NHTSA ID Number: 10044284
Manufacturer Communication Number: SP-12-01-A
TSB/Document Date: 2012-06-05
Summary
PREVOST
: INFORMATION IS BEING PROVIDED REGARDING TWO PROCEDURE METHODS OF PINNING OR REPLACING THE DOUBLE IDLER GEAR, ON CERTAIN VEHICLES ENGINE, THAT IS NECESSARY. *PE UPDATED 4/5/13. *PE
SB-10044284-2627
Special Bulletin
Release 3:
-
SP12-01A
Date
Expiration
Release
Page
01.2012
01.2014
3
1(25)
Addition of an alternate method for the repair: Pinning of the double idler gear
Title changed
VOLVO D13 ENGINE EPA2010 – DOUBLE IDLER GEAR REPAIR
Prevost vehicles
DESCRIPTION
On certain EPA2010 vehicles equipped with VOLVO D13 engines, the pinning or the replacement of the
double idler gear is necessary. US10 engines prior to serial number 964661 are involved. Before
proceeding, verify vehicle eligibility by checking SP (Service Program) status in SAP or Vehicle Warranty
Information tool on Prevost-System tab of the Volvo Trucks Dealer portal or use the Online Warranty
System tool on Prevost web site www.prevostcar.com. Once on Prevost web site, select WARRANTY on
SERVICE tab.
Note: Check SAP or Vehicle Warranty Information tool for any open software bulletin and perform update
before releasing the vehicle.
2 methods available to perform the repair
Method 1 (shorter) - Pinning of the double idler gear
This method is found on “SP215-017 DOUBLE IDLER GEAR PINNING
MODIFICATION” available on Impact and on the Prevost Service Portal under Technical
Publications.
Method 2 (longer) - Replacement of the double idler gear
This method is described in this bulletin. When this repair method has already been
performed on a fleet, you may use this method to complete the remaining vehicles of the
fleet.
Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
Special Bulletin
SP12-01A
Date
Expiration
Release
Page
01.2012
01.2014
3
2(25)
MODEL YEAR(S) AND VEHICLES INVOLVED
NOTICE TO SERVICE CENTERS
Verify vehicle eligibility by checking bulletin status with SAP or Vehicle Warranty Information tool
found on Prevost–Systems tab of the Volvo Trucks Dealer Portal
Models affected
vehicles affected
The following vehicles…
H3-41, H3-45 Coaches
Model Year : 2010 – 2012
2PCH33498AC711573
2PCH33496AC711605
2PCH33495AC711627
2PCH33496AC711636
2PCH33499BC711695
2PCH33499AC711713
And
From 2PCH33496BC711721 up to 2PCH3349XCC711920 incl.
H3 VIP Shells
Model Year : 2011 – 2012
X3-45 Coaches
Model Year : 2010 – 2012
From 2PCVS3494BC711772 up to 2PCVS3490CC711916 incl.
2PCG33498AC729907
2PCG33491BC729992
2PCG33491AC729926
2PCG33498CC735208
2PCG33499BC729965
And From 2PCG33491BC735002 up to 2PCG33497CC735099 incl.
XLII Entertainer
Model Year : 2011
X3 VIP Shells
Model Year : 2012
2PCYS3495BC729971
2PCY33498BC735003
2PCYS3493BC735011
The following vehicles…
2PCY33498BC735017
2PCYS3496BC735018
2PCYS3491BC735024
2PCYS3497BC735089
2PCBS3499CC735070
This bulletin does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified before
delivery. Please refer to SAP or Vehicle Warranty Information tool found on Prevost–Systems tab of the Volvo Trucks Dealer
Portal for exact status.
The above list of VIN was valid at the time of publishing this document. Please refer to SAP for most recent information about
outstanding vehicles
Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
Special Bulletin
SP12-01A
Date
Expiration
Release
Page
01.2012
01.2014
3
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MATERIAL NEEDED FOR METHOD 2
Part description
Deleted part No
New part No
Double Idler gear, Kit
NA
85133936
Quantity per vehicle
1
NOTE
When doing this replacement, if you encounter any signs of damages caused by idler gear failure,
replace damaged parts and repair as required. Many parts not included in the replacement kit might be
needed such as oil filters, flywheel housing etc.
Material can be obtained through regular channels.
To order parts, contact:
Prevost Parts US Customer Service Illinois
2200 Point Blvd, Suite 100
Elgin, Illinois 60123
Toll free phone: 1-800-621-5519 Coach
Tel.: 1-847-844-7680
Prevost Parts Canada Customer Service
Quebec City
2955-A, avenue Watt
Quebec, Quebec G1X 3W1
Toll free phone: 1-800-463-8876
Phone: 1-418-653-0948 Parts
To gain access to Parts Online Ordering or to contact a Regional Sales Manager, go to the Prevost
section of the trucks dealer portal at WWW.TRUCKSDEALERPORTAL.COM.
Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
Special Bulletin
SP12-01A
Date
Expiration
Release
Page
01.2012
01.2014
3
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PROCEDURE – METHOD 2
DANGER
Park vehicle safely, apply parking brake, stop engine. In the battery box, set the battery cut-off switch
to the OFF position prior to working on the vehicle.
You must read and understand the precautions and guidelines in Service Information, Impact, Function Group 20,
"Engine Safety Practices" before performing this procedure. If you are not properly trained and certified in this procedure,
ask your supervisor for training before you perform it.
DANGER
Before beginning any work on any part of the air system, be certain that the air pressure has been
released. Failure to do so may cause a component to violently separate, which can result in serious
personal injury.
DOUBLE IDLER GEAR KIT INCLUDES THE FOLLOWING PARTS
PART NO.
1543896
DESCRIPTION / USE
Crankshaft seal, rear
20817742
Gasket, timing gear cover
1
3092340
Sealant, tube
1
20850815
Gasket, EGR valve
1
21528673
flange screw M10X90, EGR valve mounting
4
20841816
Gasket, EGR hot pipe
2
992065
O-ring, air compressor
1
977030
1
1547252
Gasket, rubber coolant pipe
1
20966752
O-ring, camshaft/crankshaft sensor
2
21007187
Gasket, diffuser pipe
1
967343
2
21185086
Seal, timing cover
2
20493974
Seal, vent
1
20483919
Hexagonal socket screw, idler gear mounting
6
21826610
Idler gear
1
21095726
Seal, flexible pipe
1
21095721
Seal, flexible pipe
1
20555696
1
Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
QTY
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Page
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1)
Apply parking brake and place transmission in neutral.
2)
Open the engine compartment. Place the rear start selector
switch to the OFF position to disable the engine.
3)
Steam clean the engine.
CAUTION
When using a pressure washer to clean the vehicle, do not direct the spray at electrical
components in the engine compartment such as the alternator, starter and compressors. Water
spray from pressure washers can damage electrical components.
4)
Remove all cables from ground (negative) battery terminals to prevent personal injury from
electrical shock.
5)
Remove the engine and transmission from the vehicle. Refer to Impact, Function Group 21.
6)
Secure the engine, transmission and cradle assembly on appropriate stands.
7)
Remove the oil pan drain plug and drain the oil into a clean, suitable container. Install the drain plug
and tighten to 60 ±10 Nm (44 ±7 lbf- ft). Inspect the engine oil for metal contaminants.
CAUTION
The oil container must be clean. The removed oil will be used to fill the engine when the repair is
complete. Dirty oil may put the engine at risk of failure.
NOTE
Use only hand tools when removing and tightening the drain plug. Do not use an air ratchet or similar air
tool.
8)
Drain the air system.
9)
Drain the coolant from the radiator and engine using the coolant extractor (85112740).
NOTE
An alternate method is to connect the drain hose (9990649) to the drain fitting and drain the coolant.
10)
If the vehicle is equipped with an optional transmission oil cooler, disconnect the transmission
cooler lines from the transmission. Plug the lines and the transmission fittings.
11)
Disconnect or remove all electrical connections, air lines and or brackets around transmission.
12)
Remove the starter motor.
Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
Special Bulletin
SP12-01A
Date
Expiration
Release
Page
01.2012
01.2014
3
6(25)
NOTE
Label the wiring to the starter relay.
13)
Place transmission jack under transmission and remove transmission. Refer to Impact, Function
Group 43.
14)
Remove clutch and pressure plate from flywheel with removal jack. Refer to Impact, Function Group
41.
15)
Remove the valve cover fasteners. Remove the valve cover. Refer to Impact, Function Group 21.
16)
Install the flywheel turning tool (88800014). Rotate the
flywheel (crankshaft) until the camshaft is positioned at
top dead center (TDC) and zero mark on flywheel.
17)
Remove the crankshaft sensor.
NOTE
Label the connectors to the camshaft sensor and crankshaft sensor for correct installation.
18)
Remove the flywheel. Refer to Impact, Function Group 21.
19)
If equipped, remove the fastener and P-clamp securing
the line to the mounting bracket on the diffuser pipe.
Disconnect fuel line from aftertreatment injector. Collect
any residual fuel that might be in the line in a suitable
container.
Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
Special Bulletin
SP12-01A
Date
Expiration
Release
Page
01.2012
01.2014
3
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TSB/Document ID: SP-12-01-A
Replacement Service Bulletin Number: SP-12-01-B
MFR Communication Date: 2012-01-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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