PREVOST X3-45 Multiplex User Manual

SECTION 07: TRANSMISSION
PA1562
1
CONTENTS
1. DESCRIPTION ......................................................................................................................................3
1.1 ALLISON AUTOMATIC TRANSMISSION..................................................................................................3
1.1.1 Retarder (if applicable)............................................................................................................3
1.2 ZF-ASTRONIC TRANSMISSION ............................................................................................................3
2. WELDING PROCEDURES ...................................................................................................................4
3. MAINTENANCE ....................................................................................................................................4
3.1 ALLISON TRANSMISSION....................................................................................................................4
3.1.1 Manual Fluid Level Check.......................................................................................................4
3.1.2 Cold Check..............................................................................................................................5
3.1.3 Hot Check................................................................................................................................5
3.1.4 Fluid Level Check Using the Pushbutton Shift Selector..........................................................6
3.1.5 Importance of Proper Fluid Level............................................................................................6
3.1.6 Keeping Oil Clean ...................................................................................................................7
3.1.7 Recommended Automatic Transmission Fluid .......................................................................7
3.1.8 Oil Contamination....................................................................................................................7
3.1.9 Metal Particles.........................................................................................................................7
3.1.10 Coolant Leakage .....................................................................................................................8
3.1.11 Control System Prognostics....................................................................................................8
3.1.12 Oil And Filter Change Interval...............................................................................................11
3.2 ZF AS-TRONIC TRANSMISSION.........................................................................................................13
3.2.1 Oil Change.............................................................................................................................13
3.2.2 ZF AS-TRONIC / SACHS Clutch Installation Procedure ......................................................13
4. INSTALLATION OF ZF OR ALLISON TRANSMISSION BRACKETS ON VEHICLES EQUIPPED
WITH DETROIT DIESEL ENGINE ONLY ...................................................................................................15
5. ALLISON TRANSMISSION REMOVAL .............................................................................................15
6. TRANSMISSION OIL COOLER REMOVAL.......................................................................................16
6.1 TRANSMISSION WITHOUT RETARDER ...............................................................................................16
6.1.1 Detroit Diesel Series 60 Engine ............................................................................................16
6.1.2 Volvo D13 engine..................................................................................................................17
6.2 TRANSMISSION WITH RETARDER .....................................................................................................17
6.2.1 Detroit Diesel Series 60 Engine ............................................................................................17
6.2.2 Volvo D13 Engine..................................................................................................................18
7. CLEANING AND INSPECTION OF ALLISON AUTOMATIC TRANSMISSION................................18
7.1 BREATHER......................................................................................................................................18
8. ALLISON TRANSMISSION INSTALLATION.....................................................................................18
9. ALLISON AUTOMATIC TRANSMISSION TROUBLESHOOTING....................................................20
9.1 4
TH
GENERATION TRANSMISSION CONTROL MODULE.........................................................................20
9.2 DIAGNOSTIC TROUBLESHOOTING CODES (DTC) — ALLISON 4TH GENERATION CONTROLS .................20
9.3 DIAGNOSTIC CODES – ALLISON 4
TH
GENERATION CONTROLS ............................................................21
9.4 DIAGNOSTIC CODE DISPLAY AND CLEARING PROCEDURE – ALLISON 4
TH
GENERATION CONTROLS .....21
9.5 DIAGNOSTIC CODE RESPONSE ........................................................................................................22
9.6 DIAGNOSTIC TROUBLESHOOTING CODES (DTC) LIST - ALLISON 4
TH
GENERATION CONTROLS..............23
10. ZF-ASTRONIC TRANSMISSION SYSTEM FAULTS AND ERROR MESSAGES ........................26
10.1 SYSTEM FAULTS (ERROR MESSAGES) .............................................................................................26

PREVOST X3-45 Multiplex Specifications

General

Length	45 ft
Width	102 in
Engine	Volvo D13
Horsepower	500 hp
GVWR	54, 000 lbs
Height	146 in
Sleeping Capacity	Varies based on floor plan
Water Capacity	Varies based on floor plan