PREVOST H3 2009 Series Maintenance Manual
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PREVOST H3 2009 Series Maintenance Manual

PREVOST H3 2009 Series Maintenance Manual

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COACH MANUFACTURER
MAINTENANCE MANUAL
H3-41, H3-45, VIP
PA1561
March 2009

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Summary of Contents for PREVOST H3 2009 Series

  • Page 1 COACH MANUFACTURER MAINTENANCE MANUAL H3-41, H3-45, VIP PA1561 March 2009...
  • Page 2 PA1561 March 2009 Beginning with vehicle: A-1470 Featuring: New headlights and bumper design...

  • Page 3: Table Of Contents

    SECTION 00: GENERAL INFORMATION TABLE OF CONTENTS FOREWORD............................2 SCHEMATICS ............................2 PRECAUTIONS TO BE OBSERVED BEFORE WELDING ..............2 SAFETY NOTICE ........................... 4 DATA PLATES AND CERTIFICATIONS ..................4 4.1.1 Engine ............................4 4.1.2 Transmission ..........................4 4.1.3 Drive Axle ..........................5 4.1.4 Front Axle ..........................

  • Page 4: Foreword

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

  • Page 6: Safety Notice

    Volvo D13 engine serial and model numbers are order to assist skilled mechanics in the efficient stamped on the cylinder head (Fig. 2). repair and maintenance of PREVOST vehicles. This manual covers only the procedures as of manufacturing date. Safety features may be impaired if other than genuine PREVOST parts are installed.

  • Page 7: Drive Axle

    Section 00 : GENERAL INFORMATION FIGURE 3: WORLD TRANSMISSION 07076 FIGURE 7: ISS TYPICAL SERIAL & MODEL NUMBERS 0025 4.1.5 Power Steering Pump • DDC Series 60 Engine Power steering pump serial number is engraved on the pump casing (Fig. 8). The pump is mounted on the engine beside the crankshaft pulley.

  • Page 8: Coach Final Record

    This certifies that coaches manufactured by parts. Using the VIN when ordering parts will Prevost Car Inc., comply with all Federal Motor facilitate processing. Vehicle Safety Standards at the time of manufacture. The DOT Certification label is affixed on the wall, behind the driver's seat.

  • Page 9: Figure 13 : Vehicle Identification Number

    Section 00 : GENERAL INFORMATION FIGURE 13 : VEHICLE IDENTIFICATION NUMBER 00050 YEAR CODE YEAR CODE 2000 2006 2001 2007 2002 2008 2003 2009 2004 2010 2005 2011 PA1561...

  • Page 10: Fastener Strength Identification

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

  • Page 11: Self-Locking Fasteners

    Section 00 : GENERAL INFORMATION 5.1 SELF-LOCKING FASTENERS 5.2 RECOMMENDATIONS FOR REUSE A self-locking fastener is designed with an Clean, unrusted self-locking fasteners may be interference fit between the nut and bolt threads. reused as follows: This is most often accomplished by distortion of a) Clean dirt and other foreign matter from the the top thread of an all-metal nut or bolt or by fastener;...

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

    Section 00 : GENERAL INFORMATION FIGURE 17: METRIC - US STANDARD CONVERSION TABLE 00005 PA1561...

  • Page 13: Figure 18: Conversion Char

    Section 00 : GENERAL INFORMATION FIGURE 18: CONVERSION CHART 00006 PA1561...
  • Page 14 MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING PROCEDURE NO: SAV060034 REVISION 4 2007-05-31 Material : Equipment(s) : Phillips-head screwdriver Ratchet handle 3/8" socket Electric tape Long nose pliers Reference schematics: Safety rules : - Wear safety goggles - Set the battery master switch to the OFF position first Recommendations: This procedure should be performed by qualified personnel only.
  • Page 15 PROCEDURE NO: SAV060034 REVISION 4 SECTION 1 H3 Coaches & VIP 1.00 Location: Main power compartment and dashboard Set the battery master switch to the OFF position. Place the ignition switch to the OFF position. 1.05 Location: Main power compartment Trip circuit breakers CB2, CB4, CB6 Push the red button to open the circuit Page 2 of 15...
  • Page 16 PROCEDURE NO: SAV060034 REVISION 4 1.10 Location: Main power compartment Remove the protective cover WARNING LIVE WIRE This 12-volt terminal remains energized Disconnect the electronic ground terminals from the stud Using electric tape, insulate the 2 largest gage wires. Make sure the ring terminals do not touch each others and the vehicle body.
  • Page 17 PROCEDURE NO: SAV060034 REVISION 4 1.15 Location: Main power compartment Disconnect the electronic modules : Disconnect the I/O A and I/O B modules Disconnect C397 Disconnect connector C717 Unplug 3 connectors per I/O B modules Unplug 3 connectors on the I/O A module 1.20 Location: Front electrical compartment VIP + COACH: Disconnect the I/O A, I/O B, ABS, master ID, CECM and CPC modules.
  • Page 18 PROCEDURE NO: SAV060034 REVISION 4 Unplug 1 connector from the master ID Disconnect CPC connectors Unplug 3 connectors from the CECM Unplug connector C92 Page 5 of 15...
  • Page 19 PROCEDURE NO: SAV060034 REVISION 4 1.25 Location: pneumatic accessory panel inside right console Remove the access panel on the right console (R.H. side of dashboard) Disconnect both I/O B modules 1.30 Location: Evaporator compartment Remove protective cover disconnect the I/O B module Page 6 of 15...
  • Page 20 PROCEDURE NO: SAV060034 REVISION 4 1.40 Kidde Automatic Fire Detection and Suppression System (optional) Disconnect C466 Kidde AFSS module is located on the lateral control panel. 1.45 When all the previous steps are done, you ENSURE THAT THE WELDING GROUND RETURN can do welding on the vehicle CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC...
  • Page 21 PROCEDURE NO: SAV060034 REVISION 4 SECTION 2 X3 Coaches 2.00 Location: Rear electrical compartment and dashboard Set the battery master switch to the OFF position. Place the ignition switch to the OFF position. 2.05 Location: Rear electrical compartment Trip circuit breakers CB2-CB4-CB6 located on rear junction panel Push the red button in to open the circuit Page 8 of 15...
  • Page 22 PROCEDURE NO: SAV060034 REVISION 4 2.10 Location: Rear electrical compartment Disconnect the electronic ground terminals from this stud Warning: The remaining terminals may still be energized Use electric tape; make sure that cables do not touch each others and the vehicle body. NOTE With disconnection of the electronic ground terminals,...
  • Page 23 PROCEDURE NO: SAV060034 REVISION 4 2.20 Location: front electrical compartment Disconnect I/O A, I/O B, ABS, master ID, CECM and CPC modules and also disconnect connector C92 Disconnect the 3 connectors from the I/O B and I/O A modules Disconnect the 2 connectors from the ABS module Disconnect CPC connectors Disconnect connector from master ID...
  • Page 24 PROCEDURE NO: SAV060034 REVISION 4 Disconnect the 3 connectors from CECM Disconnect connector C92 2.25 Location: Entrance door & wiper control panel Remove windshield wiper motor access panel and disconnect both I/O B modules 2.30 When all the previous steps are done, you can do ENSURE THAT THE WELDING GROUND welding on the vehicle RETURN CLAMP IS WELL SECURED AND...
  • Page 25 PROCEDURE NO: SAV060034 REVISION 4 SECTION 3 XLII MTH 2.00 Location: Dashboard Place the ignition switch to the OFF position. 2.05 Location: Engine compartment R. H. side area Trip circuit breakers CB1-CB2 located on circuit breaker panel. Push the blue button in to open the circuit 2.10 Location: Rear Junction Box Disconnect the electronic ground terminals from this stud.
  • Page 26 PROCEDURE NO: SAV060034 REVISION 4 Location: Rear Junction Box 2.15 Disconnect the electronic modules: Disconnect all I/O A and I/O B modules Disconnect C397 Disconnect transmission module (A1) Disconnect 3 connectors from each I/O B Disconnect 3 connectors from each I/O A 2.20 Location: Front Electrical Compartment Disconnect I/O A, I/O B, ABS, master ID, CECM,...
  • Page 27 PROCEDURE NO: SAV060034 REVISION 4 Disconnect connectors from CPC Disconnect connector from master ID Disconnect 3 connectors from CECM Disconnect connector C92 Page 14 of 15...
  • Page 28 PROCEDURE NO: SAV060034 REVISION 4 Location: Wiper Control Panel Remove windshield wiper motor access panel And disconnect I/O B modules When all the previous steps are done, you can do 2.30 ENSURE THAT THE WELDING GROUND welding on the vehicle RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE...

  • Page 29: Volvo D

    DETROIT DIESEL SERIES 60 ENGINE ..................... 16 DDEC VI SYSTEM........................16 HARNESSES..........................16 ENGINE OVERVIEW........................17 DDEC VI SENSORS........................18 PREVOST INSTALLED SENSORS ..................... 19 MOTOR CONTROL MODULE (MCM)..................19 COMMON POWERTRAIN CONTROLLER (CPC) ............... 19 DDEC VI DIAGNOSTICS......................19 2.8.1 Diagnostic system .........................
  • Page 30 Section 01: ENGINE ILLUSTRATIONS ) ..................6 FIGURE F ENGINE ALTERNATOR SIDE TYPICAL ) ....................7 FIGURE F ENGINE TURBO SIDE TYPICAL ..........................9 FIGURE F OIL FILTERS ........................10 FIGURE OIL FILTER WRENCH ......................... 11 FIGURE OIL FITER REPLACEMENT ........................

  • Page 31: Volvo D13 Engine

    Section 01: ENGINE 1. VOLVO D13 ENGINE provide input to the EMS: • Ambient Air Temperature Sensor 1.1 SYSTEM OVERVIEW • Ambient Pressure sensor NOTE • Boost Air Pressure (BAP) Sensor The “Premium Tech Tool” (PTT) is the • Camshaft Position (Engine Position) Sensor preferred tool for performing diagnostic work.
  • Page 32 Section 01: ENGINE to the diaphragm causes the diaphragm to EGR Temperature Sensor deflect and the amplifier to produce an electrical The EGR temperature sensor detects exhaust signal proportional to the deflection. gas temperature for EGR system. The sensor modifies a voltage signal from the control unit. The Ambient (Atmospheric) Pressure Sensor is The modified signal returns to the control unit as built into the Engine Management System...
  • Page 33 Section 01: ENGINE temperature coefficient, which means the sensor air temperature increases. resistance will decrease as the engine oil Intake Manifold (Boost) Temperature temperature increases. Sensor is located in the intake manifold. The Engine Oil Temperature Sensor is located in the oil pan. Intake Manifold Pressure Sensor The Intake Manifold Pressure Sensor contains a Exhaust Temperature Sensor (DPF Sensors)

  • Page 34: Engine Overview

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

  • Page 35: Engine Oil

    Section 01: ENGINE FIGURE 2: D13F ENGINE, TURBO SIDE (TYPICAL) 13. Exhaust Manifold 20. Oil Filters 14. Valve Cover 21. Oil Pan 15. Engine Pre-Heater Element (Optional) 22. EGR Cooler 16. DRV Valve 23. Turbocharger 17. Coolant Pump 24. Starter Motor 18.

  • Page 36: Oil Change Intervals

    Section 01: ENGINE symbol should be used. Lubricants meeting API standards have provided maximum engine life when used together with the recommended oil and oil filter change intervals. EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use in all 2007 emission compliant Volvo engines.

  • Page 37: Oil Filters

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

  • Page 38: Oil Change

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

  • Page 39: Checking The Oil Level

    Section 01: ENGINE FIGURE 6: ENGINE OIL FILLING TUBE FIGURE 5: OIL FITER REPLACEMENT FIGURE 7: ENGINE OIL LEVEL DIPSTICK • Start the engine and check for leaks around the oil filter housing and filters. 1.4 POWER PLANT ASSEMBLY REMOVAL •...
  • Page 40 Section 01: ENGINE 9. Disconnect and remove the air intake duct WARNING mounted between the turbocharger outlet and the air cooler inlet. Due to the heavy load of the rear bumper 10. Disconnect and remove section of coolant assembly, it must be adequately supported pipe assembly mounted between the radiator before attempting to remove it.
  • Page 41 Section 01: ENGINE 19. From under the vehicle, disconnect the 34. On partition wall, disconnect connector C397 propeller shaft as detailed in Section 09, located between engine compartment and under heading "Propeller Shaft Removal". main power compartment. 20. On vehicles equipped with an automatic 35.

  • Page 42: Power Plant Assy. Installation

    Section 01: ENGINE FIGURE 9: ENGINE COMPARTMENT H3 COACHES (TYPICAL) 01193 1.5 POWER PLANT ASSY. INSTALLATION It is recommended that new rubber mounts be installed at each major overhaul. To install a power plant assembly, follow the NOTE same procedure as in "Power Plant Assembly Removal"...
  • Page 43 Section 01: ENGINE FIGURE 10: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION DRY TORQUES REFERENCE DESCRIPTION Lbf-ft SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G8.8 SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G10.9 SCREW, CAP HEXAGONAL HEAD M10 – 1.5 G10.9 SCREW, CAP HEXAGONAL HEAD M12 –...

  • Page 44: Detroit Diesel Series 60 Engine

    Section 01: ENGINE 2. DETROIT DIESEL SERIES 60 ENGINE system has a chassis-mounted control unit for vehicle engine management, the Common The DDC series 60 engine is a 6-cylinder, four- Powertrain Controller (CPC). The connection to cycle, 14.0 liters Detroit Diesel series 60 engine, the vehicle is made via a CAN interface which equipped with an electronic control system digitally transmits the nominal values (e.g.

  • Page 45: Engine Overview

    Section 01: ENGINE 2.3 ENGINE OVERVIEW 1- Starter motor 2- Oil pan drain plug 3- Primary fuel-filter/water- separator 4- MCM (DDEC VI Electronics) 5- Secondary fuel filter shutoff valve 6- Secondary fuel filter 7- Fuel pump 8- Air compressor 9- Engine oil filling tube 10- Bosch alternators (2) 11- Engine oil dipstick 12- EGR delta pressure sensor...

  • Page 46: Ddec Vi Sensors

    Section 01: ENGINE 24- Water pump 25- EGR cooler 26- Oil filter (2) 27- Crankcase breather tube 28- EGR tube FIGURE 12: DETROIT DIESEL 2007 SERIES 60 ENGINE (TYPICAL) 01179 • Engine Pressure Sensor (EOP 2.4 DDEC VI SENSORS Sensor): Senses gallery oil pressure for •...

  • Page 47: Prevost Installed Sensors

    Section 01: ENGINE 2.5 PREVOST INSTALLED SENSORS 2.7 COMMON POWERTRAIN CONTROLLER (CPC) • Engine Coolant Level Sensor (ECL Sensor): Senses coolant level for engine The CPC is the interface between the MCM and protection (mounted on coolant surge tank). the vehicle/equipment for engine control and manages other vehicle/equipment functions.

  • Page 48: Check Engine Telltale Light (Awl)

    Section 01: ENGINE problem solving in the form of a code. The MCM 2.8.3 Stop Engine Warning Light (RSL) and CPC continuously perform self diagnostic This light, also mounted on the telltale light checks monitor other system panel, illuminates to indicate that a major engine components.

  • Page 49: Ddec Vi Cpc Diagnostic Codes List

    Section 01: ENGINE Active Codes: Codes that are currently keeping the Check Engine or Stop Engine telltale light illuminated. Active codes are flashed via the Stop Engine Light when checked with the stop-engine-override switch. Inactive Codes: These are all the codes logged in the CPC, which have previously occurred, (whether or not they are currently turning on the Stop or Check Engine Light).
  • Page 50 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2113 Vehicle Speed Sensor Circuit Failed High 2113 Vehicle Speed Sensor Circuit Failed Low 2113 VSS Anti Tamper Detection via Virtual Gear Ratio 2113 VSS Anti Tamper Detection via Fixed Frequency Device 2113 VSS Anti-Tamper Detection via ABS Vehicle Speed...
  • Page 51 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2123 Coolant Temperature Very High 2124 Coolant Level Low 2124 Coolant Level Circuit Failed High 2124 Coolant Level Circuit Failed Low 2124 Coolant Level Very Low 2125 Battery Voltage Very Low 2125 Battery Voltage High 2125...
  • Page 52 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2135 J1939 Cruise Control Enable Switch Signal from Source #1 is erratic 2135 J1939 Cruise Control Enable Switch Signal from Source #1 is missing 2135 J1939 Cruise Control Enable Switch Signal from Source #2 is erratic 2135 J1939 Cruise Control Enable Switch Signal from...
  • Page 53 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2144 J1939 Cruise Control Accelerate Switch Signal from Source #3 is erratic 2144 J1939 Cruise Control Accelerate Switch Signal from Source #3 is missing 2145 J1708 Data Link Failure 2145 CPC2 Hardware Failure 2615 J1939 DM1 Message from Transmission is missing 2151...
  • Page 54 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2615 MCM Fault Code Table Inconsistant - Upgrade MCM Software 2153 J1939 Data Link Failure 2211 Digital Output 4 09 Circuit Failed High 2211 Digital Output 4 09 Circuit Failed Low 2212 Digital Output 3 17 Circuit Failed High 2212...
  • Page 55 Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 2244 J1939 Engine Retarder Selection Signal Erratic 2245 Remote Accelerator Pedal Supply Voltage Out of Range 2245 Remote Accelerator Pedal Circuit Failed High 2245 Remote Accelerator Pedal Circuit Failed Low 2311 PTO CC+ and CC- Switches Pressed Simultaneously 2615...

  • Page 56: Ddec Vi Mcm Diagnostic Codes List

    Section 01: ENGINE PID/SID FLASH PID/SID FAULT DESCRIPTION CODES 3695 2334 DPF Regen Inhibit MUX Switch Message Not Received this Ign Cycle 3696 2335 DPF Regen Force MUX Switch Message Contains Data Error Indicator 3696 2335 DPF Regen Force MUX Switch Message Contains SNV Indicator 3696 2335...
  • Page 57 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1212 Engine Coolant Outlet Temperature Circuit Failed Low 1212 Engine Coolant Outlet Temperature Circuit Failed High 1212 Coolant Temperature High 1212 Coolant Temperature / Engine Oil Temperature Plausibility Fault 1212 Engine Coolant Sensor (OUT), General Temp. Plausibility Error 1213 Intake Air Throttle Valve Closure Detection- Positive Torque 1213...
  • Page 58 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High 1615 MU_ISP_T_TBD2_SRH Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low 1615 MU_ISP_T_TBD3_SRL Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High 1615 MU_ISP_T_TBD3_SRH 1615...
  • Page 59 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1615 Volute Shut Off Valve, Shorted to Battery 1615 Volute Shut Off Valve, Open Load 1615 Function 30 Circuit Failed Low 1615 Function 30 Circuit Failed High 1615 Function 30 Circuit Failed Open 1615 Function 31 Circuit Failed Low 1615...
  • Page 60 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1334 Fan Stage 1 Circuit Failed Open 1242 Injector Cylinder #1 Needle Control Valve Abnormal Operation 1242 Injector Cylinder #1 Needle Control Valve Abnormal Rate of Change Injector Cylinder 1, Nozzle Control Valve or Spill Control Valve, Jammed 1242 Closed Injector Cylinder 1, Nozzle Control Valve or Spill Control Valve, Jammed...
  • Page 61 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1253 Injector Cylinder #7 Needle Control Valve Abnormal Rate of Change 1253 Injector Cylinder #7 Needle Control Valve, Valve Shorted Circuit 1253 Engine Smoothness Control / Cylinder #7 Value Out of Range 1254 Injector Cylinder #8 Needle Control Valve Abnormal Operation 1254...
  • Page 62 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 1172 1425 Turbocharger Compressor Inlet Temperature Circuit Failed High 1172 1425 Coolant Temp/Compressor Inlet Temp Plausibility Error Turbocharger Compressor Inlet Temp. Sensor, General Temp. Plausibility 1172 1425 Error 1176 1431 Turbocharger Compressor Inlet Pressure Circuit Failed Low 1176 1431 Turbocharger Compressor Inlet Pressure Circuit Failed High...
  • Page 63 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 2629 1513 Turbocharger Out Temperature, Temperature Too Low (High Box) Turbocharger Compressor Outlet Temp. Sensor, General Temp. Plausibility 2629 1513 Error 2630 1514 Charge Air Cooler Outlet Temperature Circuit Failed Low 2630 1514 Charge Air Cooler Outlet Temperature Circuit Failed High...
  • Page 64 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3050 1525 Engine Air Flow Out of Range Low 3050 1525 Active Regen Temp Out of Range Low 3058 1615 EGR System Parametrization Failure 3064 1615 DPF System Parametrization Failure 3242 1531 DOC Inlet Temperature Circuit Failed Low 3242...
  • Page 65 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3509 1631 Multiplexer 1 Channel 2, Shorted High 3510 1632 Multiplexer 2 Channel 1, Shorted High 3510 1632 Multiplexer 2 Channel 2, Shorted High 3511 1633 Multiplexer 3 Channel 1, Shorted High 3511 1633 Multiplexer 3 Channel 2, Shorted High...
  • Page 66 Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 3661 1613 Injector Cylinder #3 Spill Control Valve Abnormal Operation Injector Cylinder #3 Spill Control Valve ("Amplifier") Abnormal Rate of 3661 1613 Change 3661 1613 Injector Cylinder #3 Spill Control Valve ("Amplifier"), Valve Shorted Circuit 3662 1614 Injector Cylinder #4 Spill Control Valve Abnormal Operation...

  • Page 67: Engine Oil Level

    Section 01: ENGINE PID/SID FLASH PID/SID CODE FAULT DESCRIPTION 4227 1324 Electrostatic Oil Separator Circuit Failed Open 4227 1615 Oil Separator Circuit Failed Low 4227 1615 Oil Separator Circuit Failed High 4227 1615 Oil Separator, Max. Duration Time Reached 1241 Smart Remote Actuator 5 (VGT), Temperature Fault 4228 1241...

  • Page 68: Engine Oil And Filter Change

    Section 01: ENGINE 2.13 ENGINE OIL AND FILTER CHANGE 2. Reinstall the drain plug. 3. Remove the spin-on filter cartridge using a 1/2" drive socket wrench and extension. MAINTENANCE 4. Dispose of the used oil and filter in an Both the engine oil and filter should be environmentally responsible manner...

  • Page 69: Recommended Engine Oil Type

    Section 01: ENGINE NOTE MAINTENANCE COLD WEATHER STARTING The proper selection of the engine oil grade Engine oil temperature should be checked will ease cold weather starting (refer to the every 25,000 miles (40 000 km) to determine lubrication and servicing schedule for the oil cooler efficiency.
  • Page 70 Section 01: ENGINE 3. Drain the engine cooling system. Refer to 13. Disconnect fan-clutch electrical Section 05 under "Draining Cooling connector. COOLING System". 14. Disconnect the radiator fan drive shaft. 15. Disconnect the small heater hose located on the cylinder head at the back of the engine. 16.
  • Page 71 Section 01: ENGINE pressure regulator output. The pressure regulator is mounted in the upper section of engine compartment backwall accessible through the engine compartment R.H. side door. 29. On vehicles equipped with an electrically operated cold-starting aid, disconnect the delivery hose from the starting-aid cylinder solenoid valve.
  • Page 72 Section 01: ENGINE FIGURE 21: ENGINE COMPARTMENT H3 COACHES (TYPICAL) 01177 FIGURE 22: ENGINE COMPARTMENT VIP (TYPICAL) 01178 PA1561...

  • Page 73: Power Plant Assy. Installation

    Section 01: ENGINE 2.17 JAKE BRAKE 2.16 POWER PLANT ASSY. INSTALLATION Refer to both "The Jake Brake Troubleshooting To install a power plant assembly, follow the and Maintenance Manual" and "Installation same procedure as in "Power Plant Assembly Manual for Model 797 Engine Brakes" for Removal"...

  • Page 74: Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor

    Section 01: ENGINE 3. ELECTRONIC FOOT PEDAL ASSEMBLY the CPC will signal diagnostic codes of 21-12 for idle error and 21-23 for wide-open throttle error. (EFPA) & THROTTLE POSITION SENSOR The Electronic Foot Pedal Assembly (EFPA) connects the accelerator pedal to a Throttle Position Sensor (TPS).

  • Page 75: Engine Troubleshooting Guide

    Section 01: ENGINE 4. ENGINE TROUBLESHOOTING GUIDE START go to does the is the engine engine step 2 rotate ? starting ? note 1 plug the Diagnostics Data Reader DDR into the receptacle does the red or momentarily depress the go to "Stop Engine"...
  • Page 76 Section 01: ENGINE step 3 with diagnostic code in hand, contact your note 1 Detroit Diesel service REFERENCES center -Operator's Manual chap. 3,4 & 8 -Detroit Diesel pamphlet "DDEC III/IV diagnostic codes and MPSI reader functions" -8V92 series engine, switch is located in service compartment note 1 plug the Diagnostics Data...

  • Page 77: Specifications

    Detroit Diesel Series 60 engine ratings Series 60 engine ratings used in Prevost Car Models are listed in the following tables. The standard engine ratings are written in bold, customer may easily switch from one rating to another within the same table by having the DDEC VI system reprogrammed.
  • Page 78 Oil Pan Capacity; High Limit .....................34 quarts/32 liters Total Engine Oil Capacity with Filters ................45 quarts/42.5 liters Lubricating oil filter elements Prevost number....................... 478736 (Full Flow) Prevost number.........................510938 (By-pass) Torque specification Engine oil filter................Tighten 3/4 to 1 turn after gasket contact...
  • Page 79 Section 01: ENGINE NOTE For primary and secondary fuel filters, refer to Specifications in section 03. PA1561...
  • Page 80 SECTION 03: FUEL SYSTEM CONTENTS FUEL SYSTEM WITH DETROIT DIESEL SERIES 60 ENGINE ............3 DESCRIPTION ..........................3 FUEL VALVES..........................3 FUEL FILTERS ..........................4 RACOR FUEL /WATER SEPARATOR SERVICING..............4 SPIN-ON TYPE FUEL FILTER SERVICING (PRIMARY AND SECONDARY) ......5 FUEL PUMP INSTALLATION......................
  • Page 81 Section 03: FUEL SYSTEM ILLUTRATIONS )..................3 FIGURE FUEL SYSTEM SCHEMATIC DDC S ENGINE ) ..............3 FIGURE MANUAL SHUT OFF VALVES LOCATION DDC S ENGINE 382 ( ) ........... 4 FIGURE MANUAL SHUT OFF VALVE WITH DAVCO FUEL PRO DDC S ENGINE ..........................

  • Page 82: Fuel System With Detroit Diesel Series 60 Engine

    Section 03: FUEL SYSTEM 1. FUEL SYSTEM WITH DETROIT DIESEL SERIES 60 ENGINE 1.1 DESCRIPTION Figure 1 shows a schematic of the fuel system. Fuel is drawn from the fuel tank through a manual shut-off valve, a primary fuel filter (fuel-filter/water-separator) before it enters the MCM and the fuel pump. If the vehicle is equipped with the optional “Davco Fuel Pro 382”, this one replaces the primary fuel filter.

  • Page 83: Fuel Filters

    Section 03: FUEL SYSTEM NOTE For information on the Davco Fuel Pro 382 fuel filter, refer to paragraph 4.3. 1.4 RACOR FUEL/WATER SEPARATOR SERVICING MAINTENANCE The Racor fuel/water separator should be drained periodically, when water separator telltale light on the dashboard illuminates.

  • Page 84: Spin-On Type Fuel Filter Servicing (Primary And Secondary)

    Section 03: FUEL SYSTEM pressure at the cylinder head inlet is 58-72 psi CAUTION (400-50 kPa). Change the fuel filters whenever the inlet restriction at the fuel pump reaches 12 Do not use tool to tighten. Tighten by hand inches of mercury (41 kPa) at normal operating only.

  • Page 85: Fuel Pump Installation

    Section 03: FUEL SYSTEM Connect the fuel inlet and outlet lines to the fuel NOTE pump and tighten. There is a fuel system shut-off valve on the discharge side of the secondary fuel filter. This check valve is designed to prevent fuel loss at time of filter replacement.

  • Page 86: Fuel System With Volvo D13 Engine

    Section 03: FUEL SYSTEM 2. FUEL SYSTEM WITH VOLVO D13 ENGINE 2.1 DESCRIPTION NOTE For additional information concerning Volvo D13 engine components or engine-related components, consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On Volvo web site, you will find detailed service procedures for parts replacement, repair and maintenance.

  • Page 87: Fuel Valves

    Section 03: FUEL SYSTEM removed. It is not necessary to bleed the fuel FUEL LINE FITTINGS – VOLVO D13 ENGINE system after replacing the filter, since this is 13 ± 2 ft-lb (18 ± 3 Nm) performed automatically when the engine is 20.5 ±...

  • Page 88: Primary Fuel Filter Replacement

    Section 03: FUEL SYSTEM 4. Unscrew and remove the primary fuel filter from the fuel filter housing. Drain filter. MAINTENANCE 5. Unscrew and remove the separation bowl The primary and secondary fuel filters are of a from the filter cartridge. spin-on type and must be replaced at every 6.

  • Page 89: Secondary Fuel Filter Replacement

    Section 03: FUEL SYSTEM about 5 minutes to remove air pockets from CAUTION the fuel system. 2.3.2 Secondary Fuel Filter Replacement When priming the system, movement of the primer pump should be as up and down as 1. Stop engine, close the fuel supply line shut- possible.

  • Page 90: Davco Fuel Pro 382

    Section 03: FUEL SYSTEM 3. DAVCO FUEL PRO 382 Filter replacement: The optional Fuel Pro 382 diesel fuel filter 1. Stop engine; system consists of a permanently mounted fuel 2. Place a suitable container under the fuel processor, a replaceable filter element, a filter processor;...

  • Page 91: Fuel Lines And Flexible Hoses

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

  • Page 92: Tank Removal

    Section 03: FUEL SYSTEM to escape during filling. For 95% of the tank volume, 5% of tank inside space is kept filled with air with no exit opening, allowing for a fuel expansion safety margin. drain plug, accessible from under the vehicle, is fitted at the bottom of the tank.

  • Page 93: Fuel Tank Verification

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

  • Page 94: Fuel Specifications

    Section 03: FUEL SYSTEM NYLON WASHER SCREW CAUTION Owners of 2007 and later model year on- highway diesel engine must refuel only with ULSD fuel. FUEL TANK INTERIOR ANCHOR NUT NOTE FIGURE 18: FUEL TANK REPAIR 03014 Burning Low Sulfur Diesel fuel (instead of ULSD fuel) in 2007 and later model year diesel engines is illegal and punishable with 7.

  • Page 95: Air Cleaner (Dry Type)

    Volvo, The pre-filter should be installed snugly in the air Detroit Diesel or Prevost product warranty. Also, duct and clamped tightly to the air cleaner inlet any engine performance problem related to the...

  • Page 96: Air Cleaner Restriction Indicator

    Section 03: FUEL SYSTEM CAUTION Do not ignore the Warning given by the air restriction indicator. This could result in serious engine damage. 8. Store new elements in a closed area free from dust and possible damage. FIGURE 21: FUEL COOLER LOCATION 03071 8.4 AIR CLEANER RESTRICTION INDICATOR 10.
  • Page 97 Section 03: FUEL SYSTEM 2. Loosen screws remove potentiometer. Retain for re-assembly. 3. Discard potentiometer (Fig. 20). 4. Position potentiometer. Press potentiometer onto the potentiometer shaft, matching cutouts in shaft to drive tangs of potentiometer. Apply hand pressure until potentiometer has bottomed out in housing. Reinstall screws (Fig.

  • Page 98: Specifications

    Section 03: FUEL SYSTEM 11. SPECIFICATIONS Davco Fuel Pro 382 Fuel Filter / Water Separator Element Prevost number ............................510795 Racor Primary Fuel Filter / Water Separator (optional) (May be used instead of regular spin-on primary filter). Make ................................Racor Type ..........................Replaceable element filter ELEMENT Prevost number ............................531390...
  • Page 99 Capacity..........................235 US gal (890 liters) Air Cleaner Make ................................Nelson Prevost Number ............................530206 Service Part No ............................7182 8N Prevost number (element cartridge) ......................530197 Air Cleaner Restriction Indicator Make ..............................Donaldson Model ..............................RBX00-2220 Indicates .........................at 20" (508 mm) of water Prevost number ............................530161...

  • Page 100: Section 04: Exhaust System

    Section 04: EXHAUST SYSTEM 1. EXHAUST AND AFTERTREATMENT 1.1 MAINTENANCE SYSTEM OVERVIEW Inspect the exhaust system periodically for restrictions and leaks. Figure 1 presents the technology behind clean emissions major components of the exhaust system. technology exhaust Aftertreatment Exhaust leaks are commonly the result of loose Device (ATD), which replaces today’s muffler.

  • Page 101: Hot Surfaces

    Section 04: EXHAUST SYSTEM straight when installed. This piece of equipment you the opportunity to plan for the DPF ash- handles vibration and thermal expansion. cleaning interval. cleaning is not performed proactively, and the backpressure increases beyond the system limit, DDEC VI or CAUTION EMS will flag the amber warning light on the telltale panel, notifying the operator that an ash...
  • Page 102 Section 04: EXHAUST SYSTEM 2.1 DIESEL PARTICULATE FILTER (DPF) will move up with the ATD later in this REMOVAL – BOTH ENGINES procedure. To remove the DPF, proceed as follow: 5. To ease proper positioning of the ATD and the diffuser at the time of reinstallation, using CAUTION a marker, draw a line along the support strap bracket on the ATD.
  • Page 103 Section 04: EXHAUST SYSTEM compartment. Use appropriate handling equipment. CAUTION HEAVY DEVICE A suitable lifting or holding device is required. Properly support and attach lifting equipment to prevent the DPF from falling when servicing. The DPF cartridge weighs between 50 to 54 lbs. FIGURE 7: PRESSURE DIFFERENTIAL SENSOR AND CAUTION TAKE UP TUBES (VOLVO D13 ONLY)

  • Page 104: Diffuser Assembly

    Section 04: EXHAUST SYSTEM 3. DIFFUSER ASSEMBLY CAUTION During stationary regeneration, exhaust gases temperature may reach up to 1200°F (650°C) at Tighten clamps properly in order to prevent the DPF outlet. The diffuser decreases the any movement of the diffuser assembly. An exhaust gasses temperature to 475°F (246°C) impact wrench is necessary.
  • Page 105 (Prevost #040710) x Make sure that the water drain tube is not available through Prevost Parts to permit clogged. Pour a cup of water into the diffuser connection with current exhaust gas collecting housing and assure that all the water drains system.
  • Page 106 SECTION 04: EXHAUST SYSTEM CONTENTS CONTENTS ..............................1 ILLUSTRATIONS ............................1 EXHAUST AND AFTERTREATMENT SYSTEM OVERVIEW ............. 2 MAINTENANCE ..........................2 FLEXIBLE COUPLING INSTALLATION .................... 2 AFTERTREATMENT DEVICE (ATD) ....................3 DIESEL PARTICULATE FILTER (DPF) REMOVAL – BOTH ENGINES..........4 DIFFUSER ASSEMBLY........................
  • Page 107 SECTION 05: COOLING SYSTEM CONTENTS DESCRIPTION ............................3 MAINTENANCE ............................ 4 GENERAL RECOMMENDATIONS ....................4 WITH DETROIT DIESEL SERIES 60 ..................... 4 2.2.1 Vehicles without coolant filters ....................5 2.2.2 Vehicles with coolant filters ..................... 5 WITH VOLVO D13 ENGINE ......................5 HOSES ..............................
  • Page 108 Section 05: COOLING SYSTEM 14.1.1 Electrical Locking ........................18 14.1.2 Mechanical Locking....................... 18 14.2 MAINTENANCE..........................19 14.3 INSPECTION..........................19 14.4 FAN REMOVAL / INSTALLATION....................19 FAN RIGHT ANGLE GEARBOX..................... 20 15.1 MAINTENANCE..........................20 15.2 OIL CHANGE..........................20 15.3 REMOVAL / INSTALLATION......................20 COOLING FAN DRIVE BELT......................

  • Page 109: Description

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

  • Page 110: Maintenance

    Section 05: COOLING SYSTEM • Inspect the water pump operation. A leaky pump sucks in air, increasing corrosion. • Repair all leaks promptly. Unrepaired leaks can lead to trouble. Inspect and tighten radiator mounts periodically. Test replace thermostats regularly. NOTE In order to ensure the integrity of the system, it is recommended that a periodic cooling system pressure check be made.

  • Page 111: Vehicles Without Coolant Filters

    Section 05: COOLING SYSTEM MAINTENANCE MAINTENANCE Drain, flush, thoroughly clean and refill the Drain, flush, thoroughly clean and refill the system every two years or every 200,000 system with Extended Life Coolant (ELC) every miles (320 000 km), whichever comes first. four years or every 600,000 miles (1 000 000 For vehicle equipped with coolant filters, km), whichever comes first.

  • Page 112: Constant-Torque Hose Clamps On Charge Air Cooler (Cac) System

    Section 05: COOLING SYSTEM clamp automatically adjusts to keep a consistent sealing pressure, there is no need to retorque hose clamps on a regular basis. During vehicle operation and shutdown, the screw tip will adjust according to the temperature and pressure changes.

  • Page 113: Thermostat Operation

    Section 05: COOLING SYSTEM system, and allowing a portion of the coolant to recirculate through the radiator. When the CAUTION coolant temperature reaches approximately 202°F (95°C) thermostat valves are fully open, The hose clamps will break if over-tighten. Do the bypass system is blocked off and the coolant over-tighten, especially during...

  • Page 114: Coolant

    Section 05: COOLING SYSTEM 1. Warm up water in a receptacle to 75°C 5.3 THAWING COOLING SYSTEM (167°F) and immerse the thermostat in the If the cooling system becomes frozen solid, water. Use a piece of wire attached to the place the coach in a warm area until the ice is thermostat.

  • Page 115: Coolant Recommendations For Detroit Diesel Series 60 Engine

    6. Do not mix different base inhibitor packages. 7. Always maintain proper coolant level. Recommended phosphate free coolants for Detroit Diesel S60 engine: CAUTION • Prevost #685125; Always test the solution before adding water • Detroit Diesel “DDC Power Cool” (P/N or antifreeze. 23512138);...

  • Page 116: Inhibitor Test Procedures

    50 –- 250 ppm Silicon (ppm) 0 ppm MAX Phosphorus (ppm) 8.0 -– 11.0 Recommended coolants for Volvo D13 engine: 40 ppm MAX Chlorides (ppm) • Prevost #685241 (pre-diluted 50/50 100 ppm MAX Sulfates (ppm) mixture); • Texaco CPS#227998 (pre-diluted 50/50 NOTE mixture);...

  • Page 117: Draining Cooling System

    Section 05: COOLING SYSTEM CAUTION WARNING On Volvo D13 engine, use only Extended Life Before proceeding with the following steps, Coolant (ELC). Do not add supplemental make sure the coolant has cooled down. The coolant additives (SCA) to extended life sudden release of pressure from a heated coolant.

  • Page 118: Filling Cooling System

    Section 05: COOLING SYSTEM NOTE CAUTION The coolant level should remain within two inches of the surge tank filler neck. If freezing weather is anticipated and the engine is not protected with antifreeze, drain 4. Install the filler and pressure caps, then start the cooling system completely when vehicle is the engine and run it at fast idle until not in use.

  • Page 119: Cooling System Descalers

    Section 05: COOLING SYSTEM 4. Fully drain system. from clogging the radiator tubes or being forced through pump. Reverse flushing 5. Refill with clean water and operate for 15 accomplished by hot water, under pressure, minutes after the thermostats have opened. being forced through the cooling system in a direction opposite to the normal flow of coolant, 6.

  • Page 120: Spin-On Coolant Filter

    PRECHARGE ELEMENT FILTER Prevost number: 550629 MAINTENANCE ELEMENT FILTER Prevost number: 550630 CORROSION INHIBITOR & COOLANT STABILIZER Make: Detroit Diesel Number: 23507857 Make: Nalco...

  • Page 121: Radiator

    Section 05: COOLING SYSTEM 10. RADIATOR 12. RADIATOR & CHARGE AIR COOLER REMOVAL The radiator is mounted at the L.H. side of engine compartment. It is designed to reduce the temperature of the coolant under all WARNING operating conditions. It is essential that the radiator core be kept clean and free from Potential Accident Risk.

  • Page 122: Cooling Fan Drive Mechanism

    Section 05: COOLING SYSTEM 13. COOLING FAN DRIVE MECHANISM FIGURE 18: REMOVAL OF THE RADIATOR & THE CHARGE AIR COOLER 05130 5. Open the radiator door and remove the door FIGURE 19: COOLING FAN DRIVE MECHANISM auxiliary arm (not the hinges) and lower square tube (see fig.

  • Page 123: Idler Replacement

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

  • Page 124: Locking Radiator Fan For Emergency Operation

    Section 05: COOLING SYSTEM The settings are (values below are for DDC 3. In the engine compartment, set the starter S60 engine): selector switch to REAR START and then start the engine from the rear. Engine Air intake Allison coolant temp.

  • Page 125: Fan Removal / Installation

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

  • Page 126: Oil Change

    Section 05: COOLING SYSTEM 15. FAN RIGHT ANGLE GEARBOX 10. Start the engine and allow running a few minutes. Stop the engine and check for The radiator fan is belt driven from the engine leaks. crankshaft pulley through a drive belt, a universal joint shaft, a right angle gear and 15.3 REMOVAL / INSTALLATION clutch assembly.
  • Page 127 With Detroit Diesel Series 60 engine Type: 14PK2310 Prevost number: 550921 With Volvo D13 engine Type: 14PK2172 Prevost number: 5060096 FIGURE 28: DRIVE BELT ROUTING (DDC S60 ENGINE)
  • Page 128 Fully closed............................185°F (85°C) Cooling Fan Drive Belt - Detroit Diesel Series 60 Engine Type ............................Poly-Rib 14PK2310 Qty ..................................1 Prevost number ............................550921 Cooling Fan Drive Belt – Volvo D13 Engine Type ............................Poly-Rib 14PK2172 Qty ..................................1 Prevost number ............................5060096 Coolant - Detroit Diesel Series 60 Engine Prevost Number ............................685125...
  • Page 129 Section 05: COOLING SYSTEM Coolant Filter Cartridge – Volvo D13 Engine Number used................................ 1 Type ................................Spin-on Prevost number ............................. 20458771 PA1561...
  • Page 130 SECTION 06: ELECTRICAL CONTENTS GENERAL DESCRIPTION........................4 WIRING DIAGRAMS ........................4 1.1.1 Using Wiring Diagrams......................4 1.1.2 Testing Circuits........................5 WIRE SIZES AND COLORS......................5 SPARE WIRES ..........................5 CLEANING CONNECTORS......................6 CIRCUIT BREAKERS........................6 MULTIPLEX FUSES........................6 RELAYS............................7 PRECAUTIONS..........................
  • Page 131 Section 06: ELECTRICAL ESSENTIAL FUNCTIONS TO OPERATE THE VEHICLE............38 4.8.1 Available Functions ....................... 38 LOWER PRIORITY MODULES FOR BREAKDOWN SERVICE ..........38 4.10 MULTIPLEX MODULES ....................... 38 4.10.1 CECM ............................ 38 4.10.2 MASTER ID ........................... 38 4.10.3 IO-A ............................38 4.10.4 IO-B ............................
  • Page 132 Section 06: ELECTRICAL LAVATORY NIGHT-LIGHT......................53 8.3.1 Bulb Removal And Replacement ..................53 DRIVER’S AREA LIGHTS ......................53 8.4.1 Bulb Removal And Replacement ..................53 PASSENGER SECTION LIGHTING .................... 54 8.5.1 Fluorescent Tube Replacement .................... 54 8.5.2 Removal And Replacement Of In-Station Fluorescent Tubes ..........54 8.5.3 Removal And Replacement Of Reading Lamp Bulb.............

  • Page 133: Section 06: Electrical

    12, you will find the location, the b) At item CB systems are controlled through individual main Prevost number, the breaker function, the battery relays. One or two 24-volt self-rectified breaker ampere rating and the page on alternators are belt driven from the engine, and which to find the corresponding diagram.

  • Page 134: Testing Circuits

    Section 06: ELECTRICAL b) In first column DEVICE ID, look for device Yellow Multiplex modules communication CAN-H (twisted with green) SW61, SW62. Green Multiplex modules communication c) At device SW61,SW62, find the fault CAN-L (twisted with yellow) message, the minimum condition to activate, Orange Connected to multiplex outputs White...

  • Page 135: Cleaning Connectors

    Section 06: ELECTRICAL NOTE Spare wires are identified by the word "SPARE" followed by the wire identification number. CLEANING CONNECTORS When the pins and sockets of connectors become dirty, clean them with a good quality solvent containing HFC 134A refrigerant as its active ingredient.

  • Page 136: Relays

    Section 06: ELECTRICAL There is also hardware fuses used to protect the incoming power to the multiplex modules. These NOTE fuses are located inside the VECF (Vehicle When the ignition switch is set to the OFF Electrical Center Front) and VECR (Vehicle position, the electrical components are not Electrical Center Rear).
  • Page 137 SECONDARY LOCK grey YAZAKI IO-A See above green EXTRACTOR/TOOL: Prevost #682256 (Packard 12094429) INSERT EXTRACTOR Remove the terminal by disengaging the flexible lock tab on the HERE terminal. Gently remove the terminal from the connector by pulling on the wire.

  • Page 138: H3 Series Vehicles Electrical Compartments

    Section 06: ELECTRICAL 2. H3 SERIES VEHICLES ELECTRICAL COMPARTMENTS FIGURE 4: ELECTRICAL COMPARTMENTS wheelhousing. This compartment contains the following components (Fig. 5 & 6): MAINTENANCE • Four 12-volt batteries; A Cortec VCI-238 corrosion inhibitor has been • Main circuit breakers for 12-volt and 24-volt sprayed in all electrical compartments to protect electrical system;...
  • Page 139 Section 06: ELECTRICAL Main Power Compartment (coaches) Main Power Compartment ( VIP) Multiplex Modules Multiplex Modules I/O-A I/O-B I/O-A I/O-B I/O-B I/O-B I/O-B I/O-B I/O-B I/O-B Relays Relays Master relay Reading lamps 24V Master relay 24V Door lock LH 12V IGN & A/C Option 12V IGN &...

  • Page 140: Battery Charger Or In-Station Lighting Connector

    Section 06: ELECTRICAL FIGURE 5: MAIN POWER COMPARTMENT (PARTIAL VIEW) 06594 The front electrical and service compartment is located on front L.H. side of vehicle. It contains the front junction panel with the following components (Fig. 7). • Resistors; • ABS module; •...
  • Page 141 Section 06: ELECTRICAL Front Electrical & Service Compartment Front Electrical & Service Compartment (coaches) (VIP) Multiplex Modules Multiplex Modules MASTER Interface I/O-A MASTER Interface I/O-A ABS-ECU ABS system I/O-B ABS-ECU ABS system I/O-B 12 volts 12 volts CECM Multiplex chassis I/O-B CECM Multiplex chassis...

  • Page 142: Engine Rear Start Panel

    Section 06: ELECTRICAL Front Electrical & Service Compartment Fuses & Diode (HVAC) Pre-heating & Upper driver liquid windshield solenoid valve defroster Auxiliary unit fan HVAC & telltale panel Defroster unit Driver unit liquid solenoid valve (VIP) The following components are located in the Evaporator Compartment (HVAC).

  • Page 143: Pneumatic Accessory Panel

    Section 06: ELECTRICAL Each relay or resistor is identified to facilitate its To access the pneumatic accessory panel of the location (Fig. 9). right console, remove the panel under the larger utility compartment at the right of the dashboard. NOTE It is important when checking the A/C and 3.
  • Page 144 Section 06: ELECTRICAL atmosphere. This prevents terminal oxidation The battery has four (4) major functions: and corrosion that may cause starting and 1. Providing a source of current for starting the charging problems. If new cables are required, engine. sealed terminal cable replacements should be 2.

  • Page 145: Battery Discharge Protection

    2. Remove supports. Unscrew terminal nuts of been disconnected. We recommend the use each defective battery. of Cortec VCI-238 (Prevost #682460) on all electrical connections. NOTE Main battery relays should be in the “Off”...

  • Page 146: Battery Rating

    Section 06: ELECTRICAL BATTERY RATING Each of the 12-volt batteries used on the vehicle has the following rating: • Reserve capacity: 195 minutes • Cold cranking (amps): 950 @ 0 F (-18 • Cold cranking (amps): 745 @ -20 F (-29 •...

  • Page 147: Load Test

    Section 06: ELECTRICAL 3.5.3 Load Test This test is one means of checking the battery to Voltage and Temperature Chart determine its ability to function as required in the Ambient Temperature Minimum Voltage vehicle. 70ºF (21ºC) and above To make this test, use test equipment that will withstand a heavy electrical load from the 60ºF (16ºC) battery, such as a carbon pile resistor or other...

  • Page 148: Battery Charging

    Section 06: ELECTRICAL 3. Check voltage drop between the starter CAUTION housing and a good ground on the vehicle. The electrical system on this vehicle is The reading should be less than 0.2 volt. negative ground. Installing the batteries WARNING with the positive terminals grounded or incorrect use of the booster battery and Any procedure other than the following...

  • Page 149: Battery Charging Guide

    Section 06: ELECTRICAL event that the green dot does not appear, replace the battery. 3.6.1 Battery Charging Guide Fast Charging Rate 3-3/4 hours @ 20 amps 2-1/2 hours @ 30 amps 2 hours @ 40 amps 1-1/2 hours @ 50 amps Slow Charging Rate 15 hours @ 5 amps 7-1/2 hours @ 10 amps...

  • Page 150: Emergency Jump Starting With Auxiliary (Booster) Battery

    Section 06: ELECTRICAL 3.6.2 Emergency Jump Starting With Auxiliary 1. Connect one end of one red jumper cable to (Booster) Battery the positive (+) terminal of the booster power source and the other end to the positive (+) post of the booster power block, located in WARNING the engine R.H.

  • Page 151: Common Causes Of Battery Failure

    Section 06: ELECTRICAL hold-down cover (proper tightening torque: 45-55 1. Vehicle accessories and disconnect switches lbf-in (5-6 Nm). inadvertently left on overnight. To insure good contact, the battery cable ring 2. Defects in the charging system, such as high terminals should be tight on the battery posts. If wiring resistance, faulty alternator, regulator the posts or cable ring terminals are corroded, or battery equalizer.

  • Page 152: Troubleshooting And Testing The Multiplex Vehicles

    Section 06: ELECTRICAL Battery Balance NOTE NOTE When performing an electrical system diagnostic with the MCD (message center display), the Allow at least 15 minutes to balance batteries message « No Response ModA41» indicates after any corrective measure has been taken. either module A41 is not responding due to a CAN link problem or module A41 is not 1.

  • Page 153: Can Network

    Section 06: ELECTRICAL connectors installed at each end to facilitate swapping from the regular CAN network to the spare CAN network. Refer to the vehicle wiring diagram and the section 4.2.3 for more CAN NETWORK information. The CAN link wiring is separated in sections and uses connectors that are not shared with other TEST MODE FOR SWITCHES AND circuits.

  • Page 154: Test Mode For Electric Motors

    Section 06: ELECTRICAL • WCL switch, Engine ignition front switch • Driver's Power Window Switch (up & down), Engine ignition rear switch • Fog Lights Switch, Entrance door inside closing switch • Alternator Sensors 1 & 2, Entrance door outside opening /closing switch •...

  • Page 155: Test Sequence - Coaches Only

    Section 06: ELECTRICAL 11. Hot water pump starts running for 5 seconds to advise people that may be working on the and hot water pneumatic valve cycles 3 vehicle. times. To enter this mode: 5 beeps from the back-up alarm indicate to go to the overhead storage compartment inside the •...

  • Page 156: Test Sequence - Vip With Small Hvac System

    Section 06: ELECTRICAL 5 beeps from the back-up alarm indicate to go to 7. Auxiliary unit refrigerant solenoid valve the evaporator compartment. activates 3 times. [10 seconds delay] In the evaporator compartment: 8. Hot water pump starts running for 5 seconds. 11.

  • Page 157: Can Network Layout And Troubleshooting

    Section 06: ELECTRICAL CAN NETWORK LAYOUT AND TROUBLESHOOTING Pneumatic accessory panel (right console) Main power comp. panel 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 158 Section 06: ELECTRICAL Use the spare "Front to Rear" CAN Front electrical comp. panel: Disconnect C1 Plug and connect C1S Plug into C1 Socket. Main power comp panel: Disconnect C3 Socket and connect C3S socket into Pneumatic C3 Plug. accessory 5th baggage comp.: Disconnect C100 Socket and reconnect it to C100S Plug.
  • Page 159 Section 06: ELECTRICAL Pneumatic Use the spare "Front to Pneumatic Accessory Panel" CAN accessory panel Pneumatic accessory panel: disconnect C13 Socket and connect C13S socket into C13 Plug. Front electrical comp. panel: Disconnect C5 Plug and connect C5S Plug into C5 Socket.
  • Page 160 Section 06: ELECTRICAL Pneumatic Isolate the evaporator module from the network accessory panel Disconnect C100. No need to connect a termination resistor there since C100 is a stub connection. If the short circuit problem is in the evaporator panel, all modules except A54 will respond normally.
  • Page 161 Section 06: ELECTRICAL Isolate the main power comp. panel from the network Disconnect C3 Plug and connect the termination resistor into C3 Socket. If the short circuit problem is in the main power comp. panel, all front modules + the evaporator module will respond normally.

  • Page 162: Roadside Troubleshooting

    Section 06: ELECTRICAL ROADSIDE TROUBLESHOOTING Problem/Symptom Probable Causes Actions Vehicle does not Start Rear Start selector switch is 1. Check that the rear start selector not at the NORMAL position switch is flipped up to NORMAL start position and battery master switch is flipped up to ON and retry cranking Battery master switch in the 2.
  • Page 163 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions see if the limp-home functions (start of the vehicle from the engine compartment, wipers speed flashers, etc ) are functioning Many secondary functions The CECM module does not 1. Check / reset circuit breaker CB6 (4 (not essential for driving) receive 24 V power from the top on the right side column)
  • Page 164 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions HVAC condenser fans not Circuit breaker CB7 was 1. Check / reset circuit breaker CB7 functioning in speed 2 manually tripped and not reset Lower upper Module A46 is not powered 1. Check the SYSTEM DIAGNOSTIC windshield washer or is faulty...
  • Page 165 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions functioning the module. (A CAN network problem would show the same message but doesn't produce this symptom). 2. Check / reset circuit breaker CB2 3. Check / replace fuse F80 4. Probe gray connector on module to see if it is powered.
  • Page 166 Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions Sound system Circuit breaker CB4 or CB11 1. Check / reset circuit breaker CB4 or functioning was manually tripped and not CB11 reset Fire alarm telltale light Short-circuited fire sensor or 1. Prior to start the vehicle, cycle the and audible alarm always defective sensor ignition key to the ON position, OFF...

  • Page 167: Essential Functions To Operate The Vehicle

    Section 06: ELECTRICAL Problem/Symptom Probable Causes Actions manual. ESSENTIAL FUNCTIONS TO OPERATE LOWER PRIORITY MODULES FOR THE VEHICLE BREAKDOWN SERVICE Even with a defective CECM (Chassis Electronic Modules A43 (IO-A) and A44 (IO-B) affect lower Control Module) or a CAN network problem, priority functions.

  • Page 168: Io-B

    Section 06: ELECTRICAL 4.10.4 IO-B 4.11.2 Replacing The CECM Module IO-B modules receive inputs and control outputs. • Set the ignition key to the ON position and IO-B's are used for outputs up to 30 amps. leave it in that position at all time while performing this procedure.

  • Page 169: Alternators

    Section 06: ELECTRICAL 5. ALTERNATORS bracket and the flanged nuts at the transmission end of the bracket; BOSCH T1 24-volt 140 ampere or BOSCH HD10 24-volt 120 ampere, self regulated, belt driven, 2. Bolt the upper alternator to the bracket using air-cooled alternators may be used in the 24-volt the 4 inch bolt at the top (2, fig 19) and two electrical system.
  • Page 170 Section 06: ELECTRICAL MAINTENANCE Check for wear and proper tension every 6,250 miles (10 000 km) or twice a year, whichever comes first. FIGURE 18: ALTERNATOR DRIVE BELT 01181 FIGURE 17: ALTERNATOR DRIVE BELT 01180 FIGURE 19: TWIN BOSCH ALTERNATORS INSTALLATION WITH DDC SERIES 60 ENGINE (VIP MOTORHOMES) 01077 PA1561...
  • Page 171 Section 06: ELECTRICAL FIGURE 20: ALTERNATORS AND ACCESSORIES MOUNTING TORQUES 01182 CAUTION electrical system NEGATIVE GROUNDED. Connecting the batteries or a battery charger with the positive terminal grounded will endanger the alternator diodes and vehicle wiring by a high current flow.
  • Page 172 Section 06: ELECTRICAL 3. On the drive shafts of both alternators, 4. Install the alternators belt, the coolant pump install key, pulley, spring washer and nut; belt, the A/C compressor belt and then the radiator fan driving mechanism belt (figure 23).

  • Page 173: Series Coaches)

    Section 06: ELECTRICAL 2. If removed, reinstall ring bracket (1, figure 19) and L-shaped bracket (1.1, figure 25). 5.2.1 Alternator Drive Belt Fix the ring bracket using bolt (1a, figure 25) Removal and also bolt and nut (1b, figure 19) for the ring bracket and L-shaped bracket.
  • Page 174 Section 06: ELECTRICAL MAINTENANCE Check for wear and proper tension every 6,250 miles (10 000 km) or twice a year, whichever comes first. FIGURE 24: TWIN BOSCH HD10 ALTERNATOR 01180 PA1561...
  • Page 175 Section 06: ELECTRICAL FIGURE 25: TWIN BOSCH HD10 ALTERNATORS INSTALLATION (H3 SERIES COACHES) 01077 FIGURE 26: TWIN BOSCH HD10 ALTERNATORS AND ACCESSORIES MOUNTING TORQUES (H3 SERIES COACHES) PA1561...

  • Page 176: Engine Block Heater

    Section 06: ELECTRICAL NOTE 6. ENGINE BLOCK HEATER If vehicle is equipped with optional Xenon headlights, refer to paragraph 6.1.6. The vehicle may be equipped with an engine immersion-type electric block heater to assist cold weather starting. The heater male electric plug is located on the engine compartment door (Fig.

  • Page 177: Replacing Front Turn Signal Led Module

    Section 06: ELECTRICAL Phillips head screws indicated by arrows, pull CAUTION the retainer and bulb out (figure 30). • To prevent burning yourself, do not CAUTION replace the light bulbs while they are hot. During this step, avoid contacting the bulb •...

  • Page 178: Aiming Headlights

    Section 06: ELECTRICAL When switching on the Xenon headlamp using can be performed without opening headlight the rocker switch, a short-circuit test is assembly. Vertical aiming of each module is performed. provided by one adjusting screw that pivot the entire module in the housing for proper Current is detected in the lamp circuit before the alignment (Fig.

  • Page 179: Lamp Removal And Replacement

    Section 06: ELECTRICAL unit. The back-up light sealed unit uses a 7.2.2 High-Mounted Stop Light Removal And regular tungsten bulb. Replacement The hazard warning flashing system uses the This vehicle is equipped with a high-mounted front, side rear directional lights stop light (LED).

  • Page 180: Clearance, Identification And Marker Lights

    Section 06: ELECTRICAL CLEARANCE, IDENTIFICATION AND automatically when reverse range is selected to MARKER LIGHTS facilitate back-up or docking procedure. vehicle equipped with marker, On the V.I.P. model, these lights do not operate identification and clearance lights (LED). The automatically when reverse range...

  • Page 181: Interior Lighting Equipement

    Section 06: ELECTRICAL 3. Unscrew the outer ring. Disconnect the light NOTE unit connection and remove the bulb. Switches are lighted by the use of LED. When lighting on a switch fails, replace defective switch as a unit. FIGURE 35: FOG LIGHT EXPLODED VIEW CAUTION FIGURE 36: SWITCH During this step, avoid contacting the bulb...

  • Page 182: Vip Entrance And Bus Entrance Door

    Section 06: ELECTRICAL 2. Unfasten the three fixing screws, remove LAVATORY NIGHT-LIGHT and disconnect LED light assembly. The lavatory night-light is illuminated as soon as 3. Connect and install the new LED assembly the ignition switch is set to the “ON” position. in position.
  • Page 183 Section 06: ELECTRICAL 2. Pull the defective bulb out of the socket. 3. Install the new bulb by pushing it in position. 4. Replace the lamp by snapping it back in place. CAUTION Do not touch halogen bulbs with bare hands as natural oils on skin will shorten bulb life span.
  • Page 184 Section 06: ELECTRICAL Two lights illuminate the engine compartment upon opening of the engine door (Fig. 40). Each light is sealed and can be replaced as follows: 1. Disconnect the light unit connection. 2. Remove the lamp. 3. Position new lamp. 4.

  • Page 185: Interior Lighting

    When replacing a light bulb, special attention must be paid to the voltage rating (refer to light bulb data hereafter). NOTE Exterior and interior lights can be 12 volts or 24 volts. Application Prevost Trade or SAE Watts or Volts part no. number Candle Power...
  • Page 186 Section 06: ELECTRICAL Application Prevost Trade or SAE Watts or Volts part no. number Candle Power Step (VIP) 562278 6429 10 W Step (Coaches) 830173 0.7 W Lavatory 561009 6423 Parcel rack 561553 1.6 cp Driver’s area 830176 Q20MR16 20 W “EMERGENCY EXIT”...
  • Page 187 Battery cover .........................45-50 ft-lbf (5-6 N m) Alternator Make..............................BOSCH Series ................................T1 Hot output -Amperes........................140 at 25°C (AMBIENT) -Volts ................................28 -Approximate rpm............................ 6000 Ground .............................. negative Prevost Number ..........................562752 Alternator Make..............................BOSCH Series ..............................HD10 Hot output PA1561...
  • Page 188 Section 06: ELECTRICAL Amperes ........................120 at 25°C (AMBIENT) Volts ................................. 28.4 Power output ............................3 Kw Ground .............................. negative Prevost Number ..........................564119 Battery equalizer Make..............................Vanner Model..............................60-100D Amperes ............................100 amps Prevost Number ..........................562542 Starter Make....................Mitsubishi Electric Corporation (MELCO) Model Number..........................M009T82479...
  • Page 189 Section 06: ELECTRICAL Over voltage.............................35 V Number of inputs............................10 Number of outputs............................6 Prevost number........................... 565865 CECM Volvo multiplex module Rated voltage ............................. 24 VDC Operating voltage..........................8-24 V Over voltage.............................35 V Number of inputs............................10 Analog inputs ..............................1 Number of outputs............................
  • Page 190 SECTION 07: TRANSMISSION CONTENTS DESCRIPTION ............................3 ALLISON AUTOMATIC TRANSMISSION ..................3 1.1.1 Retarder (if applicable) ......................3 ZF-ASTRONIC TRANSMISSION ....................3 WELDING PROCEDURES ........................4 ALLISON TRANSMISSION MAINTENANCE..................4 MANUAL FLUID LEVEL CHECK....................4 3.1.1 Cold Check ..........................4 3.1.2 Hot Check..........................
  • Page 191 Section 07: TRANSMISSION 10.2.2 Diagnostic Code Display And Clearing Procedure – Allison 4 Generation Controls ..22 10.2.3 Diagnostic Code Response....................23 10.2.4 Diagnostic Troubleshooting Codes (DTC) List - Allison 4 Generation Controls ....24 ZF-ASTRONIC TRANSMISSION SYSTEM FAULTS AND ERROR MESSAGES ......27 11.1 SYSTEM FAULTS (ERROR MESSAGES)...................

  • Page 192: Description

    Section 07: TRANSMISSION With this information, it computes shift points DESCRIPTION and clutch pressures to meet immediate needs. H3 Series vehicles may be provided with either Using closed loop adaptive logic, the electronic an Allison automatic transmission or a ZF- control looks at a number of parameters during Astronic transmission.

  • Page 193: Welding Procedures

    Section 07: TRANSMISSION constant-mesh gearbox and an automated dry Clean all dirt from around the end of the oil filler clutch. tube before removing the dipstick. Dirt or foreign matter must not be permitted to enter the oil If the ASTRONIC transmission system is to be system since it will cause valves to stick, undue used, the vehicle must have an electronic wear...

  • Page 194: Hot Check

    Section 07: TRANSMISSION 1. If the engine has been shut down for an result from extended operation at improper fluid extended period of time, park the vehicle on a level conditions. level surface and apply the parking brake. CAUTION CAUTION Obtain an accurate fluid level by imposing the The oil level rises as sump temperature following conditions:...

  • Page 195: Fluid Level Check Using The Pushbutton Shift Selector

    Section 07: TRANSMISSION contact your nearest Allison dealer DISPLAY INTERPRETATION distributor. O L…H I… 2 Oil Level is HIgh 2 quarts Oil Level is HIgh 3 or more O L…H I… 3 quarts Oil Level is invalid. Source of invalid reading is defined O L…...

  • Page 196: Keeping Fluid Clean

    Drain Intervals. TranSynd™ is fully qualified to the Allison TES295 specifications and is 3.3.1 Oil Contamination available through Prevost Parts. At each oil change, examine the drained oil for NOTE evidence of dirt or water. A nominal amount of The prognostics package requires the use of condensation will emulsify during operation of the TranSynd™...

  • Page 197: Coolant Leakage

    Section 07: TRANSMISSION external circuits, coolers, and all other areas that the service condition will develop into a where the particles could lodge. more serious condition. To access the Prognostic Mode functions, CAUTION simultaneously press the (Up) and (Down) arrow buttons repeatedly. See the reference If excessive metal contamination has occurred, table at the end of this section.
  • Page 198 Section 07: TRANSMISSION the shift selector, pausing briefly (less than 3 CAUTION seconds) between each selector movement, with the ignition on and the engine not running. Required calendar-based oil & filter change intervals (based on month) still apply because 3.4.3 Transmission Health Monitor Oil Life Monitor function cannot measure time The display message denotes clutch life status,...
  • Page 199 Section 07: TRANSMISSION The following table illustrates how to access Oil Level Check, Prognostics & Diagnostic Troubleshooting Codes functions on the Allison pushbutton shift selector. Description SELECT MONITOR (up) & (down) arrow buttons pressed simultaneously " - " " - " press Allison transmission oil level check Other codes will be displayed...

  • Page 200: Oil And Filter Change Interval

    Section 07: TRANSMISSION OIL AND FILTER CHANGE INTERVAL 3.5.1 Oil And Filter Change Interval With Prognostics Mode Disabled Allison transmissions are factory fill with Castrol TranSynd™ fluid. Oil change must be performed with the vehicle on a flat and level surface and with parking brake applied.
  • Page 201 Section 07: TRANSMISSION TABLE 1 Recommended Fluid and Filter Change Intervals Using Dexron-III/ Dexron-VI/ Non-TranSynd / Non-TES 295 / Mixture Severe General Coaches or MTH equipped with retarder Coaches or MTH without retarder Filters Filters Fluid Fluid Main Internal Lube/ Main Internal Lube/...

  • Page 202: Oil And Filter Change Interval With Prognostics Mode Enabled

    Section 07: TRANSMISSION TABLE 3 Recommended Fluid and Filter Change Intervals Using 100% TranSynd /TES 295 Approved Fluid And Gold Series Filters Coaches or MTH equipped with retarder Coaches or MTH without retarder Filters Filters Main Main Fluid Fluid Internal Lube/ Internal Lube/...

  • Page 203: Zf As-Tronic Transmission Maintenance

    Section 07: TRANSMISSION into a suitable container. Check the condition When changing main and lube filters at of the oil as described previously. recommended intervals, approximate fluid loss for each filter as follows: 3. To replace the integral filters, remove twelve bolts (6 on each cover), two filter covers, two Main filter = 2 quarts (1.9 liters) O-rings, two square cut seals and the two...
  • Page 204 Section 07: TRANSMISSION disk along the full length of the input shaft to shaft may result. When aligned, push the transfer grease to the clutch hub splines. transmission towards the engine. Be sure Remove clutch disc, and remove any excess that the bell housing contacts the flywheel grease from the exterior of the clutch disc housing.

  • Page 205: Installation Of Zf Or Allison Transmission Brackets

    Section 07: TRANSMISSION INSTALLATION OF ZF OR ALLISON TRANSMISSION BRACKETS FIGURE 9: ZF OR ALLISON TRANSMISSION BRACKETS 07114 3. Remove engine splash guards and protective ALLISON TRANSMISSION REMOVAL panels surrounding transmission. 4. Remove cross member from under The following procedure deals with the removal of the Allison transmission without removing the transmission.

  • Page 206: Transmission Oil Cooler Removal

    Section 07: TRANSMISSION 8. Disconnect the two oil cooler hoses from to unfasten the 12 converter-to-flexible plate transmission. Cover hose ends and fittings to attaching screws. Remove the plug located below starter motor and install cranking tool (88800014). prevent fluid contamination. Cranking the engine to gain access to the attaching screws may be done by turning the WARNING...

  • Page 207: Volvo D13 Engine

    Section 07: TRANSMISSION 1. Disconnect and remove the engine air intake WARNING duct mounted between the air cleaner housing and the turbocharger inlet. A significant amount of oil may drain from oil lines when they are disconnected. CAUTION 3. Unfasten the constant-torque hose clamps To avoid damage to turbocharger, cover the and remove the two hoses.

  • Page 208: Cleaning And Inspection Of The Allison Transmission

    Section 07: TRANSMISSION 4. Damaged or loose oil lines; 5. Worn or frayed electrical harnesses, improper routing; 6. Worn or out of phase drive line U-joint and slip fittings. CAUTION FIGURE 13: COOLER WITH RETARDER 07073 DO NOT pressure wash the transmission 6.
  • Page 209 Section 07: TRANSMISSION 3. Lubricate the flywheel center pilot boss with Reinstall starter motor and connect cables. molybdenum disulfide grease (Molycote G, or Reinstall access plug below starter motor. equivalent). 8. Remove jack from under transmission. 4. Raise transmission and position the flywheel pilot boss into the flexible plate adapter.

  • Page 210: Allison Transmission Troubleshooting

    Section 07: TRANSMISSION • Replace by reversing the procedure. CAUTION Place the battery master switch to the ‘’OFF’’ position. 10.2 DIAGNOSTIC TROUBLESHOOTING CODES (DTC) — ALLISON 4TH GENERATION CONTROLS Diagnostic codes (DTC) numerical indications relating malfunction FIGURE 14: AIR PRESSURE REGULATOR (TYPICAL) 07037 transmission operation.

  • Page 211: Th Generation Controls

    Section 07: TRANSMISSION The code list position is the first item displayed, To display stored codes: followed by the DTC. Each item is displayed for 1. Simultaneously press the (Up) and about second. display cycles (Down) arrow buttons twice to access the continuously until the next code list position is Diagnostic Display Mode.
  • Page 212 Section 07: TRANSMISSION • Press simultaneously the NNC - Neutral No Clutches Response (Up) and (Down) arrow buttons at the same time on When certain speed sensor ratio or C3 pressure the pushbutton shift selector. switch tests are not successful, the TCM •...
  • Page 213 Section 07: TRANSMISSION 10.2.4 Diagnostic Troubleshooting Codes (DTC) List - Allison 4 Generation Controls CHECK Inhibited Operation Description TRANS Description Light May inhibit retarder operation if not C1312 Retarder Request Sensor Failed Low using J1939 datalink May inhibit retarder operation if not C1313 Retarder Request Sensor Failed High using J1939 datalink...
  • Page 214 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P071D General Purpose Input Fault None P0720 Output Speed Sensor Circuit P0721 Output Speed Sensor Circuit Performance DNS, Lock in current range P0722 Output Speed Sensor Circuit No Signal DNS, Lock in current range P0726 Engine Speed Sensor Circuit Performance Default to turbine speed...
  • Page 215 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P0974 Shift Solenoid 1 (SS1) Control Circuit High DNS, SOL OFF (hydraulic default) P0975 Shift Solenoid 2 (SS2) Control Circuit Open 7-speed: Allow 2 through 6, N, R 7-speed: Allow 2 through 6, N, R P0976 Shift Solenoid 2 (SS2) Control Circuit Low Inhibit TCC operation...
  • Page 216 Section 07: TRANSMISSION CHECK Inhibited Operation Description TRANS Description Light P278A Kickdown Input Failed ON Inhibit kickdown operation Ignores PWM input from shift P2793 Gear Shift Direction Circuit selector P2808 Pressure Control Solenoid 6 (PCS6) Stuck Off DNS, RPR P2809 Pressure Control Solenoid 6 (PCS6) Stuck On DNS, RPR P2812...
  • Page 217 Section 07: TRANSMISSION Switch on ignition Press “N” key and at the same time depress the foot-operated brake Hold down the foot-operated brake and depress and hold down “ ” key The errors stored in the transmission ECU are shown display after another.

  • Page 218: Error Codes

    Section 07: TRANSMISSION ERROR CODES Remark to titles in table: ZF fault number: defined by ZF. Display SM-Symbol : (0=NO, 1=YES) Display shows “SM“(severe failure) Warning lamp : (0=NO, 1=YES) Telltale panel warning lamp “check trans“(less severe failure) Shift schemes of transmissions: 10/12-Gear Scheme Y2 Splitter K2 Y3 Splitter K1...
  • Page 219 Section 07: TRANSMISSION DESCRIPTION 33,14 Stabilised voltage supply at output AU (clutch sensor supply) too high or too low 33,13 Error in clutch self-adjustment process 33,2 Error on clutch travel signal 34,7 Mechanical failure of small clutch disengagement valve 34,7 Mechanical failure of large clutch disengagement valve 34,7 Mechanical failure of small clutch engagement valve...
  • Page 220 Section 07: TRANSMISSION DESCRIPTION 40,5 Interruption at output stage to Y6 (Valve Shift) 40,6 Short circuit to ground at output stage to Y6 (Valve Shift) 40,3 Short circuit to positive at output stage to Y6 (Valve Shift) 43,2 Error on ”Ignition lock” signal (terminal 15) 48,3 No shift sensor signal (Short circuit to positive) 48,6...
  • Page 221 Section 07: TRANSMISSION DESCRIPTION 60,6 No gate select sensor signal (Short circuit to ground) 60,5 No gate select sensor signal (Interruption) 60,13 Gate select sensor self adjustment error 61,7 Splitter (GV) does not disengage 61,7 Change over error during splitter shifting 61,7 Splitter (GV) does not engage 63,14...
  • Page 222 Section 07: TRANSMISSION DESCRIPTION 230,1 Error on ”Wheel-based vehicle speed” signal (CCV 231,7 Engine does not react on torque intervention 231,1 Error on ”Drivers demand engine percent torque” (EEC1) 231,1 Error on ”Accelerator pedal position” (EEC2) 231,1 Error on ”Percent load at current speed” signal (EEC2) 231,1 Error on ”Actual engine percent torque”...
  • Page 223 Section 07: TRANSMISSION DESCRIPTION 231,1 Error on ”Actual engine retarder - percent torque” signal (ERC1_ER) 231,1 Error on ”Engine retarder configuration message” (Engine retarder configuration) 231,1 CAN ”Engine retarder configuration” timeout 231,1 CAN EBC1 timeout 231,1 Error on ”ABS active” signal (EBC1) 231,1 Error on ”ASR engine control active”...

  • Page 224: Specifications

    Capacity (excluding external circuits) ..............Initial fill 47 US qts (45 liters) Oil change..........................24 US qts (23 liters) Oil change (with retarder)....................27.6 US qts (26.5 liters) Oil Filters: Make ............................. Allison Transmission Type ............................Disposable cartridge Prevost part number (2-filters replacement kit) ..................571709 PA1561...

  • Page 225: Propeller Shaft

    SECTION 09: PROPELLER SHAFT CONTENTS PROPELLER SHAFT ..........................2 ............................ 2 ESCRIPTION REMOVAL, DISASSEMBLY, REASSEMBLY AND INSTALLATION ..........2 CLEANING, INSPECTION AND LUBRICATION ................. 3 ....................... 3 LEANING AND NSPECTION ............................ 3 UBRICATION EXPLANATION OF COMMON DAMAGES..................3 TROUBLESHOOTING .......................... 3 SPECIFICATIONS..........................

  • Page 226: Removal, Disassembly, Reassembly And Installation

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

  • Page 227: Cleaning, Inspection And Lubrication

    Section 09: PROPELLER SHAFT CLEANING, INSPECTION AND EXPLANATION OF COMMON DAMAGES LUBRICATION 1. Cracks: Stress lines due to metal fatigue. CLEANING AND INSPECTION Severe and numerous cracks will weaken the metal until it breaks. Thoroughly clean grease from bearings, journal, lubricating grease fittings and other parts.

  • Page 228: Specifications

    U-joint kit (slip yoke), Prevost number .......................580062 Cap and bolt kit, bolt torque 115-135 lbf•ft (156-183 N•m), Supplier number ........6.5-70-18X Cap and bolt kit, bolt torque 115-135 lbf•ft (156-183 N•m), Prevost number ...........580063 Bolts kit, bolt torque 38-48 lbf•ft (52-65 N•m), Supplier number ............6-73-209 Bolts kit, bolt torque 38-48 lbf•ft (52-65 N•m), Prevost number ..............580071...
  • Page 229 SECTION 10: FRONT AXLE CONTENTS FRONT AXLE ............................2 ............................ 2 DESCRIPTION LUBRICATION ............................2 MAINTENANCE ............................ 2 ......................3 IE ROD END PLAY ADJUSTMENT REMOVAL AND REPLACEMENT......................3 ............................3 REMOVAL ..........................3 REPLACEMENT SERVICE INSTRUCTIONS FOR STEER AXLE................... 3 FRONT WHEEL ALIGNMENT ......................

  • Page 230: Front Axle

    Section 10: FRONT AXLE FRONT AXLE (Fig. 2). Tie rod ends and knuckle pins are provided with grease fittings for pressure DESCRIPTION lubrication. These grease fittings should be serviced every 6,250 miles (10 000 km) or twice This front axle is of the ‘’Reverse Elliot’’ type a year whichever comes first.

  • Page 231: Tie Rod End Play Adjustment

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

  • Page 232: Front Wheel Alignment

    Section 10: FRONT AXLE FRONT WHEEL ALIGNMENT Check and adjust the caster angle. Check and adjust the toe-in. Correct front wheel alignment must be maintained for steering comfort and satisfactory tire life. Road INSPECTION BEFORE ALIGNMENT shocks and vibrations, as well as normal stress and strains on the front-end system can, under Check the following before doing a front wheel normal operating conditions, result in loss of front...

  • Page 233: Turn Adjustment

    Section 10: FRONT AXLE Proceed with the following method to check the 5. The steering stopper screw must be in steering maximum turning angle : contact before the steering stabilizer reaches the end of the stroke. 6.4.1 R.H. Turn Adjustment 6.

  • Page 234: Camber Check

    Section 10: FRONT AXLE bearings, steering knuckle pins or by a bent knuckle or sagging axle center. Steering effort is affected by improper camber, and uneven tire wear will result. Excessive positive camber causes an irregular wear of tire at the outer shoulder excessive negative...

  • Page 235: Inspection And Adjustment

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

  • Page 236: Troubleshooting

    Section 10: FRONT AXLE TROUBLESHOOTING CONDITION CAUSE CORRECTION Tires wear out 1. Tires have incorrect air pressure. 1. Put specified air pressure in tires. quickly or have 2. Tires out-of-balance. 2. Balance or replace tires. uneven tire tread 3. Incorrect tag axle alignment. 3.
  • Page 237 Section 10: FRONT AXLE SPECIFICATIONS Front Axle Make ..........................DANA SPICER EUROPE Model ................................NDS Front Track ........................84.4 inches (2 145 mm) Rated load capacity......................16,500 lbs (7 500 kg) Torque specifications FIGURE 7: AIR BELLOWS MOUNTING SUPPORT AND AXLE 10009 For more torque specifications, see ‘Dana Spicer Maintenance Manual NDS Axles and Maintenance Manual Model NDS’’...
  • Page 238 Section 10: FRONT AXLE FRONT WHEEL ALIGNMENT SPECIFICATIONS Front Wheel Alignment Minimal Nominal Maximal Camber, (degrees) -0.250 0.125 0.375 R.H. and L.H. * Caster, (degrees) 2.75 R.H. and L.H. Toe-in (A minus B), 0.06 0.08 0.10 (degrees) Note : Camber angle changes with loading. The given numbers are for an empty vehicle. PA1561...
  • Page 239 SECTION 11: REAR AXLES CONTENTS DRIVE AXLE ............................2 ............................ 2 DESCRIPTION )................. 2 DCDL DRIVER CONTROLLED MAIN DIFFERENTIAL LOCK ........................2 DRIVE AXLE LUBRICATION ........................... 3 MAINTENANCE 1.4.1 Checking And Adjusting The Oil Level..................3 1.4.2 Draining And Replacing The Oil....................3 1.4.3 Speed Sensors (Anti-Lock Brake System, Abs) ..............

  • Page 240: Section 11: Rear Axles

    Section 11: REAR AXLES DRIVE AXLE DESCRIPTION The Meritor drive axle is equipped with a single reduction standard carrier mounted in front of the axle housing. The carrier consists of a hypoid drive pinion, a ring gear set and gears in the differential assembly.
  • Page 241 Section 11: REAR AXLES burns. Also, a correct reading is not obtained when the axle is warm or hot. 2. Make sure the axle is "cold" or at room temperature. 3. Clean the area around the fill plug. Remove the fill plug from the differential axle housing bowl (Fig.

  • Page 242: Removal And Reinstallation

    Section 11: REAR AXLES 1.4.3 Speed Sensors (Anti-Lock Brake NOTE system, ABS) Position the hoses so they will not be damaged when removing the axle. For removing and installing the drive axle speed sensors (for anti-lock brake systems, ABS), refer 7.

  • Page 243: Tire Matching

    Section 11: REAR AXLES GEAR SET IDENTIFICATION The drive axle alignment consists in aligning the axle according to the frame. The axle must be Gear identification covered under perpendicular to the frame. The alignment is applicable heading in Meritor's "MAINTENANCE achieved with the use of shims inserted between MANUAL NO.

  • Page 244: Tag Axle

    Section 11: REAR AXLES DRIVE AXLE ALL VEHICLES Alignment / value Minimum value Nominal value Maximum value Thrust angle (deg.) -0.04 0.04 Total Toe (deg.) 0.18 Toe-in 0.18 Toe-in TAG AXLE ALIGNMENT • Remove and reinstall all wheel mount sensors on the drive and tag axles (fig. 8); NOTE For an accurate alignment, the tag axle must be aligned with the drive axle.

  • Page 245: Retracting Tag Axle For Repair Purposes

    2. Apply a continuous thin bead of silicone CAUTION sealant* (Prevost P/N 680053) on the mounting surfaces and around the edge of all fastener holes of both the axle shaft flange Do not use tag axle in raised position for an and wheel hub.

  • Page 246: Grease Lubricated Wheel Bearings

    Section 11: REAR AXLES WARNING WARNING Install protective cover prevent Install a protective cover to prevent unfortunate unfortunate lever operation while work is lever operation while work is being carried out being carried out under the vehicle. under the vehicle. •...

  • Page 247: Specifications

    Section 11: REAR AXLES CAUTION NOTE Refer to section 13 "Wheels, Hubs And Tires" Position the hoses so they will not be damaged for correct wheel bearing adjustment procedure. when removing axle. TAG AXLE ALIGNMENT Disconnect hose from the air spring upper mounting plate.
  • Page 248 The drive axle alignment consists in aligning the axle with reference to the frame. The axle must be perpendicular to the frame. Tag Axle Make ................................Prevost Rear track ........................83.6 inches (2 124 mm) Axle type ......................Dana Spicer Europe TS8U Hub Unit NOTE The tag axle alignment consists in aligning the tag axle parallel to the drive axle.
  • Page 249 SECTION 12: BRAKE AND AIR SYSTEM CONTENTS AIR SYSTEM ............................. 5 BRAKES ............................5 AIR RESERVOIRS..........................5 ..........................5 AINTENANCE 3.1.1 Wet (Main) Air Tank ........................ 6 3.1.2 Primary Air Tank........................6 3.1.3 Accessory Air Tank ......................... 6 3.1.4 Emergency/Parking Brake Overrule Air Tank ................. 6 3.1.5 Secondary Air Tank.........................
  • Page 250 Section 12: BRAKE AND AIR SYSTEM BRAKE RELAY VALVE (R-12 & R-14) ..................12 QUICK RELEASE VALVES (QR-1) ....................13 SPRING BRAKE VALVE (SR-7) ..................... 13 PRESSURE PROTECTION VALVE (PR-2 & PR-4) ............... 13 LOW PRESSURE INDICATORS (LP-3) ..................14 SHUTTLE-TYPE DOUBLE CHECK VALVE (DC-4)...............

  • Page 251: Figure

    Section 12: BRAKE AND AIR SYSTEM 32.1 ..........................31 OMPONENTS 32.1.1 The EC-60 controller’s ABS function utilizes the following components: ......31 32.1.2 The EC-60 controller’s ATC function utilizes the following components: ......31 32.1.3 The EC-60 controller’s ESP/RSP function utilizes the following components:....31 32.1.4 Bendix®...
  • Page 252 Section 12: BRAKE AND AIR SYSTEM ................24 IGURE BASIC AIR OPERATED BRAKING SYSTEM ..................26 IGURE BEAM FRONT AXLE BRAKE AIR CHAMBER ................26 IGURE TAG AXLE OR DRIVE AXLE BRAKE AIR CHAMBER ....................34 IGURE M CONFIGURATION .................... 29 IGURE FIRST L AGGAGE COMPARTMENT...

  • Page 253: Section 12: Brake And Air System

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

  • Page 254: Wet (Main) Air Tank

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

  • Page 255: Air System Emergency Fill Valves

    Check condition of all will pass through the standard air filtering three O’rings for damage. Replace when system provided by Prevost. Do not fill system necessary (Fig. 4). by any point on the system. CLEANING The front valve is located in the front electrical and service compartment close to R.H.

  • Page 256: Air Filter/Dryer

    Section 12: BRAKE AND AIR SYSTEM AIR FILTER/DRYER following table for the complete color identifica- tion code. Service instructions for each type of air line are also provided under the applicable headings. Color Circuit Secondary Green Primary and Delivery Yellow Parking Brake Blue Suspension...

  • Page 257: Air Line Operating Test

    Section 12: BRAKE AND AIR SYSTEM vehicles equipped with the world transmission CAUTION output retarder. The belt tensioner pressure regulating valve is Nylon air lines should be used to replace located in the engine compartment at the back existing nylon lines only, and must comply of the engine starting control panel.

  • Page 258: Air Compressor (Ba-921)

    Section 12: BRAKE AND AIR SYSTEM 2. Turn the adjustment screw clockwise to Lubricating oil returns to the engine crankcase increase the pressure slowly until the through the air compressor drive assembly. required pressure setting is reached. Tighten Maintenance and repair information on the the locking nut.

  • Page 259: Emergency / Parking Brake Overrule Control Valve (Rd-3)

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

  • Page 260: Brake Relay Valve (R-12 & R-14)

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

  • Page 261: Quick Release Valves (Qr-1)

    Section 12: BRAKE AND AIR SYSTEM Maintenance and repair information on the spring brake valve is supplied in the applicable booklet annexed to this section under reference number SD-03-9043. FIGURE 16: R-14 12207 18. QUICK RELEASE VALVES (QR-1) One quick release valve is installed on this vehicle and is used on Low Buoy rear release system.

  • Page 262: Low Pressure Indicators (Lp-3)

    Section 12: BRAKE AND AIR SYSTEM externally adjustable while the PR-4 has a fixed 23. EMERGENCY DOOR OPENING VALVES setting. Two emergency door opening three-way valves are installed on coaches. One is in the front 21. LOW PRESSURE INDICATORS (LP-3) service compartment, readily accessible.

  • Page 263: Brake Operation

    Section 12: BRAKE AND AIR SYSTEM • Defective air gauge (registering incorrectly). driver’s seat (see "Operator's Manual" for more details). • Excessive leaking in air system. Furthermore, brake application or release, which • Reservoir drain cock open. is sped up by a pneumatic relay valve (R-12 & •...

  • Page 264: Important Note

    Remove clip and washer (26 & 45, Fig. 24), replacement components are used, neither push down retainer bar (11), pull out pin (44) Prevost Car nor Bendix Spicer Foundation and remove retainer bar. Push caliper toward Brake LLC will accept any air disc brake- actuator (center of vehicle) for maximum related warranty returns or claims.

  • Page 265: Roadside Inspection For Knorr -Bremse Air Disc Brakes

    Section 12: BRAKE AND AIR SYSTEM CAUTION Use only a standard box wrench on the adjuster hexagonal pinion. Do not overtorque the pinion as overtorquing will damage the pinion. a) Remove cap (37, Fig. 26). b) Using a box wrench (8 mm), turn the adjuster pinion (23, Fig.

  • Page 266: Pad Removal

    Section 12: BRAKE AND AIR SYSTEM FIGURE 29: RADIAL MOVEMENT INSPECTION 12187 FIGURE 31: PAD REMOVAL 12111 The pad thickness can be seen but would require removal of the tire and rim. An indicator 27.5 CHECKING PAD WEAR of the pad wear condition is available by Minimum friction material thickness is 2 mm (A, inspecting the floating pin location in relation to Fig.

  • Page 267: Checking Caliper Guidance And Seal Condition

    Use special green grease (Prevost corrosion and may affect the function of the #683344) to reassemble the slide pin into actuation mechanism and adjuster unit. the bushing, white or yellow grease (Prevost #683345) may be used for all other lubrica- b) If boots...

  • Page 268: Pad Installation

    FIGURE 37: RUNNING CLEARANCE 12116 27.11 BRAKE TOOLS Four brake tools are available from Prevost to facilitate disc brake maintenance: a) #641321, Tappet with boot (item 13). b) #641322, Caliper inner boot (item 9). c) #641323, Caliper bushing (item 7).

  • Page 269: Safe Service Procedures

    Section 12: BRAKE AND AIR SYSTEM WARNING Whenever possible, work on brakes in a separate area away from other operations. Always wear a respirator approved by NIOSH (National Institute of Occupational Safety and Health) or MSHA (Mine Safety and Health Administration) during brake...

  • Page 270: Air Brake Troubleshooting

    Section 12: BRAKE AND AIR SYSTEM AIR BRAKE TROUBLESHOOTING The following tests and check lists have been designed to identify the cause(s) of a sluggish performance and/or leaks in the system. These tests require very little time to perform, and give you a general idea of the system condition.
  • Page 271 Section 12: BRAKE AND AIR SYSTEM FIGURE 40: H3.COACHES AIR-OPERATED BRAKING SYSTEM 12197 PA1561...
  • Page 272 Section 12: BRAKE AND AIR SYSTEM FIGURE 41: VIP-45 BASIC AIR-OPERATED BRAKING SYSTEM PA1561...
  • Page 273 Section 12: BRAKE AND AIR SYSTEM • If discharge valves leak, pull head and Pressure Build-Up / Low Pressure Warning / Cutoff Point Filter/Dryer Built-in correct or replace cylinder head. Governor Cutout • If drive is slipping, replace gear. CONDITION: Vehicle leveled, parking brake •...

  • Page 274: Brake Air Chamber

    Section 12: BRAKE AND AIR SYSTEM Excessive leakage on brake service side: • With the primary air system at normal operating pressure (95 - 125 psi (655 - 860 kPa)) and foot brake applied, coat all air line connections brake pneumatic components with a water and soap solution.

  • Page 275: Emergency /Parking Brake Manual Release

    Section 12: BRAKE AND AIR SYSTEM 30.3 BRAKE CHAMBER REMOVAL b) Coat clamping ring(s) with a soapy solution. If leakage is detected, tighten clamping ring WARNING only enough to stop leakage. Do not over- tighten as this can distort sealing surface or clamping ring.

  • Page 276: Brake Chamber Disassembly

    Section 12: BRAKE AND AIR SYSTEM 30.5 BRAKE CHAMBER DISASSEMBLY 5. Remove clamp ring, remove and discard the existing diaphragm. Install the new dia- DANGER phragm squarely on body. 6. Reverse the procedure for assembly. Tap Spring brake chambers, on drive and tag clamp ring to ensure proper seating.

  • Page 277: Troubleshooting And Testing

    Section 12: BRAKE AND AIR SYSTEM NOTE The ABS system is inoperative at speeds under 4 mph (6 Km/h). Illumination of ABS telltale indicator at these speeds is normal. CAUTION Disconnect the ECU or pull the ABS fuse before towing vehicle. 31.1 TROUBLESHOOTING AND TESTING For troubleshooting and testing of the vehicle's...

  • Page 278: Sensors

    Maintenance and repair information on this valve axle servicing. In such a case, sensors should is supplied in the applicable booklet annexed to be lubricated with special grease (Prevost this section under...
  • Page 279 Section 12: BRAKE AND AIR SYSTEM 3. Push the sensor completely inside the The Bendix ESP system is an ABS-based spring clip until it is in contact with the tooth stability system that enhances vehicle stability wheel. Ensure mounting is rigid, as it is an by both reducing engine throttle and by applying important criterion for adequate sensor vehicle...
  • Page 280 Section 12: BRAKE AND AIR SYSTEM • ESP features include Roll Stability Program Bendix SAS-60 Steering Angle Sensor (RSP) and Yaw Control. During operation, the (mounted to the steering column); ECU of the Bendix Advanced ABS system • Bendix YAS-60TM Rate/Lateral constantly compares performance models to the Acceleration Sensor (mounted to a cross...

  • Page 281: Steering Angle

    YAS-60 sensor. The controller supplies the power and ground inputs to the SAS-60 sensor. The SAS-60 sensor installed on Prevost vehicles is the 90° connector. PA1561...
  • Page 282 Section 12: BRAKE AND AIR SYSTEM FIGURE 48: VIP-45 ABS 6S/5M CONFIGURATION 12190 PA1561...
  • Page 283 Section 12: BRAKE AND AIR SYSTEM Diagnostic V4.0 or higher. See “Troubleshooting Removal: Diagnostic Trouble Codes: Steering Angle 1. Remove steering column upper, middle and Sensor (SAS-60)” for the calibration procedure lower covers. using this tool. 2. The steering angle sensor is located near The sensor must be recalibrated after any of the universal joint.
  • Page 284 Section 12: BRAKE AND AIR SYSTEM 1 ¼ 5/16 1 ¾ 2 ¼ 2 ¼ 2 ¼ 2 ¼ 2 ¼ FIGURE 50: HOSE FITTING 12054 NTA-Type Plastic Tubing: Hand tighten nut (Fig. 51). From that point, tighten using a wrench the number of turns indicated in the following chart.

  • Page 285: Specifications

    Prevost number........................... 641987 Cylinder Head Gasket Kit Prevost number........................... 641986 Air Dryer Make..............................Haldex Model............................... AT-87192 Prevost number..........................70303498 Desiccant cartridge Prevost number....................3097369 Flip-Flop Control Valve Make..........................Bendix Westinghouse Model..............................TW-1 Type ..............................On-Off Prevost number........................... 640136 Emergency/Parking Brake Control Valve Make..........................
  • Page 286 Type ........................... With manual drain Prevost number........................... 641338 Front Axle Brake Chambers Make............................Knorr-Bremse Type ................................22 Prevost number (R.H.) ........................641414 Prevost number (L.H.)......................... 641413 Drive Axle Brake Chambers Make............................Knorr-Bremse Type ......................24 as service -24 as emergency Prevost number........................... 641432...
  • Page 287 Section 12: BRAKE AND AIR SYSTEM Tag Axle Brake Chambers Make............................Knorr-Bremse Type ......................14 as service – 16 as emergency Prevost number........................... 641308 Brake Lining (All Axles) Make............................Knorr-Bremse Prevost number........................... 611049 ABS ANTILOCK BRAKING SYSTEM (if applicable) ABS Modulator Valve Make............................Meritor Wabco Voltage ..............................24 V...
  • Page 288 SECTION 13: WHEELS, HUBS & TIRES CONTENTS WHEELS..............................3 WHEEL MAINTENANCE ........................3 INSPECTION..........................3 SINGLE WHEEL REMOVAL ......................3 SINGLE WHEEL INSTALLATION ....................4 DUAL WHEELS............................. 4 OUTER WHEEL REMOVAL......................4 INNER WHEEL..........................4 INNER WHEEL INSTALLATION ....................4 OUTER WHEEL INSTALLATION ....................
  • Page 289 Section 13: WHEELS, HUBS & TIRES ILLUSTRATIONS ....................3 IGURE ALUM STEEL WHEEL ARRANGEMENT ........................3 IGURE TIGHTENING SEQUENCE ....................... 5 IGURE DIAL GAUGE INSTALLATION ........................6 IGURE STUD MOUNTED WHEELS ........................6 IGURE MOUNTED WHEELS ......................9 IGURE SPARE WHEEL COMPARTMENT ....................

  • Page 290: Section 13: Wheels, Hubs & Tires

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

  • Page 291: Single Wheel Installation

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

  • Page 292: Aluminum Wheel Anti-Corrosion Protection

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

  • Page 293: Wheel Studs

    Section 13: WHEELS, HUBS & TIRES 6. WHEEL STUDS Caution: The two wheel mounting systems are not interchangeable. They have their Stripped threads may be the result of excessive specific wheel, nut and stud types. Use only the torquing or may have been damaged during specific hardware suitable for a mounting type.

  • Page 294: Hub Bearing Inspection

    Section 13: WHEELS, HUBS & TIRES Note: 7.1 CARE OF WHEELS If original bearing unit is re-fitted, and end-float is measured at 1 mm, with hub not fully Check for cracks in wheels, especially around tightened to correct torque, then the retaining the fixing holes, studs, nuts and washers.

  • Page 295: Disassembly And Repair

    Section 13: WHEELS, HUBS & TIRES 9.2 DISASSEMBLY AND REPAIR 10. SPARE WHEEL (IF APPLICABLE) 1. Jack vehicle as per “Bearing Adjustment" and Tire failure is a rare event if tires are properly remove axle shaft as indicated in "Meritor - cared for.

  • Page 296: Spare Wheel (If Applicable)

    Section 13: WHEELS, HUBS & TIRES Note: For hydraulic jack placement, refer to Section 18 "Body", under heading "Vehicle Jacking Points". Warning: Place jack on stable and level ground; if necessary, place a board under the jack. Do not raise the vehicle until you are sure the jack is securely engaged.

  • Page 297: Inflation Pressure

    NOTE tions. For other tire and wheel specifications, see Prevost tire pressure tabulation in "Coach It is more accurate to use the TPMS display to Final Record". set the tire pressures than a pressure gauge.

  • Page 298: Tire Matching

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

  • Page 299: Specifications

    (105 km/hr). Do not drive vehicle at a higher speed than 65 mph (105 km/h) or above the posted speed limit. ALUMINUM WHEEL CLEANING AND MAINTENANCE PRODUCTS Aluminum Wheel Cleaner (22 Oz bottle) ................Prevost #683529 Aluminum Wheel Polish (16 Oz bottle) ................Prevost #683528 Aluminum Wheel Sealer (13 Oz bottle) ................Prevost #683527...
  • Page 300 SECTION 14: STEERING CONTENTS STEERING SYSTEM..........................3 DESCRIPTION ..........................3 INDEPENDENT FRONT SUSPENSION STEERING SYTEM DESCRIPTION......4 POWER STEERING GEAR ........................5 DESCRIPTION ..........................5 POWER STEERING GEAR REMOVAL ..................6 POWER STEERING GEAR INSTALLATION ................. 6 BLEEDING POWER STEERING HYDRAULIC SYSTEM..............6 HYDRAULIC PRESSURE TEST......................
  • Page 301 Section 14: STEERING SPECIFICATIONS ........................... 16 ILLUSTRATIONS ......................3 FIGURE STEERING SYSTEM AXLE SETUP ......................4 FIGURE IFS STEERING SYSTEM SETUP ........................5 FIGURE POWER STEERING GEAR ......................5 FIGURE FRONT SERVICE COMPARTMENT ........................7 FIGURE FUEL PUMP REMOVAL ........................7 FIGURE FUEL PUMP DRIVE AXLE ....................

  • Page 302: Steering System

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

  • Page 303: Independent Front Suspension Steering Sytem Description

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

  • Page 304: Power Steering Gear

    Section 14: STEERING POWER STEERING GEAR FIGURE 4: FRONT SERVICE COMPARTMENT 14050 A torsion bar, which is pinned with the valve slide and the worm, keeps the control valve in the neutral position as long as no opposing force is applied to the steering wheel. The steering FIGURE 3: POWER STEERING GEAR 14035 housing contains a pressure relief valve, which...

  • Page 305: Power Steering Gear Removal

    TROUBLESHOOTING positioned before reinstalling the pump. Perform troubleshooting of the steering gear as outlined "ZF-SERVOCOM REPAIR 1. Install a new gasket (Prevost P/N 510488). MANUAL", "ZF-SERVOCOM Operating, 2. Bleed air from the system as per step 3, Servicing/Maintenance Inspection "Bleeding Power Steering Hydraulic System".

  • Page 306: Maintenance

    Section 14: STEERING 6.1.3 Maintenance 4. Check that the adapter and fuel pump drive axle are not damaged. Refer to the "ZF-SERVOCOM Repair Manual" and the "TRW - Power Steering Pump Service Manual" annexed to this section. WITH VOLVO D13 ENGINE 6.2.1 Description The power steering pump is a vane type, gear...

  • Page 307: Steering Column

    Section 14: STEERING 10. Install the fuel pump. Torque-tighten bolts to U-joint and the steering slip joint are accessible specification. from the front driver's area. To access these joints, proceed as follows: NOTE Use a new sealing ring. Check that the fuel pump drive axle sits correctly in the power steering pump.

  • Page 308: Installation

    Section 14: STEERING 3. Disconnect the horn wire (white) connected 7. Once the steering wheel is removed, it is to the horn pad and the steering wheel important to block any rotating movement of harness 4-pin connector. the clockspring in order to prevent it from loosing its neutral position.

  • Page 309: Steering Linkage Adjustment

    Section 14: STEERING Hydraulic Stop Caution: Reduce or shut off the power steering hydraulic pressure before the boss on the axle touches the stop screw. If not, the components of the front axle will be damaged (refer to "ZF- SERVOCOM REPAIR MANUAL"...
  • Page 310 1. Position pitman arm on sector gear shaft with 4. When adjustment is achieved, replace fixing reference marks aligned. nut and torque Tighten as per “Torque 2. Install fixing nut (Prevost #661050). Tighten Specifications” in this section. as per “Torque Specifications” in this section. 12. MAINTENANCE...

  • Page 311: Filter Replacement

    Section 14: STEERING When the slightest evidence of dirt, sludge or water is discovered in the system, disconnect MAINTENANCE fluid lines at the power steering gear to drain the system. Drain and refill the system with "Dexron- At regular intervals, fluid level should be IIE, Dexron-III Dexron-VI"...

  • Page 312: Steering Stabilizer Cylinder (Damper)

    Section 14: STEERING FIGURE 19: STEERING STABILIZER (DAMPER) 14053 12.3 DRAG LINK MAINTENANCE Lubricate the fittings every 6,250 miles (10 000 km) or twice a year, whichever comes first. Good quality lithium-base grease NLGI No. 1 and 2 are recommended (refer to section 24 "LUBRICATION").

  • Page 313: Torque Specifications

    Section 14: STEERING 14. TORQUE SPECIFICATIONS FIGURE 20: DRAG LINK COMPONENTS 14054 FIGURE 22: FRONT AXLE COMPONENTS FIGURE 21: TIE ROD END 14055 14036 PA1561...
  • Page 314 Section 14: STEERING TORQUES Description Reference Lbf-ft dry Nm dry Drag Link End Stud Nut (on steering arm) Fig. 20, T1 150-200 203-271 Drag Link End Pinch Bolt Nuts Fig. 20, T2 65-75 88- 101 Pitman Arm Fixing Nut Fig. 20, T3 470-570 637-773 Steering Gear Fixing Bolts (5)

  • Page 315: Specifications

    Oil capacity ..........................4 US qts (3.7 liters) Supplier number ............................91410A Prevost number ............................660982 Make ............................... Nelson Muffler Element filter - Supplier number ......................83804 E Element filter - Prevost number .........................660987 Steering Stabilizer Cylinder (Damper) Make ................................Arvin Extended length..........................32.73±0.12" Collapsed length..........................20.26±0.12"...
  • Page 316 SECTION 16: SUSPENSION CONTENTS DESCRIPTION ............................5 AIR SPRINGS............................7 INSPECTION..........................7 REMOVAL ............................7 INSTALLATION ..........................7 SHOCK ABSORBERS.......................... 8 INSPECTION..........................8 REMOVAL ............................8 INSTALLATION ..........................9 RADIUS RODS............................9 INSPECTION..........................9 REMOVAL ............................9 BUSHING REMOVAL........................10 BUSHING INSTALLATION......................
  • Page 317 Section 16: SUSPENSION 6.10.1 Visual Inspection ........................24 6.10.2 Play Measurement ........................ 24 6.11 FRONT END ALIGNMENT ......................24 6.11.1 Alignment Terminology......................25 6.11.2 Front End Inspection ......................25 6.11.3 Front Wheel Camber ......................26 6.11.4 Front Wheel Toe-In ....................... 26 6.11.5 Front Axle Caster ........................
  • Page 318 Section 16: SUSPENSION AIR SYSTEM ........................... 39 13.1 AIR TANK MAINTENANCE ......................40 13.1.1 Wet Air Tank.......................... 40 13.1.2 Primary Air Tank........................40 13.1.3 Secondary Air Tank....................... 40 13.1.4 Accessory Air Tank ....................... 41 13.1.5 Expansion Air Tank ....................... 41 13.2 EMERGENCY FILL VALVES......................
  • Page 319 Section 16: SUSPENSION ..........................29 FIGURE AIR SPRINGS ....................30 FIGURE AIR SPRING AND SHOCK ABSORBER ........................31 FIGURE SHOCK ABSORBER FIGURE SWAY BAR INDEPENDENT FRONT SUSPENSION ....................33 FIGURE HEIGHT CONTROL VALVE LOCATION ....................33 FIGURE TYPICAL AIR SPRING CLEARANCE ....................

  • Page 320: Section 16: Suspension

    Section 16: SUSPENSION DESCRIPTION The vehicle is provided with an air suspension system. The system consists of air springs, height control valves, radius rods, sway bars, tripod and shock absorbers (Fig. 1, 2, 3 and 4). The system operation is fully automatic and maintains a constant vehicle height regardless of load, or load distribution.
  • Page 321 Section 16: SUSPENSION FIGURE 4: REAR SUSPENSION COMPONENTS 16003 PA1561...

  • Page 322: Air Springs

    Section 16: SUSPENSION AIR SPRINGS 2. Exhaust compressed air from accessory air tank by opening drain cock under reservoir. The air springs are made from a special compound rubber molded to the proper contour 3. Disconnect the height control valve link and and dimensions.
  • Page 323 Section 16: SUSPENSION and none is permissible. Repair or replace 3. Fully extend shocks and check for leaks in defective parts. the seal cover area. Shock fluid is a very thin hydraulic fluid that has a characteristic 8. Reinstall wheel. odor and dark brown tint.

  • Page 324: Torque Specifications

    Section 16: SUSPENSION RADIUS RODS Radius rods are used to secure the axles in the proper transversal and longitudinal positions. Four radius rods are provided on the front I- beam axle suspension (three longitudinal and one transversal), four on the drive axle suspension (three longitudinal...

  • Page 325: Bushing Installation

    1. Lightly spray the radius rod support with water. Place the radius rod end over the radius rod support (Fig. 10). 2. Put 3 drops of Loctite243 (Prevost #680038) in each radius rod support tapped blind FIGURE 8: RADIUS ROD BUSHING REMOVAL 16011 holes and a line of Loctite on bolts.

  • Page 326: Sway Bar

    Section 16: SUSPENSION Caution: It is extremely important upon reconnection of the rods that the proper clearance height between the axle and body be maintained. Otherwise, the rubber bushings in radius rod ends will become preloaded, thus reducing their life span. SWAY BAR A sway bar is provided on the front and drive axles to increase vehicle stability.
  • Page 327 Section 16: SUSPENSION affected. Any time steering linkage components are replaced or adjusted, steering geometry and front wheel alignment must be checked as explained in this section. FIGURE 12: INDEPENT FRONT SUSPENSION AND STEERING LINKAGE 16124 Turning Angle To check steering maximum turning angle, proceed with the following method: The maximum turning angle is set mechanically through the two steering stop screws installed...
  • Page 328 Section 16: SUSPENSION 14, "Steering", under heading: "Setting and Functional Test". FIGURE 13: LOCATION OF CLAMPS 16147 PA1561...

  • Page 329: Power Steering Hydraulic Pump

    Section 16: SUSPENSION FIGURE 17: TORQUE SPECIFICATIONS 16149 FIGURE 14: TORQUE SPECIFICATIONS 16148 FIGURE 18: CLAMP POSITIONING 16150 FIGURE 15: TORQUE SPECIFICATIONS 16152 FIGURE 19: TORQUE SPECIFICATIONS 16151 6.1.1 Power Steering Hydraulic Pump Refer to the "TRW Power Steering Pump Service Manual"...

  • Page 330: Steering Linkage Adjustment

    Section 16: SUSPENSION Caution: Heating of components to aid in disassembly is not allowed because it has a detrimental effect on axle components and steering linkages. FIGURE 21: TORQUE SPECIFICATIONS 16154 FIGURE 20: PITMAN ARM ALIGNMENT 14056 3. Remove pitman arm fixing nut. 6.1.2 Steering Linkage Adjustment 4.

  • Page 331: Drag Link

    Front wheels should turn from right to left 6.2.3 Bell Crank or Idler Arm Ball Joint extremities without noticeable binding at Reassembly drag link ends. Note: For bearing installation use tool Prevost # 110684. 1. Install backup ring on bell crank or idler arm mounting spindle. PA1561...
  • Page 332 Install grease retainer according to figure 13. Grease must be able to exit the bell crank or idler arm mechanism. For grease retainer installation use tool Prevost # 110683. 3. Install bell crank or idler arm onto its mounting spindle, while holding the bell...

  • Page 333: Relay Rod

    Section 16: SUSPENSION RELAY ROD Relay rod ends are equipped with lubrication fittings and should be lubricated as directed in paragraph "6.6 Lubrication Fittings. Note: The relay rod is crimped in place and it is not possible to remove the ball joints. 6.3.1 Replacement 1.

  • Page 334: Removal

    Section 16: SUSPENSION 6.4.1 Removal 3. Remove bolts securing steering arm to steering knuckle assembly. Remove 1. Remove cotter pins and stud nuts which steering arm from steering knuckle. attach tie rod socket ends to bell crank and left steering arm (or idler arm) and right 6.5.2 Installation steering arm.
  • Page 335 Section 16: SUSPENSION 3. Tie Rod Ends: Lubricate at four fittings, one at each end of both tie rods, every 6,250 miles (10 000 km) with good quality lithium-base grease NLGI No. 2 (Shell Retinax LX or equivalent). 4. Swivel Assembly: Refer DANA...
  • Page 336 Section 16: SUSPENSION FIGURE 27: LUBRICATION FITTINGS LOCATION DIAGRAM 16046 PA1561...

  • Page 337: Ball Joints

    Section 16: SUSPENSION BALL JOINTS FIGURE 28: BALL JOINTS LOCATION LOWER AND UPPER A-ARM BALL -Free play; JOINT -Radial cracking of the external sheet-metal The assembly work may be done only by a race. recognized specialized workshop. Ensure that Ball pin old and new parts do not get mixed up with each other.

  • Page 338: Lower A- Arm Central Ball Joint

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

  • Page 339: Upper A-Arm Central Ball Joint

    Section 16: SUSPENSION that the retaining ring eyelets are located at arm from the upright in order to have the ball each side of the housing shaft axis joint to its maximum extent. Measure (retaining ring eyelet lug points to tube), and dimension A again.

  • Page 340: Alignment Terminology

    Section 16: SUSPENSION c) Installing a longer bolt if less than 2 threads are remaining after the nut. d) Using a torque mark on the nut for future visual inspection. FIGURE 34: STEERING LINKAGE MEASURE 16050 Front Axle Caster 6.11.1 Alignment Terminology The inclination of the king pin from vertical in the fore and aft direction (C, Fig.

  • Page 341: Front Wheel Camber

    Section 16: SUSPENSION 4. Check wheel bearing adjustment. the floor. Incorrect toe-in results in excessive tire wear and steering instability with a tendency to 5. Check tie rods and drag link ends for wander. looseness. 6. Check king pins for looseness. Toe-In Check 1.

  • Page 342: Alignment Specifications

    Section 16: SUSPENSION Variations from the specified caster will affect steering stability, cause wandering, wheel INDEPENDENT FRONT SUSPENSION shimmy, and reduce returnability when pulling out of curves. Minimum Nominal Maximum value value value NOTE Load On Independent Front Suspension, caster on right wheel must be equal or greater than caster on left wheel, without exceeding 0.3°.
  • Page 343 Section 16: SUSPENSION WHEEL CAMBER KING PIN INCLINATION CASTER FIGURE 35: FRONT END ALIGNMENT DIAGRAM 16051 PA1561...

  • Page 344: Front Air Springs

    Section 16: SUSPENSION 6.12 FRONT AIR SPRINGS Two "rolling lobe" type air springs are used with the independent front suspension, one at each wheel. These air springs are special and use the complete piston as an extra reservoir to lower the spring stiffness.
  • Page 345 Section 16: SUSPENSION FIGURE 37: AIR SPRING AND SHOCK ABSORBER 16145 PA1561...

  • Page 346: Shock Absorber

    Section 16: SUSPENSION 6.13 SHOCK ABSORBERS The two front shock absorbers are double-acting and telescopic type. Shock absorbers ensure a smooth ride and enhance vehicle stability on the road. Front shock absorbers have eye-type mountings on the upper side and bayonet type on lower side.

  • Page 347: Sway Bar

    Section 16: SUSPENSION 6.14 SWAY BAR regardless of load, or load distribution. The control solenoid valve supplies air to the five A sway bar is provided on the IFS to increase way three-position air control valve, which vehicle stability. It controls lateral motion bypasses the height control valve, and opens a (swaying movement) of vehicle.

  • Page 348: Level-Low" Leveling System - Vip Series Option Only

    Section 16: SUSPENSION FIGURE 42: FRONT HEIGHT CONTROL VALVE 16100 The normal ride height is obtained by adjusting FIGURE 40: HEIGHT CONTROL VALVE LOCATION 16057 air spring clearance of both front and rear The appropriate vehicle body height is obtained suspension as follows: by measuring the clearance of all the air springs installed on the vehicle.

  • Page 349: Principles Of Operation

    Section 16: SUSPENSION system controls are located on L.H. side control SUSPENSION AIR SYSTEM panel. The suspension air system has its own air reservoir (accessory tank) which is located in 6.17.1 Principles of Operation the reclining bumper compartment. Pressurized air from the main tank (wet tank) flows through a Down pressure protection...

  • Page 350: Air Tank Maintenance

    Section 16: SUSPENSION AIR TANK MAINTENANCE I-beam axle air springs and 11½ ± ¼” (292 ± 6 mm) for those on the drive axle. Refer to Section 12, “Brakes and Air System” under “MAINTENANCE” complete instructions on air tank maintenance. SUSPENSION HEIGHT ADJUSTMENT The flow of pressurized air from the accessory air tank to the air springs is controlled by three...

  • Page 351: Height Control Valves

    Section 16: SUSPENSION HEIGHT CONTROL VALVES 9.1.1 Removal and installation Before disconnecting any height control valve air lines, securely support the vehicle by its jacking points on the body, and place safety support underneath body. Refer to "VEHICLE JACKING POINTS" in Section 18, "Body". 1.

  • Page 352: Front Kneeling System

    Section 16: SUSPENSION 8. If no leaks are found, remove valve Both the air spring control and air spring exhaust assembly from water, then with air pressure solenoid valves are energized, so the air control still connected to the air spring port, actuate valves release air from front air springs.

  • Page 353: Principles Of Operation

    Section 16: SUSPENSION 11 HIGH-BUOY SYSTEM The purpose of the full high-buoy system is to raise the entire vehicle body about 4” (100 mm) in order to increase ground clearance to board a ferryboat, to jump a curb, etc. This system can be put into service during normal vehicle operation.
  • Page 354 Section 16: SUSPENSION approach the desired pressure from a lower 12.1 PRINCIPLES OF OPERATION pressure. When reducing from a higher to a On H3-41 and H3-45 coaches, the rear low- lower setting, first reduce the pressure at a buoy is added over the front kneeling system. lower pressure, and then increase it to the The control valve on the left console panel desired level of pressure.
  • Page 355 Section 16: SUSPENSION FIGURE 46: LOCATION OF AIR TANKS 12195 13.1 AIR TANK MAINTENANCE Ensure that the accessory air tank is purged during pre-starting inspection. A good practice is to purge this tank at the end of every driving day by the remote air tank drain valve located in the steering compartment (Fig.
  • Page 356 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. 14 HUB UNIT AND SWIVEL ASSEMBLY Refer to “DANA SPICER Service Manual...
  • Page 357 Section 16: SUSPENSION 15 TORQUE SPECIFICATIONS FIGURE 49: TORQUE SPECIFICATIONS – DRIVE AXLE 16158 FIGURE 50: TORQUE SPECIFICATIONS – DRIVE AXLE 16159 PA1561...
  • Page 358 Section 16: SUSPENSION TORQUE TABLE TORQUE TABLE REFERENCE 6 REFERENCE 6 TORQUE TABLE TORQUE TABLE REFERENCE 5 REFERENCE 5 FRONT TORQUE TABLE TORQUE TABLE REFERENCE 7 REFERENCE 7 FIGURE 51: TORQUE SPECIFICATIONS – TAG AXLE 16160 TORQUE TABLE REFERENCE 10 TORQUE TABLE REFERENCE 2 FRONT...
  • Page 359 Section 16: SUSPENSION TORQUE TABLE REFERENCE 6 TORQUE TABLE REFERENCE 8 TORQUE TABLE REFERENCE 6 FRONT TORQUE TABLE TORQUE TABLE REFERENCE 8 REFERENCE 6 FIGURE 53: TORQUE SPECIFICATIONS – REAR SUBFRAME 16162 TORQUE TABLE REFERENCE 3 TORQUE TABLE TORQUE TABLE REFERENCE 1 REFERENCE 11 TORQUE TABLE...
  • Page 360 Section 16: SUSPENSION 16157 FIGURE 55: TORQUE SPECIFICATIONS 16146 PA1561...

  • Page 361: Torque Table

    Section 16: SUSPENSION TORQUE TABLE DESCRIPTION QTY REFERENCE TORQUE DRY ( lbf-ft / Nm Air Spring Upper Stud Nut (8 air springs) 20-25 27-34 Transversal Radius Rod Retaining Bolts (Tag, drive & front axle) 140-155 190-210 Sway Bar Link Upper & Lower Nut 70-85 95-115 Shock Absorber Pin Nut...

  • Page 362: Troubleshooting

    Front I-Beam axle air springs and tag axle air springs Make........................Goodyear Tire and Rubber Model............................... 1200 Type ..............................Mae West Nominal diameter ........................12” (304 mm) Prevost number........................... 630258 Drive axle air springs Make........................Goodyear Tire and Rubber Model............................... 1100 Type ............................Double Flare Nominal diameter ........................
  • Page 363 Color............................... Black Type ............................N45X225HA Ext. Diam.............................. 75 mm Collapsed length ........................15.51” (394 mm) Extended length ........................24.37” (619 mm) Prevost number........................... 630252 Drive and tag axle shock absorbers Make..............................Sachs Color............................... Black Type ............................N45X225HA Ext. Diam.............................. 75 mm Collapsed length ........................
  • Page 364 Section 16: SUSPENSION Solenoid valve manifold Prevost number........................... 641130 Coil Voltage .............................. 24 V DC Current draw ..........................29 amperes Prevost number........................... 641144 Valve (3 way, 2 positions) Type ................................N/C Supplier number........................411-C-456235W Prevost number........................... 641357 Type ................................N/O Prevost number........................... 641356 Radius rod bushing Make..............................Prevost...
  • Page 365 Section 16: SUSPENSION High-Buoy Pressure regulator Make..............................Norgren Recommended pressure setting ..................90 psi (621 kPa) Prevost number........................... 641352 PA1561...
  • Page 366 SECTION 18: BODY CONTENTS VEHICLE EXTERIOR ..........................6 STRUCTURE............................9 WELDING ............................9 EXTERIOR MAINTENANCE......................... 9 CORROSION PREVENTION ......................9 PREVENTIVE MAINTENANCE SCHEDULE ................10 RUST INHIBITOR APPLICATION ....................10 FIBERGLASS REPAIR ........................15 REPAIR USING FIBERGLASS CLOTH ..................15 REPAIR USING FIBERGLASS PASTE..................
  • Page 367 Section 18: BODY DOOR LATCH MECHANISM ....................... 27 DRIVER’S POWER WINDOW ......................27 POWER WINDOW REMOVAL ..................... 27 POWER WINDOW INSTALLATION..................... 27 ROOF ESCAPE HATCH ......................... 28 10.1 REPAIR ............................28 10.2 SEALING ............................28 10.3 ESCAPE HATCH PANEL ASSEMBLY..................29 10.4 ESCAPE HATCH FRAME ......................
  • Page 368 Section 18: BODY 19.1 PANTOGRAPH ADJUSTMENT ....................57 DOOR HANDLES ..........................58 ENGINE COMPARTMENT DOOR ....................58 21.1 ENGINE DOOR ADJUSTMENT ....................58 21.2 MINOR TOP EDGE DEPTH ADJUSTMENT ................59 21.3 MINOR LOWER EDGE DEPTH ADJUSTMENT: ................. 59 ENGINE AIR INTAKE GRILL ......................59 RADIATOR DOOR ADJUSTMENT....................
  • Page 369 Section 18: BODY 36.1 LIFTING AND TOWING........................ 75 36.2 TOWING WITHOUT LIFTING....................... 75 SPECIFICATIONS ........................... 77 ILLUSTRATIONS 3-45 ( ) ..........................6 FIGURE TYPICAL 3-41 ( ) ..........................7 FIGURE TYPICAL 3-45 ........................ 8 FIGURE VIP EXTERIOR VIEW ........................16 FIGURE FIBERGLASS REPAIR ........................
  • Page 370 Section 18: BODY .................... 52 FIGURE WINDSHIELD INSTALLATION SIDE VIEW ....................52 FIGURE APPLICATION OF SIKA BLACK ........................53 FIGURE BODY PANEL SPACING ....................54 FIGURE WCL SLIDING DOOR INSTALLATION ......................54 FIGURE WCL UPPER ARM AND RAIL ....................55 FIGURE WCL LOWER RAIL INSTALLATION ..................

  • Page 371: Vehicle Exterior

    Section 18: BODY 1. VEHICLE EXTERIOR FIGURE 1: H3-45 (TYPICAL) 18681 1. Engine air intake 11. 120-volt connector for engine block heater 2. Engine compartment curb-side door 12. Engine compartment rear door 3. Main power compartment (battery 13. Rear-view mirror compartment) 14.
  • Page 372 Section 18: BODY FIGURE 2: H3-41 (TYPICAL) 18682 1. Engine air intake 10. 120-volt connector for block heater 2. Engine compartment curb-side door 11. Engine compartment rear door 3. Main power compartment (battery 12. Rear-view mirror compartment) 13. Spare wheel compartment 4.
  • Page 373 Section 18: BODY FIGURE 3: H3-45 VIP EXTERIOR VIEW 18677 1. Engine air intake 12. Front electrical and service compartment 2. Engine R.H. side access door 13. Driver’s power window 3. Main power compartment 14. Front Slide-out 4. Baggage compartment 15.

  • Page 374: Structure

    Prevost or by an independent decision of the components and should be examined regularly owner, the following information pertaining to for corrosion. Other areas include the front welding should be read before beginning any...

  • Page 375: Preventive Maintenance Schedule

    Section 18: BODY PREVENTIVE MAINTENANCE SCHEDULE Note: TECTYL 185 GW rust inhibitor may have been applied on your vehicle underbody as an option, if this is the case, follow this procedure thoroughly. For future application of product, refer to paragraph 3.3 in this section.
  • Page 376 Section 18: BODY 2.0 Dry all water sprayed parts. Surface temperature and Air pressure system may be used, refer to annex 1 for dew point must be respected before applying rust surface temperature and dew point. inhibitor. 3.0 Front wheelhousing a) Mask all rubber joints.
  • Page 377 Section 18: BODY 3.3 Front wheelhousing (Entire braking system) 4.0 Rear wheelhousing a) Mask all rubber joints. Braking system must also be protected (refer to arrows). Commercial aluminum foil may be used for masking (Entire braking system) 4.1 Rear wheelhousing (Entire braking system) PA1561...
  • Page 378 Section 18: BODY 4.2 Rear wheelhousing (Entire braking system) 4.3 Rear wheelhousing 5.0 Close off wheelhousing using masking paper. Prevent rust inhibitor from coming in contact with paint. To close off wheelhousing, a polythene sheet may be used. 6.0 Apply TECTYL 185 GW black rust inhibitor onto A spray gun and pumping system are required to apply wheelhousing mechanical parts.

  • Page 379: Dew Point

    Section 18: BODY DEW POINT Relative Humidity (%) Temp (c) PA1561...

  • Page 380: Fiberglass Repair

    Section 18: BODY Caution: 4. FIBERGLASS REPAIR Temperature should not exceed F (60 C) during 30 minutes in order to All repairs to fiberglass parts consist of filling the avoid distortion. damaged area with fiberglass cloth and resin or Cut fiberglass cloth with scissors or tin snips, 1 strand fiberglass and resin.

  • Page 381: Typical Fiberglass Repair Procedure

    Section 18: BODY A hacksaw blade, held flat to adjacent contour Apply another mat, followed by a cloth patch, and then moved in a sawing action across the and another mat. All layers must be thoroughly repair when the resin is in a gel state, will impregnated with polyester resin, brushed well remove excess resin from repair.

  • Page 382: New Paint Care

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

  • Page 383: Surface Preparation And Paint Application

    Section 18: BODY 5.3.2 Surface Preparation and Paint Application Aluminum and / or Fiberglass Comments Stainless Steel Sand using P-150 grit sandpaper. It Sand using P-180 or Do not use paint remover is recommended to sandblast rivets Surface Preparation P-240 sandpaper. over aluminum or fiberglass.

  • Page 384: Front Bumper Skin Removal

    (Fig. 9). Let the bumper rest face down on the lifting equipment platform. FIGURE 11: FRONT BUMPER ASSEMBLY Note: A special tool kit is available from Prevost Car Inc: Kit # 410671 including tool #410708. FIGURE 9: BUMPER ATTACHING BOLTS 18498 2.

  • Page 385: Coach Entrance Door

    Section 18: BODY air from cylinder. When entrance door latch is 1. Remove 6 nuts (3 on each side) holding grounded with the door frame, the air lock bumper assembly to vehicle and remove solenoid valve is de-energized and loads the bumper (Fig.

  • Page 386: Emergency Exit Valves

    Section 18: BODY EMERGENCY EXIT VALVES GREASE FITTING From inside the vehicle, an emergency exit valve located near the door on the dash panel, DOOR CYLINDER releases the pressure from the lock cylinders. DOOR HINGE From the exterior, an emergency exit valve DAMPER located in the front service compartment, also DAMPER SUPPORT...

  • Page 387: Horizontal And Vertical Adjustment

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

  • Page 388: Depth Adjustment

    Section 18: BODY FIGURE 19: UPPER DOOR HINGE (COACH) 18058 5. Pull and fasten the rod end to the hinge with the washer and the button screw. 6. Screw the plastic moldings covering the FIGURE 20: DOOR LATCH (COACH) 18059 hinges.

  • Page 389: Troubleshooting

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

  • Page 390: Entrance Door (V.i.p)

    Section 18: BODY 8.2.1 Horizontal and Vertical Adjustments 8. ENTRANCE DOOR (V.I.P) 1. Remove the screws and the plastic molding covering each of the hinges. There are three ways of unlocking the entrance Note: Ask an assistant to help you to perform door from the inside of vehicle.

  • Page 391: Door Lower Section

    1. Slightly loosen the door strikers. 10. Apply Sika #252 (Prevost #682462) compound where it was previously applied. 2. Ask your assistant to press the door from the exterior, until it will adjust with the 11. Remove protective paper from the adhesive vehicle structure.

  • Page 392: Door Lubrication

    Section 18: BODY DOOR LUBRICATION POWER WINDOW REMOVAL 1. Raise the driver's power window. Part Lubricant Frequency 2. Set the battery master switch to the OFF Latches position. temperature Every six months Upper door grease 3. The window must be held in upper position. catch To do so, use duct tape to hold it in place.

  • Page 393: Roof Escape Hatch

    Seal joint should be toward rear of hatch. vehicle. Caution: Ensure that cleaning solutions are 3. Apply rubber adhesive CA-40 (Prevost # compatible with the materials used on the 681285) in the gap between the seal ends. escape hatch. 4. Apply Sikaflex 221 sealant (Prevost #...

  • Page 394: Escape Hatch Panel Assembly

    Section 18: BODY 8. Install the frame in place and fix it with rivets. 9. Remove excess adhesive and clean all around. FIGURE 25: ESCAPE HATCH 18105 10.3 ESCAPE HATCH PANEL ASSEMBLY The frame of the escape hatch is riveted to the roof of the vehicle.

  • Page 395: Repair Or Replacement Of "Tarabus" Floor Covering

    Section 18: BODY 11. REPAIR OR REPLACEMENT OF “TARABUS” FLOOR COVERING “Tarabus” covering installed in H3 coaches may be replaced or repaired. The purpose of this paragraph is to explain the steps to be followed to ensure the best results and adherence. MATERIAL Part No Description...
  • Page 396 Section 18: BODY FIGURE 26: TARABUS FLOOR COVERING ADHESIVE APPLICATION FIGURE 27: APPLICATION OF SIKA 221 GRAY PA1561...

  • Page 397: Front Steps Replacement Procedure

    Section 18: BODY 11.1 FRONT STEPS REPLACEMENT PROCEDURE MATERIAL Part No Description 682989 Anti-silicone 683097 Sika 205 (1 liter) 685101 Sika Remover 208 683916 Sika 215 (1 liter) 684654 Adhesive, Contact (3M) 3.8L 684655 Adhesive, Contact (3M) 18.9L 684517 Sealant, gray 1.
  • Page 398 Section 18: BODY Section D Sika Primer 215 Shake bottle to mix product CHIX cloth Apply a thin layer 3. Allow drying Mandatory Minimum time : 20 minutes After 2 hours : Remove dust using damp cloth (pure water) If surface seems dusty, dust using damp cloth. Before applying any other product If surface seems greasy or with finger marks, reactivate with Aktivator.
  • Page 399 Section 18: BODY GLUING OF WHITE SAFETY STRIP BETWEEN STEP AND “TARABUS” FLOOR COVERING 1. Sand fiberglass using “Scotchbrite”. 2. Clean using tack cloth. 3. Clean twice using anti-silicone (refer to Section A). 4. Protect surfaces around the step with masking tape. 5.

  • Page 400: Welding Of Joint Between White Safety Strip And "Tarabus" Floor

    Section 18: BODY Note: Keep a gap of 1 to 1.5 mm between “Tarabus” covering and white safety strip. 7. Remove masking tape. 11.2 WELDING OF JOINT BETWEEN WHITE SAFETY STRIP AND “TARABUS” FLOOR COVERING 1. Pre-heat welding torch; Set welding torch to position #4.5 (temperature of 500 °C), Heating time: 5 minutes.
  • Page 401 Section 18: BODY 5. Add (about 6 inches) some length to the required length of filler bead to make the joint then cut. 6. Take position with welding torch. The proper position is with a slight slope to the rear. 7.
  • Page 402 Section 18: BODY 10. Shave filler bead to make it level to the floor. Use supplied knife designed for that purpose. Note: To facilitate the cut, you can spray some soapy water onto the joint. Caution: The procedure for turning the torch off must absolutely be followed. If this step is not taken, the element may burn.

  • Page 403: Repair Of A Welded Joint

    Section 18: BODY 11.3 REPAIR OF A WELDED JOINT Note: In wintertime, condensation and cold temperature may greatly influenced bonding parameters. Working area must be at a temperature sufficient to prevent reaching condensation point. Mechanically preheat working area (heat lamp or heat gun) or wait until vehicle reaches room temperature. 1.

  • Page 404: Upholstery Maintenance

    Section 18: BODY Note: 1. Remove 1 nut holding each seat bottom On newer vehicles, the rod consists of a cushion from under the front part of the seat carriage bolt inserted in a square plate sliding in frame. the floor track. Removal is possible only by the front or rear end of track.

  • Page 405: Coach Side Windows

    Section 18: BODY In addition, when it becomes necessary to lay Sponge the suds from the fabric with a clean down the unprotected edges of the glass sponge or cloth moistened with water. Rinse the window, never use a steel or concrete floor sponge or cloth often and change the water support.

  • Page 406: Emergency Exit Window Adjustment

    Section 18: BODY Note: Check the legal twenty pound maximum resistance to be sure to comply with regulations. FIGURE 32: EMERGENCY EXIT WINDOW 18391 13.2.1 Emergency Exit Window Adjustment Emergency exit windows should be checked periodically for easy opening and closing. Pulling the lower part of the release bar with both hands placed near the safety latches should disengage both locks on the window simultaneously.

  • Page 407: Trapezoidal Window Replace-Ment

    Note where adhesives are used and apply • Masking tape; gluing techniques at these areas to complete • Tremshield tape (Prevost #681089); replacement of these windows. • Chix cloths (Prevost #682384); 13.6 SMALL REAR WINDOWS •...

  • Page 408: Electric Awning Window

    Section 18: BODY Note: Use small shims to raise the glass in 7. Install Tremshield tape around the sealing surface of the window opening. proper position. Shims can be cut from the tremshield tape (Fig. 36). FIGURE 36: ADHESIVE-MOUNTED WINDOW 18079 3.

  • Page 409: Operation

    Section 18: BODY As a result, they can be operated regardless of 14.2 WINDOW REMOVAL the state open or close of the master switch. However, the circuit is protected with fuse F41 Replacement awning window does not include a (10A) located in the front service compartment. new motor.

  • Page 410: Actuator Replacement

    Section 18: BODY Actuators Horizontal latch handle Latch guide Proximity sensor Relay Guide Roller Swivelling arm Window pane Window ajar sensor Motor support Releasing bar Releasing bar Guide roller FIGURE 40: ELECTRIC AWNING WINDOW EXPLODED VIEW (SASH) 18583 3. Remove actuator access cover by taking out 14.3 ACTUATOR REPLACEMENT screws #1 (8x).
  • Page 411 Section 18: BODY ELECTRIC AWNING WINDOW – CONVERTER CHECKLIST Check the electrical circuit & A: The latching system will not operate without power. proximity sensor Is there electrical power to the latching circuit? The horizontal latch handle, on the sill sash will be seen to move if there is power on this circuit, or it can be checked with an electrical tester.

  • Page 412: Electric Sliding Window

    Section 18: BODY 15. ELECTRIC SLIDING WINDOW FIGURE 41: ELECTRIC SLIDING WINDOW EXPLODED VIEW Sash Removal 1. Remove the Screen Assembly 2. Pull down on both release latches simultaneously and rotate the sash inwards approximately 10 degrees.(Figure 43) PA1561...
  • Page 413 Section 18: BODY FIGURE 42: REMOVING THE SASH 3. Lift the sash up and out to disengage the bottom of the sash from the window frame. (Figure 42) FIGURE 43: 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 414 Section 18: BODY Lower Cam Sash Stop Follower FIGURE 44: PROPER ALIGNMENT 2. Position the left hand lower corner of the sash over the front cam follower block (Figure 45) FIGURE 45: POSITIONING THE LOWER LEFT CORNER OF THE SASH 3.
  • Page 415 Section 18: BODY Correct Position Incorrect Position FIGURE 46: RELEASE LATCH PROPER POSITION 7. * Failure to confirm this step may lead to the sash becoming disengaged with the frame and could result in personal injury. 8. Operate the window to confirm that it opens and closes properly. Install the screen assembly.

  • Page 416: Windshield

    18098 installing a replacement windshield obtained 3. From inside of vehicle, push against the top from Prevost Parts to ensure proper fit. L.H. side corner of windshield for the Windshields obtained from other sources should removal of a R.H. side windshield. If the L.H.

  • Page 417: Installation Of Rubber Extrusion And Windshield

    Section 18: BODY 7. At the top of windshield, clean surface between fiberglass and rubber extrusion using Sika 205 (Fig. 51). FIGURE 49: WINDSHIELD INSTALLATION USING ROPE FIGURE 51: APPLICATION OF SIKA 221 BLACK 8. Apply Sika 221 black between fiberglass and rubber extrusion.

  • Page 418: Body Panels And Doors

    Section 18: BODY 1. Clean windshield opening sealing 17. BODY PANELS AND DOORS surfaces with Sika 205 and let dry 1 to 2 Each of the doors should be checked for proper minutes. operation. This includes latching. Also, inspect 2. Clean the rubber extrusion with wiping each of the doors for damage, missing, or loose towels soaked with Sika 205 and let dry 1 to parts.

  • Page 419: Adjustment

    Section 18: BODY FIGURE 53: WCL SLIDING DOOR INSTALLATION 18.2 ADJUSTMENT 1. Adjust sliding door height with reference to the side panels and windows. 2. Slide the top rail into the upper arm then bolt the rail to the structure. Do not fully tighten (Refer to fig. 54).
  • Page 420 Section 18: BODY - Push the lower rail towards the outside in order to remove the play between the roller and the lower rail then tighten the rail fixing bolt at the back. FIGURE 55: WCL LOWER RAIL INSTALLATION 5. Adjust the gap between the positioning lugs and their housing, required gap: 0.5 – 1.5mm. Add shims underneath the lugs to get the proper adjustment.
  • Page 421 Section 18: BODY FIGURE 56: WCL SLIDING DOOR OPENING MECHANISM PA1561...

  • Page 422: Baggage Compartment Doors

    Section 18: BODY Note: In case of malfunctioning or in specific situations, use door stoppers to secure the door 19. BAGGAGE COMPARTMENT DOORS in the open position. 19.1 PANTOGRAPH ADJUSTMENT Warning: Park vehicle safely, apply parking brake, stop engine and set batteries master switches to the “OFF”...

  • Page 423: Door Handles

    FIGURE 59: PANTOGRAPH DOOR ADJUSTMENT rises in the same way as the baggage 18062 compartment doors and is held open by three gas-charged cylinders (Prevost # 980024). The engine compartment opens by lifting a handle accessed from the R.H. side of the engine compartment.

  • Page 424: Minor Top Edge Depth Adjustment

    Section 18: BODY 2. With the help of an assistant, pull down one 22. ENGINE AIR INTAKE GRILL side of door while holding up the other side When needed, the engine air intake grill can be to bend the pantograph arms in the desired changed: position;...

  • Page 425: Door Lateral Adjustment

    Section 18: BODY FIGURE 66: PROPER DOOR POSITIONING 23.3 DOOR DEPTH ADJUSTMENT 1. Close radiator door. 2. Check parallelism between radiator door and rear fender (max. 0 ± 2 mm). FIGURE 64: PANTOGRAPH ARM ADJUSTMENT 3. Tighten the bolt. 23.2 DOOR LATERAL ADJUSTMENT FIGURE 67: DOOR DEPTH ADJUSTMENT 3.

  • Page 426: Condenser Door Adjustment

    Section 18: BODY FIGURE 69: DOOR LATCHES ADJUSTMENT 24. CONDENSER DOOR ADJUSTMENT 1. Open the condenser door. 2. Loosen the nuts (1, Fig. 70) holding the hinge (3, Fig. 70) to hinge attachment (4, Fig. 77). Loosening nuts (1, Fig. 70) allows the condenser assembly to be shifted "LEFT or RIGHT"...

  • Page 427: Fuel Filler Door

    Section 18: BODY FIGURE 70: CONDENSER DOOR D280201 25. FUEL FILLER DOOR 26. FRONT SERVICE COMPARTMENT 1. Open the fuel filler door (1, Fig. 71). Adjustment of the front service compartment door can be done by following these steps: 2. Loosen the screws (3, Fig. 71) holding the panel to hinge (2, Fig.

  • Page 428: Latch Mechanism Adjustment

    Section 18: BODY SECTION 8 ± 2 mm SECTION FIGURE 73: FRONT SERVICE DOOR 18195 REF .: 9,5 ± 2 mm 26.1 LATCH MECHANISM ADJUSTMENT FIGURE 72: DOOR HINGE 18194 To adjust the latch mechanism and the striker 7. Loosen screws (5, Fig. 73) to allow the door pin, open the door to access the striker pin.

  • Page 429: Latch Mechanism Adjustment

    Section 18: BODY 7. Adjust the door in accordance with the 3. Move part as shown in figure for "LEFT or required distance between exterior finishing RIGHT" adjustment. parts (Fig. 52). 4. Tighten nut (1, Fig. 76). 8. Loosen screws (4, Fig. 75). 5.

  • Page 430: Main Power Compartment

    Section 18: BODY 41,2 ± 8 ± 2 mm 41 ± 2 mm FIGURE 76: EVAPORATOR DOOR 18198 5. Hinge allows the door to be shifted "IN or OUT". 29. MAIN POWER COMPARTMENT 6. Adjust door panel to have the same gap To adjust the main power compartment door: space as neighboring panels or refer to figure 45 for specified gap space...

  • Page 431: Rear Fender Removal

    It is held in place with bolts and nuts. If it ever it has to be replaced, make 2. Support or have somebody hold the fender an appointment at a Prevost service center near you. 3. As in 1, repeat to release both remaining holding devices.

  • Page 432: Side Panel Installation Procedure For Coaches And Vip

    Section 18: BODY 33. SIDE PANEL INSTALLATION PROCEDURE FOR COACHES AND VIP Material: √ √ Scotchbrite gray (680226) Sika 206 G+P 1 liter (683446) √ Anti-silicone (682989) √ Tack cloth √ CHIX cloth (682384) √ √ Blue cloth (682383) Sika 252 black √...
  • Page 433 Section 18: 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. PR000001 Section D Sika Primer 206 G+P Shake bottle to mix product Apply a thin layer CHIX cloth 3.
  • Page 434 Section 18: BODY 1.15 Seal entrance door perimeter using Sika 252 black, Smooth down the excess. Install lateral panel supports onto bottom 1.20 structural tubing. Install lateral panel onto supports to verify proper positioning. 1.25 Glue application Set (timer) or record time. No more than 45 minutes should elapse between beginning of glue application and panel installation.
  • Page 435 Section 18: BODY Gap between lateral panel and rear cap must be 6mm +4/-3 and panels must be aligned within 1.5mm. Using a ruler, adjust front of lateral panel. Verify if panel upper corner is in the middle of window post. 1.55 Remove excess of glue using a spatula.

  • Page 436: Section #3 Repair

    Section 18: BODY SECTION #2 DRIP MOLDING INSTALLATION Clean using Anti-silicone 2.00 * See SAV000001 section A. Apply Sika 206 G+P See SAV000001 section D. 2.05 Remove blue paper from drip molding. Remove protective tape from double- face self adhesive tape 2.10 Glue drip molding.

  • Page 437: Rear View Mirrors (Ramco)

    Section 18: BODY 34.3 ASSEMBLY 34. REAR VIEW MIRRORS (RAMCO) Mount the mirror arm base to the coach. Insert the ball stem into the mirror arm and Your vehicle is equipped with two exterior tighten the socket setscrews. mirrors. Note: Position the ball cup halves so the joint The mirrors may be equipped with an optional electric...

  • Page 438: Vehicle Jacking Points

    Section 18: BODY adjustment, then push down on either of the Equipment for lifting the rear of the vehicle must button’s (4) sides to adjust the selected mirror have a combined lifting capacity of at least viewing angle. 40,000 lb. (18 200 kg). Warning: DO NOT tow or jack vehicle with 34.5.2 Disassembly...

  • Page 439: Towing The Vehicle

    Section 18: BODY FIGURE 85: 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 81: JACKING POINTS ON FRONT UNDERFRAME –...
  • Page 440 Section 18: BODY • Accelerate Caution: decelerate slowly Do not tow the vehicle without cautiously. external air pressure applied to the emergency fill valve if the engine does not operate. Without brake system air pressure, the brakes may apply automatically if system air drops below 40 Tow eyes psi (275 kPa).
  • Page 441 Section 18: BODY 4. Attach the tow truck chains only in the tow eyes of the vehicle under the bumper and take up all the slack. 5. Attach safety chains as applicable. 6. Observe safety precautions when towing. PA1561...

  • Page 442: Specifications

    37. 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 443 SECTION 22: HEATING AND AIR CONDITIONING CONTENTS HEATING AND AIR CONDITIONING....................5 AIR CIRCULATION WITH CENTRAL HVAC SYSTEM ............... 5 DRIVER’S AREA ..........................5 2.1.1 Coaches only........................... 5 2.1.2 VIP only ........................... 5 PASSENGER’S (CABIN) AREA ..................... 5 AIR CIRCULATION WITH SMALL HVAC SYSTEM ................7 AUXILIARY UNIT..........................
  • Page 444 Section 22: HEATING AND AIR CONDITIONING 9.1.4 Longitudinal Compressor Alignment ..................24 9.1.5 Horizontal Compressor Alignment ..................24 9.1.6 Vertical Compressor Alignment..................... 24 9.1.7 Compressor Maintenance ..................... 25 9.1.8 Troubleshooting Guide ......................25 MAGNETIC CLUTCH ........................26 9.2.1 HVAC Control Unit and Clutch Operation ................26 BRUSHLESS ....................
  • Page 445 Section 22: HEATING AND AIR CONDITIONING 11.8.4 Pilot Solenoid Valve ......................46 11.8.5 Valve Troubleshooting......................46 11.9 HOT WATER RECIRCULATING PUMP..................47 11.9.1 Removal ..........................47 11.9.2 Disassembly .......................... 47 11.9.3 Brushes ..........................47 11.9.4 Assembly ..........................48 11.9.5 Installation ..........................48 11.10 BYPASS SOLENOID WATER VALVE (OPTIONAL) ..............

  • Page 446: Section 22: Heating And Air Conditioning

    Section 22: HEATING AND AIR CONDITIONING ...........................28 FIGURE CONDENSER FANS ......................28 FIGURE C CONDENSER COMPARTMENT ...........29 FIGURE CHECK OF THE MOISTURE INDICATOR AND THE RECEIVER TANK SIGHT GLASS ......................30 FIGURE REFRIGERANT SOLENOID VALVE ..........................31 FIGURE EXPANSION VALVE ......................32 FIGURE SUPERHEAT ADJUST INSTALLATION &...

  • Page 447: Driver's Area

    Section 22: HEATING AND AIR CONDITIONING 1. HEATING AND AIR CONDITIONING Optionally, the coach may be equipped with a defogger/defroster system in the windshield The coach’s interior is pressurized by its upper-section, refer to paragraph: “Central Heating, Ventilation, Conditioning Heating System” for more information. (HVAC) system.
  • Page 448 Section 22: HEATING AND AIR CONDITIONING FIGURE 2: CENTRAL HVAC SYSTEM – PASSENGER’S UNIT AIR CIRCULATION (COACH) 22264 PA1561...

  • Page 449: Auxiliary Unit

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

  • Page 450: Passenger's Unit

    Section 22: HEATING AND AIR CONDITIONING 1. The outside temperature is above 32°F 7263 5658 (0°C). 4441 The passenger's area temperature has 3511 reached 7°F (4°C) under the set point. 2795 2240 NOTE 1806 1465 Upon starting, if the outside temperature is 1195 above 32 °F (0°C) and then drops below...

  • Page 451: Overhead Compartment Unit

    Section 22: HEATING AND AIR CONDITIONING The condenser coil mounted on the opposite side of the evaporator is ventilated by four brushless axial fans. The fan motors are protected by a manual-reset 70 amp circuit breaker (CB 7) mounted in the main power compartment on rear R.H.

  • Page 452: Coil Cleaning

    Section 22: HEATING AND AIR CONDITIONING exception of cleaning their respective coil air filters. NOTE Squeeze rubber hose located under the concerned compartment, to eliminate water and dirt when you make routine maintenance. 6.1 COIL CLEANING Check the external surface of the coil at regular intervals for dirt or any foreign matter.
  • Page 453 Section 22: HEATING AND AIR CONDITIONING MAINTENANCE To clean filter, back flush with water or soapy water, then dry with air every 12,500 miles (20 000 km) or once a year, whichever comes first. CAUTION Do not use high pressure water jet to avoid damaging filter.
  • Page 454 Section 22: HEATING AND AIR CONDITIONING MAINTENANCE NOTE When starting the A/C compressor wait 5 Slide out the filters, then back flush with water, seconds before checking pressures in order to dry with air and replace. This procedure should give the system a chance to build its pressure. be done every 12,500 miles (20,000 km) or During the first 5 seconds after startup, the once a year, whichever come first.

  • Page 455: Particularities

    Section 22: HEATING AND AIR CONDITIONING 7.3 PARTICULARITIES Conditions for engaging the The 2 speed engages if the passenger's area temperature is 1 speed on the evaporator degree above the set point and it revert to speed 1 if the temperature motor (cooling demand).

  • Page 456: Fault Diagnostic

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

  • Page 457: A/C Cycle

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

  • Page 458: Refrigerant

    Section 22: HEATING AND AIR CONDITIONING within the vehicle. All windows and intake It is a good practice to replace the cap after vents should be closed. An opening of each use of the cylinder for the same reason. If approximately 8 in (5162 mm ) could easily...

  • Page 459: Refrigerant System Clean-Out After Compressor Failure

    Section 22: HEATING AND AIR CONDITIONING 8.2.4 Precautions in Handling Refrigerant torque. The O-rings are designed to seal at Lines the specified torque and overtightening the connection does not result in a satisfactory All metal tubing lines should be free of and permanently sealed connection.

  • Page 460: Pumping Down

    Section 22: HEATING AND AIR CONDITIONING Run the unit for 2 hours on high speed cool 7. If the oil is not contaminated, change the only. filter dryer again and replace the moisture- liquid indicator. Check compressor oil level to ensure compressor is not overcharged with oil.
  • Page 461 Section 22: HEATING AND AIR CONDITIONING 3. Disconnect the “Low Pressure Switch” connector (mounted near compressor. 4. Start the engine, press the “Passenger ON/OFF” switch then the A/C switch, and adjust “A/C Temperature” control maximum A/C. 5. Run the compressor until pressure reaches 1-2 psi (7-14 kPa).
  • Page 462 Section 22: HEATING AND AIR CONDITIONING FIGURE 18: CENTRAL HVAC SYSTEM – AIR CONDITIONING 22220 PA1561...

  • Page 463: Evacuating System

    Section 22: HEATING AND AIR CONDITIONING 10. Reinstall the caps at the suction valve take- off points. 8.5 ADDING REFRIGERANT (VAPOR STATE) Use the suction service valve on the compressor 8.6.1 Double Sweep Evacuation Procedure to add a small quantity of refrigerant to the system.

  • Page 464: Charging System

    Section 22: HEATING AND AIR CONDITIONING FIGURE 19: DOUBLE SWEEP EVACUATION SET-UP This will eliminate any possibility of overfilling. A 8.7 CHARGING SYSTEM nominal charge requires 24 pounds (10,9 kg). When a system has been opened or if there are 1.
  • Page 465 Section 22: HEATING AND AIR CONDITIONING 5. Backseat the upper receiver valve by turning out all the way. 6. Remove the cover cap from the service fitting in the top receiver valve. 7. Attach a charging hose to the R-134a tank. Open the tank valve slightly permitting R- 134a to escape thus purging the hose of air.
  • Page 466 Section 22: HEATING AND AIR CONDITIONING NOTE Both belts must always replaced simultaneously to ensure an equal distribution of load on each of them. NOTE Belts specifications may vary. For proper belt selection, always consult your vehicle Coach Final Record. FIGURE 24: BELT PLAY (H3 COACH SHOWN) 9.1.4 Longitudinal Compressor Alignment...

  • Page 467: Compressor Maintenance

    Section 22: HEATING AND AIR CONDITIONING 9.1.8 Troubleshooting Guide A preliminary check may be made by simply feeling the cylinder heads with the unit in operation at ambient temperatures of 35 C) and over. The cylinder heads are internally divided into suction and discharge valves. The lower half of the cylinder head is the suction side, and it should be relatively cool to the touch, as opposed to the hot upper discharge side.

  • Page 468: Magnetic Clutch

    Section 22: HEATING AND AIR CONDITIONING Broken Suction Valves NOTE Symptom: Upon starting, if the outside temperature is above 30 °F (-1°C) and then drops below • Loss of unit capacity at all temperatures. °F (-1°C), the compressor will keep •...
  • Page 469 Section 22: HEATING AND AIR CONDITIONING 4. Remove the motor access panel. the hot refrigerant, it is important to keep the cooling coils and fins clean. A clogged coil will 5. Disconnect electrical motor speed control cause high discharge pressure and insufficient wire (white wire, circuit 2F), power cable and cooling.

  • Page 470: Receiver Tank

    Section 22: HEATING AND AIR CONDITIONING In case of extreme pressure there will be a rise in the liquid receiver tank. A pressure relief valve will break at 450 psi (3103 kPa) and relieve the receiver tank pressure. The receiver tank incorporates an inlet valve on the inlet side (upper section) which allows the tank to be isolated or serviced.

  • Page 471: Moisture Indicator

    Section 22: HEATING AND AIR CONDITIONING handle in a well ventilated area. 9.6.2 Moisture Indicator The moisture sensitive element consists of a color changing ring which is reversible from yellow to green and vice versa as the moisture content in the refrigerant changes. Yellow indicates refrigerant, yellow...

  • Page 472: Valve Disassembly

    Section 22: HEATING AND AIR CONDITIONING 3. Place the new coil and yoke assembly on 9.7.4 Valve Reassembly the enclosing tube. Lay data identification 1. Place the diaphragm in the body with the plate in place. pilot port extension up. 4.
  • Page 473 Section 22: HEATING AND AIR CONDITIONING 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. The spring is adjusted to give 12 to F (-11.1 to -8.8 C) of superheat at the evaporator...
  • Page 474 Section 22: HEATING AND AIR CONDITIONING Example of readings taken at Erreur ! Source du renvoi introuvable.: A/C pressure gauge Temperature on converted to remote bulb temperature at expansion valve fitting Low- High swing swing 40°F(4,4°C) 44°F 54°F (6,6°C) (12,2°C) Formula for superheat Average of low and 49°F-40°F=9°F...

  • Page 475: Driver's System

    Section 22: HEATING AND AIR CONDITIONING Disconnect the external equalizer line from the under side of the power head, and unclamp the remote control bulb from the evaporator coil outlet line. Remove the two cap screws holding the power assembly to the valve body flange. Lift off the power assembly and remove the cage assembly.

  • Page 476: Troubleshooting

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

  • Page 477: Compressor

    Section 22: HEATING AND AIR CONDITIONING 9.10.2 A/C Compressor TROUBLE CAUSE Low suction pressure and frosting at dryer outlet. Clogged filter. Low Oil Level. Check for oil leaks and for leaking oil seal. Do not attempt to check oil level unless system has been stabilized at least 20 minutes.
  • Page 478 Section 22: HEATING AND AIR CONDITIONING TROUBLE CAUSE An evaporator just does a proper cooling job without sufficient air. Shortage of air can be caused by the following: o Dirty filters; or o Dirty coils. Testing condenser pressure. Note: R-134A pressure is function of the temperature variation. Example, for an exterior temperature of 100°F.

  • Page 479: Temperatures & Pressures

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

  • Page 480: Leak Testing

    Section 22: HEATING AND AIR CONDITIONING WARNING 9.12 LEAK TESTING Read the cautionary information in the ICE Some methods such as nitrogen pressure and Compressor Service Manual included at the soap, and electronic sniffer can be used for leak end of this section. testing.

  • Page 481: Evacuating System Prior Addition Of Refrigerant (Driver's Or Auxiliary System)

    Section 22: HEATING AND AIR CONDITIONING 10.3 OIL ADDITION The chart below shows the approximate amount of oil to be added to the system when replacing a component. Component replaced Typical amount of oil Evaporator 50 cm³ (1.7 ozs) Condenser 30 cm³...
  • Page 482 Section 22: HEATING AND AIR CONDITIONING FIGURE 38: SMALL HVAC SYSTEM - AIR CONDITIONING 22344 FIGURE 39: SMALL HVAC SYSTEM - DRIVER'S AND AUXILIARY UNIT 22290 PA1561...
  • Page 483 Section 22: HEATING AND AIR CONDITIONING FIGURE 40: SMALL HVAC SYSTEM 22345 PA1561...
  • Page 484 Section 22: HEATING AND AIR CONDITIONING FIGURE 41: CENTRAL HVAC SYSTEM – HEATING 22262 PA1561...

  • Page 485: Heating System

    Section 22: HEATING AND AIR CONDITIONING 11. HEATING SYSTEM silicone hose from hot water pneumatic valve. The schematics of figure 40 & 41 show respectively, the small HVAC system heating 4. From inside of vehicle, remove the grill and and air conditioning arrangement and the central the access panels.

  • Page 486: Filling Heating System

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

  • Page 487: Bleeding Heating System

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

  • Page 488: Hot Water Pneumatic Valve Disassembly

    Section 22: HEATING AND AIR CONDITIONING maintenance is needed unless a malfunction 11.8.3 Hot Water Pneumatic Valve occurs. Reassembly 1. Assemble the actuator casing, tube, nipple, 11.8.2 Hot Water Pneumatic Valve spindle and closure member. Disassembly 2. Tighten the nipple in place in the body cavity Assemble Shut off air supply pressure and as per Figure 49.
  • Page 489 Section 22: HEATING AND AIR CONDITIONING 11.9 HOT WATER RECIRCULATING PUMP 2. Close shutoff valves on the heater line. Refer to "Preheater System" in this section This vehicle provided with water to gain access to the heater line shutoff recirculating pump which is located in the valve.
  • Page 490 Section 22: HEATING AND AIR CONDITIONING Chips can be caused by improper handling or Install O-ring into housing and assemble installation. Badly chipped brushes should be housing to the adapter. replaced regardless of their length. Secure housing to adapter using 4 Annealed brush spring screws.
  • Page 491 Section 22: HEATING AND AIR CONDITIONING 11.10.2 To Remove or Change the Coil • Stop engine and allow engine coolant to cool. • Close shutoff valve on the line located in the rear electric compartment. Refer "Preheater System" in this section to gain access to the heater line shutoff valve.
  • Page 492 Section 22: HEATING AND AIR CONDITIONING preventing local overheats. Once the delayed cutout time is over, both the combustion air blower and the water circulation pump switch off automatically. A cutout will take place in case of any failure of the preheater.
  • Page 493 Section 22: HEATING AND AIR CONDITIONING WARNING 1. Press button (5) for more than 2 seconds (time display flashes). Preheating system must not operate when 2. Press (8) or (9) button to set the time of day. vehicle is parked inside or during fuel fill stops.
  • Page 494 Section 22: HEATING AND AIR CONDITIONING 4. Press button (8) or (9) to select the correct NOTE startup day of week. If there are no heater faults, the heater will go 5. Wait 5 seconds. The startup day of week is through a normal start cycle and regulate stored.
  • Page 495 Section 22: HEATING AND AIR CONDITIONING Failure Symptom Probable Cause Check and Correct - Fuel system - Fuel level 1X Flash (F 01) No combustion after completion - Type of fuel being used - Fuel filter of start up sequence. - Fuel line connections (air bubbles in fuel lines) - Fuel nozzle plugged - Combustion air...

  • Page 496: Specifications

    Voltage ............................27.6 V DC Current draw ............................. 68 amps Horsepower..............................2 Revolution ........................... 1400 & 1700 rpm Insulation .............................Class F Motor Prevost number......................... 563586 Passenger’s unit condenser fan motors Make............................EBMPAPST Type .........................12” AXIAL BRUSHLESS Voltage .............................. 24 V DC Qty.................................
  • Page 497 Compressor unloader valve Make........................... Carrier Transicold Type ............................Electric (AMC) Voltage ............................. 24 V DC) Watts ................................15 Prevost number (without coil) ......................950095 Coil Prevost numbert........................... 950096 Magnetic clutch Make........................... Carrier Transicold Type ....................Housing mounted 9” dia., 2-B grooves...
  • Page 498 C)................... 5.15 – 5.69 ohms Prevost number........................... 950204 Compressor V belts Make..............................Dayco Model (matching set of 2) ........................BX97 Prevost number (with Delco 270/300 Amp Alternator) ............... 506664 Compressor V belt Make..............................Dayco Model..............................BX100 Prevost number (with two BOSH Alternators) ..................506681 Condenser coil Make...........................
  • Page 499 Section 22: HEATING AND AIR CONDITIONING Watts ................................16 Prevost number (without coil) ......................95-0054 Coil Prevost number..........................950055 Repair kit Prevost number ........................950056 Driver’s & passenger’s hot water pneumatic valve Make...............................BURKERT Type ............................Normally open Voltage .............................. 24 V DC Pressure range..........................
  • Page 500 Section 22: HEATING AND AIR CONDITIONING Fuel consumption...................1,2 US gallons/hr (4,5 liters/hr) Prevost number........................... 871202 PA1561...
  • Page 501 SECTION 23: ACCESSORIES CONTENTS AUDIO AND VIDEO SYSTEM DESCRIPTION..................4 DASHBOARD RADIO........................6 1.1.1 Removal/Installation ........................ 6 VSS-05 SOUND SELECTOR ......................6 1.2.1 Removal/Installation ........................ 6 VD-404 MOBILE DVD PLAYER...................... 7 MULTICHANNEL POWER AMPLIFIER VA400.8 ................7 SPEAKERS ............................ 7 BOOM-TYPE MICROPHONE ......................
  • Page 502 Section 23: ACCESSORIES 7.7.1 Fresh Water Tank Heater (Optional)..................16 7.7.2 Fresh Water Tank Draining ....................16 7.7.3 Fresh Water Tank Filling ....................... 16 LIQUID SOAP DISPENSER ......................17 FLUSH PUSH-BUTTON ....................... 17 7.9.1 Pneumatic Timer Removal and Installation................18 7.9.2 Timer Adjustment ........................
  • Page 503 Section 23: ACCESSORIES ILLUSTRATIONS FIGURE 1: AUDIO-VIDEO PANEL ..........................4 FIGURE 2: AUDIO-VIDEO CONNECTIONS .........................5 FIGURE 3: AUDIO-VIDEO CONNECTIONS .........................6 FIGURE 4: RACKS ON AUDIO-VIDEO PANEL......................6 FIGURE 5: DASDBOARD RADIO..........................6 FIGURE 6: VSS-05 SOUND SELECTOR ........................6 FIGURE 7: VD-404 MOBILE DVD PLAYER ........................7 FIGURE 8:MULTICHANNEL POWER AMPLIFIER VA400.8..................7 FIGURE 9: CROSSOVER ADJUSTMENT........................7 FIGURE 10: 10CM COAXIAL SPEAKER........................8...

  • Page 504: Section 23: Accessories

    Section 23: ACCESSORIES AUDIO AND VIDEO SYSTEM DESCRIPTION The rack mounted components are gathered on the audio-video panel which is located in the first driver’s side overhead compartment (Fig. 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 505 Section 23: ACCESSORIES FIGURE 2: AUDIO-VIDEO CONNECTIONS PA1561...

  • Page 506: Dashboard Radio

    Section 23: ACCESSORIES FIGURE 3: AUDIO-VIDEO CONNECTIONS 1. Place the ignition switch in the ‘’OFF’’ position. 2. Remove the dashboard cover. 3. Unplug the connectors from the radio and unfasten back plate securing nuts/screws. 4. On the front side of the unit, insert the removal tool #20584494 in the holes found each side in order to to separate the unit from the support.

  • Page 507: Mobile Dvd Player

    Section 23: ACCESSORIES 5. From behind, push the unit through the front MULTICHANNEL POWER AMPLIFIER dashboard panel. VA400.8 6. Installation of a new unit is the same as This 400-watt, 6-channels brings an added removal but in reverse order. dimension to your stereo equipment and The operating instructions are included in the increases the total output of the system.

  • Page 508: Boom-Type Microphone

    Section 23: ACCESSORIES 4. Insert spacer block and install mounting screws. 5. Place the battery master switch in the ‘’ON’’ position. HANDHELD PRIORITY MICROPHONE FIGURE 10: 10CM COAXIAL SPEAKER The vehicle may be equipped with two additional Hi-Fi speakers in the driver’s area, mounted one on each side.

  • Page 509: Tv Tuner

    Section 23: ACCESSORIES TV TUNER 1.12 MONITOR 1. Place the ignition switch in the ‘’OFF’’ For TV tuner control descriptions, refer to fig. 14. position. 2. Unfasten the retaining screw located on the monitor R.H. side. 3. Slide the monitor to the right to release it from the mounting bracket.

  • Page 510: Back-Up Camera And Monitor

    Section 23: ACCESSORIES • 4. With SIKA 205, wash the vehicle hole edge Selection of the video sources (CA1 CA1). Press less than 1.5 seconds; and the antenna base surface, wait at least • Selection of the functions e.g. picture setting (after calling up the two (2) minutes for chemical evaporation.
  • Page 511 Section 23: ACCESSORIES TIME - Hour-Month adjustable by UP BUTTON - Minute/Date adjustable by DOWN BUTTON TIME 08:25 - Year adjustable by UP/DOWN BUTTON DATE MAY01 YEAR 2005 For calling up the menu INSTALL press the key MENU once again. The menu TIME appears.

  • Page 512: Hubodometer

    Section 23: ACCESSORIES ° ° HUBODOMETER when temperature is below 35 F (2 C) may be installed. DESCRIPTION On vehicles equipped with cold starting aid, the system consists of the main following parts: An optional wheel hubodometer (Fig. 18) may have been installed on the R.H.

  • Page 513: Preventive Maintenance

    Section 23: ACCESSORIES PREVENTIVE MAINTENANCE at thermal cutout valve from port "Tube from valve". During the summer months, remove cylinder to 3. Actuate the solenoid valve. avoid high temperature actuation of the cylinder safety relief device. Always screw valve cap into •...

  • Page 514: Destination Sign

    Section 23: ACCESSORIES DESTINATION SIGN 1. Push the two (black and yellow) buttons into lock position. This cancels the pre-adjusted stop positions. DESCRIPTION 2. Move the sunshade into the requested The destination sign is located at upper front of upper limit position by using the electric mo- the vehicle.

  • Page 515: Maintenance

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

  • Page 516: Dip Switch Settings

    Section 23: ACCESSORIES wall (over cleaning cabinet), supplies water to the washbasin by gravity. Two tubes are connected in the upper section of tank (Fig. 27). One serves as overflow as well as vent tube and runs along the wall to the underside of the lavatory close to the engine air filter housing, while the other tube is connected to the fresh water fill valve which is mounted besides the...

  • Page 517: Liquid Soap Dispenser

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

  • Page 518: Pneumatic Timer Removal And Installation

    Section 23: ACCESSORIES This timer allows an electric current flow during a assistant to activate the flush pushbutton and preset time to a pump into the sump tank. check the liquid projection while you manually adjust the control valve 7.9.1 Pneumatic Timer Removal and Installation 7.11 SUMP TANK...

  • Page 519: Cleaning Cabinet

    Section 23: ACCESSORIES 7.12 CLEANING CABINET The headlights cleaning system is independent A coiled hose located in the cleaning cabinet from the windshield washer system and has its above the toilet can be used during lavatory own washer fluid reservoir located in the front cleaning.

  • Page 520: Windshield Wipers And Washers

    Section 23: ACCESSORIES The windshield wipers are controlled by two CAUTION electric wiper motors that are accessible for Because they are made of plastic, firmly maintenance after raising the appropriate access tighten nozzle and bulkhead fittings by panel at the front of the coach (refer to figure 32). hand only.

  • Page 521: Wiper Arm

    Section 23: ACCESSORIES motor may occur. If it is necessary to adjust the sweep of blades, remove the arms and make adjustment by positioning the arms using serration on the wiper arm pivot shafts. 10.2.1 Sweep Adjustment On a dry windshield, to avoid possible damage to the arm assembly or wiper motors, hold the wiper arms away from the windshield by inserting a small nail, or other such object,...

  • Page 522: Removal

    Section 23: ACCESSORIES 4. Remove the drive and idler arms or arm 10.2.3 Installation assembly; 1. Make sure the wiper motor is in the stop 5. Relocate the drive arm or arm assembly on position. Lower windshield wiper: position the its knurled pivot shaft to obtain the desired wiper arm on the knurled drive shaft and idler position;...

  • Page 523: Windshield Wiper Motors

    3. Loosen clamping screw retaining the lever at the end of the motor driving shaft. 4. Remove the three bolts holding the motor to the steel plate. 5. Remove the windshield wiper motor (Prevost #800304), reverse removal procedure to reinstall. PA1561...
  • Page 524 Section 23: ACCESSORIES FIGURE 38: LOWER WINDSHIELD WIPER INSTALLATION 23088 PA1561...

  • Page 525: Upper Windshield Wiper Motor Replacement

    Section 23: ACCESSORIES 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 526: Automatic Fire Suppression System (Afss) (Optional)

    – if necessary, clean using a water soaked non-abrasive towel. activated by the operator at any time. • Verify that mounting is secure and Refer to Prevost Operator’s Manual or Owner’s taught. Manual for system operation and operational sequence (fire). Electrical Harness...
  • Page 527 Section 23: ACCESSORIES EVERY 18000 MILES OR SEMI-ANNUALLY (whichever comes first) o Perform a comprehensive fire system test using a Kidde Dual Spectrum System Test Set (Optical Test Kit P/N 420871-2). o Service the extinguisher in accordance with Document 160296, “KDS Pre- Engineered Fire Suppression System: Instal-...
  • Page 528 Section 23: ACCESSORIES FIGURE 40: VIP AUTOMATIC FIRE SUPPRESSION SYSTEM (AFSS) INSTALLATION PA1561...
  • Page 529 Section 23: ACCESSORIES FIGURE 41: VIP NOZZLE BRACKETS AND COMPONENTS IDENTIFICATION AND INSTALLATION FIGURE 42: VIP NOZZLE BRACKETS AND COMPONENTS IDENTIFICATION AND INSTALLATION PA1561...
  • Page 530 Section 23: ACCESSORIES FIGURE 43: H3 COACHES AUTOMATIC FIRE SUPPRESSION SYSTEM (AFSS) INSTALLATION FIGURE 44: H3 COACHES NOZZLE BRACKETS AND COMPONENTS IDENTIFICATION AND INSTALLATION PA1561...
  • Page 531 Section 23: ACCESSORIES FIGURE 45: H3 COACHES NOZZLE BRACKETS AND COMPONENTS IDENTIFICATION AND INSTALLATION PA1561...

  • Page 532: Tire Pressure Monitoring System (Tpms)

    All wheels a) Install Beru valve Torque valve to 44.5lb- in +/- 9.5 b) no extension piece #Prevost 681083 Front axle and tag axle wheels with 365 tires– a) Remove Alcoa valve b) Install Beru valve Torque valve to 102lb-...
  • Page 533 Drive axle inner and outer wheels with 315 tires– a) Remove Alco valve b) Install Beru valve Torque valve to 102lb- #Prevost 651081 in +/- 22 c) no extension piece “Super Single” Tires a) Remove Alcoa valve b) Install Beru valve...

  • Page 534: Beru Sensors Installation

    Section 23: ACCESSORIES 12.2 BERU SENSORS INSTALLATION IMPORTANT NOTE Beru sensors have a limited lifespan (5 years on average) Install sensor onto valve. Torx screw T- 20. Torque to 35lb-in (4Nm) (supplier specification for the screw). Make sure sensor rests against rim flange.
  • Page 535 Section 23: ACCESSORIES 13. SPECIFICATIONS AMPLIFIER Model..............................VA400-8 Output................400 watts, 6 channel RMS at 4 ohm @ 0.5 T.H.D. Prevost number........................... 901191 SOUND SELECTOR Model..............................VSS-05 Power source ............................12 volts Prevost number..........................21116371 DASHBOARD RADIO (standard) Power source ............................12 volts Prevost number...........................
  • Page 536 Section 23: ACCESSORIES 16 CHANNEL WIRELESS MICROPHONE Make............................... R.E.I. Prevost number........................... 900954 16 CHANNEL WIRELESS MICROPHONE CHARGING STATION Make............................... R.E.I. Prevost number........................... 900953 16 CHANNEL WIRELESS MICROPHONE RECEIVER Make............................... R.E.I. Prevost number........................... 900952 KARAOKE Make............................... Panasonic Model......................MOBILE DVD PLAYER DV1500 Prevost number...........................
  • Page 537 Section 23: ACCESSORIES Prevost number........................... 870844 EMERGENCY BUZZER SWITCH (PUSH BUTTON) Make............................. Cole Hersee Co. Voltage ..............................24 V Prevost number........................... 562117 FRESH WATER TANK Make..............................Prevost Capacity ......................... 18 US gal (68 liters) Prevost number........................... 403030 FRESH WATER TANK HEATER Make..............................Hot Watt Wattage ..............................75 watts...

  • Page 538: Section 24: Lubrication

    SECTION 24: LUBRICATION CONTENTS GENERAL RECOMMENDATIONS ....................... 2 ..................... 2 IRST ERVICE EHICLE 1.1.1 Hot Water Filter (H3 Coaches Only) ..................2 OTHER VERIFICATIONS ........................3 .......................... 3 NSPECTIONS 2.1.1 Hose Inspection ........................3 2.1.2 Hose Service Life ........................3 ............................
  • Page 539 Dispose of used lubricants and filters in an environmentally safe manner, according to Report all problems affecting passenger or federal and/or local recommendations. driver safety to a Prevost service center or an authorized service center. Have problems • Understand basic...

  • Page 540: Wheels And Tires

    When special tires parts. Since hose clamps and ties can vibrate are installed by Prevost on a new vehicle, a loose or fail over time, inspect frequently and special tire inflation chart is added next to the tighten or replace as necessary.

  • Page 541: Parking Brake Test

    SECTION 24: LUBRICATION Rim Association Manual. before. Once these commands tested, activate the test mode to check the exterior lighting. SERVICE BRAKE TEST Check for correct pressure build-up. Stop Using the test mode: engine and check pressure gauge Pressure loss should be imperceptible with engine stopped and First, test the functionality of the commands without brake pedal applied.
  • Page 542 SECTION 24: LUBRICATION FIGURE 1: EXTERIOR LIGHTING IDENTIFICATION PA1561 SECTION 24: LUBRICATION (REVISED 05/2010)
  • Page 543 SECTION 24: LUBRICATION WALK-AROUND INSPECTION (BEFORE EVERY TRIP) It is good practice to make a visual inspection of key areas on the vehicle every day (or before every trip for private coaches) and to correct any problem found. FIGURE 2: WALK-AROUND INSPECTION 18667 NOTE Inspect the coach in a circular manner as shown in the illustration.
  • Page 544 SECTION 24: LUBRICATION • Step 6: Front of the Coach Check wiring harness for signs of damage. • Check for damage and clean if dirty. • Check for loose, worn or broken belts. • Check windshield wiper arms for proper •...
  • Page 545 SECTION 24: LUBRICATION and buzzers should all be OFF before driving. • Using the message center display, perform a system diagnostic to check if error codes anomalies were recorded vehicle electronic modules. • Check for proper operation of electric and air horns and back-up alarm. •...
  • Page 546 SECTION 24: LUBRICATION FIGURE 3: LUBRICATION AND SERVICING POINTS ON I-BEAM FRONT SUSPENSION VEHICLES (TYPICAL) 24039 PA1561 SECTION 24: LUBRICATION (REVISED 05/2010)
  • Page 547 SECTION 24: LUBRICATION FIGURE 4: LUBRICATION AND SERVICING POINTS ON INDEPENDENT FRONT SUSPENSION VEHICLES (TYPICAL) 24038 PA1561 SECTION 24: LUBRICATION (REVISED 05/2010)
  • Page 548 SECTION 24: LUBRICATION FLUIDS AND LUBRICANTS SPECIFICATIONS FLUIDS & LUBRICANTS DESCRIPTION SPECIFICATIONS DETROIT DIESEL SERIES 60 SAE Viscosity Grade: 15W-40 API Classification: CJ-4 Engine Oil VOLVO D13 SAE Viscosity Grade: 15W-40 API Classification CJ-4 meeting Volvo specification VDS-4 Power Steering Oil Automatic Transmission Oil, Dexron-III DETROIT DIESEL SERIES 60 Low silicate, ethylene glycol coolant...
  • Page 549 SECTION 24: LUBRICATION LUBRICATION AND SERVICING SCHEDULE For lubrication and servicing schedule, refer to table A. IMPORTANT NOTE Refer to the manufacturers documentation included in this maintenance manual for specific manufacturer’s maintenance requirements. PA1561 SECTION 24: LUBRICATION (REVISED 05/2010)

  • Page 550: Distance Traveled

    DISTANCE TRAVELED (miles / km) LUBRICATION AND SERVICING SCHEDULE proceed to maintenance operation at each GENERAL - 12 ● ● ● Flexible hoses, thoroughly inspect all hoses Front discharge tube, qty:2, check to see if clogged 01 ENGINE ● ● ●...
  • Page 551 DISTANCE TRAVELED (miles / km) LUBRICATION AND SERVICING SCHEDULE proceed to maintenance operation at each 15 12 ● ● ● ● ● ● ● ● ● ● ● ● Coolant surge tank, test coolant solution 15 24 ● DDC S60 - Cooling system, drain, flush and refill 15 12 ●...
  • Page 552 DISTANCE TRAVELED (miles / km) LUBRICATION AND SERVICING SCHEDULE proceed to maintenance operation at each ● Volvo I-Shift Transmission, change fluid & filter ● ZF-Astronic Automatic Transmission, change fluid & filter 11 24 09 PROPELLER SHAFT 31 6 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Grease one fitting on each universal joint and slip joint 10 FRONT AXLE - 12...
  • Page 553 DISTANCE TRAVELED (miles / km) LUBRICATION AND SERVICING SCHEDULE proceed to maintenance operation at each 14 STEERING 4 6 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Drag link ends, grease one fitting at each end 23 6 ●...

This manual is also suitable for:

H3-41 2009H3-41 vip 2009H3-45 2009H3-45 vip 2009

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