PREVOST X3-45 Multiplex User manual

COACH MANUFACTURER
MAINTENANCE MANUAL
X3 COACHES
PA1562
(4th edition)

PA1562 4th edition
Date: April 2009
Starting from vehicle: 9-9640
Featuring: New Bosch alternators on DDEC, new Sound System & new evaporator compartment motor

SECTION 00: GENERAL INFORMATION
PA1562
1
CONTENTS
1. FOREWORD...........................................................................................................................................2
2. SCHEMATICS........................................................................................................................................2
3. PRECAUTIONS TO BE OBSERVED BEFORE WELDING..................................................................2
4. SAFETY NOTICE...................................................................................................................................4
4.1 DATA PLATES AND CERTIFICATIONS ...................................................................................................4
4.1.1 Engine ......................................................................................................................................4
4.1.2 Transmission............................................................................................................................5
4.1.3 Drive Axle.................................................................................................................................5
4.1.4 Front Axle.................................................................................................................................5
4.1.5 Power Steering Pump ..............................................................................................................6
4.1.6 Coach Final Record..................................................................................................................6
4.1.7 Safety Certification...................................................................................................................6
4.1.8 DOT Certification Label............................................................................................................6
4.1.9 EPA Engine Label....................................................................................................................6
4.1.10 Fuel Tank Label........................................................................................................................6
4.1.11 Vehicle Identification Number (VIN).........................................................................................7
5. FASTENER STRENGTH IDENTIFICATION..........................................................................................9
5.1 SELF-LOCKING FASTENERS..............................................................................................................10
5.2 RECOMMENDATIONS FOR REUSE......................................................................................................10
5.3 SIX LOBED SOCKET HEAD ................................................................................................................10
ILLUSTRATIONS
FIGURE 1: DETROIT DIESEL SERIES 60 ..............................................................................................................5
FIGURE 2: VOLVO D13 ENGINE DATA PLATE.......................................................................................................5
FIGURE 3: ALLISON TRANSMISSION ...................................................................................................................5
FIGURE 4: ZF-ASTRONIC TRANSMISSION............................................................................................................5
FIGURE 5: TYPICAL SERIAL &MODEL NUMBERS..................................................................................................5
FIGURE 6: ISS TYPICAL SERIAL &MODEL NUMBERS ............................................................................................5
FIGURE 7: I-BEAM AXLE TYPICAL SERIAL &MODEL NUMBERS ..............................................................................5
FIGURE 8: POWER STEERING PUMP NAMEPLATE ................................................................................................6
FIGURE 9: POWER STEERING PUMP...................................................................................................................6
FIGURE 10: DOT CERTIFICATION PLATE .............................................................................................................6
FIGURE 11: VEHICLE I.D. ..................................................................................................................................7
FIGURE 12: VEHICLE IDENTIFICATION NUMBER...................................................................................................8
FIGURE 13: THREAD NOTATION.........................................................................................................................9
FIGURE 14: BOLT STRENGTH MARKINGS............................................................................................................9
FIGURE 15: SELF-LOCKING FASTENERS...........................................................................................................10
FIGURE 16: METRIC -US STANDARD CONVERSION TABLE..................................................................................11
FIGURE 17:CONVERSION CHART.....................................................................................................................12

Section 00: GENERAL INFORMATION
PA1562
2
1. FOREWORD
This manual includes procedures for diagnosis,
service, maintenance and repair for components
of the X3 series coaches 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.
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 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
Precautions are to be observed before welding
to minimize the risk of major and costly
damage caused to the vehicle electronic
components.
NOTE
For X3-45 Multiplex vehicles, also execute
procedure no: PR060034 "MULTIPLEX
MODULES DISCONNECTION PROCEDURE
PRIOR TO WELDING" included at the end of
this section.
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
3
PA1562
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 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:
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.
STEEL - STAINLESS STEEL OR STAINLESS STEEL - 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);
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

Section 00: GENERAL INFORMATION
PA1562
4
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.
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:
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
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
•DDC Series 60 Engine
The engine serial and model numbers 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 are
written on the option plates. Refer to this
information when ordering replacement parts
(Fig. 1).
•Volvo D13 Engine
Volvo D13 engine serial and model numbers are
stamped on the cylinder head (Fig. 2).

Section 00: GENERAL INFORMATION
5
PA1562
FIGURE 1 : DETROIT DIESEL SERIES 60 00043
FIGURE 2: VOLVO D13 ENGINE DATA PLATE 00052
4.1.2 Transmission
The transmission identification plate is located
on the oil level dipstick side of the transmission
(WT) or on transmission, on the vehicle R.H.
side (ZF) (Fig. 3 & 4). The identification plate
shows the transmission serial number, part
number (assembly number), and model number.
Use all three numbers when ordering parts.
FIGURE 3: ALLISON TRANSMISSION 07076
FIGURE 4: ZF-ASTRONIC TRANSMISSION 00040
4.1.3 Drive Axle
FIGURE 5: TYPICAL SERIAL & MODEL NUMBERS 00007
4.1.4 Front Axle
FIGURE 6: ISS TYPICAL SERIAL & MODEL NUMBERS16136
FIGURE 7: I-BEAM AXLE TYPICAL SERIAL & MODEL
NUMBERS 00008

Section 00: GENERAL INFORMATION
PA1562
6
4.1.5 Power Steering Pump
•DDC SERIES 60 ENGINE
Power steering pump serial number is located
on a tag on the pump (Fig. 8). The pump is
mounted on the engine beside the crankshaft
pulley.
FIGURE 8 : POWER STEERING PUMP NAMEPLATE 00035
•Volvo D13 Engine
Power steering pump is mounted on the engine
and located underneath the air compressor (Fig.
9).
FIGURE 9: POWER STEERING PUMP
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. 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 to the side of the L.H. control panel.
FIGURE 10: DOT CERTIFICATION PLATE 00016
4.1.9 EPA Engine Label
The exhaust emission certification label affixed
inside the engine compartment above the
lavatory maintenance service valves certifies
that the engine conforms to federal and any
state exhaust emission regulations. It gives the
operating conditions under which certification
was made.
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.

Section 00: GENERAL INFORMATION
7
PA1562
4.1.11 Vehicle Identification Number (VIN)
The seventeen digit vehicle identification
number (VIN) is located on a plate (Fig. 11 & 12)
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 11 : VEHICLE I.D. 00048
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
PA1562
8
FIGURE 12 : VEHICLE IDENTIFICATION NUMBER 00050
YEAR CODE YEAR CODE
2000 Y2006 6
2001 1 2007 7
2002 2 2008 8
2003 3 2009 9
2004 4 2010 A
2005 5 2011 B

Section 00: GENERAL INFORMATION
PA1562
9
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. 14 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 13 : THREAD NOTATION 00002
FIGURE 14: 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
PA1562
10
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. 15).
FIGURE 15 : 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 8 10 12 14 16 20
NUTS AND Nm 0.4 0.8 1.4 2.2 3.0 4.2 7.0
ALL-METAL BOLTS Lbf-in 4.0 7.0 12 18 25 35 57
ADHESIVE OR NYLON Nm 0.4 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 ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾
NUTS AND Nm 0.4 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 Nm 0.4 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
11
PA1562
FIGURE 16: METRIC - US STANDARD CONVERSION TABLE 00005

Section 00: General Information
PA1562
12
FIGURE 17: CONVERSION CHART 00006

MULTIPLEX MODULES DISCONNECTION PROCEDURE PRIOR TO
WELDING
PROCEDURE NO: PR060034
REVISION 4
2007-05-31
Page 1 de 15
Material : N/A
Equipment(s) : Phillips-head screwdriver
Ratchet handle
3/8" socket
Electric tape
Long nose pliers
Reference schematics: N/A
Safety rules : - Wear safety goggles
- Set the battery master switch to the OFF position first
Recommendations: This procedure should be performed by qualified personnel only.
Effective
Revision 0 : Issued with multiplex
Revision 1 : Modified for Fire Protection System and also for VIP with multiplex
Revision 2 : Step 5 modified for introduction of VIP with multiplex -0436
Revision 3 : Step 1.15 added C397
Addition of SECTION 2 for X3 Coaches
Addition of SECTION 3 for XLII MTH
Revision 4 : Modified for introduction of CPC module for VIP,H3 Coach, X3 7-0942VIP
8-1037 H3
8-9282 X3

PROCEDURE NO: PR060034 REVISION 4
Page 2 of 15
SECTION 1 H3 Coaches & VIP
1.00 Location: Main power compartment and
dashboard
Set the battery master switch to the OFF
position.
Place the ignition switch to the OFF
position.
1.05 Location: Main power compartment
Trip circuit breakers CB2, CB4, CB6
Push the red button to open the circuit

PROCEDURE NO: PR060034 REVISION 4
Page 3 of 15
1.10 Location: Main power compartment
Remove the protective cover
WARNING
LIVE WIRE
This 12-volt terminal remains
energized
Disconnect the electronic ground terminals
from the stud
Using electric tape, insulate the 2 largest
gage wires. Make sure the ring terminals
do not touch each others and the vehicle
body.
NOTE
With disconnection of the electronic
ground terminals, disconnecting the
engine ECM, transmission TCM and the
dashboard electronic components
(telltale module, HVAC module, radio,
control head, …) is not required.

PROCEDURE NO: PR060034 REVISION 4
Page 4 of 15
Location: Main power compartment
Disconnect the electronic modules :
Disconnect the I/O A and I/O B modules
Disconnect C397
Disconnect connector C717
Unplug 3 connectors per I/O B modules
Unplug 3 connectors on the I/O A module
1.15
1.20
Location: Front electrical compartment
VIP + COACH: Disconnect the I/O A, I/O B, ABS,
master ID, CECM and CPC modules. Unplug connector
C92
VIP: Disconnect all keyless module connectors.
Unplug 3 connectors per I/O B modules
and 3 connectors per I/O A modules.
Unplug 2 connectors from the ABS module

PROCEDURE NO: PR060034 REVISION 4
Page 5 of 15
Unplug 1 connector from the master ID
Disconnect CPC connectors
Unplug 3 connectors from the CECM
Unplug connector C92

PROCEDURE NO: PR060034 REVISION 4
Page 6 of 15
1.25 Location: pneumatic accessory panel
inside right console
Remove the access panel on the right
console (R.H. side of dashboard)
Disconnect both I/O B modules
1.30 Location: Evaporator compartment
Remove the protective cover and
disconnect the I/O B module