PREVOST H3-41 User manual

COACH MANUFACTURER
MAINTENANCE MANUAL
H3-41, H3-45, VIP
PA1217
(5th edition)

SECTION 26: VIP SLIDE-OUT
CONTENTS
1SLIDE-OUT .............................................................................................................................................. 5
1.1 INNER STOPPER ............................................................................................................................... 5
1.1.1 Maintenance ........................................................................................................................... 5
1.1.2 Adjustment ............................................................................................................................. 5
1.2 "IN LIMIT" STOPPER .......................................................................................................................... 5
1.2.1 Maintenance ........................................................................................................................... 6
1.2.2 Adjustment ............................................................................................................................. 6
1.3 EXTERIOR EXTRUSION .................................................................................................................... 6
1.3.1 Maintenance ........................................................................................................................... 6
1.3.2 Removal ................................................................................................................................. 6
2SECURITY PIN ........................................................................................................................................ 7
2.1 MAINTENANCE .................................................................................................................................. 7
2.2 AIR CYLINDER REPLACEMENT ....................................................................................................... 7
3ROOF REINFORCING ROD ................................................................................................................... 7
4RACK ....................................................................................................................................................... 8
4.1 MAINTENANCE .................................................................................................................................. 8
4.2 FRONT SLIDE-OUT RACK REPLACEMENT ..................................................................................... 8
4.3 REAR SLIDE-OUT RACK REPLACEMENT ....................................................................................... 8
5PINION ..................................................................................................................................................... 9
5.1 PINION AND KEYLESS BUSHING POSITIONING ............................................................................ 9
5.2 FRONT SLIDE-OUT SHAFT PINION REPLACEMENT ...................................................................... 9
5.3 REAR SLIDE-OUT SHAFT PINION REPLACEMENT ...................................................................... 10
5.4 KEYLESS BUSHING ........................................................................................................................ 10
5.4.1 Installation ............................................................................................................................ 10
6ELECTRIC MOTOR ............................................................................................................................... 13
6.1 MAINTENANCE ................................................................................................................................ 13
6.2 REPLACEMENT ............................................................................................................................... 13
7SPEED REDUCTION GEARBOX ......................................................................................................... 13
7.1 MAINTENANCE ................................................................................................................................ 13
7.2 GEARBOX REPLACEMENT ............................................................................................................ 13
8JAW COUPLING ................................................................................................................................... 14
8.1 MAINTENANCE ................................................................................................................................ 14
8.2 REPLACEMENT & ADJUSTMENT ................................................................................................... 14
9FLANGE BEARING ............................................................................................................................... 14
10 LOCKING COLLAR .............................................................................................................................. 14
10.1 INSTALLATION ............................................................................................................................. 15
11 LINEAR BEARING ................................................................................................................................ 15
11.1 MAINTENANCE ............................................................................................................................ 15
11.2 REPLACEMENT & ADJUSTMENT ............................................................................................... 15
11.3 LEVEL & TILT ADJUSTMENT ....................................................................................................... 15
11.3.1 Procedure ............................................................................................................................. 15
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Section 26: VIP SLIDE-OUT
12 RAIL ....................................................................................................................................................... 16
12.1 MAINTENANCE ............................................................................................................................ 17
12.2 REPLACEMENT ........................................................................................................................... 17
13 ACETAL PLASTIC BLOCKS ................................................................................................................ 17
13.1 REMOVAL / INSTALLATION ........................................................................................................ 17
14 SLIDE-OUT PNEUMATIC SYSTEM ..................................................................................................... 18
14.1 DESCRIPTION .............................................................................................................................. 18
14.2 MAINTENANCE ............................................................................................................................ 19
14.3 SEAL ............................................................................................................................................. 20
14.3.1 Maintenance ......................................................................................................................... 20
14.3.2 Seal assembly removal ........................................................................................................ 21
14.3.3 Seal assembly installation .................................................................................................... 21
14.3.4 Slide-out 2" inside retraction ................................................................................................ 22
15 SLIDE-OUT ELECTRICAL SYSTEM .................................................................................................... 22
15.1 ELECTRICAL INTERCONNECTION WITH PREVOST VEHICLE ............................................... 23
15.2 SLIDE-OUT BREAKERS .............................................................................................................. 23
15.3 PROBING VOLTAGE ON THE MULTIPLEX CIRCUITS .............................................................. 23
15.4 MODULE REPLACEMENT ........................................................................................................... 23
15.5 SLIDE-OUT LIMIT SENSORS ....................................................................................................... 23
15.5.1 Maintenance and adjustment ............................................................................................... 24
16 SLIDE-OUT EXTERIOR FINISHING PANELS & WINDOWS .............................................................. 25
16.1 FACE PANEL REMOVAL .............................................................................................................. 25
16.2 FACE PANEL INSTALLATION ...................................................................................................... 25
16.3 SIDE PANEL REMOVAL ............................................................................................................... 25
16.4 SIDE PANEL INSTALLATION ....................................................................................................... 26
16.5 TOP AND BOTTOM PANEL REMOVAL ....................................................................................... 27
16.6 TOP AND BOTTOM PANEL INSTALLATION ............................................................................... 28
16.7 SIDE WINDOW & HALF-WINDOW REMOVAL ............................................................................ 29
16.8 HALF-WINDOW & SIDE WINDOW INSTALLATION .................................................................... 30
16.9 FACE WINDOW INSTALLATION .................................................................................................. 31
16.10 AWNING WINDOW INSTALLATION ............................................................................................ 32
16.11 SLIDING WINDOW INSTALLATION ............................................................................................. 34
16.12 FINISHING JOINT ......................................................................................................................... 35
17 WELDING PRECAUTION ..................................................................................................................... 37
18 SLIDE-OUT MANUAL OVERRIDE PROCEDURES ............................................................................. 37
18.1 PRELIMINARY CONDITIONS FOR MANUAL OVERRIDE PROCEDURE ................................. 37
18.1.1 Manual retracting procedure – Front and rear slide-out ...................................................... 37
18.1.2 Manual extending procedure – Front and rear slide-out ...................................................... 39
19 SLIDE-OUT MAXIMUM LOAD .............................................................................................................. 40
20 CONVERSION CHECKLIST ................................................................................................................. 41
21 TROUBLESHOOTING .......................................................................................................................... 42
21.1 ERROR CONDITION OR MISSING OPERATION CONDITION ................................................... 42
21.2 TROUBLESHOOTING – OPERATING CONDITIONS & CONTROL ............................................ 42
21.3 TROUBLESHOOTING - MECHANICAL COMPONENTS ............................................................. 45
21.4 SLIDE-OUT FAULT MESSAGE ON MESSAGE CENTER DISPLAY (MCD) ................................ 48
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Section 26: VIP SLIDE-OUT
LIST OF ILLUSTRATIONS
FIGURE 1 : FRONT SLIDE-OUT ........................................................................................................................... 5
FIGURE 2 : REAR SLIDE-OUT ............................................................................................................................. 5
FIGURE 3 : SIDE INNER STOPPER ADJUSTMENT .................................................................................................. 5
FIGURE 4: UPPER INNER STOPPERS ADJUSTMENT .............................................................................................. 5
FIGURE 5: LOWER "IN LIMIT" STOPPER ............................................................................................................... 6
FIGURE 6: UPPER "IN LIMIT" STOPPER ............................................................................................................... 6
FIGURE 7 : EXTERIOR EXTRUSION ..................................................................................................................... 6
FIGURE 8: SECURITY PIN AIR CYLINDER REMOVAL .............................................................................................. 7
FIGURE 9 : FRONT SLIDE-OUT ROOF REINFORCING ROD ...................................................................................... 7
FIGURE 10 : RACK............................................................................................................................................ 8
FIGURE 11: PINION AND KEYLESS BUSHING POSITIONING .................................................................................... 9
FIGURE 12: PINION AND KEYLESS BUSHING (BOTTOM VIEW) ................................................................................ 9
FIGURE 13: MECHANICAL COMPONENTS (TYPICAL) ............................................................................................ 9
FIGURE 14 : KEYLESS BUSHING TIGHTENING .................................................................................................... 10
FIGURE 15 : TORQUE WRENCH FORMULA ........................................................................................................ 10
FIGURE 16 : KEYLESS BUSHING INSTALLATION INSTRUCTION ............................................................................ 12
FIGURE 17: ELECTRIC MOTOR AND SPEED REDUCTION GEARBOX ...................................................................... 13
FIGURE 18: MOTOR/GEARBOX ASSEMBLY MOUNTING BOLTS ............................................................................. 13
FIGURE 19: CLAMPING HUB POSITION ON SHAFTS ............................................................................................ 14
FIGURE 20: JAW COUPLING ............................................................................................................................ 14
FIGURE 21: SLIDE-OUT LEVEL ADJUSTEMENT ................................................................................................... 15
FIGURE 22 : SLIDE-OUT LEVELING ................................................................................................................... 16
FIGURE 23: TILT ADJUSTMENT ........................................................................................................................ 16
FIGURE 24 : RAIL POSITIONING ....................................................................................................................... 17
FIGURE 25: ACETAL PLASTIC BLOCKS .............................................................................................................. 17
FIGURE 26: REMOVE THE UPPER ACETAL PLASTIC BLOCKS WITH A PICKING TOOL ............................................... 17
FIGURE 27: LOWER ACETAL PLASTIC BLOCK INSERTION .................................................................................... 18
FIGURE 28 : FRONT SERVICE COMPARTMENT ................................................................................................... 19
FIGURE 29: PNEUMATIC CONTROL UNIT ........................................................................................................... 20
FIGURE 30 : SEAL ASSEMBLY .......................................................................................................................... 20
FIGURE 31: REAR SLIDE-OUT INFLATABLE SEAL AIR INLET ................................................................................. 20
FIGURE 32: WIPER SEAL CUT-OUT ................................................................................................................... 21
FIGURE 33: SLIDE-OUT 2" INSIDE – UPPER PART .............................................................................................. 22
FIGURE 34 : DASHBOARD SLIDE-OUT TELLTALE LIGHT ...................................................................................... 23
FIGURE 35: MAIN BREAKER IN MAIN POWER COMPARTMENT ............................................................................. 23
FIGURE 36 : SLIDE-OUT CONTROL PANEL ......................................................................................................... 23
FIGURE 37: FRONT SLIDE-OUT SENSORS ........................................................................................................ 24
FIGURE 38: REAR SLIDE-OUT SENSORS ........................................................................................................... 24
FIGURE 39 : MAGNETS ON SLIDE-OUT UNDERBODY .......................................................................................... 24
FIGURE 40 : SLIDE-OUT PANELS AND WINDOWS ............................................................................................... 25
FIGURE 41 : SIDE PANEL INSTALLATION ........................................................................................................... 26
FIGURE 42 : SIDE PANEL INSTALLATION ........................................................................................................... 26
FIGURE 43 : SIDE PANEL INSTALLATION – SIKA 221 APPLICATION ON STRUCTURE .............................................. 27
FIGURE 44 : SIDE PANEL INSTALLATION – SIKA 221 OR 252 APPLICATION ON STRUCTURE .................................. 27
FIGURE 45 : SIDE PANEL INSTALLATION – SIKA 206 G+P APPLICATION ............................................................... 27
FIGURE 46 : SIDE PANEL INSTALLATION – SIKA 221 OR 252 APPLICATION ON SIDE PANEL ................................... 27
FIGURE 47 : SIDE PANEL INSTALLATION – SIKA TACK+BOOSTER APPLICATION ................................................... 27
FIGURE 48 : SIDE PANEL INSTALLATION ........................................................................................................... 27
FIGURE 49 : TOP AND BOTTOM PANEL INSTALLATION - DOUBLE FACE ADHESIVE TAPE APPLICATION ..................... 28
FIGURE 50 TOP AND BOTTOM PANEL INSTALLATION - SIKA 206 G+P APPLICATION ............................................. 29
FIGURE 51 : TOP AND BOTTOM PANEL INSTALLATION - SIKA TACK+BOOSTER APPLICATION ................................. 29
FIGURE 52 : TOP PANEL INSTALLATION ............................................................................................................ 29
FIGURE 53 : BOTTOM PANEL INSTALLATION ..................................................................................................... 29
FIGURE 54 : FACE WINDOW - RUBBER SEAL INSTALLATION ................................................................................ 30
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Section 26: VIP SLIDE-OUT
FIGURE 55 : SIDE WINDOW – ¼ X ½ DOUBLE FACE ADHESIVE TAPE INSTALLATION.............................................. 30
FIGURE 56 : HALF-WINDOW – SIKA AKTIVATOR ................................................................................................. 30
FIGURE 57 : SIDE WINDOW – SIKA AKTIVATOR ................................................................................................. 30
FIGURE 58 : HALF-WINDOW INSTALLATION – SIKA AKTIVATOR ........................................................................... 31
FIGURE 59 : HALF-WINDOW INSTALLATION ....................................................................................................... 31
FIGURE 60 : SIDE WINDOW – SIKA TACK + BOOSTER ......................................................................................... 31
FIGURE 61 : HALF-WINDOW INSTALLATION – SIKA TACK+BOOSTER .................................................................... 31
FIGURE 62 : SIDE WINDOW ............................................................................................................................. 31
FIGURE 63 : FACE WINDOW INSTALLATION - ANCHORING BLOCKS ..................................................................... 32
FIGURE 64 : FACE WINDOW INSTALLATION ....................................................................................................... 32
FIGURE 65: SIDE BUMPERS ............................................................................................................................ 32
FIGURE 66: SIKA 255 APPLICATION ................................................................................................................. 32
FIGURE 67: MASKING TAPE APPLICATION ......................................................................................................... 32
FIGURE 68 : AWNING WINDOW – SIKA AKTIVATOR ............................................................................................. 32
FIGURE 69: AWNING WINDOW - RUBBER BUMPER INSTALLATION ....................................................................... 33
FIGURE 70: AWNING WINDOW – SIKA 252 APPLICATION .................................................................................... 33
FIGURE 71 : CORRECT TIGHTENING SEQUENCE ............................................................................................... 33
FIGURE 72 : SMOOTH DOWN THE JOINT ........................................................................................................... 33
FIGURE 73 : AWNING WINDOW – SEAL THE UPPER CORNERS ............................................................................ 33
FIGURE 74 : AWNING WINDOW – SEAL THE CHINK ............................................................................................. 34
FIGURE 75 : SLIDING WINDOW - SIKA AKTIVATOR .............................................................................................. 34
FIGURE 76 : SLIDING WINDOW - RUBBER BUSHING ............................................................................................ 34
FIGURE 77 : SLIDING WINDOW - SIKA 252 APPLICATION ................................................................................... 34
FIGURE 78 : CORRECT TIGHTENING SEQUENCE ............................................................................................... 35
FIGURE 79 : SLIDING WINDOW – SEAL THE UPPER CORNERS ............................................................................. 35
FIGURE 80 : SLIDE-OUT CIRCUIT BREAKERS CB9 & CB11 IN MAIN POWER COMPARTMENT ................................... 37
FIGURE 81 : SLIDE-OUT CONTROL PANEL IN FIRST BAGGAGE COMPARTMENT ..................................................... 37
FIGURE 82 : INFLATABLE SEAL RELIEVING SHUT-OFF VALVE .............................................................................. 38
FIGURE 83 : SLIDE-OUT MOTOR ROTATION....................................................................................................... 38
FIGURE 84 : INFLATABLE SEAL PRESSURE GAGE .............................................................................................. 38
FIGURE 85 : INFLATABLE SEAL RELIEVING SHUT-OFF VALVE .............................................................................. 39
FIGURE 86 : SLIDE-OUT MOTOR ROTATION....................................................................................................... 39
FIGURE 87 : INFLATABLE SEAL PRESSURE GAGE .............................................................................................. 39
FIGURE 88 : FRONT SLIDE-OUT DEFLECTION .................................................................................................... 40
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Section 26: VIP SLIDE-OUT
1 SLIDE-OUT
1.1 INNER STOPPER
The front slide-out is equipped with six inner
stoppers laid out in the following way: two
stoppers on the top horizontal member of the
slide-out, and two stoppers on each vertical
upright, while the rear slide-out is equipped with
only three stoppers (FIGURE 1 and figure 2).
The upper inner stoppers are used to provide a
support to position the slide-out perpendicularly
with the vehicle structure.
The side inner stoppers are used to block the
extension of the slide-out. They act as ultimate
physical limits but take note that when the “out
limit” sensors are properly adjusted, the slide-out
extension stops before the side inner stoppers
reach the side structure keys (figure 1 & 2).
FIGURE 1 : FRONT SLIDE-OUT
1.1.1 Maintenance
Check that the inner stopper screws are tight
and that no damage or deformation has taken
place for both the side and the upper stoppers.
1.1.2 Adjustment
1. Adjust the side inner stoppers at 1/8" from
the vehicle side structure keys, and tighten
the screws. Make sure there is a minimum
gap of 2mm (0.079”) between the side inner
stopper and the side window pane (figure 3).
Use shim as required.
2. Adjust the upper inner stoppers according to
FIGURE 4 with the seal deflated. When
inflating, the seal presses the roof structure
upward and at that moment, the upper inner
stopper comes into contact with the structure
key.
FIGURE 2 : REAR SLIDE-OUT
FIGURE 3 : SIDE INNER STOPPER ADJUSTMENT
FIGURE 4: UPPER INNER STOPPERS ADJUSTMENT
1.2 "IN LIMIT" STOPPER
Each slide-out has four "in limit" stoppers. Two
"in limit" stoppers are mounted on the exterior
extrusion at the top of the slide-out (FIGURE 6)
and two other "in limit" stoppers are mounted
under the slide-out, next to the rail (Figure 5).
These stoppers are use to position the outer
PA1217 5

Section 26: VIP SLIDE-OUT
face of the slide-out flush with the vehicle body
when retracted.
1.2.1 Maintenance
Check that the "in limit" stoppers are clean and
that there is no foreign matter accumulated
between the stopper and its bearing surface.
Check that the screws and set screws (where
applicable) locking the stoppers in proper
position are tight.
1.2.2 Adjustment
NOTE
To properly adjust the “in limit” stoppers, the
slide-out system must be turned off to prevent
the “in limit” sensors from stopping the slide-
out movement before having the “in limit”
stoppers contacting their bearing surface.
1. Extend the slide-out partially.
2. Set the ignition switch to the OFF position.
3. To adjust the lower "in limit" stoppers,
loosen the set screw and then rotate the
stopper CW or CCW to move it back or
forward depending on the required
adjustment. To adjust the upper plastic "in
limit" stoppers, add or remove shims as
required between the stopper and the
extrusion.
4. Using the manual override procedure
(paragraph 18), move the slide-out up to its
full "in" position.
5. Using a straight edge, check if the outer face
of the slide-out is flush with the vehicle body
with the stoppers contacting their bearing
surface. Readjust the stoppers if necessary.
6. Readjust the “in limit” sensor.
LOWER “IN LIMIT” STOPPER
SET
SCREW
FIGURE 5: LOWER "IN LIMIT" STOPPER
FIGURE 6: UPPER "IN LIMIT" STOPPER
NOTE
To make sure that the lower “in limit” stoppers are
contacting their bearing surface (the acetal plastic
blocks) when the slide-out is closed, put white paint
on the “in limit” stopper before and check if the
acetal plastic blocks are marked with paint.
1.3 EXTERIOR EXTRUSION
The exterior extrusion assembly function is to
provide a leaning surface for the inflatable seal.
When inflating, the seal presses against the
extrusion support (angle), lifting the roof
structure upward until it rests on the inner side of
the extrusion support.
FIGURE 7 : EXTERIOR EXTRUSION
1.3.1 Maintenance
Inspect the exterior extrusion & support for any
deformation or deterioration. Check that the
screws are tight. Inspect the sealant condition on
screw head and between the extrusion and the
vehicle structure, and also at both ends of the
extrusion. If needed, clean old sealant and
replace with Sika 221 sealant or equivalent
product.
1.3.2 Removal
Using a knife, cut the sealant between the
extrusion and the roof (figure 7). Unscrew and
remove the central exterior extrusion screws and
the two end extrusion screws.
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Section 26: VIP SLIDE-OUT
2 SECURITY PIN
During normal ride, the slide-out cannot extend
by itself because the 740:1 ratio speed reduction
worm gear type gearbox system is not
reversible, the output shafts are self-locking. The
security pin purpose is to lock the slide-out in
retracted position if an accident occurs. It is built
to stand a great lateral acceleration of the slide-
out.
The system consists of a stainless steel pin
connected to a single action/spring return
pneumatic cylinder (FIGURE 8). The pin
engages in the slide-out receptacle with
releasing of the parking brake. A knocking sound
may be heard at this moment. An O-ring is
located at the base of the pin housing to reduce
knocking when the pin retracts. The lower hole
on the pin housing permits water to drain. The
upper hole permits to insert a small screwdriver
to prevent the pin from rotating when the air
cylinder has to be removed.
FIGURE 8: SECURITY PIN AIR CYLINDER REMOVAL
2.1 MAINTENANCE
Inspect air cylinder and fitting for air leaks.
Periodically, check that the pin retracts and
engages in the receptacle as it should when the
parking brake is applied or released. To do so,
the slide-out must be in its full “IN” position with
the engine running. If the pin produces
excessive knocking when it engages with
releasing of the parking brake, reduce air
cylinder speed by adjusting the air flow regulator
on the pneumatic control module (FIGURE 29,
item 11).
2.2 AIR CYLINDER REPLACEMENT
1. Assure the parking brake is applied.
2. Disconnect the cylinder air tubing from the
2nd baggage compartment (front slide-out) or
under the bed structure (rear slide-out).
3. Using a wrench at its lower end, unscrew
the air cylinder from the pin housing.
4. Insert a small screwdriver through the pin
and housing to prevent rotation of the pin an
then, unscrew the cylinder rod from the pin.
5. Transfer the fitting on the new cylinder.
Place Teflon on threads.
6. Cylinder installation is the same as removal
but in reverse order.
3 ROOF REINFORCING ROD
The roof reinforcing rod is located near the
upper horizontal member of the front slide-out
opening and is welded on the roof arches (figure
9).
FIGURE 9 : FRONT SLIDE-OUT ROOF REINFORCING
ROD
CAUTION
The maximum allowed upward shifting is
0.118” (3mm)
. To prevent permanent
warping of the roof arches, never exceed
that measurement.
The roof reinforcing rod may have already
been adjusted up to the maximum shifting
limit at the factory, do not attempt to move
the roof any further
. If an adjustment is
required
after a load variation inside the
vehicle or on top of the vehicle, it must be
done under supervision of a Prevost
service representative.
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Section 26: VIP SLIDE-OUT
4 RACK
Slide-out movement is made by a system of
racks and pinions. There are two racks on each
slide-out.
4.1 MAINTENANCE
Once a year, check the racks for broken or worn
tooth, especially the front slide-out racks. Also,
check the rack fastening hole teeth that are
weaker and might break (figure 10). Replace the
racks if excessive wear is present. Clean racks
from sand or other debris. Check that the racks
are properly secured. Check the backlash
between the gear and the rack. Excessive
backlash indicates rack wear.
FIGURE 10 : RACK
4.2 FRONT SLIDE-OUT RACK
REPLACEMENT
1. Remove the slide-out from the vehicle
(removal must be performed according to
the Slide-Out Removal Procedure. Ask to
your Prevost service representative).
2. From under the slide-out, unscrew all the
rack screws and remove the rack.
3. Install a new rack. Tighten the 2 screws
located at each ends first and then the other
screws to a maximum torque of 2 ft-lbs. Use
Loctite™ 242 or equivalent product on
threads. The clearance between rack and
rail can be verified with jig #30710.
CAUTION
The counterborings required for recessed
screw heads reduce plastic thickness. Do
not torque higher than specified.
4. Reinstall the front slide-out inside the
vehicle.
4.3 REAR SLIDE-OUT RACK
REPLACEMENT
1. Using the slide-out handheld control or the
manual override procedure (paragraph 18, if
using the manual override procedure, do not
forget to deflate the inflatable seal
completely), extend the slide-out about one
foot.
2. From outside, unscrew and remove only the
first two screws of the rack to be changed.
3. Using the manual override procedure
(paragraph 18) only, retract the slide-out to
its fully closed position.
4. Loosen the pinion keyless bushing of the
rack to be changed.
5. From under the slide-out, unscrew all the
rack screws and remove the rack.
6. Install a new rack between the slide out
structural rack seat and the pinion. Tighten
the screws to a maximum torque of 2 ft-lbs.
Use Loctite™ 242 or equivalent product.
CAUTION
The counterborings required for recessed
screw heads reduce plastic thickness. Do
not torque higher than specified.
7. Tighten the pinion keyless bushing as
described in paragraph 5.4.
8. Using the slide-out manual override
procedure only, extend the slide-out about
one foot.
9. Tighten the two remaining crews to a
maximum torque of 2 ft-lbs. Use Loctite™
242 or equivalent product.
10. Using the slide-out handheld control switch
or the manual override procedure, retract
the slide-out to its fully closed position.
11. Re-inflate the air seal at 10 psi.
PA1217 8

Section 26: VIP SLIDE-OUT
5 PINION
CAUTION
Make sure all keyless bushings are
tightened to 125 lb-
ft before moving the
slide-out. Refer to paragraph 5.4 for torque
wrench settings. A lower torque value may
cause the bushing to slip on the shaft, and
a higher torque value may break the
bushing.
5.1 PINION AND KEYLESS
BUSHING POSITIONING
For proper functioning, respect the positioning
shown on the following figure.
FIGURE 11: PINION AND KEYLESS BUSHING
POSITIONING
FIGURE 12: PINION AND KEYLESS BUSHING (BOTTOM
VIEW)
5.2 FRONT SLIDE-OUT SHAFT
PINION REPLACEMENT
CAUTION
Before reinstalling the pinion, clean the
following surfaces with alcohol to prevent
slippage.
o Pinion bore;
o Keyless bushing I.D. and O.D.;
o Shaft.
Before proceeding with the front slide-out shaft
pinion replacement, check the following
conditions:
- The locking collars located on the side of the
pinion being replaced are disengaged;
- The drive motor/gearbox assembly is
removed (see paragraph 7.2);
FIGURE 13: MECHANICAL COMPONENTS (TYPICAL)
1. Loosen the keyless bushing (see paragraph
5.4) of the pinion to be replaced. Slide the
pinion and its bushing out of the shaft.
Check the keyless bushing condition and
replace if needed.
NOTE
If necessary, loosen the blue and gray flange
bearing to move the pinion away from the
rack.
2. Assemble new pinion on the keyless
bushing and then slide on the shaft. Do not
tighten the bushing at this moment.
3. Properly position the shaft end in relation to
the linear bearing support plate (see
FIGURE 11) and then tighten the locking
collars to maintain the shaft in that position.
4. Position pinion and keyless bushing as
shown on FIGURE 11 and tighten the
PA1217 9