AT500 OWNERS MANUAL - weller truck parts

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Why Shift LinkageIs Important(continued from page 9)3. Electric – Most commonly used with electronically governed engines where thegovernor has no mechanical moving parts. Electric modulators are either on oroff. They get their signal from engines ECU or data link translator to move themodulator pin.4. Vacuum – Only used on gas engines. Under full engine load, vacuum will drop off.This signal is relayed to the modulator via a tube or hose, actuating a diaphragminside the modulator and releasing the plunger outward. Once there is no load,vacuum will return, pulling the plunger back against spring pressure.Typical modulator Complaints:Downshifts HardCable Modulator – cable at pedal or governor is not fully returning to its relaxedposition. You may need a return spring to help the cable backVacuum Modulator – No vacuum signal or a torn diaphragm in modulatorAir Modulator – Struck plunger in modulator or full air pressure under all throttlepositionsElectric Modulator – Power to modulator on, under all throttle positionsUp shifts Hard (low RPM or too early)Cable Modulator – Cable not adjusted correctly or inoperable. To correctly adjust, pushor pull the throttle to full fuel. There should be no more than 1/8" slack left in the cable.Keep in mind there are mechanical parts inside the box end of the cable that do wear.Replacement of the cable may be necessary if adjustment won’t cure an early up shift.Air Modulator – seals inside the modulator have worn allowing air pressure into thecase, or low or no air pressure signal to the modulator. If you notice oil leaking out thebreather, chances are the air modulator is leaking.Electric Modulator – no power to modulator or modulator malfunctions. To checkloosen but do not remove the retaining clip. With the key on, engine off, fully depressthe throttle. This should push the modulator out away from the transmission. This testwill require one person in the cab and one person at the transmission. If no modulatoraction is observed, voltage tests will be required back to the source, usually a relay inthe cab.A harsh downshift may also be caused by higher than normal idle or slow to return throttle. Itmay also be caused by a sticky transmission governor valve. An early up shift may be causedby using two O-rings in the modulator valve. This happens quite often as most reman units areshipped with an O-ring already installed in the case. BE SURE ONLY TO USE ONE “O” RINGWHEN INSTALLING MODULATOR OR MODULATOR PLUG!THE WELLER REMAN NETWORK10
ALLISON JOB AIDAllison Job AidSHIFT SELECTOR AND CABLE ADJUSTMENT PROCEDUREFor Allison Transmission Models:1000 Product Family, 2000 Product Family, AT 500 Series, MT 600 Series,HT / CLT 700 SeriesThe shift cable must be adjusted after the shift selector has been installed in its permanent mounting location, theshift cable routing is finalized, and the cable has been secured.NOTE: All changes to the shift cable routing,including changes to the shift selectorlocation, will affect the adjustment of theshift cable. Therefore, the shift cable mustbe readjusted if its routing is modified bya body builder or during transmission orvehicle service.When properly adjusted, the handle of a lever shiftershould be centered in each gate position when thetransmission selector shaft is held in place by theinternal transmission detent. See Figure C–2.“Gates” inshift selectorpermit transmissiondetent to determineactual selectorshaft orientationRN5421Figure C–2. Proper Shift SelectorAdjustmentFollow procedure below to attach and adjust the shiftselector cable at shift lever on the transmission.1. With the engine off, set the park brake and blockthe wheels to prevent vehicle movement.2. Place both the shift selector and the transmissionselector shaft in the Neutral position.SHIFT LEVERHELD INNEUTRAL BYTRANSMISSIONDETENTPIVOTCABLE3. Attach the cable to the shift selector at theoperator’s station.4. At the transmission end of the cable, push thecable to move the shift handle against the end ofthe shift selector Neutral gate. Note the positionof the pivot at the end of the cable with respect tothe hole in the shift lever. Refer to Figure C–3.ñPush cable to moveselector handle againstend of NEUTRAL gate.Figure C–3. Proper Shift SelectorCable Adjustment5. Pull the cable to move the shift handle against the opposite end of the shift selector Neutral gate. Note theposition of the pivot at the end of the cable with respect to the hole in the shift lever. Refer to Figure C–4.6. Center the position of the cable at the midpoint of the travel determined by Steps 3 and 4. See Figure C–5.JA3344EN (2008/01)P.O. Box 894 Indianapolis, Indiana 46206-0894 (317) 242-5000 www.allisontransmission.comTHE WELLER REMAN NETWORK11
Page 1 and 2: AT500 OWNERS MANUALTag #Mileage In:
Page 3 and 4: PROGRAMDESCRIPTIONWeller’s Unit E
Page 5 and 6: DYNO TESTINGAll transmissions aredy
Page 7 and 8: INSTALLATIONGUIDEIV. DRIVELINE• C
Page 9: Why Shift LinkageIs ImportantThe sh
Page 13 and 14: SERVICE TIPSTHE WELLER REMAN NETWOR
Page 15 and 16: CORE RETURNINSTRUCTIONSThe Weller T
Page 17 and 18: WELLER WARRANTYCALL WELLER FIRST!Po
Page 19 and 20: WELLER WARRANTYWarrantyIt is essent

AT500 OWNERS MANUAL - weller truck parts

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