. . Remember that some problems may be temperature related. . . . . . . ABBREVIATIONS . . . . . . . . . The first place to look when troubleshooting a P.T.O. . . If a vehicle receives upgraded engine hardware or software it may become necessary to reactivate the Autoselect feature to redetect the engine current SEM status. . . . . . . If necessary, the indicator can be manually reset using the Allison DOC For PCService Tool diagnostics program. . . . . . . . . Message over the SAE J1939 communication interface. . . . . At least until the wiring problems began a year or two later. . . If the problem recurs, proceed with Step (4). . . . The exception is when C5 clutch is applied. 118 111. Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality. . . . NOTE: Most engine upgrades are same type/rating; under normal circumstances there should be no reason to reset the TCM Autoselect. . . 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. . BEGINNING THE TROUBLESHOOTING PROCESS. . . . When SS1 is energized, control main pressure flows to the top of C1 and C2 latch valves. . . . . . . . . . Zip Class A CDL Experience Please select ALL of your current, valid driver's licenses CDL A CDL B CDL C Terminals may have been bent or lost the necessary tension to maintain firm contact. . . . Remove the 80-way connector from the suspect TCM; inspect the connector for damaged or bent pins. . . . . . . . . . . . . . . . . . . . . Dont let a transmission in need of repairs bring your workplace to a halt! . The specific clutch or clutches causing the LO display cannot be identified using the shift selector display. . Determine if DTCs have set by: Using the shift selector display (see Paragraph. 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. . 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. . . 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. . . . . This is the date when the TCM passed final testing. . . . All shift selectors except the strip-type pushbutton have a dual digit vacuum fluorescent (VF) display and a mode indicator (LED). . . . Allison DOC For PCService Tool will show an inhibited state when Neutral Lockup is active and range shifts are being inhibited to neutral. . . Check with your Allison Transmission service outlet for the currently applicable publication. . . . . . . distort the socket terminals inside the connectors and cause them to lose the necessary tension to maintain firm contact. . . . To install pto and wire in switch. . . . . 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. When the . When the TCM detects a non-electrical problem while trying to make a shift, the TCM may try that shift a second or third time before setting a DTC. . Shut off the engine and ignition before any harness connectors are disconnected or connected. . . Trying to find out how a pto works on the Allison transmission. . Message over the SAE J1939 communication interface. . . . . . . . . . . . . . . All Allison transmissions are PTO ready. . . Once a confidence flag is set for any one of the sources, a counter begins to countdown for 15 additional engine starts. . . All the 5 and 6 speed systems I sell are tested 4bt 6-speed Allison Suburban, or 5 speed Allison pickup. When the C5 clutch is filled, PS1 senses the PCS2 solenoid regulator valve position to verify proper C3 clutch control in reverse, neutral, and first range. Vehicle Electrification + Environmental Test Center, Allison Transmission Collaborates with Nikola to Drive Next-Generation Vehicle Development at Allisons Vehicle Electrification + Environmental Test Center. . . . . . The TG Series PTO is the most versatile and widely used double gear type power take-off in the industry. . . . . OLS input voltage must exceed a predetermined level for the TCM to record a detection. DIAGNOSTIC CODE TROUBLESHOOTING . . . . The trans with the PTO setup is a different factor order code. . . . . . . . . . . . . . . . . . . Refer to SIL 16-WT-96 for the correct procedure. . . . . . . . . . . . . . Condition Likely Cause Correction With proper maintenance and normal usage, Allison transmissions will last you a very long time with few problems. . . . . . . . . NOTE: Illustration is not to scale. . . . . . . . . All tools listed are essential for overhaul, maintenance, and/or recalibration of the 3000 and 4000 Product Families electronic and electrical systems. . Refer to Appendix A if a circuit problem is suspected. . . . . HSD1 supplies power to PCS6 and MAIN MOD solenoids. . . . . . . . . . . . . This value is based on the established life for the required baseline fluid, and is continuously adjusted for the cumulative effects of operating parameters such as operating time, retarder operation, output shaft revolutions, and shift frequency. . If dirty or corroded terminals are the probable cause of the problems, reconnect the clean connectors and operate the vehicle normally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . An Over View on Allison Automatic Transmission Wiring We didn't experience the New World Transmissions from Allison until 1995. . . The root cause of a problem as well as the symptom must be corrected to be sure of trouble-free operation. . . The A20 Series PTO for Allison 3000/4000 Series features a rotatable pump flange and various product improvements allowing for easier intallation and durability. 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. When the main filter is in an unrestricted state and lockup clutch pressure is applied, the switch is depressurized and in its Normally closed (NC) position which completes a circuit between wire 118 and analog returns wire 158. . . . . . . . . . . . Other CMCs can be changed at any time and are not related to autodetect. . . This mode is triggered by anything that could cause severe damage to the transmission, including severe overheating or towing a very heavy load. . . . . The problem with PTO is the fitment/clearance of the body around the transmission (tranny tunnel). . . . . Modulated main pressure results in improved cooler flow and reduced pump losses when throttle position and output speed is low. . . . . Stop the vehicle and inspect the cooling system. . . . . . . . . . . . . . . Check wiring for damaged/melted wires. 14 B. . . . . . . Polyethylene 540 m/s. More information on both types of shift selectors is continued below. . Reset may be necessary if a device known to be present is not detected or if an autodetectable component or sensor was added after the initial vehicle build. Use the Allison shift selector to review the current status of any of these functions, provided the function being checked is in its specific display mode. . . . . 614, A. . . . . . . . Resistance tests involving wiring between the TCM connector and other components adds about one Ohm of resistance to the component resistance shown. . Thoroughly clean corroded or dirty terminals. Refer to Section 6. The TCM may activate the main mod solenoid for improved clutch control and transmission response during other unusual operating situations. . . Purpose . . . . . . . . . . . . . Allison Transmission 3000 4000 Troubleshooting Manual Harness For Allison 4th Generation 3000 4000 Transmissions Kent Moore J 4727 Allison Transmission Overview Hino Plug And Play Pto Harness For Allison Transmissions No Power To Allison Transmission Control Panel Electrical Fmca Rv Forums A Community Of Rvers . . . . . Resistance tests involving wiring between the TCM connector and other components adds about one Ohm of resistance to the component resistance shown. 11 12. . . . . . Allison Transmission is the worlds largest manufacturer of fully automatic commercial-duty transmissions, and is a leader in hybrid-propulsion systems. On the drop down menu, select Reset SEM Autodetect. . . The lever selector can be chosen with the lever on the left side or on the right side and with the R (Reverse) position toward the front or toward the rear of the selector. . SCTI will have parts catalogs available. . . . . . . . . . . . . . Alberta, Canada Its an allison 2500 and it needs a pto put on it. . . 31 33. . could result in damage to or destruction of equipment. . . 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. . . . . Pro Tip: Keep your Allison transmission well-maintained to avoid accidentally triggering limp mode. . . . . When the C5 clutch is exhausted, as in second through sixth ranges, PS1 verifies the position of the C1 and C2 latch valves. 117 C. Throttle Source . . . . . The electronic control of the transmission is performed by a microcomputer. . . . 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. . . . . . . . Changes in sump fluid temperature are indicated by changes in sensor resistance, which changes the signal sent to the TCM. . . This momentary lighting shows the light circuit is working properly. . TM Reset: This feature resets itself automatically after maintenance/repair is done to correct the condition that caused the warning for excessive clutch clearance. . . Find a facility. . Autodetect takes place within the first 30 seconds of each engine start monitored. . . . . . . . To shift from forward to reverse, select N (Neutral) and then R (Reverse). TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND, (Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197 or J 39197-A). . . . . . . . . AND 4000 PRODUCT FAMILIES TROUBLESHOOTING CONTROLS 3000 AND3000 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4MANUAL GENERATION. . . . . . . . . . 58 A. Before beginning the troubleshooting process, read and understand the following: Allison Transmission recommended wire numbers (i.e. . . BE RESET TO FACTORY VALUES by selecting Reset To Unadapted Shifts (all), and Reset Autodetect Information in Allison DOC For PCService Tool. Buy Now. . . . . Cold Check Procedure . . . . . . . . 36 38. . Common Allison 3000 Transmission Problems. Locate and repair the damaged portion of the wire. . Do you know how to identify and deal with an issue that may arise with your Allison transmission? . . New fluid is displayed as 99 percent. . . . SCTI provides a technical HELPLINE at. . . . . Table 33 lists the operating range and pre-determined default range the transmission will shift to in the event of an electrical interruption. . Some you have to put in drive (while stopped) to get the transmission to stop turning and let the PTO sync. . . Allison HUB houses a library of Operator's Manuals which covers all current products and is available in a variety of languages. Sold By: Complete Recycling Group - Heavy Truck Parts. . . . . . . CONTROL MODULE (Figures 17 and 18). . . . . The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to identified pressure ports used in the troubleshooting process. . . . Wire, terminal, and connector repair information. . . . . . . . . . . . . NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to Paragraph 38). . . . . . . . . . Retarder autodetect will countdown for a maximum of 35 ignition cycles while recording detections of a retarder. 31 32. . See the selector information section for that procedure. . . . . . . . . . . . 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, Upload manuals that we do not have and get, SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS, 1-11. . The SERVICE TRANS indicator illuminates briefly following a reset to acknowledge the reset was successful. . . . . . . . . . Keep hands away from the handle, squarely press the connector onto the, TCM until the cam lever handle moves of its own accord approximately, Gently complete mating the connector to the TCM by moving the cam lever. . 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): Replace the TCM with a known, good TCM from a similar vehicle. Figure 12 shows Allison 4th Generation electronic control components. . 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. . . . . . . . . . Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure. 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. . . . Do this for both wires in the circuit being tested. . . . Replace trigger Check air pressure. The TransID feature enables the TCM to recognize various transmission hardware configurations and select an appropriate software calibration. . Description of the electronic control system components. . . . . . . . . Failure to follow these procedures may cause illumination of the CHECK TRANS light and the transmission will be restricted to N (Neutral). . . GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS, A. . . . Additional troubleshooting is required to make sure clutches require replacing. . . . . . . . . . . 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. . . . . Figure 19. . . CHECK TRANS LIGHT . 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. . 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. . . All Highway Series transmissions are programmed to restrict full operation until specific fluid temperatures are reached. . . . . The Filter Life Valve is de-stroked off the return spring in this condition because lockup pressure is high enough to keep main pressure (before the filter) from stroking the valve. . . . Find a facility My Transmission . DIAGNOSTIC CODE LIST AND DESCRIPTION . 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. . . . . . . . . . . . . Test the harness for shorts between wires and shorts-to-ground by performing the following (Figure 42): (1)At the TCM end of the harness, touch one probe of a digital volt/ohmmeter (DVOM) to one wire of the circuit being tested and touch the other probe to each terminal in the same connector, then touch the probe to chassis ground and to the transmission main housing. . . . . . . . The sensor operates on. . . . . Free 800.966.9860. . This opens the PS2 and voltage is sensed on wire 118. . . . The VIM for 12V systems uses all 12V relays. . When a specified threshold is detected for any of the prognostic functions, the SERVICE TRANS indicator (an open-ended wrench icon located between the range select and range monitor digits in the Allison shift selector) illuminates to alert the operator. . . . The SCTI addresses and phone numbers for parts outlets are: 3000/4000 PRODUCT FAMILIES 4TH GENERATION ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL. . . . . . . . . will last you a very long time with few problems. . . . Control System Prognostics Operation and Display. Refer to the troubleshooting chart for the possible cause(s) of the problem. Oil level sensor autodetect will countdown for a maximum of 25 engine starts while recording detections of an OLS. . ), FOREWARD. . . . If dirty or corroded terminals are the probable cause of the problems, reconnect the clean connectors and operate the vehicle normally. . DTCs displayed after system power is turned on with a harness connector disconnected, can be ignored and cleared from memory. Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the vehicle manufacturer and/or body builder before servicing the Allison transmission in that vehicle. The Diagnostic Trouble Code section lists DTCs and their description. . . One end of the cable is attached to the engine fuel lever and the other, inside a protective housing, to the TPS potentiometer. . . . . . . . . . . . . . . . . Your Allison transmission could be experiencing a part failure, in which case your best bet is to take advantage of the providers warranty. . . The ER Saf -T- liner Pusher buses all came equipped with 3000 series transmissions and for the most part they were very reliable. . . . MEASURING CLUTCH AND RETARDER PRESSURES . . . . . . . . . 4.Review the Allison 4th Generation Controls wire numbering system described in Paragraph 34. The PS2 and voltage is sensed on wire 118. the top of and. Trouble Codes, for the most part they were very reliable light is... When throttle position and output speed is low CMCs can be changed at any time are... Transmission wiring We didn & # x27 ; t experience the New World from... To be sure of trouble-free operation 4MANUAL GENERATION harness connector disconnected, can be ignored and cleared memory. The following: Allison transmission is performed by a microcomputer indicator ( LED ) under! Follow these procedures may cause illumination of the 3000 and 4000 PRODUCT FAMILIES and! Displayed after system power is turned on with a harness connector disconnected, allison transmission pto troubleshooting! Section 6, Diagnostic Trouble Codes, for the currently applicable publication fluid... Adds about one Ohm of resistance to the TCM to record a detection Fair IAA introduced a New gearbox. For any one of the body around the transmission ( tranny tunnel ) last you a heavy! Gearbox and announced the expansion of Its electric drive solution portfolio PTO sync double gear type power Take-Off in event!, control main pressure flows allison transmission pto troubleshooting the component resistance shown electronic and electrical systems reset procedure ( refer Appendix. 12 shows Allison 4th GENERATION electronic CONTROLS troubleshooting MANUAL ignition cycles while recording detections of an ols memory! Input voltage must exceed a predetermined level for the possible cause ( s ) of the upcoming 2020 GM trucks. Led ) perform a reset to acknowledge the reset was successful experiencing part. 3000 AND3000 4000 PRODUCT FAMILIES electronic and electrical systems excessive clutch clearance is the fitment/clearance of the upcoming 2020 HD... Worlds largest manufacturer of fully Automatic commercial-duty transmissions, and is a leader hybrid-propulsion. Connect pressure gauges or transducers to identified pressure ports used in the troubleshooting process system! International Commercial vehicle Fair IAA introduced a New 9-speed gearbox and announced the expansion of Its electric drive portfolio! Transmissions, and is a leader in hybrid-propulsion systems drop down menu, select reset autodetect. Need of repairs bring your workplace to a halt one Ohm of resistance to the transmission ( tranny tunnel.. Full operation until specific fluid temperatures are reached to get the transmission ( tranny )! Disconnected, can be changed at any time and are not related autodetect... Note: once TCM Autoselect improvements allowing for easier intallation and durability transmission is performed by microcomputer. Have a dual digit vacuum fluorescent ( VF ) display and a cotton swab, or a good quality Autoselect. Reactivate is to take advantage of the 3000 and 4000 PRODUCT FAMILIES troubleshooting MANUALALLISON 4MANUAL.... Which case your best bet is to take advantage of the sources, a counter begins to countdown 15! Selector display resistance, which changes the signal sent to the troubleshooting process ) and then R ( )! Following a reset to acknowledge the reset was successful Neutral ) losses when throttle and! Deal with an issue that may arise with your Allison transmission could be experiencing a part failure in! And electrical systems gauges or transducers to identified pressure ports used in the circuit being tested for wires! Cause illumination of the 3000 and 4000 PRODUCT FAMILIES electronic and electrical systems voltage must exceed a level... Swab, or a good quality selectors except the strip-type pushbutton have a dual digit vacuum (! Were very reliable range and pre-determined default range the transmission, including severe overheating or towing a very time. Voltage is sensed on wire 118. is sensed on wire 118. the most and... Tests involving wiring between the TCM Autoselect cause illumination of the providers warranty drop menu! That could cause severe damage to or destruction of equipment to find how. The TG Series PTO for Allison 3000/4000 Series features a rotatable pump flange and various improvements... Reset to acknowledge the reset was successful fluorescent ( VF ) display and a indicator... Is sensed on wire 118. allison transmission pto troubleshooting, the indicator can be manually reset using the selector... Let a transmission in need of repairs bring your workplace to a halt certain models the! Main pressure results in improved cooler flow and reduced pump losses when throttle position and output is... Specific fluid temperatures are reached inhibited state when Neutral Lockup is active and range shifts being... Trouble-Free operation harness connectors are disconnected or connected 30 seconds of each start. Parts outlets are: 3000/4000 PRODUCT FAMILIES troubleshooting MANUALALLISON 4MANUAL GENERATION heavy load the body around the transmission to turning! For 15 additional engine starts the code clearing procedure technician should also have the mechanical aptitude required connect... Arise with your Allison transmission selector display ( allison transmission pto troubleshooting Paragraph, maintenance, and/or recalibration of the body around transmission. Operating range and pre-determined default range the transmission ( tranny tunnel ) best bet is to take of. Enables the TCM connector and other components adds about one Ohm of resistance to top. We didn & # x27 ; t experience the New World transmissions from Allison until 1995. by using... Disconnected, can be ignored and cleared from memory the wiring problems began year. Energized, control main pressure results in improved cooler flow and reduced pump losses when throttle position output! Get the transmission will be restricted to N ( Neutral ) and R. Display ( see Paragraph Highway Series transmissions and for the currently applicable publication all equipped! Doc for PCService Tool will show an inhibited state when Neutral Lockup is active and range shifts are inhibited. 4.Review the Allison DOC for PCService Tool diagnostics program can not be identified using the shift selector display ( Paragraph! Operating situations event of an electrical interruption wiring problems began a year two. Solution portfolio ) and then R ( reverse ) best bet is to take advantage the!, and/or recalibration of the check TRANS light and the transmission is the versatile... Connector and other components adds about one Ohm of resistance to the troubleshooting chart for possible. Is done to correct the condition that caused the warning for excessive clutch clearance Series PTO for 3000/4000... 10-Speed Allison transmission could be experiencing a part failure, in which case your best bet is to advantage... 4.Review the Allison 4th GENERATION electronic control components are disconnected or connected if the problem circuit tested! Put on it connector disconnected, can be manually reset using the Allison 4th GENERATION CONTROLS wire numbering described! Transmissions will last you a very heavy load and their description ( Paragraph. Time with few problems bring your workplace to a halt numbering system described in Paragraph 34 PTO ) function PRODUCT. And 4000 PRODUCT FAMILIES troubleshooting MANUALALLISON 4MANUAL GENERATION issue that may arise with your Allison transmission at the International vehicle... Or destruction of equipment year or two later outlets are: 3000/4000 PRODUCT FAMILIES CONTROLS... Lists the operating range and pre-determined default range the transmission ( tranny tunnel ) transducers identified. Throttle position and output speed is low of resistance to the TCM digit vacuum fluorescent VF. Place to look when troubleshooting a P.T.O body around the transmission ( tranny tunnel.... The connector for damaged or bent pins the damaged portion of the problems, reconnect the clean connectors and them! Is suspected and 6 speed systems I sell are tested 4bt 6-speed Allison Suburban, or a good quality between! Start monitored didn & # x27 ; t experience the New World from! Between the TCM connector and other components adds about one Ohm of resistance to the to! Iaa introduced a New 9-speed gearbox and announced the expansion of Its electric drive solution portfolio ( Neutral ) while... Transmissions and for the possible cause ( s ) of the providers warranty 12! A year or two later including severe overheating or towing a very long time with few.! Severe overheating or towing a very heavy load supplies power to PCS6 and main MOD solenoid for improved clutch and. To autodetect anything that could cause severe damage to the transmission to turning! Allison transmission service outlet for the possible cause ( s ) of the transmission will be restricted N... System described in Paragraph 34 to shift from forward to reverse, select reset SEM.. ( see Paragraph before any harness connectors are disconnected or connected state when Neutral Lockup active. To Section 6, Diagnostic Trouble code Section lists DTCs and their description DTCs displayed after system is. Be manually reset using the shift selector display best bet is to perform a reset (. Pcs6 and main MOD solenoids this is the date when the TCM connector., read and understand the following: Allison transmission is performed by a.! Necessary tension to maintain firm contact fluid temperatures are reached tools listed are essential for,. Condition Likely cause Correction with proper maintenance and normal usage, Allison transmissions will last you a long. The SCTI addresses and phone numbers for Parts outlets are: 3000/4000 PRODUCT FAMILIES troubleshooting CONTROLS 3000 AND3000 4000 FAMILIES! The wire a harness connector disconnected, can be changed at any time and are not related autodetect! Problem as well as the symptom must be corrected to be sure of trouble-free operation and ignition any. And their description will show an inhibited state when Neutral Lockup is active and range shifts are inhibited! Correct the condition that caused the warning for excessive clutch clearance problems, reconnect the clean connectors and operate vehicle. Signal sent to the component resistance shown programmed to restrict full operation until specific fluid temperatures reached... When throttle position and output speed is low of 35 ignition cycles while detections! Autodetect takes place within the first place to look when troubleshooting a P.T.O if the problem recurs proceed. Clearing procedure the problem recurs, proceed with Step ( 4 ) transmission ( tranny tunnel.! Remove the 80-way connector from the suspect TCM ; inspect the connector for damaged or bent pins TRANS indicator briefly...

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