Home

Operator`s Manual 1000 And 2000 Product Families International

1. Repeat the check procedure to verify the reading ing level is within the HOT RUN band on the NOTE Safe dipstick Geor to yos 4 The width of the HOT RUN band represents approximately 1 0 liter 1 06 quart of fluid at normal operating sump temperature 8 If the fluid level is not within the HOT RUN band add or drain as necessary to bring the fluid level to within the HOT RUN band Consistency of Readings Always check the fluid level at least twice using the procedure described above Consistency repeatable readings is important to maintaining proper fluid level If inconsistent readings persist check the transmission breather to be sure it is clean and unclogged If readings are still inconsistent contact your nearest Allison distributor or dealer KEEPING FLUID CLEAN Prevent foreign material from entering the transmission by using clean containers fillers etc Lay the dipstick in a clean place while filling the transmission 9 CAUTION Containers or fillers that have been used for antifreeze solution or engine coolant must NEVER be used for transmission fluid Antifreeze and coolant solutions contain ethylene glycol which if put into the transmission can cause the clutch plates and some seals to fail FLUID RECOMMENDATIONS Hydraulic fluids oils used in the transmission are important influences on transmission performance reliability and durability Any fluids meeting DEXRONC III specific
2. 4 a eR a 39 PARK PAWL morem RR a apse eee eg apie 40 PARKING LEAVING VEHICLE WITH ENGINE RUNNING 41 TOWING OR PUSHING 24x m Re CR Wa qawas a 42 SURGING NATURAL GAS ENGINES 43 POWER TAKEOFF POWER TAKEOFF PTO SYSTEMS 44 TURBINE DRIVEN POWER TAKEOFF 44 SPLIT SHAFT POWER TAKEOFF PTO 48 CARE AND MAINTENANCE PERIODIC INSPECTIONS AND CARE 49 IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL 50 TRANSMISSION FLUID CHECK 50 KEEPING FLUID CLEAN 2 RR REI RES RS xx XY 54 FLUID RECOMMENDATIONS 54 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS 56 TRANSMISSION FLUID CONTAMINATION 58 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE 59 BREATHER ande dus eon te a me Ras A i Bes Ud Ba 61 DIAGNOSTICS DIAGNOSTIC CODES AND TOOLS 62 CUSTOMER SERVICE OWNER ASSISTANCE RER UE OR oye X d 63 SERVICE LITERATURE 255 nc RE alee 65 ALLISON TRANSMISSION REGIONAL OFFICES 66 TRADEMARK USAGE The following trademarks are the property of the companies indicated DEKRON is a
3. Allison Transmission Operator s Manual 1000 and 2000 Product Families International Models OM4118EN 2005 MAY Rev 1 2005 SEPTEMBER Manual OM4118EN Allison Transmission INTERNATIONAL MODELS 1000 and 2000 Product Families Includes Allison 4th Generation Controls 1000 2100 2200 2500 1000 2100 2200 2500 MH 1000 SP 2100 SP 2200 5 2500 SP Allison Transmission llis ri ission General Motors Corporation P O Box 894 Indianapolis Indiana 46206 0894 www allisontransmission com Printed in USA Copyright 2005 General Motors Corporation NOTES TABLE OF CONTENTS INTRODUCTION KEEPING THAT ALLISON ADVANTAGE 7 DESCRIPTION THE ALLISON 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS iar Qusa pus E Rue eR IH ELECTRONIC CONTROL SYSTEM sse adoa 85266 IA H TORQUE CONVERTER 5 24 53 3c PS uuu Rr Rr p Se eee 12 PLANETARY GEARS AND CLUTCHES 13 COOLER CIRCUIT 5224 eth wee e pe 13 SHIFT SELECTORS DESCRIPTION OF AVAILABLE TYPES 14 OPERATION OF THE SHIFT SELECTOR 14 RANGE SELECTION ALL 1000 AND 2200 TRANSMISSION MODELS WITH PARK PAWL AND PARK POSITION 17 RANGE SELECTION ALL 2100 AND 2500 TRANSMISSION MODELS WITH PB AUTO APPLY PARKING BRAKE
4. PERIODIC INSPECTIONS AND CARE Transmission Inspection CAUTION Do not spray steam water or cleaning solution directly at electrical connectors or the breather Fluids forced into electrical connectors can cause false codes and cross talk Steam water or cleaning solution forced into the breather will contaminate the transmission fluid Seal all openings the breather and electrical connections before spraying steam water or cleaning solution on the transmission Clean and inspect the exterior of the transmission at regular intervals Severity of service and operating conditions determine the frequency of these inspections Inspect the transmission for the following Loose bolts transmission and mounting components Fluid leaks repair immediately Loose dirty or improperly adjusted throttle sensor or shift selector linkage Damaged or loose hoses Worn frayed or improperly routed electrical harnesses Worn or damaged electrical connectors e Worn or out of phase driveline U joints and slip fittings Clogged or dirty breather Vehicle Inspection Check the vehicle cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler and for blocked or restricted air flow through the radiator or transmission cooler 49 Welding CAUTION When welding on the vehicle DO NOT WELD on the vehicle without disconnecting all control system wiring harness connectors f
5. POSITION 21 RANGE SELECTION ALL 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT EITHER P PARK OR PB AUTO APPLY PARKING BRAKE POSITIONS 25 DRIVING TIPS PREVENT MAJOR PROBLEMS i m Ret EE UE EG 29 TURNING THE VEHICLE ON OFF 29 MAXIMUM VEHICLE LOADING 30 ACCELERATOR CONTROL 2255555 a eR Ry chaw 31 PRIMARY SECONDARY SHIFT SCHEDULES 31 KICKDOWN ru y eed ace eoe ie ee Toothache 31 OUTPUT SPEED INDICATOR 24 4 veh asse Pow ORG VOY ee 32 DIAGNOSTIC CODES ERE deme ep RERO 32 RANGE INHIBIT ED 32 CHECK TRANS OR MALFUNCTION INDICATOR LIGHT 32 SHIFT INHIBITS ey e UR Ox oe WE u a 33 USING THE ENGINE TO SLOW THE VEHICLE 35 RANGE PRESELECTION 36 REVERSE pud yasa doe eR ee ee eee Ed eng e E te 37 REFUSE PACKER STEP SWITCH 37 TWO SPEED AXLE Some General Transmission Applications 37 DRIVING ON SNOW OR ICE 222258554 ROOM Rp ede OR E hne 37 ROCKING OUT ttt dn ad Se 38 OPERATING TEMPERATURES 38 HIGH FLUID TEMPERATURE 39 PARKING BRAKE ee Ge
6. THIRD or 2 SECOND for heavy city traffic and braking on steeper downgrades 3 for shift selectors with PB R N D 4 3 1 Actual ranges available depend on programming by vehicle manufacturer Use 1 FIRST range for the following When pulling through mud and deep snow e When maneuvering in tight spaces While driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect 24 RANGE SELECTION ALL 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT EITHER P PARK OR PB AUTO APPLY PARKING BRAKE POSITIONS ALL 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT EITHER P PARK OR PB AUTO APPLY PARKING BRAKE POSITIONS WARNING For vehicles containing 1000 and 2000 Product Family transmissions without either P Park or PB Auto Apply Parking Brake selector positions each time you park the vehicle or leave the operator s station with the engine running do the following 1 Bring the vehicle to a complete stop using the service brake 2 Make sure the engine is at low idle rpm 3 Put the transmission in N Neutral 4 Apply the emergency brake and or parking brake and make sure they are properly engaged 5 If the operator s station will be unoccupied with the engine running chock the wheels and take any other steps necessary to keep the vehicle from moving If the procedure is not followed the vehicle may move suddenly and cause inju
7. prevent automatic upshifting above the lower range selected However during downhill operation if engine governed speed is exceeded in the lower range the transmission will upshift to the next higher range to prevent engine damage This will reduce engine braking and could cause a loss of control Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected Use 4 FOURTH or 3 THIRD for city traffic and braking on steep downgrades 3 for shift selectors with P R N D 3 2 1 Actual ranges available depend on programming by vehicle manufacturer Use 3 THIRD or 2 SECOND for heavy city traffic and braking on steeper downgrades 3 for shift selectors with P R N D 4 3 1 Actual ranges available depend on programming by vehicle manufacturer Use 1 FIRST range for the following When pulling through mud and deep snow e When maneuvering in tight spaces While driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect 20 RANGE SELECTION ALL 2100 AND 2500 TRANSMISSION MODELS WITH PB AUTO APPLY PARKING BRAKE POSITION ALL 2100 AND 2500 TRANSMISSION MODELS WITH PB AUTO APPLY PARKING BRAKE POSITION WARNING For vehicles containing 2100 and 2500 transmission models with PB Auto Apply Parking Brake selector position follow this procedure each time the operator s sta
8. 408600 FRANCE GERMANY Allison Transmission Allison Transmission Opel France Eisenstrasse 2 1 9 Avenue du Marais D 65428 R sselsheim Germany B P 84 49 6142 602 322 95 101 Argenteuil Cedex France 33 1 3426 2153 SPAIN ITALY Allison Transmission Spain Allison Transmission Italy c o Transdiesel c o Delphi Automotive Systems E 28820 Coslada Madrid Via Torino 166 Spain 10097 Collegno TO 34 91 6699 759 Italy 39 011 4043 1 SWEDEN SOUTH AFRICA Allison Transmission Norden Allison Transmission Division P O Box 100 Entrance 2 Second Floor 517 23 Bollebygd Sweden Sanlam Arena 46 33 2857 99 10 Cradock Avenue Rosebank Johannesburg South Africa 27 11 788 4682 66 ASIA JAPAN AISIN GM Allison Co Ltd Shinagawa East One Tower 3F 2 16 1 Konan Minato ku Tokyo 108 0075 Japan 81 3 6718 1660 BEIJING Allison Transmission Beijing Representative Branch General Motors China Investment Company Ltd Block C Guo Men Building Rm 319 1 Zuo Jia Zhuang Chao Yang District Beijing 100028 People s Republic of China 86 10 6468 7850 86 10 6468 7788 KOREA No 2110 21 Fl KEC Bldg 275 7 Yangjea dong Seocho ku Seoul 137 895 Korea 82 2 3497 0401 SHANGHAI Asia Pacific Office 23rd Floor Aurora Plaza No 99 Fucheng Road Pudong Shanghai 200120 China 86 2 1 28996888 SOUTH EAST ASIA AND OCEANA AUSTRALIA MTU Detroit Diesel Australia Pty Ltd 569 Grand Junction Road Gepps Cross
9. PTO operation e g paint stripers and feedlot trucks DO NOT use the vehicle brakes to control vehicle speed during PTO operation Use ONLY throttle to control both engine and vehicle speed when the transmission is in reverse or a forward range Applying BOTH brakes and throttle will cause the transmission to overheat Extended operation at elevated temperatures will damage the transmission 46 CAUTION Do not exceed the engagement and operational speed limits imposed on the driven equipment during the operation of the PTO Exceeding the speed limits produces high hydraulic pressure in the PTO that can damage the PTO components Consult the vehicle manufacturer s literature for these speed limits PTO Operation The transmission operates in either converter mode or torque converter clutch mode In converter mode the torque converter lockup clutch is not engaged and the PTO is driven through the torque converter producing a torque at the PTO drive gear that is always greater than the input torque In torque converter clutch mode the torque converter lockup clutch is engaged the PTO drivetrain is driven at a speed proportional to the engine speed The PTO drive is normally in continuous converter mode operation when the transmission is in P Park PB Auto Apply Parking Brake R Reverse N Neutral and D Drive Torque converter clutch operation in N Neutral is available for some applications If the PTO is used wi
10. South Australia Australia 5094 61 8 8300 8 100 SINGAPORE Allison Transmission 15 Benoi Sector Jurong Town Singapore 629849 65 6267 1600 SOUTH AMERICA BRAZIL Allison Transmission Rua Agostinho Togneri 57 Jardim Jurubatuba Santo Amaro Sao Paulo SP Brazil CEP 04690 090 55 11 5633 2599 ARGENTINA CHILE PARAGUAY URUGUAY VENEZUELA Av Leandro Alem 855 Piso 2 Buenos Aires Capital Federal CP C1001 AAP Argentina 54 11 45 10 2758 67 OM4118EN 200509 www allisontransmission com Printed in USA 200509
11. TURN after gasket contact will damage the filter 7 Using the J 45023 tool or by hand turn the filter ONE FULL TURN ONLY after gasket contact 8 Reinstall the drain plug and sealing washer Tighten the drain plug to 30 40 N m 22 30 Ib ft 60 Refill Transmission The amount of refill fluid is less than the amount used for the initial fill Fluid remains in the external circuits and transmission cavities after draining the transmission After refill check the fluid level using the TRANSMISSION FLUID CHECK paragraph of this Manual lines and cooler hose NOTE Quantities listed are approximations and do not include external Transmission Fluid Capacity Initial Fill Refill 1000 and 2000 Product Family BREATHER Location and Purpose The breather is located at the top left rear of the transmission main housing The breather prevents air pressure buildup within the transmission and its passage must be kept clean and open CAUTION Do not spray steam water or cleaning solution directly at electrical connectors or the breather Fluids forced into electrical connectors can cause false codes and cross talk Steam water or cleaning solution forced into the breather will contaminate the transmission fluid Seal all openings the breather and electrical connections before spraying steam water or cleaning solution on the transmission Maintenance The amount of dust and dirt encountered will determine the frequ
12. This shift schedule keeps the transmission from shifting above the selected range This shift schedule permits upshifts to occur if an engine overspeed condition could result by the transmission remaining by operator selection in a range lower than its highest range When the hold feature is activated transmission upshift points occur at engine speeds which are higher than normal upshifts in order to hold the transmission from upshifting beyond the current range WARNING The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving For downhill operation select a lower transmission range If the engine governed speed is exceeded in the held range however the transmission will upshift to the next higher range to prevent engine damage To avoid injury and or property damage due to loss of vehicle control use the vehicle brakes to prevent exceeding engine governed speed in the held range Preselect Downshift This shift schedule is used when the driver preselects a lower range The operator may preselect any range below D Drive on the shift selector at any time When a range has been preselected in this manner shift points to and from ranges above the preselected range are higher than the normal shift points The transmission will downshift when an engine overspeed condition will not result after the shift Shifts below the preselected range are not affected 36 REVER
13. a high speed can cause re engagement shock that could damage a high inertia PTO driven system PTO re engagement speed parameters must be set by qualified Allison trained personnel PTO Overspeed Protection All 1000 and 2000 Product Family equipped vehicles with PTO enable have engagement and operational speed limits programmed into the TCM to help protect PTO equipment The PTO will deactivate when operational speeds either engine or transmission output are exceeded When the PTO is disengaged due to overspeed the PTO will be automatically re engaged at a user specified speed which is relatively low SPLIT SHAFT POWER TAKEOFF PTO For many split shaft PTOs holding the transmission in direct drive at all engine speeds is desirable In this manner the automatic range shifts are eliminated thereby eliminating rapid torque changes which would occur at the driven equipment during a shift in the transmission Such a condition for instance could create an undesirable pressure surge and directional control problem at the nozzle end of a fire hose with Allison 4 Generation Controls have a control provision that supports a split shaft PTO application This function will allow for THIRD range lockup operation only Consult your Allison distributor for additional requirements and operational information associated with this feature NOTE Transmissions for General and Specialty applications equipped 48 CARE AND MAINTENANCE
14. brake Make sure the engine is at low idle rpm with fast idle disabled Put the transmission in P Park PB Auto Apply Parking Brake or N Neutral Apply any other parking brake if present and make sure it is properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving Run the engine at 1000 1500 rpm for at least one minute to purge air from the system Apply the service brakes and shift to D Drive then to N Neutral and then shift to R Reverse to fill the hydraulic system Finally shift to P Park or PB Auto Apply Parking Brake if available or N Neutral and allow the engine to idle 500 800 rpm Slowly release the service brakes With the engine running remove the dipstick from the tube and wipe the dipstick clean Insert the dipstick into the tube and remove Check the fluid level reading Repeat the check procedure to verify the reading If the fluid level is within the COLD CHECK band refer to Figure 4 the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD CHECK band add or drain as necessary to bring it to the middle of the COLD CHECK band 52 10 Perform a hot check at the first opportunity after the normal operating sump temperature of 71 C 93 C 160 200 is reached Hot Check Procedure be at operating
15. depressed upshifts will occur automatically at high engine speeds A partially depressed position of the pedal will cause the upshifts to occur at lower engine speeds An electronic throttle position signal tells the TCM how much the operator has depressed the pedal Excessive throttle position may inhibit the directional shift PRIMARY SECONDARY SHIFT SCHEDULES The points at which shifts occur depend upon predetermined speeds and other operating conditions A transmission shift calibration includes several sets of shift points which may be used according to current or anticipated operating conditions Some shift schedules may be inhibited as a result of operating conditions such as engine or transmission fluid temperature Shift schedules may be changed through selection of a remote usually dash mounted switch which is typically associated with a change in anticipated vehicle operation The TCM includes the capacity for two separate and distinct shift calibrations customer selectable one for use in primary mode of operation and one in secondary mode e Primary This shift schedule is typically used for all normal vehicle operations Secondary This is an alternate shift schedule that the TCM uses upon request Not all vehicles will be equipped with a secondary shift schedule The request can be interlocked with a vehicle component or be operator controlled using a dash mounted switch Your vehicle may have a dash mounted
16. first range when D Drive is selected As vehicle speed increases the transmission will upshift automatically through each available range up to 4 FOURTH or 5 FIFTH As the vehicle slows the transmission will downshift automatically NOTE Turn off the vehicle HIGH IDLE switch if present before 1 from N Neutral to D Drive R Reverse D Drive or R Reverse will not be attained unless the shift is made with the The shift selector position representing this gear range may be labeled 5 for the highest gear in the range OD for Overdrive D for the normal Drive position or 1 5 for the complete gear range 19 ALL 1000 AND 2200 TRANSMISSION MODELS WITH P PARK POSITION WARNING The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving For downhill operation select a lower transmission range If the engine governed speed is exceeded in the held range however the transmission will upshift to the next higher range to prevent engine damage To avoid injury and or property damage due to loss of vehicle control use the vehicle brakes to prevent exceeding engine governed speed in the held range WARNING To avoid loss of control use a combination of downshifting braking and other retarding devices Downshifting to a lower transmission range increases engine braking and can help you maintain control The transmission has a feature to
17. is no engine braking in N Neutral You could lose control of the vehicle causing property damage or personal injury Coasting in neutral can cause severe transmission damage Use N Neutral for the following e To turn on or turn off the engine e To check vehicle accessories To operate the engine at idle for longer than five minutes e For stationary operation of the power takeoff if your vehicle is equipped with a PTO WARNING D Drive and other forward ranges may not be obtained due to an active inhibitor The range selected may not be obtained resulting in unexpected vehicle movement To help avoid injury and or property damage always apply the service brake when selecting D Drive or other forward ranges Check for the RANGE INHIBIT ED light or the CHECK TRANS CHECK ENGINE light 26 ALL 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT EITHER P PARK OR PB AUTO APPLY PARKING BRAKE POSITIONS WARNING To help avoid injury and or property damage caused by unexpected vehicle movement do not make shifts from a forward range to N Neutral without applying the service brakes parking brake or emergency brake Selecting N Neutral does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed CAUTION Do not idle in D Drive or any forward range for more than five minutes Extended idling in D Drive can cause transmission overheating and damage Always select N Neutral w
18. registered trademark of the General Motors Corporation e TranSynd is a trademark of Castrol Ltd e Allison DOC is a trademark of General Motors Corporation WARNINGS CAUTIONS NOTES IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions described in this manual It is however important to understand that these warnings and cautions are not exhaustive Allison Transmission could not possibly know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way The vehicle manufacturer is responsible for providing information related to the operation of vehicle systems including appropriate warnings cautions and notes Consequently Allison Transmission has not undertaken any such broad evaluation Accordingly ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR THE VEHICLE MANUFACTURER MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected Proper service and repair is important to the safe reliable operation of the equipment The service procedures recommended by Allison Transmission or the vehicle manufacturer and described in this manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The speci
19. speed is exceeded the transmission will upshift automatically to the next range CAUTION Using the engine brake on wet or slippery roads may cause e loss of traction on the drive wheels your vehicle may slide out of control To help avoid injury or property damage turn the engine brake enable to OFF when driving on wet or slippery roads 35 RANGE PRESELECTION Range preselection means selecting a lower range to match driving conditions you encounter or expect to encounter Learning to take advantage of preselected shifts will give you better control on slick or icy roads and on downgrades Downshifting to a lower range increases engine braking The selection of a lower range often prevents cycling between that range and the next higher range on a series of short up and down hills NOTE Preselecting during normal operation may result in reduced fuel economy Manual range downshifts will not occur until a calibration value of output speed is reached When a range downshift is manually selected and the transmission output speed is above the calibration value the transmission will stay in the range it was in even though a lower range was requested Apply the vehicle service brakes or some retarding device to reduce the transmission output speed to the calibration value and then the shift to the lower range will occur Two shift schedules are used with range preselection hold upshift and preselect downshift Hold Upshift
20. speed models have four forward ranges first through fourth When a forward range has been selected the transmission automatically upshifts through each range As the vehicle slows the transmission will downshift automatically through each range The shift selector position representing this gear range may be labeled 5 for the highest gear in the range OD for Overdrive D for the normal Drive position or 1 5 for the complete gear range n calibrations with five forward ranges one of these selector positions will not be available The following tables list the shift selector positions and corresponding ranges for all 1000 and 2000 Product Family transmissions 14 All 1000 And 2200 Transmission Models With P Park Position Shift Shift Shift Selector Selector Selector Position Range Position Position P Park P Park P Park R Reverse R Reverse R Reverse N Neutral N Neutral N Neutral D Drive 1 5 D Drive 1 5 D Drive 1 5 With Park Pawl engaged The shift selector position representing this gear range may be labeled 5 for the highest gear in the range for Overdrive D for the normal Drive position or 1 5 for the complete gear range 1 4 in Trailering Mode or 4 Speed Calibration All 2100 And 2500 Transmission Models With PB Auto Apply Parking Brake Position Shift Selector Shift Selector Shift Selector Position Ra
21. temperature to be sure of an accurate check and help prevent transmission damage The fluid rises as temperature increases During operation an overfull transmission can become overheated leading to transmission damage CAUTION When performing the Hot Check procedure the fluid must NOTE If a transmission temperature gauge is not present check fluid J level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour Operate the transmission in D Drive until the following normal operating temperatures are reached Sump temperature 71 C 93 C 160 F 200 F Converter out temperature 82 C 104 C 180 F 220 F in HOT RUN BAND NS COLD CHECK ND BA V06713 Figure 4 Typical Dipstick Markings Check the fluid level as follows 1 Bring the vehicle to a complete stop on a level surface using the service brake 2 Make sure the engine is at low idle rpm with fast idle disabled 23 3 Put the transmission in P Park PB Auto Apply Parking Brake or N Neutral 4 Apply any other parking brake if present and make sure it is properly engaged 5 Chock the wheels and take any other steps necessary to keep the vehicle from moving 6 With the engine running remove the dipstick from the tube and wipe the dipstick clean 7 Insert the dipstick into the tube and remove Check the fluid level reading
22. 20 000 12 000 miles 12 000 miles Overhaul 12 000 miles 6 months 6 months 6 months 500 hours 500 hours 500 hours Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd that is required to fill the transmission to the proper level A mixture of TranSynd or TES 295 equivalent vs non TranSynd other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 2 Control Main Spin on Filters Only Initial 5000 miles Schedule 2 Recommended Fluid and Filter Change Intervals TranSynd TES 295 Fluid Filters Control Main Lube Auxiliary 160 000 km 80 000 km 80 000 km 100 000 miles 50 000 miles 50 000 miles General 48 months 24 months Overhaul 24 months 4000 hours 2000 hours 2000 hours 80 000 km 80 000 km 80 000 km 50 000 miles 50 000 miles 50 000 miles Bevery 24 months 24 months Overnaul 24 months 2000 hours 2000 hours 2000 hours Control Main Spin on Filter Only Initial 5000 miles Abnormal Conditions Transmissions used in high cycle rate applications should use fluid analysis to be certain that a proper fluid change interval is established Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition A high temperature condition is indicated by the transmission fluid bei
23. At each fluid change examine the drained fluid for evidence of dirt or water A normal amount of condensation not to exceed 0 2 percent maximum will appear in the fluid during operation Water Obvious water contamination of the transmission fluid or transmission fluid in the cooler water in heat exchanger indicates a leak between the water and fluid areas of the cooler Inspect and pressure test the cooler to confirm the leak Replace leaking coolers locate the correct source of cooler water contamination NOTE Cooler water can also be contaminated by engine oil be sure to 58 Engine Coolant CAUTION If the transmission fluid is contaminated by water not to e exceed 0 2 percent maximum by volume or any trace of ethylene glycol disassemble the transmission and replace the following Seals e Gaskets Clutch Friction plates Bearings Torque converters that cannot be disassembled Components that have rusted Solenoids that do not meet resistance specifications Pressure switch manifold PSM Internal Mode Switch IMS Remove all traces of ethylene glycol and varnish deposits Failure to follow this procedure decreases transmission reliability and durability Metal Metal particles in the fluid except for the minute particles normally trapped in the oil filter indicate internal transmission damage If these particles are found in the sump the transmission must be disassembled and closely inspected to find their source M
24. NIVA TOHINOO NOI1V901 1 115 WO 318VTIVAV Old 1108 9 JYS ld4VHS 90193135 YOSNAS 03345 LNdLNO Q33dS 3NI9N3 NOISIAOHd ONLLNNOW A 4OSN3S 04445 8 ONDYVd u3H1V3ug Figure 2 1000 and 2000 Product Family Left Front View Allison 4 Generation Controls gt o az Oft z g ox m 2 5 8 m o 355 S S 559 SAE 6 BOLT PTO PAD MAIN ELECTRICAL CONNECTOR 85 a 2 2 ms uo s n 58 uo z z JIZ a zuo c 2495 Oro ui FOS oc lt m ag Ow gt a gt o V06693 00 03 Figure 3 1000 and 2000 Product Family Right Rear View 10 A BRIEF DESCRIPTION OF THE ALLISON 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS The 1000 and 2000 Product Family transmissions are fully automatic torgue converter driven electronically controlled transmissions best suited for light medium duty on highway applications 1000 and 2200 Models These transmission models are best suited for light duty on highway truck and bus applications 2100 and 2500 Models These transmission models are best suited for single axle medium duty on highway truck and bus applications including rear engine vehicle configurations All transmissions have up to five forward ranges and one reverse All clutches
25. SE Putting the transmission into R Reverse may activate vehicle backup lights and or reverse warning devices To achieve REVERSE range in some European transit and tour buses an instrument panel mounted switch must be pressed simultaneously with the R Reverse shift selector button REFUSE PACKER STEP SWITCH When personnel are on the rear step of a refuse packer the transmission will operate in FIRST and NEUTRAL only e An operator request to upshift beyond FIRST or to shift to REVERSE is ignored by the TCM If the transmission is in REVERSE the TCM will cause the transmission to shift to NEUTRAL e If the transmission is in a forward range higher than FIRST the TCM will invoke preselect downshifts until FIRST is attained TWO SPEED AXLE Some General Transmission Applications The two speed axle may be shifted while the vehicle is moving However the axle or vehicle manufacturer s recommendations should be followed for shifting the axle It is recommended that axle shifts be made with the transmission in the highest range or vehicle stopped to prevent a transmission shift from coinciding with an axle shift DRIVING ON SNOW OR ICE If possible reduce your speed and select a lower range before you lose traction Select the range that will not exceed the speed you expect to maintain Accelerate or decelerate very gradually to prevent losing traction It is very important to reduce speed gradually when a lower range
26. T ED LIGHT or CHECK TRANS OR MALFUNCTION NDICATOR LIGHT section in this manual for further information Depending on the severity of the Diagnostic Trouble Code DTC the transmission may default to an operating state predefined by the TCM such as Limp Home Limp Home will temporarily limit normal transmission operation until the vehicle can be driven to a service location and the severity of the problem is determined The transmission will remain in the Limp Home state until the problem has been corrected Following an engine restart the transmission may obtain THIRD NEUTRAL or REVERSE Reference the Sales and Service Directory SA2229EN for the current listing of Allison Transmission authorized distributor and service dealers See the RANGE INHIBIT ED LIGHT and SHIFT INHIBITS sections in this manual for further information 34 Auziliary Eguipment Operation The TCM will prevent shifts from P Park PB Auto Apply Parking Brake or N Neutral to range when auziliary eguipment is in operation e g a wheelchair lift For some vehicles such as buses shifts from P Park PB Auto Apply Parking Brake or N Neutral to range will be prevented unless the brake pedal is depressed USING THE ENGINE TO SLOW THE VEHICLE WARNING The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving For downhill operation select a lower transmission range If the engine gove
27. al for further information 33 Forward Reverse Directional Shifts WARNING To avoid injury or property damage caused by sudden movement of the vehicle do not make shifts from N Neutral to a forward range or R Reverse when the throttle is open The vehicle will lurch forward or rearward and the transmission can be damaged Avoid this condition by making shifts from N Neutral to a forward range or R Reverse only when the throttle is closed and service brakes are applied Forward reverse directional changes are typically not permitted if appreciable output shaft speed is detected When these shifts are inhibited the RANGE INHIBIT ED light will illuminate See the RANGE INHIBIT ED LIGHT section in this manual for further information Transmission Problems Lights such as the RANGE INHIBIT ED CHECK TRANS or Malfunction Indicator Light MIL and a flashing PRNDL display will be illuminated when the transmission detects a functional concern An illuminated RANGE INHIBIT ED light or a flashing PRNDL display indicates that the Transmission Control Module TCM has detected a condition where directional shifts are not allowed to be made This inhibited state can be a self clearing or lasting condition depending on the amount of time the condition is present The following conditions may cause an inhibited state e Engine speed too high e Throttle percentage incorrect Output speed movement See the RANGE INHIBI
28. al planetary gear sets and shafts provides the mechanical gear ratios and direction of travel for the vehicle The planetary gear sets are controlled by five multiplate clutches that work in pairs to produce up to five forward speeds and one reverse speed The clutches are applied and released hydraulically in response to electronic signals from the TCM to the appropriate solenoids COOLER CIRCUIT The transmission fluid is cooled by a remote mounted oil cooler The bottom of the transmission torgue converter housing provides for the direct mounting of a control main filter and includes two ports to facilitate the attachment of the oil cooler lines 13 SHIFT SELECTORS DESCRIPTION OF AVAILABLE TYPES The 1000 and 2000 Product Family transmissions use lever type shift selectors The shift positions on the shift selector can vary according to the OEM supplied shift selector installed OPERATION OF THE SHIFT SELECTOR The shift selector is used by the operator to select the following ranges P Park for transmissions with park pawls PB Auto Apply Parking Brake for vehicles with automatically engaged parking brakes e R Reverse e N Neutral e D Drive e 4 Fourth Range e 3 Third Range e 2 Second Range e 1 First Range Ranges are selected by moving the lever to the desired selector position P PB R N D 4 3 2 or 1 Five speed transmission models have five forward ranges first through fifth Four
29. al tools should be used when and as recommended Three types of headings are used in this manual to attract your attention These warnings and cautions advise of specific methods or actions that can result in personal injury damage to the equipment or cause the equipment to become unsafe WARNING A warning is used when an operating procedure practice etc if not correctly followed could result in personal injury or loss of life CAUTION A caution is used when an operating procedure practice etc if not strictly observed could result in damage to or destruction of equipment NOTE A note is used when an operating procedure practice etc is essential to highlight INTRODUCTION KEEPING THAT ALLISON ADVANTAGE 01724 Allison 1000 and 2000 Product Family transmissions provide many advantages for the driver who must stop and go or change speeds frequently Driving is easier safer and more efficient The 1000 and 2000 Product Family transmissions are rugged and designed to provide long trouble free service This manual will help you gain maximum benefits from your ALLISON equipped vehicle 0 00 6990 431113 110 NIVIN NOILV9O1 1115 110 318VTIVAV QVd Old HOSN3S qaads LAdLNO HOSN3S 03395 3NI9N3 if ava SNDIHVd 2 iivaa Figure 1 1000 and 2000 Product Family Left Front View Prior to Allison 4 Generation Controls 8 mene TIO
30. are hydraulically actuated spring released and have automatic compensation for wear Gearing is helical type arranged in planetary sets Electronic controls provide automatic gear selection in each drive range and automatic engagement of the torque converter lockup clutch Each transmission series contains features which have been designed for specific vocational needs Refer to your nearest Allison distributor or dealer for information about feature availability for a specific transmission vocation 1000 and 2000 Product Family transmissions may include a provision to mount a Power Takeoff PTO a PTO drive gear and a park pawl The park pawl exists but cannot be engaged in some vehicle configurations e g some rear engine vehicles with air brakes For these configurations the P Park position is not used ELECTRONIC CONTROL SYSTEM The 1000 and 2000 Product Family control system consists of five major components connected by customer furnished wiring harnesses The five major components are e Transmission Control Module TCM Engine throttle position sensor TPS or direct electronic communication of throttle information Engine turbine and output speed sensors e Internal Mode Switch IMS Control valve body The control valve body contains solenoids and a pressure switch manifold to position and monitor control valve operation The pressure switch manifold also contains a thermistor to monitor sump fluid temperatu
31. ations are acceptable for use in the 1000 and 2000 Product Family transmissions TranSynd fluids fully meet the DEXRON III specifications 54 Make sure the fluid is gualified for use in Allison transmissions check for a DEXRON III fluid license or approval numbers on the container or consult the lubricant manufacturer Consult your Allison Transmission dealer or distributor before using other fluid types in transmission malfunction or reduced transmission life CAUTION Disregarding minimum fluid temperature limits can result When choosing the optimum viscosity grade of fluid to use duty cycle preheat capabilities and or geographical location must be taken into consideration The table below lists the minimum fluid temperatures at which the transmission may be safely operated without preheating the fluid Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in P Park or PB Auto Apply Parking Brake if available or N Neutral for a minimum of 20 minutes before attempting range operation Transmission Fluid Operating Temperature Requirements Ambient Temperature Below Which Preheat is Required Viscosity Grade Fahrenheit TranSynd Ref SIL 13 TR 90 Shifting will be inhibited and torque converter clutch mode will not be reached until the transmission fluid operating temperature requirements have been met Refer to the Transmission Fl
32. can cause severe transmission damage WARNING To help avoid injury or property damage caused by unexpected vehicle movement do not make shifts to or from N Neutral without manually or automatically applying an appropriate vehicle brake N This position places the transmission in N Neutral Used for starting the engine and stationary operation 18 ALL 1000 AND 2200 TRANSMISSION MODELS WITH P WARNING D Drive and other forward ranges may not be obtained due to an active inhibitor The range selected may not be obtained resulting in unexpected vehicle movement To help avoid injury and or property damage always apply the service brake when selecting D Drive or other forward ranges Check for the RANGE INHIBIT ED light or the CHECK TRANS CHECK ENGINE light WARNING To help avoid injury and or property damage caused by unexpected vehicle movement do not make shifts from a forward range to N Neutral without applying the service brakes parking brake or emergency brake Selecting N Neutral does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed CAUTION Do not idle in D Drive or any forward range for e more than five minutes Extended idling in D Drive can cause transmission overheating and damage Always select P Park whenever time at idle exceeds five minutes engine at idle Use D Drive for normal driving The transmission will initially attain
33. cle to rock in R Reverse as far as it will go Again apply and hold the service brakes and allow the engine to return to idle This procedure may be repeated in D Drive and R Reverse if each directional shift continues to move the vehicle a greater distance Never make N Neutral to D Drive or directional shift changes when the engine rpm is above idle OPERATING TEMPERATURES To properly operate the transmission adhere to the following minimum and maximum transmission operating temperatures Sump minimum continuous 40 C 100 F Sump maximum intermittent 121 C 250 F To cooler maximum intermittent 149 C 300 F Your transmission may have a converter out transmission temperature gauge near the to cooler port on the transmission converter housing 38 HIGH FLUID TEMPERATURE CAUTION Always select P Park PB Auto Apply Parking Brake or N Neutral whenever time at idle exceeds five minutes Extended idling in any other ranges can cause transmission overheating and damage CAUTION Sustained use of the parking brake with the engine running and the transmission in range can cause an overheating failure of the transmission The vehicle can contain a buzzer or dash mounted light to alert the operator when the ignition switch is ON the parking brake is applied and the transmission selector is in range CAUTION The engine should never be operated for more than 10 seconds at full throttle with the
34. e TORQUE CONVERTER The torque converter consists of the following four elements Pump input element driven directly by the engine e Turbine output element hydraulically driven by the pump e Stator reaction torque multiplying element Lockup Clutch mechanically couples the pump and turbine when engaged controlled by TCM When the pump turns faster than the turbine the torque converter is multiplying torque When the turbine approaches the speed of the pump the stator starts to rotate with the pump and turbine When this occurs torque multiplication stops and the torque converter functions as a fluid coupling The lockup clutch is located inside the torque converter and consists of the following elements e Piston and backplate driven by the engine Clutch plate damper located between the piston and the backplate splined to the converter turbine The lockup clutch torsional damper is engaged and released in response to electronic signals from the TCM Lockup clutch engagement provides a direct drive from the engine to the transmission gearing This eliminates converter slippage and maximizes fuel economy and vehicle speed The lockup clutch releases at lower speeds or when the TCM detects conditions requiring it to be released 12 The torsional damper absorbs engine torsional vibration to prevent transmitting vibrations through the powertrain PLANETARY GEARS AND CLUTCHES A series of three helic
35. e removal of 100 percent of the used fluid Allison Transmission requires an initial filter change for the Spin On Control Main Filter during the first 8000 km 5000 miles or 200 hours of service whichever comes first Following the initial filter change change fluid filters after recommended mileage months or hours have elapsed whichever occurs first Refer to the fluid change intervals listed in Schedule 1 or Schedule 2 for recommendations The transmission sump filter is permanent and does not require replacement except at overhaul Severe Vocations include On Off Highway Refuse City Transit Shuttle and Motorhomes General Vocations include all other vocations Local conditions severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended fluid change intervals of Allison Transmission Transmission protection and fluid change intervals can be optimized by the use of fluid analysis The following tables are given only as a general guide for fluid and filter change intervals 56 Schedule 1 Recommended Fluid and Filter Change Intervals DEXRON III and Mixtures of TranSynd TES 295 and Non TranSynd Non TES 295 Fluids Filters Control Main Lube Auxiliary 80 000 km 80 000 km 80 000 km 50 000 miles 50 000 miles 50 000 miles General 24 months 24 months 24 months 2000 hours 2000 hours 2000 hours 20 000 20 000
36. e when selecting D Drive or other forward ranges Check for the RANGE INHIBIT ED light or the CHECK TRANS CHECK ENGINE light WARNING To help avoid injury and or property damage caused by unexpected vehicle movement do not make shifts from a forward range to N Neutral without applying the service brakes parking brake or emergency brake Selecting N Neutral does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed CAUTION Do not idle in D Drive or any forward range for e more than five minutes Extended idling in D Drive can cause transmission overheating and damage Always select PB Auto Apply Parking Brake whenever time at idle exceeds five minutes engine at idle Use D Drive for normal driving The transmission will initially attain first range when D Drive is selected As vehicle speed increases the transmission will upshift automatically through each available range up to 4 FOURTH or 5 FIFTH As the vehicle slows the transmission will downshift automatically The shift selector position representing this gear range may be NOTE Turn off the vehicle HIGH IDLE switch if present before 1 from N Neutral to D Drive or R Reverse D Drive or R Reverse will not be attained unless the shift is made with the labeled 5 for the highest gear in the range OD for Overdrive D for the normal Drive position or 1 5 for the complete gear
37. ed and direction changes may not occur Illumination of the CHECK TRANS light or MIL at any time after start up ma indicate a problem with the engine or transmission Refer to the DIAGNOSTICS section for more information on diagnostic codes SHIFT INHIBITS The transmission control system will inhibit shifting to protect the transmission from some types of abusive operation in response to diagnostic trouble codes and to satisfy transmission feature option reguirements These shift inhibits fall within the following types e Above idle neutral to range shifts Forward reverse directional shifts e Transmission problems e Auxiliary equipment operation Above Idle Neutral to Range Shifts WARNING To avoid injury or property damage caused by sudden movement of the vehicle do not make shifts from N Neutral to a forward range or R Reverse when the throttle is open The vehicle will lurch forward or rearward and the transmission can be damaged Avoid this condition by making shifts from N Neutral to a forward range or R Reverse only when the throttle is closed and service brakes are applied Above idle greater than 900 rpm shifts from N Neutral to R Reverse or N Neutral to a forward range are normally inhibited except in emergency vehicles or some other type of specialized equipment When these shifts are inhibited the RANGE INHIBIT ED light will illuminate See the RANGE INHIBIT ED LIGHT section in this manu
38. en contacting the Home Office please keep in mind that ultimately the problem will likely be resolved at the distributorship or dealership using their facilities equipment and personnel Therefore it is suggested that Step One be followed when experiencing a problem Your purchase of an Allison Transmission product is greatly appreciated and it is our sincere desire to assure complete satisfaction 64 SERVICE LITERATURE Additional service literature is available This service literature provides fully illustrated instructions for the operation maintenance service overhaul and parts support of your transmission To be sure you get maximum performance and service life from your unit you may order publications from SGI Inc Attn Allison Literature Fulfillment Desk 8350 Allison Avenue Indianapolis IN 46268 TOLL FREE 888 666 5799 INTERNATIONAL 317 471 4995 www allisontransmission com Service Literature GN3433EN GN2055EN JA3664EN N N N 65 ALLISON TRANSMISSION REGIONAL OFFICES EUROPE MIDDLE EAST AFRICA AND INDIA Allison Transmission Europe BV AUSTRIA Baanhoek 188 Allison Transmission 3361 GN Sliedrecht The Netherlands Almrauschweg 31 78 6422 100 A 4400 Steyr Austria 43 7252 46843 ENGLAND FINLAND Allison Transmission Allison Transmission Millbrook Proving Grounds General Motors Finland OY Midbrook Bedford MK45 2JQ Pajuniityntie 5 UK 00320 Helsinki Finland 44 1525
39. ency of breather cleaning Use care when cleaning the transmission 61 DIAGNOSTICS DIAGNOSTIC CODES AND TOOLS The illumination of the CHECK TRANS light or MIL Malfunction Indicator Light any time after start up indicates that the TCM has registered a Diagnostic Trouble Code DTC DTCs are used to identify the nature of a malfunction Use any Allison DOC diagnostic tool to access DTCs and troubleshoot transmission complaints The following Allison DOC diagnostic tools are available Allison DOC For 5 Tool full feature service tool e Allison DOC For Fleets Service Tool diagnostic only For more information regarding Allison DOC diagnostic tools please visit www allisontransmission com Click on Service and then click on Diagnostic Tools For additional help contact an authorized Allison Transmission distributor or service dealer or the Allison Technical Assistance Center at 800 252 5283 Refer to the Sales and Service Directory SA2229EN or use the Allison Transmission Sales and Service Locator Tool on the Allison Transmission web site at www allisontransmission com for current Allison Transmission authorized distributors and service dealers 62 CUSTOMER SERVICE OWNER ASSISTANCE The satisfaction and goodwill of the owners of Allison transmissions are of primary concern to Allison Transmission its distributors and their dealers As an owner of an Allison transmissio
40. engaged Apply the emergency brakes and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage WARNING For vehicles containing 1000 2100 2200 and 2500 transmission models without either P Park or PB Auto Apply Parking Brake selector positions each time you park the vehicle or leave the operator s station with the engine running do the following 1 Bring the vehicle to a complete stop using the service brake 2 Make sure the engine is at low idle rpm 3 Put the transmission in N Neutral 4 Apply the emergency brakes and or parking brake and make sure they are properly engaged 5 If the operator s station will be unoccupied with the engine running chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage TOWING OR PUSHING CAUTION Failure to lift the driving wheels off the road disconnect the driveline or remove the axle shafts before pushing or towing can cause serious transmission damage The engine cannot be started by pushing or towing Before pushing or towing a vehicle lift the drive wheels off the road disconnect the driveline or remove the axle shafts from the drive wheels When the ax
41. etal contamination requires complete transmission disassembly Clean all internal and external hydraulic circuits cooler and all other areas where the particles could lodge TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE Drain Fluid 1 Drain the fluid when the transmission is at normal operating sump temperature of 71 939 160 200 Hot fluid flows quicker and drains more completely 2 Remove the drain plug from the oil pan and allow the fluid to drain into a suitable container 3 Examine the fluid as described in the TRANSMISSION FLUID CONTAMINATION paragraph in this Section Replace Control Main Filter 1 Using a standard strap type filter wrench or the J 45023 tool remove the control main filter refer to Figure 5 by rotating it in the counterclockwise direction 2 Remove the magnet from the filter attachment tube or from the top of the filter element 59 3 Clean any metal debris from the magnet Report any metal pieces larger than dust to your service management or an Allison distributor or dealer 4 Reinstall the magnet onto the filter attachment tube 5 Lubricate the gasket on the control main filter with transmission fluid 6 Install by hand the control main filter until the gasket on the control main filter touches the converter housing or cooler manifold V06712 01 00 Figure 5 Replacing the Control Main Filter CAUTION Turning the control main filter more than ONE FULL
42. f downshifting braking and other retarding devices Downshifting to a lower transmission range increases engine braking and can help you maintain control The transmission has a feature to prevent automatic upshifting above the lower range selected However during downhill operation if engine governed speed is exceeded in the lower range the transmission will upshift to the next higher range to prevent engine damage This will reduce engine braking and could cause a loss of control Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected Use 4 FOURTH or 3 THIRD for city traffic and braking on steep downgrades 3 for shift selectors with R N D 3 2 1 Actual ranges available depend on programming by vehicle manufacturer Use 3 THIRD or 2 SECOND for heavy city traffic and braking on steeper downgrades 3 for shift selectors with R N D 4 3 1 Actual ranges available depend on programming by vehicle manufacturer Use 1 FIRST range for the following When pulling through mud and deep snow e When maneuvering in tight spaces e While driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect 28 DRIVING TIPS PREVENT MAJOR PROBLEMS Minor problems can be kept from becoming major problems if you notify your service management or an Allison Transmission distributor o
43. fer case The split shaft transfer case is then shifted to deliver this power to either the driveline or PTO drive Flywheel Driven A flywheel driven PTO often called a sandwich PTO mounts between the engine and transmission The PTO is normally driven directly by the engine TURBINE DRIVEN POWER TAKEOFF PTO The following pertains to Transmission Mounted Turbine Driven PTOs only PTO Configuration The PTO is mounted on the left and or right side of the transmission housing The PTO drivetrain consists of a large drive gear in the transmission an idler gear arrangement and a smaller driven gear in the PTO The drive gear is integral to the transmission rotating clutch housing which rotates at the same speed as the torque converter turbine With this drive configuration the PTO rotates in the same direction as the engine 44 Two types of transmission mounted PTOs may be used with these transmission models Constant drive PTO Used in applications which require full time PTO operation The PTO driven gear is in constant mesh with the drive gear and cannot be disengaged Clutch shift Used in applications which require only part time operation of the PTO or the capability to engage or disengage the driven equipment Clutch shift PTO engagement disengagement is accomplished by a hydraulic clutch mechanism in the PTO assembly The PTO can be engaged or disengaged at any time except when the PTO is co
44. he power takeoff if your vehicle is equipped with a PTO This position places the transmission in N Neutral and engages the park pawl WARNING R Reverse may not be obtained due to an active inhibitor Check for the illumination of the RANGE INHIBIT ED light or CHECK TRANS CHECK ENGINE light See the SHIFT INHIBITS section of this manual 17 ALL 1000 AND 2200 TRANSMISSION MODELS WITH P PARK POSITION WARNING To help avoid injury and or property damage caused by unezpected vehicle movement do not make shifts from R Reverse to N Neutral without applying the service brakes parking brake or emergency brake Selecting N Neutral does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed CAUTION Do not idle in R Reverse for more than W five minutes Extended idling in R Reverse can cause transmission overheating and damage Always select P Park whenever time at idle exceeds five minutes R Reverse is used to back the vehicle Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R Reverse or from R Reverse to a forward range The reverse warning signal is activated when the shift selector is in this position WARNING DO NOT allow the vehicle to coast in N Neutral There is no engine braking in N Neutral You could lose control of the vehicle causing property damage or personal injury Coasting in neutral
45. hen the condition is detected the clutch will be disengaged concurrently with the activation of the RANGE INHIBIT ED light Each time the engine is started the RANGE INHIBIT ED light will illuminate then turn off after two seconds If the light does not illuminate during ignition or if the light remains on after ignition the transmission system should be checked immediately For the conditions under which shift inhibits occur see the SHIFT INHIBITS section in this manual CHECK TRANS OR MALFUNCTION INDICATOR LIGHT The red or amber CHECK TRANS light or Malfunction Indicator Light MIL is located on the dash panel A MIL is present on vehicles that meet industry On Board Diagnostics II OBD II requirements A CHECK TRANS light is present on vehicles not subject to industry OBD II requirements Each time the engine is started the CHECK TRANS light or MIL will illuminate then turn off after two seconds If the light does not illuminate during ignition or if the light remains on after ignition the transmission system should be checked immediately 32 Illumination of the CHECK TRANS light or MIL at any time after start up indicates that a problem has been detected The TCM will register a diagnostic code and shifts may be restricted Depending upon the severity of the problem operation may continue in order to reach service assistance The TCM may not respond to shift selector reguests since upshifts and downshifts may be restrict
46. henever time at idle exceeds five minutes NOTE Turn off the vehicle HIGH IDLE switch if present before shifting from N Neutral to D Drive or R Reverse D Drive or R Reverse will not be attained unless the shift is made with the engine at idle Use D Drive for normal driving The transmission will initially attain first range when D Drive is selected As vehicle speed increases the transmission will upshift automatically through each available range up to 4 FOURTH or 5 FIFTH As the vehicle slows the transmission will downshift automatically The shift selector position representing this gear range may be labeled 5 for the highest gear in the range OD for Overdrive D for the normal Drive position or 1 5 for the complete gear range WARNING The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving For downhill operation select a lower transmission range If the engine governed speed is exceeded in the held range however the transmission will upshift to the next higher range to prevent engine damage To avoid injury and or property damage due to loss of vehicle control use the vehicle brakes to prevent exceeding engine governed speed in the held range 27 ALL 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT EITHER P PARK OR PB AUTO APPLY PARKING BRAKE POSITIONS WARNING To avoid loss of control use a combination o
47. is selected It is important that you reach the selected lower range before attempting to accelerate This will avoid an unexpected downshift during acceleration clutch is automatically disengaged NOTE If the Anti lock Brake System ABS is activated the lockup 37 ROCKING OUT WARNING To avoid injury or property damage caused by sudden movement of the vehicle do not make shifts from N Neutral to a forward range or R Reverse when the throttle is open The vehicle will lurch forward or rearward and the transmission can be damaged Avoid this condition by making shifts from N Neutral to a forward range or R Reverse only when the throttle is closed and service brakes are applied CAUTION If the wheels are stuck and not turning do not apply full power for more than 10 seconds in either D Drive or R Reverse Full power for more than 10 seconds under these conditions will cause the transmission to overheat If the transmission overheats shift to Neutral and operate the engine at 1200 1500 rpm until it cools 2 3 minutes If the vehicle is stuck in deep sand snow or mud it may be possible to rock it out Shift to D Drive and apply steady light throttle never full throttle When the vehicle has rocked forward as far as it will go apply and hold the vehicle service brakes Allow the engine to return to idle then select R Reverse Release the brakes and apply a steady light throttle and allow the vehi
48. ke sure that the engine is at low idle 500 800 rpm e Apply the park brake or emergency brake and make sure it is properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving On automatic transmissions the gears in the transmission turn when the transmission is in neutral therefore gears clashing will occur if the PTO is shifted into range or out of range at this time With Turbine Driven Gear 1 Engine idle With the operator seated in the driver s seat and while activating the vehicle s brake shift transmission lever into any of the drive positions This will stop transmission gear from turning 2 Shift PTO into or out of range 3 If the PTO does not engage release the PTO to the disengage position Shift the transmission to N Neutral and repeat the above steps from step 1 4 Shift the transmission into P Park or N Neutral This will start transmission gears turning If you hear a grinding or ratcheting sound turn PTO off and repeat these procedures from step 1 PTO Engagement Clutch Driven The PTO will engage only when the PTO switch is on the throttle position is low and engine speed and output speed are within user specified limits If the PTO is controlled by the TCM your vehicle may have a light on the dash that illuminates when the PTO is engaged CAUTION Some vehicles creep in range at low vehicle speeds while maintaining a specified engine speed for
49. l a small amount to release the pressure on the park pawl and permit a shift out of P Park 2 Shift the transmission out of P Park while applying the service brakes 3 Release the parking brake PARKING LEAVING VEHICLE WITH ENGINE RUNNING WARNING For vehicles containing 1000 and 2200 transmission models with P Park selector position follow this procedure each time the operator s station will be unoccupied with the engine running Bring the vehicle to a complete stop using the service brake Make sure the engine is at low idle rpm Put the transmission in P Park Engage the park pawl by slowly releasing the service brake If a parking brake is present apply the parking brake Make sure the parking brake is properly engaged Apply the emergency brakes and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage 41 WARNING For vehicles containing 2100 and 2500 transmission models with PB Auto Apply Parking Brake selector position follow this procedure each time the operator s station will be unoccupied with the engine running Bring the vehicle to a complete stop using the service brake 2 Make sure the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure the parking brake is properly
50. le shafts are removed be sure to cover the wheel openings to prevent loss of lubricant and entry of dust and dirt An auxiliary air supply will usually be required to release the vehicle brake system 42 SURGING NATURAL GAS ENGINES NOTE Engine surging or engine speed cycling may occur on natural gas powered eguipment This condition typically occurs when the transmission is being operated in a hold position with throttle applied and the engine speed above full load engine governed speed Surging may also occur at closed and part throttle This condition is an engine characteristic and NOT a transmission concern 43 POWER TAKEOFF POWER TAKEOFF PTO SYSTEMS Three types of PTO systems may be used with 1000 and 2000 Product Family transmissions e Transmission Mounted Turbine Driven PTO A transmission mounted turbine driven PTO drive provides both an infinitely variable PTO drive ratio and a protective hydraulic cushion against abrupt loading unloading during converter mode operation and engine driven PTO speed control during torque converter clutch mode operation Split Shaft split shaft PTO a chassis mounted component is typically used in applications which require full engine power being available to either propel the vehicle or to power auxiliary equipment through the PTO drive but not both simultaneously In both cases the transmission output shaft delivers power to the split shaft trans
51. light that illuminates when the secondary mode is active KICKDOWN Some vehicles have a kickdown feature that allows the operator to choose between an Economy primary shift schedule and Performance secondary shift schedule The throttle pedal will have a detent feel when full throttle is achieved 31 using Economy shift points When the operator steps through this detent the function is activated and Performance shift points are achieved OUTPUT SPEED INDICATOR Your vehicle may contain a light or other indicator that is activated when a preset output speed has been exceeded in the vehicle transmission or auxiliary equipment The output speed may occur in either the forward or reverse direction This indicator may be used to alert the operator that a specific overspeed condition has occurred or to indicate that a minimum or maximum operating speed was attained DIAGNOSTIC CODES See detailed information in the DIAGNOSTICS section RANGE INHIBIT ED LIGHT The red or amber RANGE INHIBIT ED warning light is located on or near the shift selector The purpose of this indicator is to alert the operator that transmission operation is being inhibited and that range shifts being requested by the operator may not occur When certain operating conditions are detected by the TCM the controls will command the transmission to be locked in the range currently in use If the torque converter clutch is applied w
52. manual With an Allison equipped vehicle selecting the right moment to upshift or downshift during changing road and traffic conditions is not necessary The Allison 1000 and 2000 Product Family transmission does it for you However knowledge of the ranges and when to select them will make vehicle control and your job even easier RANGE SELECTION ALL 1000 AND 2200 TRANSMISSION MODELS WITH PARK PAWL AND P PARK POSITION ALL 1000 AND 2200 TRANSMISSION MODELS WITH P PARK POSITION WARNING For vehicles containing 1000 and 2200 transmission models with P Park selector position follow this procedure each time the operator s station will be unoccupied with the engine running 1 Bring the vehicle to a complete stop using the service brake Make sure the engine is at low idle rpm Put the transmission in P Park Engage the park pawl by slowly releasing the service brake If a parking brake is present apply the parking brake Make sure the parking brake is properly engaged Apply the emergency brakes and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage Use P Park for the following To turn on or turn off the engine To check vehicle accessories To operate the engine at idle for longer than five minutes For stationary operation of t
53. n you have service locations throughout the world that are eager to meet your parts and service needs with e Expert service by trained personnel e Emergency service 24 hours a day in many areas Complete parts support Sales teams to help determine your transmission requirements Product information and literature Normally any situation that arises in connection with the sale operation or service of your transmission will be handled by the distributor or dealer in your area Check the telephone directory for the Allison Transmission service outlet nearest you or utilize Allison Transmission s Sales and Service Locator tool on the Allison Transmission web site at www allisontransmission com You may also refer to Allison Transmission s Worldwide Sales and Service Directory SA2229EN We recognize however that despite the best intentions of everyone concerned misunderstandings may occur To further assure your complete satisfaction we have developed the following three step procedure to be followed in the event a problem has not been handled satisfactorily Step One Discuss your problem with a member of management from the distributorship or dealership Frequently complaints are the result of a breakdown in communication and can quickly be resolved by a member of management If you have already discussed the problem with the Sales or Service Manager contact the General Manager All Allison Transmission dealers are associa
54. ng discolored or having a strong odor or by fluid analysis Local conditions severity of operation or duty cycle may require more or less frequent fluid or filter change intervals 97 Fluid Analysis Transmission protection and fluid change intervals can be optimized by monitoring fluid oxidation according to the tests and limits shown in the following table Fluid oxidation can be monitored through a fluid analysis firm and or by using an oil analysis kit Allison Transmission recommends that customers use fluid analysis as the primary method for determining fluid and filter change intervals In the absence of a fluid analysis program the fluid change intervals listed in Schedule 1 or Schedule 2 should be followed e Fluid analysis firms Consult your local telephone directory for fluid analysis firms To make sure fluid analysis is consistent and accurate use only one fluid analysis firm Refer to the Technician s Guide for Automatic Transmission Fluid GN2055EN for additional information Oil analysis kits part number 29537805 are available through your normal Allison Transmission parts source Refer to the Technician s Guide for Automatic Transmission Fluid GN2055EN for additional information Fluid Oxidation Measurement Limits 25 percent change from new fluid Total Acid Number 3 0 change from new fluid mg of KOH required to neutralize a gram of fluid TRANSMISSION FLUID CONTAMINATION Fluid Examination
55. nge Position Range Position Range PB Neutral PB Neutral PB Neutral Auto Apply Auto Apply Auto Apply Parking Brake Parking Brake Parking Brake D Drive 1 5 D Drive 115 D Drive 1 5 4 Fourth 4 Fourth 3 Third 3 Third 2 Second 2 Second 1 First 1 First 1 First With Auto Apply Parking Brake engaged The shift selector position representing this gear range may be labeled 5 for the highest gear in the range for Overdrive D for the normal Drive position or 1 5 for the complete gear range 1 4 in Trailering Mode or 4 Speed Calibration 15 All 1000 and 2000 Product Family Transmissions Without Either P Park or PB Auto Apply Parking Brake Positions Shift Shift Shift Selector Selector Selector Position Range Position Range Position Range R Reverse R Reverse N Neutral N Neutral N Neutral D Drive D Drive D Drive 1 5 1 4 13 iso Go First r The shift selector position representing this gear range may be labeled 5 for the highest gear in the range OD for Overdrive D for the normal Drive position or 1 5 for the complete gear range 1 4 in Trailering Mode or 4 Speed Calibration R 1 5 1 5 L3 1 1 2 1 1 There are several features of the 1000 and 2000 Product Family transmissions that can inhibit transmission shifting See the SHIFT INHIBITS section of this
56. ntrolled by the TCM PTO Engagement PTO With Internal Slide Engagement CAUTION Only use constant mesh PTOs DO NOT use manual shift PTOs which engage disengage with the PTO drive gear in the transmission or the transmission may be damaged Only use PTOs where the sliding gear is within the PTO Engage the PTO drivetrain as follows 1 With the vehicle stopped put the shift selector in a forward range while keeping the service brakes applied 2 Set the engine speed at idle 3 Engage the PTO If gears do not engage release the brakes momentarily to allow slight vehicle movement Engage the PTO Repeat as needed until the PTO is engaged 4 Shift to N Neutral and operate the PTO as needed Disengage the PTO drivetrain as follows 1 Idle the engine Set the brake Place the shift selector in a drive range Stop the PTO driven equipment Disengage the PTO Operate the vehicle in the normal matter NN Engagement Manual Shift PTO Manually shifted Cable Electrical Air shifted PTOs that engage internally inside the PTO can be used 45 vehicle can move unexpectedly and you or others could be injured DO NOT leave the vehicle with the engine running unless you have taken all of the following precautions e Shift the transmission to N Neutral P Park or PB Auto Apply Parking Brake 1 WARNING you leave the vehicle the engine is running the e Ma
57. park pawl will ratchet will not engage and will not hold the vehicle Repeated park pawl ratcheting can cause transmission damage WARNING If the vehicle has four wheel drive and the transfer case is in Neutral the vehicle can be free to roll even if the P Park position is selected To avoid injury and or property damage caused by unexpected movement of the vehicle be certain that the transfer case is in high drive range not Neutral whenever the vehicle is parked 40 WARNING If the vehicle is equipped with a two speed axle or 1 two speed transfer case which is engaged low even very low vehicle speeds can produce appreciable transmission output shaft speed Even the slightest vehicle motion can deter engagement of the park pawl in such cases To help avoid injury and or property damage caused by unexpected vehicle movement be certain that the axle or transfer case is in high drive range whenever the vehicle is parked and the park pawl is engaged Torque Lock If the vehicle is parked on an incline and P Park is properly engaged the weight of the vehicle may generate an excessive amount of torque on the park pawl in the transmission In this situation it may be difficult to shift the transmission out of the P Park position This condition is commonly called torque lock To alleviate torque lock do the following 1 Taking the vehicle s weight into consideration push the vehicle uphil
58. pply the transmission mounted parking brake with the vehicle in motion Transmission and or driveline damage can result In the event of a dynamic brake apply recheck the torgue of all brake mounting bolts to verify the integrity of the mount CAUTION Sustained use of the parking brake with the engine running and the transmission in range can cause an overheating failure of the transmission The vehicle can contain a buzzer or dash mounted light to alert the operator when the ignition switch is ON the parking brake is applied and the transmission selector is in range PARK PAWL A park pawl is standard on 1000 and 2200 transmission models and is not available on 2100 and 2500 transmission models The park pawl effectively grounds the transmission output shaft thereby preventing rotation of the driveline Provided the vehicle is stationary selecting P Park on the shift selector places the transmission in NEUTRAL and engages the park pawl The park pawl exists but cannot be engaged in some vehicle configurations using 1000 and 2200 transmission models e g some rear engine vehicles with air brakes For these configurations the P Park position is not used WARNING To help avoid injury and or property damage caused by unexpected vehicle movement do not attempt to engage P Park with the vehicle in motion 2 km hr 1 mph or higher If you attempt to engage P Park with the vehicle in motion 2 km hr 1 mph or higher the
59. r dealer when any of these conditions occur Shifting feels abnormal e Transmission leaks fluid Unusual transmission related sounds changes in sound caused by normal engine thermostatic fan cycling while climbing a long grade with a heavy load have been mistaken for transmission related sounds CHECK TRANS light or RANGE INHIBIT ED light comes on frequently TURNING THE VEHICLE ON OFF Before turning on or off the engine the driver must verify that the service brake is engaged and one of the following ranges has been selected and engaged e P Park PB Auto Apply Parking Brake N Neutral if P Park or PB Auto Apply Parking Brake is not available NOTE The vehicle should not start unless these ranges have been selected If the vehicle starts in any other range seek service immediately Transmission operation at cold ambient temperatures may require preheating or the use of a lower viscosity transmission fluid See the FLUID RECOMMENDA TIONS section in this manual Even when the engine is warm and capable of full throttle output the transmission should not be taken out of P Park PB Auto Apply Parking Brake or N Neutral for at least thirty seconds to allow for buildup of transmission fluid pressure 29 MAXIMUM VEHICLE LOADING WARNING Operation with excessive loads can cause transmission damage and unexpected vehicle movement To help avoid injury property damage and or transmi
60. range 23 ALL 2100 AND 2500 TRANSMISSION MODELS WITH PB AUTO APPLY PARKING BRAKE POSITION WARNING The transmission incorporates a hold feature to prohibit upshifting above the range selected during normal driving For downhill operation select a lower transmission range If the engine governed speed is exceeded in the held range however the transmission will upshift to the next higher range to prevent engine damage To avoid injury and or property damage due to loss of vehicle control use the vehicle brakes to prevent exceeding engine governed speed in the held range WARNING To avoid loss of control use a combination of downshifting braking and other retarding devices Downshifting to a lower transmission range increases engine braking and can help you maintain control The transmission has a feature to prevent automatic upshifting above the lower range selected However during downhill operation if engine governed speed is exceeded in the lower range the transmission will upshift to the next higher range to prevent engine damage This will reduce engine braking and could cause a loss of control Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected Use 4 FOURTH or 3 THIRD for city traffic and braking on steep downgrades 3 for shift selectors with PB R N D 3 2 1 Actual ranges available depend on programming by vehicle manufacturer Use 3
61. re The throttle position sensor or engine to transmission communication link speed sensors pressure switch manifold and IMS communicate information to the TCM The TCM processes this information and then sends signals to actuate specific solenoids located within the control valve body in the transmission These solenoids control both oncoming and off going clutch pressures to provide closed loop shift control by matching input rpm during a shift to a previously established desired profile that is programmed into the TCM The 1000 and 2000 Product Family electronic control system has an adaptive shifting feature Adaptive shifting helps optimize shift quality by monitoring critical characteristics of clutch engagement and making on going adjustments to improve subsequent shifts The transmission shift calibration is based on several different types of shifts e g full throttle part throttle closed throttle upshifts downshifts etc Each shift is associated with specific speed and throttle position parameters In order to optimize each type of shift for normal driving shift controls must experience operation and shifting in a wide variety of operating conditions A drive in period under varied driving conditions is required before the adaptive controls can be expected to optimize each and every shift In general shift quality will begin to converge to their adapted level following several shifts of a particular shift typ
62. rned speed is exceeded in the held range however the transmission will upshift to the nezt higher range to prevent engine damage To avoid injury and or property damage due to loss of vehicle control use the vehicle brakes to prevent exceeding engine governed speed in the held range WARNING To avoid loss of control use a combination of downshifting braking and other retarding devices Downshifting to a lower transmission range increases engine braking and can help you maintain control The transmission has a feature to prevent automatic upshifting above the lower range selected However during downhill operation if engine governed speed is exceeded in the lower range the transmission will upshift to the next higher range to prevent engine damage This will reduce engine braking and could cause a loss of control Apply the vehicle brakes or other retarding device to prevent exceeding engine governed speed in the lower range selected To use the engine as a braking force select the next lower range If the vehicle is exceeding the maximum speed for this range use the service brakes and or other retarding devices to slow the vehicle When a lower speed is reached the TCM will automatically downshift the transmission Engine braking provides good speed control for going down grades When the vehicle is heavily loaded or the grade is steep it may be desirable to preselect a lower range before reaching the grade If the engine governed
63. rom the TCM DO NOT WELD on the vehicle without disconnecting TCM battery power and ground leads DO NOT WELD on any control components DO NOT CONNECT welding cables to any control components PROTECT CONTROL COMPONENTS FROM SPARKS AND HEAT DURING WELDING A label describing on vehicle welding precautions ST2067EN is available from your authorized Allison service dealer and should be installed in a conspicuous place A vehicle used in a vocation that requires frequent modifications or repairs involving welding must have an on vehicle warning label IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL Transmission fluid cools lubricates and transmits hydraulic power Always maintain proper fluid level If fluid level is too low the torque converter and clutches do not receive an adequate supply of fluid and the transmission overheats If the fluid level is too high the fluid aerates causing the transmission to shift erratically and overheat Fluid may be expelled through the breather or dipstick tube when the fluid level is too high TRANSMISSION FLUID CHECK WARNING For vehicles containing 1000 and 2200 transmission models with P Park selector position follow this procedure each time the operator s station will be unoccupied with the engine running Bring the vehicle to a complete stop using the service brake Make sure the engine is at low idle rpm Put the transmission in P Park Engage the park pawl by slowl
64. ry and or property damage WARNING R Reverse may not be obtained due to an active inhibitor Check for the illumination of the RANGE INHIBIT light or CHECK TRANS CHECK ENGINE light See the SHIFT INHIBITS section of this manual WARNING To help avoid injury and or property damage caused by unexpected vehicle movement do not make shifts from R Reverse to N Neutral without applying the service brakes parking brake or emergency brake Selecting N Neutral does not apply vehicle brakes unless an auxiliary system to apply a parking brake is installed CAUTION Do not idle in R Reverse for more than five minutes Extended idling in R Reverse can cause transmission overheating and damage Always select N Neutral whenever time at idle exceeds five minutes 25 ALL 1000 AND 2000 PRODUCT FAMILY TRANSMISSIONS WITHOUT EITHER P PARK OR PB AUTO APPLY PARKING BRAKE POSITIONS R Reverse is used to back the vehicle Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R Reverse or from R Reverse to a forward range The reverse warning signal is activated when the shift selector is in this position WARNING To help avoid injury or property damage caused by unexpected vehicle movement do not make shifts to or from N Neutral without manually or automatically applying an appropriate vehicle brake WARNING DO NOT allow the vehicle to coast in N Neutral There
65. ry system to apply a parking brake is installed CAUTION Do not idle in R Reverse for more than Y five minutes Extended idling in R Reverse can cause transmission overheating and damage Always select PB Auto Apply Parking Brake whenever time at idle exceeds five minutes R Reverse is used to back the vehicle Completely stop the vehicle and let the engine return to idle before shifting from a forward range to R Reverse or from R Reverse to a forward range The reverse warning signal is activated when the shift selector is in this position WARNING DO NOT allow the vehicle to coast in N Neutral There is no engine braking in N Neutral You could lose control of the vehicle causing property damage or personal injury Coasting in neutral can cause severe transmission damage WARNING To help avoid injury or property damage caused by unexpected vehicle movement do not make shifts to or from N Neutral without manually or automatically applying an appropriate vehicle brake N This position places the transmission in N Neutral Used for starting the engine and stationary operation 22 ALL 2100 AND 2500 TRANSMISSION MODELS WITH PB APPLY PARKING POSITION WARNING D Drive and other forward ranges may not be obtained due to an active inhibitor The range selected may not be obtained resulting in unexpected vehicle movement To help avoid injury and or property damage always apply the service brak
66. ssion damage do not exceed the GVW and GCW values listed in the Maximum Vehicle Loading table or the OEM vehicle rating whichever is less Maximum Vehicle Loading Model Application GVW GCW kg Ibs Ibs 1000 11 800 N A Transit Bus 7500 16 540 N A A Shuttle Bus Coach and Non North American School Bus T C NNASB 0 N N N 6 000 0 1000 10 000 22 000 11 80 1000 SP Specialty 10000 22 000 11800 26 000 T C NNASB 12000 26 500 2100 MH 12 000 26 500 13 600 30000 30 000 2100 12 000 26 500 12 000 26 500 11000 24200 s 11 800 11 80 11 800 11 80 2200 MH 11 800 11 80 11 800 11 800 2500 15 000 15 000 11 000 N Non North 15 000 33 000 15 000 33 000 American School 2100 SP Specialty 12 000 26 500 13 600 30 000 A A A Bus 2500 MH 15 000 33 000 15 000 33 000 2500 SP Specialty 15000 33 000 15000 33 000 30 ACCELERATOR CONTROL WARNING To avoid injury or property damage caused by sudden movement of the vehicle do not make shifts from N Neutral to a forward range or R Reverse when the throttle is open The vehicle will lurch forward or rearward and the transmission can be damaged Avoid this condition by making shifts from N Neutral to a forward range or R Reverse only when the throttle is closed and service brakes are applied The position of the accelerator pedal influences when automatic shifting occurs When the pedal is fully
67. ted with an Allison Transmission distributor If the problem originates with a dealer explain the matter to a management member of the distributorship with whom the dealer has his service agreement The dealer will provide his Allison Transmission distributor s name address and telephone number on request 63 Step Two When it appears the problem cannot be readily resolved at the distributor level without additional assistance contact the Allison Technical Assistance Center at 800 252 5283 They will place you in contact with the Regional Customer Support Manager for your area For prompt assistance please have the following information available e Name and location of authorized distributor or dealer Type and make of vehicle equipment Transmission model number serial number and assembly number if equipped with electronic controls also provide the TCM assembly number e Transmission delivery date and accumulated miles and or hours of operation Nature of problem Chronological summary of your transmission s history Step Three If you are still not satisfied after contacting the Regional Customer Support Manager present the entire matter to the Home Office by writing to the following address Allison Transmission Manager Warranty Administration PO Box 894 Mail Code 462 470 PF9 Indianapolis IN 46206 0894 The inclusion of all pertinent information will assist the Home Office in expediting the matter Wh
68. th the transmission in D Drive or another forward range transmission shifts both converter torque converter clutch mode shifts and shifts between gears are based on the automatic shift sequence of the transmission shift controls PTO drive gear speed will be affected each time a shift occurs With the vehicle stopped and the engine at idle PTO output speed is dependent upon the transmission gear selection e If the transmission is in D Drive or R Reverse the PTO output speed is zero e If the transmission is in N Neutral P Park or PB Auto Apply Parking Brake the PTO output will rotate In some vehicles the transmission will shift into N Neutral regardless of the shift selector position under the following conditions e The PTO is enabled e The transmission output speed is near zero e The throttle position is near zero To reselect a range after the PTO is turned off the operator must shift into N Neutral then shift to the desired range e CAUTION Do not exceed the engagement and operational speed limits imposed on the driven equipment during the operation of the PTO Exceeding the speed limits produces high hydraulic pressure in the PTO that can damage the PTO components Consult the vehicle manufacturer s literature for these speed limits 47 CAUTION When PTO disengagement occurs due to an overspeed condition the PTO will automatically re engage at a lower user specified speed Re engaging the PTO at
69. tion will be unoccupied with the engine running Bring the vehicle to a complete stop using the service brake Make sure the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure the parking brake is properly engaged Apply the emergency brake and make sure it is properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage Use PB Auto Apply Parking Brake for the following To turn on or turn off the engine To check vehicle accessories To operate the engine at idle for longer than five minutes For stationary operation of the power takeoff if your vehicle is equipped with a PTO This position places the transmission in N Neutral and engages the parking brake WARNING R Reverse may not be obtained due to an active inhibitor Check for the illumination of the RANGE INHIBIT light or CHECK TRANS CHECK ENGINE light See the SHIFT INHIBITS section of this manual 21 ALL 2100 AND 2500 TRANSMISSION MODELS WITH PB AUTO APPLY PARKING BRAKE POSITION WARNING To help avoid injury and or property damage caused by unezpected vehicle movement do not make shifts from R Reverse to N Neutral without applying the service brakes parking brake or emergency brake Selecting N Neutral does not apply vehicle brakes unless an auxilia
70. tral 4 Apply the emergency brakes and or parking brake and make sure they are properly engaged 5 If the operator s station will be unoccupied with the engine running chock the wheels and take any other steps necessary to keep the vehicle from moving 1 WARNING For vehicles containing 1000 2100 2200 and 2500 If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage 51 Fluid Check Procedure Clean all dirt from around the end of the fluid fill tube before removing the dipstick Do not allow dirt or foreign matter to enter the transmission Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Check the fluid level using the following procedure and report any abnormal fluid levels to your service management or an Allison distributor or dealer Cold Check Procedure The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made CAUTION The fluid level rises as fluid temperature rises DO NOT fill the transmission above the COLD CHECK band if the transmission fluid is below normal operating temperatures During operation an overfull transmission can become overheated leading to transmission damage Check the fluid level as follows 1 Bring the vehicle to complete stop level surface using the service
71. transmission in range and the output stalled Prolonged operation of this type will cause the transmission fluid temperature to become excessively high and will cause severe overheat damage to the transmission Your vehicle may have a dash indicator or other alarm that turns on when the transmission sump temperature or to cooler temperature exceeds specified limits If the transmission overheats during normal operations do the following Check the fluid level in the transmission See the CARE AND MAINTENANCE section of this manual e Safely stop the vehicle and check the cooling system If it appears to be functioning properly run the engine at 1200 1500 rpm with the transmission in N Neutral This should reduce the transmission and engine temperatures to normal operating levels in 2 or 3 minutes If temperatures do not decrease reduce the engine rpm e If high temperature in either the engine or transmission persists stop the engine and have the overheating condition investigated by service management PARKING BRAKE For shift selectors with a PB Auto Apply Parking Brake position selecting PB Auto Apply Parking Brake places the transmission in NEUTRAL and automatically engages the parking brake For shift selectors without a PB Auto Apply Parking Brake position the parking brake must be manually engaged Your vehicle may have an indicator light that illuminates when the parking brake is applied 39 CAUTION Do not a
72. uid Operating Temperature Requirements table As the transmission reaches normal operating temperature all shift ranges and the torque converter clutch mode will begin to function 55 TRANSMISSION FLUID AND FILTER CHANGE INTERVALS determined by the severity of transmission service To help avoid transmission damage more frequent changes can be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating CAUTION Transmission fluid and filter change frequency is Frequency New vehicles delivered from the OEM with a mixture of TranSynd and non TranSynd fluid must follow fluid filter change recommendations outlined in Schedule 1 bf the Recommended Fluid and Filter Change Intervals schedules If the customer fills the transmission with TranSynd or TES 295 equivalent the change recommendations of Schedule 1 must be followed Upon the next oil change if the customer reinstalls TranSynd or TES 295 equivalent the fluid filter change recommendations outlined in Schedule 2 may be used The recommendations in Schedale based upon Allison fluid change procedures and the transmission containing 100 percent of TranSynd fluid For transmissions that contain a mixture of TranSynd and non TranSynd fluids refer to Schedule 1 NOTE Fluid Exchanging Machines are not recommended or recognized J due to variation and inconsistencies that may not guarante
73. y releasing the service brake If a parking brake is present apply the parking brake Make sure the parking brake is properly engaged Apply the emergency brakes and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage 50 WARNING For vehicles containing 2100 and 2500 transmission models with PB Auto Apply Parking Brake selector position follow this procedure each time the operator s station will be unoccupied with the engine running Bring the vehicle to a complete stop using the service brake 2 Make sure the engine is at low idle rpm Put the transmission in PB Auto Apply Parking Brake Make sure the parking brake is properly engaged Apply the emergency brakes and make sure they are properly engaged Chock the wheels and take any other steps necessary to keep the vehicle from moving If this procedure is not followed the vehicle can move unexpectedly and cause injury and or property damage transmission models without either P Park or PB Auto Apply Parking Brake selector positions each time you park the vehicle or leave the operator s station with the engine running do the following 1 Bring the vehicle to a complete stop using the service brake 2 Make sure the engine is at low idle rpm 3 Put the transmission in N Neu

Operator`s Manual 1000 And 2000 Product Families International

Contents

Download Pdf Manuals

Related Search

Related Contents