SECTION G: PARKING BRAKE PROVISION

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ALLISON AT500 and AT1500P SERIES MODELS
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Items discussed in the PARKING BRAKE PROVISION section are:

1.0 DESIGN CONSIDERATIONS

1.1 Physical Arrangement (General)

1.2 The Allison 9" x 3" Parking Brake

1.3 The Allison 11" x 2" Parking Brake

1.4 Other Parking Brakes

1.5 Brake Apply System Design Requirements

2.0 INSTALLATION INSTRUCTIONS

2.1 Mounting the Parking Brake Assembly to the Transmission

2.2 Installing the Parking Brake Apply System

2.3 Burnishing the Parking Brake

TDATIMG March, 1999

 INSTALLATION DRAWING REFERENCES
AT500 and AT1500P-SERIES MODELS

Allison installation drawings are frequently referenced in this section to clarify items discussed in the text.
More than one drawing may exist for some topics – and the correct reference for your installation will depend
upon the transmission model and options involved.

The following reference chart will assist in identifying the correct installation drawings for your transmission,
options, and installation. All drawings are filed in the "Installation Drawings" section.

To use the chart:

1. Use the flow diagram at the top to select the column relating to your transmission configuration.
2. Scan down the page to the desired topic on the drawing subject list.
3. Scan across the page to the column for your transmission configuration.
4. Read the installation drawing number for your installation. "N/A" denotes that the subject topic is
not applicable to the transmission configuration selected in the flow chart.

Basic Transmission Model?

Without Lockup Clutch With Lockup Clutch

ò ò
ò ò ò ò
MODEL NAME(S) AT542 AT545 AT1542P AT1545P
AT542N AT545N AT1542NP AT1545NP
AT545NR
AT545R
DRAWING SUBJECT ò ò ò ò
Basic Installation Drawing AS20-032 AS20-007 AS20-039 AS20-037
Adaptation Design Requiements AS20-008 AS20-008 AS20-035 AS20-035
Engine Adaptation Designs AS04-xxx Series AS04-xxx Series AS04-xxx Series AS04-xxx Series
Retarder Option* N/A AS20-041 N/A N/A
Converter Driven PTO Provision** N/A N/A AS20-010 AS20-010
Yoke / Flange Availability AS20-053 AS20-053 AS20-053 AS20-053
Yoke / Flange Design Requirements AS20-014 AS20-014 AS20-014 AS20-014
Parking Brake Mounting Provision AS20-011 AS20-011 AS20-011 AS20-011
Oil Pan Options
5.3-inch Oil Pan and Provisions N/A AS20-030 N/A AS20-030
3.8-inch Oil Pan and Provisions AS20-031 AS20-031 AS20-031 AS20-031
Allison Filter Installation Requirements AS00-097 AS00-097 AS00-097 AS00-097
Neutral Start Switch Information AS00-164 AS00-164 AS00-164 AS00-164
External Hydraulic Circuit Requirements AS20-009 AS20-009 AS20-009 AS20-009
Controls
Range Selector Control Data AS20-012 AS20-012 AS20-012 AS20-012
Shift Modulator Installation Requirements AS20-023 AS20-023 AS20-023 AS20-023
Electric Signal Provisions AS20-016 AS20-016 AS20-016 AS20-016
Speedometer Drive Data AS20-013 AS20-013 AS20-013 AS20-013
Retarder Controls AS20-041 AS20-041 AS20-041 AS20-041

*Retarder option is not avialable with PTO.

**PTO provision is not avialable with retarder.

Page 2 March, 1999 AT500 and AT1500P Series Installation Manual

SECTION G: PARKING BRAKE PROVISION
The purpose of this section is to summarize design
considerations and installation instructions relating to
parking brakes.
Several significant elements should be considered in
designing a parking brake installation: physical arrange-
ment, operation principles, brake performance and apply
linkage requirements.
In addition to physical attachment of the parking brake
to the transmission, other issues such as apply linkage
installation, various adjustments and a burnishing
procedure are discussed.
1.0 DESIGN CONSIDERATIONS
1.1 PHYSICAL ARRANGEMENT
(GENERAL)
The typical parking brake installation consists of the
parking brake mounting provision on the transmission
rear cover and five basic brake system components
(brake apply lever, brake assembly, transmission output
flange, brake drum and flanged output yoke). Refer to
Figure G-1. A customer-supplied brake apply mechanism
is used to apply the brake from the operator's station.
BRAKE
APPLY
LEVER
FLANGED
YOKE
OUTPUT
FLANGE
BRAKE
ASSEMBLY
BRAKE
RB264 DRUM
Figure G-1: Basic Parking Brake Components
The parking brake is actuated from the operator’s station
by a mechanism, or assembly of components, which
subsequently moves the brake-apply lever. Note that
the apply system may include a provision (bell crank,
etc.) to increase or decrease torque to the brake apply
mechanism — depending upon its operating geometry.
When the brake apply lever is moved by the apply
mechanism, a cam is rotated in the brake assembly to
actuate the brake. The mechanics of this process vary
by brake designs — if further information is desired,
consult the brake manufacturer. Attachment and support
of the operator control and apply mechanism are the
responsibility of the vehicle manufacturer.
AT500 and AT1500P Series Installation Manual
The parking brake drum pilots onto a land area on the
transmission output flange. A flanged output yoke, in
turn, pilots into the center bore of the parking brake
drum. The flanged yoke provides the vehicle driveline-
to-transmission output connection.
A rear support is frequently required for transmissions
which use the parking brake. Refer to Section B:
Transmission / Engine Packaging section of this manual
for mounting requirements.
1.2 THE ALLISON 9" X 3" PARKING
BRAKE
A 9" x 3" parking brake assembly for AT-series transmis-
sion models, similar to that illustrated in Figure G-1 is
available from Allison P.D.C. Contact Allison Sales for
additional information.
1.3 THE ALLISON 11" X 2" PARKING
BRAKE
An 11" x 2" parking brake assembly for AT-series
transmission models is available from Allison P.D.C.
Refer to Figure G-2.
PARKING BRAKE
APPLY CABLE
V
Shown coiled and
attached to transmission
V
REAR
SUPPORT
PROVISION N870-29A
Figure G-2: Allison Parking Brake and Cable
This brake assembly contains an internal brake apply
mechanism/cam assembly (replacing the brake apply
lever) which simplifies the installation of the brake apply
system. Installation of the apply system consists of the
attachment of an operator control (customer-supplied) to
an integral apply cable which enters the front of the
brake assembly at the 2 o'clock position, as viewed from
the rear. The control is a "pull-to-apply" type. Refer to
Section 1.5 to determine cable travel and force require-
ments.
The Allison 11" x 2" brake assembly also incorporates an
integral rear mounting provision for the transmission.
This provision accomodates the attachment of a support
bracket to the rear of the transmission while also serving
March, 1999 Page G-3
as a required longitudinal spacer for the parking brake
assembly. See Figure G-3. All details of the Allison
parking brake assembly are illustrated on Installation
Drawing AS20-011.

RB137

Figure G-4: Typical Parking Brake Control - Cable

N670-04b

Figure G-3: Allison Parking Brake /Rear Mount

1.4 OTHER PARKING BRAKES

Other commercially-available parking brakes for the
AT500(R) and AT1500P-series transmissions are normally
used in either of two sizes — 9" x 3" or
10" x 3". In the configurations typically used, the brake RB136
and components attach to the rear of the transmission as
illustrated in Figure G-1. Installation Drawing AS20-011 Figure G-5: Typical Parking Brake Control - Lever
provides installation details.

The parking brake is actuated from the operator's station

by a customer-supplied mechanism (a cable is commonly 1.5 BRAKE APPLY SYSTEM DESIGN
used) which applies a force to move a bell crank, which REQUIREMENTS
subsequently moves the brake apply lever. Typical
arrangement of the controls components for a cable-
CAUTION: Sustained use of the parking brake
apply system are illustrated in Figure G-4. Similar details
with the engine running and the transmission in
for a lever-apply system are shown in Figure G-5.
gear can cause an overheating failure of the
transmission.
The mechanics of this process vary by brake designs —
if further information is desired, consult the brake
A recommended solution to this concern is to integrate
manufacturer.
the use of a buzzer or dash-mounted light in the apply
system to alert the operator when the ignition switch is
Mounting provisions for the brake system components
"on", the parking brake is applied, and the transmission
and attachment provisions for the bellcrank, etc. are
selector is in range . Components to complete an
illustrated on Installation Drawing AS20-011.
installation of this type (with a buzzer) are available as a
kit from a source shown in Section K: Support Equip-
ment, of this manual.

Page G-4 March, 1999 AT500 and AT1500P Series Installation Manual
To obtain adequate performance from the parking brake,
an adequate force must be applied to the brake apply
mechanism to create the desired capacity in the brake
system. Note that a bell crank (or other component used
to transfer the brake apply force) may increase or
decrease torque to the brake apply mechanism —
depending upon its operating geometry.
NOTE: Industry standards and/or legal
requirements typically demand a fully-loaded
vehicle to be held on a minimum incline of 20%
(11.3 degrees). The vehicle manufacturer is
responsible for confirming the applicable brake
requirements and assuring that they are met.
Refer to Figure G-6. The required brake torque (T)
necessary to hold the vehicle on the specified incline
may be calculated by the equation:
T = W sin Q R/K where:
W = Total weight of the vehicle(s) to be held (lbs)
Q = Angle of the incline (degrees)
R = Tire rolling radius (inches)
K = Lowest numerical axle ratio
A100
Figure G-6: Drum Rotation and Brake Apply Force
"Forward" torque on the parking brake drum (acting in a
counter-clockwise direction as viewed from the rear), is
equivalent to that of a vehicle facing nose-down on an
incline. Parking brakes with a capacity up to approxi-
mately 4065 N-m (3000 lb-ft) have been used successfully
with AT-series transmissions. Experience has also
shown that serious transmission damage can occur if the
brake is applied abruptly with the vehicle in motion. In
order to minimize this risk, maximum brake capacity
should be limited to 4750 N-m (3500 lb-ft) and the
operator should be advised through use of a placard,
decal, or operating instructions, that the brake should
normally be applied only after the vehicle has been
brought to a complete stop.
AT500 and AT1500P Series Installation Manual
Refer to Figure G-7 for the Allison 11" x 2" brake. This
figure should be used to determine if the Allison brake
has sufficient capacity for the intended application and,
if so, the force on the brake apply cable which relates to
the required torque capacity of the brake. The customer-
furnished parking brake apply system must be capable of
applying this minimum force to the brake apply cable.
Also note a maximum force limit on the brake apply lever.
Allison Transmission assumes no responsibility for
failure due to abuse and/or application beyond that
defined in Figure G-7.
A400
Figure G-7: Parking Brake Performance
(with Allison 11" x 2" Brake)
The vehicle manufacturer is responsible for the design
and installation of the parking brake control system.
Based on past experience, however, Allison notes the
following items as being significant considerations in the
control system design:
• Minimize the number of bends in the control cable
routing. Make bends, when necessary, as gradual as
possible. Consult cable manufacturer for minimum
bend radius. Avoid "S"-bends if at all possible.
• Install an indicator light, activated by the brake apply
mechanism, to alert the operator that the brake is
applied. Driver training and/or dash-mounted labels
regarding brake operation should be used.
• The transmission main housing includes threaded
bosses which may be used for mounting the parking
brake linkage. Special attention is required to avoid
interference between the transmission housing and
the brake apply levers.
March, 1999 Page G-5
Refer to Section K: Support Equipment section of this
manual for source information relating to parking brakes
and components.
In certain applications of the AT500(R) and AT1500P-
series transmissions, especially those in which it is
desirable to have driver control functions which are
similar to those of passenger cars (e.g. rental trucks),
systems have been designed to provide a "PARK
BRAKE" position on the shift selector. Unlike an
automobile or light truck which includes a parking pawl
inside the transmission, this provision for the AT
transmission is used to apply a transmission-mounted
parking brake or the vehicle "park" function in the brake
system.
This arrangement is available only with transmissions
which are equipped with a shift control system which
has two Neutral positions, one of which is dedicated to
the "PARK BRAKE" function. Refer to the AT500(R) /
AT1500P Series Application Manual for further details
regarding the AT500N(R)-series and AT1500NP-series
transmission models.
For further installation details, consult Allison for
Engineering Memorandum EM-45, which discusses
general requirements for three types of vehicle systems:
• For vehicles with air brakes and no transmission-
mounted parking brake
• For vehicles with an air system, but no air brakes -
with a transmission-mounted parking brake
• For vehicles without an air system - with a transmis-
sion-mounted parking brake
2.0 INSTALLATION INSTRUCTIONS
2.1 MOUNTING THE PARKING BRAKE
ASSEMBLY
Installation requirements of the parking brake typically
consist of the following general steps. Consult the
manufacturer(s) of the parking brake and/or apply
mechanism for specific instructions regarding installation
and use of their components.
1. Mount parking brake shoe assembly and brake cam
lever (if applicable) to the transmission rear cover
using four bolts as specified on the Parking Brake
Installation Drawing. Follow any specific instruc-
tions which were provided with the parking brake.
2. Install the output flange on the transmission output
shaft, following instructions in Section C: Transmis-
sion / Driveline Adaptation section of this manual.
Page G-6
3. Install the parking brake drum onto the output flange
per instructions included with the brake. The brake
drum is piloted by a land area on the transmission
output flange. Ensure that the bolt holes in the
brake drum are aligned with the holes in the output
flange.
4. Slide the pilot of the flanged-yoke into the center
bore of the parking brake drum. Ensure that the bolt
holes in the yoke are aligned with the holes in the
brake drum and transmission output flange.
5. Secure the flanged yoke and brake drum to the
transmission output flange with hardware (locknuts,
patchlock bolts, etc.) which is appropriate for the
flange/flanged yoke used in the installation.
6. Attach the driveline to the transmission output
(flanged yoke) following the recommendations of
both Allison and the driveline manufacturer. Allison
recommendations are discussed in Section C of this
manual.
7. Burnish and adjust the parking brake per instructions
of the brake manufacturer or sections 2.2 and 2.3.
2.2 INSTALLING THE PARKING BRAKE
APPLY SYSTEM
The exact procedure for installing these components will
depend upon the configuration of the control system
used. (The transmission main housing does, however,
include threaded bosses for mounting the parking brake
linkage. Special attention is required to avoid interfer-
ence between the transmission housing and the brake
apply levers.) In general, the installation procedure
should verify that the following steps are completed
before the transmission is placed into service. Refer to
the appropriate Parking Brake Installation Drawing as
necessary. (If the parking brake control is integrated as
a "PARK BRAKE" position on the transmission shift
mechanism, see Section 1.4 and refer to Allison
Engineering Memorandum EM-45).
1. Set the cab-mounted control linkage (pedal or lever)
to the released ("OFF") position.
2. With the cable disconnected from the operator
control, pull the cable in the "apply" direction
sufficiently to take up slack between the brake shoes
and drum.
3. Adjust the clevis (or other adjustment device in the
control system) as required until the operator control
and cable are aligned. Attach cable to operator
control.
March, 1999 AT500 and AT1500P Series Installation Manual
4. Remove plug from parking brake drum. Using a brake
adjustment tool, rotate the star wheel until the
parking brake will not turn. (Refer to Figure G-8).
Loosen star wheel by 2 to 4 notches, which should
provide the proper operating clearance.
5. Install a provision to adequately protect against
transmission overheat in the event of improper
vehicle operation. (See Section 1.5).
N870-29
Figure G-8: Adjusting the Parking Brake
AT500 and AT1500P Series Installation Manual
2.3 BURNISHING THE PARKING BRAKE
Many parking brakes are shipped unburnished and
require burnishing to attain full brake capacity. Follow
burnishing procedure of brake manufacturer.
CAUTION: In performing the manufacturer's
burnishing procedure, care must be taken to
apply the brake gradually and decelerate evenly
for 10-15 seconds, or as specified by the brake
manufacturer, during each stop. Dynamic
braking is not an accepted practice for normal
operation. Transmission damage may occur if
the brake is applied abruptly during dynamic
braking conditions.
Adjust the brake apply system after completing the
burnishing procedure.
March, 1999 Page G-7