IS-18025A Service Bulletin/Repair Instructions

Instruction Sheet
IS-18025 A
KNEELING LEVEL SENSOR REPLACEMENT

REVISION : A
THIS BULLETIN SUPERSEDES PREVIOUS VERSION.
2019 06 03
Reference for air spring clearance values updated
Description:

This instruction sheet shows how to replace kneeling level sensor #21643575 by sensor #22194741.
APPLICATION FOR FRONT I-BEAM AXLE SUSPENSION

Model
VIN

From 2PCH33499CC712007

up to

2PCH33498EC712504 incl.
H3-45 coaches

Model Year : 2012 - 2014
KIT

TO

ORDER
PAGE
132117
2
132119
10
KIT

TO

ORDER
PAGE
132118
19
From 2PCH33491EC712506

up to

2PCH33491FC712815 incl.
H3-45 coaches

Model Year : 2014 - 2015
From 2PCG33493EC735538

up to

2PCG33491FC735796 incl.
X3-45 coaches

Model Year : 2014 - 2015

X3-45 Commuter
4RKG33497F9737001
Model Year : 2015
APPLICATION FOR INDEPENDENT FRONT SUSPENSION (IFS)

Model

H3-45 coaches

Model Year : 2012 - 2013
X3-45 coaches

Model Year : 2012 - 2013
VIN

2PCH33495CC712019

2PCH33499DC712235

2PCH33494DC712272
2PCH33491CC712020

2PCH33490DC712236

2PCH33495DC712362
2PCG33496CC735241 2PCG33498CC735242

2PCG33491CC735275 2PCG33493CC735276

2PCG3349XCC735291 2PCG33490DC735382

2PCG33492DC735383 2PCG3349XDC735387

2PCG33491DC735388 2PCG3349XDC735390

2PCG33491DC735391 2PCG33493DC735392

2PCG33495DC735393 2PCG33497DC735444

2PCG33496DC735449
NOTE

Material can be obtained through regular channels.
Writer: ml
IS-18025 A

Page 2 / 26
H3 FRONT I-BEAM AXLE SUSPENSION (2012-2014)

Order kit # 132117 that contains the following parts:

Part No.

22194741
Description
Qty
SENSOR
1
132123
C-SHAPE ADAPTOR
1
132121
SENSOR ARM ASSEMBLY
1
5001745
SCR CAP HEX N500 M8X25 G8.8
4
502851
NUT HEX N500 M8-1.25
5
500321
WSH BEL SPR N500 .331X.827X.098(M8,5/16)
5
5001736
WSH FL N500 8.4X18X2 (M8,5/16)
2
504637
CABLE TIE MIDDLE SIZE
4
IS-18025
INSTRUCTION SHEET
1
FI-18025
FEUILLE D’INSTRUCTIONS
1
PROCEDURE
DANGER

Park vehicle safely, apply parking brake, stop the engine. Prior to working on the vehicle, set the

ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On

Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
EXISTING ARM AND LEVEL SENSOR REMOVAL

1. Raise the vehicle with safe lifting equipment

and procedures.

2. Remove cable ties that support the sensor

wiring.

3. Unscrew the sensor connector cap and

disconnect the wiring.
FIGURE 1
Writer: ml
IS-18025 A

Page 3 / 26
4. Disconnect the top of the valve connecting

rod with the valve lever.

5. Keep fasteners for reinstallation.
FIGURE 2
6. Dismount the existing sensor arm from the

existing sensor and from the valve lever.

7. Discard the arm and the fasteners.
FIGURE 3
8. Dismount sensor (2 screws).

9. Discard sensor and fasteners.
FIGURE 4
Writer: ml
IS-18025 A

Page 4 / 26
10. Remove rust on the valve lever, clean it and

apply liquid lubricant. Do these operations on

four faces and only half of the lever

(connecting rod side).
FIGURE 5
11. Remove rust on the sensor bracket mounting

faces and clean it.
FIGURE 6
Writer: ml
IS-18025 A

Page 5 / 26
NEW ARM AND LEVEL SENSOR INSTALLATION

12. Assemble the sensor with the ‘’C-shape’’

support.
NOTE

Never alter the sensor for any reason.

Make sure the flat on the sensor rotor is

orientated as shown in Figure 7.
NOTE

Screw head must be inside the ‘’C-shape’’

support.

Install flat washers with the screw head side

and Belleville washers on the nut side.
FIGURE 7
13. The ‘’C-shape’’ support has arced slots to

allow angle adjustment of the sensor.

Orientate the sensor with the screws in the

middle of the arced slots and tighten.
FIGURE 8
14. Install the ‘’C-shape’’ support with the sensor

on the vehicle structural bracket.

15. Tighten the nuts.
NOTE

Screw head must be inside the ‘’C-shape’’

support.

Install Belleville washers on the nut side.
FIGURE 9
Writer: ml
IS-18025 A

Page 6 / 26
16. Install the sensor arm slider on the valve

lever.

17. Reinstall the connecting rod on the valve

lever.
FIGURE 10
18. Install new arm on the sensor. Use Belleville

washer and tighten the nut.
FIGURE 11
Writer: ml
IS-18025 A

Page 7 / 26
19. Connect existing wiring to sensor and screw

the sensor connector cap.

20. Secure the wiring with cable ties.
FIGURE 12
LEVEL SENSOR ANGLE ADJUSTMENT
FOR VEHICLES C-2007 UP TO D-2363 USE DIAGRAM D061140 P32.1 REV.04 or REV.06
FOR VEHICLES D-2364 UP E-2504 USE DIAGRAM D061340 PAGE 32.1 REV.0
Writer: ml
IS-18025 A

Page 8 / 26
21. Run the vehicle 5 minutes to fill the

pneumatic system with air pressure.

22. Go on the Technical Publications website at

this link:

23. https://techpub.prevostcar.com/en/manuals

24. Select the Technical Manual tab.

25. Enter the short VIN of you vehicle.

26. Select ‘’Maintenance’’ as Manual type and

click on the Search button.

27. Click on ‘’File List’’ button.

28. Download the Suspension section file.
FIGURE 13
29. Use ‘’spring clearance’’ words with the

search tool to find the information about the

clearance for I-Beam and Independent

suspension clearance values.
FIGURE 14
30. Into the front service compartment, locate

A46 module for vehicles C-2007 up to D2363 or A45 module for vehicles D-2364 up

E-2504.
FIGURE 15
Writer: ml
IS-18025 A

Page 9 / 26
31. Locate pin 13 on connector A46-J1 for

vehicles C-2007 up to D-2363 or on

connector A45-J1 for vehicles D-2364 up E2504.
NOTE

The wire color is white and the wire ID should

be ‘’KneelLevel’’.
FIGURE 16
32. With a voltmeter, back probe pin 13. The

voltage should be around 2.5 volts with the

normal clearance.
FIGURE 17
33. If the voltage is higher or lower than 2.5

volts, loosen the nuts that fix the sensor to

the ‘’C-shape’’ support and apply a slight

rotation.

34. Tighten the nuts, check the suspension

below clearance and the voltage.

35. Repeat previous steps until you reach 2.5

volts with the clearance.
FIGURE 18
36. Using the kneeling dash switch, adjust the vehicle at its maximum height by pressing and maintaining

the upper part of the switch. Check the voltage. It should be around 3.5 volts.

37. Using the kneeling dash switch, adjust the vehicle at its minimum height. Check the voltage. It should

be around 1.8 volts.

38. Bulletin is complete for this installation.
Writer: ml
IS-18025 A

Page 10 / 26
H3/X3 FRONT I-BEAM AXLE SUSPENSION (2014-2015)

Order kit # 132119 that contains the following parts:

Part No.

22194741
Description
Qty
SENSOR
1
132126
C-SHAPE ADAPTOR
1
132124
SENSOR ARM ASSEMBLY
1
5001745
SCREW CAP HEX N500 M8X25 G8.8
4
502851
NUT HEX N500 M8-1.25
5
500321
WASHER BELLEVILLE N500 .331X.827X.098(M8,5/16)
5
5001736
FLAT WASHER N500 8.4X18X2 (M8,5/16)
2
504637
CABLE TIE MIDDLE SIZE
4
IS-18025
INSTRUCTION SHEET
1
FI-18025
FEUILLE D’INSTRUCTIONS
1
PROCEDURE
DANGER

Park vehicle safely, apply parking brake, stop the engine. Prior to working on the vehicle, set the

ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On

Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
EXISTING ARM AND LEVEL SENSOR REMOVAL

39. Raise the vehicle with safe lifting equipment

and procedures.

40. Remove cable ties that support the sensor

wiring.

41. Unscrew the sensor connector cap and

disconnect the wiring.
FIGURE 19
Writer: ml
IS-18025 A

Page 11 / 26
42. Disconnect the top of the valve connecting

rod with the valve lever.

43. Keep fasteners for reinstallation.
FIGURE 20
44. Dismount the existing sensor arm from the

existing sensor and from the valve lever.

45. Discard the arm and the fasteners.
FIGURE 21
46. Dismount sensor (2 screws).

47. Discard sensor and fasteners.
FIGURE 22
Writer: ml
IS-18025 A

Page 12 / 26
48. Remove rust on the valve lever, clean it and

apply liquid lubricant. Do these operations on

four faces and only half of the lever

(connecting rod side).
FIGURE 23
49. Remove rust on the sensor bracket mounting

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