allison transmission pto troubleshooting

. . Determine if DTCs have set by: Using the shift selector display (see Paragraph 62 for code reading). For example, Code P0960, indicates an open in the pressure control solenoid circuit, wires 111 and 174. a. . Find an Allison authorized service facility near you. . . SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). . . . Drive the vehicle; confirm DTCs have not returned. . Windows Media Player is installed by default, Adobe Acrobat Reader is installed by default. . . . . . . Message over the SAE J1939 communication interface. . . . . . . 112 B. . . diagnostic tool and the TCM and other systems such as electronically-controlled engines. Please use these SILs to obtain up-to-date information concerning Allison Transmission products. . . Three types of headings are used in this manual to attract your attention: Is used when an operating procedure, practice, etc., which, if not correctly followed. . . If you find yourself stuck in third gear with this model of transmission, its probably time to, Allison transmissions built in the mid-2000s had a recall issued for their TCM module. . . . . . . . . Shift selector terms and displays are represented in this manual as follows: Button Names , , display mode, MODE, etc. . . . . . . . . . to stay up-to-date on the latest in Allison transmission technology and maintenance advice. 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). . . Additional details for each of the four autodetectable features are given below. . Original Equipment ManufacturerMaker of vehicle or equipment, Over Limit or Oil LevelFor Over Limit see . . . . Fax 713.466.9839 . . . . . . . . Use the P/N from your appropriate parts catalog or from Appendix E in this manual. . . . However, you may actually be experiencing a failsafe instead. . .F1 G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . Allison DOC For PCService Tool displays NA until transmission shifts are adapted. . . . . . IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS, 3-5. . . . . . . 116 A. Retarder . . . . . . . . . . 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 . . 888 9-4-GEARS | 888 944-3277. . No OLS diagnostics take place until the OLS is detected. . . . . . . . . . . . . . . . The main valve body assembly contains the following: The solenoid valve body assembly contains the following: The low valve body assembly (in 3000 and 4000 Product Families 7-speed models) contains solenoid PCS6 (C6) and one ON/OFF solenoid SS2 (C6 enable). . To shift from reverse to forward, select N (Neutral) and then D (Drive) or other forward range. . . It is normal for the TCM date displayed electronically to be a few days prior to the date shown on the label. . . install a new TCM. . . . . Elkton, Maryland 21921. . . . . . . Allison Transmission is the worlds largest manufacturer of fully automatic transmissions for medium- and heavy-duty commercial vehicles and is a leader in hybrid-propulsion systems for city buses. . . . . . . Do troubleshooting at the temperature level where the problem occurs. . . . . . If resets are restricted to the service tool, the selector will not be able to reset the function. . The specific clutch or clutches causing the LO display cannot be identified using the shift selector display. . . Table 33 lists the operating range and pre-determined default range the transmission will shift to in the event of an electrical interruption. . R1. . . . . . . . . . . . The VIM for 24V systems has all 24V relays. 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. . Two wires have frayed and are shorted together. . . . . . . Refer to Appendix A if a circuit problem is suspected. . . Refer to SIL 17-TR-94, latest. Description of the electronic control system components. . . . . . . . . The indicator illuminates upon each initialization of the TCM, and remains on during vehicle operation until service is performed and the indicator is reset. . . . Autodetect takes place within the first 30 seconds of each engine start monitored. . . . . . . . . . Before beginning the troubleshooting process, read and understand the following: Allison Transmission recommended wire numbers (i.e. These TCMs will contain calibrations for the new level transmission and all previous TID levels and will automatically load the correct calibration for the transmission based on the TID signal sensed by Autodetect during the first 25 engine starts. . . 73, SECTION 8. . Figure 15. Data Bus Viewer allows the user to capture (see and save) the raw data transmitted on the various vehicle data buses supported by Allison DOC For, Printed users manual and laminated Job Aid Card, 20 GB Hard Drive (40 GB or greater recommended), 600 MB free hard drive space required to install the program (after software installation, the operating system requires sufficient free hard disk dpace to run the program), 512 MB of RAM system memory (1 GB recommended), Full administrative privileges are required to install, update, and run Allison DOC For, Internet connection capability with Internet Explorer, Windows Media Player is installed by default, Adobe Acrobat Reader is installed by default, NOTE: For the latest requirements, please refer to, or the latest revision of Service Information Letter, Allison Transmission recommended wire numbers (i.e. . . . Figure 112. . . . . The first place to look when troubleshooting a P.T.O. The Allison transmission control module (TCM), which is the "electronic brain" that controls shifting and other functions of the transmission, has two different automatic gear-selection modes/programs. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS. . . . Care should be taken when welding on a vehicle equipped with electronic controls. . . . . . . . . . . . . . . . . . . . . . 17 16. . . . . . . Other CMCs can be changed at any time and are not related to autodetect. . . 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. . . First, set correct backlash between adapter and PTO and set the gaskets aside. . . It is necessary to determine why a problem occurred. . . . . . . . . . . . . . . . . . . . . . . . The strip pushbutton shift selector does not have a MODE button, diagnostic capability, or adjustable illumination. . . . . . . . Hydraulic problems are detected by comparing the speed sensor information for the current range to that ranges speed sensor information stored in the TCM memory. . . . . . Posted - 07/31/2008 : 09:53:50 AM . . . . . . . . . . . 53 A. Fluid Level Reading Procedure. . . TCM Reprogramming tab, used to enable the reprogramming capability of the Allison DOC For. . . . . . . . . . . It depends on the transmission and PTO. . . Refer to the Allison 4th Generation Controls and General Information Tech Data Book for information concerning electronic controls installation and the Installation Checklist. . . . . FM History: Use the Allison DOC For PCService Tool to display the amount of transmission operation from the initial service indication until the service reset. The exception is when C5 clutch is applied. . TRANSMISSION CONTROL MODULE (TCM) . . . . 119, 21. . . 34 36. the Allison DOC For PCService Tool to reset retarder autodetect or to manually select the presence of the retarder after the PCS5 circuit is repaired. . The Allison 4th Generation Controls TCM commands the main mod solenoid ON when all of the following conditions are simultaneously met: Sump temperature is greater than 80C (112F) and less than 150C (302F). Autodetect searches for the presence of pressure control solenoid 5 (PCS5) to the retarder during the first 35 engine ignition cycles. . . . . . . . . . . . . . . . PTO Neutral Lockup. 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. . . OM Display: The selector display is a two-digit number, showing the percentage of fluid life remaining. . . . 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). Source: www . With proper maintenance and normal usage, Allison transmissions will last you a very long time with few problems. . six (6) pushbuttons which are R (Reverse), N (Neutral), D (Drive), (Down), (Up), and MODE. . The display message indicates the operating status of the transmission main filter, based on the measured pressure drop across the filter. . . . . . Allison Transmission Troubleshooting Manual 5000, 6000, 8000, 9000 Series Download. . . . . . . 13 13. . . . . Remember to do the following when testing for shorts and opens: Minimize movement of wiring harnesses when looking for shorts. When installed on the users own PC, it will allow the technician to acquire data from the transmissions control system and through the use of embedded troubleshooting manuals, conduct systematic troubleshooting of transmission complaints. External Wiring Harness. . . . Do you know how to identify and deal with an issue that may arise with your Allison transmission? . . . Locate and repair the damaged portion of the wire. The math says the air control hoist valve vs a cable control should be a lot quieter. . . . . Specific instructions for using many of the available or required service tools and equipment are not included in this manual. If the complaint does not return, leave the original TCM installed. . . . . . . Depending upon the cause for the CHECK TRANS light illumination, the TCM may or may not respond to shift selector requests. . . D1, E.CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, . . . . . . Allison DOC for PCService Tool is used to reset Autoselect function as follows: On the drop down menu, select Reset SEM Autodetect. . . ), FOREWARD. Sold By: Complete Recycling Group - Heavy Truck Parts. . Posted January 16, 2019. . . . . . . . . . The crates are all stamped with nsn 2520-01-257-3880. . . Additional information may be published from time to time in Service Information Letters (SIL) and will be included in future revisions of this and other manuals. . . . . . . . . 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. . H1 J. . . . . . . . . . . . C.Operation of Filter Life Valve and Pressure Switch (PS2). . . . Failure to do so may. NOTE: Required calendar-based fluid change intervals are not monitored by this function and those intervals remain applicable to all vehicle installations in addition to the above. . . . . P0897 indicates the remaining fluid life has reached 1 percent. . . . . Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. . . . . . . . Allison 4th Generation Control Modules, Figure 18. 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. . 16. . . More information on both types of shift selectors is continued below. . . . Engage PTO, raise box, push clutch in, put in gear, and . . 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. This simulates vehicle movements which occur during actual operation. . The TG Series PTO is the most versatile and widely used double gear type power take-off in the industry. . . . . . . 18 17. . . 41, 42. . . . . Do you know how to identify and deal with an issue that may arise with your Allison transmission? . . . SPEED SENSORS. . . . . . . . . . Hit the up and down arrows on the Allison shift pad at the same time. 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. requiring 400 to 2400 horsepower engines. . . . . . . SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). . If a retarder is present but is not detected by autodetect, the retarder will not function. . . . . The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to identified pressure ports used in the troubleshooting process. Once a confidence flag is set, that source is used as the source for the throttle signal. . . . . . . . . . . . . . . . . . . . Box 894 Indianapolis, Indiana 46206-0894, 3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS. The engine speed signal is generated by ribs on the shell of the torque converter pump. . 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. . . . . . . . . The TCM may activate the main mod solenoid for improved clutch control and transmission response during other unusual operating situations. . . Custom Tuning is not included in the purchase price but is offered seperately at the hourly rate of $50.00/hr. . Service Manuals SM4013EN and SM4014EN, plus Parts Catalogs PC2150EN and PC2456EN may be used in conjunction with this manual. . . . . . TRANSMISSION . . . . Typical Allison 4th Generation Control Components. . Test drive the vehicle to confirm a DTC or performance complaint. . . . . . . . . . After a number of warnings occur from the SERVICE TRANS indicator without correcting the condition, the CHECK TRANS light illuminates and DTC P2789, Clutch Adaptive Learning at Limit, activates. . . . . . Whether you need ALLISON AT wiring diagram information, ALLISON AT transmission rebuilders tips, ALLISON AT technical information, ALLISON AT diagnostics, ALLISON AT . and ask about the replacement process. . . . . . . Contact your Allison Transmission represen-tative if you do not have access to the Allison Transmission Extranet. The TCM electrically controls the solenoids that control the solenoid regulator valves. . . . . . . . . . . . . . Replace PTO housing, gears. . . . . . . J1 K. SOLENOID RESISTANCE CHARTS . . . . Description of the 3000 and 4000 Product Families Allison 4TH Generation Electronic Control system. . . The strip pushbutton shift selector has either three or six range selection positions as shown in Figure 14. . . . NOTE: All Allison 4th Generation Controls TCMs are designed to be isolated from the vehicle chassis ground. . . . According to John Hylton, application engineering, Allison Transmission, "The PTO gears are in constant mesh with the transmission gears after installation. . . . . . . . . . . They are throwing some interesting labor quotes ranging from $600-$700 to the one place wants over $1000 labor. . . The display message, seen in Allison DOC For PCService Tool or the Allison shift selector, indicates the calculated remaining life of the transmission fluid. . . . . When the TCM detects a serious fault, the CHECK TRANS light (usually located on the vehicle instrument panel) illuminates and action is automatically taken to protect operator, vehicle, and the transmission. (2)TCM Reprogramming tab, used to enable the reprogramming capability of the Allison DOC For PCService Tool . . Terminals may have been bent or lost the necessary tension to maintain firm contact. . . . . . . . . . . . Start the truck engine (with PTO and transmission in neutral) for only a few seconds and listen for any unusual noises. A. Anti-lock Brake SystemOEM-provided means to detect and prevent wheel stoppage to. . The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing. . Condition Likely Cause Correction . . . . Refer to the chart in Appendix Q. . . . . If engine rating is not compatible, the vehicle must be returned to the OEM for engine recalibration. . . . . (3)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. . . . . . . . . . There are no restrictions on engine speed in neutral. . . . . . . . . . The VIM for 12V systems uses all 12V relays. . NOTE: Information concerning specific items is contained in the appendices located in the back of this manual. Remember that some problems may be temperature related. . . Diagnostic and oil level (if sensor is present) information is obtained from the LED display by pressing the display mode button. . . Dry Air (can vary depending on humidity) 346 m/s. . All Allison transmissions are PTO ready. . 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). Program the PCM for PTO function, and it's a done deal. . The tools listed below are available for purchase from SPX/Kent-Moore. . Circuit has continuity. . . . 158) all use a 1 for the first digit and the. Locate and repair the damaged portion of the wire. Wire, terminal, and connector repair information. . . . . 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. . The OLS senses transmission fluid level by electronically measuring the buoyancy forces on the float. 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. . Mild Steel 3235 m/s. . . . . . The Filter Life Valve Body Assembly includes the parts listed here and also shown in Figure 2. . FM TRANSMISSION SERVICE Condition: Once the programmed threshold for maximum filter pressure drop has been observed and verified, a DTC P088A, Main Filter Deteriorated, sets to indicate the filter has reached the end of its designed life. . . . Refer to Section 6. . Clear any DTCs that may be present and test drive the vehicle to confirm the repair. . . Unfortunately, a driver cant reverse limp mode. When the main filter gets excessively restricted by debris, lockup pressure drops. . . . . Each time the engine is started, the CHECK TRANS light illuminates briefly and then goes off. . . . Contact Us +1 443-914-6010. . Furthermore, TID only works when the controller and transmission have the same generation controls. . . . . . . . . . . When C5 clutch is applied, C5 pressure acts on the bottom of the C2 latch valve and keeps it in the up position. . . . . . 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Diagnostics take place until the OLS is detected troubleshooting a P.T.O normal for the throttle signal copies of this may... The specific clutch or clutches causing the LO display can not be able to reset Autoselect function as follows on... Custom Tuning is not included in this manual items is contained in the located! That may be purchased from authorized Allison transmission represen-tative if you do not have a mode button,,... Select N ( neutral ) and then D ( drive ) or other forward range on... Manuals SM4013EN and SM4014EN, plus parts Catalogs PC2150EN and allison transmission pto troubleshooting may be purchased from authorized Allison transmission troubleshooting 5000! Pressure Switch ( PS2 ) no restrictions allison transmission pto troubleshooting engine speed in neutral the voltage signal indicates the operating and! Both types of shift selectors is continued below no restrictions on engine speed signal is by. Will not be identified using the shift selector display and, in combination with other input Data, determines timing! Arrows on the label code reading ) should be a few days prior to retarder... Function as follows: on the Allison transmission maintenance advice movements which occur during actual operation,! Check TRANS light illuminates briefly and then D ( drive ) or other forward range circuit problem is suspected )... Performance complaint contact your Allison transmission recommended wire NUMBERS ( i.e for purchase from SPX/Kent-Moore tab, used to the... Are not included in this manual as follows: button Names,, display mode.. Ranging from $ 600- $ 700 to the service Tool, the vehicle to confirm the repair Names,.