PREVOST X3-45 2016

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PROCEDURE NO: PR060041 REVISION 01

Page 5 of 7

Disconnect 3 connectors from VECU

Disconnect 3 connectors from CECM

Disconnect connector A 83 under Volvo Link

module

Main Page

Table of Contents5
Section 00: General Information6
Foreword6
Schematics6
Precautions to be Observed before Welding6
Safety Notice8
Data Plates and Certifications8
Engine8
Transmission9
Drive Axle9
Front Axle9
Power Steering Pump9
Coach Final Record9
Safety Certification9
Figure 3: Typical Serial & Model Numbers9
Figure 4: I - Beam Axle Typical Serial & Model Numbers9
Figure 5: Power Steering Pump9
DOT Certification Label10
Fuel Tank Label10
Vehicle Identification Number (VIN)10
Figure 6: Dot Certification Plate10
Figure 7 : Vehicle I . D10
Figure 8 : Vehicle Identification Number11
Fastener Strength Identification12
Figure 9 : Thread Notation12
Figure 10: Bolt Strength Markings12
Standard Torque Specifications13
Self-Locking Fasteners15
Recommendations for Reuse15
Six Lobed Socket Head15
Figure 11 : Self-Locking Fasteners15
Figure 12: Metric - Us Standard Conversion Table16
Figure 13: Conversion Chart17
Volvo D27
Figure27
Volvo D13 Engine28
System Overview28
Engine Overview32
Engine Oil33
General33
Oil Quality33
Oil Change Intervals34
Oil Filters34
Synthetic Lubrication34
Oil Viscosity34
Oil Additives35
Oil Consumption35
Oil Change35
Oil Filters Change36
Checking the Oil Level37
Power Plant Assembly Removal37
Power Plant Assy. Installation40
Engine Mounts41
Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor42
Specifications43
Fuel System with Volvo D13 Engine47
Description47
Fuel Valves48
Fuel Filters48
Primary Fuel Filter Replacement49
Secondary Fuel Filter Replacement49
Priming the Fuel System50
Fuel Pump Removal and Installation50
Fuel Lines and Flexible Hoses51
Fuel Tank51
Tank Removal52
Tank Installation52
Fuel Tank Verification52
Polyethylene Fuel Tank Repair52
Fuel Specifications53
Fuel Type53
Blending54
Biodiesel Fuels54
Air Cleaner (Dry Type)54
Pre-Cleaner Servicing54
Air Cleaner Servicing55
General Recommendations55
Air Cleaner Restriction Indicator55
Fuel Pedal55
Fuel Pedal Adjustment55
Potentiometer Replacement56
Specifications56
Exhaust Aftertreatment System Overview60
Maintenance60
Flexible Coupling Installation61
Diesel Particulate Filter (Dpf)61
Catalytic Converter63
Removal63
Assembling Catalytic Converter65
Diffuser Assembly66
Diffuser Adjustment66
Maintenance67
Diesel Exhaust Fluid (Def) Tank and Injection System67
Diesel Exhaust Fluid68
Def Tank Cleaning68
Pump Assembly Filter Element Replacement69
Aftertreatment Fuel Injector70
Replacement70
Torque Specifications72
Description79
Maintenance80
General Recommendations80
Mta Vehicles Equipped with Volvo D13 Engine80
Hoses80
Constant-Torque Hose Clamps on Coolant Lines -Volvo D1381
Installation81
Maintenance81
Constant-Torque Hose Clamps81
Cac )81
Thermostat Operation82
Thermostat Replacement82
Checking Thermostat82
Coolant82
Coolant Level Verification82
Coolant Level Sensor83
Thawing Cooling System83
Cooling System Recommendations83
Coolant Recommendations for83
Mta Coaches Equipped with Volvo D 13 Engine83
Draining Cooling System84
Filling Cooling System85
Flushing85
Cooling System Descalers86
Reverse Flushing86
Spin-On Coolant Filter86
Radiator87
Maintenance87
Radiator Removal & Installation87
Charge Air Cooler Leakage90
Cooling Fan Drive Mechanism90
Drive Pulley and Universal Joint Shaft90
Idler Replacement91
Variable Speed Cooling Fan91
Locking Radiator Fan for Emergency Operation92
Electrical Locking92
Mechanical Locking92
Maintenance93
Inspection93
Fan Removal Installation93
General Description100
Wiring Diagrams100
Using Wiring Diagrams100
Testing Circuits101
Wire Sizes and Colors101
Spare Wires101
Cleaning Connectors102
Circuit Breakers102
X3-45 Coaches102
Multiplex Fuses102
Relays103
Precautions103
X3 Series Coach105
Maintenance105
Rear Electrical Panel, Junction Panel, Battery Compartment & Equalizer105
Rear Electrical Panel106
Rear Junction Panel106
Battery Compartment106
Front Electrical and Service Compartment106
A/C Junction Box106
Engine Rear Start Panel107
Entrance Door & Wiper Control Panel107
Batteries107
Battery Discharge Protection108
Main Battery Relays108
Battery Removal and Installation108
Battery Rating109
Battery Maintenance110
Visual Inspection110
Removing Surface Charge110
Testing Battery Cables110
Battery Charging111
Emergency Jump Starting with Auxiliary (Booster) Battery111
Common Causes of Battery Failure112
Troubleshooting113
Battery Voltage Warning" Pictogram113
Voltmeter Gauge Definitions113
Troubleshooting and Testing the Multiplex Vehicles113
Electrical System Diagnostic113
Probing Voltage on the Multiplex Circuits114
Can Network114
Spare CAN114
Multiplex Input Test Mode114
Test Sequence116
Forced Activation of the Radiator Fan Clutch116
Can Network Layout and Troubleshooting117
Troubleshooting117
Available Functions123
Lower Priority Modules for Breakdown Service123
Multiplex Modules123
MCM123
Io-A123
Io-B123
Multiplex Modules Replacement123
Replacing IO-A or IO-B Modules123
Replacing the MCM Module124
Bosch Alternators124
Alternator Brush Replacement125
Identifying the Defective Alternator126
Alternator Drive Belt126
Adjustment126
Battery Equalizer126
Battery Charger126
Power Inverter127
Starter127
Exterior Lighting127
Headlights127
Headlight Beam Toggle Switch127
Maintenance127
Headlight Adjustment128
Sealed-Beam Unit129
Front Turn Signal130
Stop, Tail, Directional, Back-Up, and Hazard Warning Lights130
Lamp Removal and Replacement130
Center Stoplights and Center High-Mounted Stop Light (CHSL) Removal and Replacement130
License Plate Light130
Clearance, Identification and Marker Lights130
Clearance and Identification Light Removal and Replacement131
Interior Lighting Equipement131
Control Panel Lighting131
Switch Lighting131
Telltale Light Replacement131
Gauge Light Bulb Replacement131
Stepwell Lights131
Description182
Welding Procedures182
Maintenance183
Manual Fluid Level Check183
Cold Check183
Hot Check184
Fluid Level Check Using the Pushbutton Shift Selector184
Importance of185
Keeping Oil Clean185
Recommended Automatic Transmission185
Oil Contamination186
Metal Particles186
Coolant Leakage186
Control System Prognostics186
Oil and Filter Change Interval190
Allison Transmission Removal191
Transmission Oil Cooler Removal192
Cleaning and Inspection of Allison Automatic Transmission193
Breather193
Allison Transmission Installation193
Allison Automatic Transmission Troubleshooting194
Diagnostic Troubleshooting Codes (Dtc) - Allison 4Th Generation Controls195
Diagnostic Codes - Allison 4 Generation Controls195
Diagnostic195
Allison195
Diagnostic Troubleshooting Codes (Dtc) List - Allison198
Section 09: Propeller Shaft204
Propeller Shaft204
Description204
Removal, Disassembly, Reassembly and Installation204
Cleaning, Inspection and Lubrication204
Cleaning and Inspection204
Lubrication204
Explanation of Common Damages206
Troubleshooting206
Specifications206
Front Axle208
Description208
Lubrication208
Maintenance208
Removal and Replacement210
Removal210
Replacement210
Service Instructions for Steer Axle211
Steering Knuckle (King) Pin Inspection211
Checking Lateral Slackness211
Checking Vertical Slackness212
Front Wheel Alignment212
Inspection before Alignment212
Minor Front Wheel Alignment212
Major Front Wheel Alignment213
Turning Angle Adjustment213
Turn Adjustment213
Hydraulic Stop214
Front Wheel Camber214
Camber Check214
Front Axle Caster214
Front Wheel Toe-In215
Inspection and Adjustment216
Troubleshooting217
Specifications218
Torque Specifications218
Drive Axle220
Description220
Drive Axle Lubrication220
Maintenance220
Checking and Adjusting the Oil Level221
Draining and Replacing the Oil221
Speed Sensors (Anti-Lock Brake System, ABS)221
Removal and Reinstallation221
Disassembly and Reassembly222
Gear Set Identification222
Adjustments222
Fastener Torque Chart222
Tire Matching222
Drive Axle Alignment223
Procedure223
Axle Shaft Sealing Method224
Tag Axle225
Unloading Tag Axle225
Retracting Tag Axle225
Retracting Tag Axle for Repair Purposes226
Grease Lubricated Wheel Bearings226
Removal and Installation226
Removing Tag Axle Only226
Removing Tag Axle Along with Suspension Components226
Removing Transversal Radius Rod227
Specifications228
Drive Axle228
Air System232
Brakes232
Air Reservoirs232
Maintenance232
Wet (Main) Air Tank232
Primary Air Tank232
Accessory Air Tank232
Secondary Air Tank233
Kneeling Air Tank233
Parking Brakes Overrule Air Tank233
Ping Tank233
Air System Emergency Fill Valves233
Accessory Air Filter234
Filter Element Replacement234
Cleaning234
Air Gauges (Primary, Secondary and Accessory)234
Air Filter/Dryer234
Air Filter Dryer Purge Tank235
Haldex Consep Condenser / Separator235
Maintenance235
Air Lines235
Copper Piping235
Flexible Hoses236
Nylon Tubing236
Air Line Operating Test236
Air Line Leakage Test236
Maintenance236
Pressure Regulating Valves236
Pressure Setting Procedure237
Air Compressor237
Compressor Removal and Installation238
Emergency/Parking Brake Control Valve (Pp-1)238
Emergency / Parking Brakes Overrule Control Valve (Rd-3)238
Flip-Flop Control Valve (Tw-1)239
Dual Brake Application Valve (E-10P)239
Brake239
Stoplight Switches239
Parking Brake Alarm Switch240
Brake Relay Valve (R-12 & R-14)240
Quick Release Valves (Qr-1)240
Spring Brake Valve (Sr-7)240
Pressure Protection Valve (Pr-4)241
Low Pressure Indicator (Lp-3)241
Shuttle-Type Double Check Valve (DC-4)241
Emergency Bi-Fold Entrance Door Opening Valves242
Air System Troubleshooting242
Brake Operation242
Air Brakes242
Checking Disc Brake Pads243
Drive Axle - Equipped with a Solid Rubber Bushing and Exposed Guide Pin243
Front and Tag Axle - Equipped with L-Bracket Wear Indicator243
Vehicles Equipped with a Continuous Wear Sensor243
Brake Pads and Discs Minimal Tolerance Limits244
Brake Pads244
Brake Disc244
Caliper Running Clearance244
Torque Specifications245
Safe Service Procedures245
Air Brake Troubleshooting246
Maintenance248
Brake Air Chamber248
X3-45 Commuter PA1593 DOB 2400-2489249
Emergency/Parking Brake Manual Release249
Brake Chamber Removal249
Brake Chamber Installation249
Brake Chamber Disassembly249
Anti-Lock Braking System (Abs)250
Troubleshooting and Testing250
Abs Components250
Electronic Control Unit (ECU)251
ABS Modulator Valve251
Sensors251
Spring Clip252
Fitting Tightening Torques252
Specifications253
Wheels258
Wheel Maintenance258
Inspection258
Single Wheel Removal258
Single Wheel Installation259
Dual Wheels259
Outer Wheel Removal259
Inner Wheel Removal259
Inner Wheel Installation259
Outer Wheel Installation259
Inspection259
Wheel Straightness Test260
Wheel Studs260
Drive Axle Wheel Studs260
Front and Tag Axle Wheel Studs260
Hub Mounted Wheels261
Care of Wheels262
Front and Tag Axle Wheel Hubs262
Hub Bearing Inspection262
Hub Bearing Removal263
Hub Bearing Installation263
Drive Axle Wheel Hubs263
Bearing Adjustment263
Disassembly and Repair264
Tire Maintenance264
Inflation Pressure265
Tire Matching266
Wheel Balancing266
Tire Rotation266
Specifications278
Description289
I-Beam Axle Front Suspension289
Air Springs289
Inspection289
Removal290
Installation290
Shock290
Inspection291
Removal291
Installation292
Radius Rods292
Radius Rod Inspection292
Radius Rod Removal292
Bushing Removal292
Bushing Installation293
Radius Rod Installation293
Sway Bar294
Removal294
Installation294
Torque Specifications295
Rear Suspension299
Air Springs300
Inspection300
Removal300
Installation301
Shock Absorbers301
Inspection302
Removal302
Installation302
Radius Rods303
Rear Underframe Suspension303
Tag Axle Suspension304
Torque Specifications306
Suspension Height Adjustment307
Height Control Valve308
Installation308
Air System309
Air Tank Maintenance309
Wet Air Tank309
Primary Air Tank309
Secondary Air Tank309
Accessory Air Tank310
Kneeling Air Tank310
Parking Brakes Overrule Air Tank310
Emergency Fill Valves311
Vehicle Exterior318
Vehicle Structure319
Vehicle Exterior Maintenance319
Corrosion320
Preventive Maintenance Schedule320
Rust320
Application323
Common Fiberglass Repair Procedure325
Repair Using Fiberglass Cloth325
Repair Using Fiberglass Paste325
Procedure326
Common Painting Procedure327
New Paint Care327
Paint Touchup327
Painting328
Safety328
Surface Preparation and Paint Application328
X3-45 Coaches Exterior Finishing and Body Repair329
Front Bumper329
Headlights330
Rear View Mirrors (Rosco)331
Windshield Wipers332
Windshield332
Front Cap341
Rear Cap346
Rear Bumper347
Rear Fender348
Front Fender356
Passengers' Area402
S Section Operation403
Driver ' S Section403
Filters407
Filter407
Hvac407
Adding Refrigerant (V Apor State )415
Evacuating System415
Charging System416
Refrigerant System Clean - out after Compressor Failure417
Compressor418
Belt Replacement418
Pulley Alignment419
Compressor Maintenance420
Troubleshooting Guide420
Magnetic Clutch421
Evaporator Motor421

PREVOST X3-45 2016 - Page 23

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