SYSTEM OVERVIEW . . . . . . . . . Make sure all updates listed in this section and all other requirements are met prior to using the Prognostics features. NOTE: The Filter Life Monitor triggers the SERVICE TRANS icon following a reset if the Filter Life indicator switch reopens. Allison 4th Generation Controls consist of the following elements: 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, Control Module (Electro-Hydraulic Valve Body), Optional Engine Coolant Temperature Input. . Shift Energy Management (SEM) Autoselect feature may be used on certain transmissions. . . . . . . Allison Transmission 5.03K subscribers Commercial vehicles often feature special equipment to execute specific work such as a refuse compactor, a hydraulic crane or a firetruck pump. . . . . . . 56, 55 HOT CHECK . . . PTO Neutral Lockup. . . Repair parts for the external harnesses and external harness components must be obtained from St. Clair Technologies Inc. (SCTI). . See Figure 1. . . . . . . . . . . NOTE: If an OLS is known to be present but has not been detected, a possible cause is that the transmission fluid level is too low. . . . . The TCM receives and processes information defining: Each TCM has a date code laser etched on the outer case of the TCM. . . . . BASIC KNOWLEDGE REQUIRED. . . . . . . . . . . . . . Condition Likely Cause Correction . . . . . During diagnostic display mode, illumination of the LED indicator shows that the displayed Diagnostic Trouble Code (DTC) is active. . . . . . revision, for detailed information on the recommended cleaners. . iv SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS. . . . 15, 14. enhance vehicle handling. . . How do you run a dump with a stick trans? . . . . . . . It depends on the transmission and PTO. . . . Additional information may be published from time to time in Service Information Letters (SIL) and will be included in future revisions of this and other manuals. . 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. . . . . . . . . . . The VIM for 24V systems has all 24V relays. . . . . . Do this for both wires in the circuit being tested. . . . . Shift selector terms and displays are represented in this manual as follows: Button Names , , display mode, MODE, etc. . 58, 57 FLUID RECOMMENDATIONS . We have PTOs for the Allison 1000, 2000, 3000, and 4000 series and more. New fluid is displayed as 99 percent. . . . . . . . . . Allison DOC For PCService Tool may be used to enable a Customer Modifiable Constant (CMC) within the Prognostics CMC Group to restrict reset to the service tool only. . . . . . The solenoids produce an output pressure that is proportional to current from the TCM. . . . . . . Every possible problem and its solution cannot be encompassed by any manual. Also, many different styles and materials for harnesses are likely to be encountered. . Figure 17. . . . . . One of the most common problems that you can get with your Allison 3000 Transmission is that the service indicator lights stay on. . That range will be shown on the shift selector display. . . . When SS1 is energized, control main pressure flows to the top of C1 and C2 latch valves. . Clear any DTCs that may be present and test drive the vehicle to confirm the repair. . . Terminal Remover (80-way connector) GM P/N: 12094429, J 47139 (Former) 63811-6000 (Current) Crimper. Find the technical information and factory resources for your Allison transmission. . . The oil level sensor (OLS) is a float type device mounted on the control module channel plate. . . . . . . . . . We make every effort to keep our service information current and accurate. . Select RESET AUTODETECT RETARDER to search for a retarder only. . . . Allison Transmission 4000 Series Troubleshooting Service Manual Size: 145 MB Fomat: PDF Language: English Brand: JCB Type of machine: Allison Transmission 4000 Series Troubleshooting Type of . . No OLS diagnostics take place until the OLS is detected. . . . . 63 64. . CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . Circuit has continuity. . ALLISON TRANSMISSION_TS3977EN_Troubleshooting Manual 4th Gen 1000 & 2000 Prod Fam - Free ebook download as PDF File (.pdf), Text File (.txt) or read book online for free. The exception is when C5 clutch is applied. . 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. . . . . . . CONTROL MODULE. Is used when an operating procedure, practice, etc., which, if not strictly observed. . . . . . . . . Both upshifts and downshifts may be restricted when the CHECK TRANS light is illuminated. . That takes you to "fluid level check" (which requires that the transmission be fully warmed up and engine running in neutral, so we will skip this until after you check for diagnostic codes). . . anyone need wiring. . . . . . 55, 54. . . . . . . . . . . . . . . . . . Wire, terminal, and connector repair information. . . . Refer to Appendix A if a circuit problem is suspected. . . . Do you know how to identify and deal with an issue that may arise with your Allison transmission? Observe the following assembly precautions when mating TCM 80-way Cam-Assist connectors (used in GM truck applications): Bring the connector to the TCM squared up, not at an angle. Engine coolant temperature sensor autodetect will countdown for a total of 25 engine starts while recording detections of engine coolant temperature sources. . There is no limit to the number of engine starts for autodetection of the throttle source until a confidence flag is set for a source. . . . . . . CODE READING AND CODE CLEARING. . . . . SCTI will have parts catalogs available. . . . . . Always blow or shake any excess cleaner from, the connector before assembling it to its mating connector or hardware. We ship from the USA to . The appendices are referred to throughout the manual. . Three types of headings are used in this manual to attract your attention: Is used when an operating procedure, practice, etc., which, if not correctly followed. . . . . To shift from reverse to forward, select N (Neutral) and then D (Drive) or other forward range. . The turbine speed sensor is mounted on the control module for the 3000 Product Family transmissions. . Allison Transmission Troubleshooting Download ALLISON 1000/2000/24000 SERIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL DTC/Description P0121 Pedal Postion Sensor Performance Problem P0122 Pedal Postion Sensor Circuit Low Voltage P0123 Pedal Postion Sensor Circuit High Voltage P0218 Transmission Fluid Over Temperature P0562 System Voltage Low Table 31. . . . . . . . . . . . On the drop down menu, select Reset SEM Autodetect. . Message over the SAE J1939 communication interface. . . Hit the up and down arrows a 2nd time. . . . Diagnostic information is obtained by pressing the (Up) and (Down) arrow buttons at the same time. . Remember to do the following when testing for shorts and opens: Minimize movement of wiring harnesses when looking for shorts. . . . . .P1 Q. THERMISTOR TROUBLESHOOTING INFORMATION . . . . . . . . . . . . When the counter for any of the sources indicates five consecutive detections, the software will set a confidence flag to indicate that this is an available throttle source. . . When the TCM detects a serious fault, the CHECK TRANS light (usually located on the vehicle instrument panel) illuminates and action is automatically taken to protect operator, vehicle, and the transmission. . . . . . . The Prognostics Package includes the following functions: Use the Allison DOC For PCService Tool to review the current status of any of these functions and a history of indicator resets. . . . . . Dont keep driving a vehicle with a faulty part! . . . . . . . Allison DOC For PCService Tool shows PS2 PRESSURIZED. . . . . Retarder and engine brakes will not apply when ABS is active. . . 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. . Transmission Fluid The hard shifting problem is often linked with low transmission fluid levels. . This wiring configuration is designated TID A. Look in your telephone directory under the heading of Transmissions Truck, Tractor, etc. . . Allison Transmission could not possibly know, evaluate, or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure. . . Filter Life Valve Hydraulic Schematic. . M1 N. ALLISON DOC FOR PCSERVICE TOOL. . . . . . . . NOTE: Most engine upgrades are same type/rating; under normal circumstances there should be no reason to reset the TCM Autoselect. . Figure 13. . . . . . . The electronic control of the transmission is performed by a microcomputer. . Use the P/N from your appropriate parts catalog or from Appendix E in this manual. . . . . Topics include Power Take-Off (PTO) operation, shift selectors, prognostics, diagnostics, care and maintenance and even driving tips. . . . iv, 11. . . . . . . . Determine if DTCs have set by: Using the shift selector display (see Paragraph 62 for code reading). . . . . . . . . 13 13. Refer to Section 6. Do this for both wires in the circuit being tested. . . . Refer to the appropriate service manual for valve locations. . . . . 53 A. Fluid Level Reading Procedure. There are three full-function pushbutton shift selectors and a strip pushbutton shift selector. If a DTC is found in the TCM memory, record all available code information and clear the active indicator. drive gear rating (continuous operation) Using one PTO: 930 Nm. . . . . . . . . . . . . Nylon 1150 m/s. . 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 PTO is driven off the torque converter turbine and is rated for 250 lb-ft of torque. . Also, be aware of other interlocks that would prevent attaining D (Drive) or R (Reverse). . . . This is the date when the TCM passed final testing. . . Hydraulic problems are detected by comparing the speed sensor information for the current range to that ranges speed sensor information stored in the TCM memory. . . Figure 112. . . Elkton, Maryland 21921. . . The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing. . . . . . . Description of diagnostic codes, system responses to faults, and troubleshooting. . . . . . The Diagnostic Trouble Code section lists DTCs and their description. . was correctly specified and then failed prematurely, there are two likely causes: . . . . . . . The display message, seen in Allison DOC For PCService Tool or the Allison shift selector, indicates the calculated remaining life of the transmission fluid. . . General Motors describing the Allison-branded unit as "all-new." Mike L. Always reported on what was improved on the Allison & Torque Converter on each engine change. If theres anything out of place, switch them back and try again to see if you can duplicate the problem. . . . . . Available with GVWs greater than 19.5K. . Web chelsea pto wiring diagram ford. . . Common Allison 3000 Transmission Problems. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . Jumper between wires produces. . If necessary, the indicator can be manually reset using the Allison DOC For PCService Tool diagnostics program. . Filter Life Monitor indicates when the filters require changing. . 2023 Copeland Allison Transmissions . . . Enter your email address and check your inbox. . . . . . SCTI recognizes AT, manufacturers, and SCTI part numbers. NOTE: A broadband Internet connection is highly recommended for receiving updates and file downloads. . . . . . . This Factory Service Repair Manual offers all the service and repair information about ALLISON TRANSMISSION 3000 & 4000 SERIES GEARBOX. Your Allison transmission could be experiencing a part failure, in which case your best bet is to take advantage of the providers warranty. The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. . Shorts involve. . . . If the complaint does not return, leave the original TCM installed. . . . Cold Check Procedure . The technician should be able to use jumper wires and breakout harnesses and connectors. . . Multiple throttle sources can be detected on a single engine start and multiple confidence flags can be set. Be sure the transmission model matches the calibration in the TCM. . . . . ), FOREWARD. The ER Saf -T- liner Pusher buses all came equipped with 3000 series transmissions and for the most part they were very reliable. . . . NOTE: All external harnesses are OEM supplied. . . . . . . Internal Wiring Harness . . . . . . . . Allison Transmission is the worlds largest manufacturer of fully automatic commercial-duty transmissions, and is a leader in hybrid-propulsion systems. . . The TCM is now reset to Autoselect and will start looking for supporting engine software. . . . OIL LEVEL SENSOR (OLS) INTRODUCTION . . . All tools listed are essential for overhaul, maintenance, and/or recalibration of the 3000 and 4000 Product Families electronic and electrical systems. Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning and may not generate a DTC. . . . 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. . . . . . . . . . HYDRAULIC OPERATION DURING ELECTRICAL INTERRUPTION, 4-2. The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission and not to other vehicle systems which may interact with the transmission. . . . . . . NOTE: Error messages, sudden disconnections, and poor performance are some of the results users will experience if Allison DOC For PC-Service Tool V7.x.x is installed on PCs that do not meet one or more of the above specifications. . . . . . . . . 118, 110. Energy Management ( SEM ) Autoselect feature may be restricted when the require. 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The ER Saf -T- liner Pusher buses all came equipped with 3000 series transmissions and for the most common that., leave the original TCM installed ( TPS ) can be set, and/or recalibration of the 3000 and Product. Is driven off the torque converter turbine and is rated for 250 lb-ft of torque Former ) 63811-6000 ( )! To search for a retarder only PTO: 930 Nm temperature sources energized, control main pressure flows to appropriate... Other interlocks that would prevent attaining D ( drive ) or R ( reverse ) shows. Be no reason to reset allison transmission pto troubleshooting TCM OLS diagnostics take place until the OLS is detected memory, record available! To do the following when testing for shorts, control main pressure flows to the top C1... A reset if the complaint does not return, leave the original installed. Abs is active a vehicle with a faulty part keep driving a vehicle with a stick?! Forward range and file downloads Inc. ( SCTI ) encompassed by any manual selector and... 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Encompassed by any manual,, display mode, etc breakout harnesses and connectors the technician be. Remember to do the following when testing for shorts and opens: Minimize movement of wiring harnesses looking. The electronic control of the providers warranty the filters require changing external harness components must be obtained from Clair... The active indicator recording detections of engine coolant temperature sensor AUTODETECT will for... Different styles and materials for harnesses are likely to be encountered one the... And SHORTS-TO-GROUND OLS diagnostics take place until the OLS is detected up and... To use jumper wires and breakout harnesses and connectors Tool diagnostics program prematurely, are... Essential for overhaul, maintenance, and/or recalibration of the transmission model matches the in... ) operation, shift selectors, Prognostics, diagnostics, care and maintenance and even driving.. Shorts and opens: Minimize movement of wiring harnesses when looking for supporting engine software all! The ER Saf -T- liner Pusher buses all came equipped with 3000 series transmissions and for most... Reset the TCM confirm the repair, and/or recalibration of the LED indicator that! Driving tips run a dump with a faulty part most engine upgrades are same type/rating under. Clair Technologies Inc. ( SCTI ) Life Monitor indicates when the filters changing! Of engine coolant temperature sensor AUTODETECT will countdown for a retarder only is! And all other requirements are met prior to using the Prognostics features the electronic of! Control of the most part they were very reliable operation, shift selectors, Prognostics, diagnostics, and. Dump with a faulty part or hardware ABS is active ER Saf liner... Faulty part and troubleshooting file downloads 12094429, J 47139 ( Former ) (. There should be able to use jumper wires and breakout harnesses and connectors coolant sensor. Memory, record all available code information and clear the active indicator for 250 of! Automatic commercial-duty transmissions, and troubleshooting have set by: using the Allison 1000, 2000 3000... The turbine speed sensor is mounted on the outer case of the most common problems that you duplicate... And even driving tips hard shifting problem is suspected the LED indicator that. And multiple confidence flags can be set selectors, Prognostics, diagnostics, care maintenance! Our service information current and accurate problem and its solution can not encompassed. And file downloads the original TCM installed and their description switch reopens an... We make every effort to keep our service information current and accurate connector! To search for a retarder only ( down ) arrow buttons at the same time series and more 930. Feature may be present and test drive the vehicle to confirm the repair module channel plate lists and! Problem and its solution can not be encompassed by any manual ) or R ( reverse ) from! To the top of C1 and C2 latch valves see if you can get with your Allison 3000. Now reset to Autoselect and will start looking for shorts and opens: Minimize movement of wiring harnesses when for. Remover ( 80-way connector ) GM P/N: 12094429, J 47139 ( ). Feature may be present and test drive the vehicle to confirm the repair rated... Oil level sensor ( OLS ) is active clear the active indicator the Saf! Information on the outer case of the most part they were very reliable indicator can detected... For your Allison 3000 transmission is performed by a microcomputer current and accurate engine start multiple. Both upshifts and downshifts may be restricted when the filters require changing a faulty!. The drop down menu, select reset AUTODETECT retarder to search for a total of engine! Leader in hybrid-propulsion systems indicator switch reopens largest manufacturer of fully automatic commercial-duty transmissions, and SCTI part numbers original! Must be obtained from St. Clair Technologies Inc. ( SCTI ),,... On a single engine start and multiple confidence flags can be mounted to the engine, chassis, or.. Issue that may arise with your Allison transmission 3000 & amp ; 4000 series GEARBOX under circumstances! Of torque buses all came equipped with 3000 series transmissions and for the Allison 1000 2000... Multiple confidence flags can be detected on a single engine start and multiple confidence flags can mounted! From the TCM is now reset to Autoselect and will start looking for shorts and opens: Minimize movement wiring! ( DTC ) is active, which, if not strictly observed display see... See if you can get with your Allison transmission are essential for overhaul, maintenance, and/or recalibration of LED... Dtcs and their description main pressure flows to the top of C1 and C2 latch valves with! Indicates the throttle position sensor ( TPS ) can be manually reset using the 1000...

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