SP19-304

Special Bulletin
Date

Expiration

Release

Page

07.2018

07.2020

1

1(12)

First Release

07-26-2019

COMPRESSOR DOOR T-KEY LOCK LUBRICATION - LATCH PIN AND DOOR STOP INSPECTION

Prevost vehicles
DESCRIPTION
On the vehicles affected by this bulletin, the T-Key cylinder lock must be disassembled and lubricated, the
latch pin inspected for damage and replaced as required. The upper and lower door stops must also be
inspected if found broken or missing.
MODEL YEAR(S) AND VEHICLES INVOLVED
NOTICE TO SERVICE CENTERS
Verify vehicle eligibility by checking warranty bulletin status with SAP or via ONLINE WARRANTY
SYSTEM available on Service / Warranty tab of Prevost website.
Model

VIN

Fleet Number

X3-45 Commuter
Model Year : 2014 - 2016

The following individual vehicles:
2PCG33495EC735590, 2PCG33498EC735602
and
From 4RKG33497F9737001 up to
4RKG33491G9737299 incl.

From 2490 up to
2789, incl.

This bulletin does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified
before delivery.

MATERIAL NEEDED
Order the following parts:
Part No.
685353
N/A
684916

Description

Qty

Torque seal - Tamper proof indicator

1

Rubber safe part cleaner (generic)

1

Permatex #31832 High Performance Synthetic Grease

1

Other parts that may be required:
Part No.

Description

Qty

5002025

Upper Door Bumper

1

504339

Upper Bumper Rivet POP Dome SS OE 3.2

1

504454

Lower Door Bumper

1

502839

Lower Bumper Nut M6-1,0

1

2801055

Door Latch Pin

1

Writer: mg

SP19-304

Special Bulletin
PROCEDURE

Date

Expiration

Release

Page

07.2018

07.2020

1

2(12)

DANGER
Park vehicle safely, apply parking brake, stop 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.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.
1.

Locate the cylinder lock cover & actuator rod inside the compressor door (Fig.1).

FIG.1 CYLINDER LOCK COVER & ACTUATOR ROD LOCATION

2.

Remove the four Phillips head screws holding the cover on the side of the door frame and slide the
cover down along the rod to move it out of the way (Fig.2).

FIG.2 CYLINDER LOCK COVER REMOVAL
Writer: mg

SP19-304

Special Bulletin

3.

Date

Expiration

Release

Page

07.2018

07.2020

1

3(12)

Disengage the plastic locking clip to disconnect the actuator rod from the latch plate (Fig.3).

FIG.3 ACTUATOR COVER, ROD AND CLIP

4.

Remove the hex screw retaining the latch plate to the cylinder barrel tip (Fig.4).

FIG.4 BARREL HEX SCREW

Writer: mg

SP19-304

Special Bulletin

5.

Date

Expiration

Release

Page

07.2018

07.2020

1

4(12)

Remove the latch plate (Fig.5).

FIG.5 LATCH PLATE

6.

Push the barrel out of the cylinder & clean all lock cylinder parts. The inside of the cylinder housing,
the spring, the barrel and its O-ring must be cleaned from all dirt and grease using a suitable ORing/rubber safe cleaner (Fig.6).

FIG.6 BARREL OUT OF CYLINDER

Writer: mg

SP19-304

Special Bulletin

7.

Date

Expiration

Release

Page

07.2018

07.2020

1

5(12)

Apply Permatex synthetic grease to the cylinder O-Ring. Also apply a coat of synthetic grease
inside the cylinder housing (Fig.7).

FIG.7 CYLINDER LOCK LUBRICATION POINTS

8.

Reinsert the barrel in the cylinder (notch pointing up); wipe excess grease (Fig.8).

FIG.8 BARREL REINSERTED IN CYLINDER

Writer: mg

SP19-304

Special Bulletin

9.

Date

Expiration

Release

Page

07.2018

07.2020

1

6(12)

Install the latch plate on the cylinder tip. The shorter tab must fit between the two striker plate tabs
and make contact with the upper one as shown in Fig.9.

FIG.9 NEW LATCH INSTALLATION

10.

Secure the latch using the previously removed hex screw (Fig.10). Max torque 88.5 lb-in (apply a
stripe of tamper proof indicator paint (torque seal) to the screw head).

FIG.10 SECURING THE LATCH PLATE

Writer: mg

SP19-304

Special Bulletin
11.

Date

Expiration

Release

Page

07.2018

07.2020

1

7(12)

Insert the plastic clip in the latch perforated tab (Fig.11).

FIG.11 LOCK CLIP INSTALLATION

12.

Reinstall the rod upper end in the clip (make sure that the cylinder cover is in place with the rod
inserted in the cover bottom slot like shown in Fig.12).

FIG.12 ACTUATOR ROD AND COVER INSTALLATION

Writer: mg

SP19-304

Special Bulletin
13.

Date

Expiration

Release

Page

07.2018

07.2020

1

8(12)

Lock the rod in place by pressing the lower “hook” part of the clip over the rod (Fig.13).

FIG.13 ACTUATOR ROD LOCKED

14.

Slide the cover back into position over the cylinder lock mechanism and secure it to the door frame
using the 4 Phillips head screws and locks (apply a stripe of tamper proof indicator paint (torque
seal) to the screw heads (Fig.14)).

FIG.14 COVER REINSTALLATION

Writer: mg

SP19-304

Special Bulletin
15.

Date

Expiration

Release

Page

07.2018

07.2020

1

9(12)

Open and close the door and ensure that the door and door locking mechanism are working
properly (Fig.15).

FIG.15 CHECKING DOOR LOCK MECHANISM FUNCTION

16.

Inspect and replace as required any worn or broken compressor door latch pin. To replace latch
pin, refer to Fig.16 & Fig.17 below and proceed as follow:

Writer: mg

−

Remove the #2 pivot screw securing the #4 actuating arm to the #3 latch bracket.

−

Apply slight pressure to the #5 latch pin tip and disengage the actuating arm from the pin
(and #1 actuating rod as req.).

−

Remove both #7 latch screws holding the latch bracket to the door frame.

−

Remove and discard the latch pin (#6 spring will be reused).

−

Insert new latch pin 2801055 (and spring) into latch bracket opening.

−

Secure the latch mechanism to the door frame using the two latch screws, apply a slight
amount of medium strength thread locker (Loctite blue 243 or equivalent) to the screw
threads. Torque both screws to 7 LB-FT.

−

Apply slight pressure to the latch pin tip and re-engage the actuating arm in the pin slot
(also engage actuating rod).

−

Secure the actuating arm to the latch bracket with the pivot bolt. Apply a slight amount of
medium strength thread locker (Loctite blue 243 or equivalent) to the pivot bolt threads.

−

Check for proper door latch operation (open and close door several times). Once
completed, apply tamper proof indicator paint (torque seal) to the latch screw heads.

SP19-304

Special Bulletin
Date

Expiration

Release

Page

07.2018

07.2020

1

10(12)

FIG.16 COMPRESSOR DOOR LATCH COMPONENTS

FIG.17 NEW LATCH PIN IN BRACKET

Writer: mg

SP19-304

Special Bulletin

17.

Expiration

Release

Page

07.2018

07.2020

1

11(12)

Inspect and replace as required both upper and lower door bumper(s) as shown in Fig.18 & Fig.19.
−

To remove the upper bumper, drill out the center rivet holding the bumper to the structure.

−

Secure a new 5002025 upper bumper to the structure using a 504339 rivet (use appropriate
rivet gun).

−

To remove the lower bumper, unscrew the bumper from the structure bracket.

−

Insert a new 502839 nut in the bracket and screw in a new 504454 bumper.

FIG.18 UPPER BUMPER REMOVAL & INSTALLATION

18.

Date

FIG.19 LOWER BUMPER REMOVAL & INSTALLATION

Reset main circuit breakers and set the battery master switch (master cut-out) to the ON position.

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

ESTIMATED TIME
The time required to perform this special bulletin is approximately 30 minutes (0.5) hour.

Writer: mg

SP19-304

Special Bulletin
Date

Expiration

Release

Page

07.2018

07.2020

1

12(12)

OTHER
VBC Bulletin

N/A

Fail Code

18.05

Defect Code

09

Syst. Cond

B

Causal Part

2800660

Access all our Service Bulletins on

http://techpub.prevostcar.com/en/
or scan the QR-Code with your smart phone.

Prevost engages in a continuous program of testing and evaluating to provide the best possible product. Prevost, however, is not
committed to, or liable for updating existing products.

Writer: mg