Allison Transmission 2200 HS

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Summary

INTRODUCTION

TRADEMARK USAGE

Lists trademarks and their owners as property of various companies.

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

Explains the meaning and usage of Warning, Caution, and Note headings in the manual.

SECTION 1-GENERAL INFORMATION

SCOPE OF MANUAL

Defines the scope of the manual, including models, series, and engineering changes.

SUPPLEMENTARY INFORMATION

Explains how supplementary information is issued and how to obtain the latest updates.

ORDERING PARTS

Details how to identify transmission models and order replacement parts using the nameplate and parts catalog.

GENERAL DESCRIPTION

Details the transmission design features, including coupling, torque converter, planetary gearing, and clutches.

DIAGNOSIS

Provides guidance on identifying and troubleshooting transmission faults and issues.

Before Starting

Outlines initial steps to identify faulty conditions and probable causes before repair.

CHECK TRANS Light

Explains the function, illumination, and effects of the CHECK TRANS warning light on the transmission.

Allison DOCTM Personal Computer (PC)-Based Diagnostic System

Describes the Allison DOC diagnostic system for accessing TCM data and troubleshooting.

Troubleshooting When No Diagnostic Codes Are Present

Provides guidance on troubleshooting transmission issues when no diagnostic codes are logged.

Troubleshooting Intermittent Diagnostic Codes

Lists common causes and checks for intermittent diagnostic codes in the transmission.

PRESERVATION AND STORAGE

Details procedures for preserving and storing transmissions to prevent damage over time.

RESTORING TRANSMISSION TO SERVICE

Procedures for returning a transmission to service after storage or new installation.

OPERATING INSTRUCTIONS

Guidance on the proper operation of the transmission.

SPECIFICATIONS AND DATA

Provides key technical specifications and data for the transmissions.

Summary

INTRODUCTION

TRADEMARK USAGE

Lists trademarks and their owners as property of various companies.

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

Explains the meaning and usage of Warning, Caution, and Note headings in the manual.

SECTION 1-GENERAL INFORMATION

SCOPE OF MANUAL

Defines the scope of the manual, including models, series, and engineering changes.

SUPPLEMENTARY INFORMATION

Explains how supplementary information is issued and how to obtain the latest updates.

ORDERING PARTS

Details how to identify transmission models and order replacement parts using the nameplate and parts catalog.

GENERAL DESCRIPTION

Details the transmission design features, including coupling, torque converter, planetary gearing, and clutches.

DIAGNOSIS

Provides guidance on identifying and troubleshooting transmission faults and issues.

Before Starting

Outlines initial steps to identify faulty conditions and probable causes before repair.

CHECK TRANS Light

Explains the function, illumination, and effects of the CHECK TRANS warning light on the transmission.

Allison DOCTM Personal Computer (PC)-Based Diagnostic System

Describes the Allison DOC diagnostic system for accessing TCM data and troubleshooting.

Troubleshooting When No Diagnostic Codes Are Present

Provides guidance on troubleshooting transmission issues when no diagnostic codes are logged.

Troubleshooting Intermittent Diagnostic Codes

Lists common causes and checks for intermittent diagnostic codes in the transmission.

PRESERVATION AND STORAGE

Details procedures for preserving and storing transmissions to prevent damage over time.

RESTORING TRANSMISSION TO SERVICE

Procedures for returning a transmission to service after storage or new installation.

OPERATING INSTRUCTIONS

Guidance on the proper operation of the transmission.

SPECIFICATIONS AND DATA

Provides key technical specifications and data for the transmissions.

Overview

Function Description:
Important Technical Specifications:
Models (General, Refuse (On-Highway), Motorhome, Transit Bus):
Specific Vocational Models (1000/2000 Product Families):
Usage Features:
Maintenance Features:

This document is a service manual for Allison Transmission vocational models, specifically covering the 1000 and 2000 Product Families. It was published in December 2004 and is identified by the number SM3191EN. The manual provides comprehensive information for the maintenance, diagnosis, disassembly, rebuild, and assembly of these automatic transmissions.

Function Description:

The Allison 1000 and 2000 Product Families are torque-converter driven, electronically controlled, fully automatic transmission systems designed for vocational applications. These transmissions are capable of providing up to five forward speeds, neutral, and reverse, with the fifth range featuring an overdrive gear ratio. They are designed to mate directly to SAE No. 2 or No. 3 flywheel housings or, in some cases, directly to the engine block, utilizing flexplate drive for engine-to-transmission torque transfer.

Key components and their functions include:

Torque Converter: A single-stage, polyphase, three-element unit (pump, stator, turbine) that multiplies torque at lower output speeds and provides fluid coupling to the engine. At higher speeds, the torque converter clutch (TCC) automatically engages for direct drive. It also features an integral damper to minimize engine vibration.
Planetary Gearing: Comprises three constant-mesh, helical gear planetary sets. These sets, through various clutch engagements, provide the different forward ranges, neutral, and reverse.
Clutches: Five clutches (two rotating and three stationary) hydraulically actuated and spring-released, with automatic wear compensation. They direct torque flow and are cooled by transmission fluid. The electronic control module (TCM) signals solenoid valves to apply and release clutches based on speed, power, and operator selection.
Hydraulic System: A common system for the torque converter and transmission, supplying fluid for all hydraulic operations, lubrication, and cooling from the sump via a charging pump.
Fluid Filtration: Two filter systems are used: a suction filter in the sump for large particulates and an external spin-on filter on the converter housing for full-time protection of control solenoids and multipass protection for the entire system.
Electronic Controls: A microcomputer-based Transmission Control Module (TCM) provides electronically-controlled automatic gear selection and TCC engagement. It uses adaptive logic for optimal shift quality and can be customized for four-speed or five-speed operation to meet vocational requirements.
Parking Pawl/Parking Brake: All 1000 models, 2200 models, 1000 Series™, and 2400 Series™ transmissions include an internal park pawl engaged by selecting the P (Park) position. This feature is not available on 2100 and 2500 models or 2000 Series™ models without a park pawl. Some models offer an optional rear cover for an OEM-installed two-shoe, expanding-type drum brake.
Power Takeoff (PTO): Most 1000 and 2000 Product Families transmissions (except Highway Series and Pupil Transport/Shuttle Series) have provisions for a PTO unit on the left and/or right side, driven by the torque converter turbine.
Output Yokes/Flanges: A variety of OEM-installed yokes or flanges are available to meet vehicle driveline requirements.

Important Technical Specifications:

The manual provides detailed specifications for various models within the 1000 and 2000 Product Families, including:

Models (General, Refuse (On-Highway), Motorhome, Transit Bus):

Max Full Load Gov. Speed: 4600 rpm
Min Full Load Gov. Speed: 2200 rpm
Max Idle Speed in Drive: 900 rpm
Min Idle Speed in Drive: 500 rpm
Maximum Net Input Power: 254 kW (340 hp) for General, Refuse, Motorhome; 134 kW (180 hp) for Transit Bus.
Maximum Net Input Torque: 705 N·m (520 lb ft) for General, Refuse, Motorhome; 603 N·m (445 lb ft) for Transit Bus.
Maximum Net Turbine Torque: 1152 N·m (850 lb ft) for General, Refuse, Motorhome; 1017 N·m (750 lb ft) for Transit Bus.
Maximum Output Shaft Speed: 5000 rpm
Gross Vehicle Weight (GVW): 9000 kg (19,850 lbs) for General; 7500 kg (16,540 lbs) for Refuse, Transit Bus; 9980 kg (22,000 lbs) for Motorhome.
Gross Combined Weight (GCW): 11 800 kg (26,000 lbs) for General, Motorhome; N/A for Refuse, Transit Bus.
Max Angular Rotation of Output Shaft After Static Apply of Park Provision: 18.5 Degrees

Specific Vocational Models (1000/2000 Product Families):

The manual lists various vocational models and their corresponding specifications, including:

1000 EVS, 2100 EVS, 2200 EVS, 2500 EVS (Emergency Vehicle Series)
1000 HS, 2100 HS, 2200 HS, 2500 HS (Highway Series)
1000 MH, 2100 MH, 2200 MH, 2500 MH (Motorhome Series)
1000 PTS, 2100 PTS, 2200 PTS, 2500 PTS (Pupil Transport/Shuttle Series)
1000 RDS, 2100 RDS, 2200 RDS, 2500 RDS (Rugged Duty Series)
1000 SP, 2100 SP, 2200 SP, 2500 SP (Specialty Series)
B210, B220 (Bus Series)

These models have varying maximum net input torque, power, turbine torque, GVW, and GCW ratings, generally ranging from 550 lb ft to 565 lb ft input torque, 300 hp to 340 hp input power, 850 lb ft turbine torque, and GVW/GCW up to 33,000 lbs. Output shaft speed is typically 4500 rpm or 5000 rpm.

Usage Features:

Model Year 04 (MY04) and 04i (MY04i) Updates: The manual details engineering changes introduced in MY04 (June 2003) and MY04i, including modulated main pressure hardware, internal wiring harness, separator plate, main regulator valve, converter relief valve, lube regulator valve, and various clutch components. These updates affect part interchangeability.
Shift Valve Body Casting: Improved shift valve body casting was introduced with specific serial number breaks.
Diagnostic System: The Allison DOC™ Personal Computer (PC)-Based Diagnostic System provides tabular, graphical, and chart displays of real-time and recorded TCM data, facilitating troubleshooting, DTC retrieval, and clutch diagnostics.
Safety Notices: Emphasizes the importance of understanding warnings and cautions to prevent personal injury, equipment damage, or unsafe conditions. It warns against exceeding GCW limits, operating with the CHECK TRANS light on, and improper parking procedures.
Operational Guidelines: Provides instructions for restoring transmissions to service, including cleaning, refilling, and resetting the TCM to unadapted shifts after storage.

Maintenance Features:

Periodic Inspections and Care: Covers routine transmission and vehicle inspections, and welding precautions.
Fluid Level and Quality: Stresses the importance of proper fluid level, with detailed procedures for cold and hot fluid checks. It also covers keeping fluid clean, fluid recommendations (TranSynd™ or DEXRON®-III), and fluid/filter change intervals.
Fluid Contamination: Provides methods for fluid examination to detect water or engine coolant contamination and instructions for flushing the oil cooler.
Vent Assembly Maintenance: Details the location, purpose, and maintenance of the vent assembly.
Main Pressure Check Procedure: Outlines the steps for checking main pressure.
Stall Test and Neutral Cool-Down Check: Describes procedures for performing transmission stall tests and neutral cool-down checks to diagnose performance issues.
Fluid Leak Diagnosis: Offers methods for finding and repairing fluid leaks, including powder and black light/dye methods.
On-Vehicle Maintenance: Covers maintenance procedures that can be performed without removing the transmission from the vehicle.
General Overhaul Information: Includes sections on tools and equipment (improvised, special, and mechanic's tools), replacement parts ordering, careful handling of components, cleaning and inspection procedures, and assembly guidelines (lubrication, sealing compounds, clutches, pistons, etc.).
Disassembly and Rebuild: Provides detailed, step-by-step instructions for transmission disassembly and module rebuild, covering components such as the torque converter, input/output speed sensors, NSBU switch, vent, converter housing/front support module, rotating clutch assembly, oil pan, filters, wiring harness, control valve, rear ball bearing, rear components, park pawl, planetary modules, clutches, and main shaft.
Wear Limits and Spring Data: Includes specifications for wear limits and spring data to guide replacement decisions during overhaul.
Torque Specifications: Provides critical torque values for various fasteners throughout the transmission.
Preservation and Storage: Offers detailed methods for storing new transmissions before installation and for extended periods (one year or more), both with and without fluid, to prevent rust, corrosion, and organic growth. This includes using VCI #10 and Biobor® JF additives.