PREVOST X3-45 Owner's manual

COACH MANUFACTURER

OPERATOR’S MANUAL

X3-45 COACH

PA1581

PA1581 1ST Edition

Date: January, 2011

Starting from vehicle: A-9926, B-9965, B-9971, B-9992, B-5002

Featuring: EPA 2010

Foreword

i

This Operator's Manual for the PREVOST X3-

45 coach conforms with the new EPA 2010

regulations, featuring an engine with selective

catalytic reduction SCR system. This manual

has been prepared to thoroughly acquaint you,

the driver, with the equipment and features of

the coach in order for you to fully appreciate and

safely enjoy this vehicle. Prevost is committed to

the continuous improvement of coach quality,

reliability, durability and safety. With innovative

features, the X3 series coach was designed with

passenger and driver safety and comfort in mind.

This manual contains information available at the

time of publication. Because standard and

optional equipment is covered in this manual,

some of the optional equipment described may

not apply to your coach. If in doubt, refer to the

technical documentation package provided with

the coach.

Driver's controls and instruments incorporate

advanced technology for enhanced driving ease

and security. This manual describes the main

features, instruments and controls, and servicing

requirements for both standard and optional

equipment. Read this manual carefully to take

advantage of the coach's advanced features and

to ensure optimum safety and passenger comfort.

Keep this manual in the coach at all times. Make

sure this manual is kept with the coach when

ownership is transferred. Please use the

appropriate card at the end of this manual to

promptly notify Prevost of any change of address

or transfer of ownership. This will ensure we

provide fast and reliable coach service to all

coach operators.

DANGER, WARNING, CAUTION and NOTE. are

used throughout this manual to emphasize

important points when necessary:

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.

The service life of the coach depends on the kind

of attention it receives. Pay close attention to the

DANGER, WARNING, CAUTION and NOTE.

Read the various notices and instructions posted

throughout the coach and attached to equipment.

Since continuous improvement is a primary focus at Prevost,

we reserve the right to make changes anytime, without notice,

and without incurring any obligation.

Before reproducing or copying this manual, in whole or in

part, written consent must be obtained from Prevost.

Table of Contents

iii

SAFETY PRECAUTIONS................................................................................................ 1

COACH EXTERIOR......................................................................................................... 5

COACH INTERIOR ....................................................................................................... 19

CONTROLS AND INSTRUMENTS ............................................................................... 29

OTHER FEATURES ...................................................................................................... 89

STARTING AND STOPPING PROCEDURE............................................................... 123

SAFETY FEATURES AND EQUIPMENT.................................................................... 129

CARE AND MAINTENANCE....................................................................................... 143

TECHNICAL INFORMATION ...................................................................................... 163

ABBREVIATIONS ....................................................................................................... 175

APPENDIX A – SERVICE LITERATURE.................................................................... 177

APPENDIX B – TROUBLESHOOTING GUIDE FOR MULTIPLEX VEHICLES.......... 181

APPENDIX C – ALLISON DIAGNOSTIC TROUBLESHOOTING CODES ................. 187

APPENDIX D – SPHEROS PREHEATER FLASH CODES ........................................ 199

APPENDIX E – TPMS TROUBLESHOOTING GUIDE................................................ 201

INDEX ......................................................................................................................... 203

Safety Precautions 1

SAFE OPERATING PRACTICES ................................................................................................................ 2

DEFENSIVE DRIVING PRACTICES............................................................................................................ 2

OTHER PRECAUTIONS .............................................................................................................................. 3

Safety Precautions

2

SAFE OPERATING PRACTICES

To ensure safe and reliable operation, heed the

following safety precautions.

• Operation and maintenance of the vehicle

must be performed only by qualified

personnel.

• Before driving, conduct a walk around

inspection and check that all baggage

compartment doors and equipment access

doors are securely shut.

• Make sure good visibility is maintained at all

times. Keep windshields clean and free of

obstructions.

• Adjust the driver's seat so that all controls

can be reached easily.

• Always wear your safety belt when driving.

• Check the instrument panel frequently. Do

not operate the vehicle when dials or

indicators do not indicate normal operating

conditions.

• Always pay attention to pedestrians passing

in front and behind the vehicle. Always yield

to pedestrians at pedestrian walkways.

• Do not drive over obstacles on the road.

Empty boxes, piles of leaves, and snowdrifts

could conceal hidden dangers that could

damage the vehicle suspension and

underbody.

• When turning or changing lanes, signal your

intention well in advance.

• When approaching to make a right turn,

reduce the space between the vehicle and

the curb to make sure another vehicle

cannot pass on the right. Since the vehicle

makes wide turns, allow enough space to

make safe turns.

• Switch from high beams to low beams when

meeting or following other vehicles within

500 feet (150 meters).

• Never leave the vehicle unattended with the

engine running or with the key in the ignition.

Turn off the engine, remove keys and apply

the parking brake before leaving the vehicle.

• Shut-off the engine before refueling, adding

oil, performing maintenance or servicing

tasks, unless stated otherwise.

• Fuel is highly flammable and explosive. Do

not smoke when refueling. Keep away from

open flames or sparks.

• Do not run the engine or HVAC system with

access doors left open. Close compartment

doors before operating any equipment.

• Do not remove the surge tank filler cap or

the cooling system pressure cap when the

engine is hot. Let the engine cool down

before removing filler caps.

• Do not attempt to push or pull-start the

vehicle.

• The service life of the vehicle depends on

the kind of maintenance it receives. Always

record any problems and report them

immediately to maintenance personnel.

DEFENSIVE DRIVING PRACTICES

• For city driving, allow a four to six second

travel interval between your vehicle and the

vehicle ahead. Increase this travel interval to

six to eight seconds for highway driving.

Increase time interval for driving at night or

in foul weather.

• Be prepared to stop when approaching an

intersection. The stopping distance of the

vehicle increases with the weight and speed.

• Establish eye-to-eye contact with other

drivers and with pedestrians. Use, high

beam and low beam headlights, turn signals

and horn as needed.

• On highway, don't stare at the road ahead.

Keep your eyes moving. Check mirrors and

dashboard instruments frequently.

• To keep the vehicle from drifting across

lanes during highway driving, always look

over the horizon on the road ahead.

• Adjust your speed to road conditions, traffic

and visibility. Never exceed the posted

speed limits.

• If another vehicle is following close behind,

reduce your speed to let the vehicle pass.

• For additional information about safe

operation and defensive driving practices,

contact the local department of motor

vehicles authority.

Safety Precautions

3

OTHER PRECAUTIONS

DANGER

Make sure that electrical current or air

pressure is removed before performing any

work. A part may be energized even if the

ignition switch is OFF. A part may be under

pressure even if all tanks are empty. Before

performing any work on the vehicle, refer to

wiring diagrams and/or air schematics to

thoroughly understand the system.

CAUTION

Disconnect all electronic control modules

before welding. If modules (ECM, TCM, ECU,

ABS) are not disconnected before welding is

done, there is a high risk of destroying the

electronic components (EPROM, Chip). Refer

to procedure described in Maintenance

Manual.

Coach Exterior

5

ENGINE COMPARTMENT COMPONENTS................................................................................................ 7

ENGINE COMPARTMENT........................................................................................................................... 8

ENGINE COMPARTMENT CURB-SIDE DOOR ..................................................................................... 8

ENGINE COMPARTMENT REAR DOORS............................................................................................. 8

EXHAUST AFTERTREATMENT SYSTEM ACCESS DOOR...................................................................... 9

ENGINE RADIATOR DOOR ........................................................................................................................ 9

CATALYTIC CONVERTER ACCESS DOOR .............................................................................................. 9

CONDENSER COMPARTMENT (A/C)...................................................................................................... 10

EVAPORATOR COMPARTMENT ............................................................................................................. 10

COOLANT HEATER COMPARTMENT..................................................................................................... 11

FRONT ELECTRICAL AND SERVICE COMPARTMENT ........................................................................ 11

BAGGAGE COMPARTMENTS.................................................................................................................. 12

SPARE WHEEL COMPARTMENT ............................................................................................................ 13

FUEL AND DIESEL EXHAUST FLUID (DEF) FILLER DOOR.................................................................. 13

ENTRANCE DOOR .................................................................................................................................... 14

DOOR OPERATION LOGIC.................................................................................................................. 14

EMERGENCY ENTRANCE DOOR OPENING ..................................................................................... 15

WHEELCHAIR LIFT ACCESS DOORS..................................................................................................... 15

REAR VIEW MIRRORS.............................................................................................................................. 15

BACK-UP CAMERA................................................................................................................................... 16

110-120 VOLTS CONNECTOR.................................................................................................................. 16

HUBODOMETER........................................................................................................................................ 16

TRAILER HITCH......................................................................................................................................... 16

Coach Exterior

6

X3-45 EXTERIOR VIEW (TYPICAL) 18606

1. Engine air intake

2. Engine compartment curb-side door

3. Hinged rear fender

4. Baggage compartment

5. Fuel filler door

6. Condenser compartment

7. Entrance door control switch

8. Entrance door

9. Engine compartment rear doors

10. Rear-view mirrors

11. Spare wheel compartment

12. Front electrical and service compartment

13. Driver’s power window

14. Evaporator compartment and coolant heater compartment

15. Radiator door

16. Catalytic converter access door

17. Exhaust aftertreatment system access door

Coach Exterior

7

ENGINE COMPARTMENT COMPONENTS

ENGINE COMPARTMENT FEATURING VOLVO D13 ENGINE 01184

1. Diesel Oxidation Catalyst (DOC) & Diesel Particulate Filter (DPF) Assembly;

2. Transmission fluid dipstick (if equipped with Allison transmission);

3. Coolant fluid surge tank filler cap;

4. Coolant fluid surge tank sight glass;

5. Air filter restriction indicator;

6. Engine oil dipstick;

7. Belt tensioner control valve;

8. Starter selector switch and Engine rear start push-button switch, Engine compartment Lights Switch;

9. Power steering fluid reservoir;

10. Radiator fan;

11. Radiator fan drive mechanism support;

12. Alternators;

13. Engine oil filler tube;

14. Central A/C compressor;

15. Air filter;

16. Auxiliary A/C compressor (if equipped with parcel rack cooling system);

Coach Exterior

8

ENGINE COMPARTMENT

ENGINE COMPARTMENT CURB-SIDE DOOR

The engine compartment curb-side door

provides access to the following (if equipped):

• Engine compartment rear doors release

handle;

• Booster terminals;

• Rear electrical panel;

• Rear junction panel;

• Battery compartment;

• Fuel filter/water separator (Optional);

• Air circuit fill valve and drain cock;

• Sump tank access cap;

• 110 - 120 volt connector;

• Lavatory maintenance valve and

connectors;

• Fresh water reservoir fill connector;

ENGINE COMPARTMENT CURB-SIDE DOOR 18559

This door can be locked or unlocked using the

exterior compartment key or, if so equipped, by

the central door locking system. To open, push

sideways on the small lever located between the

marker lights.

NOTE

This compartment can be locked/unlocked

using the central locking system by pressing

the switch located on the L.H. side dashboard

panel.

ENGINE COMPARTMENT R.H. SIDE 18607

A telltale light illuminates when one or more

compartments are unlocked.

ENGINE COMPARTMENT REAR DOORS

To open the engine compartment rear doors,

open the engine compartment curb side door

and pull the handle located on the rear door,

close to the bottom door hinge.

WARNING

Unless otherwise stated, do not run the

engine when the engine compartment is

open.

These doors swing out to provide access to the

following:

• Engine;

• Alternator(s);

• Compressor(s);

• Belt tension control valve (refer to chapter,

Care and Maintenance);

• Engine starting selector (refer to chapter,

Starting and Stopping Procedures);

• Coolant line shutoff valves;

• Certification plates;

• Engine coolant surge tank and filler cap;

• Air filter restriction indicator;

• Engine oil dipstick;

• Power steering fluid reserve tank;

• Allison automatic transmission fluid dipstick;

Coach Exterior

9

A catch holding each door open engages when

the door is fully open. Release the catches

before closing the doors. Close the L.H. door

first, then firmly shut the R.H. door.

OPENING ENGINE COMPARTMENT REAR DOORS 18608

Turn the lights ON in the engine compartment

using the switch on the rear start panel.

WARNING

Unless otherwise specified, do not run engine

when the engine compartment rear doors are

open. Close the engine compartment rear

doors before starting the engine.

EXHAUST AFTERTREATMENT

SYSTEM ACCESS DOOR

The engine door must be

open before opening the

exhaust aftertreatment

system access door. To

open the access door,

lower the latch release

lever, using a flat tip

screwdriver.

To close the door, lower the door and push

against the release lever spring to latch the door

shut.

ENGINE RADIATOR DOOR

Open the engine radiator door by pushing the

release lever sideways.

RADIATOR DOOR 18560

CATALYTIC CONVERTER ACCESS

DOOR

To gain access to the catalytic converter, open

the radiator door first. At the top of the radiator

compartment, pull the catch connecting rod to

unlock the catalytic converter access door and

lift the door open.

Hold the door open by inserting the support rod

free end into the receptacle located on the left

side of the DPF.

Coach Exterior

10

ACCESS TO THE CATALYTIC CONVERTER 04023

WARNING

After inserting the support rod into the

receptacle, make sure the rod supports the

door securely from falling down on to your

head or body.

WARNING

External and internal temperatures remain hot

long after engine has been shutdown. Allow

the Exhaust Aftertreatment System to cool

before handling. Wear protective clothing and

glove while servicing.

CONDENSER COMPARTMENT (A/C)

Pull the release latch located inside the adjacent

baggage compartment to open the condenser

door.

The condenser compartment provides access to

the following:

• Diesel Exhaust Fluid (DEF) Tank

• Condenser;

• Condenser fans and motors;

• Filter dryer and moisture indicator;

• Receiver tank;

CONDENSER COMPARTMENT (A/C) 22299

EVAPORATOR COMPARTMENT

The HVAC (Heating, Ventilating and Air-

Conditioning) evaporator blower and coolant

heater are located in this compartment. The

compartment door release latch is located on

the right side of the baggage compartment and

to the left of the HVAC compartment door. Pull

the release latch then swing the HVAC

compartment door open.

EVAPORATOR COMPARTMENT

Coach Exterior

11

EVAPORATOR COMPARTMENT 22274

RECIRCULATION DAMPER 22302

In case of damage or malfunction of the

evaporator compartment door release latch, the

door can still be opened using the access hole

located forward of the compartment.

Insert a small rod through the access hole to

release the latch.

EVAPORATOR COMPARTMENT DOOR RELEASE LATCH

ACCESS HOLE

COOLANT HEATER COMPARTMENT

The vehicle may be equipped with the optional

preheater located aft of the evaporator

compartment, inside the engine coolant heater

compartment and accessible through the

evaporator compartment door.

COOLANT HEATER COMPARTMENT

The water recirculating pump is also located in

the engine coolant heater compartment.

FRONT ELECTRICAL AND SERVICE

COMPARTMENT

To open the front electrical and service

compartment door, pull the rod inside the

vehicle, next to the driver’s power window or use

the key to open from outside the coach. The

front electrical and service compartment

provides access to the following:

• Front terminal block;

• VECU with Volvo D13 engine;

• Vehicle Electrical Center Front (VECF),

CECM and Multiplex Modules;

• Relays and fuses;

• ABS Electronic Control Unit (ECU);

• Emergency door opening unlatch valve;

• Windshield washer reservoir & headlights

washer reservoir (optional);

• Accessory system fill valve;

• Accessory air tank drain valve;

• Jack and tools.

Coach Exterior

12

FRONT SERVICE COMPARTMENT DOOR 18610

This compartment door can be locked/unlocked

using the exterior compartment key.

The light in the front electrical and service

compartment turns ON automatically when the

door is opened.

NOTE

Jack and tools are located inside the front

electrical and service compartment.

FRONT ELECTRICAL COMPARTMENT 06673

FRONT SERVICE COMPARTMENT 18611

BAGGAGE COMPARTMENTS

The baggage compartments of the X3-45 Coach

provide 406 ft3 (11.5 m3) of storage capacity.

The compartments can be locked or unlocked

by using the exterior compartment key. Pull up

operating handle to release the latch, and then

pull the door open. Pressurized cylinders assist

the opening and closing of the baggage

compartment doors and hold the doors open.

BAGGAGE DOOR LOCK AND LEVER 18043

To close, pull the door down by the handle rod.

Complete the closing of the door by returning

the operating handle to its initial position.

CAUTION

Do not slam shut the baggage compartment

doors. Damage to door weather-stripping or

locking mechanism could result.

Lights in the baggage compartments turn ON

automatically when the door is opened.

BAGGAGE DOOR CATCH 18612

Coach Exterior

13

NOTE

For added safety, open the door until the

catch assist in holding the door in the open

position.

NOTE

The baggage compartment doors can be

locked/unlocked from the driver's position by

the optional central locking system. The switch

is on the L.H. control panel. Refer to "Controls

& Instruments" chapter.

WARNING

To avoid injury, keep hands clear of baggage

compartment door edge and door frame when

closing.

NOTE

To prevent theft and vandalism, always lock

the baggage compartment doors before

leaving the vehicle unattended.

SPARE WHEEL COMPARTMENT

The front bumper can be tilted downward to give

access to the spare wheel.

WARNING

The compartment behind the bumper is not

designed for miscellaneous storage. Never

store loose objects in this compartment since

they can interfere with the steering linkage

mechanism.

Pull the release handle located inside front

service compartment to tilt down the entire

bumper assembly.

RELEASE HANDLE 18613

SPARE WHEEL IN FRONT BUMPER COMPARTMENT 18614

WARNING

Although a powerful spring assists in reclining

the bumper, it remains heavy and rests low

when open. Caution should be used when

reclining.

Check that bumper is securely closed shut

before driving.

FUEL AND DIESEL EXHAUST FLUID

(DEF) FILLER DOOR

The fuel and Diesel Exhaust Fluid (DEF) filler

door is located on the R.H. side of the coach

providing easy filling. A spring keeps the door

either open or shut. A key is provided for

unlocking the door if the option was chosen.

FUEL & DEF FILLER DOOR 03046

NOTE

Provided the vehicle is parked on level

ground, an automatic nozzle will automatically

shut off when fuel tank is approximately 95%

full.

NOTE

The fuel & DEF filler door must be in the

unlocked position before closing

Coach Exterior

14

CAUTION

Diesel exhaust fluid DEF will begin to

crystallize and freeze at 12°F (-11°C) and

expand by 7% when frozen. To allow

expansion without damaging the DEF tank, do

not fill the tank with more than 15.9 gallons

(60 liters).

CAUTION

Do not fill to more than 95% of the fuel tank

capacity. Do not "top off" the tank, doing so

may result in fuel spillage when the fuel

expands.

ENTRANCE DOOR

Lock or unlock the entrance door from outside

the vehicle by turning the key in the door lock

(counterclockwise to lock, clockwise to unlock).

From outside, open the door by pushing the

switch forward, close by pushing the switch

rearward.

The only way to unlock the entrance door from

the inside is by sliding its lock lever to the left. If

the orange tab on the door-lock lever is visible,

the door is unlocked.

ENTRANCE DOOR EXTERIOR SWITCH 18599

From the inside, open the door by pressing the

door opening switch (L.H. button) on the R.H.

dashboard panel. Close by pressing the door

closing switch (R.H. button) on the dashboard.

Refer to “Controls and Instruments” chapter for

more information.

ENTRANCE DOOR 18001

ENTRANCE DOOR & WIPER CONTROL PANEL 06614

DOOR OPERATION LOGIC

If the switch is held in position until the door is

fully open or closed, the system holds pressure

in the door cylinder, locking the door in that

position. The door can be opened to any

position by releasing the switch (or button, if

inside) when the desired position is attained.

However, the door is not locked in any position

other than fully open or fully closed. The door

can then be opened or closed further by pushing

or pulling on the door.

A proximity sensor will finish the closing of the

door when it senses the door is almost shut.

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PREVOST X3-45 Owner's manual

PREVOST X3-45 Owner's manual

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