Download Allison Transmission MT3190EN 1000 & 2000 Product Family Mechanic’s Tips Manual PDF

Description

Allison Transmission MT3190EN 1000 & 2000 Product Family Mechanic’s Tips Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission MT3190EN 1000 & 2000 Product Family Mechanic’s Tips Manual – PDF DOWNLOAD

1000 EVS 2100 EVS 2200 EVS 2500 EVS
1000 HS 2100 HS 2200 HS 2500 HS
1000 MH 2100 MH 2200 MH 2500 MH
1000 PTS 2100 PTS 2200 PTS 2500 PTS
1000 RDS 2100 RDS 2200 RDS 2500 RDS
1000 SP 2100 SP 2200 SP 2500 SP
B 210 B 220
1000 Series™ 2000 Series™ 2000 MH Series 2400 Series™

PREFACE :

• This handbook is a mechanic’s reference for maintaining, removing, or installing
  1000 and 2000 Product Families transmissions. All features of the transmission and
  the vehicle involved in installation procedures are discussed. The information
  presented will help the mechanic maintain, remove, or install the transmission in a
  manner that assures satisfactory operation and long service life. For additional
  detailed information, refer to the appropriate transmission service manual and
  electronic controls troubleshooting manual.
  Unless specifically indicated otherwise, this handbook refers to all 1000 and 2000
• Product Families transmissions. The differences between the various transmissions
  are explained as required.

TABLE OF CONTENTS:

Allison Transmission MT3190EN 1000 & 2000 Product Family Mechanic’s Tips Manual – PDF DOWNLOAD

MT3190EN………………………………………………………………………………………………. 0
TITLE PAGE…………………………………………………………………………………………….. 2
WARNINGS, CAUTIONS, AND NOTES……………………………………………………………………………. 3
TRADEMARK INFORMATION…………………………………………………………………………………… 3
TABLE OF CONTENTS………………………………………………………………………………………. 4
PREFACE……………………………………………………………………………………………….. 6
1000 AND 2000 PRODUCT FAMILIES — CROSS SECTION………………………………………………………… 7
1000 AND 2000 PRODUCT FAMILIES — CROSS SECTION with Optional Converter Housing, Rear Cover, and Shallow pan….8
1000 AND 2000 PRODUCT FAMILIES TRANSMISSION – LEFT-FRONT VIEW………………………………………….. 9
1000 AND 2000 PRODUCT FAMILIES TRANSMISSION – RIGHT-REAR VIEW…………………………………………..10
SECTION I – PREVENTIVE MAINTENANCE………………………………………………………………………..12
1–1. PERIODIC INSPECTIONS AND CARE…………………………………………………………………….12
1–2. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL………………………………………………………14
1–3. TRANSMISSION FLUID CHECK…………………………………………………………………………14
Figure 1–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)……………………………………16
Figure 1–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)…………………………………….17
1–4. KEEPING FLUID CLEAN……………………………………………………………………………..21
1–5. FLUID RECOMMENDATIONS……………………………………………………………………………21
Table 1–1. Transmission Fluid Operating Temperature Requirements……………………………………..22
1–6. TRANSMISSION FLUID AND FILTER CHANGE INTERVALS……………………………………………………..22
Table 1–2. 1000 and 2000 Product Families Transmission Fluid and Filter Change…………………………23
Table 1–3. Fluid Oxidation Measurement Limits………………………………………………………24
1–7. TRANSMISSION FLUID CONTAMINATION………………………………………………………………….24
1–8. TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE……………………………………………………..25
Figure 1–3. ……………………………………………………………………………………26
Table 1–4. Transmission Fluid Capacity…………………………………………………………….27
1–9. OIL VENT (BREATHER)……………………………………………………………………………..27
SECTION II – REMOVING TRANSMISSION………………………………………………………………………..28
2–1. DRAINING TRANSMISSION……………………………………………………………………………28
2–2. DISCONNECTING CONTROLS…………………………………………………………………………..28
2–3. UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE……………………………………………………..29
2–4. REMOVING THE TRANSMISSION………………………………………………………………………..29
2–5. REMOVING THE FLEXPLATE ADAPTER……………………………………………………………………30
2–6. REMOVING OUTPUT FLANGE OR YOKE……………………………………………………………………30
SECTION III – PREPARING THE TRANSMISSION FOR INSTALLATION……………………………………………………31
3–1. CHECKING INPUT COMPONENTS………………………………………………………………………..31
3–2. INSTALLING OUTPUT FLANGE OR YOKE………………………………………………………………….31
3–3. INSTALLING PTO………………………………………………………………………………….32
Figure 3–1. Cooler Port and Main Pressure Tap Location………………………………………………33
Figure 3–2. PTO Lube Plumbing Schematic……………………………………………………………34
Figure 3–3. PTO Clutch Pressure Plumbing Schematic………………………………………………….35
3–4. INSTALLING FILL TUBE AND SEAL…………………………………………………………………….35
3–5. CHECKING PLUGS AND OPENINGS………………………………………………………………………36
SECTION IV – PREPARING VEHICLE FOR TRANSMISSION INSTALLATION…………………………………………………37
4–1. ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS……………………………………………………….37
Figure 4–1. 1000 and 2000 Product Families Engine Adaptation (No. 3 Housing)…………………………..38
Figure 4–2. 1000 and 2000 Product Families Engine Adaptation (No. 2 Housing)…………………………..39
Figure 4–3. Typical Arrangement Of Adaptation Components…………………………………………….40
4–2. CHECKING FLEXPLATE DRIVE ASSEMBLY…………………………………………………………………41
4–3. CHASSIS AND DRIVELINE INSPECTION………………………………………………………………….41
4–4. COOLER, FILTER, AND LINES………………………………………………………………………..42
4–5. CHECKING CONTROLS……………………………………………………………………………….43
Figure 4–4. Hitch-Pin Throttle Position Sensor Installation Diagram…………………………………..45
SECTION V – INSTALLING TRANSMISSION INTO VEHICLE……………………………………………………………46
5–1. HANDLING……………………………………………………………………………………….46
5–2. MOUNTING TO ENGINE ……………………………………………………………………………..46
Figure 5–1. Pilot Tool For Transmission-To-Engine Alignment………………………………………….47
5–3. INSTALLING TRANSMISSION MOUNTING COMPONENTS………………………………………………………..48
5–4. COUPLING TO DRIVELINE……………………………………………………………………………48
5–5. CONNECTING POWER TAKEOFF CONTROLS…………………………………………………………………48
5–6. CONNECTING PARKING BRAKE CONTROL………………………………………………………………….49
5–7. CONNECTING COOLER……………………………………………………………………………….49
Figure 5–2. Cooler Port Location…………………………………………………………………..49
5–8. CONNECTING CONTROLS……………………………………………………………………………..50
5–9. FILLING HYDRAULIC SYSTEM…………………………………………………………………………50
5–10. INSTALLATION CHECKLIST………………………………………………………………………….51
5–11. ROAD TEST AND VEHICLE OPERATION CHECKLIST…………………………………………………………53
SECTION VI – CUSTOMER SERVICE…………………………………………………………………………….55
6–1. OWNER ASSISTANCE………………………………………………………………………………..55
6–2. SERVICE LITERATURE………………………………………………………………………………55
Table 6–1. 1000 and 2000 Product Families Service Literature………………………………………….55

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