allison transmission pto troubleshooting
. . . was correctly specified and then failed prematurely, there are two likely causes: Pushbutton and lever shift selectors for the Allison 4th Generation Series are remote mounted from the TCM and communicate to the TCM via the J1939 communications data link. . . . . Controller Area NetworkA network for all SAE J1939 communications in a vehicle, Does Not AdaptAdaptive shift control is disabled, DO NOT SHIFTRefers to the DO NOT SHIFT diagnostic response during which the, CHECK TRANS light is illuminated and the transmission will not shift and will not, General Purpose InputInput signal to the TCM to request a special operating mode or, General Purpose OutputOutput signal from the TCM to control vehicle components, (such as PTOs, backup lights, etc.) . . . . 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. This, is usually caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. . . . . . With proper maintenance and normal usage, Allison transmissions will last you a very long time with few problems. revision, for detailed information on the recommended cleaners. . . . . . . . . NOTE: Information concerning specific items is contained in the appendices located in the back of this manual. . . . Jumper between wires produces. . . . . . . . . SYSTEM OVERVIEW . . . If high temperature in either the engine or transmission persists, stop the engine and have the overheating condition investigated by maintenance personnel. . . . . To service Allison 4th Generation Controls, the technician must understand basic electrical concepts. . . Some procedures require using specially designed tools. . . Technicians unsure of making the required tests should ask questions of experienced personnel or find instruction. install a new TCM. . . . . . . Consequently, Allison Transmission has not undertaken any such broad evaluation. . . . . . Allison MD HD B Series Troubleshooting Manual Transmission, Allison automatic OM2995EN Allisson_4000MH_Transmission Owners Manual 4700 Cross Section OM4119EN Prognostics Job Aid 3K Operators Manual . . . . . . Allison DOC For PCService Tool shows PS2 EXHAUSTED. . . . RESTTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE . . Shorts involve wire-to-wire or wire-to-ground contacts and moving the harnesses may eliminate the problem. . The turbine speed sensor is directed at the rotating-clutch housing. The 3700 SP, 4700 RDS, 4700/ 4800 EVS, 4700/4800 SP, and 4700 OFS have up to seven forward ranges and one reverse. . . . . . . . Welcome to the TS3989EN Troubleshooting Manual. . . . . .F1 G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . The Allison 4th Generation controls system includes a main modulation solenoid. Use special tools when and in the manner recommended. . . 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. . . . . 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). . . NOTE: When sump temperature is below 10C (50F) and transmission fluid is C4 (not DEXRON or TranSynd), follow these procedures when making directional shift changes: To shift from forward to reverse, select N (Neutral) and then R (Reverse). . . . . . . 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. . . * A power take-off (PTO) is optional on the Allison 1000 in the 3500 cab and chassis trucks. . . . First, set correct backlash between adapter and PTO and set the gaskets aside. Repeated or premature failure may be a sign of an incorrect application. . . . . . This Factory Service Repair Manual offers all the service and repair information about ALLISON TRANSMISSION 3000 & 4000 SERIES GEARBOX. . . A retarder will be identified as present and the retarder autodetect logic will stop once it is detected for three consecutive ignition cycles. . . . . . Some procedures require using specially designed tools. Reliable transmission operation and performance depend upon a correctly installed transmission. . . . We make every effort to keep our service information current and accurate. . . . . This will also improve your vehicles overall functionality! . We ship from the USA to . If the complaint is confirmed. . . . . . . . . . . . Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure. . . Repair parts for the external harnesses and external harness components must be obtained from St. Clair Technologies Inc. (SCTI). . . . The Allison transmission 1000 model has a feature called limp mode, in which the transmission locks itself into third gear. . Engage PTO, raise box, push clutch in, put in gear, and . . . Displays o, L; o, K, etc. 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. . . . . . . . Second, mount the adapter with proper backlash to the transmission. . . . . . . . If the complaint does not return, leave the original TCM installed. . 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 . . . . TCM DIAGNOSTIC PROCEDURE . . . . . . . If the engine is not supported, the TCM will lock to a non-SEM state. . . . . . . . Dont keep driving a vehicle with a faulty part! . . . The TCM senses the transmission configuration using TID wire 176. . Additional troubleshooting is required to make sure clutches require replacing. . . Refer to the appropriate parts catalog for the transmission assembly number that you are servicing for detailed parts information. 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 5.If all connectors are clean and connected correctly, determine which wires in the chassis harness are indicated by the DTC. . D1, E.CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, . . . ALLISON TRANSMISSION DIAGNOSTIC TOOL. . . Using genuine Muncie repair parts is key to the life of your PTO. . . . Find a facility My Transmission . . . . . . . . . . ELECTRONIC FLUID LEVEL CHECK (ALLISON DOC FOR PCSERVICE TOOL) . . . 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. . . . . . . Common Allison 3000 Transmission Problems. . . Is your Allison transmission not shifting properly? Figure 19. . However, there are instances when the . . 71 72. . . . 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. . 1.Make sure all connectors are tightly connected and re-test the circuit. . . . . . . 13 13. and ask about the replacement process. . Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service procedures used. . . . . . Custom Tuning is not included in the purchase price but is offered seperately at the hourly rate of $50.00/hr. Locate and repair the damaged portion of the wire. . . . Find a facility. . This feature is not available with 7-speed transmission models. . . Three speed sensorsengine speed, turbine speed, and output speedprovide information to the TCM. If your implement/pump will fit, it is PTO capable. . . These warnings and cautions are not exhaustive. Remember that some problems may be temperature related. . . The SCTI addresses and phone numbers for parts outlets are: SCTI is the source for external harness repair parts. . . . shorted-to-ground. . . . . . Use the P/N from your appropriate parts catalog or from Appendix E in this manual. . 1.Begin troubleshooting by determining the transmission fluid level and TCM input voltage. . . . 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). . . . . But things may go wrong rather unexpectedly. The exception is when C5 clutch is applied. . . . . . . . . . . . . . . . . . . . . . . . . . This feature is not functional until transmission sump temperatures are between 40150C (105302F). Control System Prognostics Operation and Display. . Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure. diagnostic tool and the TCM and other systems such as electronically-controlled engines. Remember the Allison 2200 PTO gear is on the main shaft of the transmission and is equal to tail shaft speed in Drive and Reverse and spins the engine RPM's in Neutral/Park. . . Hence, the solenoids are referred to as pressure control solenoids (PCS). . Seek service assistance as soon as possible. . By Brett Wolfe, F252125. . . . . . 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 vehicle interface module (VIM) provides relays, fuses, and connection points for interface with the output side of the vehicle electrical system. The Filter Life Valve strokes because of the higher main pressure (before the filter). . . Figure 11 is a block diagram of the basic system inputs and outputs. . . . . . . . 614, 71. . . . . . . Location: Logan Indiana (Near Cincinnati Ohio) Posts: 751. . . . . . Refer to the chart in Appendix Q. . . . If the engine temperature indicates a high temperature, an engine or radiator problem is indicated. . 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. . . . . . . . . . . If resets are restricted to the service tool, the selector will not be able to reset the function. . . . Nylon 1150 m/s. . . . . . . . . . . . 5VDC supplied by the TCM. Shorts involve. . C1 D. WIRE/CONNECTOR CHART . . . . . . . . . . . All Allison transmissions are PTO ready. NOTE: Transmission shifts will now be in the unadaptive (base) state, so it will be necessary to drive the vehicle to allow shift to converge. . . . Description of the electronic control system components. . . . . . . . . . . . . . . . . . . . . Dont let a transmission in need of repairs bring your workplace to a halt! . Vehicle Interface Module (VIM). . . 2.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. . . . The 3000 and 4000 Product Families transmissions configurations can be programmed to have up to six forward ranges, neutral, and one reverse range. . . . . . . BEGINNING THE TROUBLESHOOTING PROCESS, 3-7. NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to Paragraph 38). . . It is necessary to determine why a problem occurred. . . TranSyndTM is a trademark of Castrol Ltd. . . . . . . . . . NOTE: Most engine upgrades are same type/rating; under normal circumstances there should be no reason to reset the TCM Autoselect. SCTI recognizes AT, manufacturers, and SCTI part numbers. . With the ignition ON and the engine OFF, shift between, Display the Oil Life Monitor information and press and hold the, Reset by using the specific Action Request in the Allison DOC For, Display the Filter Life Monitor information and press and hold the, Operation of Filter Life Valve and Pressure Switch (PS2), User selected views of multiple transmission parameters, Active and historical diagnostic trouble codes (DTCs), Graphical instrument panel view of transmission parameters, 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. Remove the 80-way connector from the suspect TCM; inspect the connector for damaged or bent pins. . . . . . . . The oil level sensor is available on any 3000 and 4000 Product Families transmissions except the 3000 7-speed transmissions. A. Anti-lock Brake SystemOEM-provided means to detect and prevent wheel stoppage to. . . . . . . Allison, PTO internal leak "from" transmission. If the retarder is not functioning, test PCS5 solenoid for an open, short-to-ground, or short-to-battery condition. The strip pushbutton shift selector does not have a MODE button, diagnostic capability, or adjustable illumination. 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 diagnostic pressure switch PS1 is mounted on the solenoid valve body assembly and performs the following two functions: 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. . . . . Location. . . We have PTOs for the Allison 1000, 2000, 3000, and 4000 series and more. 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. . . . . . . . . . . . . . iii TRADEMARKS USED IN THIS MANUAL . . . . . . Topics include Power Take-Off (PTO) operation, shift selectors, prognostics, diagnostics, care and maintenance and even driving tips. . . Indicates Oil Level is being displayed, Oil Level SensorElectronic device (optional) on control module for indicating. . . . . . . . Then the TCM concludes that no OLS is present. . . . . . . Shouldn't have anything to do with the Allison ecm.