PREVOST H3-41 User manual

COACH MANUFACTURER
MAINTENANCE MANUAL
H3-41, H3-45, VIP
PA1217

SECTION 00: GENERAL INFORMATION
00-1
CONTENTS
1. FOREWORD................................................................................................................................ 00-2
2. SCHEMATICS .............................................................................................................................00-2
3. PRECAUTIONS TO BE OBSERVED BEFORE WELDING .........................................................00-2
4. SAFETY NOTICE........................................................................................................................00-4
4.1 DATA PLATES AND CERTIFICATIONS................................................................................00-4
4.1.1 Engine............................................................................................................................00-4
4.1.2 Transmission..................................................................................................................00-4
4.1.3 Drive Axle....................................................................................................................... 00-5
4.1.4 Front Axle.......................................................................................................................00-5
4.1.5 Power Steering Pump.....................................................................................................00-5
4.1.6 Coach Final Record........................................................................................................00-5
4.1.7 Safety Certification......................................................................................................... 00-5
4.1.8 DOT Certification Label ..................................................................................................00-5
4.1.9 EPA Engine Label ..........................................................................................................00-6
4.1.10 Fuel Tank Label..............................................................................................................00-6
4.1.11 Vehicle Identification Number (VIN) ................................................................................00-6
5. FASTENER STRENGTH IDENTIFICATION................................................................................00-8
5.1 SELF-LOCKING FASTENERS ......................................................................................................00-9
5.2 RECOMMENDATIONS FOR REUSE ..............................................................................................00-9
5.3 SIX LOBED SOCKET HEAD ........................................................................................................00-9
ILLUSTRATIONS
FIGURE 1: DETROIT DIESEL SERIES 60..........................................................................................00-4
FIGURE 2: WORLD TRANSMISSION................................................................................................ 00-4
FIGURE 3: ZF-ASTRONIC TRANSMISSION......................................................................................00-4
FIGURE 4: TYPICAL SERIAL & MODEL NUMBERS..........................................................................00-5
FIGURE 5: TYPICAL SERIAL AND MODEL NUMBERS.....................................................................00-5
FIGURE 6: ISS TYPICAL SERIAL & MODEL NUMBERS ...................................................................00-5
FIGURE 7 : POWER STEERING PUMP SERIAL NUMBER............................................................... 00-5
FIGURE 8: DOT CERTIFICATION PLATE..........................................................................................00-5
FIGURE 9: ENGINE COMPARTMENT ............................................................................................... 00-6
FIGURE 10: VEHICLE I.D................................................................................................................... 00-6
FIGURE 11: VEHICLE IDENTIFICATION NUMBER ...........................................................................00-7
FIGURE 12 : THREAD NOTATION.....................................................................................................00-8
FIGURE 13: BOLT STRENGTH MARKINGS......................................................................................00-8
FIGURE 14 : SELF-LOCKING FASTENERS....................................................................................... 00-9
FIGURE 15: METRIC -US STANDARD CONVERSION TABLE....................................................... 00-10
FIGURE 16: CONVERSION CHART................................................................................................. 00-11

Section 00 : GENERAL INFORMATION
00-2
1. FOREWORD
This manual includes procedures for diagnosis,
service, maintenance and repair for components
of the H3 series coaches or VIP model listed on
the front cover page.
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 24
pertains to standard equipment items, systems
and components as well as the most commonly
used optional equipment and special equipment
offered on the coach models covered by this
manual.
At the beginning of each section; a Table of
Contents and a list of illustrations give the page
number on which each subject begins and where
each figure is located.
Coach operating information is provided in a
separate Operator's Manual. Audio/Video
system operator instructions are also included in
a separate manual.
More specific information on engine and
transmission operating, maintenance, and
overhaul information is contained in the
applicable engine or transmission service
manual published by the engine or transmission
manufacturer. Engine and transmission parts
information is contained in the applicable engine
or transmission parts catalog published by the
engine or transmission manufacturer.
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: Typical illustrations may be used;
therefore minor illustration difference may exist
when compared to actual parts or other
publications.
Prévost Car 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 AIR SCHEMATICS are provided at the
end of Section 12, "Brake". SUSPENSION AIR
SCHEMATICS are provided at the end of
Section 16, "Suspension". Moreover,
ELECTRICAL SCHEMATICS are provided in the
technical publications box. Refer to those
schematics for detailed circuit information or
during diagnosis.
3. PRECAUTIONS TO BE OBSERVED
BEFORE WELDING
Caution: Cut off battery power in main power
compartment using battery safety switch.
1. Disconnect “Ground” cables from battery
terminals.
Note: Disconnect “Ground” cables only.
2. If welding must be done near the dashboard
i.e. steering column, you must disconnect all
electronic control modules (radio & control
head, HVAC, TTLT cluster Volvo). You must
also disconnect alternator module located in
rear electrical compartment.
3. Disconnect three wiring harness connectors
from ECM (Electronic Control Module). The
ECM is mounted on the starter side of the
engine.
4. For vehicles equipped with an Allison
automatic transmission, disconnect three
wiring harness connectors from ECU
(Electronic Control Unit). The ECU is located
in main power compartment.
5. For vehicles equipped with a WCL system,
disconnect electronic controller connector.
6. For vehicles equipped with ABS (Anti-Lock
Brake System), disconnect wiring harness
connectors from ABS Electronic Control Unit.
The ABS Electronic Control Unit is located in
the 1st baggage compartment.
7. Cover electronic control components and
wiring to protect from hot sparks, etc.
8. Do not connect welding cables to electronic
control components.
9. Do the appropriate welding on vehicle.
Caution: Position welding machine ground
clamp as close as possible to the work.
10.When welding is complete, reconnect ECM,
ECU, ABS electronic control units, etc.
11.Terminate by reconnecting “Ground” cables
to battery terminals.

SECTION 00 : GENERAL INFORMATION
00-3
STEEL –STEEL WELDING
Caution:Before welding, disconnect electronic modules and battery terminals.
Warning: Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign
material that would render welding impossible.
Warning:Only a qualified and experienced person must do welding.
FCAW (Flux Cored Arc Welding) process ;
Electrode wire conforms to A5.20 AWS (American Welding Society) specifications ;
E4801T-9-CH, type electrode wire with 0,045“ diameter (1,14 mm) ;
Material Thickness Voltage Current Wire Feed Rate Shielding 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:
SMAW (Shielded Metal-Arc Welding) process ;
Welding rod conforms to A5.1 of AWS (American Welding Society) specifications; E 7018 type
welding rod with 1/8” diameter (3,2 mm).
Current: 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.
STEEL -STAINLESS STEEL OR STAINLESS STEEL -STAINLESS STEEL WELDING
Caution:Before welding, disconnect electronic modules and battery terminals.
Warning: Welding surfaces must be free of scale, slag, rust, paint, grease, humidity or other foreign
material that would render welding impossible.
Warning:Only a qualified and experienced person must do welding.
GMAW (Gas Metal-Arc Welding) process;
Welding wire conforms to AWS (American Welding Standards) A5.9 specifications;
308LSi type welding wire with 0.035" diameter (0,9 mm);
STEEL -STAINLESS STEEL WELDING
Steel Thickness SS Thickness Voltage Current Wire Feed Rate Shielding 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 Voltage Current Wire Feed Rate Shielding 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:
SMAW (Shield Metal-Arc Welding) process;
Welding rod conforms to AWS (American Welding Standards) A5.4 specifications; 308L-17 type
welding rod with 3/32" diameter (2,4 mm);
Current: -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
00-4
4. SAFETY NOTICE
This maintenance manual has been prepared in
order to assist skilled mechanics in the efficient
repair and maintenance of PRÉVOST vehicles.
This manual covers only the procedures as of
manufacturing date.
Safety features may be impaired if other than
genuine PRÉVOST 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:
Warning:Identifies an instruction which, if not
followed, could cause personal injuries.
Caution:Outlined an instruction which, if not
followed, could severely damage vehicle
components.
Note:Indicates supplementary information
needed to fully complete an instruction.
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
coach 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
The engine serial and model number are
stamped on the cylinder block (as viewed from
the flywheel end) on the left side just below the
fire deck and above the cast-in Detroit Diesel
logo (Fig. 1).
In addition, option plates made of laminated
paper are located on the rocker cover (starter
side). The engine serial and model number and
a list of the optional engine equipment is written
on the option plate. Refer to this information
when ordering replacement parts (Fig. 1).
FIGURE 1: DETROIT DIESEL SERIES 60 00043
4.1.2 Transmission
The transmission identification plate is located
on the right-rear side or output side of the
transmission. The identification plate shows the
transmission serial number, part number
(assembly number), and model number. Use all
three numbers when ordering parts.
FIGURE 2: WORLD TRANSMISSION 07076
FIGURE 3: ZF-ASTRONIC TRANSMISSION00040

Section 00 : GENERAL INFORMATION
00-5
4.1.3 Drive Axle
FIGURE 4: TYPICAL SERIAL & MODEL NUMBERS 11019
4.1.4 Front Axle
FIGURE 5: TYPICAL SERIAL AND MODEL NUMBERS10024
FIGURE 6: ISS TYPICAL SERIAL & MODEL NUMBERS00025C
4.1.5 Power Steering Pump
Power steering pump serial number is engraved
on the pump casing (Fig. 7). The pump is
mounted on the engine beside the crankshaft
pulley.
FIGURE 7: POWER STEERING PUMP SERIAL NUMBER
00035
4.1.6 Coach Final Record
The Coach Final Record is a record of all data
pertaining to the assembly of the coach. This
record is included in the technical publication
package supplied with the coach. Retain this
record in the company records office for
reference and safe-keeping.
4.1.7 Safety Certification
Coach 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.
4.1.8 DOT Certification Label
This certifies that coaches manufactured by
Prevost Car Inc., comply with all Federal Motor
Vehicle Safety Standards at the time of
manufacture. The DOT Certification label is
affixed on the wall, behind the driver's seat.
FIGURE 8: DOT CERTIFICATION PLATE 00016

Section 00 : GENERAL INFORMATION
00-6
4.1.9 EPA Engine Label
The exhaust emission certification label affixed
above the oil reserve tank certifies that the
engine conforms to federal and any state
exhaust emission regulations (Fig. 9). It gives
the operating conditions under which
certification was made.
FIGURE 9: ENGINE COMPARTMENT 23229
4.1.10 Fuel Tank Label
The fuel tank label is molded on the side of the
fuel tank. To read this label, unscrew the fuel
tank access panel nuts located at the left in the
condenser compartment.
4.1.11 Vehicle Identification Number (VIN)
The seventeen digit vehicle identification
number (VIN) is located on a plate (Fig. 10 & 11)
located on the windshield frame pillar (driver's
side). The VIN is visible from the outside of the
coach. Make sure the correct vehicle
identification number is given when ordering
replacement parts. Using the VIN when ordering
parts will facilitate processing.
FIGURE 10 : VEHICLE I.D. 18479
Note:Record the VIN in the coach
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
00-7
FIGURE 11 : VEHICLE IDENTIFICATION NUMBER VIN
YEAR CODE YEAR CODE
1995 S2001 1
1996 T2002 2
1997 V2003 3
1998 W2004 4
1999 X2005 5
2000 Y2006 6

SECTION 00 : GENERAL INFORMATION
00-8
5. 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. Fig. 13 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 12 : THREAD NOTATION 00002
FIGURE 13: 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
00-9
5.1 SELF-LOCKING FASTENERS
A self-locking fastener is designed with an
interference fit between the nut and bolt threads.
This is most often accomplished by distortion of
the top thread of an all-metal nut or bolt or by
using a nylon patch on the threads. A nylon
insert or the use of adhesives may also be used
as a method of interference between nut and
bolt threads (Fig. 14).
FIGURE 14 : SELF-LOCKING FASTENERS 00004
5.2 RECOMMENDATIONS FOR REUSE
Clean, unrusted self-locking fasteners may be
reused as follows:
a) Clean dirt and other foreign matter from the
fastener;
b) Inspect the fastener to ensure there is no
crack, elongation, or other sign of fatigue or
overtightening. If there is any doubt, replace with
a new self-locking fastener of equal or greater
strength;
c) Assemble parts and hand start fastener;
d) Observe that, before the fastener seats, it
develops torque per the chart in table two. If
there is any doubt, replace with a new self-
locking fastener of equal or greater strength;
e) Tighten the fastener to the torque specified in
the applicable section of this manual;
Fasteners which are rusty or damaged should be
replaced with new ones of equal or greater
strength.
SELF-LOCKING FASTENER TORQUE CHART
METRIC 6 & 6.3 810 12 14 16 20
NUTS AND Nm0.4 0.8 1.4 2.23.0 4.2 7.0
ALL-METAL BOLTS Lbf-in 4.0 7.0 12 18 25 35 57
ADHESIVE OR NYLON Nm0.4 0.6 1.2 1.6 2.4 3.4 5.6
COATED BOLTS Lbf-in 4.0 5.0 10 14 20 28 46
US STANDARD .250 .312 .375 .437 .500 .562 .625 .750
NUTS AND Nm0.4 0.6 1.4 1.8 2.4 3.2 4.2 6.2
ALL-METAL BOLTS Lbf-in 4.0 5.0 12 15 20 27 35 51
ADHESIVE OR NYLON Nm0.4 0.6 1.0 1.4 1.8 2.6 3.4 5.2
COATED BOLTS Lbf-in 4.0 5.0 9.0 12 15 22 28 43
5.3 SIX LOBED SOCKET HEAD
Six lobed socket head (Torx) fasteners are used
in some applications on vehicles covered in this
manual. The tools designed for these fasteners
are available commercially. However, in some
cases, if the correct tool is not available, a hex
socket head wrench may be used.

Section 00 : GENERAL INFORMATION
00-10
FIGURE 15: METRIC -US STANDARD CONVERSION TABLE 00005

Section 00 : GENERAL INFORMATION
00-11
FIGURE 16: CONVERSION CHART 00006

ELECTRONIC MODULES DISCONNECTION PROCEDURE PRIOR TO
WELDING
PROCEDURE NO: PR060013 REVISION 3
2003-03-05
Page 1 de 6
Materiel: N/A
Equipment(s): Flat blade screwdriver
Ratchet handle
¼" socket
Reference schematics: N/A
Safety rules: - Wear safety goggles.
- Set the battery master switch to the OFF position first.
- Always be very precautious when disconnecting and reconnecting the battery
cables.
Recommendations: This procedure should be performed by qualified personnel only.
Effective
Revision 3 : updated for cooling and ZF transmission H 4758
XL2 8165

PROCEDURE NO: PR060013 REVISION 3
Page 2 de 6
1.00 Set the battery master switch to the
OFF position. VERY IMPORTANT
2.00 Disconnect all the "GROUND" cables
connected to the battery terminals.
"GROUND" only

PROCEDURE NO: PR060013 REVISION 3
Page 3 de 6
3.00 When welding has to be done near the
dashboard, the following electronic
components must be disconnected.
RADIO & CONTROL HEAD
HVAC CONTROL UNIT
TELLTALE MODULE & CLUSTER
also disconnect the M2S MODULE
(ELECTRICAL SYSTEM MONITOR)
located in front service compartment (XL2)
located in main power compartment (H3)
In the engine compartment, unplug
connector C397
4.00
*
H3
In the main power compartment, trip
circuit breakers CB19 & CB20

PROCEDURE NO: PR060013 REVISION 3
Page 4 de 6
4.50 * XL2
In engine compartment, unplug connector
C158 & C159
Allison Transmission
5.00 *
Location: Main power compartment (H3)
Front service compartment (XL2)
H3 - Unplug the 3 connectors (gray, black, blue) from
the ECU
CAUTION
The connectors are secured by a red locking tab.
OR
XL2 - Unplug the 3 connectors (gray, black, blue)
from the ECU

PROCEDURE NO: PR060013 REVISION 3
Page 5 de 6
ZF Transmission
H3 In the main power compartment,
unplug connector C717
5.50 *
XL2 In front service compartment,
unplug connector C717

PROCEDURE NO: PR060013 REVISION 3
Page 6 de 6
6.00 H3 - In the first baggage compartment,
disconnect the ABS module
OR
XL2 - in the front service compartment ,
disconnect the ABS module
7.00 When all the previous steps are done,
you can do welding on the vehicle
ENSURE THAT THE WELDING GROUND CLAMP IS
WELL SECURED AND MAKES A GOOD ELECTRICAL
CONTACT WITH A LARGE METALLIC AREA OF THE
CHASSIS LOCATED NEAR THE WELDING POINT AS
MUCH AS POSSIBLE.
8.00 When welding is completed, reconnect
ECM, ECU, & ABS modules and
connectors.
Make sure that the connectors locking
tab are well engaged.
Reinstall the battery ground cables.
Be careful to make the proper connections, if not, some
systems or components may not be usable.