SP16-19 Service Bulletin/Repair Instructions

Special Bulletin
SP16-19

Date
Expiration
Release
Page
04.2016
04.2018
1
1(3)
VOLVO D13 ENGINE – DOUBLE IDLER GEAR PINNING

Prevost vehicles
DESCRIPTION

On certain vehicles equipped with VOLVO D13 engines, the pinning of the double idler gear is necessary.

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.
PROCEDURE
Please refer to Impact service procedure “SP215-017 DOUBLE IDLER GEAR PINNING

MODIFICATION”., found under Function Group 215.

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
X3-45 Coaches equipped

with Volvo engine

Model Year : 2012
vehicles affected
2PCG33491CC735115
2PCG33499CC735122
2PCG33493CC735116
2PCG33496CC735126
2PCG33495CC735117
2PCG33498CC735127
2PCG33497CC735118
2PCG3349XCC735128
2PCG33499CC735119
2PCG33491CC735129
2PCG33495CC735120
2PCG33498CC735130
2PCG33497CC735121
2PCG33491CC735132
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
SP16-19

Date
Expiration
Release
Page
04.2016
04.2018
1
2(3)
MATERIAL NEEDED

Part description
Deleted part No
New part No
Consumable Kit
NA
21934132
1
21925072
1
Fixture Kit
Quantity
Note: One Consumable Kit 21934132 contains the parts required to perform 5 pinning modifications.
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.
PARTS / WASTE DISPOSAL

Return the double idler gear to Prevost.
WARRANTY

This modification is covered by Prevost’s normal warranty.
 Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
Special Bulletin
SP16-19

Date
Expiration
Release
Page
04.2016
04.2018
1
3(3)
The estimated time required to perform this Special Bulletin SP16-19 is approximately 7 hrs.

Please use the standard text SP16-19 with system condition letter “B”.
OTHER

VBC Bulletin
tbc
Fail Code
01.00-2
Defect Code
09
System Condition
B
Causal Part
21760930
 Special Bulletin SP - [Diffusé] No. Révision: 4 - Date de diffusion: 2011-06-22 15:28:22
S ervic e P rogram

Bus
Vo l v o B u s C o rp o ra t i o n

Göteborg, Sweden
Date
This service program replaces program 215-017 dated

5.2012.
8.2012
Group
No.
215 017
Release
Page
02
1(23)
Double Idler Gear Pinning Modification

D13
S P 215-017, Doubl e Idler Gear P inni ng

Modifi cati on

(Au gust 2 012)

Volvo Bus Corporation has authorized a pinning modification of the double idler gear on

certain US07 and EPA2010 emission level vehicles equipped with VOLVO D13F and D13H

engines. The double idler gear must be pinned on all vehicles involved in this campaign.

B e fore perf ormi ng th is p roc e dure, y ou mus t v iew th e D oubl e Idl er Ge ar P i nni ng

M o d i f i c a t i o n a n i m a t i o n . G o t o Tr u c k s D e a l e r P o r t a l , c l i c k o n S E R V I C E t a b , s e l e c t “ t e c h

s u p p o rt ” i n l i s t o n l e ft s i d e o f p a g e a n d s e l e c t “t e c h n i c a l v i d e o s ” to v i e w a n i ma ti o n .

N ot e: Whe n perfo rmi ng thi s proc edu re if y ou enc ount er any s ig ns of i dl er gear fa il ure

or the idler bearing nu t loo se, s top the repair and ope n an E-Se rvice c ase . As sign it to

Te c h n i c a l S u p p o r t a n d i n t h e D e s c r. / C o m p l . f i e l d p u t “ I d l e r Ge a r C a mp a i g n F a i l u r e ” .

Des cribe th e d etails of th e failure a nd attach pic tures of the fa ilure to the cas e.

You must make an appointment as soon as possible at one of Prevost Service Centers or

Prevost Certified Service Providers. Please, contact your Prevost Regional Service Manager

to find out the nearest service center location.
R eq ui red P a rt s
•

•
1 — 21934132 - Consumable Kit

1 — 21925072 - Fixture Kit
One Fixture Kit 21925072 was pre-shipped to each Dealer through the essential tool

program.

One Consumable Kit 21934132 was also pre-shipped to each Dealer through the essential

tool program and contains the parts required to perform 5 pinning modifications. The

Consumable Kit can only be shipped Class 3 (ground freight).

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.
USA55203
89069765

English
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
P roc edu re

You must read and understand the precautions and guidelines in Service Information,

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.

1 Apply parking brake and place shift lever in neutral.

2 Open the engine compartment. Move the starter select switch to the OFF position to

disable the engine.
W2006494
3 Remove all cables from ground (negative) battery terminals to prevent personal injury from

electrical shock.

4 Drain coolant from radiator and engine using coolant extractor (85112740). Save coolant.

N o t e : An alternate method is to connect drain hose (9990649) to drain fitting and drain

coolant. Save the coolant in an appropriate container and cover container to prevent

contaminates from getting in the coolant.

5 On 9700 and PrevX vehicles, remove transmission. Refer to Function Group 43.

6 Remove rear engine coolant pipe mounts.

7 Uncouple coolant lines at rear of engine. Clean rear of engine with shop towels and

cleaner adjacent to the crankshaft speed sensor and PTO cover. Remove PTO cover and

discard O-ring.

8 On 9700 vehicles, remove hydraulic pump.
Page

2(23)
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
9 Set up a magnetic stand (9999696) and dial indicator (9999683) on timing gear plate.

Position indicator perpendicular to rear face of double idler gear. Zero indicator.
10 By hand, with moderate force, attempt to move gear back and forth in direction of

measurement. D O N O T U S E A P R Y B A R . Measure gear movement in three evenly

spaced locations on gear by turning engine with flywheel turning tool (88800014).

If gear movement is greater than 0.05 mm (0.002 in) in any position, a possible nut/gear

failure has occurred. Stop the repair and open an E-Service case. Assign it to Technical

Support and in the Descr./Compl. field put “Idler Gear Campaign Failure”. Describe the

details of the failure and attach pictures of the failure to the case.

If gear movement is less than or equal to 0.05 mm (0.002 in) in each position, continue to next

step.

11 Remove flywheel turning tool.

12 Reinstall PTO cover with new O-ring (part number 976068) provided in Consumable kit.
Page

3(23)
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
13 Loosely chuck 5/8 x 6 inch drill bit provided in Fixture kit into high speed drill. Slide 5/8 inch

drill stop provided in Fixture kit over drill bit and allow it to rest against chuck. Set drill

protrusion beyond drill stop to 80 ±3 mm (3.125 ±0.125 in) to drill bit shoulder and tighten

chuck securely.
CAUTION

The drill stop must be positioned correctly. If drill stop is not positioned correctly, severe

damage to engine can result.
14 If necessary, remove clamp and bracket securing air compressor discharge line.

15 Disconnect crankshaft speed sensor and clip ties securing harness. Remove crankshaft

speed sensor and discard sensor O-ring. Disconnect EGR valve oil drain hose from

flywheel housing and cover hose opening to prevent contamination.
Page

4(23)
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
16 Install 5/8 inch flywheel housing drill fixture provided in Fixture kit into crankshaft speed

sensor hole. Use M18 hold down bolt provided in Fixture kit in EGR valve oil drain port to

secure drill fixture to flywheel housing. Tighten bolt to 24 ±4 Nm (18 ±3 ft-lb).
5/8 inch Flywheel Drill Fixture and M18 Hold Down Bolt

17 Use chip vacuum (PT2900) or put a crevice tool attachment on a shop vacuum and

position crevice tool over top of drill fixture. Start vacuum.
Page

5(23)
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
18 Use light pressure to drill an access hole in flywheel housing. Clean drill flutes repeatedly

by pulling drill back until bit is clear of fixture and then continue into flywheel housing.

Chips should clear freely out of rotating flutes. If chips are becoming packed in flutes,

perform flute cleaning process more often. Position vacuum crevice tool over drill area,

between flywheel housing and fixture, during entire drilling process. Once the drilling is

complete, remove drill and continue to use vacuum to collect any chips that may not have

been picked up previously.
WA R N I N G

When drilling always wear proper eye protection. Failure to wear proper eye protection

can result in serious personal injury.
CAUTION

Do not use shop air to blow debris as it could introduce foreign matter into engine and

cause serious engine damage.

N o t e : The flywheel housing is only approximately 6 mm (0.25 in) thick in the drilling area,

so the drill will penetrate the housing relatively quickly.
Page

6(23)
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
19 Make sure all visible debris is cleared away from crankshaft speed sensor hole before

removing drill fixture to prevent anything from dropping into flywheel/clutch area. Remove

drill fixture and install EGR valve oil drain hose.
CAUTION

Carefully follow drilling procedure. Failure to properly follow procedure can result in

significant metal debris entry into engine and potential damage including engine failure.

20 Visually inspect gear through access hole to ensure nut is not loose. If nut is loose, stop

the repair and open an E-Service case. Assign it to Technical Support and in the Descr./

Compl. field put “Idler Gear Campaign Failure”. Describe the details of the failure and

attach pictures of the failure to the case.
Page

7(23)
Vo l v o B u s C o rp o ra t i o n

S e rv ic e P ro gra m
Date

8.2012
Group
No.
Release
215
017
02
21 Chuck 1/4 inch center drill bit provided in Consumable kit into high speed drill. Use Go/No

Go depth gauge provided in Fixture kit to confirm drill protrusion is 69 mm (2.7 in) from

collar to drill bit shoulder (white mark on depth gauge). Make sure drill stop screws are

tightened securely.
CAUTION

The drill stop must be positioned correctly. If drill stop is not positioned correctly, severe

damage to engine can result.

N o t e : The drill stops are pre-assembled with Loctite® to 1/4 inch drill bits. If the drill stop is

not positioned correctly, use heat to break Loctite® loose and reinstall drill stop to correct

depth.

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