The transmission is considered to be overheated when any of the temperatures in Table 32 are exceeded:. . Filter Life Monitor indicates when the filters require changing. . will last you a very long time with few problems. . . . . . 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. . . 18 17. Shorts involve wire-to-wire or wire-to-ground contacts and moving the harnesses may eliminate the problem. . . . . . . Engine speed less than 1200 rpm in all ranges except neutral. . . . . Do this for both wires in the circuit being tested. If the gears do not mesh at installation, the wrong PTO has been installed." Don't assume that a PTO intended for a specific purpose will suffice for another. . . . . BEGINNING THE TROUBLESHOOTING PROCESS, 3-7. 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. . . . . . . . When the C5 clutch is exhausted, as in second through sixth ranges, PS1 verifies the position of the C1 and C2 latch valves. . The display message indicates the operating status of the transmission main filter, based on the measured pressure drop across the filter. We ship from the USA to . . . . . . . NVL is, attained by turning D solenoid ON (in addition to E solenoid) and the C4 and C5. If the engine temperature indicates a high temperature, an engine or radiator problem is indicated. If the code does not reappear, it may be an intermittent problem. Figure 13. . . If the engine temperature gauge indicates a high temperature, the transmission is probably overheated. Circuit does not have continuity due to a broken wire (open circuit). . . .ii IMPORTANT SAFETY NOTICE . . . Engine coolant temperature sensor autodetect will countdown for a total of 25 engine starts while recording detections of engine coolant temperature sources. N1 P. INPUT/OUTPUT FUNCTIONS . . Control System Prognostics Operation and Display. Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure. G1 H. HYDRAULIC SCHEMATICS . . . See the selector information section for that procedure. . To service Allison 4th Generation Controls, the technician must understand basic electrical concepts. . . . . If the light does not come on during engine start, request service immediately. Take time to review the Table of Contents and the manual. . . . . . . Maximum Allowable Transmission Fluid Temperature. . . This feature is not available with 7-speed transmission models. The PTO input to the TCM indicates the PTO is OFF. A loose dipstick, clogged breather, improper dipstick marking and water in the transmission are also probable causes of the problem. . . The TransID feature enables the TCM to recognize various transmission hardware configurations and select an appropriate software calibration. . . . . * Some transmissions used in oil field service default to neutral, 41. If display is flashing, shift is inhibited. . (2)On the opposite end of the harness, test the continuity of the jumpered pair. . . . . . The TPS contains a pull actuation cable and a potentiometer. . . . . SPECIAL ELECTRONIC/ELECTRICAL TOOLS, 2-2. . . . . . . . . Allison transmissions are custom-designed for several different industries and provide valuable power and work. . . . . . . . . . . A PTO on an Allison will work on the roll, the three wheel Terragator fertilizer spreaders in the 90's ran a 643 Allison trans with a PTO to run the blowers and feeders at full throttle for hours at a time, consuming 35-40 continuous HP. . 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. Is your Allison transmission giving you trouble? . . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. . . . . . . . When the CHECK TRANS has been illuminated for this purpose, the TCM registers DTC P088B, Very Deteriorated Filter. . . . . . . . If the autodetect logic is not satisfied during the first 35 engine starts, the retarder is not detected and will not function on subsequent engine starts. 1.Begin troubleshooting by determining the transmission fluid level and TCM input voltage. Replace trigger Check air pressure. . . Retarder autodetect will countdown for a maximum of 35 ignition cycles while recording detections of a retarder. SPECIAL ELECTRONIC/ELECTRICAL TOOLS . . . . . . . . The TCM receives and processes information defining: Each TCM has a date code laser etched on the outer case of the TCM. . PTO mounting pads. . Diagnostic and oil level (if sensor is present) information is obtained from the LED display by pressing the display mode button. . . . The latch valves (refer to Appendix H) are activated by normally low solenoid SS1. The MODE button is pressed to select a secondary or special operating condition, such as ECONOMY shift schedule. If the pto light in the dash cluster ( has to be the one in the cluster) is on , then the VECU should be getting the " PTO on" signal and operate as per the Pto parameters that were programmed in the VECU ( Vechicle control unit) . . . . . . . To shift from reverse to forward, select N (Neutral) and then D (Drive) or other forward range. . . . Transmission Fluid The hard shifting problem is often linked with low transmission fluid levels. . . . . . . . Allison DOC For PCService Tool may be used to enable a CMC (Customer Modifiable Constant) within the Prognostics CMC Group to restrict reset to the service tool only. . . . . . A confidence flag will be set once a source is detected for five consecutive engine starts. 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. TCM Reprogramming tab, used to enable the reprogramming capability of the Allison DOC For. NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive). . . . . . . . NOTE: All external harnesses are OEM supplied. . Engine speed less than 1200 rpm in all ranges except neutral. . . . . . . Do not insert test probes larger than 0.81 mm into the TCM 80-way and transmission 20-way connectors. . . . . . . . . . . . . . . . . . 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. . Working underneath the truck while it was still running, a protruding set screw on the PTO drive shaft caught the collar of his coveralls and quickly entangled him. . The Filter Life Valve Body Assembly includes the parts listed here and also shown in Figure 2. . . . . . . . . . . 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. High transmission fluid levels and a failed vacuum modulator may throw fluid out in an Allison transmission. . Allison 4th Generation Control Modules, Figure 18. The Transmission Rebuilders Network is the place where the industries best transmission rebuilders work together to help solve the most complex automatic transmission problems. . . . . . . . . . Drive the vehicle; confirm DTCs have not returned. 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. will cause severe overheat damage to the transmission. Do troubleshooting at the temperature level where the problem occurs. . . . . . . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. . Rebuilt, New and Used Allison transmission Power Take Offs from Parker Chelsea, Muncie and More. . . . . OM Reset: The function may be reset by one of the following methods: NOTE: Prognostic information can only be reset in the higher of two shift schedules, if applicable. The Allison Transmission 9000 Series is designed for extreme operating conditions in highly demanding applications up to 1,939 kW (2,600 hp). . . . . . . All shift selectors except the strip-type pushbutton have a dual digit vacuum fluorescent (VF) display and a mode indicator (LED). . . . . One end of the cable is attached to the engine fuel lever and the other, inside a protective housing, to the TPS potentiometer. . approximately 10 percent or the running clearance exceeds a maximum value, which may indicate a non-wear-related issue. . . . . . . . . . . Oil Level Sensor (OLS) . . . . . . . . Diagnostic information is obtained by pressing the (Up) and (Down) arrow buttons at the same time. . . . . This takes you to diagnostic codes. . . . How do you run a dump with a stick trans? . . . . . . Check wiring for damaged/melted wires. . . . . Dont let a transmission in need of repairs bring your workplace to a halt! . . . . . . . . . Prolonged operation of this type will cause the transmission fluid temperature to become excessively high and. . . . Every possible problem and its solution cannot be encompassed by any manual. . . Terminals may have been bent or lost the necessary tension to maintain firm contact. RESTTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE . Take advantage of our extensive warranty coverage to have your transmissions fixed or replaced with new models. Throttle Position Sensor (Without Mounting Brackets). . SPEED SENSORS. . The exception is when C5 clutch is applied. . . SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. . Determine if DTCs have set by: Using the shift selector display (see Paragraph. . DIAGNOSTIC CODE MEMORY. . . . . Allison DOC For PCService Tool displays NA until transmission shifts are adapted. . Whenever a transmission is overhauled, exchanged, or has undergone internal repairs, the TCM MUST. Dont keep driving a vehicle with a faulty part! . . . Not available with (PTO) Power take-off. . . . . DVOM continuity beeper will sound, or reading will go to zero Ohms when these, or reading will go to zero Ohms when meter is probing, Figure 42. Welcome to the TS3989EN Troubleshooting Manual. . . . . . . The PTO input to the TCM indicates the PTO is OFF. . . . . . . . . NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to Paragraph 38). Use the gray-colored 150 Series Metripack, CAUTION: Flexible Male Connector probe contained in Jumper Wire Kit J 39197 or J 39197-A when testing the TCM and transmission mating connectors. . Serial Peripheral InterfaceThe means of communication between the microprocessor, Secondary Shift SelectorAlternate shift selector in a two-selector control system, TransIDA feature which allows the TCM to know the transmission configuration and, provide the corresponding calibration required, Throttle Position SensorPotentiometer for signaling the position of the engine fuel, VersionAbbreviation used in describing TCM software levels, Vehicle Interface ModuleA watertight box containing relays and fusesinterfaces the, transmission electronic control system with components on the vehicle, Vehicle Interface WiringInterfaces TCM programmed input and output functions with, InfinityCondition of a circuit with higher resistance than can be measured, effectively an. . . When the main filter gets excessively restricted by debris, lockup pressure drops. . . . . . . . . . . Allison Transmission (AT) is responsible for warranty on these parts. . . . . The math says the air control hoist valve vs a cable control should be a lot quieter. Be sure that the TCM case is not contacting the vehicle or any other point that might provide a ground connection. . . . . TESTING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL HARNESS OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND, 5-2. . . TCM DIAGNOSTIC PROCEDURE . . . . . . . . . . The output speed signal is generated by a toothed member attached to the output shaft (except for the 3000 Product Family 7-speed models, where the toothed member is the transfer case idler gear). . . . . . . . . . . . The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing. . New animated screen by screen help support (found in Help. . . . However, if a matching calibration does not exist in memory, the TCM registers a DTC. TroubleshooTing guide. . . . . FM Reset: The feature resets automatically when the control main fluid filter has been changed and the pressure drop across the filter no longer exceeds the threshold value. . . . . . . . . . . Refer to the troubleshooting chart for the possible cause(s) of the problem. . THROTTLE POSITION SENSOR . . . (2)If at any time the DVOM shows zero to low resistance, or the meters continuity beeper sounds, there is a short between the two points being probedwire-to-wire or wire-to-ground. . . . . . . . . . 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.
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The transmission is considered to be overheated when any of the temperatures in Table 32 are exceeded:. . Filter Life Monitor indicates when the filters require changing. . will last you a very long time with few problems. . . . . . 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. . . 18 17. Shorts involve wire-to-wire or wire-to-ground contacts and moving the harnesses may eliminate the problem. . . . . . . Engine speed less than 1200 rpm in all ranges except neutral. . . . . Do this for both wires in the circuit being tested. If the gears do not mesh at installation, the wrong PTO has been installed." Don't assume that a PTO intended for a specific purpose will suffice for another. . . . . BEGINNING THE TROUBLESHOOTING PROCESS, 3-7. 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. . . . . . . . When the C5 clutch is exhausted, as in second through sixth ranges, PS1 verifies the position of the C1 and C2 latch valves. . The display message indicates the operating status of the transmission main filter, based on the measured pressure drop across the filter. We ship from the USA to . . . . . . . NVL is, attained by turning D solenoid ON (in addition to E solenoid) and the C4 and C5. If the engine temperature indicates a high temperature, an engine or radiator problem is indicated. If the code does not reappear, it may be an intermittent problem. Figure 13. . . If the engine temperature gauge indicates a high temperature, the transmission is probably overheated. Circuit does not have continuity due to a broken wire (open circuit). . . .ii IMPORTANT SAFETY NOTICE . . . Engine coolant temperature sensor autodetect will countdown for a total of 25 engine starts while recording detections of engine coolant temperature sources. N1 P. INPUT/OUTPUT FUNCTIONS . . Control System Prognostics Operation and Display. Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure. G1 H. HYDRAULIC SCHEMATICS . . . See the selector information section for that procedure. . To service Allison 4th Generation Controls, the technician must understand basic electrical concepts. . . . . If the light does not come on during engine start, request service immediately. Take time to review the Table of Contents and the manual. . . . . . . Maximum Allowable Transmission Fluid Temperature. . . This feature is not available with 7-speed transmission models. The PTO input to the TCM indicates the PTO is OFF. A loose dipstick, clogged breather, improper dipstick marking and water in the transmission are also probable causes of the problem. . . The TransID feature enables the TCM to recognize various transmission hardware configurations and select an appropriate software calibration. . . . . * Some transmissions used in oil field service default to neutral, 41. If display is flashing, shift is inhibited. . (2)On the opposite end of the harness, test the continuity of the jumpered pair. . . . . . The TPS contains a pull actuation cable and a potentiometer. . . . . SPECIAL ELECTRONIC/ELECTRICAL TOOLS, 2-2. . . . . . . . . Allison transmissions are custom-designed for several different industries and provide valuable power and work. . . . . . . . . . . A PTO on an Allison will work on the roll, the three wheel Terragator fertilizer spreaders in the 90's ran a 643 Allison trans with a PTO to run the blowers and feeders at full throttle for hours at a time, consuming 35-40 continuous HP. . 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. Is your Allison transmission giving you trouble? . . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. . . . . . . . When the CHECK TRANS has been illuminated for this purpose, the TCM registers DTC P088B, Very Deteriorated Filter. . . . . . . . If the autodetect logic is not satisfied during the first 35 engine starts, the retarder is not detected and will not function on subsequent engine starts. 1.Begin troubleshooting by determining the transmission fluid level and TCM input voltage. Replace trigger Check air pressure. . . Retarder autodetect will countdown for a maximum of 35 ignition cycles while recording detections of a retarder. SPECIAL ELECTRONIC/ELECTRICAL TOOLS . . . . . . . . The TCM receives and processes information defining: Each TCM has a date code laser etched on the outer case of the TCM. . PTO mounting pads. . Diagnostic and oil level (if sensor is present) information is obtained from the LED display by pressing the display mode button. . . . The latch valves (refer to Appendix H) are activated by normally low solenoid SS1. The MODE button is pressed to select a secondary or special operating condition, such as ECONOMY shift schedule. If the pto light in the dash cluster ( has to be the one in the cluster) is on , then the VECU should be getting the " PTO on" signal and operate as per the Pto parameters that were programmed in the VECU ( Vechicle control unit) . . . . . . . To shift from reverse to forward, select N (Neutral) and then D (Drive) or other forward range. . . . Transmission Fluid The hard shifting problem is often linked with low transmission fluid levels. . . . . . . . Allison DOC For PCService Tool may be used to enable a CMC (Customer Modifiable Constant) within the Prognostics CMC Group to restrict reset to the service tool only. . . . . . A confidence flag will be set once a source is detected for five consecutive engine starts. 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. TCM Reprogramming tab, used to enable the reprogramming capability of the Allison DOC For. NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive). . . . . . . . NOTE: All external harnesses are OEM supplied. . Engine speed less than 1200 rpm in all ranges except neutral. . . . . . . Do not insert test probes larger than 0.81 mm into the TCM 80-way and transmission 20-way connectors. . . . . . . . . . . . . . . . . . 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. . Working underneath the truck while it was still running, a protruding set screw on the PTO drive shaft caught the collar of his coveralls and quickly entangled him. . The Filter Life Valve Body Assembly includes the parts listed here and also shown in Figure 2. . . . . . . . . . . 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. High transmission fluid levels and a failed vacuum modulator may throw fluid out in an Allison transmission. . Allison 4th Generation Control Modules, Figure 18. The Transmission Rebuilders Network is the place where the industries best transmission rebuilders work together to help solve the most complex automatic transmission problems. . . . . . . . . . Drive the vehicle; confirm DTCs have not returned. 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. will cause severe overheat damage to the transmission. Do troubleshooting at the temperature level where the problem occurs. . . . . . . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. . Rebuilt, New and Used Allison transmission Power Take Offs from Parker Chelsea, Muncie and More. . . . . OM Reset: The function may be reset by one of the following methods: NOTE: Prognostic information can only be reset in the higher of two shift schedules, if applicable. The Allison Transmission 9000 Series is designed for extreme operating conditions in highly demanding applications up to 1,939 kW (2,600 hp). . . . . . . All shift selectors except the strip-type pushbutton have a dual digit vacuum fluorescent (VF) display and a mode indicator (LED). . . . . One end of the cable is attached to the engine fuel lever and the other, inside a protective housing, to the TPS potentiometer. . approximately 10 percent or the running clearance exceeds a maximum value, which may indicate a non-wear-related issue. . . . . . . . . . . Oil Level Sensor (OLS) . . . . . . . . Diagnostic information is obtained by pressing the (Up) and (Down) arrow buttons at the same time. . . . . This takes you to diagnostic codes. . . . How do you run a dump with a stick trans? . . . . . . Check wiring for damaged/melted wires. . . . . Dont let a transmission in need of repairs bring your workplace to a halt! . . . . . . . . . Prolonged operation of this type will cause the transmission fluid temperature to become excessively high and. . . . Every possible problem and its solution cannot be encompassed by any manual. . . Terminals may have been bent or lost the necessary tension to maintain firm contact. RESTTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE . Take advantage of our extensive warranty coverage to have your transmissions fixed or replaced with new models. Throttle Position Sensor (Without Mounting Brackets). . SPEED SENSORS. . The exception is when C5 clutch is applied. . . SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. . Determine if DTCs have set by: Using the shift selector display (see Paragraph. . DIAGNOSTIC CODE MEMORY. . . . . Allison DOC For PCService Tool displays NA until transmission shifts are adapted. . Whenever a transmission is overhauled, exchanged, or has undergone internal repairs, the TCM MUST. Dont keep driving a vehicle with a faulty part! . . . Not available with (PTO) Power take-off. . . . . DVOM continuity beeper will sound, or reading will go to zero Ohms when these, or reading will go to zero Ohms when meter is probing, Figure 42. Welcome to the TS3989EN Troubleshooting Manual. . . . . . . The PTO input to the TCM indicates the PTO is OFF. . . . . . . . . NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to Paragraph 38). Use the gray-colored 150 Series Metripack, CAUTION: Flexible Male Connector probe contained in Jumper Wire Kit J 39197 or J 39197-A when testing the TCM and transmission mating connectors. . Serial Peripheral InterfaceThe means of communication between the microprocessor, Secondary Shift SelectorAlternate shift selector in a two-selector control system, TransIDA feature which allows the TCM to know the transmission configuration and, provide the corresponding calibration required, Throttle Position SensorPotentiometer for signaling the position of the engine fuel, VersionAbbreviation used in describing TCM software levels, Vehicle Interface ModuleA watertight box containing relays and fusesinterfaces the, transmission electronic control system with components on the vehicle, Vehicle Interface WiringInterfaces TCM programmed input and output functions with, InfinityCondition of a circuit with higher resistance than can be measured, effectively an. . . When the main filter gets excessively restricted by debris, lockup pressure drops. . . . . . . . . . . Allison Transmission (AT) is responsible for warranty on these parts. . . . . The math says the air control hoist valve vs a cable control should be a lot quieter. Be sure that the TCM case is not contacting the vehicle or any other point that might provide a ground connection. . . . . TESTING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL HARNESS OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND, 5-2. . . TCM DIAGNOSTIC PROCEDURE . . . . . . . . . . The output speed signal is generated by a toothed member attached to the output shaft (except for the 3000 Product Family 7-speed models, where the toothed member is the transfer case idler gear). . . . . . . . . . . . The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing. . New animated screen by screen help support (found in Help. . . . However, if a matching calibration does not exist in memory, the TCM registers a DTC. TroubleshooTing guide. . . . . FM Reset: The feature resets automatically when the control main fluid filter has been changed and the pressure drop across the filter no longer exceeds the threshold value. . . . . . . . . . . Refer to the troubleshooting chart for the possible cause(s) of the problem. . THROTTLE POSITION SENSOR . . . (2)If at any time the DVOM shows zero to low resistance, or the meters continuity beeper sounds, there is a short between the two points being probedwire-to-wire or wire-to-ground. . . . . . . . . . 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.
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