. . If the replacement TCM corrects the original complaint, reinstall the original TCM to verify that the complaint returns. The Allison transmission 1000 model has a feature called limp mode, in which the transmission locks itself into third gear. . These warnings and cautions advise against using specific service procedures that can result in personal injury, equipment damage, or cause the equipment to become unsafe. . . . . Some are live and synchronized all the time and can be turned on and off at will as long as the engine is near or at idle. . . . . . . Disconnecting and reconnecting the TCM can often correct faulty wiring harness connections that may have been present. . . . . The PTO input to the TCM indicates the PTO is OFF. . . . . . . . Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure. . . . . D1, E.CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, . . . . . . . . . . . . . . Hit the up and down arrows on the Allison shift pad at the same time. . . *NOTE: The first number displayed in the digital display is the highest forward range available and second number is range attained in selected position. C.Operation of Filter Life Valve and Pressure Switch (PS2). . Chelsea PTO and Pumps For All Allison Transmission Models. Resistance tests involving wiring between the TCM connector and other components adds about one Ohm of resistance to the component resistance shown. . . . . Multiple sources can be detected on a single engine start cycle. . . . . . The turbine speed sensor on the 4000 Product Family transmission is located on the outside of the main housing. . . . If the light does not come on during engine start, request service immediately. . . . . . . When SS2 is on, the valve is kept up by SS2. . . . . Wiggle connectors, harnesses, and splices when looking for opens. . . Do you know how to identify and deal with an issue that may arise with your Allison transmission? . . . . . SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. 57 A. . . . OM History: A historical record of the last 6 resets, including mileage at the time of each reset, may be viewed using the Allison DOC For PCService Tool . . Remember that some problems may be temperature related. . The strip pushbutton shift selector has either three or six range selection positions as shown in Figure 14. . . . . . . . . . . When a problem exists but a DTC is not indicated, refer to the Performance Complaint Section (Section 8) for a listing of various electrical and hydraulic problems, their causes, and remedies. . . . Refer to the appropriate parts catalog for the transmission assembly number that you are servicing for detailed parts information. . . . . . Replace the TCM with a known, good TCM from a similar vehicle. . . DIAGNOSTIC CODE TROUBLESHOOTING . . . . . . . . . . The Prognostics pressure switch is activated when fluid exiting the main filter drops below a predetermined pressure. . . . . . . Hence, the solenoids are referred to as pressure control solenoids (PCS). . . . . . Once a confidence flag is set, that source is used as the source for the throttle signal. . . . . . . . SCTI recognizes AT, manufacturers, and SCTI part numbers. . . . OIL LEVEL SENSOR (OLS) INTRODUCTION . . . All shift selectors except the strip-type pushbutton have a dual digit vacuum fluorescent (VF) display and a mode indicator (LED). After the OLS circuit is repaired, reset autodetect or manually select the OLS function using the Allison DOC For PCService Tool. Allison DOC For PCService Tool uses a Windows style graphical user interface (GUI) and includes: User selected views of multiple transmission parameters, Active and historical diagnostic trouble codes (DTCs), Graphical instrument panel view of transmission parameters, Code driven links to embedded Allison 4th Generation Control System Troubleshooting Manuals, Reprogramming capability (available after satisfying Allison Transmission training certification requirements), Demo Mode which allows the user to practice the program without being connected to a vehicle, New animated screen by screen help support (found in Help, Video-based training materials, Allison DOC For PCService Tool Training Videos). . TG Series PTO . . Multiple throttle sources can be detected on a single engine start and multiple confidence flags can be set. . . . . . . . . Remove the 80-way connector from the suspect TCM; inspect the connector for damaged or bent pins. . Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning and may not generate a DTC. . . . . . . . . Shut off the engine and ignition before any harness connectors are disconnected or connected. . . . Available with GVWs greater than 19.5K. Repeated or premature failure may be a sign of an incorrect application. . . . . . . . . 3.0 PTO SYSTEM DESIGN CONSIDERATIONS The PTO system consists of the following: the transmission PTO drive gear and mounting pad on . . If the code reappears, refer to Section 6, Diagnostic Trouble Code, and the appropriate code chart. . . . . . . . Technicians unsure of making the required tests should ask questions of experienced personnel or find instruction. Terminals may have been bent or lost the necessary tension to maintain firm contact. . TM Display: An acceptable clutch life status is displayed as OK in the shift selector; an unacceptable clutch life status is displayed as LO. If engine rating is not compatible, the vehicle must be returned to the OEM for engine recalibration. . . iii TRADEMARKS USED IN THIS MANUAL . . . . . Verify a new engine rating by checking the engine data tag. . . . . Oil Level Sensor (OLS) . . The TCM receives and processes information defining: Each TCM has a date code laser etched on the outer case of the TCM. . . The trans with the PTO setup is a different factor order code. . 4.Test drive the vehicle to confirm a DTC or performance complaint. . Two wires have frayed and are shorted together. . . . . . . . . . The specific clutch or clutches causing the LO display cannot be identified using the shift selector display. . . . ALLISON TRANSMISSION DIAGNOSTIC TOOL. . . . . . . . . . . . . . . . . . . 18 17. . . . . . Wire, terminal, and connector repair information. 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. . 73, SECTION 8. Main mod may be commanded ON in neutral at any throttle position. . . . . . . . The TCM (Figure 13) contains the microcomputer which is the brain of the control system. . . 55, 54. . Its also possible that the transmission itself is just fine, but was installed incorrectly. All TCMs programmed and sold after that date will be loaded with the new TID calibration. . . . . . . . . Determine the fluid level before beginning the OLS troubleshooting. . . . . . . . . . Purpose . During normal transmission operation, illumination of the LED indicator shows that a secondary or special operating condition has been selected by pressing the MODE button. . Description of the 3000 and 4000 Product Families Allison 4TH Generation Electronic Control system. . . . . All tools listed are essential for overhaul, maintenance, and/or recalibration of the 3000 and 4000 Product Families electronic and electrical systems. Give us a call and we will assist you in locating the proper part for your Allison transmission PTO repair. . . Table 33 lists the operating range and pre-determined default range the transmission will shift to in the event of an electrical interruption. . 32 35. If an OLS is known to be present, but has not been detected, troubleshooting the OLS circuit is required. . The SCTI addresses and phone numbers for parts outlets are: SCTI is the source for external harness repair parts. . . . 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. . . . . . Description of the 3000 and 4000 Product Families Allison 4. . The TCM uses a single 80-way connector, which is used to receive input from the following: Many harnesses will include a bulkhead fitting to separate cab and chassis components. . . . . . Topics include Power Take-Off (PTO) operation, shift selectors, prognostics, diagnostics, care and maintenance and even driving tips. . . . . . b.If the continuity test is good (02 Ohms resistance), remove the jumpers. . . . . . . Dont keep driving a vehicle with a faulty part! . The sensor operates on. The speed ratios between the various speed sensors allow the TCM to determine if the transmission is in the selected range. . anyone need wiring. . . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. . . . . Manual forward range downshifts and upshifts are made by pressing the (Down) or (Up) arrow buttons after selecting D (Drive). . . . Hot Check Procedure. Engine speed less than 1200 rpm in all ranges except neutral. . . . . . . . . . . . . . . . 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. . . . . . . Dont let a transmission in need of repairs bring your workplace to a halt! . . . . . . . . . . . . . Re-install shift cover. . . . . A retarder will be identified as present and the retarder autodetect logic will stop once it is detected for three consecutive ignition cycles. . . . . . . DEXRON is a registered trademark of General Motors Corporation. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS, 3-5. . . Use special tools when and in the manner recommended. . . This simulates vehicle movements which occur during actual operation. . . Autodetect is active on the first 25 engine starts and, in the case of throttle source detection logic, may continue past 25 ignition cycles until a valid source is determined (details follow in A through D below). . . Harness has been chafed and one or more wires are. . . . . Description of diagnostic codes, system responses to faults, and troubleshooting. . . . Allison Transmission at the International Commercial Vehicle Fair IAA introduced a new 9-speed gearbox and announced the expansion of its electric drive solution portfolio. . . . . . . If the replacement TCM corrects the original complaint, reinstall the original TCM to verify that the complaint returns. If the code does not reappear, it may be an intermittent problem. Please use these SILs to obtain up-to-date information concerning Allison Transmission products. Allison 4th Generation Control Modules, Figure 18. . Then, mount the PTO to the adapter with the correct gasket which you set aside. . . . 119, 21. . . 27, 31. . . any latin characters (a-z, A-Z) any numbers (0-9) special characters ("-", "_" and ". . Lever Shift Selector . . . . . . . . . . . . . Check for contaminates in air cylinder. . . Filter Life Valve Hydraulic Schematic. . . . . . . . . . . Isolate and repair the short. . . . . . Failure to do so could cause damage to the internal latching mechanism. . SHIFT SELECTOR . . . . Display brightness is regulated by the same vehicle potentiometer that controls dash light display brightness. . . . . . . . . . . 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 Output speed is less than 250 rpm in neutral, reverse, low (7-speed), first, or second range. . . Some procedures require using specially designed tools. . . . Replace trigger Check air pressure. . . . . . . . . . . . . . . 114, 18. . . . . . . . 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. Wiggle connectors, harnesses, and splices when looking for opens. . . . . . . They are throwing some interesting labor quotes ranging from $600-$700 to the one place wants over $1000 labor. Description of the electronic control system components. . Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-residue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner or LPS NoFlash Electro Contact Cleaner. . . SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). . . . . . . . Refer to Pages D15 and D16 for VIM wire number and terminal information. . . . . If display is flashing, shift is inhibited. . . . . . . . . . . . . What I have is a Monaco with the 4000 series transmission that I believe is putting transmission fluid from the transmission . TRANSFER CASE CONNEC TOR (3000 PRODUCT FAMILY 7-SPEED), STRIP PUSHBUTTON SHIFT SELEC TORS (EUROPEAN. . . . All Rights Reserved. . . . . . . . . . . . . . 614, A. . . . . . Figure 15. . Subject: anyone ever put a chelsea pto on a allison automatic? . . . . . . . . If temperatures do not decrease, reduce the engine rpm. 116 19. . . approximately 10 percent or the running clearance exceeds a maximum value, which may indicate a non-wear-related issue. . A. Anti-lock Brake SystemOEM-provided means to detect and prevent wheel stoppage to. . Zip Class A CDL Experience Please select ALL of your current, valid driver's licenses CDL A CDL B CDL C . . . Every possible problem and its solution cannot be encompassed by any manual. . . . . . . . . . . . . . . . Throttle Position Sensor (Without Mounting Brackets). During the entire autodetect period, the software will use the highest priority source as the throttle source if multiple sources are detected before any confidence flags are set. The PTO input to the TCM indicates the PTO is OFF. . NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive). . . . . . Reset is accomplished by using Allison DOC For PCService Tool. could result in damage to or destruction of equipment. . . . Figure 21. . . Web chelsea pto wiring diagram ford. . 64 65. . . . . . . . . . . . or allow a special operating mode or condition, Engine/transmission serial data communications link, High-speed vehicle serial data communications link, Light-Emitting DiodeElectronic device used for illumination, Neutral No ClutchesNeutral commanded with no clutches applied, Neutral Very LowThe TCM has sensed turbine speed below 150 rpm when output speed, is below 100 rpm and engine speed is above 400 rpm when N (Neutral) was selected. . . . . . . SCTI recognizes Allison Transmission, manufacturers, and SCTI part numbers. The TCM is now reset to Autoselect and will start looking for supporting engine software. . In Economy Mode, the transmission will not downshift even at wide-open throttle until the engine pulls . . . . . . . . . . If high temperature in either the engine or transmission persists, stop the engine and have the overheating condition investigated by maintenance personnel. When the countdown period is complete, the software will use the highest priority throttle source having a confidence flag set and the autodetect logic will stop. . . . . . . . . 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. . . NOTE: Required calendar-based filter change intervals are not monitored by this feature and remain applicable to all vehicle installations in addition to the above. . . . . 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. . . Displays o, L; o, K, etc. The service procedures recommended by Allison Transmission and described in this manual are effective methods for performing troubleshooting operations. . . Just like a cable shift PTO or Air Shift PTO, if the teeth in the PTO are not exactly in line with each other, the PTO will be difficult to engage or won't engage at all. The lever shift selector can have as many as six forward range positions (seven for the 7-speed models), as well as R (Reverse) and N (Neutral). Allison, PTO internal leak "from" transmission. . Repair parts for the internal wiring harness and for wiring harness components attached to the shift selector will be available through the Allison Transmission Parts Distribution Center (PDC). . . . If the problem recurs, proceed with Step (4). . . THROTTLE POSITION SENSOR (Figure 15). . Indicates Oil Level is being displayed, Oil Level SensorElectronic device (optional) on control module for indicating. Like all transmissions on the market, the Allison transmissions also use transmission fluid that keeps the components lubricated. The default system enables the transmission to revert to total hydraulic operation and provides safe operation during an electrical interruption by shifting to a specific pre-determined range. . MEASURING CLUTCH AND RETARDER PRESSURES . . . . Owning Continue reading Allison Automatic Transmission Wiring . . . . 51 52. . NOTE: All Allison 4th Generation Controls TCMs are designed to be isolated from the vehicle chassis ground. 71 72. . . . . . . . . The Diagnostic Trouble Code section lists DTCs and their description. . . . This takes you to diagnostic codes. . . . . . . . Before beginning the troubleshooting process, read and understand the following: Allison Transmission recommended wire numbers (i.e. . . Figure 112. Locate and repair the damaged portion of the wire. The display message, seen in Allison DOC For PCService Tool or the Allison shift selector, indicates the calculated remaining life of the transmission fluid. . . . . . . During diagnostic display mode, illumination of the LED indicator shows that the displayed Diagnostic Trouble Code (DTC) is active. . 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 ), FOREWARD. Not available with (PTO) Power take-off. . . 20-WAY TRANSMISSION FEEDTHROUGH HARNESS CONNECTOR, Figure 12. . . . Location. . . iii WARNINGS, CAUTIONS, AND NOTES . According to John Hylton, application engineering, Allison Transmission, "The PTO gears are in constant mesh with the transmission gears after installation. . . . . . . . SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. However, there may be a small chance that transmission performance, shift quality, or codes may result from the use of different models within the same engine family or when a recalibration of engine software has taken place. . DIAGNOSTIC CODE LIST AND DESCRIPTION . . . . . . . . . . . Description of the electronic control system components. Select RESET AUTODETECT RETARDER to search for a retarder only. . . . . . . The Allison DOC For PCService Tool can also be used to override autodetect and manually enter the component or sensor to be recognized by the TCM by changing appropriate customer modifiable constants (CMC). Frequently test for the presence of oil level diagnostics if the transmission is known to contain an OLS. . . . . . . The engine must be compatible with the transmission rating. . . . If during the first 20 starts the TCM recognizes an engine to be on its list of certified engines, it will lock to the SEM active state. . Find an Allison authorized service facility near you. . TM TRANSMISSION SERVICE Condition: The SERVICE TRANS indicator illuminates, indicating the need for clutch maintenance. . . . . . . . . DIAGNOSTIC TROUBLE CODE TROUBLESHOOTING, DTC C1312 Retarder Request Sensor Failed Low, DTC C1313 Retarder Request Sensor Failed High, DTC P0122 Pedal Position Sensor Low Voltage, DTC P0123 Pedal Position Sensor High Voltage, DTC P0218 Transmission Fluid Over-Temperature, DTC P0610 TCM Vehicle Options (TransID) Error, DTC P0634 TCM Internal Temperature Too High, DTC P063E Auto Configuration Throttle Input Not Present, DTC P063F Auto Configuration Engine Coolant Temp Input Not Present, DTC P0657 Actuator Supply Voltage 1 (HSD1) Open, DTC P0658 Actuator Supply Voltage 1 (HSD1) Low, DTC P0659 Actuator Supply Voltage 1 (HSD1) High, DTC P0702 Transmission Control System Electrical (TransID), DTC P0703 Brake Switch Circuit Malfunction, DTC P0708 Transmission Range Sensor Circuit High Input, DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance, DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input, DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input, DTC P0716 Turbine Speed Sensor Circuit Performance, DTC P0717 Turbine Speed Sensor Circuit No Signal, DTC P0721 Output Speed Sensor Circuit Performance, DTC P0722 Output Speed Sensor Circuit No Signal, DTC P0726 Engine Speed Sensor Circuit Performance, DTC P0727 Engine Speed Sensor Circuit No Signal, DTC P0741 Torque Converter Clutch System Stuck Off, DTC P0752 Shift Solenoid 1 (SS1) Valve Performance-Stuck On, DTC P0776 Pressure Control Solenoid 2 Stuck Off, DTC P0777 Pressure Control Solenoid 2 Stuck On, DTC P0796 Pressure Control Solenoid 3 Stuck Off, DTC P0797 Pressure Control Solenoid 3 Stuck On, DTC P0842 Transmission Pressure Switch 1 Circuit Low, DTC P0843 Transmission Pressure Switch 1 Circuit High, DTC P0847 Pressure Switch 2 (PS2) Circuit Low, DTC P0848 Pressure Switch 2 (PS2) Circuit High, DTC P0881 TCM Power Input Signal Performance, DTC P088A Transmission Fluid Filter Deteriorated, DTC P088B Transmission Fluid Filter Very Deteriorated (Expired), DTC P0894 Transmission Component Slipping, DTC P0897 Transmission Fluid Deteriorated, DTC P0960 Pressure Control Solenoid Main Mod Control Circuit Open, DTC P0962 Pressure Control Solenoid Main Mod Control Circuit Low, DTC P0963 Pressure Control Solenoid Main Mod Control Circuit High, DTC P0964 Pressure Control Solenoid 2 (PCS2) Control Circuit Open, DTC P0966 Pressure Control Solenoid 2 (PCS2) Control Circuit Low, DTC P0967 Pressure Control Solenoid 2 (PCS2) Control Circuit High, DTC P0968 Pressure Control Solenoid 3 (PCS3) Control Circuit Open, DTC P0970 Pressure Control Solenoid 3 (PCS3) Control Circuit Low, DTC P0971 Pressure Control Solenoid 3 (PCS3) Control Circuit High, DTC P0973 Shift Solenoid 1 (SS1) Control Circuit Low, DTC P0974 Shift Solenoid 1 (SS1) Control Circuit High, DTC P0975 Shift Solenoid 2 (SS2) Control Circuit Open, DTC P0976 Shift Solenoid 2 (SS2) Control Circuit Low, DTC P0977 Shift Solenoid 2 (SS2) Control Circuit High, DTC P0989 Retarder Pressure Sensor Failed Low, DTC P0990 Retarder Pressure Sensor Failed High, DTC P1891 Throttle Position Sensor PWM Signal Low Input, DTC P1892 Throttle Position Sensor PWM Signal High Input, DTC P2184 Engine Coolant Temperature Sensor Circuit Low Input, DTC P2185 Engine Coolant Temperature Sensor Circuit High Input, DTC P2637 Torque Management Feedback Signal (SEM), DTC P2641 Torque Management Feedback Signal (LRTP), DTC P2669 Actuator Supply Voltage 2 (HSD2) Open, DTC P2670 Actuator Supply Voltage 2 (HSD2) Low, DTC P2671 Actuator Supply Voltage 2 (HSD2) High, DTC P2684 Actuator Supply Voltage 3 (HSD3) Open, DTC P2685 Actuator Supply Voltage 3 (HSD 3) Low, DTC P2686 Actuator Supply Voltage 3 (HSD3) High, DTC P2714 Pressure Control Solenoid 4 (PCS4) Stuck Off, DTC P2715 Pressure Control Solenoid 4 (PCS4) Stuck On, DTC P2718 Pressure Control Solenoid 4 (PCS4) Control Circuit Open, DTC P2720 Pressure Control Solenoid 4 (PCS4) Control Circuit Low, DTC P2721 Pressure Control Solenoid 4 (PCS4) Control Circuit High, DTC P2723 Pressure Control Solenoid 1 (PCS1) Stuck Off, DTC P2724 Pressure Control Solenoid 1 (PCS1) Stuck On, DTC P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit Open, DTC P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit Low, DTC P2730 Pressure Control Solenoid 1 (PCS1) Control Circuit High, DTC P2736 Pressure Control Solenoid 5 (PCS5) Control Circuit Open, DTC P2738 Pressure Control Solenoid 5 (PCS5) Control Circuit Low, DTC P2739 Pressure Control Solenoid 5 (PCS5) Control Circuit High, DTC P2789 Clutch Adaptive Learning at Limit, DTC P2808 Pressure Control Solenoid 6 (PCS6) Stuck Off, DTC P2809 Pressure Control Solenoid 6 (PCS6) Stuck On, DTC P2812 Pressure Control Solenoid 6 (PCS6) Control Circuit Open, DTC P2814 Pressure Control Solenoid 6 (PCS6) Control Circuit Low, DTC P2815 Pressure Control Solenoid 6 (PCS6) Control Circuit High, DTC U0001 Hi Speed CAN Bus Reset Counter Overrun (IESCAN), DTC U0100 Lost Communication with ECM/PCM (J1587), DTC U0103 Lost Communication With Gear Shift Module (Shift Selector) 1, DTC U0115 Lost Communication With ECM/PCM (CAN), DTC U0291 Lost Communication With Gear Shift Module (Shift Selector) 2, DTC U0304 Software Incompatible with Gear Shift Control Module 1, DTC U0333 Software Incompatible with Gear Shift Control Module 1, DTC U0404 Software Incompatible with Gear Shift Control Module 1, DTC U0442 Invalid Data Received from ECM/PCM B (CAN1/J1939), DTC U0592 Software Incompatible with Gear Shift Control Module 1.
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