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X3-45 Multiplex
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FIGURE 5 -
E-8P BRAKE V
AL
VE - EXPLODED VIEW
FIGURE 6 -
E-10P BRAKE V
AL
VE - EXPLODED VIEW
FIGURE 5 -
E-8P BRAKE V
AL
VE - EXPLODED VIEW
FIGURE 6 -
E-10P BRAKE V
AL
VE - EXPLODED VIEW
561
563
Table of Contents
Main Page
English
3
Table of Contents
3
Precautions to be Observed before Welding
4
Data Plates and Certifications
6
Safety Notice
6
Figure 1: Detroit Diesel Series 60
7
Figure 2: Volvo D 13 Engine Data Plate
7
Figure 4: Zf - Astronic Transmission
7
Figure 5: Typical Serial & Model Numbers
7
Figure 6: Iss Typical Serial & Model Numbers
7
Figure 7: I - Beam Axle Typical Serial & Model Numbers
7
Fuel Tank Label
8
Figure 9: Power Steering Pump
8
Figure 8: Power Steering Pump Nameplate
8
Figure 10: Dot Certification Plate
8
EPA Engine Label
8
DOT Certification Label
8
Safety Certification
8
Coach Final Record
8
Power Steering Pump
8
Vehicle Identification Number (VIN)
9
Figure 11: Vehicle I . D
9
Figure 12: Vehicle Identification Number
10
Figure 14: Bolt Strength Markings
11
Figure 13: Thread Notation
11
Fastener Strength Identification
11
Self-Locking Fasteners
12
Recommendations for Reuse
12
Six Lobed Socket Head
12
Figure 15 : Self-Locking Fasteners
12
Figure 16: Metric - Us Standard Conversion Table
13
Figure 17: Conversion Chart
14
Illustrations
32
Volvo D13 Engine
33
System Overview
33
Engine Overview
37
Oil Quality
38
General
38
Engine Oil
38
Oil Filters
39
Synthetic Lubrication
39
Oil Viscosity
40
Oil Additives
40
Oil Consumption
40
Oil Change
40
Oil Filters Change
41
Power Plant Assembly Removal
42
Checking the Oil Level
42
Power Plant Assy. Installation
45
Engine Mounts
46
DDC Series 60 Engine
47
Ddec VI System
47
Harnesses
48
Engine Overview
49
Ddec VI Sensors
50
Ddec VI Diagnostics
51
Diagnostic System
51
Other Sensors
51
Common Powertrain Controller (Cpc)
51
Motor Control Module (MCM)
51
Check Engine Telltale Light (AWL)
52
Stop Engine Warning Light (RSL)
52
Stop Engine Override Switch (SEO)
52
Diagnostic Data Link (DDL) Connectors
52
Reading Diagnostic Codes - Flashing Light Method
52
Ddec VI MCM Diagnostic Codes List
60
Engine Oil Level
72
Engine Oil and Filter Change
72
Recommended Engine Oil Type
74
Power Plant Assembly Removal
74
Power Plant Assy. Installation
77
Jake Brake
77
Engine Mounts
77
Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor
78
Engine Troubleshooting Guide
79
Specifications
80
Fuel Valves
85
Fuel System with Detroit Diesel Series 60 Engine
85
Description
85
Fuel Filters
86
Racor Fuel/Water Separator Servicing
86
Spin-On Type Fuel Filter Servicing (Primary & Secondary)
87
Fuel Pump Installation
88
Fuel System with Volvo D13 Engine
89
Description
89
Engine
90
Fuel Valves
90
Fuel Filters
90
Primary Fuel Filter Replacement
91
Secondary Fuel Filter Replacement
92
Priming the Fuel System
92
Fuel Pump Removal and Installation
93
Davco Fuel Pro 382
93
Tank Removal
95
Fuel Lines and Flexible Hoses
95
Fuel Tank
95
Preheater Fuel Filter
95
Tank Installation
96
Fuel Tank Verification
97
Polyethylene Fuel Tank Repair
97
Fuel Specifications
97
Fuel Type
97
Blending
98
Biodiesel Fuels
98
Air Cleaner (Dry Type)
98
Pre-Cleaner Servicing
98
Air Cleaner Servicing
98
General Recommendations
99
Air Cleaner Restriction Indicator
99
Fuel Cooler - Detroit Diesel Series 60 Only
99
Potentiometer Replacement
100
Fuel Pedal Adjustment
100
Fuel Pedal
100
Exhaust and Aftertreatment System Overview
104
Maintenance
104
Flexible Coupling Installation
105
Aftertreatment Device (Atd)
105
Diesel Particulate Filter (Dpf) Removal - both Engines
106
Diffuser Assembly
108
Diffuser Adjustment
108
Maintenance
109
Exhaust Gas Collection Adapter
109
Section 05: Cooling System
113
Description
113
Maintenance
114
General Recommendations
114
Vehicles Equipped with DDC Series 60 Engine
114
Constant-Torque Hose Clamps on Coolant Lines - DDC S60 & Volvo D13
115
Hoses
115
Vehicles Equipped with Volvo D13 Engine
115
Vehicles with Coolant Filters
115
Vehicles Without Coolant Filters
115
Installation
116
Maintenance
116
Constant-Torque Hose Clamps on Charge Air Cooler (Cac)
116
Detroit Diesel Series 60 Engine
117
Volvo D13 Engine
117
Thermostat Operation
117
Maintenance
117
Thermostat Checking
118
Coolant
118
Coolant Level Verification
118
Coolant Level Sensor
118
Thawing Cooling System
118
Cooling System Recommendations
118
Coolant Recommendations for Detroit Diesel Series 60 Engine
119
Inhibitor Test Procedures
120
Additives Not Recommended
120
Inhibitors
120
Coolant Not Recommended
120
Coolant Recommendations for Volvo D13 Engine
121
Draining Cooling System
122
Filling Cooling System
122
Flushing
123
Cooling System Descalers
123
Reverse Flushing
124
Spin-On Coolant Filter
124
Radiator
125
Maintenance
125
Charge Air Cooler Leakage
126
Cooling Fan Drive Mechanism
126
Drive Pulley and Universal Joint Shaft
126
Idler Replacement
126
Variable Speed Cooling Fan
127
Using Wiring Diagrams
140
Wiring Diagrams
140
General Description
140
Testing Circuits
141
Wire Sizes and Colors
141
Spare Wires
141
Cleaning Connectors
142
Circuit Breakers
142
Multiplex Fuses
143
Relays
143
Precautions
143
X3 Coaches Electrical Compartments
145
Maintenance
145
Rear Electrical Compartment
145
Front Electrical and Service Compartment
146
Engine Rear Start Panel
147
Entrance Door & Wiper Control Panel
148
Batteries
148
Battery Equalizer
148
Condenser Compartment
148
Battery Discharge Protection
150
Main Battery Relays
150
Battery Removal and Installation
150
Battery Rating
151
Battery Testing
151
Load Test
152
Visual Inspection
152
Removing Surface Charge
152
Testing Battery Cables
153
Battery Charging
153
Battery Charging Guide
155
Emergency Jump Starting with Auxiliary (Booster) Battery
155
Cleaning and Inspection
156
Common Causes of Battery Failure
156
Troubleshooting and Testing the Multiplex Vehicles
157
Electrical System Diagnostic
157
Bat" Telltale Light Definitions
157
Troubleshooting
157
Bat" Battery Voltage Incorrect Telltale Light
157
Probing Voltage on the Multiplex Circuits
158
Can Network
158
Can Connection on the Telltale Panel and the Hvac Control Unit
158
Spare Can
159
Test Mode for Switches and Sensors
159
Information Available and Impact on the Functions in Switch/Sensor Test Mode
159
Test Sequence
160
Test Mode for Electric Motors
160
Can Network Layout and Troubleshooting
161
Troubleshooting
162
Essential Functions to Operate the Vehicle
167
Available Functions
167
Lower Priority Modules for Breakdown Service
167
Io-B
168
Replacing the CECM Module
168
Multiplex Modules Replacement
168
Replacing IO-A or IO-B Modules
168
Io-A
168
Multiplex Modules
168
Master ID
168
Cecm
168
Ddec Series 60 Twin Bosch Alternators Installation
169
Alternator Drive Belt
169
Adjustment
169
Bosch Alternators
169
Volvo D13 Twin Bosch Alternators Installation
171
Alternator Drive Belt
173
Adjustment
173
Battery Equalizer
173
Starter
173
Engine Block Heater
173
Maintenance
173
Headlight Beam Toggle Switch
174
Maintenance
174
Headlights
174
Exterior Lighting
174
Headlight Adjustment
175
Sealed-Beam Unit
176
Front Turn Signal
177
Optional Xenon Headlamp
177
Stop, Tail, Directional, Back-Up, and Hazard Warning Lights
178
Lamp Removal and Replacement
178
Center Stoplights and Cyclops Light Removal and Replacement
178
License Plate Light
178
Clearance, Identification and Marker Lights
179
Clearance and Identification Light Removal and Replacement
179
Fog Lights
179
Bulb Removal and Replacement
179
Interior Lighting Equipement
179
Control Panel Lighting
179
Switch Lighting
179
Bulb Removal and Replacement
180
Drivers Area Lights
180
Lavatory Night-Light
180
Stepwell Lights
180
Gauge Light Bulb Replacement
180
Telltale Light Replacement
180
Passenger Section Lighting
181
Fluorescent Tube Replacement
181
General
195
Edition
195
Explosion Risk
196
Compressed Air
196
Fire Risk
196
Special Tool Usage
196
Safety Precautions
196
Skin Protection
196
Specifications
197
Electrical Test Specifications
197
Mechanical Test Specifications
198
Tightening Torques
198
Alternator Schematic
199
Alternator Coding
200
Parts Cleaning
201
Special Tools
202
Tools, Test Equipment Lubricants and Adhesives
202
Test Equipment
202
Lubricants and Adhesives
203
Lubricant Quantities
203
Exploded View
204
Alternator Disassembly and Testing
205
Rear Cover Removal
205
Voltage Regulator Removal
205
Brush Replacement
206
Noise Suppression Capacitor Testing and Removal
206
Pulley and Fan Removal
207
Separation of Drive Shield and Collector End Shield
207
Rectifier Assembly Testing
208
Removal and Testing of Stator Assembly
209
Rectifier Assembly Removal
210
Dampening Resistor Testing and Removal
211
Removal of Collector End Shield Bearing and Seal
211
Removal of Sliding Bushing in Collector End Shield
212
Removal of Rotor from Drive End Shield
212
Removal of Collector Ring End Inner Bearing Race from Rotor
214
Removal of Bearing and Seal from Drive End Shield
214
Rotor Inspection
215
Collector Ring Replacement
216
Alternator Assembly
217
Rotor Assembly
217
Drive End Shield Assembly
218
Collector Ring End Shield Assembly
219
Rectifier Assembly
220
Stator Assembly
222
Rotor and Drive End Shield Installation
222
Regulator and Capacitor Installation
223
Functional Testing
225
General Information
225
Power Output Tests
225
Voltage Trace Evaluation
225
Power Output Testing
225
Test Bench Mounting
225
Power Output Test
226
Oscilloscope Hook-Up
227
Voltage Trace Evaluation
227
Normal Pattern
228
Open Positive Rectifier Diode
230
Bus Instrument Cluster (BIC)
256
The Instrument Display
256
The Windscreen Wiper Handle
256
Display Menus
257
Setting the Display Language
257
Read Fault Codes from ECU
258
Comparing Chassis Number with the VIC
260
Comparing HW/SW ID with the VIC
260
Fault Codes, ABS (MID 136)
262
Fault Codes, BIC (MID 140 & 234)
265
Fault Codes, CECM (MID 164)
266
Fault Codes, CIM (MID 164)
267
Fault Codes, EECU (MID 128)
268
Fault Codes, TECU Voith 863,3 Retarders and Transmission (MID 130)
271
Fault Codes, Voith 115V Retarder (MID 222)
274
Figure 3: Allison Transmission
281
Description
283
Allison Automatic Transmission
283
Retarder (if Applicable)
283
Zf-Astronic Transmission
283
Welding Procedures
284
Maintenance
284
Manual Fluid Level Check
284
Hot Check
285
Cold Check
285
Fluid Level Check Using the Pushbutton Shift Selector
286
Importance of Proper Fluid Level
286
Coolant Leakage
288
Control System Prognostics
288
Oil and Filter Change Interval
291
Zf As-Tronic Transmission
293
Oil Change
293
ZF AS-TRONIC / SACHS Clutch Installation Procedure
293
Installation of Zf or Allison Transmission Brackets on Vehicles Equipped with Detroit Diesel Engine Only
295
Allison Transmission Removal
295
Transmission Oil Cooler Removal
296
Transmission Without Retarder
296
Detroit Diesel Series 60 Engine
296
Volvo D13 Engine
297
Transmission with Retarder
297
Detroit Diesel Series 60 Engine
297
Allison Transmission Installation
298
Breather
298
Cleaning and Inspection of Allison Automatic Transmission
298
Allison Automatic Transmission Troubleshooting
300
Diagnostic Troubleshooting Codes (Dtc ) - Allison 4 Th Generation Controls
300
Diagnostic Codes - Allison 4 Generation Controls
301
Diagnostic Code Display and Clearing Procedure - Allison
301
Diagnostic Troubleshooting Codes (Dtc) List - Allison
303
Zf-Astronic Transmission System Faults and Error Messages
306
System Faults
306
Maintenance
362
Description
362
Lubrication
362
Front Axle
362
Removal
363
Tie Rod End Play Adjustment
363
Removal and Replacement
363
Replacement
364
Service Instructions for Steer Axle
364
Hub Bearing Inspection
364
King Pin Inspection
364
Checking Lateral Slackness
364
Checking Vertical Slackness
364
Front Wheel Alignment
365
Minor Front Wheel Alignment
365
Major Front Wheel Alignment
365
Inspection before Alignment
365
Turning Angle Adjustment
365
Turn Adjustment
366
Hydraulic Stop
366
Camber
366
Front Wheel Toe-In
367
Front Axle Caster
367
Camber Check
367
Inspection and Adjustment
368
Troubleshooting
369
Specifications
370
4: Camber
371
5: Caster
371
Drive Axle Lubrication
422
Dcdl (Driver-Controlled Main Differential Lock)
422
Description
422
Drive Axle
422
Maintenance
423
Checking and Adjusting the Oil Level
423
Draining and Replacing the Oil
423
Speed Sensors (Anti-Lock Brake System, ABS)
424
Removal and Reinstallation
424
Disassembly and Reassembly
424
Procedure
425
Drive Axle Alignment
425
Adjustments
425
Tire Matching
425
Fastener Torque Chart
425
Gear Set Identification
425
Method
427
Unloading Tag Axle
427
Retracting Tag Axle
427
Retracting Tag Axle for Repair Purposes
428
Grease Lubricated Wheel Bearings
428
Removal and Installation
428
Removing Tag Axle Only
428
Removing Tag Axle Along with Suspension Components
428
Tag Axle Alignment
429
Specifications
435
Illustrations
453
Figure
453
Maintenance
455
Air Reservoirs
455
Brakes
455
Primary Air Tank
456
Ping Tank
457
Cleaning
457
Air Filter Dryer Purge Tank
458
Air Lines
458
Copper Piping
458
Flexible Hoses
459
Air Line Operating Test
459
Air Line Leakage Test
459
Maintenance
459
Pressure Regulating Valves
459
Nylon Tubing
459
Pressure Setting Procedure
460
Engine
460
Compressor Removal and Installation
461
With Volvo D13 Engine
461
Flip-Flop Control Valve (Tw-1)
462
Emergency/Parking Brake Control Valve (Pp-1)
462
Emergency / Parking Brake Overrule Control Valve (Rd-3)
462
Dual Brake Application Valve (E-10P)
463
Drive Axle
475
Brake
475
Adjustment
488
Figure 3.1
505
Figure 3.2
506
Torque Specification
520
Drive Axle
694
Safety
706
Wheel Specifications
707
Inspection and Maintenance
710
Inspect Thoroughly and Frequently
710
Wheel Alteration
710
Dimension Checks
712
Mounting Alcoa Wheels with Tubeless Tires
724
Mounting Tubeless Tires
725
Recommendations for Mounting Tubeless Tires
725
Rim Width to Tire Matching
727
Recommendations for Demounting Tubeless Tires
728
Demounting of Tubeless Tires
728
Wheel Installation
729
Proper Torque, Wheel Identification and Valves
741
OSHA Regulations
744
Glossary of Common Terms
749
Wheel Measurement
751
Conversion Tables
752
Design and Operation
882
Servicing Work
887
Hints
887
Maintenance
888
Inspection
890
Oil Change and Bleeding
893
Setting the Hydraulic Steering Limitation
897
Repair of External Leakages
902
Replacing and Setting the Switch (222) and the Potentiometer
903
Removal and Re-Installation of the Steering Gear
906
Special Tools
912
Troubleshooting
914
Key to Numbers in Figures and Exploded Drawing
926
Introduction
934
Oil Flow Illustration
936
Approved Hydraulic Fluids
936
Torque Chart
937
Service Parts List
938
Initial Installation
941
Maintenance Tips
943
Reseal & Repair
944
Inspection
951
Assembly
953
Input Shaft Replacement
959
Needle Bearing Removal
960
Reinstallation
962
Maintenance Tips
964
Glossary
965
Glossary
966
Figure
971
Front Axle
990
PARAGRAPH NUMBER Page
1201
Seal End Main Bearings
1201
Bottom Plate, Strainer, and Connecting Rod Caps
1201
Table 1-1. Compressor Reference Data
1201
Table 1-2. Oils
1203
Pistons, Rods, and Rings
1214
Crankshaft and Seal End Thrust Washer
1214
Compressor Running Gear Reassembly
1215
Suction Strainer
1216
Adding Oil
1216
Installing Compressor
1216
Table 3-1. Torque Values
1217
Table 3-2. Wear Limits
1218
Français
1296
English
1303
Introduction
1303
Safe Operation of the Radio
1303
Radio / CD Controls Quick Reference Guide
1304
Steering Wheel Controls Quick Reference Guide
1306
Remote Control Quick Reference Guide
1307
Display Quick Reference Guide
1308
Radio LCD Display
1308
Band Selection (FM and AM)
1309
Power
1309
Seek in Radio Mode
1309
Scan Mode
1310
Satellite Radio Service - (Optional Feature)
1311
Switching to CD Mode
1312
Changing to Another Folder on a CD - (Optional Feature)
1313
Repeating Tracks on a CD - (Optional Feature)
1313
Disconnecting a USB Device
1314
External Audio Input - (Optional Feature)
1314
Switching to USB Mode
1314
USB Mode - (Optional Feature)
1314
Connecting an Ipod
1316
Disconnecting an Ipod Device
1316
Ipod Mode - (Optional Feature)
1316
Switching to Ipod Mode
1316
Adjusting Balance Left and Right
1318
Adjusting Bass up and down
1318
Adjusting Fader Front and Back
1318
Adjusting Volume up and down
1318
AUX Mode - (Optional Feature)
1318
Activate Speed Dependant Volume (ASC) - (Optional Feature)
1319
Adjusting MID (Medium Frequency Range) up and down - (Optional Feature)
1319
Speakers Selection
1319
Activating Another Phone
1320
Bluetooth Activation
1320
Switching Phone Calls between the Vehicle and an Active Phone
1321
12- or 24-Hour Format
1322
Clock
1322
Displaying the Time
1322
Setting the Clock
1322
Turning the Alarm on or off - (Optional Feature)
1322
Anti Theft Code (Guard)
1323
In Case of Malfunction
1323
Setting the Alarm - (Optional Feature)
1323
Deactivating Guard
1324
Bluetooth
1325
Ipod
1325
Français
1326
Introduction
1326
Sécurité et Utilisation de la Radio
1326
Guide de Référence Rapide des Commandes de la Radio/Du Lecteur de CD
1327
Guide de Référence Rapide de la Télécommande
1330
Guide de Référence Rapide de L'afficheur
1331
Mise en Marche, Mise à L'arrêt, Sourdine et Pause du Système
1332
Syntonisation Manuelle
1332
Mode Balayage
1333
Service de Radio Par Satellite - (Caractéristiques en Option)
1334
Sélection du Mode CD
1335
Changement de Fichier Sur un CD - (Caractéristiques en Option)
1336
Répétition de Plage Sur un CD - (Caractéristiques en Option)
1336
Déconnexion D'un Appareil USB
1337
Entrée Audio Externe - (Caractéristiques en Option)
1337
Mode USB - (Caractéristiques en Option)
1337
Sélection du Mode USB
1337
Activation des Plages D'un Appareil USB Dans un Ordre Aléatoire
1338
Mode Ipod - (Caractéristiques en Option)
1339
Sélection du Mode Ipod
1339
Mode aux - (Caractéristiques en Option)
1341
Activation de la Commande Automatique de Sensibilité (CAS) - (Caractéristiques en Option)
1342
Réglage MID (Plage des Moyennes Fréquences) Vers le Haut et
1342
Sélection de Haut-Parleurs
1342
Équilibreur Avant-Arrière
1342
Activation Bluetooth
1343
Mode Téléphone Mains Libres Bluetooth
1343
Activation D'un Autre Téléphone
1344
Suppression D'un Téléphone
1344
Transmission
1420
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