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Section 05: COOLING SYSTEM

Section 05 Updated Sept.2016

X3-45 Commuter PA1593 DOB 2400-2489

5

When installing a new hose, clean pipe
connections and apply a thin layer of a
non-hardening sealing compound. Replace worn
out clamps or clamps that pinch hoses.

3.1 CONSTANT-TORQUE HOSE CLAMPS ON
COOLANT LINES –VOLVO D13

All hose clamps of 1 3/8" ID and over, used on
the heating and cooling systems, are of the

"Constant-torque"

type. These clamps are

worm-driven, made of stainless steel, and
supplied with a series of Belleville spring
washers. They also feature an extended integral
liner that covers the band slots to protect
soft/silicone hoses from damage, and help
maintain consistent sealing pressure.

This type of clamp is designed to automatically
adjust its diameter to compensate for the normal
expansion/contraction of a hose and metal
connection that occurs during vehicle operation
and shutdown. The constant-torque clamp
virtually eliminates coolant losses due to

"Cold

flow"

leakage and greatly minimizes clamp

maintenance.

FIGURE 3: COOLANT FLOW TO RADIATOR (VOLVO D13)

3.1.1 Installation

A torque wrench should be used for proper
installation. The recommended torque is 90 to

100 lbf-in. (10 to 11 Nm). The Belleville spring
washer stacks should be nearly collapsed flat
and the screw tip should extend ¼" (6 mm)
beyond the housing (Fig. 4).

CAUTION

The hose clamps will break if over-torqued.
Do not over-tighten, especially during cold
weather when hose has contracted.

FIGURE 4: CONSTANT-TORQUE CLAMP

05037

3.1.2 Maintenance

The constant-torque clamps contain a

"Visual

torque check

“

feature.

When the tip of the screw

is extending ¼" (6 mm) out of the housing, the
clamp is properly installed and maintains a
leak-proof connection. Since the constant-torque
clamp automatically adjusts to keep a consistent
sealing pressure, there is no need to re-torque
hose clamps on a regular basis. During vehicle
operation and shutdown, the screw tip will adjust
according to the temperature and pressure
changes.

Checking for proper torque should be done
at room temperature.

3.2 CONSTANT-TORQUE HOSE CLAMPS ON
CHARGE AIR COOLER (CAC)

If for any reason such as an accident, hose
clamps need to be changed; install and tighten
hose clamps to 10±1 lbf-ft (dry) (Fig. 5).

CAUTION

The hose clamps will break if over-tighten. Do
not over-tighten, especially during cold
weather when hose has contracted.

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Summary of Contents for X3-45 2016

Page 1: ...COACH MANUFACTURER MAINTENANCE MANUAL X3 45 COACH DOB Bus Number Series 2400 2489 Revision 03 September 2016...

Page 2: ...ectrical System Minor edit 10 Front Axle Addition of steering knuckle exploded view tie rod ends information moved to section 14 Steering 12 Brake And Air System Addition of information regarding brak...

Page 3: ...factory were certified to the U S EPA Greenhouse Gas GHG and National Highway Traffic Safety Administration NHTSA Fuel Efficiency regulations Replacement of these tires should be with a tire of equal...

Page 4: ......

Page 5: ...NER STRENGTH IDENTIFICATION 8 5 1 STANDARD TORQUE SPECIFICATIONS 9 5 2 SELF LOCKING FASTENERS 11 5 3 RECOMMENDATIONS FOR REUSE 11 5 4 SIX LOBED SOCKET HEAD 11 ILLUSTRATIONS FIGURE 1 VOLVO D13 ENGINE D...

Page 6: ...n difference may exist when compared to actual parts or other publications Prevost occasionally sends Maintenance Information Warranty Bulletins Safety Recalls or other literature to update users with...

Page 7: ...ss o Welding rod conforms to A5 1 of AWS American Welding Society specifications E 7018 type welding rod with 1 8 diameter 3 2 mm o Current 100 amperes to 150 amperes optimum at 120 amps It is importa...

Page 8: ...be installed or replaced by new ones where specified If the efficiency of a locking device is impaired it must be replaced This manual emphasizes particular information outlined by the wording and sy...

Page 9: ...ng Pump Power steering pump is mounted on the engine and located underneath the air compressor Fig 5 FIGURE 5 POWER STEERING PUMP 4 1 6 Coach Final Record The Coach Final Record is a record of all dat...

Page 10: ...he side of the fuel tank To read this label unscrew the fuel tank access panel nuts located at the left in the condenser compartment 4 1 10 Vehicle Identification Number VIN The seventeen digit vehicl...

Page 11: ...NFORMATION 7 PA1593 FIGURE 8 VEHICLE IDENTIFICATION NUMBER 00056 YEAR CODE YEAR CODE YEAR CODE 2000 Y 2006 6 2012 C 2001 1 2007 7 2013 D 2002 2 2008 8 2014 E 2003 3 2009 9 2015 F 2004 4 2010 A 2016 G...

Page 12: ...same or greater strength than the original fasteners the same number marking or higher It is also important to select replacement fasteners of the correct size Correct replacement fasteners are avail...

Page 13: ...rance 10 SAE 1 4 20 unc 5 100 lbf in dry SAE 1 4 20 unc 8 143 lbf in dry SAE 1 4 28 unf 5 115 lbf in dry SAE 1 4 28 unf 8 163 lbf in dry SAE 5 16 18 unc 5 210 lbf in dry SAE 5 16 18 unc 8 305 lbf in d...

Page 14: ...C M8 X 1 25 nut 10 screw 10 9 22 METRIC M10 X 1 5 nut 9 screw 8 8 32 METRIC M10 X 1 5 nut 10 screw 10 9 43 METRIC M12 X 1 75 nut 9 screw 8 8 60 METRIC M12 X 1 75 nut 10 screw 10 9 74 METRIC M14 X 2 nu...

Page 15: ...t develops torque per the chart in table two If there is any doubt replace with a new self locking fastener of equal or greater strength e Tighten the fastener to the torque specified in the applicabl...

Page 16: ...Section 00 GENERAL INFORMATION PA1593 12 FIGURE 12 METRIC US STANDARD CONVERSION TABLE 00005...

Page 17: ...Section 00 GENERAL INFORMATION 13 PA1593 FIGURE 13 CONVERSION CHART 00006...

Page 18: ......

Page 19: ...ad screwdriver Ratchet handle 3 8 socket Electric tape Long nose pliers Reference schematics N A Safety rules Wear safety goggles Set the battery master switch to the OFF position first Recommendation...

Page 20: ...ear Electrical Panel and Dashboard Set the battery master switch to the OFF position Place the ignition switch to the OFF position 2 05 Location Rear Junction Panel Lift cover trip circuit breakers CB...

Page 21: ...ith disconnection of the electronic ground terminals disconnecting the engine ECM transmission TCM and the dashboard electronic components telltale module HVAC module radio control head is not require...

Page 22: ...Location Front Electrical Compartment Disconnect the I O A I O B ABS master ID VECU CECM BERU Volvo Link Gsecu modules Disconnect 3 connectors from I O B and I O A modules Disconnect 4 connectors from...

Page 23: ...PROCEDURE NO PR060041 REVISION 01 Page 5 of 7 Disconnect 3 connectors from VECU Disconnect 3 connectors from CECM Disconnect connector A 83 under Volvo Link module...

Page 24: ...Page 6 of 7 2 30 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 2 40 Location Condenser Compa...

Page 25: ...ing on the vehicle ENSURE THAT THE WELDING GROUND RETURN CLAMP IS WELL SECURED AND MAKES A GOOD ELECTRICAL CONTACT WITH A LARGE METALLIC AREA OF THE CHASSIS LOCATED NEAR THE WELDING POINT AS MUCH AS P...

Page 26: ......

Page 27: ...CTRONIC FOOT PEDAL ASSEMBLY EFPA THROTTLE POSITION SENSOR 16 3 SPECIFICATIONS 17 ILLUSTRATIONS FIGURE 1 ENGINE SENSORS LOCATION 5 FIGURE 2 D13F ENGINE TURBO SIDE TYPICAL 6 FIGURE 3 D13F ENGINE ALTERNA...

Page 28: ...rough the instrument cluster display if equipped The Premium Tech Tool PTT is the preferred tool for performing diagnostic work Using a diagnostic computer or PTT connected to the Serial Communication...

Page 29: ...e Sensor is located on the left or right side of the engine EGR Temperature Sensor The EGR temperature sensor detects exhaust gas temperature for EGR system The sensor modifies a voltage signal from t...

Page 30: ...or has a negative temperature coefficient which means the sensor resistance will decrease as the inlet air temperature increases The Intake Manifold Boost Temperature Sensor is located in the intake m...

Page 31: ...Pressure 8 Air Temperature 2 Crankcase Pressure 9 Humidity Ambient Air Temperature 3 Oil Level Temperature 10 Camshaft Speed 4 EGR Differential Pressure 11 Crankshaft Speed 5 EGR Temperature 12 Oil Pr...

Page 32: ...a or Volvo Trucks North America Web Site under Parts Service purchase engine literature D13F engine FIGURE 2 D13F ENGINE TURBO SIDE TYPICAL 1 EGR Valve 8 Coolant Pump 2 Aftertreatment Fuel Injector 9...

Page 33: ...General Keep the engine oil at the proper level and change it at the recommended intervals Always replace the oil filters at the same time as when the oil is changed 1 3 2 Oil Quality Volvo North Amer...

Page 34: ...7 More than 3 7 Total Fuel Consumption L 100 KM Less than 39 Less than 50 Less than 64 Engine Oil and Filter Change Interval miles km 41 U S quarts 39L Oil capacity 35 000 55 000 25 000 40 000 15 000...

Page 35: ...ed in heavy duty operation will consume more oil than one in normal operation 1 3 9 Oil Change WARNING A hot engine or engine oil can be dangerous Serious burns can result from contact with a hot engi...

Page 36: ...the oil filter housing and remove the filters using the oil filter wrench or the oil filter socket FIGURE 5 OIL FILTER WRENCH Prefill the new oil filters with approved engine oil Also lubricate the f...

Page 37: ...EECU as a unit First 1 Shut off the heater line shut off valves 2 Disconnect the battery or batteries from the starting system by removing one or both of the battery cables from each battery system W...

Page 38: ...ply shut off valve on primary fuel filter Disconnect the fuel line located above fuel filters and connected to inlet port Disconnect fuel return line located above fuel filters Disconnect alternators...

Page 39: ...emove surge tank hose connected to pump inlet pipe and hose connected to engine Unfasten and put aside engine compartment lighting fixture and turbocharger fire suppression nozzle if applicable Discon...

Page 40: ...emove bolts B and D Untighten bolts A and C then pivot oil cooler as per figure 12 Install bolts B and D and tighten all bolts 3 Refill cooling system with saved fluid refer to Section 05 COOLANT SYST...

Page 41: ...the front of the engine while two rubber mounts are mounted underneath the engine radiator fan drive mechanism support and the engine alternator support Fig 13 It is recommended that new rubber mounts...

Page 42: ...ing Fig 14 The TPS converts the operator s foot pedal input into a signal for the MCM When installed by the equipment manufacturer the TPS should not require adjustment If the TPS is suspected of bein...

Page 43: ...FICATIONS Volvo D13 Engine Make Volvo Type Diesel four cycle in line direct injection engine Description Turbo Air to air charge cooled No of cylinders 6 Operating range 1400 1800 RPM X3 45 Coaches Pe...

Page 44: ...Limit 34 quarts 32 liters Total Engine Oil Capacity with Filters 41 quarts 39 liters Lubricating oil filter elements Type By pass Prevost number 510938 Type Full Flow Prevost number 488736 Torque spe...

Page 45: ...FUEL LINES AND FLEXIBLE HOSES 7 3 FUEL TANK 7 3 1 TANK REMOVAL 8 3 2 TANK INSTALLATION 8 3 3 FUEL TANK VERIFICATION 8 3 4 POLYETHYLENE FUEL TANK REPAIR 8 4 FUEL SPECIFICATIONS 9 4 1 FUEL TYPE 9 4 2 B...

Page 46: ...O D13 ENGINE 4 FIGURE 3 FUEL LINE COMPRESSION FITTING 4 FIGURE 4 FUEL FILTERS WITH VOLVO D13 ENGINE 5 FIGURE 5 HAND PRIMING PUMP 6 FIGURE 6 FUEL PUMP REMOVAL 7 FIGURE 7 FUEL PUMP DRIVE AXLE 7 FIGURE 8...

Page 47: ...ing through the secondary filter main to a cylinder head longitudinal gallery 8 This channel supplies each unit injector 9 with pressurized fuel by a circular groove around each unit injector in the c...

Page 48: ...ff valve is located at the inlet side of the primary fuel filter FIGURE 2 MANUAL SHUT OFF VALVE VOLVO D13 ENGINE 03088 Shut off valve is designed to prevent loss of fuel prime No manual valve is requi...

Page 49: ...ngine oil to the surface of the water separation bowl 9 Install a new gasket to the water separation bowl and then reinstall the separation bowl to the new primary fuel filter cartridge 10 Apply a thi...

Page 50: ...acing fuel filter cartridges The engine is new or rebuilt CAUTION When priming the system movement of the primer pump should be as up and down as possible Avoid putting any side load on the pump or ca...

Page 51: ...ce of hoses is an important step in ensuring efficient economical and safe operation of engine and related equipment MAINTENANCE Check hoses daily as part of the pre start up inspection Examine hoses...

Page 52: ...result in injury as well as damage to the tank 6 From under the vehicle on R H side unscrew the 4 bolts 2 in front 2 in back retaining the tank support to the frame 7 From under the vehicle on the L H...

Page 53: ...leaner burning diesel engines and vehicles To meet EPA standards the petroleum industry produces Ultra Low Sulfur Diesel ULSD fuel also referred to as S15 containing a maximum 15ppm parts per million...

Page 54: ...ct kerosene with a maximum of 15ppm sulfur Blend rates remain the same as with Low Sulfur Diesel fuel 4 3 BIODIESEL FUELS ULSD B5 biodiesel may be used B5 tells you the percentage of biodiesel mixed i...

Page 55: ...he air cleaner housing the inside surface of the housing must be cleaned with a soft clean cloth 6 Periodically inspect the entire system Dust laden air can pass through an almost invisible crack or o...

Page 56: ...ended 2 Position new potentiometer Press potentiometer onto the potentiometer shaft matching cutouts in shaft to drive tangs of potentiometer Apply hand pressure until potentiometer has bottomed out i...

Page 57: ...Section 03 FUEL SYSTEM PA1593 13 Air Cleaner Restriction Indicator Indicates at 20 508 mm of water Prevost number 530161...

Page 58: ......

Page 59: ...DEF TANK AND INJECTION SYSTEM 9 5 1 DIESEL EXHAUST FLUID 10 5 2 DEF TANK CLEANING 10 5 3 PUMP ASSEMBLY FILTER ELEMENT REPLACEMENT 11 6 AFTERTREATMENT FUEL INJECTOR 12 6 1 REPLACEMENT 12 7 TORQUE SPECI...

Page 60: ...he particulate matter soot in the engine exhaust gases and to reduce NOx To achieve this goal the exhaust aftertreatment system is split into two main sections the exhaust gases first enter the Diesel...

Page 61: ...tion due to overuse of active or stationary regeneration 1 2 FLEXIBLE COUPLING INSTALLATION The flexible coupling contains a rigid interior pipe Fig 2 To allow appropriate flexibility once installed b...

Page 62: ...a closed area like a garage Stationary regeneration must be undertaken outdoors only 2 1 DIESEL PARTICULATE FILTER ASSEMBLY REMOVAL To remove the DPF proceed as follows CAUTION External and internal t...

Page 63: ...to facilitate gaskets positioning For proper DPF assembly installation inlet and outlet alignment is important When reassembling the DPF a straight edge must be used to align inlet and outlet 10 Torq...

Page 64: ...diator assembly it must be adequately supported before attempting to remove it Safely support catalytic converter from the top Disconnect catalytic converter outlet NOx sensor Remove clamps holding ca...

Page 65: ...t any piece of equipment or component that might be in the way or that might prevent removing the catalytic converter 3 2 ASSEMBLING CATALYTIC CONVERTER Before removing Mark with a vertical line the a...

Page 66: ...aust inlet 4 DIFFUSER ASSEMBLY During stationary regeneration exhaust gases temperature may get very hot at the DPF outlet The diffuser decreases the exhaust gasses temperature by about half approxima...

Page 67: ...ide the diffuser housing make sure that it moves freely Make sure that the water drain tube is not clogged Pour a cup of water into the diffuser housing and assure that all the water is drained at onc...

Page 68: ...remove contaminated clothing If urea solution comes into contact with the eyes rinse for several minutes and call for medical help if necessary If inhaled breathe fresh air and call for medical help i...

Page 69: ...EMENT Remove filter cover CAUTION Contamination or damage of the sealing surface on the housing is not acceptable Remove the equalizing element a and the filter element b CAUTION Protect filter area i...

Page 70: ...DIAGNOSTICS menu then FAULT DIAGNOSTICS and ENGINE ECU submenus Check status of the aftertreatment system through the Driver Information Display Select AFTERTREATMENT menu then ATS STATUS Then check t...

Page 71: ...ing to135 lbf in FIGURE 10 FUEL LINE FITTING 7 Install the P clamp and fastener to secure the line to the mounting bracket on the diffuser pipe 8 Start the service regeneration process When fuel dosin...

Page 72: ...Section 04 EXHAUST AND AFTERTREATMENT SYSTEM PA1593 14 7 TORQUE SPECIFICATIONS...

Page 73: ...SECTION 04 EXHAUST AND AFTERTREATMENT SYSTEM PA1593 15...

Page 74: ...Section 04 EXHAUST AND AFTERTREATMENT SYSTEM PA1593 16...

Page 75: ...E DESCRIPTION QTY REFERENCE TORQUE DRY 10 lbf ft DEF injection nozzle mounting bolt 3 1 7 5 DPF outlet temperature sensor 1 2 33 V band clamp 5 inch 7 3 8 NOx sensor 1 4 37 DPF outlet pressure sensor...

Page 76: ......

Page 77: ...T LEVEL SENSOR 7 5 3 THAWING COOLING SYSTEM 7 5 4 COOLING SYSTEM RECOMMENDATIONS 7 5 5 COOLANT RECOMMENDATIONS FOR MTA COACHES EQUIPPED WITH VOLVO D13 ENGINE 7 6 DRAINING COOLING SYSTEM 8 7 FILLING CO...

Page 78: ...OR DRAIN PLUG 11 FIGURE 11 ACCESS PANEL TYPICAL 12 FIGURE 12 RADIATOR SEALING FRAME 12 FIGURE 13 RADIATOR HOSE CLAMPS 12 FIGURE 14 CHARGE AIR COOLER HOSE CLAMPS 12 FIGURE 15 UPPER SUPPORT BRACKET TUBE...

Page 79: ...created by the revolving fan and the motion of the vehicle Upon starting a cold engine or when the coolant is below normal operating temperature the closed thermostat directs coolant flow from the th...

Page 80: ...leaks Make sure the cause of the internal leak has been corrected before flushing the contaminated system Leaks at the thermostat housing hose connections may be caused by deformation of connections...

Page 81: ...stallation A torque wrench should be used for proper installation The recommended torque is 90 to 100 lbf in 10 to 11 Nm The Belleville spring washer stacks should be nearly collapsed flat and the scr...

Page 82: ...r radiator hose to the thermostat housing Position the clamp and tighten to secure 6 Fill the system with the recommended coolant 7 Start the engine check for leaks and proper operation After shutdown...

Page 83: ...veyed through the cylinder walls and the cylinder head into the coolant Without adequate coolant normal heat transfer cannot take place within the engine and engine temperature rapidly rises Coolant m...

Page 84: ...oss of coolant and possible personal injury scalding from the hot liquid 2 Close the shut off valve on the coolant filter mounting head and remove filter perform only if filter as to be replaced 3 Ope...

Page 85: ...NOTE The coolant level should remain within two inches of the surge tank filler neck 4 Install the filler and pressure cap then start the engine and run it at fast idle until reaching normal operating...

Page 86: ...the bottom of the radiator and insert a flushing gun in the hose 4 Connect the water hose of the gun to the water outlet and the air hose to the compressed air outlet 5 Turn on the water and when the...

Page 87: ...ial that the radiator core be kept clean and free from corrosion and scale at all times 10 1 MAINTENANCE MAINTENANCE Inspect the exterior of the radiator core every 25 000 miles 40 000 km or once a ye...

Page 88: ...nfasten 4 cap screws and remove access panel located behind tag axle L H side wheel refer to figure 11 FIGURE 11 ACCESS PANEL TYPICAL 8 Open radiator door to access radiator assembly Unfasten upper ar...

Page 89: ...Y LOWER MOUNTING FASTENERS 15 Cut cable tie and disconnect electrical connector from fan clutch Remove fan drive shaft fasteners at the gear box FIGURE 17 DISCONNECTING FAN DRIVE SHAFT 16 Position a f...

Page 90: ...assembly 11 CHARGE AIR COOLER LEAKAGE Spec for CAC acceptable leakage The CAC is considered acceptable if it can hold 30 psi 206 kpa gauge pressure with less than 5 psi 34 5 kpa loss in 15 seconds aft...

Page 91: ...ng the idler make sure it rests perfectly against the bearing surface on the cast aluminum support If not the drive belt may slip of the idler See following figure FIGURE 24 TIGHTENING SPECIFICATION V...

Page 92: ...te the starter 4 Press the push button one time to engage the clutch to 1st speed press a second time to engage to 2nd speed press a third time to stop the fan press once again to return to 1st speed...

Page 93: ...rs securing fan blade assembly to fan clutch Visually inspect fan driving mechanism fan blade assembly shroud radiator and surrounding area for evidence of contact between rotating and non rotating pa...

Page 94: ...ge intervals is not respected 14 3 REMOVAL INSTALLATION To remove the right angle gearbox proceed as follow 1 Turn the ignition switch and set starter selector switch to the OFF position to prevent ac...

Page 95: ...ase the tensioner slowly and let it return to its natural position COOLING FAN DRIVE BELT With Volvo D13 engine Type 14PK2526 Prevost number 5060097 16 SPECIFICATIONS Cooling System Capacity Approxima...

Page 96: ......

Page 97: ...3 3 BATTERY REMOVAL AND INSTALLATION 12 3 4 BATTERY RATING 13 3 5 BATTERY MAINTENANCE 14 3 5 1 Visual Inspection 14 3 5 2 Removing Surface Charge 14 3 5 3 Testing Battery Cables 14 3 6 BATTERY CHARGIN...

Page 98: ...10 1 2 Maintenance 31 10 1 3 Headlight Adjustment 32 10 1 4 Sealed Beam Unit 33 10 1 5 Front Turn Signal 34 10 2 STOP TAIL DIRECTIONAL BACK UP AND HAZARD WARNING LIGHTS 34 10 2 1 Lamp Removal and Repl...

Page 99: ...IFTING HANDLES 13 FIGURE 17 HYDRAULIC FLOOR CRANE 13 FIGURE 18 ALLIGATOR CLAMPS 15 FIGURE 19 BOOSTER BLOCK 15 FIGURE 20 X3 45 COACHES CAN NETWORK LAYOUT 21 FIGURE 21 IO B MODULE REMOVAL 27 FIGURE 22 A...

Page 100: ...on the vehicle o Glossary o Circuit number listing o Circuit breaker code o Connector code o Diode number code o Resistor number code o Fuse code 1 1 1 Using Wiring Diagrams Three methods are used to...

Page 101: ...l connection 1 2 WIRE SIZES AND COLORS Each wire in the electrical system has a specific size as designated on the wiring diagram When replacing a wire the correct size must be used Never replace a wi...

Page 102: ...e circuit manually to do so simply press down the red tab on breaker to open the circuit repair defective circuit and afterwards depress black button in center of breaker to close the circuit Smaller...

Page 103: ...to the appropriate wiring and pneumatic diagrams prior to working on electrical and or pneumatic systems NOTE When the ignition switch is set to the OFF position the electrical components are not ene...

Page 104: ...31 EXTRACTOR TOOL Prevost 683766 Using a small flat blade screwdriver open both hinged secondary locks Insert the extractor on the front of the connector over the terminal cavity Remove the terminal b...

Page 105: ...se or other product on the multiplex modules connector terminals DANGER Use sprayed sealer in a well ventilated area Do not smoke Avoid prolonged contact with skin and breathing of spray mist 2 2 REAR...

Page 106: ...mpartment provides access to the batteries 2 battery equalizer and master relay R1 FIGURE 9 BATTERY COMPARTMENT 2 6 FRONT ELECTRICAL AND SERVICE COMPARTMENT The front electrical and service compartmen...

Page 107: ...tightly sealed to prevent leaks Water never needs to be added to this type of battery There are no filler caps in the cover The battery is sealed except for small vent holes in the cover The vents mus...

Page 108: ...ctivate these functions for a period of 30 seconds before they switch off again If a prolonged use of the functions with the engine not running is necessary connect the battery to a charger 3 2 MAIN B...

Page 109: ...ed to 13 15 lbf ft 18 20 Nm A torque wrench is required to ensure an accurate tightening torque DANGER To prevent possible electric shock or sparking the battery master switch must be set to the Off p...

Page 110: ...onnections to determine if they are in good condition Excessive resistance generally caused by poor connections produces an abnormal voltage drop which may lower voltage at the starter to such a low v...

Page 111: ...ting or disconnecting booster leads or cable clamps on chargers Poor connections are a common cause of electric arcs which cause explosions 3 The electrical system on this vehicle is negative ground I...

Page 112: ...OFF before connecting and must remain OFF during jump starting 3 Disconnect the jumper cables in reverse order 4 Install protective plug on the booster block terminal DANGER Any procedure other than...

Page 113: ...heck battery equalizer connections Voltmeter exceeds 30 volts dc o Check alternator output o Check voltage regulator o Check battery connections Battery Balance NOTE Allow at least 15 minutes to balan...

Page 114: ...by disconnecting one module zone at a time while verifying if this makes inactive the errors in the modules still connected Connector C1 front electrical service compartment disconnects all the modul...

Page 115: ...Horn selector switch Outside rear view mirror heat Mirror control switches Low buoy switch Starter sensor ABS warning input WCL switch Driver s power window switch Fog lights switch Alternator sensor...

Page 116: ...econds then runs at speed 2 for 2 seconds Hot water pump starts running for 5 seconds and hot water pneumatic valve cycles 3 times 5 beeps from the back up alarm indicate to get to the driver s area i...

Page 117: ...is flipped up to ON and retry cranking 2 Flip the rear start selector switch to Rear Start and start the vehicle from the rear CAN network problem Multiplex Module A53 not powered or is defective Engi...

Page 118: ...of the vehicle from the engine compartment wipers speed 1 flashers etc are functioning Many secondary functions not essential for driving not functioning interior lighting driver s area lighting wipe...

Page 119: ...ooling available in the driver area Module A46 is not powered or is faulty 1 Check the Diagnostics menu of Driver Information Display DID Select Fault Diagnostics and Electrical System The message No...

Page 120: ...nse ModA51 Active indicates a power problem on 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...

Page 121: ...t circuited fire sensor or defective sensor Prior to start the vehicle cycle the ignition key to the ON position OFF position and then ON position again and then start the vehicle This will deactivate...

Page 122: ...IST Multiplex error messages that can be displayed on Driver Information Display DID are alphabetically listed in Section 06B at the end of Section 06 along with FMI Description Fault Condition Possib...

Page 123: ...nel module and other IO A IO B modules When a multiplex module is being replaced the MCM will inform the new module of its role and function accordingly to the vehicle options It keeps the specific ba...

Page 124: ...A laptop computer equipped with VPG Vehicle Program Generator software must be connected to the DB9 9 pin connector identified C226 found in the electrical harness near the MCM Please contact your Pr...

Page 125: ...NOTE Final tightening of the pulleys can be performed once the belt is installed This will help keep the pulley from turning when tightening 5 1 ALTERNATOR BRUSH REPLACEMENT 1 Disconnect the electric...

Page 126: ...following messages MID 188 ELECTRICAL SYSTEM PSID 34 ALTERNATOR 1 FMI 5 OPEN CIRCUIT MID 188 ELECTRICAL SYSTEM PSID 35 ALTERNATOR 2 FMI 5 OPEN CIRCUIT 5 3 ALTERNATOR DRIVE BELT Removal 1 Insert a sock...

Page 127: ...ssembly consists of two 90 mm 3 inch headlamp module the high beam lamp is equipped with a 12 volt halogen bulb the low beam lamp is a 12 volt LED lamp The turn signal lamp is a 100 mm 4 inch 12 volt...

Page 128: ...s shall be spaced either side of the fixed centerline on the screen by the lateral distance between the light source centers of the pertinent headlights The horizontal tapes should be located on the s...

Page 129: ...1 4 Sealed Beam Unit Bulb Removal and Replacement 1 Pull the release handle located inside the front service compartment to tilt down the entire bumper assembly 2 Remove the headlight screw fixing th...

Page 130: ...simultaneously with the stoplights on the sides for increased safety The L H and R H side center stop lights are also used as directional signal and marker lights The stop tail directional signal and...

Page 131: ...ccording to the application 11 1 1 Switch Lighting 1 Slightly pull the switch with a defective LED away from the control panel 2 Disconnect the electric cable from the switch 3 To install a new switch...

Page 132: ...lb 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 11 4 ENGINE COMPARTM...

Page 133: ...roximate weight wet dry 130 80 Torque specifications Battery cable to post 10 15 Ft lbs 13 20 Nm Alternator Make BOSCH Series HD 10 Amperes 120 Volts 28 4 Output Power 3 Kw Ground negative Prevost Num...

Page 134: ......

Page 135: ...24 Nyogel Grease Grease type product It is used to facilitate connectors or terminals insertion Refer to table for proper use of Nyogel grease It is preferable to apply Nyogel into the female part of...

Page 136: ...nectors except those specified in this zone X Nothing A Front Service Compt All connectors except those specified in this zone X Nothing B Rear Electrical panel Customer Terminal Block X Nothing B Rea...

Page 137: ...odule X Nothing D Battery Compt All connectors except those specified in this zone X Nothing D Battery Compt Battery Equalizer X Kent E Condenser Compt Fuel sender X Kent E Condenser Compt Structure G...

Page 138: ...e Interior Audio video Connection X Nothing I Vehicle Interior Defrost Compt Ground X Kent I Vehicle Interior Video Plate Direct Ground X Nothing I Vehicle Interior Structure Ground X Kent I Vehicle I...

Page 139: ...ailure Connector C91 corroded Circuit 77BA shorted to ground FMI 5 Open Circuit A52 module does not detect A C clutch So9 A C clutch not working A52 module failure So9 open circuit Se29 failure Circui...

Page 140: ...A42 module failure Sw142 failure Connector C71 corroded Connector C171 corroded Circuit AuxBP shorted to battery FMI 4 Shorted Low Voltage below normal on A42 J1 10 Aux bypass switch always ON A52 mo...

Page 141: ...ult FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage above normal on A45 J1 14 Brake interlock pressure not displayed on dash A45 module failure Se77 failur...

Page 142: ...Connector C45 corroded Circuit 35 shorted to battery FMI 4 Shorted Low Output A44 J1 5 shorted to ground L17 not working A44 module failure Connector C45 corroded Circuit 35 shorted to ground FMI 5 Op...

Page 143: ...age present on output A50 J1 8 but output not active L67 and L69 always ON A50 module failure Connector C21 corroded Connector C58 corroded Connector C15 Corroded Circuit 46B shorted to battery FMI 4...

Page 144: ...rnal software fuse active for overcurrent Condenser fans always ON speed 2 A49 module failure Condenser motors failure Connector C21 corroded Connector C58 corroded Circuit 2B shorted to ground MID 18...

Page 145: ...nd FMI 5 Open Circuit A47 module does not detect Defroster Speed Ctrl A24 Defroster fans Mo24 and Mo25 on full speed A47 module failure A24 module failure Circuit 86 open FMI 6 Current above normal Ou...

Page 146: ...igh Voltage above normal on A55 J1 5 Driver Light not working A55 module failure Sw24 failure Circuit 39 shorted to battery FMI 4 Shorted Low Voltage below normal on A55 J1 5 Driver light always ON A5...

Page 147: ...Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage above normal on A54 J1 13 Following message appears on the DID PSID 26 PASS SENSOR psid 26 188 pass sensor Out of range A54...

Page 148: ...J1 4 internal software fuse active for overcurrent Recirculation mode not working Low A C performance A47 module failure Circuit 65D shorted to ground LH L283 or RH L203 low resistance value MID 188...

Page 149: ...m not working A36 module failure Relay R21 open circuit Circuit 911 open FMI 6 Current above normal Output A36 JA 24 internal software fuse active for overcurrent Emergency cutout system not working A...

Page 150: ...detect radiator fan clutch Mo2 Radiator fan clutch Mo2 not working on speed 1 A52 module failure Radiator fan clutch Mo2 open circuit Circuit 291 open FMI 6 Current above normal Output A52 J1 1 inter...

Page 151: ...e failure Se76 failure Connector CXC1 corroded Circuit 3 shorted to battery FMI 4 Shorted Low Voltage below normal on A47 J1 10 Entrance door cannot be closed with switch A47 module failure Se76 failu...

Page 152: ...ground MID 188 PSID 67 Ent Open Sol A47 J1 7 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A47 J1 7 but output not activ...

Page 153: ...ssible Causes FMI 3 Shorted High Voltage present on output A54 J1 7 but output not active Evaporator fan always ON A54 module failure Evaporator Relay R12 failure Circuit 67 shorted to battery FMI 4 S...

Page 154: ...rent Foot damper Mo4 not working A45 module failure Connector C72 corroded Circuit 65A shorted to ground MID 188 PSID 137 FR Clearance lights A44 J1 8 Type of fault FMI Description Fault Condition Pos...

Page 155: ...dule failure Circuit 23AA shorted to ground MID 188 PSID 58 Fr Start Sw A36 JB 22 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on...

Page 156: ...output A48 J1 7 but output not active Front Flasher RH L61 and Marker L63 always ON A48 module failure Connector C243 corroded Circuit 46 shorted to battery FMI 4 Shorted Low Output A48 J1 7 shorted...

Page 157: ...8 HdLamp Wsh Pmp A46 J1 21 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A46 J1 21 but output not active Headlamp washer...

Page 158: ...rcuit 57L shorted to battery FMI 4 Shorted Low Output A45 J1 6 shorted to ground LH High beam Headlamp L60B not working A45 module failure Connector C4 corroded Connector C242 corroded Circuit 57L sho...

Page 159: ...and L186 not working A45 module failure Electrical horn L185 or L186 open circuit Circuit 52A open FMI 6 Current above normal Output A45 J1 20 internal software fuse active for overcurrent Electrical...

Page 160: ...roded Circuit 12W shorted to ground MID 188 PSID 93 Knee Down Sw A41 J1 7 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on input A4...

Page 161: ...rcuit A52 module does not detect Air Exhaust Fan Mo14 Air Exhaust Fan Mo14 not working A52 module failure Air Exhaust Fan Mo14 open circuit Circuit 225 open FMI 6 Current above normal Output A52 J1 4...

Page 162: ...uit 82Low shorted to ground MID 188 PSID 181 Lower Washer pmp A46 J1 3 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 4 Shorted Low Output A46 J1 3 shorted to grou...

Page 163: ...ing A42 module failure Connector C70 corroded Connector C25A corroded Circuit 4C shorted to battery FMI 4 Shorted Low Input A42 J1 9 shorted to ground Next Stop Request always ON A42 module failure Co...

Page 164: ...ith Inside switches A44 module failure Connector C72 corroded Circuit 2mph shorted to ground MID 188 PSID 19 P Rack Fan A54 J1 1 Type of fault FMI Description Fault Condition Possible Symptoms Possibl...

Page 165: ...ge present on input A36 JB 9 Parking Brake sensor not working Vehicle ECU failure A36 module failure Connector C4 or C48 corroded Circuit 91 shorted to battery FMI 4 Shorted Low Input A36 JB 9 shorted...

Page 166: ...lay R26 not working A54 module failure Pre Heat relay R26 open circuit Circuit 13 open FMI 6 Current above normal Output A54 J1 21 internal software fuse active for overcurrent Pre Heat relay R26 not...

Page 167: ...3 Shorted High Voltage present on output A54 J1 4 but output not active Pass Water pump always ON A54 module failure Water pump relay R20 failure Connector C9 corroded Circuit 57G shorted to battery...

Page 168: ...Voltage present on input A41 J1 10 but switch Sw26 not active Reading Lights not working A41 module failure Reading Lamp Switch Sw26 failure Connector C71 corroded Circuit 74 shorted to battery FMI 4...

Page 169: ...Transmission ECU failure A50 module failure Connector C717 corroded Circuit 125 shorted to battery FMI 4 Shorted Low Input A50 J1 12 shorted to ground Retarder active lamp always ON A50 module failure...

Page 170: ...ng rear start switch Sw59 will not function A53 module failure Rear Start Selector Switch Sw58 failure Connector C91 corroded Circuit 85D shorted to ground MID 188 SID 49 Ser Brake Trans A51 J1 1 Type...

Page 171: ...d Circuit 35 shorted to battery FMI 4 Shorted Low Output A47 J1 5 shorted to ground Step Lights L18 L19 or L20 not working A47 module failure Connector C63 corroded Circuit 35 shorted to ground FMI 5...

Page 172: ...smission Shifting not working A50 module failure Connector C717 corroded Circuit 185 shorted to ground FMI 5 Open Circuit A50 module does not detect Transmission ECU Transmission Shifting not working...

Page 173: ...cription Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A52 J1 21 but output not active Unloader RH L199 always ON A52 module failure Connector C91 or C...

Page 174: ...Upper Defrost RH Heater Res37 failure Circuit 5B open FMI 6 Current above normal Output A46 J1 2 internal software fuse active for overcurrent Upper Defrost RH Heater Res37 not working A46 module fail...

Page 175: ...07 not working A53 module failure WCL Door open Relay R47 failure Connector C27 C31 or C29 corroded Circuit 304 shorted to ground FMI 6 Current above normal Output A53 J1 5 internal software fuse acti...

Page 176: ...SECTION 06B ELECTRICAL 38 overcurrent working Circuit 306 shorted to ground...

Page 177: ...e not responding on CAN network A43 module all inputs and outputs not responding CAN network open Address Jumper open circuit Fuse F12 or F13 defective MID 188 PSID 219 A44 MODULE NO RESPONSE Type of...

Page 178: ...le all inputs and outputs not responding CAN network open Address Jumper open circuit Fuse F33 or F34 defective Relay R19 defective A C JUNCTION BOX MODULE MID 188 PSID 229 A54 MODULE NO RESPONSE Type...

Page 179: ...MODULE NO RESPONSE Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 2 Data Error A51 Module not responding on CAN network A51 module all inputs and outputs not resp...

Page 180: ......

Page 181: ...SSION INSTALLATION 13 8 ALLISON AUTOMATIC TRANSMISSION TROUBLESHOOTING 14 8 1 4TH GENERATION TRANSMISSION CONTROL MODULE 14 8 2 DIAGNOSTIC TROUBLESHOOTING CODES DTC ALLISON 4TH GENERATION CONTROLS 15...

Page 182: ...ed loop adaptive logic the electronic control looks at a number of parameters during the shift and makes minute adjustments to match the shift to desired profile stored in its memory It then looks at...

Page 183: ...y of the reading If inconsistent readings persist check the transmission breather to ensure it is clean and free of debris 3 1 1 Cold Check The purpose of the Cold Check is to determine if the transmi...

Page 184: ...til it stops 4 Remove the dipstick and observe the fluid level The safe operating level is anywhere within the HOT RUN band on the dipstick Repeat the check procedure to verify the reading 5 If the le...

Page 185: ...TANCE OF PROPER FLUID LEVEL It is important that the proper fluid level be maintained at all times because the transmission fluid cools lubricates and transmits hydraulic power If the fluid level is t...

Page 186: ...This however may also indicate leakage from the engine oil system 3 7 METAL PARTICLES Metal particles in the oil except for minute particles normally trapped in the oil filter indicate damage has occu...

Page 187: ...econds while the Oil Life Monitor function is displayed It may also be reset by selecting N D N D N R N on the shift selector pausing briefly less than 3 seconds between each selector movement with th...

Page 188: ...main on steady during all vehicle operation until service is performed and the indicator is reset Failure to perform maintenance and reset the monitor after a number of warnings will result in the ill...

Page 189: ...l vehicles equipped with a retarder and using High Capacity Filters Fluid Filters Main Internal Lube Auxiliary 150 000 Miles 240 000 km 48 Months 6000 Hrs 75 000 Miles 120 000 km 36 Months 3000 Hrs Ov...

Page 190: ...Monitor of the Prognostics mode provide indicators of required maintenance actions They are designed to maximize fluid and filter utilization Prognostics enabled requires the use of 100 TranSynd or a...

Page 191: ...ies listed above are approximations and do not include external oil cooler lines Using the oil level dipstick filler tube refill with 24 US qts 23 liters 28 US qts 26 5 liters if equipped with retarde...

Page 192: ...plate attaching screws Remove the plug located below starter motor and install cranking tool 88800014 Cranking the engine to gain access to the attaching screws may be done by turning the cranking to...

Page 193: ...are when removing the hose connector from transmission to prevent the entry of foreign matter 7 ALLISON TRANSMISSION INSTALLATION NOTE For more clearance between the tag axle and transmission the tag...

Page 194: ...ulator is located in the engine compartment on engine cradle R H side Fig 9 19 Make sure that the drain plug is in place and then remove the transmission dipstick and pour approximately 24 US quarts 2...

Page 195: ...ay automatically delete a code from memory if it has not recurred If the MODE INDICATOR LED is not illuminated the displayed code is not active An illuminated MODE INDICATOR LED during normal operatio...

Page 196: ...as normal Have the transmission checked at the earliest opportunity by an Allison Transmission distributor or dealer NOTE All active indicators are cleared at TCM power down Some codes will clear the...

Page 197: ...electrically cause them to be on hydraulically RPR Return to Previous Range Response When the speed sensor ratio or C3 pressure switch test associated with a shift not successful the TCM commands the...

Page 198: ...throttle values P063F Auto Configuration Engine Coolant Temp Input Not Present No None P0658 Actuator Supply Voltage 1 HSD1 Low Yes DNS SOL OFF hydraulic default P0659 Actuator Supply Voltage 1 HSD1 H...

Page 199: ...P0842 Transmission Pressure Switch 1 Circuit Low Yes DNS Lock in current range P0843 Transmission Pressure Switch 1 Circuit High Yes DNS Lock in current range P0847 Transmission Pressure Switch 2 Circ...

Page 200: ...L OFF hydraulic default P2686 Actuator Supply Voltage 3 HSD3 High Yes DNS SOL OFF hydraulic default P2714 Pressure Control Solenoid 4 PCS4 Stuck Off Yes DNS RPR P2715 Pressure Control Solenoid 4 PCS4...

Page 201: ...lutch with torsional damper Integral standard Gearing Type Patented constant mesh helical planetary Ratio First 3 51 1 Second 1 91 1 Third 1 43 1 Fourth 1 00 1 Fifth 0 74 1 Sixth 0 64 1 Reverse 4 80 1...

Page 202: ......

Page 203: ...RIPTION 2 2 REMOVAL DISASSEMBLY REASSEMBLY AND INSTALLATION 2 3 CLEANING INSPECTION AND LUBRICATION 2 3 1 CLEANING AND INSPECTION 2 3 2 LUBRICATION 2 4 EXPLANATION OF COMMON DAMAGES 4 5 TROUBLESHOOTIN...

Page 204: ...olts to the specified torque Fig 1 3 CLEANING INSPECTION AND LUBRICATION 3 1 CLEANING AND INSPECTION Thoroughly clean grease from bearings journal lubricating grease fittings and other parts Needle be...

Page 205: ...Section 09 PROPELLER SHAFT PA1593 3 FIGURE 1 PROPELLER SHAFT ASSEMBLY 09002...

Page 206: ...g can lead to surface wear and eventual failure 5 Brinelling Surface wear failure due to the wearing of grooves in metal It is often caused by improper installation procedures Do not confuse the polis...

Page 207: ...SPECTION BEFORE ALIGNMENT 6 6 2 MINOR FRONT WHEEL ALIGNMENT 6 6 3 MAJOR FRONT WHEEL ALIGNMENT 7 6 4 TURNING ANGLE ADJUSTMENT 7 6 4 1 R H Turn Adjustment 7 6 4 2 L H Turn Adjustment 7 6 5 HYDRAULIC STO...

Page 208: ...manufactured by KNORR BREMSE Steering ball joints with hardened balls and rubbing pads incorporate compression springs which automatically take up any wear The tie rod simplifies toe in adjustment Th...

Page 209: ...5 375 lbf ft 12 36 Bottom Steering Lever Stud 4 12 Nut Self Lock 133 155 lbf ft 4 37 Abs Sensor Bush 2 13 Brake 1 38 Back Lock Stop Bolt 85 103 lbf ft 2 14 Brake Chamber 2 Front Lock Stop Bolt 85 103...

Page 210: ...EMOVAL 1 Raise the vehicle by its jacking points on the body see Section 18 Body under heading 16 Vehicle Jacking Points until vehicle body is approximately 30 inches 760 mm from the floor Place jack...

Page 211: ...l loading While this is being carried out the brake must be applied Upper Bushing Lateral Inspection 1 Mount dial indicator on the axle Reference the upper part of the steering knuckle 2 Move the tire...

Page 212: ...o correct a tire wear condition There are two types of front wheel alignment minor alignment and major alignment 6 1 INSPECTION BEFORE ALIGNMENT Check the following before doing a front wheel alignmen...

Page 213: ...e or if the steering gear has been serviced Proceed with the following method to check the steering maximum turning angle 6 4 1 R H Turn Adjustment CAUTION To prevent the steering damper from interfer...

Page 214: ...ins 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...

Page 215: ...icle front wheels are closer together than the rear part measured at wheel centerline height with the wheels in the normal straight ahead position of the steering gear Incorrect toe in results in exce...

Page 216: ...uts and bolts on each tie rod end b Turn the tie rod until the specified toe in measurement is obtained c Tighten the pinch bolt nuts alternately and progressively to 65 75 lbf ft 88 102 Nm thus secur...

Page 217: ...d on correctly 4 Power steering system not installed correctly 1 Replace damaged part s adjust power steering system to specified pressure 2 Make sure vehicle is powered on correctly 3 Correctly insta...

Page 218: ...d load capacity 16 500 lbs 7 500 kg 9 TORQUE SPECIFICATIONS The torque specifications applicable to the front axle are grouped with information regarding the front suspension Please refer to Section 1...

Page 219: ...AXLE 7 2 2 RETRACTING TAG AXLE 7 2 3 RETRACTING TAG AXLE FOR REPAIR PURPOSES 8 2 4 GREASE LUBRICATED WHEEL BEARINGS 8 2 5 REMOVAL AND INSTALLATION 8 2 5 1 Removing Tag Axle Only 8 2 5 2 Removing Tag...

Page 220: ...ed in the Meritor Technical Bulletin Approved Rear Drive Axle Lubricants annexed to this section In extreme conditions or for better performance fill with synthetic gear oil MAINTENANCE Check oil leve...

Page 221: ...evel surface Put a large container under the axle s drain plug NOTE Drain the oil when the axle is warm 2 Remove the drain plug from the bottom of the axle Drain and discard the oil in an environment...

Page 222: ...le sub frame as outlined in Section 16 Suspension under heading Radius Rod Removal 12 Remove the transversal radius rod support from the vehicle sub frame 13 Remove the two retaining nuts from each of...

Page 223: ...a level surface then chock front vehicle wheels 2 Using two jacking points which are at least 30 inches 76 cm apart on drive axle raise the vehicle sufficiently so that wheels can turn freely at abou...

Page 224: ...URE 6 FRONT DRIVE AXLE ALIGNMENT 11025 FIGURE 7 TAG AXLE ALIGNMENT 11026 NOTE Refer to Section 16 Suspension for proper torque tightening of the longitudinal radius rod support nuts NOTE When the driv...

Page 225: ...Install the lock washers and nuts on the studs Tighten nuts to the correct torque value NOTE Torque values are for fasteners that have a light application of oil on the threads refer to Meritor Mainte...

Page 226: ...or twice a year whichever comes first NOTE For more information on front and tag axle wheel hub refer to DANA SPICER Service Manual NDS Axle Range found in the OEM manuals folder 2 5 REMOVAL AND INSTA...

Page 227: ...CAUTION On vehicles equipped with an output retarder and an automatic transmission move tag assembly very carefully Pay special attention to the U shaped section as the transmission end components ma...

Page 228: ...f all parts are reinstalled exactly in their previous locations axle alignment is not necessary However if the suspension supports have been replaced or have changed position proceed with the followin...

Page 229: ...PRIMARY SECONDARY AND ACCESSORY 6 7 AIR FILTER DRYER 6 7 1 AIR FILTER DRYER PURGE TANK 7 8 HALDEX CONSEP CONDENSER SEPARATOR 7 8 1 MAINTENANCE 7 9 AIR LINES 7 9 1 COPPER PIPING 7 9 2 FLEXIBLE HOSES 8...

Page 230: ...in 15 27 1 2 Front and Tag Axle Equipped With L bracket Wear Indicator 15 27 1 3 Vehicles Equipped with a Continuous Wear Sensor 15 27 2 BRAKE PADS AND DISCS MINIMAL TOLERANCE LIMITS 16 27 2 1 Brake P...

Page 231: ...12 12074 12 FIGURE 17 R 14 12207 12 FIGURE 18 QR 1 12075 12 FIGURE 19 SR 7 12206 13 FIGURE 20 PR 4 12174 13 FIGURE 21 LP 3 12214 13 FIGURE 22 DC 4 12134 13 FIGURE 23 THREE WAY VALVE 12186 14 FIGURE 2...

Page 232: ...ck Braking System ABS which is detailed later in this section The drive axle is provided with spring loaded emergency parking brakes which are applied automatically whenever the control valve supply p...

Page 233: ...art ment it is accessible through the engine compartment R H side door It is used to dissipate heat and to reduce noise produced by the air compressor cycling on and off 4 AIR SYSTEM EMERGENCY FILL VA...

Page 234: ...GES PRIMARY SECONDARY AND ACCESSORY The air pressure gauges located on the dashboard see Operator s Manual are connected to the DC 4 double check valve located on the pneumatic accessory panel in the...

Page 235: ...e life An automatic drain valve installed on the Consep saves time while ensuring that liquids are removed regularly for optimum performance The drain valve s integrated filter prevents damage from la...

Page 236: ...E TEST With air system fully charged and the brakes applied coat all tubing and hose connections with a soapy solution to check for air leakage No leakage is permitted Leakage can sometimes be correct...

Page 237: ...ed Tighten the locking nut 3 Remove pressure gauge and replace dust cap on the air pressure check valve 11 AIR COMPRESSOR The Wabco System Saver 636 Twin Cylinder air compressor is located on the alte...

Page 238: ...d on the L H lateral console is provided for parking brake application or release The spring brakes are self actuated whenever the control valve supply pressure drops below 60 psi 414 kPa In the UP po...

Page 239: ...hreaded rod lock nuts and screw or unscrew the threaded adjustment rod in order to obtain a 45 o brake pedal inclination Fig 13 2 Tighten threaded rod lock nuts 15 1 1 Maintenance Maintenance and repa...

Page 240: ...hicle at the level of the tag axle Maintenance and repair information on these valves is supplied in the applicable booklet annexed to this section under reference number SD 03 1064 FIGURE 16 R 12 120...

Page 241: ...system refer to Fig 1 for accessory air tank location 22 LOW PRESSURE INDICATOR LP 3 Maintenance and repair information on the low pressure indicators is supplied in the applicable booklet annexed to...

Page 242: ...rnor and compressor unloading mechanism Air pressure drops quickly when engine is stopped Leaks in compressor discharge valve Leaks in governor Leaks in air lines Leaks in air system valves 26 BRAKE O...

Page 243: ...el by checking the position of the caliper 1 compared to the fixed guide pin 4 MEASUREMENT C WITH NEW BRAKE PADS AND DISC MEASUREMENT C WITH WORN DISC BRAKE PADS FIGURE 24 BRAKE PAD WEAR CHECK ON DRIV...

Page 244: ...ack plate SN7 type 0 354 in 9 mm C Minimal thickness of friction material 0 079 in 2 mm D Minimum allowed thickness in worn condition for back plate and friction material 0 433 in 11 mm 27 2 2 Brake D...

Page 245: ...cently manufactured brake linings no longer contain asbestos fibers Instead of asbestos these linings contain a variety of ingredients including glass fibers mineral wool aramid fibers ceramic fibers...

Page 246: ...eaners and handling used rags Wash your hands before eating drinking or smoking Do not wear your work clothes home Vacuum your work clothes after use and then launder them separately without shaking t...

Page 247: ...if found defective Check compressor strainer or inlet line If restricted clean or replace element or faulty line Check compressor head or discharge line for carbonization or restriction Clean or repla...

Page 248: ...d at the end of Section 12 of Maintenance Manual 30 BRAKE AIR CHAMBER If this vehicle is equipped with Knorr Bremse SN7000 disc brakes on all axles it also uses Knorr Bremse brake chambers The drive a...

Page 249: ...nd Tires 4 Exhaust compressed air from system by opening the drain valve of each reservoir 5 For the drive axle brake chambers manually release spring brakes refer to Emergency Parking Brake Manual Re...

Page 250: ...ssor which senses when any wheel is about to lock Modulator valves quickly adjust the brake pressure up to 5 times per second to prevent wheel locking Each wheel is therefore controlled according to t...

Page 251: ...located between the brake chamber and the relay valve or quick release valve Fig 32 Note that on the basic ABS system there is only one solenoid valve controlling the drive and tag axle wheels on the...

Page 252: ...only this type of grease on the sensors 2 Insert spring clip in the holder on hub Make sure the spring clip tabs are on the inboard side of the vehicle Push in until the clip stops 3 Push the sensor...

Page 253: ...ollowing hand tightening 1 4 3 3 8 to 1 2 4 5 8 to 3 4 3 FIGURE 38 HOSE FITTING 12055 AB Type Copper Piping Hand tighten nut Fig 38 From that point tighten with a wrench the number of turns indicated...

Page 254: ...1462 Brake Relay Valves Make Bendix Westinghouse Model R 12 Brake Relay Valve Make Meritor Wabco Model R 14 Quick Release Valve Make Bendix Westinghouse Model QR 1 Prevost number 641429 Spring Brake V...

Page 255: ...r Bremse Type 24 as service 24 as emergency Prevost number 641432 Piggy Back On Drive Brakes Make Knorr Bremse Type 24 as emergency Prevost number 641433 Tag Axle Brake Chambers Make Knorr Bremse Type...

Page 256: ......

Page 257: ...7 FRONT AND TAG AXLE WHEEL HUBS 6 7 1 HUB BEARING INSPECTION 6 7 2 HUB BEARING REMOVAL 7 7 3 HUB BEARING INSTALLATION 7 8 DRIVE AXLE WHEEL HUBS 7 8 1 BEARING ADJUSTMENT 7 8 2 DISASSEMBLY AND REPAIR 8...

Page 258: ...nuts should be tightened every 100 miles 160 km for the first 500 miles 800 km to allow setting in of clamping surfaces Wheel studs and nuts must be kept free from grease and oil No lubricant whatsoe...

Page 259: ...TION Mount the wheel over studs being careful not to damage stud threads 3 4 OUTER WHEEL INSTALLATION With inner and outer wheels installed tighten the stud nuts progressively as shown in Figure 2 The...

Page 260: ...outlined in step 2 If within specifications the hub is correct but the suspected wheel must be replaced 5 WHEEL STUDS Stripped threads may be the result of excessive torquing or may have been damaged...

Page 261: ...ve Using a calibrated torque wrench tighten wheel nuts to 450 500 lbf ft 610 680 Nm of torque Do not use power tools or long bars for tightening Tighten wheel nuts alternately as shown in figure 2 NOT...

Page 262: ...ichever comes first Apply parking brake raise wheels off the ground and support axle on stands When the wheels are raised they should revolve quite freely without roughness Place magnetic base of a di...

Page 263: ...ite LX PEP 2 Prevost 685325 into the bottom of the hub flange cap Mount hub flange onto rotor Apply some Loctite 243 blue onto cap screw threads then secure hub flange and rotor to unitized hub bearin...

Page 264: ...e bearings should be replaced Seals should be replaced each time they are removed from the hub To install new oil seal use a suitable adapter and drive the seal into the retainer bore until it bottoms...

Page 265: ...ransport s certification plate affixed on the panel behind the driver s seat For special tire selection a PREVOST COACH SPECIAL SPECIFICATION chart is supplied with the vehicle and is affixed on the l...

Page 266: ...tires on coach be of the same type 9 3 WHEEL BALANCING Before balancing wheels must be clean and free from all foreign matter The tires should be in good condition and properly mounted An unbalanced...

Page 267: ...TIRE INFLATION PRESSURE AT MAXIMUM LOAD cold NOTE Vehicle is delivered with the specific inflation pressure certification plate according to the tire selection WARNING Special tire selection may lowe...

Page 268: ......

Page 269: ...8 9 STEERING LINKAGE ADJUSTMENT 9 10 PITMAN ARM 9 10 1 REMOVAL 9 10 2 INSTALLATION 10 10 3 ADJUSTMENT 10 10 4 TAG AXLE UNLOADING SWITCH ADJUSTMENT 10 11 MAINTENANCE 10 11 1 POWER STEERING RESERVOIR AN...

Page 270: ...EMOVING THE HORN PAD 7 FIGURE 10 STEERING HARNESS HORN WIRE 7 FIGURE 11 LOCKING THE CLOCKSPRING IN PLACE 8 FIGURE 12 CLOCKSPRING INSTALLATION 8 FIGURE 13 PROPER CLOCKSPRING POSITION 8 FIGURE 14 PITMAN...

Page 271: ...od Hydraulic components are added to transmit increase and regulate steering control forces These elements are 1 Steering stabilizer damper 2 A vane type hydraulic pump and 3 Hydraulic reservoir and h...

Page 272: ...heel is turned FIGURE 3 FRONT SERVICE COMPARTMENT 18611 A torsion bar which is pinned with the valve slide and the worm keeps the control valve in the neutral position as long as no opposing force is...

Page 273: ...Inspection Instructions 3 BLEEDING POWER STEERING HYDRAULIC SYSTEM To bleed the power steering hydraulic system refer to the ZF SERVOCOM Repair Manual annexed to this section under heading Setting An...

Page 274: ...ING PUMP REMOVAL Install the new power steering pump Torque tighten bolts to specification NOTE Use a new gasket Connect the hydraulic lines to the power steering pump Install the fuel pump Torque tig...

Page 275: ...nting straight ahead aligned with the vehicle 1 Set the battery master switch located on the rear electrical panel to the OFF position 2 Pull the horn pad straight up gently to detach it from the stee...

Page 276: ...ring You will have to disconnect the clockspring harness connector located lower along the steering wheel column If necessary remove the steering column covers Fig 8 3 Route the new clockspring harnes...

Page 277: ...oseness can be visually detected while rotating the steering wheel in both directions Replace defective parts CAUTION Front wheel alignment should be checked and adjusted if necessary any time a compo...

Page 278: ...Remove the pitman arm according to the procedure outlined under previous heading Pitman arm removal Adjust to the proper angle 4 When adjustment is achieved replace fixing nut and torque to 470 570 lb...

Page 279: ...s as well as the recommended lubricants for the steering components are given in the Lubrication And Servicing Schedule in Section 24 of this manual The intervals given in the schedule are recommended...

Page 280: ...for wear and replace if necessary Good quality lithium base mineral grease NLGI No 1 and 2 like Shell Retinax LX are recommended FIGURE 19 STEERING STABILIZER DAMPER 14042 11 3 DRAG LINK Visually ins...

Page 281: ...procedure 2 Use an appropriate inspection tool e g spatula with cut out to push up sealing boot or down dirt seal the seal without damaging it until ball pin surface is visible Degrease the ball pin s...

Page 282: ...ting thrust cup onto ball pin 6 Still with tool located on adjuster piece back off carefully LEAST AMOUNT until adjuster piece split pin is allowed to pass through body and that ball pin shank can be...

Page 283: ...optimum steering but you do still have a safe linkage When all compression is lost it s time to replace the linkage This wear can be caused by impact lack of lubrication and normal wear 1 With vehicle...

Page 284: ...and consequently cause the hydraulic fluid to become overheated CAUTION Never maintain the hydraulic system at the relief pressure for longer than 5 10 seconds to avoid damaging the power steering pum...

Page 285: ...adjusted 3 Vehicle not powered on correctly 4 Power steering system not installed correctly 1 Replace damaged part s adjust power steering system to specified pressure 2 Make sure vehicle is powered o...

Page 286: ...8098 Prevost number 661045 F E W 16 600 lbs 7 545 kg Pressure rating 2 175 psi 150 Bar Gear ratio center 22 2 1 Gear ratio extremities 26 2 1 Minimum pump flow for 1 5 hwt sec 4 22 gpm 16 lpm Power S...

Page 287: ...ECIFICATIONS 9 3 Rear Suspension 13 3 1 AIR SPRINGS 14 3 1 1 Inspection 14 3 1 2 Removal 14 3 1 3 Installation 15 3 2 SHOCK ABSORBERS 15 3 2 1 Inspection 16 3 2 2 Removal 16 3 2 3 Installation 16 3 3...

Page 288: ...7 FIGURE 10 I BEAM FRONT AXLE SWAY BAR 8 FIGURE 11 REAR SUSPENSION COMPONENTS 13 FIGURE 12 SWAY BAR REAR SUSPENSION 13 FIGURE 13 REAR UNDERFRAME SUSPENSION 14 FIGURE 14 TAG AXLE SUSPENSION 14 FIGURE 1...

Page 289: ...orted by these springs The I beam front axle is provided with air springs that are attached to the subframe and to the axle Fig 3 FIGURE 3 AIR SPRING 16052 2 1 1 Inspection 1 Check operation of bellow...

Page 290: ...upper nut a few turns NOTE To facilitate air spring installation compress it manually then put a piece of tape over the air line threaded fitting This prevents air from getting back into the bag and...

Page 291: ...ndition indicates a scored rod Units with scored rods should be replaced 3 Fully extend shocks and check for leaks in the seal cover area Shock fluid is a very thin hydraulic fluid that has a characte...

Page 292: ...e front axle suspension four longitudinal and one transversal FIGURE 6 TYPICAL RADIUS ROD SETUP 16010 Refer to figures 1 2 and 6 for details These rods transmit both braking and driving forces from th...

Page 293: ...d until it extends equally on both sides of the rod 5 It is also possible to proceed differently Place radius rod bushing on a plane surface Spray a light coat of water on the inner and outer surfaces...

Page 294: ...motion swaying movement of the vehicle Fig 10 FIGURE 10 I BEAM FRONT AXLE SWAY BAR 16099 2 4 1 Removal 1 Disconnect the two links from sway bar 2 Safely support the sway bar Unbolt the four bushing c...

Page 295: ...SECTION 16 SUSPENSION PA1593 9 2 5 TORQUE SPECIFICATIONS...

Page 296: ...Section 16 SUSPENSION PA1593 10...

Page 297: ...Section 16 SUSPENSION PA1593 11...

Page 298: ...RING ARM STUD NUT 2 5 520 575 705 780 TIE ROD ARM STUD NUT 4 6 520 575 705 780 I BEAM AXLE MOUNT 8 7 230 280 311 378 SHOCK ABSORBER UPPER MOUNTING PIN STUD NUT 2 8 99 121 134 164 SHOCK ABSORBER PIN 2...

Page 299: ...SUSPENSION PA1593 13 3 REAR SUSPENSION For a description of all these systems refer to the appropriate heading in this section FIGURE 11 REAR SUSPENSION COMPONENTS 16167 FIGURE 12 SWAY BAR REAR SUSPEN...

Page 300: ...km or twice a year whichever comes first 3 With the primary air system at normal operating pressure 95 125 psi 655 860 kPa coat all suspension air line connections and bellows mounting areas with a w...

Page 301: ...on the remaining upper nut large nut and tighten to 20 25 lbf ft 27 34 Nm 4 Install elbow if applicable then connect air line 5 Connect the height control valve link 6 Build up air pressure in system...

Page 302: ...he shock to bind Also check for a bent rod 5 Extend and collapse shock several times to determine that it has control resistance in both rebound and compression 6 Visually inspect the shock mountings...

Page 303: ...nd cracks We recommend the Magnaflux process to detect cracks in the radius rod Any damaged part should be replaced with a new one NOTE New bushings should be used when rods are replaced 3 The radius...

Page 304: ...correctly FIGURE 20 RADIUS ROD BUSHING INSTALLATION 16012 Radius Rod Installation 1 Lightly spray the radius rod support with water Place the radius rod end over the radius rod support Fig 21 2 Positi...

Page 305: ...ipping Down Strip down the defective joint through removal of retaining ring annular spacer and ball pin bushing assembly and thereafter clean out housing bore and locking circlips groove Radius Rod A...

Page 306: ...ual SPECIFIC TORQUE TABLE 2 REAR SUSPENSION DESCRIPTION QTY TORQUE DRY lbf ft Nm Radius Rod Stud 2 20 40 27 54 Radius Rod Retaining Nut or Bolt 2 110 130 150 175 Radius Rod Support Nut 4 110 130 150 1...

Page 307: ...clearance should be 11 292 6 mm FIGURE 24 TYPICAL AIR SPRING CLEARANCE 16058 At this point it should not be necessary to make an adjustment under normal service conditions However if an adjustment is...

Page 308: ...de height the height control valve overtravel lever reaches the neutral position and keeps both the supply and exhaust ports closed to ensure normal ride height is maintained This condition remains st...

Page 309: ...of every driving day by the remote air tank drain valve located in the front service compartment Fig 29 Moreover purge all tanks by their bottom drain valves at specified intervals 6 1 1 Wet Air Tank...

Page 310: ...vice compartment Fig 29 underneath the accessory air filter Refer to Section 12 paragraph 4 Accessory Air Filter of the maintenance manual for daily purge procedure 6 1 5 Kneeling Air Tank The kneelin...

Page 311: ...kneeling action is achieved by exhausting air from the front air springs bellows This system bypasses the height control valve to provide a fast up and down movement of the front suspension Only four...

Page 312: ...has been cut during removal procedure should be replaced with a new one 8 TROUBLESHOOTING Condition Cause Correction Bellows deflate over time 1 Defective check valve assembly 2 Defective exhaust valv...

Page 313: ...st number 630253 Height control valve Front only Quantity used 1 Prevost number 630157 Height control valve Rear only Quantity 2 Prevost number 630156 Bellows control and exhaust solenoid valve assemb...

Page 314: ......

Page 315: ...6 1 1 Front Bumper 15 6 1 2 Headlights 16 6 1 3 Rear View Mirrors Rosco 16 6 1 4 Windshield Wipers 18 6 1 5 Windshield 18 6 1 6 Bi Fold Entrance Door 19 6 1 7 Front Electrical Service Compartment Door...

Page 316: ...FIBERGLASS REPAIR 12 FIGURE 5 FIBERGLASS REPAIR 13 FIGURE 6 FIBERGLASS REPAIR 13 FIGURE 7 X3 COACHES ZONING 15 FIGURE 8 ZONE 1 15 FIGURE 9 FRONT BUMPER RELEASE HANDLE 16 FIGURE 10 FRONT BUMPER COMPART...

Page 317: ...RE 44 SIDE CREST POSITIONING 49 FIGURE 45 BODY PANEL AND WINDOW SPACING TYPICAL 50 FIGURE 46 ARMREST 51 FIGURE 47 SEAT PEDESTAL ASSEMBLY 51 FIGURE 48 TARABUS FLOOR COVERING ADHESIVE APPLICATION 54 FIG...

Page 318: ...Entrance door control switch 10 Bi fold entrance door 11 Electronic destination sign or route number 12 Exhaust aftertreatment system access door 13 Engine compartment rear doors 14 Rear view mirrors...

Page 319: ...ing corrosion and must be considered as part of the regular service intervals The entire underside of the vehicle is sprayed with a heavy application of asphalt base undercoating The operating environ...

Page 320: ...USING COATING MAKE SURE DISCHARGE TUBES ARE FREE FROM OBSTRUCTIONS APPLY UNDERCOATING LOCALLY AS NECESSARY APPLY UNDERCOATING LOCALLY AS NECESSARY REMOVE ANY OBSTRUCTION OR REPLACE DEFECTIVE TUBE SUSP...

Page 321: ...1 Avoid rubber parts 2 0 Dry all water sprayed parts Surface temperature and dew point must be respected before applying rust inhibitor Air pressure system may be used refer to annex 1 for surface tem...

Page 322: ...sing 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...

Page 323: ...mping system are required to apply the rust inhibitor If the application is done inside a paint room select high speed ventilation Minimum required thickness is 10 mils wet or 5 mils dry 7 0 Remove al...

Page 324: ...7 10 11 13 15 7 3 1 4 6 9 10 12 14 14 6 1 2 5 7 10 11 13 15 14 6 1 2 6 8 10 12 14 16 13 5 0 4 6 9 11 14 15 17 12 4 1 4 7 10 12 14 16 18 11 4 1 5 9 11 13 15 17 19 10 3 2 6 9 12 14 16 18 20 10 2 3 7 10...

Page 325: ...clean with solvent Grind or file the damaged area to form a V at the broken or cracked portion Sides of V should have a shallow pitch for maximum bonding area NOTE Roughening the surface improves adh...

Page 326: ...apping hole approximately 1 to 1 25 40 mm all around Remove all dirt grease and paint from area to ensure good bonding surface Feather the cleaned area all around Fig 4 FIGURE 2 FIBERGLASS REPAIR 1808...

Page 327: ...cold Park vehicle in the shade whenever possible Do not park under trees which drop sap or near factories with heavy smoke fallout Tree sap and industrial fallout may mar or spot a freshly painted su...

Page 328: ...ations 3 Maintain adequate ventilation at all times 4 Dispose of any leftover paint mix properly 5 Wear rubber gloves rubber apron and face shield during all phases of paint and chemical handling 5 3...

Page 329: ...components Refer to the appropriate zone then component for complete procedure FIGURE 7 X3 COACHES ZONING 18623 6 1 ZONE 1 FIGURE 8 ZONE 1 18624 6 1 1 Front Bumper The front bumper is hinged to give a...

Page 330: ...is equipped with two Rosco exterior mirrors The mirrors can easily be adjusted by using the remote controls located on the L H side control panel The mirrors have easy to replace glass in case of bre...

Page 331: ...s to adjust the selected mirror viewing angle o Disassembly At end of mirror arm loosen the setscrews to relieve tension on the ball stud Remove the ball stud Remove the ball stud from the arm and gen...

Page 332: ...er or metal rod remove black butyl sealant residue from rubber seal then clean with Sika 205 Windshield Installation NOTE Rubber seal may have to be replaced if it was used on several windshield repla...

Page 333: ...e door with an air door cylinder and damper assembly installed under the right hand dash for the R H door panel opening Another air door cylinder is installed behind the wall to the right of the first...

Page 334: ...e the vehicle by turning the key in the door lock counterclockwise to lock clockwise to unlock The entrance door can be unlocked from the inside using the small lever located on the door The air opera...

Page 335: ...he emergency exit valve to the UNLOCK position Move the lever From the exterior turn the emergency exit valve to the UNLOCK position Open the door Close it lock with the key and reset the outside emer...

Page 336: ...m The dust cap or piston rod may now be turned freely 5 The damper can now be refitted in the vehicle FIGURE 23 DAMPER 18643 NOTE Where a bump rubber was installed refit same inside the dust cap and b...

Page 337: ...36 Lbf ft 40 50 Nm Remove the jack and the wooden block CAUTION Make sure the front side door does not interfere with the exterior panel 5 Pull and fasten the rod end to the hinge with the washer and...

Page 338: ...r Open service door Remove interior finishing panels to access rub rail fixing bolts then remove rub rail Remove windshield washer reservoir door lock and power window connector Using the Zip Gun cut...

Page 339: ...ound door frame using Sika 208 From the inside of the door apply some Sika 221 between door body panel and frame and on welding spots as per figure Apply some 680066 glue inside fiber glass groove and...

Page 340: ...Secure window pane to raising mechanism Adjust window travel 6 3mm above window wiper Driver s Window Gutter Dry fit the gutter on the vehicle If re quired straighten up gutter using a ham mer and a...

Page 341: ...Cap The fiberglass front cap does not need any maintenance except painting as needed It is held in place with adhesive If ever it has to be replaced make an appointment at a Pr vost service center nea...

Page 342: ...open when needed The single glazed windows are made of tinted tempered safety glass while the double glazed windows are made of tinted tempered safety glass outside and clear tempered glass inside Fo...

Page 343: ...Sika perform the following steps Clean using anti silicone Remove from structure old primer using a sander 120 150 grit Clean again using anti silicone Apply 206 G P primer Reactivate 206 G P primer...

Page 344: ...both locks on the window simultaneously The tension required to release the window should not exceed twenty pounds 9 kg of force The release bar mechanism itself has been designed such as no adjustmen...

Page 345: ...epresents a possible hazard when improperly reattached to a hidden tapping plate itself often damaged whenever the hinge is damaged The tapping plate is permanently laminated between the inner and out...

Page 346: ...with SIKA 205 7 Apply rubber adhesive SIKA 221 under the hatch frame surface 8 Install the frame in place and fix it with rivets 9 Remove excess adhesive and clean all around 6 3 ZONE 3 FIGURE 32 ZON...

Page 347: ...nter it in the door latch mechanism 4 Tighten the striker pin 5 Check doors fit and operation FIGURE 33 ENGINE COMPARTMENT DOORS 18633 6 3 3 Rear Bumper Remove three bolts on each side holding bumper...

Page 348: ...n the gap needed between exterior finishing panels 4 Tighten the bolts 5 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operat...

Page 349: ...its Pneumatic Zip gun type tool Razor sharp window scraper or putty knife Open damaged compartment door and unfasten rub rail fixing bolts Remove rub rail Unfasten bolts and disconnect cable if necess...

Page 350: ...Sika bead around handle housing Using the window scraper remove any Sika bead or self adhesive tape residue left on the door frame Upper Panel Preparation and Installation Use a Chix cloth and anti s...

Page 351: ...andle must remain tight against its plastic housing NOTE Adjustment is made by moving UP or DOWN the lock plates Open baggage compartment door and adjust height using the catch plates Tighten cylinder...

Page 352: ...o accelerate curing Allow drying for at least 2 hours then repaint as per paragraph Minor Repair Baggage Compartment Floor Installation Preparation and Installation Clean baggage compartment support s...

Page 353: ...structure Evenly distribute and install conforming weights 6 to 8 80 to 100 lbs total onto panel for at least 4 hours Make sure panel does not move Finishing Joints In the case of lateral finishing j...

Page 354: ...Rear baggage compartment without WCL Remove masking tape Smooth down joints using soapy water 6 5 3 Evaporator Compartment Door 1 Open the evaporator door 2 Loosen the screws fixing the hinge to hing...

Page 355: ...LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust condenser door assembly position at the hinge 4 Tighten the screws 5 Respect the required gap between exterior finishing panels 6 Check that the do...

Page 356: ...E 42 ZONE 6 18629 6 6 1 Front Fender Front fender may be removed using the following procedure Remove the nuts on the inside of the fender Remove the fender from the vehicle To reinstall reverse the p...

Page 357: ...l bit to remove rivet heads C Grind tig weld spots at each end of side panel D Safely support or temporary fix side panel Warning Panel weights over 200 pounds E Insert a flat screwdriver between the...

Page 358: ...lean using anti silicone until all clothes come clean See PR000001 section A B Use the belt sander grit coarse Use a new paper on each vehicle side panel C Clean using anti silicone until all clothes...

Page 359: ...minutes After 2 hours Reactivate surface with Sika 205 Before applying any other product If surface seems dusty greasy or with finger marks start operation again SECTION 3 SIDE PANEL INSTALLATION 3 00...

Page 360: ...whole perimeter Section A A Section B B Section C C 3 15 A Install side panel onto support jig B Position side panel in front of vehicle structure Section A A Section B B C Perform final adjustment t...

Page 361: ...imum 3 30 Remove pulling equipment 3 40 A Remove protective film from double face self adhesive tape B Compress top and bottom section of side panel 3 50 A Cut excess of side panel Make sure that cut...

Page 362: ...step 2 00 4 10 Prepare air intake panel as for side panel Refer to step 2 05 4 15 Install foam tape 1 8 X onto structure as shown in picture 4 20 Install foam tape 1 16 X onto air intake panel pleat 4...

Page 363: ...Sika 205 reaches as far as the corner See PR000001 section B C Apply Sika 252 black at the junction of both tubing Smooth down the joint D Remove protective tape 6 7 2 Side Crest FIGURE 44 SIDE CREST...

Page 364: ...Section 18 BODY PA1593 50 6 8 BODY PANEL AND WINDOW SPACING FIGURE 45 BODY PANEL AND WINDOW SPACING TYPICAL 18631...

Page 365: ...of cushions and remove cushions 3 Remove 4 finishing screws holding plastic cover between side wall and seat frame 4 Remove 2 cap screws nuts and washers holding seat frame to side wall and retain the...

Page 366: ...oam upholstery cleaner or with a mild household detergent Thoroughly vacuum the upholstery Remove any spots or stains before the seats are washed to avoid a cleaning ring Dilute household detergent or...

Page 367: ...t under two rows of seats so that repair is not as noticeable 3 Clean plywood using a scraper NOTE Make sure that no staples are sticking out beyond surface Adjacent plywood sheets must be leveled 4 F...

Page 368: ...Section 18 BODY PA1593 54 FIGURE 48 TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 49 APPLICATION OF SIKA 221 GRAY18641...

Page 369: ...to prevent reaching condensation point Mechanically preheat working area heat lamp or heat gun or wait until vehicle reaches room temperature PREPARATION OF TARABUS FLOOR COVERING 1 Sand under step u...

Page 370: ...er to Section B Section B Sika 205 1 Apply 2 Allow drying Mandatory Minimum time For a smooth surface aluminum stainless steel fiberglass gelcoat side etc 2 minutes For a porous surface fiberglass non...

Page 371: ...ng position step nosing then press Drill and fix using screws 7 Clean top of step nosing using Sika 205 refer to Section B 8 Apply some Sika 221 onto white safety strip spread with a spatula to cover...

Page 372: ...eating time 5 minutes 2 Before welding visually ensure that a 1 to 1 5 mm gap exists between white safety strip and Tarabus floor covering Use a knife if this is not the case NOTE There should be no e...

Page 373: ...iller 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 Once the welding torch is ready insert the filler bead into the nozzle...

Page 374: ...procedure for turning the torch off must absolutely be followed If this step is not taken the element may burn 11 Set temperature potentiometer to 0 position Fan will evacuate residual heat Leave the...

Page 375: ...nd at the end of repair 5 Perform steps indicated in paragraphs 9 10 and 11 7 VEHICLE JACKING POINTS The vehicle can be lifted by applying pressure under body jacking points or front and drive axle ja...

Page 376: ...00 lb 18 200 kg 7 1 HYDRAULIC JACK To raise turn release valve clockwise Insert handle in socket and raise vehicle by pumping To lower remove handle and turn the release valve slowly counterclockwise...

Page 377: ...us transmission damage and void the warranty The towed vehicle must be lifted from under the front end only The tow truck must be equipped with the proper lifting equipment to reach under the tow eyes...

Page 378: ...p down the access door located in the front bumper connect an auxiliary air supply to the two quick connectors so the emergency parking brakes don t apply while towing FIGURE 57 FRONT TOWING AIR SUPPL...

Page 379: ...supports onto tow bar and install onto engine cradle CAUTION To prevent damage to the vehicle structure it is not recommended to tow the vehicle from the rear In case of damage to the drive train comp...

Page 380: ......

Page 381: ...2 06 18 L H SIDE DOOR PANEL HINGE ARM PIVOT 10 Pivot p n 281162 qty 1 11 Stop p n 281296 qty 1 12 Machine screw p n 5001670 qty 2 machine screw pan head PH M4 0 7x8mm R H SIDE DOOR PANEL HINGE ARM PIV...

Page 382: ...Rod end Tighten jam nuts to lock rod ends Pre adjustment distance between rod end and hinge arm should be 1 3 16 inch 30mm Center the flat sides of the stud between the nuts p n 502196 qty 2 R H SIDE...

Page 383: ...r 068358 Page 1 of 2 AIR PRESSURE RELEASE Prior to perform the following procedure release the air pressure from the bi fold door air cylinders and latch cylinders To do so turn the emergency release...

Page 384: ...SOR GAP ADJUSTMENT 10 To gain access to the sensor probe remove the R H side hinge cover item 4 11 Sensor 068358 qty 1 11 Place sensor probe at 0 059 1 5mm from hinge lever arm as shown on the image a...

Page 385: ...side hinge arm pivot To remove the R H side hinge arm pivot you must remove the dashboard cover first 11 Unscrew the upper hinge arm pivot support 12 Bolt Torque as per bolt type and grade 16 lbf ft p...

Page 386: ...ype and grade 16 lbf ft p n 5001780 cap screw hex M8 1 25X16 grade 8 8 qty 3 23 Bearing 24 Unscrew tighten bearing bolts green on the image Apply Loctite 243 on threads prior tightening Torque see ste...

Page 387: ...end p n 502252 qty 1 14 Rod end left hand threads p n 502253 qty 1 15 Adjust length as shown from rod end to center of eye 37 5mm 1 15 32 Do not tighten nuts do not apply thread locker Rod ends must...

Page 388: ......

Page 389: ...llowing procedure release the air pressure from the bi fold door air cylinders and latch cylinders To do so turn the emergency release valve clockwise This valve is located on the lower R H side of th...

Page 390: ...e the cylinder out 34 To prevent faulty installation properly identify the air hoses and fittings Unscrew fittings apply thread sealant and install on the new cylinder 35 Installation of the new cylin...

Page 391: ...445 qty 1 46 Item C spring nut p n 502601 qty 2 TO PRESSURIZE A DAMPER THAT HAS LOST PRESSURIZATION 50 Place damper vertically as shown and extend rod at maximum stroke 51 Turn the damper upside down...

Page 392: ...rod end p n 5001615 qty 1 cap screw button hex socket head M12 1 75X30 73 Remove the cylinder 74 To prevent faulty installation properly identify the air hoses and fittings Unscrew fittings apply thre...

Page 393: ...the bi fold door air cylinders and latch cylinders To do so turn the emergency release valve clockwise This valve is located on the lower R H side of the dashboard Releasing the air pressure will unl...

Page 394: ...in order to have approximately 13 32 28 mm between seal jamb and the exterior surface painted of the door panel at the upper hinge arm level 3 Adjust the door panel position in order to have approxim...

Page 395: ...acket must be level once bolted Torque 16 lbf ft bolts B FIXING CENTER PART OF DOOR PANEL 50 If required adjust threaded rod length C until bolt A can be easily inserted through ball joint and attachm...

Page 396: ...nce arm s length so that they can be easily mounted on the pivots there must be no tension on the arms Door panels must remain in the same position as they are when solely maintained with air pressure...

Page 397: ...rque specification at step 21 2011 10 07 Page 1 of 2 AIR PRESSURE RELEASE Prior to perform the following procedure release the air pressure from the bi fold door air cylinders and latch cylinders To d...

Page 398: ...the 3 bolts identified on the image will maintain proper door panel adjustment No adjustment will be required at time of reinstallation Reinstallation 21 2 upper bolts Torque 74 lbf ft p n 5001615 ca...

Page 399: ...T 13 6 2 1 Procurement 13 6 2 2 Precautions in Handling Refrigerant 13 6 2 3 Treatment in Case of Injury 13 6 2 4 Precautions in Handling Refrigerant Lines 13 6 3 PUMPING DOWN 16 6 4 ADDING REFRIGERAN...

Page 400: ...8 4 SOLDERING 37 8 5 DRIVER S HOT WATER PNEUMATIC VALVE ASSEMBLY 38 8 6 CENTRAL HOT WATER PNEUMATIC VALVE ASSEMBLY 39 8 7 WATER RECIRCULATING PUMP 40 9 SPECIFICATIONS 42 ILLUSTRATIONS FIGURE 1 DRIVER...

Page 401: ...DENSER FAN MOTOR 24 FIGURE 30 A C CONDENSER COMPARTMENT 24 FIGURE 31 DRIVER S EVAPORATOR LIQUID SOLENOID VALVE 26 FIGURE 32 REFRIGERANT SOLENOID VALVE 27 FIGURE 33 EXPANSION VALVE 27 FIGURE 34 SUPERHE...

Page 402: ...IRCULATION 22307 X3 45 coaches are also equipped with a windshield upper section de icing system Also one additional air register is located in the driver s area but supplied by the passengers air duc...

Page 403: ...refrigerant and coolant and are linked to the same condenser and compressor even if they are individually controlled It requires the passengers HVAC section to engage the A C compressor magnetic clut...

Page 404: ...trol is provided in conjunction with a thermistor sensor inside register duct located on L H side of vehicle Figs 3 6 FIGURE 6 THERMISTOR SENSOR The flow of water to the vehicle s main heater core is...

Page 405: ...d Compt D20 Lugg 1 st Compt D25 Evap Fan D30 Water Pump D73 Opt D80 Opt 4 HVAC UNIT MAINTENANCE No special maintenance is required on the passengers and driver s HVAC units with the exception of clean...

Page 406: ...ssure Do not use hot water steam or caustic soap FIGURE 13 CONDENSER COMPARTMENT 22311 4 2 DRIVER S SECTION AIR FILTERS The driver HVAC system is located behind the dashboard s R H side lateral plasti...

Page 407: ...de the overhead compartments MAINTENANCE Slide out filters back flush with water then dry with air and replace This procedure should be done every 12 500 miles 20 000 km or once a year whichever come...

Page 408: ...ICULARITIES Conditions for engaging the 2nd speed on the evaporator motor cooling demand The 2nd speed engages if the passenger s area temperature is 1 degree above the set point and it revert to spee...

Page 409: ...A54 is not powered or is faulty 1 Check the Diagnostics menu of Driver Information Display DID Select Fault Diagnostics and Electrical System The message No Response ModA54 Active indicates a power pr...

Page 410: ...nted inside the condenser compartment 6 1 A C CYCLE Refrigeration may be defined as the transfer of heat from a place where it is not wanted to a place where it is unobjectionable Components required...

Page 411: ...e reason If the cylinder is exposed to the sun s radiant heat pressure increase resulting may cause release of the safety plug or the cylinder may burst For the same reason the refrigerant cylinder sh...

Page 412: ...e exhaust manifold 3 Use only sealed lines from parts stock 4 When disconnecting any fitting in the refrigeration system the system must first be discharged of all refrigerant However proceed very cau...

Page 413: ...Section 22 HEATING AND AIR CONDITIONING PA1593 15 FIGURE 18 REFRIGERANT CIRCUIT CENTRAL SYSTEM...

Page 414: ...rocedure is intended to reduce refrigerant loss by isolating it in the compressor and the receiver tank as well as in their connecting line in order to carry out repairs on other sections of the air c...

Page 415: ...a of the absolute system pressure 7 Backseat the compressor valves by turning out all the way 8 Shut down the vacuum pump 9 Remove the hoses 10 Reinstall the caps at the suction valve take off points...

Page 416: ...receiver tank This may be accomplished by placing the refrigerant cylinder upside down on a scale with the valves at the bottom This ensures that only liquid will enter the receiver tank When chargin...

Page 417: ...ng upon the severity of the failure the system should be thoroughly cleaned out using one of the clean out procedures mentioned 6 7 1 Determining Severity of Failure The severity of compressor failure...

Page 418: ...idity using instructions supplied above If the oil is contaminated replace the oil and repeat step 7 If the oil is not contaminated change the filter dryer again and replace the moisture liquid indica...

Page 419: ...he outer face of crankshaft pulley positioning the other end close to the compressor clutch pulley Figs 24 25 2 Check the distance between each extremity of straight edge 1 Fig 25 and the first drive...

Page 420: ...l be circulated between the suction and discharge sides of the head The affected cylinder head will then have a relatively even temperature across its surface and be neither as hot as the normal disch...

Page 421: ...reakers CB3 Open the last L H side baggage compartment door Pull the black release button located on the L H side in order to unlock and open the evaporator compartment door Remove the evaporator moto...

Page 422: ...psi the motors will run at low speed and if the pressure continues to drop to 90 psi a pressure switch stops the motors so that fans do not operate needlessly When pressure rises to 120 psi the press...

Page 423: ...oride or similar solvents to clean parts Do not use steam guns Use mineral spirits or naphtha All parts should be thoroughly cleaned Use a stiff brush to wash dirt from grooves holes etc DANGER Cleani...

Page 424: ...lectric operation 7 7 2 Coil Replacement 1 Disconnect connector from the coil connector 2 Take out the retaining screw at the top of the coil housing The entire coil assembly can then be lifted off th...

Page 425: ...ion pressure of the refrigerant temperature leaving the evaporator and moves the valve pin in the opening direction Opposed to this force on the under side of the diaphragm and acting in the closing d...

Page 426: ...nued absorption of heat from the surrounding atmosphere The degree to which the gas refrigerant is superheated is related to the amount of refrigerant being fed to the evaporator and the load to which...

Page 427: ...se conditions will give a high superheat Maintenance 1 Pump down the system as previously indicated in this section 2 Disconnect the external equalizer line from the under side of the power head and u...

Page 428: ...ly or replace valve Air filter screen clogged Clean or replace air filter Plugged lines Clean repair or replace lines LOW SUCTION PRESSURE LOW SUPERHEAT Uneven or inadequate evaporator loading due to...

Page 429: ...condition of air filter and motors Insufficient air flow Dirty or iced evaporator Dirty air filter Blowers inactive Clogged ducts No flow of refrigerant through expansion valve Filter dryer is clogged...

Page 430: ...psi 171 9 psi 199 8 psi the pressure in the condenser is inferior to the pressure corresponding to the exterior temperature in this case the condenser pressure may be too low Check for refrigerant le...

Page 431: ...8 5 127 6 40 40 0 14 7 101 4 30 34 4 9 8 67 6 20 29 3 8 26 2 10 23 1 8 12 4 0 18 6 3 43 4 10 12 11 6 80 20 7 18 0 124 1 30 1 25 6 176 5 40 4 34 5 237 9 50 10 44 9 309 6 60 16 56 9 392 3 70 21 1 70 7 4...

Page 432: ...l concentration is indicated by a green tint and a large concentration by an intense blue Do not confuse this change in color with the change caused by shutting off the air supply through the hose by...

Page 433: ...Section 22 HEATING AND AIR CONDITIONING PA1593 35 FIGURE 36 CENTRAL HEATING SYSTEM COMPONENTS...

Page 434: ...umatic valve on the ceiling of the spare wheel compartment Fig 37 move the pilot solenoid valve red tab to close the valve FIGURE 37 CEILING OF THE SPARE WHEEL COMPARTMENT WARNING Before proceeding wi...

Page 435: ...the water recirculating pump should be energized to assist in circulating coolant through the heating system To perform this operation start the engine switch on the HVAC control unit both driver and...

Page 436: ...is needed unless a malfunction occurs FIGURE 41 DRIVER S HOT WATER PNEUMATIC VALVE ASSEMBLY Pneumatic Water Valve Disassembly 1 Shut off air supply pressure and electrical current to the pilot soleno...

Page 437: ...lot solenoid valve no air pressure is admitted to the actuator casing the cylinder spring pushes up against the cylinder thereby allowing the hot water to enter the main heater core The central heater...

Page 438: ...icle is provided with a Rotron brushless DC sealess water circulation pump which is located in the engine coolant heater compartment Fig 45 The assembly consists of a centrifugal pump and an electric...

Page 439: ...ket Remove the pump with the motor as an assembly Installation 1 Apply gasket cement to the line flanges put the two gaskets in place and connect water lines to the pump at the flange connections Posi...

Page 440: ...Evaporator air filter Central system Type Polypropylene Prevost number 874272 Driver s unit evaporator motors Voltage 24 V DC Quantity 1 Prevost number 871135 Driver s unit evaporator air filters TYP...

Page 441: ...oil Prevost numbert 950096 Magnetic clutch Type Housing mounted 9 dia 2 B grooves Voltage 24 V DC Coil resistance at 68 o F 20 o C 5 15 5 69 ohms Prevost number 950204 Compressor V belt Carrier Model...

Page 442: ...l kit Water Side 871389 Seal kit Actuator Side 871388 Seal kit Pilot Solenoid Valve 871390 Driver s hot water pneumatic valve Type Normally open Voltage 24 V DC Prevost number 871252 Seal kit Water Si...

Page 443: ...UPPRESSION SYSTEM AFSS 6 4 1 PERIODIC MAINTENANCE 6 5 SPECIFICATIONS 8 ILLUSTRATIONS FIGURE 1 HUBODOMETER 2 FIGURE 2 ELECTRIC HORN INSTALLATION 2 FIGURE 3 R H DASHBOARD PANEL 3 FIGURE 4 WINDSHIEL WASH...

Page 444: ...m the front body understructure Refer to Operator s Manual for operation FIGURE 2 ELECTRIC HORN INSTALLATION 23420 2 1 ELECTRIC HORN MAINTENANCE When needed the electric horn can be serviced or replac...

Page 445: ...voir is located in the front service compartment Fig 5 This unit pumps the washer liquid to the spray nozzles where it is dispersed across the windshield 3 2 WIPER ARM Check operation of the wipers fo...

Page 446: ...ck the adjustment on a wet windshield FIGURE 9 DRIVING MECHANISM DRIVER SIDE 23284 FIGURE 10 DRIVING MECHANISM MOTOR SIDE 23285 3 3 WINDSHIELD WIPER MOTOR 3 3 1 Windshield Wiper Motor Replacement The...

Page 447: ...tions A Add proper fluid B Store coach or parts in heated area then purge system with low temperature solution C Remove with compressed air if severely clogged replace items D Replace section E Realig...

Page 448: ...ning lamps and the audible alarm are operational by pressing the TEST RESET button Manual Activation Switch o Verify that the tamper seal is intact and access to the switch is unobstructed Fire Detect...

Page 449: ...company familiar with Kidde Dual Spectrum equipment and in accordance with KDS Document 160296 KDS Pre Engineered Fire Suppression System Installation Operation and Maintenance Manual Rebuilt shall in...

Page 450: ...ONS HUBODOMETER US model miles Prevost number 650002 ELECTRIC HORN HIGH Prevost number 563023 ELECTRIC HORN LOW Prevost number 563015 WINDSHIELD WIPER MOTOR Prevost number 800328 WIPER BLADE Prevost n...

Page 451: ...CHEDULE 2 2 1 FLEXIBLE HOSE MAINTENANCE 2 2 1 1 Hose Inspection 2 2 1 2 Leaks 2 2 1 3 Service life 2 2 2 LUBRICANT AND COOLANT SPECIFICATIONS 5 2 3 LUBRICATION AND SERVICING SCHEDULE 6 ILLUSTRATIONS F...

Page 452: ...erforms at its best safest and longest Also unscheduled maintenance will be minimized since inspection should expose potential problems before they become major ones 2 1 FLEXIBLE HOSE MAINTENANCE The...

Page 453: ...ended that all hoses in this vehicle be replaced during major overhaul and or after a maximum of five service years Quality of replacement hose assemblies should always be equal to or superior to thos...

Page 454: ...Section 24 LUBRICATION PA1593 4 FIGURE 1 LUBRICATION AND SERVICING POINTS ON I BEAM AXLE FRONT SUSPENSION VEHICLES 24030_1...

Page 455: ...nditions or for better performance full synthetic gear oil can be used F Differential Oil Full Synthetic Multigrade gear oil meeting MIL L 2105 E 85W140 If temperature drops below 10 F 12 C 80W90 shou...

Page 456: ...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 manu...

Page 457: ...lean with low pressure water jet if necessary 5 Radiator fan gearbox change oil 20 G 6 Cooling system drain flush refill Fleet Charge 50 50 Fully Formulated Coolant 21 C 06 ELECTRICAL 1 HD10 Bosch alt...

Page 458: ...ect 5 Brakes check caliper movement along guide pins check sealing elements boots Check proper functioning of the adjuster 6 Accessories air filter change filter element 3 7 Air dryer change cartridge...

Page 459: ...50 000mi changed to 30 000mi 10 02 2014 4 UPDATED 01 ENGINE Automatic belt tensioners idlers bearing play etc was 30 000mi changed to 50 000mi 12 08 2014 5 UPDATED 12 BRAKE AIR SYSTEM Caliper running...

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