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PREVOST X3-45 COMMUTER, Maintenance Manual

The Prevost X3-45 Commuter Maintenance Manual is a comprehensive guide for owners to keep their luxury coach in top condition. This manual covers all aspects of maintenance and troubleshooting for the X3-45 model. Download your free manual from manualshive.com to ensure optimal performance and longevity of your vehicle.

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SECTION 06B: ELECTRICAL

 

 

 

22

 

DOB 2490-2789 | X3-45 Commuter PA1605 Maintenance Manual (Final Version – Rev.2 April 2016)

 

 

FMI 4 

Shorted Low 

Output A45 J1:20 
shorted to ground 

Electrical horn 
L185 and L186 
not working 

•

  A45 module failure 

•

  Electrical horn L185 or L186 

failure 

•

  Connector C4 corroded 

•

  Connector C101 corroded 

•

  Circuit 52A shorted to ground 

FMI 5 

Open Circuit 

A45 module does not 
detect Electrical horn 
L185 or L186 

Electrical horn 
L185 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 horn 
L185 and L186 
not working 

•

  A45 module failure 

•

  Connector C4 corroded 

•

  Connector C101 corroded 

•

  Circuit 52A shorted to ground 

 
 
 
 
 

MID 188 PSID # 110 Indir Lts Rly (A49 J1:12) 

Type of 
fault: 

FMI 
Description: 

Fault Condition: 

Possible 
Symptoms: 

Possible Causes: 

FMI 3 

Shorted High 

Voltage present on 
output A49 J1:12 but 
output not active 

Indirect lighting 
always ON 

•

  A49 module failure 

•

  Indirect Light Relay R13 failure 

•

  Circuit 132 shorted to battery 

FMI 4 

Shorted Low 

Output A49 J1:12 
shorted to ground 

Indirect lighting 
not working 

•

  A49 module failure 

•

  Indirect Light Relay R13 failure 

•

  Circuit 132 shorted to ground 

FMI 5 

Open Circuit 

A49 module does not 
detect Indirect Light 
Relay R13 

Indirect lighting 
not working 

•

  A49 module failure 

•

  Indirect Light Relay R13 open 

circuit 

•

  Circuit 132 open 

FMI 6 

Current 
above normal 

Output A49 J1:12 
internal software fuse 
active for overcurrent 

Indirect lighting 
not working 

•

  A49 module failure 

•

  Circuit 132 shorted to ground 

•

  Relay R13 coil shorted to 

ground 

 

MID 188 PSID # 89 Knee down Sol (A41 J1:14) 

Type of 
fault: 

FMI 
Description: 

Fault Condition: 

Possible 
Symptoms: 

Possible Causes: 

FMI 3 

Shorted High 

Voltage present on 
output A41 J1:14 but 
output not active 

Kneeling down 
always ON, 
coach cannot 
be raised 

•

  A41 module failure 

•

  Kneeling down solenoid valve 

So16 failure 

•

  Connector C4 corroded 

•

  Connector C172 corroded 

•

  Circuit 126F shorted to battery 

FMI 4 

Shorted Low 

Output A41 J1:14 
shorted to ground 

Kneeling down 
not working 

•

  A41 module failure 

•

  Kneeling down solenoid valve 

So16 failure 

•

  Connector C4 corroded 

•

  Connector C172 corroded 

Summary of Contents for X3-45 COMMUTER

Page 1: ...COACH MANUFACTURER MAINTENANCE MANUAL X3 45 COMMUTER DOB Bus Number Series 2490 2789 Final Version Rev 2...

Page 2: ...ection Tightening torques changed in Section 16 Refer to Section 16 Change Log April 2016 Addition of steering play inspection See Section 14 lubrication and SERVICING SCHEDULE August 2016 Fuel tank s...

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: ...cation Number VIN 6 5 FASTENER 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 6 SECTION CHAN...

Page 6: ...e only and may differ slightly from the actual vehicle however key components addressed in the manual are represented as accurately as possible Prevost occasionally sends Maintenance Information Warra...

Page 7: ...the material it is possible to use a conventional electric arc welding machine according to the following specifications o SMAW Shielded Metal Arc Welding process o Welding rod conforms to A5 1 of AWS...

Page 8: ...manual covers only the procedures as of manufacturing date Safety features may be impaired if other than genuine PREVOST parts are installed Torque wrench tightening specifications must be strictly o...

Page 9: ...umber part number assembly number and model number Use all three numbers when ordering parts FIGURE 2 ALLISON TRANSMISSION 07076 4 1 3 Drive Axle FIGURE 3 TYPICAL SERIAL MODEL NUMBERS 00007 4 1 4 Fron...

Page 10: ...ion pressure is also etched on this plate The DOT Certification plate is affixed to the side of the L H control panel FIGURE 6 DOT CERTIFICATION PLATE 00016 4 1 9 Fuel Tank Label The fuel tank label i...

Page 11: ...PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 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 200...

Page 12: ...teners be careful to use fasteners of the 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 siz...

Page 13: ...RQUE lbf ft dry otherwise specified Tolerance 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 l...

Page 14: ...ETRIC M8 X 1 25 nut 9 screw 8 8 16 METRIC 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 7...

Page 15: ...spect the fastener to ensure there is no crack elongation or other sign of fatigue or overtightening If there is any doubt replace with a new self locking fastener of equal or greater strength c Assem...

Page 16: ...m 0 4 0 8 1 4 2 2 3 0 4 2 7 0 ALL METAL BOLTS Lbf in 4 0 7 0 12 18 25 35 57 ADHESIVE OR NYLON Nm 0 4 0 6 1 2 1 6 2 4 3 4 5 6 COATED BOLTS Lbf in 4 0 5 0 10 14 20 28 46 US STANDARD 5 16 3 8 7 16 9 16 5...

Page 17: ...SECTION 00 GENERAL INFORMATION DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 13 FIGURE 12 METRIC US STANDARD CONVERSION TABLE 00005...

Page 18: ...SECTION 00 GENERAL INFORMATION 14 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 13 CONVERSION CHART 00006...

Page 19: ...SECTION 00 GENERAL INFORMATION DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 15 6 SECTION CHANGE LOG DESCRIPTION DATE 1 2 3 4 5 6...

Page 20: ......

Page 21: ...s Phillips head screwdriver Ratchet handle 3 8 socket Electric tape Long nose pliers Reference schematics N A Safety rules Wear safety goggles Set the battery master switch to the OFF position first...

Page 22: ...6 Page 2 of 8 X3 Series Coaches 2 00 Location Rear 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 Jun...

Page 23: ...uch each others and the vehicle body Note With disconnection of the electronic ground terminals disconnecting the engine ECM transmission TCM and the dashboard electronic components telltale module HV...

Page 24: ...CEDURE NO PR060041 REVISION 02 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 Page 4 of 8 2 15 2 Location battery compartment Disconnect data connector on equali...

Page 25: ...Version Rev 2 April 2016 Page 5 of 8 2 20 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...

Page 26: ...PROCEDURE NO PR060041 REVISION 02 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 Page 6 of 8 Disconnect 3 connectors from VECU Disconnect 3 connectors from CECM...

Page 27: ...nance Manual Final Version Rev 2 April 2016 Page 7 of 8 2 30 Location Pneumatic accessory panel inside right console Remove the access panel on the right console R H side of dashboard Disconnect both...

Page 28: ...vious steps are done you can do welding 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...

Page 29: ...IC BELT TENSIONER BUSHING WEAR 18 3 3 BELTS AND IDLERS VISUAL INSPECTION 19 4 ENGINE PROTECTION STRATEGY 19 5 SPECIFICATIONS 20 6 SECTION CHANGE LOG 21 ILLUSTRATIONS FIGURE 1 ENGINE SENSORS LOCATION 5...

Page 30: ...be read via a diagnostic computer or through the instrument cluster display if equipped The Premium Tech Tool PTT is the preferred tool for performing diagnostic work Using a diagnostic computer or PT...

Page 31: ...e 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 the control unit The modif...

Page 32: ...ture 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 manifold Intake Manifold P...

Page 33: ...S LOCATION 1 Intake Air Temperature Pressure Sensor 8 Camshaft Position CMP 2 Engine Oil Pressure EOP 9 Turbine Speed 3 Crankcase pressure CCP 10 EGR Temperature 4 Aftertreatment Fuel Pressure 11 EGR...

Page 34: ...s North America Web Site under Parts Service purchase engine literature D13H engine FIGURE 2 D13H ENGINE OVERVIEW ALTERNATOR SIDE TYPICAL 1 Breather tube 10 Hand priming Pump 2 Intake Manifold 11 Cran...

Page 35: ...April 2016 7 FIGURE 3 D13H ENGINE OVERVIEW TURBO SIDE TYPICAL 17 Exhaust Manifold 24 Venturi Pipe 18 Valve Cover 25 Oil Filters 19 Intake Air Heater IAH Opt 26 Oil Pan 20 Thermostat 27 EGR Cooler 21 B...

Page 36: ...break in oils top oils graphitizers and friction reducing liquids are not necessary and can harm the engine 1 3 3 Oil Change Intervals The length of time an engine can operate before an oil change dep...

Page 37: ...s 1 3 7 Oil Additives CAUTION Extra oil additives must never be added to any engine oil used Additives such as break in oils top oils graphitizers and friction reducing liquids are not necessary and m...

Page 38: ...Total oil fill empty 39 NOTE Since about 1 liter of oil remains in the engine after draining approximately 38 liters will be needed for a complete oil change 1 3 10 Oil Filters Change WARNING Hot oil...

Page 39: ...ON DO NOT let the oil level fall below the marking on the dipstick DO NOT overfill so the level is above the upper marking on the dipstick This could lead to excessive oil temperature and or poor cran...

Page 40: ...COOLING SYSTEM 5 If applicable disconnect the block heater connector located near the EGR mixing chamber With Vehicle Raised 1 Using a vehicle lift or jack raise vehicle to access transmission fastene...

Page 41: ...earbox when pulling the engine out Disconnect and remove section of coolant pipe assembly mounted between the radiator outlet and the water pump inlet Disconnect and remove a section of coolant pipe a...

Page 42: ...mounting bolts to 190 lbf ft 258 Nm 2 Remove 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 save...

Page 43: ...o engine support brackets are used at the front of the engine while two rubber mounts are mounted underneath the engine radiator fan drive mechanism support and the engine alternator support Figure 12...

Page 44: ...ure 13 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 being mi...

Page 45: ...SECTION 01 ENGINE DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 17 FIGURE 13 ELECTRONIC FOOT PEDAL ASSEMBLY 03035...

Page 46: ...stem Torque lbs ft T 1 cooling fan drive 32 2x T 2 water pump drive 43 T 3 alternator drive 43 3 1 BEARING INSPECTION 1 First set parking brake turn the ignition OFF and set the rear start selector sw...

Page 47: ...ltale light comes on and an audible alarm will sound if the engine is running Prior to an actual automatic shutdown the engine will automatically derate go to idle and then stop in 30 seconds ENGINE P...

Page 48: ...Ft lb 2304 Nm Low Idle 600 rpm Fast Idle 2150 rpm Maximum full load revolutions 1900 rpm Engine oil level quantity Oil pan capacity low limit 25 quarts 24 liters Oil pan capacity high limit 34 quarts...

Page 49: ...SECTION 01 ENGINE DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 21 6 SECTION CHANGE LOG DESCRIPTION DATE 1 2 3 4 5 6...

Page 50: ......

Page 51: ...5 3 AIR CLEANER RESTRICTION INDICATOR 12 6 FUEL PEDAL 12 6 1 FUEL PEDAL ADJUSTMENT 12 6 2 POTENTIOMETER REPLACEMENT 13 7 SECTION CHANGE LOG 14 ILLUTRATIONS FIGURE 1 FUEL SYSTEM SCHEMATIC VOLVO D13 ENG...

Page 52: ...ection 03 revised May 2018 FIGURE 18 VISIBLE GAP ON TRANSVERSAL SCREW JOINT 10 FIGURE 19 SHIM INSTALLATION TRANSVERSE SCREW ARRANGEMENT MAY VARY 10 FIGURE 20 RESTRICTION INDICATOR 01052_1 12 FIGURE 21...

Page 53: ...a circular groove around each unit injector in the cylinder head The overflow valve 10 controls the fuel supply pressure to the unit injectors The return fuel from the overflow valve 10 is returned ba...

Page 54: ...UT OFF VALVE VOLVO D13 ENGINE 03088 Shut off valve is designed to prevent loss of fuel prime No manual valve is required on preheater fuel supply line since the positive displacement fuel pump located...

Page 55: ...cked 8 Apply a thin coating of clean engine oil to the surface of the water separation bowl 9 Install a new gasket to the water separation bowl and then reinstall the separation bowl to the new primar...

Page 56: ...or example cleaning or replacing 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...

Page 57: ...ant 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 for leaks and check all...

Page 58: ...g brake stop engine and set battery master switch es to the OFF position prior to working on the vehicle Before working under an air suspended vehicle it is strongly recommended to support the chassis...

Page 59: ...e Tank Removal procedure Apply Valvoline anti corrosion compound on retainer strap studs nuts and fuel tank cradle mounting bolts FIGURE 11 FUEL TANK SUPPORT MOUNTING BOLTS FIGURE 12 FUEL TANK SUPPORT...

Page 60: ...ark Torque 82 lbf ft Hardware part number and description 5001941 screw cap hex M12x1 75x120 g10 9 500806 screw cap hex M12x1 75x35 g10 9 500811 nut hex sto M12 1 75 G10 500958 flat washer ss 531x1 06...

Page 61: ...ene No 1 diesel with no more than 15ppm sulfur may be blended with ULSD fuel to improve cold weather performance With so many kerosene formulations on the market care must be taken to select kerosene...

Page 62: ...e without an element in the air cleaner assembly 8 Store new elements in a closed area free from dust and possible damage 5 3 AIR CLEANER RESTRICTION INDICATOR A resettable restriction indicator is in...

Page 63: ...ng locations of the cable before disassembly Proper cable routing and fastening is critical to the operation of this system Marking the foot pedal assembly to record cable routing is recommended 2 Pos...

Page 64: ...X3 45 Commuter PA1605 Maintenance Manual Section 03 revised May 2018 7 SECTION CHANGE LOG DESCRIPTION DATE 1 Fuel tank strap torque was 60 lb ft changed to 20 lb ft Oct 2016 2 Paragraph 3 4 Fuel Tank...

Page 65: ...K CLEANING 11 5 3 PUMP ASSEMBLY FILTER ELEMENT REPLACEMENT 11 6 AFTERTREATMENT FUEL INJECTOR 12 6 1 REPLACEMENT 12 7 TORQUE SPECIFICATIONS 14 8 SECTION CHANGE LOG 17 ILLUSTRATIONS FIGURE 1 EXHAUST SYS...

Page 66: ...NOx To achieve this goal the exhaust aftertreatment system is split into two main sections the exhaust gases first enter the Diesel Oxidation Catalyst DOC and Diesel Particulate Filter DPF assembly t...

Page 67: ...onsumption due to overuse of active or stationary regeneration 1 2 FLEXIBLE COUPLING INSTALLATION The flexible coupling contains a rigid interior pipe Figure 2 To allow appropriate flexibility once in...

Page 68: ...eneration in 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 a...

Page 69: ...aking apart CAUTION FRAGILE HANDLE WITH CARE Use extreme care when handling DPF cartridge as it could be damaged or destroyed by dropping or sudden impact Clean remanufactured DPF cartridge will be av...

Page 70: ...ced However if the catalytic converter must be replaced use one of the two following procedures 3 1 REMOVAL Procedure 1 Radiator must be removed in order to lower the catalytic converter for replaceme...

Page 71: ...rom entering the system Disconnect and remove section of coolant pipe assembly mounted between the radiator outlet and the water pump inlet Disconnect and remove a section of coolant pipe assembly mou...

Page 72: ...per Assembling Position the upper clamps above the upper emboss and the lower clamps below the lower emboss of the catalytic converter Lower Upper Using the lines made earlier line up the lower and up...

Page 73: ...caused by hot exhaust gases the diffuser louvered cover must be flush with the roof surface or may exceed the roof surface not more than 3 32 2mm CAUTION Tighten clamps properly in order to prevent a...

Page 74: ...pressed air will not help since DEF quickly oxidizes certain metals If a disconnected connector comes into contact with the DEF solution it must be replaced immediately to prevent the DEF solution fro...

Page 75: ...the DEF tank filler neck insert To do so release the retaining tab and remove filler neck insert Replace old seal if damaged 5 Flush the tank with hot water Let all of the water drain from the tank 6...

Page 76: ...order to obtain efficient regeneration process of the DPF Clogged aftertreatment fuel injector will result in clogged DPF In addition to the activation of the CHECK telltale emission of diagnostic tro...

Page 77: ...njector onto the diffuser pipe which attaches to the turbocharger outlet Tighten the fasteners to 125 lbf in NOTE The fasteners already include pre applied high temperature anti seize compound 6 Conne...

Page 78: ...EXHAUST AND AFTERTREATMENT SYSTEM 14 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 TORQUE SPECIFICATIONS FIGURE 11 TORQUE SPECIFICATIONS FIGURE 12 TORQUE SPEC...

Page 79: ...SECTION 04 EXHAUST AND AFTERTREATMENT SYSTEM DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 15 FIGURE 13 TORQUE SPECIFICATIONS FIGURE 14 TORQUE SPECIFICATIONS...

Page 80: ...SECTION 04 EXHAUST AND AFTERTREATMENT SYSTEM 16 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 15 TORQUE SPECIFICATIONS FIGURE 16 TORQUE SPECIFICATIONS...

Page 81: ...N 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 1 5 4 DPF in...

Page 82: ......

Page 83: ...5 5 COOLANT RECOMMENDATIONS FOR MTA COACHES EQUIPPED WITH VOLVO D13 ENGINE 8 5 6 COOLANT SAMPLING 9 6 DRAINING COOLING SYSTEM 10 7 FILLING COOLING SYSTEM 11 8 FLUSHING 11 8 1 COOLING SYSTEM DESCALERS...

Page 84: ...E 15 EXTRACTING COOLANT 10 FIGURE 16 COOLANT FILTER VOLVO D13 12 FIGURE 17 ACCESS TO FILTER SHUT OFF VALVE 12 FIGURE 18 RADIATOR DRAIN PLUG 13 FIGURE 19 ACCESS PANEL TYPICAL 13 FIGURE 20 RADIATOR SEAL...

Page 85: ...he 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 thermostat housing through the by pas...

Page 86: ...he thermostat housing hose connections may be caused by deformation of connections or by rough surfaces on the castings of the hose mounting surfaces It is recommended that Dow Corning RTV 102 Compoun...

Page 87: ...S FIGURE 4 PROPER HOSE CLAMP INSTALLATION All connections equal or greater than of 2 in OD have doubled clamps two clamps side by side with screw housing separated from at least 90 A torque wrench sho...

Page 88: ...g 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 4 THERMOSTAT OPERATION 1 Drai...

Page 89: ...r proper coolant type specifications or see the label affixed near the coolant surge tank on the vehicle When the coolant level reaches the low coolant sensor the red warning light located next to the...

Page 90: ...lected and properly maintained Select and maintain coolant in order to meet the following basic requirements Provide for adequate heat transfer Provide protection from cavitation damage Provide a corr...

Page 91: ...ination Hand vacuum pump should be used for coolant sampling only to prevent cross contamination Also ensure cleanliness throughout this procedure to make sure the coolant sample is not contaminated a...

Page 92: ...ressure cap counterclockwise turn to let air enter the system and permit the coolant to drain completely from system 5 Connect coolant extractor Figure 15 Use coolant extractor to drain the coolant fr...

Page 93: ...to permit coolant circulation Complete the procedure by bleeding the heater cores as explained in Section 22 under Bleeding Heating System 8 FLUSHING If the cooling system is contaminated flush the c...

Page 94: ...ch a hose to the water outlet at the top of the cylinder head thermostat housing and insert the flushing gun in the hose 4 Turn on the water until the jackets are filled and then turn on the air in sh...

Page 95: ...eral spirits and dry with compressed air Do not use fuel oil kerosene gasoline or any caustic material It may be necessary to clean the radiator more frequently if the vehicle is operated in extremely...

Page 96: ...FIGURE 21 RADIATOR CHARGE AIR COOLER HOSE CLAMPS 11 Remove rear coolant and charge air hose clamps then break hoses loose 12 Remove the upper radiator assembly support bracket Figure 22 FIGURE 22 UPP...

Page 97: ...Transfer radiator assembly to a secure location 18 Separate charge air cooler from radiator 19 Lay radiator face down Remove the fasteners that connect lower radiator mounts to radiator FIGURE 26 REM...

Page 98: ...ne WARNING Potential Accident Risk Always use extreme caution when working in the vicinity of hot rotating or moving parts 1 Wrap the new drive belt around the fan drive mechanism pulley the idlers an...

Page 99: ...t may slip of the idler See following figure FIGURE 32 IDLER MOUNTED ON THE CAST ALUMINUM SUPPORT 4 Bolt the new idler on the cast aluminum support Tighten as prescribed 5 Place a new protective cap I...

Page 100: ...s mode the rear start push button can be used to manually engage the fan clutch The multiplex system knows when the engine is already running and it will not activate the starter 4 Press the push butt...

Page 101: ...the oil to drain into a suitable container 5 Replace the seal and screw the drain plug back in Torque as prescribed 6 Unscrew and remove the oil level plug and the top filler plug vent 7 Add gear lub...

Page 102: ...he proper side of the fan Tighten in a star pattern to 32 lbf ft FIGURE 39 RADIATOR FAN MOUNTING BOLTS 05125 15 1 MAINTENANCE 1 Clean the fan and related parts with clean fuel oil and dry them with co...

Page 103: ...ying cracking and proper tension Turn fan through at least 360 of rotation It should turn smoothly with no resistance 16 SPECIFICATIONS Cooling System Capacity Approximation Includes heating system 24...

Page 104: ...TION 05 COOLING SYSTEM 22 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 17 SECTION CHANGE LOG DESCRIPTION DATE 1 Added 5 6 coolant sampling April 8 2016 2 3 4 5...

Page 105: ...NCE DOOR WIPER CONTROL PANEL 14 1 11 1 Parcel Rack Junction Box 14 1 11 2 NYCT Auxiliary Systems And Radio 14 1 11 3 Motorola Radio Power Mode 15 2 BATTERIES 15 2 1 BATTERY DISCHARGE PROTECTION 16 2 2...

Page 106: ...ng the vehicle specific multiplex program in the mcm 37 5 BOSCH ALTERNATORS 39 5 1 ALTERNATOR PERIODIC INSPECTION 40 5 1 1 Identifying a Single Defective Alternator 40 5 2 ALTERNATOR DRIVE BELT 40 5 3...

Page 107: ...MENT OVERVIEW 16 FIGURE 16 BATTERY PROTECTIVE COVER REMOVAL 17 FIGURE 17 LATERAL PANEL OPENING 17 FIGURE 18 BATTERY FIXING CLAMPS REMOVAL 17 FIGURE 19 NEGATIVE TERMINALS 17 FIGURE 20 ALLIGATOR CLAMPS...

Page 108: ...43 FIGURE 46 PROPER LOWER BEAM HIGH INTENSITY ZONE AT 25FT 44 FIGURE 47 AIM INSPECTION LIMITS FOR UPPER BEAM HEADLIGHTS 44 FIGURE 48 AIM INSPECTION LIMITS FOR LOWER BEAM HEADLIGHTS 44 FIGURE 49 REAR...

Page 109: ...Circuit number listing Circuit breaker code Connector code Diode number code Resistor number code Fuse code Relay Code 1 1 1 Using Wiring Diagrams Three methods are used to work with electric wiring d...

Page 110: ...he side locking tabs must have the locks latched in place to ensure a proper electrical connection 1 1 3 Wire Sizes And Colors Each wire in the electrical system has a specific size as designated on t...

Page 111: ...will eliminate the possibility of having cleaning agent tapered in the connector possibly affecting the connector seal To specifically clean oxidized cables a product that offers the same qualities m...

Page 112: ...ion to control a high energy circuit without running great lengths of costly high capacity cable and also eliminates the need for high amperage switches and heavy connectors NOTE Each relay is identif...

Page 113: ...batteries from discharging This will prevent small current drawn by the mcm memory and the instrument cluster clock from draining the battery Note that the diagnostic codes history will be erased and...

Page 114: ...the terminal by disengaging the flexible lock tab on the terminal Gently remove the terminal from the connector by pulling on the wire Io A Green Blue Mcm Jae Extractor Tool Prevost 683766 Using a sm...

Page 115: ...ual Final Version Sec 06 revised June 2017 11 VECF INS ERT EXT RACT OR HERE Bussman Extractor Tool Prevost 682256 Packard 12094429 Remove the terminal by disengaging the flexible lock tab on the termi...

Page 116: ...this section for recommended products and where they are used CAUTION Never put grease or other product on the multiplex modules connector terminals DANGER Use sprayed sealer in a well ventilated area...

Page 117: ...ays 2 and to the prime battery monitoring components FIGURE 7 BATTERY COMPARTMENT 06773 1 9 FRONT ELECTRICAL AND SERVICE COMPARTMENT The front electrical and service compartment is located on L H side...

Page 118: ...from the batteries is cut off with the exception of the fire detection system the engine transmission electronic controls the battery equalizer and the cluster digital clock 1 11 ENTRANCE DOOR WIPER C...

Page 119: ...prevents spills and results in greater resistance to vibration Always replace these batteries with identical make and model batteries as the system is balanced and optimized for this type of battery D...

Page 120: ...r 2 2 MAIN BATTERY RELAYS Main battery master relays 12v and 24v are provided for this vehicle The relays are located in the battery compartment and in the rear electrical panel The 24 volt battery re...

Page 121: ...tery relay Figure 15 is still powered after battery master switch is set at the off position 3 Unscrew tie down nuts 6x and remove clamps 2x Figure 18 FIGURE 18 BATTERY FIXING CLAMPS REMOVAL 4 Remove...

Page 122: ...Volts 12 Load test amperage 1 2 cca 575 Reserve capacity minutes 205 Cold cranking in amps at 0o f 1150a Maximum dimensions Length including flange 13in 330mm Width 6 8in 173mm Height including top po...

Page 123: ...s circuit Note If it is necessary to extend the voltmeter lead for this test use a 16 awg or larger wire 3 Check voltage drop between the starter housing and a good ground on the vehicle The reading s...

Page 124: ...irm contact with the terminal battery adapter Never clamp charger or tester directly onto threaded studs or nuts FIGURE 20 ALLIGATOR CLAMPS Warning Always turn off the charger before connecting or dis...

Page 125: ...your charger is multi staged and minimally provides the following voltage values Charge stage voltage 13 8 14 6 77 f 25 c Float stage voltage 13 4 13 6 77 f 25 c Charging agm battery on a typical con...

Page 126: ...ded driving at a slow speed while using many accessories 6 Loose or poor battery cable to post connections previous improper charging of a run down battery or loose hold down clamp bolts 7 High resist...

Page 127: ...mat agm batteries and a new vanner 80 series battery equalizer that monitors battery state of charge soc Battery temperature voltage and current are also monitored to prevent overcharging and overhea...

Page 128: ...g range 12v current sensor fault scsf 520451 2 data erratic intermittent or incorrect most severe 24v current sensor fault dcsf 520452 0 data valid but above normal operating range most severe 24v cur...

Page 129: ...4v o For a 12v module an active voltage would be 12v or 0v but not in between If you measure the intermediate tensions ex 6v 2v or 4v this must be interpreted as if the input or the output is inactive...

Page 130: ...fan switch Engine rear start selector switch rear start Engine rear start selector switch normal Engine ignition front switch Engine ignition rear switch Entrance door inside opening closing switch E...

Page 131: ...overhead compartments a c unit refrigerant solenoid valve activates 2 times audible clicks will be heard The haldex consep oil separator automatic drain valve activates 3 times audible clicks will be...

Page 132: ...vehicle tests submenu and then activate radiator fan speed 1 or activate radiator fan speed 2 as required 2 The DID status line will show test to confirm the forced activation of the radiator fan clu...

Page 133: ...ion engine abs allison Dl 2 can iso for engine diagnostics and software download Dl 3 can 2 or d bus Dl 4 j1587 drive train information network Dl 5 6 not used Dl 7 power train subnet or engine can Dl...

Page 134: ...b Check reset circuit breaker cb2 check replace fuse f78 None of the multiplexed functions are operating including the basic limp home functions door opening flashers wipers in speed 1 Note the sunsh...

Page 135: ...oor opening button is still functioning Entrance door does not open nor close using the control buttons Defroster fan not functioning Windshield wipers not functioning in speed 1 or intermittent Modul...

Page 136: ...ctioning Electric horn not functioning Module a45 is not powered or is faulty 1 Check the diagnostics menu of driver information display DID Select fault diagnostics and electrical system The message...

Page 137: ...ot engage Module a52 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 moda52 active ind...

Page 138: ...key to the on position off position and then on position again and then start the vehicle This will deactivate the fire alarm function This has to be repeated each time the vehicle is re started The...

Page 139: ...he maintenance manual 4 9 MULTIPLEX ERROR MESSAGES TROUBLESHOOTING LIST Multiplex error messages that can be displayed on driver information display DID are alphabetically listed in section 06b at the...

Page 140: ...e ceiling lights Front clearance lights 4 13 MULTIPLEX MODULES 4 13 1 MCM Module The mcm plays the role of interface between the engine ECM the transmission TCM the telltale panel module and other IO...

Page 141: ...Select fault diagnostics and electrical system Verify the fault message to be certain the module is reprogrammed If the module is not reprogrammed the message axx not responding appears where axx is...

Page 142: ...out to update example file mp_00125146a11 for bus 2408 which as vin 2pcg33491cc735146 6 Double click on the specific multiplex program file a dialog box will open You must enter a valid communication...

Page 143: ...URE 35 ALTERNATORS DRIVE BELT 3 Mount the a c compressor idler pulley onto alternators support assembly 3 Figure 36 Torque tighten to 150 lb ft use some Loctite 243 blue 680038 onto the threads 4 Inst...

Page 144: ...tor pin 9 1 Back probe pin 8 A49 J1 8 If multimeter reads 1 2 volts the lower alternator is defective If multimeter reads 12 volts you have an open circuit If multimeter reads 26 volts or greater the...

Page 145: ...n drive Keep clear of curbside door cooling fan when engine is running Fan may engage without warning The engine compartment curbside door fan will blow outside air toward the alternators according th...

Page 146: ...and circuit breakers are shown on the applicable wiring diagrams Wiring diagrams are located in the technical publication box Headlights Each headlight assembly consists of two 90 mm 3 inch headlamp m...

Page 147: ...ted on the screen at the upper and lower limits called for in the specification with reference to the height of beam centers and the plane on which the vehicle rests not the floor on which the screen...

Page 148: ...Remove the bulb by pushing and rotating it out of the socket 5 Install the new bulb by reversing the previous procedure Caution During this step avoid contacting the bulb with the fingers not to alte...

Page 149: ...side of the vehicle Furthermore when braking two center stoplights led and a center high mounted stop light chsl led will illuminate simultaneously with the stoplights on the sides for increased safe...

Page 150: ...learance and identification lights are red and the front ones are amber The amber marker lights are mounted along the sides of vehicle The side marker light is a sealed unit led and should be replaced...

Page 151: ...Replace the rear dashboard housing 11 2 STEPWELL LIGHTS Two stepwell lights are illuminated when the door opening system is activated 11 2 1 Bulb removal and replacement Proceed as follows to replace...

Page 152: ...al Final Version Sec 06 revised June 2017 Each light is sealed and can be replaced as follows 1 Disconnect the light unit connection 2 Unfasten the two fixing screws then remove the lamp 3 Position an...

Page 153: ...e To Post 17 Lbf Ft 200 Lbf In Alternator Make Bosch Series Hd 10 Amperes 150 Volts 28 4 Output Power 3 Kw Ground Negative Battery Equalizer Make Vanner Model Vann Guard 80 Series Amperes 100 Amps Bat...

Page 154: ...ltage 24 No Load Test Volts 23 5 Max Current Draw 125 Amperes Min Rpm 3000 Rpm Starter Solenoid Make Mitsubishi Electric Corporation Melco Pull In Voltage 16 Volts Max 13 SECTION CHANGE LOG DESCRIPTIO...

Page 155: ...ct Nyogel Grease 3 Oz tube 681095 Container 500g 683409 Grease type product It is used to facilitate connectors or terminals insertion Refer to table for proper use of Nyogel grease It is preferable t...

Page 156: ...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 157: ...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 158: ...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 159: ...ground A C clutch not working A52 module failure 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 f...

Page 160: ...69 Aux Bypass Sw A42 J1 10 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage above normal on A42 J1 10 Aux bypass switch not working A42 modul...

Page 161: ...internal software fuse active for overcurrent Brake interlock not working A42 module failure Connector C172 corroded Connector C8 corroded Circuit BrkAux shorted to ground So55 Low resistance value ex...

Page 162: ...nd Circuit 79A shorted to ground Circuit 953 shorted to ground MID 188 PSID 108 Ceiling Door Lt A44 J1 5 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted H...

Page 163: ...MI 6 Current above normal Output A50 J1 7 internal software fuse active for overcurrent L68 not working A50 module failure Connector C58 corroded Connector C21 corroded Circuit 23A shorted to ground L...

Page 164: ...er fans not working on speed 2 A49 module failure Connector C21 corroded Connector C58 corroded Circuit 2B shorted to battery FMI 4 Shorted Low Output A49 J1 16 shorted to ground Condenser fans always...

Page 165: ...tion Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A47 J1 1 but output not active Defroster fans Mo24 and Mo25 not working A47 module failure A24 modul...

Page 166: ...open circuit Circuit 39D open FMI 6 Current above normal Output A44 J1 3 internal software fuse active for overcurrent Driver Light L16 not working A44 module failure Connector C45 corroded Circuit 3...

Page 167: ...int above 70 F and full A C with set point below 70 F A55 module failure Se21 failure Circuit ANA 89 shorted to ground FMI 5 Open Circuit A55 module does not detect Driver Temperature Sensor Se21 Driv...

Page 168: ...3 failure Circuit 65D shorted to battery FMI 4 Shorted Low Output A47 J1 4 shorted to ground Recirculation mode not working low A C performance A47 module failure Gaz Cylinder driver LH L283 failure G...

Page 169: ...High Voltage present on output A36 JA 24 but output not active Engine will shut down or cannot be started A36 module failure Relay R21 failure Connector C2 corroded Connector C21 corroded Circuit 911...

Page 170: ...ground MID 188 PSID 53 Engine Fan Spd1 A52 J1 1 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A52 J1 1 but output not act...

Page 171: ...en FMI 6 Current above normal Output A52 J1 2 internal software fuse active for overcurrent Radiator fan clutch Mo2 not working on speed 2 A52 module failure Connector C91 corroded Connector C426 corr...

Page 172: ...module failure Circuit 49A shorted to ground Close solenoid valve So6 shorted to ground MID 188 PSID 64 Ent Door Close A36 JB 10 Type of fault FMI Description Fault Condition Possible Symptoms Possibl...

Page 173: ...8 but output not active Unlk Solenoid Valve So3 or Unlk Solenoid Valve So4 always ON Entrance door cannot be locked A47 module failure Unlk solenoid valve So3 failure Unlk dolenoid valve So4 failure C...

Page 174: ...und MID 188 PSID 130 Flasher LH A45 J1 9 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on input A45 J1 9 but output not active LH f...

Page 175: ...J1 3 but output not active Front LH flasher and marker lights always ON A45 module failure Connector C4 corroded Connector C242 corroded Circuit 21A shorted to battery FMI 4 Shorted Low Output A45 J1...

Page 176: ...e failure Connector C243 corroded Circuit 23A shorted to ground FMI 6 Current above normal Output A48 J1 6 internal software fuse active for overcurrent Front Flasher RH L61 not working A48 module fai...

Page 177: ...oltage present on input A53 J1 9 but switch Sw58 not active Engine cannot be started or stopped from rear A53 module failure Rear start switch Sw58 failure Connector C91 corroded Circuit 85C shorted t...

Page 178: ...re fuse active for overcurrent Headlamp washer pump Mo54 not working A46 module failure Connector C4 corroded Circuit 202 shorted to ground MID 188 PSID 143 Head Lights Pos1 A43 J1 4 Type of fault FMI...

Page 179: ...o ground MID 188 PSID 145 High Beam RH A48 J1 3 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A48 J1 3 but output not act...

Page 180: ...module failure Indirect Light Relay R13 failure Circuit 132 shorted to battery FMI 4 Shorted Low Output A49 J1 12 shorted to ground Indirect lighting not working A49 module failure Indirect Light Rel...

Page 181: ...e Connector C71 corroded Connector C170 corroded Circuit 126A shorted to ground MID 188 PSID 94 Knee Up Sw A41 J1 6 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI...

Page 182: ...I 3 Shorted High Voltage present on output A45 J1 7 but output not active LH Low beam Headlamp L60A always ON A45 module failure Connector C4 corroded Connector C242 corroded Circuit 58L shorted to ba...

Page 183: ...eld washer pumps Mo19 and Mo20 not working A46 module failure Windshield washer pump Mo19 or Mo20 failure Connector C4 corroded Connector C61 corroded Circuit 53F shorted to ground FMI 5 Open Circuit...

Page 184: ...ossible Causes FMI 3 Shorted High Voltage present on input A42 J1 9 but switch Sw5 not active Next Stop Request not working A42 module failure Connector C70 corroded Connector C25A corroded Circuit 4C...

Page 185: ...cannot be opened with Inside switches A44 module failure Inside switch open Sw33 or Inside switch close Sw32 open circuit Circuit 2mph open FMI 6 Current above normal Output A44 J1 4 internal software...

Page 186: ...re Parcel Rack Fan switch Sw27 failure Connector C74 corroded Circuit 43G shorted to ground MID 188 PSID 162 Park brak Sens A36 JB 9 Type of fault FMI Description Fault Condition Possible Symptoms Pos...

Page 187: ...lure Circuit 13 shorted to battery FMI 4 Shorted Low Output A54 J1 21 shorted to ground Pre Heat relay R26 not working A54 module failure Pre Heat relay R26 failure Circuit 13 shorted to ground FMI 5...

Page 188: ...1 open circuit Circuit 77C or 77B open FMI 6 Current above normal Output A54 J1 3 internal software fuse active for overcurrent Pass Liquid Solenoid Valve So11 not working A54 module failure Connector...

Page 189: ...not detect Reading Lights Master Relay R14 Reading Lights not working A49 module failure Reading Lights Master Relay R14 open circuit Circuit 74C open FMI 6 Current above normal Output A49 J1 15 inter...

Page 190: ...Light RH L73 upper rear RH L285 and Rear Side markers RH L76 not working A51 module failure Connector C91 or C119 corroded Circuit 23AA shorted to ground FMI 6 Current above normal Output A51 J1 3 int...

Page 191: ...9 always ON A53 module failure Rear Start Switch Sw59 failure Connector C91 corroded Circuit 85E shorted to battery FMI 4 Shorted Low Output A53 J1 11 shorted to ground Rear Start Switch Sw59 not work...

Page 192: ...ses FMI 3 Shorted High Voltage present on output A43 J1 30 but output not active Step Nozzle Light L20A always ON A43 module failure Connector C6 or C65 corroded Circuit 35A shorted to battery FMI 4 S...

Page 193: ...cuit 46 shorted to ground FMI 5 Open Circuit A51 module does not detect Tail Lights L72 L74 L77 L78 L79 L80 L82 or L83 Tail Lights L72 L74 L77 L78 L79 L80 L82 or L83 not working A51 module failure Cir...

Page 194: ...188 PSID 31 Unloader LH A52 J1 8 Type of fault FMI Description Fault Condition Possible Symptoms Possible Causes FMI 3 Shorted High Voltage present on output A52 J1 8 but output not active Unloader LH...

Page 195: ...Res37 Upper Defrost LH Heater Res37 not working A46 module failure Upper Defrost LH Heater Res37 failure Circuit 5A open FMI 6 Current above normal Output A46 J1 1 internal software fuse active for ov...

Page 196: ...Various WUp Relays failure Connector C2 or C21 corroded Circuit 85B shorted to ground FMI 5 Open Circuit A36 module does not detect 24v Fr WUp relay R18 12v Fr WUp relay R19 12v Rr WUp relay R17 or 12...

Page 197: ...47 failure Connector C27 C31 or C29 corroded Circuit 306 shorted to battery FMI 4 Shorted Low Output A53 J1 7 shorted to ground WCL Door open Relay R47 not working A53 module failure WCL Door open Rel...

Page 198: ......

Page 199: ...2 Data Error A43 Module 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 MODUL...

Page 200: ...n CAN network A48 module 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 M...

Page 201: ...uit Fuse F72 defective MID 188 PSID 226 A51 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...

Page 202: ......

Page 203: ...LICATION Model VIN X3 45 Commuter Model Year From 2012 APPLICABLE TO DOB Bus Number Series 2400 2489 DOB Bus Number Series 2490 2789 MATERIAL Parts and product that might be required Part No Descripti...

Page 204: ...PECIAL TOOLS REQUIRED TO TIGHTEN THE ALTERNATOR PULLEY MOUNTING NUT METRIC 10mm 12 POINTS SPLINE DRIVE LONG CARLYLE SLTS3810M AVAILABLE FROM NAPA OFFSET 7 8 WRENCH CYLINDER HEAD WRENCH SNAP ON PART NU...

Page 205: ...PROCEDURE DANGER Park vehicle safely apply parking brake stop engine In the battery box set the battery cut off switch to the OFF position prior to working on the vehicle 1 Remove the A C compressor b...

Page 206: ...e 2 FIGURE 2 5 Remove the existing alternators To do so unscrew identified mounting bolts on figure 3 and retain for use if in good condition 6 Identify alternator cables and then disconnect cables Pr...

Page 207: ...n damaged pitted eroded 8 In order to assure proper installation it is important to tighten the alternator mounting bolts in proper sequence Use Loctite 243 blue on threads figure 4 1st Bolt Nut B 43...

Page 208: ...MI14 40B Page 6 10 QF7720955 rev 2 10 Install the alternator belt figure 6 FIGURE 6 11 Cable connection overview Upper and lower alternator figure 7 FIGURE 7...

Page 209: ...0 lbf ft figure 8 prior installing main battery cable power cable d Fit the main battery cable onto adaptor stud place one new flat washer 5001341 against the battery cable terminal and screw a new nu...

Page 210: ...new flat washer 5001341 against the jumper cable ring terminal and screw new nut 5001787 nut torque 10 lbf ft figure 10 16 Fit the ground cable onto the alternator ground stud place one new flat wash...

Page 211: ...pressor belts FIGURE 12 20 Finally check that all cables are properly installed start engine and check for proper functioning Check for proper functioning of charging system PARTS WASTE DISPOSAL Disca...

Page 212: ......

Page 213: ...NTERVAL 8 3 4 1 Oil and Filter Change Interval 9 3 5 FLUID AND FILTER CHANGE PROCEDURE 9 3 5 1 Drain 9 3 5 2 Refill transmission 10 3 6 CLEANING AND INSPECTION OF ALLISON AUTOMATIC TRANSMISSION 10 3 6...

Page 214: ...RATIONS FIGURE 1 ALLISON TRANSMISSION 3 FIGURE 2 ALLISON TRANSMISSION CONTROL PAD 3 FIGURE 3 OIL LEVEL DIPSTICK AUTO TRANS 4 FIGURE 4 COLD CHECK 5 FIGURE 5 HOT CHECK 5 FIGURE 6 DRAIN PLUG AND FILTERS...

Page 215: ...ic sensors With this information it computes shift points and clutch pressures to meet immediate needs Using closed loop adaptive logic the electronic control looks at a number of parameters during th...

Page 216: ...nsmission parts and clogged passages Check the oil level using the procedures in Cold Check and Hot Check Record any abnormal level on your Maintenance Records Always check the oil level reading at le...

Page 217: ...500 800 rpm 3 Remove the dipstick from the tube and wipe it clean Insert the dipstick into the fill tube pushing down until it stops 4 Remove the dipstick and observe the fluid level The safe operatin...

Page 218: ...O HIGH Engine speed rpm too high MUST BE IN NEU N Neutral must be selected OIL TEMP TOO LOW Sump fluid temperature too low OIL TEMP TOO HIGH Sump fluid temperature too high VEH SPD TOO HI Output shaft...

Page 219: ...ndling transmission fluid Antifreeze and coolant solutions contain ethylene glycol that if introduced into the transmission can cause the clutch plates to fail 3 3 3 Oil Contamination At each oil chan...

Page 220: ...ters Fluid Filters Main Lube Internal Main Lube Internal Whichever is the first of the following 150 000 Miles 240 000 km 48 Months 6000hrs Note always replace main and lube filters with the fluid cha...

Page 221: ...a fluid analysis program the fluid change interval listed in TABLE 1 TABLE 2 should be used IMPORTANT NOTE A mixture of TES295 and TES389 fluid must continue to use the TES389 fluid change intervals u...

Page 222: ...ns will determine the frequency of such inspections Inspect the transmission for 1 Loosen bolts transmission and mounting components 2 Oil leaks correct immediately 3 Loose dirty or improperly adjuste...

Page 223: ...ed 4 Unfasten the constant torque hose clamps and remove the two hoses 5 Unscrew the holding bolts and nuts and remove the oil cooler from engine compartment 5 ALLISON TRANSMISSION INSTALLATION 1 Plac...

Page 224: ...ube 16 Install cross member under transmission 17 Install engine splash guards 18 Adjust the retarder pressure to 80 3 psi with the air pressure regulator For more information refer to Section 12 BRAK...

Page 225: ...d1 in the queue after a number of engine starts without becoming active again 6 1 1 Using Shift Selector for Accessing Diagnostics Information DTCs can be displayed on the display portion of the shif...

Page 226: ...4 Turn off power to the TCM shut off the engine using the ignition key NOTE Be sure to record all codes displayed before they are cleared This is essential for troubleshooting NOTE If clearing a code...

Page 227: ...ion Fluid Level Sensor Circuit Low Input No None P070D Transmission Fluid Level Sensor Circuit High Input No None P0712 Transmission Fluid Temperature Sensor Circuit Low Input Yes Use default sump tem...

Page 228: ...ntrol Circuit High Yes 7 speed Allow 2 through 6 N R P097A Shift Solenoid 1 SS1 Control Circuit Open Yes Lock in range P097B Shift Solenoid 2 SS2 Control Circuit Open Yes 7 speed Allow 2 through 6 N R...

Page 229: ...nsmission Clutch Life Expired Clutch Adaptive Learning at Limit No None P2793 Gear Shift Direction Circuit Yes Ignores PWM input from shift selector P2808 Pressure Control Solenoid 6 PCS6 Stuck Off Ye...

Page 230: ...tage three element polyphase Stall torque ratio TC 551 1 8 Lockup clutch with torsional damper Integral standard Gearing Type Patented constant mesh helical planetary Ratio First 3 51 1 Second 1 91 1...

Page 231: ...SECTION 07 TRANSMISSION DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 19 8 SECTION CHANGE LOG DESCRIPTION DATE 1 2 3 4 5 6...

Page 232: ......

Page 233: ...G MARKS 7 3 4 GREASE ZERKS 7 3 5 OTHER INSPECTIONS 7 4 REMOVAL 7 4 1 PROPELLER SHAFT REMOVAL 7 4 1 1 Inspect Companion Flange Flange Yokes 8 4 2 REMOVAL PROCEDURE FOR UNIVERSAL JOINT KITS 9 4 2 1 Remo...

Page 234: ...NTATION 8 FIGURE 12 COLD FORMED BEARING RETAINERS 8 FIGURE 13 UNSEATING BEARING CUP ASSEMBLIES 8 FIGURE 14 RAISED METAL OR FRETTING ON OPEN YOKE CROSS HOLES 8 FIGURE 15 SPRING TAB BOLTS REMOVAL 9 FIGU...

Page 235: ...SECTION 09 PROPELLER SHAFT DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 3 1 PROPELLER SHAFT DESCRIPTION FIGURE 1 PROPELLER SHAFT ASSEMBLY DOB 2490 2789 09002_2...

Page 236: ...eline failure which can result in separation of the driveline from the vehicle MAINTENANCE Lubricate propeller shaft universal joints periodically every 24 000 miles Apply grease gun pressure to the l...

Page 237: ...is checked The driveshaft guard hoop must be in place Driveshaft universal joints must be greased properly NOTE If necessary rotate driveshaft to allow access to all grease fittings It is the respons...

Page 238: ...move the bearing retainer bolts and bearing retainers and discard Do NOT reuse c Once the bearing cups are free allow the propeller shaft to rest on the support strap d Apply a c clamp around the inbo...

Page 239: ...ace damaged zerks Torque zerks to 15 lbf ft Zerks should be lined up with outboard bearings Clean zerk nipples before greasing 3 5 OTHER INSPECTIONS Refer to Spicer Driveshaft s Service Manual DSSM 01...

Page 240: ...open end yoke cross holes Allow the propeller shaft to rest on support strap FIGURE 13 UNSEATING BEARING CUP ASSEMBLIES 5 Remove bearing retainers and bolts at the front end 6 Inspect all end yoke cr...

Page 241: ...until the shoulder of the journal cross makes contact with the inside of the yoke ear CAUTION DO NOT over press the bearing cup and journal cross This can damage the inside of the yoke ear FIGURE 18...

Page 242: ...the spline sleeve for damage If the splines are damaged missing or twisted complete propeller shaft replacement is necessary 7 Inspect the entire slip assembly for contaminants If the slip assembly sh...

Page 243: ...er clamp torque If clamps still are not stationary repeat disassembly and assembly procedure DO NOT reuse clamps 5 2 PROPELLER SHAFT INSTALLATION 1 Before installing the propeller shaft inspect the yo...

Page 244: ...ross holes with the grease zerk fitting inward toward tubing The double headed grease 1 Prevost production line torque value zerk nipple fitting should be perpendicular to the yoke cross holes Note Fa...

Page 245: ...EXPLANATION OF COMMON DAMAGES 1 Cracks Stress lines due to metal fatigue Severe and numerous cracks will weaken the metal until it breaks 2 Galling Scraping off of metal or metal displacement due to f...

Page 246: ...ROPELLER SHAFT 14 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 SPECIFICATIONS PROPELLER SHAFT Make Spicer Series SPL250 8 SECTION CHANGE LOG DESCRIPTION DATE...

Page 247: ...RONT WHEEL ALIGNMENT 7 6 1 INSPECTION BEFORE ALIGNMENT 7 6 2 MINOR FRONT WHEEL ALIGNMENT 7 6 3 MAJOR FRONT WHEEL ALIGNMENT 7 6 4 TURNING ANGLE ADJUSTMENT 7 6 4 1 R H Turn Adjustment 8 6 4 2 L H Turn A...

Page 248: ...no need or facility for re lubrication Brakes are manufactured by KNORR BREMSE Steering ball joints with hardened balls and rubbing pads incorporate compression springs which automatically take up an...

Page 249: ...SECTION 10 FRONT AXLE DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 3 FIGURE 1 FRONT AXLE ASSEMBLY 10025...

Page 250: ...et 2 33 Screw 26 32 lbf ft 4 9 Stud 16 34 Cap Knuckle Bottom 2 10 Knuckle 2 35 Bottom Steering Lever 2 11 Brake Fixing Bolt 350 393 lbf ft 12 36 Bottom Steering Lever Stud 4 12 Nut Self Lock 133 155 l...

Page 251: ...teering knuckles knuckle pins and bushings can be overhauled or replaced without removing the axle from the vehicle However if extensive overhaul work is necessary the axle assembly should be removed...

Page 252: ...commencing checks apply parking brake raise wheels off ground and support axle on stands 5 1 1 Checking Lateral Slackness Following regular and thorough greasing practices will maximise bushing life...

Page 253: ...torque Use a torque wrench for verification As soon as the fastener starts to move record the torque Correct if necessary Replace any worn or damaged fasteners 6 2 MINOR FRONT WHEEL ALIGNMENT Perform...

Page 254: ...oint of contact of the ball socket body with the air bellows support assembly Measure the distance between those two points 3 The distance between these two points should be approximately 1 8 inch 3 m...

Page 255: ...ring around corners A shimmy may also develop when returning to the straight ahead position pulling out of curves Insufficient caster will cause wandering and steering instability Caster variations ma...

Page 256: ...els will not return to their normal operating position due to the tires gripping the floor surface when the vehicle jack is lowered NOTE Toe in measurements must be taken at the horizontal axis of the...

Page 257: ...improperly 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 i...

Page 258: ...ated 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 Sectio...

Page 259: ...QUE CHART 5 1 5 DRIVE AXLE ALIGNMENT 6 1 5 1 Procedure 6 2 TAG AXLE 8 2 1 UNLOADING TAG AXLE 8 2 2 RETRACTING TAG AXLE 8 2 3 RETRACTING TAG AXLE FOR REPAIR PURPOSES 9 2 4 GREASE LUBRICATED WHEEL BEARI...

Page 260: ...pension 1 1 1 Differential Oil Type Use Mobil Delvac synthetic gear oil 80W140 for best performance and extreme conditions Additional lubrication information is covered in ZF s list of lubricants TE M...

Page 261: ...the drain plug and tighten to 96 lbf ft 130 Nm 10 Add the specified oil at the filler plug until the oil level is even with the bottom of the level check bore Filling volume is about 19 quarts 18 lit...

Page 262: ...oving and installing the drive axle speed sensors for anti lock brake systems ABS refer to Section 12 Brake and Air System 1 2 DRIVE AXLE FLANGE SHAFT REMOVAL INSTALLATION Refer to Replacement of Axle...

Page 263: ...t the air brake supply hoses over the differential carrier NOTE Position the hoses so they will not be damaged when removing the axle 8 Install jack stands under the drive axle subframe at the four lo...

Page 264: ...removed for repairs or servicing and if all the parts are reinstalled exactly in the same place the axle alignment is not necessary However if the suspension supports have been replaced or altered pro...

Page 265: ...Total toe 0 15 toe in 0 0 15 toe out TAG AXLE ALIGNMENT Remove and reinstall all wheel mount sensors on the drive and tag axles Figure 6 NOTE For an accurate alignment the tag axle must be aligned wit...

Page 266: ...lly reduced by 75 when the coach is moving at speed lower than 5 mph 8 km h and with more than 1 turn from the steering 2 2 RETRACTING TAG AXLE The standard tag axle retraction system is controlled by...

Page 267: ...ag axle wheel hub refer to DANA SPICER Service Manual NDS Axle Range found in the OEM manuals folder 2 5 REMOVAL AND INSTALLATION 2 5 1 Removing Tag Axle Only The following procedure deals with the re...

Page 268: ...through a false maneuver 14 Reverse removal procedure to reinstall tag axle NOTE Refer to Section 16 Suspension for proper torque tightening of suspension components NOTE Refer to section 13 Wheels H...

Page 269: ...previous locations axle alignment is not necessary However if the suspension supports have been replaced or have changed position proceed with the following instructions to verify or adjust the tag ax...

Page 270: ......

Page 271: ...GAUGES PRIMARY SECONDARY AND ACCESSORY 6 7 AIR DRYER 7 7 1 AIR DRYER REPLACEMENT 8 7 1 1 Testing the installation 8 7 1 2 Final check 9 7 2 DESICCANT CARTRIDGE REPLACEMENT 9 8 HALDEX CONDENSER SEPARA...

Page 272: ...NCE 21 25 6 TORQUE SPECIFICATIONS 21 26 SAFE SERVICE PROCEDURES 21 27 AIR BRAKE TROUBLESHOOTING 23 28 BRAKE AIR CHAMBER 24 28 1 MAINTENANCE 24 28 2 EMERGENCY PARKING BRAKE MANUAL RELEASE 25 28 3 BRAKE...

Page 273: ...TR 6 14 FIGURE 22 SR 7 15 FIGURE 23 PR 4 15 FIGURE 24 DC 4 15 FIGURE 25 THREE WAY VALVE 15 FIGURE 26 BRAKE COMPONENTS 18 FIGURE 27 BRAKE PAD WEAR CHECK ON DRIVE AXLE 19 FIGURE 28 PAD WEAR CHECK FRONT...

Page 274: ...oad The vehicle is also equipped with an Anti Lock Braking System ABS which is detailed later in this section The drive axle is provided with spring loaded emergency parking brakes which are applied a...

Page 275: ...the front axle and is provided with a bottom drain valve Figure 1 Purge the reservoir by its drain valve every 12 000 miles FIGURE 3 EMERGENCY AIR SYSTEM FILL VALVES AND DRAIN COCK 12211_1 3 2 5 Secon...

Page 276: ...s Check condition of all three O rings for damage Replace when necessary Figure 5 5 2 CLEANING Clean filter body and bowl with a warm water and soap solution Rinse thoroughly with clean water Blow dry...

Page 277: ...DRYER LOCATION The air dryer has a built in function to prevent freezing or blockage The function provides temporary relief air dryer blow clean at engine shut down This function eliminates the proble...

Page 278: ...21 12 Unscrew and remove three bolts mounting the air dryer to the bulkhead 13 Remove and transfer the inlet port 1 fittings assembly as a single unit to the new air dryer assembly Install the fittin...

Page 279: ...mergency air fill valve drain cock Figure 3 4 Loosen and remove the old cartridge Use strap wrench if necessary 5 Remove and discard O ring from dryer base Inspect and clean seal seat Figure 10 6 Repa...

Page 280: ...use copper or nylon tubing due to constant flexing during operation such as brake chamber hoses Hose connections should be tested for leakage at least every 6 250 miles 10 000 km or twice a year which...

Page 281: ...IGURE 12 AIR PRESSURE REGULATING VALVE 12141A 10 2 PRESSURE SETTING PROCEDURE Remove the dust cap from the pressure check valve Figure 12 Attach a pressure gauge at this port and check the pressure re...

Page 282: ...he spring brakes are self actuated whenever the control valve supply pressure drops below 60 psi 414 kPa In the UP position brakes are ON In the DOWN position brakes are RELEASED A protective case aro...

Page 283: ...138 15 DUAL BRAKE APPLICATION VALVE E 8P The E 8P dual brake application valve is a floor mounted foot operated type brake valve with two separate supply and delivery circuits This valve is located in...

Page 284: ...NC relay to sound a warning alarm by completing the electrical circuit when the ignition switch is turned OFF with parking brake released 17 BRAKE RELAY VALVE R 14 The primary air system includes thre...

Page 285: ...ted in the front service compartment beside the air filter FIGURE 23 PR 4 12174 The other valve is installed on the accessory air tank and insures a minimum pressure of 75 psi 517 kPa in the accessory...

Page 286: ...eaks in compressor discharge valve Leaks in governor Leaks in air lines Leaks in air system valves 24 BRAKE OPERATION The vehicle braking system uses both service and parking air operated brakes The a...

Page 287: ...procedures about these inspection points MAINTENANCE Every 6 000 miles Check brake pad wear visually This is independent of any electronic wear indicator fitted to the vehicle Check condition of the s...

Page 288: ...on 6 for the latest brake pad replacement procedure 25 3 CHECKING DISC BRAKE PADS Brake pads have to be checked on a regular basis depending on the vehicle operation The remaining thickness of the pad...

Page 289: ...ition of the caliper compared to the tip of the wear indicator or carrier depending on vehicles In one variant of the visual wear indicator Figure 28 the side of the caliper flat surface around guide...

Page 290: ...orresponding to any legal requirements that may apply Even if a wear indicator is fitted and connected this must be at least every 12 months FIGURE 31 MINOR BREAKOUTS AT THE EDGES ARE PERMITTED FIGURE...

Page 291: ...CALIPER CARRIER MOUNTING BOLTS TORQUE SPECIFICATION I BEAM AXLE FIGURE 36 CALIPER CARRIER MOUNTING BOLTS TORQUE SPECIFICATION ZF A132 DRIVE AXLE FIGURE 37 CALIPER CARRIER MOUNTING BOLTS TORQUE SPECIFI...

Page 292: ...contact with fiber dust is higher during these operations In addition to wearing an approved respirator do such work in an area with exhaust ventilation When cleaning the work area NEVER use compress...

Page 293: ...onent Pressure Build Up Low Pressure Warning Cutoff Point Air Filter Dryer Built in Governor Cutout CONDITION Vehicle leveled parking brake applied 4 Completely drain wet primary and secondary air res...

Page 294: ...nd foot brake applied coat all air line connections and brake pneumatic components with a water and soap solution Bubbles will indicate an air leak and none should be permissible Repair or replace def...

Page 295: ...ake release bolt arrow with a maximum of 26 lbf ft 35 Nm to the release position 3 To manually reset the emergency parking brake screw in the spring brake release bolt with a maximum of 52 lbf ft 70 N...

Page 296: ...es refer to Emergen cy Parking Brake Manual Release proce dure in this section 5 Remove clamp ring remove and discard the existing diaphragm Install the new dia phragm squarely on body 6 Reverse the p...

Page 297: ...l with this reference speed to determine which wheel is accelerating or decelerating As soon as wheel deceleration or wheel slip threshold values are exceeded the electronic control unit signals a sol...

Page 298: ...pe 29 5 SPRING CLIP The spring clip retains the sensor in its mounting bracket close to the toothed pulse wheel The gap between the sensor end and teeth is set automatically by pushing the sensor in t...

Page 299: ...ted to a cross member forward of the drive axle Brake Demand Sensors installed in the primary and secondary delivery circuits An additional Modulator Valve Bendix M 40QRTM Pressure Modulator Valve tha...

Page 300: ...conditions In the case of a potential roll event the ECU will override the throttle and quickly apply pressure at all wheel ends to slow the vehicle combina tion The level of braking application durin...

Page 301: ...screws that hold the body of the sensor to the steering column body 6 Slide the sensor over the column to remove Take note if the sensor label is facing up ward or downward Installation 1 Obtain a new...

Page 302: ...ntrol system may not function properly which can result in incidents leading to loss of vehicle control 31 FITTING TIGHTENING TORQUES NTA Type Plastic Tubing Hand tighten nut Figure 45 From that point...

Page 303: ...SS636 Capacity at 1250 rpm 37 4 cfm 1 059 m3 min Air dryer Make WABCO Model System Saver 1200 Series Prevost number 21440978 Electrical control 12 Volt Desiccant cartridge Prevost number 642199 Cut in...

Page 304: ......

Page 305: ...WHEEL STUDS 5 5 1 DRIVE AXLE WHEEL STUDS 5 5 2 FRONT AND TAG AXLE WHEEL STUDS 5 6 HUB MOUNTED WHEELS 5 6 1 CARE OF WHEELS 6 7 TAG AXLE WHEEL HUBS 6 7 1 TAG AXLE HUB BEARING INSPECTION 8 7 2 TAG AXLE H...

Page 306: ...11 INSTALL THRUST WASHER AND HUB NUT 9 FIGURE 12 CLEANING HUB BEARING ROTOR AND HUB FLANGE CLAMPING SURFACES 9 FIGURE 13 ROTOR 10 FIGURE 14 HUB FLANGE HEX CAP SCREW 10 FIGURE 15 HUB FLANGE HEX CAP SCR...

Page 307: ...ow setting in of clamping surfaces Wheel studs and nuts must be kept free from grease and oil No lubricant whatsoever should be used Cleanliness of the wheel and its rotor mating surfaces is important...

Page 308: ...progressively as shown in Figure 2 The final tightening should be done with a torque wrench Tighten stud nuts to 450 500 lbf ft 610 680 Nm for all steel wheel CAUTION Insufficient mounting torque can...

Page 309: ...t be replaced Broken studs are a direct result of operating with loose stud nuts or improperly seated wheels When a broken stud is replaced the adjacent studs on each side of the broken one must also...

Page 310: ...occurred retighten Relaxation of initial torque may occur because of the bedding down of the hub and wheel surfaces NOTE Torque relaxation occurs when wheel ends are hot but should revert to original...

Page 311: ...ION 13 WHEELS HUBS TIRES DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 FIGURE 6 TAG AXLE HUB AND ROTOR ASSEMBLY FIGURE 7 TAG AXLE UNITIZED BEARING WHEEL HUB 1...

Page 312: ...ing Axial Endplay Maximum axial clearance end play 0 0024 inch 0 061mm based on clamp load of 20000 lbf 90kN Tag Axle Unitized Hub Bearing Axial Endplay In Service If the endplay is between 0 0 002 in...

Page 313: ...there is a risk of separation of inner rings The clip can be dislodged as per the two pictures below 5 Clean thrust washer both sides and hub nut using EFX degreaser 6 Install thrust washer and hub n...

Page 314: ...run out of the brake disc Refer to 7 1 tag axle Hub Bearing Inspection FIGURE 14 HUB FLANGE HEX CAP SCREW FIGURE 15 HUB FLANGE HEX CAP SCREW TIGHTENING SEQUENCE 13 Mount the wheel over studs being ca...

Page 315: ...ever comes first 1 Apply parking brake raise wheels off the ground and support axle on stands 2 When the wheels are raised they should revolve quite freely without roughness 3 Place magnetic base of a...

Page 316: ...nual NO 1963 A B iss A See OVERHAUL PROCEDURES HUB END DISASSEMBLY pages No B3 B4 B5 B6 8 3 FRONT AXLE HUB BEARING INSTALLATION You can refer to the following manual included on your vehicle Technical...

Page 317: ...itted it is necessary to check the axial run out of the brake disc Refer to page No B29 of the following manual included on your vehicle Technical Publications CD in PDF format to complete this step D...

Page 318: ...ar tire wear Inflation pressure should be checked weekly and always before long distance trips 10 1 INFLATION PRESSURE The condition and pressure of the tires can greatly affect both useful tire life...

Page 319: ...and pressurize according to tire manufacturer s recommendations For other tire and wheel specifications see Prevost tire pressure tabulation in Coach Final Record WARNING Incorrect tire pressures caus...

Page 320: ...t be clean and free from all foreign matter The tires should be in good condition and properly mounted An unbalanced wheel can be due to a bent wheel or improper mounting Before removing the wheel fro...

Page 321: ...is delivered with the specific inflation pressure certification plate according to the tire selection WARNING Special tire selection may lower maximum allowable speed limit even below posted speed li...

Page 322: ......

Page 323: ...9 10 2 INSTALLATION 10 10 3 ADJUSTMENT 10 10 4 TAG AXLE UNLOADING SWITCH ADJUSTMENT 10 11 DRAG LINK 11 11 1 FINE ADJUSTMENT 11 12 STEERING SYSTEM MAINTENANCE 11 12 1 STEERING SYSTEM PLAY INSPECTION 1...

Page 324: ...E 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 ARM ADJUS...

Page 325: ...ms and tie rod 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 res...

Page 326: ...s together with the worm as the steering wheel 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...

Page 327: ...ual the ZF SERVOCOM Operating Servicing Maintenance and Inspection Instructions 3 BLEEDING POWER STEERING HYDRAULIC SYSTEM To bleed the power steering hydraulic system refer to the ZF SERVOCOM Repair...

Page 328: ...Use a new gasket Connect the hydraulic lines to the power steering pump Install the fuel pump Torque tighten bolts to specification NOTE Use a new sealing ring Check that the fuel pump drive axle sit...

Page 329: ...lectrical panel to the OFF position 2 Pull the horn pad straight up gently to detach it from the steering wheel Figure 9 3 Disconnect the horn wire white connected to the horn pad and the steering whe...

Page 330: ...screws and then remove the clockspring You will have to disconnect the clockspring harness connector located lower along the steering wheel column If necessary remove the steering column covers Figure...

Page 331: ...e OEM manuals folder Steering linkage pivot points should be checked each time they are lubricated Looseness can be visually detected while rotating the steering wheel in both directions Replace defec...

Page 332: ...ter pin CAUTION Input shaft marks must be aligned before adjusting pitman arm 10 3 ADJUSTMENT 1 Disconnect the drag link from pitman arm Center steering wheel by dividing the total number of steering...

Page 333: ...er the system should be kept clean to ensure maximum operating performance and trouble free service Periodic inspections should also be made to check for leakage and all parts for damage or distortion...

Page 334: ...ere is a perceptible movement of a front wheel If a point on the steering wheel rim moves more than the value indicated below before perceptible return movement of the wheel under observation there is...

Page 335: ...t replacement coincide with the power steering fluid replacement check for trapped metal particle before installation of the new filter cartridge element Pass the reservoir threaded rod through the el...

Page 336: ...ads are firmly seated Also a visual inspection should be carried out looking for damage or corrosion to the adjustment system components Replace any part showing corrosion or damage Functional inspect...

Page 337: ...g spatula with cut out to push up sealing boot or down dirt seal the seal without damaging it until ball pin surface is visible Degrease the ball pin surface and inspect carefully 3 If there is corro...

Page 338: ...from body Thoroughly clean all parts and check for wear renewing where necessary 12 6 4 Assembling Drop Type Ball Joint 1 Apply a bead of Loctite 638 sealant to mating corner of rubbing pad in socket...

Page 339: ...adjustment was used to compensate for another problem e g bent steering arm 12 7 2 Straight Body Type Ball Joint End Play And Looseness What creates movement in sockets In each straight body type bal...

Page 340: ...en service brakes are applied wheel locking will oppose the effect of steering geometry which tends to make the front wheels rotate in opposite directions Persisting in turning or maintaining the stee...

Page 341: ...improperly 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 i...

Page 342: ...98 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 Steering Reservoir Make Ne...

Page 343: ...val 8 2 4 2 Installation 8 2 5 TORQUE SPECIFICATIONS FRONT I BEAM AXLE SUSPENSION AND STEERING 8 3 REAR SUSPENSION 12 3 1 AIR SPRINGS 13 3 1 1 Inspection 13 3 1 2 Removal 13 3 1 3 Installation 13 3 2...

Page 344: ...ON 6 FIGURE 6 BALL PIN BUSHING 6 FIGURE 7 SWAY BAR 8 FIGURE 8 REAR SUSPENSION COMPONENTS 12 FIGURE 9 SWAY BAR REAR SUSPENSION 12 FIGURE 10 TAG AXLE SUSPENSION 12 FIGURE 11 AIR SPRING 13 FIGURE 12 TYPI...

Page 345: ...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 water and soap solution Bubbles will indicate an air l...

Page 346: ...cifications 5 Install fitting if applicable then connect air line 6 Connect the height control valve link 7 Build up air pressure in system NOTE To accelerate this operation air reservoirs can be fill...

Page 347: ...signed to permit a very slight seepage to lubricate the rod Units that leak should be replaced 4 Visually check shock for dents that could cause the shock to bind Also check for a bent rod 5 Extend an...

Page 348: ...of shearing deterioration or damage Any defective part should be replaced with a new one Take off the load from the ball joint by lifting the vehicle Apply a load on the joint in all of the degrees o...

Page 349: ...d Assembly The assembly work may be done only by a recognized specialized workshop Ensure that old and new parts do not get mixed up with each other It is for this reason that all the old parts are to...

Page 350: ...the axle and body be maintained Otherwise the rubber bushings in radius rod ends will become preloaded thus reducing their life span 2 4 SWAY BAR A sway bar is provided on the front axle to increase v...

Page 351: ...SECTION 16 SUSPENSION DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Section 16 revised April 2019 9...

Page 352: ...SECTION 16 SUSPENSION 10 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Section 16 revised April 2019...

Page 353: ...IE ROD END BALL PIN NUTS 2 150 200 203 271 5 STEERING ARM STUD NUTS 2 285 315 386 427 6 TIE ROD ARM STUD NUTS 4 285 315 386 427 7 I BEAM AXLE MOUNT NUTS 8 230 280 311 378 8 SHOCK ABSORBER UPPER LOWER...

Page 354: ...nance Manual Section 16 revised April 2019 3 REAR SUSPENSION For a description of all these systems refer to the appropriate heading in this section FIGURE 8 REAR SUSPENSION COMPONENTS 16184 16144 FIG...

Page 355: ...ury do not apply more than 10 psi 69 kPa of air pressure to the uninstalled air spring 3 1 2 Removal NOTE Suspension air springs drive and tag axles can be removed without removing the entire axle ass...

Page 356: ...our of them Figure 12 Figure 13 Shock absorbers are non adjustable and non repairable Maintenance requirements involve replacement of the rubber mounting bushings and tightening of all shock absorber...

Page 357: ...Ensure that the shock absorber mounting pin is tight and that the threads are not stripped 2 Install new rubber mounting bushings on shock absorbers upper and lower 3 At the upper mounting pin place t...

Page 358: ...DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Section 16 revised April 2019 4 REAR SUSPENSION TORQUE SPECIFICATIONS FIGURE 13 TORQUE SPECIFICATIONS DRIVE AXLE 16158_A FIGURE 14 TORQUE SPECIFI...

Page 359: ...CIFICATIONS TAG AXLE 16160 FIGURE 16 TORQUE SPECIFICATIONS TAG AXLE 16161 The following table lists the tightening torques of bolts and nuts requiring a specific torque value When no torque specificat...

Page 360: ...pply port of the tank This valve controls the pressure at which compressed air is delivered to the accessory air tank The valve remains closed until a preset pressure is reached approximately 70 psi 4...

Page 361: ...d on the vehicle Refer to Figure 17 Figure 18 Figure 19 to identify the correct area to take measurement and proper value At this point it should not be necessary to make an adjustment under normal se...

Page 362: ...ing to the following conditions Loading Position As the load increases and lowers the vehicle body the overtravel lever commands the height control valve to add air to air springs Neutral Position Whe...

Page 363: ...ommended to purge the wet air tank by its bottom drain valve every 12 000 miles A remote valve located in engine compartment and accessible through engine R H side door is used to drain the air dryer...

Page 364: ...s This system bypasses the height control valve to provide a fast up and down movement of the front suspension Only four seconds are required to lower vehicle from normal level to the lowered position...

Page 365: ...te over time 1 Defective check valve assembly 2 Defective exhaust valve assembly 3 Leak in air line and or bellows 4 Defective valve cover rubber O rings or gasket 1 Replace check valve assembly 2 Rep...

Page 366: ...revised April 2019 11 SECTION CHANGE LOG DESCRIPTION DATE 1 page 11 reference 12 was 171 209 lbf ft changed for 207 253 lbf ft page 18 reference 7 was 228 252 lbf ft changed for 171 209 lbf ft Apr 04...

Page 367: ...engine compartment door These products are not compatible with polycarbonate They cause cracking of the polycarbonate taillights housing and cracking of the bosses in which the mounting threaded rods...

Page 368: ...MI15 41 Page 2 4 QF7720956 rev3 High PH cleaning product compatible with polycarbonate product sheet FIGURE 1 PRODUCT SHEET...

Page 369: ...3 Cracking of the outer surface of the taillight due to the use of engine degreaser Access all our Service Bulletins on https secureus5 volvo com technicalpublications en pub asp Or scan the QR Code...

Page 370: ......

Page 371: ...N 18 15 X3 45 COACHES EXTERIOR FINISHING AND BODY REPAIR 19 15 1 ZONE 1 19 15 1 1 Front Bumper 20 15 1 2 Headlights 21 15 1 3 Rear View Mirrors Rosco 21 15 1 4 Windshield Wipers 22 15 1 5 Windshield 2...

Page 372: ...EPAIR 15 FIGURE 4 FIBERGLASS HOLE REPAIR 15 FIGURE 5 FIBERGLASS HOLE REPAIR 16 FIGURE 6 FIBERGLASS HOLE REPAIR 16 FIGURE 7 X3 SERIES COACH ZONES 19 FIGURE 8 ZONE 1 19 FIGURE 9 BUMPER TOP RETAINING BOL...

Page 373: ...DIATOR DOOR DETAILS 41 FIGURE 41 STRIKER PIN ENGAGEMENT 41 FIGURE 42 HINGE DETAIL 42 FIGURE 43 ZONE 5 42 FIGURE 44 EVAPORATOR DOOR ALUMINUM 47 FIGURE 45 CONDENSER DOOR 49 FIGURE 46 FUEL FILLER DOOR 49...

Page 374: ...echanism access door 7 Wheelchair access door 8 Baggage compartment 9 Entrance door control switch 10 Bi fold entrance door 11 Electronic destination sign or route number 12 Exhaust aftertreatment sys...

Page 375: ...SECTION 18 BODY DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 5 22 SCR converter access door...

Page 376: ...leaning your vehicle 4 CORROSION PREVENTION Preventive maintenance is a key factor in avoiding corrosion and must be considered as part of the regular service intervals The entire underside of the veh...

Page 377: ...CTION 18 BODY DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 3 Apply correct primer paint and undercoating after removing all corrosion to prevent further dama...

Page 378: ...SPECT SEALING BEADS CONDITION VISUALLY INSPECT IF UNDERFLOOR IS PEALING VISUALLY INSPECT WHEELHOUSING COATING MAKE SURE DISCHARGE TUBES ARE FREE FROM OBSTRUCTIONS APPLY UNDERCOATING LOCALLY AS NECESSA...

Page 379: ...r may be hot to reduce washing time especially during winter If parts are soiled with oil clean using R1KG21 Avoid rubber parts 2 0 Dry all water sprayed parts Surface temperature and dew point must b...

Page 380: ...l Final Version Rev 2 April 2016 3 2 Front wheelhousing 3 3 Front wheelhousing Entire braking system 4 0 Rear wheelhousing a Mask all rubber joints Braking system must also be protected refer to arrow...

Page 381: ...sing 5 0 Close off wheelhousing using masking paper Prevent rust inhibitor from coming in contact with paint To close off wheelhousing a polythene sheet may be used 6 0 Apply TECTYL 185 GW black rust...

Page 382: ...100 Temp c 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 16 11 8 5 3 1 0 1 3 15 10 7 5 3 1 1 2 4 14 10 6 4 1 0 2 3 5 13 9 5 3 1 1 2 4 6 13 8 5 2 0 2 4 5 7 11 7 4 1 1 3 5 6...

Page 383: ...X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 13 28 29 30 31 32 3 6 11 16 19 22 25 27 29 31 2 6 12 17 20 23 26 28 30 32 1 7 13 17 21 24 27 29 31 33 1 8 14 19 22 25 27 30 32 3...

Page 384: ...ne and one or more heat lamps 8 REPAIR USING FIBERGLASS CLOTH Where necessary sand paint away around damaged area and scrape away undercoating if any and wipe clean with solvent Grind or file the dama...

Page 385: ...lass cloth 10 TYPICAL FIBERGLASS HOLE REPAIR PROCEDURE Remove all loose particles or damaged material using a power sander or rasp Clean area overlapping hole approximately 1 to 1 25 40 mm all around...

Page 386: ...unlight Do not dry wipe vehicle always use clean water Dry wiping could scratch the finish Avoid extreme heat and cold Park vehicle in the shade whenever possible Do not park under trees which drop sa...

Page 387: ...designed for exposure to extreme conditions Other types of paint may be called for as options by owner but are not dealt with in this section 14 1 SAFETY Care should be exercised in storing handling m...

Page 388: ...13908 Wait 30 minutes then apply STANDOX HS primer ST 15161 STANDOX Non Stop F llprimer ST 11000 68 2973 Refer to product Technical Data sheet for proper mixing Basecoat Refer to paint scheme or coac...

Page 389: ...ures explain the steps to be followed for proper repair installation and replacement for various doors panels and windows The paragraph divides the vehicle into zones to facilitate the search each zon...

Page 390: ...r supply lines from the bumper hoses are not pressurized FIGURE 10 FRONT BUMPER AIR LINES 18701 Using the spring adjustment hex nut remove bumper spring tension until the end hook can be disconnected...

Page 391: ...e to the coach Insert the ball stem into the mirror arm and tighten the socket setscrews NOTE Position the ball cup halves so the joint between them lies on the centerline of the arm Ensure that the s...

Page 392: ...dge insert the edge under the over hang tab covering the mirror glass Raise the wedge to spread the over hang tab By continuing to raise the wedge the glass will begin to pop out Do not force the glas...

Page 393: ...rubber seal groove starting with the bottom curved side edge Using a plastic spatula move the rubber seal lip aside to gradually insert the windshield into the groove Spray soapy water on a regular b...

Page 394: ...ration by a two air cylinder locking mechanisms Figure 20 FIGURE 20 ENTRANCE DOOR VIEW FROM INSIDE Air cylinders with return spring in the cylinder body are used Air cylinders are controlled by an ele...

Page 395: ...H button on the R H dashboard panel The door will open to full open position within 5 seconds Close by pressing and holding the door closing switch R H button on the dashboard If the closing switch i...

Page 396: ...y moving the lever on the door or by using the key then open the door manually With Air but Without Electricity From inside the vehicle turn the emergency exit valve to the UNLOCK position Move the le...

Page 397: ...nted The total range is about five half turns Pull the damper out vertically without turning for at least 3 8 1cm to disengage the adjusting mechanism The dust cap or piston rod may now be turned free...

Page 398: ...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 Sika bead located inch 7 8...

Page 399: ...ody panel flatness using a 2 foot ruler must be within 2mm Check proper power window sliding inside window frame If applicable remove excess of Sika adhesive all around door frame using Sika 208 From...

Page 400: ...ng to applicable environmental regulations use dangerous waste containers Electrical Power Window Insert 2 seals in the window frame Apply some 680066 glue at the intersec tion of the 2 seals and also...

Page 401: ...or at the bottom of driver s window Install gutter under driver s window then compress in order to fix double face self adhesive tape Install 3 clamps and allow curing for 4 hours 15 1 8 FRONT CAP The...

Page 402: ...SECTION 18 BODY 32 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 15 2 ZONE 2 FIGURE 28 ZONE 2 18625...

Page 403: ...read the wire into the small hole Reinsert the rod and the wire into the hole far enough so that the person inside the vehicle can pull the rod using a pair of pliers Attach the wire ends to the speci...

Page 404: ...e release bar Emergency Exit Release Bar The emergency exit release bar system is generally maintenance free It has been designed to answer the twenty pound resistance criteria for opening the emergen...

Page 405: ...als used on the escape hatch Graffiti removing cleaners often contain acetone ether lacquer thinner or other solvents known to destroy the high strength properties of many plastics Use of these cleane...

Page 406: ...en installing roof escape hatch s hinge must be toward the front of vehicle to prevent the hatch from being ripped out if accidentally opened while vehicle is running FIGURE 32 ESCAPE HATCH 18105 Esca...

Page 407: ...SECTION 18 BODY DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 37 15 3 ZONE 3 FIGURE 33 ZONE 3 18626...

Page 408: ...lding two of the door supporting arm and gas springs bracket to the door Figure 34 3 Adjust the door FORE AFT position by screwing unscrewing the rubber door stops on each side of the door opening Fig...

Page 409: ...SECTION 18 BODY DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 39 15 4 ZONE 4 FIGURE 36 ZONE 4 18627...

Page 410: ...o shift the door LEFT or RIGHT 2 Loosening the bolts 2 Figure 38 allows the door to be shifted UP or DOWN FIGURE 38 ENGINE COMPARTMENT R H SIDE DOOR 18635 3 Adjust the door position depending on the g...

Page 411: ...or swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation To adjust the latch mechanism 3 Figure 40 and the striker pin 6 Open the door to acces...

Page 412: ...SECTION 18 BODY 42 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 42 HINGE DETAIL 15 5 ZONE 5 FIGURE 43 ZONE 5 18628...

Page 413: ...ts Remove rub rail Unfasten bolts and disconnect cable if necessary in order to remove door from vehicle Preferably install the door onto a work surface where it can be solidly fixed Door Panel replac...

Page 414: ...IN or OUT the lock plates Adjust one corner at a time Check handle adjustment Handle must remain tight against its plastic housing NOTE Adjustment is made by moving UP or DOWN the lock plates Open bag...

Page 415: ...ift WCL cassette compartment door body panel you will need A drill with drill bits Pneumatic hammer tool Zip Gun Razor sharp window scraper or putty knife Open damaged compartment door and unfasten ru...

Page 416: ...3 Door should close flush with the larger door panel Maximum flatness deviation within 1mm 4 Install the remaining screws and seal with liquid Teflon 680098 WCL Cassette Door latch adjustment To allo...

Page 417: ...allows the evaporator door assembly to be shifted LEFT or RIGHT and UP or DOWN or IN and OUT 3 Adjust evaporator door assembly posi tion at the hinge 4 Door exterior panel on hinge side should be posi...

Page 418: ...llel to structure before tightening hardware 13 Make sure that skid bar only touches slightly bus structure at bottom The door should not move up when closing 14 Check that the door swings freely and...

Page 419: ...between exterior finishing panels 5 Tighten the screws 6 Check that the door swings freely and closes properly It may be necessary to adjust the door latch to get proper fit and operation 15 5 5 FUEL...

Page 420: ...a 221 grey onto the damaged area Remove masking tape and protection around damaged area Spray pure water onto Sika Use a floor sample to create some texture onto the adhesive If possible spray some mo...

Page 421: ...v 2 April 2016 51 Rear baggage compartment equipped with WCL Prepare baggage compartment Mantex floor Clean panel underside and edges Using a triangular nozzle apply Simson glue 685126 onto support st...

Page 422: ...not move Finishing Joints In the case of lateral finishing joint apply some masking tape from panel edge and above panel In the case of front finishing joint apply some masking tape on each side of jo...

Page 423: ...e Smooth down joints using soapy water 15 5 7 FUEL FILLER DOOR 6 Open the fuel filler door 7 Loosen the screws holding the panel to hinge assembly 8 Adjust the fuel filler door position according to d...

Page 424: ...l Final Version Rev 2 April 2016 15 6 ZONE 6 FIGURE 48 ZONE 6 18629 15 6 1 FRONT FENDER Front fender may be removed using the following procedure Remove the nuts on the inside of the fender Remove the...

Page 425: ...ar finishing molding supports Use a 11 titanium drill 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...

Page 426: ...tion B 2 05 SIDE PANEL PREPARATION A Clean 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...

Page 427: ...ace fiber glass non gelcoat side etc 10 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 agai...

Page 428: ...lication Bead must be continuous for the 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...

Page 429: ...pot welding Quantity of tig spot 30 minimum 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 e...

Page 430: ...cle surface as for side panel Refer to 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 ta...

Page 431: ...tula inside a Chix cloth to ensure that 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 tap...

Page 432: ...SECTION 18 BODY 62 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 16 BODY PANEL AND WINDOW SPACING...

Page 433: ...t side seats are not interchangeable To remove fixed seats proceed as follows 1 For ease of access remove the nuts holding each seat cushion from under the front part of the seat frame 2 Lift front pa...

Page 434: ...m to the fabric with a sponge or brush Clean a small area of the fabric at a time with the foam DO NOT SOAK Rub vigorously Sponge the suds from the fabric with a clean sponge or cloth moistened with w...

Page 435: ...E It would be preferable to cut 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 plyw...

Page 436: ...ION 18 BODY 66 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 55 TARABUS FLOOR COVERING ADHESIVE APPLICATION 18640 FIGURE 56 APPLICATION OF SIKA 221 GRAY1...

Page 437: ...ea must be at a temperature sufficient to prevent reaching condensation point Mechanically preheat working area heat lamp or heat gun or wait until vehicle reaches room temperature PREPARATION OF TARA...

Page 438: ...tory Minimum time For a smooth surface aluminum stainless steel fiberglass gelcoat side etc 2 minutes For a porous surface fiberglass non gelcoat side etc 10 minutes After 2 hours Reactivate surface w...

Page 439: ...ite safety strip then press using hands If Sika overflows clean with Sika 208 10 Temporarily fix white safety strip with a piece of duct tape leaving 1 to 2 inches free at each end 11 Apply some maski...

Page 440: ...r to cut to the side to prevent damaging Tarabus covering 5 Add about 6 inches some length to the required length of filler bead to make the joint then cut 6 Take position with welding torch The prope...

Page 441: ...on one side If this is the case repair the joint 18 2 Repair Of A Welded Joint NOTE In wintertime condensation and cold temperature may greatly influenced bonding parameters Working area must be at a...

Page 442: ...SECTION 18 BODY 72 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 19 SECTION CHANGE LOG DESCRIPTION DATE 1 2 3 4 5 6...

Page 443: ...2489 DOB Bus Number Series 2490 2789 Revision A Addition of comments following front tow demonstration at Zerega CMF Bus 2491 March 19 2014 Addition of comments following rear tow demonstration at Zer...

Page 444: ...2 1 2 Drive Axle Flange Shafts Removal 12 2 2 TOWING FROM THE FRONT 14 2 2 1 First Lift 15 2 2 2 Second Lift Front Tow Eye Pads as Lifting Point for Towing 17 2 2 3 Second Lift Front Axle as Lifting P...

Page 445: ...hicle cannot be supported from an axle on which repair or maintenance is being done otherwise use wheels as lifting points When using the chassis hoisting points to support the bus the tag axle must b...

Page 446: ...TAG AXLE ROAD SIDE FIG 8 JACK STAND AT CHASSIS HOISTING RECEPTACLE AFT OF TAG AXLE CURB SIDE FIG 9 10 TON CAPACITY JACK STAND FIG 10 16500 LBF CAPACITY FIG 11 20 TON CAPACITY JACK STAND WARNING Prior...

Page 447: ...oints are located under the tag axle Using the tag axle as rear hoisting points for the vehicle should be avoided When possible use the drive axle as hoisting point The vehicle can be lifted from the...

Page 448: ...DOB Bus Number Series 2400 2489 FIG 12 FRONT AXLE HOISTING POINT CURBSIDE FIG 13 FRONT AXLE HOISTING POINT ROAD SIDE FRONT AXLE HOISTING POINTS DOB Bus Number Series 2490 2789 FIG 14 FRONT AXLE HOIST...

Page 449: ...G POINTS DOB Bus Number Series 2400 2489 FIG 16 DRIVE AXLE UNDERFRAME HOISTING POINTS DOB BUS NUMBER SERIES 2400 2489 DRIVE AXLE UNDERFRAME HOISTING POINTS DOB Bus Number Series 2490 2789 FIG 17 DRIVE...

Page 450: ...Use the front and drive axle wheels to lift the bus when using mobile column lifts When doing so the tag axle must be unloaded at all time Using the tag axle wheels as the only lifting point for the...

Page 451: ...llow passengers to ride onboard the towed bus Tow the bus at a safe speed as dictated by road and weather conditions Accelerate and decelerate slowly and cautiously Avoid sharp turns where possible WA...

Page 452: ...ow truck in the eventuality of a mechanical failure of the tow truck lifting equipment FIG 20 2 1 1 Air Supply Operate the engine when towing to maintain brake system air pressure If the engine cannot...

Page 453: ...r dryer fig 21 22 FIG 22 FRONT TOWING AIR SUPPLY ACCESS PANEL QUICK CONNECT FITTINGS FIG 21 Engine compartment emergency air fill valve An additional emergency fill valves is available to supplement t...

Page 454: ...r cap screws with ZF drive axle from the flange shaft NOTE there is oil behind the flange shaft which comes out during disassembly FIG 24 ZF A 132 AXLE FIG 25 MERITOR RC23 165 AXLE CAUTION Do not use...

Page 455: ...removed This will prevent dirt from entering the bearing cavity and loss of lubricant After Towing 1 Remove the covers from the hubs 2 Install the gasket or O ring and axle shaft into the axle housing...

Page 456: ...e front bumper Use only a solid link tow bar and safety chains to tow the bus 1 Block the wheels to prevent the bus from moving 2 Perform the BEFORE TOWING PREPARATION Refer to paragraphs 2 1 and 2 1...

Page 457: ...points This first lift will allow tow cans or blocks to be placed underneath front tires 1 Retract the tow truck stinger arm 2 On the first lift position the tow bar fork holders under the front tow e...

Page 458: ...he axle fork holders under the tow eye pads fig 30 FIG 30 4 Lift the front end of the bus high enough to allow installation of tow cans or blocks Place the tow cans or blocks perfectly centered undern...

Page 459: ...if not already done 2 Place the axle forks on the tow bar fork holders fig 32 Use 3 to 4 mouth axle forks preferably REGULAR FIG 32 Pre adjust spacing between axle forks to 37 inches 3 Lower the tow...

Page 460: ...nder the stinger arm for support and safety purposes and then lower the stinger arm so it rests on the jack stand fig 36 The tow cans or blocks can be removed from under the front axle wheels FIG 36 8...

Page 461: ...es to the service and brake supply air quick connect fittings adjacent and right above the front bumper for more details refer to paragraph 2 1 1 Air Supply in this document FIG 38 FIG 39 11 Raise the...

Page 462: ...st point on the bus does not exceed the maximum allowable height for towing fig 41 15 Make sure the parking brake is released before moving the vehicle 16 Observe safety precautions when towing FIG 41...

Page 463: ...2 1 if not already done 2 Install regular axle forks onto tow bar fork holders TALL REGULAR Pre adjust spacing between axle forks Minimum spacing 25 inches Maximum spacing 33 inches FIG 43 3 Lower the...

Page 464: ...d maintain proper tension on chains 8 Attach the two tow truck safety chains from each of the two front tow eyes of the bus to the truck s tow eyes fig 47 48 9 Connect the two truck air lines to the s...

Page 465: ...3 31 Rev June 26 2014 FIG 48 12 Use bungee cords to support the safety chains fig 49 FIG 49 13 Make sure that the parking brake is released before moving the vehicle 14 Observe safety precautions when...

Page 466: ...istance is kept between the front of the bus and the tow truck This space ensures that bus does not suffer damages when being towed CAUTION Make sure axle shafts or driveshaft are installed correctly...

Page 467: ...surface chains can be looped around or hooked to the rear tow eyes This method should be used when the bus has to be moved with its wheels on the ground over a short distance only After the bus has be...

Page 468: ...t rails should be avoided Doing so may cause structural damage see image further in this document 3 1 PRECAUTIONS In an emergency situation or if the vehicle has to be moved over a short distance the...

Page 469: ...5 No axle forks will be used for this first lift TALL REGULAR FIG 55 5 Deploy the tow truck stinger arm Place the fork holders under the engine cradle transverse beam as shown on fig 56 Lift the tow b...

Page 470: ...front service compartment located on street side and move the tag axle air valve lever forward as shown on figure 57 FIG 57 7 Lift the rear end of the bus high enough to allow installation of tow can...

Page 471: ...ers to 43 inches FIG 59 4 Install either long or short axle forks into fork holders or TALL REGULAR 5 Deploy the tow truck stinger arm Place the axle forks under the rear tow eyes if equipped or under...

Page 472: ...e bumper FIG 61 PROPER LOCATION WHEN LIFTING THE SIDE MEMBERS 7 Place the fork s shorter finger outboard for better clearance see fig 62 FIG 62 PROPER LOCATION WHEN LIFTING THE SIDE MEMBERS ON THIS PI...

Page 473: ...he tow truck to allow the towed bus to be as close as possible to the truck yet allowing enough room for the bus to avoid collision with the tow truck during turns Stinger to the rear bumper Between 5...

Page 474: ......

Page 475: ...TION 15 5 5 HVAC SYSTEM MULTIPLEX TROUBLESHOOTING 16 6 AIR CONDITIONING SYSTEM 18 6 1 A C CYCLE 18 6 2 REFRIGERANT 18 6 2 1 Procurement 18 6 2 2 Precautions in Handling Refrigerant 18 6 2 3 Treatment...

Page 476: ...lve Disassembly 33 7 9 5 Valve Reassembly 34 7 10 THERMOSTATIC EXPANSION VALVE 35 7 10 1 Passengers Section HVAC Unit 35 7 10 2 Driver s HVAC Unit 37 7 11 TORCH BRAZING 37 7 12 TROUBLESHOOTING 38 7 12...

Page 477: ...22 RECOVERY UNIT CONNECTED TO RECEIVER SERVICE PORT 22 FIGURE 23 MOISTURE INDICATOR SIGHT GLASS 23 FIGURE 24 COMPRESSOR BELT TENSIONER 26 FIGURE 25 STANDARD BELT ARRANGEMENT 26 FIGURE 26 TORQUES 26 F...

Page 478: ...RE 52 HEATER LINE SHUT OFF VALVES 44 FIGURE 53 EVAPORATOR COMPARTMENT 44 FIGURE 54 TYPE 1 UP TO VIN F 7014 DRIVER S UNIT HOT WATER PNEUMATIC VALVE ASSEMBLY 45 FIGURE 55 TYPE 2 FROM VIN F 7015 DRIVER S...

Page 479: ...d moisture from entering vehicle Each section has its own fresh air returning air and discharge air ducting The exhaust is mainly done through the rear ventilator and through normal air tightness loss...

Page 480: ...SECTION 22 HEATING AND AIR CONDITIONING 6 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 3 REFRIGERANT CIRCUIT 22220C...

Page 481: ...SECTION 22 HEATING AND AIR CONDITIONING DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 FIGURE 4 EVAPORATOR COMPARTMENT ARRANGEMENT...

Page 482: ...r extreme weather or highly polluted areas Refer to the Operator s Manual for more details The recirculation REC button is located on the HVAC control unit Press down the button to partially close the...

Page 483: ...run down the central HVAC unit will not operate if the battery voltage drops below 24 volts When the HVAC system is in operation park at least 4 feet from other vehicles or buildings to allow sufficie...

Page 484: ...45 113 1195 50 122 980 55 131 808 60 140 670 3 2 PASSENGERS SECTION OPERATION The passengers section has a preset temperature of 68 F 20 C FIGURE 8 HVAC SYSTEM CONTROL UNIT Temperature control is prov...

Page 485: ...ater Relay Diodes D8 Parcel rack Liq Sol Valve D9 Water circulating pump D10 Water circulating pump D11 Pass Liq Sol Valve D17 3 rd Bagg Cmpt Lights D19 2 nd Bagg Cmpt Lights D20 1 st Bagg Cmpt Lights...

Page 486: ...CAL 22309 FIGURE 14 EVAPORATOR COIL CLEANING 22373 FIGURE 15 CONDENSER COMPARTMENT 22311 4 2 DRIVER S SECTION AIR FILTERS The driver s HVAC unit is located behind the dashboard s R H side panel To gai...

Page 487: ...ab fixed on the side of the filter Figure 19 FIGURE 19 PARCEL RACK FAN AIR FILTER MAINTENANCE Slide out filters back flush with water then dry with air and reinstall This procedure should be done ever...

Page 488: ...ication of the circulating pump when inside a garage This is also useful when working on the heating system to remove air pockets trapped in the system In normal operation the heating system circulati...

Page 489: ...ed on pressure and on the difference between the passengers area temperature and set point right compressor cylinders Stop if The passengers area decreasing temperature becomes less than 0 4 F above t...

Page 490: ...power circuit 67A should be 24 volts 4 Check the Diagnostics menu of Driver Information Display DID Select Fault Diagnostics and Electrical System The message No Response ModA54 Active indicates a po...

Page 491: ...ics and Electrical System The message No Response ModA52 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...

Page 492: ...retaining the conditioned air within the vehicle All windows and intake vents should be closed An opening of approximately 8 in2 5162 mm2 could easily neutralize the total capacity of the system 6 Ot...

Page 493: ...ly drops of sterile mineral oil obtainable at any drugstore in the eyes to reduce the possibility of infection The mineral oil will also help in absorbing the refrigerant 6 2 4 Precautions in Handling...

Page 494: ...r must be replaced after a severe system failure or if a line in the system has been opened over a prolonged period of time The line will then have to be properly evacuated Best practice would be to r...

Page 495: ...be disconnected to isolate the section of the system located between the receiver tank outlet shut off valve and the passengers unit liquid solenoid valve Doing so would be useful to perform replaceme...

Page 496: ...in evaporator compartment or C44 for the driver s area located on the ceiling of the spare wheel compartment 6 Start the vacuum pump 7 The pressure will drop to approximately 29 in HG gauge vacuum 8...

Page 497: ...the gage set to the discharge shut off valve service port Hoses should be purged of air at installation evacuated WARNING Secure manifold gage hoses so they will not be damaged by engine belts and pu...

Page 498: ...shut off valve Figure 36 7 Attach an evacuated charging hose purged from air and moisture to the R 134a tank 8 Connect the evacuated charging hose to the service port on the receiver tank inlet shut...

Page 499: ...id valves check valves and any other mechanical component that may have collected contaminants 6 Evacuate and charge the system normally 7 Run the unit for 8 hours and monitor the pressure drop across...

Page 500: ...f the blue unloader coil remains tight Should the idler bearing need to be serviced tighten shoulder bolt C to 35 lbf ft at reassembly FIGURE 24 COMPRESSOR BELT TENSIONER FIGURE 25 STANDARD BELT ARRAN...

Page 501: ...e the cause for operation outside the application ranges However compressor oil does wear down therefore it is strongly recommended to change the oil approximately every 4 years 10000 12000 operating...

Page 502: ...cuum with suction shut off valve frontseated Cause Repeated liquid refrigerant floodback Flooded starts Overcharge of oil Discharge valves not seated properly liquid drainback during shutdown Expansio...

Page 503: ...motor output shaft 7 3 2 Installation To reinstall the evaporator motor reverse Evaporator Motor Removal procedure FIGURE 33 EVAPORATOR MOTOR ASSEMBLY 7 4 CONDENSER The A C system condenser coil is hi...

Page 504: ...valve will break at 450 psi and relieve the receiver tank pressure MAINTENANCE Check refrigerant level and add if necessary every 12 000 miles or twice a year whichever comes first The receiver tank...

Page 505: ...cts are flammable and may explode under certain conditions Always handle in a well ventilated area 7 7 MOISTURE INDICATOR The moisture sensitive element consists of a color changing ring which is reve...

Page 506: ...icted filter dryer MILKY CLOUDED Contaminated system OIL STREAKS Oil contamination FIGURE 38 CONDITIONS THAT MAY BE OBSERVED IN THE MOISTURE INDICATOR SIGHT GLASS 7 8 SHUT OFF VALVE WITH SERVICE PORT...

Page 507: ...dule in evaporator compartment or C44 for the driver s unit liquid solenoid valve located on the ceiling of the spare wheel compartment During normal use both plug and socket housings of connector C24...

Page 508: ...reads 3 Hold the plunger with one hand so that the pointed end is resting in the pilot port of the disk Make sure the small spring is in place on the top of the plunger 4 With the other hand place the...

Page 509: ...on Opposed to this force on the underside of the diaphragm and acting in the closing direction is the force exerted by the spring As the temperature of the refrigerant gas at the evaporator outlet inc...

Page 510: ...vaporator is exposed Superheat Adjustment Expansion valves are factory preset for optimum superheat settings This setting should be modified only if absolutely necessary The readjustment should be at...

Page 511: ...adjustment check for restriction on suction side for plugged filter dryer and partially open valves These conditions will give a high superheat Maintenance 1 Pump down the system as previously indica...

Page 512: ...ial loss of charge Replace power assembly 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 o...

Page 513: ...ing Check for refrigerant leaks Check 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 e...

Page 514: ...mperature of 130 F 199 8 psi Read the condenser pressure example 171 9 psi 171 9 psi 199 8 psi the pressure in the condenser is inferior to the pressure corresponding to the exterior temperature in th...

Page 515: ...2 50 45 6 18 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...

Page 516: ...d refer to the following instructions Draining Driver s Heater Core 1 Stop engine and allow engine coolant to cool 2 Locate the normally open hot water pneumatic valve on the ceiling of the spare whee...

Page 517: ...SECTION 22 HEATING AND AIR CONDITIONING DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 1 Feb 2015 43 FIGURE 50 DRIVER S HVAC UNIT FIGURE 51 DRIVER S HVAC UNIT...

Page 518: ...Ensure that the drain hose is reconnected and the manual vent and drain cock are closed 2 Open the surge tank filler cap and slowly fill the system to level of filler neck 3 After initial filling the...

Page 519: ...heater water valve requires a minimum amount of maintenance The valve should be free of dirt sediment that might interfere with its operation No other maintenance is needed unless a malfunction occurs...

Page 520: ...ing pushes up against the cylinder thereby allowing the hot water to enter the main heater core The central heater water valve requires a minimum amount of maintenance The valve should be free of dirt...

Page 521: ...om the actuator casing 3 Make sure that pilot solenoid valve operates properly 8 7 HOT WATER CIRCULATING PUMP This vehicle is provided with a brushless sealess water circulation pump which is in the c...

Page 522: ...onnect water lines from pump at flange connections Place a container to recover the residual coolant in the line 5 Remove the two clamps holding the pump motor to its mounting bracket Remove the pump...

Page 523: ...24 V DC Qty 4 Driver s unit evaporator motors Make MCC Voltage 24 V DC Quantity 1 Hot water circulating pump Make AMETEK Flow 15 gpm Inlet outlet OD 3 8 Driver s unit evaporator air filters Make MCC...

Page 524: ...clutch Make Lang Type KK73 1 Voltage 24 V DC Liquid refrigerant solenoid valve Make Sporlan Parker Hannifin Type Normally closed with manual bypass Voltage 24 V DC Driver s unit hot water pneumatic v...

Page 525: ...COMMUNICATION RADIO POWER 9 5 3 MOBILE VIEW BUS CAMERA SECURITY SYSTEM BCSS 9 6 SECTION CHANGE LOG 10 ILLUSTRATIONS FIGURE 1 HUBODOMETER 2 FIGURE 2 ELECTRIC HORN INSTALLATION 2 FIGURE 3 R H DASHBOARD...

Page 526: ...s accessible from 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 se...

Page 527: ...e windshield washer reservoir is located in the front service compartment Figure 5 This unit pumps the washer liquid to the spray nozzles where it is dispersed across the windshield 3 2 WIPER ARM Chec...

Page 528: ...bing at the base of the wiper arm 6 Check 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...

Page 529: ...g bent kinked or off one or more connections 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 r...

Page 530: ...gine System operation is fully automatic and does not require assistance from the operator However the system may be manually activated by the operator at any time Refer to Prevost Operator s Manual f...

Page 531: ...that mounting is secure and taught Electrical Harness o Verify that electrical connectors and electrical wiring have no visible damage and all connectors are securely seated Extinguisher Distribution...

Page 532: ...r these particular items FIGURE 14 MONITORING AND COMMUNICATION EQUIPMENT 5 1 CLEVER DEVICES IVN4 AND SPEAK EASY2 Installed in the vehicle s first left road side overhead compartment you will find an...

Page 533: ...wer open the first left hand road side overhead compartment and disconnect the two connectors shown in Figure below FIGURE 17 RADIO POWER MODE CHANGE 5 3 MOBILE VIEW BUS CAMERA SECURITY SYSTEM BCSS In...

Page 534: ...OB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 18 CAMERAS AND MICROPHONE UPPER FRONT OF VEHICLE FIGURE 19 CAMERA LOCATIONS TOP VIEW 6 SECTION CHANGE LOG DE...

Page 535: ...EDULE 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 LUBRICATION AND SERVICING SCHEDULE 5 3 SECTION CHANGE LOG 7 ILLUSTRATIONS FIGURE 1 LUBRICATION AN...

Page 536: ...nd easiest way to ensure your vehicle performs at its best safest and longest Also unscheduled maintenance will be minimized since inspection should expose potential problems before they become major...

Page 537: ...on Rev 2 April 2016 3 It is also recommended that all hoses in this vehicle be replaced during major overhaul and or after a maximum of five service years Quality of replacement hose assemblies should...

Page 538: ...SECTION 24 LUBRICATION 4 DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 FIGURE 1 LUBRICATION AND SERVICING POINTS I BEAM AXLE FRONT SUSPENSION VEHICLES 24030_1...

Page 539: ...2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 5 2 2 LUBRICATION AND SERVICING SCHEDULE 24039_4 FIGURE 2 COMPONENTS IDENTIFICATION COMPONENTS REPRESENTATION MAY DIFFER S...

Page 540: ...valve rear 37 Air compressor 14 Wet air tank 38 Alternators 15 Primary air tank 39 Emergency parking Brakes Overrule Control Valve 16 Differential 40 Air dryer purge tank 17 Propeller shaft 41 Haldex...

Page 541: ...CTION 24 LUBRICATION DOB 2490 2789 X3 45 Commuter PA1605 Maintenance Manual Final Version Rev 2 April 2016 7 3 SECTION CHANGE LOG DESCRIPTION DATE 1 Item numbers added in figure 2 12 Oct 2016 2 3 4 5...

Page 542: ......

Page 543: ...r noise or binding in the bearing 03 FUEL 1 Primary secondary fuel filters change at every engine oil change 21 2 Fuel tank perform yearly inspection 35 04 EXHAUST AND AFTERTREATMENT SYSTEM 1 DEF tank...

Page 544: ...2 BRAKE AIR SYSTEM 1 Brakes check caliper running clearance at brake pad replacements 46 2 Brakes check pad wear indicator Visually check condition of the slack adjuster cap guide pin covers 46 3 Air...

Page 545: ...gers HVAC unit disposable return air filters 2 replace 2 Evaporator compartment door fresh air intake filter clean 3 Parcel rack fans air filter clean 4 Driver HVAC unit return fresh air filters clean...

Page 546: ...ing hub unit Fuchs Europe Schmierstoffe GMBS Renolit LXPEP 2 Lithium saponified multipurpose grease NLGI No 2 F Differential Oil Mobil Delvac Synthetic Gear Oil 80W 140 G Radiator Fan Gearbox Syntheti...

Page 547: ...co Fuel Pro 382 system 6 collar spanner wrench 530224 04 EXHAUST AND AFTERTREATMENT SYSTEM 4 DPF filter either clean or replace 7 DPF removal tool 680790 05 COOLING 1 test coolant solution 8 refractom...

Page 548: ...65 24 pry bar 5870 345 071 N78017 20 12 BRAKE AIR SYSTEM 6 ABS Electronic Stability Control systems check proper functioning 25 ACOM diagnostic software available free of charge Bendix website 13 WHEE...

Page 549: ...n fluid was 150 000 mi changed to 84 000 mi 12 ADDED 07 TRANSMISSION Severe vocation filled with TranSynd or TES295 synthetic fluid only no mixture using High Capacity filters change Main Lube filters...

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