PREVOST Le Mirage XL II Ultimate Service Manual Download

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PREVOST

SLIDE-OUT TECHNOLOGY

THE "ULTIMATE" CLASS

CONVERSION BUS SHELLS

SLIDE-OUT SERVICE MANUAL RELEASE 3

Summary of Contents for Le Mirage XL II Ultimate

Page 1: ...PREVOST SLIDE OUT TECHNOLOGY THE ULTIMATE CLASS CONVERSION BUS SHELLS SLIDE OUT SERVICE MANUAL RELEASE 3...

Page 2: ...3 FRONT SLIDE OUT LOWER RACK REPLACEMENT 14 4 4 REAR SLIDE OUT LOWER RACK REPLACEMENT 14 5 PINION 15 5 1 MAINTENANCE 15 5 2 UPPER SHAFT PINION REPLACEMENT 15 5 3 FRONT SLIDE OUT DRIVER SIDE LOWER SHA...

Page 3: ...ERS 27 13 3 1 Motor controller replacement 28 13 3 2 Logic controller replacement 28 13 3 3 EPROM memory chip replacement 29 13 3 4 Rear slide out program set up 29 13 3 5 Slide out stroke limits set...

Page 4: ...FIGURE 15 PIN RECEPTACLE ON GLASS 13 FIGURE 16 PIN RECEPTACLE ON STAINLESS STEEL PANELS 13 FIGURE 17 FRONT SLIDE OUT ROOF REINFORCING ROD 13 FIGURE 18 BOTTOM RACK 14 FIGURE 19 PILLOW BLOCK SUPPORTING...

Page 5: ...BOTTOM PANEL INSTALLATION 34 FIGURE 47 TOP AND BOTTOM PANEL INSTALLATION 34 FIGURE 48 WINDOWS ABOVE SIDE PANELS 34 FIGURE 49 WINDOW LOCATED OVER THE CORNER PANEL 35 FIGURE 50 PINION PILLOW BLOCK ADJUS...

Page 6: ...XL2 SLIDE OUT SERVICE MANUAL FIGURE 1 SLIDE OUT MECHANICAL COMPONENTS R3 6 May 3 2002...

Page 7: ...tight and that no damage or deformation has taken place for both the side and the upper stoppers 1 1 2 Adjustment 1 Adjust the side inner stoppers at 1 8 from the vehicle structure stoppers and tight...

Page 8: ...ttom racks Rise up the tables to support the slide out without lifting it 4 From inside the vehicle loosen the upper shaft pillow block nuts and remove the shims behind the pillow blocks Keep note of...

Page 9: ...lf and or its seal When moving the slide out check constantly its four corners from inside and outside to avoid contact with the locking pins and or the vehicle structure 2 Bring the slide out close t...

Page 10: ...ocedure 1 3 1 6 REAR SLIDE OUT INSTALLATION The procedure for installing the rear slide out is almost the same as the procedure for the front slide out Before adjusting the stroke limits procedure 1 4...

Page 11: ...ntrol panel while the ignition key is switched to the ON position When the tag axle is unloaded switch the ignition to the OFF position 4 Loosen the locking pin nuts 5 Align the locking pin with the s...

Page 12: ...rew 4 Using a compressed air nozzle manually retract the locking pin 5 Slide the pin unlocked sensor PU in the air cylinder groove 6 Place the PU sensor in the zone where it is activated Move slowly t...

Page 13: ...plastic cap back on 9 One by one replace the threaded rods with the washers and the screws FIGURE 16 PIN RECEPTACLE ON STAINLESS STEEL PANELS 10 Clean excess sealant with alcohol 11 Readjust the lock...

Page 14: ...e pinion 4 From inside the slide out unscrew all the rack screws figure 2 and figure 3 5 Move the pinion away from the rack and remove the rack from its location by pulling it out 6 Remove the old wat...

Page 15: ...after a load variation in the slide out section 5 6 Caution Make sure all keyless bushings are tightened to 125 lb ft before unlocking the pins or moving the slide out Refer to section 5 6 for torque...

Page 16: ...lb ft before unlocking the pins or moving the slide out Refer to section 5 6 for torque wrench settings 5 3 FRONT SLIDE OUT DRIVER SIDE LOWER SHAFT PINION REPLACEMENT 1 Remove the front slide out as d...

Page 17: ...motor side pinion only Remove the gearbox support see section 7 2 5 Remove the pinion and the keyless bushing from the shaft 6 Check the keyless bushing and the guide wheel condition and replace them...

Page 18: ...shaft is not accessible when the slide out is installed Therefore it must be tightened before installing the slide out Follow these steps to adjust and synchronize the front slide out pinions 1 The sl...

Page 19: ...e motor from the gearbox 4 Fasten the new motor to the gearbox using screws FIGURE 23 ELECTRIC MOTOR 5 Replace and tighten the motor holding metal strap figure 23 6 Re connect the motor electric cable...

Page 20: ...6 2 13 Reinstall the universal joint and the jaw coupling on the right angle drive Use the motor output shaft to align the keyseats 14 For the front slide out Reinstall the reinforcement plate 8 RIGHT...

Page 21: ...crews are tight 9 2 REPLACEMENT The jaw coupling replacement procedure is the same as for the right angle drive section 8 2 and 8 3 10 UHMW SLIDING PAD The UHMW sliding pads support the slide out and...

Page 22: ...from moving Use Loctite 242 or equivalent product on all set screws 5 Paint the universal joints to prevent rust 11 3 VERTICAL SHAFT REPLACEMENT Use the same procedure as for the universal joint sect...

Page 23: ...cted and pins unlocked A 3 port 2 position normally open valve is connected in line to the parking brake system and prevents the conductor from releasing the parking brake as long as both slide out ar...

Page 24: ...e slide out sealing device is used to prevent any type of infiltration that may occur between the structure body and the slide out itself It is composed of an inflatable seal which is used as a primar...

Page 25: ...ime Caution Always apply product in the same direction to prevent dirt from being brought back Caution Check before using any cleaning or adhesive product on seal panel or glass to prevent alteration...

Page 26: ...nt on the exterior extrusion screws and between the extrusion the roof and the edges to prevent water infiltration figure 6 13 SLIDE OUT ELECTRICAL SYSTEM Warning Never modify the slide out electrical...

Page 27: ...the driver side figure 35 LOGIC CONTROLLER The slide out logic controller is used to analyze the input signal conditions and activate outputs like the pneumatic valves and a predefined sequence progr...

Page 28: ...up its memory section 13 3 4 FUSE INTERLOCK VALVE RELAY FIGURE 37 FUSE AND INTERLOCK VALVE RELAY Note The stroke limits and the rear slide out information are programmed in an EEPROM Then it is not n...

Page 29: ...re version written on the chip on the controller sticker if it had changed and inform Prevost service department for controller tracking FIGURE 39 EPROM MEMORY CHIP LOCALIZATION 8 Reinstall the contro...

Page 30: ...ze the slide out outer limit by pushing once the logic controller black push button see figure 40 The green LED OUT6 confirms that the stroke limit is set in the logic controller memory see figure 52...

Page 31: ...of the logic 3 Loosen two metal screws on one side of the controller Unscrew the other side screws Remove the used safety controller and replace it by a new one 4 To reinstall the new safety controlle...

Page 32: ...tween the side panels and the corner panels and also between side panels and bottom and top panels Apply sealant both inside and outside the slide out panels 14 3 CORNER PANELS REMOVAL Note The corner...

Page 33: ...gure 15 and figure 16 Refer to figure 44 and figure 45 for adhesive tape and rivet position 14 5 TOP AND BOTTOM PANELS REMOVAL Note The top and bottom panels are made of aluminum sheets 1 Remove the s...

Page 34: ...tween the windows and the structure Make sure not to damage the rubber seal between the windows 4 With a helper remove the window from the slide out For awning and sliding windows unscrew the window f...

Page 35: ...e 6 Install the exterior extrusion as described in section 12 4 4 step 5 7 Install the finishing molding supports and the molding 16 WELDING PRECAUTION 1 Disconnect logic controller wiring connectors...

Page 36: ...NT SLIDE OUT PIN VALVE 8 REAR SLIDE OUT PIN VALVE 9 FRONT SLIDE OUT RACK CLEANING 10 REAR SLIDE OUT RACK CLEANING 11 FRONT SLIDE OUT SEAL VACUUM VALVE 12 REAR SLIDE OUT SEAL VACUUM VALVE 13 PRESSURE R...

Page 37: ...L2 SLIDE OUT SERVICE MANUAL FIGURE 52 SLIDE OUT LOGIC CONTROLLER LED PANEL PNEUMATIC CYLINDER SPRING PIN SLEEVE SEGMENT HEAD BASE SENSOR SWITCH INNER PIN FIGURE 53 LOCKING PIN ASSEMBLY R3 37 May 3 200...

Page 38: ...limits section 13 3 5 B Check the linear position transducer potentiometer condition Regular flashing ten flashes every second 10 Hz and no abnormal LED flashing on the motor controller refer to secti...

Page 39: ...air pressure inlet valve not completely opened C Locking pin not adjusted properly D Air line pin cylinder or pin valve obstruction malfunction or leakage E Locking pin sensor switch malfunction or w...

Page 40: ...output LED 1 power LED 1 communication LED ERR and 1 diagnostic LED figure 52 When the ignition key is turned to the ON position the power LED comes on A slow flashing of the communication LED 0 1 se...

Page 41: ...he motor controller section 13 3 1 C Check the safety controller and the electrical connections conditions Change the safety controller if necessary refer to section 13 3 7 Reset the power on the cont...

Page 42: ...n section 5 6 B Readjust the stroke limits section 13 3 5 Slide out stops before having reached the limits without control switch LED light A Bad stroke limit adjustment A Readjust the stroke limits s...

Page 43: ...ated the inflatable seal B Vacuum switch malfunction or bad set up C Excessive load on roof or bad roof reinforcing rod adjustment D Guide wheel excessive wear E Plastic stopper bad adjustment F Seal...

Page 44: ...extended 2000 lb Maximum load when moving 1200 lb When the load is distributed in the slide out to prevent a deflection of the inside lower member over 1 4 that could damage the seal FIGURE 54 FRONT...

Page 45: ...XL2 SLIDE OUT SERVICE MANUAL FIGURE 56 KEYLESS BUSHING INSTALLATION INSTRUCTION R3 45 May 3 2002...

Page 46: ...d against peak voltage 6 outputs High Side of continuous 2A with protection against spike voltage peaks produced by inductive loads 2 high side output relay device 10A continuous Operating supply volt...

Page 47: ...ynchronize the upper shaft pinion Make sure the slide out does not move when locking or unlocking the pins If necessary readjust the locking pins Make sure the pin receptacle plastic caps are present...

Page 48: ...ALL WIRES ARE 18 AWG EXCEPT WHEN SPECIFIED EFFECTIVE FROM SERIAL NUMBER Y 7450 TO 1 7718 AND FROM 1 7724 TO 1 7773 2002 04 26 XL2 DOUBLE SLIDE OUT ELECTRIC DIAGRAM RETROFIT...

Page 49: ...XL2 SINGLE SLIDE OUT ELECTRIC DIAGRAM RETROFIT EFFECTIVE FROM SERIAL NUMBER Y 7450 TO 1 7718 AND FROM 1 7724 TO 1 7773 ALL WIRES ARE 18 AWG EXCEPT WHEN SPECIFIED 2002 04 26...

Page 50: ...XL2 DOUBLE SLIDE OUT ELECTRIC DIAGRAM RETROFIT ALL WIRES ARE 18 AWG EXCEPT WHEN SPECIFIED 2002 04 26 EFFECTIVE FROM SERIAL NUMBER Y 7003 TO Y 7446...

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