PREVOST H3-41 User manual

MAINTENANCE MANUAL
H3-41, H3-45, H3-45 VIP
X3-45, X3-45 VIP
PA1621

PA1621
First issue: January 2017
Featuring: GHG17 engine, X series new electrical architecture and electric cooling fans.
This manual is applicable to the following model year 2017 vehicles,
From: H-3735 (H Series); H-6180 (X Series CAN); H-7417 (X-Series US)
Including the following individual vehicles: H-3670, H-6175, H-7386, H-7395
REV FROM V.I.N. DESCRIPTION ISSUED
00 Initial release Jan 2017

CRITICAL EMISSION-RELATED MAINTENANCE
Source of parts and repair:
A repair shop or person of the owner’s choosing must maintain, replace, or repair emission control
devices and systems per manufacturer's recommendations.
Replacement of tires that are GHG certified:
The original equipment tires installed on this vehicle at the 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 or lower rolling
resistance levels (TRRL or Crr). Please consult your tire supplier(s) for appropriate replacement tires.
Maintaining a GHG certified tire:
In order to maintain the certified rolling resistance of the tires which optimize fuel economy, the
maintenance procedures provide by the tire manufacturermust be followed.

CONTENTS
PA1621 Maintenance Manual All Series |
1
CONTENTS
•SECTION 00: GENERAL INFORMATION
•MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO WELDING
•SECTION 01: ENGINE
•MI16-16 STARTER REMOVAL AND INSTALLATION
•SECTION 03: FUEL SYSTEM
•SECTION 04: EXHAUST AND AFTERTREATMENT
•SECTION 05a: H3 SERIES COOLING SYSTEM
•SECTION 05b: X3 SERIES COOLING SYSTEM
•SECTION 06a: H3 SERIES ELECTRICAL
•SECTION 06b: X3 SERIES ELECTRICAL
•ELECTRICAL CONNECTORS PROTECTION
•MI15-24 POWER CABLES INSPECTION GUIDELINES
•MI16-17 TWIN BOSCH HD10 ALTERNATOR REMOVAL AND INSTALLATION
•SECTION 07: TRANSMISSION
•SECTION 09: PROPELLER SHAFT
•SECTION 10: FRONT I-BEAM AXLE
•SECTION 11: REAR AXLES
•SECTION 12: BRAKE AND AIR SYSTEM
•SECTION 13: WHEELS, HUBS AND TIRES
•SECTION 14: STEERING
•SECTION 16: SUSPENSION
•SECTION 18A: H3 SERIES BODY
•SECTION 18B: X3 SERIES BODY
•SECTION 18C: MI15-18 STRUCTURE INSPECTION FOR CORROSION
•SECTION 18D: MI15-41 CRACKING OF POLYCARBONATE TAILLIGHTS
•SECTION 22: HEATING AND AIR CONDITIONING
•SECTION 23A: H3 SERIES ACCESSORIES
•SECTION 23B: X3 SERIES ACCESSORIES
•SECTION 24: LUBRICATION & SERVICING
•SECTION 26a: H3 SERIES SLIDE-OUT
•SECTION 26b X3 SERIES SLIDE-OUT

SECTION 00: GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 1
CONTENTS
SECTIONCHANGELOG.......................................................................................................................................2
1.FOREWORD................................................................................................................................................3
2.SCHEMATICS...............................................................................................................................................3
3.PRECAUTIONSTOBEOBSERVEDBEFOREWELDING....................................................................................3
4.SAFETYNOTICE...........................................................................................................................................7
4.1DATAPLATESANDCERTIFICATIONS..............................................................................................................7
4.1.1Engine....................................................................................................................................................7
4.1.2Transmission..........................................................................................................................................7
4.1.3DriveAxle...............................................................................................................................................8
4.1.4FrontAxles.............................................................................................................................................8
4.1.5CoachFinalRecord.................................................................................................................................8
4.1.6SafetyCertification................................................................................................................................8
4.1.7DOTCertificationLabel..........................................................................................................................8
4.1.8FuelTankLabel......................................................................................................................................8
4.1.9EPAEngineLabel....................................................................................................................................9
4.1.10VehicleIdentificationNumber(VIN)......................................................................................................9
5.FASTENER..................................................................................................................................................11
5.1FASTENERSTRENGTHIDENTIFICATION.......................................................................................................11
5.2STANDARDTORQUESPECIFICATIONS..........................................................................................................12
5.2.1SAE.......................................................................................................................................................12
5.2.2Metric...................................................................................................................................................14
5.3SELF‐LOCKINGFASTENERS..................................................................................................................................16
5.4RECOMMENDATIONSFORREUSE.........................................................................................................................16
5.5SIXLOBEDSOCKETHEAD...................................................................................................................................17
5.6HOSECLAMPTORQUE........................................................................................................................................19


SECTION 00 : GENERAL INFORMATION
2PA1621 Maintenance Manual All Series | January 2017
SECTIONCHANGELOG
DESCRIPTION DATE
1
2
3
4
5
6


SECTION 00 : GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 3
1. FOREWORD
This manual includes procedures for diagnosis,
service, maintenance and repair for components
of all series of Prevost coaches and
motorhomes listed on the front cover. This
manual should be kept in a handy place for
ready reference by the technician. If properly
used, it will meet the needs of the technician and
owner.
Information provided in Section 1 through 26
pertains to standard equipment items, systems
and components as well as the most commonly
used optional equipment and special equipment
offered on the vehicle models covered by this
manual. At the beginning of each section: a
Table of Contents gives the page number on
which each subject begins.
Vehicle operating information is provided in a
separate Operator’s Manual for coaches or
Owner’s Manual. Audio/Video system operator
instructions are also included in a separate
manual.
More specific information on engine,
transmission and other systems or components
operating, maintenance, and overhaul
information is contained in the applicable service
manual published by the OEM. Parts information
may be contained in the applicable OEM parts
catalog or service manual published by the
OEM. All information, illustrations and
specifications contained in this manual are
based on the latest product information available
at the time of publication approval. The right is
reserved to make product changes at any time
without notice.
NOTE
Illustrations in this manual are used for
reference 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, Warranty Bulletins, Safety Recalls
or other literature to update users with the latest
service procedures. They are issued, when
required, to supplement or supersede
information in this manual. Update sheet should
be filled out and bulletins should be filed at the
end of their respective section for future
reference.
2. SCHEMATICS
Vehicle pneumatic and electrical schematics can
be found in your technical publications box.
Refer to those schematics for detailed circuit
information and diagnosis.
3. PRECAUTIONS TO BE OBSERVED
BEFORE WELDING
CAUTION
For vehicles equipped with a WCL system,
disconnect electronic controller connector.
CAUTION
Cover electronic control components and
wiring to protect from hot sparks, etc.
CAUTION
Position welding machine ground clamp as
close as possible to the work. Ensure that the
welding machine ground return clamp is well
secured and makes a good electrical contact
with a large metallic area of the chassis
located as close as possible to the welding
point.
CAUTION
Do not use TIG welding process on the
vehicle. This high frequency current process
can seriously damage the electronic
components.

SECTION 00 : GENERAL INFORMATION
4PA1621 Maintenance Manual All Series | January 2017
STEEL – STEEL WELDING
CAUTION
Before welding, perform multiplex modules disconnection procedure.
NOTE
Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that
would render welding impossible.
DANGER
Only a qualified and experienced person must do welding.
oFCAW (Flux Cored Arc Welding) process ;
oElectrode wire conforms to A5.20 AWS (American Welding Society) specifications ;
oE4801T-9-CH, type electrode wire with 0,045“ diameter (1,14 mm) ;
Material Thickness
V
olta
g
e Current Wire Feed Rate Shieldin
g
Gas
1/8” to ½” 26 ± 2 volts 260 Amps 450 ipm approx. 75% argon – 25%
CO2 or 100% CO2
If necessary and with great care to prevent perforating the material, it is possible to use a conventional
electric arc welding machine according to the following specifications:
oSMAW (Shielded Metal-Arc Welding) process ;
oWelding rod conforms to A5.1 of AWS (American Welding Society) specifications; E 7018 type
welding rod with 1/8” diameter (3,2 mm).
oCurrent: 100 amperes to 150 amperes; optimum at 120 amps.
It is important to grind weld bead starts and stops and also to grind arc strikes from surfaces.

SECTION 00 : GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 5
STEEL with STAINLESS STEEL ou STAINLESS STEEL with STAINLESS STEEL WELDING
CAUTION
Before welding, perform multiplex modules disconnection procedure.
NOTE
Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign material that
would render welding impossible.
DANGER
Only a qualified and experienced person must do welding.
oGMAW (Gas Metal-Arc Welding) process;
oWelding wire conforms to AWS (American Welding Standards) A5.9 specifications;
o308LSi type welding wire with 0.035" diameter (0,9 mm);

SECTION 00 : GENERAL INFORMATION
6PA1621 Maintenance Manual All Series | January 2017
STEEL - STAINLESS STEEL WELDING
Steel Thickness SS Thickness
V
olta
g
eCurrent Wire Feed Rate Shieldin
g
Gas
Less than 1/8” Any type 20±1.5 volts 130±15 Amps 290 ipm approx. 90% He, 7.5%
Ar, 2.5% CO2
1/8” and more Any type 22±1.5 volts 160±15 Amps 330 ipm approx. 90% He, 7.5%
Ar, 2.5% CO2
STAINLESS STEEL - STAINLESS STEEL WELDING
SS Thickness
V
olta
g
e Current Wire Feed Rate Shieldin
g
Gas
Any type 20 ± 1.5 volts 130 ± 15 Amps 290 ipm approx. 90% He – 7.5% Ar,
2.5% CO2
If necessary and with great care to prevent perforating the material, it is possible to use a conventional
electric arc welding machine according to the following specifications:
oSMAW (Shield Metal-Arc Welding) process;
oWelding rod conforms to AWS (American Welding Standards) A5.4 specifications; 308L-17 type
welding rod with 3/32" diameter (2,4 mm);
oCurrent: - 50 amperes to 90 amperes, optimum at 60 amperes.
It is important to grind weld bead starts and stops and also to grind arc strikes from surfaces.

SECTION 00 : GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 7
4. SAFETY NOTICE
This maintenance manual has been prepared in
order to assist skilled mechanics in the efficient
repair and maintenance of PREVOST vehicles.
This 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 observed. Locking devices must be
installed or replaced by new ones, where
specified. If the efficiency of a locking device is
impaired, it must be replaced.
This manual emphasizes particular information
outlined by the wording and symbols:
DANGER
Directs the operator’s attention to unsafe
practices which could result in serious
personal injury or death.
WARNING
Directs the operator’s attention to unsafe
practices which could result in serious
personal injury or severe damage to the
vehicle.
CAUTION
Directs the operator’s attention to unsafe
practices where personal injury is not likely
but damage to vehicle components could
occur.
NOTE
Indicates supplementary information essential
to the proper operation of the vehicle.
Although, the mere reading of such
information does not eliminate the hazard,
understanding of the information will promote
its correct use.
4.1 DATA PLATES AND CERTIFICATIONS
Delay and confusion can be avoided by placing
the complete vehicle identification number of the
vehicle and the serial numbers of the engine on
parts orders and correspondence. Also, the
transmission, axles, power steering pump
chassis and other major components are
identified by serial numbers.
4.1.1 Engine
FIGURE 1: VOLVO D13 ENGINE DATA PLATE 00052
Volvo D13 engine serial and model numbers are
stamped on the cylinder head. Also, the engine
data plate certifies that the engine conforms to
federal and any state exhaust emission
regulations. It gives the operating conditions
under which certification was made (Figure 1).
4.1.2 Transmission
The transmission identification plate is located
on the oil level dipstick side of the transmission
Allison (World) (Figure 2) or on transmission I-
Shift (Figure 3). The identification plate shows
the transmission serial number, part number
(assembly number), and model number. Use all
three numbers when ordering parts.
FIGURE 2: ALLISON TRANSMISSION 07076

SECTION 00 : GENERAL INFORMATION
8PA1621 Maintenance Manual All Series | January 2017
FIGURE 3: I-SHIFT TRANSMISSION
4.1.3 Drive Axle
FIGURE 4: DATA PLATE LOCATION WITH MODEL NO.,
SERIAL NO. AND RATIO 00007
4.1.4 Front Axles
FIGURE 5: IFS TYPICAL SERIAL & MODEL NUMBERS
16136
FIGURE 6: I-BEAM AXLE TYPICAL SERIAL & MODEL
NUMBERS 00008
4.1.5 Coach Final Record
The Coach Final Record is a record of all data
pertaining to the assembly of the vehicle. This
record is given to the new customer on the
vehicle delivery. Retain this record in the
company records office for reference and safe-
keeping.
4.1.6 Safety Certification
Vehicle components meet specifications and
standards as follows:
- Material and parts conform to ASTM and/or
SAE standards in effect at the time of
manufacture.
- All factory-installed interior materials meet
FMVSS 302 for fire resistance.
- Certified according to Provincial, State and
Federal Safety standards (Canadian and US)
BMCSS, FMVSS, and CMVSS.
Other applicable certification labels are affixed
to the component.
4.1.7 DOT Certification Label
This certifies that vehicles manufactured by
Prevost Car Inc., comply with all Federal Motor
Vehicle Safety Standards at the time of
manufacture. Information such as date of
manufacture, model year, gross vehicle weight
rating, tire types and inflation pressure is also
etched on this plate. The DOT Certification plate
is affixed behind the driver’s seat.
FIGURE 7: DOT CERTIFICATION PLATE 00016
4.1.8 Fuel Tank Label
The fuel tank label is molded on the side of the
fuel tank. To read this label, unscrew the fuel

SECTION 00 : GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 9
tank access panel nuts located at the left in the
condenser compartment.
4.1.9 EPA Engine Label
The exhaust emission certification label affixed
in the engine compartment certifies that the
engine conforms to federal and any state
exhaust emission regulations (Figure 8). It gives
the operating conditions under which
certification was made.
FIGURE 8: EMISSION CONTROL LABEL 23229
4.1.10 Vehicle Identification Number (VIN)
The seventeen digit vehicle identification
number (VIN) is located on a plate (Figure 9)
located on the windshield frame pillar (driver's
side). The VIN is visible from the outside of the
vehicle. Make sure the correct vehicle
identification number is given when ordering
replacement parts. Using the VIN when ordering
parts will facilitate processing.
FIGURE 9: VEHICLE I.D. 00048
NOTE
Record the VIN in the vehicle documentation
and keep with company records. The VIN will
normally be used for vehicle registration and
for obtaining vehicle insurance coverage.

SECTION 00 : GENERAL INFORMATION
10 PA1621 Maintenance Manual All Series | January 2017
FIGURE 10: VEHICLE IDENTIFICATION NUMBER 00057_5
YEAR CODE YEAR CODE YEAR CODE
1997 V 2005 5 2013 D
1998 W 2006 6 2014 E
1999 X 2007 7 2015 F
2000 Y 2008 8 2016 G
2001 1 2009 9 2017 H
2002 2 2010 A 2018 J
2003 3 2011 B 2019 K
2004 4 2012 C 2020 L

SECTION 00 : GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 11
5. FASTENER
5.1 FASTENER STRENGTH IDENTIFICATION
Most commonly used metric fastener strength
property classes are 9.8 and 10.9 with the class
identification embossed on the head of each
bolt. Customary (inch) strength classes range
from grade 2 to 8 with radial line identification
embossed on each bolt head actual grade (i.e.,
a grade 7 bolt will have 5 embossed radial lines
on the bolt head). Some metric nuts will be
marked with single digit strength identification
numbers on the nut face. Figure 12 shows the
different strength markings. When replacing
metric fasteners, 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 size. Correct
replacement fasteners are available through the
parts division. Some metric fasteners available
in after-market parts sources were designed to
metric standards of countries other than the
United States and may be of a lower strength,
may not have the numbered head marking
system, and may be of a different thread pitch.
FIGURE 11: THREAD NOTATION 00002
FIGURE 12: BOLT STRENGTH MARKINGS 00003
The metric fasteners used on the coach are
designed to new standards and may not yet be
manufactured by some non-domestic fastener
suppliers. In general, except for special
applications, the common sizes and pitches are:
M 8 X 1.25;
M 10 X 1.5;
M 12 X 1.75;
M 14 X 2;

SECTION 00 : GENERAL INFORMATION
12 PA1621 Maintenance Manual All Series | January 2017
5.2 STANDARD TORQUE SPECIFICATIONS
The following table lists the standard tightening torques for bolts and nuts, relating tightening torque to
thread diameter. Use the following table as a general guide for tightening torques. Use this table only for
the bolts and nuts which do not require a specific torque value. All of the values are for use with dry
solvent-cleaned threads.
5.2.1 SAE
TYPE DESCRIPTION THREAD GRADE
RECOMMENDED
TORQUE
Tolerance: ±10%
SAE 1/4-20 unc 5 96 lb-in (11 Nm)
SAE 1/4-20 unc 8 135 lb-in (15 Nm)
SAE 1/4-28 unf 5 106 lb-in (12 Nm)
SAE 1/4-28 unf 8 149 lb-in (17 Nm)
SAE 5/16-18 unc 5 188 lb-in (21 Nm)
SAE 5/16-18 unc 8 266 lb-in (30 Nm)
SAE 5/16-24 unf 2 131 lb-in (15 Nm)
SAE 5/16-24 unf 5 202 lb-in (23 Nm)
SAE 5/16-24 unf 8 286 lb-in (32 Nm)
SAE 3/8-16 unc 5 27 lb-ft (37 Nm)
SAE 3/8-16 unc 8 38 lb-ft (52 Nm)
SAE 3/8-24 unf 5 30 lb-ft (41 Nm)
SAE 3/8-24 unf 8 42 lb-ft (57 Nm)
SAE 7/16-14 unc 5 43 lb-ft (58 Nm)
SAE 7/16-14 unc 8 60 lb-ft (81 Nm)
SAE 7/16-20 unf 5 46 lb-ft (62 Nm)
SAE 7/16-20 unf 8 65 lb-ft (88 Nm)
SAE 1/2-13 unc 5 65 lb-ft (88 Nm)
SAE 1/2-13 unc 8 92 lb-ft (125 Nm)
SAE 1/2-20 unf 5 71 lb-ft (96 Nm)
SAE 1/2-20 unf 8 100 lb-ft (136 Nm)
SAE 9/16-12 unc 5 94 lb-ft (127 Nm)
SAE 9/16-12 unc 8 132 lb-ft (179 Nm)
SAE 9/16-18 unf 5 101 lb-ft (137 Nm)
SAE 9/16-18 unf 8 143 lb-ft (194 Nm)
SAE 5/8-11 unc 5 130 lb-ft (176 Nm)
SAE 5/8-11 unc 8 184 lb-ft (249 Nm)
SAE 5/8-18 unf 5 142 lb-ft (193 Nm)

SECTION 00 : GENERAL INFORMATION
PA1621 Maintenance Manual All Series | January 2017 13
TYPE DESCRIPTION THREAD GRADE
RECOMMENDED
TORQUE
Tolerance: ±10%
SAE 5/8-18 unf 8 200 lb-ft (271 Nm)
SAE 3/4-10 unc 5 228 lb-ft (309 Nm)
SAE 3/4-10 unc 8 321 lb-ft (435 Nm)
SAE 3/4-16 unf 5 245 lb-ft (332 Nm)
SAE 3/4-16 unf 8 346 lb-ft (469 Nm)
SAE 7/8-9 unc 5 368 lb-ft (499 Nm)
SAE 7/8-9 unc 8 519 lb-ft (704 Nm)
SAE 7/8-14 unf 5 392 lb-ft (531 Nm)
SAE 7/8-14 unf 8 554 lb-ft (751 Nm)
SAE A2-70 (NSS-SS)
DESCRIPTION
COARSE THREAD
RECOMMENDED TIGHTENING (LB-FT)
Tolerance: ±10%
DRY
8-32
10-32
1/4-20
5/16-18
21
34
77
152
DESCRIPTION
COARSE THREAD
RECOMMENDED TIGHTENING (LB-FT)
Tolerance: ±10%
DRY
3/8-16
7/16-14
1/2-13
22
34
53

SECTION 00 : GENERAL INFORMATION
14 PA1621 Maintenance Manual All Series | January 2017
5.2.2 Metric
TYPE DESCRIPTION THREAD GRADE
RECOMMENDED
TORQUE, ±10%
lb-ft (dry) otherwise
specified
Tolerance: ±10%
METRIC M6 X 1 nut 8 / screw 8.8 7 lb-ft (10 Nm)
METRIC M6 X 1 nut 10 / screw 10.9 10 lb-ft (13 Nm)
METRIC M6 X 1 nut 12 / screw 12.9 12 lb-ft (16 Nm)
METRIC M8 X 1.25 nut 8 / screw 8.8 17 lb-ft (23 Nm)
METRIC M8 X 1.25 nut 10 / screw 10.9 24 lb-ft (32 Nm)
METRIC M8 X 1.25 nut 12 / screw 12.9 28 lb-ft (38 Nm)
METRIC M10 X 1.5 nut 8 / screw 8.8 35 lb-ft (47 Nm)
METRIC M10 X 1.5 nut 10 / screw 10.9 48 lb-ft (65 Nm)
METRIC M10 X 1.5 nut 12 / screw 12.9 56 lb-ft (76 Nm)
METRIC M12 X 1.75 nut 8 / screw 8.8 59 lb-ft (80 Nm)
METRIC M12 X 1.75 nut 10 / screw 10.9 82 lb-ft (111 Nm)
METRIC M12 X 1.75 nut 12 / screw 12.9 96 lb-ft (130 Nm)
METRIC M14 X 2 nut 8 / screw 8.8 94 lb-ft (128 Nm)
METRIC M14 X 2 nut 10 / screw 10.9 130 lb-ft (176 Nm)
METRIC M14 X 2 nut 12 / screw 12.9 152 lb-ft (206 Nm)
METRIC M16 X 2 nut 8 / screw 8.8 143 lb-ft (194 Nm)
METRIC M16 X 2 nut 10 / screw 10.9 198 lb-ft (268 Nm)
METRIC M16 X 2 nut 12 / screw 12.9 231 lb-ft (314 Nm)
METRIC M16 X 1.5 nut 10 / screw 10.9 206 lb-ft (279 Nm)
METRIC M16 X 1.5 nut 12 / screw 12.9 241 lb-ft (326 Nm)
METRIC M20 X 2.5 nut 8 / screw 8.8 280 lb-ft (379 Nm)
METRIC M20 X 2.5 nut 10 / screw 10.9 387 lb-ft (524 Nm)
METRIC M20 X 2.5 nut 12 / screw 12.9 452 lb-ft (613 Nm)
METRIC M20 X 1.5 nut 10 / screw 10.9 415 lb-ft (563 Nm)
METRIC M20 X 1.5 nut 12 / screw 12.9 485 lb-ft (658 Nm)
METRIC M22 X 2.5 nut 8 / screw 8.8 373 lb-ft (506 Nm)
METRIC M22 X 2.5 nut 10 / screw 10.9 516 lb-ft (700 Nm)
METRIC M22 X 2.5 nut 12 / screw 12.9 604 lb-ft (818 Nm)
METRIC M24 X 3 nut 8 / screw 8.8 481 lb-ft (652 Nm)
METRIC M24 X 3 nut 10 / screw 10.9 665 lb-ft (902 Nm)