NOTE: If using a TCM from another vehicle is unavoidable, the TCM MUST BE set to factory values and the vehicle MUST BE driven carefully to adapt the shifts to the test vehicle. TRANSMISSION . . . . . . . . . . . . . . If the problem recurs, proceed with Step (4). . If the code reappears, refer to Section 6, Diagnostic Trouble Code, and the appropriate code chart. 2. . . . Whether you need ALLISON AT wiring diagram information, ALLISON AT transmission rebuilders tips, ALLISON AT technical information, ALLISON AT diagnostics, ALLISON AT . . . . Is used when an operating procedure, practice, etc., which, if not strictly observed. . . . . . . Throttle autodetect will increment a counter for a throttle source on each engine start during which the possible throttle source is detected. . . . Copeland International, Inc. . . . . . . . . . . . . . . . Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service procedures used. . 41, 42. . . Always blow or shake any excess cleaner from, the connector before assembling it to its mating connector or hardware. . Even if the vehicle is moving. . . . . . . . . At one end of the harness, using jumper wire kit J 39197 or J 39197-A, connect wires 111 and 174 to each other, being careful not to distort the terminals. . Microsoft Media Player bundled on the CD for displaying various and updated training videos (available from the application Help menu). . . . Mild Steel 3235 m/s. . . . . . . TCM Reprogramming tab, used to enable the reprogramming capability of the Allison DOC For. . . . . . . . . . . . Make sure all updates listed in this section and all other requirements are met prior to using the Prognostics features. . This occurs when the remaining fluid life is approximately 1 percent. . . . . . . Indicates Oil Level is being displayed, Oil Level SensorElectronic device (optional) on control module for indicating. . . . If the engine is not supported, the TCM will lock to a non-SEM state. 55, 54. . . . The PTO is driven off the torque converter turbine and is rated for 250 lb-ft of torque. . . . . . . . The indicator is lit upon each initialization of the TCM, and remains on for approximately 1 2 minutes after the first selection of a drive range, until service is performed and the indicator is reset. . . . . . . . . . Control System Prognostics Operation and Display. . . . . ELECTRONIC FLUID LEVEL READING (SHIFT SELECTOR) . There are no restrictions on engine speed in neutral. . . . . Repair parts for the external harnesses and external harness components must be obtained from St. Clair Technologies Inc. (SCTI). . . . . . MGU Transmission, Allison 10-Speed automatic with integrated Power Take-Off (PTO) . . . Lever Shift Selector . . . IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS. . . . . . . . . . . OLS input voltage must exceed a predetermined level for the TCM to record a detection. . . . . . . . . Furthermore, TID only works when the controller and transmission have the same generation controls. Zip Class A CDL Experience Please select ALL of your current, valid driver's licenses CDL A CDL B CDL C The Allison 4th Generation Controls feature closed-loop clutch control to provide superior shift quality over a wide range of operating conditions. . Allison DOC For PCService Tool shows PS2 PRESSURIZED. . . . . . The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. . . . 31 32. . . . . . . . . . MagiKey is a registered trademark of NEXIQ Technologies, Inc. Teflon is a registered trademark of the DuPont Corporation. . . VIMs are available for both 12V and 24V electrical systems. . . . . . Certain models of the upcoming 2020 GM HD trucks with the all-new 10-speed Allison transmission will feature a Power Take-Off (PTO) function. . . The N (Neutral) button has a raised lip to aid in finding it by touch. . A loose dipstick, clogged breather, improper dipstick marking and water in the transmission are also probable causes of the problem. . OIL LEVEL SENSOR (OLS) INTRODUCTION . . . If temperatures do not decrease, reduce the engine rpm. . . . . . . . . . . . . . . Unfortunately, a driver cant reverse limp mode. Second. . . . If display is flashing, shift is inhibited. . . . . . . Then the TCM concludes that no OLS is present. . . . . . NOTE: All Allison 4th Generation Controls TCMs are designed to be isolated from the vehicle chassis ground. . . . . . Selecting RESET ADAPTIVE SHIFT PARAMETERS will not reset autodetect logic. . 112 B. . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. . . . . . . . . . . . . Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning and may not generate a DTC. . . . . Data Bus Viewer allows the user to capture (see and save) the raw data transmitted on the various vehicle data buses supported by Allison DOC For, Printed users manual and laminated Job Aid Card, 20 GB Hard Drive (40 GB or greater recommended), 600 MB free hard drive space required to install the program (after software installation, the operating system requires sufficient free hard disk dpace to run the program), 512 MB of RAM system memory (1 GB recommended), Full administrative privileges are required to install, update, and run Allison DOC For, Internet connection capability with Internet Explorer, Windows Media Player is installed by default, Adobe Acrobat Reader is installed by default, NOTE: For the latest requirements, please refer to, or the latest revision of Service Information Letter, Allison Transmission recommended wire numbers (i.e. . 16 15. . 15, 14. . . . . IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in this manual. Description of diagnostic codes, system responses to faults, and troubleshooting. . . . . . . . . . . . . . . . Pushbutton and lever shift selectors for the Allison 4th Generation Series are remote mounted from the TCM and communicate to the TCM via the J1939 communications data link. . . . Refer to the troubleshooting chart for the possible cause(s) of the problem. . . . . . . . . . . . . . . . Multiple sources can be detected on a single engine start cycle. This feature is not functional until transmission sump temperatures are between 40150C (105302F). . . . Do this for both wires in the circuit being tested. Find a facility My Transmission . . . . . The service procedures recommended by Allison Transmission and described in this manual are effective methods for performing troubleshooting operations. SHIFT SELECTOR . . . . . . . . . . . If the replacement TCM corrects the original complaint, reinstall the original TCM to verify that the complaint returns. . Remember that some problems may be temperature related. . . Find a facility. . SCTI recognizes Allison Transmission, manufacturers, and SCTI part numbers. . Consequently, Allison Transmission has not undertaken any such broad evaluation. . . . . . . . This acts on the other end of the Filter Life Valve, compressing the return spring and allowing control main pressure through the valve to PS2, which pressurizes the switch. Dry Air (can vary depending on humidity) 346 m/s. Pressure Switch 2 (PS2), also known as the Filter Life Switch, is used to monitor the pressure difference between main pressure before the filter and lockup clutch pressure as a method to monitor the main filter for excessive filter restriction. . . . . . This takes you to diagnostic codes. . . . . 118 111. . . . . . . . . . . . Two wires have frayed and are shorted together. Look in your telephone directory under the heading of Transmissions Truck, Tractor, etc. . . . . . . . . The oil level sensor is available on any 3000 and 4000 Product Families transmissions except the 3000 7-speed transmissions. . No continuity in a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested. . . . . . . . . . . . . . . . . . . . will cause severe overheat damage to the transmission. Autodetect searches for the presence of pressure control solenoid 5 (PCS5) to the retarder during the first 35 engine ignition cycles. . Typical Allison 4th Generation Control Components. . If dirty or corroded terminals are the probable cause of the problems, reconnect the clean connectors and operate the vehicle normally. . . . . . The Allison Transmission 9000 Series is designed for extreme operating conditions in highly demanding applications up to 1,939 kW (2,600 hp). . . . . iii TRADEMARKS USED IN THIS MANUAL . This can be discovered by using HY25-3000/US Applications Catalog. . . . Allison DOC For PCService Tool displays clutch condition as OK or NOT OK for each clutch, C1 through C5. Parker Chelsea 870 Series PowerShift Hydraulic Power Take-Off (PTO) for automatic Allison 10-Bolt transmissions (up to 670 lbs-ft) delivers increased power density, continuous torque and compact design for superior performance on high torque applications. . SCTI provides a technical HELPLINE at, Remote 12V or 12/24V Max Feature Sealed Transmission Control Module (TCM), Remote Pushbutton or Lever Shift Selector, Throttle Position Sensor (TPS) or electronic engine throttle data or PWM signal, Engine, Turbine, and Output Speed Sensors, Optional Engine Coolant Temperature Input. . . . The turbine speed sensor on the 4000 Product Family transmission is located on the outside of the main housing. . Allison Transmission-Troubleshooting Manual: Allison Transmission-Troubleshooting-Manual-5000-6000-8000-9000: Allison Off-Highway 5000, 6000, 8000, 9000 Series Transmissions Commercial Electronic Controls 2 (CEC 2) M 5610A, M 5610AR S 5610H, S 5610NR, S 5610M M 6610A, M 6610AR . . The system that enables the transmission to default to totally hydraulic operation has been incorporated to minimize the impact of an electrical interruption. Find an Allison authorized service facility near you. . . . . . . . . . Fax 713.466.9839 . . 51 52. . Contact your Allison Transmission represen-tative if you do not have access to the Allison Transmission Extranet. . . . Web chelsea pto wiring diagram ford. . . . Description of the 3000 and 4000 Product Families Allison 4. . . . . Retarder and engine brakes will not apply when ABS is active. . . . The engine must be compatible with the transmission rating. Failure to do so may. . . . 36 39. . NOTE: Information concerning specific items is contained in the appendices located in the back of this manual. Failure to perform maintenance and reset the monitor after a calibration-defined number of warnings results in the illumination of the CHECK TRANS light. Examples are wheelchair lift not stored and service brakes not applied (service brake interlock present). . . . . . . . Allison 4th Generation Control functions are controlled by the TCM. Not available with (PTO) Power take-off. . . . . Chelsea PTO and Pumps For All Allison Transmission Models. . . . . . . . THROTTLE POSITION SENSOR . . . . . Using genuine Muncie repair parts is key to the life of your PTO. . . This feature is not available with 7-speed transmission models. . . . . . . . Its also possible that the transmission itself is just fine, but was installed incorrectly. Do this for both wires in the circuit being tested. Once that shift has been retried, and a fault is still detected, the TCM sets a DTC and holds the transmission in a fail-to-range mode of operation. . . will last you a very long time with few problems. . . . . . . Be sure to review and observe any vehicle system information provided by the vehicle manufacturer and/or body builder at all times the Allison transmission is being serviced. . . . . Your Allison transmission could be experiencing a part failure, in which case your best bet is to take advantage of the providers warranty. . . Diagnostic and oil level (if sensor is present) information is obtained from the LED display by pressing the display mode button. . . . . Beginning the Troubleshooting Process . . . . . Once a confidence flag is set, that source is used as the source for the throttle signal. . . . . (3)Update Application tab, which provides access to a URL containing minor updates for the diagnostic tool to support changes in the various transmission control systems. . . Foreign Material . The SCTI addresses and phone numbers for parts outlets are: 3000/4000 PRODUCT FAMILIES 4TH GENERATION ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL. When the main filter gets excessively restricted by debris, lockup pressure drops. . . . . . . . . . . . . . The selector lever can be moved freely between D and the numbered forward ranges without pressing the hold override button. When disconnecting a harness connector, be sure the pulling force is applied to the connector itself and not the wires extending from the connector. . . Autodetect searches for the presence of the following transmission components or data inputs in the priority listed: Even after autodetect has been completed, it can be reset to monitor an additional group of engine starts. . . . Engine-driven helical gear. . . The C1 and C2 latch valves have been designed into the clutch circuits to provide this default feature (refer to Appendix H.). NOTE: J 47277 is now included in the J 39197-A Kit. . . . . . . . . . . . . . . . . . Unfortunately, a driver cant reverse limp mode. Allison Transmission is responsible for warranty on these parts. Shift Energy Management (SEM) Autoselect feature may be used on certain transmissions. . . . Whenever a transmission is overhauled, exchanged, or has undergone internal repairs, the TCM MUST. . Because of the time lag involved with writing and printing processes, the transmission TCM may report a code that has not yet been added to this document. . . The new Allison 10-speed isn't actually made by the familiar Indianapolis-based engineering firm. . . Locate the appropriate troubleshooting chart and follow the instructions. . . PTO mounting pads. . . Please use these SILs to obtain up-to-date information concerning Allison Transmission products. . . . . . If the problem recurs, proceed with Step (4). . . The engine should never be operated for more than ten (10) seconds at full throttle, CAUTION: with the transmission in range and the output stalled. . The code display procedure will indicate the number of times the DTC has occurred. . 5.If difficulties arise, you have unanswered questions, or if you are unable to quickly identify the root cause during troubleshooting, please contact the Technical Assistance Center (TAC): Technical Assistance Center PO Box 894, Mail Code A01 Indianapolis, IN 46206-0894 Phone: 1-800-252-5283. Changes in sump fluid temperature are indicated by changes in sensor resistance, which changes the signal sent to the TCM. . . . The VIM for 12V systems uses all 12V relays. . . . . . . * Some transmissions used in oil field service default to neutral, 41. A working knowledge of the Allison 4th Generation Controls vehicle installation is necessary in troubleshooting installation-related problems. . . . . . . . . . . To shift from reverse to forward, select N (Neutral) and then D (Drive) or other forward range. . A. Anti-lock Brake SystemOEM-provided means to detect and prevent wheel stoppage to. . . . . . . . FM History: Use the Allison DOC For PCService Tool to display the amount of transmission operation from the initial service indication until the service reset. Wiggle connectors, harnesses, and splices when looking for opens. No continuity in a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested. . . . . . . Hence, the solenoids are referred to as pressure control solenoids (PCS). . . . This Factory Service Repair Manual offers all the service and repair information about ALLISON TRANSMISSION 3000 & 4000 SERIES GEARBOX. . 57 56 KEEPING FLUID CLEAN . . . . . . 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