belt tensioner bolt –...

  • Page 143: Cooling Assembly

    SECTION 05B: X3 SERIES COOLING SYSTEM COOLING ASSEMBLY COOLING ASSEMBLY DESCRIPTION TORQUE CAC upper & lower mounting bolts (with plastic bushings) 9 lb-ft (12 Nm) Radiator to cooling pack frame mounting bolts (pass through) 9 lb-ft (12 Nm) Cooling pack frame bolts (all 8mm bolts – both sides) 9 lb-ft (12 Nm) Brackets, fan shroud hinge, shroud support &...

  • Page 144: Miscellaneous

    SECTION 05B: X3 SERIES COOLING SYSTEM MISCELLANEOUS 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) Electric cooling fan mounting bolts 30 lb-in (3 Nm) Coolant level sensor (arrow on side must point up) 2 Threads out MAX*...
  • Page 145 SECTION 05B: X3 SERIES COOLING SYSTEM Upon starting a cold engine or when the coolant DESCRIPTION is below normal operating temperature, the closed thermostat directs coolant flow from the A radiator and variable speed electric cooling thermostat housing through the by-pass tube to fans are used to effectively dissipate the heat the water pump.
  • Page 146 SECTION 05B: X3 SERIES COOLING SYSTEM FIGURE 1: COOLING ASSEMBLY & RELATED COMPONENTS FIGURE 2: COOLANT SURGE TANK PA1621 Maintenance Manual All Series January 2017...

  • Page 147: Maintenance

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

  • Page 148: Constant-Torque Hose Clamps On Charge Air Cooler (Cac)

    SECTION 05B: X3 SERIES COOLING SYSTEM CONSTANT-TORQUE HOSE CLAMPS ON CHARGE AIR COOLER (CAC) If for any reason hose clamps need to be replaced; install and tighten hose clamps to specified torque (dry) (Figure 6). TORQUE: 4.5-5.5 lb-ft (6.1-7.46 Nm) CAUTION The hose clamps will break if over-tighten.

  • Page 149: Coolant

    SECTION 05B: X3 SERIES COOLING SYSTEM 2. After at least 30 seconds, check that the thermostat is still closed. 3. Now warm the water to 100°C (212°F). After at least 30 seconds at the boiling point, check that the thermostat has opened at least 7mm (9/32in).

  • Page 150: Coolant Recommendations For Volvo D13 Engine

    SECTION 05B: X3 SERIES COOLING SYSTEM COOLANT RECOMMENDATIONS FOR VOLVO D13 ENGINE The coolant provides a medium for heat transfer and controls the internal temperature of the engine during operation. In an engine having proper coolant flow, some of the combustion Recommended coolants for Volvo D13 heat is conveyed through the cylinder walls and engine:...
  • Page 151 SECTION 05B: X3 SERIES COOLING SYSTEM FIGURE 8: LOCATION OF HEATER LINE SHUT-OFF VALVES IN ENGINE COMPARTMENT PA1621 Maintenance Manual All Series January 2017...

  • Page 152: Coolant Sampling

    SECTION 05B: X3 SERIES COOLING SYSTEM Sampling should be performed on the surge COOLANT SAMPLING tank, on a cold engine. Providing a sample of coolant for lab analysis If the vehicle has been standing still for a may be required at some point in the life of the significant period, drive it around 30 min up to vehicle.
  • Page 153 SECTION 05B: X3 SERIES COOLING SYSTEM NOTE Refer to section 22 under "Preheating System" for information about preheater access and heater line shutoff valve. MAINTENANCE Cooling system Drain, flush, thoroughly clean and refill the system at the intervals specified by the Lubrication And Servicing Schedule in Section 24: LUBRICATION &...

  • Page 154: Filling Cooling System

    SECTION 05B: X3 SERIES COOLING SYSTEM FILLING COOLING SYSTEM cores as explained in Section 22, under “Bleeding Heating System”. If only the engine and related components were drained, maintain the two heater line shutoff FLUSHING valves in their closed position, then proceed as If the cooling system is contaminated, flush the follows: cooling system as follows:...

  • Page 155: Reverse Flushing

    SECTION 05B: X3 SERIES COOLING SYSTEM 3. Add the required amount of a reputable The radiator is reverse flushed as follows: commercially available de-scaling product 1. Remove the radiator inlet and outlet hoses (aluminum & copper compatible). It is and replace existing radiator cap with a new important that product...

  • Page 156: Cooling Assembly

    SECTION 05B: X3 SERIES COOLING SYSTEM the engine. The two first fans are used by the To replace a filter: charge air cooler (CAC) to cool the hot 1. Close the filter shutoff cock on the filter compressed air coming from the turbocharger; mounting head and unscrew the old filter the remaining 6 fans are used by the radiator.
  • Page 157 SECTION 05B: X3 SERIES COOLING SYSTEM 11.1 MAINTENANCE FIGURE 12: COOLING ASSEMBLY MAIN COMPONENTS WARNING WARNING Cooling fans may activate at any moment Cooling fans may start when the engine is when engine is running. shut down in the following conditions: ...

  • Page 158: Cooling Fan Replacement

    SECTION 05B: X3 SERIES COOLING SYSTEM CAUTION MAINTENANCE Fans are factory balanced by the use of small Inspect fan blades regularly, check for dirt or metal weight clipped to the fan blades, to grime accumulations on the blade that could avoid damaging vibrations...

  • Page 159: Cooling Fan Shroud Removal & Installation

    SECTION 05B: X3 SERIES COOLING SYSTEM  Reverse removal procedure to reinstall the Turn the smaller wiring connector 1/3 fan and apply specified torque to the fan turn counterclockwise. frame mounting screws.  Remove wires from wire TORQUE: 30 lb-in (3 Nm) separator and move them out of the way.

  • Page 160: Cooling Pack (Radiator & Cac) Removal & Installation

    SECTION 05B: X3 SERIES COOLING SYSTEM 5. Unfasten the limiter strap at the bottom of 11.4 COOLING PACK (RADIATOR & CAC) the shroud assembly. REMOVAL & INSTALLATION NOTE 6. Support the bottom of the shroud assembly with a lift table or other suitable equipment. For CAC only replacement, removal of the entire cooling pack is not necessary.
  • Page 161 SECTION 05B: X3 SERIES COOLING SYSTEM When replacing the CAC or radiator unit only, ensure that: The rubber seal is present all around the radiator perimeter and that it is in good condition (replace as necessary). Both rubber strips (upper & lower) are present and in good shape at the edge of the upper and lower support section (fan side only).
  • Page 162 SECTION 05B: X3 SERIES COOLING SYSTEM 5. Access the heater shut-off valve located 9. Also disconnect the upper CAC pipe at the behind the access panel and set it to the mid pipe junction. closed position. 6. Set the second heater shut-off valve, located in the engine compartment below the turbocharger outlet to CAC pipe, at the closed position.
  • Page 163 SECTION 05B: X3 SERIES COOLING SYSTEM FIGURE 24: COOLING PACK SUPPORTS AND COMPONENTS 14. Remove the radiator door lower hinge 15. Remove the protective (splash) plate fixed to bracket. the cooling pack lower support. FIGURE 25: RADIATOR DOOR LOWER HINGE BRACKET FIGURE 26: PROTECTIVE PLATE MOUNTING BOLTS PA1621 Maintenance Manual All Series January 2017...
  • Page 164 SECTION 05B: X3 SERIES COOLING SYSTEM 16. Support the cooling assembly with a lift table 20. To proceed to the radiator replacement, positioned under the lower support. remove radiator upper pipe section, bracket and hardware, unbolt the four support bolts passing through the radiator and holding it to 17.
  • Page 165 SECTION 05B: X3 SERIES COOLING SYSTEM NOTE Reinstallation of the cooling components as a complete assembly is recommended. - Install fan shroud on the cooling pack frame then install complete assembly to vehicle structure. 24. Lay the cooling pack horizontally at working height (use large workbench or sawhorses) FIGURE 31: SHROUD HINGES INSTALLATION exterior face pointing up.

  • Page 166: Charge Air Cooler (Cac) In Vehicle Removal

    SECTION 05B: X3 SERIES COOLING SYSTEM 32. Slide back the cooling assembly into 5. Disconnect the upper CAC pipe at the position and reverse removal procedure to middle section junction, also loosen the reinstall in vehicle. hose clamps at the CAC connection and pivot down the pipe to clear radiator.
  • Page 167 SECTION 05B: X3 SERIES COOLING SYSTEM FIGURE 36: COOLING PACK EXPLODED VIEW 7. Remove CAC upper front frame structure by 8. Remove the CAC lower front frame structure unscrewing the 11 hex bolts holding it. by unscrewing the 8 hex bolts holding it. FIGURE 37: UPPER FRAME BOLTS FIGURE 38: LOWER FRAME BOLTS PA1621 Maintenance Manual All Series...
  • Page 168 SECTION 05B: X3 SERIES COOLING SYSTEM 9. Also remove the CAC lateral support (3 hex WARNING bolts). To prevent galvanic corrosion, the CAC upper brackets need to be electrically insulated from the CAC body. When reinstalling brackets, make sure the plastic insulating bushings (two per bracket) &...
  • Page 169 SECTION 05B: X3 SERIES COOLING SYSTEM 14. Install CAC on the vehicle and secure to the lower support using both lower hex bolts, washers and remaining plastic insulating bushings. TORQUE: 9 lb-ft (12 Nm) WARNING To prevent galvanic corrosion, the CAC is electrically insulated from the support by the use of plastic insulating bushings.

  • Page 170: Specifications

    Coolant (ELC) - Volvo D13 Engine Volvo Number ............................20358716 Texaco CPS .............................. 227998 Chevron CPS ............................227811 Coolant Filter Cartridge – Volvo D13 Engine Number used ................................ 1 Type ................................Spin-on Prevost number ............................. 20458771 PA1621 Maintenance Manual All Series January 2017...
  • Page 171 SECTION 06A : H3 SERIES ELECTRICAL CONTENTS    SECTION CHANGE LOG ............................ 4     TORQUE TABLES ............................ 5     ALTERNATORS AND SURROUNDING COMPONENTS  ..................  5     ELECTRICAL CONNECTIONS AND BATTERIES ....................  6     GENERAL DESCRIPTION  .......................... 7     WIRING DIAGRAMS ............................  7     2.1.1 Using Wiring Diagrams  ..........................  7     2.1.2 Testing Circuits ...
  • Page 172 SECTION 06A: H3 SERIES ELECTRICAL     4.14.2 BATTERY warning Pictogram MAY appear as a reminder ..............  2 6     PRIME ENERGY MANAGEMENT SYSTEM ....................  2 6     DESCRIPTION ...............................  2 6     COMPONENTS .............................  2 6     5.2.1 Vanner 80 Series Battery Equalizer Fault Codes ..................  2 8     DID DISPLAY ..............................  2 9     TROUBLESHOOTING AND TESTING THE MULTIPLEX VEHICLES ..............  2 9  ...
  • Page 173 SECTION 06A: H3 SERIES ELECTRICAL     11.1.4 Replacing Front Turn Signal LED module .....................  5 0     11.1.5 Optional Xenon Headlamp (Low Beam)  ....................  5 0     11.1.6 Aiming headlights ..........................  5 1     11.2 STOP, TAIL, DIRECTIONAL, BACK‐UP, AND HAZARD WARNING LIGHTS ............  5 2     11.2.1 Lamp Removal And Replacement ......................  5 2     11.2.2 High‐Mounted Stop Light Removal And Replacement ................ ...

  • Page 174: Section Change Log

    SECTION 06A: H3 SERIES ELECTRICAL SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...

  • Page 175: Torque Tables

    SECTION 06A: H3 SERIES 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 176: Electrical Connections And Batteries

    SECTION 06A: H3 SERIES ELECTRICAL Alternator mounting bolts inner (2) 48 lb-ft (65 Nm) Alternator mounting bolts outer (2) 82 lb-ft (111 Nm) Alternator bottom bracket mounting bolt (small A/C system) 48 lb-ft (65 Nm) 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)

  • Page 177: General Description

    12, you will find the location, the b) At item CB differently and feature AGM batteries and a Prevost number, the breaker function, the Vanner Vann-Bus 80 Series battery equalizer. breaker ampere rating and the page on which to find the corresponding diagram.

  • Page 178: Testing Circuits

    SECTION 06A: H3 SERIES ELECTRICAL the display. Use the down arrow to see all the WIRE SIZES AND COLORS fault messages. Each wire in the electrical system has a specific Problem: DID displays the fault "Elec. Horn size as designated on the wiring diagram. When SW61 SW62;...

  • Page 179: Circuit Breakers

    SECTION 06A: H3 SERIES ELECTRICAL Consequently 2.4.1 H3 coaches , 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. CAUTION Wire size is calibrated according to the breaker or fuse that protects it.

  • Page 180: H3-45 Vip

    SECTION 06A: H3 SERIES ELECTRICAL 2.4.2 H3-45 VIP NOTE Smaller circuit breakers may be located in the Each relay is identified with “12V” or “24V” VECF of the front service compartment. printed on its casing in order to identify the coil operating voltage.
  • Page 181 SECTION 06A: H3 SERIES ELECTRICAL the diagnostic codes history and the instrument cluster clock will have to be reset. CAUTION Prior to arc welding on the vehicle, refer to "Multiplex Modules Disconnection Procedure Prior To Welding" in section 00 GENERAL of this manual to avoid serious damage to the vehicle components.
  • Page 182 Gently remove the terminal from the connector 06630 by pulling on the wire. EXTRACTOR/TOOL: Prevost #682256 (Packard 12094429) INS ERT EXT RACT OR Remove the terminal by disengaging the flexible lock tab on the HERE terminal.

  • Page 183: Electrical Compartments

    SECTION 06A: H3 SERIES ELECTRICAL ELECTRICAL COMPARTMENTS FIGURE 4: ELECTRICAL COMPARTMENTS MAINTENANCE MAIN POWER COMPARTMENT A corrosion inhibitor has been sprayed on The main power compartment is located on rear certain electrical components in order to protect R.H. side vehicle behind rear them from corrosion.

  • Page 184: Battery Charger

    SECTION 06A: H3 SERIES ELECTRICAL  OBD13 3.2.1 Battery Charger connector C464A (On-Board Diagnostic); The vehicle may be equipped with a battery  Electronic ground stud. charger. Connect it to an external 110-120 VAC power source using the receptacle located on the engine compartment R.H.

  • Page 185: A/C And Heating Controls

    SECTION 06A: H3 SERIES ELECTRICAL A/C AND HEATING CONTROLS To access the pneumatic accessory panel of the right console, remove the panel under the larger utility compartment at the right of the dashboard. The following components are located in the Evaporator Compartment (HVAC).

  • Page 186: Group 31 Agm Batteries

    SECTION 06A: H3 SERIES ELECTRICAL WARNING ° DO NOT tip battery by more than 45 when carrying or installing the battery. NOTE Evidence of electrolyte leakage does not necessarily mean the battery is defective. GROUP 31 AGM BATTERIES If your vehicle is equipped with PRIME energy management system, it is provided with four (4) Absorbed Glass Mat (AGM) 12-volt batteries connected in series-parallel (...
  • Page 187 SECTION 06A: H3 SERIES ELECTRICAL CAUTION Replace only with AGM type batteries of the same specification and capacity. PRIME system is programmed for the charging capacity of the batteries installed. Installing a higher capacity battery will affect the battery life as the system will not fully charge the batteries, which is detrimental to battery performance.
  • Page 188 SECTION 06A: H3 SERIES ELECTRICAL FIGURE 12: H3 SERIES AGM BATTERY CONNECTIONS (PRIME SYSTEM) PA1621 Maintenance Manual All Series | January 2017...

  • Page 189: Battery Discharge Protection

    SECTION 06A: H3 SERIES ELECTRICAL DANGER BATTERY DISCHARGE PROTECTION prevent possible electric shocks To prevent discharge of the batteries when the sparking, the battery master switches should engine in not running, some functions are be in the "Off" position before disconnecting automatically switched off if the batteries voltage cables from the batteries.

  • Page 190: Battery Rating

    SECTION 06A: H3 SERIES ELECTRICAL 4.7.1 Visual Inspection NOTE 1. Check the outside of the battery for a broken A protective coating should be applied on or cracked cover or case that could permit certain power connections that have been loss of electrolyte.

  • Page 191: Testing Battery Cables

    SECTION 06A: H3 SERIES ELECTRICAL CAUTION DANGER Observe polarity of the meters and the battery To prevent the engine from starting during when making connections, and select the these tests, remove fuses F78 and F79 correct meter range. located in the VECR of the rear electrical compartment.

  • Page 192: Battery Charging

    SECTION 06A: H3 SERIES ELECTRICAL BATTERY CHARGING The batteries used on this vehicle can be charged either on or off the vehicle; however, when they are removed from the vehicle, it is recommended that an adapter kit, which is available from any "A/C DELCO" dealer, be used in charging sealed-terminal batteries.

  • Page 193: Emergency Jump Starting With Auxiliary (Booster) Battery

    SECTION 06A: H3 SERIES ELECTRICAL 4.8.2 Emergency Jump Starting With Auxiliary Charge voltage: 13.8-14.6 Volt @77°F (25°C) (Booster) Battery. Float voltage: 13.4-13.6 Volt @77°F (25°C) DANGER Charging AGM battery on a typical constant current or taper current charger – even one time –...

  • Page 194: Agm Battery Charging Precautions

    SECTION 06A: H3 SERIES ELECTRICAL Apply parking brake and place the transmission BATTERY CHARGING shift lever or push-button pads in Neutral (N) PRECAUTIONS position in both vehicles. Turn off lights, heater and other electrical loads. AGM (Absorbed Glass Mat) batteries require a The following procedure should be used only voltage-limited, temperature corrected charger.

  • Page 195: Common Causes Of Battery Failure

    SECTION 06A: H3 SERIES ELECTRICAL 4. Dirt and electrolyte on top of the batteries causing a constant drain. MAINTENANCE 5. Hardened battery plates, due to battery being in a low state of charge over a long Battery terminals period of time. Clean and coat terminals with Nyogel at the 6.

  • Page 196: Battery Voltage Warning" Pictogram

    SECTION 06A: H3 SERIES ELECTRICAL 4.14 "BATTERY VOLTAGE WARNING” appear even if the batteries are in the right PICTOGRAM voltage range. Confirm battery voltage is indeed correct with the DID Gauges screen and if you do need to leave the ignition ON for a prolonged period, If the “BATTERY VOLTAGE WARNING"...
  • Page 197 SECTION 06A: H3 SERIES ELECTRICAL The compressor duty cycle control is achieved by an electric air dryer. This is covered in section 12 of this manual. FIGURE 16: PRIME ELECTRICAL COMPONENT PA1621 Maintenance Manual All Series | January 2017...

  • Page 198: Vanner 80 Series Battery Equalizer Fault Codes

    SECTION 06A: H3 SERIES ELECTRICAL 5.2.1 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 199: Did Display

    SECTION 06A: H3 SERIES ELECTRICAL Inactive Multiplex input = Residual voltage of 50% of supply voltage. DID DISPLAY NOTE In the DID you will find the percentage of trip o Verify on the wiring diagram whether the made with regenerated electricity displayed voltage is 12V or 24V, along with the instantaneous fuel consumption.

  • Page 200: Can Connection On The Telltale Panel And The Hvac Control Unit

    SECTION 06A: H3 SERIES ELECTRICAL 6.2.1 CAN Connection On The Telltale Panel MCM can store up to 20 faults, i.e. the first 10 And The Hvac Control Unit and the last 10. Middle faults will be erased. If the breakers are tripped, the fault history will be The telltale panel module and HVAC module are erased from the MCM memory.
  • Page 201 SECTION 06A: H3 SERIES ELECTRICAL that allows verification of the sensors at the rear Headlights switch, 2 positions of the vehicle. Multi-function lever headlights beam toggle Certain inputs are doubled (for example, turn switch signal switch on multi-function lever, door operating buttons) and also other inputs activate Baggage compartment door lock/unlock switch at the same time (ex.

  • Page 202: Motor Test Sequence

    SECTION 06A: H3 SERIES ELECTRICAL just set the passenger set point temperature to  During the entire test, the telltale panel the minimum 64°F (18°C) to shut off the pump. audible alarm gives a signal each second to remind that the motor test mode is underway. MOTOR TEST SEQUENCE 6.5.1 Test Sequence –...

  • Page 203: Test Sequence - Vip With Central Hvac System

    SECTION 06A: H3 SERIES ELECTRICAL  Left and right overhead compartment fans [3 seconds delay] start running one after the other for 5  seconds. Fan clutch engages in speed 1 (fan can be turned hand with certain  The upper windshield defroster (optional) resistance).

  • Page 204: Forced Activation Of The Radiator Fan Clutch

    SECTION 06A: H3 SERIES ELECTRICAL  The main power compartment door fan starts running for 3 seconds (will not run if door is open). seconds delay]  A/C compressor clutch activated 3 times. seconds delay] On the Driver Information Display, select ...

  • Page 205: Can Network Layout And Troubleshooting

    SECTION 06A: H3 SERIES 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 206 SECTION 06A: H3 SERIES 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.
  • Page 207 SECTION 06A: H3 SERIES 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 208 SECTION 06A: H3 SERIES 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 209 SECTION 06A: H3 SERIES 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 210: Troubleshooting

    SECTION 06A: H3 SERIES ELECTRICAL TROUBLESHOOTING Problem/Symptom Probable Causes Actions Vehicle does not Start Rear Start selector switch is 1. Check that the rear start selector not in the NORMAL position switch is flipped up to NORMAL start position and master cut-out switch is Master cut-out switch on the flipped up to ON and retry cranking rear electrical panel is in the...
  • Page 211 SECTION 06A: H3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions (not essential for driving) receive 24 V power. Check / replace fuse F1 not functioning (interior 2. Operate limp-home mode lighting, driver's area starting the vehicle from the engine The CAN network is not lighting, wiper speed 2 compartment (REAR START).
  • Page 212 SECTION 06A: H3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions or is faulty (DID). Select FAULT DIAGNOSTIC Windshield upper section and ELECTRICAL SYSTEM. The de-icing system message “No Response ModA46, functioning Active” indicates a power problem on the module. (A CAN network problem Defroster would show the same message but functioning but no heat or...
  • Page 213 SECTION 06A: H3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions 2. Check / reset circuit breaker CB2 3. Check / replace fuse F80 4. Probe gray connector on module to see if it is powered. Engine is overheating and Module A52 is not powered 1.
  • Page 214 SECTION 06A: H3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions Sound system not Circuit breaker CB4 or CB11 Check / reset circuit breaker CB4 or CB11 functioning was manually tripped and not reset Fire alarm telltale light Short-circuited fire sensor or Prior to start the vehicle, cycle the ignition and audible alarm always defective sensor...

  • Page 215: Essential Functions To Operate The Vehicle

    SECTION 06A: H3 SERIES ELECTRICAL be used as spare parts for breakdown service while on the road. ESSENTIAL FUNCTIONS TO OPERATE Functions lost if A43 is removed and used as THE VEHICLE spare part: Even with a defective MCM (Chassis Electronic ...

  • Page 216: Multiplex Modules Replacement

    If this is the case, press serial port DB9 connector (identified C226) ESCape button repeatedly to acknowledge found front service compartment the higher priority messages. electrical panel. Please contact your Prevost PA1621 Maintenance Manual All Series | January 2017...

  • Page 217: Bosch Alternators

    SECTION 06A: H3 SERIES ELECTRICAL Service Representative in order to get the Mid (188) electrical system vehicle specific multiplex program and upload Psid 35 (alt 2) Lower alt procedure. Save the specific multiplex program on your laptop computer. Fmi (5) open circuit Confirm status...
  • Page 218 SECTION 06A: H3 SERIES ELECTRICAL  If multimeter reads 12 volts, you have an open circuit;  If multimeter reads 26 volts or greater, the upper alternator operates normally. Note Validation Confirm back-probing results before removing defective alternator. fact, connectors on the alternators may have been interchanged by mistake.
  • Page 219 SECTION 06A: H3 SERIES ELECTRICAL your Technical Publications USB flash drive for shown on the applicable wiring diagrams. Wiring information and maintenance instruction on diagrams located Technical MELCO 105P70 starter. Publication box. CAUTION 11.1 HEADLIGHTS Do not engage starter for more than 15 Inner headlights are used for high beam and seconds at a time.
  • Page 220 SECTION 06A: H3 SERIES ELECTRICAL make sure the ignition switch and light switch are off. CAUTION  To prevent burning yourself, do not replace the light bulbs while they are hot.  Halogen bulbs have pressurized gas inside and require special handling. They can burst or shatter if scratched or dropped.
  • Page 221 SECTION 06A: H3 SERIES ELECTRICAL 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 shock even...
  • Page 222 SECTION 06A: H3 SERIES ELECTRICAL FIGURE 26: VERTICAL AIMING 11.2 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 223 SECTION 06A: H3 SERIES ELECTRICAL FIGURE 27: VARIOUS LIGHT LOCATIONS 18588_4 PA1621 Maintenance Manual All Series | January 2017...
  • Page 224 SECTION 06A: H3 SERIES ELECTRICAL 11.3 LICENCE PLATE LIGHT 11.5 DOCKING AND CORNERING LIGHTS Two LED units are mounted above the rear This vehicle is provided with two halogen license plate(s) of vehicle. In case of burn out, sealed-beam units that serve as cornering lights. the LED unit must be changed according to the They are mounted on the vehicle as follows: one following procedure.
  • Page 225 SECTION 06A: H3 SERIES ELECTRICAL foggy weather, or to improve the range of vision 12. SERIES INTERIOR LIGHTING just ahead of the coach. 11.7.1 Bulb Removal And Replacement 12.1 CONTROL PANEL LIGHTING 1. Pull on the release handle located in the The instrument gauges and switches mounted front electrical and service compartment, on all control panels are energized whenever...
  • Page 226 SECTION 06A: H3 SERIES ELECTRICAL 12.1.3 Gauge Light Bulb Replacement 1. For any gauge light bulb replacement, the dashboard panel must be removed in order to have access to the rear of gauges. 2. Remove bulb socket from the gauge, turn the defective bulb counterclockwise and pull it out of the gauge.
  • Page 227 SECTION 06A: H3 SERIES ELECTRICAL 12.2.3 Bulb Removal And Replacement 12.3.2 DRIVER’S AREA LIGHTS Proceed as follows to replace defective bulb: One halogen ceiling light is installed over the stepwell and another one over the driver’s area. 1. Unscrew the two Phillips-head screws These lights are frequently used for nighttime retaining the lens to the wall, and remove it.
  • Page 228 SECTION 06A: H3 SERIES ELECTRICAL 1. Open the parcel rack access door, if so 12.4.3 Removal And Replacement Of Reading equipped, unscrew the two Phillips screws Lamp Bulb (one each end). Let the hinged cover down. 1. Engage the tool (#830164) over the lamp 2.
  • Page 229 SECTION 06A: H3 SERIES ELECTRICAL Proceed as follows to replace the bulb: 1. Unsnap lamp with flat head screwdriver and remove it. 2. Pull the defective bulb out of the socket. 3. Install the new bulb by pushing it in position. 4.
  • Page 230 Series ..............................HD 10 Amperes ..............................150 Volts ................................. 28.4 Output Power ............................3 Kw Ground .............................. negative Prevost Number ..........................564593 Battery equalizer standard Make ..............................Vanner Model ........................... Vann-Guard 70-Series Amperes ............................100 amps Battery equalizer ( with PRIME option ) Make ..............................
  • Page 231 SECTION 06B : X3 SERIES ELECTRICAL CONTENTS    SECTION CHANGE LOG ............................ 4     TORQUE TABLES ............................ 5     ALTERNATORS AND SURROUNDING COMPONENTS ..................  5     ELECTRICAL CONNECTIONS – BATTERIES, MISCELLANEOUS .................  7     GENERAL DESCRIPTION  ..........................  1 1     WIRING DIAGRAMS............................  1 1     2.1.1 Using Wiring Diagrams ........................  1 1     TESTING CIRCUITS ...
  • Page 232 SECTION 06B: X3 SERIES ELECTRICAL     ELECTRICAL COMPARTMENTS ........................  4 2     MAINTENANCE ............................  4 4     BATTERY INSTALLATION & REAR JUNCTION BOX ..................  4 4     REAR JUNCTION BOX (RJB) ..........................  4 4     FRONT ELECTRICAL AND SERVICE COMPARTMENT (FJB) ................  4 7     A/C MODULE  ..............................  4 9     ENGINE REAR START PANEL  .........................  4 9  ...
  • Page 233 SECTION 06B: X3 SERIES ELECTRICAL     X3 SERIES EXTERIOR LIGHTING .......................  6 7     11.1 HEADLIGHTS..............................  6 7     11.1.1 Headlight Beam Toggle Switch ......................  6 7     11.1.2 Maintenance  ............................  6 7     11.1.3 Headlight Adjustment ..........................  6 8     11.1.4 Bulb Replacement ..........................  6 9  ...
  • Page 234 SECTION 06B: X3 SERIES ELECTRICAL SECTION CHANGE LOG  DESCRIPTION DATE Added missing images in Torque Table, items 20 & 21 2017 07 06 PA1621 Maintenance Manual All Series | Jul 2017...
  • Page 235 SECTION 06B: X3 SERIES ELECTRICAL TORQUE TABLES ALTERNATORS AND SURROUNDING COMPONENTS COLD SIDE ALTERNATORS 06783 COLD SIDE ALTERNATORS 06784 COLD SIDE ALTERNATORS 06785 COLD SIDE ALTERNATORS 06786 HOT SIDE ALTERNATORS (motorhomes) HOT SIDE ALTERNATOR, LOW LH (coaches) PA1621 Maintenance Manual All Series | Jul 2017...
  • Page 236 SECTION 06B: X3 SERIES ELECTRICAL HOT SIDE ALTERNATORS (motorhomes) 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 48 lb-ft (65 Nm)
  • Page 237 SECTION 06B: X3 SERIES ELECTRICAL ELECTRICAL CONNECTIONS – BATTERIES, MISCELLANEOUS HOT SIDE ALTERNATOR, LOW LH (single) COLD SIDE ALTERNATORS PA1621 Maintenance Manual All Series | Jul 2017...
  • Page 238 SECTION 06B: X3 SERIES ELECTRICAL ELECTRICAL CONNECTIONS - BATTERIES, MISC. DESCRIPTION TORQUE AGM battery Ground, 12VD & 24VD terminal nut 170 lb-in (19 Nm) AGM battery connections, cap nut 170 lb-in (19 Nm) Alternator power connection – nut & adaptor 11 lb-ft (15 Nm) Alternator ground connection –...
  • Page 239 SECTION 06B: X3 SERIES ELECTRICAL ELECTRICAL CONNECTIONS – MAIN POWER COMPARTMENT DESCRIPTION TORQUE Main circuit breaker 3/8-16 stud nut 135 lb-in (15 Nm) Main circuit breaker (switchable, manual reset) 3/8-16 stud nut 135 lb-in (15 Nm) Power relay stud nut 44 lb-in (5 Nm) Master relay R1- Port 30 –...
  • Page 240 SECTION 06B: X3 SERIES ELECTRICAL MISCELLANEOUS COMPONENTS DESCRIPTION TORQUE Battery cover vent mounting nut 40-48 lb-in (4.5-5.4 Nm) Cable pass-through assembly nut 90-110 lb-in (10-12 Nm) Strain relief mounting lock nut 90-110 lb-in (10-12 Nm) Screw - power cable support- electrical cooling fans 50-60 lb-in (5.6-6.8 Nm) Battery cover stud nut 86-106 lb-in (10-12 Nm)
  • Page 241 24V self-regulated 5, you will find the location, the b) At item CB alternators, belt driven from the engine, and can Prevost number, the breaker function, the be reached through the engine compartment breaker ampere rating and the page on doors.
  • Page 242 SECTION 06B: X3 SERIES ELECTRICAL c) At device SW63, find the fault message, the minimum condition to activate, other inputs involved in logic, the multiplex module Yellow Data link High related to switch 63, the connector and pin Green Data link Low number on the module and the page on Orange Connected to multiplex outputs...
  • Page 243 SECTION 06B: X3 SERIES ELECTRICAL VOLTAGE READING OR NETWORK J1939 J2284 0/12 BBUS 0/24 DATA DBUS J1587 …other CIRCUIT IDENTIFICATION Ground circuits Electronic: I/O module number followed by an R, followed by the connector number and pin number (cavity) (ex: A47RJ1.8, A54 RJ2.14). Electronic ground studs: Number 00 followed with the stud location and sequential number (ex: 00R1, 00F4).
  • Page 244 SECTION 06B: X3 SERIES 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, connection additional accessory, refer to page "Spare wires" in master wiring diagram to determine the FIGURE 1: BREAKER WITH MANUAL TRIP BUTTON number, the gauge and location of these wires.
  • Page 245 SECTION 06B: X3 SERIES ELECTRICAL 2.6.2 X3 VIP main circuit breakers FIGURE 3: MAIN CIRCUIT BREAKERS – X3 VIP SERIES FIGURE ELECTRIC COOLING CIRCUIT MAIN CIRCUIT BREAKERS – X3 VIP BREAKER BOX 24 WUP front distribution 24 VI 90 A 12VD front distribution –...
  • Page 246 SECTION 06B: X3 SERIES ELECTRICAL If one CAC fan and three radiator fans are not functioning, then you should suspect that one of the multiplex modules (AE49 or AE52) is defective. MULTIPLEX FUSES The multiplex outputs are protected in current by internal “soft-fuse”.
  • Page 247 SECTION 06B: X3 SERIES ELECTRICAL 2.11 PRECAUTIONS DANGER Prior to working on a system inside vehicle, make sure to cut electrical power and air 86 coil supply. A component could be supplied with 85 coil electricity even if the ignition switch is set to 30 common feed the OFF position and/or a component could 87 normally open contact NO...
  • Page 248 SECTION 06B: X3 SERIES ELECTRICAL 2.12 ELECTRONIC MODULES CONNECTOR PIN-OUT FIGURE 8: VECR/VECF & MULTIPLEX MODULE CONNECTORS PIN-OUT PA1621 Maintenance Manual All Series | Jul 2017...
  • Page 249 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 9: I/O-EB MODULE FIGURE 10: I/O-EA MODULE I/O-EA & I/O-EB MUX modules Connector: AMP MCP 2.8 Contact loading of housings Loading the contacts is only possible if the secondary lock is in the unlock position. Proper orientation of the contact is important.
  • Page 250 Multiplex modules Connector type Contact removal 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 251 SECTION 06B: X3 SERIES ELECTRICAL 3. TROUBLESHOOTING AND TESTING THE panel. Connector C3 (rear electrical panel) MULTIPLEX VEHICLES disconnects all the modules at the rear of the vehicle from the network. 3.1 PROBING VOLTAGE ON THE MULTIPLEX Example: Disconnect C5 and C1 and then verify the CIRCUITS status of the errors.
  • Page 252 SECTION 06B: X3 SERIES ELECTRICAL Once the problem corrected, the DID still shows Instrument panel audible alarm emits a beep the fault as being active. You have to leave the each time an OFF/ON transition is detected on a FAULT DIAGNOSTIC menu, wait approximately multiplex input.
  • Page 253 SECTION 06B: X3 SERIES ELECTRICAL 3.5 MOTOR TEST SEQUENCE Multi-function lever courtesy blinkers switch This test mode allows testing of the electric Headlights switch, 2 positions motors, the A/C compressor clutch and unloader Multi-function lever headlights beam toggle and the HVAC system solenoid valves without switch the need to have the engine running.
  • Page 254 SECTION 06B: X3 SERIES ELECTRICAL  During the entire test, the telltale panel audible alarm gives a signal each second to remind that the motor test mode is underway. 3.5.1 Test Sequence – Coaches only Test Sequence – Coaches only ...
  • Page 255 SECTION 06B: X3 SERIES ELECTRICAL 3.5.2 Test Sequence – VIP With Central HVAC System Test Sequence – VIP With Central HVAC System  Driver’s & passenger’s unit fresh air damper open. [20 seconds delay] Go to the condenser compartment  The condenser fans start.
  • Page 256 SECTION 06B: X3 SERIES ELECTRICAL 3.5.3 Test Sequence – VIP With Small HVAC System Test Sequence – VIP With Smal System  Driver’s unit fresh air damper opening. [20 seconds delay]  Go to the condenser compartment The condenser fan start. Speed will gradually increase to maximum speed.
  • Page 257 SECTION 06B: X3 SERIES ELECTRICAL 3.6 FORCED ACTIVATION OF THE COOLING fan clutch. To cancel, turn the ignition FANS switch to the OFF position or press ESCAPE button, select STOP TEST To prevent the engine from overheating in case submenu and then press ENTER button of malfunction of the cooling fans activation twice.
  • Page 258 SECTION 06B: X3 SERIES ELECTRICAL 3.7 DL0 (BBUS MUX) NETWORK LAYOUT AND TROUBLESHOOTING MUX MODULE IDENTIFICATION MODULE TYPE LOCATION AE41 I/O-EA AE42 I/O-EA AE43 I/O-EB AE44 I/O-EB AE45 I/O-EB AE46 I/O-EB AE47 I/O-EB R.H. CONSOLE AE48 I/O-EB R.H. CONSOLE AE49 I/O-EB AE50 I/O-EB...
  • Page 259 SECTION 06B: X3 SERIES ELECTRICAL If all 17 modules (A41 to A57) are showed as Not Responding and Active Fault, the problem could be: A short circuit somewhere on the DL0H, DL0L (BBUS MUX) network. • The network is completely open circuit. That means none of the two termination resistors are •...
  • Page 260 SECTION 06B: X3 SERIES ELECTRICAL NOTE All modules including Wake-up modules and MCM have to be powered OFF prior to probe the DL0 (BBUS MUX) lines with an ohmmeter. Probing the resistance between the DL0H and DL0L wire is a useful method to localize short circuits or open circuit on the DL0 (BBUS MUX) network.
  • Page 261 SECTION 06B: X3 SERIES ELECTRICAL Isolate the front from the rear Take one of the termination resistors in the RJB. Disconnect C1 and connect the termination resistor to C1 pin housing. If all the front modules respond normally, the short circuit is in the rear portion. Isolate the evaporator module from the network Disconnect C100.
  • Page 262 SECTION 06B: X3 SERIES ELECTRICAL Isolate the pneumatic accessory panel modules from the network In the FJB, disconnect C5. Take the spare termination resistor on C3S in the RJB and connect it to C5 pin housing. If the short circuit problem is in the pneumatic accessory panel all modules except AE47 and AE48 located into the pneumatic accessory panel will respond normally.
  • Page 263 SECTION 06B: X3 SERIES ELECTRICAL DL0 (BBUS MUX) wires are not like other common electrical wires. Maintaining a proper wire twisting is important. The two yellow and green wires must be twisted • and in close contact all along the network to maintain the transmission line impedance. A slack handmade twisting is not acceptable.
  • Page 264 SECTION 06B: X3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions None of the Multiplexed The program version in the 1. Engage the auto-programming of the functions are operating, MCM is different than the I/O modules: Turn the ignition key to including the basic limp- program in the I/O modules the ON position, trip and reset circuit home functions (door...
  • Page 265 SECTION 06B: X3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions Entrance door does not Module AE47 is not powered 1. Check the SYSTEM DIAGNOSTIC open nor close using the or is faulty menu of Driver Information Display control buttons (DID). Select FAULT DIAGNOSTIC and ELECTRICAL SYSTEM.
  • Page 266 SECTION 06B: X3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions Module AE47 is not powered 1. Check the SYSTEM DIAGNOSTIC Defroster or is faulty menu of Driver Information Display functioning but no heat or (DID). Select FAULT DIAGNOSTIC cooling available in the and ELECTRICAL SYSTEM.
  • Page 267 SECTION 06B: X3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions Rear flashers not Module AE51 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 268 SECTION 06B: X3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions Evaporator fan not Circuit breaker CB3 tripped 1. Check circuit breaker CB3 functioning 2. Check relay R12 Module AE54 is not powered or is faulty 3. Check the SYSTEM DIAGNOSTIC menu of Driver Information Display (DID).
  • Page 269 SECTION 06B: X3 SERIES ELECTRICAL Problem/Symptom Probable Causes Actions The vehicle is parked and Short-circuited fire sensor or Cycle the ignition key between the ON the electrical horn is acti- defective sensor and OFF position twice within 3 seconds. vated to indicate a fire in This will deactivate the fire alarm function.
  • Page 270 SECTION 06B: X3 SERIES ELECTRICAL 3.10.1 Available Functions 3.9 DRIVER INFORMATION DISPLAY LIMP-  Startup: Turn on the ignition in the driver's HOME MODE area and rear start the vehicle from the In case of malfunction of unavailability of the engine compartment, steering wheel UP, DOWN, ENTER &...
  • Page 271 A laptop computer running Windows XP or Windows 7 must be connected to the RS232 serial port DB9 connector (identified C226) found front service compartment electrical panel. Please contact your Prevost Service Representative in order to get the PA1621 Maintenance Manual All Series | Jul 2017...

  • Page 272: Electrical Compartments

    SECTION 06B: X3 SERIES ELECTRICAL vehicle specific multiplex program and upload procedure. Save the specific multiplex program on your laptop computer. WARNING WHEN UPLOADING SOFTWARE INTO THE MCM … Cooling fans WILL start running for a short while. Keep hands away from cooling fans or keep the radiator door closed.
  • Page 273 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 13: ELECTRICAL COMPARTMENTS (X3-45 VIP) FIGURE 14: ELECTRICAL COMPARTMENTS (X3-45 VIP COMMERCIAL BUS SHELL) PA1621 Maintenance Manual All Series | Jul 2017...

  • Page 274: Maintenance

    SECTION 06B: X3 SERIES ELECTRICAL REAR JUNCTION BOX (RJB) MAINTENANCE The main power compartment panel provides A corrosion inhibitor has been sprayed on access to the following: certain electrical components in order to protect them from corrosion. Refer to procedure ...
  • Page 275 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 17: 12VD / 24VD CURRENT SENSORS IN MPC FIGURE 18: MAIN CIRCUIT BREAKERS IN MPC PA1621 Maintenance Manual All Series | Jul 2017...
  • Page 276 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 19: MAIN POWER COMPARTMENT COMPONENTS IDENTIFICATION PA1621 Maintenance Manual All Series | Jul 2017...

  • Page 277: Front Electrical And Service Compartment (Fjb)

    SECTION 06B: X3 SERIES ELECTRICAL FRONT ELECTRICAL AND SERVICE COMPARTMENT (FJB) The front electrical and service compartment is located on L.H. side of vehicle, under the driver's window. It contains the following components (Figure 20):  Front terminal block;  Master Control Module (MCM);...
  • Page 278 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 21: FRONT ELECTRICAL & SERVICE COMPARTMENT COMPONENTS IDENTIFICATION PA1621 Maintenance Manual All Series | Jul 2017...

  • Page 279: A/C Module

    SECTION 06B: X3 SERIES ELECTRICAL ENTRANCE DOOR & WIPER CONTROL MODULES A/C MODULE To access the entrance door & wiper control The A/C junction box is located on the panel of the right console, remove the panel evaporator fan housing. under the larger utility compartment at the base of the windshield.

  • Page 280: Batteries

    SECTION 06B: X3 SERIES ELECTRICAL BATTERY INSTALLATION The battery bank is composed of four AGM batteries. To prevent improper installation of the batteries, the positive (+) and negative (-) signs are laser cut on the battery deck steel sheet. When installing new batteries, place the battery negative and positive poles according to the signs on the battery deck (Figure 26).
  • Page 281 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 27: BATTERY CONNECTIONS SCHEMATIC FIGURE 28: AGM BATTERY CONNECTIONS PA1621 Maintenance Manual All Series | Jul 2017...

  • Page 282: Agm Batteries

    SECTION 06B: X3 SERIES ELECTRICAL AGM BATTERIES CAUTION This vehicle is equipped with PRIME energy AGM (Absorbed Glass Mat) batteries require a management system, it is provided with four (4) voltage-limited charger, ideally fitted with a Absorbed Glass Mat (AGM) 12-volt batteries battery temperature sensor for temperature connected in series-parallel ( FIGURE 28...

  • Page 283: Battery Removal And Installation

    SECTION 06B: X3 SERIES ELECTRICAL  ECM;  TCM (Allison transmission);  Aftertreatment Control Module (ACM);  Preheater electronic timer;  Preheater and water recirculating pump;  Entrance door;  Radio memory;  Fire suppression system (momentarily);  Horn, Hazard: ...
  • Page 284 SECTION 06B: X3 SERIES ELECTRICAL FIGURE 36 FIGURE 33 Battery Installation 5. Unscrew three nuts (indicated with arrows) and then remove the front angle (FIGURE 34). Reinstalling the batteries is quite similar as the removal procedure but in reverse order. However, special care should be taken to the following points: 1.
  • Page 285 SECTION 06B: X3 SERIES ELECTRICAL 4. Tighten the rod nut to the following torque: TORQUE: 45-55 lb-in (5-6 Nm) FIGURE 41: INSTALL THE BATTERY CABLE LUGS 6. Connect the ground cable last (FIGURE 42). Tighten the ground cable nut to the following torque: TORQUE: 170 lb-in (19 Nm) FIGURE 39: SHAPE OF THE ROD...

  • Page 286: Battery Rating

    SECTION 06B: X3 SERIES ELECTRICAL 5.7.2 Removing Surface Charge Disconnect cables from the battery and attach BATTERY RATING alligator clamps to the contact lead pad on the battery as shown in Figure 44. Connect a load Each of the 12 volt batteries used on the vehicle equal to half the CCA across the terminal for 5 has the following rating: seconds to remove surface charge from the...

  • Page 287: Battery Charging

    SECTION 06B: X3 SERIES ELECTRICAL temperatures of 70ºF (21ºC) and above. For they are left on vehicle and make sure that the temperatures below 70ºF (21ºC), refer to the main battery disconnect switch is set to the following "Voltage and Temperature Chart". “On”...

  • Page 288: Battery Charging Guide

    SECTION 06B: X3 SERIES ELECTRICAL 5.8.1 Battery Charging Guide NOTE AGM (Absorbed Glass Mat) batteries require a voltage-limited charger, ideally fitted with a battery temperature sensor for temperature correction of charging parameters. Do not manually charge AGM batteries. Look for the following voltage values on your voltage- limited charger.

  • Page 289: Emergency Jump Starting With Auxiliary (Booster) Battery

    SECTION 06B: X3 SERIES ELECTRICAL Charger Capacity Wear eye protection and remove rings, watches with metal bands and other metal jewelry. A charger supplying only 5 amperes will require a much longer period of charging than a charger Apply parking brake and place the transmission that can supply 30 amperes or more.

  • Page 290: Agm Battery Charging Precautions

    SECTION 06B: X3 SERIES ELECTRICAL 8. Disconnect the jumper cables in reverse battery design prevents chemical order given in steps 2 through 5; unbalance of the electrolyte. Manufacturers of this type of battery generally do not recommend 9. Install protective cap on the booster block performing equalization.

  • Page 291: Common Causes Of Battery Failure

    SECTION 06B: X3 SERIES ELECTRICAL 5.12 COMMON CAUSES BATTERY 2. Defects in the charging system, such as FAILURE high wiring resistance, faulty alternator, regulator or battery equalizer. When a battery fails, the cause of failure may be 3. A vehicle electrical load exceeding the related to something other than the battery.

  • Page 292: Battery Warning Pictogram May Appear As A Reminder

    SECTION 06B: X3 SERIES ELECTRICAL Check equalizer cables for proper gauge. Battery temperature, voltage and current are Check battery connections. also monitored to prevent overcharging and overheating. 2. Demand for 12-volt power exceeding rated amperage output of battery equalizers Maximum fuel economy is obtained on a ride causing batteries to go out of balance.
  • Page 293 SECTION 06B: X3 SERIES ELECTRICAL CURRENT SENSORS EQUALIZER FIGURE 46: PRIME ELECTRICAL COMPONENTS PA1621 Maintenance Manual All Series | Jul 2017...

  • Page 294: Vanner 80 Series Battery Equalizer Fault Codes

    SECTION 06B: X3 SERIES ELECTRICAL 7.1.1 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 295: Identifying A Defective Alternator

    SECTION 06B: X3 SERIES ELECTRICAL IDENTIFYING A DEFECTIVE DID DISPLAY ALTERNATOR In the DID you will find the percentage of trip When an alternator is not charging, made with regenerated electricity displayed the charging system warning light will along with the instantaneous fuel consumption. illuminate.

  • Page 296: Alternator Drive Belt

    SECTION 06B: X3 SERIES ELECTRICAL b) Parking brake applied. 8.2.1 Removal and installation 1. Insert a ½″ socket drive into the automatic belt tensioner opening. Alternator Up RH =pin J1:20, module AE49 Alternator Low RH=pin J2:8, module AE52 2. Twist the tensioning arm to slacken belt. Alternator Low LH= pin J2:9, module AE52 3.

  • Page 297: Engine Block Heater

    SECTION 06B: X3 SERIES ELECTRICAL 11. X3 SERIES EXTERIOR LIGHTING CAUTION The circuit for exterior lights, as well as their control switches, relays and circuit breakers are Do not engage starter for more than 15 shown on the applicable wiring diagrams. Wiring seconds at a time.

  • Page 298: Headlight Adjustment

    SECTION 06B: X3 SERIES ELECTRICAL installed. Headlights must be properly aimed to limits called for in the specification with provide maximum allowable road illumination. reference to centerlines ahead of each When using mechanical aiming devices, follow headlight assembly. manufacturer’s instructions. The headlight centerlines shall be spaced either Aiming can be performed without opening side of the fixed centerline on the screen by ½...

  • Page 299: Bulb Replacement

    SECTION 06B: X3 SERIES ELECTRICAL 7. The inspection limits in the vertical direction for low-beam headlights or the low beam of dual-beam headlight, shall described in Table 1. In the horizontal direction, the left edge of the high-intensity zone shall be located from 10 cm (4 in) left to 10 cm (4 in) right of the vertical centerline of the beam.

  • Page 300: Front Turn Signal Replacement

    SECTION 06B: X3 SERIES ELECTRICAL 2. Remove the screw fixing the headlight 11.1.7 Optional Xenon Headlamp assembly, then tilt headlight assembly down The outer lamps of each headlight assembly (Figure 52). may be equipped with the optional Xenon lamps. 3. Remove connector from headlight bulb. These lamps improve visibility and provide better lifespan.

  • Page 301: Stop, Tail, Directional, Back-Up, And Hazard Warning Lights

    SECTION 06B: X3 SERIES ELECTRICAL seconds so that there is no immediate danger of NOTE electric shock even if the warning is disregarded. Do not disrupt headlight adjustment screws. With this safety concept there is no danger to check the ballast with a new bulb. There is a CAUTION very high probability that the ballast is OK if the ballast can ignite the bulb.

  • Page 302: Lamp Removal And Replacement

    SECTION 06B: X3 SERIES ELECTRICAL FIGURE 59: REAR TAIL LAMPS FIGURE 60: TAILLAMP POD RETAINING SCREWS & NUTS 11.2.1 Lamp Removal and Replacement 1. Open engine compartment rear door. 11.3 LICENSE PLATE LIGHT 2. Remove the lamp pod from the engine Two LED units are mounted above the rear compartment door by unscrewing the Torx license plate(s) of vehicle.

  • Page 303: Fog Lights

    SECTION 06B: X3 SERIES ELECTRICAL 1. Unscrew both “Phillips” light screws, and 12. X3 SERIES INTERIOR LIGHTING then remove the light assembly. EQUIPMENT 2. Position the new light assembly and install the “Phillips” screws. 12.1 CONTROL PANEL LIGHTING The instrument gauges and switches mounted 11.4.1 Clearance Identification Light...

  • Page 304: Gauge Light Bulb Replacement

    SECTION 06B: X3 SERIES ELECTRICAL 3. Unscrew and remove the telltale module. 2. Remove bulb socket from the gauge, turn the defective bulb counterclockwise and pull 4. To reinstall the telltale module, reverse the it out of the gauge. procedure. 3.

  • Page 305: Bulb Removal And Replacement

    SECTION 06B: X3 SERIES ELECTRICAL 12.3 DRIVER’S AREA LIGHTS Two halogen ceiling lights are installed over the stepwell and the driver’s area. These lights are frequently used for night-time operation when passengers board or leave coach. 12.3.1 Bulb Removal and Replacement 1.

  • Page 306: Removal And Replacement Of Reading Lamp Bulb

    SECTION 06B: X3 SERIES ELECTRICAL 4. Replace the screen lens by first inserting one side in the seat, then push the other side in and snap it in place by running it in from one corner to the next. FIGURE 66: ENGINE COMPARTMENT LIGHT FIGURE 65: LED DIRECT LIGHTING AND LENS 12.4.3 Removal and Replacement of Reading Lamp Bulb...
  • Page 307 SECTION 06B: X3 SERIES ELECTRICAL 13. SPECIFICATIONS AGM Battery Make ............................... Volvo Type ..........................Absorbed Glass Mat Terminal type ........................... Top Stud Group size ............................... 8A31 Volts ................................12 Load test amperage ..........................400 Reserve capacity (minutes)........................200 Cold cranking (in amps) -At 0 F (-18 C) ........................
  • Page 308 SECTION 06B: X3 SERIES ELECTRICAL PA1621 Maintenance Manual All Series | Jul 2017...
  • Page 309 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 310 PROCEDURE NO: SAV00002E REVISION 02 Vehicle Zoning REAR FRONT REAR FRONT Page 2 of 6...
  • Page 311 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 312 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 313 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 314 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 315 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 316 MI15-24 / Page 2 / 12 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 317 MI15-24 / Page 3 / 12 Figure 4 Figure 5: starter cables • In the electrical compartment, connected to Bussman junction block (Figure 6). Figure 6 QF7720956 rev3>...
  • Page 318 MI15-24 / Page 4 / 12 • 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 319 MI15-24 / Page 5 / 12 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 320 MI15-24 / Page 6 / 12 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 321 MI15-24 / Page 7 / 12 • 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 322 MI15-24 / Page 8 / 12 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 323 MI15-24 / Page 9 / 12 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 324 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 325 MI15-24 / Page 11 / 12 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 326 MI15-24 / Page 12 / 12 QF7720956 rev3>...
  • Page 327 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 329 SECTION 07: TRANSMISSION CONTENTS     SECTION CHANGE LOG ............................ 3     TORQUE TABLES ............................ 5     ALLISON TRANSMISSION  ..........................  5       VOLVO I‐SHIFT TRANSMISSION  ........................  6         DESCRIPTION  .............................. 7     AUTOMATIC TRANSMISSION ......................  7 ALLISON     ...
  • Page 330 SECTION 07: TRANSMISSION     7.1.4 Exiting Diagnostic Mode ........................  2 3     7.1.5 Diagnostic Trouble Code Response ......................  2 4     DIAGNOSTIC TROUBLESHOOTING CODES (DTC) ‐ ALLISON CONTROLS  ......  2 5         IST       G RATION      ALLISON TRANSMISSION REMOVAL ......................  2 7  ...

  • Page 331: Section Change Log

    SECTION 07: TRANSMISSION SECTION CHANGE LOG  DESCRIPTION DATE   PA1621 Maintenance Manual All Series | January 2017...
  • Page 332 SECTION 07: TRANSMISSION         PA1621 Maintenance Manual All Series | January 2017...

  • Page 333: 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) PA1621 Maintenance Manual All Series | January 2017...
  • Page 334 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) PA1621 Maintenance Manual All Series | January 2017...

  • Page 335: Allison Automatic Transmission

    SECTION 07: TRANSMISSION the shift, and makes minute adjustments to match the shift to desired profile stored in its DESCRIPTION memory. It then looks at these adjustments and resets parameters, which allow H3 and X3 Series vehicles may be provided with transmission quickly compensate...

  • Page 336: Welding Procedures

    SECTION 07: TRANSMISSION If the I-Shift transmission system is to be used, Allison 5th generation shift selector, you can get the vehicle must have an electronic engine a more accurate electronic fluid level check than control unit as well as CAN communication. with a dipstick.

  • Page 337: Cold Check

    SECTION 07: TRANSMISSION the transmission breather to ensure it is clean and CAUTION free of debris. DO NOT operate the transmission for extended periods of time until a Hot Check has verified 4.1.1 Cold Check proper fluid level. Transmission damage can result from extended operation at improper fluid The purpose of the Cold Check is to determine if level conditions.

  • Page 338: Fluid Level Check Using The Pushbutton Shift Selector

    SECTION 07: TRANSMISSION  Oil level sensor present and working. 6. Be sure fluid level checks are consistent. Check level more than once and if readings 5. Correct fluid level are not consistent, check to be sure the displayed as shown. transmission breather is clean and not clogged.

  • Page 339: Recommended Automatic Transmission Fluid

    SECTION 07: TRANSMISSION CODE CAUSE OF FAULT CODE SENSOR FAILED Sensor failure NOTE RECOMMENDED AUTOMATIC TRANSMISSION FLUID arctic preheat recommended at temperatures below -25ºF (- Only use fluids meeting Allison Transmission 32ºC). If a preheat kit is not available, the TCM specification TES295 TES389...

  • Page 340: Coolant Leakage

    SECTION 07: TRANSMISSION transmission must be disassembled and closely When a specified threshold is detected for any inspected to find the source. Metal contamination serviceable conditions, will require complete disassembly TRANSMISSION SERVICE indicator transmission and cleaning of all internal and illuminated to alert the operator.
  • Page 341 SECTION 07: TRANSMISSION Failure to perform maintenance and reset the Verify prognostics fluid type setting matches TRANSMISSION SERVICE indicator within a transmission fluid type. Oil Life Monitor defined period will result in the illumination of the notifications will inaccurate when CHECK light with associated message in the mismatched.
  • Page 342 SECTION 07: TRANSMISSION initialization of the TCM, the TRANSMISSION just after ignition on until ignition is turned off. SERVICE indicator will flash for 2 minutes after Thereafter, the indicator will be lit upon each first selection “D” (drive) range. initialization of the TCM, and will remain on Thereafter, the indicator will illuminate and flash steady during all vehicle operation until service upon each TCM initialization, continuing to flash...

  • Page 343: Transmission Health Monitor

    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 344: 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 345: 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 ASSEMBLY FILTERS CHANGE INTERVALS CHANGE INTERVAL TES295 Whichever is the first of the following: Whichever is the first of the following: time transmission overhaul...

  • Page 346: Fluid And Filter Change Procedure

    SECTION 07: TRANSMISSION could result missed maintenance TORQUE: 38-45 lb-ft (52-61 Nm) activities resulting in transmission damage. See 7. Inspect the drain plug and O-ring. Replace if "TABLE 3 for oil and filter change intervals with necessary. Reinstall the drain plug. PROGNOSTIC MODE enabled.

  • Page 347: Cleaning And Inspection Of Allison Automatic Transmission

    SECTION 07: TRANSMISSION Using the oil level dipstick filler tube, refill with ALLISON TRANSMISSION OIL COOLER 24 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 348: 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 349 SECTION 07: TRANSMISSION 8. Apply clear silicone (Prevost #680457 or equivalent) around edge transmission housing (Figure 12: silicone application transmission housing). FIGURE 13: CRISS CROSS PATTERN 12. Remove the headless guide bolt from the flex FIGURE 12: SILICONE APPLICATION TRANSMISSION...

  • Page 350: Allison Transmission Troubleshooting

    SECTION 07: TRANSMISSION 23. Install engine splash guards. 24. Adjust the retarder pressure to 80 ± 3 psi with pressure regulator. more information refer to Section 12, "BRAKE AND SYSTEM", under heading "AIR PRESSURE REGULATOR". The air pressure regulator is located at back of engine compartment, on R.H.

  • Page 351: Using Shift Selector For Accessing Diagnostics Information

    SECTION 07: TRANSMISSION (historic) is dropped from the list. If all DTCs are DOC™ diagnostic tool, refer to the User active, the DTC with the lowest priority is Guide. dropped from the list. o Using the pushbutton shift selector. An active code is any code that is current in the To begin the diagnostic process: TCM decision-making process and has failed the DTC test(s) associated with that specific...

  • Page 352: Diagnostic Trouble Code Response

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

  • Page 353: Diagnostic Troubleshooting Codes (Dtc) List - Allison 5 Th

    SECTION 07: TRANSMISSION DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST - ALLISON 5 GENERATION CONTROLS CHECK Inhibited Operation Description Light Description May inhibit retarder operation if not C1312 Retarder Request Sensor Failed Low using J1939 datalink May inhibit retarder operation if not C1313 Retarder Request Sensor Failed High using J1939 datalink...
  • Page 354 SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description P0797 Pressure Control Solenoid 3 Stuck On DNS, RPR P0842 Transmission Fluid Pressure Switch 1 Circuit Low DNS, Lock in current range P0843 Transmission Fluid Pressure Switch 1 Circuit High DNS, Lock in current range P0847 Transmission Fluid Pressure Switch 2 Circuit Low None...

  • Page 355: Allison Transmission Removal

    SECTION 07: TRANSMISSION CHECK Inhibited Operation Description Light Description P2723 Pressure Control Solenoid 1 (PCS1) Stuck Off DNS, RPR P2724 Pressure Control Solenoid 1 (PCS1) Stuck On DNS, RPR P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit Open DNS, SOL OFF (hydraulic default) P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit Low DNS, SOL OFF (hydraulic default)

  • Page 356: Volvo I-Shift Transmission Maintenance

    SECTION 07: TRANSMISSION 4. Remove cross member from under transmission. 5. Remove the transmission drain plug and allow oil to drain. Inspect the drain plug washer and replace it if necessary. Reinstall the drain plug (see "3.5 Oil and Filter Change" in this section.

  • Page 357: Checking Oil Level

    SECTION 07: TRANSMISSION  Add oil through the oil filling point if CAUTION necessary (3) ;  Torque tighten fill plug. Never reuse drained I-Shift oil. The oil must be replaced along with the oil filter. Reusing TORQUE: 22-30 lb-ft (30-41 Nm) drained oil can result in damage to transmission components.
  • Page 358 SECTION 07: TRANSMISSION Inspect the drain plug and O-ring. Replace if necessary. Reinstall the drain plug. TORQUE: 18-24 lb-ft (24-33 Nm) CAUTION Always dispose of all lubricants (engine oil, coolant, transmission oil, etc) and filters according to Federal or local regulations. Change the oil filter (#20779040) at every oil change.

  • Page 359: Volvo I-Shift Transmission Tecu Fault Codes

    SECTION 07: TRANSMISSION 10. VOLVO I-SHIFT TRANSMISSION TECU FAULT CODES PID/SID FUNCTION 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 360 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 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 above gear 4 in Clutch load...
  • Page 361 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 5. The PCB valves are inactive temperature is - There is no active fault above a specific code on any of the clutch limit cylinder position sensor (SEPoC) the clutch valves Deactivate: The clutch response - There is no active fault...
  • Page 362 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 active fault code set point -1mm] after control on any of the of the clutch to near the slip clutch cylinder point position during 1.0s valves and, - The clutch position is more 5.
  • Page 363 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 calibration Yellow lamp is sent Cranking is Digital input inhibited Activate: The Engine can not flash Voltage voltage level for start NVRAM above normal DIEE-pin is high The boot-program does not FMI3 PSID254 or shorted...
  • Page 364 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 sensor for the split cylinder position (SEPoS) low air pressure. The following conditions must be fulfilled for one activation of the gearbox brake in order to deactivate: - The minimum value of the derivative of the countershaft speed during the activation is greater than...
  • Page 365 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 the valve for shift to 1:st gear the valve for shift to reverse gear - There is no active fault code for low air pressure Note: The fault will always have the state inactive.
  • Page 366 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 engaged - There is an 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 Detailed conditions to activate/deactivate The following conditions...
  • Page 367 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 The fault is deactivated if any of the following conditions are fulfilled: - The 1/R position sensor indicates that neutral position is engaged - There is an 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...
  • Page 368 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 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 row in order to set the fault code: (engagement of another gear will reset the count)
  • Page 369 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 of 3:rd gear code: Loss of torque The following conditions system -The 3:rd gear The 3:rd gear will must be fulfilled three times can not engage not be selected (only once if the fault code- by the system for filter is switched OFF) in a a short while.
  • Page 370 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 the valve for shift to 2:nd gear the valve for shift to 3:rd gear Activate: The FMI shall be set if any of the messages* have Yellow lamp is not been sent received on the Fault codes can...
  • Page 371 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Activate: The FMI shall be set if message ACC1 from ACC Missing data (MID219) is not on J1939 received within Yellow lamp from the Abnormal 1s, and ACC is The retarder PSID211 FMI9 update rate...
  • Page 372 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 normal rate Yellow lamp If pedal pos is undefined, automatic gear selection enters Activate: The backup mode FMI shall be set with gear if the acc pedal changes only at pos or service certain vehicle brake-switch...
  • Page 373 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 intermittent or CS error or sent memory incorrect program code Cranking is missing inhibited Engine can not Deactivate: start Flash CS OK 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...
  • Page 374 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 engagement set the fault sent activate/deactivate: engagement of low range code: Loss of torque system The following conditions -The low range gear can not must be fulfilled three times engage (only once if the fault code- filter is switched OFF) in a row, in order to set the fault...
  • Page 375 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 air pressure the range cylinder valves Detailed conditions to activate / deactivate: Activate: The position sensor is distributing a temperature-signal from the sensor ASIC, if the value Activate: The from this sensor deviates position sensor too much this fault code is is distributing a...
  • Page 376 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 sensor signal is uphill gear in the normal change range performance may be reduced Activate: temp Data valid but Sensor for above 125dgC above normal Yellow lamp is the PCB FMI0 PPID55 Deactivate:...
  • Page 377 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 calibrated Detailed conditions to activate / deactivate: Activate: The position sensor is distributing a temperature-signal from the sensor ASIC, if the value Activate: The from this sensor deviates position sensor too much this fault code is is distributing a triggered, the diagnostics...
  • Page 378 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Deactivate: means that if the value differs more than +/- 20dgC from the average-temp, if the temperature is out of boundary -60dgC to +160dgC or if the temperature changes at a rate higher than 10dgC during 15s, then this fault code is set.
  • Page 379 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 sensor signal is in normal range Activate: The Sensor for sensor signal is Current below below normal the pressure Yellow lamp is FMI5 normal or range sent of the supply open circuit Deactivate: The air (SEPrSA)
  • Page 380 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 speed calculated from the countershaft speed sensor (SESC) is more than 300rpm, or -the value of the input shaft speed calculated from the main shaft speed sensor (SESM) is more than 300rpm -The values of the input shaft speed calculated from...
  • Page 381 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 engagement only possible at standstill and when the vehicle speeds is high enough to synchronize the main box with the engine Yellow lamp is sent Reduced gear change performance Gearbox brake up shifts can not be used Activate: The...
  • Page 382 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 vehicle ECU differ less than 30rpm There is no active fault on any of The sensor for the countershaft speed (SECS) The sensor for the position of the split cylinder (SEPoS) The sensor for the position of the shift cylinder1R (SEPo1R)
  • Page 383 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 (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) indicates reverse movement...
  • Page 384 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 -The sensor for the clutch position (SePoC) -The sensor for the position of the split cylinder (SePoS) -The sensor for the position of the shift cylinder (1R SEPo1R) -The sensor for the position of the shift cylinder (23 SEPo23) -The sensor for the range...
  • Page 385 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 2. Temperature is below 120dgC Activate high: 1. The sensor signal is in normal range 2. Temperature is above 140dgC during 30s Deactivate high: 1. The sensor signal is in normal range Temperature is below 140dgC Sensor for...
  • Page 386 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 range Activate: 1. Open circuit on any of the sensor signals is detected when: one of the sensor signals is within normal range and the Yellow lamp is other sensor sent signal is below Sensor...
  • Page 387 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 low-side drive is disabled Reduced clutch performance, especially at start and marshalling Activate: 1. The low-side drive is Yellow lamp is short circuit to sent Slow Gnd and engagement Current above 2.
  • Page 388 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 (SEPoS) the valve for shift to direct split the valve for shift to indirect split - There is no active fault code for low air pressure Note: The fault will always have the state inactive.
  • Page 389 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 conditions are fulfilled: - The split cylinder position sensor indicates that indirect position is engaged - There is an active fault 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...
  • Page 390 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 split cylinder position sensor indicates that neutral position is engaged - There is an active fault code on any of the sensor...
  • Page 391 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Deactivate: The not be activated PTO number high side drive is The PTO does 2 (VAP2) not work Activate: The Yellow lamp is high side drive is Valve for Current above sent short circuit to activating the...
  • Page 392 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Gear changes are slow Yellow lamp is sent The valve is activated Activate: The Indirect and high side drive is neutral split Valve for Voltage short circuit to gears are shifting to above normal SID37...
  • Page 393 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 changes only at certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated high side drive is Gears are Valve for Current above short circuit to missing shifting to normal or...
  • Page 394 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 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 FMI5 normal or Automatic gear...
  • Page 395 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 speeds Yellow lamp is sent The valve is Activate: The activated high side drive is Low range gears Valve for Voltage short circuit to are missing shifting to above normal FMI3 Ubatt Automatic gear...
  • Page 396 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 certain vehicle speeds Yellow lamp is sent The valve can Activate: The not be activated high side drive is Split gears are Valve for Current above short circuit to missing shifting to normal or FMI6...
  • Page 397 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 Valve for Yellow lamp is Activate: The sent slow high-side drive is Current below Slow disengage- open circuit FMI5 normal or disengagement ment of the Deactivate: The open circuit disabled high-side drive is clutch Reduced clutch...
  • Page 398 SECTION 07: TRANSMISSION FUNCTION PID/SID ERROR CONDITION SYMPTOM COMMENT J1587 normal or high side drive is sent gearbox grounded short circuit to The valve can brake circuit not be activated (VAGB) Shifting to the Deactivate: The start gear takes high side drive is long time 11.
  • Page 399 SECTION 07: TRANSMISSION PID/PPID LAMP CONTENT TEXT COMMENT CONSEQUENCES SID/PSID Only when second Not possible to switch Data Link, gear PSID214 None to/from secondary gear MID249 selector is lever installed, Boot 12. SPECIFICATIONS ALLISON AUTOMATIC TRANSMISSION WITH OR WITHOUT RETARDER Over-the-road coaches.
  • Page 400 SECTION 07: TRANSMISSION 6 speed ................................. 5.48:1 Gear ratios do not include torque converter multiplication. Oil System: Oil type ......................... TRANSYND, TES295, TES389 Capacity (excluding external circuits) ..............Initial fill 47 US qts (45 liters) Oil change ..........................24 US qts (23 liters) Oil change (with retarder) ....................
  • Page 401 SECTION 09: PROPELLER SHAFT CONTENTS     SECTION CHANGE LOG ............................ 2     STANDARD TORQUE SPECIFICATION TABLES .................... 3     PROPELLER SHAFT ............................ 3     DESCRIPTION ..............................  3     INSPECTION, LUBRICATION, REMOVAL AND INSTALLATION ................ 4     EXPLANATION OF COMMON DAMAGES  ...................... 5     SPECIFICATIONS ............................ 6 PA1621 Maintenance Manual All Series | January 2017...

  • Page 402: Section Change Log

    SECTION 09: PROPELLER SHAFT SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series January 2017...

  • Page 403: Standard Torque Specification Tables

    Furthermore, a slip joint on the propeller shaft compensates for variations in distance between FIGURE 3: COLD FORMED BEARING RETAINER AND BOLTS AS USED ON PREVOST VEHICLES the transmission and the differential, or between the output retarder (optional on the automatic...

  • Page 404: Inspection, Lubrication, Removal And Installation

    SECTION 09: PROPELLER SHAFT NOTE INSPECTION, LUBRICATION, REMOVAL Do not assume that bearing cavities have been AND INSTALLATION filled with new grease unless it has expelled around all seals. Please, refer to Spicer Driveshaft’s Service Manual DSSM-0100 for further details. MAINTENANCE Perform “Inspection Procedures”...
  • Page 405 SECTION 09: PROPELLER SHAFT FIGURE 4: PROPELLER SHAFT ASSEMBLY (TYPICAL) 4. Pitting: Small pits or craters in metal EXPLANATION OF COMMON DAMAGES surfaces due to corrosion. If excessive, pitting can 1. Cracks: Stress lines due to metal fatigue. lead to surface wear and eventual failure. Severe and numerous cracks will weaken the 5.

  • Page 406: Specifications

    SECTION 09: PROPELLER SHAFT tubing to twist under strain or it may cause cracks or breaks in U-joints and spline plugs. SPECIFICATIONS PROPELLER SHAFT Make ............................Dana-Spicer Inc. Series ................................. SPL250 PA1621 Maintenance Manual All Series January 2017...
  • Page 407 SECTION 10: FRONT I-BEAM AXLE CONTENTS   SECTION CHANGE LOG ............................ 2     TORQUE TABLES ............................ 3     FRONT I‐BEAM AXLE AND RELATED COMPONENTS  ..................  3     FRONT I‐BEAM AXLE HUB, ROTOR AND BRAKES  ...................  5     DESCRIPTION  .............................. 6     REFERENCE MANUALS  ...........................  6     LUBRICATION ............................. 9     MAINTENANCE ............................ 9  ...

  • Page 408: Section Change Log

    SECTION 10: FRONT I-BEAM AXLE SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series January 2017...

  • Page 409: Torque Tables

    SECTION 10: FRONT I-BEAM AXLE TORQUE TABLES 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 410 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 411: Front I-Beam Axle Hub, Rotor And Brakes

    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 412: Description

    SECTION 10: FRONT I-BEAM AXLE DESCRIPTION The Dana Spicer S84U front axle is of the ‘’Reverse Elliot’’ type. The front axle consists of a girder section beam with knuckles. Each knuckle is carried on a parallel king pin, with a steep angle taper roller bearing at its top and a plain phosphor bronze bush at bottom.
  • Page 413 SECTION 10: FRONT I-BEAM AXLE FIGURE 1: FRONT AXLE ASSEMBLY (I-BEAM) PA1621 Maintenance Manual All Series January 2017...
  • Page 414 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 415: Lubrication

    SECTION 10: FRONT I-BEAM AXLE looseness can be visually detected while rotating the steering wheel in both directions. LUBRICATION Steering knuckles, knuckle pins and bushings can be overhauled or replaced without removing the MAINTENANCE axle from the vehicle. However, if extensive overhaul work is necessary, the axle assembly should be removed.

  • Page 416: Replacement

    SECTION 10: FRONT I-BEAM AXLE 6. Disconnect the height control valve link from its support on the axle. 7. Disconnect lines from front brake chambers, and cover line ends and fittings to prevent the entry of foreign matter. CAUTION Position the air lines and electric wires so they will not be damaged while removing the front axle assembly.

  • Page 417: Service Instructions For Steer Axle

    SECTION 10: FRONT I-BEAM AXLE SERVICE INSTRUCTIONS FOR STEER NOTE AXLE To avoid inaccurate measurements, be careful not to let the knuckle turn while moving assembly in and out. Applying brakes will help lock wheel assembly. MAINTENANCE 6.1.2 Checking Vertical Slackness An inspection should be made at the intervals 1.

  • Page 418: Minor Front Wheel Alignment

    SECTION 10: FRONT I-BEAM AXLE Hubs and Tires’’. Inspect the tires for wear Check the hub bearings. See section 13, patterns indicating suspension damage or ‘’Wheels, hubs and Tires’’ under heading 8: misalignment. Front and Tag Axle Wheel Hubs. Make sure the tires are inflated to the NOTE specified pressure.

  • Page 419: Turn Adjustment

    SECTION 10: FRONT I-BEAM AXLE 4. Verify the nearest point of contact of the drag HYDRAULIC STOP link with the tire. Measure the distance NOTE between those two points. Before steering limiter readjustment, verify 5. The distance should be 1 inch (25 mm) or vehicle wheel alignment and ensure that oil more.

  • Page 420: Front Axle Caster

    Section 13, ‘’Wheels, Hubs and needs adjustment; it can be adjusted by means Tires’’ under heading, ‘’Checking for Distort- of shims (Prevost #110663) on the left-hand ed Wheel on Vehicle’’. If distortion is exces- side upper radius rod support in order to obtain sive, straighten or replace wheel(s).

  • Page 421: Inspection And Adjustment

    SECTION 10: FRONT I-BEAM AXLE been jacked up in order to mark the tires. Otherwise, the front wheels will not return to their normal operating position due to the tires gripping the floor surface when the vehicle jack is lowered. NOTE ‘’Toe-in’’...

  • Page 422: Troubleshooting

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

  • Page 423: Specifications

    SECTION 10: FRONT I-BEAM AXLE 10. SPECIFICATIONS Front Axle Make ..........................DANA SPICER EUROPE Model ................................S84U Front Track ........................84.4 inches (2 145 mm) Rated load capacity ......................16,500 lbs (7 500 kg) PA1621 Maintenance Manual All Series January 2017...
  • Page 424 SECTION 10: FRONT I-BEAM AXLE PA1621 Maintenance Manual All Series January 2017...
  • Page 425 SECTION 11: REAR AXLES CONTENTS       TORQUE TABLES ............................ 3      ............................  3 MERITOR DRIVE AXLE      ............................  4 ZF A  DRIVE AXLE       ................................  5 TAG AXLE     MERITOR DRIVE AXLE .......................... 6      ..............................  6 ESCRIPTION     DCDL ‐ ) ....................  6  ...
  • Page 426 SECTION 11: REAR AXLES SECTION CHANGE LOG  DESCRIPTION DATE       PA1621 Maintenance Manual All Series | January 2017...

  • Page 427: Torque Tables

    SECTION 11: REAR AXLES TORQUE TABLES MERITOR DRIVE AXLE MERITOR DRIVE AXLE DESCRIPTION TORQUE Breather 12-18 lb-pi (16-24 Nm) Fill / Level check plug 35 lb-pi (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 428: 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 429: 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 430: Dcdl

    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 431: Drive Axle Lubrication

    SECTION 11: REAR AXLES 2.3.1 Drive Axle Lubrication multigrade gear meeting specification GL-5. Petroleum based gear oil may be used for standard drains interval. Fully synthetic gear oil must be used for extended drains interval. In extreme conditions, or for better performance, fill with synthetic gear oil.

  • Page 432: Draining And Replacing The Oil

    SECTION 11: REAR AXLES b. If the oil level is below the bottom of the Rockwell WABCO Maintenance Manual: “Anti- hole of the fill plug, add the specified oil. Lock Brake Systems For Trucks, Tractors and Buses", found on your Technical Publications 5.

  • Page 433: Disassembly And Reassembly

    SECTION 11: REAR AXLES DISASSEMBLY AND REASSEMBLY remember to replace them afterwards. Disassembly and re-assembly procedures are 7. Disconnect the brake chamber hoses. covered under applicable headings in Meritor's "MAINTENANCE MANUAL, NO. 5A", found on NOTE your Technical Publications USB flash drive. Position the hoses so they will not be damaged when removing the axle.

  • Page 434: Drive Axle Alignment Specifications

    SECTION 11: REAR AXLES NOTE When drive axle alignment is modified, tag axle alignment must be re-verified. 2.10.1 Procedure Park vehicle on a level surface, then chock front vehicle wheels. Using two jacking points (which are at least 30 inches [76 cm] apart) on drive axle, raise the vehicle sufficiently so that wheels can turn freely at about ½...

  • Page 435: Zf A132 Drive Axle

    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 436: Maintenance

    SECTION 11: REAR AXLES WARNING Check the oil level when the axle is at room temperature. When hot, the oil temperature may be 190ºF (88ºC) or more and can cause burns. Also, a correct reading is not obtained FIGURE 10: ZF A132 DRIVE AXLE 11019 when the axle is warm or hot.

  • Page 437: Compact Bearing (Hub Unit) Axial Play Check

    SECTION 11: REAR AXLES  Put a large container under the differential case drain plug. The differential case contains approximately 19 quarts of oil. MAINTENANCE  Remove the drain plug from the bottom of the differential case. Drain all the oil and discard Oil change interval –...

  • Page 438: Compact Bearing (Hub Unit) Grease Change

    SECTION 11: REAR AXLES MAINTENANCE Compact bearing (hub unit) axial play Check the bearing axial play once a year or every 100 000 miles (160 000 km) whichever occurs first. 3.1.5 Compact bearing (hub unit) Grease Change Perform compact bearing (hub unit) grease change as described in paragraph 7.3 GREASE CHANGE IN THE HUB of the following manual: OPERATING INSTRUCTIONS ZF AXLE A132...
  • Page 439 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 PA1621 Maintenance Manual All Series | January 2017...

  • Page 440: Removal And Reinstallation

    SECTION 11: REAR AXLES 16. Disconnect the lower ends of the four shock REMOVAL AND REINSTALLATION absorbers as outlined in Section 16, "Suspension" under heading "Shock The following procedure deals with the removal Absorber Removal". of the drive axle assembly and its attachments as a unit.

  • Page 441: Tag Axle

    SECTION 11: REAR AXLES If the axle has been removed for repairs or 4. With the system installed as in Figure 7, servicing and if all the parts are reinstalled adjust drive axle according to specifications' exactly in the same place, the axle alignment is chart below.

  • Page 442: Retracting Tag Axle

    SECTION 11: REAR AXLES RETRACTING TAG AXLE MAINTENANCE The standard tag axle retraction system is controlled by a valve located on the right lateral Front and tag axle hub bearings need to be console and enables unloading and raising the checked at the intervals specified by the tag axle (refer to the "OPERATOR'S MANUAL"...

  • Page 443: Removing Transversal Radius Rod

    SECTION 11: REAR AXLES 14. Use the jacks to move the axle forward to clear the axle off the transmission. Lower the 1. Raise vehicle by its jacking points on the axle. body (Figure 5) or see Section 18, "Body" under heading: "Vehicle Jacking Points").

  • Page 444: Tag Axle Alignment

    SECTION 11: REAR AXLES wheel alignment systems which work with angle CAUTION measurements only, such as Josam or Hunter systems. It is strongly suggested to use the extractor tool in order to remove transversal radius rod. TAG AXLE Alignment / Minimum Nominal Maximum...
  • Page 445 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 PA1621 Maintenance Manual All Series | January 2017...
  • Page 446 SECTION 11: REAR AXLES PA1621 Maintenance Manual All Series | January 2017...
  • Page 447 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS    SECTION CHANGE LOG ............................ 4     TORQUE TABLES ............................ 5     BRAKE AND AIR SYSTEM ..........................  5     MISCELLANEOUS TORQUES ...........................  7     AIR SYSTEM .............................. 8     BRAKES .............................. 8     AIR RESERVOIRS ............................ 8     MAINTENANCE ..............................  8     4.1.1 Wet Air Tank ............................  9     4.1.2 Primary Air Tank ............................ ...
  • Page 448 SECTION 12: BRAKE AND AIR SYSTEM     FLIP‐FLOP CONTROL VALVE (TW‐1)  ......................  1 6     DUAL BRAKE VALVE (E‐8P) ........................  1 6     15.1.1 Brake Pedal Adjustment ........................  1 7     15.1.2 Maintenance  ............................  1 7     STOPLIGHT SWITCHES ..........................  1 7     PARKING BRAKE ALARM SWITCH ......................  1 7  ...
  • Page 449 SECTION 12: BRAKE AND AIR SYSTEM     31.1 TROUBLESHOOTING AND TESTING  ......................  3 0     31.2 ABS COMPONENTS ............................  3 0     31.3 BENDIX EC‐60 ADVANCED CONTROLLER  .....................  3 0     31.4 SENSORS ..............................  3 1     31.4.1 Spring clip.............................  3 2  ...

  • Page 450: Section Change Log

    SECTION 12: BRAKE AND AIR SYSTEM SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...

  • Page 451: Torque Tables

    SECTION 12: BRAKE AND AIR SYSTEM 1. TORQUE TABLES 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 &...
  • Page 452 SECTION 12: BRAKE AND AIR SYSTEM BRAKE AND AIR SYSTEM DESCRIPTION TORQUE Meritor hub to disc cap screws 110-165 lb-ft (149-224 Nm) ZF drive axle caliper mounting bolts 200 lb-ft (271 Nm) ZF drive axle brake chamber mounting bolts 120-150 lb-ft (163-203 Nm) Steering angle sensor mounting screws 9-12 lb-in (1-1 Nm) Steering column U-joint bolts...

  • Page 453: Miscellaneous Torques

    SECTION 12: BRAKE AND AIR SYSTEM MISCELLANEOUS TORQUES MISCELLANEOUS TORQUES DESCRIPTION TORQUE Air filter/dryer connections - 3/8”-18 NPTF 12 lb-ft (16 Nm) Air filter/dryer connections - 1/4”-18 NPTF 12 lb-ft (16 Nm) Air filter/dryer connections - 1/2”-14 NPTF 37 lb-ft (50 Nm) 1/4"...

  • Page 454: Air System

    SECTION 12: BRAKE AND AIR SYSTEM system allows the driver to release spring brakes, and to move the vehicle to a safe 2. AIR SYSTEM parking place, such as in the case of a self- application of these brakes due to a drop in air pressure.

  • Page 455: Wet Air Tank

    SECTION 12: BRAKE AND AIR SYSTEM FIGURE 1: INDEPENDENT SUSPENSION AIR TANKS LOCATIONS (SHOWN WITH VIP EXPANSION TANKS) FIGURE 2: I-BEAM AXLE SUSPENSION AIR TANKS LOCATIONS (TYPICAL WITH VIP EXPANSION TANKS) 4.1.1 Wet Air Tank This reservoir located in front and above the L.H.

  • Page 456: Kneeling Air Tank

    (965 kPa). Air filled through these two points will pass through the standard air filtering 4.1.5 Kneeling Air Tank system provided by Prevost. Do not fill system by any other point on the system. The kneeling air tank is installed on vehicles...

  • Page 457: Accessory Air Filter Element

    SECTION 12: BRAKE AND AIR SYSTEM Its main function consists in filtering the air gauge is connected to the front pneumatic panel supplied to the accessory air system, when in the front compartment of the vehicle. The connected to an external supply line. Ensure vehicle should never be set in motion until the filter is purged whenever supplying the system buzzer alarm and warning lights turn off, i.e.

  • Page 458: Replacing The Desiccant Cartridge

    SECTION 12: BRAKE AND AIR SYSTEM guaranteed and fuel consumption is reduced. REPLACING THE DESICCANT This will be noticed as a different compressor CARTRIDGE start/stop pattern. To replace the desiccant cartridge: The air dryer has a built-in function to prevent freezing or blockage.

  • Page 459: Air Lines

    SECTION 12: BRAKE AND AIR SYSTEM This icon may appear in the DID if the Nylon air lines must never be routed in areas compressor is charging abnormally which is where temperature could exceed 200 F (93 usually an indication of an air leak. CAUTION 9.

  • Page 460: Pressure Regulating Valves

    SECTION 12: BRAKE AND AIR SYSTEM chafing or cutting may occur. Replace with new material as required. In general, lines should be securely located in position and free from any binding condition, which would hinder air flow. 10. PRESSURE REGULATING VALVES There is one pressure regulator (Figure 8) for small compressor...

  • Page 461: Compressor Removal And Installation

    SECTION 12: BRAKE AND AIR SYSTEM engine, at the flywheel end (Figure 10). Its Item Description Notes function is to provide and maintain air under pressure to operate devices in brake and air Air Compressor Wabco 636 systems. O-ring The compressor is driven by the ring gear, and Stud (3) is water cooled.

  • Page 462: Flip-Flop Control Valve

    SECTION 12: BRAKE AND AIR SYSTEM FIGURE 11: PP-1 12142 Maintenance and repair information on this valve is supplied in the applicable booklet, found on FIGURE 12: RD-3 12136 your Technical Publications USB flash drive, under reference number SD-03-3611. 14. FLIP-FLOP CONTROL VALVE (TW-1) Remove the valve the following way: A flip-flop control valve mounted on the L.H.

  • Page 463: Brake Pedal Adjustment

    SECTION 12: BRAKE AND AIR SYSTEM 15.1.1 Brake Pedal Adjustment After brake pedal replacement or repair, adjust the pedal to its proper position according to the following procedure: 1. Replace the linkage, loosen threaded rod lock nut and screw or unscrew the threaded adjustment rod in order to obtain a 45 brake pedal inclination (Figure 14).

  • Page 464: Antilock Traction Relay Valve (Atr-6)

    SECTION 12: BRAKE AND AIR SYSTEM  Modulates spring brake actuator application using the dual brake valve should a primary failure occur in the service brake system.  Prevents compounding of service and spring forces. Maintenance and repair information on the spring brake valve is supplied in the applicable booklet, found on your Technical Publications USB flash drive, under reference number...

  • Page 465: Emergency Door Opening Valves

    SECTION 12: BRAKE AND AIR SYSTEM 23. EMERGENCY DOOR OPENING VALVES Two emergency door opening three-way valves are installed on passenger coaches. One is in front service compartment, readily accessible. The other one is on the R.H. side lateral console, close to the entrance door. When used, the valve releases pressure in the door locking cylinder, thus allowing the door to be manually opened.

  • Page 466: Brake Operation

    SECTION 12: BRAKE AND AIR SYSTEM the drive and tag axle brakes, while the secondary circuit is connected to the front axle Air pressure doesn't rise to or doesn't brakes. The tag axle service brakes operate maintain a normal setting: only when the axle is in the normal driving (loaded) position.

  • Page 467: Inspection Points

    Y006471 Service Manual). Technical Publications Check the caliper running clearance USB flash drive and also available Prevost Check that caliper operates smoothly over its Technical Publications site. full range of movement. Inspect all sealing elements (boots and caps). 27.1 INSPECTION POINTS...

  • Page 468: Pad Replacement - Adjuster

    SECTION 12: BRAKE AND AIR SYSTEM FIGURE 22: BRAKE COMPONENTS Depending on the age of the vehicle, it may have installed on it two different design levels of 27.2 PAD REPLACEMENT - ADJUSTER disc brake and so there may be 2 different clicking noises and final positions of the adjuster Brake pad replacement procedure has slightly on the vehicle.

  • Page 469: Drive Axle - Equipped With A Solid Rubber Bushing And Exposed Guide Pin

    SECTION 12: BRAKE AND AIR SYSTEM 27.3.1 Drive Axle – Equipped With a Solid Alternately, brake pad wear can be checked Rubber Bushing and Exposed Guide Pin using carrier to caliper position. When points “P” and “R” align the brake pad thickness and brake disc must be checked with the wheels removed The condition of the pads can be visually (Figure 25).

  • Page 470: 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 471: Brake Disc

    SECTION 12: BRAKE AND AIR SYSTEM 27.4.2 Brake Disc with inhaling non-asbestos fibers. Nonetheless some experts think that long-term Measure the thickness of the brake disc at the exposure to some non-asbestos fibers could thinnest point. Be aware of possible burring at cause diseases of the lung, including pneumo- the edge of the disc.

  • Page 472: Air Brake Troubleshooting

    SECTION 12: BRAKE AND AIR SYSTEM with care to avoid getting dust into the air. the use of those tools. Use an approved respirator when emptying Always clean connecting piping and/or fittings, vacuum cleaners and handling used rags. and coat pipe threads with Teflon pipe sealant Wash your hands before eating, drinking or before installing...

  • Page 473: Brake Air Chamber

    SECTION 12: BRAKE AND AIR SYSTEM  Check compressor strainer or inlet line. If 2. Hold down foot valve for 1 minute while observing air pressure gauge on the dash- restricted, clean or replace element or faulty board. line.  Check compressor head or discharge line for 3.

  • Page 474: Maintenance

    SECTION 12: BRAKE AND AIR SYSTEM 30.2 EMERGENCY/PARKING BRAKE MANUAL RELEASE DANGER Never stand in the axis line of the spring brake chambers, especially when caging the spring. Drive Axle 1. Block the wheels to prevent the vehicle from moving. 2.

  • Page 475: Brake Chamber Removal

    2. Safely support vehicle at the recommended dations must be applied: body jacking points. o Prevost recommends the installation of a new spring brake chamber if it is found to 3. To gain access to a given brake air be defective.

  • Page 476: Anti-Lock Braking System (Abs)

    SECTION 12: BRAKE AND AIR SYSTEM 4. For the drive and tag axles brake chambers, manually release spring brakes (refer to NOTE “Emergency/Parking Brake Manual lease" procedure in this section). ABS is active on service brake, transmission retarder, engine brake, but is inactive on 5.

  • Page 477: Sensors

    FIGURE 33: ABS SENSOR LOCATION Maintenance 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 FIGURE 32: ABS ECU LOCATION paragraph “Sensor Installation”...

  • Page 478: Spring Clip

    SECTION 12: BRAKE AND AIR SYSTEM 3. Push the sensor completely inside the 32. BENDIX AUTOMATIC TRACTION spring clip until it is in contact with the tooth CONTROL (ATC) – ELECTRONIC STABILITY wheel. Ensure mounting is rigid, as it is an CONTROL (ESC) important criterion for adequate sensor operation.

  • Page 479: The

    Dash-mounted TCS Mud/Snow switch;  J1939 serial communication to engine 6s/5m Configuration control module. Prevost vehicles utilize a 6 sensors/5 pressure modulator valves configuration, with the tag axle having two sensors, but only one Pressure 32.1.3 The EC-60 controller’s ESC/RSP Modulator Valve.
  • Page 480 SECTION 12: BRAKE AND AIR SYSTEM surface and the tires is not sufficient to oppose lateral (side) forces, one or more of the tires can slide, causing the vehicle to spin. These events are referred to as either an “under-steer” situation (where there is a lack of vehicle response to steering input due to the slide on the front axle) or an “over-steer”...

  • Page 481: Removal Of The Steering Angle Sen- Sor

    SECTION 12: BRAKE AND AIR SYSTEM The SAS-70 sensor installed on Prevost vehicles TORQUE: 35-39 lb-ft (47-53 Nm) is the 90° connector. 4. Reconnect the connector. Ensure that there will be no force applied to the sensor 32.4.1 Removal of the steering angle sen- because the connector is pulling on the sensor body.

  • Page 482: Fitting Tightening Torques

    12055 Tubing Number of additional diameter turns required following (inch) manual tightening 3/8 to 1/2 5/8 to 3/4 3 ½ NOTE Use Loctite pipe sealant to seal pipe thread (Prevost number 680098). PA1621 Maintenance Manual All Series | January 2017...
  • Page 483 Model ............................... SR-1 Pressure Protection Valve Make ..............................Bendix Model ............................... PR-4 Nominal closing pressure ...................... 70 psi (482 kPa) Prevost number ........................... 641137 Shuttle-Type Double Check Valve Make ..............................Bendix Model ............................... DC-4 Air Pressure Regulator Make ..............................Norgren Adjustable output range ..................
  • Page 484 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 PA1621 Maintenance Manual All Series | January 2017...
  • Page 485 SECTION 13: WHEELS, HUBS AND TIRES CONTENTS     SECTION CHANGE LOG ............................ 3     TORQUE TABLES ............................ 4     WHEEL NUTS  ..............................  4     TAG AXLE ...............................  4     FRONT AXLE ..............................  5     MERITOR DRIVE AXLE ............................  5     ZF A132 DRIVE AXLE ............................  6     WHEELS  .............................. 7  ...
  • Page 486 SECTION 13: WHEELS, HUBS AND TIRES     ZF DRIVE AXLE WHEEL HUBS ........................  2 0     12.1 COMPACT BEARING (HUB UNIT) AXIAL PLAY CHECK  ...................  2 0     12.2 COMPACT BEARING (HUB UNIT) GREASE CHANGE ..................  2 1     SPARE WHEEL ............................  2 1     13.1 SUPER SINGLE TIRE REPLACEMENT ......................  2 2     13.2 PULLING OUT SPARE WHEEL ........................  2 2  ...

  • Page 487: Section Change Log

    SECTION 13: WHEELS, HUBS AND TIRES SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...

  • Page 488: 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 489: Front Axle

    SECTION 13: WHEELS, HUBS AND TIRES 1.3 FRONT AXLE 13041_4 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)

  • Page 490: 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) PA1621 Maintenance Manual All Series | January 2017...

  • Page 491: 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 492: 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 493: 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 494: 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 495: 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 496 SECTION 13: WHEELS, HUBS AND TIRES FIGURE 7: TAG AXLE HUB AND ROTOR ASSEMBLY FIGURE 8: TAG AXLE UNITIZED BEARING & WHEEL HUB PA1621 Maintenance Manual All Series | January 2017...

  • Page 497: Tag Axle Hub Bearing Inspection

    20000 lbf clearance/end (90kN). play FIGURE 9: INSERTION TOOL PREVOST P/N 491115 Tag Axle Unitized Hub Bearing Axial Apply a thin layer of antifriction/antifretting Endplay In Service lubricant on spindle where bearing will be located (use Gleitmo 805 grease, Prevost ...
  • Page 498 The clip can be dislodged as per the two pictures below. Always use the insertion tool PREVOST p/n 491115 FIGURE 13: CLEANING HUB BEARING, ROTOR AND HUB FLANGE CLAMPING SURFACES Install rotor onto hub bearing.
  • Page 499 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 500: 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 501: Front Axle Hub Bearing Removal

    The difference between readings is the amount of mounted end play in bearing unit. The mounted end play figure should not FIGURE 18: INSERTION TOOL PREVOST P/N 491115 exceed: Apply a thin layer of lubricant on spindle where bearing will be located, use Gleitmo ...
  • Page 502 The clip can be dislodged as per the two pictures below. Always use the insertion tool PREVOST p/n 491115 FIGURE 21: INSTALL THRUST WASHER Check the bearing end play as described in 10.1 FRONT AXLE Hub Bearing Inspection...

  • Page 503: Meritor Drive Axle Wheel Hubs

    SECTION 13: WHEELS, HUBS AND TIRES vehicle Technical Publications USB flash lubricant (refer to Section 24 "Lubrication" for drive in PDF format to complete this step: proper oil grade selection) to ensure adequate oil supply to wheel bearings at all times. Dana Parts &...

  • Page 504: Zf Drive Axle Wheel Hubs

    SECTION 13: WHEELS, HUBS AND TIRES No. 23A" annexed to Section 11 of this manual. 2. Remove wheels and tires. NOTE It is good practice to mark position of the wheel on the axle before removal and replace wheel same position during reinstallation.

  • Page 505: Compact Bearing (Hub Unit) Grease Change

    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. FIGURE 27: ZF A-132 DRIVE AXLE HUB ASSEMBLY 12.2 COMPACT BEARING (HUB UNIT) GREASE CHANGE hub carrier...

  • Page 506: Super Single Tire Replacement

    SECTION 13: WHEELS, HUBS AND TIRES The spare wheel is stored in a dedicated On H3 series vehicles, Untighten the pressure compartment behind the front bumper. To screw holding the tire in place. Lift the pressure access, pull the release handle located in the screw arm and move to the side.

  • Page 507: Changing A Flat Tire (Coaches Only)

    SECTION 13: WHEELS, HUBS AND TIRES NOTE NOTE On H3 series vehicles, the pressure screw Check the inflation pressure of the spare tire must return initial position periodically to keep it ready for use. Inflate otherwise, the bumper cannot be latched in spare tire to the pressure of the tire, which has upper position.

  • Page 508: Spare Wheel Maintenance

    SECTION 13: WHEELS, HUBS AND TIRES the triangular reflectors in accordance with applicable highway regulations. It is strongly suggested that you do not attempt to change a wheel, the wheel and tire are very heavy and there is usually no space available to put the removed flat.

  • Page 509: 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 510: 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 511: 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 512 For other control. tire and wheel specifications, see Prevost tire pressure tabulation in "Coach Final Record". PA1621 Maintenance Manual All Series | January 2017...

  • Page 513: 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 514: 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 515 SECTION 14: STEERING CONTENTS     SECTION CHANGE LOG ............................ 3     TORQUE TABLES ............................ 4     STEERING COLUMN ............................  4     MISCELLANEOUS TORQUES ...........................  5     STEERING SYSTEM ............................ 7     FRONT I‐BEAM AXLE STEERING SYSTEM DESCRIPTION  .................  7     INDEPENDENT FRONT SUSPENSION STEERING SYSTEM DESCRIPTION  ............  8     POWER STEERING GEAR .......................... 9     DESCRIPTION ..............................  9  ...
  • Page 516 SECTION 14: STEERING     13.1 POWER STEERING FLUID CONDITION  ......................  1 9     13.1.1 Power Steering Fluid Visual Inspection  ....................  1 9     13.2 POWER STEERING FLUID CHANGE  .......................  2 0     13.3 POWER STEERING FLUID LEVEL CHECK .......................  2 0     13.3.1 Filter Element Replacement .......................  2 1    ...

  • Page 517: Section Change Log

    SECTION 14: STEERING SECTION CHANGE LOG DESCRIPTION DATE New paragraphs added: 13.1 Power Steering Fluis Condition; 13.1.1 Power Steering Nov. 2017 Fluid Visual Inspection PA1621 Maintenance Manual All Series | January 2017...

  • Page 518: 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) PA1621 Maintenance Manual All Series | January 2017...

  • Page 519: 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 520 SECTION 14: STEERING Drag Link Ball Joint Stud Nut - IFS 245-270 lb-ft (332-366 Nm) Draglink Clamp Bolt - IFS 50-60 lb-ft (68-81 Nm) PA1621 Maintenance Manual All Series | January 2017...

  • Page 521: Steering System

    SECTION 14: STEERING These elements are: 1. Steering stabilizer (damper); STEERING SYSTEM 2. A vane type hydraulic pump; 3. Hydraulic reservoir and hoses. FRONT I-BEAM AXLE STEERING The steering stabilizer reduces road shocks and SYSTEM DESCRIPTION vibrations in the system. The steering gearbox is self-powered and provides movement with power assistance to the left wheel.

  • Page 522: Independent Front Suspension Steering System Description

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

  • Page 523: Power Steering Gear

    SECTION 14: STEERING FIGURE 2: IFS STEERING SYSTEM SETUP 14076 shaft connection, turns together with the worm as the steering wheel is turned. 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 FIGURE 3: POWER STEERING GEAR 14035...

  • Page 524: Power Steering Gear Removal

    SECTION 14: STEERING TROUBLESHOOTING functional aspects maintenance procedure of the steering gear. Perform troubleshooting of the steering gear as outlined in the "ZF-SERVOCOM Repair Manual" POWER STEERING GEAR REMOVAL “ZF-SERVOCOM Design, Operation, Maintenance, Inspection” found your Technical Publications USB flash drive. WARNING The steering gearbox weighs approximately 100 BLEEDING...
  • Page 525 SECTION 14: STEERING 2. Clean around the fuel pump and fuel lines. Position a container to catch any fuel that might drain from the pump or lines. 3. Remove the fuel pump. NOTE Only unfasten the bolts marked with arrows. FIGURE 7: FUEL PUMP DRIVE AXLE 5.

  • Page 526: Steering Column

    SECTION 14: STEERING NOTE Use a new sealing ring. Check that the fuel pump drive axle sits correctly in the power steering pump. 11. Start the engine and let run for 5 minutes. Make sure that there are no leaks. STEERING COLUMN REMOVAL To disassemble the steering column from system,...

  • Page 527: Steering Wheel

    SECTION 14: STEERING FIGURE 12: STEERING HARNESS & HORN WIRE 4. Unscrew the steering wheel nut. To simplify installation ensure steering wheel alignment, mark the relationship of the spline shaft to the steering wheel hub (if marks don’t already exist or don’t line up). 5.

  • Page 528: 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. 3.

  • Page 529: Steering Linkage Adjustment

    SECTION 14: STEERING 10. STEERING LINKAGE ADJUSTMENT Steering linkage pivot points should be checked each time they are lubricated. Looseness can be visually detected while rotating the steering wheel in both directions. Replace defective parts. 10.1 COACHES The steering linkage includes the pitman arm, drag link, steering arm, tie rod arms and tie rod.

  • Page 530: Installation

    SECTION 14: STEERING WARNING Always wear approved eye protection when operating pullers. CAUTION Do not drive (hammer in) pitman arm on or off pitman shaft as this can damage the steering gear. CAUTION FIGURE 19: IFS PITMAN ARM ADJUSTMENT Heating of components to aid in disassembly is 7.

  • Page 531: Tag Axle Unloading Switch Adjustment (Optional)

    SECTION 14: STEERING the rod end. Install washers. Tighten nut and install a new cotter pin. Depending on axle type, select the appropriate torque, IFS, TORQUE: 245-270 lb-ft (332-366 Nm) I-BEAM, TORQUE: 165-236 lb-ft (224-320 Nm) CAUTION Input shaft marks must be aligned before adjusting pitman arm.

  • Page 532: Fine Adjustment

    SECTION 14: STEERING CAUTION Too little pressure on the clamp can destroy the threaded adjustment system sleeve. Apply the recommended torque for clamp nut. TORQUE: 118-133 lb-ft (160-180 Nm) Fine adjustment of the drag link length should be performed exclusively by turning the adjuster sleeve.

  • Page 533: Maintenance

    SECTION 14: STEERING lubricant containers. Replace fittings that have become broken damaged. Lubrication 13. MAINTENANCE intervals, as well as the recommended lubricants for the steering components, are given in the "LUBRICATION AND SERVICING SCHEDULE" power steering system requires little in Section 24 of this manual. The intervals given maintenance.

  • Page 534: Power Steering Fluid Change

    SECTION 14: STEERING POWER STEERING FLUID CONDITION MAINTENANCE COLOR CHART Translucent red At regular intervals, fluid level should be checked in the reservoir and filter assembly. New fluid Furthermore, the oil filter element in the power steering reservoir should be replaced at the intervals specified by the Lubrication And Servicing Schedule...

  • Page 535: Filter Element Replacement

    Take note that the maximum travel covered value specified in ZF’s manual doesn’t apply 2. Unscrew and remove the cover nut located on to the Prevost design which uses a 18-inch top of the power steering fluid reservoir steering wheel.

  • Page 536: Drag Link Maintenance

    SECTION 14: STEERING MAINTENANCE 13.6 DRAG LINK MAINTENANCE Steering damper ball joint (rod end) is provided Visually inspect drag link components for with grease fitting for pressure lubrication. Under broken, corroded or deformed clamps, loose, normal conditions, it should be serviced at the bent or corroded nuts and gauges on tube from intervals specified by the Lubrication And rubbing parts.

  • Page 537: Front I-Beam Axle Drag Link

    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 Erreur ! Source du renvoi introuvable. ) should be serviced at the intervals specified by the Lubrication And Servicing Schedule Section...

  • Page 538: Tie Rods

    SECTION 14: STEERING To verify that the threads are tight and do not 13.7 TIE RODS present any play, use one of the following methods:  Visual inspection  Place a finger on the separation line from the adjuster sleeve to the threaded ball joint shaft.

  • Page 539: Drop Type Ball Joint

    SECTION 14: STEERING 2. Use an appropriate inspection tool (e.g. spatula with cut out) to push up (sealing boot) or down (dirt seal) the seal (without damaging it) until ball pin surface is visible. Degrease the ball pin surface and inspect carefully.

  • Page 540: Straight Body Type Ball Joint

    SECTION 14: STEERING 2. Thoroughly grease rubbing pad and ball pin 17. Re-charge ball joint with Shell “Retinax LX” with Shell Retinax LX or equivalent. or equivalent grease through grease fitting. 3. Insert ball pin into body. 13.10 STRAIGHT BODY TYPE BALL JOINT 4.

  • Page 541: Straight Body Type Ball Joint End Play And Looseness

    SECTION 14: STEERING 13.10.2 Straight Body Type Ball Joint End Play when the vehicle is stationary, and especially and Looseness when service brakes are applied (wheel locking will oppose the effect of steering geometry which tends to make the front wheels rotate in opposite What creates movement in sockets? directions).

  • Page 542: Alignment Terminology

    SECTION 14: STEERING 5. Check tie rods and drag link ends for WARNING looseness. 6. Check kingpins for looseness. During alignment, both camber and caster among other angles are adjusted. When 7. Check that the length of the torque rod is adjusting these, we install or remove shims at 21 17/64"...

  • Page 543: Front Wheel Caster

    SECTION 14: STEERING NOTE CAUTION Use only tie rods to adjust toe-in. Once perfect shim combination achieved, always install new Stover nuts because the self-locking effect is lost after tightening and loosening of the nut. It is recommended to punch marks to detect loosening of the nuts during future visual inspections.

  • Page 544: Alignment Specifications

    SECTION 14: STEERING 15.1.7 Alignment Specifications X3-45 Coaches Use static wheel alignment systems which work WITH INDEPENDENT FRONT SUSPENSION with angle measurements only, such as Josam or Hunter systems. Minimum Nominal Maximum value value value NOTE Right 0.0° 0.150° 0.30° On Independent Front Suspension, caster on camber right wheel must be equal or greater than...
  • Page 545 SECTION 14: STEERING FIGURE 35: IFS NOMINAL DIMENSIONS FIGURE 36: NOTE 2 INDICATES WHERE ADJUSTMENT MAY BE PERFORMED AT IFS ALIGNMENT PA1621 Maintenance Manual All Series | January 2017...
  • Page 546 SECTION 14: STEERING WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 37: FRONT END ALIGNMENT DIAGRAM 16051 PA1621 Maintenance Manual All Series | January 2017...

  • Page 547: I-Beam Axle - Front Wheel Alignment

    SECTION 14: STEERING Check radius rods for bending and rubber bushings for evidence of excessive wear. 15.2 I-BEAM AXLE - FRONT WHEEL ALIGNMENT Make sure all fasteners are tightened to the 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.

  • Page 548: Turning Angle Adjustment

    SECTION 14: STEERING Check and adjust the toe-in. thickness are available: 1/16 inch and 3/16 inch. 15.2.4 Turning Angle Adjustment 15.2.6 L.H. Turn Adjustment The maximum turning angle is set through the two steering stop screws installed on the axle 1.

  • Page 549: Camber Check

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

  • Page 550: Inspection And Adjustment

    SECTION 14: STEERING 15.2.11 Front Wheel Toe-In NOTE ‘’Toe-in’’ measurements must be taken at the Wheel toe-in is the degree (usually expressed in horizontal axis of the wheel centerline. fractions of an inch) to which the forward part of 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 551: Troubleshooting

    SECTION 14: STEERING 16. TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.

  • Page 552: 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 553 SECTION 16 : SUSPENSION CONTENTS SECTION CHANGE LOG ............................4 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 ..............................
  • Page 554 SECTION 16 : SUSPENSION 4.11 FRONT-END ALIGNMENT ..........................31 4.11.1 Alignment Terminology ........................31 4.11.2 Front End Inspection ..........................32 4.11.3 Front Wheel Camber ..........................32 4.11.4 Front Wheel Toe-In ..........................32 4.11.5 Front Wheel Caster ..........................33 4.11.6 Major Damage ............................. 33 4.11.7 Alignment Specifications ........................
  • Page 555 SECTION 16 : SUSPENSION MAINTENANCE............................. 49 FRONT KNEELING SYSTEM (COACHES ONLY)....................50 PRINCIPLE OF OPERATION ........................... 50 MAINTENANCE............................. 50 AIR SPRING CONTROL SOLENOID VALVES....................50 9.3.1 Removal and installation ........................50 HIGH-BUOY SYSTEM (COACHES ONLY) ...................... 50 10.1 PRINCIPLES OF OPERATION ......................... 50 10.2 MAINTENANCE.............................

  • Page 556: Section Change Log

    SECTION 16 : SUSPENSION SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...

  • Page 557: Torque Tables

    SECTION 16 : SUSPENSION TORQUE TABLES FRONT I-BEAM AXLE AND RELATED COMPONENTS 16188 16187 16192 PA1621 Maintenance Manual All Series | January 2017...
  • Page 558 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 559: Independent Front Suspension

    SECTION 16 : SUSPENSION INDEPENDENT FRONT SUSPENSION 16204 PA1621 Maintenance Manual All Series | January 2017...
  • Page 560 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 561 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 562 SECTION 16 : SUSPENSION 16158_C: Meritor Drive Axle PA1621 Maintenance Manual All Series | January 2017...
  • Page 563 SECTION 16 : SUSPENSION 16159_B 16162_B PA1621 Maintenance Manual All Series | January 2017...

  • Page 564: 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) PA1621 Maintenance Manual All Series | January 2017...
  • Page 565 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 566: 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 567: 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 568: 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 569: 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 570: 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 571: 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 572: Independent Front Suspension (Ifs)

    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 arm and steering arm at the right side of the STEERING LINKAGE coach.
  • Page 573 SECTION 16 : SUSPENSION and being connected to the R.H. wheel, makes it such that the total steering forces are produced with minimal stress on mechanical linkages. CAUTION Lower and upper A-arms are widely spaced. Clamp bolts are either in a vertical or They are mounted on ball joints.
  • Page 574 SECTION 16 : SUSPENSION FIGURE 10: IFS STEERING LINKAGE OVERVIEW PA1621 Maintenance Manual All Series | January 2017...

  • Page 575: Steering Linkage Installation Sequence

    SECTION 16 : SUSPENSION section (for proper tightening torque, refer to STEERING LINKAGE INSTALLATION Torque Table 2). SEQUENCE NOTE PITMAN ARM Whenever a steering linkage component has been removed and replaced, check steering 4.3.1 Removal geometry and front end alignment as directed 1.

  • Page 576: 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 577: Bell Crank Or Idler Arm Hub Disassembly

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

  • Page 578: Relay Rod

    SECTION 16 : SUSPENSION 11. Unscrew nut until bell crank or idler arm 4.6.1 Replacement starts to turn with the application of 1 to 3 lbs 1. Remove cotter pins from bell crank and idler force load as shown on Figure 16. arm end of relay rod.

  • Page 579: 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 4.7.2 Installation...

  • Page 580: Removal

    SECTION 16 : SUSPENSION 4.8.1 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 581 SECTION 16 : SUSPENSION FIGURE 19: STEERING LINKAGE NOMINAL LENGTHS 16202 PA1621 Maintenance Manual All Series | January 2017...

  • Page 582: Lubrication Fittings

    SECTION 16 : SUSPENSION FIGURE 20: LUBRICATION FITTINGS LOCATION 16046 product quality. Figure 20 shows approximate 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 583: 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 584: 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 585: 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 586 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 587 SECTION 16 : SUSPENSION FIGURE 25: IFS ADJUSTMENT Note 2 indicates where adjustment may be performed if needed when proceeding to IFS ALIGNMENT PA1621 Maintenance Manual All Series | January 2017...
  • Page 588 SECTION 16 : SUSPENSION WHEEL CAMBER KINGPIN INCLINATION CASTER TOE-IN FIGURE 26: FRONT END ALIGNMENT DIAGRAM 16051 PA1621 Maintenance Manual All Series | January 2017...
  • Page 589 SECTION 16 : SUSPENSION FIGURE 27: A-ARM JOINT IDENTIFICATION PA1621 Maintenance Manual All Series | January 2017...

  • Page 590: Lower And Upper A-Arm Ball Pin Bushing Repair

    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 591: 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 592: 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 593: 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 594: Shock Absorber Installation

    SECTION 16 : SUSPENSION 4.16.2 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 595: 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 PA1621 Maintenance Manual All Series | January 2017...

  • Page 596: Air Springs

    SECTION 16 : SUSPENSION AIR SPRINGS 5.1.2 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 597: 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 598: 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 599: 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 600: Height Control Valves

    SECTION 16 : SUSPENSION HEIGHT CONTROL VALVES 7.3.1 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 601: Air Leakage Test

    SECTION 16 : SUSPENSION PRINCIPLES OF OPERATION 7.3.2 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 602: Maintenance

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

  • Page 603: Maintenance

    SECTION 16 : SUSPENSION (with front high-buoy). A solenoid valve is added 10.3.2 Disassembly to send air to the double shuttle valves for the 1. Shut off inlet pressure and reduce pressure rear end. It uses the same dash switch as the in inlet and outlet lines to zero.

  • Page 604: 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 605: Air Tank Maintenance

    SECTION 16 : SUSPENSION FIGURE 45: LOCATION OF AIR TANKS 12195 12.1 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 606: Secondary Air Tank

    SECTION 16 : SUSPENSION 12.1.3 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 607: 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 608 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 609 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 610 SECTION 16 : SUSPENSION PA1621 Maintenance Manual All Series | January 2017...
  • Page 611 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 612 MI16-14 / Page 2 / 10 The two rear suspension height control valves are mounted to the chassis and connected to the fore air springs of the rear underframe through a control arm and link. One front suspension valve is mounted to the chassis and connected to the front axle through a control arm and link.
  • Page 613 MI16-14 / Page 3 / 10 NORMAL RIDE HEIGHT The normal ride height is obtained by measuring and adjusting air spring height of front and rear suspension. TABLE 1 – PRESCRIBED AIR SPRING HEIGHTS FRONT SUSPENSION (I-BEAM AXLE) 2 air springs INDEPENDENT X = 12 7/8 ±...
  • Page 614 MI16-14 / Page 4 / 10 PROCEDURE DANGER Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
  • Page 615 MI16-14 / Page 5 / 10 5. Loosen the lower mounting bolt shown. Take note that the bolt is equipped with a nylon insert. The bolt should be replaced after three (3) tightenings. INCREASING CLEARANCE 6. Rotate the valve body to increase or decrease the clearance as shown (the mounting bracket has a slotted hole).
  • Page 616 MI16-14 / Page 6 / 10 FRONT SUSPENSION AIR SPRINGS ADJUSTMENT (I-BEAM AXLE) Measurement 1. Make sure that the air system pressure is at least 90 psi. 2. Measure the front axle springs clearance (two air springs). To do measure clearance between the support above the air spring and the lower end...
  • Page 617 MI16-14 / Page 7 / 10 5. Loosen the lower mounting bolt shown. Take note that the bolt is equipped with a nylon insert. This bolt should be replaced after three (3) tightenings. 6. Rotate the valve body to INCREASING CLEARANCE DECREASING CLEARANCE increase or decrease the clearance as shown (the...
  • Page 618 MI16-14 / Page 8 / 10 INDEPENDENT FRONT SUSPENSION ADJUSTMENT Measurement 1. Make sure that the air system pressure is at least 90 psi. 2. Measure that the air springs clearance (two air springs). To do so, measure the clearance between the support found above the air spring and the lower end of the air spring (if needed, use a metal ruler to reach the lower end of the...
  • Page 619 MI16-14 / Page 9 / 10 Air springs height adjustment Adjust the air springs clearance with the height control valve 5. It is necessary to adjust clearance on "fill cycle". a) Disconnect the link. It is equipped with a rubber bushing that allows easy disconnection.
  • Page 620 MI16-14 / Page 10 / 10 <QF7720955 rev 6>...
  • Page 621 SECTION 18A: H3 SERIES BODY CONTENTS    SECTION CHANGE LOG .......................... 5     TORQUE TABLES .......................... 6     VEHICLE EXTERIOR  ......................... 8     VEHICLE JACKING POINTS ...................... 10     TOWING THE VEHICLE  ........................ 11     LIFTING AND TOWING ........................ 12     TOWING WITHOUT LIFTING ...................... 12     VOLVO I‐SHIFT ALTERNATE TOWING MODE ................ 13     STRUCTURE .......................... 13     WELDING ............................ 13    ...
  • Page 622 SECTION 18A: H3 SERIES BODY     10.5 DEPTH ADJUSTMENT ........................ 30     10.6 ROD END ADJUSTMENT  ........................ 30     10.7 LUBRICATION .......................... 30     10.8 TROUBLESHOOTING ........................ 31     ENTRANCE DOOR (V.I.P) ...................... 32     11.1 KEYLESS ENTRY SYSTEM  ........................ 32     11.2 DOOR ADJUSTMENT ........................ 32     11.2.1 Horizontal and Vertical Adjustments .................. 32  ...
  • Page 623 SECTION 18A: H3 SERIES BODY     17.3 ACTUATOR REPLACEMENT ...................... 52     17.4 MOTOR REPLACEMENT ........................ 52     ELECTRIC SLIDING WINDOW  ..................... 54     WINDSHIELD  .......................... 57     19.1 REMOVAL  ............................ 57     19.2 WINDSHIELD INSTALLATION ONLY .................... 57     19.3 INSTALLATION OF RUBBER EXTRUSION AND WINDSHIELD ............ 59     BODY PANELS AND DOORS ...................... 59  ...
  • Page 624 SECTION 18A: H3 SERIES BODY     REAR CAP .......................... 73     FRONT CAP .......................... 73     SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP .......... 74     REAR VIEW MIRRORS (RAMCO) .................... 79     37.1 ADJUSTMENT  .......................... 79     37.2 DISASSEMBLY  .......................... 79     37.3 ASSEMBLY ............................. 80     37.4 REPLACEMENT OF MIRROR GLASS .................... 80     37.5 HEATED / REMOTE CONTROLLED REAR VIEW MIRRORS ............. 80  ...

  • Page 625: Section Change Log

    SECTION 18A: H3 SERIES BODY SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series January 2017...

  • Page 626: Torque Tables

    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) PA1621 Maintenance Manual All Series January 2017...
  • Page 627 SECTION 18A: H3 SERIES BODY WHEELCHAIR LIFT DOOR DESCRIPTION TORQUE Wheelchair lift door – Center hinge bolts 31-38 lb-ft (42-52 Nm) Wheelchair lift door - striker pin adjustment bolts 54-66 lb-ft (73-89 Nm) Wheelchair lift door - opening mechanism nuts 2.5-3.5 lb-ft (3.39-4.75 Nm) PA1621 Maintenance Manual All Series January 2017...

  • Page 628: Vehicle Exterior

    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 629 SECTION 18a: H3 SERIES BODY 18677 FIGURE 2: H3-45 VIP EXTERIOR VIEW PA1621 Maintenance Manual All Series January 2017...

  • Page 630: Vehicle Jacking Points

    SECTION 18A: H3 SERIES BODY 1. Engine air intake WARNING 2. Engine R.H. side access door When it is necessary to raise the vehicle, care 3. Main power compartment should be taken to ensure that pressure is applied only at the points indicated in Figure 3 4.

  • Page 631: Towing The Vehicle

    SECTION 18a: H3 SERIES BODY FIGURE 9: 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. FIGURE 5: JACKING POINTS ON FRONT UNDERFRAME –...

  • Page 632: Lifting And Towing

    SECTION 18A: H3 SERIES BODY pressure line from the tow truck to the Tow eyes emergency fill valve engine compartment. The emergency fill valve in the front service compartment does not supply air pressure to the brake system. The air pressure must be a minimum of 75 psi (520 kPa), and the line should be attached to the air line with a clip-on chuck.

  • Page 633: Volvo I-Shift Alternate Towing Mode

    3. Position the tow truck so that the tow bar contacts the front bumper of the vehicle. The body of the H3-41, H3-45 and VIP vehicles is an integral structure made of 14, 16 and 18 4. Attach the tow truck chains only in the tow...

  • Page 634: Exterior Maintenance

    SECTION 18A: H3 SERIES BODY 4. Always wear appropriate safety ledges. These places accumulate dirt and salt equipment. and hold it in direct contact with steel and aluminum surfaces. Use an understructure high Weld in clean and well-ventilated area, and pressure spray as part of a regular wash.
  • Page 635 SECTION 18a: H3 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 636: Rust Inhibitor Application

    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 637 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) PA1621 Maintenance Manual All Series January 2017...
  • Page 638 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 639 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 640: Fiberglass Repair

    SECTION 18A: H3 SERIES BODY DEW POINT Relative Humidity (%) Temp (c) performed. Use of the various materials is 7. FIBERGLASS REPAIR determined by the type of repair to be made. Large holes, torn sections and separate joints All repairs to fiberglass parts consist of filling the require the adhesive qualities of the resin and damaged area with fiberglass cloth and resin or the reinforcing qualities of the fiberglass.

  • Page 641: Repair Using Fiberglass Cloth

    SECTION 18a: H3 SERIES BODY Small dents, scratches or pits can be repaired CAUTION using resin and strand fiberglass and filler mixed into paste. Instructions for either mix are Temperature should not exceed 140 F (60 explained under their respective headings in this C) during 30 minutes in order to avoid section.

  • Page 642: Typical Fiberglass Repair Procedure

    SECTION 18A: H3 SERIES BODY tendency of hot resin to flow or run. Apply the material with a putty knife or similar object, building material up to the desired contour. For deep filling and on vertical surfaces, several layers of material may be used. A hacksaw blade, held flat to adjacent contour and then moved in a sawing action across the repair when the resin is in a gel state, will...

  • Page 643: New Paint Care

    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. In the event you sand through to the gelcoat...

  • Page 644: Surface Preparation And Paint Application

    SECTION 18A: H3 SERIES BODY 8.3.1 Safety 2. Wear respirators approved by the governing safety and health regulations. Care should be exercised in storing, handling, mixing, and applying paint and chemicals listed 3. Maintain adequate ventilation at all times. in this manual. The topcoat, primer, solvent, 4.

  • Page 645: Front And Rear Bumpers

    SECTION 18a: H3 SERIES BODY FRONT AND REAR BUMPERS 8.4.1 Paint touchup and surface preparation for vehicles equipped with urethane bumpers COMMENTS COACHES Clean using red wool and Standoflex 11100 (ST-11425) thinner Cleaning Clean again twice using Standoflex 11100 (ST-11425) thinner Apply Non-Stop primer (ST-13320) with flexible agent dilution Priming 2:1 10% in 2 or 3 coats, 15 min.

  • Page 646: Front Bumper Assembly Removal Including Spare Wheel Compartment Door

    FIGURE 19: FRONT BUMPER ASSEMBLY bumper (Figure 21). NOTE 2. Let the bumper rest face down on the lifting A special tool kit is available from Prevost: Kit equipment platform. # 410671 including tool #410708. 3. To install bumper, reverse the procedure.

  • Page 647: Coach Entrance Door

    SECTION 18a: H3 SERIES BODY Emergency exit valves, which open the air valve circuit, should be used only in emergencies, or when the door control system does not function properly. Refer to the air system schematic and page 22 of the wiring diagram available on the technical publications web site.

  • Page 648: Without Air And/Or Without Electricity

    SECTION 18a: H3 SERIES BODY located in the front service compartment, also releases the air from the lock cylinders. CAUTION It is important to make sure that damper does not reach end of stroke when door is completely closed or opened. The door cylinder must stop the door on opening.

  • Page 649: Horizontal And Vertical Adjustment

    SECTION 18a: H3 SERIES BODY 3. The damper may have already been 10.4 HORIZONTAL AND VERTICAL ADJUSTMENT adjusted. Therefore check whether the damper is adjusted or not by keeping it Before attempting to correct any door operating closed and gently turning further CCW, problem by adjusting any part of the air cylinder counting at the same time the half-turns until assembly, first perform the following mechanical...

  • Page 650: Depth Adjustment

    SECTION 18a: H3 SERIES BODY FIGURE 28: DOOR LATCH (COACH) 18059 10.6 ROD END ADJUSTMENT 10.5 DEPTH ADJUSTMENT 1. Turn the emergency exit valve to the 1. Turn the emergency exit valve to the “UNLOCK” position. “UNLOCK” position. 2. Remove screws plastic 2.
  • Page 651 SECTION 18a: H3 SERIES BODY 10.8 TROUBLESHOOTING SYMPTOM PROBABLE CAUSE REMEDY Manual door locks engaged. Release manual door locks. Check voltage at solenoid locks when Upper and lower solenoid locks do not door is open. If the voltage is 24 volts disengage.

  • Page 652: Entrance Door (V.i.p)

    SECTION 18a: H3 SERIES BODY 11.2.1 Horizontal and Vertical Adjustments 11. ENTRANCE DOOR (V.I.P) 1. Remove the screws and the plastic molding There are three ways of unlocking the entrance covering each of the hinges. door from the inside of vehicle. The two first consist in actuating the rocker switch on the NOTE dashboard, but this last operation will also...

  • Page 653: Door Lower Section

    When a plastic door lower section replacement 10. Apply Sika #252 (Prevost #682462) is needed, proceed the following way: compound where it was previously applied. 1. Remove the reflective stripe at the top edge 11. Remove protective paper from the adhesive of the door’s lower section.

  • Page 654: Door Lubrication

    SECTION 18a: H3 SERIES BODY WARNING Wear rubber gloves and do not smoke when cleaning. 5. Peel of protective paper from the seal. Position the seal in order to leave ¼" (6 mm) from the upper molded edge of the door and 3/16"...

  • Page 655: Power Window Installation

    SECTION 18a: H3 SERIES BODY 9. Detach the motor and actuator guide from CAUTION the support and plastic shield. Replace parts as required. Use of lubricants, paints, or other coatings such as graffiti deterring sprays is not recommended. Suggested maintenance includes periodic inspection of fasteners for evidence of loosening...
  • Page 656 5. Drill holes (if needed) in the new metal Seal joint should be toward rear of vehicle. frame. 3. Apply rubber adhesive CA-40 (Prevost # 6. Clean both vehicle top and new hatch frame 681285) in the gap between the seal ends.
  • Page 657 SECTION 18a: H3 SERIES BODY 14. 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 658 SECTION 18a: H3 SERIES BODY FIGURE 34: TARABUS FLOOR COVERING ADHESIVE APPLICATION FIGURE 35: APPLICATION OF SIKA 221 GRAY PA1621 Maintenance Manual All Series January 2017...
  • Page 659 SECTION 18a: H3 SERIES BODY 14.1 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 660 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 661 SECTION 18a: H3 SERIES BODY –– H3 VEHICLE FRONT STEPS GLUING 1. Remove adhesive tape from underneath step. 2. Apply a thin and even layer of contact adhesive (3M) (684655 or 684654) onto fiberglass and step surfaces. Allow drying for 3 to 5 minutes. 3.
  • Page 662 SECTION 18a: H3 SERIES BODY 14.2 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. 2. Before welding, visually ensure that a 1 to 1.5 mm gap exists between white safety strip and “Tarabus”...
  • Page 663 SECTION 18a: H3 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 9. Allow cooling down of filler bead (about 5 will be a loss of adhesion on one side.

  • Page 664: Passenger Seats

    15. PASSENGER SEATS To remove fixed seats, proceed as follows: H3-41 and H3-45 coaches can be equipped with 1. Remove 1 nut holding each seat bottom any of 2 basic seat models and installed in a...

  • Page 665: Upholstery Maintenance

    SECTION 18a: H3 SERIES BODY pile. If the fabric become excessively dirty, particles of grit will cause gradual wear, reducing the life span of the fabric. 15.3.2 Dry Cleaning If covers are to be removed for cleaning, dry cleaning is recommended since washing might cause some shrinkage, preventing the covers from being reapplied to the seats without damage.
  • Page 666 16. COACH SIDE WINDOWS Seven passenger side windows are provided on each side on H3-41, while the H3-45 has eight. They are made of fixed, single or double-glazed, heat absorbing AS-3 glass. Windows are...
  • Page 667 SECTION 18a: H3 SERIES BODY 5. Reverse procedure to install a new one. FIGURE 40: EMERGENCY EXIT WINDOW 18391 16.2.1 Emergency Exit Window Adjustment Emergency exit windows should be checked periodically for easy opening and closing. Pulling the lower part of the release bar with both hands placed near the safety latches should disengage both locks on the window simultaneously.
  • Page 668 Note where adhesives are used and apply  Masking tape; gluing techniques at these areas to complete replacement of these windows.  Tremshield tape (Prevost #681089);  Chix cloths (Prevost #682384); 16.6 SMALL REAR WINDOWS  Isopropyl alcohol or enamel reducer or NAPA REPLACEMENT 6383 surface cleaner;...
  • Page 669 SECTION 18a: H3 SERIES BODY (shake well before applying). Let dry 5-6 NOTE minutes minimum but no more than 8 hours. Hardened adhesive will not remove easily. A new blade works best to remove all adhesive CAUTION residue using care not to damage the fiber structure.

  • Page 670: Window Removal

    SECTION 18a: H3 SERIES BODY material around both sides of the window as 17.2 WINDOW REMOVAL soon as possible before adhesive dries. NOTE Replacement awning window does not include a new motor. If in working order, transfer the Remove most of the adhesive from the motor replaced window...
  • Page 671 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 47: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 Actuators...
  • Page 672 SECTION 18a: H3 SERIES BODY 17.3 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 673 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 674 SECTION 18a: H3 SERIES BODY 18. ELECTRIC SLIDING WINDOW FIGURE 49: 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 50) FIGURE 50: REMOVING THE SASH PA1621 Maintenance Manual All Series January 2017...
  • Page 675 SECTION 18a: H3 SERIES BODY 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 51) FIGURE 51: 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 676 SECTION 18a: H3 SERIES BODY FIGURE 53: 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 677 FIGURE 56: 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 678 SECTION 18a: H3 SERIES BODY NOTE Spray lubricant on a regular basis to ease windshield insertion. FIGURE 58: WINDSHIELD INSTALLATION SIDE VIEW 8099 6. Insert the top curved corner then finish with the top of windshield. FIGURE 57: WINDSHIELD INSTALLATION USING ROPE 7.
  • Page 679 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 680 SECTION 18a: H3 SERIES BODY 21. WHEELCHAIR LIFT ACCESS DOOR 21.1 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 681 SECTION 18a: H3 SERIES BODY FIGURE 62: 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 682 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 683 SECTION 18a: H3 SERIES BODY FIGURE 64: WCL SLIDING DOOR OPENING MECHANISM 18740 PA1621 Maintenance Manual All Series January 2017...
  • Page 684  SAV00589 FIGURE 65: BAGGAGE COMPARTMENT DOOR  SAV00590 There are 6 pantograph doors serving as baggage compartment doors on the H3-41, NOTE while there are 8 on the H3-45 and the V.I.P Refer, if needed, to Figure 65 for identification (depending on options, VIP model may have of door components.
  • Page 685 SECTION 18a: H3 SERIES BODY 3. Install another piece of 2x4 between the first piece and the bottom of the pivot of the lowest (or shortest) pantograph arm, (Figure 66). 4. Pull down on the opposite side of the door to bend the door around the pantograph arm pivot (prevented from moving by the 2x4).
  • Page 686 4. Repeat until satisfied. compartment doors and is held open by three gas-charged cylinders (Prevost # 980024). The engine compartment opens by lifting a handle 24.2 MINOR TOP EDGE DEPTH accessed from the R.H. side of the engine ADJUSTMENT compartment.
  • Page 687 SECTION 18a: H3 SERIES BODY 3. On the vehicle grill opening, using the knife, remove as much adhesive as possible. 4. Sand the new grill backing edge to remove the glossy surface. 5. Clean with alcohol, wipe dry. 6. Apply SIKA 205 primer to the grill opening and the grill edges.
  • Page 688 SECTION 18a: H3 SERIES BODY 26.3 DOOR DEPTH ADJUSTMENT 1. Close radiator door. 2. Check parallelism between radiator door and rear fender (max. 0 ± 2 mm). 3. If the door is too far inside, adjust using a rubber mallet (Refer to Figure 76). 4.
  • Page 689 SECTION 18a: H3 SERIES BODY 8. Respect the required gap between exterior 5. Loosen bracket nuts holding the panel to finishing panels (Figure 60). condenser. Panel (6, Figure 78) may be shifted "IN or OUT", "LEFT or RIGHT" and 9. Check that the door swings freely and "UP or DOWN".
  • Page 690 SECTION 18a: H3 SERIES BODY 6. Adjust door panel to have the same gap space as neighboring panels or refer to Figure 60 for specified gap space. Only if necessary, use the adjustment allowed by SECTION moving part 1, Figure 80. 8 ±...
  • Page 691 SECTION 18a: H3 SERIES BODY 7. Adjust the door in accordance with the required distance between exterior finishing parts (Figure 60). 8. Loosen screws (4, Figure 83). 9. Screws allow the door to be shifted "UP or DOWN". 10. Adjust the door position according to the 31.
  • Page 692 SECTION 18a: H3 SERIES BODY 41,2 ± 41 ± 2 mm 8 ± 2 mm FIGURE 84: EVAPORATOR DOOR 18198 6. Adjust door panel to have the same gap 32. MAIN POWER COMPARTMENT space as neighboring panels or refer to Figure 60 for specified gap space To adjust the main power compartment door: 7.
  • Page 693 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. 33.2 FRONT FENDER REMOVAL 1.
  • Page 694 SECTION 18a: H3 SERIES BODY 36. 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 695 SECTION 18a: H3 SERIES BODY Clean using tack cloth. Repeat if surface seems dusty. Clean using anti-silicone See SAV000001 section A. Apply primer 206 G+P. See SAV000001 section D. SAV000001 Section D Sika Primer 206 G+P Shake bottle to mix product Apply a thin layer CHIX cloth 3.
  • Page 696 SECTION 18a: H3 SERIES BODY Apply 206 G+P onto structure. See SAV000001 section D. 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.
  • Page 697 SECTION 18a: H3 SERIES BODY At the rear, adjust panel height so that it is level with rear cap 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. ...
  • Page 698 SECTION 18a: H3 SERIES BODY 1.70 Do not move the vehicle for 48 hours Make sure room temperature is superior to 20°C (68°F) before gluing Perform a visual inspection before installing side windows SECTION #2 DRIP MOLDING INSTALLATION 2.00 * A) Clean using Anti-silicone See SAV000001 section A.
  • Page 699 SECTION 18a: H3 SERIES BODY SECTION #3 REPAIR 4.00 Remove fiberglass from structure using a screwdriver. Use wedges if necessary to hold down panel during the work. 4.05 Remove as much glue as possible. If primer is removed, apply primer 206 G+P locally. If primer is OK, reactivate as per SAV000001 section D.
  • Page 700 SECTION 18a: H3 SERIES BODY 37.3 ASSEMBLY through the arm support. The remote motor is mounted to the mirror head behind the mirror Mount the mirror arm base to the coach. glass. Insert the ball stem into the mirror arm and Turn pointer knob to the left for mirror head tighten the socket setscrews.
  • Page 701 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 702 SECTION 18a: H3 SERIES BODY PA1621 Maintenance Manual All Series January 2017...
  • Page 703 SECTION 18B: X3 SERIES BODY CONTENTS       TORQUE TABLES ............................ 5     VEHICLE EXTERIOR  ............................ 7     VEHICLE JACKING POINTS ..........................  1 0     HYDRAULIC JACK ............................  1 1       TOWING THE VEHICLE  ..........................  1 1     LIFTING TOWING  ..........................  1 2  ...
  • Page 704 SECTION 18B: X3 SERIES BODY     9.3.2 Rear Bumper ............................  5 0     9.3.3 Exhaust Aftertreatment System Access Door ..................  5 0     ZONE 4 .................................  5 0       9.4.1 Rear Fender  ............................  5 1     9.4.2 Engine R. H. Side Access Door  ......................  5 1  ...
  • Page 705 SECTION 18B: X3 SERIES BODY     10.4.1 Rear Fender  ............................  1 15     10.4.2 Engine R. H. Side Access Door  ......................  1 15     10.4.3 Engine Radiator Door  .........................  1 20     10.5 ZONE 5 ...............................  1 22       10.5.1 Pantograph Baggage Compartment Doors (Aluminum) .............. ...
  • Page 706 SECTION 18B: X3 SERIES BODY SECTION CHANGE LOG  DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...
  • Page 707 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) Radiator door hinges bolts 68 lb-in (8 Nm) PA1621 Maintenance Manual All Series | January 2017...
  • Page 708 SECTION 18B: X3 SERIES BODY WHEELCHAIR LIFT DOOR DESCRIPTION TORQUE Wheelchair lift door – Center hinge bolts 31-38 lb-ft (42-52 Nm) Wheelchair lift door - striker pin adjustment bolts 54-66 lb-ft (73-89 Nm) Wheelchair lift door - opening mechanism nuts 2.5-3.5 lb-ft (3.39-4.75 Nm) PA1621 Maintenance Manual All Series | January 2017...
  • Page 709 SECTION 18b: X3 SERIES BODY VEHICLE EXTERIOR FIGURE 1: X3 COACHES EXTERIOR VIEW 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 710 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 711 SECTION 18b: X3 SERIES BODY FIGURE 3: X3-45 VIP COMMERCIAL 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 712 SECTION 18b: X3 SERIES BODY 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 713 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 714 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 715 SECTION 18b: X3 SERIES BODY CAUTION Failure to disconnect the driveshaft, remove the drive axle shafts or lift the drive wheels off the ground before towing can cause serious transmission damage and void the warranty. 2. Operate the engine when towing to maintain FIGURE 11: TOW EYES brake system air pressure.
  • Page 716 Prevost or by an independent decision of the for corrosion. Other areas include the front owner, the following information pertaining to wheelhousing area engine welding should be read before beginning any compartment.
  • Page 717 SECTION 18b: X3 SERIES BODY bulkheads, brackets and other structural members. It should not be used for exterior side paneling. Extreme care should be taken not to sandblast excessively. 3. Apply correct primer, paint and undercoating after removing all corrosion to prevent further damage.
  • Page 718 SECTION 18b: X3 SERIES BODY Failure to follow this preventive maintenance schedule will result in warranty void. 6.3 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.
  • Page 719 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) PA1621 Maintenance Manual All Series | January 2017...
  • Page 720 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 721 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 722 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 723 SECTION 18b: X3 SERIES BODY NOTE COMMON FIBERGLASS REPAIR PROCEDURE Roughening the surface improves adhesion of All repairs to fiberglass parts consist of filling the resin. damaged area with fiberglass cloth and resin or If part is warped from original shape, use strand fiberglass and resin.
  • Page 724 SECTION 18b: X3 SERIES BODY area. On underside of coach, scrape away hole and press onto surface with brush to obtain undercoating from damaged area, and wipe good adherence. Another coat of general clean with solvent. purpose polyester resin can be applied at this time (Figure 13).
  • Page 725 When paint touchup or partial repainting is CAUTION necessary, refer to the vehicle’s paint scheme for color codes and paint brand. Apply these recommendations after repainting vehicle. Prevost recommends using the original paint brand to ease color matching. PA1621 Maintenance Manual All Series | January 2017...
  • Page 726 SECTION 18b: X3 SERIES BODY In the event you sand through to the gelcoat surface you should prime the area with Standox 8.3.1 Safety “Non Stop Fill Primer (ST-11000)”. Care should be exercised in storing, handling, If you sand through to metal surface, first prime mixing, and applying paint and chemicals listed with Standox “Etch Primer (ST-11858)”...
  • Page 727 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 728 SECTION 18b: X3 SERIES BODY 9.1.1 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 729 SECTION 18b: X3 SERIES BODY FIGURE 22: REAR VIEW MIRROR (RAMCO) 18398A  Adjustment 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 730 SECTION 18b: X3 SERIES BODY activated before the mirror heating element will Convex & Flat Mirror Removal energize. Once energized, the mirror heating The mirror glass assembly is mounted to the element is kept at a sustained temperature control mechanism or to mirror base with Velcro (between 60-80°F) by a thermostat.
  • Page 731 SECTION 18b: X3 SERIES BODY   Remove the entire damaged windshield and Then, working from both sides of windshield broken glass if applicable. bottom to top, gradually move the rubber seal lip aside to insert the windshield into  If applicable, using a screwdriver or metal the groove.
  • Page 732 SECTION 18b: X3 SERIES BODY 9.1.7 Entrance Door Emergency exit valve, which opens the air valve circuit should be used only in emergencies, or An air operated “sedan type” entrance door, with when the door control system does not function an air door cylinder and damper assembly are properly.
  • Page 733 SECTION 18b: X3 SERIES BODY To open the door, the switch must be pushed towards the front of the coach and held in position. When the door reaches the fully opened position, the system will keep pressure in the cylinder locking the door in that position. The door can be stopped in any position by releasing the switch.
  • Page 734 SECTION 18b: X3 SERIES BODY CAUTION It is important to make sure that damper does not reach end of stroke when door is completely closed or opened. The door cylinder must stop the door on opening. Screw or unscrew rod end to adjust if necessary. To adjust opening and closing cycle speed on damper (Figure 31): 1.
  • Page 735 SECTION 18b: X3 SERIES BODY 3. Support the door with a wooden block and a hydraulic jack. 4. Loosen the horizontal bolts retaining the door to the hinges. Adjust the door horizontally and vertically with the jack. Tighten the bolts. TORQUE: 55-65 lb-ft (75-88 Nm) Remove the jack and the wooden block.
  • Page 736 SECTION 18b: X3 SERIES BODY  Troubleshooting SYMPTOM PROBABLE CAUSE REMEDY Manual door locks engaged. Release manual door locks. Check voltage at solenoid locks when Upper and lower solenoid locks do not door is open. If the voltage is 24 volts disengage.
  • Page 737 SECTION 18b: X3 SERIES BODY SYMPTOM PROBABLE CAUSE REMEDY Lock solenoid works in reverse. Reverse air hoses at solenoid locks. Relay does not function. Replace relay.  Clean window using window cleaner.  Lubrication  Apply Sika Aktivator around window Part Lubricant Frequency perimeter.
  • Page 738 SECTION 18b: X3 SERIES BODY  Apply some Sika 206 G+P onto door frame.  Install and center window onto door frame. Using your hands, compress window.  Discard waste according to applicable environmental regulations, use dangerous waste containers.  Apply masking tape before applying Sika ...
  • Page 739 SECTION 18b: X3 SERIES BODY  Line-up body panel with window. There must be a gap of 4±2mm between window and body panel.  Apply some masking tape 1mm from window edge and body panel.  Apply Sika 255 onto door frame structure. ...
  • Page 740 SECTION 18b: X3 SERIES BODY  Prepare new body panel using a scratch 9.1.8 Front Electrical & Service Compartment Door Body Panel and pad “Scotch Brite”.  Use a tack cloth to remove any dust or Window residue from the body panel surface. Door Body Panel ...
  • Page 741 SECTION 18b: X3 SERIES BODY  Apply some #680066 glue inside fiber glass groove and fix power window wiper. NOTE Anti-friction side must be on glass side.  Check body panel flatness using a 2-foot ruler (must be within 2mm). ...
  • Page 742 SECTION 18b: X3 SERIES BODY  Clean window using window cleaner.  Insert window into frame.  Secure Driver’s Window Gutter window pane raising mechanism.  Dry fit the gutter on the vehicle. If required, straighten up gutter using a hammer and a wooden block.
  • Page 743 SECTION 18b: X3 SERIES BODY  Apply 1/16 x1/4 double face self-adhesive tape onto gutter.  Peel the back from double face self-  Upper Lateral Window adhesive tape. For the removal of driver’s window or upper  Apply Sika 252 inside right angle. lateral window, you will need: Pneumatic hammer tool (Zip Gun);...
  • Page 744 SECTION 18b: X3 SERIES BODY  To seal screw holes, remove screw, apply Before applying Sika cleaner, fold “Chix” cloth twice for proper width. Sika 205 inside the hole then apply Sika 252. Apply an even coat onto the inside of window frame and allow drying for 2 minutes (maximum 2 hours).
  • Page 745 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 paragraph 7 “COMMON FIBERGLASS ...
  • Page 746 SECTION 18b: X3 SERIES BODY 9.2 ZONE 2 FIGURE 34: ZONE 2 18625 For the removal or installation of a fixed side window, you will need: 9.2.1 Lateral Fixed Window Nine passenger side windows are provided on each side on X3-45. They are made of fixed, Hammer or drill equipped with a sharp pointed single or double-glazed, heat absorbing AS-3 rod into which a small hole was drilled;...
  • Page 747 SECTION 18b: X3 SERIES BODY window. For single pane, apply a sticky Installation of Window plastic film on both sides of window.  Use window cleaner around window interior perimeter and edges to remove Method B any oily film while inspecting for damages. ...
  • Page 748 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 749 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 750 SECTION 18b: X3 SERIES BODY  bolts fastening the 2 hinges to the escape hatch Escape Hatch Frame frame and retain the 4 flat washers. Reinstall the When necessary, the escape hatch frame can panel assembly by fastening the 2 hinges with be removed and replaced in the following way: the 4 bolts and flat washers removed earlier.
  • Page 751 The fiberglass rear cap does not need any maintenance except painting as needed. It is held in place with adhesive. If ever it has to be replaced, take an appointment at a Prevost service center near you. For minor damages, refer to Paragraph 4 "Common Fiberglass Repair Procedure"...
  • Page 752 SECTION 18b: X3 SERIES BODY 9.3.2 Rear Bumper Remove three bolts on each side holding bumper to vehicle and remove bumper. To install bumper, reverse the procedure. FIGURE 41: REAR BUMPER 18634 9.3.3 Exhaust Aftertreatment System Access Door 1. Open exhaust aftertreatment system access door. 2.
  • Page 753 SECTION 18b: X3 SERIES BODY 9.4.1 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 754 SECTION 18b: X3 SERIES BODY FIGURE 48 6. If the longitudinal position is out of tolerance, adjust using the adjustment provided on the inner side of the door, at the upper attachment point of the arm on the door FIGURE 46 (FIGURE 49).
  • Page 755 SECTION 18b: X3 SERIES BODY 8. If the longitudinal position is out of tolerance, adjust using the adjustment provided on the 10. Check that the two items identified with lower attachment point of the arm on the arrows are snug but not tight (FIGURE 53). vehicle chassis (FIGURE 51).
  • Page 756 SECTION 18b: X3 SERIES BODY FIGURE 55 13. Open the door and perform a final tightening FIGURE 57: USE A RULER (SHOWN IN BLACK) TO to the items indicated with arrows (FIGURE CHECK THAT SURFACES ARE EVEN 56). 15. Use the pin to adjust the door so it is even with the adjacent steel sheet.
  • Page 757 SECTION 18b: X3 SERIES BODY 17. Perform the transversal adjustment by moving the strike plate using the slotted holes (FIGURE 60). FIGURE 62 FIGURE 60 18. The latch bolt must engage not less than 13/32” (10mm) behind the strike plate. 13/32”...
  • Page 758 SECTION 18b: X3 SERIES BODY 9.4.3 Engine Radiator Door 4. Check door fit and operation. Radiator door may be adjusted for proper fit by untightening hinge bolts: 1. Loosen the bolts, (“A” & “C”, Figure 65) holding the hinge to the vehicle structure to shift the door "LEFT or RIGHT".
  • Page 759 SECTION 18b: X3 SERIES BODY 9.5 ZONE 5 FIGURE 66: ZONE 5 PA1621 Maintenance Manual All Series | January 2017...
  • Page 760 SECTION 18b: X3 SERIES BODY 9.5.1 Baggage Compartment Doors (Aluminum) NOTE For the removal and installation of a baggage compartment door body panel, you will need: Vertical adjustment is achieved by moving the door along the mounting plate slots. A drill with drill bits; Pneumatic hammer tool (Zip Gun);...
  • Page 761 SECTION 18b: X3 SERIES BODY the lock plates. 4. Adjust door position and evenness with reference to adjacent panels and doors. 6. Open baggage compartment door and adjust using the cylinder mounting block. NOTE Adjustment is made by moving IN or OUT the lock plates.
  • Page 762 SECTION 18b: X3 SERIES BODY 10. Door bottom edge compression can be adjusted moving pantograph arms at this location. 9. Tighten cylinder block fixing screws. 9.5.2 Wheelchair Lift Cassette Compartment Door For the removal and installation of a wheelchair  Preferably install the door onto a work lift (WCL) cassette compartment door body surface where it can be solidly fixed.
  • Page 763 SECTION 18b: X3 SERIES BODY The small door has a piano hinge on its lower edge. Install only two of the mounting screws, at each end to adjust the door. Close door and adjust in opening. A 1mm maximum difference between left and right measured gap is accepted.
  • Page 764 SECTION 18b: X3 SERIES BODY 9.5.3 Wheelchair Lift access door 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 765 SECTION 18b: X3 SERIES BODY FIGURE 68: 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 766 SECTION 18b: X3 SERIES BODY 8. - Pull the upper rail towards the inside in order to remove the play between the roller and rail then bolt the rail at front and center. Add some shims if necessary between the rail and the structure before tightening the bolts.
  • Page 767 SECTION 18b: X3 SERIES BODY FIGURE 70: WCL SLIDING DOOR OPENING MECHANISM 18740 Minor Repair 9.5.4 Baggage Compartment Floor Use “Dupont IMRON” paint. Apply using a paint  brush or roller depending on gravity. Repair of Mantex Urethane Covering Paint Code: #J4099U PA1621 Maintenance Manual All Series | January 2017...
  • Page 768 SECTION 18b: X3 SERIES BODY  Major Repair (Hole) Baggage Compartment Floor Installation Chamfer the whole perimeter of the damaged Preparation and Installation area. If applicable, remove loose covering. Clean baggage compartment support structure Remove dust and particles. using anti-silicone. Cover and protect damaged area surroundings.
  • Page 769 SECTION 18b: X3 SERIES BODY Using a triangular nozzle, apply “Simson” glue (685126) onto support structure. Rear baggage compartment equipped with WCL Rear baggage compartment without WCL. Prepare baggage compartment Mantex floor. Rear baggage compartment equipped with WCL Clean panel underside and edges. PA1621 Maintenance Manual All Series | January 2017...
  • Page 770 SECTION 18b: X3 SERIES BODY Clean with anti-silicone the area where the Simson glue will be applied. Apply some Simson glue to fill the gap. Carefully install panel onto support structure. Evenly distribute and install conforming weights (6 to 8) (80 to 100 lbs total) onto panel for at least 4 hours.
  • Page 771 SECTION 18b: X3 SERIES BODY Rear baggage compartment equipped with WCL Rear baggage compartment without WCL. Remove masking tape. Smooth down joints using soapy water. PA1621 Maintenance Manual All Series | January 2017...
  • Page 772 SECTION 18b: X3 SERIES BODY 9.5.5 Evaporator Compartment Door FIGURE 71: EVAPORATOR DOOR (ALUMINUM) For the adjustment of an evaporator door, you will need:  Centering tool G34148_500  Door adjustment 1. Open the evaporator door. 2. Loosen the screws fixing the hinge to hinge attachment or hinge to door assembly.
  • Page 773 SECTION 18b: X3 SERIES BODY 12. Make sure that backing plate is parallel to structure before tightening hardware 13. Make sure that skid bar only touches slightly bus structure at bottom. The door should not move up when closing. 9. Close door to center the latch assembly. 10.
  • Page 774 SECTION 18b: X3 SERIES BODY 9.5.6 Condenser Compartment Door FIGURE 72: CONDENSER DOOR 1. Open the condenser door. PA1621 Maintenance Manual All Series | January 2017...
  • Page 775 SECTION 18b: X3 SERIES BODY 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" and "UP or DOWN" or “IN and OUT”.
  • Page 776 SECTION 18b: X3 SERIES BODY 9.6 ZONE 6 FIGURE 74: ZONE 6 18629 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.
  • Page 777 SECTION 18b: X3 SERIES BODY 9.7 ZONE 7 FIGURE 75: ZONE 7 18630 9.7.1 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 ...
  • Page 778 SECTION 18b: X3 SERIES BODY Grind tig weld spots at each end of side panel. Safely support or temporary fix side panel. Warning: Panel weights over 200 pounds Insert a flat screwdriver between the side panel and Be careful not to damage the adjacent the vehicle chassis, in the top left and right corners.
  • Page 779 SECTION 18b: X3 SERIES BODY SAV00001 Section A Alcohol or Anti-silicone 1. Apply 2. Dry immediately CHIX cloth Blue cloth 3. Allow to dry Mandatory Minimum time : Wait for product to evaporate After 2 hours: Start cleaning operation again If surface seems dusty, greasy or with finger marks, start Before applying any other cleaning operation again.
  • Page 780 SECTION 18b: X3 SERIES BODY SECTION 3 SIDE PANEL INSTALLATION 3.00 Using a pencil, mark the double-face self-adhesive tape position onto vehicle side. Apply 1/8 X ½”double-face tape as per marking. Compress tape Remove protective film from double-face self-adhesive tape center section. 3.05 Install 1/8 X ½”...
  • Page 781 SECTION 18b: X3 SERIES BODY Section A-A Section B-B Position side panel in front of vehicle structure Perform final adjustment to make sure that side 30 mm. ± 2 with reference to bottom – panel is true and square tubing 6 mm ±...
  • Page 782 SECTION 18b: X3 SERIES BODY Compress top and bottom section of side panel Cut excess of side panel. Make sure that cut is 3.50 parallel with tubing. Grind side panel end to line up with door tubing. To seal each panel end, apply masking tape on each side of 3.60 side panel joint.
  • Page 783 SECTION 18b: X3 SERIES BODY 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 Prepare air intake panel as for side panel 4.10 Install foam tape 1/8"...
  • Page 784 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 785 SECTION 18b: X3 SERIES BODY 9.7.2 Side Crest FIGURE 76: SIDE CREST POSITIONING 18639  Clean vehicle surface using anti-silicone where the side crest and stickers will be applied.  Using hands apply and compress side crest.  Apply required stickers. PA1621 Maintenance Manual All Series | January 2017...
  • Page 786 SECTION 18b: X3 SERIES BODY 9.8 BODY PANEL AND WINDOW SPACING FIGURE 77: BODY PANEL AND WINDOW SPACING 18631 PA1621 Maintenance Manual All Series | January 2017...
  • Page 787 SECTION 18b: X3 SERIES BODY 6. Reinstall seat bottom cushions with wing nuts. 9.9 PASSENGER SEATS X3 coaches can be equipped with any of 3 basic seat models and installed in a variety of seating arrangements: 9.9.2 Removing Fixed Seats 1.
  • Page 788 SECTION 18b: X3 SERIES BODY from being reapplied to the seats without damage. Other than spot cleaning the covers 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 789 SECTION 18b: X3 SERIES BODY 9.10 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 790 SECTION 18b: X3 SERIES BODY FIGURE 80: TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 81: APPLICATION OF SIKA 221 GRAY 18641 PA1621 Maintenance Manual All Series | January 2017...
  • Page 791 SECTION 18b: X3 SERIES BODY 9.10.1 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 792 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 793 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 794 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. 9.10.2 Welding Of Joint Between White Safety Strip And “Tarabus”...
  • Page 795 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 796 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 797 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 798 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. 10 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 799 SECTION 18b: X3 SERIES BODY FIGURE 83: X3-45 VIP FITTED WITH SLIDE-OUT 10.1 ZONE 1 FIGURE 84: ZONE 1 PA1621 Maintenance Manual All Series | January 2017...
  • Page 800 SECTION 18b: X3 SERIES BODY 10.1.1 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 801 SECTION 18b: X3 SERIES BODY Compress the crest three pieces using your hands. FIGURE 87: REAR VIEW MIRROR (RAMCO) 18398A  Adjustment At the base of the mirror arm, loosen the 10.1.3 Headlights mounting bolt to swing arm in or out. Refer to Paragraph Headlights, included in To pivot the mirror head, loosen the setscrews Section 06: Electrical of the Maintenance...
  • Page 802 SECTION 18b: X3 SERIES BODY  Heated/remote controlled external rear view Assembly mirrors may be provided to prevent the mirrors Attach a stiff wire (snake) to the end of the from frosting up in cold weather. harness and insert the wire through the mirror The remote controlled external rear view mirrors arm base and arm, gently pull the harness attach to support arms using a pivot collar...
  • Page 803 SECTION 18b: X3 SERIES BODY From outside of vehicle, remove filler located inside rubber seal ease damaged windshield removal. From inside of vehicle, push against the top L.H. side corner of windshield for the removal of a R.H. side windshield. If the L.H.
  • Page 804 SECTION 18b: X3 SERIES BODY stainless steel molding is located on the entrance door or service door frame side depending on body panel to be removed. Using the Olfa knife, cut the Sika bead and the double-face self-adhesive tape. Remove the Sika bead and self-adhesive tape residue with the scraper.
  • Page 805 SECTION 18b: X3 SERIES BODY Remove from door surface Sika bead and For the installation of front electrical & service double-face self-adhesive tape residue compartment door, refer procedure using a razor sharp window scraper. SAV280022. Use a Chix cloth and anti-silicone to remove any dust or residue.
  • Page 806 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 paragraph 4 "Common Fiberglass Repair procedure"...
  • Page 807 SECTION 18b: X3 SERIES BODY 10.2 ZONE 2 FIGURE 91: ZONE 2 This procedure requires accuracy and it is possible not to succeed on the first 10.2.1 Upper Side Panel attempt. From the inside of vehicle, a For structure preparation, refer to procedure second person ensures the rod passes SAV00035.
  • Page 808 SECTION 18b: X3 SERIES BODY 1. Push the vertical latch handle downwards to Do not stretch plastic film and leave enough release the track and then open the window play to be able to push window out without using the horizontal latch handle. tearing the plastic film.
  • Page 809 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 92: ELECTRIC AWNING WINDOW EXPLODED VIEW (FRAME) 18586 Actua tors...
  • Page 810 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 811 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 812 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 95) FIGURE 95: REMOVING THE SASH 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 96) FIGURE 96: DISENGAGING THE BOTTOM OF THE SASH PA1621 Maintenance Manual All Series | January 2017...
  • Page 813 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 97) Lower Cam Sash Stop Follower FIGURE 97: PROPER ALIGNMENT 2.
  • Page 814 10.3 ZONE 3 FIGURE 100: ZONE 3 held in place with adhesive. If ever it has to be replaced, make an appointment at a Prevost 10.3.1 Rear Cap service center near you. The fiberglass rear cap does not need any maintenance except painting as needed.
  • Page 815 SECTION 18b: X3 SERIES BODY For minor damages, refer to Paragraph 4 "Common Fiberglass Repair Procedure" and Paragraph 5 "Common Painting Procedure". 10.3.2 Engine Compartment Doors  Engine Compartment Doors Adjustment The engine compartment door may be adjusted for proper fit by untightening support bolts: NOTE Consult the “BODY PANEL AND WINDOW SPACING DIAGRAM”...
  • Page 816 SECTION 18b: X3 SERIES BODY 10.3.3 Rear Bumper  Engine Compartment Door Body Panel Removal Remove three bolts on each side holding bumper to vehicle and remove bumper. For the removal of engine compartment door To install bumper, reverse the procedure. body panel, you will need: Pneumatic hammer tool (Zip Gun);...
  • Page 817 SECTION 18b: X3 SERIES BODY 10.4 ZONE 4 FIGURE 103: ZONE 4 10.4.1 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 818 SECTION 18b: X3 SERIES BODY FIGURE 105: HINGES FIGURE 107 A – ENGINE R.H. SIDE ACCESS DOOR B - BOLT 4. If the vertical position is out of tolerance, C - BELLEVILLE WASHER D - BOLT rotate the door using the adjustment E - WASHER provided on the inner side of the door, at the F –SPACER...
  • Page 819 SECTION 18b: X3 SERIES BODY Tolerance is ± 3/64" (± 1mm) 8. If the longitudinal position is out of tolerance, adjust using the adjustment provided on the lower attachment point of the arm on the vehicle chassis (FIGURE 112). FIGURE 109 6.
  • Page 820 SECTION 18b: X3 SERIES BODY 10. Check that the two items identified with arrows are snug but not tight (FIGURE 114). 12. Close the door gently. FIGURE 116 FIGURE 114 13. Open the door and perform a final tightening to the items indicated with arrows (FIGURE 11.
  • Page 821 SECTION 18b: X3 SERIES BODY 14. Perform the transversal adjustment by moving the strike plate using the slotted holes (FIGURE 121). FIGURE 118: USE A RULER (SHOWN IN BLACK) TO CHECK THAT SURFACES ARE EVEN 15. Use the pin to adjust the door so it is even with the adjacent steel sheet.
  • Page 822 SECTION 18b: X3 SERIES BODY 10.4.3 Engine Radiator Door Radiator door may be adjusted for proper fit by untightening hinge bolts: 6. Loosen the bolts, (details “A” & “C”, Figure 125) holding the hinge to the vehicle structure to shift the door "LEFT or RIGHT". 7.
  • Page 823 SECTION 18b: X3 SERIES BODY FIGURE 126: RADIATOR DOOR DETAILS NOTE The striker pin must engage at least 13/32” (10mm). Add spacers between the latch and the vehicle body to adjust the engagement. NOTE There should be no gap between the washer and the hinge upper and lower halves.
  • Page 824 SECTION 18b: X3 SERIES BODY 10.5 ZONE 5 FIGURE 127: ZONE 5 10.5.1 Pantograph Baggage Compartment Doors (Aluminum) PA1621 Maintenance Manual All Series | January 2017...
  • Page 825 SECTION 18b: X3 SERIES BODY For the removal and installation of a baggage 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 826 SECTION 18b: X3 SERIES BODY NOTE Adjustment is made by moving UP or DOWN the lock plates. 19. Tighten cylinder block fixing screws. 20. Door bottom edge compression can be adjusted moving pantograph arms at this location. 16. Open baggage compartment door and adjust using the cylinder mounting block.
  • Page 827 SECTION 18b: X3 SERIES BODY 10.5.2 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 828 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 829 SECTION 18b: X3 SERIES BODY 10.5.3 Condenser Compartment Door FIGURE 128: 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 830 SECTION 18b: X3 SERIES BODY 10.5.4 Evaporator Compartment Door (Aluminum) FIGURE 129: 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 831 SECTION 18b: X3 SERIES BODY 12. Make sure that backing plate is parallel to structure before tightening the retainer 9. Close door to center the latch assembly. support hardware 10. Tighten the receptacle screws only. 13. Make sure that skid bar only touches slightly 11.
  • Page 832 SECTION 18b: X3 SERIES BODY 10.5.5 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 833 SECTION 18b: X3 SERIES BODY 10.6 ZONE 6 FIGURE 131: ZONE 6 10.6.1 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 834 SECTION 18b: X3 SERIES BODY 10.7 ZONE 7 FIGURE 132: ZONE 7 10.7.1 Side Panel for Vehicles Not Fitted With Slide-Out  Removal Remove top and bottom finishing moldings. Insert Be careful not to damage the adjacent surfaces a screwdriver into snap-on finishing molding joint. You need to remove the finishing molding support Bend finishing molding enough to be able to fix a and rivets in the case of engine air intake panel.
  • Page 835 SECTION 18b: X3 SERIES BODY using a straight edge. Take measurements with a towards the inside. ruler. structure preparation before CAUTION installation of a ridged side panel, refer to procedure SAV00027. Because most junction panels are only riveted For gluing of ridged side panels, refer to and not spot welded, be careful when procedure SAV00028.
  • Page 836 SECTION 18b: X3 SERIES BODY 10.8 ZONE 8 FIGURE 133: ZONE 8 10.8.1 Slide-Out Exterior Finishing Panels & Windows For maintenance and procedures, refer to paragraphs on the vehicle’s finishing panels and windows. Methods, procedures, tools, cleaning products, adhesives and other products are the same as those used for the vehicle body.
  • Page 837 SECTION 18b: X3 SERIES BODY 10.9 ZONE 9 FIGURE 134: ZONE 9 10.9.1 Slide-Out Exterior Finishing Panels & Windows For maintenance and procedures, refer to paragraphs on the vehicle’s finishing panels and windows. Methods, procedures, tools, cleaning products, adhesives and other products are the same as those used for the vehicle body.
  • Page 838 SECTION 18b: X3 SERIES BODY 10.10 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP NOT FITTED WITH SLIDE-OUT FIGURE 135: BODY PANEL & WINDOW SPACING FOR X3-45 VIP NOT FITTED WITH SLIDE-OUT PA1621 Maintenance Manual All Series | January 2017...
  • Page 839 SECTION 18b: X3 SERIES BODY 10.11 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP WITH FRONT AND REAR SLIDE-OUT FIGURE 136: BODY PANEL & WINDOW SPACING FOR X3-45 VIP WITH SLIDE-OUT, FRONT AND REAR PA1621 Maintenance Manual All Series | January 2017...
  • Page 840 SECTION 18b: X3 SERIES BODY 10.12 BODY PANEL AND WINDOW SPACING FOR X3-45 VIP FITTED WITH FRONT SLIDE-OUT FIGURE 137: BODY PANEL & WINDOW SPACING FOR X3-45 VIP WITH SLIDE-OUT, FRONT PA1621 Maintenance Manual All Series | January 2017...
  • Page 841 11 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 843 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 844 ) 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 845 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 846 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 847 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 848 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 849 (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 850 MI15-41 / Page 2 / 4 High PH cleaning product compatible with polycarbonate - product sheet FIGURE 1: PRODUCT SHEET QF7720956 rev3>...
  • Page 851 MI15-41 / Page 3 / 4 IMAGES SHOWING THE CRACKING ISSUE FIGURE 2: Cracks at the boss and ribs due to the use of engine degreaser FIGURE 3: Cracking of the outer surface of the taillight due to the use of engine degreaser Access all our Service Bulletins on https://secureus5.volvo.com/technicalpublications/en/pub.asp Or scan the QR-Code with your smart phone.
  • Page 852 MI15-41 / Page 4 / 4 QF7720956 rev3>...
  • Page 853 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS      TORQUE TABLES ............................ 5     HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM)  ................  5     HIGH/LOW PRESSURE SERVICE AND RECEIVER TANK VALVES ..............  6     IDLERS & TENSIONERS ...........................  6     SMALL A/C SYSTEM X3‐45 VIP ........................  7     HVAC SYSTEM OVERVIEW  ........................... 8     CENTRAL HVAC SYSTEM EVAPORATOR COMPARTMENT ARRANGEMENT ...........  8     CENTRAL HVAC SYSTEM – H SERIES  .......................  9  ...
  • Page 854 SECTION 22: HEATING AND AIR CONDITIONING     SHUT‐OFF VALVE WITH SERVICE PORT  ......................  3 2     4.10 LIQUID REFRIGERANT SOLENOID VALVE .....................  3 2     4.10.1 Typical malfunctions ..........................  3 2     4.10.2 Electrical Bypass/On Demand Opening of liquid refrigerant solenoid valves ........  3 3     4.10.3 Coil Replacement ..........................  3 3     4.10.4 Valve Disassembly ...
  • Page 855 SECTION 22: HEATING AND AIR CONDITIONING     EVACUATING SYSTEM  ..........................  6 3     SMALL HVAC SYSTEM ..........................  6 4     SYSTEM CONFIGURATION H‐SERIES ......................  6 4     SYSTEM CONFIGURATION X SERIES ......................  6 4     AIR CIRCULATION  ............................  6 4     7.3.1 Auxiliary Unit ............................  6 5  ...
  • Page 856 SECTION 22: HEATING AND AIR CONDITIONING SECTION CHANGE LOG  DESCRIPTION DATE Added low pressure switch on High capacity A/C compressor. From J-7446 (X series US), J-6245 (X series Nov. 2017 CAN), J-3997 (H series). PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 857: High Capacity Compressor (Central Hvac System)

    SECTION 22: HEATING AND AIR CONDITIONING TORQUE TABLES HIGH CAPACITY COMPRESSOR (CENTRAL HVAC SYSTEM) 22378_1 22379 22407 22406 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) 74 lb-ft (100 Nm) Compressor mounting bolts...

  • Page 858: High/Low Pressure Service And Receiver Tank Valves

    SECTION 22: HEATING AND AIR CONDITIONING HIGH/LOW PRESSURE SERVICE AND RECEIVER TANK VALVES 1-HIGH PRESSURE SERVICE VALVE 2-LOW PRESSURE SERVICE VALVE 3-RECEIVER TANK VALVE SERVICE AND RECEIVER TANK VALVE DESCRIPTION TORQUE High pressure service valve (both positions) 43 lb-ft (58 Nm) Low pressure service valve (both positions) 21 lb-ft (28 Nm) Receiver tank valve (both positions)

  • Page 859: Small A/C System X3-45 Vip

    SECTION 22: HEATING AND AIR CONDITIONING SMALL A/C SYSTEM X3-45 VIP SMALL A/C SYSTEM X3-45 VIP DESCRIPTION TORQUE Upper mounting screws 48 lb-ft (65 Nm) Belt Tensioner 48 lb-ft (65 Nm) Lower mounting screws 82 lb-ft (111 Nm) Compressor mounting fore bracket screws 35 lb-ft (47 Nm) Compressor mounting screws 35 lb-ft (47 Nm)

  • Page 860: Hvac System Overview

    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.  Small HVAC System Driver’s unit only ...

  • Page 861: Central Hvac System - H Series

    SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM – H SERIES FIGURE 2: H3 COACHES CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION PA1621 Maintenance Manual All Series | Section Revised November 2017...
  • Page 862 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 3: H3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT 22262 PA1621 Maintenance Manual All Series | Section Revised November 2017...
  • Page 863 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 4: H3 SERIES CENTRAL SYSTEM – REFRIGERANT CIRCUIT WITH OVERHEAD COMPARTMENT EVAPORATOR PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 864: Central Hvac System - X Series

    SECTION 22: HEATING AND AIR CONDITIONING CENTRAL HVAC SYSTEM – X SERIES FIGURE 5: X3 COACHES CENTRAL HVAC SYSTEM - PASSENGER’S UNIT AIR CIRCULATION FIGURE 6: X3 SERIES CENTRAL HVAC SYSTEM – HEATING CIRCUIT PA1621 Maintenance Manual All Series | Section Revised November 2017...
  • Page 865 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 7: X3 SERIES CENTRAL HVAC SYSTEM –CIRCUIT W/ OVERHEAD COMPARTMENT EVAPORATORS PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 866: Small Hvac System - H Series

    SECTION 22: HEATING AND AIR CONDITIONING SMALL HVAC SYSTEM – H SERIES FIGURE 8: H SERIES SMALL HVAC SYSTEM – HEATING AND AIR CONDITIONING 22345 PA1621 Maintenance Manual All Series | Section Revised November 2017...
  • Page 867 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 9: SMALL HVAC SYSTEM - DRIVER'S AND AUXILIARY UNIT (H3 VIP ONLY) FIGURE 10: H SERIES SMALL HVAC SYSTEM – AIR CONDITIONING 22377 PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 868: Small Hvac System - X Series

    SECTION 22: HEATING AND AIR CONDITIONING SMALL HVAC SYSTEM – X SERIES FIGURE 11: X3 SERIES SMALL HVAC SYSTEM - REFRIGERANT CIRCUIT PA1621 Maintenance Manual All Series | Section Revised November 2017...
  • Page 869 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 12: X-SERIES CONDENSER ARRANGEMENT FIGURE 13: X-SERIES SMALL HVAC SYSTEM - HEATING CIRCUIT PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 870: Hvac System Basic Maintenance

    SECTION 22: HEATING AND AIR CONDITIONING 3.1.2 Passenger’s Unit 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 871: Driver's Unit Air Filter

    SECTION 22: HEATING AND AIR CONDITIONING assembly. Clean the steel wire screen as required. FIGURE 17: R.H CONSOLE AIR FILTER ACCESS GRILL (COACHES) 18505 FIGURE 16: 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.

  • Page 872: Overhead Compartment Fan Air Filter

    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 19: PASSENGER’S UNIT EVAPORATOR COIL 22332...

  • Page 873: Compressor Belts

    SECTION 22: HEATING AND AIR CONDITIONING Twin BX71 belt proper tension New: 90-100 lbs FIGURE 23: OVERHEAD COMPARTMENT FAN AIR Used: 75-85 lbs FILTER Belt tension Tool:7770002 22201 FIGURE 24: STANDARD BELT LAYOUT WITH CENTRAL COMPRESSOR BELTS HVAC SYSTEM 3.6.1 Belt Replacement –...

  • Page 874: Belt Tension Adjustment - Small Hvac System H-Series

    SECTION 22: HEATING AND AIR CONDITIONING adjustment screw (B). Tighten the lock bolt (A) 3.6.3 Belt Tension Adjustment – Small HVAC to preserve adjustment. System H-SERIES Belt tensioning is applied through air bellows TORQUE: 43 lb-ft (58 Nm) which are adjusted by an air pressure regulating Should the idler bearing need to be serviced, valve (Figure 27).

  • Page 875: Hvac System Components

    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 876: Troubleshooting Guide

    SECTION 22: HEATING AND AIR CONDITIONING 4.1.4 Troubleshooting Guide A preliminary check may be made by simply MAINTENANCE feeling the cylinder heads with the unit in operation at ambient temperatures of 35 F (2 A/C compressor oil and over. The cylinder heads are internally Check compressor oil level at the intervals divided into suction and discharge areas.

  • Page 877: Electro-Magnetic Clutch

    SECTION 22: HEATING AND AIR CONDITIONING  Compressor unable to pull extremely low NOTE vacuum with suction service valve Belts specifications may vary. For proper belt frontseated. selection, always consult your vehicle Coach Cause: Final Record.  Repeated liquid refrigerant floodback. 4.2.2 Removal - When the Compressor Is ...
  • Page 878 SECTION 22: HEATING AND AIR CONDITIONING CAUTION Never support evaporator motor assembly by its output shafts while moving it. Always use double blower fan unit base. FIGURE 34: H3 SERIES EVAPORATOR COMPARTMENT FIGURE 36: EVAPORATOR MOTOR BOLTS 22315 8. Install the complete unit on a work bench, unfasten the fan square head set screws, the Phillips head screws retaining cages to base and slide out the assemblies from the...

  • Page 879: Condenser Fan Control

    SECTION 22: HEATING AND AIR CONDITIONING CONDENSER (CENTRAL A/C) The central A/C system condenser coil is hinge mounted on the R.H. side of the vehicle on the condenser compartment door. Since condenser’s purpose is to dissipate heat from the hot refrigerant, it is important to keep the cooling coils and fins clean.

  • Page 880: Condenser Fan Removal

    SECTION 22: HEATING AND AIR CONDITIONING FIGURE 39: CONDENSER FAN SPEED AND COMPRESSOR EVENTS IN RELATION WITH HIGH SIDE PRESSURE 4.4.2 Condenser Fan Removal Set the battery master switch to the OFF position. Unplug the fan harness connector (Figure 40). Remove the four hexagonal head cap screws retaining the fan assembly to the shroud.

  • Page 881: Receiver Tank

    SECTION 22: HEATING AND AIR CONDITIONING FIGURE 41 X SERIES SMALL A/C CONDENSER FIGURE 42: RECEIVER TANK (H SERIES) ASSEMBLY. RECEIVER TANK The receiver tank is located in the condenser compartment (Figure 42). The function of the receiver tank is to store the liquid refrigerant. During normal operation, the level of the refrigerant should be approximately at the mid- point of the lower sight glass.

  • Page 882: Filter-Dryer

    SECTION 22: HEATING AND AIR CONDITIONING FILTER-DRYER Backseat the outlet shut-off valve and then disconnect the vacuum pump hose. A filter-dryer, also located in the condenser compartment, is installed on the liquid refrigerant line after the receiver tank. It is used to absorb CAUTION moisture and foreign matter from refrigerant before it reaches the expansion valves.
  • Page 883 SECTION 22: HEATING AND AIR CONDITIONING COLOR INDICATOR LIGHT BLUE PINK CLEAR TEMPERATURE VIOLET (ppm) (ppm) Normal, system OK (ppm) 75°F (24°C) 100°F (38°C) Temporary condition, normal when A/C system is turned on. Wait a few minutes 125°F (52°C) for the system to stabilize. p.p.m.= parts per million (moisture content) A moisture level of less than 15 p.p.m.

  • Page 884: Shut-Off Valve With Service Port

    SECTION 22: HEATING AND AIR CONDITIONING SHUT-OFF VALVE WITH SERVICE On H3 VIP, one identical refrigerant solenoid PORT valve is used on the small HVAC system auxiliary unit (Figure 9). This shut-off valve (FIGURE 46) is located in the condenser compartment. It is used to isolate one section of the refrigerant circuit.

  • Page 885: Electrical Bypass/On Demand Opening Of Liquid Refrigerant Solenoid Valves

    SECTION 22: HEATING AND AIR CONDITIONING Excessive leakage: Disassemble valve and 4.10.4 Valve Disassembly clean all parts. Replace worn or damaged parts Because of possible damage to valve with a complete repair kit for best results. components due to the high temperature of soldering and brazing, it is necessary to There are only three main possible malfunctions: completely disassemble the A &...

  • Page 886: Thermostatic Expansion Valve

    SECTION 22: HEATING AND AIR CONDITIONING FIGURE 50: TYPICAL REFRIGERANT SOLENOID VALVE CAUTION The filter-dryer must be replaced after a severe system failure or if a line in the system has been opened over a prolonged period of time. The line will then have to be FIGURE 51: EXPANSION VALVE 22215 properly evacuated.

  • Page 887: Superheat Adjustment

    SECTION 22: HEATING AND AIR CONDITIONING pin to full open position, is of vital importance because it provides savings in both initial evaporator cost of operation. Accurate and sensitive control of the refrigerant liquid flowing to the evaporator is necessary to provide maximum evaporator capacity under load conditions.

  • Page 888: Driver's Unit

    F (4,4 C) of superheat. 4.12 HOT WATER PNEUMATIC VALVE No maintenance is needed unless a malfunction occurs. Refer to Prevost parts manual for available service kits. Valve is normally closed. PA1621 Maintenance Manual All Series | Section Revised November 2017...
  • Page 889 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 54: PASSENGER’S UNIT PNEUMATIC HOT WATER VALVE – TYPICAL CUT-OUT VIEW PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 890: Valve Troubleshooting

    SECTION 22: HEATING AND AIR CONDITIONING 4.12.1 Valve Troubleshooting PROBLEM PROCEDURE Valve fails to close 1. Check electrical supply with a voltmeter. It should agree with nameplate rating. 2. Check pressure at pilot solenoid valve inlet. It must be at least equal to the minimum pressure stamped on the nameplate.
  • Page 891 SECTION 22: HEATING AND AIR CONDITIONING NOTE For complete information on seal-less water circulating pump, refer to Ametek 18 GPM Seal-Less ECDC Water Circulating Pump manual. Take note that the motor described in this manual is different from the one installed on your circulating pump which is not repairable.
  • Page 892 SECTION 22: HEATING AND AIR CONDITIONING 3. Open both shutoff valves. NOTE 4. Fill the cooling system as previously When starting the A/C compressor, allow instructed in this section under 6.4.4 Filling enough time before checking pressures in Heating System and then bleed the system order to give the system a chance to build its as previously instructed in this section.

  • Page 893: Temperature Sensors

    SECTION 22: HEATING AND AIR CONDITIONING TEMPERATURE SENSORS following table used TEMPERATURE SENSOR troubleshooting following temperature Resistance Ohms sensors: Temp °C Temp °F (temperature sensor disconnected) 1) Driver area temperature sensor (SE21); 100865 2) Passenger area temperature sensor (SE25); 72437 3) Outside air temperature sensor (SE20).
  • Page 894 SECTION 22: HEATING AND AIR CONDITIONING vehicle is traveling to check the A/C compressor TEST MODE FOR ELECTRIC pressure values. MOTORS In test mode, with the parking brake applied and The test mode allows testing the motors and the passenger set point set to a value higher electric contactors without the need to have the than 64°F (18°C), the hot water circulating pump engine running.
  • Page 895 SECTION 22: HEATING AND AIR CONDITIONING HVAC ELECTRICAL SYSTEM TROUBLESHOOTING Always check DID for electrical faults before performing repairs. Address any modules not responding and take corrective action. This should be the first step in troubleshooting. Problem/Symptom Probable Causes Actions No temperature control in the Problem with the temperature Instruct the driver to manually control the...
  • Page 896 SECTION 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions HVAC condenser fans not Module A49 (A54 on H3 VIP & Check the Diagnostics menu of Driver functioning in speed 1 X3 VIP) is not powered or is Information Display (DID). Select Fault faulty Diagnostics and Electrical System.

  • Page 897: Air Conditioning

    SECTION 22: HEATING AND AIR CONDITIONING Problem/Symptom Probable Causes Actions Evaporator fan not Circuit breaker CB3 (CB6 on X3 Check / reset circuit breaker CB3 (CB6 on functioning VIP) tripped X3 VIP) Check the Diagnostics menu of Driver Module A54 is not powered or is Information Display (DID).
  • Page 898 SECTION 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE Superheat too high. Reset superheat adjustment. Check for clogged external equalizer line, or filter-dryer. Reduced air flow: Dirty or iced evaporator coil. Clean air filter a. Dirty or clogged air filter; screen. Check return ducts for obstructions. b.
  • Page 899 SECTION 22: HEATING AND AIR CONDITIONING 5.7.2 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 900: Leak Testing

    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 used is a "Halide" torch consisting of an TEMPERATURE PRESSURE acetylene tank, a burner and a suction test hose.

  • Page 901: Air Circulation In Driver's Area

    SECTION 22: HEATING AND AIR CONDITIONING in the main power compartment/junction panel Multiplex Module (evaporator compartment) (Figure 60 & Figure 61). 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 902: Air Circulation In Passenger'sarea

    SECTION 22: HEATING AND AIR CONDITIONING direct air to his knees and/or upper body with adjustable HVAC air registers and to his feet with the appropriate button (see FIGURE 62 and Owner’s or Operator’s manual). FIGURE 63: X3 SERIES PASSENGERS' AREA FRESH AIR DAMPER FIGURE 62: DRIVER’S UNIT AIR CIRCULATION An additional air is located in the stepwell for...

  • Page 903: Hvac System Operation

    SECTION 22: HEATING AND AIR CONDITIONING 6.3.1 Control Unit The temperature control in the driver’s area is provided directly by the DRIVER control on the L.H. side of the HVAC control unit. FIGURE 65: CONTROL UNIT - CENTRAL HVAC SYST FIGURE 64: OVERHEAD COMPARTMENT VENTILATION 22276 SYSTEM...

  • Page 904: Driver's Unit Hot Water Pneumatic Valve

    SECTION 22: HEATING AND AIR CONDITIONING air conditioning unit permits a wider temperature 6.4.2 Passenger’s Unit Hot Water Pneumatic range in the passenger’s area. Valve The flow of hot water to the vehicle’s central HEATING heater core is controlled by a normally-open NO The schematic of FIGURE 3 shows the central 3-way pneumatic water valve assembly (Figure 67).
  • Page 905 SECTION 22: HEATING AND AIR CONDITIONING WARNING Before proceeding with the following steps, check that coolant has cooled down. 3. Loosen hose clamp, install an appropriate container to recover coolant, and disconnect silicone hose from hot water pneumatic valve. 4. From inside of vehicle, remove the two finishing panels in front of unit.
  • Page 906 SECTION 22: HEATING AND AIR CONDITIONING FIGURE 71: DRIVER'S HVAC UNIT FIGURE 72 X SERIES HEATER LINE SHUT-OFF VALVES- (ALLISON TRANS. PIPING ARRANGEMENT SHOWN) PA1621 Maintenance Manual All Series | Section Revised November 2017...

  • Page 907: Filling Heating System

    SECTION 22: HEATING AND AIR CONDITIONING Draining Passenger’s Unit Heater Core 1. Stop engine and allow engine coolant to cool. 2. Close both heater line shutoff valves (Figure 72 or Figure 73). One is located in the engine compartment, lower road side, near the radiator while the other one is located behind the L.H.

  • Page 908: Refrigeration Cycle

    SECTION 22: HEATING AND AIR CONDITIONING Locate the purge valve illustrated in Figure 69 & refrigerant to vaporize in a vapor-liquid state Figure 74, and open them momentarily until no at a low temperature pressure. air escapes from the lines. If present, open the The cold low pressure refrigerant passes manual vent located inside the HVAC unit, on through the passenger’s and driver’s unit...
  • Page 909 SECTION 22: HEATING AND AIR CONDITIONING Refrigerant charge (Approximate) WARNING Central A/C system: 24 lbs Small A/C system: 4 lbs Overhead comp. A/C system: 2 lbs One of the most important precautions when handling refrigerant consists in protecting the It will be impossible to draw the entire refrigerant eyes.

  • Page 910: Refrigerant System Clean-Out After Compressor Failure

    SECTION 22: HEATING AND AIR CONDITIONING cases, carbonized oil, which could contaminate the system. To prevent repeated failures, the WARNING problem which caused the failure should be corrected, and depending upon the severity of Always wear safety goggles and gloves when the failure, the system should be thoroughly opening refrigerant lines.

  • Page 911: Pumping Down

    SECTION 22: HEATING AND AIR CONDITIONING Clean-out After Major Compressor Failure NOTE Once this pull down procedure has been Reclaim the refrigerant into a refrigerant properly done, any component from the outlet bottle through a filter-dryer to filter out hose on the receiver tank, the filter-dryer, the contaminants.
  • Page 912 SECTION 22: HEATING AND AIR CONDITIONING connector housings of C24 together for the passengers’ area (found on the HVAC 3. Close (frontseat) the receiver tank outlet module in evaporator compartment) and shut-off valve by turning the stem clockwise C44 for the driver's area (located on the (Figure 42 and Figure 76).

  • Page 913: Adding Vapor State Refrigerant

    SECTION 22: HEATING AND AIR CONDITIONING At fast idle, the high side pressure should NOTE be near the following calculation: add 30° F During this operation, care must be taken not to the ambient temperature in Fahrenheit. to fill the receiver tank over the upper sight In the refrigerant chart (see paragraph 5.8), glass.

  • Page 914: Charging System

    SECTION 22: HEATING AND AIR CONDITIONING After charging the system, it may be necessary to WARNING add refrigerant. Vapor state refrigerant addition will be done from the suction side of the If discharge pressure is above 100 psig, the compressor while the compressor is in operation. condenser fans will be running.

  • Page 915: Liquid Refrigerant Recovery

    SECTION 22: HEATING AND AIR CONDITIONING 5. Perform the recovery of the refrigerant as CAUTION prescribed recovery unit manufacturer. The evacuation of the system must be made by authorized and qualified personnel only. EVACUATING SYSTEM Refer to local laws for R-134a recuperation. When A/C system has been opened or if there are any questions about the air or moisture in LIQUID REFRIGERANT RECOVERY...

  • Page 916: Small Hvac System

    SECTION 22: HEATING AND AIR CONDITIONING Shut down the vacuum pump. Validate that the vacuum holds. If the pressure rises, it indicates a leak. 10. Backseat the compressor shut-off valves by turning “out” all the way. 11. Remove the hoses. 12.

  • Page 917: Auxiliary Unit

    SECTION 22: HEATING AND AIR CONDITIONING Both right and left discharge ducts defrost one NOTE half of the windshield. The driver can also divert X3 Series - The outside air temperature sensor his air flow to the dashboard, from which he can is located near the RH headlight.

  • Page 918: Oil Addition

    SECTION 22: HEATING AND AIR CONDITIONING Shut down the vacuum pump. the system or replacing any system component, the compressor must be run in advance to Check to insure that vacuum holds. (If the ensure return. This procedure is as follows: pressure continues to rise, it indicates a ...

  • Page 919: Preheater Fuel Filter

    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 operates intermittently, i.e.

  • Page 920: Preheating System Timer

    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 To avoid running down the batteries, do not of the preheating system. The system indicator turn on the preheating system for more than light, located on the timer, illuminates when the one hour before starting the engine.
  • Page 921 SECTION 22: HEATING AND AIR CONDITIONING Failure Symptoms Probable Cause Check and Correct - Fuel system - Fuel level 1X Flash (F 01) No combustion after completion - Type of fuel being used 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 922: Specifications

    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 .............................
  • Page 923 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) Condenser Fan (Small HVAC system) Diameter ............................12 in (30.5 cm) Power ................................850W Voltage (nominal) ............................
  • Page 924 SECTION 22: HEATING AND AIR CONDITIONING Hot water circulating pump Make ..............................AMETEK Flow ..............................15 gpm Inlet/outlet OD ............................3/8” Main expansion valve Make ............................Emerson-Alco Preheating system Make .............................. SPHEROS Model ............................THERMO 300 Capacity ........................104 000 Btu/h (30 kW) Heating medium ..........................
  • Page 925 SECTION 23A: ACCESSORIES - H3 SERIES CONTENTS    SECTION CHANGE LOG ..............................  3     TORQUE TABLES ............................ 5     AUDIO AND VIDEO SYSTEM DESCRIPTION  .................... 6     TROUBLESHOOTING ............................  9     HOW TO RECEIVE SERVICE FOR YOUR REI AUDIO AND VIDEO PRODUCTS  ...........  9     DASHBOARD RADIO  .............................  1 0     2.3.1 Removal/Installation ...........................  1 0  ...
  • Page 926 SECTION 23A: ACCESSORIES - H3 SERIES     7.5.1 Removal and Installation ........................  2 1     7.5.2 Dip Switch Settings ..........................  2 1     EMERGENCY BUZZER ...........................  2 1     FRESH WATER TANK ............................  2 1     7.7.1 Fresh Water Tank Heater (Optional) ....................  2 1     7.7.2 Fresh Water Tank Draining  ........................  2 1  ...
  • Page 927 SECTION 23A: ACCESSORIES - H3 SERIES SECTION CHANGE LOG DESCRIPTION DATE PA1621 Maintenance Manual All Series | January 2017...
  • Page 928 SECTION 23A: ACCESSORIES - H3 SERIES PA1621 Maintenance Manual All Series | January 2017...
  • Page 929 SECTION 23A: ACCESSORIES - H3 SERIES TORQUE TABLES MISCELLANEOUS DESCRIPTION TORQUE Hub odometer 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 155-165 lb-in (18-19 Nm)
  • Page 930 Each passenger’s overhead console mounted to the underside of the overhead compartments 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 931 SECTION 23A: ACCESSORIES - H3 SERIES 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 PA1621 Maintenance Manual All Series | January 2017...
  • Page 932 SECTION 23A: ACCESSORIES - H3 SERIES 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 PA1621 Maintenance Manual All Series | January 2017...
  • Page 933 SECTION 23A: ACCESSORIES - H3 SERIES 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 934 SECTION 23A: ACCESSORIES - H3 SERIES 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, FLIP 19” MICROPHONE, 10” CB TYPE MONITOR, 16:9 CENTRAL LCD 19”...
  • Page 935 SECTION 23A: ACCESSORIES - H3 SERIES 400W DSP POWER AMPLIFIER speakers (24 in H3-41 or 28 in H3-45) in the passenger’s section, wired in stereo and arranged in a delta configuration are powered by This 400-watt, 8 channels digital amplifier brings the amplifier.
  • Page 936 SECTION 23A: ACCESSORIES - H3 SERIES 3. Disconnect wiring. 2.7.2 Installation 1. Reconnect wiring. 2. Align mounting flange with holes and install screws. 3. Remove spacer block mounting screws. 4. Insert spacer block and install mounting screws. 5. Place the battery master switch in the ‘’ON’’ position.
  • Page 937 SECTION 23A: ACCESSORIES - H3 SERIES 2.12 MONITOR REMOVAL 2.14 ROOF ANTENNA INSTALLATION 1. Place the ignition switch in the ‘’OFF’’ 1. Find the desire location and drill a hole position. according to specification. 2. Unfasten the retaining screw located on the 2.
  • Page 938 SECTION 23A: ACCESSORIES - H3 SERIES  By pressing this key when putting in the reverse gear, the distance markings move downwards; BACK-UP CAMERA AND MONITOR An optional back-up camera is available which 4) SELECT This key has 3 functions provides the driver with visual assistance when ...
  • Page 939 SECTION 23A: ACCESSORIES - H3 SERIES INSTALL POSSIBLE SETTINGS: Selection priority camera REAR CAM1 (CAM1 CAM2) which triggered by rear gear. Selection of real picture or CAM1 mirrored picture for camera 1. Selection of real picture or CAM2 Select the function (e.g. contrast) by pressing mirrored picture for camera 2.
  • Page 940 SECTION 23A: ACCESSORIES - H3 SERIES PA1621 Maintenance Manual All Series | January 2017...
  • Page 941 SECTION 23A: ACCESSORIES - H3 SERIES HUB ODOMETER NOTE Do not use paint, solvent or thinner on hub DESCRIPTION odometer face or on plastic hubcaps. Do not weld on hub odometer. An optional wheel hub odometer (Figure 17) may have been installed on the R.H. side of the drive axle.
  • Page 942 SECTION 23A: ACCESSORIES - H3 SERIES SUNSHADES WINDSHIELD SUNSHADES electrically-operated sunshades installed in the driver’s area at the top of the windshields. Two control buttons located on the steering wheel and two on the dashboard operate each sunshade individually. Refer to Operator’s Manual: “Controls and Instruments”...
  • Page 943 The special tool can be ordered from your sign is located on the outer wall of the lavatory Prevost part center under part # 685594 and another sign is located over the windshield. An indicator light on the dashboard will illuminate to inform the driver when the lavatory is occupied.
  • Page 944 SECTION 23A: ACCESSORIES - H3 SERIES able odors and provides a constant air circula- tion in the lavatory compartment by heating or cooling the lavatory with the vehicle ambient air. Air flows in the lavatory compartment through a vent grill located in the upper section of the lavatory door and exhausts through a grill located next to the toilet.
  • Page 945 SECTION 23A: ACCESSORIES - H3 SERIES FRESH WATER TANK 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 27).
  • Page 946 SECTION 23A: ACCESSORIES - H3 SERIES until the overflow tube leaks, signaling that tank CAUTION is full. Do not use "BOBRICK" key to turn cover. WARNING 3. Lift out piston and spout, cover and supply Never put antifreeze in fresh water tank; tube.
  • Page 947 SECTION 23A: ACCESSORIES - H3 SERIES to decrease time. To gain access to the time adjustment screw, repeat steps 1, 2 and 3 in the previous paragraph. 7.10 FLUSH PUMP The submersible-type flush pump is mounted inside an enclosure in the sump tank (Figure 28). The enclosure is provided with a screened side which, serves as a strainer to prevent solid matters from entering the pump.
  • Page 948 SECTION 23A: ACCESSORIES - H3 SERIES during cold weather, drain the hose after every use. To drain the hose, uncoil and open the nozzle near the lavatory floor drain. Have an assistant push on the spring ball of the quick- release coupling to allow air into the system.
  • Page 949 SECTION 23A: ACCESSORIES - H3 SERIES WASHER FLUID REFILLING Open the filler neck cap and had regular HEADLIGHTS CLEANING SYSTEM windshield washer fluid as required. The tank has a capacity of 10 liters (2.6 US gallons). You may use water or windshield washer fluid as GENERAL DESCRIPTION well but, during cold weather days, use windshield washer fluid suitable for freezing...
  • Page 950 SECTION 23A: ACCESSORIES - H3 SERIES 10. WINDSHIELD WIPERS AND WASHERS 10.1 GENERAL DESCRIPTION NOTE When installing a wiper motor, arm or blade, follow recommended procedures to prevent misalignment, binding or malfunc- tion. Check the windshield washer liquid hoses, fittings and connectors to be sure they are properly connected and seal with no restriction to the flow of washer liquid.
  • Page 951 SECTION 23A: ACCESSORIES - H3 SERIES The windshield washer reservoir is located in the front service compartment (Figure 35). This unit pumps the washer liquid to the spray nozzles where it is dispersed across the windshield. Adjust nozzles with a flat tip screw- driver as needed to get proper spray coverage.
  • Page 952 SECTION 23A: ACCESSORIES - H3 SERIES 8. Connect the windshield washer tubing at the base of the wiper arm; 9. Check the adjustment on a wet windshield. FIGURE 36: LOWER WINDSHIELD WIPER 23086 1. Remove the cap nuts from the wiper arm pivot shafts (Figure 36 &...
  • Page 953 4. Remove the three bolts holding the motor to 8. The left wiper arm final adjustment is made the steel plate. by adjusting the longest rod length. 5. Remove the windshield wiper motor (Prevost 9. Check the adjustment on a wet windshield. #800304), reverse removal procedure to reinstall.
  • Page 954 SECTION 23A: ACCESSORIES - H3 SERIES FIGURE 38: LOWER WINDSHIELD WIPER INSTALLATION 23088 PA1621 Maintenance Manual All Series | January 2017...
  • Page 955 SECTION 23A: ACCESSORIES - H3 SERIES 10.5.2 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 956 General activated by the operator at any time. o Verify that neither the protected equipment Refer to Prevost Operator’s Manual or Owner’s nor the hazard has changed. Manual for system operation and operational o Verify that no obvious physical damage or sequence (fire).
  • Page 957 SECTION 23A: ACCESSORIES - H3 SERIES  Rebuilt shall include actuator, O-ring seals and Verify that the status lamp on the detec- dry chemical replacement. tor face is on solid green.  Verify that nothing is blocking the detec- tor’s field of view. MAINTENANCE ...
  • Page 958 SECTION 23A: ACCESSORIES - H3 SERIES The VECT includes the following components: Relay 51 Relay 52 Relay 53 Relay 54 Relay 55 CB301, 20 Amp FIGURE 41: A40 CONNECTOR Fuse 302, 20 Amp Four circuits: Fuse 303, 20 Amp black 12V power (from ignition) Fuse 304, 20 Amp white...
  • Page 959 SECTION 23b: ACCESSORIES - X3 SERIES CONTENTS   SECTION CHANGE LOG  ...............................  3         TORQUE TABLES ............................ 4     DESCRIPTION OF AUDIO AND VIDEO SYSTEM INSTALLED ON X3‐45 COACHES .......... 5     RECEIVE SERVICE YOUR AUDIO VIDEO PRODUCTS  .............  8                ...
  • Page 960 SECTION 23b: ACCESSORIES - X3 SERIES     7.6.1 FLUSH PUSH BUTTON REMOVAL AND INSTALLATION  .................  2 1     FLUSH PUMP ..............................  2 1       7.7.1 FLUSH PUMP REMOVAL  ........................  2 1     SUMP TANK  ..............................  2 2       7.8.1 SUMP TANK FILLING .......................... ...
  • Page 961 SECTION 23b: ACCESSORIES - X3 SERIES SECTION CHANGE LOG DESCRIPTION DATE Additional information: sump tank tubing and fill couplings Dec. 2017 PA1621 Maintenance Manual All Series | Section 23b updated December 2017...
  • Page 962 SECTION 23b: ACCESSORIES - X3 SERIES 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) PA1621 Maintenance Manual All Series | Section 23b updated December 2017...
  • Page 963 SECTION 23b: ACCESSORIES - X3 SERIES 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 964 SECTION 23b: ACCESSORIES - X3 SERIES FIGURE 2: AUDIO & VIDEO CONNECTIONS PA1621 Maintenance Manual All Series | Section 23b updated December 2017...
  • Page 965 SECTION 23b: ACCESSORIES - X3 SERIES FIGURE 3: AUDIO-VIDEO CONNECTIONS FIGURE 4: RACKS ON AUDIO-VIDEO PANEL 23059 PA1621 Maintenance Manual All Series | Section 23b updated December 2017...
  • Page 966 SECTION 23b: ACCESSORIES - X3 SERIES 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). Prior to calling REI, please have the part number, serial number, VIN number and detailed description of the problem ready to provide to the REI service representative.
  • Page 967 SECTION 23b: ACCESSORIES - X3 SERIES Place the ignition switch in the ‘’OFF’’ position. DASHBOARD AM/FM RADIO Remove the dashboard cover. Disconnect the electrical connectors from unit and unfasten back plate securing nut/screw. To separate the Sound Selector from its support, insert removal...
  • Page 968 SECTION 23b: ACCESSORIES - X3 SERIES 1 rear camera video input SPEAKERS 3 video outputs with one dedicated self- switching rear view monitor Each passenger’s overhead console mounted to the underside of the overhead compartments  ADDITIONAL VIDEO FEATURES contains a 20-watt Dual cone or coaxial 10cm speaker.
  • Page 969 SECTION 23b: ACCESSORIES - X3 SERIES 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 970 SECTION 23b: ACCESSORIES - X3 SERIES If so equipped, instructions for proper use of the 2.14 SCENIC VIEWING SYSTEM Karaoke system are included in the ‘’Operating Manual’’ that is provided in the technical publica- scenic viewing system enables tions box delivered with the vehicle. passengers to view the road ahead of the vehicle.
  • Page 971 SECTION 23b: ACCESSORIES - X3 SERIES  Deleting and calling OSD letters of title & activated when the transmission is put in reverse gear and the ignition switch is "ON". time (press longer than 1.5 seconds) during normal operation; 5) MENU: This key has 2 functions ...
  • Page 972 SECTION 23b: ACCESSORIES - X3 SERIES For calling up the menu USER press the key MENU once again. The menu USER appears. Select the function (e.g. SELECTION) by pressing the key SELECT repeatedly as necessary. The setting within the function can be modified with the keys UP and DOWN.
  • Page 973 SECTION 23b: ACCESSORIES - X3 SERIES HUB ODOMETER DESCRIPTION An optional wheel hub odometer (Figure 18) may have been installed on the R.H. side of the drive axle. It indicates the total distance in miles or kilometers covered by the coach since it has left the factory, including road testing.
  • Page 974 SECTION 23b: ACCESSORIES - X3 SERIES FIGURE 19: DESTINATION SIGN – ELECTRONIC 23123 NOTE FIGURE 18: HUB ODOMETER 23024 The destination sign must be programmed with a computer connected to the RS-232 OPERATION connector prior to first use. Follow the instructions on the computer disk to install and run the software.
  • Page 975 SECTION 23b: ACCESSORIES - X3 SERIES 2. Insert a small nail or similar thin object into 8. Press the sunshade DOWN (opposite sunshade adjustment button access hole direction) button to save #2 end position. and press the appropriate sunshade DOWN The confirmation tone will sound.
  • Page 976 SECTION 23b: ACCESSORIES - X3 SERIES NOTE When installed, lower the sunshade 6po (15cm) and release. The sunshade should retract freely to the full open position. Re- adjust preload as needed. Sunshade Type Req. Preload Std Sunshade 12 turns Large WCL Sunshade 12 turns LAVATORY INSTALLED ON X3-45 COACHES...
  • Page 977 SECTION 23b: ACCESSORIES - X3 SERIES FIGURE 23: LAVATORY PA1621 Maintenance Manual All Series | Section 23b updated December 2017...
  • Page 978 SECTION 23b: ACCESSORIES - X3 SERIES NOTE VENTILATION FAN Make sure fan shroud seal is in good condition prior to installation, replace as necessary 7.2.1 Description The lavatory ventilation fan (Figure 24), mounted in engine compartment, serves two purposes. It exhausts objectionable odors and provides a constant air circulation in the lavatory compart- ment by heating or cooling the lavatory with the...
  • Page 979 SECTION 23b: ACCESSORIES - X3 SERIES emergency button. Press on push-button to actuate the pump located in the sump tank. 7.6.1 Flush push button removal and installa- tion 1. Remove both Phillips-head screws retaining pushbutton switch plate to wall. 2. Remove stainless steel plate located on L.H. side of pushbutton switch.
  • Page 980 SECTION 23b: ACCESSORIES - X3 SERIES 6. Remove the enclosure cover to access and remove the pump. FIGURE 27: SUMP TANK PUMP ACCESS SUMP TANK 1 – fresh water sump tank filler tube 2 – sump tank overflow 7.8.1 Sump Tank Filling 3 –...
  • Page 981 Close cocks and pour a pack of commercial toilet deodorant (Prevost part #900329) in toilet before adding the antifreeze and starting final filling of sump tank. WARNING The toilet deodorant contains products that can be very irritating to skin.
  • Page 982 SECTION 23b: ACCESSORIES - X3 SERIES connected and seal with no restriction to the flow of washer fluid. Check that the washer HORN INSTALLATION nozzles are properly aimed. The electric and air horns are located in a plastic The headlights cleaning system is independent box under the front step well and are accessible from the windshield washer system and has its from the front body understructure.
  • Page 983 SECTION 23B: ACCESSORIES - X3 SERIES FIGURE 31: HEADLIGHTS CLEANING SYSTEM 23380 FIGURE 33: WASHER NOZZLES ADJUSTMENT 23382 CAUTION 10. WINDSHIELD WIPERS AND WASHERS Because they are made of plastic, firmly tighten nozzle and bulkhead fittings by hand only. 10.1 GENERAL DESCRIPTION NOTE When installing a wiper motor, arm or blade, follow recommended procedures to prevent...
  • Page 984 SECTION 23b: ACCESSORIES - X3 SERIES speed. Turning the lever backwards will operate Check operation of the wipers for proper blade the wipers in the intermittent mode. sweep and angle. 10.2.1 Wiper Arms Positioning 1. Reinstall the wiper arms and position as shown in figure 40.
  • Page 985 SECTION 23B: ACCESSORIES - X3 SERIES FIGURE 40: DRIVING MECHANISM (MOTOR SIDE) 23285 10.3 WINDSHIELD WIPER MOTOR FIGURE 38: WINDSHIELD WIPER (DRIVER SIDE) 23328 3. When the final position is found, tighten wiper arm nuts. Wait 30 minutes and tighten again. 10.3.1 Windshield Wiper Motor Replacement TORQUE 22 lb-ft (30 Nm) The windshield wiper motor is located at lower...
  • Page 986 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 windshield wiper motor (Prevost #800328), reverse removal procedure to reinstall. FIGURE 41: WIPER ARMS POSITIONING 23253 10.4 TROUBLESHOOTING...
  • Page 987 “Operation & detected. Maintenance Manual’’. For more information on the operation and troubleshooting of the system, refer to Prevost X3-45 Coaches Operator’s Manual, chapters 12.1 STARTING THE VEHICLE AFTER A “Controls and Instruments” and “Safety Features FIRE ALARM and Equipment”...
  • Page 988 SECTION 23b: ACCESSORIES - X3 SERIES  o Linear Thermal Turn to OFF, return to ON and START vehicle within 2 seconds.  Verify that there is no obvious physical damage and that the unit is free of ex- cess contamination (dirt, oil, grease, etc) –...
  • Page 989 SECTION 23B: ACCESSORIES - X3 SERIES Seven circuits: Have the Extinguisher cylinder hydrostatically tested by a qualified fire protection equipment white ground company familiar with Kidde Dual Spectrum blue output: brake application signal equipment and in accordance with KDS Docu- to the trailer ment 160296,...
  • Page 990 SECTION 23b: ACCESSORIES - X3 SERIES 13.3 VECT The VECT includes the following components: Relay 51 Relay 52 Relay 53 Relay 54 Relay 55 CB301, 20 Amp Fuse 302, 20 Amp Fuse 303, 20 Amp Fuse 304, 20 Amp FIGURE 45: VECT (CURB SIDE) Spare fuses: SP1-SP4 FIGURE 44: VECT PA1621 Maintenance Manual All Series | Section 23b updated December 2017...
  • Page 991 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 LUBRICATION AND SERVICING SCHEDULE - COACHES ..............8 COACHES LUBRICATION AND SERVICING SCHEDULE CHANGE LOG ..........
  • Page 992 SECTION 24: LUBRICATION & SERVICING LUBRICATION FLEXIBLE HOSE MAINTENANCE The efficiency and life expectancy of mechanical The performance of engine and equipment are equipment is largely dependent on proper greatly related to the ability of flexible hoses to lubrication servicing. mechanical supply lubricating oil, air, coolant, and fuel oil.
  • Page 993 SECTION 24: LUBRICATION & SERVICING It is also recommended that all hoses in this vehicle be replaced during major overhaul and/or after a maximum of five service years. Quality of replacement hose assemblies should always be equal to or superior to those supplied by the Original Equipment Manufacturer.
  • Page 994 SECTION 24: LUBRICATION & SERVICING FIGURE 2: LUBRICATION AND SERVICING POINTS (I-BEAM FRONT AXLE SHOWN) TYPICAL PA1621 Maintenance Manual All Series | Sec 24 revised Nov.2017...
  • Page 995 SECTION 24: LUBRICATION & SERVICING Accessories air tank drain cock Primary fuel filter Accessories air filter Secondary fuel filter Drag link Power steering fluid tank Height control valve (front) Engine oil filter Tie rod Cooling fan gearbox Accessories air tank Allison transmission oil dipstick Steering column U-joints Engine coolant surge tank...
  • Page 996 SECTION 24: LUBRICATION & SERVICING 24039_5 FIGURE 3: X3 SERIES COMPONENTS IDENTIFICATION (COMPONENTS REPRESENTATION MAY DIFFER SLIGHTLY FROM ACTUAL VEHICLE) PA1621 Maintenance Manual All Series | Sec 24 revised Nov.2017...
  • Page 997 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 Alternators Accessories air tank Allison transmission oil dipstick Steering column U-joints Engine coolant surge tank...
  • Page 998 SECTION 24: LUBRICATION & SERVICING 24039_3 FIGURE 4: 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 999 SECTION 24: LUBRICATION & SERVICING OPERATING CONDITION Use the information that follows to determine the operating condition and usage applicable to your vehicle Heavy Normal Between 5 and 6 mpg Greater than 6 mpg Between 39 and 50 L/100km Less than 39 L/100km PROCEED TO MAINTENANCE OPERATION EVERY Proceed to maintenance operation at mileage indicated on odometer or specified number of month, whichever comes first...
  • Page 1000 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY Proceed to maintenance operation at mileage indicated on odometer or specified number of month, whichever comes first LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use A red stripe in the left margin of the schedule highlights the latest changes ...
  • Page 1001 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY Proceed to maintenance operation at mileage indicated on odometer or specified number of month, whichever comes first LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use A red stripe in the left margin of the schedule highlights the latest changes In addition, change filters with every fluid change.
  • Page 1002 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY Proceed to maintenance operation at mileage indicated on odometer or specified number of month, whichever comes first LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use A red stripe in the left margin of the schedule highlights the latest changes 1 I-beam: Tie rod end ball joints –...
  • Page 1003 SECTION 24: LUBRICATION & SERVICING PROCEED TO MAINTENANCE OPERATION EVERY Proceed to maintenance operation at mileage indicated on odometer or specified number of month, whichever comes first LUBRICATION AND SERVICING SCHEDULE H3 Series coaches X3 Series coaches H3 VIP commercial use X3 VIP commercial use A red stripe in the left margin of the schedule highlights the latest changes 23 ACCESSORIES...
  • Page 1004 SECTION 24: LUBRICATION & SERVICING SPECIALTY TOOLS REQUIRED FOR REGULAR MAINTENANCE OF THE VEHICLES Use this list of specialty tools in conjunction with the LUBRICATION AND SERVICING SCHEDULE SPECIALTY TOOLS REQUIRED FOR REGULAR MAINTENANCE MAINTENANCE DESCRIPTION SPECIALITY TOOL PART # DESCRIPTION 01 ENGINE 8,11,12...

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