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SECTION 12: BRAKE AND AIR SYSTEM
PA1621 Maintenance Manual All Series | January 2017
5
1. TORQUE
TABLES
1.1
BRAKE AND AIR SYSTEM
BRAKE AND AIR SYSTEM
No
DESCRIPTION
TORQUE
1
Compressor flange mounting nuts
63 lb-ft (85 Nm)
2
Front IFS suspension caliper mount
ing bolts
405-495 lb-ft (549-671 Nm)
3
Front I-beam caliper mounting bolts
350-393 lb-ft (475-533 Nm)
4
Meritor drive axle & Tag axle caliper mounting bolts
405-495 lb-ft (549-671 Nm)
450
452
Table of Contents
Section 00: General Information
7
Table of Contents
7
Section Change Log
8
Foreword
9
Schematics
9
Precautions to be Observed before Welding
9
Safety Notice
13
Data Plates and Certifications
13
Engine
13
Transmission
13
Drive Axle
14
Front Axles
14
Coach Final Record
14
Safety Certification
14
DOT Certification Label
14
Fuel Tank Label
14
Vehicle Identification Number (VIN)
15
EPA Engine Label
15
Fastener
17
Fastener Strength Identification
17
Standard Torque Specifications
18
Sae
18
Metric
20
Self-Locking Fasteners
22
Recommendations for Reuse
22
Six Lobed Socket Head
23
Hose Clamp Torque
25
Section 01: Engine
35
Section Change Log
36
Torque Tables
37
X-Series Power Plant Cradle Installation
37
Belt Tensioners and Idlers
38
H-Series Power Plant Cradle Installation
40
System Overview
41
Volvo D13 Engine
41
Overview
42
Engine Oil
48
Oil Change Intervals
48
Oil Filters
48
Oil Quality
48
Oil Viscosity
49
Synthetic Lubrication
49
Oil Additives
50
Oil Change
50
Oil Consumption
50
Checking the Oil Level
51
Oil Filters Change
51
Power Plant Assembly Removal
53
Engine Mounts
55
Power Plant Assy. Installation
55
Automatic Belt Tensioners and Idler Pulleys Inspection
56
Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor
56
Automatic Belt Tensioner Bushing Wear
58
Bearing Inspection
58
Belts and Idlers Visual Inspection
58
Engine Protection Strategy
58
Specifications
60
Section 03 : Fuel System
67
Section Change Log
68
Fuel System
69
Miscellaneous Torques
69
Torque Tables
69
Fuel Filters
70
Fuel System
70
Fuel Valves
70
Primary Fuel Filter Replacement
71
Priming the Fuel System
73
Secondary Fuel Filter Replacement
73
Davco Fuel Pro 382
74
Filter Replacement
74
Priming Fuel System
74
Fuel Pump Removal and Installation
75
Fuel Lines and Flexible Hoses
76
Preheater Fuel Filter
76
Fuel Tank
77
Tank Removal
77
Fuel Tank Verification
78
Tank Installation
78
Fuel Specifications
79
Fuel Type
79
Polyethylene Fuel Tank Repair
79
Air Cleaner (Dry Type)
80
Biodiesel Fuels
80
Biodiesel Fuels and Preheater
80
Biodiesel Fuels and the Engine
80
Blending
80
Air Cleaner Servicing
81
Checking Restriction Indicator
81
Pre-Cleaner Servicing
81
Replacing the Filter
81
General Recommendations
82
Air Cleaner Restriction Indicator
83
Fuel Pedal
83
Fuel Pedal Adjustment
83
Potentiometer Replacement
83
Specifications
85
Section 04 : Exhaust and Aftertreatment
87
Section Change Log
88
Torque Tables
89
X3 Series
89
H3 Series
91
Miscellaneous Torques
94
Exhaust Aftertreatment System Overview
95
Diesel Particulate Filter (Dpf)
96
Flexible Coupling Installation
96
Maintenance
96
Diesel Particulate Filter Assembly Removal
97
Catalytic Converter
98
Removal
99
Assembling Catalytic Converter
100
Diffuser Adjustment
102
Diffuser Assembly
102
Diesel Exhaust Fluid (Def) Tank and Injection System
103
Diffuser Extension - (H3-45 Vip / X3-45 Vip)
103
Maintenance
103
Diesel Exhaust Fluid
104
Def Tank Cleaning
105
Pump Assembly Filter Element Replacement
106
Aftertreatment Hydrocarbon Doser
107
Filler Nec Kstrainer
107
Replacement
107
Section 05A: H3 Series Cooling System
109
Section Change Log
111
Hose Clamps
112
Torque Tables
112
Pulley, Idlers & Tensioners
113
Cooling Fan Drive Mechanism
114
Right Angle Gearbox
115
Description
116
Miscellaneous Torques
116
General Recommendations
118
Hose Clamps on Coolant Lines
118
Hoses
118
Maintenance
118
Constant-Torque Hose Clamps on Charge Air Cooler (Cac) System
120
Oetiker Screw Clamps
120
Checking New Thermostat
121
Thermostat Operation
121
Thermostat Replacement
121
Coolant
122
Coolant Level Sensor
122
Coolant Level Verification
122
Coolant Recommendations for Volvo D13 Engine
122
Thawing Cooling System
122
Coolant Sampling
123
Draining Cooling System
124
Filling Cooling System
125
Cooling System Descalers
126
Flushing
126
Reverse Flushing
127
Spin-On Coolant Filter
127
Maintenance
128
Radiator
128
Radiator Removal & Installation
128
Charge Air Cooler (Cac) Leakage
132
Cooling Fan Drive Mechanism
132
Drive Pulley and Universal Joint Shaft
132
Idler Replacement
132
Variable Speed Cooling Fan
133
Electrical Locking
134
Inspection
134
Locking Radiator Fan Clutch for Emergency Operation
134
Maintenance
134
Mechanical Locking in Case of Power Failure
134
Fan Removal / Installation
135
Fan Right Angle Gearbox
135
Maintenance
135
Oil Change
135
Cooling Fan Drive Belt
136
Maintenance
136
Mounting the Drive Belt
136
Removal / Installation
136
Section 05B: X3 Series Cooling System
139
Section Change Log
140
Hose Clamps
141
Torque Tables
141
Pulleys, Idlers & Tensionners
142
Cooling Assembly
143
Description
144
Miscellaneous
144
General Recommendations
147
Hose Clamps on Coolant Lines
147
Hoses
147
Maintenance
147
Constant-Torque Hose Clamps on Charge Air Cooler (Cac)
148
Maintenance
148
Thermostat Operation
148
Thermostat Replacement
148
Coolant
149
Coolant Level Sensor
149
Coolant Level Verification
149
Thawing Cooling System
149
Coolant Recommendations for Volvo D13 Engine
150
Coolant Sampling
152
Draining Cooling System
152
Cooling System Descalers
154
Filling Cooling System
154
Flushing
154
Reverse Flushing
155
Spin-On Coolant Filter
155
Cooling Assembly
156
Maintenance
156
Cooling Fan Replacement
158
Cooling Fan Shroud Removal & Installation
159
Cooling Pack (Radiator & Cac) Removal & Installation
160
Charge Air Cooler (Cac) in Vehicle Removal
166
Specifications
170
Section 06A : H3 Series Electrical
171
Section Change Log
174
Alternators and Surrounding Components
175
Torque Tables
175
Electrical Connections and Batteries
176
General Description
177
Using Wiring Diagrams
177
Wiring Diagrams
177
Spare Wires
178
Testing Circuits
178
Wire Sizes and Colors
178
Circuit Breakers
179
H3 Coaches
179
H3-45 Vip
180
Multiplex Fuses
180
Precautions
180
Relays
180
Electrical Compartments
183
Main Power Compartment
183
Maintenance
183
Battery Charger
184
Engine Rear Start Panel
184
Front Electrical and Service Compartment
184
A/C and Heating Controls
185
Batteries
185
Pneumatic Accessory Panel
185
Group 31 Agm Batteries
186
Battery Discharge Protection
189
Battery Removal and Installation
189
Main Battery Relays
189
Battery Rating
190
Battery Testing
190
Load Test
190
Removing Surface Charge
190
Visual Inspection
190
Testing Battery Cables
191
Battery Charging
192
Battery Charging Guide
192
Emergency Jump Starting with Auxiliary (Booster) Battery
193
Agm Battery Charging Precautions
194
Battery Equalization and Agm Batteries
194
Cleaning and Inspection
194
Common Causes of Battery Failure
195
Troubleshooting
195
Battery Voltage Warning" Pictogram
196
Battery Warning Pictogram May Appear as a Reminder
196
Components
196
Description
196
Prime Energy Management System
196
Voltage Gauge Definitions
196
Vanner 80 Series Battery Equalizer Fault Codes
198
Can Network
199
DID Display
199
Probing Voltage on the Multiplex Circuits
199
Troubleshooting and Testing the Multiplex Vehicles
199
CAN Connection on the Telltale Panel and the Hvac Control Unit
200
Electrical System Diagnostic
200
Multiplex Input Test Mode
200
Spare CAN
200
Motor Test Sequence
202
Test Sequence - Coaches Only
202
Test Sequence - VIP with Central HVAC System
203
Test Sequence - VIP with Small HVAC System
203
Forced Activation of the Radiator Fan Clutch
204
Can Network Layout and Troubleshooting
205
Troubleshooting
210
Available Functions
215
Essential Functions to Operate the Vehicle
215
Lower Priority Modules for Breakdown Service
215
MCM
215
Multiplex Modules
215
Multiplex Modules Replacement
216
Replacing IO-A or IO-B Modules
216
Replacing the MCM Module
216
Uploading the Vehicle Specific Multiplex Program in the MCM
216
Bosch Alternators
217
Table of Contents
232
Electrical Compartments
272
Battery Installation & Rear Junction Box
274
Maintenance
274
Rear Junction Box (Rjb)
274
Front Electrical and Service Compartment (Fjb)
277
A/C Module
279
Engine Rear Start Panel
279
Entrance Door & Wiper Control Modules
279
Overhead Compartment Module
279
Batteries
280
Battery Installation
280
Agm Batteries
282
Battery Discharge Protection
282
Main Electrical Shut-Off Switch
282
Battery Removal and Installation
283
Battery Rating
286
Battery Testing
286
Load Test
286
Removing Surface Charge
286
Visual Inspection
286
Battery Charging
287
Battery Charging Guide
288
Emergency Jump Starting with Auxiliary (Booster) Battery
289
Agm Battery Charging Precautions
290
Battery Equalization and Agm Batteries
290
Cleaning and Inspection
290
Battery Voltage Warning" Pictogram
291
Common Causes of Battery Failure
291
Troubleshooting
291
Voltage Gauge Definitions
291
Battery Equalizer
292
BATTERY Warning Pictogram MAY Appear as a Reminder
292
Components
292
Prime Energy Management System
292
Vanner 80 Series Battery Equalizer Fault Codes
294
Alternator Identification
295
Bosch Alternators
295
DID Display
295
Identifying a Defective Alternator
295
Identifying a Defective Alternator - Back-Probing AE49 & AE52 Multiplex Modules Method
295
Identifying a Defective Alternator Using the Instrument Cluster DID
295
Adjustment
296
Alternator Drive Belt
296
Removal and Installation
296
Starter
296
Engine Block Heater
297
Headlight Beam Toggle Switch
297
Headlights
297
Maintenance
297
PA1621 Maintenance Manual All Series | Jul
297
X3 Series Exterior Lighting
297
Headlight Adjustment
298
Bulb Replacement
299
Headlight Unit Replacement
299
Front Turn Signal Replacement
300
Optional Xenon Headlamp
300
Stop, Tail, Directional, Back-Up, and Hazard Warning Lights
301
Center Stoplights and Cyclops Light Removal and Replacement
302
Clearance, Identification and Marker Lights
302
Lamp Removal and Replacement
302
Licence Plate Light
302
License Plate Light
302
Bulb Removal and Replacement
303
Clearance and Identification Light Removal and Replacement
303
Control Panel Lighting
303
Fog Lights
303
Switch Lighting
303
Telltale Light Replacement
303
X3 Series Interior Lighting Equipment
303
Bulb Removal and Replacement
304
Gauge Light Bulb Replacement
304
Stepwell Lights
304
Bulb Removal and Replacement
305
Driver's Area Lights
305
LED Direct Lighting
305
LED Indirect Lighting / Overhead Compartment Interior Lighting
305
Passenger Section Lighting
305
Engine Compartment Lighting
306
Removal and Replacement of Reading Lamp Bulb
306
Section 07: Transmission
329
Section Change Log
331
Allison Transmission
333
Description
333
Torque Tables
333
Allison Automatic Transmission
335
Retarder
335
Volvo I-Shift Transmission
335
Allison Transmission Maintenance
336
Manual Fluid Level Check
336
Welding Procedures
336
Cold Check
337
Hot Check
337
Fluid Level Check Using the Pushbutton Shift Selector
338
Importance of Proper Fluid Level
339
Keeping Fluid Clean
339
Metal Particles
339
Oil Contamination
339
Recommended Automatic Transmission Fluid
339
Control System Prognostics
340
Coolant Leakage
340
Filter Life Monitor
340
Normal Prognostics Indication at Engine Start
340
Oil Life Monitor
340
Transmission Health Monitor
343
Oil and Filter Change Interval
344
Oil and Filter Change Interval with Prognostics Mode Disabled
345
Oil and Filter Change Interval with Prognostics Mode Enabled
345
Drain
346
Fluid and Filter Change Procedure
346
Refill Transmission
346
Allison Transmission Oil Cooler Removal
347
Breather
347
Cleaning and Inspection of Allison Automatic Transmission
347
Transmission with Retarder
347
Transmission Without Retarder
347
Allison Transmission Installation
348
Allison Transmission Troubleshooting
350
Diagnostic Troubleshooting Codes (Dtc) - Allison 5Th Generation Controls
350
Diagnostic Code Display and Clearing Procedure
351
Display Sequence
351
Exiting Diagnostic Mode
351
Using Shift Selector for Accessing Diagnostics Information
351
Diagnostic Trouble Code Response
352
Diagnostic Troubleshooting Codes (Dtc) List - Allison 5 Th
353
Allison Transmission Removal
355
Transmission Oil Type
356
Volvo I-Shift Transmission Maintenance
356
Checking Oil Level
357
Oil Change
357
Oil Drains Interval
357
Volvo I-Shift Transmission Tecu Fault Codes
359
Section 09: Propeller Shaft
401
Section Change Log
402
Description
403
Propeller Shaft
403
Standard Torque Specification Tables
403
Inspection, Lubrication, Removal and Installation
404
Specifications
406
Section 10: Front I-Beam Axle
407
Section Change Log
408
Front I-Beam Axle and Related Components
409
Torque Tables
409
Front I-Beam Axle Hub, Rotor and Brakes
411
Description
412
Reference Manuals
412
Lubrication
415
Maintenance
415
Removal
415
Removal and Replacement
415
Replacement
416
Checking Lateral Slackness
417
Checking Vertical Slackness
417
Front Wheel Alignment
417
Inspection before Alignment
417
Service Instructions for Steer Axle
417
Steering Knuckle Kingpin Inspection
417
Major Front Wheel Alignment
418
Minor Front Wheel Alignment
418
Turning Angle Adjustment
418
Camber Check
419
Front Wheel Camber
419
Hydraulic Stop
419
Turn Adjustment
419
Front Axle Caster
420
Front Wheel Toe
420
Alignment Specifications
421
Inspection and Adjustment
421
Troubleshooting
422
Specifications
423
Section 11: Rear Axles
425
Meritor Drive Axle
427
Torque Tables
427
Zf A132 Drive Axle
428
Description
429
Tag Axle
429
Dcdl
430
Maintenance
430
Checking and Adjusting the Oil Level
431
Drive Axle Lubrication
431
Draining and Replacing the Oil
432
Removal and Reinstallation
432
Adjustments
433
Disassembly and Reassembly
433
Drive Axle Alignment
433
Fastener Torque Chart
433
Gear Set Identification
433
Procedure
433
Tire Matching
433
Axle Shaft Sealing Method
434
Drive Axle Alignment Specifications
434
Zf A132 Drive Axle
435
Checking and Adjusting the Differential Oil Level
436
Differential Oil Change
436
Differential Oil Type
436
Maintenance
436
Compact Bearing (Hub Unit) Axial Play Check
437
Compact Bearing (Hub Unit) Grease Change
438
Drive Axle Flange Shaft Removal/Installation
438
Speed Sensors (Anti-Lock Brake System, ABS)
438
Disassembly, Reassembly, Adjustment and Torque Chart
440
Procedure
440
Removal and Reinstallation
440
Zf A132 Drive Axle Alignment
440
Tag Axle
441
Unloading Tag Axle (Optional)
441
Removal and Reinstallation
442
Removing Tag Axle Along with Suspension Components
442
Removing Tag Axle Only
442
Retracting Tag Axle
442
Retracting Tag Axle for Repair Purposes
442
Tag Axle Wheel Bearings
442
Removing Transversal Radius Rod
443
Tag Axle Alignment
444
Section 12: Brake and Air System
447
Section Change Log
450
Brake and Air System
451
Torque Tables
451
Miscellaneous Torques
453
Air Reservoirs
454
Air System
454
Brakes
454
Maintenance
454
Accessory Air Tank
455
Primary Air Tank
455
Secondary Air Tank
455
Wet Air Tank
455
Accessory Air Filter
456
Air System Emergency Fill Valves
456
I-Shift Transmission Air Tank
456
Kneeling Air Tank
456
Optional Parking Brakes Overrule Air Tank
456
Ping Tank
456
Accessory Air Filter Element
457
Air Filter/Dryer
457
Air Gauges (Primary, Secondary and Accessory)
457
Cleaning
457
Air Leak Check / Warning
458
Replacing the Desiccant Cartridge
458
Air Line Leakage Test
459
Air Line Operating Test
459
Air Lines
459
Flexible Hoses
459
Maintenance
459
Nylon Tubing
459
Air Compressor
460
Maintenance
460
Pressure Regulating Valves
460
Pressure Setting Procedure
460
Compressor Removal and Installation
461
Emergency / Parking Brake Control Valve
461
Flip-Flop Control Valve
462
Brake Pedal Adjustment
463
Brake Relay Valve
463
Maintenance
463
Parking Brake Alarm Switch
463
Stoplight Switches
463
Antilock Traction Relay Valve (Atr-6)
464
Air Horn Valve
465
Air System Troubleshooting
465
Emergency Door Opening Valves
465
Interior Valve Maintenance
465
Air Brakes
466
Brake Operation
466
Inspection Points
467
Checking Disc Brake Pads
468
Pad Replacement - Adjuster
468
Drive Axle - Equipped with a Solid Rubber Bushing and Exposed Guide Pin
469
Front and Tag Axle - Equipped with Visual Wear Indicator
469
Brake Pads
470
Brake Pads and Discs Minimal Tolerance Limits
470
Brake Disc
471
Caliper Running Clearance
471
Safe Service Procedures
471
Air Brake Troubleshooting
472
Brake Air Chamber
473
Emergency/Parking Brake Manual Release
474
Maintenance
474
Brake Chamber Disassembly
475
Brake Chamber Installation
475
Brake Chamber Removal
475
Abs Components
476
Anti-Lock Braking System (Abs)
476
Bendix Ec-60 Advanced Controller
476
Troubleshooting and Testing
476
Sensors
477
Bendix Automatic Traction Control (Atc) - Electronic Stability Control (Esc)
478
Components
478
Spring Clip
478
The
478
Bendix M-40Qr Pressure Modulator Valve
479
Bendix SAS-70 Steering Angle Sensor
479
The
479
Removal of the Steering Angle Sen- Sor
481
Fitting Tightening Torques
482
Section 13: Wheels, Hubs and Tires
485
Section Change Log
487
Tag Axle
488
Torque Tables
488
Wheel Nuts
488
Front Axle
489
Meritor Drive Axle
489
Zf A132 Drive Axle
490
H3-45 & X3-45 Coaches
491
H3-45 Vip & X3-45 Vip Motorhomes
491
Wheel Maintenance
491
Wheels
491
Dual Wheels
492
Inner Wheel Installation
492
Inner Wheel Removal
492
Inspection
492
Outer Wheel Installation
492
Outer Wheel Removal
492
Single Wheel Installation
492
Single Wheel Removal
492
Aluminum Wheel Anti-Corrosion Protection (Without Dura-Bright)
493
Inspection
493
Drive Axles Wheel Studs
494
Wheel Straightness Test
494
Wheel Studs
494
Care of Wheels
495
Front and Tag Axle Wheel Studs
495
Hub Mounted Wheels
495
Tag Axle Wheel Hubs
495
Tag Axle Hub Bearing Inspection
497
Tag Axle Hub Bearing Installation
497
Tag Axle Hub Bearing Removal
497
Front Axle Hub Bearing Inspection
500
Front Axle Wheel Hubs
500
Front Axle Hub Bearing Installation
501
Front Axle Hub Bearing Removal
501
Bearing Check/Adjustment
503
Disassembly and Repair
503
Meritor Drive Axle Wheel Hubs
503
Compact Bearing (Hub Unit) Axial Play Check
504
Zf Drive Axle Wheel Hubs
504
Compact Bearing (Hub Unit) Grease Change
505
Spare Wheel
505
Pulling out Spare Wheel
506
Super Single Tire Replacement
506
Changing a Flat Tire (Coaches Only)
507
Changing a Flat Tire (Vip & Converted Bus Shells)
507
Spare Wheel Maintenance
508
Valve Installation
509
Tpms Sensors Installation
510
Inflation Pressure
511
Tire Maintenance
511
Tire Matching
513
Tire Rotation
513
Wheel Balancing
513
Specifications
514
Section 14: Steering
515
Section Change Log
517
Steering Column
518
Torque Tables
518
Miscellaneous Torques
519
Front I-Beam Axle Steering System Description
521
Steering System
521
Independent Front Suspension Steering System Description
522
Description
523
Power Steering Gear
523
Bleeding Power Steering Hydraulic System
524
Description
524
Hydraulic Pressure Test
524
Power Steering Gear Installation
524
Power Steering Gear Removal
524
Power Steering Hydraulic Pump
524
Removal and Installation
524
Troubleshooting
524
Removal
526
Steering Column
526
Removal
527
Steering Wheel
527
Clockspring Replacement
528
Installation
528
Turning Angle Adjustment
528
Coaches
529
Pitman Arm
529
Removal
529
Steering Linkage Adjustment
529
Vip & Bus Shells
529
Adjustment
530
Installation
530
Drag Link (I-Beam Axle)
531
Tag Axle Unloading Switch Adjustment (Optional)
531
Adjustment System Thread Lengths
532
Fine Adjustment
532
Maintenance
533
Power Steering Fluid Condition
533
Power Steering Fluid Visual Inspection
533
Power Steering Fluid Change
534
Power Steering Fluid Level Check
534
Filter Element Replacement
535
Steering System Play Inspection
535
Drag Link Maintenance
536
IFS Drag Link
536
Lubrication Fittings
536
Front I-Beam Axle Drag Link
537
Drag Link and Tie Rod Ball Joints Inspection for Corrosion
538
Tie Rods
538
Assembling Drop Type Ball Joint
539
Dismantling Drop Type Ball Joint
539
Drop Type Ball Joint
539
Drop Type Ball Joint End Play
539
Straight Body Type Ball Joint
540
Visual Inspection
540
Driving Tips
541
Front Wheel Alignment
541
Independent Front Suspension Alignment
541
Straight Body Type Ball Joint End Play and Looseness
541
Alignment Terminology
542
Front End Inspection
542
Front Wheel Camber
542
Front Wheel Caster
543
Major Damage
543
Alignment Specifications
544
I-Beam Axle - Front Wheel Alignment
547
Inspection before Alignment
547
Major Front Wheel Alignment
547
Minor Front Wheel Alignment
547
Front Wheel Camber
548
Hydraulic Stop
548
Turn Adjustment
548
Turning Angle Adjustment
548
Camber Check
549
Front Axle Caster
549
Inspection and Adjustment
550
Troubleshooting
551
Specifications
552
Torque Specifications
552
Section 16 : Suspension
553
Section Change Log
556
Front I-Beam Axle and Related Components
557
Torque Tables
557
Independent Front Suspension
559
Description
564
Rear Suspension
564
Air Springs
566
Front I-Beam Axle Suspension
566
Inspection
566
Removal
566
Installation
567
Shock Absorbers
567
Inspection
568
Removal
568
Inspection
569
Installation
569
Radius Rods
569
Radius Rod Removal
570
Installation
571
Radius Rod Assembly
571
Radius Rod Installation
571
Removal
571
Stripping down
571
Sway Bar
571
Independent Front Suspension (Ifs)
572
Steering Linkage
572
Installation
575
Pitman Arm
575
Removal
575
Steering Linkage Installation Sequence
575
Adjustment
576
Bell Crank and Idler Arm
576
Bell Crank or Idler Arm Removal
576
Drag Link
576
Bell Crank or Idler Arm Hub Disassembly
577
Bell Crank or Idler Arm Hub Reassembly
577
Relay Rod
578
Removal
578
Replacement
578
Tie Rods
578
Installation
579
Steering Arms
579
Installation
580
Removal
580
Lubrication Fittings
582
Alignment Terminology
583
Ball Joints - General Recommendations
583
Front-End Alignment
583
Front End Inspection
584
Front Wheel Camber
584
Front Wheel Toe-In
584
Alignment Specifications
585
Front Wheel Caster
585
Major Damage
585
Assembly
590
Lower and Upper A-Arm Ball Pin Bushing Repair
590
Stripping down
590
Assembly
591
Lower A-Arm Ball Joint Repair
591
Play Measurement
591
Stripping down
591
Upper A-Arm Ball Joint
591
Visual Inspection
591
Front Air Springs
592
Inspection
592
Removal
592
Installation
593
Shock Absorber Removal
593
Shock Absorbers
593
Installation
594
Removal
594
Shock Absorber Installation
594
Sway Bar
594
Rear Suspension
595
Air Springs
596
Inspection
596
Installation
596
Removal
596
Inspection
597
Shock Absorbers
597
Installation
598
Radius Rods
598
Removal
598
Suspension Air System
598
Air Line Test
599
Inspection
599
Normal Ride Height
599
Suspension Height Adjustment
599
Height Control Valves
600
Maintenance
600
Removal and Installation
600
"Level-Low" Leveling System - Vip Series Option Only
601
Air Leakage Test
601
Principles of Operation
601
Air Spring Control Solenoid Valves
602
Front Kneeling System (Coaches Only)
602
High-Buoy System (Coaches Only)
602
Maintenance
602
Principle of Operation
602
Principles of Operation
602
Removal and Installation
602
Adjustment
603
Cleaning
603
Disassembly
603
High-Buoy - Pressure Regulator
603
Maintenance
603
Air System
604
Low-Buoy System (Coaches Only)
604
Maintenance
604
Principles of Operation
604
Reassembly
604
Air Tank Maintenance
605
Primary Air Tank
605
Wet Air Tank
605
Accessory Air Tank
606
Emergency Fill Valves
606
Expansion Air Tank
606
Secondary Air Tank
606
Troubleshooting
607
Section 18A: H3 Series Body
621
Section Change Log
625
Torque Tables
626
Vehicle Exterior
628
Vehicle Jacking Points
630
Towing the Vehicle
631
Lifting and Towing
632
Towing Without Lifting
632
Volvo I-Shift Alternate Towing Mode
633
Corrosion Prevention
634
Exterior Maintenance
634
Rust Inhibitor Application
636
Fiberglass Repair
640
Repair Using Fiberglass Cloth
641
Repair Using Fiberglass Paste
641
Typical Fiberglass Repair Procedure
642
New Paint Care
643
Paint Touchup
643
Surface Preparation and Paint Application
644
Front and Rear Bumpers
645
Front Bumper Removal
645
Front Bumper Removal and Installation
645
Front Bumper Skin Removal
645
Paint Touchup and Surface Preparation for Vehicles Equipped with Urethane Bumpers
645
Front Bumper Assembly Removal Including Spare Wheel Compartment Door
646
Front Bumper License Plate Support Installation
646
Rear Bumper Removal and Installation
646
Coach Entrance Door
647
Emergency Exit Valves
647
Door Cycle Speed Adjustment
648
With Air but Without Electricity
648
Without Air And/Or Without Electricity
648
Horizontal and Vertical Adjustment
649
Depth Adjustment
650
Rod End Adjustment
650
Depth Adjustment
652
Door Adjustment
652
Entrance Door (V.I.p)
652
Horizontal and Vertical Adjustments
652
Keyless Entry System
652
Door Lower Section
653
Door Seal Replacement
653
Reflector Stripe Installation
653
Door Latch Mechanism
654
Door Lubrication
654
Driver's Power Window
654
Power Window Removal
654
Power Window Installation
655
Roof Escape Hatch
655
Passenger Seats
664
Rotating Seats
664
Dry Cleaning
665
Routine Cleaning
665
Upholstery Maintenance
665
Window Removal
670
Section 22: Heating and Air Conditioning
853
High Capacity Compressor (Central Hvac System)
857
High/Low Pressure Service and Receiver Tank Valves
858
Small A/C System X3-45 Vip
859
Central Hvac System Evaporator Compartment Arrangement
860
Hvac System Overview
860
Central Hvac System - H Series
861
Central Hvac System - X Series
864
Small Hvac System - H Series
866
Small Hvac System - X Series
868
Coil Cleaning
870
Driver's Unit
870
Hvac System Basic Maintenance
870
Passenger's Unit
870
Driver's Unit Air Filter
871
Overhead Compartment Fan Air Filter
872
Belt Replacement - Central System
873
Belt Tension Adjustment - Central System
873
Compressor Belts
873
Belt Tension - Small HVAC System X-SERIES
874
Belt Tension Adjustment - Small HVAC System H-SERIES
874
Torch Brazing
874
Compressor - Central A/Csystem
875
Compressor Maintenance
875
Hvac System Components
875
Oil Level Check and Oil Change
875
Suction and Discharge Hose Connection
875
Troubleshooting Guide
876
Brushless Evaporator Motor
877
Compressor - Small Hvac System
877
Electro-Magnetic Clutch
877
Removal - When the Compressor Is Inoperable
877
Removal - When the Compressor Is Operational
877
Condenser Fan Control
879
Condenser Fan Removal
880
Receiver Tank
881
Filter-Dryer
882
Moisture Indicator
882
Replacement of the Filter-Dryer after Pumping down
882
Liquid Refrigerant Solenoid Valve
884
Shut-Off Valve with Service Port
884
Typical Malfunctions
884
Coil Replacement
885
Electrical Bypass/On Demand Opening of Liquid Refrigerant Solenoid Valves
885
Valve Disassembly
885
Valve Reassembly
885
Central System
886
Thermostatic Expansion Valve
886
Superheat Adjustment
887
Driver's Unit
888
Hot Water Pneumatic Valve
888
Hot Water Circulating Pump
890
Valve Troubleshooting
890
Temperature Sensors
893
Air Conditioning
897
Expansion Valve
897
Leak Testing
900
Air Circulation in Driver's Area
901
Air Circulation in Passenger'sarea
902
Control Unit
903
Hvac System Operation
903
Overhead Compartment Unit
903
Draining Heating System
904
Driver's Unit Hot Water Pneumatic Valve
904
Passenger's Unit Hot Water Pneumatic Valve
904
Bleeding Heating System
907
Filling Heating System
907
Refrigeration Cycle
908
Refrigerant System Clean-Out after Compressor Failure
910
Pumping down
911
Adding Vapor State Refrigerant
913
Charging System
914
Evacuating System
915
Liquid Refrigerant Recovery
915
Air Circulation
916
Small Hvac System
916
System Configuration H-Series
916
System Configuration X Series
916
Auxiliary Unit
917
Auxiliary Unit - H3 VIP Vehicles Only
917
Driver's Unit
917
Evacuating System Prior Addition of Refrigerant (Driver's or Auxiliary System)
917
Refrigerant Recovery
917
System Operation
917
Compressor Oil Contamination
918
Oil Addition
918
Oil Return Operation
918
Preheating System (Option)
918
Operation
919
Preheater Fuel Filter
919
Preheater Timer Instructions
920
Preheater Troubleshooting and Maintenance
920
Preheating System Timer
920
Specifications
922
Other manuals for PREVOST H3-41
Operator's Manual
151 pages
Manual
146 pages
5
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PREVOST H3-41 Specifications
General
Brand
PREVOST
Model
H3-41
Category
Motorhomes
Language
English
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