Allison Transmission PO4009EN 1000 & 2000 Product Families Principles of Operation Manual – PDF DOWNLOAD

Description

Allison Transmission PO4009EN 1000 & 2000 Product Families Principles of Operation Manual – PDF DOWNLOAD

DESCRIPTION:

Allison Transmission PO4009EN 1000 & 2000 Product Families Principles of Operation Manual – PDF DOWNLOAD

FOREWORD :

Principles of Operation will help you become familiar with the operation of the Allison 1000 and 2000 Product
Families transmissions with Allison 4 th
Generation Controls. This manual supplements other Allison publications
as a useful reference for service, diagnosis, and repair of these transmissions. Review the Table of Contents to
quickly locate information. This manual includes:
• General description of the 1000 and 2000 Product Families transmissions and detailed descriptions
of major components.
• Description of the electronic control system components and its diagnostic capability.
• Description of the hydraulic control system components.
• Detailed hydraulic schematics and torque flow diagrams.

• All specifications and data are subject to change without notice. This publication is periodically revised to include
  new models and new product features. To ensure that you have the latest information, check with your Allison
  Transmission service outlet for the current publication version.
• Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look
  in your telephone directory under the heading of Transmissions—Truck, Tractor, etc.

TABLE OF CONTENTS:

Allison Transmission PO4009EN 1000 & 2000 Product Families Principles of Operation Manual – PDF DOWNLOAD

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Important Safety Notice . . . . . . . . . . . . . . . . . . . . i
Trademarks Used In This Manual . . . . . . . . . . . . .ii
Abbreviations And Acronyms . . . . . . . . . . . . . . . .ii
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . iv
SECTION 1. GENERAL DESCRIPTION
1–1. SCOPE OF THE MANUAL
A. Coverage . . . . . . . . . . . . . . . . . . . . . . . . . .1
B. Illustrations . . . . . . . . . . . . . . . . . . . . . . . .1
1–2. GENERAL DESCRIPTION
A. Transmission Design Features. . . . . . . . . .1
i. Transmission-to-Engine
Coupling . . . . . . . . . . . . . . . . . . . . . .1
ii. Torque Converter . . . . . . . . . . . . . . . .1
iii. Planetary Gearing . . . . . . . . . . . . . . .1
v. Clutches . . . . . . . . . . . . . . . . . . . . . . .1
v. Hydraulic System . . . . . . . . . . . . . . .1
vi. Transmission Fluid Filtration . . . . . .1
vii. Electronic Controls . . . . . . . . . . . . . .3
viii. Oil Cooler Manifold . . . . . . . . . . . . .3
ix. Remote Oil Cooler. . . . . . . . . . . . . . .3
x. Oil Fill Tube/Dipstick Provision . . . .3
xi. Parking Pawl/Parking Brake . . . . . . .3
xii. Power Takeoff . . . . . . . . . . . . . . . . . .3
xiii. Output Flanges/Yokes . . . . . . . . . . . .3
B. Vocational Model Nomenclature. . . . . . . .3
C. Transmission Identification . . . . . . . . . . . .3
D. Metric Configuration . . . . . . . . . . . . . . . . .4
SECTION 2. MODULE DESCRIPTION
AND OPERATION
2–1. MODULAR DESIGN
. . . . . . . . . . . . . . . . . .5
2–2. INPUT MODULE
A. Torque Converter. . . . . . . . . . . . . . . . . . . .5
i. Vortex Flow . . . . . . . . . . . . . . . . . . . .6
ii. Rotary Flow. . . . . . . . . . . . . . . . . . . .6
iii. Torque Converter Clutch
Operation . . . . . . . . . . . . . . . . . . . . . .7
B. Converter Housing. . . . . . . . . . . . . . . . . . .7
C. Front Support. . . . . . . . . . . . . . . . . . . . . . .7
D. Charging Pump . . . . . . . . . . . . . . . . . . . . .7
2–3. GEARBOX MODULE—ROTATING
CLUTCH AND POWER TAKEOFF
A. Rotating Clutch . . . . . . . . . . . . . . . . . . . . .7
B. Power Takeoff (PTO) Provision . . . . . . . .8
C. Tone Wheel for Turbine Speed Input . . . .8
2–4. GEARBOX MODULE—PLANETARY
GEARS AND STATIONARY CLUTCHES
A. Planetary Gear Operation . . . . . . . . . . . . .8
i. Input Element—Sun Gear . . . . . . . .10
ii. Input Element—Carrier . . . . . . . . . .10
iii. Input Element—Ring Gear . . . . . . .10
B. Mechanical Gear Ratios . . . . . . . . . . . . .10
C. Main Housing and Stationary
Clutches. . . . . . . . . . . . . . . . . . . . . . . . . .11
D. P1 Planetary. . . . . . . . . . . . . . . . . . . . . . .11
E. P2 Planetary. . . . . . . . . . . . . . . . . . . . . . .11
F. P3 Planetary . . . . . . . . . . . . . . . . . . . . . .11
G. Main Shaft . . . . . . . . . . . . . . . . . . . . . . . .12
2–5. OUTPUT MODULE
A. Rear Cover and Output Shaft . . . . . . . . .12
B. Parking Provisions. . . . . . . . . . . . . . . . . .12
i. Parking Pawl . . . . . . . . . . . . . . . . . .12
ii. Transmission-Mounted Parking
Brake . . . . . . . . . . . . . . . . . . . . . . . .12
2–6. OIL PAN/CONTROL VALVE MODULE
A. Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Electro-Hydraulic Control
Valve Assembly . . . . . . . . . . . . . . . . . . . 14
SECTION 3. ELECTRONIC CONTROL
SYSTEM
3–1. EXTERNAL COMPONENTS
A. Transmission Control Module . . . . . . . . 15
i. Inputs . . . . . . . . . . . . . . . . . . . . . . . 15
ii. Shift Calibration . . . . . . . . . . . . . . . 16
iii. Adaptive Control. . . . . . . . . . . . . . . 16
iv. Inhibits . . . . . . . . . . . . . . . . . . . . . . 16
v. Diagnostic Functions . . . . . . . . . . . 16
B. Throttle Position Input . . . . . . . . . . . . . . 16
i. Throttle Position Sensor
(Non-Electronic Engines) . . . . . . . . 16
ii. Auto Cal (Automatic Throttle
Position Calibration). . . . . . . . . . . . 17
iii. Throttle Position
(Electronic Engines) . . . . . . . . . . . . 18
C. Speed Sensors. . . . . . . . . . . . . . . . . . . . . 18
i. Input Speed Sensor . . . . . . . . . . . . . 18
ii. Turbine Speed Sensor . . . . . . . . . . . 18
iii. Output Speed Sensor. . . . . . . . . . . . 18
D. Shift Selector . . . . . . . . . . . . . . . . . . . . . 18
i. Shift Selector Range Positions . . . . 19
ii. Manual Selector Valve . . . . . . . . . . 19
iii. Internal Mode Switch (IMS). . . . . . 20
3–2. INTERNAL COMPONENTS
A. Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 20
i. Normally Closed (N/C) Solenoids . . 20
ii. Clutch Pressure Control Solenoids . 22
B. Pressure Switch Manifold . . . . . . . . . . . 23
C. Internal Wiring Harness . . . . . . . . . . . . . 23
3–3. SHIFT SCHEDULES
A. Primary Shift Schedule. . . . . . . . . . . . . . 25
B. Secondary Shift Schedule. . . . . . . . . . . . 25
C. Shift Schedule Features . . . . . . . . . . . . . 25
i. Hold Upshift . . . . . . . . . . . . . . . . . . 25
ii. Preselect Downshift . . . . . . . . . . . . 25
3–4. GENERAL CLUTCH CONTROL
i. Pre-Shift . . . . . . . . . . . . . . . . . . . . . 25
ii. Clutch Control . . . . . . . . . . . . . . . . 25
iii. Post-Shift . . . . . . . . . . . . . . . . . . . . 25
3–5. COMMUNICATIONS INTERFACES
A. SAE J1850 Interface. . . . . . . . . . . . . . . . 26
B. SAE J1939 Interface. . . . . . . . . . . . . . . . 26
3–6. VEHICLE INTERFACE WIRING
. . . . . . 26
3–7. SPECIAL INPUT AND OUTPUT
FUNCTIONS
A. Input Functions. . . . . . . . . . . . . . . . . . . . 26
B. Output Functions . . . . . . . . . . . . . . . . . . 27
3–8. EXTERNAL HARNESSES
. . . . . . . . . . . . 27
SECTION 4. ELECTRONIC
DIAGNOSTICS
4–1. DIAGNOSTICS CAPABILITY
A. Diagnostic Tool . . . . . . . . . . . . . . . . . . . 29
B. Diagnostic Trouble Codes . . . . . . . . . . . 29
i. Diagnostic Trouble Codes (DTC). . 29
ii. Display Procedure. . . . . . . . . . . . . . 29
4–2. CHECK TRANS LIGHT
. . . . . . . . . . . . . . 29
4–3. RANGE/SHIFT TESTS
A. Range Verification Test. . . . . . . . . . . . . . 29
B. Off-Going Ratio Test . . . . . . . . . . . . . . . 30
C. Oncoming Ratio Test . . . . . . . . . . . . . . . 30
D. Shift Valve Integrity Test . . . . . . . . . . . . 30
SECTION 5. HYDRAULIC CONTROL
SYSTEM
5–1. HYDRAULIC CONTROL SYSTEM
A. Overview . . . . . . . . . . . . . . . . . . . . . . . . .31
B. Schematics. . . . . . . . . . . . . . . . . . . . . . . .31
C. Hydraulic Passage Identification . . . . . . .31
5–2. HYDRAULIC CONTROL SYSTEM
COMPONENTS
A. Main-Pressure Circuit . . . . . . . . . . . . . . .32
B. Modulated Main Pressure . . . . . . . . . . . .32
C. Control Main Circuit . . . . . . . . . . . . . . . .32
i. Control Main Relief Valve. . . . . . . .32
ii. Control Main Filter . . . . . . . . . . . . .33
D. Torque Converter Circuit. . . . . . . . . . . . .33
i. Converter Operation . . . . . . . . . . . .33
ii. Torque Converter Clutch
Operation . . . . . . . . . . . . . . . . . . . . .33
iii. Converter Relief Valve. . . . . . . . . . .33
E. Cooler/Lubrication Circuit . . . . . . . . . . .33
F. Exhaust Circuit . . . . . . . . . . . . . . . . . . . .34
G. Suction Circuit. . . . . . . . . . . . . . . . . . . . .34
H. Exhaust Backfill Circuit . . . . . . . . . . . . .34
I. PCS1 and PCS2. . . . . . . . . . . . . . . . . . . .34
5–3. HYDRAULIC CONTROL SYSTEM
CIRCUITS
A. Neutral Operation . . . . . . . . . . . . . . . . . .36
B. First Range Operation . . . . . . . . . . . . . . .37
C. Second Range Operation. . . . . . . . . . . . .38
D. Lockup Operation . . . . . . . . . . . . . . . . . .38
E. Third Range Operation . . . . . . . . . . . . . .39
F. Fourth Range Operation . . . . . . . . . . . . .40
G. Fifth Range Operation. . . . . . . . . . . . . . .41
H. Sixth Range Operation . . . . . . . . . . . . . .42
I. Reverse Operation . . . . . . . . . . . . . . . . . .43
5–4. CLUTCH APPLICATION
A. Normal Operation . . . . . . . . . . . . . . . . . .43
B. Operation During Electrical
Interruption . . . . . . . . . . . . . . . . . . . . . . .45
SECTION 6. TORQUE PATHS
THROUGH THE
TRANSMISSION
6–1. TORQUE FLOW
A. Torque Converter Operation . . . . . . . . . . .47
B. Torque Converter Clutch Operation . . . . .47
6–2. TORQUE PATHS
A. Neutral Torque Path. . . . . . . . . . . . . . . . .47
B. First Range Torque Path . . . . . . . . . . . . .48
C. Second Range Torque Path . . . . . . . . . . .49
D. Third Range Torque Path. . . . . . . . . . . . .50
E. Fourth Range Torque Path. . . . . . . . . . . .51
F. Fifth Range Torque Path . . . . . . . . . . . . .52
G. Sixth Range Torque Path . . . . . . . . . . . .53
H. Reverse Torque Path . . . . . . . . . . . . . . . .54

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ALLISON TRANSMISSION PO4009EN 1000 & 2000 PRODUCT FAMILIES PRINCIPLES OF OPERATION MANUAL – PDF DOWNLOAD:

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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