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SECTION 01: ENGINE

10

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

Always dispose of all lubricants (motor oil,
coolant, gear box oils, etc.) and filters
according to Federal or local regulations.
Used oil disposed of in nature or waterways
contaminates our drinking water and kills
wildlife.

WARNING

Prolonged contact with used engine oil may
be harmful. Use rubber gloves when handling
used oil. Wash skin thoroughly if it comes in
contact with used oil.

It is important to drain as much oil as possible.
Try to change oil immediately after driving, when
the oil is warm. Always replace the oil filters
when changing the oil.

Component Capacity

(L)

Oil pan

24 (min) – 32 (max)

Engine block

1

Filters (3)

6

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 can cause severe burns. DO NOT
allow hot oil to contact the skin. When
changing oil, wear protective gloves.

CAUTION

Volvo-branded oil filters are designed to
provide the proper level of filtration and
protection for Volvo engines. Filters that do
not meet the same stringent requirements
may cause unsatisfactory results.



Clean around the oil filter housing and

remove the filters using the oil filter
wrench or the oil filter socket.

FIGURE 5: OIL FILTER WRENCH



Prefill the new oil filters with approved

engine oil. Also, lubricate the filter gaskets
with engine oil (1). Hand tighten the oil
filters until they contact the sealing surface
of the oil filter housing (2). Manually
tighten the oil filters an additional ¾ to 1
full turn (3).

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Содержание X3-45 COMMUTER

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

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 20: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 50: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 82: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 198: ......

Страница 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...

Страница 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...

Страница 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...

Страница 202: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 212: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 232: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 270: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 304: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 322: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 370: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 474: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 542: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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