PREVOST X3-45 COMMUTER Manuals

Manuals and User Guides for PREVOST X3-45 COMMUTER. We have 2 PREVOST X3-45 COMMUTER manuals available for free PDF download: Maintenance Manual

PREVOST X3-45 COMMUTER Maintenance Manual (744 pages)

Brand: PREVOST | Category: Buses | Size: 31 MB

Section 00: General Information

9
- Table of Contents
  9
- Section Change Log
  10
- Foreword
  11
- Schematics
  11
- Safety Notice
  11
- Data Plates and Certifications
  12
- Engine
  12
- Transmission
  12
- Drive Axle
  12
- Front Axles
  12
- Power Steering Pump
  12
- EPA Engine Label
  13
- Vehicle Identification Number (VIN)
  13
- Safety Certification
  13
- Fuel Tank Label
  13
- DOT Certification Label
  13
- Coach Final Record
  13
- Fastener
  16
- Fastener Strength Identification
  16
- Standard Torque Specifications
  17
- Sae
  17
- Metric
  19
- Self-Locking Fasteners
  21
- Recommendations for Reuse
  21
- Six Lobbed Socket Head
  22
- Hose Clamp Torque
  25
- Welding Process
  26
- Steel - Steel Welding
  26
- Steel with Stainless or Stainless with Stainless Welding
  26
- Steel - Stainless Steel Welding
  27
Table of Contents

31
- Section Change Log
  32
- Power Plant Cradle Installation
  33
- Torque Tables
  33
- Belt Tensioners and Idlers
  34
- System Overview
  35
- Volvo D13 Engine
  35
- Engine Harness
  36
- Engine Overview
  39
- Engine & Exhaust Aftertreatment System Diagram
  41
- Engine Oil
  43
- General
  43
- OBD20 Emission Compliant Volvo Engines Oil Viscosity
  43
- Oil Additives
  43
- Oil Quality
  43
- Oil Change
  44
- Oil Change Intervals
  44
- Oil Consumption
  44
- Synthetic Lubrication
  44
- Oil Filters
  45
- Oil Filters Change
  45
- Checking the Oil Level
  46
- Power Plant Assembly Removal
  47
- Power Plant Assy. Installation
  51
- Engine Mounts
  52
- Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor
  53
- Automatic Belt Tensioners and Idler Pulley Inspection
  54
- Bearing Inspection
  54
- Automatic Belt Tensioner Bushing Wear
  55
- Belts and Idlers Visual Inspection
  55
- Engine Protection Strategy
  56
- Specifications
  57
Section 03 : Fuel System

65
- Section Change Log
  67
- Fuel System
  68
- Miscellaneous Torque
  68
- Torque Tables
  68
- Fuel System
  69
- Davco Fuel Pro 382 Primary Fuel Filter
  70
- Fuel Valve
  70
- Priming Fuel System
  70
- Filter Replacement
  71
- Secondary Fuel Filter
  72
- Secondary Fuel Filter Replacement
  72
- Fuel Pump Removal and Installation
  73
- Drain Plug
  74
- Fuel Lines and Flexible Hoses
  74
- Fuel Tank (Steel)
  74
- Removal
  75
- Fuel Tank Inspection
  76
- Installation
  76
- Fuel Tank Cradle Corrective Measures
  77
- Biodiesel Fuels
  78
- Biodiesel Fuels and the Engine
  78
- Blending
  78
- Fuel Specifications
  78
- Fuel Type
  78
- Air Cleaner (Dry Type)
  79
- Air Cleaner Servicing
  79
- Checking Restriction Indicator
  79
- Replacing the Filter
  79
- Accelerator Pedal
  81
- General Recommendations
  81
- Pedal Adjustment
  81
- Potentiometer Replacement
  81
- Specifications
  83
Section 04 : Exhaust and Aftertreatment

85
- Section Change Log
  86
- Exhaust System
  87
- Torque Tables
  87
- Miscellaneous Torques
  90
- Exhaust Aftertreatment System (Eats) Overview
  91
- Flexible Coupling Installation
  92
- Maintenance
  92
- Diesel Particulate Filter (Dpf)
  93
- Diesel Particulate Filter Assembly Removal
  95
- Removal
  97
- Selective Catalytic Reduction Converter
  97
- Assembling Catalytic Converter
  99
- Diffuser Adjustment
  101
- Diffuser Assembly
  101
- Diesel Exhaust Fluid
  102
- Diesel Exhaust Fluid (Def) Tank and Injection System
  102
- Maintenance
  102
- Def Tank Cleaning
  104
- Filler Neck Strainer
  104
- Pump Assembly Filter Element Replacement
  105
- Aftertreatment Hydrocarbon Doser
  106
- Replacement
  106
Section 05: Cooling System

109
- Section Change Log
  110
- Hose Clamps
  111
- Torque Tables
  111
- Pulleys, Idlers & Tensioners
  112
- Cooling Assembly
  113
- Miscellaneous
  114
- Description
  115
- Coolant Filter Housing Shut-Off Valve - Spindle Servicing
  117
- General Recommandations
  117
- Maintenance
  117
- Hose Clamps on Coolant Lines
  119
- Hoses
  119
- Constant-Torque Hose Clamps on Charge Air Cooler (Cac)
  120
- Maintenance
  120
- Thermostat Operation
  120
- Thermostat Replacement
  120
- Checking New Thermostat
  121
- Coolant
  121
- Coolant Level Sensor
  121
- Coolant Level Verification
  121
- Coolant Recommendations for Volvo D13 Engine
  122
- Thawing Cooling System
  122
- Coolant Sampling
  123
- Draining Cooling System
  124
- Filling Cooling System
  125
- Cooling System Descalers
  126
- Flushing
  126
- Reverse Flushing
  127
- Spin-On Coolant Filter
  127
- Cooling Assembly
  128
- Cooling Fan Replacement
  130
- Maintenance
  130
- Cooling Fan Shroud Removal & Installation
  131
- Cooling Pack (Radiator & Cac) Removal & Installation
  132
- Charge Air Cooler (Cac) in Vehicle Removal
  138
Section 06: Electrical

143
- Section Change Log
  146
- Alternators and Surrounding Components
  147
- Torque Tables
  147
- Electrical Connections - Batteries, Miscellaneous
  148
- General Description
  153
- Using Wiring Diagrams
  153
- Wiring Diagrams
  153
- Testing Circuits
  154
- Wire Identification
  154
- Wire Sizes and Colors
  154
- Circuit Breakers
  156
- Electric Cooling Fan Circuit Breakers
  156
- Main Circuit Breakers on Coaches
  156
- Spare Wires
  156
- VECR/VECF Circuit Breakers
  156
- Multiplex Fuses
  157
- Relays
  157
- Cooling Fan Connections
  158
- Electronic Ground
  158
- Corrosion Inhibitor
  159
- Electronic Modules
  159
- MCM
  159
- Precautions
  159
- Replacing the MCM
  159
- I/O-Ea and I/O-Eb Modules
  160
- Replacing I/O-EA or I/O-EB Modules
  160
- Uploading a Multiplex Program Update into the MCM
  160
- Electronic Modules Connector Pin-Out
  161
- Available Test Modes
  165
- Multiplex Input Test
  165
- Electric Motor Test Sequence
  166
- Test Sequence - Coaches
  167
- Alternator Test
  168
- Cooling Fans Cleaning Mode Validation
  168
- Forced Activation of the Cooling Fans
  168
- Driver Information Display Limp-Home Mode
  169
- Essential Functions to Operate the Vehicle
  169
- Limp-Home Modes
  169
- Lower Priority I/O-Ea & I/O-Eb Modules for Breakdown Service
  169
- Available Functions
  170
- Dl0 (Bbus Mux) Connection on the Telltale Panel and the Hvac Control Unit
  171
- Dl0 (Bbus Mux) Network
  171
- Networks
  171
- Spare Dl0 (Bbus Mux)
  171
- Probing Voltage on the Multiplex Circuits
  172
- Troubleshooting
  172
- Dl0 (Bbus Mux) Network Layout and Troubleshooting
  173
- Multiplex Troubleshooting Table
  178
- Electrical System Diagnostic through the DID
  185
- Electrical Compartments
  186
- Main Power Compartment (Rjb)
  187
- Front Electrical and Service Compartment (Fjb)
  189
- A/C Module
  191
- Engine Rear Start Panel
  191
- Entrance Door & Wiper Control Modules
  191
- Overhead Compartment Module
  192
- Nyct Auxiliary Systems in Parcel Rack
  193
- Batteries
  194
- Battery Installation
  194
- Agm Batteries
  195
- Battery Discharge Protection
  196
- Battery Removal and Installation
  196
- Main Electrical Shut-Off Switch
  196
- Agm Battery Rating
  200
- Battery Testing
  200
- Load Test
  200
- Removing Surface Charge
  200
- Visual Inspection
  200
- Battery Charging
  201
- Seat Usb Power Supply
  201
- Agm Battery Charging Precautions
  203
- Battery Equalization and Agm Batteries
  203
- Emergency Jump Starting
  203
- Cleaning and Inspection
  204
- Common Causes of Battery Failure
  204
- Troubleshooting
  204
- Battery Equalizer
  205
- Battery Voltage Warning" Pictogram
  205
- BATTERY Warning Pictogram MAY Appear as a Reminder
  205
- Supercapacitor Starting Module
  205
- Voltage Gauge Definitions
  205
- Starting Module Status Led
  206
- Starting the Vehicle with Depleted Batteries
  206
- Troubleshooting
  206
- Handling and Storage
  207
- Maintenance
  207
- Components
  208
- Prime Energy Management System
  208
- DID Display
  209
- Vanner 80 Series Battery Equalizer Fault Codes
  209
- Alternator Identification
  210
- Alternator Periodic Inspection
  210
- Alternators
  210
- Identifying a Defective Alternator - Back-Probing AE49 & AE52 Multiplex Modules Method
  210
- Adjustment
  211
- Alternator Drive Belt
  211
- Removal and Installation
  211
- Starter
  212
- Exterior Lighting
  213
- Headlamps
  214
- Led Modules and Turn Signal Module Replacement
  214
- Maintenance
  214
- Directional Turn Signal Replacement
  215
- Headlamp Aim Adjustment
  215
- Low & High Beam LED Module Replacement
  215
- Center Stoplights and Cyclops Light Removal and Replacement
  217
- Lamp Removal and Replacement
  217
- Stop, Tail, Directional, Back-Up, and Hazard Warning Lights
  217
- Clearance and Identification Lights Removal and Replacement
  218
- Clearance, Identification and Marker Lights
  218
- High-Mounted Stop Light Removal and Replacement
  218
- Lamp Removal and Replacement
  218
- License Plate Light
  218
- Baggage Compartment, Main Power Compartment Lights
  219
- Docking and Cornering Lights
  219
- Lamp Removal and Replacement
  219
- Marker Lights Removal and Replacement
  219
- Engine Compartment Lighting
  220
- Perimeter Lights
  220
- Replacement
  220
- Bulb Removal and Replacement
  221
- Control Panel Lighting
  221
- Driver's Area Ceiling Lights
  221
- Instrument Cluster Lights
  221
- Interior Lighting Equipment
  221
- Passenger Section Lighting
  221
- Stepwell Lights
  221
- Switch Lighting
  221
- LED Direct Lighting
  222
- LED Indirect Lighting / Overhead Compartment Interior Lighting
  222
- Removal and Replacement of Reading Lamp Bulb
  222
- Light Bulb Data
  223
Section 07: Transmission

241
- Allison Transmission
  243
- Torque Tables
  243
- Allison Automatic Transmission
  244
- Allison Transmission Maintenance
  244
- Description
  244
- Manual Fluid Level Check
  244
- Retarder
  244
- Cold Check
  245
- Fluid Level Check Using the Pushbutton Shift Selector
  246
- Hot Check
  246
- Recommended Automatic Transmission Fluid
  247
- Coolant Leakage
  248
- Fluid Contamination
  248
- Importance of Proper Fluid Level
  248
- Keeping Fluid Clean
  248
- Metal Particles
  248
- Fluid and Filter Change Information
  249
- Fluid and Filter Change Interval
  249
- Drain
  250
- Fluid and Filter Change Procedure
  250
- Refill Transmission
  250
- Allison Transmission Fluid Cooler Removal
  251
- Allison Transmission Removal
  251
- Breather
  251
- Cleaning and Inspection of Allison Automatic Transmission
  251
- Transmission with Retarder
  251
- Allison Transmission Installation
  253
- Allison Transmission Troubleshooting
  255
- Diagnostic Troubleshooting Codes (Dtc) - Allison 5Th Generation Controls
  255
- Display Sequence
  255
- Using Shift Selector for Accessing Diagnostics Information
  255
- Diagnostic Code Display and Clearing Procedure
  256
- Diagnostic Trouble Code Response
  256
- Exiting Diagnostic Mode
  256
- Diagnostic Troubleshooting Codes (Dtc) List - Allison
  257
- Specifications
  262
Section 09: Propeller Shaft

263
- Standard Torque Specification Tables
  265
- Propeller Shaft Description
  266
- Nyct Propeller Shaft Maintenance Directive
  267
- Lubrication Procedure
  268
- U-Joint Service - Quick Reference Guide
  268
- Inspection Recommendations
  269
- Grease Zerks
  270
- Mark Propeller Shaft (Phasing Marks)
  270
- Other Inspections
  270
- Propeller Shaft Removal
  271
- Removal
  271
- Inspect Companion Flange/Flange Yokes
  272
- Removal Procedure for Universal Joint Kit
  272
- Inspect Tube Yoke and Flange Yoke (if Applicable)
  273
- Removal Procedure for Slip Member Boot
  273
- Installation
  274
- Slip Member and Boot Installation
  274
- Propeller Shaft Installation
  275
- Universal Joint Installation
  276
- Explanation of Common Damages
  277
- Specifications
  278
Section 10: Front I-Beam Axle

279
- Section Change Log
  281
- Front I-Beam Axle and Related Components
  282
- Torque Tables
  282
- Front I-Beam Axle Hub, Rotor and Brakes
  284
- Description
  285
- Reference Manuals
  285
- Lubrication
  287
- Maintenance
  287
- Removal
  288
- Removal and Replacement
  288
- Replacement
  288
- Checking Lateral Slackness
  289
- Checking Vertical Slackness
  289
- Service Instructions for Steer Axle
  289
- Steering Knuckle Kingpin Inspection
  289
- Steering Tie Rod Inspection
  289
- Front Wheel Alignment
  290
- Inspection before Alignment
  290
- Major Front Wheel Alignment
  290
- Minor Front Wheel Alignment
  290
- Turning Angle Adjustment
  290
- Front Wheel Camber
  291
- Hydraulic Stop
  291
- Turn Adjustment
  291
- Camber Check
  292
- Front Axle Caster
  292
- Front Wheel Toe-In
  292
- Inspection and Adjustment
  293
- Alignment Specifications
  294
- Troubleshooting
  295
- Specifications
  296
Section 11: Rear Axles

297
- Section Change Log
  299
- Torque Tables
  300
- Zf A132 Drive Axle
  300
- Tag Axle
  301
- Checking and Adjusting the Differential Oil Level
  302
- Differential Oil Type
  302
- Maintenance
  302
- Zf A132 Drive Axle
  302
- Compact Bearing (Hub Unit) Axial Play Check
  303
- Differential Oil Change
  303
- Compact Bearing (Hub Unit) Grease Change
  304
- Drive Axle Flange Shaft Removal/Installation
  304
- Speed Sensors (Anti-Lock Brake System, ABS)
  304
- Removal and Reinstallation
  306
- Disassembly, Reassembly, Adjustment and Torque Chart
  307
- Procedure
  307
- Zf A132 Drive Axle Alignment
  307
- Removal and Reinstallation
  308
- Removing Tag Axle Along with Suspension Components
  308
- Removing Tag Axle Only
  308
- Tag Axle
  308
- Tag Axle Wheel Bearings
  308
- Unloading Tag Axle
  308
- Removing Transversal Radius Rod
  309
- Tag Axle Alignment
  310
- Specifications
  312
Section 12: Brake and Air System

313
- Section 12: Brake and Air System
  316
- Section Change Log
  316
- Brake and Air System
  317
- Torque Tables
  317
- Miscellaneous Torques
  318
- Air System
  320
- Air Tanks
  320
- Brakes
  320
- Installation
  320
- Wet Tank Automatic Drain Valve
  320
- Emergency/Parking Brakes Overrule Air Tank
  321
- Maintenance
  321
- Ping Tank
  321
- Primary Air Tank
  321
- Wet Air Tank
  321
- Accessory Air Tank
  323
- Kneeling Air Tank
  323
- Secondary Air Tank
  323
- Emergency Air System Fill Valves
  324
- Accessory Air Filter
  325
- Accessory Air Filter Drain
  325
- Accessory Air Filter Element Replacement
  325
- Air Dryer
  326
- Air Gauges (Primary, Secondary and Accessory)
  326
- Replacing the Desiccant Cartridge
  330
- Air Lines
  332
- Haldex Condenser - Separator
  332
- Periodic Inspection
  332
- Air Line Leakage Test
  333
- Air Line Operating Test
  333
- Flexible Hoses
  333
- Maintenance
  333
- Nylon Tubing
  333
- Air Compressor
  334
- Compressor Removal and Installation
  334
- Miscellaneous Valves
  335
- DOB 1300-1556 | X3-45 Commuter PA-1648 Maintenance Manual Section 12 Revised Jan 2021
  338
- Emergency / Parking Brake Control Valve (Pp-1)
  338
- Emergency / Parking Brake Overrule Control Valve (Rd-3)
  338
- Flip-Flop Control Valve (Tw-1)
  338
- Brake Pedal Adjustment
  339
- Dual Brake Application Valve (E-8P)
  339
- Maintenance
  339
- Parking Brake Alarm Switch
  339
- Stoplight Switches
  339
- Antilock Traction Relay Valve (Atr-6)
  340
- Brake Relay Valve (R-14)
  340
- Spring Brake Valve (Sr-7)
  340
- Pressure Protection Valve (Pr-4)
  341
- Pressure Reducing Valve Rv-3
  341
- Shuttle-Type Double Check Valve (DC-4)
  341
- Antilock Modulator (M-32Qr)
  342
- Inline Quick Release Valve (Qr-L)
  342
- Inversion Valve (Tr-2, Tr-3)
  342
- Emergency Door Opening Valves
  343
- Emergency Door Release System Inspection
  343
- Air System Troubleshooting
  344
- Brake Operation
  344
- Disc Brakes
  345
- Inspection Points
  345
- Visual and Functional Check
  349
- Wear Check of Pads
  349
- Wear Check of Disc
  351
- Wear Check of Pad/Disc -Drive Axle - Equipped with L-Bracket Wear Indicator
  352
- Wear Check of Pads/Disc - Front and Tag Axle - Equipped with Visual Wear Indicator
  352
- Checking Correct Functioning of the Adjuster / Checking that Caliper Operates Smoothly over Its Full Range of Movement
  353
- Continuous Wear Sensor Option
  353
- Caliper Check - Caliper Movement Along Guide Pins
  356
- Caliper Check - Caliper Running Clearance
  356
- Clearance Measurement Check of Bearing Variants (6)
  357
- Brake Pad Replacement
  358
- Checking Sealing Elements - Caliper Guide Pin Seals
  358
- Checking Sealing Elements - Tappets and Boot Assemblies
  358
- Air Brake Troubleshooting
  359
- Safe Service Procedures
  359
- Brake Chamber
  362
- Emergency/Parking Brake Manual Release
  362
- Maintenance
  362
- Brake Chamber Disassembly
  363
- Brake Chamber Installation
  363
- Brake Chamber Removal
  363
- Abs Components
  364
- Anti-Lock Braking System (Abs)
  364
- Bendix Ec-80 Controller
  364
- Troubleshooting and Testing
  364
- Sensors
  365
- Spring Clip
  366
- Bendix M-40Qr Pressure Modulator Valve
  367
- Bendix SAS-70 Steering Angle Sensor
  367
- Components
  367
- Removal of the Steering Angle Sensor
  369
- Fitting Tightening Torques
  370

PREVOST X3-45 COMMUTER Maintenance Manual (549 pages)

Brand: PREVOST | Category: Buses | Size: 38 MB

Section 00: General Information

5
- Table of Contents
  5
- Precautions to be Observed before Welding
  6
- Foreword
  6
- Schematics
  6
- Safety Notice
  8
- Data Plates and Certifications
  8
- Safety Certification
  9
- Figure 3: Typical Serial & Model Numbers
  9
- Figure 2: Allison Transmission
  9
- Figure 1: Volvo D13 Engine Data Plate
  9
- Engine
  9
- Coach Final Record
  9
- Power Steering Pump
  9
- Front Axle
  9
- Drive Axle
  9
- Transmission
  9
- Fuel Tank Label
  10
- Vehicle Identification Number (VIN)
  10
- Figure 6: Dot Certification Plate
  10
- Figure 7: Vehicle I.D
  10
- DOT Certification Label
  10
- Figure 8: Vehicle Identification Number
  11
- Fastener Strength Identification
  12
- Figure 9: Thread Notation
  12
- Figure 10: Bolt Strength Markings
  12
- Standard Torque Specifications
  13
- Figure 11: Self-Locking Fasteners
  15
- Self-Locking Fasteners
  15
- Six Lobed Socket Head
  15
- Recommendations for Reuse
  15
- Figure 12: Metric - Us Standard Conversion Table
  17
- Figure 13: Conversion Chart
  18
- Section Change Log
  19
Section 01: Engine

29
- System Overview
  30
- Volvo D13 Engine
  30
- Engine Overview
  34
- Engine Oil
  36
- General
  36
- Oil Change Intervals
  36
- Oil Filters
  36
- Oil Quality
  36
- Oil Additives
  37
- Oil Change
  37
- Oil Consumption
  37
- Oil Viscosity
  37
- Synthetic Lubrication
  37
- Oil Filters Change
  38
- Checking the Oil Level
  39
- Power Plant Assembly Removal
  39
- Power Plant Assy. Installation
  42
- Engine Mounts
  43
- Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor
  44
- Automatic Belt Tensioner Bushing Wear
  46
- Automatic Belt Tensioners and Idler Pulleys Inspection
  46
- Bearing Inspection
  46
- Belts and Idlers Visual Inspection
  47
- Engine Protection Strategy
  47
- Specifications
  48
- Section Change Log
  49
Section 03: Fuel System

51
- Fuel System Description
  53
- Fuel Filters
  54
- Fuel Valves
  54
- Primary Fuel Filter Replacement
  55
- Secondary Fuel Filter Replacement
  55
- Fuel Pump Removal and Installation
  56
- Priming the Fuel System
  56
- Fuel Lines and Flexible Hoses
  57
- Fuel Tank
  57
- Fuel Tank Drain Plug
  58
- Tank Removal
  58
- Fuel Tank Yearly Inspection
  59
- Tank Installation
  59
- Air Cleaner (Dry Type)
  61
- Air Cleaner Servicing
  61
- Biodiesel Fuels
  61
- Blending
  61
- Fuel Specifications
  61
- Fuel Type
  61
- Air Cleaner Restriction Indicator
  62
- Fuel Pedal
  62
- General Recommendations
  62
- Fuel Pedal Adjustment
  63
Section 04: Exhaust and Aftertreatment System

65
- Exhaust and Aftertreatment System Overview
  66
- Maintenance
  66
- Diesel Particulate Filter (Dpf)
  67
- Flexible Coupling Installation
  67
- Diesel Particulate Filter Assembly Removal
  68
- Catalytic Converter
  70
- Removal
  70
- Assembling Catalytic Converter
  71
- Diffuser Adjustment
  73
- Diffuser Assembly
  73
- Maintenance
  73
- Diesel Exhaust Fluid
  74
- Diesel Exhaust Fluid (Def) Tank and Injection System
  74
- Def Tank Cleaning
  75
- Pump Assembly Filter Element Replacement
  75
- Aftertreatment Fuel Injector
  76
- Replacement
  76
- Torque Specifications
  78
- Section Change Log
  81
Section 05: Cooling System

83
- Description
  85
- General Recommendations
  86
- Hose Clamps on Coolant Lines
  86
- Hoses
  86
- Maintenance
  86
- Mta Vehicles Equipped with Volvo D13 Engine
  86
- Checking Thermostat
  88
- Constant-Torque Hose Clamps on Charge Air Cooler (Cac)
  88
- Maintenance
  88
- Thermostat Operation
  88
- Coolant
  89
- Coolant Level Sensors
  89
- Coolant Level Verification
  89
- Coolant Recommendations for Mta Coaches Equipped with Volvo D13 Engine
  90
- Cooling System Recommendations
  90
- Thawing Cooling System
  90
- Coolant Sampling
  91
- Draining Cooling System
  92
- Cooling System Descalers
  93
- Filling Cooling System
  93
- Flushing
  93
- Reverse Flushing
  93
- Spin-On Coolant Filter
  94
- Maintenance
  95
- Radiator
  95
- Radiator Removal & Installation
  95
- Charge Air Cooler Leakage
  98
- Cooling Fan Drive Mechanism
  98
- Drive Pulley and Universal Joint Shaft
  98
- Mounting the Drive Belt
  98
- Idler Replacement
  99
- Variable Speed Fan Clutch
  99
- Electrical Locking
  100
- Locking Fan Clutch for Emergency Operation
  100
- Mechanical Locking
  100
- Oil Change
  101
- Removal / Installation
  101
- Right Angle Gearbox
  101
- Fan Removal and Installation
  102
Section 06: Electrical

105
- General Description
  109
- Using Wiring Diagrams
  109
- Wiring Diagrams
  109
- Live Power Cables Color Code
  110
- Testing Circuits
  110
- Wire Sizes and Colors
  110
- Circuit Breakers
  111
- Cleaning Connectors
  111
- Spare Wires
  111
- Multiplex Fuses
  112
- Precautions
  112
- Relays
  112
- Maintenance
  116
- Rear Electrical Panel, Junction Panel, Battery Compartment & Equalizer
  116
- X3 Series Commuter Coach Electrical Compartment Overview
  116
- A/C Junction Box
  117
- Battery Compartment
  117
- Front Electrical and Service Compartment
  117
- Rear Electrical Panel
  117
- Engine Rear Start Panel
  118
- Entrance Door & Wiper Control Panel
  118
- NYCT Auxiliary Systems and Radio
  118
- Parcel Rack Junction Box
  118
- Batteries
  119
- Motorola Radio Power Mode
  119
- Battery Discharge Protection
  120
- Battery Removal and Installation
  120
- Main Battery Relays
  120
- Battery Maintenance
  122
- Battery Rating
  122
- Visual Inspection
  122
- Battery Charging
  123
- Removing Surface Charge
  123
- Testing Battery Cables
  123
- Booster Block
  124
- Agm Battery Charging Precautions
  125
- Battery Equalization and Agm Batteries
  125
- Common Causes of Battery Failure
  125
- Battery Voltage Warning" Pictogram
  126
- Troubleshooting
  126
- Voltmeter Gauge Definitions
  126
- Components
  127
- Prime Energy Management System
  127
- DID Display
  128
- Electrical System Diagnostic
  128
- Troubleshooting and Testing the Multiplex Vehicles
  128
- Vanner 80 Series Battery Equalizer Fault Codes
  128
- Can Network
  129
- Probing Voltage on the Multiplex Circuits
  129
- Spare CAN
  129
- Motor Test Sequence
  130
- Multiplex Input Test Mode
  130
- Test Sequence
  131
- Can Network Overview
  132
- Forced Activation of the Radiator Fan Clutch
  132
- Multiplex Troubleshooting
  133
- Essential Functions to Operate the Vehicle
  139
- Multiplex Error Messages Troubleshooting List
  139
- Multiplex Module "No Response" Troubleshooting List
  139
- Available Functions
  140
- IO-A Module
  140
- IO-B Module
  140
- Lower Priority Modules for Breakdown Service
  140
- MCM Module
  140
- Multiplex Modules
  140
- Multiplex Modules Replacement
  140
- Replacing IO-A or IO-B Modules
  140
- Replacing the MCM
  141
- Uploading the Vehicle Specific Multiplex Program in the MCM
  141
- Bosch Alternators
  143
- Alternator Drive Belt
  144
- Alternator Periodic Inspection
  144
- Identifying a Single Defective Alternator
  144
- Adjustment
  145
- Battery Charger
  145
- Battery Equalizer
  145
- Curbside Door Fan - Alternator Cooling
  145
- Exterior Lighting
  146
- Maintenance
  146
- Power Inverter
  146
- Starter
  146
- Headlight Adjustment
  147
- Front Turn Signal
  148
- Sealed Beam Unit
  148
- Lamp Removal and Replacement
  149
- Center Stoplights and Center High-Mounted Stop Light (Chsl) Removal and Replacement
  150
- Clearance, Identification and Marker Lights
  150
- Control Panel Lighting
  150
- Interior Lighting Equipment
  150
- License Plate Light
  150
- Switch Lighting
  150
- Gauge Light Bulb Replacement
  151
- Stepwell Lights
  151
- Telltale Light Replacement
  151
Section 07: Transmission

213
- Allison Automatic Transmission
  215
- Description
  215
- Retarder (if Applicable)
  215
- Welding Procedures
  215
- Allison Transmission Maintenance
  216
- Cold Check
  216
- Manual Fluid Level Check
  216
- Fluid Level Check Using the Pushbutton Shift Selector
  217
- Hot Check
  217
- Recommended Automatic Transmission Fluid
  218
- Coolant Leakage
  219
- Importance of Proper Fluid Level
  219
- Keeping Fluid Clean
  219
- Metal Particles
  219
- Oil Contamination
  219
- Allison Recommended Oil and Filter Change Interval
  220
- Drain
  221
- Fluid and Filter Change Procedure
  221
- Oil and Filter Change Interval
  221
- Breather
  222
- Cleaning and Inspection of Allison Automatic Transmission
  222
- Refill Transmission
  222
- Transmission Oil Cooler Removal
  222
- Transmission Without Retarder
  222
- Allison Transmission Installation
  223
- Transmission with Retarder
  223
- Allison Transmission Troubleshooting
  224
- Diagnostic Code Display and Clearing Procedure
  225
- Diagnostic Troubleshooting Codes (Dtc) - Allison 5Th Generation Controls
  225
- Display Sequence
  225
- Using Shift Selector for Accessing Diagnostics Information
  225
- Diagnostic Trouble Code Response
  226
- Exiting Diagnostic Mode
  226
- Diagnostic Troubleshooting Codes (Dtc) List - Allison
  227
- Th Generation Controls
  227
- Specifications
  230
- Section Change Log
  231
Section 09: Propeller Shaft

233
- Propeller Shaft Description
  235
- Nyct Propeller Shaft Maintenance Directive
  236
- U-Joint Service - Quick Reference Guide
  237
- Inspection Recommendations
  238
- Lubrication Procedure
  238
- Grease Zerks
  239
- Mark Propeller Shaft (Phasing Marks)
  239
- Other Inspections
  239
- Propeller Shaft Removal
  239
- Removal
  239
- Inspect Companion Flange/Flange Yokes
  240
- Inspect Tube Yoke and Flange Yoke (if Applicable)
  241
- Removal Procedure for Universal Joint Kits
  241
- Remove Universal Joint Kit
  241
- Installation
  242
- Removal Procedure for Slip Member Boot
  242
- Slip Member and Boot Installation
  242
- Propeller Shaft Installation
  243
- Universal Joint Installation
  244
- Explanation of Common Damages
  245
- Section Change Log
  246
- Specifications
  246
Section 10: Front Axle

247
- Description
  248
- Reference Manuals
  248
- Lubrication
  251
- Maintenance
  251
- Removal
  251
- Removal and Replacement
  251
- Checking Lateral Slackness
  252
- Checking Vertical Slackness
  252
- Replacement
  252
- Service Instructions for Steer Axle
  252
- Steering Knuckle Kingpin Inspection
  252
- Front Wheel Alignment
  253
- Inspection before Alignment
  253
- Major Front Wheel Alignment
  253
- Minor Front Wheel Alignment
  253
- Turning Angle Adjustment
  253
- Front Wheel Camber
  254
- Hydraulic Stop
  254
- Turn Adjustment
  254
- Camber Check
  255
- Front Axle Caster
  255
- Front Wheel Toe-In
  255
- Inspection and Adjustment
  256
- Troubleshooting
  257
- Section Change Log
  258
- Specifications
  258
- Torque Specifications
  258
Section 11: Rear Axles

259
- Checking and Adjusting the Differential Oil Level
  260
- Differential Oil Change
  260
- Differential Oil Type
  260
- Drive Axle
  260
- Maintenance
  260
- Compact Bearing (Hub Unit) Axial Play Check
  261
- Compact Bearing (Hub Unit) Grease Change
  261
- Drive Axle Flange Shaft Removal/Installation
  262
- Speed Sensors (Anti-Lock Brake System, ABS)
  262
- Disassembly, Reassembly, Adjustment and Torque Chart
  263
- Removal and Reinstallation
  263
- Drive Axle Alignment
  265
- Tag Axle
  265
- Retracting Tag Axle
  266
- Unloading Tag Axle
  266
- Grease Lubricated Wheel Bearings
  267
- Removal and Installation
  267
- Removing Tag Axle Along with Suspension Components
  267
- Removing Tag Axle Only
  267
- Retracting Tag Axle for Repair Purposes
  267
- Removing Transversal Radius Rod
  268
- Tag Axle Alignment
  268
- Section Change Log
  269
- Specifications
  269
Section 12: Brake and Air System

271
- Air Reservoirs
  274
- Air System
  274
- Brakes
  274
- Installation
  274
- Wet Tank Automatic Drain Valve
  274
- Accessory Air Tank
  275
- Air System Emergency Fill Valves
  275
- Kneeling Air Tank
  275
- Maintenance
  275
- Parking Brakes Overrule Air Tank
  275
- Ping Tank
  275
- Primary Air Tank
  275
- Secondary Air Tank
  275
- Wet (Main) Air Tank
  275
- Accessory Air Filter
  276
- Air Gauges (Primary, Secondary and Accessory)
  276
- Cleaning
  276
- Filter Element Replacement
  276
- Air Dryer
  277
- Air Dryer Replacement
  278
- Testing the Installation
  278
- Desiccant Cartridge Replacement
  279
- Final Check
  279
- Haldex Condenser - Separator
  279
- Air Line Leakage Test
  280
- Air Line Operating Test
  280
- Air Lines
  280
- Flexible Hoses
  280
- Maintenance
  280
- Nylon Tubing
  280
- Air Compressor
  281
- Maintenance
  281
- Pressure Regulating Valves
  281
- Pressure Setting Procedure
  281
- Compressor Removal and Installation
  282
- Emergency / Parking Brakes Overrule Control Valve (Rd-3)
  282
- Emergency/Parking Brake Control Valve (Pp-1)
  282
- Brake Pedal Adjustment
  283
- Dual Brake Application Valve (E-8P)
  283
- Flip-Flop Control Valve (Tw-1)
  283
- Antilock Traction Relay Valves (Atr-6)
  284
- Brake Relay Valve (R-14)
  284
- Parking Brake Alarm Switch
  284
- Spring Brake Valve (Sr-7)
  284
- Stoplight Switches
  284
- Emergency Bi-Fold Entrance Door Opening Valves
  285
- Pressure Protection Valve (Pr-4)
  285
- Shuttle-Type Double Check Valve (DC-4)
  285
- Air System Troubleshooting
  286
- Brake Operation
  286
- Disc Brakes
  287
- Inspection Points
  287
- Checking Disc Brake Pads
  288
- Drive Axle - Equipped with L-Bracket Wear Indicator
  288
- Pad Replacement Procedure
  288
- Front and Tag Axle - Equipped with L-Bracket Wear Indicator
  289
- Brake Disc
  290
- Brake Pads
  290
- Brake Pads and Discs Minimal Tolerance Limits
  290
- Continuous Wear Sensor
  290
- Caliper Running Clearance
  291
- Safe Service Procedures
  291
- Torque Specifications
  291
- Air Brake Troubleshooting
  293
- Brake Air Chamber
  294
- Maintenance
  294
- Brake Chamber Removal and Installation
  295
- Emergency/Parking Brake Manual Release
  295
- Anti-Lock Braking System (Abs)
  296
- Brake Chamber Disassembly
  296
- Abs Components
  297
- Bendix Ec-60 Advanced Controller
  297
- Sensors
  297
- Troubleshooting and Testing
  297
- Bendix Automatic Traction Control (Atc) - Electronic Stability Control (Esc)
  298
- Spring Clip
  298
- Bendix M-40Qr Pressure Modulator Valve
  299
- Components
  299
- The
  299
- Advanced Abs with Electronic Stability Control (Esc)
  300
- Removal of the Steering Angle Sensor
  301
- Fitting Tightening Torques
  302

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PREVOST X3-45 COMMUTER Manuals

PREVOST X3-45 COMMUTER Maintenance Manual (744 pages)

Table of Contents

Section 00: General Information

Table of Contents

Section 03 : Fuel System

Section 04 : Exhaust and Aftertreatment

Section 05: Cooling System

Section 06: Electrical

Section 07: Transmission

Section 09: Propeller Shaft

Section 10: Front I-Beam Axle

Section 11: Rear Axles

Section 12: Brake and Air System

PREVOST X3-45 COMMUTER Maintenance Manual (549 pages)

Table of Contents

Section 00: General Information

Section 01: Engine

Section 03: Fuel System

Section 04: Exhaust and Aftertreatment System

Section 05: Cooling System

Section 06: Electrical

Section 07: Transmission

Section 09: Propeller Shaft

Section 10: Front Axle

Section 11: Rear Axles

Section 12: Brake and Air System

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